Land Rover Range Rover L322 2007 2010 User Manual

1: General Information

100: Service Information

2: Chassis

204: Suspension

CONTENTS

100-00: General Information

Description and Operation

About This Manual
How To Use This Manual
Important Safety Instructions
Standard Workshop Practices
General Service Information
Health and Safety Precautions
Solvents, Sealants and Adhesives
Special Tool Glossary
Road/Roller Testing
DTC: Module Name: Bluetooth Module

100-01: Identification Codes

Description and Operation

Identification Codes

100-02: Jacking and Lifting

Description and Operation

Jacking
Lifting
Vehicle Recovery

100-03: Maintenance Schedules

Description and Operation

Maintenance Schedules - Gasoline Engines
Maintenance Schedules - Diesel Engines

204-00: Suspension System - General Information

Specification

General Procedures

Front Camber, Caster and Toe Adjustment
Four-Wheel Alignment (57.65.04)

204-01: Front Suspension

Specification

Description and Operation

Front Suspension

Removal and Installation

Front Lower Arm (60.35.02) (60.35.03)
Front Lower Arm Bushing (60.35.26)
Front Shock Absorber (60.30.02)
Front Stabilizer Bar (60.10.01)
Front Stabilizer Bar Link (60.10.02/60.10.04)
Rear Lower Arm (60.40.09)
Rear Lower Arm Ball Joint (60.15.04)

Rear Lower Arm Bushing (60.35.26)
Shock Absorber and Spring Assembly (60.30.25/99)
Front Wheel Bearing and Wheel Hub (60.25.14)
Wheel Knuckle (60.25.01)

Disassembly and Assembly

Shock Absorber and Spring Assembly

204-02: Rear Suspension

Specification

Description and Operation

Rear Suspension

Removal and Installation

Lower Arm (64.35.54)
Lower Arm Ball Joint (64.15.08)
Lower Arm Bushing (64.35.15)
Lower Arm Rear Bushing (64.35.15)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Toe Link (64.35.70)

Upper Arm (64.35.60) - TDV8 3.6L Diesel
Upper Arm (64.35.60) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Upper Arm Ball Joint (64.15.07)
Upper Arm Bushing (64.35.22) - TDV8 3.6L Diesel
Upper Arm Bushing (64.35.22) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Upper Arm Front Bushing (64.35.20)
Upper Arm Rear Bushing (64.35.21)
Wheel Bearing and Wheel Hub (64.15.14)
Wheel Knuckle (64.35.10)

204-04: Wheels and Tires

Description and Operation

Wheels and Tires

Diagnosis and Testing

Wheels and Tires
Tire Pressure Monitoring System (TPMS)

Removal and Installation

Tire Low Pressure Sensor (74.10.05)
Tire Pressure Monitoring System (TPMS) Front Antenna (86.53.16)
Tire Pressure Monitoring System (TPMS) Module (86.54.05)
Tire Pressure Monitoring System (TPMS) Rear Antenna (86.53.17)
Wheel and Tire (60.25.06)

204-05: Vehicle Dynamic Suspension

Specification

Description and Operation

Vehicle Dynamic Suspension

General Procedures

Air Suspension System Depressurize and Pressurize (60.50.38)
Ride Height Adjustments (60.90.03)

Removal and Installation

Air Spring Solenoid Valve
Air Suspension Air Filter (64.50.12)

204-06: Ride and Handling Optimization

205: Driveline

205-00: Driveline System - General Information

205-01: Driveshaft

205-02: Rear Drive Axle/Differential

Air Suspension Compressor (60.50.10)
Air Suspension Compressor Drier (60.50.09)
Air Suspension Control Module (60.50.04)
Air Suspension Front Solenoid Valve Block (60.50.11)
Air Suspension Muffler (64.50.01)
Air Suspension Rear Solenoid Valve Block (64.50.11)
Air Suspension Reservoir (60.50.03)
Air Suspension Reservoir Solenoid Valve Block (60.50.05)
Air Suspension Solenoid Valve Block (60.50.11)
Air Suspension Switch
Fill Solenoid Valve
Front Air Shock Absorber (60.30.02.45)
Front Air Spring (60.21.01)
Front Vertical Accelerometer
Rear Air Shock Absorber (64.30.02.45)
Rear Air Spring (64.21.01)
Suspension Height Sensor (60.36.01)

Specification

Description and Operation

Ride and Handling Optimization

Diagnosis and Testing

Ride and Handling Optimization

Removal and Installation

Ride and Handling Optimization Switch (86.65.11)

Specification

Specification

Description and Operation

Driveshaft
Universal Joints

Removal and Installation

Front Driveshaft (47.15.02) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Front Driveshaft (47.15.02) - TDV8 3.6L Diesel

Rear Driveshaft (47.15.03) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Rear Driveshaft (47.15.03) - TDV8 3.6L Diesel

Disassembly and Assembly

Driveshaft Universal Joint (47.15.06)
Driveshaft Center Bearing
Driveshaft Slip Yoke
Driveshaft Alignment Bushing

Specification

Description and Operation

Rear Drive Axle and Differential

General Procedures

Differential Draining and Filling (51.25.02)

205-03: Front Drive Axle/Differential

205-04: Front Drive Halfshafts

205-05: Rear Drive Halfshafts

206: Brake System

206-00: Brake System - General Information

In-Vehicle Repair

Axle Housing Bushing (51.15.43) - 4.4L NA V8 - AJ41/4.2L SC V8 -

AJV8

Axle Housing Bushing (51.15.43) - TDV8 3.6L Diesel
Axle Shaft Seal
Differential Locking Module (51.30.01)
Differential Locking Motor (51.15.03)
Drive Pinion Seal (51.20.01)
Rear Axle Oil Temperature Sensor (51.15.06)

Removal and Installation

Axle Assembly (51.15.01)
Differential Support Insulator - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8

Specification

Description and Operation

Front Drive Axle and Differential

General Procedures

Differential Draining and Filling (54.15.02)

In-Vehicle Repair

Drive Pinion Seal (54.10.20)

Removal and Installation

Differential Breather Tube

Specification

Description and Operation

Front Drive Halfshafts
Halfshaft Joint

Removal and Installation

Front Halfshaft LH (47.10.01)
Front Halfshaft RH (47.10.02)
Halfshaft Bearing (47.10.41)
Halfshaft Seal LH (54.10.18)
Halfshaft Seal RH (54.10.21)

Specification

Description and Operation

Rear Drive Halfshafts

Removal and Installation

Rear Halfshaft (47.11.01)
Outer Constant Velocity (CV) Joint Boot (47.11.03)
Inner Constant Velocity (CV) Joint Boot (47.11.16)
Halfshaft Bearing (51.10.29)

Specification

General Procedures

Front Brake Disc Runout Check (70.12.15.01)
Rear Brake Disc Runout Check (70.12.36.01)
Brake System Bleeding (70.25.02) - Vehicles With: High Performance

Brakes

Brake System Bleeding (70.25.02) - Vehicles With: Standard Brakes
Brake System Pressure Bleeding (70.25.02)
Component Bleeding - Vehicles With: High Performance Brakes
Component Bleeding - Vehicles With: Standard Brakes

206-03: Front Disc Brake

Specification

Description and Operation

Front Disc Brake

Removal and Installation

Brake Disc (70.12.10) - Vehicles With: Standard Brakes
Brake Disc (70.12.10) - Vehicles With: High Performance Brakes
Brake Pads (70.40.02) - Vehicles With: Standard Brakes
Brake Pads (70.40.02) - Vehicles With: High Performance Brakes
Brake Caliper (70.55.24) - Vehicles With: Standard Brakes
Brake Caliper (70.55.24) - Vehicles With: High Performance Brakes

206-04: Rear Disc Brake

Specification

Description and Operation

Rear Disc Brake

Removal and Installation

Brake Disc (70.12.33)
Brake Pads (70.40.03)
Brake Caliper (70.55.25)

Disassembly and Assembly

Brake Caliper

206-05: Parking Brake and Actuation

Specification

Description and Operation

Parking Brake

General Procedures

Parking Brake Shoe and Lining Adjustment (70.40.11)
Parking Brake Shoes Bedding-In (70.40.12)

Removal and Installation

Parking Brake Actuator (70.35.48)
Parking Brake Cable LH
Parking Brake Cable RH
Parking Brake Shoes (70.40.09)
Parking Brake Switch (70.35.46)

206-06: Hydraulic Brake Actuation

Description and Operation

Hydraulic Brake Actuation

Removal and Installation

Brake Fluid Reservoir (70.25.31) - Vehicles With: Standard Brakes
Brake Fluid Reservoir (70.25.31) - Vehicles With: High Performance

Brakes
Brake Master Cylinder (70.30.08) - Vehicles With: Standard Brakes
Brake Master Cylinder (70.30.08) - Vehicles With: High Performance

Brakes
Brake Pedal (70.35.01) - Vehicles With: 6-Speed Automatic

Transmission - 6HP26

206-07: Power Brake Actuation

Specification

Description and Operation

Removal and Installation

206-09A: Anti-Lock Control - Traction Control

Specification

Description and Operation

Diagnosis and Testing

Removal and Installation

206-09B: Anti-Lock Control - Stability Assist

Specification

Removal and Installation

211: Steering System

211-00: Steering System - General Information

Specification

General Procedures

211-02: Power Steering

Specification

Description and Operation

General Procedures
Removal and Installation

211-03: Steering Linkage

Specification

Removal and Installation

Brake Pedal and Bracket (70.35.03) - Vehicles With: 6-Speed Automatic

Transmission - 6HP26
Brake Pedal Motor

Brake Booster

Brake Booster (70.50.01) - Vehicles With: Standard Brakes
Brake Booster (70.50.01) - Vehicles With: High Performance Brakes
Brake Vacuum Pump (70.50.19) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8

Anti-Lock Control - Traction Control

Anti-Lock Control - Traction Control - VIN Range: 263535->ONWARDS

Anti-Lock Brake System (ABS) Module (70.25.12) - Vehicles With:

Standard Brakes
Anti-Lock Brake System (ABS) Module (70.25.12) - Vehicles With: High

Performance Brakes
Front Wheel Speed Sensor (70.65.30)
Rear Wheel Speed Sensor (70.65.31)

Yaw Rate Sensor (70.70.35)

Power Steering System Filling and Bleeding
Power Steering System Flushing

Power Steering

Power Steering Control Valve Actuator (57.10.05)
Power Steering Fluid Cooler (57.15.11) - 4.2L SC V8 - AJV8
Power Steering Pump (57.20.14) - 4.2L SC V8 - AJV8
Steering Angle Sensor (57.40.02)

Steering Gear Boot (57.10.29)
Tie Rod End (57.55.07) - 3-Door
Tie Rod End (57.55.07)

3: Powertrain

303: Engine

211-04: Steering Column

Specification

Description and Operation

Steering Column

Removal and Installation

Ignition Switch Lock Cylinder
Steering Column (57.40.01) (57.40.06)
Steering Column Shaft (57.40.22)
Steering Column Tilt Motor
Steering Column Telescopic Motor
Steering Wheel (57.61.01)
Tilt/Telescopic Motors

211-05: Steering Column Switches

Specification

Removal and Installation

Hazard Flasher Switch (86.65.50)
Ignition Switch (86.65.02)
Steering Column Control Switch
Steering Column Multifunction Switch LH (86.65.55)

303-00: Engine System - General Information

Specification

Diagnosis and Testing

Engine (12.90.09.01) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8

General Procedures

Bearing Inspection
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Crankshaft Main Bearing Journal Clearance
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter

303-01A: Engine - 4.2L SC V8 - AJV8

Specification

Description and Operation

Engine

General Procedures

Valve Clearance Check (12.29.73)
Valve Clearance Adjustment (12.29.76)
Engine Oil Draining and Filling (12.60.05)

In-Vehicle Repair

Camshafts RH (12.13.20)
Camshafts LH (12.13.21)
Crankshaft Pulley (12.21.01)
Crankshaft Front Seal (12.21.14)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH (12.29.04)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
Engine Mount LH (12.45.11)
Engine Mount RH (12.45.12)
Flexplate (12.53.13)
Oil Level Indicator and Tube (12.60.09)
Auxiliary Oil Cooler Thermostat (12.60.17)
Oil Pump (12.60.26)
Oil Filter Housing (12.60.27)
Oil Pan (12.60.44)
Oil Cooler (12.60.68)
Engine Front Cover (12.65.01)
Exhaust Manifold LH (30.15.10)
Exhaust Manifold RH (30.15.11)
Auxiliary Oil Cooler

Removal and Installation

Crankshaft Main Bearing Carrier (12.21.42)

Removal

Engine (12.41.01.99)

Disassembly

Engine

Assembly

Engine

Installation

Engine (12.41.01.99)

303-03A: Engine Cooling - 4.2L SC V8 - AJV8

Specification

Description and Operation

Engine Cooling

General Procedures

Cooling System Draining, Filling and Bleeding (26.10.01)
Cooling System Pressure Test

Removal and Installation

Coolant Expansion Tank (26.15.01)
Cooling Fan (26.25.19)
Radiator (26.40.01)

Thermostat (26.45.01)
Coolant Pump (26.50.01)
Coolant Manifold (26.30.64)

303-03D: Supercharger Cooling

Specification

Description and Operation

Supercharger Cooling

General Procedures

Supercharger Cooling System Draining, Filling and Bleeding (19.46.01)

Removal and Installation

Coolant Pump (26.50.26)
Radiator (26.40.10)
Intercooler Hose

303-04A: Fuel Charging and Controls - 4.2L SC V8 - AJV8

Specification

Description and Operation

Fuel Charging and Controls

Removal and Installation

Fuel Rail (19.60.04)
Fuel Injector (19.60.10)
Throttle Body Gasket

303-04D: Fuel Charging and Controls - Turbocharger

Description and Operation

Turbocharger

Diagnosis and Testing

Turbocharger

Removal and Installation

Turbocharger LH
Turbocharger RH
Turbocharger Actuator Rod

303-05A: Accessory Drive - 4.2L SC V8 - AJV8

Specification

Description and Operation

Accessory Drive

Removal and Installation

Cooling Fan Belt (26.25.01)
Cooling Fan Belt Tensioner (26.25.02)
Accessory Drive Belt (86.10.03)
Accessory Drive Belt Tensioner (86.10.06)
Accessory Drive Belt Idler Pulley (86.10.23)

303-06A: Starting System - 4.2L SC V8 - AJV8

Specification

Description and Operation

Starting System

Removal and Installation

Starter Motor (86.60.01)

303-07A: Engine Ignition - 4.2L SC V8 - AJV8

Specification

Description and Operation

Engine Ignition

Removal and Installation

Spark Plugs (18.20.02)
Ignition Coil-On-Plug (18.20.44)

303-07C: Glow Plug System

Specification

Description and Operation

Glow Plug System

Diagnosis and Testing

Glow Plug System

Removal and Installation

Glow Plugs (19.60.31)

303-08B: Engine Emission Control - 4.2L SC V8 - AJV8

Description and Operation

Engine Emission Control

303-12A: Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8

Specification

Description and Operation

Intake Air Distribution and Filtering

Removal and Installation

Air Cleaner (19.10.01)
Air Cleaner Element (19.10.10)
Supercharger (19.46.15)
Supercharger Outlet Pipe (19.46.16)
Intake Air Resonator (19.70.03)
Charge Air Cooler LH (19.46.19)
Charge Air Cooler RH (19.46.18)
Throttle Body Elbow (19.22.43)

303-13A: Evaporative Emissions - 4.2L SC V8 - AJV8

Specification

Description and Operation

Evaporative Emissions

General Procedures

Evaporative Emission System Leak Test (17.90.02.01)

Removal and Installation

Evaporative Emission Canister Purge Valve (17.15.39)
Evaporative Emission Canister Vent Solenoid
Evaporative Emission Canister (17.15.13)

303-14A: Electronic Engine Controls - 4.2L SC V8 - AJV8

Specification

Description and Operation

Electronic Engine Controls

Diagnosis and Testing

Electronic Engine Controls

General Procedures

Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test

Removal and Installation

Engine Oil Pressure (EOP) Sensor (12.60.50)

Oil Temperature Sensor (12.60.65)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Crankshaft Position (CKP) Sensor (18.30.12)
Throttle Position (TP) Sensor (18.30.17)
Camshaft Position (CMP) Sensor LH (18.30.25)
Camshaft Position (CMP) Sensor RH (18.30.26)
Knock Sensor (KS) (18.30.30)
Manifold Absolute Pressure (MAP) Sensor (18.30.56)
Fuel Temperature Sensor (19.22.08)
Heated Oxygen Sensor (HO2S) LH (19.22.16)
Mass Air Flow (MAF) Sensor (19.22.25)
Catalyst Monitor Sensor LH (19.22.71)
Intake Air Temperature (IAT) Sensor (18.30.09)
Fuel Rail Pressure (FRP) Sensor (19.22.29)

307: Automatic Transmission/Transaxle

307-01A: Automatic Transmission/Transaxle - 4.2L SC V8 - AJV8

Specification

Description and Operation

Automatic Transmission

General Procedures

Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check (44.24.06)

In-Vehicle Repair

Selector Shaft Seal (44.15.34)
Transmission Control Module (TCM) (44.15.46)
Output Shaft Seal (44.20.21)
Fluid Pan, Gasket and Filter (44.24.04)
Main Control Valve Body (44.40.01)
Transmission Support Insulator (12.45.08)

