MG MG6 Series 2011 User manual

ServiceManual2011
MG6
Version2.0
Thismanualprovidesinformationonthespecications,thesystemintroduction,theserviceproceduresandthe
adjustmentsforthe2011seriesMG6Vehicle.
Thetechnicians,workedfortheservicingstationauthorizedbyMGMotor,canprovidebetterservicefortheownersof
MG6vehiclebasedonaprofoundunderstandingthismanualandrelatedupdatedServiceBulletins.
Y ouaresuggestedthatpleasecontactMGMotor.ifyouwanttoobtainrelatedinformationmentionedinthismanual
aboutthebrand,thepartsnumber,andspecialtoolsetc.
MGMotor.
CopyRightReserved
AllinformationreceivedcutoffdateisAugust2011
AnyinformationcontainedinthismanualarethepropertyoftheMGMotor.Nopartofthismanualmaybecopied,
storedinanyretrievalsystem,orspreadbyanymeans(includingbutnotlimitedinelectronic,mechanical,photocopying
andrecording)withoutwrittenMGMotorauthorization.Thisappliestoalltext,illustrations,andtables(notlimitedin
above)mentionedinthismanual.

HowT oUseThisManual
General
T oassistintheuseofthisManual,itisdividedintosections
andsub-sections.Therelevantsub-sectiontitleisgivenatthe
headerofeachpage.
ThereisasingleContentssectionatthefrontoftheManual,
whichisdividedbysectionandsub-section.Thebookis
numberedfrompage1.Thepagenumberisgivenatthe
bottomofeachpage.
Theindividualactionsoftherepairoperationsmustbe
followedinthesequenceinwhichtheyappear.Itemnumbers
intheillustrationsrefertotherelevantnumberedtextunder
theillustration.
AdjustmentandrepairoperationsincludereferencetoService
toolnumbersandtheassociatedillustrationdepictsthetoolin
use.Adjustmentandrepairoperationsalsoincludereference
towearlimits,relevantdata,torquegures,andspecialist
informationandusefulassemblydetails.Eachadjustmentor
repairoperationisgivenauniqueRepairOperationnumber.
WARNINGS,CAUTIONS,NOTESandTIPShavethe
followingmeanings:
WhenencounteringaWARNING,youwillbeaskedtotake
anecessaryactionornottotakeaprohibitedaction.Ifa
WARNINGisnotheeded,thefollowingconsequencesmay
occur:
•Seriousbodilyinjuryordeathtothetechnician.
•Seriousbodilyinjuryordeathtoothertechniciansinthe
workplacearea.
•Seriousbodilyinjurytothedriverand/orpassenger(s)of
thevehicle,ifthevehiclehasbeenimproperlyrepaired.
CAUTIONcallspecialattentiontoanecessaryactionortoa
prohibitedaction.IfaCAUTIONisnotheeded,thefollowing
consequencesmayoccur:
•Damagetothevehicle.
•Unnecessaryvehiclerepairs.
•Unnecessarycomponentreplacement.
•Improperoperationorperformanceofthesystemor
componentunderrepair.
•Damagetoanysystemsorcomponentswhichare
dependentupontheproperoperationofthesystemor
componentunderrepair.
•Improperoperationorperformanceofanysystems
orcomponentswhicharedependentupontheproper
operationorperformanceofthesystemorcomponent
underrepair.
•Damagetofasteners,basictools,orspecialtools.
•Theleakageofcoolant,lubricant,orothervitaluids.
NOTEstatementsemphasizeanecessarycharacteristicof
adiagnosticorrepairprocedure.NOTEstatementsare
designedtodothefollowing:
•Clarifyaprocedure.
•Presentadditionalinformationforaccomplishinga
procedure.
•Giveinsightintothereasonorreasonsforperforminga
procedureinthemannerrecommended.
•Presentinformationthatwillhelptoaccomplisha
procedureinamoreeffectivemanner.
•Presentinformationthatgivesthetechnicianthebenet
ofpastexperienceinaccomplishingaprocedurewith
greaterease.
TIP:Giveshelpfulinformation.
References
ReferencestotheLHorRHsidegiveninthisManualaremade
whenviewingthevehiclefromtherear.Withtheengineand
gearboxassemblyremoved,thecrankshaftpulleyendofthe
engineisreferredtoasthefront.
OperationscoveredinthisManualdonotincludereference
totestingthevehicleafterrepair.Itisessentialthatwork
isinspectedandtestedaftercompletionandifnecessarya
roadtestofthevehicleiscarriedout.Thisisofparticular
importancewheresafetyrelateditemsareconcerned.
Dimensions
Thedimensionsquotedaretodesignengineeringspecication.
Servicelimitsareincludedwhereapplicable.
Ourcompanyareconstantlyseekingtoimprovethe
specication,designandproductionoftheirvehiclesand
alterationstakeplaceaccordingly.Whileeveryefforthasbeen
madetoensuretheaccuracyofthisManual,itshouldnotbe
regardedasaninfallibleguidetocurrentspecicationsofany
particularvehicle.
Version2.01

RepairsandReplacements
Parts
Whenreplacementpartsarerequireditisessentialthatonly
ourcompany’srecommendedpartsareused.
Attentionisparticularlydrawntothefollowingpoints
concerningrepairsandthettingofreplacementpartsand
accessories.
•Safetyfeaturesandcorrosionpreventiontreatments
embodiedinthevehiclemaybeimpairedifotherthan
SMCrecommendedpartsaretted.
•T orquewrenchsettingguresgiveninthisManualmust
beused.
•Lockingdevices,wherespecied,mustbetted.Ifthe
efciencyofalockingdeviceisimpairedduringremoval
itmustberenewed.
•Thetermsofthevehiclewarrantymaybeinvalidatedby
thettingofpartsotherthanSMCrecommendedparts.
AllSMCrecommendedpartshavethefullbackingofthevehicle
warranty.
SMCDealersareobligedtosupplyonlySMCrecommended
parts.
Specialtools
Specialtoolshavebeendevelopedtofacilitateremoval,
dismantlingandassemblyofmechanicalcomponentsinacost
effectiveandtimeefcientmanner.Theuseofspecialtools
alsohelpspreventthepotentialfordamagetocomponents.
Someoperationsinthemanualcannotbecarriedoutproperly
withouttheaidoftherelevantspecialtools.
Specialtoolscanbeobtainedfromthefollowingsupplier.
ShanghaiXiangzhiIndustrialDevelopmentCo.,Ltd
Address:17F ,BuildingC,No.900,YishanRoad,Shanghai
PostCode:200233
T el:021-54234810
Version2.02

