Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1/Place vehicle on ramp or axle stands. Open Bonnet/Hood. Remove the 4xT20 torx screws from the top edge of the bumper. Remove the T20 torx screw within each wheelarch. Remove the 2×10mm bolts and the 4 plastic clips that retain the lower edge of the bumper. Remove the front sections of both front wheelarch liners by removing the plastic retaining clips. Once the arch liners are loose you can gain access to the 2×10mm bolts each side that retain the bumper to the front wing/fender. Disconnect the fog light connections either side and lift the whole front bumper section clear. See pictures below. 2/ Remove the plastic grille on the upper right of the engine bay by turning the 2 slots through 90 degrees to the right. Remove both complete headlamps, these are retained by 3×10mm screws and the single electrical connection to each headlight. 3/ Remove the 2×13mm bolts at the top of the radiator panel as shown below. Loosen the 2x hose clips at the top of the convoluted hoses from the intercooler. Completely remove the 2 plastic air pipes located on top of the engine (the 2 leading to the intercooler hoses) by removing the 2×10mm bolts that retain each pipe. Remove the single air conditioning pipe bracket on the lower left as you look at the front of the car (see picture below). Push the top intercooler retaining clip through the radiator panel so the top edge of the intercooler is free. Disconnect the single electrical connection to the intercooler fan system. Remove the crash bar by removing the 6×13mm bolts. Lift the radiator panel slightly upwards and forwards so it is free from the locators. Now lift the intercooler upwards and o ut from the engine bay (you may need help here to lift both the radiator panel and the intercooler from its location at the same time) Be careful not to damage the small bore water overflow pipes that run just behind the intercooler.

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1. Remove both front wheels from the car. 2. Unclip the hard plastic breather hose from the breather nipple by squeezing the blue retaining clip. 3. Lift up and remove the steel bracket securing the purge solenoid valve (PSV) to the inlet hose. Leave the PSV attached to the valve and move it out of the way. 4. Unplug the MAF sensor from the wiring harness. 5. Unclip the MAF sensor wiring harness from the side of the air filter housing 6. Loosen the hose clamps securing the inlet hose to the throttle body and the air filter housing. Remove the inlet tube.(View B, #5) 7. Remove the air filter housing lid (View B, #1) by unhooking the metal retaining clips and sliding the lid out. 8. Remove the air filter element (View B, #2). 9. Remove the lower air filter housing (View B, #3) by removing the two nuts securing the housing to the chassis. Next, lift up on the back side of the housing and remove it from the vehicle. 10. Remove the retaining clips and bolts securing the driver and passenger side splash shields to the bumper and chassis. Remove the splash shields. 11. Disconnect the front fog light connectors for vehicles equiped with fog lights. 12. Disconnect the side marker light connectors. View C: Bumper Removal / Installation 13. Remove the parts in the order indicated in Table A: 14. Remove the fresh air duct by removing the two plastic clips and the bolt securing it to the chassis (View B,#6). 15. Remove the plastic fasteners (View D, #1) securing the plastic shroud seal plate (View D, #2) between the steel bumper support (View D, #4) and the chassis. 16. Unhook the wiring harness from the horn and unclip it (View D, #3) from the bumper support. 17. Remove the 8 bolts securing the bumper support to 7.8-11.8 the chassis. Remove the bumper support. {80-120, 18. Remove the stock MAF sensor from the air filter 70-104} housing lid (View B, #1). 19. Remove the plastic breather nipple, spring clamp, and two hose clamps from the stock inlet hose. 1. Install the plastic breather hose nipple (View E, #2) removed in step #18 into the supplied throttle body coupler (View E, #3) and secure using the stock spring clamp (See View F). 2. Install the two hose clamps removed in step #18 (View B) onto the supplied throttle body coupler. Install the coupler onto the throttle body. Do not tighten hose clamp. 3. Install the steel PSV bracket (View E, #1) from the stock inlet tube by sliding it into the mount on the throttle body coupler. Be sure bracket is fully seated at top guide pin. 4. Plug the plastic breather hose onto the nipple. Be sure both the breather hose and PSV bracket are secure before proceeding. 5. Install the MAF sensor into the upper intake pipe (View E, #4) and secure using the two supplied 8-32 bolts (View E, #5). Torque the bolts to 12-15 in-lbs (1.4-1.7 N-m).

