1 - Ford Bantam Workshop Manual

Bantam - Workshop Manual
FOREWORD
This workshop manual is intended for use by Service Technicians of authorized
FORD Dealers to help them provide efficient and correct service and
maintenance of BANTAM vehicles.
To ensure customer satisfaction with FORD products, proper service and

maintenance by FORD Technicians is essential. Consequently it is important that
service personnel fully understand the contents of this manual, which should be
kept in a place for quick and easy reference.
All the contents of this manual, including photographs, drawings and
specifications are the latest available at the time of printing.
As modifications affecting service occurs, Dealers will be issued with Technical
Bulletins, Service Information sheets or supplementary volumes.
This manual should be carefully kept up-to-date upon receipt of new information.
The manufactures reserve the right to alter the manual's specifications and
contents without obligation or advance notice.
All rights reserved. No part of this manual may be reproduced or utilized in any
form or by any means, electronic or mechanical, including photocopying,
recording or by any information storage and retrieval system without permission
in writing.
© 2002 Ford Motor Company of Southern Africa

(PTY) Ltd
MAIN INDEX: FORD BANTAM
Workshop Manual
Group 1 – General Information GI
Group 2 – Chassis CH
Group 3 – Powertrain PT
Group 4 – Electrical EL
Group 5 – Body and Paint BP
1
Group
General Information
SECTION TITLE PAGE
Service Information
General Information 100-00
Identification Codes 100-01
Jacking and Lifting 100-02
Noise, Vibration and Harshness 100-04
FORD BANTAM
SECTION 100-00 General Information

PAGE 1 OF 2
VEHICLE APPLICATION: 2002 Bantam
SUBJECT PAGE
DESCRIPTION AND OPERATION

About This Manual ................................................................................................................................ 100-00-5
Introduction ........................................................................................................................................100-00-5
Replacement Parts ............................................................................................................................100-00-5
Special Tools .....................................................................................................................................100-00-5
Important Safety Instructions .............................................................................................................100-00-5
Warnings, Cautions and Notes in This Manual .................................................................................100 -00-5
How to Use This Manual....................................................................................................................100-00-5
Samples .............................................................................................................................................100-00-6
Health and Safety Precautions ............................................................................................................. 100-00-7
Introduction ........................................................................................................................................100-00-7
Acids and Alkalis................................................................................................................................100-00-7
Air Bags .............................................................................................................................................100-00-7
Air Conditioning Refrigerant...............................................................................................................100-00-7
Adhesives and Sealers ......................................................................................................................100-00-8
Antifreeze...........................................................................................................................................100-00-9
Asbestos ............................................................................................................................................100-00-9
Battery Acids......................................................................................................................................100-00-9
Brake and Clutch Linings and Pads ..................................................................................................100-00-9
Brakes Fluids (Polyalkylene Glycols) ................................................................................................100-00-9
Brazing...............................................................................................................................................100-00-9
Chemical Materials ............................................................................................................................100-00-9
Chlorofluorocarbons (CFC)................................................................................................................100-00-10
Clutch Fluids ......................................................................................................................................100-00-10
Clutch Linings and Pads ....................................................................................................................100-00-10
Corrosion Protection Materials ..........................................................................................................100-00-10
Cutting................................................................................................................................................100-00-10
Dewaxing ...........................................................................................................................................100-00-10
Dusts..................................................................................................................................................100-00-10
Electric Shock ....................................................................................................................................100-00-10
Engine Oils.........................................................................................................................................100-00-11
Exhaust Fumes..................................................................................................................................100-00-11
Fibre Insulation ..................................................................................................................................100-00-11
Fire.....................................................................................................................................................100-00-11
First Aid..............................................................................................................................................100-00-11
Fluoroelastomer.................................................................................................................................100-00-11
Foams - Polyurethane .......................................................................................................................100-00-12
Freon..................................................................................................................................................100-00-12
Fuels ..................................................................................................................................................100-00-12
Gas Cylinders ....................................................................................................................................100-00-13
Gases.................................................................................................................................................100-00-13
Gaskets (Fluoroelastomer) ................................................................................................................100-00-13
General Workshop Tools and Equipment..........................................................................................1 00-00-13
High Pressure Air, Lubrication and Oil Test Equipment ....................................................................100-00 -13
Halon..................................................................................................................................................100-00-13
Legal Aspects ....................................................................................................................................100-00-13
Lubricants and Greases.....................................................................................................................100-00-14
Noise..................................................................................................................................................100-00-14
Noise Insulation Materials..................................................................................................................100-00-14
O-Rings (Fluoroelastomer) ................................................................................................................100-00-14
Paints .................................................................................................................................................100-00-14
FORD BANTAM
SECTION 100-00 General Information

PAGE 2 OF 2
Pressurized Equipment...................................................................................................................... 100-00-15
Solder................................................................................................................................................. 100-00-15
Solvents ............................................................................................................................................. 100-00-15
Sound Insulation ................................................................................................................................ 100-00-15
Suspended Loads .............................................................................................................................. 100-00-15
Transmission Brake Bands................................................................................................................ 100-00-15
Underseal........................................................................................................................................... 100-00-15
Viton................................................................................................................................................... 100-00-15
Welding .............................................................................................................................................. 100-00-16
Warning Symbols on Vehicles ........................................................................................................... 100-00-17
White Spirit......................................................................................................................................... 100-00-18
Standard Workshop Practices .............................................................................................................. 100-00-19
Vehicle in Workshop .......................................................................................................................... 100-00-19
Alternative Fuel .................................................................................................................................. 100-00-19
Alternative Fuel — Do's ..................................................................................................................... 100-00-19
Alternative Fuel — Do Nots ............................................................................................................... 100-00-19
Towing the Vehicle ............................................................................................................................ 100-00-20
Connecting a Slave Battery Using Jumper Cables ........................................................................... 100-00-20
Component Cleaning ......................................................................................................................... 100-00-21
Calibration of Essential Measuring Equipment.................................................................................. 100-00-21
Solvents, Sealers and Adhesives ......................................................................................................... 100-00-22
Introduction ........................................................................................................................................ 100-00-22
General Specifications....................................................................................................................... 100-00-22
Road/Roller Testing .............................................................................................................................. 100-00-23
Pre-Test Checks ................................................................................................................................ 100-00-23
Starting the Engine ............................................................................................................................ 100-00-23
On Road or Roller Test Check: ......................................................................................................... 100-00-23
Brake Testing..................................................................................................................................... 100-00-24
FORD BANTAM
100-00-5 General Information 100-00-5

About This Manual
Introduction Warnings, Cautions and Notes in This Manual
This manual has been written in a format that is WARNING: Warnings are used to indicate that
designed to meet the needs of Ford technicians failure to follow a procedure correctly may
worldwide. The objective is to use common formats result in personal injury.
and include similar content in each manual worldwide.
CAUTION: Cautions are used to indicate that
This manual provides general descriptions for failure to follow a procedure correctly may
accomplishing service and repair work with tested, result in damage to the vehicle or equipment
effective techniques. Following them will help assure being used.
reliability.
NOTE: Notes are used to provide additional essential
information required to carry out a complete and
Replacement Parts
satisfactory repair.
Ford and Motorcraft parts are made to the same
As you read through this manual, you will come across
exacting standards as the original factory fitted
WARNINGS, CAUTIONS and NOTES.
components. For this reason, it is recommended that
only genuine Ford or Motorcraft parts are installed A warning, caution or note is placed at the beginning
during service or repair. of a series of steps if it applies to multiple steps. If the
warning, caution or note only applies to one step, it is
placed at the beginning of the specific step (after the
Special Tools step number).
The Special Tool(s) Table provided at the beginning of
each procedure shows all special tools required to How to Use This Manual
carry out a repair. Where possible, illustrations are
This manual covers service and repair procedures.
provided to assist in identifying the special tool
required. This manual is structured into groups and sections,
with specific system sections collected together under
Special tools may be ordered from Grundy South
their relevant group.
Africa (PTY) Ltd
A group covers a specific portion of the vehicle. The
Korsten
manual is divided into five groups, General
Port Elizabeth Information, Chassis, Powertrain, Electrical and Body
and Paint. The number of the group is the first number
P.O Box 14119
of a section number.
(Ph) 041 4031300
Pages at the start of the manual list all sections
(Fax) 041 4532765 available. Each section has a contents list detailing
General Specifications, Description and Operation and
Service Adjustment and Checks.
Important Safety Instructions
If components need to be removed or disassembled in
Appropriate service methods and correct repair sequence, the sequence will be identified numerically
procedures are essential for the safe, reliable in a graphic and the corresponding text will be
operation of all motor vehicles as well as the personal numbered accordingly (refer to `Samples').
safety of the individual carrying out the work.
All left and right-hand references to the vehicle are
This manual cannot possibly anticipate all such taken from a position sitting in the driver seat looking
variations and provide advice or cautions as to each. forward.
Anyone who departs from the instructions provided in
All left and right-hand references to the engine are
this manual must first establish that he compromises
taken from a position at the flywheel looking towards
neither his personal safety nor the vehicle integrity by
the front camshaft pulley.
his choice of methods, tools or parts.
Where appropriate, instructions will be given for the
use of WDS, diagnostic equipment.
E849 EN 06/2001 2002 Bantam

FORD BANTAM
DESCRIPTION AND OPERATION (CONTINUED)

Inspection and Verification A representative tester graphic is used for voltmeters
and ohmmeters.
Visual Inspection Charts, Symptom Charts and other
information charts (such as diagnostic routines), If multiple measurements are made in a single
supplement test procedures with technical graphic, the test leads are drawn with a solid line until
specifications, or navigate the user to a specific test the test lead splits to indicate the multiple
procedure. measurements, at which point dashed lines are used.
Sympton Chart Breakout box-type testers are represented by a double
circle test pin. Test pins are labelled with the pin
The symptom chart indicates symptoms, sources and
number.
actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are used to Samples
identify the source of a concern in a logical, step-by- Special Tools and Torque Figures
step manner. Pinpoint tests have two columns:
CONDITIONS and DETAILS/RESULTS/ACTIONS. Any requirement for special tools will picture the tool,
showing it in use and with its tool number shown.
The CONDITIONS column is used exclusively for Torque settings will be given at the relevant point in
graphics and icons (with or without captions) and the the procedure.
DETAILS/RESULTS/ACTIONS column provides
direction to another test step or specific corrective
actions.
The boxed numbers indicate the order in which the
described action is to be performed.
Component Tests
A component test is used when a component is tested
in multiple pinpoint tests, or if a procedure is too
complicated to be formatted within a single page of the
pinpoint test.
Graphics
Test graphics show the measurement or test to be
performed in a test step.
E849 EN 06/2001 2002 Bantam


Health and Safety Precautions
this will lead to the risk of exposure to Sodium Azide. If
Introduction a gas generator is ruptured, full protective clothing
Many of the procedures associated with vehicle should be worn when dealing with the spillage.
maintenance and repair involve physical hazards or After normal deployment, gloves and safety goggles
other risks to health. This subsection lists, should be worn during the handling process.
alphabetically, some of these hazardous operations
and the materials and equipment associated with Deployed air bags should be disposed of in a plastic
them. Precautions necessary to avoid these hazards bag in accordance with local regulations at an
are identified. approved chemical waste site.
The list is not exhaustive and all operations and Following any direct contact with gas generant.
procedures, and the handling of materials, should be • wash affected areas thoroughly with water.
carried out with health and safety in mind.
• seek medical assistance if necessary.
Before using any product the Materials Safety Data
Air Bags - Do's
Sheet supplied by the manufacturer or supplier should
be consulted. • do store modules in an upright position.
• do keep modules dry.
Acids and Alkalis • do carry modules with the cover side pointing
away from the body.
See also Battery Acids.
• do place modules with their cover side upwards.
For example caustic soda, sulphuric acid. • do carefully inspect modules for damage.
Used in batteries and cleaning materials. • do stand to one side when connecting modules.
Irritant and corrosive to the skin, eyes, nose and • do make sure all test equipment is properly
throat. Cause burns. Can destroy ordinary protective calibrated and maintained.
clothing. • do wash hands after handling deployed air bags.
Avoid splashes to the skin, eyes and clothing. Wear Air Bags - Do Nots
suitable protective impervious apron, gloves and
• do not store highly flammable material together
goggles. Do not breath mists.
with modules or gas generators.
Make sure access to eye wash bottles, shower and • do not store gas generators at temperatures
soap are readily available for splashing accidents. exceeding 80°C.
Display Eye Hazard sign. • do not store modules upside down.
• do not attempt to open a gas generator housing.
• do not expose gas generators to open flame or
Air Bags
sources of heat.
See also Fire, Chemical Materials • do not place anything on top of a module cover.
Highly flammable, explosive – observe No Smoking • do not use damaged modules.
policy. • do not touch a fired module or gas generator for at
Used as a safety restraint system mounted in the least 10 minutes.
steering wheel and passenger side of the instrument • do not use any electrical probes on the wiring
panel. circuit.
The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS Air Conditioning Refrigerant
(2500°C). See also Chlorofluorocarbon, Chemical Materials
The gas generant used in air bags is Sodium Azide. Highly flammable, combustible – observe No Smoking
This material is hermetically sealed in the module and policy.
is completely consumed during deployment. No
attempt should be made to open an air bag inflator as Skin contact may result in frostbite.
E850 EN 02/2001 2002 Bantam


Instructions given by the manufacturer must be Use appropriate protective clothing and a
followed. Avoid naked lights; wear suitable protective thermostatically controlled heater with a thermal cut-
gloves and goggles. out and adequate extraction.
If refrigerant comes into contact with the skin or eyes, Resin-based Adhesives/Sealers, for example
rinse the affected areas with water immediately. Eyes
Epoxide and Formaldehyde Resin-based
should also be rinsed with an appropriate irrigation
solution and should not be rubbed. SEEK MEDICAL Mixing should be carried out in well-ventilated areas,
ASSISTANCE IF NECESSARY. as harmful or toxic volatile chemicals may be
released.
Air Conditioning Refrigerant - Do Nots
Skin contact with uncured resins and hardeners can
• do not expose refrigerant bottles to sunlight or result in irritation, dermatitis, and absorption of toxic or
heat. harmful chemicals through the skin. Splashes can
• do not stand refrigerant bottles upright; when damage the eyes.
filling, hold them with the valve downwards. Provide adequate ventilation and avoid skin and eye
• do not expose refrigerant bottles to frost. contact.
• do not drop refrigerant bottles.
• do not vent refrigerant to atmosphere under any Anaerobic, Cyanoacrylate (super-glues) and other
circumstance. Acrylic Adhesives
• do not mix refrigerants, for example R12 (Freon)
Many are irritant, sensitising or harmful to the skin and
and R134a.
respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the
Adhesives and Sealers manufacturers instructions followed.
See also Fire, Chemical Materials Cyanoacrylate adhesives (super-glues) MUST NOT
contact the skin or eyes. If skin or eye tissue is
Highly flammable, flammable, combustible – observe bonded, cover with a clean moist pad and SEEK
No Smoking policy. IMMEDIATE MEDICAL ATTENTION. Do not attempt
Generally should be stored in No Smoking areas. to pull tissue apart. Use in well ventilated areas as
Cleanliness and tidiness in use should be observed, vapours can cause irritation to the nose and eyes.
for example disposable paper covering benches; For two-pack systems
should be dispensed from applicators where possible; see Resin-based and Isocyanate Adhesives/Sealers.(BELOW)
containers, including secondary containers, should be
labelled appropriately.
Isocyanate (Polyurethane) Adhesives/Sealers
Solvent-based Adhesives/Sealers - See Solvents See also Resin-based Adhesives
Follow manufacturers instructions. Individuals suffering from asthma or respiratory

allergies should not work with or near these materials
as sensitivity reactions can occur.
Water-based Adhesives/Sealers
Over exposure is irritating to the eyes and respiratory
Those based on polymer emulsions and rubber system. Excessive concentrations may produce
latexes may contain small amounts of volatile toxic effects on the nervous system including drowsiness. In
and harmful chemicals. Skin and eye contact should extreme cases, loss of consciousness may result.
be avoided and adequate ventilation provided during Long-term exposure to vapour concentrations may
use. result in adverse health effects.
Prolonged contact with the skin may have a defatting
Hot Melt Adhesives effect which may lead to skin irritation and in some
cases, dermatitis.
In the solid state, they are safe. In the molten state
they may cause burns and health hazards may arise Splashes entering the eye will cause discomfort and
from the inhalation of toxic fumes. possible damage.
E850 EN 02/2001 2002 Bantam


Any spraying should preferably be carried out in Brake and Clutch Linings and Pads
exhaust-ventilated booths, removing vapours and
See Asbestos.
spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory Brakes Fluids (Polyalkylene Glycols)
protection.
See also Fire.
Splashes to the skin and eyes are slightly irritating.
Antifreeze Avoid skin and eye contact as far as possible.
See also Fire, Solvents. Inhalation vapour hazards do not arise at ambient
temperatures because of the very low vapour
For example isopropanol, ethylene glycol, methanol. pressure.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure Brazing
systems, screen wash solutions.
See Welding.
Vapours may be given off from coolant antifreeze
(glycol) when heated. Avoid breathing these vapours.
Chemical Materials
Antifreeze may be absorbed through the skin in toxic
See also Legal Aspects.
or harmful quantities. Antifreeze, if swallowed, can be
fatal and MEDICAL ATTENTION SHOULD BE Chemical materials such as solvents, sealers,
SOUGHT IMMEDIATELY. adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease should
These products must not be used in any cooling or
always be used with caution and stored and handled
industrial water system, which is connected or linked
with care. They may be toxic, harmful, corrosive,
to general, food preparation or drinking water supplies.
irritant or highly flammable and give rise to hazardous
fumes and dusts.
Asbestos The effects of excessive exposure to chemicals may
be immediate or delayed; briefly experienced or
See also Warning Symbols on Vehicles
permanent; cumulative; superficial; life threatening; or
at the end of this subsection.
may reduce life expectancy.
Breathing asbestos dust may cause lung damage or,
in some cases, cancer.
Chemical Materials - Do's
Used in brake and clutch linings, transmission brake
bands and gaskets. Ford original production and • Do carefully read and observe hazard and
replacement items for this model are asbestos free. precaution warnings given on material containers
(labels) and in any accompanying leaflets, posters
The use of drum cleaning units, vacuum cleaning or or other instructions. Material health and safety
damp wiping is preferred. data sheets can be obtained from manufacturers.
Asbestos dust waste should be dampened, placed in a • Do remove chemical materials from the skin and
sealed container and marked for safe disposal. If any clothing as soon as practicable after soiling.
cutting or drilling is attempted on materials containing Change heavily soiled clothing and have it
asbestos the item should be dampened and only hand cleaned.
tools or low speed power tools used. • Do organise work practices and protective clothing
to avoid soiling of the skin and eyes; breathing
vapours, aerosols, dusts or fumes; inadequate
Battery Acids container labelling; fire and explosion hazards.
See also Acids and Alkalis. • Do wash before job breaks, before eating,
smoking, drinking or using toilet facilities when
Gases released during charging are explosive. Never
handling chemical materials.
use naked flames or allow sparks near charging or
recently charged batteries. • Do keep work areas clean, uncluttered and free of
spills.
Make sure there is adequate ventilation.
E850 EN 02/2001 2002 Bantam


• Do store chemical materials according to national affiliates should phase out CFC usage as soon as
and local regulations. acceptable substitutes are commercially available.
• Do keep chemical materials out of the reach of
children.
Clutch Fluids
Chemical Materials - Do Nots See Brake fluids.
• Do not mix chemical materials except under the
manufacturers instructions; some chemicals can
form other toxic or harmful chemicals, give off Clutch Linings and Pads
toxic or harmful fumes or become explosive when
See Asbestos.
mixed together.
• Do not spray chemical materials, particularly those
based on solvents, in confined spaces, for Corrosion Protection Materials
example when people are inside a vehicle.
See also Solvents, Fire.
• Do not apply heat or flame to chemical materials
except under the manufacturers instructions. Highly flammable, flammable – observe No Smoking
Some are highly flammable and some may policy.
release toxic or harmful fumes.
These materials are varied and the manufacturers
• Do not leave containers open. Fumes given off instructions should be followed. They may contain
can build up to toxic, harmful or explosive solvents, resins or petroleum products. Skin and eye
concentrations. Some fumes are heavier than air contact should be avoided. They should only be
and will accumulate in confined areas such as sprayed in conditions of adequate ventilation and not
pits. in confined spaces.
• Do not transfer chemical materials to unlabelled
containers. Cutting
• Do not clean hands or clothing with chemicals. See Welding.
Chemicals, particularly solvents and fuels, will dry
skin and may cause irritation leading to dermatitis
or be absorbed through the skin in toxic or harmful
Dewaxing
quantities.
• Do not use emptied containers for other materials See Solvents and Fuels (Kerosene).
except when they have been cleaned under
supervised conditions.
Dusts
• Do not sniff or smell chemical materials. Brief
exposure to high concentrations of fumes can be Powder, dusts or clouds may be irritant, harmful or
toxic or harmful. toxic. Avoid breathing dusts from powdery chemical
materials or those arising from dry abrasion
operations. Wear respiratory protection if ventilation is
Chlorofluorocarbons (CFC)
inadequate.
There is concern in the scientific community that CFCs
Fine dusts of combustible material can present an
and Halons are depleting the upper ozone layer, which
explosion hazard. Avoid explosive limits and sources
filters out harmful ultraviolet radiation. Decreased
of ignition.
filtration of ultraviolet radiation may result in increases
in skin cancer, cataracts and immune system
suppression in humans, as well as decreased
Electric Shock
productivity of crops and aquatic systems.
Electric shock can result from the use of faulty
CFCs are used primarily as refrigerants in vehicle air
electrical equipment or from the misuse of equipment
conditioning systems and as aerosol propellants.
in good condition.
Halons are used as fire extinguishants.
Make sure that electrical equipment is maintained in
Ford supports worldwide elimination of CFC usage
good condition and frequently tested. Faulty
and it is recommended that Company subsidiaries and
E850 EN 02/2001 2002 Bantam


equipment should be labelled and preferably removed Fibre Insulation
from the workstation.
See also Dusts.
Make sure that flexes, cables, plugs and sockets are
Used in noise and sound insulation.
not frayed, kinked, cut, cracked or otherwise
damaged. The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and not
Make sure that electrical equipment and flexes do not
a chemical effect.
come into contact with water.
Precautions should be taken to avoid excessive skin
Make sure that electrical equipment is protected by
contact through careful organization of work practices
the correct rated fuse.
and the use of gloves.
Never misuse electrical equipment and never use
equipment, which is in any way faulty. The results
could be fatal. Fire
Make sure that the cables of mobile electrical See also Welding, Foams, Legal Aspects.
equipment cannot get trapped and damaged, such as
Many of the materials found on or associated with the
in a vehicle hoist.
repair of vehicles are highly flammable. Some give off
Make sure that the designated electrical workers are toxic or harmful fumes if burnt.
trained in basic First Aid.
Observe strict fire safety when storing and handling
In cases of electrocution: flammable materials or solvents, particularly near
• switch off the power supply before approaching electrical equipment or welding processes.
the victim. Make sure, before using electrical or welding
• if this is not possible push or drag the victim from equipment, that there is no fire hazard present.
the source of electricity using dry non-conductive Have a suitable fire extinguisher available when using
material. welding or heating equipment.
• commence resuscitation if trained to do so.
• SUMMON MEDICAL ASSISTANCE. First Aid
Apart from meeting any legal requirements it is
Engine Oils desirable for someone in the workshop to be trained in
First Aid procedures.
See Lubricants and Greases.
Splashes in the eye should be flushed carefully with
clean water for at least ten minutes.
Exhaust Fumes
Soiled skin should be washed with soap and water.
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides, In case of cold burns, from alternative fuels, place
nitrogen oxides, aldehydes, lead and aromatic affected area in cool to cold water.
hydrocarbons. Engines should be run only under Individuals affected by inhalation of gases and fumes
conditions of adequate exhaust extraction or general should be removed to fresh air immediately. If effects
ventilation and not in confined spaces. persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor
Gasolene (petrol) engine giving him the information on the container or label.
There may not be adequate warning of odour or of Do not induce vomiting unless this action is indicated
irritation before toxic or harmful effects arise. These on the label.
may be immediate or delayed.
Fluoroelastomer
Diesel engine
See Viton.
Soot, discomfort and irritation usually give adequate
warning of hazardous fume concentrations.
E850 EN 02/2001 2002 Bantam


Foams - Polyurethane
Gasolene dries the skin and can cause irritation and
See also Fire. dermatitis on prolonged or repeated contact. Liquid in
Used in sound and noise insulation. Cured foams the eye causes severe smarting.
used in seat and trim cushioning. Motor gasolene may contain appreciable quantities of
Follow manufacturers instructions. benzene, which is toxic upon inhalation, and the
concentration of gasolene vapours must be kept very
Unreacted components are irritating and may be low. High concentrations will cause eye, nose and
harmful to the skin and eyes. Wear gloves and throat irritation, nausea, headache, depression and
goggles. symptoms of drunkenness. Very high concentrations
Individuals with chronic respiratory diseases, asthma, will result in rapid loss of consciousness.
bronchial medical problems, or histories of allergic Make sure there is adequate ventilation when handling
diseases should not work in or near uncured and using gasolene. Great care must be taken to
materials. avoid the serious consequences of inhalation in the
The components, vapours or spray mists can cause event of vapour build up arising from spillages in
direct irritation, sensitivity reactions and may be toxic confined spaces.
or harmful. Special precautions apply to cleaning and
Vapours and spray mists must not be inhaled. These maintenance operations on gasolene storage tanks.
materials must be applied with adequate ventilation Gasolene should not be used as a cleaning agent. It
and respiratory protection. Do not remove the must not be siphoned by mouth. See First Aid.
respirator immediately after spraying; wait until the
vapour/mists have cleared. Gas-oil (Diesel Fuel)
Burning of the uncured components and the cured Combustible.
foams can generate toxic and harmful fumes.
Gross or prolonged skin contact with high boiling point
Smoking, naked flames or the use of electrical
gas oils may also cause serious skin disorders
equipment during foaming operations and until
including skin cancer.
vapours/mists have cleared should not be allowed.
Any heat cutting of cured foams or partially cured
foams should be conducted with extraction ventilation. Kerosene (Paraffin)
See also the vehicle Body Repair Manual.
Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Freon
Irritation of the mouth and throat may result from
See Air Conditioning Refrigerant. swallowing. The main hazard from swallowing arises if
liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or
Fuels
dermatitis. Splashes in the eye may be slightly
See also, Fire, Legal Aspects, Chemicals and irritating.
Solvents.
In normal circumstances the low volatility does not
Avoid skin contact with fuel where possible. Should give rise to harmful vapours. Exposure to mists and
contact occur, wash the affected skin with soap and vapours from kerosene at elevated temperature
water. should be avoided (mists may arise in dewaxing).
Avoid skin and eye contact and make sure there is
adequate ventilation.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy. Alternative Fuel
Swallowing can result in mouth and throat irritation Highly flammable. Observe ``NO SMOKING" signs.
and absorption from the stomach can result in Make sure there is adequate ventilation when working
drowsiness and unconsciousness. Small amounts can on alternative fuelled vehicles. Great care must be
be fatal to children. Aspiration of liquid into the lungs, taken to avoid the serious consequences of inhalation
through vomiting, is a very serious hazard. in the event of vapour build up in confined spaces.
E850 EN 02/2001 2002 Bantam


General Workshop Tools and Equipment
Inhalation in high concentrations may cause dizziness,
headache, nausea and loss of co-ordination. Very high It is essential that all tools and equipment are
concentrations may result in loss of consciousness. maintained in good condition and the correct safety
equipment is used where required.
Contact with liquidified petroleum gas (LPG) or
compressed natural gas (CNG) to skin may cause Never use tools or equipment for any purpose other
cold burns and may cause frostbite. than that for which they were designed. Never
overload equipment such as hoists, jacks, axle and
Long sleeved cotton overalls, steel toe capped safety
chassis stands or lifting slings. Damage caused by
boots and rubber neoprene gloves should be worn
overloading is not always immediately apparent and
during removal and installation of LPG/CNG fuel
may result in a fatal failure the next time that the
system components.
equipment is used.
LPG/CNG fuel leaks could cause a fire and be a
Do not use damaged or defective tools or equipment,
hazard to health that can lead to personal injury,
particularly high-speed equipment such as grinding
illness or even death.
wheels. A damaged grinding wheel can disintegrate
If a leak is detected, under no circumstances attempt without warning and cause serious injury.
to seal the leak by tightening the union/connection
Wear suitable eye protection when using grinding,
until the fuel in the system or component is
chiselling or sand blasting equipment.
depressurised. Once tightened the system should be
checked for integrity following the specified Wear a suitable breathing mask when using abrasive
procedures. blasting equipment, working with asbestos-based
materials or using spraying equipment.
If the fuel tank is to be removed for service or repair
the fuel must be evacuated using dedicated Make sure there is adequate ventilation to control
equipment and following the specified procedures. dusts, mists and fumes.
Gas Cylinders
High Pressure Air, Lubrication and Oil Test
See also Fire. Equipment
Gases such as oxygen, acetylene, argon and propane See also Lubricants and Greases.
are normally stored in cylinders at pressures of up to
Always keep high-pressure equipment in good
138 bar (2000 psi) and great care should be taken in
condition, and regularly maintained, particularly at
handling these cylinders to avoid mechanical damage
joints and unions.
to them or to the valve gear attached. The contents of
each cylinder should be clearly identified by Never direct a high-pressure nozzle, for example
appropriate markings. diesel injector, at the skin as the fluid may penetrate to
the underlying tissue, and cause serious injury.
Cylinders should be stored in well-ventilated
enclosures, and protected from ice and snow, or direct
sunlight. Fuel gases, for example acetylene and
Halon
propane, should not be stored in close proximity to
oxygen cylinders. See CFCs.
Care should be exercised to prevent leaks from gas
cylinders and lines, and to avoid sources of ignition.
Legal Aspects
Only trained personnel should undertake work
involving gas cylinders. There are many laws and regulations relating to health
and safety in the use and disposal of materials and
equipment in a workshop.
Gases For a safe working environment and to avoid
See Gas Cylinders. environmental pollution, workshops should be familiar,
in detail, with the many health and safety laws and
regulations within their country, published by both
national and local authorities.
Gaskets (Fluoroelastomer)
See Viton.
E850 EN 02/2001 2002 Bantam


Lubricants and Greases Environmental Precautions
Avoid all prolonged and repeated contact with mineral Burning used engine oil in small space heaters or
oils. All lubricants and greases may be irritating to the boilers can be recommended only for units of
eyes and skin. approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
Used Engine Oil
Dispose of used oil and used oil filters through
Prolonged and repeated contact with mineral oil will authorized waste disposal contractors or licensed
result in the removal of natural fats from the skin, waste disposal sites, or to the waste oil reclamation
leading to dryness, irritation and dermatitis. In trade. If in doubt, contact the relevant local authority
addition, used engine oil contains potentially harmful for advice on disposal facilities.
contaminants, which may cause skin cancer.
Adequate means of skin protection and washing It is illegal to pour used oil on to the ground, down
facilities must be provided. sewers or drains, or into water courses.
Do not employ used engine oils as lubricants or for

any application where appreciable skin contact is likely Noise
to occur.
Some operations may produce high noise levels,
which could, in time, damage hearing. In these cases,
Health Protection Precautions suitable ear protection must be worn.
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Noise Insulation Materials
• Wear protective clothing, including impervious
gloves where practicable. See Foams, Fibre Insulation.
• Do not put oily rags into pockets.
• Avoid contaminating clothes, particularly
underpants, with oil. O-Rings (Fluoroelastomer)
• Heavily soiled clothing and oil-impregnated See Viton.
footwear should not be worn. Overalls must be
cleaned regularly. Paints
• First Aid treatment should be obtained See also Solvents, Chemical Materials.
immediately for open cuts and wounds.
Highly flammable, flammable - observe No Smoking
• Use barrier creams, applying them before each
policy
work period, to help the removal of oil from the
skin.
• Wash with soap and water to make sure all oil is One Pack
removed (skin cleansers and nail brushes will Can contain harmful or toxic pigments, driers and
help). Preparations containing lanoline replace the other components as well as solvents. Spraying
natural skin oils, which have been removed. should be carried out only with adequate ventilation.
• Do not use gasolene (petrol), kerosene (paraffin),
diesel fuel (gas oil), thinners or solvents for
cleaning skin. Two Pack
• If skin disorders develop, obtain medical advice Can also contain harmful and toxic unreacted resins
without delay. and resin hardening agents. The manufacturers instructions
• Where practicable, degrease components prior to should be followed. See also Resin-based Adhesives
handling. and Isocyanate Adhesives and Sealers
under Adhesives and Sealers.
• Where there is a risk of eye contact, eye
protection should be worn, for example chemical Spraying should preferably be carried out in
goggles or face shields; in addition an eye wash exhausted ventilated booths removing vapour and
facility should be provided. spray mists from the breathing zone. Individuals
working in booths should wear appropriate respiratory
E850 EN 02/2001 2002 Bantam


protection. Those doing small scale repair work in the Repeated or prolonged exposure to excessive but
open workshop should wear air-fed respirators. lower concentrations of vapours or mists, for which
there might not be adequate warning indications, can
Pressurized Equipment cause more serious toxic or harmful effects.
See High Pressure Air, Lubrication Aspiration into the lungs, for example through
and Oil Test Equipment. vomiting, is the most serious consequence of
swallowing.
Solder Avoid splashes to the skin, eyes and clothing. Wear
protective gloves, goggles and clothing if necessary.
Solders are mixtures of metals such that the melting
point of the mixture is below that of the constituent Make sure there is good ventilation when in use, avoid
metals (normally lead and tin). Solder application does breathing fumes, vapours and spray mists and keep
not normally give rise to toxic lead fumes, provided a containers tightly sealed. Do not use in confined
gas/air flame is used. Oxy-acetylene flames should spaces.
not be used, as they are much hotter and will cause
When spraying materials containing solvents, for
lead fumes to be produced.
example paints, adhesive, coatings, use extraction
Some fumes may be produced by the application of ventilation or personal respiratory protection in the
any flame to surfaces coated with grease, and absence of adequate general ventilation.
inhalation of these should be avoided.
Do not apply heat or flame except under specific and
Removal of excess solder should be undertaken with detailed manufacturers instructions.
care, to make sure that fine lead dust is not produced,
which can give toxic effects if inhaled. Respiratory
protection may be necessary. Sound Insulation
Solder spillage and filings should be collected and See Fibre Insulation, Foams.
removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary in Suspended Loads
order to avoid ingestion of lead or inhalation of solder
CAUTION: Never improvise lifting tackle.
dust from clothing.
There is always a danger when loads are lifted or
suspended. Never work under an unsupported,
Solvents suspended or raised load, for example a suspended
engine.
See also Chemical Materials, Fuels (Kerosene), Fire.
Always make sure that lifting equipment such as jacks,
For example acetone, white spirit, toluene, xylene, hoists, axle stands and slings are adequate and
trichloroethane. suitable for the job, in good condition and regularly
Used in cleaning and dewaxing materials, paints, maintained.
plastics, resins and thinners.
Transmission Brake Bands
Some may be highly flammable or flammable.
See Asbestos.
Skin contact will degrease the skin and may result in
irritation and dermatitis following repeated or
Underseal
prolonged contact. Some can be absorbed through the
skin in toxic or harmful quantities. See Corrosion Protection.
Splashes in the eye may cause severe irritation and
could lead to loss of vision.
Viton
Brief exposure of high concentrations of vapours or
mists will cause eye and throat irritation, drowsiness, In common with many other manufacturers vehicles,
dizziness, headaches and, in the worst circumstances, some components fitted to the Ford range have O-
unconsciousness. rings, seals or gaskets, which contain a material
known as `Viton'.
E850 EN 02/2001 2002 Bantam


Viton is a fluoroelastomer that is a synthetic rubber welding processes are particularly hazardous in this
type, which contains Fluorine. It is commonly used for respect. Personal protection must be worn, and
O-rings, gaskets and seals of all types. Although Viton screens used to shield other people.
is the most well known fluoroelastomer, there are
CONTACT LENS WEARERS ARE ADVISED TO
others, including Fluorel and Tecmoflon.
REVERT TO ORDINARY SPECTACLES WHEN ARC
When used under design conditions fluoroelastomers WELDING as the arc spectrum is believed to emit
are perfectly safe. If, however, they are exposed to microwaves which dry out the fluid between the lens
temperatures in excess of 400°C, the material will not and the eye. This may result in blindness when the
burn, but will decompose, and one of the products lens is removed from the eye.
formed is hydrofluoric acid.
Metal spatter will also occur, and appropriate eye and
This acid is extremely corrosive and may be absorbed skin protection is necessary.
directly, through contact, into the general body
The heat of the welding arc will produce fumes and
system.
gases from the metals being welded, the rods and
O-rings, seals or gaskets which have been exposed to from any applied coatings or contamination on the
very high temperatures will appear charred or as a surfaces being worked on. These gases and fumes
black sticky substance. may be toxic and inhalation of these should be
avoided. The use of extraction ventilation to remove
DO NOT; under any circumstances touch them or the
the fumes from the working area may be necessary
attached components.
particularly in cases where the general ventilation is
Enquiries should be made to determine whether Viton poor, or where considerable welding work is
or any other fluoroelastomer has been used in the anticipated. In extreme cases or confined spaces
affected O-ring, seal or gasket. If they are of natural where adequate ventilation cannot be provided, air-fed
rubber or nitrile there is no hazard. If in doubt, be respirators may be necessary.
cautious, as the material may be Viton or any
fluoroelastomer.
Gas Welding (and Cutting)
If Viton or any other fluoroelastomers have been used,
the affected area should be decontaminated before Oxy-acetylene torches may be used for welding and
the commencement of work. cutting, and special care must be taken to prevent
leakage of these gases, with consequent risk of fire
Disposable heavy duty plastic gloves should be worn and explosion.
at all times, and the affected area washed down using
wire wool and a limewater (calcium hydroxide) solution The process will produce metal spatter and eye and
to neutralise the acid before disposing of the skin protection is necessary.
decomposed Viton residue and final cleaning of the The flame is bright, and eye protection should be
area. After use, the plastic gloves should be discarded used, but the ultra-violet emission is much less than
carefully and safely. that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such
fumes and gases may be produced from coatings on
Welding
the work, particularly during cutting away of damaged
See also Fire, Electric Shock, Gas Cylinders. body parts, and inhalation of the fumes should be
Welding processes include Resistance Welding (Spot avoided.
Welding), Arc Welding and Gas Welding. In brazing, toxic fumes may be produced from the
metals in the brazing rod, and a severe hazard may
arise if brazing rods containing cadmium are used. In
Resistance Welding
this event particular care must be taken to avoid
This process may cause particles of molten metal to inhalation of fumes and expert advice may be
be emitted at a high velocity, and the eyes and skin required.
must be protected.
SPECIAL PRECAUTIONS MUST BE TAKEN
BEFORE ANY WELDING OR CUTTING TAKES
Arc Welding PLACE ON VESSELS, WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, FOR EXAMPLE
This process emits a high level of ultra-violet radiation, BOILING OR STEAMING OUT OF FUEL TANKS.
which may cause arc-eye, and skin burns to the
operator and to other persons nearby. Gas-shielded
E850 EN 02/2001 2002 Bantam


Warning Symbols on Vehicles
Decals showing warning symbols will be found on
various vehicle components.
These decals must not be removed. The warnings are
for the attention of owners/operators and persons
carrying out service or repair operations on the
vehicle.
The most commonly found decals are reproduced
below together with an explanation of the warnings.
3. Ford vehicles and replacement parts, which

contain asbestos, are identified by this symbol.
See Asbestos in this subsection.
1. Components or assemblies displaying the caution

triangle and open book symbol advise
consultation of the relevant section of the owners
handbook before touching or attempting
adjustments of any kind.
4. Components or assemblies displaying this symbol

give warning that the component contains a
corrosive substance.
See Acids and Alkalis in this subsection.
2. Components or assemblies displaying the

warning triangle with the èlectrified' arrow and
open book symbol give warning of inherent high
voltages. Never touch these with the engine
running or the ignition switched on.
See Electric Shock in this subsection. 5. Displaying the caution circle with a deleted lighted
match symbol, caution against the use of naked
lights or flames within the immediate vicinity due
to the presence of highly flammable or explosive
liquids or vapours. See Fire in this subsection.
E850 EN 02/2001 2002 Bantam

6. Displaying this symbol (normally in conjunction 7. Displaying this symbol warn that children should
with 5 above) warn of the presence of potentially not be allowed in the immediate vicinity
explosive matter within the immediate vicinity. unsupervised.
White Spirit
See Solvents.
E850 EN 02/2001 2002 Bantam


Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always Alternative Fuel — Do's
make sure that:
• do work on the vehicle in a designated area that is
• the parking brake is applied or the wheels are well ventilated and its access restricted to
securely chocked to prevent the vehicle moving qualified personnel only
forwards or backwards. • install new warning labels to their original
• the key is removed from key operated hood locks locations
before any work is carried out around the front of • if possible always isolate the alternative fuel tank,
the vehicle. run the vehicle on the alternative fuel until it
• if the engine is to be run, there is adequate automatically switches to its normal fuel prior to
ventilation, or an extraction hose to remove taking the vehicle into the workshop/service area
exhaust fumes. • only use tested and approved components and
• there is adequate room to raise the vehicle and pipes when repairing or servicing LPG and CNG
remove the wheels, if necessary. systems
• fender covers are always fitted if any work is to be
carried out in the engine compartment.
• the battery is disconnected if working on the Alternative Fuel — Do Nots
engine, underneath the vehicle, or if the vehicle is • do not vent off LPG fuel
raised. • do not use shop air pressure to force LPG fuel
CAUTION: When electric arc welding on a from the fuel tank
vehicle, always disconnect the generator • do not use paint drying ovens above 40°C for any
wiring to prevent the possibility of a surge of alternative fuel vehicles. LPG and CNG fuel tanks
current causing damage to the internal should be removed from the vehicles prior to
components of the generator. being put into paint drying ovens above 40°C
• If using welding equipment on the vehicle, a • do not modify the system or install new
suitable fire extinguisher is readily available. components with parts not designed for gas
vehicles
• do not evacuate fuel tanks unless there is repair
Alternative Fuel that requires removed of the fuel tank
• do not work on the fuel lines or system
WARNING: When servicing the fuel system
components unless the alternative fuel has been
always follow the recommended procedures.
evacuated and the pressure in the system is
Failure to follow these instructions may
reduced to atmospheric, or less
result in personal injury.
• do not use anything other than the specified leak
If the odour of liquefied petroleum gas (LPG) or detector fluid to trace fuel leaks
compressed natural gas (CNG) is present in the air in
the workshop, warn all persons in the area to: Be aware of situations that may cause the LPG or
CNG fuel system to vent off fuel, such as:
• extinguish all flames and lighted tobacco.
• extremely hot days
• shut off electrical and air-powered equipment.
• parking by a space heater
• evacuate the area.
• hoisting a vehicle up near a ceiling heater
• ventilate the area.
• contact fire control authorities. Only personnel fully trained to Ford and local
standards are to work on alternative fuel vehicles.
• remove the vehicle to a dedicated, ventilated area.
E4251 EN 02/2001 2002 Bantam


Towing the Vehicle
recharged immediately after jump-starting to
WARNING: When the vehicle is being towed
avoid permanent damage.
the ignition switch must be in position II
(steering lock released and warning lights • Always make sure that the jumper cables are
illuminated). Only then will the steering, turn adequate for the task. Heavy duty cables must be
signal lamps, horn and stop lamps be used.
operational. Failure to follow these • Always make sure that the slave battery is of the
instructions may result in personal injury. same voltage as the vehicle battery. The batteries
NOTE: The removable towing eye (if equipped) has a must be connected in parallel.
left-hand thread and must be fully tightened before • Always make sure that switchable electric circuits
towing can commence. are switched off before connecting jumper cables.
This reduces the risk of arcing occurring when the
When towing is necessary, the vehicle towing eyes
final connection is made.
should be used. The rope must be securely fastened
to the towing eyes and must also be attached to the
other vehicle such that the rope will not foul the
bodywork.
When a vehicle with automatic transmission is towed,
the gear selector must be in position N (Neutral).
Never tow a vehicle with automatic transmission faster
than 30 mph (50 km/h) or further than 30 miles (50
km). If it is necessary to tow the vehicle a greater
distance, the drive wheels must be lifted clear off the
ground.
Alternatively the vehicle can be transported on a low
loader or a trailer.
WARNING: Make sure that the ends of the
jumper cables do not touch each other or
Connecting a Slave Battery Using Jumper Cables ground against the vehicle body at any time
while the cables are attached to the battery.
WARNING: If the slave battery has recently A fully charged battery, if shorted through
been charged and is gassing, cover the vent jumper cables, can discharge at a rate well
plugs or covers with a damp cloth to reduce above 1000 amps causing violent arcing and
the risk of explosion should arcing occur very rapid heating of the jumper cables and
when connecting the jumper cables. Failure terminals, and can even cause the battery to
to follow these instructions may result in explode. Failure to follow these instructions
personal injury. may result in personal injury.
CAUTION: A discharged battery condition Always connect the jumper cables in the following
may have been caused by an electrical short sequence:
circuit. If this condition exists there will be an • slave battery positive first then vehicle battery
apparently live circuit on the vehicle even positive
when all normal circuits are switched off.
• slave battery negative next and then vehicle
This can cause arcing when the jumper
ground at least 12 inches (300 mm) from the
cables are connected.
battery terminal, for example engine lifting eye
CAUTION: While it is not recommended that Always reduce the engine speed to idle before
the vehicle is jump started, it is recognized disconnecting the jumper cables.
that this may occasionally be the only
practical way to mobilize a vehicle. In such Before removing the jumper cables from the vehicle
an instance the discharged battery must be that had the discharged battery, switch on the heater
blower (high) or the heated rear window, to reduce the
voltage peak when the cables are removed.
Always disconnect the jumper cables in the reverse
order to the connecting sequence and do not short the
ends of the cables.
E4251 EN 02/2001 2002 Bantam


Do not rely on the generator to restore a discharged • removal of dry dust using vacuum equipment. This
battery. For a generator to recharge a battery, it would method should always be used to remove friction
take in excess of eight hours continuous driving with lining material dust (asbestos particles)
no additional loads placed on the battery. • steam cleaning
Component Cleaning WARNING: Most solvents require careful

handling and some are harmful.
To prevent ingress of dirt, accumulations of loose dirt
Refer to Health and Safety Precautions
and greasy deposits should be removed before
and to the manufacturers literature for
disconnecting or dismantling components or
safety precautions. Failure to follow these
assemblies.
instructions may result in personal injury.
Components should be thoroughly cleaned before
Various solvents are available which are suitable for
inspection prior to reassembly.
component cleaning. Some components such as
brake hydraulic parts and electrical assemblies should
Cleaning Methods: be cleaned only with recommended solvents —
refer to Solvents, Sealers and Adhesives or to
• dry cleaning the section of the manual relevant to the component.
• removal of loose dirt with soft or cable brushes
• scraping dirt off with a piece of metal or wood
• wiping off with a rag Calibration of Essential Measuring Equipment
CAUTION: Compressed air is sometimes 'wet' WARNING: Failure to follow these

so use with caution, especially on hydraulic instructions may result in personal injury or
systems. damage to components.
• blowing dirt off with compressed air. (Eye It is of fundamental importance that certain essential
protection must be worn when using this method) equipment, for example torque wrenches, multimeters,
exhaust gas analysers or rolling roads, are regularly
calibrated in accordance with the manufacturers
instructions.
E4251 EN 02/2001 2002 Bantam


Solvents, Sealers and Adhesives
Introduction CAUTION: If in doubt about the suitability of
any proprietary solvent or sealer for a
WARNING: Always handle all solvents,
particular application, contact the
sealers and adhesives with extreme care.
manufacturer of the product for information
Some contain chemicals or give off fumes,
regarding storage, handling and application.
which can be dangerous to health. Always
follow the manufacturers instructions. If in The Health and Safety Precautions subsection refers
doubt about any substance, particularly a to some commonly used chemicals and materials;
solvent, DO NOT use it. hazards associated with their use, and safety
measures to be taken. Some of these chemicals may
be included in the following list either in their own right
or as an ingredient in a sealer or adhesive.
General Specifications
Anti-Seize Compound
General
SAM-1C-9107A KluberUnimoly
Spark plug threads ESE-M1244-A `Never-Seize'
Sealers
Application Ford Spec. Manufacturer and
Identification
For camshaft bearing caps ESK-M4G260-A Loctite 518
For cylinder block WSK-M4G320-A Hylosil 502
For fitting rear lamp assembly WSK-M4G329-ABC
E852 EN 02/2001 2002 Bantam


Road/Roller Testing
Road or roller testing may be carried out for various With the ignition switched on, check:
reasons and a procedure detailing pre-test checks,
• Ignition controlled warning lights come on.
through engine starting and stopping, pre-driving
checks, on-test checks to final checks on completion • Engine temperature gauge registers a reading
of the test is given overleaf. compatible with the engine temperature.
• Fuel gauge registers a reading appropriate to the
Unless complete vehicle performance is being
fuel level in the tank.
checked, the full road test procedure need not be
carried out. Instead, those items particularly relevant • The operation of the handbrake warning light and
to the system/s being checked can be extracted. fluid level warning indicator light.
Pre-Test Checks On Road or Roller Test Check:
WARNING: If the brake system hydraulic fluid CAUTION: If road testing, check the brake
level is low, pedal travel is excessive or a operation while still travelling at low speed
hydraulic leak is found, do not attempt to before continuing with the test. If the brakes
road test the vehicle until the reason for the pull to one side, or appear to be otherwise
low fluid level, excessive pedal travel or faulty, do not continue with the road test until
hydraulic leak is found and rectified. the fault has been found and rectified.
• Clutch pedal operation is not stiff or heavy.
It is suggested that pre-test checks, and functional
tests of those systems/circuits which affect the safe • Initial gear engagement is smooth and there is no
and legal operations of the vehicle, such as brakes, evidence of clutch drag.
lights and steering, should always be carried out • Handbrake control operates smoothly and the
before the road or roller test. handbrake releases quickly and completely.
• Engine oil level • Clutch takes up the drive smoothly, without slip or
judder.
• Engine coolant level
• Gear changing is smooth, and there are no
• Tires, for correct pressure, compatible types and
abnormal noises or vibrations from the
tread patterns, and wear within limits.
transmission.
• There is sufficient fuel in the tank to complete the
• The engine power output is satisfactory, full power
test.
is achieved, acceleration is smooth and pedal
• All around the engine, transmission and under the operation not stiff or heavy, and engine speed
vehicle for oil, coolant, hydraulic and fuel leaks. returns to idle correctly.
Make a note of any apparent leaks and wipe off
• There is no excessive or abnormally colored
the surrounding areas to make it easier to identify
smoke from the engine under normal driving,
the extent of the leak on completion of the test.
heavy load or overrun conditions.
• Steering operation, including power steering
Starting the Engine where fitted, is smooth, accurate, not excessively
heavy or with excessive free play or vibration.
NOTE: On initial drive away from cold and within the Does not pull to one side and self centres
first 1.5 km (1 mile), do not depress accelerator pedal smoothly after cornering.
beyond half travel until the vehicle has attained a • Speedometer, oil pressure warning lamp, coolant
minimum speed of 25 km/h (15 miles/h). Never temperature gauge and tachometer (where fitted)
operate at high engine speed or with the accelerator register the correct readings or operate correctly.
pedal at full travel whilst the engine is cold.
• Switches and controls operate smoothly and
With the ignition switched off, check: positively, warning or indicator lights operate
• The handbrake is applied. correctly and the direction indicator control self
cancels when the steering is returned to the
• The gear lever is in neutral.
straight ahead position.
• All instrument gauges (except fuel gauge) read
• Heating and ventilation systems work correctly
zero.
and effectively.
• Brake operation and efficiency.
E853 EN 02/2001 2002 Bantam


Brake Testing
WARNING: When brake testing, avoid

breathing the smoke or fumes from hot
brakes, this may contain asbestos dust
which is hazardous to health,
see Health and Safety Precautions.
Avoid brake testing on busy roads where it can cause
inconvenience or danger to other road users.
CAUTION: Brake testing, which includes

heavy brake applications should not be
carried out with new brake pads/discs or
linings/drums until the components have
bedded-in. New brake friction components
will not reach full efficiency until the
bedding-in process is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or drag,
and any undue delay in application or release.
Allow the vehicle to coast and note any tendency to
pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature. A disc, which feels hot, or appreciably
hotter than the others, indicates that the brake is
binding.
After completion of the test, check for:
• Oil, coolant, hydraulic, air and fuel leaks.
• Abnormal temperature of any moving components
or assemblies, e.g. wheel hubs, transmission, axle
etc., which might indicate over tightness or lack of
lubrication.
E853 EN 02/2001 2002 Bantam

100-01-25 Identification Codes 100-01-25
SECTION 100-01 Identification Codes

SUBJECT PAGE
Identification Codes ............................................................................................................. 100-01-26

Vehicle Identification Number (VIN) .................................................................................. 100-01-26/27
World manufacturer........................................................................................................... 100-01-27
Year of manufacture.......................................................................................................... 100-01-27
Month of manufacture ....................................................................................................... 100-01-28
Vehicle certification or Vehicle identification plate (Vin)..................................................... 100-01-29
Body colour code .............................................................................................................. 100-01-30
Interior trim code ............................................................................................................... 100-01-30
E5827 EN 06/2001 2002 Bantam


Identification Codes
Vehicle Identification Number (VIN)
NOTE: The vehicle identification number (VIN) The codes stamped on the plate during
can be identified by an asterisk at its start and production enable precise details of the vehicle
finish. build specification to be established.
The vehicle identification plate is located in the The Vehicle Identification Number (VIN) may also
engine compartment on the front body be checked through the windshield.
crossmember.
E5827 EN 06/2001 2002 Bantam


Vehicle Identification Number
AFA ACMC41 AR 1 0 0 6 5 7
1 3
Item Description Item Description

1 World manufacturer identifier code 3 Sequential chassis number
2 Model code
VIN Position 1
Code World Manufacturer
AFA Ford Motor Company of Southern Africa (PTY) Limited
Year of Manufacture
Code Year of manufacture
A 2001
B 2002
C 2003
D 2004
E 2005
F 2006
G 2007
H 2008
J 2009
K 2010
L 2011
E5827 EN 06/2001 2002 Bantam


Month of Manufacture
Month 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
January T E G P T E G P T E G
February J L C B J L C B J L C
March U Y K R U Y K R U Y K
April M S D A M S D A M S D
May P T E G P T E G P T E
June B J L C B J L C B J L
July R U Y K R U Y K R U Y
August A M S D A M S D A M S
September G P T E G P T E G P T
October C B J L C B J L C B J
November K R U Y K R U Y K R U
December D A M S D A M S D A M
E5827 EN 06/2001 2002 Bantam


Vehicle Certification Label (typical) or VIN Plate
11 FORD MOTOR COMPANY OF SOUTHERN AFRICA 1
10 2
8
3
6
7
5
4

1 Chassis number 7 Gross combination mass
2 Trim 8 Maximum permissible front axle
loading
3 Engine output kW
9 Tare
4 Build code
10 Model
5 Maximum permissible rear axle loading
11 Vehicle identification number (Vin)
6 Gross vehicle mass
E5827 EN

Body Colour Code
Body Colour
Code Body Colour
PA3 Satin white
PGV Dolphin blue
PA4 Solid red
PD5 Atlantic blue
PD6 Desert wind
PD7 Titanium grey
PB1 Pure silver
PHU Desert glow
PVV Ice blue
PHL Aquarius blue
PWG Berry red
PDC Champagne silver
Interior Trim
Interior Trim Colour
Code Trim
TXRJ Esquire printed vinyl
TXRK Cosmic pattern
TXRL Chequers pattern
TXHV Midnight black leather
E5827 EN 06/2001 2002 Bantam

100-02-31 Jacking and Lifting 100-02-31
SECTION 100-02 Jacking and Lifting

SUBJECT PAGE
Jacking ................................................................................................................................ 100-02-32
Lifting................................................................................................................................... 100-02-33
06/2001 2002 Bantam


Jacking
Before commencing any repairs that involve
WARNING: Always position the vehicle jacking the vehicle, it is essential that the
on a hard level surface. If the vehicle following instructions are fully understood.
must be jacked up on a soft surface use
load spreading blocks under the jack. It is important that only the correct jacking points
Always use a chock at the wheel are used at all times. The vehicle may be lifted by
diagonally opposite the jack. Failure to positioning a jack under the sill, forward of the
follow these instructions may result in rear wheel or behind the front wheel openings.
personal injury. Use a cushioned pad, if possible, to avoid
damaging the body paint.
E857 EN 06/2001 2002 Bantam


Lifting
NOTE: When lifting a vehicle with a two-post lift, It is important that only the correct lifting points
vehicle levelling pads must be used under the are used at all times.
lifting points.
E4448 EN 06/2001 2002 Bantam

100-04-34 Noise, Vibration and Harshness 100-04-34
SECTION 100-04 Noise, Vibration and Harshness

SUBJECT PAGE
Noise, Vibration and Harshness (NVH) ................................................................................ 100-04-35

Diagnostic Theory ............................................................................................................. 100-04-35
Know the System .............................................................................................................. 100-04-35
Know the History of the System ........................................................................................ 100-04-35
Know the History of the Condition ..................................................................................... 100-04-35
Know the Probability of Certain Conditions Developing..................................................... 100-04-35
Do Not Cure the Symptom and Leave the Cause.............................................................. 100-04-35
Be Positive the Cause is Found ........................................................................................ 100-04-35
Diagnostic Charts.............................................................................................................. 100-04-35/36
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH) ................................................................................ 100-04-37

Inspection and Verification ................................................................................................ 100-04-37
Noise Diagnostic Procedure.............................................................................................. 100-04-37/38
Road Test ......................................................................................................................... 100-04-39
Road Test Quick Checks................................................................................................... 100-04-39
Road Conditions ............................................................................................................... 100-04-40
Vehicle Preparation........................................................................................................... 100-04-40
Lift Test ............................................................................................................................. 100-04-40
Symptom Chart ................................................................................................................. 100-04-41A
Pinpoint Tests ................................................................................................................... 100-04-41B/53
GENERAL PROCEDURES
Powertrain/Drive train Mount Neutralizing ....................................................... (14 001 0) 100-04-54

Exhaust System Neutralizing .......................................................................... (25 001 0) 100-04-55
SPECIFICATIONS
Specifications ...................................................................................................................... 100-04-56

Lubricants, Fluids, Sealers and Adhesives........................................................................ 100-04-56
06/2001 2002 Bantam


Noise, Vibration and Harshness (NVH)
• What is the service history?
Noise, vibration and harshness (NVH) is
becoming more important as vehicles become Know the History of the Condition
more sophisticated and passenger comfort levels • Did it start suddenly or appear gradually?
increase. This section is designed to aid in the • Was it related to some other occurrence such
diagnosis and testing and repair of NVH as a collision or previous part replacement?
concerns.
• Know how the condition made itself known; it
• Noise is defined as sounds not associated may be an important clue to the cause.
with the operation of passenger compartment
equipment that interface with customer
satisfaction. Know the Probability of Certain Conditions
• Vibration is defined as impulses felt by the Developing
customers that are not caused by road
• Look for the simple rather than the complex.
surface changes.
• For example:
• Harshness is a ride quality issue where the
customer feels that the vehicle response to - Electrical conditions usually occur at
the road surface is sharply transmitted to the connections rather than components.
customer. - An engine no-start is more likely to be
caused by a loose wire or small adjustment
rather than a sheared-off camshaft.
Diagnostic Theory • Know the difference between impossible and
Diagnosis is more than just following a series of improbable. Certain failures in a system can
interrelated steps in order to find the solution to be improbable but still happen.
the specific condition. It is a way of looking at • New parts are just that, new. It does not
systems that are not functioning the way they mean they are always good functioning parts.
should and finding out why. Also it knows how
the system should work and whether it is working
correctly. Do Not Cure the Symptom and Leave the
There are basic rules for diagnosis. If these rules Cause
are followed, the cause of the condition is usually Lowering the pressure in a front tyre may correct
found the first time through the system. the condition of a vehicle leaning to one side, but
it does not correct the original condition.
Know the System

• Know how the parts go together. Be Positive the Cause is Found
• Know how the system operates as well as its • Double check findings.
limits and what happens when the system • What caused a worn component?
goes wrong. • A loose transmission or engine mount could
• Sometimes this means checking the system indicate that other mounts are also loose.
against one that is known to be working
correctly.
Diagnostic Charts
Charts are a simple way of expressing the
Know the History of the System
relationship between basic logic and a physical
A clue in any one of these areas may save time: system of components. They help discover the
• How old or new is the system? cause of a condition in the least time. Diagnostic
charts combine many areas of diagnosis into one
• What kind of treatment has it had? visual display:
• Has it been serviced in the past in such a
manner that might relate to the present
condition?
E858 EN 06/2001 2002 Bantam


• Probability of certain things occurring in a • Certainty of narrowing down the search to a
system. small portion before performing in-depth
• Speed of checking certain components or testing.
functions before others. The fastest way to find a condition is to work with
• Simplicity of performing certain tests before the tools that are available. This means working
others. with proven diagnostic charts and the correct
• Elimination of checking huge portions of a special equipment for the system.
system by performing simple tests.
E858 EN 02/2001 2002 Bantam


Noise, Vibration and Harshness (NVH)
Inspection and Verification
1. Verify the customer concern by operating the Customer Interview
vehicle to duplicate the condition. The road test and customer interview (if
2. Visually inspect the vehicle to determine any available) provide information that will help
obvious causes of the concern(s). identify the concern and will provide direction to
3. If the inspection reveals obvious concern(s) the correct starting point or diagnosis.
that can be readily identified, repair as • Use the Customer Concern Evaluation form
necessary. to record customer concerns.
4. If the concern(s) remains after the inspection,
determine the symptom(s) and
Identifying the Condition
go to the Symptom Chart.
Noise, vibration, and harshness (NVH) usually
occur in four areas:
How To Use This Diagnostic Procedure Section
• Tires
• Noise, vibration and harshness concerns
• Engine accessories
have become more important as vehicles
have become more sensitive to these • Suspension
vibrations. This section is designed to aid in • Driveline/driveshaft centre bearing
identifying these situations. NOTE: If the driveshaft centre bearing cap is
• The section provides diagnostic procedures removed, a new bearing cap must be installed.
based on symptom. If the condition occurs at It is important, therefore, that an NVH concern be
high speed, for instance, the most likely place isolated into its specific areas as soon as
to start is under High Speed Shake. possible. The easiest and quickest way to do this
• The road test procedure will tell how to sort is to carry out the Road Test as outlined.
the conditions into categories and how to tell
a vibration from a shake.
• A series of Road Test Quick Checks is Noise Diagnostic Procedure
provided to make sure that a cause is either
Non-Axle Noise
pinpointed or eliminated.
• Use the Vehicle Road Test Evaluation form to The five most common sources of non-axle noise
record road test results. are exhaust, tires, roof racks, trim mouldings and
transaxle.
• Use the Glossary to become familiar with the
terms. Therefore, make sure that none of the following
• Name the condition, proceed to the conditions are the cause of the noise before
appropriate section and locate the correct proceeding with a driveline teardown and
diagnosis. When the condition is identified, diagnosis.
the job is partly done. • In certain conditions, the pitch of the exhaust
• Follow the diagnostic procedure as outlined. may sound very much like gear noise. At
• Quick Checks are described within the step, other times, it can be mistaken for a wheel
while more involved tests and adjustments bearing rumble.
are outlined in Service Procedures and • Tires, especially snow tires, can have a high
Adjustments. pitched tread whine or roar, similar to gear
• Always follow each step exactly and make noise. Radial tires, to some degree, have this
notes to recall important findings later. characteristic. Also, any non-standard tyre
with an unusual tread construction may emit a
roar or whine-type noise.
• Trim and mouldings can also cause whistling
or whining noise.
E859 EN 02/2001 2002 Bantam

DIAGNOSIS AND TESTING (CONTINUED)
• Clunk may be a metallic noise heard when • Out-of-balance front or rear wheels.
the automatic transaxle is engaged in • Out-of-round tires.
REVERSE or DRIVE, or it may occur when
NOTE: Halfshafts are not balanced and do not
throttle is applied or released. It is caused by
backlash somewhere in the driveline. contribute to rotational vibration disturbances.
• Bearing rumble sounds like marbles being Shudder or vibration during acceleration may be
tumbled. This condition is usually caused by a caused by the following:
malfunctioning wheel bearing. • Excessively worn or damaged outboard or
inboard CV joint stub shaft pilot bearing
Noise Conditions housing.
• Gear noise is typically a howling or whining • Excessively high CV joint operating angles
due to gear damage or incorrect bearing caused by incorrect ride height. Check ride
preload. It can occur at various speeds and height, verify correct spring rate and check
driving conditions, or it can be continuous. items under Inoperative Conditions.
• Chuckle is a particular rattling noise that
sounds like a stick against the spokes of a Leakage Conditions
spinning bicycle wheel. It occurs while 1. Inspect CV joint boots for evidence of cracks,
decelerating from 64 km/h (40 mph) and can tears or splits.
usually be heard all the way to a stop. The 2. Inspect underbody for any indication of
frequency varies with vehicle speed. grease splatter in the vicinity of front wheel
• Knock is very similar to chuckle, through it halfshaft joint boot, outboard and inboard CV
may be louder and occurs on acceleration or joint stub shaft pilot bearing housing
deceleration. The teardown will disclose what locations, which is an indication of front
has to be corrected. wheel halfshaft joint boot and/or front wheel
Check and rule out tires, exhaust and trim items halfshaft joint boot clamp damage.
before disassembling the transaxle to diagnose 3. Inspect inboard CV joint stub shaft pilot
and correct gear noise. bearing housing seal leakage at inboard CV
joint stub shaft pilot bearing housing.
The noises described under Road Test usually
have specific causes that can be diagnosed by 4. Make sure the front axle wheel hub retainer
observation as the unit is disassembled. The is the correct prevailing torque type.
initial clues are the type of noise heard on the
road test and the driving conditions. Inoperative Conditions
If a CV joint or halfshaft pullout occurs, check the
Vibration Conditions following:
NOTE: Constant velocity joints (CV) should not • Suspension components for correct location,
be changed for new ones unless disassembly damage or wear.
and inspection revealed unusual wear. • Bushings for wear
Clicking, popping or grinding noises may be • Sub-frame for damage
caused by the following: • Bent or worn components:
• Cut or damaged front wheel halfshaft joint - stabilizer bar link
boots resulting in inadequate or contaminated - left-hand front suspension lower arm and
lube in the outboard or inboard CV joint stub bushing
shaft pilot bearing housings.
- right-hand front suspension lower arm and
• Loose front wheel halfshaft joint boot clamps. bushing
• Another component contacting halfshaft - front wheel hub and spindle
assembly.
• Worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Vibration at highway speeds may be caused by
the following:
E859 EN 02/2001 2002 Bantam


Road Test Road Test Quick Checks
A gear-driven unit will produce a certain amount 1. 24-80 km/h (15-50 mph): With light
of noise. Some noise is acceptable and may be acceleration, a moaning noise is heard and
audible at certain speeds or under various driving possibly a vibration is felt in the front floor
conditions, as on a new asphalt road. The slight pan. It is usually worse at a particular engine
noise is in no way detrimental and must be speed and at a particular throttle setting
considered normal. during acceleration at that speed. It may also
produce a moaning sound, depending on
The road test and customer interview (if what component is causing it.
available) provide information needed to identify Refer to Tip-In Moan in the Symptom Chart.
the condition and give direction to the correct
starting point for diagnosis. 2. Acceleration/Deceleration: With slow
acceleration and deceleration, a shake is
1. Make notes throughout the diagnosis routine. sometimes noticed in the steering
Use a Road Test form that includes space for wheel/column, seats, front floor pan, front
comments. Make sure to write down even the door trim panel or front end sheet metal. It is
smallest bit of information, because it may a low frequency vibration (around 9-15 cycles
turn out to be the most important. per second). It may or may not be increased
2. Do not touch anything until a road test and a by applying brakes lightly.
thorough visual inspection of the vehicle Refer to Idle Boom/Shake/Vibration in the
have been carried out. Leave the tyre Symptom Chart.
pressures and vehicle load just where they 3. High Speed: A vibration is felt in the front
were when the condition was first observed. floor pan or seats with no visible shake, but
Adjusting tyre pressures, vehicle load or with an accompanying sound or rumble,
making other adjustments may reduce the buzz, hum, drone or booming noise. Coast
conditions' intensity to a point where it cannot with the clutch pedal depressed and engine
be identified clearly. It may also inject idling. If vibration is still evident, it may be
something new into the system, preventing related to wheels, tires, front brake discs,
correct diagnosis. wheel hubs or front wheel bearings. Refer to
3. Make a visual inspection as part of the High Speed Shake in the Symptom Chart.
preliminary diagnosis routine, writing down 4. Engine rpm Sensitive: A vibration is felt
anything that does not look right. Note tyre whenever the engine reaches a particular
pressures, but do not adjust them yet. Note rpm. It will disappear in neutral coasts. The
leaking fluids, loose nuts and/or bolts, or vibration can be duplicated by operating the
bright spots where components may be engine at the concern rpm while the vehicle
rubbing against each other. Check the is sitting still. It can be caused by any
luggage compartment for unusual loads. component, from the accessory drive belt to
4. Road test the vehicle and define the the clutch, which turns at engine speed when
condition by reproducing it several times the vehicle is stopped. Refer to Engine
during the road test. Accessory Vibration in the Symptom Chart.
5. Carry out the Road Test Quick Checks as 5. Noise and Vibration While Turning: Clicking,
soon as the condition is reproduced. This will popping, or grinding noises may be due to
identify the correct diagnostic procedure. the following:
Carry out the Road Test Quick Checks more • Cut or damaged front wheel halfshaft joint
than once to verify they are providing a valid boot resulting in inadequate or contaminated
result. Remember, the Road Test Quick lube fill in the outboard front wheel halfshaft
Checks may not tell where the concern is, joint or inboard front wheel halfshaft joint.
but they will tell where it is not. • Loose front wheel halfshaft joint boot clamp.
• Other component contacting the halfshaft
assembly.
• Worn, damaged, or incorrectly installed front
wheel bearing.
E859 EN 02/2001 2002 Bantam


• Worn, contaminated, or dry inboard front 3. Carryout a coast down in NEUTRAL. If the
wheel halfshaft joint or outboard front wheel vehicle is free of vibration when operating at
halfshaft joint. a steady indicated speed and behaves very
differently in DRIVE and COAST, a transaxle
Road Conditions concern is likely.
An experienced technician will always establish a Note, however, that a test on the vehicle lift may
route that will be used for all NVH diagnosis road produce different vibrations and noises than a
tests. The road selected should be reasonably road test because of the effect of the lift. It is not
smooth, level and free of undulations (unless a unusual to find vibrations on the lift that were not
particular condition needs to be identified). A found in the road test. If the condition found on
smooth asphalt road that allows driving over a the road can be duplicated on the lift, carrying out
range of speeds is best. Gravel or bumpy roads experiments on the vehicle lift may save a great
are unsuitable because of the additional road deal of time.
noise produced. Once the route is established
and consistently used, the road noise variable is NOTE: Some concerns may be apparent only on
eliminated from the test results. smooth asphalt roads.
If a customer complains of a noise or vibration on When carrying out the high-speed shake
a particular road and only on a particular road, diagnosis or engine accessory vibration
the source of the concern may be the road diagnosis on a vehicle lift, observe the following
surface. If possible, try to test the vehicle on the precautions:
same type of road. WARNING: If only one drive wheel is
allowed to rotate, speed must be limited
to 55 km/h (35 mph) indicated on the
Vehicle Preparation speedometer since actual wheel speed
Carry out a thorough visual inspection of the will be twice that indicated on the
vehicle before carrying out the road test. Note speedometer. Speed exceeding 55 km/h
anything, which is unusual. Do not repair or (35 mph) or allowing the drive wheel to
adjust any condition until the road test is carried hang unsupported could result in tyre
out, unless the vehicle is inoperative or the disintegration, differential failure and/or
condition could pose a hazard to the technician. constant velocity joint and halfshaft
failure, which could cause serious
After verifying the condition has been corrected, personal injury and extensive vehicle
make sure all components removed have been damage.
installed.
CAUTION: The suspension should not be
allowed to hang free. When the constant
Lift Test velocity joint is run at a very high angle,
After a road test, it is sometimes useful to do a extra vibration as well as damage to
similar test on a vehicle lift. seals and joints can occur.
1. Raise the vehicle on a vehicle lift. The front suspension lower arm should be
REFER to Section 100-02. supported as far outboard as possible. To bring
the vehicle to its correct ride height, the full
2. Explore the speed range of interest using the weight of the vehicle should be supported in front
Road Test Quick Checks as previously by floor jacks. REFER to Section 100-02.
described.
E859 EN 02/2001 2002 Bantam

100-04-41A Noise, Vibration and Harshness 100-04-41A

Symptom Chart
Symptom Chart
Condition Possible Sources Action
• High speed shake • Suspension/front wheel halfshaft • GO to Pinpoint Test A.
and joints.
• Tires/wheels.
• Wheel bearings.
• Front wheel halfshaft joint boots.
• Brake discs.
• Engine.
• Transaxle.
• Tip-in moan • Air cleaner. • GO to Pinpoint Test B.
• Powertrain.
• Engine mounts.
• Exhaust system.
• Idle boom/shake/vibration • Cables/hoses. • GO to Pinpoint Test C.
• Engine mounts.
• Exhaust system.
• Accessory drive belt/pulleys.
• Engine accessory vibration • Accessory drive belt/pulleys. • GO to Pinpoint Test D.
• Mounting hardware.
• Tyre/wheel run out • Tires/wheels. • GO to Pinpoint Test E.
• Wheel bearings.
• Brakes, front disc- • Brake discs. • GO to Pinpoint Test F.
vibration/shudder • Worn/damaged brake pads.
• Foreign material on brake pads.
• Damaged front/rear brake disc
contact surface.
• Loose caliper mounting bolt.
• Loose front wheel bearing.
• Disc thickness variance.
• Wheel end vibration analysis • Brake drum/disc imbalance. • GO to Pinpoint Test G.
• Engine or transaxle mounts.
• Worn or damaged front wheel
bearing.
• Engine run-up check • A/C compressor. • GO to Pinpoint Test H.
• Engine/transaxle mounts.
• Exhaust system components.
E859 EN 02/2001 2002 Bantam

PAGE 1 OF 2
PINPOINT TESTS................................................................................... 100-04-41B
PINPOINT TEST A: HIGH SPEED SHAKE
A1: INSPECT THE TIRES ................................................................................... 100-04-42
A2: INSPECT THE WHEEL BEARINGS .............................................................. 100-04-42
A3: INSPECT THE FRONT WHEEL HALFSHAFT
JOINT BOOTS..................................................................................................... 100-04-42
PINPOINT TEST B: TIP-IN MOAN
B1: CHECK THE AIR CLEANER ......................................................................... 100-04-43
B2: CHECK THE ENGINE MOUNTS ................................................................... 100-04-43
B3: CHECK THE EXHAUST SYSTEM................................................................. 100-04-43
B4: CHECK FOR DRIVE TRAIN NOISE .............................................................. 100-04-43
PINPOINT TEST C:
IDLE BOOM/SHAKE/VIBRATION
C1: CHECK THE CABLES/HOSES ..................................................................... 100-04-44
C2: CHECK THE ENGINE MOUNTS................................................................... 100-04-44
PINPOINT TEST D:
ENGINE ACCESSORY VIBRATION
D1: CHECK THE ENGINE RUN-UP..................................................................... 100-04-44
D2: INSPECT THE ACCESSORY DRIVE BELT
AND PULLEYS .................................................................................................... 100-04-45
D3: CHECK THE MOUNTING HARDWARE........................................................ 100-04-45
D4: CHECK WITH THE ENGINE IDLING ............................................................ 100-04-45
D5: CHECK FOR ACCESSORY DRIVE BELT NOISE......................................... 100-04-46
D6: CHECK THE ACCESSORIES ....................................................................... 100-04-46
PINPOINT TEST E: TYRE/WHEEL RUN OUT
E1: TYRE AND WHEEL BEARING INSPECTION.................................................100-04-46
E2: BALANCE THE WHEELS.............................................................................. 100-04-47
E3: ROTATE THE WHEELS................................................................................ 100-04-47
E4: CHECK THE RUN OUT................................................................................. 100-04-47
E5: CHECK THE TYRE MOUNT ON THE WHEEL ............................................... 100-04-47
E6: BALANCE THE WHEELS AFTER CHECKING THE MOUNT
ON THE WHEEL ................................................................................................. 100-04-48
PINPOINT TEST F: FRONT DISC BRAKES
– VIBRATION/SHUDDER
F1: ROAD TEST .................................................................................................. 100-04-48
F2: APPLY THE PARKING BRAKE ..................................................................... 100-04-48
F3: CHECK THE FRONT SUSPENSION............................................................. 100-04-49
F4: REFINISH THE BRAKE DISCS ..................................................................... 100-04-49
PAGE 2 OF 2
F5: CHECK THE REAR SUSPENSION ............................................................... 100-04-49
F6: REFINISH THE REAR BRAKES.................................................................... 100-04-49
F7: INSTALL NEW FRONT BRAKE DISCS......................................................... 100-04-50
F8: INSTALL NEW REAR BRAKE DRUMS ......................................................... 100-04-50
PINPOINT TEST G:
WHEEL END VIBRATION ANALYSIS
G1: NEUTRAL COAST TEST .............................................................................. 100-04-50
G2: INSPECT THE TIRES................................................................................... 100-04-50
G3: INSPECT THE WHEEL AND TYRE RUN OUT .............................................. 100-04-51
G4: CARRY OUT A STATIC BALANCE TEST..................................................... 100-04-51
G5: CARRY OUT A ROAD TEST ........................................................................ 100-04-51
PINPOINT TEST H: ENGINE RUN-UP CHECK
H1: CARRY OUT SETUP FOR THE ENGINE RUN-UP CHECK ......................... 100-04-51
H2: CARRY OUT THE ENGINE RUN-UP CHECK ............................................... 100-04-52
PINPOINT TEST I: ACCESSORY DRIVE BELT
CHECK
I1: INSPECT THE ACCESSORY DRIVE BELT.................................................... 100-04-52
I2: CHECK THE BELT TENSION......................................................................... 100-04-52
I3: CHECK FOR PULLEY RUN OUT/BELT WHIP ............................................... 100-04-53
I4: INSPECT THE BELT RIDE............................................................................. 100-04-53
I5: CHECK THE BELT ......................................................................................... 100-04-53
100-04-41B Noise, Vibration and Harshness 100-04-41B
Pinpoint Tests
NOTE: These Pinpoint Tests are designed to follow the chart to its conclusion. Perform only
take the technician through a step-by-step the Pinpoint Test Steps necessary to correct the
diagnosis procedure to determine the cause of a condition. Then check operation of the system to
condition. It may not always be necessary to make sure the condition has been corrected.
After verifying that the condition has been
corrected, make sure all components removed
have been installed.
E859 EN 02/2001 2002 Bantam


PINPOINT TEST A: HIGH SPEED SHAKE
CONDITIONS DETAILS/RESULTS/ACTIONS
A1: INSPECT THE TIRES
1 Inspect the tires.
- Raise and support the vehicle.
REFER to Section 100-02.
- Inspect the tires for extreme wear or damage,
cupping or flat spots.
• Are the tires OK?
Yes
GO TO A2
No
A2: INSPECT THE WHEEL BEARINGS
1 Inspect the wheel bearings.
- Carry out the vibration diagnosis.
• Are the wheel bearings OK?
Yes
GO TO A3
No
INSTALL a new wheel bearing as
necessary. REFER to Section 204-01.
(front) or REFER to Section 204-02A / 204-02B.
(rear). TEST the system for normal
operation.
A3: INSPECT THE FRONT WHEEL HALFSHAFT JOINT BOOTS
1 Inspect the front wheel halfshaft joint boots.
- Spin the front tyre by hand.
- Inspect the front wheel halfshaft joint boots
for cracks, tears, splits or splattered grease.
• Are the front wheel halfshaft joint boots OK?
Yes
CARRY OUT Pinpoint Test E.
No
INSTALL new front wheel halfshaft joint
boot(s). REFER to Section 205-04. TEST
the system for normal operation.
E859 EN 02/2001 2002 Bantam


PINPOINT TEST B: TIP-IN MOAN
B1: CHECK THE AIR CLEANER
1 Check the air cleaner
- Check the air cleaner, inlet tube, outlet tube,
resonators and all other components
associated with the air induction system for
correct installation and tightness of all
connections.
• Are the components OK?
Yes
GO TO B2
No
CORRECT the condition as necessary.
TEST the system for normal operation. If the
moan persists, GO TO B2
B2: CHECK THE ENGINE MOUNTS
1 Check the engine mounts
- Refer to the Engine/Transaxle Mount
Neutralizing procedure in this section.
• Are the engine mounts OK?
Yes
GO TO B3
No
GO TO B4
B3: CHECK THE EXHAUST SYSTEM
1 Check the exhaust system.
- Refer to the Exhaust System Neutralizing
procedure in this section.
• Is the exhaust system OK?
Yes
GO TO B4
No
REPAIR as necessary. TEST the system for
normal operation.
B4: CHECK FOR DRIVE TRAIN NOISE
1 Check for drive train noise.
REFER to Section 100-02. With the engine off,
visually inspect isolation components for
damaged and/or misaligned mounting.
• Are the vehicle components OK?
Yes
REFER to Pinpoint Test D, Engine
Accessory Vibration.
No
INSTALL new components as necessary.
ALIGN the powertrain. TEST the system
normal operation.
E859 EN 02/2001 2002 Bantam


PINPOINT TEST C: IDLE BOOM/SHAKE/VIBRATION
C1: CHECK THE CABLES/HOSES
1 Check the cables/hoses.
- CHECK the engine compartment for any
component that may be grounding between
the engine and body or chassis. Example:
Control cables, A/C hoses, accelerator cable,
etc.
• Are the components OK?
Yes
GO TO C2
No
CORRECT the condition as necessary.
moan persists, GO TO C2
C2: CHECK THE ENGINE MOUNTS
1 Check the engine mounts.
- Inspect the engine support insulators for
correct operation. REFER to Section 303- 01A.
or REFER to Section 303-01B.
• Is the condition resolved?
Yes
Vehicle condition corrected.
No
GO to Pinpoint Test D.
PINPOINT TEST D: ENGINE ACCESSORY VIBRATION
D1: CHECK THE ENGINE RUN-UP
1 Check the engine run-up.
- Run the engine up to the concern rpm
observed in the road test, with the vehicle
stationary.
• Does the vibration occur?
Yes
GO TO D2
No
CARRY OUT the stall test with the brakes
locked (load the engine by slipping the
clutch in gear). If the vibration occurs,
GO to Pinpoint Test B.
E859 EN 02/2001 2002 Bantam


D2: INSPECT THE ACCESSORY DRIVE BELT AND PULLEYS
1 Inspect the belt and pulleys.
- With the engine stopped, inspect the
accessory drive belt and pulleys for wear or
damage, and check the belt tension.
• Are the belt, automatic tensioner or pulleys
worn or damaged?
Yes
REFER to Section 303-05. TEST the
system for normal operation. If the vibration
still exists. GO TO D3
No
GO TO D3
D3: CHECK THE MOUNTING HARDWARE
1 Check the mounting hardware.
- Check the mounting brackets and adjusting
components for correct alignment and
tightness.
• Are the mounting and adjusting components
secure?
Yes
GO TO D4
No
ALIGN and TIGHTEN the mounting hardware
to specifications. REFER to Section 303-05.
CORRECT the belt tension.
START the engine and run-up to the
concern rpm. If the vibration still exists.
GO TO D4
D4: CHECK WITH THE ENGINE IDLING
1 Check with the engine idling.
- With the engine idling, visually check the
accessory drive belt and pulleys for
misalignment, run out or irregular motion.
Maximum run out is 3.175 mm.
- Increase the engine rpm.
• Are the belt and pulleys OK?
Yes
GO TO D5
No
Diagnose the accessory drive belt concern.
E859 EN 02/2001 2002 Bantam


D5: CHECK FOR ACCESSORY DRIVE BELT NOISE
1 Check for accessory drive belt noise.
- Check for chirps or squeal from the belt by
spraying a small amount of water on the
grooved side of the belt (use a spray bottle or
equivalent).
• Does the noise change?
Yes
CHECK for misalignment. CHECK tensioner
position. CHECK for worn belt. REPAIR as
TEST the system for normal operation.
No
CHECK the accessory bushings/bearings.
REFER to Section 412-00. (Climate Control
System) and REFER to Section 414-02.
(Generator and Regulator). INSTALL new
components as necessary. GO TO D6
D6: CHECK THE ACCESSORIES
1 Check the accessories
- Run-up the engine to the concern rpm and
check each component.
• Is the noisy component located?
Yes
INSTALL a new accessory drive belt. If the
vibration still exists, REPAIR the
component. TEST the system for normal
operation.
No
Engine component imbalance.
REFER to Section 303-00. REPAIR or
INSTALL a new component as necessary.
PINPOINT TEST E: TYRE/WHEEL RUN OUT
E1: TYRE AND WHEEL BEARING INSPECTION
1 Tyre and wheel bearing inspection.
REFER to Section 100-02. Inspect the tires.
REFER to Section 204-03. Inspect the
wheel bearings. REFER to Section 204-00.
• Are the bearings OK?
Yes
GO TO E2
No
INSTALL new bearings as necessary.
REFER to Section 204-01. (front) or
REFER to Section 204-02A / 204-02B. (rear).
GO TO E2
E859 EN 02/2001 2002 Bantam


E2: BALANCE THE WHEELS
1 Balance the wheels. REFER to Section 204-03.
- Balance the wheels and install on the vehicle.

• Does the vehicle function correctly?
Yes
Condition corrected.
No
GO TO E3
E3: ROTATE THE WHEELS
1 Rotate the wheels. REFER to Section 204-03.
- Rotate the wheels front to rear, and rear to
front.
• Does the vehicle function correctly?
Yes
No
GO TO E4
E4: CHECK THE RUN OUT
1 Check the run out. REFER to Section 204-03.
- Check total radial run out and total lateral run
out of the wheel.
• Is the run out less than 1.01 mm for the front
wheels and less than 1.187 mm for the rear
wheels?
Yes
GO TO E5
No
GO TO E6
E5: CHECK THE TYRE MOUNT ON THE WHEEL
1 Check the tyre mount on the wheel.
- Check the total radial run out again as
outlined in Pinpoint Test E4.
• Is the total radial run out less than 1.01 mm?
Yes
GO TO E6
No
INSTALL new tyre(s) as necessary. TEST
E859 EN 02/2001 2002 Bantam


E6: BALANCE THE WHEELS AFTER CHECKING THE MOUNT ON THE WHEEL
1 Balance the tires after checking the mount on
the wheel.
- Check and balance the wheels.
- Road test.
• Is the vibration eliminated?
Yes
No
In some cases a vibration concern may be
caused by the tyre internal construction
inducing force variations, which cannot be
detected through run out measurement.
This condition is diagnosed by installing
tyre/wheel assemblies (one at a time) from a
different vehicle to isolate the offending
tyre(s). INSTALL new tires as necessary.
BALANCE tires. TEST the system for
normal operation.
PINPOINT TEST F: FRONT DISC BRAKES – VIBRATION/SHUDDER
F1: ROAD TEST
1 Road test.
- With standard wheels and tires installed, road
test the vehicle and verify the condition.
• Is brake shudder/vibration or brake chirp
present when the brakes are applied?
Yes
GO TO F2
No
GO to Pinpoint Test G.
F2: APPLY THE PARKING BRAKE
1 Apply the parking brake.
- Lightly apply the parking brake and road test
the vehicle. (Release the parking brake
immediately after test).
• Is a shudder or vibration present?
Yes
CHECK the rear brakes.
REFER to Section 206-02A / 206-02B. GO TO F5
No
CHECK the front brakes.
REFER to Section 206-03. GO TO F3
E859 EN 02/2001 2002 Bantam


F3: CHECK THE FRONT SUSPENSION
1 Check the front suspension.
- Check the front suspension units, wheel
bearings, front suspension lower arm bushing
and other front suspension components.
- Compare component condition vehicle-side-
to-vehicle-side and to a known good vehicle.
• Are all the suspension components in good
condition?
Yes
GO TO F4
No
F4: REFINISH THE BRAKE DISCS
1 Refinish the brake discs.
- Refinish brake discs and linings and road test
the vehicle. REFER to Section 206-03.
Yes
GO TO F7
No
F5: CHECK THE REAR SUSPENSION
1 Check the rear suspension.
- Check the rear suspension units, wheel
bearings and other rear suspension
components.
REFER to Section 204-02A / 204-02B.
- Compare component condition vehicle-side-
to-vehicle-side and to a known good vehicle.
• Are all the suspension components in good
condition?
Yes
GO TO F6
No
F6: REFINISH THE REAR BRAKES
1 Refinish the rear brakes.
- Refinish the brake drums and install new rear
brake shoes. Road test the vehicle.
Yes
GO TO F8
No
E859 EN 02/2001 2002 Bantam


F7: INSTALL NEW FRONT BRAKE DISCS
1 Install new front brake discs.
- Install new brake discs and road test the
vehicle.
Yes
GO TO F5
No
F8: INSTALL NEW REAR BRAKE DRUMS
1 Install new rear brake drums and road test the
vehicle.
Yes
CHECK the following: engine or transaxle
mounts or worn or damaged wheel bearings
for wear/damage. INSTALL new
components as necessary. TEST the
system for normal operation.
No
PINPOINT TEST G: WHEEL END VIBRATION ANALYSIS
G1: NEUTRAL COAST TEST
1 Carry out the neutral coast test.
• Does the vibration disappear during the neutral
coast test?
Yes
Procedure under development
No
GO TO G2
G2: INSPECT THE TIRES
1 Inspect the tires.
REFER to Section 100-02. Inspect the tires for:
- correct tyre size.
- tyre/wheel compatibility.
- wear or damage.
- tyre beads correctly seated.
• Are the tires OK?
Yes
GO TO G3
No
E859 EN 02/2001 2002 Bantam


G3: INSPECT THE WHEEL AND TYRE RUN OUT
1 Inspect the wheel and tyre run out.
• Are the wheels and tires OK?
Yes
GO TO G4
No
REPAIR or INSTALL new wheels and tires
as necessary. REFER to Section 204-03.
G4: CARRY OUT A STATIC BALANCE TEST
1 Carry out a static balance test.
• Are the wheels and tires OK?
Yes
GO TO G5
No
INSTALL new wheels or tires as necessary.
G5: CARRY OUT A ROAD TEST
1 Carry out a road test.
• Does the condition still exist?
Yes
CHECK the following items and REPAIR or
INSTALL new components as necessary;
air conditioning. REFER to Section 412-00.
Engine. REFER to Section 303-00.
Transaxle REFER to Section 308-00. TEST
No
PINPOINT TEST H: ENGINE RUN-UP CHECK
H1: CARRY OUT SETUP FOR THE ENGINE RUN-UP CHECK
1 Carry out setup.
- Block the wheels.
- Apply the parking brake.
• Are the setup preconditions met?
Yes
GO TO H2
No
CARRY OUT the setup procedures again.
E859 EN 02/2001 2002 Bantam


H2: CARRY OUT THE ENGINE RUN-UP CHECK
1 Carry out the engine run-up check.
- Select NEUTRAL and operate the engine at
the rpm where the condition occurs.
- Carry out this procedure with the clutch
engaged and disengaged.
• Does the vibration still exist?
Yes
CHECK the following systems, A/C,
Engine, REFER to Section 303-00.
Transaxle, REFER to Section 308-00.
REPAIR or INSTALL new components as
necessary.
No
CHECK the engine/transaxle mounts and/or
the exhaust system components. TEST the
PINPOINT TEST I: ACCESSORY DRIVE BELT CHECK
I1: INSPECT THE ACCESSORY DRIVE BELT
1 Inspect the accessory drive belt.
- Inspect the belt system for:
- worn, frayed, glazed, or nicked belt.
- loose, bent, or nicked pulleys.
• Is any damage evident?
Yes
necessary. TEST the system for normal
operation.
No
GO TO I2
I2: CHECK THE BELT TENSION
1 Check the belt tension.
- Ignition switch OFF.
- Check the belt automatic tensioner operation.
• Is the belt automatic tensioner operating
correctly?
Yes
GO TO I3
No
INSTALL a new tensioner.
E859 EN 02/2001 2002 Bantam


I3: CHECK FOR PULLEY RUN OUT/BELT WHIP
1 Check for pulley run out/belt whip.
- Ignition switch ON, engine running.
- Select NEUTRAL.
- Run the engine at the vibration speed.
- Check the belt for belt whip.
- Check the drive pulleys at idle for radial or
axial run out greater than 3.175 mm.
• Does the vehicle experience belt whip or pulley
run out?
Yes
For belt whip, CHECK/INSTALL new
accessories and drive system as necessary.
REFER to Section 303-05. For pulley run
out, CHECK/INSTALL new pulley or
accessory as necessary. TEST the system
for normal operation.
No
GO TO I4
I4: INSPECT THE BELT RIDE
1 Inspect the belt ride.
- Inspect the belt ride in each pulley at idle.
• Does the belt ride up and down the pulley?
Yes
INSTALL a new pulley.
No
GO TO I5
I5: CHECK THE BELT
1 Check the belt.
- Ignition switch OFF. Remove the drive belt.
- Ignition switch in RUN, engine running.
• Has the vibration been reduced or eliminated?
Yes
INSTALL a new belt. TEST the system for
normal operation. If the condition still occurs
after installation GO to Pinpoint Test C.
No
E859 EN 02/2001 2002 Bantam

GENERAL PROCEDURES
Powertrain/Drive train Mount Neutralizing (14 001 0)
1. NOTE: An abnormal vibration can be caused
by a component, such as an engine or
transaxle support insulator mount, which is
acting in a rigid manner because of a
distorted or twisted mounting position. As a
result, the support insulator does not absorb
vibration, as it should.
Loosen the engine insulator mounting bolts
by three turns.
2. Start the engine and shift into drive.
3. While the tires are in contact with the

ground, rock the vehicle back and forth.
4. Shift back into neutral and shut off the

engine. Retighten the engine insulator
mounting bolts.
E4449 EN 02/2001 2002 Bantam

GENERAL PROCEDURES
Exhaust System Neutralizing (25 001 0)
1. Loosen the muffler inlet pipe and resonator
pipe to exhaust manifold fasteners at the
flanges and the muffler inlet connection.
2. Place a stand to support the muffler parallel

to the vehicle frame with the muffler pipe
bracket free of stress.
3. Tighten the muffler connection.
4. Position the exhaust pipes to the manifolds

and tighten. Make sure that the heat shield
does not contact the frame rails.
5. With the complete exhaust system tight

(and cooled) the rear hanger insulator
should be angled forward, to allow the
system to expand rearward when heated
during normal running.
E3122 EN 02/2001 2002 Bantam

SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Information not available at this time.
E861 EN 062/2001 2002 Bantam

2
Group
Chassis
SECTION TITLE PAGE
Suspension
Suspension - General Information 204-00
Front Suspension 204-01
Rear Suspension 204-02
Wheels and Tyres 204-03
Driveline
Front Drive Halfshafts 205-04
Brake System
Brake System - General Information 206-00
Drum Brake 206-02
Front Disc Brake 206-03
Wheels and Tyres 206-04
Parking Brake and Actuation 206-05
Hydraulic Brake Actuation 206-06
Power Brake Actuation 206-07
Steering System
Steering System - General Information 211-00
Manual Steering 211-01
Power Steering 211-02
Steering Linkage 211-03
Steering Column 211-04
Steering Column Switches 211-05
204-00-2 Suspension — General Information 204-00-2
SECTION 204-00 Suspension — General Information

SECTION TITLE PAGE
Suspension System ............................................................................................................. 204-00-2
Inspection and Verification ................................................................................................ 204-00-2/4
Symptom Chart ................................................................................................................. 204-00-4/8
Pinpoint Tests ................................................................................................................... 204-00-9/18

Suspension System
• The speed at which the vibration occurs.
CAUTION: Make sure the tyres are
• What type of vibration occurs in each speed
inflated to their correct pressures before
range – mechanical or audible.
and after this check is completed.
• How the vibration is affected by changes in
Vibrations, roughness, tramp, shimmy and thump engine torque, vehicle speed and engine
may be caused by excessive tyre or wheel run speed.
out, worn or cupped tyres, or wheel and tyre
• Type of vibration sensitivity – torque
imbalance.
sensitive, vehicle speed sensitive, or engine
These conditions may also be caused by rough speed sensitive.
or undulating road surfaces. Driving the vehicle
If the road test indicates the vibration is related to
on different types of road surfaces will indicate if
the tyres or wheels, use the Tyre Wear Condition
the road surfaces are actually causing the
Chart to help pinpoint the cause of the concern. If
conditions.
the road test indicates that there is tyre whine but
Do not immediately suspect the tyres when no shake or vibration, the noise originates with
attempting to diagnose a vibration concern. Other the contact between the tyre and the road
sources of vibration include: surface.
• Loose or worn front wheel bearing. Use the following explanation of terms to help
• Loose or worn suspension or steering isolate the source of the vibration:
components.
• Excessive front brake disc run out. Torque Sensitive
• Loose engine or transaxle supports.
This means that the condition can be improved or
• Engine driven accessories. worsened by accelerating, decelerating, coasting
This section covers those vibrations related to the or maintaining a steady vehicle speed.
suspension, tyres and wheels.
A thumping noise usually means that the tyre has Vehicle Speed Sensitive
flat or soft spots making a noise as they slap the
This means that the vibration always occurs at
roadways. Tyre whine can be distinguished from
the same vehicle speed and is not affected by the
axle noise because axle noise diminishes or
application of engine torque, engine speed, or
changes according to load or speed. Tyre noise
transaxle gear.
remains the same over a range of speeds.
To verify that tyre noise is not associated with
shake or vibration, over inflate the tyres one at a Engine Speed Sensitive
time and check for a change in the sound. The This means that the vibration occurs at varying
pitch or whine will change as the increased vehicle speeds when a different transaxle gear is
pressure changes the tyre frequency. selected and the engine speed is constant.
Check for other types of vibration. Increasing or decreasing engine speed with the
REFER to Section 100-04. transaxle in NEUTRAL or by stall testing with the
transaxle in gear can sometimes isolate it. If the
condition is engine speed sensitive, the condition
Inspection and Verification is not related to tyres.
A vibration diagnostic procedure always begins

with a road test. REFER to Section 100-04. The Front End
road test and customer interview (if available) will NOTE: Do not check or carry out a front
provide much of the information needed to find suspension alignment without first making the
the source of a vibration. following inspection for front-end damage or
During the road test, drive the vehicle on a road wear.
that is smooth and free of undulations. If a 1. Check for specified air pressure in all four
vibration is apparent, note and record the tyres.
following:
E1049 EN 06/2001 2002 Bantam


2. Raise and support the front of the vehicle. collection of dust in this area. Suspension
REFER to Section 100-02. Check the front units, which exhibit this seepage condition,
suspension ball joints and mounts for are functional units and new parts should not
looseness, wear and damage. be installed. Leakage is a condition in which
For additional information the entire suspension unit body is covered
refer to Ball Joint Lower,Inspection in this section. with oil and the oil will drip from the
Tighten all loose nuts and bolts to specification. suspension unit onto the pavement.
When parts are worn install new parts.
3. Check the steering gear mountings and tie- If this condition exists:
rod connections for tightness. Tighten all • Make sure that fluid observed is not from
mountings to specification. If tie-rod ends are sources other than the suspension unit.
worn or bent, install new parts. • When the unit is worn or damaged install a
REFER to Section 211-03. new suspension unit.
4. Remove the front wheels. Check the wheels 2. Vehicle sag: Many new front or rear
for out-of-round and bent rims. Balance suspension units are installed in an effort to
wheel and tyre assemblies on high-speed solve a vehicle sag concern. Suspension
balancing equipment. units by design are hydraulic damping units
5. Check action of suspension units and the only and unlike suspension springs, do not
condition of their attachment. support any suspension loads. Therefore,
Refer to Suspension Unit Checks. installing a new suspension unit will not
A sticking or binding suspension unit correct a vehicle sag concern.
may not allow the vehicle to settle in a
normal level position, possibly affecting 3. NOTE: New suspension units do not need to
the front wheel alignment. be installed in pairs when only one unit is
worn or damaged.
Ball Joint – Lower, Inspection Installing new suspension units in pairs: In the
1. Raise and support the vehicle. past it was recommended that new suspension
REFER to Section 100-02. units or springs be installed in pairs if one unit
became unserviceable. Improved sealing, due to
2. Firmly grasp the outer end of the lower
new technology and improved manufacturing
suspension arm and try to move it up and
quality checks, have added to the functional
down, watching and feeling for any
reliability of suspension units. Installation of new
movement. Free movement will usually be
front suspension units or spring assemblies and
accompanied by an audible `click'. There
rear suspension units or springs in pairs is not
should be no free movement.
necessary.
3. If there is any free movement install a new
ball joint. REFER to Section 204-01.
4. If a new ball joint is installed it will be Vehicle Inspection
necessary to check and adjust the front 1. Check all tyres for correct inflation pressure.
wheel alignment. 2. Check tyre condition to confirm correct front-
Refer to General Procedures. end alignment, tyre balance and overall tyre
condition such as separation or bulges.
Suspension Unit Checks 3. Check the vehicle for optional suspension
equipment such as heavy-duty handling or
All vehicles are equipped with low-pressure gas
trailer tow suspensions. These suspensions
pressurized hydraulic suspension units. These
will have a firmer ride feeling than standard
suspension units are not adjustable or refillable.
suspensions.
1. Oil Leak: A light film of oil (seepage) on the 4. Check vehicle attitude for evidence of
upper portion of the front or rear suspension possible overload or sagging. Check luggage
unit is permissible and is a result of correct compartment area of heavy objects.
suspension unit lubrication. Seepage is a
5. Road test the vehicle to confirm customer
condition in which a thick film of oil may be
concern after performing the above steps.
deposited on the suspension unit outer tube
(body) and is normally noticed due to the
E1049 EN 06/2001 2002 Bantam


Lift Check
1. Noise: Noise can be caused by loose CAUTION: If the combination dust
suspension or suspension unit attachments. shield/jounce bumper has been removed
Verify that all attachments for the suspension from the suspension unit, care must be
components are tight. If suspension units taken to avoid excessive bottoming of
have a damaged integral lower mounting the rod during the compression stroke to
bushing, install new units. Check front and avoid internal damage.
rear suspension units for external damage.
Place the suspension unit right side up in a vise.
2. Bottom/Hopping: Check condition of the Hand stroke the suspension unit as fast as
rubber suspension travel stops (front possible using as much travel as possible. Action
suspension unit jounce bumper). Install new
should become smooth and uniform throughout
parts if worn or missing. Examine for
each stroke. Higher resistance on extension than
evidence of previous overload, which may
have damaged components. on compression is normal.
3. Only install one new unit in place of the worn The following conditions are abnormal:
or damaged suspension unit. Suspension
• A lag or skip at reversal of travel near mid-
units do not need to be installed in pairs,
stroke when the suspension unit is correctly
unless both units are worn or damaged.
aligned and in the installed position.
Bench Test • Seizing.
The suspension units are gas-pressurized which • Noise, other than a faint swish, such as a
results in them being fully extended when not clicking upon fast stroke reversal.
restrained. If a suspension unit does not fully • Excessive fluid leakage.
extend, it is damaged and a new unit should be
installed. Check the overall length (specification • With the rod fully extended, any lateral motion
478 ± 3 mm). of the rod in relation to outer suspension unit
478 + - 3 mm
body.
If the suspension unit action remains erratic after
purging air, install a new suspension unit.
REFER to Section 204-01. (front).
REFER to Section 204-02. (rear).
Rear Suspension
At regulator intervals, the following rear
If the suspension unit does not meet the overall suspension checks should be made:
length requirements, there is a good indication
something internal is out of specification and a 1. Check for evidence of fluid leaks on rear
new suspension unit should be installed. suspension units. (A light film of fluid is
With the suspension unit in the normal upright permissible. Verify fluid is not from other
position, compress it and allow it to extend three sources).
times to purge the pressure chamber of any gas 2. Check the rear leaf spring condition.
that may have been introduced during handling. 3. Check the condition of the upper and lower
Symptom Chart rear suspension bushings.
Symptom Chart
• Wander/pull/drift • Excessive side to side differ- • CARRY OUT wheel alignment.
ence in caster or camber an- Refer to General Procedures in
gles. this section.
• Toe setting out of specification. • CARRY OUT wheel alignment.
Refer to General Procedures in
this section.
• Vehicle ride height incorrect • CHECK for abnormal loading,
(front or rear, high or low). spring sag or non-standard
springs.
E1049 EN 06/2001 2002 Bantam


• Steering gear or tie-rods worn or • CHECK the steering system.
damaged. REFER to Section 211-00.
• Worn, damaged or defective • INSPECT the tyres.
tyre(s). REFER to Section 204-03.
• Hard steering • Excessive positive caster angle. • CARRY OUT wheel alignment.
Refer to General procedures in
this section.
• Vehicle ride height incorrect • CHECK for abnormal loading,
(front or rear, high or low). spring sag or non-standard
springs.
• Steering gear or tie-rods worn or • CHECK the steering system.
damaged. REFER to Section 211-00.
• Front suspension lower arm ball • REFER to the Service
joint worn or damaged. Procedures in this section.
• Damaged tyres or unbalanced • CHECK the tyres.
wheels. REFER to Section 204-03.
• Insufficient power steering as- • CHECK the power steering sys-
sist. tem. REFER to Section 211-02.
• Brake pull • Unequal tyre pressures. • INFLATE the tyres to the correct
pressures.
• Brake system failure. • CHECK the brakes.
• Shimmy or vibration • Wheel tyre imbalance, damage • CHECK the tyres.
or excessive run out. REFER to Section 204-03.
• Front wheel driveshaft(s) worn • CHECK the front wheel Half-
or damaged. shafts.
• Steering system damaged or • CHECK the steering system.
worn. REFER to Section 211-00.
• Suspension unit assembly • CHECK the suspension unit as-
loose, worn or damaged. semblies.
Refer to the procedure in
this section
• Loose suspension unit assembly • TIGHTEN components to speci-
mounting. fication.
• Damaged or worn front suspen- • INSTALL a new front suspen-
sion lower arm ball joint. sion lower arm ball joint.
• Damaged, loose or worn front • INSTALL a new front suspen-
suspension lower arm mounting sion lower arm mounting bolt
bolt bushing. bushing.
E1049 EN 06/2001 2002 Bantam


• Damaged or worn stabilizer bar • INSTALL new stabilizer bar end
end bushings (if equipped). bushings or connecting links.
REFER to Section 204-01(front).
• Damaged, loose or worn rear • INSTALL new rear suspension
suspension and bushings. and bushings as necessary.
• Damaged or worn wheel bear- • INSTALL a new wheel bearing.
ing. REFER to Section 204-01(front).
• Crabbing • Rear suspension damage. • REPAIR or INSTALL new rear
suspension components as
necessary.
• Caster angle out of specifica- • CARRY OUT wheel alignment.
tion. Refer to the procedure in
this section.
• Bump steer • Worn, loose or damaged steer- • REPAIR or INSTALL new
ing gear mounting brackets and mounting brackets and bushings
bushings. as necessary.
• Loose, worn or damaged front • REPAIR or INSTALL new sus-
suspension unit(s). pension units as necessary.
• Front/rear suspension noises • Loose, worn or damaged sus- • REPAIR or INSTALL new sus-
pension unit mounting compo- pension unit mounting compo-
nents. nents as necessary.
• Worn or damaged wheel bear- • CHECK the wheel bearings.
ings. REFER to Section 204-01.(front).
• Body rolls • Worn, missing or damaged front • INSTALL new front stabilizer bar
stabilizer bar connecting links or connecting links or bushings.
bushings (if equipped). REFER to Section 204-01.
• Damaged or loose front suspen- • REPAIR or INSTALL a new front
sion lower arm mounting bolt suspension lower arm mounting
bushing. bolt bushing.
• Loose, damaged or worn sus- • CHECK the suspension units.
pension unit(s). REFER to Section 204-01. (front).
E1049 EN 06/2001 2002 Bantam


• Body leans • Weak or damaged front coil • CHECK the coil / leaf springs.
spring or rear leaf spring REFER to Section 204-01.(front).

• Incorrect tyre pressures. • ADJUST the tyre pressures.
• Poor riding comfort • Weak front or rear leaf spring. • CHECK the coil / leaf springs.
REFER to Section 204-01.(front).

• Damaged or worn front or rear • CHECK the suspension units.
suspension unit(s). REFER to Section 204-01.(front).

• General drive instability • Wheel, tyre imbalance, damage • CHECK the tyres.
• Toe setting out of specification. • CARRY OUT wheel alignment.
Refer to General Procedures in
this section.
• Damaged front suspension • INSTALL a new front suspen-
lower arm ball joint. sion lower arm ball joint.
• Weak front coil spring / rear leaf • CHECK the coil springs.
spring. REFER to Section 204-01.(front).
REFER to Section 204- 02. (rear).

• Damaged or worn front or rear • CHECK the suspension units.
suspension unit(s). REFER to Section 204-01. (front).

• Damaged, loose or worn rear • CHECK the rear suspension.
suspension, bushing or bolts. REFER to Section 204-02.
• Damaged or worn stabilizer bar • INSTALL new stabilizer bar end
end bushings or connecting bushings or connecting links.
links (if equipped). REFER to Section 204-01.
• Steering wheel does not return • Incorrect wheel alignment. • CARRY OUT wheel alignment.
correctly Refer to General Procedures in
this section.
• Damaged or stuck front suspen- • INSTALL a new front suspen-
E1049 EN 06/2001 2002 Bantam


• Steering wheel pulls to one side • Wheel, tyre imbalance, damage • CHECK the tyres.
• Brake system damaged or worn. • CHECK the brake system.
• Incorrect wheel alignment. • CARRY OUT wheel alignment.
Refer to General Procedure in
this section.
• Damaged or stuck front suspen- • INSTALL a new front suspen-
• Weak front coil spring. • CHECK the front coil springs.
• Abnormal noise from the sus- • Damaged or stuck front suspen- • INSTALL a new front suspen-
pension system sion lower arm ball joint. sion lower arm ball joint.
• Damaged, loose or worn front • REPAIR or INSTALL new stabi-
stabilizer bar components (if lizer bar components.
equipped). REFER to Section 204-01. (front).
• Loose front or rear suspension • REPAIR or INSTALL new
components. suspension components.
REFER to Section 204-02 (rear).
• Loose, damaged or worn sus- • CHECK the suspension units.
pension unit(s). REFER to Section 204-01.(front).
E1049 EN 06/2001 2002 Bantam

Pinpoint Tests
PINPOINT TEST A: DRIFT LEFT OR RIGHT
A1: CHECK FOR DRIFT LEFT OR RIGHT .......................................................... 204-00-9
A2: CHECK THE STEERING LINKAGE............................................................... 204-00-9
A3: CHECK THE WHEEL ALIGNMENT............................................................... 204-00-10
A4: CHECK THE TYRES ..................................................................................... 204-00-10
A5: ROTATE THE TYRES................................................................................... 204-00-10
PINPOINT TEST B: STEERING WHEEL OFF-CENTER
B1: INSPECT THE STEERING COMPONENTS.................................................. 204-00-10
B2: CHECK THE WHEEL ALIGNMENT............................................................... 204-00-11
PINPOINT TEST C: TRACKS INCORRECTLY
C1: CHECK THE CASTER ANGLE ..................................................................... 204-00-11
C2: CHECK THE REAR SUSPENSION............................................................... 204-00-11
PINPOINT TEST D: ROUGH RIDE
D1: CHECK THE SUSPENSION UNITS .............................................................. 204-00-12
PINPOINT TEST E: EXCESSIVE NOISE
E1: INSPECT THE SUSPENSION....................................................................... 204-00-12
E2: INSPECT THE SPRINGS.............................................................................. 204-00-12
E3: INSPECT THE FRONT SUSPENSION LOWER ARM................................... 204-00-13
E4: INSPECT THE BALL JOINT .......................................................................... 204-00-13
E5: INSPECT THE FRONT WHEEL BEARINGS................................................. 204-00-13
E6: INSPECT THE TYRES .................................................................................. 204-00-13
PINPOINT TEST F: INCORRECT TYRE WEAR
F1: INSPECT THE TYRES .................................................................................. 204-00-14
F2: CHECK FOR CUPPED TYRES ..................................................................... 204-00-14
PINPOINT TEST G: VIBRATION
G1: INSPECT THE TYRES.................................................................................. 204-00-14
G2: INSPECT THE FRONT WHEEL BEARINGS ................................................ 204-00-15
G3: MEASURE THE FRONT WHEEL BEARING END PLAY ............................. 204-00-15
G4: INSPECT THE REAR WHEEL BEARINGS................................................... 204-00-15
G5: MEASURE THE REAR WHEEL BEARING END PLAY ................................. 204-00-16
G6: MEASURE THE WHEEL/TYRE RUN OUT ON THE VEHICLE ..................... 204-00-16
G7: MEASURE THE WHEEL/TYRE RUN OUT OFF THE VEHICLE ................... 204-00-16
G8: MATCH MOUNTING ..................................................................................... 204-00-17
G9: MEASURE THE WHEEL RUN OUT.............................................................. 204-00-17
G10: REAR HUB AND STUD CIRCLE RUN OUT ................................................ 204-00-17
G11: FRONT HUB AND STUD CIRCLE RUN OUT.............................................. 204-00-18
G12: WHEEL BALANCE...................................................................................... 204-00-18

Pinpoint Tests
PINPOINT TEST A: DRIFT LEFT OR RIGHT
A1: CHECK FOR DRIFT LEFT OR RIGHT
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection
should be performed by two people to maintain safe driving conditions. One person
should drive while the other checks the time. Adequate grip should always be maintained
on the steering wheel. Failure to follow these instructions may result in personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
1 Check the cold tyre pressure
- Drive the vehicle at 88 km/h on a level and
straight road. Drive in the center lane of a
three-lane highway.
- Be sure that no crosswinds or gusting
breezes are present.
- Drive the vehicle in both (opposing) directions
at least twice.
- If the vehicle changes one complete 3,65
meter wide lane within seven seconds, it has
a drift.
• Does the vehicle have drift?
Yes
GO TO A2
No
GO to Pinpoint Test B.
A2: CHECK THE STEERING LINKAGE
1 Raise and support the vehicle.
- Check the steering linkage for indications of
excessive wear or damage.
• Is there indication of excessive wear or
damage?
Yes
INSTALL new or REPAIR worn or damaged
components as necessary. TEST the
No
GO TO A3
E1049 EN 06/2001 2002 Bantam


A3: CHECK THE WHEEL ALIGNMENT
1 Check the wheel alignment.
• Is the steering wheel straight and the alignment
within specification?
Yes
GO TO A4
No
ADJUST the alignment as necessary. TEST
A4: CHECK THE TYRES
1 Inspect the tyres for excessive wear or
damage.
• Are the tyres excessively worn or damaged?
Yes
INSTALL new tyres. TEST the system for
normal operation.
No
GO TO A5
A5: ROTATE THE TYRES
1 Raise and support vehicle.
- Rotate the wheels in a cross pattern.
• Does the vehicle drift?
Yes
INSPECT the front suspension components
for wear or damage. INSTALL new or
REPAIR worn or damaged components as
No
normal operation.
PINPOINT TEST B: STEERING WHEEL OFF-CENTER
B1: INSPECT THE STEERING COMPONENTS
- Inspect the steering components for
excessive wear or damage.
• Are the steering components excessively worn
or damaged?
Yes
INSTALL new or REPAIR worn
components. REFER to Section 211-00.
No
GO TO B2
E1049 EN 06/2001 2002 Bantam


B2: CHECK THE WHEEL ALIGNMENT
1 Check the wheel alignment.
• Is the steering wheel centered and the
alignment within specification.
Yes
GO to Pinpoint Test C.
No
ADJUST the alignment as necessary. TEST
PINPOINT TEST C: TRACKS INCORRECTLY
C1: CHECK THE CASTER ANGLE
1 Check the caster angle.
• Is the caster angle within specification?
Yes
GO TO C2
No
CHECK all suspension components for
wear or damage. INSTALL new or REPAIR
worn or damaged components as neces-
sary. REFER to Section 204-01. (front).
C2: CHECK THE REAR SUSPENSION
1 Measure the vehicle wheelbase left-hand and
right-hand.
- Compare the measurements.
• Are the measurements the same?
Yes
GO to Pinpoint Test D.
No
INSPECT the rear suspension components
for wear or damage. INSTALL new or
REPAIR worn or damaged components as
E1049 EN 06/2001 2002 Bantam


PINPOINT TEST D: ROUGH RIDE
D1: CHECK THE SUSPENSION UNITS
1 Make sure the tyres are at the correct
pressure.
- Inspect the suspension units for oil leaks or
damage.
• Are the suspension units leaking or damaged?
Yes
INSTALL new suspension units as
No
Verify the customer concern.
PINPOINT TEST E: EXCESSIVE NOISE
E1: INSPECT THE SUSPENSION
- Inspect the suspension unit mounting bolts.
• Are the mounting bolts loose or broken?
Yes
TIGHTEN or INSTALL new suspension unit
mounting bolts. REFER to Section 204-01.
(front) REFER to Section 204-02. (rear).
No
GO TO E2
E2: INSPECT THE SPRINGS
1 Inspect the springs for damage.
• Are the springs damaged?
Yes
INSTALL new springs.
REFER to Section 204-01. (front)
No
GO TO E3
E1049 EN 06/2001 2002 Bantam


E3: INSPECT THE FRONT SUSPENSION LOWER ARM
1 Inspect the front suspension lower arm
bushings for excessive wear or damage.
• Are the front suspension lower arm bushings
worn or damaged?
Yes
INSTALL new front suspension lower arm
bushings. REFER to Section 204-01. TEST
No
GO TO E4
E4: INSPECT THE BALL JOINT
- Firmly grasp the outer end of the lower
suspension arm and try to move it up and
down. Feel for any free movement. There
must be no free movement.
• Is there any free movement?
Yes
INSTALL a new ball joint.
No
GO TO E5
E5: INSPECT THE FRONT WHEEL BEARINGS
1 Inspect the front wheel bearings.
- Rock each front wheel by gripping the top and
bottom and alternately pushing and pulling in
and out. Feel for excessive looseness of the
bearings.
- Spin each front wheel by hand checking for
roughness.
• Are the bearings loose or rough?
Yes
INSTALL new wheel bearings as necessary.
No
E6: INSPECT THE TYRES
1 Inspect the tyres for uneven wear.
• Is there uneven wear?
Yes
INSTALL new tyres. CHECK the wheel
alignment. TEST the system for normal
operation.
No
GO TO E5
E1049 EN 06/2001 2002 Bantam


PINPOINT TEST F: INCORRECT TYRE WEAR
F1: INSPECT THE TYRES
- Inspect the tyres for uneven wear on inner or
outer shoulder, or saw tooth pattern.
• Is there uneven tyre wear?
Yes
INSTALL new tyres if badly worn. CHECK
wheel alignment. TEST the system for
normal operation.
No
GO TO F2
F2: CHECK FOR CUPPED TYRES
1 Inspect the tyres for cupping or dishing.
• Are the tyres cupped or dished?
Yes
INSTALL new tyre(s). BALANCE and
ROTATE the tyres.
No
PINPOINT TEST G: VIBRATION
G1: INSPECT THE TYRES
- Inspect the tyres for damage or excessive
wear.
• Are the tyres damaged or worn?
Yes
normal operation.
No
GO TO G2
E1049 EN 06/2001 2002 Bantam


G2: INSPECT THE FRONT WHEEL BEARINGS
1 Inspect the front wheel bearings.
- Rock each front wheel by gripping the top and
bottom and alternately pushing and pulling in
bearings.
- Spin each front wheel by hand, checking for
roughness.
Yes
GO TO G3
No
GO TO G4
G3: MEASURE THE FRONT WHEEL BEARING END PLAY
1 Remove the wheel, the front disc brake caliper
and brake disc.
- Position a dial test indicator gauge with
mounting bracket against the front wheel hub.
- Push and pull the wheel hub by hand in the
axial direction and check for endplay of the
wheel hub and front wheel bearing assembly.
There must be no endplay.
• Is the front wheel bearing endplay within limits?
Yes
REFER to the Component Tests
in this section
and CHECK the ball joint.
GO TO G4
No
INSTALL a new wheel hub bearing assem-
bly as necessary. TEST the system for nor-
mal operation.
G4: INSPECT THE REAR WHEEL BEARINGS
1 Inspect the rear wheel bearings.
- Rock each rear wheel by gripping the top and
bottom, then alternately push/pull the wheel in
bearings.
- Spin each wheel by hand and check for
roughness.
Yes
GO TO G5
No
GO TO G6
E1049 EN 06/2001 2002 Bantam


G5: MEASURE THE REAR WHEEL BEARING END PLAY
1 Remove the rear wheel
- Position a dial test indicator gauge with
mounting bracket to the rear brake drum.
- Push and pull the wheel hub by hand in the
axial direction and check for rear wheel
bearing endplay. There must be no endplay.
• Is the rear wheel bearing endplay within limits?
Yes
GO TO G6
No
INSTALL a new wheel bearing as neces-
sary. REFER to Section 204-02. TEST the
G6: MEASURE THE WHEEL/TYRE RUN OUT ON THE VEHICLE
1 Measure the wheel and tyre run outs on the
vehicle using a radial run out gauge. Assembly
run out should be less than 1.14 mm radial and
lateral.
• Is the measurement in specification?
Yes
GO TO G12
No
GO TO G7
G7: MEASURE THE WHEEL/TYRE RUN OUT OFF THE VEHICLE
1 Measure the wheel and tyre from any position
that exceeds 1.14 mm radial or lateral. Before
removing the wheel, mark the wheel stud and
the corresponding stud hole so the wheel can
be installed in the same position. Remove the
wheel and mount on a wheel balancer.
Measure the run out. Wheel and tyre run out
should be less than 1.14 mm radial and lateral.
• Is the measurement in specification?
Yes
GO TO G10
No
GO TO G8
E1049 EN 06/2001 2002 Bantam


G8: MATCH MOUNTING
1 Mark the high run out location on the tyre and
also on the wheel. Break the wheel and tyre
down and rotate the tyre 180 degrees (half-way
around) on the wheel. Inflate the tyre and
measure the run outs.
• Are the wheels and tyres match mounted?
Yes
BALANCE the wheel and tyre and INSTALL
on the vehicle. TEST the system for normal
operation.
No
If the high spot is not within 101.6 mm of the
first high spot INSTALL a new tyre. If a high
spot is within 101.6 mm of the first high spot
on the tyre, GO TO G9
G9: MEASURE THE WHEEL RUN OUT
1 Remove the tyre and mount the wheel on a
wheel balancer. Measure the run out on both
flanges. Run out should be less than 1.14 mm
radial and lateral.
• Is there run out correct?
Yes
LOCATE and MARK the low spot on the
wheel and INSTALL the tyre matching the
high spot on the wheel. BALANCE the
assembly. TEST the system for normal
operation.
No
INSTALL a new wheel. CHECK the run out
on the new wheel. If the new wheel is within
limits, LOCATE and MARK the low spot.
INSTALL the tyre, matching the high spot of
the tyre with the low spot of the wheel.
BALANCE the assembly and INSTALL on
the vehicle. TEST the system for normal
operation.
G10: REAR HUB AND STUD CIRCLE RUN OUT
1 Measure the drum flange face run out (greater
than 0.254 mm), stud circle run out (greater
than 0.08 mm) and pilot radial run out (greater
than 0.05 mm).
• Are the measurements correct?
Yes
GO TO G11
No
INSTALL a new rear hub.
E1049 EN 06/2001 2002 Bantam


G11: FRONT HUB AND STUD CIRCLE RUN OUT
1 Remove the front wheel.
- Remove the front brake disc.
- Measure the stud circle run out (greater than
0.06 mm) and rotor pilot radial run out
(greater than 0.05 mm).
• Are the measurements correct?
Yes
CHECK the front brake disc run out.
No
INSTALL a new hub.
G12: WHEEL BALANCE
1 Balance all the wheels. Road test the vehicle.
• Is a vibration felt?
Yes
No
E1049 EN 06/2001 2002 Bantam

204-01-1 Front Suspension 204-01-1
SECTION 204-01 Front Suspension

SUBJECT PAGE
Front Suspension................................................................................................................. 204-01-2
GENERAL PROCEDURES
Front Toe Adjustment ..................................................................................... (14 117 0) 204-01-3/4

Wheel Bearing Inspection ............................................................................... (14 117 0) 204-01-5/6
REMOVAL AND INSTALLATION
Wheel Bearing ................................................................................................ (14 411 0) 204-01-7/9

Lower Arm ...................................................................................................... (14 707 0) 204-01-10/11
Wheel Knuckle................................................................................................ (14 343 0) 204-01-12/17
Lower Arm Ball Joint ....................................................................................... (14 735 0) 204-01-18
Strut and Spring Assembly.............................................................................. (14 781 0) 204-01-19/23
DISASSEMBLY AND ASSEMBLY

Strut and Spring Assembly.............................................................................. (14 783 4) 204-01-24/25
SPECIFICATIONS
Specifications ...................................................................................................................... 204-01-26

Torque Specifications........................................................................................................ 204-01-26/27
06/2001 2002 Bantam


Front Suspension
E1054 EN 06/2001 2002 Bantam

GENERAL PROCEDURES
Front Toe Adjustment (14 117 0)
General Equipment
Wheel alignment gauges
Check
1. This operation should be carried out on a
flat surface and in accordance with the
instructions for the particular Wheel
alignment gauges.
• Examine all suspension and steering
components to make sure there are no
signs of damage or wear.
• Check and, if necessary, adjust the tyre
pressure to specification.
• Make sure the vehicle is at curb weight
and that the spare wheel, jack and vehicle
tools are stowed in their designated
positions. Additional tools or goods should
be removed from the vehicle.
• Bounce the vehicle to make sure that the
suspension is in its natural position.
Adjustment
1. Center the steering wheel and lock in
position.
2. Loosen both tie rod end lock nuts.

1. Loosen the tie rod end lock nuts.
2. Remove the boot outer retaining clips.
E1051 EN 06/2001 2002 Bantam

GENERAL PROCEDURES (CONTINUED)

3. Rotate each tie rod equally clockwise or
counterclockwise to adjust the toe setting.
4. Tighten the tie rod end locknuts.
5. Check the toe setting.
E1051 EN 06/2001 2002 Bantam

GENERAL PROCEDURES
Wheel Bearing Inspection (14 117 0)
Special Tool(s) General Equipment
Holding Fixture, Dial Indicator Dial indicator gauge
Gauge
205-044 (15-008)
Check
1. NOTE: Do not to confuse lower arm ball joint
looseness with bearing looseness.
Raise and support the front of the vehicle.
For additional information,
refer to Section 100-02.
2. Check for loose front wheel bearings by

rocking the wheels at the top and bottom.
3. Spin the wheel quickly by hand and make

sure the wheel turns smoothly without noise
from the wheel bearings.
4. Remove the front brake caliper and anchor

plate. For additional information,
5. Position a suitable Dial indicator gauge

fixture or equivalent, against the wheel hub,
then push and pull the wheel hub. Measure
the endplay of the wheel hub and front
wheel bearing assembly. There should be
no endplay. If endplay exists, install new
wheel bearings.
E3137 EN 06/2001 2002 Bantam

6. Install the front brake caliper. For additional

information, refer to Section 206-03.
E3137 EN 06/2001 2002 Bantam


Wheel Bearing (14 411 0)
Special Tool(s) Special Tool(s)
Adapter for 204-158 (Thrust Installer/Aligner, Crankshaft
Pad) Rear Oil Seal
204-158-01 (14-038-01) 303-171-03 (21-102-03)
Collet for 205-295 Installer, Front Wheel

204-158 (14-038) Bearing
204-160 (14-040)
Remover, Bearing (Main Installer, Front Hub Oil Seal

Tool) 204-256 (14-046)
205-295 (15-050A)
Installer, Rear Hub Oil Seal

205-075 (15-036) Material Specification
Engine oil WSS-M2C913-A
Removal
1. Remove the wheel knuckle. For additional
information,
refer to Wheel Knuckle in this section.
2. NOTE: When removing the hub from the

wheel knuckle the bearing will be destroyed.
The bearing inner ring will be on the hub and
the bearing outer ring will be in the wheel
knuckle.
Using the special tools, remove the wheel
hub from the wheel knuckle.
E1056 EN 06/2001 2002 Bantam

REMOVAL AND INSTALLATION (CONTINUED)

3. CAUTION: The special tools must be
used to prevent damage to the hub. If
the hub is damaged a new hub must
be installed.
CAUTION: Do not use heat to remove the
bearing inner ring.
Using the special tools, remove the inner
race from the wheel hub.
4. Remove the circlip from the wheel knuckle.
5. Install the old bearing inner ring.

1. Install the bearing cage on to the
bearing.
2. Install the bearing cage and inner ring
assembly to the wheel knuckle.
6. Using the special tools, remove the bearing

outer ring from the wheel knuckle.
E1056 EN 06/2001 2002 Bantam


Installation
CAUTION: Avoid any impact on the

wheel bearing seals.
CAUTION: Make sure the wheel bearing

seals are clean.
1. NOTE: Lubricate the bore of the wheel
knuckle with engine oil.
Using the special tools, install the bearing
to the wheel knuckle.
2. NOTE: Make sure the ends of the circlip are

positioned in line with the lower ball joint
housing.
Install the circlip to the wheel knuckle.
3. Using the special tools, install the wheel

hub to the wheel knuckle.
4. Install the wheel knuckle. For additional

information,
refer to Wheel Knuckle in this section.
E1056 EN 06/2001 2002 Bantam


Lower Arm (14 707 0)
Removal
1. Loosen the front wheel nuts.
2. Raise and support the vehicle.

3. Remove the front wheel.
4. CAUTION: Protect the ball joint seal

using a soft cloth to prevent damage.
Detach the lower arm ball joint.
1. Remove the bolt.
2. Detach the lower arm ball joint.
5. Remove the lower arm.

• Remove the bolts.
Installation
1. Install the lower arm.
E1057 EN 06/2001 2002 Bantam

2. CAUTION: Make sure a heat shield is

installed to prevent damage to the
ball joint.
Install the heat shield.
3. Install the lower arm to the wheel knuckle.
4. Install the wheel.
5. Lower the vehicle.
E1057 EN 06/2001 2002 Bantam


Wheel Knuckle (14 343 0)
Separator, Ball Joint Lever, Wheel Knuckle
211-020 (13-006) 204-159 (14-039)
Adaptor for 204-158 Installer, Halfshaft

204-158-01 (14-038-01) 204-161 (14-041)
General Equipment
Three leg puller
Removal
All Vehicles
1. CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Loosen the top mount nut by five turns.
1. Remove the cover (if equipped).
2. Loosen the nut five turns.
2. CAUTION: Use a socket to protect the

retaining nut.
Loosen the wheel hub-retaining nut.
1. Remove the hub cap (if fitted).
2. Bend back the locking tab.
3. Loosen the hub-retaining nut.
3. Remove the front wheel and tyre. For

additional information,
E1055 EN 06/2001 2002 Bantam

4. CAUTION: Leave the tie-rod end-

retaining nut in place to protect the
ball joint stud.
Loosen the tie rod end-retaining nut.

Using the special tool, detach the tie rod
end from the wheel knuckle.
• Discard the tie-rod end-retaining nut.
6. CAUTION: Secure the brake caliper

and anchor plate assembly out of the
way to prevent damage to the brake
hose.
Detach the brake caliper and anchor plate
assembly.
7. Remove the brake disc.

1. Remove the disc retainer (if equipped).
2. Remove the disc.
E1055 EN 06/2001 2002 Bantam

8. CAUTION: Use a socket to remove the

hub-retaining nut to prevent damage.
Remove the wheel hub retaining nut and
washer.
• Discard the hub-retaining nut.

Detach the lower arm ball joint from the
wheel knuckle.
1. Remove the pinch bolt.
10. Remove the heat shield.
11. Remove the wheel knuckle to suspension

unit pinch bolt.
E1055 EN 06/2001 2002 Bantam


12. NOTE: The inner joint must not bend more
than 18 degrees; the outer joint must not
bend more than 45 degrees.
Using the special tool and a puller, detach
the halfshaft from the wheel hub.
13. Remove the wheel knuckle from the

suspension unit.
1. Insert the special tool and rotate through
90 degrees.
2. Remove the wheel knuckle.
• Secure the halfshaft out of the way.
Installation
1. Install the wheel knuckle to the suspension
unit.
2. CAUTION: Make sure the halfshaft is

completely installed into the wheel
hub.
Using the special tool, install the halfshaft
into the wheel hub.
E1055 EN 06/2001 2002 Bantam


3. Install the brake disc.
4. CAUTION: Make sure the heat shield is

ball joint.
6. Install the brake caliper and anchor plate to

the wheel knuckle.
7. WARNING: Install a new tie-rod end-

retaining nut. Failure to follow this
instruction may result in personal
injury.
Install the tie-rod end to the wheel knuckle.
• Install a new tie-rod end-retaining nut.
E1055 EN 06/2001 2002 Bantam

8. WARNING: Install a new wheel hub-

retaining nut. Failure to follow this
injury.
With the aid of another technician, apply the
brakes and pre load the wheel bearing.
• Install a new wheel hub-retaining nut.
9. Install the wheel and tyre. For additional

11. Tighten the wheel hub-retaining nut.

• Using a suitable punch, stake the nut to
the halfshaft.
12. Tighten the strut and spring assembly top

mount nut.
E1055 EN 06/2001 2002 Bantam


Lower Arm Ball Joint (14 735 0)
Removal
1. Remove the lower arm.
Refer to the procedure in this section.
2. Drill out the rivets.
Installation
1. Install the new ball joint.
2. Install the lower arm.

3. Check the front wheel alignment.

E1058 EN 06/2001 2002 Bantam


Strut and Spring Assembly (14 781 0)
Special Tool(s)
Lever, Wheel Knuckle
204-159 (14-039)
Removal
All Vehicles
2. Raise and support the vehicle. For

3. Remove the front wheel.
4. Detach the stabiliser bar connecting link

and the flexible brake hose from the
suspension unit.
5. CAUTION: Secure the caliper and

anchor plate assembly out of the way
to prevent damage to the flexible
brake hose.
Detach the caliper and anchor plate
assembly.
E1060 EN 06/2001 2002 Bantam


Detach the lower arm ball joint.
1. Remove the bolt.
7. Remove the wheel knuckle to suspension

unit pinch bolt.
8. Remove the wheel knuckle from the

suspension unit.
1. Insert the special tool and rotate through
90 degrees.
2. Remove the wheel knuckle.

