2003 Land Rover Range Rover L322 Service Procedures Workshop Manual LRL0477NAS – PDF DOWNLOAD
FILE DETAILS:
2003 Land Rover Range Rover L322 Service Procedures Workshop Manual LRL0477NAS – PDF DOWNLOAD
Language : English
Pages : 938
Downloadable : Yes
File Type : PDF
Size: 26.5 MB
DESCRIPTION:
How To Use This Manual:
Introduction:
- This Manual is designed to assist skilled technicians in the efficient repair and maintenance of Range Rover 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:
2003 Land Rover Range Rover L322 Service Procedures Workshop Manual LRL0477NAS – PDF DOWNLOAD
INTRODUCTION 01-1
How To Use This Manual 01-1
Testbook – Fault Diagnostic Equipment 01-2
Repairs and Replacements 01-2
Specifications 01-3
Abbreviations and Symbols 01-4
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 03-10
Screw Threads 03-11
Bolt and Nut Identification 03-11
Flexible Pipes and Hoses 03-14
Service Tools 03-16
Rolling Road Testing 03-17
Fuel Handling Precautions 03-18
Electrical Precautions 03-19
Supplementary Restraint System (SRS) Precautions 03-21
SRS Component Replacement Policy 03-28
Air Conditioning System Precautions 03-29
Body Repairs 03-32
GENERAL DATA 04-1
Engine – Td6 04-1
Engine – V8 04-5
Fuel system – Td6 04-8
Fuel system – V8 04-8
Cooling system – Td6 04-9
Cooling system – V8 04-9
Transfer box 04-10
Automatic gearbox – Td6 engine 04-11
Automatic gearbox – V8 engine 04-11
Propeller and drive shafts 04-12
Front differential 04-12
Rear differential 04-12
Steering 04-13
Front and rear suspension 04-14
Brakes 04-15
Wheels and tyres 04-16
Air conditioning 04-17
Electrical – Td6 04-18
Electrical – V8 04-18
Dimensions 04-19
Weights 04-19
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 Td6 06-2
Engine V8 06-4
Emission control – Td6 06-6
Emission control – V8 06-6
Engine management system – Td6 06-7
Engine management system – V8 06-8
Fuel Delivery System – Td6 06-9
Fuel Delivery System – V8 06-9
Cooling System – Td6 06-10
Cooling System – V8 06-10
Manifold and Exhaust System – Td6 06-11
Manifold and Exhaust System – V8 06-11
Transfer Box 06-12
Automatic Gearbox – Td6 06-13
Automatic Gearbox – V8 06-14
Driveshafts 06-15
Final Drive 06-15
Front Differential 06-15
Steering 06-16
Front Suspension 06-17
Rear Suspension 06-18
Brakes 06-19
Restraint Systems 06-20
Body 06-21
Heating and Ventilation 06-22
Air Conditioning 06-22
Wipers and Washers 06-22
Electrical 06-23
LIFTING AND TOWING 08-1
Lifting 08-1
Towing 08-4
Transporting 08-5
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
Td6 Diesel engine underbonnet view 10-1
V8 Engine 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
Road wheels 10-6
Tyres 10-7
Brake pads, discs and calipers 10-7
Brake fluid 10-8
Fuel filter element – Td6 engine 10-8
Anti-freeze 10-9
Cooling system 10-9
Spark plugs – V8 engine 10-10
Air cleaner element – Td6 engine 10-10
Air cleaner element – V8 engine 10-10
Ancillary drive belt 10-11
Fluid reservoirs 10-11
Battery 10-12
Engine oil and filter – Td6 engine 10-13
Engine oil and filter – V8 engine 10-14
Gearbox fluid – Td6 10-15
Gearbox fluid – V8 10-16
Brake hose, brake pipes, fuel pipes, hydraulic pipes and unions/electrical harnesses 10-17
