Peugeot 306 - Service Manual - Manual de Taller - Manuel de Reparation - Manuale di Officina - Reparaturanleitung View larger

Peugeot 306 - Service Manual - Manual de Taller - Manuel de Reparation - Manuale di Officina - Reparaturanleitung

Multilanguage (Francais, Deutsch, English, Italiano, Nederlands, Suomi, Español, Svenska, Dansk, Portugês, Polish, Hungarian, Czech, Turkish and Russian) Service Manual, to vehicles Peugeot 306 models N3 and N5.

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PEUGEOT 306 - MANUAL DE TALLER - SERVICE MANUAL - MANUEL REPARATION


- Multilanguage (Francais, Deutsch, English, Italiano, Nederlands, Suomi, Español, Svenska, Dansk, Portugês, ???????a, Polish, Hungarian, Czech, Turkish and Russian) Service Manual, to vehicles Peugeot 306 models N3 and N5


CONTENTS:
.
.
VEHICLE / GENERAL
DATA - IDENTIFICATION
General Repair Time Schedule Presentation
Model Code 306
Modification Body Colours
Modification Identification Plate Marking
Numbering Of The Repair Time Schedule Groups And Sub-Groups
Paint Repair Time Schedule Presentation
PRECAUTIONS TO BE TAKEN
Modifications 2000 1/2 Model Year Dam From 842181
OPERATING INSTRUCTIONS
Catalogue Of The Services Documentation - Info Flashes
Catalogue Of The Services Documentation
MODIFICATIONS
Modification Location Of Build Code (Dam)
Modification(S) To The Range 306
New Coolant

MECHANICAL / ENGINE / GENERAL
DATA - IDENTIFICATION
Engine Introduction Dw10 - Dw10td Engine
Identification Engine - Dw10td Engine
Identification Engines - Xu Injection
Identification, Data, Tightening Torque(S) (Tu) Engines ( Not Tu5j4) - Tu Engine
Identification, Data, Tightening Torque(S) Engine - Xud7 Engine - Xud9 Engine
Presentation Dw8 (Wjz) Engine - Dw8 Engine
CHECKS
Check : Oil Tightness Of The Engines And Gearboxes
DRAINING - FILLING - BLEEDING
Engine Capacities
Suction Draining Engine - Xu Injection - Tu/Tud Engine - Ew/Dw Engine
SPECIAL TOOLS USED FOR REPAIRS
Presentation Tooling Engine - Dw10td Engine

MECHANICAL / ENGINE / ENGINE ASSEMBLY
DATA - IDENTIFICATION
Presentation Dw8 (Wjz) Engine - Dw8 Engine
Tightening Torque(S) Engine (Not Tu5j4 ) - Tu Engine
FAULT(S) READING
Tightening Torques Xu Engines 8 Valves - Xu7jb Engine - Xu7jp Engine
Tightening Torques Xu Engines : 16 Valves - Xu10j4r Engine - Xu10j4rs Engine - Xu7jp4 Engine
REMOVAL-FITTING
Reassembly Engine (Cylinder Block) - Dw10td Engine
Removal - Refitting Power Unit - Diesel Xud
Removal - Refitting Power Unit - Dw10td Engine
Removal - Refitting Power Unit - Dw8 Engine
Removal - Refitting Power Unit - Xu Injection
OVERHAUL
Dismantling Engine (Not Tu5j4 ) - Tu Engine
Dismantling - Dismantling Engine - Xu Injection
STRIPPING/REFITTING
Dismantling - Dismantling Engine - Dw10td Engine
MODIFICATIONS
Modification Oil Sump Fixing - Tu Injection
New Coolant

MECHANICAL / ENGINE / ENGINE BLOCK
DATA - IDENTIFICATION
Data - Identification Aluminium Cylinder Block (Not Tu5j4 ) - Tu Engine
Data - Identification Cast Cylinder Block ( Not Tu5j4 ) - Tu Engine
Data - Identification Cylinder Block - Xu Injection
Identification - Data Cylinder Block - Dw10td Engine
CHECKS
Check Liner Protrusion (Aluminium Cylinder Block) - Tu Engine
REMOVAL-FITTING
Reassembly Engine (Aluminium Cylinder Block Not Tu5j4 ) - Tu Engine
OVERHAUL
Reassembly 16 Valve Engine(S) - (Timing) - Xu10j4r Engine - Xu10j4rs Engine - Xu7jp4 Engine
Reassembly 8 Valve Engine(S) (Timing) - Xu7jb Engine - Xu7jp Engine
Reassembly Cylinder Head -Engine - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Reassembly Engine (Cylinder Block) - Xu Injection
Reassembly Engine (Timing - High Pressure Fuel Pump) - Dw10td Engine
Reassembly - Assembly Engines - Xu Injection
Stripping/Refitting
Reassembly Engine (Engine Dress) - Tu Engine

MECHANICAL / ENGINE / ENGINE BLOCK
MODIFICATIONS
Modification Dw8 Engine - Dw8 Engine

