Table Of Contents - MG TF Workshop Manual

Table of Contents

Contents3
Repairs And Replacements6
Specification6
Abbreviations And Symbols7
General Information9
Vehicle Identification Number11
Location11
Vin Plate Details11
Vin Code Key11
Identification Number Locations12
Paint And Trim Colour Codes12
Engine Number12
Gearbox Number12
Body Number13
Automatic Gearbox13
Dangerous Substances15
Synthetic Rubber15
Lubricating Oils15
Health Protection Precautions15
Environmental Precautions16
Exhaust Fumes16
Solvents16
Refrigerant16
Spill Kits17
Land Contamination17
Legal Compliance17
Local Issues17
Use Of Resource18
Burning Used Engine Oil18
Waste Management18
Disposal Of Waste18
Precautions Against Damage19
Safety Instructions20
Jacking20
Brake Hydraulics20
Cooling System Caps And Plugs20
General Fitting Instructions21
Component Removal21
Dismantling21
Cleaning Components21
Ball And Roller Bearings22
Oil Seals23
Joints And Joint Faces24
Locking Devices24
Screw Threads25
Bolt Identification25
Nut Identification26
Self-Locking Nuts26
Self-Locking Bolts And Screws27
Encapsulated Bolts And Screws27
Flexible Pipes And Hoses28
Fuel System Hoses28
Cooling System Hoses28
Hose Orientation And Connection28
Hose Clips29
Heat Protection29
Service Tools30
Testbook30
Body Repairs30
Dynamometer Testing31
Four Wheel Dynamometers31
Two Wheel Dynamometers31
Fuel Handling Precautions33
Fuel Tank Draining33
Fuel Tank Removal33
Fuel Tank Repairs33
Quick Fit Fuel Hose Connectors34
Electrical Precautions35
Equipment35
Polarity35
High Voltage Circuits35
Supplementary Restraint System Precautions37
Making The System Safe37
Installation38
Srs Component Testing Precautions39
Handling And Storage39
Srs Harnesses And Connectors41
Rotary Coupler Precautions41
Warning Labels42
Bonnet Locking Platform42
Rotary Coupler42
Airbag Module - Driver43
Diagnostic Control Unit43
Airbag Module - Passenger43
Front Seat Belt Pre-Tensioners43
Vehicle Recovery44
Srs Component Deployment44
Srs Component Replacement Policy45
Rear Impacts46
Periodic Replacement Of Srs Components46
Air Conditioning System Precautions47
Remedial Actions47
Air Conditioning Compressor Replacement49
Information51
Engine - K Series Information53
Engine - Lubrication Information58
Fuel System Information58
Cooling System Information58
Clutch Information59
Manual Gearbox Information59
Stepspeed (Em-Cvt) Gearbox Information60
Gearbox - Lubrication Information60
Final Drive Information61
Steering Information63
Front Suspension Information64
Rear Suspension Information64
Brakes Information65
Wheels Information66
Tyre Sizes Information66
Tyre Pressures Information67
Air Conditioning Information67
Electrical Information68
Dimensions68
Weights Information69
Bulbs Information70
Engine Tuning Data71
Engine Information73
Jacking, Supporting And Towing Information85
Workshop Jack86
Wheel-Free Lift86
Recovery86
Towing87
Transporter Or Trailer Lashing87
Capacities89
Brake Fluid89
Anti-Freeze Solutions89
Organic Acid Technology (Oat) Anti-Freeze89
Replacing Coolant90
Lubrication91
Engine Oil91
Manual Gearbox91
Maintenance93
Engine Compartment Locations - Vvc Mems 395
Engine Compartment Locations - Mpi Mems 396
Under Bonnet Locations97
Engine Oil Level Check98
Engine Oil Drain And Refill98
Oil Filter Renewal99
Camshaft Timing Belt Mpi & Vvc99
Fuel Filter99
Air Cleaner Element99
Fuel System Hoses, Pipes And Unions100
Ignition Coils - Mpi/Vvc Mems 3101