Engine, automatic gearbox, transfer box, front and rear and differentials 10-17
Exhaust system 10-18
Underbody 10-18
Body 10-18
Steering rod ball joints and dust covers 10-18
Road/roller test 10-19
CONTENTS
4 CONTENTS
Engine – V8 12-2-1
ADJUSTMENTS
Engine oil pressure check 12-2-1
REPAIRS
Pulley – crankshaft 12-2-3
Oil seal – crankshaft – front 12-2-3
Oil seal – crankshaft – rear 12-2-4
Gasket – cylinder head – LH 12-2-6
Gasket – cylinder head – RH 12-2-9
Gasket – camshaft cover – LH 12-2-13
Gasket – camshaft cover – RH 12-2-15
Acoustic cover – engine 12-2-17
Control solenoid – variable camshaft control (VCC) – LH 12-2-18
Control solenoid – variable camshaft control (VCC) – RH 12-2-19
Variable camshaft unit – variable camshaft control (VCC) – LH 12-2-20
Variable camshaft unit – variable camshaft control (VCC) – RH 12-2-26
Engine & ancillaries – remove for access & refit 12-2-32
Mounting – rear 12-2-45
Engine mounting – LH 12-2-47
Engine mounting – RH 12-2-51
Torque converter drive plate 12-2-53
Filter – engine oil 12-2-54
Tube – dipstick 12-2-54
Strainer – oil pick up 12-2-55
Pump – oil 12-2-56
Gasket – lower oil sump 12-2-57
Gasket – oil sump 12-2-58
Baffle Plate 12-2-60
Switch – oil pressure 12-2-60
Timing chain – includes align gears 12-2-61
Cover – timing gear – upper – RH 12-2-62
Cover – timing gear – upper – LH 12-2-66
Cover – timing gear – lower 12-2-69
OVERHAUL
Piston assemblies – engine set 12-2-73
Bearings – connecting rods – engine set 12-2-76
Pulley – crankshaft 12-2-78
Oil seal – crankshaft – front 12-2-79
Crankshaft and main bearings 12-2-80
Oil seal – crankshaft – rear 12-2-84
Gasket – cylinder head 12-2-85
Cylinder head – overhaul 12-2-89
Gasket – covers – camshaft 12-2-93
Variable camshaft unit – variable camshaft control (VCC) 12-2-95
Strainer – oil pick up 12-2-101
Pump – engine oil 12-2-101
Gasket – sump bottom plate 12-2-103
Gasket – oil sump 12-2-104
Cover – timing gear – upper 12-2-106
Cover – timing gear – lower 12-2-110
Timing chain & guides 12-2-113
Pipe(s) – water pump to coolant manifold 12-2-114
Gasket(s) – induction manifold 12-2-115
CONTENTS
CONTENTS 5
EMISSION CONTROL – V8 17-2-1
ADJUSTMENTS
Evaporative loss control system (EVAPS) – leak test – NAS 17-2-1
REPAIRS
Solenoid – canister purge 17-2-3
Charcoal canister 17-2-4
Valve – vacuum activation – secondary air injection (SAI) 17-2-5
Relay – secondary air injection pump (SAI) 17-2-6
Pump – secondary air injection (SAI) 17-2-6
Module – Tank Leakage Diagnostic (DMTL) 17-2-8
Catalytic converter 17-2-9
Sensor – heated oxygen (HO2S) – pre-catalyst 17-2-10
Sensor – heated oxygen (HO2S) – post catalyst 17-2-10
ENGINE MANAGEMENT SYSTEM – V8 18-2-1
REPAIRS
Spark plugs 18-2-1
Relay – ignition coils 18-2-1
Ignition coils – multiple – set 18-2-2
Cover – Ignition coils – LH 18-2-3
Cover – Ignition coils – RH 18-2-4
Engine control module (ECM) 18-2-5
Relay – combined ignition & fuel ECU 18-2-6
Sensor – engine coolant temperature (ECT) 18-2-6
Sensor – crankshaft position (CKP) 18-2-7
Sensor – camshaft position (CMP) – LH 18-2-9
Sensor – camshaft position (CMP) – RH 18-2-10
Sensor – knock (KS) – LH 18-2-11
Sensor – knock (KS) – RH 18-2-11
Sensor – temperature – ‘E’ box 18-2-12
