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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

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Summary of Contents for Ford 2002 Bantam

  • Page 1 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.
  • Page 2: General Information

    MAIN INDEX: FORD BANTAM Workshop Manual Group 1 – General Information Group 2 – Chassis Group 3 – Powertrain Group 4 – Electrical Group 5 – Body and Paint...
  • Page 3 Group General Information SECTION TITLE PAGE Service Information 100-00 General Information Identification Codes 100-01 Jacking and Lifting 100-02 Noise, Vibration and Harshness 100-04...
  • Page 4 FORD BANTAM SECTION 100-00 General Information PAGE 1 OF 2 VEHICLE APPLICATION: 2002 Bantam PAGE SUBJECT 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...
  • Page 5 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 ......................
  • Page 6: Description/Operation

    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.
  • Page 7 Graphics Test graphics show the measurement or test to be performed in a test step. E849 EN 06/2001 2002 Bantam...
  • Page 8 Highly flammable, combustible – observe No Smoking This material is hermetically sealed in the module and policy. is completely consumed during deployment. No Skin contact may result in frostbite. attempt should be made to open an air bag inflator as E850 EN 02/2001 2002 Bantam...
  • Page 9 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...
  • Page 10 Chemical Materials - Do's Used in brake and clutch linings, transmission brake • Do carefully read and observe hazard and bands and gaskets. Ford original production and precaution warnings given on material containers replacement items for this model are asbestos free.
  • Page 11 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...
  • Page 12 There may not be adequate warning of odour or of on the label. irritation before toxic or harmful effects arise. These 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...
  • Page 13 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...
  • Page 14 Gases environmental pollution, workshops should be familiar, See Gas Cylinders. 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...
  • Page 15 Individuals working in booths should wear appropriate respiratory E850 EN 02/2001 2002 Bantam...
  • Page 16 Brief exposure of high concentrations of vapours or In common with many other manufacturers vehicles, mists will cause eye and throat irritation, drowsiness, some components fitted to the Ford range have O- dizziness, headaches and, in the worst circumstances, rings, seals or gaskets, which contain a material unconsciousness.
  • Page 17 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...
  • Page 18 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...
  • Page 19 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...
  • Page 20 • evacuate the area. • hoisting a vehicle up near a ceiling heater • ventilate the area. Only personnel fully trained to Ford and local • contact fire control authorities. standards are to work on alternative fuel vehicles. • remove the vehicle to a dedicated, ventilated area.
  • Page 21 (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...
  • Page 22 • blowing dirt off with compressed air. (Eye equipment, for example torque wrenches, multimeters, protection must be worn when using this method) exhaust gas analysers or rolling roads, are regularly calibrated in accordance with the manufacturers instructions. E4251 EN 02/2001 2002 Bantam...
  • Page 23 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...
  • Page 24 • 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...
  • Page 25 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...
  • Page 26: Identification Codes

    100-01-25 Identification Codes 100-01-25 DESCRIPTION AND OPERATION SECTION 100-01 Identification Codes VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION 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 .......................
  • Page 27 The Vehicle Identification Number (VIN) may also The vehicle identification plate is located in the be checked through the windshield. engine compartment on the front body crossmember. E5827 EN 06/2001 2002 Bantam...
  • Page 28 Item Description Item Description Sequential chassis number World manufacturer identifier code Model code VIN Position 1 Code World Manufacturer Ford Motor Company of Southern Africa (PTY) Limited Year of Manufacture Code Year of manufacture 2001 2002 2003 2004 2005 2006...
  • Page 29 100-01-28 Identification Codes 100-01-28 DESCRIPTION AND OPERATION (CONTINUED) Month of Manufacture Month 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 January February March April June July August September October November December E5827 EN 06/2001 2002 Bantam...
  • Page 30 100-01-29 Identification Codes 100-01-29 DESCRIPTION AND OPERATION Vehicle Certification Label (typical) or VIN Plate FORD MOTOR COMPANY OF SOUTHERN AFRICA Item Description Item Description Gross combination mass Chassis number Maximum permissible front axle Trim loading Engine output kW Tare Build code...
  • Page 31 Titanium grey Pure silver Desert glow Ice blue Aquarius blue Berry red 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...
  • Page 32: Jacking And Lifting

    100-02-31 Jacking and Lifting 100-02-31 SECTION 100-02 Jacking and Lifting VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION 100-02-32 Jacking ..........................100-02-33 Lifting........................... 06/2001 2002 Bantam...
  • Page 33 Failure to rear wheel or behind the front wheel openings. follow these instructions may result in Use a cushioned pad, if possible, to avoid personal injury. damaging the body paint. E857 EN 06/2001 2002 Bantam...
  • Page 34 DESCRIPTION AND OPERATION 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...
  • Page 35: Noise, Vibration And Harshness

    100-04-34 Noise, Vibration and Harshness 100-04-34 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION 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 ..................
  • Page 36 • 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...
  • Page 37 • Simplicity of performing certain tests before the tools that are available. This means working others. with proven diagnostic charts and the correct special equipment for the system. • Elimination of checking huge portions of a system by performing simple tests. E858 EN 02/2001 2002 Bantam...
  • Page 38 • Always follow each step exactly and make characteristic. Also, any non-standard tyre notes to recall important findings later. 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...
  • Page 39 • 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...
  • Page 40 • 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...
  • Page 41 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...
  • Page 42 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 43 DIAGNOSIS AND TESTING 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 .................
  • Page 44 DIAGNOSIS AND TESTING 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 ................
  • Page 45 It may not always be necessary to After verifying that the condition has been corrected, make sure all components removed have been installed. E859 EN 02/2001 2002 Bantam...
  • Page 46 • Are the front wheel halfshaft joint boots OK? CARRY OUT Pinpoint Test E. 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...
  • Page 47 • Are the vehicle components OK? REFER to Pinpoint Test D, Engine Accessory Vibration. INSTALL new components as necessary. ALIGN the powertrain. TEST the system normal operation. E859 EN 02/2001 2002 Bantam...
  • Page 48 • Does the vibration occur? GO TO D2 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...
  • Page 49 Maximum run out is 3.175 mm. - Increase the engine rpm. • Are the belt and pulleys OK? GO TO D5 Diagnose the accessory drive belt concern. REFER to Section 303-05. E859 EN 02/2001 2002 Bantam...
  • Page 50 Inspect the wheel bearings. REFER to Section 204-00. • Are the bearings OK? GO TO E2 INSTALL new bearings as necessary. REFER to Section 204-01. (front) REFER to Section 204-02A / 204-02B. (rear). GO TO E2 E859 EN 02/2001 2002 Bantam...
  • Page 51 - Check the total radial run out again as outlined in Pinpoint Test E4. • Is the total radial run out less than 1.01 mm? GO TO E6 INSTALL new tyre(s) as necessary. TEST the system for normal operation. E859 EN 02/2001 2002 Bantam...
  • Page 52 (Release the parking brake immediately after test). • Is a shudder or vibration present? CHECK the rear brakes. REFER to Section 206-02A / 206-02B. GO TO F5 CHECK the front brakes. REFER to Section 206-03. GO TO F3 E859 EN 02/2001 2002 Bantam...
  • Page 53 F6: REFINISH THE REAR BRAKES 1 Refinish the rear brakes. - Refinish the brake drums and install new rear brake shoes. Road test the vehicle. • Is a shudder or vibration present? GO TO F8 Condition corrected. E859 EN 02/2001 2002 Bantam...
  • Page 54 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? GO TO G3 REFER to Section 204-03. E859 EN 02/2001 2002 Bantam...
  • Page 55 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? GO TO H2 CARRY OUT the setup procedures again. E859 EN 02/2001 2002 Bantam...
  • Page 56 - Check the belt automatic tensioner operation. REFER to Section 303-05. • Is the belt automatic tensioner operating correctly? GO TO I3 INSTALL a new tensioner. REFER to Section 303-05. TEST the system for normal operation. E859 EN 02/2001 2002 Bantam...
  • Page 57 - Ignition switch in RUN, engine running. • Has the vibration been reduced or eliminated? INSTALL a new belt. TEST the system for normal operation. If the condition still occurs after installation GO to Pinpoint Test C. REFER to Section 303-00. E859 EN 02/2001 2002 Bantam...
  • Page 58 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...
  • Page 59 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...
  • Page 60 100-04-56 Noise, Vibration and Harshness 100-04-56 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Specification Information not available at this time. E861 EN 062/2001 2002 Bantam...
  • Page 61: Table Of Contents

    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...
  • Page 62: Suspension - General Information

    204-00-2 Suspension — General Information 204-00-2 SECTION 204-00 Suspension — General Information VEHICLE APPLICATION: 2002 Bantam SECTION TITLE PAGE DIAGNOSIS AND TESTING Suspension System ......................204-00-2 Inspection and Verification ....................204-00-2/4 Symptom Chart ......................... 204-00-4/8 Pinpoint Tests ........................204-00-9/18...
  • Page 63: Front Suspension

    During the road test, drive the vehicle on a road 1. Check for specified air pressure in all four that is smooth and free of undulations. If a tyres. vibration is apparent, note and record the following: E1049 EN 06/2001 2002 Bantam...
  • Page 64: Rear Suspension

    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...
  • Page 65 • 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...
  • Page 66 REFER to Section 204-01. • Damaged, loose or worn front • INSTALL a new front suspen- suspension lower arm mounting sion lower arm mounting bolt bolt bushing. bushing. REFER to Section 204-01. E1049 EN 06/2001 2002 Bantam...
  • Page 67 REFER to Section 204-01. • Loose, damaged or worn sus- • CHECK the suspension units. pension unit(s). REFER to Section 204-01. (front). REFER to Section 204-02. (rear). E1049 EN 06/2001 2002 Bantam...
  • Page 68 • CHECK the steering system. worn. REFER to Section 211-00. • Damaged or stuck front suspen- • INSTALL a new front suspen- sion lower arm ball joint. sion lower arm ball joint. REFER to Section 204-01. E1049 EN 06/2001 2002 Bantam...
  • Page 69 REFER to Section 204-01. • Loose, damaged or worn sus- • CHECK the suspension units. pension unit(s). REFER to Section 204-01.(front). REFER to Section 204-02. (rear). E1049 EN 06/2001 2002 Bantam...
  • Page 70 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..........
  • Page 71 - Check the steering linkage for indications of excessive wear or damage. • Is there indication of excessive wear or damage? INSTALL new or REPAIR worn or damaged components as necessary. TEST the system for normal operation. GO TO A3 E1049 EN 06/2001 2002 Bantam...
  • Page 72 REFER to Section 100-02. - Inspect the steering components for excessive wear or damage. • Are the steering components excessively worn or damaged? INSTALL new or REPAIR worn components. REFER to Section 211-00. GO TO B2 E1049 EN 06/2001 2002 Bantam...
  • Page 73 • Are the measurements the same? GO to Pinpoint Test D. INSPECT the rear suspension components for wear or damage. INSTALL new or REPAIR worn or damaged components as necessary. REFER to Section 204-02. TEST the system for normal operation. E1049 EN 06/2001 2002 Bantam...
  • Page 74 E2: INSPECT THE SPRINGS 1 Inspect the springs for damage. • Are the springs damaged? INSTALL new springs. REFER to Section 204-01. (front) REFER to Section 204-02. (rear). TEST the system for normal operation. GO TO E3 E1049 EN 06/2001 2002 Bantam...
  • Page 75 Verify the customer concern. E6: INSPECT THE TYRES 1 Inspect the tyres for uneven wear. • Is there uneven wear? INSTALL new tyres. CHECK the wheel alignment. TEST the system for normal operation. GO TO E5 E1049 EN 06/2001 2002 Bantam...
  • Page 76 1 Raise and support the vehicle. REFER to Section 100-02. - Inspect the tyres for damage or excessive wear. • Are the tyres damaged or worn? INSTALL new tyres. TEST the system for normal operation. GO TO G2 E1049 EN 06/2001 2002 Bantam...
  • Page 77 Feel for excessive looseness of the bearings. - Spin each wheel by hand and check for roughness. • Are the bearings loose or rough? GO TO G5 GO TO G6 E1049 EN 06/2001 2002 Bantam...
  • Page 78: Wheels And Tyres

    Measure the run out. Wheel and tyre run out should be less than 1.14 mm radial and lateral. • Is the measurement in specification? GO TO G10 GO TO G8 E1049 EN 06/2001 2002 Bantam...
  • Page 79 0.08 mm) and pilot radial run out (greater than 0.05 mm). • Are the measurements correct? GO TO G11 INSTALL a new rear hub. REFER to Section 204-02. TEST the system for normal operation. E1049 EN 06/2001 2002 Bantam...
  • Page 80 REFER to Section 204-01. TEST the system for normal operation. G12: WHEEL BALANCE 1 Balance all the wheels. Road test the vehicle. • Is a vibration felt? REFER to Section 100-04. Verify the customer concern. E1049 EN 06/2001 2002 Bantam...
  • Page 81 204-01-1 Front Suspension 204-01-1 SECTION 204-01 Front Suspension VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DIAGNOSIS AND TESTING 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 ....................
  • Page 82 204-01-2 Front Suspension 204-01-2 DIAGNOSIS AND TESTING Front Suspension REFER to Section 204-00. E1054 EN 06/2001 2002 Bantam...
  • Page 83 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...
  • Page 84 204-01-4 Front Suspension 204-01-4 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...
  • Page 85 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...
  • Page 86 204-01-6 Front Suspension 204-01-6 GENERAL PROCEDURES (CONTINUED) 6. Install the front brake caliper. For additional information, refer to Section 206-03. E3137 EN 06/2001 2002 Bantam...
  • Page 87 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...
  • Page 88 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...
  • Page 89 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...
  • Page 90 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...
  • Page 91 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...
  • Page 92 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, refer to Section 204-03. E1055 EN 06/2001 2002 Bantam...
  • Page 93 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...
  • Page 94 Detach the lower arm ball joint from the wheel knuckle. 1. Remove the pinch bolt. 2. Detach the lower arm ball joint. 10. Remove the heat shield. 11. Remove the wheel knuckle to suspension unit pinch bolt. E1055 EN 06/2001 2002 Bantam...
  • Page 95 • Secure the halfshaft out of the way. Installation 1. Install the wheel knuckle to the suspension unit. 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...
  • Page 96 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...
  • Page 97 Section 204-03. 10. Lower the vehicle. 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...
  • Page 98 2. Drill out the rivets. Installation 1. Install the new ball joint. 2. Install the lower arm. Refer to the procedure in this section. 3. Check the front wheel alignment. For additional information, refer to Section 204-00. E1058 EN 06/2001 2002 Bantam...
  • Page 99 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...
  • Page 100 90 degrees. 2. Remove the wheel knuckle. CAUTION: Use an Allen key to prevent the piston rod from rotating. Remove the suspension unit top mount nut. 1. Remove the cover, (if equipped). 2. Remove the nut. E1060 EN 06/2001 2002 Bantam...
  • Page 101 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...
  • Page 102 Install the heatshield. 6. Install the lower arm to the wheel knuckle. 7. Install the stabiliser bar connecting link and the flexible brake hose bracket to the suspension unit. E1060 EN 06/2001 2002 Bantam...
  • Page 103 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. For additional information, refer to Section 204-00. E1060 EN 06/2001 2002 Bantam...
  • Page 104 WARNING: As the spring is under extreme tension care must be taken at all times. Failure to follow this instruction may result in personal injury. Partially compress the spring. E1061 EN 06/2001 2002 Bantam...
  • Page 105 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...
  • Page 106 Front Wheel Alignment (at kerb weight) - Total Toe Setting Derivative Tolerance Range Setting Adjustment, if required - 0° 12' to 0° 12' Torque Specifications Description Tie-rod locknut Front hub retaining nut Rear hub retaining nut E1062 EN 06/2001 2002 Bantam...
  • Page 107 Connecting link to strut and spring assembly re- taining nut Strut and spring assembly thrust bearing retaining Exhaust front pipe flange retaining nuts Gearshift linkage support bracket retaining bolts Flexible brake hose to strut and spring assembly retaining nut E1062 EN 06/2001 2002 Bantam...
  • Page 108 204-02-1 Rear Suspension 204-02-1 SECTION 204-02 Rear Suspension VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Rear Suspension ......................... 204-02-2 DIAGNOSIS AND TESTING Rear Suspension ......................... 204-02-3 REMOVAL AND INSTALLATION Beam Axle and Suspension Assembly Removal..........(15 231 0) 204-02-4/6 Tube - Rear Axle - Replace................
  • Page 109 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...
  • Page 110 204-02-3 Rear Suspension 204-02-3 DIAGNOSIS AND TESTING Rear Suspension REFER to Section 204-00. E1064 EN 06/2001 2002 Bantam...
  • Page 111 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...
  • Page 112 "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). Refit two bolts on each side of the shock absorber upper mounting plates. E6581 EN 06/2001 2002 Bantam...
  • Page 113 Refer to Section 204-02-17 8. Adjust the parking brake cable. For additional information, refer to Section 206-05. 9. Adjust the Load Active Valve (LAV). For additional information, refer to Section 206-00 E6581 EN 06/2001 2002 Bantam...
  • Page 114 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...
  • Page 115 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...
  • Page 116 6. Lower the vehicle to the ground and finally tighten all nuts and bolts to the specified 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...
  • Page 117 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...
  • Page 118 5. Lower the vehicle to the ground and finally tighten all nuts and bolts to the specified torque. Refer to Section 204-02-17. 6. Adjust the Load Active Valve (LAV). For additional information, refer to Section 206-00 E6583 EN 06/2001 2002 Bantam...
  • Page 119 A sitable tube is a 36.0 mm socket or similar dimensioned tube. E6584 EN 06/2001 2002 Bantam...
  • Page 120 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. Remove bolt securing the bump rubber to axle mounting plate. 3. Remove the bump stop. E6585 EN 06/2001 2002 Bantam...
  • Page 121 Rear Suspension 204-02-14 REMOVAL AND INSTALLATION (CONTINUED) 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...
  • Page 122 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...
  • Page 123 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 E6586 EN 06/2001 2002 Bantam...
  • Page 124 204-03-1 Wheels and Tyres 204-03-1 SECTION 204-03 Wheels and Tyres VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Safety Precautions....................... 204-03-2 Wheels and Tyres........................ 204-03-3 Winter Tyres........................204-03-3 DIAGNOSIS AND TESTING Wheels and Tyres........................ 204-03-4 Inspection and Verification ....................
  • Page 125 Failure to follow these instructions can result in personal injury. WARNING: Retighten the wheel nuts at 800 Km after any wheel change or anytime the wheel nuts are loosened. E1074 EN 07/2001 2002 Bantam...
  • Page 126 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...
  • Page 127 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...
  • Page 128 • 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...
  • Page 129 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...
  • Page 130 INSTALL new parts. TIGHTEN to specifi- cation. • Damaged wheel nuts • Loose wheel assembly. • INSTALL new wheel nuts. TIGHTEN to specification. • Over tightened wheel nuts. • FOLLOW correct tightening pro- cedure. E1076 EN 07/2001 2002 Bantam...
  • Page 131 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...
  • Page 132 Failure to follow this instruction may result in personal injury. Clean the wheel hub and mounting surfaces. 2. Install the wheel and tyre assembly. 3. Lower the vehicle. 4. Tighten the wheel nuts in a diagonally opposed pattern. E8680 EN 07/2001 2002 Bantam...
  • Page 133 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 Torque Specifications Description Wheel nuts – steel/alloy wheels E5837 EN 07/2001 2002 Bantam...
  • Page 134: Front Drive Halfshafts

