" • 1: General Information pag. 20 • 2: Chassis pag. 77 • 3: Powertrain pag. 269 # 4: Electrical pag. 816 # 5: Body and Paint pag. 985
$ 1: General Information pag. 20 ! 100: Service Information " 100-00: General Information " Description and Operation " How To Use This Manual " Important Safety Instructions " General Service Information " Standard Workshop Practices " Health and Safety Precautions " Special Tool Glossary " 100-01: Identification Codes " Description and Operation " Identification Codes " 100-02: Jacking and Lifting " Description and Operation " Vehicle Recovery " Jacking " Lifting " 100-03: Maintenance Schedules " Description and Operation " Maintenance Schedules - Diesel Engines • • • 2: Chassis pag. 77 ! 204: Suspension " 204-00: Suspension System - General Information " Specification " General Procedures " Front Toe Adjustment " " 204-01: Front Suspension " Description and Operation " Front Suspension " Removal and Installation " Front Stabilizer Bar " Front Stabilizer Bar Link " Panhard Rod " Spring " Front Wheel Bearing and Wheel Hub " Wheel Studs " Front Shock Absorber " Bump Stop " Radius Arm " " 204-02: Rear Suspension " Description and Operation " Rear Suspension " Removal and Installation " Wheel Bearing and Wheel Hub " Spring " Wheel Studs
% " Rear Stabilizer Bar " Rear Shock Absorber " Rear Stabilizer Bar Link " Upper Arm " Lower Arm " Axle Bump Stop " " 204-04: Wheels and Tires " Specification " Description and Operation " Wheels and Tires " Removal and Installation " Wheel and Tire " " 204-05: Vehicle Dynamic Suspension " Removal and Installation " Rear Air Shock Absorber " ! 205: Driveline " 205-01: Driveshaft " Description and Operation " Driveshaft " Removal and Installation " Front Driveshaft " Rear Driveshaft " Disassembly and Assembly " Driveshaft Universal Joint " " 205-02: Rear Drive Axle/Differential " Specification " Description and Operation " Rear Drive Axle and Differential " Diagnosis and Testing " Rear Drive Axle and Differential " In-Vehicle Repair " " Removal and Installation " Axle Assembly " Disassembly and Assembly " " 205-03: Front Drive Axle/Differential " Specification " Description and Operation " Front Drive Axle and Differential " Diagnosis and Testing " Front Drive Axle " In-Vehicle Repair " " Removal and Installation " Axle Assembly " Differential Carrier
& " Disassembly and Assembly " Front Stub Axle, Constant Velocity (CV) Joint and Swivel Pin Housing " ! 206: Brake System " 206-00: Brake System - General Information " Specification " Description and Operation " Brake System " General Procedures " Brake System Bleeding " " 206-03: Front Disc Brake " Removal and Installation " Brake Disc " Brake Pads " Brake Caliper " " 206-04: Rear Disc Brake " Removal and Installation " Brake Disc " " 206-05: Parking Brake and Actuation " General Procedures " Parking Brake Shoe and Lining Adjustment " Removal and Installation " Parking Brake Cable " Shoes " Parking Brake Switch " " 206-06: Hydraulic Brake Actuation " Removal and Installation " Brake Master Cylinder " Brake Pedal and Bracket " Brake Pressure Control Valve " Disassembly and Assembly " Brake Master Cylinder " " 206-07: Power Brake Actuation " Specification " Removal and Installation " Brake Booster " Brake Booster Non-Return Valve " Brake Vacuum Pump " " 206-09: Anti-Lock Control - Traction Control " Diagnosis and Testing " Anti-Lock Control - Traction Control " Removal and Installation " Anti-Lock Brake System (ABS) Module " Hydraulic Control Unit (HCU)
' " Front Wheel Speed Sensor " Rear Wheel Speed Sensor " ! 211: Steering System " 211-00: Steering System - General Information " Specification " Description and Operation " Steering System " Diagnosis and Testing " Steering System " General Procedures " Power Steering System Filling and Bleeding " Power Steering System Flushing " Steering Gear Adjustment " Steering Gear Centralization " Steering Lock Stop Adjustment " " 211-02: Power Steering " Specification " Description and Operation " Power Steering " Removal and Installation " Steering Gear " Power Steering Fluid Reservoir " Power Steering Pump " Disassembly and Assembly " Steering Gear " " 211-03: Steering Linkage " Removal and Installation " Tie Rod End " Steering Linkage Damper " Sector Shaft Arm Drag Link " Steering Gear Drop Arm " " 211-04: Steering Column " Removal and Installation " Steering Column " Steering Column Lower Shaft " Steering Wheel " " 211-05: Steering Column Switches " Description and Operation " Steering Column Switches " Removal and Installation " Ignition Switch " Steering Column Lock and Ignition Switch Housing " Steering Column Multifunction Switch RH " Steering Column Multifunction Switch LH
