ROADSTER SERVICE MANUAL

Build 20180918_1350

Build 20180918_1350

  • SERVICE MANUAL 8
    • INTRODUCTION
    • GENERAL INFORMATION
    • CHARGING
    • TECHNICAL DATA
    • SPECIAL TOOLS
    • IDENTIFICATION NUMBERS
    • LIFTING AND JACKING
    • CAPACITIES, FLUIDS, AND LUBRICANTS
  • 10 - BODY 9
    • 1001 - Body Panels 9
      • CHIN SPOILER ASSEMBLY
      • BUMPER ASSEMBLY - FRONT
      • FENDER ASSEMBLY - FRONT - LH
      • BUMPER ASSEMBLY - REAR
      • PANEL - DECKING
      • ARMATURE ASSEMBLY - BUMPER - FRONT - ROADSTER 1.5
      • DIFFUSER TRIM - REAR
      • TRUNK ASSEMBLY - ROADSTER 1.5
      • TRUNK ASSEMBLY - ROADSTER 2.X
    • 1004 - Crash Structures 1
      • RAISE VEHICLE ON 2 POST LIFT
    • 1005 - Air Ducting 6
      • CONDENSER - INLET DUCT - LOWER - FRONT - ROADSTER 1.5
      • CONDENSER - INLET DUCT - LOWER - FRONT - ROADSTER 2.X
      • CONDENSER - INLET DUCT - UPPER - FRONT - ROADSTER 1.5
      • CONDENSER - INLET DUCT - UPPER - FRONT - ROADSTER 2.X
      • CONDENSER - EXIT DUCT - HOOD - FRONT
      • CONDENSER - EXIT DUCT - HOOD - REAR
    • 1009 - Access Panel/Hood Assembly 2
      • HOOD ASSEMBLY
      • HINGE - HOOD - LH
    • 1011 - Trunk Cover & Latch Mechanism 5
      • STRUT - TRUNK LID
      • LATCH - TRUNK LID - LH
      • CABLE - TRUNK LID RELEASE - LH
      • HINGE - TRUNK LID - LH
      • TRUNK LID ASSEMBLY
    • 1015 - Door Shells & Beams 7
      • DOOR BEAM ASSEMBLY - LH
      • DOOR ASSEMBLY - LH - ROADSTER 1.5
      • DOOR ASSEMBLY - LH - ROADSTER 2.X
      • DOOR ASSEMBLY - RH - ROADSTER 1.5
      • HINGE - DOOR - LH
      • BEARING - HINGE - DOOR - LH
      • SPRING PLATE - DOOR CHECK - LH
    • 1017 - Door Latches 5
      • LATCH - DOOR - LH
      • LOCK BARREL - EMERGENCY RELEASE - LH
      • HANDLE - INTERIOR RELEASE - DOOR - LH
      • MOULDING - DOOR SWITCH - EXT - LH
      • STRIKER - DOOR - LH
    • 1020 - Roll Hoop Cover 1
      • ROLL HOOP COVER ASSEMBLY
    • 1025 - Undertray & Diffuser 4
      • PANEL - UNDERSHIELD - FRONT
      • PANEL - UNDERSHIELD - MIDDLE
      • PANEL - DIFFUSER TRAY - REAR
      • TRIM - DIFFUSER TRAY - LH
  • 11 - GLAZING 2
    • 1101 - Windscreen, Rear Screen & Door Glass 3
      • DOOR GLASS - LH - ADJUST
      • DOOR GLASS - LH
      • SEAL - DOOR GLASS - LH
    • 1102 - Door Window Lift Mechanisms 2
      • WINDOW GUIDE RAIL - REAR - LH
      • WINDOW MOTOR/REGULATOR ASSEMBLY - LH
  • 12 - EXTERIOR FITTINGS 2
    • 1201 - Wheel Arch Liners 5
      • WHEEL ARCH LINER - UPPER - FRONT - LH
      • WHEEL ARCH LINER - REAR - LH
      • WHEEL ARCH LINER - LOWER - FRONT - LH