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1 STOCK INTAKE REMOVAL 1. Start by removing the engine cover. Gently lift up at the base then pull the cover towards the front of the car. 2. Remove the strut tower brace. 3. Remove the three hoses attached to the inlet tube secured to the throttle body (View B, #1). 4. Loosen hose clamp at the throttle body and the air box (View B). Then remove the inlet tube. 5. Unplug the MAF sensor and the wire mount. 6. Gently pull up on air box, but do not completely remove. Unplug the vaccum soloniod (View B, #3) and the vacuum line attached to it. 7. Disconnect the vacuum line (View B) from the intake manifold (View B, #8). 8. Unclasp and remove the vacuum assembly from the air box (View B, #3 & #4). Unclip the wire mount from the air box. STOCK INTAKE REMOVAL (CONTINUED) #1: Inlet Air Hose Stock MAF Sensor #2: Air Filter Housing Lid Location #3: VFAD Solenoid Valve #4: Vacuum Chamber #5: Air Filter Element #6: Lower Air Filter Housing #7: Fresh Air Duct #8: Intake Manifold 9. Lift up and gently remove the air box from the vehicle (View B, #2, #5, & #6) 10. Remove both front wheels to access the fender liners for bumper removal. 11. Disconnect the front fog light connectors for vehicles equiped with fog lights. 12. Remove the front side marker lights. 13. Remove the parts in the order indicated in Table A. 14. Remove the fresh air duct and vacuum assembly by removing the three plastic clips and the bolt securing it to the chassis (View B,#7). 15. Remove the fasteners (View D, A) securing the energy-absorbing foam (View D, #2) to the steel bumper support (View D, #1). 16. Remove the fasteners (View D, B) securing the front bumper retainer (View D, #3) between the steel bumper support (View D, #1) and the chassis. 17. Remove the 8 bolts (View D) securing the bumper support to the chassis and remove the bumper support. 18. Remove the stock MAF sensor from the air filter housing lid (View B, #2).

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1. Disconnect the negative battery cable. 2. Disconnect the front fog light connector. 3. To remove the bumper reinforcement, remove the front bumper and washer tank, then remove the bumper reinforcement installation nuts. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the front fog light aiming. (See FRONT FOG LIGHT ADJUSTMENT .) FRONT BUMPER REMOVAL NOTE 1. While supporting the connection between the front bumper and bracket, pull the front bumper forward to disengage the connection. NOTE: The connection between the front bumper and bracket does not disengage until the front bumper is pulled forward. Be sure to pull the front bumper forward to disengage it from the bracket. 2. Remove the front bumper.

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Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 – Auxiliary Emergency Flasher Relay (404) 2 – Relay for Motor Remote Unlock Rear Lid (79) 3 – Starting Interlock Relay (53) (185) (465) 4 – Fog Light Relay (53) 5 – Control Module for Multi-function Steering Wheel (450) 6 – Control Module for Multi-function Steering Wheel (450) 7 – Daytime Running Lights Change-over Relay (173), from April 1999 8 – Daytime Running Lights Change-over Relay (173), through March 1999 9 – Dual Horn Auxiliary Relay (53) 10 – Glow Plug Relay (180) 10 – Warning Lamp Auxiliary Relay (200) 11 – Park/Neutral Position (PNP) Relay (175) 12 – Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 – Dual Horn Relay (53) 2 – Load Reduction Relay (18) (100) 4 – Fuel Pump (FP) Relay (409) V – Wiper/Washer Intermittent Relay (192) (377) (389) VI – Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing.