Land Rover Freelander Workshop Manual LRL0144ENG – PDF DOWNLOAD
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Land Rover Freelander Workshop Manual LRL0144ENG – PDF DOWNLOAD
Language : English
Pages : 989
Downloadable : Yes
File Type : PDF
Size: 12.7 MB
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Land Rover Freelander Workshop Manual LRL0144ENG – PDF DOWNLOAD
For ease of use, this Manual is structured to display the section title at the top of each page and the relevant sub-section at the bottom of each page. In addition, a section icon is displayed at the top outer corner of right-hand pages. Each major section is preceded by a contents page, which lists titles of the topics and procedures contained in the relevant sub-sections.
- Technical data is subject to change; to facilitate the periodic revision of technical information, each sub-section is numbered from page 1 so that revised sub-sections can be replaced if required.
- Repair operations are to be performed in the sequence and manner described. Item numbers annotated in the illustration are referred to in the accompanying text. Adjustment and repair operations may include reference to service tool numbers and the associated illustration depicts the tool.
- Where usage is not obvious the tool is shown in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details. Each adjustment or repair operation is given its Scheduled Repair Operation number.
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TABLE OF CONTENTS:
Land Rover Freelander Workshop Manual LRL0144ENG – PDF DOWNLOAD
CarParc 0
Library 0
Video Clips 0
Freelander Workshop Manual – 5th Edition 4
0
INTRODUCTION 8
INTRODUCTION 8
INTRODUCTION 8
REPAIRS AND REPLACEMENTS 9
SPECIFICATION 10
ABBREVIATIONS AND SYMBOLS 11
GENERAL INFORMATION 16
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 16
GENERAL PRECAUTIONS 16
Health Protection Precautions 17
SAFETY INSTRUCTIONS 18
GENERAL FITTING INSTRUCTIONS 19
BALL AND ROLLER BEARINGS 21
OIL SEALS 22
JOINTS AND JOINT FACES 23
LOCKING DEVICES 23
SCREW THREADS 24
BOLT IDENTIFICATION 24
NUT IDENTIFICATION 25
FLEXIBLE HYDRAULIC PIPES AND HOSES 26
COOLING SYSTEM HOSES 27
SERVICE TOOLS AND GARAGE EQUIPMENT 28
DYNAMOMETER TESTING – NON ANTI-LOCK BRAKE VEHICLES 29
DYNAMOMETER TESTING – VEHICLES WITH ANTI-LOCK BRAKES (ABS) 29
FUEL HANDLING PRECAUTIONS 30
FUEL HANDLING PRECAUTIONS 30
ELECTRICAL PRECAUTIONS 32
ELECTRICAL PRECAUTIONS 32
SRS PRECAUTIONS 34
SUPPLEMENTARY RESTRAINT SYSTEM PRECAUTIONS 34
AIRBAG AND PRE-TENSIONER MANUAL DEPLOYMENT 41
COMPONENT REPLACEMENT POLICY 48
AIR CONDITIONING PRECAUTIONS 50
AIR CONDITIONING SYSTEM PRECAUTIONS 50
REMEDIAL ACTIONS 51
SERVICE PRECAUTIONS 52
PRECAUTIONS FOR REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 54
