P. 1
Landrover Discovery Workshop Manual

Landrover Discovery Workshop Manual

|Views: 8|Likes:
Published by Richard Wilson

More info:

Published by: Richard Wilson on May 20, 2012
Copyright:Attribution Non-commercial

Availability:

Read on Scribd mobile: iPhone, iPad and Android.
download as PDF, TXT or read online from Scribd
See more
See less

06/30/2012

pdf

text

original

DISCOVERY

Wo r k s h o p M a n u a l

Workshop manual

DISCOVERY

01 04 05 07 09 10

This manual covers vehicles from 1995 model year
01 04 05 07 09 10 12 12 12 12 17 19 19 19 19 19 26 26 26 30 33 37 41 44 47 51 54 57 60 64 70 74 75 76 80 82 84 86 INTRODUCTION GENERAL SPECIFICATION DATA ENGINE TUNING DATA GENERAL FITTING REMINDERS LUBRICANTS, FLUIDS AND CAPACITIES MAINTENANCE ENGINE Tdi ENGINE 3.9 V8 ENGINE 4.0 V8 ENGINE Mpi EMISSION CONTROL FUEL SYSTEM Tdi FUEL SYSTEM MFI FUEL SYSTEM SFI FUEL SYSTEM Mpi CRUISE CONTROL COOLING SYSTEM Tdi COOLING SYSTEM V8 COOLING SYSTEM Mpi MANIFOLD AND EXHAUST SYSTEM CLUTCH MANUAL GEARBOX TRANSFER GEARBOX AUTOMATIC GEARBOX PROPELLER SHAFTS REAR AXLE AND FINAL DRIVE FRONT AXLE AND FINAL DRIVE STEERING FRONT SUSPENSION REAR SUSPENSION BRAKES WHEELS AND TYRES SUPPLEMENTARY RESTRAINT SYSTEM CHASSIS AND BODY HEATING AND VENTILATION AIR CONDITIONING WIPERS AND WASHERS ELECTRICAL Published by Rover Technical Communication © 1996 Rover Group Limited Publication Part No. LRL 0079 ENG (2nd Edition)

12

17 19

26

30

33

37 41 44 47 51 54

57

60 64 74

70

75 76

80 82

84 86

INTRODUCTION

INTRODUCTION This workshop manual covers vehicles from 1995 model year onwards. Amendments and additional pages will be issued to ensure that the manual covers latest models. Amendments and additions will be identified by the addition of a dated footer at the bottom of the page. This Workshop Manual is designed to assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles. Individuals who undertake their own repairs should have some skill and training, and limit repairs to components which could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as steering, brakes, suspension or supplementary restraint system should be carried out by a Land Rover Dealer. Repairs to such items should NEVER be attempted by untrained individuals. WARNINGS, CAUTIONS and NOTES are given throughout this Manual in the following form: WARNING: Procedures which must be followed precisely to avoid the possibility of personal injury. CAUTION: This calls attention to procedures which must be followed to avoid damage to components. NOTE: This calls attention to methods which make a job easier or gives helpful information.

REFERENCES References to the left or right hand side in the manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the water pump end of the engine is referred to as the front. To reduce repetition, some operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned.

REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that Land Rover parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories: Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer’s specification. Torque spanner values given in the Workshop Manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be replaced with a new one. Certain fasteners must not be re-used. These fasteners are specified in the Workshop Manual.

DIMENSIONS The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification.

POISONOUS SUBSTANCES Many liquids and other substances used are poisonous and therefore must not be consumed. It is also advisable to keep all substances away from open wounds. These substances among others include anti-freeze, brake fluid, fuel, windscreen washer additives, air conditioning refrigerant, lubricants and various adhesives.

INFORMATION

1

01

INTRODUCTION

FUEL HANDLING PRECAUTIONS The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines the other areas of risk which must not be ignored. This information is issued for basic guidance only, and in any case of doubt, appropriate enquiries should be made of your local Fire Officer or Fire Department. Fuel vapour is highly flammable and in confined spaces is also very explosive and toxic. When fuel evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air current, consequently, even a small spillage of fuel is very dangerous. Always have a fire extinguisher containing FOAM CO2 GAS, or POWDER close at hand when handling fuel, or when dismantling fuel systems and in areas where fuel containers are stored. WARNING: lt is imperative that the battery is not disconnected during fuel system repairs as arcing at the battery terminal could ignite fuel vapour in the atmosphere. Always disconnect the vehicle battery BEFORE carrying out work on the fuel system. Whenever fuel is being handled, transferred or stored, or when fuel systems are being dismantled all forms of ignition must be extinguished or removed, any leadlamps used must be flame proof and kept clear of spillage. No one should be permitted to repair components associated with fuel without first having had fuel system training.

Hot fuel handling precautions WARNING: Before commencing any operation requiring fuel to be drained from the fuel tank, the following procedure must be adhered to: 1. Allow sufficient time for the fuel to cool, thus avoiding contact with hot fuels. 2. Vent the system by removing the fuel filler cap in a well ventilated area. Refit the filler cap until the commencement of fuel drainage. Fuel transfer WARNING: Fuel must not be extracted or drained from any vehicle while it is standing over a pit. The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved transfer tank must be used according to the transfer tank manufacturer’s instructions and local regulations, including attention to grounding of tanks. Fuel tank removal A FUEL VAPOUR warning label must be attached to the fuel tank upon removal from the vehicle. Fuel tank repair Under no circumstances should a repair to any tank be attempted.

2

INFORMATION

INTRODUCTION

SYNTHETIC RUBBER Many ’0’ ring seals, flexible pipes and other similar items which appear to be natural rubber are made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe, and does not present a health hazard. However, if the material is damaged by fire or excessive heat, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious burns on contact with skin. Should the material be in a burnt or overheated condition handle only with seamless industrial gloves. Decontaminate and dispose of the gloves immediately after use. If skin contact does occur, remove any contaminated clothing immediately and obtain medical assistance without delay. In the meantime, wash the affected area with copious amounts of cold water or limewater for fifteen to sixty minutes.

USED ENGINE OIL WARNING: Prolonged and repeated contact with engine or motor oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. Used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Handling precautions 1. Avoid prolonged and repeated contact with oils, particularly used engine oils. 2. Wear protective clothing, including impervious gloves where applicable. 3. Do not put oily rags in pockets. 4. Avoid contaminating clothes, particularly underwear, with oil. 5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. 6. First aid treatment must be obtained immediately for open cuts and wounds. 7. Use barrier creams, before each work period, to help the removal of oil from the skin. 8. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. 9. Do not use gasoline, kerosene, diesel fuel, petrol, thinners or solvents for washing the skin. 10. If skin disorders develop, obtain medical advice. 11. Where practicable, degrease components prior to handling. 12. Where there is a risk of eye contact, eye protection should be worn, for example, goggles or face shields; in addition an eye wash facility should be provided. Disposing of used oils Environmental protection precaution It is illegal to pour used oil onto the ground, down sewers or drains, or into waterways. Dispose of used oil through authorised waste disposal contractors. If in doubt contact your Local Authority for advice on disposal facilities.

RECOMMENDED SEALANTS A number of branded products are recommended in this manual for use during maintenance and repair work. These items include: HYLOMAR GASKET AND JOINTING COMPOUND and HYLOSIL RTV SILICON COMPOUND. They should be available locally from garage equipment suppliers. If there is any problem obtaining supplies, contact the following company for advice and the address of the nearest supplier. MARSTON LUBRICANTS LTD. Hylo House, Cale Lane, New Springs, Wigan WN2 1JR Tel 01942 824242

INFORMATION

3

01

INTRODUCTION

ACCESSORIES AND CONVERSIONS DO NOT FIT unapproved accessories or conversions, as they could affect the safety of the vehicle. Land Rover will not accept liability for death, personal injury, or damage to property which may occur as a direct result of the fitting of non-approved conversions to the vehicle.

SPECIAL SERVICE TOOLS The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where special tools are specified, only these tools should be used to avoid the possibility of personal injury or damage to the components. Also the amount of time which they save can be considerable. Every special tool is designed with the close co-operation of Land Rover, and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely. Special tools bulletins will be issued periodically giving details of new tools as they are introduced. All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countries where there is no distributor may order direct from: V. L. Churchill Limited, PO Box 3, Daventry, Northants, England, NN11 4NF. The tools recommended in this Workshop Manual are listed in a multi-language illustrated catalogue, obtainable from: Messers. V. L. Churchill at the above address, or from: Land Rover Merchandising Service, PO Box 534, Erdington, Birmingham, B24 0Q5,

WHEELS AND TYRES WARNING: DO NOT replace the road wheels with any type other than genuine Land Rover wheels which are designed for multi-purpose on and off road use and have very important relationships with the proper operation of the suspension system and vehicle handling. Replacement tyres must be of the make and sizes recommended for the vehicle, and all tyres must be the same make, ply rating and tread pattern.

STEAM CLEANING To prevent consequential rusting, any steam cleaning within the engine bay MUST be followed by careful re-waxing of the metallic components affected. Particular attention must be given to the steering column, engine water pipes, hose clips and ignition coil clamp.

SPECIFICATION The specification details and instructions set out in this Manual apply only to a range of vehicles and not to any one. For the specification of a particular vehicle purchasers should consult their Dealer The Manufacturer reserve the right to vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer’s policy of constant product improvement. Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer or Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof.

COPYRIGHT © Land Rover 1996 All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission of Land Rover.

4

INFORMATION

INTRODUCTION

JACKING The following instructions must be carried out before raising the vehicle off the ground. 1. 2. 3. 4. Use a solid level ground surface. Apply parking brake. Select ’P’ or 1st gear in main gearbox. Select Low range in transfer gearbox.

Vehicle jack The jack provided with the vehicle is only intended to be used in an emergency, for changing a tyre. Do NOT use the jack for any other purpose. Refer to Owner’s Manual for vehicle jack location points and procedure. Never work under a vehicle supported by the vehicle jack. Hydraulic jack

CAUTION: To avoid damage occurring to the under body components of the vehicle the following jacking procedures must be adhered to. DO NOT POSITION JACKS OR AXLE STANDS UNDER THE FOLLOWING COMPONENTS.

A hydraulic jack with a minimum 1500 kg, 3,300 lbs load capacity must be used. CAUTION: Do not commence work on the underside of the vehicle until suitable axle stands have been positioned under the axle.

Body structure Bumpers Fuel lines Brake lines Front radius arms Panhard rod Steering linkage Rear Trailing links Fuel tank Engine sump Gearbox bell housing Jack or support vehicle by axles only.

Raise the front of the vehicle 1. Position cup of hydraulic arm under differential casing. NOTE: The differential casing is not central to the axle. Care should be taken when raising the front road wheels off the ground as the rear axle has less sway stiffness.

INFORMATION

5

01

INTRODUCTION

2. Raise front road wheels to enable an axle stand to be installed under left hand axle tube. 3. Position an axle stand under right hand axle tube, carefully lower jack until axle sits securely on both axle stands, remove trolley jack. 4. Before commencing work on underside of vehicle re-check security of vehicle on stands. 5. Reverse procedure when removing vehicle from stands. Raise rear of vehicle 1. Position cup of hydraulic arm under differential casing. 2. Raise vehicle to enable axle stands to be installed under left and right hand axle tubes. 3. Lower jack until axle sits securely on axle stands, remove trolley jack. 4. Before commencing work on underside of vehicle re-check security of vehicle on stands. 5. Reverse procedure when removing vehicle from stands.

DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES Viscous coupling The front and rear axles cannot be driven independently due to the viscous coupling. This eliminates the need for differential lock by progressively locking the centre differential automatically if slip occurs at any wheel. WARNING: DO NOT attempt to drive individual wheels with vehicle supported on floor jacks or stands. Four wheel dynamometers Provided that front and rear dynamometer 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 tyres. Two wheel dynamometers

HYDRAULIC VEHICLE RAMP (FOUR POST) Use only a ’drive on’ type ramp which supports vehicle by its own road wheels. If a ’wheel-free’ condition is required, use a ’drive on’ ramp incorporating a ’wheel-free’ system that supports under axle casings. Alternatively, place vehicle on a firm, flat floor and support on axle stands.

IMPORTANT: Use a four wheel dynamometer for brake testing if possible. If brake testing on a single axle rig is necessary it must be carried out with propeller shaft to rear axle removed, AND neutral selected in BOTH main gearbox and transfer gearbox. When checking brakes, run engine at idle speed to maintain servo vacuum. If checking engine performance, the transfer box must be in high range and propeller shaft to stationary axle must be removed.

TWO POST VEHICLE RAMPS The manufacturer of LAND ROVER VEHICLES DOES NOT recommend using ’Two Post’ ramps that employ four adjustable support arms. These are NOT considered safe for Land Rover vehicles. If vehicle is installed on a Two Post ramp responsibility for safety of vehicle and personnel performing service operations is in the hands of the Service Provider.

6

INFORMATION

INTRODUCTION

DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) WARNING: Do not attempt to test ABS function on a dynamometer Four wheel dynamometers NOTE: Before testing a vehicle on a four wheel dynamometer disconnect the valve relay. See Electrical Trouble Shooting Manual. The ABS function will not work, the ABS warning light will illuminate. Normal braking will be available. 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 tyres. Two wheel dynamometers IMPORTANT: Use a four wheel dynamometer for brake testing if possible. NOTE: ABS will not function on a two wheel dynamometer. The ABS light will illuminate during testing. Normal braking will be available. If brake testing on a single rig is necessary it must be carried out with propeller shaft to the rear axle removed, AND neutral selected in BOTH main and transfer boxes. If checking engine performance, the transfer box must be in high range and drive shaft to stationary axle removed.

3. Secure tow rope, chain or cable to towing eye. 4. Release the parking brake. CAUTION: The brake servo and power assisted steering system will not be functional without the engine running. Greater pedal pressure will be required to apply the brakes, the steering system will require greater effort to turn the front road wheels. The vehicle tow connection should be used only in normal road conditions, ’snatch’ recovery should be avoided. Suspended tow by breakdown vehicle CAUTION: To prevent vehicle damage, front or rear propeller shaft MUST BE removed, dependent upon which axle is being trailed. 1. Mark propeller shaft drive flanges at transfer gearbox and axles with identification lines to enable the propeller shaft to be refitted in its original position. 2. Remove the propeller shaft fixings, remove the shaft from the vehicle. 3. If the front axle is to be trailed turn ignition key to position ’1’ to release steering lock. CAUTION: The steering wheel and/or linkage must be secured in a straight ahead position. DO NOT use the steering lock mechanism for this purpose.

TOWING CAUTION: The vehicle has permanent four-wheel drive. The following towing instructions must be adhered to: Towing the vehicle on all four wheels with driver operating steering and brakes. 1. Turn ignition key turn to position ’1’ to release steering lock. 2. Select neutral in main gearbox and transfer gearbox.

INFORMATION

7

01

INTRODUCTION

TRANSPORTING THE VEHICLE BY TRAILER Lashing eyes are provided on front and rear of the chassis side members, to facilitate the securing of the vehicle to a trailer or other means of transportation. CAUTION: Underbody components must not be used as lashing points. Install vehicle on trailer and apply park brake. Select neutral in main gearbox. Selecting ’N’ will prevent damage to parking pawl of the automatic gearbox. FRONT OF CHASSIS

JUMP STARTING WARNING: Hydrogen and oxygen gases are produced during normal battery operation. This gas mixture can explode if flames, sparks or lighted tobacco are brought near battery. When charging or using a battery in an enclosed space, always provide ventilation and shield your eyes. Keep out of reach of children. Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also, shield eyes when working near battery to protect against possible splashing of acid solution. In case of acid contact with skin, eyes, or clothing, flush immediately with water for a minimum of fifteen minutes. If acid is swallowed, drink large quantities of milk or water, followed by milk of magnesia, a beaten egg, or vegetable oil. SEEK MEDICAL AID IMMEDIATELY. To Jump Start - Negative Ground Battery WARNING: To avoid any possibility of injury use particular care when connecting a booster battery to a discharged battery. 1. Position vehicles so that jump leads will reach, ensuring that vehicles DO NOT TOUCH, alternatively a fully charged slave battery may be positioned on floor adjacent to vehicle. 2. Ensuring that ignition and all electrical accessories are switched off, that parking brake is applied and neutral is selected on a manual gearbox, with an automatic gearbox select neutral (N) or park (P) and then connect the jump leads as follows; A. Connect one end of first jumper cable to positive (+) terminal of booster battery. B. Connect other end of first jumper cable to positive (+) terminal of discharged battery. C. Connect one end of second jumper cable to negative terminal of booster battery.

REAR OF CHASSIS

8

INFORMATION

INTRODUCTION

D. Connect other end of second jumper cable to a good earth point on the engine, NOT TO NEGATIVE TERMINAL OF DISCHARGED BATTERY. Keep jumper lead away from moving parts, pulleys, drive belts and fan blade assembly. WARNING: Making final cable connection could cause an electrical arc which if made near battery could cause an explosion. 3. If booster battery is installed in another vehicle, start engine and allow to idle. 4. Start engine of vehicle with discharged battery, following starting procedure in Owners’ Manual. CAUTION: If vehicle fails to start within a maximum time of 12 seconds, switch ignition off and investigate cause. Failing to follow this instruction could result in irrepairable damage to catalysts. 5. Remove negative (-) jumper cable from the engine and then terminal of booster battery. 6. Remove positive (+) jumper cable from positive terminals of booster battery and discharged battery.

INFORMATION

9

01

INTRODUCTION

ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL Across flats (bolt size) ............................................ AF After bottom dead centre ................................... ABDC After top dead centre ......................................... ATDC Alternating current ................................................. a.c. Ampere ................................................................ amp Ampere hour .................................................... amp hr Before bottom dead centre ................................ BBDC Before top dead centre ...................................... BTDC Bottom dead centre ............................................. BDC Brake horse power ................................................ bhp British Standards .................................................... BS Carbon monoxide .................................................. CO Centimetre ............................................................. cm Centigrade (Celsius) ................................................ C Cubic centimetre ................................................... cm3 Cubic inch ............................................................... in3 Degree (angle) ............................................... deg or ° Degree (temperature) ..................................... deg or ° Diameter ............................................................... dia. Direct current ......................................................... d.c. Electronic Control Unit ........................................ ECU Electronic Fuel Injection ........................................ EFI Fahrenheit ................................................................. F Feet ........................................................................... ft Feet per minute .................................................. ft/min Fifth ........................................................................ 5th First ........................................................................ 1st Fluid ounce .......................................................... fl oz Foot pounds (torque) ............................................ lbf ft Fourth ..................................................................... 4th Gramme (force) ........................................................ gf Gramme (mass) ........................................................ g Gallons ................................................................... gal Gallons (US) ..................................................... US gal High tension (electrical) ........................................ H.T. Internal diameter ................................................... I.D. Inches of mercury .............................................. in. Hg Inches ...................................................................... in Kilogramme (force) ................................................. kgf Kilogramme (mass.) ................................................ kg Kilogramme centimetre (torque) ....................... kgf.cm Kilogramme per square millimetre ................. kgf/mm2 Kilogramme per square centimetre ................. kgf/cm2 Kilogramme metres (torque) .............................. kgf.m Kilometres .............................................................. km Kilometres per hour ............................................. km/h Kilovolts ................................................................... kV Left-hand ................................................................ LH Left-hand steering ............................................. LHStg Left-hand thread ............................................... LHThd Litres ..................................................................... litre Low tension ............................................................. l.t. Maximum ............................................................ max. Metre ........................................................................ m Millilitre .................................................................... ml Millimetre ............................................................... mm Miles per gallon .................................................... mpg Miles per hour ...................................................... mph Minute (angle) ............................................................ ’ Minus (of tolerance) ................................................... Negative (electrical) ................................................... Newton metres (torque) ........................................ Nm Number ................................................................. No. Ohms ................................................................... ohm Ounces (force) ....................................................... ozf Ounces (mass) ........................................................ oz Ounce inch (torque) .......................................... ozf.in. Outside diameter ................................................. O.D. Part number ................................................... Part No. Percentage ............................................................... % Pints ......................................................................... pt Pints (US) ........................................................... US pt Plus (tolerance) ......................................................... + Positive (electrical) .................................................... + Pound (force) .......................................................... lbf Pounds inch (torque) .......................................... in.lbf. Pound (mass) ........................................................... lb Pounds per square inch ..................................... P.S.I. Ratio ........................................................................... : Reference .............................................................. ref. Revolution per minute ..................................... rev/min Right-hand ............................................................. RH Second (angle) ........................................................... " Second (numerical order) ...................................... 2nd Specific gravity ................................................... sp.gr. Square centimetres ............................................... cm2 Square inches ......................................................... in2 Standard wire gauge ......................................... s.w.g. Synchroniser/Synchromesh .......................... synchro. Third ....................................................................... 3rd Top dead centre .................................................. TDC United Kingdom ...................................................... UK Vehicle Identification Number ............................... VIN Volts ......................................................................... V Watts ....................................................................... W SCREW THREADS American Standard Taper Pipe ......................... NPTF British Standard Pipe ........................................... BSP Unified Coarse .................................................... UNC Unified Fine ......................................................... UNF

10

INFORMATION

INTRODUCTION

CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY NEW TERM (ACRONYM) OLD TERM (ACRONYM)

Accelerator pedal ................................................. (AP) Air cleaner .......................................................... (ACL) Air conditioning .................................................... (AC) Battery positive voltage ........................................ (B+) Closed loop .......................................................... (CL) Closed throttle position ...................................... (CTP) Canister purge valve .................................... (CANPV) Data link connector ........................................... (DLC) Diagnostic trouble code ..................................... (DTC) Distributor ignition ................................................. (DI) Engine control module ...................................... (ECM) Engine coolant level ........................................... (ECL) Engine coolant temperature .............................. (ECT) Engine coolant temperature sensor ................ (ECTS) Engine speed .................................................... (RPM) Evaporative emission system .......................... (EVAP) Engine fuel temperature sensor ...................... (EFTS) 4th gear, 3rd gear etc. .............................. (4GR, 3GR) Fuel pump ............................................................ (FP) Fan control module ........................................... (FCM) Generator .......................................................... (GEN) Ground .............................................................. (GND) Heated oxygen sensor .................................... (H02S) Idle air control ...................................................... (IAC) Idle air control valve ......................................... (IACV) Ignition control module ....................................... (ICM) Inertia fuel shutoff ................................................ (IFS) Inertia fuel shutoff switch .................................. (IFSS) Intake air temperature ......................................... (IAT) Malfunction indicator lamp .................................. (MIL) Manifold vacuum zone ...................................... (MVZ) Mass air flow sensor ....................................... (MAFS) Multiport fuel injection ........................................ (MFI) On board diagnostic .......................................... (OBD) Open loop ............................................................ (OL) Park/neutral position ......................................... (PNP) Park/neutral position switch ............................ (PNPS) Programmable read only memory .................. (PROM) Relay module ...................................................... (RM) Service reminder indicator .................................. (SRI) Solid state relay module ................................. (SSRM) Three way catalytic converter .......................... (TWC) Throttle body ........................................................ (TB) Throttle position sensor ...................................... (TPS) Torque converter clutch .................................... (TCC) Transmission range .............................................. (TR) Transmission range selector ............................. (TRS) Vehicle speed sensor ........................................ (VSS) Wide open throttle ............................................ (WOT)

Throttle pedal .......................................................... (-) Air cleaner ............................................................... (-) Air conditioning .................................................... (AC) Battery plus, bat +, bat feed ................................. (B+) Closed loop ............................................................. (-) Closed throttle, idle position .................................... (-) Charcoal canister purge valve ................................. (-) Serial link ................................................................ (-) Fault code ............................................................... (-) Electronic ignition .................................................... (-) Electronic control unit ........................................ (ECU) Coolant level ........................................................... (-) Coolant temperature ......................................... (temp) Coolant temperature thermistor .............................. (-) Engine speed ................................................ (rev/min) Evaporative loss system ................................... (ELC) Fuel temperature thermistor .................................... (-) Fourth gear, 3rd gear .............................................. (-) Fuel pump ............................................................... (-) Condenser fan timer ................................................ (-) Alternator ................................................................ (-) Ground, earth ........................................................ (B-) Lambda (02) sensor ................................................ (-) Idle speed control ................................................ (ISC) Stepper motor ......................................................... (-) Ignition module ........................................................ (-) Inertia switch ........................................................... (-) Inertia switch ........................................................... (-) Intake temperature/ambient temperature ................ (-) EFI warning lamp .................................................... (-) Manifold depression, vacuum ................................. (-) Air flow meter .......................................................... (-) Electronic fuel injection ....................................... (EFI) Fault code display unit ............................................ (-) Open loop ............................................................... (-) Park or neutral ......................................................... (-) Start inhibit switch ................................................... (-) Chip, PROM ................................................... (PROM) Relay ....................................................................... (-) Check engine light ................................................... (-) Control unit .............................................................. (-) Catalyst, catalytic converter .............................. (CAT) Throttle housing ...................................................... (-) Throttle potentiometer ............................................. (-) Direct drive clutch .............................................. (DDC) Transmission gear ................................................... (-) Shift lever, shifter .................................................... (-) Road speed transducer ........................................... (-) Full throttle, wide open throttle ......................... (WOT)

INFORMATION

11

01

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER (VIN) The Vehicle Identification Number and the recommended maximum vehicle weights are stamped on a plate located under the bonnet [hood] riveted to the front of the engine compartment. Vehicle Identification Number Plate (UK, Australia, R.O.W., Europe)

Vehicle Identification Number Plate (Saudi Arabia)

A. B. C. D. E. F.

Year of manufacture Month of manufacture Maximum vehicle weight Maximum road weight-front axle Maximum road weight-rear axle VIN (17 digits)

A. B. C. D. E. F.

Build date (Australia). Type approval VIN (17 digits) Maximum permitted laden weight for vehicle Maximum vehicle and trailer weight Maximum road weight-front axle Maximum road weight-rear axle

The vehicle identification number identifies the manufacturer, model range, wheel base, body type, engine, steering, transmission, model year and place of manufacture. The following example shows the coding process. SAL LH LJ G B F V 8 7 M A World manufacturer identifier Range Rover or Discovery Class 100 inch 2 door 300 Tdi or V8i Petrol 5 speed LHD or 5 speed RHD 1995 MY Solihull site

The number is also stamped on the right side of the chassis forward of the spring mounting turret.

12

INFORMATION

INTRODUCTION

European vehicle identification number (VIN)

Vehicle identification number (VIN) An adhesive label containing the Vehicle Identification Number, date of manufacture and gross axle weight ratings is fixed to the lock face of the front left hand door. The information includes wheel and tyre sizes and tyre pressures at gross axle weight ratings.

Stamped on the right hand side chassis forward of rear wheel. Federal (USA) vehicle identification number

Key to vehicle identification label A. B. C. D. E. F. Month and year of manufacture Gross vehicle weight rating Gross axle weight rating for front axle Gross axle weight rating for rear axle Vehicle identification number (17 digits) Vehicle identification number - bar code

Stamped on a plate rivetted to the upper left hand ’A’ post, visible through the front screen of the vehicle.

INFORMATION

13

01

INTRODUCTION

LOCATION OF IDENTIFICATION NUMBERS Engine serial number - 300Tdi Engine The 300Tdi engine number is stamped on the cylinder block on the right hand side of the engine above the camshaft front cover plate. Engine serial number - Mpi engine Stamped on the R.H. face of the cylinder block adjacent to the gearbox. Engine serial number - V8i engine Stamped on a cast pad on the cylinder block, between numbers 3 and 5 cylinders. NOTE: The appropriate engine compression ratio is stamped above the serial number.

Main gearbox R380 Stamped on a cast pad on the bottom right hand side of the gearbox.

Transfer gearbox LT230 The serial number is stamped on the left hand side of the gearbox casing below the mainshaft rear bearing housing adjacent to the bottom cover.

Front and rear axles Serial number is stamped on top of the left hand axle tube.

14

INFORMATION

INTRODUCTION

Automatic gearbox Stamped on a plate riveted to the bottom left hand side of the gearbox casing.

INFORMATION

15

Relevant information is contained within each of these sections. Torque. For example: bonnet [hood]. Structured diagnostics to accommodate all skill levels. Where this occurs the American word is placed inside brackets. a cross reference is given to direct the reader to where the information is sited. Overhaul.Sub-section: Repairs . Fault diagnosis. alongside a range of icons. 16 INFORMATION . ELECTRICAL TROUBLESHOOTING MANUAL The Electrical Troubleshooting Manual is a separate publication that is intended for use by trained Land Rover technicians as an aid to diagnosing electrical concerns. Sections that contain derivatives such as engines are further separated within that section. American terminology. A few words used in this manual differ to words used in America. Specifications. This repair manual is produced with Testbook in mind. Touch screen operation. It provides circuit diagrams. electrical component location tables. READING THIS MANUAL This manual is divided into sections shown on the contents page.Heading: Drive belt renew.01 INTRODUCTION FAULT DIAGNOSTIC EQUIPMENT TESTBOOK Todays Land Rover Vehicles are equipped with a large amount of electronics to provide the best performance of the vehicles systems.Fully upgradable support for the technician. ramp [hoist]. To avoid repeating information through the sections. Service tools. system diagnosis flow charts. Features of Testbook include :. wing [fender]. Repair. Diagnostic equipment named TESTBOOK is available to expand the diagnostic abilities of the dealer workshop. where part of the repair operation impacts on another section. familiar to service technicians. These are further divided into the following sub-sections which appear at the foot of each page :Description and operation. For example: The maintenance section states the need to renew V8i drive belt. Direct print out of screen information and test results. Adjustment. electrical component location views and circuit operation details. A cross reference sites this information in: Section: V8i Engine .

...................36mm 0........ 0....................... Compression ratio .......................35:1 Overhead by push-rod 127kW at 4550 rev/min 134kW at 4750 rev/min 58......35:1 ..... Horizontally split big-end....................................... Number of cylinders ..............13:1 or 9.79 mm 22.................... Valve operation ................ Minimum regrind diameter .....................002-0............................................................. Piston pins Length .. Stroke ............00 mm 71..................007 mm Lead-indium 0........... two banks of four 94........... Diameter ........................................... Crankshaft Main journal diameter ...............................................................20 mm Main bearings Number and material .................81-143................................................. Crankpin journal diameter . Minimum regrind diameter .............................................. 0.................. Fit-in connecting rod ................508 mm INFORMATION 1 ............010-0.. 0.254 mm....................... Capacity ............. .........GENERAL SPECIFICATION DATA ENGINE 3.................393-57...............71 mm Big-end bearings Type and material ..........8..........................................048 mm Undersize bearing shells .............................812 mm 49...12 mm 3950 cc 8..........67-72............. Maximum power ............. Clearance in piston ...... 0.... Crankshaft end thrust/(end float) ......................................................... 72.................................................13:1 ..... Undersize bearing shells ................ V8i Eight...........220 mm Press fit 0.............215-22....................................................................409-58............................................784-49...................... 143..... plain small-end Length between centres ..........................254 mm..................15-0.............................................055 mm 0...................................................................................508 mm Connecting rods Type ..........................................406 mm 50...........422 mm 57.................................... End-float crankpin ..................... 5............... Diametrical clearance ............................................................................9......................................................9 V8i Type .....015-0...........................10-0....800-50..... Lead-indium Diametrical clearance ................ Bore ..................................797 mm Taken on thrust washers of centre main bearing 0.......................

...478-1................ Wire screen....................................... pressure fed Oil pump type ...............................................65 mm 3...........5 kg 2 INFORMATION ..............................................0 mm 0.................. Exhaust ................... Exhaust ....... Number of control rings .................................................664-8..... pump intake filter................................ Valve lift (Inlet and Exhaust) .........................................................59-117......................................666 mm 0................................................ Eccentric rotor Oil pressure ..................... Head diameter: Inlet ...... 2 1 Molybdenum barrel faced Tapered and marked ’T’ or ’TOP’ 1.............................00 mm 34............................... Full flow................ Seat angle: Inlet ...................679 mm 8.............................. Oil control ring rail gap ....... Camshaft Location ............................. Width of compression rings ...........025-0.....226-34...................04 Pistons GENERAL SPECIFICATION DATA Clearance in bore............................. Bearings .............................041 mm Piston rings Number of compression rings .............................. Stem to guide clearance: Inlet .................038-0............................................ Oil control ring width ........480 mm 8.................................. Exhaust ....... No 1 compression ring .........................4 mm at pressure of 29... self-contained cartridge 116............ Hydraulic-self-adjusting Valves Length: Inlet .............75-40................................. Valve spring length fitted ............ Stem diameter: Inlet ...........40-0....35 mm 116........................... Lubrication System type ................. Drive ...........................................................49 mm 40.........018-0..............................38-1............. 2.........49 mm 0....................078 mm 9.............. No 2 compression ring ........... Wet sump.... Exhaust ..................................40 mm Tappets ......... Compression ring gap .......................................... measured at bottom of skirt at right angles to piston pin .....................................................75 bar (40 lb/in2) at 2500 rev/min with engine at running temperature Oil filter-internal ..........................................................................................................651-8...............................................35 mm 45°to 45 1/2° 45°to 45 1/2° 39............066 mm 0.........52 mm pitch x 54 pitches........................aluminium 5 Chain 9.....................59-117.......... Number of bearings .................... Exhaust . 0. Central Tin ..... Oil filter-external ...

.......00 mm 71.050 mm 0........ plain small-end Length between centres ...... 0..55..........2...0................................................................3622 ..........................................................004 ....0..9449 in 0............................. Horizontally split big-end.............0020 in INFORMATION 3 ...........016 mm 0.............500 ......015 ...................................................0......0 litre V8 Eight.. Bore ....0......................24...... Capacity ....... 63............. Maximum power: 9........................80 in 241 cu in Low Compression 8. Valve operation .............9447 ................................2:1 Crankshaft Main journal diameter .....................63............12 mm 3950 cm3 Overhead by push-rod High Compression 9...50 mm 23......................... measured at bottom of skirt at right angles to piston pin ............................... 155..0024 in Connecting rods Type ..........................060 mm 0...................... Stroke ........2....015 ........... Valve operation ...................50 .........020 .. Vandervell VP3 Lead bronze with lead-indium overlay Diametrical clearance .....0.500 mm 2................................00 .......................................10 .................... 0..............2..........35:1 Overhead by push-rod 140kW at 4750 rev/min 132kW at 4750 rev/min 3.......................70 in 2...............008 in Main bearings Number and type .995 .. 55...........1855 ...............0......20 mm 0........006 mm 2.......................................4995 in Crankpin journal diameter ..22 mm 6.......................... 8.. Taken on thrust washers of centre main bearing 0.. 5.......155...............................513 ................................................. two banks of four 94..........2:1 .............................................................................................................0..12 ............................... Number of cylinders .....0006 .........................0......................487 mm 2...000 mm Press fit 0....................0 V8 Type ................1850 in Crankshaft end thrust/end float ......................................................0024 in Piston pins Length ..........0..... Fit-in connecting rod .........35:1 ..............0008 ... Vandervell shells Material .0002 in Pistons Clearance in bore.... Lead bronze with lead-indium overlay Diametrical clearance .................0006 ......015 ...............0006 ................GENERAL SPECIFICATION DATA ENGINE 4.............................0.......... Clearance in piston ....1110 in Big-end bearings Type and material .................. Diameter .....60...........0.......................................... 0. 60.......... 4......................3819 in 0..................................... Compression ratio .6.........1071 ..............

... pressure fed Oil pump type ...... (Top) ...0197 in Aclonoform 3................... Compression ring gap ...025 ............. self-contained cartridge 4 INFORMATION ....478 .3575 in 8..................................0582 ........227 ........................................00 mm 1.....................3417 in 8.....75 ..........................0484 in 0...............0.23 mm 0... Camshaft End Float ....................................0............. Drive . Valve lift (Inlet and Exhaust) ..............575 in 34.......0...............1181 in 0.............0031 in 9.................0157 .........3 ..........0..038 .....0587 in 1.......................5 kg (65 lb) Lubrication System type . Oil control ring rail gap ..................59 ......................59 ......0476 ....................38-1....65 mm 0.............81 kg/cm2 (30 to 40 psi) at 2400 rev/min with engine warm Oil filter-internal ......3411 ................0............ Exhaust ............................ 116.. No 1 compression ring ..8........................ No 2 compression ring .....................................52 mm pitch x 54 pitches......................94 mm 0....................4 mm (1.......40..620 in 46°..0.. Stem diameter: Inlet ..078 mm 0............5 mm 0.. 2 1 Nitrided steel barrel faced Tapered spherical barrel marked ’TOP’ 1.49 mm 0............. Seat angle: Inlet .3475 ................... Exhaust ............666 mm 0....11 to 2..0.......... 2...0... Valve spring length fitted ............590 ...4...... Exhaust ...40-0................651 ........1....3913 in 40.............. Bearings ............................ (Top) ............................ pump intake filter in sump Oil filter-external ................34....... Number of bearings .... Wire screen..............565 ...0 mm 0.46°25’ 39...........0........0015 ....117.......... Full flow...0...0........................................................0256 in 0....1..............1......................59 in) at pressure of 29..... Wet sump.35 mm 4........................................21 .................0..........................................679 mm 0...... Stem to guide clearance: Inlet .04 GENERAL SPECIFICATION DATA Piston rings Number of compression rings .................0..8................1.....3406 ...................... Hydraulic self-adjusting Valves Length: Inlet ........ Exhaust .....117......................... Head diameter: Inlet ..........................066 mm 0.............48 mm 1................4.............. Oil control ring width .................................................0......... Exhaust ... Camshaft Location .......................003 .......0026 in 0.......................................... Oil control ring type .....35 mm 4.........620 in 116.....................0118 ............................................................................664 .014 in Tappets . Width of compression rings ...590 ..355 mm 0....... Number of control rings ..........................................................................................40 mm 0..............................................076 .46°25’ 46°. 0.....................3412 in 0...... Rotor Oil pressure ............0010 .0150 ......0551 in Central Non serviceable 5 Chain 9.......................................

6 bar (34-37 lbf/in2) Fuel filter .....................................................................................................................................................9 V8i Fuel system type ................................................................................................................................................................... Lucas 8RV Fuel temperature sensor Make and type ....................... Lucas 2ACM Throttle potentiometer Make and type ..................................... Lucas ’Hot Wire’ 5AM Injectors Make and type .. Lucas 6TT Coolant temperature sensor Make and type .GENERAL SPECIFICATION DATA FUEL SYSTEM 3........................................................................................ Lucas 3LS INFORMATION 5 . Lucas 14CUX Fuel pressure regulator Make and type ............catalyst vehicles Make and type ................................................................ Lucas 14CUX hot wire system electronically controlled Fuel pump-make/type ................................................ Lucas 215SA Lambda sensor . Bosch in-line filter ’canister’ type Airflow Sensor Make and type .........................................4-2................. Lucas 8NJ Electronic Control Unit Make and type ............... 2..... ACX delco high pressure electrical......... Lucas 3TT Bypass Airvalve (Stepper motor) Make and type ................................................................ immersed in the fuel tank Fuel pump delivery pressure .....................................................................................

................ Lucas 3TP Heated oxygen sensor ......... Lucas ’Hot Wire’ 20AM Injectors Make and type .......................... Bosch in-line filter ’canister’ type Mass airflow sensor Make and type ..........................................6 bar (34-37 lbf/in2) Fuel filter ......... Lucas 3VRS................. High pressure electrical........................................... Lucas ERR6170 Crankshaft position sensor Make and type ............................................................................................................... Lucas 10TT Ignition coils Make and type ............................ ......... Lucas D1000 Electronic Control Module Make and type ............................................. Lucas 8RV Coolant temperature sensor Make and type ......................................................................3 Fuel pressure regulator Make and type ...........................................................................................0 V8 ENGINE Type .......................................... Lucas GEMS 8...catalyst vehicles Make and type .................04 GENERAL SPECIFICATION DATA FUEL SYSTEM (GEMS) 4. Lucas 6TT 6 INFORMATION ... Lucas 3ACM Throttle position sensor Make and type ......................................................... Lucas 8TT Bypass Air valve (Stepper motor) Make and type .................................. 2...............................4-2....Lucas Gems 8 hot wire system electronically controlled Fuel pump-make/type ................... Lucas 4LS Camshaft position sensor Make and Land Rover part no.............................................................................................. Sagem .............................................................. Lucas 2DIS2 Fuel temperature sensor Make and type .................. Lucas 2KS Intake air temperature sensor Make and type .................................... Honeywell ERR6049 Knock sensor Make and type ................................................................................... immersed in the fuel tank Fuel pump delivery pressure .................................................................................................................................

2 FT3 .2 D 3(D) 2(D.60 29 .9 V8i OPERATION SELECTOR POSITON VEHICLE SPEED APPROX ENGINE SPEED APPROX (RPM) KICKDOWN MPH KD4 .3 KD3 .54 29 .2000 1825 .67 40 .1650 1420 .104 56 .3 PT3 .2) 26 .4650 PART THROTTLE PT4 .34 98 .2) 61 .56 N/A 96 .22 9 .1220 ZERO THROTTLE ZT4 .5200 4600 .4 KD2 .73 119 .2 PT2 .1 D D(3) D(3.108 64 .2) 47 .37 10 .5250 FULL THROTTLE FT4 .15 6-7 31 .99 44 .4330 4350 .150 91 .41 19 .56 3980 .49 29 .25 12 .46 74 .52 81 .16 1430 .1930 NOTE: The speeds given in the above chart are approximate and only intended as a guide.86 78 .2) 84 .4800 3950 .1820 1180 .2 D D(3) D(3.11 TORQUE CONVERTER Lock up (IN) Unlock (OUT) D D 51 .3) D D(3) D(3.35 14 .GENERAL SPECIFICATION DATA SHIFT SPEED AUTOMATIC ZF ON 3. INFORMATION 7 .1 KD3 . Maximum shift changes should take place within these tolerance parameters.4 LT2 .30 18 .92 57 .1 D D(3) D(3.129 88 .62 27 .24 10 .3 ZT3 .63 34 .40 KPH 136 .12 75 .59 16 .2 KD2 .86 48 .34 N/A 60 .54 49 .3 FT3 .3 KD1 .96 48 .2) 19 .3 FT1 .10 43 .83 1875 .80 55 .4 FT2 .2 D 3(D) D D(3) D(3.19 LIGHT THROTTLE LT3 .2 ZT2 .3 LT1 .64 4750 .

2 KD2 . Maximum shift changes should take place within these tolerance parameters.1900 ZERO THROTTLE ZT4 .2) 62 .2) 39 .78 72 .49 45 .2) 24 .122 74 .1 KD3 .3 PT3 . 8 INFORMATION .3 KD1 .43 29 .72 38 .2 D 3(D) 2(D.49 23 .2 PT2 .29 KPH 99 .14 38 .28 21 .115 69 .2 ZT2 .3 LT1 .3) D D(3) D(3.22 1300 .48 29 .22 9 .72 43 .82 42 .37 21 .3800 PART THROTTLE PT4 .51 26 .77 1600 .23 13 .11 35 .3 ZT3 .58 102 .3 KD3 .2) 22 .1 D D(3) D(3.20 62 .3900 3500 .04 GENERAL SPECIFICATION DATA SHIFT SPEED AUTOMATIC ZF ON Tdi ENGINE OPERATION SELECTOR POSITON VEHICLE SPEED APPROX ENGINE SPEED APPROX (RPM) KICKDOWN MPH KD4 .32 LIGHT THROTTLE LT3 .4 KD2 .27 18 .30 18 .46 3400 .1800 1700 .35 14 .1850 1700 .48 74 .45 34 .1400 1700 .45 24 .76 46 .4 LT2 .4000 3600 .2 D D(3) D(3.78 37 .36 64 .1 D D(3) D(3.1800 NOTE: The speeds given in the above chart are approximate and only intended as a guide.18 TORQUE CONVERTER Lock up (IN) Unlock (OUT) D D 46 .

...............................5mm..... fully floating shafts Angularity of universal joint on full lock ............................................................... Rear axle Type .................................................... enclosed constant velocity joints......................... Front ......................Catalyst vehicles ..54:1 Front axle Type ..........................................................................GENERAL SPECIFICATION DATA TRANSMISSION 3.............................................9 V8i Manual gearbox Type R380 ............................................................. Four speed and reverse with fluid torque converter Transfer box Type LT230T ...... Two speed reduction on main gearbox output............ 266........................... 5 forward 1 reverse all synchromesh Clutch Make and type ....... Rear ............................................ Spiral bevel................... Clutch plate diameter .................................... Propeller shafts Type Front ................................................................................................................. Borg and beck diaphram type...54:1 Tubular 51mm diameter Solid bar 28......................................................................................................... front and rear drive permanently engaged via a lockable differential............................. 3............................................... Automatic gearbox Type ZF4HP ...................... Single helical constant mesh Speeds ...............6mm diameter Tubular 51mm diameter Open type Hookes O3EHD INFORMATION 9 .......... Universal joints .......................................................................................... Spiral bevel.... fully floating shafts Ratio ...................................... 32° Ratio .......... 3................................

7˚ .s............. it to take up a position 10 INFORMATION .....................................................................Mpi & Tdi ....... spill return..........Unicorn Make/type ...... ZF ............. STEERING Power steering box Make/type ............. Camber angle ............................................... Pressurised................ that is.................................. 3˚ .......................3:1 on lock 14. belt driven......................................................... Variable: straight ahead 19....................... Toe-out measurement .................. Castor angle ........... 15 p........................................9 V8i System type ............................... 405mm 400mm 0 to 2mm toe out 0˚ to 0˚ 16’ 0˚ ...... Check with vehicle in static unladen condition.......................... Toe-out included angle ......... 11 blade axial flow 433mm diameter.................................................................375 Steering pump Make/type -V8i ...................... 3............. Pump assisted thermo syphon... (system pressure)........i....... oil and five gallons of fuel......................... Thermostat opening .worm and roller box Ratio ........................... Expansion tank cap pressure ....................................... 88 degrees............ Coolant radiator combined with oil cooler....... Pump type ......................... Steering wheel diameter airbag model .................... Rock the vehicle up and down at the front to allow Swivel pin inclination static .. impellor.............. lock-to-lock ................................................................04 GENERAL SPECIFICATION DATA COOLING SYSTEM 3..... Adwest Varamatic ....................................... Fan and viscous coupling assembly ............................................................. vehicle with water.......................... Centifugal.................3:1 Steering wheel turns..................... Hobourn-Eaton series 500 Steering geometry Steering wheel diameter .................. thermostatically controlled water and anti-freeze mixture...