Removal and Installation

Transmission (44.20.01)

307-01D: Automatic Transmission/Transaxle - 3.6L V8 - TdV8/4.4L NA V8 - AJ41/4.2L SC

V8 - AJV8

Removal and Installation

Input Shaft Seal

307-02A: Transmission/Transaxle Cooling - 4.2L SC V8 - AJV8

Description and Operation

Transmission Cooling

Removal and Installation

Transmission Fluid Cooler (44.24.10)

307-05A: Automatic Transmission/Transaxle External Controls - 4.2L SC V8 - AJV8

Specification

Description and Operation

External Controls

General Procedures

Selector Lever Cable Adjustment (44.30.04)

308: Manual Transmission/Transaxle, Clutch and Transfer Case

308-07A: Four-Wheel Drive Systems

Specification

Description and Operation

Removal and Installation

308-07B: Transfer Case

Specification

Description and Operation

General Procedures

In-Vehicle Repair

Removal

Installation

309: Exhaust System

309-00A: Exhaust System - 4.2L SC V8 - AJV8

Specification

Description and Operation

Removal and Installation

310: Fuel System

310-00: Fuel System - General Information

Specification

General Procedures

310-01A: Fuel Tank and Lines - 4.2L SC V8 - AJV8

Specification

Description and Operation

Removal and Installation

310-02A: Acceleration Control - 4.2L SC V8 - AJV8

Four-Wheel Drive Systems - 3.6L (TdV8) Diesel
Four-Wheel Drive Systems - 4.2L/4.4L

Transfer Case Shift Motor (41.30.03)
High/Low Range Sensor (41.30.07)
Transfer Case Clutch Solenoid (41.30.08)

Transfer Case

Transfer Case Draining and Filling (41.20.04)

Transfer Case Input Shaft Seal (41.20.50) - 4.2L SC V8 - AJV8
Transfer Case Front Output Shaft Seal (41.20.51) - 4.2L SC V8 - AJV8
Transfer Case Rear Output Shaft Seal (41.20.54) - 4.2L SC V8 - AJV8

Transfer Case (41.20.25.99) - 4.2L SC V8 - AJV8

Transfer Case (41.20.25) - 4.2L SC V8 - AJV8

Exhaust System

Catalytic Converter LH (17.50.03)
Catalytic Converter RH (17.50.04)
Exhaust System (30.10.08)
Tailpipe (30.10.22)

Diesel Filter Water Drain-Off
Fuel System Pressure Release (19.50.02) - 4.2L SC V8 - AJV8
Fuel System Pressure Check (19.50.13) - 4.4L NA V8 - AJ41/4.2L SC

V8 - AJV8
Fuel Tank Draining (19.55.02)

Fuel Tank and Lines

Fuel Pump Module (19.45.03)
Fuel Tank Filler Pipe (19.55.07)
Vapor Vent Box
Fuel Tank (19.55.01)
Fuel Filter (19.25.03)

Description and Operation

Acceleration Control

303-01C: Engine - TDV8 3.6L Diesel

Specification

Description and Operation

Engine

Diagnosis and Testing

Engine

General Procedures

Engine Oil Draining and Filling (12.60.05)

In-Vehicle Repair

Camshaft LH (12.13.02)
Camshaft RH (12.13.03)
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.01)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH (12.29.04)
Cylinder Head RH (12.29.05)
Engine Mount LH (12.45.11)
Engine Mount RH (12.45.12)
Exhaust Manifold LH (30.15.10)
Exhaust Manifold RH (30.15.11)
Flexplate (12.53.13)
Intake Manifold Plenum Chamber
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)

Removal

Engine (12.41.01.99)

Disassembly

Engine

Assembly

Engine

Installation

Engine (12.41.01.99)

303-03C: Engine Cooling - TDV8 3.6L Diesel

Specification

Description and Operation

Engine Cooling

Diagnosis and Testing

Engine Cooling

General Procedures

Cooling System Partial Draining, Filling and Bleeding
Cooling System Partial Draining and Vacuum Filling
Cooling System Pressure Test

Removal and Installation

Auxiliary Radiator
Coolant Expansion Tank (26.15.01)
Cooling Fan (26.25.19)
Cooling Fan Shroud (26.25.11)
Cooling Module
Coolant Pump (26.50.01)
Radiator (26.40.01)

Thermostat (26.45.01)

303-03D: Supercharger Cooling

Specification

Description and Operation

Supercharger Cooling

General Procedures

Supercharger Cooling System Draining, Filling and Bleeding (19.46.01)

Removal and Installation

Coolant Pump (26.50.26)
Radiator (26.40.10)
Intercooler Hose

303-04C: Fuel Charging and Controls - TDV8 3.6L Diesel

Specification

Description and Operation

Fuel Charging and Controls

Diagnosis and Testing

Fuel Charging and Controls

General Procedures

Fuel Injection Component Cleaning
Fuel Injector Balance and Spill Check (19.90.08)

Removal and Installation

Fuel Injectors LH
Fuel Injectors RH
Fuel Pump (19.45.08)
Fuel Rail LH
Fuel Rail RH
Throttle Body (19.22.44)

303-04D: Fuel Charging and Controls - Turbocharger

Description and Operation

Turbocharger

Diagnosis and Testing

Turbocharger

Removal and Installation

Turbocharger LH
Turbocharger RH
Turbocharger Actuator Rod

303-05C: Accessory Drive - TDV8 3.6L Diesel

Specification

Description and Operation

Accessory Drive

Diagnosis and Testing

Accessory Drive

Removal and Installation

Accessory Drive Belt (86.10.03)
Accessory Drive Belt Tensioner (86.10.06)
Accessory Drive Belt Idler Pulley (86.10.23)

303-06C: Starting System - TDV8 3.6L Diesel

Specification

Description and Operation

Starting System

Diagnosis and Testing

Starting System

Removal and Installation

Starter Motor (86.60.01)

303-07C: Glow Plug System

Specification

Description and Operation

Glow Plug System

Diagnosis and Testing

Glow Plug System

Removal and Installation

Glow Plugs (19.60.31)

303-08A: Engine Emission Control - TDV8 3.6L Diesel

Specification

Description and Operation

Engine Emission Control

Diagnosis and Testing

Engine Emission Control

Removal and Installation

Crankcase Vent Oil Separator (17.10.04)
Exhaust Gas Recirculation (EGR) Cooler (17.45.38)
Exhaust Gas Recirculation (EGR) Valve LH (17.45.16)
Exhaust Gas Recirculation (EGR) Valve RH (17.45.17)
Exhaust Gas Recirculation (EGR) Valve Outlet Tube (17.45.18)

303-12C: Intake Air Distribution and Filtering - TDV8 3.6L Diesel

Description and Operation

Intake Air Distribution and Filtering

Diagnosis and Testing

Intake Air Distribution and Filtering

Removal and Installation

Air Cleaner (19.10.01)
Air Cleaner Element (19.10.10)
Charge Air Cooler (19.46.19)

303-14C: Electronic Engine Controls - TDV8 3.6L Diesel

Specification

Description and Operation

Electronic Engine Controls

Diagnosis and Testing

Electronic Engine Controls - 3.6L (TdV8) Diesel

Removal and Installation

Camshaft Position (CMP) Sensor (18.30.24)
Crankshaft Position (CKP) Sensor (18.30.12)
Crankshaft Position (CKP) Sensor Ring (18.30.14)
Engine Control Module (ECM) (18.30.03)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Engine Oil Pressure (EOP) Sensor (12.60.50)
Exhaust Gas Temperature Sensor
Fuel Rail Pressure (FRP) Sensor (19.22.29)
Fuel Temperature Sensor (19.22.08)
Knock Sensor (KS) LH (18.30.28)
Knock Sensor (KS) RH (18.30.30)
Manifold Absolute Pressure and Temperature (MAPT) Sensor
Mass Air Flow (MAF) Sensor (19.22.25)

307: Automatic Transmission/Transaxle

307-01C: Automatic Transmission/Transaxle - TDV8 3.6L Diesel

Specification

Description and Operation

Automatic Transmission

General Procedures

Transmission Fluid Drain and Refill (44.24.02)

Transmission Fluid Level Check (44.24.06)

In-Vehicle Repair

Fluid Pan, Gasket and Filter (44.24.04)
Main Control Valve Body (44.40.01)
Output Shaft Seal (44.20.21)
Selector Shaft Seal (44.15.34)
Transmission Control Module (TCM) (44.15.46)
Transmission Support Insulator (12.45.08)

Removal and Installation

Transmission (44.20.01)

307-01D: Automatic Transmission/Transaxle - TDV8 3.6L Diesel/V8 4.4L Petrol/V8 S/C

4.2L Petrol

Removal and Installation

Input Shaft Seal

307-02C: Transmission/Transaxle Cooling - TDV8 3.6L Diesel

Specification

Description and Operation

Transmission Cooling

Removal and Installation

Transmission Fluid Cooler (44.24.10)

307-05C: Automatic Transmission/Transaxle External Controls - TDV8 3.6L Diesel

Specification

Description and Operation

External Controls

General Procedures

Selector Lever Cable Adjustment (44.30.04)

Removal and Installation

Selector Lever Assembly (44.15.04)
Selector Lever Cable (44.15.08)
Selector Lever Gate Finish Panel
Selector Lever Knob (44.15.07)
Selector Lever Position Sensor

308: Manual Transmission/Transaxle, Clutch and Transfer Case

308-07A: Four-Wheel Drive Systems

Specification

Description and Operation

Four-Wheel Drive Systems - TDV8 3.6L Diesel

Diagnosis and Testing

Four-Wheel Drive Systems

Removal and Installation

Transfer Case Shift Motor (41.30.03)
High/Low Range Sensor (41.30.07)
Transfer Case Clutch Solenoid (41.30.08)

308-07B: Transfer Case

Specification

Description and Operation

Transfer Case

General Procedures

Transfer Case Draining and Filling (41.20.04)

In-Vehicle Repair

Transfer Case Input Shaft Seal (41.20.50) - TDV8 3.6L Diesel
Transfer Case Front Output Shaft Seal (41.20.51) - TDV8 3.6L Diesel
Transfer Case Rear Output Shaft Seal (41.20.54) - TDV8 3.6L Diesel

Removal

Transfer Case (41.20.25.99) - TDV8 3.6L Diesel

Installation

309: Exhaust System

309-00C: Exhaust System - TDV8 3.6L Diesel

Specification

Description and Operation

Removal and Installation

310: Fuel System

310-00: Fuel System - General Information

Specification

General Procedures

310-01C: Fuel Tank and Lines - TDV8 3.6L Diesel

Specification

Description and Operation

Diagnosis and Testing

Removal and Installation

310-02C: Acceleration Control - TDV8 3.6L Diesel

Specification

Description and Operation

Removal and Installation

310-03B: Speed Control - TDV8 3.6L Diesel

Description and Operation

Removal and Installation

Transfer Case (41.20.25) - TDV8 3.6L Diesel

Exhaust System

Catalytic Converter (17.50.01)
Catalytic Converter LH (17.50.03) - Vehicles Without: Diesel Particulate

Filter (DPF)

Catalytic Converter RH (17.50.04) - Vehicles Without: Diesel Particulate

Filter (DPF)

Catalytic Converter LH (17.50.03) - Vehicles With: Diesel Particulate

Filter (DPF)

Catalytic Converter RH (17.50.04) - Vehicles With: Diesel Particulate

Filter (DPF)
Diesel Particulate Filter (DPF)
Diesel Particulate Filter (DPF) Differential Pressure Sensor
Exhaust System (30.10.08) - Vehicles Without: Diesel Particulate Filter

(DPF)
Exhaust System (30.10.08) - Vehicles With: Diesel Particulate Filter

(DPF)
Tailpipe (30.10.22)

Diesel Filter Water Drain-Off
Fuel System Pressure Check (19.50.13) - TDV8 3.6L Diesel
Fuel Tank Draining (19.55.02)
High-Pressure Fuel System Bleeding - TDV8 3.6L Diesel
Low-Pressure Fuel System Bleeding (19.50.07) - TDV8 3.6L Diesel

Fuel Tank and Lines

Fuel Tank and Lines

Auxiliary Fuel Cooler
Fuel Cooler
Fuel Filter Element (192502)
Fuel Tank (19.55.01)
Fuel Tank Filler Pipe (19.55.07)

Acceleration Control

Accelerator Pedal (19.20.01)

Speed Control

Speed Control Switch

4: Electrical

412: Climate Control System

412-00: Climate Control System - General Information

Specification

General Procedures

Air Conditioning (A/C) System Recovery, Evacuation and Charging

(82.30.02)

412-01: Air Distribution and Filtering

Specification

Description and Operation

Air Distribution and Filtering

Removal and Installation

Center Registers
Driver Side Register
Driver Side Register Trim Panel (76.46.12)
Passenger Side Register
Passenger Side Register Trim Panel (76.46.13)
Plenum Chamber (80.15.62)
Upper Center Registers

412-02A: Heating and Ventilation

Specification

Description and Operation

Heating and Ventilation

Removal and Installation

Blower Motor (80.20.15)
Heater Control Valve
Heater Core (80.20.29)
Heater Core and Evaporator Core Housing

412-02B: Auxiliary Heating

Specification

Description and Operation

Auxiliary Heater

Removal and Installation

Auxiliary Heater
Fuel Fired Booster Heater - 4.2L SC V8 - AJV8

412-03A: Air Conditioning

Specification

Description and Operation

Air Conditioning

Removal and Installation

Air Conditioning (A/C) Compressor (82.10.20) - 4.2L SC V8 - AJV8
Condenser Core (82.15.07) - 4.2L SC V8 - AJV8
Condenser Fan - 4.2L SC V8 - AJV8
Evaporator Core (82.25.20) (82.25.22)
Thermostatic Expansion Valve (82.25.01)

Air Conditioning (A/C) Compressor (82.10.20) - TDV8 3.6L Diesel
Condenser Core (82.15.07) - TDV8 3.6L Diesel
Condenser Fan - TDV8 3.6L Diesel
Evaporator Core (82.25.20) (82.25.22)

Receiver Drier (82.17.03) - TDV8 3.6L Diesel
Thermostatic Expansion Valve (82.25.01)

412-03B: Auxiliary Climate Control

Specification

Description and Operation

Auxiliary Climate Control

Removal and Installation

Auxiliary Climate Control Assembly (82.26.22)
Auxiliary Evaporator Outlet and Inlet Line
Auxiliary Footwell Vent/Duct Blend Door Actuator
Auxiliary Heater Core and Evaporator Core Housing
Auxiliary Temperature Blend Door Actuator (82.26.34)
Auxiliary Blower Motor (82.26.33)
Auxiliary Blower Motor Resistor
Evaporator Core (82.26.20)
Heater Core (82.26.19)
Register

412-04: Control Components

Description and Operation

Control Components

Removal and Installation

Ambient Air Temperature Sensor (80.40.31)
Climate Control Assembly (80.10.02)
Defrost Vent/Register Blend Door Actuator (80.10.36)
Driver Side Recirculation Blend Door Actuator
Driver Side Temperature Blend Door Actuator (80.10.37)
Footwell Vent/Duct Blend Door Actuator
Instrument Panel Blend Door Actuator (80.20.09)
In-Vehicle Temperature Sensor (82.20.93)
Passenger Side Recirculation Blend Door Actuator
Passenger Side Temperature Blend Door Actuator (80.10.38)
Sunload Sensor (82.20.92)

413: Instrumentation and Warning Systems

413-00: Instrument Cluster and Panel Illumination

Specification

Description and Operation

Instrument Cluster and Panel Illumination

413-01: Instrument Cluster

Specification

Description and Operation

Instrument Cluster

Removal and Installation

Instrument Cluster (80.20.01.99) (88.20.01)

413-06: Horn

Specification

Removal and Installation

Horn (86.30.09)
Horn Switch (86.30.01)

413-07: Clock

Removal and Installation

Clock (88.15.07)

413-08: Information and Message Center

Description and Operation

Information and Message Center

413-09A: Warning Devices

Specification

Removal and Installation

Low Washer Fluid Warning Indicator Switch

413-09B: Engine Protection System

Specification

Removal and Installation

Engine Protection System Module

413-13: Parking Aid

Specification

Description and Operation

Parking Aid

Diagnosis and Testing

Parking Aid

Removal and Installation

Front Inner Parking Aid Sensor (86.54.21)
Front Parking Aid Speaker
Front Outer Parking Aid Sensor (86.54.22)
Parking Aid Camera
Parking Aid Module (86.54.10)
Rear Parking Aid Sensor
Rear Parking Aid Speaker (86.54.19)

414: Battery and Charging System

414-00: Charging System - General Information

Specification

Description and Operation

Charging System

General Procedures

Battery Charging

414-01: Battery, Mounting and Cables

Specification

Description and Operation

Battery and Cables

Removal and Installation

Battery (86.15.01)
Battery Tray (76.10.30)
Auxiliary Battery Tray (76.10.31)

414-02A: Generator and Regulator - 4.2L SC V8 - AJV8

Specification

Description and Operation

Generator

Removal and Installation

Generator (86.10.02)

414-02C: Generator and Regulator - TDV8 3.6L Diesel

Specification

Description and Operation

Generator

Removal and Installation

Generator (86.10.02)

415: Information and Entertainment Systems

415-00: Information and Entertainment System - General Information

Diagnosis and Testing

Information and Entertainment System
Cellular Phone

415-01A: Audio Unit

Specification

Description and Operation

Audio System

Removal and Installation

Audio Unit (86.50.81)
Audio Unit Amplifier
Compact Disc (CD) Changer
Integrated Control Panel (ICP)
Rear Auxiliary Audio Controls
Satellite Radio Tuner
Steering Wheel Audio Controls
Subwoofer Amplifier
Television (TV) Amplifier
Television (TV) Amplifier and Fuel Fired Booster Heater Transceiver

Unit
Television (TV) Receiver

415-01B: Information and Entertainment System

Description and Operation

Intercom System

415-02: Antenna

Specification

Description and Operation

Antenna

Removal and Installation

Antenna
Antenna Module
Power Antenna

415-03: Speakers

Specification

Description and Operation

Speakers

Removal and Installation

Front Door Speaker (86.50.10)
Rear Door Speaker (86.50.12)
Instrument Panel Speaker (86.50.11)
Quarter Panel Speaker (86.50.48)
Tailgate Speaker (86.50.47)

415-07: Video System

Description and Operation

Diagnosis and Testing

Removal and Installation

417: Lighting

417-01: Exterior Lighting

Specification

Description and Operation

Diagnosis and Testing

General Procedures

Removal and Installation

417-02: Interior Lighting

Description and Operation

Removal and Installation

417-04: Daytime Running Lamps (DRL)

Description and Operation

418: Electrical Distribution

418-00: Module Communications Network

Specification

Description and Operation

Removal and Installation

418-01: Module Configuration

Video System

Video System

Digital Versatile Disc (DVD) Player
Portable Camera
Portable Camera Docking Station
Rear Passenger Entertainment Control Panel
Video System Module

Exterior Lighting

Headlamps

Headlamp Adjustment (86.40.17)

Adaptive Front Lighting Module (86.54.06)
Front Fog Lamp (86.40.96)
Headlamp Assembly (86.40.49)
Headlamp Bulb (86.40.09)
Headlamp Switch (86.65.09)
High Mounted Stoplamp (86.41.32)
Lamp Outage Module
License Plate Lamp (86.40.86)
Rear Lamp Assembly (86.40.70)
Side Turn Signal Lamp (86.40.53)
Stoplamp Switch (70.35.42)
Trailer Module

Interior Lighting

Center Interior Lamp

Daytime Running Lamps (DRL)

Communications Network

Central Junction Box (CJB) (86.70.56)
Engine Junction Box (EJB)

419: Electronic Feature Group

5: Body and Paint

General Procedures

Module Configuration

418-02: Wiring Harnesses

Specification

Description and Operation

Wiring Harness

General Procedures

Wiring Harness Repair

Removal and Installation

Engine Wiring Harness (86.70.17) - 4.2L SC V8 - AJV8
Tailgate Wiring Harness

419-01A: Anti-Theft - Active

Specification

Description and Operation

Anti-Theft - Active

Removal and Installation

Anti-Theft Transceiver Module
Hood Switch (86.77.20)
Inclination Sensor
Intrusion Sensor

419-01B: Anti-Theft - Passive

Description and Operation

Anti-Theft - Passive

Removal and Installation

Passive Anti-Theft System (PATS) Module (86.77.07)

419-07: Navigation System

Description and Operation

Navigation System

Diagnosis and Testing

Navigation System

Removal and Installation

Navigation System Digital Versatile Disc (DVD) Unit
Navigation System Traffic Module

419-08: Cellular Phone

Description and Operation

Cellular Phone

Removal and Installation

Cellular Phone Antenna (86.53.11)
Microphone
Portable Support Electronics (PSE) Module

419-10: Multifunction Electronic Modules

Description and Operation

Module Controlled Functions

Removal and Installation

Generic Electronic Module (GEM)
Information and Entertainment Module
Multifunction Voice Activated Module

501: Body and Paint

501-00: Body System - General Information

Specification

Description and Operation

501-02: Front End Body Panels

Removal and Installation

501-03: Body Closures

Description and Operation

Removal and Installation

501-05: Interior Trim and Ornamentation

Specification

Removal and Installation

501-08: Exterior Trim and Ornamentation

Description and Operation

Body
Body
Body

Cowl Panel Grille
Engine Undershield (76.10.50)
Fender (76.10.24)
Fender Splash Shield (76.10.48)
Headlamp Mounting Bracket
Radiator Grille Support (76.10.12)
Radiator Splash Shield (76.11.81)

Body Closures

Door
Liftgate Strut
Tailgate Strut

A-Pillar Trim Panel (76.13.26)
B-Pillar Trim Panel
C-Pillar Lower Trim Panel (76.13.34) (76.13.37)
C-Pillar Upper Trim Panel (76.13.35)
Cowl Side Trim Panel (76.13.27)
Engine Cover (12.30.50) - 4.2L SC V8 - AJV8
Front Door Speaker Grille
Front Door Trim Panel (76.34.01)
Front Scuff Plate Trim Panel (76.49.17)
Headliner (76.64.15)
Liftgate Lower Trim Panel
Liftgate Upper Trim Panel
Loadspace Trim Panel
Rear Door Trim Panel (76.34.04)
Rear Scuff Plate Trim Panel
Rear Quarter Trim Panel (76.13.12)
Sun Visor
Tailgate Trim Panel (76.49.23)

Exterior Trim
Exterior Trim
Exterior Trim

Diagnosis and Testing

Power Side Step

Removal and Installation

Front Fender Moulding (76.43.54)
Front Fender Trim Panel
Front Door Lower Moulding
Power Side Step
Power Side Step Hinge
Power Side Step Motor
Radiator Grille (76.55.03)
Rear Door Lower Moulding
Rear Fender Splash Shield (76.10.49)
Roof Moulding (76.43.68)
Rear Quarter Panel Moulding (76.43.55)
Rear Spoiler
Rocker Panel Moulding
Tailgate Moulding (76.43.99)
Towbar

501-09: Rear View Mirrors

Specification

Description and Operation

Rear View Mirrors

Removal and Installation

Exterior Mirror (76.11.10)
Exterior Mirror Glass (76.11.08)
Exterior Mirror Motor (76.11.09)
Interior Rear View Mirror

501-10: Seating

Description and Operation

Seats

Diagnosis and Testing

Seats

Removal and Installation

Climate Controlled Seat Switch
Front Seat (78.10.44/99)
Front Seat Backrest Cover (78.90.08)
Front Seat Backrest Lower Rear Cover
Front Seat Backrest Heater and Blower Assembly
Front Seat Cushion Heater and Blower Assembly
Front Seat Cushion Cover (78.30.01)
Front Seat Head Restraint - Vehicles With: Head Restraint Video

Display
Front Seat Head Restraint - Vehicles Without: Head Restraint Video

Display
Front Seat Head Restraint Motor
Front Seat Recliner Motor (78.70.34)
Lumbar Assembly
Lumbar Control Switch
Seat Armrest (78.10.01)
Seat Control Switch

Rear Seat (78.10.70/78.10.71)
Rear Seat Armrest
Rear Seat Backrest Cover (78.90.72)
Rear Seat Cushion Cover (78.40.70)

501-11: Glass, Frames and Mechanisms

Description and Operation

Glass, Frames and Mechanisms

Diagnosis and Testing

Glass, Frames and Mechanisms

General Procedures

Heated Window Grid Wire Repair
Lead Terminal Repair
Door Window Glass Adjustment
Door Window Glass Adjustment
Rear Quarter Window Glass Adjustment
Rear Quarter Window Glass Adjustment
Liftgate Window Glass Adjustment
Power Door Window Initialization
Power Door Window Initialization
Power Rear Window Initialization
Heated Window Grid Wire Repair
Lead Terminal Repair
Windshield Reseal
Door Window Glass and Rear Quarter Window Glass Adjustment

Removal and Installation

Driver Door Window Control Switch
Front Door Window Regulator Motor
Front Door Window Glass (76.31.01)
Liftgate Window Glass (76.31.22)
Rear Door Window Glass (76.31.02)
Rear Door Window Regulator Motor
Rear Quarter Window Glass (76.81.20)
Windshield Glass (76.81.01)
Windshield Moulding
Rear Door Fixed Window Glass (76.31.31)

501-12: Instrument Panel and Console

Description and Operation

Instrument Panel
Floor Console
Overhead Console

Removal and Installation

Floor Console (76.25.01)
Floor Console Cup Holder
Floor Console Extension
Floor Console Stowage Compartment
Floor Console Stowage Compartment Lid
Floor Console Upper Panel (76.25.11)
In-Vehicle Crossbeam
Instrument Panel Center Reinforcement (76.46.34)

Instrument Panel Lower Section (76.46.05)
Instrument Panel Reinforcement
Instrument Panel Upper Section (76.46.04)
Lower Center Registers Panel Assembly
Lower Glove Compartment
Lower Glove Compartment Lid
Overhead Console (76.25.02)
Upper Glove Compartment
Upper Glove Compartment Lid

501-14: Handles, Locks, Latches and Entry Systems

Description and Operation

Handles, Locks, Latches and Entry Systems

Diagnosis and Testing

Locks, Latches and Entry Systems

General Procedures

Tailgate Striker Adjustment (76.28.03)
Liftgate Striker Adjustment (76.37.28)

Removal and Installation

Exterior Front Door Handle (76.58.07)
Exterior Door Handle Mechanism
Front Door Latch (76.37.12)
Ignition Lock Cylinder (57.40.28)
Liftgate Latch (76.37.19)
Tailgate Latch (76.37.83)
Tailgate Latch Actuator
Tailgate Release Switch

501-16: Wipers and Washers

Specification

Description and Operation

Wipers and Washers

Removal and Installation

Rain Sensor (84.12.11)
Rear Window Wiper Motor (84.35.12)
Rear Window Wiper Pivot Arm
Windshield Washer Pump (84.10.21)
Windshield Washer Reservoir (84.10.03)
Windshield Wiper Intermittent Wipe Relay
Windshield Wiper Motor (84.15.12)
Windshield Wiper Pivot Arm
Wiper Linkage Assembly

501-17: Roof Opening Panel

Description and Operation

Roof Opening Panel

General Procedures

Roof Opening Panel Alignment (76.84.82)

Removal and Installation

Air Deflector
Roof Opening Panel Glass (76.84.03)
Lifter Arms

Roof Opening Panel (76.84.01)
Roof Opening Panel Motor (76.84.07)
Roof Opening Panel Shield

501-19: Bumpers

Specification

Removal and Installation

Front Bumper (76.22.49)
Front Bumper Cover (76.22.72)
Front Bumper Lower Cover (76.22.78)
Rear Bumper (76.22.52)
Rear Bumper Cover (76.22.74)

501-20A: Safety Belt System

Specification

Description and Operation

Safety Belt System

Removal and Installation

Front Safety Belt Buckle (76.73.30)
Front Safety Belt Retractor (76.73.13)
Rear Center Safety Belt Buckle (76.73.64)
Rear Center Safety Belt Retractor
Rear Safety Belt Buckle (76.73.30)
Rear Safety Belt Retractor

501-20B: Supplemental Restraint System

Specification

Description and Operation

Air Bag and Safety Belt Pretensioner Supplemental Restraint System

(SRS)

Diagnosis and Testing

Air Bag Supplemental Restraint System (SRS)

General Procedures

Air Bag Disposal

Removal and Installation

B-Pillar Side Impact Sensor (76.74.23)
Clockspring (76.74.20)
Driver Air Bag Module (76.74.01)
Driver Lower Air Bag Module
Front Seat Side Air Bag Module
Front Side Air Curtain Module
Occupant Classification Sensor (76.74.76)
Passenger Air Bag Deactivation (PAD) Switch (76.74.19)
Passenger Air Bag Module (76.74.02)
Side Air Bag Module (76.74.30)
Side Air Curtain Module (76.74.40)

501-25A: Body Repairs - General Information

Description and Operation

Sealer, Underbody Protection Material and Adhesives

501-25B: Body Repairs - Water Leaks

Description and Operation

Water Leaks

501-25C: Body Repairs - Corrosion Protection

Description and Operation

501-26: Body Repairs - Vehicle Specific Information and Tolerance Checks

Description and Operation

501-27: Front End Sheet Metal Repairs

Removal and Installation

501-28: Roof Sheet Metal Repairs

Removal and Installation

501-29: Side Panel Sheet Metal Repairs

Removal and Installation

501-30: Rear End Sheet Metal Repairs

Removal and Installation

501-36: Paint - General Information

Description and Operation

502: Frame and Mounting

502-00: Uni-Body, Subframe and Mounting System

Corrosion Protection

Body and Frame

Auxiliary Front Crossmember
Fender Apron Panel
Fender Apron Panel Closing Panel
Fender Apron Panel Front Extension
Fender Apron Panel Inner Reinforcement
Fender Apron Panel Reinforcement Front Section
Fender Apron Panel Reinforcement Rear Section
Front Side Member and Suspension Top Mount Assembly
Front Side Member Closing Panel
Front Side Member Extension
Hood Latch Panel (76.16.22)
Side Member Deformation Element

Roof Panel

A-Pillar Assembly
A-Pillar Reinforcement
B and C-Pillar Assembly
Rocker Panel (77.40.60)
Rocker Panel Inner Reinforcement
Rocker Panel Section

Inner Quarter Panel (77.40.37)
Quarter Panel (77.40.09)
Quarter Panel Lower Extension
Rear Crossmember
Rear Crossmember Section
Rear Floor Panel
Rear Floor Panel Section (77.70.02)
Rear Lamp Mounting Panel (77.80.25)
Rear Quarter Upper Panel
Rear Side Member
Rear Side Member Section (77.70.07)
Spare Wheel Well

Tools and Equipment for Paint Repairs

Removal and Installation

Rear Subframe Bushing - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8

502-02: Full Frame and Body Mounting

Specification

Removal and Installation

Transmission Support Crossmember (76.10.09 or 76.10.92) - 4.4L NA

V8 - AJ41/4.2L SC V8 - AJV8

Service Bulletins

Fuel Fired Burning Heater Diagnostic's
Range Rover (LM) - Drone Noise on Supercharged Vehicles with 20

inch Wheels
E-Box Cooling Fan Noise
All Land Rover - Special Equipment Release Notification
All Land Rover - Electronic Product Quality Report (EPQR)

Enhancements
All Land Rover - Special Service Tools on EPQR
Range Rover (LM) - Sensor Cluster Fault Diagnosis
Range Rover (LM) - Internal Control Module Faults Relating to the

ABS Module Diagnosis
Range Rover (LM) - CAN Faults Relating to the ABS Module

Diagnosis
Range Rover (LM) - Wheel Speed Sensor Concerns Diagnosis
Range Rover (LM) - Storage Location of Front Towing Eye
Range Rover (LM) - Spare Key Location
Range Rover (LM) - Special Tool Notification
Height Sensor Procedure Change

General Information - About This Manual

Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of technicians worldwide. The
objective is to use common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with
tested and effective techniques. Following them will help to ensure reliability.

Important Safety Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all
motor vehicles as well as the personal safety of the individual carrying out the work.

Anyone who departs from the instructions provided in this manual must first establish that personal safety or
vehicle integrity is not compromised by the choice of method, tools or components.

Warnings, Cautions and Notes in This Manual

WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in

personal injury.

CAUTION: Cautions are used to indicate that failure to follow a procedure correctly may result in damage

to the vehicle or equipment being used.

• NOTE: Notes are used to provide additional essential information required to carry out a complete and
satisfactory repair.

Generic warnings or cautions are in their relevant description and operation procedure within section 100-00. If
the generic warnings or cautions are required for a procedure, there will be a referral to the appropriate
description and operation procedure.

If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.

Trustmark Authoring Standards (TAS) Removal and Installation Procedures

• NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the

magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be
followed when removing/disassembling or installing/assembling a component.

Many of the TAS procedures will have the installation information within the removal steps. These procedures
will have the following note at the beginning of the procedure:

• NOTE: Removal steps in this procedure may contain installation details.

Items such as O-ring seals, gaskets, seals, self-locking nuts and bolts are to be discarded and new components
installed unless otherwise stated within the procedure. Coated nuts or bolts are to be reused, unless damaged
or otherwise stated within the procedure.

Specification procedures will contain all technical data that are not part of a repair procedure.

TAS Graphics

Colors used in the graphic are as follows:

 Blue - Indicates the target item, item to be removed/installed or disassembled/assembled
 Green and Brown - Indicates a secondary item that needs to be detached, removed/installed or

disassembled/assembled prior to the target item

 Magenta - Indicates electrical connectors and fasteners such as nuts, bolts, clamps or clips
 Pale Blue - is for the special tool(s) and general equipment.

There may be multiple steps assigned to one illustration.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts,
clamps or clips.

Items in the illustration can be transparent or use cutouts to show hidden detail(s).

TAS Symbols

Symbols are used inside the graphics and in the text area to enhance the information display. The following
paragraphs describe the various types and categories of symbols.

Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks.

Health and Safety symbols recommend the use of particular protection equipment to avoid or at least reduce
the risk or severity of possible injuries.

Warning symbols are used to indicate potential risks resulting from a certain component or area.

Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a component.

Location symbols are used to show the location of a component or system within the vehicle.

Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector lever
position is to be set.

Pointer symbols are used to draw the attention to components and give special instructions such as a required
sequence or number of components. The number of components is reflected by the value inside the luty arrow.
A sequence number is located inside the circle. Numbers inside circles are also used to allocate special
information such as tightening torques or chemicals to a particular component.

Movement arrows are used to show three dimensional or rotational movements. These movements can include
specific values inside the symbol if required.

Standard tool symbols recommend the use of certain standard tools. These tools can include dimension values
if required.

The following graphic illustrates a set of symbols that are used to provide detailed information on where to
apply a material.

Measurement symbols provide detailed information on where to carry out a specific measurement. These
symbols can include specific values if required.

Special Tools and Torque Figure(s)

Special tools will be shown with the tool number in the illustration. The special tool number(s), general
equipment, material(s) and torque figure(s) used for the procedure step will be shown in the text column.

General Information - How To Use This Manual

Description and Operation

Copyright Statement

Copyright.© Land Rover Ltd., 2005

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, photocopying, recording or other means, without prior written permission
of Land Rover Ltd., Banbury Road, Lighthorne, Warwick, CV35 0RG

How to use This Manual

This manual covers all aspects of 2006 model year updates in order to service the vehicle effectively, and is to
be used in conjunction with the existing workshop manual Part number: LRL0477.

The manual is structured into five main sections, General Information, Chassis, Powertrain, Electrical and Body
and Paint with each section dealing with a specific part of a vehicle system.

Each of the five main sections contain sub-sections dealing with items which form a part of that specific
system.

Pages at the start of the manual list all sections available. Each section has a contents list detailing, where
applicable, Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair
Procedures.

Where components need to be removed or disassembled in sequence, each operation in the sequence will be
identified numerically and also graphically in an accompanying illustration.

• NOTE: Dimensions quoted are to design engineering specifications with service limits quoted, where

applicable.

Workshop Manual Organization

The five main sections, together with the areas which they cover are given below:

 Section 1 - General Information.
 Section 2 - Chassis.
 Section 3 - Powertrain.
 Section 4 - Electrical.
 Section 5 - Body and Paint.

Sub-section numbers appear after the initial section number, for example, Section 412-03 covers air
conditioning, which is part of the electrical section.

In the number given above, the first digit of the number '4' indicates the section i.e. Electrical.

The second and third digits '12' of the number indicate the vehicle system i.e. Air Conditioning.

The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e. Air

Conditioning Compressor.

General Information - Important Safety Instructions

Description and Operation
Safety Notice

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all
motor vehicles, as well as the safety of the person doing the work. This manual provides general directions for
accomplishing service and repair work with tested effective techniques. Following them will help assure
reliability.

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in
the skill of the person doing the work. This manual cannot possibly anticipate all such variations and provide
advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in the manual
must first establish that neither personal safety or vehicle integrity is compromised from choices of methods,
tools or parts.

General Information - Standard Workshop Practices

Description and Operation

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

 Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the

vehicle moving forwards or backwards.

 Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
 If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove

exhaust fumes.

 There is adequate room to raise the vehicle and remove the wheels, if necessary.
 Fender covers are always installed if any work is to be carried out in the engine compartment.
 Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if

the vehicle is raised.

• CAUTIONS:

Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery
disconnection/connection and the following paragraphs.
For additional information, refer to: Specifications (414-00 Charging System - General Information,
Specifications).

When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility
of a surge of current causing damage to the internal components of the generator.

 If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Battery - General

WARNING: It is essential that a period of 10 minutes elapses after the battery is disconnected
before any work is undertaken on any part of the SRS.

• CAUTIONS:

After re-connecting the battery, the steering wheel must be turned to full left-hand and right-hand lock
(with engine running). This allows the DSC system to relearn the steering wheel position. Failure to do so will
result in a variety of instrument warning lights being illuminated.

Prior to carrying out any procedures which involve disconnecting/connecting the battery, refer to the
Electrical Section of this manual - Battery disconnection/connection.
For additional information, refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).

A discharged battery condition may have been caused by an electrical short circuit. If this condition
exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This
can cause arcing when the jumper cables are connected.

Jump Starting a Vehicle

• CAUTIONS:

While it is not recommended that a vehicle is jump started, it is recognized that this may occasionally be
the only practical way to mobilize a vehicle. Reference should be made to the following and also to the
Electrical Section of this manual - Jump Starting.

It is advisable not to use starter/charger sets for jump starting but if this is unavoidable, make sure that
the sets are not used in the 'START' mode.

 Always make sure that the jumper cables are adequate for the task.
 Always make sure that the slave battery is of the same voltage (12 volts) as the vehicle battery. The

batteries must be connected in parallel.

 Make sure that the battery terminals of both batteries are fully tightened.
 Where another vehicle is used to jump start a disabled vehicle, make sure that the two vehicles are

not touching.

 It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to

make sure that the battery of the donor vehicle does not also become discharged.

 Always make sure that switchable electric circuits are OFF before connecting jump cables. This

reduces the risk of arcing occurring when the final connection is made.

Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and
recharged as soon as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would
take in excess of eight hours continuous driving with no additional loads placed on the battery.

Trickle charging (defined as voltages <16 volts) may be carried out with the battery connected. Make sure that
the battery terminals are fully tightened prior to trickle charging.

CAUTION: Boost charging may only be carried out with the battery disconnected from the vehicle.

Towing the Vehicle

WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section
of this Manual.

When the vehicle is being towed the ignition switch must be in position II (steering lock released and warning
lights illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure
to follow these instructions may result in personal injury. It must be noted that with the engine not running,
the power steering and brake booster will be inoperative therefore, greater effort will be needed to steer the
vehicle and apply the brakes.

General Installation Instructions

Component removal

Whenever possible, clean components and the surrounding area before removal.

 Blank off openings exposed by component removal.
 Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or

caps.

 Seal open ends of exposed oil ways using suitable tapered hardwood plugs or conspicuous plastic

plugs.

 Immediately a component is removed, place it in a suitable container; use a separate container for

each component and its associated parts.

 Clean bench and provide marking materials, labels and containers before disassembling components.

Disassembling

Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension
or hydraulic system parts are disassembled. A particle of dirt or cloth fragment could cause a serious
malfunction if trapped in these systems.

 Blow out all tapped holes, crevices, oil ways and fluid passages with dry, compressed air.

WARNING: Suitable eye protection must be worn.

 Discard all seals and O-rings and replace with new when reassembling.
 Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could

initiate cracks or distortion.

 Wire or tape mating parts together where necessary to prevent accidental interchange.
 Suitably identify parts which are to be renewed and parts requiring further inspection. Keep these

parts separate.

 To make sure that the correct replacement part has been obtained, do not discard a part due for

renewal until after comparing it with the new part.

Cleaning components

Always use cleaning agents which are suitable for the work being undertaken and the components being
cleaned. NEVER use gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component
being cleaned is compatible with the cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the
environment in which the work is being undertaken is suitable. See Health and Safety Precautions for further
information regarding cleaning.

General inspection of components

All components should be inspected for wear or damage before reassembling.

 Always make sure that component to be inspected is clean and free from oil or grease.
 When a component is to be checked dimensionally against design specified values, use the

appropriate measuring equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).

 Always make sure that all measuring equipment is correctly calibrated before use.
 Reject a component which is not within specified values/limits or if it appears to be damaged.
 A component may be reinstalled if dimensions obtained during checking are at the maximum

tolerance limit and it is in an undamaged condition.

 Bearing journal clearances should be checked where necessary using Plastigage.
 Gaskets, seals and O-ring seals are to be re-used unless damaged.

Joints and Joint Faces

All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and
install O-rings using the fingers only.

Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.

CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.

Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together
with its part number will be found listed in the relevant repair operation and also in the sealants table.

CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified
solvents where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may
damage the sealing surfaces. Make sure that sealing surfaces are free from oil or grease as sealants will not
adhere properly to contaminated surfaces.

Do not allow sealant to enter tapped holes or oil ways.

Locking Devices

Always replace locking devices with one of the same design and of the correct size.

Tab washers

Always release locking tabs before loosening fixings, do not re-use tab washers.

Locknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always install new roll pins of the correct size.

Circlips

Always install new circlips ensuring that they are of the correct size for the groove.

Woodruff keys

Woodruff keys may be re-used provided there is no indication of wear or distortion.

Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and re-use a split pin, always make sure that replacement pins are of the correct
size for the hole in which they are to be installed.

Screw Threads

 Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged

threads with a tap or die impairs the strength and fit of the threads and is not recommended.

• NOTE: During certain repair operations, it may be necessary to remove traces of thread locking agents using
a tap. Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential
that a tap of the correct size and thread is used.

 Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be re-

used. New bolts having the same part number as the original must always be installed. When nuts or
bolts are to be discarded, the repair operation and relevant torque chart will include an instruction to
that effect. Do not use proprietary thread locking agents as they may not meet the specification
required. See also Encapsulated ('Patched') Bolts and Screws.

 Always make sure that replacement nuts and bolts are at least equal in strength to those that they

are replacing. Castellated nuts must not be loosened to accept a split pin except in recommended
cases when this forms part of an adjustment.

 Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt

or stud can split the housing and also give a false torque reading.

 Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can

give a false torque reading.

 Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion

of components or faulty sealing of joints will result if the sequences are not followed. Where an
instruction is given to tighten in stages, these stages must be adhered to; do not attempt to combine
stages particularly where certain stages involve tightening by degrees.

 To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to

the specified torque figure.

 Unless instructed otherwise, do not lubricate bolt or nut threads prior to installation.

Where it is stated that bolts and screws may be re-used, the following procedures must be carried out:

 Check that threads are undamaged.
 Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.

 make sure that threads are clean and free from oil or grease.
 Apply the specified locking agent to the bolt threads.

Bolt and Nut Identification

An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the
symbols ISO M or M embossed or indented on top of the bolt head.

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols
indicating the strength grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and
strength grade symbol stamped on the flats of the hexagon.

Encapsulated ('Patched') bolts and screws

Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during
manufacture. Most thread locking agents are colored, the band of color extending for 360° around the thread.
Some locking agents however, are neutral in color and may not be so easily identified apart from a slightly
darker area of thread where the locking agent has been applied. The locking agent is released and activated by
the tightening process and is then chemically cured to provide the locking action.

Self-locking bolts and screws

Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread
can be re-used provided that resistance is felt when the locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion.
They are identified by the presence of a colored section of thread extending approximately 180° around the
thread or by a colored plug inserted into the bolt.

Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut
into which it is screwed.

CAUTION: Do Not re-use self-locking fasteners in critical locations e.g. drive plates/flywheel or engine
bearings. Do not install non self-locking fasteners where a self-locking fastener is specified.

Trilobular bolts should not be used as a substitute for patched bolts.

Nut identification

A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade
symbol 8, 12, 14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric
symbol M on the hexagonal flat opposite the strength grade marking.

A clock face system is sometimes used as an alternative method of indicating the strength grade. The external
chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to
indicate the strength grade.

A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above
12, two dots identify the 12 o'clock position.

When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part
of an adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or
nuts should be selected.

Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.

Self-locking nuts

Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same type and
strength grade installed.

Air Suspension

Always make sure that suitable eye protection is worn when working on the air suspension system.

Ball and Roller Bearings

When removing and installing bearings, make sure that the following practices are observed to make sure
component serviceability:

CAUTION: Service tools have been developed for removing the majority of bearings; these must always
be used where specified.

 Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain

absolute cleanliness throughout operations.

 Conduct a visual inspection for markings on rolling elements, raceways, outer surfaces of outer or

inner surfaces of inner rings. Reject any bearings found to be marked since marking in these areas
indicates onset of wear.

 Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that

it revolves absolutely smoothly. Repeat holding outer race and rotating inner race. DO NOT spin the
bearing.

 Rotate outer ring gently using a reciprocating movement whilst holding inner ring; feel for any check

or obstruction to rotation. Reject bearing if movement is not absolutely smooth.

 Check bearing for blueing or signs of overheating.
 Lubricate bearing with the specified lubricant.
 Inspect bearing surface of shaft and bearing housing for discoloration or other markings which

indicate overheating of bearing or movement between bearing and seating.

 Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
 If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a

pair unless it is suspected that one bearing may have been faulty when installed, was installed
incorrectly or the fault arose due to oil seal failure.

 Never reinstall a bearing unless it is in a fully serviceable condition.

 When installing a bearing to a shaft, only apply force to the inner ring of the bearing. When installing

a bearing into a housing, only apply force to the outer ring of the bearing.

CAUTION: Service tools have been developed for installing the majority of bearings; these must always
be used where specified.

 In the case of grease lubricated bearings, fill the space between the bearing and outer seal with the

recommended grade of grease before installing the seal.

CAUTION: When a waxed oil seal (installed dry) type of oil seal is to be installed, take great care that
grease does not contaminate the running surface of the seal.

 Always make suitable reference marks between the components of separable bearings e.g. taper roller

bearings when disassembling to make sure correct location of components when assembling. Never
install new rollers in an outer ring, always install a new bearing assembly.

Brake Pads and Linings

Always install the correct grade and specification of brake pads and linings. When replacing these items,
always replace as complete axle sets.

Brake Hydraulics

Always observe the following recommendations when working on the braking system:

WARNING: Do not mix brake fluid of different specifications.

 Always use two spanners when loosening or tightening brake pipes or hose connections.
 Make sure that hoses run in a natural curve and are not kinked or twisted.

 Install brake pipes and hoses securely in their retaining clips and make sure that they cannot contact

a potential chafing point.

 Containers used for brake fluid must be kept absolutely clean.
 Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling

point of the fluid.

 Do not allow brake fluid to be contaminated with other fluids such as mineral oil and do not put brake

fluid in a container which has previously been used for storing other fluids.

 Do not re-use brake fluid which has been bled from the system.
 Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
 Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
 Always install blanking plugs to hoses, pipes or components immediately after disconnection.
 Check thread compatibility of original equipment with replacement components.
 Observe absolute cleanliness when working with hydraulic components.

Pipes and Hoses

When removing or installing flexible hydraulic pipes and hoses, make sure that the following procedures are
observed to make sure component serviceability:

 Prior to removal, clean area around hose or pipe end which is to be disconnected.
 Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that

connections can be plugged immediately following disconnection.

 Always install blanking plugs or caps to pipes and unions immediately following disconnection.
 Clean hose or pipe and blow through with an air line.

WARNING: Suitable eye protection must be worn.

 Check hoses externally for cracks, separation of plies, security of end fittings and external damage;

replace faulty hoses.

 Check pipes for signs of corrosion and chafing, replace as necessary.

CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further problems
in service.

 When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not

kinked, twisted or positioned close to potential chafing points.

 When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing

points.

 Always replace sealing washers installed to banjo bolts, sealing plugs etc.
 Always use a backing spanner when tightening unions and do not over tighten union nuts or banjo

bolts.

 After engagement of 'quick-fit' connection hoses, perform a 'tug' test to make sure connection is

secure.

 After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies

working pressure to the brake pedal or operates the system that has been worked on.

Fuel system hoses

Some fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core.
Whenever a hose is removed, make sure that the inner bore is inspected to check that the viton lining has not
become separated from the outer sleeve.

WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors. The fuel hose and
connectors must be replaced as an assembly.

Fuel system hose clips

Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when
the clip is tightened to a specific torque. These clips may be removed using a screwdriver and must be
replaced with new clips on reassembly. Clips must be tightened until the portion of the slot shears off. Do not
attempt to tighten clips by any other method, do not install any other type of clip.

'Quick-fit' connections are also installed to certain fuel hoses. After engagement of 'quick-fit' connections,
perform a 'tug' test to make sure connection is secure.

Other fuel system hose clips are of the 'Jubilee' type and there may be a tamper proof cover installed over the
screw head. This cover must be carefully removed before slackening the clip and should be replaced after final
tightening, ensuring that the internal hexagon on the cover is correctly located on the clip screw.

Cooling system hoses

CAUTION: The following precautions must be observed to make sure that the integrity of the cooling
system hoses and their connection to the system is maintained.

Hose orientation and connection

Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or
damaged through contact with adjacent components.

Where orientation marks are provided on the hose and corresponding component, the marks must be aligned
when the hose is installed. Hoses must be installed fully on to their connection points, usually a moulded form
on a pipe provides a positive indicator.

Hose clips

Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided,
position the clip directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be
orientated with the crimped side of the drive housing facing towards the end of the hose or the hose may
become pinched between the clip and the stub pipe retaining lip. Unless otherwise stated, worm drive clips
should be tightened to 3 Nm (2 lb-ft). Make sure that hose clips do not foul adjacent components.

Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must
not be re-used. When installing new clips, make sure clip is positioned on hose before tightening and make
sure that when clip is tightened, the tag is located in the longitudinal slot in the free end of the clip (arrowed in
illustration).

'Quick-fit' connections are also installed to certain hoses/pipes. Inspect 'quick-fit' connections for damage, prior
to connection. Replace if damaged. After engagement of 'quick-fit' connections, perform a 'tug' test to make
sure connection is secure.

Heat protection

Always make sure that heat shields and protective sheathing are in good condition; replace if damage is
evident. Particular care must be taken when routing hoses close to hot engine components such as the exhaust
manifolds and exhaust gas recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure
this movement is taken into account when routing and securing hoses.

