Land Rover Free Lander 2001 thru 2004, service e-manual (in Russian) - Скачать книгу бесплатно

Content Introduction How to use this manual Repair work and replacement of components Features Abbreviations and symbols General information General safety rules Safe working practices Environmental protection measures General recommendations when performing plumbing work Ball and roller bearings Oil seals Joints and butt surfaces Locking parts of connections Parts with cylindrical threads Bolt symbols Nut designation Flexible lines and hoses Dedicated tool for repair and maintenance Using roller road test benches Fuel safety measures Electrical precautions Rules for working with airbags and seat belt pretensioners Forcing the SRS component Replacing SRS system components Air conditioning precautions Urgent assistance to the victim Maintenance precautions Replacing the air conditioning compressor Specifications Diesel engine Td4 Gasoline engine K18 Gasoline engine КV6 Fuel system of Td4 diesel engine Fuel system of the K18 gasoline engine Fuel system of the KV6 petrol engine Diesel engine cooling system Td4 Cooling system of the gasoline engine K18 Cooling system of the KV6 gasoline engine Clutch Getrag manual transmission Manual transmission PG1 Intermediate crawler gear (IRD) Jatco automatic transmission Rear axle and final drive Steering Front suspension Rear suspension Braking system Wheels and tires Tire pressure Heating and ventilation Air conditioner Electrical equipment of diesel engine Td4 Electrical equipment of the K18 gasoline engine Electric equipment of the gasoline engine KV6 Dimensions Vehicle weight Identification numbers Vehicle identification number Locations of identification numbers Tightening torques for threaded connections Maintenance Td4 engine K18 engine KV6 engine Exhaust gas toxicity control Diesel engine management system Modular engine management system Siemens engine management system Fuel supply system diesel engine Gasoline engine power supply system Cooling system engine Td4 Cooling system of the K18 engine Cooling system engine KV6 Intake and exhaust manifolds and exhaust system Td4 engine Intake and exhaust manifolds and exhaust system K18 engine Intake and exhaust manifolds and exhaust system KV6 engine Clutch Manual transmission PG Getrag manual transmission Intermediate crawler gear Jatco automatic transmission Drive shafts Rear axle and final drive Steering Front suspension and subframe Rear suspension and subframe Braking system Airbag system Body Heating and ventilation Air conditioner Windscreen wiper and washers Electrical equipment Towing and lifting a car on a lift Lifting the car on a jack Car towing Starting the engine with a discharged battery Refueling containers, liquids and oils Refueling tanks Working fluids Lubrication system Sealants Maintenance Td4 - diesel engine - top view with the hood removed K18 - gasoline engine - top view with the hood removed KV6 - petrol engine - top view with the hood removed Seats and seat belts Headlights, horn and warning lights Windscreen wipers and washers Parking brake Anti-theft alarm control panel battery Wheels Tires Brake pads and calipers Brake fluid Vehicle wheel speed sensors Fuel filter petrol engine Fuel filter car with diesel engine High pressure fuel pump and fuel filter assembly diesel engine (hereinafter 2003 car model) Diesel sludge diesel engine hereinafter car model year 2003 Door locks, hinges, check of stops and bonnet latches Coolant for cooling system Cooling system and charge air intercooler Vent filter turbocharger boost pressure control solenoid valve Td4 Spark plugs K18 Spark plugs KV6 Air cleaner for cars with gasoline engines Td4 ancillary drive belt K18 ancillary drive belt KV6 ancillary drive belt Timing belt K18 Timing belt KV6 Brake / clutch fluid reservoir Power steering fluid level (PAS) Intermediate final drive (IRD) for vehicles not supplied to the US and Canada Intermediate final drive (IRD) for vehicles supplied to the USA and Canada Manual transmission PG Manual transmission GETRAG Automatic transmission - JATCO Rear axle Clutch tubes and connections Capacity for windscreen and rear door washer fluid Battery Engine oil and oil filter - Td4 Engine oil and oil filter - K18 Engine oil and oil filter - KV6 Fuel pipes and hoses Brake pipes and hoses Checking the exhaust system Car suspension Steering Road test More information Td4 engine Adjustments