1999MY Land Rover Discovery Series II Workshop Manual VDR100330NAS(6) – PDF DOWNLOAD

1999MY Land Rover Discovery Series II Workshop Manual VDR100330NAS(6) – PDF DOWNLOAD

DESCRIPTION:

1999MY Land Rover Discovery Series II Workshop Manual VDR100330NAS(6) – PDF DOWNLOAD

How To Use This Manual
Introduction

• This Manual is designed to assist skilled technicians in the efficient repair and maintenance of Discovery vehicles. Individuals who undertake their own repairs should have some skill and training, and limit repairs to components which could not affect the safety of the vehicle or its passengers.
• Any repairs required to safety critical items such as steering, brakes, suspension or supplementary restraint system should be carried out by a Land Rover Dealer. Repairs to such items should NEVER be attempted by untrained individuals.

General :

To assist in the use of this Manual, it is divided into sections and sub-sections. The section title is given at the top of each page and the relevant sub-section is given at the bottom.

• There is a single contents section at the front of the Manual, which is divided by section and sub-section. Each section is numbered from page 1.
• The individual items comprising repair operations are to be followed in the sequence in which they appear. Items numbers in the illustration are referred to in the text.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

1999MY Land Rover Discovery Series II Workshop Manual VDR100330NAS(6) – PDF DOWNLOAD

INTRODUCTION 01-1
How To Use This Manual 01-1
Repairs and Replacements 01-2
Specifications 01-2
Abbreviations and Symbols 01-3
GENERAL INFORMATION 03-1
General Precautions 03-1
Safety Instructions 03-2
Environmental Precautions 03-3
General Fitting Instructions 03-6
Ball and Roller Bearings 03-7
Oil Seals 03-8
Joints and Joint Faces 03-9
Locking Devices 03-9
Screw Threads 03-10
Bolt and Nut Identification 03-11
Flexible Pipes and Hoses 03-13
Rolling Road Testing 03-15
Fuel Handling Precautions 03-16
Electrical Precautions 03-17
Supplementary Restraint System Precautions 03-18
SRS Component Replacement Policy 03-23
Air Conditioning System Precautions 03-24
Air Conditioning Compressor Replacement 03-26
Body Repairs 03-27
GENERAL DATA 04-1
Engine – Td5 04-1
Engine – V8 04-4
Fuel system – Td5 04-8
Fuel system – V8 04-8
Cooling system – Td5 04-9
Cooling system – V8 04-10
Clutch – Td5 04-11
Clutch – V8 04-12
Manual gearbox – R380 04-13
Transfer box – LT230SE 04-14
Automatic gearbox – ZF4HP22/24 04-15
Rear axle 04-16
Front axle 04-16
Steering 04-17
Suspension 04-18
Brakes 04-19
Wheels and tyres 04-20
Air conditioning 04-21
Electrical – Td5 04-22
Electrical – V8 04-22
Dimensions 04-23
Weights 04-24
CONTENTS
2 CONTENTS
IDENTIFICATION NUMBERS 05-1
Vehicle Identification Number 05-1
Identification Number Locations 05-3
TORQUE WRENCH SETTINGS 06-1
Maintenance 06-1
Engine Td5 06-2
Engine V8 06-4
Emission control – Td5 06-5
Emission control – V8 06-5
Engine management system – Td5 06-6
Engine management system – V8 06-6
Cooling system 06-7
Manifolds and exhaust systems – Td5 06-8
Manifolds and exhaust systems – V8 06-8
Clutch 06-9
Manual gearbox – R380 06-10
Transfer box – LT230SE 06-11
Automatic gearbox – ZF4HP22 06-12
Propeller shafts 06-13
Axles 06-13
Steering 06-14
Front suspension 06-15
Rear suspension 06-16
Brakes 06-17
Restraint systems 06-18
Body 06-19
Heating and air conditioning 06-20
Wipers and washers 06-20
Electrical 06-21
LIFTING AND TOWING 08-1
LIFTING 08-1
TOWING 08-2
TRANSPORTING 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS 09-1
Capacities 09-1
Fluids 09-2
Anti-Freeze Concentration 09-2
Lubrication 09-3
Sealants 09-4
CONTENTS
CONTENTS 3
MAINTENANCE 10-1
PROCEDURES
V8 engine underbonnet view 10-1
Diesel underbonnet view 10-2
Seats and seat belts 10-3
Lamps, horns and warning indicators 10-5
Wipers and washers 10-5
Handbrake 10-6
Alarm handset battery 10-6
Road wheels 10-6
Tyres 10-6
Brake pads, discs and calipers 10-6
Road wheel speed sensors 10-7
Brake fluid 10-7
Fuel filter – diesel engine 10-7
Fuel filter sedimenter 10-7
Road wheels 10-8
Radiator/Intercooler 10-8
Ambient air Temperature and pressure sensor 10-8
Doors, bonnet and fuel filler flap 10-8
Air suspension intake filter 10-9
Anti-freeze 10-9
Cooling system 10-9
Spark plugs – V8 engine 10-10
Air cleaner – V8 engine 10-10
Air cleaner and dump valve – diesel engine 10-10
Auxiliary drive belt 10-11
Auxiliary drive belt – V8 engine 10-11
Auxiliary drive belt – diesel engine 10-11
Fluid reservoirs 10-12
Steering box 10-13
Battery 10-13
Intercooler – diesel engine 10-14
Engine oil – V8 engine 10-14
Engine oil – diesel engine 10-15
Centrifuge rotor – diesel engine 10-15
Engine oil filter – diesel engine 10-16
Engine oil filter – V8 engine 10-16
Manual gearbox 10-17
Automatic gearbox 10-18
Transfer box 10-19
Front and rear axle 10-20
Propeller shafts 10-20
Anti-roll bar links 10-22
ACE actuators 10-23
ACE filter 10-23
CONTENTS
4 CONTENTS
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses 10-24
Engine, gearbox, transfer box and axles 10-25
Exhaust system 10-25
Steering box and front suspension 10-25
Steering rod ball joints 10-27
Dampers and SLS height sensors 10-27
Front and rear axle suspension links 10-28
Towing bracket 10-29
Engine mountings – V8 engine 10-30
Road/roller test 10-31
CONTENTS
CONTENTS 5
ENGINE – V8 12-2-1
DESCRIPTION AND OPERATION
V8 Engine 12-2-1
Cylinder head components 12-2-2
Cylinder block components 12-2-4
Description 12-2-6
ADJUSTMENTS
Engine oil pressure check 12-2-11
REPAIRS
Seal – crankshaft – rear 12-2-13
Gasket – cylinder head – LH 12-2-14
Gasket – cylinder head – RH 12-2-16
Gasket – rocker cover – LH 12-2-19
Gasket – rocker cover – RH 12-2-20
Mounting – front – LH 12-2-22
Mounting – front – RH 12-2-23
Mounting – rear – LH 12-2-24
Mounting – rear – RH 12-2-25
Engine assembly 12-2-26
Flywheel 12-2-31
Plate – drive – automatic 12-2-32
Ring gear – starter 12-2-34
Filter – oil 12-2-35
Strainer – oil pick-up 12-2-35
Pump – oil 12-2-36
Gasket – sump 12-2-37
Switch – oil pressure 12-2-39
Cooler – engine oil 12-2-39
Gasket – timing gear cover 12-2-41
Seal – cover – timing gears 12-2-43
OVERHAUL
Gasket – inlet manifold 12-2-45
Gasket – exhaust manifold 12-2-48
Seal – crankshaft – rear – automatic models 12-2-49
Seal – crankshaft – rear – manual models 12-2-50
Bearing – spigot – crankshaft 12-2-52
Gasket – engine sump 12-2-53
Strainer – oil pick-up 12-2-54
Seal – timing gear cover 12-2-55
Gasket – timing gear cover 12-2-56
Timing chain and gears 12-2-58
Rocker shaft – overhaul 12-2-59
Gasket – cylinder head 12-2-61
Cylinder head – overhaul 12-2-63
Piston assemblies 12-2-67
Bearings – connecting rods 12-2-72
Crankshaft and main bearings 12-2-73
Camshaft 12-2-77
CONTENTS
6 CONTENTS
EMISSION CONTROL – V8 17-2-1
DESCRIPTION AND OPERATION
Crankcase emission control system 17-2-1
Exhaust emission control 17-2-2
Evaporative emission system component layout 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram 17-2-5
Secondary air injection system component layout 17-2-6
Secondary air injection system control diagram 17-2-8
Emission Control Systems 17-2-9
Crankcase Emission Control System 17-2-10
Exhaust Emission Control System 17-2-11
Evaporative Emission Control System 17-2-15
Secondary Air Injection System 17-2-26
Crankcase Emission Control Operation 17-2-34
Exhaust Emission Control Operation 17-2-35
Evaporative Emission Control Operation 17-2-39
Secondary Air Injection System Operation 17-2-43
SAI System Fault Finding and Check Malfunctions 17-2-44
REPAIRS
Canister – EVAP 17-2-51
Canister – EVAP – Models with Fuel Leak Detection Pump – up to 03MY 17-2-52
Canister – EVAP – Models with Fuel Leak Detection Pump – from 03MY 17-2-53
Valve – purge control 17-2-54
Solenoid – evap canister vent solenoid (CVS) valve 17-2-55
Sensor – heated oxygen (HO2S) – pre-catalytic converter 17-2-56
Sensor – heated oxygen (HO2S) – post-catalytic converter 17-2-57
Control Valve – Secondary Air Injection (SAI) 17-2-58
Reservoir – Vacuum – Secondary Air Injection (SAI) – up to 03MY 17-2-58
Reservoir – vacuum – Secondary Air Injection (SAI) – from 03MY 17-2-59
Pump – Air – Secondary Air Injection (SAI) 17-2-59
Air Manifold – LH – Secondary Air Injection (SAI) 17-2-60
Air Manifold – RH – Secondary Air Injection (SAI) 17-2-61
Solenoid – Vacuum – Secondary Air Injection (SAI) 17-2-62
Pipe – Secondary Air Injection (SAI) 17-2-62
Pump – Fuel Leak Detection – up to 03MY 17-2-64
Pump – fuel leak detection – from 03MY 17-2-64
Filter – fuel leak detection pump – up to 03MY 17-2-65
Filter – fuel leak detection pump – from 03MY 17-2-65
CONTENTS
CONTENTS 7
ENGINE MANAGEMENT SYSTEM – V8 18-2-1
DESCRIPTION AND OPERATION
Engine management component location – Passenger compartment 18-2-1
Engine management component location – Engine compartment 18-2-2
Engine management block diagram 18-2-4
Description – engine management 18-2-6
Operation – engine management 18-2-49
DESCRIPTION AND OPERATION
Cruise control component layout 18-2-61
Cruise control block diagram 18-2-62
Description – cruise control 18-2-63
Operation – cruise control 18-2-74
ADJUSTMENTS
Cable – throttle 18-2-77
Cable – cruise control 18-2-77
REPAIRS
Spark plugs 18-2-79
Coil – ignition 18-2-80
Engine control module (ECM) 18-2-81
Sensor – engine coolant temperature (ECT) 18-2-82
Sensor – crankshaft position (CKP) 18-2-83
Sensor – radiator temperature 18-2-84
Sensor – camshaft position (CMP) 18-2-84
Knock sensor (KS) 18-2-85
Air cleaner assembly 18-2-86
Element – air filter 18-2-87
Cable – throttle 18-2-88
Sensor – Mass Air Flow (MAF) 18-2-89
Throttle Body 18-2-90
Plenum chamber 18-2-91
Sensor – throttle position (TP) 18-2-91
Valve – idle air control (IACV) 18-2-92
Injectors 18-2-92
Actuator – cruise control 18-2-94
Vacuum control unit – up to 03MY 18-2-94
Vacuum control unit – from 03MY 18-2-95
Cable – cruise control 18-2-96
Switch – cruise control (on/off) 18-2-96
Switch – cruise control (set/resume) 18-2-97
Switch – clutch pedal – cruise control 18-2-97
ECU – Cruise control 18-2-98
CONTENTS
8 CONTENTS
FUEL DELIVERY SYSTEM – V8 19-2-1
DESCRIPTION AND OPERATION
Fuel delivery system 19-2-1
Fuel tank and breather components (all except NAS) 19-2-2
Fuel tank and breather components (NAS) 19-2-3
Description 19-2-4
Operation 19-2-10
ADJUSTMENTS
Fuel tank – drain 19-2-11
REPAIRS
Switch – inertia – fuel cut-off 19-2-13
Pump – fuel 19-2-13
Tank – fuel 19-2-15
Filler tube – fuel 19-2-16
Solenoid – fuel filler flap release 19-2-17
Switch – fuel filler flap release – up to 03MY 19-2-17
Switch – fuel filler flap release – from 03MY 19-2-18
COOLING SYSTEM – V8 26-2-1
DESCRIPTION AND OPERATION
Cooling system component layout 26-2-2
Cooling system coolant flow 26-2-4
Description 26-2-6
Operation 26-2-10
ADJUSTMENTS
Drain and refill 26-2-13
REPAIRS
Fan – viscous 26-2-15
Radiator 26-2-15
Thermostat 26-2-18
Gasket – coolant pump 26-2-19
MANIFOLDS AND EXHAUST SYSTEMS – V8 30-2-1
DESCRIPTION AND OPERATION
Exhaust manifold component layout 30-2-1
Inlet manifold component layout 30-2-2
Exhaust system component layout 30-2-4
Description 30-2-5
REPAIRS
Front pipe 30-2-7
Intermediate pipe/silencer 30-2-8
Tail pipe 30-2-9
Heat shield – brake servo – Without Secondary Air Injection 30-2-9
Heat shield – brake servo – With Secondary Air Injection 30-2-10
Gasket – inlet manifold – lower 30-2-10
Gasket – exhaust manifold 30-2-14
Gasket – inlet manifold – upper – Without Secondary Air Injection 30-2-15
Gasket – inlet manifold – upper – With Secondary Air Injection 30-2-18
CONTENTS
CONTENTS 9
CLUTCH – V8 33-2-1
DESCRIPTION AND OPERATION
Clutch components 33-2-2
Hydraulic operation 33-2-4
Description 33-2-6
Operation 33-2-9
ADJUSTMENTS
Clutch hydraulic system – bleed 33-2-11
REPAIRS
Clutch assembly 33-2-13
Master cylinder 33-2-14
Bearing and lever – clutch release 33-2-15
Slave cylinder 33-2-15
CONTENTS
10 CONTENTS
MANUAL GEARBOX – R380 37-1
DESCRIPTION AND OPERATION
R380 gearbox 37-1
Gearbox casings, gear change and oil pump 37-2
Selector shaft and forks, synchromesh assemblies and gear train 37-4
R380 gearbox cross section 37-6
Description 37-7
Operation 37-8
ADJUSTMENTS
Spring – gear lever bias 37-9
REPAIRS
Housing – gear selector 37-11
Gearbox – V8 37-12
Gearbox – Diesel 37-16
Seal – gearbox mainshaft 37-20
Seal – input shaft 37-21
Cooler – oil – gearbox – Diesel 37-23
Cooler – oil – gearbox – V8 37-24
Switch – Reverse light 37-25
OVERHAUL
Shaft – output 37-27
Synchroniser – gearbox – set 37-32
Fork – set – selector shaft 37-34