Remove the suspension unit top mount nut.
1. Remove the cover, (if equipped).
2. Remove the nut.
E1060 EN 06/2001 2002 Bantam


10. Remove the suspension unit.
Installation
All Vehicles
1. Position the suspension unit.

NOTE: Do not fully tighten the suspension unit
top mount nut.
Install the suspension unit top mount nut.
3. Install the wheel knuckle to the suspension

unit.
1. Install the special tool and rotate through
90 degrees.
2. Install the wheel knuckle.
E1060 EN 06/2001 2002 Bantam


4. Install the wheel knuckle to suspension unit
pinch bolt.
5. CAUTION: Make sure a heatshield is

ball joint.
Install the heatshield.
7. Install the stabiliser bar connecting link and

the flexible brake hose bracket to the
suspension unit.
E1060 EN 06/2001 2002 Bantam


8. Install the wheel.
9.Lower the vehicle.

10. Tighten the suspension top-mounting nut.
1. Tighten the nut.
2. Install the cover (if equipped).
11. Check the front wheel alignment.

E1060 EN 06/2001 2002 Bantam


Strut and Spring Assembly (14 783 4)
Compressor, Coil Spring Adapters for 204-157
204-167 (14-042) 204-167-01 (14-042-01)
Disassembly
1. Remove the suspension unit.
refer to the procedure in this section.
2. WARNING: As the spring is under

extreme tension care must be taken
at all times. Failure to follow this
injury.
Partially compress the spring.
E1061 EN 06/2001 2002 Bantam

DISASSEMBLY AND ASSEMBLY (CONTINUED)

3. Disassemble the strut and spring assembly.
Spring clamps removed for clarity.
1. Remove the thrust-bearing nut.
2. Remove the thrust bearing.
3. Remove the spring seat.
4. Remove the spring.
5. Remove the boot.
6. Remove the bump stop.
7. Remove the dust cover.
Assembly
1. NOTE: Make sure that the spring ends butt

correctly against the upper and lower spring
seats.
To assemble, reverse the disassembly
procedure.
E1061 EN 06/2001 2002 Bantam

SPECIFICATIONS
Front Wheel Alignment (at kerb weight) - Caster and Camber
Derivative Derivative Caster Caster Camber Camber
Model Steering Nominal Tolerance Nominal Tolerance Range
Range
1.3L Standard Manual 1° 34' 2° 47' - 0° 17' - 0° 40' 0° 44' to -2° 04'
All Other Power 2° 14' 3° 29' - 0° 59' - 0° 37' 0° 47' to - 2° 01'
Maximum variation - left to right-hand side - camber 1° 00' Caster 1° 15'
Front Wheel Alignment (at kerb weight) - Total Toe Setting

Derivative Tolerance Range Setting Adjustment, if required
All - 0° 12' to 0° 12'
Torque Specifications
Description Nm
Tie-rod locknut 63
Front hub retaining nut 290
Rear hub retaining nut 235
E1062 EN 06/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Tie rod end retaining nut 37
Lower arm to crossmember retaining nuts 80
Stabiliser bar retaining bolts 23
Crossmember retaining bolts 103
Roll restrictor to transmission retaining bolt 50
Lower arm to wheel knuckle pinch bolt 52
Gear shift linkage retaining bolts 23
Wheel nuts 85
Flexible coupling to steering shaft pinch bolt 28
Flexible coupling to steering gear pinion shaft 28
pinch bolt
Wheel knuckle to strut and spring assembly pinch 85
bolt
Caliper and anchor plate assembly retaining bolts 58
Strut and spring assembly top mount retaining nut 50
Wheel hub retaining nut 290
Connecting link to strut and spring assembly re- 50
taining nut
Strut and spring assembly thrust bearing retaining 59
nut
Exhaust front pipe flange retaining nuts 48
Gearshift linkage support bracket retaining bolts 24
Flexible brake hose to strut and spring assembly 50
retaining nut
E1062 EN 06/2001 2002 Bantam

204-02-1 Rear Suspension 204-02-1
SECTION 204-02 Rear Suspension

SUBJECT PAGE
Rear Suspension ................................................................................................................. 204-02-2
Rear Suspension ................................................................................................................. 204-02-3
Beam Axle and Suspension Assembly Removal............................................. (15 231 0) 204-02-4/6

Tube - Rear Axle - Replace............................................................................. (15 730 0) 204-02-7/9
Leaf Spring ..................................................................................................... (15 366 0) 204-02-10/11
Spring Bushes ................................................................................................ (15 781 0) 204-02-12
Bump Rubber ................................................................................................. (15 413 4) 204-02-13/14
Shock Absorber (Rear)……………………………………………………………..………………. 204-02-15
SPECIFICATIONS
Specifications ...................................................................................................................... 204-02-16

Torque Specifications........................................................................................................ 204-02-16
06/2001 2002 Bantam


Rear Suspension
Item Description A stub axle is welded to each end of the axle

tube. These stub axles each carry two taper roller
1 Shock absorber bearings, which support the rear hubs. The rear
brake drums and hubs form an integral unit.
2 Bushes
Although the rear wheel bearings are adjustable,
3 U-Bolts their initial packing of grease is sufficient for the
service life of the bearings and there is no routine
4 Leaf springs maintenance requirement to readjust them in
5 Shackle pins service.
6 Axle The multi leaf rear springs are colour coded Blue
of Yellow to indicate below or above the mean
The rear axle and suspension system consists of load and rate specification.
a transverse beam axle supported and located at
each end by a single leaf spring. The bump
rubbers mounted on top of the axle tube limit the
vertical movement.
E1063 EN 06/2001 2002 Bantam


Rear Suspension
E1064 EN 06/2001 2002 Bantam


Beam Axle and Suspension Assembly Removal (15 231 0)
Removal
1. Jack up the rear of the vehicle, fit stands
under the body and chock the front wheels.
refer to Section 100-02
NOTE: It is essential that the vehicle does not
exceed the maximum kerb weight if it is to be
raised and supported on the axle tube.
2. Support the axle assembly with a suitable

jack.
3. Remove the wheels.
4. Detach the parking brake equalizer yoke.

1. Detach the primary cable from the
equalizer yoke.
2. Remove the rear cable retaining clip.
3. Detach the rear cables from the retaining
bracket.
4. Detach the equalizer yoke from the rear
cable.
5. Disconnect the fuel line and unhook the

exhaust from its rubber mountings.
Disconnect the brake hoses from the rear
axle tube bracket.
6. Remove the nuts securing the rear end of

the spring to the under body. Remove the
inner shackle plates.
NOTE: An alternative method of securing the
spring to the shackle plates may be
encountered. Remove the nut and bolt
from both the rear spring eyes, slacken
the upper shackle nut and lower the
spring.
E6581 EN 06/2001 2002 Bantam

7. Remove the two bolts securing the shock

absorber upper mounting plate to the body on
either side of the vehicle.
8. Remove the nut and bolt from both the front

spring eyes.
9. Remove the complete axle and suspension

assembly by withdrawing it towards the rear
of the vehicle, lowering the axle to separate
the Load Active Valve (LAV) link rod from
its spacer.
Installation
1. Reposition the rear axle and suspension
assembly ensuring the Load Active Valve
(LAV) link rod engages into its spacer tube.
NOTE: If necessary wipe the link rod clean and
re-grease.
2. Refit the spring front eye nut and bolt, both

sides.
3. Proceed with either "A" or "B" below:
"A" - Fit the rear shackle plates to each rear

spring eye and fit the securing nut (s).
Position the upper part of the plate over the
body stud and fit securing nut (s), both
sides.
"B" - Align the spring rear eye to the shackle

plates and refit the securing nut (s) and
bolt (s), both sides. Tighten the upper
shackle nut (s).
4. Refit two bolts on each side of the shock

absorber upper mounting plates.
E6581 EN 06/2001 2002 Bantam

5. Feed the handbrake cable over the exhaust

system and the fuel lines.
Re-hang the exhaust and reconnect the fuel
lines.
Connect the handbrake cable to the
equaliser and fit the clevis pin and spring clip,
reconnect both brake hoses to the axle
bracket.
6. Bleed the brake system. For additional

7. Lower the vehicle to the ground and finally

tighten all nuts and bolts to the specified
torque. Refer to Section 204-02-17
8. Adjust the parking brake cable. For

9. Adjust the Load Active Valve (LAV). For

E6581 EN 06/2001 2002 Bantam


Tube - Rear Axle - Replace (15 730 0)
Removal
1. Jack up the rear of the vehicle, fit
stands under the body and chock the
front wheels. For additional information,
2. Remove the rear wheels and the brake

hoses from the axle tube bracket.
3. Remove the brake drum and hub assembly

from the axle flange, four bolts.
NOTE: Protect the hub from dust and dirt.
4. Remove the two rivets securing the brake

carrier plate assembly to the rear axle and
remove the carrier assembly.
NOTE: Support the brake carrier assembly

to prevent damage to the brake flexible
hoses.
E6582 EN 06/2001 2002 Bantam

5. Repeat steps 3 to 4 for the remaining brake

drum assembly.
6. Remove the "U" bolts nuts securing the axle

to the springs.
7. Remove the axle tube from the vehicle, whilst

sliding the Load apportioning valve (LAV) link
rod and bush from the axle tube.
E6582 EN 06/2001 2002 Bantam


Installation
1. Refit the Load Active Valve (LAV) link rod and

bush to the axle tube. Wipe the link rod
clean and re-grease and align the rod with
its spacer tube.
2. Secure the axle tube to the springs with the

"U" bolts and nuts.
3. Refit the carrier plate assembly with two new

rivets.
4. Refit the brake drum and hub assembly.

Torque specification for retaining bolts
(four off) 66 Nm
5. Repeat steps 3 to 4 for the remaining side.

torque. Refer to Section 204-02-17
7. Adjust Load apportioning valve (LAV). For

additional information, refer to Section 206-00
E6582 EN 06/2001 2002 Bantam


Leaf Spring (15 366 0)
Removal
1. Jack up the rear of the vehicle, fit stands
2. Support the axle with stands or a jack.
3. Remove the nuts securing the "U" bolts to

the rear springs.
4. Remove nuts and shackle plate from the

rear end of the leaf spring.
NOTE: An alternative method of securing the
spring to the shackle plates may be
encountered. Remove the nut and bolt
from both the rear spring eyes, slacken
the upper shackle nut and lower the
spring.
5. Remove leaf spring front eye nut and bolt.
6. Remove the leaf spring from the vehicle.
E6583 EN 06/2001 2002 Bantam


Installation
1. Fit the leaf spring into position on the axle
ensuring the colour code is facing towards
the rear of the vehicle.
2. Fit the leaf spring eyebolt and nut.
3. Either fit the rear shackle plate to the spring

and body and refit the spring eye to shackle
plates securing nut and bolt, tighten shackle
upper nut, depending on design fitted.
4. Fit the "U" bolts to the axle and spring,

ensuring that the bump rubber plate is
correctly located regarding shock absorber
mounting. Secure the "U" bolts with there
nuts.

torque. Refer to Section 204-02-17.
6. Adjust the Load Active Valve (LAV).

E6583 EN 06/2001 2002 Bantam


Spring Bushes (15 781 0)
Removal
1. Remove the leaf spring.
Refer to Section 204-02-6
2. Align the leaf spring front eye under a press

and using a suitable tube press out the
bush, it is preferable to use a tube of
suitable diameter so as to locate on the
bush metal outer sleeve.
3. Repeat sub-operation 2 for the spring rear

eye bush.
Installation
1. Clean the spring in the region of both front
and rear eyes.
2. Prior to pressing new bushes into the spring

eyes lightly apply a thin film of grease to the
outer metal sleeves of each bush to facilitate
installation.
3. Press the new bushes into the spring

eyes.
Note: To prevent damaging the bush when
pressing it into the spring eye it is essential
to use a suitable tube so as to locate on the
bush outer metal sleeve. A sitable tube is a
36.0 mm socket or similar dimensioned
tube.
E6584 EN 06/2001 2002 Bantam


Bump Rubber (15 413 4)
Removal
1.Jack up the rear of the vehicle, fit stands
2. Remove bolt securing the bump rubber to

axle mounting plate.
3. Remove the bump stop.
E6585 EN 06/2001 2002 Bantam


Installation
1. Clean the axle mounting plate before
installing the bump stop.
2. Slide the bump stop rubber plate locating tag

into the slot in the axle mounting plate.
E6585 EN 06/2001 2002 Bantam


Shock Absorber - Rear (15 783 4)
Removal
1.Jack up the rear of the vehicle, fit stands
2. Remove the nut and bolt securing the

shock absorber to its lower mounting.
3. Remove the two bolts securing the shock

absober top mounting bracket to the body.
Installation
1. Install the new shock absorbers in reverse
order.
E1072 EN 06/2001 2002 Bantam

SPECIFICATIONS
Model Centre Distances Leaf thickness (mm)

Between Eyes (mm)
Pick-up 1194* ± 3 1 - 7.0
2 - 7.0
3 - 6.5
4 - 15.0
* Spring flat.
Wheel Alingment - Note: Rear wheel alignment is not adjustable.
Nominal Tolerence
Camber 0° 0' 0" 0° 30' 00"
Toe 0° 0' 0" 0° 30' 00"
Tigntening Torques
Item Nm
Spring eye bolts (front / rear) 70 - 95
Shackle plate to body / spring 43 - 54
Shock absorber top mounting 41 - 58
Shock absorber lower mounting 41 - 58
Shock absorber plate to body 21 - 28
Brake drum & hub assy to axle 66
E6586 EN 06/2001 2002 Bantam

204-03-1 Wheels and Tyres 204-03-1
SECTION 204-03 Wheels and Tyres

SUBJECT PAGE
Safety Precautions............................................................................................................... 204-03-2

Wheels and Tyres................................................................................................................ 204-03-3
Winter Tyres...................................................................................................................... 204-03-3
Wheels and Tyres................................................................................................................ 204-03-4

Symptom Chart ................................................................................................................. 204-03-5/8
Wheel and Tyre ................................................................................................................... 204-03-9
SPECIFICATIONS
Specifications ...................................................................................................................... 204-03-10

Tyre Pressures - Bar ......................................................................................................... 204-03-10
Tyre Rating ....................................................................................................................... 204-03-10
Wheel and Tyre Size......................................................................................................... 204-03-10
07/2001 2002 Bantam


Safety Precautions
WARNING: Do not mix different types of WARNING: Failure to retighten the wheel
tyres on the same vehicle such as radial, nuts at the specified mileage could
bias or bias belted tyres except in cause the wheels to come off while the
emergencies (temporary spare usage). vehicle is in motion.
WARNING: Never run the engine with one WARNING: Each individual axle, wheel
wheel off the ground, for example when and tyre has its own maximum weight or
changing a wheel. The wheel resting on tyre inflation rating. Do not overload or
the ground may cause the vehicle to over-inflate beyond the capacity of the
move. lowest rated components of the system.
WARNING: Aftermarket aerosol tyre CAUTION: Do not clean aluminum wheels

sealants are extremely flammable. with steel wool, abrasive type cleaners or
Always question the customer to make detergents.
sure that these products have not been
used. CAUTION: Reduce air pressure as much
as possible by pushing the valve core
WARNING: Always wear safety goggles plunger in before removing the valve
or a face shield when performing any core.
work with wheel and tyre assemblies. Failure to follow these instructions can result in
WARNING: Retighten the wheel nuts at personal injury.
800 Km after any wheel change or
anytime the wheel nuts are loosened.
E1074 EN 07/2001 2002 Bantam


Wheels and Tyres
Winter Tyres
Always fit winter tyres to all four wheels. Do not
exceed the maximum speed specified by the tyre
manufacturer. When using winter tyres, the tyre
pressures supplied by the tyre manufacturer must
be adhered to.
E1075 EN 07/2001 2002 Bantam


- mechanical or audible
Wheels and Tyres
• How the vibration is affected by changes in
Inspection and Verification the following:
To maximize tyre performance, inspect the tyres - engine torque
for signs of incorrect inflation and uneven wear, - vehicle speed
which may indicate a need for balancing, rotation - engine speed
or front suspension alignment. Tyres should also
• Type of vibration – sensitivity: torque
be checked frequently for cuts, stone bruises,
sensitive, vehicle speed sensitive or engine
abrasions, blisters, and for objects that may have
speed sensitive.
become embedded in the tread. More frequent
inspections are recommended when rapid or The following explanations help isolate the
extreme temperature changes occur or when source of the vibration.
road surfaces are rough or occasionally littered
with debris. Torque Sensitive
As a further visible check of tyre condition, tread This means that the condition can be improved or
wear indicators are molded into the bottom of the made worse by accelerating, decelerating,
tread grooves. When these indicator bands are coasting, maintaining a steady vehicle speed or
exposed to the road surface, new tyres should be applying engine torque.
installed.
Vehicle Speed Sensitive
Tyre Wear Diagnosis This means that the vibration always occurs at
New tyres should be installed if the wear indictors the same vehicle speed and is not affected by
are exposed or if there is severe shoulder wear. engine torque, engine speed or the transaxle
Shoulder wear is usually caused by either gear selected.
excessive camber or excessive toe on radial
tyres. Engine Speed Sensitive
Sometimes incorrect rear toe settings or This means that the vibration occurs at varying
damaged struts will cause severe `cupping' or
vehicle speeds when a different transaxle gear is
`scalloped' tyre wear on non-drive wheels.
selected. Increasing or decreasing engine speed
Severely misadjusted rear toe will also cause with the transaxle in NEUTRAL or by stall testing
other unusual wear patterns. with the transaxle in gear can sometimes isolate
it. If the condition is engine speed sensitive, the
cause is probably not related to the tyres.
Road Test
If the road test indicates that there is tyre whine,
A tyre vibration diagnostic procedure always but no shake or vibration, the noise originates
begins with a road test. The road test and with the contact between the tyre and the road
customer interview (if available) will provide much surface.
of the information needed to find the source of a
vibration. A thumping noise usually means that the tyre has
flat or soft spots making a noise as they slap the
During the road test, drive the vehicle on a road roadway. Tyre whine can be distinguished from
that is smooth and free of undulations. If vibration axle noise. Tyre whine remains the same over a
is apparent, note and record the following: range of speeds.
• The speed at which the vibration occurs.
• What type of vibration occurs in each speed
range.
E1076 EN 07/2001 2002 Bantam


Symptom Chart
Symptom Chart
• Tyres show excess wear on • Under-inflated tyres. • ADJUST air pressure in tyres.
edge of tread
• Vehicle overloaded. • CORRECT as necessary.
• High-speed cornering. • CORRECT as necessary.
• Incorrect toe setting. • SET toe to specification.
• Incorrect camber setting. REFER to Section 204-00.
• Tyres show excess wear in cen- • Tyres over-inflated. • ADJUST air pressure in tyres.
ter of tread
• Excessive acceleration or brak- • CORRECT as necessary.
ing.
• Other excessive tyre wear con- • Incorrect tyre pressure. • ADJUST air pressure in tyres.
cerns
• Tyres need rotating. • ROTATE tyres.
• Front end out of alignment. • ALIGN front end.
• Vehicle overloaded. • CHECK load specification
against workload requirement.
• Loose or leaking front suspen- • TIGHTEN or INSTALL new
sion unit. parts as necessary.
REFER to Section 204-01. (Front)
• Wheel bearings worn. • INSTALL new wheel bearings
and/or wheel hub.
REFER to Section 204-01(Front)
REFER to Section 204-02(Rear)
• Loose, worn or damaged • INSPECT, REPAIR or INSTALL

suspension components, new parts as necessary.
bushings and ball joints.
• Excessive lateral or radial run • CHECK, REPAIR or INSTALL
out of wheel or tyre. new parts as necessary. Use a
dial indicator gauge to deter-
mine run out accurately.
• Wheel mounting is difficult • Incorrect application or mis- • FOLLOW manufacturers
matched parts, including wheel specifications.
studs and nuts.
• Corroded, worn or damaged • CLEAN or INSTALL new parts.
parts.
• Wheel rust or corrosion • Poor maintenance. • CLEAN and PROTECT with
paint
E1076 EN 07/2001 2002 Bantam


• Wobble or shimmy affecting • Damaged wheel (eventually • INSPECT wheel rims for dents.
wheel run out damages front wheel bearing INSTALL new parts as neces-
outer cone and roller bearings sary.
and causes uneven tyre wear).
• Excessive vehicle vibration, • Loose suspension components. • TIGHTEN or INSTALL new
rough steering parts.
• Vehicle vibrations from wheels • Inflation pressure too high or • ADJUST air pressure in tyres.
and tyres low.
• Wheel or tyre imbalance. • BALANCE wheel and tyre
assembly.
• Uneven tyre wear. • INSTALL new tyre if necessary
to correct vibration.
• Brake disc imbalance. • CHECK brake disc fins for mud
or debris. If no damage or debris
is seen, brake disc may have a
heavy spot.
• Water in tyres. • REMOVE water.
• Bent wheel. • INSTALL new wheel. Attempts
to straighten a wheel can cause
fractures in the wheel and
weaken wheel strength.
• Incorrectly seated tyre bead. • SPIN wheel on vehicle.
EXAMINE area where the tyre
and the wheel meet. If that sec-
tion of the tyre appears to waver
while being rotated, the tyre
bead may not be seated on the
wheel. REMOVE the tyre and
CLEAN bead seat areas on both
wheel and tyre.
• Excessive radial run out of • Use a dial indicator gauge to
wheel or tyre. check the radial run outs of both
the wheel and the tyre. If either
the wheel or tyre is out of speci-
fication CHECK the radial run
out of the wheel stud. When
components are out of specifica-
tion INSTALL new components.
• Loose or damaged wheel stud, • TIGHTEN or INSTALL new
wheel nut or enlarged stud parts as necessary.
holes.
• Debris between wheel mounting • CLEAN mounting surfaces.
face and hub mounting surface.
E1076 EN 07/2001 2002 Bantam


• Excessive lateral run out of • Use a dial indictor gauge to
wheel or tyre. check the lateral run outs of
both the wheel and the tyre. If
either the wheel or tyre is out of
specification CHECK the lateral
run out of the wheel hub. When
components are out of specifica-
tion INSTALL new components.
• Damaged front wheel bearing. • REFER to Section 204-01.
• Cracks develop in rim base back • Overloading or abusive use. • INSTALL new wheel. CHECK
(rim bead seat) or the gutter loading and operating condi-
area (drop well radii) tions. Avoid over inflation of
tyres. CHECK specifications for
rim load capacity, working load,
tyre size, ply rating and tyre
construction.
• Incorrect use of tools. • CHECK mounting, demounting,
and maintenance procedures.
• Damaged wheel stud threads • Sliding wheel across wheel • INSTALL new wheel studs.
studs during assembly. TIGHTEN to specification.
• Loose brake drum • Wheel studs too long. • INSTALL new wheel stud of cor-
rect length.
• Broken wheel studs • Loose wheel nuts. • INSTALL new wheel studs.
TIGHTEN to specification.
• Overloading. • INSTALL new wheel studs.
TIGHTEN to specification. Com-
pare actual load against vehicle
load ratings.
• Stripped wheel stud threads • Excessive torque. • INSTALL new wheel studs.
• Rust streaks from wheel stud • Loose wheel nuts. • CHECK complete assembly. If
holes parts are damaged INSTALL
new parts. TIGHTEN to specifi-
cation.
• Damaged wheel nuts • Loose wheel assembly. • INSTALL new wheel nuts.
• Over tightened wheel nuts. • FOLLOW correct tightening pro-
cedure.
E1076 EN 07/2001 2002 Bantam


• Seized wheel nuts • Corrosion or galling. • CAUTION: Do not permit lubri-
cant to get on cone sets of stud
holes or on cone angle of wheel
nuts. If corrosion is slight, wire
brush away corrosion. If corro-
sion is excessive, INSTALL new
wheel studs and nuts. If condi-
tion persists, LUBRICATE first
three threads of each wheel
stud with a graphite-based lubri-
cant.
• Overloading. • REDUCE weight.
E1076 EN 07/2001 2002 Bantam


Wheel and Tyre
Removal
CAUTION: Do not use heat to loosen a

seized wheel nut. Heat may damage the
wheel and wheel hub.
1. Loosen the wheel nuts.

refer to Section 100- 02.
3. Remove the wheel and tyre assembly.
Installation
1. WARNING: Remove the corrosion or

dirt from the mounting surfaces of
the wheel, wheel hub, brake drum or
brake disc, as this may cause the
wheel nuts to loosen and the wheel to
come off while the vehicle is in
motion. Failure to follow this
injury.
Clean the wheel hub and mounting
surfaces.
2. Install the wheel and tyre assembly.
4. Tighten the wheel nuts in a diagonally

opposed pattern.
E8680 EN 07/2001 2002 Bantam

204-03-10 Wheels and Tyres 204-03-10
SPECIFICATIONS
Tyre Pressures - kPa
Normally Laden * Fully Laden *
Tyre size Engine Variant Front (kPa) Rear (kPa) Front (kPa) Rear (kPa)
1.3 RoCam Standard
165 / 80R135 210 210 210 300
1.6 RoCam Standard
1.3 RoCam Hi-line

175 / 65R14T 210 210 210 300
1.6 RoCam Hi-line
175 / 65R14T 1.8 Diesel All 240 210 240 300
Wheel and Tyre Size

Wheel Type Model Variants Rim Size Tyre Size
Steel wheels
1.3 / 1.6 RoCam (Base) 5 X 13 165 / 80R13S
1.3 / 1.6 RoCam / 1.8 5.5 X 14 175 / 65R14T
Diesel (High)
Alloy Wheels
5.5 X 14 175 / 65R14T
Description Nm
Wheel nuts – steel/alloy wheels 85
E5837 EN 07/2001 2002 Bantam

205-04-1 Front Drive Halfshafts 205-04-1
SECTION 205-04 Front Drive Halfshafts

SUBJECT PAGE
Front Drive Halfshafts .......................................................................................................... 205-04-2

Front Drive Halfshafts ....................................................................................................... 205-04-2/3
Working principle of the front drive halfshafts .................................................................... 205-04-4
Handling front drive halfshafts........................................................................................... 205-04-4
Wheel balancing, front ...................................................................................................... 205-04-4
Raise the vehicle............................................................................................................... 205-04-4
Towing the vehicle ............................................................................................................ 205-04-4
Underbody protection and corrosion prevention ................................................................ 205-04-4
Front Drive Halfshafts .......................................................................................................... 205-04-5

Symptom chart.................................................................................................................. 205-04-5
Halfshaft LH.................................................................................................... (14 320 0) 205-04-6/9

Halfshaft RH ................................................................................................... (14 321 0) 205-04-10/13
Inner Constant Velocity (CV) Joint Boot .......................................................... (14 336 4) 205-04-14/18
Outer Constant Velocity (CV) Joint Boot ......................................................... (14 338 4) 205-04-19/21
Outer Constant Velocity (CV) Joint ...................................................................................... 205-04-22/26
Halfshaft LH.................................................................................................... (14 320 8) 205-04-27/30

Halfshaft RH ................................................................................................... (14 320 8) 205-04-31/35
SPECIFICATIONS
Specifications ...................................................................................................................... 205-04-36

Capacities ......................................................................................................................... 205-04-36
Fill Capacities.................................................................................................................... 205-04-36
2002 Bantam

Front Drive Halfshafts
1. The front drive halfshafts have constant 4. The left-hand tripod joint is secured in the
velocity joints at both ends, providing low differential with a snap-ring.
friction operation. 5. The intermediate shaft (right-hand side) is
2. Tripod joints (with tripod, running rollers and secured in the differential and by the
tripod housing) are fitted nearest the intermediate shaft bearing.
transmission. 6. The tripod bell housing on the right-hand
3. Nearest the wheel, fixed ball joints are fitted tripod joint of the right-hand front drive
(consisting of a tripod, ball cage and shell). halfshaft is rigidly fixed to the intermediate
shaft.
7. The wheel-side constant velocity joints are
attached to the wheel hubs.
E7823 EN 07/2001 2002 Bantam


Exploded view of the front drive halfshaft
E7823 EN 07/2001 2002 Bantam

Item Description 5. Do not drop the front axle drive halfshafts, as

this can cause interior damage to the boots,
1 Fixed ball joint which may not be visible from the outside.
2 Clamping strap (large) 6. Do not use the front drive halfshafts as levers
to install other vehicle components. The front
3 Boot drive halfshafts must always be left hanging
4 Clamping strap (small) freely.
7. The tripod joint can be damaged by knocks
5 Drive halfshaft retaining snap-ring,
outside the joint housing.
wheel end
6 Front drive halfshaft
7 Drive halfshaft retaining snap-ring, Wheel balancing, front
transmission end CAUTION: Using a portable wheel
8 Tripod star with constant velocity roll- balancing unit when the vehicle is lifted
ers completely off the ground will result in
damage to the tripod joints or boots, as
9 Tripod housing the joint is bent at a large angle and
10 Intermediate shaft with intermediate therefore overheats.
shaft bearing If using portable wheel balancing equipment,
place a workshop jack under the lower
suspension arm of the wheel opposite the one
Working principle of the front drive halfshafts being balanced. This prevents the joints being
bent too far when the vehicle is lifted.
1. The front drive halfshafts transmit torque
from the engine to the wheels. If possible, wheels should be removed from the
vehicle and balanced in a stationary balancing
2. In order to allow engine movement and
machine.
vertical movement of the wheels, the front
drive halfshafts operate at varying lengths
and angles.
Raise the vehicle.
3. The tripod joints allow for changes in drive
halfshaft length during axial movements. CAUTION: Never use the joints or front
drive halfshafts as jacking points.
Handling front drive halfshafts

NOTE: Never hold the front drive halfshaft just by
the tripod joint. Towing the vehicle
The greatest care must be taken when installing, CAUTION: Do not attach the towrope to
removing, disassembling or assembling the front the front drive halfshaft.
drive halfshafts. Observe the following points:
1. When removing front drive halfshafts do not
pull on the tripod joints.
2. The inner tripod joint must not be bent at Underbody protection and corrosion
more than 18 degrees, the outer one no prevention
more than 45 degrees.
NOTE: The boots should be covered during
3. Check polished surfaces and splines for
application of underbody protection or corrosion
damage.
prevention.
4. Do not allow the boots to come into contact
with sharp edges, the engine when it is hot or Foreign matter on the boots can cause premature
the exhaust system. ageing of the material. Foreign matter on the
front drive halfshafts can cause imbalance.
E7823 EN 07/2001 2002 Bantam


Symptom chart
NOTE: Do not re-install front drive halfshafts 2. Carry out a visual check of the underbody for
without first checking for wear. signs of splashes of grease around the front
1. Carry out a visual check of the boots for tears axle drive halfshafts; this may indicate that
and cracks. one of the boots or boot clamps is faulty.
3. Carry out a check of the joint housing for
leaks.
4. Ensure that the correct self-locking stub axle
nut has been fitted.
Pinpoint Tests
• Cracking, banging or grinding • Insufficient or contaminated • Check, clean and renew the
noises whilst driving. grease in the joints of the front high-durability grease as neces-
axle drive halfshaft. sary.
• Another component is touching • Check and repair as necessary.
a front axle drive halfshaft.
• Worn or damaged wheel bear- • Check and repair as necessary.
ing, brakes, suspension or
steering components.
• Vibrations at high speeds. • Wheel imbalance. • Balance the wheels.
• Front wheel radial run out. • Observe the removal and instal-
lation instructions for the front
axle drive halfshafts.
• Front axle drive halfshafts incor- •
rectly installed.
• Shaking vibrations when • Tripod joint angle is too large • Check that the vehicle height
accelerating. because of unsuitable ride and spring height are correct.
height.
• Front drive halfshaft has exces- • Check and renew as necessary.
sive wear or is faulty.
• Tripod joint has come apart. • The front drive halfshaft snap- • Renew the snap-ring.
ring is missing or has not en-
gaged correctly in the differen-
tial.
• Engine and transmission not • Check engine mountings for
aligned correctly. faults and wear.
• Subframe or chassis distorted or • Measure frame.
buckled.
• Front suspension components • Check for worn bushes or de-
worn or faulty. formed components (stabiliser,
suspension arm, etc.) and re-
new as necessary.
E4451 EN 07/2001 2002 Bantam


Halfshaft LH (14 320 0)

Installer, drive halfshaft Two legged puller
204-161 (14-041)
Material Specification
Transmission fluid - SAE 75W90
manual transmission
Remover, drive halfshaft
308-256 (16-089)
Removal
1. NOTE: Stop the piston rod from turning using

an Allen key.
Undo the suspension strut top nut by five
turns.
2. Loosen the axle stub nut.
3. Detach the front wheel. For additional

E6319 EN 07/2001 2002 Bantam

4. Detach the lower suspension arm from the

spindle carrier.
5. CAUTION: The axle stub nut can be re-

used four times. Mark the nut.
CAUTION: Support the halfshaft. The
inner joint must not be bent at more
than 18 degrees. The outer joint must
not be bent at more than 45 degrees.
Unscrew and remove the axle stub nut and
remove the washer.
• Press the axle stub out of the wheel hub
using a two-legged puller and tie the
halfshaft up using cable ties.
6. CAUTION: Do not damage the oil seal.

NOTE: Escaping oil. Collect the oil in a suitable
container.
NOTE: Plug the openings in the transmission to
prevent oil being lost and to stop dirt entering.
Remove the front drive halfshaft from the
transmission using the special tool.
• Discard the snap ring.
E6319 EN 07/2001 2002 Bantam

Installation
1. CAUTION: Do not damage the oil seal

when inserting the front drive
halfshaft. Use an installation sleeve
on a manual transmission (supplied
with each new oil seal).
NOTE: Make sure the snap ring snaps securely
into place.
Install the front halfshaft in the transmission
using a new snap ring.
2. Pull the halfshaft into the wheel hub using

the special tool.

used four times; mark the nut.
NOTE: Do not tighten the axle stub nut yet.
Put on the axle stub nut.
• Insert the washer and screw on the axle
stub nut.
4. Attach the lower suspension arms to the

spindle carriers.
E6319 EN 07/2001 2002 Bantam

5. Install the front wheel. For additional

6. Tighten the axle stub nut.
7. NOTE: Use an Allen key to stop the piston

rod from turning.
Tighten the suspension strut top nut.
8. Park the vehicle on a level surface and fill

the transmission with oil until the level is to
the bottom edge of the filler hole.
E6319 EN 07/2001 2002 Bantam


Halfshaft RH (14 321 0)

Installer, drive halfshaft Two-legged puller
204-161 (14-041) Allen key
Boot clamp tightening tool

204-169 (14-044)
Removal

rod from turning.
turns.
2. Loosen the axle stub nut.
3. Detach the front wheel. For additional

E6365 EN 07/2001 2002 Bantam


spindle carrier.

Unscrew and remove the axle stub nut and
remove the washer.
• Press the axle stub out of the wheel hub
using a two-legged puller and tie the
halfshaft up using cable ties.
6. NOTE: Do not damage the boot.

Remove the boot.
• Remove and discard the clamping
straps.
• Slide the boot onto the halfshaft.
7. Remove the halfshaft.

• Pull out the front drive halfshaft from the
tripod housing.
E6365 EN 07/2001 2002 Bantam

Installation
1. CAUTION: Support the halfshaft. The

Install the front halfshaft.
• Install the front drive halfshaft into the
tripod joint.
2. NOTE: Do not damage the boot.

Install the boot.
• Slide the boot onto the halfshaft.
• Install new clamping straps and secure
them using the special tool.
3. Pull the halfshaft into the wheel hub using

the special tool.

CAUTION: Do not tighten the axle stub
nut yet.
Put on the axle stub nut.
• Insert the washer and screw on the axle
stub nut.
E6365 EN 07/2001 2002 Bantam


spindle carriers.
6. Install the front wheel. For additional

7. Tighten the axle stub nut.

rod from turning.
E6365 EN 07/2001 2002 Bantam


Inner Constant Velocity (CV) Joint Boot (14 336 4)

Boot clamp tightening tool Snap-ring pliers
204-169 (14-044) Clamping straps
High-durability grease WSD-M1C230-A
Removal

rod from turning.
turns.
2. Raise the vehicle. For additional


spindle carrier.
E6459 EN 07/2001 2002 Bantam

4. Undo the clamping straps on the left-hand

front drive halfshaft boot.
• Slide the boot onto the front drive
halfshaft.

Separate the tripod joint of the left-hand
halfshaft.
• Remove the grease from inside the joint.
6. Undo the boot clamps on the right-hand

halfshaft and slide the boot back.

Pull the right-hand front drive halfshaft out
of the tripod joint.
• Secure the front drive halfshaft to the
side with cable ties.
E6459 EN 07/2001 2002 Bantam

8. Remove the tripod star and the boot.

• Detach the snap-ring using snap-ring
pliers and pull off the tripod star.
• Pull off the boot.
Installation
1. NOTE: Chamfer points towards the front drive

halfshaft.
Fit the tripod assembly.
• Push on the boot.
• Push on the tripod and secure it.

Assemble the left-hand front drive halfshaft
tripod joint using high-durability grease.
E6459 EN 07/2001 2002 Bantam

3. Make a clamp head for Special Tool 204-169.
• Material: aluminium or steel plate
4. Position the tripod joint boot and secure it

with clamping straps.
• Apply the special tool so that the clamp
head is vertical to the clamping strap
head.
NOTE: Tighten 0,8 mm thick clamping straps to
12 Nm and 1,1 mm thick clamping straps to
20 Nm.
• Tighten the clamping strap using the
special tool.

Assemble the right-hand front drive
halfshaft tripod joint using high-durability
grease.
6. Position the tripod joint boot and secure it

with clamping straps.
head.
20 Nm.
special tool.
E6459 EN 07/2001 2002 Bantam


spindle carriers.

rod from turning.
E6459 EN 07/2001 2002 Bantam


Outer Constant Velocity (CV) Joint Boot (14 338 4)

204-169 (14-044)
Clamping straps
Removal

rod from turning.
Loosen the suspension strut top nut by five
turns.


spindle carrier.
E5892 EN 07/2001 2002 Bantam

4. Release the clamping straps from the boot.

halfshaft.

CAUTION: Carefully push the wheel
suspension outwards to avoid damage
to the tripod joint (inner joint).
Detach the front drive halfshaft from the
halfshaft joint.
• Pull off the boot and tie up the front drive
halfshaft.
• Open the snap-ring using snap-ring
pliers and hold it open.
• Remove the snap-ring.
Installation

NOTE: Make sure the circlip snaps securely into
place.
Install the front drive halfshaft.
• Insert a new snap-ring into the drive
halfshaft joint groove.
halfshaft.
• Insert the front drive halfshaft into the
halfshaft joint until the snap-ring engages.
NOTE: Fill level for models with Endura-DE
diesel engines: 40 g on each side.
• Capacity for all other models: 30 g on
each side.
E5892 EN 07/2001 2002 Bantam

2. Pack the halfshaft joint with high-durability

grease (WSD-M1C230-A).
3. Make a clamp head for Special Tool 204-169.
4. Position the halfshaft joint boot and secure

it using new clamping straps.
• Insert the clamp head in the special tool.
head.
20 Nm.
special tool.

spindle carriers.

rod from turning.
E5892 EN 07/2001 2002 Bantam


Outer Constant Velocity (CV) Joint

Installer, Halfshaft 32 mm socket
204-161 (14-041) Two-legged puller
Clamping Tool, Boot
Retaining Clamp Boot clamps
204-169 (14-044)
Removal
1. NOTE: Use an Allen key to prevent the piston

rod turning.
Loosen the left-hand and the right-hand
strut and spring assembly upper retaining
nut five turns (right-hand side shown).
2. Loosen the left-hand wheel nuts and loosen

the stub axle nut.
• Release the front drive halfshaft stub nut
and loosen it with a 32 mm socket
wrench.

additional information, refer to Section 100-02.
E6671 EN 07/2001 2002 Bantam

4. Detach the right-hand and the left-hand

lower arms (left-hand side shown).
5. Separate and discard the boot clamps.

1. Slide the boot back onto the halfshaft.
2. Remove the grease from inside the joint.
6. CAUTION: The inner joint must not be

bent at more than 18 degrees; the
outer joint must not be bent at more
than 45 degrees.
Remove the front drive halfshaft from the
constant velocity joint.
1. Lever open the retaining ring and hold it
open.
2. Carefully push the spindle carrier
outwards and withdraw the front drive
halfshaft.
3. Lift up the front drive halfshaft and tie it
up.
4. Remove the retaining ring from the
constant velocity joint.
7. Remove the front drive halfshaft nut and

take off the washer.
• Using a two-legged puller to press the
left-hand halfshaft out of the wheel hub
and tie it up.
E6671 EN 07/2001 2002 Bantam

Installation
NOTE: Use all new circlips, self-locking nuts

and clamps.
1. Draw the front drive halfshaft stub into the
wheel hub.
• Insert the washer and screw on the front
drive halfshaft stub nut.
2. CAUTION: The inner constant velocity

joint must not be bent at more than
18 degrees, the outer joint must not
be bent at more than 45 degrees.
NOTE: Make sure the retaining ring is securely
in place.
Install the drive halfshaft in the constant
velocity joint.
• Guide the front drive halfshaft into the
constant velocity joint until the retaining
ring clips in place.
3. Fabricate an adapter for special tool 14-044.
• Material: aluminium or steel plate, 5 mm

thick.
E6671 EN 07/2001 2002 Bantam

4. Pack the constant velocity joint with high-

durability grease.
• Amount: 40 grams on each side.
5. NOTE: Tighten 0,8 mm thick boot clamps to

12 Nm and 1,1 mm thick boot clamps to 20
Nm.
Position the boot and using the special tool
and adapter secure the boot clamps.
6. Install the lower suspension arm and the

front wheel.
8. Tighten the wheel nuts and the front drive

halfshaft stub nut.
1. Using a 32 mm socket wrench, tighten
the front drive halfshaft stub nut and
secure it, using a lock pin.
2. Wheel nuts.
E6671 EN 07/2001 2002 Bantam


rod turning.
Tighten the left-hand and the right-hand
side strut and spring assembly upper
retaining nut.
E6671 EN 07/2001 2002 Bantam


Halfshaft LH (14 320 8)

204 - 169 (14 - 044)
Clamping straps
Disassembly
NOTE: Use protective covers.

1. Disconnect the front drive halfshaft at the
transmission end.
• Clamp the front drive halfshaft in a
clamp.
1. Separate and discard the clamping
straps. Push back the boot.
2. Separate the tripod joint.
2. Remove the tripod star and the boot.

1. Detach the snap-ring using snap-ring
pliers and pull off the tripod star.
2. Pull off the boot.
E1088 EN 07/2001 2002 Bantam

3. Detach the drive halfshaft joint gaiter.

1. Loosen the clamping straps from the
boot.
4. Detach the front drive halfshaft from the

halfshaft joint.
• Open the circlip with circlip pliers and
hold it.
• Pull the front drive halfshaft from the
halfshaft joint.
• Remove the circlip from the halfshaft
joint.
Assembly
NOTE: Renew all snap-rings and clamping

straps.
1. NOTE: Chamfer points towards the front drive
halfshaft.
Fit the tripod star assembly.
halfshaft.
• Push the tripod star onto the front drive
halfshaft.
• Fit the circlip.
E1088 EN 07/2001 2002 Bantam

2. Make a clamp head for Special Tool 14- 044.
3. NOTE: Tighten 0,8 mm thick clamping straps

to 12 Nm and 1,1 mm thick clamping straps
to 20 Nm.
Insert the clamping strap in the groove of
the boot and tighten using the special tool.
4. Install the constant velocity joint at the

transmission end.
• Fill the tripod joint with 125 grams of
high-durability grease and fit.
1. Slide a small screwdriver under the boot
seat to allow the air to escape.
2. Slide the tripod joint inwards as far as
the stop, then pull it out 20 mm.
• Remove the screwdriver.
5. NOTE: Tighten 0,8 mm thick clamping straps

to 12 Nm and 1,1 mm thick clamping straps
to 20 Nm.
Insert the clamping strap in the groove of
the boot and tighten with the special tool.
6. NOTE: Make sure the snap-ring snaps

securely into place.
Fit the front drive halfshaft into the halfshaft
joint.
• Slide on the boot with the inner clamping
strap.
• Insert a new circlip into the drive
halfshaft joint groove.
• Insert the front drive halfshaft into the
drive halfshaft joint until the snap-ring
engages.
E1088 EN 07/2001 2002 Bantam

7. Pack the outer drive halfshaft joint with

high-durability grease and attach the boot.
• Fill level for vehicles with Endura-DE
diesel engines: 40 g each side.
• Fill level for all other vehicles: 30 g each
side.
• Push on the boot.
head is vertically on the clamping strap
head.
E1088 EN 07/2001 2002 Bantam


Halfshaft RH (14 320 8)

Boot clamp tightening tool Bridge, drive pinion bearing
14-044 remover
15-092
Separating tool
15-091 Material Specification
Disassembly
1. NOTE: Use protective covers.

Loosen the clamping straps from the boot.
• Detach the front drive halfshaft from the
intermediate shaft.
• Clamp the intermediate shaft in a vice.
• Separate and discard the clamping
2. CAUTION: Constant velocity rollers

can drop out.
Separate the tripod joint.
E1089 EN 07/2001 2002 Bantam

3. Dismantle the tripod assembly

1. Remove the rollers.
2. Detach the snap-ring.
4. Pull off the tripod assembly

• Remove the boot.
5. CAUTION: Do not damage the bearing

cage.
Release the constant velocity joint at the
wheel end.
1. Separate and discard the clamping
2. Release the constant velocity joint from
the snap-ring seat using a brass drift.
6. Detach the constant velocity joint.

1. Pull off the constant velocity joint.
E1089 EN 07/2001 2002 Bantam

7. Press off the centre bearing.
Assembly
1. General note.
• Renew all snap-rings and clamping
straps.
2. Press on the centre bearing.
3. Fit the boot at the transmission end.

1. Slide on the boot with the inner clamping
strap.
2. Locate the boot in position.
E1089 EN 07/2001 2002 Bantam

4. Insert the clamping strap in the groove of

the boot and tighten with the special tool.
5. CAUTION: Do not damage the bearing

seat of the rollers.
Fit the tripod star.
• Drive the tripod star onto the front drive
halfshaft as far as it will go, using a
suitable tube.
6. NOTE: Use a new snap-ring.

Assemble the tripod joint.
1. Snap-ring
2. Fit the constant velocity rollers, applying
high-durability grease.
7. Attach the intermediate shaft to the front

drive halfshaft.
• Fill the tripod joint with 100 grams of
high-durability grease and fit.
2. Slide the tripod joint inwards as far as
the stop, then pull it out 20 mm.
• Remove the screwdriver.
E1089 EN 07/2001 2002 Bantam

8. Insert the clamping strap in the groove of

the sleeve and tighten with the special tool.
9. NOTE: Use a new snap-ring. Make sure the

circlip clicks into place.
Install the constant velocity joint at the
wheel end.
1. Slide on the boot with the inner clamping
strap.
2. Fit the snap-ring.
3. Fill the constant velocity joint with 80
grams of high-durability grease and push
onto the driveshaft.
10. Fit the boot.

• Press the boot into the groove on the
driveshaft.
2. Locate the boot in position and remove
the screwdriver.
• Tension the clamping straps (see
previous step).
E1089 EN 07/2001 2002 Bantam

SPECIFICATIONS
Item Specification
Transmission fluid (iB5 manual transmission) SAE 75W90
Capacities
Litres
Transmission fluid (iB5 manual transmission) 2,8
Fill Capacities
Grams
High-durability grease, tripod joint 125
High-durability grease, CV joints, Endura - DE engine 40
All other engines 30
Description Nm
Intermediate shaft centre bearing 24
Suspension arm to spindle carrier 52
Driveshaft stub nut 290
Suspension strut top nut 46
Tightening tool, for 0,8 mm boot retaining straps 12
Tightening tool, for 1,1 mm boot retaining straps 20
E6460 EN 07/2001 2002 Bantam

206-00-1 Brake System — General Information 206-00-1
SECTION 206-00 Brake System —

General Information
SUBJECT PAGE
Brake System ...................................................................................................................... 206-00-2
Brake System ...................................................................................................................... 206-00-3

Road Test ......................................................................................................................... 206-00-3
Symptom Chart…………………………………………………………………………………… 206-00-4/5
Pinpoint Tests ................................................................................................................... 206-00-6/16
Component Tests.............................................................................................................. 206-00-16
Brake System Check......................................................................................................... 206-00-17
Brake Booster Functional Test .......................................................................................... 206-00-17/18
GENERAL PROCEDURES
Brake System Bleeding................................................................................... (12 141 0) 206-00-19/20

Load Active Valve (LAV) ................................................................................. (12 141 0) 206-00-21/22
Load Apportioning Valve Adjust………………………………………………………………….. 206-00-23/24
Brake Disc Run out Check ................................................................................................... 206-00-25/26
SPECIFICATIONS
Specifications ...................................................................................................................... 206-00-27

Front Disc Brake Specification .......................................................................................... 206-00-27
Drum Brake Specification.................................................................................................. 206-00-27
07/2001 2002 Bantam


Brake System
The braking system is a diagonally split, dual The parking brake control is located between the
circuit system with front disc and rear drum front seats and operates the rear brakes through
brakes. a cable system. The parking brake is adjusted
from inside the passenger compartment with the
The hydraulic system provides separate circuits
vehicle on the ground.
for each pair of diagonally opposed wheels (left
front, right rear and right front, left rear). The front The brake master cylinder is of a tandem design
calipers are mounted on the wheel knuckle and a and is linked to a brake booster to reduce the
single sliding piston design, which make sure that brake pedal effort. The tandem design will make
equal effort is applied through both brake pads. sure that in the event of one brake circuit failure
the other will remain fully operational. The brake
The brake drums are of conventional design.
master cylinder and brake booster are located on
They consist of one primary and one secondary
the left-hand side of the engine compartment.
shoe with bonded thick/thin asbestos free linings.
The thick/thin linings allow the brake shoes to Vehicles fitted with the standard braking system
wear at proportional rates. The brakes self adjust have a Load Active Valve (LAV) connected to the
during foot brake operation. rear axle. The LAV control the hydraulic pressure
applied to the rear brakes reducing the risk of
rear wheel lock-up under braking.
E6591 EN 07/2001 2002 Bantam


Brake System
The brakes system operates by transferring effort road tests. The road selected will be reasonably
applied to the brake pedal by the driver to the smooth and level. Gravel or bumpy roads are not
brakes at each wheel. suitable because the surface does not allow the
tyres to grip the road equally. Crowned roads
The braking effort is distributed to each wheel, should be avoided because of the large amount
using a hydraulic system. The system is assisted of weight shifted to the low set of wheels on this
using a vacuum brake booster that reduces pedal type of road. Once the route is established and
effort and increases hydraulic pressure. consistently used, the road surface variable can
The parking brake operates on the rear wheels be eliminated from the test results.
and is applied using a hand-operated control. Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able
Inspection and Verification to match possible causes with symptoms. Certain
NOTE: Before carrying out any diagnosis, make components will be identified, as possible
sure that the brake system-warning indicator is sources while others will be eliminated by the
functional. evidence. More importantly, the customer
1. Verify the customer concern. description can reveal unsafe conditions, which
should be checked or corrected before a road
2. Visually inspect for obvious signs of test. The description will also help form the basic
mechanical damage. approach to the road test by narrowing the
concern to specific components, vehicle speed or
Visual Inspection Chart conditions.
Mechanical Begin the road test with a general brake
performance check. Using the description of the
• Tyre pressure concern, test the brakes at different vehicle
• Wheels and tyres speeds using both light and heavy pedal
• Fluid leak from brake line(s) pressure. Determine if the concern is in the front
or rear braking system. First use the foot brake
3. If an obvious cause for an observed or and then the parking brake. If the condition (i.e.
reported concern is found, correct the case (if pull, vibration, pulsation) occurs only on operation
possible) before proceeding to the next step. of the parking brake, the concern is in the rear
4. If the cause if not visually evident, verify the brake system. If the condition occurs when the
symptom and refer to the Symptom Chart. foot brake is depressed, the concern is in the
front brake system.
Road Test Avoid locking the brakes and sliding the tyres.
This condition will not indicate brake efficiency. A
Perform a road test to compare actual vehicle heavily braked but turning wheel will stop the
braking performance with the performance vehicle in a shorter distance than locked wheels.
standards expected by the driver. The ability of
the test driver to make valid comparisons and If the concern becomes evident during this check,
detect performance deficiencies will depend on make sure it fits the description given before the
experience. road test. If the concern is not evident, attempt to
duplicate the condition using the information from
The driver should have a thorough knowledge of the description.
the brake system operation and accepted general
performance guidelines to make good If a concern exists, use the Brake System Symp-
comparisons and detect performance concerns. tom Chart in order to isolate it to a specific sub-
system and condition description. From this de-
An experienced technician will always establish a scription, a list of possible sources can be used
route that will be used for all brake diagnosis to further narrow the cause to a specific compo-
nent or condition.
E1092 EN 07/2001 2002 Bantam


Symptom Chart

• Brakes pull or drift • Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads and linings. brake pads.
• Abnormal wear or distortion of • INSTALL a new front brake disc.
front brake disc.
• Incorrect rear brake adjustment. • PERFORM a parking brake ca-
ble adjustment.
• Incorrect wheel alignment ad- • PERFORM a wheel alignment
justment. adjustment.
• Incorrect wheel bearing preload • ADJUST or INSTALL a new
adjustment. wheel bearing.
• Unequal air pressure in the • INFLATE the tyres to the correct
tyres. pressure.
• Grease or fluid on the brake • INSTALL new brake shoes or
shoes or brake pads; glazed lin- brake pads.
ings.
• Stuck or seized calipers. • GO to Pinpoint Test A.
• Brake warning indicator always • Low brake fluid level. • FILL the reservoir. CHECK the
on brake and clutch system for
leaks including brake fluid in the
brake booster.
• Leaking brake master cylinder • INSTALL a new brake master
primary piston cup. cylinder.
• Parking brake control not fully • FREE UP and ADJUST the park-
released. ing brake cable.
INSTALL new components as
necessary.
• Shorted indicator circuit. • GO to Pinpoint Test B.
• Vibration when the brakes are • Grease or fluid on the brake • INSTALL new brake shoes or
applied shoes or brake pads; glazed lin- brake pads
ings.
• Worn or damaged brake shoes • INSTALL new brake shoes or
or brake pads. brake pads.
• Loose caliper mounting bolt(s). • TIGHTEN the caliper mounting
bolt(s).
• Insufficient grease on sliding • APPLY grease where necessary.
parts.
• Damaged brake drum contact • INSTALL a new brake drum.
surface.
E1092 EN 07/2001 2002 Bantam


• Loose or missing wheel hub • TIGHTEN or INSTALL new
bolts. wheel hub bolts.
• Go to Pinpoint Test C.
• Pedal goes down fast • Leak in the hydraulic system. • REPAIR the leak. CHECK the
entire hydraulic system. FILL
and BLEED the brake system.
• Air in the system. • CHECK for leaks. BLEED the
brake system.
• Worn brake master cylinder pis- • INSTALL a new brake master
ton cups or scored cylinder cylinder.
bore.
• Brake disc brake `knock back' • Install a new brake disc.
(Brake pads push the brake REFER to Section 206-03
caliper piston back into brake REFER to Section 204-01.
caliper. Caused by excessive
brake disc lateral run out or
loose wheel bearings.)
• Worn brake shoes or brake • INSTALL new brake shoes or
pads. brake pads.
• GO to Pinpoint Test D.
• Pedal eases down slowly • Air in the system. • BLEED the brake system.
• Malfunctioning brake master • GO to Pinpoint Test E.
cylinder.
• Pedal is low or feels spongy • Worn brake shoes. • INSTALL new brake shoes or
brake pads.
• Hydraulic system. • GO to Pinpoint Test F.
• Brake lockup during light brake • Incorrect tyre pressures. • INFLATE the tyres to the correct
pedal force pressure.
• Tyres worn. • INSTALL new tyres.
• Glazed or worn brake shoes or • INSTALL new brake shoes or
brake pads. brake pads.
• Brake booster • GO to Pinpoint Test G.
• Excessive or erratic pedal travel • Worn brake shoes or brake • INSTALL new brake shoes or
pads. brake pads.
• Brake discs. • GO to Pinpoint Test H.
E1092 EN 07/2001 2002 Bantam


• Brake drag • Brake booster. • GO to Pinpoint Test I.
• Incorrectly adjusted brake light • ADJUST the brake light switch.
switch.
• Seized brake caliper or wheel
cylinder.
• Parking brake applied or
malfunction
• Seized parking brake cables.
• Seized brake caliper slide pins.
• Excessive brake pedal effort • Brake booster inoperative. • PERFORM a brake booster
functional test
• Worn or contaminated brake • INSTALL new brake shoes or
shoes or brake pads. brake pads.
• GO to Pinpoint Test J.
• Brake noise • Worn brake shoes or brake • INSTALL new brake shoes or
pads. brake pads.
• Brake booster. • GO to Pinpoint Test K.
• Slow or incomplete brake pedal • Brake booster. • GO to Pinpoint Test L.
return • Brake master cylinder.
E1092 EN 07/2001 2002 Bantam

Pinpoint Tests
PAGE 1 OF 2
PINPOINT TEST A: BRAKES PULL OR DRIFT
A1: ROAD TEST THE VEHICLE.......................................................................... 206-00-6
A2: TYRE INSPECTION ....................................................................................... 206-00-6
A3: BRAKE SHOE OR BRAKE PADS AND LINING INSPECTION ...................... 206-00-6
PINPOINT TEST B: BRAKE WARNING INDICATOR ALWAYS ON
B1: CHECK BRAKE WARNING INDICATOR ...................................................... 206-00-7
B2: CHECK BRAKE SYSTEM FOR LEAKAGE.................................................... 206-00-7
B3: CHECK BRAKE WARNING SWITCH OR WIRING ....................................... 206-00-8
PINPOINT TEST C: VIBRATION WHEN BRAKES ARE APPLIED
C1: ROAD TEST THE VEHICLE.......................................................................... 206-00-8
C2: CHECK FOR REAR BRAKE VIBRATION...................................................... 206-00-8
C3: CHECK FOR FRONT BRAKE VIBRATION ................................................... 206-00-9
PINPOINT TEST D: PEDAL GOES DOWN FAST
D1: ROAD TEST THE VEHICLE.......................................................................... 206-00-9
D2: CHECK BRAKE FLUID LEVEL...................................................................... 206-00-9
D3: PRESSURIZE THE SYSTEM........................................................................ 206-00-9
D4: CHECK FOR BRAKE SYSTEM LEAKS......................................................... 206-00-10
D5: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION CHECK . 206-00-10
PINPOINT TEST E: PEDAL EASES DOWN SLOWLY
E1: CHECK BRAKE PEDAL OPERATION........................................................... 206-00-10
E2: CHECK FOR BRAKE SYSTEM LEAKS......................................................... 206-00-10
E3: PERFORM A BRAKE MASTER CYLINDER BYPASS TEST ......................... 206-00-11
PINPOINT TEST F: PEDAL IS LOW OR FEELS SPONGY
F1: ROAD TEST THE VEHICLE .......................................................................... 206-00-11
F2: CHECK BRAKE FLUID LEVEL ...................................................................... 206-00-11
F3: CHECK FILLER CAP VENT........................................................................... 206-00-11
F4: BLEED THE BRAKE SYSTEM ...................................................................... 206-00-12
F5: CHECK FRONT WHEEL HUB RETAINING NUT........................................... 206-00-12
PINPOINT TEST G: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
G1: ROAD TEST THE VEHICLE ......................................................................... 206-00-12
G2: TYRE INSPECTION ....................................................................................... 206-00-12
G3: BRAKE SHOES OR BRAKE PADS INSPECTION ........................................ 206-00-13
PINPOINT TEST H: EXCESSIVE OR ERRATIC BRAKE PEDAL TRAVEL
H1: ROAD TEST THE VEHICLE.......................................................................... 206-00-13
H2: CHECK WHEEL BEARING ........................................................................... 206-00-13
PINPOINT TEST I: BRAKES DRAG
I1: CHECK BRAKE BOOSTER ............................................................................ 206-00-13
I2: ROAD TEST THE VEHICLE ........................................................................... 206-00-14
Pinpoint Tests
PAGE 2 OF 2
PINPOINT TEST J: EXCESSIVE BRAKE PEDAL EFFORT
J1: CHECK BRAKE APPLICATION ..................................................................... 206-00-14
J2: CHECK BRAKE BOOSTER FOR LEAKS....................................................... 206-00-14
J3: CHECK BRAKE BOOSTER CHECK VALVE.................................................. 206-00-14
J4: CHECK BRAKE BOOSTER CHECK VALVE VACUUM.................................. 206-00-15
J5: CHECK BRAKE BOOSTER ........................................................................... 206-00-15
J6: CHECK BRAKE PEDAL LINKAGE................................................................. 206-00-15
PINPOINT TEST K: BRAKE NOISE
K1: CHECK FOR PEDAL NOISE......................................................................... 206-00-15
K2: CHECK PUSH ROD ALIGNMENT................................................................. 206-00-16
PINPOINT TEST L: SLOW OR INCOMPLETE BRAKE PEDAL RETURN
L1: CHECK FOR BRAKE PEDAL RETURN......................................................... 206-00-16
L2: CHECK FOR BRAKE PEDAL BINDING......................................................... 206-00-16
PINPOINT TEST A: BRAKES PULL OR DRIFT
A1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brake
pedal.
• Does the vehicle pull or drift?
Yes
GO TO A2
No
Vehicle OK.
A2: TYRE INSPECTION
1 Check for excessive wear or incorrect tyre
pressures.
• Are the tyres in good condition?
Yes
GO TO A3
No
INFLATE the tyres to the correct pressure.
INSTALL new tyres if excessively worn.
A3: BRAKE SHOE OR BRAKE PADS AND LINING INSPECTION
1 Inspect the brake shoes or brake pads for
grease or fluid on the linings and or wear
concerns.
• Are any concerns present?
Yes
INSTALL new brake shoes or brake pads.
E1092 EN 07/2001 2002 Bantam

PINPOINT TEST B: BRAKE WARNING INDICATOR ALWAYS ON

B1: CHECK BRAKE WARNING INDICATOR
NOTE: The brake-warning indicator should only illuminate when the ignition switch is in the START or
RUN position and the parking brake is applied.
1.
2 Release the parking brake.

- Check the fluid level in the reservoir is at the
MAX mark.
• Does the brake warning indicator illuminate?
Yes
No
GO TO B2
B2: CHECK BRAKE SYSTEM FOR LEAKAGE
1 Check the brake master cylinder reservoir
sealing points and external brake and clutch
system for leaks.
Refer to the brake master
cylinder component tests in this section.
• Does the system leak?
Yes
REPAIR as necessary. ADD fluid and
BLEED the brake system.
No
GO TO B3
E1092 EN 07/2001 2002 Bantam

B3: CHECK BRAKE WARNING SWITCH OR WIRING
1.
2 Remove the brake master cylinder reservoir

filler cap or switch. Allow the float to rest at its
lowest (maximum) point.
Yes
The switch or wiring is OK. TEST the
No
PINPOINT TEST C: VIBRATION WHEN BRAKES ARE APPLIED
C1: ROAD TEST THE VEHICLE
1 Road test the vehicle without applying the
brakes at 40-80 km/h.
• Is a vibration present?
Yes
REFER to Section 100-04. After servicing.
No
GO TO C2
C2: CHECK FOR REAR BRAKE VIBRATION
NOTE: With a manual release parking brake control, hold the parking brake control release button in
the release position during parking brake control application.
1 Road test the vehicle at 40-80 km/h with a
medium application on the parking brake
control.
Yes
CHECK the rear brake drums for excessive
wear. INSTALL new components as
operation.
No
GO TO C3
E1092 EN 07/2001 2002 Bantam

C3: CHECK FOR FRONT BRAKE VIBRATION
1 Road test the vehicle at 40-80 km/h with light
and medium application of the foot brake.
Yes
CHECK the front brake discs for excessive
wear or cracks. INSTALL new components
as necessary. TEST the system for normal
operation.
No
Vehicle OK.
PINPOINT TEST D: PEDAL GOES DOWN FAST
D1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the foot brake.
• Was the brake pedal effort normal?
Yes
Vehicle OK.
No
GO TO D2
D2: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid
level.
• Is the fluid level acceptable?
Yes
GO TO D3
No
CHECK the brake master cylinder reservoir
sealing points for leaks.
Refer to the brake master cylinder
component tests in this section
ADD fluid and BLEED the brake system
D3: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then
hold?
Yes
CHECK parking brake adjustment and
ADJUST as necessary. REFER to Section 206-05.
If the condition still exists. BLEED
the brake system. REFER to Section 206-00.
No
GO TO D4
E1092 EN 07/2001 2002 Bantam


D4: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks
Refer to brake master cylinder
component tests in this section.
• Are any leaks found?
Yes
No
GO TO D5
D5: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION CHECK
1 Test for a brake master cylinder bypass.
Refer to the brake master cylinder component
tests in this section.
• Was a concern found?
Yes
INSTALL a new brake master cylinder. ADD
fluid and BLEED the brake system.
No
System OK.
PINPOINT TEST E: PEDAL EASES DOWN SLOWLY
E1: CHECK BRAKE PEDAL OPERATION
1 Check if the condition occurs when applying
the brake pedal while the vehicle is moving.
• Does the condition occur with the vehicle
stationary?
Yes
GO TO E2
No
Refer to the brake master cylinder
component tests in this section.
E2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks
Refer to the master cylinder component tests
in this section.
• Are any leaks found?
Yes
No
GO TO E3
E1092 EN 07/2001 2002 Bantam

E3: PERFORM A BRAKE MASTER CYLINDER BYPASS TEST
1 Test for a brake master cylinder bypass.
Yes
INSTALL a new brake master cylinder. ADD
fluid and BLEED the bake system.
No
System OK. TEST the system for normal
operation.
PINPOINT TEST F: PEDAL IS LOW OR FEELS SPONGY
F1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the foot brake.
• Did the brake pedal feel spongy?
Yes
GO TO F2
No
Vehicle OK.
F2: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid
level.
• Is the fluid level OK?
Yes
GO TO F3
No
CHECK the brake master cylinder reservoir
sealing points.
ADD fluid and BLEED the brake system.
F3: CHECK FILLER CAP VENT
1 Check if the filler cap vent holes are clogged or
dirty.
Yes
CLEAN as necessary. TEST the system for
normal operation.
No
GO TO F4
E1092 EN 07/2001 2002 Bantam

F4: BLEED THE BRAKE SYSTEM
1 Check for air in the brake system. Bleed the
brake system. REFER to Section 206-00.
• Is the condition still present?
Yes
GO TO F5
No
Vehicle OK.
F5: CHECK FRONT WHEEL HUB RETAINING NUT
1 Check the front wheel hub-retaining nut for
looseness. REFER to Section 204-01.
• Is the front wheel hub-retaining nut loose?
Yes
INSTALL a new front wheel hub-retaining
nut. Do not reuse the front wheel hub-
retaining nut. TEST the system for normal
operation.
No
CHECK the parking bake adjustment.
PINPOINT TEST G: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
G1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brake
pedal lightly.
• Do the rear brakes lock up?
Yes
GO TO G2
No
Vehicle OK.
G2: TYRE INSPECTION
1 Check for excessive tyre wear or incorrect tyre
pressures.
• Are the tyres in good order?
Yes
GO TO G3
No
SUBSTITUTE known good tyres. INFLATE
to the correct pressure. TEST the system for
normal operation.
E1092 EN 07/2001 2002 Bantam

G3: BRAKE SHOES OR BRAKE PADS INSPECTION
1 Inspect the brake shoes or brake pads are
correctly fitted and for grease or fluid
contamination or wear concerns.
• Are there any concerns?
Yes
operation.
PINPOINT TEST H: EXCESSIVE OR ERRATIC BRAKE PEDAL TRAVEL

H1: ROAD TEST THE VEHICLE
1 Road test the vehicle under rough road
conditions. Apply the brakes slowly.
• Is the pedal travel OK?
Yes
Vehicle OK.
No
GO TO H2
H2: CHECK WHEEL BEARING
1 Check for loose front wheel bearings.
• Are the front wheel bearings loose?
Yes
CHECK the front wheel hub-retaining nut.
INSTALL a new front wheel bearing(s) if
worn or damaged,REFER to Section 204-01.
No
CHECK the front brake disc(s) for thickness
variances. INSTALL new components as
necessary. TEST the system for normal op-
eration.
PINPOINT TEST I: BRAKES DRAG
I1: CHECK BRAKE BOOSTER
1 Check the brake booster push rod alignment
and pedal travel.
• Is the push rod and pedal travel OK?
Yes
GO TO I2
No
INSTALL a new brake booster. TEST the
E1092 EN 07/2001 2002 Bantam

I2: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brakes.
• Are the brakes functioning correctly?
Yes
Vehicle OK.
No
INSPECT individual wheel cylinders or cali-
pers for binding or sticking components.
PINPOINT TEST J: EXCESSIVE BRAKE PEDAL EFFORT
J1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the
brake pedal five times to deplete all vacuum
from the brake booster. Apply the brake pedal,
hold with light pressure. Start the engine.
• Does the brake pedal hold?
Yes
GO TO J2
No
GO TO J6
J2: CHECK BRAKE BOOSTER FOR LEAKS
1 Run the engine at medium idle, release the
accelerator pedal and turn the engine off. Wait
90 seconds and apply the brakes. Two or more
brake applications should be power assisted.
• Does the brake booster work?
Yes
Vehicle OK.
No
GO TO J3
J3: CHECK BRAKE BOOSTER CHECK VALVE
1 Disconnect the vacuum hose, for the brake
booster check valve at the manifold. Blow into
the hose attached to the brake booster check
valve.
• Does air pass through the valve?
Yes
INSTALL a new brake booster check valve.
No
GO TO J4
E1092 EN 07/2001 2002 Bantam

J4: CHECK BRAKE BOOSTER CHECK VALVE VACUUM
1 Disconnect the vacuum hose from the brake
booster check valve. Run the engine at idle.
Check the supply with a vacuum gauge.
• Is the vacuum pressure above 40.5 kPa (12 in-
Hg) with the brake booster non-operational?
Yes
GO TO J5
No
REPAIR or INSTALL a new vacuum hose
and fittings. TEST the system for normal
operation.
J5: CHECK BRAKE BOOSTER
1 Check the brake booster. GO to the
component test procedure in this section.
• Is the brake booster OK?
Yes
GO TO J6
No
J6: CHECK BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin
and apply the brake pedal fully.
• Did the pedal move freely?
Yes
No
REPAIR or INSTALL new brake pedal bush-
ings. TEST the system for normal operation.
PINPOINT TEST K: BRAKE NOISE

K1: CHECK FOR PEDAL NOISE
1 Inspect the brake pads and brake shoes for
excessive wear.
- Run the engine at idle for 10 seconds or
longer. Apply the brake pedal and listen for
noise. Compare results with a known good
system.
• Was a noise present?
Yes
GO TO K2
No
Vehicle OK.
E1092 EN 07/2001 2002 Bantam

K2: CHECK PUSH ROD ALIGNMENT
1 Check the brake booster push rod alignment
and travel.
• Is the push rod OK?
Yes
EFER to Section 206-00.
R
No
PINPOINT TEST L: SLOW OR INCOMPLETE BRAKE PEDAL RETURN
L1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at fast idle while making
several brake applications. Pull the brake pedal
rearward with approximately 44.5 N force.
Release the brake pedal and measure the
distance to the floor pan. Make a hard brake
application. Release the brake pedal and
measure the brake pedal to floor pan distance.
The brake pedal should return to its original
position.
• Did the brake pedal return to its original
position?
Yes
Vehicle OK.
No
GO TO L2
L2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
• Is the brake pedal operating freely?
Yes
No
REPAIR or INSTALL new brake pedal bush-
ings. TEST the system for normal operation.
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid operated in rain or snow, as brake fluid is water-
reservoir; therefore it is possible that a clutch leak soluble. Refill the system, bleed then apply the
can lead to reduction in the reservoir level. brakes several times. Examine the system to
verify that the reservoir fluid level is actually
It is possible that all evidence of fluid leakage dropping. Locate and repair the external leak. If
may have washed off if the vehicle has been the fluid level drops and no external leak can be
found, check for a brake master cylinder bore
end seal leak.
E1092 EN 07/2001 2002 Bantam


Brake System Check
will tend to move downward under constant
Brake Pedal Reserve Check foot pressure. If no motion is felt, the vacuum
Where a low brake pedal or the feel of a booster system is not functioning.
bottomed-out condition exists, check for brake 4. Remove the vacuum hose from the brake
pedal reserve. booster. Manifold vacuum should be
available at the brake booster end of the
1. Operate the engine at idle with the transaxle hose with the engine at idle speed and the
in NEUTRAL. transaxle in NEUTRAL. Make sure that all
2. Apply the brake pedal lightly three or four unused vacuum outlets are correctly capped,
times. hose connectors are correctly secured and
3. Allow 15 seconds for vacuum to replenish the vacuum hoses are in good condition. When it
brake booster. is established that manifold vacuum is
NOTE: This increased resistance may feel like available to the brake booster, connector the
something has bottomed out. vacuum hose to the brake booster and
repeat Step 3. If no downward movement of
4. Apply the brake pedal until it stops moving
the brake pedal is felt, install a new brake
downward or an increased resistance to the
booster.
pedal travel occurs.
5. Operate the engine a minimum of 10
5. Hold the brake pedal in the applied position
seconds at fast idle. Stop the engine and let
and raise the engine speed to approximately
the vehicle stand for 10 minutes. Then, apply
2000 rpm.
the brake pedal with approximately 89 N. The
NOTE: The additional movement of the brake pedal feel (brake application) should be the
pedal is the result of the increased engine same as that noted with the engine
manifold vacuum, which exerts more force on the operating. If the brake pedal feels hard (no
brake booster during engine rundown. This power assist), install a new vacuum check
means that additional stroke is available in the valve and then repeat the test. If the brake
brake master cylinder and the brake system is pedal still feels hard, install a new brake
not bottoming out. booster. If the brake pedal movement feels
6. Release the accelerator pedal and observe spongy, bleed the brake system.
that the brake pedal moves downward as the REFER to Section 206-06.
engine returns to idle speed.
Brake Master Cylinder
Usually, the first and strongest indicator of
Brake Booster Functional Test
anything wrong with the braking system is a
Inspect all hoses and connections. All unused feeling through the brake pedal. In diagnosing the
vacuum connectors should be capped. Hoses condition of the brake master cylinder, check
and their connections should be correctly pedal feel as evidence of a brake concern. Check
secured and in good condition with no holes and for the brake warning indicator illumination and
no collapsed areas. Inspect the check valve on the fluid level in the master cylinder reservoir.
the brake booster for damage.
Normal Conditions
Brake Booster Operation Check
The following conditions are considered normal
1. Check the hydraulic brake system for leaks and are not indications that the brake master
or low fluid. cylinder is in need of service.
2. With the transaxle in NEUTRAL, stop the • Modern brake systems are not designed to
engine and apply the parking brake. Apply produce as hard a pedal effort as in the past.
the brake pedal several times to exhaust all Complaints of light pedal efforts should be
vacuum in the system. compared to pedal efforts of another vehicle,
3. With the engine turned off and all vacuum in of the same model and year.
the system exhausted, apply the brake pedal • During normal operation of the brake the fluid
and hold it down. Start the engine. If the level in the reservoir will rise during brake
vacuum system is operating, the brake pedal application and fall during release. The net
E1092 EN 07/2001 2002 Bantam

fluid level (i.e., after brake application and damaged or incorrectly adjusted Load Active
release) will remain unchanged. Valve.
• A trace of brake fluid will exists on the brake • The brake pedal effort is erratic. This
booster shell below the master cylinder- condition could be caused by a brake booster
mounting flange. This results from the normal malfunction; extreme caliper piston knock
lubricating action of the master cylinder bore back or incorrectly installed brake shoes and
end seal. linings.
• The fluid level will fall with brake shoe and • The brake-warning indicator is ON. This may
lining wear. be caused by low fluid level, ignition wire
routing too close to the fluid level indicator
assembly, or float assembly damage.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make
Bypass Condition Test
sure the brake system-warning indicator is
functional. 1. Check the fluid in brake master cylinder. Fill
the brake master cylinder reservoir if low or
Changes in brake pedal feel or travel are
empty.
indicators that something could be wrong with the
braking system. The diagnostic procedure and 2. Observe the fluid level in the brake master
techniques use brake pedal feel, warning cylinder reservoir. If after several brake
indicator illumination and low brake fluid level as applications, the fluid level remains the
indicators in diagnosing braking system same, measure the wheel turning torque
concerns. The following conditions are required to rotate the wheels with the brakes
considered abnormal and indicate that the brake applied as follows:
master cylinder is in need of service. Place the transaxle in NEUTRAL and raise and
• The brake pedal goes down fast. This could support the vehicle. REFER to Section 100-02.
be caused by an external or internal leak. Apply the brakes with a minimum of 445 N and
• The brake pedal eases down slowly. This hold for approximately 15 seconds. With the
could be caused by an external or internal brakes still applied, exert a torque on the front
leak. wheels of 10.1 Nm. If either wheel rotates, install
• The brake pedal is low and or feels spongy. a new brake master cylinder.
This condition may be caused by no fluid in
the brake master cylinder reservoir, reservoir Non-Pressure Leaks
cap vent holes clogged or air in the hydraulic
system. Any empty brake master cylinder reservoir
• The brake pedal effort is excessive. This may condition may be caused by two types of non-
be caused by a bind or obstruction in the pressure external leaks.
pedal or linkage, clogged fluid control valve or Type 1: An external leak may occur at the master
insufficient booster vacuum. cylinder reservoir cap because of incorrect
• The rear brakes lock up during light pedal positioning of the gasket and cap. Reposition the
force. This may be caused by incorrect tyre cap and gasket.
pressures, grease or fluid on the brake shoes Type 2: An external leak may occur at the
and linings, damaged brake shoes and reservoir mounting seals. Service such a leak by
linings, incorrectly adjusted parking brake, or installing new seals.
E1092 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Brake System Bleeding (12 141 0)
Bleeding
1. Disconnect the battery ground cable.

All Vehicles
WARNING: Brake fluid contains polygly-

col ethers and polyglycols. Avoid con-
tact with the eyes. Wash hands thor-
oughly after handling. If brake fluid con-
tacts the eyes, flush the eyes for 15
minutes with cold running water. Get
medical attention if irritation persists. If
taken internally, drink water and induce
vomiting. Get medical attention immedi-
ately. Failure to follow these instruc-
tions may result in personal injury.
CAUTION: If brake fluid is spilt on the

paintwork, the affected area must be
immediately washed down with cold wa-
ter.
NOTE: Make sure that the vehicle is standing on
a level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear
wheel. Each circuit can be bled independently.
1. CAUTION: The brake fluid reservoir

must remain full with new, clean
brake fluid at all times during
bleeding.
NOTE: Start bleeding the brake system from the
furthest bleed nipple from the brake master
cylinder.
Install the bleed tube to the bleed nipple.
2. Immerse the end of the bleed tube in a

bleed jar containing a small quantity of
approved brake fluid.
3. Position the bleed jar base at least 300 mm

above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
4. Loosen the bleed nipple by one-half turn.
E3164 EN 07/2001 2002 Bantam

5. Operate the brake pedal fully (pumping

brake fluid and air into the bleed jar) and
allow the brake pedal to return to the rest
position.
6. Fill the brake fluid reservoir.
7. Continue operating the brake pedal until air-

free fluid is being pumped into the bleed jar.
8. With the brake pedal fully depressed tighten

the bleed nipple.
9. CAUTION: Make sure the bleed nipple

cap is installed after bleeding the
brake line(s). This will prevent
corrosion to the bleed nipple. Failure
to follow this instruction may result
in the bleed nipple becoming seized.
Repeat the procedure for the remaining
brake lines.
E3164 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Load Active Valve (LAV)
Removal

ately. Failure to follow these instruc-
CAUTION: Make sure that the vehicle is

standing on a level surface.

paintwork, the affected areas must be
ter.
1. Disconnect the brake pipes from the valve

and drain the brake fluid.
2. Remove the two bolts securing the valve to

the body-mounting bracket.
3. Lower the valve and remove by sliding the

spacer tube assembly off the link rod in the
axle bracket.
4. Remove the link rod from the axle tube

bracket
E4252 EN 07/2001 2002 Bantam

5. If the bush is worn or damaged remove it from

the axle tube bracket and replace it.
Installation
1. If the bush requires replacement (step 5

above), fit a new bush by coiling the bush and
pressing it into the aperture in the bracket.
2. Apply a small smear of grease to the axle end

of the link rod and a liberal amount of grease
to the other end. Slide the link rod into the
axle bracket bush.
3. Slide the spacer tube assembly over the link

rod and refit the valve to the body bracket,
secure with two bolts.
4. Reconnect the brake pipes.
5. Bleed the brakes, refer to Section 206-00-21

Note: Ensure that the valve is kept "open" (valve
actuating lever hard against valve body) dur-
ing operation, by using a suitable clip or wire.
Ensure that the vale is not damaged.
6. Adjust the valve linkage.
E4252 EN 07/2001 2002 Bantam

Load Apportioning Valve Adjust
Note: Vehicle must be in the unladen condition.
Important: Two adjusting procedures are detailed

below. Procedure "A" should always be used ex-
cept when two new rear leaf springs have been fit-
ted, then procedure "B" must be followed.
Setting distance of adjusting nut
Procedure "A" To be used except when new

rear leaf springs are fitted.
1. If new valve linkage has been fitted.
Measure the distance from the end of the

threaded adjustment rod to the end of the adjust-
ing nut face, the measurement should be 10 to
12 mm, if not adjust accordingly. This measure-
ment is a datum to allow futures measurements.
Rotate the spacer tube "B" so that the distance

between the end of the spacer tube and the
stepped shoulder of the link rod "A" is 16.5 to
18.5 mm, dimension "C".
Crimp the end of the spacer tube, adjacent to

the knurled section of the tube, against the
flats of the threaded adjustment rod using a
suitable tool. This is to prevent the tube from
turning thus altering the adjustment.
2. For existing valve linkage.
Measure the distance between the end of the

spacer tube and the stepped shoulder of the link
rod.
To adjust, hold the threaded adjustment rod flats

at the end of the rod "E" to prevent it turning and
rotate the adjusting nut "C" one way or another
until the correct measurement is obtained.
E3166 EN 07/2001 2002 Bantam

Procedures "B" to be used when new

rear springs are fitted.
1. Follow sub operation 1 (for new valve linkage)

or sub operation 2 (for existing linkage) of "A"
above, except that the setting position for the end
of the spacer tube is now to align to the groove in
the link rod.
E3166 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Brake Disc Run out Check

Holding Fixture, Dial Indicator Dial indicator gauge
Gauge
Micrometer
205-070 (15-022A)
Check

3. Remove the wheel.
4. Remove the brake pads. For additional

information, refer to Section 206-03
5. Reverse and install the wheel nuts to hold

the brake disc in place.
6. Install a Dial indicator gauge and holding

fixture to the suspension strut.
7. NOTE: If the run out is outside the

specification, check the wheel hub face run
out.
Using a suitable dial indicator gauge
measure the inner and outer faces of the
disc.
1. Position the gauge so that it contacts the

disc 10 mm from the outer edge.
2. Slowly rotate the disc. The total dial
reading should not exceed the given
specification. For additional information,
refer to Specification. in this section
E3166 EN 07/2001 2002 Bantam

6
8. Check the brake disc thickness variation.

• Using a suitable Micrometer measure
the disc thickness at eight positions 45°
apart and 15 mm in from the outer edge of
the brake disc.
• If any of the readings vary by 0.015 mm
or more, or the brake disc thickness is
less than the specified minimum, a new
brake disc should be installed.
9. Remove the brake disc. For additional

10. NOTE: Make sure the wheel hub face is

clean and free of rust and foreign material.
Using the special tool, check the wheel hub
face run out.
• Slowly rotate the wheel hub and check
the run out. If the run out exceeds the
given specification. Install a new wheel
hub and recheck. For additional
11. If the hub face run out is within specification

install a new brake disc and recheck the
brake disc run-out. For additional
E3166 EN 07/2001 2002 Bantam

SPECIFICATIONS
Item Specification
High temperature grease SAM - 1C9111-A
Super DOT 4 brake fluid SAM - 6C9103-A
Front Disc Brake Specification

mm
Brake disc diameter 239.5
New brake disc nominal thickness 20
Worn brake disc discard thickness * 18
Maximum brake disc run out (installed) 0.1
Maximum brake disc thickness variation 0.025
Brake caliper piston diameter 54
Minimum brake pad thickness 1.5
*When the discard thickness has been reached install a new brake
disc.
Drum Brake Specification

mm
New brake drum nominal diameter 203
Worn brake drum discard diameter * 204
Brake shoe width 30
Wheel cylinder bore diameter 17.78
New primary brake shoe lining thickness 6
New secondary brake shoe lining thickness 3.1
Minimum brake shoe lining thickness 1.0
*When the discard diameter has been reached install a new brake
drum.
E9395 EN 07/2001 2002 Bantam

206-02-1 Drum Brake 206-02-1
SECTION 206-02 Drum Brake

SUBJECT PAGE
Drum Brake ......................................................................................................................... 206-02-2

Drum Brake ......................................................................................................................... 206-02-3

Brake Drum Replacement .............................................................................. (12 275 0) 206-02-4/5
Brake Shoes ................................................................................................... (12 285 0) 206-02-6/10
Wheel Cylinder ............................................................................................... (12 305 0) 206-02-11/12
Backing Plate.................................................................................................. (12 313 0) 206-02-13
SPECIFICATIONS
Specifications ...................................................................................................................... 206-02-14
Drum Brake Specifications ................................................................................................ 206-02-14
07/2001 2002 Bantam

206-02-2 Drum Brake 206-02-2

Drum Brake

1 Backing plate 3 Brake shoes
2 Wheel cylinder 4 Brake drum
E6593 EN 07/2001 2002 Bantam

206-02-3 Drum Brake 206-02-3

Drum Brake
E1097 EN 07/2001 2002 Bantam

206-02-4 Drum Brake 206-02-4

Brake Drum Replacement (12 275 0)
Removal
1. Remove the parking brake control cover
trim. For additional information,
2. Lower the parking brake control lever and

loosen the adjustment nut.

6. CAUTION: If the grease cap is

damaged during removal install a
new cap.
Remove the grease cap.
7. Loosen the drum-retaining nut.
E6594 EN 07/2001 2002 Bantam

206-02-5 Drum Brake 206-02-5
8. NOTE: When removing the drum make sure

the wheel bearing is not displaced from its
housing.
Remove the drum.
1. Remove the nut.
2. Remove the drum.
• Ensure the wheel bearing is not
displaced from its housing.
Installation
CAUTION: Once tightened, the hub-

retaining nut must not be disturbed. If
the torque setting requires to be
checked the nut must be loosened two
full turns and re-tightened.
NOTE: Rotate the hub while tightening the hub-
retaining nut.
1. To install, reverse the removal procedure.
4. Adjust the parking brake cable.

E6594 EN 07/2001 2002 Bantam

206-02-6 Drum Brake 206-02-6

Brake Shoes (12 285 0)
Grease SAM1C-9107-A
Removal
1. Remove the brake drum, wheel spindle and
wheel hub assembly.
refer to Brake Drum in this section.
2. Remove the brake shoe hold down springs.
3. Hold the wheel cylinder pistons in place

with a rubber band.
4. CAUTION: Do not damage the wheel

cylinder boots when detaching the
brake shoes.
Detach the brake shoes from the wheel
cylinder pistons.
5. Detach the brake shoes from the abutment

bracket.
E6595 EN 07/2001 2002 Bantam

206-02-7 Drum Brake 206-02-7
6. Detach the parking brake cable.

1. Pull the secondary brake shoe lever
backwards.
2. Disconnect the cable from the secondary
brake shoe.
7. Remove the brake shoe return springs.

1. Remove the lower spring.
2. Remove the upper spring.
8. Detach the primary brake shoe from the

strut support.
1. Pull the primary brake shoe away from
the support.
2. Detach the primary brake shoe.
9. Detach the secondary brake shoe from the

strut support.
1. Rotate the brake shoe through 90
degrees.
2. Detach the spring.
E6595 EN 07/2001 2002 Bantam

206-02-8 Drum Brake 206-02-8
Installation
1. Clean, check and apply grease to the
backing plate contact points.
2. Install the strut support to the secondary

brake shoe.
1. Install the spring.
2. Rotate the brake shoe through 90
degrees into position.
3. Install the primary brake shoe to the strut

support.
1. Position the brake shoe.
2. Push the primary brake shoe onto the
support.
4. Install the brake shoe return springs.

1. Install the upper return spring.
2. Install the lower return spring.
E6595 EN 07/2001 2002 Bantam

206-02-9 Drum Brake 206-02-9
5. Install the parking brake parking brake

cable.
1. Connect the parking brake cable.
2. Push the secondary brake shoe lever
forwards.
6. Remove the rubber band holding the wheel

cylinder pistons in place.
7. CAUTION: Do not damage the wheel

cylinder boots.
Connect the brake shoes to the wheel
cylinder.
8. Attach the brake shoes to the abutment

block.
9. Install the hold down springs.
E6595 EN 07/2001 2002 Bantam

206-02-10 Drum Brake 206-02-10
10. Install the brake drum, wheel spindle and

wheel hub assembly.

07/2001 2002 Bant am

206-02-11 Drum Brake 206-02-11

Wheel Cylinder (12 305 0)
General Equipment
Brake hose clamp
Removal
1. Remove the brake shoes. For additional
information,
refer to Brake Shoes in this section.
2. Using a suitable brake hose clamp, clamp

the brake hose.
3. Remove the wheel cylinder.

1. Disconnect the brake hose union.
2. Remove the bolts.
Installation
NOTE: Make sure a gasket is installed between

the wheel cylinder and back plate.
E1100 EN 07/2001 2002 Bantam

206-02-12 Drum Brake 206-02-12
1. Install the wheel cylinder.

1. Install the wheel cylinder bolts.
2. Install the brake hose union.
2. Remove the brake hose clamp.

E1100 EN 07/2001 2002 Bantam

206-02-13 Drum Brake 206-02-13

Backing Plate (12 313 0)
Removal
1. Remove the brake shoes.
refer to Brake Shoes in this section.

refer to Wheel Cylinder in this section.

1. Depress the retaining clip.
2. Remove the cable.
4. Remove the backing plate.

• Drill out the rivets.
Installation
E1101 EN 07/2001 2002 Bantam

206-02-14 Drum Brake 206-02-14
SPECIFICATIONS
Item Specification
Grease – Brake shoe contact pads on backing plate SAM-1C9111-A
Super Dot 4 Brake fluid SAM-6C9103-A
Drum Brake Specifications

mm
New brake drum nominal diameter 203
Worn brake drum discard diameter * 204
Brake shoe width 30
Wheel cylinder bore diameter 17.78
New primary brake shoe lining thickness 6
New secondary brake shoe lining thickness 3.1
Minimum brake shoe lining thickness 1.0
* When the discard brake drum diameter has been reached a new brake drum must be in-
stalled. Particular care must be taken when refinishing brake drums that the discard brake
drum diameter dimensions are not exceeded.
Description Nm
Wheel hub retaining nut 235
Wheel nuts 85
Brake drum and wheel hub assembly bolts 66
Wheel cylinder retaining bolts 15
Brake hose union 13
E6596 EN 07/2001 2002 Bantam

206-03-1 Front Disc Brake 206-03-1
SECTION 206-03 Front Disc Brake

SUBJECT PAGE
Front Brake Disc .................................................................................................................. 206-03-2
Front Brake Disc .................................................................................................................. 206-03-3
Brake Pads .......................................................................................................................... 206-03-4/6
Brake Caliper .................................................................................................. (12 243 0) 206-03-7/8
Brake Caliper ....................................................................................................................... 206-03-9/10
SPECIFICATIONS
Specifications ...................................................................................................................... 206-03-11
Front Disc Brake Specification .......................................................................................... 206-03-11
03/2001 2002 Bantam


Front Brake Disc

1 Brake disc 3 Brake caliper retaining clip
2 Brake pad 4 Brake caliper
5 Brake caliper anchor plate
E9360 EN 03/2001 2002 Bantam


Front Brake Disc
E490 EN 03/2001 2002 Bantam


Brake Pads
Special Tool(s) Material Specification

Retractor, Caliper Piston Super DOT 4 brake ESD-M6C57-A
206-005 (12-014) fluid
Removal

ter.
1. Remove the wheel and tyre. For additional
2. Remove the brake caliper retaining clip.
CAUTION: Suspend the brake caliper to

prevent load being placed on the brake
hose.
3. Detach the brake caliper from the anchor
plate.
1. Remove the covers.
E9414 EN 03/2001 2002 Bantam

4. Remove the brake pads.
Installation
CAUTION: When the brake caliper pis-

tons are retracted into the piston hous-
ing, brake fluid will be displaced into the
brake fluid reservoir.
1. Using the special tool, retract the brake
caliper pistons.
CAUTION: Make sure the disc faces are

clean and free from grease, dirt or rust
prior to assembly.
2. Install the brake pads.
E9414 EN 03/2001 2002 Bantam

3. Attach the brake caliper to the anchor plate.

1. Install the bolts.
2. Install the covers.
4. Install the brake caliper retaining clip.
5. Install the wheel and tyre. For additional

6. Depress the brake pedal, check the fluid

level in the brake fluid reservoir and top up
if necessary with brake fluid.
E9414 EN 03/2001 2002 Bantam


Brake Caliper (12 243 0)
General Equipment
Brake hose clamp
Removal

ter.
1. Remove the wheel and tyre. For additional
2. Loosen the flexible hose brake union.

1. Using a suitable brake hose clamp,
clamp the brake hose.
2. Loosen the brake hose union.
3. Remove the brake caliper and anchor plate

assembly.
E9415 EN 03/2001 2002 Bantam

4. CAUTION: Cap the brake hose to

prevent fluid loss or dirt ingress.
Detach the brake caliper and anchor plate
assembly from the flexible brake hose.
• Turn the caliper and anchor plate
assembly counter clockwise to remove.
Installation

E9415 EN 03/2001 2002 Bantam


Brake Caliper
Super DOT 4 brake ESD-M6C57-A
fluid
Disassembly

ter.
1. Remove the brake caliper dust seal.
• Discard the seal.
2. Place a suitable block of wood between the

body of the brake caliper and the brake
caliper piston.
3. WARNING: Use only as much

compressed air as is necessary to
remove the brake caliper piston.
Failure to follow these instructions
may result in personal injury.
CAUTION: Do not use a screwdriver or
any other similar tool to pry the brake
caliper piston out of the brake caliper
bore.
Apply compressed air through the brake
hose housing to remove the brake caliper
piston.
E9361 EN 03/2001 2002 Bantam

206-03-10 Front Disc Brake 206-03-10
4. CAUTION: Do not use a screwdriver or

any other similar tool to pry the brake
caliper piston seal out of the brake
caliper bore.
Remove the brake caliper piston seal.
• Discard the seal.
Assembly
WARNING: Install a new brake caliper

piston if rust, pitting or scores are evi-
dent. Failure to follow these instructions
WARNING: Install a new brake caliper if

rust, pitting or scores are evident in the
brake caliper bore. Failure to follow
these instructions may result in per-
sonal injury.
NOTE: Install a new brake caliper piston seal
and a new brake caliper dust seal.
NOTE: Lubricate the piston, piston bore and pis-
ton seal with Super DOT 4 brake fluid prior to
installation.
1. To assemble, reverse the disassembly
procedure.
E9361 EN 03/2001 2002 Bantam

206-03-11 Front Disc Brake 206-03-11
SPECIFICATIONS
Item Specification
Super DOT 4 brake fluid SAM 6C9103-A
Front Disc Brake Specification

mm
Brake disc diameter 239.5
New brake disc nominal thickness 20
Worn brake disc discard thickness * 18
Maximum brake disc run out (installed) 0.1
Maximum brake disc thickness variation 0.025
Brake caliper piston diameter 54
Minimum brake pad thickness 1.5
* When the discard thickness has been reached, install a new brake disc.
Description Nm
Wheel nuts 85
Brake caliper piston housing retaining bolts 58
Brake caliper anchor bracket retaining bolts 58
Brake hose to brake caliper union 13
E9396 EN 03/2001 2002 Bantam

SECTION 206-04 Wheels and Tyres

SUBJECT PAGE
Wheel and Tyre .................................................................................................................. 206-04-2
07/2001 2002 Bantam


Wheel and Tyre
Removal
CAUTION: Do not use heat to loosen a

seized wheel nut. Heat may damage the
wheel and wheel hub.

3. Remove the wheel and tyre assembly.
Installation
1. WARNING: Remove the corrosion or

dirt from the mounting surfaces of
the wheel, wheel hub, brake drum or
brake disc, as this may cause the
wheel nuts to loosen and the wheel to
come off while the vehicle is in
motion. Failure to follow this
injury.
Clean the wheel hub and mounting
surfaces.
2. Install the wheel and tyre assembly.
4. Tighten the wheel nuts in a diagonally

opposed pattern.
E8680 EN 07/2001 2002 Bantam

206-05-1 Parking Brake and Actuation 206-05-1
SECTION 206-05 Parking Brake and Actuation

SUBJECT PAGE
Parking Brake ...................................................................................................................... 206-05-2
Parking Brake ...................................................................................................................... 206-05-3

Symptom Chart ................................................................................................................. 206-05-3/5
Parking Brake Control..................................................................................... (12 664 0) 206-05-6/7

Parking Brake Cable and Conduit ................................................................... (12 675 0) 206-05-8/10
Parking Brake Warning Indicator Switch ......................................................... (33 546 0) 206-05-11
GENERAL PROCEDURES
Parking Brake Cable Adjustment .................................................................... (12 662 0) 206-05-12
SPECIFICATIONS
Specifications ...................................................................................................................... 206-05-13

07/2001 2002 Bantam


Parking Brake

1 Adjusting nut 6 Push button
2 Bolt 7 Return spring
3 Parking brake lever 8 Equaliser
4 Parking brake switch coupler 9 Return spring
5 Grip 10 Front parking brake cable
11 Rear parking brake cable
E5844 EN 07/2001 2002 Bantam


Parking Brake
1. Verify the customer concern by operating the 3. If an obvious cause for an observed or
parking brake system. reported concern is found, correct the cause
2. Visually inspect for obvious signs of (if possible) before proceeding to the next
mechanical or electrical damage. step.
4. If the concern is not visually evident, verify
Visual Inspection Chart the symptom and refer to the Symptom
Chart.
Mechanical Electrical
• Parking brake control • Parking brake warn-
• Parking brake cable ing circuit.
Symptom Chart
Symptom Chart
• The parking brake will not apply • Parking brake control. • GO to Pinpoint Test A.
• Parking brake cable.
• The parking brake will not re- • Parking brake control. • GO to Pinpoint Test B.
lease • Parking brake cable.
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY

A1: CHECK FOR MISADJUSTED REAR PARKING BRAKE CABLE
1 Operate the parking brake control several
times to adjust the cable.
• Does the parking brake now engage correctly?
Yes
Vehicle OK.
No
GO TO A2
A2: CHECK FOR WORN BRAKE SHOES
1 Inspect the brake shoes for excessive wear.
• Are the brake shoes and linings OK?
Yes
GO TO A3
No
INSTALL new brake shoes.
E1109 EN 07/2001 2002 Bantam

A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables for damage,
rust or fraying.
• Are the parking brake cables OK?
Yes
CHECK for other causes such as loose
parking brake control or conventional brake
system components.
No
REPAIR or INSTALL the parking brake ca-
bles as necessary. TEST the system for
normal operation.
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
B1: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
- Rotate the rear wheels by hand.
• Did the rear wheel turn freely?
Yes
INSTALL a new parking brake control.
REFER to Parking Brake Control in this section
TEST the system for normal
operation.
No
GO TO B3
B2: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
- Release the parking brake by pulling upwards
on the control level and pushing the release
button.
• Did the parking brake release?
Yes
CHECK for other causes such as
conventional brake system components.
No
GO TO B1
E1109 EN 07/2001 2002 Bantam

B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the front parking brake cable from
the rear parking brake cable at the equalizer.
- Rotate the rear wheels by hand.
• Did the rear wheel turn freely?
Yes
INSTALL a new front parking brake cable.
REFER to Parking Brake Cable in this section
operation.
No
GO TO B4
B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the rear parking brake cable at the
rear brakes, one at a time.
- Rotate the wheel affected by the
disconnected parking brake cable.
• Did the wheel turn freely?
Yes
INSTALL a new rear parking brake cable.
REFER to Parking Brake Cable in this section
operation.
No
CHECK for other causes such as conven-
tional brake system components. REPAIR
or INSTALL new components as necessary.
E1109 EN 07/2001 2002 Bantam


Parking Brake Control (12 664 0)
Removal
trim.
2. Lower the parking brake control lever.
3. Remove the adjusting nut.
4. Remove the parking brake control nuts.
5. Pull the cable out from the parking brake

control lever.
E1110 EN 07/2001 2002 Bantam

6. Remove the parking brake control.

1. Disconnect the parking brake warning
indicator switch electrical connector.
Installation

refer to Parking Brake Cable Adjustment
in this section
E1110 EN 07/2001 2002 Bantam


Parking Brake Cable and Conduit (12 675 0)
Removal
trim.
2. Lower the parking brake control lever and

loosen the adjusting nut.
3. Loosen the rear wheel nuts.

6. Detach the exhaust system from the rear

hanger insulators.
7. Disconnect the equalizer from the front

parking brake cable.
• Turn the front parking brake cable nipple
through 90 degrees.
E6602 EN 07/2001 2002 Bantam

8. Disconnect the rear parking brake cable.
9. Detach the rear parking brake cable.
10. Detach the parking brake cable from the

rear axle (both sides).
11. Remove the brake drum. For additional


1. Pull the secondary brake shoe lever
backwards.
2. Disconnect the cable from the secondary
brake shoe.
E6602 EN 07/2001 2002 Bantam

Installation
2. Adjust the parking brake.

refer to Parking Brake Cable Adjustment
in this section
E6602 EN 07/2001 2002 Bantam

Parking Brake Warning Indicator Switch (33 546 0)
Removal
refer to Parking Brake Control in this section
2. Remove the switch.
Installation
E1113 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Parking Brake Cable Adjustment (12 662 0)
Adjustment
trim.
2. Lower the parking brake control lever.
3. Loosen the adjusting nut.
4. Depress the foot brake six times.

1. Raise the parking brake control lever by
six clicks of the ratchet.
2. Tighten the adjusting nut.
6. Test the parking brake for normal operation.
7. Install the parking brake control cover trim.
E1114 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Parking brake cable adjusting nut 4
Parking brake control nuts 24
Wheel nuts 85
E1115 EN 07/2001 2002 Bantam

206-06-1 Hydraulic Brake Actuation 206-06-1
SECTION 206-06 Hydraulic Brake Actuation

SUBJECT PAGE
Hydraulic Brake Actuation.................................................................................................... 206-06-2
Hydraulic Brake Actuation.................................................................................................... 206-06-3
Brake Master Cylinder .................................................................................... (12 343 0) 206-06-4/5

Brake Pedal .................................................................................................... (12 133 0) 206-06-6/7
Brake Fluid Reservoir ..................................................................................... (12 341 0) 206-06-8/9
Brake Pedal Cross-Shaft ................................................................................ (12 338 0) 206-06-10/12
Brake Pedal and Bracket ..................................................................................................... 206-06-13/15
SPECIFICATIONS
Specifications ...................................................................................................................... 206-06-16

03/2001 2002 Bantam


Hydraulic Brake Actuation

1 Brake pedal 3 Brake pedal cross-shaft
2 Brake master cylinder and fluid reser-
voir
E9397 EN 03/2001 2002 Bantam


Hydraulic Brake Actuation
E1117 EN 03/2001 2002 Bantam

Brake Master Cylinder (12 343 0)
Removal

paintwork the affected area must be
ter.

cap must not become contaminated.
Remove the brake fluid reservoir cap.
1. Disconnect the low brake fluid warning
2. Remove the cap.
2. NOTE: It will be necessary to carry out this

step on both sides in order to completely
drain the brake fluid reservoir.
Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of
clear plastic pipe to the bleed nipple and
place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all of the
brake fluid is drained from the brake fluid
reservoir.
4. Tighten the bleed nipple.
3. CAUTION: Cap the clutch master

cylinder hose to prevent fluid loss or
dirt ingress.
Disconnect the clutch master cylinder hose
from the brake fluid reservoir.
E9398 EN 03/2001 2002 Bantam

4. Disconnect the brake tubes from the brake

master cylinder.
5. Remove the brake master cylinder and

brake fluid reservoir assembly.
1. Remove the nuts.
2. Remove the brake master cylinder.
Installation
CAUTION: Make sure the brake booster

actuator rod is correctly positioned be-
fore installation.
CAUTION: Make sure the brake master

cylinder vacuum seal is correctly posi-
tioned before installation.

E9398 EN 03/2001 2002 Bantam

Brake Pedal (12 133 0)
Removal
2. Remove the stop lamp switch.
3. Disengage the clutch pedal return spring.
4. Remove the brake pedal.

1. Remove the brake pedal cross-shaft
retaining clip (clutch side).
2. Push the brake pedal cross-shaft
towards the brake pedal.
retaining clip (brake side).
4. Push the brake pedal cross-shaft
towards the clutch and remove the brake
pedal.
5. Remove the brake pedal bushings.
E5852 EN 03/2001 2002 Bantam

Installation
1. NOTE: When Installing the brake pedal make

sure the brake booster actuator rod locates
correctly into the brake pedal.
NOTE: As the brake pedal cross-shaft has to be
disturbed, adjustment of the clutch pedal travel
will be required. Clutch pedal travel
measurement must be 56.0 mm
To install, reverse the removal procedure.
E5852 EN 03/2001 2002 Bantam


Brake Fluid Reservoir (12 341 0)
Removal

paintwork the affected area must be
ter.
1. Disconnect the low brake fluid warning

cap must not become contaminated.
Remove the brake fluid reservoir cap.
3. NOTE: It will be necessary to carry out this

step on both sides in order to completely
drain the brake fluid reservoir.
Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of
clear plastic pipe to the bleed nipple and
place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all of the
brake fluid is drained from the brake fluid
reservoir.
4. Tighten the bleed nipple.
4. CAUTION: Cap the clutch master

cylinder hose to prevent fluid loss or
dirt ingress.
Disconnect the clutch master cylinder hose
from the brake fluid reservoir.
E9399 EN 03/2001 2002 Bantam

5. Remove the brake fluid reservoir.

• Detach the securing pin.
Installation

E9399 EN 03/2001 2002 Bantam

Brake Pedal Cross-Shaft (12 338 0)
Removal
1. Remove the brake booster. For additional
2. Disconnect the accelerator cable from the

accelerator pedal.
3. Remove the accelerator pedal.

1. Remove the clip.
2. Remove the pedal.
4. Detach the brake pedal cross-shaft

actuating rod from the brake pedal.
• Remove the clip.
E9400 EN 03/2001 2002 Bantam


mounting bracket from the bulkhead.

1. Pull the bracket from the bulkhead.
2. Move the brake pedal cross-shaft to the
left.
7. Disconnect the connecting link spring from

the brake booster support bracket.
8. Remove the brake pedal cross-shaft.

• Rotate the connecting link in a counter
clockwise direction.
E9400 EN 03/2001 2002 Bantam

9. Remove the brake pedal cross-shaft from

the brake booster support bracket.
Installation
E9400 EN 03/2001 2002 Bantam


Brake Pedal and Bracket
Removal
2. Disconnect the brake pedal position (BPP)

switch and clutch on/off switch electrical
connectors from the brake pedal bracket.
3. Remove the steering linkage bolt.

accelerator pedal.
E9362 EN 03/2001 2002 Bantam

5. Remove the accelerator pedal.

1. Remove the clip.
2. Remove the pedal.

actuating rod from the brake pedal.
7. Detach the clutch master cylinder from the

brake pedal and bracket.
8. Detach the clutch master cylinder actuating

rod from the clutch pedal.

E9362 EN 03/2001 2002 Bantam

10. Remove the brake pedal and bracket
Installation
E9362 EN 03/2001 2002 Bantam

SPECIFICATIONS
Item Specification
DOT 4 brake fluid SAM-6C9103-A
Description Nm
Brake master cylinder brake tube unions 13
Brake master cylinder retaining nuts 25
Brake pedal cross-shaft mounting bracket nuts 25
E1124 EN 03/2001 2002 Bantam

206-07-1 Power Brake Actuation 206-07-1
SECTION 206-07 Power Brake Actuation

SUBJECT PAGE
Brake Booster ...................................................................................................................... 206-07-2

Power Brake System ........................................................................................................... 206-07-3

Brake Booster ................................................................................................. (12 451 0) 206-07-4/5
SPECIFICATIONS
Specifications ...................................................................................................................... 206-07-6
07/2001 2002 Bantam


Brake Booster
Item Description
1 Brake booster
E1125 EN 07/2001 2002 Bantam


Power Brake System
E1126 EN 07/2001 2002 Bantam


Brake Booster (12 451 0)
Removal
1. Remove the battery tray. For additional
2. Remove the brake master cylinder.

3. Disconnect the vacuum hose from the

brake booster.
4. Detach the brake booster.
5. Detach the brake booster actuating rod

from the brake pedal.
1. Pull the brake booster forwards.
2. Remove the actuating rod clip and pin.
6. Remove the brake booster.
E9401 EN 07/2001 2002 Bantam

Installation
E9401 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Brake booster retaining nuts 25
Brake master cylinder retaining nuts 25
E1128 EN 07/2001 2002 Bantam

211-00-1 Steering System — General Information 211-00-1
SECTION 211-00 Steering System —

General Information
SUBJECT PAGE
Steering System .................................................................................................................... 211-00-2

Principles of Operations ...................................................................................................... 211-00-2
Inspection and Verification .................................................................................................. 211-00-2
Symptom Chart ................................................................................................................... 211-00-2/4
Component Tests................................................................................................................ 211-00-4
GENERAL PROCEDURES
Power Steering System Filling ......................................................................... (13 416 1) 211-00-5

Power Steering System Bleeding .................................................................... (13 416 1) 211-00-6/7
Power Steering System Flushing..................................................................... (13 416 1) 211-00-8/10
Power Steering System Purging ...................................................................... (13 416 1) 211-00-11/13
SPECIFICATIONS
Specifications......................................................................................................................... 211-00-14
Turning Circles .................................................................................................................... 211-00-14
Torque Specifications.......................................................................................................... 211-00-14
07/2001 2002 Bantam


Steering System
Principles of Operations Inspection and Verification

The steering wheel rotational movement is 1. Verify the customer concern.
transferred to the steering gear through the 2. Visually inspect the obvious signs of
steering column shaft. The steering gear converts mechanical or electrical damage.
this rotational movement, through the action of
the rack and pinion gear into lateral movement. Visual Inspection Chart
This movement in turn is transferred to the wheel Mechanical Electrical
knuckle through the tie-rods and tie-rod ends.
• Tyre pressure. • Power steering pressure
Hydraulic fluid under pressure is supplied to the • Accessory drive belt. (PSP) switch.
steering gear by the power steering pump. As the • Wheels and tyres. • Fuse(s).
steering wheel is rotated, the hydraulic fluid is • Power steering line • Electrical connector(s).
allowed to pass through the steering gear valve fluid leaks.
to one side of a double-acting piston, dependent
on which direction the steering wheel is rotated. 3. If an obvious cause for an observed or
The fluid moves the piston, which forms part of reported concern is found, correct the cause
the steering gear, giving power assistance to the (if possible) before proceeding to the next
effort required to turn the front road wheels. step.
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
• The steering is very difficult/very • Loose or worn accessory drive • CHECK the accessory drive
easy belt. belt. REFER to Section 303-05.
• Power steering fluid. • CHECK the power steering fluid
reservoir level. CHECK for aera-
tion and contamination. For ad-
ditional information, refer to
Power Steering Systems Purg-
ing in this section.
• Worn mechanical power steer- • INSTALL a new power steering
ing pump. pump.
REFER to Section 211- 02.
• Power steering hose restriction. • CHECK the power steering
hoses for damage, kinks or re-
strictions. INSTALL new com-
ponents as necessary.
• Seized suspension ball joints. • CARRY out a ball joint compo-
nent test.
• Moan type noise • Routing of power steering • CHECK the security and routing
hoses. of the power steering hoses.
E6308 EN 07/2001 2002 Bantam


• Air in the power steering sys- • BLEED the power steering sys-
tem. tem. For additional information,
refer to the Power Steering Sys-
tem Bleeding in this section.
• Power steering pump. • INSTALL a new power steering
pump.
• Whine type noise • Power steering pump. • INSTALL a new power steering
pump.
• Hiss type noise • Steering gear valve. • INSTALL a new steering gear.
• Belt noise • Accessory drive belt worn. • INSTALL a new accessory,
drive belt.
• Loose generator/power steering • TIGHTEN the mountings to
pump mounting. specification.
REFER to Section 211-02 / 414-02.
• Damaged pulley(s). • INSPECT the water pump, g en-
erator, air conditioning and
power steering pump pulleys for
damage. INSTALL new compo-
nents as necessary.
• Knock type noise • Suspension components. • CHECK the suspension system.
• Steering linkage. • CHECK the steering linkage
components for security and
wear. For additional information,
refer to Steering Linkage Com-
ponent Test in this section.
• The steering does not vary with • Steering column to steering gear • CHECK the flexible coupling for
increased steering wheel rota- flexible coupling. security and damage. INSTALL
tion a new flexible coupling as re-
quired.
• Worn tie-rod ends. • CHECK the tie-rod ends for
wear. INSTALL new compo-
nents as necessary.
• Worn steering column shaft. • INSTALL a new steering col-
umn. REFER to Section 211-04.
• The steering does not vary with • Loose steering gear retaining • CHECK and INSTALL new bolts
increased steering wheel rotation bolts. as necessary.
REFER to Sec tion 211-02.
• Excessive steering gear back- • INSTALL a new steering gear.
lash. REFER to Section 211-02.
E6308 EN 07/2001 2002 Bantam


• Steering assist does not vary • Power steering pressure (PSP) • For additional information,
with vehicle speed switch. refer to the Wiring Diagrams.
• Circuit. Petrol and Diesel.
Section 700-06 for schematic
and connector information.
Component Tests or the steering column is worn, or the
Steering Linkage backlash of the steering gear is excessive.
Inspect the steering gear boots for cuts, 3. If the steering linkage is worn, install new compo-
deterioration, twisting or distortion. Make sure the nents as necessary. REFER to Section 211-03.
boots are secure. Install new boots or clamps as The steering column cannot
necessary. be repaired, install a new steering column.
REFER to Section 211-04. Steering gear
1. Park the vehicle on a dry, even surface and
backlash cannot be adjusted. Install a new
apply the parking brake. Place the steering in
steering gear. REFER to Section 211-02.
the straight-ahead position.
4. With the engine OFF, hold the steering wheel
2. With the engine running, gently turn the
firmly with both hands. Attempt to move the
steering wheel to the right and left to check
steering wheel up and down and also to the
free play. Free play is measured at the
left and right without turning the wheel, to
steering wheel rim and should be within the
check the steering column bearing wear,
limits stated in the specifications. If free play
steering, column shaft joint play and steering
exceeds the limit stated the steering linkage
wheel or steering column looseness. If free
play is detected, check the correct torque of
the steering column, coupling shaft and
steering wheel retaining bolts. The steering
column cannot be repaired, install a new
steering column. REFER to Section 211-04.
07/2001 2002 Bantam

GENERAL PROCEDURES
Power Steering System Filling (13 416 1)

Adaptor, Power Steering Hand Vacuum/Pressure
Bleeding Pump
211-189 (13-016) 416-D001 (23-036A)
Refill
1. NOTE: When filling the reservoir, make sure
the power steering fluid is clean and not
agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize
the possibility of aeration. The fluid level
should be checked with the fluid cold.
Fill the reservoir to the MAX mark.
2. Using the special tools, apply a vacuum of

84-101 kPa (25-30 in-Hg) for 30 seconds.
3. Observe the vacuum gauge reading.

• If the vacuum decreases by more than 7
kPa (2 in-Hg) in 5 minutes, the system
should be checked for leaks.
4. Remove the hand vacuum/pressure pump

and stopper. Fill the reservoir to the MAX
mark is necessary.
E3220 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Power Steering System Bleeding (13 416 1)

Adaptor, Power Steering Hand Vacuum/Pressure
Bleeding Pump
211-189 (13-016) 416-D001 (23-036A)
Bleeding
1. NOTE: When filling the reservoir, make sure
the power steering fluid is clean and not
agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize
the possibility of aeration. The fluid level
should be checked with the fluid cold.
Fill the reservoir to the MAX mark.
2. NOTE: Make sure that the fluid in the

reservoir does not fall below the MIN mark,
as air could enter the system.
Start the engine and slowly turn the
steering wheel from lock to lock.
3. Switch OFF the engine and examine the

hose connections, steering gear boots,
valve body and pump for external leaks.
4. Check the fluid level. Fill up as necessary.
E3218 EN 07/2001 2002 Bantam

5. NOTE: When bleeding the system the

vacuum will decrease. Maintain a sufficient
vacuum of 51 kPa (15 in-Hg), using the hand
vacuum/pressure pump. If the vacuum
decreases by more than 7 kPa (2 in-Hg) in 5
minutes, the system should be checked for
leaks.
Using the special tools, bleed the system.
• Start the engine and slowly turn the
steering wheel from lock to lock once;
then turn the steering wheel to the right,
just off the stop.
• Switch OFF the engine and using the
hand vacuum/pressure pump apply a
vacuum of 51 kPa (15 in-Hg). Maintain the
vacuum until the air is evacuated from the
system (minimum of five minutes).
• Release the vacuum at the hand
vacuum/ pressure pump.
• Repeat the bleed procedure, turning the
steering wheel to the left, just off the stop.
6. Remove the hand vacuum/pressure pump

and stopper. Fill the reservoir if necessary.
7. Start the engine; turn the steering wheel

from lock to lock. If excessive noise is
apparent, repeat the bleed procedure.
8. If the noise level is still unacceptable, leave

the vehicle standing overnight then repeat
the bleed procedure.
E3218 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Power Steering System Flushing (13 416 1)
Special Tool(s)
Remover, Oil Cooling Pipe
307-242 (17-049)
All vehicles
additional information, refer to Section 100- 02.
2. Using the special tool, (if required)

disconnect the power steering fluid return
line.
1. Insert the special tool into the quick-
release coupling.
2. Slide the special tool along the pipe to
release the locking tangs.
• Allow the fluid to drain into a suitable
container.
3. Attach a tube of suitable length to the fluid

return line.
1. Using a suitable blanking cap, cap the
end of the fluid cooler line.
2. Attach a tube of suitable length to the
fluid cooler to power steering gear line
and place the other end into a suitable
container.
All except vehicles with diesel engine

4. Disconnect the crankshaft position sensor
(CKP) electrical connector.
Refer to the Wiring Diagram Section 700-06
for schematic and electrical information.
E3217 EN 07/2001 2002 Bantam


All vehicles
Vehicles with diesel engine
6. Disconnect the fuel injection pump electrical
connector.
1. Pull out the locking handle.
2. Disconnect the electrical connector.
All vehicles
7. NOTE: When filling the power steering fluid
reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The
fluid should be poured slowly into the
reservoir to minimize the possibility of
aeration. The fluid level should be checked
with the fluid cold.
Fill the power steering fluid reservoir to the
MAX mark with power steering fluid.
8. CAUTION: Do not continuously crank

the engine for more than 30 seconds,
as damage to the starter motor may
result.
Turn the ignition switch to the START
position, with the aid of another technician
add 2.2 litres of clean power steering fluid.
9. When all the fluid has been used, turn the

ignition switch to the OFF position.

11. Remove the blanking cap from the power

steering fluid cooler return line and connect
the line from the power steering gear.
E3217 EN 07/2001 2002 Bantam


12. Connect the CKP electrical connector.
All vehicles
14. Connect the fuel injection pump electrical
connector.
1. Connect the electrical connector.
2. Push in the locking handle.
All vehicles
15. Fill and bleed the power steering system.
refer to Power Steering System Bleeding
in this section
E3217 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Power Steering System Purging (13 416 1)
Purging
All vehicles
1. NOTE: When filling the power steering fluid
reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The
fluid should be poured slowly into the
reservoir to minimize the possibility of
aeration. The fluid level should be checked
with the fluid cold.
Fill the power steering fluid reservoir to the

3. Disconnect the crankshaft position sensor

(CKP) electrical connector.

4. Disconnect the fuel injection pump electrical
connector.
1. Pull out the locking handle.
E3219 EN 07/2001 2002 Bantam

All vehicles
5. NOTE: The vehicle must be raised with the
wheels clear of the floor to allow the steering
wheel to be rotated from lock to lock.
Raise and support the vehicle until the
wheels are clear of the floor. For additional
6. CAUTION: Do not continuously crank

the engine for more than 30 seconds,
as damage to the starter motor may
result.
CAUTION: Do not hold the steering
wheel against the full lock stops for
more than five seconds, as damage to
the steering pump may result.
While cranking the engine for no more than
30 seconds, turn the steering wheel from
lock to lock.
• With the aid of another technician, add
fluid to the reservoir until the level remains
constant.
7. Turn the ignition switch to the OFF position.
8. Fill the power steering fluid reservoir to the

9. Connect the CKP electrical connector.
E3219 EN 07/2001 2002 Bantam


10. Connect the fuel injection pump electrical
connector.
2. Push in the locking handle.
All vehicles
11. Start the engine. Turn the steering wheel
from lock to lock; if excessive noise is
apparent bleed the system.
refer to Power Steering System Bleeding
in this section
E3219 EN 07/2001 2002 Bantam

SPECIFICATIONS
Range
Wall to wall
Rack travel
Description Nm
Steering gear retaining nuts and bolts 48
Track rod end locknuts 37
Wheel nuts 85
Flexible coupling to steering column shaft pinch bolt 22
Flexible coupling to pinion shaft pinch bolt 28
Track rod locknuts 63
Steering wheel retaining bolt 45
Steering column retaining nuts 12
07/2001 2002 Bantam

211-01-15 Manual Steering 211-01-15
SECTION 211-01 Manual Steering

SUBJECT PAGE
Manual Steering..................................................................................................................... 211-01-16
Manual Steering..................................................................................................................... 211-01-17
Steering Gear .................................................................................................. (13 116 0) 211-01-18/23
SPECIFICATIONS
Specifications......................................................................................................................... 211-01-24
07/2001 2002 Bantam


Manual Steering
The manual steering gear is of the conventional pinion shaft with a pinch bolt. A floor seal protects
rack and pinion type as used on most previous the flexible coupling's entry into the engine
models. The steering gear is mounted on the compartment.
crossmember. This type of steering gear may be The steering column incorporates a well proven
fitted to either left or right-hand drive variants. multi-position steering lock with a high security
The steering column is attached, at the lower lock barrel. The steering column assembly is
end, to a flexible coupling by means of a pinch fixed at its upper end to a dash panel extension
bolt, cage and aligner assembly. The flexible with two nuts.
coupling, in turn, is attached to the steering gear

1 Track rod 5 Flexible coupling
2 Steering gear 6 Steering column assembly
3 Track rod end 7 Steering wheel
4 Steering gear gaiter
E5853 EN 07/2001 2002 Bantam


Manual Steering
E5854 EN 07/2001 2002 Bantam


Steering Gear (13 116 0)
Special Tool(s)
Separator, ball joint
13-006
Removal
2. From inside the passenger compartment,

remove the flexible coupling to pinion shaft
pinch bolt.
3. From inside the passenger compartment

slacken the flexible coupling to column
shaft pinch bolt.
4. Slacken the wheel nuts, raise the vehicle

and remove the front road wheels.
E5855 EN 07/2001 2002 Bantam

5. Remove the track rod end locknuts.

1. Hold the ball joint studs with an Allen
key.
2. Remove the locknuts.
6. NOTE: When the track rod ends are

separated from the spindle carriers the ball
joint seals should be wrapped in a cloth to
protect them.
Disconnect the track rod end ball joints from
the spindle carriers.
Vehicles with manual transaxle

8. Disconnect the gearshift linkage.
9. Remove the roll restrictor to transmission

retaining bolt.
E5855 EN 07/2001 2002 Bantam

10. Support the crossmember assembly.
11. Remove the crossmember assembly

retaining bolts.
12. Lower the crossmember assembly to gain

access to the steering gear retaining nuts
and bolts.
13. Remove the pinion shaft body seal.
14. Remove the steering gear retaining nuts

and bolts.
E5855 EN 07/2001 2002 Bantam

15. Remove the steering gear.
Installation
1. Install the steering gear.
2. Install the crossmember.
3. Install the roll restrictor.
E5855 EN 07/2001 2002 Bantam


4. Install the gearshift linkage.
5. Install the tie rods.
6. Install the wheels.
7. CAUTION: Make sure that the steering

is in the straight ahead position.
Install the upper steering coupling pinch

bolt.
E5855 EN 07/2001 2002 Bantam

8. Install the lower steering coupling pinch

bolt.
E5855 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Track rod end to spindle carrier locknuts 37
Track rod end to tie rod locknuts 63
E6376 EN 07/2001 2002 Bantam

211-02-25 Power Steering 211-02-25
SECTION 211-02 Power Steering - Petrol

SUBJECT PAGE
Power Steering ...................................................................................................................... 211-02-26/28
Power Steering ...................................................................................................................... 211-02-29
Power Steering Pump — Vehicles with 1.8l Endura DE diesel Engine .......... (13 434 0) 211-02-30/33
Power Steering Pump — Vehicles with 1.3l petrol engine............................... (13 434 0) 211-02-34/37
Power Steering Pump — Vehicles with 1.6l petrol engine............................... (13 434 0) 211-02-38/45
Power Steering Gear ....................................................................................... (13 116 0) 211-02-46/54
Steering Gear Pinion Oil Seal .......................................................................... (13 468 0) 211-02-55/57
Power Steering Fluid Cooler ............................................................................ (13 444 0) 211-02-58/59
Power Steering Pump to Steering Gear Pressure line ........................................................... 211-02-60/69
Steering Gear to Fluid Cooler Return Hose ........................................................................... 211-02-70/78
SPECIFICATIONS
Specifications......................................................................................................................... 211-02-79
Lubricants, Fluids, Sealers and Adhesives ......................................................................... 211-02-79
Turning Circles .................................................................................................................... 211-02-79
07/2001 2002 Bantam

211-02-26 Power Steering 211-02-26

Power Steering

1 Power steering fluid reservoir 7 Steering gear
2 Power steering pump 8 Tie-rod end
3 Power steering pressure switch (PSP) 9 Steering gear boot
4 Steering wheel 10 Steering column coupling
5 Power steering fluid cooler 11 Steering column
6 Tie-rod The power assisted steering gear is of the
conventional rack and pinion type. The steering
E5895 EN 07/2001 2002 Bantam

211-02-27 Power Steering 211-02-27

gear is mounted on the crossmember. The steering pump cannot be disassembled. Install a
steering gear cannot be disassembled. new unit.
Hydraulic fluid is supplied under pressure to the A power steering pressure (PSP) switch located
steering gear by a hydraulic pump. The hydraulic in the power steering pressure line is normally
pump is driven by the accessory drive belt and closed. When the power steering load is
has a remote fluid reservoir located on the right- increased, the PSP switch opens, signalling the
hand side of the engine compartment. The power powertrain control module to increase the engine
idle speed.
Vehicles with 1.8L Endura DE engine.
E5895 EN 07/2001 2002 Bantam

211-02-28 Power Steering 211-02-28

1 Mounting bracket 3 High-pressure line
2 Electro-hydraulic power steering reser- 4 Low-pressure line
voir / pump
5 Steering gear
Vehicles with the 1.8 Endura DE engine have an

electo-hydrulic power steering pump.
The electro-hydraulic power steering pump
consists of an electro hydraulic motor and
reservoir and is located in the engine
compartment on the left hand side. The fuse and
relay are located next to one another on the
battery mounting tray.
As soon as the engine is running, the control
relay of the electric power steering pump
receives a signal from the EEC V PCM. The relay
then closes and the pump starts to operate.
E5895 EN 07/2001 2002 Bantam

211-02-29 Power Steering 211-02-29

Power Steering
E1209 EN 07/2001 2002 Bantam

211-02-30 Power Steering 211-02-30

Power Steering Pump — Vehicles with 1.8l Endura DE diesel Engine.

Expander, Teflon seal Installer, camshaft pulley
13-015 21-192
Remover, power steering

pump pulley
13-022
Removal
2. Raise the vehicle.
3. Remove the power steering pump cover.

• Remove the tie strap
4. Disconnect the power steering pump

electrical connector.
5. Disconnect the low pressure line.

Allow the fluid to drain into a suitable container.
E6317 EN 07/2001 2002 Bantam

211-02-31 Power Steering 211-02-31
6. Remove the cable tie.
E6317 EN 07/2001 2002 Bantam

211-02-32 Power Steering 211-02-32
7. Disconnect the high pressure line.

container.
8. Disconnect the power steering pump

ground cable.
9. Remove the power steering pump mounting

bracket upper bolts.
10. Remove the power steering pump, and

mounting bracket.
1 Remove the bolts.

2 Remove the power steering pump and
mounting bracket.
11. Remove the power steering pump from the

mounting bracket.
E6317 EN 07/2001 2002 Bantam

211-02-33 Power Steering 211-02-33
Installation
1. CAUTION: Install a new "O" ring seal

on the power steering high pressure line.
2. Refit the components in the reverse order.

E6317 EN 07/2001 2002 Bantam

211-02-34 Power Steering 211-02-34

Power Steering Pump — Vehicles with 1.3L Engine (13 434 0)

Remover, Power Steering Installer, Pulley, Camshaft
Pump Pulley 303-458 (21-192)
13-022 (211-199)
Removal
2. Detach the accessory drive belt from the

power steering pump pulley.
• Rotate the accessory drive belt tensioner
clockwise.
3. CAUTION: To prevent ingress of

power steering fluid into the
generator, the power steering fluid
must be drained.
Disconnect the power steering fluid cooler
lines from the power steering fluid cooler.
container.
E6613 EN 2002 Bantam

211-02-35 Power Steering 211-02-35
5. CAUTION: Using a suitable cloth,

cover the generator to prevent
ingress of power steering fluid.
Disconnect the power steering low-pressure
line from the power steering pump.
container.
6. Disconnect the power steering high-

pressure line.
pressure line from the power steering
pump.
2. Remove the power steering pump and
power steering high-pressure line support
bracket bolt.
container.
7. Remove the power steering pump.
8. NOTE: When installing a new power steering

pump, the power steering pump pulley should
be removed and retained.
Using the special tool, remove the power
steering pump pulley.

211-02-36 Power Steering 211-02-36
Installation

pump, install the power steering pump pulley.
Using the special tool, install the power
2. Install the power steering pump.
3. Connect the power steering high-pressure

line.
1. Connect the power steering high-
pressure line.
2. Install the power steering pump and
power steering high-pressure line support
bracket bolt.
4. Connect the power steering low-pressure

line.

211-02-37 Power Steering 211-02-37

6. Attach the accessory drive belt to the power
• Rotate the accessory drive belt tensioner
clockwise.
7. Connect the power steering fluid cooler

lines to the power steering fluid cooler.


211-02-38 Power Steering 211-02-38

Power Steering Pump — Vehicles with 1.6L Engine (13 434 0)

Expander, Teflon Seal Installer Camshaft Pulley
211-188 (13-015) 303-458 (21-192)
Remover, Power Steering

Pump, Pulley
211-199 (13-022)
Removal
1. Remove the auxiliary drive belt. For

pump, remove the power steering pump drive
pulley.
Using the special tool, remove the power
steering pump drive pulley.
3. Remove the low-pressure line.

container.

211-02-39 Power Steering 211-02-39
4. Remove the high-pressure line.

container.
Installation
1. NOTE: If installing a new power steering

pump the unions that are supplied fitted to
the pump should be removed and discarded.
Install a new union O-ring.
1. Push the O-ring onto the tool.
2. Locate the tool on the union and push on
the O-ring.
2. Install the power steering pump.

211-02-40 Power Steering 211-02-40
3. Install the high-pressure line.
4. Install the low-pressure line.
5. CAUTION: When installing a new

power steering pump make sure a
new power steering pump drive
pulley is installed.
CAUTION: Make sure the pulley is flush
with the end of the power steering pump
shaft.
Using the special tool, install a new power
steering pump drive pulley.
6. Install the auxiliary drive belt. For additional


For additional information, refer to Section 211-00.

211-02-41 Power Steering 211-02-41
Drive Belt - Power Steering Pump

(with Air Conditioning) - Remove
6. Remove the power steering drive belt.

1 Slacken the drive belt tensioner pulley
centre bolt.
2 Slacken the adjusting bolt.
3 Remove the drive belt.
7. Remove the power steering pump pulley

• Hold the centre of the pump shaft
with an Allen key if necessary.
9. Detach the high pressure pipe support

bracket.
10. Remove the auxiliary drive belt tensioner

bracket.
E6318 EN 07/2001 2002 Bantam

211-02-42 Power Steering 211-02-42
11. Disconnect the high pressure pipe union.

container.
Installation
1. Note: If the power steering pump is being
renewed the unions that are supplied fitted
to the pump should be removed and
retained for future use.
1. Renew the union sealing ring.
1 Push the sealing ring onto the tool.

2 Locate the tool on the union and push on
the sealing ring.
E6318 EN 07/2001 2002 Bantam

211-02-43 Power Steering 211-02-43
Note: Install the pump front retaining bolts first.
2. Refit the components in reverse order.
E6318 EN 07/2001 2002 Bantam

211-02-44 Power Steering 211-02-44
E6318 EN 07/2001 2002 Bantam

211-02-45 Power Steering 211-02-45
Drive Belt -Power Steering Pump (Endura-DE

with Air Conditioning) - Installation
1. Install the power steering pump drive

belt.
1. Slacken the drive belt tensioner
pulley centre bolt.
2. Install the drive belt.
3. Tension the drive belt with the
adjusting bolts. Finger deflection
= 1 to 3 mm (used belt) or 1 to 2
mm (new belt).
4. Tighten the drive belt tensioner
pulley centre bolt.
E6318 EN 07/2001 2002 Bantam

211-02-46 Power Steering 211-02-46

Power Steering Gear (13 116 0)

Separator, ball joint Guide pins, subframe
13-006 15-097A
Expander, Teflon seal

13-015
Removal

pinch bolt.

shaft pinch bolt.

E6320 EN 07/2001 2002 Bantam

211-02-47 Power Steering 211-02-47

key.

joint seals should be wrapped in cloth to
protect them.

8. Detach the gearshift control assembly and

secure to one side.
E6320 EN 07/2001 2002 Bantam

211-02-48 Power Steering 211-02-48
All vehicles
retaining bolt.
10. CAUTION: There is a limited amount

of space in which to remove the
cooling fan and shroud assembly. Do
not damage the radiator matrix.
Remove the cooling fan and shroud
assembly.
1. Disconnect the cooling fan motor and
speed control assembly multiplug.
2. Ease the fan and shroud assembly
upwards to release the retaining clips.
3. Remove the fan and shroud assembly.
11. Disconnect the exhaust front pipe.
12. Disconnect the power steering fluid hose.