MECHANICAL / ENGINE / CRANKSHAFT
DATA - IDENTIFICATION
Data Connecting Rods - Dw10td Engine
Data Crankshaft And Connecting Rods - Cast-Iron Cylinder Block
Data Crankshaft - Dw10td Engine
Data Identification Connecting Rods - Tu Injection
Data Pistons Piston Rings - Dw10td Engine
Data - Identification Connecting Rods - Xu Injection
Data - Identification Crankshaft - Xu Injection
Data - Identification Half Shells - Xu Injection
Data - Identification Liners - Xu7 Injection
Data - Identification Pistons - Piston Rings - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine - Tu5jp Engine
Data - Identification Pistons - Piston Rings - Xu Injection
Identification Data (Aluminium Cylinder Block ) - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine - Tu5jp Engine
CHECKS
Check Liner Protrusion - Xu7 Injection
ADJUSTMENTS CHECK
Check Crankshaft Pulley - Xu10. Injection - Xu7 Injection
ADJUSTMENTS

Adjustment - Voltage Ancillary Drive Belt - Tu Injection
REMOVAL-FITTING
Removal - Refitting Ancillary Drive Belt (Power Steering - Air Conditioning - Xu10j2cte Engine) - Diesel Xud
Removal - Refitting Ancillary Drive Belt - Dw8 Engine
Removal - Refitting Ancillary Drive Belt - Xu Injection
Removal - Refitting Ancillary Drive Belt - Xud7 Engine - Xud9 Engine - Xud9te Engine
OVERHAUL
Assembly Connecting Rods - Pistons - Tu Engine
Assembly Connecting Rods - Pistons - Xu Injection
Matching Main Bearing Shells (Engine With Identification) - Tu Engine
Matching Of Bearing Half Shells, Engine Not Marked - Tu Engine
MODIFICATIONS
New Drift For Fitting Crankshaft Nose Seals - Tu Engine

MECHANICAL / ENGINE / CYLINDER HEAD
DATA - IDENTIFICATION

Data Rockers - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine - Tu5jp Engine
Data Thrust Washer - Valve Spring - Dw10td Engine
Data Valve Guides - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Data Valve Seats - Dw10td Engine
Data Valve Seats - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Data Valve Springs - Dw10td Engine
Data Valves - Dw10td Engine
Data Valves - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Data - Identification Cylinder Head Bolt - Xu Injection
Data - Identification Cylinder Head Gasket - Xu Injection
Data - Identification Cylinder Heads - Xu Injection
Data - Identification Valve Guides - Xu Injection
Data - Identification Valve Seats - Xu Injection
Data - Identification Valve Springs - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Data - Identification Valve Springs - Xu Injection
Data - Identification Valves - Xu Injection
Identification - Data Cylinder Head Gasket - Dw10td Engine
Identification - Data Cylinder Head Gasket - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Identification - Data - Tightening Torques Cylinder Head - Tu Engine
ADJUSTMENTS CHECK
Checks And Adjustments Valve Clearances - Diesel Xud - Dw8 Engine
ADJUSTMENTS
Adjustment Valve Clearances (8 Valve Engine(S)) - Xu7jb Engine - Xu7jp Engine
REMOVAL-FITTING
Reassembly Engine (Cylinder Head) - Dw10td Engine
Removal - Refitting Cylinder Head (On The Vehicle) - Tu Engine
Removal - Refitting Cylinder Head - Dw10td Engine

Removal - Refitting Cylinder Head - Dw8 Engine
Removal - Refitting Cylinder Head - Xu Injection
Removal - Refitting Cylinder Head - Xu7jp Engine
Removal - Refitting Cylinder Head - Xu7jp4 Engine - Xu10j4r Engine
Removal - Refitting Cylinder Head - Xud7 Engine - Xud9 Engine
Removal - Refitting Cylinder Head - Xud9te Engine
OVERHAUL
Dismantling - Assembly 16 Valve Cylinder Head - Xu10j4r Engine - Xu10j4rs Engine - Xu7jp4 Engine
Dismantling - Assembly 8 Valve Cylinder Head - Xu7jb Engine - Xu7jp Engine
Overhaul Cylinder Head - Dw10td Engine
Overhaul Cylinder Head - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Reassembly Cylinder Head -Engine - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Refitting Cylinder Head - Xu Injection


MECHANICAL / ENGINE / TIMING
DATA - IDENTIFICATION
Data Camshafts - Dw10td Engine
Data - Identification Camshafts - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Data - Identification Camshafts - Xu Injection
REMOVAL-FITTING
Removal - Refitting Ancillary Drive Belt - Dw8 Engine
Removal - Refitting Camshaft - Diesel Xud
Removal - Refitting Camshaft - Dw10td Engine
Removal - Refitting Camshaft - Dw8 Engine - Dw8b Engine
Removal - Refitting Camshaft - Xu Injection
Removal - Refitting Timing Belt - Dw10td Engine
Removal - Refitting Timing Belt - Dw8 Engine
Removal - Refitting Timing Belt - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine - Tu1m+ Engine
Removal - Refitting Timing Belt - Xu7jp4 Engine - Xu10j4r Engine
Removal - Refitting Timing Belt - Xud7 Engine - Xud9 Engine
OVERHAUL
Reassembly 16 Valve Engine(S) - (Timing) - Xu10j4r Engine - Xu10j4rs Engine - Xu7jp4 Engine
Reassembly 8 Valve Engine(S) (Timing) - Xu7jb Engine - Xu7jp Engine
Reassembly - Assembly Engines - Xu Injection
MODIFICATIONS
Modification Engine Timing - Xu10j4rs Engine
Modification Removal-Refitting Of The Timing Belt - Xu10j4rs Engine
Modification To The Fitting Of The Camshaft Pulley (New Tightening Torques) - Tu/Tud Engine Dam From 854781