Drive Shaft Gaiters101
Cooling System102
Exhaust System102
Gearbox Fluid - Manual Models103
Gearbox Fluid - Stepspeed (Em-Cvt) Models103
Clutch Fluid104
Steering Column, Rack, Joints And Gaiters105
Suspension Dampers, Ball Joints, Fixings And Gaiters106
Front Suspension106
Rear Suspension107
Road Wheels And Fastenings108
Tyre Pressures And Condition108
Footbrake108
Handbrake109
Renew Fluid, Abs And Non-Abs Brake Systems110
Brake Hoses And Pipes111
Renew Brake Hose - Front112
Renew Brake Hose - Rear112
Front Disc Brakes113
Rear Disc Brakes114
Body115
Locks, Hinges And Latch Mechanism (Not Steering Lock)115
Exterior Paintwork And Body Panels115
Underbody Sealer115
Driver Air Bag Module116
Passenger Air Bag Module116
Seats And Seat Belts116
Screen Wipers And Blades116
Windscreen Washers117
Lamps, Horns And Warning Indicators118
Heater Blower118
Battery Connections118
Fusebox118
Road Test119
Oil Seal - Front - Exhaust Camshaft - Front/Lh - Em-Cvt Models123
Oil Seal - Front - Exhaust Camshaft - Front/Lh - Vvc Models126
Camshaft Rear Oil Seal - Exhaust129
Oil Seal - Front - Inlet Camshaft - Rear/Rh - Em-Cvt Models130
Oil Seal - Front - Inlet Camshaft - Rear/Rh - Vvc Models133
Camshaft Rear Oil Seal - Inlet137
Pulley - Crankshaft - Manual Gearbox Models138
Pulley - Crankshaft - Stepspeed (Em-Cvt) Models139
Pulley - Crankshaft - Vvc Models140
Crankshaft Front Oil Seal141
Crankshaft Rear Oil Seal142
Gasket - Cylinder Head - Vvc Models144
Gasket - Cylinder Head - Em-Cvt Models148
Gasket - Camshaft Cover151
Valve Stem Oil Seal152
Engine & Gearbox Assembly - Remove - For Access & Refit - Stepspeed (Em-Cvt) Models153
Engine & Gearbox Assembly - Remove - For Access & Refit - Manual Gearbox Models162
Engine Cover Remove170
Engine Cover Refit170
Engine Mounting - Rear Removal171
Engine Mounting - Rear Refit171
Mounting Bracket - Lh - Manual Gearbox Models Remove171
Mounting Bracket - Lh - Stepspeed (Em-Cvt) Models172
Mounting Bracket - Rh - All Models173
Flywheel - Manual Gearbox Models175
Flywheel - Stepspeed (Em-Cvt) Models176
Torsion Damper - Stepspeed (Em-Cvt) Models177
Flywheel Starter Ring Gear177
Oil Filter Remove178
Oil Filter Refit178
Gasket - Oil Pump Remove178
Oil Sump Remove179
Switch - Oil Pressure Remove181
Switch - Oil Pressure Refit181
Oil Pressure Relief Valve Remove182
Oil Pressure Relief Valve Refit182
Sensor - Oil Temperature Remove183
Sensor - Oil Temperature Refit183
Cooler - Engine Oil - Vvc Remove183
Cooler - Engine Oil - Vvc Refit184
Timing Belt - Camshaft - Conventional Valve Control184
Timing Belt - Camshaft - Vvc189
Camshaft Timing Belt Gear193
Crankshaft Timing Belt Gear193
Timing Belt Upper Front Cover194
Camshaft Timing Belt Rear Cover - Mpi And Vvc - Manual Gearbox Models194
Cover - Timing Belt Lower Front195
Engine Management System196
Mpi/Vvc Mems 3 Control Diagram201
Engine Management System - Mpi/Vvc Mems 3203
Engine Control Module (Ecm)203
Heated Oxygen Sensor (Ho2S)204
Crankshaft Position (Ckp) Sensor205
Camshaft Position (Cmp) Sensor206
Manifold Absolute Pressure (Map) Sensor208
Engine Coolant Temperature (Ect) Sensor208
Intake Air Temperature (Iat) Sensor209
Engine Oil Temperature Sensor209
Throttle Position (Tp) Sensor210
Idle Air Control (Iac) Valve210
Ignition Coils211
Fuel Injectors211
Evaporative Emissions (Evap) Canister Purge Valve212
Alternator212
Air Conditioning (A/C) Trinary Switch213
A/C Trinary Switch Pressure Settings213