VEHICLE IDENTIFICATION NUMBER 56
VEHICLE IDENTIFICATION NUMBER 56
IDENTIFICATION NUMBER LOCATIONS 57
INFORMATION 60
LIFTING AND TOWING 60
JACKING 60
TOWING 63
TRANSPORTING THE VEHICLE BY TRAILER 64
EMERGENCY STARTING 64
GENERAL DATA 66
ENGINE – ’K’ SERIES 66
ENGINE – ’L’ SERIES 69
FUEL SYSTEM – ’K’ SERIES 72
FUEL SYSTEM – ’L’ SERIES 72
COOLING SYSTEM – ’K’ SERIES 73
COOLING SYSTEM – ’L’ SERIES 73
CLUTCH 74
MANUAL GEARBOX – PG1 75
FINAL DRIVE 77
INTERMEDIATE REDUCTION DRIVE 77
REAR AXLE 77
VISCOUS COUPLING 78
STEERING 78
SUSPENSION 79
WHEELS 79
TYRE SIZES 79
TYRE PRESSURES 80
BRAKES 80
AIR CONDITIONING 81
ELECTRICAL – ’K’ SERIES 82
ELECTRICAL – ’L’ SERIES 82
DIMENSIONS 83
WEIGHTS 83
ENGINE TUNING DATA 84
MODEL: 1 8 – ’K’ SERIES 84
2 0 – ’L’ SERIES 84
TORQUE WRENCH SETTINGS 86
GENERAL 86
ENGINE – ’K’ SERIES 86
ENGINE – ’L’ SERIES 87
ENGINE MANAGEMENT SYSTEM – MEMS 89
ENGINE MANAGEMENT SYSTEM – EDC 90
FUEL DELIVERY SYSTEM 91
COOLING 91
MANIFOLD AND EXHAUST 92
CLUTCH 92
MANUAL GEARBOX – PG1 93
INTERMEDIATE REDUCTION DRIVE 94
DRIVE SHAFTS 94
STEERING 95
SUSPENSION AND SUBFRAME 96
BRAKES 97
SUPPLEMENTARY RESTRAINT SYSTEMS 97
BODY 98
HEATING AND VENTILATION 101
AIR CONDITIONING 101
WIPERS AND WASHERS 101
ELECTRICAL 102
INSTRUMENTS 103
CAPACITIES, FLUIDS AND LUBRICANTS 104
CAPACITIES 104
FLUIDS 105
LUBRICATION 106
MAINTENANCE 110
MAINTENANCE 110
VEHICLE INTERIOR 110
VEHICLE EXTERIOR 111
UNDER BONNET 115
ENGINE – ’K’ SERIES 128
DESCRIPTION AND OPERATION 128
TIMING BELT COMPONENTS 128
CYLINDER BLOCK COMPONENTS 130
CYLINDER HEAD COMPONENTS 132
OPERATION 133
ENGINE NUMBER LOCATION 135
ADJUSTMENTS 136
ENGINE OIL PRESSURE CHECK 136
REPAIRS 138
SEAL – FRONT – INLET AND EXHAUST CAMSHAFT 138
SEAL – REAR – EXHAUST CAMSHAFT 139
SEAL – REAR – INLET CAMSHAFT 140
HOUSING – CAMSHAFT – RESEAL AND RENEW OIL SEALS 141
PULLEY – CRANKSHAFT – ’K’ SERIES 143
SEAL – FRONT – CRANKSHAFT 144
CRANKSHAFT REAR OIL SEAL – ’K’SERIES 145
GASKET – CYLINDER HEAD – ’K’ SERIES 146
TAPPETS 152
VALVE STEM OIL SEAL – ENGINE SET 153
ENGINE ASSEMBLY – REMOVE/REFIT – ’K’ SERIES 155
GASKET – CAMSHAFT COVER – ’K’ SERIES 161
MOUNTING – ENGINE – LH – ’K’ SERIES 162
MOUNTING – ENGINE – RH – ’K’ SERIES 164
FLYWHEEL 165
FILTER – ENGINE OIL 166
PUMP – ENGINE OIL 167
OIL SUMP – ’K’ SERIES 168
SWITCH – OIL PRESSURE – ’K’ SERIES 170
TIMING BELT – CAMSHAFT – ’K’ SERIES 171
MANUAL TENSIONER – CAMSHAFT – TIMING BELT 179
COVER – TIMING BELT – FRONT UPPER – ’K’ SERIES 179
COVER – INNER – TIMING BELT 180
COVER – TIMING BELT – FRONT LOWER 181
ENGINE – ’L’ SERIES 186
DESCRIPTION AND OPERATION 186
CAMSHAFT TIMING BELT COMPONENTS 186
CYLINDER BLOCK COMPONENTS 188
CYLINDER HEAD COMPONENTS 189
DESCRIPTION 190
ADJUSTMENTS 194
ENGINE OIL PRESSURE CHECK 194
REPAIRS 196