MECHANICAL / ENGINE / LUBRICATION
DATA - IDENTIFICATION
Data - Tightening Torques - Lubrication - Tu/Tud Engine - Xu/Xud Engine - Ew/Dw Engine
Data - Lubrication - Dw8 Engine - Xud7 Engine - Xud9 Engine - Xud9te Engine
Identification - Engine Oil Filter Cartridge - Xu/Xud Engine - Tu/Tud Engine - Ew/Dw Engine
CHECKS
Check Oil Pressure - Tu5jp Engine - Tu3-2 Engine - Tu3jp Engine
Check Oil Pressure - Xud7 Engine - Xud9 Engine - Dw8 Engine
REMOVAL-FITTING
Removal - Refitting Oil Filter - Tu5jp Engine - Tu3jp Engine
DRAINING - FILLING - BLEEDING
Engine Capacities
Suction Draining Engine - Xu Injection - Tu/Tud Engine - Ew/Dw Engine
PRECAUTIONS TO BE TAKEN
Recommendations Lubricants

MECHANICAL / ENGINE / COOLING SYSTEM
REMOVAL-FITTING
Removal - Refitting Coolant Pump - Xud7 Engine - Xud9 Engine - Dw8 Engine - Dw10td Engine
Removal - Refitting Radiator Outlet Click-On Connector - Xu Injection
Removal - Refitting Radiator - Diesel Xud - Dw8 Engine
Removal - Refitting Radiator - Xu Injection
DRAINING - FILLING - BLEEDING
Draining - Filling - Bleeding Cooling System - Dw10td Engine
Draining - Filling - Bleeding Cooling System - Dw8 Engine - Xu10j4r Engine - Xu7jp4 Engine - Xud9te Engine - Xud9 Engine - Xud7 Engine - Xu10j4rs Engine - Xud9sd Engine - Xud9bsd Engine
Draining - Filling - Bleeding Cooling System - Xu Injection - Tu Injection
Draining - Filling - Bleeding Cooling System
MODIFICATIONS
Improvement In Engine Cooling Dw8 (Temperate Climates) - Dw8 Engine - Without Air Conditioning
New Coolant

MECHANICAL / ENGINE / SUPPLY
DATA - IDENTIFICATION
Data Injector Carrier Seals - Dw10td Engine
Data Injector Fixing Fork Support Pin - Dw10td Engine
ADJUSTMENTS CHECK
Checks And Adjustments Carburettor (Solex 32-34 Z2) - Tu Engine
Checks And Adjustments Injection Pump (Bosch) - Diesel Xud
Checks And Adjustments Injection Pump - Dw8 Engine - Xu/Xud Engine
Checks And Adjustments Load Lever Switch (Engine(S) Xud9 With Front Air Exchanger)
Timing - Check Injection Pump (Bosch) - Diesel Xud
Timing - Check Injection Pump (Lucas) - Diesel Xud
ADJUSTMENTS
Adjustment Pressure Relief Valve - Xu7jp4 Engine
Cylinder Reference Sensor Air Gap Adjustment - Dw10td Engine
REMOVAL-FITTING
Removal - Refitting Diesel Filter Assembly - Dw10td Engine
Removal - Refitting Distributor Valve - Xu7jp4 Engine
Removal - Refitting Filling Valve - Xu7jp4 Engine
Removal - Refitting Fuel Filter - Dw10td Engine
Removal - Refitting Fuel Filter - Xu Injection
Removal - Refitting Fuel Gauge Sender Unit
Removal - Refitting Fuel High Pressure Regulator On Fuel High Pressure Pump - Dw10td Engine
Removal - Refitting Fuel Tank - Xu Injection - Tu Injection
Removal - Refitting High Pressure Fuel Injection Common Rail - Dw10td Engine
Removal - Refitting High Pressure Fuel Pump
Removal - Refitting Injection Pump (Bosch) - Diesel Xud
Removal - Refitting Injection Pump (Lucas) - Diesel Xud
Removal - Refitting Injection Pump (Lucas) - Dw8 Engine
Removal - Refitting Injector - Xu7jp4 Engine
Removal - Refitting Injectors - Diesel Xud
Removal - Refitting Injectors - Dw10td Engine
Removal - Refitting Injectors - Dw8 Engine
Removal - Refitting Lpg Reservoir - Xu7jp4 Engine
Removal - Refitting Pressure Relief Valve - Xu7jp4 Engine
Removal - Refitting Safety Valve - Xu7jp4 Engine
Removal - Refitting Solenoid Valve - Vaporiser-Pressure Relief Valve Filter - Xu7jp4 Engine
REPLACEMENT
Replacement Fuel Filter - Dw8 Engine
DRAINING - FILLING - BLEEDING
Bleeding Fuel Supply System - Dw10td Engine
Draining Fuel Tank
Draining Lpg Reservoir - Xu7jp4 Engine
OVERHAUL
Overhaul Injectors - Dw8 Engine - Xud7 Engine - Xud9 Engine - Xud9te Engine
CHECK AFTER OPERATION
Check After Operation (Lpg) - Xu7jp4 Engine
SPECIAL TOOLS USED FOR REPAIRS
Recommended Tools - Dw10td Engine
MODIFICATIONS
Modification Throttle Housing - Tu3jp Engine

MECHANICAL / ENGINE / EXHAUST
REMOVAL-FITTING
Removal - Refitting Exhaust Manifold