................. Lateral location of axle by Panhard rod...... Rear ........................................ ROAD SPRING DATA V8i ..... Front ......................................................Mpi LEFT HAND DRIVE Left hand front Right hand front Left/Right hand rear Part No NRC 4306 572315 ANR 3477 or ANR 4352 Part No 572315 572315 ANR 3477 or ANR 4352 Colour Code Blue/White Blue Brown/Green Orange/Orange * Colour Code Blue Blue Brown/Green Orange/Orange * RIGHT HAND DRIVE Left hand front Right hand front Left/Right hand rear Tdi Diesel RIGHT HAND DRIVE Left hand front Right hand front Left/Right hand rear Part No ANR 1975 or ANR 4350 ANR 1976 or ANR 4351 ANR 3477 or ANR 4352 Part No ANR 1976 or ANR 4351 ANR 1975 or ANR 4350 ANR 3477 or ANR 4352 Colour Code Blue/Pink/Red Brown/Brown ** Blue/Pink/Yellow Grey/Grey ** Brown/Green Orange/Orange * Colour Code Blue/Pink/Yellow Grey/Grey ** Blue/Pink/Red Brown/Brown ** Brown/Green Orange/Orange * LEFT HAND DRIVE Left hand front Right hand front Left/Right hand rear * VIN 119534 onwards ** VIN 116461 onwards INFORMATION 11 ........GENERAL SPECIFICATION DATA SUSPENSION Type ........................... and longitudinal location by two radius arms............................ Longitudinal location of axle by two tubular trailing links................ Lateral location of axle by a centrally positioned ’A’ frame bolted at the apex to a ball joint mounting........................................... Coil springs controlled by telescopic dampers front and rear......

.................................................... Lucas Master cylinder type ..................................................................... Mechanical-cable operated drum brake on the rear of the transfer gearbox output shaft Lining material .......................................................................................................................... Hydraulic........................................................ Outboard discs with four piston calipers Operation ................ Telescopic........ CV/CV 12 INFORMATION ........................................................ non asbestos Rear service brake Type ........ servo assisted...........................................................47mm BRAKES Front service brake Type ................................................... Servo/master cylinder ABS Manufacturer ................................................... non asbestos Parking brake Type ................................................ servo assisted self-adjusting Pad material .................04 GENERAL SPECIFICATION DATA SHOCK ABSORBERS Type .. 35.......................................................................... Lucas Servo type .............................................................................................. non asbestos Servo/master cylinder non ABS Manufacturer ............................................................ Hydraulic........ AS/AS Anti-lock brake system Manufacturer/type ........................ Outboard discs with two piston calipers Operation ....................................................................... self-adjusting Pad material ......................... LSC 115 Master cylinder type ........................................... double-acting non-adjustable Bore diameter ................................................................................................................. Wabco 4 wheel sensed add on anti-lock brake system...

..................... 1......................... Charge quantity with rear air conditioning . Control voltage ............. Worn............................................................................ Land Rover Parts and Equipment/Lucas maintenance free 9-plate-YGD 10017 Make/type ...9Kg 1.... 1..................................................................0 to 2..................................................... Magnetti Marelli A127i 100amp Negative ground 17 mm 5 mm 1......................... Compressor .. 60 to 73 rev/min (high speed) ELECTRICAL System .....................................................................5 amps at 39 to 45 rev/min (normal speed) Rotary link speed ........................... Nippon Denso Nippon Denso 10 PA 17 R134a 0................. Brush spring pressure flush with moulding ....... negative ground Battery Make/type ...... 12 volt.. Charge quantity ........................GENERAL SPECIFICATION DATA AIR CONDITIONING System ................................................................. wet screen at 20°C ambient .... Nominal output Generator speed ...........................................................................7N 13........................................6 to 14.................... minimum free protrusion from moulding ........................................................................................... Brush length New ................................................................. 37 to 43 cycles per minute Windscreen wiper motor Make/type .heavy duty ..... Polarity .........................................4 volts 6000 rev/min 14 volt 100 amp INFORMATION 13 .........................................................................................................basic ........................................ Regulator voltage ............. wet screen at 20°C ambient .................................................3N to 2............................................................ Amp ............. Refrigerant ..............15Kg WIPER MOTORS Tailgate wiper motor Make/type ... IMOS (non-serviceable) Running current........................................ Type ..... Delco AMR 1514/5 Running current (Link disconnected) ................ Land Rover Parts and Equipment/Lucas maintenance free 14-plate-YGD 10015 Generator Manufacturer ................................................................................8 amps Wiper speed........................................................................

........... Klamix (Mixo) TR99 Starter motor Make and type ............................................................... Bosch 0221 122 392 Distributor Make/type ......................... Autofuse (blade type) blow ratings to suit individual circuits Horns Make/type ......... Pick-up air gap adjustment (Pick-up limb/reluctor tooth) ...04 Coil GENERAL SPECIFICATION DATA Make/type ................................................................. Fuses Type ...........................................................90°(every 45°) ± 1° 12V Negative ground 0.........................................................35 mm 2k to 5k ohms 14 INFORMATION ................... Firing angles ..................................................................... Application .....................................45°..................................................................................... Bosch 12v Lucas 35 DLM8 0°................................................20 mm to 0......................................... Pick-up winding resistance .......

France amber Auxiliary driving lamps Sidelamps Tail lamps Reverse lamps Stop lamps Direction indicator lamps Rear side marker lamps Number plate lamps Interior lights Instrument panel lamps and warning lamps Ignition warning lamp (Instrument panel) Interior roof lamps Clock illumination Cigar lighter illumination Door shut face/puddle lamps Auxiliary switch panel illumination (green) Heated rear screen warning lamp (amber) Hazard warning lamp Automatic graphics illumination Heater/air conditioning graphics illumination Differential lock warning lamp Column switch illumination 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 1.2W 1.2W 2W 10W 1.2W 1.2W bulb/holder unit capless ’Festoon’ capless capless capless capless capless capless capless bulb/holder unit bulb/holder unit capless 12V 12V 12V 12V 12V 12V 12V 12V 12V 12V 60/55W 60/55W 55W H3 5W 5/21W 21W 21W 21W 5W 5W (Halogen) (Halogen) (Halogen) bayonet bayonet bayonet bayonet bayonet capless capless CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage to vehicle wiring and switches.2W 1.2W 5W 1.2 1.2W 1.2W 5W 1. INFORMATION 15 .GENERAL SPECIFICATION DATA BULBS REPLACEMENT BULBS TYPE Exterior lights Headlamps Headlamps .

................................................... 2720 kg 970 kg 1055 kg 2025 kg VEHICLE WEIGHTS ............. Maximum EEC kerb weight and distribution ........... 970 kg Rear axle ............................................................................... 1010 kg Total ........... consideration must be taken of the unladen vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values...................................................... 1980 kg Maximum axle weights Front axle ......................................................................................................................... 1650 kg Gross vehicle weight ........................... 1200 kg Rear axle .........................................................................................................................................................300 Tdi Front axle ..... 2055 kg Maximum axle weights Front axle ................ It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither maximum axle loads nor Gross Vehicle Weight are exceeded..all optional equipment VEHICLE WEIGHTS ....................................................................V8i Front axle ....Mpi 3 Door Front axle ............................................................................................................ 2720 kg EEC kerb weight = Unladen weight + Full fuel tank + 75 kg driver............................ 930 kg Rear axle ................................................... 2720 kg 5 Door 930 kg 1055 kg 1985 kg VEHICLE WEIGHTS .....................04 GENERAL SPECIFICATION DATA VEHICLE WEIGHTS AND PAYLOAD When loading a vehicle to its maximum (Gross Vehicle Weight)......... 1110 kg Rear axle ...................... 1100 kg Rear axle .......................... 1040 kg 1060 kg 2100 kg 16 INFORMATION ................................. 1650 kg Gross vehicle weight ................... 1040 kg Rear axle .............................................................. 1015 kg Total ........................................................ 1650 kg Gross vehicle weight ................................................................................................................................................................................................................ 1010 kg Total ................. 1940 kg Maximum axle weights Front axle ...........................

........................7 Off-road ’emergency’ soft use maximum speed of 40 kph (25 mph) Front 1.. 205R16 (tubeless) Type and size ............................. Steel 6......GENERAL SPECIFICATION DATA TYRE PRESSURES Pressures: Check with tyres cold 205R16 Radial bars lbf/in2 kgf/cm2 Normal on and off-road use................. Max speed 40km/h (25mph).......................................................6 38 2...................... Alloy 7....................00JK X 16 Tyre size ...... NOTE: Emergency soft pressures should only be used in extreme conditions where extra floatation is required........................................ WHEELS AND TYRES Type and size ......................... note that these wheels DO NOT accept inner tubes and tubed tyres MUST NOT be fitted..2 17 1....9 28 2.......8 WARNING: Vehicles fitted with tubeless alloy road wheels as original equipment........................ 205R16 (tubed) ’Freestyle’ choice tyre specification Tyre size ....................0 Rear 2.....................2 Rear 1.....00J X 16 Tyre size ......... 235/70 R16 Front Tyre pressure ..... Rear 34 lbf/in2 INFORMATION 17 ...................................... All speeds and loads Front 1.... 26 lbf/in2 NOTE: Petrol vehicles must be fitted with ’S’ or ’T’ rated tyres........................................8 25 1...............

................. 63............ 0....... 0......................... intercooled 4 90.....5:1 O... Valve operation ..........15 mm Main bearings Number and type ............0307 mm Connecting rods Length between centres ...................38 .... pushrod operated 18 INFORMATION ............................. Skirt diametrical clearance (at right angle to gudgeon pin) ......5:1 ± 0.................. turbocharged.............. Graphite coating on sidewalls..................................010 in U/S bearings Crankpin journal diameter ..... 175...................................................... 0..025 ....................... Fit in piston ...............744 mm Regrind dimensions ...................................................0. Number of cylinders ...............0........................................... 0..... 0........................................................................ 5 halved shells with oil grooves Diametrical clearance ............................................1564 .......... Floating Hand push fit 30.......47 mm 97. 58.......1625 mm 0.58................ Capacity ........................ Taken on thrust washers at centre main bearing Crankshaft end float .......................................48985 mm Use 0....175.......63... Bore ...............05 ........ Stroke .................63......15 ..............04 GENERAL SPECIFICATION DATA 300 Tdi ENGINE Type ..........................475 ............................................ Aluminium alloy...0....................................... Clearance in connecting rod ......................V.................................................................................................................0163 mm Direct injection... combustion chamber in crown....................0...........................0.H....... 58.......... 0..........025 ................................................................43 mm Diametrical clearance (big-end bearings) ...............................487 mm Regrind dimensions ..58.........................010 in U/S bearings Crankshaft end thrust .............0792 .356 mm Pistons Type .. Compression ratio ...... Crankshaft Main bearing journal diameter .725 ..............................................0025 .......................8 mm Gudgeon pins Type ............................................0........ Diameter ............00 mm 2495 cc 19..........4708 .............05 mm Maximum height above combustion face ........075 mm End float on crankpin .30.................................................................................2333 ...................................246 mm Use 0................................................... 63...

........................ Cam lift: ..................................Top ...... .............Oil control ....................................................... Location ..............Inlet ...1..........................................................97 mm 6... ..... Camshaft Drive ................050 ............................................................................Oil control .................Exhaust .................0........................Exhaust ...................Top ............................................Second .........................7....085 mm 0..40 ..............65 mm 7.................................36...............................975 mm 7.....................................................Second .....................Second ...GENERAL SPECIFICATION DATA Piston rings Type: ............81 mm 7.............. ..........60 mm 0..............20 mm 30° 45° 38...............Inlet ..7..............35 .................... ....940 ........................................................ ...................................... Clearance in piston grooves: ...81 ...Inlet ...6 mm 0............................................960 mm 9..........................86 .........................................05 mm 36................................................ Stem diameter: .......... free .................. ...75 .................................30 .........................50 mm 0........ Valves Tappet clearance: .................................................................................................................................... Material ................ ...................................39..............28 mm Length..............Exhaust .......Exhaust ...09 mm 0..... Single coil Length................................2 mm 4 Steel shell... ...........06 mm 0.. .....................................Oil control ........ Seat angle: .................. Valve lift: ...050 ...................Inlet ........14 mm INFORMATION 19 ......................0..0...Exhaust .........................30 mm 30 mm wide dry toothed belt Right hand side (thrust side) 0.................. Number of bearings ...................................................................Inlet .........1 ..............................Exhaust .............Inlet and exhaust ......................................................................... white metal lined Barrel edge............................................................. Gap in bore: ... End float . Valve springs Type ......................... chrome plated Taper faced Expander and rails 0................... Valve head stand down ......... under 21 kg load .............. .. Head diameter: .... 40.. 46..........67 mm 9...085 mm 0. ......................................0......................0..Inlet .............................0..3 .................................................1...........960 ...............

.71Kg load ........................ belt driven................................... Oil pump: .............. Engine oil cooler .............Drive .........................................................................300 Tdi Type .................................55lbf/in2 = 1.......300 Tdi Fuel lift pump type ................................................ Centrifugal...... Fuel filter .................................................. impellor.......................... Wet sump......................................................300 Tdi System type ................. pressure fed 25 ................................................Compressed length at 7..... spill return................3.. Centre plate diameter .............Full length .....Type .......................... Thermostat opening ...................................................... Valeo diaphragm spring 235 mm Verto F202 grooved Ball journal 20 INFORMATION ........................................................... Fuel lift pump pressure .............. Air cleaner .................... Coolant radiator combined with oil cooler and turbo intercooler...............06Kgf cm 2 (system pressure) CLUTCH ....................................................................................... Mechanical with hand primer 42 . Pump type ........................................................... Oil filter ..6mm 31mm Screw-on disposable canister Combined with coolant radiator and intercooler FUEL SYSTEM ....................... 1....55 kpa at 1800 rpm Paper element in disposable canister Paper element type COOLING SYSTEM ............... Relief valve spring: ....... 11 blade axial flow 433 mm diameter....................... Cooling fan ...............87Kgf cm 2 G-rotor integral with front cover.04 Lubrication GENERAL SPECIFICATION DATA System ........................ Viscous coupling....... Oil pressure relief valve .................................. thermostatically controlled water and anti freeze mixture........................................................ off crankshaft nose Non-adjustable 51...................... 88° Expansion tank cap pressure .................................... engine warm at normal operating speeds .................... . Release bearing ..........................29:1 drive ratio.. Facing material ........................................................... ...........76 ................................ Pressurised.............. Pressure................................................................. 15lbf/in2 = 1...... Pump assisted thermo syphon......................................................

.............................................. Front and rear drive permanently engaged via a lockable differential INFORMATION 21 .....................................................................................GENERAL SPECIFICATION DATA TRANSMISSION .............................................. 5 forward 1 reverse all synchromesh Automatic gearbox Type ZF4HP ..................................................................... Four speed and reverse with fluid torque converter Transfer box Type LT230T ......300 Tdi Manual gearbox Type R380 .................. Single helical constant mesh Speeds ............ Two speed reduction on main gearbox output......

........... 10 : 1 Oil pump Outer rotor to body clearance ......325 in Stroke ................................................................................ Diagonal warp ..............10 mm Inner rotor tip clearance ..1 mm 0..............................05 to 0........................................................0 LITRE Type ....................................................................68 in3 Firing order ............................................ 20 T4 ..................1 mm 0...............................................5 mm Cylinder head Longitudinal warp ......................................... 1-3-4-2 Compression ratio ...............................................................060 to 0................ 0.................................................504 in Capacity ...........................maximum .................... Valve springs Free length .................................................................................. Load at fitted length ...............Mpi . Cylinder head height ................................. 0....................... 88°C Open travel A .............0 mm Cooling system Starts to open ...............5 N 22 INFORMATION .......................................0 mm 255 ± 12 N 560 ± 22........ 57............00 mm 3............................ 82 to 86°C Thermostat fully open .....................................1 mm 135.........25 mm Bearing clearance .................5 to 58........................ Transverse warp ..............................................................maximum ............................025 to 0............06 to 0........ 0...15 mm Timing belt tensioner Spring free length ........................ 84...................25 mm 37..................................... Load at valve open length ........................ 0........ 4 in line Bore ..... 0................................... 42....2.1 mm 46..........................................................04 GENERAL SPECIFICATION DATA ENGINE ......16 valve twin overhead camshaft Cylinder arrangement ......08 mm Oil pressure relief valve Spring free length ........................12 mm Outer rotor end float ...maximum ............................. 0................ 1994 cm3 121.................... 0..............................................................................................45 mm 3.........03 to 0.............................. 89. 9 mm Camshaft Camshaft end-float ...........................094 mm Service limit ......0 to 135.................. Fitted length ............

..................................... Exhaust .................. Exhaust .09 to 7..........2 mm 2.............................................. Exhaust ...............09 mm 31.09 mm 0.......Inlet and Exhaust .....010 mm 0...36 mm 54........................................ 84..5 mm 0... Service limit .... Valve head diameter: Inlet ....................................07 mm 0..............................95 mm 29.................... 52........................................................06 mm 0.............................................661 mm 0.........2 to 29...... Main bearing diametric clearance ....................455 mm Grade B ...................................... Oil control rails ..........................................3 to 0...............09 mm 0............423 to 84..........................................010 mm 0............7 to 31. Valve stem to guide clearance: Inlet ...... Valve installed height ..............................03 to 0............ Thrust washer halves thickness ......... 2nd compression ..........08 mm 0....................10 mm Valve guides Internal diameter ..........................................456 to 84.......................04 to 0...................................01 to 0.................................................................................................expander fitted . 84............................162 mm Overall length: Inlet ..............................................................07 to 7........03 to 0.................................... 84........................................469 mm INFORMATION 23 ...................................04 to 0...................05 mm 0.......................................................................... 0................07 mm 47................. Service limit .... Main journal diameter ... 2nd compression .................... 0............ 45°to 45°15’ Crankshaft End-float ........137 to 7...................................... 1............Inlet and Exhaust ..... Ring fitted gap: Top compression .....................648 to 47.....06 to 0.......................005 to 54...442 to 84....... 48....... Maximum out of round ....25 to 0......5 mm Exhaust ......... 7..............05 to 0...38 to 1..........9 mm Valve seats Valve seat angle ...................03 mm Cylinder bore Grade A .........Inlet and Exhaust .................... Big-end journal diameter .... 84...............409 to 84....422 mm Grade B ...................................0 mm Valve face angle: Inlet and Exhaust .......... Maximum out of round .. 7...............GENERAL SPECIFICATION DATA Valves Valve stem diameter: Inlet ..........................07 mm 0................ Oil control rails .....................03 to 0.................... 45° Valve seat width ..06 to 0................................4 mm 0...............................35 mm 0.......................10 mm 7..............5 to 2..........................43 mm 43...........................maximum ..............................................................31 to 2..................... Piston rings New ring to groove clearance: Top compression ..436 mm Clearance in bore ..................... Big-end bearing diametric clearance ..........14 mm Pistons Piston diameter: Grade A .......................................................................026 mm 0......................

...................................................................... A...............................................0 Litre Fuel Pump: Make/Type .......................................... 5 forward 1 reverse all synchromesh Transfer box Type LT230T ............. 15lbf/in2 (1..............518:1 11.......Mpi Pressure cap ..........463:1 In low transfer 9........ Single helical constant mesh Speeds ...................... Second .............................................884:1 18................. Diaphragm spring................109:1 43......... Third ............. hydraulically operated Adjustment ..2...............................................................701:1 27.......................................2 bar 2............ Regulated pressure range .......472:1 24 INFORMATION .......................................................................... Delivery at 3 bar pressure & 12V (min) . Rochester/Electric immersible 3..........109:1 42.........03 bar) (system pressure) Thermostat ..................................................................Mpi Manual gearbox Type R380 .....0 æ 0.................. Information.........................................................................................2 bar 64 litre/h 3.............. Fuel filter ........................................761:1 11.....................479:1 17....746:1 17............. See ENGINE TUNING DATA......................................Mpi .................................................5 kgf/cm2 Bosch in-line filter ’canister’ type COOLING SYSTEM .........Mpi Electronic fuel injection data ........... Two speed reduction on main gearbox output........................................................... Fourth .............................C.......................................................................... Self adjusting Clutch plate diameter ...............Mpi Type ......................................... 88 ˚C CLUTCH ......3 .... Fuel pump delivery pressure ............................................................................. In high transfer 4... Pump pressure ....................2..........................989:1 7...... Front and rear drive permanently engaged via a lockable differential Overall ratios (final drive): Fifth .... Reverse ........... First ..13 mm TRANSMISSION ....04 GENERAL SPECIFICATION DATA FUEL SYSTEM ............146:1 4........................... 215.................................................................................................. Engine ..

Towing weights On road 750 kg 2750 kg 3500 kg 4000 kg Off road 500 kg 1000 kg 1000 kg 1000 kg 205 R16 radial 235/70 R16 radial 45° 35° 20° 29° 33° 204 mm 500 mm 4538 mm 4581 mm 2189 mm 1914 mm 2540 mm 1486 mm 1080 mm 5 to 7 Unbraked trailers ........... Overall length (including tow hitch) ............................................................... Trailers with overrun brakes ....................................... Ramp break over angle ............................ INFORMATION 25 ...... ground clearance (unladen) ....... Track front/rear ...... gradient (EEC kerb weight) ..............................................................................................................Mpi ................. Overall width .............................................................................................................................................................. Performance Tyre size fitted ...................................................................... Trailers with overrun brakes .................................. Seating capacity ......... 4 wheel trailers with coupled brakes (FULLY BRAKED)* ............................................................................................ NOTE: * Only applies to vehicles modified to accept coupled brakes............................. Max... Width between wheel boxes ......... NOTE: All weight figures are subject to local restrictions......................... Wheelbase ........... Min.................................GENERAL SPECIFICATION DATA VEHICLE DIMENSIONS Dimensions Overall length (including spare wheel) .......................................................... Departure angle without tow hitch (EEC kerb weight) ...........................................................................V8i & Tdi ............... Overall height ........................................ Departure angle with tow hitch (EEC kerb weight) .......................................... Tyre size fitted .................................... Approach angle (EEC kerb weight) ............................ Wading depth .......

... On crankshaft vibration damper Spark plugs Make/type(8.......... .............................................. air con operating ................................ 4°BTDC ± 1° 9.............96mm Champion RN11YCC 0.......................... 1-8-4-3-6-5-7-2 Cylinder Numbers Left bank ................................96mm Coil Make/type ...................... Pulley end of left bank Timing marks ........ Gap ......... Gap ............................................................................ 1-3-5-7 Right bank .......................................manual gearbox ..35:1 compression... air con operating ................ Lucas 14 CUX Hot-wire air flow sensor system electronically controlled Valve Timing Opens .......................... non catalyst .. Inlet 32°BTDC 73°ABDC 285° 104°ATDC Exhaust 70°BBDC 35°ATDC 285° 114°BTDC 665 to 735 rev/min 650 ± 28 rev/min 600 ± 28 rev/min 700 ± 28 rev/min 750 ± 28 rev/min Base idle speed ....... ........................ Base idle speed setting......................................................................................... Compression ratio ........... non catalyst ...........84-0.................................................. Duration .......... 3.35:1 Compression) ................ Ignition Timing ... 2-4-6-8 No 1 Cylinder location ..... 525 ± 25 rev/min See FUEL SYSTEM..auto gearbox in gear.................................................... Valve peak ........................................................ air con off ........ INFORMATION 1 ........................................................................................................ vacuum disconnected 8................................ 5°BTDC ± 1° Exhaust gas CO content at idle ................ Champion RN11YCC 0............. 8...... catalyst .........................................9 V8i Type ........ 2°BTDC ± 1° 9.........................84-0......35:1 Fuel injection system ......................................... ......0% max.. 0....................13:1 Compression) ..............controlled by MFI system ....................................................... Bosch 0-221-122-392...............................dynamic at 800 rev/min max...............................................all loads off in neutral .. ....auto gearbox in gear.........................13:1 compression..............................................................................................................9 Litre V8i Firing order .................................................................................. Fault diagnosis...manual gearbox.......13:1 or 9....................................................ENGINE TUNING DATA ENGINE 3......5 to 1.35:1 compression....................................................... Make/type(9.................................. Idle speed ................................. Closes ............................

.......... 91 RON minimum unleaded 8................... Lucas 42584A 42582A 42583A Rover ERR 4753 ERR 4754 ERR 4755 5°30’ to 8°30’ 6°18’ to 8°30’ 2°to 4° 7°to 10° 7°48’ to 10° 1°to 3° 5°30’ to 8°30’ 6°18’ to 8°30’ 2°to 4° 91 RON minimum unleaded 95 RON minimum unleaded 95 RON minimum unleaded CLC or AKI 90 octane minimum 95 RON minimum Australian market variations Fuel .....................................................................................038 in) 2°BTDC ± 1° 1% max (hot) 2 INFORMATION ........................... catalyst .............................................................. 9................................ non catalyst ..35:1 catalyst 2200 ......... non catalyst ........ Spark plug gap ..........35:1.................................................................................033-0...............13:1......................................................................20-0.................................... 9...............35:1................................................................................... Ignition Timing at 800 rev/min max (vacuum pipe disconnected) ................................................................................................... Centrifugal Advance Decelerating check-vacuum hose disconnected Distributor rpm decelerating speeds 8..................................35:1............................................................................................................................................................ 9. 0...................... non catalyst ...................................................................................................................... Exhaust gas idle CO ....................84-0...................................................................13:1 non catalyst 2000 ......................................... 9............... 800 .................35:1..................... catalyst ...............................35mm Part number 8................... non catalyst ....................................... USA-Premium unleaded (PUG) .... 650 ............................13:1 Champion RN12YC 0........................................................................................................................................................... Spark plug ........ Distributor advance 1400 ...... Lucas 35DLM8 electronic Rotation ....................................................... 800 .. Fuel 8....... Distributor advance 1400 ...............35:1 non catalyst 2200 ....................................................... 9......................96mm (0.... Clockwise Air gap .................. Compression ratio .................... Distributor advance 1400 .............................13:1. 9..................05 ENGINE TUNING DATA Distributor Make/type .....................................................

........................... 8.......... Closes .......Premium unleaded (PUG) ......................................................................................................ENGINE TUNING DATA ENGINE 4..................................... Not adjustable Idle air control valve position..........5% Fuel 9...........................2:1 Fuel injection system ..5% æ 0............. Sagem .............Lucas GEMS8 Hot-wire air flow sensor system electronically controlled Valve Timing Opens ....................controlled by GEMS system all loads off ..................... Valve peak ........ Duration .........0 V8 Type ..... Champion RN11YCC Gap ......................................... Inlet 28°BTDC 77°ABDC 285° 108°ATDC Exhaust 66°BBDC 39°ATDC 285° 110°BTDC Idle speed ................................................................. Lucas 2D1S2 Type ..................035 ........................................................ Pulley end of left bank Spark plugs Make/type ..... 700 ± 20 rev/min Base idle speed ................................................................................................... checked via TestBook CO at idle vehicles without heated oxygen sensors ............ 2-4-6-8 No 1 Cylinder location ................ USA vehicles ................................................0.040 in Low Compression 8.................................. Non catalyst ............... 95 RON minimum unleaded 95 RON minimum 91 RON minimum unleaded 91 RON minimum unleaded or leaded INFORMATION 3 .....................................................................35:1 0. Twin coils.................................... 9..................................................................... 1.............................90 .....................................................................................................................0 Litre V8 Firing order ......................1............. 1-8-4-3-6-5-7-2 Cylinder Numbers Left bank .................................................00 mm Coils Make .....................................................35:1 catalyst .......................................................................... 0.....................................................2:1 catalyst .................................. 4........................... bank of 4 High Compression Compression ratio . 1-3-5-7 Right bank ................................................................................

... 9....C.....D.................T.... Constant pressure delivery valves........ 13°A....................C.......... ....D. 1-3-4-2 Injection timing ..............Opens .....................C............................................... 4600 + 40 ........... Constant volume delivery valves........................................... 1...... 42°A.... Timing pin (service tool) Tappet clearances inlet and exhaust ...Peak ..Lift ....... Inlet 16°B........................... 4 INFORMATION ..................... Throttle position sensor for EGR control.......... Constant volume delivery valves Make & type ............................No load (neutral/full throttle) .........C............ Tamper proof sealing on........D.manual . 0................................... Tamper proof sealing on flight speed and fuel adjustment screws......... .....................D...Electronic diesel control ... 720 ± 20 rev/min ........ Make & type ...........C......................B......... Timing marks: Valve timing ......EDC .......................Closes .........D...........C.40 mm lift at T.....T............................ Slot for pin in flywheel and TDC mark on front pulley.....67 mm Exhaust 51°B....................................97 mm Maximum governed speeds: ................. Slot for pin in ring gear.................B................D...... 103°A....................................... . no load governed speed and fuel adjustment screws..............................................................D...... 1.20 mm cold Valve timing: ... 9.................45 mm lift at T............. Bosch rotary R509/1 type with boost control and two speed mechanical governor with auto advance and solenoid electrical shut-off........Idle speed at running temperature ...automatic .................................................T...........05 ENGINE TUNING DATA 300 Tdi ENGINE Type ...........Electronic EGR ............Die-down time .................. Bosch rotary R509 type with boost control and two speed mechanical governor with auto advance and solenoid electrical shut-off............. 0...................120 rev/min ......................................... 4 seconds INJECTION PUMP Make & type .........T..... Bosch rotary R500 type with full electronic control of fuelling and timing...............D.... Injection timing with electronic EGR ......54 mm lift at T... 2.... Valve timing ..........standard ...................... Injection timing with EDC ..D..................C......5 Litre Turbo diesel intercooled Firing order ..C. 109°B... TDC mark on front pulley Injection timing .................C..... Access through rear engine plate........

....... 0.......... Initial pressure 200 atmospheres Secondary 300 atmospheres TURBOCHARGER Make & type ..................................................... DSLA 145P365 Opening pressure (working pressure) ........... Bosch KBAL 90 P38 Nozzle type ........................... No.............. Initial pressure 200 atmospheres Secondary 280 atmospheres Make & type .......................................... DSLA 145P365 Opening pressure (working pressure) ............... DSLA 145P366 Opening pressure (working pressure) .................8-1.................. 8 seconds INJECTORS Make & type ........................................................0 bar (12-15lbf/in2) measured at wastegate actuator ’T’ piece INFORMATION 5 ....................................................................EDC standard injector 3 in each engine ..........................0100226129A Beru 12 volts Time to reach operating temperature of 850°C .................. Initial pressure 200 atmospheres Secondary 300 atmospheres Make & type ...............EDC feedback 1 in each engine ...............................................................standard ... Bosch KBAL 90 P36 Nozzle type ....... Bosch KBAL 90 P37 Nozzle type ...............................................ENGINE TUNING DATA GLOW PLUGS Make & type ...................................... Allied signal Maximum boost pressure ...................... Probe type.....

.........................1 Volt ... 1................0 ± 25% adjustable using Testbook Ignition Knock sensor ........................................... .......................................................................... 20 T4/1994 cm3 1-3-4-2 10 : 1 875 ± 50 rev/min 0................................................... NEC 10049 Primary resistance at 20°C ........0 LITRE Type/Capacity .... MKC 10121 95 RON minimum ..........UNLEADED fuel CAUTION: Do not use LEADED fuel as it will damage the catalyst.... ADU 7340 Ignition Coils Type ........ MKW 10011 Fuel pump delivery pressure ..................................... 2.............. Not adjustable...5 Volts MEMS engine control module ..................... 6 INFORMATION ............................... Firing order .....................Throttle open ...............Mpi ......05 ENGINE TUNING DATA ENGINE ......................................................2........................ Fuel pressure regulator ................................................ Serious damage to the engine may occur if a lower octane number fuel than that recommended is used............................Throttle closed ...2. 4 ........................ ADU 8229 Crankshaft sensor .........................3 ........................................................61 ohm Consumption ................ Indirect multipoint injection with engine control module using speed/density method of air flow measurement............engine idling ........ Compression ration ..............................Catalyst .......................................................... Idle speed: Controlled by ECM .............5% Max.......................................... Exhaust gas Co content: .... 0...... 0 ......Non Catalyst ..............................................5 bar Throttle potentiometer voltage ................25 to 0.......................4 to 0................................................. 0...................................75 amp Spark Plugs Type/Gap ............................................................. GSP 6662 -0.................85 mm Multipoint Fuel Injection Type ......

Ensure that a suitable form of fire extinguisher is conveniently located. fluids. as well as causing damage to protective coatings. Cover seats and carpets. cautions and warnings in the section are intended to serve as reminders for trained and experienced mechanics. 5. 7. SAFETY PRECAUTIONS 1. and chemicals are subject to government regulations which are intended to provide a level of safety. 2. where specified. and the use and disposal of solvents. there is a risk of damage to electronic equipment and brake linings from stray heat. 3. Wash off with water immediately if this occurs. INFORMATION 1 . PRECAUTIONS AGAINST DAMAGE 1. 5. WARNING: Do not disconnect any pipes in air conditioning refrigeration system. Disconnect battery negative lead. unless trained and instructed to do so.GENERAL FITTING REMINDERS GENERAL FITTING REMINDERS WORKSHOP SAFETY IS YOUR RESPONSIBILITY! The suggestions. Use axle stands carefully placed at jacking points to provide rigid support. Ensure that adequate ventilation is provided when volatile degreasing agents are being used. 2. Chock wheels as well as applying parking brake. Always use a recommended Service Tool. 4. Protect temporarily exposed screw threads by replacing nuts or fitting plastic caps. Do not apply heat in an attempt to free stiff nuts or fittings. WARNING: Do not use a pit when removing fuel system components. This manual is not a course in automotive mechanics or workshop safety. or a satisfactory equivalent. in preference to jacking. Never rely on a jack alone to support vehicle. A refrigerant is used which can cause blindness if allowed to contact eyes. Always fit covers to protect fenders before commencing work in engine compartment. 6. Shop equipment. Use Polythene sheets to protect carpets and seats. shop environment. Avoid spilling hydraulic fluid or battery acid on paint work. Whenever possible use a lift or pit when working beneath vehicle. 4. Check that any lifting equipment used has adequate capacity and is fully serviceable. It is your responsibility to know and comply with such regulations. 3. wear clean overalls and wash hands or wear gloves before working inside vehicle.

to ensure that its correct replacement has been obtained. and to parts requiring further inspection before being passed for reassembly. to ensure correct reassembly. using plastic caps or plugs. crevices. using greaseproof paper and masking tape. Reject a component if its dimensions are outside limits quoted. containers and locking wire before dismantling a component. Blank off any openings exposed by component removal. 6. When a component is to be checked dimensionally against figures quoted for it. Use marking ink to identify mating parts. If a centre punch or scriber is used they may initiate cracks or distortion of components. use a separate container for each component and its associated parts. DISMANTLING 1. labels. dial gauges. 2. and is otherwise satisfactory. Before dismantling a component. clean it thoroughly with a recommended cleaning agent.) in serviceable condition. 2 INFORMATION . be refitted if its critical dimension is exactly limit size. INSPECTION-GENERAL 1. Do not discard a part due for renewal until after comparing it with a new part. Never inspect a component for wear or dimensional check unless it is absolutely clean.g. place these parts in separate containers from those containing parts for rebuild.0025 mm steps are provided with it. 4. or if damage is apparent. fuel or hydraulic system parts are being worked on. oil or hydraulic lines when separated. Before removing a component. 4. etc. Blow out all tapped holes. however. Ensure that any O-rings used for sealing are correctly replaced or renewed. Clean bench and provide marking materials. particularly when brake. roller bearing components). and a scale giving bearing clearances in 0. 7. A particle of dirt or a cloth fragment could cause a dangerous malfunction if trapped in these systems.07 GENERAL FITTING REMINDERS PREPARATION 1. micrometers. 2. 3. oilways and fluid passages with an air line. to prevent loss of fluid and entry of dirt. with tapered hardwood plugs or readily visible plastic plugs. Wire together mating parts where necessary to prevent accidental interchange (e. Immediately seal fuel. 6. Makeshift checking equipment can be dangerous. Immediately a component is removed. a slight smear of grease can conceal an incipient failure. Use ’Plastigauge’ 12 Type PG-1 for checking bearing surface clearances. 3. 2. Directions for its use. check that agent is suitable for all materials of component. place it in a suitable container. Close open ends of oilways. Wire labels on to all parts which are to be renewed. A part may. 5. exposed by component removal. if disturbed. 3. use correct equipment (surface plates. Observe scrupulous cleanliness when dismantling components. 4. clean it and its surrounding areas as thoroughly as possible. 5.

an exception could be made if the faulty bearing had covered a low mileage. 3. since any marking in these areas indicates onset of wear. If one bearing assembly of a pair shows an imperfection it is generally advisable to replace both with new bearings. 2.g. Inspect shaft and bearing housing for discoloration or other marking suggesting that movement has taken place between bearing and seatings. 1. Remove all traces of lubricant from bearing under inspection by washing in a suitable degreaser. 11. apply force only to inner ring of bearing. (Refer to ST1042M). INFORMATION 3 . 7.g. hub bearings) fill space between bearing and outer seal with recommended grade of grease before fitting seal. spin outer race and check that it revolves absolutely smoothly. 6. Reject any bearings found to be marked. Inspect visually for markings of any form on rolling elements. always fit a complete new bearing assembly. Holding inner race between finger and thumb of one hand. 8. maintain absolute cleanliness throughout operations. and reject bearing if action is not perfectly smooth. to ensure correct reassembly. Lubricate bearing generously with lubricant appropriate to installation. taper roller bearings) in dismantling. raceways. feel for any check or obstruction to rotation. and it could be established that damage was confined to it only. Never fit new rollers in a used outer ring. Repeat. while holding inner ring. 9. 4. Ensure that shaft and housing are clean and free from burrs before fitting bearing. outer surface of outer rings or inner surface of inner rings. Rotate outer ring gently with a reciprocating motion. (This is particularly to be expected if related markings were found in operation 2). When fitting bearing to shaft. Always mark components of separable bearings (e. holding outer race and spinning inner race. 5.GENERAL FITTING REMINDERS BALL AND ROLLER BEARINGS CAUTION: Never refit a ball or roller bearing without first ensuring that it is in a fully serviceable condition. and only to outer ring when fitting into housing. 10. In the case of grease lubricated bearings (e.

7. 6.4mm (0. pack dust excluder seals with grease. Always fit new oil seals when rebuilding an assembly. 4. and resulting damage to both seals and sealing surfaces. and heavily grease duplex seals in cavity between sealing lips. 3. use plastic tube or tape to prevent damage to sealing lip. or flush with face of housing where no shoulder is provided.07 OIL SEALS GENERAL FITTING REMINDERS NOTE: Ensure that the seal running track is free from pits. Coat the sealing lips with clean grease. Carefully examine seal before fitting to ensure that it is clean and undamaged. (In some cases it may be preferable to fit seal to housing before fitting to shaft).015 in) smaller than outside diameter of seal. 4 INFORMATION . 1. threads or splines. If correct service tool is not available. 8. use a suitable drift approximately 0. Ensure that the seal does not enter the housing in a tilted position. if provided. Grease outside diameter of seal. using great care and if possible a ’bell piece’ to ensure that seal is not tilted. Use a hammer VERY GENTLY on drift if a press is not suitable. is correctly fitted. NEVER use a seal which has been improperly stored or handled. scores. If fitting sleeve is not available. Care in fitting is essential if good results are to be obtained. place square to housing recess and press into position. NOTE: Most cases of failure or leakage of oil seals are due to careless fitting. 5. Place lip of seal towards fluid to be sealed and slide into position on shaft. Never let weight of unsupported shaft rest in seal. corrosion and general damage prior to fitting replacement seal. such as hung on a hook or nail. Ensure that seal spring. Press or drift seal in to depth of housing if housing is shouldered. 2. using fitting sleeve when possible to protect sealing lip from damage by sharp corners.

GENERAL FITTING REMINDERS JOINTS AND JOINT FACES 1. fit new ’O’ rings or seals displaced by air blast. apply in a thin uniform film to metal surfaces. 11. 7. so that ports can be immediately covered to exclude dirt. Use jointing compound only when recommended. 12. 2. 6. do not allow removed material or dirt to enter tapped holes or enclosed parts. 5. After any work on hydraulic systems. Obtain appropriate plugs or caps before detaching hose end fittings. Reject any hose found faulty. Before removing any brake or power steering hose. 8. INFORMATION 5 . clean end fittings and area surrounding them as thoroughly as possible. Remove all traces of old jointing materials prior to reassembly. 10. Examine carefully for cracks. 6. 5. Otherwise fit joints dry. channels or crevices with compressed air. take great care to prevent it from entering oilways. Always use correct gaskets where they are specified. separation of plies. Containers for hydraulic fluid must be kept absolutely clean. HOSES 1. Clean hose externally and blow through with airline. pipes or blind tapped holes. and fluid in this condition would be dangerous to use due to a lowering of its boiling point. or use a container which has previously contained mineral oil. Do not use a tool which could damage joint faces. 2. When refitting hose. 3. 4. Blow out any pipes. 3. FLEXIBLE HYDRAULIC PIPES. Always use clean brake fluid to clean hydraulic components. Do not allow brake fluid to be contaminated with mineral oil. It will absorb water. ensure that no unnecessary bends are introduced. When jointing compound is used. Do not store brake fluid in an unsealed container. and that hose is not twisted before or during tightening of union nuts. security of end fittings and external damage. Fit a cap to seal a hydraulic union and a plug to its socket after removal to prevent ingress of dirt. Do not re-use brake fluid bled from system. 4. Absolute cleanliness must be observed with hydraulic components at all times. 9. Inspect joint faces for scratches or burrs and remove with a fine file or oil stone. inspect carefully for leaks underneath the vehicle while a second operator applies maximum pressure to the brakes (engine running) and operates the steering.

Always fit a new tab washer. a gold-bronze colour. KEYS AND KEYWAYS 1. An ISO metric bolt or screw. 12 or 14. the head is also marked with symbols to indicate the strength grade. METRIC BOLT IDENTIFICATION 1. 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. two dots identify the 12 o’clock position. Zinc plated ISO metric bolts and nuts are chromate passivated. TAB WASHERS 1. Clean and inspect key closely. 2.9. If the grade is above 12.8. 2. an armoured rubber outer sleeve and an inner viton core. 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking. Fit new washers in all places where they are used. as any indentation may indicate the onset of wear. In addition to marks to identify the manufacture. A clock face system is used as an alternative method of indicating the strength grade. METRIC NUT IDENTIFICATION 1. A dot is used to locate the 12 o’clock position and a dash to indicate the strength grade.g. 12. keys are suitable for refitting only if indistinguishable from new. e.07 GENERAL FITTING REMINDERS FUEL SYSTEM HOSES CAUTION: All fuel hoses are made up of two laminations. 8. 2. where the first figure gives the minimum tensile strength of the bolt material in tens of kgf/mm2.9 or 14. 3. Some nuts with a strength 4. 6 INFORMATION . Remove burrs from edges of keyways with a fine file and clean thoroughly before attempting to refit key. 3. A nut with an ISO metric thread is marked on one face or on one of the flats of the hexagon with the strength grade symbol 8. Ensure that the new tab washer is of the same design as that replaced. it is imperative that the internal bore is inspected to ensure that the viton lining has not become separated from the amoured outer sleeve. 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 head. If any of the fuel system hoses have been disconnected. A new hose must be fitted if separation is evident. 2.

To check or re-tighten a bolt or screw to a specified torque value first loosen a quarter of a turn. Do not allow oil. 2. Always tighten a nut or bolt to the recommended torque value. 2. NUTS 1. Arrange wire so that its tension tends to tighten the bolt heads. INFORMATION 7 . Do not substitute spring washers: there is always a good reason for the use of a cotter pin. and self-locking nuts. Cleaning up threads with a die or tap impairs the strength and closeness of fit of the threads and is not recommended. 3. grease or jointing compound to enter blind threaded holes. NOTE: Where bearing pre-load is involved nuts should be tightened in accordance with special instructions. The component is reduced to the core diameter for a short length at its extremity. or nuts. See below for thread identification. Bolts A circular recess is stamped in the upper surface of the bolt head. alternative washers or nuts should be selected. 2. Fit new locking wire of the correct type for all assemblies incorporating it. Damaged or corroded threads can affect the torque reading. Studs. 7. Always ensure that replacement bolts are at least equal in strength to those replaced. 2. Damaged threads must always be discarded. or washer thickness reduced. Fit new cotter pins throughout when replacing any unit. The hydraulic action on screwing in the bolt or stud could split the housing. except in the case of threads treated with sealant/lubricant. 2. Both UNF and Metric threads to ISO standards are used. to which it is fitted. LOCKING WIRE 1. 3. 6. SCREW THREADS 1. Where self-locking nuts have been removed it is advisable to replace them with new ones of the same type. Nuts A continuous line of circles is indented on one of the flats of the hexagon. When tightening a slotted or castellated nut never loosen it back to insert cotter pin or locking wire except in those recommended cases where this forms part of an adjustment. Brake Rods. Oil thread lightly before tightening to ensure a free running thread. 3.GENERAL FITTING REMINDERS COTTER PINS 1. parallel to the axis of the nut. UNIFIED THREAD IDENTIFICATION 1. Always fit cotter pins where cotter pins were originally used. All cotter pins should be fitted as shown unless otherwise stated. then re-tighten to the correct value. If difficulty is experienced. etc. 4. 5.