      • WHEEL ARCH LINER - FORWARD - REAR - LH
      • MUDFLAP - LEADING EDGE - FRONT - LH
    • 1209 - Exterior Mirrors 1
      • GLASS - DOOR MIRROR - LH
  • 13 - SEATS AND SEATBELTS 2
    • 1302 - Seat Assemblies 3
      • SEAT ASSEMBLY - DRIVER
      • SEAT ASSEMBLY - PASSENGER - ROADSTER 1.5
      • SEAT ASSEMBLY - PASSENGER - ROADSTER 2.X
    • 1327 - Seat Belts 2
      • SEAT BELT REEL ASSEMBLY - DRIVER
      • SEAT BELT BUCKLE - DRIVER
  • 14 - PEDAL BOX AND DASH 3
    • 1401 - Pedal Box 2
      • SWITCH - BRAKE LIGHT
      • THROTTLE ASSEMBLY
    • 1405 - Dash Board 3
      • TRIM - DASH PANEL - UPPER
      • SHROUD - STEERING COLUMN - LOWER
      • SHROUD - STEERING COLUMN - UPPER
    • 1410 - Instrument Cowling 1
      • TRIM - INSTRUMENT PACK
  • 15 - INTERIOR TRIM 5
    • 1511 - Rear Bulkhead & Storage 2
      • FINISHER - REAR WINDOW - UPPER
      • TRIM - B-PILLAR - LH
    • 1513 - Door Trim 4
      • PANEL - DOOR TRIM - DRIVER - FOR ACCESS
      • PANEL - DOOR TRIM - DRIVER
      • PANEL - DOOR INSERT - LH
      • PULL HANDLE - DOOR - LH
    • 1518 - Interior Trim, Chassis Trim 5
      • TRIM - SILL PANEL - LH
      • TRIM - DASH - LH
      • TRIM - DASH - RH
      • TRIM - TOUCH SCREEN
      • STORAGE BIN - LOWER
    • 1519 - Center Tunnel Trim 6
      • TRIM - CENTER CONSOLE - LOWER
      • TRIM - CENTER CONSOLE - ROADSTER 1.5
      • TRIM - CENTER CONSOLE - ROADSTER 2.X
      • TRIM - POWER SOCKET - ROADSTER 1.5
      • TRIM - POWER SOCKET - ROADSTER 2.X
      • TRIM - CENTER CONSOLE - REAR
    • 1530 - Carpeting & Mats 4
      • CARPET - FOOTWELL - LH - ROADSTER 1.5
      • CARPET - FOOTWELL - LH - ROADSTER 2.X
      • CARPET - BULKHEAD
      • CARPET - SILL - LH
  • 16 - BATTERY SYSTEM 1
    • 1601 - Battery Assembly 3
      • VEHICLE ELECTRICAL ISOLATION PROCEDURE
      • BATTERY ASSEMBLY
      • BATTERY ASSEMBLY - ROADSTER 2.X
  • 17 - ELECTRICAL 12
    • 1701 - Harnesses 3
      • CABLE - HIGH VOLTAGE - PEM TO MOTOR - ROADSTER 1.5
      • CABLE - HIGH VOLTAGE - PEM TO MOTOR - ROADSTER 2.X
      • CABLE - HIGH VOLTAGE - CHARGE PORT TO PEM
    • 1703 - Modules, Fuses, Inertia Switch & Horn 13
      • HORN
      • MODULE - RADIATOR FAN CONTROL
      • MODULE - HOMELINK TRANSMITTER
      • RECEIVER - REMOTE KEYLESS ENTRY (RKE) / IMMOBILIZER - ROADSTER 1.5
      • RECEIVER - REMOTE KEYLESS ENTRY (RKE) / IMMOBILIZER - ROADSTER 2.X
      • TRANSMITTER - REMOTE KEYLESS ENTRY (RKE) - REPLACE / REPROGRAM
      • SWITCHPACK
      • MODULE - HVAC - 12V CONTROLLER - ROADSTER 1.5
      • MODULE - HVAC - 12V CONTROLLER - ROADSTER 2.X