    205-04-1 Front Drive Halfshafts 205-04-1 SECTION 205-04 Front Drive Halfshafts VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION 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...................
  • Page 135 3. Nearest the wheel, fixed ball joints are fitted halfshaft is rigidly fixed to the intermediate (consisting of a tripod, ball cage and shell). shaft. 7. The wheel-side constant velocity joints are attached to the wheel hubs. E7823 EN 07/2001 2002 Bantam...
  • Page 136 205-04-3 Front Drive Halfshafts 205-04-3 DESCRIPTION AND OPERATION Exploded view of the front drive halfshaft E7823 EN 07/2001 2002 Bantam...
  • Page 137 Foreign matter on the boots can cause premature with sharp edges, the engine when it is hot or ageing of the material. Foreign matter on the the exhaust system. front drive halfshafts can cause imbalance. E7823 EN 07/2001 2002 Bantam...
  • Page 138 • 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...
  • Page 139 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 information, refer to Section 204-03. E6319 EN 07/2001 2002 Bantam...
  • Page 140 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...
  • Page 141 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...
  • Page 142 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...
  • Page 143 1. NOTE: Use an Allen key to stop the piston rod from turning. Undo the suspension strut top nut by five turns. 2. Loosen the axle stub nut. 3. Detach the front wheel. For additional information, refer to Section 204-03. E6365 EN 07/2001 2002 Bantam...
  • Page 144 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...
  • Page 145 CAUTION: The axle stub nut can be re- used four times. Mark the nut. 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...
  • Page 146 6. Install the front wheel. For additional information, refer to Section 204-03. 7. Tighten the axle stub nut. 8. NOTE: Use an Allen key to stop the piston rod from turning. Tighten the suspension strut top nut. E6365 EN 07/2001 2002 Bantam...
  • Page 147 1. NOTE: Use an Allen key to stop the piston rod from turning. Undo the suspension strut top nut by five turns. 2. Raise the vehicle. For additional information, refer to Section 100-02. 3. Detach the lower suspension arm from the spindle carrier. E6459 EN 07/2001 2002 Bantam...
  • Page 148 45 degrees. Pull the right-hand front drive halfshaft out of the tripod joint. • Remove the grease from inside the joint. • Secure the front drive halfshaft to the side with cable ties. E6459 EN 07/2001 2002 Bantam...
  • Page 149 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. Assemble the left-hand front drive halfshaft tripod joint using high-durability grease. E6459 EN 07/2001 2002 Bantam...
  • Page 150 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. E6459 EN 07/2001 2002 Bantam...
  • Page 151 REMOVAL AND INSTALLATION (CONTINUED) 7. Attach the lower suspension arms to the spindle carriers. 8. Lower the vehicle. 9. NOTE: Use an Allen key to stop the piston rod from turning. Tighten the suspension strut top nut. E6459 EN 07/2001 2002 Bantam...
  • Page 152 1. NOTE: Use an Allen key to stop the piston rod from turning. Loosen the suspension strut top nut by five turns. 2. Raise the vehicle. For additional information, refer to Section 100-02. 3. Detach the lower suspension arm from the spindle carrier. E5892 EN 07/2001 2002 Bantam...
  • Page 153 • 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...
  • Page 154 5. Attach the lower suspension arms to the spindle carriers. 6. Lower the vehicle. 7. NOTE: Use an Allen key to stop the piston rod from turning. Tighten the suspension strut top nut. E5892 EN 07/2001 2002 Bantam...
  • Page 155 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. 3. Raise and support the vehicle. For additional information, refer to Section 100-02. E6671 EN 07/2001 2002 Bantam...
  • Page 156 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...
  • Page 157 • 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...
  • Page 158 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...
  • Page 159 205-04-26 Front Drive Halfshafts 205-04-26 REMOVAL AND INSTALLATION (CONTINUED) 9. NOTE: Use an Allen key to prevent the piston rod turning. Tighten the left-hand and the right-hand side strut and spring assembly upper retaining nut. E6671 EN 07/2001 2002 Bantam...
  • Page 160 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...
  • Page 161 1. NOTE: Chamfer points towards the front drive halfshaft. Fit the tripod star assembly. • Slide the boot onto the front drive halfshaft. • Push the tripod star onto the front drive halfshaft. • Fit the circlip. E1088 EN 07/2001 2002 Bantam...
  • Page 162 • 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...
  • Page 163 40 g each side. • Fill level for all other vehicles: 30 g each side. • Push on the boot. • Apply the special tool so that the clamp head is vertically on the clamping strap head. E1088 EN 07/2001 2002 Bantam...
  • Page 164 • Clamp the intermediate shaft in a vice. • Separate and discard the clamping straps. Push back the boot. CAUTION: Constant velocity rollers can drop out. Separate the tripod joint. • Remove the grease from inside the joint. E1089 EN 07/2001 2002 Bantam...
  • Page 165 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. 2. Detach the snap-ring. 3. Pull off the boot. E1089 EN 07/2001 2002 Bantam...
  • Page 166 • 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...
  • Page 167 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. E1089 EN 07/2001 2002 Bantam...
  • Page 168 • Press the boot into the groove on the driveshaft. 1. Slide a small screwdriver under the boot seat to allow the air to escape. 2. Locate the boot in position and remove the screwdriver. • Tension the clamping straps (see previous step). E1089 EN 07/2001 2002 Bantam...
  • Page 169 Torque Specifications Description Intermediate shaft centre bearing Suspension arm to spindle carrier Driveshaft stub nut Suspension strut top nut Tightening tool, for 0,8 mm boot retaining straps Tightening tool, for 1,1 mm boot retaining straps E6460 EN 07/2001 2002 Bantam...
  • Page 170: Drum Brake

    206-00-1 Brake System — General Information 206-00-1 SECTION 206-00 Brake System — General Information VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Brake System ........................206-00-2 DIAGNOSIS AND TESTING Brake System ........................206-00-3 Inspection and Verification ....................206-00-3 Road Test .........................
  • Page 171: Brake System

    Load Active Valve (LAV) connected to the wear at proportional rates. The brakes self adjust rear axle. The LAV control the hydraulic pressure during foot brake operation. applied to the rear brakes reducing the risk of rear wheel lock-up under braking. E6591 EN 07/2001 2002 Bantam...
  • Page 172 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...
  • Page 173 • 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...
  • Page 174 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...
  • Page 175 • 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...
  • Page 176 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 ............
  • Page 177 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 ................
  • Page 178 1 Inspect the brake shoes or brake pads for grease or fluid on the linings and or wear concerns. • Are any concerns present? INSTALL new brake shoes or brake pads. TEST the system for normal operation. E1092 EN 07/2001 2002 Bantam...
  • Page 179 Refer to the brake master cylinder component tests in this section. • Does the system leak? REPAIR as necessary. ADD fluid and BLEED the brake system. REFER to Section 206-00. TEST the system for normal operation. GO TO B3 E1092 EN 07/2001 2002 Bantam...
  • Page 180 1 Road test the vehicle at 40-80 km/h with a medium application on the parking brake control. • Is a vibration present? CHECK the rear brake drums for excessive wear. INSTALL new components as necessary. TEST the system for normal operation. GO TO C3 E1092 EN 07/2001 2002 Bantam...
  • Page 181 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. TEST the system for normal operation. GO TO D4 E1092 EN 07/2001 2002 Bantam...
  • Page 182 Refer to the master cylinder component tests in this section. • Are any leaks found? REPAIR as necessary. ADD fluid and BLEED the brake system. REFER to Section 206-00. TEST the system for normal operation. GO TO E3 E1092 EN 07/2001 2002 Bantam...
  • Page 183 TEST the system for normal operation. F3: CHECK FILLER CAP VENT 1 Check if the filler cap vent holes are clogged or dirty. • Was a concern found? CLEAN as necessary. TEST the system for normal operation. GO TO F4 E1092 EN 07/2001 2002 Bantam...
  • Page 184 1 Check for excessive tyre wear or incorrect tyre pressures. • Are the tyres in good order? GO TO G3 SUBSTITUTE known good tyres. INFLATE to the correct pressure. TEST the system for normal operation. E1092 EN 07/2001 2002 Bantam...
  • Page 185 I1: CHECK BRAKE BOOSTER 1 Check the brake booster push rod alignment and pedal travel. • Is the push rod and pedal travel OK? GO TO I2 INSTALL a new brake booster. TEST the system for normal operation. E1092 EN 07/2001 2002 Bantam...
  • Page 186 Blow into the hose attached to the brake booster check valve. • Does air pass through the valve? INSTALL a new brake booster check valve. TEST the system for normal operation. GO TO J4 E1092 EN 07/2001 2002 Bantam...
  • Page 187 - 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? GO TO K2 Vehicle OK. E1092 EN 07/2001 2002 Bantam...
  • Page 188 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...
  • Page 189 • 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...
  • Page 190 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...
  • Page 191 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...
  • Page 192 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...
  • Page 193 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...
  • Page 194 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...
  • Page 195 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...
  • Page 196 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...
  • Page 197 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...
  • Page 198 Section 204-01. 11. If the hub face run out is within specification install a new brake disc and recheck the brake disc run-out. For additional information, refer to Section 206-03 refer to Section 206-04. E3166 EN 07/2001 2002 Bantam...
  • Page 199: Front Disc Brake

    Brake shoe width Wheel cylinder bore diameter 17.78 New primary brake shoe lining thickness New secondary brake shoe lining thickness Minimum brake shoe lining thickness *When the discard diameter has been reached install a new brake drum. E9395 EN 07/2001 2002 Bantam...
  • Page 200 206-02-1 Drum Brake 206-02-1 SECTION 206-02 Drum Brake VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Drum Brake ......................... 206-02-2 DIAGNOSIS AND TESTING Drum Brake ......................... 206-02-3 REMOVAL AND INSTALLATION Brake Drum Replacement ................(12 275 0) 206-02-4/5 Brake Shoes ....................(12 285 0) 206-02-6/10 Wheel Cylinder ....................
  • Page 201 206-02-2 Drum Brake 206-02-2 DESCRIPTION AND OPERATION Drum Brake Item Description Item Description Brake shoes Backing plate Brake drum Wheel cylinder E6593 EN 07/2001 2002 Bantam...
  • Page 202 206-02-3 Drum Brake 206-02-3 DIAGNOSIS AND TESTING Drum Brake REFER to Section 206-00. E1097 EN 07/2001 2002 Bantam...
  • Page 203 4. Raise and support the vehicle. For additional information, refer to Section 100-02. 5. Remove the wheel. 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...
  • Page 204 NOTE: Rotate the hub while tightening the hub- retaining nut. 1. To install, reverse the removal procedure. 4. Adjust the parking brake cable. For additional information, refer to Section 206-05. E6594 EN 07/2001 2002 Bantam...
  • Page 205 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...
  • Page 206 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...
  • Page 207 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...
  • Page 208 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...
  • Page 209 206-02-10 Drum Brake 206-02-10 REMOVAL AND INSTALLATION (CONTINUED) 10. Install the brake drum, wheel spindle and wheel hub assembly. 11. Adjust the parking brake cable. For additional information, refer to Section 206-05. 07/2001 2002 Bant...
  • Page 210 3. Remove the wheel cylinder. 1. Disconnect the brake hose union. 2. Remove the bolts. 3. Remove the wheel cylinder. Installation NOTE: Make sure a gasket is installed between the wheel cylinder and back plate. E1100 EN 07/2001 2002 Bantam...
  • Page 211 1. Install the wheel cylinder. 1. Install the wheel cylinder bolts. 2. Install the brake hose union. 2. Remove the brake hose clamp. 3. Bleed the brake system. For additional information, refer to Section 206-00. E1100 EN 07/2001 2002 Bantam...
  • Page 212 Wheel Cylinder in this section. 3. Detach the parking brake cable. 1. Depress the retaining clip. 2. Remove the cable. 4. Remove the backing plate. • Drill out the rivets. Installation 1. To install, reverse the removal procedure. E1101 EN 07/2001 2002 Bantam...
  • Page 213 Particular care must be taken when refinishing brake drums that the discard brake drum diameter dimensions are not exceeded. Torque Specifications Description Wheel hub retaining nut Wheel nuts Brake drum and wheel hub assembly bolts Wheel cylinder retaining bolts Brake hose union E6596 EN 07/2001 2002 Bantam...
  • Page 214 206-03-1 Front Disc Brake 206-03-1 SECTION 206-03 Front Disc Brake VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Front Brake Disc ........................206-03-2 DIAGNOSIS AND TESTING Front Brake Disc ........................206-03-3 REMOVAL AND INSTALLATION Brake Pads .......................... 206-03-4/6 Brake Caliper ....................(12 243 0)
  • Page 215 206-03-2 Front Disc Brake 206-03-2 DESCRIPTION AND OPERATION Front Brake Disc Item Description Item Description Brake caliper retaining clip Brake disc Brake caliper Brake pad Brake caliper anchor plate E9360 EN 03/2001 2002 Bantam...
  • Page 216 206-03-3 Front Disc Brake 206-03-3 DIAGNOSIS AND TESTING Front Brake Disc REFER to Section 206-00. E490 EN 03/2001 2002 Bantam...
  • Page 217 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. 2. Remove the bolts. E9414 EN 03/2001 2002 Bantam...
  • Page 218 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...
  • Page 219 5. Install the wheel and tyre. For additional information, refer to Section 204-03. 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...
  • Page 220 Section 204-03. 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...
  • Page 221 • Turn the caliper and anchor plate assembly counter clockwise to remove. Installation 1. To install, reverse the removal procedure. 2. Bleed the brake system. For additional information, refer to Section 206-00. E9415 EN 03/2001 2002 Bantam...
  • Page 222 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...
  • Page 223 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...
  • Page 224 * When the discard thickness has been reached, install a new brake disc. Torque Specifications Description Wheel nuts Brake caliper piston housing retaining bolts Brake caliper anchor bracket retaining bolts Brake hose to brake caliper union E9396 EN 03/2001 2002 Bantam...
  • Page 225 206-04-1 Wheels and Tyres 206-04-1 SECTION 206-04 Wheels and Tyres VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Wheel and Tyre ........................206-04-2 07/2001 2002 Bantam...
  • Page 226 Failure to follow this instruction may result in personal injury. Clean the wheel hub and mounting surfaces. 2. Install the wheel and tyre assembly. 3. Lower the vehicle. 4. Tighten the wheel nuts in a diagonally opposed pattern. E8680 EN 07/2001 2002 Bantam...
  • Page 227: Parking Brake And Actuation

    206-05-1 Parking Brake and Actuation 206-05-1 SECTION 206-05 Parking Brake and Actuation VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Parking Brake ........................206-05-2 DIAGNOSIS AND TESTING Parking Brake ........................206-05-3 Inspection and Verification ....................206-05-3 Symptom Chart .........................
  • Page 228 DESCRIPTION AND OPERATION Parking Brake Item Description Item Description Push button Adjusting nut Return spring Bolt Equaliser Parking brake lever Return spring Parking brake switch coupler Front parking brake cable Grip Rear parking brake cable E5844 EN 07/2001 2002 Bantam...
  • Page 229 1 Inspect the brake shoes for excessive wear. REFER to Section 206-00. • Are the brake shoes and linings OK? GO TO A3 INSTALL new brake shoes. REFER to Section 206-02. TEST the system for normal operation. E1109 EN 07/2001 2002 Bantam...
  • Page 230 • Did the parking brake release? CHECK for other causes such as conventional brake system components. REPAIR or INSTALL new components as necessary. REFER to Section 206-00. GO TO B1 E1109 EN 07/2001 2002 Bantam...
  • Page 231 REFER to Parking Brake Cable in this section TEST the system for normal operation. CHECK for other causes such as conven- tional brake system components. REPAIR or INSTALL new components as necessary. REFER to Section 206-00. E1109 EN 07/2001 2002 Bantam...
  • Page 232 1. Remove the parking brake control cover 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...
  • Page 233 2. Remove the parking brake control. Installation 1. To install, reverse the removal procedure. 2. Adjust the parking brake cable. For additional information, refer to Parking Brake Cable Adjustment in this section E1110 EN 07/2001 2002 Bantam...
  • Page 234: Parking Brake Cable/Conduit

    5. Remove the wheel. 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...
  • Page 235 11. Remove the brake drum. For additional information, refer to Section 206-02. 12. Detach the parking brake cable. 1. Pull the secondary brake shoe lever backwards. 2. Disconnect the cable from the secondary brake shoe. E6602 EN 07/2001 2002 Bantam...
  • Page 236 206-05-10 Parking Brake and Actuation 206-05-10 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. To install, reverse the removal procedure. 2. Adjust the parking brake. For additional information, Adjustment refer to Parking Brake Cable in this section E6602 EN 07/2001 2002 Bantam...
  • Page 237 Parking Brake Warning Indicator Switch (33 546 0) Removal 1. Remove the parking brake control. For additional information, refer to Parking Brake Control in this section 2. Remove the switch. Installation 1. To install, reverse the removal procedure. E1113 EN 07/2001 2002 Bantam...
  • Page 238 5. Adjust the parking brake cable. 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...
  • Page 239 206-05-13 Parking Brake and Actuation 206-05-13 SPECIFICATIONS Torque Specifications Description Parking brake cable adjusting nut Parking brake control nuts Wheel nuts E1115 EN 07/2001 2002 Bantam...
  • Page 240: Hydraulic Brake Actuation

    206-06-1 Hydraulic Brake Actuation 206-06-1 SECTION 206-06 Hydraulic Brake Actuation VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Hydraulic Brake Actuation....................206-06-2 DIAGNOSIS AND TESTING Hydraulic Brake Actuation....................206-06-3 REMOVAL AND INSTALLATION Brake Master Cylinder ..................(12 343 0) 206-06-4/5 Brake Pedal ....................
  • Page 241 206-06-2 Hydraulic Brake Actuation 206-06-2 DESCRIPTION AND OPERATION Hydraulic Brake Actuation Item Description Item Description Brake pedal cross-shaft Brake pedal Brake master cylinder and fluid reser- voir E9397 EN 03/2001 2002 Bantam...
  • Page 242 206-06-3 Hydraulic Brake Actuation 206-06-3 DIAGNOSIS AND TESTING Hydraulic Brake Actuation REFER to Section 206-00. E1117 EN 03/2001 2002 Bantam...
  • Page 243 4. Tighten the bleed nipple. 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...
  • Page 244 CAUTION: Make sure the brake master cylinder vacuum seal is correctly posi- tioned before installation. 1. To install, reverse the removal procedure. 2. Bleed the brake system. For additional information, refer to Section 206-00. E9398 EN 03/2001 2002 Bantam...
  • Page 245 2. Push the brake pedal cross-shaft towards the brake pedal. 3. Remove the brake pedal cross-shaft 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...
  • Page 246 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...
  • Page 247 4. Tighten the bleed nipple. 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...
  • Page 248 REMOVAL AND INSTALLATION (CONTINUED) 5. Remove the brake fluid reservoir. • Detach the securing pin. Installation 1. To install, reverse the removal procedure. 2. Bleed the brake system. For additional information, refer to Section 206-00. E9399 EN 03/2001 2002 Bantam...
  • Page 249 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...
  • Page 250 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...
  • Page 251 206-06-12 Hydraulic Brake Actuation 206-06-12 REMOVAL AND INSTALLATION (CONTINUED) 9. Remove the brake pedal cross-shaft from the brake booster support bracket. 10. Remove the brake pedal cross-shaft Installation 1. To install, reverse the removal procedure. E9400 EN 03/2001 2002 Bantam...
  • Page 252 414-01. 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. 4. Disconnect the accelerator cable from the accelerator pedal. E9362 EN 03/2001 2002 Bantam...
  • Page 253 7. Detach the clutch master cylinder from the brake pedal and bracket. 8. Detach the clutch master cylinder actuating rod from the clutch pedal. • Remove the clip. 9. Detach the brake pedal cross-shaft mounting bracket from the bulkhead. E9362 EN 03/2001 2002 Bantam...
  • Page 254 206-06-15 Hydraulic Brake Actuation 206-06-15 REMOVAL AND INSTALLATION (CONTINUED) 10. Remove the brake pedal and bracket Installation 1. To install, reverse the removal procedure. E9362 EN 03/2001 2002 Bantam...
  • Page 255 Hydraulic Brake Actuation 206-06-16 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Specification DOT 4 brake fluid SAM-6C9103-A Torque Specifications Description Brake master cylinder brake tube unions Brake master cylinder retaining nuts Brake pedal cross-shaft mounting bracket nuts E1124 EN 03/2001 2002 Bantam...
  • Page 256: Power Brake Actuation

    206-07-1 Power Brake Actuation 206-07-1 SECTION 206-07 Power Brake Actuation VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Brake Booster ........................206-07-2 DIAGNOSIS AND TESTING Power Brake System ......................206-07-3 REMOVAL AND INSTALLATION Brake Booster ....................(12 451 0)
  • Page 257 206-07-2 Power Brake Actuation 206-07-2 DESCRIPTION AND OPERATION Brake Booster Item Description Brake booster E1125 EN 07/2001 2002 Bantam...
  • Page 258 206-07-3 Power Brake Actuation 206-07-3 DIAGNOSIS AND TESTING Power Brake System REFER to Section 206-00. E1126 EN 07/2001 2002 Bantam...
  • Page 259 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...
  • Page 260 206-07-5 Power Brake Actuation 206-07-5 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. To install, reverse the removal procedure. E9401 EN 07/2001 2002 Bantam...
  • Page 261 206-07-6 Power Brake Actuation 206-07-6 SPECIFICATIONS Torque Specifications Description Brake booster retaining nuts Brake master cylinder retaining nuts E1128 EN 07/2001 2002 Bantam...
  • Page 262 211-00-1 Steering System — General Information 211-00-1 SECTION 211-00 Steering System — General Information VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DIAGNOSIS AND TESTING Steering System ........................211-00-2 Principles of Operations ...................... 211-00-2 Inspection and Verification ....................211-00-2 Symptom Chart ........................
  • Page 263: Power Steering

    • Seized suspension ball joints. • CARRY out a ball joint compo- nent test. REFER to Section 204-00. • Moan type noise • Routing of power steering • CHECK the security and routing hoses. of the power steering hoses. E6308 EN 07/2001 2002 Bantam...
  • Page 264: Steering Linkage

    • 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...
  • Page 265: Steering Column