MECHANICAL / ENGINE / EMISSION CONTROL
DATA - IDENTIFICATION
Emission Control Euro 3 - Eobd
REMOVAL-FITTING
Removal - Refitting Egr Valve - Dw10td Engine

MECHANICAL / ENGINE / TURBO-CHARGING
REMOVAL-FITTING
Removal - Refitting Turbocharger - Diesel Xud
Removal - Refitting Turbocharger - Dw10td Engine

MECHANICAL / TRANSMISSION / CLUTCH
DATA - IDENTIFICATION
Presentation Tooling Clutch - Dw10td Engine
REMOVAL-FITTING
Removal - Refitting Clutch Fork Shaft - Be3/6 Gearbox
Removal - Refitting Clutch Release Bearing Guide - Be3/6 Gearbox
Removal - Refitting Clutch - Ma Gearbox
REPLACEMENT
Removal/Refitting Of The Converter - Al4 Automatic Gearbox

MECHANICAL / TRANSMISSION / GEARBOX
PRINCIPLES OF OPERATION
Function : Oil Wear Counter (Al4) Autoadaptive Automatic Gearbox - Al4 Automatic Gearbox
DATA - IDENTIFICATION

Diagnosis Oil Leak - Al4 Automatic Gearbox
General (Automatic Gearbox) - Al4 Automatic Gearbox
Identification Automatic Gearbox - Al4 Automatic Gearbox
Identification Of Tightening Torques Gearbox - Ma Gearbox
Identification - Data - Tightening Torques Gearbox - Be3/6 Gearbox
Presentation Tooling Gearbox - Be3/6 Gearbox - Be3/5 Gearbox - Be3r Gearbox
CHECKS
Check : Oil Tightness Of The Engines And Gearboxes
Mechanical Action Function : Shift-Lock - Al4 Automatic Gearbox
Adjustments Check
Adjustment Input Shaft Bearings - Be3/6 Gearbox
Check - Adjustment Input Shaft Bearings - Be3 Gearbox
ADJUSTMENTS
Adjustment Ball Blade - Al4 Automatic Gearbox
Adjustment Multi-Function Switch - Al4 Automatic Gearbox
Gearbox Controls Adjustment - Al4 Automatic Gearbox
REMOVAL-FITTING
Assembly Gearbox Casing - Ma Gearbox
Assembly Gearbox - Ma Gearbox
Dismantling Gearbox - Ma Gearbox
Dismantling - Assembly Clutch Housing - Be3 Gearbox
Dismantling - Assembly Input Shaft - Be3 Gearbox
Dismantling - Assembly Input Shaft - Ma Gearbox
Dismantling - Assembly Output Shaft - Be3 Gearbox
Dismantling - Assembly Synchronisers - Ma Gearbox
Dismantling - Reassembling Output Shaft - Ma Gearbox
Dismantling-Assembly Differential - Ma Gearbox

Dismantling-Assembly Gearbox Casing - Ma Gearbox
Dismantling-Reassembling Gearbox Controls - Ma Gearbox
Dismantling/Assembly Differential Box - Be3r Gearbox
Refitting Input, Output Shafts And Differential - Ma Gearbox
Removal Input And Output Shafts - Be3/5 Gearbox
Removal Input, Output Shafts And Differential - Ma Gearbox
Removal - Refitting Automatic Gearbox Fluid Temperature Sensor Autoadaptive (Al4) - Al4 Automatic Gearbox
Removal - Refitting Automatic Gearbox Input Speed Sensor (Al4) - Al4 Automatic Gearbox
Removal - Refitting Automatic Gearbox Oil Pressure Sensor - Al4 Automatic Gearbox
Removal - Refitting Differential Box - Be3 Gearbox
Removal - Refitting Differential Box - Be3/6 Gearbox
Removal - Refitting Fork - Gear Selection Shaft - Input And Output Shafts - Be3/6 Gearbox
Removal - Refitting Gearbox Casing - Be3 Gearbox
Removal - Refitting Gearbox Casing - Be3/6 Gearbox
Removal - Refitting Gearbox Controls - Al4 Automatic Gearbox
Removal - Refitting Gearbox Output Speed Sensor - Al4 Automatic Gearbox
Removal - Refitting Gearbox - Al4 Automatic Gearbox
Removal - Refitting Heat Exchanger Flow Control Solenoid - Al4 Automatic Gearbox
Removal - Refitting Heat Exchanger - Al4 Automatic Gearbox
Removal - Refitting Heat Exchanger - Al4 Automatic Gearbox
Removal - Refitting Hydraulic Block Harnesses - Al4 Automatic Gearbox
Removal - Refitting Hydraulic Block - Solenoid Valves - Al4 Automatic Gearbox
Removal - Refitting Input And Output Shafts - Be3r Gearbox
Removal - Refitting Multi-Function Switch - Al4 Automatic Gearbox
Removal - Refitting Power Unit - Diesel Xud
Removal - Refitting Power Unit - Dw8 Engine
Removal - Refitting Power Unit - Xu Injection
Removal - Refitting Torque 5th - 6th - Be3/6 Gearbox
Removal - Refitting Vehicle Speed Sensor Autoadaptive Automatic Gearbox (Al4) - Al4 Automatic Gearbox
REPLACEMENT
Dismantling / Assembly Gearbox - Be3 Gearbox
Removal - Refitting Drive Shaft Seals - Al4 Automatic Gearbox
Removal - Refitting Gear Change Shaft Seal - Al4 Automatic Gearbox
DRAINING - FILLING - BLEEDING
Draining - Filling - Level Gearbox - Ma Gearbox
Draining/Refilling/Check Of Level Oil - Al4 Automatic Gearbox
Gearbox Capacity
OVERHAUL
Removal Gearbox Casing - Ma Gearbox
PRECAUTIONS TO BE TAKEN
Cleaning And Refitting Conditions Gearbox - Be3r Gearbox
Cleaning And Refitting Conditions Gearbox - Ma Gearbox
REPAIR PROCEDURE
General Function Shift-Lock (Al4) - Al4 Automatic Gearbox
Repair Procedure Mb3/4hp20 Automatic Gearbox/(Al4) Autoadaptive Automatic Gearbox - Al4 Automatic Gearbox
Special Tools Used For Repairs
Presentation Tooling Drive Shafts - Al4 Automatic Gearbox
Stripping/Refitting
Dismantling / Assembly Gear Selection Shaft - Be3/6 Gearbox
Dismantling / Assembly - Input Shaft - Output Shaft - Be3/6 Gearbox
Modifications
Modification Oil Capacity - Al4 Automatic Gearbox