L .L .2105B. FLUIDS AND CAPACITIES RECOMMENDED LUBRICANTS AND FLUIDS USA VEHICLES AMBIENT TEMPERATURE °C COMPONENT Engine SPECIFICATION Use oils to API service level SGSH or RES. C or D 80W EP ATF Dexron IID API GL4 or GL5 MIL .LUBRICANTS.2105 or MIL . etc.2105B Brake fluid must have a minimum boiling point of 260°C (500˚F) and comply with FMVSS/116/DOT 4 NLGI-2 multipurpose lithium based grease Power steering LT 230T transfer gearbox Brake reservoir Lubrication nipples (hubs.L .OL.2105 or MIL . ball joints.) See table on page 3 for remaining vehicle components INFORMATION 1 .G4 or CCMC G4 VISCOSITY 5W/20 ) 5W/30 ) 5W/40 ) -30 -20 -10 0 10 20 30 40 50 10W/30 10W/40 ) 10W/50 ) 15W/40 ) 15W/50 ) 20W/40 ) 20W/50 ) Automatic gearbox Final drive units Swivel pin housings ATF Dexron IID API or GL5 90 EP MIL .L .22.

FLUIDS AND CAPACITIES RECOMMENDED LUBRICANTS AND FLUIDS All climates and conditions AMBIENT TEMPERATURE °C COMPONENT Petrol models Engine sump SPECIFICATION Oils must meet: RES.L .22.2105B C or D 90 EP 80 EP Power steering Transfer box LT230T 90 EP 80 EP 2 INFORMATION .OL.L .2105 or MIL .2105B C or D ATF Dexron IID API GL4 or GL5 MIL .09 LUBRICANTS.L .OL.G-4 or CCMC G-4 or API SG or SH VISCOSITY 5W/30 5W/40 5W/50 10W/30 10W/40 10W/50 15W/40 15W/50 20W/40 20W/50 25W/40 25W/50 Diesel Engine sump RES.22.2105 or MIL .PD-2 or CCMC PD-2 or API CD ATF Dexron IID 15W/40 -30 -20 -10 0 10 20 30 40 50 Main Gearbox Automatic Main Gearbox manual ATF Dexron IID Final drive units Swivel pin housings API or GL5 MIL .L .

2 Multi-purpose Lithium based GREASE Brake fluids having a minimum boiling point of 260°C (500°F) and complying with FMVSS 116 DOT4 Use an ethylene glycol based anti-freeze (containing no methanol) with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure the protection of the cooling system against frost and corrosion in all seasons.Wabco 830 502. minimum 25% anti-freeze in coolant otherwise damage to engine is liable to occur. Or a maximum of 60%. NOTE: Do not use Silicone Grease Battery lugs. WARNING: Many liquids and other substances used in motor vehicles are poisonous.Wabco 830 502. Use one part anti-freeze to one part water for protection down to -36°C (-33°F). The use of oil not to the correct specification can lead to high oil and fuel consumption and ultimately to damaged components. lubricants and various adhesives. Tdi. Additional oil additives should not be used. among others. They must not be consumed and must be kept away from open wounds. Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and prevent the formation of sludge which can block the oilways. include anti-freeze windscreen washer additives. IMPORTANT: Coolant solution must not fall below proportions one part anti-freeze to three parts water. FLUIDS AND CAPACITIES Propeller shaft Front and Rear Lubrication nipples (hubs. Mpi NLGI . These substances. Earthing surfaces where paint has been removed Air Conditioning System Refrigerant Compressor Oil ABS Sensor bush-rear Use only refrigerant R134a Nippon Denso ND-oil8 Unipart ND-oil8 Silicone grease: Staborags NBU . ball joints etc.LUBRICANTS.0634 Wacker chemie 704 .e.) Seat slides Door lock striker Brake and clutch reservoirs Engine coolant V8i. Petroleum jelly. Always adhere to the recommended servicing intervals. i. INFORMATION 3 .0164 Kluber GL301 LUBRICATION PRACTICE Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and when topping up.

.............................. .......................................00 pt 6......................Mpi ...Mpi ..)* Engine sump oil ..................20 pt 10...............90 pt 3.................. Washer bottle ....60 pt 3.............00 pt 3........70 pt 8...80 pt NOTE: * All levels must be checked by dipstick or level plugs as applicable...................................85 pt 5.50 11.......80 pt 1.20 pt 0............1 2..............................70 pt 4......Mpi petrol models ..............60 pt 19.........................00 pt 0...................................................... .70 2....................................................0 11.....300Tdi models .... .00 pt 7........90 0..........00 pt 0........20 pt 0.30 10......... Transfer gearbox oil ............00 7. Fuel tank usable fuel ............................85 0....................................................40 pt 1.. When draining oil from the ZF automatic gearbox................................. Manual gearbox ...........56 0.........70 pt 19.1 4...... FLUIDS AND CAPACITIES CAPACITIES The following capacity figures are approximate and are provided as a guide only.....70 pt 1... 4 INFORMATION ...........9 ...00 pt 4..90 pt 10.. oil will remain in the torque converter.60 pt 6..40 0....... Litres 5........V8i petrol models ... .V8i petrol models 3......... Swivel pin housing oil (each) .....300Tdi models ........5 gall 20....8 6..............30 pt 12. refill to high level on dipstick only..300Tdi models ..00 pt 17..00 pt 5.......20 pt 20.....................V8i petrol models ........... . ...................60 pt 12..4 2...................................................... Power steering box and reservoir RHD ........................67 9..00 pt 3.......09 LUBRICANTS........................Unit 10.............................. Rear differential .. Front differential .............90 3................75 pt 23 gall 24.......................00 pt 14......................30 pt US unit 12........0 Imp.. Capacities (approx....20 pt 4... Cooling system ............30 pt 23... Extra when refilling after fitting new filter ..........35 89.70 1..... Automatic gearbox ...............90 pt 21..30 1........... Power steering box and reservoir LHD ............70 pt 16.........50 pt 1....................

53°F CAUTION: Anti-freeze content must never be allowed to fall below 25% otherwise damage to the engine is liable to occur. The effectiveness of the catalysts in the catalytic converters will be seriously impaired if leaded fuel is used. exhaust system corrosion and engine oil deterioration. Leaded fuel will damage the sensors. FLUIDS AND CAPACITIES ANTI-FREEZE ENGINE TYPE MIXTURE STRENGTH PERCENTAGE CONCENTRATION PROTECTION LOWER TEMPERATURE LIMIT V8i Engine Diesel Engine One part anti-freeze One part water 50% . which includes two oxygen sensors.36°C .42°F Complete protection Vehicle may be driven away immediately from cold Safe limit protection Coolant in mushy state. INFORMATION 5 . FUEL REQUIREMENTS Catalyst vehicles Vehicles equipped with catalytic converter are designed to use ONLY unleaded fuel. anti-freeze content should not exceed 60% as this will greatly reduce the cooling effect of the coolant. Its use will also reduce spark plug fouling. and will deteriorate the emission control system. The vehicle is equipped with an electronic fuel injection system. Regulations require that pumps delivering unleaded fuel be labelled UNLEADED. Also. Engine may be started and driven away after warm-up period Lower protection Prevents frost damage to cylinder head.33°F . Using fuel that contains lead will result in damage to the emission control system and could result in loss of warranty coverage. Unleaded fuel must be used for the emission control system to operate properly.LUBRICANTS.41°C . block and radiator. Thaw out before starting engine . Only these pumps have nozzles which fit the filler neck of the vehicle fuel tank.47°C .

............. Diesel engines unleaded only....... Class A1 or A2 Using fuel with an octane rating lower than stated above could seriously impair vehicle performance...................g..Australia ...... 6 INFORMATION .35:1 compression ratio ...........non catalytic......................... automotive gas or Derv to British standard 2869.............. FLUIDS AND CAPACITIES RECOMMENDED FUEL Petrol engines .............non catalytic.. 9.... ..with catalytic converter ........................................ 95 RON (USA 90 CLC or AKI) leaded 97 RON/unleaded 95 RON leaded 90 RON/unleaded 95 RON minimum 91 RON unleaded 300Tdi ..... ......... Diesel fuel oil........... Take care not to spill fuel during refuelling...distillate........... ’Gasohol’).....diesel fuel......................................09 LUBRICANTS.... CAUTION: Do not use oxygenated fuels such as blends of methanol/ gasoline or ethanol/gasoline (e.. . 8..........13:1 compression ratio .

Bleed hydraulic system Check all hoses and pipes for security.MAINTENANCE SERVICE SCHEDULE This section gives information on the range of service procedures. Check visually for signs of damage. seat belts. AIR BAG MODULE(S) Check air bag module covers. Lubricate seat tilt pivots. See BRAKES. Brake System Bleed or. VEHICLE INTERIOR CHECK SEATS & BELTS Check condition and security of seats. England. Where required. The procedures given must be used in conjunction with the Service Schedule sheets. buckles and opertion of inertia seat belts. seat belt mountings. Fit new hoses and pipes as necessary. fractures and leaks. Repair. horns and warning indicators. or a cross reference is given. The Service Schedule sheets are available from:Land Rover Merchandising PO Box 534 Erdington Birmingham B24 0QS. CHECK OPERATION OF LAMPS Check operation of all lamps. MAINTENANCE 1 . CHECK OPERATION OF FOOT BRAKE AND CLUTCH If pedal feels ’spongy’ bleed system. Renew every ten years. See CLUTCH. CHECK OPERATION OF WIPERS Check operation of front/rear screen wipers and washers and condition of wiper blades. Repair. instructions are given for carrying out each service procedure. where the procedure can be found in this manual. Service Schedule sheets are published separately to reflect the maintenance needs and intervals for each vehicle variant and model year.

Rotate adjustment thumbwheel below parkbrake lever until parking brake is fully operational on third notch of ratchet. 2 MAINTENANCE . 6. Refit switch panel. Recheck parkbrake is fully operational on third notch of ratchet. It MUST NOT be used to take up brake shoe wear. Underneath vehicle. 9.10 MAINTENANCE CHECK SECURITY AND OPERATION OF PARK BRAKE Parking brake adjust 1. Operate parking brake to settle shoes. Readjust if necessary. Remove switch panel from centre console. rotate brake adjuster clockwise until brake shoes are fully expanded against drum. 5. Select a gear or ’P’ in main gearbox. 4. which MUST be adjusted at brake drum. 3. Release parkbrake lever. 8. 2. NOTE: Cable adjustment must ONLY be used for initial setting and to compensate for cable stretch. 7. Back off adjuster until drum is free to rotate. Chock road wheels.

Front Wheel Alignment REMOVE WHEELS. CHECK/TIGHTEN TOWING BRACKET FITTINGS LUBRICATE ALL HINGES. bulges.MAINTENANCE VEHICLE EXTERIOR INSPECT BRAKE PADS FOR WEAR. Front Brake Pads or. fit new pads if minimum thickness is less than 3. Repair. DOOR CHECK MECHANISMS. Fit road wheels in original hub position. Check visually for cuts.0mm. See BRAKES. See BRAKES. lumps. Always fit new pads as complete axle sets. Check brake pads for oil contamination. Steel wheels: 130 Nm. BONNET [HOOD] CATCHES AND FUEL FILLER FLAP MAINTENANCE 3 . Adjustment. do not fully tighten wheel nuts at this stage. Repair. uneven tread wear and tread depth. CALIPERS FOR LEAKS AND CONDITION Check thickness of brake pads. CHECK FRONT WHEEL ALIGNMENT Use recognised wheel alignment equipment to perform this check and adjustment. lower vehicle and finally tighten wheel nuts to correct torque. Check road wheels for damage. Alloy wheels: 130 Nm. If new brake pads required. Rear Brake Pads WARNING: When renewing brake pads. it is essential that only genuine components with correct grade of lining are used. Check/adjust tyre pressures. Refit road wheels CHECK/ADJUST HEADLAMP ALIGNMENT Check/adjust headlamp and auxiliary alignment. See STEERING. Secure in position with wheel nuts. NEVER individually or as a single wheel set. CHECK TYRES Check tyres (including spare) for compliance with manufacturers’ specification. Serious consequences could result from out of balance braking due to mixing of linings.

check cap for cracks. otherwise costly damage to cylinder head will result. chafing and deterioration.V8i The electronic ignition employs a Lucas 35DLM8 distributor.V8i . CHECK FUEL FILLER CAP SEAL FOR LEAKS . Clean outer surfaces of distributor cap to remove dirt.V8i CHECK FUEL EVAPORATIVE LOSS CONTROL SYSTEM FOR LEAKS .CATALYST. adjust and renew 1. Unclip cap. grease etc. CHECK COOLING/HEATER SYSTEMS Check cooling/heater systems for leaks and hoses for security and condition. Internal operating parts of distributor are pre-set at factory and do not normally require resetting.V8i CATALYST CHECK CONDITION OF HEATER PLUG WIRING FOR FRAYING. Mpi CLEAN/ADJUST SPARK PLUGS . 1. CHAFING AND DETERIORATION Tdi Clean.10 MAINTENANCE UNDER BONNET [HOOD] MAINTENANCE CLEAN DISTRIBUTOR CAP . 3. DO NOT DISTURB clear plastic insulating cover (flash shield) which protects magnetic pick-up module.V8i CATALYST. Check rotor arm. Adjustments should only be made if unit is known to be faulty or damaged. Mpi Apply a spot of clean engine oil into rotor spindle after rotor arm has been removed. Cooling system hoses should be changed at first signs of deterioration. Wipe inside cap with lint free cloth. 4. CHECK IGNITION WIRING Check ignition wiring and high tension leads for fraying. 2. Take great care when fitting spark plugs not to cross-thread plug. Distributor maintenance consists of following items. cap and flash shield tracking.V8i CATALYST RENEW SPARK PLUGS V8i . CHECK CONDITION OF ENGINE MOUNTING RUBBERS CHECK BRAKE SERVO HOSE FOR SECURITY AND CONDITION LUBRICATE DISTRIBUTOR ROTOR SPINDLE . 4 MAINTENANCE .

Clean or replace spark plugs as applicable. 6.MAINTENANCE 2. Failure to observe this instruction may result in cross-firing between two closely fitted leads which are consecutive in firing order. 3. 4. leads are correctly refitted as illustrated. ensure that shrouds are firmly seated. It is essential that correct type of spark plugs are fitted. Remove plugs and washers. leads from spark plugs.T. leads 8. Incorrect grade of plugs may lead to piston overheating and engine failure. Remove 5.9 V8 7. 4.T. 3. Disconnect battery negative lead. Fitting H.T. When pushing leads onto plugs. Remove H.0 V8 MAINTENANCE 5 . Ensure replacement H.

Refit 5. Release plug leads from securing clips. Remove spark plugs from cylinder head. Set plug gaps. Refit spark plug cover.Mpi Remove 1. CAUTION: Use correct type and grade of plug. 9. Apply anti-seize to plug threads. 8. Inspect spark plugs. 6 MAINTENANCE . 2. 4. 6. 3. Connect and route spark plug leads as illustrated.Mpi Spark plugs . Release 4 screws and remove spark plug cover. 7.10 MAINTENANCE RENEW SPARK PLUGS . Disconnect 4 plug leads. Fit spark plugs.

V8i NON CATALYST To renew air cleaner element . Air Cleaner MAINTENANCE 7 .Tdi .Tdi Drain off water and sediment CAUTION: It is essential that any water and sediment in fuel filter is drained off. Screw new filter into position. RENEW AIR CLEANER ELEMENT V8i CATALYST Mpi . 1. place a container beneath. Ensure that drain cock is secure. Tighten the drain cock immediately fuel starts to flow from drain cock. 2. 300 Tdi Engine RENEW FUEL FILTER ELEMENT . Repair. Hold a small receptacle beneath drain cock. Clean area around filter.V8i. Drain off water and sediment. Renew fuel filter element 1. See GENERAL SPECIFICATION DATA.MAINTENANCE CHECK/ADJUST VALVE CLEARANCES. Unscrew the drain cock half a turn.Tdi See FUEL SYSTEM. Information. 3. Unscrew filter. 2. 5. a quantity of fuel will be released. NOTE: Any delay in tightening drain cock when fuel starts to flow could possibly mean bleeding fuel system. as water in fuel can result in damage to injection pump. and discard filter. 3. . Mpi. Wet seal of new filter with fuel. 4.Tdi Valve adjustment.

1. Loosen bolt. Pry out purge valve. Finally blow out passageway again to remove remaining debris. tighten hose clamps securely. Release hose clamp and remove hose from plenum chamber inlet.10 MAINTENANCE CLEAN PLENUM CHAMBER VENTILATION PASSAGEWAY . RENEW CHARCOAL CANISTER . clean as necessary.Mpi Charcoal canister Remove 1. 3. Disconnect pipe. Remove charcoal canister. 8. 4. Disconnect battery negative lead. 7. Reverse removal procedure. Insert a piece of lint free cloth down throttle butterfly bore to prevent debris passing throttle butterfly. 2. Remove small ’T’ piece between crankcase ventilation hoses and check it is free from blockages. Refit 6. Use a compressed air line with a slim bent nozzle to enable passageway to be cleaned out from within throttle butterfly bore. 6.V8i Cleaning plenum chamber ventilation passageway can be carried out without removing plenum chamber from ram housing. CAUTION: Care must be taken to prevent debris from passageway passing beyond throttle butterfly disc. Remove crankcase ventilation hose from side of plenum chamber.V8i. 8 MAINTENANCE . 3. 2. 9. WARNING: Safety glasses must be worn when performing this operation. Ensure that debris is not blown into atmosphere which could be harmful to other persons closeby. 5. 5. Disconnect battery negative lead. Refit ’T’ piece and hoses. Place a cloth over tube protruding from side of plenum from which ventilation hose was removed to prevent debris from passageway being blown into atmosphere. 4. Any remaining matter can be dislodged using soft bent wire or pipe cleaner.

belt must be renewed before indicator reaches R. Clean drive belt pulley grooves and ensure grooves are not damaged. renew a belt that shows signs of wear. Repair. 5. Drive Belt Renew Renew drive belt Tdi. splitting or oil contamination. Fit new drive belt around pulley.H.Mpi 1. Check condition of drive belt. Check fluid level registers between MAX and MIN marking on dipstick. Check belt length indicator.Tdi Mpi RENEW . 7. Ensure vehicle is on level ground. See ENGINE. See ENGINE. Release drive belt from tensioner pulley and remove ring wrench. RENEW ANCILLARY DRIVE BELTS CHECK/TOP UP AUTOMATIC TRANSMISSION FLUID LEVEL NOTE: Transmission fluid level is checked when fluid is cold with engine idling in neutral. Use 15mm ring wrench on bolt and hold tensioner pulley fully clockwise. Repair.V8i . 6. RENEW .V8i . 4. 8.Tdi Renew drive belt V8i.MAINTENANCE CHECK CONDITION OF DRIVE BELT . 1. Remove belt from between pulleys. Drive Belt Renew 3. except tensioner pulley. end of slot. 2. ensuring all grooves are correctly engaged. 2. MAINTENANCE 9 . Hold tensioner pulley fully clockwise and fit drive centrally around tensioner pulley.

2. Adjustment. See COOLING SYSTEM. turn cap slowly anti-clockwise. CHECK/TOP UP WASHER RESERVOIR Top up washer reservoir to within 25 mm of filler neck. Refer to Coolant Requirements.9 V8i 6. If necessary. rainwater should be used. pause and allow all pressure to escape. Continue to turn until cap is removed. if local water supply is hard. Engine 3. Use soft water whenever possible.V8i CATALYST Check ignition timing. with possible damage to engine The cooling system should be drained and flushed at 2 year intervals or at onset of second winter.10 MAINTENANCE CHECK/TOP UP COOLING SYSTEM 1. See ENGINE TUNING DATA. 5. 3. Never fill or top up with plain water. WARNING: Do not remove filler cap when engine is hot because cooling system is pressurised and personal scalding could result. winter or summer. Use a screen washer solvent/anti-freeze solution to assist removing mud. When replacing filler cap it is important that it is tightened down fully. Failure to tighten filler cap properly may result in water loss. When removing filler cap. wash affected area IMMEDIATELY with a large quantity of water. Remove fluid reservoir cap. top up cooling system with premixed coolant. LUBRICATE ACCELERATOR AND CRUISE CONTROL LINKAGES CHECK/ADJUST IGNITION TIMING . flies and road film and protect against freezing. To prevent corrosion of aluminium alloy engine parts it is imperative that cooling system is filled with a solution of water and phosphate free anti-freeze. If spillage occurs. visible inside tank through filler hole. Check that fluid is up to high mark on dipstick. CHECK/ TOP UP POWER STEERING FLUID RESERVOIR 1. CHECK/ TOP UP CLUTCH AND BRAKE FLUID RESERVOIRS CAUTION: Brake fluid can damage paintwork. When engine is cold expansion tank coolant should be level with top of indicator post. Information. 4. Coolant Requirements 10 MAINTENANCE .

In adverse operating conditions such as work in dusty atmospheres.000 miles) or every 6 years whichever occurs earlier. Check that there is no backlash in steering box in straight ahead position.Tdi Renew camshaft drive belt. In adverse conditions every 80. CHECK ENGINE IDLE SPEED . CHECK CAMSHAFT DRIVE BELT .000 km (48.Mpi For details of checking camshaft drive belt. Check Camshaft Drive Belt . See ENGINE. Adjust steering box if necessary. See ENGINE TUNING DATA.000 miles). CAUTION: If the drive belt is not renewed at the correct interval. See ENGINE TUNING DATA. See ENGINE. it could fail. Camshaft Drive Belt .Mpi Renew every 160. Camshaft Drive Belt and Gears The engine timing gears are driven by a flexible rubber belt which must be renewed at intervals determined by the severity of operating conditions.Mpi For idle speed. Battery Remove battery terminals.2.000 km (72. Adjustment. high ambient temperatures and desert and tropical zones. See STEERING. renew the belt every 120.000 miles) or every 6 years. See ENGINE. For details of renewing camshaft drive belt. clean and coat with petroleum jelly. Repair.Tdi . Engine . resulting in serious damage. Repair.Mpi MAINTENANCE 11 . renew the belt every 60. Information. Information.Tdi For idle speed.000 km (96.000 miles) or every 3 years whichever occurs earlier. 300 Tdi Engine RENEW CAMSHAFT DRIVE BELT . In reasonable. Power Steering Box RENEW CAMSHAFT DRIVE BELT . Dependent upon climate conditions electrolyte levels should be checked as follows: Temperate climates every three years.MAINTENANCE CHECK/ADJUST ENGINE IDLE SPEED .Mpi CLEAN BATTERY CONNECTIONS NOTE: Some 96 models are fitted with battery backed-up sounder See ELECTRICAL. A low maintenance battery is installed in vehicle.0 Litre CHECK/ADJUST STEERING BOX V8i .Mpi Check steering box for fluid leaks. Repair. Hot climates every year.000 km (36.Mpi . temperate climate operation. Repair.

Remove oil filler level plug. inject new oil into the gearbox until it runs out of filler hole.V8i RENEW ENGINE OIL AND FILTER . If airlock does occur fill oil pump with petroleum jelly.V8i RENEW ENGINE OIL AND FILTER . mud and water should have oils changed and lubrication carried out at more frequent intervals than is recommended in maintenance schedules.Tdi . Flush intercooler with ICI ’GENKLENE’or oD-SOLVE’ propriety cleaner. CAUTION: To prevent an airlock occuring after removing filter. 2. Refit intercooler element.V8i 1.Tdi Remove 1. Tighten to 30 Nm.V8i 12 MAINTENANCE . 3.Tdi Clear any trapped dirt or flies from vanes of intercooler UNDER VEHICLE MAINTENANCE Vehicles operating under severe conditions of dust. sand. CAUTION: Serious damage to the turbocharger will result if engine is run above idling speed before oil pressure is restored.Mpi CHECK/TOP UP MANUAL GEARBOX OIL . following the ˆ manufacturer’s instructions. RENEW MANUAL GEARBOX OIL . 2. Refit 4. CLEAN INTERCOOLER ELEMENT . fill new filter with oil and fit immediately after removing old filter. Fit plug.Mpi RENEW MANUAL GEARBOX OIL . Site vehicle on lift or level ground.Tdi RENEW ENGINE OIL AND FILTER . If necessary.10 MAINTENANCE EXTERNALLY CHECK INTERCOOLER FOR OBSTRUCTION . Dry the intercooler completely ensuring that no liquid remains in the element. RENEW ENGINE OIL . Remove intercooler element.

Refill or top-up with correct quantity and grade of fluid. Site vehicle on lift or level ground.MAINTENANCE RENEW AUTOMATIC GEARBOX FLUID AND OIL SCREEN 1. 5. Check fluid level. Disconnect battery negative lead. Recommended Lubricants and Fluids MAINTENANCE 13 . Oil screen replacement ZF automatic gearbox. Release plug from bottom of sump and allow fluid to drain completely. Information. Apply footbrake. Oil Screen Refill ZF Automatic Gearbox and Check Fluid Level. FLUIDS AND CAPACITIES. Start and run engine. Remove gearbox dipstick. 4. Tighten to 10 Nm 6. NOTE: The fluid level must checked when fluid is cold and engine idling in park. Ensure vehicle is on level ground. to aid oil drainage. See LUBRICANTS. Place container to drain gearbox fluid into. 2. Repair. 3. located at rear of right hand rocker cover. this must be between the two marks on the dipstick. See AUTOMATIC GEARBOX. Refit plug using a new sealing washer. select position 1 then back to park.

Clean immediate area around filler/level plug. 10. 8. Reconnect battery negative lead.10 MAINTENANCE RENEW TRANSFER GEARBOX OIL 1. Apply Hylomar sealant to threads of plug and refit plug. 4. Disconnect battery negative lead. 7. 6. 4. 6. Wipe away any surplus oil. Reconnect battery negative lead. Thoroughly clean drain plug threads prior to applying fresh ’Hylomar’ sealant. 2. Clean immediate area around filler/level and drain plugs. 8. Fit plug Tighten to 30 Nm. Remove plug and fill gearbox with recommended grade of oil. Tighten to 30 Nm. WARNING: When draining gearbox care should be taken to ensure that oil is not hot as personal scalding could result. 14 MAINTENANCE . 7. 3. 5. Site vehicle on lift or level ground. Place a container under gearbox to drain oil into. Fill gearbox with correct quantity and grade of oil until oil seeps from filler level hole. Remove drain plug and allow oil to drain. Remove filler/level plug to vent gearbox and assist draining. Wipe away any surplus oil. 9. Clean any previously applied sealant from filler/level plug. Thoroughly clean filler/level plug threads prior to applying fresh ’Hylomar’ sealant. Disconnect battery negative lead. 5. Fit plug Tighten to 30 Nm. 3. Site vehicle on lift or level ground. 2. until oil starts to seep from filler/level hole. CHECK/TOP UP TRANSFER GEARBOX OIL 1.

3. 2. remove filler/level plug from axle. Inject new oil of recommended make and grade until it reaches level hole. Clean and refit filler/level plug and wipe away surplus oil. MAINTENANCE 15 . Place container under swivel to be drained. 4. remove drain and filler/level plugs from axle. Remove filler plug and inject recommended make and grade of oil it reaches level hole. Site vehicle on lift or level ground. clean and refit drain plug. wipe away any surplus oil. Site vehicle on lift or level ground. Allow oil to drain completely. Using a 13mm square drive wrench. 2. CHECK/TOP UP SWIVEL PIN HOUSING OIL RENEW SWIVEL PIN HOUSING OIL 1. Clean and refit level and filler plugs. allow oil to drain completely. 3. Place container under axle to be drained. Clean and refit filler/level plug and wipe away surplus oil. 3. Site vehicle on lift or level ground. Clean and refit drain plug. Using a 13mm square drive wrench. CHECK/TOP UP FRONT AND REAR AXLE OIL 1. 2.MAINTENANCE RENEW FRONT AND REAR AXLE OIL 1. If necessary inject new oil of recommended make and grade until it reaches level hole. Remove drain and level plugs.

16 MAINTENANCE . Using a low pressure hand grease gun. 1. Clean all grease nipples on front and rear propeller shafts. NOTE: The rear propeller shaft flexible coupling is not fitted with a grease nipple. to grease nipples at front and rear propeller shaft universal and sliding joints. Check for wear in joints by moving ball joint up and down vigorously. CHECK VISUALLY BRAKE. FUEL. CHECK CONDITION OF OF BALL JOINTS AND DUST COVERS Ball joints are lubricated for their normal life during manufacture and require no further lubrication. This applies ONLY if rubber boot has not been dislodged or damaged. HYDRAULIC PIPES AND UNIONS FOR CHAFING AND CORROSION CHECK/TIGHTEN STEERING UNIT AND STEERING ROD BALL JOINT FIXINGS. Joints should be checked at specified mileage intervals but more frequently if vehicle is used under arduous conditions. CLUTCH PIPES/UNIONS FOR CHAFING LEAKS AND CORROSION CHECK EXHAUST SYSTEM FOR LEAKS. apply recommended grease. If free movement is apparent fit a new joint assembly. AND UNIVERSAL JOINTS 1. 2.10 MAINTENANCE LUBRICATE PROPELLER SHAFT SLIDING . SECURITY AND DAMAGE CHECK FOR FLUID LEAKS FROM POWER STEERING AND SUSPENSION SYSTEMS.

Repair. Thoroughly clean area around hose connections to prevent ingress of foreign matter into fuel system. Loosen two fuel unions and remove hoses from filter canister. CHECK CONDITION OF MOUNTING RUBBERS RENEW FUEL FILTER WARNING: Ensure that fuel handling precautions given in Section 01 Introduction regarding fuel handling are strictly adhered to when carrying out following instructions. Fit a new filter observing direction of flow arrow on canister. See FUEL SYSTEM. Recode radio. Release securing bolt and bracket. Refit fuel pump relay. Information. DRAIN FUEL SEDIMENTER . Depressurising Fuel System 2.Tdi Fuel sedimenter The sedimenter is attached to left-hand side of chassis frame near fuel tank. 10. Tighten to 30 Nm. It increases the working life of the fuel filter by removing larger droplets of water and larger particles of foreign matter from fuel. 8. Reconnect battery negative lead. allow water to run out. 1. 6. Start engine and inspect hose connections for fuel leaks.MAINTENANCE CHECK/TIGHTEN FRONT AND REAR AXLE SUSPENSION LINK FIXINGS. 9. 4. 5. 3. Fuel Handling Precautions WARNING: The spilling of fuel is unavoidable during this operation. remove filter from chassis side member. Fit inlet and outlet hoses. Loosen drain plug. Depressurise fuel system. See INTRODUCTION. MAINTENANCE 17 . The fuel line filter is located on right hand chassis side member forward of fuel tank filler neck. Tighten plug immediately pure diesel fuel starts to flow. 11. 7. Drain off water 1. Access to filter is gained through right hand rear wheel arch. Ensure that all necessary precautions are taken to prevent fire and explosion.

Steering for abnormal noise/effort. 11.high/low range. Clutch for slip. 12. 5. Information.10 MAINTENANCE ABS VEHICLES . Body noises. Gear selection/noise . 13. 19. Report any unusual features of vehicle condition and additional work required. 14. See INTRODUCTION. Endorse service record. Foot brake.Vehicles with Anti-lock brakes (ABS) Check following items: 1. 10. check operation of retraction and latching. pedal effort. on emergency stop. 15. Repair.ride irregularities. All instruments. squeaks and rattles.CHECK ROAD WHEEL SPEED SENSOR ELECTRICAL HARNESS FOR DAMAGE CARRY OUT ROAD TEST For details of dynamometer testing. Road wheel balance. 9. binding. Heated rear screen. Inhibitor switch only operates in P and N.Non Anti-lock brake vehicles See INTRODUCTION. 22. Information. 8. Inertia belts lock when snatched or vehicle on slope. Steering for free play. Fully extend seat belt. Dynamometer Testing . Exhaust System Complete REPORT ANY UNUSUAL FEATURES OF VEHICLE CONDITION AND ADDITIONAL WORK REQUIRED 16. Engine for excessive noise. pulling to one side. Shock absorbers . 2. 7. Repair. Parkbrake efficiency. 20. 6. gauges and warning indicators. Dynamometer Testing . 4. 3. 18. Heater and air conditioning systems. Transmission for vibrations. Automatic gear selection/shift speeds. RENEW OXYGEN SENSORS See EMISSION CONTROL. ENDORSE SERVICE RECORD 18 MAINTENANCE . 17. Excessive exhaust smoke. Heated Oxygen Sensor (HO2S) RENEW CATALYTIC CONVERTERS See MANIFOLD AND EXHAUST SYSTEM. judder or spin. Engine idle speed. Seat reclining and latching. 21.

3.500 and 105. RECOMMENDED SERVICE ITEMS Refer Service Schedule sheets for intervals. 2. brake servo filter and flexible hoses.000 miles respectively and will illuminate a ’Service Engine’ red warning light in instrument binnacle. Repair. Identify control unit and remove from plug. frequent attention to the air cleaner may be required. Remove tamperproof label to reveal access hole for resetting. Renew the hydraulic brake fluid. clean and lubricate guide rails and slides. Air cleaner . See BRAKES. All working surfaces of the master cylinder and caliper cylinders should be examined and renewed where necessary. ABS vehicles used extensively in arduous off-road conditions . The control unit is located in the passenger footwell. Place a thin metallic probe into access hole and momentarily electrically short between reset pins inside unit. Clean sunroof drain tubes.When the vehicle is used in dusty or field conditions or deep wading. ABS vehicles only . This emission maintenance reminder is part of the Emission Control System Reset 1. 4. MAINTENANCE 19 .MAINTENANCE RESET EMISSION MAINTENANCE REMINDER USA The emission maintenance reminder is designed to activate at 52. seals. Brake System Bleed Renew all hydraulic brake fluid.check the rear wheel road speed sensor for abrasive wear.renew hydraulic brake fluid and flexible hoses examine the working surfaces of the caliper cylinders and renew the seals or cylinders where necessary. The emission maintenance reminder must be reset after required maintenance has been carried out and a new tamperproof label fitted by a Land Rover of North America dealer.

splitting or oil contamination. The vehicle driver should be requested to identify the type of mileage the vehicle has covered. It is essential that the belts are fitted exactly as shown. Check condition Check condition of drive belt. A drive belt tensioner automatically tensions the drive belt. eliminating the need for tensioning individual drive belts. It should also be noted that the water pump/viscous fan is driven in a clockwise direction. A new belt must be fitted at the next service or before. If belt has jumped.Tdi DRIVE BELT INFORMATION A single ’serpentine drive belt’ drives all the ancilliaries bar the air conditioning compressor. reposition belt correctly. REPAIR 1 . Turning the tensioner pulley in a clockwise direction will release drive belt tension. which has a separate drive belt.000 kilometres.000 miles or eight years whichever occurs first. Off road driving Regular examination of the drive belt is essential if the vehicle is used off road. The drive belt must be examined at every service and replaced if necessary. Fan cowl To ensure easy access to the drive belt the top portion of the fan cowl is detachable. 96. After every off road session the owner should inspect the belt for cuts and possible damage caused by stones. Under normal highway use the belt must be changed at 160. dependant on the type of damage sustained. Renew a belt that shows signs of wear.

6. 2. 3. 4. Reapply and hold a torque of 35 Nm to tensioner. Remove compressor drive belt. then fully loosen and retighten 3 tensioner retaining screws to 25 Nm. Remove auxiliary drive belt. 7. 5. Mark direction on belt if refitting.86. Complete removal of belt. Rotate crankshaft 2 full turns. 8. Remove 1. Remove compressor shield. COMPRESSOR DRIVE BELT Service repair no .03 NOTE: If cast lines on tensioner arm and tensioner spring case are aligned. 6. Turn spanner to release pulley tension from belt. Fit torque meter to centre of tensioner and apply and hold a torque of 35 Nm. 3. 2 REPAIR . Detach belt from pulley. 4. Refit 7. Release tensioner. See Drive Belt Renew 2. a new drive belt must be fitted.02 Remove 1.10. Loosen tensioner retaining bolts. Tighten 3 tensioner retaining bolts. Mark direction on belt if refitting.10. Apply ring spanner to tensioner pulley retaining bolt. Refit 5.86. Remove fan cowl upper. Fit compressor drive belt.12 ENGINE DRIVE BELT RENEW Service repair no . Reverse removal procedure.

Remove split pin securing inner throttle cable to injector pump. Remove bolt securing transmission breather pipe clip to cylinder head. 3. Refrigerant Recovery Recycling Recharging Remove retaining bolts and disconnect both pipe adaptors from rear of compressor. Disconnect bypass hose from thermostat housing. and move aside. 7.12. remove RH footwell side trim panel and disconnect harness multiplug from relay. Park vehicle on level ground and apply park brake. 15. REPAIR 3 . Adjustment. 14. 19. Repair. Repair. 16. Bonnet [Hood] 4. Disconnect the two engine harness multiplugs on LH side of footwell. Disconnect heater hoses from cylinder head and heater rails. If air conditioning is fitted. 10. Remove feed pipe/hose from turbocharger and intercooler.01 Remove CAUTION: Seal all exposed pipe ends against ingress of dirt after disconnection. 6. Discharge air conditioning system.Tdi ENGINE Service repair no . 11. 12. Remove air cleaner hose from turbocharger. Disconnect battery negative lead. 1. 2. 8. Release bypass hose from retaining clips on front timing cover. Remove engine harness grommet from bulkhead and move harness into engine bay. Disconnect cyclone hose from air cleaner hose. 21. Remove rocker cover insulation. 20. If automatic transmission is fitted. See COOLING SYSTEM.41. 13. 5. Remove bonnet [hood]. Remove Radiator Assembly. 18. See CHASSIS AND BODY. Radiator 9. 17. remove cable from mounting bracket. move breather pipes aside. Disconnect inlet and outlet hoses from power steering pump. release kickdown cable from injector pump and mounting bracket. Depress tags on outer cable adjusting nut. Release battery positive lead from retaining clip at base of suspension turret. See AIR CONDITIONING.

Remove three retaining nuts and disconnect exhaust down pipe. 35. 4 REPAIR . On vehicles with automatic transmission. Using suitable hoist. rotating crankshaft to gain access to each individual bolt. Remove two bolts. securing front engine mounting bracket to bell housing. Working through drive plate housing aperture mark the torque convertor and drive plate to facilitate reassembly. remove fixings and detach drive plate housing access panel and gasket. 27. Disconnect both pipes from fuel lift pump. from both sides. Disconnect ground strap from starter motor. Remove four bolts. disconnect feed and return pipes at gearbox oil cooler.12 ENGINE 22. 29. Support gearbox. 28. 24. from both sides. 31. Disconnect servo hose from vacuum pump. If automatic transmission is fitted. Fit engine lifting bracket to the two RH rear cylinder head fixing bolts. fit lifting chains to engine. 34. securing front engine mounting brackets to cylinder block. 23. Remove retaining bracket from LH side of cylinder block and release both oil cooler pipes. Disconnect feed pipe and spill return pipe from injector pump. 33. 26. 36. 30. 32. 25. Remove oil cooler pipes from oil filter adaptor. Remove the four convertor to flexible drive securing bolts.

Tdi Refit 42. 45. Remove nuts and plain washers securing front engine mountings to chassis. Tighten to 46 Nm. Remove gearbox support and lower engine. Reverse removal procedure. Tighten front engine mountings to chassis fixings. 40. 47. Remove engine. Lubricate splines of gearbox primary pinion with Rocol MV 3. 46. Fit engine to bell housing fixings. Tighten to 40 Nm. 39. REPAIR 5 . Lower engine and locate with transmission. Raise engine. Check all connections to engine have been disconnected. 41. If manual transmission locate primary pinion into clutch and engage bell housing dowels. refit front engine mounting brackets to cylinder block and bell housing. coat the four drive plate to torque convertor bolts with Loctite 290.and lift both engine mounting bracket assemblies from vehicle. 44. Apply Hylomar to mating faces of bell housing. Tighten to 45 Nm. If automatic transmission. 1 to 37. If automatic transmission fixings. Raise engine to separate from transmission. Tighten to 39 Nm. 38. 37. Remove engine to bell housing fixings. 43. Leave starter motor attached.

Drain coolant. Tighten to 80 Nm + 90°. 4. Remove viscous fan and coupling. 2. Remove crankshaft pulley retaining bolt using socket and suitable long bar.21.01 Remove 1. 6 REPAIR . See COOLING SYSTEM. See Drive Belt Renew Fit crankshaft pulley retainer LRT-12-080 and secure with four bolts. 3. Remove pulley retainer. 9. Remove drive belt. lightly greasing pulley spigot. 5. 7. Repair. Pulley and Fan Cowl Remove fan cowl. Refit in reverse order.12 ENGINE CRANKSHAFT PULLEY Service repair no . 11.12. Remove top hose from radiator. 10. Remove pulley. 8. Fan Blades. Viscous Coupling. Refit 12. if necessary using extractor LRT-12-049 with thrust pad from LRT-12-031. Disconnect battery negative lead. Remove intercooler to induction manifold hose. 6.

Drain coolant. Refit in reverse order to removal using new gaskets. See Crankshaft Pulley Remove 14 bolts securing front cover plate. Disconnect battery negative lead. Tighten to 25 Nm. Support cover and fit new seal. Remove drive belt. See COOLING SYSTEM. 11.Tdi FRONT COVER PLATE Service repair no . noting top two bolts also retain thermostat hose clips.12. Viscous Coupling. Remove cover plate complete with gasket. Remove top hose from radiator. 2. Remove inter-cooler to induction manifold hose. Seal replacement 12. See Drive Belt Renew Remove crankshaft pulley. REPAIR 7 . Pulley and Fan Cowl Remove fan cowl. Refit 14. 10.01 Remove 1. 5. open side fitted into recess. 8. 13. using special tool LRT-12-077. Remove small gasket from centre bolt boss. 6. Remove viscous coupling and fan. Repair. 3. fitting the securing bolts as shown in illustration ST3475.65. 7. Fan Blades. 4. 9. Remove worn seal from cover and clean recess.

a belt develops a wear pattern relative to its running direction. Remove idler pulley. 8.12. Check correct alignment of timing mark on camshaft gear and that crankshaft key aligns with cast arrow on housing. CAUTION: Belts must be stored on edge on a clean surface and in such a manner that bends are not less than 50 mm radius. Slacken belt tensioner bolt. Engage timing tool pin with slot in flywheel. Remove 2 blanking plate bolts and insert timing tool LRT-12-044 into the larger bolt hole. 8 REPAIR .timing tool LRT-12-085 must be used. 5. if the original belt is to be re-used it must be refitted so that it rotates in the original direction. NOTE: During use. Insert pin from special tool LRT-12-045 in injection pump gear and through into pump flange. Remove timing belt. If manual gearbox: Remove blanking plug from flywheel housing and insert timing tool LRT-12-044. If EDC . Do not bend belts at an acute angle or radius of less than 50 mm. See Front Cover Plate 2. otherwise premature failure could result. Mark belt direction of rotation. NOTE: If the camshaft gear is to be removed during these operations its retaining bolt should be slackened before the timing belt is removed. Remove front cover plate. 6. 1 cylinder. to ensure correct refitment.12 ENGINE CAMSHAFT DRIVE BELT AND GEARS Service repair no . 7. 9. 10.18 TIMING BELT Remove 1. 3. 4.65. If automatic gearbox:Sited to the rear of the engine sump on engine backplate is a blanking plate. using soft chalk. Position engine at TDC on No.

Lubricate a new crankshaft oil seal with clean engine oil. Remove securing bolt and withdraw tensioner complete with spacer.13. CAMSHAFT GEAR/FRONT COVER OIL SEAL Service repair no . use special tool LRT-12-078 with main body and thrust button from special tool LRT-12-031 as illustrated ST3478M. 11. Remove existing oil seal from front cover using special tool LRT-12-038.12. 16. 13. With lip side leading. 15. Fit crankshaft gear. Withdraw gear complete with ’O’ ring seal. tap fully home ensuring ’O’ ring seal is properly seated. 19. Lubricate new ’O’ ring seal with petroleum jelly and slide onto shaft. If necessary prise out oil seal from front cover. 17. 14.Tdi Belt tensioner NOTE: The belt tensioner need only be removed if it is being replaced or for access purposes to remove front cover. Crankshaft gear/front cover oil seal 12.05 18. Lubricate a new camshaft oil seal with clean engine oil. If the crankshaft gear cannot be removed by hand. taking care not to damage seal on the woodruff keys. 20. REPAIR 9 . Remove centre bolt from camshaft gear and withdraw gear. drive-in seal squarely using special tool LRT-12-079.

Refit gear. With lip side leading. Remove special tool pin from gear. 27. Insert pin from special tool LRT-12-045 in injection pump gear and through into pump flange. Remove three bolts and withdraw plate and gear. 21.19. Take care not to allow the crankshaft to be turned. Slacken the three bolts on front of gear. drive-in seal squarely using special tool LRT-12-082. Refit FUEL INJECTION PUMP GEAR Service repair no . 25.30. 26.12 ENGINE 24. Fit gear and plate and secure with three bolts. 22. CAUTION: It is important to ensure that when the injection pump is locked no attempt must be made to rotate it. 10 REPAIR .06 Remove 23.