Electrical Precautions

General

The following guidelines are intended to make sure the safety of the operator whilst preventing damage to the
electrical and electronic components of this vehicle.

Equipment

Prior to commencing any test procedure on the vehicle, make sure that the relevant test equipment is working
correctly and that any harness or connectors are in good condition. It is particularly important to check the
condition of all plugs and leads of mains operated equipment.

Polarity

Never reverse connect the vehicle battery and always make sure the correct polarity when connecting test
equipment.

High voltage circuits

Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead
to contact other components, particularly ECU's.

Vehicles installed with Navigation

CAUTION: The following precaution must be observed as failure to comply may result in damage to the
navigation system computer hardware.

A minimum period of two minutes must have elapsed from the ignition being switched to the 'OFF' position
prior to disconnection of the battery.

Vehicles with Bi-Xenon headlamp bulbs installed

WARNING: The following precautions must be observed as failure to comply may result in exposure to
ultra-violet rays, severe electric shock, burns or risk of an explosion.

 Safety goggles and gloves must be worn.
 Make sure that headlamps are switched off before removing bulbs.
 Do not touch the glass portion of the bulb.
 On no account should headlamps be switched on with the bulb removed from the headlamp.
 Bulb testing may only be carried out with the bulb installed in the headlamp.
 Bulbs must be disposed of in accordance with the local authority bye-laws.

Connectors and harnesses

The engine compartment of a vehicle is a particularly hostile environment for electrical components and
connectors. Always observe the following:

 Make sure electrically related items are dry and oil free before disconnecting/connecting test

equipment.

 Make sure that disconnected electrical connectors and sensors are protected from any possible oil,

coolant or other liquid contamination. Any such contamination could impair performance or lead to
component failure.

 Never force connectors apart or pull on the wiring harness.
 Always make sure locking tabs are disengaged before disconnecting electrical connectors etc. and

make sure that correct orientation is achieved before connection.

 Make sure that any protection covers, insulation etc. are replaced if disturbed.

Having confirmed that a component is faulty, carry out the following:

 Switch off the ignition and disconnect the battery.
 Remove the component and support the disconnected harness.
 When replacing electrical components, keep oily hands away from electrical connections and make

sure that locking tabs on connectors are fully engaged.

Battery Disconnection/Connection

Always refer to the Electrical Section of this manual - Battery Disconnect/Connect prior to attempting to
connect or disconnect the battery.
For additional information, refer to: Specifications (414-00 Charging System - General Information,
Specifications).

Fuel Handling Precautions

The following information lists basic precautions which must be observed if fuel is to be handled safely. It also
outlines other areas of risk which must not be ignored. As this information is issued for basic guidance only,
consult your local Fire Department where any doubt as to personal and environmental safety exists - See also
Health and Safety Precautions.

General precautions

Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when
handling or draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where
fuel is stored.

Make sure that suitable warning signs are exhibited.

Keep all sources of ignition well away from areas where fuel is being handled.

Make sure that any lead lamps are flameproof and kept clear of spillage.

• WARNINGS:

Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.

No one should be permitted to repair components associated with fuel without first having specialist
training.

Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel
system.

Fuel tank and system draining

Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of
this manual.

• WARNINGS:

Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel
must be carried out in a well ventilated area.

Never switch on or operate mobile (cellular) phones in the vicinity of vehicles when operations are being
carried out on the fuel system.

Always attach fuel vapor warning labels to fuel tanks immediately after draining.

Containers used for storing fuel must be clearly marked with the contents and placed in a safe storage
area which meets the requirements of the local authority.

CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged,
no attempt must be made to repair the connector, a new fuel line and connector(s) assembly must be
installed.

Always release pipe clips fully before attempting to disconnect fuel pipes.

Fuel tank repairs

CAUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is
damaged, a new tank must be installed.

Oil seals

Never use a seal which has been improperly stored or handled.

 Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
 Carefully examine seal before installation to make sure that it is clean and undamaged.
 Make sure that the surface on which the seal is to run and also the seal housing is clean and free from

burrs or scratches. Renew the component if the sealing surface cannot be restored.

 Special tools and protection sleeves are provided for installing the majority of seals and must be used

when specified.

 Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to

installation. Always check the relevant repair procedure which will state if a seal must be installed dry.
Never touch these seals with oily hands as the oil will contaminate the protective coating and affect
the sealing properties of the seal; also, make sure that installation tools and protection sleeves are
free from oil and grease. Seals which must be lubricated prior to installation should have the
recommended lubricant applied to the areas specified in the repair procedure.

 Make sure that a seal is installed the correct way round. For example, the lip of the seal must face

towards the lubricant which it is sealing.

 When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal

is to be installed to a housing prior to installing over a shaft, take care not to allow the weight of an
unsupported shaft to rest on the seal.

 Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is

specified, use a suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter
of the seal. Use adhesive tape on the shaft to protect the sealing lip of the seal.

 Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face

of the housing where no shoulder is provided. Make sure that the seal is not tilted in the housing when
it is installed.

Supplemental Restraint System (SRS) Precautions

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly.
The following guidelines and precautions are intended to alert personnel to potential sources of danger and
emphasise the importance of ensuring the integrity of the SRS components installed to the vehicle.

WARNING: The following precautions MUST be adhered to when working on the SRS:

 The correct procedures must always be used when working on SRS components.
 Persons working on the SRS must be fully trained and have been issued with the safety

guidelines.

 The air bag modules contain extremely flammable and hazardous compounds. Contact with

water, acids or heavy metals may produce harmful or explosive results. Do not dismantle,
incinerate or bring into contact with electricity before the unit has been deployed.

 Always replace a safety belt assembly that has withstood the strain of a severe vehicle

impact or if the webbing shows signs of fraying.

 Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking

any work on the SRS.

 Always disconnect the vehicle battery before carrying out any electric welding on a vehicle

installed with SRS.

CAUTION: Do not expose air bag modules or safety belt pre-tensioners to temperatures exceeding 85° C
(185° F).

It should be noted that these precautions are not restricted to operations performed when servicing the SRS.
The same care should be exercised when working on ancillary systems and components located in the vicinity
of SRS components; these include but are not limited to:

 Driver air bag, clockspring.
 Passenger air bag.
 Side Air Curtains - front and rear.
 Safety belt pre-tensioners.
 SRS harnesses, link leads and connectors.

Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing
the following operations:

 Remove the ignition key.
 Disconnect the battery, earth lead first.
 Wait 10 minutes for the SRS power circuit to discharge before commencing work.

• NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply
failure under crash conditions. It is necessary to allow the capacitors sufficient time to discharge (10 minutes)
in order to avoid the risk of accidental deployment.

Installation

In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained
so that it is ready for effective operation in the event of a collision. Carefully inspect SRS components before
installation. Do not install a part that shows signs of being dropped or improperly handled, such as dents,
cracks or deformation.

WARNING: The integrity of the SRS is critical for safety reasons. Make sure the following precautions are
always adhered to:

 Do not install accessories or other objects to trim panels which cover air bags.
 Never install used SRS components from another vehicle or attempt to repair an SRS

component.

 When repairing an SRS system, only use genuine new parts.
 Never apply electrical power to an SRS component unless instructed to do so as part of an

approved test procedure.

 Special fixings are necessary for installing an air bag module – do not use other fixings and

make sure that all fixings are tightened to the correct torque.

 Always use new fixings when replacing an SRS component.

• CAUTIONS:

Take care not to trap air bag modules when installing interior trim components.

Make sure SRS components are not contaminated by oil or grease.

• NOTE: Following safety belt pre-tensioner deployment, the safety belts can still be used as conventional
safety belts but will need to be replaced as soon as possible to make sure full SRS protection.

• NOTE: If the SRS components are to be replaced, the part number/bar code of the new unit must be

recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following:

WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only
T4 to diagnose system faults.

WARNING: Do not use electrical test equipment on the SRS harness while it is connected to any of the
SRS components, it may cause accidental deployment and injury.

Handling and storage

Always observe the following precautions when handling SRS components:

 Never drop an SRS component. The air bag diagnostic control unit is a particularly shock sensitive

device and must be handled with extreme care. Air bag modules and safety belt pre-tensioners could
deploy if subjected to a strong shock.

 Never wrap your arms around an air bag module. If a module has to be carried, hold it by the cover

with the cover uppermost and the base away from your body.

 Never transport air bag modules or safety belt pre-tensioners in the passenger compartment of a

vehicle. Always use the luggage compartment of the vehicle for carrying air bag modules and safety
belt pre-tensioner units.

 Never attach anything to an air bag cover or any trim component covering an air bag module. Do not

allow anything to rest on top of an air bag module.

 Always keep components cool, dry and free from contamination.
 Never apply grease or cleaning solvents to safety belt pre-tensioner units, component failure could

result.

 Always store an air bag module with the deployment side uppermost. If it is stored deployment side

down, accidental deployment will propel the air bag module with sufficient force to cause serious
injury.

 Keep new air bag modules in their original packaging until just prior to installation. Place the old

module in the empty packaging for carriage.

• WARNINGS:

When handling any SRS component, hold by the gas generator housing, DO NOT hold by the air bag. Do
not wrap the thumb around the gas generator while holding. Do not drape air bag over shoulder or around
neck. For safety belt buckle type pre-tensioners, hold by the piston tube, with the open end of the piston tube
pointing towards the ground and the buckle facing away from your body. Do not cover the end of the piston
tube. DO NOT hold buckle type pre-tensioners by the bracket assembly or cable. Never point the piston tube
towards your body or other people.

Air bag modules and safety belt pre-tensioners are classed as explosive devices. For overnight and
longer term storage, they must be stored in a secure steel cabinet which has been approved as suitable for the
purpose and has been registered with the local authority.

Store air bag modules or safety belt pre-tensioners in a designated storage area. If there is no
designated storage area available, store in the locked luggage compartment of the vehicle and inform the
workshop supervisor.

CAUTION: Improper handling or storage can internally damage the air bag module making it inoperative.
If you suspect the air bag module has been damaged, install a new module and refer to the
deployment/disposal procedures for disposal of the damaged module.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:

 Never attempt to modify, splice or repair SRS wiring.

 Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment

system in such a way that it could generate electrical interference in the air bag harness. Seek
specialist advice when installing such equipment.

• NOTE: SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow

stripe protective coverings are sometimes used).

WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the
SRS wiring.

WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their
harnesses. Look for possible chafing points.

Impact sensors - inspection

After any degree of side or frontal body damage, inspect the impact sensors. Replace a sensor if there is any
sign of damage.

CAUTION: Take extra care when painting or carrying out bodywork repairs in the vicinity of the impact
sensors. Avoid direct exposure of the impact sensors or link harnesses to heat guns, welding or spraying
equipment. Take care not to damage sensor or harness when reinstalling components.

Clockspring

CAUTION: Always follow the procedure for installing and checking the clockspring as instructed in the
SRS repairs section. Comply with all safety and installation procedures to make sure the system functions
correctly. Observe the following precautions:

 Do not unlock and rotate the clockspring when it is removed from the vehicle.
 Do not turn the road wheels when the clockspring is removed from the vehicle.
 Always make sure the clockspring is removed and installed in its central position and with the front

road wheels in the straight ahead position - refer to SRS repair section for the correct removal and
installation procedure.

 If a new clockspring is being installed, make sure the locking tab holding the spring's rotational

position is not broken; units with a broken locking tab must not be used.

Air bag and pre-tensioner deployment

WARNING: During deployment parts of the air bag module become hot enough to burn you. Wait 30
minutes after deployment before touching the air bag module.

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only
personnel who have undergone the appropriate training should undertake deployment of air bag and pre­tensioner modules. The following precautions must be complied with:

 Only use deployment equipment approved for the intended purpose.
 Deployment of air bag/pre-tensioner modules must be performed in a well ventilated area which has

been designated for the purpose.

 Make sure air bag/pre-tensioner modules are not damaged or ruptured before attempting to deploy.
 Where local legislation exists, notify the relevant authorities of intention to deploy air bag and

pretensioner units.

 When deploying air bag pre-tensioner units, make sure that all personnel are at least 15 metres (45

feet) away from the deployment zone.

 Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the

SRS section of this manual. In particular, make sure deployment tool is NOT connected to battery
supply before connecting to air bag module connector.

 When deploying safety belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the

seat.

 When removing deployed air bag modules and pre-tensioner units, wear protective clothing. Use

gloves and seal deployed units in a plastic bag.

 Following deployment of any component of the SRS system within the vehicle, all SRS components

must be replaced. DO NOT re-use or salvage any parts of the SRS system.

 Do not lean over an air bag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed air bag modules and pre-tensioner units must be manually deployed.
In this case air bags can be deployed in the vehicle. Before deployment, make sure the air bag module is
secure within its correct mounting position. Deployment of the driver air bag in the vehicle may damage the
steering wheel; if the vehicle is not being scrapped, deploy the module outside of the vehicle.

SRS Component Replacement Policy

• CAUTIONS:

The Restraints Control Module (RCM) will log a crash fault after every impact which is severe enough to
cause air bag deployment. It is possible to have three crashes/impacts logged after one event where,

for example, a front, side and rollover has occurred. After the third fault is logged, the SRS warning
lamp will be illuminated and the restraints control module (RCM) must be replaced.

The SRS side/front impact sensor(s) must be replaced if there are any signs of physical damage or if the
restraints control module (RCM) is registering a fault.

The following information details the policy for replacement of SRS components as a result of a vehicle
accident.

Impacts which do not deploy the air bags or pre-tensioners

Check for structural damage in the area of the impact paying particular attention to bumper armatures,
longitudinals and bracketry.

Impacts which deploy the air bags or pre-tensioners

The replacement and inspection policy is dependent on the type and severity of the crash condition. The
following guidelines are the minimum that should be exercised as a result of the deployment of specific SRS
components.

Check for structural damage in the area of impact paying particular attention to bumper armatures,
longitudinals and bracketry.

Front Air Bag Deployment - Driver and Passenger

CAUTION: If the front air bags are deployed, the following components must be replaced:

 Driver air bag module
 Passenger air bag module
 Fly leads (where applicable) connecting front air bag modules to SRS harness
 Front safety belt buckle pre-tensioner
 Rear safety belt pre-tensioners - if installed
 Driver safety belt retractor - if installed
 Clockspring
 Any front impact sensors that have been physically damaged or if a fault is being registered
 Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

 Front passenger safety belt retractor and webbing, tongue latching function, 'D' loop and body

anchorage point

 Rear safety belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
 Instrument panel moulding adjacent to passenger air bag module
 Steering wheel
 Front seat frames and head restraints
 Steering column - if adjustment is lost or if there are signs of collapse
 Safety belt height adjusters
 Rear safety belts

Side Air Bags

CAUTION: If the side air curtains are deployed, the following components must be replaced on the side of
the vehicle on which the deployment occurred:

 Side air curtains
 Any side impact sensors that have been physically damaged or if a fault is being registered
 Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

 Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage

points

 Rear safety belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
 Front seat frame and head restraints
 Door trim casing
 Safety belt height adjusters

 Rear safety belts

Side Air Curtain modules

CAUTION: If the side air curtain modules are deployed, the following components must be replaced on
the side of the vehicle on which the deployment occurred:

 Side air curtain modules
 Link lead between side air curtain gas generator and restraints control module (RCM) harness
 Side air curtain module retaining clips
 Internal trim finisher
 Front safety belt buckle pre-tensioners
 Any side impact sensors that have been physically damaged or if a fault is being registered
 Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

 Headlining
 Component mounting brackets
 Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage

points

 Rear safety belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
 Adjacent trim components
 Safety belt height adjusters

Rear impacts

CAUTION: If the safety belt pre-tensioners are deployed during a rear impact, the following components
must be replaced:

 Safety belt pre-tensioners
 Front and rear safety belt retractors deployed during the impact
 Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

 Safety belt height adjusters
 Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage

points

 Rear safety belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Air Conditioning (A/C) System Precautions

The A/C system contains fluids and components which could be potentially hazardous to the service engineer
or the environment if not serviced and handled correctly. The following guidelines are intended to alert the
service engineer to potential sources of danger and emphasise the importance of ensuring the integrity of the
A/C operating conditions and components installed to the vehicle.

Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in
the Health and Safety Section. These precautions must be referred to prior to commencing repair operations.

The refrigerant used in the A/C system is HC-134a (Hydrofluorocarbon) R134a.

• WARNINGS:

Servicing must only be carried out by personnel familiar with both the vehicle system and the charging
and testing equipment. All operations must be carried out in a well ventilated area away from open flame and
heat sources.

R134a is a hazardous liquid and when handled incorrectly can cause serious injury. Suitable protective
clothing, consisting of face protection, heat proof gloves, rubber boots and rubber apron or waterproof overalls,
must be worn when carrying out operations on the A/C system.

Remedial actions

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed
on any part of the body will cause immediate freezing of that area. Also, refrigerant cylinders and
replenishment trolleys when discharging will freeze skin to them if contact is made.

If an accident involving R134a should occur, conduct the following remedial actions:

 If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye

to raise the temperature. If an eye wash is not available, cool, clean water may be used to flush the
eye. After rinsing, cover the eye with a clean pad and seek immediate medical attention.