    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...
  • Page 266 • 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...
  • Page 267 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...
  • Page 268 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...
  • Page 269 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...
  • Page 270 10. Raise and support the vehicle. For additional information, refer to Section 100- 02. 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...
  • Page 271 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. For additional information, refer to Power Steering System Bleeding in this section E3217 EN 07/2001 2002 Bantam...
  • Page 272 Refer to the Wiring Diagram Section 700-06 for schematic and electrical information. Vehicles with diesel engine 4. Disconnect the fuel injection pump electrical connector. 1. Pull out the locking handle. 2. Disconnect the electrical connector. E3219 EN 07/2001 2002 Bantam...
  • Page 273 8. Fill the power steering fluid reservoir to the MAX mark with power steering fluid. All except vehicles with diesel engine 9. Connect the CKP electrical connector. Refer to the Wiring Diagram Section 700-06 for schematic and electrical information. E3219 EN 07/2001 2002 Bantam...
  • Page 274 11. Start the engine. Turn the steering wheel from lock to lock; if excessive noise is apparent bleed the system. For additional information, refer to Power Steering System Bleeding in this section 12. Lower the vehicle. E3219 EN 07/2001 2002 Bantam...
  • Page 275 Roll restrictor to transmission retaining bolt Track rod end locknuts Wheel nuts Flexible coupling to steering column shaft pinch bolt Flexible coupling to pinion shaft pinch bolt Track rod locknuts Steering wheel retaining bolt Steering column retaining nuts 07/2001 2002 Bantam...
  • Page 276: Manual Steering

    211-01-15 Manual Steering 211-01-15 SECTION 211-01 Manual Steering VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Manual Steering........................211-01-16 DIAGNOSIS AND TESTING Manual Steering........................211-01-17 REMOVAL AND INSTALLATION Steering Gear ....................(13 116 0) 211-01-18/23 SPECIFICATIONS Specifications......................... 211-01-24 Torque Specifications......................
  • Page 277 The flexible coupling, in turn, is attached to the steering gear Item Description Item Description Flexible coupling Track rod Steering column assembly Steering gear Steering wheel Track rod end Steering gear gaiter E5853 EN 07/2001 2002 Bantam...
  • Page 278 211-01-17 Manual Steering 211-01-17 DIAGNOSIS AND TESTING Manual Steering REFER to Section 211-00. E5854 EN 07/2001 2002 Bantam...
  • Page 279 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...
  • Page 280 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...
  • Page 281 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...
  • Page 282 211-01-21 Manual Steering 211-01-21 REMOVAL AND INSTALLATION (CONTINUED) 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...
  • Page 283 Vehicles with manual transaxle 4. Install the gearshift linkage. 5. Install the tie rods. 6. Install the wheels. 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...
  • Page 284 211-01-23 Manual Steering 211-01-23 REMOVAL AND INSTALLATION (CONTINUED) 8. Install the lower steering coupling pinch bolt. E5855 EN 07/2001 2002 Bantam...
  • Page 285 Track rod end to spindle carrier locknuts Flexible coupling to steering column shaft pinch bolt Flexible coupling to pinion shaft pinch bolt Track rod end to tie rod locknuts Steering wheel retaining bolt Steering column retaining nuts E6376 EN 07/2001 2002 Bantam...
  • Page 286 211-02-25 Power Steering 211-02-25 SECTION 211-02 Power Steering - Petrol VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Power Steering ........................211-02-26/28 DIAGNOSIS AND TESTING Power Steering ........................211-02-29 REMOVAL AND INSTALLATION Power Steering Pump — Vehicles with 1.8l Endura DE diesel Engine ..(13 434 0) 211-02-30/33 Power Steering Pump —...
  • Page 287 Steering gear boot Power steering pressure switch (PSP) Steering column coupling Steering wheel Steering column Power steering fluid cooler Tie-rod The power assisted steering gear is of the conventional rack and pinion type. The steering E5895 EN 07/2001 2002 Bantam...
  • Page 288 PSP switch opens, signalling the has a remote fluid reservoir located on the right- powertrain control module to increase the engine hand side of the engine compartment. The power idle speed. Vehicles with 1.8L Endura DE engine. E5895 EN 07/2001 2002 Bantam...
  • Page 289 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...
  • Page 290 211-02-29 Power Steering 211-02-29 DIAGNOSIS AND TESTING Power Steering REFER to Section 211-00. E1209 EN 07/2001 2002 Bantam...
  • Page 291 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...
  • Page 292 211-02-31 Power Steering 211-02-31 REMOVAL AND INSTALLATION (CONTINUED) 6. Remove the cable tie. E6317 EN 07/2001 2002 Bantam...
  • Page 293 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...
  • Page 294 CAUTION: Install a new "O" ring seal on the power steering high pressure line. 2. Refit the components in the reverse order. 3. Fill and bleed the power steering system. For additional information, refer to Section 211-00. E6317 EN 07/2001 2002 Bantam...
  • Page 295 Disconnect the power steering fluid cooler lines from the power steering fluid cooler. • Allow the fluid to drain into a suitable container. 4. Lower the vehicle. E6613 EN 2002 Bantam...
  • Page 296 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. E6613 EN 2002 Bantam...
  • Page 297 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. E6613 EN 2002 Bantam...
  • Page 298 • Rotate the accessory drive belt tensioner clockwise. 7. Connect the power steering fluid cooler lines to the power steering fluid cooler. 8. Lower the vehicle. 9. Fill and bleed the power steering system. For additional information, refer to Section 211-02. E6613 EN 2002 Bantam...
  • Page 299 2. NOTE: When installing a new power steering 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. • Allow the fluid to drain into a suitable container. E6614 EN 2002 Bantam...
  • Page 300 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. E6614 EN 2002 Bantam...
  • Page 301 Using the special tool, install a new power steering pump drive pulley. 6. Install the auxiliary drive belt. For additional information, refer to Section 303-05. 7. Fill and bleed the power steering system. refer to Section 211-00. For additional information, E6614 EN 2002 Bantam...
  • Page 302 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...
  • Page 303 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...
  • Page 304 211-02-43 Power Steering 211-02-43 REMOVAL AND INSTALLATION (CONTINUED) Note: Install the pump front retaining bolts first. 2. Refit the components in reverse order. E6318 EN 07/2001 2002 Bantam...
  • Page 305 211-02-44 Power Steering 211-02-44 REMOVAL AND INSTALLATION (CONTINUED) E6318 EN 07/2001 2002 Bantam...
  • Page 306 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...
  • Page 307 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. E6320 EN 07/2001 2002 Bantam...
  • Page 308 Disconnect the track rod end ball joints from the spindle carriers. Vehicles with manual transaxle 7. Disconnect the gearshift linkage. 8. Detach the gearshift control assembly and secure to one side. E6320 EN 07/2001 2002 Bantam...
  • Page 309 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...
  • Page 310 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...
  • Page 311 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...
  • Page 312 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. 2. Refit the components in the reverse order. E6320 EN 07/2001 2002 Bantam...
  • Page 313 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...
  • Page 314 211-02-53 Power Steering 211-02-53 REMOVAL AND INSTALLATION (CONTINUED) Vehicles with manual transaxle 6. Install the gearshift linkage. For additional information, refer to Section 308-06. All vehicles E6320 EN 07/2001 2002 Bantam...
  • Page 315 211-02-54 Power Steering 211-02-54 REMOVAL AND INSTALLATION (CONTINUED) 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...
  • Page 316 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...
  • Page 317 CAUTION: Make sure no particles of the 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...
  • Page 318 • 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 (refer to procedure contained in this section). E5858 EN 07/2001 2002 Bantam...
  • Page 319 4. Disconnect the fluid cooler pipe and hose connections. 1. Disconnect the right-hand side pipe union and hose connection. • Allow the fluid to drain into a suitable container. 2. Disconnect the left-hand side pipe unions. E5857 EN 07/2001 2002 Bantam...
  • Page 320 5. Remove the high-pressure pipe bracket (one bolt). 6. Remove the fluid cooler (two bolts). Installation 1. Refit the components in the reverse order. 2. Bleed the power steering system (refer to procedure contained in this section). E5857 EN 07/2001 2002 Bantam...
  • Page 321 1. Remove the steering column coupling to steering gear pinion shaft pinch bolt. 2. Loosen the steering column shaft coupling pinch bolt. 6. Raise and support the vehicle. For additional information, refer to Section 100- 02. E5861 EN 07/2001 2002 Bantam...
  • Page 322 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...
  • Page 323 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. • Allow the fluid to drain into a suitable container. E5861 EN 07/2001 2002 Bantam...
  • Page 324 2. Disconnect the power steering high- pressure line union. • Allow the fluid to drain into a suitable container. Left-hand drive vehicles 22. Detach the power steering high-pressure line support brackets. E5861 EN 07/2001 2002 Bantam...
  • Page 325 Vehicles with 1.6L / 1.3L engine 24. Detach the power steering high-pressure line support bracket. All Vehicles 25. Remove the power steering high-pressure line from the steering gear. • Allow the fluid to drain into a suitable container. E5861 EN 07/2001 2002 Bantam...
  • Page 326 2. Locate the special tool onto the union and push on the O-ring seal. 2. Install the power steering high-pressure line. Vehicles with 1.6L / 1.3L engine 3. Install the power steering high-pressure line support bracket. E5861 EN 07/2001 2002 Bantam...
  • Page 327 1. Connect the power steering pump high- pressure line. 2. Install the power steering pump high- pressure line support bracket. All Vehicles 7. Install the power steering pump high- pressure line to the accessory drive belt lower guard. E5861 EN 07/2001 2002 Bantam...
  • Page 328 2. Install the power steering pump high- pressure line support brackets. 10. Install the PSP switch. 1. Install the PSP switch. 2. Connect the electrical connector. All Vehicles 11. Install the power steering gear floor seal. E5861 EN 07/2001 2002 Bantam...
  • Page 329 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...
  • Page 330 25. Install the steering column coupling to the power steering gear pinion. 26. Tighten the steering column shaft coupling pinch bolt. 27. Fill and bleed the power steering system. refer to Section 211-00. For additional information, E5861 EN 07/2001 2002 Bantam...
  • Page 331 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...
  • Page 332 5. Disconnect the power steering fluid cooler line to the power steering gear. • Allow the fluid to drain into a suitable container. 6. Detach the power steering fluid cooler line to the power steering gear support bracket. E5862 EN 07/2001 2002 Bantam...
  • Page 333 9. Disconnect the exhaust front pipe. • Discard the gasket and nuts. Vehicles with manual transaxle 10. Detach the shift rod and gearshift stabilizer. 1. Shift rod. 2. Gearshift stabilizer. E5862 EN 07/2001 2002 Bantam...
  • Page 334 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...
  • Page 335 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...
  • Page 336 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...
  • Page 337 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...
  • Page 338 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...
  • Page 339 19. Install the steering column coupling to the power steering gear pinion. 20. Tighten the steering column shaft coupling pinch bolt. 21. Fill and bleed the power steering system. For additional information, refer to Section 211-00. E5862 EN 07/2001 2002 Bantam...
  • Page 340 Accessory drive belt tensioner pulley centre bolt (Endura-DE) Drive belt guard retaining bolts (Endura-DE) Power steering pressure (PSP) switch Steering wheel retaining bolt Steering column retaining nuts Exhaust front pipe flange Gearshift linkage pinch bolt E6321 EN 07/2001 2002 Bantam...
  • Page 341 211-03-80 Steering Linkage 211-03-80 SECTION 211-03 Steering Linkages VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Steering Linkage........................211-03-81 DIAGNOSIS AND TESTING Steering Linkage........................211-03-82 REMOVAL AND INSTALLATION Tie-Rod End ..................... (13 273 0) 211-03-83/84 Steering Gear Boot................... (13 134 0)
  • Page 342 The tie rod is an extension of the steering gear. the tie rod articulates between the inner and The steering gear movement is transferred to the wheels by means of: outer ball joint. E1216 EN 07/2001 2002 Bantam...
  • Page 343 211-03-82 Steering Linkage 211-03-82 DIAGNOSIS AND TESTING Steering Linkage REFER to Section 211-00. E1217 EN 07/2001 2002 Bantam...
  • Page 344 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...
  • Page 345 1. To install, reverse the removal procedure. 3. Check the toe setting and adjust as necessary. For additional information, refer to Section 204-00. E1219 EN 07/2001 2002 Bantam...
  • Page 346 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 1. To install, reverse the removal procedure. E1218 EN 07/2001 2002 Bantam...
  • Page 347 211-03-86 Steering Linkage 211-03-86 SPECIFICATIONS Torque Specifications Description Tie rod end retaining nut Tie rod end lock nut Wheels nuts E1220 EN 07/2001 2002 Bantam...
  • Page 348 211-04-87 Steering Column 211-04-87 SECTION 211-04 Steering Column VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Steering Column ........................211-04-88 REMOVAL AND INSTALLATION Steering Wheel ....................(13 524 0) 211-04-89 Air Bag Sliding Contact ..................(33 392 0) 211-04-90 Steering Column ....................
  • Page 349 211-04-88 Steering Column 211-04-88 DESCRIPTION AND OPERATION Steering Column Item Description Item Description Flexible coupling Steering wheel Steering column E1221 EN 07/2001 2002 Bantam...
  • Page 350 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. To install, reverse the removal procedure. E1222 EN 07/2001 2002 Bantam...
  • Page 351 211-04-90 Steering Column 211-04-90 REMOVAL AND INSTALLATION Air Bag Sliding Contact (33 392 0) For additional information, refer to Section 501-20B. E1224 EN 07/2001 2002 Bantam...
  • Page 352 Section 211-05. 2. Centre the steering wheel and lock in position. 3. Remove the PATS transceiver. 1. Disconnect the electrical connector. 2. Remove the retaining screw. 4. Disconnect the ignition switch electrical connector. E1223 EN 07/2001 2002 Bantam...
  • Page 353 7. Disconnect the hood latch remote control cable. 8. From inside the passenger compartment, 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...
  • Page 354 Steering Column 211-04-93 REMOVAL AND INSTALLATION (CONTINUED) 9. Remove the steering column. • Remove the two retaining nuts. Installation CAUTION: Make sure the steering is in the straight ahead position. To install, reverse the removal procedure. E1223 EN 07/2001 2002 Bantam...
  • Page 355 211-04-94 Steering Column 211-04-94 SPECIFICATIONS Torque Specifications Description Steering wheel retaining bolt Steering column retaining nuts Steering column coupling to steering column pinch bolt E1225 EN 07/2001 2002 Bantam...
  • Page 356: Steering Column Switches

    211-05-95 Steering Column Switches 211-05-95 SECTION 211-05 Steering Column Switches VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Steering Column Switches..................... 211-05-96 Multi-function Switch ......................211-05-96/97 Ignition Switch ........................211-05-97 DIAGNOSIS AND TESTING Steering Column Switches..................... 211-05-98A Inspection and Verification ....................
  • Page 357 The multi-function switch located on the right- hand side of the steering column controls the Multi-function Switch following: The multi-function switch located on the left-hand • Windshield wipers/washers. side of the steering column controls the following: E1226 EN 07/2001 2002 Bantam...
  • Page 358 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...
  • Page 359 • 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...
  • Page 360 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 ..............
  • Page 361 1 Remove the steering column shrouds and check the ignition switch connector. • Is the ignition switch connector clean and secure? GO TO A2 CLEAN and SECURE the ignition switch connector as required. TEST the system for normal operation. E1227 EN 07/2001 2002 Bantam...
  • Page 362 • Is the resistance greater than 10,000 ohms? GO TO A2 REPAIR circuit 30 (RD). TEST the system for normal operation. A4: CHECK FOR OPEN ON CIRCUIT 30 (RD) Fuse 40 (60A) Ignition switch con- nector C61 E1227 EN 07/2001 2002 Bantam...
  • Page 363 C61 pin 1, circuit 75 (YE) and the fuse 19 (10A) less than 5 ohms? INSTALL a new ignition switch. TEST the system for normal operation. REPAIR circuit 75 (YE). TEST the system for normal operation. E1227 EN 07/2001 2002 Bantam...
  • Page 364 1 Carry out the ignition switch component test. Refer to the procedure in this section. • Does the ignition switch test OK? GO TO C4 INSTALL a new ignition switch. TEST the system for normal operation. E1227 EN 07/2001 2002 Bantam...
  • Page 365 C47 pin 2, circuit 31 (BK) and ground. • Is the resistance less than 5 ohms? GO TO C6 Repair circuit 31 (BK). TEST the system for normal operation. C6: CHECK THE IGNITION RELAY POWER FEED Interior light relay E1227 EN 07/2001 2002 Bantam...
  • Page 366 INSTALL a new ignition relay. TEST the system for normal operation. REPAIR circuit 15 (GN). TEST the system for normal operation. PINPOINT TEST D: NO POWER IN START CONDITIONS DETAILS/RESULTS/ACTIONS D1: CHECK FUSE 36 (60A) Fuse 36 (60A) E1227 EN 07/2001 2002 Bantam...
  • Page 367 • Does the ignition switch test OK? GO TO D4 INSTALL a new ignition switch. TEST the system for normal operation. D4: CHECK FOR SHORT/OPEN ON CIRCUIT 50 (GY) Start inhibit relay Ignition switch C61 C163 E1227 EN 07/2001 2002 Bantam...
  • Page 368 1 Measure the voltage between the start inhibit relay connector C163 pin 5, circuit 30 (RD) and ground. • Is the voltage greater than 10 volts? GO TO D7 REPAIR circuit 30 (RD). TEST the system for normal operation. E1227 EN 07/2001 2002 Bantam...
  • Page 369 E2: CHECK THE WIPER AND WASHER 1 Operate the wipers and washers. • Do the wipers and washers work OK? VERIFY the customer concern. REFER to Section 501-16 to diagnose the wipers and washers. E1227 EN 07/2001 2002 Bantam...
  • Page 370 2. Remove the steering column upper and lower shrouds. 3. Remove the multifunction switch. 1. Disconnect the multi-function switch electrical connectors. 2. Remove the retaining screw. 3. Remove the switch. Installation 1. To install, reverse the removal procedure. E1230 EN 07/2001 2002 Bantam...
  • Page 371 2. Remove the steering column upper and lower shrouds. 3. Disconnect the ignition switch electrical connector. 4. Remove the ignition switch. • Release the switch retaining clips. Installation 1. To install, reverse the removal procedure. E1231 EN 07/2001 2002 Bantam...
  • Page 372 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 —...
  • Page 373 303-00-1 Engine System — General Information 303-00-1 SECTION 303-00 Engine System — General Information VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DIAGNOSIS AND TESTING Engine ..........................303-00-2 Inspection and Verification ....................303-00-2 Symptom Chart ......................... 303-00-2 Pinpoint Tests ........................303-00-2 Component Tests......................
  • Page 374 303-00-2 Engine System — General Information 303-00-2 DIAGNOSIS AND TESTING Engine Inspection and Verification Pinpoint Tests Symptom Chart Component Tests E6626 EN 07/2001 2002 Bantam...
  • Page 375 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...
  • Page 376 • 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...
  • Page 377 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...
  • Page 378 • 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...
  • Page 379 303-00-7 Engine System — General Information 303-00-7 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...
  • Page 380 Engine System — General Information 303-00-8 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...
  • Page 381 • 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...
  • Page 382 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...
  • Page 383 303-00-11 Engine System — General Information 303-00-11 GENERAL PROCEDURES Crankshaft Main bearing Journal Clearance Main bearings - Minimum 0.020 mm Maximum 0.056 mm E4546 EN 07/2001 2002 Bantam...
  • Page 384 • 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...
  • Page 385 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...
  • Page 386 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...
  • Page 387 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...
  • Page 388 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...
  • Page 389 • 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...
  • Page 390 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...
  • Page 391 Engine System — General Information 303-00-19 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...
  • Page 392 303-00-20 Engine System — General Information 303-00-20 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...
  • Page 393 303-00-21 Engine System — General Information 303-00-21 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...
  • Page 394 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...
  • Page 395 Engine lifting eye order no.: 6630411 Assembly stand Workshop jack Material Specification 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...
  • Page 396 303-01A-24 Engine — 1.6L / 1.3L RoCam 303-01B24 SECTION 303-01B Engine — 1.6L / 1.3L RoCam PAGE 1 OF 2 VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine ..........................303-01B-26 General..........................303-01B-26/33 DIAGNOSIS AND TESTING Engine ..........................303-0IB-34 IN-VEHICLE REPAIR Intake Manifold ....................
  • Page 397 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...
  • Page 398 • 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...
  • Page 399 • 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...
  • Page 400 Roller finger cam follower camshaft operates the cam followers through their roller bearings. Hydraulic lash adjuster This has the advantage of lowering friction and Cylinder head therefore increasing durability. E6630 EN 07/2001 2002 Bantam...
  • Page 401 Rear oil seal retainer NOTE: A special "Assembly Guide" (for installing Oil pan mating surface the retainer) is provided with each new rear oil Bolt seal retainer. Assembly guide NOTE: The sealing lip must be free of oil. E6630 EN 07/2001 2002 Bantam...
  • Page 402 M8 bolts The laminated (two layer) design cylinder head M11 bolts gasket is made of steel. Cylinder head gasket NOTE: Always use a new gasket when installing Guide dowels the cylinder head. E6630 EN 07/2001 2002 Bantam...
  • Page 403 The structural oil pan is made of cast aluminum core with an external vulcanized rubber surface. and provides a mounting bracket for the air conditioner (A/C) compressor. NOTE: Always use a new gasket when installing the oil pan. E6630 EN 07/2001 2002 Bantam...
  • Page 404 Chain guide (intake side) position is fixed by a guide lug to a slot in the camshaft. The timing mark is stamped into the Tensioner arm (exhaust side) face of the sprocket. Timing chain Hydraulic chain tensioner E6630 EN 07/2001 2002 Bantam...
  • Page 405 The ECT sensor is fixed by a clip to its mounting NOTE: Install a new gasket if the original is which is integrated in the coolant flow control housing. damaged. The gasket is made of rubber. E6630 EN 07/2001 2002 Bantam...
  • Page 406 303-01B-34 Engine — 1.6L / 1.3L RoCam 303-01B-34 DIAGNOSIS AND TESTING Engine REFER to Section 303-00. E3278 EN 07/2001 2002 Bantam...
  • Page 407 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...
  • Page 408 2. Camshaft position (CMP) sensor. 7. Raise and support the vehicle. For additional information, refer to Section 100- 02. 8. Remove the engine undershield. 9. Remove the intake manifold lower retaining bolts (shown with the engine removed). E6632 EN 07/2001 2002 Bantam...
  • Page 409 1. NOTE: Install a new gasket if the original is damaged. Install the intake manifold. 2. Raise and support the vehicle. For refer to Section 100- 02. additional information, 3. Install the intake manifold lower retaining bolts (shown with engine removed). E6632 EN 07/2001 2002 Bantam...
  • Page 410 4. ECT sensor electrical connector. 5. Brake booster vacuum hose. 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...
  • Page 411 303-01B-39 Engine — 1.6L / 1.3L RoCam 303-01B-39 IN-VEHICLE REPAIR (CONTINUED) 9. Connect the fuel lines. 10. Install the air cleaner intake pipe. 11. Connect the battery ground cable. E6632 EN 07/2001 2002 Bantam...
  • Page 412 (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...
  • Page 413 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...
  • Page 414 303-01B-42 Engine — 1.6L / 1.3L RoCam 303-01B-42 IN-VEHICLE REPAIR (CONTINUED) 4. Connect the PCM, CMP sensor and EI coil electrical connectors. 5. Connect the battery ground cable. E6633 EN 07/2001 2002 Bantam...
  • Page 415 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 information, refer to Section 100-02. 3. Remove the accessory drive belt cover. E6634 EN 07/2001 2002 Bantam...
  • Page 416 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...
  • Page 417 5. Install the crankshaft pulley bolt. 6. Install the accessory drive belt cover. 7. Lower the vehicle. 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...
  • Page 418 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...
  • Page 419 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...
  • Page 420 (Cylinder head shown removed). 6. Install the camshaft. For additional information, refer to Camshaft in this section. 7. Install the spark plugs. 8. Install the valve cover. For additional information, refer to Valve Cover in this section. E6635 EN 07/2001 2002 Bantam...
  • Page 421 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...
  • Page 422 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...
  • Page 423 Remove the wire tie and using the special tool, install the camshaft sprocket with the timing chain. 3. Install the timing chain hydraulic tensioner. 4. Install the valve cover. For additional information, refer to Valve cover in this section. E6636 EN 07/2001 2002 Bantam...
  • Page 424 4. NOTE: The camshaft sprocket timing mark and both colored links of the timing chain must line up. Set the engine to TDC on cylinder No. 1. 5. Remove the timing chain hydraulic tensioner. E6637 EN 07/2001 2002 Bantam...
  • Page 425 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...
  • Page 426 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. 6. Install the timing chain hydraulic tensioner. E6637 EN 07/2001 2002 Bantam...
  • Page 427 Engine — 1.6L / 1.3L RoCam 303-01B-55 IN-VEHICLE REPAIR (CONTINUED) 7. Install the valve cover. For additional information, refer to Valve Cover in this section. 8. Install the oil pump. For additional information, refer to Oil Pump in this section. E6637 EN 07/2001 2002 Bantam...
  • Page 428 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...
  • Page 429 2. Install the oil pan. For additional information, refer to Oil Pan in this section. 3. Install the flywheel. 4. Install the clutch. For additional information, refer to Section 308-01. 5. Install the transaxle. For additional information, refer to Section 308-03. E6638 EN 07/2001 2002 Bantam...
  • Page 430 (for bent spark plug connectors use Special Tool 303-662). 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...
  • Page 431 7. Remove the upper heat shield (shown on removed engine). 8. Remove the exhaust manifold (shown on removed engine). • Remove and discard the gasket. Installation 1. NOTE: Use a new gasket. Install the exhaust manifold. 2. Install the upper heat shield. E6639 EN 07/2001 2002 Bantam...
  • Page 432 Section 100- 02. 6. Connect the exhaust down pipe to the exhaust manifold. 1. Install the nuts. 2. Attach the exhaust hanger insulator. 7. Lower the vehicle. 8. Connect the battery ground cable. E6639 EN 07/2001 2002 Bantam...
  • Page 433 Angle Gauge, Bolt Tightening 303-174 (21-540) Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner intake pipe. WARNING: Escaping fuel. Observe the safety regulations for working with fuel. Disconnect the fuel lines. E6640 EN 07/2001 2002 Bantam...
  • Page 434 CAUTION: Pull off the spark plug connectors in line with the spark plugs (For bent spark plug connectors, use Special Tool 303-622). Remove the spark plugs. • Disconnect the electrical connectors. E6640 EN 07/2001 2002 Bantam...
  • Page 435 • Install the drain plug after draining. 9. Disconnect the coolant hoses. 10. Raise and support vehicle. For additional information, refer to Section 100-02. 11. Remove the engine undershield. 12. Remove the lower intake manifold bolts (engine shown removed for clarity). E6640 EN 07/2001 2002 Bantam...
  • Page 436 NOTE: The camshaft sprocket timing mark must be at the 12 o'clock position. Set the engine to TDC on cylinder No. 1. 17. Remove the timing chain hydraulic tensioner. E6640 EN 07/2001 2002 Bantam...
  • Page 437 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. 21. Remove the intake manifold. 22. Remove the engine front mounting bracket. E6640 EN 07/2001 2002 Bantam...
  • Page 438 • Stage 3: Tighten all M8 bolts in the indicated alphabetical order to 45 degrees. • Stage 4: Tighten all M11 bolts in the indicated numerical sequence to 120 degrees. 2. Install the engine front mounting bracket. 3. Remove the trolley jack. E6640 EN 07/2001 2002 Bantam...
  • Page 439 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. 7. Install the timing chain hydraulic tensioner. E6640 EN 07/2001 2002 Bantam...
  • Page 440 Section 100- 02. 10. Connect the exhaust down pipe. 1. Install the nuts. 2. Connect the retaining hanger insulator. 11. Install the intake manifold lower retaining bolts (engine shown removed for clarity). 12. Install the engine undershield. E6640 EN 07/2001 2002 Bantam...
  • Page 441 Install the valve cover. 16. Install the spark plugs and connect the spark plug wires. 17. Connect the PCM, CMP sensor and EI coil electrical connectors. 1. PCM connector 2. CMP connector 3. EI coil connector E6640 EN 07/2001 2002 Bantam...
  • Page 442 20. Connect the fuel lines. 21. Install the air cleaner intake pipe. 22. Fill the cooling system. For additional information, refer to Section 303-03. 23. Connect the battery ground cable. E6640 EN 07/2001 2002 Bantam...
  • Page 443: Oil Pan

    Section 308-01. 3. Remove the flywheel. 4. Lower the vehicle. 5. Turn the belt tensioner clockwise and remove the belt. 6. Raise and support the vehicle. For additional information, refer to Section 100- 02. E6641 EN 07/2001 2002 Bantam...
  • Page 444 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. • Remove and discard the gasket. E6641 EN 07/2001 2002 Bantam...
  • Page 445 • 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...
  • Page 446 10. Install the clutch and pressure plate. For refer to Section 308- 01. additional information, 11. Install the transaxle. For additional information, refer to Section 308-03. 12. Fill the engine with low friction oil meeting SAE 15W40 SH specification. E6641 EN 07/2001 2002 Bantam...
  • Page 447 Oil Pan in this section. 2. Remove the crankshaft pulley. 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...
  • Page 448 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 information, refer to Oil Pan in this section. E6647 EN 07/2001 2002 Bantam...
  • Page 449 2. Remove the battery. For additional information, refer to Section 414-01. 3. Remove the battery tray. 1. Cut the cable ties. 2. Remove the bolts. 4. Remove the air cleaner intake pipe. E6642 EN 07/2001 2002 Bantam...
  • Page 450 1. Remove the clip and pull the cable from the bracket. 2. Unhook the inner cable. WARNING: Danger of scalding if the engine is warm. Drain the coolant (shown from below). • Screw in the drain plug after draining. E6642 EN 07/2001 2002 Bantam...
  • Page 451 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...
  • Page 452 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 electrical connector. E6642 EN 07/2001 2002 Bantam...
  • Page 453 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...
  • Page 454 • Turn the belt tensioner clockwise and slip the belt off the pulleys. 22. Raise and support the vehicle. For additional information, refer to Section 100- 02. 23. Remove the engine undershield. 24. Remove the accessory drive belt cover. E6642 EN 07/2001 2002 Bantam...
  • Page 455 2. Detach the exhaust hanger insulator. • Remove and discard the gasket. 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...
  • Page 456 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...
  • Page 457 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...
  • Page 458 41. Disconnect the engine wiring harness electrical connectors. 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...
  • Page 459 Engine — 1.6L / 1.3L RoCam 303-01B-87 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...
  • Page 460 303-392 (21-167) 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 • Remove and discard the gasket. E6643 EN 07/2001 2002 Bantam...
  • Page 461 Engine — 1.6L / 1.3L RoCam 303-01B-89 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...
  • Page 462 7. Remove the generator bracket. 8. Drain the engine oil. 9. Install the drain plug. 10. Disconnect the vacuum hoses. 11. Disconnect the camshaft position (CMP) sensor and the engine coolant temperature (ECT) sensor electrical connectors. E6643 EN 07/2001 2002 Bantam...
  • Page 463 CAUTION: Pull off the spark plug 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...
  • Page 464 Engine — 1.6L / 1.3L RoCam 303-01B-92 DISASSEMBLY (CONTINUED) 15. Remove the valve cover. 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...
  • Page 465 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...
  • Page 466 303-01B-94 Engine — 1.6L / 1.3L RoCam 303-01B-94 DISASSEMBLY (CONTINUED) 23. Remove the water pump pulley. 24. Remove the water pump. 25. Remove the crankshaft pulley. 26. Remove the flywheel. E6643 EN 07/2001 2002 Bantam...
  • Page 467 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...
  • Page 468 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...
  • Page 469 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. • Remove and discard the gasket. E6644 EN 07/2001 2002 Bantam...
  • Page 470 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...
  • Page 471 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...
  • Page 472 1. Remove the camshaft bearings caps. 2. Remove the camshaft. Assembly 1. Install the camshaft and the camshaft bearing caps. 1. Install the camshaft. 2. Install the camshaft bearing caps. 2. Install the valves. 1. Exhaust valve. 2. Intake valve. E6644 EN 07/2001 2002 Bantam...
  • Page 473 1. Compress the valve spring and the valve spring retainer. 2. Insert the valve collets. 5. Remove the camshaft bearing caps and the camshaft. 1. Remove the camshaft bearing caps. 2. Remove the camshaft. 6. Install the hydraulic lash adjusters. E6644 EN 07/2001 2002 Bantam...
  • Page 474 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...
  • Page 475 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 10. NOTE: Install a new gasket if the original is 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...
  • Page 476: Engine Assembly

    Section 303-00. 2. Measure the camshaft. For additional information, refer to Section 303-00. 3. Measure the cylinder bore. For additional information, refer to Section 303-00. 4. Measure the pistons. For additional information, refer to Section 303-00. E6645 EN 07/2001 2002 Bantam...
  • Page 477 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...
  • Page 478 • 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...
  • Page 479 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...
  • Page 480 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...
  • Page 481 • 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. 24. Install the flywheel. E6645 EN 07/2001 2002 Bantam...
  • Page 482 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...
  • Page 483 Tighten the oil level indicator tube retaining bolt. 31. Install the timing chain hydraulic tensioner. 32. NOTE: Install a new gasket if the original is damaged. Install the coolant flow control housing. E6645 EN 07/2001 2002 Bantam...
  • Page 484 33. Install the oil filter with a new gasket. 34. Install the crankshaft position (CKP) sensor and the oil pressure switch. Vehicles with 1.3L engine. 35. Install the knock sensor. Note: intake manifold removed for clarity. E6645 EN 07/2001 2002 Bantam...
  • Page 485 37. Install the spark plugs and connect the spark plug wires. 38. NOTE: Install a new gasket if the original is damaged. Install the intake manifold. 39. Connect the camshaft position (CMP) sensor and engine coolant temperature (ECT) sensor electrical connectors. E6645 EN 07/2001 2002 Bantam...
  • Page 486 303-01B-114 Engine — 1.6L / 1.3L RoCam 303-01B-114 ASSEMBLY (CONTINUED) 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...
  • Page 487 303-01B-115 Engine — 1.6L / 1.3L RoCam 303-01B-115 ASSEMBLY (CONTINUED) 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...
  • Page 488: Engine Installation

    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...
  • Page 489 7. Raise and support the vehicle. For additional information, refer to Section 100- 02. 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...
  • Page 490 For additional information, refer to Section 206-00. Connect the clutch slave cylinder hydraulic line. 13. Remove the retaining straps from the engine. 14. Raise and support the vehicle. For refer to Section 100- 02. additional information, E6646 EN 07/2001 2002 Bantam...
  • Page 491 (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...
  • Page 492 21. Connect the exhaust down pipe to the exhaust manifold with a new gasket. 1. Install the nuts. 2. Attach the exhaust hanger insulator. Vehicles with air conditioning 22. Install the air conditioning (A/C) compressor. E6646 EN 07/2001 2002 Bantam...
  • Page 493 • Turn the belt tensioner clockwise and slip the belt onto all the pulleys. 27. NOTE: Use an Allen key to stop the piston rod turning. Tighten the suspension strut retaining nut on both sides (right-hand side shown). E6646 EN 07/2001 2002 Bantam...
  • Page 494 Engine — 1.6L / 1.3L RoCam 303-01B-122 INSTALLATION (CONTINUED) 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 electrical connector. E6646 EN 07/2001 2002 Bantam...
  • Page 495 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...
  • Page 496 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...
  • Page 497 41. Connect the fuel lines. 42. Install the hoses and the vacuum lines. 1. EVAP solenoid valve vacuum hose 2. Positive crankcase ventilation hose 3. Brake booster vacuum hose 43. Install the air cleaner intake pipe. E6646 EN 07/2001 2002 Bantam...
  • Page 498 47. Fill the cooling system. For additional information, refer to Section 303-03. 48. Adjust the gearshift linkage. For additional information, refer to Section 308-06. 49. Bleed the clutch system. For additional information, refer to Section 308-00. E6646 EN 07/2001 2002 Bantam...
  • Page 499: Specifications