Housing – air cleaner 18-2-13
Element – air cleaner 18-2-14
Hose – air flow meter to throttle body 18-2-15
Sensor – accelerator pedal position (APP) 18-2-16
Sensor – combined mass air flow (MAFS) & intake air temperature (IAT) 18-2-16
Throttle body 18-2-17
Fuel rail – remove for access & refit 18-2-18
Injectors – set 18-2-22
Sensor – brake pedal position 18-2-23
CONTENTS
6 CONTENTS
FUEL DELIVERY SYSTEM – V8 19-2-1
ADJUSTMENT
Fuel system – depressurise 19-2-1
Fuel system – pressure test 19-2-2
Tank – drain 19-2-3
REPAIRS
Filter – main 19-2-5
Vapour separator 19-2-6
Pump – fuel tank 19-2-7
Tank – fuel 19-2-9
Filler neck 19-2-13
Cover – tank module – LH 19-2-15
COOLING SYSTEM – V8 26-2-1
ADJUSTMENTS
Coolant – drain, flush & refill 26-2-1
REPAIRS
Coupling unit – viscous fan 26-2-3
Manifold – coolant 26-2-4
Pipe(s) – coolant pump to coolant manifold 26-2-6
Gasket – coolant gallery sealing plate 26-2-7
Radiator 26-2-7
Thermostat 26-2-8
Gasket – coolant pump 26-2-9
MANIFOLD AND EXHAUST SYSTEM – V8 30-2-1
REPAIRS
Exhaust system & mountings 30-2-1
Front pipe 30-2-3
Intermediate pipe 30-2-4
Tail pipe & silencer 30-2-5
Gasket(s) – inlet manifold 30-2-6
Gasket(s) – exhaust manifold – RH 30-2-12
Gasket(s) – exhaust manifold – LH 30-2-14
CONTENTS
CONTENTS 7
TRANSFER BOX 41-1
ADJUSTMENTS
Drain and refill 41-1
REPAIRS
Transfer gearbox – Td6 41-3
Transfer gearbox – V8 41-6
Oil seal – input shaft 41-9
Oil seal – front output shaft 41-10
Oil seal – rear output shaft 41-11
Fuse – transfer gearbox – electronic control unit (ECU) 41-12
Damper – vibration – Td6 41-13
Electronic control unit (ECU) – transfer gearbox 41-13
Actuator – ratio control 41-14
AUTOMATIC TRANSMISSION – ZF 5HP24 44-2-1
ADJUSTMENTS
Gearbox fluid – drain & refill 44-2-1
Selector cable – check and adjust 44-2-2
REPAIRS
Lever – gearshift selector assembly 44-2-3
Knob – selector lever 44-2-3
Rod/cable assembly – selector 44-2-4
Switch – starter inhibitor 44-2-5
Fluid seal – selector shaft 44-2-6
Solenoid – shift 44-2-7
Electronic control unit (ECU) – Electronic automatic transmission (EAT) 44-2-8
Harness – solenoid valve 44-2-9
Pick up – speed sensor – countershaft 44-2-10
Fluid seal – torque converter 44-2-11
Gearbox & converter 44-2-12
Gearbox/converter & transfer gearbox assembly – remove for access and refit 44-2-13
Fluid seal – rear 44-2-18
Gasket – fluid pan 44-2-18
Filter – fluid 44-2-19
Fluid cooler 44-2-20
Thermostat – fluid cooler 44-2-21
Valve body assembly 44-2-21
CONTENTS
8 CONTENTS
DRIVESHAFTS 47-1
REPAIRS
Drive shaft – front – LH 47-1
Drive shaft – front – RH 47-4
Gaiter – bell & joint – outer – front 47-8
Gaiter – inner joint 47-9
Seal – drive shaft – front – RH 47-10
Bearing driveshaft support 47-14
‘O’ Ring – driveshaft housing 47-15
Drive shaft – rear 47-15
Gaiter – bell & joint – outer – rear 47-17
Gaiter – inner joint 47-18
Propeller shaft – front 47-20
Propeller shaft – rear 47-21
Support bearing – rear 47-23
FINAL DRIVE 51-1
ADJUSTMENTS
Rear differential – drain and refill 51-1
REPAIRS
Differential assembly 51-3
Gasket – cover – rear – differential 51-6
Bush – differential mounting – each 51-6
Bush – differential mounting – rear 51-8
Oil seal – pinion 51-10
Oil seal – differential housing 51-12