 If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise

the temperature. Implement the same action if the skin comes in contact with discharging cylinders.
Wrap the contaminated body parts in blankets (or similar materials) and seek immediate medical
attention.

 If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected

person is unconscious, move them away from the contaminated area to fresh air and apply artificial
respiration and/or oxygen and seek immediate medical attention.

Service precautions

Observe the following precautions when handling components used in the system:

 A/C units must not be lifted by their hoses, pipes or capillary lines.
 Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be

impaired by kinks or restrictions. Make sure that hoses are correctly positioned before tightening
couplings, and make sure that all clips and supports are utilised.

 Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless

protected by heat shielding.

 Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct

contact of components and panels may transmit noise and so must be eliminated.

 The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated

value. An additional spanner must be used to hold the union to prevent twisting of the pipe when
tightening connections.

 Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-

rings, BUT NOT to the threads of the connection.

 All protective plugs or caps must remain in place in the component until immediately prior to

connection.

 Make sure components are at room temperature before uncapping/unplugging, to prevent

condensation of moisture from the air that enters it.

 When disconnecting, immediately plug or cap all pipes to prevent ingress of dirt and moisture into the

system.

 Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for

24 hours or longer, a new receiver/drier must be installed.

 The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times.

A receiver/drier that has been left uncapped for longer than 24 hours must not be used; install a new
unit.

 The receiver/drier should be the last component connected to the system to make sure optimum

dehydration and maximum moisture protection of the system.

 Whenever a component of the refrigeration system is replaced, it will also be necessary to install a

new receiver/drier unit.

 Use alcohol and a clean lint-free cloth to clean dirty connections.
 Make sure that all new parts installed are marked for use with R134a.
 When a major repair has been completed, a leak test should be conducted; refer to the Repairs

Section of this manual for the correct procedure.

Refrigerant oil

CAUTION: Refrigerant oil (ND-8 PAG) easily absorbs water and must not be stored for long periods. Do
not pour unused refrigerant oil back into the container. Always use an approved refrigerant oil.

When replacing components in the system, drain the refrigerant oil from the component being replaced into a
graduated container. On assembly, add the quantity of refrigerant oil drained to the new component - See
Compressor Replacement in this Section.

A/C Compressor

A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly
release the sealing cap; gas pressure should be heard to vent as the seal is broken.

CAUTION: A new compressor should always be sealed and should be pressurised with nitrogen gas. To
avoid possible oil loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to
connecting the pipes to the compressor.

Rapid refrigerant discharge

If the A/C system is damaged as a result of an accident and the system is punctured, the refrigerant will
discharge rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the
system. The compressor must be removed and all the remaining oil in the compressor drained and refilled as
instructed in the air conditioning section of this manual.

Precautions for refrigerant recovery, recycling and recharging

When the A/C system is recharged, any existing refrigerant is first recovered from the system and recycled.
The system is then charged with the required weight of refrigerant and volume of refrigerant oil.

WARNING: Refrigerant must always be recycled before re-use to make sure that the purity of the
refrigerant is high enough for safe use in the system. Recycling should always be carried out with equipment
which is design certified by Underwriter Laboratory Inc. for compliance with SAE J1991. Other equipment may
not recycle refrigerant to the required level of purity.

• CAUTIONS:

A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of
refrigerant. Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle
systems.

The system must be evacuated immediately before recharging commences. Delay between evacuation
and recharging is not permitted.

A/C Compressor Replacement

A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.

A calculated quantity of oil must be drained from the new compressor before installation. To calculate the
quantity of oil to be drained:

 Remove the drain plug from the old compressor.

Item

kg

lb

* Maximum Gross Vehicle Weight (GVW)

3200

7055

Maximum front axle load

1530

3373

Maximum rear axle load

1850

4078

Approximate EEC kerb weights (full fuel tank):

Petrol engine vehicles

2440-2570

5379-5666

Diesel engine vehicles

2435-2570

5368-5666

Maximum weight of unbraked trailer:

On-road

750

1650

Off-road

750

1650

Maximum weight of trailer with overrun brakes:

On-road

3500

7700

Off-road

1000

2205

Maximum roof rack load (Including the mass of the roof rack):

On-road

100

220

Off-road

30

66

Item

mm

in

Length - including number plate plinth - All models

4950

194.8

Width - All models:

Mirrors extended

2191

86.3

Mirrors folded

2009

79.1

Overall height - All models:

Access height

1820

74.4

Motorway height

1840

72.4

Standard height

1863

73.3

Off-road height

1913

75.3

Wheelbase - All models

2880

113.4

Front overhang - All models

875

34.5

Rear overhang - Vehicles without towbar

1195

47

Rear overhang - Vehicles with towbar

1260

49.6

Front track

1629

64.0

Rear track

1626

64.0

Wading depth

500

19.7

Minimum ground clearance (off-road height)

281

11.06

Approach angle (at EEC kerb weight)

35°

35°

Breakover angle (at EEC kerb weight)

30°

30°

Departure angle - Towbar NOT installed (at EEC kerb weight)

29°

29°

Departure angle - Towbar installed (at EEC kerb weight) - Vehicle at Standard ride height

15.1°

15.1°

Departure angle - Towbar installed (at EEC kerb weight) - Vehicle at Off-road ride height

17.4°

17.4°

 Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the

compressor clutch to make sure the compressor is completely drained.

 Note the quantity of oil drained (Y cm³).
 Calculate the quantity of oil to be drained from the new compressor using the following formula:X

cm³ — (Y cm³ + 20 cm³) = Q cm³

 Remove the drain plug from the new compressor and drain Q cm³ of oil. Install and tighten the

compressor drain plug.

Vehicle Weights

* Weight quoted is the maximum weight possible for vehicles in this model range; weights may be
less for certain variants depending upon trim level, territorial requirements etc.

Vehicle Dimensions

Published: 11-May-2011

General Information - General Service Information

Description and Operation

Copyright Statement

Copyright.© Land Rover Ltd., 2005

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, photocopying, recording or other means, without prior written permission
of Land Rover Ltd., Banbury Road, Lighthorne, Warwick, CV35 0RG

How to use This Manual

This manual covers all aspects of 2006 model year updates in order to service the vehicle effectively, and is to
be used in conjunction with the existing workshop manual Part number: LRL0477.

The manual is structured into five main sections, General Information, Chassis, Powertrain, Electrical and Body
and Paint with each section dealing with a specific part of a vehicle system.

Each of the five main sections contain sub-sections dealing with items which form a part of that specific
system.

Pages at the start of the manual list all sections available. Each section has a contents list detailing, where
applicable, Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair
Procedures.

Where components need to be removed or disassembled in sequence, each operation in the sequence will be
identified numerically and also graphically in an accompanying illustration.

• NOTE: Dimensions quoted are to design engineering specifications with service limits quoted, where

applicable.

Workshop Manual Organization

The five main sections, together with the areas which they cover are given below:

 Section 1 - General Information.
 Section 2 - Chassis.
 Section 3 - Powertrain.
 Section 4 - Electrical.
 Section 5 - Body and Paint.

Sub-section numbers appear after the initial section number, for example, Section 412-03 covers air
conditioning, which is part of the electrical section.

In the number given above, the first digit of the number '4' indicates the section i.e. Electrical.

The second and third digits '12' of the number indicate the vehicle system i.e. Air Conditioning.

The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e. Air

Conditioning Compressor.

General Information - Health and Safety Precautions

Description and Operation

Introduction

Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both
personal health and the environment. Also, many of the procedures associated with vehicle maintenance and
repair involve physical hazards or other risks to health.

This subsection lists some of these hazardous operations and the materials and equipment associated with
them. Precautions necessary to avoid these hazards are identified.

The list is not exhaustive and all operations and procedures and the handling of materials, should be carried
out with health and safety in mind.

Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be
consulted.

WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no
circumstances be consumed and should, as far as possible, be kept from contact with the skin. These liquids
and substances include acid, anti-freeze, brake fluid, fuel, windscreen washer additives, lubricants, refrigerants
and various adhesives.

Acids and Alkalis

For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in
batteries.

Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can
destroy ordinary protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles.
Do not breath mists.

Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.

Display Eye Hazard sign.

Air Bags

Highly flammable, explosive – observe No Smoking policy.

Used within the vehicle as safety restraints.

The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C).

The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air
bag module and is completely consumed during deployment. No attempt should be made to open an air bag
inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective
clothing should be worn when dealing with the spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved
chemical waste site.

Following any direct contact with Sodium Azide:

 Wash affected areas thoroughly with water.
 SEEK IMMEDIATE MEDICAL ASSISTANCE.

Air Bags - Do's

 Do store modules in an upright position.
 Do keep modules dry.
 Do carry modules with the cover side pointing away from the body.
 Do place modules with their cover side upwards.
 Do carefully inspect modules for damage.
 Do stand to one side when connecting modules.
 Do make sure all test equipment is properly calibrated and maintained.
 Do wash hands after handling deployed air bags.

Air Bags - Do Not

 Do Not store highly flammable material together with modules or gas generators.
 Do Not store gas generators at temperatures exceeding 80°C.
 Do Not store modules upside down.
 Do Not attempt to open a gas generator housing.
 Do Not expose gas generators to open flame or sources of heat.
 Do Not place anything on top of a module cover.
 Do Not use damaged modules.
 Do Not touch a fired module or gas generator for at least 10 minutes after firing.
 Do Not use any electrical probes on the wiring circuit.

Air Suspension

Whenever work is being undertaken on the air suspension system, suitable eye protection must be worn.

Air Conditioning Refrigerant

Highly flammable, combustible – observe No Smoking policy.

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves
and goggles.

If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes
should also be rinsed with an appropriate irrigation solution such as a solution of 9% Sodium Chloride and
Purified Water. DO NOT RUB THE EYES AND SEEK IMMEDIATE MEDICAL ATTENTION.

Air Conditioning Refrigerant

Do Not

 Do Not expose refrigerant bottles to sunlight or heat.
 Do Not expose refrigerant bottles to frost.
 Do Not drop refrigerant bottles.
 Do Not vent refrigerant to atmosphere under any circumstance.
 Do Not mix refrigerants.

Adhesives and Sealants

Many adhesives and sealants are highly flammable – OBSERVE NO SMOKING POLICY. These items, should be
stored in flameproof cabinets in No Smoking areas. Cleanliness and tidiness in use should be observed, for
example disposable paper covering benches. All adhesives and sealants should be dispensed from applicators
where possible; containers, including secondary containers, should be labelled appropriately.

Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives

Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturer's instructions followed.

Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded,
cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull skin
tissue apart. Use in well ventilated areas as vapors can cause irritation to the nose and eyes.

For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Solvent-based Adhesives/Sealers - See Solvents

Follow manufacturers instructions.

Water-based Adhesives/Sealers

Those based on polymer emulsions and rubber/latex may contain small amounts of volatile, toxic and harmful
chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives

In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from
the inhalation of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and
adequate extraction.

Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based

Mixing should be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or
harmful chemicals through the skin. Splashes can damage the eyes.

Provide adequate ventilation and avoid skin and eye contact.

Isocyanate (Polyurethane) Adhesives/Sealers

See also Resin-based Adhesives

Individuals suffering from asthma or respiratory allergies should not work with or near these materials as
sensitivity reactions can occur.

Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects
on the nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term
exposure to vapour concentrations may result in adverse health effects.

Prolonged contact with the skin may lead to skin irritation and in some cases, dermatitis.

Splashes entering the eye will cause discomfort and possible damage.

Any spraying should preferably be carried out in ventilated booths which incorporate facilities for removing
vapors and spray droplets from the breathing zone.

Wear appropriate gloves, eye and respiratory protection.

Antifreeze

May be flammable when undiluted.

Vapors may be given off from coolant antifreeze when heated. Avoid breathing these vapors.

Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be
fatal; SEEK IMMEDIATE MEDICAL ATTENTION.

Battery Acids

See also Alkalis and Acids.

Gases released during battery charging are explosive. Always remove the battery from the vehicle prior to
charging. Never use naked flames or allow sparks near charging or recently charged batteries. NEVER add acid
to a battery, the chemical reaction produced will be violent and explosive. In cases of eye contact, wash
affected area with copious amounts of water and SEEK IMMEDIATE MEDICAL ATTENTION.

Make sure there is adequate ventilation during battery charging, observe NO SMOKING POLICY.

Brake Pads and Linings

Always fit the correct grade and specification of brake pads and linings. When renewing pads and linings,
always replace as complete axle sets.

Brake and Clutch Fluid

Splashes to the skin and eyes are irritating and in the long term can be damaging, avoid prolonged skin
contact. In cases of eye contact, wash affected area with copious amounts of water and SEEK IMMEDIATE
MEDICAL ATTENTION.

Chemical Materials

All chemical materials should always be used with caution and stored and handled with care. They may be
toxic, harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.

The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or
permanent; cumulative; superficial; life threatening; or may reduce life expectancy.

Chemical Materials - Do's

 Do carefully read and observe hazard and precaution warnings given on material containers (labels)

and in any accompanying leaflets, posters or other instructions. Material health and safety data sheets
can be obtained from manufacturers.

 Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change

heavily soiled clothing and have it cleaned.

 Do organise work practices and protective clothing to avoid soiling of the skin and eyes.
 Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and

explosion hazards.

 Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling

chemical materials.

 Do keep work areas clean, uncluttered and free of spills.
 Do store chemical materials according to national and local regulations.
 Do keep chemical materials out of the reach of children.

Chemical Materials - Do Not

 Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form

other toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed
together.

 Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example

when people are inside a vehicle.

 Do Not apply heat or flame to chemical materials except under the manufacturers instructions. Some

are highly flammable and some may release toxic or harmful fumes.

 Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive

concentrations. Some fumes are heavier than air and will accumulate in confined areas such as pits.

 Do Not transfer chemical materials to unlabelled containers.
 Do Not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin

and may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful
quantities.

 Do Not use emptied containers for other materials except when they have been cleaned under

supervised conditions.

 Do Not sniff or smell chemical materials, even brief exposure to high concentrations of fumes can be

toxic or harmful.

Corrosion Protection Materials

Some corrosion protection materials are highly flammable – observe NO SMOKING POLICY.

These materials are varied and the manufacturers instructions must always be followed. The materials may
contain solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be
sprayed in conditions of adequate ventilation and not in confined spaces.

Dust

Dust or powder produced during repair operations may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if
ventilation is inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of
ignition.

Electrical Equipment

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good
condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment
should be labelled and preferably removed from the work station.

Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. If
using cable reel extension equipment, ALWAYS ensure that the cable is fully unwound from the reel.

Make sure that electrical equipment and flexes do not come into contact with water.

Make sure that electrical equipment is protected by the correct rated fuse.

Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be
fatal.

Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle
hoist.

Make sure that the designated electrical workers are trained in basic First Aid.

In cases of electrocution:

 Switch off the power supply before approaching the victim.
 If this is not possible, DO NOT TOUCH THE VICTIM but push or drag the person from the source of

electricity using dry, non-conductive material.

 Commence resuscitation if trained to do so.
 SEEK IMMEDIATE MEDICAL ATTENTION.

Exhaust Fumes

These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides,
aldehydes, lead and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust
extraction or general ventilation and not in confined spaces.

Gasoline (Petrol) engine

There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be
immediate or delayed.

Gas Oil (Diesel engine)

Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

Fibre Insulation

The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a
chemical effect.

Precautions should be taken to avoid excessive skin contact through careful organization of work practices and
the use of gloves.

Fire

Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off
toxic or harmful fumes if burnt; others such as fluoroelastomers when burnt or damaged by excessive heat can
break down and produce highly corrosive hydrofluoric acid - See Fluoroelastomers.

Should any material be in a burnt or overheated condition, handle with extreme caution and wear protective
clothing when handling such items. Dispose of such material in accordance with local regulations.

Decontaminate and dispose of protective clothing immediately after use.

Observe strict fire safety when storing and handling flammable materials or solvents, particularly near
electrical equipment or welding processes.

Make sure, before using electrical or welding equipment, that there is no fire hazard present.

Have a suitable fire extinguisher available when using welding or heating equipment.

First Aid

Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First
Aid procedures.

Splashes in the eye should be flushed carefully with clean water for at least ten minutes.

Soiled skin should be washed with soap and water.

In case of cold burns, from alternative fuels, place affected area in cool to cold water.

Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects
persist, consult a doctor.

If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do
not induce vomiting unless this action is indicated on the label.

Fluoroelastomers (Synthetic Rubber)

Many 'O' rings, seals, hoses, flexible pipes and other similar which appear to be manufactured from natural
rubber are, in fact, made of synthetic materials called Fluoroelastomers.

Under normal operating conditions, these materials are safe and do not constitute a health hazard. However, if
the materials are damaged by burning or exposure to excessive heat, they can break down and produce highly
corrosive hydrofluoric acid.

WARNING: Contact with hydrofluoric acid can cause serious burns on contact with the skin. If skin
contact does occur, carry out the following steps immediately:

Remove any contaminated clothing.

SEEK IMMEDIATE MEDICAL ATTENTION

Irrigate affected area of skin with copious amounts of cold water or limewater for 15 to 60 minutes.

Foams - Polyurethane

Used in sound and noise insulation. Cured foams used in seat and trim cushioning.

Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.

Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic
diseases should not work in or near uncured materials.

The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or
harmful.

Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and
respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapour/mists
have cleared.

Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking,
naked flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared
should not be allowed. Any heat cutting of cured foams or partially cured foams should be carried out in areas
having suitable fume extraction equipment.

Fuels

Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

Gasoline (Petrol)

Highly flammable - OBSERVE NO SMOKING POLICY.

Swallowing gasoline (petrol) can result in mouth and throat irritation and absorption from the stomach can
result in drowsiness and unconsciousness. Small amounts can be fatal to children. Inhalation into the lungs,
through vomiting, is a very serious hazard.

Gasoline (petrol) dries the skin and can cause irritation and prolonged or repeated contact may cause
dermatitis; if it is allowed to enter the eyes, it will cause severe smarting. Wash affected area with copious
amounts of water and SEEK IMMEDIATE MEDICAL ATTENTION.

Gasoline (petrol) may contain appreciable quantities of benzene, which is toxic upon inhalation and the
concentration of vapors must be kept very low. High concentrations will cause eye, nose and throat irritation,
nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss
of consciousness.

Make sure there is adequate ventilation when handling and using gasoline (petrol). Great care must be taken
to avoid the serious consequences of inhalation in the event of vapour build up arising from spillages in
confined spaces.

Special precautions apply to cleaning and maintenance operations on gasoline (petrol) storage tanks.

Gasoline (petrol) should not be used as a cleaning agent. It must not be siphoned by mouth.

Gas-oil (Diesel Fuel)

Combustible.

Prolonged skin contact with high boiling point gas oils (diesel fuel) may cause serious skin disorders including
skin cancer.

Inhalation into the lungs will cause internal bleeding - SEEK IMMEDIATE MEDICAL ATTENTION.

If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.

Kerosene (Paraffin)

Used also as heating fuel, solvent and cleaning agent.

Flammable - OBSERVE NO SMOKING POLICY.

Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid
aspiration into the lungs occurs.

Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly
irritating.

In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors
from kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye
contact and make sure there is adequate ventilation.

If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.

Gas Cylinders

Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138
bar (13800 kPa) (2000 lbf/in²) and great care should be taken in handling these cylinders to avoid mechanical
damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by
appropriate markings.

Cylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight.
Fuel gases, for example acetylene and propane should not be stored in close proximity to oxygen cylinders.

Care should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.

Only trained personnel should undertake work involving gas cylinders.

General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment
is used where required.

Never use tools or equipment for any purpose other than that for which they were designed. Never overload
equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not
always immediately apparent and may result in a fatal failure the next time that the equipment is used.

Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding
wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury.

Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipment

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and
unions.

Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the
underlying tissue and cause serious injury.

Jacking

Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.

When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake
is applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack
has sufficient load capacity for the weight of the vehicle.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on
safety stands.

Ensure that hoists have sufficient load capacity for the weight of the vehicle.

Legal Aspects

There are many laws and regulations relating to health and safety in the use and disposal of materials and
equipment in a workshop.

For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail,
with the many health and safety laws and regulations within their country, published by both national and local
authorities.

Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the
eyes and skin.

Used Engine Oil

Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to
occur.

Health Protection Precautions

 Avoid prolonged and repeated contact with oils, particularly used engine oils.
 Wear protective clothing, including impervious gloves where practicable.
 Do not put oily rags into pockets.
 Avoid contaminating clothes, particularly underpants, with oil.
 Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned

regularly.

 First Aid treatment should be obtained immediately for open cuts and wounds.
 Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
 Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help).

Preparations containing lanoline replace the natural skin oils which have been removed.

 Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning

skin.

 If skin disorders develop, obtain medical advice without delay.
 Where practicable, degrease components prior to handling.
 Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or

face shields; in addition an eye wash facility should be provided.

Environmental Precautions

This section provides general information which can help to reduce the environmental impacts from the
activities carried out in workshops.

Emissions to air

Many of the activities that are carried out in workshops emit gases and fumes which can contribute to global
warming, depletion of the ozone layer and/or the formation of photochemical smog at ground level. By
considering how the workshop activities are carried out, these gases and fumes can be minimised, thus
reducing the impact on the environment.

Exhaust fumes

Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to
atmosphere. However, the amount of time engines are running and the position of the vehicle should be
carefully considered at all times, to reduce the release of poisonous gases and minimise the inconvenience to
people living nearby.

Solvents

Some of the cleaning agents used are solvent based and will evaporate rapidly to atmosphere if used
carelessly, or if containers are left unsealed. All containers must be firmly closed when not required and solvent
should be used sparingly. Wherever possible, solvents having a low toxicity and flammability should be
selected. Always follow the instructions supplied by the solvent manufacturer. Similarly, many paints are
solvent based and the spray should be used in such a way as to reduce emissions to a minimum.

Refrigerant

It is illegal to release any refrigerant into the atmosphere. Discharge and replacement of these materials from
air conditioning units should only be carried out using the appropriate equipment.

Discharges to water

Most workshops will have two systems for discharging waste water - storm drains and foul drains. Storm drains
should only receive clean water i.e. rainwater. Foul drains will accept many of the normal waste water i.e.
washing water, detergents and domestic type waste BUT NOT oil, petrol, solvent, acids, hydraulic fluid,
antifreeze and similar fluids. If in doubt, always consult the local authority or water company.

Spillages

Every precaution must be taken to prevent spillage of oil, fuel, solvents etc., reaching the drains. All handling
of such materials must take place well away from drains and preferably in an area with a suitable containing
wall to prevent discharge into drains or watercourses. If a spillage occurs, it must be soaked up immediately
using a spill kit where provided.

Checklist

Spillage prevention:

 Store liquids in a secure area.

 Make sure that taps on liquid containers are secure and cannot be accidentally turned on.

 Protect bulk storage tanks from vandalism by locking the valves.

 Transfer liquids from one container to another in an area away from open drains.

 Ensure lids are replaced securely on containers.

 Have spill kits available near to points of storage and liquid handling areas.

Spill Kits

Special materials are available to absorb a number of different substances. They can be in granular form, ready
to use and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste
management.

Land contamination

Oils, fuels and solvents etc. can contaminate any soil with which they come into contact. Such materials MUST
never be disposed of by pouring on to soil and every precaution must be taken to avoid spillage reaching soil.
Waste materials stored on open ground could either leak or have contaminating substances washed off them
that would contaminate the land. Always store these materials in suitable skips or similarly robust containers.

Legal compliance

Some sites may have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is
essential to know the types of effluent which are allowed to be discharged into the drain and to check the
results of any monitoring carried out by the Water Company.

Where paint spraying operations are carried out it may be necessary to apply to the Local Authority for an air
emissions licence to operate the plant. If such a licence is necessary, additional precautions will be necessary
to comply with the requirements and the results of any air quality monitoring must be checked regularly.

Checklist

Always adhere to the following:

 Know what legal consents and licences apply to the operations.

 Check that the emissions and discharges comply with legal requirements.

Waste Management

Pollution can be reduced by careful handling, storage and disposal of all waste materials that occur on sites.
Legislation makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal
sites.

This means that it is necessary to not only know what the waste materials are but also to have the necessary
documentation and licences.

Handling and storage of waste

Ensure that waste materials are not poured down the drain or on to soil and are stored in such a way that they
do not escape on to land or soil.

All waste must be segregated into individual types e.g. oils, metals, batteries, scrap components etc. This will
prevent any reaction between different materials and assist in disposal.

Disposal of waste

Dispose of waste in accordance with the following guidelines:

 Fuel, hydraulic fluid, anti-freeze and oil: Keep separate and dispose of to specialist contractors.

 Refrigerant: Collect in specialist equipment and reuse.

 Detergents: Safe to pour down the foul drain if diluted.

 Paint, thinners: Keep separate and dispose of to specialist contractor.

 Components: Return to supplier for refurbishment or disassemble and reuse any suitable parts.

Dispose of remainder in ordinary waste.

 Small parts: Reuse any suitable parts, dispose of the remainder in ordinary waste.

 Metals: Can be sold if separate from general waste.

 Tyres: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of tyres by

burning.

 Components/materials containing asbestos: Keep separate and dispose of to specialist

contractor.

 Oil and fuel wastes (e.g. rags, used spill kit material): Keep separate and dispose of to specialist

contractors.

 Air filters: Keep separate and dispose of to specialist contractors.

 Rubber/plastics: Dispose of in ordinary waste.

 Hoses: Dispose of in ordinary waste.

 Batteries: Keep separate and dispose of to specialist contractors.

 Air bags - DANGER EXPLOSIVES: Keep separate and dispose of to specialist contractors.

 Electrical components: Return to supplier for refurbishment or disassemble and reuse any suitable

components. Dispose of remainder in ordinary waste.

 Catalytic converters: May be sold if kept separate from general waste.

 Packaging: Compact/recycle as much as possible and dispose of in ordinary waste.

 Office/paper waste: Recycle paper and toner and ink cartridges, dispose of remainder in ordinary

waste.

Noise

Car alarm testing, panel beating, running engines, using air tools etc. are operations which invariably produce
a large amount of noise. The location of such activities and also the time of day must be carefully considered
having regard to the proximity of houses schools etc.

Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable
ear protection must be worn.

Solder

Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent
metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a
gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead
fumes to be produced.

Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of
these should be avoided.

Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced,
which can give toxic effects if inhaled. Respiratory protection may be necessary.

Solder spillage and filings should be collected and removed promptly to prevent general air contamination by
lead.

High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust
from clothing.

Solvents

For example acetone, white spirit, toluene, xylene, trichloroethane.

Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.

Some may be highly flammable or flammable.

Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged
contact. Some can be absorbed through the skin in toxic or harmful quantities.

Splashes in the eye may cause severe irritation and could lead to loss of vision.

Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness,
dizziness, headaches and, in the worst circumstances, unconsciousness.

Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there
might not be adequate warning indications, can cause more serious toxic or harmful effects.

Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.

Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep
containers tightly sealed. Do not use in confined spaces.

When spraying materials containing solvents, for example paints, adhesives, and metal coatings, use
extraction ventilation or personal respiratory protection in the absence of adequate general ventilation.

Do not apply heat or flame except under specific and detailed manufacturers instructions.

Suspended Loads

CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or
raised load, for example a suspended engine.

Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable
for the job, in good condition and regularly maintained.

Viton

In common with many other manufacturers vehicles, some components installed to Land Rover vehicles have
seals, 'O' rings or gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. Although Viton is the most
well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to
temperatures in excess of 400°C, the material will not burn, but will decompose, and one of the products
formed is hydrofluoric acid.

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.
WHERE CASES OF SKIN CONTACT OCCUR, SEEK IMMEDIATE MEDICAL HELP.

O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black
sticky substance.

DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the
affected O-ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be
cautious as the material may be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the
commencement of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using
wire wool and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the
decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be discarded
carefully and safely.

Welding

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Resistance Welding

This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must
be protected.

Arc Welding

This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator
and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect.
Personal protection must be worn, and screens used to shield other people.

CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the
arc spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may
result in blindness when the lens is removed from the eye.

Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any
applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and
inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working
area may be necessary particularly in cases where the general ventilation is poor, or where considerable
welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be
provided, air-fed respirators may be necessary.

CAUTION: Some of the components installed to the vehicle e.g. the interior cross beam and underbonnet
cross member are manufactured from magnesium alloy. On no account should any welding operations be
attempted on these components.

Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage
of these gases, with consequent risk of fire and explosion.

The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that
from arc welding, and lighter filters may be used.

The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the
work, particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if
brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of
fumes and expert advice may be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON
VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR
STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.

These decals must not be removed. The warnings are for the attention of owners/operators and persons
carrying out service or repair operations on the vehicle.

Published: 11-May-2011

General Information - Solvents, Sealants and Adhesives

Description and Operation

Solvents

WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals
or give off fumes which can be dangerous to health. Always follow the manufacturers instructions. If in doubt
about any substance, particularly a solvent, DO NOT use it.

CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application,
contact the manufacturer of the product for information.

The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards
associated with their use, and safety measures to be taken. Some of these chemicals may be included as an
ingredient in a sealer or adhesive.

Sealers

Certain procedures in this manual involve the use of sealants during installation of components. Where a
sealant is required, the application, together with the Land Rover part number is given in the General
Specification at the start of each section and an instruction that a sealant must be used appears in the relevant
repair procedure.

It is essential that the sealant(s) specified for a particular procedure are used, DO NOT use any other sealant.

Always remove traces of old sealant using a plastic scraper or suitable solvent, never use emery cloth or metal
scrapers.

Adhesives

Whenever a procedure involves the use of an adhesive, the adhesive specified must be used and the
manufacturer's instructions regarding application together with any health and safety precautions must be
followed.

Published: 11-May-2011

General Information - Special Tool Glossary

Description and Operation

Service Tools

Special service tools have been developed to facilitate removal, dismantling and assembly of mechanical
components in a cost effective and time efficient manner. The use of such special tools also helps prevent the
potential for damage to components.

Some operations described in this manual cannot be carried out properly without the aid of the relevant service
tools.

All orders and enquiries from the United Kingdom and European countries except Germany, Austria,
Switzerland and Spain and countries not in the following list should be sent direct to:

SPX UK Ltd.,

Genoa House,

Everdon Park,

Daventry,

Northants,

NN11 5YJ

England

Tel: [phone]/303455

Fax: [phone]

e-mail: [e-mail]

Overseas orders for the following countries should be placed with the local distributor.

Germany, Austria and Switzerland

SPX Europe GMBH,

Porschestrasse 4,

63512 Hainburg,

Germany

Tel: [phone] 0049 61829590

Fax: [phone]

Spain

SPX Iberica SA,

C/Francisco Aritio,

158 nave 72 (Nudo Oeste),

19004 Guadalajara,

Spain

Tel: [phone] 0034 949208381

Fax: [phone]

North America

SPX Corporation

665, Eisenhower Drive,

Owatonna,

MN 55060,

USA

Tel: [phone] 0018 772979110

Fax: [phone]

Australia

SPX Australia,

28, Clayton Road,

Notting Hill,

Victoria 3168,

Australia

Tel: [phone] 0061 00395446222

Fax: [phone]

e-mail: [e-mail]

Japan and East Asia

Jatek Ltd.,

5 - 53, Minawacho 2-chome,

Kohoku-ku,

Yokohama,

Kanagawa 223-0051,

Japan

Tel: [phone] 0081 455627700

Fax: [phone]

Published: 11-May-2011

General Information - Road/Roller Testing

Description and Operation
Road or rolling road testing may be carried out for various reasons and a procedure detailing pre-test checks,
through engine starting and stopping, pre-driving checks, on-test checks to final checks on completion of the
test are given.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out.
Instead, those items particularly relevant to the system(s) being checked can be extracted.

Pre-Test Checks

WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is
found, do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or
hydraulic leak is found and rectified.

It is suggested that pre-test and functional tests of those systems/circuits which affect the safe and legal
operations of the vehicle, such as brakes, lights and steering, should always be carried out before the road or
rolling road test.

 Engine oil level
 Engine coolant level
 Tires, for correct pressure, compatible types and tread patterns, and wear within limits.
 There is sufficient fuel in the tank to complete the test.
 Check all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel

leaks. Make a note of any apparent leaks and wipe off the surrounding areas to make it easier to
identify the extent of the leak on completion of the test.

Starting the Engine

• NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal
beyond half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at
high engine speed or with the accelerator pedal at full travel whilst the engine is cold.

With the ignition switched off, check:

 The parking brake is applied.
 Automatic gearbox: The selector lever is in 'P' - Park
 Transfer case: 'H' - High is selected
 All instrument gauges read zero.

With the ignition switched on, check:

 Ignition controlled warning lights come on.
 Engine temperature gauge registers a reading compatible with the engine temperature.
 Fuel gauge registers a reading appropriate to the fuel level in the tank.
 The operation of the parking brake warning light and fluid level warning indicator light.

On Road Test Check:

CAUTION: At commencement of road testing, check the brake operation while still travelling at low speed
before continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue
with the road test until the fault has been found and rectified.

 The parking brake releases completely.
 Gear changing is smooth, and there are no abnormal noises or vibrations from the gearbox.
 The engine power output is satisfactory, acceleration is smooth and accelerator pedal operation is not

stiff or heavy, and engine speed returns to idle correctly.

 There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load

or overrun conditions.

 Steering operation is smooth, accurate, not excessively heavy or with excessive free play or vibration.

Does not pull to one side and self centres smoothly after cornering.

 All instruments register the correct readings and operate correctly.
 Switches and controls operate smoothly and positively, warning or indicator lights operate correctly

and the direction indicator control self cancels when the steering is returned to the straight ahead
position.

 Heating and ventilation systems work correctly and effectively.
 Brakes operate efficiently.

Brake Testing

Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users.

CAUTION: Brake testing which includes heavy brake applications should not be carried out with new
brake pads/discs until the components have bedded-in. New brake friction components will not reach full
efficiency until the bedding-in process is complete. Note that when new parking brake shoes or rear brake discs
have been installed, it is essential that the 'bedding-in' procedure given in Section 206-05 - Parking Brake
Removal and Installation is carried out.

Test the brakes at several speeds within the normal operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or drag, and any undue delay in application or release.

Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding.

After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake
temperature. A disc which feels appreciably hotter than the others, could indicate that the pads on that disc
are binding.