    Engine oil, including filter change 3.25 Engine oil, excluding filter change 2.75 Coolant Transmission fluid (iB5) Oil Pressure Oil pressure (min. oil temperature 80°C) at 880 l/min 1.0-3.5 Oil pressure (min. oil temperature 80°C) at 2,000 l/min 2.5-5.5 E6648 EN 07/2001 2002 Bantam...
  • Page 500 Piston ring end gap position, second 90 degrees offset from oil scraper ring end gap Piston pin length 60.2-59.9 Piston pin diameter 18.03-18.034 Piston pin to bore diameter interference 0.012-0.036 Piston pin slide clearance (21°C) 0.014-0.020 E6648 EN 07/2001 2002 Bantam...
  • Page 501 Valve lift (intake) Valve lift (exhaust) Cylinder block Number of main bearings Cylinder bore diameter (standard) 82.7-82.085 Cylinder bore diameter (oversize No.1) 82.22-82.235 Cylinder bore diameter (oversize No.2) 82.57-82.585 Camshaft Drive system Chain Number of chain links E6648 EN 07/2001 2002 Bantam...
  • Page 502 Oil filter adaptor Crankshaft position sensor retaining bolts Water pump retaining bolts Water pump pulley retaining bolts Flywheel retaining bolts Clutch bolts A/C compressor retaining bolts Starter motor retaining bolts Oil pressure switch Oil drain plug E6648 EN 07/2001 2002 Bantam...
  • Page 503 Engine mounting rear bracket to transaxle bolts Gearshift stabilizer Transaxle upper flange bolt Transaxle lower flange bolts Transaxle left-hand flange bolt Transaxle right-hand flange bolts Engine roll restrictor to body retaining bolts Engine roll restrictor to transaxle retaining bolts Lower arm E6648 EN 07/2001 2002 Bantam...
  • Page 504 Engine — 1.6L / 1.3L RoCam 303-01B-132 SPECIFICATIONS (CONTINUED) Description Suspension strut retaining nuts Cooling fan retaining bolts Left-hand coolant hose bracket nut Right-hand coolant hose bracket nut Accessory drive belt cover Engine undershield Battery tray Knock sensor retaining bolt E6648 EN 07/2001 2002 Bantam...
  • Page 505 303-01D-1 Engine — 1.8L Diesel - Endura DE 303-01D-1 SECTION 303-01D Engine — 1.8L Diesel - Endura DE PAGE 1 OF 2 VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine ............................303-01D-3 Crankshaft ..........................303-01D-3 Timing belt pulley - crankshaft ....................
  • Page 506 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 Torque Specifications......................303-01D-173 Torque Specifications......................303-01D-173 Torque Specifications......................303-01D-173/174 Torque Specifications......................303-01D-174/175 Torque Specifications......................303-01D-175 09/2001 2002 Bantam...
  • Page 507 The camshaft timing pulley is a taper fit on the Crankshaft central bolt 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...
  • Page 508 Like all crankcase requires a certain thickness of gasket and this is ventilation components, the valve must always be determined by the number of notches on the kept clean to ensure optimal engine operation. gasket thickness indicator. E5893 EN 09/2001 2002 Bantam...
  • Page 509 303-01D-5 Engine — 1.8L Diesel - Endura DE 303-01D-5 DIAGNOSIS AND TESTING Engine REFER to Section 303-00. E3278 EN 09/2001 2002 Bantam...
  • Page 510 21-140-02 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. 2. Disconnect the battery ground cable. E5881 EN 09/2001 2002 Bantam...
  • Page 511 Engine — 1.8L Diesel - Endura DE 303-01D-7 IN-VEHICLE REPAIR (CONTINUED) 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...
  • Page 512 • 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...
  • Page 513 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...
  • Page 514 • 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. 19. Lower the vehicle. E5881 EN 09/2001 2002 Bantam...
  • Page 515 22. Tighten the clamp bolt of the timing belt tensioner. Remove the timing belt. 23. Raise the vehicle. 24. Remove the flange of the crankshaft front timing pulley. 25. Remove the crankshaft rear timing pulley. E5881 EN 09/2001 2002 Bantam...
  • Page 516 NOTE: Position of the flattened area on the 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...
  • Page 517 • 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. 5. Lower the vehicle. E5881 EN 09/2001 2002 Bantam...
  • Page 518 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...
  • Page 519 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...
  • Page 520 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...
  • Page 521 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...
  • Page 522 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. 20. Lower the vehicle. 21. Raise the engine with the engine support bar. E5881 EN 09/2001 2002 Bantam...
  • Page 523 IN-VEHICLE REPAIR (CONTINUED) 22. Screw in the remaining bolts of the lower 23. Lower the engine with the engine support bar. 24. Fit the upper timing belt cover. 25. Fit the front engine mounting bracket. E5881 EN 09/2001 2002 Bantam...
  • Page 524 28. Connect the battery ground cable. 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...
  • Page 525 Remove the camshaft timing belt as described in Operation No. 21 304 0. 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...
  • Page 526 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...
  • Page 527 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. in Operation No. 21 304 0. E6965 EN 09/2001 2002 Bantam...
  • Page 528 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 additional information, refer to Section 303-03. E5882 EN 09/2001 2002 Bantam...
  • Page 529 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...
  • Page 530 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. 2. Remove the bolts. 12. Remove the oil baffle. E5882 EN 09/2001 2002 Bantam...
  • Page 531 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...
  • Page 532 18. Remove the valve stem seals. Installation 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...
  • Page 533 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...
  • Page 534 (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...
  • Page 535 • 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...
  • Page 536 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...
  • Page 537 22. Turn the crankshaft to the TDC position. 23. Lower the vehicle. 24. Attach the engine support bar. 25. Fit a new camshaft timing belt as described in Operation No. 21 304 0. E5882 EN 09/2001 2002 Bantam...
  • Page 538 Sealer SPM-4G-9112-F/G Removal 1. Preparatory measures. • Make a note of the radio keycode. • Make a note of the pre-set radio stations. 2. Disconnect the battery ground lead. 3. Attach the engine support bar. E6447 EN 09/2001 2002 Bantam...
  • Page 539 303-01D-35 IN-VEHICLE REPAIR (CONTINUED) 4. Remove the front engine mounting auxiliary bracket. 5. Remove the front engine mounting bracket. 6. Remove the upper timing belt cover. 7. Raise the engine with the engine support bar. E6447 EN 09/2001 2002 Bantam...
  • Page 540 2. Unclip the drive belt cover. 3. Unclip the power steering high-pressure pipe. 12. Remove the drive belt. 1. Release the bolt. CAUTION: To slacken, turn the bolt clockwise. 2. Slacken the drive belt and remove it. E6447 EN 09/2001 2002 Bantam...
  • Page 541 Engine — 1.8L Diesel - Endura DE 303-01D-37 IN-VEHICLE REPAIR (CONTINUED) 13. Remove the crankshaft belt pulley/vibration damper. 14. Remove the lower timing belt cover. 15. Remove the belt tensioner. 16. Remove the generator and lay it to one side. E6447 EN 09/2001 2002 Bantam...
  • Page 542 NOTE: The timing pin must be screwed in as far as its stop. • Screw in the timing pin. • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin. 22. Lower the vehicle. E6447 EN 09/2001 2002 Bantam...
  • Page 543 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...
  • Page 544 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...
  • Page 545 • Screw in the timing pin. • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin. 6. Undo the bolt on the adjusting cam half a turn. E6447 EN 09/2001 2002 Bantam...
  • Page 546 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...
  • Page 547 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...
  • Page 548 NOTE: The timing pin must be screwed in as far as its stop. • Screw in the timing pin. • Carefully turn the crankshaft in the normal direction of rotation until it rests against the timing pin. E6447 EN 09/2001 2002 Bantam...
  • Page 549 If it is in good condition, it can be used several times. NOTE: Before fitting the gasket, coat it lightly with engine oil. Fit the cylinder head cover. 1. Screw in the bolts. 2. Attach the PCV hoses. E6447 EN 09/2001 2002 Bantam...
  • Page 550 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...
  • Page 551 Operation No. 31 413 0. 2. Tighten the bolt. 30. Lower the vehicle. 31. Raise the engine with the engine support bar. 32. Attach the lower timing belt cover. 33. Lower the engine with the engine support bar. E6447 EN 09/2001 2002 Bantam...
  • Page 552 38. Connect the battery ground lead. 39. Standard finishing operations. • Enter the radio keycode. • Re-program the preset radio stations. • Reset the clock. • Carry out a road test to enable the PCM (EEC V) to collect data. E6447 EN 09/2001 2002 Bantam...
  • Page 553 303-290-02 (2114002) Removal 1. Preparatory operations • Make a note of the radio keycode. • Make a note of the preset radio stations. 2. Disconnect the battery negative lead. 3. Attach the engine support bar. E6346 EN 09/2001 2002 Bantam...
  • Page 554 303-01D-50 IN-VEHICLE REPAIR (CONTINUED) 4. Remove the front engine mounting auxiliary bracket. 5. Remove the front engine mounting bracket. 6. Remove the upper timing belt cover. 7. Raise the engine with the engine support bar. E6346 EN 09/2001 2002 Bantam...
  • Page 555 9. Lower the engine with the engine support bar. 10. Raise the vehicle. 11. Remove the drive belt. 1. Undo the bolt. CAUTION: To slacken, turn the bolt clockwise. 2. Slacken and remove the drive belt. 12. Remove the crankshaft pulley/vibration damper. E6346 EN 09/2001 2002 Bantam...
  • Page 556 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...
  • Page 557 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...
  • Page 558 2. The timing pin must be able to be inserted in the camshaft timing belt pulley. 3. Slacken the bolts of the camshaft timing belt pulley. E6346 EN 09/2001 2002 Bantam...
  • Page 559 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. 5. Fit the belt tensioner. E6346 EN 09/2001 2002 Bantam...
  • Page 560 7. Fit the crankshaft pulley/vibration damper. 8. Fit the drive belt. 1. Fit the drive belt and tension as described in Operation No. 31 413 0. 2. Tighten the bolt. 9. Lower the vehicle. E6346 EN 09/2001 2002 Bantam...
  • Page 561 IN-VEHICLE REPAIR (CONTINUED) 10. Raise the engine with the engine support bar. 11. Attach the lower timing belt cover. 12. Lower the engine with the engine support bar. 13. Fit the upper timing belt cover. E6346 EN 09/2001 2002 Bantam...
  • Page 562 17. Connect the battery negative lead. 18. Standard finishing operations. • Enter the radio keycode. • Re-program the preset radio stations. • Reset the clock. • Carry out a road test to enable the PCM (EEC V) to collect data. E6346 EN 09/2001 2002 Bantam...
  • Page 563 For additional information, refer to Section 303-03. 2. Remove camshaft timing belt as described in Operation No. 21 304 0. CAUTION: Support the engine with a trolley jack. Detach the engine support bar. E5883 EN 09/2001 2002 Bantam...
  • Page 564 IN-VEHICLE REPAIR (CONTINUED) 4. Slacken the flange bolt of the camshaft timing pulley. 5. Remove the camshaft timing pulley. 6. Detach the crankcase ventilation hose. 7. Remove the flange bolt of the camshaft timing pulley. E5883 EN 09/2001 2002 Bantam...
  • Page 565 CAUTION: Slacken the nuts of the camshaft bearing caps uniformly 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. E5883 EN 09/2001 2002 Bantam...
  • Page 566 • 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). 3. Align the camshaft. E5883 EN 09/2001 2002 Bantam...
  • Page 567 NOTE: The bearing caps must lie flat. • Locate camshaft bearing caps nos. 1, 3 and 5 in position. NOTE: Tightening sequence. • Screw on the nuts and tighten them. 7. Fit the oil baffle. E5883 EN 09/2001 2002 Bantam...
  • Page 568 Fit the camshaft oil seal using the special tool and an M8 bolt. 11. Fit the flange of the camshaft timing pulley. • Insert the Woodruff key. • Draw on the flange with the bolt. E5883 EN 09/2001 2002 Bantam...
  • Page 569 13. Attach the crankcase ventilation hose. 14. Tighten the flange bolt of the camshaft timing pulley. 15. Attach the engine support bar. 16. Fit a new camshaft timing belt as described in Operation No. 21 304 0. E5883 EN 09/2001 2002 Bantam...
  • Page 570 2. Remove camshaft timing belt as described in Operation No. 21 304 0. CAUTION: Support the engine with a trolley jack. Detach the engine support bar. 4. Slacken the flange bolt of the camshaft timing pulley. E5884 EN 09/2001 2002 Bantam...
  • Page 571 5. Remove the camshaft timing pulley. 6. Remove the flange bolt of the camshaft timing pulley. 7. Pull off the flange of the camshaft timing pulley. • Take out the Woodruff key. 8. Remove the camshaft oil seal. E5884 EN 09/2001 2002 Bantam...
  • Page 572 10. Fit the flange of the camshaft timing pulley. • Insert the Woodruff key. • Draw on the flange with the bolt. 11. Fit the camshaft timing pulley. 12. Tighten the flange bolt of the camshaft timing pulley. E5884 EN 09/2001 2002 Bantam...
  • Page 573 303-01D-69 Engine — 1.8L Diesel - Endura DE 303-01D-69 IN-VEHICLE REPAIR (CONTINUED) 13. Attach the engine support bar. 14. Fit a new camshaft timing belt, as described in Operation No. 21 304 0. E5884 EN 09/2001 2002 Bantam...
  • Page 574 2. Standard preparatory measures • Make a note of the radio keycode. • Make a note of the preset radio stations. WARNING: Risk of scalding when the engine is at operating temperature. • Open the coolant recovery tank. E5970 EN 09/2001 2002 Bantam...
  • Page 575 6. Detach the coolant hose. 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...
  • Page 576 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...
  • Page 577 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...
  • Page 578 20. Support the engine with a trolley jack, so that the front engine mounting is free of load. 21. Detach the engine support bar. 22. Remove the cylinder head cover. 1. Detach the crankcase ventilation hoses. 2. Remove the bolts. E5970 EN 09/2001 2002 Bantam...
  • Page 579 Engine — 1.8L Diesel - Endura DE 303-01D-75 IN-VEHICLE REPAIR (CONTINUED) 23. Remove the oil baffle. 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...
  • Page 580 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...
  • Page 581 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...
  • Page 582 NOTE: Before fitting the gasket, lightly coat it in engine oil. Fit the cylinder head cover. 1. Tighten the bolts. 2. Attach the crankcase ventilation hoses. 9. Attach the catalytic converter to the exhaust manifold. E5970 EN 09/2001 2002 Bantam...
  • Page 583 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...
  • Page 584 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...
  • Page 585 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. 24. Connect the battery negative lead. E5970 EN 09/2001 2002 Bantam...
  • Page 586 • Carry out a road test to enable the PCM (EEC V) to collect data. • Check the fluid levels and correct as necessary. • Check the engine and cooling system for leaks (visual inspection). 26. Standard finishing operations. E5970 EN 09/2001 2002 Bantam...
  • Page 587 • Open the coolant recovery tank. 4. Disconnect the battery ground cable. 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...
  • Page 588 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...
  • Page 589 (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...
  • Page 590 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...
  • Page 591 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. 21. Remove the belt tensioner. 22. Remove the front engine mounting auxiliary bracket. E5886 EN 09/2001 2002 Bantam...
  • Page 592 Engine — 1.8L Diesel - Endura DE 303-01D-88 REMOVAL (CONTINUED) 23. Remove the battery. • Detach the retaining strap. • Lift out the battery. 24. Remove the battery box. 25. Raise the vehicle. 26. Detach the lower coolant hose. E5886 EN 09/2001 2002 Bantam...
  • Page 593 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...
  • Page 594 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...
  • Page 595 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. • Remove the seal. 38. Disconnect the generator. E5886 EN 09/2001 2002 Bantam...
  • Page 596 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 42. Remove the front driveshaft center bearing. E5886 EN 09/2001 2002 Bantam...
  • Page 597 • 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...
  • Page 598 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...
  • Page 599 303-01D-95 Engine — 1.8L Diesel - Endura DE 303-01D-95 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...
  • Page 600 303-01D-96 Engine — 1.8L Diesel - Endura DE 303-01D-96 REMOVAL (CONTINUED) 57. Press the transmission off the engine and remove it. • Remove the adapter plate. E5886 EN 09/2001 2002 Bantam...
  • Page 601 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...
  • Page 602 3. Remove the alternator bolts. 5. Remove the injection pump belt pulley. 6. Remove the crankshaft pulley/vibration damper. • Immobilise the crankshaft using the ring gear. • Remove the bolts. 7. Remove the timing belt upper cover. E6007 EN 09/2001 2002 Bantam...
  • Page 603 9. Remove the injection pump timing belt cover. 10. Slacken the bolt of the auxiliary shaft timing belt pulley. 11. Remove the cylinder head cover. 1. Detach the crankcase ventilation hoses. 2. Remove the bolts. E6007 EN 09/2001 2002 Bantam...
  • Page 604 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...
  • Page 605 • Tighten the timing belt tensioner clamp bolt. • Remove timing belt and discard. 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...
  • Page 606 1. Timing belt tensioner bolts 2. Camshaft timing belt pulley bolts All vehicles 18. Remove the engine mounting bracket. 19. Remove the timing belt side cover. 20. Remove the oil dipstick tube. E6007 EN 09/2001 2002 Bantam...
  • Page 607 Engine — 1.8L Diesel - Endura DE 303-01D-103 DISASSEMBLY (CONTINUED) 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...
  • Page 608 27. Remove the alternator bracket. 28. Remove the coolant pipe bracket. 29. Remove the oil baffle. 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...
  • Page 609 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...
  • Page 610 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...
  • Page 611 Engine — 1.8L Diesel - Endura DE 303-01D-107 DISASSEMBLY (CONTINUED) 38. Remove the clutch. 39. Remove the flywheel. 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...
  • Page 612 • 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...
  • Page 613 DISASSEMBLY (CONTINUED) 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...
  • Page 614 Adaptor for 21-024 General Equipment 21-024-05 Two-legged puller Material Specification Installer, oil seal Sealer SPM-4G-9112-F/G 21-110 Hypoid oil SQM-2C-9002-AA Engine Oil ACEA B3 / E3 Valve stem installation sleeves Disassembly 1. Remove the upper inlet manifold. E6008 EN 09/2001 2002 Bantam...
  • Page 615 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. • Remove the seal. E6008 EN 09/2001 2002 Bantam...
  • Page 616 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...
  • Page 617 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...
  • Page 618 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...
  • Page 619 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...
  • Page 620 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...
  • Page 621 (with the larger semi-circle at the top). 12. Align the camshaft. 13. Put the camshaft bearing upper shell halves in place and coat them with engine oil. 14. Apply sealer (SPM-4G-9112-F/G) to bearing cap no. 1 in the areas indicated. E6008 EN 09/2001 2002 Bantam...