      • MAXI FUSE - UNDER DASH
      • SWITCH - INERTIA
      • MODULE - WIPER DELAY
      • RELAY - HORN
    • 1704 - Vehicle Management 5
      • MODULE - VEHICLE MANAGEMENT SYSTEM (VMS) - ROADSTER 1.5
      • MODULE - VEHICLE MANAGEMENT SYSTEM (VMS) - ROADSTER 2.X
      • MODULE - GPS RECEIVER
      • MODULE - TRANSMISSION CONTROL - ROADSTER 1.5
      • MODULE - TRANSMISSION CONTROL - ROADSTER 2.X
    • 1705 - Interior Switches & Aux Power Socket 18
      • COLUMN SWITCH - HIGH BEAM/TURN/CRUISE
      • COLUMN SWITCH - WASH/WIPE
      • POWER SOCKET - ROADSTER 1.5
      • POWER SOCKET - ROADSTER 2.X
      • SWITCH - STARTER
      • SWITCH - EXTERIOR LIGHTING - ROADSTER 1.5
      • SWITCH - EXTERIOR LIGHTING - ROADSTER 2.X
      • SWITCH - TRUNK RELEASE - ROADSTER 1.5
      • SWITCH - TRUNK RELEASE - ROADSTER 2.X
      • SWITCH - INSTRUMENT PANEL - DIMMER - ROADSTER 1.5
      • SWITCH - INSTRUMENT PANEL - DIMMER - ROADSTER 2.X
      • SWITCH - CENTRAL LOCKING
      • SWITCH - TRACTION CONTROL - ROADSTER 1.5
      • SWITCH - TRACTION CONTROL - ROADSTER 2.X
      • SWITCH - WINDOW LIFT - DRIVER
      • SWITCH - SEAT HEATER
      • SWITCH - REAR FOG LAMP
      • SWITCH - GLOVE BOX
    • 1706 - Air Bags 6
      • DRIVER AIRBAG
      • CLOCKSPRING - AIRBAG
      • MODULE - AIRBAG
      • PASSENGER AIRBAG
      • COVER - PASSENGER AIRBAG
      • COVER CLIPS - PASSENGER AIRBAG
    • 1707 - Instrument Panel Lights 3
      • VEHICLE - TOUCH SCREEN - ROADSTER 1.5
      • VEHICLE - TOUCH SCREEN - ROADSTER 2.X
      • INSTRUMENT PACK
    • 1711 - Exterior Lights (excluding Headlights) 5
      • TAIL LIGHT ASSEMBLY - LH
      • LAMP - BRAKE - HIGH MOUNTED
      • LIGHT - LICENCE PLATE
      • LAMP - SIDE MARKER - FRONT - LH
      • LAMP - SIDE MARKER - REAR - LH
    • 1713 - Headlights 7
      • HEADLIGHT - ADJUST
      • HEADLIGHT ASSEMBLY - LH
      • HEADLIGHT ASSEMBLY - RH
      • BULB - LOW BEAM
      • BULB - HIGH BEAM
      • BULB - SIDE LIGHT
      • BULB - TURN SIGNAL
    • 1717 - Interior Lamps 1
      • LIGHT - TRUNK ASSEMBLY
    • 1721 - Wiper & Washers 4
      • WIPER MOTOR ASSEMBLY - ROADSTER 1.5
      • WIPER MOTOR ASSEMBLY - ROADSTER 2.X
      • PUMP - WINDSHIELD WASHER RESERVOIR
      • RESERVOIR - WINDSHIELD WASHER
    • 1727 - Audio System 7
      • AMPLIFIER - AUDIO SYSTEM - ROADSTER 1.5
      • AMPLIFIER - AUDIO SYSTEM - ROADSTER 2.X
      • AMPLIFIER - AUDIO SYSTEM - ROADSTER 2.X RHD
      • SPEAKER - DASH - LH/RH
      • SPEAKER - DOOR - LH/RH
      • SPEAKER - REAR - LH/RH
      • HEAD UNIT - AUDIO SYSTEM
    • 1733 - Alarm 1
      • SWITCH - TELESCOPIC FRONT/REAR