FRONT DIFFERENTIAL 54-1
ADJUSTMENTS
Front differential – drain and refill 54-1
REPAIRS
Differential assembly – Td6 54-3
Differential assembly – V8 54-6
Oil seal – differential housing 54-9
CONTENTS
CONTENTS 9
STEERING 57-1
ADJUSTMENTS
Power assisted steering (PAS) system – bleed 57-1
Front wheel alignment – check & adjust 57-2
Steering geometry 57-2
Power steering pressure test – Td6 57-4
Power steering pressure test – V8 57-5
REPAIRS
Power steering rack – left hand drive – Td6 57-7
Power steering rack – left hand drive – V8 57-10
Power steering rack – right hand drive – V8 57-14
Power steering rack – right hand drive – Td6 57-19
Oil cooler – power steering – Td6 57-24
Oil cooler – power steering – V8 57-25
Pump – power steering – Td6 57-26
Pump – power steering – V8 57-28
Column assembly – inner & outer 57-29
Sensor- steering angle/column 57-32
Nacelle – column – complete 57-32
Switch – column adjustment – control 57-33
Ball joint – track rod 57-33
Steering wheel 57-34
Switch unit – steering wheel 57-36
Electronic control unit (ECU) – heated steering wheel 57-36
FRONT SUSPENSION 60-1
ADJUSTMENTS
Air suspension system – depressurise and repressurise 60-1
Calibrate – air suspension 60-1
REPAIRS
Anti-roll bar 60-3
Link – anti roll bar 60-4
Ball joint – tie rod 60-5
Air spring assembly 60-7
Hub 60-10
Bearings – hub 60-13
Lower arm 60-15
Bush – lower arm 60-16
Height sensor 60-17
Tie rod 60-18
Bushes – tie rods 60-20
Air reservoir 60-20
Electronic Control Unit (ECU) – air suspension 60-22
Air supply unit 60-22
Valve block assembly 60-23
Valve assembly – cross link 60-25
CONTENTS
10 CONTENTS
REAR SUSPENSION 64-1
ADJUSTMENTS
Suspension – depressurise and repressurise 64-1
REPAIRS
Hub 64-3
Ball joint – upper 64-5
Ball joint – lower 64-6
Bearing(s) – hub 64-7
Air spring 64-10
Damper 64-11
Anti-roll bar 64-13
Tie rod 64-14
Bushes – upper arm 64-15
Bushes – lower arm – front 64-16
Bushes – lower arm – rear 64-17
Link – anti roll bar 64-17
Arm assembly – lower 64-18
Arm assembly – upper 64-19
Bushes – rear subframe 64-21
Height sensor 64-25
Valve assembly – cross link 64-26
Valve – safety – air pressure 64-27
BRAKES 70-1
ADJUSTMENTS
Thickness and run out check – brake disc – front 70-1
Thickness and run out check – brake disc – rear 70-2
Brake system bleeding 70-4
Handbrake adjustment 70-5
REPAIRS
Brake disc – front 70-7
Brake disc – rear 70-8
Pump – pre-charge 70-9
Reservoir – brake fluid 70-10
Cylinder – master – tandem 70-11
Pedal box 70-12
Lever assembly – handbrake 70-13
Cable – handbrake 70-14
Switch – handbrake warning 70-16
Pads – front 70-16
Pads – rear 70-18
Sensor – pad wear – front 70-19
Sensor – pad wear – rear 70-20
Shoes – rear set 70-21
Servo assembly 70-22
Vacuum pump – Td6 70-23
ABS Electronic control unit (ECU) 70-23
ABS sensor – front wheel 70-24
ABS sensor – rear wheel 70-25
ABS Modulator unit 70-26
Sensor – pressure – ABS modulator 70-27
Sensor – dynamic stability control (DSC) 70-28
CONTENTS
CONTENTS 11
RESTRAINT SYSTEMS 75-1
REPAIRS
Seat belt – front 75-1
Seat belt – centre – rear 75-2
Seat belt – rear 75-4
Pre-tensioner – front seat belt 75-5
Airbag module – steering wheel 75-6
Airbag module – passenger 75-7