Checking the protrusion of the pistons with the cylinder head removed Valve timing check and adjustment Checking oil pressure Intake and exhaust camshafts Intake and exhaust camshafts Crankshaft pulley Replacing the front crankshaft oil seal Replacing the crankshaft rear oil seal Cylinder head gasket: manual transmission models Cylinder head gasket: automatic transmission models Hydraulic lifters, motor kit Valve cover gasket Soundproof engine cover, models manufactured before May 2002 Engine and manual transmission Engine and automatic transmission Left engine mount Engine hydraulic support, right Engine mounting cross member, upper right Lower engine mounting cross member Flywheel Torque converter drive disc Oil filter head gasket Oil filter Oil collection tube with strainer Oil pump Pallet bottom gasket Pallet top gasket Contact oil pressure switch Engine oil cooling heat exchanger gasket Camshaft gear cover gasket Piston group Piston group Replacing the connecting rod bearings Crankshaft and main bearings Cylinder head Engine modification K, volume 1.8 Adjustments Checking oil pressure Exhaust camshaft front oil seal Exhaust camshaft front oil seal Exhaust camshaft rear oil seal Intake camshaft rear oil seal Integral camshaft cover: sealing and replacing oil seals Replacing the connecting rod bearings Crankshaft pulley Front crankshaft oil seal Crankshaft rear oil seal Cylinder head gasket Valve cover gasket Valve seals Engine and gearbox Bracket for the right engine support assembly Engine hydraulic support, right Flywheel Oil pump Oil pan sealing Contact oil pressure switch Pressure reducing valve for lubrication system Oil temperature sensor Timing Belt Top timing cover Rear timing belt cover Lower part of the front timing belt cover: vehicles without air conditioning Lower part of the front timing belt cover: vehicles with air conditioning Piston group Front crankshaft oil seal Crankshaft pulley Replacing the crankshaft rear oil seal Crankshaft and main bearings Cylinder head gasket Cylinder head overhaul Valve cover gasket Overhaul of the oil pump Pallet Timing Belt KV6 engine, modification K Adjustments Checking oil pressure Camshafts, left cylinder head Right cylinder head camshafts Front intake camshaft oil seal Replacing the rear camshaft oil seal Crankshaft pulley Replacing the front crankshaft oil seal Replacing the crankshaft rear oil seal Left cylinder head gasket Right cylinder head gasket Left cylinder head valve cover gasket: up to May 2003 Left Cylinder Head Valve Cover Gasket: After May 2003 Valve cover gasket, right cylinder head Soundproof engine cover Engine and automatic transmission: up to May 2003 Engine and automatic transmission: after May 2003 Right engine mount bracket assembly Left engine mount Engine hydraulic support, right Engine mounting cross member, upper right Lower engine mounting cross member Torque converter drive disc Oil filter Oil receiver strainer Oil pump gasket Pallet sealing Contact oil pressure switch Oil pump pressure reducing valve Engine oil cooling heat exchanger Timing belt Right front timing belt cover Left front timing belt cover Left rear timing belt cover Right rear timing belt cover Left rear timing belt Right rear timing belt Piston group Replacing the front crankshaft oil seal Replacing the crankshaft rear oil seal Crankshaft Left cylinder head gasket Right cylinder head gasket Cylinder head overhaul and carbon removal Bulkhead oil pump Lower oil pan cover Timing belt Toxicity reduction system Adjustments Fuel tank leakage detection system (EVAPS): leak detection for North American markets Positive crankcase ventilation valve: Td4 engine Positive crankcase ventilation valve: Td4 engine Evaporative emission canister purge solenoid valve: KV6 engine Coal adsorber of gasoline vapors: except for the countries of the North American market Coal adsorber: North American market countries Canister valve: K18 engine Exhaust gas recirculation valve: Td4 engine Recirculation modulator (vacuum valve): Td4 engine Recirculation thermostatic valve: Td4 engine, automatic transmission (hot countries), from May 2003 Exhaust gas recirculation heat exchanger: Td4 engine Fuel tank tightness control unit (DMTL unit) Fuel tank leakage pump filter: KV6 engine North American Catalytic converter RH: KV6 engine, North American market Control system engine influences: EDC Renovation work Engine control unit (ECM) Sensors: coolant