Vvc Mechanism Control214
Stepspeed Gearbox214
Ignition Switch Signal215
Main Relay215
Gearbox Shaft Speed Sensor215
Park/Neutral Switch215
Fuel Pump Relay216
A/C Compressor Clutch Relay216
Cooling Fans217
Engine Coolant Cooling Fan217
Engine Bay Cooling Fan217
Ambient Air Temperature (Aat) Sensor (Engine Bay)218
Engine Bay Cooling Fan Relay218
Engine Bay Overheat Warning Lamp218
Tachometer Drive218
Vehicle Immobilisation219
Rough Road Detection219
Fuel Pump219
Fuel Pressure Regulator220
Inertia Fuel Cut-Off Switch220
Diagnostics221
Diagnostic Socket221
Malfunction Indicator Lamp221
Ecm Harness Connector Details222
Connector C0914 - Black, 52 Pin222
Connector C0159 - Black, 28 Pin224
Acceleration Enrichment225
Over-Run Fuel Cut-Off225
Fuel Quantity225
Ignition Switch Off225
Ignition Timing226
Idle Speed Control227
Evaporative Emissions (Evap) Control System228
Air Intake System - Mpi/Vvc Mems 3229
Fuel Delivery System230
Recirculating Fuel System230
Fuel Tank Breathing System231
Emission Control Systems232
Crankcase Emission Control System232
Exhaust Emission Control232
Evaporative Emission Control233
Evaporative Emission Canister233
Evaporative Emission Canister, Purge Valve233
Throttle Cable Adjust234
Fuel System Depressurise235
Air Cleaner Remove236
Air Cleaner Refit236
Element Air Cleaner Remove236
Element Air Cleaner Refit237
Sensor - Camshaft Position (Cmp) - Vvc237
Sensor - Camshaft Position (Cmp) - Mpi238
Catalytic Converter239
Sensor - Crankshaft Position (Ckp)240
Engine Control Module (Ecm) - Mpi241
Sensor - Engine Coolant Temperature (Ect)242
Engine Management Relay Module242
Fuel Injectors - Mpi244
Fuel Injectors - Vvc244
Fuel Rail And Injectors - Mpi245
Filler Neck247
Hose - Breather - Tank To Filler Neck249
Fuel Rail - Vvc250
Fuel Tank251
Ht Lead - Set - Mpi254
Valve - Idle Air Control (Iac) - Mpi254
Hydraulic Control Unit Solenoids (Hcu) - Vvc255
Ignition Coil - Mpi256
Switch - Inertia Fuel Shut-Off256
Sensor - Intake Air Temperature (Iat) - Mpi257
Sensor - Manifold Absolute Pressure (Map) - Vvc257
Sensor - Manifold Absolute Pressure (Map) - Mpi258
Sensor - Oil Temperature - Vvc258
Sensor - Heated Oxygen (Ho2S) - Pre Cat259
Sensor - Heated Oxygen (Ho2S) - Post Cat260
Spark Plugs260
Throttle Housing - (Includes Tuning)261
Throttle Cable262
Sensor - Throttle Position (Tp)264
Cooling System Components268
Cooling System Operation269
Drain And Refill272
Expansion Tank274
Radiator Fan And Motor274
Engine Compartment Cooling Fan275
Engine Compartment Ambient Air Temperature (Aat) Sensor275
Radiator276
Thermostat - Vvc277
Thermostat - Mpi278
Engine Coolant Pump280
Manifold & Exhaust Systems282
Exhaust Pipe284
Exhaust Manifold285
Inlet Manifold - Mpi285
Inlet Manifold - Vvc286
Front Pipe288
Silencer289
Gasket - Exhaust Manifold To Front Pipe - Vvc290
Silencer Heat Shield291
Fuel Tank Heat Shield291
Manifold - Inlet - Mpi292
Gasket - Inlet Manifold - Mpi295
Gasket - Inlet Manifold - Vvc298
Gasket - Exhaust Manifold - Mpi300
Gasket(S) - Manifold Chamber - Vvc302
Exhaust Mountings304
Clutch Components308
Hydraulic Clutch System309
Clutch System Operation310
Master Cylinder Components311
Slave Cylinder Components312
Clutch - Bleed314
Clutch Assembly/Drive Plate & Release Bearing - Manual Transmission Models316
Clutch Master Cylinder318
Clutch Slave Cylinder319
Damper - Clutch - Vvc319
Gear Lever323
Gear Change Cable324