  • Page 622 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...
  • Page 623 Fit the timing belt rear cover. Fit the timing belt pulley. 23. Fit the oil pressure switch. 24. NOTE: Tightening sequence. 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...
  • Page 624 25. Fit the EGR valve. 1. Tighten the bolts. 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...
  • Page 625 Centering tool, remover and Socket, injectors installer, oil seal 23-045 21-148A Adjustment tool, camshaft Timing pin, crankshaft position sensor (CKP sensor) 21-162B 23-049 Socket, cylinder head bolts Remover/installer, cooling hose clamp 21-164 24-003 Locking tool, crankshaft 21-168 E6005 EN 09/2001 2002 Bantam...
  • Page 626 • 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...
  • Page 627 • 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...
  • Page 628 • 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...
  • Page 629 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...
  • Page 630 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...
  • Page 631 • 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...
  • Page 632 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...
  • Page 633 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. 3. Remove the special tool. E6005 EN 09/2001 2002 Bantam...
  • Page 634 • 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...
  • Page 635 • 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...
  • Page 636 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...
  • Page 637 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...
  • Page 638 ASSEMBLY (CONTINUED) 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...
  • Page 639 303-01D-135 ASSEMBLY (CONTINUED) 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...
  • Page 640 • Compress the spring of the timing belt tensioner and lock it with the clamp bolt. Engines with automatic timing belt tensioner. 54. Align the camshaft. • Fit the timing tool into the groove in the camshaft eccentric. E6005 EN 09/2001 2002 Bantam...
  • Page 641 Engines with mechanical timing belt tensioner. 56. Align the camshaft timing belt pulley. • Align the camshaft timing belt pulley by inserting the timing pin through the cutout in the pulley and the hole in the cylinder head. E6005 EN 09/2001 2002 Bantam...
  • Page 642 Tighten the timing belt tensioner bolt. NOTE: The bolts must not be at the ends of their slots. 3. Tighten the bolts of the timing belt pulley. E6005 EN 09/2001 2002 Bantam...
  • Page 643 • Tighten the bolt of the camshaft timing belt pulley. CAUTION: Remove the special tools. Turn the crankshaft six turns in the normal direction of rotation of the engine. E6005 EN 09/2001 2002 Bantam...
  • Page 644 • Slacken the bolt of the adjusting cam. Engines with automatic timing belt tensioner 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...
  • Page 645 2. Tighten the bolt of the injection pump timing belt tensioner. 3. Tighten the bolts of the injection pump timing belt pulley. E6005 EN 09/2001 2002 Bantam...
  • Page 646 • Torque for M8 bolt: 35 Nm. • Torque for M10 bolt: 48 Nm. CAUTION: Remove the special tools. Turn the crankshaft four turns in the normal direction of rotation of the engine. E6005 EN 09/2001 2002 Bantam...
  • Page 647 2. Tighten the clamp bolt of the camshaft timing belt tensioner. 3. Tighten the bolts of the camshaft timing 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...
  • Page 648 NOTE: Before fitting, lightly coat the gasket with engine oil. Fit the cylinder head cover. 1. Screw in the bolts. 2. Attach the crankcase ventilation hoses. 77. Fit the injection pump timing belt cover. E6005 EN 09/2001 2002 Bantam...
  • Page 649 78. Tighten the bolt of the auxiliary shaft timing belt pulley. 79. Fit the lower timing belt cover. 80. Fit the upper timing belt cover. 81. Fit the crankshaft pulley/vibration damper. • Then remove Special Tool 21-168. E6005 EN 09/2001 2002 Bantam...
  • Page 650 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...
  • Page 651 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...
  • Page 652 303-01D-148 Engine — 1.8L Diesel - Endura DE 303-01D-148 ASSEMBLY (CONTINUED) 89. Detach the engine from the assembly stand. E6005 EN 09/2001 2002 Bantam...
  • Page 653 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- sion input shaft, guide...
  • Page 654 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...
  • Page 655 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...
  • Page 656 14. Raise the vehicle. 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 17. Lower the vehicle. E5915 EN 09/2001 2002 Bantam...
  • Page 657 45 degrees. 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...
  • Page 658 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...
  • Page 659 (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...
  • Page 660 Engine — 1.8L Diesel - Endura DE 303-01D-156 INSTALLATION (CONTINUED) 32. Attach the speedometer drive cable. 33. Connect the generator. 34. Connect the starter motor. 35. Connect the plug of the multi-function switch (where fitted). E5915 EN 09/2001 2002 Bantam...
  • Page 661 For additional information, refer to Section 303-05. 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...
  • Page 662 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...
  • Page 663 Engine — 1.8L Diesel - Endura DE 303-01D-159 INSTALLATION (CONTINUED) 44. Connect the bottom right-hand coolant hose to the radiator. 45. Connect the bottom coolant hose. 46. Lower the vehicle. 47. Attach the front engine mounting auxiliary bracket. E5915 EN 09/2001 2002 Bantam...
  • Page 664 50. NOTE: Insert new O-rings. Attach the hydraulic pipe of the clutch operating mechanism. 51. Attach the transmission ground lead. 52. Connect the fuel lines. 1. Fuel return line 2. Fuel feed line to diesel fuel heater E5915 EN 09/2001 2002 Bantam...
  • Page 665 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...
  • Page 666 Engine — 1.8L Diesel - Endura DE 303-01D-162 INSTALLATION (CONTINUED) 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...
  • Page 667 Tighten the nut on both suspension struts. 65. Bleed the hydraulic clutch system. For additional information, refer to Section 308-01. • If necessary, fill up the brake fluid reservoir with Ford brake fluid (SAM- 6C9103-A). E5915 EN 09/2001 2002 Bantam...
  • Page 668 • Carry out a road test to enable the PCM (EEC V) to collect data. • Check the engine and cooling system for leaks (visual inspection). • Check the fluid levels and correct as necessary. E5915 EN 09/2001 2002 Bantam...
  • Page 669 • When removing and installing coolant and ventilation hoses, if necessary. For additional information, refer to Section 303-03. 2. Remove the cylinder head cover. 1. Detach the crankcase ventilation hoses. 2. Remove the screws. 3. Remove the oil baffle. E5885 EN 09/2001 2002 Bantam...
  • Page 670 2. Change the valve shims. 6. Fit the oil baffle. 7. 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). E5885 EN 09/2001 2002 Bantam...
  • Page 671 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. E5885 EN 09/2001 2002 Bantam...
  • Page 672 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...
  • Page 673 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...
  • Page 674 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...
  • Page 675 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-...
  • Page 676 Hexagon socket head bolt - tensioning pulley Front engine mounting reinforcing bracket Drive belt tensioner Driveshaft stub nut Wheel nuts Resonator Starter motor Flange bolts - transmission to engine Ground lead to transmission Suspension strut nut Torque Specifications Description Injection pump 09/2001 2002 Bantam...
  • Page 677 Crankshaft main bearing caps - stage 1 Crankshaft main bearing caps - stage 2 75° Big-end bearing caps, stage 1 Big-end bearing caps, stage 2 60° Big-end bearing caps - stage 3 20° Front plate Crankshaft rear oil seal housing 09/2001 2002 Bantam...
  • Page 678 Cylinder head bolts - stage 4. Cylinder head bolts - stage 5. 120° Cylinder Head Cover Fuel filter bracket Vacuum pump Thermostat housing Exhaust Manifold Exhaust gas re-circulation valve (EGR valve) EGR pipe clip Upper inlet manifold Intake manifold to cylinder head 09/2001 2002 Bantam...
  • Page 679 Adjusting cam Upper and lower timing belt cover Side timing belt cover Torque Specifications Description Oil intake pipe bracket Oil pan Oil drain plug on sump Oil pump Oil baffle Oil dipstick tube bracket Oil Pressure Switch 09/2001 2002 Bantam...
  • Page 680 303-03-177 Engine Cooling 303-03-177 SECTION 303-03 Engine Cooling - 1.8L Diesel - Endura DE VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine Cooling......................... 303-03-178 Antifreeze ..........................303-03-178 Changing coolant ........................303-03-178 DIAGNOSIS AND TESTING Engine Cooling......................... 303-03-179 Inspection and Verification ....................303-03-179...
  • Page 681 L405F antifreeze skin after prolonged contact. to the correct proportion (50% antifreeze). E6434 EN 09/2001 2002 Bantam...
  • Page 682 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 4. If the concern is not visually evident, verify the symptom and refer to WDS. E7832 EN 09/2001 2002 Bantam...
  • Page 683 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. Refer to the procedure in this section. 2. Disconnect the coolant hose. 3. Remove the thermostat housing. 4. Remove the thermostat. E5887 EN 09/2001 2002 Bantam...
  • Page 684 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. Refer to the procedure in this section. E5887 EN 09/2001 2002 Bantam...
  • Page 685 • Use suitable wire to support the radiator to the front panel. 3. Raise the vehicle. 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...
  • Page 686 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...
  • Page 687 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...
  • Page 688 303-03-185 Engine Cooling 303-03-185 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. Refit the components in reverse order. • Make sure the lugs on the fan/shroud assembly are located correctly. E6343 EN 09/2001 2002 Bantam...
  • Page 689 Cooling System Draining, Filling and Bleeding in this section 3. Disconnect the radiator hoses. 4. Raise and support the vehicle. For additional information, refer to Section 100-02. 5. Remove the lower air deflector (if equipped). E5890 EN 09/2001 2002 Bantam...
  • Page 690 6. Disconnect the fan multiplug and unclip the wiring loom. 7. Detach the multiplug from the radiator support. 8. Disconnect the lower radiator hose. Vehicles with air conditioning 9. Detach and secure the air conditioning condenser from the radiator. E5890 EN 09/2001 2002 Bantam...
  • Page 691 12. If the radiator is to be renewed, remove the fan assembly. Installation 1. To install, reverse the removal procedure. 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...
  • Page 692 Section 303-01C. For Ikon For additional information, 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...
  • Page 693 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...
  • Page 694 • Take care not to put undue stress on any pipes or wiring. 12. Raise the engine using a suitable jack and packing material, until the water pump can be removed. Installation 1. To install, reverse the removal procedure. E6441 EN 09/2001 2002 Bantam...
  • Page 695 303-03-192 Engine Cooling 303-03-192 REMOVAL AND INSTALLATION (CONTINUED) E6441 EN 09/2001 2002 Bantam...
  • Page 696 2. Remove the expansion tank from the supporting bracket. Installation 1. To install, reverse the removal procedure. 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...
  • Page 697 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. 8. Lower the vehicle. E2465 EN 09/2001 2002 Bantam...
  • Page 698 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...
  • Page 699 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...
  • Page 700 5. Fill the cooling system as described, using a 50/50 mixture of L405F cooling system fluid and water. For additional information, refer to Specifications in this section. 6. Test the system for correct heater operation within the engine cooling system conditions. E3374 EN 09/2001 2002 Bantam...
  • Page 701 7. Fill the cooling system as described, using 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...
  • Page 702 Endura DE Diesel Engine Water pump retaining bolts Endura DE Diesel Engine Thermostat housing retaining bolts Endura DE Diesel Engine Water pump pulley retaining bolts Radiator support bracket retaining bolts Air conditioning condenser retaining bolts E6442 EN 09/2001 2002 Bantam...
  • Page 703 303-06-200 Starting System 303-06-200 SECTION 303-06 Starting System - 1.8L Diesel - Endura DE VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Starting System........................303-06-201 DIAGNOSIS AND TESTING Starting System........................303-06-202 Inspection and Verification ....................303-06-202 Symptom Chart ........................303-06-202 Pinpoint Tests........................303-06-202/210...
  • Page 704 Irrespective of model, all starter motors have an Microfiche for detailed information. Starter motors integral solenoid and all types have pinions, should be serviced as an assembly and should which engage with a ring gear during starting. not, therefore, be dismantled. E5908 EN 09/2001 2002 Bantam...
  • Page 705 • 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...
  • Page 706 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..........
  • Page 707 3 Measure the voltage between the starter motor solenoid connector single pin, circuit 50 (GY/BK) and ground when the starter is operated. • Is the voltage greater than 10 volts? GO TO A4 GO TO A6 A4: CHECK B+ TO THE STARTER E1017 EN 09/2001 2002 Bantam...
  • Page 708 2 Measure the voltage between the starter relay connector pin 5, circuit 30 (RD) and ground. • Is the voltage greater than 10 volts? GO TO A7 REPAIR circuit 30 (RD). TEST the system for normal operation. E1017 EN 09/2001 2002 Bantam...
  • Page 709 A9: CHECK FUSE 40 (60A) • Is the fuse OK? GO TO A10 INSTALL a new fuse 40 (60A). TEST the system for normal operation. If fuse fails again GO TO A15 Fuse 40 (60A) E1017 EN 09/2001 2002 Bantam...
  • Page 710 2 Measure the resistance between pin 4 and pin 3 of the ignition switch connector. • Is the resistance less than 5 ohms? GO TO A12 INSTALL a new ignition switch. TEST the system for normal operation. A12: CHECK CIRCUIT 50 (GY) CONTINUITY E1017 EN 09/2001 2002 Bantam...
  • Page 711 3, circuit 50 (GY/BK) and ground. • Is the resistance less than 5 ohms? INSTALL a new starter relay. TEST the system for normal operation. REPAIR circuit 50 (GY/BK). TEST the sys- tem for normal operation. E1017 EN 09/2001 2002 Bantam...
  • Page 712 1 Measure the voltage between the battery terminals. • Is the voltage greater than 12.5 volts? GO TO B2 CHARGE or INSTALL a new battery as re- quired. REFER to Section 414-00. TEST the system for normal operation. E1017 EN 09/2001 2002 Bantam...
  • Page 713 1 Check the starter and mounting brackets for correct alignment. • Is the starter mounted correctly? GO TO C2 INSTALL the starter motor. Refer to the procedure in this section. TEST the system for normal operation. E1017 EN 09/2001 2002 Bantam...
  • Page 714 2 Inspect the ring gear for damage and wear. • Is the ring gear damaged? REPAIR ring gear as required. TEST the system for normal operation. INSTALL a new starter motor. TEST the system for normal operation. E1017 EN 09/2001 2002 Bantam...
  • Page 715 Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle. 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...
  • Page 716 303-06-212 Starting System 303-06-212 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. Refit the components in reverse order. E5909 EN 09/2001 2002 Bantam...
  • Page 717 303-06-213 Starting System 303-06-213 SPECIFICATIONS Torque Specifications Description Starter motor retaining bolts Support bracket retaining bolt Support bracket retaining nuts Starter motor solenoid power cable retaining nut Starter motor solenoid power cable retaining nut E6453 EN 09/2001 2002 Bantam...
  • Page 718 303-08B-214 Engine Emission Control — Diesel Engine 303-08B-214 SECTION 303-08B Engine Emission Control — Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine Emission Control ......................303-08B-215 DIAGNOSIS AND TESTING Engine Emission Control ......................303-08B-216 Inspection and Verification ....................
  • Page 719 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...
  • Page 720 • Exhaust gas 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...
  • Page 721 Examine the exhaust manifold and exhaust gas re-circulation valve orifices for signs of corrosion and carbon deposits. Clean as required. 5. Refit the components in reverse order. E6362 EN 09/2001 2002 Bantam...
  • Page 722 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...
  • Page 723 Recirculation valve. Clean the gasket surfaces of the exhaust gas re-circulation valve and inlet manifold. 2. Refit the components in reverse order. E6363 EN 09/2001 2002 Bantam...
  • Page 724 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) sensor electrical connector. 3. Disconnect the air cleaner outlet pipe. E7850 EN 09/2001 2002 Bantam...
  • Page 725 REMOVAL AND INSTALLATION (CONTINUED) 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. 8. Remove and discard the gasket. E7850 EN 09/2001 2002 Bantam...
  • Page 726 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. 2. To install, reverse the removal procedure. E7850 EN 09/2001 2002 Bantam...
  • Page 727 SPECIFICATIONS Torque Specifications Description Endura DE Diesel Engine Exhaust gas Recirculation valve retaining bolts Endura DI Diesel Engine Exhaust gas Recirculation valve/tube retaining bolts Endura DI Diesel Engine Exhaust gas Recirculation valve retaining clamp bolt E6364 EN 09/2001 2002 Bantam...
  • Page 728 303-14D-224 Electronic Engine Controls — Diesel Engine 303-14D-224 SECTION 303-14D Electronic Engine Controls — Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine Emission Controls......................303-14D-225 DIAGNOSIS AND TESTING Electronic Engine Controls ...................... 303-14D-226 Inspection and Verification ....................
  • Page 729 The sensors and the clutch pedal position switch Vehicle speed sensor (VSS) supply the PCM with input signals, which relate to Intake air temperature (IAT) sensor engine operating conditions. Crankshaft position (CKP) sensor E7854 EN 09/2001 2002 Bantam...
  • Page 730 Mechanical Electrical • 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...
  • Page 731 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the CKP sensor. Installation 1. To install, reverse the removal procedure. E4569 EN 09/2001 2002 Bantam...
  • Page 732 Engine Coolant Temperature (ECT) Sensor (21 190 0) Removal 1. Drain the cooling system. For additional information, refer to Section 303-03. 2. Disconnect the engine coolant temperature sensor electrical connector. . Remove the sensor. Installation 1. To install, reverse the removal procedure. E1037 EN 09/2001 2002 Bantam...
  • Page 733 303-14D-229 Electronic Engine Controls — Diesel Engine 303-14D-229 SPECIFICATIONS Torque Specifications Description Exhaust gas Re-circulation valve retaining bolts Engine coolant temperature sensor E5898 EN 09/2001 2002 Bantam...
  • Page 734 303-03-133 Engine Cooling 303-03-133 SECTION 303-03 Engine Cooling VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine Cooling ........................303-03-134 Vehicles with Petrol engines....................303-03-135/136 Vehicles with Diesel engine....................303-03-137 DIAGNOSIS AND TESTING Engine Cooling ........................303-03-138 Inspection and Verification ....................
  • Page 735 303-03-134 Engine Cooling 303-03-134 DESCRIPTION AND OPERATION Engine Cooling Vehicles with 1.6L / 1.3L engine Item Description Item Description Thermostat housing Water pump Engine coolant temperature (ECT) sender unit E6861 EN 07/2001 2002 Bantam...
  • Page 736: Vehicles With Diesel Engine