temperature (ECT) sensor Sensors: crankshaft position sensor (CK18P) Sensors: camshaft position (CMP) sensor Sensors: combined mass air flow (MAF) and intake air temperature (IAT) sensor Throttle position sensor: Before May 2003 Throttle position sensor: After May 2003 Engine management system: MEMS Renovation work Spark plugs Ignition coil Engine control module (ECM): ignition and fuel strategy implementation unit Idle air control (IAC) Sensors: coolant temperature (ECT) sensor Sensors: crankshaft position sensor (CK18P) Throttle position sensor Sensors: camshaft position (CMP) sensor Contact pedal position sensor Manifold absolute pressure (MAP) sensor Engine management system: SIEMENS Renovation work Spark plugs: before May 2003 Spark plugs: from May 2003 Ignition coil (separate) for left cylinder head: up to May 2003 Ignition coil (separate) left cylinder head: after May 2003 Ignition coil (separate) right cylinder head: up to May 2003 Ignition coil (separate) right cylinder head: after May 2003 Engine control unit (ECM): except for the North American market Engine control module (ECM): North American Markets Idle air control (IACV) Intake air temperature (IAT) sensor: North American markets Sensors: coolant temperature (ECT) sensor Sensors: crankshaft position sensor (CK18P) Throttle position sensor Thermostat sensor, KV6 Engine: North American markets Sensors: camshaft position (CMP) sensor Knock sensor (K18S) Throttle pedal position sensor: except for the North American Market Integrated intake manifold pressure and intake air temperature (MAP / IAT) sensor Throttle position sensor, N American market: Before May 2003 Throttle position sensor Non-N American markets: After May 2003 Diesel fuel supply system Adjustments Checking the pressure in the fuel system Draining fuel from the tank Renovation work Air cleaner filter element Fuel system bimetal valve: up to May 2003 Fuel system bimetal valve: after May 2003 Inertial fuel cut-off switch Low fuel pressure sensor: from May 2003 Fuel pressure sensor Fuel priming pump relay: before May 2003 Fuel priming pump relay: after May 2003 Fuel line filter / sump: after May 2003 Fine fuel filter: until May 2003 Fine fuel filter: after May 2003 Fuel cooling radiator: until May 2003 Fuel cooling radiator: after May 2003 High pressure fuel pump Turbocharger Radiator for intercooler air Solenoid (electrovacuum) boost pressure control valve Boost pressure sensor Elektrovacuum boost control valve atmospheric hose filter: Td4 engine Intake air ducts Fuel priming pump complete with filter: after May 2003 Submersible fuel priming module: until May 2003 Fuel pressure regulator Fuel priming pump: after May 2003 Fuel priming pump: before May 2003 Fuel tank Filling pipe Injector High pressure pipe Glow plug Glow plug electronics: up to May 2003 Glow plug relay: after May 2003 Nozzle cover: after May 2003 Cruise control switch: until May 2003 Mode resume switch (mode activation / deactivation): from May 2003 Multifunction switch Fuel supply system of a gasoline engine Adjustments Throttle cable check and adjust: KV6 engine Throttle control cable check and adjustment: K18 engine Depressurizing the fuel supply system, KV6 engine: Except for the North American market Fuel pressure relief, kv6 engine: North American markets Pressure relief in the fuel supply system: K18 Fuel pressure measurement, KV6 engine: except for the North American market Fuel Pressure Measurement, KV6 Engine: North American market Pressure measurement in the fuel supply system: K18 engine Draining fuel from the tank Air purification filter, engine K18 Air filter element, engine K18 Air filter element, engine KV6 Air Filter Element, KV6 engine: North American market Throttle cable, KV6 engine Inertial fuel cut-off switch Front left oxygen sensor, KV6 engine: except for the North American market Front Left Oxygen Sensor, KV6 Engine: North American market Front oxygen sensor, engine K18 Front right oxygen sensor, KV6 engine: except for the North American market Front right oxygen sensor, KV6 Engine: North American market Mass air flow (MAF) sensor: North American Market Fuel pump relay Throttle body, K18 engine Throttle body, KV6 engine: except for the North American market Throttle Body, KV6 Engine: North American market Intake system flap motor: KV6 Rear left oxygen sensor, KV6 engine: except countries rear left oxygen sensor, KV6 engine: North American market