• Drain the fluid into a suitable container.
E6320 EN 07/2001 2002 Bantam

211-02-49 Power Steering 211-02-49
13. CAUTION: There is a limited amount

of space available to tilt the engine.
Do not overstress or damage any
pipes or cables.
Tilt the engine forwards.
14. Detach the power steering pipes from the

retaining bracket.
15. Disconnect the fluid cooler to steering gear

pipes.
16. Support the crossmember assembly using

a suitable jack.
17. Remove the crossmember assembly

retaining bolts (jack not shown for clarity).
E6320 EN 07/2001 2002 Bantam

211-02-50 Power Steering 211-02-50
18. Lower the crossmember assembly enough

to allow removal of the steering gear.
19. Remove the pinion shaft body seal.
20. Remove the steering gear retaining nuts

and bolts.
21. CAUTION: There is a very limited

amount of space in which to remove
the steering gear. Do not overstress
or damage the power steering pipes.
Remove the steering gear.
1. Ease the steering gear to the right.
2. Ease the steering gear out towards the
rear.
E6320 EN 07/2001 2002 Bantam

211-02-51 Power Steering 211-02-51
22. Disconnect the power steering pipes.
Installation
1. NOTE: If the steering gear is being renewed

the unions that are supplied fitted to the
steering gear should be removed and
retained for future use.
Renew the union sealing rings.
1. Push the sealing ring onto the tool.
2. Locate the tool on the union and push on
the sealing ring.
E6320 EN 07/2001 2002 Bantam

211-02-52 Power Steering 211-02-52
3. Align the crossmember.

1. Push the guide pins through the
crossmember aligning holes.
2. Slide the locking plates into the locking
grooves and tighten the guide pin sleeves.
4. Raise the crossmember engaging the guide

pins into the alignment holes.
5. Renew the union sealing O-rings.
E6320 EN 07/2001 2002 Bantam

211-02-53 Power Steering 211-02-53

6. Install the gearshift linkage. For additional
All vehicles
E6320 EN 07/2001 2002 Bantam

211-02-54 Power Steering 211-02-54
7. CAUTION: Make sure the steering is

in the straight ahead position.
8. Bleed the power steering system

(refer to procedure contained in this section).
E6320 EN 07/2001 2002 Bantam

211-02-55 Power Steering 211-02-55

Steering Gear Pinion Oil Seal (13 468 0)

Adaptor for 16-042A-01 Remover, oil seal
16-042A 21-151
Remover, oil seal

Grease power steering ESA-MIC45-A
gear
Removal
1. Remove the steering gear
2. Remove the water splash shield from the

pinion shaft.
3. CAUTION: Make sure the pinion shaft

or oil seal housing is not damaged.
CAUTION: Make sure no particles of the
seal enter the steering gear.
Drive a hole into the dust cap approximately
3 mm from the outer edge.
E5858 EN 07/2001 2002 Bantam

211-02-56 Power Steering 211-02-56
4. CAUTION: Make sure the self tapping

screw is not inserted more than 2
mm.
Remove the dust cap.
1. Insert the self tapping screw.
2. Ease the dust cap upwards.
5. NOTE: Remove any grease with lint free

paper.
Remove the circlip.
6. CAUTION: Make sure the pinion

bearing underneath the seal is not
damaged by the punch.
Drive a hole into the oil seal steel cage
approximately 3 mm from the outer edge.
7. CAUTION: Make sure the pinion shaft

or oil seal housing is not damaged.
seal or contamination is left inside the
steering gear.
Remove the oil seal.
• Insert the self tapping screw into the seal
no more than 3 mm and prise out the seal.
E5858 EN 07/2001 2002 Bantam

211-02-57 Power Steering 211-02-57

Installation
1. CAUTION: Make sure the oil seal is

only installed to the minimum depth
in the oil seal housing, which allows
correct location of the circlip into the
retaining groove.
NOTE: Make sure the oil seal housing and
pinion shaft are thoroughly cleaned with lint free
paper. Examine the pinion shaft for signs of
pitting, scoring, wear or corrosion.
Install a new seal.
2. NOTE: Make sure the circlip is correctly

located.
Install the circlip.
• Coat the oil seal and circlip with grease.
3. Install a new dust cap.
4. Install the water splash shield.

• Coat the inside of the splash shield with
grease.
5. Install the steering gear

E5858 EN 07/2001 2002 Bantam

211-02-58 Power Steering 211-02-58

Power Steering Fluid Cooler (13 444 0)
Removal
2. Remove the lower radiator shield (five

screws).
3. Remove the lower engine compartment

shield (10 screws).
4. Disconnect the fluid cooler pipe and hose

connections.
1. Disconnect the right-hand side pipe
union and hose connection.
container.
2. Disconnect the left-hand side pipe
unions.
E5857 EN 07/2001 2002 Bantam

211-02-59 Power Steering 211-02-59
5. Remove the high-pressure pipe bracket

(one bolt).
6. Remove the fluid cooler (two bolts).
Installation
2. Bleed the power steering system

E5857 EN 07/2001 2002 Bantam

211-02-60 Power Steering 211-02-60

Power Steering Pump to Steering Gear Pressure line

Alignment Pins, Subframe Expander, Teflon Seal
205-316 (15-097-A) 211-188 (13-015)
General Equipment
Transmission jack
Removal
All Vehicles
1. Remove the steering column coupling to
steering gear pinion shaft pinch bolt.
2. Loosen the steering column shaft coupling

pinch bolt.

E5861 EN 07/2001 2002 Bantam

211-02-61 Power Steering 211-02-61
7. CAUTION: Over-bending or twisting of

the flexible pipe may cause damage
resulting in failure.
Support the flexible pipe with a support
wrap or suitable splint assembly.
Vehicles with manual transaxle 9.

Detach the shift rod and gearshift stabilizer.
1. Shift rod.
2. Gearshift stabilizer.
All Vehicles
12. Remove the rear support insulator to
transmission bolt.
All Vehicles
14. Using a suitable Transmission jack support
the crossmember.
E5861 EN 07/2001 2002 Bantam

211-02-62 Power Steering 211-02-62
15. NOTE: Lower the crossmember to gain

access to the power steering gear.
Remove the bolts.
16. Remove the steering gear floor seal.
Vehicles with 1.6L / 1.3L engine

17. Remove the PSP switch.
2. Remove the PSP switch.
18. Disconnect the power steering pump high-

pressure line.
1. Detach the power steering high-pressure
line support brackets.
2. Disconnect the union.
container.
E5861 EN 07/2001 2002 Bantam

211-02-63 Power Steering 211-02-63

All Vehicles
19. Detach the accessory drive belt lower
guard.
20. Remove the accessory drive belt lower

guard.

21. Disconnect the power steering pump high-
pressure line.
1. Detach the power steering line high-
pressure line support bracket.
pressure line union.
container.
Left-hand drive vehicles

line support brackets.
E5861 EN 07/2001 2002 Bantam

211-02-64 Power Steering 211-02-64
Right-hand drive vehicles

line support bracket.

line support bracket.
All Vehicles
25. Remove the power steering high-pressure
line from the steering gear.
container.
E5861 EN 07/2001 2002 Bantam

211-02-65 Power Steering 211-02-65
Installation
All Vehicles
1. Using the special tool, install a new O-ring
seal.
1. Push the new O-ring seal onto the
special tool.
2. Locate the special tool onto the union
and push on the O-ring seal.
2. Install the power steering high-pressure

line.

3. Install the power steering high-pressure line
support bracket.
E5861 EN 07/2001 2002 Bantam

211-02-66 Power Steering 211-02-66
Right-hand drive vehicles

support bracket.
Left-hand drive vehicles

support brackets.

6. Install the power steering pump high-
pressure line.
1. Connect the power steering pump high-
pressure line.
pressure line support bracket.
All Vehicles
pressure line to the accessory drive belt
lower guard.
E5861 EN 07/2001 2002 Bantam

211-02-67 Power Steering 211-02-67
8. Install the accessory drive belt lower guard.

9. Connect the power steering high-pressure
line to the power steering pump.
pressure line.
pressure line support brackets.
10. Install the PSP switch.

1. Install the PSP switch.
All Vehicles
11. Install the power steering gear floor seal.
E5861 EN 07/2001 2002 Bantam

211-02-68 Power Steering 211-02-68
12. Using the special tools, align the

crossmember.
1. Insert the guide pins through the
crossmember alignment holes.
2. Slide the locking plate into the grooves
and tighten the alignment pin sleeves.
3. Raise the crossmember engaging the
guide pins into the chassis aligning holes.
13. Install the crossmember retaining bolts.
14. Install the rear support insulator to

transmission bolt.
15. Remove the transmission jack and

alignment pins.
16. NOTE: Install a new gasket and nuts.
E5861 EN 07/2001 2002 Bantam

211-02-69 Power Steering 211-02-69
17. Remove the flexible pipe support.

20. NOTE: Make sure the washer is fitted
between the gearshift stabilizer and
transmission.
Install the shift rod and gearshift stabilizer.
1. Connect the gearshift stabilizer.
2. Connect the shift rod.
21. NOTE: Before lowering the vehicle make

sure the steering is in the straight ahead
position.
Lower the vehicle.
25. Install the steering column coupling to the

power steering gear pinion.
26. Tighten the steering column shaft coupling

pinch bolt.

E5861 EN 07/2001 2002 Bantam

211-02-70 Power Steering 211-02-70

Steering Gear to Fluid Cooler Return Hose

Alignment Pins, Subframe Expander, Teflon Seal
205-316 (15-097A) 211-188 (13-015)
General Equipment
Transmission jack
Removal
All Vehicles
1. Remove the steering column coupling to
steering gear pinion shaft pinch bolt.
2. Loosen the steering column shaft coupling

pinch bolt.
E5862 EN 07/2001 2002 Bantam

211-02-71 Power Steering 211-02-71
3. Detach the accessory drive belt lower

guard.
4. Remove the accessory drive belt lower

guard.
• Detach the clips.

5. Disconnect the power steering fluid cooler
line to the power steering gear.
container.
6. Detach the power steering fluid cooler line

to the power steering gear support bracket.
E5862 EN 07/2001 2002 Bantam

211-02-72 Power Steering 211-02-72
All Vehicles
7. Disconnect the power steering fluid cooler
to the power steering gear return line.
container.

wrap or suitable splint assembly.
9. Disconnect the exhaust front pipe.

• Discard the gasket and nuts.

10. Detach the shift rod and gearshift stabilizer.
1. Shift rod.
2. Gearshift stabilizer.
E5862 EN 07/2001 2002 Bantam

211-02-73 Power Steering 211-02-73
All Vehicles
13. Remove the rear support insulator to
transmission bolt.
15. Using a suitable Transmission jack support

the crossmember.
16. NOTE: Lower the crossmember to gain

access to the power steering gear.
Remove the bolts.
17. Remove the power steering gear to floor

seal.
E5862 EN 07/2001 2002 Bantam

211-02-74 Power Steering 211-02-74
18. Remove the power steering fluid cooler to

power steering gear return line.
container.
Installation
All Vehicles
1. Using the special tool, install a new O-ring
seal.
1. Push the new O-ring seal onto the
special tool.
2. Locate the special tool onto the union
and push on the O-ring seal.
2. Install the power steering fluid cooler to

power steering gear return line.
E5862 EN 07/2001 2002 Bantam

211-02-75 Power Steering 211-02-75

3. Connect the power steering fluid cooler line.
4. Connect the power steering fluid cooler line

to the power steering gear support bracket.
All Vehicles
5. Connect the power steering fluid cooler to
the power steering gear return line.
6. Install the power steering gear to floor seal.
E5862 EN 07/2001 2002 Bantam

211-02-76 Power Steering 211-02-76
7. Using the special tools, align the

crossmember.
1. Insert the guide pins through the
crossmember alignment holes.
2. Slide the locking plates into the grooves
and tighten the alignment pin sleeves.
3. Raise the crossmember engaging the
guide pins into the chassis aligning holes.
8. Install the crossmember retaining bolts.
9. Install the rear support insulator to

transmission bolt.
10. Remove the transmission jack and

alignment pins.
11. NOTE: Install the new gasket and nuts.

Tighten the exhaust front pipe flange joint
nuts.
E5862 EN 07/2001 2002 Bantam

211-02-77 Power Steering 211-02-77
15. NOTE: Make sure the washer is fitted

between the gearshift stabilizer and
transmission.
Install the shift rod and gearshift stabilizer.
1. Connect the gearshift stabilizer.
2. Connect the shift rod.
All Vehicles
16. Install the power steering fluid cooler to
power steering gear return line to the
accessory drive belt lower guard.
17. Secure the accessory drive belt lower

guard.
18. NOTE: Before lowering the vehicle make

sure the road wheels are in the straight
ahead position.
Lower the vehicle.
E5862 EN 07/2001 2002 Bantam

211-02-78 Power Steering 211-02-78
19. Install the steering column coupling to the

power steering gear pinion.
20. Tighten the steering column shaft coupling

pinch bolt.

E5862 EN 07/2001 2002 Bantam

211-02-79 Power Steering 211-02-79
SPECIFICATIONS
Item Specification
Power steering fluid ESPM-2C166-H
Power steering fluid alternative WSA-M2C195-A
Power steering lubricant SL-M1C9110-A
Power steering gear grease ESA-MIC45-A
Description Nm
Steering gear pipe unions 31
Tie-rod end locknuts 37
Wheel nuts 85
Tie-rod rod locknuts 63
Power steering pump retaining bolts 24
Power steering pump pressure pipe union 65
Power steering pump retaining bolts (Endura-DE) 25
Power steering pump pressure pipe union (Endura-DE) 65
Power steering pump pulley retaining bolts (Endura-DE) 25
Accessory drive belt tensioner pulley centre bolt (Endura-DE) 20
Drive belt guard retaining bolts (Endura-DE) 10
Power steering pressure (PSP) switch 11
Exhaust front pipe flange 47
Gearshift linkage pinch bolt 23
E6321 EN 07/2001 2002 Bantam

211-03-80 Steering Linkage 211-03-80
SECTION 211-03 Steering Linkages

SUBJECT PAGE
Steering Linkage.................................................................................................................... 211-03-81
Steering Linkage.................................................................................................................... 211-03-82
Tie-Rod End ..................................................................................................... (13 273 0) 211-03-83/84

Steering Gear Boot........................................................................................... (13 134 0) 211-03-85
SPECIFICATIONS
Specifications ........................................................................................................................ 211-03-86

Torque Specifications ......................................................................................................... 211-03-86
07/2001 2002 Bantam


Steering Linkage
Item Description • Tie rods.

1 Steering gear • Tie rod ends.
• Wheel knuckles.
2 Steering gear boot
The tie rod end is secured to the tie rod with a
3 Tie rod lock nut.
4 Tie rod end lock nut The tie rod entry into the steering gear is
5 Tie rod end protected by a rubber boot to prevent dirt ingress
into the tie rod end inner ball joint.
6 Tie rod end retaining nut
To allow for the movement of the suspension as
The tie rod is an extension of the steering gear. the vehicle is driven on an uneven road surface,
The steering gear movement is transferred to the the tie rod articulates between the inner and
wheels by means of: outer ball joint.
E1216 EN 07/2001 2002 Bantam


Steering Linkage
E1217 EN 07/2001 2002 Bantam


Tie-Rod End (13 273 0)
Special Tool(s)
Separator, ball joint
13-006
Removal

3. Remove the front road wheel.
4. Loosen the tie rod end nuts.

1. Loosen the lock nut.
2. Loosen the retaining nut.
5. CAUTION: When the tie rod end is

separated from the knuckle the ball
joint seal should be protected.
Detach the tie rod end from the wheel
knuckle.
1. Release the tie rod end.
2. Remove the retaining nut.
E1219 EN 07/2001 2002 Bantam

6. NOTE: Make a note of the number of turns

required to remove the tie rod end.
Remove the tie rod end and lock nut.
Installation
NOTE: Make sure the tie rod end is screwed on

by the same number of turns as was required to
remove it. If the number of turns is not known,
install the tie rod end so that the visible screw
threads on the tie rod are of equal length both
sides.
3. Check the toe setting and adjust as

necessary. For additional information,
E1219 EN 07/2001 2002 Bantam

Steering Gear Boot (13 134 0)
Removal
1. Remove the tie rod end.
2. Remove the steering gear boot retaining

clips.
3. CAUTION: Make sure the tie rod is

clean before removing the steering
gear boot.
Remove the steering gear boot.
1. Disconnect the breather pipe.
2. Slide the boot off the tie rod.
Installation
E1218 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Tie rod end retaining nut 37
Tie rod end lock nut 63
Wheels nuts 85
E1220 EN 07/2001 2002 Bantam

211-04-87 Steering Column 211-04-87
SECTION 211-04 Steering Column

SUBJECT PAGE
Steering Column .................................................................................................................... 211-04-88
Steering Wheel ................................................................................................ (13 524 0) 211-04-89

Air Bag Sliding Contact .................................................................................... (33 392 0) 211-04-90
Steering Column .............................................................................................. (13 542 0) 211-04-91/93
SPECIFICATIONS
Specifications......................................................................................................................... 211-04-94
07/2001 2002 Bantam


Steering Column

1 Steering wheel 3 Flexible coupling
2 Steering column
E1221 EN 07/2001 2002 Bantam

Steering Wheel (13 524 0)
Removal
1. Remove the air bag module. For additional
information, refer to Section 501-20B.
2. Centre the steering wheel and lock in

position.
3. NOTE: Turn the ignition key to position I to

remove the steering wheel and return to
position 0 when removed.
Remove the steering wheel.
1. Disconnect the air bag sliding contact
2. Remove the steering wheel retaining
bolt.
4. Remove the air bag sliding contact.

refer to Section 501-20B.
Installation
1. WARNING: When installing the

steering wheel make sure that the air
bag sliding contact tangs engage
correctly over the steering column.
CAUTION: Make sure the steering is in
the straight ahead position.
E1222 EN 07/2001 2002 Bantam


Air Bag Sliding Contact (33 392 0)

E1224 EN 07/2001 2002 Bantam


Steering Column (13 542 0)
Removal
CAUTION: Wait at least two minutes after

disconnecting the battery before pro-
ceeding or there may the possibility of
accidentally deploying the air bag(s)
and pyrotechnic safety belt pre-
tensioner's.
1. Remove the multi-function switch.
2. Centre the steering wheel and lock in

position.
3. Remove the PATS transceiver.

2. Remove the retaining screw.
4. Disconnect the ignition switch electrical

connector.
E1223 EN 07/2001 2002 Bantam

5. Disconnect the air bag sliding contact

6. Detach the wiring harness electrical

connectors from the steering column
bracket.
7. Disconnect the hood latch remote control

cable.

disconnect the flexible coupling.
1. Remove the pinch bolt.
2. Remove the retaining cage.
3. Remove the shaft aligner.
E1223 EN 07/2001 2002 Bantam

9. Remove the steering column.

• Remove the two retaining nuts.
Installation
1. CAUTION: Make sure the steering is in

the straight ahead position.
E1223 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Steering column coupling to steering column pinch bolt 22
E1225 EN 07/2001 2002 Bantam

211-05-95 Steering Column Switches 211-05-95
SECTION 211-05 Steering Column Switches

SUBJECT PAGE
Steering Column Switches..................................................................................................... 211-05-96

Multi-function Switch ........................................................................................................... 211-05-96/97
Ignition Switch ..................................................................................................................... 211-05-97
Steering Column Switches..................................................................................................... 211-05-98A

Inspection and Verification .................................................................................................. 211-05-98A
Symptom Chart ................................................................................................................... 211-05-98A
Pinpoint Tests ..................................................................................................................... 211-05-98B/106
Steering Column Multifunction Switch ............................................................. (33 612 0) 211-05-107

Ignition Switch.................................................................................................. (36 424 0) 211-05-108
07/2001 2002 Bantam


Steering Column Switches
Item Description • Exterior lights.

1 Multi-function switch • Direction indicator lamps.
• Headlamp high beam.
2 Ignition switch lock cylinder
• Headlamp flash feature.
3 Ignition switch
The multi-function switch located on the right-
Multi-function Switch hand side of the steering column controls the
following:
The multi-function switch located on the left-hand
side of the steering column controls the following: • Windshield wipers/washers.
E1226 EN 07/2001 2002 Bantam


The hazard flasher switch, located in the centre
of the assembly, is an integral part of the multi-
function switch and operates independently from
the ignition switch. The direction indicator system
is deactivated when the hazard flasher system is
in operation.
Ignition Switch
The ignition switch is mounted on the steering
column and is activated by the ignition switch
lock cylinder. The ignition switch lock cylinder
also controls the mechanism, which provides a
positive lock for the steering column.
E1226 EN 07/2001 2002 Bantam

211-05-98A Steering Column Switches 211-05-98A

Steering Column Switches

1. Verify the customer concern. 3. If inspection reveals an obvious cause, rectify
2. Visually inspect for obvious signs of damage. this before continuing. If the concern
Refer to the following chart: remains, proceed to the Symptom Chart.
4. Additional information on connectors is
available.
Visual Inspection Chart Refer to the relevant wiring diagrams,
Mechanical Electrical Petrol and Diesel
• Ignition switch. • Fuse.
• Battery. • Wiring.
• Connector(s).
Symptom Chart
Symptom Chart
• The ignition switch is inoperative • Switch. • GO to Pinpoint Test A.
• Circuit.
• Fuse.
• No power in ACC • Switch. • GO to Pinpoint Test B.
• Circuit.
• No power in RUN • Switch. • GO to Pinpoint Test C.
• Circuit.
• Relay.
• No power in START • Switch. • GO to Pinpoint Test D.
• Circuit(s).
• Relay.
• The multifunction switch hazard • Fuse(s). • GO to Pinpoint Test E.
warning switch does not operate • Circuit.
correctly • Switch.
E1226 EN 07/2001 2002 Bantam

Pinpoint Tests
PINPOINT TEST A: THE IGNITION SWITCH IS INOPERATIVE
A1: CHECK THE IGNITION SWITCH CONNECTOR .......................................... 211-05-98B
A2: CHECK FUSE 40 (60A) ................................................................................. 211-05-99
A3: CHECK CIRCUIT 30 RD) FOR SHORT TO GROUND .................................. 211-05-99
A4: CHECK FOR OPEN ON CIRCUIT 30 (RD).................................................... 211-05-99/100
A5: CHECK THE IGNITION SWITCH .................................................................. 211-05-100
PINPOINT TEST B: NO POWER IN ACC
B1: CHECK FOR OPEN /SHORT TO GROUND ON CIRCUIT 75 (YE) ............... 211-05-100
PINPOINT TEST C: NO POWER IN RUN
C1: CHECK FUSE 38 (60A) ................................................................................ 211-05-101
C2: CHECK FOR SHORT TO GROUND ON CIRCUIT 30 (RD)........................... 211-05-101
C3: CHECK THE IGNITION SWITCH.................................................................. 211-05-101
C4: CHECK FOR OPEN ON CIRCUITS 15 (GN) AND 15 (GN/BU) ..................... 211-05-102
C5: CHECK THE IGNITION RELAY GROUND.................................................... 211-05-102
C6: CHECK THE IGNITION RELAY POWER FEED............................................ 211-05-102/103
C7: CHECK FOR OPEN ON CIRCUIT 15 (GN) ................................................... 211-05-103
PINPOINT TEST D: NO POWER IN START
D1: CHECK FUSE 36 (60A) ................................................................................ 211-05-103/104
D2: CHECK FOR SHORT TO GROUND ON CIRCUIT 30 (RD)........................... 211-05-104
D3: CHECK THE IGNITION SWITCH.................................................................. 211-05-104
D4: CHECK FOR SHORT/OPEN ON CIRCUIT 50 (GY) ...................................... 211-05-104/105
D5: CHECK THE START INHIBIT RELAY GROUND........................................... 211-05-105
D6: CHECK THE START INHIBIT RELAY POWER FEED .................................. 211-05-105
D7: CHECK FOR OPEN ON CIRCUIT 50 (GY/BK).............................................. 211-05-106
PINPOINT TEST E: THE MULTIFUNCTION SWITCH/HAZARD WARNING
SWITCH DOES NOT OPERATE CORRECTLY
E1: CHECK THE EXTERIOR LIGHTING ............................................................. 211-05-106
E2: CHECK THE WIPER AND WASHER ............................................................ 211-05-106
211-05-98B Steering Column Switches 211-05-98B
Pinpoint Tests
PINPOINT TEST A: THE IGNITION SWITCH IS INOPERATIVE
A1: CHECK THE IGNITION SWITCH CONNECTOR
1 Remove the steering column shrouds and
check the ignition switch connector.
• Is the ignition switch connector clean and
secure?
Yes
GO TO A2
No
CLEAN and SECURE the ignition switch
connector as required. TEST the system for
normal operation.
E1227 EN 07/2001 2002 Bantam

A2: CHECK FUSE 40 (60A)
1.
Fuse 40 (60A)
2 Check the fuse 40 (60A).
• Is the fuse OK?
Yes
GO TO A4
No
INSTALL a new fuse 40 (60A). TEST the
system for normal operation. If the fuse fails
again GO TO A3
A3: CHECK CIRCUIT 30 (RD) FOR SHORT TO GROUND
1.
Fuse 40 (60A)
2 Measure the resistance between the fuse 40
connector pin 1, circuit 30 (RD) and ground.
• Is the resistance greater than 10,000 ohms?
Yes
GO TO A2
No
REPAIR circuit 30 (RD). TEST the system
A4: CHECK FOR OPEN ON CIRCUIT 30 (RD)

1. 2.
Fuse 40 (60A) Ignition switch con-

nector C61
E1227 EN 07/2001 2002 Bantam

3 Measure the resistance between the ignition
switch connector C61 pin 4, circuit 30 (RD) and
fuse 40 connector pin 1, circuit 30 (RD).
• Is the resistance less than 5 ohms?
Yes
GO TO A5
No
for normal operation
A5: CHECK THE IGNITION SWITCH

1 Carry out the ignition switch component test as
described in this section.
• Does the ignition switch test OK?
Yes
VERIFY the customer concern.
No
INSTALL a new ignition switch. TEST the
PINPOINT TEST B: NO POWER IN ACC
B1: CHECK FOR OPEN /SHORT TO GROUND ON CIRCUIT 75 (YE)
1. 2.
Ignition switch Fuse 19 (10A)

connector C61
switch connector C61 pin 1, circuit 75 (YE) and
ground, and between the ignition switch
connector C61 pin 1, circuit 75 (YE) and the
fuse 19 (10A).
• Is the resistance between connector C61 pin 1,
circuit 75 (YE) and ground greater than 10,000
ohms, and is the resistance between connector
C61 pin 1, circuit 75 (YE) and the fuse 19 (10A)
less than 5 ohms?
Yes
No
REPAIR circuit 75 (YE). TEST the system
E1227 EN 07/2001 2002 Bantam


PINPOINT TEST C: NO POWER IN RUN
C1: CHECK FUSE 38 (60A)
1.

• Is the fuse OK?
Yes
GO TO C3
No
again GO TO C2
C2: CHECK FOR SHORT TO GROUND ON CIRCUIT 30 (RD)
1. 2.
Fuse 38 (60A) Ignition relay C47

Yes
GO TO C1
No
C3: CHECK THE IGNITION SWITCH

1 Carry out the ignition switch component test.
Yes
GO TO C4
No
E1227 EN 07/2001 2002 Bantam

C4: CHECK FOR OPEN ON CIRCUITS 15 (GN) AND 15 (GN/BU)
1.
Ignition switch
2 Measure the voltage between ignition relay
C47 pin 1, circuit 15 (GN) and 15 (GN/BU) and
ground
• Is the voltage greater than 10 volts?
Yes
GO TO C5
No
Repair circuit 15 (GN) or 15 (GN/BU). TEST
C5: CHECK THE IGNITION RELAY GROUND

1. 2.
Interior light relay Ignition switch

relay C47 pin 2, circuit 31 (BK) and ground.
Yes
GO TO C6
No
Repair circuit 31 (BK). TEST the system for
normal operation.
C6: CHECK THE IGNITION RELAY POWER FEED

1.
Interior light relay
E1227 EN
07/2001 2002 Bantam
2 Measure the voltage between the ignition relay
C47 pin 3, circuit 30 (RD) and ground.
Yes
GO TO C7
No
C7: CHECK FOR OPEN ON CIRCUIT 15 (GN)

1.
Fuse 17 (15A)
2 Measure the resistance between ignition relay
C47 pin 5, circuit 15 (GN) and supply side of
Fuse F17 (15A).
Yes
INSTALL a new ignition relay. TEST the
No
REPAIR circuit 15 (GN). TEST the system
PINPOINT TEST D: NO POWER IN START

D1: CHECK FUSE 36 (60A)
1.
Fuse 36 (60A)
E1227 EN 07/2001 2002 Bantam

• Is the fuse OK?
Yes
GO TO D3
No
again GO TO D2
D2: CHECK FOR SHORT TO GROUND ON CIRCUIT 30 (RD)
1.
Fuse 36 (60A)
(60A) connector pin 1, circuit 30 (RD) and
ground.
Yes
GO TO D1
No
D3: CHECK THE IGNITION SWITCH

1 Carry out the ignition switch component test.
Yes
GO TO D4
No
D4: CHECK FOR SHORT/OPEN ON CIRCUIT 50 (GY)
1. 2.
Start inhibit relay Ignition switch C61

C163
E1227 EN 07/2001 2002 Bantam

switch connector C61 pin 3, circuit 50 (GY) and
ground, and between the ignition switch
connector C61 pin 3, circuit 50 (GY) and the
start inhibitor relay connector C163 pin 2,
circuit 50 (GY).
• Is the resistance between connector C61 pin 3,
circuit 50 (GY) and ground greater than 10,000
ohms, and is the resistance between connector
C61 pin 3, circuit 50 (GY) and pin 2, circuit 50
(GY) less than 5 ohms?
Yes
GO TO D5
No
REPAIR circuit 50 (GY). TEST the system
D5: CHECK THE START INHIBIT RELAY GROUND
1 Measure the resistance between the start
inhibit relay connector C163 pin 1, circuit 315
(BK/RD) and ground.
• Is the resistance between 45 and 50 ohms?
Yes
GO TO D6
No
REPAIR circuit 315 (BK/RD). TEST the sys-
tem for normal operation.
D6: CHECK THE START INHIBIT RELAY POWER FEED

1 Measure the voltage between the start inhibit
relay connector C163 pin 5, circuit 30 (RD) and
ground.
Yes
GO TO D7
No
E1227 EN 07/2001 2002 Bantam

D7: CHECK FOR OPEN ON CIRCUIT 50 (GY/BK)
1.
Connector C188
2 Measure the resistance between start inhibit
relay connector C163 pin 5, circuit 50 (GY/BK)
and connector C188 pin 1, circuit 50 (GY/BK).
Yes
INSTALL a new start inhibit relay. TEST the
No
REPAIR circuit 50 (GY/BK) TEST the sys-
PINPOINT TEST E: THE MULTIFUNCTION SWITCH/HAZARD WARNING SWITCH DOES NOT

OPERATE CORRECTLY
E1: CHECK THE EXTERIOR LIGHTING
1 Operate the exterior lights.
• Do the exterior lights work OK?
Yes
GO TO E2
No
REFER to Section 417-01 to diagnose the
exterior lighting.
E2: CHECK THE WIPER AND WASHER
1 Operate the wipers and washers.
• Do the wipers and washers work OK?
Yes
No
REFER to Section 501-16 to diagnose the
wipers and washers.
E1227 EN 07/2001 2002 Bantam


Steering Column Multifunction Switch (33 612 0)
Removal
2. Remove the steering column upper and

lower shrouds.
3. Remove the multifunction switch.

1. Disconnect the multi-function switch
electrical connectors.
Installation
E1230 EN 07/2001 2002 Bantam


Ignition Switch (36 424 0)
Removal

lower shrouds.
3. Disconnect the ignition switch electrical

connector.
4. Remove the ignition switch.

• Release the switch retaining clips.
Installation
E1231 EN 07/2001 2002 Bantam

3
Group
Powertrain
SECTION TITLE PAGE
Engine
Engine System - General Information 303-00
Engine - 1.6 / 1.3 RoCam 303-01B
Engine —1.8L Diesel - Endura DE 303-01D
Engine Cooling — 1.8L Diesel - Endura DE 303-03
Starting System —1.8L Diesel - Endura DE 303-06
Engine Emission Control — Diesel Engine 303-08B
Electronic Engine Controls — Diesel Engine 303-14D
Engine Cooling 303-03
Fuel Charging and Controls - 1.6 / 1.3 RoCam 303-04B
Fuel Charging and Controls - 1.8L Diesel Engine 303-04D
Accessory Drive 303-05
Starting System 303-06
Engine Ignition 303-07
Intake Air Distribution and Filtering 303-12
Electronic Engine Control 303-14
Manual Transaxle, Clutch

Manual Transaxle, Clutch - General Information 308-00
Clutch 308-01
Clutch Controls 308-02
Manual Transaxle 308-03
Manual transaxle External Controls 308-06
Exhaust System
Exhaust System - General Information 309-00
Fuel System
Fuel System - General Information 310-00
Fuel Tank and Lines
Petrol Engines 310-01A
Diesel Engines 310-01B
Acceleration Control 310-02
303-00-1 Engine System — General Information 303-00-1
SECTION 303-00 Engine System —

General Information
SUBJECT PAGE

Engine ................................................................................................................................. 303-00-2
Symptom Chart ................................................................................................................. 303-00-2
Pinpoint Tests ................................................................................................................... 303-00-2
Component Tests.............................................................................................................. 303-00-2
GENERAL PROCEDURES
Bearing Inspection ............................................................................................................... 303-00-3
Camshaft Journal Diameter ................................................................................................. 303-00-4
Camshaft Journal Clearance................................................................................................ 303-00-5
Camshaft End Play .............................................................................................................. 303-00-6
Camshaft Lobe Surface ....................................................................................................... 303-00-7
Camshaft Lobe Lift............................................................................................................... 303-00-8
Crankshaft End Play ............................................................................................................ 303-00-9
Crankshaft Main Bearing Journal Diameter.......................................................................... 303-00-10
Crankshaft Main bearing Journal Clearance ........................................................................ 303-00-11
Cylinder Bore Taper............................................................................................................. 303-00-12
Piston Diameter ................................................................................................................... 303-00-13
Piston Ring End Gap ........................................................................................................... 303-00-14
Piston Pin Diameter ............................................................................................................. 303-00-15
Piston Pin to Bore Diameter................................................................................................. 303-00-16
Piston Inspection ................................................................................................................. 303-00-17
Piston Ring-to-Groove Clearance ........................................................................................ 303-00-18
Connecting Rod Large End Bore ......................................................................................... 303-00-19
Cylinder Head Distortion ...................................................................................................... 303-00-20
Valve Stem Diameter ........................................................................................................... 303-00-21
Valve Seat Inspection .......................................................................................................... 303-00-22
Exhaust Manifold Inspection ................................................................................................ 303-00-23
Flywheel Inspection ............................................................................................................. 303-00-23
07/2001 2002 Bantam

Engine
Inspection and Verification Pinpoint Tests
Symptom Chart Component Tests
E6626 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Bearing Inspection
1. Inspect bearings for the following defects.

1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or
bearing not seated.
E255 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Camshaft Journal Diameter
1. Determine the diameter of the camshaft

journals.
• Using a micrometer measure the
diameter at 90 degrees intervals to
determine if the journals are out-of-round.
• Measure at two different points on the
journal to determine if there is any
tapering.
• If the measurements are out of the
specified range, install a new camshaft.
E231 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Camshaft Journal Clearance
NOTE: Make sure that the following stages are

followed exactly. The tappets or followers must
be removed to carry out this measurement.
NOTE: Make sure that the camshaft is to speci-
fication.
NOTE: The bearing caps and journals should be
free from engine oil and dirt.
1. Position on a length of plastigage on the
bearing cap.
• Insert the camshaft, without lubrication,
into the cylinder head.
• Position a plastigage strip, which should
be equal to the width of the bearing cap,
on the bearing journal.
2. Following the tightening specification, install

the camshaft bearing caps.
refer to the corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.

Remove the camshaft bearing caps;
refer to the corresponding Section 303-01.
4. Using the Plastigage, read off the

measurement.
• Compare the length of plastigage with
the plastigage scale.
• The value that is read off is the bearing
clearance.
E232 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Camshaft End Play
1. NOTE: Make sure that the camshaft is to

specification.
Using a Dial Indicator Gauge, measure the
endplay.
• Slide the camshaft in both directions.
Read and note the maximum and
minimum values on the Dial Indicator
Gauge.
• End play = maximum value minus minimum
value
• If the measurement is out of
specification, install new components.
E4119 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Camshaft Lobe Surface
1. Inspect the camshaft lobes for pitting or

damage in the active area. Minor pitting is
acceptable outside the active area.
E234 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Camshaft Lobe Lift
1. Determine the cam lift.

• Using a micrometer measure the cam in
two directions.
• The difference between the two
measurements is the cam lift.
E3255 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Crankshaft End Play
General Equipment
Dial indicator
Dial indicator fixture
Determine the end float
• Place on the dial indicator and bracket.
• Determine the end float by raising the
crankshaft with the aid of a screwdriver.
• If necessary, correct the end float by
using new thrust half washers.
E3257 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Crankshaft Main Bearing Journal Diameter
General Equipment
Micrometer
1. Measure the diameter of the main bearing

journals and the big-end bearing journals.
• Repeat the measurement using the
micrometer offset by 90° to establish any
eccentricity.
• Measure the bearing journal in two
different places to measure any possible
tapering.
E2395 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Crankshaft Main bearing Journal Clearance
Main bearings - Minimum 0.020 mm

Maximum 0.056 mm
E4546 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Cylinder Bore Taper
1. NOTE: The main bearing caps or lower

crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
• Carry out the measurements in different
directions and at different heights to
determine if there is any out-of-roundness
or tapering.
• If the measurement is out of the
specified range, install a new block or
hone out the cylinder block (if applicable /
allowed).
E238 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Piston Diameter
General Equipment
Micrometer
1. NOTE: Mark piston in case a piston has to be

again installed.
Using a Micrometer measure the piston in
two directions.
• Measure the piston diameter at the
height of the piston pin bore, but offset by
90 degrees.
E241 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Piston Ring End Gap
1. CAUTION: Do not mix up the piston

rings. Install the piston rings in the
same position and location.
Take the piston ring and use a piston
without rings to push the piston ring about
30 mm into the cylinder bore.
2. Using the Feeler Gauge, measure the

piston ring gap.
E3975 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Piston Pin Diameter
1. NOTE: The piston and piston pins are a

matched pair. Do not mix up the components.
Measure the piston pin diameter.
• Measure the diameter in two directions.
• If the values are not to specification,
install a new piston and a new piston pin.
E245 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Piston Pin to Bore Diameter
1. NOTE: The piston and piston pin form a

matched pair. Do not mix up the components.
Measure the diameter of the piston pin
bore.
• Measure the diameter in two directions.
• If the values are not to specification,
install both a new piston and a new piston
pin.
E240 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Piston Inspection
1. CAUTION: Do not use any aggressive

cleaning fluid or a wire brush to clean
the piston.
Carry out a visual inspection.
• Clean the piston skirt, pin bush, ring
grooves and crown and check for wear or
cracks.
• If there are signs of wear on the piston
skirt, check whether the connecting rod is
twisted or bent.
E3974 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Piston Ring-to-Groove Clearance
General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from the

piston groove. To determine the piston ring
clearance, insert the Feeler Gauge right to
the back of the groove, behind the wear
ridge.
Using the Feeler Gauge, measure the
piston ring clearance.
E244 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Connecting Rod Large End Bore
1. Measure the bearing bore in two directions.

The difference is the connecting rod bore
out-of-round. Verify the out-of-round and
the bearing bore is within specification.
E247 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Cylinder Head Distortion
Cylinder Head Flatness - 0.050 mm over any

0.150 mm
Surface Finish "Waveness" -

Specification R326 WT 10 RMAX 20
E4547 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Valve Stem Diameter
1. Using a micrometer measure the diameter

of the valve stems.
• If the measurements are not to
specification, install a new valve.
E248 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Valve Seat Inspection
General Equipment
Valve seat width scale
1. Measure the width of the valve seat.

• Measure the valve seat width using the
Valve seat width scale.
• If the value is not to specification rework
the valve seat.
E250 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Exhaust Manifold Inspection
1. Inspect the cylinder head joining flanges of
the exhaust manifold for evidence of
exhaust gas leaks.
2. Inspect the exhaust manifold for cracks,

damaged gasket surfaces, or other damage
Flywheel Inspection that would make it unfit for further use.
1. Inspect the flywheel for:

1. Any cracks.
2. Worn ring gear teeth.
3. Chipped or cracked ring gear teeth.
Special Tool(s)
Angle gauge
303-174 (21-540)
General Equipment
Engine lifting eye order no.: 6630411
Assembly stand
Workshop jack
Lubricant for spark Loctite "Never Seize"
plugs.
Coolant L405F
Engine oil SAE 15W 40 SH
Cable ties
Silicone grease ESE - M1C171 - AA
E254 EN 07/2001 2002 Bantam

303-01A-24 Engine — 1.6L / 1.3L RoCam 303-01B24
SECTION 303-01B Engine — 1.6L / 1.3L RoCam

PAGE 1 OF 2
SUBJECT PAGE

Engine .................................................................................................................................303-01B-26
General............................................................................................................................. 303-01B-26/33

Engine ................................................................................................................................. 303-0IB-34
IN-VEHICLE REPAIR
Intake Manifold ............................................................................................... (21 183 0) 303-01B-35/39
Valve Cover.................................................................................................... (21 140 0) 303-01B-40/42
Crankshaft Front Oil Seal ............................................................................... (21 467 0) 303-01B-43/45
Valve Seals .................................................................................................... (21 238 0) 303-01B-46/48
Camshaft........................................................................................................ (21 283 0) 303-01B-49/51
Timing Chain ....................................................................................................................... 303-01B-52/55
Crankshaft Rear Oil Seal ..................................................................................................... 303-01B-56/57
Exhaust Manifold............................................................................................ (21 186 0) 303-01B-58/60
Cylinder Head................................................................................................. (21 163 0) 303-01B-61/70
Oil Pan ........................................................................................................... (21 154 0) 303-01B-71/74
Oil Pump ........................................................................................................ (21 154 0) 303-01B-75/76
REMOVAL
Engine ............................................................................................................ (21 132 0) 303-01B-77/87
DISASSEMBLY
Engine ............................................................................................................ (21 134 8) 303-01B-88/96
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head................................................................................................. (21 165 6) 303-01B-97/103
ASSEMBLY
Engine ............................................................................................................ (21 134 8) 303-01B-104/115
INSTALLATION
Engine ............................................................................................................ (21 132 0) 303-01B-116/126
SPECIFICATIONS
Specifications ...................................................................................................................... 303-01B-127
Engine Data...................................................................................................................... 303-01B-127
Engine Oil ......................................................................................................................... 303-01B-127
Lubricants, Fluids, Sealers and Adhesives........................................................................ 303-01B-127
Capacities......................................................................................................................... 303-01B-127
Oil Pressure...................................................................................................................... 303-01B-127/128
07/2001 2002 Bantam

303-01B-25 Engine — 1.6L / 1.3L RoCam 303-01B-25
SECTION 303-01B Engine — 1.6L / 1.3L RoCam

PAGE 2 OF 2
Crankshaft......................................................................................................................... 303-01B-128
Piston................................................................................................................................ 303-01B-128
Connecting rod.................................................................................................................. 303-01B-129
Valve train ......................................................................................................................... 303-01B-129
Cylinder block ................................................................................................................... 303-01B-129
Camshaft........................................................................................................................... 303-01B-129/130
Torque Specifications........................................................................................................ 303-01B-130/132
07/2001 2002 Bantam


Engine
General
The Rocam SOHC engine is of 1.6 and 1.3 litre • Cast iron cylinder block with integrated timing
capacity and has a power output of 70 kW and 55 chain housing
kW respectively. • Cast iron crankshaft with five main bearings
The engine is a 4-cylinder in-line, four stroke unit • Lightweight pistons with three piston rings
with single overhead camshaft and cross-flow • Cast aluminum alloy cylinder head with
cylinder head. The engine is a new development integrated timing chain housing and camshaft
and includes the following technical features: bearings
E6630 EN 07/2001 2002 Bantam

• Five bearing single overhead camshaft and manifold absolute pressure (T-MAP)
• Two valves per cylinder sensor and fuel rail with four injectors
• Roller finger cam followers • Four-into-one exhaust manifold
• Hydraulic lash adjusters • Crankshaft driven oil pump
• Laminated (two layer) steel head gasket • Lightweight plastic coolant flow control
housing with integrated double acting
• Structural aluminum oil pan
thermostat, coolant bypass and mounting
• Plastic intake manifold with integrated throttle boss for the engine coolant temperature
body including throttle position (TP) sensor, (ECT) sensor
idle air control (IAC) valve, manifold absolute
• Electronic engine control (Bosch) engine
pressure sensor with integrated temperature
management system
Serial Number and Engine Code Location
The engine serial number and the engine code

are both stamped on the rear face of the cylinder
block.
E6630 EN 07/2001 2002 Bantam


Valve Train
Item Description The five bearing camshaft runs directly in the

aluminum cylinder head.
1 Camshaft bearing cap
An additional reference cam is provided for the
2 Camshaft camshaft position (CMP) sensor.
3 Reference cam The cam followers are supported across the
hydraulic lash adjusters and valves and the
4 Roller finger cam follower camshaft operates the cam followers through
5 Hydraulic lash adjuster their roller bearings.
6 Cylinder head This has the advantage of lowering friction and
therefore increasing durability.
E6630 EN 07/2001 2002 Bantam


The use of hydraulic lash adjusters removes the need for valve clearance adjustment.
Rear Oil Seal Retainer
The rear oil seal retainer is made of plastic. It

Item Description
incorporates an integral crankshaft oil seal (made
1 Rear oil seal retainer of PTFE) and a cylinder block to retainer gasket.
2 Oil pan mating surface NOTE: A special "Assembly Guide" (for installing
the retainer) is provided with each new rear oil
3 Bolt seal retainer.
4 Assembly guide NOTE: The sealing lip must be free of oil.
E6630 EN 07/2001 2002 Bantam


Cylinder Head
The cylinder head is made of cast aluminum alloy

Item Description
and is accurately positioned on the cylinder block
1 M8 bolts with two guide dowels.
2 M11 bolts The laminated (two layer) design cylinder head
gasket is made of steel.
3 Cylinder head gasket
NOTE: Always use a new gasket when installing
4 Guide dowels the cylinder head.
E6630 EN 07/2001 2002 Bantam


Oil Pan
The structural oil pan is made of cast aluminum The single piece oil pan gasket has an aluminum
and provides a mounting bracket for the air core with an external vulcanized rubber surface.
conditioner (A/C) compressor. NOTE: Always use a new gasket when installing
the oil pan.
E6630 EN 07/2001 2002 Bantam


Camshaft Chain Drive
Item Description The overhead camshaft is driven from the

crankshaft by the timing chain.
1 Camshaft sprocket
The steel camshaft sprocket has 38 teeth and is
2 Crankshaft sprocket produced by the "fine blanking" process, which
enables the flat design. The camshaft sprocket
3 Chain guide (intake side) position is fixed by a guide lug to a slot in the
4 Tensioner arm (exhaust side) camshaft. The timing mark is stamped into the
face of the sprocket.
5 Timing chain
6 Hydraulic chain tensioner
E6630 EN 07/2001 2002 Bantam


The sintered steel crankshaft sprocket has 19 The plastic chain guide and tensioner arm and
teeth and is positioned by a woodruff key. The are fixed to the cylinder block with one bolt each.
timing mark is stamped into the sprocket. The chain guide and tensioner arm reduce chain
The single timing chain has 114 links. Chain and vibration and noise.
sprocket alignment is indicated by colored chain The hydraulic chain tensioner is operated by
links. engine oil pressure.
Coolant Flow Control Housing
The coolant flow control housing is made of WARNING: The cooling system must be
plastic and bolts to the rear of the cylinder head. de-pressurized before the retaining clip
The ECT sensor is fixed by a clip to its mounting of the ECT sensor is removed.
which is integrated in the coolant flow control NOTE: Install a new gasket if the original is
housing. damaged.
The gasket is made of rubber.
E6630 EN 07/2001 2002 Bantam


Engine
E3278 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Intake Manifold (21 183 0)
Cable ties
Removal
2. Remove the air cleaner intake pipe.
3. WARNING: Watch for and collect

escaping fuel. Observe the safety
regulations for working with fuel.
Disconnect the fuel lines.
4. Disconnect the accelerator cable.

1. Remove the clip and pull cable from the
retaining bracket.
2. Disconnect the inner cable.
E6632 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR (CONTINUED)
5. Remove the hoses and the electrical

connector.
1. EVAP solenoid valve vacuum hose.
2. Positive crankcase ventilation (PCV)
hose.
3. Crankcase breather hose.
4. Engine coolant temperature (ECT)
sensor electrical connector.
5. Brake booster vacuum hose.
6. Disconnect the electrical connectors.

1. Powertrain control module (PCM).
2. Camshaft position (CMP) sensor.

8. Remove the engine undershield.
9. Remove the intake manifold lower retaining

bolts (shown with the engine removed).
E6632 EN 07/2001 2002 Bantam

11. Remove the intake manifold.
Installation
1. NOTE: Install a new gasket if the original is

damaged.
Install the intake manifold.

3. Install the intake manifold lower retaining

bolts (shown with engine removed).
E6632 EN 07/2001 2002 Bantam

4. Install the engine undershield.
6. Connect the PCM and CMP electrical

connectors.
7. Install the hoses and connect the electrical

connector.
2. PCV hose.
4. ECT sensor electrical connector.
8. Install the accelerator cable.

1. Connect the inner cable.
2. Install the cable into the retaining
bracket, check the cable setting and
secure using the clip.
E6632 EN 07/2001 2002 Bantam

9. Connect the fuel lines.
10. Install the air cleaner intake pipe.
11. Connect the battery ground cable.
E6632 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Valve Cover (21 140 0)
Removal

1. Disconnect the power control module
(PCM).
2. Disconnect the camshaft position (CMP)
sensor.
3. Disconnect the electronic ignition (EI)
coil.
3. CAUTION: Do not pull the cable when

removing spark plug connector. If
necessary, remove the ignition
cables from the ignition coil to avoid
kinking the cables. Turn the spark
plug connector slightly before
removing to loosen the seal.
CAUTION: Pull off the spark plug
connectors in line with the spark plugs
(for bent spark plug connectors use
Special Tool 303-622).
Disconnect the spark plug wires from the
spark plugs.
4. Disconnect the hoses.

1. EVAP solenoid valve vacuum hose
2. Positive crankcase ventilation hose
3. Crankcase breather hose
E6633 EN 07/2001 2002 Bantam

5. Remove the valve cover.
Installation

damaged.
Install the valve cover.
2. Connect the hoses.

1. Connect the EVAP solenoid valve
vacuum hose.
2. Connect the PCV hose.
3. Connect the crankcase breather hose.
3. Connect the spark plug wires to the spark

plugs.
E6633 EN 07/2001 2002 Bantam


4. Connect the PCM, CMP sensor and EI coil
E6633 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Crankshaft Front Oil Seal (21 467 0)

Remover, Oil Seal Installer, Oil Seal
303-112 (21-051) 303-656 (21-233)
Removal
1. Remove the accessory drive belt.
• Turn the belt tensioner clockwise and
slip the belt off the pulleys.
2. Raise and support vehicle. For additional

3. Remove the accessory drive belt cover.
E6634 EN 07/2001 2002 Bantam

4. Remove the crankshaft pulley.
5. Using the special tool, remove the oil seal.

(Shown with the oil pan removed).
Installation
1. NOTE: The pulley, installation sleeve,

housing and sealing lip must be free of oil.
NOTE: The new oil seal is supplied with a
plastic installation sleeve.
Install the oil seal to the crankshaft pulley.
1. Place the installation sleeve on the
crankshaft pulley.
2. Carefully install the oil seal on the
crankshaft pulley.
• Remove the installation sleeve.
2. Using the special tool, install the crankshaft

pulley.
1. Crankshaft pulley bolt.
2. Special tool.
3. Crankshaft pulley.
4. New oil seal.
E6634 EN 07/2001 2002 Bantam

3. NOTE: To prevent damage to the oil seal, do

not pull the crankshaft pulley out more than 3
mm during seal installation.
Tighten the crankshaft pulley bolt until the
oil seal is fully installed.
4. Remove the crankshaft pulley bolt.
5. Install the crankshaft pulley bolt.
6. Install the accessory drive belt cover.
8. Install the accessory drive belt.

• Turn the drive belt tensioner clockwise
and install the belt onto the pulleys.
E6634 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Valve Seals (21 238 0)

Adapter, Air Supply (Cylinder Adapter for 303-461
Head) 303-461-01 (21-194-01)
303-363 (21-157)
Compressor Valve Spring Pliers, Valve Stem Oil Seal

303-461 (21-194) 303-508 (21-211)
Removal
1. Remove the valve cover. For additional
information, refer to Valve Cover in this section.
2. Remove the camshaft. For additional

information, refer to Camshaft in this section.
3. Remove the spark plugs.
4. Remove the camshaft roller followers

(Cylinder head shown removed).
5. Install the camshaft without the cam

followers. For additional information,
refer to Camshaft in this section
E6635 EN 07/2001 2002 Bantam

6. Install the special tool and high-pressure

airline.
• Connect an air supply, pressurized to 7-
10 bar.
7. NOTE: To aid correct reassembly, keep all

parts in the order removed.
Using special tools, remove the valve
spring.
1. Compress the valve spring.
2. Remove the valve collets, the valve
spring retainer and the valve spring.
8. Using the special tool, remove the valve

seals.
Installation
1. NOTE: The valve seals are fully installed by

the pressure of the valve springs.
Using the special tool, install the valve
seals.
E6635 EN 07/2001 2002 Bantam

2. Using the special tools, install the valve

springs.
1. Compress the valve spring and valve
spring retainer.
2. Insert the valve collets.
3. Remove the high-pressure airline and

special tool.
4. Remove the camshaft. For additional

5. Install the roller finger cam followers.

(Cylinder head shown removed).
6. Install the camshaft. For additional

7. Install the spark plugs.
8. Install the valve cover. For additional

E6635 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Camshaft (21 283 0)
Universal Flange Holding Hypoid oil SAE 90
Wrench
205-072 (15-030 A)
Removal
2. NOTE: The camshaft sprocket timing mark

and both colored links on the timing chain
must line up.
Set the engine to TDC on cylinder No. 1.
and wire together the chain and sprocket.
3. Remove the timing chain hydraulic

tensioner.
E6636 EN 07/2001 2002 Bantam

4. Using the special tool, remove the camshaft

sprocket.
5. NOTE: Slackening sequence.

NOTE: Keep the camshaft bearing caps in order
for installation.
Slacken each bolt of the camshaft bearing
caps by one turn until the camshaft is
released.
6. Remove the camshaft bearing caps and the

camshaft.
Installation
1. NOTE: Make sure the sprocket alignment slot

in the camshaft is uppermost (12 o'clock)
when installing the camshaft.
NOTE: Apply a drop of hypoid oil (WSQ-
2C9002-AA) to each cam bearing (upper and
lower) half.
Install the camshaft and tighten the bolts in
two stages.
1. Tighten each of the camshaft bearing
cap bolts by 90° degrees in the indicated
sequence.
2. Tighten the bolts to the specified torque
in the indicated sequence.
E6636 EN 07/2001 2002 Bantam

2. NOTE: The mark on the camshaft sprocket

must line up.
Remove the wire tie and using the special
tool, install the camshaft sprocket with the
timing chain.
3. Install the timing chain hydraulic tensioner.

information, refer to Valve cover in this section.
E6636 EN 07/2001 2002 Bantam

303-01B-52 Engine — 1.6L 303-01B-52
IN-VEHICLE REPAIR
Timing Chain
Special Tool(s)
Universal Flange Holding
Wrench
205-072 (15-030 A)
Removal
1. Remove the oil pump. For additional
information, refer to Oil Pump in this section.


and both colored links of the timing chain
must line up.

tensioner.
E6637 EN 07/2001 2002 Bantam

6. Using the special tool, remove the camshaft

sprocket.

8. Remove the timing chain.

1. Remove the chain tensioner arm.
2. Remove the chain guide.
• Remove the timing chain and the
crankshaft sprocket.
Installation
1. NOTE: The crankshaft sprocket timing mark

and the single colored link on the timing chain
must line up.
NOTE: The crankshaft sprocket timing mark
must be in the 6 o'clock position.
Install the crankshaft sprocket and the
timing chain.
E6637 EN 07/2001 2002 Bantam

2. Install the timing chain tensioner arm and

the chain guide.
1. Install the chain tensioner arm.
2. Install the chain guide.

must line up.
NOTE: The mark on the camshaft sprocket
must be in 12 o'clock position.
Install the timing chain onto the camshaft
sprocket.
5. Using the special tool, tighten the camshaft

sprocket retaining bolt.
E6637 EN 07/2001 2002 Bantam


8. Install the oil pump. For additional

information, refer to Oil Pump in this section.
E6637 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Crankshaft Rear Oil Seal
Removal
1. Remove the transaxle. For additional
2. Remove the clutch. For additional

3. Remove the flywheel.
4. Remove the oil pan. For additional

information, refer to Oil Pan in this section.
5. Remove and discard the rear oil seal

retainer and the gasket.
Installation
1. NOTE: An aligning guide is supplied with

each new rear oil seal retainer.
NOTE: The sealing lip must be free of oil.
NOTE: Make sure the aligning dowels are
located.
Install a new rear oil seal retainer.
E6638 EN 07/2001 2002 Bantam


2. Install the oil pan. For additional
3. Install the flywheel.
4. Install the clutch. For additional

5. Install the transaxle. For additional

E6638 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Exhaust Manifold (21 186 0) Removal

3. Disconnect the exhaust down pipe from the

exhaust manifold and position it to one side.
1. Remove the nuts.
2. Detach the exhaust hanger insulator.
• Remove and discard the gasket.

removing the spark plug connector. If
necessary remove the ignition cables
from the ignition coil to prevent
connectors in line with the spark plug
(for bent spark plug connectors use
Pull off the spark plug connector.
6. Remove the electronic ignition (EI) coil and

position it to one side.
E6639 EN 07/2001 2002 Bantam


7. Remove the upper heat shield (shown on
removed engine).
8. Remove the exhaust manifold (shown on

removed engine).
Installation
1. NOTE: Use a new gasket.

Install the exhaust manifold.
2. Install the upper heat shield.
E6639 EN 07/2001 2002 Bantam

3. Install the EI coil.
4. Install the spark plug electrical connectors.

6. Connect the exhaust down pipe to the

exhaust manifold.
1. Install the nuts.
2. Attach the exhaust hanger insulator.
E6639 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Cylinder Head (21 163 0)
Socket, Cylinder Head Bolt Trolley jack
303-392 (21-167)
Sealer Green Loctite 648 re-
taining compound
Universal Flange Holding Engine oil SAE 15W 40 SH
Tool
205-072 (15-030 A)
Angle Gauge, Bolt Tightening

303-174 (21-540)
Removal
3. WARNING: Escaping fuel. Observe the

safety regulations for working with
fuel.
E6640 EN 07/2001 2002 Bantam


1. Remove the clip and pull the cable from
the retaining bracket.
5. Remove hoses and the electrical connector.

hose.
4. Engine coolant temperature (ECT)

3. Electronic ignition (EI) coil.

necessary, remove the ignition
cables from the ignition coil to avoid
connectors in line with the spark plugs
(For bent spark plug connectors, use
Remove the spark plugs.
• Disconnect the electrical connectors.
E6640 EN 07/2001 2002 Bantam

8. WARNING: Danger of scalding if the

engine is warm.
Drain the coolant (shown from below).
• Install the drain plug after draining.
9. Disconnect the coolant hoses.
10. Raise and support vehicle. For additional

12. Remove the lower intake manifold bolts

(engine shown removed for clarity).
E6640 EN 07/2001 2002 Bantam


13. Separate the exhaust down pipe from the
1. Remove the nuts.
2. Disconnect the hanger insulator.
16. NOTE: The camshaft sprocket mark and

both colored links on the timing chain must
line up.
NOTE: The camshaft sprocket timing mark
must be at the 12 o'clock position.

tensioner.
E6640 EN 07/2001 2002 Bantam

18. Remove the oil level indicator tube retaining

bolt.
19. NOTE: Secure the timing chain to a wire

hook to prevent it from falling down into the
cylinder block.
Using the special tool, remove the camshaft
sprocket.
20. Place a trolley jack with a wooden block

under the oil pan and raise slowly until the
engine front mounting is free from strain.
22. Remove the engine front mounting bracket.
E6640 EN 07/2001 2002 Bantam

23. NOTE: Loosen the bolts in the indicated

sequence.
Using the special tool, remove the cylinder
head.
Installation
1. CAUTION: Use new cylinder head

bolts.
NOTE: Use a new gasket.
Using the special tool, tighten the bolts in
four stages.
• Stage 1: Tighten all M11 bolts in the
indicated numerical sequence to 40 Nm.
indicated alphabetical order to 15 Nm.
indicated alphabetical order to 45
degrees.
indicated numerical sequence to 120
degrees.
2. Install the engine front mounting bracket.
3. Remove the trolley jack.
E6640 EN 07/2001 2002 Bantam


must line up.
Install the timing chain on the camshaft
sprocket.
• The camshaft sprocket timing mark must
be at the 12 o'clock position.
5. Using the special tool, install the camshaft

sprocket.
6. NOTE: If the oil level indicator tube was

removed apply sealer (WSK-M2G349-A4) to
the lower end.
Tighten the oil level indicator tube bolt.
E6640 EN 07/2001 2002 Bantam


damaged.

10. Connect the exhaust down pipe.

2. Connect the retaining hanger insulator.

bolts (engine shown removed for clarity).
E6640 EN 07/2001 2002 Bantam


14. Connect the coolant hoses.

1. To coolant expansion tank
2. To cabin heater
3. From cabin heater

damaged.
16. Install the spark plugs and connect the

spark plug wires.
17. Connect the PCM, CMP sensor and EI coil

1. PCM connector
2. CMP connector
3. EI coil connector
E6640 EN 07/2001 2002 Bantam


18. Install the hoses and the electrical
connector.
2. PCV
3. Crankcase breather hose
4. ECT sensor electrical connector
5. Brake booster vacuum hose

1. Hook in the inner cable.
2. Install the cable in the bracket, adjust
cable and secure with the clip.
22. Fill the cooling system. For additional

E6640 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Oil Pan (21 154 0)
Sealer Loctite 5910 Flange
Sealant
Engine oil SAE 15W 40 SH
Removal
All vehicles
1. Remove the transaxle. For additional
2. Remove the clutch. For additional

5. Turn the belt tensioner clockwise and

remove the belt.

E6641 EN 07/2001 2002 Bantam

Vehicles with air conditioning

7. Remove the air conditioning compressor
and secure it to the radiator crossmember.
All Vehicles
8. Drain the engine oil.
9. Install the drain plug.
10. Remove the oil pan.

E6641 EN 07/2001 2002 Bantam


Installation
All vehicles
1. Preparatory operations
NOTE: Do not damage the mating faces.
• Using a spatula or scraper remove any
traces of sealer or gasket residue from the
mating faces.
NOTE: The mating faces must be free of oil and
gasket residue.
• Clean the oil pan to remove any oil
residue or sludge.
2. NOTE: Apply a 3 to 5 mm bead of sealer

(LOCTITE 5910) to the marked areas.
NOTE: Install the oil pan within 5 minutes of
applying the sealer beads.
Using a straightedge, align the oil pan flush
to the rear cylinder block surface.
• Wait no longer than 5 minutes to install
the oil pan gasket.
3. Install and tighten the oil pan retaining bolts

(stage 1).
4. Tighten the oil pan retaining bolts (stage 2).
E6641 EN 07/2001 2002 Bantam


5. Install the A/C compressor.
All Vehicles

install the belt.

10. Install the clutch and pressure plate. For

11. Install the transaxle. For additional

12. Fill the engine with low friction oil meeting

SAE 15W40 SH specification.
E6641 EN 07/2001 2002 Bantam

IN-VEHICLE REPAIR
Oil Pump (21 154 0)
Special Tool(s)
Remover, Oil Seal
303-112 (21-051)
Removal
1. Remove the oil pan. For additional
3. Using the special tool, remove the front oil

seal.
4. Remove the oil pump.

• Remove and discard the oil pump and
gasket.
E6647 EN 07/2001 2002 Bantam

303-01B-76 Engine — 1.6L 303-01B-76
Installation
1. NOTE: Ensure gasket mating surfaces are

clean.
NOTE: Use a new oil pump and gasket.
NOTE: The oil pump sealing flange must be
within ±20mm of cylinder block bottom
sealing flanges.
Install oil pump bolts.
2. Install a new front oil seal. For additional

information, refer to Front Oil Seal in this section
3. Install the oil pan. For additional

E6647 EN 07/2001 2002 Bantam

REMOVAL
Engine (21 132 0)
General Equipment
Retaining strap
Assembly stand
Removal
All vehicles
1. General notes.
• The locations of the engine mountings
and the engine support insulators are
described looking from the transaxle to
the engine.
• Steps, which apply only to particular
variants, are indicated with a note.
• If necessary, cut the cable ties and install
new during installation.
2. Remove the battery. For additional

3. Remove the battery tray.

1. Cut the cable ties.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
5. Remove the hoses.

6. WARNING: Escaping fuel. Observe the

safety regulations for working with
fuel.
7. Remove the accelerator cable.

1. Remove the clip and pull the cable from
the bracket.
2. Unhook the inner cable.

engine is warm.
Drain the coolant (shown from below).
• Screw in the drain plug after draining.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
9. Remove the coolant hoses.
10. Remove the right-hand coolant hose

bracket.
11. Remove the left-hand coolant hose bracket.
12. Disconnect the ground cable, the electrical

connectors and the transmission breather.
1. Disconnect the ground cable.
2. Disconnect the generator electrical
connector.
3. Disconnect the starter motor electrical
connector.
4. Disconnect the transmission breather.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)

1. Disconnect the heated oxygen sensor
(HO2S).
2. Disconnect the powertrain control
module (PCM).
3. Disconnect the electronic ignition (EI)
coil.
4. Disconnect the vehicle speed (VSS)
sensor.
Vehicles with 1.3L engine.
14. Remove the knock sensor.
Note: Inlet manifold removed for clarity.
All vehicles.
15. Disconnect the reversing lamp switch
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
16. Disconnect the speedometer drive cable

from the transaxle.
17. Disconnect the clutch slave cylinder

hydraulic line.
18. Disconnect the cooling fan electrical

connectors.
19. Remove the cooling fan.

• First slide the fan upwards and then
remove it from underneath the vehicle.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)

rod from turning.
Loosen the suspension strut retaining nut
five turns on both sides (right-hand side
shown).

slip the belt off the pulleys.

24. Remove the accessory drive belt cover.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)

25. Remove the A/C compressor and secure it
to the radiator crossmember.
All Vehicles
26. Disconnect the exhaust down pipe from the
1. Remove the nuts.
2. Detach the exhaust hanger insulator.
27. Remove the exhaust lower heat shield.
28. Disconnect the shift rod and gearshift

stabiliser.
1. Remove the shift rod.
2. Remove the gearshift stabiliser.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
29. Disconnect the lower arm from the wheel

knuckle on both sides (left-hand side
shown).
30. Remove the inner constant velocity (CV)

joint boot clamp on both sides (right-hand
side shown).
31. CAUTION: To prevent damage to the

halfshaft joints and boots, do not
bend the inner halfshaft joints by
more than 18 degrees, the outer one
by not more than 45 degrees.
NOTE: Remove the grease from out of the
housing.
Remove the halfshafts on both sides (left-
hand side shown).
• Secure the halfshafts to one side.
32. NOTE: The engine roll restrictor is under

tension.
Remove the engine roll restrictor.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
33. Remove the coolant return hose.
34. Position the assembly stand with wooden

blocks on it under the vehicle.
35. Carefully lower the vehicle until the engine

and transaxle assembly is on the assembly
stand.
36. Secure the engine and transaxle assembly

on the assembly stand with a retaining
strap.
37. Remove the engine rear mounting bracket.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
39. Move the assembly stand forward with the

engine and transaxle assembly.
40. Install an engine lifting eye.
41. Disconnect the engine wiring harness

1. Remove the generator electrical
connectors.
2. Remove the oil pressure switch
3. Remove the (CKP)- sensor
42. Remove the starter motor and the transaxle

left-hand flange bolt.
E6642 EN 07/2001 2002 Bantam

REMOVAL (CONTINUED)
43. Remove the transaxle right-hand flange

bolts.
44. Remove the transaxle lower flange bolts.
45. Remove the transaxle upper flange bolt.
46. Separate the transaxle from the engine.
E6642 EN 07/2001 2002 Bantam

DISASSEMBLY
Engine (21 134 8)

Universal Flange Holding Mounting Bracket for 21–187
Tool 303-435-06 (21-031 B)
205-072 (15-030 A)
Lifting Bracket, Engine Mounting Plate for 21–031

303-122 (21-068 A) 303-435-11 (21-146 C)
Socket, Cylinder Head Bolt

303-392 (21-167) Material Specification
Wire
Cable ties
Mounting Stand
303–435 (21–187)
Disassembly
1. General remarks.
• Cut cable ties as necessary and install
new during installation.
2. Remove the exhaust manifold

E6643 EN 07/2001 2002 Bantam

DISASSEMBLY (CONTINUED)
3. Using the special tools, secure the engine

to the mounting stand.
4. Remove the special tool.
5. Remove the engine mounting bracket.
6. Remove the generator.
E6643 EN 07/2001 2002 Bantam

7. Remove the generator bracket.
8. Drain the engine oil.
9. Install the drain plug.
10. Disconnect the vacuum hoses.

sensor and the engine coolant temperature
(ECT) sensor electrical connectors.
E6643 EN 07/2001 2002 Bantam

Note: Inlet manifold removed for clarity.
All vehicles

necessary remove the ignition cables
from the ignition coil to prevent
plug connectors before removing to
loosen the seal.
connectors in line with the spark
plugs (for bent spark plug
connectors use Special Tool 303- 622).
Remove the spark plugs.
E6643 EN 07/2001 2002 Bantam

16. Remove the crankshaft position (CKP)

sensor and the oil pressure switch.
17. Remove the oil filter.
18. Remove the coolant flow control housing.
E6643 EN 07/2001 2002 Bantam


tensioner.
20. Remove the oil level indicator tube retaining

bolt.
21. CAUTION: Secure the timing chain

with a wire hook to prevent it from
falling down into the cylinder block.
Using the special tool, remove the

camshaft sprocket.
22. NOTE: Loosen the bolts in the indicated

sequence.
Using the special tool, remove the cylinder
head.
1. Remove the cylinder head bolts.
2. Remove and discard the gasket.
E6643 EN 07/2001 2002 Bantam

23. Remove the water pump pulley.
24. Remove the water pump.
E6643 EN 07/2001 2002 Bantam

27. CAUTION: Remove the oil pan by

pulling it downwards to prevent oil
deposits or abraded particles from
entering the engine.
Remove the oil pan.

28. Remove and discard the rear oil seal

retainer.
29. Remove the oil pump screen and pick up

tube.
30. Remove the oil pump.

• Remove and discard the gasket and the
crankshaft front oil seal.
• Remove the timing chain.
E6643 EN 07/2001 2002 Bantam

31. Remove the chain guide, the chain

tensioner arm and the crankshaft sprocket.
32. Remove the oil pan baffle.
33. NOTE: Do not damage the cylinder liner

surfaces. Keep the connecting rods, bearing
shells and bearing caps in order for
reassembly.
Remove the pistons.
1. Remove the connecting rod bearing cap.
2. Push out the pistons with connecting
rods and bearing shells.
34. NOTE: Keep the bearing shells and thrust

half-washers in order.
Remove the crankshaft.
1. Remove the main bearing caps.
2. Remove the crankshaft.
3. Remove the bearing shells and thrust
washers. Keep all parts in order for
reassembly.
E6643 EN 07/2001 2002 Bantam



Compressor, Valve Spring Pliers, Valve Stem Oil Seal
303-461 (21-194) 303-508 (21-211)
Adapter for 303-461

303-461-01 (21-194-01)
Disassembly
1. Remove the exhaust heat shield.
2. Remove the exhaust manifold.

E6644 EN 07/2001 2002 Bantam

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED)

3. Remove the coolant flow control housing.

camshaft.
• Slacken each bolt of the camshaft
bearing caps by one turn until the
camshaft is released.
1. Remove the camshaft bearings caps.
2. Remove the camshaft.
6. NOTE: Keep all parts in order for reassembly.

Remove the roller finger cam followers.
E6644 EN 07/2001 2002 Bantam


Remove the hydraulic lash adjusters.
8. Install the camshaft and the camshaft

bearing caps.
1. Install the camshaft.
2. Install the camshaft bearing caps.

Using the special tool, remove the valve
springs.
1. Compress the valve springs.
2. Remove the valve collets, the valve
spring retainers and the valve springs.
10. Using the special tool, remove the valve

seals.
E6644 EN 07/2001 2002 Bantam

11. NOTE: Keep all parts in order for

reassembly.
Remove the valves.
1. Exhaust valve.
2. Intake valve.
12. NOTE: Keep all parts in order for

reassembly.
Remove the camshaft bearing caps and the
camshaft.
1. Remove the camshaft bearings caps.
Assembly
1. Install the camshaft and the camshaft
bearing caps.
2. Install the camshaft bearing caps.
2. Install the valves.

1. Exhaust valve.
2. Intake valve.
E6644 EN 07/2001 2002 Bantam

3. NOTE: The valve seals are fully pressed in by

valve spring pressure.
Using the special tool, install the valve
seals.
4. Using the special tools, install the valve

spring.
1. Compress the valve spring and the valve
spring retainer.
2. Insert the valve collets.

camshaft.
1. Remove the camshaft bearing caps.
6. Install the hydraulic lash adjusters.
E6644 EN 07/2001 2002 Bantam

7. Install the roller finger cam followers.
8. NOTE: Make sure that the camshaft sprocket

alignment slot in the camshaft slot is
uppermost (12 o'clock) when installing the
camshaft.
NOTE: Apply a drop of hypoid oil (WSQ-
2C9002-AA) to each cam bearing (upper
and lower) half.
Install the camshaft and the camshaft
bearing caps.
1. Install the camshaft and tighten the
bearing caps in two stages.
2. Tighten each of the camshaft bearing
cap bolts by 90° degrees in the indicated
sequence.
3. Tighten the bolts to the specified torque
in the indicated sequence.
9. Install the engine mounting bracket.
E6644 EN 07/2001 2002 Bantam


damaged.
Install the coolant flow control housing.
11. Install the exhaust manifold with a new

gasket.
12. Install the exhaust heat shield.
E6644 EN 07/2001 2002 Bantam

ASSEMBLY
Engine (21 134 8)
Universal Flange Holding Mounting Plate
Tool 303-435-11 (21-146 C)
205-072 (15-030 A)
Lifting Bracket, Engine Installer, Oil Seal

303-122 (21-068 A) 303-656 (21-233)
Angle gauge
303-174 (21-540)
General Equipment
Assembly stand
Cable ties
Socket, Cylinder Head Bolt
Wire
303-392 (21-167)
Piston ring compressor
Mounting Stand Engine oil SAE 15W 40 SH
303-435 (21-187)
Sealer Loctite 5910
Sealer Loctite 648
Mounting Bracket
303-435-06 (21-031 B)
Assembly
1. Measure the crankshaft. For additional
2. Measure the camshaft. For additional

3. Measure the cylinder bore. For additional

4. Measure the pistons. For additional

E6645 EN 07/2001 2002 Bantam

ASSEMBLY (CONTINUED)
5. Measure the piston ring end gaps. For
6. Check the cylinder head for distortion. For

7. NOTE: The oil grooves on the thrust half

washers must be visible.
Install the main bearing shells.
1. Insert the main bearing shells.
2. Insert the thrust half washers into the
center main bearing.
8. NOTE: The bearing cap numbering starts at

the timing chain end, to which the arrows also
point.
Install the crankshaft.
1. Lubricate the main bearing journals and
bearing shells with engine oil.
2. Install the crankshaft main bearing caps
with their associated bearing shells.
3. Tighten the bolts.
4. Make sure that the crankshaft is in TDC
cylinder No. 1 position.
E6645 EN 07/2001 2002 Bantam

9. NOTE: The connecting rod numbering starts

at the timing chain end. The arrow on the
piston crown points towards the timing chain
end.
Install the pistons.
• Lubricate the pistons and cylinder liners
with engine oil.
• Distribute the piston ring end gaps
uniformly around the circumference. This
also applies to the elements of the oil
scraper ring.
• Compress the piston rings using a piston
ring compressor.
• Using the handle of a hammer, press
pistons 1 and 4 into the cylinders. The
connecting rod bearing journal must be at
BDC.
• Check the bearing shells are clean and
dry and install them in the associated
connecting rods and bearing caps.
• Install the bearing caps.
• Turn the crankshaft through 180 degrees
and install pistons Numbers 2 and 3.
10. CAUTION: Use new bolts.

NOTE: The connecting rods and connecting
rod bearing caps have the same
numbering.
Fit the bearing caps.
• Lubricate the bearing shells and journals
with engine oil.
• Install the appropriate connecting rod
bearing caps and bearing shells and
tighten them in two stages.
• Stage I : 4 Nm
• Stage II : 90° degrees
11. Install the oil pan baffle.
E6645 EN 07/2001 2002 Bantam

12. Install the chain guide, the chain tensioner

arm, and the crankshaft timing sprocket.
13. NOTE: The mark on the crankshaft timing

sprocket and the single colored link of the
timing chain must line up.
Install the timing chain.
14. NOTE: Use a new oil pump.

NOTE: Use a new gasket.
NOTE: The oil pump sealing flange must be
within ±0.20 mm of cylinder block bottom
sealing flanges.
Install the oil pump.
15. NOTE: The pulley, sleeve, housing and

sealing lip must be free of oil.
NOTE: Each new oil seal is supplied with a
plastic assembly sleeve.
Install the oil seal to the crankshaft pulley.
1. Install the plastic sleeve to the crankshaft
pulley.
2. Install the oil seal to the crankshaft
pulley.
• Remove the plastic sleeve.
E6645 EN 07/2001 2002 Bantam

16. Using the special tool, install the crankshaft

pulley.
1. Crankshaft pulley bolt
2. Special tool
3. Crankshaft pulley
4. New oil seal
17. CAUTION: To prevent damage to the

oil seal, do not pull the crankshaft
pulley out more than 3 mm during
seal installation.
Tighten the crankshaft pulley bolt until the
oil seal is fully installed.
18. Remove the crankshaft pulley bolt.
19. Install the crankshaft pulley bolt.
20. NOTE: Make sure that the O-ring seal is

correctly located.
Install the oil pump screen and pick up
tube.
E6645 EN 07/2001 2002 Bantam

21. NOTE: A special guide for assembly is

supplied with the new rear oil seal retainer.
NOTE: The sealing lip must be free of oil.
NOTE: Make sure that the dowel pins are
correctly located
Install a new rear oil seal retainer.
22. NOTE: Apply a bead of sealer (LOCTITE

5910) 3 to 5 mm wide to the marked areas.
Apply sealer to the cylinder block joints.
• Wait no longer than 5 minutes to install
the oil pan gasket.
23. Stage II - Install the oil pan.

• Tighten the oil pan bolts in the indicated
sequence.
E6645 EN 07/2001 2002 Bantam

25. Install the water pump with a new gasket.
26. Install the water pump pulley.
27. CAUTION: Use new cylinder head

bolts.
Install a new gasket and tighten the cylinder
head bolts in four stages.
indicated numerical sequence to 40 Nm.
indicated alphabetical order to 15 Nm.
indicated alphabetical order to 45
degrees.
indicated numerical sequence to 120
degrees.

must line up.
Install the timing chain on the camshaft
sprocket.
• The camshaft sprocket timing mark must
be at the 12 o'clock position with cylinder
No.1 at TDC.
E6645 EN 07/2001 2002 Bantam

29. Using the special tool, install the camshaft

sprocket.
30. NOTE: Apply sealer (Loctite 648) to the

lower end of the oil level indicator tube.
Tighten the oil level indicator tube retaining
bolt.

damaged.
Install the coolant flow control housing.
E6645 EN 07/2001 2002 Bantam

33. Install the oil filter with a new gasket.
34. Install the crankshaft position (CKP) sensor

and the oil pressure switch.
35. Install the knock sensor.
Note: intake manifold removed for clarity.
E6645 EN 07/2001 2002 Bantam


damaged.
37. Install the spark plugs and connect the

spark plug wires.

damaged.
39. Connect the camshaft position (CMP)

sensor and engine coolant temperature
(ECT) sensor electrical connectors.
E6645 EN 07/2001 2002 Bantam

40. Install the vacuum hoses.
41. Install the generator bracket.
42. Install the generator.
43. Install the engine mounting bracket.
E6645 EN 07/2001 2002 Bantam

44. Install the special tool.
45. Secure the engine to the assembly table

with retaining straps.
46. Install the exhaust manifold with a new

gasket.
E6645 EN 07/2001 2002 Bantam

INSTALLATION
Engine (21 132 0)
Clamping Tool, Boot Engine oil SAE 15W 40 SH
Retaining Strap
204-169 (14-044) High temperature WSD-M1C230-A
grease
General Equipment
Retaining straps
Assembly stand Installation
All vehicles
1. Install the transaxle to the engine.
2. Install the transaxle upper flange bolt.
3. Install the transaxle lower flange bolts.
E6646 EN 07/2001 2002 Bantam

INSTALLATION (CONTINUED)
4. Install the transaxle right-hand flange bolts.

1. Transmission left-hand flange bolt
2. Starter motor bolts
6. Connect the engine wiring harness

1. Connect the generator electrical
connectors.
2. Connect the oil pressure switch electrical
connectors.
3. Connect the CKP- sensor electrical
connector.

8. Secure the engine and transmission

assembly with a retaining strap to the
assembly stand and position for installation
underneath the vehicle.
E6646 EN 07/2001 2002 Bantam

10. NOTE: Install the nuts finger tight.

Install the engine front mounting bracket.
11. NOTE: Install the bolts and nuts finger tight.

Install the engine rear mounting bracket.
12. CAUTION: Brake fluid will escape.

Observe the safety regulations for the
use of brake fluid. For additional
Connect the clutch slave cylinder hydraulic

line.
13. Remove the retaining straps from the

engine.

E6646 EN 07/2001 2002 Bantam

15. Install the coolant return hose.
16. Install the engine roll restrictor.
17. CAUTION: The inner part of the

constant velocity joint must not be
bent at more than 18 degrees, the
outer part no more than 45 degrees.
NOTE: Fill the joint housing with 60 grams
of high temperature grease (WSD-
M1C230-A).
NOTE: Using the special tool, secure a new
boot clamp.
Install both front drive halfshafts.
18. Connect the lower arms to the wheel

knuckles on both sides (left-hand side
shown).
E6646 EN 07/2001 2002 Bantam

19. Install the shift rod and gearshift stabilizer.

1. Install the shift rod.
2. Install the gearshift stabilizer.
20. Install the exhaust lower heat shield.
21. Connect the exhaust down pipe to the

exhaust manifold with a new gasket.
2. Attach the exhaust hanger insulator.

22. Install the air conditioning (A/C)
compressor.
E6646 EN 07/2001 2002 Bantam

All Vehicles
23. Install the accessory drive belt cover.

slip the belt onto all the pulleys.

rod turning.
Tighten the suspension strut retaining nut
on both sides (right-hand side shown).
E6646 EN 07/2001 2002 Bantam

28. Install the cooling fan.
29. Connect the cooling fan electrical

connectors.
30. Connect the speedometer drive cable to the

transaxle.
31. Connect the reversing lamp switch

E6646 EN 07/2001 2002 Bantam

32. Remove the engine lifting eye.
33. Tighten the engine front mounting bracket.
34. Tighten the engine rear mounting bracket.
35. Connect the heated oxygen (HO2S) sensor,

powertrain control module (PCM),
electronic ignition (EI) coil, and vehicle
speed sensor (VSS) electrical connectors.
1. HO2S sensor
2. PCM
3. EI coil
4. VSS sensor
E6646 EN 07/2001 2002 Bantam

36. Install the ground cable, the electrical

connectors and the transmission breather.
1. Ground cable
2. Generator electrical connector
3. Starter motor electrical connector
4. Transmission breather
37. Install the left-hand coolant hose bracket.
38. Install the right-hand coolant hose bracket.
39. Install the coolant hoses.

1. To coolant expansion tank
2. To cabin heater
3. From cabin heater
E6646 EN 07/2001 2002 Bantam


1. Hook in the inner cable.
2. Install the cable into the bracket, adjust
and secure using the clip.
42. Install the hoses and the vacuum lines.

E6646 EN 07/2001 2002 Bantam

44. Install the battery tray.

1. Install new cable ties.
45. Check the engine oil level. If necessary, fill

the engine with low friction oil meeting
specification SAE 15W 40 or SAE 10W 30
46. Install the battery. For additional

47. Fill the cooling system. For additional

48. Adjust the gearshift linkage. For additional

49. Bleed the clutch system. For additional

E6646 EN 07/2001 2002 Bantam

SPECIFICATIONS
Engine Data
Description 1.6L 1.3L
Bore mm 82.070 73.96
Stroke mm 75.480 75.480
Cubic capacity cm 3
1597 1297
Compression ratio 9.5 : 1 10.2 : 1
Power output kW 70 55
at rpm 1/min 5500 5500
Torque Nm 135 110

at rpm 1/min 2500 2500
Max. Engine speed (intermittent) 1/min 6175 6175
Max. Engine speed (continuous) 1/min 5950 5950
Idle speed (electric cooling fan on) 1/min 850-910 850-910
Engine Oil
Recommended engine oil Viscosity/Temperature Specification
SAE 15W 40 SH WSD-M2C 904-B

Item Specification
Sealer WSK-M2G349-A4
Sealer LOCTITE 59104
High-temperature grease WSD-M1C230-A
Coolant ESD-M97B49-A
Transmission fluid iB5 WSD-M2C200-C
Ford-Hypoid oil SQM-2C9002-AA
Capacities
Liters
Engine oil, initial fill including filter 3.5
Engine oil, including filter change 3.25
Engine oil, excluding filter change 2.75
Coolant 6.4
Transmission fluid (iB5) 2.8
Oil Pressure
Oil pressure (min. oil temperature 80°C) at 880 l/min bar 1.0-3.5
Oil pressure (min. oil temperature 80°C) at 2,000 l/min bar 2.5-5.5
E6648 EN 07/2001 2002 Bantam

SPECIFICATIONS (CONTINUED)
Pressure relief valve opening pressure bar 4.0-5.0
Crankshaft
Description Specification
Crankshaft main bearing journal diameter (standard) mm 56.98-57.0
Crankshaft main bearing journal diameter (undersize) mm 56.726-56.746
Crankshaft main bearing journal shell width mm 18.29-18.69
Crankshaft connecting rod journal diameter (standard) mm 40.99-41.01
Crankshaft connecting rod journal diameter (undersize) mm 40.74-40.76
Crankshaft connecting rod journal diameter (service 0.508) mm 40.49-40.51
Crankshaft connecting rod journal diameter (service 0.762) mm 40.24-40.26
Crankshaft end play mm 0.075-0.285
Crankshaft thrust washer thickness (standard) mm 2.80-2.85
Crankshaft thrust washer thickness (oversize) mm 2.99-3.04
Crankshaft must not be re-machined.
Piston
Piston diameter (standard) mm 82.015-82.030

Piston diameter (oversize No. 1) mm 82.165-82.180
Piston diameter (oversize No. 2) mm 82.515-82.53
Piston to cylinder bore clearance (production) mm 0.04-0.07
Piston to cylinder bore clearance (service) mm 0.04-0.07
Piston ring end gap (installed) (top) mm 0.20-0.40
Piston ring end gap (installed) second mm 0.25-0.50
Piston ring-to-groove clearance (top) mm 0.051-0.088
Piston ring-to-groove clearance (second) mm 0.03-0.07
Piston ring end gap position, top 180 degrees offset from oil
scraper ring end gap
Piston ring end gap position, second 90 degrees offset from oil
scraper ring end gap
Piston pin length mm 60.2-59.9
Piston pin diameter mm 18.03-18.034
Piston pin to bore diameter interference mm 0.012-0.036
Piston pin slide clearance (21°C) mm 0.014-0.020
E6648 EN 07/2001 2002 Bantam

Connecting rod
Connecting rod large end bore diameter mm 43.99-44.01

Connecting rod small end bore diameter mm 17.998-18.018
Connecting rod bearing shell, vertical internal diameter, mm 41.016-41.05
standard
Connecting rod bearing clearance (radial) mm 0.006-0.060
Connecting rod bearing clearance (axial) mm 0.100-0.250
Valve train
1.6L 1.3L
Valve spring free length mm 43.2 43.2
Valve spring inner diameter (intake) mm 18.8 - 19.9 18.8 - 19.9
Valve spring inner diameter (exhaust) mm 18.8-19.2 18.8-19.2
Valve spring material diameter mm 3.7 3.7
Number of valve spring coils mm 6.7 6.7
Valve (intake) overall length mm 109.37-109.83 109.37-109.83
Valve (exhaust) overall length mm 109.95-110.05 109.95-110.05
Valve head (intake) diameter mm 39.87-40.13 34.97 - 35.23
Valve head (exhaust) diameter mm 33.87-34.13 29.57 - 29.83
Valve stem diameter (intake) mm 5.957 - 5.975 5.957 - 5.975
Valve stem diameter (exhaust) mm 5.957-5.975 5.957 - 5.975

Valve stem to valve guide clearance (intake) mm 0.025-0.063 0.025 - 0.063
Valve stem to valve guide clearance (exhaust) mm 0.028-0.068 0.028-0.068
Valve lift (intake) mm 9.8 9.8
Valve lift (exhaust) mm 9.8 9.8
Cylinder block
Number of main bearings 5

Cylinder bore diameter (standard) mm 82.7-82.085
Cylinder bore diameter (oversize No.1) mm 82.22-82.235
Cylinder bore diameter (oversize No.2) mm 82.57-82.585
Camshaft
Drive system Chain

Number of chain links 114
E6648 EN 07/2001 2002 Bantam

Pitch of chain mm 8.0

Valve timing, intake opens (1 mm lift) after TDC degree 12
Valve timing, intake closes (1 mm lift) after BDC degree 24
Valve timing, exhaust opens (1 mm lift) before BDC degree 24
Valve timing, exhaust closes (1 mm lift) before TDC degree 12
Valve lift cam intake mm 5.25
Valve lift cam exhaust mm 5.25
Camshaft bearing journal diameter mm 23.96-23.98
Camshaft bearing journal bore diameter mm 24.0-24.03
Camshaft end float mm 0.075-0.185
Description Nm
Oil gallery plug 22
Main bearing bolts 95
Rear oil seal retainer 10
Connecting rod bolts-Stage 1 4
Connecting rod bolts-Stage 2 90 degrees
Hydraulic timing chain tensioner 40
Chain tensioner arm bolt 26
Chain guide bolt 26
Oil pump 20
Crankshaft pulley bolt 125
Oil pump screen and pickup tube retaining bolt 10
Oil pan baffle bolt 19
Oil pan retaining bolts -Stage 1 6
Oil pan retaining bolts -Stage 2 9
Oil filter adaptor 20
Crankshaft position sensor retaining bolts 10
Water pump retaining bolts 10
Water pump pulley retaining bolts 12
Flywheel retaining bolts 67
Clutch bolts 29
A/C compressor retaining bolts 25
Starter motor retaining bolts 35
Oil pressure switch 20
Oil drain plug 25
E6648 EN 07/2001 2002 Bantam

Description Nm
Engine lifting eye 20
Camshaft cap bolts 9
Cylinder head bolts-Stage 1 (M11 bolts) 40
Cylinder head bolts-Stage 2 (M8 bolts) 15
Cylinder head bolts-Stage 3 (M8 bolts) 45 degrees
Cylinder head bolts-Stage 4 (M11 bolts) 120 degrees
Camshaft sprocket bolt 75
Valve cover bolts 9
Camshaft position sensor retaining bolt 5
Ignition coil retaining bolts 6
Oil level indicator tube retaining bolts 20
Coolant flow control housing retaining bolts 10
Spark plugs 15
Intake manifold retaining nuts 18
Intake manifold retaining bolts 18
Exhaust manifold retaining nuts 15
Exhaust manifold heat shield upper retaining bolts 10
Exhaust manifold heat shield upper retaining nut 10
Lower heat shield retaining nuts 10
Exhaust down pipe retaining nuts 47
Engine mounting front bracket to body nuts 30
Engine mounting front bracket to cylinder head 50
nuts
Engine mounting front bracket to cylinder head 25
bolts
Engine mounting rear bracket to retaining body 30
bolts
Engine mounting rear bracket to transaxle bolts 69
Gearshift stabilizer 55
Transaxle upper flange bolt 44
Transaxle lower flange bolts 44
Transaxle left-hand flange bolt 44
Transaxle right-hand flange bolts 44
Engine roll restrictor to body retaining bolts 50
Engine roll restrictor to transaxle retaining bolts 69
Lower arm 52
E6648 EN 07/2001 2002 Bantam

Description Nm
Suspension strut retaining nuts 45
Cooling fan retaining bolts 12
Left-hand coolant hose bracket nut 20
Right-hand coolant hose bracket nut 20
Accessory drive belt cover 10
Engine undershield 30
Battery tray 25
Knock sensor retaining bolt 20
E6648 EN 07/2001 2002 Bantam

303-01D-1 Engine — 1.8L Diesel - Endura DE 303-01D-1
SECTION 303-01D Engine — 1.8L Diesel - Endura DE

PAGE 1 OF 2
SUBJECT PAGE
Engine ...................................................................................................................................... 303-01D-3
Crankshaft ............................................................................................................................. 303-01D-3
Timing belt pulley - crankshaft .............................................................................................. 303-01D-3
Crankshaft central bolt .......................................................................................................... 303-01D-3
Camshaft timing belt ............................................................................................................. 303-01D-3
Valve tappets & adjusting shims........................................................................................... 303-01D-4
Cylinder head ........................................................................................................................ 303-01D-4
Crankshaft oil seals ............................................................................................................... 303-01D-4
Crankcase ventilation ............................................................................................................ 303-01D-4

Engine ...................................................................................................................................... 303-01D-5
IN-VEHICLE REPAIR
Crankshaft Front Oil Seal .................................................................................. (21 467 0) 303-01D-6/20
Auxiliary Shaft Oil Seal ...................................................................................... (21 556 0) 303-01D-21/23
Valve Seals ........................................................................................................ (21 238 0) 303-01D-24/33
Timing Belt — Engines with Automatic Timing Belt Tensioner......................... (21 304 0) 303-01D-34/48
Timing Belt — Engines with Manual Timing Belt Tensioner ............................. (21 304 0) 303-01D-49/58
Camshaft............................................................................................................ (21 283 0) 303-01D-59/65
Camshaft Oil Seal .............................................................................................. (21 288 0) 303-01D-66/69
Cylinder Head .................................................................................................... (21 163 0) 303-01D-70/82
REMOVAL
Engine ................................................................................................................ (21 132 0) 303-01D-83/96
DISASSEMBLY
Engine ................................................................................................................ (21 134 8) 303-01D-97/109

Cylinder Head .................................................................................................... (21 165 6) 303-01D-110/120
ASSEMBLY
Engine ................................................................................................................ (21 134 8) 303-01D-121/148
INSTALLAT ION
Engine ...................................................................................................................................... 303-01D-149/164
GENERAL PROCEDURES
Valve Clearance................................................................................................. (21 213 0) 303-01D-165/167
09/2001 2002 Bantam

SECTION 303-01D Engine — 1.8L Diesel - Endura DE

PAGE 2OF 2
SPECIFICATIONS
Specifications ........................................................................................................................... 303-01D-168

Engine Data........................................................................................................................... 303-01D-168
Dimensions............................................................................................................................ 303-01D-168/171
Engine Oil .............................................................................................................................. 303-01D-171
Engine Lubrication ................................................................................................................ 303-01D-171
Lubricants, Fluids and Sealers.............................................................................................. 303-01D-171
Filling Capacities ................................................................................................................... 303-01D-171/172
Torque Specifications............................................................................................................ 303-01D-172
Torque Specifications............................................................................................................ 303-01D-172/173
09/2001 2002 Bantam


Engine Camshaft timing belt
The 44kW (60PS) indirect injection Diesel engine

is based on the familiar swirl chamber Diesel
engine, which has been revised in line with the
latest technology.
The engine not only conforms to European
Emission Regulations, but also meets all other
expectations in relation to fuel consumption, quiet
running, flexibility and power delivery.
Crankshaft
The crankshaft runs in five main bearings. Thrust
half bearings are fitted at the third bearing to
control the crankshaft end float.
Timing belt pulley - crankshaft
Item Description
1 Timing belt tensioner
2 Adjusting cam
3 Timing belt
The timing belt pulleys used to drive the valve
train and fuel injection pump are a sliding fit on 4 Camshaft timing gear
the crankshaft and are retained by the crankshaft
central bolt. The toothed timing belt drives the camshaft and
maintains the correct relationship between
The fuel injection pump drive pulley is positively camshaft and crankshaft.
located by pins that locate into the crankshaft on
one surface and the camshaft timing belt pulley CAUTION: Because a new timing belt is
on the other. On the front pulley there is an O- very stiff when first installed, the
ring seal, which must be renewed during every adjustment procedure must be adhered
installation. It is important not to assemble the O- to exactly.
ring seal dry; always lubricate it with clean engine The timing belt tension is maintained by the
oil prior to installation. automatic tensioner. However, the first time the
belt is tensioned, the adjusting cam is used.
Crankshaft central bolt The camshaft timing pulley is a taper fit on the
camshaft and is retained by friction applied by a
The crankshaft central bolt is a "Torque to Yield clamping bolt.
bolt" which must be renewed each time it is
undone.
E5893 EN 09/2001 2002 Bantam


Valve tappets & adjusting shims Crankshaft oil seals
NOTE: The crankshaft rear oil seal is supplied
complete with the oil seal carrier. It must be fitted
using the tool shown.
The camshaft operates the valves directly via the

valve tappets.
CAUTION: When installing adjustment
shims, the writing must face the tappet. CAUTION: Removing the support ring too
early will cause the oil seal to shrink
Adjustment shims are available for setting the thereby making it unusable.
valve clearances. The thickness of each shim is
marked on one face. Both the front and rear oil seals are made from
PTFE and therefore must be fitted dry.
Cylinder head When supplied as a service parts, both oil seals
have a support ring, which should only be
removed after fitting. Some support rings may
drop out of their own accord after an oil seal has
been fitted.
Crankcase ventilation
Item Description
1 Guide dowel holes
2 Gasket thickness indicator
The cylinder head gasket is available in three

thicknesses. A particular piston protrusion The crankcase ventilation valve is on the upper
requires a certain thickness of gasket and this is surface of the valve cover. Like all crankcase
determined by the number of notches on the ventilation components, the valve must always be
gasket thickness indicator. kept clean to ensure optimal engine operation.
E5893 EN 09/2001 2002 Bantam


Engine
E3278 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Crankshaft Front Oil Seal (21 467 0)
Universal flange holding Centering tool, remover and
wrench installer, oil seal
15-030 A 21-148 A
Timing peg, crankshaft TDC Remover, crankshaft timing

position pulley
21-104 21-200
Engine support bar Angle gauge, bolt tightening

21-140 21-540
Adapter for 21-140 Timing pin, injection pump

21-140-01 timing
23-019
Adapter for 21-140 Timing pin, injection pump

21-140-02 timing
23-029
Adapter for 21-140

21-140-03
Removal
1. Standard preparatory operations.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
E5881 EN 09/2001 2002 Bantam


3. Attach the engine support bar.
4. Remove the front engine mounting auxiliary

bracket.
5. Remove the front engine mounting bracket.
6. Remove the upper timing belt cover.
E5881 EN 09/2001 2002 Bantam


7. Raise the engine with the engine support
bar.
8. Remove the top bolts of the lower timing

belt cover.
9. Remove the injection pump timing belt

cover.
10. Remove the injection pump timing belt.

• Slacken the bolts of the timing pulley.
• Loosen the clamp bolt of the timing belt
tensioner and slacken the timing belt.
• Tighten the clamp bolt of the timing belt
tensioner.
• Remove the timing belt.
E5881 EN 09/2001 2002 Bantam


11. Lower the engine with the engine support
bar.

1. Undo the bolt.
CAUTION: To slacken, turn the bolt
clockwise.
2. Slacken and remove the drive belt.
13. Remove the drive belt.
14. Remove the crankshaft pulley/vibration

damper.
15. Remove the lower timing belt cover.
E5881 EN 09/2001 2002 Bantam

16. Remove the drive belt tensioner.
17. Disconnect the alternator and remove it.
18. Turn the crankshaft to the TDC position.

• Unscrew the blanking plug from the
cylinder block.
NOTE: The timing pin must be screwed in as far

as it will go.
• Screw in the timing pin.
• Carefully turn the crankshaft in the
normal direction of rotation of the engine
until it comes up against the timing pin.
E5881 EN 09/2001 2002 Bantam


20. Slacken the bolts of the camshaft timing
pulley.
21. Remove the camshaft timing belt.

1. Slacken the clamp bolt of the timing belt
tensioner.
2. Slacken the timing belt by compressing
the spring using water pump pliers.
22. Tighten the clamp bolt of the timing belt

tensioner. Remove the timing belt.
24. Remove the flange of the crankshaft front

timing pulley.
25. Remove the crankshaft rear timing pulley.
E5881 EN 09/2001 2002 Bantam

26. Mount the special tool.

• Screw in the flange bolt of the crankshaft
front timing pulley.
NOTE: Position of the flattened area on the
special tool.
• Locate the special tool.
• Pre-punch four holes with a punch and
screw in the self-tapping screws.
27. Pull out the oil seal, together with the flange
bolt, from the crankshaft front timing pulley.
Installation
1. CAUTION: Only install the timing belt

when the engine has cooled down.
The engine must have been switched
off for at least four hours.
special tool.
Check the alignment of the front plate. If
necessary, center the front plate.
1. Front plate
2. Crankshaft
3. Special Tool
E5881 EN 09/2001 2002 Bantam

2. CAUTION: Carry out Step 3

immediately after Step 2 to prevent
the oil seal from contracting. Only
remove the support ring immediately
prior to installation of the oil seal.
special tool.
NOTE: The support ring must not yet be
removed from the oil seal.
NOTE: Fit the oil seal dry.
Fit the oil seal, together with the bolt of the
crankshaft front timing pulley flange.
• Remove the special tool and the support
ring.
3. Fit the crankshaft rear timing pulley.

Coat the O-ring and the end of the
crankshaft with engine oil.
NOTE: The guide pin in the end of the
crankshaft and the hole in the timing pulley must
line up.
• Carefully slide the timing pulley on as far
as the stop.
4. NOTE: Use a new bolt.

NOTE: Coat the contact face of the bolt head
with engine oil.
Fit the flange of the crankshaft front timing
pulley.
E5881 EN 09/2001 2002 Bantam


6. Align the injection pump timing pulley and
turn the crankshaft to the TDC position.
1. Slacken the bolts of the timing pulley.
2. Align the injection pump timing pulley by
inserting the timing pin through the cutout
in the timing pulley and the hole in the
injection pump housing. Unscrew the
blanking plug from the cylinder block.
as it will go; the crankshaft must be resting
against the timing pin.
3. Screw the timing pin into the cylinder
block. Carefully turn the crankshaft in the
7. CAUTION: Renew the timing belt.

CAUTION: Only install the timing belt
when the engine has cooled down. The
engine must have been switched off for
at least four hours.
NOTE: Make sure the belt is seated correctly.
NOTE: The running direction of the timing belt is
marked.
NOTE: The bolts must not be at the ends of
their slots.
Fit the injection pump timing belt.
1. Fit the timing belt with the slack side
nearest the timing belt tensioner. Slacken
the bolt of the timing belt tensioner and let
the timing belt tensioner snap against the
timing belt.
2. Tighten the timing belt tensioner bolt.
3. Tighten the bolts of the timing pulley.
E5881 EN 09/2001 2002 Bantam

8. CAUTION: Renew the timing belt.

NOTE: The direction of rotation is marked.
their slots.
Fit the timing belt with the slack side
nearest the timing belt tensioner. Slacken
the clamp bolt of the timing belt tensioner
and let the timing belt tensioner snap
against the belt.
tensioner.
2. Tighten the bolts of the timing pulley.
9. Remove timing pins 21-104, 23-019 and

23-029.
10. Preparations for tensioning the timing belts.

NOTE: Turn the crankshaft two turns in the
normal direction of rotation of the engine until
the slot in the injection pump timing pulley is at
12 o'clock.
NOTE: Turn the slot back counter to the normal
direction of rotation to 11 o'clock.
1. Screw in the timing pin.
NOTE: Carefully turn the crankshaft in the
normal direction of rotation of the engine until it
comes up against the timing pin.
2. The timing pin must be able to be
inserted in the camshaft timing pulley.
3. Timing pin 23-029 must be able to be
inserted in the injection pump timing
pulley.
E5881 EN 09/2001 2002 Bantam

11. CAUTION: Used timing belts must

not be re-tensioned.
NOTE: Slacken the bolts of the timing pulleys
just half a turn each.
NOTE: The crankshaft must remain in the TDC
position.
Tension the injection pump timing belt.
Slacken the bolts of the camshaft timing
pulley. Slacken the bolts of the injection
pump timing pulley.
1. Slacken the bolt of the injection pump
timing belt tensioner a quarter turn so that
the timing belt tensioner presses against
the timing belt.
2. Tighten the bolt of the injection pump
timing belt tensioner.
3. Tighten the bolts of the injection pump
timing pulley.
12. CAUTION: Used timing belts must

not be re-tensioned.
Tension the camshaft timing belt.
NOTE: Leave timing pin 23-029 inserted.
1. Slacken the bolt of the camshaft timing
belt tensioner a quarter turn so that the
timing belt tensioner presses against the
timing belt.
NOTE: All the timing pins must be properly
inserted; the crankshaft must be resting against
the timing pin.
2. Tighten the bolt of the camshaft timing
belt tensioner.
3. Tighten the bolts of the camshaft timing
pulley. Take out the timing pins.
4. Fit the blanking plug.
E5881 EN 09/2001 2002 Bantam

13. Fit the injection pump timing belt cover.
15. Screw in the lower bolts of the lower timing

belt cover.
16. Fit the crankshaft pulley/vibration damper.
17. CAUTION: Position the generator and

screw in the bolts finger tight. First
tighten the bolt on the pulley side,
then the rear upper long bolt and
finally the rear lower short bolt.
Install the alternator and connect it.
E5881 EN 09/2001 2002 Bantam


18. Fit the drive belt tensioner.
19. Fit the drive belt.

1. Fit the drive belt and tension it as
described in Operation No. 31 413 0.
2. Tighten the bolt.

bar.
E5881 EN 09/2001 2002 Bantam


22. Screw in the remaining bolts of the lower

bar.
24. Fit the upper timing belt cover.
25. Fit the front engine mounting bracket.
E5881 EN 09/2001 2002 Bantam


26. Attach the front engine mounting auxiliary
bracket.
27. Detach the engine support bar.
29. Standard finishing operations.

• Enter the radio keycode.
• Reprogram the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the PCM
(EEC V) to collect data.
E5881 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Auxiliary Shaft Oil Seal (21 556 0)
Engine Oil ACEA A3/B3
1. NOTE: Immobilise the timing belt pulley with

the old timing belt.
Remove the camshaft timing belt as
Slacken the bolt of the auxiliary shaft timing
belt pulley.
2. Remove the timing belt side cover.
3. Remove the auxiliary shaft oil seal housing.
E6965 EN 09/2001 2002 Bantam


Installation
1. Install the auxiliary shaft oil seal housing.
1. Coat the auxiliary shaft bearing journal
with engine oil.
2. Slide the new oil seal housing with the
integrated oil seal and the plastic fitting
bush onto the auxiliary shaft bearing
journal.
3. Oil seal
4. Tighten the oil seal housing bolts.
5. Remove the support ring after installation
and check that the seal is sitting correctly.
2. Fit the timing belt side cover.
E6965 EN 09/2001 2002 Bantam

3. NOTE: The auxiliary shaft guide pin and the

hole in the timing belt pulley must line up.
NOTE: Immobilise the timing belt pulley with the
old timing belt.
Fit the auxiliary shaft timing belt pulley.
4. Fit a new camshaft timing belt as described

in Operation No. 21 304 0.
E6965 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Valve Seals (21 238 0)

Universal flange holding Installer, valve stem collets
wrench 21-156
15-030 A
Installer, valve stem seals Pliers, valve stem oil seals

21-007 A 21-165
Valve spring compressor Remover/installer, cooling

21-024 hose clamp
24-003
Adapter for 21-024

21-024-05 General Equipment
Two-legged puller
Timing peg, crankshaft TDC Sealer SPM-4G-9112-F/G
position
21-104 Valve stem installation
sleeves
Engine Oil ACEA B3 / E3
Installer, oil seal
21-110
Removal
1. General note.
• This operation was carried out on an
engine with a mechanical timing belt
tensioner.
• When removing and installing coolant
and ventilation hoses, if necessary. For
E5882 EN 09/2001 2002 Bantam

2. Remove the camshaft timing belt as

5. CAUTION: Support the engine with a

trolley jack.
Detach the engine support bar.
6. Slacken the flange bolt of the camshaft

timing pulley.
7. Remove the camshaft timing pulley.
8. Detach the crankcase ventilation hose.
E5882 EN 09/2001 2002 Bantam

9. Remove the flange bolt of the camshaft

timing pulley.
10. Pull off the flange of the camshaft timing

pulley using a proprietary two-legged puller.
• Remove the Woodruff key.
11. Remove the cylinder head cover.

1. Detach the crankcase ventilation hoses.
12. Remove the oil baffle.
E5882 EN 09/2001 2002 Bantam

13. CAUTION: Slacken the nuts of the

camshaft bearing caps evenly, a turn
at a time.
Remove the camshaft.
• Take out the bearing caps, bearing
shells and camshaft and put them down in
order.
• Remove the camshaft seal.
14. NOTE: Put down the valve tappets in order.

Remove the valve tappets and the valve
shims and check them for wear.
15. Release the valve spring retainers by

tapping lightly on the ends of the valve
stems.
16. Turn the crankshaft to bring the pistons of

cylinders nos. 1 and 4 to TDC.
• Mark the position.
E5882 EN 09/2001 2002 Bantam

17. NOTE: Only carry out the following

operations for cylinders nos. 1 and 4.
Remove the valve springs.
2. Remove the valve collets. Remove the
valve spring retainers and valve springs
and put them down in order.
18. Remove the valve stem seals.
Installation
1. CAUTION: Cover the grooves in the

valve stems with installation sleeves.
NOTE: Remove the installation sleeves after
installation.
Lubricate the new valve stem seals with
engine oil and fit them.
E5882 EN 09/2001 2002 Bantam


2. Fit the valve springs. Locate the valve
springs and valve spring retainers in
position.
2. Fit the valve collets.
3. Turn the crankshaft to bring the pistons of

cylinders nos. 2 and 3 to TDC.
• Turn the crankshaft on through 180°.
4. Carry out steps xx to xx on cylinders nos. 2

and 3.
5. Adjust the positions of the valve collets.
E5882 EN 09/2001 2002 Bantam

6. NOTE: The lettering on the valve shims faces

downwards.
NOTE: Installation order.
Lubricate the valve tappets and valve shims
with engine oil and fit them.
7. Turn the crankshaft a further 1 1/3 turns

until it is just before TDC.
8. Put the camshaft bearing shell lower halves

in place and coat them with engine oil.
• Fit the camshaft and turn it until the slot
in the eccentric on the camshaft is parallel
with the upper edge of the cylinder head
(with the larger semi-circle at the top).
9. Align the camshaft.
10. Put the camshaft bearing shells upper

halves in place and coat them with engine
oil.
E5882 EN 09/2001 2002 Bantam

11. Apply sealer (SPM-4G-9112-F/G) to

bearing cap no. 1 in the areas indicated.

NOTE: The bearing caps must lie flat.
• Fit camshaft bearing caps nos. 1, 3 and
5.
NOTE: Tightening sequence.
• Screw on the nuts and tighten them.
13. Fit the oil baffle.
14. Seal the parting line between the bearing

cap and the cylinder head on both sides
with a thin bead of sealer (SPM-4G9112-
F/G).
E5882 EN 09/2001 2002 Bantam

15. NOTE: Clean the cylinder head cover gasket

and check it for damage. Only renew it if it is
damaged. The gasket can be reused several
times if it is in good condition.
NOTE: Before fitting the gasket, coat it lightly
with engine oil.
Fit the cylinder head cover.
1. Screw in the bolts.
2. Attach the crankcase ventilation hoses.
16. NOTE: Coat the running surface and the

sealing lip of the oil seal with engine oil. The
text on the oil seal faces outwards during
installation.
Fit the camshaft oil seal using the special
tool and an M8 bolt.
17. Fit the flange of the camshaft timing pulley.

• Insert the Woodruff key.
• Draw on the flange with the bolt.
18. Fit the camshaft timing pulley.
E5882 EN 09/2001 2002 Bantam


19. Connect the PCV hose.
20. Tighten the flange bolt of the camshaft

timing pulley.

as it will go.
• Fit the timing pin.

E5882 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Timing Belt — Engines with Automatic Timing Belt Tensioner (21 304 0)
Timing pin, crankshaft TDC Adapter for 303-290 (21140)
303-193 (21104) 303-290-03 (2114003)
Engine support bar Timing tool, camshaft

303-290 (21140) 303-376 (21162B)
Adapter for 303-290 (21140) Universal flange holding

303-290-01 (2114001) wrench
205-072 (15030A)
Adapter for 303-290 (21140)

303-290-02 (2114002) Material Specification
Sealer SPM-4G-9112-F/G
Removal
1. Preparatory measures.
• Make a note of the pre-set radio stations.
2. Disconnect the battery ground lead.
E6447 EN 09/2001 2002 Bantam


bracket.

bar.
E6447 EN 09/2001 2002 Bantam


8. Unscrew the top bolts of the lower timing
belt cover.

bar.
11. Remove the lower drive belt cover.

1. Remove the bolts from the drive belt
cover.
2. Unclip the drive belt cover.
3. Unclip the power steering high-pressure
pipe.

1. Release the bolt.
clockwise.
2. Slacken the drive belt and remove it.
E6447 EN 09/2001 2002 Bantam


13. Remove the crankshaft belt pulley/vibration
damper.
15. Remove the belt tensioner.
16. Remove the generator and lay it to one

side.
E6447 EN 09/2001 2002 Bantam

17. Preparing to remove the timing belt.

• Turn the crankshaft further in the normal
direction of rotation of the engine until the
slot in the injection pump timing pulley is
at 11 o'clock.
18. Remove the cylinder head cover. Remove

the gasket.
1. Detach the PCV hoses.
2. Unscrew the bolts.
19. Turn the crankshaft approximately to TDC.

21. Turn the crankshaft to TDC.
• Unscrew the blanking plug from the
cylinder block.
as its stop.
normal direction of rotation until it rests
E6447 EN 09/2001 2002 Bantam


23. Slacken the bolt of the adjusting cam.
• Turn the adjusting cam to 6 o'clock.
24. Insert the timing tool in the camshaft

groove.
25. Loosen the camshaft timing pulley.

NOTE: Hold the camshaft timing pulley with the
special tool.
• Undo the camshaft timing pulley bolt
three turns.
26. NOTE: Position a screwdriver between the

camshaft timing pulley and the rear timing
belt cover.
Release the camshaft timing belt pulley
from its conical seat by tapping lightly with a
light metal drift.
E6447 EN 09/2001 2002 Bantam


• Detach the camshaft timing pulley and
take it off with the camshaft timing belt.
• Discard the timing belt.
Installation
1. CAUTION: Always renew the camshaft

timing belt and the fuel pump timing
belt.
CAUTION: Only carry out work on the
timing belt at workshop temperature.
The engine must have been switched off
for at least four hours.
CAUTION: The crankshaft must be
resting against the timing pin and the
timing tool must be inserted in the
camshaft.
NOTE: Running direction of the timing belt
(arrows). Make sure that the timing belt is sitting
centrally on all the timing pulleys.
NOTE: Lubricate the bolt contact face with
engine oil.
NOTE: Make sure that the camshaft timing
pulley can still turn freely on the camshaft.
Lay a new camshaft timing belt in place.
1. Fit the camshaft timing belt.
2. Locate the camshaft timing pulley and
the camshaft timing belt in installation
position. Tighten the camshaft pulley bolt
finger tight and then undo it a quarter turn.
E6447 EN 09/2001 2002 Bantam


2. Pretension the camshaft timing belt.
NOTE: Coat the bolt contact surface of the
adjusting cam with engine oil.
• Turn the adjusting cam clockwise to 9
o'clock and tighten the center bolt of the
adjusting cam.
3. CAUTION: Remove the special tools.

NOTE: Use special tool 15-030A to prevent
movement of the camshaft timing belt pulley.
Tighten the bolt of the camshaft timing
pulley.
4. Turn the crankshaft six turns in the normal

direction of rotation to settle the timing belt.
5. Preparations for tensioning the timing belt.

at 11 o'clock.
6. Undo the bolt on the adjusting cam half a

turn.
E6447 EN 09/2001 2002 Bantam

7. NOTE: If necessary, turn the camshaft using

water pump pliers until the timing tool can be
inserted.
Insert the timing tool in the camshaft
groove.
8. NOTE: Hold the camshaft timing pulley with

the special tool.
Undo the camshaft timing pulley bolt three
turns.

camshaft timing pulley and the rear timing
belt cover.
Release the camshaft timing pulley from the
conical seat by tapping it lightly with a light
metal drift.
10. NOTE: Make sure that the camshaft timing

pulley can still be turned freely on the conical
seat.
Tighten the camshaft timing pulley bolt
finger tight.
• Tighten the camshaft pulley bolt finger
tight and then undo it one half turn.
E6447 EN 09/2001 2002 Bantam

11. NOTE: Use a mirror to get a better view.

NOTE: The adjustment range of the adjusting
cam is between 6 o'clock (MIN) and 12 o'clock
(MAX).
• Tension the camshaft timing belt using
the Allen key socket on the adjustment
cam in a clockwise direction, so that the
arrow on the camshaft timing belt
tensioner points to the right-hand corner
of the adjustment range.
12. NOTE: Use the Allen key socket on the

adjustment cam to stop the adjustment cam
turning.
Evenly tighten the bolt on the adjusting
cam.
13. CAUTION: To avoid engine damage

make sure that the pointer is within
range A.
Check the position on the automatic
camshaft timing belt tensioner.
• If the pointer is in range A: continue with
the next step.
• If the pointer is not in area A:
repeat steps 10 and 11.
E6447 EN 09/2001 2002 Bantam

14. NOTE: Hold the camshaft timing pulley.

Tighten the bolt of the camshaft timing
pulley.
• Tightening torque for M8 bolt: 35 Nm.
• Tightening torque for M10 bolt: 48 Nm.

range A.
Checking the position of the automatic
the next step.
• If the pointer is not in range A:
repeat the adjustment procedure from step 10.
17. Remove the special tools.
18. Turn the crankshaft six turns in the normal

direction of rotation.
19. Checking the valve timing

at 11 o'clock.
as its stop.
E6447 EN 09/2001 2002 Bantam

20. Insert the timing tool in the camshaft

groove. If it is not possible to insert the
timing tool into the slot on the camshaft,
repeat the adjustment from step 10.

range 'A'.
Check the position on the automatic timing
belt tensioner.
the next step.
• If the pointer is not in range A:
repeat the adjustment procedure from step 10
22. Remove the special tools and tighten the

blanking plug to 24 Nm.

F/G).
24. NOTE: Clean the cylinder head gasket and

check it for damage. Only renew if damaged.
If it is in good condition, it can be used
several times.
with engine oil.
2. Attach the PCV hoses.
E6447 EN 09/2001 2002 Bantam

25. CAUTION: Position the generator and

Install the generator.
26. Fit the belt tensioner.
27. Fit the lower timing belt cover (two bolts at

the bottom).
28. Fit the crankshaft belt pulley / vibration

damper.
E6447 EN 09/2001 2002 Bantam


1. Fit the drive belt and tension as

bar.
32. Attach the lower timing belt cover.

bar.
E6447 EN 09/2001 2002 Bantam

36. Install the front engine mounting auxiliary

bracket.
38. Connect the battery ground lead.

• Re-program the preset radio stations.
E6447 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Timing Belt — Engines with Manual Timing Belt Tensioner (21 304 0)

Timing pin, crankshaft TDC Adapter for 303-290 (21140)
position 303-290-03 (2114003)
303-193 (21104)
Engine support bar Timing pin, injection pump

303-290 (21140) 310-018 (23019)
Adapter for 303-290 (21140)

303-290-01 (2114001) Material Specification
Adapter for 303-290 (21140)

303-290-02 (2114002)
Removal
2. Disconnect the battery negative lead.
E6346 EN 09/2001 2002 Bantam


bracket.

bar.
E6346 EN 09/2001 2002 Bantam

8. Unscrew the top bolts of the lower timing

belt cover.

bar.

1. Undo the bolt.
clockwise.

damper.
E6346 EN 09/2001 2002 Bantam


15. Disconnect the alternator and remove it.
16. NOTE: Turn the engine in the direction of

engine rotation.
Turn the crankshaft approximately to TDC.
• Turn the crankshaft in the direction of
engine rotation until the slot in the
injection pump timing belt pulley is at the
11 o'clock position.
E6346 EN 09/2001 2002 Bantam


• Remove the blanking plug from the
cylinder block.
NOTE: The alignment pin must be screwed in
as far as it will go.
19. Insert the alignment pin into the camshaft

timing belt pulley.

belt pulley.

1. Slacken the clamp bolt of the timing belt
tensioner.
2. Slacken the timing belt by compressing
the spring using water pump pliers.
• Tighten the clamp bolt of the timing belt
tensioner.
• Remove the timing belt.
E6346 EN 09/2001 2002 Bantam


Installation
1. CAUTION: Always renew the camshaft

timing belt and the injection pump
timing belt.
CAUTION: The crankshaft must touch
the alignment pin and the alignment tool
must be fitted into the camshaft timing
belt pulley.
NOTE: Slots. The camshaft timing belt bolts
must be centered.
NOTE: Fit the timing belt with the slack side
nearest the timing belt tensioner.
NOTE: Slacken the clamp bolt of the timing belt
tensioner and let the timing belt tensioner snap
against the belt.
Fit the new camshaft timing belt.
tensioner.
belt pulley.
2. CAUTION: Remove Special Tools

303-193 (21-104) and 310-018 (23-019).
Preparations for tensioning the timing belt.
• Turn the crankshaft six turns in the
normal direction of rotation of the engine.
1. Screw in the timing pin. Carefully turn the
crankshaft in the normal direction of
rotation of the engine until it comes up
inserted in the camshaft timing belt pulley.
belt pulley.
E6346 EN 09/2001 2002 Bantam

3. CAUTION: Used timing belts must not

be re-tensioned.
NOTE: All timing pins must be inserted
correctly. The crankshaft must touch the timing
pin.
NOTE: Slacken the camshaft timing belt
tensioner bolt by one quarter turn, so that the
timing belt tensioner presses against the timing
belt.
Tension the timing belt.
1. Tighten the camshaft timing belt
tensioner bolt.
2. Tighten the camshaft timing belt pulley
bolts.
3. Remove the timing pin.
4. Remove the alignment pin and tighten
the blanking bolt to 24 Nm.
4. CAUTION: Position the alternator and

Install the alternator and connect it.
E6346 EN 09/2001 2002 Bantam

6. Fit the lower timing belt cover (two bolts at

the bottom).

1. Fit the drive belt and tension as
E6346 EN 09/2001 2002 Bantam


bar.
11. Attach the lower timing belt cover.

bar.
E6346 EN 09/2001 2002 Bantam

15. Install the front engine mounting auxiliary

bracket.
17. Connect the battery negative lead.

E6346 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Camshaft (21 283 0)
15-030 A Universal flange Two-legged puller
holding wrench
15-030 A Universal flange Material Specification
holding wrench
Sealer SPM-4G-9112-F
Valve stem installation
Installer, camshaft oil seal sleeves
21-110
Remover/installer, cooling
hose clamp
24-003
Removal
1. General note.
tensioner.
2. Remove camshaft timing belt as described


trolley jack.
E5883 EN 09/2001 2002 Bantam


timing pulley.
6. Detach the crankcase ventilation hose.

timing pulley.
E5883 EN 09/2001 2002 Bantam


pulley using a proprietary two-legged puller.
• Remove the Woodruff key.

2. Remove the screws.

camshaft bearing caps uniformly a
turn at a time.
• Take out the bearing caps, bearing
shells and camshaft and put them down in
order.
• Remove the camshaft seal.
E5883 EN 09/2001 2002 Bantam

12. NOTE: Put down the valve tappets in order.

Remove the valve tappets and the valve
shims and check them for wear.
Installation
1. NOTE: The lettering on the valve shims faces

downwards.
Coat the valve tappets and valve shims with
2. Lay the camshaft bearing shell lower halves

• Fit the camshaft and turn it until the slot
in the eccentric on the camshaft is parallel
with the upper edge of the cylinder head
(with the larger semi-circle at the top).
E5883 EN 09/2001 2002 Bantam

4. Put the camshaft bearing shell upper halves



NOTE: The bearing caps must lie flat.
• Locate camshaft bearing caps nos. 1, 3
and 5 in position.
• Screw on the nuts and tighten them.
E5883 EN 09/2001 2002 Bantam


F/G).

with engine oil.

installation.
Fit the camshaft oil seal using the special
tool and an M8 bolt.

E5883 EN 09/2001 2002 Bantam

13. Attach the crankcase ventilation hose.

timing pulley.

E5883 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR
Camshaft Oil Seal (21 288 0)

15-030 A Universal flange Remover, camshaft oil seal
holding wrench 21-143
15-030 A Universal flange
holding wrench
Installer, camshaft oil seal

21-110 General Equipment
Two-legged puller
Removal
1. General note.
tensioner.
2. Remove camshaft timing belt as described


trolley jack.

timing pulley.
E5884 EN 09/2001 2002 Bantam


timing pulley.

pulley.
• Take out the Woodruff key.
8. Remove the camshaft oil seal.
E5884 EN 09/2001 2002 Bantam


installation.
Draw in the camshaft seal using the
installer and an M8 bolt.


timing pulley.
E5884 EN 09/2001 2002 Bantam


14. Fit a new camshaft timing belt, as described

E5884 EN 09/2001 2002 Bantam

IN-VEHICLE REPAIR

Timing pin, crankshaft TDC Timing pin, camshaft pulley
position 23-019
21-104
Socket, cylinder head bolts Remover/installer, cooling

21-164 hose clamp
24-003
Angle gauge, bolt tightening

Coolant L405F
sleeves
Removal
1. General Remarks.
tensioner.
• If necessary, use remover 303-03 when
removing coolant hoses and vent hoses.
2. Standard preparatory measures

WARNING: Risk of scalding when the
engine is at operating temperature.
• Open the coolant recovery tank.
E5970 EN 09/2001 2002 Bantam


Drain off the coolant.
WARNING: Risk of scalding when the
engine is at operating temperature.
• Tighten the plug again after draining.

trolley jack.
Remove camshaft timing belt as described
5. Remove the camshaft timing belt pulley.

• Take out the special tool.
6. Detach the coolant hose.
7. WARNING: The timing belt tensioner is

spring-loaded.
Detach the timing belt rear cover.
1. Remove the camshaft timing belt
tensioner.
2. Detach the timing belt pulley.
• Detach the cover plate.
E5970 EN 09/2001 2002 Bantam

8. NOTE: Seal the opening with adhesive tape.

Detach the air intake hose.
9. Detach the coolant hoses from the

thermostat housing.
10. Disconnect the following plugs and wiring.

1. Glow plug wiring
2. Plug - engine coolant temperature
sensor (ECT sensor)
3. Plug - coolant temperature gauge sender
unit.
4. Plug - oil pressure switch
11. Detach the vacuum pump oil return hose.
E5970 EN 09/2001 2002 Bantam

12. Detach bracket of the glow plug wiring.
13. Detach the brake servo vacuum line.
14. Detach the fuel feed line.
15. Detach the fuel line to the fuel heater.

• Unclip the fuel heater.
16. Disconnect vacuum hose and plug of the

exhaust gas re-circulation valve (EGR
valve).
17. Detach the heater coolant hose.
E5970 EN 09/2001 2002 Bantam

18. Remove the injection pipes and disconnect

the leak-off hoses.
19. Detach the catalytic converter from the

exhaust manifold.
20. Support the engine with a trolley jack, so

that the front engine mounting is free of
load.

E5970 EN 09/2001 2002 Bantam


24. NOTE: Loosening sequence

Remove the cylinder head.
• Take off the cylinder head and put it
down on wooden blocks.
• Remove the seal.
E5970 EN 09/2001 2002 Bantam


Installation
1. Measure the piston protrusion.
NOTE: Carry out two measurements per
cylinder a distance of 5 mm from the edge of the
piston.
• Measure the protrusion of the piston of
each cylinder at TDC.
• Measure the difference in height
between the piston crown and the cylinder
block.
• The largest measurement determines
the choice of cylinder head gasket
(see General Specifications).
2. Line up the crankshaft and camshaft.

• Turn the crankshaft until the piston of
cylinder no. 1 is at TDC.
• Turn the camshaft until the groove in the
eccentric on the camshaft is parallel with
the upper edge of the cylinder head (with
the larger semi-circle at the top).
• The crankshaft and camshaft must not
be turned any more.
3. NOTE: The cylinder head gasket is marked

"TOP / OBEN".
Fit a new cylinder head gasket.
1. Check that the locating sleeves are
seated correctly.
2. Thickness marking as measured in step
E5970 EN 09/2001 2002 Bantam

4. NOTE: Do not oil the cylinder head bolts.

Fit the cylinder head and tighten the new
cylinder head bolts in two stages.
5. Fit the cylinder head (continued).

NOTE: For stage 3, slacken one cylinder head
bolt by itself, and then tighten it to the specified
torque and angle. Only then move on to the next
cylinder head bolt.
• Wait three minutes and then tighten the
cylinder head bolts according to tightening
sequence in stage 3.
E5970 EN 09/2001 2002 Bantam


F/G).

and check it for damage. Only renew if
damaged. If it is in good condition, re-use it
several times.
NOTE: Before fitting the gasket, lightly coat it in
engine oil.
9. Attach the catalytic converter to the exhaust

manifold.
E5970 EN 09/2001 2002 Bantam


10. Fit the injection pipes and connect the leak-
off hoses.
11. Connect the vacuum hose and plug to the

EGR valve.
12. Attach the heater coolant hose.
13. Attach the fuel line to the fuel heater.

• Clip on the fuel heater.
14. Attach the brake servo vacuum line.
E5970 EN 09/2001 2002 Bantam


15. Attach the fuel feed line.
16. Attach the bracket of the glow plug wiring.
17. Attach the vacuum pump oil return hose.
18. Connect the following plugs and wiring.

1. Glow plug wiring
2. Plug - ECT sensor
3. Plug - temperature gauge sender unit
4. Plug - oil pressure switch
19. Attach the coolant hoses to the thermostat

housing.
E5970 EN 09/2001 2002 Bantam

20. NOTE: Remove the adhesive tape.

Fit the air intake hose.
21. Fit the camshaft timing belt tensioner.

1. Timing belt tensioner
2. Compress the spring of the timing belt
tensioner and secure it with the clamp
bolt.
22. NOTE: Do not tighten the bolts.

Fit the camshaft timing belt pulley.
23. Attach the coolant hose.
E5970 EN 09/2001 2002 Bantam


• Fill up with coolant.
• Carry out an oil change.
• Check the routing of the vacuum hoses
and wiring and secure them with cable
ties where necessary.
• Check the fluid levels and correct as
necessary.
• Check the engine and cooling system for
leaks (visual inspection).
E5970 EN 09/2001 2002 Bantam

REMOVAL
Engine (21 132 0)
Remover, driveshaft Remover/installer, radiator
16-087 hose clamps
24-003
21-068 A Engine lifting

bracket General Equipment
21-068 A Engine lifting Puller
bracket
Removal
1. General note.
2. When removing coolant and ventilation

hoses, if necessary. For additional
3. WARNING: Risk of scalding if the

engine is hot.
Preparatory operations
• Open the coolant recovery tank.
5. NOTE: When slackening the nuts, hold with

an Allen key to prevent from turning.
Slacken the nuts on the two suspension
struts five turns each.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)

engine is warm.
NOTE: After draining, tighten the drain plug to
22 Nm.
Drain off the coolant.
7. Remove the air intake pipe.

1. From the intake manifold (clamp).
2. Unclip
3. Pull it out of the air cleaner housing
(push fit).
4. Detach the resonator hose (clamp).
8. Detach the upper coolant hose.
9. Detach the hoses.

1. Vent hose.
2. Heater coolant hoses.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
10. Detach the radiator vent hose.
12. Disconnect the plugs and wiring:

1. Plug of injection pump wiring loom
2. Glow plug wiring
3. Plug of the temperature gauge sender
unit.
4. Plug of the engine coolant temperature
sensor (ECT sensor)
5. Plug of oil pressure switch
6. Plug of diesel fuel heater
13. Detach the brake servo vacuum line.
14. Disconnect the plug of the exhaust gas re-

circulation valve (EGR valve).
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
15. Detach the accelerator cable.
1. Detach the accelerator cable with the
rubber bush and retainer from the bracket.
2. Unhook the accelerator cable.
16. Disconnect the fuel lines.

1. Fuel return line
2. Fuel feed line
17. Detach the transmission ground lead.

• Lift the clip and pull off the hydraulic
pipe.
• Plug the openings.
18. Detach the hydraulic pipe of the clutch

operating system.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
19. Detach the bracket of the power steering

pressure pipe.
20. NOTE: Collect the power steering fluid.

Detach the power steering hose and
pressure pipe.

bracket.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
23. Remove the battery.

• Detach the retaining strap.
• Lift out the battery.
24. Remove the battery box.
26. Detach the lower coolant hose.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
27. Disconnect the air conditioning plug.
• Cut the two cable ties.
28. Detach the lower right-hand coolant hose.
29. Disconnect the three plugs at the bottom of

the radiator on the left-hand side.
30. NOTE: Do not remove the air conditioning

condenser.
Detach the air conditioning condenser at
the bottom and tie up.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
31. Remove the radiator (two bolts on each

side; right-hand side shown).
• Carefully withdraw the radiator, radiator
crossmember and fan plate with the fan
from below.
32. Detach the air conditioning compressor.

• Let the compressor hang down and tie it
securely.
33. Disconnect the starter motor.
34. Disconnect the plug of the multi-function

switch (where fitted).
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
35. Disconnect the plug of the reversing lamp

36. Detach the shift rod and gearshift stabilizer

and tie up.
1. Shift rod
2. Shift rod stabilizer
37. Detach the rear exhaust pipe from the

flexible intermediate pipe.
38. Disconnect the generator.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
39. Detach the left and right-hand lower
suspension arms (left-hand side shown).
40. Disconnect the speedometer drive cable.
41. CAUTION: The inner joint must not

be bent at more than 18 degrees and
the outer joint must not be bent at
NOTE: Escaping oil. Close off the opening with
an auxiliary plug.
Press the left-hand front driveshaft out of
the transmission.
• Swing the driveshaft forward and tie it
up.
42. Remove the front driveshaft center bearing.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)

CAUTION: After loosening the driveshaft,
immediately secure the differential,
using suitable plugs, to prevent it from
turning.
Extract the right-hand front driveshaft from
the transmission.
All vehicles

NOTE: Do not damage the boots of the drive
shaft.
Tie up the right-hand front driveshaft at the
front.
46. Remove the engine roll restrictor.
47. Preparatory measures for removing the

engine and transmission assembly.
• Position an assembly table with wooden
blocks under the engine and transmission
assembly.
• Lower the vehicle until the engine and
transmission assembly rests on the
wooden blocks.
NOTE: Make sure that the assemblies are
secure.
• Secure the engine on the assembly table
with the tensioning straps.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
48. Remove the rear engine mounting.