Shaft – gearbox – input 37-35
Extension – gearbox rear 37-38
Pump – gearbox oil 37-41
Filter – gearbox oil 37-41
Gear – 5th gear set 37-42
Synchronizer assembly – 5th/reverse 37-43
5th gear – layshaft 37-44
Bearing – layshaft rear support 37-46
Bearing – output shaft rear support 37-47
Shaft – reverse idler 37-48
Housing – gear selector mechanism 37-50
Lever – gear change 37-51
Housing – clutch 37-52
Cover – front 37-53
CONTENTS
CONTENTS 11
TRANSFER BOX – LT230SE 41-1
DESCRIPTION AND OPERATION
LT230SE transfer box 41-1
Transfer box cross section 41-2
Main casing components – Vehicles up to 03 model year 41-4
Main casing components – Vehicles from 03 model year 41-5
Differential components – Vehicles up to 03 model year 41-6
Differential components – Vehicles from 03 model year 41-7
Front output housing components – Vehicles up to 03 model year 41-8
Front output housing components – Vehicles from 03 model year 41-10
Rear output housing components 41-12
Description 41-13
Operation 41-18
ADJUSTMENTS
Cable – selector – differential lock – adjust 41-21
Cable – high/low selector 41-21
REPAIRS
Bottom cover – transfer box 41-23
Cable – selector – differential lock 41-24
Transfer box – Diesel 41-25
Transfer box – V8 41-29
Gasket – rear cover plate 41-33
Switch – differential lock – Up to 03 MY 41-34
Cable – high/low selector 41-35
Oil seal – input shaft 41-36
Seal – front output shaft 41-36
Seal – rear output shaft 41-38
Gasket – rear output shaft housing 41-39
Solenoid – interlock – Up to 03 MY 41-40
Solenoid – interlock – from 03 MY 41-40
Sensor – neutral 41-41
Sensor – oil temperature – If fitted 41-41
Switch – high low – warning 41-42
Switch(es) – differential lock warning From 03 MY 41-42
OVERHAUL
Intermediate gear assembly 41-43
Differential assembly 41-46
Dog clutch – differential lock 41-64
Input gear/bearing 41-68
Low gear – differential 41-70
CONTENTS
12 CONTENTS
AUTOMATIC GEARBOX – ZF4HP22 – 24 44-1
DESCRIPTION AND OPERATION
Automatic gearbox component layout 44-1
Control schematic 44-2
Description 44-4
Operation 44-17
ADJUSTMENTS
Cable – selector 44-21
Stall test 44-21
REPAIRS
Cable and lever assembly – selector 44-23
Selector indicator 44-24
Switch – starter inhibitor 44-25
Seal – selector shaft 44-26
Gearbox – convertor and transfer gearbox – Diesel 44-27
Gearbox – convertor and transfer gearbox – V8 44-32
Torque converter and oil seal 44-37
Housing – torque converter 44-38
Gasket – intermediate plate 44-39
Intermediate plate 44-41
Pump – fluid 44-43
Seal – rear extension housing 44-44
Gasket – rear extension housing 44-45
Parking pawl assembly 44-46
Gasket – oil sump 44-47
Filter – oil 44-48
Cooler – fluid – Td5 44-49
Cooler – fluid – V8 44-50
Valve body assembly 44-51
Seal – valve body 44-53
Pressure regulator 44-54
Lock-up solenoid valve (MV 3) 44-55
Solenoids – shift control valves
(MV 1 & 2) 44-56
Harness – solenoid valves 44-57
Electronic control unit – automatic transmission 44-58
PROPELLER SHAFTS 47-1
DESCRIPTION AND OPERATION
Propeller shaft component layout 47-1
Description 47-2
REPAIRS
Propeller shaft – front 47-5
Propeller shaft – rear 47-5
Bush – spigot – rear propeller shaft 47-6
Flexible coupling 47-7
OVERHAUL
Propeller shaft 47-9
CONTENTS
CONTENTS 13
REAR AXLE 51-1
DESCRIPTION AND OPERATION
Rear axle component layout 51-1
Description 51-2
REPAIRS
Differential – assembly 51-5
Seal – differential pinion 51-7
OVERHAUL
Differential assembly 51-9
FRONT AXLE 54-1
DESCRIPTION AND OPERATION
Front axle component layout 54-1
Description 54-2
REPAIRS
Differential – assembly 54-5
Seal – differential pinion 54-7
Seal – oil – front axle casing 54-9
Constant velocity joint – drive shaft 54-11
CONTENTS
14 CONTENTS
STEERING 57-1
DESCRIPTION AND OPERATION
Steering system component layout 57-1
Steering column assembly and intermediate shaft 57-2
Steering box 57-4
Description 57-5
Operation 57-16
ADJUSTMENTS
Steering box – check and adjust 57-17
Hydraulic system – bleed 57-18
Steering linkage – centralise 57-18
Wheel alignment – front 57-19
Power steering pressure check – diesel models 57-20
Power steering pressure check – V8 LHD models 57-22
Power steering pressure check – V8 RHD models 57-24
REPAIRS
Power steering box – V8 57-27
Power steering box – LHD – diesel 57-30
Steering box – RHD – diesel 57-34
Seal – input shaft – steering box 57-37
Seal – output shaft – steering box 57-38
Pump – power steering – V8 57-39
Pump – power steering – diesel 57-42
Steering column assembly and lock 57-43
Shaft – intermediate and universal joint – steering column 57-45
Nacelle – steering column 57-47
Drop arm – steering box 57-47
Ball joint – track rod 57-48
Ball joint – drag link 57-49
Drag link 57-50
Damper – steering 57-51
Steering wheel 57-52
CONTENTS
CONTENTS 15
FRONT SUSPENSION 60-1
DESCRIPTION AND OPERATION
Front suspension component layout (ACE torsion bar shown) 60-1
Front suspension components (ACE torsion bar shown) 60-2
Description 60-4
DESCRIPTION AND OPERATION
ACE system component layout 60-7
ACE system control diagram 60-8
Description – ACE 60-9
Operation 60-22
ADJUSTMENTS
ACE hydraulic system bleeding 60-25
Fluid level check – ACE system 60-25
REPAIRS
Bushes – Panhard rod 60-27
Ball joint – upper – steering knuckle 60-28
Ball joint – lower – steering knuckle 60-29
Steering knuckle 60-30
Road spring – front 60-32
Wheel hub 60-33
Damper – front 60-35
Bushes – radius arm 60-37
ECU – ACE 60-39
Accelerometer – ACE – upper 60-40
Accelerometer – ACE – lower 60-40
Pump – ACE – V8 60-41
Pump – ACE – diesel 60-42
Valve block – ACE 60-44
Filter – high pressure – ACE 60-47
Pressure transducer – ACE 60-48
Solenoid – pressure control valve – ACE 60-49
Solenoid – directional control valve – ACE 60-49
Pipe assembly – valve block to front actuator – ACE 60-50
Pipe assembly – pump or reservoir to valve block – ACE – V8 60-52
Pipe assembly – pump or reservoir to valve block – ACE – diesel 60-55
Pipe assembly – valve block to rear actuator – ACE 60-59
Actuator – front – ACE 60-61
Bushes – front long arm – ACE 60-63
CONTENTS
16 CONTENTS
REAR SUSPENSION 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) 64-2
Rear suspension component layout (vehicles without SLS) 64-3
Rear suspension components 64-4
Description 64-6
DESCRIPTION AND OPERATION
SLS component layout 64-9
SLS system control diagram 64-10
Description – SLS 64-12
Operation 64-21
ADJUSTMENTS
SLS calibration blocks 64-25
REPAIRS
Wheel hub 64-27
Road spring – rear 64-29
Air spring – SLS 64-30
Damper – rear 64-31
Bushes – radius arm 64-31
Bushes – Watts linkage 64-34
Sensor – height – SLS 64-35
Compressor unit – air – SLS 64-35
Filter – intake – SLS 64-37
Switch – ride height 64-37
Air valve – SLS 64-38
Actuator – rear – ACE 64-39
Bushes – rear long arm – ACE 64-41
CONTENTS
CONTENTS 17
BRAKES 70-1
DESCRIPTION AND OPERATION
Brake system control component layout 70-1
Brake system control diagram 70-2
Brake system hydraulic component layout 70-4
Description 70-5
Operation 70-20
DESCRIPTION AND OPERATION
Handbrake component layout 70-25
Description 70-26
ADJUSTMENTS
Handbrake 70-29
Brake system bleeding 70-30
REPAIRS
Brake disc – front 70-33
Brake disc – rear 70-34
Master cylinder – brake 70-35
Cable – handbrake 70-36
Switch – brake light 70-37
Brake pads – front 70-38
Brake pads – rear 70-39
Brake shoes – handbrake 70-40
Servo – brake 70-42
Vacuum pump – servo 70-43
Housing – caliper – front 70-45
Housing – caliper – rear 70-46
ECU – Self levelling and anti locking brakes (SLABS) 70-47
Sensor – ABS – front 70-48
Sensor – ABS – rear 70-48
Modulator unit – ABS 70-49
Switch – Hill descent control 70-50
Switch – handbrake 70-50
CONTENTS
18 CONTENTS
RESTRAINT SYSTEMS 75-1
DESCRIPTION AND OPERATION
SRS component layout 75-1
SRS block diagram 75-2
Description – SRS 75-3
Operation – SRS 75-9
DESCRIPTION AND OPERATION
Description – seat belts 75-11
REPAIRS
Seat belt – front 75-13
Seat belt – rear – centre 75-13
Seat belt – rear – side 75-15
Mounting – seat belt – ‘B’ post 75-16
Seat belts – third row 75-17
Pre-tensioner – front seat belt 75-18
Pre-tensioner – seat belt – front – deployment – in vehicle 75-19
Pre-tensioner – seat belt – front – deployment – off vehicle 75-20
Airbag module – drivers 75-22
Airbag module – passenger 75-23
DCU 75-24
Air bag – steering wheel – deployment – off vehicle 75-25
Air bag – fascia – passenger – deployment – in vehicle 75-26