countries Rear oxygen sensor, engine K18 Rear right oxygen sensor, KV6 Engine: North American market Main fuel filter Electric fuel pump Fuel tank: except for North American market Fuel Tank: North American Market Countries Filling pipe Fuel rail, KV6 engine: except for the North American market Fuel Rail, KV6 engine: North American market Injector, engine KV6 Injectors (set), engine К18 Cruise control actuator, KV6 engine: except for the North American market Vacuum pump for cruise control, KV6 engine: except for the North American market Cruise control switch, engine KV6: up to May 2003 Mode resume switch (mode activation / deactivation): from May 2003 Multifunction switch Cruise controller, engine KV6 Cruise controller interface KV6 engine Cooling system: Td4 engine Adjustments Draining the coolant, flushing the system and filling Cooling fan and fan motor: before May 2003 Cooling fan and fan motor: Before May 2003 Cooling fan and fan motor: after May 2003 Cooling fan controller: vehicles before May 2003 Cooling fan controller: vehicles built after May 2003 Radiator assembly Coolant pump and thermostat Cooling system: modification K, volume 1.8 Adjustments Draining the coolant, flushing the system and filling Filling the cooling system Expansion tank Cooling fan and fan motor: Non-A / C models Cooling fan and fan motor: air conditioned models Cooling fan controller Radiator assembly Thermostat Cooling system: mod K, engine KV6 Adjustments Draining the coolant, flushing the system and filling Renovation work Cooling fan and motor Cooling fan controller: vehicles from May 2003 Radiator assembly Thermostat Coolant pump Manifolds and exhaust system Td4 Renovation work Downpipe Middle section of the exhaust system Rear exhaust section Intake manifold gaskets Exhaust manifold gaskets: vehicles with manual transmission Exhaust manifold gaskets: vehicles with automatic transmission Manifolds and exhaust system: MOD K, volume 1.8 Renovation work Downpipe Middle section of the exhaust system Rear exhaust section Replacing the left intake manifold gasket (s) Exhaust manifold heat shield: vehicles without air conditioning Exhaust manifold heat shield: vehicles with air conditioning Exhaust manifold gasket (s) Manifolds and exhaust system: mod K, engine V6 Renovation work Downpipe: except for the North American market Downpipe: North American countries Middle section of the exhaust system: except for the countries of the North American market Middle section of the exhaust system: countries of the North American market Rear section of exhaust system with silencer A / C Compressor heat shield: KV6 N American market Intake manifold gaskets, left side Right exhaust manifold gasket: except for North American market Right exhaust manifold gasket (s), KV6, North American market Left exhaust manifold gasket: except for North American market Left exhaust manifold gasket (s): North American Market Inlet receiver seals: vehicles built before May 2003 Inlet receiver seals: vehicles built after May 2003 Intake manifold gaskets, right side Inlet compressor seals: vehicles manufactured prior to May 2003 intake receiver seals: vehicles manufactured prior to May 2003 Inlet receiver seals: vehicles built after May 2003 Clutch Renovation work Clutch assembly / driven plate and clutch release bearing (release) Td4 Clutch assembly / driven plate and clutch release bearing (release) K18 Hydraulic clutch: K18 right-hand drive vehicles Master cylinder: left hand drive Td4 Master cylinder: Td4 right hand drive vehicles Manual transmission PG Adjustments Changing the transmission oil in the box Gearbox Gearbox Gear selector shaft oil seal Reversing light switch Contact sensor for engaging the first gear Mechanical transmission GETRAG Adjustments Changing the transmission oil in the box Back cover Gear selector: top link and ball joints Gearbox Input shaft oil seal Gear selector shaft oil seal Reversing light switch Contact sensor for engaging the first gear Transfer case Adjustments Changing transmission oil in the transfer case: except for the North American market Changing Transmission Oil in the Transfer Case: North American market Renovation work Transfer case: models with Td4 engine Transfer case: models with K18 engine Transfer case: models with KV6 engine Transfer case rear cover gasket: Td4 models Rear cover gasket, transfer case: models with KV6 engine Transfer case rear cover gasket: models