1. Screws
2. Nuts
3. Remove the transmission breather.
49. Remove the front engine mounting.
50. Raise the vehicle slowly until the engine

and transmission are clear.
51. Attach the engine lifting bracket.
52. Lift the engine, together with the

transmission, using the workshop hoist.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
53. Remove the resonator.
54. Remove the starter motor.
55. Unscrew the front flange bolts.
56. Unscrew the rear flange bolts.
E5886 EN 09/2001 2002 Bantam

REMOVAL (CONTINUED)
57. Press the transmission off the engine and
remove it.
• Remove the adapter plate.
E5886 EN 09/2001 2002 Bantam

DISASSEMBLY
Engine (21 134 8)

Universal flange holding Crankshaft locking tool
wrench 21-168
15-030A
Mounting bracket, engine Puller, crankshaft timing belt

21-031B pulley
21-200
Socket, cylinder head bolts Socket, injectors

21-164 23-045
Disassembly
1. General Remarks.
• It is not possible to renew any of the
gears or the belt itself with replacement
parts from previous build years.
• If necessary, when removing coolant and
ventilation hoses, For additional
2. Secure the engine to the assembly stand.

• Attach the mounting bracket.
• Secure the engine to the assembly
stand.
3. NOTE: Escaping oil.

Drain off the engine oil.
Detach the oil pump with the oil filter.
E6007 EN 09/2001 2002 Bantam

4. Remove the alternator (shown with the air
conditioning compressor).
2. Detach the belt tensioner.
3. Remove the alternator bolts.
5. Remove the injection pump belt pulley.

damper.
• Immobilise the crankshaft using the ring
gear.
7. Remove the timing belt upper cover.
E6007 EN 09/2001 2002 Bantam

8. Remove the timing belt lower cover.
9. Remove the injection pump timing belt

cover.
10. Slacken the bolt of the auxiliary shaft timing

belt pulley.

E6007 EN 09/2001 2002 Bantam

Engines with automatic timing belt tensioner

1. Unscrew the bolt of the adjusting cam
and remove the adjusting cam and the
timing belt.
2. Detach the camshaft timing belt
tensioner.
3. Undo the bolt of the camshaft timing belt
pulley.

camshaft timing belt pulley and the timing belt
rear cover.
Detach the camshaft timing belt pulley
(continued).
• Release the camshaft timing belt pulley
from its conical seat by tapping it lightly
with a light metal drift.
E6007 EN 09/2001 2002 Bantam

Engines with mechanical timing belt tensioner

14. Remove the camshaft timing belt pulley.
• Undo the bolts of the timing belt pulley.
• Release the timing belt tensioner clamp
bolt and slacken the timing belt.
• Tighten the timing belt tensioner clamp
bolt.
• Remove timing belt and discard.
All vehicles
15. Remove the injection pump timing belt.
• Undo the bolts of the timing belt pulley.
• Release the timing belt tensioner clamp
bolt and slacken the timing belt.
• Tighten the timing belt tensioner clamp
bolt.
• Remove timing belt and discard.
16. WARNING: The timing belt tensioner

is spring-loaded.
Remove the timing belt tensioner and the
injection pump timing belt pulley.
1. Timing belt tensioner
2. Timing belt pulley
E6007 EN 09/2001 2002 Bantam

17. WARNING: The timing belt tensioner

is spring-loaded.
Remove the timing belt tensioner and the
camshaft timing belt pulley.
1. Timing belt tensioner bolts
2. Camshaft timing belt pulley bolts
All vehicles
19. Remove the timing belt side cover.
20. Remove the oil dipstick tube.
E6007 EN 09/2001 2002 Bantam

21. Detach the hose.
22. Remove the fuel feed line.
23. Disconnect the injection pipes and leak-off

hoses.
24. Remove the injection pump bracket.
25. Remove the injection pump.
E6007 EN 09/2001 2002 Bantam

26. Remove the thermostat housing, coolant

hose and coolant pipe.
27. Remove the alternator bracket.
28. Remove the coolant pipe bracket.
30. Remove injectors and heat shields.

Remove the glow plugs.
1. Injectors
2. Glow plug wiring
3. Glow plugs
E6007 EN 09/2001 2002 Bantam

31. NOTE: Loosening sequence

Remove the cylinder head.
• Take off the cylinder head and put it
down on wooden blocks.
32. Remove the flange of the crankshaft front

timing belt pulley.
33. Remove the auxiliary shaft timing belt

pulley and oil seal housing.
NOTE: Immobilise the timing belt pulley with the
old timing belt.
1. Bolt of the auxiliary shaft timing belt
pulley
2. Bolts of the auxiliary shaft oil seal
housing
E6007 EN 09/2001 2002 Bantam

34. Remove the auxiliary shaft with the thrust
plate.
35. Remove the coolant pump.
36. CAUTION: Only use a collet.

Remove the crankshaft rear timing belt
pulley.
1. Fit the collet.
2. Pull the collet back as far as the stop.
37. Pull off the crankshaft rear timing belt pulley

(continued)
• Screw in the spindle and pull off.
E6007 EN 09/2001 2002 Bantam

38. Remove the clutch.
40. Remove the crankshaft position sensor

(CKP).
41. NOTE: The oil seal is integrated in the

housing.
Remove crankshaft rear oil seal housing.
E6007 EN 09/2001 2002 Bantam

42. Remove the CKP sensor bracket.
43. CAUTION: Remove the sump

downwards so that no oil sludge or
abraded particles get into the engine.
Remove the sump.
44. Remove the front plate.

• Press out the crankshaft front oil seal.
45. Remove the oil intake pipe with the bracket.
46. CAUTION: Do not damage the piston

ring zone.
Remove the pistons.
NOTE: Put the big-end bearing caps and big-
end bearing shells down in order.
• Detach the big-end bearing caps.
• Remove the ring of carbon around the
upper edge of the cylinders using a
proprietary scraper.
• Press out the pistons with the connecting
rods and big-end bearing shells.
E6007 EN 09/2001 2002 Bantam

47. Remove the crankshaft.

• Remove the main bearing caps.
• Take out the crankshaft.
• Take out the bearing shells and thrust
half washers and put them down in order
for re-use.
E6007 EN 09/2001 2002 Bantam



Universal flange holding Installer, valve stem collets
wrench 21-156
15-030A
21-007 A Installer, valve Pliers, valve stem oil seals

stem seals 21-165
21-007 A Installer, valve
stem seals
Valve spring compressor Socket, injectors

21-024 23-045
Adaptor for 21-024

21-024-05 General Equipment
Two-legged puller
Installer, oil seal Sealer SPM-4G-9112-F/G
21-110
Hypoid oil SQM-2C-9002-AA
sleeves
Disassembly
1. Remove the upper inlet manifold.
E6008 EN 09/2001 2002 Bantam

2. Remove the vacuum pump.
3. Remove the retaining plate with the fuel

heater and remove the fuel filter.
4. Remove the exhaust gas re-circulation

valve (EGR valve).
5. Remove the exhaust manifold.

E6008 EN 09/2001 2002 Bantam

6. NOTE: Immobilise the timing belt pulley with

the old timing belt.
Remove the timing belt pulley.
7. Remove the oil pressure switch.
8. Remove the bracket of the power steering

pump.
9. Remove the injectors and glow plugs.

1. Injectors Remove the heat shields.
2. Glow plug wiring
3. Glow plugs
10. NOTE: Hold steady with

Special Tool 15-030A.
Remove the flange bolt of the camshaft
timing belt pulley.
E6008 EN 09/2001 2002 Bantam


belt pulley using a proprietary two-legged
puller.
• Take out the Woodruff key.

remaining bearing caps evenly a turn
at a time.
1. Remove camshaft bearing caps nos. 2
and 4.
2. Slacken the nuts of the remaining
camshaft bearing caps evenly a turn at a
time. Remove the bearing caps, bearing
shells and camshaft with the oil seal and
put them down in order.
3. Remove the vacuum pump plunger.
13. NOTE: Put the valve tappets down in order.

Remove the valve tappets with the
adjusting shims.
14. Detach the parts on the right-hand side of

the cylinder head.
1. Coolant connector
2. Engine lifting eye
3. Coolant hose
4. Lower inlet manifold
E6008 EN 09/2001 2002 Bantam

15. Remove the valve springs.

• Lay the cylinder head on wooden blocks.
• Release the valves by tapping lightly with
a brass drift on the ends of the valve
stems.
1. (1). Compress the valve springs.
2. (2). Remove the valve collets.
• Remove the valves, valve spring
retainers and valve springs and put them
down in order.
16. Remove the valve stem seals.
17. Remove the swirl chambers.
E6008 EN 09/2001 2002 Bantam

Assembly
1. Preparatory measures.
• Check all parts for wear.
• Thoroughly clean all reusable parts.
2. Renew the studs for the inlet and exhaust

manifold.
3. Grind in the valves.

1. Valve collets
2. Valve spring retainer
3. Valve spring
4. Valve stem seal
5. Cylinder Head
6. Valve
4. Sectional view of valve.
5. Press the swirl chambers home.
E6008 EN 09/2001 2002 Bantam

6. CAUTION: Cover the grooves on the

valve stems with the installation
sleeves.
NOTE: Remove the installation sleeves after
fitting the valve stem seals.
Lubricate the new valve stem seals with
7. Fit the valve springs with the valve spring

retainers.
1. Compress the valve springs using the
installer.
2. Insert the valve collets in the grooves in
the valve stem.
8. NOTE: Tightening sequence.

Fit the inlet manifold with a new gasket.
9. Fit the parts on the right-hand side of the

cylinder head.
1. Coolant connector
2. Engine lifting eye
3. Coolant hose
E6008 EN 09/2001 2002 Bantam

10. NOTE: The lettering on the adjusting shims

faces downwards.
Install the valve tappets.
• Coat the valve tappets and adjusting
shims with engine oil and fit them.
11. Lay the camshaft bearing shell lower halves

• Fit the camshaft and turn it until the
groove in the eccentric on the camshaft is
parallel with the upper edge of the cylinder
head (with the larger semi-circle at the
top).
13. Put the camshaft bearing upper shell halves


E6008 EN 09/2001 2002 Bantam

15. NOTE: The arrows on the camshaft bearing

caps point towards the front.
NOTE: The camshaft bearing caps must lie flat.
Install the camshaft.
• Place camshaft bearing caps nos. 1, 3
and 5 in installation position and screw on
the nuts.
• Tighten the nuts.
16. Fit the vacuum pump plunger.

Tighten the nuts of the camshaft bearing
caps.
18. NOTE: Coat the camshaft taper and the

sealing lip of the new oil seal with engine oil.
Fit the camshaft oil seal.
19. NOTE: Hold steady with

Special Tool 15-030A.
Fit the flange of the camshaft timing belt
pulley. Insert the Woodruff key.
1. Fit the flange.
2. Draw the flange on with the bolt and
tighten the bolt.
E6008 EN 09/2001 2002 Bantam

20. NOTE: Fit the new injector heat shields.

Fit the glow plugs and injectors.
1. Glow plugs
2. Glow plug wiring
3. Injectors
21. Fit the power steering pump bracket.
22. NOTE: Immobilise the timing belt pulley

using the old timing belt.
Fit the timing belt rear cover.
Fit the timing belt pulley.
23. Fit the oil pressure switch.

NOTE: Plastic sleeve on the right-hand upper
stud (no. 7).
Fit the exhaust manifold with a new gasket.
E6008 EN 09/2001 2002 Bantam

25. Fit the EGR valve.

2. Tighten the retaining clip bolt.
26. Install the retaining plate with the fuel

heater and the fuel filter.
27. Fit the vacuum pump.
28. Fit the upper inlet manifold.
E6008 EN 09/2001 2002 Bantam

ASSEMBLY
Engine (21 134 8)

Universal flange holding Aligner, crankshaft rear oil
wrench seal
15-030A 21-217
Aligner, clutch disk Angle gauge, bolt tightening

16-067 21-540
Mounting bracket, engine Timing pin, injection pump

21-031B 23-019
Timing pin, crankshaft TDC Timing pin, injection pump

position 23-029
21-104
Centering tool, remover and Socket, injectors

installer, oil seal 23-045
21-148A
Adjustment tool, camshaft Timing pin, crankshaft

TDC position sensor (CKP sensor)
21-162B 23-049
Socket, cylinder head bolts Remover/installer, cooling

21-164 hose clamp
24-003
Locking tool, crankshaft

21-168
E6005 EN 09/2001 2002 Bantam

General Equipment Material Specification
Dial gauge with magnetic fixture Sealer SPM-4G9112-F/G
Piston ring compressor Engine Oil ACEA B3 / E3
Micrometer screw Hypoid oil SQM-2C9002-AA
Internal gauge Plastigage
Feeler gauge
Steel straightedge
Assembly
• Thoroughly clean all mating faces and
reusable parts and check for damage.
2. Clean the piston cooling oil splash nozzles

and oil ways.
3. Measure the diameter of the main and big-

end bearing journals using a proprietary
micrometer screw.
• Repeat the measuring operation at
intervals of 90°.
• Different crankshaft sizes are used in
production. The different crankshafts are
not marked.
• If the measurements do not tally with the
values indicated in the General
Specifications, the crankshaft should be
overhauled or renewed.
E6005 EN 09/2001 2002 Bantam

4. NOTE: Fit the main bearing caps without the

bearing shells and tighten them to the
specified torque.
Measure the cylinder bores with a
proprietary internal gauge.
• If the measured diameter of the cylinder
bore is too large in relation to the piston
classification, overhaul or renew the
cylinder block.
5. Preparations for measuring the bearing

clearance.
NOTE: Carry out the following steps to the
letter.
• Measure each bearing individually using
a length of Plastigage thread.
• The bearing shells and journals must be
free of oil and dirt.
• Fit the bearing cap of the bearing being
measured and tighten to the specified
torque.
• The measurement should be carried out
near the respective dead center position.
6. Measure the crankshaft main bearing

clearance.
• Place the appropriate bearing shells dry
in the cylinder block.
• Place the crankshaft dry in the cylinder
block.
• Lay a length of Plastigage thread across
the bearing on the bearing journal.
E6005 EN 09/2001 2002 Bantam

7. Measure the crankshaft main bearing
clearance (continued).
NOTE: The main bearing cap numbering starts
at the timing belt end, to which the arrows also
point.
• Fit the main bearing cap with the
associated main bearing shell as
described in step and tighten the bolts.
• Remove the main bearing cap.
8. CAUTION: Do not turn the crankshaft

during the measuring procedure.
Compare the Plastigage thread with the
Plastigage scale.
• The reading corresponds to the main
bearing clearance.
• The main bearing shells should be
renewed as necessary according to the
bearing clearance measurement.
9. Install the crankshaft.

NOTE: The main bearing cap numbering starts
at the timing belt end, to which the arrows also
point.
• Lubricate the main bearing journals,
main bearing shells and thrust half
washers with engine oil.
• Fit the thrust half washers in main
bearing no. 3 with the lubricating groove
facing outwards.
• Fit the main bearing caps with the
associated bearing shells.
• Tighten the bolts.
10. Measure the end float of the crankshaft.

• Set up the dial gauge.
• Measure the end float by lifting the
crankshaft as shown.
• Rectify the end float as necessary by
fitting new thrust half washers to main
bearing no. 3.
E6005 EN 09/2001 2002 Bantam

11. Classifications.
1. Cylinder bore classification
2. Piston diameter classification
3. The piston weight classes are marked
with '+' and '-'.
12. NOTE: Piston classification, if a piston has

to be renewed.
Measure the piston diameter.
13. NOTE: Measure the piston ring clearance

with the piston ring protruding.
Measure the piston ring clearances.
• The maximum clearance of the upper
compression ring is 0,09 - 0,12 mm.
• The maximum clearance of the 2nd
compression ring is 0,05 - 0,08 mm.
14. CAUTION: Do not mix up the piston

rings. Re-fit the piston rings in the
same position and location.
Measure the piston ring gaps.
• The values given in the General
Specifications refer to a reference gauge
ring used in production. When measured
in the cylinder, the values can be
exceeded by 0,15 mm.
E6005 EN 09/2001 2002 Bantam

15. Fit the pistons.

• Lubricate the pistons and cylinder liners
with engine oil.
• Distribute the piston ring gaps evenly on
the circumference at intervals of 120°.
This also applies to the elements of the oil
scraper ring.
NOTE: The numbering on the connecting-rod
begins from the timing belt end. The arrow on
the piston crown points towards the timing belt
end.
• Compress the piston rings using a
proprietary piston ring compressor.
• Press the pistons into the cylinders with
the handle of a hammer, guiding the
connecting rods onto the big-end bearing
journals.
• Place the appropriate bearing shells,
clean and dry, in the connecting rods.
16. Measure the big end bearing clearances

and fit the big-bearing caps.
• Measure the big-end bearing clearance
as described in steps to
• Lubricate the big-end bearing shells and
journals with engine oil.
NOTE: The numbering of the connecting rods
and big-end bearing caps must tally.
• Fit the appropriate big-end bearing caps
and bearing shells and tighten the bolts.
17. Fit the oil intake pipe with the bracket.

NOTE: Make sure that the O-ring is seated
correctly.
1. Locate the oil intake pipe in position with
a new O-ring.
2. Fit the bracket.
E6005 EN 09/2001 2002 Bantam

18. NOTE: The front plate mating face must be

flush with the lower edge of the cylinder block
(tolerance ± 0,1mm).
Fit the front plate with a new gasket and
new oil way seals.
1. Center the front plate using the aligner.
2. Fit the front plate.
19. CAUTION: The steps must be carried

out immediately after each other to
prevent the oil seal from contracting.
Do not remove the support ring from
the oil seal until immediately before
installation.
NOTE: Install the oil seal dry.
Draw in the crankshaft front oil seal.
• Draw in the oil seal with the installer and
the bolt of the crankshaft timing belt
pulley.
20. Install the crankshaft timing belt pulley.

NOTE: Make sure the O-ring in the timing belt
pulley is in perfect condition.
• Lubricate the O-ring and the end of the
crankshaft with engine oil.
NOTE: The guide pin in the end of the
crankshaft and the hole in the timing belt pulley
must line up.
• Carefully slide on the timing belt pulley
as far as the stop.
21. NOTE: The sump bolts must be tightened

within 20 minutes of applying the sealer.
Apply sealer (SPM-4G-9112-F/G) to the
cylinder block mating face intersections.
E6005 EN 09/2001 2002 Bantam

22. Fit the sump.

• Locate the sump in position with a new
gasket and screw in the bolts (x 14) finger
tight.
• Using a steel straightedge, align the
sump so that it is flush with the mating
face of the oil seal housing.
23. Tighten the oil pan bolts.
24. CAUTION: The sealing lip of the oil

seal and the crankshaft sealing
surface must be free of oil.
NOTE: The support ring must sit in the oil seal.
Install the crankshaft rear oil seal housing.
1. Place the new crankshaft oil seal
housing, together with the integrated oil
seal, in the installation position.
2. Screw in the bolts finger tight.
3. Fit the aligner and center the oil seal
housing on the crankshaft.
4. Crankshaft
5. Remove the support ring.
E6005 EN 09/2001 2002 Bantam

25. CAUTION: If the special tool cannot

be removed, realign the sump.
Tighten the bolts of the crankshaft oil seal
housing, working diagonally.
• Remove the locator.
26. NOTE: Use new bolts.

Fit the flywheel.
• Immobilise the crankshaft with the ring
gear.
27. Center the clutch disc on the pressure

plate.
28. Fit the clutch.

1. Place the clutch pressure plate, together
with the centered clutch disc, in the
installation position.
2. Tighten the bolts uniformly, working
diagonally.
E6005 EN 09/2001 2002 Bantam

29. Install the coolant pump.
• Place the coolant pump, together with a
new gasket, and the bracket for the spring
of the timing belt tensioning pulley, in the
installation position.
30. Install the auxiliary shaft with the thrust

plate.
• Lubricate the auxiliary shaft, the bearing
bush in the cylinder block and the thrust
plate with engine oil.
NOTE: The lubricating grooves on the thrust
plate must face outwards.
• Fit the auxiliary shaft together with the
thrust plate.
• Tighten the thrust plate bolts.
31. NOTE: Do not tighten the bolt of the

auxiliary shaft timing belt pulley.
NOTE: The auxiliary shaft guide pin and the
corresponding hole in the timing belt pulley must
line up.
Install the auxiliary shaft oil seal housing.
• Lubricate the end of the auxiliary shaft
with engine oil.
• Slide the new oil seal housing with the
integrated oil seal and the support ring
onto the end of the auxiliary shaft.
• Tighten the bolts of the oil seal housing.
• After securing the oil seal housing,
detach the support ring and check that the
seal is seated correctly.
32. Install the auxiliary shaft timing belt pulley.
E6005 EN 09/2001 2002 Bantam

33. NOTE: Use a new bolt.

NOTE: Lubricate the bolt head contact face with
oil.
Fit the flange of the crankshaft front timing
belt pulley.
34. Measure the piston protrusion.

NOTE: Carry out two measurements per
cylinder a distance of 5 mm from the edge of the
piston.
• Measure the protrusion of the piston of
each cylinder at TDC.
• Measure the difference in height
between the piston crown and the cylinder
block mating face.
• The largest measurement determines
the choice of cylinder head gasket
(see General Specifications).
35. NOTE: The straightedge must be at least

500 mm long.
Check the cylinder head mating face for
distortion.
• Permitted distortion at the steps between
the combustion chambers: 0,80 mm.
• Lay the straightedge transversely across
all the steps between the combustion
chambers and check the distortion at
three points in each case.
• Lay the straightedge lengthways over the
cylinder head in three places in the area
of the combustion chambers and check
the distortion at all the steps between the
combustion chambers.
• Lay the straightedge diagonally across
the cylinder head and check the distortion
at all the steps between the combustion
chambers.
E6005 EN 09/2001 2002 Bantam

36. Line up the crankshaft and camshaft.
• Turn the crankshaft until the piston of
cylinder no. 1 is at TDC.
• Turn the camshaft until the slot in the
eccentric on the camshaft is parallel with
the upper edge of the cylinder head (with
the larger semi-circle at the top).
• The crankshaft and camshaft must not
be turned any more.
37. NOTE: The cylinder head gasket is marked

"TOP / OBEN".
Fit a new cylinder head gasket.
1. Check that the locating sleeves are
seated correctly.
2. Thickness marking as measured in step
38. NOTE: Do not oil the cylinder head bolts.

Fit the cylinder head and tighten the new
cylinder head bolts in two stages.
E6005 EN 09/2001 2002 Bantam

39. Fit the cylinder head (continued).

CAUTION: For stage 3, slacken one
cylinder head bolt by itself, and then
tighten it to the specified torque and
angle. Only then move on to the next
bolt.
• Wait three minutes and then tighten the
cylinder head bolts according to tightening
sequence in stage 3.
40. Fit the injectors and glow plugs.

1. Glow plugs
2. Glow plug wiring
NOTE: Fit new injector heat shields.
3. Injectors
41. Fit the alternator bracket.
E6005 EN 09/2001 2002 Bantam

42. Fit the coolant pipe bracket.
43. Fit the thermostat housing, coolant hose

and coolant pipe.
44. Fit the injection pump.
45. Fit the injection pump bracket.

• Connect the fast idle cable.
E6005 EN 09/2001 2002 Bantam

46. Connect the injection pipes and the leak-off

hoses.
47. Connect the fuel feed line.
48. Install the oil dipstick tube.
49. Attach the hose.
50. Fit the timing belt side cover.
E6005 EN 09/2001 2002 Bantam

51. Fit the engine mounting bracket.
52. NOTE: Do not tighten the bolts.

NOTE: Center the slots on the injection pump
timing belt pulley.
Fit the injection pump timing belt pulley.
53. Fit the injection pump timing belt tensioner.

• Compress the spring of the timing belt
tensioner and lock it with the clamp bolt.
Engines with automatic timing belt tensioner.

• Fit the timing tool into the groove in the
camshaft eccentric.
E6005 EN 09/2001 2002 Bantam

55. Fit the camshaft timing belt pulley and
NOTE: Do not tighten the bolts of the camshaft
timing belt pulley.
1. Fit the camshaft timing belt pulley.
2. Fit the timing belt tensioner (two bolts).
3. Squeeze the springs of the timing belt
tensioner together and fix in place with the
clamping bolt.
Engines with mechanical timing belt tensioner.

56. Align the camshaft timing belt pulley.
• Align the camshaft timing belt pulley by
in the pulley and the hole in the cylinder
head.
E6005 EN 09/2001 2002 Bantam

All vehicles
57. Align the injection pump timing belt pulley
and turn the crankshaft to the TDC position.
1. Align the injection pump pulley by
in the pulley and the hole in the injection
pump housing.
NOTE: Screw in the timing pin as far as it will
go; the crankshaft must rest against the timing
pin.
2. Remove the bolt and screw the timing
pin into the cylinder block.
• Turn the crankshaft to the TDC position.
58. CAUTION: Renew the toothed belt.

Fit the injection pump timing belt.
1. Fit the timing belt with the slack side
nearest the timing belt tensioner.
2. Slacken the bolt of the timing belt
tensioner and allow the tensioner to snap
against the timing belt. Tighten the timing
belt tensioner bolt.
their slots.
3. Tighten the bolts of the timing belt pulley.
E6005 EN 09/2001 2002 Bantam

Engines with automatic timing belt tensioner.

Install the camshaft timing belt.
1. Fit the camshaft timing belt tensioner.
2. Fit the adjusting cam.
3. Fit the timing belt and lay it over the
camshaft timing belt pulley.
• Slide the camshaft timing belt pulley onto
its conical seat and screw in the bolt until
the camshaft timing belt pulley can still
just be turned on the camshaft.

Install the camshaft timing belt. Fit the
timing belt with the slack side nearest the
1. Release the timing belt tensioner clamp
bolt and allow the tensioner to snap
against the timing belt. Tighten the timing
belt tensioner clamp bolt.
their slots.
2. Tighten the timing belt pulley bolts.
61. Remove timing pins 21-104, 23-019 and

23-029.
62. NOTE: Hold the camshaft timing belt pulley
steady.
Pretension the camshaft timing belt.
• Turn the adjusting cam clockwise to 9
o'clock and tighten the center bolt of the
adjusting cam.
• Tighten the bolt of the camshaft timing
belt pulley.

Turn the crankshaft six turns in the normal
direction of rotation of the engine.
E6005 EN 09/2001 2002 Bantam


64. Preparations for tensioning the timing belts.
slot in the injection pump timing belt pulley
is at 11 o'clock.
• Insert Special Tool 23-029.

65. NOTE: Hold the camshaft timing belt pulley
steady.
Loosen the bolt of the camshaft timing belt
pulley and slacken the camshaft timing belt.

camshaft timing belt pulley and the timing belt
rear cover.
Release the camshaft timing belt pulley.
• Release the camshaft timing belt pulley
from its conical seat by tapping on it lightly
with a light metal drift.
• Slacken the bolt of the adjusting cam.

67. NOTE: If necessary, turn the camshaft using
water pump pliers until the timing tool can be
inserted.
Insert the special tool in the camshaft.
E6005 EN 09/2001 2002 Bantam

68. Preparations for tensioning the timing belt

(mechanical timing belt tensioner shown).
• Remove Special Tool 21-162B.
• Turn the crankshaft two revolutions in
the direction of rotation of the engine until
the slot in the injection pump timing belt
pulley is at 12 o'clock.
• Turn the slot back counter to the normal
direction of rotation of the engine to 11
o'clock.
1. Screw in the timing pin.
inserted into the camshaft timing belt
pulley.
inserted into the injection pump timing belt
pulley.
69. Tension the injection pump timing belt

(mechanical timing belt tensioner shown)
NOTE: Slacken the bolts of the timing belt
pulleys just half a turn each.
• Slacken the bolts of the camshaft timing
belt pulley.
• Slacken the bolts of the injection pump
timing belt pulley.
1. Slacken the clamp bolt of the injection
pump timing belt tensioner a quarter turn
so that the timing belt tensioner presses
against the timing belt.
2. Tighten the bolt of the injection pump
3. Tighten the bolts of the injection pump
timing belt pulley.
E6005 EN 09/2001 2002 Bantam

70. NOTE: Hold the bolt of the adjusting cam
steady. Adjusting cam must be between the 6
o'clock and the 9 o'clock position or between
the 9 o'clock position and the 12 o'clock
position.
NOTE: Tighten the bolt smoothly.
NOTE: Hold the camshaft timing belt pulley
steady. Tighten the bolt smoothly.
1. Tension the camshaft timing belt
clockwise via the hexagon socket of the
adjusting cam until the arrows of the
camshaft timing belt tensioner meet.
2. Tighten the bolt of the adjusting cam.
3. Tighten the bolt of the camshaft timing
belt pulley.
• Torque for M8 bolt: 35 Nm.
• Torque for M10 bolt: 48 Nm.

Turn the crankshaft four turns in the normal
direction of rotation of the engine.
E6005 EN 09/2001 2002 Bantam


72. NOTE: If the special tools cannot be
inserted, then the adjustment must be
repeated from step
Check the valve timings.
slot in the injection pump timing belt pulley
is at 11 o'clock.
• Special Tool 23-029 must be able to be
inserted.
• The timing tool must be able to be
inserted in the camshaft.
• The arrows on the camshaft timing belt
tensioner must not be offset by more than
3 mm.
• Remove the special tools and fit the
blanking plug in the place of the timing
pin.
73. Tension the camshaft timing belt.

NOTE: Leave timing pin 23-029 inserted.
1. Slacken the clamp bolt of the camshaft
timing belt tensioner a quarter turn so that
the timing belt tensioner presses against
the timing belt.
NOTE: All timing pins must be correctly
inserted; the crankshaft must be resting against
the timing pin.
2. Tighten the clamp bolt of the camshaft
belt pulley.
4. Take out the timing pins. Unscrew the
timing pin and tighten the blanking plug for
the TDC setting bore.
E6005 EN 09/2001 2002 Bantam


F/G).

and check it for damage. Only renew if
damaged. If it is in good condition, re-use it
several times.
NOTE: Before fitting, lightly coat the gasket with
engine oil.
77. Fit the injection pump timing belt cover.
E6005 EN 09/2001 2002 Bantam

78. Tighten the bolt of the auxiliary shaft timing

belt pulley.
79. Fit the lower timing belt cover.

• Then remove Special Tool 21-168.
E6005 EN 09/2001 2002 Bantam

82. CAUTION: The setting value of 10°

for the injection pump timing must be
strictly observed.
Position the crankshaft to 10° after the TDC
position of the first cylinder.
• Locate the CKP sensor bracket in
position without the sensor and attach it
loosely.
NOTE: When using the angle gauge 21-540
make sure that the disc is not moved out of
position by the movement of the special tool.
The special tool must be kept under tension. If
the 10° mark is not quite reached, unscrew the
gauge disc so that it is no longer within the
measuring range and readjust it again.
• Place the angle gauge on the
pulley/vibration damper and position the
disc to 10°.
• Turn the pulley/vibration damper until the
arrows on the angle gauge are exactly
lined up together.
83. Align the CKP sensor bracket (shown on an

engine that has been removed).
• Insert the special tool into the CKP
sensor bracket and the flywheel bore hole.
• Tighten the CKP sensor bracket bolts
and remove the special tool.
84. Check the alignment of the CKP sensor.

• Position the crankshaft to 10° after TDC
of the first cylinder, as described in steps.
NOTE: If it is not possible to insert the special
tool into the flywheel bore hole, repeat the
adjustment procedure as described in steps
and. Check the alignment again.
• The special tool must be able to be
inserted in the flywheel.
E6005 EN 09/2001 2002 Bantam

85. Install the CKP sensor.
86. Fit the injection pump belt pulley.
87. CAUTION: Position the alternator and

Install the alternator (shown with the air
conditioning compressor).
1. Tighten the alternator bolts in
accordance with the tightening sequence.
• Tension the drive belt. For additional
88. NOTE: Before installing the oil pump, add

approx. 10 cc of engine oil to the rotor
chamber and lubricate the oil pump drive
gear and driven gear with engine oil.
Install the oil pump with the oil filter.
E6005 EN 09/2001 2002 Bantam

89. Detach the engine from the assembly

stand.
E6005 EN 09/2001 2002 Bantam

INSTALLATION
Engine

Remover, driveshaft Coolant L405F
16-087 High-pressure SQM-2C9008-A
transmission fluid
Power steering ESPM-2C-166-H
hydraulic fluid
21-068 A Engine lifting
Ford DOT 4 brake fluid SAM-6C9103-A
bracket
for hydraulic clutch
21-068 A Engine lifting system
bracket
High temperature ESD-M1C220-A
grease for transmis-
Remover/installer, radiator sion input shaft, guide
hose clamps sleeve - clutch release
24-003 bearing, pilot bearing -
crankshaft and clutch
splines
General Equipment
Puller
New 9 mm twist drill bit
Installation
• Clean the internal splines of the clutch
disc, the splines on the transmission input
shaft and the clutch release bearing guide
sleeve.
• Apply a thin coating of high-temperature
grease (ESD-M1C220-A) to the
transmission input shaft, the clutch
release bearing guide sleeve, the
crankshaft pilot bearing and the clutch
splines.
E5915 EN 09/2001 2002 Bantam

2. NOTE: Make sure the guide sleeves are

correctly seated.
Align the adapter plate on the two guide
sleeves on the cylinder block.
• Fix the adapter plate with a small amount
of high-temperature grease (ESD-
M1C220-A).
3. NOTE: The transmission is centered with two

guide sleeves on the engine.
Locate the transmission in position and
tighten the rear flange bolts.
4. Tighten the front flange bolts.
5. NOTE: Fit the bracket for the cable tie for the
starter motor wiring.
Install the starter motor.
E5915 EN 09/2001 2002 Bantam

6. Install the resonator.
7. Lower the engine and transmission

assembly onto the assembly table and
secure it with tensioning straps.
8. Unhook the workshop hoist and detach the

engine lifting bracket.
9. General Remarks.
• Renew circlips and self-locking nuts.
• When installing coolant and ventilation
hoses, if necessary. For additional
10. Locate the engine and transmission

assembly in position under the vehicle.
11. Slowly lower the vehicle and guide the

engine and transmission assembly into the
engine compartment.
12. Attach the rear engine mounting.

NOTE: Do not tighten the nuts and bolts.
1. Bolts
2. Nuts
3. Fit the transmission breather.
E5915 EN 09/2001 2002 Bantam

13. NOTE: Do not tighten the nuts.

Attach the front engine mounting.
• Remove the tensioning straps.
15. Fit the engine roll restrictor.
16. NOTE: Do not tighten the bolt on the shift

rod.
NOTE: Washer
Fit the gearshift stabilizer.
1. Gearshift stabilizer
2. Shift rod
E5915 EN 09/2001 2002 Bantam

18. CAUTION: Always tighten the front

engine mounting bracket before the
rear engine mounting bracket so that
the studs can be seated in the
elongated holes of the rear engine
mounting bracket.
Tighten the nuts of the front engine
mounting bracket.
19. Tighten the bolts and nuts of the rear

engine mounting bracket.
20. Put the transmission into 4th gear.

CAUTION: When inserting the
intermediate shaft, use the locating
sleeve (supplied with every new oil
seal), to protect the oil seal.
Install the right-hand driveshaft, together
with the intermediate shaft, in the
transmission.
E5915 EN 09/2001 2002 Bantam

All vehicles

Tighten the driveshaft center bearing.

CAUTION: When inserting the front axle
driveshafts always use the installation
sleeve (supplied with every new oil seal)
to protect the oil seal.
NOTE: Make sure the circlip engages correctly.
Install the left-hand driveshaft, together with
new retaining ring, in the transmission.
26. Top up the transmission fluid to 10 - 15 mm

below the lower edge of the filler/check
bore.
27. Attach the left and right-hand lower

suspension arm (left-hand side shown).
E5915 EN 09/2001 2002 Bantam

28. Attach the rear exhaust pipe to the flexible

intermediate pipe.
29. Adjust the gearshift mechanism.

• Lock the gearshift mechanism in the 4th
gear position using the shank of a new 9
mm twist drill bit.
30. Adjust the gearshift mechanism

(continued).
• The detailed illustration shows the shank
of the drill bit inserted.
31. Adjust the gearshift mechanism

(continued).
• Tighten the shift rod clamp
• Withdraw the drill bit from the gearshift
mechanism housing.
E5915 EN 09/2001 2002 Bantam

32. Attach the speedometer drive cable.
33. Connect the generator.
34. Connect the starter motor.
35. Connect the plug of the multi-function

E5915 EN 09/2001 2002 Bantam

36. Connect the plug of the reversing light

37. Fit the A/C compressor.

1. Lay the drive belt in place and tension it
via the bolt of the belt tensioner. For
2. Tighten the hexagon socket head bolt of
the tensioning pulley.
39. Locate the radiator and the fan plate with

the fan in position on the radiator
crossmember.
E5915 EN 09/2001 2002 Bantam

40. NOTE: The radiator is a push fit at the top.

NOTE: Secure the ground lead on the left-hand
side using the radiator bolt.
Install the radiator (two bolts on each side;
right-hand side shown).
41. NOTE: The air conditioning condenser is a

push fit at the top.
Align the air conditioning condenser and
screw it in place at the bottom.
42. Connect the three plugs at the bottom of

the radiator on the left-hand side.
43. Connect the plug of the air conditioning

wiring.
• Secure the wiring to the radiator
crossmember with cable ties.
E5915 EN 09/2001 2002 Bantam

44. Connect the bottom right-hand coolant hose

to the radiator.
45. Connect the bottom coolant hose.
47. Attach the front engine mounting auxiliary

bracket.
E5915 EN 09/2001 2002 Bantam

48. Connect the power steering hose and

pressure pipe.
49. Connect the bracket of the power steering

pressure pipe to the cylinder block.
50. NOTE: Insert new O-rings.

Attach the hydraulic pipe of the clutch
operating mechanism.
51. Attach the transmission ground lead.

1. Fuel return line
2. Fuel feed line to diesel fuel heater
E5915 EN 09/2001 2002 Bantam

53. Attach the throttle cable.

1. Slide the rubber bush and clip onto the
bracket.
2. Hook the accelerator cable in place.
55. Connect the plugs and wiring:

1. Plug of the injection pump wiring loom.
2. Glow plug wiring
3. Plug of the coolant temperature gauge
sender unit.
4. Plug of ECT sensor
5. Plug of oil pressure switch
6. Plug of diesel fuel heater
56. Attach the brake servo vacuum line.
57. Connect the plug of the EGR valve.
E5915 EN 09/2001 2002 Bantam

58. Fit the battery box.
59. Install the battery.
60. Attach the radiator vent hose.
61. Attach the hoses.

1. Vent hose
2. Heater coolant hoses
E5915 EN 09/2001 2002 Bantam

62. Attach the upper coolant hose.
63. Install the air intake pipe.

1. Attach the resonator hose (clamp).
2. Insert it in the air cleaner housing (push
fit).
3. Clip it in place.
4. Attach it to the intake manifold (clamp).
64. NOTE: When tightening the nuts, hold with

an Allen key to prevent from turning.
Tighten the nut on both suspension struts.
65. Bleed the hydraulic clutch system. For

• If necessary, fill up the brake fluid
reservoir with Ford brake fluid (SAM-
6C9103-A).
E5915 EN 09/2001 2002 Bantam

66. Fill up the power steering reservoir and

bleed the power steering. For additional

• Fill up with coolant.
• Check the transmission fluid level and
correct as necessary.
• Check the routing of vacuum hoses and
wiring and secure with cable ties.
• Connect the battery.
• Set the clock.
• Check the engine and cooling system for
leaks (visual inspection).
• Check the fluid levels and correct as
necessary.
E5915 EN 09/2001 2002 Bantam

GENERAL PROCEDURES
Valve Clearance (21 213 0)

Compressor, bucket tappets Feeler gauge
21-106
Valve shims
Pliers, valve adjustment
shims
21-107
Remover/installer, cooling
hose clamp
24-003
1. General note.

E5885 EN 09/2001 2002 Bantam


4. Check the valve clearances.
• Turn the crankshaft until the two cams of
the cylinder to be checked face evenly
upwards.
• Check the valve clearances with a feeler
gauge and rectify as necessary by
changing the shims as described in step
5. NOTE: Turn the crankshaft further through

approx. 90 degrees. The piston of the
cylinder that is to be adjusted must not be at
TDC.
NOTE: The lettering on the valve shims faces
downwards.
Change the valve shims.
1. Press down the two valve tappets
simultaneously.
2. Change the valve shims.

F/G).
E5885 EN 09/2001 2002 Bantam


with engine oil.
E5885 EN 09/2001 2002 Bantam

303-03-168 Engine — 1.8L Diesel - Endura DE 303-01D-168
SPECIFICATIONS
Engine Data
Engine management Endura - DE
Fuel Diesel
Engine code RTK RTJ
Injection sequence 1-3-4-2
Bore mm 82,5 mm
Stroke 82,0 mm
3
Cubic capacity, effective 1753 cm
Compression ratio 21,5 : 1
Compression pressure at starter motor speed 28 - 34 bar
Power output (EEC) 44 kW
at 4800 rev/min
Torque (EEC) 105 Nm
at 2500 rev/min
Idle speed 920 rev/min - 950 rev/min
Idle speed (with air conditioning) 950 rev/min
Max. engine speed, continuous 5350 rev/min ± 50 rev/min
Max. intermittent engine speed 5200 rev/min ± 50 rev/min
Dimensions
Endura - DE
Cylinder Block
Number of main bearings 5
Dimensions in mm
Cylinder bore-Ø - Class A 82,500 - 82,515
Cylinder bore-Ø - Class B 82,515 - 82,530
Cylinder bore-Ø - Class C 82,660 - 82,675
Cylinder bore-Ø - Class D 82,675 - 82,690
Cylinder bore-Ø - Class E 83,000 - 83,015
Cylinder bore-Ø - Class F 83,500 - 83,515
Main bearing clearances (radial) 0,025 - 0,085
Main bearing parent bore 54,005 - 54,042
Crankshaft
Main bearing journal-Ø - standard 53,970 - 53,990
1st undersize 0,25 53,720 - 53,740
2nd undersize 0,50 53,470 - 53,490
Big-end bearing journal-Ø - standard 48,970 - 48,990
09/2001 2002 Bantam

303-03- 169 Engine — 1.8L Diesel - Endura DE 303-03-169
Endura - DE
1st undersize 0,25 48,720 - 48,740
2nd undersize 0,50 48,470 - 48,490
Big-end bearing clearances 0,025 - 0,085
Crankshaft end float 0,1436 - 0,3688
Connecting rod end float relative to crank web 0,125 - 0,325
Max. turning torque without connecting rods and pistons 10
Connecting rods
Bore Ø - big-end 52,000 - 52,020
Bore Ø - small-end 26,012 - 26,020
Distance between connecting rod bores - Class A 129,872 - 129,948
Distance between connecting rod bores - Class B 129,932 - 130,008
Distance between connecting rod bores - Class C 129,992 - 130,068
Distance between connecting rod bores - Class D 130,052 - 130,128
Big-end bearing radial clearance 0,016 - 0,074
Pistons
Piston Ø - Class A 82,460 - 82,475
Piston Ø - Class B 82,475 - 82,490
C 82,621 - 82,639
Piston Ø - Class D 82,636 - 82,654
Piston Ø - Class E 82,961 - 82,979
Piston Ø - Class F 83,461 - 83,479
Measured at right-angles to piston pin bore
Piston clearance (initial fit) - Class A-F 0,025 - 0,055
Piston protrusion at TDC 0,500 - 0,840
Piston ring gaps (fitted) Dimensions in mm
Upper compression ring 0,30 - 0,32
Lower compression ring 0,30 - 0,32
Oil scraper ring 0,250 - 0,580
Piston ring clearance in piston groove, upper ring 0,090 - 0,122
Lower ring 0,050 - 0,082
Oil scraper ring 0,030 - 0,062
09/2001 2002 Bantam

Endura - DE
Ring gap position The piston-ring gaps must be evenly
distributed on the circumference of the
piston. This also applies to the ele-
ments of the oil scraper ring. In each
case, offset the ring gaps by 120°_with
respect to each other.
Piston pins
Dimensions in mm
Piston pins 25,96 - 26,00
Piston pin type "Floating" in piston and connecting rod
Piston pin retention Snap-ring
Cylinder head
Dimensions in mm
Camshaft bearing Ø - standard 30,500 - 30,525
Camshaft bearing-Ø - oversize 30,575 - 30,600
Bore Ø - valve tappet - standard 35,000 - 35,030
Bore Ø - valve tappet - oversize 35,500 - 35,530
Bore Ø - valve stem guide - standard 8,000 - 8,025
Bore Ø - valve stem guide - 1st oversize 8,263 - 8,288
Bore Ø - valve stem guide - 2nd oversize 8,463 - 8,488
Thickness of cylinder head gasket Number of tooth marks
with piston protrusion of 0,500 - 0,680 mm 1,36 (2)
Max. permissible unevenness over entire cylinder head area 0,08 mm
Do not overhaul cylinder head mating face.
Camshaft
Valve timings, inlet valve opens BTDC 6°
Valve timings, inlet valve closes ABDC 32°
Valve timings, exhaust valve opens BBDC 57°
Valve timings, exhaust valve closes ATDC 7°
Cam lift (camshaft) - Inlet 9,0 mm
Cam lift - Exhaust 10,0 mm
End float 0,100 mm - 0,240 mm
Dimensions in mm
Bearing journal Ø 27,960 - 27,980
09/2001 2002 Bantam

Endura - DE
Bearing clearances 0,020 - 0,079
Valve clearances (cold) - Inlet 0.35 ± 0,05
Valve clearances (cold) - Exhaust 0.50 ± 0.05
Adjustment shim thickness 3,000 - 4,750
in steps of 0,050
Engine Oil
Viscosity Description Specification
Recommended engine oil
15W40 API CG4 / ACEA B3 / E3
Engine Lubrication
Oil Pressure bar
Oil pressure (minimum) - at idle speed 0,75
(oil temperature approx. 80 °C) - at 2000 rev/min 1,50
Pressure relief valve opening pressure 2-4
Oil pump, max. inner/outer rotor clearance 0,174 mm
Lubricants, Fluids and Sealers

Ford Specification
Transmission fluid WSD-M2C200-C
Hypoid oil SQM-2C9002-AA
Power steering hydraulic fluid ESPM-2C-166-H
Ford DOT 4 brake fluid for hydraulic clutch system SAM 6C9103A
Motorcraft Super-Plus 4 coolant concentrate ESD M97B-49A
Sealer for camshaft bearing cap no. 1; sump/cylinder block SPM-4G-9112-F/G
High temperature grease for transmission input shaft, guide sleeve - clutch re- ESD-M1C220-A
lease bearing, pilot bearing - crankshaft and clutch splines
Filling Capacities
Liters
Engine oil, initial fill with filter 5,0
with filter change 5,0
without filter change 4,5
Coolant - vehicles with manual transmission 9,3
Transmission fluid 2,8
09/2001 2002 Bantam

Liters
Transmission fluid 10 - 15 mm
below
filler/check
bore
Description Nm
Rear engine mounting bracket (nuts) 70
Rear engine mounting bracket (bolts) 50
Front engine mounting bracket (outer nut) 120
Front engine mounting bracket (inner nut) 70
Front engine mounting reinforcing bracket 50
Bracket, front engine mounting 33
Bracket, right-hand engine mounting 45
Engine roll restrictor to cylinder block 50
Engine roll restrictor to front axle 70
Right-hand front driveshaft center bearing 24
Lower suspension arm to spindle carrier 52
Track rod to spindle carrier 36
Stabiliser link rod to suspension strut 47
Rear exhaust pipe to flexible intermediate pipe 47
Stabiliser bar to transmission 55
Shift linkage to transmission 23
Compressor - Air Conditioning 25
Hexagon socket head bolt - tensioning pulley 6
Front engine mounting reinforcing bracket 50
Drive belt tensioner 6
Wheel nuts 85
Resonator 11
Starter motor 44
Flange bolts - transmission to engine 44
Ground lead to transmission 44
Suspension strut nut 45
Description Nm
Injection pump 24
09/2001 2002 Bantam

Description Nm
Injection pump cover 7
Injection pump bracket to cylinder block 23
Injection pump to bracket 20
Injection pump to bracket 20
Injection pipes 25
Injectors 70
Injection pump timing belt pulley 23
Timing belt tensioner for injection pump timing belt 45
Description Nm
Coolant pump 23
Coolant pipe bracket to cylinder block 23
Radiator 24
Coolant drain plug to radiator 22
Description Nm
Power steering pump bracket 23
Tensioning pulley for power steering drive belt 6
Power steering pump 23
Bracket for power steering fluid feed pipe 24
Belt pulley of power steering pump 23
Cover of power steering pump 10
Description Nm
Flywheel - stage 1 18
Flywheel - stage 2 45°
Flywheel - stage 3 45°
Clutch 30
Crankshaft main bearing caps - stage 1 27
Crankshaft main bearing caps - stage 2 75°
Big-end bearing caps, stage 1 25
Big-end bearing caps, stage 2 60°
Big-end bearing caps - stage 3 20°
Front plate 24
Crankshaft rear oil seal housing 20
09/2001 2002 Bantam

Description Nm
Auxiliary shaft thrust plate 9
Auxiliary shaft oil seal housing 23
Bracket of engine mounting to cylinder block 33
Blanking plug for TDC adjustment hole 24
Auxiliary shaft timing belt pulley 45
Bolt of rear cover 24
Flange of crankshaft front timing belt pulley - 150
stage 1
Flange of crankshaft front timing belt pulley - -90° (undo)
stage 2
Flange of crankshaft front timing belt pulley - 120
stage 3
Flange of crankshaft front timing belt pulley - 60°
stage 4
Crankshaft pulley/vibration damper 35
Alternator bracket 46
Alternator to bracket 25
Clamp bolt for alternator belt tensioner 6
Crankshaft position sensor (CKP sensor) to 10
cylinder block
CKP sensor bracket 14
Description Nm
Cylinder head bolts, stage 1. 10
Cylinder head bolts, stage 2. 100
Cylinder head bolts, stage 3. -180°(undo)
Cylinder head bolts - stage 4. 70
Cylinder head bolts - stage 5. 120°
Cylinder Head Cover 5
Fuel filter bracket 23
Vacuum pump 20
Thermostat housing 22
Exhaust Manifold 24
Exhaust gas re-circulation valve (EGR valve) 20
EGR pipe clip 10
Upper inlet manifold 23
Intake manifold to cylinder head 23
09/2001 2002 Bantam

Description Nm
Exhaust manifold studs 13
Catalytic converter to exhaust manifold 24
Retaining plate for oil separator, fuel filter, fuel 20
heater
Vacuum pump 20
Engine lifting eye 23
Camshaft bearing caps 20
Oil pressure switch 20
Flange for camshaft timing belt pulley 30
Injectors 70
Glow plugs 28
EGR valve 20
EGR pipe clip 10
Clamp bolt of camshaft timing belt tensioner 50
Camshaft timing belt pulley 9
Camshaft timing belt pulley (with automatic timing 35
belt tensioner) with M8 bolt
Camshaft timing belt pulley (with automatic timing 48
belt tensioner) with M10 bolt
Adjusting cam 45
Upper and lower timing belt cover 7
Side timing belt cover 8
Description Nm
Oil intake pipe bracket 22
Oil pan 11
Oil drain plug on sump 24
Oil pump 23
Oil baffle 20
Oil dipstick tube bracket 10
Oil Pressure Switch 20
09/2001 2002 Bantam

303-03-177 Engine Cooling 303-03-177
SECTION 303-03 Engine Cooling -

1.8L Diesel - Endura DE
SUBJECT PAGE
Engine Cooling.........................................................................................................................303-03-178
Antifreeze ..............................................................................................................................303-03-178
Changing coolant ..................................................................................................................303-03-178

Engine Cooling.........................................................................................................................303-03-179
Inspection and Verification ....................................................................................................303-03-179
Symptom Chart .....................................................................................................................303-03-179
Pinpoint Tests........................................................................................................................303-03-179
Component Tests..................................................................................................................303-03-179

Thermostat — Vehicles with 1.8L Endura DE Diesel Engine ........................... (24 454 0) 303-03-180/181
Cooling Fan Motor ............................................................................................. (24 222 0) 303-03-182/185
Radiator — Vehicles with 1.8L Endura DE Diesel Engine ................................ (24 254 0) 303-03-186/188
Water Pump — Vehicles with 1.8L Endura DE Diesel Engine ......................... (24 404 0) 303-03-189/192
Coolant Expansion Tank.................................................................................... (24 284 0) 303-03-193
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding — Vehicles with 1.8L Endura (24 122 0) 303-03-194/195
Cooling System Flushing ......................................................................................................... 303-03-196
Cooling System Back flushing ................................................................................................. 303-03-197
Heater Core Back flushing ....................................................................................................... 303-03-198
SPECIFICATIONS
Specifications ...........................................................................................................................303-03-199
Fluids .....................................................................................................................................303-03-199
Torque Specifications............................................................................................................303-03-199
09/2001 2002 Bantam

303-03-178 Engine Cooling 303-03-178

Engine Cooling
Antifreeze content should be checked through
WARNING: For reasons of safety, care the neck of the expansion tank with a
should be taken to ensure that the hydrometer. The specific gravity (sg) of correctly
ignition is switched off when working in balanced fluid is 1,061 (sg) at 15°C, which
the vicinity of the fan as an increase in indicates an antifreeze concentration of 50%. If
coolant temperature may cause the fan the concentration falls below 50% there is
to operate without warning. insufficient low temperature protection and the
The major cooling system components comprise corrosion resistance will be inadequate. In such
an aluminum radiator core with plastic end tanks, cases the concentration must be brought back to
water circulation pump, thermostat expansion specification.
tank and electrically driven cooling fan.
The wax type thermostat ensures rapid engine
Changing coolant
warm up by restricting coolant flow at lower
operating temperatures, it also assists in WARNING: When draining the engine
maintaining engine operating temperatures coolant or changing any cooling system
between pre-determined limits. components. It is imperative that no
The cooling fan is mounted within a shroud coolant comes into contact with the
behind the radiator. camshaft or auxiliary drive belts. If
necessary the drive belts should be
removed. Contamination of the drive belt
Antifreeze can result in drive belt failure.
Engine coolant is formulated to last for the
WARNING: Antifreeze contains lifetime of the vehicle and does not require
monoethylene glycol and other replacement at regular intervals. If however the
constituents which are toxic if taken coolant is lost or topping up is required the
internally and can be absorbed into the system should be refilled using L405F antifreeze
skin after prolonged contact. to the correct proportion (50% antifreeze).
E6434 EN 09/2001 2002 Bantam

303-03-179 Engine Cooling 303-03-179

Engine Cooling
Inspection and Verification Symptom Chart

1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of
mechanical or electrical damage. Pinpoint Tests
3. If an obvious cause for an observed or
reported concern is found, correct the cause
(if possible) before proceeding to the next
step.
Component Tests
the symptom and refer to WDS.
E7832 EN 09/2001 2002 Bantam

303-03-180 Engine Cooling 303-03-180

Thermostat — Vehicles with 1.8L Endura DE Diesel Engine (24 454 0)
Special Tool(s)
Remover/Installer, cooling
hose clamp
24-003
Removal
1. Drain the cooling system.
2. Disconnect the coolant hose.
3. Remove the thermostat housing.
4. Remove the thermostat.
E5887 EN 09/2001 2002 Bantam

303-03-181 Engine Cooling 303-03-181
Installation
1. Install a new O-ring seal.
2. Install the thermostat and thermostat

housing.
3. Install the remaining components in the

reverse order.
4. Refill the cooling system.

E5887 EN 09/2001 2002 Bantam

303-03-182 Engine Cooling 303-03-182

Cooling Fan Motor (24 222 0)
Removal
2. Support the radiator.

• Use suitable wire to support the radiator
to the front panel.
4. Remove the lower air deflector (four

screws).
5. Disconnect the fan multiplug and unclip the

wiring loom.
6. Disconnect the multiplug if fitted.
E6343 EN 09/2001 2002 Bantam

303-03-183 Engine Cooling 303-03-183
7. Detach the multiplug from the radiator

support.
8. Remove the radiator support (four bolts).
Vehicles with automatic transmission

9. Loosen the transmission fluid cooler pipes.
10. Unclip the transmission fluid pipe from the

fan shroud.
E6343 EN 09/2001 2002 Bantam

303-03-184 Engine Cooling 303-03-184
11. Remove the transmission fluid cooler

retaining bolt.
12. Detach the transmission fluid cooler from

the radiator.
1. Move the bottom of the cooler away from
the radiator.
2. Move the cooler downwards.
• Take care not to stress the pipes whilst
moving the cooler.
All vehicles
13. Remove the fan/shroud assembly.
14. Remove the fan and motor assembly from

the shroud (three nuts).
E6343 EN 09/2001 2002 Bantam

303-03-185 Engine Cooling 303-03-185
Installation
• Make sure the lugs on the fan/shroud
assembly are located correctly.
E6343 EN 09/2001 2002 Bantam

303-03-186 Engine Cooling 303-03-186

Radiator — Vehicles with 1.8L Endura DE Diesel Engine (24 254 0)
Removal
All vehicles
1. Disconnect the battery ground cable. For
2. Drain the cooling system. For additional

information, refer to Cooling System
Draining, Filling and Bleeding in this section
3. Disconnect the radiator hoses.

5. Remove the lower air deflector (if

equipped).
E5890 EN 09/2001 2002 Bantam

303-03-187 Engine Cooling 303-03-187
6. Disconnect the fan multiplug and unclip the

wiring loom.
7. Detach the multiplug from the radiator

support.
8. Disconnect the lower radiator hose.

9. Detach and secure the air conditioning
condenser from the radiator.
E5890 EN 09/2001 2002 Bantam

303-03-188 Engine Cooling 303-03-188

All vehicles
10. Support the radiator assembly and remove
the four support retaining bolts (left-hand
side shown).
11. Remove the fan and radiator assembly

complete.
12. If the radiator is to be renewed, remove the

fan assembly.
Installation
2. Refill the cooling system and check for

leaks. For additional information,
refer to Cooling System Draining,
Filling and Bleeding in this section
E5890 EN 09/2001 2002 Bantam

303-03-189 Engine Cooling 303-03-189

Water Pump — Vehicles with 1.8L Endura DE Diesel Engine (24 404 0)
Removal

3. Remove the timing belt. For additional

information, refer to Section 303-01C. For
Ikon
refer to Section 303-01D.
4. Remove the timing belt tensioner.

• Collect the tensioner spring.
5. Accurately mark the position of the engine

support insulator and remove the insulator.
E6441 EN 09/2001 2002 Bantam

303-03-190 Engine Cooling 303-03-190
6. Detach the engine front mounting bracket.

1. Completely remove the three bolts.
2. Fully loosen the remaining bolt.
7. Raise the engine using a suitable jack and

packing material, to allow the bolt to be
withdrawn through the body bracket.
8. Remove the engine front mounting bracket

and bolts (bracket shown removed for
clarity).
• The lower bolt hole is slotted to allow the
bracket to be removed.
9. Remove the idler pulley.
E6441 EN 09/2001 2002 Bantam

303-03-191 Engine Cooling 303-03-191
10. Disconnect the coolant hose from the water

pump.
11. Remove the remaining water pump bolts.

• Take care not to put undue stress on any
pipes or wiring.

packing material, until the water pump can
be removed.
Installation
E6441 EN 09/2001 2002 Bantam

303-03-192 Engine Cooling 303-03-192
E6441 EN 09/2001 2002 Bantam

303-03-193 Engine Cooling 303-03-193

Coolant Expansion Tank (24 284 0)
Removal
information,
refer to Cooling System Draining, Filling
and Bleeding. In this section
2. Disconnect the expansion tank hoses.

1. Disconnect the radiator to expansion
tank hose.
2. Disconnect the engine to expansion tank
hose.
3. Disconnect the engine supply hose.
3. Remove the expansion tank.

1. Remove the expansion tank retaining
screw.
2. Remove the expansion tank from the
supporting bracket.
Installation
2. Refill the cooling system. For additional

information,
refer to Cooling System Draining, Filling
and Bleeding. In this section
E1001 EN 09/2001 2002 Bantam

303-03-194 Engine Cooling 303-03-194
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding
Drain
1. WARNING: When releasing the system

pressure, cover the expansion tank
cap with a thick cloth to prevent the
possibility of coolant scalding.
Relieve the cooling system pressure.
• Unscrew the cap slowly.
2. Remove the cap.

4. Remove the radiator undershield.
5. Remove the drain plug.

• Drain the coolant into a suitable
container.
6. Refit the drain plug when all coolant has

drained.
7. Refit the radiator undershield.
E2465 EN 09/2001 2002 Bantam

303-03-195 Engine Cooling 303-03-195

Refill
1. NOTE: For vehicles with a diesel engine, it is
necessary to add a further one litre of coolant
above the MAX mark to make sure that the
correct level is achieved after the system
degasses.
Refill the expansion tank to the MAX mark.
2. Start the engine and run until normal

operating temperature is achieved. Check
for leaks and add coolant if necessary.
E2465 EN 09/2001 2002 Bantam

303-03-196 Engine Cooling 303-03-196
GENERAL PROCEDURES
Cooling System Flushing
1. To remove rust, sludge and other foreign

material from the cooling system, use
Premium Cooling System Flush that is safe
for use with aluminum radiators, For
refer to Specifications in this section.
Remove the thermostat prior to pressure flushing.
This cleaning restores cooling system efficiency
and helps prevent overheating. A pulsating
or reversed direction of flushing water will
loosen sediment more quickly than a steady
flow in the normal coolant flow direction. In
severe cases where cleaning solvents will
not properly clean the cooling system for
efficient operation, it will be necessary to
use the pressure flushing method using
Cooling System Flusher. Dispose of old
coolant and flushing water contaminated
with antifreeze and cleaning chemicals in
accordance with local, state or federal laws.
2. Remove the radiator.
3. CAUTION: Radiator internal pressure

must not exceed 138 kPa. Damage
may result.
Back flush the radiator with the radiator in
an upside down position with a high-
pressure water hose in the lower hose
location and back flush.
4. Remove thermostat.
Refer to Thermostat in this Section.
5. Back flush the engine. Position the high-

pressure water hose into the engine
through the engine return and back flush
the engine.
E3373 EN 09/2001 2002 Bantam

303-03-197 Engine Cooling 303-03-197
GENERAL PROCEDURES
Cooling System Back flushing
CAUTION: The heater core must be back

flushed separately from the engine cool-
ing system to make sure correct back
flush water flow direction through the
heater core. All engine cooling system
flushing and back flushing procedures
must include a separate back flushing
of the heater core or A/C system heater
core after the flushing or back flushing
of the engine cooling system to prevent
the engine cooling system particles
from clogging the heater core tubes and
reducing (or preventing) coolant flow
through the heater core.
1. Disconnect the heater outlet hose from the
engine intake connector and install a
garden hose (from a tap), with a male
adapter into the end of the heater outlet
hose. Secure with a hose clamp.
2. Connect a garden hose to the engine intake

connector and secure with a hose clamp.
Allow the open end to drain into a suitable
container or drain.
3. Turn the water supply tap ON and OFF

several times, so that the surge action will
help to dislodge larger, stubborn particles
from the heater core tubes. Allow water
pressure to flow for approximately five
minutes.
4. Remove the garden hose with the male

adapter from the heater outlet hose.
Remove the garden hose from the engine
intake connector and reconnect the heater
outlet hose onto the engine intake
connector.
5. Fill the cooling system as described, using

a 50/50 mixture of L405F cooling system
fluid and water. For additional information,
6. Test the system for correct heater operation

within the engine cooling system conditions.
E3374 EN 09/2001 2002 Bantam

303-03-198 Engine Cooling 303-03-198
GENERAL PROCEDURES
Heater Core Back flushing

ing system for proper back flush water
flow direction through the heater core.
All engine cooling system flushing and
back flushing procedures must include
a separate back flushing of the heater or
A/C system heater core after the flush-
ing or back flushing of the engine cool-
ing system to prevent the engine cool-
ing system particles from clogging the
heater core tubes and reducing (or
eliminating) coolant flow through the
heater core.
1. Disconnect the outlet heater water hose
from the engine and install a female garden
hose and fitting adapter in the end of the
heater outlet water hose. Secure with a
hose clamp.
2. Connect the female hose end of the heater

outlet water hose to the male end of a water
supply garden hose.
3. Disconnect the heater inlet water hose from

the engine and allow it to drain into a
suitable container.
4. Turn the water supply valve ON and OFF

several times so that the surge action will
minutes.
5. Remove the hose clamp and female garden

hose end adapter from the heater outlet
water hose and reconnect the heater outlet
water hose onto the engine.
6. Connect the heater inlet water hose onto

the engine.

a 50/50 mixture of L405F Cooling System
Fluid and water.
8. Test the system for proper heater

performance with the specified engine
cooling system conditions.
E1690 EN 09/2001 2002 Bantam

303-03-199 Engine Cooling 303-03-199
SPECIFICATIONS
Fluids
Ford
Specification
L405F antifreeze L405F
Description Nm
Endura DE Diesel Engine Water pump retaining 33
bolts
Endura DE Diesel Engine Thermostat housing 18
retaining bolts
Endura DE Diesel Engine Water pump pulley 11
retaining bolts
Radiator support bracket retaining bolts 25
Air conditioning condenser retaining bolts 6
E6442 EN 09/2001 2002 Bantam

303-06-200 Starting System 303-06-200
SECTION 303-06 Starting System - 1.8L Diesel - Endura DE

SUBJECT PAGE
Starting System........................................................................................................................303-06-201

Starting System........................................................................................................................303-06-202
Inspection and Verification ....................................................................................................303-06-202
Symptom Chart .....................................................................................................................303-06-202
Pinpoint Tests........................................................................................................................303-06-202/210

Starter Motor — Vehicles with 1.8L Endura DE Diesel Engine ........................ (26 204 0) 303-06-211/212
SPECIFICATIONS
Specifications ........................................................................................................................... 303-06-213
Torque Specifications............................................................................................................ 303-06-213
09/2001 2002 Bantam

303-06-201 Starting System 303-06-201

Starting System
The ring gear is located on the outside of the
Pre-engaged starter motors of Bosch or Magnetti flywheel.
Morelli manufacture are used. Some starter motors are interchangeable in
Irrespective of model, all starter motors have an certain circumstances; refer to the Parts
integral solenoid and all types have pinions, Microfiche for detailed information. Starter motors
which engage with a ring gear during starting. should be serviced as an assembly and should
not, therefore, be dismantled.
E5908 EN 09/2001 2002 Bantam

303-06-202 Starting System 303-06-202

Starting System
Inspection and Verification Visual Inspection Chart
WARNING: When performing engine Mechanical Electrical

compartment work near the starter, be • Starter motor • Fuse
aware that the heavy gauge battery input • Battery • Wiring
lead to the starter is electrically hot at all • Connectors
times.
3. If inspection reveals an obvious cause rectify
1. Verify the customer concern. this before continuing. If the concern
2. Check for concerns with the following. remains, proceed to the symptom chart.
Symptom Chart
Symptom Chart
• The engine does not crank relay • Battery • GO to Pinpoint Test A
clicks • Circuits
• Starter motor
• The engine cranks slowly • Battery • GO to Pinpoint Test B
• Circuits
• Starter motor
• Unusual starter noise • Starter motor • GO to Pinpoint Test C
• Ring gear
• Starter motor spins but engine • Solenoid • GO to Pinpoint Test D
does not crank
E1017 EN 09/2001 2002 Bantam

Pinpoint Tests
PINPOINT TEST A: THE ENGINE DOES NOT CRANK OR
THE RELAY CLICKS
A1: CHECK THE BATTERY CONNECTIONS...................................................... 303-06-203
A2: CHECK THE BATTERY VOLTAGE............................................................... 303-06-203
A3: CHECK SWITCHED POWER SUPPLY TO THE SOLENOID........................ 303-06-203
A4: CHECK B+ TO THE STARTER ..................................................................... 303-06-203/204
A5: CHECK THE STARTER GROUND CIRCUIT................................................. 303-06-204
A6: CHECK B+ TO STARTER RELAY................................................................. 303-06-204
A7: CHECK RELAY GROUND CIRCUIT.............................................................. 303-06-205
A8: CHECK RELAY SWITCHING CIRCUIT......................................................... 303-06-205
A9: CHECK FUSE 40 (60A) ................................................................................. 303-06-205
A10: CHECK CIRCUIT 30 (RD) CONTINUITY ..................................................... 303-06-206
A11: CHECK THE IGNITION SWITCH ................................................................ 303-06-206
A12: CHECK CIRCUIT 50 (GY) CONTINUITY ..................................................... 303-06-206/207
A13: CHECK THE CONTINUITY OF CIRCUIT 50 (GY/BK) ................................. 303-06-207
A14: CHECK CIRCUIT 50 (GY/BK) FOR SHORT TO GROUND.......................... 303-06-207
A15: CHECK CIRCUIT 30 (RD) FOR SHORT TO GROUND ............................... 303-06-208
A16: CHECK CIRCUIT 50 FOR SHORT TO GROUND........................................ 303-06-208
PINPOINT TEST B: THE ENGINE CRANKS SLOWLY
B1: CHECK THE BATTERY VOLTAGE............................................................... 303-06-208
B2: CHECK THE SUPPLY TO STARTER............................................................ 303-06-209
B3: CHECK THE STARTER GROUND CIRCUIT................................................. 303-06-209
PINPOINT TEST C: UNUSUAL STARTER MOTOR NOISE
C1: CHECK THE STARTER MOUNTING ............................................................ 303-06-209
C2: CHECK THE STARTER DRIVE .................................................................... 303-06-210
303-06-203 Starting System 303-06-203

Pinpoint Tests
PINPOINT TEST A: THE ENGINE DOES NOT CRANK OR THE RELAY CLICKS
A1: CHECK THE BATTERY CONNECTIONS
1 Inspect the battery connections for
loose/corroded connections.
• Are the battery terminals clean and tight?
Yes
GO TO A2
No
CLEAN and TIGHTEN connections as re-
quired. TEST the system for normal opera-
tion.
A2: CHECK THE BATTERY VOLTAGE
1 Check the battery. Refer to Section 414-00.
• Is the battery OK?
Yes
GO TO A3
No
CHARGE or INSTALL a new battery as re-
quired. Refer to Section 414-00. TEST the
A3: CHECK SWITCHED POWER SUPPLY TO THE SOLENOID
1. 2.
Solenoid single
pin
3 Measure the voltage between the starter motor
solenoid connector single pin, circuit 50
(GY/BK) and ground when the starter is
operated.
Yes
GO TO A4
No
GO TO A6
A4: CHECK B+ TO THE STARTER

1.
E1017 EN 09/2001 2002 Bantam

303-06-204 Starting System 303-06-204

terminal B, circuit 30 (RD) and ground.
Yes
GO TO A5
No
A5: CHECK THE STARTER GROUND CIRCUIT

1 Measure the resistance between the starter
motor casing and negative (-) battery terminal.
Yes
INSTALL a new starter motor. TEST the
No
CLEAN and REPAIR grounds as required.
A6: CHECK B+ TO STARTER RELAY

1.
Starter relay
2 Measure the voltage between the starter relay
Yes
GO TO A7
No
E1017 EN 09/2001 2002 Bantam

303-06-205 Starting System 303-06-205

A7: CHECK RELAY GROUND CIRCUIT
relay connector pin 1, circuit 31 (BK) and
ground.
Yes
GO TO A8
No
REPAIR circuit 31 (BK). TEST the system
A8: CHECK RELAY SWITCHING CIRCUIT

1.

connector pin 2, circuit 50 (GY) and ground.
Yes
GO TO A13
No
GO TO A9

1.
• Is the fuse OK?
Yes
GO TO A10
No
system for normal operation. If fuse fails
again GO TO A15
Fuse 40 (60A)
E1017 EN 09/2001 2002 Bantam

303-06-206 Starting System 303-06-206

A10: CHECK CIRCUIT 30 (RD) CONTINUITY
1.
Ignition switch
2 Remove the fuse 40 (60A).
connector pin 1, circuit 30 (RD) and ignition
switch connector pin 4, circuit 30 (RD).
Yes
GO TO A11
No

1.
2 Measure the resistance between pin 4 and pin

3 of the ignition switch connector.
Yes
GO TO A12
No
A12: CHECK CIRCUIT 50 (GY) CONTINUITY

1.
E1017 EN 09/2001 2002 Bantam

303-06-207 Starting System 303-06-207

switch connector pin 3, circuit 50 (GY) and the
starter relay connector pin 2, circuit 50 (GY).
Yes
RECONNECT the ignition switch.
GO TO A8
No
A13: CHECK THE CONTINUITY OF CIRCUIT 50 (GY/BK)

motor solenoid connector, circuit 50 (GY/BK)
and starter relay connector pin 3, circuit 50
(GY/BK).
Yes
GO TO A14
No
REPAIR circuit 50 (GY/BK). TEST the sys-
A14: CHECK CIRCUIT 50 (GY/BK) FOR SHORT TO GROUND

relay connector pin 3, circuit 50 (GY/BK) and
ground.
Yes
INSTALL a new starter relay. TEST the
No
E1017 EN 09/2001 2002 Bantam

303-06-208 Starting System 303-06-208

1 Remove fuse 36 (60A).
2 Measure the resistance between fuse 36
Yes
GO TO A16
No
A16: CHECK CIRCUIT 50 FOR SHORT TO GROUND

1.
Ignition switch
switch connector pin 3, citcuit 50 (GY) and
ground.
Yes
CONNECT the ignition switch. GO TO A8
No

B1: CHECK THE BATTERY VOLTAGE
1 Measure the voltage between the battery
terminals.
• Is the voltage greater than 12.5 volts?
Yes
GO TO B2
No
quired. REFER to Section 414-00.
E1017 EN 09/2001 2002 Bantam

303-06-209 Starting System 303-06-209

B2: CHECK THE SUPPLY TO STARTER
1.
2 Measure the voltage between the starter

Yes
GO TO B3
No
B3: CHECK THE STARTER GROUND CIRCUIT

Yes
No

C1: CHECK THE STARTER MOUNTING
1 Check the starter and mounting brackets for
correct alignment.
• Is the starter mounted correctly?
Yes
GO TO C2
No
INSTALL the starter motor.
E1017 EN 09/2001 2002 Bantam

303-06-210 Starting System 303-06-210

C2: CHECK THE STARTER DRIVE
1 Remove the starter motor. Refer to the
procedure in this section.
2 Inspect the ring gear for damage and wear.
• Is the ring gear damaged?
Yes
REPAIR ring gear as required. TEST the
No
E1017 EN 09/2001 2002 Bantam

303-06-211 Starting System 303-06-211

Starter Motor — Vehicles with 1.8L Endura DE Diesel Engine (26 204 0)
Removal
3. Disconnect the starter motor wiring.
4. Remove the starter motor support bracket

(two nuts, one bolt).
5. Remove the starter motor (three bolts).
E5909 EN 09/2001 2002 Bantam

303-06-212 Starting System 303-06-212
Installation
E5909 EN 09/2001 2002 Bantam

303-06-213 Starting System 303-06-213
SPECIFICATIONS
Description Nm
Support bracket retaining bolt 25
Support bracket retaining nuts 6
Starter motor solenoid power cable retaining nut 12
M10
Starter motor solenoid power cable retaining nut 6
M8
E6453 EN 09/2001 2002 Bantam

303-08B-214 Engine Emission Control — Diesel Engine 303-08B-214
SECTION 303-08B Engine Emission Control —

Diesel Engine
SUBJECT PAGE
Engine Emission Control ......................................................................................................... 303-08B-215

Engine Emission Control ......................................................................................................... 303-08B-216
Inspection and Verification .................................................................................................... 303-08B-216
Exhaust Manifold to Exhaust Gas Re-circulation (EGR) Valve Tube ............... (23 301 0) 303-08B-217
Exhaust Gas Re-circulation (EGR) Valve.......................................................... (23 312 0) 303-08B-218/219
Exhaust Gas Re-circulation (EGR) Valve — Vehicles with 1.8L Endura DE
Diesel Engine .................................................................................................. (23 312 0) 303-08B-220/222
SPECIFICATIONS
Specifications ........................................................................................................................... 303-08B-223

Torque Specifications............................................................................................................ 303-08B-223
09/2001 2002 Bantam


Engine Emission Control
Exhaust Gas Re-circulation

Item Description
The exhaust gas re-circulation system reduces
1 Exhaust manifold to exhaust gas the formation of NOx (oxides of nitrogen) by
Recirculation (EGR) valve tube recycling measured quantities of exhaust gas
2 EGR vacuum regulator solenoid back through the engine where they mix with the
incoming air charge.
3 EGR valve
The exhaust gas re-circulation vacuum regulator
Positive Crankcase Ventilation solenoid is controlled by the powertrain control
module with ground pulses. This regulates the
The positive crankcase ventilation system amount and duration of the signal supplied to the
recycles crankcase gases back through the exhaust gas re-circulation valve and therefore the
engine where they mix with the incoming air valve lift and opening times are controlled.
charge. All the combustion gases, which enter
the crankcase, flow through hoses out of the
valve cover into the intake air system. It is a
completely sealed system, which helps to reduce
hydrocarbon emissions from the engine.
E7849 EN 09/2001 2002 Bantam


Engine Emission Control

system. reported concern is found, correct the cause
Visual Inspection Chart the symptom and refer to WDS.
• Sensors and controls • Loose or corroded
• Exhaust gas connection to the
recirculation clamps exhaust gas
• Exhaust gas recirculation vacuum
Recirculation tube for regulator
cracks • Loose or corroded
• Vacuum pipes for powertrain control
leaks module electrical
• Coolant pipes for connectors.
leaks • Wiring harness
• Exhaust gas
recirculation gaskets
E4565 EN 09/2001 2002 Bantam


Exhaust Manifold to Exhaust Gas Re-circulation (EGR) Valve Tube (23 301 0)
Removal
valve.
Refer to procedure contained in this section.
2. CAUTION: When removing the exhaust

manifold to exhaust gas re-
circulation pipe from the exhaust
manifold, make sure that the sealing
ring comes away with the pipe and
does not fall into the exhaust
manifold.
Remove the exhaust manifold to exhaust
gas re-circulation valve pipe (one bolt).
Installation
1. Remove and discard the two exhaust
manifold to exhaust gas re-circulation valve
pipe sealing rings.
2. Examine the exhaust manifold to exhaust

gas re-circulation pipe for corrosion and
carbon deposits. Clean as required.
3. Renew the two exhaust manifold to exhaust

gas Re-circulation valve pipe sealing rings.
4. NOTE: When cleaning is required, take care

not to allow debris to fall into the exhaust
manifold or exhaust gas re-circulation valve.
Examine the exhaust manifold and exhaust
gas re-circulation valve orifices for signs of
corrosion and carbon deposits. Clean as
required.
E6362 EN 09/2001 2002 Bantam


Exhaust Gas Re-circulation (EGR) Valve (23 312 0)
Removal
1. Remove the air intake pipe (two clips).
2. Disconnect the exhaust gas re-circulation

valve lift sensor multiplug.
3. Disconnect the vacuum pipe from the

exhaust gas re-circulation valve.
E6363 EN 09/2001 2002 Bantam


valve (two bolts).
Installation
1. CAUTION: When cleaning is required,

take care not to allow debris to fall
into the inlet manifold, exhaust
manifold or exhaust gas
Recirculation valve.
Clean the gasket surfaces of the exhaust
gas re-circulation valve and inlet manifold.
E6363 EN 09/2001 2002 Bantam


Exhaust Gas Re-circulation (EGR) Valve — Vehicles with 1.8L Endura DE
Diesel Engine (23 312 0)
Removal
1. Disconnect the exhaust gas re-circulation
(EGR) valve electrical connector and
vacuum line.
2. Disconnect the intake air temperature (IAT)

3. Disconnect the air cleaner outlet pipe.
E7850 EN 09/2001 2002 Bantam

4. Detach the exhaust manifold to EGR valve

tube.
5. Discard the EGR valve clamp.
6. Remove and discard the EGR valve gasket.
7. Remove the EGR valve.
E7850 EN 09/2001 2002 Bantam


Installation
NOTE: Install a new exhaust manifold to EGR

valve tube gasket.
NOTE: Install a new EGR valve gasket.
NOTE: Install a new exhaust manifold to EGR
valve tube clamp.
E7850 EN 09/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Endura DE Diesel Engine Exhaust gas 20
Recirculation valve retaining bolts
Endura DI Diesel Engine Exhaust gas 19
Recirculation valve/tube retaining bolts
Endura DI Diesel Engine Exhaust gas 19
Recirculation valve retaining clamp bolt
E6364 EN 09/2001 2002 Bantam

303-14D-224 Electronic Engine Controls — Diesel Engine 303-14D-224
SECTION 303-14D Electronic Engine Controls —

Diesel Engine
SUBJECT PAGE
Engine Emission Controls........................................................................................................ 303-14D-225

Electronic Engine Controls ...................................................................................................... 303-14D-226
Inspection and Verification .................................................................................................... 303-14D-226

Crankshaft Position (CKP) Sensor — Vehicles with 1.8L Endura DE Diesel
Engine ............................................................................................................. (29 230 0) 303-14D-227
Engine Coolant Temperature (ECT) Sensor..................................................... (21 190 0) 303-14D-228
SPECIFICATIONS

09/2001 2002 Bantam


Engine Emission Controls
Item Description The engine management system consists of a

powertrain control module (PCM), a number of
1 Clutch pedal position (CPP) switch sensors and a clutch pedal position switch. The
PCM is located inside the vehicle, behind the left-
2 Manifold absolute pressure (MAP)
hand cowl side trim panel and provides precise
sensor control of basic engine calibration parameters.
3 Vehicle speed sensor (VSS) The sensors and the clutch pedal position switch
supply the PCM with input signals, which relate to
4 Intake air temperature (IAT) sensor engine operating conditions.
5 Crankshaft position (CKP) sensor
E7854 EN 09/2001 2002 Bantam


Electronic Engine Controls

Visual Inspection Chart the symptom and refer to WDS to diagnose
Mechanical Electrical the system.
• Fuel leak(s) • Wiring harness

• Vacuum line(s) • Loose or corroded
• Sensor(s) electrical connector(s)
• Clutch pedal position • Powertrain control
switch module
• Sensor(s)
• Clutch pedal position
switch
E7855 EN 09/2001 2002 Bantam


Crankshaft Position (CKP) Sensor — Vehicles wi th 1.8L Endura DE
Diesel Engine (29 230 0)
Removal
2. Disconnect the crankshaft position (CKP)

3. Remove the CKP sensor.
Installation
E4569 EN 09/2001 2002 Bantam


Engine Coolant Temperature (ECT) Sensor (21 190 0)
Removal
2. Disconnect the engine coolant temperature

3. Remove the sensor.
Installation
E1037 EN 09/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Exhaust gas Re-circulation valve retaining bolts 20
Engine coolant temperature sensor 12
E5898 EN 09/2001 2002 Bantam

303-03-133 Engine Cooling 303-03-133
SECTION 303-03 Engine Cooling

SUBJECT PAGE

Engine Cooling .................................................................................................................... 303-03-134
Vehicles with Petrol engines.............................................................................................. 303-03-135/136
Vehicles with Diesel engine............................................................................................... 303-03-137

Engine Cooling .................................................................................................................... 303-03-138
Symptom Chart ................................................................................................................. 303-03-138/139
Component Tests.............................................................................................................. 303-03-140

Thermostat — Vehicles with 1.6L / 1.3L Engine.............................................. (24 454 0) 303-03-141/142
Thermostat — Vehicles with 1.8L Endura DE Diesel Engine........................... 303-03-143/144
Thermostat Housing — Vehicles with 1.6L / 1.3L Engine ................................ (24 001 0) 303-03-145/147
Water Pump — Vehicles with 1.6L / 1.3L Engine ............................................ (24 404 0) 303-03-148/150
Water Pump — Vehicles with Diesel Engine................................................... (24 404 0) 303-03-151/154
Radiator .......................................................................................................... (24 254 0) 303-03-155/163
Cooling Fan Motor .......................................................................................... (24 222 0) 303-03-164/166
Coolant Expansion Tank ................................................................................. (24 284 0) 303-03-167
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding................................................ (24 122 0) 303-03-168/169
Cooling System Flushing ..................................................................................................... 303-03-170
Cooling System Back flushing.............................................................................................. 303-03-171
Heater Core Back flushing ................................................................................................... 303-03-172
SPECIFICATIONS
Specifications....................................................................................................................... 303-03-173
Lubricants, Fluids, Sealers and Adhesives ........................................................................ 303-03-173
Capacities ......................................................................................................................... 303-03-173
Coolant ............................................................................................................................. 303-03-173
Pressures.......................................................................................................................... 303-03-173
07/2001 2002 Bantam

303-03-134 Engine Cooling 303-03-134

Engine Cooling

1 Water pump 3 Thermostat housing
2 Engine coolant temperature (ECT)
sender unit
E6861 EN 07/2001 2002 Bantam

303-03-135 Engine Cooling 303-03-135

Item Description All Vehicles

1 Water pump WARNING: Never remove the coolant
2 Engine coolant temperature (ECT) expansion tank cap under any
sender unit circumstances while the engine is
operating. Failure to follow this
3 Thermostat instruction may result in personal injury,
damage to the cooling system or damage
to the engine.
E6861 EN 07/2001 2002 Bantam

303-03-136 Engine Cooling 303-03-136
WARNING: To avoid having scalding hot In such cases the concentration must be brought
water or steam blow out of the cooling back to specification.
system, use extreme care when
An orange colored engine antifreeze conforming
removing the coolant expansion tank cap
to Ford specification L405F is used. This is
from a hot cooling system. Wait until the
monoethylene glycol and Organic Additive
engine has cooled and then wrap a thick
Technologies corrosion inhibitors and should not
cloth around the coolant expansion tank
be mixed with other antifreeze types. For cooling
cap and turn it slowly until the pressure
system top up, only use antifreeze, which meets
begins to release. Step back while the
Ford specification L405F.
pressure is fully released from the
cooling system. Failure to follow this Engine coolant should be changed after a period
instruction may result in personal injury. of 10 years or 240,000 km, whichever occurs
sooner.
WARNING: Disconnect the battery when
working in the vicinity of the cooling fan. Radiator
The cooling fan is controlled by the The radiator is of the tube and louvered fin core-
engine management system and an type with the tubes arranged horizontally for
increase in engine coolant temperature crossflow of the coolant. Two tanks, one on each
may cause it to operate even with the side of the radiator, provide uniform distribution of
ignition in the OFF position. Failure to the coolant to the crossflow tubes.
follow this instruction may result in
personal injury. Water Pump
The water pump is belt driven from the
WARNING: Do not operate the engine crankshaft.
with the hood open until the cooling fan
has been examined for damage. Failure Thermostat
to follow this instruction may result in The thermostat is of the wax type. It allows rapid
personal injury. engine warm up by restricting engine coolant flow
CAUTION: When draining the coolant or to the cylinder block, cylinder head and heater
changing any cooling system system at lower operating temperatures. It also
components, it is imperative that no assists in maintaining engine operating
engine coolant comes into contact with temperatures between pre-determined limits.
the timing belt or accessory drive belt. If Coolant Expansion Tank
necessary, the drive belt(s) should be
The coolant expansion tank is fitted with a
removed as contamination may result in
pressure cap. It helps to maintain the correct
their failure.
level of coolant in the cooling system, separating
NOTE: The cooling system must be maintained trapped air and replenishing the cooling system
with the correct concentration and specification of with coolant through a hose. It also serves as a
engine coolant to prevent corrosion damage. location for service filling, cooling system
pressurization, coolant expansion during warm-
NOTE: Providing that the engine coolant has not up and air separation during operation. It is
been contaminated with other fluids or foreign designed to have approximately 0.5 to 1 liter of
matter, its robust corrosion resistance properties air when cold to allow for coolant expansion.
allow it to be reused after changing any cooling
system components, although the concentration Cooling Fan
should always be checked and maintained within The cooling fan is electrically operated and
specification. consists of a fan and motor mounted within a
Engine coolant concentration should be checked shroud, behind the radiator.
through the neck of the coolant expansion tank
with a hydrometer. The acceptable range of
specific gravity (sg) of correctly balanced fluids is
between 1.06 and 1.07 kg/l, which represents an
engine coolant concentration of between 28%
and 32%. If the concentration falls below 28%
there is insufficient low temperature protection
and the corrosion resistance will be inadequate.
E6861 EN 07/2001 2002 Bantam

303-03-137 Engine Cooling 303-03-137
Vehicles with Petrol or Diesel engine The ECT sender unit measures engine coolant
temperature and controls the position of the
Engine Coolant Temperature (ECT) Sender Unit
temperature gauge pointer.
E6861 EN 07/2001 2002 Bantam

303-03-138 Engine Cooling 303-03-138

Engine Cooling Visual Inspection Chart
Special Tool(s)
• Coolant leak(s) • Fuse(s)
Pressure Tester, Cooling • Radiator • Relay(s)
System • Water pump • Wiring harness
303-396 (24-001 A) • Thermostat • Electrical
• Coolant expansion connector(s)
tank • Cooling fan motor
• Cooling fan • Engine coolant
Adapter for 303-396 • Accessory drive belt temperature (ECT)
303-396-01 (24-001-01 A) sender unit
• ECT sensor
• Cooling fan motor
switch
• Powertrain control
module (PCM)

1. Verify the customer concern. 3. If an obvious cause for an observed or
2. Visually inspect for obvious signs of reported concern is found, correct the cause
mechanical or electrical damage. (if possible) before proceeding to the next
step.
the symptom and refer to the Symptom
Symptom Chart Chart.
• Loss of coolant • Radiator. • CHECK the radiator. INSTALL a
new radiator if necessary.
• Water pump. • CHECK the water pump.
INSTALL a new water pump if
necessary.
• Coolant expansion tank. • CHECK the coolant expansion
tank. INSTALL a new coolant
expansion tank if necessary.
• Engine. • CHECK the engine.
• Coolant hose(s). • CHECK the coolant hose(s).
INSTALL a new coolant hose(s)
if necessary.
• Heater core. • CHECK the heater core.
INSTALL a new heater core if
necessary.
• The engine overheats • Coolant level. • CHECK the coolant level. FILL
as necessary.
• System restriction. • INSPECT the system for restric-
tions. REPAIR as necessary.
E6862 EN 07/2001 2002 Bantam

303-03-139 Engine Cooling 303-03-139

• Radiator grille. • INSPECT the radiator grille for
restrictions. REPAIR as neces-
sary.
• Water pump. • CHECK the water pump.
INSTALL a new water pump if
necessary.
• Thermostat. • CHECK the thermostat for cor-
rect specification and operation.
INSTALL a new thermostat if
necessary.
• Cooling fan. • CHECK the cooling fan.
INSTALL a new cooling fan if
necessary.
• Cooling fan motor. • CHECK the cooling fan motor
for correct operation. REFER to
WDS to diagnose the system.
• Accessory drive belt. • CHECK the accessory drive
belt. INSTALL a new accessory
drive belt if necessary.
• ECT sensor. • CHECK the ECT sensor for cor-
rect operation. REFER to
• Cooling fan motor switch. • CHECK the cooling fan motor
switch for correct operation.
REFER to WDS to diagnose the
system.
• Powertrain control module • CHECK the PCM for correct op-
(PCM). eration. REFER to
• Circuit(s). • CHECK the circuit(s). REFER to
• Relay(s). • CARRY OUT the Relay Compo-
nent Test.
REFER to the Wiring Diagrams.
• Engine. • CHECK the engine for correct
operation.
• The engine does not reach nor- • Coolant level. • CHECK the coolant level. FILL
mal operating temperature as necessary.
• System restriction. • INSPECT the system for restric-
tions. REPAIR as necessary.
• Thermostat. • CHECK the thermostat for cor-
rect specification and operation.
INSTALL a new thermostat if
necessary.
E6862 EN 07/2001 2002 Bantam

303-03-140 Engine Cooling 303-03-140

• ECT sender unit. • CHECK the ECT sender unit for
correct operation. REFER to
• ECT sensor. • CHECK the ECT sensor for cor-
rect operation. REFER to
• Cooling fan motor switch. • CHECK the cooling fan motor
switch for correct operation.
REFER to WDS to diagnose the
system.
• PCM. • CHECK the PCM for correct op-
eration. REFER to
• Circuit(s). • CHECK the circuit(s). REFER to
• Relay(s). • CARRY OUT the Relay Compo-
nent Test.
Component Tests
Pressure Test Thermostat Test
1. Remove the coolant expansion tank cap. Remove and inspect the thermostat, note its
2. Install the special tools. opening temperature and immerse it in water.
Heat the water until that temperature is reached.
3. Pressurize the system to the coolant
The thermostat should begin to open. If it does
expansion tank cap release pressure.
not begin to open, install a new thermostat.
4. Observe the cooling system pressure tester Continue to heat the water until the thermostat
gauge reading for approximately two fully opens, 5.8 mm or more off the valve seat. If
minutes. The pressure should not drop it does not fully open, install a new thermostat.
during this time. If the system holds pressure,
proceed to Step 5. If the system does not
hold pressure, check it thoroughly for coolant Radiator Leak Test, Removed From Vehicle
leaks. If a coolant leak cannot be found, Clean the radiator thoroughly before leak testing
check the engine for cylinder leakage. it to prevent contamination of the water in the test
REFER to Section 303-00. Repair any tank. Leak test the radiator in clean water with
coolant leaks and refill the system as 1.38 bar air pressure. Check it thoroughly for air
necessary. leaks. Install a new radiator if necessary.
5. Recheck the system by repeating Steps 3
and 4 at least twice.
E6862 EN 07/2001 2002 Bantam

303-03-141 Engine Cooling 303-03-141

Thermostat — Vehicles with 1.6L / 1.3L Engine (24 454 0)
Removal
Draining, Filling and Bleeding in this section.
2. Detach the thermostat cover.
4. Remove and discard the O-ring seal.
E5887 EN 07/2001 2002 Bantam

303-03-142 Engine Cooling 303-03-142
Installation
1. NOTE: Install a new thermostat O-ring seal.

E5887 EN 07/2001 2002 Bantam

303-03-143 Engine Cooling 303-03-143

Thermostat — Vehicles with 1.8L Endura DE Diesel Engine (24 454 0)
Special Tool(s)
Remover/Installer, cooling
hose clamp
24-003
Removal
1. Drain the cooling system.
2. Disconnect the coolant hose.
E5887 EN 07/2001 2002 Bantam

303-03-144 Engine Cooling 303-03-144
Installation
1. Install a new O-ring seal.
2. Install the thermostat and thermostat

housing.
3. Install the remaining components in the

reverse order.
4. Refill the cooling system.

E5887 EN 07/2001 2002 Bantam

303-03-145 Engine Cooling 303-03-145

Thermostat Housing — Vehicles with 1.6L / 1.3L Engine (24 001 0)
Special Tool(s)
Remover/Installer, Hose
Clamp
303-397 (24-003)
Removal
3. Using the special tool, disconnect the

coolant hoses from the thermostat housing.
4. Detach the engine coolant temperature

(ECT) sensor.
1. Remove the clip.
2. Detach the ECT sensor.
E6653 EN 07/2001 2002 Bantam

303-03-146 Engine Cooling 303-03-146

coolant hose from the thermostat housing.
6. Disconnect the coolant hose from the

thermostat housing.
E6653 EN 07/2001 2002 Bantam

303-03-147 Engine Cooling 303-03-147
Installation
1. NOTE: Install a new thermostat housing

gasket.
E6653 EN 07/2001 2002 Bantam

303-03-148 Engine Cooling 303-03-148

Water Pump — Vehicles with 1.6L / 1.3L Engine (24 404 0)
Removal
2. Remove the splash shield.
3. Loosen the water pump pulley bolts.

1. Rotate the tensioner clockwise.
E6655 EN 07/2001 2002 Bantam

303-03-149 Engine Cooling 303-03-149
5. Remove the water pump pulley.
6. Remove the water pump (crankshaft pulley

shown removed for clarity).
7. Remove and discard the water pump

gasket (crankshaft pulley shown removed
for clarity).
Installation
1. NOTE: Install a new water pump gasket.

E6655 EN 07/2001 2002 Bantam

303-03-150 Engine Cooling 303-03-150
E6655 EN 07/2001 2002 Bantam

303-03-151 Engine Cooling 303-03-151

Water Pump — Vehicles with Diesel Engine (24 404 0)
Removal

3. Remove the timing belt. For additional

information, refer to Section 303-01A. For
additional information, refer to Section 303-01B.
4. Remove the timing belt tensioner.

• Collect the tensioner spring.
5. Accurately mark the position of the engine

support insulator and remove the insulator.
E6441 EN 07/2001 2002 Bantam

303-03-152 Engine Cooling 303-03-152
6. Detach the engine front mounting bracket.

1. Completely remove the three bolts.
2. Fully loosen the remaining bolt.

packing material, to allow the bolt to be
withdrawn through the body bracket.
8. Remove the engine front mounting bracket

and bolts (bracket shown removed for
clarity).
• The lower bolt hole is slotted to allow the
bracket to be removed.
9. Remove the idler pulley.
E6441 EN 07/2001 2002 Bantam

303-03-153 Engine Cooling 303-03-153
10. Disconnect the coolant hose from the water

pump.
11. Remove the remaining water pump bolts.

• Take care not to put undue stress on any
pipes or wiring.

packing material, until the water pump can
be removed.
Installation
E6441 EN 07/2001 2002 Bantam

303-03-154 Engine Cooling 303-03-154
E6441 EN 07/2001 2002 Bantam

303-03-155 Engine Cooling 303-03-155

Radiator (24 254 0)
Special Tool(s)
Remover/Installer, Hose
Clamp
303-397 (24-003)
Removal
All vehicles

2. Remove the radiator grille.
1. Detach the clips.
3. Secure the air conditioning (A/C) condenser

to the hood latch panel.
All vehicles
E6656 EN 07/2001 2002 Bantam

303-03-156 Engine Cooling 303-03-156

coolant hose from the thermostat housing.

coolant hose from the radiator.

coolant hose from the radiator and detach
the ventilation hose.
9. Disconnect the coolant hose from the

radiator.
E6656 EN 07/2001 2002 Bantam

303-03-157 Engine Cooling 303-03-157
All vehicles
10. Remove the engine undershield. For
11. Remove the splash shield.

13. Detach the diode from the radiator support

bracket.
E6656 EN 07/2001 2002 Bantam

303-03-158 Engine Cooling 303-03-158
14. Disconnect and detach the cooling fan

motor resistor electrical connector.

motor relay electrical connector.
16. Disconnect the cooling fan motor electrical

connector.

E6656 EN 07/2001 2002 Bantam

303-03-159 Engine Cooling 303-03-159
18. Disconnect the cooling fan motor resistor,

cooling fan motor and cooling fan motor
relay electrical connectors.
19. Detach the cooling fan motor wiring.

20. Remove the A/C condenser upper retaining
bolts. (Left-hand upper bolt shown, right-
hand similar).
21. Remove the A/C condenser left-hand lower

retaining bolt.
E6656 EN 07/2001 2002 Bantam

303-03-160 Engine Cooling 303-03-160
22. Remove the A/C condenser right-hand

retaining bolt.
All vehicles
23. Remove the radiator support bracket right-
hand retaining bolts.
24. Remove the radiator support bracket.
25. Remove the radiator, cooling fan motor and

shroud.
E6656 EN 07/2001 2002 Bantam

303-03-161 Engine Cooling 303-03-161
26. Remove the cooling fan motor and shroud.

1. Loosen the cooling fan shroud nuts.
2. Remove the cooling fan motor and
shroud.
27. Using the special tool, remove the coolant

hose from the radiator.
28. Remove the radiator left-hand insulators

and the cooling fan shroud nut and bolt.
29. Remove the radiator right-hand insulators

and the cooling fan shroud nut and bolt.
E6656 EN 07/2001 2002 Bantam

303-03-162 Engine Cooling 303-03-162
Installation
All vehicles
1. NOTE: Make sure the A/C condenser upper
locating tangs are correctly installed into the
radiator upper locating brackets.
E6656 EN 07/2001 2002 Bantam

303-03-163 Engine Cooling 303-03-163
E6656 EN 07/2001 2002 Bantam

303-03-164 Engine Cooling 303-03-164

Cooling Fan Motor (24 222 0)
Removal
2. Remove the cooling fan shroud right-hand

retaining nut.
3. Remove the cooling fan shroud left-hand

retaining nut.


motor resistor electrical connector.
E6657 EN 07/2001 2002 Bantam

303-03-165 Engine Cooling 303-03-165

motor relay electrical connector.
7. Disconnect the cooling fan motor electrical

connector.
8. Remove the cooling fan motor and shroud.

• Raise the cooling fan motor and shroud
upwards out of the radiator lower locating
brackets.
9. Detach the cooling fan motor wiring

harness.
E6657 EN 07/2001 2002 Bantam

303-03-166 Engine Cooling 303-03-166
10. Remove the cooling fan motor.
Installation
E6657 EN 07/2001 2002 Bantam

303-03-167 Engine Cooling 303-03-167

Coolant Expansion Tank (24 284 0)
Removal
Draining, Filling and Bleeding. In this section
2. Disconnect the expansion tank hoses.

1. Disconnect the radiator to expansion
tank hose.
2. Disconnect the engine to expansion tank
hose.
3. Disconnect the engine supply hose.
3. Remove the expansion tank.

1. Remove the expansion tank retaining
screw.
2. Remove the expansion tank from the
supporting bracket.
Installation
2. Refill the cooling system. For additional

Draining, Filling and Bleeding. In this section
E1001 EN 07/2001 2002 Bantam

303-03-168 Engine Cooling 303-03-168
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding (24 122 0)
Drain
1. WARNING: When releasing the system

pressure, cover the expansion tank
cap with a thick cloth to prevent the
possibility of coolant scalding.
Relieve the cooling system pressure.
• Unscrew the cap slowly.
2. Remove the cap.

4. Remove the radiator undershield.
5. Remove the drain plug.

• Drain the coolant into a suitable
container.
6. Refit the drain plug when all coolant has

drained.
7. Refit the radiator undershield.
E2465 EN 07/2001 2002 Bantam

303-03-169 Engine Cooling 303-03-169
Refill
1. NOTE: For vehicles with a diesel engine, it is
necessary to add a further one liter of coolant
above the MAX mark to make sure that the
correct level is achieved after the system
degasses.
Refill the expansion tank to the MAX mark.
2. Start the engine and run until normal

operating temperature is achieved. Check
for leaks and add coolant if necessary.
E2465 EN 07/2001 2002 Bantam

303-03-170 Engine Cooling 303-03-170
GENERAL PROCEDURES
Cooling System Flushing
1. To remove rust, sludge and other foreign
material from the cooling system, use
Premium Cooling System Flush that is safe
for use with aluminum radiators, for additional information,
Remove the thermostat prior
to pressure flushing. This
cleaning restores cooling system efficiency
and helps prevent overheating. A pulsating
or reversed direction of flushing water will
loosen sediment more quickly than a steady
flow in the normal coolant flow direction. In
severe cases where cleaning solvents will
not properly clean the cooling system for
efficient operation, it will be necessary to
use the pressure flushing method using
Cooling System Flusher. Dispose of old
coolant and flushing water contaminated
with antifreeze and cleaning chemicals in
accordance with local, state or federal laws.
2. Remove the radiator.
3. CAUTION: Radiator internal pressure

must not exceed 138 kPa. Damage
may result.
Back flush the radiator with the radiator in
an upside down position with a high-
pressure water hose in the lower hose
location and back flush.
4. Remove thermostat.
Refer to Thermostat in this Section.
5. Back flush the engine. Position the high-

pressure water hose into the engine
through the engine return and back flush
the engine.
E3373 EN 07/2001 2002 Bantam

303-03-171 Engine Cooling 303-03-171
GENERAL PROCEDURES
Cooling System Back flushing

ing system to make sure correct back
flush water flow direction through the
heater core. All engine cooling system
flushing and back flushing procedures
must include a separate back flushing
of the heater core or A/C system heater
core after the flushing or back flushing
of the engine cooling system to prevent
the engine cooling system particles
from clogging the heater core tubes and
reducing (or preventing) coolant flow
through the heater core.
1. Disconnect the heater outlet hose from the
engine intake connector and install a
garden hose (from a tap), with a male
adapter into the end of the heater outlet
hose. Secure with a hose clamp.
2. Connect a garden hose to the engine intake

connector and secure with a hose clamp.
Allow the open end to drain into a suitable
container or drain.
3. Turn the water supply tap ON and OFF

several times, so that the surge action will
minutes.
4. Remove the garden hose with the male

adapter from the heater outlet hose.
Remove the garden hose from the engine
intake connector and reconnect the heater
outlet hose onto the engine intake
connector.

a 50/50 mixture of Ford cooling system fluid
and water. For additional information,
6. Test the system for correct heater operation

within the engine cooling system conditions.
E3374 EN 07/2001 2002 Bantam

303-03-172 Engine Cooling 303-03-172
GENERAL PROCEDURES
Heater Core Back flushing

ing system for proper back flush water
flow direction through the heater core.
All engine cooling system flushing and
back flushing procedures must include
a separate back flushing of the heater or
A/C system heater core after the flush-
ing or back flushing of the engine cool-
ing system to prevent the engine cool-
ing system particles from clogging the
heater core tubes and reducing (or
eliminating) coolant flow through the
heater core.
1. Disconnect the outlet heater water hose
from the engine and install a female garden
hose and fitting adapter in the end of the
heater outlet water hose. Secure with a
hose clamp.
2. Connect the female hose end of the heater

outlet water hose to the male end of a water
supply garden hose.
3. Disconnect the heater inlet water hose from

the engine and allow it to drain into a
suitable container.
4. Turn the water supply valve ON and OFF

several times so that the surge action will
minutes.
5. Remove the hose clamp and female garden

hose end adapter from the heater outlet
water hose and reconnect the heater outlet
water hose onto the engine.
6. Connect the heater inlet water hose onto

the engine.

a 50/50 mixture of L405F antifreeze and
water.
8. Test the system for proper heater

performance with the specified engine
cooling system conditions.
E1690 EN 07/2001 2002 Bantam

303-03-173 Engine Cooling 303-03-173
SPECIFICATIONS
Item Specification
Antifreeze L405F
Premium Cooling System Flush EGR-M14P7-A
Capacities
Description Liters
Cooling system, including heater system and 5.6
coolant expansion tank (1.3L)
coolant expansion tank (1.6L)
coolant expansion tank (diesel)
Coolant
Specific gravity (pro- Approximate percent- Remains fluid to Solidifies at
viding no other addi- age of antifreeze (by
tive is in the coolant) volume)
1.061 at +15°C 30% -25°C (-13°F) -30°C (-22°F)
Pressures
Description Pressure bar
Radiator pressure test 1.38
Coolant expansion tank cap release pressure 0.89-1.28
Description Nm
Thermostat housing screws (1.6L) 10
Thermostat housing retaining bolts (1.6L) 10
Thermostat housing retaining bolts (diesel) 10
Water pump retaining bolts (1.3L and 1.6L) 10
Water pump retaining bolts (diesel) 33
Water pump pulley retaining bolts (1.3L) 11
Water pump pulley retaining bolts (1.6L) 12
Idler pulley retaining bolt (diesel) 46
Engine mounting bracket retaining bolts (diesel) 33
Cooling fan shroud retaining nuts 7
Air conditioning (A/C) condenser retaining bolts 6
Cooling fan motor retaining bolts 8
E6658 EN 07/2001 2002 Bantam

303-04B-174 Fuel Charging and Controls — 1.6L / 1.3L Engine 303-04B-174
SECTION 303-04B Fuel Charging and Controls —

1.6L / 1.3L Engine
SUBJECT PAGE

Fuel Charging and Controls................................................................................................. 303-04B-175/176

Fuel Charging and Controls................................................................................................ 303-04B- 177
Inspection and Verification............................................................................................... 303-04B- 177

Throttle Body .................................................................................................. (23 198 0) 303-04B- 178/180
Fuel Injectors.................................................................................................. (23 455 0) 303-04B-181/184
Fuel Charging Wiring Harness........................................................................ (36 437 0) 303-04B-185/187
SPECIFICATIONS
Specifications ...................................................................................................................... 303-04B-188
Torque Specifications ....................................................................................................... 303-04B-188
07/2001 2002 Bantam


Fuel Charging and Controls
Item Description Fuel Charging Wiring Harness
1 Fuel charging wiring harness The fuel charging wiring harness links the fuel
injectors to the engine management system.
2 Fuel injector
Fuel Pressure Regulator
3 Fuel pressure regulator
The fuel pressure regulator is vacuum operated
4 Throttle body with a spring loaded diaphragm. It is designed to
maintain a constant fuel pressure in the fuel
5 Fuel injection supply manifold
injection supply manifold with excess fuel being
returned to the fuel tank. Sealing is achieved by
means of two O-ring seals.
E6659 EN 07/2001 2002 Bantam

303-04B-176 Fuel Charging and Controls — 1.6L Engine 303-04B-176
Fuel Injection Supply Manifold Fuel Injectors

The fuel injection supply manifold is a one piece The fuel injectors are of the top feed type. They
plastic molding with holes for the fuel pressure are activated sequentially by the powertrain
regulator and the fuel injectors. Sealing is control module (PCM), which modifies fuelling by
achieved by means of six O-ring seals. adjusting the fuel injector opening times
according to engine operating conditions. Sealing
Throttle Body
is achieved by means of upper and lower O-ring
The throttle body is of aluminum construction with seals.
a hole for the throttle position sensor. Sealing is
achieved by means of a gasket and an O-ring
seal.
E6659 EN 07/2001 2002 Bantam


Fuel Charging and Controls
Visual Inspection Chart the symptom and refer to WDS to diagnose
Mechanical Electrical the system.
• Fuel leak(s) • Wiring harness
• Fuel pressure • Loose or corroded
regulator vacuum line electrical connector(s)
• Fuel injector(s) • Fuel injector(s)
• Fuel pressure
regulator
• Throttle body
• Fuel injection supply
manifold
E6660 EN 07/2001 2002 Bantam


Throttle Body (23 198 0)
Removal
CAUTION: Do not attempt to clean the
throttle body. The bore and throttle plate
have a special coating applied during
manufacture which should not be re-
moved.
1. Remove the accelerator cable clip.
2. Detach the accelerator outer cable.
3. Disconnect the accelerator inner cable.
E6661 EN 07/2001 2002 Bantam

4. Disconnect the air cleaner outlet pipe.
5. Remove the air cleaner outlet pipe.
6. Disconnect the throttle position (TP) sensor

7. Remove the throttle body.

• Discard the gasket.
E6661 EN 07/2001 2002 Bantam

Installation
CAUTION: Do not attempt to clean the

throttle body. The bore and throttle plate
have a special coating applied during
manufacture which should not be re-
moved.
1. NOTE: Install a new gasket.
E6661 EN 07/2001 2002 Bantam


Fuel Injectors (23 455 0)
Removal
WARNING: This procedure involves fuel

handling. Be prepared for fuel spillage
at all times and always observe fuel
handling precautions. Failure to follow
sonal injury.
WARNING: Do not smoke or carry

lighted tobacco or open flame of any
type when working on or near any fuel
related components. Highly flammable
mixtures are always present and can ig-
nite. Failure to follow these instructions
1. Release the fuel system pressure. For

3. Disconnect the engine ventilation hose.
4. Disconnect the engine ventilation hoses

and secure to one side.
E6662 EN 07/2001 2002 Bantam

5. Detach the fuel charging wiring harness.

• Remove the cable ties.
6. Disconnect the fuel injector electrical

connectors.
7. Disconnect the fuel lines. For additional

8. Detach the fuel injection supply manifold.
E6662 EN 07/2001 2002 Bantam

9. Remove the fuel injection supply manifold.

• Disconnect the fuel pressure regulator
vacuum line.
10. Remove the fuel injectors.

1. Remove the clip.
2. Remove the fuel injectors.
11. Remove and discard the O-ring seals.
Installation

sonal injury.
E6662 EN 07/2001 2002 Bantam


1. CAUTION: Do not use silicone grease

to lubricate the O-ring seals, as it will
block the fuel injectors.
NOTE: Install new O-ring seals.
NOTE: Lubricate the O-ring seals with clean
engine oil to aid installation.
NOTE: Install new cable ties.
E6662 EN 07/2001 2002 Bantam


Fuel Charging Wiring Harness (36 437 0)
Removal
1. Detach the fuel charging wiring harness
and disconnect the electrical connector.

sensor electrical connector and detach the
fuel charging wiring harness.
• Remove the cable tie.
3. Detach the fuel charging wiring harness.

• Remove the cable ties.
4. Disconnect the fuel injector electrical

connectors.
E6663 EN 07/2001 2002 Bantam

5. Disconnect the temperature and manifold

absolute pressure T-MAP) sensor electrical
connector.
6. Disconnect the idle air control (IAC) valve

7. Disconnect the throttle position (TP) sensor


(ECT) sensor electrical connector and
remove the fuel charging wiring harness.
E6663 EN 07/2001 2002 Bantam

Installation
E6663 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Throttle body retaining bolts 10
Fuel injection supply manifold retaining bolts 18
E6664 EN 07/2001 2002 Bantam

303-04D-1 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-1
SECTION 303-04D Fuel Charging and Controls —

1.8L Diesel Engine
SUBJECT PAGE
Fuel Charging and Controls ..................................................................................................... 303-04D-2

Fuel Injection Pump .............................................................................................................. 303-04D-2
Light Load Retard Device ..................................................................................................... 303-04D-2
Cold Start Advance Solenoid................................................................................................ 303-04D-2
Fuel Injectors......................................................................................................................... 303-04D-2
Glow Plugs ............................................................................................................................ 303-04D-2
Waxstat.................................................................................................................................. 303-04D-2
Idle Speed Control Motor ...................................................................................................... 303-04D-2/3
09/2001 2002 Bantam

DESCRIPTION AND OPERATION engine speed is just above idle to improve

Fuel Charging and Controls drivability take off.
The diesel injection equipment fitted to the 1,8 Fuel Injectors

litre naturally aspirated Endura -DE diesel engine
The engine is equipped with four Bosch fuel
comprises a fuel injection pump, four fuel
injectors, which have throttling pintle nozzles.
injectors and four glow plugs. The glow plugs and
The fuel injectors are screwed into the cylinder
certain fuel injection pump components are
head and sealed by means of copper sealing
controlled by the powertrain control module
washers.
(EEC V).
Fuel Injection Pump Glow Plugs

The engine is equipped with a Bosch VE The engine is equipped with four glow plugs,
distributor type fuel injection pump, which is which are screwed into the cylinder head below
driven by the crankshaft via a toothed rubber the fuel injectors. The glow plugs improve
drive belt. The fuel injection pump is retained to starting, especially from cold.
the engine by three bolts at the front and a The glow plugs and the glow plug indicator lamp
support bracket at the rear (two bolts). Setting the are controlled by the powertrain control module.
injection timing is achieved using the familiar peg When the ignition is switched on, the glow plugs
timing method. are switched on and the glow plug indicator lamp
The fuel injection pump is fitted with a light load is illuminated for between 1 and 10 seconds
retard device and a cold start advance solenoid, dependent on engine coolant temperature.
both of which change the natural injection timing (1 second at 80 ° C and 10 seconds at -30 ° C).
characteristics dependent on engine operating The glow plugs remain on for a period of 3
conditions. seconds after the glow plug indicator lamp has
been extinguished. However, if the engine is
started during this 3-second period, the glow
Light Load Retard Device plugs will remain on for a further 0 to 40 seconds
The light load retard device is a dependent on engine coolant temperature.
mechanical/hydraulic device incorporating a (0 seconds at 80 ° C and 40 seconds at -40 ° C.
solenoid, which is controlled by the powertrain
control module. Under normal operating
conditions, and for engine loads up to Waxstat
approximately 80% full load, the device retards A waxstat system is fitted to all vehicles, except
the injection timing by approximately 3 °. Where those with air conditioning. The waxstat system
engine load is above 80% of full load, engine comprises a wax element, which is located inside
coolant temperature is below 50 ° C or engine the thermostat housing and a control cable,
speed is above 3500 rev/min, the powertrain which extends from the wax element and
control module energizes the solenoid which connects to the idle lever on the fuel injection
inhibits the operation of the light load retard pump.
device, thus advancing the injection timing.
When the engine is cold, the cable pulls the idle
lever to the high idle position. When the engine is
Cold Start Advance Solenoid warm, the cable is released allowing the idle
lever to return to the normal idle position.
The cold start advance solenoid is controlled by
the powertrain control module. When engine
coolant temperature is below 50 ° C, the Idle Speed Control Motor
powertrain control module energizes the
solenoid, which advances the injection timing An idle speed control motor is fitted to all vehicles
throughout the engine speed/load range. The with air conditioning. The idle speed control
amount of time, which the solenoid is, energized motor system comprises an idle speed control
decreases as engine coolant temperature
increases. The solenoid is also energized when
engine coolant temperature is below 0 ° C and
E6443 EN 09/2001 2002 Bantam


motor, which is located under the battery tray and
a control cable, which extends from the idle
speed control motor and connects to the idle
lever on the fuel injection pump.
Engine idle speed is controlled by the powertrain
control module, which alters the position of the
motor, and therefore, the position of the idle
lever. To prevent excess slack in the control
cable, the idle speed control motor is fitted with
an idle tracking switch, which prevents further
movement of the motor once the tension on the
control cable is released.
In addition to giving an increased engine idle
speed when the engine is cold, the idle speed
control motor system provides accurate idle
speed control when the engine is warm,
increased idle speed when air conditioning is on
and/or a low battery voltage condition exists and
dashpot engine speed deceleration control.
E6443 EN 09/2001 2002 Bantam


1.8L Diesel Engine
SUBJECT PAGE
GENERAL PROCEDURES
Idle Speed Adjustment (Vehicles Without Air Conditioning) ............................. (23 413 0) 303-04D-5
Idle Speed Adjustment (Vehicles With Air Conditioning) .................................. (23 413 0) 303-04D-6/7
09/2001 2002 Bantam

GENERAL PROCEDURES
Idle Speed Adjustment (23 413 0) (Vehicles Without Air Conditioning)
NOTE: This adjustment must be carried out with

the engine at normal operating temperature.
1. Connect a tachometer to the engine in
accordance with the manufacturer's
instructions.
2. Start the engine and allow it to idle.
3. Loosen the idle speed adjustment screw

lock nut.
4. Adjust the idle speed screw as necessary

(refer to Specifications contained in this section).
5. Tighten the idle speed adjustment screw lock

nut.
6. Check to ensure the idle speed is still within

specification.
7. Momenentarily move the idle lever away from

the stop.

specification.
9. Switch the engine off.
10. Disconnect the tachometer from the engine.
E6450 EN 09/2001 2002 Bantam

GENERAL PROCEDURES
Idle Speed Adjustment — (Vehicles with Air Conditioning) (23 413 0)

the engine at normal operating temperature.
accordance with the manufacturer's
instructions.
2. Remove the idle speed control cable

retaining clip.
4. Loosen the idle speed adjustment screw

lock nut.
5. Adjust the minimum engine speed as

necessary
(refer to Specifications contained in this section).
6. Tighten the idle speed adjustment screw lock

nut.
7. Check to ensure the minimum engine speed

is still within specification.
8. Momenentarily move the idle lever away

from the stop.

specification.
10. Adjust the idle speed control cable

(refer to operation in this section).
E6451 EN 09/2001 2002 Bantam


11. Refit the idle speed control cable retaining
clip.
12. Disconnect the tachometer from the engine.
E6451 EN 09/2001 2002 Bantam


1.8L Diesel Engine
SUBJECT PAGE
Fuel Injection Pump (Removal) ......................................................................... (23 414 0) 303-04D-9/17
Fuel Injection Pump (Install) .............................................................................. (23 414 0) 303-04D-18/22
09/2001 2002 Bantam


Fuel Injection Pump (23 414 0)
Timing Peg, Crankshaft TDC Adapter for 303-290
303-193 (21-104) 303-290-03 (21-140-03)
Support Bar, Engine Timing Peg, Fuel Injection

303-290 (21-140) Pump Timing
310-018 (23-019)
Adapter for 303-290 Timing Peg, Fuel Injection

303-290-01 (21-140-01) Pump Timing
310-033 (23-029)
Adapter for 303-290

303-290-02 (21-140-02)
Removal
All vehicles
WARNING: This procedure in-

volves fuel handling. Be prepared for
fuel spillage at all times and always ob-
serve fuel handling precautions.
CAUTION: Diesel fuel injection

equipment is manufactured to very pre-
cise tolerances and fine clearances. It is
therefore essential that absolute
cleanliness be observed when working
with these components. Always fit
blanking plugs to any open orifices or
pipes.
E6448 EN 09/2001 2002 Bantam


2. Install the special tools.
3. Remove the engine front mounting auxiliary

bracket.

6. Loosen the crankshaft pulley/vibration

damper retaining bolts.
7. Remove the generator. For additional

E6448 EN 09/2001 2002 Bantam


damper.
9. Remove the timing belt lower cover

retaining bolts.

Vehicles with power steering
11. Loosen the power steering pump pulley
retaining bolts.
12. De-tension the accessory drive belt.

1. Loosen the Allen bolt.
2. De-tension the belt.
E6448 EN 09/2001 2002 Bantam


14. Remove the power steering pump pulley.
All vehicles
15. Remove the timing belt cover.
16. Turn the engine clockwise until the slot in

the fuel injection pump pulley reaches the
11 o'clock position.

18. Remove the blanking plug from the cylinder

block. (Generator bracket shown removed
for clarity).
E6448 EN 09/2001 2002 Bantam


19. Install the special tool to the cylinder block.
CAUTION: When turning the
engine to lock the crankshaft, do so slowly
to avoid bending the special tool.
Turn the engine clockwise until the
crankshaft locks against the special tool.
20. Install the special tool, to lock the camshaft.
21. Install the special tool, to lock the fuel

injection pump.
22. Remove and discard the timing belt. For

refer to Section 303-01C.
23. Remove the accelerator cable adjuster clip.
E6448 EN 09/2001 2002 Bantam


24. Detach the accelerator cable from the
retaining bracket.

fuel injection pump fuel lever.
Vehicles without air conditioning

26. Remove the waxstat cable retaining clip.
27. Disconnect the waxstat cable from the fuel

injection pump idle lever.

28. Remove the idle speed compensation cable
retaining clip.
E6448 EN 09/2001 2002 Bantam


29. Disconnect the idle speed compensation
cable from the fuel injection pump idle
lever.
All vehicles
30. Detach the fuel injection pump wiring from
the retaining clip and disconnect the
31. Disconnect the fuel return line from the fuel

injection pump.
32. Disconnect the fuel supply and return lines

from the fuel injection pump.
33. Remove the fuel injector delivery pipes.

refer to Fuel Injector Delivery Pipes
in this section
E6448 EN 09/2001 2002 Bantam


34. Loosen the fuel injection pump drive belt
tensioner bolt.
35. De-tension the fuel injection pump drive

belt.
36. Tighten the fuel injection pump drive belt

tensioner bolt.
37. Loosen the fuel injection pump pulley

retaining bolts.
38. Remove the fuel injection pump drive belt.

• Discard the fuel injection pump drive
belt.
E6448 EN 09/2001 2002 Bantam


39. Remove the special tool from the fuel
injection pump.
40. Remove the fuel injection pump pulley.

42. Remove the three bolts which retain the

fuel injection pump rear support bracket to
the cylinder block.
44. CAUTION: Before removing

the three bolts which retain the fuel
injection pump to the front cover, make
sure that the fuel injection pump is
adequately supported.
Remove the fuel injection pump.
45. Remove the fuel injection pump from the

rear support bracket.
E6448 EN 09/2001 2002 Bantam

Installation
All vehicles
volves fuel handling. Be prepared for fuel
spillage at all times and always observe
fuel handling precautions.

equipment is manufactured to very precise
tolerances and fine clearances. It is there-
fore essential that absolute cleanliness be
observed when working with these compo-
nents. Always fit blanking plugs to any
open orifices or pipes.
1. Install the fuel injection pump rear support
bracket.
• Do not tighten the bolts at this stage.
2. Install the fuel injection pump.

4. Install the three bolts which retain the fuel

injection pump rear support bracket to the
cylinder block.
E6448 EN 09/2001 2002 Bantam


6. Tighten the rear support bracket bolts.
7. Install the fuel injection pump pulley.

• Do not tighten the bolts at this stage.
8. Install the special tool to lock the fuel

injection pump.
9. Install a new fuel injection pump drive belt.
10. Loosen the bolt and allow the tensioner to

tension the fuel injection pump drive belt.
E6448 EN 09/2001 2002 Bantam


11. Tighten the fuel injection pump drive belt
tensioner bolt.
12. Tighten the fuel injection pump pulley

retaining bolts.
• Make sure that the elongated holes in
the fuel injection pump pulley are
centralized with the retaining bolts.
13. Install a new timing belt. For additional

information, refer to Section 301-01C.
14. Remove the special tool from the fuel

injection pump.
15. Remove the special tool from the camshaft.

E6448 EN 09/2001 2002 Bantam


17. Remove the special tool from the cylinder
block.
19. Turn the engine clockwise two full turns

until the slot in the fuel injection pump
pulley reaches the 11 o'clock position.

21. Install the special tool to the cylinder block.

CAUTION: When turning the
engine to lock the crankshaft, do so slowly
to avoid bending the special tool.
Turn the engine clockwise until the
crankshaft locks against the special tool.
22. Remove the special tool from the cylinder

block.
23. Install the remainder of the components in

reverse order.
E6448 EN 09/2001 2002 Bantam

26. Adjust the accelerator cable. For

27. Check the engine idle speed and adjust as

refer to Idle Speed Adjustment
in this section
Vehicles without air conditioning
28. Remove the waxstat cable retaining clip.
29. NOTE: This adjustment must be carried out

with the engine cold.
Hold the fuel injection pump idle lever
against its stop and install the retaining clip,
so that there is between 1 mm and 2 mm of
slack in the waxstat cable.
30. Adjust the idle speed compensation cable
(refer to WDS).
E6448 EN 09/2001 2002 Bantam


1.8L Diesel Engine
SUBJECT PAGE
Fuel Injectors ..................................................................................................... (23 455 0) 303-04D-24/25
E6445 EN 09/2001 2002 Bantam


Fuel Injectors
Special Tool(s)
Socket SW 27, injectors
23 - 034

observed when working with these com-
ponents. Always fit blanking plugs to any
Removal
2. Remove the fuel injector delivery pipes

3. NOTE: It is normal for the fuel injectors to be

very stiff in the threads and considerable
effort may be required to remove them.
Remove the fuel injectors.
Installation
• Install new fuel injector copper sealing
washers.
E6445 EN 09/2001 2002 Bantam

E6445 EN 09/2001 2002 Bantam


1.8L Diesel Engine
SUBJECT PAGE
Fuel Injector Delivery Pipes (Removal) .................................................................................. 303-04D-27/28
Fuel Injector Delivery Pipes (Install) ....................................................................................... 303-04D-28/29
E6446 EN 09/2001 2002 Bantam


Fuel Injection Delivery Pipes
observed when working with these com-
ponents. Always fit blanking plugs to any
Removal
2. Remove the four fuel injector leak-off pipes.
3. Detach the fuel supply pipe from the two

retaining clips.
4. Unscrew the four fuel injector delivery pipe

unions from the fuel injection pump.
E6446 EN 09/2001 2002 Bantam

5. Unscrew the four unions from the fuel

injectors and remove the fuel injector
delivery pipes.
Installation
1. Refit the fuel injector delivery pipes and
loosely assemble the four unions to the fuel
injectors.
2. Loosely assemble the four unions to the

fuel injection pump.
3. Tighten the four fuel injector delivery pipe

unions to the fuel injectors.
E6446 EN 09/2001 2002 Bantam

4. Tighten the four fuel injector delivery pipe

unions to the fuel injection pump.
5. Refit the remaining components in reverse

order.
E6446 EN 09/2001 2002 Bantam


1.8L Diesel Engine
SUBJECT PAGE
GENERAL PROCEDURES
Waxstat Cable (Adjustment)................................................................................................... 303-04D-31
Cable Idle Speed Control (Adjustment)................................................................................... 303-04D-32
09/2001 2002 Bantam

GENERAL PROCEDURES
Waxstat Cable Adjustment

the engine cold.
1. Remove the waxstat cable adjuster clip.
2. Hold the idle lever against its stop and refit

the adjuster clip so that there is between 1
and 2 mm of slack in the waxstat cable.
E6449 EN 09/2001 2002 Bantam


Cable - Idle Speed Control - (Adjust)
Equipment
WDS
NOTE: The idle speed control cable can only be

adjusted with the aid of the WDS.
Adjust
1. Connect the WDS to the vehicle data link

connector and select Idle Cable Adjust
option from the Toolbox menu.
2. Remove the idle speed control cable
retaining clip.
3. Using WDS, extend the idle speed control
motor plunger, by using the plus (+) icon.
Note: When adjusting the idle speed control

cable, the practice of pushing rather than pulling
must be used to prevent stretching of the outer
cable.
4. Push the outer section of the idle speed
control cable away from the idle lever until
the idle lever is pulled against the high
idle screw and refit the retaining clip.
5. Exit the Idle Cable Adjust screen and
disconnect the WDS from the vehicle data
link connector.
accordance with the manufactures
instructions.
8. Move the main fuel lever so that the
engine speed rises above 1400 rev/min
and ensure that the idle speed control
cable pulls the idle lever against the high
idle screw and then backs off slightly. If
this does not occur, carry out the idle
speed control adjustment again.
9. Switch the engine off.
10. Disconnect the tachometer from the
engine.
E6449 EN 09/2001 2002 Bantam

SPECIFICATIONS

1.8L Diesel Engine
SUBJECT PAGE
SPECIFICATIONS

Fuel Injection Pump .............................................................................................................. 303-04D-34
Fuel Injectors......................................................................................................................... 303-04D-34
Glow Plugs ............................................................................................................................ 303-04D-34
E6452 EN 09/2001 2002 Bantam

Fuel Injection Pump
Specification
Manufacturer Bosch
Type Distributor
Governor type Two speed
Maximum no load speed (rev/min) 5350 ± 50
Idle speed (vehicles without air conditioning) (rev/min) 920 ± 50
Idle speed (vehicles with air conditioning) (rev/min) 950 ± 10
Minimum engine speed (vehicles with air conditioning) (rev/min) 905 ± 35
Deceleration time (seconds) 5 (max)
Fuel Injectors
Specification
Manufacturer Bosch
Type Pintle
Nozzle opening pressure (bar) 158 - 165
Back leakage (bar) (maximum of 5 seconds allowed for the pressure to fall 125 - 100
from the upper to the lower value quoted)
Needle seat leakage (bar) (hold for 10 seconds) 125
Glow Plugs
Specification
Type EZD 8
Description Nm
Endura DE Diesel Engine Crankshaft 35
pulley/vibration damper retaining bolts
Endura DE Diesel Engine mounting bracket 50
retaining bolts
retaining nut (center)
retaining nuts (outer)
Endura DE Diesel Engine Fuel injection pump 45
drive belt tensioner retaining bolt
drive gear retaining bolts
Endura DE Diesel Engine Fuel injection pump rear 20
support bracket retaining bolts
E6452 EN 09/2001 2002 Bantam

Description Nm
retaining bolts
Endura DE Diesel Engine Fuel injector delivery 20
pipe unions
Endura DE Diesel Engine Fuel injectors 75
Endura DE Diesel Engine Glow plugs 28
TDC timing peg blanking plug 24
Air conditioning compressor retaining bolts 25
E6452 EN 09/2001 2002 Bantam

303-05-189 Accessory Drive 303-05-189
SECTION 303-05 Accessory Drive

SUBJECT PAGE

Accessory Drive - Vehicles with 1.6L / 1.3L engine ..............................................................303-05-190/191
Accessory Drive - Vehicles with Diesel engine.....................................................................303-05-191

Accessory Drive................................................................................................................... 303-05-192
Inspection and Verification ................................................................................................ 303-05-192/193
Symptom Chart ................................................................................................................. 303-05-193/194
Component Tests.............................................................................................................. 303-05-194/195

Accessory Drive Belt Tensioner — Vehicles with 1.6L / 1.3L Engine ................................... 303-05-196/198
Accessory Drive Belt Tensioner — Vehicles with Diesel Engine .......................................... 303-05-199
Accessory Drive Belt - Vehicles with Diesel engine and Air Conditioning……………………. 303-05-200
SPECIFICATIONS
Specifications....................................................................................................................... 303-05-201
07/2001 2002 Bantam

303-05-190 Accessory Drive 303-05-190

Accessory Drive
Vehicles with 1.6L / 1.3L Engine

1 Accessory drive belt 5 Air conditioning (A/C) compressor pul-
ley
2 Power steering pump pulley or idler
pulley (vehicles without power steering) 6 Crankshaft pulley
3 Generator pulley 7 Belt tensioner pulley
4 Idler pulley 8 Water pump pulley
E6668 EN 07/2001 2002 Bantam

303-05-191 Accessory Drive 303-05-191

Accessory Drive Belt
The accessory drive belt is a multigroove belt. aluminum die cast bracket. This bracket also
Idler Pulley(s)
serves as a mounting for the generator and
power steering pump. The belt tensioner is
The idler pulley(s) is of the roller bearing type. calibrated to provide the correct amount of
Belt Tensioner tension to the drive belt for a given accessory
drive system.
The belt tensioner is of the automatic type and is
supplied, as an assembly together with an
Vehicles with Diesel Engine

1 Crankshaft pulley 9 Air conditioning (A/C) compressor pul-
ley
2 Accessory drive belt
3 Generator pulley Accessory Drive Belts
4 Power steering pump pulley The accessory drive belts are mutligroove belts.
Belt Tensioner's
5 Belt tensioner pulley
The belt tensioner's are of the manual type. To
6 Fuel injection pump pulley
increase the belt tension, rotate the adjustment
7 Power steering pump belt bolt counterclockwise and to decrease the belt
tension, rotate the adjustment bolt clockwise.
8 Belt tensioner pulley
E6668 EN 07/2001 2002 Bantam

303-05-192 Accessory Drive 303-05-192

Accessory Drive
1. Verify the customer concern.
mechanical damage.
Visual Inspection Chart
Mechanical
• Cracked, damaged or contaminated accessor y
drive belt
• Belt tension
• Belt tensioner
• Idler pulley(s)
• Pulley(s)
• Loose hardware
step.
CAUTION: Do not lubricate the belt, belt

tensioner or idler pulley(s) as potential
damage to the belt material construction;
belt tensioner damping mechanism, belt
tensioner pulley bearing and idler
pulley(s) bearing may occur.
4. The condition of the belt should be compared
NOTE: Up to 15 cracks in a belt rib over a against the illustration and appropriate action
distance of 100 mm may be considered taken.
acceptable. If the cracks exceed the acceptable Small scattered deposits of rubber debris is not a
limit or any chunks are found to be missing, concern and therefore a new belt should not be
install a new belt. installed.
Longer deposits of rubber debris building up to
50% of the belt rib height is not a concern but
may result in excessive noise. If excessive noise
is apparent, install a new belt.
Heavy deposits of rubber debris building up along
the grooves is a concern and may result in
excessive noise and a belt stability concern. If
heavy deposits or excessive belt noise are
apparent, install a new accessory drive belt.
E6727 EN 07/2001 2002 Bantam

303-05-193 Accessory Drive 303-05-193
5. Check the belt for cracks. If the damage 6. Check the belt for damage. If any chunks are
exceeds the acceptable limit, install a new found to be missing, install a new accessory
accessory drive belt. drive belt.
Symptom Chart
• Belt noise or squeal • Accessory drive components • CHECK the system with the en-
worn or damaged. gine running and the belt re-
moved (only run the engine for a
very short period). If a noise is
apparent, the cause is not the
accessory drive system. If a
noise is not apparent, the cause
is the accessory drive system so
determine where the noise is
coming from and REPAIR or
INSTALL new components as
necessary.
• Accessory drive components • CHECK the accessory drive
incorrectly installed. components are correctly in-
stalled. REPAIR as necessary.
• Belt incorrectly installed. • CHECK the belt is correctly in-
stalled in the pulley grooves.
REPAIR or INSTALL a new ac-
cessory drive belt as necessary.
• Pulley(s). • DETERMINE where the noise is
coming from. CHECK the pul-
ley(s) for damage, freedom of
rotation or alignment. REPAIR
or INSTALL new components as
necessary.
E6727 EN 07/2001 2002 Bantam

303-05-194 Accessory Drive 303-05-194

• Lubricant or other contamina- • CHECK the drive belt for
tion. contamination or damage.
REMOVE the drive belt and
wash with detergent and water.
If the drive belt will not clean or
is damaged, INSTALL a new
drive belt.
• Belt. • CHECK the drive belt for correct
application.
• Idler pulley(s). • CHECK the pulley(s) for dam-
age, freedom of rotation or
alignment. REPAIR or INSTALL
new components as necessary.
• Belt cracking • Belt. • INSPECT the belt for cracks or
damage. If the cracks are within
the acceptable limit, the belt is
OK. If the cracks exceed the ac-
ceptable limit, INSTALL a new
accessory drive belt.
• Belt chunking • Belt. • INSTALL a new accessory drive
belt.
• Belt does not hold tension • Belt cracked or damaged. • INSPECT the belt for cracks or
damage. If the cracks are within
the acceptable limit, the belt is
OK. If the cracks exceed the ac-
ceptable limit, INSTALL a new
accessory drive belt.
• Belt tensioner worn or damaged. • CHECK the belt tensioner for
correct operation or damage.
INSTALL a new belt tensioner
as necessary.
Component Tests
Manual Belt Tensioner and Idler Pulley(s) Automatic Tensioner - Static Check
The manual belt tensioner and idler pulley(s) may The automatic tensioner may be checked
be checked as follows: statically as follows:
1. Detach the accessory drive belt in the area of 1. Detach the drive belt in the area of the
the belt tensioner or idler pulley(s). tensioner.
2. Rotate the belt tensioner pulley or idler 2. Using the correct tool, move the tensioner
pulley(s) and check for damage, freedom of from its relaxed position through its full stroke
rotation or alignment. Install a new belt and back to the relaxed position to make
tensioner or idler pulley(s) as necessary. sure there is no stick, grab or bind, and to
3. Inspect the area surrounding the belt make sure there is tension on the tensioner
tensioner or idler pulley(s) for lubricant or spring.
other contamination. Rectify any leaks before
installing a new belt tensioner or idler
pulley(s). If the belt tensioner pulley or idler
pulley(s) is contaminated, do not attempt to
clean it as the bearing inside may be
damaged. Install a new belt tensioner or idler
pulley(s) as necessary.
E6727 EN 07/2001 2002 Bantam

303-05-195 Accessory Drive 303-05-195

3. Rotate the tensioner pulley and check for Automatic Tensioner - Dynamic Check
damage, freedom of rotation or alignment.
The automatic tensioner may be checked
Install a new tensioner as necessary.
dynamically as follows:
4. Inspect the area surrounding the tensioner
for lubricant or other contamination. Rectify 1. With the engine running, observe the
any leaks before installing a new tensioner. If tensioner movement. The tensioner should
the tensioner is contaminated, do not attempt move (respond) when the engine is
to clean it as the damping mechanism inside accelerated rapidly or when the air
may be damaged. Install a new tensioner as conditioning (A/C) clutch cycles. If the
necessary. tensioner movement is not constant without
engine acceleration or A/C clutch cycling, a
5. If the tensioner meets the above criteria
pulley or shaft is possibly bent, out of round,
proceed to test the tensioner dynamically. If
or the damping mechanism inside the
the tensioner does not meet the above
tensioner may be damaged. Excessive drive
criteria install a new tensioner.
belt ride out (uneven depth of grooves in the
drive belt) may cause excessive tensioner
movement. Check the condition by installing
a new accessory drive belt.
E6727 EN 07/2001 2002 Bantam

303-05-196 Accessory Drive 303-05-196

Accessory Drive Belt Tensioner — Vehicles with 1.6L / 1.3L Engine
Removal
All vehicles
1. Remove the generator. For additional
3. Remove the accessory drive belt tensioner

pulley.