SEAL – CAMSHAFT – FRONT 196
SEAL – CAMSHAFT – REAR 200
CRANKSHAFT PULLEY 203
SEAL – CRANKSHAFT – FRONT 206
SEAL – CRANKSHAFT – REAR 207
GASKET – CYLINDER HEAD 208
GASKET – CAMSHAFT COVER 213
COVER – ENGINE ACOUSTIC 214
ENGINE AND GEARBOX 215
MOUNTING – ENGINE – LH 224
MOUNTING – ENGINE – RH 226
TIE ROD – UPPER 227
TIE ROD – LOWER 228
FILTER – ENGINE OIL 228
PUMP – ENGINE OIL 229
SUMP – ENGINE 232
SWITCH – OIL PRESSURE 234
COOLER – ENGINE OIL 235
BELT – CAMSHAFT DRIVE 236
Video Clip 236
COVER – TIMING GEAR – UPPER 243
COVER – TIMING GEAR – LOWER 245
FIP TIMING BELT COVER 246
BELT – TIMING – FUEL INJECTION PUMP (FIP) 246
EMISSION CONTROL 254
DESCRIPTION AND OPERATION 254
TYPES OF EMISSION 254
EMISSION CONTROL SYSTEMS 254
REPAIRS 262
EVAPORATIVE EMISSION (EVAP) CANISTER – ’K’ SERIES 262
PURGE CONTROL VALVE – EVAPORATIVE EMISSION CANISTER – ’K’ SERIES 263
EXHAUST GAS RECIRCULATION (EGR) VALVE – ’L’ SERIES 264
SOLENOID VALVE – EGR – ’L’ SERIES 264
CATALYTIC CONVERTER 265
ENGINE MANAGEMENT SYSTEM – MEMS 268
DESCRIPTION AND OPERATION 268
ENGINE COMPARTMENT COMPONENT LOCATIONS 268
PASSENGER COMPARTMENT COMPONENT LOCATIONS 269
MODULAR ENGINE MANAGEMENT SYSTEM OPERATION 270
ECU Harness Pin-out Connections 273
ECU Harness Pin-out Connections – Continued 274
ADJUSTMENTS 288
THROTTLE CABLE – CHECK AND ADJUST 288
Video Clip 288
REPAIRS 290
FUEL SYSTEM – DEPRESSURISE 290
AIR – CLEANER 290
ELEMENT – AIR FILTER 291
SWITCH – INERTIA – FUEL CUT-OFF 291
HEATED OXYGEN SENSOR (HO2S) 292
HOUSING – THROTTLE 292
THROTTLE CABLE 294
SPARK PLUGS 295
DISTRIBUTOR CAP AND ROTOR ARM 296
COIL – IGNITION 296
ENGINE CONTROL MODULE (ECM) 297
IDLE AIR CONTROL (IAC) VALVE 297
SENSOR – ENGINE COOLANT TEMPERATURE (ECT) 298
SENSOR – CRANKSHAFT POSITION (CKP) 298
SENSOR – INTAKE AIR TEMPERATURE (IAT) 299
SENSOR – THROTTLE POSITION (TP) 299
FUEL – RAIL 300
INJECTORS – SET 301
ENGINE MANAGEMENT SYSTEM – EDC 306
DESCRIPTION AND OPERATION 306
ENGINE COMPARTMENT COMPONENT LOCATIONS 306
PASSENGER COMPARTMENT COMPONENT LOCATIONS 307
ELECTRONIC DIESEL CONTROL OPERATION 308
REPAIRS 328
SENSOR – ENGINE COOLANT TEMPERATURE (ECT) 328
SOLENOID – FUEL CUT OFF 328
SENSOR – CRANKSHAFT POSITION (CKP) 329
ELEMENT – AIR FILTER 330
ENGINE CONTROL MODULE – (ECM) 330
SENSOR – INTAKE AIR TEMPERATURE (IAT) 331
SENSOR – MANIFOLD ABSOLUTE PRESSURE (MAP) 331
RELAY MODULE – ENGINE MANAGEMENT 332
AIR – CLEANER 332
SENSOR – MASS AIR FLOW (MAF) 333
THROTTLE POTENTIOMETER – RHD 334
THROTTLE POTENTIOMETER – LHD 335
FILTER – FUEL 336
PUMP – FUEL INJECTION (FIP) 337
TURBOCHARGER 341
CHAMBER – PLENUM 342
INTERCOOLER 343
INJECTORS 344
HIGH PRESSURE PIPES – FUEL INJECTION 346
GLOW PLUGS – SET 347
RELAY – GLOW PLUGS 348
FUEL DELIVERY SYSTEM 352
DESCRIPTION AND OPERATION 352
FUEL DELIVERY SYSTEM – ’K’ SERIES 352