After completion of the test, check for:

 Oil, coolant, hydraulic, air and fuel leaks.
 Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission etc.,

which might indicate over tightness or lack of lubrication.

Rolling Road Testing

DTC

Description

Possible Causes

Action

B1D79­84

Microphone Input ­Signal below allowable
range

 The 'Receive Audio over MOST

Test' failed and means that the
audio received at the
microphone detection point is
too low

 Microphone fault
 Harness/connector fault
 Integrated head unit (IHU) fault

Check the operation of the
microphone. Refer to the electrical
circuit diagrams and check the
microphone (MIC) circuits.
Renew/repair as necessary. Refer to
the warranty policy and procedures
manual if a module is suspect.

Four-Wheel Rolling Road

CAUTION: When utilising a four-wheel rolling road for testing, ensure all relevant health and safety
requirements are adhered to.

Provided that front and rear rollers are rotating at identical speeds and that normal workshop safety standards
are applied, there is no speed restriction during testing except any that may apply to the tires.

Ensure that the parking brake is released prior to engaging roller driving mechanism.

Two-Wheel Rolling Road

CAUTION: On no account should an attempt be made to carry out any form of testing on a two-wheel
rolling road.

Published: 11-May-2011

General Information - Diagnostic Trouble Code (DTC) IndexDTC:
Module Name: Bluetooth Module

Description and Operation

Bluetooth Module (TEL)

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control
modules does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being
tested and/or the donor vehicle.

• NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer
warranty, refer to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior
approval programme is in operation, prior to the installation of a new module/component.

• NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits
from the scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra
information read by the manufacturer-approved diagnostic system).

• NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

• NOTE: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.

• NOTE: If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent

concern may be the cause. Always check for loose connections and corroded terminals.

The table below lists all Diagnostic Trouble Codes (DTCs) that could be logged in the Bluetooth Module, for
additional Diagnosis and Testing information refer to the relevant Diagnosis and Testing Section. For additional
information, refer to: Cellular Phone (415-00 Information and Entertainment System - General Information,
Diagnosis and Testing).

DTC

Description

Possible Causes

Action

U1A00­88

Private Communication
Network - Bus off

 Internal communications failure

Clear the DTC and retest. If the
problem persists, renew the
Bluetooth Module. Refer to the
warranty policy and procedures
manual if a module is suspect.

U2001­9A

Reduced System
Function - Component
or system operating
conditions

 Bluetooth error - system over-

temperature

Allow the system to cool, clear the
DTC and check /monitor for re­occurrence. If DTC re-occurs suspect
the module. Check and install a new
module as required. Refer to the
Warranty Policy and Procedures
manual if a module is suspect.

U201A­54

Control Module Main
Calibration Data ­Missing calibration

 Local configuration file is

missing (not loaded) in the
control module

Configure the module using the
manufacturers approved diagnostic
system (file download may take
several minutes).

U3000­44

Control module - Data
memory failure

 Bluetooth Module RAM fault

(data memory failure leading to
possible corrupt local
configuration file)

Configure the module using the
manufacturers approved diagnostic
system and download the local
configuration file. Clear the DTC and
retest. If the problem persists, renew
the Bluetooth Module. Refer to the
warranty policy and procedures
manual if a module is suspect.

U3000­45

Control module ­Program memory
failure

 Bluetooth Module ROM fault

(data memory failure leading to
possible corrupt local
configuration file)

Configure the module using the
manufacturers approved diagnostic
system and download the local
configuration file. Clear the DTC and
retest. If the problem persists, renew
the Bluetooth Module. Refer to the
warranty policy and procedures
manual if a module is suspect.

U3000­54

Control module ­Missing calibration

 MOST not configured correctly -

incorrect voice language
installed

Check and amend the Car
Configuration File in the Information
and Entertainment Control Module
using the manufacturer approved
diagnostic system.

U3000­56

Control module ­Invalid/incomplete
configuration

 One or more of the received car

configuration file (CCF) data
parameters is deemed to be
invalid

Check and amend the Car
Configuration File using the
manufacturer approved diagnostic
system.

U3003­16

Battery Voltage ­Circuit voltage below
threshold

 Battery voltage below threshold

Check vehicle battery and charging
system. Refer to the relevant section
in the workshop manual. Refer to the
electrical circuit diagrams and check
the power supply circuits to the
module.

U3003­17

Battery Voltage ­Circuit voltage above
threshold

 Battery voltage above threshold

Check vehicle battery and charging
system. Refer to the relevant section
in the workshop manual. Refer to the
electrical circuit diagrams and check
the power supply circuits to the
module.

Identification Codes - Identification Codes

Description and Operation
VIN Number

The VIN number will be found in three locations:

 1. Stamped on the front of the RH front suspension turret.
 2. At the bottom of the windshield glass on the LH side of the vehicle and visible from the outside.
 3. UK, Europe and ROW - Not NAS/Canada -On the VIN plate attached to the LH inner wing,

forward of the suspension turret.

Published: 11-May-2011

 4. NAS/Canada - On the Tire Data/Specification label attached to the front of the LH B-pillar.

RH Front Suspension Turret VIN

Windscreen VIN

LH Inner Wing VIN

VIN number - UK, EU and ROW

VIN Position

Character

Identifies

1 - 3 - World identifier

SAL

Land Rover (UK)

4,5 - Vehicle type

LM

Range Rover

6 - Class

A

Standard

7 - Body style

M

4 Door

8 - Engine

3

428PS - AJV8 4.2 SC Petrol

8 - Engine

5

448PN - AJV8 4.4 Petrol

8 - Engine

C

306D1 - 6 Cyl 3.0 diesel

9 - Transmission and steering

3

RHD Automatic

9- Transmission and steering

4

LHD Automatic

10 - Model year

6

2006

10 - Model year

7

2007

10- Model year

8

2008

11 - Plant

A

Solihull

12 - 17 - Serial number

1 2 3 4 5 6

Unique six digit serial number

VIN number - NAS and Canada

VIN Position

Character

Identifies

1 - 3 - World identifier

SAL

Land Rover (UK)

4 - Model range

M

Range Rover

5 - Class

E

HSE (without luxury pack, with logic 7 and Bi-Xenon)

5 - Class

F

HSE (with luxury pack, logic 7 and Bi-Xenon)

5 - Class

H

Westminster/Autobiography

5 - Class

N

Standard

6 - Body style

1

4 Door Station Wagon

7 - Engine

3

428PS - AJV8 4.2 SC Petrol

7 - Engine

5

448PN - AJV8 4.4 Petrol

8- Transmission and steering

4

LHD Automatic

9 - Check digit

*

Derived by calculation

10 - Model year

6

2006

10 - Model year

7

2007

VIN Position

Character

Identifies

10- Model year

8

2008

11 - Plant

A

Solihull

12 -17 - Serial number

1 2 3 4 5 6

Unique six digit serial number

LH Inner Wing, Forward of Suspension Turret, VIN Plate - Not NAS/Canada

The VIN plate contains the following information:

 A - Reserved
 B - Engine Description
 C - Country
 D - Diesel Indicator
 E - Reserved
 F - Headlamp Code/initial aim value - If shown
 G - Colour code/group
 H - Type/Approval Number - If shown
 I - VIN Number
 J - Gross Vehicle Weight
 K - Gross Trailer Weight
 L - Front Axle Weight
 M - Rear Axle Weight

VIN/Certification/Tire Data Label - NAS only

The Certification Label contains the following VIN information:

 A - VIN Number
 B - Bar code identification

VIN/Tire Pressure Specification Label - Canada only

The Tire Pressure Certification Label contains the following VIN information:

 A - VIN Number
 B - Vehicle Type

Unit/Assembly Serial Number Locations

3.0 Litre TD6 Diesel Engine Serial Number

The 3.0 Litre TD6 Diesel Engine Serial Number is stamped on the LH side of the cylinder block.

The 4.0 Litre V6 Petrol Engine Serial Number is stamped on the LH side of the cylinder block.

4.2 Litre SC and 4.4 Litre V8 Petrol Engine Serial Number

The 4.2 Litre SC and 4.4 Litre V8 Petrol Engine Serial Number is etched into the LH side of the engine block.

TD6 Automatic Transmission Serial Number

The transmission serial number is on a plate attached to the LH side of the transmission casing.

4.2 SC and 4.4 Litre Automatic Transmission Serial Number

The automatic transmission serial number is stamped on the rear LH side of the transmission casing.

Front Differential Serial Number

The Front Differential Serial Number is stamped on the underside of the differential casing and is located above
the removable cross member.

Rear Differential Serial Number

The Rear Differential Serial Number is stamped on the underside of the differential casing adjacent to the front
mounting.

Transfer Case Serial Number

The Transfer Case serial number is stamped on the RH side of the transfer case and may also be on a bar
coded self-adhesive label attached to the case.

Published: 11-May-2011

Jacking and Lifting - Jacking

Description and Operation

General

WARNING: The following instructions must be adhered to before raising the vehicle off the ground:

 Position vehicle on a solid, level surface.
 Apply the parking brake.
 Select 'P' - PARK on automatic transmission selector and 'H' High on transfer case.

WARNING: If the drive shaft(s) are to be disconnected, it will be necessary to raise all four wheels off the
ground in order that the shaft(s) can be rotated. DO NOT use the customer jack and ensure that the vehicle is
adequately supported on axle stands. With the vehicle raised, it will be necessary to release the park brake and
select Neutral - 'N' in the main transmission to enable the drive shaft(s) to be rotated

• CAUTIONS:

To avoid damage to the underbody components of the vehicle, the following instructions must be
adhered to:

Do not position jacks or axle stands under the following components:

 Body structure other than any approved jacking or lifting points
 Bumpers

 Fuel lines

 Fuel tank

 Brake lines

 Front or rear suspension arms

 Steering linkage

 Transfer case

 Front or rear differential units

 Transmission

 Engine oil pan - See note below

• NOTE: For certain repair operations, it may be necessary to support the engine under the oil pan. In this

case, a block of hardwood or a rubber pad must be positioned on the jack lifting pad to protect the oil pan.

Vehicle jack

The jack provided with the vehicle is only intended for use in an emergency such as changing a tire. DO NOT
use the jack for any other purpose. Refer to the Owner's Handbook for the vehicle jack location points and
jacking procedures.

WARNING: Never work under a vehicle supported solely by the vehicle jack.

Hydraulic jack

A hydraulic jack with a minimum lifting capacity of 1500 kg, (3,300 lbs) must be used.

• WARNINGS:

Do not commence work on the underside of the vehicle until suitable axle stands have been placed in the
correct position.

Always chock the wheels when jacking. The parking brake may be ineffective when the wheel(s) are off
the ground.

Raising and Supporting the Vehicle

To assist in raising the vehicle, jacking points are provided as shown in the following illustrations.

Raising the Front of the Vehicle

Apply the parking brake.

Select 'P' - PARK on automatic transmission selector.

WARNING: Always chock the rear wheels when jacking the front of the vehicle.

Position the lifting pad of the hydraulic jack under the centre of the front sub-frame, front cross member.

With the vehicle raised to the desired height, position axle stands under, either, the front sub-frame or the
recommended customer jacking points.

CAUTION: Position suitable material between axle stands and component/body to prevent damage.

Carefully lower jack until vehicle rests on axle stands.

WARNING: Before commencing work on the underside of the vehicle, ensure that axle stands are
correctly positioned and vehicle is securely supported.

Reverse procedure when removing vehicle from stands.

Raising the Rear of the Vehicle

Select 'P' - PARK on automatic transmission selector.

WARNING: Always chock the front wheels when jacking the rear of the vehicle.

Position the lifting pad of the hydraulic jack under the centre of the rear sub-frame, rear cross member as
shown.

With vehicle raised to desired height, position axle stands under the rear sub-frame. Alternatively, the axle
stands may be positioned under, either, the recommended customer jacking points or the front mounting
points of the rear sub-frame.

CAUTION: Position suitable material between axle stands and component/body to prevent damage.

Carefully lower jack until vehicle rests on axle stands.

WARNING: Before commencing work on underside of vehicle, ensure that axle stands are correctly
positioned and vehicle is securely supported.

Reverse procedure when removing vehicle from stands.

Published: 11-May-2011

Jacking and Lifting - Lifting

Description and Operation
Vehicle on Wheels - Four-Post Ramp

WARNING: If the drive shaft(s) are to be disconnected, it will be necessary to raise all four wheels off the
ramp in order that the shaft(s) can be rotated. Refer to the 'Wheel Free Lift - Four-Post Ramp' section below
for lifting instructions then release the parking brake and select NEUTRAL 'N' in the transmission.

WARNING: Do not push the vehicle backwards and forwards along the ramp in order to gain access to
the drive shaft fixings.

Position the vehicle on the ramp with the front and rear of the vehicle equidistant from the ends of the ramp.
Chock the wheels, select NEUTRAL in the transmission and where practicable, apply the parking brake.

Wheel Free Lift - Four-Post Ramp

WARNING: The vehicle cannot be supported safely in a wheel free condition using the wheel free facility
of a four-post ramp, and under no circumstances must this method be used.

Raising and Supporting the Vehicle

1. Position vehicle on ramp.

2. Position suspension in 'off-road' height.

3. Apply parking brake.

4. Raise ramp to desired height.

5. Using suitable equipment, raise the vehicle to the desired height and position axle stands to recommended
customer jacking points.

CAUTION: Place suitable material between axle stands and body to avoid damage to vehicle.

6. Lower vehicle slowly until weight of vehicle rests on axle stands and road wheels are just clear of ramp.

7. Ensure that the vehicle is correctly supported on all four axle stands.

8. Lower the ramp to suitable working height.

WARNING: Make sure that the vehicle is stable before commencing work.

• NOTE: Return the suspension to 'normal ride height' when the vehicle is removed from the ramp.

Two-Post Lift

CAUTION: If the drive shaft(s) are to be removed, release the parking brake and select NEUTRAL 'N' in
the transmission in order that the shaft(s) can be rotated when the vehicle is raised to the desired height.

1. Position the vehicle with the centre of the lift pillars aligned approximately with the front of the
driver/passenger seat cushions.

2. Extend the lifting arms and position the pad of each lifting arm beneath the recommended customer jacking
points.

3. Raise the vehicle until the wheels are just clear of the ground and check that the pads of each lifting arm are
still correctly positioned.

4. Raise the vehicle to the desired height.

5. Ensure that the vehicle is correctly supported on all four lifting pads, that pads are still correctly positioned
and are in full contact with the body.

WARNING: Ensure that the vehicle is stable before commencing work.

Published: 11-May-2011

Jacking and Lifting - Vehicle Recovery

Description and Operation

Towing/Lashing eyes

CAUTION: The single towing/lashing eyes at the front and rear of the vehicle are designed for vehicle
recovery purposes only and MUST not be used to tow a trailer or caravan.

The front towing/lashing eye is accessible after releasing the towing eye access panel and removing the panel.

• CAUTIONS:

Ensure that during towing, the towing attachment does not contact the bumper.

The rear towing/lashing eye should only be used for towing another vehicle or for recovery purposes to
enable this vehicle to be positioned in order that the front towing eye may be used for recovery/towing.

4 Wheel Towing

• CAUTIONS:

Suspended towing of this vehicle MUST NOT be attempted, if four wheel towing is not possible, vehicle
must be recovered on a suitable trailer.

The vehicle may be towed for a maximum of 1 hour or 31 miles (50 km) at a maximum speed of 31 mph
(50 km/h), these limits MUST NOT be exceeded.

The following procedures must be followed to ensure that the vehicle is towed in a safe condition and
damage to the vehicle transmission system is prevented.

1. Remove the front towing/lashing eye access panel.

2. Secure the towing attachment from the recovery vehicle to the towing/lashing eye.

CAUTION: Ensure that the towing attachment will not contact the front bumper during towing.

3. Apply the parking brake.

4. Insert ignition key and turn the ignition switch to position 'II'.

CAUTION: If 'N' - Neutral cannot be selected, front and rear driveshafts must be removed before vehicle
is towed.

6. Apply the footbrake and move the automatic transmission selector lever to the 'N' Neutral position.

• NOTE: If electrical power is not available, use the manual interlock release tab on the selector lever to move
the selector lever to the Neutral position.

7. Select 'H' - HIGH on the transfer box.

CAUTION: If electrical power is not available, and 'H' - HIGH cannot be selected, the vehicle may not be
towed but must be recovered on a suitable trailer. If, however, the transfer box was in 'H' - HIGH when
electrical power was lost, the vehicle may still be towed.

8. Release the parking brake.

WARNING: Do not release the parking brake until towing is about to commence. Whilst towing, do not
attempt to remove the ignition key and do not turn the key to any position other than 'II'. With the engine
switched off, the power assisted steering system and brake booster will be inoperative thereby resulting in an
increase in the effort required to turn the steering wheel and apply the brakes.

CAUTION: The vehicle tow connections should only be used in normal road conditions, 'snatch' recovery
must be avoided.

On completion of 4 wheel towing

1. Apply the parking brake.

2. Detach towing equipment from towing/lashing eyes.

3. Install the towing eye access panel.

Transporting by trailer

CAUTION: Use the towing/lashing eyes at the front and rear of the vehicle, DO NOT secure lashing hooks
or restraints to any other part of the vehicle.

Position the vehicle, apply the parking brake and select 'N' - Neutral on the automatic transmission selector
lever.