  • 18 - HEATING, VENTILATION, AIR CONDITIONING (HVAC) 6
    • 1801 - HVAC 6
      • ACTUATOR - HEATER/AC FLAPS - ROADSTER 1.5
      • ACTUATOR - HEATER/AC FLAPS - ROADSTER 2.X
      • HVAC ASSEMBLY - ROADSTER 1.5
      • HVAC ASSEMBLY - ROADSTER 2.X
      • MODULE - HVAC - HIGH VOLTAGE CONTROLLER
      • SENSOR - AMBIENT AIR TEMPERATURE
    • 1803 - A/C Compressor Pipes & Hoses 25
      • PIPE - LOW PRESSURE - MANIFOLD TO COMPRESSOR - ROADSTER 1.5
      • PIPE - LOW PRESSURE - MANIFOLD TO COMPRESSOR - ROADSTER 2.X
      • PIPE - HIGH PRESSURE - COMPRESSOR TO CONDENSER - ROADSTER 1.5
      • PIPE - HIGH PRESSURE - COMPRESSOR TO CONDENSER - ROADSTER 2.X
      • PIPE - LOW PRESSURE - CHARGE PORT
      • PIPE - LOW PRESSURE - MANIFOLD - ROADSTER 1.5
      • PIPE - LOW PRESSURE - MANIFOLD - ROADSTER 2.X
      • PIPE - EVAPORATOR - SOLENOID VALVE TO TXV - ROADSTER 1.5
      • PIPE - EVAPORATOR - SOLENOID VALVE TO TXV - ROADSTER 2.X
      • RECEIVER DRIER - ROADSTER 1.5
      • RECEIVER DRIER - ROADSTER 2.X
      • COMPRESSOR - ROADSTER 1.5
      • COMPRESSOR - ROADSTER 2.X
      • SOLENOID VALVE - HEAT EXCHANGER
      • PRESSURE TRANSDUCER
      • PRESSURE TRANSDUCER
      • FAN - CONDENSER
      • CONDENSER
      • SOLENOID VALVE - EVAPORATOR - ROADSTER 1.5
      • SOLENOID VALVE - EVAPORATOR - ROADSTER 2.X
      • A/C REFRIGERANT RECOVERY AND RECHARGE - ROADSTER 1.5
      • A/C REFRIGERANT RECOVERY AND RECHARGE - ROADSTER 2.X
      • TXV VALVE - HEAT EXCHANGER
      • PIPE - HIGH PRESSURE - CONDENSER TO RECEIVER DRIER - ROADSTER 1.5
      • PIPE - HIGH PRESSURE - CONDENSER TO RECEIVER DRIER - ROADSTER 2.X
    • 1807 - Blower Motor 2
      • BLOWER MOTOR - HVAC - ROADSTER 1.5
      • BLOWER MOTOR - HVAC - ROADSTER 2.X
    • 1809 - HVAC Driver Controls 2
      • CONTROL PANEL ASSEMBLY - HVAC - ROADSTER 1.5
      • CONTROL PANEL ASSEMBLY - HVAC - ROADSTER 2.X
    • 1812 - Air Distribution Plenum 4
      • AIR DISTRIBUTION UNIT - ROADSTER 1.5
      • AIR DISTRIBUTION UNIT - ROADSTER 2.X
      • ACTUATOR - AIR DISTRIBUTION - ROADSTER 1.5
      • ACTUATOR - AIR DISTRIBUTION - ROADSTER 2.X
    • 1814 - Air Recirculation 2
      • FRESH AIR UNIT - ROADSTER 1.5
      • FRESH AIR UNIT - ROADSTER 2.X
  • 30 - CHASSIS 2
    • 3001 - Chassis & Subframes 2
      • SUBFRAME ASSEMBLY - REAR - ROADSTER 1.5
      • SUBFRAME ASSEMBLY - REAR - ROADSTER 2.X
    • 3002 - Seat Belt Mounting Frame & Stays 1
      • STAY - SEAT BELT ANCHORAGE FRAME - LH
  • 31 - SUSPENSION 2
    • 3101 - Front Suspension (including Hubs) 11
      • UPRIGHT - SUSPENSION - LH