FUEL DELIVERY SYSTEM – ’L’ SERIES 355
REPAIRS 358
FILTER – FUEL – ’K’ SERIES 358
PUMP – FUEL – ’K’ SERIES 359
FUEL TANK 361
FUEL TANK DRAINING 363
FUEL FILLER NECK 363
COOLING SYSTEM – ’K’ SERIES 368
DESCRIPTION AND OPERATION 368
COOLING SYSTEM COMPONENTS 368
COOLING SYSTEM OPERATION 369
ADJUSTMENTS 372
DRAIN AND REFILL 372
REPAIRS 374
EXPANSION – TANK – COOLANT 374
MOTOR – COOLING FAN – WITH AIR CONDITIONING 375
MOTOR – COOLING FAN 376
RADIATOR 377
THERMOSTAT 378
PUMP – COOLANT 379
COOLING SYSTEM – ’L’ SERIES 383
DESCRIPTION AND OPERATION 383
COOLING SYSTEM COMPONENTS 383
COOLING SYSTEM OPERATION 385
ADJUSTMENTS 388
DRAIN AND REFILL 388
REPAIRS 390
EXPANSION – TANK – COOLANT 390
MOTOR – COOLING FAN 390
RADIATOR 392
THERMOSTAT 393
PUMP – COOLANT 394
PUMP – COOLANT – WITH AIR CONDITIONING 395
MANIFOLD & EXHAUST SYSTEMS 400
DESCRIPTION AND OPERATION 400
INLET AND EXHAUST MANIFOLD – ’K’ SERIES 400
INLET AND EXHAUST MANIFOLD – ’L’ SERIES 401
INLET MANIFOLD 402
EXHAUST MANIFOLD 403
EXHAUST SYSTEM -’K’ SERIES 404
EXHAUST SYSTEM – ’L’ SERIES 405
EXHAUST SYSTEM 406
REPAIRS 410
EXHAUST PIPE – FRONT – ’K’ SERIES 410
EXHAUST PIPE – FRONT – ’L’ SERIES 411
EXHAUST PIPE – INTERMEDIATE 412
GASKET – INLET AND EXHAUST MANIFOLD – ’L’ SERIES 413
EXHAUST PIPE – TAIL 416
GASKET – INLET MANIFOLD – ’K’ SERIES 417
GASKET – EXHAUST MANIFOLD – ’K’ SERIES 419
CLUTCH 424
DESCRIPTION AND OPERATION 424
CLUTCH COMPONENTS 424
CLUTCH SYSTEM DESCRIPTION 425
CLUTCH SYSTEM OPERATION 428
REPAIRS 430
CLUTCH PLATE AND RELEASE BEARING – ’K’ SERIES 430
CLUTCH ASSEMBLY AND RELEASE BEARING – ’L’ SERIES 432
HYDRAULIC ASSEMBLY – RHD 435
HYDRAULIC ASSEMBLY – LHD 437
MANUAL GEARBOX – ’PG1’ 442
REPAIRS 442
SWITCH – HILL DESCENT 442
GEARBOX – ’K’ SERIES 443
GEARBOX – ’L’ SERIES 447
TRANSFER BOX – ’IRD’ 456
DESCRIPTION AND OPERATION 456
INTERMEDIATE REDUCTION DRIVE 456
REPAIRS 460
INTERMEDIATE REDUCTION DRIVE (IRD) UNIT 460
SEAL – DRIVE SHAFT – FRONT LH 463
SEAL – DRIVE SHAFT – RH 464
SEAL – PINION GEAR HOUSING 464
GASKET – END COVER – IRD HOUSING 466
SEALS – PRIMARY GEAR SHAFT 469
SEAL – PINION GEAR 471
DRIVE SHAFTS 474
DESCRIPTION AND OPERATION 474
DRIVE/PROPELLER SHAFTS 474
DRIVE SHAFTS 475
PROPELLER SHAFTS AND VCU 477
REPAIRS 482
DRIVE SHAFT – FRONT 482
DYNAMIC DAMPER – FRONT 483
GAITER – OUTER – FRONT 484
DRIVE SHAFT JOINT – OUTER – FRONT 484
GAITER – INNER – FRONT 485
DRIVE SHAFT – REAR 486
GAITER – INNER – REAR 487
GAITER – OUTER – REAR 488
JOINT – OUTER – REAR 488
PROPELLER SHAFT – ASSEMBLY 489
Video Clip 489
PROPELLER SHAFT 491
PROPELLER SHAFT – FRONT/REAR – OVERHAUL 492
VISCOUS COUPLING ASSEMBLY 493
SUPPORT BEARING – VISCOUS COUPLING – FRONT 495
SUPPORT BEARING – VISCOUS COUPLING – REAR 496
REAR AXLE AND FINAL DRIVE 500
DESCRIPTION AND OPERATION 500