Slacken injection pump gear retaining bolts. Tighten injection pump gear bolts. Remove pin from injection pump gear. The torque meter should be used in the almost vertical position. Remove pin from injection pump gear. Rotate crankshaft one and three quarter turns in a clockwise direction. 31. Insert 13 mm square drive extension bar in tensioner plate. Fit belt observing rotational marks made during removal. Adjust belt to correctly sit in gears.Tdi Timing belt fitting and tensioning NOTE: It is important that belt tensioning is carried out carefully and accurately. 30. Fit front cover plate using new gaskets. 43. Disengage timing pin from timing slot in flywheel or ring gear. Or if automatic: Timing tool LRT-12-044 is fitted to engine backplate and pin located in ring gear. 41. then continue rotation until timing pin in timing tool can be engaged with slot in flywheel or ring gear. Slacken tensioner and retension belt. Feed belt over gears keeping it tight on drive side. 35. 28. 36. Tighten injection pump gear retaining bolts. 33. Ensure timing marks are correctly aligned. 39. 45. NOTE: Belt tensioning should be carried out using a dial type torque meter having a range not exceeding 60 Nm. 44. New and original belts are tensioned to different figures. See Front Cover Plate REPAIR 11 . Fit idler pulley. Slacken belt tensioner securing bolt to finger tight. 37. Disengage timing pin. Remove timing tool and refit plug. pin from special tool LRT-12-045 is correctly inserted in injection pump gear and timing tool LRT-12-044 (LRT-12-085 if EDC) is fitted to flywheel housing with pin located in flywheel slot. Insert pin from special tool LRT-12-045 in injection pump gear and through into pump flange. 40. Slacken injection pump gear retaining bolts. The following procedure involves tensioning the belt twice to ensure that it is equally tensioned between each gear. 29. 34. 42. Apply a tension of 14 to 16 Nm for a new belt or 11 to 13 Nm for an original belt. When tension is correct tighten clamp bolt. 47. 46. 32. 38.

10. See Oil Pick-Up Strainer 16. Repair. See Oil Sump 4. Clean all gasket material from mating faces. Fit oil sump. 14. Secure with bolts of correct length in locations where slave studs are not fitted (ST3482). Remove engine oil sump.12. 11. Fit front cover to block taking care not to damage oil seal. Refit 8. Refit fuel injection pump. 7. Fit oil pick-up strainer. to cylinder block. Fuel Injection Pump and Timing 12 REPAIR . Remove oil pick up strainer. See Camshaft Drive Belt and Gears 2. Fit new gasket.12 ENGINE FRONT COVER/TIMING GEAR HOUSING GASKET Service repair no . 15. Remove fuel injection pump. Tighten to 25 Nm.65. 6. 12. Remove timing belt and gears. Align flats on oil pump with flats on crankshaft.10 Remove 1. over slave studs. 13. Repair. See FUEL SYSTEM. Fuel Injection Pump and Timing 3. Withdraw timing gear housing complete with gasket. See Oil Pick-Up Strainer 5. See Oil Sump 17. Remove bolts securing timing gear housing to block. See FUEL SYSTEM. Fit slave guide studs to locate gasket. Remove slave studs and fit correct length bolts. 9.

Tighten to 25 Nm. Tighten to 9 Nm. 9. 3. Tighten to 25 Nm. 3. fitting a new ’O’ ring seal at oil pump connection. Reconnect battery negative lead. Remove bolts and withdraw sump. Refill engine oil. 8.60. Clean mating faces of sump. using a sharp knife. Disconnect battery negative lead. ensuring bead is applied inboard of the bolt holes. break sealant around sump flange. Fit bolts to pipe flanges. Refit 5. 2. 6. Apply a 2. 6. See LUBRICANTS. 8. Secure sump to block with bolts. Recommended Lubricants and Fluids 9. Information. Refit 7. OIL PICK-UP STRAINER Service repair no . 2.12. FLUIDS AND CAPACITIES. Reconnect battery negative lead. Withdraw pick-up strainer assembly. timing gear housing and cylinder block. See Oil Sump 11. Drain engine oil. 7. Refit engine oil sump. Refit pick-up strainer assembly. Remove bolts from pipe flanges.60. 10. Remove engine oil sump. REPAIR 13 . 4. See Oil Sump Remove bolts securing pipe support bracket. Apply Loctite 242E to the two screws at the bearing cap.20 Remove 1.12. Disconnect battery negative lead. 5.44 Remove 1. 4.Tdi OIL SUMP Service repair no . Drain engine oil. Slacken sump securing bolts and.0 mm bead of ’Hylosil RTV102’ to the sump flange.

07mm. Repair. Remove clutch. 9.07 Remove 1. Remove fan cowl 6.12 FLYWHEEL ENGINE Service repair no . 5. Check the flywheel for possible run-out by mounting a dial test indicator with the stylus in a loaded condition resting on the flywheel face at a radius of 114mm from the centre. 7.12.53. 10. See CLUTCH. diametrically opposite.05 to 0. Disconnect battery negative lead. Remove gearbox. Turn the flywheel and check that run-out does not exceed 0. Repair. to use as handles when lifting the flywheel off the crankshaft. Should run-out be excessive. Fit two long 8mm bolts into the clutch bolt holes. Remove the bolts and lift off flywheel. Locate the flywheel on the crankshaft and secure with new patched retaining bolts. remove the flywheel and check again for irregularities on the crankshaft and flywheel mating faces and the dowel. 1 to 6. Refit 8. NOTE: To prevent excessive flywheel run-out. R380 Manual Gearbox 3. Reverse removal procedure. 2. to restrain crankshaft while removing flywheel retaining bolts. 11. Clutch Assembly 4. See MANUAL GEARBOX. ensure that the mating faces of the flywheel and crankshaft are clean. 14 REPAIR . Fit crankshaft pulley retainer LRT-12-080 and secure with four bolts. progressively tighten to 147 Nm.

12. 1. Disconnect battery negative lead. See Flywheel 5. Used formers/guides must be discarded immediately after use. See CLUTCH. Remove gearbox. If a seal and housing assembly is received without a former/guide fitted it must be returned to the supplier. See MANUAL GEARBOX.20 Remove NOTE: The crankshaft rear oil seal is retained in its own housing. under no circumstances should they be reused on other assemblies. Housing and seal assemblies are supplied with their own former/seal guide (2) already fitted. Remove clutch. Repair. if the seal requires replacing the housing and seal assembly (1) must be renewed complete with the housing seal (3). Repair. Insert slave studs to seal housing mounting face. 2. 7.21. Clutch Assembly 4. Remove flywheel. Refit 6.Tdi CRANKSHAFT REAR OIL SEAL Service repair no . 3. Position new seal housing gasket over slave studs and crankshaft flange onto cylinder block. This former must not be removed before fitting the assembly to the engine. Remove five bolts and withdraw seal housing and seal assembly complete with gasket. R380 Manual Gearbox REPAIR 15 .

Pack the bore with grease and insert the steel rod into the end of the bore. Repair. See CLUTCH. See MANUAL GEARBOX. give a sharp blow with a hammer and the grease should drive out the bush. Method 1. Obtain a short length of steel rod of a diameter having a good slide fit in the bore of the bush.45 1. Refit gearbox. Remove flywheel. 10. 2. 16 REPAIR . It is recommended that the bush and rod be covered by a suitable cloth or rag to prevent grease from splashing. this action will eject former/guide. Repair. See Flywheel 12.21. Remove bearing bush. Clutch Assembly 13. 11. Disconnect battery negative lead. Ensure housing seal is correctly seated in its groove in new housing and seal assembly. See Flywheel 5. R380 Manual Gearbox 3. See CLUTCH. Secure assembly to cylinder block with five bolts tightened to correct torque. Refit flywheel. with former/guide in-situ.12 ENGINE 8. Refit clutch. Clutch Assembly 4. NOTE: The bearing bush can be removed by using one of the following methods. Fit new assembly.12. 9. Repair. CRANKSHAFT BEARING BUSH Service repair no . Repair. R380 Manual Gearbox 14. Remove gearbox. Remove clutch. over crankshaft flange. removing slave studs individually and inserting bolts. See MANUAL GEARBOX. Reconnect battery negative lead.

Disconnect battery negative lead. Reconnect battery negative lead. 8.53. R380 Manual Gearbox 3. Repair. Repair. See CLUTCH. 6.01 Remove 1. See MANUAL GEARBOX. 2. 7. Refit flywheel. Refit 9. Refit clutch. Remove flywheel. See Flywheel 5. See CLUTCH. See Flywheel 8. ensuring all old sealant is removed. Thread the bore of the existing bush and using a suitable bolt extract the bush. Fitting 6. R380 Manual Gearbox 10. 7.12. See MANUAL GEARBOX. Remove clutch. Remove gearbox. Repair. Repair. Clutch Assembly 9. Refit gearbox. Thoroughly clean bush location ensuring all swarf is removed. inserting bush flush with end of crankshaft.Tdi Method 2. Remove starter motor. Remove six inner bolts and lift off flywheel housing. Clutch Assembly 4. REPAIR 17 . Clean rear face of housing and mating face on block. Remove two bolts from top of flywheel housing. Fit new bush using a suitable shouldered drift. FLYWHEEL HOUSING Service repair no . Remove four bolts from bottom of flywheel housing.

Remove surplus sealant from block. Unscrew filter anti-clockwise. Screw on filter until sealing ring touches machined face. Clutch Assembly 16. Refit 3. 11. Refit gearbox. 4. Refit starter motor. 18 REPAIR . using a strap or spanner. Place drain tray under filter.12 ENGINE 10. Do not over tighten. Tighten to 45 Nm. Refit clutch.01 Remove 1. 2. OIL FILTER Service repair no . R380 Manual Gearbox 17. Repair. Repair. Fit housing to cylinder block and secure with bolts as removed. See CLUTCH. Refit flywheel. Apply sealant to flywheel housing mating face on cylinder block (Fig.60. 14. See MANUAL GEARBOX. 12. See Flywheel 15.12. Smear clean engine oil on seal of new filter. J5944). 13. Reconnect battery negative lead. then tighten a further half turn by hand only.

60. Tighten to 9 Nm. 6. Insert spring into adaptor and secure extension housing to adaptor with bolts. 5. OIL FILTER HEAD GASKET Service repair no . Disconnect oil cooler pipes. two washers (4) and spring (5). 4. 2. Remove two bolts and carefully withdraw thermostat extension housing (1) complete with O ring seal (2). Clean mating faces. 6. 7. REPAIR 19 .12. Refit head with new gasket. Fit a new ’O’ ring to extension housing. 8. Tighten to 45 Nm.69 Remove 1.60. 4. thermostat (3). Refit 5. Disconnect pressure switch lead. 7. 3. Secure with bolts. 3. Clean adaptor housing. Fit two washers and spring to thermostat. Fit thermostat to extension housing ensuring pin locates in hole. Remove securing bolts and withdraw head complete with gasket. 2. Inspect all parts and renew as necessary.12. Refit pipes and reconnect pressure switch.Tdi OIL TEMPERATURE CONTROL VALVE Service repair no . Disconnect oil cooler pipes.03 Renew 1.

11. Disconnect battery negative lead.12 ENGINE CYLINDER HEAD GASKET Service repair no . Glow Plugs 15. Disconnect by-pass hose from thermostat. Remove fuel injectors and sealing washers. Remove glow plugs. Remove induction manifold. See CHASSIS AND BODY. Disconnect water temperature sensor lead. See MANIFOLD AND EXHAUST SYSTEM.02 Remove 1. Remove inter-connecting harness from glow plugs. Remove bolt securing harness bracket to cylinder head. 20. 4. Repair. Repair. this will also release clips securing transmission and engine breather pipes and multiplug. thermostat to water pump. See MANIFOLD AND EXHAUST SYSTEM. Remove air cleaner assembly.Tdi 18. Detach crankcase ventilation valve and side breather hose from rocker cover and move to one side. Exhaust Manifold . See FUEL SYSTEM. See FUEL SYSTEM. See FUEL SYSTEM.12. Remove injection pipes. Disconnect heater hose from rear of cylinder head. 21. Remove hose inter-cooler to induction manifold. Disconnect spill rail from fuel injectors. Remove top hose.29. 13. Injectors 9. Repair. 22. Identify each injector to the location from which it is removed. Repair. 19. Remove bonnet [Hood]. radiator to thermostat. 7. Remove exhaust manifold and turbocharger assembly. Remove rear lifting bracket. Remove bolt securing air cleaner mounting bracket to support strut. Bonnet [Hood] 3. 10.Tdi 17. Disconnect heater hose from water pump and move heater rail aside. Note loose spacer under clip securing engine breather pipe and multiplug. 6. Drain coolant. Repair. 2. Air Cleaner 5. 8. 20 REPAIR . 16. 14. Exhaust Manifold . 12. Disconnect hose. Repair.

32. Refit 29. When renewing gaskets the gasket being fitted must be of the same thickness as the one removed. bolts retaining cylinder head to block. different thicknesses are identified by the number of small holes punched in the right hand side of the gasket. 31. Therefore if the removed gasket had two holes punched in the side the replacement gasket must also have two holes punched in the side. Two of the bolts also secure the air cleaner mounting bracket. 26. Ensure face of cylinder block is thoroughly clean. One hole identifies the thinnest gasket and three holes the thickest. CAUTION: Three thicknesses of gasket are available. then remove. 25. Clean mating face of cylinder head. 24. Place gasket on cylinder block with identification holes positioned towards rear on right hand side and side marked TOP uppermost. Lower cylinder head onto block ensuring correct location with dowels. Remove push rods. Remove nuts and bolts and withdraw rocker shaft assembly. 28. 33. Evenly slacken. store as an identified set to allow refitment to same location. 27. REPAIR 21 . Remove valve stem caps. 30. Lift off cylinder head and remove gasket.Tdi 23. Remove rocker cover. Select new gasket of correct thickness.

10. the pointer can be fitted to the rocker shaft securing studs using two nuts. 8. Fit rocker shaft assembly evenly tightening securing nuts and bolts to correct torque. 22 REPAIR . and 13. 6. 44. Attach degree disc special tool LRT-12-007 to a power bar. Bolt sizes: M10 x 117mm locations 3. NOTE: Repositioning of the pointer will be necessary to reach all bolts. Following the sequence illustrated tighten all bolts to 40 Nm. 37. 16. M12 x 100mm locations 4. M12 x 140mm locations 1. 11. Fit push rods to locations from which they were removed. 15. Fit rocker cover ensuring oil seal is satisfactory for continued use. again strictly in sequence illustrated. Tighten all bolts through 60°strictly in sequence illustrated. Repeat 60°tightening procedure. 46. 35. 17. Lubricate threads of bolts with light oil and fit to positions illustrated. 43. Secure rocker cover with special seal washers and nuts tightened to correct torque. 9. 36. 2. 12. 45. 42. 7. 40. Fit valve stem caps. 39. otherwise damage to the cylinder head may occur. 47. 5. again following the sequence illustrated. Tighten the ten longer bolts (M12 x 140mm) a further 20°. Tighten bolts so that underside of heads just make contact with cylinder head.12 ENGINE NOTE: Cylinder head retaining bolts can be used up to a maximum of five times. Make a suitable pointer from welding rod and attach to a bolt screwed into a rocker shaft securing bolt hole. NOTE: Rocker cover seals can be re-used up to a maximum of five times. on no account should tightening be performed in one operation. 14. and 18. 34. 41. CAUTION: The double tightening procedure must be carried out. 38. Refit remainder of items by reversing operations 1 to 22 tightening securing bolts to correct torque where applicable.

3. 2.86.70. REPAIR 23 . See Drive Belt Renew 3. on No. 6. Evenly tighten bolts. Loosely assemble pump to block with a new gasket and with harness bracket located under head of bolt noted during removal. Disconnect electrical leads from rear of generator. Detach servo hose from vacuum pump. Remove long through bolt from top fixing and withdraw generator. Remove six bolts securing vacuum pump. 7. 1. 5. 8. Detach pump complete with harness bracket. Reconnect battery negative lead.C.1 cylinder. 2. GENERATOR Service repair no . 4. Remove securing bolt from bottom of generator. 9. Clean mating faces of pump and block. Disconnect battery negative lead.19 Remove NOTE: To ease pump removal set engine to T. to depress pump plunger.10. Remove drive belt.Tdi VACUUM PUMP Service repair no . 4. finally tightening to 25 Nm. Note location of bracket for refitting. Disconnect battery negative lead. Connect vacuum hose and secure with clip. 5.D. Refit Refit 6. Reverse removal procedure.50.02 Remove 1.

........... 25 Flywheel housing ......................................................................... 7 Connecting rod to cap ..... 25 Oil drain pipe to block (external) ...... cylinder block ........ 13 Oil cooler unions to filter adaptor ....................................................................................... vacuum pump cam .............. 45 Engine mounting foot rubber to mounting foot (bolt and nut) ... 25 Engine mounting foot to cylinder block ............................................ 34 Flex drive plate to crankshaft (auto) ............................................................................................. rear ............................................................. Nm Engine block Bearing cap ...................... 17 Drain plug........................................................ 9 Oil pressure switch ...... 25 Drain plug................ 25 Camshaft thrust plate ..................................................................................................................................... 45 Waxstat adaptor to oil filter adaptor ................................................................................................................................ 85 Flywheel to crankshaft ......................... 133 Blanking plug.............................. 45 Flywheel housing clutch cover stud ............................................................................................................................................................................................................... TORQUE 1 .................................... 25 Flex drive plate to torque converter (auto) .................................. 45 SPECIFICATIONS.................... oil sump .................................................................................................................................................................. 25 Fuel lift pump ................... 12 Rear oil seal assembly ................................................................... 45 Oil level tube .............................................. 9 Oil pick up assembly to front cover .................................. 25 Baffle plate to breather side cover ....................................................................................... 25 Oil filter adaptor ........................................ 10 Plug............................................................................................... 14 Breather side cover assembly ............................. 146 Clutch cover plate to flywheel ........ 37 Oil squirt jet assembly ............................................ 25 Sump to cylinder block and front cover . 9 Oil drain pipe to block (internal) .................... 17 Oil filter.......... oil gallery.............................................................................................................................................. 85 Engine mounting foot to flywheel housing .............................................................................................................................................. flywheel housing .... 146 Flex drive plate to ring gear (auto) ...................................................................................... 59 Oil pick up assembly to bearing cap ............. spin on ......................................................................................................... 25 Oil squirt jet.................... 35 Tappet guide .....................................................................................................................................................................................Tdi TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque......................................................................... 4 Vacuum pump ..........................

.. 22 Water temperature sensor ........................................ 2 Injector clamp (stud) .............. 10 Static idler ............................................... inlet manifold .................................................................................................................................................... 45 Inlet manifold stud ............................................... 25 Water outlet elbow to thermostat housing . 45 Auxiliary mounting bracket to cylinder block (stud) ........... 25 Thermostat housing ........ 25 Water pump pulley to hub .......................................................................................................................................... 25 Front cover plate to front cover ... auxiliary drive (nut) .................................................................................. 8 Fuel injection pump (nut) .................................................................. 25 Fuel injection pump (stud) ..................................................................................................................................... 5 + 50° Rocker cover (stud) ..................................................................................................................... 25 Fan and viscous coupling to hub ........................................................................................................ 45 Camshaft hub bolt .. 20 Glow plug terminal nut .............................................................................................................................. 25 Support bracket injection pump to cylinder block ......................................................................................................... 25 Exhaust manifold stud ................. 25 Static idler ........... 25 Timing pulley to injection pump hub ............. inlet manifold ..... 14 Blanking plug......... 8 Inlet manifold nut and bolt .................................... 11 Plug thermostat housing .......................................................................................................................................................................................................... 10 Exhaust manifold nut ..................................................... 25 Abutment bracket to injection pump .................................. 9 Tappet adjusting nut ................................................................................................... TORQUE ........................................................................ 25 Water temperature switch............................................................. 80 Timing pulley to camshaft hub ....................................................................................................................................................................................... 25 2 SPECIFICATIONS......................... 16 Front cover to cylinder block ....................... 10 Breather cyclone to rocker cover ......................................................................................... 25 Fuel injection pump access plte to front cover plate ............... 80 + 90° Fan pulley to hub ..12 ENGINE Cylinder head Cylinder head to cylinder block ....... 14 Auto tensioner.......................................... auxiliary drive (stud) .... See repair section Stub pipe heater feed ................................................................................................................................... 45 Auto tensioner................................................................................................................. 14 Heatshield to inlet manifold .......................... 25 Air temperature sensor...................................................................... 6 Rocker shaft pedestal bolt ............................................................................................. 6 Glow plug .. 14 Blanking plug cylinder head ................................................................................................................................................................................. 25 Water pump to block and mounting plate .........................................timing belt (nut) .................. 8 Injector clamp (nut) ............................................. 14 Engine lifting brackets .... 45 Tensioner (timing belt) ........ 8 Rocker cover (fixing nut) ...................................................................................................................................................................................... 25 Electrical harness clip bracket .................................... 25 TV Damper pulley bolt to crankshaft ......... 8 Auxiliary mounting bracket to cylinder block (bolt and nut) ......................................timing belt (stud) .... thermostat housing .........................................................................................

..................... TORQUE 3 . 45 Belt tensioner assembly to front cover plate ............................................ 25 Sensors to water outlet elbow (air/con) ............................................... Turbocharger oil feed pipe to adaptor ................................................................. 4 Air conditioning compressor Compressor mounting bracket to front cover ................ 25 Blanking plug...................................................................................... Generator belt guard ........... rear of injection pump ................................................................................................. Oil drain pipe to turbocharger ................. water outlet elbow (air/con) ....................... Turbocharger oil drain pipe to adaptor .................................................................... 8 Compressor to mounting bracket (nut) ........... 25 Boost pipe injection pump (banjo bolt) ........................ 45 85 95 25 SPECIFICATIONS................................. 25 Idler pulley to front cover plate ................................................................ Generator to mounting bracket .................................................................................................................................................... 45 Tachometer electrical connection ...................................................................................................... 42 25 38 25 25 19 10 45 25 25 25 25 Fuel lift pump to filter (union) .. 25 Generator mounting bracket to front cover .................................Tdi Turbo charger oil drain adaptor to block ............................................................................................. EGR delivery tube to mixing tube ...................... 29 Spill rail to injectors (banjo bolt) .......................... Turbocharger to EGR valve ...... Turbocharger to cylinder head (stud) ..................... 29 PAS pump to mounting plate .............. Turbocharger oil feed pipe adaptor to block .............. 33 Fuel filter to fuel injection pump (banjo bolt) ............................... 15 Fuel filter from lift pump (banjo bolt) ................................................................................................. 25 Starter motor (bolt and nut) ..................................................................................................................................................................................................................................................................................................................................................... 45 Compressor belt guard (nut) ............................................ 25 Generator to auxiliaries mounting bracket ................. EGR delivery tube to valve ........................................................................................... 25 Belt tensioner pulley to tensioner arm ................. 45 Compressor to mounting bracket (stud) ......................................................................................... 25 PAS pump mounting plate to auxiliaries mounting bracket . Oil feed pipe to turbocharger ... Generator pulley to hub ......................................................... 25 PAS pump pulley to hub .............................................................................................................................................................................................................................. 33 Fuel injection pump from fuel filter (banjo bolt) ................. 10 Plug.............................. 10 Spill rail to injection pump (banjo bolt) ....................................................................................................................................... Turbocharger to blanking plate . Turbocharger to cylinder head (nut) ................ 25 Injector pipes to injectors and fuel injection pump .......................................

.................. 6 M6 ............................................................12 ENGINE METRIC Nm M5 ................................................................................................................................................................................................... 4 SPECIFICATIONS.................................................................... 24 3/8 ................................................................... 9 M8 ................................................................................................................................................................................................................................................................................ 90 5/8 ............... 90 M14 ................................................... 78 1/2 .......................................... 39 7/16 ............................................................................................................................ 136 NOTE: Torque values above are for all screws and bolts used except for those specified...................................................................................................................................... 180 UNC / UNF 1/4 ................................. 105 M16 ................................................................. 9 5/16 .......................... 45 M12 ................................................ 25 M10 ................................................................................. TORQUE .....

V8i DESCRIPTION The V8i engine has cast aluminium cylinder heads and cylinder block. economy and exhaust emissions are automatically correct for the demands of highway and off road operation. The electronic ignition distributor is driven by a gear off the front of the camshaft and the lubrication oil pump is driven by a gear off the front of the crankshaft. DESCRIPTION AND OPERATION 1 . The overhead inlet and exhaust valves are operated by rocker shafts. Multiport fuel injection ensures that engine performance. which drives the centrally located camshaft via a duplex type chain. pushrods and self adjusting hydraulic tappets. are set at 90°to one another. The three ringed aluminium pistons transmit the power through the connecting rods to a cast iron five bearing crankshaft. The two banks of steel cylinder liners which are pressed down to stops in the block.

20. 8. 5. shell and side seals Connecting rod caps Main bearing caps and shell bearings Oil filter Oil pump suction pipe/strainer Oil sump Oil sump drain plug Oil pump drive key 2 DESCRIPTION AND OPERATION . 24. 26. 4. 29. 19. 9. 3. 31. Crankshaft sprocket Crankshaft sprocket key Crankshaft Centre main bearing shells (2) Crankshaft rear oil seal Spacer Adaptor plate Rear main bearing cap. 28.12 ENGINE 1. 10. 11. 12. 22. 25. 18. 13. 15. Cylinder block Pistons and gudgeon pins (8) Connecting rods (8) Core plugs Camshaft Dipstick Camshaft key Timing chain Camshaft sprocket Distance piece Distributor drive gear Distributor Front cover Front cover oil seal Coolant pump Crankshaft damper / pulley 17. 6. 7. 27. 2. 23. 30. 14. 16. 21.

cap and collets (8) Exhaust valve seal. 7. 17. 3. 11. 19. 18. 20. 24. cap and collets (8) Inlet valve and seat (8) Exhaust valve and seat (8) Inlet manifold gasket and seals Cylinder head gaskets (2) Valve guides (16) DESCRIPTION AND OPERATION 3 . 12.V8i 1. Plenum chamber upper PCV air intake filter Oil filler Thermostat Thermostat cover Inlet valve seal. spring. 16. 23. 8. 22. 15. 14. Cylinder heads (2) Rocker covers (2) PCV filter Rocker shafts (2) Hydraulic tappets (8) Pushrods (8) Rocker brackets (8) Rocker arms (4) left and (4) right Rocker shaft springs (6) Inlet manifold Plenum chamber lower Ram pipes (8) 13. 5. 10. spring. 21. 9. 6. 2. 4.

before being distributed from the main gallery via drillings. Oil from cooler 4 DESCRIPTION AND OPERATION . warning light switch and filter are also fitted to the front cover. Lubrication to the thrust side of the cylinders is by oil grooves machined in each connecting rod big end joint face. is pumped under pressure through oil cooler located in the lower half of the main coolant radiator. which are timed to align with holes in the big end journals on the power and exhaust strokes. to the various components in the engine. The cooled oil then passes through the filter. Oil to cooler 2. Oil drawn through the centrally located steel gauze strainer in the sump. The oil pump gears are housed in the front cover and the pressure relief valve. Lubrication system 1.12 ENGINE Lubrication system The V8i full flow lubrication system uses a gear type oil pump which is driven from the front of the crankshaft.

It achieves its designed purpose by utilizing engine oil pressure to eliminate the mechanical clearance between the rockers and the valve stems. When the cam begins to lift the outer sleeve 7. causes the inner sleeve 3. DESCRIPTION AND OPERATION 5 . 2. 1. 3. the resistance of the cylinder valve spring felt through the pushrod seat 2. 6. engine oil pressure present in the upper chamber 4. key and spacer where it sprays onto the chain. The feed to the timing chain is channelled along the camshaft sprocket. 6. This slight downward movement of the inner sleeve closes the ball valve 5 and increases the hydraulic pressure in the high pressure chamber. Bearing Camshaft Key Camshaft timing chain sprocket Spacer Distributor drive gear Clip Pushrod seat Inner sleeve Upper chamber Non-return ball valve Spring Outer sleeve Lower chamber . Hydraulic tappets 1.high pressure The purpose of the hydraulic tappet is to provide maintenance free and quiet operation of the inlet and exhaust valves. As the tappet assembly moves off the peak of the cam the ball valve 5 opens to equalize the pressure in both chambers which ensures that the valve fully closes when the tappet is on the back of the cam. to move downwards inside the outer. 2. 5. passes through the non-return ball valve 5 and into the lower (high pressure) chamber 8. 8.V8i Distributor and timing chain lubrication The distributor and timing chain are lubricated from the camshaft front bearing. 7. During normal operation. sufficient to ensure that the push rod opens the valve fully. 4. 5. 3. 4.

crank engine until reading stabilises. 8.2-10. Start and run engine to normal operating temperature. battery fully charged: 8. 2. 3. throttle fully open. At a steady engine speed of 2500 rev/min engine oil pressure reading should be . 5. 2. 3.TEST Equipment: Compression pressure gauge Test 1.75 bar (40 lbf/in 2). Fit the test gauge. 7.5-12. 150-160lbf/in2 9. Expected readings. if test is being carried out in workshop.V8i ENGINE OIL PRESSURE TEST Service tools: LRT-12-052: Pressure test equipment WARNING: Use suitable exhaust extraction equipment.35:1 = 11. 6. Start and run engine until normal engine operating temperature is achieved (thermostat open). care must be taken when fitting equipment to prevent personal injury due to scalding. engine oil will be hot. Insert compression gauge. Disconnect battery negative lead.9 bar.2. Reconnect battery negative lead. Check lubricant is to correct level. Place vehicle on a ramp [hoist]. Test 1. 5.Remove and overhaul oil pump CYLINDER COMPRESSION .2 bar. Remove oil pressure switch. 4. 170-180lbf/in2 FAULT DIAGNOSIS 1 . Remove all spark plugs. If the pressure is low . Disconnect both coil negative (WB) leads 4.31:1 = 10. WARNING: If vehicle has been running.

Suspect faulty big end bearings.12 ENGINE ENGINE NOISES Excessive or obtrusive noise from the engine compartment originates from three main sources: A. light tapping noise. Engine internal mechanical noises which can vary in volume and pitch and may be a combination of. which makes an unmistakable and easy to diagnose noise. External components emit the greatest variety of noises. If noise is not conclusively diagnosed. FLUIDS AND CAPACITIES. Information. To confirm diagnosis. FLUIDS AND CAPACITIES. check the security of the flywheel and crankshaft front pulley.Top up to correct level. A faulty valve operating mechanism will emit a different noise when the feeler gauge is inserted. See LUBRICANTS.Continue. Description 1. Temporarily release the drive belt to reduce general noise level and use a stethoscope to locate source of noise. Description 1. Is the lubricating pressure correct? NO . Is the oil contaminated with metal particles? YES . particularly when engine is cold. remove the rocker covers and with the engine idling.Suspect faulty main bearings. 2. but are also easy to diagnose by simply removing the drive belt. insert a feeler gauge of 0. Recommended Lubricants and Fluids YES .Top up to correct level. Heavy rumbling noise (particularly during hard acceleration). Engine internal mechanical noises. 2. See LUBRICANTS. 3. 1. B. Recommended Lubricants and Fluids YES . Is engine oil level correct? NO . Temporarily release the drive belt to reduce general noise level and use a stethoscope to locate source of noise.Top up to correct level. C.015mm between each rocker and valve stem.Continue. tapping . short out the ignition to each spark plug in turn. See Description and operation.Drain engine oil and filter. 2. and examine for metallic contamination. FLUIDS AND CAPACITIES. Is the lubricating pressure correct? NO . Information. are the most difficult to diagnose.Suspect valve operating mechanism. Description 2 FAULT DIAGNOSIS . The exhaust system. Rocker Shaft Renew Heavy knocking noise (particularly on load and when engine is hot).See Engine Oil Pressure Test YES . To confirm diagnosis. See Description and operation. See Description and operation. 3. The following is therefore a guide to diagnosis of engine internal mechanical noises only. Is engine oil level correct? NO . 4. Recommended Lubricants and Fluids YES . Is the oil contaminated with metal particles? YES . and examine for metallic contamination. See LUBRICANTS. Information. Single or multiple.Drain engine oil and filter. check the security of the flywheel and crankshaft front pulley.See Engine Oil Pressure Test YES . 3. See Repair. The noise will disappear or be reduced when the cylinder with the faulty big end is shorted out.See Engine Oil Pressure Test YES . Is the lubricating pressure correct? NO .knocking or rumbling. If noise is not conclusively diagnosed. Is engine oil level correct? NO .Continue.

See ELECTRICAL.V8i Check brake vacuum connections. Repair. Fuel pump and Sender Unit See EMISSION CONTROL.See INTRODUCTION.See Electrical Trouble Shooting Manual. Emission Control If problem is not diagnosed repeat tests.V8i ENGINE STARTING PROBLEMS Engine fails to crank in park or neutral (Automatic Transmission) 1. Is throttle travel restricted or cable incorrectly adjusted? YES . Is battery in good state of charge? NO . See BRAKES. Repair.See INTRODUCTION.V8i YES . Repair. Are HT leads correctly routed and clipped? NO . starting at 2. YES .V8i See Electrical Trouble Shooting Manual. Jump Starting YES . ventilation and emission control systems in correct working order or the fuel contaminated? NO . Is battery in good state of charge? NO . Distributor . Throttle Cable See FUEL SYSTEM. tank.See Electrical Trouble Shooting Manual. Repair. starting at 1. See Electrical Trouble Shooting Manual. Repair.See ELECTRICAL. Heating and Ventilation Unit If problem is not diagnosed continue.See FUEL SYSTEM. Lucas Constant Energy Ignition System . See HEATING AND VENTILATION. ventilation and emission control systems in correct working order or the fuel contaminated? NO .See INTRODUCTION.See Electrical Trouble Shooting Manual.V8i See ELECTRICAL. Fault diagnosis. Fuel Tank See FUEL SYSTEM. If problem is not diagnosed repeat tests. Are the fuel supply. Fault diagnosis. Brake Servo Unit Check heater/ventilation unit vacuum connections. Are the Ignition and Multiport Fuel Injection systems in order? NO . Repair. Engine cranks but fails to start 1. Accelerator Pedal NO . Fuel Pump and Sender Unit See EMISSION CONTROL. Is fuel supply. Fuel Tank See FUEL SYSTEM.V8i YES . Jump Starting YES . Description and operation. Description and operation. Is there combustion in any cylinder? NO . Engine lacks power/poor performance 1. Repair. starting at 1. tank. FAULT DIAGNOSIS 3 . pump.Continue. Repair. Fuel Filter See FUEL SYSTEM. Repair. Emission control If problem is not diagnosed repeat tests. 2. 3. Distributor .See FUEL SYSTEM. Information. Information.Continue. Is the cranking speed fast enough (120 rpm)? NO . Description and operation.Continue. Fuel Filter See FUEL SYSTEM.See ELECTRICAL.See AUTOMATIC GEARBOX. NO . 3. Lucas Constant Energy Ignition System . Engine fails to crank (Manual Transmission) 1. Multiport fuel injection. Is automatic transmission inhibitor switch faulty or gear selection linkage incorrectly adjusted? YES . Repair. Repair. Fault diagnosis. If problem is not diagnosed repeat tests. Jump Starting If necessary also.Continue. ENGINE RUNNING PROBLEMS Engine runs at high speed but will not idle (stops) Engine idle speed erratic Engine starts but stops immediately Engine stalls Engine misfires/hesitation 1. See Electrical Trouble Shooting Manual. 2. Inhibitor Switch .Continue.A1 See ELECTRICAL. Lucas Constant Energy Ignition System . Information. 2. 2.Check thickness of carpets. pump. See FUEL SYSTEM. Description and operation.Continue. YES . starting at 1.

Test See Repair.Renew YES . See HEATING AND VENTILATION.See Repair. Distributor .V8i YES . See Cylinder Compression . 3. Is distributor fitted correctly. If problem is not diagnosed: repeat tests starting at 1. Description and operation. Fuel Tank See FUEL SYSTEM.Suspect valves held open by hydraulic tappets due to high oil pressure.Carry out cylinder compression tests to determine condition of head gaskets and valves. See BRAKES.Remove oil filter and cooler adaptor and check pressure relief valve strainer gauze for blockage and that the relief valve is not stuck closed.Investigate cause of binding. Description and operation. Repair. Exhaust System Complete NO .Carry out compression test to check for leaking gaskets valves etc. Description and operation. Repair. 4 FAULT DIAGNOSIS .12 ENGINE 3. 7. HT leads in correct firing order and routed correctly? NO . Description NO . See EMISSION CONTROL. See BRAKES. tank.Check brake vacuum connections.Continue. Automatic Transmission only. Description and operation. Cylinder Heads . Is oil pressure high? YES . Are cylinder compressions satisfactory? NO .Renew If problem is not diagnosed: repeat tests starting at 1.Continue.See ELECTRICAL.Continue. Emission Control YES . Are there any leaking joints/connections or holes in the exhaust system? YES . Fuel Filter See FUEL SYSTEM. Are cylinder compressions satisfactory? NO . Brake Servo Unit Check heater/ventilation unit vacuum connections. Are the brakes binding? YES . Are fuel supply. Static tests and Stall tests to determine condition of Automatic transmission. See Electrical Trouble Shooting Manual. Repair. Check brake vacuum connections. 4. Is the Torque Converter and Transmission operating correctly? Carry out Road test.See MANIFOLD AND EXHAUST SYSTEM. pump. See HEATING AND VENTILATION. 2. See Description and operation. Repair. Heating and Ventilation Unit Check the crank case and fuel tank ventilation system. Fuel Pump and Sender Unit YES . NO .Continue.See FUEL SYSTEM. See Cylinder Compression Test 5. See Engine Oil Pressure Test 4. Cylinder Heads . Brake Servo Unit Check heater/ventilation unit vacuum connections.Check multiport fuel injection. Engine backfires into exhaust system 1. Description and operation. Heating and Ventilation Unit If problem is not diagnosed: Continue. ventilation and emission control systems in correct working order or the fuel contaminated? NO . Repair. 6. Is air fuel ratio correct? NO .

3. Description and operation. Are cylinder compressions satisfactory? NO . Description and operation. Check brake vacuum connections.Test For repair See Repair.Continue.V8i Engine backfires into inlet system 1. Description and operation.Continue. Is air fuel ratio correct? NO . Brake Servo Unit Check heater/ventilation unit vacuum connections. HT connections and routing correct? NO .Check multiport fuel injection. Emission Control YES . 2. Is the Distributor. See Cylinder Compression . Distributor . Heating and Ventilation Unit Check the crank case and fuel tank ventilation system. See BRAKES.See ELECTRICAL. Repair.Carry out compression test to check for leaking gaskets valves etc. Cylinder Heads Renew If problem is not diagnosed: repeat tests starting at 1. See EMISSION CONTROL. See Electrical Trouble Shooting Manual. See HEATING AND VENTILATION. FAULT DIAGNOSIS 5 .V8i YES .

86. It is essential that the belt is fitted exactly as shown in illustrations RR3956 and RR3957. 75.000 kilometres. It should also be noted that the water pump/viscous fan is driven in a counter clockwise direction. reposition belt correctly. Turning the tensioner pulley in a clockwise direction will release drive belt tension.03 Air conditioning Non air conditioning REPAIR 1 . splitting or oil contamination. A drive belt tensioner automatically tensions the drive belt.000 miles or five years whichever occurs first. Under normal highway use the belt must be changed at 120. This belt drives the water pump and all the ancilliaries.V8i DRIVE BELT A single ’serpentine drive belt’ is introduced for 1995 model year. Off road driving Regular examination of the drive belt is essential if the vehicle is used off road. After every off road session the owner should inspect the belt for cuts and possible damage caused by stones. A new belt must be fitted at the next service or before. eliminating the need for tensioning individual drive belts. The vehicle driver should be requested to identify the type of mileage the vehicle has covered. Check condition Check condition of drive belt. dependant on the type of damage sustained. If belt has jumped.10. Renew a belt that shows signs of wear. The drive belt must be examined at every service and replaced if necessary. Fan cowl To ensure easy access to the drive belt the top portion of the fan cowl is detachable. DRIVE BELT RENEW Service repair no .

12 Remove ENGINE DRIVE BELT . Position belt correctly around all pulleys except generator. 2 REPAIR . The checks should be made at the same point on the belt. If the drive belt is believed to be slack carry out the following checks: 1. Visually check drive belt tension. With tension released. 270N. check belt tension several times. Remove drive belt. Turn drive belt tensioner clockwise. See Drive Belt Tensioner 3. 5. Release tensioner pulley. Ensure drive belt is squarely located on pulleys with all grooves engaged. 2. 10. Mark direction of rotation on belt if refitting Refit 6. 5 mm ’bounce’ is normal. Locate drive belt on generator pulley. 11. with used tensioner and used drive belt should be more than:- 1. 4. Non air conditioning or 295N with air conditioning. Clean drive belt pulley grooves and ensure grooves are not damaged. no tension check or adjustment should be necessary. 8. Drive belt tension. If tensioner movement is 12 mm or more. Inspect tensioner. 3. running engine between checks. 2. fit a new tensioner. Using a recognised drive belt tensioning gauge. Watch movement of tensioner with engine running. Release drive belt tension by turning tensioner clockwise. away from the tensioner.CHECK TENSION As the drive belt is automatically tensioned. Is the tensioner arm and spring case in contact? If so fit a new tensioner. 7. 12. 4. 9. Release tensioner to tension drive belt. Remove fan cowl upper. remove belt from generator pulley. Fit upper fan cowl section. Illustrations RR3956 and RR3957 show correct drive belt run.

Loosen tensioner centre bolt. Reverse removal procedure.09 Remove 1. REPAIR 3 . Refit 4. See Drive Belt Renew 2. Remove bolt and tensioner. 3.86.V8i DRIVE BELT TENSIONER Service repair no . Remove drive belt from tensioner.10.

Repair. word TOP uppermost. Remove ground leads from rear of left hand cylinder head 11. 4. See FUEL SYSTEM. Repair. Remove air cleaner assembly. Remove air flow sensor. arrow points to front of vehicle. Intake Manifold 3. 4. See Rocker Shaft Renew 6. 96 mm long bolts .01 1. Oil cylinder bores. 14. Remove cylinder head gaskets. 18. 1 to 11. shown to 20 Nm then a further 180° ± 5° 23. 7. Adjustment. 3. See COOLING SYSTEM. 17. Repair. Air Cleaner Assembly 9. 22. If fitted. Repair.RENEW Service repair no .12. DO NOT use sealant. Remove rocker shafts. NOTE: Left hand cylinder head illustrated. Fit new cylinder head gaskets. 6. Remove inlet manifold. 9. Locate cylinder head bolts in position illustrated. 20. See MANIFOLD AND EXHAUST SYSTEM. 21.V8i 8. Right hand cylinder head . 16.29. reversing tightening sequence. Locate cylinder heads on block. Remove push rods. 10 66 mm long bolts . 4 REPAIR . 12. Compressor 5. See FUEL SYSTEM.12 ENGINE CYLINDER HEAD GASKETS . Air Flow Sensor 10. 8. Coolant 2. Loosen cylinder head bolts. Exhaust Manifold . Reverse removal procedure. remove compressor. Tighten bolts progressively in sequence.remove breather pipe from lifting bracket. 5 NOTE: There are no bolts fitted in the four lower holes in each cylinder head. Remove generator. Clean exhaust mating faces. Remove cylinder heads. Remove both exhaust manifolds.2. 15. See FUEL SYSTEM. Clean threads of head bolts and lightly oil. Drain cooling system. Clean head and block faces. Repair. 7. See AIR CONDITIONING.1. 19. 13.

Remove plug lead retaining clips from rocker cover.41 1. 6. It must be fitted accurately. Subsequent movement will destroy bonding. 5. Remove spark plug leads from plugs and retaining clips. fit to new rocker cover.RENEW Service repair no . Disconnect purge pipe from charcoal canister at plenum.12. remove rear lifting bracket. springs. Disconnect battery negative lead. CAUTION: Keep components in fitted order ROCKER COVER . 9. compress springs. Fit cylinder heads with new gaskets.Renew 10. Remove three bolts securing power steering pump mounting bracket to cylinder head. 4. Remove four rocker cover bolts. Fit mounting brackets and earth lead studs to new cylinder head. Remove breather pipe from rocker cover. springs and caps. See Cylinder Head Gaskets . fit valves. REPAIR 5 . Remove coolant pipes from inlet manifold. Tap valve to check correct collet seating. Using spring compressor LRT-12-034. 3. See Cylinder Head Gaskets . Using spring compressor LRT-12-034. Remove four bolts securing generator mounting bracket to cylinder head. 5. Remove cylinder heads and gaskets.29. and caps. Right hand cylinder head. Allow adhesive to become touch dry. Apply Bostik 1775 impact adhesive to rocker cover seal face and gasket. 7. 6. Lubricate valve stems. 3.Renew 2. 9. fit collets. Fit spark plugs. Remove spark plugs. Clean and dry rocker cover and cylinder head mating faces.RIGHT HAND . 4. 10. NOTE: Gasket fits one way round only. Regrind valves. using a brush to ensure an even film. 7.29. first time. 14. 8.15 1. Fit lifting bracket to new right hand cylinder head. 12. valves. From left hand cylinder head.refer to engine overhaul publication 11. Discard rocker cover gasket. 2. using Bostik cleaner 6001. Fit new inlet and exhaust valve stem seals.12. Tighten bolts to 30 Nm. remove seals.V8i CYLINDER HEADS .RENEW Service repair no . Moving fuel pipes aside. remove earth lead studs. collets. 13. remove rocker cover. 8.