Air bag – fascia – passenger – deployment – off vehicle 75-27
Rotary coupler 75-29
DOORS 76-1-1
REPAIRS
Door – front 76-1-1
Door – rear 76-1-2
Door – tail 76-1-3
Glass – front or rear door 76-1-5
Quarter light 76-1-6
Regulator and motor – front and rear door glass 76-1-7
Trim casing – front door 76-1-8
Trim casing – rear door 76-1-9
Trim casing – tail door 76-1-10
Latch and motor – front door 76-1-11
Latch and motor – rear door 76-1-12
Latch and motor – tail door 76-1-13
Handle – exterior – rear door 76-1-13
Handle – exterior – tail door 76-1-14
Handle – exterior – front door 76-1-14
CONTENTS
CONTENTS 19
EXTERIOR FITTINGS 76-2-1
REPAIRS
Wing – front – up to 03MY 76-2-1
Wing – front – from 03MY 76-2-2
Rear folding step 76-2-4
Liner – wheel arch – front 76-2-5
Liner – wheel arch – rear 76-2-6
Panel – underbelly 76-2-7
Mirror – exterior – electric 76-2-7
Roof bars 76-2-8
Bonnet 76-2-9
Cable – bonnet release – up to 03MY 76-2-9
Cable – bonnet release – from 03MY 76-2-11
Bumper assembly – front 76-2-12
Bumper assembly – rear – from 03MY 76-2-13
Trim finisher – bumper – front – from 03MY 76-2-14
Bumper assembly – rear – up to 03MY 76-2-15
Side finisher – windscreen 76-2-16
Grille – front – up to 03MY 76-2-16
Grille – front – from 03MY 76-2-17
INTERIOR TRIM COMPONENTS 76-3-1
REPAIRS
Trim casing – tail door speaker 76-3-1
Trim casing – side – loadspace 76-3-2
Trim casing – upper – ‘B’ post 76-3-3
Trim casing – lower – ‘B’ post 76-3-3
Trim casing – ‘D’ post 76-3-4
Console – centre – automatic models 76-3-5
Console – centre – manual models 76-3-7
Fascia 76-3-10
Panel – auxiliary switch 76-3-14
Panel – fascia access – driver’s side 76-3-15
Drink tray assembly – centre fascia 76-3-15
Louvre panel assembly – centre fascia 76-3-16
Carpet – front 76-3-18
Carpet – rear 76-3-19
Carpet – loadspace 76-3-20
Headlining 76-3-20
Stowage pocket – front 76-3-24
CONTENTS
20 CONTENTS
SCREENS 76-4-1
REPAIRS
Glass/sealing rubber – tail door 76-4-1
Windscreen 76-4-2
Glass – body side – rear 76-4-4
Glass – alpine light 76-4-6
SEATS 76-5-1
DESCRIPTION AND OPERATION
Electric seat component location 76-5-1
Electric seat block diagram 76-5-2
Description – electric seats 76-5-4
Operation – electric seats 76-5-8
DESCRIPTION AND OPERATION
Heated seat component location 76-5-9
Heated seat block diagram (electric seats) 76-5-10
Description – heated seats 76-5-11
Operation – heated seats 76-5-13
REPAIRS
Seat – front 76-5-15
Seat – third row 76-5-16
Seat – rear 76-5-18
Bolster assembly – rear armrest 76-5-19
Cover – cushion – front seat 76-5-20
Heating element – cushion – front seat 76-5-21
Cover – cushion – rear seat 76-5-22
Bladder – lumbar support 76-5-23
Motor – fore and aft – front seat 76-5-23
Motor – rise and fall – front seat 76-5-24
Motor – tilt – front seat 76-5-24
Motor – recline 76-5-25
Switch – electric seats 76-5-25
Cable – rear squab latch 76-5-26
Latch – rear seat 76-5-26
Cover – squab – front seat 76-5-28
Cover – squab – RH rear seat 76-5-31
Heating element – squab – front seat 76-5-33
Head restraint – third row seat 76-5-33
CONTENTS
CONTENTS 21
SUNROOF 76-6-1
DESCRIPTION AND OPERATION
Electric sunroof component location 76-6-1
Sunroof components 76-6-2
System block diagram 76-6-4
Description 76-6-5
Operation 76-6-13
REPAIRS
Sunroof – front 76-6-15
Sunroof – rear 76-6-16
Glass panel – sunroof 76-6-17
Motor – sunroof 76-6-18
Drive cable assembly 76-6-19
Switch pack – sunroof 76-6-20
ECU – sunroof 76-6-20
CHASSIS AND BODY DIMENSIONS 77-1-1
CHASSIS DIMENSIONS
Chassis body mounting points – front end 77-1-1
Chassis body mounting points – rear end 77-1-2
Chassis dimensions – front end 77-1-3
Chassis dimensions – rear end 77-1-4
BODY DIMENSIONS
Body Dimensions 77-1-5
Gaps and profiles 77-1-13
CONTENTS
22 CONTENTS
PANEL REPAIRS 77-2-1
REPLACEMENT PANELS
Replacement panels 77-2-1
Front end inner panels 77-2-2
Valance panels 77-2-3
Body side panels 77-2-4
Body side assembly 77-2-5
‘D’-post assembly 77-2-6
Rear floor assembly 77-2-7
Rear end panels 77-2-8
Front and rear doors 77-2-9
Taildoor 77-2-10
Roof panels 77-2-11
Replacement panels 77-2-12
PROCEDURES
General welding precautions 77-2-13
Electronic control units 77-2-14