REAR DIFFERENTIAL 500
REPAIRS 502
DIFFERENTIAL ASSEMBLY 502
Video Clip 502
PINION SEAL 503
OIL SEAL – DIFFERENTIAL 505
STEERING 510
DESCRIPTION AND OPERATION 510
STEERING COMPONENTS – ’K’ SERIES 510
STEERING COMPONENTS – ’L’ SERIES 511
STEERING DESCRIPTION 512
STEERING OPERATION 525
ADJUSTMENTS 532
POWER ASSISTED STEERING (PAS) SYSTEM BLEED 532
WHEEL ALIGNMENT – FRONT 533
WHEEL ALIGNMENT – REAR 534
POWER STEERING SYSTEM – PRESSURE TEST 535
REPAIRS 538
RACK – POWER ASSISTED STEERING (PAS) 538
GAITER – STEERING RACK 540
BELT – DRIVE – PAS PUMP – ’K’ SERIES 541
PUMP – POWER ASSISTED STEERING – L SERIES 542
COOLER – PAS FLUID 546
NACELLE – STEERING COLUMN 547
LOCK – STEERING COLUMN 548
STEERING COLUMN ASSEMBLY 548
TRACK ROD 551
STEERING WHEEL 552
PUMP – POWER ASSISTED STEERING – K SERIES 553
FRONT SUSPENSION 558
DESCRIPTION AND OPERATION 558
FRONT SUSPENSION COMPONENT LOCATIONS 558
FRONT SUSPENSION COMPONENT DETAIL 559
FRONT SUSPENSION DESCRIPTION 561
REPAIRS 564
ANTI-ROLL BAR 564
BEARING – HUB – FRONT 565
DAMPER – FRONT 569
LOWER ARM – FRONT 571
REAR SUSPENSION 576
DESCRIPTION AND OPERATION 576
REAR SUSPENSION COMPONENT LOCATIONS 576
REAR SUSPENSION COMPONENT DETAIL 577
REAR SUSPENSION DESCRIPTION 579
REPAIRS 582
BUSH – TRAILING LINK – REAR 582
BEARING – HUB – REAR 583
DAMPER – REAR 586
TRANSVERSE LINK – ADJUSTABLE – REAR 589
BRAKES 592
DESCRIPTION AND OPERATION 592
BRAKES 592
FRONT BRAKES 592
REAR BRAKES 592
HYDRAULIC SYSTEM 597
ABS 608
HANDBRAKE 621
ADJUSTMENTS 622
BRAKE BLEED 622
CABLE – HANDBRAKE 623
Video Clip 623
SWITCH – BRAKE LIGHT 624
REPAIRS 626
BRAKE DRUM – REAR 626
BRAKE DISC – FRONT 627
MASTER CYLINDER 628
CABLE – HANDBRAKE 629
SWITCH – BRAKE LIGHT 631
BRAKE PADS – FRONT SET 631
BRAKE SHOES – REAR SET 633
SERVO – LHD 636
SERVO – RHD 637
PUMP – VACUUM – BRAKE SERVO – ’L’ SERIES 638
HOUSING – CALIPER – FRONT 638
WHEEL CYLINDER – REAR 639
ELECTRONIC CONTROL UNIT (ECU) – ABS 640
SENSOR AND HARNESS – ABS – FRONT 641
SENSOR AND HARNESS – ABS – REAR 642
MODULATOR – ABS 643
RESTRAINT SYSTEMS 648
DESCRIPTION AND OPERATION 648
SEAT BELTS & SUPPLEMENTARY RESTRAINT SYSTEM 648
SEAT BELTS 648
SUPPLEMENTARY RESTRAINT SYSTEM (SRS) 651
REPAIRS 662
SEAT BELT – FRONT – 3 DOOR 662
SEAT BELT – FRONT – 5 DOOR 663
SEAT BELT – CENTRE – REAR – 5 DOOR 664
SEAT BELT – SIDE – REAR – 5 DOOR 665
ADJUSTABLE MOUNTING – SEAT BELT – ’B/C’ POST 666
SEAT BELT BUCKLE – REAR – 3 DOOR 667
SEAT BELT BUCKLE – REAR – 5 DOOR 668
PRETENSIONER – SEAT BELT – FRONT 668
SEAT BELT BUCKLE – CENTRE – REAR – 5 DOOR 669
AIRBAG – STEERING WHEEL 671
AIRBAG – PASSENGER 672
ROTARY COUPLER 673
DIAGNOSTIC CONTROL UNIT (DCU) 674
BODY 680
DESCRIPTION AND OPERATION 680
FRONT WINDOW REGULATOR 680
REAR WINDOW REGULATOR 681
TAIL DOOR WINDOW REGULATOR 682