MECHANICAL / TRANSMISSION / TRANSFER BOX
REMOVAL-FITTING
Dismantling / Assembly Differential Box - Be3/6 Gearbox

MECHANICAL / TRANSMISSION / DRIVE SHAFTS
PRINCIPLES OF OPERATION
Presentation Drive Shafts
REMOVAL-FITTING
Removal - Refitting Drive Shafts - Al4 Automatic Gearbox
Removal - Refitting Drive Shafts - Al4 Automatic Gearbox
REPLACEMENT
Replacement Drive Shaft Bearing All Types

Replacement Drive Shaft Gaiters Type Glaenzer Spicer (Gkn)
Replacement Drive Shaft Gaiters Type Psa
Replacement Gaiter Bearing At Gearbox End (Mb3 Drive Shaft)
REPAIR PROCEDURE
Use Ligarex Clips

MECHANICAL / TRANSMISSION / WHEELS
MODIFICATIONS

Modification Wheel Bolts Dam From 857681 Dam From 857682

MECHANICAL / SUSPENSION / GENERAL
ADJUSTMENTS CHECK
Setting The Reference Height - Adjustment Front Suspension
Setting The Reference Height - Adjustment Front Suspension
MODIFICATIONS
Modification Suspension Setting - 5 Estate Dam From 888482

MECHANICAL / SUSPENSION / FRONT SHOCK ABSORBER
REMOVAL-FITTING
Removal - Refitting Front Suspension Strut

MECHANICAL / SUSPENSION / REAR SUSPENSION
REMOVAL-FITTING
Removal - Refitting Anti-Roll Bar (Rear)
Removal - Refitting Torsion Bar (Rear)

MECHANICAL / SUSPENSION / REAR DAMPER
REMOVAL-FITTING
Removal - Refitting Rear Damper

MECHANICAL / FRONT AXLE / FRONT PIVOT
REMOVAL-FITTING
Overhaul Front Hub
Removal - Refitting Front Lower Arm
Removal - Refitting Front Pivot

MECHANICAL / REAR AXLE / GENERAL
REMOVAL-FITTING
Removal - Refitting Arm Pivot (Rear)
Removal - Refitting Rear Cross Tube Needle Roller Bearing (Inner End)
Removal - Refitting Rear Cross Tube Needle Roller Bearing (Outer End)
Removal - Refitting Rear Suspension
Removal - Refitting Self Steering Mount

MECHANICAL / REAR AXLE / REAR HUB
REMOVAL-FITTING
Removal - Refitting Rear Cross Tube Needle Roller Bearing (Inner End)
Removal - Refitting Rear Cross Tube Needle Roller Bearing (Outer End)
Removal - Refitting Rear Hubs
Removal - Refitting Rear Suspension Arm (Fitting The Bearing Without Clearance)
Removal - Refitting Rear Suspension Arm
OVERHAUL
Replacement Rear Bearing (Drum)


MECHANICAL / STEERING / STEERING WHEEL
REMOVAL-FITTING
Removal - Refitting Driver's Airbag System
PRECAUTIONS TO BE TAKEN
Discarding Centralised System For Airbag(S) And Seatbelts

MECHANICAL / POWER STEERING / GENERAL
DATA - IDENTIFICATION
Recommendations Power Steering Fluid (Service)

MECHANICAL / BRAKES / GENERAL
DATA - IDENTIFICATION
Identification - Data - Tightening Torques Brakes

MECHANICAL / BRAKES / FRONT DISC BRAKES
REMOVAL-FITTING
Removal - Refitting Front Brake Calipers (Assembly Ate Teves)
Removal - Refitting Front Brake Calipers (Bendix Sv Z0 Caliper) (Lucas C54/C57 Caliper)
Removal - Refitting Front Brake Pads ( Lucas C54/C57 Caliper - (Bendix Svz0 Caliper)
Removal - Refitting Front Brake Pads (Assembly Ate Teves)

Removal - Refitting Front Brake Pads (Bosch Caliper Series 5)
Removal - Refitting Front Brake Pads -Bendix Caliper
MODIFICATIONS
Modification Front Brake Pads

MECHANICAL / BRAKES / REAR DISC BRAKES
REMOVAL-FITTING
Removal - Refitting Rear Brake Calipers (Bendix ) Caliper
Removal - Refitting Rear Brake Disc
Removal - Refitting Rear Brake Pads (Assembly Bendix )