Disconnect HT lead from coil.40 1. 12. Remove spark plug leads from plugs and retaining clips. Fit air flow meter. Allow cover to stand for thirty minutes before fitting. 8. Clean and dry rocker cover and cylinder head mating faces. 18. Connect spark plug leads to plugs and retaining clips. 20. Remove generator heat shield securing nut from rocker cover. Fit spark plug leads to plugs and retaining clips. 7. 13. Remove plenum chamber. Fit generator heat shield to rocker cover. Remove dipstick. 17. 19. Tighten to 9 Nm. pressing gasket into place ensuring edge firmly contacts recess wall. 16. Remove air flow meter harness clip. Discard gasket 11. tighten clip. 15. holding remainder of gasket clear. 14. Fit plenum chamber. 4. Fit breather pipe to rocker cover. tighten to 9 Nm. Remove air flow sensor. 9. 24. using a brush to ensure an even film.12. Remove bolt securing dipstick tube clip. remove rocker cover. See FUEL SYSTEM. Allow adhesive to become touch dry. See FUEL SYSTEM. 5. 18. 22. Position fuel pipes. 21. Fit rocker cover to cylinder head with four screws. Connect HT lead to coil. Fit rocker cover to cylinder head with four screws. NOTE: Gasket fits one way round only. Fit dipstick.29. Place one end of gasket into cover recess with edge firmly against recess wall. Connect purge pipe from charcoal canister at plenum. Air Flow Sensor 2. 13. Repair. short screws inboard. Fit and tighten air flow meter harness clip. approximately fifteen minutes. Fit coolant pipes to inlet manifold. first time. Subsequent movement will destroy bonding. Plenum Chamber 3. Apply Bostik 1775 impact adhesive to rocker cover seal face and gasket. 14. Work around cover. 16. Position dipstick tube clip. Fit and tighten bolts. ROCKER COVER . Remove plug lead retaining clips from rocker cover.RENEW Service repair no . tighten bolts. Allow cover to stand for thirty minutes before fitting. 17. 6. Repair. It must be fitted accurately. 10. short screws inboard.12 ENGINE 11. Remove four rocker cover bolts. pressing gasket into place ensuring edge firmly contacts recess wall. using Bostik cleaner 6001. Work around cover. Place one end of gasket into cover recess with edge firmly against recess wall. tighten clip. 15. 12.LEFT HAND . 6 REPAIR . 23. fit to new rocker cover. holding remainder of gasket clear.

57 1. retain in removal sequence.29.29 1. See Rocker Cover . Remove intake manifold. See FUEL SYSTEM. Remove push rods. Remove rocker covers as required. Repair. Loosen four rocker shaft fixings.Left Hand . Remove rocker shafts. 7. 5. See Rocker Shaft Renew 2. NOTE: Each rocker shaft is notched at ONE end.29. See V8i Overhaul Manual. Remove hydraulic tappets 5. towards rear on left hand side. Reverse removal procedure.V8i ROCKER SHAFT RENEW Service repair no . 4. REPAIR 7 . Tighten rocker shaft fixings to 38 Nm.Right Hand .Renew 2. Intake Manifold 3.12. push rods and rocker assemblies. 6.Renew or. Fit inlet manifold. 4. Fit rocker covers. Notch must be uppermost and towards front of engine on right hand side. Fit rocker shaft assembly. 6. 7. Clean rocker pedestal locations on cylinder head. locating push rods to rockers.12. See Rocker Cover . HYDRAULIC TAPPETS RENEW Service repair no . 3. Remove rocker shaft assembly. Fit tappets.

With assistance to stop flywheel rotation. 12. See Drive Belt 3. Raise vehicle on ramp [hoist]. Repair. If required: Place assembly in vice and remove pulley. 13. Fit crankshaft pulley assembly. Remove eight screws and remove mud excluder. 8 REPAIR . 7. Fit adaptor 18G1291/5 to 18G1291/4. 12. 2. 4. See COOLING SYSTEM. 8. 11. Remove drive belt. 8. fit extractor to seal. Fit pulley assembly. See Crankshaft Pulley Assembly. 15. Remove seal from extractor. Lubricate seal face of assembly. 10. Fan Blades. 9. Fit button of 18G1328 to crankshaft. Fit tool to seal. Clean seal seating. 6. remove crankshaft pulley assembly retaining bolt.RENEW Service repair no . 3. Turn centre bolt of extractor to remove seal. Tighten to 280 Nm. With assistance to stop flywheel rotation. Fit mud excluder and tighten screws.12. tighten centre locknut to seat seal. Fit pulley to torsional vibration damper. Reverse removal procedure. 10. Slacken locknut and remove tool. 14. Remove viscous coupling. 5. 7. Remove engine undertray.12. Do not remove pulleys. Fit and tighten centre bolt to crankshaft. Remove crankshaft pulley.21. Pulley and Fan Cowl 2. Locate seal in front cover. 11. FRONT COVER OIL SEAL .21. 1 to 5. Lubricate seal lip. Lubricate outside diameter of seal. 4. 13.12 ENGINE CRANKSHAFT PULLEY ASSEMBLY Service repair no . 5.14 1. 6. Remove crankshaft pulley assembly. Viscous Coupling. fit retaining bolt. 9.01 1. Remove bell housing bottom cover.

Fit power steering pump to bracket. 21. Remove water pump bottom hose. 39. Connect vacuum pipe to distributor.V8i FRONT COVER GASKET Service repair no . 18. 50. 38. 1 piston is at T. 15. Fit distributor in position marked. Fit timing cover. Tighten to 28 Nm. 30. clean block face. Remove power steering pump bracket from water pump. 28. apply Loctite 372 to threads. Remove clips securing wiring to generator tensioner. 5. Disconnect distributor feed wire. 11. 9. Refill cooling system.V8i 20. 48. Tighten to 28 Nm. Clean timing cover. Clip distributor cap in position. Remove front cover gasket. Place cap and leads to one side. 36. Fit new gasket to block face. 6. Refit 25. 51. 32. Fit power steering pump bracket to water pump. 26. 46. 44. 42. Check ignition timing. Mark distributor position to front cover. Connect heater hose. See Crankshaft Pulley Assembly. Disconnect vacuum pipe from distributor. fit fixing bolts. Fit generator support strut to front cover. Fit water pump pulley. 8. See ELECTRICAL. move strut aside. Repair. 7. Release plug leads from plugs and clips. Distributor . 27. Lubricate distributor O ring.C. remove distributor. Apply hylosil to sump gasket. Loosen four adjacent sump fixings. Connect wire ties to generator tensioner. Lightly grease gasket faces.12. 54. Fit crankshaft pulley. 53. 12. 29. 40.65. Clean threads of cover fixing bolts. 16. 41. Connect distributor feed wire. Remove crankshaft pulley. Turn engine until No. Locate generator tensioner on water pump bracket. Remove distributor clamp. 34. REPAIR 9 . 10. Fit distributor clamp. Remove fixings sump to front cover. 47. 23. 31. 14. Remove water pump pulley. Align oil pump drive. Tighten to 20 Nm. Do not remove pulleys 2. 45. Connect bottom hose. Connect oil pressure switch. Loosen power steering pump pivot.D. 37. Fit plug leads to plugs and clips. lower pump. Position distributor cap. 43. Remove generator tensioner from water pump. Tighten to 10 Nm. Pivot power steering pump away from front cover. move tensioner aside. Tighten sump to timing cover fixings to 10 Nm. Tighten sump fixings to 10 Nm. Remove generator support strut from front cover. 13. Check position of rotor arm. See Crankshaft Pulley Assembly Tension drive belts correctly. Loosen remaining front cover fixings and remove front cover. 24. Disconnect oil pressure switch. 19. 33. 3. tighten clip. tighten clip. 22. 35. Release distributor cap clips. Disconnect heater hose at water pump. tighten pivot to retain in position. 4. if distributor does not seat correctly. 49. 17.04 1. Remove fixings securing power steering pump bracket to water pump bracket. 52.

Remove gearbox and clutch. Repair. Check alignment of timing marks with straight edge. See Front Cover Gasket FLYWHEEL Service repair no . ensure chain wheels are fully located. Fit flywheel.07 Remove 1. 7. 6.53. See V8i Overhaul Manual. 7. Tighten to 58 Nm. Ensure number one piston is at TDC. 4. 11. 13. 9. 12. 5. Loosen starter motor bolts. Remove chainwheels and chain as an assembly.12 Remove 1. fit flywheel bolts. See CLUTCH. 3. Clean components for reassembly. Lock flywheel. 10. Lock flywheel. Fit retaining bolt and washer.12. apply Loctite 270 to threads. Fit distributor drive gear with groove towards spacer. aligning timing marks. Refit 4. Fit front cover. Clean chainwheels and chain. Fit spacer with flange to front. remove flywheel bolts and flywheel. Engage chainwheel assembly on camshaft and crankshaft keys. Remove retaining bolt and washer.12 ENGINE TIMING CHAIN AND CHAINWHEELS Service repair no . 10 REPAIR . See Front Cover Gasket 2. 8. Remove front cover. Tighten to 80 Nm. Clutch Assembly 2. Ensure camshaft key is fitted parallel to shaft axis to ensure adequate lubrication to distributor drive gear. Clean threads.65. Fit chainwheels to chain. Refit 5. remove distributor drive gear and spacer.12. 6. 3.

21. See Flexible Drive Plate and Ring Gear OR manual transmission. 8.V8i 2.12. Fit bearing cap. Apply Hylomar SQ32M to block as illustrated. Remove flexible drive plate and ring gear assembly. Fit transmission. Clean main bearing cap and oil seal area of block. See Oil Sump Remove rear main bearing cap. 9. 6. CRANKSHAFT REAR OIL SEAL Service repair no . Clean all components for reassembly. 10. 5. REPAIR 11 . 4. Remove crankshaft rear oil seal. do not tighten bolts.53.20 1. 2. See AUTOMATIC GEARBOX.V8i FLEXIBLE DRIVE PLATE AND RING GEAR Service repair no . Lubricate bearing shell and cross seals using clean engine oil. Repair. Fit ring gear and flexible drive plate assembly. 4. Refit 3. 5. Remove cross seals from cap. remove flywheel. 7. 3. Ensure cap is fully home and seated squarely on the block. Fit new cross seals to bearing cap. remove drive plate. 11. Remove transmission. See Flywheel Remove sump. See V8i Overhaul Manual. See V8i Overhaul Manual. Automatic transmission.12. LT230T Transfer Gearbox with Automatic Gearbox Assembly .13 Remove 1.

lipped side towards engine. Remove Generator. Ensure service tools LRT-12-010 and LRT-12-091 are scrupulously clean. Repair. Position oil seal guide LRT-12-010 on crankshaft flange.12 ENGINE ENGINE Service repair no . Fit sump. 12 REPAIR . Repair. NOTE: Lubricant coating must cover seal guide outer surface completely to ensure that oil seal lip is not turned back during assembly.41. on seal guide. See FUEL SYSTEM. See AIR CONDITIONING. See CHASSIS AND BODY. See FUEL SYSTEM. check it is not damaged. See ELECTRICAL. Position oil seal. 10. Battery 5. Repair. Remove vacuum hose from rear of regulator. Park vehicle on level ground and apply park brake. Depressurising Fuel System 3. Description and operation. Air Flow Sensor 12.12. DO NOT discharge air conditioning system. See FUEL SYSTEM. Remove feed hose from rail. Repair. 16. 8. Place an absorbent cloth around fuel feed hose at fuel rail and release compression nut. Plenum Chamber DO NOT DISTURB KICK DOWN CABLE SETTING. Repair. Manual vehicles: Disconnect throttle cable from bracket. Remove air cleaner assembly. Air Cleaner Assembly 13. Repair. De-pressurise fuel system. Remove battery. Remove radiator/oil coolers. Repair. See FUEL SYSTEM. Remove seal guide. Automatic vehicles: Detach throttle bracket from plenum chamber and lay assembly to one side. Radiator/Oil Coolers 6. See FUEL SYSTEM. 14. Remove ram housing. Seal outside diameter MUST be clean and dry. Fit flywheel or flexible drive plate and ring gear. Ensure outside diameter remains clean and dry. 13. Coat seal guide and oil seal journal with clean engine oil. Tighten rear main bearing cap to 90 Nm. See ELECTRICAL. Fit oil seal using tool LRT-12-091. Generator 14. 15. Bonnet [Hood] 4. Compressor 12. Remove bonnet [hood]. 17. Remove air flow sensor. seal end of pipes with masking tape to prevent ingress of dirt. 7. Release air conditioning compressor from its mounting and lay to one side. Repair. 9. 2. CAUTION: Do not handle oilseal lip. seal both openings with masking tape to prevent ingress of dirt. See COOLING SYSTEM. Release fuel return hose clamp and remove hose from pressure regulator. Repair. Ram Housing 11.01 Remove 1.

30. 28. Manoeuvre harness from behind fuel rails and place to one side clear of engine assembly. 34. NOTE: Instructions 37. and withdraw rubber mountings. R/H Rear chain 457mm total overall length. 38 and 39 refer to automatic vehicles only. Lower hoist until engine rests securely on engine mounting brackets. 2. if fitted. Seal hose and pump openings with masking tape to prevent ingress of dirt. 18. Place drain tray underneath vehicle. Mark one access hole and one bolt hole to ensure unit is reassembled in its original position 38. Remove gasket from bell housing face. Fit chain lifting eye to a suitable engine hoist. Leave lifting eye attached until engine is reinstalled in vehicle. Disconnect multi-plug from oil level sensor on side of sump. Fit lifting chains to engine lifting eyes as shown in illustration RR1780E. 31. 3. NOTE: All chain dimensions are measured from end of lifting hook to end of last link in chain. With assistance rotate engine at crankshaft pulley until two access holes in drive plate/ring gear assembly are visible. 17. 22. remove heat shield from right hand side downpipe. Secure hose end above level of fluid reservoir to avoid unnecessary loss of fluid. 26. Rotate crankshaft 180˚ until two remaining access holes are visible. Remove electrical leads from starter motor solenoid. Wipe away any fluid spillage from chassis or steering box. DO NOT remove from retaining clip. Disconnect power steering pump to power steering box hose. 36. 29. 37. Remove bell housing bottom cover. Remove ground strap from rear of left hand cylinder head. Remove top two bolts securing bell housing to cylinder block.V8i NOTE: Release bolts securing compressor mounting bracket to engine and remove bracket to enable temporary lifting eye ETC 5964 to be fitted. pitch and thread. 20. Disconnect two heater hoses located on top of right hand rocker cover. L/H Front chain 356mm total overall length. R/H Front chain 330mm total overall length. Remove engine mounting fixings on both sides of cylinder block. 19. Raise front of vehicle. Remove transmission breather pipes from retaining clip on rear lifting eye. Disconnect fuel temperature and coolant temperature sensor multi-plugs. REPAIR 13 . Disconnect hose from reservoir to power steering pump. 23. Remove all electrical harnesses from retaining clips at rear of engine. Secure lifting eye to mounting bracket fixing points with suitable bolts of equivalent size. lower vehicle on to axle stands. Remove two clamps securing gearbox oil cooler pipes to engine block. Remove lifting chains and hoist. 21. 33. 27. 24. Raise hoist high enough to enable engine mountings to be removed. Remove nuts securing exhaust downpipes to manifolds. 25. Disconnect leads from coil. 1. 16. Identify each injector multi-plug for re-assembly and disconnect plugs from injectors. Remove two bolts visible through access holes. 32. 35. remove two bolts. 15.

42. Position hydraulic trolley jack under bell housing to support gearbox when engine and gearbox are separated. 57. Fit two bolts and partially tighten. 41. rotate crankshaft pulley. 51. 52. 50. ensuring that all electrical plugs and harnesses are fitted in correct locations. Remove starter motor ground strap from chassis. Fit new exhaust flange gaskets. 44. 45. tighten bolts to 9 Nm. Remove remaining bell housing to cylinder block bolts. Slowly raise engine clear of engine compartment. fit exhaust to manifold. 54. tighten nuts to 20 Nm. 43. Carefully raise hoist a little. Tighten to 40 Nm. Raise engine using hoist. 59. Ensure no components remain that will prevent engine being removed. Tighten to 40 Nm. Refit all harnesses. ground straps breather pipes and hoses at rear of engine. 40. Refit 46. Raise engine and refit engine mounting rubbers. 53. Remove jack and lower hoist until engine rests securely on engine mounting brackets. 58. 47. 55. 48. steady engine on hoist. Fit lifting chains to engine. Fit two bolts. 14 REPAIR . Fit lifting chains to engine. 56. 49. Ensure all components are clear of engine assembly. Fit remaining bell housing to cylinder block bolts. Engage bell housing dowels. Automatic vehicles: With assistance. Fit new gasket and refit bottom cover. Lower engine into engine compartment. Fit top two bell housing securing bolts. manoeuvre engine until bottom two engine and bellhousing bolt holes align. Locate primary pinion into clutch. Manual vehicles: Lower engine into position. Ensure that two cylinder block dowels locate in bell housing. Remove stands and lower vehicle. Move engine away from vehicle and place on a suitable engine stand. Remove temporary lifting eye ETC 5964 and reverse instructions 1 to 23. Automatic vehicles: With assistance. Rotate crankshaft 180°and fit remaining two bolts tighten to correct torque. line up marked holes in drive plate and torque converter. 40 Nm. ease engine and gearbox apart. Tighten to 40 Nm.12 ENGINE 39.

Remove bolt securing dipstick tube to rocker cover. 3. cylinder block and front cover. Tighten bolts progressively in sequence shown. Position sump. REPAIR 15 . 9. 10. Degrease mating surfaces of sump.V8i OIL SUMP Service repair no . 4. tighten bolts finger tight. 11. Fit bolt securing dipstick tube to rocker cover. connect low oil level sensor multiplug. progressively loosen and remove 17 bolts securing sump.12. cylinder block and front cover. If fitted. Tighten to 18 Nm. 5. Apply RTV Hylosil White sealant to mating surface of sump. Maintenance. 7. Under Vehicle Maintenance 2. disconnect low oil level sensor multiplug. Refit 8. Remove all traces of sealant from mating surfaces of sump.60. Working form the centre outwards. Tighten to 40 Nm. using a suitable solvent or plastic scraper. Fit drain plug. 12.44 Remove 1. 6. Drain engine oil See SECTION 10. Remove sump. If fitted.

................ 78 1/2 ............. 90 M14 .......... 136 NOTE: Torque values above are for all screws and bolts used except for those specified.................................................................................................................. 21 Starter motor attachment ........................................... 39 7/16 ........... 45 M12 .......................... 78 ** Lifting eye to cylinder heads ......................................................................................................................................................... 40 Oil sump to cylinder block ..................................................................................................................... 41 ** Flywheel to crankshaft bolts .................................................................................................................Further 180° ± 5° Drive plate to converter ............................................................................................... ** These bolts must have threads coated in sealant Loctite 270 METRIC Nm M5 ............ 25 M10 ................................................................................................................................................................................................. 24 3/8 .................... Nm Engine Adaptor plate to crankshaft ... 9 5/16 . 38 Spark plug .......................................................................................................................................................... 44 * These bolts must have threads coated in lubricant EXP16A before assembly.................................................................................................................... 20 Stage 2: ........... 92 * Oil sump drain plug .......................................................................................................................... 55 Engine mounting rubbers to brackets ........................................................................................................................................................... 90 5/8 ......................................................... 39 Engine mountings to engine and chassis ................................................................................ 9 M8 .............................................................................................................................................................................................................. 39 Main bearing cap rear bolts ..................... 84 Generator and power steering mounting bracket to cylinder head ................................ TORQUE 1 ............................................................................................................... 18 Rocker cover to cylinder head ............................... SPECIFICATIONS......................................................................................... 105 M16 ................................................................................................. 6 M6 ....... 30 Flexible drive plate to crankshaft adaptor plate ........................... 30 Cylinder head: Stage 1: ................................ 180 UNC / UNF 1/4 ........... 9 Rocker shaft bracket to cylinder head ..V8i TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque............................................................................

V8i ENGINE LRT-12-034 MS1519A Spring compressor LRT-12-010 RO1014 Crankshaft rear seal guide LRT-12-052 Oil pressure test kit SERVICE TOOLS 1 .

0 V8 DESCRIPTION For description and operation refer to overhaul manual 4.0 V8 engines appear in the repair sub-section of this section. DESCRIPTION AND OPERATION 1 . CONTENT OF THIS SECTION Only service repair operations not covered in engine section V8i or unique to 4.6 V8 engine.4.0/4.

22. Tighten to 10 Nm.01 . Ensure mating faces between water pump pulley and pump are clean. Viscous Coupling. REPAIR 1 . NOTE: It will be necessary to have an assistant position a large flat ended screwdriver between ring gear and adaptor plate to prevent ring gear rotating. Collect pulley and tool. See COOLING SYSTEM. Refit water pump pulley. Refit cooling fan. Reconnect battery negative lead.9 V8. Refit crankshaft pulley bolt. Ensure mating faces between bell housing access cover and mating face are clean. Repair. Fit drive belt. Viscous Coupling. Raise and support front of vehicle.0 V8 CRANKSHAFT PULLEY Service repair no . Repair. Tighten water pump pulley bolts to Tighten to 24 Nm. Remove cooling fan.21. 17.4. 13. 15. Pulley and Fan Cowl 9. Fit cover bolts. Fit bolts finger tight. 18. 12. Fan Blades.12. 3. Tighten to 270 Nm. Slacken 3 water pump pulley securing bolts. See ENGINE 3. Fan Blades. Remove drive belt. Drive Belt Renew 21. See ENGINE 3. Remove 9 bolts securing bell housing access cover (2 dowel bolts). 11.9 V8. Remove water pump pulley bolts. Clean key and keyway. 14. 6.Crankshaft Pulley Remove 1. NOTE: It will be necessary to have an assistant position a large flat ended screwdriver between ring gear and adaptor plate to prevent ring gear rotating. Fit crankshaft pulley. Repair. 19. Refit 10. Remove water pump pulley. 4. 16. See COOLING SYSTEM. Drive Belt Renew 5. Clean seal running surface on pulley. 2. 7. Disconnect battery negative lead. 8. Remove access plate. Remove supports and lower vehicle. Remove crankshaft pulley bolt. Repair. 20. Pulley and Fan Cowl 23. Fit access cover.

14 . 9. 7. Turn centre bolt of tool to extract oil seal.12. Repair. Crankshaft Pulley Assembly. Locate oil seal in housing and drive into place using LRT-12-089. 6. Refit 5.Crankshaft Front Oil Seal Remove 1. See ENGINE 3.21. Repair. 10. Screw tool LRT-12-088 into oil seal. Locate seat in front cover. Remove oil seal from tool.9 V8. Refit crankshaft pulley. Lubricate seal with oil. Clean seal seating and pulley seal register. Drift seat into position using tool LRT-12-089. 4. 11. 3. Remove crankshaft pulley.12 ENGINE CRANKSHAFT FRONT OIL SEAL Service repair no . Lubricate oil seal lip. See ENGINE 3.9 V8. Crankshaft Pulley Assembly 2. 8. Refit 2 REPAIR .

8. Plug connections. 23. Disconnect feed hose from inlet manifold. Ignition Coils 29. 10. Release purge hose from ram pipe housing. See FUEL SYSTEM SFI. Disconnect leads from spark plugs and remove ignition coils. Position vehicle on ramp. Bonnet [Hood] 3. Disconnect fuel temperature sensor multiplug. Release harness brackets. 15. 33. 35. 24. 31. Disconnect battery sensing lead Lucar from generator. 27. Disconnect hose. Disconnect oil pressure switch Lucar. Remove 2 nuts securing expansion tank. Radiator 4. 13.41. Plenum Chamber 5. Remove radiator. Remove bolts securing gearbox breather pipes to engine lifting bracket. Disconnect hose. 22. Slacken clip securing heater return hose to pipe. Remove plenum chamber. Repair. See COOLING SYSTEM. 34. See FUEL SYSTEM SFI. 19. Remove nut and bolt securing expansion tank. Repair. Disconnect hose. Disconnect fuel feed hose union. Position cloth to absorb fuel spillage.01/99 Remove 1. 20. 21. 38. Mass Air Flow Sensor (MAF Sensor) 6. Disconnect air intake temperature sensor multiplug. 16. Remove bolt securing pipe bracket. REPAIR 3 . Disconnect temperature gauge sensor lead. 7. Repair. 28. Remove 4 nuts securing harness brackets to inlet manifold. Disconnect hose/pipe assembly. 30. Slacken hose clip securing bottom hose to expansion tank. See FUEL SYSTEM SFI. 32. Disconnect 8 injector multiplugs. 25.12. Remove generator terminal cover.4. 17. 18. Release camshaft sensor multiplug from bracket and disconnect multiplug. 26. 14. Disconnect coolant sensor multiplug. See CHASSIS AND BODY. Plug connections. Repair. Repair. 37. 12. 9. Remove expansion tank. 36. Remove mass air flow sensor. Slacken clip securing fuel return hose to fuel rail. Position hoses aside.0 V8 ENGINE ASSEMBLY Service repair no . Disconnect servo vacuum hose from ram housing. Slacken clip securing heater feed adaptor hose to inlet manifold. 2. Remove bonnet. Remove 2 terminal nuts and release leads from terminals. 11.

52. Remove terminal nut Release terminal from battery. Position battery cable over engine. Release engine mountings and remove. 68. 72. Plug pump and steering box. Repair. Raise engine sufficiently to release engine mountings. 73. 67. rotate crankshaft for access to first bolt (torque converter to drive plate). Release unions and remove hose. Remove catalytic converter/front pipe assembly. Release fusebox main feed lead. 41. 46. Remove 2 bolts securing tie bar to tranmission. Slacken clip securing PAS hose to pump. 66. 53. 42. Remove heatshield. Remove 9 bolts securing bell housing bottom cover. Remove first bolt. Disconnect hose. Plug hose and pump. 61. Remove locknut securing transfer box tie bar. 65. 76.0 V8 71. 48. Repair. Mark drive plate to torque converter relationship. 44. 70. 55. 62. 51. Pivot jockey pulley downwards to release drive belt tension. 43.4. 47. 69. 58. securing bell housing access plate and position aside. 40. 64. See FUEL SYSTEM SFI. Remove cover. 50. Remove 2 bolts securing crankshaft sensor shield to engine backplate. 45. 54. 75. Disconnect chains. Position lifting chains and attach hooks to engine lifting eyes. Remove and discard ’O’ rings. 57. Disconnect PAS hose connection at pump and steering box. Remove LH and RH engine mounting nuts. Catalytic Converter/Front Pipe . Lower engine until it just rests on engine mounting brackets.12 39. Remove drive belt. 63. With assistance. See EMISSION CONTROL. Repeat steps for the remaining 3 bolts. Crankshaft Position Sensor (CKP Sensor) 4 REPAIR . Remove tie bar. Release compressor from bracket and tie aside. Remove 2 and slacken 1 bolt. 59. Note position of 2 dowel bolts. Release belt from pulleys. 49. 60. 56. Raise ramp. 74. Disconnect compressor multiplug Remove 4 bolts securing compressor. ENGINE Release battery positive lead terminal cover.

Disconnect solenoid Lucar. 96. Support gearbox on a jack. Remove bolt securing oil cooler pipe bracket to REPAIR 5 . Release sensor/shield and remove. See FUEL SYSTEM SFI. Raise jack. 85. See ELECTRICAL. Raise engine. 101. 89. 91. Remove 3 bolts from top of bell housing. 87. Disconnect top oil cooler pipe union from transmission. 78. Disconnect sensor multiplug. Raise engine. Knock Sensor 83.4. Remove sensor. Disconnect RH and LH knock sensor multiplugs. 99. 94. sump. 103. 90. 80. 95.0 V8 77. Break engine to gearbox joint. 92. Release harness from engine. 86. 105. Release speed sensor lead from clip on heatshield. 97. 104. Repair. Plug pipe and transmission. Position lifting chains and attach hooks to engine lifting eyes. Repair. Collect spacer. 100. LH and RH side of bell housing. 79.4. Remove 2 lower bolts from bell housing. Remove centre LH bell housing bolt using long extension. 93. Remove ’O’ ring and discard. Release union. Remove nut securing handbrake cable heatshield. 88. 82. 98. 84. Remove starter motor heatshield. Remove 2 bolts. Remove heatshield. Lower ramp.0 V8 81. Starter Motor Heatshield . Secure block with cover plate and tighten one cover plate bolt. 102. Collect 2 harness brackets. Fit suitable wooden block in access plate hole to retain torque converter.

Untie compressor and position to engine bracket. Fit 2 remaining bolts and tighten all bolts to Tighten to 9 Nm. raise engine. 159. 160. Fit bolts. Remove plugs from feed hose and PAS pump. Refit 110. align to transmission and fit bolts. Move plate aside. Tighten to 9 Nm. Position cover plate and fit bolts. Tighten to 6 Nm. Align unions to pump and steering box. Fit engine mounting nuts. Secure transducer lead to clip on heatshield. 163. Connect pipe to transmission and secure with union. 143. 132. 157. 164. Move engine over. Position engine harness around engine. 170. Fit and tighten nut. Align shield bracket to engine mounting bracket and fit bolt. Tighten to 25 Nm. Fit 2 torque converter bolts.12 ENGINE 131. 151. Tighten to 45 Nm. 136. Fit tie bar. 155. 116. Fit catalytic converter/front pipe assembly. Repair. Position starter motor heatshield and secure clip to solenoid. 111. Align pipe bracket to sump. Clean dowel and dowel holes. Tighten to 30 Nm. Fit centre LH bell housing bolt. Clean engine and gearbox mating faces. 121. 124. Slacken bell housing access plate bolt. 134. Rotate engine and fit second 2 bolts. 150. 6 REPAIR . 158. 152. Tighten to 46 Nm. Tighten to 55 Nm. Lubricate ’O’ rings and fit to hose unions. Lower engine. Clean cover plate and mating face. Remove nut securing kick-down cable clip to LH cylinder head. With assistance. Connect compressor multiplug. lubricate NEW ’O’ ring and fit to pipe. Tighten to 45 Nm. Remove top starter bolt securing engine earth cable. Tighten 14mm thread to 15 Nm . 109. 169. Position sensor and connect multiplug. 147. Fit bolts. Lower engine onto mounting brackets. Connect hose to pump and tighten clip. Remove block. 166. 106. 168. Lower and guide engine into engine compartment ensuring no wires or pipes become trapped. 125. Position heatshield and fit bolts. 153. 142. 122. Position/align sensor and shield to backplate. 167. 114. 141. 135. 16mm thread to Tighten to 20 Nm. Fit 3 bottom bell housing bolts. 145. Rotate engine and tighten first 2 bolts to Tighten to 45 Nm. Move engine clear of vehicle. 165. With assistance. engage engine with gearbox. Lower engine onto bench. Tighten to 45 Nm. 146. 137. 144. Lower jack supporting gearbox. 126. 148. With assistance raise engine off bench. 154. Disconnect hoist.0 V8 Raise engine. 108. 118. 120. Remove plugs from tranmission and oil cooler pipe. position spacer and fit bolt. 123. 161. Tighten to 46 Nm. Connect starter solenoid Lucar. Clean crankshaft sensor mating faces. Catalytic Converter/Front Pipe . 140. 156. Fit tie bar securing nut. Clean PAS hose unions. 130. Tighten to 25 Nm. 139. 129. 133. Clean pipe. 149. 113. Position engine earth cable and secure to starter with top bolt. See EMISSION CONTROL. Remove plugs from steering pump and steering box. Position drive belt. Lower engine. 127. 115. 119. Fit harness brackets to 2 top bell housing bolts.4. 117. Position clip securing kick-down cable to LH cylinder head. Fit centre RH bell housing bolt. Position hose. move aside all pipes and wires. Fit RH mounting rubber. Fit LH mounting rubber. Fit heatshield and secure with nut. Tighten to 18 Nm. 162. Tighten to 45 Nm. 138. 128. 112. Align drive plate and torque converter. 107. Position access plate. Connect knock sensor multiplug.

12. Connect sensing Lucar. Repair. 210. 206. Connect injector multiplugs.Front Cover Gasket Remove 1. 182. Power Steering System . 193. 195. Tighten to 9 Nm. See FUEL SYSTEM SFI. Remove radiator See COOLING SYSTEM. Remove water pump pulley. See COOLING SYSTEM. Disconnect Lucar from oil pressure switch. 187. See LUBRICANTS. Fit ignition coil bracket. 190. 179. 209. 203.Bleed Drain engine oil and refill. 178. Fit mass air flow sensor. Information. Clean feed unions. tighten terminal nuts and fit cover. Mass Air Flow Sensor (MAF Sensor) Fit plenum chamber. Radiator 4. Bleed power steering system. 175. See COOLING SYSTEM. 202. Lower ramp. Coolant 3. 7. Tighten hose clip. 201. Connect camshaft sensor multiplug and secure to bracket. 192. Check for fuel. See STEERING. See CHASSIS AND BODY. 186. 177. 196. 198. Adjustment. Remove plugs from fuel feed and return hose connections. Repair. Align pipe to bracket and fit bolt. Disconnect oil cooler hoses from front cover and position aside. 2. 197. Tighten to 9 Nm. 191. See FUEL SYSTEM SFI. 174. Repair. 176. Raise vehicle on ramp. Remove cloth. Repair. Tighten to 9 Nm. Route drive belt around pulleys. 200. Connect battery positive lead and tighten. Align and secure engine harness brackets to inlet manifold and fit nuts. REPAIR 7 . FLUIDS AND CAPACITIES. Remove hose from water pump.USA Vehicles Start engine. Connect leads to generator.4. 205. 208. Plenum Chamber Fit radiator. Position expansion tank and secure with fixings. Disconnect battery negative lead. Fan Blades. 183. Recommended Lubricants and Fluids . Plug hoses and connections. 194. Slacken bottom hose clip. Pulley and Fan Cowl 5. Align belt to tensioner and release tensioner. 8.0 V8 171. Connect servo vacuum hose. 172. Ignition Coils Position heater hose/pipe assembly. Connect fuel temperature sensor multiplug. Connect coolant temperature multiplug. 189. Bonnet [Hood] Reconnect battery negative lead. coolant and oil leaks. Repair. Align gearbox breather pipe. clip to engine lifting eye and fit bolt. Connect air intake temperature sensor multiplug. Pivot tensioner downwards. 185. Connect oil pressure switch Lucar. Repair. Drain cooling system. Connect hose and tighten clip. Viscous Coupling. FRONT COVER GASKET Service repair no . Repair. Repair. 207. Radiator Fit bonnet. 6. Connect feed hose union and tighten. Connect heater return hose and tighten clip. See FUEL SYSTEM SFI. Connect purge hose.04 . Connect hose to inlet manifold. 188. 181. Secure terminal cover. 184.65. Connect temperature gauge connector. 180. 199. 204. Connect return hose and tighten clip. 173. See COOLING SYSTEM V8.

23. Loosen 4 bolts securing sump adjacent to front cover (2 each side). Clean sealant from threads of cover bolts. Press and rotate tool to engage drive gear until drive gear keyway aligns with Woodruff key. 26. 18. 21. 25. Ensure oil seal register in cover is clean. Lubricate outer face of NEW oil seal. Fit cover to cylinder block. 9. Repair. 20. Position front cover over crankshaft. 17. Using LRT-12-089. 19. 11. Camshaft Position Sensor (CMP Sensor) 10. 15. Lubricate oil pump drive gear and position in pump with groove away from engine. 12. Remove 2 bolts securing sump to front cover. Clean old sealant from front cover and block joint face. Apply Hylosil jointing compound to gasket position on cover and block.12 ENGINE Refit 16. Remove and discard gasket. Fit new gasket to block face. Disconnect multiplug from camshaft sensor. 24. fit seal to cover. 14. 8 REPAIR . CAUTION: Use a plastic scraper. 13. 22. See FUEL SYSTEM SFI. 27. Remove 9 bolts securing front cover. Locate alignment tool LRT-12-090 on front cover and oil pump drive gear. Remove oil seal. Release front cover assembly.

35. Tighten to 23 Nm. Connect camshaft sensor multiplug. See COOLING SYSTEM. Remove alignment tool LRT-12-090. Lower ramp. Fan Blades. Tighten clip. Refit radiator assembly. Pulley and Fan Cowl 37. 29. Refill cooling system. Viscous Coupling. Connect Lucar to oil pressure switch terminal. 36. 40. Fit sump bolts. 41. Refit water pump pulley. 32. Tighten to 15 Nm. Apply a small amount of Loctite 242 to threads and refit front cover bolts. See COOLING SYSTEM V8. Radiator 38. REPAIR 9 .0 V8 28. Tighten to 22 Nm. Adjustment. Repair.4. 33. 34. Fit new ’O’ ring seals. See COOLING SYSTEM. CAUTION: Over tightening of oil cooler pipe unions can crack front cover. 30. Coolant 39. Check/top-up engine oil. Reconnect battery negative lead. reconnect oil cooler pipes. Refit bottom hose to water pump. 31. Remove plugs from oil cooler pipes and cover. Repair.

Refit 8. 4. Remove 4 bolts securing rocker cover to cylinder head.40 . Repair. Allow adhesive to become touch dry. CAUTION: Allow cover to stand for thirty minutes before fitting. Fit rocker cover to cylinder head. Apply a thin coating of impact adhesive (Bostick 1775 or equivalent) to mating faces of rocker cover seal face and new gasket. Place one end of gasket into cover recess with edge firmly against recess wall. Remove screw securing dipstick tube to rocker cover. 6. Release plug leads from guide clips and disconnect from 4 spark plugs.29. Repair.29. 10.RH Cover Gasket Remove 1.12 ENGINE ROCKER COVER GASKET . 2. Tighten to 9 Nm. See FUEL SYSTEM SFI. 10 REPAIR . Remove rocker cover. 12. holding remainder of gasket clear. 3. Use a brush to ensure an even film. Plenum Chamber 5. Refit plenum chamber. Subsequent movement will destroy bonding.41 . See FUEL SYSTEM SFI. Reconnect battery negative lead. 7. NOTE: Gasket fits one way round only. pressing gasket into place ensuring edge firmly contacts recess wall. first time. Secure dipstick tube to rocker cover. ensure short screws are inboard. 14. Remove and discard rocker cover gasket. 9.12. It must be fitted accurately.LEFT HAND Service repair no .12. Remove plenum chamber. Disconnect battery negative lead. Work around cover.LH Cover Gasket Service repair no . Plenum Chamber 15. Connect leads to spark plugs and secure to guide clips on rocker cover. Allow to dry. 13. Clean mating faces between rocker cover and cylinder head using Bostick cleaner 6001 or equivalent. 11.

Disconnect breather pipe from rocker cover.RH Cover Gasket 3. CAUTION: Plug connection. Loosen hose clip and disconnect coolant return hose from pipe. Repair. 7. Disconnect fuel hose from injector pipe.4. 1. See FUEL SYSTEM SFI. 4. 11. Disconnect battery negative lead. Disconnect purge pipe from plenum chamber hose. Remove bolt securing coolant pipe brackets and nut securing bracket to manifold. See COOLING SYSTEM V8. Depressurise fuel system.RIGHT HAND Service repair no . 9. Loosen clip and disconnect fuel return hose from pipe.29. Remove 2 nuts securing engine harness brackets to manifold. Adjustment.12. 6. Coolant NOTE: Leave hose disconnected. 5.41 .0 V8 ROCKER COVER GASKET . Fuel System .Depressurise 2. 10. Drain cooling system. REPAIR 11 . 8. Release 4 ht leads from 2 brackets on rocker cover. CAUTION: Use 2 spanners.

26. Refill cooling system. Adjustment. 12. pressing gasket into place ensuring edge firmly contacts recess wall. Remove rocker cover. 21. 24. holding remainder of gasket clear. NOTE: Gasket fits one way round only. 17. Coolant 27. first time. Allow to dry. Work around cover. It must be fitted accurately. Secure engine harness to brackets. Remove and discard rocker cover gasket. Connect breather hose to rocker cover. 18. Place one end of gasket into cover recess with edge firmly against recess wall. CAUTION: Allow cover to stand for thirty minutes before fitting. 19. 20. Connect purge hose to plenum chamber. Fit rocker cover to cylinder head. 16. 25. Remove 4 bolts securing rocker cover to cylinder head. Subsequent movement will destroy bonding. Clean mating faces between rocker cover and cylinder head using Bostick cleaner 6001 or equivalent. See COOLING SYSTEM V8. Apply a thin coating of impact adhesive (Bostick 1775 or equivalent) to mating faces of rocker cover seal face and new gasket. Connect bottom hose to radiator. 14. Allow adhesive to become touch dry. Connect fuel feed and return hoses. Tighten to 9 Nm. ensure short screws are inboard. Use a brush to ensure an even film. Connect coolant pipes to hoses and secure brackets. 23. 12 REPAIR . 22.12 ENGINE Refit 15. Reconnect battery negative lead. 13. Refit ht leads into retaining brackets.

Lubricate oil seal lip. Position over crankshaft boss.9 V8. 10. 8. Lubricate seal guide LRT-12-095 with clean engine oil. Drift seal into location using LRT-12-091.0 V8 CRANKSHAFT REAR OIL SEAL Service repair no . Manual vehicles: Fit flywheel.9 V8. Position seal squarely. 9. Flywheel 2. Repair. Flywheel 11. Repair. Drive Plate Automatic 7.0 V8.4. See ENGINE 3. Remove oil seal from location. Manual vehicles: Remove flywheel. Repair. Ensure mating faces of flywheel and crankshaft are clean.0 V8. Drive Plate Automatic 3. See ENGINE 4. See ENGINE 3. CAUTION: Do not damage seal location or running surface on crankshaft. Ensure both seal location and running surface on crankshaft are clean. Automatic vehicles: Remove drive plate.21. Automatic vehicles: Fit drive plate. 6. REPAIR 13 .12. Remove guide. See ENGINE 4. Refit 4. 5.20 Remove 1. Repair.

Fit hub aligner screws. Check drive plate for distortion or cracks. Collect shim. Fit drive plate and clamp ring. Remove 6 screws from hub aligner.6 V8 Engine 2. Fit automatic gearbox and converter assembly.V8i Refit 6. Remove 4 clamp ring bolts. 9. 10. 11. Remove hub aligner from crankshaft.6 V8 Engine TAPPETS . Fit clamp ring bolts. Collect clamp ring.V8i ROCKER SHAFT .29. 5. Tighten to 85 Nm. Remove automatic gearbox and torque converter. Ensure all mating surfaces are clean.53.Tappets . Remove flexible drive plate/starter ring gear assembly from hub aligner.12 ENGINE DRIVE PLATE .engine set See Overhaul Manual 4. fit a new assembly. NOTE: It is only necessary to reshim the drive plate when a new crankshaft or hub aligner is fitted. LT230T Transfer Gearbox with Automatic Gearbox Assembly . Repair.0/4. Repair.29.12.AUTOMATIC Service repair no . 8. 14 REPAIR . See AUTOMATIC GEARBOX. LT230T Transfer Gearbox with Automatic Gearbox Assembly .ENGINE SET Service repair no . 3.29 . If either component shows signs of damage.0/4.12. Fit shim and hub aligner to crankshaft.13 Remove 1. 7. Tighten to 45 Nm. See AUTOMATIC GEARBOX.12. Check starter ring gear for chipped or broken teeth.57 . 4.Rocker shaft overhaul See Overhaul Manual 4.OVERHAUL Service repair no .

Mpi DESCRIPTION The ’T’ Series engine is a four cylinder. the bearing shells fitted to Nos. 2 and 4 bearings are plain. DESCRIPTION AND OPERATION 1 . end-float being controlled by thrust washers positioned each side of the centre main bearing. The plastic camshaft covers are bolted to the camshaft carriers. Both camshafts are driven by the timing belt and run directly in journals line bored in the cylinder head and camshaft carriers. The main bearing caps are located to the cylinder block by dowels. The cylinder block incorporates direct bored. aluminium alloy cylinder head and twin aluminium alloy camshaft carriers. The cylinder head carries twin camshafts operating four valves per cylinder via hydraulic tappets. 3 and 5 bearings are fully grooved whilst those fitted to Nos. siamesed cylinder bores which provide good structural rigidity. 1. water cooled unit comprising a cast iron cylinder block. The crankshaft is carried in five main bearings.

Drive to the pump is via a Woodruff key inserted in the crankshaft. belt tension being controlled by a semi-automatic tensioner. Gudgeon pins are offset towards the thrust side of the pistons to reduce frictional drag. The internally toothed timing belt is driven from a gear which is keyed to the crankshaft. tin coated pistons have two compression and an oil control ring and are secured to the connecting rods by semi-floating gudgeon pins which are an interference fit in the small-end bush.12 ENGINE The aluminium alloy. 2 DESCRIPTION AND OPERATION . big-end bearing shells are fitted to each connecting rod. Plain. The trochoidal type oil pump is mounted on the front of the engine and carries the crankshaft front oil seal.

Mpi Lubrication Oil is drawn from the pressed steel sump through a strainer (1) and into the oil pump (2). Gudgeon pin and small-end bush lubrication is by splash from the big-end bearings. An internal drilling in the cylinder block directs oil. 1. DESCRIPTION AND OPERATION 3 . Crankcase ventilation With the exception of two hoses connected from the inlet camshaft cover to the inlet manifold and throttle housing all crankcase ventilation is via internal voids in the cylinder head and block. The low oil pressure sensor (4) registers the oil pressure in the main oil gallery on the outflow side of the filter. via a restrictor (7) to the cylinder head where it passes through further internal drillings to the hydraulic tappets and camshaft journals (8). excess pressure being relieved by a pressure relief valve (3) integral with the pump. Pressurised oil passes through the full flow oil filter (5) to internal drillings in the crankshaft where it is directed to each main bearing and to the big end bearings via Nos. 3 and 5 main bearings (6). The inlet camshaft cover carries a wire gauze flame trap located over the breather pipe connections.