Gearbox - Manual - Remove For Access & Refit327
Selector Shaft Oil Seal328
Reverse Lamp Switch330
Automatic Gearbox - "Em-Cvt"333
Stepspeed (Em-Cvt) Component Location335
Stepspeed (Em-Cvt) Gearbox336
Stepspeed (Em-Cvt) Gearbox - Sectional View338
Stepspeed (Em-Cvt) Control Diagram340
Giu Connector C0932 Pin Details345
Engine Control Module - Em-Cvt Control347
Gear Selector Lever Assembly347
Shift Lock Solenoid348
Led Module348
Manual/Sport Switch348
Prnd Switch349
Brake Switch Giu Input349
Steering Wheel Switches349
Instrument Pack349
Liquid Crystal Display (Lcd)350
Gearbox Fault Lamp350
Fluid Cooler350
Driving - Automatic Mode351
Driving - Manual/Sport Mode352
Fast Adaptation Procedure352
Fault Diagnosis353
Engine Will Not Start In "P" Or "N"N353
Park Lock Does Not Hold Vehicle353
Vehicle Moves When "N" Is Selected353
Engine Can Be Started In All Selector Positions354
No Drive When "D" Or "R" Is Selected354
Vehicle Moves Above 6 Mph (10Km/H) When "D" Or "R" Selected354
Vehicle Judders When "D" Or "R" Is Selected With Engine At Idle354
Acceleration Poor But Engine Racing When Hot355
Engine Stalls During Braking355
Kick Down Delayed Or Insufficient355
Delayed Response When Sport Selected From "D" While Vehicle Moving355
Delayed Response When Manual Mode Is Selected From "D" Sport With Vehicle Moving356
Vehicle Moves Forward Or Backward When Starting In "P" Or "N"356
Hydraulic Cavitation Noises From Gearbox356
Fluid Leaks From Gearbox357
Fluid Condition Check358
Park/Neutral Switch Check358
Kick-Down Check358
Delayed Shift Response358
Lever - Gear Change361
Cable - Gear Change363
Led Module - Gear Selection365
Switch - Prnd365
Park/Neutral And Reverse Light Switch366
Solenoid - Shift Lock366
Differential Speed Sensor367
Switch - Steering Wheel Remote368
Microswitch - Manual/Sport And +/- Switch368
Gearbox Interface Unit (Giu)369
Gearbox & Converter - Stepspeed (Em-Cvt) - Remove For Access & Refit369
Secondary Cover Seals372
Gasket - Fluid Pan373
Filter - Gearbox Fluid374
Cooler - Gearbox Fluid374
Hose/Pipe - Feed - Intermediate To Fluid Cooler375
Hose/Pipe - Return - Intermediate To Fluid Cooler376
Hose-Pipe - Intermediate - Feed377
Hose/Pipe - Intermediate - Return378
Hose/Pipe - Feed - Intermediate To Gearbox378
Hose/Pipe - Return - Intermediate To Gearbox379
Primary Bearing380
Road Speed Transducer382
Drive Shafts383
Drive Shaft Components385
Drive Shaft Operation386
Shaft With Both Joints387
Drive Shaft Outer Gaiter389
Drive Shaft Outer Joint390
Drive Shaft Inner Gaiter391
Dynamic Damper - Drive Shaft - Rh391
Oil Seal - Differential Housing - Lh - Manual Transmission Models392
Oil Seal - Differential Housing - Lh - Stepspeed (Em-Cvt) Gearbox Models393
Oil Seal - Differential Housing - Rh - Manual Transmission Models393
Steering395
Epas System Component Location397
Steering Wheel398
Steering Rack399
Steering Column (With Electrical Pas)400
Epas System Control Diagram401
Steering Description402
Steering Column402
Epas System402
Steering Motor402
Epas Ecu403
Epas Ecu Connector C0316 Pin Details404
Epas Ecu Connector C0317 Pin Details405
Steering Operation406
Epas Mechanical Operation406
Epas Electrical Operation407
Front Wheel Alignment409
Rear Wheel Alignment410
Rack & Pinion Assembly411
Steering Rack Gaiter413
Steering Column Nacelle417
Ignition Switch And Steering Lock417
Track-Rod End422
Front Suspension Components428
Anti-Roll Bar435
Link - Anti-Roll Bar436