PROCEDURES
Panel replacement procedure 77-2-15
REPAIRS
Front bulkhead assembly 77-2-21
Bonnet locking platform 77-2-23
Front cross member 77-2-24
Headlamp mounting panel – RH 77-2-25
Headlamp mounting panel – LH 77-2-26
Valance upper assembly – LH 77-2-28
Valance upper assembly – RH 77-2-29
Valance upper assembly (front section) – LH 77-2-30
Valance upper assembly (front section) – RH 77-2-32
Front valance assembly – RH 77-2-33
Front valance assembly – LH 77-2-34
‘A’ post assembly 77-2-35
Dash side assembly 77-2-37
Sill outer assembly 77-2-38
Sill inner assembly 77-2-39
‘B/C’ post assembly 77-2-40
Panel body side assembly 77-2-41
Body side inner rear assembly 77-2-43
‘D’ post outer assembly 77-2-44
Wheelarch rear outer assembly 77-2-45
‘E’ post assembly 77-2-46
‘E’ post closing assembly 77-2-47
Cross member outer rear panel 77-2-47
Cross member outer rear panel (centre section) 77-2-48
Cross member outer rear panel (RH/LH section) 77-2-49
Cross member closing rear panel 77-2-49
Cross member rear assembly 77-2-50
Cross member rear assembly (RH/LH section) 77-2-50
Rear floor complete assembly 77-2-51
Rear floor (rear section) 77-2-52
Rear floor (RH/LH section) 77-2-53
Roof assembly 77-2-53
TIMES
TIME SCHEDULES 77-2-55
CONTENTS
CONTENTS 23
BODY SEALING MATERIALS 77-3-1
MATERIALS AND APPLICATIONS
Materials applications 77-3-1
Approved materials 77-3-2
Application equipment 77-3-4
CORROSION PREVENTION AND SEALING 77-4-1
CORROSION PREVENTION
Cavity wax treatment areas and injection holes – ‘A’ post and sill 77-4-1
Cavity wax treatment area and injection hole – fuel filler neck 77-4-2
Cavity wax treatment areas and injection holes – rear cross member 77-4-3
Cavity wax treatment areas and injection holes – front door, rear door and tail door 77-4-4
Corrosion prevention 77-4-6
SEALING
Body Sealing 77-4-9
Water leaks 77-4-22
PAINTING 77-5-1
PROCEDURES
Panel preparation 77-5-1
Paint preparation 77-5-2
HEATING AND VENTILATION 80-1
DESCRIPTION AND OPERATION
Heating and ventilation component layout 80-1
Fuel burning heater component layout 80-2
Description 80-3
Operation 80-13
REPAIRS
Heater control and fan switch 80-15
Cables – heater control 80-15
Servo – recirculation flap 80-17
Switch – recirculation control 80-18
Servo – air distribution control 80-19
Servo – air temperature control 80-20
Plenum Air Intake 80-21
Heater assembly – models without air conditioning 80-22
Heater assembly – models with air conditioning 80-24
Blower assembly 80-26
Motor – blower 80-27
Resistor pack – power resistor A/C 80-28
Heater matrix 80-29
Pipe – Heater – Feed 80-29
Pipe – Heater – Return 80-30
Fuel burning heater – (FBH) – Td5 80-31
CONTENTS
24 CONTENTS
AIR CONDITIONING 82-1
DESCRIPTION AND OPERATION
A/C refrigerant system component layout 82-1
A/C control system component layout 82-2
Description 82-3
Operation 82-16
DESCRIPTION AND OPERATION
Rear A/C refrigerant system component layout 82-21
Rear A/C distribution and control component layout 82-22
Description 82-23
Operation 82-26
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery, recycling and recharging 82-27
REPAIRS
Compressor – diesel 82-29
Compressor – V8 82-30
Fan – condenser 82-31
Condenser 82-31
Receiver drier and dual pressure switch 82-33
ECU – air temperature control 82-35
Sensor – ambient air temperature 82-35
Sensor – solar light 82-36
Sensor – air temperature 82-37
Evaporator, evaporator thermistor and thermal expansion valve (TXV) 82-38
Expansion valve – (TXV) – rear 82-41
Evaporator – rear 82-42
Evaporator and motor assembly – rear 82-43
Blower motor assembly – rear 82-44
Resistor – blower motor 82-45
Duct – centre – rear 82-45
CONTENTS
CONTENTS 25
WIPERS AND WASHERS 84-1
DESCRIPTION AND OPERATION
Wipers and washers component layout 84-1
Front wiper components 84-2
Rear wiper components 84-3
Washer components 84-4
Wipers and washers block diagram 84-6
Description 84-8
Operation 84-17
REPAIRS
Reservoir – washer – up to 03MY 84-21
Reservoir – washer – from 03MY 84-22
Jet – washer – windscreen 84-23
Pump – washer – screen and headlamp 84-24
Motor and linkage – wiper – windscreen 84-25
Switch – wiper and washer – windscreen 84-26