Cylinder block Knock sensor Crankshaft sensor Bolt .lower Woodruff keys Dipstick Bolt . 17. 9. 64.upper Locating dowel . 38.oil pump Gasket . 46. 32. 55.blanking plate Gasket Bolt . 48.gearbox adapter plate 4 DESCRIPTION AND OPERATION .crankshaft sensor Locating dowel . 51. Crankshaft Bearing shell . 29. 33. 42. 12. 24. 10. 15.oil control Gearbox adapter plate Bearing shell . 59. 44. 35.big end Nut . 53.coolant pump ’O’ ring Coolant pump body Thrust washer halves . 4. 62.main bearing . 28.sump Gasket . 57. 5. 63.oil strainer Sump Washer . 22. 60. 43. 3. 7.coolant pump cover Coolant pump cover Impeller Sealing rings ’O’ ring Bolts .main bearing cap Bearing caps . 47. 52. 41.big end bearing cap Locating dowel .flywheel Gudgeon pin 34. 2. 16.12 ENGINE CYLINDER BLOCK COMPONENTS 1. 45. 13.upper Flywheel Bolt .cylinder head Bolt . 49.dipstick tube Dipstick tube Bolts . 11. 19. 58. 30.top compression Piston ring .big end .big end . 61. 6. 27. 26. 50. 39. 21. 54. 65. 8.crankshaft rear oil seal housing Crankshaft rear oil seal and housing Bolt . 40.lower Bearing cap .oil pump Locating dowel . 67.connecting rod Piston Piston ring .flywheel Torx screw . 56.lower Bearing shell .oil pump Oil pump Oil pressure switch Crankshaft spigot bush Crankshaft spigot bearing Locating dowel . 14.upper Bearing shell .main bearings Bolt .sump ’O’ ring Oil strainer Bolts . 37. 36.drain plug Drain plug Oil filter element Crankshaft front oil seal Bolts .gearbox adapter plate Blanking plate Bolt .2nd compression Piston ring . 25. 31. 20. 23.coolant pump Connecting rod Bolts belt tensioner mounting plate Belt tensioner mounting plate Bolt .main bearing cap Thrust washer halves . 66. 18.main bearing .

Mpi DESCRIPTION AND OPERATION 5 .

inlet camshaft cover Spark plug Coolant temperature sensor NOTE: Items 15. 40. 19. 3.coolant outlet elbow Stud .inlet manifold Valve stem oil seal Valve spring Valve spring cap Collets Tappet Camshaft oil seals Drive pins .h. 23. 17. 28.exhaust camshaft carrier Exhaust camshaft carrier Exhaust camshaft Cylinder head bolt Blanking plate Bolt . 6.spark plug cover Spark plug cover h. 41. 33. 18. 27. 7. 22.exhaust valve 24.exhaust manifold Cylinder head gasket Guide . 31.blanking plate Locating dowel .16 & 36 on current engines replaced by an oil plug. 30.exhaust valve seat Exhaust valves Inlet valves Insert . 8. 4. 11. 9. 37. 2. 21. 38. 10.t. Insert . Inlet Exhaust Camshaft Rear Oil Plug 6 DESCRIPTION AND OPERATION .camshaft carrier Coolant outlet elbow Gasket Bolt .inlet valve seat Guide . 14. 12. 16. 29.camshaft timing gears Inlet camshaft Inlet camshaft carrier Bolt .exhaust camshaft cover Exhaust camshaft cover gasket/baffle plate Bolt .inlet camshaft carrier Inlet camshaft cover gasket/baffle plate Bolt . 13. 5. 42. 35. 44. 43. 36. See Repair. 39. 20.inlet valve Cylinder head Stud . 34. 32. lead plate Screw .t.12 ENGINE CYLINDER HEAD COMPONENTS 1. 15. 25. 26. lead plate Inlet camshaft cover Exhaust camshaft cover Bolt . Engine oil filler cap Filler cap seal Screw .

Mpi DESCRIPTION AND OPERATION 7 .

5. 10. Tensioner spring Tensioner pulley Tensioner clamp bolt Crankshaft timing gear Timing belt lower cover Bolt .timing belt upper cover Timing belt upper cover Bolt . 17. 19. 2.camshaft timing gear Plain washer Timing belt Inlet camshaft timing gear Exhaust camshaft timing gear Bolt .timing belt lower cover Timing belt centre cover Crankshaft pulley Crankshaft pulley/timing gear bolt Crankshaft pulley bolt 8 DESCRIPTION AND OPERATION . 14. 4. 9. Bolt . 7. 11. 18. 20. 22.upper timing cover backplate Upper timing cover backplate Lower timing cover backplate Tensioner spring sleeve Anchorage bolt 13. 8. 16. 21.12 ENGINE TIMING BELT COMPONENTS 1. 6. 12. 15. 3.

C.13.07 . REPAIR 1 . Remove drive belt.12. 7. See SECTION 10.90°B. timing belt centre cover. Fit tool LRT-12-058 to lock flywheel. 4.Inlet Remove 1. 6. Remove 5 bolts.12. 10. Remove 5 bolts. 11.D. 2. Remove timing belt upper cover. Rotate crankshaft to align camshaft gear timing marks . Disconnect battery negative lead. 5.13. Under Bonnet [Hood] Maintenance 3. Maintenance. timing belt upper cover. Move tensioner away from belt and tighten tensioner bolt. Remove belt from camshaft gears.T. Fit tool LRT-12-060 to lock camshaft gears. 12. Remove timing belt centre cover. 8. 9. Loosen camshaft belt tensioner bolt.Mpi CAMSHAFT FRONT OIL SEAL Service repair no .Exhaust Service repair no .09 .

do not scrape. Clean sealing area of cylinder head and camshaft. 15. CAUTION: Ensure sealing lip of seal is not distorted. 2 REPAIR . 2. Remove belt upper backplate. ensure all traces of rubber are removed . Remove 2 bolts securing camshaft gears to camshafts. Remove seals using tool LRT-12-063 fit thrustpad as shown. 17. CAUTION: Do not rotate camshafts. 16. 18. Remove 5 bolts securing timing belt upper backplate. 14. Refit 1. Remove tool LRT-12-060.12 ENGINE 13. Remove gears noting the ’IN’ and ’EXHAUST’ identifying marks. Using tool LRT-12-064 and LRT-12-072 fit new camshaft oil seals.

camshaft gear centre bolts. Fit camshaft gears noting the ’IN’ and ’EXHAUST’ identifying marks. 12. 4. Ensure timing marks are aligned. Fit timing belt upper cover and tighten bolts to correct torque. 3. Reconnect battery negative lead. 14. Under Bonnet [Hood] Maintenance 15. Tighten camshaft gear bolts to the correct torque. 7. Lever out. Refit cylinder head. Remove tool LRT-12-058 from flywheel. Remove cylinder head. REPAIR 3 . Torque Values 3. See SECTION 10. camshaft rear oil seal plug. 11. Fit camshaft locking tool LRT-12-060. 8. 5. See Camshaft Drive Belt 10.EXHAUST CAMSHAFT REAR OIL PLUG Remove 1. 2. 2. See Specifications. Fit timing belt upper backplate and tighten bolts to the correct torque. 6. Adjust timing belt tension. 9. Fit drive belt. Fit.Mpi INLET . Maintenance. For torque values. Fit new plug applying force to outer edge only. Refit 1. but do not tighten. Fit timing belt. torque. Fit timing belt centre cover and tighten bolts to correct torque. Clean plug housing. 13.

14 Remove 1. Fit tool LRT-12-070 onto crankshaft. Remove thrust button from crankshaft.12. Remove timing belt. 3. See Camshaft Drive Belt 2. fit and tighten tool LRT-12-073 into crankshaft front oil seal. Slide timing gear off crankshaft and remove drive key. tighten centre screw of tool to remove oil seal. Using thrustpad. 3. 4. Position new oil seal on crankshaft.21. Ensure bore of tool is burr free. Refit 1. Fit and tension timing belt. Use lint free cloth and thoroughly clean seal recess and running surface on crankshaft.12 ENGINE CRANKSHAFT FRONT OIL SEAL Service repair no . 6. Lubricate oil seal sealing surfaces with engine oil. 5. Clean crankshaft gear and pulley. 4. drift into place using LRT-12-069 and remove protector. 5. Fit drive key to crankshaft and slide timing gear onto crankshaft. See Camshaft Drive Belt 4 REPAIR . 2.

Clean seal seating area of block and accessible area of sump gasket. 2.Mpi CRANKSHAFT REAR OIL SEAL Service repair no . 6. Remove flywheel. Remove tool.20 Remove 1. Remove gearbox. Do not loosen 3 bolts A around oil pump housing. 8. Loosen 15 sump bolts by approximately 3 turns.10Nm 7. Fit and tighten seal housing bolts to correct torque in sequence shown. 4.12. Fit flywheel. Fit gearbox. Refit 1. 9. replacing sealing washer if damaged and tighten to the correct torque. Lubricate oil seal sealing surfaces with engine oil. 2.21. Remove bolts securing oil seal housing. Drain engine oil. 3. REPAIR 5 . remove seal and housing assembly. Fit tool LRT-12-061 over crankshaft boss and fit oil seal and housing assembly. 5. 4. allowing sump to drop away from rear oil seal housing. Fit sump plug. 3. Tighten sump bolts to correct torque and in the correct sequence. Fit clutch assembly. 6. See Engine Sump Gasket 7. 5. Sump gasket must be replaced if damaged. Remove clutch assembly.

Remove the drive belt.12 ENGINE ENGINE Service repair no . Drain engine oil. Repair. Position absorbent cloth around fuel pipe to fuel rail union. Bonnet [Hood] 5. Repair.12. 6 REPAIR . See COOLING SYSTEM.41. Site vehicle onto ramp [hoist]. Maintenance. Unscrew union to relieve pressure.Mpi 4. Release clip and disconnect hose from heater rail. Under Bonnet [Hood] Maintenance 3.01 Remove 1. 6. See CHASSIS AND BODY. CAUTION: Plug the connections 8. 2. Release clip and disconnect hose from coolant pump. Remove radiator. Remove bonnet [hood]. Radiator . See SECTION 10. 7.

11. 16. Feed harness between inlet manifold and cam cover. Remove rear cover. 17. Remove 3 nuts securing generator rear cover. 9. Disconnect 2 coolant temperature sensor multiplugs. 14. Release clip and disconnect breather hose from inlet manifold. 12. Release clips and disconnect the bypass and top hose. Disconnect oxygen sensor multiplug. Release harness lead from cable tie. REPAIR 7 . Remove harness. 10. 18. Release harness from cable tie.Mpi NOTE: On current models the generator cover is omitted. 19. Remove 3 nuts securing harness to generator. 20. 13. 15. Release multiplug from bracket.

Also remove coolant bypass hose from throttle housing. Release clip and disconnect hose. Release clip and disconnect inlet hose from power steering pump. 26. 27. air cleaner to throttle housing. 25. 28. Release throttle cable from cam. Disconnect fuel temperature sensor multiplug. 8 REPAIR . Disconnect outlet pipe union at power steering pump. 22.12 ENGINE 21. Disconnect stepper motor and throttle potentiometer multiplugs. discard ’O’ ring. Release throttle cable from abutment bracket. 24. Release clip and disconnect brake servo hose from manifold. CAUTION: Plug the connections 23.

Disconnect crankshaft sensor multiplug. 36. 35. 30. Release clip and disconnect fuel hose from pressure regulator. 34. 37. REPAIR 9 . CAUTION: Plug the connections.Mpi 29. Disconnect air conditioning compressor multiplug. Disconnect inlet manifold air temperature sensor multiplug. Disconnect fuel injection harness multiplug. Disconnect knock sensor multiplug. 31. Remove 3 bolts securing engine harness to manifold and fuel pipe. 32. Remove 2 nuts securing harness to starter motor solenoid. remove harness. Disconnect oil pressure switch multiplug. 33.

39. Remove 4 bolts securing air conditioning compressor. 42. Disconnect 3 vacuum hoses from manifold. Release cover and remove bolt securing earth lead to cylinder block.12 ENGINE 40. move compressor aside. 38. 41. Move earth lead aside. Disconnect 2 ignition coil multiplugs. 10 REPAIR .

mountings. and R.H. Release 4 screws and remove spark plug cover. support engine using suitable hoist. 49. Fit tool LRT-12-056. Loosen 2 nuts securing downpipe to silencer. 50. 47. 48. Release downpipe from exhaust manifold. Remove engine mounting heat shield. 44. Remove 4 nuts securing downpipe to exhaust manifold.H. 45. Remove upper nuts from engine L.Mpi 43. Raise vehicle. Collect gasket. 46. REPAIR 11 .

Connect coil multiplugs. 54.H. 5. Lower engine.12 ENGINE 51. 15. Connect harness to starter solenoid and secure with nuts. See Specifications. Position engine mountings. Remove gearbox support. torque. Refit NOTE: For torque values. 14. Tighten exhaust downpipe to silencer box nuts to the correct torque. 58. Connect earth lead to cylinder block and secure with nut. 4. 52. tighten to the correct torque. 55. 57. 13. Tighten L.H. Position engine harness to manifold. 12. Remove bell housing top nut. mounting lower nuts. Fit exhaust manifold to downpipe nuts and tighten to the correct torque. Position air conditioning compressor and secure with bolts. 8. 17. Using assistance. tighten to the correct torque. Fit bell housing top nut. 10. and R. Tighten to the correct torque. and R. Raise engine. 2. 3. Raise engine. 12 REPAIR . Remove hoist and chains. 9. Lower vehicle. Remove engine mountings. Fit new gasket to exhaust downpipe. lower engine into position. mounting nuts to the correct torque. Lower engine. 11. Raise engine and support gearbox. 7. 16. secure with bolts. Fit engine mounting heatshield. Remove engine. 59. partially tighten nuts. Remove 12 remaining bell housing nuts. Fit bell housing nuts.H. 53. Torque Values 1. 6.H. 18. Lower engine. Remove engine L. 56.

34. 40. Connect heater hose to heater rail and secure with clip. Connect alternator harness. Repair. Throttle Cable Adjustment ENGINE SUMP GASKET Service repair no . REPAIR 13 . 2. tighten to the correct torque. Radiator . use new sealing washer if necessary.Mpi 42. 26. Fit and tighten outlet pipe union to power steering pump. 5. Adjust throttle cable. Fit bonnet [hood]. secure harness with cable tie. 3. 21. Connect oil pressure switch multiplug. See CHASSIS AND BODY. 23. Position engine harness and connect breather hose to inlet manifold. inlet manifold air temperature and fuel temperature sensor multiplugs. Repair. fuel injector harness. 36. 20. Refit drain plug. Connect inlet hose to power steering pump and secure with clip. Connect coolant temperature sensor multiplugs. Connect bypass and top hose. 38. corner of sump. Bonnet [Hood] 41. 28. See FUEL SYSTEM. 35. Release sump from cylinder block. 39. Connect oxygen sensor multiplug. Connect fuel hose to pressure regulator and secure with clip. 27. Connect brake servo hose to manifold.Mpi 19. 24. knock sensor. NOTE: 25mm long bolt is fitted at rear L. Fill engine with oil. Connect crankshaft sensor. secure harness with cable tie. Position spark plug cover and secure with screws.H. Remove 18 bolts securing sump. Fit radiator.12. 4. Connect air cleaner to throttle housing hose and secure with clip. 22. 29. 33.60. Connect vacuum hose to manifold. 31. 30. 37. Connect multiplugs to throttle housing. air conditioning compressor. Adjustment. secure with clip. See COOLING SYSTEM. Drain engine oil. 32. secure with clip. Connect throttle cable to cam. 25. Discard gasket. Connect hose to coolant pump and secure with clip. secure with clip. Remove engine lifting bracket.43 Remove 1. Fit and tighten fuel pipe to fuel rail union.

1. Torque Values WARNING: Do not carry out the next instruction until the coolant is cool to avoid personal injury from scalding. Disconnect battery negative lead. 3. in the same sequence. Fill engine with oil.29. Clean sump. Then. Fit sump. See Specifications. 4. torque. Apply beads of RTV sealant to front main bearing cap. allowing coolant to drain into a suitable container. 2. Check gasket lays flat on sump flange. CAUTION: Plug the connections. Release clip and disconnect radiator bottom hose. 6. Working around the sump in the sequence illustrated. 3. Position absorbent cloth around fuel pipe to fuel rail union. Position new gasket to sump. 2.01 Remove 1. ensuring that longest bolt is inserted at position 7. Unscrew union to relieve pressure. NOTE: For torque values. Fit bolts. tighten the bolts to the stage 2 torque figure. 14 REPAIR . tighten the bolts to the stage 1 torque figure. 5.12 Refit ENGINE CYLINDER HEAD GASKET Service repair no . Visually check sump for damage.12. ensuring that location pips on gasket are located in sump. remove all traces of gasket from mating faces of sump and cylinder block.

Disconnect stepper motor and throttle potentiometer multiplugs. 9. Release clips and disconnect the bypass hose and top hose. Release harness lead from cable tie. 6. Release clip and disconnect hose from heater rail. Release harness from cable tie. Also remove coolant bypass hose from throttle housing. Release throttle cable from abutment bracket. Release clip and disconnect hose. air cleaner to throttle housing. 7. 12. REPAIR 15 . 5. 13. Disconnect 2 coolant temperature sensor multiplugs.Mpi 4. 8. 10. 11. Release throttle cable from cam. Disconnect oxygen sensor multiplug.

12 ENGINE 14. Disconnect fuel temperature sensor multiplug. Remove 3 bolts securing engine harness to manifold. CAUTION: Plug the connections 16 REPAIR . Release clips and disconnect 3 hoses from manifold. 19. 15. Disconnect inlet manifold air temperature sensor multiplug. 21. 20. 17. Remove bolt securing dipstick tube to coolant rail. Disconnect fuel injection harness multiplug. Release clip and disconnect fuel hose from pressure regulator. Release clip and disconnect brake servo hose from manifold. 18. 16.

Remove 4 nuts securing downpipe to exhaust manifold. 24. 40. Release 4 screws and remove spark plug cover. cracks and burning.1 mm max. Check cylinder block threads by running bolts into threads using fingers only. 35. Remove camshaft covers.1 mm max. See Camshaft Front Oil Seal 30. 36. using release agent and plastic scraper. Clean all traces of gasket material from head and block mating faces. Transverse warp = 0. Check cylinder head and block faces for warpage: Longitudinal warp = 0. Inspect cylinder head for damage. 25. 33. Inspect cylinder block. 29. check for damage. 39. replace if necessary. Place aside.5 mm tap. Raise vehicle 23. Remove timing belt. Clean cylinder head bolt threads with a wire brush. place on blocks to prevent damage. 27. Progressively loosen and remove 10 cylinder head bolts in sequence shown. Remove all traces of oil from bolt holes. Remove cylinder head complete with manifold. 32. 28. Ensure that the oil restrictor is clear and fitted below the block face. Clean any tight threads using M11 x 1.1 mm max. Diagonal warp = 0. REPAIR 17 . 34. 38.Mpi 22. Remove and discard cylinder head gasket. 37. Decarbonize cylinder head and pistons if necessary. Remove location dowels from cylinder block. Release downpipe from exhaust manifold. 31. Collect gasket. 26. Release spark plug leads from spark plugs and release from clips.

26. Secure engine harness to manifold with bolts. 11. Using assistance fit cylinder head to cylinder block. secure with clips. Fit cylinder head gasket to cylinder block. 21. Fit camshaft covers. Connect hose to heater rail and secure with clip. secure with clip. 13. Fit location dowels to cylinder head. Lubricate cylinder head bolts. Connect stepper motor and throttle potentiometer multiplugs. 18. Fit bolt securing dipstick tube to coolant rail. See Specifications. 3. 7. 10. Fit and adjust throttle cable. Fit spark plug cover and secure with screws. secure with cable tie. 19. NOTE: For torque values. 2. 22. Connect 3 vacuum hoses to inlet manifold. Connect air cleaner hose to throttle housing. secure with clip. 14. Connect fuel injection harness. Reconnect battery negative lead. 23. 8. secure with cable tie. 15. Fit spark plug leads to spark plugs and secure to clips.12 Refit ENGINE 1. Tighten fuel pipe to fuel rail union. 5. 20. Fit new gasket and secure downpipe to exhaust manifold with nuts. torque. Connect oxygen sensor multiplug. 18 REPAIR . 9. Fit timing belt. Fit and tighten cylinder head bolts to the correct torque and in the correct sequence. Torque values 6. 12. secure with clip. Connect fuel to pressure regulator. Connect coolant temperature sensor multiplugs. Connect the bypass and top hose. 24. 17. 4. 16. inlet manifold air temperature sensor and fuel temperature sensor multiplugs. Connect radiator bottom hose and secure with clip. 25. Connect brake servo hose to manifold.

40 . Release clips and disconnect 2 breather hoses from camshaft cover.12. 5. Inlet only 3. Release 4 screws from spark plug cover. Remove 12 bolts from camshaft cover. 4. 2. 9. Blow out bolt holes using an airline. Inlet only 8. 2. 11. Connect breather hoses to camshaft cover. REPAIR 19 . Place protective cloth over tappets. 10. 6.Inlet Remove 1. Working from the centre outwards. remove all traces of sealing compound from camshaft housing bolt holes. 4. Remove camshaft cover assemblies. Tighten support bracket to inlet manifold bolts. Position spacers and manifold support brackets.25 mm tap. 7. Remove and discard baffle/gasket plate(s). Remove 13 bolts from camshaft cover. NOTE: Fit baffle/gasket dry. Position new baffle/gasket plate to camshaft housing(s).29. 9.12.Exhaust Service repair no . Using an M8 x 1. Clean camshaft cover(s) and mating face of camshaft housing(s). progressively tighten bolts to torque. 3. 12. Remove 4 bolts securing support brackets to manifold and cover. remove protective cloth.Mpi CAMSHAFT COVER GASKET Service repair no . Remove support brackets. Remove spark plug cover. Exhaust only 7. Fit bolts finger tight.29. 10Nm Inlet and exhaust 8. Fit camshaft cover(s).41 . 6. Ensure all traces of oil are removed from bolt holes. Refit 1. 5.

crankshaft pulley or timing belt lower cover. 1.17 Remove NOTE: If the timing belt is to be removed from the camshaft gears only. Fit bolts finger tight. Remove 5 bolts securing timing belt top cover.65. 5.12 ENGINE Exhaust only 13. 6. tighten screws. 20 REPAIR .90°BTDC. Remove timing belt centre cover. 4. it is not necessary to remove the drive belt. Rotate crankshaft to align timing marks on camshaft gears .10Nm CAMSHAFT DRIVE BELT Service repair no . Inlet and exhaust 15.12. Fit spark plug cover to camshaft cover. Remove drive belt. Working from the centre outwards. 14. Remove top cover. progressively tighten bolts to the correct torque. Remove 5 bolts securing timing belt centre cover. 2. 3.

Loosen camshaft belt tensioner pulley bolt. 18. remove crankshaft pulley. Position tool LRT-12-060 to lock camshaft gears. 12. 14. 9. 8. gear retaining bolts or timing belt to rotate crankshaft. fit 2 pulley bolts to retain tool. 7. Fit tool LRT-12-058 to lock flywheel. Remove 4 bolts securing crankshaft pulley to crankshaft timing gear. 15. 13. REPAIR 21 . 16.Mpi CAUTION: Never use the camshaft gears. Remove timing belt lower cover. Fit tool LRT-12-059 to crankshaft pulley. 11. Retighten tensioner pulley bolt. mark direction of rotation of belt. If timing belt is to be refitted. 10. Remove bolts securing tool LRT-12-059. Remove timing belt. Move tensioner to release timing belt tension. 17. Restrain crankshaft pulley using tool LRT-12-059 and remove crankshaft pulley bolt.

tighten 3 bolts to the correct torque. Although the belt has a service life of 96. 2. 2. 10. Remove tool LRT-12-058 from flywheel. Do not use a timing belt which has been twisted or bent double as this can fracture reinforcing fibres. 22 REPAIR . Timing belts must be stored and handled with care. Fit timing belt centre cover. 8. Loosen timing belt tensioner pulley bolt. Clean crankshaft pulley. 80.000 miles. Torque values 1. torque. CAUTION: Ensure the belt run between the crankshaft and exhaust camshaft gear is kept taut during the fitting procedure. 4. 7. 4. 6. Fit timing belt lower cover. Remove tool LRT-12-060. tighten 5 bolts to the correct torque. Clean timing belt gears and pulleys. an existing belt should only be refitted if it has completed less than 48. 3. Do not use an oil contaminated timing belt. 5. Fit timing belt to gears. and using tool LRT-12-059 to restrain pulley. 7.000 km. Always store a timing belt on its edge with a bend radius greater than 50 mm. Fit timing belt upper cover. Tighten tensioner pulley bolt to the correct torque. Apply 40Nm anti-clockwise torque to inlet cam pulley bolt and release. Do not rotate engine with timing belt removed and cylinder head fitted. fit 2 bolts to retain tool. Metal levers may damage the belt and gears. 3. Refit NOTE: For torque values. See Specifications. Remove tool LRT-12-059 9.000 miles. 160. Fit bolts securing crankshaft pulley to timing gear. Fit tool LRT-12-059 to crankshaft pulley. tighten bolt to the correct torque. tighten 5 bolts to the correct torque. Tension belt 1.000 km. tighten bolts to the correct torque. Fit crankshaft pulley centre bolt. CAUTION: If original belt is to be refitted. ensure direction of rotation mark is facing correct way. Fit drive belt. starting at the crankshaft gear and working in an anti-clockwise direction. Fit crankshaft pulley to crankshaft timing gear. 5.12 ENGINE CAUTION: Ease timing belt off gears using fingers only. 6.

1. 7. Check timing belt condition. 4. Remove upper cover. fraying or splitting at base of teeth. 3. Remove 5 bolts securing timing belt upper cover 2. Position upper cover.Mpi CHECK CAMSHAFT DRIVE BELT Service repair no . renew any belt that shows signs of oil contamination. if present. Fit upper cover securing bolts. 5. Using a socket and extension bar on the crankshaft pulley bolt. CAUTION: Do not use camshaft gears or retaining bolts to rotate engine. cracking.65. rotate engine to allow the timing belt to be inspected. CAUTION: Cause of oil contamination. 6. REPAIR 23 .17 CAUTION: This check must be carried out at the service intervals specified and whenever carrying out any repair which requires the timing belt to be disturbed. Pay particular attention for signs of belt splitting at base of teeth.12. Clean timing belt upper cover. must be rectified.

.......................................................................................... 10 Fuel feed hose stiffening bracket bolts ......................................................................................... 45 Stage 2 ........................................................................ 5 Crankshaft pulley centre bolt ....................... 55 SPECIFICATIONS..................................... 3 Stage 2 .................................................................... 10 Tensioner pulley bolt ....... 30 Spark plugs .................................................. 65 Exhaust camshaft rear oil seal cover plate bolts ............................ 7 Fuel temperature sensor ................................................ 10 Knock sensor ............................................................................................... 30 Air conditioning compressor to engine block bolts ............ 40 L. 7 Fuel rail to inlet manifold bolts ........................................................................................................................................................ and R........... 10 Crankshaft rear oil seal housing bolts ....................................................................................................................... 10 Camshaft gear bolts ..................H................................................Further 90° Camshaft cover bolts .................................................................................................................................................................................. engine mounting nuts ................................................. TORQUE 1 ......................... 5 Timing belt centre cover bolts ................................... 27 Timing belt upper backplate bolts .................................................. 10 Exhaust downpipe to silencer box nuts .......... 7 Throttle housing mounting nuts .................................................... 15 Ignition coil bracket bolts ................... 7 Oxygen sensor ........................Mpi TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque........................................... 7 Fuel pressure regulator steady bracket bolts ....................................................................................... Nm ENGINE Timing belt upper cover bolts ........................................................................................................................................................................................................................... 80 Stage 3 .. 10 Bell housing nuts ........................ 85 Exhaust manifold to downpipe nuts ............. 25 Coolant temperature sensor ....... 15 Crankshaft sensor bolts ....................... 7 Intake air temperature sensor ....................H.......................... 85 Crankshaft pulley to timing gear bolts ................ 10 Engine sump bolts Stage 1 ............................................. 5 Timing belt lower cover bolts ..................................................................................................................................................................... 10 Inlet camshaft rear oil seal cover plate bolts .................................................................................................................................................... 45 Cylinder head bolts Stage 1 ......................................................................................................

Mpi

ENGINE LRT-12-056 18G 1644 Engine lifting bracket

LRT-12-058 18G 1523

Location pin valve timing

LRT-12-059 18G 1641

Crankshaft pulley locking tool

LRT-12-060 18G 1524

Locking tool crankshaft gear

SERVICE TOOLS

1

12

ENGINE

LRT-12-061 18G 1108

Protection sleeve crankshaft rear oil seal

LRT-12-063 18G 1476

Remover camshaft oil seals

LRT-12-064 18G 1475

Replacer pilot camshaft front

LRT-12-069 18G 1509

Replacer crankshaft front oil seal

2

SERVICE TOOLS

Mpi

LRT-12-070 18G 1510

Sleeve crankshaft front oil seal

LRT-12-072

Replacer drift camshaft front oil seals

LRT-12-073

Remover crankshaft front oil seal

LRT-12-074

Remover adapter bit

SERVICE TOOLS

3

12

ENGINE

LRT-12-076

Replacer needle crankshaft bearing

4

SERVICE TOOLS

EMISSION CONTROL

EMISSION CONTROL Three systems are used to control the vehicle atmospheric emissions these are: Engine crankcase fume emissions. Fuel tank Evaporative emissions Engine exhaust gas emissions. Crankcase ventilation system - 3.9 MFi models only The crankcase ventilation system which is an integral part of the air supply to the engine combustion chambers, is often overlooked when diagnosing problems associated with engine performance. A blocked ventilation pipe or filter or excessive air leak into the inlet system through a damaged pipe or leaking gasket can effect the mixture, performance and economy of the engine.

The purpose of the crankcase ventilation system is to ensure that any noxious gas generated in the engine crankcase is rendered harmless by burning in the combustion chambers as follows: Oil laden noxious gas in the engine crankcase is drawn through an oil separator 3 located on the right cylinder head rocker cover, where the oil is separated and returned to the sump. The gas flows through a restrictor in the three way connection 1 and into the inlet plenum chamber where it is drawn into the combustion chambers and burned. The volume of fresh air which is drawn from the atmospheric side of the throttle butterfly to mix with the gas, depends on the position of the throttle and the engine speed. The air filter 2 fitted to the left cylinder head rocker cover, must be maintained in clean condition to ensure sufficient air enters the crankcase under varying throttle openings and manifold depression, to prevent excessive crankcase pressure or depression developing.

1. Three way connector 2. Air filter 3. Oil separator

REV: 09/95

DESCRIPTION AND OPERATION

1

17

EMISSION CONTROL

Exhaust emission control. The fuel injection system provides accurately metered quantities of fuel to the combustion chambers to ensure the most efficient air to fuel ratio under all conditions of operation. A further improvement to combustion is made by measuring the oxygen content of the exhaust gases to enable the quantity of fuel injected to be varied, according to conditions, to correct any unsatisfactory composition of the exhaust. The main components of the exhaust emission system are two Catalytic converters which are an integral part of the front exhaust pipe assembly. The Catalytic converters are included in the system to reduce the emission, to atmosphere, of carbon monoxide, oxides of nitrogen, and hydrocarbons. The active constituents of the converters are platinum and rhodium. The correct functioning of the converters is dependent upon close control of the oxygen concentration in the exhaust gas entering the catalyst. The oxygen content of the exhaust gas is monitored by the heated oxygen sensors. Information on the heated oxygen sensors is contained in the relevant Fuel System section, See FUEL SYSTEM MFI, Description and operation, or See FUEL SYSTEM SFI, Description and operation, The ECM can then make an appropriate adjustment to the fuel supply to correct the composition of the exhaust. CAUTION: Unleaded fuel only must be used on vehicles fitted with catalytic converters. As a reminder,a label to indicate this is adhered to the inside of the fuel filler flap. Furthermore the filler neck is designed to accommodate only unleaded fuel pump nozzles.

2

DESCRIPTION AND OPERATION

REV: 09/95

EMISSION CONTROL

EXHAUST SYSTEM 1. 2. 3. 4. 5. 6. 7. Manifold to front pipe connection. Heated oxygen sensor - pre-catalytic converter. Front silencer support bracket. Heated oxygen sensor - post-catalytic converter. Front pipe to silencer joint. Silencer rear support bracket. Rear silencer support bracket.

REV: 09/95

DESCRIPTION AND OPERATION

3

17

EMISSION CONTROL

Evaporative emission control system - pre advanced EVAPS. The system is designed to prevent harmful fuel vapour from escaping to the atmosphere. The system consists of a vapour separator tank, connected to the fuel tank and located between the body inner and outer panels on the right hand side of the vehicle near the rear wheel arch. An adsorbtion canister, containing activated charcoal, is positioned in the engine compartment attached to the front right valance. The two components are connected by a pipe running the length of the chassis.

A pressure relief valve is fitted in the hose which is open to atmosphere. This valve acts as a safety valve should a build-up of pressure occur in the system, for example if a hose became blocked or kinked. The volume of vapour emitted, in such an instance, would be acceptable. A pressure relief valve is also fitted in the hose connected to the adsorbtion canister and releases vapor to the canister when the pressure in the separator reaches between 5 and 7 Kpa. In the top of the separator a shut-off valve is incorporated in the vapor exit port to prevent the possible presence of any liquid fuel being transmitted to the adsorbtion canister should the vehicle roll over. The adsorbtion canister, which is connected by a hose to the plenum chamber, absorbs and stores the fuel vapour from the fuel tank while the engine is not running. When the engine is started, the vapour is purged from the canister by air drawn through an orifice in the base of the canister and by the influence of vacuum at the top. The vapour drawn into the plenum chamber through a solenoid operated purge valve is finally burnt in the combustion chambers.

A B C D E F G

Pressure relief to atmosphere. From fuel tank to separator. To adsorbtion canister. Pressure relief valve. Pressure relief valve. Shut-off valve. "Speed Fit" connectors.

The purge valve, which is attached to the adsorbtion canister support bracket, is controlled by the Engine Control Module ECM which determines the most emission acceptable time at which purging should take place. This will normally be at engine speeds above idle and when the vehicle is in motion. A signal from the ECM to the purge valve operates the solenoid and opens the valve to purge the canister of fuel vapour.

4

DESCRIPTION AND OPERATION

REV: 09/95

EMISSION CONTROL

EVAPORATIVE CONTROL SYSTEM - PRE ADVANCED EVAPS 1. Adsorption canister and purge valve. 2. Location of vapour separator and pipes. 3. Fuel tank.

REV: 09/95

DESCRIPTION AND OPERATION

5

17

EMISSION CONTROL

EVAPORATIVE EMISSION CONTROL SYSTEM ADVANCED EVAPS

Component location 1. 2. 3. 4. 5. 6. 7. 8. EVAP canister EVAP canister vent solenoid (ECVS) EVAP canister purge valve Anti-trickle fill valve Liquid/vapour separator Fuel filler neck assembly Fuel tank Fuel pump and gauge sender unit

6

DESCRIPTION AND OPERATION

ADD: 09/95

EMISSION CONTROL

Identification

Fuel filler neck components A B C D E F G Anti-trickle fill valve Liquid/Vapour Separator Vent line to pressure sensor From fuel tank to liquid/vapour separator From EVAP canister to anti-trickle fill valve Fuel filler hose, Dual layer, convolute nylon Fuel tank internal breather hose The system was introduced on all North American specification vehicles from October 1996 and the vehicles can be recognised by the information contained in the EVAP. FAMILY entry on the underbonnet Emission label (mounted on the vertical face of the bonnet lock platform). A - Vehicles with advanced EVAPS VLR1124AYPFE B - Vehicles without advanced EVAPS VLR1060AYPBC

ADD: 09/95

DESCRIPTION AND OPERATION

7

17

EMISSION CONTROL

System operation The system is designed to prevent fuel vapour escaping to atmosphere, and consists of four roll-over valves fitted internally in the fuel tank, connected to the liquid/vapour separator by a nylon line. The separator is mounted to the side of the filler neck. An EVAP canister is positioned in the engine compartment mounted on the right front side valance. The liquid/vapour separator and EVAP canister are connected by a nylon line which runs the length of the chassis. Pressure/vacuum relief valves are incorporated into the fuel filler cap and are designed to protect the fuel tank from permanent deformation in the event of system pressure or vacuum exceeding the system operating parameters. There are no other relief or one-way valves in the system. A vent line flow restrictor known as an anti-trickle fill valve is fitted to the filler pipe in the line between the tank and EVAP canister. The function of this valve is to prevent overfilling the tank by trickling fuel in, thereby preserving the vapour space in the tank to allow for fuel expansion during hot weather. The valve achieves this by blocking the vent line during the fuel filling process. The valve is operated by the action of inserting the filler gun so that when the fuel in the tank reaches the level of the filling breather, flow cut off occurs due to fuel filling the filler pipe.

During normal vehicle operation and when the engine is switched off, the venting system between the fuel tank and EVAP canister is open to allow the free passage of vapour. The EVAP canister, which is connected by a nylon hose to the plenum chamber, absorbs and stores the fuel vapour from the fuel tank when the engine is not running. With the engine running, vapour is purged from the EVAP canister by allowing outside air to be drawn through the EVAP canister vent solenoid and link pipe by the influence of manifold vacuum to the EVAP canister purge connection on the canister. Filter pads are fitted above and below the charcoal and in the EVAP canister vent solenoid to prevent the ingress of foreign matter into the purge line. The EVAP canister purge valve, which is fitted in the line from the EVAP canister to the plenum, is controlled by the ECM which determines the most emission acceptable time at which purging should take place. This will normally be at engine speeds above idle and when the vehicle is in motion. The EVAP canister vent solenoid is mounted on the side of the EVAP canister bracket and is connected to the EVAP canister by a length of large bore hose. The ECVS is controlled by the ECM and is normally open. The function of the ECVS is to block the air intake side of the EVAP canister. When the system receives an ECM signal the valve closes; this allows the system leak check to take place. The leak check only occurs when pre-determined vehicle operating conditions are met.

8

DESCRIPTION AND OPERATION

ADD: 09/95

EMISSION CONTROL

TESTING EVAPORATIVE EMISSION CONTROL PRE ADVANCED EVAPS The following pressure test procedure is intended to provide a method for ensuring that the system does not leak excessively and will effectively control evaporative emissions. Equipment required. Nitrogen cylinder (compressed air may be used to pressure the system when there has NEVER been fuel present in the fuel or evaporative control systems). Water manometer (0 - 30" H2O or more). Pipework and a "T" piece. Method. 1. Ensure that there is at least two gallons of fuel in the petrol tank unless there has never been any fuel in the system. 2. Disconnect, at the adsorption canister, the pipe to the vapour separator. 3. Connect this pipe to the nitrogen cylinder and the water manometer using the "T" piece. 4. Pressurize the system to between 26.5 and 27.5 inches of water, allow the reading to stabilize, then turn off the nitrogen supply. 5. Measure the pressure drop within a period of 2 minutes 30 seconds. If the drop is greater than 2.5 inches of water the system has failed the test. Note that a fully sealed system will show a slight increase in pressure. 6. Should the system fail the test, maintain the pressure in the system and apply a soap solution round all the joints and connections until bubbles appear to reveal the source of the leak. 7. Repeat the test and if successful, dismantle the test equipment and reconnect the pipe to the adsorption canister.

LEAK DETECTION PROCEDURE - ADVANCED EVAPS 1. Connect TestBook to the vehicle and confirm that the fault code(s) displayed relate to an EVAP system fault. 2. Examine components in fuel and EVAP system for damage or poorly connected joints. 3. Repair or replace components to rectify any faults found, then reset the Check Engine light using TestBook. 4. Carry out Drive Cycle, See Drive Cycle Advanced EVAPS 5. Using TestBook confirm that the Evaporative Loss Control (ELC) Inspection and Maintenance (IM) flag has cleared. This procedure should confirm that the ELC test was carried out during the drive cycle and that the fault was cured. 6. If the IM flag is still shown, use TestBook to interrogate the engine management system to ascertain which of the following situations exists: • If a fault code is shown then further investigation is required, proceed to the next step. • If the IM flag is still shown, but no faults are indicated the conditions for the ELC check have not been met and the drive cycle must be repeated. 7. Connect the Leak Detection/EVAP Diagnostic Station to the vehicle and carry out the procedures given in the operating instructions supplied with the equipment. 8. Rectify faults indicated by the Leak Detection/EVAP Diagnostic Station and return to step 4.

REV: 09/95

FAULT DIAGNOSIS

1

17

EMISSION CONTROL

DRIVE CYCLE - ADVANCED EVAPS 1. Switch on ignition for 30 seconds. 2. Ensure that coolant temperature is less than 140 °F (30°C). 3. Start engine and allow to idle for 2 minutes. 4. Perform 2 light accelerations (0 to 35 mph with light pedal pressure). 5. Perform 2 medium accelerations (0 to 45 mph with moderate pedal pressure). 6. Perform 2 hard accelerations (0 to 55 mph with heavy pedal pressure). 7. Cruise at 60 mph for 5 minutes. 8. Cruise at 50 mph for 5 minutes. 9. Cruise at 35 mph for 5 minutes. 10. Allow engine to idle for 2 minutes. 11. Connect TestBook and check for fault codes.

2

FAULT DIAGNOSIS

ADD: 09/95

EMISSION CONTROL

POSITIVE CRANKCASE VENTILATION AIR INTAKE FILTER Service repair no - 17.10.02 The PCV air intake filter is located at the rear of the left hand rocker cover, beneath the throttle linkage bracket. Remove 1. Pry the filter outer cover upwards to release it from its mounting. 2. Remove the sponge filter from the cover and discard the sponge.

POSITIVE CRANKCASE VENTILATION BREATHER FILTER Service repair no - 17.10.03 Remove 1. Release the hose clamp and pull the hose off the canister. 2. Unscrew the canister and remove it from the rocker cover. 3. Remove the large rubber ’O’ ring and inspect for deterioration.

Refit 3. Insert a new filter into the filter cover. 4. Press the filter onto its mounting until it clips firmly into position.

4. Visually inspect the condition of the wire screen within the canister, if in poor condition, replace the whole assembly, if the filter unit is in an acceptable condition, clean as follows. 5. Immerse the canister in a small amount of solvent (mineral spirits) and allow time for the solvent to dissolve or loosen any debris. 6. Remove the canister from the solvent bath and allow to dry in still air. WARNING: Do not use a compressed air line to dry, clean or remove any remaining particles of debris within the canister as this could cause fire or personal injury. Refit 7. If the original canister is being refitted, fit a new ’O’ ring. 8. Screw the canister into the rocker cover securely - hand tight only. 9. Refit the hose and tighten the hose clamp securely.

REPAIR

1

17

EMISSION CONTROL

HEATED OXYGEN SENSOR (HO2S) Service repair no - 19.26.16 CAUTION: The removal of the sensors from the exhaust system must only be carried out when the engine is cold. Remove 1. Disconnect battery negative lead. 2. Disconnect the electrical plugs from the sensors. 3. Unscrew and remove the sensors from the two exhaust downpipes.

PURGE CONTROL VALVE Service repair no - 17.15.39 Remove 1. Disconnect battery negative lead.

2. 3. 4. 5.

Disconnect multiplug from purge control valve. Release clip and disconnect hose from valve. Release valve from charcoal canister. Remove valve.

Refit 4. Coat the threads of the sensors with anti-seize compound. CAUTION: To ensure that the efficiency of the sensor is not impaired, DO NOT allow anti-seize compound to come into contact with the sensor nose. 5. Screw in the sensor and tighten to the correct torque using special tool LST134. 6. Connect the electrical plugs and battery lead. 6. Discard ’O’ ring. Refit 7. 8. 9. 10. Clean valve and valve location. Fit new ’O’ ring to purge valve. Position and secure valve to charcoal canister. Connect hose to purge valve and secure with clip. 11. Connect multiplug to valve. 12. Reconnect battery negative lead.

2

REPAIR

EMISSION CONTROL

CHARCOAL CANISTER Service repair no - 17.15.13 Remove 1. Disconnect battery negative lead. 2. Pry out purge valve. 3. Disconnect pipe.

4. Loosen bolt. 5. Remove charcoal canister. Refit 6. Reverse removal procedure.

REPAIR

3

Release sensor lead from clips. 8.0 V8 WARNING: Do not attempt HO2S removal when the exhaust is hot. 2. Unscrew and remove sensor from exhaust pipe. 6. 4. Remove For all sensors: 1. Unscrew and remove sensor from exhaust pipe using special tool LRT-12-047 (LST134).17 EMISSION CONTROL HEATED OXYGEN SENSOR (HO2S) . RH front sensor only 3. Ignition Coils LH front sensor 7. Release multiplug from bracket behind cylinder head. Remove nuts retaining coil bracket and position bracket aside.4. See FUEL SYSTEM SFI. Raise and support front of vehicle. Disconnect multiplug and release sensor lead from clip. Disconnect multiplug and release from bracket. 4 REPAIR . 5. Repair.

If refitting existing HO2S. Release multiplug from bracket and disconnect. Unscrew and remove sensor from exhaust pipe using special tool LRT-12-047 (LST134).EMISSION CONTROL Rear sensors Refit 12. REPAIR 5 . 11. NOTE: New HO2S is supplied pre-treated with anti-seize compound. 15. Tighten to 20 Nm using special tool LRT-12-047 (not RH front sensor). coat threads with anti-seize compound. Lower vehicle. 16. 10. CAUTION: Ensure sensor leads are secured using clips provided. 13. Remove stands. CAUTION: Do not allow anti-seize compound to come into contact with HO2S nose or enter exhaust system. Failure to correctly secure leads could result in damage to HO2S. 17. Position HO2S with new sealing washer on exhaust pipe. RH front sensor only: Place coil bracket in position and fit nuts. Ensure mating faces are clean. Release sensor cable from clips. Reconnect multiplug to engine harness and secure to bracket. 14. 9. Tighten to 8 Nm.

17 EMISSION CONTROL CATALYTIC CONVERTER/FRONT PIPE . With assistance.0 V8 Service repair no .09 WARNING: The removal of the exhaust system must only be carried out when the engine is cold. 7. Disconnect battery negative lead. release front pipe from intermediate pipe.50.17. 2. With assistance. Reverse removal procedure. 10. 5. remove exhaust front pipe. With assistance. 3.4.4. Remove flange gaskets and discard. 9. lower anti-roll bar. 6. Remove 1. Refit 12. release front pipe from manifold flanges. Remove 4 nuts/bolts securing front anti-roll bar brackets. 4. Remove oxygen sensors See Heated Oxygen Sensor (HO2S) .0 V8 8. Remove 2 nuts securing front pipe to intermediate pipe. Raise vehicle on ramp. Remove 6 nuts securing front pipe flanges to manifolds. 11. With assistance. 6 REPAIR .