Ball Joint - Upper436
Ball Joint - Lower438
Bearings - Hub439
Damper - Lh441
Suspension Arm Assembly - Upper442
Suspension Arm - Lower Front445
Bearings - Suspension Arm Assembly - Upper448
Bush - Suspension Lower Arm - Front449
Sub Frame - Front Suspension - Manual Transmission Models451
Mounting - Front Sub Frame - Front458
Mounting - Front Sub Frame - Rear458
Rear Suspension Components464
Damper And Spring Unit468
Upper Suspension Arm469
Track Control Arm And Lower Link469
Trailing Arm469
Rear Subframe469
Bearings - Hub - One Side472
Damper - Rh475
Anti-Roll Bar - Rear477
Lower Link - Rear479
Track Control Arm480
Bush - Trailing Arm482
Bush - Trailing Arm To Hub483
Bush - Arm Assembly - Upper484
Arm Assembly - Upper485
Sub Frame - Rear Suspension - Manual Transmission Models486
Rear Sub Frame - Lh - Front Mounting488
Rear Sub Frame - Lh - Rear Mounting490
Brakes491
Front Brake Caliper Components494
Rear Brake Caliper Components495
Abs Anti-Lock Braking System496
Handbrake Operation499
Front Brake Disc - Standard - Check Thickness And Run-Out501
Front Brake Disc - Sports - Check Thickness And Run-Out502
Rear Brake Disc - Check504
Brake System - Bleed - Standard505
Brake System - Bleed - Sports506
Handbrake - Adjust508
Brake Light Switch - Adjust509
Front Brake Disc - Standard511
Front Brake Disc - Sports512
Rear Brake Disc513
Fluid Level Switch514
Abs Hydraulic Modulator514
Brake Proportioning Valve515
Abs Sensor - Front Wheel516
Abs Sensor - Rear Wheel517
Pedal Box Assembly518
Brake Master Cylinder519
Handbrake Lever520
Handbrake Cables520
Handbrake Warning Switch523
Brake Light Switch524
Brake Pads - Front - Standard524
Brake Pads - Front - Sports525
Brake Pads - Rear526
Brake Servo527
Brake Caliper Housing - Front - Standard529
Brake Caliper Carrier - Front - Standard530
Brake Caliper Housing - Front - Sports531
Hose - Front - Primary - Lh532
Hose - Rear533
Component Location536
Restraint Systems Description537
Restraint Systems Operation538
Airbag And Pre-Tensioner, Manual Deployment539
Deployment Tool Smd 4082/1 Self Test Procedure539
Deployment Of Seat Belt Pre-Tensioner540
Deployment Of Driver Airbag Module541
Diagnostic Control Unit (Dcu)546
Driver Airbag Module547
Passenger Airbag Module548
Srs Harness549
Seat Belt550
Seat Belt Pre-Tensioner551
Electric Window Lift Components556
Electric Window Operation557
Door - Central Locking Components558
Door Central Locking - Operation559
Door - Align On Hinges560
Door Striker - Adjust560
Door Glass - Adjust561
Mirror - Exterior - Electric561
Glass562
Door Glass Regulator563
Outer Waist Seal563
Door And Header Seal564
Trim Casing564
Plastic Sheet565
Remote Door Handle566
Private Lock566
Outside Handle567
Bonnet - Adjust570
Bonnet Lock Plate - Adjust570
Boot Lid - Adjust571
Boot Lid Striker - Adjust571
Front Wheel Arch Liner572
Underbonnet Closing Panel572
Engine Compartment Access Panel573
Panel - Front Underbelly - Centre573
Bonnet Locking Platform - R/R Access574
Bonnet Release Cable574
Private Lock - Boot Lid577
Boot Lid Latch577
Front Bumper Armature578
Rear Bumper Armature578
Bumper Valance - Front579
Rear Bumper Valance580
Air Vent - Side582
Hood Assembly Components - Soft Top584
Hood Assembly Components - Hard Top585
Hood Seals And Door Glass - Adjust586
Cantrail Tensioning Cables - Adjust590
Hardtop - Adjust590
Hard Top591
Hood Assembly592
Hood Outer Cover593
Hood Frame598
Backlight599