MECHANICAL / BRAKES / REAR DRUM BRAKES
REMOVAL-FITTING
Removal - Refitting Rear Brake Shoes (Assembly Bendix)
Removal - Refitting Rear Brake Shoes (Assembly Girling)
Removal - Refitting Rear Brake Shoes (Assembly Lucas)

MECHANICAL / BRAKES / BRAKE COMPENSATOR
ADJUSTMENTS CHECK
Check - Adjustment
ADJUSTMENTS
Checks And Adjustments Rear Brake Pressure (Rear Load Adjusted Compensator)
PRECAUTIONS TO BE TAKEN
Precautions To Be Taken Replacement Of The Compensator

MECHANICAL / ABS/TRACTION CONTROL /
DRAINING - FILLING - BLEEDING
Capacity Brake System

BODYWORK / GENERAL
DATA - IDENTIFICATION
Recommended Products Mechanical

BODYWORK / FRONT SECTION / FRONT BUMPER
REMOVAL-FITTING
Fitting Headlamp Wash (On The New Bumper)
Removal - Refitting Front Bumper - Estate
Removal - Refitting Front Bumper
Removal - Refitting Front Panel - Estate
REPLACEMENT
Replacement Bumper Grille

BODYWORK / FRONT SECTION / FRONT PANEL
REMOVAL-FITTING
Removal - Refitting Front Panel Assembly
REPLACEMENT
Replacement Front Lower Cross Member

BODYWORK / FRONT SECTION / FRONT WING
REPLACEMENT
Discontinuation Of The Heater Water Drain Tube When Replacing The Body Or A Front Wing Inner Panel - Left Hand Drive - Air Conditioning

BODYWORK / FRONT SECTION / BONNET
REMOVAL-FITTING
Removal - Refitting Bonnet Lock
REPLACEMENT
Replacement Bonnet Opening Control Assembly

BODYWORK / FRONT SECTION / WINDSCREEN
DATA - IDENTIFICATION
Identification Bonding Kit Glass
Identification Tools For Glass

BODYWORK / FRONT SECTION / BULKHEAD CROSSMEMBER
REMOVAL-FITTING
Removal - Refitting Pedal Mounting Assembly

BODYWORK / FRONT SECTION / FRONT SUB-FRAME
MODIFICATIONS
Modification : Sub-Frame Dam From 819081 Dam From 819082

BODYWORK / FRONT SECTION / FRONT CHASSIS LEG
REMOVAL-FITTING
Modification Front Chassis Leg Rear Cut (From 05/2001)
REPLACEMENT
Replacement Front Chassis Leg (Front Part) Assembly-Part Chassis Leg Flange

BODYWORK / REAR SECTION / GENERAL
DATA - IDENTIFICATION
Identification Fits And Clearances (Estate) - Estate

BODYWORK / REAR SECTION / REAR BUMPER
REMOVAL-FITTING
Removal - Refitting Rear Bumper


BODYWORK / REAR SECTION / REAR FLOOR
REPLACEMENT
Replacement Tail Panel Assembly - Part Tail Panel Inner Panel - Towing Eye - Estate
Replacement Tailgate Lower Section Outer Panel - Estate

BODYWORK / REAR SECTION / REAR WING
REPLACEMENT
Replacement C Post Assembly Inner Panel - Quarter Panel Lower Stiffener - Rear Wing Closing Panel - Estate
Replacement Part Inner Wing Closing Panel - Estate
Replacement Part Rear Outer Wheel Arch - Cabriolet
Replacement Part Rear Wing Assembly - 3 Door Saloon
Replacement Part Rear Wing Assembly - 4 Door Saloon
Replacement Part Rear Wing Assembly - Estate
Replacement Part Rear Wing Assembly
Replacement Part Rear Wing Inner Panel Assembly - Rear Structure - 3 Door Saloon
Replacement Part Rear Wing Inner Panel Assembly - Estate
Replacement Rear Wing Inner Belt Link With Hood Compartment Rear Outer Bulkhead - Cabriolet
Replacement "D" Post Inner Panel - 3 Door Saloon

BODYWORK / REAR SECTION / BOOT LID
REMOVAL-FITTING
Removal - Refitting Boot Lid - 4 Door Saloon

BODYWORK / REAR SECTION / TAILGATE
ADJUSTMENTS
Adjustment Tailgate
REMOVAL-FITTING
Removal - Refitting Boot - Estate
REPLACEMENT
Replacement Part "D" Post Inner Panel Assembly
Replacement Rear Screen - Cabriolet

BODYWORK / REAR SECTION / REAR SCREEN
DATA - IDENTIFICATION
Identification Bonding Kit Glass
Identification Tools For Glass
REMOVAL-FITTING
Removal - Refitting Rear Screen Demister - Cabriolet
Removal - Refitting Rear Screen Seal
Removal - Refitting Rear Screen (3 Door Saloon - 5 Door Saloon) - 3 Door Saloon - 5 Door Saloon
Removal - Refitting Rear Screen (4 Door Saloon) - 4 Door Saloon
Removal - Refitting Rear Screen - Estate

BODYWORK / REAR SECTION / REAR QUARTER
REMOVAL-FITTING
Removal - Refitting Quarter Light - Estate
Removal - Refitting Rear Window And Electric Window Lift Assembly - Cabriolet

BODYWORK / SIDE STRUCTURE / FRONT PILLAR
REPLACEMENT
Replacement Front Pillar Assembly, Windscreen Header Rail Assembly - Cabriolet
Replacement Passenger Compartment Side Front Stiffener - Body Side Front Part Assembly - 3 Door Saloon