      • HUB - FRONT - LH
      • STEERING ARM - LH
      • SPRING AND DAMPER ASSEMBLY - FRONT - LH
      • DAMPER - FRONT - LH
      • SPRING - FRONT - LH
      • WISHBONE ASSEMBLY - FRONT - LOWER - LH
      • LINK - SWAY BAR - LH
      • SWAY BAR - FRONT
      • BUSHING - SWAY BAR - FRONT
      • WISHBONE ASSEMBLY - FRONT - UPPER - LH
    • 3103 - Rear Suspension (including Hubs) 14
      • UPRIGHT - SUSPENSION - REAR - LH
      • HUB - REAR - LH
      • SHIM - CAMBER ADJUSTMENT - REAR
      • WISHBONE ASSEMBLY - REAR - LOWER - LH
      • WISHBONE ASSEMBLY - REAR - LOWER - RH
      • WISHBONE ASSEMBLY - REAR - UPPER - LH
      • WISHBONE ASSEMBLY - REAR - UPPER - RH
      • TRACK CONTROL ARM ASSEMBLY - LH
      • SPRING AND DAMPER ASSEMBLY - REAR - LH
      • DAMPER - REAR - LH
      • SPRING - REAR - LH
      • SWAY BAR - REAR
      • BUSHING - SWAY BAR - REAR
      • DROP LINK - SWAY BAR - REAR - LH
  • 32 - STEERING 2
    • 3201 - Steering Rack & Lower Column 3
      • STEERING RACK
      • TIE ROD END - LH
      • SHAFT - STEERING COLUMN - LOWER
    • 3205 - Upper Column, Steering Wheel, Steering Lock 2
      • STEERING WHEEL
      • STEERING COLUMN
  • 33 - BRAKES 3
    • 3301 - Brake Discs & Calipers 12
      • BRAKE DISC - FRONT - LH - ROADSTER 1.5
      • BRAKE DISC - FRONT - LH - ROADSTER 2.X
      • BRAKE DISC - REAR - LH - ROADSTER 1.5
      • BRAKE DISC - REAR - LH - ROADSTER 2.X
      • BRAKE CALIPER - FRONT - LH
      • BRAKE CALIPER - FRONT - RH
      • BRAKE CALIPER - REAR - LH
      • BRAKE CALIPER - REAR - RH
      • BRAKE PADS - FRONT - SET - ROADSTER 1.5
      • BRAKE PADS - FRONT - SET - ROADSTER 2.X
      • BRAKE PADS - REAR - SET - ROADSTER 1.5
      • BRAKE PADS - REAR - SET - ROADSTER 2.X
    • 3303 - Master Cylinder, Servo, ABS Module, Pipes & Hoses 9
      • MASTER CYLINDER
      • BRAKE HOSE - FLEXIBLE - REAR - LH
      • BLEED PROCEDURE - SYSTEM
      • SERVO ASSEMBLY
      • HOSE - VACUUM PUMP TO SERVO - ROADSTER 2.X
      • HOSE - VACUUM PUMP TO SERVO - ROADSTER 2.X RHD
      • HOSE - VACUUM PUMP TO SERVO - ROADSTER 1.5
      • VACUUM PUMP
      • ABS MODULATOR ASSEMBLY
    • 3305 - Parking Brake 5
      • PARKING BRAKE LEVER
      • CABLE - SECONDARY - PARKING BRAKE
      • SWITCH - PARKING BRAKE - ROADSTER 1.5
      • SWITCH - PARKING BRAKE - ROADSTER 2.X
      • PARKING BRAKE - ADJUST
  • 34 - WHEELS AND TIRES 1
    • 3401 - Wheels, Tires, & TPMS System 8
      • TPMS - PROGRAM - ROADSTER 2.X
      • MODULE - TPMS CONTROL UNIT
      • MODULE - TPMS ANTENNA - FRONT
      • MODULE - TPMS ANTENNA - REAR