4. Detach the power steering pump and
secure it to one side.
Vehicles without power steering

5. Remove the accessory drive belt upper
idler pulley.
E5903 EN 07/2001 2002 Bantam

303-05-197 Accessory Drive 303-05-197
All vehicles
6. Remove the accessory drive belt lower idler
pulley.
7. Remove the accessory drive belt tensioner

and bracket assembly.
Installation
All vehicles
E5903 EN 07/2001 2002 Bantam

303-05-198 Accessory Drive 303-05-198
Vehicles without power steering
All vehicles
E5903 EN 07/2001 2002 Bantam

303-05-199 Accessory Drive 303-05-199

Accessory Drive Belt — Vehicles with 1.8L Endura DE Diesel Engine (31 413 0)
Removal

1. Loosen the adjuster clamping bolt.
2. De-tension the belt by turning the
adjuster bolt anticlockwise.
Installation
1. Refit the drive belt.
• Make sure the drive belt is correctly
located on all pulleys.
2. Tension the drive belt.

1. Turn the adjuster bolt clockwise to
achieve the correct tension.
2. Tighten the clamping bolt.
3. Reconnect the battery ground cable.
E5903 EN 07/2001 2002 Bantam

303-05-200 Accessory Drive 303-05-200

Accessory Drive Belt — Vehicles with 1.8L Endura DE Diesel Engine and Air
Conditioning (31 413 0)
Removal

1. Loosen the adjuster clamping bolt.
2. De-tension the belt by turning the
adjuster bolt anticlockwise.
Installation
1. Refit the drive belt.
• Make sure the drive belt is correctly
located on all pulleys.
2. Tension the drive belt.

1. Turn the adjuster bolt clockwise to
achieve the correct tension.
2. Tighten the clamping bolt.
3. Reconnect the battery ground cable.
E5904 EN 07/2001 2002 Bantam

303-05-201 Accessory Drive 303-05-201
SPECIFICATIONS
Description Nm
Accessory drive belt tensioner and bracket as- 48
sembly retaining bolts (1.6L / 1.3L)
Accessory drive belt tensioner and bracket as- 48
sembly screw (1.6L / 1.3L)
Accessory drive belt lower idler pulley retaining 48
bolt (1.6L / 1.3L)
Accessory drive belt upper idler pulley retaining 25
bolts (1.6L / 1.3L)
Power steering pump retaining bolts (1.6L / 1.3L) 25
Accessory drive belt tensioner pulley retaining bolt 48
(1.6L / 1.3L)
Accessory drive belt tensioner retaining bolts (die- 25
sel)
Accessory drive belt tensioner pulley retaining nut 35
(diesel)
Power steering pump belt tensioner pulley retain- 35
ing nut (diesel)
Power steering pump belt cover retaining bolts 25
(diesel)
E6675 EN 07/2001 2002 Bantam

303-06-202 Starting System 303-06-202
SECTION 303-06 Starting System

SUBJECT PAGE

Starting System ................................................................................................................... 303-06-203

Starting System ................................................................................................................... 303-06-204A
Inspection and Verification................................................................................................ 303-06-204A
Symptom Chart................................................................................................................. 303-06-204A
Pinpoint Tests ................................................................................................................... 303-06-204B/212

Starter Motor — Vehicles with 1.6L / 1.3L Engine........................................... (26 204 0) 303-06-213/214
Starter Motor — Vehicles with Diesel Engine......................................................................... 303-06-215/216
SPECIFICATIONS
Specifications ...................................................................................................................... 303-06-217
Torque Specifications ....................................................................................................... 303-06-217
07/2001 2002 Bantam

303-06-203 Starting System 303-06-203

Starting System
Pre-engaged starter motors of Bosch or Magnetti The ring gear is located on the outside of the
Morelli manufacture are used. flywheel.
Irrespective of model, all starter motors have an Some starter motors are interchangeable in
integral solenoid and all types have pinions, certain circumstances;
which engage with a ring gear during starting. refer to the Parts Microfiche for detailed information.
Starter motors should be serviced as an assembly
and should not, therefore, be dismantled.
E5908 EN 07/2001 2002 Bantam

303-06-204A Starting System 303-06-204A

Starting System
Inspection and Verification Visual Inspection Chart
WARNING: When performing engine Mechanical Electrical

compartment work near the starter, be • Starter motor • Fuse
aware that the heavy gauge battery input • Battery • Wiring
lead to the starter is electrically hot at all • Connectors
times.
1. Verify the customer concern. 3. If inspection reveals an obvious cause rectify
2. Check for concerns with the following. this before continuing. If the concern
remains, proceed to the symptom chart.
Symptom Chart
• The engine does not crank relay • Battery • GO to Pinpoint Test A
clicks • Circuits
• Starter motor
• The engine cranks slowly • Battery • GO to Pinpoint Test B
• Circuits
• Starter motor
• Unusual starter noise • Starter motor • GO to Pinpoint Test C
• Ring gear
• Starter motor spins but engine • Solenoid • GO to Pinpoint Test D
does not crank
E1017 EN 07/2001 2002 Bantam

Pinpoint Tests
A1: CHECK THE BATTERY CONNECTIONS...................................................... 303-06-204B
A2: CHECK THE BATTERY VOLTAGE............................................................... 303-06-205
A3: CHECK SWITCHED POWER SUPPLY TO THE SOLENOID........................ 303-06-205
A4: CHECK B+ TO THE STARTER ..................................................................... 303-06-205/206
A5: CHECK THE STARTER GROUND CIRCUIT................................................. 303-06-206
A6: CHECK B+ TO STARTER RELAY................................................................. 303-06-206
A7: CHECK RELAY GROUND CIRCUIT.............................................................. 303-06-207
A8: CHECK RELAY SWITCHING CIRCUIT......................................................... 303-06-207
A9: CHECK FUSE 40 (60A) ................................................................................. 303-06-207
A10: CHECK CIRCUIT 30 (RD) CONTINUITY ..................................................... 303-06-208
A11: CHECK THE IGNITION SWITCH ................................................................ 303-06-208
A12: CHECK CIRCUIT 50 (GY) CONTINUITY ..................................................... 303-06-208/209
A13: CHECK THE CONTINUITY OF CIRCUIT 50 (GY/BK) ................................. 303-06-209
A14: CHECK CIRCUIT 50 (GY/BK) FOR SHORT TO GROUND.......................... 303-06-209
A15: CHECK CIRCUIT 30 (RD) FOR SHORT TO GROUND ............................... 303-06-210
A16: CHECK CIRCUIT 50 FOR SHORT TO GROUND........................................ 303-06-210
B1: CHECK THE BATTERY VOLTAGE............................................................... 303-06-211
B2: CHECK THE SUPPLY TO STARTER............................................................ 303-06-211
B3: CHECK THE STARTER GROUND CIRCUIT................................................. 303-06-211
C1: CHECK THE STARTER MOUNTING ............................................................ 303-06-212
C2: CHECK THE STARTER DRIVE .................................................................... 303-06-212
303-06-204B Starting System 303-06-204B
Pinpoint Tests
A1: CHECK THE BATTERY CONNECTIONS
1 Inspect the battery connections for
loose/corroded connections.
• Are the battery terminals clean and tight?
Yes
GO TO A2
No
CLEAN and TIGHTEN connections as re-
quired. TEST the system for normal opera-
tion.
E1017 EN 07/2001 2002 Bantam

303-06-205 Starting System 303-06-205
A2: CHECK THE BATTERY VOLTAGE
1 Check the battery. Refer to Section 414-00.
• Is the battery OK?
Yes
GO TO A3
No
quired. Refer to Section 414-00. TEST the
A3: CHECK SWITCHED POWER SUPPLY TO THE SOLENOID
1. 2.
Solenoid single
pin
solenoid connector single pin, circuit 50
(GY/BK) and ground when the starter is
operated.
Yes
GO TO A4
No
GO TO A6
A4: CHECK B+ TO THE STARTER

1.
E1017 EN 07/2001 2002 Bantam

303-06-206 Starting System 303-06-206

Yes
GO TO A5
No
A5: CHECK THE STARTER GROUND CIRCUIT

Yes
No
A6: CHECK B+ TO STARTER RELAY

1.
Starter relay
Yes
GO TO A7
No
E1017 EN 07/2001 2002 Bantam

303-06-207 Starting System 303-06-207
A7: CHECK RELAY GROUND CIRCUIT
relay connector pin 1, circuit 31 (BK) and
ground.
Yes
GO TO A8
No
A8: CHECK RELAY SWITCHING CIRCUIT

1.

connector pin 2, circuit 50 (GY) and ground.
Yes
GO TO A13
No
GO TO A9

1.
• Is the fuse OK?
Yes
GO TO A10
No
system for normal operation. If fuse fails
again GO TO A15
Fuse 40 (60A)
E1017 EN 07/2001 2002 Bantam

303-06-208 Starting System 303-06-208

A10: CHECK CIRCUIT 30 (RD) CONTINUITY
1.
Ignition switch
2 Remove the fuse 40 (60A).
connector pin 1, circuit 30 (RD) and ignition
switch connector pin 4, circuit 30 (RD).
Yes
GO TO A11
No

1.
2 Measure the resistance between pin 4 and pin

3 of the ignition switch connector.
Yes
GO TO A12
No
A12: CHECK CIRCUIT 50 (GY) CONTINUITY

1.
E1017 EN 07/2001 2002 Bantam

303-06-209 Starting System 303-06-209
switch connector pin 3, circuit 50 (GY) and the
starter relay connector pin 2, circuit 50 (GY).
Yes
RECONNECT the ignition switch.
GO TO A8
No
A13: CHECK THE CONTINUITY OF CIRCUIT 50 (GY/BK)

motor solenoid connector, circuit 50 (GY/BK)
and starter relay connector pin 3, circuit 50
(GY/BK).
Yes
GO TO A14
No
A14: CHECK CIRCUIT 50 (GY/BK) FOR SHORT TO GROUND

relay connector pin 3, circuit 50 (GY/BK) and
ground.
Yes
INSTALL a new starter relay. TEST the
No
E1017 EN 07/2001 2002 Bantam

303-06-210 Starting System 303-06-210
1 Remove fuse 36 (60A).
2 Measure the resistance between fuse 36
Yes
GO TO A16
No
A16: CHECK CIRCUIT 50 FOR SHORT TO GROUND

1.
Ignition switch
switch connector pin 3, circuit 50 (GY) and
ground.
Yes
CONNECT the ignition switch. GO TO A8
No
E1017 EN 07/2001 2002 Bantam

303-06-211 Starting System 303-06-211

B1: CHECK THE BATTERY VOLTAGE
1 Measure the voltage between the battery
terminals.
Yes
GO TO B2
No
quired. REFER to Section 414-00. TEST
B2: CHECK THE SUPPLY TO STARTER

1.
2 Measure the voltage between the starter

Yes
GO TO B3
No
B3: CHECK THE STARTER GROUND CIRCUIT

Yes
No
E1017 EN 07/2001 2002 Bantam

303-06-212 Starting System 303-06-212

C1: CHECK THE STARTER MOUNTING
1 Check the starter and mounting brackets for
correct alignment.
• Is the starter mounted correctly?
Yes
GO TO C2
No
INSTALL the starter motor.
C2: CHECK THE STARTER DRIVE
1 Remove the starter motor.
2 Inspect the ring gear for damage and wear.
• Is the ring gear damaged?
Yes
REPAIR ring gear as required. TEST the
No
E1017 EN 07/2001 2002 Bantam

303-06-213 Starting System 303-06-213

Starter Motor — Vehicles with 1.6L / 1.3L Engine (26 204 0)
Removal

3. Disconnect the electrical connector from the

starter motor.
4. Remove the starter motor.
Installation
E5909 EN 07/2001 2002 Bantam

303-06-214 Starting System 303-06-214
E5909 EN 07/2001 2002 Bantam

303-06-215 Starting System 303-06-215

Starter Motor — Vehicles with 1.8L Endura DE Diesel Engine (26 204 0)
Removal
3. Disconnect the starter motor wiring.
4. Remove the starter motor support bracket

(two nuts, one bolt).
5. Remove the starter motor (three bolts).
E5909 EN 07/2001 2002 Bantam

303-06-216 Starting System 303-06-216
Installation
E5909 EN 07/2001 2002 Bantam

303-06-217 Starting System 303-06-217
SPECIFICATIONS
Description Nm
Starter motor electrical connector upper retaining 12
nut
Starter motor electrical connector lower retaining 6
nut
E6678 EN 07/2001 2002 Bantam

303-07-218 Engine Ignition 303-07-218
SECTION 303-07 Engine Ignition

SUBJECT PAGE

Engine Ignition..................................................................................................................... 303-07-219

Engine Ignition..................................................................................................................... 303-07-220
Inspection and Verification................................................................................................ 303-07-220

Ignition Coil Pack — Vehicles with 1.6L / 1.3L Engine .................................... (22 414 0) 303-07-221/222
SPECIFICATIONS
Specifications ...................................................................................................................... 303-07-223
07/2001 2002 Bantam

303-07-219 Engine Ignition 303-07-219

Engine Ignition
The ignition system is of the distributor less type. ignition timing has been determined, the PCM
The crankshaft position sensor (CKP) signal is interrupts the current to the primary circuits of the
the basis for ignition timing calculations. The ignition coils therefore triggering ignition sparks
camshaft position (CMP) sensor signal is which are supplied to the cylinders through the
spark plug wires and spark plugs.
required only during starting as when the engine
is running, the profile ignition pick-up (PIP) signal The ignition coils are triggered by the PCM in
is used. The alternating voltage signal from the pairs, cylinders No.1 and No. 4 and cylinders No.
CKP sensor is digitized by the powertrain control 2 and No. 3, sending an ignition spark to the
module (PCM). This digitized signal is then used firing cylinder and to the corresponding cylinder
to time the closing of the ignition coils primary on the exhaust stroke. Having an ignition spark
circuits. on the exhaust strokes makes sure that any un-
Ignition timing is determined by the PCM in burnt fuel left in the cylinder is ignited to provide
cleaner exhaust emissions.
response to engine operating conditions. Once
E6679 EN 07/2001 2002 Bantam

303-07-220 Engine Ignition 303-07-220

Engine Ignition Visual Inspection Chart
General Equipment Mechanical Electrical
WDS • Damaged spark plug • Connections to spark
wires. plugs and coil.
• Damaged spark • Loose or corroded
plugs. ignition coil electrical
1. Verify the customer concern. connector.
2. Visually inspect for obvious signs of damage. • Damaged wiring har-
Refer to the following chart: ness(s).
3. If visual inspection reveals an obvious cause,

rectify this before continuing.
4. If the concern remains after visual inspection,
use WDS to diagnose the system.
E1021 EN 07/2001 2002 Bantam

303-07-221 Engine Ignition 303-07-221

Ignition Coil Pack — Vehicles with 1.6L / 1.3L Engine (22 414 0)
Removal
1. Disconnect the spark plug wires from the
ignition coil pack.
2. Disconnect the ignition coil pack electrical

connector.
3. Remove the ignition coil pack.
Installation
CAUTION: The ignition coil pack and

spark plug wires are numbered. Make
sure the spark plug wires are correctly
installed to the ignition coil pack. Fail-
ure to follow this instruction may result
in damage to the engine.
E6681 EN 07/2001 2002 Bantam

303-07-222 Engine Ignition 303-07-222
E6681 EN 07/2001 2002 Bantam

303-07-223 Engine Ignition 303-07-223
SPECIFICATIONS
Description Nm
Ignition coil pack retaining screws 6
E6682 EN 07/2001 2002 Bantam

303-12-224 Intake Air Distribution and Filtering 303-12-224
SECTION 303-12 Intake Air Distribution and Filtering

SUBJECT PAGE

Intake Air Distribution and Filtering - Vehicles with 1.6L / 1.3L engine ................................. 303-12-225
Intake Air Distribution and Filtering - Vehicles with Diesel engine ........................................ 303-12-226

Intake Air Distribution and Filtering ...................................................................................... 303-12-227

Air Cleaner Intake Pipe................................................................................... (23 175 0) 303-12-228/230
Air Cleaner ..................................................................................................... (23 174 0) 303-12-231
SPECIFICATIONS
Specifications ...................................................................................................................... 303-12-232
07/2001 2002 Bantam


Intake Air Distribution and Filtering
Vehicles with 1.3L or 1.6L Engine

1 Air cleaner outlet pipe 3 Air cleaner element
2 Air cleaner housing cover 4 Air cleaner intake pipe
5 Air cleaner housing
E6687 EN 07/2001 2002 Bantam



1 Air cleaner outlet pipe 4 Air cleaner intake pipe
2 Air cleaner housing cover 5 Air cleaner housing
3 Air cleaner element 6 Intake air resonator
E6687 EN 07/2001 2002 Bantam

Intake Air Distribution and Filtering
E1029 EN 07/2001 2002 Bantam


Air Cleaner Intake Pipe (23 175 0)
Removal
NOTE: The procedure shown is for vehicles with

1.6L / 1.3L engines, the procedure is similar for
vehicles with diesel engine.
1. Disconnect the air cleaner outlet pipe from
the throttle body.
2. Disconnect the resonator pipe from the air

cleaner outlet pipe.
3. Remove the air cleaner housing cover and

air cleaner outlet pipe.
E6688 EN 07/2001 2002 Bantam

4. Remove the air cleaner element.
5. Disconnect the air cleaner intake pipe from

the air cleaner.
• Release the tang.
6. Loosen the left-hand front wheel nuts.

8. Remove the left-hand front wheel.
9. Remove the left-hand front fender splash

shield.
E6688 EN 07/2001 2002 Bantam


1. Rotate the air cleaner intake pipe
counterclockwise.
Installation
E6688 EN 07/2001 2002 Bantam


Air Cleaner (23 174 0)
Removal
All vehicles
refer to Air Cleaner Intake Pipe in this section.
Vehicles with 1.6L / 1.3L engines
2. Disconnect the engine ventilation hose.
All vehicles
3. Detach the air cleaner housing.
• Pull the rubber strap up, to release.
4. Remove the air cleaner housing.
Installation
E6690 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Wheel nuts 85
Air cleaner housing cover retaining screws 10
E6721 EN 07/2001 2002 Bantam

303-14-233 Electronic Engine Controls 303-14-233
SECTION 303-14 Electronic Engine Controls

SUBJECT PAGE

Electronic Engine Controls................................................................................................... 303-14-234
Vehicles with 1.3L or 1.6L Engine ..................................................................................... 303-14-235
Vehicles with Diesel Engine .............................................................................................. 303-14-236

Electronic Engine Controls................................................................................................... 303-14-237

Powertrain Control Module (PCM) — Vehicles with Petrol Engine .................. (29 200 0) 303-14-238/239
Crankshaft Position (CKP) Sensor — Vehicles with Petrol Engine.................. (29 230 0) 303-14-240
Power Steering Pressure (PSP) Switch — Vehicles with Petrol Engine .......... (33 611 0) 303-14-241
Throttle Position (TP) Sensor — Vehicles with Petrol Engine.......................... (23 325 0) 303-14-242
Engine Coolant Temperature (ECT) Sensor — Vehicles with Petrol Engine ... (21 190 0) 303-14-243
Engine Knock Sensor— Vehicles with 1.3L Petrol Engine .................................................... 303-14-244/249
SPECIFICATIONS
Specifications....................................................................................................................... 303-14-250
07/2001 2002 Bantam


Electronic Engine Controls
Vehicles with 1.6L / 1.3L Engines

1 Camshaft position (CMP) sensor 7 Temperature and manifold absolute
pressure (T-MAP) sensor
2 Oxygen sensor (O2S)
8 Knock Sensor
3 Engine coolant temperature (ECT)
sensor
4 Throttle position (TP) sensor
5 Crankshaft position (CKP) sensor
6 Idle air control (IAC) valve
E6692 EN 07/2001 2002 Bantam


Vehicles with 1.3L or 1.6L Engine
reference voltage by the PCM. When the engine
The sensors supply the PCM with input signals, coolant temperature changes, the resistance of
which relate to engine operating conditions and the ECT sensor changes therefore changing the
the IAC valve responds to output signals from the output voltage. The output voltage is assigned to
PCM. These output signals are based on the a corresponding engine coolant temperature by
evaluated input signals, which are compared with the PCM.
calibrated data tables or maps before the output
signal is generated. Throttle Position (TP) Sensor
Powertrain Control Module (PCM) The TP sensor is a rotary variable resistor, which
is secured to the throttle body and operated by
The PCM is located inside the vehicle, behind the the throttle plate shaft. It is supplied with a
left-hand cowl side trim panel and provides reference voltage by the PCM. When the throttle
precise control of basic engine calibration plate is opened, a sliding contact moves over a
parameters. resistance track changing the output voltage. The
Crankshaft Position (CKP) Sensor output voltage is assigned to a corresponding
throttle plate position by the PCM.
The CKP sensor is an inductive pulse generator,
which scans 36 minus one cast protrusions on Idle Air Control (IAC) Valve
the flywheel. Minus one means that one of the The IAC valve is fitted directly into the intake
cast protrusions is missing. This missing cast manifold. It is an electronically controlled solenoid
protrusion is located at 90º before top dead valve, which allows a flow of air to bypass the
center (TDC) and is used by the PCM as a throttle plate shaft. It is controlled by grounding
reference for crankshaft position. The CKP pulses from the PCM, the length of which
sensor sends an alternating voltage signal to the determines its position. Engine speed can
PCM where it is converted into the digital profile therefore be maintained irrespective of engine
ignition pick-up (PIP) signal. load.
Camshaft Position (CMP) Sensor
Temperature and Manifold Absolute Pressure (T-
The CMP sensor is an inductive pulse generator, MAP) Sensor
which scans a reference cam on the camshaft. It The T-MAP sensor is fitted directly into the intake
sends an alternating voltage signal to the PCM manifold and is therefore able to measure
from which the position and stroke of piston vacuum accurately whilst the engine is running. It
number one is calculated. The signal from the consists of a pressure transducer and a
CMP sensor is required only during starting. temperature sensor, which provide the PCM with
When the engine is running, the PIP signal is information relating to vacuum, barometric
used to sequentially control the fuel injectors. pressure and air temperature within the intake
Oxygen Sensor (O2S) manifold. When the engine is running, it
measures vacuum and when the engine is not
The O2S is a voltage generator, which is installed
running but the ignition is switched on, it
ahead of the catalyst in the exhaust flow. When
measures barometric pressure.
the air/fuel ratio is ideal, theoretically 14.7:1
(lambda 1), a voltage signal is sent to the PCM. Knock Sensor (1.3L engine only)
When the mixture is lean, the voltage signal is The knock sensor is fitted to the engine to sense
reduced and when the mixture is rich, the voltage the onset of engine knock and to return this
signal is increased. The PCM sets the air/fuel information to the engine control module, which
mixture accordingly. This provides close control then can determine the optimum spark timing for
of exhaust emissions. the engine. The engine control module will then
Engine Coolant Temperature (ECT) Sensor adjust the timing to reduce the tendency of
engine knock. This accurate discrimination of
The ECT sensor is a temperature dependent
combustion knocking allows engines to run
resistor, which has a negative temperature
generally higher spark advance than has
coefficient. This means its resistance decreases previously been possible for improved power and
with increased temperature. It is supplied with a
fuel economy.
E6692 EN 07/2001 2002 Bantam


Air Conditioning (A/C) Cutoff Switch
The A/C cutoff switch is secured to the fuel pump throttle linkage. When the throttle linkage is
injection pump and operated by the fuel injection at full travel, the A/C cutoff switch is pressed,
therefore cutting off the A/C system to enable
maximum engine power.
E6692 EN 07/2001 2002 Bantam


Electronic Engine Controls Visual Inspection Chart
• Damaged sensors. • Damaged electrical
WDS
• Damaged actuators. connections.
• Damaged wiring
Inspection and Verification harness(s).
1. Verify the customer concern. • Loose or corroded
2. Visually inspect for obvious signs of damage. powertrain control
Refer to the following chart: module electrical
connector.

use WDS to diagnose the system.
E1036 EN 07/2001 2002 Bantam


Powertrain Control Module (PCM) — Vehicles with Petrol Engine (29 200 0)
Removal
2. Detach the left-hand door opening weather

strip.
3. Detach the cowl side trim panel.
4. Disconnect the PCM electrical connector.
E6670 EN 07/2001 2002 Bantam

5. Remove the PCM.
Installation
1. CAUTION: When installing the PCM

electrical connector start the bolt by
hand before tightening to avoid
damaging the electrical connector
pins.
E6670 EN 07/2001 2002 Bantam


Crankshaft Position (CKP) Sensor — Vehicles with 1.6L / 1.3L Engines (29 230 0)
Removal

sensor electrical connector (starter motor
removed for clarity).
3. Remove the CKP sensor (starter motor

Installation
E6693 EN 07/2001 2002 Bantam


Power Steering Pressure (PSP) Switch — Vehicles with Petrol Engine (33 611 0)
Removal
2. Disconnect the power steering pressure

switch electrical connector.
Installation
E1046 EN 07/2001 2002 Bantam


Throttle Position (TP) Sensor — Vehicles with 1.6L / 1.3L Engines (23 325 0)
Removal
1. Remove the throttle body. For additional
2. Remove the throttle position (TP) sensor.
Installation
1. NOTE: Install a new TP sensor O-ring seal.

E6694 EN 07/2001 2002 Bantam


Engine Coolant Temperature (ECT) Sensor — Vehicles with 1.6L / 1.3L Engines
(21 190 0)
Removal

(ECT) sensor electrical connector.
3. Remove the ECT sensor.

1. Remove the clip.
2. Remove the ECT sensor.
Installation
1. NOTE: Install a new ECT sensor O-ring seal.

E6694 EN 07/2001 2002 Bantam


Engine Knock Sensor — Vehicles with 1.3L Engines
Removal
3. WARNING: Watch for and collect

escaping fuel. Observe the safety
regulations for working with fuel.

1. Remove the clip and pull cable from the
retaining bracket.
5. Remove the hoses and the electrical

connector.
hose.
4. Engine coolant temperature (ECT) sensor


E6694 EN 07/2001 2002 Bantam

9. Remove the intake manifold lower retaining

bolts (shown with the engine removed).

Installation
1. Install the knock sensor.

damaged.


bolts (shown with engine removed).
E6694 EN 07/2001 2002 Bantam

7. Connect the PCM and CMP electrical

connectors.
8. Install the hoses and connect the electrical

connector.
2. PCV hose.
4. ECT sensor electrical connector.

1. Connect the inner cable.
2. Install the cable into the retaining
bracket, check the cable setting and
secure using the clip.
E6694 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Crankshaft position (CKP) sensor retaining bolt 10
Power steering pressure (PSP) switch 10
Throttle position (TP) sensor retaining screws 5
Knock sensor retaining bolt 20
E6697 EN 07/2001 2002 Bantam

308-00-1 Manual Transaxle and Clutch — General Information 308-00-1
SECTION 308-00 Manual Transaxle and Clutch —

General Information
SUBJECT PAGE

Manual Transaxle and Clutch..................................................................................................308-00-2

Manual Transaxle and Clutch..................................................................................................308-00-3
Inspection and Verification - Clutch ......................................................................................308-00-3
Inspection and Verification - Manual Transaxle ...................................................................308-00-3
Symptom Charts .................................................................................................................... 308-00-4/8A
Pinpoint Tests ........................................................................................................................ 308-00-8B/14
GENERAL PROCEDURES
Clutch Disc Check.................................................................................................................... 308-00-15
Clutch Master Cylinder Check................................................................................................. 308-00-16
Clutch Pressure Plate Check................................................................................................... 308-00-17
Clutch Slave Cylinder Check ................................................................................................... 308-00-18
Clutch System Bleeding ..................................................................................... (16 843 0) 308-00-19/20
Gearshift Linkage Adjustment............................................................................ (16 513 0) 308-00-21/23
SPECIFICATIONS
Specifications ........................................................................................................................... 308-00-24
Lubricants, Fluids, Sealers and Adhesives........................................................................... 308-00-24
Clutch .................................................................................................................................... 308-00-24
07/2001 2002 Bantam

Manual Transaxle and Clutch
Clutch iB5 Manual Transmission
For additional information, refer to Section 308-01. For additional information, refer to Section 308-03.
Clutch Controls
E4459 EN 07/2001 2002 Bantam


Manual Transaxle and Clutch
under the clutch pedal and depress the
Special Tool(s) clutch pedal as far as the stop. If 1st or 2nd
12 Volt UV Spot Lamp or gear can be selected with no problem with
equivalent the engine running and the parking brake
applied, the clutch is OK. If the gear cannot
164-R0751 be selected, repair the clutch.
2. Check the selector mechanism:
The free play in the gearshift lever must be no
more than 15 mm.
Inspection and Verification - Clutch • If the gearshift lever free play is too great,
1. Verify the customer concern by operating the check the gearshift cables and install new
system. cables if necessary.
2. Visually inspect for obvious signs of If the gearshift lever free play is OK, adjust the
mechanical or electrical damage. gearshift linkage.
3. If an obvious cause for an observed or REFER to Gearshift Linkage Adjustment in this section
reported concern is found, correct the cause 3. Check the transmission fluid level and top up
(if possible) before proceeding to the next with manual transmission fluid BOT 130, if
step. necessary.
4. If the concern is not evident, verify the
Transaxle noise
Visual Inspection Chart If transaxle noise is reported, first check the
Mechanical transmission fluid level. If damage has occurred
due to a lack of fluid, install a new transaxle.
• Fluid leaks from the transaxle.
• Visibly damaged or worn parts.
• Loose or missing bolts or nuts. Fluid leakage
• Check that the leaking fluid is actually
transmission fluid and not hydraulic fluid (from
Inspection and Verification - Manual the hydraulically operated clutch) or engine
Transaxle oil.
The following checks should be carried out • Check the transmission fluid level and, if
before repairing or installing a new transaxle: necessary, drain off any excess fluid.
• Locate the oil leak with the aid of a
fluorescent test fluid and an Ultra Violet
Poor gear shifting inspection lamp.
1. Check the operation of the clutch: Lay a • Clean the transaxle and the adjacent areas
block of wood approximately 25 mm thick carefully before the road test.
E6760 EN 07/2001 2002 Bantam


Symptom Charts
Poor Gear Shifting
• Significant effort required when • Gear synchronization is inade- • INSTALL a complete set
downshifting or synchronizer quate. (synchronizer hub with
crashing synchronizer rings) and
INSTALL two new gear wheels
belonging to the synchronizer
unit.
• Because of various changes
and the difficulty in estimating
the level of wear, a complete
new installation (as described
above) is recommended.
• Gear jumps out of engagement • Transaxle assembly error • INSTALL a new gear
while driving. (missing snap rings or set/synchronizer unit and selec-
synchronizer components). tor fork concerned as neces-
• Manufacturing error sary. CHECK the transaxle for
(INCORRECT gear wheel any resulting damage, particu-
toothing or synchronizer ring). larly on the reverse gear syn-
• Selector fork. chronizer.
• Gearshift problems in different • Transaxle assembly error: miss- • REPAIR the transaxle accord-
gears (stiff or partially seized). ing snap rings or synchronizer ingly. CHECK the transaxle for
components, foreign materials in any resulting damage.
the transaxle. Bolts of selector
components loose.
• Gearshift problems in the neu- • Reversing lamp actuating pin NOTE: There is a risk of breaking
tral slot (sticking, scraping, lock- loose. the actuating pin when screwing
ing). it in.
• TIGHTEN the actuating pin to 6
Nm.
• Reversing lamp actuating pin • REPAIR the gearshift cover or
wrongly installed (chamfer at the INSTALL a new gearshift cover
selector shaft rotated by 180 as necessary.
degrees). • Use new bolts and install them
using locking compound.
Transaxle Noises
• Slight buzzing, rattling or metal- • Rotational vibration from the en- • These noises do not affect the
lic scraping noise from the gine not sufficiently damped by operation and durability of the
transaxle at 2500 to 3500 the clutch. transaxle.
rev/min when coasting or driving
without load (particularly in 2nd
and 3rd gear).
E6760 EN 07/2001 2002 Bantam


• Brief scratching noise during • Inadequate gear synchroniza- • INSTALL a complete set
gear shifting. tion. (synchronizer hub and
synchronizer rings) and
INSTALL two new gear wheels
belonging to the synchronizer
unit.
– Because of various changes
and difficulty in estimating
the level of wear, a complete
new installation (as de-
scribed above) is recom-
mended.
Fluid Leakage
• Fluid leakage • Sealing lip of the halfshaft oil • INSTALL a new oil seal.
seal damaged.
• Fluid leaking between the trans- • Disassemble the transaxle;
axle housing sections or from clean the mating faces (CHECK
the selector mechanism mating the surfaces for damage). Seal
face. the transaxle with liquid sealer
as described in the Service Mi-
crofiche.
General Concerns
• Clicking noises in reverse gear • Gearwheels. • INSTALL new gear wheels.
• Gearwheels banging when shift- • Damaged clutch. • REFER to Section 308-01.
ing.
• Selector forks or synchronizer • CHECK the components for
rings. damage.
• Noises in the forward gears • Transmission fluid level too low. • Top up the transmission fluid.
• The engine/transaxle assembly • Look for points of contact or
is in contact with the chas- damaged engine/transaxle isola-
sis/body. tor, roll restrictor.
• Engine/transaxle flange bolts. • TIGHTEN the transaxle flange
bolts. REFER to Section 308-03.
• Input and output shaft bearings. • Remove the transaxle. CHECK

Gear wheels (usually on high- the bearings and gear wheels
mileage vehicles). and INSTALL new parts as nec-
essary.
E6760 EN 07/2001 2002 Bantam


• Stiff gearshift • Transmission fluid. • CHECK that the transaxle is
filled with the specified trans-
mission fluid and, if necessary,
fill up with transmission fluid of
the type listed under “Specifica-
tions".
• Damaged synchronizer rings or • CHECK the internal components
inner selector mechanism. for damage, INSTALL new parts
as necessary.
• Gears jump out of engagement • Malfunction between the gear- • Adjust the gearshift mechanism
shift lever and the gearshift lever or repair the fault.
housing.
• Engine/transaxle isolator, roll • REPAIR or INSTALL new com-
restrictor. ponents as necessary.
• Internal components. • CHECK the selector shafts, s e-
lector forks and synchronizer
units and INSTALL new parts as
necessary.
• One of the gears cannot be se- • Fault between the gearshift • Adjust the gearshift mechanism
lected lever and gearshift lever hous- or repair the defect.
ing.
• 3rd gear jumps out of engage- • Internal selector mechanism • TIGHTEN the pin to 25 Nm.
ment loose, causing the selector fin-
ger guide to move on the inner
selector shaft.
• Reverse gear cannot be se- • Outer gearshift mechanism. • CHECK the outer gearshift
lected mechanism for damage. As
necessary, remove it to see
whether reverse gear can then
be selected.
• Internal components. • Remove the transaxle assembly
and CHECK the reverse gear
idler and the appropriate selec-
tor fork, selector shaft and syn-
chronizer unit. INSTALL new
parts as necessary.
• Stiff gearshift • Gearshift lever housing broken • INSTALL a new gearshift lever
or damaged. housing.
• Gearshift linkage joint housing. • INSTALL a new gearshift lever
• Gearshift lever joint. as necessary.
• Gearshift lever not securely at- • TIGHTEN or INSTALL new self-
tached to mounting. tapping screws.
• Clattering, rattling or booming • Gearshift lever joint. • INSTALL a new gearshift lever.
noises
• Gearshift lever knob loose. • TIGHTEN the gearshift lever
knob or, INSTALL a new as
necessary.
E6760 EN 07/2001 2002 Bantam


• Gearshift lever not functioning - • Gearshift lever housing de- • Secure the gearshift lever hous-
no gear can be selected tached at the floor assembly. ing.
• Gearshift lever feels loose • Gearshift lever joint. • INSTALL a new gearshift lever.
• Grinding or clashing noises • Deflected lubrication condition • INSTALL a new 3rd speed gear,
when shifting into 3rd gear causing early 3rd gear wear 3rd/4th gearshift fork, outer syn-
chronizer ring, inner synchro-
nizer ring, 3rd speed synchro-
nizer cone, 3rd / 4th synchro-
nizer assembly.
Clutch
• Clutch slippage • Clutch pedal free play. • Go To Pinpoint Test A
• Sticking clutch pedal.
• Diaphragm springs.
• Clutch pressure plate.
• Clutch disc facing.
• Hardened or oiled clutch disc
facing surface.
• Flywheel.
• Clutch chatter or shudder • Engine mounts. • Go To Pinpoint Test B
• Oil on clutch disc facing.
• Clutch pressure plate.
• Clutch disc facing.
• Flywheel.
• Clutch drag • Insufficient brake fluid. • Go To Pinpoint Test C
• Air in hydraulic system.
• Clutch pedal free play.
• Clutch disc.
• Clutch disc splines.
• Oil on clutch disc facing.
• Clutch pedal pulsation • Clutch and brake pedal pivot • Go To Pinpoint Test D
shaft not correctly lubricated.
• Flywheel.
• Worn springs in pressure plate.
• Clutch related vibrations • Engine component grounding • Go To Pinpoint Test E
against frame.
• Accessory drive belt.
• Flywheel bolts.
• Flywheel
• Imbalanced clutch pressure
plate.
• Hard shifting • Insufficient brake fluid. • Go To Pinpoint Test F
• Clutch pedal free play.
• Manual transaxle concern.
E6760 EN 07/2001 2002 Bantam

308-00-8A Manual Transaxle and Clutch — General Information 308-00-8A

• Excessive noise • Clutch pedal free play. • Go To Pinpoint Test G
• Clutch release bearing.
• Poor lubrication of clutch
release bearing.
• Pilot bearing.
• Excessive crankshaft endplay.
• Fluid leakage • Clutch master cylinder. • Go To Pinpoint Test H
• Clutch slave cylinder.
• Clutch hydraulic lines.
E6760 EN 07/2001 2002 Bantam

Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
A1: CHECK FOR CLUTCH SLIPPAGE................................................................ 308-00-8B
A2: CHECK THE CLUTCH PEDAL FREE TRAVEL ............................................. 308-00-8B
A3: CLUTCH PEDAL OPERATION...................................................................... 308-00-8B
PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER
B1: CHECK FOR CLUTCH CHATTER OR SHUDDER ........................................ 308-00-9
B2: CHECK THE ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR............. 308-00-9
B3: CHECK THE CLUTCH PRESSURE PLATE .................................................. 308-00-9
B4: CHECK THE CLUTCH DISC ......................................................................... 308-00-9
PINPOINT TEST C: CLUTCH DRAG
C1: CHECK THE BRAKE FLUID LEVEL.............................................................. 308-00-10
C2: CHECK THE CLUTCH PEDAL FREE TRAVEL ............................................. 308-00-10
C3: CHECK THE BELLEVILLE SPRING WASHER OF THE
CLUTCH PRESSURE PLATE.............................................................................. 308-00-10
PINPOINT TEST D: CLUTCH PEDAL PULSATION
D1: CHECK THE CLUTCH PEDAL ...................................................................... 308-00-10
PINPOINT TEST E: CLUTCH RELATED VIBRATIONS
E1: CHECK FOR ENGINE COMPONENT GROUNDING .................................... 308-00-11
E2: CHECK FOR ACCESSORY DRIVE VIBRATIONS ........................................ 308-00-11
E3: CHECK FOR RELEASE BEARING NOISE ................................................... 308-00-11
E4: INSPECT THE FLYWHEEL........................................................................... 308-00-11/12
PINPOINT TEST F: HARD SHIFTING
F1: CHECK THE FLUID LEVEL........................................................................... 308-00-12
F2: CHECK THE CLUTCH PEDAL FREE PLAY .................................................. 308-00-12
PINPOINT TEST G: EXCESSIVE NOISE
G1: CHECK THE TRANSAXLE NEUTRAL POSITION ........................................ 308-00-13
G2: TEST THE CLUTCH PEDAL FREE TRAVEL ................................................ 308-00-13
G3: CHECK THE CLUTCH SLAVE CYLINDER WITH RELEASE BEARING ....... 308-00-13
G4: CHECK THE CLUTCH FRICTION DISK TORSION SPRINGS...................... 308-00-14
PINPOINT TEST H: FLUID LEAKAGE
H1: CHECK THE CLUTCH MASTER CYLINDER ................................................ 308-00-14
H2: CHECK THE CLUTCH SLAVE CYLINDER.................................................... 308-00-14
H3: CHECK THE SYSTEM HYDRAULIC TUBES ................................................ 308-00-14
308-00- 8B Manual Transaxle and Clutch — General Information 308-00- 8B
Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
A1: CHECK FOR CLUTCH SLIPPAGE
1 Check the road wheels and apply the parking
brake.
2.
3 Start the engine and engage fourth gear.

4 Run the engine at approximately 2000 rpm.
5 Release the clutch pedal slowly.
• Does the engine stall when the clutch pedal is
fully released?
Yes
Clutch OK.
No
GO TO A2
A2: CHECK THE CLUTCH PEDAL FREE TRAVEL
1 Depress the clutch pedal manually to the point
of resistance and release.
2 Measure the pedal travel.
• Is the measured dimension within 10 mm?
Yes
GO TO A3
No
GO TO B3
A3: CLUTCH PEDAL OPERATION
1 Check the lubrication.
• Is the clutch pedal shaft sufficiently lubricated?
Yes
GO TO B3
No
Lubricate the clutch pedal shaft.
E6760 EN 07/2001 2002 Bantam


PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER
B1: CHECK FOR CLUTCH CHATTER OR SHUDDER
1.
2 Start the engine and engage first gear.

3 Run the engine at between 1200 rev/min and
1500 rpm.
4 Release the clutch pedal slowly.
• Does the vehicle jerk when it starts off?
Yes
GO TO B2
No
Clutch OK.
B2: CHECK THE ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR
1 Check the engine/transaxle mountings isolator,
roll resistor for damage or loose bolts.
• Are the engine/transaxle isolator, roll restrictor
loose or damaged?
Yes
Tighten bolts or install new ones as
operation.
No
GO TO B3
B3: CHECK THE CLUTCH PRESSURE PLATE
1 Remove the clutch pressure plate.
- REFER to Section 308-01.
• Does the clutch pressure plate have signs of
wear or damage?
Yes
Install a new clutch pressure plate.
No
GO TO B4
B4: CHECK THE CLUTCH DISC
1 Visually check the clutch disc.
• Is the clutch friction disk oil-fouled or does it
have burn marks?
Yes
Install a new clutch friction disk. TEST the
No
Check the flywheel.
Refer flywheel in this section.
E6760 EN 07/2001 2002 Bantam


PINPOINT TEST C: CLUTCH DRAG
C1: CHECK THE BRAKE FLUID LEVEL
1 Check the brake fluid level.
• Is the brake fluid level between the MAX and
MIN marks on the brake fluid reservoir?
Yes
GO TO C2
No
Top up brake fluid reservoir, check the
brake and clutch systems for leaks.
C2: CHECK THE CLUTCH PEDAL FREE TRAVEL
1 Depress the clutch pedal manually to the point
of resistance and release.
• Is the measured dimension within 10 mm?
Yes
GO TO C3
No
GO TO B3
C3: CHECK THE BELLEVILLE SPRING WASHER OF THE CLUTCH PRESSURE PLATE
1 Remove the transaxle.
• Does the clutch pressure plate or the Belleville
spring washer of the clutch pressure plate show
signs of wear or damage?
Yes
Install a new clutch pressure plate. TEST
No
GO TO B4
PINPOINT TEST D: CLUTCH PEDAL PULSATION
D1: CHECK THE CLUTCH PEDAL
1 Check clutch pedal mechanism lubrication.
• Is the clutch pedal shaft sufficiently lubricated?
Yes
Check the flywheel.
Refer to Flywheel in this section.
No
Lubricate the clutch pedal shaft. TEST the
E6760 EN 07/2001 2002 Bantam


PINPOINT TEST E: CLUTCH RELATED VIBRATIONS
E1: CHECK FOR ENGINE COMPONENT GROUNDING
2 Check the engine mount interlocks for ground-
ing on the body or frame.
3 Check the exhaust manifold or other engine
component grounding on the body or frame.
• Is there evidence of grounding on body or
frame?
Yes
REPAIR or INSTALL a new as necessary.
No
GO TO E2
E2: CHECK FOR ACCESSORY DRIVE VIBRATIONS
1 Check for accessory vibration at the clutch en-
gage/disengage when engine torque changes.
2 Disconnect the accessory drive belt and check
for vibration.
• Does the vibration stop when the accessory
drive belt is removed from the engine?
Yes
REPAIR or INSTALL new accessory drive
belt components.
No
GO TO E3
E3: CHECK FOR RELEASE BEARING NOISE
1.
2 Depress and hold the clutch pedal.

• Is a whirring, grating or grinding noise present?
Yes
Install a new clutch slave cylinder.
No
GO TO E4
E4: INSPECT THE FLYWHEEL
2 Inspect for loose flywheel bolts.
E6760 EN 07/2001 2002 Bantam

3 Carry out flywheel run out check.
• Is the Flywheel OK?
Yes
Diagnose engine vibration concern.
No
TIGHTEN or INSTALL a new flywheel.
REFER to Section 308-01. TEST the sys-
PINPOINT TEST F: HARD SHIFTING
F1: CHECK THE FLUID LEVEL
NOTE: The hydraulic clutch fluid is supplied from the brake master cylinder.
1.
2 Inspect the brake fluid level in the brake

master cylinder reservoir.
• Is the fluid within the MAX and MIN level
marks?
Yes
GO TO F2
No
ADD brake fluid and CHECK for leaks in the
clutch and brake system. TEST the system
F2: CHECK THE CLUTCH PEDAL FREE PLAY
1 Depress the clutch pedal lightly by hand.
2 Measure the distance the clutch pedal travels.
• Is the clutch pedal free play within 1-3 mm
(0.04-0.12 inch)?
Yes
Diagnose hard shifting concern.
No
Inspect the clutch pressure plate for dam-
age.
Refer to Clutch Pressure Plate in this section.
E6760 EN 07/2001 2002 Bantam

PINPOINT TEST G: EXCESSIVE NOISE

G1: CHECK THE TRANSAXLE NEUTRAL POSITION
1.
2 Start the engine and run it in NEUTRAL.

3 Depress the clutch pedal fully.
• Are there noises when the clutch is operated?
Yes
GO TO G2
No
There is a problem with the transaxle.
REFER to Symptom Chart(s).
G2: TEST THE CLUTCH PEDAL FREE TRAVEL
1 Depress the clutch down manually until resis-
tance is felt, then release it again.
• Is the travel within 10 mm?
Yes
GO TO G3
No
REFER to the Clutch Master Cylinder
Gen eral procedure in this section.
G3: CHECK THE CLUTCH SLAVE CYLINDER WITH RELEASE BEARING
2 Check the clutch slave cylinder bolts.
3 Check the release bearing for wear and rust.
• Are the bolts loose or are there signs of wear
or rust?
Yes
TIGHTEN the bolts or install a new clutch
slave cylinder with the release bearing.
No
GO TO G4
E6760 EN 07/2001 2002 Bantam

G4: CHECK THE CLUTCH FRICTION DISK TORSION SPRINGS
1 Check the torsion springs for wear.
• Do the torsion springs have signs of wear?
Yes
Install a new clutch disc. TEST the system
No
Check the crankshaft endplay.
PINPOINT TEST H: FLUID LEAKAGE

H1: CHECK THE CLUTCH MASTER CYLINDER
1 Check clutch master cylinder for leaks.
• Is the clutch master cylinder OK?
Yes
GO TO H2
No
REPAIR or INSTALL a new clutch master
cylinder as necessary.
H2: CHECK THE CLUTCH SLAVE CYLINDER
1 Check the clutch slave cylinder for leaks.
• Is the clutch slave cylinder OK?
Yes
GO TO H3
No
REPAIR or INSTALL a new clutch slave cyl-
inder as necessary.
H3: CHECK THE SYSTEM HYDRAULIC TUBES
1 Check the clutch hydraulic lines for loose or
damaged fittings causing leakage.
• Are the clutch hydraulic lines OK?
Yes
Carry out a road test to verify customer
complaint.
No
necessary. Carry out a road test.
E6760 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Clutch Disc Check
1. CAUTION: Do not use paraffin based

cleaning agents and solvents.
Clean the clutch disc.
• Check the clutch disc for:
• Oil fouling
• Burn marks
• Thickness (wear limit: 7,0 mm)
• Check springs
• If necessary, renew the clutch disc.
E4579 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Clutch Master Cylinder Check
1. Check the clutch master cylinder:

• For leaks
• Retaining clip
E4580 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Clutch Pressure Plate Check
1. CAUTION: Do not use paraffin based

cleaning agents and solvents.
Clean the clutch pressure plate.
• Check the clutch pressure plate for:
• Broken or worn diaphragm spring tongues
• Burn marks
• Scoring
• Flatness
• If necessary, renew the clutch pressure
plate.
E4581 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Clutch Slave Cylinder Check
1. Check the clutch slave cylinder with release

bearing:
• For leaks
• Extreme wear on the inner ring of the
release bearing
E4582 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Clutch System Bleeding (16 843 0)
Vacuum and pressure hand Brake fluid collector
pump
Transparent hose
416-001D (23-036A)
Brake fluid (Dot 4) SAE J1703 JUN91
4. NOTE: If proprietary brake bleeding

equipment is available, this can be used to
bleed the clutch system.
General note:
• The clutch operation system is self-
ventilating. The components are arranged
in such a way that small amounts of air
trapped in the system are removed
automatically.
5. Remove the brake fluid from the brake fluid

reservoir under suction, until the level is at
the MIN mark.
6. Put about 100 ml of brake fluid into the

reservoir of Special Tool 416-D001.
7. NOTE: The reservoir of the special tool must

be below the bleed nipple and the hose
connection of the rising tube must be
installed pointing towards the bleed nipple.
Install the special tool, open the bleed
nipple and use the special tool to pump
about 80 ml of brake fluid into the clutch
system.
• Tighten the bleed nipple to 10 Nm.
• Remove the special tool.
• Bleed the system automatically by
operating the clutch pedal several times
(max. 4 - 5 times), using the full clutch
pedal travel.
E1142 EN 07/2001 2002 Bantam

8. NOTE: Absolute cleanliness must be

observed when topping up with brake fluid.
Check the brake fluid level.
• The brake fluid level must be between
the MIN and MAX marks. If the level drops
below the MIN mark the brake warning
light comes on.
• If necessary, top up the brake fluid
reservoir with DOT4 brake fluid.
9. NOTE: Carefully engage reverse gear.

Check that the clutch operates correctly.
• Start the engine and carefully engage
reverse gear about 2 seconds after
depressing the clutch pedal. If in doing so
the gear engagement is particularly noisy,
bleed the system automatically by
operating the clutch several times (max. 4
- 5 times), using the full clutch pedal
travel.
• After waiting about 30 seconds, check
the operation of the clutch again. If the
gearshift is still too noisy, repeat the
previous job steps.
E1142 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Gearshift Linkage Adjustment (16 513 0)
All vehicles

3. Remove the inner drive shaft joint heat
shield.

4. Remove the inner drive shaft joint heat
shield.
E6761 EN 07/2001 2002 Bantam


5. Remove the gearshift mechanism shift rod
and stabilizer.
1. Remove the shift rod
2. Remove the gearshift stabilizer bar.
6. Adjust the gearshift mechanism.

• Engage fourth gear (starting with the
selector shaft in the neutral position).
• Using 9 mm diameter drill bit, lock the
gearshift lever in fourth gear position.
7. NOTE: If the gearshift stabilizer cannot be

installed, loosen the engine and transaxle
mounting.
Install the gearshift stabilizer and the shift
rod.
1. Install the shift rod.
2. Install the gearshift stabilizer.
8. Tighten the engine and transaxle mounting

(as necessary). For additional information,
refer to Section 303-01A.
E6761 EN 07/2001 2002 Bantam


10. Install the inner drive shaft joint heat shield.

11. Install the inner drive shaft joint heat shield.
E6761 EN 07/2001 2002 Bantam

308-00- 24 Manual Transaxle and Clutch — General Information 308-00- 24
SPECIFICATIONS
Item Specification
DOT 4 brake fluid SAE J1703 JUN91
Clutch
Description mm
Clutch disc wear limit 7.00
Description Nm
Clutch bleed nipple 10
Gearshift stabilizers retaining nut 55
Heat shield retaining nut 12
Transaxle flange bolts 44
07/2001 2002 Bantam

308-01-25 Clutch 308-01-25
SECTION 308-01 Clutch

SUBJECT PAGE

Clutch....................................................................................................................................... 308-01-26

Clutch....................................................................................................................................... 308-01-27

Clutch Disc and Pressure Plate ............................................................................................... 308-01-28/29
SPECIFICATIONS
Specifications ........................................................................................................................... 308-01-30
Clutch .................................................................................................................................... 308-01-30
07/2001 2002 Bantam

308-01-26 Clutch 308-01-26

Clutch
Clutch Components
Item Description
1 Clutch pressure plate
2 Clutch plate
3 Flywheel
The clutch transfers the engine power to the

transmission.
The clutch consists of a friction disc and a
pressure plate, which is bolted to the flywheel.
When the clutch pedal is operated the power
transmission from the engine to the transmission
is interrupted. The clutch is therefore engaged
when the pedal is not depressed. Pressing down
the pedal disengages the clutch.
E1144 EN 07/2001 2002 Bantam

308-01-27 Clutch 308-01-27

Clutch
E3535 EN 07/2001 2002 Bantam

308-01-28 Clutch 308-01-28

Clutch Disc and Pressure Plate
Special Tool(s)
Aligner, clutch disc
308-206 (16-067)
Removal
1. Detach the transmission. For additional
2. Detach the clutch from the flywheel.
1. Unscrew the bolts (6x).
2. Lift the clutch off the locating dowels and
put it down with the clutch disc.
Installation
1. Center the clutch disc on the pressure
plate.
E5939 EN 07/2001 2002 Bantam

308-01-29 Clutch 308-01-29
2. Attach the clutch to the flywheel.

1. Fit the clutch pressure plate with
centered clutch disc.
2. Locate the clutch over the locating
dowels on the flywheel.
3. Secure the bolts, working diagonally.
4. Install the transmission. For additional

E5939 EN 07/2001 2002 Bantam

308-01- 30 Clutch 308-01- 30
SPECIFICATIONS
Clutch
Type Single-plate dry clutch
Operation Hydraulic
Clutch disc diameter (mm) (outer/inner) 1.6L / 1.3L SOHC 190/134
Clutch disc diameter (mm) (outer/inner) 1.8L diesel engine 210/160
Description Nm
Clutch pressure plate retaining bolts 29
Clutch bleed nipple 10
07/2001
308-02-31 Clutch Controls 308-02-31
SECTION 308-02 Clutch Controls

SUBJECT PAGE

Clutch Controls......................................................................................................................... 308-02-32/33

Clutch Controls......................................................................................................................... 308-02-34

Clutch Master Cylinder ...................................................................................... (16 856 0) 308-02-35/36
Clutch Slave Cylinder......................................................................................... (16 862 0) 308-02-37
SPECIFICATIONS
Specifications ........................................................................................................................... 308-02-38
Clutch Controls...................................................................................................................... 308-02-38
07/2001

Clutch Controls Clutch Master Cylinder
The brake fluid reservoir with separate chamber The clutch master cylinder generates the system
is used to supply the system. pressure for operating the clutch.
Depressing the clutch pedal builds up pressure in If the clutch pedal is pushed down the piston rod
the clutch master cylinder and operates the moves the clutch master cylinder piston. The
release bearing integrated in the clutch slave hydraulic fluid in the clutch master cylinder is put
cylinder. under pressure and fed through the pressure
The clutch operation system is self-ventilating. pipe to the clutch slave cylinder.
The components are arranged in such a way that Slave Cylinder - Clutch
small amounts of air trapped in the system are
removed automatically. The central clutch slave cylinder is equipped with
an integral release bearing and is attached to the
The clutch pedal operation is affected by damage clutch bell housing with three bolts. The release
in that greater pedal effort is required. The pedal bearing is an interference fit on the clutch slave
also returns to its starting position very slowly. cylinder.
The advantages of a hydraulic clutch are: The hydraulic fluid displaced by the piston in the
• automatic adjustment clutch master cylinder moves the piston in the
• low operating force required clutch slave cylinder; this piston then moves the
release bearing in an axial direction. The release
• low wear
bearing presses against the tongues of the
Reservoir
diaphragm spring with the inner bearing ring. This
The brake fluid reservoir supplies both the breaks the friction contact between the clutch
hydraulic clutch system and the brake system disc and the flywheel.
with brake fluid.
When the clutch pedal is released the diaphragm
The hydraulic clutch system and the brake spring presses the piston in the slave cylinder
system are separate inside the brake fluid back to its starting position. The spring induced
reservoir. In the event of any leaks in the adherence between the clutch disc and the
hydraulic clutch system the brake system flywheel is created again.
remains fully operative.
Pre-load valve
The pre-load is produced by a spring.
E1148 EN 07/2001

Clutch operating mechanism components

1 Brake fluid reservoir 4 Bleed nipple
2 Clutch master cylinder 5 Pressure pipe
3 Clutch slave cylinder with integral re- 6 Feed line
lease bearing
7 Retaining clip
E1148 EN 07/2001
Clutch Controls
E3543 EN 07/2001

Clutch Master Cylinder (16 856 0)
Removal

ately Failure to follow these instructions
CAUTION: If brake fluid is split on the

ter.
2. Drain the brake fluid reservoir.
3. Remove the fuel lines and the pressure

hose from the clutch master cylinder.
1. Remove the hose clamp.
• Remove and seal the feed line.
2. Remove the securing clip.
• Remove and seal the pressure hose.
E6711 EN 07/2001
4. Remove the snap rings and move clutch

pedal approximately 15 mm sidewards.
1. Remove the pedal mounting
2. Remove the piston clutch rod master
cylinder
• Move the pedal approximately 15 mm
sidewards.
5. Remove the clutch master cylinder.

1. Remove the two bolts.
2. Pull the piston rod from the clutch pedal
and remove the clutch master cylinder.
Installation
1. To install, reverse the removal procedure
2. Top up the brake fluid reservoir. For

3. Bleed the clutch system. For additional

4. Connect the battery ground cable. For

E6711 EN 07/2001

Clutch Slave Cylinder (16 862 0)
Removal
5. Remove the transmission. For additional

6. Remove the clutch slave cylinder.

Installation
4. Fit the clutch slave cylinder.

1. Coat the input shaft splines with high-
temperature grease.
2. Insert the clutch slave cylinder
All vehicles
5. Install the transmission. For additional
6. Bleed the hydraulic clutch system. For
E1151 EN 07/2001
SPECIFICATIONS
Item Specification
Clutch Controls
Description
Operation Hydraulic
Adjustment Automatic
Description Nm
Clutch master cylinder retaining bolts (two bolts) 9
Clutch slave cylinder retaining bolts (three bolts) 10
Pre-load valve 10
E6713 EN 07/2001
308-03-39 Manual Transaxle 308-03-39
SECTION 308-03 Manual Transaxle

SUBJECT PAGE
Manual Transaxle .................................................................................................................... 308-03-40
Components of the iB5 Manual Transmission...................................................................... 308-03-41/47

Manual Transaxle .................................................................................................................... 308-03-48
IN-VEHICLE REPAIR
Input Shaft Oil Seal .................................................................................................................. 308-03-49/50
LH Halfshaft Oil Seal.......................................................................................... (14 303 0) 308-03-51/52
RH Halfshaft Oil Seal......................................................................................... (14 304 0) 308-03-53/55
REMOVAL
Transaxle — Vehicles with 1.6L / 1.3L Engine.................................................. (16 114 0) 308-03-56/65
DISASSEMBLY
Transaxle............................................................................................................ (16 118 8) 308-03-66/72

Selector Plate..................................................................................................... (16 284 5) 308-03-73/75
Input Shaft .......................................................................................................... (16 146 5) 308-03-76/77
Output Shaft ............................................................................................................................. 308-03-78/84
Differential ................................................................................................................................ 308-03-85/86
ASSEMBLY
Transaxle............................................................................................................ (16 118 8) 308-03-87/98
INSTALLATION
Transaxle............................................................................................................ (16 114 0) 308-03-99/108
GENERAL PROCEDURES
Bearing Check.......................................................................................................................... 308-03-109/110
SPECIFICATIONS
Specifications ........................................................................................................................... 308-03-111
Capacities.............................................................................................................................. 308-03-111
Transaxle Ratios ................................................................................................................... 308-03-111
Measuring and Adjusting Shims ........................................................................................... 308-03-111
Torque Specifications............................................................................................................ 308-03-111/112
07/2001

Manual Transaxle
Overview
Item Description The direction of rotation of the output shaft is

reversed for reverse gear by using an idler
1 Slave Cylinder - Clutch
gearwheel.
2 Sealed bearings
3 Transmission vent
All gearwheels are helically splined, synchronized
The aluminum transmission housing features (except reverse gear) and run on friction
reinforcement ribs for additional strength. Liquid bearings.
sealer is used between the two halves of the This reduces noise to a minimum and provides
transmission (WSS - M2G348-A5) and the end easy gear changing, together with low weight and
cover (WSE - M4G323 - A4). On transmissions compactness.
using liquid sealer the end cover is painted black.
Fitting a selector lever relay with return spring
In addition to this, components in the inside the transmission eliminates the spring
transmission have been modified although their loaded return slide in the external gearshift
design has not been changed. mechanism.
The iB5 manual transmission is a "2 shaft The iB5 manual transmission is filled with 2,8
transmission". The clutch is operated liters of synthetic oil, specification BOT 130. The
hydraulically. correct filling level is 5 to 10 mm below the check
On a "2 shaft transmission" all gearwheels are bore. Fluid changes are not necessary.
constantly in mesh. Each gear ratio is achieved
through one pair of gearwheels.
E4460 EN 07/2001

Components of the iB5 Manual Transmission
Overview

1 Pre-load valve (1 bar) (vehicles built up 5 Crown wheel
to build month 08/1999) 6 Tripod housing
2 Oil seal (accessible from the outside) 7 First/second gear synchronizer clutch
3 Clutch release bearing (separately re- 8 Third/fourth gear synchronizer clutch
newable)
9 Fifth gear synchronizer clutch
4 Front drive halfshaft intermediate shaft
10 Transmission vent
E4460 EN 07/2001

When the transmission is in neutral none of the the synchronizer clutches. No power is
gearwheels are connected to the output shaft by transferred to the differential.
Internal Gearshift Mechanism

1 Main shift rod 6 Detent mechanism
2 Boot (vent pointing downwards) 7 Auxiliary shift rod
3 Radial oil seal 8 Relay lever (shift)
4 Relay lever (select) 9 Selector block
5 Shift locking plate 10 Selector gate
E4460 EN 07/2001

Input shaft

1 Ball bearing 7 Gearwheel - 3rd gear
2 Input shaft 8 Gearwheel - 4th gear
3 Reverse gear idler 9 Snap-ring
4 Gearwheel - 1st gear 10 Gearwheel - 5th gear
5 Gearwheel - reverse gear 11 Snap-ring.
6 Gearwheel - 2nd gear
E4460 EN 07/2001

Output shaft

1 Parallel roller bearing 7 1st/2nd gear synchronizer clutch with
reverse gearwheel
2 Output shaft
8 Snap-ring
3 1st gearwheel
9 Outer synchronizer ring
4 Inner synchronizer ring
10 Synchronizer cone
5 Synchronizer cone
11 Inner synchronizer ring
6 Outer synchronizer ring
12 2nd gearwheel
E4460 EN 07/2001

13 Half rings 19 Gearwheel - 4th gear
14 Snap-ring 20 Ball bearing (closed on both sides)
15 3rd gearwheel with simple synchroni- 21 Snap-ring.
zation
22 Gearwheel - 5th gear
15 3rd gearwheel with double synchroni-
23 Synchronizer ring (5th gear)
zation
24 5th gear synchronizer clutch
17 Synchronizer clutch - 3rd/4th gear
25 Retaining plate
18 Synchronizer ring (4th gear)
Double synchronization
Item Description The conical surface on the gearwheel is no

1 Gearwheel longer present. Synchronisation is achieved
through the two synchronizer rings and the
2 Inner synchronizer ring synchronizer cone which fits on the gearwheel.
3 Synchronizer cone
Differential
4 Outer synchronizer ring The basic components of the differential are:
5 Synchronizer hub • Crown wheel
Double synchronization • Differential housing with two taper roller
bearings
The first and second gears are double
synchronised. Because a second synchronizer • Differential pinions
ring is used, the effective surface compared with • Drive halfshaft pinions
the simple synchronizer is approximately
doubled. Ease of gear changing is considerably
improved through double synchronization.
The double synchronization components are:
inner synchronizer ring, synchronizer cone, outer
synchronizer ring and synchronizer hub.
E4460 EN 07/2001

The transmission and differential are located Item Description
inside an aluminum two part housing, which is
connected to the engine by a flange. 1 Input shaft
The input shafts are splined. 2 Output shaft
Driving torque is transferred to the differential 3 Output pinion
cage by the crown wheel, which is bolted to it.
4 1st gearwheel
Inside the differential housing are the differential
5 1st/2nd gear synchronizer clutch
pinions, which are located on a spindle, and the
drive halfshaft pinions, which are connected to 6 1st gear teeth
the front, drive halfshafts by splines.
When there is a speed difference between the Second gear
two front wheels (for instance when driving
through a curve), the front drive halfshaft pinions
are able to turn on the differential pinions.
Power Flow
Neutral
Item Description
1 Input shaft
2 Output shaft
3 Output pinion
Item Description
4 1st/2nd gear synchronizer clutch
1 Input shaft
5 2nd gearwheel
2 Output shaft
6 2nd gear teeth
3 Output pinion
Third gear
First gear
E4460 EN 07/2001

1 Input shaft 1 Input shaft
2 Output shaft 2 Output shaft
3 Output pinion 3 Output pinion
4 3rd gear teeth 4 5th gear teeth
5 3rd/4th gear synchronizer clutch 5 5th gear synchronizer clutch
6 3rd gearwheel 6 5th gearwheel
Fourth gear Reverse gear

1 Input shaft 1 Input shaft
2 Output shaft 2 Output shaft
3 Output pinion 3 Output pinion
4 3rd/4th gear synchronizer clutch 4 Reverse gearwheel
5 4th gear teeth 5 Teeth - reverse gear
6 4th gearwheel 6 Reverse gear idler
The reverse gear idler is driven by the input shaft

Fifth gear and its purpose is to reverse the direction of
rotation of the output shaft when reverse gear is
engaged.
The reverse gear idler is carried on a needle
roller bearing on the idler shaft, and also on a
mounting.
The detent mechanism and the gear selector
finger are mounted on a sleeve in the selector
mechanism housing, and they use a spring-
loaded ball keep the chosen gear engaged until
another gear is selected.
The selector lock mechanism has three selector
positions.
E4460 EN 07/2001

Manual Transaxle
E3553 EN 07/2001
IN-VEHICLE REPAIR
Input Shaft Oil Seal
Remover, oil seal Self-tapping screw 2,5
303-336 (21-151) x 15 mm
Removal
All vehicles
2. Detach the clutch slave cylinder from the
clutch housing.
2. NOTE: Also see the following job step.

Punch mark the input shaft oil seal
• Punch mark the input shaft oil seal using
the special tool.
3. NOTE: Carry out this step only in the position

shown.
Remove the input shaft oil seal (cont.).
1. Input shaft
2. Radial oil seal
3. Closed ball bearing
E1157 EN 07/2001
IN- VEHICLE REPAIR (CONTINUED)
4. CAUTION: Do not damage the input

shaft ball bearing.
Remove the drive halfshaft oil seal.
1. Screw a 2,5 x 15 mm self-tapping screw
a maximum of two turns into the input
shaft oil seal.
2. Lever out the input shaft oil seal.
Installation
1. Fit the drive halfshaft oil seal and the clutch
slave cylinder.
1. Position the input shaft oil seal.
2. Position the clutch slave cylinder.
3. Tighten the bolts evenly. In doing so,
press the input shaft oil seal into the
transmission housing.
E1157 EN 07/2001
IN-VEHICLE REPAIR
LH Halfshaft Oil Seal (14 303 0)
Installer, Halfshaft Oil Seal Remover, Halfshaft Oil Seal
308-039 (16-018) 308-208 (16-074)
Removal

inner joint must not be bent more
not be bent more than 45 degrees.
CAUTION: Pull the right-hand halfshaft
out straight, otherwise the oil seal will
be damaged.
NOTE: Escaping oil.
Remove the right-hand halfshaft and secure
it. For additional information,

Remove the left-hand halfshaft. For
3. Using the special tool, remove the left-hand

front drive halfshaft oil seal.
E6738 EN 07/2001
Installation
1. Using the special tool, install the left-hand
halfshaft oil seal.
2. Install the left-hand halfshaft. For additional

3. Install the right-hand halfshaft. For

E6738 EN 07/2001
IN-VEHICLE REPAIR
RH Halfshaft Oil Seal (14 304 0)
Installer, Halfshaft Oil Seal Remover, Oil Seal
308-039 (16-018) 303-112 (21-051)
Removal
1. Remove the halfshaft heat shield.

All vehicles
Remove the right-hand halfshaft. For
additional information, refer to Section 205 - 04.
E6739 EN 07/2001
4. Using the special tool, remove the right-

hand halfshaft oil seal.
Installation
1. Using the special tool, install the right-hand
halfshaft oil seal.

2. Install the halfshaft heat shield.
E6739 EN 07/2001

All Vehicles
4. Install the right-hand halfshaft. For
E6739 EN 07/2001
REMOVAL
Transaxle — Vehicles with 1.6L / 1.3L Engine (16 114 0)
Remover, Halfshaft Adapter for 303-290
308-237 (16-087) 303-290-03 (21-140-03)
Remover, Halfshaft
308-256 (16-089) General Equipment
Engine lifting eye
Transmission jack
Auxiliary plugs
Support Bar, Engine
303-290 (21-140) Retaining straps
Manual transmission BOT 130
Adapter for 303-290 fluid
303-290-01 (21-140-01) Cable ties
Removal
1. NOTE: The position descriptions for the

engine mountings and the engine roll
restrictor are given looking from the transaxle
towards the engine.
Remove the battery. For additional

1. Remove the cable ties.
E6700 EN 07/2001
RE MOVAL (CONTINUED)

1. Remove the air cleaner intake from the
intake manifold.
2. Detach the air cleaner intake pipe from
the retaining clip.
3. Remove the air cleaner housing.
4. Remove the air cleaner intake pipe from
the resonator hose.
5. Remove the resonator.
E6700 EN 07/2001
REMOVAL (CONTINUED)
All vehicles
rod turning.
Loosen the left-hand and the right-hand
suspension strut nut five turns.
7. WARNING: Escaping brake fluid. Do

not allow brake fluid to come into
contact with the skin or the eyes. If
brake fluid does come into contact
with the skin or the eyes, rinse the
affected areas with water
immediately. Failure to follow these
instructions may result in personal
injury.
immediately washed down with cold
water.
Disconnect the high-pressure line from the
clutch slave cylinder.
(HO2S) electrical connector
2. Disconnect the ignition coil electrical
connector
3. Disconnect the powertrain control
module (PCM) electrical connector
4. Disconnect the vehicle speed sensor
(VSS) electrical connector.
E6700 EN 07/2001
9. Remove the transaxle upper flange bolts
with ground cable and the hose.
1. Remove the ground cable flange bolt
connector
connector
4. Detach the transaxle ventilation hose
10. Remove the transaxle upper flange bolts.

11. Remove the transaxle upper flange bolts
with ground cable.
12. Using the special tools support the engine

and transaxle assembly.
• Using the special tool slightly raise the.
E6700 EN 07/2001
REMOVAL (CONTINUED)
13. Install an engine (cylinder No. 4) using the
existing thread in the cylinder head.
14. Using the special tools support the engine

and transaxle assembly.
All vehicles
15. Remove the engine rear mounting bracket.

E6700 EN 07/2001
All vehicles
18. Disconnect the reversing lamp switch

19. Disconnect the speedometer drive cable

from the transaxle.

E6700 EN 07/2001
REMOVAL (CONTINUED)
22. Remove the exhaust down pipe from the

exhaust manifold and secure it to one side.
1. Remove the nuts.
2. Detach the hanger insulator.
All vehicles
23. Disconnect the shift rod and shift rod
stabilizer.
1. Disconnect the shift rod
2. Disconnect the shift rod stabilizer
24. NOTE: Do not disconnect the starter motor.

Remove the starter motor bolts retaining
and secure the starter motor to one side
and the left-hand transaxle flange bolt.
E6700 EN 07/2001
25. Remove the lower arm ball joints on both

sides (left-hand side shown).
26. Remove the constant velocity joint boot

clamp.

be bent at more than 18 degrees; the
outer joint must not be bent at more
than 45 degrees.
NOTE: Remove the grease filling.
Remove the halfshafts on both sides (left-
hand side shown, right-hand side similar).
Secure halfshafts with cable ties.
28. NOTE: The engine roll restrictor is under

tension.
Remove the engine roll restrictor.
E6700 EN 07/2001
REMOVAL (CONTINUED)
30. Using the special tools, lower the transaxle.


32. Push the engine forward and position a
wooden block (260 mm) between the
crossmember and the oil pan.
All vehicles
33. Remove the transaxle right-hand flange
bolts.
E6700 EN 07/2001
34. Remove the transaxle lower flange bolts.
35. NOTE: Secure the transaxle with a retaining

strap and support it by using a transmission
jack.
Withdraw the transaxle from the engine and
remove it.
E6700 EN 07/2001
DISASSEMBLY
Transaxle (16 118 8)

Remover, input pinion oil seal Remover, fifth gearwheel
205-078 (15-048) 308-082 (16-035)
Remover, output shaft Transmission mounting

bearing cones bracket
205-176 (15-074) 303-435-06 (21-031B)
Transmission mounting Oil seal remover

bracket 303-112 (21-051)
205-329 (15-105)
Installer
Assembly stand
Disassembly
1. CAUTION: Handle the double

synchronizer components carefully.
General note:
• Always use vice jaw protectors when
working with a vice.
• Use copper or plastic headed hammers
to avoid causing any damage.
2. Fit the special tools.
E1162 EN 07/2001
All vehicles
2. Detach the clutch slave cylinder.
4. Remove the vehicle speed sensor (VSS).

1. Pull out the retaining pin.
2. Pull out the VSS.
5. Detach the cover and the detent

mechanism.
1. Cover
2. Fifth gear detent mechanism
3. Auxiliary shift rod detent mechanism
6. Remove the snap-rings and the selector

finger.
1. 5th gearwheel snap-ring
2. 5th gear synchronizer snap-ring
3. Slacken the bolt and remove the selector
finger.
E1162 EN 07/2001
7. Take out the 5th gear synchronizer and

selector fork.
8. NOTE: Mark the installation position of the

synchronizer clutch assembly before
dismantling it.
Dismantle the 5th gear synchronizer
assembly.
1. Snap-ring
2. Retaining plate
3. Synchronizer clutch
4. Synchronizer ring
5. 5th gearwheel
9. Pull off the 5th gearwheel.
E1162 EN 07/2001
10. CAUTION: Do not strike the mating

face.
Detach the 5th gear housing.
1. Unscrew the bolts and carefully tap the
housing sections apart.
2. Release and remove the housing gasket.
11. CAUTION: Do not strike the mating

face.
Remove the gasket, detach the snap-rings
and pull out the auxiliary plug.
1. Gasket
2. Output shaft snap-ring
3. Input shaft snap-ring
4. Pull out the auxiliary plug.
12. Remove both oil seals (left-hand side

shown).
• Lever out the front drive halfshaft oil
seals using the special tool.
• The reversing lamp switch only needs to
be removed for sealing work.
13. NOTE: To lift the housing off, turn it slightly

(the transmission breather pipe catches on
the input shaft).
Separate the transmission housing
sections.
• Remove the bolts and lightly tap on the
transmission housing sections to carefully
separate them.
E1162 EN 07/2001
14. Remove the upper snap-ring from the shift

rod guide sleeve.
1. Upper snap-ring
2. Slide the shift rod guide sleeve
downwards.
15. Remove the shift rod guide sleeve.

1. Remove the guide sleeve lower snap-
ring.
2. Pull out the shift rod guide sleeve.
16. NOTE: Attach a rubber band to the auxiliary

shift rod as an aid during assembly.
Lift out the input and output shafts together
with the selector forks.
17. Remove the reverse gear idler and the shift

rod with locking plate.
1. Remove the reverse gear idler.
2. Take out the shift rod and locking plate
together.
E1162 EN 07/2001
18. Remove the differential assembly, the

permanent magnet and the input shaft oil
seal.
1. Take off the housing gasket.
2. Lift out the differential assembly.
3. Permanent magnet
4. Drive out the drive halfshaft oil seal.
19. Remove the output shaft taper roller

bearing.
1. Press the rollers out of the bearing cage.
2. Remove the bearing cage.
20. CAUTION: Use the special tool only

in the position shown, otherwise the
blanking plug will be pushed out of
the housing.
Remove the output shaft bearing cone.
• Remove the oil slinger.
21. NOTE: Position the special tool in the

cutouts in the housing.
Remove the differential bearing cone.
E1162 EN 07/2001
22. NOTE: Disc pack installation position (see

following job step).
Remove the bearing cone.
23. Order of installation of differential shim

pack.
1. Bearing cone
2. Shim
3. Spring washer
E1162 EN 07/2001

Selector Plate (16 284 5)
Draw hammer Remover and installer, shift
205-102 (15-053) rod oil seal
308-040 (16-019)
Universal sealant (Hylomar)
Disassembly
1. Remove the shift rod oil seal.
• Pull off the boot.
2. CAUTION: The shift gate is set in

production. If it is undone a Service
shift gate must be installed in its
place.
Remove the auxiliary shift rod.
1. Remove the bolts from the relay lever
mounting.
2. Remove the auxiliary shift rod together
with the relay levers.
E1163 EN 07/2001
3. NOTE: Ease of movement and correct

resetting to "neutral" position.
Check the relay levers and the detent
mechanism.
1. Relay lever (shift)
2. Relay lever (select)
3. Return spring (shift mechanism neutral)
4. Remove the shift rod and the reverse gear

shift lever.
1. Detach the selector block from the shift
rod (remove the bolt).
• Pull out the shift rod and take out the
selector block.
2. Detach the snap-ring and remove the
reverse gear shift lever with spring.
Assembly
1. Install the shift rod and the reverse gear
shift lever.
1. Insert the selector block.
• Introduce the shift rod.
2. Coat the bolt with universal sealer
(Hylomar) and screw in.
3. Install the reverse gear shift lever and
spring and fit the snap-ring.
2. CAUTION: The shift gate is set in

production. If it is undone, a service
shift gate must be installed in its
place.
Install the auxiliary shift rod.
1. Insert the auxiliary shift rod together with
the relay levers.
2. Insert the bolts.
E1163 EN 07/2001
3. Install the shift rod oil seal.

• Fit the boot.
E1163 EN 07/2001

Input Shaft (16 146 5)

Installer Puller
308-045 (16-015) Press
Transmission fluid BOT 130
Disassembly
CAUTION: Handle synchronizer rings

and cones with care.
1. Pull off the ball bearing on the transmission
end.
2. Engage a proprietary puller under the
snap-ring and pull off the ball bearing.
2. Pull off the ball bearing on the clutch end.
Assembly
1. Carefully clean and check all parts and coat
with transmission fluid before assembling.
E1164 EN 07/2001
2. Press on the ball bearing (clutch end) with

the workshop press.
3. NOTE: The groove on the ball bearing should

be towards the outside.
Press on the ball bearing (transmission
end) using the workshop press.
E1164 EN 07/2001

Output Shaft
Remover, basic tool Puller
205-295 (15-050A) Press
Installer
308-045 (16-015)
Collet for 15-050 A

307-217 (17-048)
Disassembly
CAUTION: Handle synchronizer rings

and cones carefully.
1. Detach the ball bearing and the 4th
gearwheel.
1. Detach the small snap ring.
2. Remove the snap-ring.
3. Pull off the ball bearing using a
proprietary remover.
4. Remove the 4th gearwheel and
synchronizer ring.
E1165 EN 07/2001
2. Detach the 3rd/4th gearwheel

2. Remove the synchronizer clutch, the
3rd/4th gear synchronizer assembly and
the 3rd gearwheel.
3. Remove the third gear synchronizer ring.

2. Third gearwheel
4. NOTE: Double synchronisation (as shown in

the illustration) is used for service repairs.
Dismantle the 3rd/4th gear synchronizer
assembly.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. 3rd gearwheel
E1165 EN 07/2001
5. Detach the 2nd gearwheel and

synchronizer assembly.
1. Retaining ring
2. Half rings
3. 2nd gearwheel
6. NOTE: Detach the 1st gearwheel and

synchronizer assembly together.
Detach the 1st gearwheel and the reverse
gearwheel together with the synchronizer
clutch and synchronizer assembly.
2. Take off the 1st/2nd gear synchronizer
clutch with the reverse gearwheel.
6. Gearwheel - 1st gear
E1165 EN 07/2001
7. CAUTION: Mark the components to

show the way the shift ring and
synchronizer clutch hub fit together.
Dismantle the synchronizer assembly.
1. Shift ring
2. Synchronizer spring
3. Blocker bar
4. Synchronizer clutch hub
8. NOTE: Insert the thrust ring into the oil slinger

bore.
Detach the output shaft bearing cone.
1. Remove the snap-ring.
• Locate the expanding claws underneath
the bearing cone.
2. Pull off the bearing cup.
Assembly
CAUTION: Lay the double synchronizer

units in transmission fluid before install-
ing them.
1. Carefully clean and check all sliding parts
and coat with transmission fluid before
assembling.
E1165 EN 07/2001
2. Fit the output shaft bearing cone.

• Heat the bearing cone evenly to about
80 °C and slide it onto the output shaft.
• Fit the snap-ring.
3. NOTE: Assembly markings on the shift ring

and synchronizer clutch hub.
Assemble the synchronizer clutch.
1. Synchronizer clutch hub
2. Place the shift ring onto the synchronizer
clutch hub.
3. Install the blocker bar.
4. Install the synchronizer spring.
4. Fit the 1st gearwheel and the reverse

gearwheel with the synchronizer clutch and
synchronizer assembly on the output shaft.
1. 1st gearwheel
5. 1st/2nd gear synchronizer clutch with
reverse gearwheel
6. Snap-ring
E1165 EN 07/2001
5. NOTE: Assembly the synchronizer before

fitting it.
Fit the 2nd gearwheel and synchronizer
assembly on the output shaft.
4. 2nd gearwheel
5. Half rings
6. Retaining ring
6. NOTE: Double synchronizer shown - is used

for servicing.
Assemble the 3rd/4th gear synchronizer.
1. 3rd gearwheel
7. Fit the third gear synchronizer ring.

2. Third gearwheel
E1165 EN 07/2001
8. NOTE: Fit the shift ring with the annular

groove downwards and the smaller collar on
the hub upwards.
Fit the 3rd/4th gear synchronizer
1. Put on the synchronizer clutch, the
3rd/4th gear synchronizer assembly and
the 3rd gearwheel.
9. NOTE: Fit the ball bearing with the annular

groove towards the outside.
Fit the 4th gearwheel and the ball bearing.
1. Put on the 4th gear synchronizer ring
and the 4th gearwheel.
2. Press on the ball bearing using the
workshop press.
• Fit the snap-ring.
E1165 EN 07/2001

Differential
Thrust pad Collet for 15-050 A
204-158-01 (14-038-01) 308-197 (16-062)
Installer, differential bearing

205-062 (15-025A) General Equipment
Press
Remover, basic tool Transmission fluid BOT 130
205-295 (15-050A)
Disassembly
1. Pull the taper roller bearings off the
differential assembly.
1. Insert the thrust ring.
2. Pull off both taper roller bearings.
3. Remove the sensor ring for the vehicle
speed sensor (VSS)
E1166 EN 07/2001
2. Remove the differential pinions.

1. Turn the front drive halfshaft pinion gears
through 90 degrees in the differential cage
and remove them.
2. Remove the snap-ring and drive out the
shaft.
• Take out the two differential pinions and
the plastic thrust washers.
3. Remove the eight bolts and drive the
crown wheel evenly off the differential
cage.
Assembly
1. NOTE: Do not oil taper roller bearings, which

are going to be re-used. New taper roller
bearings may be fitted without lubricating
them.
Carefully clean and check all parts and coat
with transmission fluid before assembling.
2. Install the differential pinions.

1. Pull on the crown wheel evenly using the
old bolts.
• Position the plastic thrust washers and
the differential pinions.
2. Drive in the spindle and fit the snap-ring.
3. Insert the front drive halfshaft pinion
gears and turn them through 90 degrees
in the differential cage.
3. NOTE: The speedometer drive wheel must

engage in the cutouts in the differential cage.
Use new crown wheel bolts.
Install the taper roller bearings and screw in
the eight crown wheel bolts.
1. Tighten the crown wheel bolts evenly,
working diagonally.
2. Put on the VSS sensor ring.
NOTE: Do not use the lower taper roller bearing

for support.
3. Press on both taper roller bearings using
the workshop press.
E1166 EN 07/2001
ASSEMBLY
Installer, differential bearing Valve spring compressor
205-296 (15-085) 303-060 (21-024)
Installer, bush and Adapter for 21-024

transmission extension oil 303-060-02 (21-024-02)
seal
308-045 (16-015)
Drive halfshaft oil seal Adapter for 21-024

installer 303-060-07 (21-024-07)
308-039 (16-018)
Installer, bearing cone

Press
Dial gauge
Magnetic fixture
Replacer, snap-ring
308-076 (16-031)
Universal sealer (Hylomar)
End cap sealer WSE-M4G323-A4
Sealant, transmission WSK-M2G348-A5
housing
Assembly
1. Carefully clean and check all components
before assembly.
• Coat all sliding parts with transmission
fluid.
E4462 EN 07/2001
2. Install the output shaft roller bearing with
bearing cone.
1. Fit the oil slinger.
2. Drive in the roller bearing as far as the
stop.
3. Fit the differential bearing cone.
4. Install the differential assembly and

permanent magnet.
1. Permanent magnet
2. Differential
5. NOTE: Correct location of the reverse gear

idler
Put on the reverse gear idler.
E4462 EN 07/2001
6. Fit the shift rod with the locking plate.
7. Prepare input and output shaft for

installation.
1. Bring the input shaft and output shaft into
mesh with one another.
2. Move the 1st/2nd gear selector fork into
position.
3. Move the 3rd/4th gear selector fork into
position.
8. Install the input shaft and output shaft.

• Attach a rubber band to the auxiliary shift
rod as an aid to assembly.
1. Guide the input shaft in about 50 mm
and angle it slightly to the side.
2. Put in the output shaft to about the same
level as the input shaft and engage the
gearwheel teeth again.
• Move the input and output shafts into
their final positions.
9. Install the shift rod guide sleeve.

1. Slide the guide sleeve into position.
2. Fit the lower snap-ring.
E4462 EN 07/2001
10. Fit the shift rod guide upper snap-ring.

1. Raise the guide sleeve.
2. Install the upper snap-ring.
3. Fit the housing gasket.
• Move the inner selector mechanism into
5th gear position (the 5th gear selector
rod moves downwards).
11. Move the inner selector mechanism into 5th

gear.
• Turn the auxiliary shift rod clockwise until
the reverse/5th gear gate is reached.
12. Move the inner gearshift linkage into 5th

gear.
• Press the auxiliary shift rod down
together with the shift rod.
13. Fit the measuring shim and secure it with a

blow from a punch.
1. Transmission housing
2. Measuring shim (3,8 mm thick)
3. Bearing cone
E4462 EN 07/2001
14. CAUTION: On transmissions without

liquid sealers the transmission
gasket must be in place for the
following measurement.
Assemble the transmission housing.
• Fit the special tool with the longer bolt.
• Fit the auxiliary plug.
• Turn the transmission through 180
degrees.
15. Fit the special tool.

• Remove the assembly plug.
16. Prepare the differential for measuring.

• Rotate the differential at least 10
revolutions to settle the bearings.
• Put the dial gauge in position with the
magnetic fixture and zero it.
E4462 EN 07/2001
17. NOTE: Carry out steps and three times and
calculate the average measurement.
Measure the differential end float.
1. Lift the differential assembly using the
special tool.
2. Read off the measurement.
• Example:
• 1st measurement: 0,73 mm
• 2nd measurement: 0,74 mm
• 3rd measurement: 0,72 mm
• Average = 0,73 mm + 0,74 mm + 0,72
mm / 3 = 0,73 mm.
• The shim thickness should be rounded
down up to 0.05 mm and rounded up from
0.06 mm.
• The shims are available in thicknesses
from 0,1 mm to 1,1 mm in increments of
0,1 mm.
• Continue with step 18
18. Establish the required adjustment shim

(example).
• Thickness of the adjustment shim =
• measuring shim (3,80 mm) +
• average value (0,73 mm) +
• bearing preload (0,40 mm) -
• thickness of the Belleville washers
(4,42 mm) =
• 3,80 mm + 0,73 mm + 0,40 mm - 4,42
mm = 0,51 mm.
• The resulting adjustment shim thickness
is 0,51 mm, which is rounded down to 0,5
mm.
19. Separate the transmission housing halves

• Insert the upper assembly plug.
• Turn the transmission through 180
degrees.
• Detach the dial gauge, magnetic fixture
and special tool.
E4462 EN 07/2001
20. Remove the bearing cone with the

measuring shim.
21. NOTE: The Belleville washers are inserted

with the inside edges touching.
Fit the required shim and secure it with a
blow from a punch.
1. Spring washers
2. Required shim
3. Fit the bearing cone and secure it with a
blow from a punch on the edge of the
housing.
22. On transmissions with a black end cover

apply transmission housing sealer evenly
to the mating faces of the transmission
housing halves.
NOTE: On transmissions without liquid sealer

note the installation position of the housing gas-
ket.
NOTE: Tighten the studs to 33 Nm.
23. Put the housing parts together and tighten
the bolts evenly.
E4462 EN 07/2001
24. NOTE: Use a wooden support.

Fit the snap-rings for the input and output
shafts.
25. NOTE: Turn the snap-rings so that these lie

in the recesses in the gasket.
Fit the gasket.
• Insert the assembly plug.
26. Install the 5th gear housing.
CAUTION: Detach the transmission from

the assembly stand and carry out the
following steps on the press.
E4462 EN 07/2001
27. NOTE: The transmission housing must not

sit on the press table. Support the assembly
on the splined clutch input shaft on the press
table.
Press the 5th gearwheel onto the input
shaft using the workshop press.
• Detach the transmission from the
assembly stand.
• Press on the 5th gearwheel using the
workshop press.
• Mount the transmission on an assembly
stand.
28. Fit the 5th gearwheel snap-ring.

1. Fit the snap-ring on the special tool.
2. Put the special tool in place and drive on
the snap-ring.
29. NOTE: Marking showing the correct

assembly position of the synchronizer clutch.
Assemble the 5th gear synchronizer clutch.
1. 5th gearwheel
3. Synchronizer clutch
4. Retaining plate
30. Install the 5th gear synchronizer assembly

together with the selector fork.
1. Swivel the lever upwards.
2. Slide on the 5th gear synchronizer
assem bly until it reaches the actuator.
E4462 EN 07/2001
31. NOTE: Do not tighten the selector finger bolt

yet.
Install the selector finger and the snap-ring.
1. Insert the selector finger.
2. Move the selector finger and 5th gear
synchronizer unit into position together.
3. Fit the 5th gear synchronizer snap-ring.
32. NOTE: Only fit in the neutral position.

Installation setting of the auxiliary shaft
detent mechanism.
33. Fit the detent mechanisms.

• Coat the thread with universal sealer
(Hylomar).
34. Engage fifth gear.

• Press the selector fork and selector
finger down together.
E4462 EN 07/2001
• Turn the fifth gearshift rod clockwise as
far as the stop.

• Turn the main shift rod clockwise as far
as the stop and pull it out.
37. Adjust the selector finger.

1. Turn the main shift rod clockwise and
press it down.
2. Remove the end float of the selector
finger by lifting it.
3. Tighten the bolt in this position.
38. On transmissions with a black end cover

apply end cover sealer evenly to the
mating face of the end cover.
39. Fit the cover and install the input shaft oil
seal.
1. Fit the end cover with the gasket.
2. Drive in the input shaft oil seal until it is
felt to reach its stop.
• Fit the assembly plug.
E4462 EN 07/2001
40. Install the vehicle speed sensor (VSS).

1. Insert the VSS.
2. Insert the retaining pin.
42. Install the clutch release bearing in the

clutch slave cylinder.
All vehicles
43. Fit the drive halfshaft oil seal and the clutch
slave cylinder.
1. Position the input shaft oil seal.
2. Position the clutch slave cylinder.
3. Tighten the bolts evenly. In doing so,
press the input shaft oil seal into the
transmission housing.
2. Detach the transmission from the assembly

stand.
E4462 EN 07/2001
INSTALLATION
Support Bar, Engine Engine lifting eye
303-290 (21-140) Transmission jack
Auxiliary plugs
Retaining strap
Adapter for 303-290
303-290-01 (21-140-01) Material Specification
Manual transmission BOT 130
fluid
Adapter for 303-290
Cable ties
303-290-03 (21-140-03)
Installation
2. Secure the transaxle with a retaining strap

and position under the vehicle by using a
transmission jack.
E6701 EN 07/2001
3. Install the transaxle lower flange bolts.
4. Install the transaxle right-hand flange bolts.
5. Install the left-hand transaxle flange bolt

and starter motor bolts.

6. Remove the wooden block.
All vehicles
E6701 EN 07/2001
8. Using the special tools, raise the engine

and transaxle.
9. NOTE: Do not tighten the nuts and bolts.

Install the engine rear mounting bracket.
10. NOTE: Do not tighten the nuts.
Install the engine front mounting bracket.
All vehicles
12. Adjust gearshift linkage. For additional

13. Attach the shift rod and gearshift

mechanism stabilizer.
1. Attach the shift rod
2. Attach the shift rod stabilizer
E6701 EN 07/2001
14. Install the engine roll restrictor.

be bend more than 18 degrees, the
outer joint must not be bend more
than 45 degrees.
CAUTION: Use the installation sleeve
(supplied with every new oil seal) to
protect the oil seal when inserting the
front halfshaft.
NOTE: Fill the inner constant velocity housing
with High-durability grease.
NOTE: Make sure the snap rings are securely in
place.
Install the left-hand and the right-hand
halfshaft in the transaxle together with new
snap rings.
16. Install the left-hand and right-hand lower

arm ball joints.
E6701 EN 07/2001

17. NOTE: Use a new gasket.
Install the exhaust down pipe.
2. Connect the exhaust hanger insulator.

All vehicles
20. Connect the speedometer drive cable.
E6701 EN 07/2001
21. Connect the reversing lamp switch


23. Tighten the bolts and nuts of the engine
rear mounting bracket.
25. Remove the engine lifting eye.
E6701 EN 07/2001
26. CAUTION: Always tighten the engine

front mounting before tightening the
engine rear mounting.
Tighten the engine front mounting.
27. Tighten the engine rear mounting bracket.
29. Install the transaxle upper flange bolts and

the ground cable.
E6701 EN 07/2001
30. Install the resonator.

31. Install the transaxle upper flange bolt.
32. Install the transaxle upper flange bolt and

ground cable, connect the electrical
connectors and the hose.
1. Install the flange bolt with ground cable
2. Reconnect the generator electrical
connector
3. Reconnect the starter motor electrical
connector
4. Attach the transaxle ventilation hose
33. Connect the electrical connectors.

1. Heated oxygen sensor (HO2S) electrical
connector
2. Ignition coil electrical connector
3. Powertrain control module (PCM)
electrical connector
4. Vehicle speed sensor (VSS) electrical
connector
E6701 EN 07/2001
All vehicles
34. WARNING: Escaping brake fluid. Do

not allow brake fluid to come into
contact with the skin or the eyes. If
brake fluid does come into contact
with the skin or the eyes, rinse the
affected areas with water
immediately. Failure to follow these
injury.
immediately washed down with cold
water.
Install the clutch slave cylinder high-
pressure line.
• Insert the clutch slave cylinder high-
pressure line in the bracket.
35. Bleed the clutch hydraulic system . For


36. Install the air cleaner (ACL) intake pipe.

37. Install the air cleaner intake hose.
1. Install the resonator pipe (clip).
2. Install the intake pipe to the air cleaner
housing.
3. Install the clip.
4. Install the air cleaner housing to the
intake manifold.
E6701 EN 07/2001
All Vehicles
38. NOTE: Use an Allen key to prevent the
piston rod turning.
Tighten the suspension strut nut on both
sides.
39. Install the battery tray.

1. Install new the cable ties.
40. Install the battery. For additional

E6701 EN 07/2001
GENERAL PROCEDURES
Bearing Check
1. NOTE: Use the following procedure when
checking taper roller bearings and roller
bearings:
General notes.
• Check the condition of all the
components when disassembling them.
• Find out the cause of the damage with
the aid of the following illustrations.
• Remedy the problem and, if necessary,
renew the bearing (see bearing checks).
2. Bearing cage damaged at the top or side

through incorrect use of a special tool or
use of the wrong tool.
• Renew the bearing.
3. The taper roller ends are discolored as a

result of inadequate lubrication, overheating
or excessive bearing preload.
• Renew the bearings and gaskets and
make sure there is adequate lubrication.
4. Taper roller ends are worn away as a result

of incorrect installation, excessive bearing
preload or incorrect seating.
E3570 EN 07/2001
5. The bearing surfaces are gray or gray/black

with abraded particles between the taper
rollers.
6. The surface of the bearing race is notched

as a result of impacts at standstill.
• Renew the bearing if its surface is rough,
or if it is noisy.
7. Dark blue coloring from overheating (yellow

or brown color is normal) due to excessive
bearing preload or inadequate lubrication.
Overheating can cause the bearing to lose
its surface hardness. Use a file to test the
surface hardness. Material can be filed
away from soft bearings but not from hard
bearings.
• If overheating is diagnosed, renew the
bearing and check the gaskets and other
components.
8. Surface abrasion due to material fatigue.

• Renew the bearing and clean all the
affected components.
E3570 EN 07/2001
SPECIFICATIONS
Item Specification
High-temperature grease ESD-1C220-A
Manual transmission fluid BOT 130
Brake fluid (DOT 4) SAE J1703 JUN91
Universal Sealer (Hylomar)
Capacities
Liters
Manual transmission fluid (5 - 10 mm below the level check lower edge) 2.8
Transaxle Ratios
Ratio 1.6L 1.3l 1.8L diesel
First gear 3.58 3.58 3.583
Second gear 1.93 1.92 1.926
Third gear 1.28 1.41 1.281
Fourth gear 0.95 1.10 0.951
Fifth gear 0.76 0.87 0.756
Reverse gear 3.61 3.61 3.615
Differential 4.06 4.25 4.25
Speedometer driven pinion 19 19 19
Speedometer drive worm wheel 21 21 21
Measuring and Adjusting Shims

Shim Thickness
Measuring shims mm 3.8
Available shims (0,1 mm increments) mm 0.1 - 1.1
Description Nm
Crown wheel to differential 115
Clutch slave cylinder 10
Selector block to main selector shaft 14
Selector gate 26
Auxiliary selector shaft 22
Transaxle housing 28
Fifth gear housing to transaxle housing 13
Detent mechanism 25
Reversing lamp switch 18
E6702 EN 07/2001
Description Nm
Transaxle housing cover 12
Pre-load valve for clutch slave cylinder 10
Flange bolts - transaxle to engine 44
Engine roll restrictor to engine 50
Engine roll restrictor to crossmember 69
Stabiliser link rod to suspension strut 47
Lower suspension arm to spindle carrier 52
Suspension strut top nut 46
Battery box 25
Gear selector finger 17
Transaxle filler plug 35
Wheel nuts 85
Catalytic converter to exhaust manifold 47
Starter motor 44
Shift rod stabiliser 55
Heat shield 12
Rear engine mounting bracket (1.6L / 1.3L engine) 69
Rear engine mounting bracket to frame (1.6L / 30
1.3L engine)
Rear engine mounting bracket (diesel engine) 70
Front engine mounting bracket (diesel engine) 70
Front engine mounting bracket 130
E6702 EN 07/2001
308-06-113 Manual Transaxle External Controls 308-06-113
SECTION 308-06 Manual Transaxle External Controls

SUBJECT PAGE

External Controls ..................................................................................................................... 308-06-114

External Controls ..................................................................................................................... 308-06-115
Pinpoint Test ......................................................................................................................... 308-06-115/116

Gearshift Linkage ............................................................................................... (16 534 0) 308-06-117/121
Gearshift Stabilizer Bar Bushing........................................................................ (16 589 4) 308-06-122
Gearshift Stabilizer Bar...................................................................................... (16 588 0) 308-06-123

Shift Lever ................................................................................................................................ 308-06-124/126
SPECIFICATIONS
Specifications ........................................................................................................................... 308-06-127
07/2001

External Controls Item Description
Overview - Gearshift Mechanism 1 Shift rod
2 Boot - shift rod
3 Inner boot - gear lever
4 Gear lever
5 Mounting sleeve - gear lever
6 Noise damping pad
7 Gearshift mechanism housing top
cover
8 Gearshift mounting
9 Gearshift mechanism housing lower
cover
10 Gearshift stabiliser
A selector rod operates the iB5 manual

transmission in the 2002 Bantam.
In order to isolate the outer gearshift mechanism
from the bodywork, the gearshift housing is
located in the gearshift mounting. This mounting
can move lengthways to balance the rotational
movements of the engine / transmission.
The gearshift housing is rigidly joined to the
transmission by the gearshift stabiliser.
E1170 EN 07/2001

External Controls
Since troubleshooting actually begins when
repairs are taken on, the following procedure is Mechanical
recommended: • Visibly damaged or worn parts
• Loose or missing nuts or bolts
1. Check customer concern is clear. If
necessary, reconstruct the concern on the
3. If the concern can be visually identified,
vehicle. resolve it and check that the system operates
2. If the concern cannot be reproduced, carry correctly.
out a road test and/or a visual check with the
4. If the concern cannot be clearly located, use
aid of the following table:
the following troubleshooting table to exactly
identify it.
Troubleshooting Table
• Gearshift mechanism difficult to • Outer gearshift mechanism out • Adjust REFER to Section 308-00
move of alignment
• Faulty gear lever • Go to Pinpoint Test A
• Gearshift stabiliser stressed • Go to Pinpoint Test A
Pinpoint Test
PINPOINT TEST A: GEARSHIFT MECHANISM DIFFICULT TO MOVE
A1: CHECK GEAR LEVER
1 Detach shift rod from the transmission.
• Is the outer gearshift mechanism difficult to
move?
Yes
Dismantle the gear lever and check for
defective parts. REFER to Section 308-06.
No
GO TO A2
E4463 EN 07/2001

A2: CHECK FOR STRESSED GEARSHIFT STABILISER
1 Detach the gearshift stabiliser from the
transmission.
• Is the stabiliser stressed?
Yes
Undo the engine/transmission mountings;
align the engine/transmission in such a way
that the gearshift stabiliser can be installed
free from tension. Tighten the engine/
transmission mounting.
REFER to Section 303-01A.
REFER to Section 303- 01B.
Adjust the gearshift mechanism.
No
Faulty transmission. REFER to Section 308-03
E4463 EN 07/2001

Gearshift Linkage (16 534 0)
Removal
1. Remove the gearshift lever knob.
2. Remove the gearshift lever outer boot.
3. Remove the gearshift lever inner boot.

E6707 EN 07/2001
REMOVAL AND INSTALLAT ION (CONTINUED)


8. Disconnect the shift rod and the shift rod

stabilizer.
1. Disconnect the shift rod
2. Disconnect the shift rod stabilizer
9. Remove the gearshift mounting.
E6707 EN 07/2001
Installation
1. Install the gearshift mounting.
2. Adjust the gearshift mechanism. For

3. NOTE: If the gearshift stabilizer cannot be

installed without stress, loosen the
engine/transaxle mounting and align.
Install the gearshift stabilizer and shift rod.
1. Attach the shift rod
2. Attach the shift rod stabilizer
4. Tighten the engine / transmission mounting

(if necessary). For additional information,
refer to Section 303-01A. For additional
E6707 EN 07/2001
REMOVAL AND INSTALLAT ION (CONTINUED)


9. Install the inner boot to the gear lever.
10. Install the gearshift lever boot.
E6707 EN 07/2001
11. Install the gearshift lever knob.
E6707 EN 07/2001

Gearshift Stabilizer Bar Bushing (16 589 4)
Special Tool(s)
Installer
308-045 (16-015)
Removal
1. Remove the gearshift mechanism and
detach the gearshift stabiliser. For
2. Press out the stabiliser bush using a

suitable thrust element.
Installation
1. NOTE: The bush is tapered and can only be

inserted from one side.
Press in the stabiliser bush.
2. Fit the gearshift stabiliser and install the

gearshift mechanism. For additional
E1174 EN 07/2001

Gearshift Stabilizer Bar (16 588 0)
Removal
1. Remove the gearshift mechanism. For
2. Detach the gearshift stabiliser.
Installation
1. Fit the gearshift stabiliser.
2. Install the gearshift mechanism. For

E1173 EN 07/2001

Shift Lever
Special Tool(s)
Installer, Extension Housing
Bushing/Oil Seal
308-045 (16-015)
Disassembly
1. Remove the following parts:
1. Remove the stabilizer
2. Remove the noise damping pad
3. Remove the gearshift mounting
2. Remove the gearshift lever.

1. Press the mounting sleeve locking lugs
out of the housing cover using a
screwdriver.
2. Remove the gearshift lever.
3. Remove the gearshift lever mounting

sleeve from the gearshift lever.
E6748 EN 07/2001
4. Remove the shift rod boot and the housing

cover.
Assembly
1. Reassemble the gearshift mechanism.
1. Insert the shift rod.
2. Install the housing cover.
3. Slide on the shift rod boot.
4. Slide on the gearshift mounting.
5. Slide the mounting sleeve onto the
gearshift lever.
NOTE: Make sure that the gearshift lever is
placed correctly in the shift rod.
6. Install the gear lever.
7. Install the noise damping pad.
E6748 EN 07/2001
2. Install the gearshift stabilizer bar.
E6748 EN 07/2001
SPECIFICATIONS
Nm
Gearshift mechanism pilot bearing to body 14
Gearshift stabiliser to transmission 55
Gearshift stabiliser to gearshift mechanism hous- 12
ing
Shift rod to selector shaft 23
E1177 EN 07/2001
309-00-1 Exhaust System — General Information 309-00-1
SECTION 309-00 Exhaust System —

General Information
SUBJECT PAGE

Exhaust System - Diesel Engine............................................................................................ 309-00-2
Exhaust System - Petrol Engine ............................................................................................ 309-00-3

Exhaust System ..................................................................................................................... 309-00-4
Symptom Chart ................................................................................................................... 309-00-4

Exhaust System ............................................................................................... (25 250 0) 309-00-5/6
Exhaust Flexible Pipe - Diesel Engine .................................................................................. 309-00-7/8
Muffler and Tailpipe ......................................................................................... (25 202 0) 309-00-9/11
SPECIFICATIONS
Specifications......................................................................................................................... 309-00-12
07/2001 2002 Bantam


Exhaust System
Diesel engine

1 Flexible coupling 2 Rear muffler
E1178 EN 07/2001 2002 Bantam


Petrol Engine
Item Description
1 Front muffler
2 Rear muffler
E1178 EN 07/2001 2002 Bantam


Exhaust System
1. Verify the customer concern by operating the 3. If an obvious cause is observed or reported
system. concern is found, correct the cause (if
2. Visually inspect for obvious signs of possible) before proceeding to the next step.
mechanical damage. 4. If the concern is not visually evident, verify
Visual Inspection Chart Chart.
Mechanical
• Leaks
• Metal fatigue or weld failure
• Pipes, mufflers.
• Joints and flexible coupling
• Mountings and clamps
• Clearance around components
Symptom Chart
• Engine has lack of power • Fuel system • REFER to Section 310-00 /
310- 01A / 310-01B / 310-02.
• Ignition system • REFER to Section 303-00 /
303- 04D.
• Electronic engine control • REFER to Section 303-00 /
303- 04D.
• Restricted exhaust system • CHECK the exhaust system for
restriction. INSTALL new com-
ponents as necessary
E1179 EN 07/2001 2002 Bantam


Exhaust System
Anti-seize grease Loctite "Never Seize"
Removal

multiplug.
3. Remove the manifold heat shield.
4. Disconnect the exhaust downpipe from the

manifold.
• Discard the retaining nuts and any studs
that may have been extracted with the
nuts.
Note: For vehicles with diesel engines,
refer to Exhaust Flexible Pipe in this section.
5. Raise the vehicle. Refer to Section 100-02
E5946 EN 07/2001 2002 Bantam

6. Remove the bottom rear shock absorber

mountings (Refer to Section 204-02) and
lower the rear axle to allow the removal of the
center and rear muffler.
7. Disconnect the exhaust system from the

downpipe and remove the exhaust system.
Installation
1. Install components in reverse order.
Note: Petrol engine - Renew ring seal and
exhaust springs.
Diesel engine - Renew ring gasket and exhaust
pipe flange gaskets.
E5946 EN 07/2001 2002 Bantam


Exhaust Flexible Pipe — Vehicles with Diesel Engines
Removal
1. Raise the vehicle. Refer to Section 100-02
2. Support the flexible pipe with a support

wrap or suitable splint.
3. Remove the flexible pipe.

• Discard the gasket and nuts.
Installation

wrap or suitable splint.
E5947 EN 07/2001 2002 Bantam

2. Install the flexible pipe.

• Install a new gasket and nuts.
E5947 EN 07/2001 2002 Bantam


Muffler and Tailpipe (25 202 0)
Removal
NOTE: The exhaust systems are of two or three-
piece construction for production and three-piece
construction for service replacement exhaust sys-
tems. However, for the purposes of this section
only we will be referring to the exhaust system as
the portion starting from the flange joint after the
flexible coupling and in front of the center muffler.
2. NOTE: If no part of the exhaust system is to

be renewed i.e. the system is to be removed
and installed complete; it will be necessary
to lower the rear axle. For additional
Raise the vehicle.
3. Cut the exhaust pipe as specified to suit the

model type and the extent of the section to
be renewed.
4. Disconnect the flexible coupling

refer to Section 309-00-7.
Discard the gaskets and nuts.
E5949 EN 07/2001 2002 Bantam

5. Remove the exhaust system by detaching it

from the rubber insulators.
• Four or five rubber insulators depending
on variant.
Installation
1. Assemble the exhaust system.
• Loosely connect the service exhaust
components.
2. Install the exhaust system.

• Examine the rubber insulators for
damage/fatigue and renew as necessary.
• Align the exhaust system to the vehicle
and attach it into the rubber insulators.
E5949 EN 07/2001 2002 Bantam


Loosely refit the flexible coupling to the
exhaust system.
• Install new gaskets and nuts.
• Coat the studs with anti-seize grease.
4. Check alignment of the system and tighten

the nuts.
• Tighten the pipe clamps
E5949 EN 07/2001 2002 Bantam

SPECIFICATIONS
Item Specification
Description Nm
Exhaust pipe flange bolts and nuts 47
Manifold downpipe to exhaust pipe flange nuts and bolts 17
Engine manifold to down pipe manifold 37
Exhaust pipe clamp nuts 47
E5950 EN 07/2001 2002 Bantam

310-00-1 Fuel System — General Information 310-00-1
SECTION 310-00 Fuel System — General Information

SUBJECT PAGE
Fuel System.........................................................................................................................310-00-2/3
GENERAL PROCEDURES
Fuel System Pressure Relief........................................................................... (23 420 0) 310-00-4

Fuel Tank Draining.......................................................................................... (23 551 0) 310-00-5
Push Connect Fittings..........................................................................................................310-00-6/8
SPECIFICATIONS
Specifications.......................................................................................................................310-00-9
Capacities .........................................................................................................................310-00-9
Torque Specifications........................................................................................................310-00-9
09/2001 2002 Bantam


Fuel System
The fuel filter (in the case of petrol variants) is
The fuel system comprises a rear mounted fuel located at the rear chassis crossmember. The
tank, an in-tank fuel pump, a fuel tank filler pipe, fuel filter clamp is fixed to the chassis rail by
a fuel filter and a fuel heater (in the case of means of two rivets and the fuel filter is retained
Endura -DE variants) and a number of fuel supply by the clamp with a single bolt.
and return pipes.
The fuel filter (in the case of Endura -DE variants)
The fuel tank is of steel construction and has a is located on the rear face of the cylinder head,
capacity of 54 litres. The fuel tank is fixed to the adjacent to the battery tray. The fuel filter clamp
vehicle by means of four bolts. Fuel tank is fixed to the cylinder head using two of the
ventilation is achieved via a fuel vapour hose bolts, which retain the rear engine lifting eye. The
fitted to the fuel tank and vents into the chassis fuel filter is retained by the clamp with a single
crossmember. The fuel tank vapour assembly bolt.
prevents fuel loss from the fuel tank if the vehicle
becomes inverted. Both petrol and diesel fuel filters have a paper
element contained within a steel canister.
The fuel pump is located inside the fuel tank and
is fixed to the top of the fuel tank by a locking The diesel fuel heater (in the case of Endura -DE
ring. The fuel pump is of the regenerative turbine variants) is located on the right hand side of the
type and will deliver fuel at a rate of 80 lph at a cylinder block in front of the fuel filter. The diesel
pressure of 3,0 bar. The fuel pump has an fuel heater bracket is fixed to the cylinder block
integral fuel tank sender unit and features by a single bolt and the diesel fuel heater is
excellent hot fuel handling, low noise, highly retained to the bracket by two clips.
reliable operation and integral radio frequency The diesel fuel heater is designed to warm the
interference (RFI) protection. diesel fuel in order to prevent waxing at cold
The fuel tank filler pipe is of steel construction temperatures. The heating element is a
and is fixed to the vehicle by means of two bolts. temperature dependent resistance, which has a
The fuel tank filler pipe is fitted with a locking filler positive temperature coefficient, i.e., the
cap, which seals the system. resistance of the heating element increases with
increasing temperature. The heater is fitted with
The fuel supply and return pipes are made of a an integral thermo switch, which prevents
combination of plastic, steel and rubber. Plastic overheating of the heater element.
fuel pipes are connected to the fuel tank, fuel
injection pump (in the case of diesel variants) and A fuel shut -off switch (in the case of petrol
fuel filter and fuel resistant rubber pipes are variants) is located behind the passenger cowl
connected to the fuel rail (in the case of petrol side trim panel adjacent to the powertrain control
variants). The plastic and rubber pipes are joined module. Two screws retain the fuel shut -off
by means of two steel pipes, which run along the switch. The fuel shut -off switch is designed to cut
underside of the vehicle. All fuel pipe connectors the electrical supply to the fuel pump in the event
are of the quick release type. Supply pipe of an accident or parking impact, thus reducing
connectors are white or are identified by a white the risk of fire.
band and return pipe connectors are red or are
identified by a red band.
E6461 EN 09/2001 2002 Bantam


The solenoid is also energized when engine
Diesel Fuel System Description coolant temperature is below 0°C and engine
and Operation speed is just above idle to improve drivability take
off.
The diesel injection equipment fitted to the 1,8
Fuel Injectors
litre naturally aspirated Endura-DE diesel engine
in the 2002 Bantam comprises of a fuel injection The engine is equipped with four Bosch fuel
pump, four injectors and four glow plugs. injectors, which have throttling pintle nozzles.
The glow plugs and certain fuel injection pump The fuel injectors are screwed into the cylinder
components are controlled by the powertrain head and sealed by means of copper washers.
control module (EEC V).
Fuel Injection Pump
Glow Plugs
The engine is equipped with a Bosch VE
The engine is equipped with four glow plugs,
distributor type fuel injection pump, which is
which are screwed into the cylinder head below
driven by the crankshaft via a toothed rubber
the fuel injectors. The glow plugs improve
drive belt. The fuel injection pump is retained to
starting, especially from cold.
the engine by three bolts at the front and a
support bracket at the rear (two bolts). Setting the The powertrain control module controls the glow
injector pump timing is achieved using the plugs and the glow plug indicator lamp. When the
familiar peg method. ignition is switched on, the glow plugs are
switched on and the glow plug indicator lamp is
The fuel injection pump is fitted with a light load
illuminated for between 1 and 10 seconds
retard device and a cold start advance solenoid,
dependant on engine coolant temperature.
both of which change the natural injection timing
(1 second at 80°C and 10 seconds at -30°C).
characteristics dependent on engine operating
conditions. The glow plugs remain on for a period of 3
seconds after the glow plug indicator lamp has
Light Load retard Device
been extinguished. However, if the engine is
The light load retard device is a mechanical / started during this 3-second period, the glow plug
hydraulic device incorporating a solenoid which is will remain on for a further 0 to 40 seconds
controlled by the powertrain control module. dependant on engine coolant temperature.
Under normal operating conditions and for engine (0 seconds at 80°C and 40 seconds at -40°C)
loads up to approximately 80% full load, the
device retards the injection timing by
approximately 3°. Where engine load is above
80% of full load, engine coolant temperature is
below 50°C and / or engine speed is above 3500
rev/min, the powertrain control module energizes
the solenoid which inhibits the operation of the
light load retard device, thus advancing the
injection timing.
Cold Start Advance Solenoid

The powertrain control module controls the cold
start advance solenoid. When engine coolant
temperature is below 50°C, the powertrain control
module energizes the solenoid which advances
the injection timing throughout the engine speed /
load range.
The amount of time, which the solenoid is also
energized, decreases as engine coolant
temperature increases.
E6461 EN 09/2001 2002 Bantam

GENERAL PROCEDURES
Fuel System Pressure Relief (23 420 0)
Release

vapours are always present and may ig-
WARNING: The fuel system remains

pressurized for a long time after the ig-
nition is switched off. The fuel pressure
must be released before attempting any
repairs. Failure to follow this instruction
1. Remove the fuel pump fuse.
2. Start the engine and allow it to idle until the

engine stalls.
3. Crank the engine for approximately five

seconds to make sure the fuel injection
supply manifold pressure has been
released.
4. Install the fuel pump fuse.
E3611 EN 09/2001 2002 Bantam

GENERAL PROCEDURES
Fuel Tank Draining (23 551 0)
Draining

WARNING: The fuel system remains

pressurized for a long time after the ig-
nition is switched off. The fuel pressure
must be relieved before attempting any
repairs. Failure to follow these instruc-
2. Remove the fuel filler cap.
3. NOTE: To enable the hose to enter the fuel

tank it is necessary to cut a 40mm long taper
at the end.
Drain the fuel from the fuel tank using a
12.5mm nylon drain tube with the approved
Ford fuel drain tank.
E4172 EN 09/2001 2002 Bantam

GENERAL PROCEDURES
Push Connect Fittings
Disconnection
WARNING: Do not carry lighted tobacco

or open flame of any type when working
on or near any fuel related components.
Highly flammable mixtures are always
present and can ignite. Failure to follow
sonal injury.
CAUTION: Fuel injection equipment is

manufactured to very precise tolerances
and fine clearances. It is therefore es-
sential that absolute cleanliness be ob-
served when working with these com-
ponents. Always install blanking plugs
to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red
band.
1. De-pressurize the fuel system. For
additional information, refer to Fuel System
Pressure Release in this section.
2. Disconnect the fuel line quick release

coupling.
1. Press the fuel line quick release coupling
locking tangs.
coupling.

coupling.
1. Pull the fuel line quick release coupling
locking tang.
2. Push the clip through the fuel line quick
release coupling to release the fuel line.
E3614 EN 09/2001 2002 Bantam


coupling.
locking tangs.
coupling.
Connect
WARNING: Do not carry lighted tobacco

or open flame of any type when working
on or near any fuel related components.
Highly flammable mixtures are always
present and can ignite. Failure to follow
these instructions may result in
personal injury.
CAUTION: Fuel injection equipment is

manufactured to very precise tolerances
and fine clearances. It is therefore es-
sential that absolute cleanliness be ob-
served when working with these com-
ponents. Always install blanking plugs
to any open orifices or lines.
NOTE: Fuel supply line connectors are white or
are identified by a white band. Fuel return line
connectors are red or are identified by a red
band.
1. NOTE: Make sure the collar on the fuel line is
inserted fully into the fuel line quick release
coupling.
Install the fuel line quick release coupling.
E3614 EN 09/2001 2002 Bantam


coupling before the locking tang is locked.
1. Install the fuel line quick release coupling
locking tang.
2. Rotate the fuel line quick release
coupling locking tang into position.

coupling before the locking tang is locked.
1. Install the fuel line quick release
coupling.
locking tang into position.
E3614 EN 09/2001 2002 Bantam

SPECIFICATIONS
Capacities
Litres
Fuel tank capacity 54 litres
Description Nm
Engine cover retaining bolts. 6
Fuel tank retaining bolts 21
09/2001 2002 Bantam

310-01A-10 Fuel Tank and Lines — Petrol Engines 310-01A-10
SECTION 310-01A Fuel Tank and Lines —

Petrol Engines
VEHICLE APPLICATION: 1996 2002 Bantam
SUBJECT PAGE
Fuel Tank and Lines ............................................................................................................ 310-01A-11

Fuel Tank and Lines ............................................................................................................ 310-01A-12

Inspection and Verification................................................................................................ 310-01A-12
Fuel Tank ....................................................................................................... (23 554 0) 310-01A-13/16

Fuel Filter ............................................................................................................................ 310-01A-17/18
Fuel Pump Module ......................................................................................... (23 534 0) 310-01A-19/20
Fuel Tank Filler Pipe....................................................................................... (23 572 0) 310-01A-21
Fuel Pump to Fuel Filter Line.......................................................................... (23 588 0) 310-01A-22/23
Fuel Filter to Fuel Supply Manifold Line.......................................................... (23 590 0) 310-01A-24/27
Fuel Return Line............................................................................................. (23 594 0) 310-01A-28/31
Inertia Fuel Shutoff (IFS) Switch ..................................................................... (33 577 0) 310-01A-32/33
SPECIFICATIONS
Specifications ...................................................................................................................... 310-01A-34

Torque Specifications ....................................................................................................... 310-01A-34
09/2001 2002 Bantam


Fuel Tank and Lines
Refer to Section 310-00
E6462 EN 09/2001 2002 Bantam


Fuel Tank and Lines
WDS • Damaged fuel lines. • Inertia fuel shutoff
• Damaged push switch.
connect fittings. • Loose or corroded
• Fuel Leaks. electrical connectors.
1. Verify the customer concern by operating the • Damaged fuel tank
system. filler cap.
2. Visually inspect for obvious signs of • Damaged fuel tank
mechanical or electrical damage. filler pipe.
• Incorrectly fitted fuel
filter
step.
the symptom and refer to WDS.
E1189 EN 09/2001 2002 Bantam


Fuel Tank (23 554 0)
Removal

type when working on or near fuel re-
lated components. Highly flammable
1. Drain the fuel tank. For additional

3. Disconnect the fuel tank filler hose from the

fuel tank.
4. Disconnect the vent hose from the fuel tank

filler pipe.
5. Disconnect the fuel filter supply line from

the fuel filter. For additional information,
E1192 EN 09/2001 2002 Bantam

6. CAUTION: When supporting the fuel

tank, use a suitable packing material
to prevent damage to the underside
of the fuel tank.
Support the fuel tank with a suitable jack.
7. Remove the fuel tank retaining bolts (jack

8. Partially lower the fuel tank.
E1192 EN 09/2001 2002 Bantam

9. NOTE: Fuel return line connectors are red or

identified by a red band.
Disconnect the fuel return line from the fuel
tank. For additional information,
10. Disconnect the fuel tank ventilation hose

from the rear chassis cross member.
11. Detach the fuel tank vent valve from the

canister bracket.
12. Disconnect the fuel pump electrical

connector.
E1192 EN 09/2001 2002 Bantam

13. Remove the fuel tank.
Installation

type when working on or near fuel re-
lated components. Highly flammable
can result in personal injury.
E1192 EN 09/2001 2002 Bantam


Fuel Filter
Removal

handling precautions.

2. Release the fuel system pressure. For


4. Disconnect the fuel lines. For additional

5. NOTE: There is a fuel flow arrow on the fuel

filter. Note its direction.
Remove the fuel filter.
E7857 EN 09/2001 2002 Bantam

Installation

handling precautions.

1. NOTE: When the battery is disconnected and
reconnected, some abnormal drive symptoms
may occur while the vehicle relearns its
adaptive strategy. It may need to be driven
16 km or more to relearn its adaptive
strategy.
NOTE: Make sure the fuel flow arrow on the fuel
filter is in the correct direction.
E7857 EN 09/2001 2002 Bantam


Fuel Pump Module (23 534 0)
Special Tool(s)
Wrench, fuel tank sender
unit.
23-026
Removal

1. Remove the fuel tank. For additional
information,
refer to Fuel Tank in this section
2. NOTE: Fuel supply line connections are white

or are identified by a white band.
Disconnect the fuel supply line from the fuel
pump. For additional information,
3. Remove the fuel pump locking ring.
E1190 EN 09/2001 2002 Bantam

4. Remove the fuel pump nylon insert.
5. Remove the fuel pump.
Installation

1. Install a new fuel pump seal.
E1190 EN 09/2001 2002 Bantam


Fuel Tank Filler Pipe (23 572 0)
Removal

1. Remove the fuel tank filler pipe retaining
bolts.
2. Remove the fuel filler cap.

information,
4. Remove the fuel tank filler pipe.
Installation

E1193 EN 09/2001 2002 Bantam


Fuel Pump to Fuel Filter Line (23 588 0)
Removal

lighted tobacco or open flame or any
type when working near any fuel related
components. Highly flammable vapours
are always present and may ignite. Fail-
ure to follow these instructions can re-
sult in personal injury.
1. De-pressurize the fuel system. For

information,
3. Disconnect the fuel supply line from the fuel

filter. For additional information,
4. NOTE: Fuel supply line connectors are white

or are identified by a white band.
Disconnect the fuel supply line from the fuel
tank. For additional information,
E1195 EN 09/2001 2002 Bantam

Installation

E1195 EN 09/2001 2002 Bantam

Fuel Filter to Fuel Supply Manifold Line (23 590 0)

handling. Be prepared for fuel spillage at
all times and always observe fuel handling
precautions. Failure to follow these in-
structions can result in personal injury.
NOTE: It will be necessary to raise the vehicle in
order to carry out this procedure.
Removal
2. Remove the flexible coupling to pinion shaft

pinch bolt.
3. Loosen the flexible coupling to column shaft

pinch bolt.
4. Loosen the wheel nuts, raise the vehicle

E6463 EN 09/2001 2002 Bantam

6. Partially lower the front crossmember. For

7. Detach the exhaust system from the front

and centre rubber insulators.
8. Detach the exhaust system from the three

rear rubber insulators.
• Allow the exhaust system to be
supported by the rear suspension
assembly.
9. Remove the exhaust heat shields.
E6463 EN 09/2001 2002 Bantam

10. Detach the handbrake cable from the two

retaining clips.
11. Detach the fuel supply pipe from the six

retaining clips.
12. Release the fuel supply and return pipes

from the six retaining clips.
13. Disconnect the fuel supply pipe from the

fuel rail supply pipe.
• Fuel supply pipe connectors are white or
are identified by a white band.
E6463 EN 09/2001 2002 Bantam


fuel filter.
15. Remove the fuel supply pipe.
Installation
E6463 EN 09/2001 2002 Bantam


Fuel Return Line (23 594 0)
General Equipment
Fuel tank draining equipment

Removal
2. Drain the fuel tank using proprietary fuel

tank draining equipment.

pinch bolt.

pinch bolt.
5. Loosen the wheel nuts, raise the vehicle

E6464 EN 09/2001 2002 Bantam


8. Partially lower the fuel tank;

refer to procedure contained in this section.
9. Detach the handbrake cable from the six

retaining clips.
10. Detach the fuel return pipe from the six

retaining clips.
E6464 EN 09/2001 2002 Bantam


from the four retaining clips.
12. Disconnect the fuel return pipe from the fuel

rail return pipe.
• Fuel return pipe connectors are red or
are identified by a red band.

tank.
14. Remove the fuel return pipe.
E6464 EN 09/2001 2002 Bantam

Installation
E6464 EN 09/2001 2002 Bantam


Inertia Fuel Shutoff (IFS) Switch (33 577 0)
Removal
1. Detach the right-hand door weather strip.
3. Detach the inertia fuel shutoff (IFS) switch.
4. Remove the IFS switch.

• Disconnect the IFS switch electrical
connector.
E1198 EN 09/2001 2002 Bantam

Installation
1. NOTE: Make sure the IFS switch is in the

reset position.
Depress the button on the IFS switch.
E1198 EN 09/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Flexible coupling to the column shaft pinch bolt 28
Flexible coupling to steering gear pinion shaft 26
pinch bolt
E1199 EN 09/2001 2002 Bantam

310-01B-35 Fuel Tank and Lines — Diesel Engines 310-01B-35
SECTION 310-01B Fuel Tank and Lines —

Diesel Engines
VEHICLE APPLICATION: 1996 2002 Bantam
SUBJECT PAGE
Fuel Tank and Lines ............................................................................................................ 310-01B-36
Fuel Tank and Lines ............................................................................................................ 310-01B-37
Fuel Tank........................................................................................................ (23 554 0) 310-01B-38/40

Fuel Sender Unit............................................................................................. (33 286 0) 310-01B-41/43
Fuel Filter Element.......................................................................................... (23 546 0) 310-01B-44
Fuel Tank to Fuel Filter Line ........................................................................... (23 588 0) 310-01B-45/49
Fuel Return Line ............................................................................................. (23 594 0) 310-01B-50/53
SPECIFICATIONS
Specifications....................................................................................................................... 310-01B-54
Lubricants, Fluids, Sealers and Adhesives ........................................................................ 310-01B-54
Capacities ......................................................................................................................... 310-01B-54
Torque Specifications........................................................................................................ 310-01B-54
09/2001 2002 Bantam


Fuel Tank and Lines
refer to Section 310-01A.
E6465 EN 09/2001 2002 Bantam

Fuel Tank and Lines
REFER to Section 310-01A.
E6466 EN 09/2001 2002 Bantam


Fuel Tank (23 554 0)
General Equipment
Removal

sonal injury.
CAUTION: Diesel fuel injection equip-

ment is manufactured to very precise
tolerances and fine clearances. It is
therefore essential that absolute
cleanliness be observed when working
with these components. Always fit
blanking plugs to any open orifices or
pipes.
2. Release the fuel pressure. For additional

3. Drain the fuel tank. For additional


5. Disconnect the fuel tank filler tube.
6. Disconnect the fuel tank vent pipe from the

fuel filler pipe.
E6371 EN 09/2001 2002 Bantam

7. CAUTION: When supporting the fuel

tank, use a suitable packing material
to prevent damage to the underside
of the fuel tank.
Support the fuel tank with a suitable jack.
8. Remove the four fuel tank retaining bolts.
9. Partially lower the fuel tank.
10. Detach the fuel tank vent valve bracket

from chassis cross member.
11. CAUTION: When disconnecting

multiplugs do not pull on the wiring,
pull on the multiplug body.
Disconnect the fuel tank sender unit
multiplug.
E6371 EN 09/2001 2002 Bantam

12. NOTE: Fuel return pipe connectors are red

or are identified by a red band.
Disconnect the fuel return pipe from the fuel
tank.

fuel tank.
are identified by a white band.
14. Remove the fuel tank.
Installation
• Lubricate the fuel tank filler pipe seal
with clean engine oil to aid fuel tank
installation.
E6371 EN 09/2001 2002 Bantam


Fuel Sender Unit (33 286 0)

CAUTION: Diesel fuel injection equipment
is manufactured to very precise tolerances
and fine clearances. It is therefore essen-
tial that absolute cleanliness be observed
when working with these components. Al-
ways fit blanking plugs to any open ori-
fices or pipes.
Removal
2. CAUTION: When disconnecting

multiplugs do not pull on the wiring,
Disconnect the diesel fuel heater multiplug.

diesel fuel heater inlet pipe.
E5951 EN 09/2001 2002 Bantam

4. Detach the fuel filter inlet pipe from the

retaining clip.
5. Disconnect the inlet pipe from the fuel filter.
6. Remove the diesel fuel heater and bracket

assembly (one bolt).
7. Remove the diesel fuel heater from the

retaining bracket (two clips).
E5951 EN 09/2001 2002 Bantam

Installation
E5951 EN 09/2001 2002 Bantam


Fuel Filter Element (23 546 0)
Renewal
2. Drain the fuel filter.
3. Remove the bolt.