BODYWORK / SIDE STRUCTURE / UNDERSTRUCTURE
REPLACEMENT
Replacement Outer Sill - Cabriolet
Replacement Outer Sill

BODYWORK / SIDE STRUCTURE / CENTRE PILLAR
REPLACEMENT
Replacement Centre Pillar - Rear Pillar Inner Panel And Outer Bulkhead With Hood Fixing Bracket Stiffener - Cabriolet
Replacement Part Centre Stiffener - Part Centre Pillar Stiffener - Estate
Replacement Part Centre Stiffener-Part "B" Post Inner Panel

BODYWORK / SIDE STRUCTURE / SIDE PANEL
REPLACEMENT
Replacement Door Panel

BODYWORK / SIDE STRUCTURE / SIDE WINDOW
ADJUSTMENTS
Adjustment Windows - Cabriolet

BODYWORK / SIDE STRUCTURE / HINGED FRONT DOOR CONTROLS

REMOVAL-FITTING
Removal - Refitting Door Opening Mechanism

BODYWORK / SIDE STRUCTURE / HINGED FRONT DOOR CONTROLS
REPLACEMENT
Replacement Door Lock

BODYWORK / SIDE STRUCTURE / REAR-VIEW MIRROR
REMOVAL-FITTING
Removal - Refitting Exterior Mirror
REPLACEMENT
Replacement Mirror Glass

BODYWORK / SIDE STRUCTURE / FRONT DOOR GLASS
DATA - IDENTIFICATION
Identification Bonding Kit Glass
Identification Tools For Glass
REMOVAL-FITTING
Removal - Refitting Door Fixed Glass - Cabriolet
Removal - Refitting Front Door Glass
Removal - Refitting Front Door Glass
Removal - Refitting Glass Wipe Seal
Removal - Refitting Glass - Electric Window (Door) - Cabriolet

BODYWORK / SIDE STRUCTURE / DOOR PANEL TRIM
REMOVAL-FITTING
Removal - Refitting Door Trim Pad - Estate

BODYWORK / SIDE STRUCTURE / HINGED REAR DOORS
FITTING
Fitting Door When Replacing A Body Shell (Front Door)
Fitting Door When Replacing A Body Shell (Rear Door)
REMOVAL-FITTING
Removal - Refitting Rear Door Fixed Glass

BODYWORK / ROOF / GENERAL
REPLACEMENT
Replacement Roof Assembly - 3 Door Saloon
Replacement Roof Assembly
Replacement Roof - Estate

BODYWORK / ROOF / ROOF
REMOVAL-FITTING
Removal - Refitting Longitudinal Roof Bars - Estate

BODYWORK / ROOF / ROOF BOW
REPLACEMENT
Replacement Roof Bow Cantrail - Part Rear Wing Inner Panel Assembly - Front Structure - 'C' Post Stiffener Assembly - 3 Door Saloon
Replacement Roof Bow Cantrail - Part Centre Stiffener - Centre Pillar Stiffener - Seat Belt Stiffener - Centre Pillar Inner Panel
Replacement Roof Bow Cantrail - Part Centre Stiffener - Seat Belt Stiffener - Centre Pillar Inner Panel
Replacement Roof Bow Cantrail, Rear Wing Inner Panel Assembly, 'C' Post Stiffener Assembly - 3 Door Saloon

BODYWORK / BODY / GENERAL

DATA - IDENTIFICATION
Identification Anti-Chip Protection - 5 Door Saloon
Identification Anti-Chip Protection - Cabriolet
Identification Injection Of Foam Into Hollow Areas - 5 Estate
Identification Sound Deadening Pads - Cabriolet
Identification Structural Elements - 3 Door Saloon
Identification Structural Elements - Cabriolet
REPLACEMENT
Discontinuation Of The Heater Water Drain Tube When Replacing The Body Or A Front Wing Inner Panel - Left Hand Drive - Air Conditioning


EQUIPMENT / GENERAL
DATA - IDENTIFICATION
Foreword Structure
Identification Specific Repair Parts - Estate
Identification Specific Repair Parts
Identification Structural Components - 4 Door Saloon
Identification Structural Components - Estate
Identification Symbols For Resistance Welding Equipment
Identification Symbols Used In The Body Methods

EQUIPMENT / SMALL BODY FITTINGS / WINDSCREEN WIPERS
REMOVAL-FITTING
Removal - Refitting Glass - Window Regulator Mechanism - Cabriolet
Removal - Refitting Rain Sensor
Removal - Refitting Screen Wiper Mechanism Rear - Estate
Removal - Refitting Screen Wiper Mechanism
Removal - Refitting Window Regulator Mechanism

EQUIPMENT / SMALL BODY FITTINGS / REAR WIPER
REMOVAL-FITTING
Removal - Refitting Rear Screen Wiper Motor

EQUIPMENT / LIGHTING / FRONT LIGHTS
REPLACEMENT
Replacement Headlamps

EQUIPMENT / LIGHTING / TAIL LAMPS
REMOVAL-FITTING
Removal - Refitting Rear Fog Lamp

EQUIPMENT / LIGHTING / FOG LAMPS
REMOVAL-FITTING
Removal - Refitting Long-Range Headlamps

EQUIPMENT / LIGHTING / STOP LAMPS
REMOVAL-FITTING
Removal - Refitting Additional Stop Lamps