Contents
GeneralInformation...........................1
GeneralInformation.............................................1
GeneralPrecautions...........................................1
SafetyInstructions..............................................2
EnvironmentalPrecautions..................................3
GeneralFittingInstructions.................................5
BallandRollerBearings......................................6
OilSeals............................................................7
JointsandJointFaces..........................................8
LockingDevices.................................................8
ScrewThreads...................................................9
FastenersIdentication.......................................9
FlexiblePipesandHoses...................................11
FuelHandlingPrecautions.................................12
ElectricalPrecautions.......................................13
SupplementaryRestraintSystem
Precautions......................................................14
SRSComponentReplacementPolicy.................20
AirConditioningSystemPrecautions................21
AirConditioningCompressor
Replacement....................................................23
VehicleIdenticationNumber...........................24
VehicleIdentication........................................24
OtherIdenticationPlateLocations..................25
Lifting&T owing...................................................26
Lifting..............................................................26
VehicleRecovery..............................................27
Lubrication&Maintenance................................29
Capacities........................................................29
Fluids...............................................................29
Lubrication......................................................30
Engine.................................................31
EngineMechanical-1.8T......................................31
Specications...................................................31
T orque.........................................................31
Reference.....................................................32
DescriptionandOperation...............................39
EngineComponentLayout............................39
Description..................................................52
Operation....................................................54
ServiceProcedures...........................................56
CylinderHeadOverhaul-withCylinder
HeadRemoved.............................................56
CrankshaftOverhaul-withEngine
Removed......................................................61
ConnectingRodBearingsOverhaul...............65
Pistons&Liners............................................67
CrankshaftRearOilSeal...............................70
CrankshaftFrontOilSeal..............................71
Flywheel-ManualT ransmission.....................72
T orqueConverterDrivePlate-Automatic
T ransmission................................................72
CylinderHeadGasketOverhaul-with
EngineRemoved...........................................73
CamshaftCoverGasket................................77
Valves..........................................................78
HydraulicT appets.........................................82
Camshafts-InletorExhaust.........................82
IntakeManifoldGasket..................................84
ExhaustManifoldGasket...............................86
OilPump.....................................................89
EngineOilandOilFilter................................90
EngineOilPressureCheck............................91
OilPick-UpStrainer...................................92
EngineSump.................................................92
CamshaftDriveBeltCover-Front
Upper..........................................................93
CamshaftDriveBeltCover-Rear
Upper..........................................................94
CrankshaftPulley..........................................95
EngineMounting-RH...................................96
EngineMountingLowerTieRod...................96
CamshaftFrontOilSeal-Exhaust.................97
CamshaftFrontOilSeal-Inlet......................98
CamshaftDriveBelt.....................................99
EngineandManualT ransmission..................102
EngineandAutomaticT ransmission.............110
CylinderHeadGasket.................................119
T urbocharger.............................................123
Hose-CoolantDrain-T urbocharger...........126
Hose-CoolantIntake-T urbocharger...........126
Pipe-OilReturn-T urbocharger.................127
Hose-AirIntake-T urbocharger................127
Pipe-OilFeed-T urbocharger....................128
Hose-AirIntake-Electronic
Throttle.....................................................128
Intercooler.................................................129
Hose-AirIntake-Intercooler....................130
SpecialT ools..................................................131
EngineMechanical-1.8VCT.............................134
Specications.................................................134
T orque.......................................................134
Version2.01

Contents
Reference...................................................135
DescriptionandOperation.............................136
ComponentLayout.....................................136
Description................................................147
Operation..................................................149
ServiceProcedures.........................................152
CylinderHeadOverhaul-withCylinder
HeadRemoved...........................................152
CrankshaftOverhaul-withEngine
Removed....................................................157
ConnectingRodBearingsOverhaul.............161
Pistons&Liners..........................................163
CrankshaftRearOilSeal.............................166
CrankshaftFrontOilSeal............................167
Flywheel-ManualT ransmission...................168
T orqueConverterDrivePlate-Automatic
T ransmission..............................................168
CylinderHeadGasketOverhaul-with
EngineRemoved.........................................169
CamshaftCoverGasket..............................173
Valves........................................................174
HydraulicT appets.......................................178
Camshafts-InletorExhaust.......................178
IntakeManifoldGasket................................180
1.8VCTExhaustManifoldGasket................182
OilPump...................................................184
EngineOilandOilFilter..............................185
EngineOilPressureCheck..........................186
OilPick-UpStrainer.................................186
EngineSump...............................................187
CamshaftDriveBeltCover-Front
Upper........................................................188
CamshaftDriveBeltCover-Rear
Upper........................................................188
CrankshaftPulley........................................189
EngineMounting-RH.................................190
EngineMountingLowerTieRod.................191
1.8VCTCamshaftFrontOilSeal-
Exhaust......................................................191
1.8VCTCamshaftFrontOilSeal-
Inlet...........................................................192
1.8VCTCamshaftDriveBelt(New)............192
1.8VCTCamshaftPhaserUnit.....................195
1.8VCTEngineandManual
T ransmission..............................................196
1.8VCTEngineandAutomatic
T ransmission..............................................200
1.8VCTSolenoid-ExhaustCamshaft...........205
1.8VCTSolenoid-InletCamshaft...............205
1.8VCTSolenoidHousing-Exhaust
Camshaft....................................................206
1.8VCTSolenoidHousing-Inlet
Camshaft....................................................206
1.8VCTCylinderHeadGasketNew............207
SpecialT ools..................................................210
EngineCoolingSystem.....................................213
Specications.................................................213
T orque.......................................................213
Reference...................................................214
DescriptionandOperation.............................215
SystemComponentLayout.........................215
Description................................................218
Operation..................................................220
ServiceProcedures.........................................223
Coolant-DrainandRell...........................223
ExpansionT ankCap-PressureT est..............224
System-PressureT est................................225
CoolantExpansionT ank..............................226
FanAssembly.............................................227
CoolingFanResistor..................................229
RadiatorAssembly......................................229
SupplyFluidCoolerHose-Automatic
T ransmission..............................................231
ReturnFluidCoolerHose-Automatic
T ransmission..............................................232
Thermostat................................................233
Pump-Coolant............................................233
SpecialT ools..................................................234
EngineManifold&ExhaustSystem.................235
Specications.................................................235
T orque.......................................................235
DescriptionandOperation.............................236
SystemComponentLayout-1.8TInletand
ExhaustSystem..........................................236
SystemComponentLayout-1.8VCTInlet
andExhaustSystem....................................242
Description-1.8TInletandExhuast
System.......................................................247
Description-1.8VCTInletandExhuast
System.......................................................248
Operation-1.8TInletandExhuast
System.......................................................249
Operation-1.8VCTInletandExhaust
System.......................................................250
ServiceProcedures.........................................251
AirCleaner................................................251
2Version2.0