FRONT DOOR CENTRAL LOCKING COMPONENTS 683
REAR DOOR CENTRAL LOCKING COMPONENTS 684
TAIL DOOR LOCKING COMPONENTS 685
CENTRAL DOOR LOCKING OPERATION 686
ADJUSTMENTS 688
DOOR STRIKER – CHECK AND ADJUST 688
DOOR – ALIGN ON HINGES 689
DOORS 690
DOOR ASSEMBLY – FRONT 690
DOOR ASSEMBLY – REAR 691
DOOR ASSEMBLY – TAIL 692
GLASS – FRONT DOOR 693
GLASS – REAR DOOR 694
SEAL – GLASS CHANNEL – FRONT 695
SEAL – GLASS CHANNEL – REAR DOOR 696
SCREEN – REAR 697
Video Clip 697
QUARTER LIGHT – REAR DOOR 699
REGULATOR – REAR DOOR GLASS 699
REGULATOR – REAR SCREEN 700
WAIST SEAL – TAIL DOOR 701
CASING – FRONT DOOR – 3 DOOR 702
CASING – FRONT DOOR – 5 DOOR 703
CASING – REAR DOOR 705
CASING – TAIL DOOR 706
WATER SHEDDER – LOWER – 3 DOOR 707
POCKET – FRONT DOOR – 3 DOOR 707
WATER SHEDDER – UPPER – 3 DOOR 708
WATER SHEDDER – TAIL DOOR 709
WATER SHEDDER – FRONT DOOR – 5 DOOR 710
WATER SHEDDER – REAR DOOR 711
LATCH – FRONT DOOR – 3 DOOR 712
LATCH – FRONT DOOR – 5 DOOR 713
LATCH – REAR DOOR 714
LATCH – TAIL DOOR 715
DOOR RELEASE – INTERIOR – FRONT DOOR – 3 DOOR 716
DOOR RELEASE – INTERIOR – FRONT DOOR – 5 DOOR 716
DOOR RELEASE – INTERIOR – REAR DOOR 717
CABLE – INTERIOR DOOR RELEASE – FRONT DOOR 717
CABLE – INTERIOR DOOR RELEASE – REAR DOOR 718
FINISHER – UPPER – TAIL DOOR GLASS 718
FINISHER – SIDE – TAIL DOOR GLASS 719
HANDLE – EXTERIOR – REAR DOOR 720
HANDLE – EXTERIOR – TAIL DOOR 721
HANDLE – EXTERIOR – FRONT DOOR 722
DOOR PULL – FRONT 723
EXTERIOR FITTINGS 724
WING – FRONT 724
WHEEL ARCH LINER – FRONT 725
PANEL – UNDERBELLY 726
MIRROR – EXTERIOR – ELECTRIC 726
MUD FLAP – FRONT 727
MUD FLAP – REAR 727
MOUNTING BRACKET – SPARE WHEEL 728
SIDE RAIL – ROOF RACK – 5 DOOR 729
BONNET 729
CABLE – BONNET RELEASE 730
BUMPER VALANCE – FRONT 732
BUMPER VALANCE – REAR 734
FINISHER – SILL – LOWER 735
FINISHER – ROOF PANEL 736
WHEEL ARCH EXTENSION – REAR 738
GRILLE – FRONT 739
VENT – REAR QUARTER 740
INTERIOR TRIM COMPONENTS 742
SUN VISOR 742
FINISHER – ’A’ POST 742
CASING – REAR QUARTER LOWER – 3 DOOR 743
CASING – REAR QUARTER LOWER – 5 DOOR 744
CASING – REAR QUARTER UPPER – 3 DOOR 745
CASING – REAR QUARTER UPPER – 5 DOOR 746
FINISHER – ’B/C’ POST UPPER – 5 DOOR 747
FINISHER -’B/C’ POST LOWER – 5 DOOR 748
CASING – BODY SIDE – REAR 749
CONSOLE – FRONT 750
CONSOLE – REAR 752
FASCIA 753
STOWAGE BOX – FASCIA 758
CARPET – LOADSPACE 759
GLOVE BOX 760
HEADLINING – 5 DOOR 760
HEADLINING – 3 DOOR 763
SEATS AND SEAT BELTS 766
SEAT – FRONT 766
SEAT – RH REAR – 5 DOOR 767
CUSHION AND SQUAB – REAR SEAT – 3 DOOR 768
CUSHION COVER – FRONT SEAT 769
CUSHION COVER – RH REAR SEAT – 5 DOOR 771
CUSHION COVER – REAR SEAT – 3 DOOR 773
CUSHION COVER – LH REAR SEAT – 5 DOOR 775
FINISHER – SEAT BASE – FRONT SEAT 776
FINISHER – CUSHION SIDE – FRONT SEAT 777
LUMBAR SUPPORT – FRONT SEAT 777