with K18 engine Transfer case drive shaft oil seal Left drive shaft oil seal: Td4 and KV6 models Left drive shaft oil seal: vehicles with K18 engine Right drive shaft oil seal Rear axle drive shaft oil seal: vehicles with Td4 engine Rear axle drive shaft oil seal: vehicles with K18 engine Rear axle drive shaft oil seal: vehicles with KV6 engine, excluding North American market Rear axle drive shaft oil seal: vehicles with KV6 engine, for countries of the North American market Automatic transmission: JATCO Adjustments Adjusting the engine blocking switch Replacing the working fluid in the box Adjusting the selector cable Renovation work Selector body Selector knob Selector cable Selector lever position indicator: vehicles manufactured before May 2003 Selector lever position indicator: vehicles built after May 2003 Engine blocking switch Control unit (ECU) Torque converter oil seal Gearbox with KV6 engine (engine with gearbox removed) Gearbox: vehicles with KV6 engine Transmission: vehicle with Td4 engine Sealing the bottom of the gearbox A blown heat exchanger for working fluid cooling: vehicles with a Td4 engine (for hot climates) Heat exchanger for working fluid cooling: vehicles with Td4 engine Heat exchanger for working fluid cooling: vehicles with KV6 engine Heat exchanger hoses for working fluid cooling Drive shafts Renovation work Left shaft with external and internal joints Right shaft with external and internal joints Protective cover outer front hinge of constant angular velocities Protective cover hinge of constant angular velocities outer left front Protective cover internal constant velocity hinge Rear shaft with external and internal joints Protective cover for outer rear hinge Outer rear constant velocity joint Protective cover inner constant velocity hinge rear Propeller shaft assembly Front propeller shaft Rear propeller shaft Bulkhead front and rear propeller shafts Cover of the sliding fork of the universal joint of the front propeller shaft Viscous clutch assembly Front intermediate support Rear axle and final drive Renovation work Differential assembly Differential rear cover Differential housing front support bush Differential housing rear support bush Main drive shaft oil seal Rear drive shaft oil seal Steering Adjustments Bleeding the power steering system Adjusting the ignition lock cable Checking and adjusting the alignment of the front wheels Checking and adjusting rear wheel alignment Checking the pressure in the power steering system Renovation work Steering gear Steering gear cover Power steering fluid cooler (for models with Td4 or K18 engine) Power steering fluid cooler (for models with KV6 engine) Drive belt (for models with K18 engine) Power steering pump (KV6 models) Power steering pump (models with K18 engine) Power steering pump (Td4 models) Steering column shroud Steering wheel lock and ignition switch Ignition lock cable Steering column assembly, inner and outer parts Tie rod end ball joint Steering rod Steering wheel Front suspension Renovation work Anti-roll bar Stabilizer struts, transverse mustache sustainability Anti-roll bar rubber cushions Hub bearing Shock absorber Lower arm assembly Front subframe Front lower arm bushings Rear bushings of the lower arms Rear suspension Renovation work Trailing arm bushing Hub bearing Shock absorber Trailing arm Trailing arm bushing Adjustable wishbone Non-adjustable wishbone Control arm bushing Stretcher Braking system Adjustments Bleeding the brake system Checking and adjusting the parking brake cable Renovation work Rear brake drum Front brake disc Left front brake hose Rear brake hose Dual master cylinder for left-hand drive vehicles Double master cylinder for right-hand drive vehicles Parking brake lever assembly Parking brake cable Parking brake warning switch Brake light switch Accelerator pedal position sensor Front brake pads Rear brake pads Vacuum booster assembly for left-hand drive vehicles Vacuum booster assembly for right-hand drive vehicles Vacuum pump for vehicles with Td4 engine and manual gearbox Vacuum pump for vehicles with Td4 engine and automatic transmission Vacuum booster for vehicles with KV6 engine Front brake pad guide Rear brake wheel cylinder Brake fluid level sensor Front right wheel speed sensor and electrical cable Front left wheel speed sensor and its electrical cable Rear wheel speed sensor and its electrical cable ABS pressure regulator Downhill