Jet – washer – headlamp 84-27
Jet – washer – rear screen 84-27
Switch – rear wash 84-28
Motor – wiper – rear screen 84-29
Switch – wiper – rear – up to 03MY 84-30
Switch – wiper – rear – from 03MY 84-30
CHARGING AND STARTING 86-1-1
REPAIRS
Alternator – diesel 86-1-1
Alternator – V8 86-1-3
Belt – auxiliary drive 86-1-4
Battery 86-1-4
Battery carrier 86-1-5
Starter motor – diesel 86-1-6
Starter motor – V8 86-1-7
CONTENTS
26 CONTENTS
LIGHTING 86-2-1
ADJUSTMENTS
Headlamps beam alignment – up to 03MY 86-2-1
Headlamps beam alignment – from 03MY 86-2-2
REPAIRS
Lamp – front repeater – up to 03MY 86-2-3
Headlamp – up to 03MY 86-2-4
Headlamp – from 03MY 86-2-5
Lamp – tail 86-2-6
Lamp – front fog up to 03MY 86-2-6
Lamp – front fog from 03MY 86-2-7
Housing – number plate lamp 86-2-8
Motor – headlamp levelling 86-2-9
Lamp – stop – centre high mounted (CHMSL) 86-2-10
Lamp – tail/flasher – bumper 86-2-10
Lamp – interior – front 86-2-11
Lamp – interior – rear 86-2-11
Rheostat – panel lights dimmer 86-2-12
Switch – hazard warning 86-2-13
Switch – indicator and exterior lighting – combined 86-2-13
Socket – accessory 86-2-14
Switch – front/rear fog lamps 86-2-14
BODY CONTROL UNIT 86-3-1
DESCRIPTION AND OPERATION
Description 86-3-1
Operation 86-3-19
REPAIRS
Body control unit (BCU) 86-3-35
ALARM SYSTEM AND HORN 86-4-1
DESCRIPTION AND OPERATION
Alarm system component layout 86-4-2
Alarm system block diagram 86-4-4
Description 86-4-5
Operation 86-4-17
REPAIR
Switch – central door locking 86-4-25
Switches – horn 86-4-25
Vehicle horn 86-4-26
Sounder – alarm 86-4-26
Sounder – battery backed-up (BBUS) 86-4-27
Switch – bonnet 86-4-27
Receiver – alarm system – models with sunroof 86-4-28
Receiver – alarm system – models without sunroof 86-4-28
Coil – passive immobilisation 86-4-29
CONTENTS
CONTENTS 27
WINDOWS 86-5-1
DESCRIPTION AND OPERATION
Electric windows block diagram 86-5-1
Electric windows component layout 86-5-2
Description 86-5-4
Operation 86-5-11
REPAIRS
Switch – rear door 86-5-13
Switch – console 86-5-13
Switch – heated rear screen 86-5-14
IN CAR ENTERTAINMENT 86-6-1
DESCRIPTION AND OPERATION
ICE System Component layout 86-6-1
Base and mid line ICE system control diagram 86-6-2
High line ICE system control diagram 86-6-3
Description 86-6-4
DESCRIPTION AND OPERATION
DVD Player Component Layout 86-6-12
DVD Player Control Diagram 86-6-14
Description 86-6-16
Operation 86-6-27
REPAIRS
Radio 86-6-31
Speaker – low/full range – front door 86-6-32
Speaker – low range – rear door 86-6-32
Switches – remote control – ICE 86-6-33
Amplifier – aerial 86-6-33
Speaker – mid range – front door 86-6-34
Speaker – high range – rear door 86-6-34
Amplifier – power 86-6-35
Speaker – tail door 86-6-36
CD autochanger 86-6-36
DVD screen/player unit 86-6-37
Switch box – CD/DVD player 86-6-38
HARNESSES 86-7-1
REPAIRS
Harness – injectors – diesel 86-7-1
Harness – body 86-7-1
Harness – engine – V8 86-7-8
Harness – engine – diesel 86-7-12
Harness – main 86-7-15
Harness – main – DVD unit 86-7-28
Harness – link – CD/DVD switch box 86-7-32
CONTENTS
28 CONTENTS
DRIVING AIDS 86-8-1
DESCRIPTION AND OPERATION
Park Distance Control – Component Location 86-8-1
Park Distance Control – Control Diagram 86-8-2
Description 86-8-4
Operation 86-8-11
REPAIRS
Control unit (ECU) – park distance control (PDC) 86-8-13
Sounder – parking aid rear 86-8-14
Sensor – parking aid – rear – inner 86-8-15
Sensor – parking aid – rear – outer 86-8-16
NAVIGATION SYSTEM 87-1
DESCRIPTION AND OPERATION
Harman/Becker Navigation System Component Location 87-1
Description 87-2
DESCRIPTION AND OPERATION
CARiN III Navigation and Trafficmaster System Component Location 87-12
Description 87-14
Operation 87-20
REPAIRS
Interface electronic control unit (ECU) – remote control 87-29
Display unit 87-30
INSTRUMENTS 88-1
DESCRIPTION AND OPERATION
Instrument pack 88-1
Instrument component location – Engine compartment / underneath vehicle 88-2
Instrument component location – Passenger compartment 88-3
Instrument block diagram 88-4
Description 88-5
Interior rear view mirror with compass (where fitted) 88-42
REPAIRS
Clock 88-45
Instrument pack 88-45

VIDEO PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.V