LATCH ASSEMBLY – REAR SQUAB – RH 779
LATCH ASSEMBLY – REAR SQUAB – LH 779
SQUAB COVER – FRONT SEAT 780
SQUAB COVER – REAR SEAT – 3 DOOR 781
SQUAB COVER – LH REAR SEAT – 5 DOOR 783
SQUAB COVER – RH REAR SEAT – 5 DOOR 785
SCREENS 788
WINDSCREEN 788
GLASS – BODY SIDE – REAR 791
HOOD 795
HOOD OUTER COVER 795
GLASS – BODY SIDE – HARD BACK 797
SEAL – HARD BACK – PRIMARY 800
CATCH AND RETAINER – HARD-BACK – FRONT 801
CATCH AND RETAINER – HARD-BACK – REAR 802
SUNROOF 804
SUN ROOF ASSEMBLY – 3 DOOR 804
WIND DEFLECTOR – GLASS SUN ROOF – 3 DOOR 806
SEAL – SUN ROOF TRAY 807
SUN ROOF ASSEMBLY – 5 DOOR 808
PANEL GLASS – SUN ROOF – 5 DOOR 808
SEAL – PANEL GLASS – SUN ROOF – 5 DOOR 809
MOTOR – SUN ROOF 809
DRIVE CABLES & SLIDE ASSEMBLIES 810
DRAIN TUBE – SUN ROOF – FRONT – 5 DOOR 811
DRAIN TUBE – SUN ROOF – REAR – 5 DOOR 812
FINISHER – SUN ROOF FLANGE TO HEADLINING 812
WIND DEFLECTOR – SUN ROOF – 5 DOOR 813
BLIND – SUN ROOF – 5 DOOR 813
SWITCH – SUN ROOF 814
SEAL – SUN ROOF TRAY – 5 DOOR 814
HEATING & VENTILATION 818
DESCRIPTION AND OPERATION 818
HEATING AND VENTILATION 818
AIR INLET DUCT 819
HEATER ASSEMBLY 819
DISTRIBUTION 825
CONTROLS 826
OPERATION 826
REPAIRS 828
SERVO – AIR RECIRCULATION 828
SWITCH – RECIRCULATION CONTROL 829
SWITCH – HEATER FAN 830
VENTILATOR – FACE LEVEL 831
PLENUM – AIR INTAKE MOULDING 832
HEATER 833
MOTOR AND FAN ASSEMBLY 835
RESISTOR – FAN MOTOR 835
MATRIX – HEATER 836
AIR CONDITIONING 840
DESCRIPTION AND OPERATION 840
AIR CONDITIONING 840
REFRIGERANT SYSTEM 841
COOLING UNIT 849
CONTROL SYSTEM 850
OPERATION 852
ADJUSTMENTS 856
RECOVERY AND RECYCLING 856
EVACUATION AND RECHARGING 856
PERFORMANCE GUIDE-LINES 857
REPAIRS 858
COMPRESSOR – ’K’ SERIES 858
COMPRESSOR – ’L’ SERIES 860
CONDENSER 862
RECEIVER DRIER 863
SWITCH – CONTROL 864
THERMOSTATIC EXPANSION VALVE (TXV) 865
EVAPORATOR 867
THERMOSTAT – EVAPORATOR 867
WIPERS & WASHERS 872
DESCRIPTION AND OPERATION 872
WINDSCREEN WIPER COMPONENTS 872
REAR SCREEN WIPER COMPONENTS 873
WASHER COMPONENTS 874
WINDSCREEN WIPERS DESCRIPTION 875
REAR SCREEN WIPER DESCRIPTION 876
WINDSCREEN WASHERS DESCRIPTION 878
REAR SCREEN WASHER DESCRIPTION 878
REPAIRS 880
RESERVOIR – WINDSCREEN WASHER 880
WASHER JET – WINDSCREEN 881
PUMP – WINDSCREEN WASHER 881
WIPER ARM – WINDSCREEN 882
WIPER BLADE – WINDSCREEN 882
MOTOR AND LINKAGE – WINDSCREEN WIPER 883
SWITCH – WINDSCREEN WASHER AND WIPER 883
PUMP – REAR SCREEN WASHER 884
WIPER ARM – REAR SCREEN 884
WIPER BLADE – REAR SCREEN 885
MOTOR – REAR SCREEN WIPER 885
SWITCH – REAR SCREEN WASHER AND WIPER 886
RELAY – REAR SCREEN WIPER MOTOR 887
ELECTRICAL 890
DESCRIPTION AND OPERATION 890
CENTRAL CONTROL UNIT (CCU) 890
TRANSIT MODE 890
ANTI THEFT ALARM SYSTEM 891
WINDSCREEN WIPERS 901
COURTESY LAMP DELAY 902
DOOR OPEN WARNING LIGHT 903