EQUIPMENT / FASCIA / FASCIA
REMOVAL-FITTING
Removal - Refitting Centre Panel
Removal - Refitting Fascia
Removal - Refitting Upper Glove Box

EQUIPMENT / FASCIA / GLOVE-BOX
REMOVAL-FITTING
Removal - Refitting Glove Box Lid

EQUIPMENT / FRONT SEATS / SIDE AIRBAG
REPLACEMENT
Replacement Of The Pre-Tensioning Components After Triggering Of The Airbag And The Belts - Instruction For Replacement Of Faulty Parts And Repairability Of The Harness
Precautions To Be Taken
Precautions To Be Taken Air Bags

EQUIPMENT / REAR SEATS / GENERAL
REMOVAL-FITTING
Removal - Refitting Rear Seat Backrest
Removal - Refitting Rear Seat Cushion - Estate
OVERHAUL
Fitting Of An Isofix System To Fit A Child Seat - 3 Door Saloon - 4 Door Saloon Dam From 08211 - 5 Door Saloon - 5 Estate

EQUIPMENT / INTERIOR TRIM / SIDE AIRBAG
PRECAUTIONS TO BE TAKEN
Precautions To Be Taken Air Bags

EQUIPMENT / INTERIOR TRIM / HEADLINING
REMOVAL-FITTING
Removal - Refitting Headlining - Estate

EQUIPMENT / INTERIOR TRIM / INTERIOR MIRROR
REMOVAL-FITTING
Fitting Mirror Base

EQUIPMENT / INTERIOR TRIM
REMOVAL-FITTING
Removal - Refitting Fitting(S) - Estate

EQUIPMENT / INTERIOR TRIM / SEAT BELTS
REPLACEMENT
Replacement Of The Pre-Tensioning Components After Triggering Of The Airbag And The Belts - Instruction For Replacement Of Faulty Parts And Repairability Of The Harness
PRECAUTIONS TO BE TAKEN
Precautions To Be Taken Air Bags

EQUIPMENT / INTERIOR TRIM / REAR SEAT BELTS
PRECAUTIONS TO BE TAKEN
Discarding Centralised System For Airbag(S) And Seatbelts

EQUIPMENT / HEATING/VENTILATION / GENERAL
DRAINING - FILLING - BLEEDING
Draining - Filling - Bleeding Refrigerant Circuit

EQUIPMENT / HEATING/VENTILATION / GENERAL
PRECAUTIONS TO BE TAKEN
Precautions To Be Taken Air Conditioning

EQUIPMENT / HEATING/VENTILATION / TEMPERATURE REGULATION
REMOVAL-FITTING
Replacement Exterior Mirror Sensor - Estate


EQUIPMENT / HEATING/VENTILATION / AIR CONDITIONING COMPRESSOR
ADJUSTMENTS
Adjustment - Voltage Ancillary Drive Belt - Tu Injection
REMOVAL-FITTING
Removal - Refitting Air Conditioning Compressor - Dw8 Engine - Dw10td Engine
Removal - Refitting Ancillary Drive Belt (Power Steering - Air Conditioning - Xu10j2cte Engine) - Diesel Xud
Removal - Refitting Ancillary Drive Belt - Dw8 Engine
Removal - Refitting Ancillary Drive Belt - Dw8 Engine
Removal - Refitting Ancillary Drive Belt - Xu Injection
Removal - Refitting Ancillary Drive Belt - Xud7 Engine - Xud9 Engine - Xud9te Engine

EQUIPMENT / SUN ROOF
DATA - IDENTIFICATION
Identification Bonding Kit Glass
Identification Tools For Glass

ELECTRICAL / GENERAL
DATA - IDENTIFICATION

Recommended Products Electrical

ELECTRICAL / ELECTRICAL / CURRENT GENERATION
ADJUSTMENTS
Adjustment - Voltage Ancillary Drive Belt - Tu Injection
REMOVAL-FITTING
Removal - Refitting Alternator - Dw8 Engine - Dw10td Engine
Removal - Refitting Ancillary Drive Belt (Power Steering - Air Conditioning - Xu10j2cte Engine) - Diesel Xud
Removal - Refitting Ancillary Drive Belt - Dw8 Engine
Removal - Refitting Ancillary Drive Belt - Dw8 Engine
Removal - Refitting Ancillary Drive Belt - Xu Injection

Removal - Refitting Ancillary Drive Belt - Xud7 Engine - Xud9 Engine - Xud9te Engine

ELECTRICAL / CONNECTIONS / GENERAL
CHECKS
Check Continuity And Insulation Of Wire(S)
MODIFICATIONS
Modification : {{N11140}} Connectique Lève-Vitre De Porte Avant Et Arrière Dam To 08211

DEALER FIT / GENERAL
DATA - IDENTIFICATION
Recommended Products Electrical

SPECIAL TOOLS USED FOR REPAIRS / GENERAL
DATA - IDENTIFICATION
Identification Tools For Glass
Presentation Tooling Clutch - Dw10td Engine
Presentation Tooling Gearbox - Be3/6 Gearbox - Be3/5 Gearbox - Be3r Gearbox
Tooling Hdi Engine - Dw10td Engine
SPECIAL TOOLS USED FOR REPAIRS
New Special Tools
Presentation Tooling Drive Shafts - Al4 Automatic Gearbox
Presentation Tooling Engine - Dw10td Engine
Recommended Tools - Dw10td Engine