Airbag module – head – rear 75-8
Crash sensor – side 75-9
Battery – disconnect unit (SRS) 75-10
Rotary coupler 75-11
Airbag module – side impact – front door 75-12
Airbag module – head – front 75-13
Diagnostic control unit (DCU) 75-15
Pre-tensioner – seat belt – front – deployment – in vehicle 75-17
Pre-tensioner – front seat belt – deployment – off vehicle 75-18
Airbag module – steering wheel – deployment – off vehicle 75-20
Airbag module – passenger – deployment – in vehicle 75-22
Airbag module – passenger – deployment – off vehicle 75-24
Battery – disconnect unit (SRS) – deployment – in vehicle 75-26
Battery – disconnect (SRS) – deployment – off vehicle 75-27
Airbag module – side impact front door – deployment – in vehicle 75-29
Airbag module – side impact – front door – deployment – off vehicle 75-31
Airbag module – head – front – deployment – in vehicle 75-33
Airbag module – head – front – deployment – off vehicle 75-34
Airbag module – head – rear – deployment – in vehicle 75-36
Airbag module – head – rear – deployment – off vehicle 75-37
CONTENTS
12 CONTENTS
DOORS 76-1-1
ADJUSTMENTS
Tailgate lower – adjust on striker 76-1-1
Tailgate upper – adjust on striker(s) 76-1-1
REPAIRS
Glass – front door 76-1-3
Glass – rear door 76-1-3
Quarter light – fixed – rear door 76-1-4
Glass regulator – front door 76-1-6
Glass regulator – rear door 76-1-7
Seal – waist outer – front door 76-1-7
Seal – waist inner – front door 76-1-8
Trim casing – front door 76-1-8
Trim casing – rear door 76-1-11
Trim casing – tailgate upper 76-1-13
Trim finisher – tailgate – upper 76-1-13
Capping – front door arm rest 76-1-14
Plastic sheet – front door 76-1-14
Plastic sheet – rear door 76-1-15
Finisher – door frame – front 76-1-15
Finisher – upper – tailgate lower 76-1-16
Latch – front door 76-1-16
Latch – tailgate 76-1-17
Latch – outer – tailgate 76-1-18
Finisher – front door 76-1-19
Finisher – rear door 76-1-19
Handle – outside – front door 76-1-20
EXTERIOR FITTINGS 76-2-1
REPAIRS
Panel – extension – front wing 76-2-1
Wing – front 76-2-2
Liner – front wheel arch 76-2-3
Liner – rear wheel arch – single 76-2-4
Spoiler – tailgate 76-2-4
Mirror glass – exterior 76-2-5
Motor – exterior mirror 76-2-5
Mirror – exterior 76-2-6
Tow bar 76-2-7
Undertray – front 76-2-8
Bumper armature – rear 76-2-9
Bumper – assembly – front 76-2-11
Bumper – rear 76-2-13
Extension – spoiler – front bumper 76-2-14
Finisher – sill 76-2-15
Finisher – ‘E’ post 76-2-16
Side finisher – windscreen 76-2-16
Lower finisher – windscreen 76-2-17
Roof moulding 76-2-18
Finisher – tailgate – lower 76-2-18
Front grille 76-2-19
CONTENTS
CONTENTS 13
INTERIOR FITTINGS 76-3-1
REPAIRS
Sun visor 76-3-1
Mirror – interior 76-3-1
Trim casing – rear quarter – lower 76-3-2
Foot rest finisher – LHD 76-3-3
Trim finisher – ‘A’ post – upper 76-3-3
Trim finisher – ‘A’ post – lower 76-3-4
Trim finisher – ‘B’ post – upper 76-3-4
Trim finisher – ‘D’ post – upper 76-3-5
Trim finisher – ‘D’ post – lower 76-3-5
Trim finisher – ‘E’ post 76-3-6
Centre console 76-3-6
Console – headlining – front 76-3-8
Finisher – console 76-3-9
Console – headlining – rear 76-3-10
Cover – automatic transmission selector 76-3-11
Closing panel – centre console 76-3-11