• Catch the displaced fuel in a suitable
container.
4. Remove the filter element.
Installation
1. Install the components in reverse order.
• Install new O-rings.
2. Prime the fuel filter.
E2810 EN 09/2001 2002 Bantam


Fuel Tank to Fuel Filter Line (23 588 0)
General Equipment

fices or pipes.
Removal


pinch bolt.
E5952 EN 09/2001 2002 Bantam


pinch bolt.
5. Remove the exhaust down pipe

(refer to Operation Number 25 250 0).

E5952 EN 09/2001 2002 Bantam

7. Partially lower the fuel tank

8. Lower exhaust system.
9. Remove the heat sheilds.
10. Detach the handbrake cable and fuel

supply pipe from the six retaining clips.

from the five retaining clips.
E5952 EN 09/2001 2002 Bantam


diesel fuel heater inlet pipe.
are identified with a white band.

fuel tank.
are identified with a white band.
14. Remove the fuel supply pipe.
Installation
E5952 EN 09/2001 2002 Bantam

E5952 EN 09/2001 2002 Bantam


Fuel Return Line (23 594 0)
General Equipment

fices or pipes.
Removal


pinch bolt.
E5953 EN 09/2001 2002 Bantam


pinch bolt.
5. Remove the exhaust down pipe. For


7. Remove the heat sheilds.
E5953 EN 09/2001 2002 Bantam

8. Partially lower the fuel tank

9. Detach the handbrake cable and the fuel

return pipe from the five retaining clips.
10. Release the supply and return pipes from

the five retaining clips.

injection pump return pipe.

tank.
E5953 EN 09/2001 2002 Bantam

12. Remove the fuel return pipe.
Installation
E5953 EN 09/2001 2002 Bantam

SPECIFICATIONS
Item Specification
Fuel tank filler pipe seal Clean engine oil
Fuel tank roll-over valve seal Clean engine oil
Capacities
Litres
Fuel tank 54
Description Nm
Flexible coupling to steering column shaft pinch 28
bolt
E6467 EN 09/2001 2002 Bantam

310-02-55 Acceleration Control 310-02-55
SECTION 310-02 Acceleration Control

SUBJECT PAGE
Acceleration Control............................................................................................................. 310-02-56

Vehicles with Petrol Engine...............................................................................................310-02-56
Vehicles with Diesel Engine ..............................................................................................310-02-56
Acceleration Control............................................................................................................. 310-02-57

Inspection and Verification ................................................................................................310-02-57
GENERAL PROCEDURES
Accelerator Cable Adjustment — Vehicles with 1.6L / 1.3L Engine ................. (23 811 0) 310-02-58
Accelerator Cable Adjustment — Vehicles with Diesel Engine........................ (23 811 0) 310-02-59
09/2001 2002 Bantam


Acceleration Control
Vehicles with Petrol Engine Vehicles with Diesel Engine
The acceleration control system consists of an The acceleration control system consists of an
accelerator pedal, accelerator cable and accelerator pedal and accelerator cable.
accelerator cable bracket, which is fitted to the Accelerator pedal return is achieved by means of
throttle body. Accelerator pedal return is throttle return springs.
achieved by means of throttle return springs.
E6716 EN 09/2001 2002 Bantam


Acceleration Control Visual Inspection Chart
Mechanical
• Linkage
1. Verify the customer concern by operating the
• Return spring
system. • Accelerator cable
mechanical damage.
step.
the symptom and refer to the symptom chart.
Symptom Chart
• Excessive pressure required to • Worn accelerator pedal pivot or • INSTALL a new accelerator
depress the accelerator pedal bush. pivot or bushing.
• Accelerator cable binding. • INSTALL a new accelerator ca-
ble.
• Accelerator pedal feels rough or • Frayed or binding accelerator • INSTALL a new accelerator ca-
jerky cable. ble.
• Accelerator pedal binds or sticks • Kinked accelerator cable. • INSTALL a new accelerator ca-
ble.
• Foreign object caught in the • REMOVE foreign object and
accelerator pedal or linkage. CHECK the accelerator pedal
and linkage for damage.
• Broken or binding return spring. • INSTALL a new spring.
• High engine idle speed • Kinked accelerator cable. • INSTALL a new accelerator ca-
ble.
• Binding accelerator cable. • CHECK the acceleration link-
age.
• Foreign object caught in accel- • REMOVE foreign object and
erator pedal or linkage. CHECK the accelerator pedal
and linkage for damage.
• Broken or binding return spring. • INSTALL a new spring.
E1201 EN 09/2001 2002 Bantam

GENERAL PROCEDURES
Accelerator Cable Adjustment — Vehicles with 1.6L / 1.3L Engine (23 811 0)
1. Remove the accelerator cable retaining clip.
2. Pull the accelerator cable adjuster through

the grommet until the grommet is at the end
of the accelerator cable adjuster.
3. Depress the accelerator pedal to the floor

stop and hold.
4. Install the accelerator cable retaining clip.

stop to make sure that full travel is achieved
at the throttle body and release the
accelerator pedal to make sure that the
throttle plate returns to the fully closed
position.
E5955 EN 09/2001 2002 Bantam


Accelerator Cable Adjustment — Vehicles with Diesel Engine (23 811 0)
1. Remove the accelerator cable retaining clip.
2. Pull the accelerator cable adjuster through

the grommet until the grommet is at the end
of the accelerator cable adjuster.

stop and hold.
4. Install the accelerator cable retaining clip.

stop to make sure that full travel is achieved
at the throttle body and release the
accelerator pedal to make sure that the
throttle plate returns to the fully closed
position.
E5955 EN 09/2001 2002 Bantam

4
Group
Electrical
SECTION TITLE PAGE
Climate Control System

Climate Control System - General Information 412-00
Air Distribution and Filtering 412-01
Heating and Ventilation 412-02
Air Conditioning 412-03
Control Components 412-04
Instrumentation and Warning Systems

Instrument Cluster 413-01
Battery and Charging Systems

Charging System - General Information 414-00
Battery, Mounting and Cables 414-01
Generator and Regulator 414-02
Audio System
Audio System - General Information 415-00
Audio Unit 415-01
Antenna 415-02
Speakers 415-03
Lighting
Exterior Lighting 417-01
Electrical Distribution
Module Communications Network 418-00
Anti-Theft — Passive 419-01B

412-00-1 Climate Control System — General Information 412-00-1
SECTION 412-00 Climate Control System —

General Information
SUBJECT PAGE
Climate Control System ......................................................................................................... 412-00-2

Climate Control System ......................................................................................................... 412-00-3A
Inspection and Testing ........................................................................................................ 412-00-3A/3B
System Checks ................................................................................................................... 412-00-4/33
Component Test ................................................................................................................. 412-00-33/37
GENERAL PROCEDURES
Spring Lock Coupling....................................................................................... (34 639 1) 412-00-38/39
Air Conditioning (A/C) Clutch Air Gap Adjustment........................................... (34 628 6) 412-00-40
Electronic Leak Detection ................................................................................ (34 620 5) 412-00-41
Air Conditioning (A/C) System Flushing................................................................................. 412-00-42/45
Tracer Dye Leak Detection .............................................................................. (34 620 5) 412-00-46
Vacuum Leak Detection................................................................................... (34 620 5) 412-00-47
Air Conditioning (A/C) System Evacuation and Charging................................ (34 620 2) 412-00-48/50
Refrigerant Oil Addition.................................................................................... (34 621 1) 412-00-51
Air Distribution System Cleaning ........................................................................................... 412-00-52/53
Contaminated Refrigerant Handling................................................................. (34 620 5) 412-00-54
SPECIFICATIONS
Specifications......................................................................................................................... 412-00-55
General Specifications ........................................................................................................ 412-00-55
Addition of Air Conditioning Refrigerant Oil......................................................................... 412-00-55
Air conditioning compressor................................................................................................ 412-00-55
Fixed orifice tube................................................................................................................. 412-00-55
07/2001 2002 Bantam


Climate Control System
Instead of Bowden cables, air distribution is The heat exchanger and (depending on the
controlled via a splined shaft and the interior model variant) the air conditioning evaporator are
temperature is regulated via a potentiometer, easily accessible from the engine compartment.
which is integrated into the control panel. The
The vehicle is also equipped with recirculated air
potentiometer operates the control valve, which
mode, which can be activated by operating a
controls the flow of hot water through the heat
switch on the control panel.
exchanger in accordance with the selected
interior temperature.
E1232 EN 07/2001 2002 Bantam

412-00-3A Climate Control System — General Information 412-00-3A

Climate Control System Visual Inspection Chart
Refer to Wiring Diagrams Petrol and Diesel
Cell:41200,for schematic and connector information. • Vacuum hoses. • Fuse(s).
• Refrigerant (filling or • Circuit(s).
leaks). • Connector damaged
Inspection and Testing • Drive belt. or loose.
• Coolant level.
2. Visually inspect for obvious signs of 3. If an obvious cause for an observed or
mechanical or electrical damage. reported concern is found, correct the cause
step.
Symptom Chart
• No / insufficient heating power. • Fuse(s). • Go To Pinpoint Test A
• Circuit(s).
• Heater control module.
• Heater control solenoid valve.
• The A/C system is inoperative • Fuse(s). • Go To Pinpoint Test B
(the heater blower is OK). • Circuit(s).
• A/C compressor clutch.
• A/C Wide Open Throttle (W.O.T)
relay.
• A/C switch relay.
• Air conditioning high-pressure
switch.
• Air conditioning low pressure
switch.
• Heater and A/C control
assembly.
• PCM.
• The heater blower system is • Fuse(s). • Go To Pinpoint Test C
inoperative. • Circuit(s).
• Heater blower motor.
• Heater blower switch.
• Heater blower series resistor.
• The air re-circulation flap is in- • Fuse(s). • Go To Pinpoint Test D
operative. • Circuit(s).
• Re-circulation air actuator.
• A/C re-circulation flap relay.
• Re-circulation switch.
• Engine cooling fan motor is in- • Fuse(s). • REFER to Section 303-03.
• Engine cooling fan motor.
• Powertrain control module
(PCM).
E9425 EN 07/2001 2002 Bantam

412-00-3B Climate Control System — General Information 412-00-3B

• Condensed water from the air • Air conditioning outlet pipe is not • Check that the air conditioning
conditioning system in the foot- connected to the heater. outlet pipe is routed correctly.
well. • Air conditioning outlet pipe is
incorrectly routed through the
body panel.
• Air conditioning outlet pipe is
bent or blocked.
E9425 EN 07/2001 2002 Bantam

System Checks
PAGE 1 OF 3
PINPOINT TEST A: NO/INSUFFICIENT HEATING POWER
A1: CHECK THE FUSE F13................................................................................. 412-00-4
A2: CHECK THE POWER SUPPLY OF THE FUSE F13 ..................................... 412-00-4
A3: CHECK THE FUSE F2 .................................................................................. 412-00-4
A4: CHECK THE POWER SUPPLY OF THE FUSE F2 ....................................... 412-00-5
A5: DETERMINE THE FAULT CONDITION OF THE HEATING SYSTEM........... 412-00-5
A6: CHECK THE HEATER CONTROL SOLENOID VALVE ................................. 412-00-5
A7: CHECK THE POWER SUPPLY OF THE HEATER CONTROL
SOLENOID VALVE .............................................................................................. 412-00-6
A8: CHECK THE HEATER CONTROL SOLENOID VALVE ................................. 412-00-6
A9: CHECK THE POWER SUPPLY OF THE HEATER CONTROL MODULE...... 412-00-7
A10: CHECK THE POWER SUPPLY OF THE HEATER CONTROL MODULE.... 412-00-7
A11: CHECK THE SIGNAL FROM THE TACHOMETER ..................................... 412-00-7/8
A12: CHECK THE GROUND SUPPLY OF THE HEATER CONTROL
SOLENOID VALVE .............................................................................................. 412-00-8
A13: CHECK THE GROUND SUPPLY OF THE HEATER
CONTROL MODULE ........................................................................................... 412-00-8
A14: CHECK THE HEATER CONTROL SOLENOID VALVE ................................ 412-00-9
A15: CHECK THE CIRCUIT 31-CA82 FOR SHORT TO GROUND ...................... 412-00-9
PINPOINT TEST B: THE A/C SYSTEM IS INOPERATIVE
(THE HEATER BLOWER IS OK)
B1: CHECK THE FUSE F14................................................................................. 412-00-10
B2: CHECK THE POWER SUPPLY OF THE FUSE F14 ..................................... 412-00-10
B3: CHECK THE FUSE F13................................................................................. 412-00-10
B4: CHECK THE POWER SUPPLY OF THE FUSE F13 ..................................... 412-00-10/11
B5: CHECK THE POWER SUPPLY OF RELAY – A/C W.O.T ............................ 412-00-11
B6: CHECK THE POWER SUPPLY OF RELAY – A/C W.O.T ............................ 412-00-11
B7: CHECK THE A/C COMPRESSOR CLUTCH...................................................412-00-12
B8: CHECK CIRCUIT 14S-CA6 (VT/YE) FOR OPEN........................................... 412-00-12/13
B9: CHECK THE GROUND SUPPLY OF THE A/C COMPRESSOR CLUTCH..... 412-00-13
B10: CHECK THE RELAY – A/C WOT ................................................................ 412-00-13
B11: CHECK THE RELAY – A/C SWITCH ............................................................412-00-14
B12: CHECK THE POWER SUPPLY OF THE HEATER
AND A/C CONTROL ASSEMBLY ....................................................................... 412-00-14
B13: CHECK THE CIRCUIT 14S-FA90 (VT/BK) FOR OPEN ............................... 412-00-15
B14: CHECK THE GROUND SUPPLY OF THE RELAY – A/C SWITCH.............. 412-00-15
System Checks
PAGE 2 OF 3
B15: CHECK THE GROUND SUPPLY OF THE RELAY – A/C SWITCH.............. 412-00-16
B16: CHECK THE RELAY – A/C SWITCH ............................................................412-00-16/17
B17: CHECK THE A/C COMPRESSOR CYCLING SWITCH ............................... 412-00-17
B18: CHECK THE CIRCUIT 31S-CA17 (BK/RD) FOR OPEN .............................. 412-00-17/18
B19: CHECK CIRCUIT 31S-PC72 (BK/BU) FOR OPEN....................................... 412-00-18
B20: CHECK THE CIRCUIT 31S-CA11 (BK/YE) FOR OPEN............................... 412-00-18/19
B21: CHECK THE CIRCUIT 31S-CA12A (BK/BU) FOR OPEN ............................ 412-00-19
B22: CHECK THE DUAL PRESSURE SWITCH................................................... 412-00-19
B23: CHECK THE CIRCUIT 31S-CA12 (BK/BU) FOR OPEN............................... 412-00-20
B24: CHECK THE A/C INHIBIT DIODE................................................................ 412-00-20
PINPOINT TEST C: THE HEATER BLOWER SYSTEM IS INOPERATIVE
C1: DETERMINE THE FAULT CONDITION......................................................... 412-00-20
C2: CHECK THE FUSE F16 ................................................................................ 412-00-21
C3: CHECK THE POWER SUPPLY OF THE FUSE F16 ..................................... 412-00-21
C4: CHECK THE POWER SUPPLY OF THE HEATER BLOWER MOTOR ......... 412-00-21
C5: CHECK THE HEATER BLOWER MOTOR .................................................... 412-00-22
C6: CHECK THE CIRCUIT 31S-CA18 (BK/RD) FOR OPEN ................................ 412-00-22
C7: CHECK THE GROUND SUPPLY OF THE HEATER BLOWER SWITCH ...... 412-00-23
C8: CHECK THE CIRCUIT FOR HEATER BLOWER, HIGH SPEED ................... 412-00-23
C9: CHECK THE CIRCUIT FOR HEATER BLOWER, MEDIUM SPEED.............. 412-00-23
C10: CHECK THE COMMON CIRCUIT FOR HEATER BLOWER;
LOWER SPEEDS ................................................................................................ 412-00-24
C11: CHECK THE CIRCUIT FOR HEATER BLOWER, MEDIUM SPEED............ 412-00-24
C12: CHECK THE CIRCUIT FOR HEATER BLOWER, LOW SPEED.................. 412-00-25
C13: CHECK THE CIRCUIT FOR HEATER BLOWER, LOW SPEED.................. 412-00-25
C14: CHECK THE CIRCUIT FOR HEATER BLOWER, SLOW SPEED ............... 412-00-26
C15: CHECK THE CIRCUIT FOR HEATER BLOWER, SLOW SPEED ............... 412-00-26
PINPOINT TEST D: THE AIR RE-CIRCULATION FLAP IS INOPERATIVE
D1: CHECK THE FUSE F16 ................................................................................ 412-00-26
D2: CHECK THE POWER SUPPLY OF THE FUSE F16 ..................................... 412-00-27
D3: CHECK THE FUSE F13 ................................................................................ 412-00-27
D4: CHECK THE POWER SUPPLY OF THE FUSE F13 ..................................... 412-00-27
D5: CHECK THE POWER SUPPLY OF THE RE-CIRCULATION
AIR ACTUATOR .................................................................................................. 412-00-28
D6: CHECK THE GROUND SUPPLY OF THE RE-CIRCULATION
AIR ACTUATOR .................................................................................................. 412-00-28
System Checks
PAGE 3 OF 3
D7: CHECK THE CONTROL CIRCUIT OF THE RE-CIRCULATION
AIR ACTUATOR .................................................................................................. 412-00-29
D8: CHECK THE RE-CIRCULATION AIR ACTUATOR ........................................ 412-00-29/30
D9: CHECK THE GROUND SUPPLY OF THE RELAY – A/C
RE-CIRCULATION FLAP ..................................................................................... 412-00-30/31
D10: CHECK THE GROUND CONNECTION OF RELAY – A/C
RE-CIRCULATION FLAP ..................................................................................... 412-00-31
D11: CHECK THE RELAY – A/C RE-CIRCULATION FLAP ................................. 412-00-32
D12: CHECK THE CONTROL CIRCUIT OF THE RELAY – A/C
RE-CIRCULATION FLAP ..................................................................................... 412-00-32
D13: CHECK THE RE-CIRCULATION SWITCH .................................................. 412-00-32/33

System Checks
PINPOINT TEST A: NO/INSUFFICIENT HEATING POWER
A1: CHECK THE FUSE F13
1. 2.
• Is the fuse OK?
Yes
GO TO A2
No
INSTALL a new fuse F13 (15 A). If the fuse
blows again, LOCATE and REPAIR the
short to ground of the circuit(s) by using the
Fuse F13 (CJB)
wiring diagrams. TEST the system for nor-
mal operation.
A2: CHECK THE POWER SUPPLY OF THE FUSE F13
1. 2.
Fuse F13 (CJB)

3 Measure the voltage between fuse F13 and
ground.
• Is battery voltage indicated?
Yes
GO TO A3
No
REPAIR the power supply of the fuse F13
by using the wiring diagrams. TEST the sys-
1. 2.
• Is the fuse F2 OK?
Yes
GO TO A4.
No
Fuse F2 (CJB)
mal operation.
E9425 EN 07/2001 2002 Bantam

A4: CHECK THE POWER SUPPLY OF THE FUSE F2
1. 2.
Fuse F2 (CJB)
ground.
Yes
GO TO A5.
No
REPAIR the power supply of the fuse F2 by
using the wiring diagrams. TEST the system
A5: DETERMINE THE FAULT CONDITION OF THE HEATING SYSTEM
1.
2 Check the temperature of the airflow.

• Is the airflow permanently cold?
Yes
GO TO A14
No
GO TO A6
A6: CHECK THE HEATER CONTROL SOLENOID VALVE
WARNING: The heater control solenoid valve can be very hot.

1 Turn the temperature selector switch to the
medium position.
• Is the heater control solenoid valve pulsating?
Yes
CHECK the cooling system for blockages.
concern is not rectified, CHECK the heater
control solenoid valve. If necessary
INSTALL a new one. TEST the system for
normal operation.
No
GO TO A7
E9425 EN 07/2001 2002 Bantam

A7: CHECK THE POWER SUPPLY OF THE HEATER CONTROL SOLENOID VALVE
1. 2. 3.
Heater control sole-

noid valve C49
4 Measure the voltage between heater control
solenoid valve, connector C49, pin 1, circuit
14-CA82 (VT/BK), harness side and ground.
Yes
GO TO A8
No
REPAIR the open circuit(s) between fuse
F13 and heater control solenoid valve by us-
ing the wiring diagrams. TEST the system

NOTE: If the temperature adjustment is changed, the heater control solenoid valve is reacting with a
delay in time.
1.

14-CA82 (VT/BK), harness side and pin 2,
circuit 31S-CA82 (BK/GN), harness side.
• Is an alternating voltage indicated?
Yes
CHECK the heater control solenoid valve,
and INSTALL a new one if necessary. TEST
No
GO TO A9
E9425 EN 07/2001 2002 Bantam


A9: CHECK THE POWER SUPPLY OF THE HEATER CONTROL MODULE
1. 2. 3.
Heater control
module C28
module, connector C28, pin 12, circuit 14-
CA83 (VT/OG), harness side and ground.
Yes
GO TO A10.
No
F13 and heater control module by using the
mal operation.
A10: CHECK THE POWER SUPPLY OF THE HEATER CONTROL MODULE

module, connector C28, pin 2, circuit 29-CA83
(OG/GN), harness side and ground.
Yes
GO TO A11
No
REPAIR the open circuit(s) between fuse F2
and heater control module by using the wir-
ing diagrams. TEST the system for normal
operation.
A11: CHECK THE SIGNAL FROM THE TACHOMETER

NOTE: The proper function of the heater control solenoid valve is dependent from the signal of the ta-
chometer
1.
E9425 EN 07/2001 2002 Bantam

module, connector C28, pin 1, circuit 8-GB10A
(WH/BK), harness side and ground.
• Is the indicated voltage between 5 and 9 volts?
Yes
GO TO A12
No
REPAIR the open circuit(s) between instru-
ment cluster and heater control module by
for normal operation. If the concern is not
rectified REFER to Section 413-01.
A12: CHECK THE GROUND SUPPLY OF THE HEATER CONTROL SOLENOID VALVE
1.
2 Measure the resistance between heater control

31S-CA82 (BK/GN), harness side and heater
control solenoid valve, connector C28, pin 5,
circuit 31S-CA82 (BK/GN), harness side.
Yes
GO TO A13
No
REPAIR the open circuit(s) between heater
control solenoid valve and heater control
module by using the wiring diagrams. TEST
A13: CHECK THE GROUND SUPPLY OF THE HEATER CONTROL MODULE
1 Measure the resistance between heater control
module, connector C28, pin 6, circuit 91-CA83
(BK/RD), harness side and ground.
Yes
CHECK the heater control module and
INSTALL a new one if necessary. TEST the
No
control module and ground G5 by using the
mal operation.
E9425 EN 07/2001 2002 Bantam


1. 2. 3.

noid valve C49
• Is the air flow permanent cold?
Yes
CHECK the heater control solenoid valve for
blockages. TEST the system for normal
operation. If necessary INSTALL a new one.
No
GO TO A15
A15: CHECK THE CIRCUIT 31-CA82 FOR SHORT TO GROUND
NOTE: The proper function of the heater control solenoid valve is dependent from the signal of the ta-
chometer.
1. 2.

noid valve C49
3. 4.
Heater control
module C28
• Is the air flow permanent cold?
Yes
control solenoid valve and heater control
module by using the wiring diagrams. TEST
No
CHECK the heater control module. If neces-
sary INSTALL a new one. TEST the system
E9425 EN 07/2001 2002 Bantam


PINPOINT TEST B: THE A/C SYSTEM IS INOPERATIVE (THE HEATER BLOWER IS OK)
B1: CHECK THE FUSE F14
1. 2.
• Is the fuse OK?
Yes
GO TO B2
No
Fuse F14 (CJB)
wiring diagrams or if necessary CHECK the
A/C compressor clutch diode and INSTALL
a new one. TEST the system for normal op-
eration.
B2: CHECK THE POWER SUPPLY OF THE FUSE F14
1. 2.
Fuse F14 (CJB)

ground.
Yes
GO TO B3
No
REPAIR the power supply of the fuse F14.
B3: CHECK THE FUSE F13
1. 2.
• Is the fuse F13 OK?
Yes
GO TO B4.
No
Fuse F13 (CJB)
mal operation.
B4: CHECK THE POWER SUPPLY OF THE FUSE F13
1. 2.
Fuse F13 (CJB)
E9425 EN 07/2001 2002 Bantam

ground.
Yes
GO TO B5.
No
B5: CHECK THE POWER SUPPLY OF RELAY – A/C W.O.T
1. 2. 3.
Relay – A/C WOT

C18
4 Measure the voltage between relay socket –
A/C W.O.T, connector C18, pin 2, circuit 14-
CA11 (VT/YE) and ground.
Yes
GO TO B6
No
F14 and relay – A/C W.O.T by using the wir-
operation.
B6: CHECK THE POWER SUPPLY OF RELAY – A/C W.O.T

A/C W.O.T, connector C18, pin 3, circuit 14-
CA67 (VT/BK) and ground.
Yes
GO TO B7
No
F14 and relay – A/C W.O.T by using the wir-
operation.
E9425 EN 07/2001 2002 Bantam

B7: CHECK THE A/C COMPRESSOR CLUTCH
1.
2 Connect a jumper wire at the relay socket –

A/C W.O.T, connector C18, between pin 3, cir-
cuit 14-CA67 (VT/BK) and pin 5, circuit 14S-
CA1 (VT/BU).
3.
• Is the A/C compressor clutch engaged?
Yes
GO TO B10
No
GO TO B8
B8: CHECK CIRCUIT 14S-CA6 (VT/YE) FOR OPEN

1. 2.
A/C compressor
clutch C75
3. 4.
Relay – A/C
W.O.T C18
5 Switch on the A/C system and the heater
blower system.
E9425 EN 07/2001 2002 Bantam

6 Measure the voltage between A/C compressor
clutch, connector C75, pin 1, circuit 14S-CA6
(VT/YE), harness side and ground.
Yes
GO TO B9
No
REPAIR the open circuit(s) between relay –
A/C W.O.T and A/C compressor clutch by
B9: CHECK THE GROUND SUPPLY OF THE A/C COMPRESSOR CLUTCH

1.
2 Measure the resistance between A/C

compressor clutch, connector C75, pin 2,
circuit 31-CA6 (BK), harness side and ground.
Yes
CHECK the A/C compressor clutch, if
necessary INSTALL a new one. TEST the
No
REPAIR the open circuit(s) between A/C
compressor clutch and ground G9 by using
the wiring diagrams. TEST the system for
normal operation.
B10: CHECK THE RELAY – A/C WOT
1 Check the relay – A/C W.O.T referring to the
Component Test.
• Is the relay OK?
Yes
GO TO B11
No
INSTALL a new relay – A/C W.O.T. TEST
E9425 EN 07/2001 2002 Bantam

B11: CHECK THE RELAY – A/C SWITCH
1. 2. 3.
Relay – A/C switch

C19
4 Switch on the A/C system.
A/C switch, connector C19, pin 2, circuit 14S-
FA90 (VT/BK) and ground.
Yes
GO TO B14
No
GO TO B12
B12: CHECK THE POWER SUPPLY OF THE HEATER AND A/C CONTROL ASSEMBLY
1. 2. 3.
Heater and A/C

control assembly
C329
4 Measure the voltage between heater and A/C
control assembly, connector C329, pin 2,
circuit 14-FA90 (VT/BK), harness side and
ground.
Yes
GO TO B13
No
F13 and heater and A/C control assembly
E9425 EN 07/2001 2002 Bantam

B13: CHECK THE CIRCUIT 14S-FA90 (VT/BK) FOR OPEN
1.
2 Measure the resistance between heater and

A/C control assembly, connector C329, pin 1,
circuit 14S-FA90 (VT/BK), harness side and
relay socket – A/C switch, connector C19, pin
2, circuit 14S-FA90 (VT/BK).
Yes
CHECK the heater and A/C control
assembly. If necessary INSTALL a new one.
No
and A/C control assembly and relay – A/C
switch by using the wiring diagrams. TEST
B14: CHECK THE GROUND SUPPLY OF THE RELAY – A/C SWITCH
1.
2 Turn the heater blower to the LOW SPEED

position.
3 Measure the resistance between relay socket –
A/C switch, connector C19, pin 1, circuit 31S-
FA90 (BK/GN) and ground.
Yes
GO TO B15
No
A/C switch and ground by using the wiring
diagrams. TEST the system for normal op-
eration.
E9425 EN 07/2001 2002 Bantam

B15: CHECK THE GROUND SUPPLY OF THE RELAY – A/C SWITCH
A/C switch, connector C19, pin 3, circuit 31-
CA66B (BK) and ground.
Yes
GO TO B16
No
A/C switch and ground G6 by using the wir-
operation.
B16: CHECK THE RELAY – A/C SWITCH

1.
Relay – A/C
W.O.T C18
3.
E9425 EN 07/2001 2002 Bantam


A/C switch, connector C19, between pin 5,
circuit 31S-CA66B (BK/RD) and pin 3, circuit
31-CA66B (BK).
• Is the A/C compressor clutch engaged?
Yes
CHECK the relay – A/C switch according to
the Component Test. If necessary INSTALL
a new one. TEST the system for normal
operation.
No
GO TO B17
B17: CHECK THE A/C COMPRESSOR CYCLING SWITCH
1. 2. 3.
Relay – A/C switch A/C compressor

C19 cycling switch C91
compressor cycling switch, connector C91, pin
1 and pin 4, component side.
Yes
GO TO B18
No
CHECK the A/C compressor cycling switch;
system for normal operation. If the concern
is not rectified, CHECK the refrigerant cir-
cuit(s) for leakage. TEST the system for
normal operation.
B18: CHECK THE CIRCUIT 31S-CA17 (BK/RD) FOR OPEN
1.

blower.
E9425 EN 07/2001 2002 Bantam

1, circuit 31S-CA17 (BK/RD), harness side and
ground.
Yes
GO TO B19
No
GO TO B22
B19: CHECK CIRCUIT 31S-PC72 (BK/BU) FOR OPEN

1. 2.
PCM C43
compressor cycling switch, C91, pin 4, circuit
31S-PC72 (BK/BU), harness side and PCM,
connector C43, pin 40, circuit 31S-PC72
(BK/BU), harness side.
Yes
GO TO B20
No
REPAIR the open circuit(s) between A/C
compressor cycling switch and PCM by us-
B20: CHECK THE CIRCUIT 31S-CA11 (BK/YE) FOR OPEN
1.
E9425 EN 07/2001 2002 Bantam

2 Measure the voltage between PCM, connector
C43, pin 25, circuit 31S-CA11 (BK/YE),
harness side and ground.
Yes
GO TO B21
No
A/C W.O.T and PCM by using the wiring
eration.
B21: CHECK THE CIRCUIT 31S-CA12A (BK/BU) FOR OPEN

blower.
2 Measure the resistance between PCM,
connector C43, pin 41, circuit 31S-CA12A
(BK/BU), harness side and ground.
Yes
CHECK the PCM. If necessary INSTALL a
new one. TEST the system for normal
operation.
No
REPAIR the open circuit(s) between PCM
and ground by using the wiring diagrams.
B22: CHECK THE DUAL PRESSURE SWITCH
1. 2.
Dual pressure
switch C77
3 Measure the resistance between the dual
pressure switch, connector C77, pin 2 and pin
4, component side.
Yes
GO TO B23
No
CHECK the dual pressure switch; INSTALL
a new one if necessary. TEST the system
E9425 EN 07/2001 2002 Bantam

B23: CHECK THE CIRCUIT 31S-CA12 (BK/BU) FOR OPEN
1, circuit 31S-CA17 (BK/RD), harness side and
dual pressure switch, connector C77, pin 2,
circuit 31S-CA12 (BK/BU), harness side.
Yes
GO TO B24
No
REPAIR the open circuit(s) between dual
pressure switch and PCM by using the wir-
operation.
B24: CHECK THE A/C INHIBIT DIODE
1 Check the A/C inhibit diode referring to the
diode test.
• Is the A/C diode OK?
Yes
REPAIR the open circuit(s) between dual
pressure switch and relay – A/C switch by
No
INSTALL a new A/C inhibit diode. TEST the
PINPOINT TEST C: THE HEATER BLOWER SYSTEM IS INOPERATIVE
C1: DETERMINE THE FAULT CONDITION
1.
2 Turn the heater blower switch from SLOW

SPEED to HIGH SPEED position.
3 Check the airflow.
• Is the heater blower in all positions
inoperative?
Yes
GO TO C2
No
GO TO C8
E9425 EN 07/2001 2002 Bantam

C2: CHECK THE FUSE F16
1. 2.
• Is the fuse OK?
Yes
GO TO C3
No
blows again, REPAIR the short to ground of
the circuit(s) by using the wiring diagrams.
Fuse F16 (CJB)
C3: CHECK THE POWER SUPPLY OF THE FUSE F16
1. 2.
Fuse F16 (CJB)

ground.
Yes
GO TO C4
No
C4: CHECK THE POWER SUPPLY OF THE HEATER BLOWER MOTOR
1. 2. 3.
Heater blower mo-

tor C53
4 Measure the voltage between heater blower
motor, connector C53, pin 1, circuit 14-CA18
(VT/OG), harness side and ground.
Yes
GO TO C5
No
F16 and heater blower motor by using the
mal operation.
E9425 EN 07/2001 2002 Bantam

C5: CHECK THE HEATER BLOWER MOTOR
1.
2 Turn the heater blower switch to HIGH SPEED

position
3 Measure the resistance between heater blower
switch, connector C53, pin 2, circuit 31S-CA18
(BK/RD), harness side and ground.
Yes
CHECK the heater blower motor; INSTALL
No
GO TO C6
C6: CHECK THE CIRCUIT 31S-CA18 (BK/RD) FOR OPEN

1.
Heater blower
switch C72
motor, connector C53, pin 2, circuit 31S-CA18
(BK/RD), harness side and heater blower
(BK/OG), harness side.
Yes
GO TO C7
No
blower motor and heater blower switch by
E9425 EN 07/2001 2002 Bantam

C7: CHECK THE GROUND SUPPLY OF THE HEATER BLOWER SWITCH
switch, connector C72, pin 6, circuit 31-CA25
(BK), harness side and ground.
Yes
CHECK the heater blower switch; INSTALL
No
blower switch and ground by using the wir-
operation.
C8: CHECK THE CIRCUIT FOR HEATER BLOWER, HIGH SPEED
1. 2. 3.
Heater blower
switch C72
(BK/OG), harness side and ground.
Yes
GO TO C9
No
blower motor and heater blower switch by
C9: CHECK THE CIRCUIT FOR HEATER BLOWER, MEDIUM SPEED

(BK/BU), harness side and ground.
Yes
GO TO C12
No
GO TO C10
E9425 EN 07/2001 2002 Bantam

C10: CHECK THE COMMON CIRCUIT FOR HEATER BLOWER; LOWER SPEEDS
1. 2. 3.
Heater blower se-

ries resistor C90
series resistor, connector C90, pin 1, circuit
31S-CA18A (BK/RD), harness side and
ground.
Yes
GO TO C11
No
blower motor and heater blower series re-
sistor by using the wiring diagrams. TEST
C11: CHECK THE CIRCUIT FOR HEATER BLOWER, MEDIUM SPEED
1.

31S-CA32 (BK/BU), harness side and heater
blower switch, connector C72, pin 1, circuit,
31S-CA32 (BK/BU), harness side.
Yes
CHECK the heater blower series resistor;
No
blower series resistor and heater blower
E9425 EN 07/2001 2002 Bantam

C12: CHECK THE CIRCUIT FOR HEATER BLOWER, LOW SPEED
(BK/YE), harness side and ground.
Yes
GO TO C14
No
GO TO C13
C13: CHECK THE CIRCUIT FOR HEATER BLOWER, LOW SPEED

1. 2.
Heater blower se-

ries resistor C90
31S-CA31 (BK/YE), harness side and heater
blower switch, connector C72, pin 2, circuit
31S-CA31 (BK/YE), harness side.
Yes
CHECK the heater blower series resistor;
No
E9425 EN 07/2001 2002 Bantam


C14: CHECK THE CIRCUIT FOR HEATER BLOWER, SLOW SPEED
(BK/WH), harness side and ground.
Yes
CHECK the heater blower switch; INSTALL
No
GO TO C15
C15: CHECK THE CIRCUIT FOR HEATER BLOWER, SLOW SPEED

1. 2.
Heater blower se-

ries resistor C90
31S-CA30 (BK/WH), harness side and heater
blower switch, connector C72, pin 3, circuit
31S-CA30 (BK/WH), harness side.
Yes
CHECK the heater blower series resistor,
INSTALL a new on if necessary. TEST the
No
PINPOINT TEST D: THE AIR RE-CIRCULATION FLAP IS INOPERATIVE
D1: CHECK THE FUSE F16
1. 2.
• Is the fuse OK?
Yes
GO TO D2
No
blows again, REPAIR the short to ground of
the circuit(s) by using the wiring diagrams.
Fuse F16 (CJB)
E9425 EN 07/2001 2002 Bantam


D2: CHECK THE POWER SUPPLY OF THE FUSE F16
1. 2.
Fuse F16 (CJB)

ground.
Yes
GO TO D3
No
1. 2.
• Is the fuse OK?
Yes
GO TO D4
No
Fuse F13 (CJB)
mal operation.
D4: CHECK THE POWER SUPPLY OF THE FUSE F13
1. 2.
Fuse F13 (CJB)

ground.
Yes
GO TO D5
No
E9425 EN 07/2001 2002 Bantam


D5: CHECK THE POWER SUPPLY OF THE RE-CIRCULATION AIR ACTUATOR
1. 2. 3.
Re-circulation air
actuator C54
4 Measure the voltage between re-circulation air
actuator, connector C54, pin 2, circuit 14-CA76
(VT), harness side and ground.
Yes
GO TO D6
No
F16 and re-circulation air actuator by using
normal operation.
D6: CHECK THE GROUND SUPPLY OF THE RE-CIRCULATION AIR ACTUATOR

1.
2 Measure the resistance between re-circulation

air actuator, connector C54, pin 3, circuit 31-
CA76 (BK), harness side and ground.
Yes
GO TO D7
No
REPAIR the open circuit(s) between re-
circulation air actuator and ground G6 by
E9425 EN 07/2001 2002 Bantam

D7: CHECK THE CONTROL CIRCUIT OF THE RE-CIRCULATION AIR ACTUATOR
1. 2.
Relay – A/C re- Re-circulation air

circulation flap actuator C54
C342
3 Connect a jumper wire between relay socket –
A/C re-circulation flap, connector C342, pin 5,
circuit 31S-CA76 (BK/OG) and ground.
4.
• Is the re-circulation air actuator activated?
Yes
GO TO D9
No
GO TO D8
D8: CHECK THE RE-CIRCULATION AIR ACTUATOR

1.
E9425 EN 07/2001 2002 Bantam


air actuator, connector C54, pin 1, circuit 31S-
CA76 (BK/OG), harness side and relay socket
– A/C re-circulation flap relay, connector C342.
pin 5, circuit 31S-CA76 (BK/OG).
Yes
CHECK the re-circulation air actuator;
No
circulation air actuator and relay – A/C re-
circulation flap by using the wiring diagrams.
D9: CHECK THE GROUND SUPPLY OF THE RELAY – A/C RE-CIRCULATION FLAP
1.
3.
E9425 EN 07/2001 2002 Bantam


A/C re-circulation flap, connector C342,
between pin 5, circuit 31S-CA76 (BK/OG) and
pin 3, circuit 31-CA76A (BK).
Yes
GO TO D10
No
A/C re-circulation flap and ground G6 by us-
D10: CHECK THE GROUND CONNECTION OF RELAY – A/C RE-CIRCULATION FLAP
1.
3.

A/C re-circulation flap, connector C342,
between pin 5, circuit 31S-CA76 (BK/OG) and
pin 1, circuit 31-CA66 (BK).
Yes
GO TO D11
No
A/C re-circulation flap and ground G6 by us-
E9425 EN 07/2001 2002 Bantam

D11: CHECK THE RELAY – A/C RE-CIRCULATION FLAP
1 Check the relay – A/C re-circulation flap
according to the Component Testing attached
to the wiring diagrams.
• Is the relay OK?
Yes
GO TO D12
No
INSTALL a new relay – A/C re-circulation
flap. TEST the system for normal operation.
D12: CHECK THE CONTROL CIRCUIT OF THE RELAY – A/C RE-CIRCULATION FLAP
1. 2.
Re-circulation
switch C353
3 Measure the voltage between re-circulation
switch, connector C353, pin 2, circuit 14-CA66
Yes
GO TO D13
No
F13 and re-circulation switch by using the
mal operation.
D13: CHECK THE RE-CIRCULATION SWITCH

1.
E9425 EN 07/2001 2002 Bantam


switch, connector C353, pin 1, circuit 14S-
CA66 (VT/OG), harness side and relay socket
– A/C re-circulation flap, connector C342, pin
2, circuit 14S-CA66 (VT/OG).
Yes
CHECK the re-circulation switch; INSTALL a
new one if necessary. TEST the system for
normal operation.
No
circulation switch and relay – A/C re-
circulation flap by using the wiring diagrams.
Component Test
Relay – A/C W.O.T
1. Check the relay contact in normal condition
• Connect the battery positive terminal with the

Measure the resistance at the relay between pin 3 relay, pin 1.
and pin 5. • Connect the battery negative terminal with the
relay, pin 2.
Is the resistance greater than 100 Kohm?
Measure the resistance at the relay between pin 3
If yes, GO to 2.
and pin 5.
If not, INSTALL a new relay.
Does the relay switch (audible click) when battery
2. Check relay contact in activated condition voltage is applied and is the resistance less than
Using a test cable and set up the test as in the 1,0 Ohm?
following description. If yes, the relay is OK.
Relay – A/C switch

E9425 EN 07/2001 2002 Bantam

Measure the resistance at the relay between pin 3 Measure the resistance at the relay between pin 3
and pin 5. and pin 5 and between pin 3 and pin 2.
Is the resistance greater than 100 Kohm? Is in both measures the resistance greater than
100 Kohm?
If yes, GO to 2.
If yes, GO to 2.
2. Check relay contact in activated condition
2. Check relay contact (1) in activated condition
Using a test cable and set up the test as in the
following description. Using a test cable and set up the test as in the
following description.

relay, pin 2. • Connect the battery positive terminal with the
• Connect the battery negative terminal with the relay, pin 8.
relay, pin 1. • Connect the battery negative terminal with the
Measure the resistance at the relay between pin 3 relay, pin 7.
and pin 5. Measure the resistance at the relay between pin 3
and pin 5.
voltage is applied and is the resistance less than Does the relay switch (audible click) when battery
1,0 ohm? voltage is applied and is the resistance less than
1,0 ohm?
If yes, the relay is OK.
If yes, GO to 3.
Relay – high speed engine cooling fan 3. Check relay contact (2) in activated condition
1. Check the relay contacts in normal condition Using a test cable and set up the test as in the
E9425 EN 07/2001 2002 Bantam


Connecting the testing equipment
The following requirements must be met in order
to carry out an accurate test:
• Close both of the manual valves on the
pressure gauges. Connect the pressure
gauges to the high-pressure and the low-
pressure side of the air conditioning system.
• Start the engine, set the air conditioning to
maximum cooling and air re-circulation, and
set the blower to maximum power.
• Run the engine at 1500 rev/min.
• Connect the battery positive terminal with the Specified values for high and low-pressure
relay, pin 8. The measured values for high and low-pressure
• Connect the battery negative terminal with the depend on the outside temperature. This is
relay, pin 9. shown in the diagram and the table.
Measure the resistance at the relay between pin 3 The area between the two curves corresponds to
and pin 2. the tolerance range. The measured value must
lie in this range.
voltage is applied and is the resistance less than Specified values for high-pressure
1,0 ohm?
Refrigerant Circuit
Workshop Equipment
Servicing unit/pressure gauges
Stopwatch
Electronic leak tester
Leak test
Test all components and refrigerant lines with an Item Description
electronic leak tester. Follow the equipment
manufacturer's instructions. 1 High-pressure (bar)
If necessary switch on the motor and the air 2 Outside temperature (°C)
conditioning to locate any small leaks in the high-
pressure lines. Specified values for low-temperature
NOTE: Heavy oil contamination on lines or
components is an indication of leaks.
Leaks
In the event of any leaks, rectify the leak(s),
renew any faulty components and drain and refill
the air conditioning system.
System Test
Three values are used for the fault diagnosis:
• Low-pressure
• High-pressure
• Compressor switching cycles (on/off)
E9425 EN 07/2001 2002 Bantam


1 Low-pressure (bar) 2 Outside temperature (°C)
2 Outside temperature (°C)
Specified values for total cycle time
Required values: switching cycles
The following three diagrams show the required
values for the compressor switching cycles.
Measure the cycles using a stopwatch and make
a note of the result.
If the measured value lies outside the tolerance
range then there is an error in the system.
Refer to the Symptom Chart in this section.
NOTE: The total cycle time is obtained by adding
the on time to the off time.
Specified values for on time

Item Description
1 Total cycle time (s)
2 Outside temperature (°C)
Check the on/off-cycles

The following conditions must be met before
checking the switching cycle:
1. Connect the pressure gauges to the high and
low-pressure side of the air conditioning
system.
2. Start the engine and allow it to run for
Item Description approx. 10 min at 1500 rev/min.
3. Set the air conditioning to maximum cooling
1 On-time (s) and air re-circulation.
2 Outside temperature (°C) 4. Set the blower to maximum power.
5. Adjust the interior temperature to approx. 22
Specified values for off time °C.
6. Measure the switching cycles using a
stopwatch and make a note of the results.
7. Read off the pressure from the pressure
gauges, make a note of the values and
compare them with the required values in the
diagrams.
As an example, after comparison with the
diagrams the following five faults could be
present. Next compare these statements with
those in the Symptom Chart on the next page
and read off the cause of the fault.
Example:
Item Description • High-pressure - too low
1 Off-time (s) • Low-pressure - normal
• Switching cycles per minute - too many
E9425 EN 07/2001 2002 Bantam


• Clutch on time - too short Fault present: not enough refrigerant in the sys-
• Clutch off time - too short tem.
Symptom Chart - Refrigerant Circuit

High- Low- Clutch cycle Clutch cycle Clutch cycle Fault cause/action
pressure pressure times: cycle times: on- times: off-
time time
Too high Too high Compressor Compressor Compressor Condenser contaminated
running con- running con- running con-
stantly stantly stantly
Too high Normal to Compressor Compressor Compressor Engine overheated
too high running con- running con- running con-
Normal to Normal Compressor Compressor Compressor Air or contaminants in the
too high running con- running con- running con- circuit. Too much refrigerant
stantly stantly stantly in the system.
Normal Too high Compressor Compressor Compressor Fixed orifice tube, O-rings
running con- running con- running con- damaged or leaking
Normal Normal Too slow Too long or Normal or Contaminants in the circuit
constantly not at all or too much refrigerant oil
Normal Too low Too slow Too long Too long Low-pressure switch faulty
Normal to Too high Compressor Compressor Compressor Compressor faulty
too low running con- running con- running con-
Normal to Normal to Compressor Compressor Compressor Low-pressure line blocked
too low too high running con- running con- running con-
Normal to Normal Too fast Too short Normal Evaporator blocked
too low
Normal to Normal Too fast Too short Normal to Condenser, fixed orifice
too low too long tube or high-pressure line
blocked
Normal to Normal Too fast Too short Too short Not enough refrigerant in
too low the system
Normal to Normal Too fast Too short Too long Evaporator input line
too low blocked
Normal to Too low Compressor Compressor Compressor Low-pressure line
too low running con- running con- running con-
- - Irregular op- Irregular op- Irregular op- Low-pressure switch con-
eration or in- eration or in- eration or in- tacts dirty or permanently
operative operative operative open. Connector of low-
pressure switch or com-
pressor clutch dirty or dam-
aged.
E9425 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Spring Lock Coupling (34 639 1)
1. NOTE: Select special tool to suit the line

diameter.
Fit the special tool.
• Fit the special tool so that the inner collar
can be guided into the clamping spring.
2. Press the special tool into the clamping

spring.
3. Disconnect the refrigerant line.

• Discard the O-ring seals.
4. Connect the refrigerant line.

• Check the clamping spring for damage.
• Carefully pull out any damaged clamping
springs using a thin piece of wire and
install new one.
E6814 EN 07/2001 2002 Bantam

5. NOTE: Clean the connections using

refrigerant oil and a lint-free cloth.
Press the indicator ring into the clamping
spring.
6. NOTE: Install new refrigerant line O-ring

seals.
NOTE: Coat the refrigerant line O-ring seals in
clean refrigerant oil prior to installation.
Connect the refrigerant lines.
• Check that the clamping spring engages
correctly.
E6814 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment (34 628 6)
Spacer washer set
1. Check the air gap A between the drive plate

and the pulley at 60 degrees intervals
around the circumference. For additional
information,
refer to Specifications. in this section
1. Belt pulley
2. Spacer washer
3. Drive plate
NOTE: The refrigerant circuit can remain closed

if possible.
2. If the air gap A is outside the tolerance
range, if necessary detach the air
conditioning compressor. For additional
information, refer to Section 412-02/ 412-03.
• Tie up the compressor with wire if

necessary.
3. Detach the drive plate.
4. Correct air gap A as necessary using

spacer washers.
5. Attach the drive plate.
6. Check air gap A as described in step 1.

Repeat steps 3-6 if necessary.
7. Install the air conditioning compressor.

refer to Section 412-02 / 412-03.
E3640 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Electronic Leak Detection (34 620 5)

Automatic Calibration R-134a Manifold Gauge Set
Halogen Leak Detector or or equivalent
equivalent
WARNING: Good ventilation before leak

detection is necessary in the area where
it is to be performed. If the surrounding
air is contaminated with refrigerant gas,
the leak detector will indicate this gas
all the time. Odors from other chemicals
such as antifreeze, diesel fuel, disc
brake cleaner, or other cleaning sol-
vents can cause the same problem.
While leak detection air movement must
be prevented.
1. Attach R-134a Manifold Gauge Set to the
service gauge port valves.
• Leave both R-134a Manifold Gauge Set
valves closed.
• Both gauges should indicate 4,1-5,5 bar
(413-551 kPa at 24°C with the engine off.
• If little or no pressure is indicated, charge
the system with approx. 300g of
refrigerant. For additional information,
refer to Drain, Evacuate and Refill the A/C
System in this section
2. Use R-134a Automatic Calibration Halogen

Leak Detector to leak test the refrigerant
system. Follow the instructions included
with leak detector for handling and
operation techniques.
3. NOTE: Refilling the system is only permitted

when the amount of refrigerant is well known.
If a leak is found, reclaim the refrigerant if
refer to A/C System Evacuation and
Charging in this section.
E717 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Air Conditioning (A/C) System Flushing

A/C Flusher Kit or equivalent A/C Refrigerant Analyzer or
equivalent
A/C Flushing Kit or

equivalent
WARNING: Use extreme care and ob-

serve all safety precautions related to
the use of refrigerants. Warning: Due to
refrigerant hazards, always wear safety
goggles and non-penetrable gloves
when working on or flushing A/C sys-
tems.
CAUTION: The A/C refrigerant Analyzer

must be used before recovering, other-
wise the refrigerant of the refrigerant
center may contaminate. All contami-
nated A/C refrigerant must be disposed
of as hazardous waste. For all equip-
ment, follow the equipment manufactur-
ers instructions.
CAUTION: Suction accumulator, muffler,

hoses, thermal expansion valve, and
fixed orifice tube should be removed
when flushing the A/C system. Internal
plumbing of these devices makes it im-
possible to properly remove any resid-
ual flushing agent. Except for the hoses,
these components are typically dis-
carded after A/C system contamination.
Hoses can normally be reused unless
they are clogged with debris. The Ford
A/C Flushing Solvent and filter used in
A/C Flusher are intended for use on one
vehicle only. They may be used to flush
both the A/C condenser core and the
A/C evaporator core on an individual
vehicle, but under no circumstances
should they be used on more than one
vehicle. For additional information,
E719 EN 07/2001 2002 Bantam

1. NOTE: Prior to using A/C Flusher for the first

time, review its operating instructions.
A procedure to provide technicians with a
non-CFC method of flushing contaminated
A/C system heat exchangers (A/C
evaporator core and A/C condenser core)
has approved. This procedure allows the
specified components to be cleaned and
flushed while installed in their normal in-
vehicle location. The types of contamination
flushed include particle matter that results
from A/C compressor and desiccant failure
within the suction accumulator and gummy
residue that may form when refrigerant oil is
overheated during A/C compressor seizure.
The flushing process is a two-step
procedure that involves the use of an A/C
Flusher to:
• Circulate the flushing solvent through the
heat exchanger in the reverse direction of
normal refrigerant flow (back-flushing).
Particulate matter picked up during
flushing is filtered from the returning
solvent before the solvent is returned to
the reservoir for continued circulation.
• Remove the flushing solvent from the
heat exchanger. In this step of the
procedure, pressurized air 6.2-8.6 bar
(621-862 kPa) is used to push and
evaporate any remaining flush solvent
from the heat exchanger.
2. NOTE: Only A/C Flushing Kit, which includes

A/C Flusher, A/C Flusher Fitting Kit and Ford
A/C System Flushing Solvent, is approved for
use on Ford vehicles. No other flushing
device or solvent is approved for flushing
heat exchangers. Use of any other flusher or
solvent may cause damage to the A/C
system and the flushing unit.
A/C flusher components consist of:
• Valve No. 1 (Part of 014-00991)
• Valve No. 2 (Part of 014-00991)
• Flush Quick Coupler (Part of 014-00991)
• Moisture Trap (Part of 014-00991)
• Air Purge Valve (Part of 014-00991)
3. Reclaim the refrigerant. For additional

information, refer to A/C System Evacuation
and Charging in this section.
E719 EN 07/2001 2002 Bantam

4. Disconnect refrigerant lines from the heat

exchanger(s) to be flushed. For additional
information, refer to Section 412-02/
5. Connect A/C Flusher and A/C Flusher

Fitting Kit to the heat exchanger to be
flushed. Do not flush through the A/C
evaporator core orifice, mufflers or lines.
Internal plumbing and material make-up of
these components make it impossible to
properly remove debris and residual
flushing solvent.
6. Use Ford A/C Flushing Solvent to flush the

heat exchanger for a minimum of 15
minutes. The flush solvent may be used for
one or both heat exchangers in the A/C
system. However, the flush solvent is
intended for one vehicle only. The filter
used on the flushing unit is also intended
for use on one vehicle only.
7. Flush component for a minimum of 15

minutes.
8. Apply 6.2-8.6 bar (621-862 kPa)

pressurised air to the component for a
minimum of 30 minutes. The 30-minute
purge time is required to force and
evaporate all residual flush solvent from the
A/C system component. Failure to
successfully remove all residual solvent
within the component can result in system
damage when reconnected and operated.
Dispose of used flush solvent and filter in
accordance with local, state and federal
ordinances.
9. NOTE: A/C system filtering as described in

this section is optional if system flushing is
performed. However, filter kit use is
recommended after flushing if A/C system
contamination is extensive.
Install new suction accumulator and A/C
evaporator core orifice on any vehicle being
repaired for A/C compressor or desiccant
failure.
10. Install new refrigerant lines if clogged with

debris.
11. Reconnect the heat exchanger being

flushed.
E719 EN 07/2001 2002 Bantam

12. Add additional refrigerant oil as required.

For additional information, refer to
Refrigerant Oil Addition in this section
13. Evacuate, charge and leak test A/C system.
14. Check A/C system for correct operation.
E719 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Tracer Dye Leak Detection (34 620 5)

120 Watt UV Spot Lamp or R-134a Manifold Gauge Set
equivalent or equivalent
NOTE: Since July 1999 vehicles have a fluores-

cent tracer dye tablet inserted into the A/C sys-
tem. If tracer dye is present, there is a green
cross on the suction accumulator.
NOTE: If it is necessary to add tracer dye, use
the dye injector. A/C systems require 7.4 ml of
Fluoro-Light / P Fluorescent Tracer Dye. For
refer to Specification in this section
NOTE: Some vehicles may have signs of refrig-
erant oil at the spring lock couplers. This may be
caused from the assembly process, which ap-
plies to the fittings before installation to aid in
assembly. When a spring lock coupler is sus-
pected of leaking, always wipe the fitting clean
and verify the leak with R-134a Automatic Cali-
bration Halogen Leak Detector.
NOTE: The exact location of leaks can be pin-
pointed by the bright yellow-green glow of the
tracer dye. Since more than one leak may exist,
always inspect each component.
1. Check for leaks using a 120 Watt UV Spot
Lamp. Always scan all components, fittings
and lines of the A/C system.
2. After the leak is found and repaired, remove

any traces of dye with a general purpose oil
solvent.
3. Verify the repair by operating the system for

some minutes and inspecting with the UV
lamp again.
E715 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Vacuum Leak Detection (34 620 5)

R-134a refrigerant station or Refrigerant identifier or
equivalent equipment equivalent equipment
023-00106 198-0003
WARNING: Observe “Health and Safety

Precautions„.
CAUTION: The refrigerant identifier must

be used before the system is evacuated,
otherwise the service station may be-
come contaminated. Contaminated re-
frigerant must be disposed of as special
waste. The manufacturer's instructions
must be followed when dealing with the
service station.
1. Empty the air conditioning system under
suction and evacuate it. For additional
information, refer to Air Conditioning -
drain, evacuate and re-fill in this section.
2. NOTE: If an air conditioning system that was

filled with refrigerant is being evacuated, then
some refrigerant will still be in the refrigerant
oil in the compressor. This residual amount of
refrigerant may still evaporate and during the
leak test may result in a minor increase on
the pressure gauge (max. two sub-divisions).
However, despite this pressure increase the
air conditioning system is free from leaks.
Carry out the leak test.
• Close the gauge head manual valves.
• Switch off the service station vacuum
pump.
• Watch the low pressure gauge on the
service station. If the gauge reading
increases by more than 20 mbar (2 kPa),
the system is leaking.
• If there are leaks, fill the air conditioning
system with approx. 300 g of refrigerant
and check it using leak testing equipment.
refer to Leak testing in this section
• If the system is free of leaks, continue
with the filling procedure.
E3639 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Air Conditioning (A/C) System Evacuation and Charging (34 620 2)
General Equipment
Service unit
WARNING: Observe "Health and Safety

Rules". For additional information,
CAUTION: The refrigerant detector must

be used before evacuation; otherwise,
the service unit may become contami-
nated. Contaminated refrigerant must be
disposed of as hazardous waste. Al-
ways follow the manufacturer instruc-
tions when using the service units.
1. Remove the protective caps of the filler
valves and connect the service unit leads to
the filler valves.
• Pull back the lock on the quick-release
connector.
1. Larger inside diameter for high-pressure
side.
2. Smaller inside diameter for low-pressure
side.
2. WARNING: Avoid releasing the

refrigerant into the atmosphere at all
costs.
Drain the air conditioning system through
the low-pressure port in accordance with
the service unit manufacturer instructions.
3. NOTE: The air conditioning system has to be

evacuated for approximately 30 minutes in
order to make sure that the system will work
perfectly again once refilled.
NOTE: If moisture has entered the open system
over an extended period of time (several hours),
install a new accumulator / dryer and extend the
evacuation time to 2-3 hours.
Evacuate the air conditioning system in
accordance with the service unit
manufacturer instructions.
E6815 EN 07/2001 2002 Bantam

4. NOTE: If an air conditioning system is

evacuated before the refrigerant has been
drained, some of the refrigerant will remain in
the compressor refrigerant oil. This remaining
refrigerant may evaporate, causing a slight
increase (maximum two marks) in the reading
on the pressure gauge during the leak test.
This increase in pressure does not mean the
air conditioning system is leaking.
Carry out a leak test.
• To test for leaks, close the hand valves
on the pressure gauge head, switch off
the service unit vacuum pump and
observe the low-pressure gauge.
• If the reading increases by more than 20
mbar (2 kPa), this means that the system
is leaking.
• If the air conditioning system is leaking,
fill it with approximately 300 g refrigerant
and check using a leakage detector.
refer to Leak test in this section
CAUTION: Always evacuate the air con-

ditioning system before filling it.
NOTE: Depending on the service unit and
equipment (with or without heatable filler cylin-
der), the air conditioning system can be filled in
liquid form through the high-pressure port or in
gaseous form through the low-pressure port.
NOTE: Fill quantity indicated on sticker in en-
gine compartment.
5. Filling the air conditioning system through
the high-pressure port (liquid fill).
• Open the high-pressure shut-off valve on
the pressure gauge head.
• Switch the service unit to "Fill" mode and
fill the system with the prescribed quantity
of liquid refrigerant (R134a).
E6815 EN 07/2001 2002 Bantam

6. CAUTION: Filling the air conditioning

system through the low-pressure port
(gas fill only).
Filling the air conditioning system through
the low-pressure port.
• Open the low-pressure shut-off valve on
the pressure gauge head.
• Switch the service unit to "Fill" mode and
fill the system with the prescribed quantity
of gaseous refrigerant.
• Top up with the remaining refrigerant
whilst the air conditioning is switched on.
Let the engine run at about 1200-1500
rpm for this purpose. Switch the air
conditioning to maximum cooling power
and fresh air mode. Set the blower to
maximum power. Allow the remainder of
the prescribed amount to be drawn in.
7. NOTE: Do not detach the high-pressure hose

whilst the air conditioning is switched on.
Disconnect the service unit.
• Close the shut-off valves.
• Switch off the service unit.
• Disconnect the refrigerant hoses from
the air conditioning system.
• Screw the protective caps onto the filler
valves.
E6815 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Refrigerant Oil Addition (34 621 1)
1. NOTE: If more than one air conditioning

system component is being renewed, the oil
quantity to be added is the sum of each
individual quantity. For additional
information,
refer to General Specifications in this section.
NOTE: Always keep refrigerant oil in a closed
and sealed container to prevent entry of
moisture.
Top up with the calculated quantity of new
refrigerant oil.
2. NOTE: Only remove the protective caps just

before fitting, in order to prevent entry of
moisture and dirt.
When repairs are complete, evacuate the
air conditioning system, fill with R134a and
check operation. For additional
information, refer to Air Conditioning -
Drain, Evacuate and Re-fill in this section
E3649 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Air Distribution System Cleaning

Spray gun with hose Odor eliminating agent
(240 ml) (TOX Number
142040)
All vehicles
1. WARNING: Avoid contact with eyes

and skin; wear gloves and respiratory
protection. Ensure that you perform
this operation in a well ventilated
room. Keep all vehicle doors and
windows open for the duration of the
operation. Do not inhale vapors
under any circumstances. Do not
smoke and avoid open fire and
unprotected light sources.
NOTE: Precisely locate the musty or damp odor.
The odor eliminating agent can remove deposits
in the heater housing but cannot prevent
odorous that are distributed by the ventilation
system, for example those caused by damp
carpets.
Disconnect the low pressure switch
connector.
2. Turn on the ignition.
3. NOTE: All ventilation nozzles must be open.

Open all ventilation nozzles, set the
temperature switch to maximum heat, set
the heater motor switch to the highest
position and set the ventilation to "fresh air".
4. Start the engine and let it warm up to

operating temperature.
5. To dry out the system, switch off the air

conditioning system and ventilate the
vehicle for approx. 15 minutes.
6. Switch off the engine.
7. Remove the blower motor. For additional

8. Fill the spray gun with the odor eliminating

agent (240 ml).
E4466 EN 07/2001 2002 Bantam

9. CAUTION: The maximum pressure of

13.5 bar must not be exceeded.
Use the tyre inflator to apply pressure of 5.5
to 10 bar (operating pressure) to the spray
gun.
10. Insert the spray gun hose as far as possible

into the opening in the heater blower,
working towards the evaporator (Mondeo
heater housing shown).
• By moving the hose, spray the odor
eliminating agent over the entire surface
of the evaporator.
• Spray the entire odor eliminating agent
into the opening.
• Allow the odor eliminating agent to take
effect for 10 minutes.
12. Start the engine, switch off the air

conditioning system and ventilate the
vehicle for approx. 15 minutes. While this is
being done, have all ventilation nozzles
open, the temperature switch set to
maximum heat, the heater motor switch to
the highest position and the ventilation to
"fresh air".
13. Switch off the engine.
14. Connect the low pressure switch connector.
15. Ventilate the vehicle with the doors open for

another 30 minutes.
E4466 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Contaminated Refrigerant Handling (34 620 5)
1. If contaminated refrigerant is detected DO

NOT recover the refrigerant into your R-
134a OR R-12 recovery / recycling
equipment. Take the following actions:
1. Repeat the test to verify contaminated
refrigerant is present.
2. Advise the customer of the contaminated
A/C system and any additional cost to
repair the system. The customer may wish
to return to the repair facility performing
the last A/C repair.
3. Recover the contaminated refrigerant
using suitable recovery only equipment
designed for capturing and storing
contaminated refrigerant. This equipment
must only be used to recover
contaminated refrigerant to prevent the
spread to other vehicles.
E725 EN 07/2001 2002 Bantam

SPECIFICATIONS
Specification
A/C Refrigerant R134a, YN-11 WSH-M17B19-A
PAG A/C Refrigerant Oil, F2AZ-19577-AC (MC YN-12b) WSH-M1C231-B
A/C Clutch Air Gap 0.35 mm-0.75 mm
Ford A/C Flushing Solvent, F4AZ-19579-A -
Fluoro-Lite / P Florescent Tracer Dye, 164-R 3712 -
Addition of Air Conditioning Refrigerant Oil

When Installing a New: Specification
Air conditioning condenser Add 30 ml.
Air conditioning evaporator Add 90 ml.
Suction accumulator Fill with the same quantity + 90 ml.
Air conditioning compressor, if the quantity of oil Add 90 ml.
taken from the compressor is less than 90 ml.
Air conditioning compressor, if the quantity of oil Fill with the same quantity + 30 ml.
taken from the compressor is between 90 ml and
150 ml.
Air conditioning compressor, if the quantity of oil Add 150 ml.
taken from the compressor is greater than 150 ml.
Air conditioning lines, if air conditioning has been Add 60 ml.
switched on with defective line.
Per evacuation process Add 30 ml.
Air conditioning compressor

Description Type
Air conditioning compressor FS-10
Fixed orifice tube

Description Color
Fixed orifice tube Orange
Description Nm
Drive plate to compressor bolt 13
Air conditioning compressor retaining bolts 25
Manifold and tube to A/C compressor retaining bolt 20
Suction accumulator bracket retaining bolts 6
Pressure cutoff switch 10
E6732 EN 07/2001 2002 Bantam

412-01-1 Air Distribution and Filtering 412-01-1
SECTION 412-01 Air Distribution and Filtering

SUBJECT PAGE
Air Distribution and Filtering..................................................................................................... 412-01-2

Air Distribution and Filtering..................................................................................................... 412-01-3

Center Vent Nozzle............................................................................................ (34 489 0) 412-01-4
07/2001 2002 Bantam


Air Distribution and Filtering
The heating system has been improved in terms The vehicle may also have recirculated air mode
of power output, user-friendliness and ease of as an option, and which can be activated by
maintenance. operating a switch on the control panel.
A splined shaft instead of cables controls the air
distribution, and the interior temperature by a From the air intake aperture, fresh air passes
potentiometer integrated into the operating panel. through the fan, and heater / air conditioning
The potentiometer also controls the heater system and air ducts to various air distribution
control valve, which regulates the flow of hot nozzles and then into the passenger
water through the heat exchanger according to compartment.
the interior temperature setting. While the vehicle is traveling a draught free
The heat exchanger and, depending on current of air is emitted by specially shaped
equipment level, the air-conditioning evaporator demisting nozzles and passes along close to the
are easily accessible from the engine side windows and then through to the outside.
compartment. This active ventilation keeps the side windows
clear and provides constant ventilation.
The air temperature, volume and distribution
can be controlled by the operating switch. Item Description
Ventilation nozzles 1 Right / left adjustment
2 Up / down adjustment
3 Open / Closed adjustment
OPEN
• The fan is switched off completely when the
air distribution switch is turned to OFF.
CLOSED
E1238 EN 07/2001 2002 Bantam


Air Distribution and Filtering
E3103 EN 07/2001 2002 Bantam


Center Vent Nozzle (34 489 0)
Removal
1. Remove the instrument cluster bezel.
• Unclip the cover.
2. Remove the instrument cluster bezel

(continued).
1. Screws
2. Clips
• Disconnect the plug.
3. Remove the switches (bezel shown

removed).
1. Spot lights
2. Air conditioner.
3. Clock.
4. A/C re-circulation.
Installation
E1242 EN 07/2001 2002 Bantam

412-02-1 Heating and Ventilation 412-02-1
SECTION 412-02 Heating and Ventilation

SUBJECT PAGE
Heating and Ventilation............................................................................................................412-02-2

Heating and Ventilation............................................................................................................412-02-3

Blower Motor ...................................................................................................... (34 374 0) 412-02-4/7
Heater Core Housing ......................................................................................... (34 354 0) 412-02-8/11
Heater Core........................................................................................................ (34 364 0) 412-02-12/15
Heater Control Valve.......................................................................................... (34 328 0) 412-02-16/19

Heater Core Housing ......................................................................................... (34 354 8) 412-02-20/22
SPECIFICATIONS
Specifications ........................................................................................................................... 412-02-23
07/2001 2002 Bantam


Heating and Ventilation
The heater temperature is set using the operating temperature switch is set between Min
temperature control switch. Depending on the and Max. This noise is carried into the interior of
setting of this switch, the heater control module the vehicle via the fascia /crash padding and can
(located in the heater/air conditioning system be intensified if any air is trapped in the system. If
controls) monitors the position of the heater concerns are expressed over this, the noise can
control valve, which in turn controls the flow of be reduced by installing modified insulation on
hot coolant through the heat exchanger. the heater control valve along with a modified
heater coolant hose. For additional information,
A splined shaft adjusts the position of the air
distribution flap. A control motor operates the refer to Heater Control Valve in this section
recirculated air flap. Procedure if the heating cannot be controlled.
The blower motor has four speeds, controlled by If there is a concern that the heating cannot be
the blower motor operating switch through a controlled (only hot air or only cold air is
resistance. produced), the cause may be a damaged wiring
If the air conditioning system is switched on but harness, damaged multiplug, a defective heater
the blower motor switch is off, the air conditioning control valve or a defective heater control. To
system will not operate. The air conditioning resolve the concern, check the heating system
system will only operate if the blower motor is on. and renew any damaged components. An
additional cover should be installed on the heater
control valve on the vehicle. For additional
Procedure if there is regular knocking noises information,
coming from the fascia crash padding area. refer to Section 412-00 Diagnosis and Testing
The water flow through the heater control valve
can cause a regular knocking noise when the
E1243 EN 07/2001 2002 Bantam


Heating and Ventilation
E2890 EN 07/2001 2002 Bantam


Blower Motor (34 374 0)

Separator, quick-fit coupling O-rings (Green)
5/8" (black)
Adhesive butyl rubber
412-038 (34-003) strips (6 off, if required)
Sealer (if required)
Removal
NOTE: Observe the Health and Safety regula-

tions for working with refrigerant. For additional
1. Drain the air conditioning system.
All vehicles
2. Detach the coolant expansion tank.
• Remove the single screw.
• Unhook the coolant expansion tank from
its bracket.

3. Release the air cleaner intake pipe.
• Undo the hose clip.
• Lay the intake pipe to one side.
E1248 EN 07/2001 2002 Bantam

4. Remove the bulkhead extension.

• Remove the rubber seal.
• Unclip the cover of the central junction
box (CJB).
5. Remove the bulkhead extension

(continued).
2. Disconnect the plug.

(continued).

NOTE: Seal the evaporator and refrigerant lines
with plugs.
1. Disconnect the refrigerant lines.
E1248 EN 07/2001 2002 Bantam


All vehicles
8. Remove the pollen filter housing.
9. Remove the blower motor cover.
10. Remove the blower motor.

• Unscrew the bolts.
• Separate the connector located in the
passenger footwell.
• Pull out the grommet together with the
wire and the plug.
Installation
1. Install the blower motor.
NOTE: Perform steps 2 and 3 only if water is

entering through the pollen filter on the bulk-
head.
2. Thoroughly clean the area around the
pollen filter opening on the bulkhead.
E1248 EN 07/2001 2002 Bantam

3. Apply a layer of sealer (see "Materials")

approximately 10 mm thick to the horizontal
top face around the pollen filter opening.
4. Install the remaining components in reverse

order.
NOTE: Before connecting the refrigerant lines,
fit them with new O-rings. Coat the new O-rings
with refrigerant oil before fitting them.
1. Evacuate the air conditioning system and fill
All vehicles
6. Check the operation of the heating and air
conditioning system (if fitted).
E1248 EN 07/2001 2002 Bantam


Heater Core Housing (34 354 0)

Disconnecting tool, O-rings (Green)
refrigerant line 5/8" (black)
34-003
Removal
NOTE: "Health and Safety Regulations". For

• Place protective covers over the fenders.
CAUTION: Disconnect the battery nega-

tive lead.
2. On vehicles with air conditioning, drain the
system. For additional information,
3. Remove the fascia crash panel.


its bracket.
E1246 EN 07/2001 2002 Bantam


• Unclip the central junction box (CJB)
cover.

(continued).
2. Unclip the connector.

(continued).

with plugs.
E1246 EN 07/2001 2002 Bantam


NOTE: Plug the heat exchanger.
9. Pull off the connector and detach the
coolant hoses.
1. Disconnect the plug from the heater
regulating valve.
2. Undo the clamps and disconnect the
coolant hoses.
10. Separate the connectors.

1. Blower motor
2. Air re-circulation valve control motor
3. Blower motor resistor assembly
11. Remove the heater.

• Pull off the side air ducts.
1. Unscrew the three nuts.
• Undo the wiring harness.
2. Undo the heater from the bracket.

12. Pull off the air conditioning condenser drain
hose.
Installation
NOTE: Torques For additional information,
refer to Section 412-02, Specifications
E1246 EN 07/2001 2002 Bantam

2. Install the fascia crash padding.

3. Evacuate and fill the air conditioning
4. Fill the cooling system with coolant.


• Connect the battery negative lead.
• Remove the protective covers.
• Road test the vehicle to collect data for
the PCM.
6. Check the operation of the heating and air

conditioning system (if fitted).
E1246 EN 07/2001 2002 Bantam


Heater Core (34 364 0)

34-003
Removal
NOTE: "Health and Safety Regulations". For

2. Drain the air conditioning system.

tive lead.
its bracket.
E1247 EN 07/2001 2002 Bantam


cover.

(continued)

(continued)

with plugs.
E1247 EN 07/2001 2002 Bantam

NOTE: Plug the heat exchanger. Do not mix up

the heater hoses during installation (mark them
if required)
8. Disconnect the coolant hoses.
1. Pull off the connector from the heater
control valve.
2. Undo the clamps and detach the coolant
hoses.
9. Remove the heater cover.

• Remove the four bolts.

10. Pull out the evaporator/heat exchanger.
1. Evaporator (push fit)
2. Heat exchanger (push fit)
Installation
NOTE: Torques For additional information,

refer to Section 412-02, Specifications
fit them with new O-rings Coat the new O-rings
E1247 EN 07/2001 2002 Bantam


2. Evacuate the air conditioning system and
fill it. For additional information,

the PCM.
4. Check the operation of the heater and the

air conditioning system (if fitted).
E1247 EN 07/2001 2002 Bantam


Heater Control Valve (34 328 0)
Removal

tive lead.
its bracket.

box (CJB).

(continued).
E1245 EN 07/2001 2002 Bantam


(continued).

6. Remove the heater control valve.
1. Disconnect the plug from the heater
control valve.
2. Undo the four clamps and detach the
coolant hoses.
Installation
NOTE: Only carry out steps 1 to 4 if there is a

regular knocking noise coming from the fascia
crash padding when the heater control is set to
between Min and Max.
1. NOTE: Coolant will escape.
Remove the left-hand heater coolant hose
(shown without refrigerant line).
2. Remove the left-hand heater coolant
hose.
E1245 EN 07/2001 2002 Bantam

LHD vehicles
2. NOTE: Do not allow the coolant hose clamps
to touch the bodywork.
Install a new left-hand heater coolant hose.
• Route the heater coolant hose and install
the coolant hose clamps.
RHD vehicles
3. NOTE: Position of the heater coolant hose.
The coolant hose must be routed below the
connections on the heater control valve and
around the refrigerant lines.
NOTE: Do not allow the coolant hose clamps to
touch the bodywork.
Install a new left-hand heater coolant hose.
• Route the heater coolant hose and install
the coolant hose clamps.
All vehicles
4. Renew the heater control valve insulation.

order.
6. Bleed the cooling system. For additional

• Reprogram the pre-set radio stations.
to collect data.
E1245 EN 07/2001 2002 Bantam

8. Check the operation of the heater.
E1245 EN 07/2001 2002 Bantam


Heater Core Housing (34 354 8)
Disassembly
1. Remove the heater housing cover.

2. Pull out the evaporator/heat exchanger
(push fit).
1. Evaporator.
2. Heat exchanger.
3. Remove the air re-circulation valve control

motor.
E1251 EN 07/2001 2002 Bantam

4. Remove the blower motor cover.
5. Remove the blower motor.
6. Dismantle the heater housing (held together

by clips) (heater shown from the front).
7. Dismantle the heater housing (held together

by clips) (heater shown from the below).
E1251 EN 07/2001 2002 Bantam

Assembly
1. Assemble the components in reverse order.
• Use new clips if necessary.
E1251 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Heater to bulkhead 9
Pollen filter housing 5
E1252 EN 07/2001 2002 Bantam

412-03-1 Air Conditioning 412-03-1
SECTION 412-03 Air Conditioning

SUBJECT PAGE

Air Conditioning ..................................................................................................................... 412-03-2
Refrigerant Circuit with Fixed Orifice Tube ......................................................................... 412-03-2/5

Air Conditioning ..................................................................................................................... 412-03-6

Air Conditioning (A/C) Compressor.................................................................. (34 626 0) 412-03-7/8
Clutch and Clutch Field Coil............................................................................. (34 628 0) 412-03-9/12
Evaporator Core .............................................................................................. (34 622 0) 412-03-13/16
Evaporator Core Orifice ................................................................................... (34 624 0) 412-03-17/19
Suction Accumulator ........................................................................................ (34 630 0) 412-03-20/22
Low Pressure Cut-Off Switch........................................................................... (34 629 0) 412-03-23/25
High Pressure Cut-Off Switch .......................................................................... (34 631 0) 412-03-26/27
Evaporator to Condenser Line ......................................................................... (34 645 0) 412-03-28/30
Suction Accumulator to Condenser Line.......................................................... (34 643 0) 412-03-31/33
Suction Accumulator to Evaporator Line.......................................................... (34 644 0) 412-03-34/37
Specifications.......................................................................................................................... 412-03-38
07/2001 2002 Bantam


Air Conditioning
Refrigerant Circuit with Fixed Orifice Tube
Refrigerant Circuit
Function
Item Description
The gaseous refrigerant is sucked up on the
1 Condenser intake side of the compressor and is then
2 Compressor compressed. As a result of this compression, the
refrigerant heats up to a temperature between
3 Accumulator/dehydrator 70°C and 110°C.
4 Fan - heater/air conditioning The gas is then pumped to the condenser. The
condenser consists of many cooling fins, through
5 Evaporator
which the gas is passed. The refrigerant gas is
6 Fixed orifice tube cooled so much by the ram air and the air from
the radiator fan that it condenses.
7 Electric fan
The condensed, liquid refrigerant is then passed
A High-pressure, liquid and warm through a tube of constant diameter (fixed orifice
B Low-pressure, liquid and cool tube). After the fixed orifice tube the pressure and
therefore the temperature drop rapidly, and some
C Low-pressure, gaseous and cool of the refrigerant evaporates.
D High-pressure, gaseous and hot The fixed orifice tube is located in the refrigerant
line just before the evaporator, in which complete
evaporation of the refrigerant occurs. Because of
this the evaporator is cooled, and therefore the
air, which passes over it, is also cooled.
E1253 EN 07/2001 2002 Bantam

This cool air is then directed by the by the The refrigerant gas is then passed to the
heater/air conditioning system fan through the air collector/dehydrator, before being sucked up
distribution system into the vehicle. again by the compressor.
Item Description
1 Suction pipe
2 Fluid line
3 Filling valves
4 Dehydrator
E1253 EN 07/2001 2002 Bantam


Air Conditioning System Components
Item Description
1 Condenser
2 Compressor
3 Compressor line connection
E1253 EN 07/2001 2002 Bantam


Compressor
The compressor draws the gaseous refrigerant
out of the evaporator.
The compressor pumps gaseous refrigerant to
the condenser. As a result of this compression,
the gaseous refrigerant heats up to between
70°C and 110°C.
E1253 EN 07/2001 2002 Bantam


Air Conditioning
E3671 EN 07/2001 2002 Bantam


Air Conditioning (A/C) Compressor
Removal
1. Drain the air conditioning system. For


• Turn the belt tensioner clockwise.
4. Disconnect the A/C compressor clutch

CAUTION: Support the A/C compressor

before removing the retaining bolts and
secure it to prevent load being placed
on the refrigerant lines.
E6726 EN 07/2001 2002 Bantam

5. Detach the A/C compressor from the

mounting bracket.
CAUTION: Cap the refrigerant lines and

the A/C compressor to prevent dirt in-
gress.
6. Disconnect the refrigerant lines and remove
the A/C compressor.
• Discard the O-ring seals
Installation
NOTE: Install new refrigerant line O-ring seals.

E6726 EN 07/2001 2002 Bantam


Clutch and Clutch Field Coil (34 628 0)

Puller Set of spacer shims
Clamping strap Snap ring - pulley
Removal
1. NOTE: The compressor clutch can be

changed without needing to detach the
compressor from the refrigerant circuit. If
necessary the compressor must be held in
place using a cable tie, so that the refrigerant
lines are not damaged.
Remove the air-conditioning compressor.
refer to Air-conditioning Compressor in this section
2. Detach the compressor drive plate (shown

removed).
• Remove the bolt, in doing so use a
clamping strap to stop the drive plate from
turning.
3. Detach the compressor pulley.

• Detach the pulley snap-ring.
• Detach the spacer shims.
E1260 EN 07/2001 2002 Bantam

4. Pull out the compressor magnetic coil.
Installation
CAUTION: After attaching the magnetic

coil, remove the thrust washer.
NOTE: Do not skew the electromagnetic pull-in
clutch when fitting it on the compressor.
E1260 EN 07/2001 2002 Bantam

1. Fit the compressor electromagnetic pull-in

clutch.
• Press on the compressor magnetic coil
using a suitable thrust washer.
1. Bolt M6x30 with washer
2. Drive plate
3. Thrust washer
4. Electromagnetic pull-in clutch
NOTE: Renew the pulley snap ring.

2. Fit the compressor pulley.
• Fit the pulley snap-ring.
NOTE: There is a gap between the compressor

drive plate and the compressor pulley.
E1260 EN 07/2001 2002 Bantam

3. Fit the compressor drive plate.

1. Compressor pulley
2. Insert a spacer washer from spacer
washer set to set the gap.
3. Fit the compressor drive plate and check
the gap at several places around the
circumference.
4. Install the air-conditioning compressor. For

refer to Air-conditioning Compressor in this section
5. Check the operation of the air conditioning

system.
E1260 EN 07/2001 2002 Bantam


Evaporator Core (34 622 0)
Separator, quick-fit coupling O-rings (Green)
5/8" (black)
412-038 (34-003)
Removal

tive lead.
NOTE: "Safety Precautions" and "General Re-
quirements and Safety Measures for Mainte-
nance and Repair Work". For additional informa-
tion, refer to Section 100-00.

its bracket.
E1257 EN 07/2001 2002 Bantam


box (CJB).

(continued).

(continued).

with plugs.
E1257 EN 07/2001 2002 Bantam

8. Pull off the connector and detach the

coolant hoses.
1. Separate the electrical connector of the
heater control valve.
2. Undo the clamps and detach the coolant
hoses.
9. Remove the heater cover.

• Remove the four bolts.
10. Pull out the evaporator (push fit).
Installation

2. Drain and refill the air conditioning system.

E1257 EN 07/2001 2002 Bantam


the PCM.
4. Check that the heater/air conditioning

operates properly.
E1257 EN 07/2001 2002 Bantam


Evaporator Core Orifice (34 624 0)

Disconnect Tool, Spring Lock Remover, Broken Orifice
Coupling 1/2 inch (blue) 412-035 (34-005)
412-027 (34-001)
Remover/Installer, Fixed
Orifice
412-034 (34-004)
Removal
2. Detach the coolant expansion tank and

secure it to one side.
3. Remove the weather strip rubber seal.
E6718 EN 07/2001 2002 Bantam

4. Remove the bulkhead extension left hand

retaining bolt.
5. Remove the bulkhead extension right hand

retaining bolts.

2. Unclip the clips from the bulkhead
extension.

refrigerant line.
E6718 EN 07/2001 2002 Bantam

8. Using the special tool, remove the

evaporator core orifice.
• Guide the tool into the line and hook it
into the evaporator core orifice.
• Turn the tool clockwise and pull out the
9. NOTE: Only necessary if the evaporator core

orifice is broken.
Using the special tool, remove the broken
Installation
NOTE: Install new refrigerant line O-ring seals.

E6718 EN 07/2001 2002 Bantam


Suction Accumulator (34 630 0)

34-003
Removal
NOTE: "Safety Regulations". For additional


tive lead.
NOTE: Seal the accumulator/dehydrator and the

refrigerant lines with plugs.
3. Disconnect the refrigerant line at the
accumulator / dehydrator.
E1262 EN 07/2001 2002 Bantam

4. Remove the accumulator / dehydrator.

6. Remove the front right-hand wheelhouse

cover.
7. Remove the accumulator / dehydrator from

below.
Installation
NOTE: Tightening torques. For additional in-

formation, refer to Section 412-03. Specifications

E1262 EN 07/2001 2002 Bantam

2. Evacuate and refill the air conditioning


• Set the clock.
the PCM.

system.
E1262 EN 07/2001 2002 Bantam


Low Pressure Cut-Off Switch (34 629 0)
Removal
NOTE: "Safety Regulations". For additional in-
formation, refer to Section 100-00.

tive lead.
its bracket.

cover.

(continued).
2. Unclip the electrical connector.
E1261 EN 07/2001 2002 Bantam


(continued).
6. Remove the air conditioning low-pressure

switch.
7. By-pass the plug contacts for the air

conditioning low pressure switch.
• Start the engine.
• Switch on the air conditioning.
NOTE: Run the engine at idle for 30 seconds

with the air conditioning switched on before re-
moving the air conditioning low pressure switch.
8. Remove the air conditioning low pressure
switch.
Installation

formation,
refer to Section 412-03. Specifications
E1261 EN 07/2001 2002 Bantam


• Switch off the air conditioning.
• Switch off the engine.
• Remove the by-pass from the plug of the
air conditioning low pressure switch.
• Connect the plug of the air conditioning
low pressure switch.

the PCM.

system.
E1261 EN 07/2001 2002 Bantam


High Pressure Cut-Off Switch (34 631 0)
Removal

tive lead.
2. Remove the right-hand headlamp
assembly. For additional information,
3. Remove the air conditioning high-pressure

switch.
Installation

formation,
2. Install the right-hand headlamp. For

3. Check the headlamp adjustment and

correct it as necessary. For additional
E1263 EN 07/2001 2002 Bantam


the PCM.

system.
E1263 EN 07/2001 2002 Bantam


Evaporator to Condenser Line (34 645 0)

Separator, quick-fit coupling Separator, quick-fit coupling
1/2" (blue) 5/8" (black)
412-027 (34-001) 412-038 (34-003)
O-rings (Green)
Removal

tive lead.
NOTE: "Safety Precautions" and "General Re-
quirements and Safety Measures for Mainte-
nance and Repair Work". For additional informa-
tion, refer to Section 100-00.

its bracket.
E1266 EN 07/2001 2002 Bantam


box (CJB).

(continued).

(continued).
NOTE: Plug the refrigerant line and the evapo-

rator.
evaporator.
E1266 EN 07/2001 2002 Bantam

NOTE: Plug the refrigerant line and the con-

denser.
condenser.
Installation
NOTE: Fit new O-rings on the refrigerant pipes

before connecting them. Coat the new O-rings
2. Evacuate the air conditioning system and fill


the PCM.

system.
E1266 EN 07/2001 2002 Bantam


Suction Accumulator to Condenser Line (34 643 0)
Disconnecting tool, Disconnecting tool,
refrigerant line 1/2" (blue) refrigerant line 5/8" (black)
34-001 34-003
O-rings (Green)
Removal


tive lead.

NOTE: Plug the refrigerant line and the con-

denser.
condenser.
E1265 EN 07/2001 2002 Bantam

5. Separate the refrigerant line at the

compressor.
NOTE: Seal the refrigerant line and the

accumulator / dehydrator with plugs.
accumulator / dehydrator.
Installation

formation, refer to Section 412-03. Specifications



• Set the clock.
the PCM.
E1265 EN 07/2001 2002 Bantam


system.
E1265 EN 07/2001 2002 Bantam


Suction Accumulator to Evaporator Line (34 644 0)
Special Tool(s)
Disconnecting tool,
34-003
E1267 EN 07/2001 2002 Bantam


Removal
NOTE: "Safety Regulations". For additional in-
formation, refer to Section 100-00.

tive lead.

its bracket.

cover.
E5918 EN 07/2001 2002 Bantam

SPECIFICATIONS

(continued).
2. Unclip the electrical connector.

(continued).
7. Remove the air conditioning low-pressure

switch.
NOTE: Plug the refrigerant line and the

evaporator.
evaporator.
02/2002 2002 Bantam

NOTE: Seal the refrigerant line and the accumu-

lator/dehydrator with plugs.
accumulator/dehydrator.
Installation

formation,

the PCM.

system.
E5918 EN 07/2001 2002 Bantam

SPECIFICATIONS
Item Specification
Refrigerant R134a WSH-M17B19-A
Refrigerant oil for R134a WSH-M1C231-B
Fill Capacity
Grams
Refrigerant - Air Conditioning 740 g ± 15 g
Refrigerant - refrigeration system 1000 g ± 15 g
Capacities
Liters
Air conditioning system refrigerant oil, quantity for first fill 200 ml
Refrigeration system refrigerant oil, quantity for first fill 250 ml
Correction of oil quantity when components have been exchanged For additional
information,
Description Nm
Condenser to radiator 6
Collector/dehydrator to bracket 6
High pressure switch to refrigerant line 8
Compressor to bracket 25
Suction / pressure pipe to compressor 20
Drive belt tensioner lock bolt (1,8l diesel engine) 20
Drive plate to compressor (FS10) 13
Drive plate to compressor (FVS 090, diesel engine only) 17
Refrigerant line (3/8") to additional oil reservoir - refrig- 23
eration system
Union nut - de-ice line (1/2") to evaporator - refrigeration 14
system
Union nut - refrigerant line (3/8") to evaporator - refrig- 23
eration system
Union nut - refrigerant line (5/8") to evaporator - refrig- 33
eration system
Bolts for blower motor - refrigeration system 6
Bolts for evaporator cover - refrigeration system 6
02/2002 2002 Bantam

412-04-1 Control Components 412-04-1
SECTION 412-04 Control Components

SUBJECT PAGE
Control Components ................................................................................................................412-04-2

Control Components ................................................................................................................412-04-3

Climate Control Assembly ................................................................................. (34 300 0) 412-04-4/6
Blower Motor Switch.......................................................................................... (33 574 0) 412-04-7/8
Air Inlet Blend Door Actuator ............................................................................. (34 606 0) 412-04-9
07/2001 2002 Bantam


Control Components
Item Description
1 Air distribution switch
2 Air conditioning switch
3 Temperature control switch
4 Recirculated air/fresh air control switch
5 Fan motor operating switch
The fan motor operating switch sets the

heater/fresh air fan to one of four different
speeds.
The temperature control switch allows choice of
temperature and controls the heater regulator
valve.
The air distribution switch uses a cable to provide
step less control of the air distribution in the
passenger compartment.
Pressing the recirculated air/fresh air control
switch starts recirculated air operation, and the
control lamp in the switch comes on.
Pressing the air conditioning switch and when the
temperature is above +4 °C and the fan is
switched on starts the air conditioning system
and the control lamp in the switch comes on.
E1274 EN 07/2001 2002 Bantam


Control Components
E3108 EN 07/2001 2002 Bantam


Climate Control Assembly (34 300 0)
Removal

tive lead.
2. Remove the instrument cluster bezel.
3. Remove the instrument cluster bezel

(continued).
1. Screws
2. Clips
4. Remove the switches (bezel shown

removed).
1. Spot lights
2. Air conditioner.
3. Clock.
4. A/C re-circulation.
E1242 EN 07/2001 2002 Bantam

5. Remove the radio. For additional

6. Remove the bezel.

2. Unclip the clips.
• Pull the bezel forwards.
• Disconnect the plug
7. Unclip the air distribution shaft.
8. Remove the heater / air conditioning

module and the fan operating switch.
Installation
2. Install the radio. For additional information,

E1276 EN 07/2001 2002 Bantam

3. Connect the battery ground lead.

to collect data.
4. Check that the heater / air conditioning

operates correctly.
E1276 EN 07/2001 2002 Bantam


Blower Motor Switch (33 574 0)
Removal
• Ask for the radio keycode.
• Place protective covers over the wings.
CAUTION: Disconnect the battery

ground lead.
2. Remove the radio. For additional
3. Remove the bezel.

2. Unclip the clips.
• Pull the bezel forwards.
4. Unclip the air distribution shaft.
5. Remove the fan motor operating switch.
E1277 EN 07/2001 2002 Bantam

Installation
2. Install the radio. For additional information,


• Connect the battery ground lead.
4. Check the operation of the heater.
E1277 EN 07/2001 2002 Bantam


Air Inlet Blend Door Actuator (34 606 0)
Removal
NOTE: "Observe Health and Safety Regulations".

3. Remove the instrument panel.

4. Remove the actuator.

2. Remove the three screws.
Installation

• Check operation of the actuator.
E1250 EN 07/2001 2002 Bantam

413-01-1 Instrument Cluster 413-01-1
SECTION 413-01 Instrument Cluster

SUBJECT PAGE
Instrument Cluster - With Tachometer ................................................................................... 413-01-2/3
Instrument Cluster Gauges ................................................................................................. 413-01-3
Warning Indicators - With Tachometer................................................................................ 413-01-3/4
Without Tachometer............................................................................................................ 413-01-4
Instrument Cluster ................................................................................................................. 413-01-5
Inspection and Verification – All Vehicles ........................................................................... 413-01-5
Symptom Chart - (With or Without Tachometer)................................................................ 413-01-5/6
Self-Diagnostic Mode .......................................................................................................... 413-01-6/8
Worldwide Diagnostic System (WDS) Tester Diagnostics – All Vehicles ........................... 413-01-8
Instrument Cluster Diagnostic Trouble Code (DTC) Index.................................................. 413-01-8
Pinpoint Tests ..................................................................................................................... 413-01-9A/18
Instrument Cluster ........................................................................................... (33 214 0) 413-01-19/21
Instrument Cluster Printed Circuit .................................................................... (33 224 4) 413-01-22
SPECIFICATIONS
Specifications......................................................................................................................... 413-01-26
09/2001 2002 Bantam


Instrument Cluster
With Tachometer

1 Tachometer 14 Low fuel indicator
2 Malfunction Indicator Lamp (MIL) - not 15 Door ajar indicator - not specified for
specified for South Africa. South Africa.
3 Anti-lock Brake System (ABS) warning 16 Trip meter reset button
indicator - not specified for South 17 Odometer
Africa.
18 Parking brake/brake warning indicator
4 Turn signal indicator
19 Charge warning indicator
5 Traction control indicator - not specified
for South Africa. 20 Low oil pressure warning indicator
6 Speedometer The instrument cluster fitted to the 2002 Bantam
7 Low coolant warning indicator is electronic. The instrument cluster consists of
gauges, indicators and warning indicators and
8 Air bag warning indicator has a built-in self-diagnostic mode.
9 Turn signal indicator When the ignition switch is in position II with the
engine off, the instrument cluster carries out a
10 Fuel gauge
display test to verify that the warning indicators
11 Glow plug indicator (Diesel) and monitored systems are functioning correctly.
The warning indicators that illuminate during this
12 Temperature gauge
display test are:
13 High beam indicator
E1281 EN 09/2001 2002 Bantam

• Air bag system Tachometer

• Charging system The instrument cluster receives tachometer
• Park brake and low fluid level information from the powertrain control module
• Low fuel (PCM). If the engine speed (RPM) information
• Low oil pressure sent to the instrument cluster is invalid or
missing, the instrument cluster will default the
Other indicators that are incorporated into the tachometer to zero.
instrument cluster are:
• High beam
Warning Indicators
• Low washer fluid
Air Bag Warning Indicator

Instrument Cluster Gauges
The air bag module controls the air bag warning
indicator. For additional information,
Engine Coolant Temperature Gauge refer to Section 501-20B.
Temperature information is received by the
instrument cluster from the engine coolant Brake System Warning Indicator
temperature (ECT) sensor or the gauge sender
The brake system warning indicator has multiple
for diesel. If the engine coolant temperature
functions. The warning indicator illuminates if the
signal is missing or invalid, the engine coolant
brake fluid level is low or if the parking brake is
temperature gauge will indicate a default position
set.
below cold.
Charging System Warning Indicator

Fuel Gauge
The generator controls the charging system and
The instrument cluster receives the fuel level
the charging system warning indicator. The
information from the fuel sender unit (part of the
generator is therefore responsible for turning the
fuel pump module). This is a variable resistor,
warning indicator OFF when the system is
which varies the ground supply to the gauge,
running, and illuminating it under fault conditions
therefore altering the gauge position. If no input
(including stall conditions). For additional
signal or a faulty input signal is received, the fuel
gauge will indicate a default position below
empty. The fuel level input signal is dampened to
prevent movement of fuel in the tank affecting the The High Beam Indicator
gauge position. The high beam indicator is hardwired directly
Speedometer from the multifunction switch. When the high
beam is activated, the indicator illuminates.
The instrument cluster receives vehicle speed
information from the vehicle speed sensor (VSS),
which is then indicated in km/h at the gauge. If Low Oil Pressure Warning Indicator
there is no input from the VSS the instrument The low oil pressure warning indicator is
cluster defaults the speedometer to zero. hardwired to the engine oil pressure switch.
When the ignition is switched to position II, the
Odometer low oil pressure indicator illuminates. After the
engine is started and the oil pressure rises to a
The instrument cluster records the total mileage safe level, the oil pressure switch opens and
of the vehicle using information that is received switches off the oil pressure warning indicator.
from the VSS. This total mileage is shown by a
liquid crystal display (LCD) built into the Low Washer Fluid Indicator
speedometer. If VSS information is not received
the LCD will not increment. Incorporated into the The low washer fluid indicator illuminates when
odometer is a tripmeter, which is reset by using the washer fluid falls below a preset level.
the trip meter reset button.
E1281 EN 09/2001 2002 Bantam


Low Fuel Warning Indicator
The low fuel warning indicator illuminates when
the fuel level falls below a preset level.
Without Tachometer

1 Fuel gauge 12 Temperature warning indicator
2 Malfunction indicator lamp (MIL) - not 13 Glow plug indicator (Diesel)
specified for South Africa. 14 Trip meter reset button
3 Anti-lock brake system (ABS) warning 15 Odometer
indicator - not specified for South Af-
rica. 16 Parking brake / brake warning indicator
4 Turn signal indicator 17 Charge warning indicator
5 Speedometer 18 Low oil pressure warning indicator
6 Low washer fluid indicator The instrument cluster without tachometer is
7 Air bag warning indicator fitted to vehicles with low option content. This
instrument cluster differs from the high option
8 Turn signal indicator vehicles as follows:
9 Door ajar indicator - not specified for • The Tachometer is removed.
South Africa • The Temperature gauge is replaced by a
10 Low fuel indicator warning indicator, which illuminates if the
engine overheats.
11 High beam indicator
E1281 EN 09/2001 2002 Bantam


Instrument Cluster
Refer to Wiring Diagrams Petrol and Diesel Visual Inspection Chart
Cell: 41301, Instrument Cluster for schematic
and connector information.
• Damaged engine oil • Fuse(s)
Inspection and Verification – All Vehicles filter • Input sensors
1. Verify the customer concern by operating the • Low engine oil level • Wiring harness
system. • Stuck engine • Loose or corroded
temperature gauge connector(s)
• Door adjustment • Instrument cluster
mechanical or electrical damage.
• Speedometer cable
(up to 01/99)
• Low engine coolant
level
• Damaged coolant
thermostat
• Collapsed or dented
fuel tank

step.
the symptom and refer to the Symptom Chart
applicable to the vehicle build date.
Symptom Chart – (With or Without Tachometer)
Symptom Chart
• Incorrect fuel gauge indication • Circuit. • Go To Pinpoint Test A.
• Fuel pump module.
• Instrument cluster.
• The speedometer is inoperative • Circuit. • Go To Pinpoint Test B.
• Vehicle speed sensor.
• Incorrect temperature gauge • Circuit. • Go To Pinpoint Test C.
indication • Engine coolant temperature
(ECT) sensor (petrol).
• Gauge sender unit (diesel).
• PCM.
• The tachometer is inoperative • Circuit. • Go To Pinpoint Test D.
• PCM.
• The high beam indicator is inop- • Circuit. • Go To Pinpoint Test E.
erative • High beam indicator.
• Switch.
E1282 EN 09/2001 2002 Bantam


• The low oil pressure warning • Circuit. • Go To Pinpoint Test F.
indicator is inoperative • Oil pressure switch.
• Low oil pressure warning
indicator.
• The brake warning indicator is • Circuit. • Go To Pinpoint Test G.
inoperative • Brake warning indicator LED.
• Low brake fluid level switch.
• Park brake switch.
• ABS module (if equipped).
• The low fuel indicator is inopera- • Circuit. • Go To Pinpoint Test H.
tive • Low fuel warning indicator.
• Fuel pump module
• The low fuel indicator is always • Circuit. • Go To Pinpoint Test A.
on • Low fuel level.
• Fuel pump module.
• The charging system warning • Circuit. • Go To Pinpoint Test J.
indicator is inoperative • Generator.
• Charging system warning
indicator.
• The charging system warning • Circuit. • Use WDS to diagnose.
indicator is always on • Charging system.
• Accessory drive belt.
• The air-bag indicator is always • Circuit. • Use WDS to diagnose.
on • Air bag module.
• The odometer display does not • Circuit. • Go To Pinpoint Test B.
increment • Vehicle speed sensor (VSS).
Self-Diagnostic Mode
1. To select the instrument cluster Self- 3. The instrument cluster will enter the gauge
Diagnostic Mode depress and hold the trip sweep test.
meter reset button then turn the ignition 4. To navigate to the following tests (see chart),
switch to position II. depress the trip meter reset button.
2. Release the trip meter reset button when 5. The Self-Diagnostic Mode is deactivated
TEST is displayed on the odometer LCD. when the ignition is turned to the position 0.
This will take between five and eight 6. If the Self-Diagnostic Mode cannot be
seconds. accessed, use WDS to diagnose the PCM
and the ISO link.
NOTE: Additional tests are available after the fol-
lowing Self-Diagnostic Mode tests, but are not
useful for diagnostics.
E1282 EN 09/2001 2002 Bantam


Self-Diagnostic Mode
Test Odometer Gauge/Indicator/Display Description
Display Tested
1. Gauge sweep GAGE Tachometer, speedometer, All gauges go through an up
temperature and fuel and down sweep smoothness
check, which takes approxi-
mately five seconds.
2. Fill in all LCD All segments Odometer LCD Fills in LCD.
illuminated
3. Indicator LEDs Bulb Indicators and warning indica- Illuminates all the warning in-
tors dicators that are controlled by
the instrument cluster.
4. ROM level r XX PASS or Instrument cluster read only Displays the instrument clus-
FAIL memory (ROM) ter ROM revision level.
5. Non-volatile mem- EE XX PASS Instrument cluster non-volatile Displays the instrument clus-
ory level or FAIL memory ter non-volatile memory
condition.
6. DTC dtc or XXXX Diagnostic trouble codes To list the DTCs stored, press
(DTCs) the RESET button.
REFER to the instrument
cluster (DTC) index.
The DTC codes will scroll
through if there is more than 1.
7. Vehicle speed mph EXXX.X Speedometer Displays the speed signal in-
put in mph.
8. Vehicle speed km/h XXX.X Speedometer Displays the speed signal in-
put in km/h.
9. Engine speed t XXXX Tachometer Displays the tachometer input
signal (RPM).
10. Fuel volume F XXX Fuel sender system Displays the fuel volume sig-
nal input.
11. Engine type Eng -X PCM engine information Displays the engine type.
12. Engine coolant XXXC Engine coolant temperature Displays the engine coolant
temperature temperature signal input.
13. Battery voltage batXX.X Battery Voltage Displays battery voltage input.
14. Illumination IL-[H/L] Instrument cluster and instru- Displays instrument cluster
ment panel illumination and panel illumination.
15. LCD dimming LCdXXX Odometer display Displays LCD dimming (18%-
100%).
16. Crank sense Cr -X Crank sense circuit Displays the crankshaft sen-
sor input to the instrument
cluster.
17. Ignition sense IG -X Ignition sense circuit Displays the ignition input to
the instrument cluster.
18. Washer fluid input LS -X Status of the low washer fluid Displays low washer fluid
level switch switch input.
E1282 EN 09/2001 2002 Bantam


7. If the concern is still evident after the self
diagnostic mode refer to the Symptom Chart
Worldwide Diagnostic System (WDS) Tester
Diagnostics – All Vehicles
1. REFER to the Instrument Cluster Diagnostic 2. If no DTCs related to the concern are
Trouble Code (DTC) Index.(BELOW) If the DTCs retrieved, refer to the Symptom Chart
retrieved are related to the concern then applicable to the vehicle build date to
carry out the relevant action in the DTC continue diagnostics.
index.
Instrument Cluster Diagnostic Trouble Code (DTC) Index
Self- WDS DTC Description Source Action

Diagnostic
Mode Dis-
played DTC
9201 B1201 Fuel pump module circuit Instrument Go To Pinpoint Test A.
open or short to B+ cluster
9204 B1204 Fuel pump module short to Instrument Go To Pinpoint Test A.
ground cluster
9342 B1342 Instrument cluster electronic Instrument Use WDS to diagnose.
control unit is defective cluster
9317 B1317 Battery voltage high Instrument Use WDS to diagnose.
(greater than 16V) cluster
9318 B1318 Battery voltage low (less Instrument Use WDS to diagnose.
than 8V) cluster
9359 B1359 Ignition Run/Acc circuit fail- Instrument Use WDS to diagnose.
ure cluster
A143 B2143 Instrument cluster non- Instrument Use WDS to diagnose.
volatile memory failure cluster
0115 P0115 ECT sensor circuit failure Instrument Use WDS to diagnose.
cluster
E1282 EN 09/2001 2002 Bantam

Pinpoint Tests
PAGE 1 OF 2
PINPOINT TEST A: INCORRECT FUEL GAUGE INDICATION

A1: TEST OPERATION OF FUEL GAUGE.......................................................... 413-01-9A
A2: VERIFY FAULT OF FUEL GAUGE................................................................ 413-01-9B
A3: TEST FOR VALID INPUT FROM THE FUEL PUMP MODULE...................... 413-01-9B
A4: TEST FOR SHORT TO GROUND ON FUEL PUMP MODULE UNIT............. 413-01-9B
A5: TEST CIRCUIT 8-GA7 (WH/RD) FOR SHORT TO GROUND ....................... 413-01-9B/10
A6: RETRIEVE ANY STORED DTCS .................................................................. 413-01-10
A7: TEST CIRCUIT 8-GA7 (WH/RD) FOR OPEN ................................................ 413-01-10/11
A8: TEST CIRCUIT 31-GA7 (BK) FOR SHORT TO GROUND............................. 413-01-11
PINPOINT TEST B: THE SPEEDOMETER IS INOPERATIVE
B1: TEST OPERATION OF SPEEDOMETER...................................................... 413-01-11
B2: RETRIEVE ANY STORED DTCS .................................................................. 413-01-11
B3: TEST VEHICLE SPEED SENSOR (VSS) OUTPUT....................................... 413-01-12
PINPOINT TEST C: INCORRECT TEMPERATURE GAUGE INDICATION
C1: TEST OPERATION OF TEMPERATURE GAUGE ........................................ 413-01-12
C2: RETRIEVE ANY STORED DTCS .................................................................. 413-01-12
C3: TEST OPERATION OF THE ENGINE COOLANT
TEMPERATURE SENSOR .................................................................................. 413-01-13
PINPOINT TEST D: THE TACHOMETER IS INOPERATIVE
D1: TEST OPERATION OF THE TACHOMETER................................................ 413-01-13
D2: RETRIEVE ANY STORED DTCS .................................................................. 413-01-13
PINPOINT TEST E: THE HIGH BEAM INDICATOR IS INOPERATIVE
E1: CHECK OPERATION OF HIGH BEAM.......................................................... 413-01-13/14
E2: CHECK FOR VOLTAGE ON CIRCUIT 14-LE11 (VT/WH).............................. 413-01-14
E3: CHECK CIRCUIT 31-WC43B (BK) FOR GROUND ON HIGH
BEAM INDICATOR .............................................................................................. 413-01-14
PINPOINT TEST F: THE LOW OIL PRESSURE INDICATOR IS INOPERATIVE
F1: TEST OPERATION OF LOW OIL PRESSURE WARNING INDICATOR ....... 413-01-15
F2: CHECK OPERATION OF OIL PRESS RE SWITCH ...................................... 413-01-15
PINPOINT TEST G: THE BRAKE WARNING INDICATOR IS INOPERATIVE –
FROM 01/99 ONWARDS
G1: TEST OPERATION OF BRAKE WARNING INDICATOR.............................. 413-01-15
G2: CHECK OPERATION OF PARK BRAKE WARNING INDICATOR ................ 413-01-16
G3: CHECK OPERATION OF BRAKE FLUID LEVEL SWITCH ........................... 413-01-16
G4: CHECK OPERATION OF PARKING BRAKE SWITCH ................................. 413-01-16
Pinpoint Tests
PAGE 2 OF 2
G5: CHECK OPERATION OF PARKING BRAKE SWITCH ................................. 413-01-17
PINPOINT TEST H: THE LOW FUEL WARNING INDICATOR IS INOPERATIVE –
FROM 01/99 ONWARDS
H1: TEST OPERATION OF WARNING INDICATOR ........................................... 413-01-17
PINPOINT TEST J: THE CHARGING SYSTEM WARNING INDICATOR IS
INOPERATIVE – FROM 01/99 ONWARDS
J1: TEST OPERATION OF CHARGING SYSTEM WARNING INDICATOR ........ 413-01-18
413-01-9A Instrument Cluster 413-01-9A

Pinpoint Tests
PINPOINT TEST A: INCORRECT FUEL GAUGE INDICATION
A1: TEST OPERATION OF FUEL GAUGE
1 Select the instrument cluster self-diagnostic
mode test 1 – gauge sweep.
• Does the fuel gauge carry out a gauge sweep?
Yes
GO TO A2
No
INSTALL a new instrument cluster. TEST
E1282 EN 09/2001 2002 Bantam

413-01-9B Instrument Cluster 413-01-9B
A2: VERIFY FAULT OF FUEL GAUGE
1.
• Does the fuel gauge pointer indicate below the
empty (default position)?
Yes
GO TO A3
No
GO TO A6
A3: TEST FOR VALID INPUT FROM THE FUEL PUMP MODULE
1 Select the Instrument cluster self-diagnostic
mode test 10 – fuel volume input test.
• Is the value F010 or less?
Yes
GO TO A4
No
If the value is between F011 and F254
GO TO A6
If the value is F255 GO TO A7
A4: TEST FOR SHORT TO GROUND ON FUEL PUMP MODULE UNIT
1.
Fuel Pump Mod-

ule C88
2 Leave the instrument cluster in self-diagnostic
mode test 10 – fuel volume input test.
• Does the fuel input value change to F255 when
the fuel pump module is disconnected?
Yes
INSTALL a new fuel pump module. TEST
No
GO TO A5
A5: TEST CIRCUIT 8-GA7 (WH/RD) FOR SHORT TO GROUND
1. 2.
Instrument Cluster
C39
E1282 EN 09/2001 2002 Bantam


3 Measure the resistance between the
instrument cluster C39 pin 24, circuit 8-GA7
(WH/RD) and ground.
Yes
REPAIR circuit 8-GA7 (WH/RD) TEST the
No
A6: RETRIEVE ANY STORED DTCS

1. 2.
Instrument Clus- Fuel Pump Module

ter C39 C88
3 Select the Instrument cluster self-diagnostic
mode test 6 – list DTCs stored.
• Are there any DTCs stored?
Yes
REFER to the Instrument Cluster DTC Index.
No
INSTALL a new fuel pump module.
REFER to Section 310-01. TEST the
A7: TEST CIRCUIT 8-GA7 (WH/RD) FOR OPEN
1. 2. 3.
Instrument Cluster Fuel Pump Module

C39 C88
E1282 EN 09/2001 2002 Bantam

instrument cluster C39 pin 24, circuit 8-GA7
(WH/RD) and the fuel pump module C88 pin 5.
Yes
GO TO A8
No
REPAIR circuit 8-GA7 (WH/RD). TEST the
A8: TEST CIRCUIT 31-GA7 (BK) FOR SHORT TO GROUND

1 Measure the resistance between instrument
cluster C39 pin 23, circuit 31-GA7 (BK) and
ground.
Yes
INSTALL a new fuel pump module. TEST
No
REPAIR circuit 31-GA7 (BK). TEST the sys-
PINPOINT TEST B: THE SPEEDOMETER IS INOPERATIVE

B1: TEST OPERATION OF SPEEDOMETER
• Does the speedometer carry out a gauge
sweep?
Yes
GO TO B2
No
B2: RETRIEVE ANY STORED DTCS
• Are there any DTCs stored?
Yes
REFER to the Instrument Cluster DTC
Index.
No
GO TO B3
E1282 EN 09/2001 2002 Bantam

B3: TEST VEHICLE SPEED SENSOR (VSS) OUTPUT
mode test 7 for mph or self-diagnostic mode
test 8 for km/h – speed signal input.
- During this test, the vehicle has to be driven
in order that the vehicle speed sensor input
can be monitored.
• Does the vehicle speed signal vary according
to vehicle speed?
Yes
No
USE WDS to diagnose the PCM, the ISO
link and the VSS.
PINPOINT TEST C: INCORRECT TEMPERATURE GAUGE INDICATION
C1: TEST OPERATION OF TEMPERATURE GAUGE
• Does the temperature gauge carry out a gauge
sweep?
Yes
GO TO C2
No
C2: RETRIEVE ANY STORED DTCS
mode test 6 – retrieve stored DTCs.
• Are there any stored DTCs?
Yes
Index.
No
GO TO C3
E1282 EN 09/2001 2002 Bantam

BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL
TO MODEL INDEX

C3: TEST OPERATION OF THE ENGINE COOLANT TEMPERATURE SENSOR
mode test 11 – engine coolant temperature
signal input.
- Check the input when the engine is cold and
then when the engine is warm.
• Is there an input from the engine coolant
temperature sensor?
Yes
USE WDS to diagnose the PCM and the
ISO link.
No
INSTALL a new engine coolant temperature
sensor. TEST the system for normal opera-
tion.
PINPOINT TEST D: THE TACHOMETER IS INOPERATIVE
D1: TEST OPERATION OF THE TACHOMETER
• Does the tachometer carry out a gauge
sweep?
Yes
GO TO D2
No
D2: RETRIEVE ANY STORED DTCS
• Are there any stored DTCs?
Yes
Index.
No
USE WDS to diagnose the PCM and the
ISO link.
PINPOINT TEST E: THE HIGH BEAM INDICATOR IS INOPERATIVE
E1: CHECK OPERATION OF HIGH BEAM
1.
CONTINUED
E1282 EN 09/2001 2002 Bantam

TO MODEL INDEX
2 Place the headlamp switch in the LOW beam
position.
3 Place the multifunction switch in the HIGH
beam position.
• Do the high beam lamps operate?
Yes
GO TO E2
No
DIAGNOSE the high beam lamps.
E2: CHECK FOR VOLTAGE ON CIRCUIT 14-LE11 (VT/WH)
1. 2. 3.
Instrument Cluster
C39
4 Measure the voltage between the instrument
cluster C39 pin 30, circuit 14-LE11 (VT/WH),
Yes
GO TO E3
No
REPAIR circuit 14-LE11. TEST the system
E3: CHECK CIRCUIT 31-WC43B (BK) FOR GROUND ON HIGH BEAM INDICATOR
instrument cluster C39 pin 28, circuit 31-
WC43B (BK), harness side and ground.
Yes
No
REPAIR circuit 31-WC43B. TEST the sys-
CONTINUED
E1282 EN 09/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST F: THE LOW OIL PRESSURE INDICATOR IS INOPERATIVE
F1: TEST OPERATION OF LOW OIL PRESSURE WARNING INDICATOR
1. 2.
• Does the low oil pressure warning indicator
illuminate?
Yes
GO TO F2
No
F2: CHECK OPERATION OF OIL PRESSURE SWITCH
1. 2. 3.
Oil Pressure Switch

C3
4 Connect a jumper wire between the oil
pressure switch C3 pin and ground.
• Does the low oil pressure warning indicator
illuminate?
Yes
INSTALL a new oil pressure switch. TEST
No
REPAIR circuit 31S-WD9 (BK/GN) OR 31-
PC2C (BK). TEST the system for normal
operation.
PINPOINT TEST G: THE BRAKE WARNING INDICATOR IS INOPERATIVE – FROM 01/99

ONWARDS
G1: TEST OPERATION OF BRAKE WARNING INDICATOR
mode test 3 – illuminate warning indicators.
Yes
GO TO G2
No
CONTINUED
E1282 EN 09/2001 2002 Bantam

TO MODEL INDEX

G2: CHECK OPERATION OF PARK BRAKE WARNING INDICATOR
1 Make sure the parking brake is in the ON
position.
Yes
GO TO G3
No
GO TO G4
G3: CHECK OPERATION OF BRAKE FLUID LEVEL SWITCH
1. 2. 3.
Brake Fluid Level

Switch C34
4 Connect a jumper wire between the brake fluid
level switch C34 pin 2, circuit 31S-WB7
(BK/BU), harness side and C34 pin 3, circuit
31-WB7 (BK), harness side.
Yes
INSTALL a new brake fluid level switch.
No
REPAIR circuit 31-WB37 (BK) or circuit
31S-WB7 (BK/BU). TEST the system for
normal operation.
G4: CHECK OPERATION OF PARKING BRAKE SWITCH

1 Make sure that the parking brake is in ON posi-
tion.
2 Measure the resistance between the brake
fluid level switch C34 pin 1, circuit 31S-WC18
Yes
REPAIR circuit 31S-WC18 (BK). TEST the
No
GO TO G5
CONTINUED
E1282 EN 09/2001 2002 Bantam

TO MODEL INDEX
G5: CHECK OPERATION OF PARKING BRAKE SWITCH.
1.
2 Make sure the parking brake is in the ON posi-

tion.
3 Measure the resistance between the parking
brake switch C26 pin 2, circuit 31S-WC18
(BK/RD), and ground.
Yes
REPAIR circuit 31S-WC18 (BK/RD). TEST
No
INSTALL a new parking brake switch. TEST
PINPOINT TEST H: THE LOW FUEL WARNING INDICATOR IS INOPERATIVE – FROM 01/99
ONWARDS
H1: TEST OPERATION OF WARNING INDICATOR
NOTE: The low fuel warning indicator is only active when enabled by the module configuration.
• Does the low fuel warning indicator illuminate?
Yes
GO TO A1
No
CONTINUED
E1282 EN 09/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST J: THE CHARGING SYSTEM WARNING INDICATOR IS INOPERATIVE – FROM
01/99 ONWARDS
J1: TEST OPERATION OF CHARGING SYSTEM WARNING INDICATOR
• Does the charging system warning indicator
illuminate?
Yes
Charging system fault.
No
CONTINUED
E1282 EN 09/2001 2002 Bantam

TO MODEL INDEX

Instrument Cluster (33 214 0)
Removal
All vehicles
1. Remove the steering column upper shroud.
2. Remove the multi-function switch.

1. Disconnect the multi-function switch
3. Lever the instrument cluster bezel retaining

screw cover off.
CONTINUED
E1283 EN 09/2001 2002 Bantam

TO MODEL INDEX
4. Remove the bezel (steering wheel shown

6. Remove the instrument cluster.
9. CAUTION: Do not place the instrument

cluster, lens down.
Disconnect the electrical connectors and
remove the instrument cluster.
CONTINUED
E1283 EN 09/2001 2002 Bantam

TO MODEL INDEX
Installation
CONTINUED
E1283 EN 09/2001 2002 Bantam

TO MODEL INDEX

Instrument Cluster Printed Circuit (33 224 4)
Removal
1. Remove the instrument cluster.
2. Remove the lens.

1. Remove the two bulbs.
2. Release the retaining lugs and remove
the lens.
3. Remove the tachometer.
4. Remove the fuel / temperature gauge.
CONTINUED
E1284 EN 09/2001 2002 Bantam

TO MODEL INDEX
5. Remove the speedometer head.
6. Remove the bulb holders.
7. Remove the printed circuit electrical

connector retainers.
8. Release the pin contacts from the cluster

moulding.
CONTINUED
E1284 EN 09/2001 2002 Bantam

TO MODEL INDEX
9. CAUTION: Take care not to bend or

damage the printed circuit and the
electrical components when lifting it
off the locating dowels.
Remove the printed circuit.
10. Remove the pin contacts from the printed

circuit.
Installation
CAUTION: Take care not to bend or

damage the printed circuit and the elec-
trical components when installing.
CONTINUED
E1284 EN 09/2001 2002 Bantam

TO MODEL INDEX
CONTINUED
E1284 EN 09/2001 2002 Bantam

TO MODEL INDEX
SPECIFICATIONS
Description Nm
Instrument cluster bezel retaining screws 1
Instrument cluster retaining screws 1
Speedometer cable to speed sender unit retaining nut 7
Tachometer retaining screws 1
Fuel / temperature gauge retaining screws 1
CONTINUED
E1285 EN 09/2001 2002 Bantam

414-00-1 Charging System — General Information 414-00-1
SECTION 414-00 Charging System —

General Information
SUBJECT PAGE

Charging System ................................................................................................................... 414-00-2/3

Charging System ................................................................................................................... 414-00-4
Symptom Chart ................................................................................................................... 414-00-4
Pinpoint Tests ..................................................................................................................... 414-00-5/7
Component Tests................................................................................................................ 414-00-8
GENERAL PROCEDURES
Battery Charging .................................................................................................................... 414-00-9
07/2001 2002 Bantam


Charging System
Vehicles with 1.6L / 1.3L RoCam Engine shown, Vehicles with Diesel Engine similar
Item Description the crankshaft pulley at approximately twice

engine speed through a drive belt. For additional
1 Accessory drive belt information, refer to Section 303-05.
2 Charge warning indicator When the engine is started, the generator begins
to generate alternating current (AC), which is
3 Battery
converted to direct current (DC) internally. The
4 Generator DC current is controlled by the voltage regulator
and then supplied to the battery. When the
The generator is mounted solidly towards the engine is not running and the ignition is switched
front of the engine cylinder block and is driven by on, the generator will illuminate the charge
E6740 EN 07/2001 2002 Bantam

TO MODEL INDEX
warning indicator in the instrument cluster. If The generator should be repaired as an

however, there is an open circuit in the regulator assembly and not dismantled for repair. For
or generator rotor circuits, the charge warning additional information, refer to Section 414-02.
indicator will not illuminate.
CONTINUED
E6740 EN 07/2001 2002 Bantam

TO MODEL INDEX

Charging System Visual Inspection Chart
1. Verify the customer concern. • Loose or damaged • Battery.
auxiliary drive belt. • Damaged wiring.
2. Visually inspect for obvious signs of damage. • Generator mounting. • Loose or corroded
Refer to the following chart: • Loose/missing hard- electrical connectors.
ware. • Generator.

proceed to the Symptom Chart.
Symptom Chart
• The charging system warning • Auxiliary drive belt. • CHECK the auxiliary drive belt
indicator stays on tension.
• Circuit. • GO to Pinpoint Test A.
• Generator.
• Voltage regulator.
• The charging system warning • Bulb. • INSTALL a new bulb.
indicator is inoperative
• Ignition switch. • CHECK the ignition switch.
• Circuit. • GO to Pinpoint Test B.
• Generator.
• Radio interference • Circuit. • Go to Pinpoint Test C.
• Generator.
• Generator noisy • Auxiliary drive belt. • CHECK the auxiliary drive belt
• Pulley. and pulleys.
• Generator. • INSTALL a new generator.
• Mountings/hardware • CHECK security of hardware.
CONTINUED
E1297 EN 07/2001 2002 Bantam

TO MODEL INDEX

Pinpoint Tests
PINPOINT TEST A: THE CHARGING SYSTEM WARNING INDICATOR STAYS ON
A1:
1 Carry out a No-Load Component Test.
• Is there an increase in voltage?
Yes
GO TO A2
No
GO TO A4
A2: CHECK CIRCUIT 31 (BK)
1. 2. 3.
Generator (C303a) C1
4 Measure the resistance between the generator
connector C303a pin 1, circuit 31 (BK) and
ground.
Yes
GO TO A3
No
REPAIR circuit 31 (BK).
A3: CHECK CIRCUIT 64 BA9 (BU-BK)

1. 2.
Instrument clus- Heated windshield

ter (C44b) relay
CONTINUED
E1297 EN 07/2001 2002 Bantam

TO MODEL INDEX
instrument cluster C44b pin 7, circuit 64 (BU-
BK) and ground.
Yes
INSTALL a new printed circuit board.
No
REPAIR circuit 64 (BU-BK). TEST the sys-
A4: CHECK FOR VOLTAGE

1. 2.
Generator
(C303a)
3 Measure the voltage between the generator
ground.
Yes
INSTALL a new generator.
No
GO TO A2
PINPOINT TEST B: THE CHARGING SYSTEM WARNING INDICATOR IS INOPERATIVE

B1: CHECK LAMP CIRCUIT
1. 2.
Generator
(C303a)
CONTINUED
E1297 EN 07/2001 2002 Bantam

TO MODEL INDEX
3 Measure the voltage between generator D+
ground.
Yes
GO TO B2
No
GO TO B3
B2: CHECK BULB

1 Connect a jumper wire between the generator
D+ connector C303a pin 1, circuit 31 (BK) and
ground.
• Does the lamp illuminate?
Yes
INSTALL a new generator. TEST the
No
INSTALL a new bulb. TEST the system for
normal operation.
B3: CHECK CIRCUIT 64-DA1 (BU)

1.
C1
2 Measure the voltage between in-line connector
C1 pin 3 circuit 64 (BU) and ground.
Yes
No
REPAIR circuit 64. TEST the system for
normal operation.
CONTINUED
E1297 EN 07/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST C: RADIO INTERFERENCE
C1: DISABLE GENERATOR
1 Remove the auxiliary drive belt.
2.
3 Run the engine for a few seconds with the

radio turned on.
• Is interference still present?
Yes
No
REPAIR circuit 30-DA2 (RD). TEST the sys-
tem for normal operation. If interference is
still present. INSTALL a new generator.
Component Tests
No-Load Test Load Test
1. Turn off all electrical loads and the ignition 1. With the engine running, turn on the air
switch. conditioning unit, turn the blower motor to
2. Connect the leads of multimeter across the high speed and the headlamps to high beam.
battery terminals. 2. Increase the engine speed to 2000 rpm. The
3. Read the voltage (base voltage). voltage should increase a minimum of 0.5
4. Start the engine. volts above the base voltage. If the voltage
does not increase as specified,
5. Run the engine at 1500 rpm with no electrical
refer to the generator on vehicle tests in this section.
load.
If the voltage increases as specified, the
6. Read the voltage. The voltage should be in charging system is charging correctly.
the range of 14.1 to 15.1 volts. If the voltage Refer to the Symptom Chart.
increase is less than 2.5 volts above the
base voltage, perform the load test. If the
7. Voltage increase is greater than 2.5 volts;
perform the generator on-vehicle tests in this
section.
CONTINUED
E1297 EN 07/2001 2002 Bantam

TO MODEL INDEX
GENERAL PROCEDURES
Battery Charging
WARNING: Keep batteries out of reach of
children. Batteries contain sulphuric
acid; avoid contact with skin, eyes or
clothing. Shield your eyes when work-
ing near the battery to protect against
possible splashing of the acid solution.
In case of acid contact with the skin or
the eyes, flush immediately with water
for a minimum of 15 minutes and seek
prompt medical attention. If acid is swal-
lowed, call a physician immediately.
WARNING: Batteries normally produce

explosive gases, which can cause per-
sonal injury, therefore do not allow
flames, sparks or lighted substances to
come near the battery. When charging
or working near the battery always
shield your face and protect your eyes.
Always provide adequate ventilation.
WARNING: Always observe all manufac-

turers instructions when using any
charging equipment. Failure to follow
this instruction may result in personal
injury.
WARNING: Connect the charger to the

battery before switching the charger on.
Failure to follow this instruction may re-
WARNING: Switch the charger off before

disconnecting the charger from the bat-
tery. Failure to follow this instruction
CAUTION: Batteries should not be

charged in the vehicle.
CAUTION: Do not rely on the generator

to recharge a discharged battery, as it
would take in excess of eight hours of
continuous driving with no additional
loads placed on the charging system.
CONTINUED
E3742 EN 07/2001 2002 Bantam

TO MODEL INDEX
1. NOTE: The maximum level mark is

approximately 40mm below the top of the
battery.
Place the battery on a level surface and
check the electrolyte level through the
casing, reaches the indicated maximum
mark.
WARNING: It is important not to overfill a

battery, as this can cause acid leakage
and corrosion damage to the vehicle.
2. If the level is below the maximum mark,
remove the vent covers and top up the
cell(s) to the correct level.
3. Cold batteries will not readily accept a

charge. Therefore batteries should be
allowed to warm up to approximately 5°C.
before charging. This may require four to
eight hours at room temperature depending
on the initial temperature and the battery
size.
4. A battery, which has been completely

discharged, may be slow to accept a
charge initially, and in some cases may not
accept a charge at the normal charger
setting. When batteries are in this condition,
charging can be started by use of the dead
battery switch on chargers that have this
facility equipped.
5. To determine whether a battery is accepting

a charge, follow the manufacturer's
instructions for the charger, for use of the
dead battery switch. If the switch is the
spring-loaded type, it should be held in the
ON position for up to three minutes.
CONTINUED
E3742 EN 07/2001 2002 Bantam

TO MODEL INDEX
6. After releasing the dead battery switch and

with the charger still on, measure the
battery voltage. If it shows 12 volts or
higher, the battery is accepting a charge
and is capable of being recharged.
However, it may require up to two hour of
charging with batteries colder than 5°C
before the charge rate is high enough to
show a charge on an ammeter. It has been
found that all non-damaged batteries can
be charged by this procedure. If a battery
cannot be charged by this procedure, a new
one should be installed.
7. A rapid recharge procedure has been

developed for recharging batteries that
have passed the Load Test and only need a
recharge. This can be due to in-service no-
start battery failures (vehicle will not crank
due to low battery state of charge) or
battery discharged in vehicle due to key-off
loads.
8. With the cables then disconnected, the

battery can be rapidly recharged by using
either of the following methods:
• Carry out a two hour charge using 20A
constant current (manual setting on
charger).
• Carry out a two hour charge using a
constant potential (automatic setting on
charger).
CONTINUED
E3742 EN 07/2001 2002 Bantam

414-01-1 Battery, Mounting and Cables 414-01-1
SECTION 414-01 Battery, Mounting and Cables

SUBJECT PAGE
Battery and Cables .................................................................................................................. 414-01-2

Battery...................................................................................................................................... 414-01-3

Battery...................................................................................................................................... 414-01-4/5
Battery to Starter Motor Solenoid Cable — Vehicles with 1.6L / 1.3L Engine........................ 414-01-6/9
Battery to Starter Motor Solenoid Cable — Vehicles with 1.8L Endura DE Diesel Engine..... 414-01-10/12
Battery Tray.............................................................................................................................. 414-01-13
SPECIFICATIONS
Specifications ........................................................................................................................... 414-01-14
07/2001 2002 Bantam

TO MODEL INDEX

Battery and Cables

1 Battery cables 3 Battery tray
2 Battery
CONTINUED
E1300 EN 07/2001 2002 Bantam

TO MODEL INDEX

Battery
CONTINUED
E1301 EN 07/2001 2002 Bantam

TO MODEL INDEX

Battery (31 214 0)
Removal
2. Disconnect the battery power and auxiliary

power cable.
3. Remove the battery clamp.
4. Remove the battery.
CONTINUED
E1302 EN 07/2001 2002 Bantam

TO MODEL INDEX
Installation
CONTINUED
E1302 EN 07/2001 2002 Bantam

TO MODEL INDEX

Battery to Starter Motor Solenoid Cable — Vehicles with 1.6L / 1.3L Engine
Removal
2. Disconnect and detach the battery auxiliary

positive cable.
3. Disconnect the battery positive cable.
4. Disconnect and detach the electrical

connector.
CONTINUED
E6741 EN 07/2001 2002 Bantam

TO MODEL INDEX
5. Disconnect the in-line electrical connectors

below the thermostat housing.
6. Detach the electrical cables below the

battery tray.
7. Detach the battery to starter motor solenoid

cable from the transaxle mounting bracket.


cable from the transaxle.
CONTINUED
E6741 EN 07/2001 2002 Bantam

TO MODEL INDEX

cable from the oil filter housing.

sensor and oil pressure switch electrical
connectors.

connector.

connector and remove the battery to starter
motor solenoid cable.
CONTINUED
E6741 EN 07/2001 2002 Bantam

TO MODEL INDEX
Installation
CONTINUED
E6741 EN 07/2001 2002 Bantam

TO MODEL INDEX

Battery to Starter Motor Solenoid Cable — Vehicles with 1.8L Endura DE Diesel
Engine
Removal
2. Open the battery positive terminal cover.
3. Disconnect the battery auxiliary positive

cable.
4. Disconnect the battery positive cable.
CONTINUED
E7860 EN 07/2001 2002 Bantam

TO MODEL INDEX
5. Release the battery to starter motor

solenoid cable.
• Cut the tie strap.

connector.