    Engine coolant temperature (ECT) circumstances while the engine is sender unit operating. Failure to follow this Thermostat instruction may result in personal injury, damage to the cooling system or damage to the engine. E6861 EN 07/2001 2002 Bantam...
  • Page 737 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...
  • Page 738 Engine Cooling 303-03-137 DESCRIPTION AND OPERATION (CONTINUED) The ECT sender unit measures engine coolant Vehicles with Petrol or Diesel engine temperature and controls the position of the Engine Coolant Temperature (ECT) Sender Unit temperature gauge pointer. E6861 EN 07/2001 2002 Bantam...
  • Page 739 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...
  • Page 740 • 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...
  • Page 741 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...
  • Page 742 1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Detach the thermostat cover. 3. Remove the thermostat. 4. Remove and discard the O-ring seal. E5887 EN 07/2001 2002 Bantam...
  • Page 743 303-03-142 Engine Cooling 303-03-142 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. NOTE: Install a new thermostat O-ring seal. To install, reverse the removal procedure. E5887 EN 07/2001 2002 Bantam...
  • Page 744 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. Refer to the procedure in this section. 2. Disconnect the coolant hose. 3. Remove the thermostat housing. 4. Remove the thermostat. E5887 EN 07/2001 2002 Bantam...
  • Page 745 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. Refer to the procedure in this section. E5887 EN 07/2001 2002 Bantam...
  • Page 746 Draining, Filling and Bleeding in this section. 2. Lower the vehicle. 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...
  • Page 747 REMOVAL AND INSTALLATION (CONTINUED) 5. Using the special tool, disconnect the coolant hose from the thermostat housing. 6. Disconnect the coolant hose from the thermostat housing. 7. Remove the thermostat housing. 8. Remove and discard the gasket. E6653 EN 07/2001 2002 Bantam...
  • Page 748 303-03-147 Engine Cooling 303-03-147 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. NOTE: Install a new thermostat housing gasket. To install, reverse the removal procedure. E6653 EN 07/2001 2002 Bantam...
  • Page 749 Draining, Filling and Bleeding in this section. 2. Remove the splash shield. 3. Loosen the water pump pulley bolts. 4. Remove the accessory drive belt. 1. Rotate the tensioner clockwise. 2. Remove the accessory drive belt. E6655 EN 07/2001 2002 Bantam...
  • Page 750 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. To install, reverse the removal procedure. E6655 EN 07/2001 2002 Bantam...
  • Page 751 303-03-150 Engine Cooling 303-03-150 REMOVAL AND INSTALLATION (CONTINUED) E6655 EN 07/2001 2002 Bantam...
  • Page 752 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...
  • Page 753 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...
  • Page 754 • Take care not to put undue stress on any pipes or wiring. 12. Raise the engine using a suitable jack and packing material, until the water pump can be removed. Installation 1. To install, reverse the removal procedure. E6441 EN 07/2001 2002 Bantam...
  • Page 755 303-03-154 Engine Cooling 303-03-154 REMOVAL AND INSTALLATION (CONTINUED) E6441 EN 07/2001 2002 Bantam...
  • Page 756 3. Secure the air conditioning (A/C) condenser to the hood latch panel. All vehicles 4. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 5. Lower the vehicle. E6656 EN 07/2001 2002 Bantam...
  • Page 757 All except vehicles with diesel engine 8. Using the special tool, disconnect the coolant hose from the radiator and detach the ventilation hose. 9. Disconnect the coolant hose from the radiator. E6656 EN 07/2001 2002 Bantam...
  • Page 758 Section 502- 00. 11. Remove the splash shield. Vehicles with diesel engine 12. Using the special tool, disconnect the coolant hose from the radiator. 13. Detach the diode from the radiator support bracket. E6656 EN 07/2001 2002 Bantam...
  • Page 759 15. Disconnect and detach the cooling fan motor relay electrical connector. 16. Disconnect the cooling fan motor electrical connector. All except vehicles with diesel engine 17. Using the special tool, disconnect the coolant hose from the radiator. E6656 EN 07/2001 2002 Bantam...
  • Page 760 19. Detach the cooling fan motor wiring. Vehicles with air conditioning 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...
  • Page 761 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...
  • Page 762 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...
  • Page 763 REMOVAL AND INSTALLATION (CONTINUED) Installation All vehicles 1. NOTE: Make sure the A/C condenser upper locating tangs are correctly installed into the radiator upper locating brackets. To install, reverse the removal procedure. Vehicles with air conditioning E6656 EN 07/2001 2002 Bantam...
  • Page 764 303-03-163 Engine Cooling 303-03-163 REMOVAL AND INSTALLATION (CONTINUED) E6656 EN 07/2001 2002 Bantam...
  • Page 765 3. Remove the cooling fan shroud left-hand retaining nut. 4. Remove the engine undershield. For additional information, refer to Section 502- 00. 5. Disconnect and detach the cooling fan motor resistor electrical connector. E6657 EN 07/2001 2002 Bantam...
  • Page 766 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...
  • Page 767 303-03-166 Engine Cooling 303-03-166 REMOVAL AND INSTALLATION (CONTINUED) 10. Remove the cooling fan motor. Installation 1. To install, reverse the removal procedure. E6657 EN 07/2001 2002 Bantam...
  • Page 768 2. Remove the expansion tank from the supporting bracket. Installation 1. To install, reverse the removal procedure. 2. Refill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. In this section E1001 EN 07/2001 2002 Bantam...
  • Page 769 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. 8. Lower the vehicle. E2465 EN 07/2001 2002 Bantam...
  • Page 770 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...
  • Page 771 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...
  • Page 772 5. Fill the cooling system as described, using a 50/50 mixture of Ford cooling system fluid and water. For additional information, refer to Specifications in this section. 6. Test the system for correct heater operation within the engine cooling system conditions.
  • Page 773 6. Connect the heater inlet water hose onto the engine. 7. Fill the cooling system as described, using 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...
  • Page 774 Water pump pulley retaining bolts (1.6L) Idler pulley retaining bolt (diesel) Engine mounting bracket retaining bolts (diesel) Cooling fan shroud retaining nuts Radiator support bracket retaining bolts Air conditioning (A/C) condenser retaining bolts Cooling fan motor retaining bolts E6658 EN 07/2001 2002 Bantam...
  • Page 775 303-04B-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 VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Fuel Charging and Controls....................303-04B-175/176 DIAGNOSIS AND TESTING Fuel Charging and Controls....................
  • Page 776 Throttle body maintain a constant fuel pressure in the fuel 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...
  • Page 777 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...
  • Page 778 • 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...
  • Page 779 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...
  • Page 780 REMOVAL AND INSTALLATION (CONTINUED) 4. Disconnect the air cleaner outlet pipe. 5. Remove the air cleaner outlet pipe. 6. Disconnect the throttle position (TP) sensor electrical connector. 7. Remove the throttle body. • Discard the gasket. E6661 EN 07/2001 2002 Bantam...
  • Page 781 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. To install, reverse the removal procedure. E6661 EN 07/2001 2002 Bantam...
  • Page 782 Section 310- 00. 2. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 3. Disconnect the engine ventilation hose. 4. Disconnect the engine ventilation hoses and secure to one side. E6662 EN 07/2001 2002 Bantam...
  • Page 783 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 information, refer to Section 310-00. 8. Detach the fuel injection supply manifold. E6662 EN 07/2001 2002 Bantam...
  • Page 784 11. Remove and discard the O-ring seals. Installation WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in per- sonal injury. E6662 EN 07/2001 2002 Bantam...
  • Page 785 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. To install, reverse the removal procedure. E6662 EN 07/2001 2002 Bantam...
  • Page 786 2. Disconnect the camshaft position (CMP) 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...
  • Page 787 6. Disconnect the idle air control (IAC) valve electrical connector. 7. Disconnect the throttle position (TP) sensor electrical connector. 8. Disconnect the engine coolant temperature (ECT) sensor electrical connector and remove the fuel charging wiring harness. E6663 EN 07/2001 2002 Bantam...
  • Page 788 303-04B-187 Fuel Charging and Controls — 1.6L / 1.3L Engine 303-04B-187 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. To install, reverse the removal procedure. E6663 EN 07/2001 2002 Bantam...
  • Page 789 303-04B-188 Fuel Charging and Controls — 1.6L / 1.3L Engine 303-04B-188 SPECIFICATIONS Torque Specifications Description Throttle body retaining bolts Fuel injection supply manifold retaining bolts E6664 EN 07/2001 2002 Bantam...
  • Page 790 303-04D-1 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-1 SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Fuel Charging and Controls ..................... 303-04D-2 Fuel Injection Pump ......................303-04D-2 Light Load Retard Device .....................
  • Page 791 The solenoid is also energized when engine coolant temperature is below 0 ° C and E6443 EN 09/2001 2002 Bantam...
  • Page 792 E6443 EN 09/2001 2002 Bantam...
  • Page 793 303-04D-4 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-4 SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE GENERAL PROCEDURES Idle Speed Adjustment (Vehicles Without Air Conditioning) ......(23 413 0) 303-04D-5 Idle Speed Adjustment (Vehicles With Air Conditioning) ........
  • Page 794 6. Check to ensure the idle speed is still within specification. 7. Momenentarily move the idle lever away from the stop. 8. Check to ensure the idle speed is still within specification. 9. Switch the engine off. 10. Disconnect the tachometer from the engine. E6450 EN 09/2001 2002 Bantam...
  • Page 795 8. Momenentarily move the idle lever away from the stop. 9. Check to ensure the idle speed is still within specification. 10. Adjust the idle speed control cable (refer to operation in this section). E6451 EN 09/2001 2002 Bantam...
  • Page 796 303-04D-7 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-7 GENERAL PROCEDURES (CONTINUED) 11. Refit the idle speed control cable retaining clip. 12. Disconnect the tachometer from the engine. E6451 EN 09/2001 2002 Bantam...
  • Page 797 303-04D-8 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-8 SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION 303-04D-9 /17 Fuel Injection Pump (Removal) ................. (23 414 0) Fuel Injection Pump (Install) ................(23 414 0)
  • Page 798 Always fit blanking plugs to any open orifices or pipes. 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. E6448 EN 09/2001 2002 Bantam...
  • Page 799 4. Remove the engine front mounting bracket. 5. Raise and support the vehicle. For additional information, refer to Section 100-02. 6. Loosen the crankshaft pulley/vibration damper retaining bolts. 7. Remove the generator. For additional information, refer to Section 414-02. E6448 EN 09/2001 2002 Bantam...
  • Page 800 10. Lower the vehicle. 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. 13. Remove the accessory drive belt. E6448 EN 09/2001 2002 Bantam...
  • Page 801 11 o'clock position. 17. Raise and support the vehicle. For additional information, refer to Section 100-02. 18. Remove the blanking plug from the cylinder block. (Generator bracket shown removed for clarity). E6448 EN 09/2001 2002 Bantam...
  • Page 802 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 additional information, refer to Section 303-01C. 23. Remove the accelerator cable adjuster clip. E6448 EN 09/2001 2002 Bantam...
  • Page 803 Vehicles without air conditioning 26. Remove the waxstat cable retaining clip. 27. Disconnect the waxstat cable from the fuel injection pump idle lever. Vehicles with air conditioning 28. Remove the idle speed compensation cable retaining clip. E6448 EN 09/2001 2002 Bantam...
  • Page 804 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. For additional information, refer to Fuel Injector Delivery Pipes in this section E6448 EN 09/2001 2002 Bantam...
  • Page 805 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...
  • Page 806 Remove the fuel injection pump. 45. Remove the fuel injection pump from the rear support bracket. E6448 EN 09/2001 2002 Bantam...
  • Page 807 3. Raise and support the vehicle. For additional information, refer to Section 100-02. 4. Install the three bolts which retain the fuel injection pump rear support bracket to the cylinder block. 5. Lower the vehicle. E6448 EN 09/2001 2002 Bantam...
  • Page 808 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...
  • Page 809 Section 301-01C. 14. Remove the special tool from the fuel injection pump. 15. Remove the special tool from the camshaft. 16. Raise and support the vehicle. For additional information, refer to Section 100-02. E6448 EN 09/2001 2002 Bantam...
  • Page 810 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...
  • Page 811 1 mm and 2 mm of slack in the waxstat cable. Vehicles with air conditioning 30. Adjust the idle speed compensation cable (refer to WDS). E6448 EN 09/2001 2002 Bantam...
  • Page 812 303-04D-23 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-23 REMOVAL AND INSTALLATION SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Fuel Injectors ..................... (23 455 0) 303-04D-24/25 E6445 EN...
  • Page 813 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 1. Refit the components in reverse order. • Install new fuel injector copper sealing washers. E6445 EN 09/2001 2002 Bantam...
  • Page 814 303-04D-25 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-25 REMOVAL AND INSTALLATION (CONTINUED) E6445 EN 09/2001 2002 Bantam...
  • Page 815 303-04D-26 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-26 REMOVAL AND INSTALLATION SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Fuel Injector Delivery Pipes (Removal) .................. 303-04D-27/28 Fuel Injector Delivery Pipes (Install) ..................
  • Page 816 1. Disconnect the battery ground cable. 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...
  • Page 817 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...
  • Page 818 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-29 REMOVAL AND INSTALLATION (CONTINUED) 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...
  • Page 819 303-04D-30 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-30 SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE GENERAL PROCEDURES Waxstat Cable (Adjustment)....................303-04D-31 Cable Idle Speed Control (Adjustment)................... 303-04D-32 09/2001 2002 Bantam...
  • Page 820 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...
  • Page 821 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...
  • Page 822 303-04D-33 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-33 SPECIFICATIONS SECTION 303-04D Fuel Charging and Controls — 1.8L Diesel Engine VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE SPECIFICATIONS Specifications ........................... 303-04D-34 Fuel Injection Pump ......................303-04D-34 Fuel Injectors......................... 303-04D-34 Glow Plugs ..........................
  • Page 823 Endura DE Diesel Engine Fuel injection pump drive belt tensioner retaining bolt Endura DE Diesel Engine Fuel injection pump drive gear retaining bolts Endura DE Diesel Engine Fuel injection pump rear support bracket retaining bolts E6452 EN 09/2001 2002 Bantam...
  • Page 824 Endura DE Diesel Engine Fuel injection pump retaining bolts Endura DE Diesel Engine Fuel injector delivery pipe unions Endura DE Diesel Engine Fuel injectors Endura DE Diesel Engine Glow plugs TDC timing peg blanking plug Air conditioning compressor retaining bolts E6452 EN 09/2001 2002 Bantam...
  • Page 825 303-05-189 Accessory Drive 303-05-189 SECTION 303-05 Accessory Drive VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Accessory Drive - Vehicles with 1.6L / 1.3L engine .............. 303-05-190/191 Accessory Drive - Vehicles with Diesel engine..............303-05-191 DIAGNOSIS AND TESTING Accessory Drive........................
  • Page 826 Item Description Item Description Air conditioning (A/C) compressor pul- Accessory drive belt Power steering pump pulley or idler Crankshaft pulley pulley (vehicles without power steering) Belt tensioner pulley Generator pulley Water pump pulley Idler pulley E6668 EN 07/2001 2002 Bantam...
  • Page 827 The belt tensioner's are of the manual type. To Fuel injection pump pulley increase the belt tension, rotate the adjustment Power steering pump belt bolt counterclockwise and to decrease the belt tension, rotate the adjustment bolt clockwise. Belt tensioner pulley E6668 EN 07/2001 2002 Bantam...
  • Page 828 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...
  • Page 829 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...
  • Page 830 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...
  • Page 831 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...
  • Page 832 3. Remove the accessory drive belt tensioner pulley. Vehicles with power steering 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...
  • Page 833 REMOVAL AND INSTALLATION (CONTINUED) All vehicles 6. Remove the accessory drive belt lower idler pulley. 7. Remove the accessory drive belt tensioner and bracket assembly. Installation All vehicles 1. To install, reverse the removal procedure. E5903 EN 07/2001 2002 Bantam...
  • Page 834 303-05-198 Accessory Drive 303-05-198 REMOVAL AND INSTALLATION (CONTINUED) Vehicles without power steering Vehicles with power steering All vehicles E5903 EN 07/2001 2002 Bantam...
  • Page 835 • 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...
  • Page 836 • 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...
  • Page 837 (1.6L / 1.3L) Accessory drive belt tensioner retaining bolts (die- sel) Accessory drive belt tensioner pulley retaining nut (diesel) Power steering pump belt tensioner pulley retain- ing nut (diesel) Power steering pump belt cover retaining bolts (diesel) E6675 EN 07/2001 2002 Bantam...
  • Page 838 303-06-202 Starting System 303-06-202 SECTION 303-06 Starting System VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Starting System ........................303-06-203 DIAGNOSIS AND TESTING Starting System ........................303-06-204A Inspection and Verification....................303-06-204A Symptom Chart......................... 303-06-204A Pinpoint Tests ........................303-06-204B/212 REMOVAL AND INSTALLATION Starter Motor —...
  • Page 839 Parts Microfiche for detailed information. which engage with a ring gear during starting. Starter motors should be serviced as an assembly and should not, therefore, be dismantled. E5908 EN 07/2001 2002 Bantam...
  • Page 840 • 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...
  • Page 841 Pinpoint Tests PINPOINT TEST A: THE ENGINE DOES NOT CRANK OR THE RELAY CLICKS 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..........
  • Page 842 A1: CHECK THE BATTERY CONNECTIONS 1 Inspect the battery connections for loose/corroded connections. • Are the battery terminals clean and tight? GO TO A2 CLEAN and TIGHTEN connections as re- quired. TEST the system for normal opera- tion. E1017 EN 07/2001 2002 Bantam...
  • Page 843 3 Measure the voltage between the starter motor solenoid connector single pin, circuit 50 (GY/BK) and ground when the starter is operated. • Is the voltage greater than 10 volts? GO TO A4 GO TO A6 A4: CHECK B+ TO THE STARTER E1017 EN 07/2001 2002 Bantam...
  • Page 844 2 Measure the voltage between the starter relay connector pin 5, circuit 30 (RD) and ground. • Is the voltage greater than 10 volts? GO TO A7 REPAIR circuit 30 (RD). TEST the system for normal operation. E1017 EN 07/2001 2002 Bantam...
  • Page 845 A9: CHECK FUSE 40 (60A) • Is the fuse OK? GO TO A10 INSTALL a new fuse 40 (60A). TEST the system for normal operation. If fuse fails again GO TO A15 Fuse 40 (60A) E1017 EN 07/2001 2002 Bantam...
  • Page 846 2 Measure the resistance between pin 4 and pin 3 of the ignition switch connector. • Is the resistance less than 5 ohms? GO TO A12 INSTALL a new ignition switch. TEST the system for normal operation. A12: CHECK CIRCUIT 50 (GY) CONTINUITY E1017 EN 07/2001 2002 Bantam...
  • Page 847 3, circuit 50 (GY/BK) and ground. • Is the resistance less than 5 ohms? INSTALL a new starter relay. TEST the system for normal operation. REPAIR circuit 50 (GY/BK). TEST the sys- tem for normal operation. E1017 EN 07/2001 2002 Bantam...
  • Page 848 2 Measure the resistance between the ignition switch connector pin 3, circuit 50 (GY) and ground. • Is the resistance greater than 10,000 ohms? CONNECT the ignition switch. GO TO A8 REPAIR circuit 50 (GY). TEST the system for normal operation. E1017 EN 07/2001 2002 Bantam...
  • Page 849 (-) battery terminal. • Is the resistance less than 5 ohms? INSTALL a new starter motor. TEST the system for normal operation. CLEAN and REPAIR grounds as required. TEST the system for normal operation. E1017 EN 07/2001 2002 Bantam...
  • Page 850 2 Inspect the ring gear for damage and wear. • Is the ring gear damaged? REPAIR ring gear as required. TEST the system for normal operation. INSTALL a new starter motor. TEST the system for normal operation. E1017 EN 07/2001 2002 Bantam...
  • Page 851 2. Remove the engine undershield. For additional information, refer to Section 502- 00. 3. Disconnect the electrical connector from the starter motor. 4. Remove the starter motor. Installation 1. To install, reverse the removal procedure. E5909 EN 07/2001 2002 Bantam...
  • Page 852 303-06-214 Starting System 303-06-214 REMOVAL AND INSTALLATION (CONTINUED) E5909 EN 07/2001 2002 Bantam...
  • Page 853 Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle. 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...
  • Page 854 303-06-216 Starting System 303-06-216 REMOVAL AND INSTALLATION (CONTINUED) Installation 1. Refit the components in reverse order. E5909 EN 07/2001 2002 Bantam...
  • Page 855 303-06-217 Starting System 303-06-217 SPECIFICATIONS Torque Specifications Description Starter motor retaining bolts Starter motor electrical connector upper retaining Starter motor electrical connector lower retaining E6678 EN 07/2001 2002 Bantam...
  • Page 856 303-07-218 Engine Ignition 303-07-218 SECTION 303-07 Engine Ignition VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Engine Ignition........................303-07-219 DIAGNOSIS AND TESTING Engine Ignition........................303-07-220 Inspection and Verification....................303-07-220 REMOVAL AND INSTALLATION Ignition Coil Pack — Vehicles with 1.6L / 1.3L Engine ........(22 414 0)
  • Page 857 Ignition timing is determined by the PCM in cleaner exhaust emissions. response to engine operating conditions. Once E6679 EN 07/2001 2002 Bantam...
  • Page 858 2. Visually inspect for obvious signs of damage. ness(s). Refer to the following chart: 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...
  • Page 859 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...
  • Page 860 303-07-222 Engine Ignition 303-07-222 REMOVAL AND INSTALLATION (CONTINUED) 1. To install, reverse the removal procedure. E6681 EN 07/2001 2002 Bantam...
  • Page 861 303-07-223 Engine Ignition 303-07-223 SPECIFICATIONS Torque Specifications Description Ignition coil pack retaining screws E6682 EN 07/2001 2002 Bantam...
  • Page 862 303-12-224 Intake Air Distribution and Filtering 303-12-224 SECTION 303-12 Intake Air Distribution and Filtering VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Intake Air Distribution and Filtering - Vehicles with 1.6L / 1.3L engine ......... 303-12-225 Intake Air Distribution and Filtering - Vehicles with Diesel engine ........
  • Page 863 DESCRIPTION AND OPERATION Intake Air Distribution and Filtering Vehicles with 1.3L or 1.6L Engine Item Description Item Description Air cleaner element Air cleaner outlet pipe Air cleaner intake pipe Air cleaner housing cover Air cleaner housing E6687 EN 07/2001 2002 Bantam...
  • Page 864 Intake Air Distribution and Filtering 303-12-226 DESCRIPTION AND OPERATION Vehicles with Diesel Engine Item Description Item Description Air cleaner intake pipe Air cleaner outlet pipe Air cleaner housing Air cleaner housing cover Intake air resonator Air cleaner element E6687 EN 07/2001 2002 Bantam...
  • Page 865 303-12-227 Intake Air Distribution and Filtering 303-12-227 DIAGNOSIS AND TESTING Intake Air Distribution and Filtering REFER to Section 303-00. E1029 EN 07/2001 2002 Bantam...
  • Page 866 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...
  • Page 867 6. Loosen the left-hand front wheel nuts. 7. Raise and support the vehicle. For additional information, refer to Section 100- 02. 8. Remove the left-hand front wheel. 9. Remove the left-hand front fender splash shield. E6688 EN 07/2001 2002 Bantam...
  • Page 868 303-12-230 REMOVAL AND INSTALLATION (CONTINUED) 10. Remove the air cleaner intake pipe. 1. Rotate the air cleaner intake pipe counterclockwise. 2. Remove the air cleaner intake pipe. Installation 1. To install, reverse the removal procedure. E6688 EN 07/2001 2002 Bantam...
  • Page 869 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 1. To install, reverse the removal procedure. E6690 EN 07/2001 2002 Bantam...
  • Page 870 303-12-232 Intake Air Distribution and Filtering 303-12-232 SPECIFICATIONS Torque Specifications Description Wheel nuts Air cleaner housing cover retaining screws E6721 EN 07/2001 2002 Bantam...
  • Page 871 303-14-233 Electronic Engine Controls 303-14-233 SECTION 303-14 Electronic Engine Controls VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Electronic Engine Controls....................303-14-234 Vehicles with 1.3L or 1.6L Engine ..................303-14-235 Vehicles with Diesel Engine ....................303-14-236 DIAGNOSIS AND TESTING Electronic Engine Controls....................
  • Page 872 Description Temperature and manifold absolute Camshaft position (CMP) sensor pressure (T-MAP) sensor Oxygen sensor (O2S) Knock Sensor Engine coolant temperature (ECT) sensor Throttle position (TP) sensor Crankshaft position (CKP) sensor Idle air control (IAC) valve E6692 EN 07/2001 2002 Bantam...
  • Page 873 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...
  • Page 874 The A/C cutoff switch is secured to the fuel at full travel, the A/C cutoff switch is pressed, injection pump and operated by the fuel injection therefore cutting off the A/C system to enable maximum engine power. E6692 EN 07/2001 2002 Bantam...
  • Page 875 2. Visually inspect for obvious signs of damage. module electrical Refer to the following chart: connector. 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. E1036 EN 07/2001 2002 Bantam...
  • Page 876 1. Disconnect the battery ground cable. For additional information, refer to Section 414- 01. 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...
  • Page 877 REMOVAL AND INSTALLATION (CONTINUED) 5. Remove the PCM. Installation CAUTION: When installing the PCM electrical connector start the bolt by hand before tightening to avoid damaging the electrical connector pins. To install, reverse the removal procedure. E6670 EN 07/2001 2002 Bantam...