Switch panel – air suspension 76-3-12
Top rail – fascia 76-3-12
Shroud – lower – fascia 76-3-13
Closing panel – fascia end 76-3-14
Finisher – upper – drivers side 76-3-15
Finisher – upper – passenger’s side 76-3-16
Finisher – lower – passengers side 76-3-17
Finisher – lower – drivers side 76-3-17
Fascia – carrier 76-3-18
Fascia – remove for access & refit 76-3-21
Closing panel – passenger side 76-3-29
Closing panel – driver’s side 76-3-30
Carpet – front 76-3-30
Retainer – front carpet 76-3-31
Finisher – tailgate carpet 76-3-31
Glove box 76-3-32
Latch – glove box 76-3-33
Handle – grab 76-3-34
Headlining 76-3-34
SCREENS 76-4-1
REPAIRS
Glass – tailgate upper 76-4-1
Windscreen 76-4-3
Glass – quarter light – rear 76-4-6
CONTENTS
14 CONTENTS
SEATS 76-5-1
REPAIRS
Arm rest – rear seat 76-5-1
Front seat 76-5-2
Rear seat 76-5-3
Cover – one piece – front seat cushion 76-5-3
Cover – one piece – front seat cushion – models with adjustable upper squab 76-5-6
Cover – rear seat cushion – RH 76-5-9
Cover – rear seat cushion – LH 76-5-10
Finisher – rear seat squab 76-5-11
Finisher – seat base rear 76-5-12
Finisher – arm rest – rear seat – front 76-5-13
Backboard – front seat – models with adjustable upper squab 76-5-14
Bladder – lumbar support – front seat 76-5-16
Bladder – lumbar support – front seat – models with adjustable upper squab 76-5-18
Switch – lumbar support 76-5-21
Motor – squab 76-5-22
Motor – fore & aft – front seat 76-5-24
Motor – rise & fall – front seat 76-5-25
Motor – rise & fall – head rest – front seat 76-5-25
Switch – front seat control 76-5-27
Switch pack – seat memory 76-5-28
Lever assembly – rear squab release 76-5-28
Latch – rear squab 76-5-29
Cover – squab – front seat – models with adjustable upper squab 76-5-29
Cover – squab – front seat 76-5-33
Cover – squab – rear seat – side – LH 76-5-35
Cover – squab – rear seat – RH 76-5-37
Hinge – rear seat – side 76-5-38
SUNROOF 76-6-1
ADJUSTMENT
Sun roof – align to roof panel & adjust 76-6-1
REPAIRS
Sunroof 76-6-3
Motor – sunroof 76-6-4
BODY DIMENSIONS 77-1-1
BODY DIMENSIONS
Dimensional Information 77-1-1
Dimensional Illustrations 77-1-2
BODY GAPS AND PROFILES
Gap and Profile Measurements 77-1-11
CONTENTS
CONTENTS 15
PANEL REPAIRS 77-2-1
REPLACEMENT PANELS
Serviceable Panels 77-2-1
Inner front end panels 77-2-2
Outer body side panels 77-2-3
Body side inner 77-2-4
Sunroof drain tubes 77-2-5
Rear inner body side panels 77-2-6
Roof assemblies 77-2-7
Rear end panels 77-2-8
Door assemblies 77-2-9
Door assemblies 77-2-10
WELDING PROCEDURES
General Welding Precautions 77-2-11
PROCEDURES
Panel replacement procedure 77-2-13
REPAIRS
Front bulkhead assembly 77-2-19
Bonnet locking platform 77-2-20
Headlamp mounting panel 77-2-20
Radiator protection bar 77-2-21
Front sidemember end panel 77-2-21
Front sidemember (front section) 77-2-22
Front sidemember assembly 77-2-24
Valance outer 77-2-26
Valance outer extension 77-2-26
Valance inner closing panel 77-2-27
Valance inner assembly 77-2-27
Valance inner reinforcement 77-2-29
Valance inner assembly – front section 77-2-30
Body side panel – ‘A’ post 77-2-30
‘A’ post reinforcement 77-2-32
Body side panel – sill section 77-2-34
Body side panel – sill and ‘B/C’ post section 77-2-35