      • MODULE - TPMS TRIGGER - FRONT - LH/RH
      • MODULE - TPMS TRIGGER - REAR - LH/RH
      • WHEEL SENSOR - TPMS - ROADSTER 1.5
      • WHEEL SENSOR - TPMS - ROADSTER 2.X
  • 39 - POWER ELECTRONICS MODULE (PEM) 1
    • 3901 - Internals 2
      • POWER ELECTRONICS MODULE (PEM) - ROADSTER 1.5
      • POWER ELECTRONICS MODULE (PEM) - ROADSTER 2.X
  • 40 - MOTOR 1
    • 4001 - Motor, Ducting & Air Cooling 21
      • DRIVE MOTOR ASSEMBLY - ROADSTER 1.5
      • DRIVE MOTOR ASSEMBLY - ROADSTER 2.X
      • MODULE - MOTOR ENCODER - ROADSTER 1.5
      • MODULE - MOTOR ENCODER - ROADSTER 2.X
      • FAN ASSEMBLY - MOTOR
      • MOUNTING - POWER TRAIN - LH - ROADSTER 1.5
      • MOUNTING - POWER TRAIN - LH - ROADSTER 2.X
      • MOUNTING - POWER TRAIN - RH - ROADSTER 1.5
      • MOUNTING - POWER TRAIN - RH - ROADSTER 2.X
      • MOUNTING - POWER TRAIN - LOWER
      • G10 INSULATOR RING - ROADSTER 1.5
      • G10 INSULATOR RING - ROADSTER 2.X
      • SHROUD - MOTOR - UPPER - ROADSTER 1.5
      • SHROUD - MOTOR - UPPER - ROADSTER 2.X
      • SHROUD - MOTOR - LOWER - ROADSTER 1.5
      • SHROUD - MOTOR - LOWER - ROADSTER 2.X
      • DUCT - FAN TO SHROUD ASSEMBLY
      • POWER TRAIN - REMOVE FOR ACCESS - ROADSTER 1.5
      • POWER TRAIN - REMOVE FOR ACCESS - ROADSTER 2.X
      • MOTOR - TRANSMISSION SPLIT - ROADSTER 1.5
      • MOTOR - TRANSMISSION SPLIT - ROADSTER 2.X
  • 44 - CHARGING SYSTEM 1
    • 4401 - Charge System Inlet 1
      • LIGHT RING ASSEMBLY - CHARGE PORT
  • 46 - COOLING 1
    • 4601 - Cooling System & Fans 11
      • COOLING SYSTEM - DRAIN AND REFILL
      • COOLING SYSTEM - REFILL AND BLEED
      • COOLANT PUMP
      • COOLANT HOSE - MANIFOLD TO PUMP
      • BREATHER HOSE - HEAT EXCHANGER TO RESERVOIR
      • COOLANT HOSE - MANIFOLD TO HEAT EXCHANGER
      • HEAT EXCHANGER
      • COOLANT MANIFOLD - BATTERY (ASSEMBLY REMOVED)
      • HOSES - ANY - MANIFOLD TO BATTERY
      • HOSES - ANY - MANIFOLD TO BATTERY (ASSEMBLY REMOVED)
      • COOLANT HEATER
  • 47 - TRANSMISSION 3
    • 4703 - Transmission 6
      • TRANSMISSION FLUID - CHECK
      • TRANSMISSION FLUID - REPLACE
      • TRANSMISSION ASSEMBLY - REPLACE - ROADSTER 1.5
      • TRANSMISSION ASSEMBLY - REPLACE - ROADSTER 2.X
      • DRIVE COUPLER - MOTOR TO TRANSMISSION - ROADSTER 1.5
      • DRIVE COUPLER - MOTOR TO TRANSMISSION - ROADSTER 2.X
    • 4705 - Gearchange Mechanism 2
      • GEAR SELECTOR ASSEMBLY - ROADSTER 1.5
      • GEAR SELECTOR ASSEMBLY - ROADSTER 2.X
    • 4715 - Driveshafts 3
      • DRIVESHAFT ASSEMBLY - LH
      • GAITER - DRIVESHAFT - OUTER - LH
      • CV JOINT ASSEMBLY - OUTER - LH