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Lee

Posted: Sun Apr 17, 2011 11:48 am

Joined: Feb 07, 2010
Posts: 13077
Trade Rating: +65
Location: England

Build code / RPO / DAM number

ABS/Brakes
Affected vehicles
All models, DAM 09079?.
Problem
Squeal from front brakes.
Cause
Pads vibrate in caliper.
Remedy
Fit modified front pads and shims.

Airbag/SRS - Body - Electrical -Steering
Affected vehicles
All models, ?05/09/05 (RPO 10528).
Problem
Airbag warning lamp illuminates permanently or intermittently.
Cause
Airbag spiral cable faulty.
Remedy
Inspect production date code on steering column function control module. If production date before 27/05/05, replace steering column function control module.
NOTE: Airbag spiral cable is integral to steering column function control module.

Body - Driveability - Electrical -Engine management -Starting and charging
Affected vehicles
All models, 03/09/01? (RPO 9064).
Problem
Engine stalls when switching on headlamps.
Cause
Poor earth connection for engine management system.
Remedy
Check and clean earth terminals located behind both headlamps.
Ensure good earth contact.

Clutch - Noise, vibration and harshness
Affected vehicles
All models.
Problem
Clutch judder on engagement of clutch when pulling away at 2000 rpm.
Cause
Faulty clutch pressure plate.
Remedy
Replace clutch pressure plate.

Driveability - Electrical -Starting and charging
Affected vehicles
All models with quick-release battery terminals.
Problem
Failure to start.
Battery discharged.
Cause
Battery terminal(s) incorrectly fitted.
Remedy
Ensure battery terminals fitted correctly Fig.1. Repair as necessary.
NOTE: Correctly fitted battery terminal(s) should be flush with the top of the battery post Fig.1.Fig.118925

Driveability - Electrical -Starting and charging
Affected vehicles
All models, 01/06/98-02/09/01 (RPO 7875-9064).
Problem
Engine will not start.
Cause
Multifunction control module software fault. Transponder key not recognised.
Remedy

Obtain and reprogram all keys.
If programming unsuccessful, renew multifunction control module.

Driveability - Drivetrain -Engine management - Engine mechanical - Noise, vibration and harshness - Transmission
Affected vehicles
All models.
Problem
Juddering whilst driving in 1st gear with engine at idle speed.
Cause
Incorrect engine management parameters stored in engine control module (ECM).
Faulty engine/transmission mounting(s).
Remedy
Check and adjust engine management parameters using suitable diagnostic equipment.
Check engine/transmission mountings. Replace component(s) as necessary.

Electrical
Affected vehicles
All models.
Problem
Bulbs blown.
Several trouble codes stored.
Instrument panel gauges fluctuate.
Instrument panel warning lamps illuminate at random.
Cause
Alternator voltage output high.
Remedy

NOTE: Alternator harness may require modified connector to fit alternator terminal.
Fit modified alternator.

Electrical - Engine management - Starting and charging
Affected vehicles
All models with engine management relay module (RM).
Problem
Failure to start.
Cause
Corrosion to harness multi-plug connector pins, located between engine bay fuse box and engine management relay module Fig.1.
Remedy
Repair harness multi-plug connector.
Fig.113468

Electrical
Affected vehicles
All models with software version 19, 20, 22, 23, 24, 25, DAM 09065-09394 (09/01-07/02).
Problem
Fuel tank empty, but gauge reads 1/4 full.
Low fuel warning lamp NOT illuminated.
Cause
Instrumentation control module receiving incorrect data from engine control module (ECM) when vehicle used for short journeys with frequent stops.
Remedy
NOTE: Upgraded software installed DAM 09395 XX?.
Install upgraded software, version 27.

Electrical - Starting and charging
Affected vehicles
All models.
Problem
Intermittent failure to start.
Non start.
Cause
Ignition switch contacts damaged.
Remedy

Carry out diagnostic check to confirm fault.
Replace ignition switch if faulty.

Engine cooling - Engine mechanical
Affected vehicles
All models.
Problem
Engine overheating.
Cause
Coolant pump impeller broken off.
Remedy
Replace coolant pump.

Engine management
Affected vehicles
All models with DW engine.
Problem
Engine malfunction indicator lamp (MIL) illuminated.
Trouble code stored in engine control module (ECM) fault memory: P1641.
Battery discharges.
Cause
Engine coolant travelling by capillary action into engine control module (ECM) wiring harness from yellow 2-pin engine coolant temperature (ECT) switch connector Fig.1 [1] .
Engine control module (ECM) failure due to water ingress.
Remedy

Fit new engine wiring harness.
Disconnect yellow 2-pin engine coolant temperature (ECT) switch connector Fig.1 [1] . Insulate using dummy connector Fig.1 [2] .
Fit new engine control module (ECM).
Fig.105574

Suspension
Affected vehicles
All models.
Problem
Knocking from front suspension.
Cause
Worn ball joints on anti-roll bar link rods.
Remedy

NOTE: Original link rod ball joints 19 mm, modified link rod ball joints 16 mm.
Fit modified anti-roll bar link rods.

NOTE: There are more, and I'll update them when I get time, as I have to go thru every engine

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