Contents
Element-AirCleaner.................................252
T ailPipeandSilencer..................................252
IntermediatePipe.......................................253
FrontPipe-T urbocharger...........................254
HeatShield-Alternator..............................255
HeatShield-RearSilencer..........................256
HeatShield-ExhaustPipeandFuel
T ank...........................................................256
ElectricThrottle-IncludesT uning...............257
EngineFuel&ManagementSystem................258
Specications.................................................258
T orque.......................................................258
DescriptionandOperation-1.8T.....................259
SystemComponentLayout.........................259
ControlDiagram-1.8T................................261
Description................................................264
Operation..................................................275
CruiseControl-1.8T...................................288
DescriptionandOperation-1.8VCT...............289
SystemComponentLayout-1.8VCT............289
ControlDiagram-1.8VCT..........................291
Description................................................293
Operation..................................................302
CruiseControl-1.8VCT..............................314
ServiceProcedures.........................................315
SparkPlugs.................................................315
IgnitionCoils..............................................315
EngineControlModule(ECM)....................316
Sensor-EngineCoolantT emperature
(ECT)........................................................316
Switch-OilPressure..................................317
Sensor-CrankshaftPosition(CKP).............317
Sensor-camshaftposition(CMP)-
VCT..........................................................318
Sensor-inletcamshaftposition(CMP)-
VCT..........................................................318
Sensor-ExhaustCamshaftPosition(CMP)
-VCT........................................................319
Sensor-temperatureandmanifoldabsolute
pressure(TMAP)........................................319
Sensor-manifoldabsolutepressure
(MAP)........................................................320
Sensor-Knock(KS)...................................320
Sensor-HeatedOxygen(HO2S)-Front-
T urbocharger.............................................321
Sensor-HeatedOxygen(H02S)-Rear-
T urbocharger.............................................321
Solenoid-BoostControl-
T urbocharger.............................................322
FuelRail.....................................................322
Injectors....................................................323
CharcoalCanister......................................324
PurgeControlValve...................................324
PipeAssembly-BodyUnderoorFuel
Lines..........................................................325
T ank-Fuel.................................................326
FuelPump..................................................328
FuelSystem-Depressurise.........................329
FuelSystem-PressureT est.........................330
T ank-Drain&Rell.....................................331
FuelFilter...................................................331
FillerNeck.................................................332
Switch-Inertia-FuelCutOff.....................333
SpecialT ools..................................................334
EngineElectricalSystem..................................335
Specications.................................................335
T orque.......................................................335
DescriptionandOperation.............................336
ComponentLayout.....................................336
ControlDiagram........................................337
Description................................................338
Operation..................................................340
ServiceProcedures.........................................341
Belt-PASPump.........................................341
Alternator..................................................341
Bracket-Alternator-Upper......................342
Bracket-Alternator-Lower......................343
DriveBelt..................................................344
StarterMotor............................................344
BatteryT rayandSupportBracket................345
T ensioner-AlternatorDriveBelt................346
T ransmission....................................347
ShiftLockControl-AT.......................................347
Specications.................................................347
T orque.......................................................347
DescriptionandOperation.............................348
Description................................................348
ServiceProcedures.........................................349
Knob–SelectorLever–Automatic.................349
Rod/Cable
Assembly–Selector–Automatic....................349
Lever–GearshiftSelector
Assembly–Automatic..................................350
Version2.03

Contents
ShiftLockControl-MT......................................351
Specications.................................................351
T orque.......................................................351
ServiceProcedures.........................................352
Knob–GearLever–Manual...........................352
RemoteControl–Gear
Change–Manual..........................................352
T ransmission-A T................................................353
Specications.................................................353
T orque.......................................................353
Specications..............................................354
DescriptionandOperation.............................356
SystemComponentLayout.........................356
SystemControlSystem...............................361
Description................................................364
Operation..................................................370
ServiceProcedures.........................................386
Automatictransmission–Pressure
T est...........................................................386
Neutralstart(inhibitor)–Switch..................386
NeutralStart(Inhibitor)–Switch–Check
andAdjust..................................................388
T ransmissionandConverter.......................388
AutomaticT ransmissionFluid–Drainand
Rell..........................................................389
AutomaticT ransmission–T opUp.................390
ControlUnit–Automatic
T ransmission..............................................391
Harness–AutomaticT ransmission................392
Sensor–SpeedInput....................................393
Sensor–SpeedOutput.................................393
Dipstick–OilLevel......................................394
OilSeal–Differential–LH.............................394
OilSeal–Differential–RH.............................395
T orqueConverter......................................396
SideCover.................................................397
OilSeal–OilPump......................................398
SpecialT ools..................................................399
T ransmission-MT...............................................400
Specications.................................................400
T orque.......................................................400
Specications..............................................401
DescriptionandOperation.............................402
SystemComponentLayout.........................402
Description................................................409
Operation..................................................410
ServiceProcedures.........................................411
OilSeal–GearChangeRod.........................411
LubricationSystem–Drain&Rell...............412
ManualT ransmissionAssembly....................412
LampSwitch–Reverse.................................416
Cover–ReverseAccess–Reseal....................416
LubricationSystem–Manual
T ransmission–T opup..................................417
OilSeal–Differential–LH.............................417
OilSeal–Differential–RH.............................418
ManualT ransmissionDismantling................418
InputShaftAssembly...................................420
OutputShaftAssembly...............................423
ReverseIdlerGear.....................................425
DifferentialAssembly..................................426
ControlAssembly.......................................427
FittingsandReleaseMechanism...................428
SpecialT ools..................................................430
Clutch.................................................................432
Specications.................................................432
T orque.......................................................432
Specications..............................................433
DescriptionandOperation.............................434
SystemComponentLayout.........................434
Description................................................437
Operation..................................................439
ServiceProcedures.........................................440
ClutchAssembly.........................................440
ClutchReleaseBearing...............................442
ClutchMasterCylinder(A).........................442
ClutchMasterCylinder(B).........................443
ClutchSlaveCylinder(A)............................444
ClutchSlaveCylinder(B)............................445
ClutchSystemBleeding...............................445
SpecialT ools..................................................446
HVACSystem..................................447
HVACStructure................................................447
Specications.................................................447
T orque.......................................................447
Specications..............................................448
DescriptionandOperation.............................449
SystemComponentLayout.........................449
Description................................................451
Operation..................................................466
ServiceProcedures.........................................470
4Version2.0