Reverse removal procedure. Refit 7. Release purge valve rubber mounting from bracket. Release clip and remove hose from EAVP canister. Loosen bolt. 6. 3. Remove EVAP canister and purge valve complete.17.4. Disconnect multiplug from EVAP purge valve. 4.0 V8 Service repair no . 2.15.13 Remove 1. Disconnect battery negative lead. 5. REPAIR 7 .EMISSION CONTROL EVAP CANISTER AND PURGE VALVE .

Release quickfit hose connections from throttle body plenum and EVAP canister. 2.17.13 EVAP CANISTER PURGE VALVE . 3.17. 10. 1. 8. Refit 6. 8 REPAIR ADD: 09/95 . Reconnect battery negative lead. 3. 9. 4. Release vent and purge line quickfit connections from canister.39 Remove Remove 1. 7. 9. 5.15.15. Release clip securing vent solenoid hose to canister and disconnect hose. Connect quickfit hose connections to throttle body plenum and EVAP canister.17 EMISSION CONTROL EVAP CANISTER . Disconnect battery negative lead. Release purge valve rubber mounting from bracket. Reconnect battery negative lead. Disconnect battery negative lead. 7.ADVANCED EVAPS Service repair no . Refit 6. 4. Fit canister to mounting bracket.ADVANCED EVAPS Service repair no . collect fixture clamp. Remove purge valve assembly. 8. Remove nut and bolt securing canister to mounting bracket. Remove canister. Position fixture clamp and secure canister to mounting bracket with nut and bolt. Connect vent and purge line quickfit connections to canister. Conmnect multiplug to purge valve and secure purge valve rubber mounting to bracket. Locate purge valve adjacent to bracket. 5. 2. Connect vent solenoid hose to canister and secure with clip. Disconnect multiplug from purge valve.

4. Release clip securing hose to vent solenoid and disconnect hose. Refit 5. ADD: 09/95 REPAIR 9 . 3. Remove vent solenoid from mounting bracket.17.ADVANCED EVAPS Service repair no . Disconnect multiplug from vent solenoid.15.43 Remove 1. 2. 7. Disconnect battery negative lead. Reconnect battery negative lead. 8. 6.EMISSION CONTROL EVAP CANISTER VENT SOLENOID . Connect multiplug to vent solenoid. Fit vent solenoid to mounting bracket. Connect hose to vent solenoid and secure with clip.

Tdi DESCRIPTION Air intake The air cleaner is positioned to the right of the engine and connected by hoses to a cold air intake duct and the turbocharger inlet. A fuel filter. When all correct signals are received. fitted between the exhaust manifold and exhaust pipe. c. A Bosch Type injection pump. EGR valve lift position. A crankcase breather hose is fitted between the air cleaner and the separator. The tank is vented by a 2 way valve in the filler cap. Glow plugs Four glow plugs are located in the cylinder head. A single stage turbocharger. b. fitted with a replaceable element and incorporating a water separator. is connected by hoses to the air cleaner and to an intercooler mounted on the right of the radiator. DESCRIPTION AND OPERATION 1 . Engine temperature from coolant temperature transmitter in No. is mounted on the side of the engine. Exhaust gas recirculation (EGR) Exhaust gas recirculation is controlled by the EGR control unit mounted in the passenger compartment on the RH ’A’ post behind the fascia and receives the following inputs: a. A return line passes excess fuel from the injection pump and injectors back to the fuel tank. 4 cylinder head. is positioned on the LH side of the bulkhead. incorporating a cold start advance unit and a high idle setting is mounted on the LH side of the engine and is directly driven by gears from the crankshaft. driven by the camshaft. Engine speed from the tachometer. the EGR solenoid allows vacuum to open the EGR valve and recirculate a portion of the exhaust gas. Throttle position from the sensor on the injection pump. The intercooler is connected by a hose to the inlet manifold. A mechanical lift pump. directly below each injector. The pump meters and distributes fuel to 4 pintle type injectors located in pre-combustion chambers in the cylinder heads. d. Fuel system A 89 litre fuel tank is mounted at the rear of the vehicle beneath the load space floor.

Fuel tank Fuel lift pump Fuel filter Fuel injection pump Spill return line Fuel injectors Sediment plug FUEL SYSTEM COMPONENT LOCATION 1. 7. 2. 12. 10. 3. 6. 3. 11. 6. 7. 4. 2. 14. 13. 15. 5.19 FUEL SYSTEM FUEL SYSTEM LAYOUT 1. 5. 4.EGR and instruments Fuel injection pump EGR throttle position sensor Fuel lift pump Intercooler EGR Control unit 2 DESCRIPTION AND OPERATION . 9. Fuel filter bleed screw Fuel filter Turbocharger Wastegate Air cleaner Fuel injector Glow plug Glow plug controller EGR valve and valve lift position sensor Coolant temperature transmitter . 8.

Tdi DESCRIPTION AND OPERATION 3 .

via the air cleaner.19 OPERATION FUEL SYSTEM Glow plugs Glow plug operation is controlled by a timer unit. Starting the engine results in the power supply to the glow plugs passing through the resistor. Exhaust gases passing over a turbine cause it to rotate. Fuel is injected in a finely atomised form into a pre-combustion chamber in the cylinder head where it ignites. the cold start element expands releasing tension on the cable and allowing spring pressure to move the advance lever forwards. start relay and resistor. A cold start advance unit advances the injection timing to further assist starting. In addition to removing particle contamination from the fuel. Diesel engines operate by compression ignition. 4 DESCRIPTION AND OPERATION . via cable. driving a compressor mounted on the turbine shaft. which reduces their operating temperature. towards the rear of the pump against spring pressure. or by a microswitch on the injection pump which operates when the throttle is depressed. The engine is supplied with pre-compressed air by a single stage turbocharger. the glow plugs start to operate and a warning light on the dashboard illuminates. The compressed air passes to the cylinders via an intercooler. Cold start advance The cold start advance unit is connected to the engine cooling system via hoses. As coolant temperature rises. passing back to the tank via the fuel return line. During cold starting. The length of time the glow plugs will operate is dependent on under bonnet temperature. injection timing varying with engine speed. which reduces the temperature of the compressed air. causing it to self ignite. Air drawn from the cold air intake passes. The injection pump meters a precisely timed. Any excess fuel delivered to the injection pump is not injected. When the ignition is turned on the timer unit is energised. The glow plugs are cut out either by the temperature sensor in the timer. creating extreme turbulence which mixes the burning fuel thoroughly with the compressed air. providing complete combustion. to the turbocharger where it is compressed. which removes and stores both bound and unbound water. exact quantity of fuel to the injectors in response to throttle variations. increasing its density. Cold Starting is assisted by glow plugs. automatically controlled glow plugs assist in raising the temperature of the compressed air to ignition point. Idle quality is improved by the high idle setting. a cold start advance unit and a high idle setting. remaining illuminated until the glow plugs are automatically switched off. the filter incorporates a water separator. It contains a temperature sensitive element which is retracted when cold and pulls the advance lever. which is monitored by a sensor located in the timer unit. The burning fuel expands rapidly into the main combustion chamber. The rapid compression of air in the cylinder during the compression cycle heats the injected fuel. Fuel is drawn from the tank by a mechanical lift pump and passes to the injection pump via a filter.

Duration of engine idling. Engine temperature . With coolant temperature between 20 °C and 100 °C. Engine load . the engine having just returned to idle.must be between 20 °C and 100 °C approx.Tdi Exhaust Gas Recirculation (EGR) Operation of the EGR system is dependent on the following: a. the vacuum supply being taken from a ’T’ connector in the brake servo hose. DESCRIPTION AND OPERATION 5 . Throttle position is measured via a sensor mounted on the fuel injection pump throttle lever. this valve lift is compared with the actual valve lift required on the control unit map and adjusted if necessary. Engine speed is measured by monitoring the waveform present on one phase of the generator. EGR valve lift position. d. Engine speed . Under varying engine speed and load conditions the control unit sends a signal to open the vacuum modulator which allows a vacuum to be applied above the EGR valve diaphragm. e. EGR will shut off after 25-30 seconds idling.must be between 630 and 2850 rev/min. c. b.calculated by throttle position sensor. Closed loop control is achieved by allowing the control unit to continually monitor EGR valve lift via a position sensor mounted on the valve. This process is controlled by an engine speed/load map stored in the EGR control unit memory.

The ECM does this by substituting a default value for the failed component which may result in a noticeable loss in power but keeps the engine running. Safety and emergency features are built into the system which protect the engine against overspeed and overheating damage. 9. 4. FUEL SYSTEM COMPONENT LOCATION EDC 1. 6. Vehicle speed sensor No. injection timing and Exhaust Gas Recirculation (EGR) required for any running condition. sensors are fitted to the engine to measure engine parameters.19 FUEL SYSTEM DESCRIPTION ELECTRONIC DIESEL CONTROL The Electronic Diesel Control (EDC) ’drive by wire’ system derives its from the replacement of conventional mechanical controls by electronic components. The EDC system supplies the exact amount of fuel to the engine according to the prevailing engine operating conditions. To monitor these conditions. 10. 8. 11. 3. In the event of component failure the system is designed to compensate and allow emergency start and limp home facilities to operate. 7. 4 injector sensor Coolant temperature sensor Boost pressure sensor Electro-pneumatic modulator Airflow sensor Engine speed sensor Brake/clutch switches Injector pump Throttle position sensor Engine control module 6 DESCRIPTION AND OPERATION . 2. 5. Data from the sensors is received by the Engine Control Module (ECM) which determines the exact amount of fuel.

Tdi DESCRIPTION AND OPERATION 7 .

7. 4 injector sensor Air flow sensor Engine speed sensor Boost pressure sensor Vehicle speed sensor Clutch switch Brake switch Throttle position sensor Electro-pneumatic modulator Exhaust gas recirculation (EGR) valve Engine control module (ECM) Diagnostic indicator To turbo To air box. 8. To ’T’ piece on brake servo hose position Solenoid operated valve energization timing device. D. Fuel cut off Actuator current Control collar 8 DESCRIPTION AND OPERATION . 16. 3. C. 11. 14. 2. 4. A. G. Fuel injection pump Fuel temperature sensor Air temperature sensor Water temperature sensor No. 5. B. F. 10. 9. E.19 FUEL SYSTEM FUEL SYSTEM LAYOUT EDC 1. 12. 13. 6. 15.

Air flow sensor The Air Flow Sensor is mounted on a bracket attached to the wheel arch valance. fuel and air temperature and atmospheric pressure. and connected by hose to the air cleaner and turbo charger inlet. Injection timing sensor An inductive sensor in No 4 injector body monitors needle movement. injector timing and EGR relative to the appropriate engine operating conditions. will implement EGR. This forms part of a ’closed loop’ system to control start of injection. Injection pump The injection pump incorporates actuator controlled injected fuel quantity and solenoid operated timing which operate in response to ECM signals against driver demand. signals from the throttle position sensor are received by the ECM together with crank speed and position pulses. The unit consists of a microprocessor with integrated circuits and components and is connected to the main harness by a 55 pin plug. A fuel cut-off facility and fuel temperature sensor is incorporated in the pump. Inputs to the ECM from engine sensors control start of injection. The system measures timing. Pulses from the sensor activated by radial slots in the flywheel give engine speed and position information to the ECM. temperature and boost pressure. Engine speed sensor The engine speed sensor is an active inductive sensor mounted on the flywheel housing. provided that the other conditions are met. DESCRIPTION AND OPERATION 9 . The unit consists of a flap valve airflow sensor which measures the fresh air flow into the engine. The ECM signals the injection pump to adjust fuel quantity and timing relative to driver demand. injected fuel quantity. As engine coolant. fuel and air temperature changes the ECM will correct fuel delivery and injection timing for more efficient and accurate running. The ECM will also make corrections for atmospheric pressure on injection timing and EGR. The ECM will also make corrections for engine coolant. engine speed. signals from the crank speed and water temperature sensors are relayed to the ECM to control starting fuel quantity and injection timing. The sensor informs the ECM and. Once the engine has started the ECM initiates a ’closed loop’ monitoring system for fuel quantity. relating the needle movement signal to crank position (determined by flywheel pulses from the engine speed sensor).Tdi OPERATION EDC Under start up conditions. fuel cut-off and EGR. Electronic Control Unit (ECM) The EDC system is controlled by the ECM located in the drivers footwell on the ’A’ post beneath the fascia. As driver demand increases.

Brake and clutch switches The brake and clutch switches are located on the pedal box and serve as safety features to the system. Boost pressure sensor The boost pressure sensor is mounted on the bulkhead. The sensor is an additional input for engine overheat protection. They return information to the ECM which limits maximum fuel quantity under braking. This reduces NOx (Oxides of nitrogen) emissions of the engine. (a function which smooths out engine response to sharp accelerator movement and reduces vehicle ’bucking’). Throttle position sensor The accelerator pedal is connected directly to a sensor mounted in the pedal box. Fuel and Air temperature sensors monitor engine conditions and relay their information back to the ECM which makes adjustments to injected fuel quantity. Incorporated in the sensor is a backup idle switch which the system will default to in the event of sensor failure. Once open the EGR valve directs a quantity of exhaust gas back into the inlet manifold to be burnt inside the engine. The unit has a multirole as the vehicle electronic speedometer sensor and as a sensor for ’surge damping’. It regulates vacuum signals from the source to the EGR valve. Temperature sensors Water.19 FUEL SYSTEM Vehicle speed sensor The vehicle speed sensor is located on the transfer box behind the transmission brake. Driver demand is relayed back to the ECM to increase or decrease injected fuel quantity. 10 DESCRIPTION AND OPERATION . The ECM controls the modulator to open the EGR valve according to required airflow. Electro-pneumatic modulator The electro-pneumatic modulator is located on the inner wing just forward of the air cleaner. Exhaust gas recirculation valve The EGR valve is located on the engine exhaust manifold and is controlled by vacuum from the electro-pneumatic modulator. injection timing. It relays boost pressure information to the ECM which compensates fuel quantity to reduce smoke during acceleration. EGR and corrections to measured boost pressure and airflow.

Rotate sensor to achieve correct Ohmmeter readings. 3. to give 1. Re-check Ohmmeter readings. Ohmmeter should read between 850 and 900 ohms.062 in) of free play in the inner cable. 8.reconnect multiplug. Connect an Ohmmeter across pins 1 and 3 of multiplug. Run engine until normal operating temperature is reached. 4.Tdi THROTTLE CABLE Adjust EGR THROTTLE POSITION SENSOR Check 1. Hold throttle lever in fully closed position. Check that throttle opens fully when the throttle is depressed. Ohmmeter should read between 1K and 1. 4. Loosen 2 Torx screws securing sensor. by rotating ferrule. Switch off engine and disconnect sensor multiplug. then reconnect multiplug. Connect an Ohmmeter across pins 1 and 2 of multiplug. 3. 2. Adjust outer cable. EGR throttle position sensor is Ok . 6. Loosen throttle cable adjustment ferrule.57 mm (0. 1. If the readings are correct. 2. then tighten Torx screws.05K ohms. 7. ADJUSTMENT 1 . 5.

See ENGINE TUNING DATA. Connect a further length of hose to third leg of the "T" piece and other end to a pressure gauge capable of reading in excess of 61 cm Hg. See ENGINE TUNING DATA. loosen the locknut on the injector pump. Run the engine at an increased speed for a few seconds then check the idle speed again. 1.19 FUEL SYSTEM LOW AND HIGH IDLE SPEED Adjust The high idle speed (cold start idle) is automatically set by the setting of the low idle speed and can not be adjusted individually. 4. The pressure gauge hose must be capable of reaching passenger compartment so that gauge may be observed. hold the adjuster screw steady while tightening the locknut. Information. Any additional adjustments required must be entrusted to authorised Bosch agents. To check maximum boost pressure. When the correct speed has been achieved.500 and 3. hose to actuator. 3. 2 ADJUSTMENT . 2. Disconnect. Connect a short length of suitable hose to turbocharger and connect other end to "T" piece. Insert into a suitable "T" piece. NOTE: The low idle speed control is the only permitted adjustment in service. 2. 1. check the engine idle speed. Start engine and run it until normal operating temperature is reached. 300 Tdi Engine CHECK TURBOCHARGER BOOST PRESSURE For boost pressure. Check and adjust throttle cable. Using a suitable tachometer. Turn the adjustment screw either clockwise to increase the engine speed or anti-clockwise to decrease the speed.000 rev/min. from turbocharger. Information. 6. If adjustment is necessary. 3. drive vehicle normally but in such a manner that full throttle can be maintained whilst climbing a hill with engine speed held steady between 2. 300 Tdi Engine 4. 5.

2. 5. 11. Inspect the access panel seal to ensure that it is satisfactory for further use. Tighten to 45 to 50 Nm. 7. 8. Fit the access panel to the aperture in the floor and secure with the screws. 14.32 WARNING: Ensure that the WARNINGS and FUEL HANDLING PRECAUTIONS given in Section 01 are adhered to before carrying out the following operations. Refit 10. Reverse removal procedure. 4. Using special tool LST131 remove the locking ring and withdraw the sender unit from the fuel tank. Remove the rear carpet retainer. 1 to 5. Fold back the sound insulation to reveal the access panel. Ease the carpet from under the lower trim panels at the rear of the fold down seats. 13.LST131 Remove 1. Fit the sender unit to the fuel tank and secure with the locking ring. Raise the carpet to expose the sound insulation. Refit the sound insulation and carpet.88. 3. Connect multi-plug to sender unit. Disconnect the fuel pipes from the sender unit. renew as necessary. REPAIR 1 . 6. Remove the securing screws and detach the access panel from the floor. 9. Special tool . 15. 12. Disconnect the multi-plug from sender unit. Disconnect battery negative lead.25. Connect the fuel pipes to the sender unit.Tdi TANK SENDER UNIT Service repair no .

3.42. Pull ferrule from abutment bracket and withdraw throttle cable. Disconnect battery negative lead. 9. Remove pin and clevis pin securing throttle cable to throttle lever. discard clip.19 FUEL SYSTEM THROTTLE CABLE Service repair no . 4.19. 2 REPAIR .20. Refit 8. 2. INTAKE HOSE TURBOCHARGER Service repair no . Loosen clip and disconnect intake hose from turbocharger. Remove pin and clevis pin securing throttle cable to throttle lever. Use new pins to secure clevis pins. Loosen clip and disconnect breather hose from intake hose. Remove intake hose Refit 5. Throttle Cable 6. 5. Disconnect battery negative lead. Reverse removal procedure. Release grommet from bulkhead.19. Adjust throttle cable. 6. 7.06 Remove 1. 4. Withdraw throttle cable from engine compartment. Release throttle cable from clip on bulkhead. Reverse removal procedure. See Adjustment.11 Remove 1. 2. Remove clip and disconnect hose from air cleaner. 3. Use a new clip to secure intake hose to air cleaner.

See MANIFOLD AND EXHAUST SYSTEM. See MANIFOLD AND EXHAUST SYSTEM. 7. Remove exhaust front pipe. 7. Unscrew union. 5. Tighten banjo bolt to 20 Nm. Disconnect battery negative lead.12 Remove 1. turbocharger and engine block are clean. 3.Tdi TURBOCHARGER OIL DRAIN PIPE Service repair no . REPAIR 3 . Remove 2 bolts securing oil drain pipe to turbocharger. disconnect oil feed pipe from cylinder block. Remove oil drain pipe. 2. Remove banjo bolt securing oil feed pipe to turbocharger. Refit 6. 8. Tighten oil drain pipe to turbocharger bolts to 25 Nm. CAUTION: Plug the connections. 4. Reverse removal procedure. Move oil feed pipe from behind turbocharger and remove.42. Disconnect battery negative lead. Remove exhaust front pipe.Tdi 3. 4. 5.42. CAUTION: Plug the connection. 2. Check/top-up engine oil level. Reverse removal procedure. Use a new gasket. Check/top-up engine oil level. 8. use new sealing washers.19.14 Remove 1. Ensure mating surfaces of oil pipe. Manifold and Exhaust System . Repair. remove and discard gasket. Manifold and Exhaust System . discard 2 sealing washers.19. Refit 6. Unscrew union and disconnect oil drain pipe from cylinder lock. 9. Repair.Tdi TURBOCHARGER OIL FEED PIPE Service repair no .

Tighten to 45 Nm.19 FUEL SYSTEM TURBOCHARGER ACTUATOR Service repair no .Tdi 2. Repair. 3. Use new clip to secure control lever to wastegate spindle. Push the control lever as far as possible towards the actuator and apply pressure to keep the lever in this position.Tdi 1. Remove 4 bolts and 2 clamp plates securing turbocharger to exhaust manifold. 5.19. Remove 2 nuts securing the actuator to the turbocharger bracket. Exhaust Manifold .25 Remove 1. Check/top-up engine oil level.Tdi 4. Refit 6. 9.42.Gasket . Release the pressure and tighten the locknut. Remove and discard clip securing control lever to wastegate spindle. Refit exhaust manifold and turbocharger. Screw the lever in either direction until the eye on the end will locate easily over the wastegate spindle and secure with a new clip. Fit the replacement actuator and secure with nuts. 8. Pressurise the actuator to 57 . Remove exhaust manifold assembly. 9.19. Disconnect battery negative lead. Forcing the complete lever in or out will change the calibration with the possibility of damaging engine boost.42. 2. 5. Release clip and disconnect hose from actuator. Remove air cleaner assembly. 8. Remove and discard clip securing control lever to wastegate spindle. CAUTION: Use only the threaded end of the lever to make adjustments. Reverse removal procedure. Repair. 11. See Air Cleaner 3. See MANIFOLD AND EXHAUST SYSTEM.62 cm Hg and hold this pressure. Exhaust Manifold .31 Remove TURBOCHARGER AND GASKET Service repair no . 10.42.Turbocharger . Remove turbocharger actuator. Refit 7. Clean mating faces of turbocharger and exhaust manifold. Remove turbocharger and discard gaskets. 4. 4 REPAIR . Exhaust Manifold . Repair. See MANIFOLD AND EXHAUST SYSTEM. 6. See MANIFOLD AND EXHAUST SYSTEM. Remove exhaust manifold and turbocharger. 7.01 Service repair no .19.

Clean mating faces of fuel lift pump and engine block. 3. Fit securing bolts. Using a new gasket. ensure correct location of lever with camshaft. Remove fuel lift pump and discard gasket.09 Remove Refit 7. Plug the connections to prevent the ingress of foreign material. and secure unions. 8. 1. Loosen unions securing fuel injection pipes to injectors and injector pump.45. 6. Remove 2 bolts securing lift pump to engine block. Loosen unions and disconnect fuel supply and feed hoses from fuel lift pump.19. Tighten to 25 Nm. 10. 4. 5. Remove injection pipes. 2. REPAIR 5 . Tighten to 33 Nm. 9. fit fuel pump. Fit injector pipes to injectors and injection pump.Tdi FUEL LIFT PUMP Service repair no . Plug the connections to prevent the ingress of foreign material. Connect fuel hoses to pump and secure unions. Tighten to 28 Nm.

Loosen 2 clips and disconnect bottom hose from intercooler. Reconnect battery negative lead. Clean seal and seating in filter head. 9.15 Remove 1. Clean area around filter head. 6 REPAIR . Loosen bleed screw. 4. allow fuel to drain into container. Release bracket from side cover lug. Position side cover away from intercooler. 5. Position filter element to filter head and hand tighten. Disconnect battery negative lead. Remove 4 bolts securing radiator top cover. 3.42. Loosen drain tap. 2. remove top cover.19. 10. 6. 8.25. 4. discard element. 5. Place a suitable container beneath filter bowl to collect any spillage. Release 2 clips securing fan cowl to radiator top cover. Crank engine until fuel is drawn through the system and starts. 11. 6. Disconnect battery negative lead. 2. Loosen 2 clips and disconnect top hose from intercooler. INTERCOOLER Service repair no .07 Remove 1. bolt and washers securing intercooler side cover bracket to bonnet [hood] platform. Lubricate filter element seal with fuel. 3. 8. Refit 7.19. Unscrew filter element. 7. position bracket and power steering reservoir aside.19 FUEL SYSTEM FUEL FILTER ELEMENT Service repair no . Remove nut.

Reverse removal procedure. 3. withdraw valve. Remove bolt securing Hummel valve. No.air conditioning models 2. Drive Belt Renew 9.31 Remove 1.3 glow plug 4. No. Move intercooler upwards and clear of fan cowl. Repair.1 glow plug .60. move compressor aside. See ENGINE.19. Release drive belt from compressor pulley. 13. 12. Ensure foam pad is in good condition and attached to intercooler. Disconnect battery negative lead. 11. Remove 4 bolts securing compressor to front cover. Move intercooler into position. Refit 10. REPAIR 7 . Ensure locatiing lug grommets are fitted and in good condition.Tdi GLOW PLUGS Service repair no . remove and discard ’O’ ring.

Fit glow plug. Reconnect battery negative lead. Reverse removal procedure.45. 10. Repair. fit bolts. 6. 1. Disconnect vacuum pipe from EGR valve. 5. Remove glow plug. Clean mating faces of EGR valve and exhaust manifold. Position compressor to front cover. Tighten to 23 Nm. 3 glow plug: Lubricate new ’O’ ring with engine oil and fit to Hummel valve. 11.19 FUEL SYSTEM All glow plugs EGR VALVE Service repair no . Disconnect multiplug from EGR valve. Refit 7. 2. 3. No. 1 glow plug . 4 glow plug terminal. NOTE: Feed wire must be connected to No. 8. Remove EGR valve and discard gaskets.air conditioning models 12. Tighten bolts to 25 Nm. 4. Remove 2 bolts securing hose to EGR valve. Remove 2 Allen screws securing EGR valve to exhaust manifold. 13. Connect wire to glow plug terminal and secure with nut. Remove terminal nut from glow plug. See ENGINE. Tighten to 25 Nm. Fit valve and secure with bolt. 9. Fit drive belt to compressor pulley and adjust tension. 7. Clean glow plug and seating.19. No. Coat threads of glow plug with suitable anti-seize compound operational to a temperature of 1000°C.01 Remove 5. 8 REPAIR . Drive Belt Renew All models 14. disconnect wire from glow plug terminal. Refit 6. Tighten to 15 Nm.

Refit 4. Disconnect battery negative lead.Tdi GLOW PLUG CONTROL UNIT Service repair no . Reverse removal procedure. 2. Release control unit from fixings.33 Remove 1.45.19.19. Reverse removal procedure. 3. Remove 2 plastic nuts securing control unit to body.60. Disconnect multiplug and remove control unit. Remove nut and bolt securing control unit to mounting bracket.06 Remove 1. 2. 4. Disconnect multiplug and remove control unit. Release 2 glovebox stays from fascia and pivot glovebox fully downwards. 3. EGR CONTROL UNIT Service repair no . Refit 5. REPAIR 9 .

Refit 7. Remove injector. 5. Tighten injector clamp plate nut to 25 Nm. Remove nut securing injector clamp plate to cylinder head. Plug pipes and injector connections to prevent the ingress of dirt and foreign matter. EGR Throttle Position Sensor 1. 5. 10 REPAIR . Renew copper washer on injector. Remove sensor assembly.19. Disconnect spill return hose(s) from injector.60.14 Remove INJECTORS Service repair no . 3. Remove 2 screws securing sensor mounting plate to injection pump. Remove high pressure pipe from relevant injector and injection pump. Remove oil filler cap and remove sound deadening pad from top of engine.19 FUEL SYSTEM EGR THROTTLE POSITION SENSOR Service repair no . 3. See Adjustment. 2.30. 4. Disconnect sensor multiplug from harness. Position sensor assembly on injection pump and fit and tighten screws. Refit 4.10 Remove 1. 6. Connect multiplug. 6.19. Reverse removal procedure. 2. Adjust sensor.

Where reference is made to the timing tool substitute the following information for automatic and EDC variants.Tdi FUEL INJECTION PUMP AND TIMING Service repair no . Remove blanking plug from flywheel housing. 2. Disconnect battery negative lead. Fit timing tool LRT-12-044 to flywheel housing. 1 cylinder is just before TDC.19. from front cover plate. 5. Viewing valve mechanism through filler aperture. 11. 10. do not engage centre pin. 6. Continue rotating crankshaft clockwise until centre pin engages with timing slot in flywheel. Refit oil filler cap. REPAIR 11 . 7. Fit pin from LRT-12-045 to injection pump gear. 8. 9. Remove 1. Pin locates in ring gear. If automatic gearbox: Timing tool LRT-12-044 fits into the larger bolt hole of coverplate on engine backplate. Remove injection pump access plate. Remove oil filler cap from rocker cover. complete with gasket. Remove injection pipes. 3. If manual gearbox: Timing tool LRT-12-044 fits into the base of the flywheel housing If manual gearbox with EDC: Timing tool LRT-12-085 must be used and also fits into the base of the flywheel housing. 4. sited near to the rear of sump. Remove drive gear to pump hub fixing bolts and plate. turn crankshaft clockwise until No. pump to injector.30.07 NOTE: The following text refers to a Tdi vehicle with a manual gearbox without electronic diesel control.

17. sufficient for bracket to just move.19 FUEL SYSTEM 12. 13. 14. 1. Remove throttle cable and hand throttle cable if fitted. refit banjo bolts after disconnecting pipes. Remove banjo bolts securing spill return. Disconnect stop control solenoid connector. Fit gear retaining tool LRT-12-045 with an 8 mm washer.5 to 2 mm thick. main fuel and boost signal pipes. 19. 15. 20. 16. Remove pump mounting bracket bolts 2 off. Remove pin from pump gear. 18. Remove pump securing nuts at flange and withdraw pump and gasket. Fit blanks to pipe connections. Loosen pump support bracket bolts to block. under each bolt head in addition to the existing washer. 12 REPAIR .

Turn crankshaft two complete revolutions. 37. Remove special tool LRT-12-045. Tighten to 10 Nm. 34. Tighten to 25 Nm. 25. check timing pin from LRT-12-045 can be fully and easily inserted into the pump. REPAIR 13 . with the flywheel timing pin located. Connect boost signal pipe and secure with banjo bolts. 23. Attach pump to bracket and finger tighten nuts and bolts 26.D. Refit injector pipes. Fit gear lock plate. 36.Tdi Refit 21. Loosen the three pump gear retaining bolts. 33. Check that the timing pin is an easy fit in the pump and that the flywheel timing pin locates. 32. 39. 40. Connect stop control solenoid lead. fit the blanking plug to flywheel housing. (d) (e) (f) (g) 38. Tighten to 12 Nm. Turn the crankshaft the small amount necessary to enable the timing pin to be inserted into the pump. carry out the following: (a) (b) Ensure flywheel timing pin is disengaged from slot in flywheel. Fit pin from special tool LRT-12-045. At the same time check flywheel timing pin LST-12-044 can also be inserted in the flywheel slot. Tighten the pump gear retaining bolts to the correct torque. Connect spill return. 31. main fuel pipes. If. 30. Tighten to 25 Nm. Tighten to 25 Nm. Remove the timing pin from the pump and the timing tool from the flywheel housing. Remove special tool pin from pump. Clean mating faces of pump and front cover. Remove special tool pin. Fit access plate with gasket to front cover plate. Secure gear with bolts. Fit pump to cover with a new gasket and secure with nuts. 35. 24. First tighten bolts securing bracket to block and then bolts securing pump to bracket. (c) 22.. 29. Tighten to 29 Nm. Connect throttle cable and where applicable hand throttle cable. Turn the crankshaft to T. 27. the timing pin cannot be inserted cleanly into the injection pump. Using antisieze compound. Remove blanks from pump.C. 28.

Release vacuum tube from EGR vacuum capsule. in the event of failure it must be renewed. Remove AIRFLOW METER Service repair no . Reverse removal procedure. 9. Loosen air cleaner hose to air flow meter retaining clip. 14 REPAIR . 1. Ensure plug is pushed firmly into location and retaining clip secures plug in position. Manoeuvre ECM from its mounted position. Refit 10. 4. Ensure multi-plug is firmly reconnected and hose clamps are securely tightened to prevent unmetered air entering the engine. 6. Remove 1.30. Disconnect hose from airflow meter.19 FUEL SYSTEM ENGINE CONTROL MODULE (ECM) Service repair no . Remove airflow meter. 8. 3. in the event of failure it must be renewed. 2. 8. Disconnect battery negative lead. Disconnect battery negative lead. 4. 7. Remove retaining nuts from ECM. 9. Disconnect hose from airflow meter. Disconnect multi-plug from ECM. 6.03 NOTE: The ECM is not a serviceable item. Refit Loosen multi-plug screw to ECM.18.18. 5. 3.30. Refitting is the reverse of removal procedure. 10. 7. Loosen turbo charger hose to airflow meter retaining clip. 5. Remove meter to mounting bracket bolts. Secure multi-plug and harness aside. Disconnect airflow meter multi-plug.15 NOTE: The air flow meter is not a serviceable item. Tighten screw securing multi-plug. Remove ’A’ post trim pad. 2. Reconnect harness plug.

7. Disconnect spill return pipe to injector. Retrieve and discard union copper washers. Place pressure tube aside. Remove injector copper washers. 4. 5. Reverse removal procedure. REPAIR 15 . 4. 2. Remove sensor. Remove sensor to mounting bracket bolts. 6. INJECTION TIMING SENSOR Service repair no . 9. Renew all copper washers. 9. Remove copper washers. 8.30.Tdi BOOST PRESSURE SENSOR Service repair no .64 Remove 1. Refit 10. Refit Disconnect sensor multi-plug. Renew all copper washers. 7. 12.18. 5. Remove injector. Remove clamp. Check for leaks when running. 3.18. 11. Disconnect battery negative lead. 6. Remove injector clamp fixing. 2. Disconnect injector union. Disconnect sensor multi-plug. Reverse removal procedure.30. 3. Disconnect battery negative lead. Disconnect pressure tube union.63 Remove 1. 8.

16 REPAIR . Reverse removal procedure.65 Remove 1. 7.30. Remove sensor retaining nut.18. 8. Raise ramp. Clean housing mating faces. 4. 3. Refit 2. Disconnect sensor multi-plug.19 FUEL SYSTEM ENGINE SPEED SENSOR Service repair no . Remove sensor from housing. Disconnect battery negative lead. Place vehicle on ramp and apply handbrake. 6. 5.

Remove sensor from transfer box. 6. Reverse removal procedure. Disconnect switch wiring lucars. 3.67 Remove 1. 1. Remove sensor retaining screw. Refit 6. Refit 2. Remove switch from mounting bracket.18. REPAIR 17 . Reverse removal procedure. 5. 3. Disconnect sensor multi-plug. Disconnect battery negative lead. Turn rear body of switch to release locknut Remove locknut. CLUTCH PEDAL SWITCH Service repair no . 4. 2. 4.30. Remove sensor retaining plate.18.Tdi VEHICLE SPEED SENSOR Service repair no . 5.30. Disconnect battery negative lead.22 Remove NOTE: The following procedure is carried out with the ramp still raised.

COOLANT TEMPERATURE SENSOR Service repair no . Remove switch from mounting bracket.18.30.66 Remove 1. 8. 3. Refit 5. 5. 6. 2. Disconnect battery negative lead. Remove sensor. 3. 7.19 FUEL SYSTEM BRAKE PEDAL SWITCH Service repair no . Clean off water spillage from sensor area.68 Remove 1. Fit a new copper washer. check for water leaks around sensor. Reverse removal procedure. 4. 18 REPAIR . Refit Disconnect switch wiring Lucars. Fit sensor and tighten securely. Refill cooling system. Loosen rear locknut. 4.18. Run engine.30. 6. Disconnect battery negative lead. 2. Remove front locknut. Disconnect sensor multi-plug.

Remove 1. 5. Disconnect battery negative lead. Remove nut securing throttle pedal quadrant to sensor. Remove sensor. Remove throttle pedal quadrant. ELECTRO-PNEUMATIC MODULATOR Service repair no . Remove modulator. in the event of failure it must be renewed.69 Remove 1. Reverse removal procedure. Reverse removal procedure. 5. REPAIR 19 . 2. 3. Disconnect multiplug from sensor. CAUTION: DO NOT operate throttle mechanism while sensor is loosely fitted. damage may be caused to sensor wiper track. Remove two screws securing sensor to pedal box.30.30. 2. 6. Refit 6. 3. 4.18.17 NOTE: The throttle position sensor is not a serviceable item. Disconnect battery negative lead. 4.Tdi THROTTLE POSITION SENSOR Service repair no . Refit Disconnect multi-plug from modulator. Remove nut securing modulator to inner wing. Remove three vacuum pipes from modulator.18.

between the plenum chamber and bulkhead. Data from the sensors is received by the Engine control module (ECM). The idle air control valve will control engine idle speed when the vehicle is stationary. The ECM is connected to the main harness by a 40 pin plug. The ECM having received data from the sensors produces pulses. various sensors are fitted to the engine to measure engine parameters. The sensors monitor the oxygen content of the exhaust gases and provide feedback information of the air/fuel ratio to the ECM. The ECM increases the injector opening time when cold to provide improved driveability. Engine coolant temperature sensor The engine coolant temperature sensor is located in the front of the thermostat housing. Idle air control valve The idle air control valve is screwed into a housing attached to the rear of the plenum chamber. The sensor sends fuel temperature data to the ECM. To monitor these conditions. When the solenoid is energized the plunger is attracted off its seat and allows pressurized fuel into the intake manifold.Catalyst vehicles The two heated oxygen sensors are located forward of the catalysts mounted in the exhaust downpipes. Engine control module .MFI DESCRIPTION Hot Wire Multiport Fuel Injection The ’Hot Wire’ Multiport fuel injection system derives its name from the mass air flow sensor which uses one cold wire and one electrically heated wire to measure the volume of air entering the engine. Each injector comprises a solenoid operated needle valve with a movable plunger rigidly attached to the nozzle valve. The idle air control valve will open and allow extra air into the plenum chamber to maintain engine idle speed when the engine is under increased (Electrical and Mechanical) loads. which will govern the amount of fuel injected. the length of which will determine the simultaneous open time of each bank of injectors in turn. the ECM on receiving the data will adjust the injector open time accordingly to produce good hot starting in high ambient temperatures. Injectors The eight fuel injectors are fitted between the pressurized fuel rail and inlet manifold. Heated oxygen sensors (02 sensors) . Engine fuel temperature sensor The engine fuel temperature sensor is located in the rail on the RH side of the ram housing.ECM The Multiport fuel injection system is controlled by the 14 CUX Engine Control Module comprising of a microprocessor with integrated circuits and components mounted on printed circuit boards. The idle air control valve has two windings which enable the motor to be energised in both directions thus opening or closing the air valve as required by the ECM. the ECM will then determine the exact amount of fuel required at any condition. DESCRIPTION AND OPERATION 1 . Each sensor is heated by an electrical element to improve its response time when the ignition is switched on. and reduces the opening time as the engine reaches normal operating temperature. The sensor provides engine coolant information to the ECM. The function of the system is to supply the exact amount of fuel directly into the intake manifold according to the prevailing engine operating conditions.

when throttle stop wear occurs. for example. When pressure exceeds the regulator setting excess fuel is returned to the fuel tank. This is a fixed percentage and is independent of temperature. a small current is passed through the sensing wire to produce a heating effect. Air flow sensor The hot-wire air flow sensor is mounted on a bracket attached to the left hand valance. CAUTION: Do not attempt to adjust throttle position sensor. the ECM will detect the corresponding throttle position sensor voltage and will apply full load enrichment. The throttle position sensor is ’self adaptive’. The compensating wire is also connected to the module but is not heated. It also means the throttle position sensor setting is not lost. Fuel pump The electric fuel pump is located in the fuel tank. Throttle position sensor The throttle position sensor is mounted on the side of the plenum chamber inlet neck and is directly coupled to the throttle butterfly shaft.5 bar above that of the manifold. Movement of the accelerator pedal causes the throttle valve to open. rigidly connected to the air cleaner and by hose to the plenum chamber inlet neck. as engine intake air passes over the wires a cooling effect takes place. The ECM lengthens the injector open time when it detects a change in output voltage (rising) from the throttle position sensor. The regulator is a mechanical device controlled by plenum chamber vacuum. it ensures that fuel rail pressure is maintained at a constant pressure difference of 2. thus rotating the wiper arm within the throttle position sensor which in turn varies the resistance in proportion to the valve position. but reacts to the temperature of the air taken in. and is a self priming ’wet’ pump. the motor is immersed in the fuel within the tank. A proportion of this air flows through a bypass in which two wire elements are situated: one is a sensing wire and the other is a compensating wire.19 FUEL SYSTEM Fuel pressure regulator The fuel pressure regulator is mounted in the fuel rail at the rear of the plenum chamber. When the throttle is closed. The electronic module monitors the reaction of the wires in proportion to the air stream and provides output signals in proportion to the air mass flow rate which are compatible with the requirements of the ECM. 2 DESCRIPTION AND OPERATION . When the throttle is fully open. Full load enrichment is also achieved by adjusting the length of the injector open time. In addition the ECM will weaken the mixture when it detects the throttle position sensor output voltage is decreasing under deceleration and will shorten the length of time the injectors are open. The throttle position sensor is a resistive device supplied with a voltage from the ECM. which means that adjustment is not possible. The air flow sensor consists of a cast alloy body through which air flows. Under the control of an electronic module which is mounted on the air flow sensor body. overrun fuel cut off or idle speed control may be facilitated dependant on other inputs to the ECM.

Australia. Saudi non catalyst. The switch is normally closed and is in line with the fuel pump. The sensor also provides road speed data to the electric speedometer and cruise control ECU. 180 ohms. The main relay module is energized via the ECM when the ignition is switched on and supplies current to the multiport fuel injection system. European catalyst Condenser fans It should be noted that under high coolant temperatures. The value of the resistor is dependent on the market application: Red wire. The sensor provides road speed data to the ECM. Green wire. The switch is reset by pressing down the button. 470 Ohms. Yellow wire 910 Ohms. located on the bulkhead adjacent to the washer reservoir under bonnet [hood].MFI Tune select resistor To suit individual market requirements a tune select resistor is connected across pins 5 and 27 of the ECM. the condenser fans will be activated and will run for approximately ten minutes. It is located adjacent to the ECM. and disconnects the electrical feed to the fuel pump. UK and Europe . Should the vehicle speed sensor fail in service the ECM idle air control would become erratic. In the event of a sudden impact the switch opens. Vehicle speed sensor The vehicle speed sensor is located on the side of the Transfer box adjacent to the parking brake. DESCRIPTION AND OPERATION 3 . The fuel pump relay module is energized by the ECM which in turn operates the fuel pump to pressurize the fuel system. Relay modules The two multiport fuel injection relays are located in the RH footwell area behind the ’A’ post panel. The ECM in turn detects vehicle movement from the road speed input and ensures that idle air control mode is disengaged. White wire. when the engine is switched off.non catalyst. WARNING: Check the integrity of the fuel system before the inertia switch is reset. Rest of world. Inertia fuel shutoff switch The inertia fuel shutoff switch is a mechanically operated switch. 3K9 Ohms. and strapped to the MFI cable assembly.

Coolant temperature sensor. 7. Throttle potentiometer. 3. 4. 2. Fuel pressure regulator. By-pass air valve (stepper motor). 6. 5. Fuel temperature sensor. 4 DESCRIPTION AND OPERATION . Air flow meter.19 FUEL SYSTEM ENGINE MOUNTED COMPONENTS 1. Fuel injector.

Fuel filter. DESCRIPTION AND OPERATION 5 . Fuel pump (in fuel tank). 2.MFI CHASSIS MOUNTED COMPONENTS 1.

Inertia switch. 4. 5.19 FUEL SYSTEM BODY MOUNTED COMPONENTS 1. Purge control valve. Ignition coil. 3. 2. Main relay and fuel pump relay. Charcoal canister. 6. Engine control module (ECM). 6 DESCRIPTION AND OPERATION .

Spark plug gaps. 1. FUEL INJECTION SYSTEM CAUTION: The fuel system incorporates fine metering components that would be affected by any dirt in the system. MUST be sealed off to prevent ingress of dirt. DESCRIPTION AND OPERATION 7 . Information. All openings left open after the removal of any component from the fuel system. See ELECTRICAL. See ENGINE TUNING DATA. the following check and adjustments must be carried out before attempting to start the engine. therefore it is essential that working conditions are scrupulously clean.Service use only) As part of the engine starting procedure. Adjustment. ENGINE SETTING PROCEDURE If a major overhaul has been undertaken of the fuel injection/engine system. NOTE: If the previous checks and adjustments are satisfactory but the engine will not start. Ignition timing. Engine 3. If it is necessary to disconnect any part of the fuel injection system. the system MUST be depressurized. the ignition and fuel injection electrical circuits must be checked using the appropriate recommended equipment.9 V8i 2. Failure to do so will result in irreparable damage to the catalysts.if the engine is misfiring.MFI MICRO PROCESSOR POWER CHECK (Instrument binnacle . this symbol will illuminate momentarily. Ignition Timing CAUTION: Catalyst vehicle . it should be immediately shut down and the cause rectified.