assist switch for model year 2004 and up Downhill assist switch for vehicles up to model year 2004 Passive safety systems Renovation work Front inertia seat belt door car 5-door front inertia seat belt Rear seat center seat belt Seat belt left seat in the back seat Height-adjustable intermediate seat belt loop located on the B-pillar Rear seat belt buckle, left door car Left seat belt buckle in the back seat of a 5-door car Front seat belt pretensioner Deploying the removed front seat belt pretensioner Rear seat center belt buckle Driver airbag Front passenger airbag for cars up to model year 2004 Front passenger airbag for model year 2004 and later On-board diagnostic unit (DCU) The front passenger airbag removed from the vehicle is deployed Airbag rotary contactor Driver's airbag removed from the vehicle Driver's airbag deployment without removing it from the vehicle Deploying the front seat belt pretensioner without removing it from the vehicle Doors Adjustments Adjusting the front or rear door lock striker Front door hinge adjustment Dismantling the front door assembly to provide access to other elements, installing the front door Dismantling the rear door assembly to provide access to other elements, installing the rear door Dismantling the complete tailgate to provide access to other elements, installing the door luggage compartment Front door glass Rear door glass Front door rubber / felt window seal Tailgate rubber / felt window seal Tailgate glass Small rear rear door window Tailgate window regulator Inner lower tailgate window seal Front door trim panel door car 5-door front door trim panel for vehicles up to model year 2004 5-door front door trim panel for model year 2004 and up Tailgate decorative panel for vehicles up to model year 2004 Tailgate decorative panel for model year 2004 and up Tailgate trim panel Lower plastic trim for the front door of a 5-door car 5-door front door pocket Upper plastic trim for front door of 5-door car Plastic trim for tailgate Plastic trim for the front door of a 5-door car Rear door plastic trim 5-door front door lock 5-door front door lock Rear door lock Tailgate lock Front door lock release handle Rear door lock release handle Cable for the handle of unlocking the door lock of a 5-door car Side cover for rear window of 5-door car Tailgate outside handle Exterior tailgate handle Front door outside handle 5-door interior door handle for cars up to model year 2004 External parts Renovation work Front wing Front wheel arch liner Rear fender liner Lower engine shield Power outside mirror Adjustments Front mudguard Rear mudguard Spare wheel mounting bracket Side rail for the roof rack of a 5-door car Hood Bonnet release cable / pull rod Front bumper assembly for vehicles up to model year 2004 Front bumper assembly for model year 2004 and Up Rear bumper assembly for vehicles up to model year 2004 Rear bumper assembly for model year 2004 and up Sill trim 5 door car roof moldings Rear part of the rear wheel arch extender Small rear glass assembly door car Interior trim parts Renovation work Sun visor Luggage compartment lower decorative panel for a 3-door car Luggage compartment lower trim panel 5-door Upper decorative panel for luggage compartment of a 3-door car 5-door luggage compartment upper decorative panel Replacing the A-pillar upper decoration panel Replacing the 'B / C' pillar top trim B-pillar lower trim panel for 5-door car Rear side decorative panel of a 3-door car Center console for vehicles up to model year 2004 Front console assembly for model year 2004 and up Rear console Cup holder located in the control panel for model year 2004 and up Control panel for vehicles up to model year 2004 Control panel for model year 2004 and up Control panel cup holder for vehicles up to model year 2004 Detaching the control panel Luggage compartment flooring Glove box Ceiling panel of a 3-door car 5-door roof panel Glass Renovation work Windshield Rear side glass Seats Renovation work Front seat Rear seat left Rear seat right Cushion and backrest of the rear continuous seat of a 3-door car Front seat cushion padding Right rear seat cushion upholstery Left rear seat cushion padding Upholstery of a cushion of a rear non-cut seat of a 3-door car Front seat base linings Front seat cushion side pad Manual lumbar cushion, front seat Rear right seat backrest lock Left rear seat backrest lock Backrest upholstery, front Backrest upholstery, rear left Backrest upholstery, rear right Backrest upholstery of the rear solid seat of a 3-door car Roof ventilation hatch Renovation work Ventilation hatch in the roof of a 3-door car Sunroof deflector for 3-door car Sunroof seal Ventilation hatch in the roof of a 5-door car Glass panel of the ventilation hatch in the roof of a 5-door car Seal for the glass cover of the ventilation hatch in the roof of a 5-door car Motor gearbox of the electric drive of the ventilation hatch in the roof of a 5-door car Cables and drive of the ventilation hatch of a 5-door car Front drain pipes of the ventilation hatch in the roof of a 5-door car 5-door rear roof drain pipes Internal decorative strip Deflector sunroof 5-door car Ventilation sunroof for 5-door car Roof vent control button Sealing gutter ventilation hatch in the roof of a 5-door car Roof Renovation work Removable rigid roof for access to the repair site and refitting Frame and tarpaulin assembly removal for access to the place of repair and installation in place Awning Hardtop side glass Rigid roof seal Front latch and hardtop striker Rear Hard Top Latch & Striker Body geometry Control sizing information Body control charts Joint clearances and body profiles Dimensions of gaps and profiles Body parts repair Body repair General information Replaceable body parts Replaceable body parts Internal elements of the front part of the body Body side panels 3-door version Body side panels 5-door version Front inner panels of the sidewall of the 3-door version Front inner panels of the side of a body 5-door version Rear inner panels of a sidewall of a body 3-door version Rear inner panels of a sidewall of a body 5-door version Roof assembly 3-door version Roof assembly 5-door version Rear body parts Complete doors Welding operations Location of electronic control units (the diagram shows a 3-door version, the location for a 5-door version is the same) General safety rules for welding Panel replacement procedure Front panel assembly Bonnet lock panel Headlight mounting bracket Front cross member, lower Front side member assembly Front spar (front) Engine compartment sidewall assembly Upper sidewall of the engine compartment Front panel of the sidewall of the engine compartment Reinforcement of the outer wheel arch panel Pillar "A" of the body, 3-door version Pillar "A" of the body 5-door version Threshold reinforcement 3-door version Sill reinforcement 5-door version B / S center pillar reinforcement panel 3-door version B / S center pillar reinforcement panel 5-door version Rear side panel assembly 3-door version Rear side panel assembly 5-door version Rear wheel arch outer panel 3-door version Outer panel of the rear wheel arch 5-door version Inner panel of "E" pillar door version E-pillar panel 5-door version Rear floor cross member assembly Rear underbody Rear underbody member Front roof section complete 3-door version Rear roof section complete 5-door version Roof assembly 5-door version Estimated time of repair operations Time norms Body Sealing Materials Materials and their applications Approved Content Application equipment Corrosion protection and sealing Corrosion protection Coating hollow spaces with protective wax and spray holes 3-door body version Legend for the figure "Coating hollow cavities with protective wax and spray holes 5-door version of the body" Openings to protect the internal cavity of the sill 5-door version of the body Covering the hollow spaces of the doors with protective wax and spray holes 5-door version of the body Corrosion protection Sealant application process Places of the underbody treated with sealing materials Underbody sealing materials Internal sealing Foam acoustic insulation Foam acoustic insulation Water ingress into the body Painting Working with body panels Panel preparation Painting operations Preparation for painting Heating and ventilation Renovation work Heater control panel for vehicles up to model year 2004 Heater Control Panel for Model Year 2004 and Up Cabin air recirculation gear motor Interior air recirculation switch Fan speed controller Control panel left vent Air intake box Heater PTC electric heater heating element for Td4 models PTC electric heater cable for Td4 models PTC electric heater microswitch for Td4 models Heater fan assembly Fan motor resistor unit Heater radiator PTC electric heater power relay for Td4 models PTC electric heater control relay for