8. Remove the battery to starter motor

solenoid cable.
• Disconnect the starter motor electrical
connector.
CONTINUED
E7860 EN 07/2001 2002 Bantam

TO MODEL INDEX
Installation
1. NOTE: When the battery is disconnected and

reconnected, some abnormal drive symptoms
may occur while the vehicle relearns its
adaptive strategy. It may need to be driven
16 km or more to relearn its adaptive
strategy.
CONTINUED
E7860 EN 07/2001 2002 Bantam

TO MODEL INDEX

Battery Tray (44 271 4)
Removal
1. Remove the battery. For additional
information, refer to Battery in this section
2. Remove the cable tie.
Installation
CONTINUED
E1304 EN 07/2001 2002 Bantam

TO MODEL INDEX
SPECIFICATIONS
Description Nm
Battery hold-down clamp retaining nuts 8
Battery terminal clamp retaining nuts 5
Generator electrical connector retaining nut(s) 5
Starter motor electrical connector upper retaining nut 12
Starter motor electrical connector lower retaining nut 6
Battery auxiliary positive cable retaining nut 8
Battery tray retaining bolts 25
CONTINUED
E6743 EN 07/2001 2002 Bantam

414-02-1 Generator and Regulator 414-02-1
SECTION 414-02 Generator and Regulator

SUBJECT PAGE
Generator ................................................................................................................................. 414-02-2
Generator — Vehicles with 1.6L Engine ........................................................... (31 414 0) 414-02-3
Generator — Vehicles with 1.8L Endura DE diesel Engine .............................. (31 414 0) 414-02-3/13
SPECIFICATIONS
Specifications ........................................................................................................................... 414-02-14
07/2001 2002 Bantam

TO MODEL INDEX

Generator
CONTINUED
E3753 EN 07/2001 2002 Bantam

TO MODEL INDEX

Generator — Vehicles with 1.6L / 1.3L Engine (31 414 0)
Removal
All vehicles

1. Rotate the belt tensioner clockwise.

connectors.
4. Remove the generator upper retaining

bolts.
CONTINUED
E6745 EN 07/2001 2002 Bantam

TO MODEL INDEX
5. Support the right-hand side of the radiator.
6. Support the left-hand side of the radiator.

8. Remove the radiator support bracket left-

hand retaining bolts.
9. Detach the diode from the radiator support

bracket.
CONTINUED
E6745 EN 07/2001 2002 Bantam

TO MODEL INDEX
10. Remove the radiator support bracket.

11. Detach the power steering lines clamp.
All vehicles
12. Remove the generator.
CONTINUED
E6745 EN 07/2001 2002 Bantam

TO MODEL INDEX
Installation
All vehicles
All vehicles
CONTINUED
E6745 EN 07/2001 2002 Bantam

TO MODEL INDEX
CONTINUED
E6745 EN 07/2001 2002 Bantam

TO MODEL INDEX

Generator — Vehicles with 1.8L Endura DE Diesel Engine (31 414 0)
Removal
Vehicles fitted with power assisted steering
2. Remove the power assisted steering pump
assembly. For additional information,
All vehicles
3. Remove the generator drive belt.
4. Remove the drive belt tensioner (two bolts).
5. Disconnect the generator wiring.
6. Remove the generator upper bolt.
CONTINUED
E5960 EN 07/2001 2002 Bantam

TO MODEL INDEX
7. Remove the generator (two bolts).
Installation
CAUTION: Make sure the generator is

tightened using the following graphical
sequence; otherwise premature failure
of the mounting bracket may occur.
CONTINUED
E5960 EN 07/2001 2002 Bantam

TO MODEL INDEX
CONTINUED
E5960 EN 07/2001 2002 Bantam

TO MODEL INDEX

Generator — Vehicles with 1.8L Endura DE Diesel Engine and Air Conditioning
(31 414 0)
Removal
2. Remove the generator drive belt.

3. Detach the air conditioning compressor

(four bolts).
• Support the compressor using suitable
wire or cable tie.
4. Remove the drive belt tensioner (two bolts).
5. Disconnect the generator wiring.
CONTINUED
E5961 EN 07/2001 2002 Bantam

TO MODEL INDEX
6. Remove the generator upper bolt.
7. Remove the generator (two bolts).
Installation
CAUTION: Make sure the generator is

tightened using the following graphical
sequence; otherwise premature failure
of the mounting bracket may occur.
CONTINUED
E5961 EN 07/2001 2002 Bantam

TO MODEL INDEX
CONTINUED
E5961 EN 07/2001 2002 Bantam

TO MODEL INDEX
SPECIFICATIONS
Description Nm
Generator lower retaining bolt (1.6L) 45
Power steering lines bracket retaining bolt 25
Generator upper retaining bolts (1.6L) 45
Generator electrical connector retaining nut (1.6L) 5
Generator lower retaining nuts (diesel) 25
Generator upper retaining nut (diesel) 25
Air conditioning (A/C) compressor retaining bolts 24
Endura DI Diesel Engine Accessory drive belt ten- 47
sioner retaining nuts
CONTINUED
E6746 EN 07/2001 2002 Bantam

415-00-1 Audio System — General Information 415-00-1
SECTION 415-00 Audio System —

General Information
SUBJECT PAGE

Audio System......................................................................................................................... 415-00-2
Symptom Chart ................................................................................................................... 415-00-2/3A
Pinpoint Tests ..................................................................................................................... 415-00-3B/12
07/2001 2002 Bantam


Audio System Visual Inspection Chart
1. Verify the customer concern. • Audio unit damage • Fuse 2 (10 A)
• Cassette player • Fuse 19 (10 A)
2. Make sure you understand the customer jammed, not loading • Wiring harness
concern; does the concern arise during start- • Compact disc (CD) • Loose or corroded
up, with the vehicle in motion, do ambient player jammed, not electrical connectors
conditions effect, alter or induce the loading • Over stressed wiring,
concern? • Audio entertainment internally dam-
module damage aged/chaffing of
• Radio wires.
receiver/cassette
player power amplifier
damage
• Antenna/alignment
• Speakers/water
damage
• Speakers/incorrectly
mounted
• Speaker cones
damaged
• Foreign material
contacting speaker
cone
• Accessory installation
• Trim reso-
nance/incorrectly fit-
ted trim.

step.
Symptom Chart
• The audio unit is inoperative / • Fuse(s). • Go to Pinpoint Test A.
does not operate correctly. • Ground circuit.
• Power circuit.
• Audio unit.
• The display is blank-radio re- • Audio unit. • INSTALL a new audio unit.
ceiver / cassette player operates
• Poor reception AM only, FM • Antenna. • Go to Pinpoint Test B.
only or both AM/FM • Antenna connections.
• Suppression equipment.
• Audio unit.
E6747 EN 07/2001 2002 Bantam

415-00-3A Audio System — General Information 415-00-3A

• Distorted sound from one or • Speaker(s). • Go to Pinpoint Test C.
more speakers • Trim resonance.
• Wiring to speaker(s).
• Audio unit.
• No sound from all of the speak- • Speaker(s). • Go to Pinpoint Test D.
ers • Wiring to speaker(s).
• Audio unit.
E6747 EN 07/2001 2002 Bantam

Pinpoint Tests
PINPOINT TEST A: THE AUDIO UNIT IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY.
A1: CHECK THE OPERATION OF THE AUDIO UNIT ............................ 415-00-3B
A2: CHECK FOR SOUND FROM THE SPEAKERS................................ 415-00-3B
A3: CHECK BATTERY SUPPLY FUSE................................................... 415-00-3B
A4: CHECK THE ACCESSORY SUPPLY FUSE..................................... 415-00-4
A5: CHECK CIRCUIT 29-MD15/74-MD15 AUDIO UNIT SUPPLY ........... 415-00-4
A6: CHECK CIRCUIT 91-MD15 AUDIO CONTROL UNIT GROUND....... 415-00-4
A7: CHECK CIRCUIT 29 MD15/74-MD15 FOR CONTINUITY ................ 415-00-5
A8: CHECK CIRCUIT 29-MD15/74-MD15 FOR SHORT.......................... 415-00-5
A9: CHECK THE RADIO RECEIVER, CASSETTE PLAYER FOR
CORRECT OPERATION ........................................................................ 415-00-5/6
PINPOINT TEST B: POOR RECEPTION
B1: CHECK THE ANTENNA RECEPTION.............................................. 415-00-6
B2: CHECK THE ANTENNA GROUND................................................... 415-00-6/7
B3: CHECK THE ANTENNA CORE RESISTANCE................................. 415-00-7
B4: CHECK THE ANTENNA BASE CONNECTOR RESISTANCE .......... 415-00-7
B5: CHECK THE ANTENNA CORE FOR SHORT .................................. 415-00-8
B6: CHECK THE ANTENNA CABLE FOR SHORT ................................ 415-00-8
PINPOINT TEST C: DISTORTED SOUND FROM ONE OR
MORE SPEAKERS
C1: CHECK THE AUDIO CONTROL OF THE SPEAKER (S) ................ 415-00-8/9
C2: CHECK THE SPEAKER CIRCUIT RESISTANCE............................. 415-00-9
C3: CHECK THE RESISTANCE OF THE SPEAKER .............................. 415-00-9/10
C4: CHECK THE SPEAKER CIRCUIT CONTINUITY.............................. 415-00-10
PINPOINT TEST D: NO SOUND FROM ALL OF THE SPEAKERS
D1: CHECK THE ELECTRICAL CONNECTORS TO THE AUDIO UNIT . 415-00-11
D2: CHECK THE SPEAK OSITIVE CIRCUIT FOR
SHORT TO GROUND............................................................................. 415-00-11
D3: CHECK THE SPEAKER NEGATIVE CIRCUIT FOR
SHORT TO GROUND............................................................................. 415-00-12
415-00-3B Audio System — General Information 415-00-3B

Pinpoint Tests
PINPOINT TEST A: THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY.
A1: CHECK THE OPERATION OF THE AUDIO UNIT
1.
2 Switch the radio receiver on.

• Is the display illuminated?
Yes
GO TO A2
No
GO TO A3
A2: CHECK FOR SOUND FROM THE SPEAKERS
1 Verify that sound is coming from the speakers.
• Is there sound coming from the speakers?
Yes
GO TO C1
No
GO TO D1
A3: CHECK BATTERY SUPPLY FUSE
1 Check fuse 2 (10 A) in the central junction box
(CJB).
• Is fuse 2 (10 A) OK?
Yes
GO TO A4
No
INSTALL a new fuse 2 (10 A). TEST the
system for normal operation. If the fuse
blows again, GO TO A8
E6747 EN 07/2001 2002 Bantam

A4: CHECK THE ACCESSORY SUPPLY FUSE
1 Check fuse 19 (10 A) in the central junction
box (CJB).
• Is fuse 19 (10 A) OK?
Yes
GO TO A5
No
INSTALL a new fuse 19 (10 A). TEST the
system for normal operation. If the fuse
blows again, GO TO A8
A5: CHECK CIRCUIT 29-MD15/74-MD15 AUDIO UNIT SUPPLY
1 Remove the audio unit.
2.
3 Using a digital multimeter, measure the

voltages between the audio unit C52
- pin 1, circuit 29-MD15 (OG/BK)
- pin 3, circuit 74-MD15 (BU/BK)
• Are the voltages 10 volts or greater?
Yes
GO TO A6
No
GO TO A7
A6: CHECK CIRCUIT 91-MD15 AUDIO CONTROL UNIT GROUND

resistance between the audio unit C52, pin 6,
circuit 91-MD15 (BK/GN) and ground.
• Is the resistance greater than 0.1 ohms?
Yes
REPAIR circuit 91-MD15A (BK/GN) as
appropriate. TEST the system for normal
operation.
No
INSTALL a new audio unit. TEST the sys-
E6747 EN 07/2001 2002 Bantam

A7: CHECK CIRCUIT 29-MD15/74-MD15 FOR CONTINUITY
1. 2. 3.
Battery ground ca- Fuse 2 (10 A) Fuse 19 (10 A)

ble
resistance between the output side of:
- fuse 2 (10 A) and the audio unit C52, pin1,
circuit 29-MD15 (OG/BK).
- fuse 19 (10 A) and the audio unit C52, pin 3,
circuit 74-MD15 (BU/BK).
• Is the resistance greater than 0.1 ohms?
Yes
REPAIR circuit 29-MD15 (OG/BK)/74-MD15
(BU/BK) as appropriate. TEST the system
No
CHECK the CJB and associated circuits,
GO TO A8
A8: CHECK CIRCUIT 29-MD15/74-MD15 FOR SHORT
resistance between the audio control unit C52:
- pin 1, circuit 29-MD15 (OG/BK) and ground.
- pin 3, circuit 74-MD15 (BU/BK) and ground.
• Are the resistances greater than 10,000 ohms?
Yes
INSTALL a new audio unit.
No
REPAIR circuit 29-MD15 (OG/BK) or 74-
MD15 (BU/BK) as appropriate. TEST the
A9: CHECK THE RADIO RECEIVER, CASSETTE PLAYER FOR CORRECT OPERATION
1.
E6747 EN 07/2001 2002 Bantam

3 Using the Audio Guide, CHECK the audio unit
features and functions.
• Does the unit operate correctly?
Yes
Make sure the customer understands the
operation. Use the Audio Guide, supplied
with the vehicle.
No
INSTALL a new audio control unit. TEST the
PINPOINT TEST B: POOR RECEPTION
B1: CHECK THE ANTENNA RECEPTION
1.

3 Verify the radio is functioning correctly.
• Is the radio receiver retaining known preset
stations and sound coming from the speakers?
Yes
GO TO B2
No
GO TO A3
B2: CHECK THE ANTENNA GROUND
1. 2.
Audio Unit Antenna

Connector
E6747 EN 07/2001 2002 Bantam

resistance between the antenna screen and
ground.
• Is the resistance less than 1 ohm?
Yes
GO TO B3
No
GO TO B4
B3: CHECK THE ANTENNA CORE RESISTANCE

1 Remove the antenna mast.
resistance between the center pin on the
antenna connector and the antenna mast
screw thread
Yes
GO TO B5
No
CHECK the in-line connectors. INSTALL a
new antenna cable.
B4: CHECK THE ANTENNA BASE CONNECTOR RESISTANCE

resistance between the antenna base screen
connector and ground.
• Is the resistance less than 1 ohm?
Yes
GO TO B6
No
CHECK and CLEAN the antenna
screen/ground connections as required.
E6747 EN 07/2001 2002 Bantam

B5: CHECK THE ANTENNA CORE FOR SHORT
resistance between the center pin, on the
antenna connector and ground.
Yes
GO TO B2
No
GO TO B6
B6: CHECK THE ANTENNA CABLE FOR SHORT

1.
Antenna Base
Connector
resistance between the center pin, antenna
core and the antenna screen.
Yes
INSTALL a new antenna.
No
INSTALL a new antenna cable. CHECK
routing.
PINPOINT TEST C: DISTORTED SOUND FROM ONE OR MORE SPEAKERS

C1: CHECK THE AUDIO CONTROL OF THE SPEAKER (S)
1.
E6747 EN 07/2001 2002 Bantam


3 With the concern evident, use fade/balance
control to pinpoint which speaker(s) is affected.
• Is distortion present only at high volume?
Yes
Make sure the customer understands the
operation. Use the Audio Guide, supplied
with the vehicle.
No
GO TO C2
C2: CHECK THE SPEAKER CIRCUIT RESISTANCE
1. 2.
Audio Unit (C52b)

resistance at the audio unit C52b between pins
for the appropriate speaker(s).
- Pin 1; circuit 33-MD10 (YE/BK) and pin 2,
circuit 32-MD10 (WH/BK). (LHF)
- Pin 3, circuit 33 MD11 (YE/VT) and pin 4,
circuit 32-MD11 (WH/VT). (LHR)
- Pin 5; circuit 33-MD17 (YE/RD) and pin 6,
circuit 32-MD17 (WH/RD). (RHF)
- Pin 7; circuit 33-MD18 (YE) and pin 8, circuit
32-MD18 (WH). (RHR)
• Is the resistance 4.5 ohms (Rated speaker
resistance ± 0.5) ?
Yes
GO TO C4
No
If the resistance is higher than 4.5 Ohms,
GO TO C3
C3: CHECK THE RESISTANCE OF THE SPEAKER
1.
Speaker Connec-
tor
E6747 EN 07/2001 2002 Bantam

resistance between the pins on the back of the
appropriate speaker(s).
• Is the resistance 4.5 ohms? (Rated resistance
of speaker)
Yes
GO TO C4
No
INSTALL a new speaker. TEST the system
C4: CHECK THE SPEAKER CIRCUIT CONTINUITY

resistance between the audio unit C52b and
the speaker connector on the appropriate
speaker(s).
- C52b, pin 1, circuit 33-MD10 (YE/BK) and
C116, pin 1, circuit 33-MD28 (YE). (LHF)
- C52b, pin 2, circuit 32-MD10 (WH/BK) and
C116, pin 2, circuit 32-MD28 (WH). (LHF)
- C52b, pin 3, circuit 33-MD11 (YE/VT) and
C91, pin 2, circuit 33-MD28 (YE/VT). (LHR)
- C52b, pin 4, circuit 32-MD11 (WH/VT) and
C91, pin 2, circuit 32-MD11 (WH/VT). (LHR)
- C52b, pin 5, circuit 33-MD17 (YE/RD) and
C116, pin 2, circuit 33-MD28 (YE). (RHF)
- C52b, pin 6, circuit 32-MD17 (WH/RD) and
C116, pin 2, circuit 32-MD28 (WH). (RHF)
- C52b, pin 7, circuit 33-MD18 (YE) and C90,
pin 2, circuit 33-MD18 (YE). (RHR)
- C52b, pin 8, circuit 32-MD18 (WH) and C90,
pin 2, circuit 32-MD18 (WH). (RHR)
Yes
INSTALL a new appropriate speaker. TEST
No
REPAIR the appropriate circuit. TEST the
E6747 EN 07/2001 2002 Bantam


PINPOINT TEST D: NO SOUND FROM ALL OF THE SPEAKERS
D1: CHECK THE ELECTRICAL CONNECTORS TO THE AUDIO UNIT
1 Check the electrical connectors at the back of
the audio unit.
• Are the electrical connectors engaged?
Yes
GO TO D2
No
CHECK the locking tangs and connector
terminals engage fully. TEST the system for
normal operation.
D2: CHECK THE SPEAKER POSITIVE CIRCUIT FOR SHORT TO GROUND
1.
Audio Unit C52b

appropriate speaker circuit between:
- C52b, pin 1, circuit 33-MD10 (YE/BK) and
ground. (LHF)
- C52b, pin 3, circuit 33-MD11 (YE/VT) and
ground. (LHR)
- C52b, pin 5, circuit 33-MD17 (YE/RD) and
ground. (RHF)
- C52b, pin 7, circuit 33-MD18 (YE) and
ground. (RHR)
Yes
GO TO D3
No
E6747 EN 07/2001 2002 Bantam


D3: CHECK THE SPEAKER NEGATIVE CIRCUIT FOR SHORT TO GROUND
appropriate speaker circuit between;
- C52b, pin 2, circuit 32-MD10 (WH/BK) and
ground. (LHF)
- C52b, pin 4, circuit 32-MD11 (WH/VT) and
ground. (LHR)
- C52b, pin 6, circuit 32-MD17 (WH/RD) and
ground. (RHF)
- C52b, pin 8, circuit 32-MD18 (WH) and
ground. (RHR)
Yes
INSTALL a new audio unit. TEST the
No
E6747 EN 07/2001 2002 Bantam

415-01-1 Audio Unit 415-01-1
SECTION 415-01 Audio Unit

SUBJECT PAGE
Audio System ........................................................................................................................... 415-01-2

Audio Unit........................................................................................................... (38 222 0) 415-01-3
07/2001 2002 Bantam

415-01-2 Audio Unit 415-01-2

Audio System
E4281 EN 07/2001 2002 Bantam

415-01-3 Audio Unit 415-01-3

Audio Unit (38 222 0)
General Equipment
Radio removal tool
Removal
NOTE: Make a note of the audio keycode and

the preset radio stations before disconnecting
the audio control unit.
1. Detach the audio unit.
1. Insert the radio removal tools into the
locating holes until they click into place.
2. Pull the tools gently towards the side of
the unit to release the locking tangs.
3. Pull the unit out of the instrument panel.
2. Remove the audio unit.

• Disconnect the electrical connectors.
• Disconnect the antenna lead.
Installation
1. NOTE: When installing the audio unit make

sure the rear support engages on the carrier.
• Enter the audio unit keycode and
reprogram the preset radio stations.
E1314 EN 07/2001 2002 Bantam

415-02-1 Antenna 415-02-1
SECTION 415-02 Antenna

SUBJECT PAGE
Antenna .................................................................................................................................... 415-02-2

Antenna .................................................................................................................................... 415-02-3

Antenna .............................................................................................................. (38 352 0) 415-02-4/5
07/2001 2002 Bantam

415-02-2 Antenna 415-02-2

Antenna

1 Antenna mast 5 Retaining screw
2 Antenna base The fixed roof mounted mast antenna is
3 Insulator clip connected to the audio control unit by an antenna
cable routed down the A-pillar.
4 Antenna cable
E1317 EN 07/2001 2002 Bantam

415-02-3 Antenna 415-02-3

Antenna
E3772 EN 07/2001 2002 Bantam

415-02-4 Antenna 415-02-4

Antenna (38 352 0)
Removal
1. Detach the interior lamp.
2. Remove the interior lamp.
3. Detach the antenna cable.
E6865 EN 07/2001 2002 Bantam

415-02-5 Antenna 415-02-5
4. Remove the antenna and seal.
Installation
1. NOTE: Make sure the antenna cable insulator

clip is correctly located before installing the
antenna.
E6865 EN 07/2001 2002 Bantam

415-03-1 Speakers 415-03-1
SECTION 415-03 Speakers

SUBJECT PAGE
Speakers .................................................................................................................................. 415-03-2

Speakers .................................................................................................................................. 415-03-3

Front Door Speaker ........................................................................................... (38 268 0) 415-03-4
07/2001 2002 Bantam

415-03-2 Speakers 415-03-2

Speakers
Large diameter round speakers are fitted to the

front doors.
E6677 EN 07/2001 2002 Bantam

415-03-3 Speakers 415-03-3

Speakers
E3778 EN 07/2001 2002 Bantam

415-03-4 Speakers 415-03-4
Front Door Speaker (38 268 0)
Removal
1. Remove the front door trim panel.
2. Detach the loudspeaker (four screws).
3. CAUTION: When disconnecting the

multiplugs do not pull the wiring; pull
on the multiplug body.
Disconnect the multiplug and remove the
loudspeaker.
Installation
E6474 EN 07/2001 2002 Bantam

417-01-1 Exterior Lighting 417-01-1
SECTION 417-01 Exterior Lighting

PAGE 1 OF 2

SUBJECT PAGE

Exterior Lighting ..................................................................................................................... 417-01-3
Headlamp System............................................................................................................... 417-01-3
Multifunction switch ............................................................................................................. 417-01-3
Side lamps .......................................................................................................................... 417-01-3
License plate lamps ............................................................................................................ 417-01-3
Stop lamp switch ................................................................................................................. 417-01-3
Reversing lamps ................................................................................................................. 417-01-4
Stop lamps .......................................................................................................................... 417-01-4
Turn signal and hazard warning lamps ............................................................................... 417-01-4
Hazard warning lamp switch ............................................................................................... 417-01-4
Turn signal relay.................................................................................................................. 417-01-4
Fuses and Relays ............................................................................................................... 417-01-4/7

Headlamps............................................................................................................................. 417-01-8
Symptom Chart ................................................................................................................... 417-01-8
Pinpoint Tests ..................................................................................................................... 417-01-9/26
Component Tests................................................................................................................ 417-01-26
Stop lamps ............................................................................................................................. 417-01-27
Pinpoint Tests ..................................................................................................................... 417-01-27/31
Turn Signal and Hazard Lamps ............................................................................................. 417-01-32
Pinpoint Tests ..................................................................................................................... 417-01-33A/50
Parking, Rear and License Lamps......................................................................................... 417-01-51A
Inspection and Verification .................................................................................................. 417-01-51A
Pinpoint Tests ..................................................................................................................... 417-01-51B/60
Reversing Lamps ................................................................................................................... 417-01-61
Symptom Chart ................................................................................................................... 417-01-61
Pinpoint Tests ..................................................................................................................... 417-01-61/64
Fog Lamps ............................................................................................................................. 417-01-65
Symptom Chart ................................................................................................................... 417-01-65
Pinpoint Tests ..................................................................................................................... 417-01-65/72
Component Tests................................................................................................................ 417-01-72

Headlamp Assembly ........................................................................................ (32 115 0) 417-01-73
Rear Lamp Assembly ...................................................................................... (32 305 0) 417-01-74
GENERAL PROCEDURES
Headlamp Adjustment ........................................................................................................... 417-01-75
07/2001 2002 Bantam

TO MODEL INDEX
SECTION 417-01 Exterior Lighting

PAGE 2 OF 2
SPECIFICATIONS
Specifications ........................................................................................................................ 417-01-77
Exterior Lighting.................................................................................................................. 417-01-77
Headlamp Adjustment ........................................................................................................ 417-01-77
General Specifications ........................................................................................................ 417-01-77
Torque Specifications ......................................................................................................... 417-01-77
CONTINUED
07/2001 2002 Bantam

TO MODEL INDEX

Exterior Lighting
Multifunction switch
The headlamp unit consists of two
compartments. The turn signal and the high and The multifunction switch has the following
low beam, side lights are contained in two settings for the exterior lights:
separate compartments. • Off,
High and low beams each use a HB3LL bulb. • Side lamps,
Both bulbs are switched on for high beam. • Driving lamps, set to either
NOTE: Only use original equipment bulbs in - Low beam or
service. - High beam,
The turn signal lamp consists of an orange lens • Headlamp flash.
and a clear bulb.
If the multifunction switch is set to “side lamps",
Headlamp System then a voltage is supplied to the front and rear
side lamps, as well as to the license plate lamp.
The headlamp system consists of:
Low beam and high beam can only be switched
• Two headlamp assemblies,
on if the ignition is switched on. If the switch is
• A multifunction switch on the steering column, set to “low beam", the low beam relay is activated
• Low beam relay, first, which then switches the voltage to the bulbs.
• High beam relay, If the switch is set to “high beam" or “headlamp
• Turn signal and low beam switch, flash", the high beam relay is activated first,
which then switches the voltage to the bulbs.
• High beam display,
• Wiring harness,
• Fuses. Side lamps
The voltage to the multifunction switch is supplied • The voltage to the side lamps is switched
through fuse F9 and the ignition switch. Fuse F9 through the multifunction switch on the left-
is located in the central junction box (CJB). hand side of the steering column.
When the headlamps are switched on, a voltage • The circuits for left and right-hand side are
is supplied to the high and low beam switch and fused separately through fuses F6 and F7 in
to the coil of the low beam relay. The low beam the CJB.
relay is located in the CJB. • The lamps are in operation when the switch is
set to “side lamps" or “driving lamps".
CAUTION: The voltage supply to the low
beam relay, Pin 5, is not fused.
If the main and low beam switch is set to “low License plate lamps
beam", then a voltage is supplied through the low There is one license plate lamp to illuminate the
beam relay to the low beam bulb. license plate. The lamp is supplied with a voltage
The left and right-hand low beams are fused through fuse F7.
separately through fuses F10 and F11. These The license plate lamp illuminates when the
fuses are located in the CJB. switch is set to “side lamps" or “driving lamps".
CAUTION: The voltage supply to the high
beam relay, Pin 5, is not fused.
Stop lamp switch
If the high and low beam switch is set to “high
beam", then a voltage is supplied via the high The stop lamp switch is installed underneath the
beam relay to the high beam bulb. The left and instrument panel on the brake pedal bracket. It
right-hand high beams are fused separately switches the voltage to the stop lamps through
through fuses F21 and F22. These fuses are fuse F13 in the CJB.
located in the CJB. CONTINUED
E6750 EN 07/2001 2002 Bantam

TO MODEL INDEX
Reversing lamps Hazard warning lamp switch

The reversing lamp system consists of: • The hazard warning lamp switch is
incorporated in the multifunction switch on the
• Reversing lamp bulb,
steering column. It is located on top of the
• Reversing lamp switch, steering column shroud.
• Wiring harness, • When the hazard warning lamp switch is
• Fuse F13. switched on all four turn signal lamps and the
The reversing lamp switch supplies the reversing hazard warning lamp indicator in the
lamps with voltage. This circuit is fused through instrument cluster are supplied with a voltage
fuse F13 in the CJB. through fuse F5 in the CJB and the turn
signal relay.
Stop lamps
Turn signal relay
• The stop lamps are integrated in the rear
lamp assemblies. The turn signal relay operates electronically and
is plugged into the multifunction switch.
• The stop lamp switch supplies the stop lamps
with voltage.
Fuses and Relays
Battery junction box (BJB)
Turn signal and hazard warning lamps
The turn signal and hazard warning lamp system
consists of:
• Turn signal switch (included in the
multifunction switch on the steering column),
• Turn signal relay,
• Turn signal lamps,
• Turn signal and hazard warning lamp
indicator in the instrument cluster,
• Wiring harness,
• Fuses F5 and F17.
The turn signal relay is supplied with voltage
through fuse F17 in the CJB and the turn signal
lamp switch.
CONTINUED
E6750 EN 07/2001 2002 Bantam

TO MODEL INDEX

Central junction box (CJB)- front view, fuses

1 Fuse F12 - multifunction switch, wind- 7 Fuse F11 - headlamp RH
shield wiper motor, wiper relay 8 Fuse F10 - headlamp LH
2 Fuse F13 - stop lamp, transmission 9 Fuse F9 - multifunction switch
switch, instrument cluster illumination,
heating 10 Fuse F7 - front parking lamp RH, li-
cense plate lamp, rear lamp assembly
3 Fuse F15 - multifunction switch
RH
4 Fuse F17 - multifunction switch 11 Fuse F6 - front parking lamp LH, rear
5 Fuse F21 - headlamp LH, instrument lamp assembly LH, front parking lamp
cluster illumination LH, instrument cluster illumination, ra-
dio, heating
6 Fuse F22 - headlamp RH
12 Fuse F5 - multifunction switch
CONTINUED
E6750 EN 07/2001 2002 Bantam

TO MODEL INDEX

Central Junction Box (CJB)- top view

1 Ignition relay 6 WOT relay (petrol)
2 Windshield wiper relay 7 Power hold relay
3 Horn relay 8 Fuel pump relay (petrol)
4 A/C switch relay 9 Low beam relay
5 Not used 10 High beam relay
CONTINUED
E6750 EN 07/2001 2002 Bantam

TO MODEL INDEX


1 Connection point for connector C15a 2 Connection point for connector C15b
CONTINUED
E6750 EN 07/2001 2002 Bantam


Headlamps Visual Inspection Chart
Electrical
Refer to Wiring Diagram Cell: 41701,
for schematic and connector • Fuse(s).
• Bulb(s).
information.
• Wiring harnesses.
Inspection and Verification • Electrical connector(s).
step.
Symptom Chart
• Both headlamps are inoperative. • Fuse. • Go To Pinpoint Test A
• Circuit(s).
• Multifunction switch.
• Central Junction Box (CJB).
• The low beams are inoperative. • Circuit(s). • Go To Pinpoint Test B
• Relay – low beam.
• The high beams are inoperative. • Circuit(s). • Go To Pinpoint Test C
• Relay – high beam.
• One low beam headlamp is in- • Fuse(s). • Go To Pinpoint Test D
operative. • Bulb(s).
• Circuit(s).
• Headlamp, left-hand side / right-
hand side.
• One high beam headlamp is • Fuse(s). • Go To Pinpoint Test E
inoperative. • Bulb(s).
• Circuit(s).
hand side.
• The Headlamps are on continu- • Circuit(s). • Go To Pinpoint Test F
ously. • Multifunction switch.
• Relay – low beam.
• Relay – high beam.
• Flash-to-pass feature is inopera- • Multifunction switch. • Go To Pinpoint Test G
tive.
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
Pinpoint Tests
PAGE 1 OF 2
PINPOINT TEST A: BOTH HEADLAMPS ARE INOPERATIVE
A1: CHECK THE FUSE F9 ..................................................................................417-01-9
A2: CHECK THE POWER SUPPLY OF FUSE F9 ...............................................417-01-9
A3: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH ..................417-01-10
A4: CHECK THE GROUND CONNECTION OF BOTH HEADLAMPS..................417-01-10
PINPOINT TEST B: THE LOW BEAMS ARE INOPERATIVE
B1: CHECK THE CONTROL VOLTAGE OF RELAY – LOW BEAM.....................417-01-10/11
B2: CHECK THE POWER SUPPLY OF RELAY – LOW BEAM ...........................417-01-11
B3: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION ..........417-01-11
PINPOINT TEST C: THE HIGH BEAMS ARE INOPERATIVE
C1: CHECK THE CONTROL VOLTAGE OF RELAY – HIGH BEAM ....................417-01-12
C2: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION..........417-01-12
C3: CHECK THE POWER SUPPLY OF RELAY – HIGH BEAM...........................417-01-13
C4: CHECK THE GROUND CONNECTION OF RELAY – HIGH BEAM...............417-01-13
PINPOINT TEST D: ONE LOW BEAM HEADLAMP IS INOPERATIVE
D1: DETERMINE THE FAULT CONDITION.........................................................417-01-13/14
D2: CHECK THE FUSE F10 ................................................................................417-01-14
D3: CHECK THE POWER SUPPLY OF HEADLAMP, LEFT-HAND SIDE............417-01-14
D4: CHECK THE GROUND CONNECTION OF HEADLAMP, LEFT-HAND SIDE 417-01-15
D5: CHECK THE POWER SUPPLY OF FUSE F10 .............................................417-01-15
D6: CHECK THE FUSE F11 ................................................................................417-01-15/16
D7: CHECK THE POWER SUPPLY OF HEADLAMP, RIGHT-HAND SIDE .........417-01-16
D8: CHECK THE GROUND CONNECTION OF HEADLAMP,
RIGHT-HAND SIDE .............................................................................................417-01-16/17
D9: CHECK THE POWER SUPPLY OF FUSE F11 .............................................417-01-17
PINPOINT TEST E: ONE HIGH BEAM HEADLAMP IS INOPERATIVE
E1: DETERMINE THE FAULT CONDITION.........................................................417-01-17
E2: CHECK THE FUSE F21.................................................................................417-01-18
E3: CHECK THE POWER SUPPLY OF HEADLAMP, LEFT-HAND SIDE............417-01-18
E4: CHECK THE GROUND CONNECTION OF HEADLAMP, LEFT-HAND SIDE 417-01-18/19
E5: CHECK THE POWER SUPPLY OF FUSE F21 .............................................417-01-19
E6: CHECK THE FUSE F22.................................................................................417-01-19
E7: CHECK THE POWER SUPPLY OF HEADLAMP, RIGHT-HAND SIDE..........417-01-20
E8: CHECK THE GROUND CONNECTION OF HEADLAMP,
RIGHT-HAND SIDE .............................................................................................417-01-20
CONTINUED
TO MODEL INDEX
Pinpoint Tests
PAGE 2 OF 2
E9: CHECK THE POWER SUPPLY OF FUSE F22 .............................................417-01-21
PINPOINT TEST F: THE HEADLAMPS ARE ON CONTINUOUSLY
F1: CHECK THE HEADLAMPS............................................................................417-01-21
F2: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION ..........417-01-21
F3: CHECK THE RELAY – LOW BEAM F R PROPER FUNCTION .....................417-01-22
F4: CHECK THE CONTROL CIRCUIT OF RELAY –
LOW BEAM FOR SHORT TO POWER ...............................................................417-01-22
F5: CHECK THE CIRCUI TO LEFT-HAN LOW BEAM HEADLAMP
FOR SHORT TO POWER ...................................................................................417-01-22
F6: CHECK THE CIRCUI TO RIGHT-HA D LOW BEAM HEADLAMP
F7: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION ..........417-01-23
F8: CHECK RELAY – HIGH BEAM FOR PROPER FUNCTION...........................417-01-23
F9: CHECK THE CONTROL CIRCUIT OF RELAY – HIGH BEAM
F10: CHECK THE CIRCUIT TO RIGHT-HAND HIGH BEAM HEADLAMP
F11: CHECK THE CIRCUIT TO LEFT-HAND HIGH BEAM HEADLAMP
FOR SHORT TO POWER ...................................................................................417-01-24/25
F12: CHECK THE INSTRUMENT CLUSTER .......................................................417-01-25
PINPOINT TEST G: THE FLASH-TO-PASS FEATURE IS INOPERATIVE
G1: CHECK THE HIGH BEAM HEADLAMPS FOR PROPER FUNCTION ...........417-01-25/26
CONTINUED
TO MODEL INDEX

Pinpoint Tests
PINPOINT TEST A: BOTH HEADLAMPS ARE INOPERATIVE
1. 2.
Fuse F9 (CJB)
3 South Africa: Check the fuse F9 (5 A).
• Is the fuse OK?

Yes
GO TO A2
No
INSTALL a new fuse F9 (20 A) or F9 (5 A).
If the fuse blows again, LOCATE and
REPAIR the short circuit by using the wiring
eration.
A2: CHECK THE POWER SUPPLY OF FUSE F9
1. 2.
Fuse F9 (CJB)
3 Measure the voltage between fuse F9 (5 A) or
(20 A) and ground.
Yes
GO TO A3
No
REPAIR the power supply of fuse F9, by us-
for normal operation. If necessary INSTALL
a new CJB.
CONTINUED
E9418 EN 07/2001 2002 Bantam

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A3: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH
1. 2. 3.
C15a
4 Measure the voltage between multifunction
switch, connector C15a, pin 4, circuit 14-LE29
(VT/BK), harness side and ground.
Yes
GO TO A4
No
and multifunction switch, by using the wiring
eration.
A4: CHECK THE GROUND CONNECTION OF BOTH HEADLAMPS

1 Measure the resistance between headlamp,
left-hand side, connector C45, pin 7, circuit 31-
LE31A (BK), harness side and ground.
Yes
CHECK the multifunction switch, according
to Component Testing attached to the wiring
diagrams. If necessary INSTALL a new one.
No
REPAIR the open circuit(s) between splice
S24 and ground G9, by using the wiring
eration.
PINPOINT TEST B: THE LOW BEAMS ARE INOPERATIVE
B1: CHECK THE CONTROL VOLTAGE OF RELAY – LOW BEAM
1. 2. 3.
Relay – low beam

C6
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
4 Turn the multifunction switch to the LOW
BEAM position.
low beam, connector C6, pin 2, circuit 14S-
LE19 (VT/BU) and ground.
Yes
GO TO B2
No
GO TO B3
B2: CHECK THE POWER SUPPLY OF RELAY – LOW BEAM

low beam, connector C6, pin 5, circuit 30-LE20
(RD) and ground.
Yes
INSTALL a new relay – low beam. TEST the
No
REPAIR the power supply of relay – low
beam, by using the wiring diagrams. TEST
B3: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1.
2 Check the multifunction switch, according to

Component Testing attached to the wiring
diagrams.
• Is the multifunction switch OK?
Yes
REPAIR the open circuit(s) between
multifunction switch and relay – low beam,
by using the wiring diagrams. TEST the
No
INSTALL a new multifunction switch. TEST
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST C: THE HIGH BEAMS ARE INOPERATIVE
C1: CHECK THE CONTROL VOLTAGE OF RELAY – HIGH BEAM
1. 2. 3.
Relay – high beam

C5
BEAM and HIGH BEAM position.
high beam, connector C5, pin 2, circuit 14S-
LE12 (VT/YE) and ground.
Yes
GO TO C3
No
GO TO C2
C2: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1.
2 Check the multifunction switch, according to

Component Testing attached to the wiring
diagrams.
• Is the multifunction switch OK?
Yes
REPAIR the open circuit(s) between
multifunction switch and relay – high beam,
No
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
C3: CHECK THE POWER SUPPLY OF RELAY – HIGH BEAM
high beam, connector C5, pin 5, circuit 30-
LE13 (RD) and ground.
Yes
GO TO C4
No
REPAIR the power supply of relay – high
beam, by using the wiring diagrams. TEST
C4: CHECK THE GROUND CONNECTION OF RELAY – HIGH BEAM

1.

high beam, connector C5, pin 1, circuit 31-
LE12 (BK) and ground.
Yes
INSTALL a new relay – high beam. TEST
No
high beam and ground G6, by using the wir-
operation. If necessary INSTALL a new
CJB.
PINPOINT TEST D: ONE LOW BEAM HEADLAMP IS INOPERATIVE
D1: DETERMINE THE FAULT CONDITION
1.

BEAM position.
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

3 Check which low beam headlamp is
inoperative.
• Is the low beam headlamp at the left side
inoperative?
Yes
GO TO D2
No
GO TO D6
1. 2.
Fuse F10 (CJB)

3 Check the fuse F10 (10 A).
• Is the fuse OK?
Yes
GO TO D3
No
INSTALL a new fuse F10. If the fuse blows
again, LOCATE and REPAIR the short cir-
cuit by using the wiring diagrams. TEST the
D3: CHECK THE POWER SUPPLY OF HEADLAMP, LEFT-HAND SIDE
1. 2. 3.
Fuse F10 (CJB) Headlamp, left-hand

side C45
BEAM position.
5 Measure the voltage between headlamp, left-
hand side, connector C45, pin 2, circuit 14S-
LE16 (VT/OG), harness side and ground.
Yes
GO TO D4
No
GO TO D5
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
D4: CHECK THE GROUND CONNECTION OF HEADLAMP, LEFT-HAND SIDE
1.

LE31A (BK), harness side and ground.
Yes
CHECK the headlamp, left-hand side. If
No
REPAIR the open circuit(s) between head-
lamp, left-hand side and ground G9, by us-
D5: CHECK THE POWER SUPPLY OF FUSE F10
1 Measure the voltage between fuse F10 (10 A)
(CJB) and ground.
Yes
F10 and headlamp, left-hand side, by using
normal operation.
No
low beam and fuse F10, by using the wiring
eration.
1. 2.
Fuse F11 (CJB)
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
• Is the fuse OK?
Yes
GO TO D7
No
D7: CHECK THE POWER SUPPLY OF HEADLAMP, RIGHT-HAND SIDE
1. 2. 3.
Fuse F11 (CJB) Headlamp, right-

hand side C46
BEAM position.
5 Measure the voltage between headlamp, right-
LE23 (VT/WH), harness side and ground.
Yes
GO TO D8
No
GO TO D9
D8: CHECK THE GROUND CONNECTION OF HEADLAMP, RIGHT-HAND SIDE

1.
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
right-hand side, connector C46, pin 7, circuit
31-LE30A (BK), harness side and ground.
Yes
CHECK the headlamp, right-hand side. If
No
lamp, right-hand side and ground G9, by us-
D9: CHECK THE POWER SUPPLY OF FUSE F11
(CJB) and ground.
Yes
F11 and headlamp, right-hand side, by
No
low beam and fuse F11, by using the wiring
eration.
PINPOINT TEST E: ONE HIGH BEAM HEADLAMP IS INOPERATIVE
E1: DETERMINE THE FAULT CONDITION
1.

3 Check which high beam headlamp is
inoperative.
• Is the high beam headlamp at the left side
inoperative?
Yes
GO TO E2
No
GO TO E6
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

E2: CHECK THE FUSE F21
1. 2.
Fuse F21 (CJB)

• Is the fuse OK?
Yes
GO TO E3
No
E3: CHECK THE POWER SUPPLY OF HEADLAMP, LEFT-HAND SIDE
1. 2. 3.
Fuse F21 (CJB) Headlamp, left-hand

side C45
LE15 (VT/BK), harness side and ground.
Yes
GO TO E4
No
GO TO E5
E4: CHECK THE GROUND CONNECTION OF HEADLAMP, LEFT-HAND SIDE

1.
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

LE31 (BK), harness side and ground.
Yes
No
E5: CHECK THE POWER SUPPLY OF FUSE F21
(CJB) and ground.
Yes
F21 and headlamp, left-hand side, by using
normal operation.
No
high beam and fuse F21, by using the wiring
eration.
1. 2.
Fuse F22 (CJB)

• Is the fuse OK?
Yes
GO TO E7
No
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
E7: CHECK THE POWER SUPPLY OF HEADLAMP, RIGHT-HAND SIDE
1. 2. 3.
Fuse F22 (CJB) Headlamp, right-

hand side C46
LE22 (VT/OG), harness side and ground.
Yes
GO TO E8
No
GO TO E9
E8: CHECK THE GROUND CONNECTION OF HEADLAMP, RIGHT-HAND SIDE

1.

31-LE30 (BK), harness side and ground.
Yes
No
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
(CJB) and ground.
Yes
F22 and headlamp, right-hand side, by
No
high beam and fuse F22, by using the wiring
eration.
PINPOINT TEST F: THE HEADLAMPS ARE ON CONTINUOUSLY
F1: CHECK THE HEADLAMPS
1.
2 Check whether the high and low beam

headlamps are on continuously.
• Are the high and low beam headlamps on
continuously?
Yes
No
Low beam headlamps are on continuously:
GO TO F2
High beam headlamps are on continuously:
GO TO F7
F2: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION
1. 2. 3.
• Are the low beam headlamps on continuously?
Yes
GO TO F3
No
C15a
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
F3: CHECK THE RELAY – LOW BEAM FOR PROPER FUNCTION
1. 2. 3.
• Are the low beam headlamps on continuously?
Yes
GO TO F5
No
GO TO F4
Relay – low beam

C6
F4: CHECK THE CONTROL CIRCUIT OF RELAY – LOW BEAM FOR SHORT TO POWER
switch, connector C15a, pin 1, circuit 14S-
LE19 (VT/BU), harness side and ground.
Yes
REPAIR the short to power, circuit(s)
connected with the multifunction switch,
connector C15a, pin 1, by using the wiring
diagrams. TEST the system for normal
operation.
No
INSTALL a new relay – low beam. TEST the
F5: CHECK THE CIRCUIT TO LEFT-HAND LOW BEAM HEADLAMP FOR SHORT TO POWER
1. 2. 3.
Fuse F10 (10 A)

(CJB)
4 Check if the left-hand low beam headlamp is
on continuously.
• Is the left-hand low beam headlamp on
continuously?
Yes
connected with the headlamp, left-hand
side, connector C45, pin 2, by using the
wiring diagrams. TEST the system for
normal operation.
No
GO TO F6
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

F6: CHECK THE CIRCUIT TO RIGHT-HAND LOW BEAM HEADLAMP FOR SHORT TO POWER
1. 2. 3.
Fuse F11 (10 A)

(CJB)
4 Check if the right-hand low beam headlamp is
on continuously.
• Is the right-hand low beam headlamp on
continuously?
Yes
connected with the headlamp, right-hand
normal operation.
No
REPAIR the short to power, circuit(s) con-
nected with the relay – low beam, connector
C6, pin 3, by using the wiring diagrams.
1. 2. 3.
• Are the high beam headlamps on
continuously?
Yes
GO TO F8
No
C15a
F8: CHECK RELAY – HIGH BEAM FOR PROPER FUNCTION
1. 2. 3.
• Are the high beam headlamps on
continuously?
Yes
GO TO F10
No
GO TO F9
Relay – high beam
C5
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

F9: CHECK THE CONTROL CIRCUIT OF RELAY – HIGH BEAM FOR SHORT TO POWER
switch, connector C15a, pin 3, circuit 14S-
LE12 (VT/YE), harness side and ground.
Yes
connector C15a, pin 3, by using the wiring
operation.
No
INSTALL a new relay – high beam. TEST
F10: CHECK THE CIRCUIT TO RIGHT-HAND HIGH BEAM HEADLAMP FOR SHORT TO POWER
1. 2. 3.
Fuse F22 (10 A)

(CJB)
4 Check if the right-hand high beam headlamp is
on continuously.
• Is the right-hand high beam headlamp on
continuously?
Yes
connected with the headlamp, right-hand
normal operation.
No
GO TO F11
F11: CHECK THE CIRCUIT TO LEFT-HAND HIGH BEAM HEADLAMP FOR SHORT TO POWER
1. 2. 3.
Fuse F21 (10 A)

(CJB)
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX
4 Check if the left-hand high beam headlamp is
on continuously.
• Is the left-hand high beam headlamp on
continuously?
Yes
GO TO F12
No
REPAIR the short to power, circuit(s) con-
nected with the relay – high beam, connec-
tor C5, pin 3, by using the wiring diagrams.
F12: CHECK THE INSTRUMENT CLUSTER
1. 2. 3.
Instrument cluster
C37a
4 Check if the left-hand high beam headlamp is
on continuously.
• Is the left-hand high beam headlamp on
continuously?
Yes
connected with fuse F21, by using the wiring
operation.
No
CHECK the instrument cluster. If necessary
normal operation.
PINPOINT TEST G: THE FLASH-TO-PASS FEATURE IS INOPERATIVE
G1: CHECK THE HIGH BEAM HEADLAMPS FOR PROPER FUNCTION
1.
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

• Are the high beam headlamps illuminated?
Yes
No
Go To Pinpoint Test C
Component Tests
Relays
Component testing applies to the following
relays: 2. Check relay contact in activated condition
• Relay – low beam
• Relay – high beam
Connect the battery power between pin 1 and 2.

Measure the resistance between pin 3 and 5
(VFE0015898).
Measure the resistance between pin 3 and 5 Is the resistance less than 2 ohms?
(VFE0015897).
Is the resistance less than 2 ohms?
If no, INSTALL a new relay.
If yes, INSTALL a new relay.
If no, GO to step 2.
CONTINUED
E9418 EN 07/2001 2002 Bantam

TO MODEL INDEX

Stop lamps
step.
Visual Inspection Chart 4. If the cause is not visually evident, verify the
Electrical symptom and refer to the Symptom Chart.
• Fuse(s).
• Bulb(s).
• Wiring harness.
• Electrical connector(s).
Symptom Chart
• The stop lamps are inoperative. • Fuse. • Go To Pinpoint Test H
• Circuit(s).
• Stop lamp switch.
• One or more stop lamps are in- • Bulb(s). • Go To Pinpoint Test I
• Rear lamp assembly, right-hand
side / left-hand side.
• The stop lamps are on continu- • Circuit(s). • Go To Pinpoint Test J
ously. • Stop lamp switch.
Pinpoint Tests
PINPOINT TEST H: THE STOP LAMPS ARE INOPERATIVE
H1: CHECK THE FUSE F13
1. 2.
Fuse F13 (CJB)

• Is the fuse OK?
Yes
GO TO H2
No
short circuit by using the wiring diagrams.
CONTINUED
E6752 EN 07/2001 2002 Bantam

TO MODEL INDEX
H2: CHECK THE CIRCUIT TO STOP LAMP SWITCH FOR OPEN
1. 2.
Stop lamp switch

C50
3 Measure the voltage between stop lamp
switch, connector C50, circuit 14-LG23
(VT/WH), harness side and ground.
Yes
GO TO H3
No
F13 and stop lamp switch, by using the wir-
operation.
H3: CHECK THE STOP LAMP SWITCH FOR PROPER FUNCTION

1 Connect a jumper wire between stop lamp
switch, connector C50, circuit 14-LG23
(VT/WH) and circuit 14S-LG1 (VT/BK), harness
side.
• Are the stop lamps illuminated?
Yes
INSTALL a new stop lamp switch. TEST the
No
REPAIR the open circuit(s) between stop
lamp switch and splice S37, by using the
mal operation.
PINPOINT TEST I: ONE OR MORE STOP LAMPS ARE INOPERATIVE
I1: DETERMINE THE FAULT CONDITION
1.
2 Depress the brake pedal.
CONTINUED
E6752 EN 07/2001 2002 Bantam

TO MODEL INDEX
3 Check which stop lamp is inoperative.
• Is the stop lamp at the left-hand side
inoperative?
Yes
GO TO I4
No
GO TO I2
I2: CHECK THE POWER SUPPLY OF REAR LAMP ASSEMBLY, RIGHT-HAND SIDE
1. 2. 3.
Rear lamp assem-

bly, right-hand side
C42
5 Measure the voltage between rear lamp
assembly, right-hand side, connector C42,
circuit 14S-LG38 (VT), harness side and
ground.
Yes
GO TO I3
No
S37 and the rear lamp assembly, right-hand
side, by using the wiring diagrams. TEST
I3: CHECK GROUND CONNECTION OF REAR LAMP ASSEMBLY, RIGHT-HAND SIDE
1.
CONTINUED
E6752 EN 07/2001 2002 Bantam

TO MODEL INDEX
2 Measure the resistance between rear lamp
circuit 31-LF24 (BK), harness side and ground.
Yes
CHECK the rear lamp assembly, right-hand
side. If necessary INSTALL a new one.
No
REPAIR the open circuit(s) between rear
lamp assembly, right-hand side and ground
G3, by using the wiring diagrams. TEST the
I4: CHECK THE POWER SUPPLY OF REAR LAMP ASSEMBLY, LEFT-HAND SIDE
1. 2. 3.
Rear lamp assem-

bly, left-hand side
C39
assembly, left-hand side, connector C39,
circuit 14S-LG41 (VT/BK), harness side and
ground.
Yes
GO TO I5
No
S37 and the rear lamp assembly, left-hand
I5: CHECK GROUND CONNECTION OF REAR LAMP ASSEMBLY, LEFT-HAND SIDE
1.
CONTINUED
E6752 EN 07/2001 2002 Bantam

TO MODEL INDEX
Yes
CHECK the rear lamp assembly, left-hand
No
lamp assembly, left-hand side and ground
PINPOINT TEST J: STOP LAMPS ARE ON CONTINUOUSLY
J1: CHECK THE STOP LAMP SWITCH
1. 2. 3.
• Are the stop lamps on continuously?
Yes
REPAIR the short to power; circuit(s)
connected with splice S37, by using the
normal operation.
No
Stop lamp switch
INSTALL a new stop lamp switch. TEST the
C50
CONTINUED
E6752 EN 07/2001 2002 Bantam

TO MODEL INDEX

Turn Signal and Hazard Lamps 3. If an obvious cause for an observed or
Inspection and Verification (if possible) before proceeding to the next
1. Verify the customer concern. step.
2. Visually inspect for obvious signs of 4. If the cause is not visually evident, verify the
mechanical or electrical damage. symptom and refer to the Symptom Chart.
Electrical
• Fuse(s).
• Bulb(s).
• Wiring harness.
Symptom Chart
• Turn signal lamps are inopera- • Fuse F17. • Go To Pinpoint Test K
tive or on continuously. • Circuit(s).
• Hazard warning switch.
• Hazard lamps are inoperative or • Fuse(s). • Go To Pinpoint Test M
on continuously. • Circuit(s).
• Hazard warning switch.
• One turn signal/hazard lamp is • Circuit(s). • Go To Pinpoint Test L
inoperative. • Hazard warning switch.
• Turn signal lamp.
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
Pinpoint Tests
PAGE 1 OF 2
PINPOINT TEST K: TURN SIGNAL LAMPS ARE INOPERATIVE OR
ON CONTINUOUSLY
K1: DETERMINE THE FAULT CONDITION......................................................... 417-01-33A/33B
K2: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH .................. 417-01-33B
K3: CHECK THE FUSE F17................................................................................. 417-01-33B
K4: CHECK THE GROUND CONNECTION OF MULTIFUNCTION SWITCH ...... 417-01-34
K5: CHECK THE POWER SUPPLY OF RELAY – TURN SIGNAL ....................... 417-01-34
K6: CHECK THE GROUND CONNECTION OF RELAY – TURN SIGNAL ........... 417-01-34
K7: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION .......... 417-01-34/35
K8: CHECK THE CIRCU FOR LEFT-HAND TURN SIGNAL FOR OPEN ............. 417-01-35
K9: CHECK THE CIRCUIT FOR RIGHT-HAND TURN SIGNAL FOR OPEN........ 417-01-35/36
K10: CHECK THE RELAY – ANTI-THEFT FLASHER FOR
PROPER FUNCTION .......................................................................................... 417-01-36
K11: CHECK THE RELAY – TURN SIGNAL FOR PROPER FUNCTION............. 417-01-36/37
K12: CHECK THE MULT FUNCTION SWITCH FOR PROPER FUNCTION ........ 417-01-37
K13: CHECK THE INSTRUMENT CLUSTER....................................................... 417-01-37/38
K14: CHECK THE RELAY – ANTI-THEFT FLASHER FOR
PROPER FUNCTION .......................................................................................... 417-01-38
K15: CHECK THE RELAY – TURN SIGNAL FOR PROPER FUNCTION ............. 417-01-38/39
K16: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION ....... 417-01-39
K17: CHECK THE INSTRUMENT CLUSTER....................................................... 417-01-39/40
PINPOINT TEST L: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE
L1: DETERMINE THE INOPERATIVE TURN SIGNAL LAMP .............................. 417-01-40
L2: CHECK THE POWER SUPPLY OF FRONT LEFT-HAND TURN
SIGNAL LAMP ..................................................................................................... 417-01-40/41
L3: CHECK THE GROUND CONNECTION OF FRONT TURN SIGNAL,
LEFT-HAND SIDE................................................................................................ 417-01-41
L4: DETERMINE THE INOPERATIVE TURN SIGNAL LAMP................................. 417-01-41
L5: CHECK THE POWER SUPPLY OF SIDE TURN SIGNAL LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-42
L6: CHECK THE GROUND CONNECTION OF SIDE TURN SIGNAL LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-42
L7: DETERMINE THE INOPERATIVE LEFT-HAND TURN SIGNAL LAMP.......... 417-01-42
CONTINUED
TO MODEL INDEX
Pinpoint Tests
PAGE 2 OF 2
L8: CHECK THE POWER SUPPLY OF REAR TURN SIGNAL LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-43
L9: CHECK THE GROUND CONNECTION OF REAR TURN SIGNAL LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-43
L10: CHECK THE TURN SIGNAL INDICATOR .................................................... 417-01-43
L11: CHECK THE POWER SUPPLY OF TURN INDICATOR,
LEFT-HAND SIDE................................................................................................ 417-01-44
L12: CHECK THE POWER SUPPLY OF TURN INDICATOR,
RIGHT-HAND SIDE ............................................................................................417-01-44
L13: DETERMINE THE INOPERATIVE TURN SIGNAL LAMP ............................ 417-01-44
L14: CHECK THE POWER SUPPLY OF FRONT RIGHT-HAND
TURN SIGNAL LAMP .......................................................................................... 417-01-45
L15: CHECK THE GROUND CONNECTION OF FRONT RIGHT-HAND
TURN SIGNAL LAMP .......................................................................................... 417-01-45
L16: DETERMINE THE INOPERATIVE TURN SIGNAL LAMP ............................ 417-01-45
L17: CHECK THE POWER SUPPLY OF SIDE TURN SIGNAL LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-46
L18: CHECK THE GROUND CONNECTION OF SIDE TURN SIGNAL LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-46
L19: CHECK THE POWER SUPPLY OF REAR TURN SIGNAL LAMP,
RIGHT-HAND SIDE ............................................................................................ 417-01-46/47
L20: CHECK THE GROUND CONNECTION OF REAR TURN SIGNAL LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-47
PINPOINT TEST M: HAZARD LAMPS ARE INOPERATIVE OR
ON CONTINUOUSLY
M1: DETERMINE THE FAULT CONDITION ........................................................ 417-01-47
M2: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH ...................417-01-48
M3: CHECK THE GROUND CONNECTION OF MULTIFUNCTION SWITCH...... 417-01-48
M4: CHECK THE FUSE F5.................................................................................. 417-01-48
M5: CHECK THE POWER SUPPLY OF RELAY – TURN SIGNAL ...................... 417-01-49
M6: CHECK THE GROUND CONNECTION OF RELAY – TURN SIGNAL........... 417-01-49
M7: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION ......... 417-01-49
M8: CHECK THE RELAY – TURN SIGNAL FOR PROPER FUNCTION .............. 417-01-50
M9: CHECK THE RELAY – ANTI-THEFT FLASHER FOR PROPER FUNCTION 417-01-50
CONTINUED
TO MODEL INDEX
417-01-33A Exterior Lighting 417-01-33A

Pinpoint Tests
PINPOINT TEST K: TURN SIGNAL LAMPS ARE INOPERATIVE OR ON CONTINUOUSLY
K1: DETERMINE THE FAULT CONDITION
1.
2 Turn the multifunction switch to the RIGHT-

HAND TURN SIGNAL and to the LEFT-HAND
TURN SIGNAL position.
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
417-01-33B Exterior Lighting 417-01-33B

3 Check if the turn signal lamps are on
continuously or inoperative.
• Are the turn signal lamps inoperative?
Yes
All turn signal lamps: GO TO K2
All left-hand turn signal lamps: GO TO K8
All right-hand turn signal lamps: GO TO K9
No
All left-hand turn signal lamps are on
continuously: GO TO K10
All right-hand turn signal lamps are on con-
tinuously: GO TO K14
K2: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH
1. 2. 3.
C15a
switch, connector C15a, pin 9, circuit 14-LG5
(VT), harness side and ground.
Yes
GO TO K4
No
GO TO K3
K3: CHECK THE FUSE F17

1. 2.
• Is the fuse F17 (15 A) OK?
Yes
F17 and multifunction switch, by using the
normal operation.
No
Fuse F17 (CJB)
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
K4: CHECK THE GROUND CONNECTION OF MULTIFUNCTION SWITCH
1 Measure the resistance between multifunction
Yes
GO TO K5
No
REPAIR the open circuit(s) between multi-
function switch and ground G6, by using the
mal operation.
K5: CHECK THE POWER SUPPLY OF RELAY – TURN SIGNAL

turn signal, terminal 49 and ground.
Yes
GO TO K6
No
K6: CHECK THE GROUND CONNECTION OF RELAY – TURN SIGNAL

Yes
GO TO K7
No
K7: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1 Turn the multifunction switch to the LEFT-
HAND TURN SIGNAL position.
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
turn signal, terminal 49A and multifunction
(BU), component side.
Yes
INSTALL a new relay – turn signal. TEST
No
K8: CHECK THE CIRCUIT FOR LEFT-HAND TURN SIGNAL FOR OPEN
1. 2. 3.
Multifunction switch Rear turn signal

C15a lamp, left-hand side
C68
(BU), harness side and rear turn signal lamp,
left-hand side, connector C68, circuit 14S-
LG12 (BU), harness side.
Yes
No
function switch and splice S36, by using the
mal operation.
K9: CHECK THE CIRCUIT FOR RIGHT-HAND TURN SIGNAL FOR OPEN
1. 2. 3.
Multifunction switch Rear turn signal

C15a lamp, right-hand
side C66
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX

(BU/RD), harness side and rear turn signal
lamp, left-hand side, connector C66, circuit 49-
LG19 (BU/RD), harness side.
Yes
No
function switch and splice S35, by using the
mal operation.
K10: CHECK THE RELAY – ANTI-THEFT FLASHER FOR PROPER FUNCTION
1. 2.
Relay – anti-theft
flasher C323
3 Check if the left-hand turn signal lamps are on
continuously.
• Are the left-hand turn signal lamps on
continuously?
Yes
GO TO K11
No
INSTALL a new relay – anti-theft flasher.
K11: CHECK THE RELAY – TURN SIGNAL FOR PROPER FUNCTION
1. 2.
Relay – turn sig-

nal
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
continuously.
continuously?
Yes
GO TO K12
No
1. 2. 3.
C15a
continuously.
continuously?
Yes
GO TO K13
No
K13: CHECK THE INSTRUMENT CLUSTER
1. 2. 3.
Instrument cluster
C37a
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
continuously.
continuously?
Yes
normal operation.
No
CHECK the instrument cluster, If necessary
normal operation.
K14: CHECK THE RELAY – ANTI-THEFT FLASHER FOR PROPER FUNCTION
1. 2.
flasher C323
3 Check if the right-hand turn signal lamps are
on continuously.
• Are the right-hand turn signal lamps on
continuously?
Yes
GO TO K15
No
K15: CHECK THE RELAY – TURN SIGNAL FOR PROPER FUNCTION
1. 2. 3.
Relay – turn signal

CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX

on continuously.
continuously?
Yes
GO TO K16
No
1. 2. 3.
C15a
on continuously.
continuously?
Yes
GO TO K17
No
K17: CHECK THE INSTRUMENT CLUSTER
1. 2. 3.
Instrument cluster
C37a
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
on continuously.
continuously?
Yes
normal operation.
No
normal operation.
PINPOINT TEST L: ONE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE
L1: DETERMINE THE INOPERATIVE TURN SIGNAL LAMP
1.

3 Determine the inoperative left-hand turn signal
lamp.
• Is the front turn signal lamp, left-hand side
inoperative?
Yes
GO TO L2
No
GO TO L4
L2: CHECK THE POWER SUPPLY OF FRONT LEFT-HAND TURN SIGNAL LAMP
1.
Headlamp, left-
hand side C45 2 Turn the multifunction switch to the LEFT-
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
hand side, connector C45, pin 3, circuit 49-
LG11 (BU/OG), harness side and ground.
Yes
GO TO L3
No
S36 and headlamp, left-hand side, by using
normal operation.
L3: CHECK THE GROUND CONNECTION OF FRONT TURN SIGNAL, LEFT-HAND SIDE
Yes
No
1.

lamp.
• Is the side turn signal lamp, left-hand side
inoperative?
Yes
GO TO L5
No
GO TO L7
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX

L5: CHECK THE POWER SUPPLY OF SIDE TURN SIGNAL LAMP, LEFT-HAND SIDE
1.
Side turn signal

lamp, left-hand
side C145
2 Measure the voltage between side turn signal
lamp, left-hand side, connector C145, pin 2,
circuit 49-LG13 (BU/RD), harness side and
ground.
Yes
GO TO L6
No
S36 and side turn signal lamp, left-hand
L6: CHECK THE GROUND CONNECTION OF SIDE TURN SIGNAL LAMP, LEFT-HAND SIDE
1 Measure the resistance between side turn
signal lamp, left-hand side, connector C145,
pin 1, circuit 31-LG13 (BK), harness side and
ground.
Yes
CHECK the side turn signal lamp, left-hand
No
REPAIR the open circuit(s) between side
turn signal lamp, left-hand side and ground
G10, by using the wiring diagrams. TEST
L7: DETERMINE THE INOPERATIVE LEFT-HAND TURN SIGNAL LAMP
lamp.
• Is the rear turn signal lamp, left-hand side
inoperative?
Yes
GO TO L8
No
GO TO L10
CONTINUED
E9426 EN 07/2001 2002 Bantam
TO MODEL INDEX
L8: CHECK THE POWER SUPPLY OF REAR TURN SIGNAL LAMP, LEFT-HAND SIDE
1.
Rear signal lamp,

left-hand side C68
2 Measure the voltage between rear turn signal
lamp, left-hand side, connector C68, circuit 49-
LG12 (BU), harness side and ground.
Yes
GO TO L9
No
S36 and rear turn signal lamp, left-hand
L9: CHECK THE GROUND CONNECTION OF REAR TURN SIGNAL LAMP, LEFT-HAND SIDE
1 Measure the resistance between rear turn
signal lamp, left-hand side, connector C68,
circuit 31-LG12 (BK), harness side and ground.
Yes
CHECK the rear turn signal lamp, left-hand
No
turn signal lamp, left-hand side and ground
L10: CHECK THE TURN SIGNAL INDICATOR
1 Actuate the hazard warning switch.
• Is a turn signal indicator inoperative?
Yes
GO TO L11
No
GO TO L13
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
L11: CHECK THE POWER SUPPLY OF TURN INDICATOR, LEFT-HAND SIDE
1. 2. 3.
Instrument cluster
C37
4 Measure the voltage between instrument
cluster, connector C37, pin 7, circuit 49-LG15
(BU/BK), harness side and ground.
Yes
GO TO L12
No
S36 and instrument cluster, by using the
mal operation.
L12: CHECK THE POWER SUPPLY OF TURN INDICATOR, RIGHT-HAND SIDE

1 Measure the voltage between instrument
cluster, connector C37, pin 29, circuit 49-LG22
(BU/YE), harness side and ground.
Yes
normal operation.
No
S35 and instrument cluster, by using the
mal operation.
2 Determine the inoperative right-hand turn
signal lamp.
• Is the front turn signal lamp, right-hand side
inoperative?
Yes
GO TO L14
No
GO TO L16
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
L14: CHECK THE POWER SUPPLY OF FRONT RIGHT-HAND TURN SIGNAL LAMP
1. 2.
Headlamp, right-
hand side C46
3 Measure the voltage between Headlamp, right-
hand side, connector C46, pin 3, circuit 49-
LG18 (BU), harness side and ground.
Yes
GO TO L15
No
S35 and headlamp, right-hand side, by us-
L15: CHECK THE GROUND CONNECTION OF FRONT RIGHT-HAND TURN SIGNAL LAMP
Yes
No
2 Determine the inoperative right-hand turn
signal lamp.
• Is the side turn signal lamp, right-hand side
inoperative?
Yes
GO TO L17
No
GO TO L19
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
L17: CHECK THE POWER SUPPLY OF SIDE TURN SIGNAL LAMP, RIGHT-HAND SIDE
1.
Side turn signal

lamp, right-hand
side C144
2 Measure the voltage between side turn signal
lamp, right-hand side, connector C144, pin 2,
circuit 49-LG13 (BU/RD), harness side and
ground.
Yes
GO TO L18
No
S35 and side turn signal lamp, right-hand
L18: CHECK THE GROUND CONNECTION OF SIDE TURN SIGNAL LAMP, RIGHT-HAND SIDE
1 Measure the resistance between side turn
signal lamp, right-hand side, connector C144,
pin 1, circuit 31-LG13 (BK), harness side and
ground.
Yes
CHECK the side turn signal lamp, right-hand
No
REPAIR the open circuit(s) between side
turn signal lamp, right-hand side and ground
G6. TEST the system for normal operation.
L19: CHECK THE POWER SUPPLY OF REAR TURN SIGNAL LAMP, RIGHT-HAND SIDE
1.
Rear turn signal

lamp, right-hand
side C66
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
2 Measure the voltage between rear turn signal
lamp, right-hand side, connector C66, circuit
49-LG19 (BU/RD), harness side and ground.
Yes
GO TO L20
No
S35 and rear turn signal lamp, right-hand
L20: CHECK THE GROUND CONNECTION OF REAR TURN SIGNAL LAMP, RIGHT-HAND SIDE
1 Measure the resistance between rear turn
signal lamp, right-hand side, connector C66,
circuit 31-LG19 (BK), harness side and ground.
Yes
CHECK the rear turn signal lamp, right-hand
No
turn signal lamp, right-hand side and ground
PINPOINT TEST M: HAZARD LAMPS ARE INOPERATIVE OR ON CONTINUOUSLY
M1: DETERMINE THE FAULT CONDITION
1.

• Are the hazard warning lamps inoperative?
Yes
GO TO M2
No
The hazard warning lamps are on continu-
ously: GO TO M8
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
M2: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH
1.
Multifunction
switch C15a
switch, connector C15a, pin 10, circuit 29-DA1
(OG/YE), harness side and ground.
Yes
GO TO M3
No
GO TO M4
M3: CHECK THE GROUND CONNECTION OF MULTIFUNCTION SWITCH

Yes
GO TO M5
No
mal operation.
M4: CHECK THE FUSE F5

1.
Yes
and multifunction switch, by using the wiring
operation.
No
Fuse F5 (CJB)
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX

M5: CHECK THE POWER SUPPLY OF RELAY – TURN SIGNAL

Yes
GO TO M6
No
M6: CHECK THE GROUND CONNECTION OF RELAY – TURN SIGNAL

turn signal, terminal 31and ground.
Yes
GO TO M7
No
M7: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

turn signal, terminal 49A, and multifunction
(BU), component side.
Yes
No
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
M8: CHECK THE RELAY – TURN SIGNAL FOR PROPER FUNCTION
1.
Relay – turn signal

3 Check if the hazard warning lamps are on
continuously.
• Are the hazard warning lamps on
continuously?
Yes
GO TO M9
No
M9: CHECK THE RELAY – ANTI-THEFT FLASHER FOR PROPER FUNCTION
1. 2.
flasher C323
3 Check if the hazard warning lamps are on
continuously.
• Are the hazard warning lamps on
continuously?
Yes
No
CONTINUED
E9426 EN 07/2001 2002 Bantam

TO MODEL INDEX
417-01-51A Exterior Lighting 417-01-51A

Parking, Rear and License Lamps
Inspection and Verification 3. If an obvious cause for an observed or
1. Verify the customer concern. reported concern is found, correct the cause
2. Visually inspect for obvious signs of step.
Visual Inspection Chart symptom and refer to the Symptom Chart.
Electrical
• Fuse(s).
• Bulb(s).
• Wiring harness.
Symptom Chart
• One or more parking, rear or • Fuse(s). • Go To Pinpoint Test N
license plate lamp(s) is/are in- • Bulb(s).
operative. • Circuit(s)
hand side.
• Rear lamp assembly, left-hand
side / right-hand side.
• License plate lamp.
• The parking, rear or license • Circuit(s). • Go To Pinpoint Test O
plate lamps are on continuously. • Multifunction switch.
• The parking, rear or license • Fuse. • Go To Pinpoint Test P
plate lamps are inoperative. • Circuit(s).
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
Pinpoint Tests
PAGE 1 OF 2
PINPOINT TEST N: ONE OR MORE PARKING, REAR OR LICENSE PLATE

LAMP (S) IS/ARE INOPERATIVE
N1: DETERMINE THE FAULT CONDITION......................................................... 417-01-51B/52
N2: CHECK THE FUSE F6 .................................................................................. 417-01-52
N3: DETERMINE THE FAULT CONDITION......................................................... 417-01-52
N4: CHECK THE FUSE F7 .................................................................................. 417-01-52/53
N6: CHECK THE POWER SUPPLY OF FRONT PARKING LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-53
N7: CHECK THE GROUND CONNECTION OF HEADLAMP,
LEFT-HAND SIDE................................................................................................ 417-01-54
N9: CHECK THE POWER SUPPLY OF REAR PARKING LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-54
N10: CHECK THE GROUND CONNECTION OF REAR PARKING LAMP,
LEFT-HAND SIDE................................................................................................ 417-01-55
N11: DETERMINE THE FAULT CONDITION....................................................... 417-01-55
N12: CHECK THE POWER SUPPLY OF FRONT PARKING LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-55
N13: CHECK THE GROUND CONNECTION OF FRONT PARKING LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-56
N14: DETERMINE THE FAULT CONDITION....................................................... 417-01-56
N15: CHECK THE POWER SUPPLY OF REAR PARKING LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-56
N16: CHECK THE GROUND CONNECTION OF REAR PARKING LAMP,
RIGHT-HAND SIDE ............................................................................................. 417-01-57
N17: CHECK THE POWER SUPPLY OF LICENSE PLATE LAMP ...................... 417-01-57
N18: CHECK THE GROUND CONNECTION OF LICENSE PLATE LAMP .......... 417-01-57/58
PINPOINT TEST O: THE PARKING, REAR OR LICENSE PLATE LAMPS
ARE ON CONTINUOUSLY
O1: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION.......... 417-01-58
PINPOINT TEST P: THE PARKING, REAR AND LICENSE PLATE LAMPS ARE
INOPERATIVE
P1: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH .................. 417-01-59
P2: CHECK THE FUSE F15................................................................................. 417-01-59
CONTINUED
TO MODEL INDEX
Pinpoint Tests
PAGE 2 OF 2
P3: CHECK THE POWER SUPPLY OF FUSE F15 ............................................. 417-01-59/60
P4: CHECK THE POWER SUPPLY OF FUSE (S) F6 AND F7 ............................ 417-01-60
CONTINUED
TO MODEL INDEX
417-01-51B Exterior Lighting 417-01-51B

Pinpoint Tests
PINPOINT TEST N: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMP(S) IS/ARE
INOPERATIVE
N1: DETERMINE THE FAULT CONDITION
1.
2 Turn the multifunction switch to the PARKING

LIGHT position.
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
3 Determine the fault condition.
• Are both left-hand parking lamps inoperative?
Yes
GO TO N2
No
GO TO N3
N2: CHECK THE FUSE F6
1 Turn the multifunction switch to the OFF posi-
tion.
2.
Fuse F6 (CJB)
• Is the fuse OK?
Yes
and splice S9, by using the wiring diagrams.
No
• Are both parking lamps, right-hand side and
the license plate lamp inoperative?
Yes
GO TO N4
No
GO TO N5
N4: CHECK THE FUSE F7
tion.
2.
Fuse F7 (CJB)
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
• Is the fuse OK?
Yes
REPAIR the open circuit between fuse F7
and splice S10, by using the wiring
operation.
No
• Is the front parking lamp, left-hand side
inoperative?
Yes
GO TO N6
No
GO TO N8
N6: CHECK THE POWER SUPPLY OF FRONT PARKING LAMP, LEFT-HAND SIDE
tion.
2.
Headlamp, left-
hand side C45
LIGHT position.
LF7 (BK), harness side and ground.
Yes
GO TO N7
No
S9 and headlamp, left-hand side, by using
normal operation.
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
N7: CHECK THE GROUND CONNECTION OF HEADLAMP, LEFT-HAND SIDE
Yes
No
• Is the rear parking lamp, left-hand side
inoperative?
Yes
GO TO N9
No
GO TO N11
N9: CHECK THE POWER SUPPLY OF REAR PARKING LAMP, LEFT-HAND SIDE
1.
Rear lamp as-

sembly, left-hand
side C39
circuit 29S-LF11 (OG/WH), harness side and
ground.
Yes
GO TO N10
No
S9 and rear lamp assembly, left-hand side,
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
N10: CHECK THE GROUND CONNECTION OF REAR PARKING LAMP, LEFT-HAND SIDE
Yes
CHECK the rear lamp assembly, left-hand
No
lamp assembly, left-hand side and ground,
• Is the front parking lamp, right-hand side
inoperative?
Yes
GO TO N12
No
GO TO N14
N12: CHECK THE POWER SUPPLY OF FRONT PARKING LAMP, RIGHT-HAND SIDE
1.
Headlamp, right-
hand side C46
LF16 (OG/GN), harness side and ground.
Yes
GO TO N13
No
S10 and headlamp, right-hand side, by us-
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
N13: CHECK THE GROUND CONNECTION OF FRONT PARKING LAMP, RIGHT-HAND SIDE
Yes
No
• Is the rear parking lamp, right-hand side
inoperative?
Yes
GO TO N15
No
GO TO N17
N15: CHECK THE POWER SUPPLY OF REAR PARKING LAMP, RIGHT-HAND SIDE
1.
Rear lamp as-

sembly, right-hand
side C42
circuit 29S-LF20 (OG), harness side and
ground.
Yes
GO TO N15
No
S10 and rear lamp assembly, right-hand
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
N16: CHECK THE GROUND CONNECTION OF REAR PARKING LAMP, RIGHT-HAND SIDE
Yes
CHECK the rear lamp assembly, right-hand
No
lamp assembly, right-hand side and ground
N17: CHECK THE POWER SUPPLY OF LICENSE PLATE LAMP
1.
License plate
lamp C40a
2 Measure the voltage between License plate
lamp, connector C40a, circuit 29S-LF12
(OG/BK), harness side and ground.
Yes
GO TO N18
No
S10 and license plate lamp, by using the
mal operation.
N18: CHECK THE GROUND CONNECTION OF LICENSE PLATE LAMP

1.
License plate
lamp C40b
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
2 Measure the resistance between license plate
lamp, connector C40b, circuit 31-LF12 (BK),
Yes
CHECK the license plate lamp. If necessary
normal operation.
No
REPAIR the open circuit(s) between license
plate lamp and ground G3, by using the wir-
operation.
PINPOINT TEST O: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON
CONTINUOUSLY
O1: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION
1.
Multifunction
switch C15a
2 Check if the parking lamps are on
continuously.
• Are the parking lamps on continuously?
Yes
connected to multifunction switch, connector
C15a, pin 7, by using the wiring diagrams.
TEST the system for normal operation. If
necessary INSTALL a new CJB.
No
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST P: THE PARKING, REAR AND LICENSE PLATE LAMPS ARE INOPERATIVE
P1: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH
1.
Multifunction
switch C15a
(OG/BK), harness side and ground.
Yes
GO TO P4
No
GO TO P2
P2: CHECK THE FUSE F15

1.
Yes
GO TO P3
No
Fuse F15 (CJB)
P3: CHECK THE POWER SUPPLY OF FUSE F15
1.
Fuse F15 (CJB)
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX
and ground.
Yes
F15 and multifunction switch, by using the
normal operation.
No
REPAIR the power supply of fuse F15, by
P4: CHECK THE POWER SUPPLY OF FUSE (S) F6 AND F7
switch, connector C15a, pin 7, circuit 29S-DB7
(OG/YE), harness side and fuse F6 (5 A) or
fuse F7 (5A).
Yes
No
function switch and fuse(s) F6 and F7, by
CONTINUED
E9427 EN 07/2001 2002 Bantam

TO MODEL INDEX

Reversing Lamps
1. Verify the customer concern. (if possible) before proceeding to the next
2. Visually inspect for obvious signs of step.
mechanical or electrical damage. 4. If the cause is not visually evident, verify the
Electrical
• Fuse(s).
• Bulb(s).
• Wiring harness.
Symptom Chart
Symptom Chart
• The reversing lamp is inopera- • Fuse. • Go To Pinpoint Test Q
tive. • Circuit(s).
• Reversing lamp.
• Transmission switch.
• The reversing lamp is on con- • Circuit(s). • Go To Pinpoint Test R
tinuously. • Transmission switch.
Pinpoint Tests
PINPOINT TEST Q: THE REVERSING LAMP IS INOPERATIVE
Q1: CHECK THE FUSE F13
1. 2.
Fuse F13 (CJB)

• Is the fuse OK?
Yes
GO TO Q2
No
CONTINUED
E6755 EN 07/2001 2002 Bantam

TO MODEL INDEX
Q2: CHECK THE CIRCUIT TO TRANSMISSION SWITCH FOR OPEN
1. 2. 3.
Fuse F13 (CJB) Transmission switch

C51
4 Measure the voltage between transmission
switch, connector C51, pin 2, circuit 14-LG28
(VT/WH), harness side and ground.
Yes
GO TO Q3
No
F13 and transmission switch, by using the
mal operation.
Q3: CHECK THE TRANSMISSION SWITCH FOR PROPER FUNCTION

1.
2 Connect a jumper wire between transmission

switch, connector C51, pin 2, circuit 14-LG28
(VT/WH) and pin 1, circuit 14S-LG36 (VT/BK),
harness side.
3.
• Does the reversing lamp illuminate?
Yes
INSTALL a new transmission switch. TEST
No
GO TO Q4
CONTINUED
E6755 EN 07/2001 2002 Bantam

TO MODEL INDEX
Q4: CHECK THE POWER SUPPLY OF REVERSING LAMP
1. 2. 3.
Reversing lamp
C67
4 Set the transmission in the REVERSE position.
5 Measure the voltage between reversing lamp,
connector C67, circuit 14S-LG36 (VT/BK),
Yes
GO TO Q5
No
REPAIR the open circuit between transmis-
sion switch and reversing lamp, by using the
mal operation.
Q5: CHECK THE GROUND CONNECTION OF REVERSING LAMP

1.
2 Measure the resistance between reversing

lamp, connector C67, circuit 31-LG36 (BK),
Yes
CHECK the reversing lamp. If necessary
normal operation.
No
REPAIR the open circuit(s) between revers-
ing lamp and ground G3, by using the wiring
eration.
CONTINUED
E6755 EN 07/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST R: THE REVERSING LAMPS ARE ON CONTINUOUSLY
R1: CHECK THE REVERSING LAMP SWITCH
1. 2. 3.
• Are the reversing lamps on continuously?
Yes
connected with transmission switch,
connector C51, pin 1, by using the wiring
operation.
Reversing lamp
No
switch C51
INSTALL a new reversing lamp switch.
CONTINUED
E6755 EN 07/2001 2002 Bantam

TO MODEL INDEX

Fog Lamps
Electrical
• Fuse(s).
• Bulb(s).
• Wiring harness.
Symptom Chart
Symptom Chart
• The fog lamps are inoperative. • Fuse(s). • Go To Pinpoint Test S
• Circuit(s).
• Relay – fog lamps.
• Front fog lamp switch.
• The individual fog lamp is inop- • Bulb. • Go To Pinpoint Test T
erative. • Circuit(s).
• Front fog lamp.
• The fog lamps are on continu- • Circuit(s). • Go To Pinpoint Test U
ously. • Relay – fog lamps.
• Front fog lamp switch.
Pinpoint Tests
PINPOINT TEST S: THE FOG LAMPS ARE INOPERATIVE
S1: CHECK THE FUSE F14
1. 2.
Fuse F14 (CJB)
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX
• Is the fuse OK?
Yes
GO TO S2
No
S2: CHECK THE POWER SUPPLY OF FUSE F14
1.
2 Measure the voltage between fuse F14 (CJB)

and ground.
Yes
GO TO S3
No
REPAIR the power supply of fuse F14, by
a new CJB.
S3: CHECK POWER SUPPLY OF RELAY – FOG LAMPS
1. 2.
Fuse F14 (CJB)

3. 4.
Relay – fog
lamps C320
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX
fog lamps, connector C320, pin 5, circuit 14-
LD9 (VT/BK) and ground.
Yes
GO TO S4
No
F14 and relay – fog lamps, by using the wir-
operation.
S4: CHECK THE CONTROL CIRCUIT OF RELAY – FOG LAMPS

LIGHT position.
2 Switch ON the front fog lamps.
fog lamps, connector C320, pin 1, circuit 29S-
LD8 (OG) and ground.
Yes
GO TO S5
No
GO TO S7
S5: CHECK THE GROUND CONNECTION OF RELAY – FOG LAMPS

1.

fog lamps, connector C320, pin 2 and ground.
Yes
GO TO S6
No
fog lamps and ground G6, by using the wir-
operation. If necessary INSTALL a new
CJB.
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX
S6: CHECK THE RELAY – FOG LAMPS FOR PROPER FUNCTION
1.
Relay – fog lamps

C320
fog lamps, connector C320, pin 3, circuit 14S-
LD11 (VT/WH) and pin 5, circuit 14-LD9
(VT/BK).
3.
• Do the front fog lamps illuminate?
Yes
INSTALL a new relay – fog lamps. TEST the
No
REPAIR the open circuit(s) between front
fog lamp, left-hand side and ground G9.
S7: CHECK THE FRONT FOG LAMP SWITCH FOR PROPER FUNCTION
tion.
2.
Front fog lamp

switch C328
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX

3 Connect a jumper wire between front fog lamp
LD10 (OG/GN) and pin 1, circuit 29S-LD8
(OG), harness side.

LIGHT position.
• Do the front fog lamps illuminate?
Yes
INSTALL a new front fog lamp switch. TEST
No
GO TO S8
S8: CHECK THE POWER SUPPLY OF FRONT FOG LAMP SWITCH
1 Measure the voltage between front fog lamp
LD10 (OG/GN), harness side and ground.
Yes
fog lamp switch and relay – fog lamps, by
No
S9 and front fog lamp switch, by using the
mal operation.
PINPOINT TEST T: THE INDIVIDUAL FOG LAMP IS INOPERATIVE
T1: DETERMINE THE INOPERATIVE FRONT FOG LAMP
1.

LIGHT position.
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX
3 Determine the inoperative front fog lamp.
• Is the front fog lamp, left-hand side
inoperative?
Yes
GO TO T2
No
GO TO T3
T2: CHECK THE GROUND CONNECTION OF FRONT FOG LAMP, LEFT-HAND SIDE
1. 2.
Front fog lamp, left-

hand side C184
3 Measure the resistance between front fog
lamp, left-hand side, connector C184, pin 2,
circuit 31-LD11 (BK), harness side and ground.
Yes
fog lamp and front fog lamp, left-hand side,
system for normal operation. If necessary
INSTALL a new front fog lamp.
No
fog lamp, left-hand side and ground G9, by
a new front fog lamp.
T3: CHECK THE GROUND CONNECTION OF FRONT FOG LAMP, RIGHT-HAND SIDE
1. 2.
Front fog lamp,

right-hand side
C183
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX
3 Measure the resistance between front fog
lamp, right-hand side, connector C183, pin 2,
circuit 31-LD17 (BK), harness side and ground.
Yes
fog lamp and front fog lamp, right-hand side,
system for normal operation. If necessary
INSTALL a new front fog lamp.
No
fog lamp, right-hand side and ground G9, by
a new front fog lamp.
PINPOINT TEST U: THE FOG LAMPS ARE ON CONTINUOUSLY
U1: CHECK THE FRONT FOG LAMP SWITCH FOR PROPER FUNCTION
1.
Front fog lamp

switch C328
LIGHT position.
3.
4 Check if the front fog lamps are on

continuously.
• Are the front fog lamps on continuously?
Yes
GO TO U2
No
INSTALL a new front fog lamp switch. TEST
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX

U2: CHECK THE RELAY – FOG LAMPS FOR PROPER FUNCTION
1 Measure the voltage between front fog lamp
switch, connector C328, pin 1, circuit 29S-LD8
(OG), harness side and ground.
Yes
connected with the front fog lamp switch,
operation.
No
INSTALL a new relay – fog lamps. TEST the
Component Tests
Relays
Component testing applies to the following
relays:
• Relay – fog lamps
2. Check relay contact in activated condition.

Connect the terminals of power supply to pins 1
and 2 (VFE0023407).
Measure the resistance between pin 3 and pin 5
(VFE0023407).
1. Check relay contact in normal condition
Is the resistance less than 2 ohm?
Measure the resistance between pin 3 and pin 5
(VFE0023129). If yes, the relay is OK.
Is the resistance less than 2 ohm? If no, INSTALL a new relay.
If yes, INSTALL a new relay.
If no, GO to step 2.
CONTINUED
E9428 EN 07/2001 2002 Bantam

TO MODEL INDEX

Headlamp Assembly (32 115 0)
Removal
1. Remove the front bumper. For additional
2. Remove the headlamp assembly (left-hand

side shown).
• Disconnect the headlamp assembly
Installation
1. NOTE: Position the headlamp assembly with

the guide pin.
2. Adjust the headlamps. For additional

information, refer to Headlamp Adjustment
in this section.
CONTINUED
E6756 EN 07/2001 2002 Bantam

TO MODEL INDEX

Rear Lamp Assembly (32 305 0)
Removal
1. Remove the rear lamp assembly retaining
screws and the electrical connector (Right
hand side shown).
1. Screw.
2. Rear lamp.
3. Rear lamp electrical connector.
2. Unclip the lens cover.
• Push the hook up using your fingers.
4. Remove the bulbs (bayonet fit).
1 Screw
2 Lens
3 Rear turn light bulb
4 Reverse light bulb
5 Brake / taillight bulb.
Installation
NOTE: Ensure the seal is seated correctly to

prevent water ingress.
CONTINUED
E6757 EN 07/2001 2002 Bantam

TO MODEL INDEX
GENERAL PROCEDURES
Headlamp Adjustment
General Equipment
Headlamp beam setting equipment
Adjustment
1. Before starting the headlamp adjustment:
• Place the vehicle on a level surface.
• Check the correct headlamp operation,
and renew damaged components as
necessary.
• Check the tyre inflation.
• Check that no other load is in the vehicle
other than a half tank of gas.
• Set the measuring screen of the beam
setting equipment to the following
headlamp adjustment value (X): X=10
cm/10 m=0 degrees 34 minutes=1.0%.
2. Adjust the low beam.

• Switch on the low beam.
1. Vertical alignment screw.
2. Horizontal alignment screw.
3. Vertical adjustment.
• Adjust the low beam so that the
light/dark boundary touches the horizontal
line.
CONTINUED
E6758 EN 07/2001 2002 Bantam

TO MODEL INDEX
4. NOTE: Some scattered light from the low

beam may lie above the 15 degrees line.
NOTE: After horizontal adjustment readjustment
of the vertical axis might be necessary.
Horizontal adjustment (LHD variant shown).
• Adjust the low beam so that the rising
line of the light/dark boundary lies at the
intersection of horizontal and the 15
degrees line.
CONTINUED
E6758 EN 07/2001 2002 Bantam

TO MODEL INDEX
SPECIFICATIONS
Exterior Lighting
Component Type
Headlamp Reflector system, alignment achieved by adjusting
the reflector
Headlamp Adjustment
X value
Headlamp X = 10 cm/10 m = 0 degrees 34 minutes = 1.0%
Lamp Type Wattage
Halogen headlamp (high/low beam) Bayonet 55/60
Side lamps Push fit 5
Front turn signal lamps Bayonet 21
Side turn signal lamps Push fit 5
Rear turn signal lamps Bayonet 21
Stop lamps/ rear lamps Bayonet 21/5
Reversing lamps Bayonet 21
License plate lamp Bayonet 5
Description Nm
Headlamp assembly retaining bolts 6
CONTINUED
E6759 EN 07/2001 2002 Bantam

418-00-1 Module Communications Network 418-00-1
SECTION 418-00 Module Communications Network

SUBJECT PAGE

Communications Network ...................................................................................................... 418-00-2

Communications Network ...................................................................................................... 418-00-2
Pinpoint Tests ..................................................................................................................... 418-00-3/7
07/2001 2002 Bantam

TO MODEL INDEX

Communications Network
Refer to Wiring Diagrams Petrol and Diesel 3. If an obvious cause for an observed or
Cell: 41800, for schematic and connector information. reported concern is found, correct the cause
Special Tool(s) step.
Terminal probe kit symptom and refer to the symptom Chart.
29-011A
Electrical
• Powertrain control module (PCM).
Inspection and Verification • Anti-theft warning system/ central locking
module.
• Air bag module.
2. Visually inspect for obvious signs of • Connector(s) loose or oxidised.
Symptom Chart
• Powertrain control module • Circuit(s). • Go To Pinpoint Test A
(PCM) does not respond to the • PCM.
WDS.
• Instrument cluster does not re- • Circuit(s). • Go To Pinpoint Test B
spond to the WDS. • Instrument cluster.
• Air bag module does not re- • Circuit(s). • Go To Pinpoint Test C
spond to the WDS. • Air bag module.
• Anti-theft/central locking module • Circuit(s). • Go To Pinpoint Test D
does not respond to the WDS. • Anti-theft/central locking mod-
ule.
• Not one of the installed modules • Circuit(s). • Go To Pinpoint Test E
responds to the WDS.
• The diagnostic tester does not • Circuit(s). • CHECK with the WDS.
power up.
CONTINUED
E6360 EN 07/2001 2002 Bantam

TO MODEL INDEX

Pinpoint Tests
PINPOINT TEST A: POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE
WDS
A1: CHECK THE ISO 9141 LINE TO THE PCM FOR OPEN
1. 2.
PCM C43
3 Measure the resistance between PCM,
connector C43, pin 55, circuit 4-PB10 (GY/VT),
harness side and data link connector C31, pin
7, circuit 4-DA1 (GY), harness side.
Yes
CHECK the PCM. If necessary INSTALL a
new one. TEST the system for normal
operation.
No
REPAIR the open circuit(s) between PCM
and data link connector by using the wiring
eration.
PINPOINT TEST B: INSTRUMENT CLUSTER DOES NOT RESPOND TO THE WDS
B1: CHECK THE ISO 9141 LINE TO THE INSTRUMENT CLUSTER FOR OPEN
1. 2.
Instrument cluster
C37
CONTINUED
E9429 EN 07/2001 2002 Bantam

TO MODEL INDEX
3 Measure the resistance between instrument
cluster, connector C37, pin 9, circuit 4-EE8
(GY/VT), harness side and data link connector
C31, pin 7, circuit 4-DA1 (GY), harness side.
Yes
normal operation.
No
ment cluster and data link connector by us-
PINPOINT TEST C: AIR BAG MODULE DOES NOT RESPOND TO THE WDS
C1: CHECK THE ISO 9141 LINE TO THE AIR BAG MODULE FOR OPEN
1. 2.
Air bag module

C330
3 Measure the resistance between air bag
module, connector C334, pin 7, circuit 4-JA7
(GY/RD), harness side and data link connector
C31, pin 7, circuit 4-DA1 (GY), harness side.
Yes
CHECK the air bag module. If necessary
normal operation.
No
ment cluster and data link connector by us-
CONTINUED
E9429 EN 07/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST D: ANTI-THEFT/CENTRAL LOCKING MODULE DOES NOT RESPOND TO THE
WDS
D1: CHECK THE ISO 9141 LINE TO THE ANTI-THEFT/CENTRAL LOCKING MODULE FOR OPEN
1. 2.
Anti-theft/central
locking module
C330
3 Measure the resistance between anti-
theft/central locking module, connector C330,
pin 17, circuit 4-MB13 (GY), harness side and
data link connector C31, pin 7, circuit 4-DA1
(GY), harness side.
Yes
CHECK the anti-theft/central locking
module. If necessary INSTALL a new one.
No
REPAIR the open circuit(s) between anti-
theft/central locking module and data link
connector by using the wiring diagrams.
PINPOINT TEST E: NO ONE OF THE INSTALLED MODULES RESPONDS TO THE WDS
1. 2.
• Is the fuse OK?
Yes
GO TO E2
No
Fuse F2 (CJB)
mal operation.
1. 2.
Fuse F2 (CJB)
CONTINUED
E9429 EN 07/2001 2002 Bantam

TO MODEL INDEX

ground.
Yes
GO TO E3
No
REPAIR the power supply of the fuse F2 by
using the wiring diagrams by using the wir-
operation.
E3: CHECK THE POWER SUPPLY OF THE DATA LINK CONNECTOR
1.
2 Measure the voltage between data link

connector C31, pin 16, circuit 29-PB9 (OG),
Yes
GO TO E4
No
and data link connector by using the wiring
eration.
E4: CHECK THE GROUND CONNECTION OF THE DATA LINK CONNECTOR

1.
2 Measure the resistance between data link

connector C31, pin 5, circuit 91-PC3 (BK/BU)
and pin 4, circuit 31-PB9 (BK), harness side
against ground.
• Is the resistance in both measurements less
than 2 ohms?
Yes
GO TO E5
No
REPAIR the open circuit(s) between data
link connector and ground G1 or G8, by us-
CONTINUED
E9429 EN 07/2001 2002 Bantam

TO MODEL INDEX

E5: CHECK THE ISO 9141 LINE TO THE ANTI-THEFT/CENTRAL LOCKING MODULE FOR OPEN
1. 2.
Anti-theft/central
locking module
C330
3 Measure the resistance between anti-
theft/central locking module, connector C330,
pin 17, circuit 4-MB13 (GY), harness side and
data link connector C31, pin 7, circuit 4-DA1
(GY), harness side.
Yes
CHECK with the WDS.
No
S74 and data link connector by using the
mal operation.
CONTINUED
E9429 EN 07/2001 2002 Bantam

419-01B-1 Anti-Theft — Passive 419-01B-1
SECTION 419-01B Anti-Theft — Passive

SUBJECT PAGE
Anti-Theft ............................................................................................................................... 419-01B-2

Passive Anti-Theft System (PATS) ..................................................................................... 419-01B-2
Keys .................................................................................................................................... 419-01B-2
Key Programming ............................................................................................................... 419-01B-2
Anti-Theft ............................................................................................................................... 419-01B-3

Principles of Operation........................................................................................................ 419-01B-3
Inspection and Verification .................................................................................................. 419-01B-4
Symptom Chart ................................................................................................................... 419-01B-5/6
Pinpoint Tests ..................................................................................................................... 419-01B-6/10
Passive Anti-Theft System (PATS) Module ........................................................................... 419-01B-11

Fuel Injection Pump Actuator — Vehicles with Diesel Engine ............................................... 419-01B-12/15
Passive-Theft System (PATS) Transceiver ..................................................... (33 662 0) 419-01B-16
GENERAL PROCEDURES
Key Programming Using Two Programmed Keys ........................................... (33 005 0) 419-01B-17/18
Key Programming Switch State Control................................................................................. 419-01B-19
Erasing All Key Codes Using Diagnostic Equipment ....................................... (33 005 0) 419-01B-20/21
Anti-Theft Security Access............................................................................... (33 004 0) 419-01B-22
07/2001 2002 Bantam

programme additional keys by the owner /

operator. Up to a maximum of eight keys may be
Passive Anti-Theft System (PATS) programmed to the system
The Passive Anti-Theft System (PATS) is fully
passive in operation and requires no special
Key Programming
procedures by the driver to arm or disarm the
system. It is invisible to normal scrutiny and is NOTE: Additional keys can only be programmed
operated by a miniature transponder within the with the two `known' PATS keys (A and B) or
key body. This communicates with the module with WDS.
through a transceiver mounted around the NOTE: This procedure can be repeated after 20
ignition switch lock barrel. seconds. If programming is unsuccessful, the anti
The PATS functionality for vehicles fitted with a -theft indicator LED will flash when the ignition is
manual transmission is incorporated within the switched on with the key that was being
powertrain control module. programmed.
PATS may be identified by the ignition key, which Insert key A into the ignition switch and turn to
has an imprint in the casing (usually red) position II.
indicating the presence of the transponder that Turn the key to position 0 and remove key A from
controls the system. the ignition switch.
The transponder code reading is carried out Insert key B into the ignition switch and turn to
when the key, having been inserted into the position II.
ignition lock barrel, is turned from position `0' to
position ÌII' to crank the engine. If the control Turn the key to position 0 and remove key B from
module receives the correct code signal, the the ignition switch.
engine will start. Should the code received not be Insert the new key into the ignition switch and
recognised, the engine will not crank as the turn to position II.
PATS is still armed and the engine is still
immobilised. Remove the key from the ignition switch. The key
is now programmed.
Keys
The 2002 Bantam have two keys allocated to
every new vehicle. Both keys are required to
E6478 EN 07/2001 2002 Bantam

TO MODEL INDEX
Anti-Theft
seconds, turn the ignition key to the position 0
and remove the key. Then turn the ignition key to
Principles of Operation the position II with the correct programmed key.
The passive anti-theft system (PATS) uses radio
PATS Control Function
frequency identification technology to deter a
drive away theft. Passive means that it does not The PATS control function is contained in the
require any activity from the user. PCM. This module carries out all of the PATS
functions, such as receiving the identification
With this PATS system:
code from the encoded ignition key and
• No master key is required. controlling engine and starter enable. The PATS
• VIN data is stored within the powertrain control function initiates the key interrogation
control module (PCM). sequence when the vehicle ignition switch is
• Has fleet customer features. turned to position II or position III.
• Spare key learning and erasing is possible. Transceiver Module
CAUTION: There are two different types The transceiver module communicates with the
of encoded PATS keys. One with a red encoded ignition key. This module is located on
tag on the key, the other with a blue tag. the ignition key lock cylinder casting and contains
The PATS keys for this vehicle must an antenna connected to a small electronics
have a red tag or damage may be caused module. During each vehicle start sequence, the
to the control module when used. transceiver module reads the encoded ignition
key identification code and sends data to the
Encoded Ignition Key
PATS control function within the PCM. No
configuration is required with the installation of a
The PATS uses a specially encoded ignition key. new PATS transceiver.
Each encoded ignition key contains a
Anti-Theft Indicator
permanently installed electronic device called a
transponder. Each transponder contains a unique The PATS system uses a visual anti-theft
electronic identification code from millions of indicator that is controlled by the PATS control
combinations. Each encoded ignition key must be function. This indicator will self-test for three
programmed into the vehicles PATS Control seconds when the ignition switch is turned to
Function within the Powertrain Control Module position II or position III under normal operation.
(PCM) before it can be used to start the engine. If there is a PATS problem, this indicator will
There are special diagnostic repair procedures either flash rapidly or glow steadily when the
outlined in this manual that must be carried out if ignition switch is turned to position II or position
an encoded ignition key needs to be changed. III and then it will flash a fault code 10 times.
The PATS keys have a red transponder within Refer to the Diagnostic Trouble Code (DTC)
the head of the key. Only Ford approved ignition Index in this section or connect WDS and follow
keys should be used as some aftermarket the on-screen instructions. The PATS system
encoded ignition keys not purchased from a Ford also flashes the anti-theft indicator every two
approved source may fail to operate especially at seconds at ignition 0 to act as a visual deterrent.
high or low temperatures. A minimum of 2
Starter Relay
encoded ignition keys must be programmed to a
vehicle in order for the engine to start. A The starter relay is also used as an additional
maximum of 8 ignition keys can be programmed means of disabling the vehicle engine. The relay
to a vehicle. The PATS control function within the is disabled when PATS cannot read an encoded
PCM will enter Anti-Scan Mode if a non- ignition key at ignition position II. However, the
programmed ignition key (with the correct system will not store a DTC or flash the anti-theft
mechanical cut) is used to start the engine. indicator if a valid ignition key is read but a fault
occurs in the starter relay circuit. REFER to
NOTE: If a non-programmed key has been used,
Section 303-06. The relay is enabled when PATS
any further key reading is inhibited for 20
control function reads a valid encoded ignition
seconds. During these 20 seconds, no ignition
key at ignition II. The PATS will be activated and
key will start the engine. To exit anti-scan mode
will disable the vehicle from starting if there is a:
turn the ignition key to the position II and wait 30
CONTINUED
E4861 EN 07/2001 2002 Bantam
TO MODEL INDEX
• Damaged encoded ignition key Visual Inspection Chart

• Un-programmed key Mechanical Electrical
• Non-encoded key (key has no transponder or
• Ignition lock cylinder • Central Junction Box
is not the correct transponder key)
• PATS key (CJB) fuse 12 (15A)
• Damaged wiring • Use of a non-PATS • Battery Junction Box
• Damaged transceiver key (BJB) fuse 9 (20A)
• Damaged PCM • More than one PATS • PCM
• Shielded ignition key key or metal object on • Ignition switch
key chain (key • Loose or corroded
shielded by metal) connection(s)
• Using a non-encoded • PATS transceiver
ignition key • Starter relay
1. Verify the customer concern by operating the • Using a non-
system. programmed encoded
2. Visually inspect for obvious signs of ignition key
mechanical or electrical damage. • Using the incorrect
PATS key for the ve-
hicle

step.
the symptom and use WDS in conjunction
with the following Symptom Chart and Pin-
point Tests.
Diagnostic Trouble Code (DTC) Index
WDS DTC Indicator Description/Condition Possible Action
Flash Code Source
0000 - No DTC's, vehicle OK
B1681 11 Transceiver module signal is not Transceiver GO to Pinpoint
connected or wiring damage. Vehi- wiring trans- Test A.
cle does not start ceiver connec-
tor, transceiver
or PCM
B2103 12 Transceiver antenna coil fault Vehi- Transceiver Install a new
cle does not start transceiver.
B1600 13 Non-PATS key or damaged en- PATS en- REFER to
coded ignition key, or no key code coded ignition WDS. PATS
received. Vehicle does not start key test. Follow
the instruc-
tions.
B2431 13 Transponder programming failed. Ignition key REFER to
Vehicle does not start WDS. PATS
test. Follow
the instruc-
tions.
CONTINUED
E4861 EN 07/2001 2002 Bantam

TO MODEL INDEX
WDS DTC Indicator Description/Condition Possible Action

Flash Code Source
B1602 14 Partial key read of PATS key. Vehi- PATS en- REFER to
cle does not start coded ignition WDS. PATS
key. Trans- test. Follow
ceiver the instruc-
tions.
B1601 15 Incorrect key code, Un-programmed PATS en- REFER to
PATS key (keycode format OK) Ve- coded ignition WDS. PATS
hicle does not start (20 second anti- key test. Follow
scan invoked) the instruc-
tions.
U1900 16 ISO communication link to the PCM. Circuit or PCM REFER to
Vehicle does not start WDS. PATS
test. Follow
the instruc-
tions.
B1213 21 Number of programmed PATS en- Incorrect REFER to
coded keys below minimum. Vehicle number of WDS. PATS
does not start keys pro- test. Follow
grammed or the instruc-
PATS en- tions.
coded ignition
key
B2141 22 Non-volatile memory configuration New PCM REFER to
failure. Vehicle does not start WDS. PATS
test. Follow
the instruc-
tions. Re-
initialise the
system.
Symptom Chart

• The anti-theft indicator is always • Fuse. • Carry out WDS PATS test. Fol-
/ never on – no anti-theft indica- • Circuit. low the instructions.
tor self-test • Anti-theft LED.
• PCM.
• The anti-theft system does not • Starter relay. • GO to Pinpoint Test B.
operate correctly – engine does • PCM.
not crank but the anti-theft LED • Circuit.
self-test normally.
• Engine does not start • Not a PATS concern (no fuel) • If a PATS concern, check for
• PATS concern LED flashing fault code or carry
out WDS PATS test. Follow the
instructions.
CONTINUED
E4861 EN 07/2001 2002 Bantam

TO MODEL INDEX
Pinpoint Tests
PINPOINT TEST A: PATS TRANSCEIVER SIGNAL IS NOT RECEIVED
A1: CHECK THE TRANSCEIVER POWER CIRCUIT FOR VOLTAGE – CIRCUIT 7-MB37 (YE/GN)
1. 2. 3.
PATS Transceiver
C54
4 Using a digital multimeter, measure the voltage
between PATS transceiver C54 pin 1, circuit 7-
MB37 (YE/GN), harness side and ground.
Yes
GO TO A2
No
REPAIR circuit 7-MB37 (YE/GN). REPEAT
the self-test. CLEAR the DTCs.
A2: CHECK THE TRANSCEIVER GROUND FOR OPEN – CIRCUIT 91-MB37 (BK/GN)
1.

resistance between PATS transceiver C54 pin
2, circuit 91-MB37 (BK/GN), harness side and
ground.
Yes
GO TO A3
No
REPAIR circuit 91-MB37 (BK/GN). REPEAT
CONTINUED
E4861 EN 07/2001 2002 Bantam

TO MODEL INDEX
A3: CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR VOLTAGE – CIRCUIT 10-MB37
(GY/OG)
1. 2.
PATS Trans-
ceiver C54
by carefully back probing between PATS
transceiver C54 pin 3, circuit 10-MB37
(GY/OG), harness side and ground.
Yes
GO TO A6
No
GO TO A4
A4: CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR SHORT TO GROUND – CIRCUIT 10-
MB37 (GY/OG)
NOTE: When a new PCM is installed, the encoded ignition keys must be reprogrammed.
1. 2. 3.
PCM C165 PATS Transceiver

C54
3, circuit 10-MB37 (GY/OG), harness side and
ground.
Yes
GO TO A5
No
REPAIR circuit 10-MB37 (GY/OG). CLEAR
the DTCs. REPEAT the self-test. If the sys-
tem fails again, INSTALL a new PCM.
REFER to Section 303-14 / 303-14B /
303-14C / 303-14D.
CONTINUED
E4861 EN 07/2001 2002 Bantam

TO MODEL INDEX
A5: CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR OPEN-CIRCUIT
resistance between the PATS transceiver C54
pin 3, circuit 10-MB37 (GY/OG), harness side
and PCM C165 pin 38, circuit 10-MB37
(GY/OG), harness side.
Yes
INSTALL a new PCM. REFER to Section
303-14 / 303-14B / 303-14C / 303-14D.
REPROGRAM the encoded ignition keys.
REFER to Key Programming in this section .
REPEAT the self-test. CLEAR the DTC's.
No
REPAIR circuit 10-MB37 (GY/OG). CLEAR
the DTCs. REPEAT the self-test.
A6: CHECK THE TRANSCEIVER RECEIVE CIRCUIT FOR VOLTAGE – CIRCUIT 8-MB37 (WH/GN)
1. 2. 3.
PCM C165 PATS Transceiver

C54
by carefully back probing between PATS
transceiver C54 pin 4, circuit 8-MB37
(WH/GN), harness side and ground.
Yes
INSTALL a new PATS transceiver. REFER
to Module - Transceiver in this section.
REPEAT the self-test. Clear the DTC's.
No
GO TO A7
A7: CHECK THE TRANSCEIVER RECEIVE CIRCUIT FOR SHORT TO GROUND – TRANSCEIVER
CONNECTED
1. 2.
PCM C165
CONTINUED
E4861 EN 07/2001 2002 Bantam

TO MODEL INDEX
resistance between PCM C165 pin 5, circuit 8-
MB37 (WH/GN) harness side and ground.
Yes
GO TO A8
No
REPAIR circuit 8-MB37 (WH/GN). REPEAT
A8: CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR SHORT TO GROUND –

TRANSCEIVER DISCONNECTED
1.
PATS Transceiver
C54
4, circuit 8-MB37 (WH/GN), harness side and
ground.
Yes
INSTALL a new PATS transceiver. REFER
to Module-Transceiver in this section .
REPEAT the self-test. CLEAR the DTCs.
No
REPAIR circuit 8-MB37 (WH/GN). REPEAT
PINPOINT TEST B: THE ANTI—THEFT SYSTEM DOES NOT OPERATE CORRECTLY – ENGINE
DOES NOT CRANK BUT ANTI-THEFT LED PROVES OUT NORMALLY
B1: CHECK THE STARTING SYSTEM GROUND
1. 2. 3.
Starter Relay C156
CONTINUED
E4861 EN 07/2001 2002 Bantam

resistance between starter relay C156 pin 1,
circuit 31S-MB36A (BK/BU), harness side and
ground while holding the key in position III.
Yes
DIAGNOSE the starting system.
No
GO TO B2
B2: CHECK CIRCUIT 31S-MB36A (BK/BU) FOR OPEN

NOTE: When a new PCM is installed, the encoded ignition keys must be reprogrammed TURN the ig-
nition to position 0 then to position II. RETRIEVE DTCs. If PATS DTCs are present, GO to Powertrain
Control Module (PCM) Diagnostic Trouble Code (DTC) Index. If no DTCs are retrieved, the PATS sys-
tem is OK.
1. 2.
PCM C165
resistance between PCM C165 pin 32, and
starter relay pin 1, circuit 31S-MB36A (BK/BU).
Yes
INSTALL a new PCM. REFER to Section
303-14 / 303-14B / 303-14C / 303-14D.
REPROGRAM the encoded ignition keys.
REFER to Key Programming in this section .
No
REPAIR circuit 31S-MB36A (BK/BU). TEST
E4861 EN 07/2001 2002 Bantam

Passive Anti-Theft System (PATS) Module
NOTE: The immobiliser (PATS) functionality for

petrol engine variants with manual transmission is
incorporated in the powertrain control module.
NOTE: When fitting a new immobiliser (PATS)
module the new module must be coded to the im-
mobiliser system. To code the system two valid
keys must be available before fitting a new module.
NOTE: If two valid keys are not available it will be
necessary to code the system using WDS.
Removal
2. Remove the left hand side cowl side trim

panel, for further information
3. Detach the Powertrain Control Module

(PCM) for further information
4. Disconnect the multiplug and remove the

PCM module.
Installation
E6378 EN 07/2001 2002 Bantam

TO MODEL INDEX
Fuel Injection Pump Actuator — Vehicles with Diesel Engine
Removal
2. Remove the wax stat cable adjusting clip.
3. Detach the wax stat cable from the fuel

injection pump.
4. Detach the accelerator cable mounting

bracket (two bolts).
CONTINUED
E6379 EN 07/2001 2002 Bantam

TO MODEL INDEX
5. Detach the fuel supply pipe from the two

retaining clips.
6. Remove the injector delivery pipes
7. CAUTION: When disconnecting the

multiplug do not pull on the wiring;
Disconnect the fuel injection pump wiring
multiplug.
8. NOTE: When dismantling multiplugs /

connectors refer to Connector Repair
Procedure in the appropriate wiring diagram.
Remove the multiplug terminal spacer.
9. NOTE: Note the positions of the terminals in

the multiplug before removing the terminals.
Remove the immobiliser solenoid terminals
from the multiplug.
CONTINUED
E6379 EN 07/2001 2002 Bantam

TO MODEL INDEX
10. Detach the accelerator damper and

immobiliser solenoid wiring from the fuel
injection pump.
11. Remove the immobiliser solenoid shield

(five bolts).
12. Remove the immobiliser solenoid (two

bolts) (fuel injection pump shown removed
for clarity).
CONTINUED
E6379 EN 07/2001 2002 Bantam

TO MODEL INDEX
Installation
CONTINUED
E6379 EN 07/2001 2002 Bantam

TO MODEL INDEX
Passive-Theft System (PATS) Transceiver (33 662 0)
Removal
1. Remove the steering column lower shroud.
2. Disconnect the passive anti-theft system

(PATS) transceiver electrical connector.

1. Remove the PATS transceiver retaining
screw.
Installation
CONTINUED
E4862 EN 07/2001 2002 Bantam

TO MODEL INDEX
GENERAL PROCEDURES
Key Programming Using Two Programmed Keys (33 005 0)
NOTE: This procedure only works if two or more

programmed ignition keys are available and it is
desired to program additional key(s). If two keys
are not available, refer to Key Programming-
Erase All Keys and Program Two Keys in this
section
NOTE: The Spare Key Programming Switch is a
WDS programmable switch, which provides the
capability to enable / disable the normal cus-
tomer Spare Key Programming Procedure. If the
Spare Key Programming Switch is not enabled,
refer to Security Access then select Spare Key
Programming Switch; Enabled.
NOTE: If the programming procedure is not
successful, the new key(s) will not start the ve-
hicle and the anti-theft indicator will flash. If the
programming procedure was not successful
leave the ignition switch in the RUN position for
at least 30 seconds, repeat the Key Program-
ming procedure from step 1. If the failure re-
peats, refer to Diagnostic and testing to review
DTCs an carry out Pinpoint Tests.
NOTE: A maximum of eight ignition keys can be
programmed to a passive anti-theft system
(PATS) equipped vehicle.
NOTE: If the steps are not carried out as out-
lined, the programming procedure will end.
NOTE: Ignition keys must have correct me-
chanical key cut for the vehicle and must be a
PATS encoded key.
1. Insert the first programmed key into the
ignition lock cylinder and turn the lock
cylinder from the OFF position to the RUN
position (maintain ignition lock cylinder in
the RUN position for one second).
2. Turn ignition lock cylinder to the OFF

position and remove the first key from the
ignition lock cylinder.
3. Within five seconds of turning the ignition

lock cylinder to the OFF position, insert the
second programmed ignition key into the
ignition lock cylinder and turn the ignition
lock from the OFF position to the RUN
position (maintain the ignition lock cylinder
in the RUN position for one second).
CONTINUED
E3809 EN 07/2001 2002 Bantam

TO MODEL INDEX
4. Turn the ignition lock cylinder to the OFF

position and remove the second key from
the lock cylinder.
5. Within ten seconds of turning the ignition

lock cylinder to the OFF position, insert the
un-programmed ignition key (new key) into
the lock cylinder and turn the lock cylinder
from the OFF position to the RUN position
(maintain the ignition lock cylinder in the
RUN position for less than 5 seconds).
6. Check the new-programmed key starts the

engine. Turn the ignition key to the OFF
position for five seconds then try to start
vehicle with the new programmed key.
7. To programme additional key(s), repeat the

applicable key programming procedure
from step 1.
CONTINUED
E3809 EN 07/2001 2002 Bantam

TO MODEL INDEX
GENERAL PROCEDURES
Key Programming Switch State Control
NOTE: The Spare Key Programming Switch is a

WDS programmable switch which provides the
capability to enable / disable the normal cus-
tomer Spare Key Programming Procedure de-
tailed in the owner's manual (customer scan
program a spare ignition key by cycling two pro-
grammed ignition keys and then cycling the new
key). This programmable switch is provided as a
convenience for rental company fleets or other
fleet purchasers who may not want the Spare
Key Programming procedure available to the
vehicle driver.
NOTE: The default setting on delivery of all new
vehicles is ENABLE.
1. Insert a programmed ignition key into the
cylinder from the OFF position to the RUN
position.
2. Using WDS select powertrain control

module (PCM) from the menu.
3. Select Security Access. For additional

information, refer to Security Access in this
section
4. Using WDS select Spare Key Programming

Switch from the menu. Follow the on-
screen directions.
CONTINUED
E3811 EN 07/2001 2002 Bantam

TO MODEL INDEX
GENERAL PROCEDURES
Erasing All Key Codes Using Diagnostic Equipment (33 005 0)
NOTE: This procedure is used when a customer

needs keys programmed into the system and
does not have two programmed ignition keys
available. This procedure is also useful when
programmed ignition key(s) have been lost or
when the ignition lock cylinder has been re-
placed or when you are required to erase a
key(s) from the passive anti-theft alarm system
(PATS) memory.
NOTE: This procedure will erase all pro-
grammed ignition keys from the vehicle memory
and the vehicle will not start until two keys have
been reprogrammed to the vehicle.
NOTE: Two PATS encoded keys with the cor-
rect mechanical cut must be available to carry
out this procedure. One or both of them may be
the original keys.
NOTE: If the remaining keys are with the cus-
tomer and are not available with the vehicle,
then instruct the customer to refer to the
Owner's Manual under the Programming Spare
PATS Key Procedure, for instructions on pro-
gramming the remaining keys.
1. Turn the ignition lock cylinder from the OFF
position to the RUN position.
2. Using WDS select Powertrain control

module (PCM) from the menu. Obtain
security access. For additional
information, refer to Security Access in this
section
3. Using WDS menu select Ignition Key Code

Erase.
4. Turn the ignition lock cylinder to the OFF

position and disconnect WDS.
5. Insert the first encoded key into the ignition

lock cylinder and turn the lock cylinder to
the RUN position for three seconds.
6. Remove the first encoded key from the

7. Insert the second encoded key into the

cylinder to the RUN position for three
seconds.
8. Remove the second encoded key from the

CONTINUED
E3810 EN 07/2001 2002 Bantam

TO MODEL INDEX
9. The vehicle should now start with both

ignition keys.
CONTINUED
E3810 EN 07/2001 2002 Bantam

TO MODEL INDEX
GENERAL PROCEDURES
Anti-Theft Security Access (33 004 0)
NOTE: This procedure is utilized to obtain pas-

sive anti-theft system (PATS) security access.
PATS security access must be granted to erase
ignition key codes or enable/disable the spare
key programming switch. This procedure in-
vokes an inherent 10 minute time delay prior to
granting security access during which WDS
must remain connected to the vehicle. Once se-
curity access has been granted, a security ac-
cess command menu is displayed which offers
various command options.
NOTE: Once security access has been granted,

multiple security access commands should be
executed (if necessary) prior to exiting the
command menu. This avoids repeating the pro-
cedure and thus avoids any additional 10 minute
time delay.
1. Use WDS to obtain anti-theft security
access.
2. After the 10 minute security access

procedure has been completed, a new
menu will be displayed with command
options. Select the function as required
before exiting out of this menu. (do not
select more functions than the procedure
calls for). Once exited out of this menu, the
security access procedure must be carried
out again to carry out additional commands.
CONTINUED
E3812 EN 07/2001 2002 Bantam

Group
Body and Paint
SECTION TITLE
5 PAGE
Body
Interior Trim and Ornamentation 501-05
Rear View Mirrors 501-09
Seating 501-10
Glass, Frames and Mechanisms 501-11
Instrument Panel 501-12
Handles, Locks, latches and Entry Systems 501-14
Wipers and Washers 501-16
Bumpers 501-19
Occupant Restraint - Active 501-20A
Occupant Restraint - Passive - Supplementary Air Bag System 501-20B
Uni-Body, Subframe and

Mounting Frame.
Uni-Body, Subframe and Mounting Frame - General Information 502-00
501-05-1 Interior Trim and Ornamentation 501-05-1
SECTION 501-05 Interior Trim and Ornamentation

SUBJECT PAGE

Interior Trim ......................................................................................................................... 501-05-2

Front Door Trim Panel .................................................................................... (43 705 0) 501-05-3/5
Headliner ........................................................................................................ (43 612 0) 501-05-6/7
A-Pillar Trim Panel .......................................................................................... (43 616 0) 501-05-8
B-Pillar Trim Panel .......................................................................................... (43 617 0) 501-05-9/10
Cab Back Panel Trim Panel ............................................................................ (43 618 0) 501-05-11
SPECIFICATIONS
Specifications....................................................................................................................... 501-05-12
07/2001 2002 Bantam


Interior Trim
This section covers removal and installation of component before removal of the desired
the interior mouldings and trim panels. In most component.
instances, one component overlaps another The headliner is a one-piece design covering the
component. If this condition is found, it will be entire interior roof and is made of a moulded
necessary to loosen or remove the overlapping composite with a cloth covering.
The vehicle is carpeted throughout.
07/2001 2002 Bantam


Front Door Trim Panel (43 705 0)
Removal
All vehicles
1. Remove the remote control lever bezel.

1. Remove the screw cover.
2. Remove the screw.
Vehicles with Power Windows

2. Remove the power window switch and the
exterior rear view mirror switch (if
equipped).
1. Pry out the switches.
Vehicles with Manual Windows
3. Remove the window regulator handle.

• Use a suitable piece of hooked wire or
similar.
07/2001 2002 Bantam

Vehicles with Manual Windows
4. Remove two retaining screws.
Vehicles with electric Power Windows.
5. Remove the two trim panel retaining

screws.
Vehicles with electric Power Windows.

6. Remove the door mirror bezel.
07/2001 2002 Bantam

Vehicles with Manual Mirrors
7. Detach the mirror inner trim panel.

1. Remove the blanking plug.
8. Remove the mirror inner trim panel.

1. Unlock the remote control lever cover.
2. Remove the remote control lever cover.
All vehicles.
9. Remove the door panel.
• Pry the eight retaining clips out from the
door panel.
Installation
07/2001 2002 Bantam


Headliner (43 612 0)
Removal
1. Remove the A-pillar trim panels. For
refer to A-Pillar Trim Panel in this section.
2. Remove the rear panel trim panel. For

refer to Rear Trim Panel in this section.
3. Remove the B-pillar trim panels. For

refer to B-Pillar Trim Panel in this section.
4. Remove the sun visors.
5. Remove the sun visor clips.
6. Detach the interior lamp.
07/2001 2002 Bantam

7. Disconnect the electrical connectors and

remove the interior lamp.
8. Remove the passenger assist handle.
9. CAUTION: When removing fasteners,

take extreme care, as they may be
easily broken.
NOTE: Remove the headliner rear fastener
centre pins before removing the fasteners.
Remove the headliner rear fasteners.
10. Recline both front seats.
11. Remove the headliner through the door

opening.
Installation
07/2001 2002 Bantam


A-Pillar Trim Panel (43 616 0)
Removal
1. Locally detach the door aperture weather-
strip.
2. Remove the A-pillar trim panel (three clips).
Installation
07/2001 2002 Bantam


B-Pillar Trim Panel (43 617 0)
1. Detach the upper front seat belt anchor bolt
(one Torx bolt).
2. CAUTION: Extreme care should be

used when removing items of trim, as
retaining clips are easily broken.
Fully recline both seats and remove the cab

back panel trim (six clips).

Unclip and remove the trim (five clips).
07/2001 2002 Bantam

Installation
38 Nm
07/2001 07/2001 2002 Bantam


Cab Back Panel Trim (Plastic Panel)
Removal

Fully recline both seats and remove the cab

back panel trim (six clips).
Installation
07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Safety belt anchor bolts 38
07/2001 2002 Bantam

501-09-1 Rear View Mirrors 501-09-1
SECTION 501-09 Rear View Mirrors

SUBJECT PAGE

Rear View Mirrors .................................................................................................................. 501-09-2
Symptom Chart ................................................................................................................... 501-09-2
Pinpoint Test ....................................................................................................................... 501-09-2/8

Exterior Mirror - Electrically Operated.................................................................................... 501-09-9/10
Exterior Mirror - Manually Operated……………………………………………………………… 501-09-11/12
Glass removal………………………………………………………………………………………. 501-09-13
2002 Bantam

Rear View Mirrors
Refer to Wiring Diagrams
Cell: 50109, Rear View Mirrors Relay
for schematic and connector information. Electrical connector(s)
Switch
mechanical and electrical damage.
Visual Inspection Chart step.
Mechanical Electrical 4. If the cause is not visually evident, verify the
Exterior mirror(s) Fuse(s)
Symptom Chart
• The mirrors are inoperative • Exterior mirror control switch. • CARRY OUT the Exterior Mirror
Control Switch Component Test.
• Circuit(s). • Go To Pinpoint Test A
• A single mirror is inoperative • Exterior mirror control switch. • CARRY OUT the Exterior Mirror
Control Switch Component Test.
• Circuit(s). • Go To Pinpoint Test B
• Exterior mirror motor(s).
• A single mirror does not function • Exterior mirror control switch. • CARRY OUT the Exterior Mirror
with switch logic Control Switch Component Test.
• Circuit(s). • Go To Pinpoint Test C
• Exterior mirror motor(s).
Pinpoint Test
NOTE: Use a digital multimeter for all electrical
measurements.
07/2001 2002 Bantam


PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE
A1: CHECK THE VOLTAGE TO THE EXTERIOR MIRROR CONTROL SWITCH CIRCUIT 29-AD12
(OG/YE)
1.
Exterior Mirror
Control Switch
C325
2 Measure the voltage between the exterior
mirror control switch C325 pin 6, circuit 29-
AD12 (OG/YE), harness side and ground.
Yes
GO TO A2
No
REPAIR circuit 29-AD12 (OG/YE). TEST
A2: CHECK CIRCUIT 31-AD12 (BK) FOR CONTINUITY

1 Measure the resistance between the exterior
AD12 (BK), harness side and ground.
Yes
GO TO A3
No
REPAIR circuit 31-AD12 (BK). TEST the
A3: CHECK CIRCUIT 9-AD1 (BN/RD) FOR CONTINUITY

1.
Driver Door A - pil-

lar C24
07/2001 2002 Bantam


mirror control switch C325 pin 3, circuit 9-AD1
(BN/RD) harness side, and the driver door A-
pillar C24 pin 3, circuit 9-AD17 (BN/GN)
harness side.
Yes
No
REPAIR circuit 9-AD1 (BN/RD). TEST the
PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE

B1: CHECK FOR CONTINUITY TO THE INOPERATIVE EXTERIOR MIRROR
1.
Exterior Mirror
Control Switch
C325
2 Measure the resistance between:
NOTE: Driver Exterior Mirror
- the exterior mirror control switch C325 pin 3,
circuit 9-AD1 (BN/RD) and pin 2, circuit 10-
AD8 (GY/VT) harness side.
NOTE: Passenger Exterior Mirror
- the exterior mirror control switch C325 pin 3,
circuit 9-AD1 (BN/RD) and pin 1, circuit 10-
AD11 (GY/WH) harness side.
Yes
No
Driver side INSTALL a new exterior mirror.
Passenger side GO TO B2
B2: CHECK CIRCUIT 9-AD17 (BN/GN) FOR CONTINUITY
1.
Passenger Exte-
rior Mirror C311
07/2001 2002 Bantam

(BN/RD) harness side, and the passenger
exterior mirror C311 pin 6, circuit 9-AD17
(BN/GN) harness side.
Yes
INSTALL a new exterior mirror. TEST the
No
REPAIR circuit 9-AD17 (BN/GN). TEST the
PINPOINT TEST C: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC
C1: CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC
1 Operate the exterior mirror control switch.
• Does the exterior mirror function with switch
logic?
Yes
No
Driver exterior mirror up/down function
inoperative
GO TO C2
Driver exterior mirror left/right function
inoperative
GO TO C3
Passenger exterior mirror up/down function
inoperative
GO TO C4
Passenger exterior mirror left/right function
inoperative
GO TO C6
C2: CHECK THE DRIVER EXTERIOR MIRROR UP/DOWN CIRCUIT
1.
Exterior Mirror
Control Switch
C325
07/2001 2002 Bantam


(BN/RD) and pin 2, circuit 10-AD8 (GY/VT)
harness side.
Yes
No
C3: CHECK THE DRIVER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT

1.
Exterior Mirror
Control Switch
C325
(BN/RD) and pin 5, circuit 8-AD7 (WH/RD)
harness side.
Yes
No
C4: CHECK THE PASSENGER EXTERIOR MIRROR UP/DOWN CIRCUIT

1.
Exterior Mirror
Control Switch
C325
07/2001 2002 Bantam


(BN/RD) and pin 1, circuit 10-AD11 (GY/WH)
harness side.
Yes
No
GO TO C5
C5: CHECK CIRCUIT 10-AD11 (GY/WH) FOR CONTINUITY

1.
Passenger Exte-
rior Mirror C311
AD11 (GY/WH) harness side, and the
passenger exterior mirror C311 pin 2, circuit
10-AD11 (GY/WH) harness side.
Yes
No
REPAIR circuit 10-AD11 (GY/WH). TEST
C6: CHECK THE PASSENGER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
1.
Exterior Mirror
Control Switch
C325
07/2001 2002 Bantam


(BN/RD) and pin 7, circuit 8-AD10 (WH/BK)
harness side.
Yes
No
GO TO C7
C7: CHECK CIRCUIT 8-AD10 (WH/BK) FOR CONTINUITY

1.
Passenger Exte-
rior Mirror C311
(WH/BK) harness side, and the passenger
exterior mirror C311 pin 3, circuit 8-AD10
(WH/BK) harness side.
Yes
No
REPAIR circuit 8-AD10 (WH/BK). TEST the
07/2001 2002 Bantam


Exterior Mirror (Electrically operated)
Removal
1. Remove the exterior mirror trim panel.
1. Remove the screw cover.
1. Remove the front door trim panel. For

3. CAUTION: Do not touch the adhesive

surfaces, as re-bonding will be
impaired.
Detach the watershield from the door panel.
• Using a plastic knife (disposable cutlery),
cut through the Butyl strip to enable the
watershield to be peeled back.
1. Disconnect the mirror control switch

07/2001 2002 Bantam

1. Disconnect the mirror electrical connector.
6. NOTE: Note the position of the gasket.

Remove the mirror.
• Remove the mirror retaining screws.
Installation
1. NOTE: Make sure the gasket is correctly

positioned.
07/2001 2002 Bantam


Exterior Mirror — Manually Operated (43 364 0)
Removal
1. Detach the mirror inner trim panel.
1. Remove the blanking plug.
2. Remove the mirror inner trim panel.

1. Unlock the remote control lever cover.
2. Remove the remote control lever cover.
3. Push the remote control lever out of the

mirror inner trim panel.
4. NOTE: Remove any sound deadening

material from where the mirror is fixed to the
door.
Detach the mirror outer trim panel.
07/2001 2002 Bantam


5. Remove the mirror (three bolts).
Installation
07/2001 2002 Bantam


Exterior Mirror Glass (43 366 0)
Removal
1. Push in the inboard edge of the glass
towards the back of the mirror case.
2. Detach the door mirror glass.