‘B/C’ post reinforcement 77-2-36
Sill reinforcement 77-2-37
Body side panel – rear section 77-2-38
Rear wheel arch reinforcement – upper 77-2-40
‘D’ post reinforcement 77-2-40
Body side – rear extension 77-2-41
Tail lamp mounting panel 77-2-41
Body rear – outer panel 77-2-42
Body rear assembly 77-2-43
Spare wheel well 77-2-44
Rear floor extension 77-2-44
Floor longitudinal 77-2-45
Roof assembly 77-2-46
Doors 77-2-47
TIMES
TIME SCHEDULES 77-2-49
CONTENTS
16 CONTENTS
BODY SEALING MATERIALS 77-3-1
MATERIALS AND APPLICATIONS
77-3-1
APPROVED MATERIALS
77-3-3
APPLICATION EQUIPMENT
Application Equipment 77-3-5
CORROSION PREVENTION AND SEALING 77-4-1
STRUCTURAL SEALING
Structural adhesive on front sidemembers 77-4-1
Structural adhesive on front sidemembers 77-4-2
Structural adhesive on valance outer and body side panel 77-4-3
Structural adhesive on body side frame – inner 77-4-4
Structural adhesive 77-4-4
SEALING
Factory treatments 77-4-7
CAVITY WAX
Cavity wax application areas and injection holes 77-4-15
Front wing 77-4-16
Body side 77-4-17
Rear wheel arch 77-4-18
Rear end 77-4-19
Cavity wax 77-4-20
LEAK DETECTION
Water Leaks 77-4-21
PAINTING 77-5-1
PANEL PROCEDURES
Panel Preparation 77-5-1
PAINT PROCEDURES
Paint preparation 77-5-3
CONTENTS
CONTENTS 17
HEATING AND VENTILATION 80-1
REPAIRS
Controls – heater (ECU) 80-1
Sensor – pollution detection 80-2
Motor – windscreen air vent 80-2
Fresh air vent – face level 80-3
Ventilator(s) – centre 80-3
Filter – fresh air intake 80-4
Plenum – air intake 80-4
Heater unit/HEVAC – remove for access & refit 80-5
Motor assembly – select (air blend) control 80-6
Motor assembly – fresh & recirculated air control – LH 80-7
Motor assembly – fresh & recirculated air control – RH 80-7
Motor – fan 80-8
Resistor unit – fan motor – LHD 80-9
Resistor unit – fan motor – RHD 80-10
Motor – footwell air vent 80-11
Heater matrix 80-11
Fuel Burning Heater (FBH) – Td6 80-13
Receiver – fuel burning heater (FBH) 80-14
Sensor – ambient temperature 80-15
Fuel pump – Fuel Burning Heater (FBH) Td6 80-16
AIR CONDITIONING 82-1
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery – recycling and recharge 82-1
REPAIRS
Drive belt – compressor – Td6 82-3
Drive belt – compressor – V8 82-3
Tensioner – compressor drive belt – Td6 82-5
Tensioner – compressor drive belt – V8 82-5
Compressor – Td6 82-6
Compressor – V8 82-8
Motor – condenser fan 82-10
Condenser 82-13
Drier desiccant bag 82-14
Sensor – refrigerant pressure 82-16
Sensor – solar light – automatic temperature control 82-17
Sensor – air temperature – automatic temperature control 82-17
Sensor – evaporator temperature – LHD 82-18
Sensor – evaporator temperature – RHD 82-18
Valve – thermostatic expansion (TXV) – LHD 82-19
Valve – thermostatic expansion (TXV) – RHD 82-21
Evaporator 82-22
CONTENTS
18 CONTENTS
WIPERS AND WASHERS 84-1
REPAIRS
Reservoir – combined windscreen/headlamp washer 84-1
Sensor – washer reservoir level 84-1
Pump – washer 84-2
Sensor – rain 84-3
Arm – wiper – front screen 84-3
Blade – wiper – front screen 84-5
Motor & linkage – wiper 84-5
Motor – wiper 84-6
Relay – wiper delay 84-6
Arm – wiper – headlamp 84-7
Blade – wiper – headlamp 84-7
Motor – wiper – headlamp 84-8