( • 3: Powertrain pag. 269 • ! 303: Engine ! " 303-00: Engine System - General Information " General Procedures " Bearing Inspection " Camshaft Bearing Journal Clearance " Camshaft Bearing Journal Diameter " Camshaft End Play " Camshaft Lobe Lift " Camshaft Surface Inspection " Connecting Rod Cleaning " Connecting Rod Large End Bore " Crankshaft End Play " Cylinder Bore Out-of-Round " Cylinder Head Distortion " Cylinder Block Distortion " Exhaust Manifold Cleaning and Inspection " Piston Inspection " Piston Pin Diameter " Piston Pin to Bore Diameter " Piston Ring End Gap " Piston Ring-to-Groove Clearance " Valve Spring Free Length " Valve Stem Diameter " " 303-01: Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Engine " Diagnosis and Testing " Engine " General Procedures " Engine Oil Draining and Filling " In-Vehicle Repair " Camshafts " Crankshaft Pulley " Crankshaft Front Seal " Crankshaft Rear Seal " Cylinder Head " Engine Mount LH " Engine Mount RH " Exhaust Manifold " Flywheel " Intake Manifold " Oil Cooler " Oil Filter Housing " Oil Pan " Oil Pump " Rocker Arm
) " Timing Cover " Timing Chain " Valve Cover " Removal " Engine " Disassembly " Engine " Assembly " Engine " Installation " Engine " " 303-03: Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Engine Cooling " Diagnosis and Testing " Engine Cooling " General Procedures " Cooling System Draining, Filling and Bleeding " Cooling System Draining and Vacuum Filling " Removal and Installation " Coolant Expansion Tank " Cooling Fan " Cooling Fan Shroud " Coolant Pump " Radiator " Thermostat " " 303-04A: Fuel Charging and Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Fuel Charging and Controls " Diagnosis and Testing " Fuel Charging and Controls " General Procedures " Fuel Injection Component Cleaning " Removal and Installation " Fuel Injector " Fuel Injection Pump " Fuel Metering Valve " Fuel Pressure Relief Valve " Fuel Rail " " 303-04B: Fuel Charging and Controls - Turbocharger - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Turbocharger
* " Diagnosis and Testing " Turbocharger " Removal and Installation " Turbocharger " " 303-05: Accessory Drive - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Accessory Drive " Diagnosis and Testing " Accessory Drive " Removal and Installation " Accessory Drive Belt " Accessory Drive Belt Idler Pulley " Accessory Drive Belt Tensioner " Accessory Drive Component Bracket " " 303-06: Starting System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Starting System " Diagnosis and Testing " Starting System " Removal and Installation " Starter Motor " " 303-07: Glow Plug System - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Glow Plug System " Diagnosis and Testing " Glow Plug System " Removal and Installation " Glow Plug " " 303-08: Engine Emission Control - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Engine Emission Control " Diagnosis and Testing " Engine Emission Control " Removal and Installation " Exhaust Gas Recirculation (EGR) Cooler " Exhaust Gas Recirculation (EGR) Valve " " 303-12: Intake Air Distribution and Filtering - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma
+ " Specification " Description and Operation " Intake Air Distribution and Filtering " Diagnosis and Testing " Intake Air Distribution and Filtering " Removal and Installation " Air Cleaner " Air Cleaner Element " Air Cleaner Outlet Pipe " Charge Air Cooler " " 303-14: Electronic Engine Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Electronic Engine Controls " Diagnosis and Testing " Electronic Engine Controls " Removal and Installation " Accelerator Pedal Position (APP) Sensor " Camshaft Position (CMP) Sensor " Crankshaft Position (CKP) Sensor " Cylinder Head Temperature (CHT) Sensor " Engine Control Module (ECM) " Engine Oil Pressure (EOP) Sensor " Manifold Absolute Pressure and Temperature (MAPT) Sensor " Mass Air Flow (MAF) Sensor ! ! 308: Manual Transmission/Transaxle, Clutch and Transfer Case " " 308-00: Manual Transmission/Transaxle and Clutch - General Information " General Procedures " Clutch System Bleeding " Clutch Pedal Freeplay Adjustment " " 308-01: Clutch - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Clutch - Vehicles With: 6-Speed Manual Transmission - MT82 " Removal and Installation " Clutch Disc and Pressure Plate " Pilot Bearing " " 308-02: Clutch Controls - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma " Specification " Description and Operation " Clutch Controls - Vehicles With: 6-Speed Manual Transmission - MT82
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