Contents
RefrigerantRecovery,Recyclingand
Recharging.................................................470
IfRechargingisCompleted
Successfully/Unsuccessfully:.........................472
Compressor...............................................472
Evaporator.................................................473
ThermostaticExpansionValve.....................475
Condenser.................................................475
DrierDesiccantBag...................................477
PressureSensor-AirConditioning.............478
Hose-CompressortoCondenser..............478
A/CPipe-EvaporatortoCompressor
A-EvaporatortoConnection.......................479
A/CPipe-EvaporatortoCompressorB-
CompressortoConnection........................480
A/CPipe-CondensertoEvaporatorA-
CondensertoConnection..........................480
A/CPipe-CondensertoEvaporatorB-
ConnectiontoEvaporator..........................481
FilterHousing-FreshAirIntake..................481
FreshAirFilter...........................................482
HeaterAssembly........................................482
BlowerAssembly........................................483
HeaterCore..............................................484
PowerController.......................................485
HVAC-ETC.........................................................486
Specications.................................................486
T orque.......................................................486
DescriptionandOperation.............................487
SystemComponentLayout.........................487
SystemControlDiagram.............................488
Description................................................490
ServiceProcedures.........................................492
ControlAssembly......................................492
HVAC-A TC........................................................493
Specications.................................................493
T orque.......................................................493
DescriptionandOperation.............................494
SystemComponentLayout.........................494
SystemControlDiagram.............................496
Description................................................499
Operation..................................................504
ServiceProcedures.........................................507
ControlAssembly......................................507
EvaporatorT emperatureSensor..................508
SolarLightSensor.......................................508
AmbientT emperatureSensor-ATC..............509
LeftBlendFlap-ServoMotor.....................509
HeaterCoolantT emperatureSensor...........510
RightBlendFlap-ServoMotor...................510
FreshRecirculatedAirFlap-Servo
Motor........................................................511
DistributionFlap-ServoMmotor..............511
SteeringSystem..............................513
FrontWheelSteering.......................................513
Specications.................................................513
T orque.......................................................513
Specications..............................................514
DescriptionandOperation.............................515
SystemComponentLayout.........................515
Description................................................518
Operation..................................................520
ServiceProcedures.........................................524
PressureSensor..........................................524
PowerAssistedSteeringSystem-Pressure
T est...........................................................524
PowerAssistedSteeringSystem
Bleeding.....................................................525
PowerAssistedSteeringPump....................526
PASPumpT ensioner...................................527
PowerAssistedSteeringRack.....................527
T rackRodBallJoint....................................529
Pipe-PASPumptoSteeringRack...............530
Pipe-SteeringRackT oOilCooler..............531
OilCooler-Steering..................................532
SpecialT ools..................................................533
SteeringWheelandColumn...........................534
Specications.................................................534
T orque.......................................................534
DescriptionandOperation.............................535
SystemComponentLayout.........................535
Description................................................537
ServiceProcedures.........................................538
SteeringWheelAlignment-
Adjustment................................................538
Switch-CruiseControl..............................538
SteeringColumnCover..............................539
SteeringWheel..........................................540
SteeringColumn........................................541
SwitchAssembly-SteeringColumn............542
SuspensionSystem..........................543
WheelAlignment..............................................543
Version2.05

Contents
Specications.................................................543
T orque.......................................................543
Specications..............................................544
ServiceProcedures.........................................545
WheelAlignment.......................................545
FrontSuspension...............................................546
Specications.................................................546
T orque.......................................................546
Specications..............................................547
DescriptionandOperation.............................548
SystemComponentLayout.........................548
Description................................................551
ServiceProcedures.........................................553
LowerArm-Front.......................................553
OuterBallJointBoot-FrontLower
Arm...........................................................554
BushandBracket-FrontLowerArm............555
Damper-Front............................................556
Subframe-Front..........................................558
Brace-FrontSubframe.................................560
Bush-FrontSubframe..................................560
AntiRollBar-Front.....................................561
MountingRubbers-AntiRollBar-Set............563
Link-AntiRollBar.......................................564
Hub-Front..................................................564
Bearings-FrontHub....................................566
SpecialT ools..................................................568
RearSuspension................................................571
Specications.................................................571
T orque.......................................................571
RearSuspension.........................................572
DescriptionandOperation.............................573
SystemComponentLayout.........................573
Description................................................576
ServiceProcedures.........................................578
UpperArm-Rear........................................578
BushSet-Rear-UpperArm..........................579
LowerArm-Rear........................................580
BushSet-RearLowerArm..........................581
Damper-Rear.............................................582
Spring-RearSuspension...............................582
Anti-RollBar-Rear......................................583
Rubbers-Anti-RollBar.................................583
Link-AntiRollBar.......................................584
HubBearing-Rear.......................................584
SpecialT ools..................................................586
T yresandWheels..............................................587
Specications.................................................587
T orque.......................................................587
Specications..............................................588
ServiceProcedures.........................................589
Wheel........................................................589
BrakeSystem...................................591
Brake..................................................................591
Specications.................................................591
T orque.......................................................591
DescriptionandOperation.............................592
SystemComponentLayout.........................592
Description................................................598
Operation..................................................602
ServiceProcedures.........................................608
BrakePad-Front.........................................608
BrakeDisc-Front........................................609
CaliperHousing-Front..............................610
BrakePad-Rear...........................................611
BrakeDisc-Rear.........................................612
Backplate-RearBrakeDisc..........................613
BrakeShoe-Rear.........................................613
CaliperHousing-Rear.................................614
ThicknessandRun-OutCheck-RearBrake
Disc...........................................................615
ThicknessandRun-OutCheck-FrontBrake
Disc...........................................................616
PedalBox-AutomaticT ransmission..............617
PedalBox-ManualT ransmission...................618
VacuumServo-Brake...................................620
Switch-Brake..............................................621
BrakeSystemBleeding................................622
LowLevelIndicatorSwitch-Brake
Fluid..........................................................623
MasterCylinderandFluidReservoir............623
SpecialT ools..................................................625
ParkBrake.........................................................626
Specications.................................................626
T orque.......................................................626
DescriptionandOperation.............................627
SystemComponentLayout.........................627
Description................................................628
ServiceProcedures.........................................629
Cable-Handbrake........................................629
Handbrake-Adjustment...............................630
6Version2.0

Contents
HandbrakeLever........................................631
HandbrakeFrontCable...............................632
BrakeModule.....................................................634
Specications.................................................634
T orque.......................................................634
DescriptionandOperation.............................635
SystemComponentLayout.........................635
Description................................................637
ServiceProcedures.........................................640
ABS...........................................................640
Driveline/Axle..................................641
DriveAxle..........................................................641
Specications.................................................641
T orque.......................................................641
DescriptionandOperation.............................642
SystemComponentLayout.........................642
Description................................................644
Operation..................................................645
ServiceProcedures.........................................646
RHShaft&BothJoints................................646
LHShaft&BothJoints................................647
OuterCVJoint...........................................649
OuterCVJointGaiter................................649
InnerJoint..................................................650
InnerJointGaiter.......................................650
SpecialT ools..................................................651
InteriorFitting.................................653
InstrumentPanelandConsole.........................653
Specications.................................................653
T orque.......................................................653
ServiceProcedures.........................................654
Switch-CruiseControl..............................654
PanelAssembly-FasciaClosingPanel
DriverSide.................................................655
WoodT rim-CentreConsole-Rear...........655
GloveBoxAssembly...................................656
Fascia.........................................................657
Ventilator-RH...........................................659
ConsoleAssembly......................................659
CentreBezelAssembly...............................660
PanelAssembly-SteeringColumnLower
Cover-Base..............................................661
Ventilator-LH...........................................661
Seats...................................................................662
Specications.................................................662
T orque.......................................................662
DescriptionandOperation.............................663
SystemComponentLayout.........................663
SystemControlDiagram.............................666
Description................................................667
Operation..................................................669
ServiceProcedures.........................................671
SeatComplete-Passenger..........................671
SquabFoam-Passenger-Front..................672
Cover-PassengerSquab-Front.................672
Cushion-RearSeat....................................674
Cover-Cushion-RearSeat.......................674
Squab-RearSeat.......................................675
Cover-Squab-RearSeat...........................675
Striker-Squab-RearSeat..........................676
SideBoardOuter-PowerSeat...................677
Lumbarsupportassembly-frontseat...........677
Switchpackassembly-driverseat...............678
Cover-drivercushion-front.....................678
Seatcomplete-driver................................679
Foam-driversquab-front.........................680
Cover-driversquab-front........................681
DoorT rim..........................................................683
ServiceProcedures.........................................683
PlasticSheet-RearDoor...........................683
T rimCasing-RearDoor............................683
PlasticSheet-FrontDoor..........................684
T rimCasing-FrontDoor...........................685
InteriorT rimandPaneling...............................686
Specications.................................................686
T orque.......................................................686
ServiceProcedures.........................................687
T rimFinisher-'A'Post-Upper-Each...........687
T rimFinisher-'A'Post-Lower-Each...........687
T rimFinisher-'BC'Post-Upper-
Each...........................................................688
T rimFinisher-'BC'Post-Lower-
Each...........................................................689
T rimFinisher-'D'Post-Upper-Each-
Saloon........................................................689
T rimFinisher-'D'Post-Lower-Each-
Saloon........................................................690
Handle-Grab-Each..................................690
Headlining-Sunshine/SlidingRoof-
Saloon........................................................691
Carpet-MainFloor....................................693
Version2.07

Contents
ParcelT ray-Rear-Saloon..........................694
ParcelT ray-Rear-SunBlindFitted............694
SpectaclesBox-Driver..............................696
T rimCasing-LuggageCompartment-
Sill.............................................................696
T rimFinisher-Luggage
Compartment............................................697
ExteriorFitting................................699
FixedWindows..................................................699
ServiceProcedures.........................................699
Glass-RearQuarterLight..........................699
Windscreen...............................................699
Backlight....................................................700
Bumpers,FasciasandGrille.............................701
Specications.................................................701
T orque.......................................................701
ServiceProcedures.........................................702
BumperAssembly-Front...........................702
BumperAssembly-Rear...........................703
BumperAssembly-Rear-WithPark
DistanceControlFitted..............................704
ExteriorT rimandPaneling..............................705
ServiceProcedures.........................................705
Undertray-Assembly.................................705
Liner-RearWheelArch-Each..................705
Plenum-AirIntake.....................................706
Liner-FrontWheelArch-Front-
Each...........................................................707
Mirrors................................................................708
Specications.................................................708
T orque.......................................................708
DescriptionandOperation.............................709
SystemComponentLayout.........................709
SystemControlDiagram.............................710
Description................................................711
Operation..................................................712
SystemComponentLayout.........................713
SystemControlDiagram.............................714
Description................................................715
Operation..................................................717
ServiceProcedures.........................................718
Mirror-Exterior-Electric..........................718
Mirror-Interior-Dipping..........................718
Roof.....................................................................719
Specications.................................................719
T orque.......................................................719
DescriptionandOperation.............................720
SystemComponentLayout.........................720
SystemControlSystem...............................721
Description................................................722
Operation..................................................723
ServiceProcedures.........................................724
Sun/slidingRoofAssembly...........................724
GlassPanel-Sun/SlidingRoof......................724
SunshadeAssembly-Sun/SlidingRoof...........725
WipersandWasher..........................................726
Specications.................................................726
T orque.......................................................726
DescriptionandOperation.............................727
SystemComponentLayout.........................727
SystemControlDiagram.............................729
Description................................................730
Operation..................................................732
ServiceProcedures.........................................735
Arm-Wiper-Each....................................735
MotorandLinkage-Wiper.........................735
Blade-Wiper-Each..................................736
Reservoir-Washer....................................736
Pump-Washer..........................................737
Sensor-Rain..............................................737
LightingSystems.............................739
Lighting...............................................................739
DescriptionandOperation.............................739
SystemComponentLayout.........................739
SystemControlDiagram.............................740
Description................................................741
Operation..................................................743
ServiceProcedures.........................................745
MainLightSwitch(MLS)..............................745
LampAssembly-CHMSL............................745
LampAssembly-InteriorCourtesy-
Rear...........................................................746
LampAssembly-InteriorCourtesy-
Front.........................................................746
Lamps.................................................................747
DescriptionandOperation.............................747
SystemComponentLayout.........................747
SystemControlDiagram.............................748
Description................................................749
Operation..................................................751
ServiceProcedures.........................................756
8Version2.0

Contents
Bulb-Directional-Indicator.......................756
Bulb-ReverseLamp-Saloon.......................756
Bulb-NumberPlateLamp..........................757
Bulb-RearFogLamp.................................757
Bulb-RearDI............................................758
Bulb-DipBeam.........................................758
CoverAssembly-FrontFogLamp...............759
LampAssembly-FrontFog.........................759
Headlamps-DipBeam,HighBeam.............760
HeadlampAssembly....................................760
Bulb-FrontDirectionalIndicator................761
Bulb-SideLamp.........................................761
LampAssembly-T ail..................................762
Bulb-MainBeam.......................................762
BodySystems..................................763
Doors..................................................................763
Specications.................................................763
T orque.......................................................763
DescriptionandOperation.............................764
SystemComponentLayout........................764
SystemControlDiagram.............................765
Description................................................766
Operation..................................................772
ServiceProcedures.........................................773
Handle-Outside-FrontDoor...................773
DoorAssembly-Front...............................773
Hinge-FrontDoor-Upper........................774
Hinge-FrontDoor-Lower.......................775
Door-Front-AlignonHinges...................775
PrivateLock-FrontDoor..........................776
Latch-FrontDoor.....................................776
Door-Front-AdjustonStriker.................777
Handle-Outside-RearDoor....................778
DoorAssembly-Rear................................778
Hinge-RearDoor-Upper.........................779
Hinge-RearDoor-Lower.........................780
Door-Rear-AlignonHinges....................780
Latch-RearDoor......................................781
Door-Rear-AdjustonStriker..................781
DivisionBar-QuarterLight-Rear.............782
Rubber/Felt-GlassChannel-RearDoor-
Each...........................................................783
Seal-WaistInner-RearDoor-Each...........783
Seal-WaistOuter-RearDoor-
Each...........................................................784
Glass/GlassCassetteUnit-RearDoor-
Adjust........................................................784
Glass-RearDoor-Each............................785
Switch-ElectricWindowLift-RearDoor
-Each........................................................786
MotorandControlUnit-RearDoor-
Each...........................................................787
ReleaseHandle-Interior-RearDoor-
Each...........................................................788
T rimCasing-FrontDoor...........................788
T rimCasing-RearDoor............................789
SwitchPack-ElectricWindowLiftDriver
Door.........................................................790
Rubber/Felt-GlassChannel-FrontDoor-
Each...........................................................790
Seal-WaistInner-FrontDoor-
Each...........................................................791
Seal-WaistOuter-FrontDoor-
Each...........................................................792
Glass/GlassCassetteUnit-FrontDoor-
Adjust........................................................792
Glass-FrontDoor-Each...........................793
MotorandControlUnit-FrontDoor-
Each...........................................................794
ReleaseHandle-Interior-Front
Door.........................................................795
Switch-ElectricWindowLift-FrontDoor
-Passenger.................................................795
FrontClosures...................................................796
Specications.................................................796
T orque.......................................................796
ServiceProcedures.........................................797
Fender-Front-Each..................................797
MemberFrontEndPanel............................798
Bonnet–Alignment–Checkand
Adjust........................................................799
Bonnet.......................................................800
SafetyCatch–Bonnet................................801
Lock–Bonnet............................................801
ControlCablesAssembly–Bonnet.............802
RearClosures.....................................................803
Specications.................................................803
T orque.......................................................803
ServiceProcedures.........................................804
Solenoid/Motor-FuelFillerFlap
Release......................................................804
BootLid.....................................................804
BootLid–AlignonHinges.........................805
BootLid–AlignonStriker.........................806
Version2.09

Contents
T rimCasing-BootLid................................806
Latch-BootLid.........................................807
Horns..................................................................808
Specications.................................................808
T orque.......................................................808
ServiceProcedures.........................................809
Horn-each................................................809
BodyControlModule........................................810
Specications.................................................810
T orque.......................................................810
DescriptionandOperation.............................811
BodyControlModule(BCM)Component
Location.....................................................811
BodyControlModule(BCM)Component
Location.....................................................812
Description................................................814
Operation..................................................816
ServiceProcedures.........................................817
BodyControlModule(BCM)......................817
BodyRepair.....................................819
BodyDimension................................................819
ServiceProcedures.........................................819
BasicInformation........................................819
FloorInformation...........................................820
FrontEndInformation....................................821
SideInformation.............................................822
PointtoPointDimensional
Information................................................823
SideandRoofInformation..............................824
InternalInformation.......................................825
FrontEndInformation....................................826
RearEndInformation.....................................827
UnderBodyInformation.................................828
GapInformation.........................................829
SideInformation.........................................829
FrontEndInformation................................831
RearEndInformation..................................832
FuelFlapInformation..................................833
PaintandCoatings............................................834
DescriptionandOperation.............................834
General......................................................834
CollisionRepair.................................................837
DescriptionandOperation.............................837
GeneralWeldingPrecautions......................837
BodySealing...............................................842
CorrosionPrevention.................................862
Diagnostic......................................................868
WaterLeaks...............................................868
ServiceProcedures.........................................869
FrontEndPanel..........................................870
DoorPanel................................................872
RearFloorPanel.........................................873
RoofPanel.................................................874
BodysidePanel...........................................876
FrontFloorPanel.......................................878
WheelArchPanel......................................879
SafetyandRestraints......................881
VehicleAccess....................................................881
DescriptionandOperation.............................881
AlarmandLockingSystemComponent
Layout........................................................881
AlarmandLockingSystemControl
Diagram.....................................................882
ImmobilisationSystemControl
Diagram.....................................................884
Description................................................885
SeatBelts...........................................................889
Specications.................................................889
T orque.......................................................889
DescriptionandOperation.............................890
SystemComponentLayout.........................890
SystemControlDiagram.............................893
Description................................................895
Operation..................................................903
ServiceProcedures.........................................905
AdjustableMounting-SeatBelt-BCPillar
-Each........................................................905
SeatBeltAssembly-Front-Each................905
SupplementalInatableRestraints....................906
Specications.................................................906
T orque.......................................................906
ServiceProcedures.........................................907
Airbag-Fascia-Passenger..........................907
Airbag-SteeringWheel-Driver.................908
SRSElectronicControlUnitSRS................908
CurtainAirbag-Head................................909
ParkAssistantSystem......................................910
DescriptionandOperation.............................910
SystemComponentLayout.........................910
SystemControlDiagram.............................911
Description................................................912
10Version2.0

Contents
Operation..................................................913
ServiceProcedures.........................................914
ControlUnit(ECU)-PDC.........................914
.................................................................914
Informationand
Entertainment.................................915
EntertainmentandNavigation........................915
DescriptionandOperation.............................915
ICEComponentLayout..............................915
ICE-ControlDiagram................................916
INCARENTERTAINMENT
ICE-Description.........................................917
INCARENTERTAINMENT
(ICE)-Operation.........................................921
NavigationSystemComponent
Layout........................................................922
NavigationSystemControlDiagram............923
NavigationSystem-Description....................924
NavigationSystem-Operation....................926
ServiceProcedures.........................................927
Woofer-RearDoor..................................927
Woofer-FrontDoor.................................927
Speaker-T weeter-Front...........................928
DisplaysandGages............................................929
DescriptionandOperation.............................929
SystemComponentLayout.........................929
SystemControlDiagram.............................931
Description................................................932
Operation..................................................941
ServiceProcedures.........................................942
InstrumentPack.........................................942
GlossaryList......................................................943
Version2.011