  • Page 878 Section 502- 00. 2. Disconnect the crankshaft position (CKP) sensor electrical connector (starter motor removed for clarity). 3. Remove the CKP sensor (starter motor removed for clarity). Installation 1. To install, reverse the removal procedure. E6693 EN 07/2001 2002 Bantam...
  • Page 879 1. Raise and support the vehicle. For additional information, refer to Section 100- 02. 2. Disconnect the power steering pressure switch electrical connector. 3. Remove the switch. Installation 1. To install, reverse the removal procedure. E1046 EN 07/2001 2002 Bantam...
  • Page 880 Section 303-04B. 2. Remove the throttle position (TP) sensor. 3. Remove and discard the O-ring seal. Installation 1. NOTE: Install a new TP sensor O-ring seal. To install, reverse the removal procedure. E6694 EN 07/2001 2002 Bantam...
  • Page 881 3. Remove the ECT sensor. 1. Remove the clip. 2. Remove the ECT sensor. 4. Remove and discard the O-ring seal. Installation 1. NOTE: Install a new ECT sensor O-ring seal. To install, reverse the removal procedure. E6694 EN 07/2001 2002 Bantam...
  • Page 882 303-14-244 Electronic Engine Controls 303-14-244 REMOVAL AND INSTALLATION (CONTINUED) Engine Knock Sensor — Vehicles with 1.3L Engines Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner intake pipe. WARNING: Watch for and collect escaping fuel. Observe the safety regulations for working with fuel.
  • Page 883 5. Brake booster vacuum hose. 6. Disconnect the electrical connectors. 1. Powertrain control module (PCM). 2. Camshaft position (CMP) sensor. 7. Raise and support the vehicle. For additional information, refer to Section 100- 02. 8. Remove the engine undershield. E6694 EN 07/2001 2002 Bantam...
  • Page 884 303-14-246 Electronic Engine Controls 303-14-246 REMOVAL AND INSTALLATION (CONTINUED) 9. Remove the intake manifold lower retaining bolts (shown with the engine removed). 10. Lower the vehicle. 11. Remove the intake manifold. 14. Remove the knock sensor.
  • Page 885 2. NOTE: Install a new gasket if the original is damaged. Install the intake manifold. . Raise and support the vehicle. For refer to Section 100- 02. additional information, . Install the intake manifold lower retaining bolts (shown with engine removed). E6694 EN 07/2001 2002 Bantam...
  • Page 886 303-14-248 Electronic Engine Controls 303-14-248 REMOVAL AND INSTALLATION (CONTINUED) . Install the engine undershield. . Lower the vehicle. . Connect the PCM and CMP electrical connectors. . Install the hoses and connect the electrical connector. 1. EVAP solenoid valve vacuum hose. 2.
  • Page 887 303-14-249 Electronic Engine Controls 303-14-249 REMOVAL AND INSTALLATION (CONTINUED) . Connect the fuel lines. 11. Install the air cleaner intake pipe. 12. Connect the battery ground cable. E6694 EN 07/2001 2002 Bantam...
  • Page 888 303-14-250 Electronic Engine Controls 303-14-250 SPECIFICATIONS Torque Specifications Description Crankshaft position (CKP) sensor retaining bolt Power steering pressure (PSP) switch Throttle position (TP) sensor retaining screws Knock sensor retaining bolt E6697 EN 07/2001 2002 Bantam...
  • Page 889 308-00-1 Manual Transaxle and Clutch — General Information 308-00-1 SECTION 308-00 Manual Transaxle and Clutch — General Information VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Manual Transaxle and Clutch....................308-00-2 DIAGNOSIS AND TESTING Manual Transaxle and Clutch....................308-00-3 Inspection and Verification - Clutch ..................308-00-3...
  • Page 890 DESCRIPTION AND OPERATION Manual Transaxle and Clutch iB5 Manual Transmission Clutch refer to Section 308- 03. For additional information, For additional information, refer to Section 308- 01. Clutch Controls For additional information, refer to Section 308- 02. E4459 EN 07/2001 2002 Bantam...
  • Page 891 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...
  • Page 892 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...
  • Page 893 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...
  • Page 894 • 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...
  • Page 895 • 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...
  • Page 896 • 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...
  • Page 897 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.....
  • Page 898 • Is the measured dimension within 10 mm? GO TO A3 GO TO B3 A3: CLUTCH PEDAL OPERATION 1 Check the lubrication. • Is the clutch pedal shaft sufficiently lubricated? GO TO B3 Lubricate the clutch pedal shaft. E6760 EN 07/2001 2002 Bantam...
  • Page 899 1 Visually check the clutch disc. • Is the clutch friction disk oil-fouled or does it have burn marks? Install a new clutch friction disk. TEST the system for normal operation. Check the flywheel. Refer flywheel in this section. E6760 EN 07/2001 2002 Bantam...
  • Page 900 D1: CHECK THE CLUTCH PEDAL 1 Check clutch pedal mechanism lubrication. • Is the clutch pedal shaft sufficiently lubricated? Check the flywheel. Refer to Flywheel in this section. Lubricate the clutch pedal shaft. TEST the system for normal operation. E6760 EN 07/2001 2002 Bantam...
  • Page 901 Install a new clutch slave cylinder. REFER to Section 308-02. TEST the system for normal operation. GO TO E4 E4: INSPECT THE FLYWHEEL 1 Remove the transaxle. REFER to Section 308-03. 2 Inspect for loose flywheel bolts. E6760 EN 07/2001 2002 Bantam...
  • Page 902 • Is the clutch pedal free play within 1-3 mm (0.04-0.12 inch)? Diagnose hard shifting concern. REFER to Section 308-03. Inspect the clutch pressure plate for dam- age. Refer to Clutch Pressure Plate in this section. E6760 EN 07/2001 2002 Bantam...
  • Page 903 • Are the bolts loose or are there signs of wear or rust? TIGHTEN the bolts or install a new clutch slave cylinder with the release bearing. TEST the system for normal operation. GO TO G4 E6760 EN 07/2001 2002 Bantam...
  • Page 904 1 Check the clutch hydraulic lines for loose or damaged fittings causing leakage. • Are the clutch hydraulic lines OK? Carry out a road test to verify customer complaint. REPAIR or INSTALL new components as necessary. Carry out a road test. E6760 EN 07/2001 2002 Bantam...
  • Page 905 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...
  • Page 906 308-00-16 Manual Transaxle and Clutch — General Information 308-00-16 GENERAL PROCEDURES Clutch Master Cylinder Check 1. Check the clutch master cylinder: • For leaks • Retaining clip E4580 EN 07/2001 2002 Bantam...
  • Page 907 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...
  • Page 908 Manual Transaxle and Clutch — General Information 308-00-18 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...
  • Page 909 • 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...
  • Page 910 (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...
  • Page 911 Section 100-02. 2. Remove the exhaust heat shield. Vehicles with diesel engine 3. Remove the inner drive shaft joint heat shield. Vehicles with 1.6L / 1.3L engine 4. Remove the inner drive shaft joint heat shield. E6761 EN 07/2001 2002 Bantam...
  • Page 912 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. 9. Install the exhaust heat shield. E6761 EN 07/2001 2002 Bantam...
  • Page 913 GENERAL PROCEDURES (CONTINUED) Vehicles with diesel engine 10. Install the inner drive shaft joint heat shield. Vehicles with 1.6L / 1.3L engine 11. Install the inner drive shaft joint heat shield. 12. Lower the vehicle. E6761 EN 07/2001 2002 Bantam...
  • Page 914 Lubricants, Fluids, Sealers and Adhesives Item Specification DOT 4 brake fluid SAE J1703 JUN91 Clutch Description Clutch disc wear limit 7.00 Torque Specifications Description Clutch bleed nipple Gearshift stabilizers retaining nut Heat shield retaining nut Transaxle flange bolts 07/2001 2002 Bantam...
  • Page 915 308-01-25 Clutch 308-01-25 SECTION 308-01 Clutch VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Clutch............................308-01-26 DIAGNOSIS AND TESTING Clutch............................308-01-27 REMOVAL AND INSTALLATION Clutch Disc and Pressure Plate ....................308-01-28/29 SPECIFICATIONS Specifications ........................... 308-01-30 Clutch ............................ 308-01-30 Torque Specifications......................
  • Page 916 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...
  • Page 917 308-01-27 Clutch 308-01-27 DIAGNOSIS AND TESTING Clutch REFER to Section 308-00. E3535 EN 07/2001 2002 Bantam...
  • Page 918 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...
  • Page 919 2. Locate the clutch over the locating dowels on the flywheel. 3. Secure the bolts, working diagonally. 3. Remove the special tool. 4. Install the transmission. For additional information, refer to Section 308-03. E5939 EN 07/2001 2002 Bantam...
  • Page 920 308-01- 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 Torque Specifications Description Clutch pressure plate retaining bolts Clutch bleed nipple 07/2001...
  • Page 921 308-02-31 Clutch Controls 308-02-31 SECTION 308-02 Clutch Controls VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Clutch Controls......................... 308-02-32/33 DIAGNOSIS AND TESTING Clutch Controls......................... 308-02-34 REMOVAL AND INSTALLATION Clutch Master Cylinder ..................(16 856 0) 308-02-35/36 Clutch Slave Cylinder..................(16 862 0)
  • Page 922 308-02-32 Clutch Controls 308-02-32 DESCRIPTION AND OPERATION 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.
  • Page 923 308-02-33 Clutch Controls 308-02-33 DESCRIPTION AND OPERATION Clutch operating mechanism components Item Description Item Description Bleed nipple Brake fluid reservoir Pressure pipe Clutch master cylinder Feed line Clutch slave cylinder with integral re- lease bearing Retaining clip E1148 EN 07/2001...
  • Page 924 308-02-34 Clutch Controls 308-02-34 DIAGNOSIS AND TESTING Clutch Controls REFER to Section 308-00. E3543 EN 07/2001...
  • Page 925 308-02-35 Clutch Controls 308-02-35 REMOVAL AND INSTALLATION Clutch Master Cylinder (16 856 0) Material Specification DOT 4 brake fluid SAE J1703 JUN91 Removal WARNING: Brake fluid contains polygly- col ethers and polyglycols. A void con- tact with the eyes. Wash hands thor- oughly after handling.
  • Page 926 308-02-36 Clutch Controls 308-02-36 REMOVAL AND INSTALLATION (CONTINUED) 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.
  • Page 927 308-02-37 Clutch Controls 308-02-37 REMOVAL AND INSTALLATION Clutch Slave Cylinder (16 862 0) Removal 5. Remove the transmission. For additional information, refer to Section 308-03. 6. Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder. Installation 4.
  • Page 928 308-02-38 Clutch Controls 308-02-38 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Specification DOT 4 brake fluid SAE J1703 JUN91 Clutch Controls Description Operation Hydraulic Adjustment Automatic Torque Specifications Description Clutch master cylinder retaining bolts (two bolts) Clutch slave cylinder retaining bolts (three bolts) Pre-load valve E6713 EN 07/2001...
  • Page 929 308-03-39 Manual Transaxle 308-03-39 SECTION 308-03 Manual Transaxle VEHICLE APPLICATION: 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Manual Transaxle ........................308-03-40 Components of the iB5 Manual Transmission..............308-03-41/47 DIAGNOSIS AND TESTING Manual Transaxle ........................308-03-48 IN-VEHICLE REPAIR Input Shaft Oil Seal ........................
  • Page 930 308-03-40 Manual Transaxle 308-03-40 DESCRIPTION AND OPERATION Manual Transaxle Overview The direction of rotation of the output shaft is Item Description reversed for reverse gear by using an idler Slave Cylinder - Clutch gearwheel. Sealed bearings Transmission vent All gearwheels are helically splined, synchronized (except reverse gear) and run on friction The aluminum transmission housing features bearings.
  • Page 931 308-03-41 Manual Transaxle 308-03-41 DESCRIPTION AND OPERATION (CONTINUED) Components of the iB5 Manual Transmission Overview Item Description Item Description Crown wheel Pre-load valve (1 bar) (vehicles built up to build month 08/1999) Tripod housing Oil seal (accessible from the outside) First/second gear synchronizer clutch Clutch release bearing (separately re- Third/fourth gear synchronizer clutch...
  • Page 932 308-03-42 Manual Transaxle 308-03-42 DESCRIPTION AND OPERATION (CONTINUED) the synchronizer clutches. No power is When the transmission is in neutral none of the gearwheels are connected to the output shaft by transferred to the differential. Internal Gearshift Mechanism Item Description Item Description Detent mechanism Main shift rod...
  • Page 933 308-03-43 Manual Transaxle 308-03-43 DESCRIPTION AND OPERATION Input shaft Item Description Item Description Gearwheel - 3rd gear Ball bearing Gearwheel - 4th gear Input shaft Snap-ring Reverse gear idler Gearwheel - 5th gear Gearwheel - 1st gear Snap-ring. Gearwheel - reverse gear Gearwheel - 2nd gear E4460 EN 07/2001...
  • Page 934 308-03-44 Manual Transaxle 308-03-44 DESCRIPTION AND OPERATION Output shaft Item Description Item Description 1st/2nd gear synchronizer clutch with Parallel roller bearing reverse gearwheel Output shaft Snap-ring 1st gearwheel Outer synchronizer ring Inner synchronizer ring Synchronizer cone Synchronizer cone Inner synchronizer ring Outer synchronizer ring 2nd gearwheel E4460 EN...
  • Page 935 308-03-45 Manual Transaxle 308-03-45 DESCRIPTION AND OPERATION (CONTINUED) Item Description Item Description Half rings Gearwheel - 4th gear Snap-ring Ball bearing (closed on both sides) 3rd gearwheel with simple synchroni- Snap-ring. zation Gearwheel - 5th gear 3rd gearwheel with double synchroni- Synchronizer ring (5th gear) zation 5th gear synchronizer clutch...
  • Page 936 308-03-46 Manual Transaxle 308-03-46 DESCRIPTION AND OPERATION (CONTINUED) The transmission and differential are located Item Description inside an aluminum two part housing, which is Input shaft connected to the engine by a flange. Output shaft The input shafts are splined. Output pinion Driving torque is transferred to the differential cage by the crown wheel, which is bolted to it.
  • Page 937 308-03-47 Manual Transaxle 308-03-47 DESCRIPTION AND OPERATION (CONTINUED) Item Description Item Description Input shaft Input shaft Output shaft Output shaft Output pinion Output pinion 3rd gear teeth 5th gear teeth 3rd/4th gear synchronizer clutch 5th gear synchronizer clutch 3rd gearwheel 5th gearwheel Fourth gear Reverse gear...
  • Page 938 308-03-48 Manual Transaxle 308-03-48 DIAGNOSIS AND TESTING Manual Transaxle REFER to Section 308-00. E3553 EN 07/2001...
  • Page 939 308-03-49 Manual Transaxle 308-03-49 IN-VEHICLE REPAIR Input Shaft Oil Seal Special Tool(s) Material Specification Remover, oil seal Self-tapping screw 2,5 x 15 mm 303-336 (21-151) Removal All vehicles Remove the clutch slave cylinder. 1. Remove the bolts. 2. Detach the clutch slave cylinder from the clutch housing.
  • Page 940 308-03-50 Manual Transaxle 308-03-50 IN- VEHICLE REPAIR (CONTINUED) 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.
  • Page 941 308-03-51 Manual Transaxle 308-03-51 IN-VEHICLE REPAIR LH Halfshaft Oil Seal (14 303 0) Special Tool(s) Special Tool(s) Installer, Halfshaft Oil Seal Remover, Halfshaft Oil Seal 308-039 (16-018) 308-208 (16-074) Removal CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees.
  • Page 942 308-03-52 Manual Transaxle 308-03-52 IN- VEHICLE REPAIR (CONTINUED) Installation 1. Using the special tool, install the left-hand halfshaft oil seal. 2. Install the left-hand halfshaft. For additional information, refer to Section 205-04. 3. Install the right-hand halfshaft. For additional information, refer to Section 205- 04.
  • Page 943 308-03-53 Manual Transaxle 308-03-53 IN-VEHICLE REPAIR RH Halfshaft Oil Seal (14 304 0) Special Tool(s) Special Tool(s) Installer, Halfshaft Oil Seal Remover, Oil Seal 308-039 (16-018) 303-112 (21-051) Removal Vehicles with diesel engine 1. Remove the halfshaft heat shield. Vehicles with 1.6L / 1.3L engine 2.
  • Page 944 308-03-54 Manual Transaxle 308-03-54 IN- VEHICLE REPAIR (CONTINUED) 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. Vehicles with diesel engine 2. Install the halfshaft heat shield. E6739 EN 07/2001...
  • Page 945 308-03-55 Manual Transaxle 308-03-55 IN- VEHICLE REPAIR (CONTINUED) Vehicles with 1.6L / 1.3L engine 3. Install the halfshaft heat shield. All Vehicles 4. Install the right-hand halfshaft. For additional information, refer to Section 205-04. E6739 EN 07/2001...
  • Page 946 308-03-56 Manual Transaxle 308-03-56 REMOVAL Transaxle — Vehicles with 1.6L / 1.3L Engine (16 114 0) Special Tool(s) Special Tool(s) Remover, Halfshaft Adapter for 303-290 308-237 (16-087) 303-290-03 (21-140-03) Remover, Halfshaft General Equipment 308-256 (16-089) Engine lifting eye Transmission jack Auxiliary plugs Support Bar, Engine Retaining straps...
  • Page 947 308-03-57 Manual Transaxle 308-03-57 RE MOVAL (CONTINUED) Vehicles with 1.6L / 1.3L engine 3. Remove the air cleaner intake pipe. Vehicles with diesel engine 4. Remove the air cleaner intake pipe. 1. Remove the air cleaner intake from the intake manifold. 2.
  • Page 948 308-03-58 Manual Transaxle 308-03-58 REMOVAL (CONTINUED) All vehicles 6. NOTE: Use an Allen key to prevent the piston rod turning. Loosen the left-hand and the right-hand suspension strut nut five turns. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes.
  • Page 949 308-03-59 Manual Transaxle 308-03-59 RE MOVAL (CONTINUED) 9. Remove the transaxle upper flange bolts with ground cable and the hose. 1. Remove the ground cable flange bolt 2. Disconnect the generator electrical connector 3. Disconnect the starter motor electrical connector 4.
  • Page 950 308-03-60 Manual Transaxle 308-03-60 REMOVAL (CONTINUED) Vehicles with 1.6L / 1.3L engine 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.
  • Page 951 308-03-61 Manual Transaxle 308-03-61 RE MOVAL (CONTINUED) All vehicles 17. Raise and support the vehicle. For additional information, refer to Section 100-02. 18. Disconnect the reversing lamp switch electrical connector. 19. Disconnect the speedometer drive cable from the transaxle. Vehicles with diesel engine 20.
  • Page 952 308-03-62 Manual Transaxle 308-03-62 REMOVAL (CONTINUED) Vehicles with 1.6L / 1.3L engine 21. Remove the halfshaft heat shield. 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. •...
  • Page 953 308-03-63 Manual Transaxle 308-03-63 RE MOVAL (CONTINUED) 25. Remove the lower arm ball joints on both sides (left-hand side shown). 26. Remove the constant velocity joint boot clamp. 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.
  • Page 954 308-03-64 Manual Transaxle 308-03-64 REMOVAL (CONTINUED) 30. Using the special tools, lower the transaxle. 31. Raise and support the vehicle. For additional information, refer to Section 100- 02. Vehicles with 1.6L / 1.3L engine 32. Push the engine forward and position a wooden block (260 mm) between the crossmember and the oil pan.
  • Page 955 308-03-65 Manual Transaxle 308-03-65 RE MOVAL (CONTINUED) 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...
  • Page 956 308-03-66 Manual Transaxle 308-03-66 DISASSEMBLY Transaxle (16 118 8) Special Tool(s) Special Tool(s) 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)
  • Page 957 308-03-67 Manual Transaxle 308-03-67 DISASSEMBLY (CONTINUED) All vehicles 3. Remove the clutch slave cylinder. 1. Remove the bolts. 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.
  • Page 958 308-03-68 Manual Transaxle 308-03-68 DISASSEMBLY (CONTINUED) . 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.
  • Page 959 308-03-69 Manual Transaxle 308-03-69 DISASSEMBLY (CONTINUED) 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. CAUTION: Do not strike the mating face.
  • Page 960 308-03-70 Manual Transaxle 308-03-70 DISASSEMBLY (CONTINUED) 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.
  • Page 961 308-03-71 Manual Transaxle 308-03-71 DISASSEMBLY (CONTINUED) 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.
  • Page 962 308-03-72 Manual Transaxle 308-03-72 DISASSEMBLY (CONTINUED) 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...
  • Page 963 308-03-73 Manual Transaxle 308-03-73 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Selector Plate (16 284 5) Special Tool(s) Special Tool(s) Draw hammer Remover and installer, shift rod oil seal 205-102 (15-053) 308-040 (16-019) Material Specification Universal sealant (Hylomar) Disassembly 1. Remove the shift rod oil seal. •...
  • Page 964 308-03-74 Manual Transaxle 308-03-74 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 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.
  • Page 965 308-03-75 Manual Transaxle 308-03-75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 3. Install the shift rod oil seal. • Fit the boot. E1163 EN 07/2001...
  • Page 966 308-03-76 Manual Transaxle 308-03-76 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Input Shaft (16 146 5) Special Tool(s) General Equipment Installer Puller 308-045 (16-015) Press Material Specification Transmission fluid BOT 130 Disassembly CAUTION: Handle synchronizer rings and cones with care. 1. Pull off the ball bearing on the transmission end.
  • Page 967 308-03-77 Manual Transaxle 308-03-77 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 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.
  • Page 968 308-03-78 Manual Transaxle 308-03-78 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Output Shaft Special Tool(s) General Equipment Remover, basic tool Puller 205-295 (15-050A) Press Material Specification Transmission fluid BOT 130 Installer 308-045 (16-015) Collet for 15-050 A 307-217 (17-048) Disassembly CAUTION: Handle synchronizer rings and cones carefully.
  • Page 969 308-03-79 Manual Transaxle 308-03-79 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 2. Detach the 3rd/4th gearwheel 1. Detach the snap-ring. 2. Remove the synchronizer clutch, the 3rd/4th gear synchronizer assembly and the 3rd gearwheel. 3. Remove the third gear synchronizer ring. 1.
  • Page 970 308-03-80 Manual Transaxle 308-03-80 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 5. Detach the 2nd gearwheel and synchronizer assembly. 1. Retaining ring 2. Half rings 3. 2nd gearwheel 4. Inner synchronizer ring 5. Synchronizer cone 6. Outer synchronizer ring 6. NOTE: Detach the 1st gearwheel and synchronizer assembly together.
  • Page 971 308-03-81 Manual Transaxle 308-03-81 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 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.
  • Page 972 308-03-82 Manual Transaxle 308-03-82 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 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.
  • Page 973 308-03-83 Manual Transaxle 308-03-83 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 5. NOTE: Assembly the synchronizer before fitting it. Fit the 2nd gearwheel and synchronizer assembly on the output shaft. 1. Outer synchronizer ring 2. Synchronizer cone 3. Inner synchronizer ring 4.
  • Page 974 308-03-84 Manual Transaxle 308-03-84 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 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.
  • Page 975 308-03-85 Manual Transaxle 308-03-85 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Differential Special Tool(s) Special Tool(s) Thrust pad Collet for 15-050 A 204-158-01 (14-038-01) 308-197 (16-062) Installer, differential bearing General Equipment 205-062 (15-025A) Press Material Specification Remover, basic tool Transmission fluid BOT 130 205-295 (15-050A) Disassembly 1.
  • Page 976 308-03-86 Manual Transaxle 308-03-86 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (CONTINUED) 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.
  • Page 977 308-03-87 Manual Transaxle 308-03-87 ASSEMBLY Transaxle (16 118 8) Special Tool(s) Special Tool(s) 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)
  • Page 978 308-03-88 Manual Transaxle 308-03-88 ASSEMBLY (CONTINUED) 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.
  • Page 979 308-03-89 Manual Transaxle 308-03-89 ASSEMBLY (CONTINUED) 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.
  • Page 980 308-03-90 Manual Transaxle 308-03-90 ASSEMBLY (CONTINUED) 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).
  • Page 981 308-03-91 Manual Transaxle 308-03-91 ASSEMBLY (CONTINUED) 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. •...
  • Page 982 308-03-92 Manual Transaxle 308-03-92 ASSEMBLY (CONTINUED) 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: •...
  • Page 983 308-03-93 Manual Transaxle 308-03-93 ASSEMBLY (CONTINUED) 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.
  • Page 984 308-03-94 Manual Transaxle 308-03-94 ASSEMBLY (CONTINUED) 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.
  • Page 985 308-03-95 Manual Transaxle 308-03-95 ASSEMBLY (CONTINUED) 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. •...
  • Page 986 308-03-96 Manual Transaxle 308-03-96 ASSEMBLY (CONTINUED) 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.
  • Page 987 308-03-97 Manual Transaxle 308-03-97 ASSEMBLY (CONTINUED) 35. Engage fifth gear. • Turn the fifth gearshift rod clockwise as far as the stop. 36. Engage fifth gear. • Turn the main shift rod clockwise as far as the stop and pull it out. 37.
  • Page 988 308-03-98 Manual Transaxle 308-03-98 ASSEMBLY (CONTINUED) 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.
  • Page 989 308-03-99 Manual Transaxle 308-03-99 INSTALLATION Transaxle (16 114 0) Special Tool(s) General Equipment Support Bar, Engine Engine lifting eye 303-290 (21-140) Transmission jack Auxiliary plugs Retaining strap Adapter for 303-290 Material Specification 303-290-01 (21-140-01) Manual transmission BOT 130 fluid High-durability grease WSD-M1C230-A Adapter for 303-290 Cable ties...
  • Page 990 308-03-100 Manual Transaxle 308-03-100 INSTALLATION (CONTINUED) 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. Vehicles with 1.6L / 1.3L engine 6. Remove the wooden block. All vehicles 7.
  • Page 991 308-03-101 Manual Transaxle 308-03-101 INSTALLATION (CONTINUED) 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. Vehicles with diesel engine 10. NOTE: Do not tighten the nuts. Install the engine front mounting bracket.
  • Page 992 308-03-102 Manual Transaxle 308-03-102 INSTALLATION (CONTINUED) 14. Install the engine roll restrictor. CAUTION: The inner joint must not 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.
  • Page 993 308-03-103 Manual Transaxle 308-03-103 INSTALLATION (CONTINUED) Vehicles with 1.6L / 1.3L engine 17. NOTE: Use a new gasket. Install the exhaust down pipe. 1. Install the nuts. 2. Connect the exhaust hanger insulator. 18. Install the halfshaft heat shield. Vehicles with diesel engine 19.
  • Page 994 308-03-104 Manual Transaxle 308-03-104 INSTALLATION (CONTINUED) 21. Connect the reversing lamp switch electrical connector. 22. Lower the vehicle. Vehicles with 1.6L / 1.3L engine 23. Tighten the bolts and nuts of the engine rear mounting bracket. 24. Remove the special tools. 25.
  • Page 995 308-03-105 Manual Transaxle 308-03-105 INSTALLATION (CONTINUED) Vehicles with diesel engine 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. 28. Remove the special tools. 29.
  • Page 996 308-03-106 Manual Transaxle 308-03-106 INSTALLATION (CONTINUED) 30. Install the resonator. Vehicles with 1.6L / 1.3L engine 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.
  • Page 997 308-03-107 Manual Transaxle 308-03-107 INSTALLATION (CONTINUED) All vehicles 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.
  • Page 998 308-03-108 Manual Transaxle 308-03-108 INSTALLATION (CONTINUED) 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. 2. Install the bolts. 40.
  • Page 999 308-03-109 Manual Transaxle 308-03-109 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.
  • Page 1000 308-03-110 Manual Transaxle 308-03-110 GENERAL PROCEDURES (CONTINUED) 5. The bearing surfaces are gray or gray/black with abraded particles between the taper rollers. • Renew the bearings and gaskets and make sure there is adequate lubrication. 6. The surface of the bearing race is notched as a result of impacts at standstill.

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