1. Holding the outboard edge of the glass
pull it outwards.
2. While pulling the glass outwards, pull it
towards you.
3. NOTE: Disconnect the electrical connectors

where fitted.
Remove the door mirror glass.
07/2001 2002 Bantam


Installation
1. Push in the outboard edge of the door
mirror glass mounting towards the back of
the mirror case.
2. NOTE: Connect the electrical connector

where fitted.
Locate the glass onto the door mirror glass
mounting.
1. Attach the inboard edge of the door
mirror glass mounting to the glass.
2. Lay the glass across the door mirror
glass mounting.
3. Push the outboard edge of the glass onto

the door mirror glass mounting.
07/2001 2002 Bantam

501-10-1 Seating 501-10-1
SECTION 501-10 Seating

SUBJECT PAGE

Seats...................................................................................................................................... 501-10-2

Front Seat .............................................................................................................................. 501-10-3/4
Front Seat Cushion ................................................................................................................ 501-10-7
Front Seat Backrest ............................................................................................................... 501-10-8/9

Front Seat Cushion .......................................................................................... (40 104 0) 501-10-10/11
Front Seat Backrest ......................................................................................... (40 106 0) 501-10-12/14
SPECIFICATIONS
Specifications......................................................................................................................... 501-10-15
07/2001 2002 Bantam

501-10-2 Seating 501-10-2

Seats
Front seats have cut and sew covers over foam adjustable head restraints with foam pads. Seat
padding supported by sprung wire on a steel tracks allow forwards and rearwards travel. All
frame. The cushion and backrest are contoured front seats incorporate an outer trim panel; inner
for lateral support. Both front seats can be folded trim panels are fitted depending on vehicle
forward to allow access to the vehicle jack and specifications.
wheel spanner and are fitted with two way
E6724 EN 07/2001 2002 Bantam

501-10-3 Seating 501-10-3

Front Seat
Removal
Vehicles with driver air bag
WARNING: To avoid accidental deploy-

ment the air bag control module backup
power supply must be depleted. Wait at
least one minute after disconnecting the
battery ground cable(s) before com-
mencing any repair or adjustment to the
supplemental restraint system (SRS), or
any component(s) adjacent to the SRS
sensors. Failure to follow these instruc-
WARNING: Always wear safety glasses

when working on an air bag equipped
vehicle and when handling an air bag
module. Failure to follow these instruc-
All vehicles
2. Remove the head restraint.
3. Detach the seat side trim panel from the

seat track.
E9364 EN 07/2001 2002 Bantam

501-10-4 Seating 501-10-4

4. Disconnect the safety belt buckle pre-
tensioner electrical connector.
All vehicles
5. Move the seat fully rearwards.
6. Remove the seat front retaining bolts.
7. Move the seat fully forwards.
8. Remove the seat rear retaining bolts and

remove the seat.
Installation
All vehicles
1. NOTE: Do not fully tighten the seat retaining
bolts at this stage.
Install the seat.
E9364 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-5 Seating 501-10-5
2. Move the seat fully rearwards.
3. Tighten the seat in the following sequence.

1. Tighten the front inner retaining bolt.
2. Tighten the front outer retaining bolt.
4. Move the seat fully forwards.
5. Tighten the seat in the following sequence.

1. Tighten the rear inner retaining bolt.
2. Tighten the rear outer retaining bolt.

6. Connect the safety belt buckle pre-
tensioner electrical connector.
CONTINUED
E9364 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-6 Seating 501-10-6
All vehicles
7. Attach the seat side trim panel.
8. Install the head restraint.

CONTINUED
E9364 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-7 Seating 501-10-7

Front Seat Cushion
Removal
1. Remove the front seat. For additional
information, refer to Front Seat in this section.
2. CAUTION: Note the position and

routing of the safety belt buckle pre-
tensioner wiring harness to aid
assembly. An incorrectly routed
wiring harness may lead to the wiring
harness becoming damaged on the
seat mechanism.
Detach the safety belt buckle pre-tensioner

wiring harness from the underside of the
seat.
• Detach the clips.
3. Remove the front seat cushion.

Installation
CONTINUED
E9365 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-8 Seating 501-10-8

Front Seat Backrest
Removal
All vehicles
1. Remove the front seat. For additional
information, refer to Front Seat in this section.
2. Remove the seat outer trim panel.

1. Detach the front retaining clip.
2. Detach the rear locating tang.
3. Remove the backrest recliner hand wheel.

• Remove the cover.
Vehicles without driver airbag

4. Remove the safety belt buckle.
CONTINUED
E9366 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-9 Seating 501-10-9

All vehicles
5. Remove the seat inner trim panel.
1. Detach the front retaining clip.
6. Remove the front seat backrest retaining

clips.
7. NOTE: The seat may be equipped with an

additional inner trim panel, depending on seat
specifications. Care must be taken when
removing the backrest not to damage the
inner trim panel.
Remove the backrest.
1. Fold the backrest forward.
2. Detach the backrest from the spindle.
Installation
CONTINUED
E9366 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-10 Seating 501-10-10

Front Seat Cushion (40 104 0)
General Equipment
Hog ring pliers
Disassembly
1. Remove the front seat cushion.
2. Detach the seat cover.

• Cut the 15 hog rings.
3. Remove the seat cover.

1. Roll the seat cover towards the centre of
the foam pad to access the pleating hog
rings.
2. Cut the six hog rings.
4. NOTE: Note the position of the anti-squeak

mat to aid assembly.
Remove the foam pad.
CONTINUED
E6770 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-11 Seating 501-10-11
Assembly
1. To assemble, reverse the disassemble
procedure.
NOTE: The anti-squeak mat is available as a
one size service part, which should be cut to
match the mat it is replacing.
• Use hog ring pliers to close the hog
rings. Do not use any other tool. The hog
rings must be closed to overlap 8 mm as
illustrated.
CONTINUED
E6770 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-12 Seating 501-10-12

Front Seat Backrest (40 106 0)
Disassembly
1. Remove the head restraint.
2. Remove the head restraint guides.
3. Detach the retaining strip from the base of

the backrest.
4. Roll the seat cover up the backrest to

access the lower lateral tensioner rod
retaining clips.
CONTINUED
E9431 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-13 Seating 501-10-13
5. Detach the lower lateral tension rod

retaining clips.
6. Roll the cover up the backrest.
7. Detach the upper lateral tension rod

retaining clips.
8. NOTE: Make sure the lateral tension rod

retaining clips do not enter the retaining
sleeves.
Roll the backrest cover upwards to access
the pleating hog rings.
• Cut the hog rings.
9. Remove the backrest cover.

• Detach the retaining strip.
CONTINUED
E9431 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-14 Seating 501-10-14

10. Remove the front seat backrest.
11. Remove the anti-squeak mat.

• Remove the clips.
12. NOTE: Note the position of the springs to

aid assembly.
Remove the suspension mat.
• Remove the springs.
Assembly
1. To assemble, reverse the disassemble
procedure.
NOTE: The anti-squeak mat is available as a
one size service part, which should be cut to
match the mat it is replacing.
Use hog ring pliers to close the hog rings.
Do not use any other tool. The hog rings
must be closed to overlap as illustrated.
CONTINUED
E9431 EN 07/2001 2002 Bantam

TO MODEL INDEX
501-10-15 Seating 501-10-15
SPECIFICATIONS
Description Nm
Front seat, front retaining bolts 25
Front seat, rear outer retaining bolt 25
Front seat, rear inner retaining bolt 40
Front safety belt buckle bolt 50
CONTINUED
E6774 EN 07/2001 2002 Bantam

501-11-1 Glass, Frames and Mechanisms 501-11-1
SECTION 501-11 Glass, Frames and Mechanisms

SUBJECT PAGE

Glass, Frames and Mechanisms ...........................................................................................501-11-2
Inspection and Verification ..................................................................................................501-11-2
Pinpoint Tests ..................................................................................................................... 501-11-2/8
Component Tests................................................................................................................501-11-3

Front Door Window Glass................................................................................ (42 314 0) 501-11-9/12
Opera Window Glass ............................................................................................................. 501-11-13/16
Rear Window Glass ............................................................................................................... 501-11-17/20
Front Door Window Regulator and Motor ........................................................ (42 338 0) 501-11-21/23
Windshield Glass ............................................................................................. (42 115 0) 501-11-24/30
GENERAL PROCEDURES
Door Window Glass Adjustment ...................................................................... (42 001 0) 501-11-31/32
SPECIFICATIONS
Specifications......................................................................................................................... 501-11-33
08/2001 2002 Bantam

TO MODEL INDEX

Glass, Frames and Mechanisms Mechanical Electrical
Refer to Wiring Diagrams Cell: 50111, for • Window seal • Fuse(s)
schematic and connector information. • Door window frame • Electrical
connector(s)
Inspection and Verification • Switch(s)
• Circuit(s)
mechanical or electrical damage. reported concern is found, correct the cause
step.
Symptom Chart
• All power windows are inopera- • Driver power window control • CARRY OUT the Driver Power
tive switch. Window Control Switch Compo-
nent Test.
• Single power window is inopera- • Driver power window control • CARRY OUT the Driver Power
tive - driver side switch Window Control Switch Compo-
nent Test.
REFER to the Wiring diagrams.
• Circuit(s). • Go To Pinpoint Test A
• Driver power window motor.
• Single power window is inopera- • Passenger power window con- • CARRY OUT the Passenger
tive - passenger side trol switch. Power Window Control Switch
Component Test.
• Driver power window control • CARRY OUT the Driver Power
switch. Window Control Switch Compo-
nent Test.
• Circuit(s). • Go To Pinpoint Test B
• Passenger power window mo-
tor.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical
measurements. CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST A: SINGLE POWER WINDOW IS INOPERATIVE - DRIVER SIDE
A1: CHECK THE DRIVER POWER WINDOW CONTROL SWITCH LEDS
1.
• Do the driver power window control switch
LEDs illuminate?
Yes
GO TO A2
No
GO TO A5
A2: CHECK THE DRIVER POWER WINDOW MOTOR CIRCUIT FOR CONTINUITY
1. 2.
Driver Window Con-

trol Switch C55a
3 Measure the resistance between the driver
power window control switch C55a pin 1, circuit
32-AJ26 (WH) and pin 7, circuit 33-AJ26 (YE)
harness side.
Yes
No
GO TO A3
A3: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL SWITCH
AND THE DRIVER POWER WINDOW MOTOR DOWN CIRCUIT
1.
Power Window
Motor C106
CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

32-AJ26 (WH) and the driver power window
motor C106 pin 2, circuit 32-AJ26 (WH).
Yes
GO TO A4
No
REPAIR circuit 32-AJ26 (WH). TEST the
AND THE DRIVER POWER WINDOW MOTOR UP CIRCUIT
33-AJ26 (YE) and the driver power window
motor C106 pin 1, circuit 33-AJ26 (YE).
Yes
INSTALL a new motor. TEST the system for
normal operation.
No
REPAIR circuit 33-AJ26 (YE). TEST the
AND GROUND
1. 2.
Driver Window Con-

trol Switch C55a
31-AJ7 (BK) harness side and ground.
Yes
REPAIR circuit 14-AJ7 (VT/BU). TEST the
No
REPAIR circuit 31-AJ7 (BK). TEST the sys-
CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

PINPOINT TEST B: SINGLE POWER WINDOW IS INOPERATIVE - PASSENGER SIDE
B1: CHECK THE PASSENGER POWER WINDOW FUNCTION FROM THE DRIVER SIDE POWER
WINDOW CONTROL SWITCH
1.
2 Operate the passenger power window from the

driver power window control switch.
• Does the passenger power window operate?
Yes
REPAIR circuit 14-AJ18 (VT/WH). TEST the
No
GO TO B2
B2: CHECK THE DRIVER SIDE PASSENGER POWER WINDOW CONTROL SWITCH LED
1 Observe the driver side passenger power
window control switch LED.
• Is the driver side passenger power window
control switch LED illuminated?
Yes
GO TO B3
No
GO TO B8
B3: CHECK THE DOWN CIRCUIT VOLTAGE TO THE PASSENGER POWER WINDOW CONTROL
SWITCH
1. 2. 3.
Passenger Power
Window Control
Switch C56
4 Operate the driver side passenger power win-
dow control switch to the DOWN position.
CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

5 Measure the voltage between the passenger
power window control switch C56 pin 3, circuit
33-AJ18 (YE/VT) harness side and ground.
Yes
GO TO B4
No
REPAIR circuit 33-AJ18 (YE/VT). TEST the
B4: CHECK THE UP CIRCUIT VOLTAGE TO THE PASSENGER POWER WINDOW CONTROL
SWITCH
1 Operate the driver side passenger power win-
dow control switch to the UP position.
2 Measure the voltage between the passenger
32-AJ18 (WH/VT) harness side and ground.
Yes
GO TO B5
No
REPAIR circuit 32-AJ18 (WH/VT). TEST the
B5: CHECK THE PASSENGER POWER WINDOW MOTOR CIRCUIT FOR CONTINUITY
1.

passenger power window control switch C56
pin 1, circuit 32-AJ27 (WH/VT) and pin 7,
circuit 33-AJ27 (YE/VT) harness side.
Yes
VERIFY the customer concern
No
GO TO B6
CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

B6: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL
SWITCH DOWN CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR
1.
Power Window
Motor C107
2 Measure the resistance between passenger
33-AJ27 (YE/VT) and the passenger power
window motor C107 pin 1, circuit 33-AJ27
(YE/VT).
Yes
GO TO B7
No
REPAIR circuit 33-AJ27 (YE/VT). TEST the
B7: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL
SWITCH UP CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR
1 Measure the resistance between passenger
32-AJ27 (WH/VT) and the passenger power
window motor C107 pin 2, circuit 32-AJ27
(WH/VT).
Yes
INSTALL a new motor. TEST the system for
normal operation.
No
REPAIR circuit 32-AJ27 (WH/VT). TEST the
B8: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL SWITCH
AND GROUND
1. 2.
Driver Power Win-

dow Control Switch
C55b
CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

power window control switch C55b pin 3, circuit
31-AJ9 (BK) harness side and ground.
Yes
GO TO B9
No
REPAIR circuit 31-AJ9 (BK). TEST the sys-
B9: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
1.
2 Measure the voltage between the driver power

window control switch C55b pin 2, circuit 14-
AJ9 (VT/BK) harness side and ground.
Yes
No
REPAIR circuit 14-AJ9 (VT/BK). TEST the
CONTINUED
E9411 EN 08/2001 2002 Bantam

TO MODEL INDEX

Front Door Window Glass (42 314 0)
Removal
All vehicles

surface, as re-bonding will be
impaired.
Detach the watershield from the door panel.
3. Detach the door glass top run retainer.
4. Remove the door glass top run retainer.

Vehicles with power windows
5. Connect the window control switch
Vehicles with manual windows
6. Install the window regulator handle.
CONTINUED
E6777 EN 08/2001 2002 Bantam

TO MODEL INDEX

All vehicles
7. Remove the window glass retaining screws
(power window shown).
• Align the retaining screws with the
access hole.
8. Detach the window glass from the

regulator.
9. Lower the window glass to the bottom of

the door.
10. Remove the window glass weather strip.
11. Remove the front door window glass.
CONTINUED
E6777 EN 08/2001 2002 Bantam

TO MODEL INDEX
Installation
All vehicles
1. Install the front door window glass.
2. Install the door glass weather strip.
3. NOTE: Do not fully tighten the retaining

screws at this stage.
Attach the front door window glass to the
window regulator (power window shown).
• Install the retaining screws.
4. Align the retaining screws with the access

holes.
• Raise the front door window glass.
CONTINUED
E6777 EN 08/2001 2002 Bantam

TO MODEL INDEX
5. Tighten the retaining screws.
Vehicles with manual windows

6. Remove the window regulator handle.
Vehicles with power windows
7. Disconnect the window control switch
All vehicles
8. Install the door glass top run retainer.
9. Attach the watershield to the door panel.
10. Install the front door trim panel. For

CONTINUED
E6777 EN 08/2001 2002 Bantam

TO MODEL INDEX

Opera Window Glass
General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Mixer/Application gun
Removal
1. NOTE: Should the ambient temperature fall

below 10°C heat the cartridges for
approximately 15 minutes by placing them on
a warm radiator, or by using a hot air gun set
at approximately 25°C.
Heat the polyurethane (PU) adhesive if
necessary.
All vehicles
CAUTION: When removing fasteners,

easily broken.
1. Remove the C pillar trim cover.
CONTINUED
E6779 EN 08/2001 2002 Bantam

TO MODEL INDEX
1 WARNING: Wear gloves and eye

protection when working with the glass
cutting tool as the cutting operation
may produce splinters. When using the
cutter wear ear protectors. Failure to
follow these instructions may result in
personal injury.
2
CAUTION: Make sure the cutting blades
1 are changed where the cutting depth
changes to avoid damage to the body
1 and trim panels.
NOTE: Some resistance may be encountered
3 when cutting through the glass locating pegs in
the top corners of the glass.
NOTE: Carefully remove the remaining part of
the locating pegs from the window opening
flange.
From inside the vehicle cut the PU
adhesive at the given maximum depths.
Use the recommended blades, following the
2 proprietary tool manufacturers instructions.
1. 25 mm.
2. 60 mm.
3. 70 mm.
2. Use a suction cup to remove the opera

window glass.
CONTINUED
E6779 EN 08/2001 2002 Bantam

TO MODEL INDEX

Installation
1. CAUTION: During the curing period of

the PU adhesive the door windows
must be left open to avoid a build up
of pressure when the doors are
opened and closed.
CAUTION: Avoid touching the trimmed
surface, as this will inhibit the bonding
of the new adhesive.
Remove the excess PU adhesive from the
opening flange.
• Carefully trim the remaining PU adhesive
from the rear window opening flange to
leave approximately 1 mm of trimmed PU
adhesive adhered to the opening flange.
2. Check window aperture sealing area for

damaged sheet metal, rust or foreign
material, which may have caused, or may
cause glass breakage.
3. CAUTION: To make sure the PU

adhesive cures, it is essential that all
bonding surfaces are free of
moisture.
Using a hot air gun, apply warm air (25°C)
to the opera window opening flange and
glass bond line to remove all traces of
moisture.
4. Prepare the glass, opera window opening

flange and trimmed PU adhesive in
accordance with the instructions supplied
with the adhesive kit.
CONTINUED
E6779 EN 08/2001 2002 Bantam

TO MODEL INDEX
5. NOTE: Discard the first 100 mm of PU

adhesive as this may have a reduced working
time.
NOTE: To avoid water leaks, any breakage in
the continuous bead should be overlapped by
20 mm.
Apply the PU adhesive in a continuous
bead of between 8 and 10 mm height to the
rear window glass along the bond line.
6. NOTE: Firmly and evenly press in position;

tape the glass in the correct position until the
PU adhesive has cured.
7. Should the ambient temperature fall below

10°C, use a hot air gun at a distance of
approximately 50 mm from the surface and
apply warm air (25°C) continuously for 15
minutes (inside or outside the vehicle).
8. Install the C pillar trim cover.

CONTINUED
E6779 EN 08/2001 2002 Bantam

TO MODEL INDEX

Rear Window Glass
General Equipment
Hot air gun
Removal

necessary.
2. CAUTION: When removing fasteners,

easily broken.
NOTE: Remove the headliner rear fastener
centre pins before removing the fasteners.
Detach the rear of the headliner.
• Remove the headliner fasteners.
3. Lower the headliner.

• Place two blocks of suitable material
between the headliner and the roof panel
to act as spacers.
CONTINUED
E6780 EN 08/2001 2002 Bantam

TO MODEL INDEX
4. WARNING: Wear gloves and eye

protection when working with the
glass cutting tool as the cutting
operation may produce splinters.
When using the cutter wear ear
protectors. Failure to follow these
injury.
are changed where the cutting depth
and trim panels.
when cutting through the glass locating pegs in
flange.
proprietary tool manufacturers instructions.
1. 25 mm.
2. 60 mm.
3. 70 mm.
5. With the aid of another technician, use

suction cups to remove the rear window
glass.
CONTINUED
E6780 EN 08/2001 2002 Bantam

TO MODEL INDEX

Installation
opened and closed.
opening flange.
from the rear window opening flange to
2. Check the pinch weld sealing area for


moisture.
to the rear window opening flange and
glass bond line to remove all traces of
moisture.
4. Prepare the glass, rear window opening

flange and trimmed PU adhesive in
accordance with the instructions supplied
with the adhesive kit.

time.
20 mm.
rear window glass along the bond line.
CONTINUED
E6780 EN 08/2001 2002 Bantam

TO MODEL INDEX
6. NOTE: Firmly and evenly press in position;

tape the glass in the correct position until the
PU adhesive has cured.
With the aid of another technician, use
suction cups to install the rear window
glass.

10°C, use a hot air gun at a distance of
8. Install the headliner.

• Remove the spacers.
CONTINUED
E6780 EN 08/2001 2002 Bantam

TO MODEL INDEX

Front Door Window Regulator and Motor (42 338 0)
Removal

impaired.
Detach the door panel watershield.
3. Connect the window control switch

4. Remove the window glass retaining screws.

access hole.
5. Detach the window glass from the window

regulator.
6. CAUTION: Make sure the window

glass is adequately supported at the
top of the opening.
Using suitable hooks, raise and secure the
window glass.
CONTINUED
E6781 EN 08/2001 2002 Bantam

TO MODEL INDEX
7. Disconnect the window regulator motor

8. Remove the window regulator and motor.
Installation
1. Install the window regulator and motor.
2. Connect the window regulator motor

CONTINUED
E6781 EN 08/2001 2002 Bantam

TO MODEL INDEX
3. CAUTION: Make sure the window

glass is adequately supported at the
top of the opening.
Remove the hooks
4. Align the window regulator clamp with the

access hole.
5. Attach the window glass to the window

regulator clamp.
6. Adjust the window glass. For additional

information, refer to Door Window Glass
Adjustment. in this section
7. Disconnect the window control switch

8. Attach the door panel watershield.
9. Install the front door trim panel. For

CONTINUED
E6781 EN 08/2001 2002 Bantam

TO MODEL INDEX

Windshield Glass (42 115 0)
General Equipment
Hot air gun
Removal

necessary.
3. Raise the hood.
4. Remove the windshield wipers.
5. Lower the hood.
6. Remove the interior lamp.
CONTINUED
E6783 EN 08/2001 2002 Bantam

TO MODEL INDEX
7. Remove the sun visors.
8. Remove the sun visor retaining clip.

1. Open the screw cover.
9. Remove the rear view mirror.
10. Detach the door weather strip on each side.
11. Remove the A-pillar trim panels on each

side.
1. Unclip the trim panel.
2. Slide the trim panel upwards.
CONTINUED
E6783 EN 08/2001 2002 Bantam

TO MODEL INDEX

12. Detach the front of the headliner.
• Place two blocks of suitable material
between the headliner and the roof panel
to act as spacers.
13. WARNING: Wear gloves and eye

protection when working with the
glass cutting tool as the cutting
operation may produce splinters.
When using the cutter wear ear
protectors. Failure to follow these
injury.
are changed where the cutting depth
and trim panels.
when cutting through the glass locating pegs in
flange.
proprietary tool manufacturers instructions.
1. 15 mm.
2. 18 mm.
14. With the aid of another technician, use

suction cups to remove the windshield.
15. Remove the windshield weather strip.

CONTINUED
E6783 EN 08/2001 2002 Bantam

TO MODEL INDEX

Installation

opened and closed.
opening flange.
from the windshield opening flange to
2. Check the pinch weld sealing area for


moisture.
to the windshield opening flange and glass
bond line to remove all traces of moisture.
4. Prepare the glass, windshield opening and

trimmed PU adhesive in accordance with
the instructions supplied with the adhesive
kit.

time.
20 mm.
Apply a thin continuous bead of PU
adhesive to the edge of the windshield.
6. Install the windshield weather strip.

CONTINUED
E6783 EN 08/2001 2002 Bantam

TO MODEL INDEX

time.
20 mm.
windshield opening flange along the bond
line.
8. NOTE: Firmly and evenly press in position.

With the aid of another technician, use
suction cups to install the windshield.

10°C use a hot air gun at a distance of
10. Install the headliner.

• Remove the spacers.
11. Install the A-pillar trim panels on each side.
CONTINUED
E6783 EN 08/2001 2002 Bantam

TO MODEL INDEX
12. Attach the door weather strip on each side.
13. Install the rear view mirror.
14. Install the sun visor retaining clips.

1. Install the screw.
2. Close the screw cover.
15. Install the sun visors.
16. Install the interior lamp.
17. Raise the hood.
CONTINUED
E6783 EN 08/2001 2002 Bantam

18. Install the windshield wipers.
19. Lower the hood.

E6783 EN 08/2001 2002 Bantam

GENERAL PROCEDURES
Door Window Glass Adjustment (42 001 0)
Adjustment
1. Remove the door trim panel. For additional

impaired.
Detach the door panel watershield.
• Using a plastic knife (disposable cutlery),
watershield to be peeled back.
3. Connect the window operating switch

4. Loosen the window glass clamp retaining

screws.
access hole.
E899 EN 08/2001 2002 Bantam

5. Make sure the glass is inside the doorframe

outer seal.
6. Lower the glass to the bottom.
7. Standing inside the door, apply rearward

hand pressure on the outside of the window
glass, at the same time raising the glass to
its fully closed position.
8. Tighten the window glass clamp retaining

screws.
9. Attach the door panel watershield.
10. Install the door trim panel. For additional

E899 EN 08/2001 2002 Bantam

SPECIFICATIONS
Item Specification
Cleaner SKM-2G9524-A
Primer SKM-2G9525-A
1K Adhesive WSKM-2G309-B
2K Adhesive ESK-M2G369-A1
2K Hardener ESK-M2G369-A2
Description Nm
Wiper arm retaining nuts 18
Glass retaining clamp screws 5
Window regulator motor retaining nuts 8
E6784 EN 08/2001 2002 Bantam

501-12-1 Instrument Panel 501-12-1
SECTION 501-12 Instrument Panel

SUBJECT PAGE

Instrument Panel ................................................................................................ (43 644 0) 501-12-2/5
SPECIFICATIONS
Specifications ........................................................................................................................... 501-12-6
07/2001 2002 Bantam

501-12-2 Instrument Panel and Console 501-12-2

Instrument Panel (43 644 0)
Removal

when working on a vehicle equipped
with an air bag and when handling the
air bag module. Failure to follow this in-
struction may result in personal injury.
1. Remove the audio unit. For additional
2. Detach the heater control panel.
3. Disconnect the electrical connectors and

heater control cable.
4. Remove the ashtray.
5. Remove the steering column. For

E902 EN 07/2001 2002 Bantam

6. Remove the A-pillar trim panels.

1. Unclip the trim panel.
2. Slide the trim panel upwards.
7. Remove the instrument cluster. For

8. Detach the central junction box.

1. Remove the cover.
2. Remove the central junction box screws.
9. Remove the instrument panel side trim

panels (left-hand side shown, right-hand
side similar).
10. Detach the wiring harness.
E902 EN 07/2001 2002 Bantam


11. NOTE: Fold the floor covering back to reveal
the instrument panel lower bolts.
Remove the instrument panel left-hand side
retaining bolts.
12. Remove the instrument panel right-hand

side retaining bolts.
13. Remove the instrument panel upper

retaining bolts.
14. Detach the electrical connector.
15. Remove the passenger air bag module.

E902 EN 07/2001 2002 Bantam

16. Remove the air ducting.
17. Detach the instrument panel wiring

harness.
18. Remove the instrument panel.
Installation
E902 EN 07/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Instrument panel upper retaining bolts 3
Instrument panel side retaining bolts 19
Instrument panel lower retaining bolts 19
E6720 EN 07/2001 2002 Bantam

501-14-1 Handles, Locks, Latches and Entry Systems 501-14-1
SECTION 501-14 Handles, Locks, Latches

and Entry Systems
SUBJECT PAGE

Handles, Locks, Latches and Entry Systems.......................................................................... 501-14-2

Locks, Latches and Entry Systems ......................................................................................... 501-14-3
Inspection and Verification .................................................................................................... 501-14-3

Hood Latch......................................................................................................... (41 232 0) 501-14-4
Front Door Latch ................................................................................................ (41 351 0) 501-14-5/8
Hood Latch Release Handle.............................................................................. (41 226 0) 501-14-9
Exterior Door Handle ......................................................................................... (41 333 0) 501-14-10/11
Door Latch Remote Control..................................................................................................... 501-14-12
Tailgate Hinge………………………………………………………………………. ……………... 501-14-13
Tailgate Handle Assembly……………………………………………………….. ……………... 501-14-14
Tailgate Actuating Rods and Catches……………………………………………. ……………... 501-14-15
Ignition Lock Cylinder ......................................................................................... (33 513 0) 501-14-16
Door Lock Cylinder ............................................................................................ (41 336 0) 501-14-17/18

Door Lock Cylinder .................................................................................................................. 501-14-19/21
SPECIFICATIONS
Specifications ........................................................................................................................... 501-14-22
08/2001 2002 Bantam


Handles, Locks, Latches and Entry Systems
The passenger compartment doors and hood are locking, actuators supplement the door latches
of the conventional latch to striker design. and the fuel filler flap. The door latch actuators
are mounted directly onto the individual latch
The door latches are operated by the
conventional actuating rod system connected to assemblies while the fuel filler flap actuator is
mounted onto the vehicle body from inside the
the exterior door handles and the door latch
remote controls, with the front door latches also luggage compartment.
connected to the door lock cylinders. The door and fuel filler cap lock cylinders may be
overhauled using a service kit which consists of a
The door latch remote controls have a single
lever to lock, unlock and open the doors from the lock housing, tumbler magazine, tumbler set,
barrel return spring, operating lever and a sachet
interior.
of grease. For additional information,
A cable operates the hood latch and release refer to Door Lock Cylinder in this section.
handle. On vehicles equipped with central
E6785 EN 08/2001 2002 Bantam


Locks, Latches and Entry Systems
Visual Inspection Chart symptom and refer to WDS to diagnose the
system.
• Misaligned door(s) • Door latch actuator(s)
• Misaligned hood • Battery
• Door latch(s) • Fuse(s)
• Actuating rod(s) • Loose or corroded
• Exterior door electrical connector(s)
handle(s) • Wiring harness
• Door latch remote
control(s)
• Door lock cylinder(s)
• Cable(s)
E6786 EN 08/2001 2002 Bantam


Hood Latch (41 232 0)
Removal
1. Detach the hood latch release cable.
2. Remove the hood latch.
Installation
E907 EN 08/2001 2002 Bantam


Front Door Latch (41 351 0)
Removal

impaired.
Peel back the watershield.
3. Detach the front door latch remote control.
4. Remove the window top run.
E6787 EN 08/2001 2002 Bantam


5. Disconnect the door latch actuating rods.
6. Remove the front door latch and front door

latch remote control assembly.
7. Detach the front door latch actuator wiring

harness.
8. Remove the front door latch and front door

latch remote control assembly.
• Disconnect the front door latch actuator
E6787 EN 08/2001 2002 Bantam

9. Remove the front door latch cover retaining

screws.
10. Slide the front door latch cover away from

the front door latch.
• Detach the front door latch cover
grommet.
11. Remove the front door latch actuator.
12. Detach the front door latch remote control

outer cable from the door latch.
E6787 EN 08/2001 2002 Bantam

13. Remove the front door latch remote control

outer cable from the door latch.
Installation
E6787 EN 08/2001 2002 Bantam


Hood Latch Release Handle (41 226 0)
Removal
lower shrouds.
2. Detach the hood latch release cable.
3. Remove the hood release handle.
Installation
E906 EN 08/2001 2002 Bantam


Exterior Door Handle (41 333 0)
Removal

3. CAUTION: Do not touch watershield

adhesive surfaces, as re-bonding will
be impaired.
Locally detach the watershield.
• Using a plastic knife, (disposable cutlery)
cut through the butyl strip to enable the
protective sheet to be peeled back for
access. Do not attempt to peel the sheet
from the door without cutting the butyl.
4. Detach the window guide runner and lock

shield (two screws).
5. Remove the window guide runner.
E5848 EN 08/2001 2002 Bantam

6. Disconnect the door lock actuating rod.

• Prise open the clip and pull out the rod.
7. Remove the door handle (two screws).
Installation
E5848 EN 08/2001 2002 Bantam


Door Latch Remote Control
Removal

3. CAUTION: Do not touch the

watershield adhesive surfaces, as re-
bonding will be impaired.
Locally peel back the trim watershield.
• Using a plastic knife, (disposable cutlery)
protective sheet to be peeled back for
access. Do not attempt to peel the sheet
from the door without cutting the butyl.
4. Unclip and detach the remote control lever

and cable from the door.
5. Disconnect the lock actuating cable.

• Align the inner cable nipple with the
outer cable clip molding. Push the nipple
up to remove both inner and outer cables
from the handle.
Installation
E6000 EN 08/2001 2002 Bantam


Tailgate - Hinge
Removal
1. Using an axle stand and a piece of wood,
support the tailgate.
2. Remove the hinge from the tailgate.
3. Remove the hinge securing bolts.
Installation
E6000 EN 08/2001 2002 Bantam


Tailgate Handle Assembly
Removal
1. Remove the access panels (3 off)
2. Unclip the actuating rods from the han-

dle.
3. Remove the handle retaining screws and

remove the handle
Installation
E6000 EN 08/2001 2002 Bantam


Tailgate - Actuating Rods and Latches
Removal
1. Remove the access panels (3 off).
2. Unclip the actuating rods from the

handle.
3. Unclip the actuating rods from the latch.
4. Remove the two bolts and remove the

latch.
5. Remove the two screws and remove the

catch.
Installation
1. To install, reverse the removal proce-

dure.
Note: Ensure that the rubber grommet is

positioned correctly into the latch to prevent
rattles.
E6000 EN 08/2001 2002 Bantam


Ignition Lock Cylinder (33 513 0)
Removal
1. Remove the passive anti-theft system
(PATS) transceiver.
2. Remove the ignition switch lock cylinder.

1. Turn the key to accessory (position I).
2. Depress the locking detent.
3. Remove the lock cylinder.
Installation
E1229 EN 08/2001 2002 Bantam


Door Lock Cylinder (41 336 0)
Special Tool(s)
Remover/Installer, Door Lock
Cylinder
501-033 (41-020 A)
Removal

impaired.
Peel back the watershield.
3. Remove the window guide runner.
E6867 EN 08/2001 2002 Bantam

4. Disconnect the door lock actuating rod.
5. Using the special tool, remove the door lock

cylinder locking ring.
6. Remove the door lock cylinder.
Installation
1. NOTE: Make sure the door lock cylinder

gasket is correctly installed to the door lock
cylinder.
E6867 EN 08/2001 2002 Bantam


Door Lock Cylinder
Lock barrel grease WSS-M1C253-A
Disassembly
1. NOTE: Determine the key code of the lock

either by examining the key, key cutting kit
instructions, the customers service records or
by dismantling the lock and examining the
numbers stamped on each number.
Alternatively, identify the tumblers (by reading
the notches on each tumbler edge) and make
a note of the key code.
Read the key code.
• The key code can be read as follows:
• 1 notch = 1, 2 notches = 2, 3 notches = 3
and 0 notches =4
Assembly
1. NOTE: The first tumbler inserted into the

tumbler magazine should be the last number
of the key code. This should be followed by
the spring washer.
Arrange the tumblers, spring washer and
the spacers to enter the tumbler magazine.
1. Tumblers.
2. Spring washer.
3. Spacers.
2. Install the tumblers and the spacers so that

their grooves are aligned with the cutout
slot in the side of the tumbler magazine.
3. Pack the tumbler magazine with lock barrel

grease.
E6385 EN 08/2001 2002 Bantam

4. NOTE: Cover the roller with lock barrel

grease.
Insert the roller into the cutout slot in the
side of the tumbler magazine.
5. NOTE: Make sure the roller locates into the

corresponding slot in the lock housing.
Insert the tumbler magazine into the lock
housing.
6. NOTE: Keep the lock assembly in its current

position.
Insert the relevant key to make sure that
the barrel operates correctly.
7. Fit the self-locking retainer ensuring that all
of the tangs are locked into position.
E6385 EN 08/2001 2002 Bantam

8. Fit the alarm actuator.
9. NOTE: Cross the lever return spring tangs.

Install the lever return spring.
10. NOTE: An R for right-hand or L for left-hand

stamped on to the operating lever will
determine which door lock it operates.
Install the operating lever.
11. Install the retaining clip.
E6385 EN 08/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Hood latch retaining bolts 10
Luggage compartment lid latch retaining bolts 10
E6791 EN 08/2001 2002 Bantam

501-16-1 Wipers and Washers 501-16-1
SECTION 501-16 Wipers and Washers

SUBJECT PAGE

Wipers and Washers.............................................................................................................. 501-16-2
Windshield wiper ................................................................................................................. 501-16-2
Windshield wiper functions.................................................................................................. 501-16-2/3
Windshield washer .............................................................................................................. 501-16-3

Wipers and Washers.............................................................................................................. 501-16-4
Pinpoint Tests ..................................................................................................................... 501-16-5/23
Component Tests................................................................................................................ 501-16-23/25

Mounting Arm and Pivot Table......................................................................... (32 554 0) 501-16-26/27
Windshield Wiper Motor................................................................................... (32 524 0) 501-16-28/30
Windshield Washer Pump ............................................................................... (32 624 0) 501-16-31/32
Windshield Washer Reservoir.......................................................................... (32 622 0) 501-16-33/34
GENERAL PROCEDURES
Wiper Blade and Pivot Arm Adjustment........................................................... (32 591 0) 501-16-35
SPECIFICATIONS
Specifications......................................................................................................................... 501-16-36
Capacities ........................................................................................................................... 501-16-36
Setting angle between wiper arms and windshield ............................................................. 501-16-36
07/2001 2002 Bantam


Wipers and Washers
All functions are initiated by means of a multi-
function switch, which is operated by the wiper
lever on the right of the steering column.
The circuits of the windshield wash/wipe system
are protected via fuse F12 (20 A, in the central
junction box CJB).
The associated wiring diagrams are contained in
the
Wiring Diagrams Binder, see subsection 501- 16.
Precise information relating to the location of the
components is contained in the Wiring Diagrams
Wiper lever in the OFF position
Binder (component location chart and views of
the components, see subsection 501-16). If the wiper lever is moved from any other setting
to the OFF position, then the windshield wiper
motor continues to run at slow speed until the
Windshield wiper wipers reach the park position. This is affected
through a second circuit via the limit switch,
The windshield wiper comprises the following which supplies a voltage to the windshield wiper
parts: motor after it has been switched off. The voltage
• Front wiper arm (2) supply remains intact until the limit switch
interrupts the circuit through the wiper delay relay
• Windshield wiper motor on the air cowl grille
(normally closed contact) and the multi-function
• Front wiper linkage switch to the windshield wiper motor.
• Front wiper blade (2)
Wiper lever in the WIPE ONCE position
• Wiper delay relay, in the CJB
Press the wiper lever up until resistance is felt
• Multi-function switch, comprising
and then release it. The windshield wipers
- Windshield wiper switch perform an individual slow wipe. Current is
- Windshield washer switch supplied to the windshield wiper motor via the
multi-function switch.
Wiper lever in the INTERMITTENT position
Windshield wiper functions
Press the wiper lever down. The windshield
The windshield wiper motor can run at two
wipers perform intermittent slow wipes. The
speeds and incorporates a park position limit
wiper delay time is set to 9 seconds.
switch. It is controlled by the multi-function
switch on the steering column and by the wiper The multi-function switch sends a 12 V signal to
delay relay. the wiper delay relay, which picks up in 9-second
intervals and supplies a voltage to the windshield
After switching on the ignition (position II) the
wiper motor. The flow of current is routed
following five wiper functions are available:
through the wiper delay relay (normally open
• Off contact) and the multi-function switch (connector
• Wipe once C65b, pin 8) to the windshield wiper motor.
• Intermittent Wiper lever in the SLOW WIPE position
• Slow Press the wiper lever up one notch. The wipers
• Fast operate at slow speed. Current flows through the
multi-function switch to the windshield wiper
motor.
E916 EN 07/2001 2002 Bantam


Wiper lever in the FAST WIPE position position). Current flows from the multi-function
switch (connector C65b, pin 2) via the washer
Press the wiper lever up two notches. The wipers
pump back to the multi-function switch (connector
operate at high speed. Current flows through the
C65b, pin 1). The multi-function switch makes the
multi-function switch to the windshield wiper
ground connection when it is set to WINDSHIELD
motor.
WASHER ON.
Wiper lever in the position SLOW WIPE or FAST
Windshield washer WIPE
WARNING: The washer fluid contains The washer system operates together with the
methanol, which is poisonous. Follow windshield wiper as long as the end of the wiper
the safety guidelines. Failure to observe lever is pressed in. The washer pump stops
these instructions could cause personal immediately when the wiper lever is released.
injury. The current flows through the same circuit as
described before.
CAUTION: Never operate the washer
system for more than 10 seconds or
when the washer reservoir is empty. Washer fluid level warning light
The windshield washer comprises the following This consists of the following components:
parts: • Washer fluid level warning light (in the
• Washer reservoir, underneath the right-hand instrument panel)
front fender • Float-activated switch in the washer reservoir
• Washer pump, on the washer reservoir • Auxiliary warning system module
• Two washer nozzles on the hood, adjustable. The warning light comes on when the washer
Two functions are available depending on how reservoir is only a quarter full. This is sensed by a
the wipers are operating: switch, which is activated by a float in the washer
reservoir. When there is sufficient fluid in the
Wiper lever in the OFF or INTERMITTENT position
washer reservoir the switch makes a connection
The windshield wiper and washer pump operate to ground with one of the digital inputs on the
as long as the end of the wiper lever is pressed auxiliary warning module. It opens when the fluid
in. The washer pump stops immediately when level drops to a quarter full. This then prompts
the wiper lever is released. The windshield the auxiliary warning module to switch on the
wipers perform two more wipe cycles before they washer fluid level warning light. The warning light
return to intermittent operation (INTERMITTENT goes out when the washer fluid level is topped up
position) or stop at the park position (OFF and the switch in the reservoir closes again.
E916 EN 07/2001 2002 Bantam


Wipers and Washers
step.
Electrical the symptom and refer to the Symptom
• Fuse(s). Chart.
• Wiring harnesses.
Symptom Chart
• The wipers are inoperative. • Fuse. • Go To Pinpoint Test A
• Circuit(s).
• Windshield wiper motor.
• The wipers stay on continu- • Circuit(s). • Go To Pinpoint Test B
ously. • Windshield wiper motor.
• The high/low wiper speeds do • Circuit(s). • Go To Pinpoint Test C
not operate correctly (intermit- • Relay – intermittent wipe.
tent wiper mode OK). • Windshield wiper motor.
• The intermittent wiper speed • Circuit(s). • Go To Pinpoint Test D
does not operate correctly • Relay – intermittent wipe.
(high/low speeds OK). • Windshield wiper motor.
• The wash and wipe function are • Circuit(s). • Go To Pinpoint Test E
inoperative. • Relay – intermittent wipe.
• Multifunction switch
• The wipers will not park at the • Circuit(s). • Go To Pinpoint Test F
correct position. • Relay – intermittent wipe.
• Windshield wiper motor.
• The wipers do not operate cor- • Circuit(s). • Go To Pinpoint Test G
rectly in the MIST position. • Relay – intermittent wipe.
• The washer pump is inoperative. • Circuit(s). • Go To Pinpoint Test H
• Washer pump motor.
E9432 EN 07/2001 2002 Bantam

PINPOINT TESTS
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE
PAGE 1 OF 3
A1: DETERMINE THE FAULT CONDITION ........................................................ 501-16-5
A2: DETERMINE THE FAULT CONDITION ........................................................ 501-16-5
A3: CHECK THE FUSE F12 ................................................................................ 501-16-5
A4: CHECK THE POWER SUPPLY OF FUSE F12 ............................................. 501-16-6
A5: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH .................. 501-16-6
A6: CHECK THE MULTIFUNCTION SWITCH FOR PROPER
FUNCTION .......................................................................................................... 501-16-6/7
A7: CHECK THE GROUND CONNECTION OF WINDSHIELD
WIPER MOTOR ................................................................................................. 501-16-7
A8: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER
FUNCTION .......................................................................................................... 501-16-7/8
FUNCTION .......................................................................................................... 501-16-8
A10: CHECK THE WIND HIELD WIPER OTOR FOR PROPER
FUNCTION .......................................................................................................... 501-16-9
FUNCTION .......................................................................................................... 501-16-9/10
PINPOINT TEST B: THE WIPERS STAY ON CONTINUOUSLY
B1: CHECK THE RELAY – INTERMITTENT WIPE FOR SHORT TO
POWER............................................................................................................... 501-16-10
B2: CHECK THE RELAY – INTERMITTENT WIPE ............................................. 501-16-10
B3: CHECK THE CIRCUIT (WIPER PARK) TO RELAY
– INTERMITTENT WIPE FOR SHORT TO POWER ........................................... 501-16-11
B4: CHECK THE MULTIFUNCTION SWITCH FOR PROPER
FUNCTION .......................................................................................................... 501-16-11
B5: CHECK THE CIRCUIT (WIPER PARK) TO MULTIFUNCTION
SWITCH FOR SHORT TO POWER ................................................................... 501-16-12
B6: CHECK THE CIRCUIT (LOW WIPER SPEED) TO
WINDSHIELD WIPER MOTOR FOR SHORT TO POWER ................................. 501-16-12
B7: CHECK THE CIRCUIT (FAST WIPER SPEED) TO
WINDSHIELD WIPER MOTOR FOR SHORT TO POWER ................................. 501-16-13
PINPOINT TESTS
PAGE 2 OF 3
PINPOINT TEST C: THE HIGH/LOW WIPER SPEEDS
DO NOT OPERATE CORRECTLY
(INTERMITTENT WIPER MODE OK)
C1: CHECK THE POWER SUPPLY OF WINDSHIELD WIPER
MOTOR (SLOW WIPER SPEED)........................................................................ 501-16-13
C2: CHECK THE POWER SUPPLY OF WINDSHIELD WIPER
MOTOR (FAST WIPER SPEED) ......................................................................... 501-16-13/14
C3: CHECK THE CIRCUIT (FAST WIPER SPEED) FOR OPEN ......................... 501-16-14
C4: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER
FUNCTION .......................................................................................................... 501-16-15
PINPOINT TEST D: THE INTERMITTENT WIPER SPEED DOES
NOT OPERATE CORRECTLY (HIGH/LOW SPEEDS OK)
D1: CHECK THE POWER SUPPLY OF RELAY – INTERMITTENT
WIPE................................................................................................................... 501-16-15
D2: CHECK THE CONTROL VOLTAGE (INTERMITTENT WIPE)
TO RELAY – INTERMITTENT WIPE................................................................... 501-16-15/16
D3: CHECK THE MULTIFUNCTION SWITCH FOR PROPER
FUNCTION .......................................................................................................... 501-16-16
D4: CHECK THE CONTROL CIRCUIT (INTERMITTENT WIPE) TO
MULTIFUNCTION SWITCH ................................................................................ 501-16-16/17
D5: CHECK THE MULTIFUNCTION SWITCH FOR PROPER
FUNCTION .......................................................................................................... 501-16-17
D6: CHECK THE GROUND CONNECTION OF RELAY
– INTERMITTENT WIPE .................................................................................... 501-16-18
PINPOINT TEST E: THE WASH AND WIPE FUNCTION
ARE INOPERATIVE
E1: CHECK THE GROUND CONNECTION OF MULTIFUNCTION
SWITCH .............................................................................................................. 501-16-18
PINPOINT TESTS
PAGE 3 OF 3
PINPOINT TEST F: THE WIPERS WILL NOT PARK AT
THE CORRECT POSITION
F1: CHECK THE RELAY – INTERMITTENT WIPE FOR PROPER
FUNCTION .......................................................................................................... 501-16-19
F2: CHECK THE POWER SUPPLY (WIPER PARK) OF RELAY
– INTERMITTENT WIPE ..................................................................................... 501-16-19
F3: CHECK THE CIRCUIT FOR INTERMITTENT WIPE AND
WIPER PARK FOR OPEN................................................................................... 501-16-19/20
F4: CHECK THE MULTIFUNCTION SWITCH FOR PROPER
FUNCTION .......................................................................................................... 501-16-20
F5: CHECK THE CIRCUIT (WIPER PARK) TO RELAY
– INTERMITTENT WIPE FOR OPEN.................................................................. 501-16-20/21
F6: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER
FUNCTION .......................................................................................................... 501-16-21
PINPOINT TEST G: THE WIPERS DO NOT OPERATE
CORRECTLY IN THE MIST POSITION
G1: CHECK THE RELAY – INTERMITTENT WIPE FOR PROPER
FUNCTION .......................................................................................................... 501-16-21/22
PINPOINT TEST H: THE WASHER PUMP IS INOPERATIVE
H1: CHECK THE POWER SUPPLY OF WASHER PUMP MOTOR..................... 501-16-22
H2: CHECK THE MULTIFUNCTION SWITCH FOR PROPER
FUNCTION .......................................................................................................... 501-16-22/23

Pinpoint Tests
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE
A1: DETERMINE THE FAULT CONDITION
1.
2 Turn the multifunction switch to the SLOW

WIPER SPEED position.
• Is the slow wiper speed inoperative?
Yes
GO TO A2
No
GO TO A8
A2: DETERMINE THE FAULT CONDITION
1 Turn the multifunction switch to the FAST
• Is the fast wiper speed inoperative?
Yes
GO TO A3
No
GO TO A10
1. 2.
Fuse F12 (CJB)

• Is the fuse OK?
Yes
GO TO A4
No
E9432 EN 07/2001 2002 Bantam


A4: CHECK THE POWER SUPPLY OF FUSE F12
1. 2.
Fuse F12 (CJB)

and ground.
Yes
GO TO A5
No
CHECK the CJB. If necessary INSTALL a
new one. TEST the system for normal op-
eration.
A5: CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH
1. 2. 3.
C15b
switch, connector C15b, pin 7, circuit 14-AK19
Yes
GO TO A6
No
REPAIR the power supply of multifunction
switch, by using the wiring diagrams. TEST
A6: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1. 2.
C15b
E9432 EN 07/2001 2002 Bantam


3. 4.
Windshield wiper
motor C47
5 Turn the multifunction switch to the SLOW
6 Measure the voltage between windshield wiper
motor, connector C47, pin 4, circuit 14S-AK10
Yes
GO TO A7
No
A7: CHECK THE GROUND CONNECTION OF WINDSHIELD WIPER MOTOR

1 Measure the resistance between windshield
wiper motor, connector C47, pin 1, circuit 31-
AK8 (BK), harness side and ground.
Yes
CHECK the windshield wiper motor. If
No
REPAIR the open circuit(s) between wind-
shield wiper motor and ground G10, by us-
A8: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER FUNCTION
1. 2. 3.
Windshield wiper
motor C47
E9432 EN 07/2001 2002 Bantam


Yes
No
GO TO A9

1. 2.
Windshield wiper
motor C47
3. 4.
Multifunction
switch C15b
5 Connect a jumper wire between multifunction
switch, connector C15b, pin 5, circuit 14S-
AK11 (VT/OG) and pin 7, circuit 14-AK19
(VT/OG), harness side.
• Does the windshield wiper motor operate
correctly (fast wiper speed)?
Yes
No
function switch, connector C15b, pin 5 and
windshield wiper motor, by using the wiring
eration.
E9432 EN 07/2001 2002 Bantam


A10: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER FUNCTION
1. 2. 3.
Windshield wiper
motor C47
Yes
No
GO TO A11

1. 2.
Windshield wiper
motor C47
3. 4.
Multifunction
switch C15b
E9432 EN 07/2001 2002 Bantam


AK10 (VT/BK) and pin 7, circuit 14-AK19
(VT/OG), harness side.
correctly (low wiper speed)?
Yes
No
function switch, connector C15b, pin 3 and
windshield wiper motor, by using the wiring
eration.
PINPOINT TEST B: THE WIPERS STAY ON CONTINUOUSLY
B1: CHECK THE RELAY – INTERMITTENT WIPE FOR SHORT TO POWER
1. 2. 3.
• Stay the wipers on continuously?
Yes
GO TO B4
No
GO TO B2
Relay – intermittent
wipe C48
B2: CHECK THE RELAY – INTERMITTENT WIPE
intermittent wipe, connector C48, pin 1, circuit
31S-AK9 (BK/OG) and ground.
Yes
GO TO B3
No
CHECK the relay – intermittent wipe. If nec-
essary INSTALL a new one. TEST the sys-
E9432 EN 07/2001 2002 Bantam

B3: CHECK THE CIRCUIT (WIPER PARK) TO RELAY – INTERMITTENT WIPE FOR SHORT TO
POWER
1. 2. 3.
Windshield wiper
motor C47
Yes
connected with the relay – intermittent wipe,
operation.
No
CHECK the windshield wiper motor. If nec-
B4: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION
1. 2. 3.
• Stay the wiper on continuously?
Yes
GO TO B6
No
GO TO B5
C15b
E9432 EN 07/2001 2002 Bantam

B5: CHECK THE CIRCUIT (WIPER PARK) TO MULTIFUNCTION SWITCH FOR SHORT TO
POWER
AK15 (BK/RD), harness side and ground.
Yes
connector C15b, pin 9, by using the wiring
operation.
No
B6: CHECK THE CIRCUIT (LOW WIPER SPEED) TO WINDSHIELD WIPER MOTOR FOR SHORT
TO POWER
1. 2. 3.
Windshield wiper
motor C47
AK10 (VT/BK), harness side and ground.
Yes
operation.
No
GO TO B7
E9432 EN 07/2001 2002 Bantam


B7: CHECK THE CIRCUIT (FAST WIPER SPEED) TO WINDSHIELD WIPER MOTOR FOR SHORT
TO POWER
AK11 (VT/OG), harness side and ground.
Yes
operation.
No
PINPOINT TEST C: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY
(INTERMITTENT WIPER MODE OK)
C1: CHECK THE POWER SUPPLY OF WINDSHIELD WIPER MOTOR (SLOW WIPER SPEED)
1. 2. 3.
Windshield wiper
motor C47
(VT/BK) and ground.
Yes
GO TO C2
No
C2: CHECK THE POWER SUPPLY OF WINDSHIELD WIPER MOTOR (FAST WIPER SPEED).
E9432 EN 07/2001 2002 Bantam

(VT/BU) and ground.
Yes
operation.
No
GO TO C3
C3: CHECK THE CIRCUIT (FAST WIPER SPEED) FOR OPEN
1. 2.
C15b
AK11 (VT/BU), harness side and windshield
wiper motor, connector C47, pin 5, circuit 14S-
AK11 (VT/BU).
Yes
No
function switch and windshield wiper motor,
E9432 EN 07/2001 2002 Bantam


C4: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER FUNCTION
AK11 (VT/OG) and pin 7, circuit 14-AK19
(VT/BU), harness side.
correctly (fast wiper speed)?
Yes
No
PINPOINT TEST D: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY
(HIGH/LOW SPEEDS OK)
D1: CHECK THE POWER SUPPLY OF RELAY – INTERMITTENT WIPE
1. 2. 3.
wipe C48
14-AK14 (VT/BK) and ground.
Yes
GO TO D2
No
S11 and relay – intermittent wipe, by using
normal operation.
D2: CHECK THE CONTROL VOLTAGE (INTERMITTENT WIPE) TO RELAY – INTERMITTENT

WIPE
1 Turn the multifunction switch to the
INTERMITTENT WIPE position.
E9432 EN 07/2001 2002 Bantam


14S-AK14 (VT/BK) and ground.
Yes
GO TO D4
No
GO TO D3
D3: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1. 2.
C15b
AK14 (VT/BK), harness side and relay socket –
14S-AK14 (VT/BK).
Yes
No
function switch and relay – intermittent wipe,
D4: CHECK THE CONTROL CIRCUIT (INTERMITTENT WIPE) TO MULTIFUNCTION SWITCH
1. 2.
Windshield wiper
motor C47
E9432 EN 07/2001 2002 Bantam

AK10 (VT/BK), harness side and relay socket –
31S-AK19 (BK/RD).
Yes
GO TO D6
No
GO TO D5
D5: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1.
Multifunction
switch C15b
AK19 (BK/RD), harness side and relay socket
– intermittent wipe, connector C48, pin 3,
circuit 31S-AK19 (BK/RD).
Yes
No
E9432 EN 07/2001 2002 Bantam

D6: CHECK THE GROUND CONNECTION OF RELAY – INTERMITTENT WIPE
31-AK14 (BK) and ground.
Yes
INSTALL a new relay – intermittent wipe.
No
REPAIR the open circuit(s) between relay
socket – intermittent wipe and ground G6,
tem for normal operation. If necessary
INSTALL a new CJB.
PINPOINT TEST E: THE WASH AND WIPE FUNCTION ARE INOPERATIVE
E1: CHECK THE GROUND CONNECTION OF MULTIFUNCTION SWITCH
1. 2.
C15a
switch, connector 15a, pin 8, circuit 31-LE29
Yes
No
mal operation.
E9432 EN 07/2001 2002 Bantam


PINPOINT TEST F: THE WIPERS WILL NOT PARK AT THE CORRECT POSITION
F1: CHECK THE RELAY – INTERMITTENT WIPE FOR PROPER FUNCTION
1. 2. 3.
wipe C48
31S-AK9 (BK/OG) and pin 3, circuit 31S-AK19
(BK/RD).
• Actuate the SINGLE WIPE: Does the wipers
park in the correct position?
Yes
No
GO TO F2
F2: CHECK THE POWER SUPPLY (WIPER PARK) OF RELAY – INTERMITTENT WIPE
Yes
GO TO F3
No
GO TO F5
F3: CHECK THE CIRCUIT FOR INTERMITTENT WIPE AND WIPER PARK FOR OPEN
1. 2.
C15b
E9432 EN 07/2001 2002 Bantam

AK19 (BK/RD), harness side and relay socket
– intermittent wipe, connector C48, pin 3,
circuit 31S-AK19 (BK/RD).
Yes
GO TO F4
No
AK15 (BK/RD) and pin 2, circuit 31S-AK15
(BK/RD), harness side.
Yes
No
REPAIR the open circuit(s) at the multifunc-
tion switch, connector C15b, between pin 2
and pin 9, by using the wiring diagrams.
F5: CHECK THE CIRCUIT (WIPER PARK) TO RELAY – INTERMITTENT WIPE FOR OPEN
1. 2.
Windshield wiper
motor C47
E9432 EN 07/2001 2002 Bantam

AK9 (BK/OG), harness side and relay socket –
31S-AK9 (BK/OG).
Yes
GO TO F6
No
REPAIR the open circuit(s) between wind-
shield wiper motor and relay – intermittent
wipe, by using the wiring diagrams. TEST
F6: CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER FUNCTION
1.

motor, connector C47, pin 3, circuit 14-AK8
(VT/BU), harness side and ground.
Yes
No
REPAIR the power supply of windshield
wiper motor, by using the wiring diagrams.
PINPOINT TEST G: THE WIPERS DO NOT OPERATE CORRECTLY IN THE MIST POSITION
G1: CHECK THE RELAY – INTERMITTENT WIPE FOR PROPER FUNCTION
1. 2. 3.
Relay – intermittent Multifunction switch

wipe C48 C15b
E9432 EN 07/2001 2002 Bantam


(WH/GN), harness side and relay socket –
32-AK14 (WH/GN).
Yes
No
PINPOINT TEST H: THE WASHER PUMP IS INOPERATIVE
H1: CHECK THE POWER SUPPLY OF WASHER PUMP MOTOR
1. 2. 3.
Washer pump mo-

tor C121
4 Measure the voltage between washer pump
(YE/BK), harness side and ground.
Yes
GO TO H3
No
GO TO H2
H2: CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION

1. 2.
C15b
E9432 EN 07/2001 2002 Bantam


(YE/BK), harness side and washer pump
(YE/BK), harness side.
Yes
No
function switch and washer pump motor, by
H3: CHECK THE WASHER PUMP MOTOR FOR PROPER FUNCTION
1.
2 Actuate the WINDSHIELD WASHER and hold

it during the measure.
3 Measure the resistance between washer pump
(WH/BK), harness side and ground.
Yes
CHECK the washer pump motor. If
No
function switch; connector C15b, pin 4 and
washer pump motor, by using the wiring
eration.
Component Tests 1. Check the windshield wiper motor in SLOW
WIPER SPEED condition
Windshield wiper motor
Switch the ignition OFF.
Disconnect the connector.
Using a test cable and set up the test as in the
E9432 EN 07/2001 2002 Bantam

• Connect the battery positive terminal with the Measure the resistance at the windshield wiper
positive terminal of the ammeter. motor, connector C47, between pin 2 and pin 1.
• Connect the battery negative terminal with the Is the resistance less than 2 ohms?
windshield wiper motor housing (1).
If yes, GO to 4.
• Connect the negative terminal of the ammeter
with the windshield wiper motor (2), pin 4. If no, GO to 5.
The windshield wiper motor will run at slow 4. Check the windshield wiper motor out of
speed. WIPER PARK position
Measure the amperage.
Is the value at the ammeter next to 1,5 A?
If yes, GO to 2.
If no, INSTALL a new windshield wiper motor.
2. Check the windshield wiper motor in FAST
WIPER SPEED condition (figure
ELV3201285)
positive terminal of the ammeter.
• Connect the battery negative terminal with the
windshield wiper motor housing (1).
• Connect the negative terminal of the ammeter
with the windshield wiper motor (2), pin 5. • Connect the battery positive terminal with
The windshield wiper motor will run at fast windshield wiper motor, connector C47, pin 4
speed. • Connect the battery negative terminal, for a
Measure the amperage. half cycle, with the windshield wiper motor
Is the value at the ammeter next to 2,2 A? housing.
Measure the resistance at the windshield wiper
If yes, GO to 3.
motor, connector C47, between pin 2 and pin 1.
Is the resistance less than 2 ohms?
3. Check the windshield wiper motor in WIPER
If yes, GO to 6. Repeat this test step. If yes
PARK position
again, INSTALL a new windshield wiper motor.
If no, GO to 5.
5. Check the windshield wiper motor out of
WIPER PARK position
E9432 EN 07/2001 2002 Bantam

Measure the resistance at the windshield wiper • Connect the battery positive terminal with
motor, connector C47, between pin 2 and pin 3. windshield wiper motor, connector C47, pin 3.
Is the resistance less than 2 ohms? • Connect the battery negative terminal with
windshield wiper motor, connector C47, pin 1.
If yes, GO to 6.
• Connect a jumper wire with the windshield
If no, INSTALL a new windshield wiper motor. wiper motor, connector C47, between pin 2
6. Check the WIPER PARK function of the and pin 4.
windshield wiper motor Determine the condition
Does the windshield wiper motor move to the
WIPER PARK position?
If yes, the windshield wiper motor is OK.
E9432 EN 07/2001 2002 Bantam


Mounting Arm and Pivot Table (32 554 0)
Removal
NOTE: Only disassemble the wiper linkage
when overhauling it.
1. Remove the wiper motor. For additional
information, refer to 32 524 0 in this section
2. NOTE: Mark the position of the wiper motor

crank before undoing it.
Detach the wiper motor crank.
• Unscrew the nut from the crank.
• Release the crank from the taper by
moving it back and forth.
3. Detach the wiper linkage from the wiper

motor.
Installation
1. Attach the wiper motor crank.
• Put the crank into position and crew on
the crank nut.
• Clip the wiper linkage into the pivot
points using a suitable hollow tool (e.g. a
socket).

order.
E923 EN 07/2001 2002 Bantam

3. Install the wiper motor. For additional

information, refer to 32 524 0 in this section
4. Check operation of wipers.
E923 EN 07/2001 2002 Bantam


Windshield Wiper Motor (32 524 0)
Removal
• Note the radio keycode.
• Note the pre-set radio stations.

tive lead.
2. NOTE: The wiper motor must be in the park
position.
Remove the wiper arms.
• Undo the nuts two turns.
• Lift the wiper arms and release them
from the taper by moving them from side
to side.
• Unscrew the nuts and remove the wiper
arms.
• Unscrew the nuts from the pivot shaft
bearings.
3. Detach the coolant recovery tank.

• Remove the bolt.
• Pull it out and lay it to one side.
4. Remove the bulkhead cover.

• Remove the rubber sealing strip.
cover.
• Unscrew the bolt.
E921 EN 07/2001 2002 Bantam


5. Remove the bulkhead cover (cont.).
1. Unscrew the bolts.
6. Remove the bulkhead cover (cont.).

• Remove the bolt.
7. Remove the wiper motor.

• Unscrew the bolts.
• Unplug the connector.
• Take out the wiper motor with linkage.
Installation
1. Install the wiper motor.
• Connect the plug.
• Position the wiper motor with linkage.
• Tighten the pivot shaft bearing nuts
finger tight.
E921 EN 07/2001 2002 Bantam


2. Install the bulkhead cover, working through
the steps in reverse order.
3. Clip the CJB cover in place.
4. NOTE: The wiper motor must be in the park

position.
Fit the wiper arms.
• Tighten the pivot shaft bearing nuts.
• Attach the wiper arms and tighten the
nuts finger tight.
• Switch on the wipers and check that the
wiper blades move smoothly.
• Tighten the nuts.
5. Standard finishing operations

• Program the pre-set radio stations.
to collect data.
E921 EN 07/2001 2002 Bantam


Windshield Washer Pump (32 624 0)
Removal
1. Undo the right-hand front wheel nuts.

3. Detach the right-hand front wheel.
4. Remove the wheelhouse cover.
5. Remove the washer pump.

1. Disconnect the hoses and drain the
washer reservoir.
• Pull out the washer pump (push fit).
• Remove the rubber grommet from the
washer reservoir.
Installation
1. NOTE: Coat the rubber grommet with soap

solution before fitting it.
Refit the components in reverse order.
E4469 EN 07/2001 2002 Bantam

2. Install the wheelhouse cover.
3. Fit the front wheel.

• Lower the vehicle.
4. Fill up the washer reservoir.
5. Check the operation of the washer system.
E4469 EN 07/2001 2002 Bantam


Windshield Washer Reservoir (32 622 0)
Removal
1. Unscrew the nuts on the A-pillar, working
from the inside.
2. NOTE: There is no need to empty the coolant

expansion tank.
Detach the coolant expansion tank.
its bracket.
3. Pull off the filler neck.

E925 EN 07/2001 2002 Bantam

5. Remove the wheelhouse cover (shown

without wheel).
6. Remove the washer reservoir.

• Drain the reservoir by pulling off the
hoses at the pump.
7. Remove the washer reservoir (continued).

• Take out the washer reservoir.
Installation
1. NOTE: When inserting the reservoir check

that the filler neck is correctly seated.
Refit the components in reverse order.
3. Fill up the washer reservoir.
4. Check the operation of the windscreen

washer system
E925 EN 07/2001 2002 Bantam

GENERAL PROCEDURES
Wiper Blade and Pivot Arm Adjustment (32 591 0)
Special Tool(s)
Aligner, Wiper Arm
501-027 (32-006)
Adjustment
1. Position the wiper blades in the park
position.
2. Remove the wiper blade.

• Insert the wiper arm in the aligner and
lay it on the windshield.
3. NOTE: All three points of support of the

aligner must be placed on the windshield.
NOTE: Required values: For additional
information, refer to General Specifications in
this section.
Using the special tool, read off the angle
between the wiper arm and the windshield.
4. NOTE: Lift the special tool away from the

windshield when correcting the angle, in
order to prevent damage.
Using the special tool, adjust the wiper arm.
• Using an open-ended spanner on the
special tool, adjust the angle.
6. Install the wiper blade.
E3904 EN 07/2001 2002 Bantam

SPECIFICATIONS
Item Specification
Grease (for wiper linkage bearings/pivot shaft bearing bushings) SAM-1C-9111-A
Capacities
Litres
Washer reservoir 3
Setting angle between wiper arms and windshield

Description Angle
Windshield wiper arms 4 degrees
Description Nm
Windshield wiper arm retaining nut 18
Windshield wiper motor retaining bolt 8
Windshield wiper motor bracket retaining bolt 10
Windshield wiper crank arm retaining nut 24
E6794 EN 07/2001 2002 Bantam

501-19-1 Bumpers 501-19-1
SECTION 501-19 Bumpers

SUBJECT PAGE

Front Bumper ................................................................................................... (43 423 0) 501-19-2/3
Rear Bumperettes............................................................................................ (43 432 0) 501-19-4
SPECIFICATIONS
Specifications......................................................................................................................... 501-19-5
2002 Bantam
501-19-2 Bumpers 501-19-2

Front Bumper (43 423 0)
Removal
1. For additional information, refer to Section 100-02.
Raise and support the vehicle.
2. Remove the front bumper right - hand

retaining bolt.
3. Remove the front bumper left - hand

retaining bolt.
4. Disconnect the fog lamp electrical

connectors, one each side (if equipped).
08/2001 2002 Bantam

501-19-3 Bumpers 501-19-3

1. Detach the clips.
7. Remove the front bumper retaining screws.
8. Remove the front bumper.

1. Remove the fasteners.
2. Remove the front bumper.
Installation
08/2001 2002 Bantam

501-19-4 Bumpers 501-19-4

Rear Bumperette (43 432 0)
Removal
1. Remove the tail light assembly
2. Remove the foam seal.
3. Remove the bumperette retaining nuts.
4. Remove the bumperette.
Installation
08/2001 2002 Bantam

501-19-5 Bumpers 501-19-5
SPECIFICATIONS
Description Nm
Front Bumper retaining nuts 10
Rear Bumperette retaining nuts 10
08/2001 2002 Bantam

501-20A-1 Occupant Restraints — Active 501-20A-1
SECTION 501-20A Occupant Restraints — Active

SUBJECT PAGE

Occupant Restraint System ................................................................................................... 501-20A-2

Occupant Restraint System ................................................................................................... 501-20A-3
Principles of Operation........................................................................................................ 501-20A-3
Inspection and Verification .................................................................................................. 501-20A-3
Symptom Chart ................................................................................................................... 501-20A-3
Safety Belt Testing .............................................................................................................. 501-20A-4
Component Test ................................................................................................................. 501-20A-4

Front Safety Belt Retractor .............................................................................. (40 222 0) 501-20A-5/7
Safety Belt Buckle and Pretensioner ..................................................................................... 501-20A-8/9
SPECIFICATIONS
Specifications......................................................................................................................... 501-20A-10
Torque Specifications.......................................................................................................... 501-20A-10
2002 Bantam

Occupant Restraint System
WARNING: All safety belt components The safety belt system utilizes three-point lap and
including retractors, buckles, child diagonal safety belts in the front seat positions.
safety seat tether brackets and attaching
The front safety belt retractors incorporate a
hardware in use during a collision must
webbing grabber and a load limiting device. The
be removed and new components
webbing grabber is activated by sudden
installed. New safety belt components
deceleration of the vehicle, excessive vehicle tilt
should also be installed where safety
or rapid acceleration of the safety belt webbing.
belts not in use during a collision, are
When the webbing grabber is activated the safety
inspected and found to be damaged or
belt webbing is clamped against a force guide
operate incorrectly. Failure to follow
and clamp ring preventing further safety belt
these instructions may result in personal
webbing payout. The load limiting device allows
injury.
progressive payout of additional safety belt
webbing when the force exerted exceeds a
predetermined limit.
The front seat safety belt buckles incorporate
pre-tensioner's. The safety belt buckle pre-
tensioner's are connected to the air bag control
module, which monitors the circuits, and if a fault
is detected will illuminate the air bag warning
indicator located in the instrument cluster. For
additional information, refer to Section 501-20B.
In the event of a collision, the safety belt buckle
pre-tensioner's will deploy at the same time as
the front air bags.
WARNING: All vehicles fitted with a
passenger air bag have a WARNING
sticker attached to the instrument panel
PROHIBITING the use of rear facing child
seats in the front seating positions.
Failure to follow this instruction may
08/2001 2002 Bantam


Occupant Restraint System
Vehicle Motion Sensor (VMS)
Principles of Operation
The ELRs VMS is operated by sudden
WARNING: All safety belt assemblies, deceleration of the vehicle or excessive tilt. Once
including retractors, buckles and front operated the VMS causes a locking pawl to be
safety belt buckle support assemblies engaged, thus locking the retractor, preventing
(slider bar), if equipped, child safety seat webbing payout. The locking method used is
tether brackets and attaching hardware dependent on which type of ELR is fitted.
should be inspected after any collision.
New safety belt assemblies should be When the vehicle is stationary, the VMS
fitted unless a qualified technician finds stabilizes, causing the pawl to disengage and
the assemblies show no damage and unlock the retractor, allowing webbing payout.
operate correctly. Failure to follow these
instructions may result in personal Webbing Motion Sensor (WMS)
injury.
The ELRs WMS is operated by rapid acceleration
The safety belt system utilizes the conventional of the webbing. Once operated, it causes a
lap and diagonal three point fixing in both front locking pawl to be engaged thus locking the
seat positions retractor. Webbing payout is prevented in the
The front seat safety belt buckles are attached to same manner as VMS.
the seat frame of each front seat.
The front safety belt retractors incorporate a Inspection and Verification
torsion bar load limiting device. The device 1. Verify the customer concern by operating the
consists of a retractor reel, which is mounted system.
onto a spindle (torsion bar), which, once the
sensor has locked the retractor reel and a
mechanical and electrical damage.
predetermined load is applied, twists and pays
out additional webbing into the system. The Visual Inspection Chart
torsion bar load limiting device will only react if
the safety belt is in use at the time of impact. Mechanical
• Loose webbing
Emergency Locking Retractor (ELR) • Damaged/frayed webbing
• Safety belt retractor and tongue assembly
The retractors in all seat positions feature ELR. • Safety belt buckle
During normal operation the ELR allows free
movement of the belted occupant. In an 3. If an obvious cause for an observed or
emergency the ELR will lock, preventing webbing reported concern is found, correct the cause
payout and hence forward movement of the (if possible) before proceeding to the next
occupant. Locking may be achieved by one of stop.
two mechanisms: 4. If the concern is not visually evident, verify
Chart.
Symptom Chart
• Normal mode - occupant re- • Broken tooth on retractor sensor • REFER to the Functional Test in
straint system inoperative gear. this section.
• Loose webbing.
08/2001 2002 Bantam


occupants should wear the safety belts and
Safety Belt Testing the safety belt webbing must be correctly
adjusted, with no slack.
Functional Test • Proceed at a speed of 10 km/h. Do not
Poor Retraction exceed 10 km/h for this test.
• Apply the foot brake sharply to stop the
If a safety belt does not retract correctly, check
vehicle. If the vehicle motion sensitive lock
that the anchor covers and trim bezels are
mechanism is operating correctly, the safety
correctly installed and not rubbing against the
belt webbing will lock and restrain the wearer.
safety belt webbing. Where necessary, check
that the safety belt webbing is not rubbing at one • Conduct the test twice in each front
end of the retractor cover slot and, if so, correct passenger seat position.
by loosening the retaining bolt, aligning the • Any safety belt retractor, which does not
retractor to centralize the safety belt webbing and restrain the wearer during this test, must not
retighten the bolt. be reused. A new safety belt must be
Both the vehicle motion sensor and the webbing installed.
motion sensor should be fully operational and
can be checked by the following tests: Test Method 2 (turning circle)
This method requires a flat open area of private
Vehicle Motion Sensor Test road, sufficient for the vehicle to be driven in a
Either of the following two procedures may be continuous circle on full steering lock.
used to check correct operation of the vehicle • Both driver and passenger should adopt a
motion sensor. Both methods require two normal, comfortable seating position. Both
technicians but note that technicians of larger occupants should wear the safety belts and
than normal build should not be asked to conduct the safety belt webbing must be correctly
these tests. This is to avoid the possibility of a adjusted, with no slack.
fully unrolled safety belt webbing being mistaken • Start the engine and, with the steering on full
for a correctly locked safety belt retractor. right-hand lock, drive the vehicle in a
continuous circle at 16 km/h. Do not exceed
16 km/h for this test.
Test Method 1 (braking)
• When the speed is stable, the passenger
WARNING: It is important that during this should attempt to slowly extract the safety
test, the wearers allow the safety belts to belt webbing from each safety belt retractor in
provide the restraint and do not attempt turn. If the vehicle motion sensitive lock
to anticipate the sudden deceleration. mechanism is operating correctly, it will not
The steering wheel should not be used be possible to extract the webbing.
as a brace. However, both driver and • Any safety belt retractor from which it is
passenger should prepare themselves possible to extract the webbing during this
for the possibility that the safety belt will test must not be used. A new safety belt must
not lock. The passenger should hold be installed.
their hands in front of them, just clear of
the instrument panel or front seat
backrest, depending on which safety belt Component Test
is being tested. Failure to follow these
instructions may result in personal With the vehicle stationary and on level ground
injury. take firm hold of the safety belt webbing (on the
tongue side of the upper safety belt anchor) and
• Select for this test a quiet or private stretch of pull out quickly. The retractor should lock within
road. Make sure that the road is clear and 0.25 meter, preventing further webbing payout.
that full visibility is maintained at all times. Any safety belt retractor from which it is possible
• Both driver and passenger should adopt a to extract further webbing must not be used. A
normal, comfortable seating position. Both new safety belt must be installed.
08/2001 2002 Bantam


Front Safety Belt Retractor (40 222 0)
Removal
1. CAUTION: The bolt securing the safety

belt anchor is held captive by a paper
washer. The bolt, spacer and paper
washer must remain on the safety
belt anchor at all times when the
safety belt is detached or removed.
Detach the safety belt lower anchor from
the floor panel.
2. CAUTION: The bolt securing the safety

belt anchor is held captive by a paper
washer. The bolt, spacer and paper
washer must remain on the safety
belt anchor at all times when the
safety belt is detached or removed.
Detach the safety belt upper anchor from
the B-pillar.
1. Detach the trim panel.
2. Remove the retaining bolt.
3. Detach the door opening weather strips.
08/2001 2002 Bantam


• Using a suitable screwdriver remove the
four lower clips.
5. Remove the cowl side trim panel.

• Using a suitable screwdriver remove the
two front clips.
6. Remove the front safety belt retractor.

1. Remove the retaining bolt.
2. Lift the retractor to detach the locating
tang.
Installation
08/2001 2002 Bantam

08/2001 2002 Bantam


Safety Belt Buckle and Pretensioner
Removal
WARNING: Never probe the electrical
connectors of air bag modules or any
other supplemental restraint system
component. Failure to follow this in-
1. Remove the front seat backrest. For
2. CAUTION: Note the position and

routing of the safety belt buckle
pretensioner wiring harness to aid
assembly. An incorrectly routed
wiring harness may lead to the wiring
harness becoming damaged on the
seat mechanism.
Detach the safety belt buckle pretensioner
wiring harness from the underside of the
seat.
3. Remove the seat inner trim panel.

1. Remove the retaining bolt and spacer.
3. Slide the inner trim panel forwards to
detach the front locating tang.
4. Remove the safety belt buckle and

pretensioner.
08/2001 2002 Bantam

Installation

08/2001 2002 Bantam

SPECIFICATIONS
Description Nm
Pretensioner bolt 50
Safety belt Torx bolts – All 38
08/2001 2002 Bantam

501-20B-1 Occupant Restraints — Passive — Supplemental Air 501-20B-1
Bag System
SECTION 501-20B Occupant Restraints —

Passive — Supplemental Air Bag System
SUBJECT PAGE

Air Bag Supplemental Restraint System (SRS) ..................................................................... 501-20B-2/4
Lamp Fault Codes (LFC)..................................................................................................... 501-20B-4

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) ...................... 501-20B-5
Diagnosing Customer Concerns Without Hard DTCs/LFCs ............................................... 501-20B-5
Diagnosing Customer Concerns with Hard DTCs/LFCs ..................................................... 501-20B-5
Deactivation ........................................................................................................................ 501-20B-5/6
Reactivation ........................................................................................................................ 501-20B-6
Glossary .............................................................................................................................. 501-20B-6
Principles of Operation........................................................................................................ 501-20B-6/7
Diagnostic Instructions — Air Bag and Safety Belt Pretensioner Supplemental Restraint 501-20B-8
System (SRS) .....................................................................................................................
Pinpoint Tests — Air Bag and Safety Belt Pretensioner Supplemental Restraint System 501-20B-9
(SRS) ..................................................................................................................................
Pinpoint Tests ..................................................................................................................... 501-20B-9/47

Driver Air Bag Module...................................................................................... (40 700 0) 501-20B-48/49
Passenger Air Bag Module .............................................................................. (40 701 0) 501-20B-50/52
Air Bag Sliding Contact .................................................................................... (33 392 0) 501-20B-53/54
Air Bag Control Module.................................................................................... (33 650 0) 501-20B-55/56
GENERAL PROCEDURES
Unserviceable Air Bag Disposal............................................................................................. 501-20B-57/58
Scrapped Vehicle Air Bag Disposal ....................................................................................... 501-20B-59/61
Deployed Air Bag Disposal .................................................................................................... 501-20B-62
SPECIFICATIONS
Specifications......................................................................................................................... 501-20B-63
Torque Specifications.......................................................................................................... 501-20B-63
2002 Bantam
Bag System

Air Bag Supplemental Restraint System (SRS)
Item Description The supplementary restraint system (SRS) is AC

1 Driver air bag module fired and has been specifically designed to
protect the driver and passenger from sustaining
2 Air bag sliding contact severe facial and upper body injuries in the event
3 Passenger air bag module of a serious impact. Optimum protection can only
be achieved when used in conjunction with a
4 Air bag control module conventional three-point safety belt. The safety
5 Safety belt buckle and pretensioner belts form an integral part of the SRS.
08/2001 2002 Bantam

Bag System

The air bag sliding contact is designed to carry
signals between the air bag control module and
the driver air bag module. The air bag sliding
contact is fitted to the steering column and
consists of fixed and moving parts connected by
a coiled Mylar tape with integral conducting
tracks. The Mylar tape is able to `wind up' and
ùnwind' as the steering wheel (to which the
moving part is attached) is turned, maintaining
electrical contact at all times between the air bag
control module and the driver air bag module.
The driver and passenger air bag modules
consist of the following components, which
WARNING: All vehicles equipped with the cannot be disassembled:
optional passenger air bag from the
• inflator
factory have a WARNING sticker
attached to the instrument cluster. • bag
PROHIBITING the use of rear facing child • container
or baby seats. • cover
The SRS consists of the following components:
• air bag control module Driver and passenger air bag module inflator
• wiring harness
• air bag sliding contact
• warning indicator
• air bag module(s)
• safety belt buckle and pre-tensioner's
The air bag control module governs the operation
of the whole system, including the diagnostics
element. It contains two frontal impact sensors, a
crash sensor and a safing sensor. The crash
sensor produces a signal corresponding to the
rate of deceleration. The safing sensor detects
only deceleration. These two sensors are
connected in series and if they both sense a Item Description
deceleration in excess of a predetermined limit,
the air bag control module will deploy the air bag 1 Igniter
module(s) and the safety belt buckle pre- 2 Propellant charge
tensioner's. The air bag control module will
always deploy the safety belt buckle pretensioner 3 Catalyst
before or at the same time as the air bag(s) and 4 Passenger inflator unit
in that sequence only.
The inflator is screwed into a metal cup-shaped
The air bag control module performs continual
container. The air bag is then folded on top of the
system diagnostics. In the event of a fault being
inflator and the cover closes the whole sub-
detected the warning indicator is illuminated
assembly.
either constantly or intermittently. The behaviour
of the warning indicator depends on the type of The driver air bag module is fitted to the steering
fault present. The warning indicator is located in wheel, the cover forming the outer surface of the
the instrument cluster. steering wheel boss. The cover has invisible `split
lines' moulded in its surfaces allowing the air bag
The wiring harness provides power to the air bag
to easily exit though the cover when the system
control module from the vehicle supply and
deploys.
hence to the air bag module(s), safety belt
buckles pre-tensioner's and the warning indicator.
08/2001 2002 Bantam

Bag System

The passenger air bag module is located above Lamp Fault Codes (LFC)
the glove compartment and is integrated into the
instrument panel to provide an unobtrusive
appearance. The cover is a one-piece moulding
held by clips and a short retaining strap. As the
air bag deploys, the cover is forced free of the
clips, but remains attached to the instrument
panel by the short retaining strap.
The purpose of the inflator is to generate the gas
needed to fill the air bag. It consists of a high
strength steel casing filled with a solid propellant
charge and an electrically activated Igniter. The
igniter is activated by a signal from the air bag
control module, which in turn ignites the
propellant charge. The very rapid burning of the
propellant produces sufficient gas to fill the air
bag(s). As the gases expand they cool,
preventing heat damage to the air bag. The driver
air bag module has one inflator and an air bag,
with a filled volume of 30 litres. The passenger air
bag module has a single inflator and an air bag
with a filled volume of 60 litres.
The air bag(s) are a one-piece woven item with a
silicon coating to provide flame and heat
protection in the vicinity of the inflator.
The SRS will communicate concerns detected
during a driving cycle or after initial key ON by
means of a warning indicator located in the Item Flash Codes
instrument cluster. 0 Normal indicator operation
1 One flash cycle: Driver air bag circuit
LFC
2 Two flash cycle: Passenger air bag cir-
cuit LFC
3 Three flash cycle: LFC common to both
driver and passenger air bag circuits
4 Four flash cycle: LFC common to both
driver and passenger safety belt buckle
pretensioner circuits
5 Continuous light: Air bag control module
fault.
If a concern is detected, the air bag control
module will communicate by flashing the warning 6 No warning indicator: Instrument cluster
indicator to give a lamp fault code (LFC). A circuit fault.
diagnostic trouble code (DTC) is logged by the air
bag control module in a non-volatile memory. For
refer to Diagnosis and Testing in this section.
08/2001 2002 Bantam

Bag System

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Refer to Wiring Diagrams Cell: 50120, Occupant
Restraints - Passive for schematic and connector Diagnosing Customer Concerns with Hard
information. DTCs / LFCs
Special Tool(s) WARNING: Do not use substitute air bag

simulators when working on the
Test and Deployment Lead, supplemental restraint system. Use only
Air Bag/Pyrotechnic Safety the appropriate tool. Failure to follow
Belt these instructions may result in personal
418-S055 (40-007) injury.
Most air bag system diagnostic procedures
Simulator - Driver and require the use of system deactivation and
Passenger Air Bags system reactivation procedures. These
procedures require the air bag module(s) and
418-037 (40-001)
safety belt pre-tensioner's to be disconnected
from the SRS, thereby removing the risk of the air
bag deployment while diagnostics are carried out.
Simulator - Pyrotechnic Air bag simulators are required to carry out
Safety Belt diagnosis and testing of the air bag system. It is
501-074 (40-017) not acceptable to short-circuit the air bag module
connections with a 0 ohm jumper wire. If a 0 ohm
jumper wire is used to short-circuit the air bag
module connections, a LFC will be displayed and
a DTC logged by the air bag control module.
General Equipment
WDS Deactivation
WARNING: The back up power supply
must be depleted before any work is
Diagnosing Customer Concerns Without Hard carried out on the supplemental restraint
DTCs/LFCs system. Wait at least one minute after
disconnecting the battery ground cable
WARNING: The battery back up power
before disconnecting any supplemental
supply must be depleted before any work
restraint system electrical connector.
is carried out on the supplemental
restraint system and adjacent
components. Failure to follow this
instruction may result in personal injury. 1. Disconnect the battery ground cable.
NOTE: Following the pinpoint tests when a
diagnostic trouble code/lamp fault code 2. Wait at least one minute for the backup
(DTC/LFC) is not present, will result in needless power supply in the air bag control module to
replacement of air bag system components and deplete its stored energy.
repeat repairs.
WARNING: Place the air bag module(s) on
Speak with the customer to determine if a a ground wired bench, with the trim
particular set of conditions must be met in order cover facing up. Failure to follow this
to indicate a fault. If a LFC is reported by the instruction may result in personal injury.
customer but is not present when the vehicle 3. Remove the driver air bag module from the
comes in for repair, pinpoint test diagnostics vehicle.
cannot be used. Instruct the customer on how to REFER to Driver Air Bag Module in this section.
count a LFC.
4. Connect the driver air bag simulator to the
sub-harness in place of the driver air bag
module at the top of the steering column.
08/2001 2002 Bantam

Bag System

5. Remove the passenger air bag module. 9. Remove the passenger safety belt
REFER to Passenger Air Bag Module in this pretensioner simulator from the passenger
section. under seat floor harness electrical connector.
6. Connect the passenger air bag simulator to 10. Connect the passenger safety belt
the harness in place of the passenger air bag pretensioner to the under seat floor harness
module. electrical connector.
7. Disconnect the driver under seat safety belt 11. Connect the battery ground cable.
pretensioner electrical connector. REFER to Section 414-01.
8. Connect the driver safety belt pretensioner 12. Prove out the system.
simulator to the driver under seat floor
harness in place of the safety belt Glossary
pretensioner.
9. Disconnect the passenger under seat safety Air Bag Simulator
belt pretensioner electrical connector.
Air bag simulators are used to simulate air bag
10. Connect the passenger safety belt module connections to the system.
pretensioner simulator to the passenger
under seat floor harness in place of the
safety belt pretensioner. Deactivate The System
11. Connect the battery ground cable. Deactivate the system means to carry out
REFER to Section 414-01. deactivation. REFER to Deactivation in this Section.
Reactivation
WARNING: The air bag simulators must
Prove Out The System
be removed and the air bag modules
reconnected when reactivated to avoid The air bag warning indicator will illuminate for
non-deployment in a collision. Failure to approximately three seconds.
follow this instruction may result in
• Fail to illuminate
personal injury.
• Illuminate continuously
REFER to Section 414-01. • Flash
2. Wait at least one minute for the backup
power supply in the air bag control module to Reactivate The System
deplete its stored energy.
Reactivate the system means to carry out
3. Remove the driver air bag simulator from the reactivation. REFER to Reactivation in this section.
sub-harness at the top of the steering
column.
4. Connect and install the driver air bag module.
REFER to Driver Air Bag Module in this Principles of Operation
section.
5. Remove the passenger air bag simulator
from the passenger air bag module harness. Supplemental Restraint System (SRS) Operation
6. Connect and install the passenger air bag The supplemental restraint system is AC fired.
module. REFER to Passenger Air Bag In the event of a severe frontal or three-quarter
Module in this section. frontal impact, in excess of a predetermined limit,
7. Remove the driver safety belt pretensioner the driver and passenger (if equipped) front air
simulator from the driver under seat floor bag(s) will deploy.
harness electrical connector.
Air bag deployment will only occur, in the event of
8. Connect the driver safety belt pretensioner to a severe collision when the ignition key is in the
the under seat floor harness electrical RUN position.
connector.
08/2001 2002 Bantam

Bag System

Air Bag Control Module vehicles longitudinal axis into electrical signals.
When both these sensors sense an impact in
The air bag control module is mounted
excess of a predetermined limit, the air bag
horizontally to the crossmember beneath the
control module initiates the circuit to deploy the
centre console, to facilitate impact sensing along
frontal air bags. The two micro machine sensors
the longitudinal axis. The air bag control module
prevent unintentional deployment of the frontal air
retains full control of the whole system, providing
bags.
continual system checks and full diagnostic
capabilities. The non-volatile memory stores the
fault codes, which can then be downloaded Air Bag Warning Indicator
through the data link connector (DLC) to WDS. A
visual warning indicator, which is housed within The air bag warning indicator is incorporated into
the instrument cluster, is illuminated when the the instrument cluster, together with the
ignition is switched ON for approximately three automatic detach detect (ADD) circuit, the air bag
seconds then goes out. If a fault occurs the warning indicator comes on for three seconds at
warning indicator, depending on the nature of the key ON. If the system self-tests OK the indicator
fault, begins to flash or illuminates continuously goes out, if a fault is detected the indicator will
after five seconds. flash after five seconds, illuminate continually
from key ON or not illuminate at all, depending on
In the event of a failure in the vehicle power the nature of the fault.
supply during or after an accident, the air bag
control module provides an auxiliary power The ADD circuit is designed to illuminate the air
supply, sufficient to deploy the air bag(s) for a bag warning indicator continuously, if the air bag
minimum of 150mS. The air bag control module control module circuit is broken, either by loss of
discharges the back up power supply within 60 power or ground supply. The air bag control
seconds of the battery ground cable being module retaining bolts are part of the ground
disconnected. Thus making sure the circuit.
supplemental restraint system remains Diagnostic evaluation of the supplemental
operational. restraints system can be made through the data
The air bag control module contains a micro- link connector (DLC) and WDS to establish the
controller to evaluate and process impact data nature of the concern. Once the diagnostic
and two micro machine sensors. An electronic trouble code (DTC) is known the appropriate
accelerometer, which converts the actual course of action can be selected from the
acceleration and deceleration force, along the Symptom Chart.
08/2001 2002 Bantam

Bag System

Diagnostic Instructions — Air Bag and Safety Belt Pretensioner Supplemental
Restraint System (SRS)
Information not available at this time.
08/2001 2002 Bantam

Pinpoint Tests — Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS)
Pinpoint Tests
PAGE 1 OF 4
PINPOINT TEST A: NO COMMUNICATION WITH THE MODULE

A1: CHECK THAT WDS IS COMMUNICATING THROUGH THE DATA LINK
CONNECTOR (DLC) ............................................................................................. 501-20B-9
A2: CHECK THE AIR BAG WARNING INDICATOR .............................................. 501-20B-9
A3: CHECK THE DLC CIRCUIT.............................................................................. 501-20B-9/10
PINPOINT TEST B: DTC B1921: AIR BAG WARNING INDICATOR GROUND
MONITORING CIRCUIT OPEN
B1: CHECK THE AIR BAG CONTROL MODULE MOUNTING ............................... 501-20B-10/11
B2: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT.................... 501-20B-11
PINPOINT TEST C: DTC B1318: BATTERY VOLTAGE LOW
C1: CHECK THE BATTERY VOLTAGE.................................................................. 501-20B-12
C2: CHECK THE CONDITION OF THE FUSE........................................................ 501-20B-12
C3: CHECK THE AIR BAG CONTROL MODULE SUPPLY CIRCUIT ..................... 501-20B-12/13
C4: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT.................... 501-20B-13
PINPOINT TEST D: DTC B1869: AIR BAG WARNING INDICATOR OPEN
CIRCUIT OR SHORT TO GROUND
D1: CHECK THE AIR BAG WARNING INDICATOR............................................... 501-20B-13/14
D2: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT................................ 501-20B-14
D3: CHECK THE AIR BA WARNING INDICATOR FUNCTION............................... 501-20B-15
D4: CHECK THE AIR BAG WARNING INDICATOR FUNCTION............................ 501-20B-16
D5: CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS................... 501-20B-16
D6: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT................................ 501-20B-17
PINPOINT TEST E: DTC B1870: AIR BAG WARNING INDICATOR SHORT
TO BATTERY
E1: CHECK THE AIR BAG WARNING INDICATOR .............................................. 501-20B-17/18
E2: CHECK THE AIR BAG WARNING INDICATOR SUB-HARNESS..................... 501-20B-18
PINPOINT TEST F: DTC B1887: DRIVER AIR BAG SHORT TO GROUND
F1: CHECK THE DRIVER AIR BAG CIRCUIT ....................................................... 501-20B-19
F2: CHECK THE DRIVER AIR BAG MODULE ....................................................... 501-20B-19
F3: CHECK THE AIR BAG WIRING SUB-HARNESS FOR A
SHORT TO GROUND ............................................................................................ 501-20B-20
F4: CHECK THE DRIVER AIR BAG CIRCUIT ....................................................... 501-20B-20/21
Pinpoint Tests
PAGE 2 OF 4
PINPOINT TEST G: DTC B1916: DRIVER AIR BAG CIRCUIT SHORT TO BATTERY
G1: CHECK THE AIR BAG WIRING SUB - HARNESS FOR A SHORT
TO BATTERY ........................................................................................................ 501-20B-21/22
G2: CHECK THE AIR BAG WIRING HARNESS FOR A SHORT TO BATTERY .... 501-20B-22/23
PINPOINT TEST H: DTC B1932: DRIVER AIR BAG OPEN CIRCUIT OR
HIGH RESISTANCE
H1: CHECK THE DRIVER AIR BAG MODULE CIRCUIT RESISTANCE................. 501-20B-23/24
H2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE.................... 501-20B-24
H3: CHECK THE AIR BAG SLIDING CONTACT FOR OPEN CIRCUIT OR
HIGH RESISTANCE .............................................................................................. 501-20B-24/25
PINPOINT TEST I: DTC B1934: DRIVER AIR BAG CIRCUIT LOW RESISTANCE
I1: CHECK THE DRIVER AIR BAG MODULE CIRCUIT RESISTANCE ................. 501-20B-25
I2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE ..................... 501-20B-26
I3: CHECK THE AIR BAG SLIDING CONTACT FOR LOW RESISTANCE............. 501-20B-26
PINPOINT TEST J: DTC B1888: PASSENGER AIR BAG SHORT TO GROUND
J1: CHECK THE PASSENGER AIR BAG CIRCUIT ............................................... 501-20B-27
J2: CHECK THE PASSENGER AIR BAG MODULE ............................................... 501-20B-27
J3: CHECK THE PASSENGER AIR BAG CIRCUIT FOR A SHORT TO GROUND. 501-20B-28
PINPOINT TEST K: DTC: B1925: PASSENGER AIR BAG SHORT TO BATTERY
K1: CHECK THE PASSENGER AIR BAG CIRCUIT FOR A SHORT
TO BATTERY ........................................................................................................ 501-20B-28/29
PINPOINT TEST L: DTC: B1933: PASSENGER AIR BAG OPEN CIRCUIT
OR HIGH RESISTANCE
L1: CHECK THE PASSENGER AIR BAG MODULE CIRCUIT RESISTANCE......... 501-20B-29/30
L2: THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE ........................ 501-20B-30
PINPOINT TEST M: DTC B1935: PASSENGER AIR BAG CIRCUIT
LOW RESISTANCE ........................................................................................................ 501-20B-30
M1: CHECK THE PASSENGER AIR BAG MODULE CIRCUIT RESISTANCE........ 501-20B-31
M2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE........... 501-20B-31
M3: CHECK THE PASSENGER AIR BAG CIRCUIT FOR LOW RESISTANCE ...... 501-20B-32
PINPOINT TEST N: DTC B1876: DRIVER SAFETY BELT PRETENSIONER
CIRCUIT CAPACITANCE OUT OF RANGE
N1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CAPACITANCE. ...... 501-20B-32/33
Pinpoint Tests
PAGE 3 OF 4
PINPOINT TEST O: DTC B1877: DRIVER SAFETY BELT PRETENSIONER

OPEN CIRCUIT
O1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT ................. 501-20B-33
O2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT
OR HIGH RESISTANCE......................................................................................... 501-20B-34
PINPOINT TEST P: DTC B1878 DRIVER SAFETY BELT PRETENSIONER
SHORT TO BATTERY
P1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT .................. 501-20B-34/35
P2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT
TO BATTERY ....................................................................................................... 501-20B-35/36
PINPOINT TEST Q: DTC B1879: DRIVER SAFETY BELT PRETENSIONER
SHORT TO GROUND
Q1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT ................. 501-20B-36/37
Q2: CHECK THE DRIVE SAFETY BELT PRETENSIONER FOR A
SHORT TO GROUND ............................................................................................ 501-20B-37/38
PINPOINT TEST R: DTC B1885: DRIVER SAFETY BELT PRETENSIONER
LOW RESISTANCE
R1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT .................. 501-20B-38/39
R2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR
LOW RESISTANCE................................................................................................ 501-20B-39
PINPOINT TEST S: DTC B1880: PASSENGER SAFETY BELT PRETENSIONER
CIRCUIT CAPACITANCE OUT OF RANGE
S1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CAPACITANCE..501-20B-40
PINPOINT TEST T: DTC B1881: PASSENGER SAFETY BELT PRETENSIONER
OPEN CIRCUIT
T1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT ......... 501-20B-40/41
T2: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR OPEN
CIRCUIT OR HIGH RESISTANCE ......................................................................... 501-20B-41/42
Pinpoint Tests
PAGE 4 OF 4
PINPOINT TEST U: DTC B1882: PASSENGER SAFETY BELT PRETENSIONER

SHORT TO BATTERY
U1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT.......... 501-20B-42/43
U2: CHECK THE PASSENGER S FETY BELT PRETENSIONER FOR A SHORT
TO BATTERY ........................................................................................................ 501-20B-43/44
PINPOINT TEST V: DTC B1883: PASSENGER SAFETY BELT PRETENSIONER
SHORT TO GROUND
V1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT.......... 501-20B-44/45
V2: CHECK THE PASSE GER SAFETY BELT PRETENSIONER FOR A SHORT
TO GROUND.......................................................................................................... 501-20B-45/46
PINPOINT TEST W: DTC B1886: PASSENGER SAFETY BELT PRETENSIONER
LOW RESISTANCE
W1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT......... 501-20B-46/47
W2: CHECK THE PASSENGER SAFETY BELT PRETENSIONER
FOR LOW RESISTANCE ...................................................................................... 501-20B-47
Bag System

Pinpoint Tests — Air Bag and Safety Belt Pretensioner Supplemental Restraint
System (SRS)
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE MODULE
WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
instruction may result in personal injury
A1: CHECK THAT WDS IS COMMUNICATING THROUGH THE DATA LINK CONNECTOR (DLC)
1 Select an alternative system to check the DLC.
• Is WDS able to communicate with the selected
system?
Yes
GO TO A2
No
CHECK the DLC. For additional information,
refer to the Wiring Diagrams, Petrol and Diesel
A2: CHECK THE AIR BAG WARNING INDICATOR
1.
2 The air bag warning indicator should illuminate

when the ignition is in the ON position for three
seconds and then go out. If a fault is present,
the air bag warning light will begin to flash after
a further 5 seconds.
• Is the warning indicator operating?
Yes
GO TO A3
No
CHECK the instrument cluster. For
refer to the Wiring Diagrams,Petrol and Diesel
A3: CHECK THE DLC CIRCUIT
1 Deactivate the supplemental restraint system.
REFER to Air Bag and Safety Belt Preten-
sioner Supplemental Restraint System (SRS)
in this section.
08/2001 2002 Bantam

Bag System

2.
Air Bag Control

Module C334
3 Measure the resistance between the DLC C31
pin 7, circuit 4-AJ7 (GY/RD) and the air bag
control module C334 pin 7, circuit 4-JA7
(GY/RD).
Yes
If the air bag warning indicator is flashing,
count the lamp flash code and
refer to the Symptom Chart in this section.
INSTALL a new air bag control module.
REFER to Air Bag Control Module in this section.
REPEAT the self-test; CLEAR the DTCs.
REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in
this section.
No
REPAIR circuit 4-JA7 (GY/RD). REPEAT
the self-test; CLEAR the DTCs.
Bag and Safety Belt Pretensioner Supple-
mental Restraint System (SRS) in this sec tion.
PINPOINT TEST B: DTC B1921: AIR BAG WARNING INDICATOR GROUND MONITORING
CIRCUIT OPEN
instruction may result in personal injury.
B1: CHECK THE AIR BAG CONTROL MODULE MOUNTING
in this section.
08/2001 2002 Bantam

Bag System

2 Check the security of the air bag control
module.
• Is the air bag control module correctly mounted
and all bolts tightened to the correct torque?
Yes
GO TO B2
No
TIGHTEN the air bag control module.
REFER to Specifications in this section.
mental Restraint System (SRS) in this sec-
tion.
B2: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT
1.
Air Bag Control

Module C334
2 Measure the resistance between the air bag
(BK/RD) and the air bag control module
housing.
Yes
this section.
No
REPAIR circuit 91-JA10 (BK/RD); REMOVE
the air bag control module. REFER to Air
Bag Control Module in this section. CLEAN
the air bag control module mountings and
bolts. INSTALL the air bag control module.
REFER to Air Bag Control Module in this
section REPEAT the self-test; CLEAR the
DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner
this section.
08/2001 2002 Bantam

Bag System

PINPOINT TEST C: DTC B1318: BATTERY VOLTAGE LOW
C1: CHECK THE BATTERY VOLTAGE
1.
2 Check the battery voltage.

• Is the battery voltage greater than 9 volts?
Yes
GO TO C2
No
CHECK the battery and charging system.
REPEAT the self-test, CLEAR the DTCs.
C2: CHECK THE CONDITION OF THE FUSE
1. 2.
Fuse 60 (10A) Fuse 60 (10A)

3 Check the condition of fuse 60 (10A).
• Is any corrosion present on the fuse or the
terminals?
Yes
CLEAN the terminals. INSTALL a new fuse
60 (10A). REPEAT the self-test, CLEAR the
DTCs.
No
GO TO C3
C3: CHECK THE AIR BAG CONTROL MODULE SUPPLY CIRCUIT
in this section.
2.
Air Bag Control

Module C334
08/2001 2002 Bantam

Bag System

3 Measure the resistance between the output
side of fuse 60 (10A) and the air bag control
module C1511a pin 8, circuit 94-JA10
(VT/OG).
Yes
GO TO C4
No
CHECK the connector terminals for corro-
sion or dirt ingress. REPEAT the self-test;
CLEAR the DTCs. REACTIVATE the system.
REFER to Air Bag and Safety Belt
Pretensioner Supplemental Restraint Sys-
tem (SRS) in this section.
C4: CHECK THE AIR BAG CONTROL MODULE GROUND CIRCUIT
(BK/RD) and the air bag control module ground
G4.
Yes
this section.
No
CHECK the air bag control module ground
G4 for security and corrosion. REPEAT the
self-test, CLEAR the DTCs. REFER to Air
tion.
PINPOINT TEST D: DTC B1869: AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO
GROUND
D1: CHECK THE AIR BAG WARNING INDICATOR
1.
08/2001 2002 Bantam

Bag System

2 Check the air bag warning indicator.
• Is the air bag warning indicator illuminated
continuously?
Yes
GO TO D2
No
GO TO D5
D2: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
disconnecting any supplemental restraint system electrical connector. Failure to follow
this instruction may result in personal injury.
1.

in this section.
3. 4.
Air Bag Control Instrument Cluster

Module C334 C37
instrument cluster C37 pin 16, circuit 91S-JA14
(BK/GN) and the air bag control module C334
pin 4, circuit 91S-JA14 (BK/GN).
Yes
GO TO D3
No
INSTALL a new wiring harness. REPEAT
the self-test; CLEAR the DTCs.
tion.
08/2001 2002 Bantam

Bag System

D3: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1.
Instrument Cluster
C37
2 Install a fused (15A) jumper wire between the
air bag control module C334 pin 4, circuit 91S-
JA14 (BK/GN) harness side and ground.
3.
• Is the air bag warning indicator illuminated?
Yes
INSTALL a new automatic detach
circuit/instrument cluster printed circuit.
this section.
No
GO TO D4
08/2001 2002 Bantam

Bag System

D4: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1 With the fused (15A) jumper wire between the
air bag control module C334 pin 4, circuit 91S-
JA14 (BK/GN) and ground.
- Disconnect the fused jumper wire from the
ground.
• Is the air bag warning indicator illuminated?
Yes
INSTALL a new air bag control module.
REFER to Air Bag Control Module in this
section. REPEAT the self-test; CLEAR the
this section.
No
tion.
D5: CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS
disconnecting any supplemental restraint system electrical connector. Failure to follow
this instruction may result in personal injury.
NOTE: The air bag control module will only activate the audible warning if there is an air bag warning
fault AND an additional fault in the supplemental restraint system (for example an open circuit on the
driver air bag module) in all cases REPAIR the air bag warning indicator first.
in this section.
2.
3 Check the instrument cluster warning

indicators.
• Are the warning indicators illuminated when the
ignition is switched to the ON position?
Yes
GO TO D6
No
CHECK the instrument cluster. For addi-
tional information,
08/2001 2002 Bantam

Bag System

D6: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
1. 2.
Air Bag Control

Module C334
control module C334 pin 4, circuit 91S-JA14
(BK/GN) harness side and ground.
Yes
CHECK the air bag warning indicator
LED/bulb. REPEAT the self-test; CLEAR the
this section.
No
INSTALL a new air bag wiring harness.
tion.
PINPOINT TEST E: DTC B1870: AIR BAG WARNING INDICATOR SHORT TO BATTERY
E1: CHECK THE AIR BAG WARNING INDICATOR
in this section.
2. 3. 4.
Air Bag Control Instrument Cluster

Module C334 C37
08/2001 2002 Bantam

Bag System

5 Measure the voltage between the air bag
(BK/GN) harness side and ground.
• Is any voltage present?
Yes
GO TO E2
No
CHECK the instrument cluster. For additional
information, refer to the Wiring Diagrams.
Petrol and Diesel
REPEAT the self-test; CLEAR the
this section.
E2: CHECK THE AIR BAG WARNING INDICATOR SUB-HARNESS
1. 2. 3.
Instrument Cluster
C333
4 Measure the voltage between the instrument
cluster C333 pin 3, circuit 91S-JA14 (BK/GN)
Yes
REPAIR circuit 91S-JA14 (BK/GN).
this section.
No
tion.
08/2001 2002 Bantam

Bag System

PINPOINT TEST F: DTC B1887: DRIVER AIR BAG SHORT TO GROUND
F1: CHECK THE DRIVER AIR BAG CIRCUIT
in this section.
2.
3 Carry out the self-test with the simulators

installed.
• Does the system prove out correctly?
Yes
GO TO F2
No
GO TO F3
F2: CHECK THE DRIVER AIR BAG MODULE
WARNING: Do not proceed with the test unless using WDS. Failure to follow this instruc-
tion may result in personal injury.
1 Connect the Test and Deployment lead to the
driver air bag module.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment lead to
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.
Yes
this section.
No
INSTALL a new driver air bag module.
tion.
08/2001 2002 Bantam

Bag System

F3: CHECK THE AIR BAG WIRING SUB-HARNESS FOR A SHORT TO GROUND
1. 2. 3.
Air Bag Control Driver Air Bag Mod-

Module C334 ule Simulator
- the air bag control module C334 pin 2, circuit
94S-JA8 (VT) and pin 9, circuit 91-JA10
(BK/RD) harness side; and
94S-JA8 (VT) harness side and ground; and
91S-JA8 (BK/OG) and pin 9, circuit 91-JA10
91S-JA8 (BK/OG) harness side and ground.
5 Turn the steering wheel from lock to lock and
note the resistance readings.
Yes
this section.
No
GO TO F4
F4: CHECK THE DRIVER AIR BAG CIRCUIT

1.
Air Bag Sliding

Contact C349
08/2001 2002 Bantam

Bag System

94S-JA8 (VT) harness side and ground; and
91S-JA8 (BK/OG) and pin 9, circuit 91-JA10
91S-JA8 (BK/OG) harness side and ground.
3 Turn the steering wheel from lock to lock and
note the resistance readings.
Yes
INSTALL a new air bag sliding contact.
REFER to Air Bag Sliding Contact in this
this section.
No
tion.
PINPOINT TEST G: DTC B1916: DRIVER AIR BAG CIRCUIT SHORT TO BATTERY
G1: CHECK THE AIR BAG WIRING SUB - HARNESS FOR A SHORT TO BATTERY
in this section.
2 Visually check the driver air bag sub-harness
for damage.
3. 4. 5.
Driver Air Bag Mod- Air Bag Control

ule Simulator Module C334
08/2001 2002 Bantam

Bag System

6 Measure the voltage between:
- the air bag control module C1511a pin 2,
circuit 94S-JA8 (VT) harness side and
ground; and
circuit 91S-JA8 (BK/OG) and pin 9, circuit 91-
JA10 (BK/RD) harness side; and
circuit 91S-JA8 (BK/OG) harness side and
ground.
Yes
GO TO G2
No
CONNECT the driver air bag module simu-
lator and the air bag control module.
tion.
G2: CHECK THE AIR BAG WIRING HARNESS FOR A SHORT TO BATTERY
1. 2. 3.
Air Bag Sliding Con-

tact C349
08/2001 2002 Bantam

Bag System

circuit 94S-JA8 (VT) harness side and
ground; and
circuit 91S-JA8 (BK/OG) and pin 9, circuit 91-
JA10 (BK/RD) harness side; and
circuit 91S-JA8 (BK/OG) harness side and
ground.
Yes
this section.
No
this section.
PINPOINT TEST H: DTC B1932: DRIVER AIR BAG OPEN CIRCUIT OR HIGH RESISTANCE
H1: CHECK THE DRIVER AIR BAG MODULE CIRCUIT RESISTANCE
in this section.
2.
08/2001 2002 Bantam

Bag System

installed.
Yes
GO TO H2
No
GO TO H3
H2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
WARNING: Do not proceed with this test unless using WDS. Failure to follow this instruc-
1 Connect the Test and Deployment Lead to the
3 Connect the Test and Deployment Lead to
WDS.
4 Measure the resistance of the air bag module
squib.
Yes
this section.
No
tion.
H3: CHECK THE AIR BAG SLIDING CONTACT FOR OPEN CIRCUIT OR HIGH RESISTANCE
1. 2.
Air Bag Sliding Con-

tact C349
08/2001 2002 Bantam

Bag System

94S-JA8 (VT) and the air bag sliding contact
C349 pin 3, circuit 94S-JA8 (VT) harness
side; and
91S-JA8 (BK/OG) and the air bag sliding
contact C349 pin 1, circuit 91S-JA8 (BK/OG)
harness side.
• Are the resistances less than 5 ohms?
Yes
this section.
No
tion.
PINPOINT TEST I: DTC B1934: DRIVER AIR BAG CIRCUIT LOW RESISTANCE
I1: CHECK THE DRIVER AIR BAG MODULE CIRCUIT RESISTANCE
in this section.
2.

installed.
Yes
GO TO I2
No
GO TO I3
08/2001 2002 Bantam

Bag System

I2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
3 Connect the Test and Deployment Lead WDS.
4 Measure the resistance of the driver air bag
module squib.
Yes
this section.
No
tion.
I3: CHECK THE AIR BAG SLIDING CONTACT FOR LOW RESISTANCE
1. 2. 3.
Air Bag Sliding Con- Air Bag Control

tact C349 Module C334
(VT) and pin 3, circuit 91S-JA8 (BK/OG)
harness side.
Yes
this section.
No
tion.
08/2001 2002 Bantam

Bag System

PINPOINT TEST J: DTC B1888: PASSENGER AIR BAG SHORT TO GROUND
J1: CHECK THE PASSENGER AIR BAG CIRCUIT
in this section.
2.

installed.
Yes
GO TO J2
No
GO TO J3
J2: CHECK THE PASSENGER AIR BAG MODULE
passenger air bag module.
2 Select DMM Specific on WDS.
WDS.
4 Measure the resistance between each of the
terminals and the air bag module casing.
Yes
this section.
No
INSTALL a new passenger air bag module.
tion.
08/2001 2002 Bantam

Bag System

J3: CHECK THE PASSENGER AIR BAG CIRCUIT FOR A SHORT TO GROUND
1. 2.
Air Bag Control

Module C334
- - the air bag control module C334 pin 5,
circuit 94S-JA11 (VT/WH) and pin 9, circuit
91-JA10 (BK/RD) harness side; and
94S-JA11 (VT/WH) and ground; and
- - the air bag control module C334 pin 6,
circuit 91S-JA11 (BK/WH) and pin 9, circuit
91-JA10 (BK/RD) harness side; and
91S-JA11 (BK/WH) and ground.
Yes
this section.
No
tion.
PINPOINT TEST K: DTC:B1925: PASSENGER AIR BAG SHORT TO BATTERY
K1: CHECK THE PASSENGER AIR BAG CIRCUIT FOR A SHORT TO BATTERY
in this section.
2 Visually check the passenger air bag harness
for damage.
08/2001 2002 Bantam

Bag System

3. 4. 5.
Passenger Air Bag Air Bag Control

Module Simulator Module C334
94S-JA11 (VT/WH) and pin 9, circuit 91-JA10
94S-JA11 (VT/WH) harness side and ground;
and
- the air bag control C334 pin 6, circuit 91S-
JA11 (BK/WH) and pin 9, circuit 91-JA10
91S-JA11 (BK/WH) harness side and ground.
Yes
this section.
No
CONNECT the passenger air bag module
simulator and the air bag control module.
tion.
PINPOINT TEST L: DTC: B1933: PASSENGER AIR BAG OPEN CIRCUIT OR HIGH RESISTANCE
L1: CHECK THE PASSENGER AIR BAG MODULE CIRCUIT RESISTANCE
in this section.
08/2001 2002 Bantam

Bag System

2.

installed.
Yes
GO TO L2
No
tion.
L2: THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
3 Connect the Test and Deployment lead to
WDS.
squib.
Yes
this section.
No
tion.
PINPOINT TEST M: DTC B1935: PASSENGER AIR BAG CIRCUIT LOW RESISTANCE
08/2001 2002 Bantam

Bag System

M1: CHECK THE PASSENGER AIR BAG MODULE CIRCUIT RESISTANCE
in this section.
2.

installed.
Yes
GO TO M2
No
GO TO M3
M2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
WDS.
squib.
Yes
this section.
No
tion.
08/2001 2002 Bantam

Bag System

M3: CHECK THE PASSENGER AIR BAG CIRCUIT FOR LOW RESISTANCE
1. 2. 3.
Passenger Air Bag Air Bag Control

Module Simulator Module C334
(VT/WH) and pin 6, circuit 91S-JA11 (BK/WH)
harness side.
Yes
this section.
No
tion.
PINPOINT TEST N: DTC B1876: DRIVER SAFETY BELT PRETENSIONER CIRCUIT
CAPACITANCE OUT OF RANGE
N1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CAPACITANCE
in this section.
08/2001 2002 Bantam

Bag System

installed.
Yes
INSTALL a new driver safety belt
pretensioner. REFER to Section 501-20A.
this section.
No
CHECK the air bag simulator is installed
correctly. REPEAT the self-test; CLEAR the
this section
PINPOINT TEST O: DTC B1877: DRIVER SAFETY BELT PRETENSIONER OPEN CIRCUIT
O1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
2.

installed.
Yes
this section.
No
GO TO O2
08/2001 2002 Bantam

Bag System

O2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE
1. 2. 3.
Air Bag Control Driver Safety Belt

Module C335 Pretensioner Simu-
lator
- the air bag control module C335 pin 11,
circuit 94S-JA33 (VT/BU) and the driver
safety belt pretensioner C348 pin 3, circuit
94S-JA33 (VT/BU) harness side; and
circuit 91S-JA33 (BK/BU) and the driver
91S-JA33 (BK/BU) harness side.
Yes
this section.
No
tion.
PINPOINT TEST P: DTC B1878 DRIVER SAFETY BELT PRETENSIONER SHORT TO BATTERY
P1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
08/2001 2002 Bantam

Bag System

2.

installed.
Yes
REPEAT the self- test; CLEAR the DTCs.
this section.
No
GO TO P2
P2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY
1. 2.
Air Bag Control

Module C334/C335
3. 4.
Driver Safety Belt

Pretensioner
Simulator
08/2001 2002 Bantam

Bag System

circuit 94S-JA33 (VT/BU) and the air bag
circuit 94S-JA33 (VT/BU) harness side and
ground; and
circuit 91-JA33 (BK/BU) and the air bag
circuit 91S-JA33 (BK/BU) harness side and
ground.
Yes
this section.
No
tion.
PINPOINT TEST Q: DTC B1879: DRIVER SAFETY BELT PRETENSIONER SHORT TO GROUND
Q1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
2.
08/2001 2002 Bantam

Bag System

installed.
Yes
this section.
No
GO TO Q2
Q2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
1. 2. 3.

Module C334/C335 Pretensioner Simu-
lator
08/2001 2002 Bantam

Bag System

circuit 94S-JA33 (VT/BU) and the air bag
circuit 94S-JA33 (VT/BU) harness side and
ground; and
circuit 91S-JA33 (BK/BU) and the air bag
circuit 91S-JA33 (BK/BU) harness side and
ground.
Yes
this section.
No
tion.
PINPOINT TEST R: DTC B1885: DRIVER SAFETY BELT PRETENSIONER LOW RESISTANCE
R1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
2.
08/2001 2002 Bantam

Bag System

installed.
Yes
this section.
No
GO TO R2
R2: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
1. 2.

Module C335 Pretensioner Simu-
lator
(VT/BU) and pin 12, circuit 91S-JA33 (BK/BU)
harness side.
Yes
this section.
No
tion.
08/2001 2002 Bantam

Bag System

PINPOINT TEST S: DTC B1880: PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
CAPACITANCE OUT OF RANGE
S1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CAPACITANCE
in this section.
2.

installed.
Yes
INSTALL a new passenger safety belt
this section.
No
CHECK that the safety belt pretensioner
simulator is installed correctly. REPEAT the
self-test; CLEAR the DTCs. REACTIVATE
the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
PINPOINT TEST T: DTC B1881: PASSENGER SAFETY BELT PRETENSIONER OPEN CIRCUIT
T1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
08/2001 2002 Bantam

Bag System

2.

installed.
Yes
this section.
No
GO TO T2
T2: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE
1. 2. 3.
Air Bag Control Passenger Safety

Module C335 Belt Pretensioner
Simulator
08/2001 2002 Bantam

Bag System

circuit 94S-JA34 (VT/OG) and the passenger
94S-JA34 (VT/OG) harness side; and
circuit 91S-JA34 (BK/RD) and the passenger
91S-JA43 (BK/RD) harness side.
Yes
this section.
No
tion.
PINPOINT TEST U: DTC B1882: PASSENGER SAFETY BELT PRETENSIONER SHORT TO
BATTERY
U1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
2.
08/2001 2002 Bantam

Bag System

installed.
Yes
this section.
No
GO TO U2
U2: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY
1. 2.
Air Bag Control

Module C334/C335
3. 4.
Passenger Safety
Belt Pretensioner
Simulator
08/2001 2002 Bantam

Bag System

circuit 94S-JA34 (VT/OG) and the air bag
circuit 94S-JA34 (VT/OG) harness side and
ground; and
circuit 91S-JA34 (BK/RD) and the air bag
circuit 91S-JA34 (BK/RD) harness side and
ground.
Yes
this section.
No
tion.
PINPOINT TEST V: DTC B1883: PASSENGER SAFETY BELT PRETENSIONER SHORT TO
GROUND
V1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
2.
08/2001 2002 Bantam

Bag System

installed.
Yes
this section.
No
GO TO V2
V2: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
1. 2. 3.

Module C334/C335 Belt Pretensioner
Simulator
08/2001 2002 Bantam

Bag System

circuit 94S-JA34 (VT/OG) and the air bag
circuit 94S-JA34 (VT/OG) harness side and
ground; and
circuit 91S-JA34 (BK/RD) and the air bag
circuit 91S-JA34 (BK/RD) harness side and
ground.
Yes
this section.
No
tion.
PINPOINT TEST W: DTC B1886: PASSENGER SAFETY BELT PRETENSIONER LOW
RESISTANCE
W1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
in this section.
2.
08/2001 2002 Bantam

Bag System

installed.
Yes
this section.
No
GO TO W2
W2: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE
1. 2.

Module C335 Belt Pretensioner
Simulator
(VT/OG) and pin 21, circuit 91S-JA34 (BK/RD)
harness side.
• Is the resistance greater than 10,000 ohms
Yes
this section.
No
tion.
08/2001 2002 Bantam

Bag System

Driver Air Bag Module (40 700 0)
Removal
WARNING: Wait at least 15 minutes after
disconnecting the battery before dis-
connecting the air bag control module
electrical connector. For all other sup-
plementary restraints system electrical
connectors, wait two minutes. Failure to
follow these procedures could increase
the possibility of accidentally deploying
the air bag(s) and pyrotechnic pre-
tensioner's.
WARNING: Always carry the air bag

module with the cover side away from
the body and stand it with the cover up-
permost. Do not attempt to repair, open
or apply electrical power to the module.
Never use modules that are visibly
damaged. Do not expose the module to
heat sources in excess of 100°C.

lower shrouds.
3. Detach the air bag module Torx retaining

bolts.
• Rotate the steering wheel 90 degrees
from its central position to gain access to
the first Torx screw. Rotate the steering
wheel 180 degrees to access the second
Torx screw.
08/2001 2002 Bantam

Bag System

4. Remove the driver air bag module.
• Disconnect the air bag module electrical
connector.
Installation
1. CAUTION: When installing, make sure

that the inflator wiring is correctly
routed.
08/2001 2002 Bantam

Bag System

Passenger Air Bag Module (40 701 0)
Removal
WARNING: To minimize the possibility of

premature deployment, wait at least one
minute after disconnecting the battery
ground cable before disconnecting any
supplemental restraint system electrical
connectors. Failure to follow this in-

module. Failure to follow this instruction

premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure
to follow this instruction may result in
personal injury.

injury in the event of premature de-
ployment, always carry a live air bag
module with the bag and trim pointed
away from the body. Failure to follow
injury.

premature deployment, live air bag
modules must only be placed on work-
benches, which have been ground,
bonded. Failure to follow this instruc-

08/2001 2002 Bantam

Bag System
WARNING: Painting air bag module trim

covers could lead to deterioration of the
trim cover and air bag. Do not for any
reason attempt to paint discoloured or
damaged air bag module trim covers.
Install a new component. Failure to fol-
low this instruction may result in per-
sonal injury.
2. Remove the passenger air bag module trim

cover.
3. Detach the passenger air bag module from

the instrument panel.
4. Remove the passenger air bag module.

• Disconnect the electrical connector.
08/2001 2002 Bantam

Bag System

Installation

module. Failure to follow this instruction

injury.


WARNING: Painting over air bag module

trim covers could lead to deterioration
of the trim covers and air bag. Do not
for any reason attempt to paint discol-
oured or damaged air bag module trim
covers. Install a new component. Failure
personal injury.
08/2001 2002 Bantam

Bag System

Air Bag Sliding Contact (33 392 0)
Removal
WARNING: Wait at least 15 minutes after
disconnecting the battery before dis-
connecting the air bag control module
electrical connector. For all other sup-
plementary restraint system electrical
connectors, wait two minutes. Failure to
follow these procedures could increase
the possibility of accidentally deploying
the air bag(s) and pyrotechnic pre-
tensioner's.
2. Remove the steering wheel. For additional

3. Centre the steering wheel. Remove the key

to lock in position.
4. Detach the air bag sliding contact.

2. Release the retaining tangs.
08/2001 2002 Bantam

Bag System

5. Remove the air bag sliding contact.
Installation
1. Install the air bag sliding contact.
1. Connect the electrical connectors.
2. Check the retaining tangs have engaged.
2. WARNING: The sliding contact

centralizing procedure MUST be
carried out before installing the
sliding contact.
WARNING: If there is any doubt about
the centralization of the air bag sliding
contact. The centralization procedure
must be repeated.
Centralize the clockspring.
1. Depress the locking pin.
2. Rotate the inner rotor against the outer
rotor fully counter clockwise.
3. Rotate the inner rotor clockwise
approximately 3.75 turns. Release the
locking pin. Make sure the inner rotor is
locked in position.
3. Refit the steering wheel. For additional

08/2001 2002 Bantam

Bag System

Air Bag Control Module (33 650 0)
Removal

premature deployment, wait at least one
minute after disconnecting the battery
ground cable before disconnecting any
supplemental restraint system electrical
connectors. Failure to follow this in-

premature deployment, do not use radio
key code savers when working on the
supplemental restraint system. Failure
personal injury.

injury.


component. Failure to follow the in-
WARNING: Painting air bag module trim

covers could lead to deterioration of the
trim cover and air bag. Do not for any
reason attempt to paint discoloured or
damaged air bag module trim covers.
Install a new component. Failure to fol-
low this instruction may result in per-
sonal injury.
1. Disconnect the battery. For additional
08/2001 2002 Bantam

Bag System

2. NOTE: Fold back the floor covering to gain
access to the air bag control module.
Detach the air bag control module.
Installation
2. NOTE: New air bag control modules supplied

in service require configuring following
installation.
Configure the air bag control module. For
additional information, refer to WDS.
08/2001 2002 Bantam

Bag System
GENERAL PROCEDURES
Unserviceable Air Bag Disposal
module with the bag and trim cover
pointed away from the body. Failure to
follow this instruction may result in per-
sonal injury.
WARNING: To prevent premature de-

ployment, live air bag modules must
only be placed on workbenches, which
have been ground, bonded. Failure to
sonal injury.
NOTE: All unserviceable air bag modules have
been placed on the Mandatory Return List. All
discoloured or damaged air bag modules should
be treated the same as any unserviceable live
air bag module being returned.
1. Remove the unserviceable air bag module.
refer to the relevant procedure in this section.
NOTE: A prepaid, return postcard is provided

with the new air bag module. The new air bag
module serial number and the vehicle identifica-
tion number (VIN) must be recorded on the air
bag module verification card.
2. Before installing the air bag module, record
the necessary information. Return the air
bag module verification card to Ford Motor
Company (driver air bag module verification
card shown).
08/2001 2002 Bantam

Bag System
3. WARNING: Under no circumstances is

an unserviceable air bag module(s) to
be returned through the local mailing
system. Failure to follow this
injury.
Seal the unserviceable air bag module(s) in
the packaging from the new air bag
module(s) and return to the Ford Motor
Company Warranty Parts Return Centre.
08/2001 2002 Bantam

Bag System
GENERAL PROCEDURES
Scrapped Vehicle Air Bag Disposal
Test and Deployment Lead, 12 volt battery
Air Bag/Pyrotechnic Safety
Belt
418-S055 (40-007A)
All vehicles

module with the bag and trim cover
pointed away from the body. Failure to
sonal injury.

2. Remove the air bag module(s) to be

deployed. For additional information, refer
to the relevant procedure(s) in this section.
Single stage air bag modules
3. Connect the test lead to the air bag module
and the adapter (driver air bag module
shown).
08/2001 2002 Bantam

Bag System

Two stage air bag modules
4. CAUTION: Do not connect both test

leads to the adapter. Both air bag
module inflators must be deployed
separately.
Connect two test leads to the air bag
module and the other end of one of the test
leads to the adapter (driver air bag module
shown).
All air bag modules
5. CAUTION: To protect the test lead

electrical connector(s) from damage
during deployment, raise the air bag
module off the ground on two
wooden blocks.
Place the air bag module inside a suitable
rigid wire cage with the air bag module
cover uppermost.
6. Connect the deployment lead to the

adapter.
7. WARNING: Before proceeding make

sure that all personnel in the vicinity
are aware that a loud noise (bang) is
about to occur. Do not let anybody
approach closer than six meters.
Move as far away as possible from the air
bag module and connect the deployment
lead to the battery.
08/2001 2002 Bantam

Bag System
8. CAUTION: The air bag module should

not be handled immediately following
deployment as the air bag module
will be very hot.
CAUTION: After deployment, the air bag
module surface may contain deposits of
sodium hydroxide, a product of the gas
generate combustion that is irritating to
the skin. Use protective gloves when
handling any deployed air bag module.
Depress both switches to deploy the air
bag.
Two stage air bag modules
9. Connect the second test lead to the
adapter.
10. WARNING: Before proceeding make

sure that all personnel in the vicinity
are aware that a loud noise (bang) is
about to occur. Do not let anybody
approach closer than six meters.
CAUTION: The air bag module should
not be handled immediately following
deployment, as the air bag module will
be very hot.
CAUTION: After deployment, the air bag
generate combustion, which is irritating
to the skin. Use protective gloves when
Depress both switches to deploy the air
bag.
All air bag modules
11. Deployed air bag module(s) should be
sealed in a suitable bag and then disposed
of in accordance with local contaminated
waste regulations.
08/2001 2002 Bantam

Bag System
GENERAL PROCEDURES
Deployed Air Bag Disposal
WARNING: After deployment, the air bag

generate combustion, which is irritating
to the skin. Use protective gloves when
1. Remove the deployed air bag module(s).
refer to the relevant procedure in this section.
2. Seal the deployed air bag module(s) in the

packaging from the new air bag module(s)
or a suitable polythene bag, and then
dispose of in accordance with local
contaminated waste regulations.
08/2001 2002 Bantam

Bag System
SPECIFICATIONS
Description Nm
Air bag control module screws 8
Driver air bag control module screws 5
Passenger air bag control module screws 6
08/2001 2002 Bantam

502-00-1 Uni-Body, Subframe and Mounting Frame — General 502-00-1
Information
SECTION 502-00 Uni-Body, Subframe

and Mounting Frame — General Information
SUBJECT PAGE

Subframe ............................................................................................................................... 502-00-2/8
SPECIFICATIONS
Specifications......................................................................................................................... 502-00-9
08/2001 2002 Bantam

Information

Subframe
Separator, ball joint Guide pins, subframe
13-006 15-097A
Removal

pinch bolt.

shaft pinch bolt.
4. Remove the exhaust manifold upper heat

shields and remove the exhaust system
front pipe. For additional information,

E6015 EN 08/2001 2002 Bantam

Information

key.

joint seals should be wrapped in cloth to
protect them.
E6015 EN 08/2001 2002 Bantam

Information

9. Remove the lower arm to spindle carrier
pinch bolts and nuts.
10. Disconnect the lower arms from the spindle

carriers.
11. Detach the connecting link from the

suspension unit assembly.

retaining bolt.
All vehicles
13. Support the crossmember assembly.
E6015 EN 08/2001 2002 Bantam

Information

14. Remove the seven crossmember assembly
retaining bolts. (Support removed for
clarity).
15. Lower the crossmember assembly enough

to gain access to the power steering valve
body pipes.
16. Remove the pinion shaft to body seal.
17. CAUTION: Whenever the steering

gear unions are disconnected the
steering gear must be plugged to
prevent dirt ingress.
Disconnect the power steering pipes from
the steering gear valve body.
1. Disconnect the power steering pipes
container.
2. Detach the power steering pipes from
the retaining bracket.
18. Remove the crossmember assembly.
E6015 EN 08/2001 2002 Bantam

Information

Installation
2. Align the crossmember.

1. Push the guide pins through the
crossmember aligning holes.
2. Slide the locking plates into the locking
grooves and tighten the guide pin sleeves.
3. Raise the crossmember engaging the guide

pins into the alignment holes.
E6015 EN 08/2001 2002 Bantam

Information
7. CAUTION: Make sure a heat shield is

ball joint.
E6015 EN 08/2001 2002 Bantam

Information
10. Install the gearshift linkage. For additional

12. CAUTION: Make sure the steering is

in the straight ahead position.
14. Bleed the power steering system. For

E6015 EN 08/2001 2002 Bantam

Information
SPECIFICATIONS
Item Specification
Power steering fluid ESPM-2C166-H
Description Nm
Steering gear pipe unions 31
Track rod end locknuts 37
Wheel nuts 85
Flexible coupling to steering column shaft pinch 28
bolt
Track rod locknuts 63
Exhaust front pipe flange 47
Manual transaxle gearshift linkage pinch bolt 23
Manual transaxle gearshift Stabilizer bar bolt 23
Lower arm to spindle carrier pinch bolt and nut 51
E6016 EN 08/2001 2002 Bantam

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Bantam - Workshop Manual

To ensure customer satisfaction with FORD products, proper service and

© 2002 Ford Motor Company of Southern Africa

SECTION 100-00 General Information

DESCRIPTION AND OPERATION

SECTION 100-00 General Information

100-00-5 General Information 100-00-5

DESCRIPTION AND OPERATION

E849 EN 06/2001 2002 Bantam

100-00-6 General Information 100-00-6

DESCRIPTION AND OPERATION (CONTINUED)

E849 EN 06/2001 2002 Bantam

DESCRIPTION AND OPERATION

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

Solvent-based Adhesives/Sealers - See Solvents See also Resin-based Adhesives

Follow manufacturers instructions. Individuals suffering from asthma or respiratory

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

Do not employ used engine oils as lubricants or for

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

3. Ford vehicles and replacement parts, which

1. Components or assemblies displaying the caution

4. Components or assemblies displaying this symbol

2. Components or assemblies displaying the

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E850 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION

E4251 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

E4251 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

Component Cleaning WARNING: Most solvents require careful

CAUTION: Compressed air is sometimes 'wet' WARNING: Failure to follow these

E4251 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION

E852 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION

Pre-Test Checks On Road or Roller Test Check:

E853 EN 02/2001 2002 Bantam

DESCRIPTION AND OPERATION (CONTINUED)

WARNING: When brake testing, avoid

CAUTION: Brake testing, which includes

E853 EN 02/2001 2002 Bantam