GeneralInformation
GeneralInformation
GeneralPrecautions
DangerousSubstances
Modernvehiclescontainmanymaterialsandliquidswhichifnot
handledwithcarecanbehazardoustobothpersonalhealth
andtheenvironment.
Warning:Manyliquidsandothersubstancesusedin
vehiclesarepoisonousandshouldundernocircumstances
beconsumedandshould,asfaraspossible,bekept
fromcontactwiththeskin.Theseliquidsandsubstances
includeacid,antifreeze,brakeuid,fuel,windscreen
washeradditives,lubricants,refrigerantsandvarious
adhesives.
Warning:Alwaysreadcarefullytheinstructionsprinted
onlabelsorstampedoncomponentsandobeythem
implicitly.Suchinstructionsareincludedforreasonsof
yourhealthandpersonalsafety.Neverdisregardthem.
SyntheticRubber
ManyO-rings,seals,hoses,exiblepipesandothersimilar
itemswhichappeartobenaturalrubber,areinfact,made
ofsyntheticmaterialscalledFluoroelastomers.Undernormal
operatingconditionsthismaterialissafeanddoesnotpresent
ahealthhazard.However,ifthematerialisdamagedbyre
orexcessiveheating,itcanbreakdownandproducehighly
corrosiveHydrouoricacid.
ContactwithHydrouoricacidcancauseseriousburnson
contactwithskin.Ifskincontactdoesoccur
•Removeanycontaminatedclothingimmediately.
•Irrigateaffectedareaofskinwithacopiousamountof
coldwaterorlimewaterfor15to60minutes.
•Obtainmedicalassistanceimmediately.
Shouldanymaterialbeinaburntoroverheatedcondition,
handlewithextremecautionandwearprotectiveclothing
(seamlessindustrialgloves,protectiveapronetc.).
Decontaminateanddisposeofglovesimmediatelyafteruse.
LubricatingOils
Avoidexcessiveskincontactwithusedlubricatingoilsand
alwaysadheretothehealthprotectionprecautions.
Warning:Avoidexcessiveskincontactwithusedengine
oil.Usedengineoilcontainspotentiallyharmful
contaminantswhichmaycauseskincancerorother
seriousskindisorders.
Warning:Avoidexcessiveskincontactwithmineraloil.
Mineraloilsremovethenaturalfatsfromtheskin,leading
todryness,irritationanddermatitis.
HealthProtectionPrecautions
Thefollowingprecautionsshouldbeobservedatalltimes.
•Wearprotectiveclothing,includingimperviousgloves
wherepracticable.
•Avoidprolongedandrepeatedcontactwithoils,
particularlyusedengineoils.
•Donotputoilyragsinpockets.
•Avoidcontaminatingclothes(particularlythosenextto
theskin)withoil.
•Overallsmustbecleanedregularly.Discardheavilysoiled
clothingandoilimpregnatedfootwear.
•Firstaidtreatmentshouldbeobtainedimmediatelyfor
opencutsandwounds.
•Applybarriercreamsbeforeeachworkperiodtohelp
preventlubricatingoilfromcontaminatingtheskin.
•Washwithsoapandwatertoensurealloilisremoved
(proprietaryskincleansersandnailbrusheswillhelp).
•Usemoisturisersaftercleaning;preparationscontaining
lanolinhelpreplacetheskin'snaturaloilswhichhavebeen
removed.
•Donotusepetrol/gasoline,kerosene,dieselfuel,oil,
thinnersorsolventsforcleaningskin.
•Wherepracticable,degreasecomponentspriorto
handling.
•Ifskindisordersdevelop,obtainmedicaladvicewithout
delay.
•Weareyeprotection(e.g.gogglesorfaceshield)ifthere
isariskofeyecontamination.Eyewashfacilitiesshould
beprovidedinclosevicinitytotheworkarea.
Version2.01

GeneralInformation
SafetyInstructions
Jacking
Caution:Itisbesttousetheliftwhenworkingunderthe
vehicle.Besuretoholdthewheelswithchocksandapply
parkingbrake.
Alwaysusetherecommendedjackingpoints.
Alwaysensurethatanyliftingapparatushassufcientload
capacityfortheweighttobelifted.
Ensurethevehicleisstandingonlevelgroundpriortolifting
orjacking.
Applytheparkingbrakeandchockthewheels.
Warning:Donotworkonorunderavehiclesupported
onlybyajack.Alwayssupportthevehicleonsafety
stands.
Donotleavetools,liftingequipment,spiltoil,etc.aroundor
ontheworkbencharea.Alwayskeepacleanandtidywork
area.
BrakeShoesandPads
Alwaystthecorrectgradeandspecicationofbrakelinings.
Whenrenewingbrakepadsandbrakeshoes,alwaysreplaceas
completeaxlesets.
BrakeHydraulics
Observethefollowingrecommendationswhenworkingonthe
brakesystem:
•Ensurethathosesruninanaturalcurveandarenot
kinkedortwisted.
•Ensurethathosesruninanaturalcurveandarenot
kinkedortwisted.
•Fitbrakepipessecurelyintheirretainingclipsandensure
thatthepipecannotcontactapotentialchangpoint.
•Containersusedforbrakeuidmustbekeptabsolutely
clean.
•Donotstorebrakeuidinanunsealedcontainer,itwill
absorbwaterandinthisconditionwouldbedangerous
touseduetoaloweringofitsboilingpoint.
•Donotallowbrakeuidtobecontaminatedwithmineral
oil,orputnewbrakeuidinacontainerwhichhas
previouslycontainedmineraloil.
•Donotre-usebrakeuidremovedfromthesystem.
•Alwaysusecleanbrakeuidorarecommended
alternativetocleanhydrauliccomponents.
•Afterdisconnectionofbrakepipesandhoses,
immediatelytsuitableblankingcapsorplugstoprevent
theingressofdirt.
•Onlyusethecorrectbrakettingswithcompatible
threads.
•Observeabsolutecleanlinesswhenworkingwith
hydrauliccomponents.
CoolingSystemCapsandPlugs
expansiontankcapsandcoolantdrainorbleedscrewswhen
theengineishot,especiallyifitisoverheated.T oavoid
thepossibilityofscalding,allowtheenginetocoolbefore
attemptingremoval.
Version2.02