REAR FOG GUARD LIGHTS 903
LIGHTS ON ALARM 904
CATALYST OVERHEAT WARNING (MARKET SELECTABLE) 904
HANDBRAKE WARNING 905
OVERSPEED WARNING (MARKET SELECTABLE) 905
REAR SCREEN WIPER 906
TAIL DOOR WINDOW 908
HEATED REAR WINDOW (HRW) 911
ADJUSTMENTS 912
DRIVE BELT – ALTERNATOR – K SERIES – WITHOUT AIR CONDITIONING 912
DRIVE BELT – ALTERNATOR – K SERIES – WITH AIR CONDITIONING 913
HEADLAMPS ADJUSTMENT 914
REPAIRS 916
ALTERNATOR – ’L’ SERIES 916
ALTERNATOR – ’K’ SERIES WITHOUT AIR CONDITIONING 918
ALTERNATOR -’K’ SERIES WITH AIR CONDITIONING 919
DRIVE BELT – AUXILIARY – ’L’ SERIES 920
DRIVE BELT – ALTERNATOR – ’K’ SERIES WITHOUT AIR CONDITIONING 921
DRIVE BELT – ALTERNATOR – ’K’ SERIES WITH AIR CONDITIONING 922
BATTERY 922
BATTERY CARRIER 923
MOTOR AND CONTROL UNIT – FRONT DOOR GLASS – 3 DOOR 925
MOTOR AND CONTROL UNIT – FRONT DOOR GLASS – 5 DOOR 926
SWITCH – CONSOLE 926
RELAY – CONTROL – TAIL DOOR GLASS 927
MICRO-SWITCH – HARD-BACK 927
MOTOR – TAIL DOOR 928
SWITCH – HORN PUSH 929
HORN 930
HEADLAMP ASSEMBLY 930
LAMP – SIDE REPEATER 931
LAMP – TAIL 931
LAMP – NUMBER PLATE 932
LAMP – REAR FOG GUARD 932
STOP LAMP – CENTRE – HIGH MOUNTED 933
LAMP – GLOVE BOX COMPARTMENT 933
LAMP – LOAD SPACE 934
RADIO 934
SPEAKER – REAR – 3 DOOR 935
SPEAKER – REAR – 5 DOOR 935
SPEAKER – FRONT – 3 DOOR 936
SPEAKER – FRONT – 5 DOOR 936
AERIAL – 3 DOOR 937
AERIAL – 5 DOOR 938
COAXIAL LEAD – AERIAL – 3 DOOR 938
COAXIAL LEAD – AERIAL – 5 DOOR 939
SPEAKER – TWEETER – FRONT 940
COAXIAL LINK LEAD 940
RELAY – MAIN 941
RELAY MODULE 941
CENTRAL CONTROL UNIT – (CCU) 942
STARTER MOTOR – ’K’ SERIES 943
STARTER MOTOR – ’L’ SERIES 944
RELAY – STARTER 945
SWITCH – STARTER 945
SWITCH – HEADLAMP LEVELLING 946
SWITCH – GLOVE BOX LAMP 946
SWITCH – HEATED REAR SCREEN 947
SWITCH – HANDBRAKE WARNING 947
SWITCH – HAZARD WARNING LIGHTS 948
SWITCH – INDICATOR AND LIGHTS 948
CIGAR LIGHTER – FRONT 949
SWITCH – REAR FOG LAMP 949
SWITCH – EXTERIOR MIRROR 950
HARNESS – MAIN – 5 DOOR 950
HARNESS – FASCIA 958
HARNESS – ENGINE – ’K’ SERIES 960
HARNESS – ENGINE – L SERIES 963
HARNESS – TAIL DOOR 968
HARNESS – INTERIOR LIGHTS 970
HARNESS – FRONT DOOR 971
HARNESS – REAR DOOR 972
SENSOR – VOLUMETRIC – ALARM SYSTEM – 5 DOOR 973
SENSOR – VOLUMETRIC – ALARM SYSTEM – 3 DOOR 974
RECEIVER – ALARM SYSTEM 975
PASSIVE COIL 975
INSTRUMENTS 978
DESCRIPTION AND OPERATION 978
INSTRUMENT PACK 978
REPAIRS 982
CLOCK 982
PANEL – INSTRUMENT 982
FINISHER – INSTRUMENT BEZEL 983
PRINTED CIRCUIT – INSTRUMENT PANEL 983
GAUGE – COOLANT TEMPERATURE 984
TRANSMITTER – COOLANT TEMPERATURE GAUGE – ’L’ SERIES 985
GAUGE – FUEL 986
TANK UNIT ASSEMBLY – DIESEL 987
SENDER – FUEL GAUGE 988
SPEEDOMETER 989
TACHOMETER 989
VIDEO PREVIEW OF THE MANUAL:
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