Hood Catch601
Cantrail Tensioning Cable602
Backlight Zip603
Hard Top Headlining603
Hard Top Catch - Rear604
Hard Top Catch - Front604
Hard Top Seal605
Cantrail Seal606
"B" Post Seal606
Hard Top - Backlight607
Sun Visor608
Interior Mirror608
Luggage Compartment Trim609
"A" Post Trim609
Rear Bulkhead Finisher610
Header Trim610
Front Console611
Rear Console612
Gear Lever Gaiter613
Centre Console Panel614
Console Closing Panel616
Fascia Panel616
Glovebox617
Glovebox Latch618
Hoodwell Trim618
Head Restraint619
Seat620
Seat Squab Assembly621
Cover - One Piece - Front Seat Cushion623
Cover - Squab - Front Seat624
Windscreen626
Heating & Ventilation630
Heating & Ventilation Operation632
Controls - Heater634
Cable - Water Valve Control636
Cable - Air Distribution Control638
Heater Valve639
Heater Fan Switch640
Face Level Vent - Rh641
Face Level Vent - Lh642
Face Level Vent - Centre642
Air Intake Panel643
Heater643
Heater - With Air Conditioning647
Recirculation Servo Motor650
Heater Resistor652
Heater Matrix653
Air Conditioning654
Air Conditioning Components656
Schematic Layout Of Air Conditioning System657
Air Conditioning System Operation658
Air Conditioning Control System659
Condenser Cooling Fans660
Blower Control660
Heater Distribution And Blend Unit Control660
Ecm Control660
Air Conditioning Remedial Actions662
Air Conditioning Service Precautions663
Refrigerant Recovery, Recycling And Recharging664
Compressor Remove668
Fitting A New Compressor668
Fitting An Existing Compressor669
Condenser Remove669
Condenser Refit670
Receiver Drier Remove670
Switch - Trinary Remove671
Switch - Trinary Refit671
Thermostatic Expansion Valve Remove671
Control Switch672
Thermostatic Expansion Valve Refit672
Evaporator673
Windscreen Wiper Components677
Washer Components678
Windscreen Washer And Wiper Operation679
Washer Reservoir681
Reservoir And Pump681
Washer Jet682
Washer Pump682
Wiper Arm683
Wiper Motor And Linkage683
Wiper Motor684
Drive Belt - Alternator - Check & Adjust Tension - Non Air Conditioning687
Alternator Drive Belt - With Air Conditioning - Adjust688
Headlamps - Pair - Align Beam689
Alternator - Non Air Conditioning691
Alternator - With Air Conditioning692
Drive Belt - Alternator - Non Air Conditioning693
Alternator Drive Belt - With Air Conditioning694
Electric Window Switch696
Central Door Locking Motor And Latch696
Control Unit - One Touch Window698
Horn699
Headlamp Assembly699
Lamp Assembly - Fog/Driving700
Lamp Assembly - Centre High Mounted Stop (Chmsl)701
Tail Lamp Assembly702
Glovebox Lamp702
Boot Lid Lamp703
Bonnet Lamp703
Front Speaker704
Aerial704
Speaker - Tweeter705
Subwoofer Assembly705
Auto Changer - Kenwood Audio Systems706
Head Unit - Kenwood Audio Systems707
Head Unit And Auto Changer - Kenwood Audio Systems - Renew708
Anti-Theft Alarm Ecu710
Volumetric Sensor711
Starter Motor712
Starter Motor - Stepspeed (Em-Cvt) Models713
Starter Solenoid714
Panel Dimmer Resistor714
Hazard Warning Lamp Switch715
Steering Column Switch Pack716
Switch - Exterior Mirror717
Instruments719
Instrument Pack Components - Rear View721
Instrument Pack Components - Exploded View722
Clock727
Instrument Cowl728
Instrument Pack Window729
Instrument Illumination Housing729
Printed Circuit Board730
Oil Temperature Gauge730
Coolant Temperature Gaue731
Engine Coolant Temperature Gauge Sensor731
Engine Oil Temperature Gauge Sensor732
Fuel Gauge732
Speedometer733
Tachometer733