GeneralInformation
EnvironmentalPrecautions
General
Thissectionprovidesgeneralinformationwhichcanhelpto
reducetheenvironmentalimpactsfromtheactivitiescarried
outinworkshops.
EmissionstoAir
Manyoftheactivitiesthatarecarriedoutinworkshopsemit
gasesandfumeswhichcontributetoglobalwarming,depletion
oftheozonelayerand/ortheformationofphotochemical
smogatgroundlevel.Byconsideringhowtheworkshop
activitiesarecarriedout,thesegasesandfumescanbe
minimised,thusreducingtheimpactontheenvironment.
ExhaustFumes
Runningcarenginesisanessentialpartofworkshopactivities
andexhaustfumesneedtobeventilatedtoatmosphere.
However,theamountoftimeenginesarerunningandthe
positionofthevehicleshouldbecarefullyconsideredatall
times,toreducethereleaseofpoisonousgasesandminimise
theinconveniencetopeoplelivingnearby.
Solvents
Someofthecleaningagentsusedaresolventbasedandwill
evaporatetoatmosphereifusedcarelessly,orifcansareleft
unsealed.Allsolventcontainersshouldbermlyclosedwhen
notneededandsolventshouldbeusedsparingly.Suitable
alternativematerialsmaybeavailabletoreplacesomeofthe
commonlyusedsolvents.Similarly,manypaintsaresolvent
basedandthesprayshouldbeminimisedtoreducesolvent
emissions.
Refrigerant
Dischargeandreplacementofthesematerialsfromair
conditioningunitsshouldonlybecarriedoutusingthecorrect
equipment.
Engines:
Alwaysadheretothefollowing.
•Don'tleaveenginesrunningunnecessarily;
•Minimisetestingtimesandcheckwheretheexhaust
fumesarebeingblown.
Materials:
•Keeplidsoncontainersofsolvents;
•Onlyusetheminimumquantity;
•Consideralternativematerials;
•Minimiseover-spraywhenpainting.
Gases:
•Usethecorrectequipmentforcollectingrefrigerants;
•Don'tburnrubbishonsite.
DischargestoWater
Oil,petrol,solvent,acids,hydraulicoil,antifreezeandother
suchsubstancesshouldneverbepoureddownthedrainand
everyprecautionmustbetakentopreventspillagereaching
thedrains.
Handlingofsuchmaterialsmusttakeplacewellawayfromthe
drainsandpreferablyinanareawithakerborwallaroundit,to
preventdischargeintothedrain.Ifaspillageoccursitshould
besoakedupimmediately.Havingaspillkitavailablewillmake
thiseasier.
Checklist
Alwaysadheretothefollowingdisposalandspillageprevention
instructions.
•Neverpouranythingdownadrainwithoutrstchecking
thatitisenvironmentallysafetodoso,andthatitdoes
notcontraveneanylocalregulations.
•Storeliquidsinawalledarea;
•Protectbulkstoragetanksfromvandalismbylockingthe
valves;
•T ransferliquidsfromonecontainertoanotherinanarea
awayfromopendrains;
•Ensurelidsarereplacedsecurelyoncontainers;
•Makesurethattapsonliquidcontainersaresecureand
cannotbeaccidentallyturnedon;
•Havespillkitsavailableneartopointsofstorageand
handlingofliquids.
SpillKits
Specialmaterialsareavailabletoabsorbanumberofdifferent
substances.Theycanbeingranularform,readytouseand
boughtinconvenientcontainersforstorage.Disposalofused
spill-absorbingmaterialisdealtwithin'WasteManagement'
section.
LandContamination
Oils,fuelsandsolventsetc.cancontaminateanysoilthat
theyareallowedtocontact.Suchmaterialsshouldneverbe
disposedofbypouringontosoilandeveryprecautionmustbe
takentopreventspillagereachingsoil.Wastematerialsstored
onopengroundcouldalsoleak,orhavepollutingsubstances
washedoffthemthatwouldcontaminatetheland.Always
storethesematerialsinsuitablerobustcontainers.
Checklist
Alwaysadheretothefollowing.
•Don'tpourorspillanythingontothesoilorbareground;
•Don'tstorewastematerialsonbareground,see'Spillage
prevention'list.
Version2.03

GeneralInformation
LocalIssues
Anumberofenvironmentalissueswillbeofparticularconcern
toresidentsandotherneighboursclosetothesite.The
sensitivityoftheseissueswilldependontheproximityofthe
siteandthelayoutandamountofactivitycarriedonatthesite.
Caralarmtesting,panelbeating,hammeringandothersuch
noisyactivitiesshould,wheneverpossible,becarriedout
indoorswithdoorsandwindowsshutorasfarawayfrom
housesaspossible.
Besensitivetothetimeofdaywhentheseactivitiesarecarried
outandminimisethetimeofthenoisyoperation,particularly
intheearlymorningandlateevening.
Anotherlocalconcernwillbethesmellfromthevarious
materialsused.Usinglesssolvent,paintandpetrolcouldhelp
preventthisannoyance.
Localresidentsandotherbusinessuserswillalsobeconcerned
abouttrafccongestion,noiseandexhaustfumes,besensitive
totheseconcernsandtrytominimiseinconveniencefrom
deliveries,customersandservicingoperations.
Checklist
Alwaysadheretothefollowing.
•Identifywheretheneighbourswhoarelikelytobe
affectedaresituated;
•Minimisenoise,smellsandtrafcnuisance;
•Preventlitterbydisposingofwasteinthecorrect
manner;
•Havewastecontainersemptiedregularly.
WasteManagement
Oneofthemajorwaysthatpollutioncanbereducedisbythe
carefulhandling,storageanddisposalofallwastematerialsthat
occuronsites.Thismeansthatitisnecessarytonotonlyknow
whatthewastematerialsare,butalsotohavethenecessary
documentationandtoknowlocalregulationsthatapply.
HandlingandStorageofWaste
Theyshouldbestoredinsuchawayastopreventtheescape
ofthematerialtoland,waterorair.
Theymustalsobesegregatedintodifferenttypesofwaste
e.g.oil,metals,batteries,usedvehiclecomponents.Thiswill
preventanyreactionbetweendifferentmaterialsandassistin
disposal.
DisposalofWaste
Disposalofwastematerialsmustonlybetowastecarrierswho
areauthorisedtocarrythoseparticularwastematerialsand
haveallthenecessarydocumentation.Thewastecarrieris
responsibleforensuringthatthewasteistakentothecorrect
disposalsites.
Disposeofwasteinaccordancewiththefollowingguidelines.
•Fuel,hydraulicuid,anti-freezeandoil:keepseparate
anddisposeoftospecialistcontractor.
•Refrigerant:collectinspecialistequipmentandreuse.
•Detergents:safetopourdownthefouldrainifdiluted.
•Paint,thinners:keepseparateanddisposeoftospecialist
contractor.
•Components:sendbacktosupplierforrefurbishment,
ordisassembleandreuseanysuitableparts.Disposeof
theremainderinordinarywaste.
•Smallparts:reuseanysuitableparts,disposeofthe
remainderinordinarywaste.
•Metals:canbesoldifkeptseparatefromgeneralwaste.
•T yres:keepseparateanddisposeoftospecialist
contractor.
•Packaging:compactasmuchaspossibleanddisposeof
inordinarywaste.
•asbestosmaterialkeepseparateanddisposeofto
specialistcontractor.
•Oilyandfuelwastes(e.g.rags,usedspillkitmaterial):
keepseparateanddisposeoftospecialistcontractor.
•Airlters:keepseparateanddisposeoftospecialist
contractor.
•Rubber/plastics:disposeofinordinarywaste.
•Hoses:disposeofinordinarywaste.
•Batteries:keepseparateanddisposeoftospecialist
contractor.
•Airbags-explosives:keepseparateanddisposeofto
specialistcontractor.
•Electricalcomponents:sendbacktosupplierfor
refurbishment,ordisassembleandreuseanysuitable
parts.Disposeoftheremainderinordinarywaste.
•Catalysts:canbesoldifkeptseparatefromgeneralwaste
•Usedspill-absorbingmaterial:keepseparateanddispose
oftospecialistcontractor.
Version2.04