Td4 models Oil heater (FBH) Outside air temperature sensor (OT) Oil heater fuel pump for models before model year 2004 Oil heater fuel pump for models 2004 and up Air conditioning system Emptying the air conditioner, recovering refrigerant and charging Emptying the air conditioner, recovering refrigerant and charging A / C compressor drive belt for models with Td4 engine Air conditioning compressor for Td4 engine models Air conditioning compressor for models with KV6 engine Air conditioning compressor for models with K18 engine Capacitor Receiver moisture separator Air conditioner switch Refrigerant pressure sensor Thermostatic expansion valve (TXV) Evaporator Screen wipers and washers Renovation work Washer reservoir One washer nozzle Washer pump One wiper arm One cleaning brush Cleaner motor and linkage Washer / wiper switch Washer pump Cleaner lever Cleaning brush Electric motor cleaner Combined wiper / washer switch Relay glass cleaner, cargo compartment door 5-door models Engine starting and battery charging system Attachment drive belt K18 engine Attachment drive belt K18 engine with air conditioning Renovation work Generator engine Td4 Generator KV6 Generator K18 Ancillary drive belt Td4 engine Attachment drive belt K18 engine without air conditioning Attachment drive belt K18 engine with air conditioning Attachment belt KV6 engine Tensioner attachment belt Td4 engine Battery Battery support tray Relay main relay Starter engine Td4 Starter motor KV6 Starter engine K18 Starter relay Lighting Adjustments Headlamps, pair of headlights for cars up to model year 2004 Headlights headlights pair light adjustment cars from model year 2004 Headlight assembly up to model year 2004 Headlight assembly from model year 2004 Turn signal repeater Combination rear lamp License plate light Combined fog light / dimensions from model year 2004 Combined rear lamp Central upper brake light (CHMSL) Glove box lamp Lantern cargo compartment Headlight dimmer switch Glove box switch Alarm switch Combined switch, direction indicators / headlights / sound signal Rear fog lamp switch Control modules Renovation work Window regulator control module Relay folding mirrors model 02MY Central control unit (CCU) Control module for folding mirrors up to 02MY Security system Renovation work Electromagnet / electric motor, cargo compartment door Non-latching switch beep Sound signal Immobilizer electronic control unit (ECU) Volume control sensor alarm system 3-door models Module (ECU) volume control alarm system 5 and door models models without hatch Module (ECU) volume control alarm system 5 and door models models with sunroof Alarm system receiver Coil passive immobilizer alarm system Windows Renovation work Electric motor & window regulator mechanism front door 3-door model Electric motor & window regulator mechanism front door 5-door model Window regulator switch 5 and door models 02MY models Load compartment door glass control relay Microswitch determination of hardtop installation 3-door models Heated windshield relay Load compartment door glass heater switch Entertainment systems Renovation work Radio receiver up to 02MY Radio / CD player 02MY model Rear speaker 3-door models Rear speaker 5-door models Front speaker Aerial mechanical 3-door models Aerial mechanical 5-door models Coaxial wire front antenna 3-door models Coaxial wire front antenna 5 and door models High frequency front loudspeaker Loudspeaker high-frequency rear 3-door models Amplifier power amplifier Subwoofer Coaxial wire extension Cable harnesses Renovation work Passenger compartment fuse box Main wiring harness Cable harness, load compartment door Cable harness interior lighting 5 door models Cable harness front door 5t door models Rear door cable harness Governing bodies Renovation work Audio system remote control switch Park assist switch (PDC) 04MY models Electronic control unit (ECU) parking assist model 04MY Rear parking aid sensor from 04MY Acoustic warning system parking aid rear model from 04MY Parking brake warning switch Alarm switch for 04MY model Front cigarette lighter Outside rearview mirror control switch Navigation system Renovation work Remote control interface module Display navigation system Devices Renovation work Clock Control panel up to 04MY 04MY model toolbar Cover for instrument panel up to 04MY Dashboard cover for model 04MY Fuel level gauge Meter fuel tank model with Td4 engine model from 03MY