Arm – wiper – tailgate 84-9
Blade – wiper – tailgate 84-9
Motor – wiper – tailgate 84-10
CHARGING AND STARTING 86-1-1
REPAIRS
Alternator – Td6 86-1-1
Alternator – V8 86-1-2
Ancillary drive belt – Td6 86-1-3
Ancillary drive belt – V8 86-1-4
Tensioner – ancillary drive belt – Td6 86-1-6
Tensioner – ancillary drive belt – V8 86-1-7
Battery 86-1-9
Carrier – battery 86-1-10
Starter motor – Td6 86-1-11
Starter motor – V8 86-1-12
Switch – ignition/starter 86-1-14
Barrel – lock- ignition switch 86-1-14
CONTENTS
CONTENTS 19
LIGHTING 86-2-1
ADJUSTMENTS
Headlamps – align beam 86-2-1
REPAIRS
Control unit – gas discharge – Xenon headlamps 86-2-3
Electronic control unit (ECU) headlamp levelling – Xenon headlamps only 86-2-3
Bulb – headlamp 86-2-4
Lamp assembly – side & indicator 86-2-5
Lamp assembly – indicator side repeater 86-2-6
Headlamp assembly 86-2-6
Lamp assembly – tail 86-2-7
Bulb – reverse lamp 86-2-8
Lamp – driving 86-2-9
Lamp assembly – stop – centre high mounted 86-2-9
Lamp assembly – interior – front and rear 86-2-10
Switch – master – lighting 86-2-10
Switch – hazard warning 86-2-11
Switch – combined direction indicator/headlight 86-2-12
Light check module (LCM) 86-2-12
CONTROL UNITS AND RELAYS 86-3-1
REPAIRS
Electronic control unit (ECU) – trailer 86-3-1
Relay – horn 86-3-1
Relay – heated front screen 86-3-2
Relay – heated rear screen 86-3-2
Body Control Unit (BCU) 86-3-3
DRIVING AIDS 86-4-1
REPAIRS
Sensor – tyre pressure monitoring (TPM) system 86-4-1
Antenna – front wheel – tyre pressure monitoring (TPM) system 86-4-2
Antenna – rear wheel – tyre pressure monitoring (TPM) system 86-4-3
Electronic control unit (ECU) – tyre pressure monitoring (TPM) 86-4-3
Electronic control unit (ECU) – parking aid 86-4-4
Sensor – parking aid – rear – each 86-4-5
Sounder – parking aid – front 86-4-5
Sounder – parking aid – rear 86-4-6
Sensor – parking aid – front – inner 86-4-6
Sensor – parking aid – front – outer 86-4-7
CONTENTS
20 CONTENTS
ALARM SYSTEM AND HORN 86-5-1
REPAIRS
Solenoid – motor – tailgate 86-5-1
Switch – tailgate release – lower 86-5-1
Horn 86-5-2
Sensor – alarm – tilt 86-5-3
Electronic control unit (ECU) – immobilisation 86-5-4
Switch – bonnet 86-5-4
Receiver – alarm 86-5-5
Sensor – ultrasonic 86-5-5
WINDOWS 86-6-1
REPAIRS
Switch – window – master 86-6-1
Switch pack – rear door 86-6-1
NAVIGATION AND IN CAR ENTERTAINMENT 86-7-1
REPAIRS
Radio 86-7-1
Grille – front door speaker 86-7-2
Speaker – front door 86-7-3
Speaker – top rail 86-7-3
Cassette/CD unit 86-7-4
Power amplifier 86-7-4
Head unit – multi-information display 86-7-6
Computer – navigation 86-7-7
Amplifier – aerial – diversity 86-7-8
Antenna – telephone 86-7-8
Control unit – telephone (TCU) 86-7-9
Voice recognition module 86-7-10
Amplifier – television (TV) – LH 86-7-11
Amplifier – television (TV) – RH 86-7-11
Amplifier – aerial – TV and FBH 86-7-12
Video unit 86-7-12
HARNESSES 86-8-1
REPAIRS
Fuse box – passenger compartment 86-8-1
Harness – engine – Td6 86-8-2
Harness – engine – V8 86-8-7
Environmental box (‘E’ box) 86-8-12
Harness – tailgate – lower 86-8-13
CONTENTS
CONTENTS 21
INSTRUMENTS 88-1
REPAIRS
Instrument pack 88-1
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