FAULT DIAGNOSIS 1 . Testbook will guide the operator by visual prompts through a series of diagnostic checks. See Electrical Trouble Shooting Manual. check for consistent colouration of plugs. 6. remove and examine the spark plugs. Leak Test CAUTION: Catalyst exhaust: If engine is misfiring or fails to start within 12 seconds the cause must be rectified. Check HT cables for correct firing order and routing. Failure to do so will result in irreparable damage to the catalysts. should circuit diagnosis begin. 1. The following test may only be carried out using suitable injector test equipment. Check air inlet system for possible leaks into the intake manifold.MFI ENGINE TUNING Circuit fault diagnosis may be carried out on all V8i vehicles. 4. A leaking injector will result in the appropriate spark plug being ’sooted up’. Check that the inertia fuel shut off switch is not tripped. or 180-195cc per minute using petrol at 20°C ± 2°C. the following preminary checks must be carried out. Check for ample fuel in tank. using Testbook. Check fuse in main fuse panel. fuel delivery from each injector should be 160-175cc per minute using white spirit.54 Kgf/cm2. 3. 5. Leak test with the injectors closed but pressurise to 2. Only when the above checks have been carried out. No injector should leak more than 2 drops of fuel per minute. 2. Fuel Delivery Test Fuel delivery test with the injector open and pressurised as above. Before commencing any fault diagnosis. Preliminary checks INJECTOR TESTS NOTE: Before removing any of the injectors. After rectification the engine must be run at 1500 rev/min (no load) for 3 minutes to purge any accumulation of fuel in the system. Check ignition timing.

Stop engine. 7. these are manufactured using a new air by-pass valve hose .Part No. since this will affect idle speed. Cut two equal pieces 90mm long from hose and seal one end of each. Check all electrical loads are OFF. 5. 2 FAULT DIAGNOSIS . Drill tamper proof plug and insert a self tapping screw to enable plug to be extracted. Information. See ENGINE TUNING DATA. Start engine and check idle speed is within limits. Drive vehicle at least two miles until engine and transmission are hot. Fit new tamper proof plug. Use a suitable clamp to ensure an air tight seal.ETC7874. adjust idle screw clockwise to decrease or counter-clockwise to increase idle speed. Ensure hoses are securely fitted to prevent air leaks. Reconnect hose to plenum. Check ignition timing before attempting following procedure.19 FUEL SYSTEM BASE IDLE SPEED SETTING NOTE: Base idle speed is set at factory. Equipment required Two blanking hoses. Fit blanking hoses to both plenum chamber and air by-pass valve. Switch off engine. It should not require further adjustment unless plenum chamber is changed.9 v8i Adjusting base idle speed 6. Engine 3. Start engine. using 13mm diameter bar. 3. The adjustment screw is sealed with a plug to prevent unauthorised alteration. remove blanking hoses. 2. 8. Checking procedure 1. 4. 9. Note throttle cable and cruise control actuator have been omitted from illustration. including air conditioning. Remove air by-pass valve hose.

NOTE: Fuel at low pressure will remain in system. Ensure that all necessary precautions are taken to prevent fire and explosion. Multiport Fuel Injection Relay 2. 5.3 to 2. Disconnect battery negative lead. The spilling of fuel is unavoidable during this operation. If vehicle has not been run there will be a small amount of residual pressure in fuel line. injectors will become inoperative. located on the chassis under the right rear wheel arch. Fuel Pressure Regulator A B C D E Pressure gauge 18G1500 Fuel tank and pump Fuel filter Fuel injectors x 8 Regulator FAULT DIAGNOSIS 3 . If pressure is still low renew regulator.39-2. 3. Reconnect the battery and turn the ignition to position II while observing the pressure gauge.5 bar.7 kgf/cm2 in one minute. resulting in engine stall. To prevent pressurised fuel escaping and to avoid personal injury it is necessary to depressurise multiport fuel injection system before any service operations are carried out. Connect the pressure gauge on the outlet from the filter. Then recheck pressure. When engine is stationary pressure is maintained within system. Remove fuel pump relay module. 1. Switch off ignition. The depressurising procedure must still be carried out before disconnecting any component within the fuel system. place absorbent cloth around fuel pipe at the filter during disconnection. To remove low pressure fuel. operating at up to 2. When sufficient fuel has been used to cause fuel line pressure to drop. Start and run engine. If pressure is low check that filter is not blocked and pump is operating satisfactorily. See Repair.MFI FUEL PRESSURE CHECK In order to check the fuel pressure it is necessary to first depressurise the fuel system as follows: WARNING: Under normal operating conditions the multiport fuel injection system is pressurised by a high pressure fuel pump. 4. See Repair. Results Expected reading 2. 6. .672 kgf/cm2 Pressure drop-max 0.

Slide air cleaner backwards and release from mounting bracket. Release four clips retaining air cleaner cover. Fit new air cleaner element and secure in position. Remove air cleaner assembly. retain air flow meter ’O’ring. Remove air cleaner cover. 4. 9. 3. 4. Intake Air Temperature Sensor 3. REPAIR 1 .10. Refit 5. 6. 3. Fit new element. 8. Repair. Fit O ring. 4. Release 4 clips securing top of air cleaner and remove.19. From below wheel arch. Fit rubber mountings to new body. Refit 10. 8. 12. 5. 3. Position air cleaner cover.08 Remove 1. Remove element. Withdraw air cleaner element and discard. 4. Secure four air cleaner cover clips.01 Remove AIR CLEANER ELEMENT Service repair no .0 V8 only: Release clip and disconnect multiplug from intake air temperature sensor. Release 2 clips securing air cleaner to air flow sensor. 6.9 V8 only: Release clip and disconnect hose from air cleaner. Tighten to 8Nm.19. 13.9 V8 vehicle illustrated 1. Remove rubber mountings. NOTE: Pull rubber mountings from below to secure unit to wheel arch.MFI AIR CLEANER ASSEMBLY Service repair no .0 V8 only: Remove intake air temperature sensor from cover. 2. Reverse removal procedure. Release two clips to air flow meter. secure two clips to air flow meter. 4. 11. Do not carry out further dismantling if component is removed for access only.10. 2.0 V8 only: Fit intake air temperature sensor to new cover. 7. release 2 rubber mountings securing bottom of air cleaner to body. 7. See FUEL SYSTEM SFI.

Align sensor and shaft flats. damage may be caused to throttle position sensor wiper track. Fit new gasket. 4. Release two clips securing air cleaner to air flow sensor. 2 REPAIR . In event of failure or damage the complete unit must be replaced. Disconnect battery negative lead. Remove two screws securing sensor to plenum chamber and carefully pull sensor off throttle shaft. to prevent unmetered air entering engine. Disconnect multi-plug. Ensure multi-plug is firmly reconnected. and hose clamp at the rear of sensor is securely tightened. disconnect from sensor.25 Remove NOTE: The air flow sensor is not a serviceable item.19. Refit 5. Remove sensor from engine compartment. Refit 5. Disconnect multi-plug from harness. 4. Disconnect battery negative lead. Reverse removal procedure.22.19 FUEL SYSTEM AIR FLOW SENSOR Service repair no . 3. 3. CAUTION: DO NOT operate throttle mechanism while throttle position sensor is loosely fitted. 1. Secure sensor to plenum chamber.22. Release intake hose clamp.49 Remove 1. THROTTLE POSITION SENSOR Service repair no . 2. 6. Remove old gasket. 2.19. slide sensor on to throttle shaft.

2. 6. Apply Loctite 241 to threads of valve before reassembly. 4. Refit 6. REPAIR 3 . 7.88. Disconnect battery negative lead. Remove 1. Fit NEW sealing washer.19.MFI IDLE AIR CONTROL VALVE Service repair no . VEHICLE SPEED SENSOR Service repair no .54 Remove 1. Reverse removal procedure. Reverse removal procedure. Disconnect multi-plug. 3. Remove vehicle speed sensor Refit 5. Remove screw securing sensor to transfer box. Place vehicle on lift. 3.14 The vehicle speed sensor is located in the LH side of the transfer box.22. Disconnect battery negative lead. NOTE: If same idle air control valve is being refitted clean sealing compounds from threads. 2. 4. apply parking brake. Raise lift. Unscrew valve from rear plenum chamber. Remove washer. disconnect multiplug from vehicle speed sensor. 5.30. Tighten valve to 20 Nm.

Refit 4. 4. 9. Remove 1. Maneouvre the front of the plug (in the direction of the bold arrow) and detach the other end of the plug from the retaining peg. Withdraw the ECM from the clip.Blue base B. 4 REPAIR .22. 5. Refit the ECM securely in the clip and fit the two screws. The fuel injection relays can be identified as follows: A. 7. 2.22.34 NOTE: The ECM is not serviceable. 6. Ensure that the plug is pushed firmly into its location and that the retaining clip secures the plug in position. Release the two screws securing the ECM to the right-hand footwell side panel.19 FUEL SYSTEM MULTIPORT FUEL INJECTION RELAYS Service repair no . Remove lower ’A’ post trim panel. 10. Disconnect battery negative lead. Release front door seal from ’A’ post. Pull relay from base. Release ECM plug retaining clip. in event of unit failure it must be replaced.Black base ENGINE CONTROL MODULE (ECM)-14 CUX Service repair no . 3. 3. Refit 8. Remove the fascia right-hand closing panel. Remove 1. Fuel pump relay . 2. Main relay . Reconnect the ECM harness plug. Remove the right-hand footwell side panel trim.19. Reverse removal procedure. Reverse removal procedure.08 The two Multiport fuel injection relays are located in the RH footwell area behind the ’A’ post trim panel.19.

6.08 Remove NOTE: Fuel leakage will not occur when sensor is removed from fuel rail.MFI INERTIA FUEL SHUTOFF SWITCH Service repair no . Disconnect battery negative lead. Release sensor from fuel feed rail. Remove inertia switch. Connect multiplug to inertia switch. 2. 2. 7. 3. ENGINE FUEL TEMPERATURE SENSOR Service repair no . 4.22. Reconnect battery negative lead. Disconnect multi-plug from sensor. 3.19. Remove 2 screws securing inertia switch to mounting bracket. Remove 1. Disconnect multiplug from inertia switch. 4. Ensure sensor is tightened securely in fuel rail. Refit Refit 5. 1. Reverse removal procedure.18. REPAIR 5 . Disconnect battery negative lead. therefore it is not necessary to depressurise the fuel system. Position inertia switch to mounting bracket and secure with screws.30.35 The inertia fuel shutoff switch is located on the bulkhead next to the washer reservoir under bonnet [hood].

The depressurising procedure must still be carried out before disconnecting any component within the fuel system. Refit 6. place absorbent cloth around fuel feed hose at fuel rail. Remove and discard copper washer. Start and run engine. 4. DEPRESSURISING FUEL SYSTEM WARNING: Under normal operating conditions the Multiport fuel injection system is pressurised by a high pressure fuel pump. Fit a new copper washer. 3. Top-up cooling system. 7. Remove sensor from thermostat housing. See Multiport Fuel Injection Relays 2. Switch off ignition. 8. Refit fuel pump relay module. 6. To remove low pressure fuel. 2. 6 REPAIR . 7. operating at up to 2. Ensure that all necessary precautions are taken to prevent fire and explosion.19. Remove fuel pump relay module. resulting in engine stall. Refit fuel feed hose. injectors will become inoperative. Fit sensor and tigten securely. The spilling of fuel is unavoidable during this operation.5 bar When engine is stationary pressure is maintained within system. 8. To prevent pressurised fuel escaping and to avoid personal injury it is necessary to depressurise multiport fuel injection system before any service operations are carried out. Disconnect either: a) Nut and olive at fuel rail OR b) Hose at inlet end of fuel filter. check for water leaks around sensor.3 to 2. Disconnect multiplug from coolant sensor. 1. 4. Disconnect battery negative lead. Refit 5.22. 5.19 FUEL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR Service repair no .18 Remove 1. When sufficient fuel has been used to cause fuel line pressure to drop. If vehicle has not been run there will be a small amount of residual pressure in fuel line. 3. Crank engine (engine will fire in approximately 6 to 8 seconds). NOTE: Fuel at low pressure will remain in system. reconnect battery. Position drain tray to collect coolant spillage. Run engine.

See Depressurising Fuel System 2. Reverse removal procedure. Disconnect battery negative lead. See Ram Housing NOTE: Place cloth over ram tube openings to prevent ingress of dirt.19. Loosen clip and disconnect fuel return hose from regulator. Remove plenum chamber. Remove plenum chamber. See Plenum Chamber 4. Remove four bolts securing fuel rail support brackets to intake manifold. Disconnect vacuum hose from regulator. Disconnect battery negative lead. See Depressurising Fuel System 2. 8. Disconnect multi-plugs from injectors.Injectors Remove 1. Release clip and disconnect fuel return hose from regulator. 3. Release regulator from fuel rail and withdraw.60. Disconnect multi-plug from fuel temperature sensor. 5. 1. 6.06 Remove FUEL RAIL-INJECTORS R/H AND L/H Service repair no . REPAIR 7 .Rail Service repair no . Loosen union and disconnect fuel supply hose from fuel rail.19. See Plenum Chamber 4. Remove and discard ’O’ ring.45. Depressurise fuel system. 5.60. 8. Lay injector harnesses to one side. 11. 7. Refit 9.19.01 . Lightly coat ’O’ ring with silicon grease 300 and fit to regulator.04 . 7. Remove 2 bolts securing pressure regulator to fuel rail. 10. Depressurise fuel system. Reconnect battery and pressurise fuel system. Remove ram housing. 3. Check there are no fuel leaks around regulator connections.MFI FUEL PRESSURE REGULATOR Service repair no . 6. 9.

8 REPAIR . 11. 9. Secure rail and pipes in position with five bolts. Remove PCV breather hose. 8. Refit 13. Remove clevis pin from throttle cable. Fit a NEW ’O’ ring to pressure regulator lightly coat ’O’ ring with silicon grease 300 and secure regulator to the fuel rail. 18. 12. ease injectors from rail. Remove intake hose from neck of plenum chamber. 4. Remove retaining clip and clevis pin from kick down cable (automatic vehicles). 11. Pry adjustment thumb wheel from throttle bracket. Pressurise fuel system and check for fuel leaks around injectors and pressure regulator. 7.22. Disconnect battery negative lead. Fit NEW ’O’ rings. Remove front lock nut. 12. Remove fuel pressure regulator if required. Mark an identification line on throttle cable outer to assist re-assembly. Remove cable and lay aside. 17. multi-plug connections facing outwards. 16. Remove and discard ’O’ rings from injectors. Disconnect two coolant hoses and plug each hose to prevent excessive loss of coolant. to injectors. Apply adhesive tape behind rear adjustment nut on kick down cable to prevent nut moving. Identify each hose for re-assembly. Lay cable aside. 13.19 FUEL SYSTEM 10. 3. Disconnect throttle position sensor multi-plug. 10. 6. 2. 5. PLENUM CHAMBER Service repair no . Remove fuel rail and injectors. 15. CAUTION: Care must be taken when refitting the fuel rail and injectors to intake manifold to prevent damage to ’O’ rings. Remove cruise control vacuum hose. Reverse removal procedure. Disconnect electrical multi-plug from bypass air valve. 14. 2 to 7. Remove injector retaining clips. Fit fuel rail and heater pipe assemblies to intake manifold. Insert injectors into fuel rail.46 Includes throttle levers and throttle disc Remove 1. 14. Lightly coat ’O’ rings with silicon grease 300.19. Refit retaining clips. Disconnect vacuum hose adjacent to bypass air valve.

Remove six screws securing plenum chamber. 24. 21. 22. 20. release nut from throttle shaft.unclip cruise control actuator link. 16. Remove plenum chamber. 15. Remove distributor vacuum hose.MFI Throttle lever assembly . 17.remove 19. REPAIR 9 . Remove air idle air control valve hose. Release tension on outboard throttle spring. Release two screws and remove throttle position sensor. 18. Hold throttle stop lever in closed position. Release tension on inboard throttle spring. Hold throttle fully open. Carefully return lever assembly to close throttle. If fitted . Remove overtravel spring. 23. release link from countershaft assembly. Bend back lock washer tabs.

2. Spherical bush/housing Retaining clips (2) Countershaft assembly Overtravel spring Throttle shaft nut Throttle return spring (2) Tab washer Throttle stop lever Throttle bracket assembly Pop rivets (2) 10 REPAIR . 3.19 FUEL SYSTEM KEY 1. 5. 8. 7. 6. 9. 4. 10.

26. Grease shaft with Admax L3 or Energrease LS3. If spherical bush worn. Split assembly. (3/16 in) diameter drill). 34. 35. drill out two securing rivets (4. Assemble bush into housing. fit a new lever if necessary.MFI 25. Examine bearing surface of countershaft assembly. Wind new spring onto countershaft assembly. REPAIR 11 . Grease new bush with Admax L3 or Energrease LS3. 28. Throttle lever assembly . Examine throttle stop lever for wear. otherwise wind throttle return spring off levers. discard worn bush. 31. Remove the countershaft assembly. withdraw bracket assembly. Remove tab washer and throttle stop lever from throttle shaft. 32. 30. If worn fit new assembly. Remove three bolts securing throttle bracket to plenum chamber.7 mm. secure with two clips. 33. 29. Remove two retaining clips from spherical bush. Assemble to throttle bracket using two 4.inspect and overhaul 27. small hooked end of spring is wound on first. fit countershaft assembly to spherical bearing.7 mm (3/16 in) diameter domed head rivets.

42.inspect and overhaul 36. 38. Use screw driver to spread split. CAUTION: Take care not to damage shaft. Remove shaft and air seal from plenum chamber. as they will interfere with movement of throttle disc. CAUTION: Take care not to damage plenum chamber bores 40. Press in new bushes until flush with throttle disc bore.19 FUEL SYSTEM Throttle disc . Examine throttle shaft for excessive wear between bushes in plenum chamber and shaft. 39. Using suitable drift. 43. Rotate throttle shaft 360˚ once or twice to centralise disc in bore. Fit throttle shaft and disc. A small amount of clearance is permissible. Rotate shaft. Do not fully tighten screws. CAUTION: Ensure that bushes do not protrude into bore. Tighten split screws. Remove two split screws securing throttle disc and withdraw disc. drive out bushes. secure with two split screws. 12 REPAIR . 37. 41. If excessive wear is evident fit new shaft and bushes as follows.

MFI 44.0 mm (0. Wind up straight end one full turn and locate in appropriate slot. 54. a new tab washer and secure with throttle shaft nut. Push seal down shaft. Secure throttle bracket assembly to plenum. Fit stop lever to throttle shaft. tighten throttle shaft nut securely. Fit countershaft to interconnecting nut of throttle valve shaft. Clean joint faces of plenum and ram housing.5 mm (0. Using a depth vernier or depth micrometer. Refit 55. Fit inboard throttle return spring noting that small hooked end of spring is nearest plenum. 46. Fit overtravel spring. Secure with three retaining bolts. into counterbore until seal is 6. 53. If dimension is out of limits. wind spring up one full turn and locate free end in appropriate slot. bend over tabs to lock nut in position. REPAIR 13 . NOTE: If new throttle levers have been fitted. Dimension must be within 0. 48. 49. See Actuator Link Setting 56. Holding stop lever on stop. 50. refit plenum chamber. Tighten bolts to 26 Nm. Throttle levers and bracket . Locate hooked end of inboard spring on stop lever. Ensure hooked end of outboard spring is retained by lever. 47. 51. Apply ’Hylomar’ sealant. 57. Lightly grease throttle return and overtravel springs with Admax L3 or Energrease LS3. check dimension from mouth of bore to top and bottom of valve disc.236 in) below face of plenum. 52. adjust small set screw below stop lever. Reconnect and adjust cruise control actuator link. Reverse removal procedure. Grease new air seal with Admax L3 or Energrease LS3.assemble 45. minimum throttle setting of disc must be checked to ensure it is 90˚ to bore.019 in) total indicator reading across diameter of disc.

10. Remove plenum chamber. Clean all mating faces.19. Disconnect coolant sensor multiplug. 6. 10. Remove six through bolts (with plain washers) securing ram housing to intake manifold. See Plenum chamber 5. Disconnect instrument pack temperature thermistor. Disconnect the fuel temperature sensor and injector multiplugs. Apply ’Hylomar’ sealant to intake manifold face. Depressurise fuel system. See COOLING SYSTEM. 9. See Plenum Chamber 3. Disconnect multiplug from coolant temperature sensor. See Depressurising Fuel System 2. 3. Tighten bolts. Radiator 4.70. diagonally towards outer four bolts. See Ram Housing CAUTION: Place a protective cover over intake manifold openings to prevent the ingress of dirt. 6. Tighten to 26 Nm. Place a protective cover over inlet bores to prevent ingress of dirt.04 Remove 1. Disconnect battery negative lead. Refit 7. INTAKE MANIFOLD Service repair no . Disconnect battery negative lead.19 FUEL SYSTEM RAM HOUSING Service repair no . See Fuel Pressure Regulator 5. Remove ram housing from intake manifold. 4. 9. Fit ram housing. Remove plenum chamber. 2.08 Remove 1. Drain cooling system.15. 14 REPAIR .30. working from two centre bolts. Remove fuel pressure regulator. Release hoses from ram housing. Remove ram housing. 8. 7. Repair. 8.

Fit new ’O’ ring to coolant pipe. NOTE: The intake manifold can be removed from the cylinder block without removing the fuel rail and injectors. Remove and discard gasket seals.MFI 11. Remove bolt securing coolant pipe to intake manifold. 14. 19. Noting their fitted position. 12. Loosen union and disconnect fuel return hose from fuel rail. REPAIR 15 . Loosen clip and disconnect hose from heater valve. Remove 2 bolts securing thermostat housing to intake manifold. Remove fuel rail and injectors. Remove and discard ’O’ ring. 23. 17. 18. 29. Position fuel rail to intake manifold. fit and tighten bolts. Loosen union and remove coolant pipe. 20. Fit thermostat housing to intake manifold using a new gasket. 25. Remove thermostat housing. 28. Clean mating faces of thermostat housing and intake manifold. 26. 15. Position coolant pipe to intake manifold. Loosen clip and disconnect top hose from thermostat housing. Remove 5 nuts securing fuel rail support brackets to intake manifold. Remove injector harnesses from behind fuel rail and lay to one side. remove 12 bolts securing the intake manifold to cylinder block. 22. 13. Using the sequence shown. 21. Do not carry out further dismantling if component is removed for access only. Remove and discard gasket. remove bolts and clamps securing intake manifold gasket to cylinder block. Disconnect multiplug from distributor amplifier module. Remove the intake manifold. 16. fit and tighten retaining bolts. Fit bolt securing coolant pipe support bracket to intake manifold and tighten pipe union. 27. 24.

6. Radiator 12. See COOLING SYSTEM. Apply RTV sealant between ends of seals. Fit gasket clamps and tighten bolts finger tight. 4. 2. Start engine check for water and fuel leaks.19 Refit FUEL SYSTEM 1. Locate intake manifold onto cylinder heads. clean threads of manifold securing bolts. 5. 10. 11. Locate NEW seals in position with ends engaged in notches formed between the cylinder heads and block. Allow 10 minutes for RTV sealant to cure. Fit manifold bolts finger tight. 8. Clean mating faces of cylinder heads. Repair. cylinder block and intake manifold. cylinder head and block. Fit intake manifold gasket with the word ’FRONT’ to the front and open bolts hole to the front RH side. Reverse removal procedure. 9. 7. 16 REPAIR . Fill cooling system. 3. Tighten the gasket clamp bolts to 18 Nm. Working in the sequence shown tighten the bolts to 38 Nm.

Release securing bolt and bracket and remove filter from chassis side member. Ensure all necessary precautions are taken to prevent fire and explosion. Depressurise fuel system. Plug ends of hoses to prevent ingress of dirt. Tighten securing nut and bolt. REPAIR 17 . WARNING: Ensure fuel handling precautions given in Section 01 Introduction are strictly adhered to when carrying out following instructions. Fit a new filter observing direction of flow arrows stamped on canister. 9. See Depressurising Fuel System 2.25. 10.MFI FUEL FILTER Service repair no . reconnect battery. Access to filter is gained through right hand rear wheel arch.02 Remove WARNING: Spilling of fuel is unavoidable during this operation. Refit fuel pump relay module. 3. Tighten to 30Nm. Start engine and inspect for fuel leaks around hose connections. Fit inlet and outlet hoses. 7. Clean area around hose connections to prevent ingress of foreign matter into fuel system. 1. Loosen two fuel line unions and remove hoses. 8. Clamp inlet and outlet hoses to prevent fuel spillage when disconnecting hoses.19. Refit 6. 4. 5.

7.92 WARNING: Depressurise fuel system. Fuel filter. Rigid fuel feed pipe. 9. 5. 6. 8.19 FUEL PIPES FUEL SYSTEM Service repair no .19.40. 2. Rigid fuel return pipe. In-tank fuel pump. Fuel tank. KEY 1. Fuel return hose to fuel tank. 10. Breather hose. 18 REPAIR . 4. Fuel filler neck. 3. Rigid fuel feed pipe to filter. See Depressurise Fuel System before disconnecting any fuel pipes ensure that all necessary precautions are taken against fuel spillage WARNING: Ensure fuel handling precautions given in Section 01 introduction are strictly adhered to when carrying out following instructions. Fuel feed hose to fuel rail.

7. Disconnect cable from accelerator pedal and release cable locknut. using a new cotter pin. Remove clevis pin securing cable to lever. Feed cable through bulkhead grommet into engine compartment. 2. Refit 8.06 Remove 1. Check throttle operation. Adjust outer cable to give 1.MFI THROTTLE CABLE Service repair no . 10. Carefully pry throttle cable adjustment nut out of mounting bracket. Clip outer cable adjustment nut into mounting bracket. Feed new cable from engine compartment through bulkhead grommet.20. REPAIR 19 . 5. Release outer cable from retaining clips in engine compartment. 12. 9. 3. Remove cable from mounting bracket.19. Connect cable to accelerator pedal. 6. 4. Connect cable to throttle linkage.57 mm free play in inner cable. Remove lower dash panel. 11.

Remove lower dash panel. 5.35 Remove 1.45. Disconnect battery negative lead. Remove clevis pin securing throttle cable to accelerator pedal. The fuel pump/sender unit is accessed through a panel in the load space floor. Reverse removal procedure. Fold back loadspace sound insulation to reveal access panel. 3. See Depressurising Fuel System 2. Service Tools: LRT-19-001 wrench . Withdraw pivot pin. Syphon at least 9 litres (2 gallons) of fuel from fuel tank into a suitable container that can be sealed.03 A plastic fuel tank with a combined fuel pump/sender unit is fitted. 2. CAUTION: Before disconnecting any part of fuel system. Fuel pump/sender unit WARNING: Ensure that fuel handling precautions given in Section 01 Introduction are strictly adhered to when carrying out following instructions.19 FUEL SYSTEM ACCELERATOR PEDAL Service repair no .pump retaining ring LRT-19-002 ’Speedfit’ disconnector Remove 1. 5. Remove carpet from loadspace floor and tailgate. 3. Lightly grease pivot and clevis pins. 20 REPAIR . Fit clevis pin using a NEW cotter pin. dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system. 4. 6.30. 8. FUEL PUMP AND SENDER UNIT Service repair no .19. Remove accelerator pedal. Refit 7. Release tension from pedal return spring. NOTE: It may be necessary to lower steering column to gain access to pivot pin circlip. Remove circlip from pedal pivot pin. Depressurise fuel system.18. it is imperative that all dust. 9. 4.

Refit 10. care must be taken to prevent fuel spillage when unit is removed. Fit retaining ring. 13. 8. Disconnect multi-plug from fuel sender unit. Fit access panel and tighten screws. WARNING: A quantity of fuel will be retained in body of unit. Remove access panel from floor. Using service tool no.5. Connect fuel lines to pump. Fit insulation and carpet. fit a new seal if necessary. Insert fuel pump into tank. 17. sealing rings and hose connections are secure. REPAIR 21 . LRT-19-001. 7. Run engine to check for fuel leaks. Disconnect two fuel line unions from fuel pump. 11. Reverse removal procedure. Tighten to 48 Nm. 9. Connect multi-plug to sender unit. Withdraw unit from fuel tank. check all fuel pipes. After assembly. 12. 15. 4 . 16. Inspect access panel seal. remove pump unit retaining ring. 14.MFI 6.

dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system. Depressurise fuel system. NOTE: To disconnect ’speedfit’ connector. Remove rear anti-roll [sway] bar straps. Remove 1. 10. CAUTION: Before disconnecting any part of fuel system. Remove carpet loadspace floor and tailgate.01 WARNING: Ensure that fuel handling precautions given in Section 01 introduction are strictly adhered to when carrying out following instructions.19 FUEL TANK FUEL SYSTEM Service repair no . 9. Press down on collet and simultaneously pull pipe from connector. Disconnect evaporative control pipe at green end of ’speedfit’ connector. Working underneath vehicle mark location of anti-roll [sway] bar straps. Disconnect two fuel line unions from fuel pump. 11. Fold back sound insulation to reveal access panel. 3. Disconnect electrical multi-plug.55. Remove tank filler and vent hoses at fuel tank. 7. insert forked end of LRT-19-002 into slots of connector see illustration. 2. 6. Remove access panel. (refer to Warning concerning fuel vapour and spillage at start of procedure). 12. Syphon fuel tank into a suitable container that can be sealed afterwards. 22 REPAIR . and allow bar to swing down clear of tank. Disconnect battery negative lead. 8. 5. it is imperative that all dust. ENSURE TANK IS DRAINED COMPLETELY. 4. Remove nut and bolt securing right hand side fuel tank strap.19.

bolts and washers. Run engine. Remove back two bolts and nut plates securing fuel tank cradle. Refit 16. fuel pipe and hose connections are secure. REPAIR 23 .MFI 13. 17. Ensuring sealing ring. 14. check all connections for fuel leaks. With assistance. tilt right hand side of tank upwards and manoeuvre tank through chassis to remove. Remove fuel tank cradle. Reverse removal procedure. Remove front nuts. 15.

................................. M10 .................................................................................................................................................. 9 24 39 78 90 136 NOTE: Torque values above are for all screws and bolts used except for those specified.......................................................MFI TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque.......................................................................................... M14 ......................................................................................................................................................................................................................... Nm 20 1............... 5/8 .......................................................... 5/16 ...................................... M6 .....................................7 METRIC M5 ......................... M12 ............................................................................................hose to fuel rail ........3 22 31 Air-Bypass valve (stepper motor) ........................... Fuel filter .............................................................................................. Fuel feed pipe ................. 3/8 ...... All flexible hose securing clamps ............................................................................................................... M8 ............................................................ SPECIFICATIONS............................. Nm 6 9 25 45 90 105 180 UNC / UNF 1/4 ............ EVAPORATIVE LOSS CONTROL SYSTEM All flexible hose securing clamps ... 1............................................................ M16 ........................ 7/16 .......... TORQUE 1 ........ 1/2 .................................................

MFI FUEL SYSTEM LRT-19-004 18G 500 Test equipment fuel pressure LRT-19-003 LST 143 MFI pressure test adaptor LRT-19-002 LST 144 Connector splitter LRT-19-001 LST 131 Fuel pump remover SERVICE TOOLS 1 .

how fast the engine is turning . Camshaft position sensor (CMP Sensor) The camshaft position sensor is located in the engine front cover. The system incorporates certain default strategies to enable the vehicle to be driven in case of sensor failure. failure will result in the engine starting. The signal is used in two areas.SFI ENGINE MANAGEMENT SYSTEM Description The engine management system (EMS) maintains optimum engine performance over the entire operating range. The fuel injection system uses a hot wire Mass Air Flow Sensor to calculate the amount of air flowing into the engine. If the camshaft sensor fails. when the ECM detects no MAF Sensor signal. Crankshaft position sensor (CKP Sensor) The crankshaft position sensor is the most important sensor on the engine. A further feature of the system is ’robust immobilisation’. changing its resistance. This may mean that a fault is not detected by the driver. The fuel injectors will be actuated sequentially. The on board diagnostic system detects any faults which may occur within the EMS. a sensing wire which is heated and a compensating wire which is not heated. DESCRIPTION AND OPERATION 1 . using four double ended coils. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. emissions related items. Injection will either be correct or one revolution out of synchronisation.which stage the engine is at in the cycle. The ignition system does not use a distributor. and dying when it reaches 550 rev/min. Fault diagnosis includes failure of all EMS sensors and actuators. The sensing element of the MAF Sensor is a hot wire anenometer consisting of two wires. The fault is not easily detected by the driver. The signal it produces informs the ECM: . The circuit to each coil is completed by switching inside the ECM. injector timing corrections for fully sequential fuelling and active knock control. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. default operation is to continue normal ignition timing.the engine is turning . fuel supply and exhaust systems. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. Air flows across the wires cooling the heated one. As there is no default strategy. The system is controlled by the ENGINE CONTROL MODULE (ECM) which receives data from sensors located on and around the engine. The ECM measures this change in resistance and calculates the amount of air flowing into the engine. timing the injection with respect to top dead centre. From this information it provides the correct fuel requirements and ignition timing at all engine loads and speeds. It is a direct ignition system (DIS). As there is no default strategy. It produces one pulse every two revolutions. failure of the crankshaft sensor will result in the engine failing to start. Mass air flow sensor (MAF Sensor) The ’hot wire’ type mass air flow sensor is mounted rigidly to the air filter and connected by flexible hose to the plenum chamber inlet. It is located in the left hand side of the flywheel housing and uses a different thickness of spacer for manual and automatic gearboxes. The correct amount of fuel is metered into each cylinder inlet tract and the ignition timing is adjusted at each spark plug. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles.

Engine control module Ignition coils Fuel pressure regulator Mass air flow sensor Relay module . Throttle position sensor 2 DESCRIPTION AND OPERATION REV: 09/95 . 2.19 FUEL SYSTEM ENGINE MANAGEMENT SYSTEM COMPONENT LOCATION .Main relay . 3.PRE ADVANCED EVAPS 1.Fuel pump relay 6. Camshaft position sensor 8. 4. Engine coolant temperature sensor 7. 5.

3. 9.SFI 1. 8. 6. 5. 2. EVAP purge valve Inertia switch Engine fuel temperature sensor Crankshaft position sensor Oxygen sensor (4 off) Injectors Idle air control Knock sensors (2 off) Intake air temperature sensor DESCRIPTION AND OPERATION 3 . 7. 4.

Intake air temperature sensor (IAT Sensor) This is another resistive sensor.5V) informs the ECM of the actual position of the throttle disc. programmed for each default value. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. If the sensor is disconnected or failure occurs a default value will be supplied to the system. there may be a hot restart problem. i. The resistance of the strip varies considerably with coolant temperature. The fault may not be evident to the driver.19 FUEL SYSTEM Throttle position sensor (TP Sensor) The throttle position sensor is mounted on the plenum chamber and connected directly to the throttle shaft. This will increase to a nominal warmed up value over an individual time. The initial default value selected will be based on the value of the air intake temperature. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles.30°C to 90 ohms at 130°C. If failure occurs in the closed position the engine will only reach 1750 rev/min when the ECM will initiate overrun fuel cut off. The resistance varies with changes in air temperature.e. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. from 28K ohms at . richer mixture at low temperatures. The default value selected will represent normal operating conditions. 4 DESCRIPTION AND OPERATION . there may be slight power loss in high ambient temperatures. the signal from which (0 . Engine coolant temperature sensor (ECT Sensor) This sensor consists of a temperature dependant resistive metal strip. If the sensor is disconnected or failure occurs a default value will be supplied to the system. As there is no default strategy.e. as the correct fuelling is dependant upon engine temperature i. The ECT Sensor signal is vital to engine running. and 300 Ohms at 85°C. The signal from the IAT Sensor is used to retard the ignition timing if the air temperature rises above 55°C. The sensor is a variable resistor. located in the body of the air cleaner. failure of the sensor will result in poor idle and lack of throttle response. The fault may not be evident to the driver.

g. It is possible that all eight cylinders could have different advance angles at the same time.SFI Engine fuel temperature sensor (EFT Sensor) This is another resistive sensor. If the knock sensor fails engine knock will not be detected and corrected. one injector per cylinder. one on compression stroke. 1 instead of 6. coil 2 feeds cylinders 5 and 8. Located on the fuel rail it measures temperature of the rail rather than the fuel. REV: 09/95 DESCRIPTION AND OPERATION 5 . the fuel squirts into the cylinder in a fine spray to aid combustion. The circuit to each coil is completed by switching within the ECM. The ECM can also work out exactly which cylinder is knocking and retards the ignition on that particular cylinder until the knock disappears. The resistance varies with changes in temperature. vapourisation occurs in the rail and bubbles can occur in the injectors. Coil failure will result in a lack of sparks and misfire in the affected cylinders. Sparks are produced in two cylinders simultaneously. In the unlikely event of injector failure a misfire will occur as there will be no fuel to the affected cylinder. but as the engine may be running one revolution out of sychronisation the ECM may retard the wrong cylinder of the pair e. Due to the ease of combustion in the cylinder on the compression stroke. If the camshaft sensor fails. Knock sensors The knock sensor produces an output voltage in proportion to mechanical vibration caused by the engine. When the fuel is hot. Each injector consists of a small solenoid which is activated by the ECM to allow a metered amount of fuel to pass into the combustion chamber. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. The ECM calculates if the engine is knocking due to camshaft and crankshaft sensor signals regarding the position of the engine in the cycle. the other on exhaust stroke. and coil 4 feeds cylinders 2 and 3. Note that coil 1 feeds cylinders 1 and 6. They are mounted on a bracket fitted to the rear of the engine. and cools the fuel rail with fuel from the tank. coil 3 feeds cylinders 4 and 7. The fault may not be evident to the driver. more energy is dissipated in that cylinder. allowing each coil to charge up and fire. Increasing the pulse time flushes the bubbles away. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. the knock sensor will continue to work. Ignition coils The electronic ignition system uses four double ended coils. there may be a hot restart problem. A sensor is located in each cylinder bank between 2/4 and 3/5 cylinders. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. Injectors A multiport fuel injection system (MFI) is used. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. Due to the pressure in the fuel rail and the shape of the injector orifice. The signal is used to increase the injection pulse time when undergoing hot restarts. The ECM can adjust the timing of each cylinder for knock simultaneously. It then advances the ignition to find the optimum ignition timing for that cylinder.

and oxides of nitrogen (NO2). with possible catalyst damage. Care must be exercised when working on the exhaust system not to damage the sensor housing or tip. Operation and fuelling will be calculated using signals from the remaining ECM inputs. North American vehicles have two extra HO2 sensors mounted one after each catalyst. thus reducing the emissions of carbon monoxide (CO). The stepper motor controls idle speed by moving the plunger a set distance called a step. and reacts with the titanium wire altering the resistance of the wire. The fault is indicated by illumination of the malfunction indicator light (MIL). Two HO2 sensors are fitted. ECM diagnostics also uses HO2 sensors to detect catalyst damage. Failure of the stepper motor will result in low or high idle speed. the vehicle will start and idle correctly until the sensors reach operating temperature. 6 DESCRIPTION AND OPERATION REV: 09/95 .19 FUEL SYSTEM Idle air control (IAC) Idle speed is controlled by a stepper motor which consists of two coils. misfire and fuel system faults. From this resistance change the ECM calculates the amount of oxygen in the exhaust gas. engine stall or non start. CAUTION: Although robust within the vehicle environment. In the event of sensor failure. Note that if the wiring to these sensors is crossed. Then the ECM will read the signals from them and send one bank of cylinders very rich and the other very weak. excessive heat and contamination. The injected fuel quantity is then adjusted to achieve the correct air/fuel ratio. When energised in the correct sequence the coils move a plunger which opens and closes the throttle bypass controlling the quantity of idle air. have a rough idle and emit black smoke. poor idle. the system will default to ’open loop’. one in each exhaust downpipe just ahead of the catalyst. These are used to determine whether the catalysts are operating efficently. hydrocarbons (HC). Fully open is zero steps and fully closed 180 steps. Heated oxygen sensor (HO2S) The oxygen sensors consist of a titanium metal sensor surrounded by a gas permeable ceramic coating. The fault is indicated by illumination of the malfunction indicator light (MIL) on North American specification vehicles. Oxygen in the exhaust gas diffuses through the ceramic coating on the sensor. HO2 sensors are easily damaged by dropping. The engine will misfire.

Relay module The engine management system employs a relay module. outlet. faults caused by the failure may be indicated. Main relay The main relay supplies the power feed to the ECM with a tap off to feed the fuel injectors (8 amps) and air flow sensor (4 amps). During this ’ECM power down routine’ the ECM records all temperature readings and powers the stepper motor to the fully open position. Although the fault will not illuminate the MIL. resulting in overfuelling if the pressure remained constant. which houses the main relay and the fuel pump relay. Failure of this relay will result in the engine management ECM not being switched on resulting in engine not starting due to absence of fuel and ignition. allowing fuel to return to the tank. the applied vacuum sucks the diaphragm of its seat. or a rich mixture resulting in engine flooding. It is reset by depressing the central plunger at the top of the switch. It consists of a fuel inlet.SFI Fuel pressure regulator The fuel pressure regulator is located at the rear of the engine in the fuel rail. The relay is activated in ignition key position 2 to prime the fuel system for a period of time controlled by the ECM. This enables the ECM to remain powered up after ignition is switched off. vacuum port and internal diaphragm. This is necessary because the high depression will try to suck the fuel from the injector. The inertia switch is located in the engine compartment. This relay is controlled by the engine management ECM. Fuel pump relay The fuel pump relay is fed from the ignition relay and controlled by the engine management ECM. Inertia switch The inertia switch isolates the power supply to the fuel pump in the event of sudden deceleration. When the engine is under high manifold depression. Failure of this relay will result in no fuel pressure. or a weak mixture. Failure will result in a rich mixture at idle but normal at full load. REV: 09/95 DESCRIPTION AND OPERATION 7 . resulting in a lower fuel pressure.

Camshaft position (CMP) sensor 8. 2. Engine control module (ECM) Ignition coils Fuel pressure regulator Mass air flow (MAF) sensor Relay module . Throttle position (TP) sensor 8 DESCRIPTION AND OPERATION ADD: 09/95 . 4.Main relay .19 FUEL SYSTEM ENGINE MANAGEMENT SYSTEM COMPONENT LOCATION .Fuel pump relay 6. 5. Engine coolant temperature (ECT) sensor 7. 3.ADVANCED EVAPS 1.

SFI 1. 3. 7. 9. 5. 10. EVAP canister purge valve EVAP canister vent solenoid (ECVS) Inertia fuel shut-off (IFS) Engine fuel temperature (EFT) sensor Crankshaft position (CKP) sensor Heated oxygen (HO2) sensor (4 off) Fuel injectors Idle air control valve (IACV) Knock sensors (2 off) Intake air temperature (IAT) sensor ADD: 09/95 DESCRIPTION AND OPERATION 9 . 2. 8. 6. 4.

3. The pump assembly is sealed to the tank with a rubber seal and secured in place using a coated steel locking ring.19 FUEL SYSTEM DESCRIPTION AND OPERATION .ADVANCED EVAPS 1. The pump also incorporates a fuel tank pressure sensor in the top flange. The pump is a self priming æwet" type where the motor is immersed in fuel. 2. Fuel filter Fuel pump and gauge sender unit Fuel feed hose Fuel return hose Fuel filler neck assembly Fuel Tank Assembly The fuel tank consists of a moulded High Density Polyethylene (HDPE) fuel cell into which is fitted an electric fuel pump and four roll-over valves. NOTE: If the pump is removed. a new seal must always be fitted. 4. 5. 10 DESCRIPTION AND OPERATION ADD: 09/95 .

ADD: 09/95 DESCRIPTION AND OPERATION 11 . if removed a new clip of the same type must be fitted. The fuel lines in the engine compartment are made from a braided nylon material. via a fuel filter on the feed line. The nylon lower is joined at one end to the tank and at the other to the stainless upper section where both joints utilise a short piece of rubber hose. NOTE: When the fuel filter is serviced or the fuel rail joints are disconnected. NOTE: The spring assisted clip must never be re-used. Tank vent connections are achieved using serviceable plastic quickfit connectors. while those at the filter and fuel rail are threaded unions utilising "O" rings for effective sealing. new "O" rings must always be fitted. Connections at the pump are metal quickfits. The filler cap is tethered to the body of the vehicle. Fuel Lines The fuel lines consist of two coated steel lines fitted along the length of the chassis from the fuel pump at the rear of the vehicle to the connections at the fuel rail on the engine. NOTE: This material must not be clamped or kinked as this impairs its performance. The joint at the fuel tank is secured using a spring assisted hose clip which has a shear off cap. Only a cap of this type must be used as a replacement.SFI Fuel Filler Neck Assembly The filler neck consists of a stainless steel upper section and a convolute nylon lower section. Connections at the fuel rail are made using "Saginaw" screw thread type connectors with "O" rings as the sealing medium.

All vehicles: 1. 2. Vehicle must be in neutral or park with air suspension in kneel and disabled. The bypass screw is covered by a tamper proof plug which can be extracted using a self tapping screw. Carry out tuning or base idle setting procedure as applicable using TestBook. ADJUSTMENT 1 . Ensure air conditioning and all electical loads are off.SFI ENGINE TUNING Service repair no .22.19.13 The position of the Idle Air Control (IAC) valve can be checked using TestBook and adjusted if necessary through the by-pass screw in the plenum chamber.

6. Lower ramp. Clean sensor and mating face on front cover. Disconnect multiplug. Refit 8. Remove ’O’ ring from sensor and discard.19. Reconnect battery negative lead. Connect sensor multiplug and secure to bracket. Remove bolt securing sensor. 4. 3. 12.SFI CAMSHAFT POSITION SENSOR (CMP SENSOR) Service repair no . Raise vehicle on a ramp. 2. Remove sensor from front cover. Release sensor mutiplug from clip located on front cover. Lubricate NEW ’O’ ring and fit to sensor.07 Remove 1. 13. 11. Disconnect battery negative lead. 5.22. 9. 7. REPAIR 1 . Tighten to 8 Nm. Engage CMP sensor in front cover location. 10. Secure with bolt.

4. Check for leaks around ECT sensor. 7. Ensure spacer is correctly refitted. Position shield to sensor and align sensor/shield to engine backplate.18. Remove sensor/shield. 2. 8. Refit 8. 11. 11. 5. Fit ECT sensor. 4. Run engine to normal operating temperature. CAUTION: All vehicles have a spacer fitted to the sensor.19 FUEL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) Service repair no . Raise vehicle on ramp. Position sensor and connect multiplug. Remove ECT sensor. 10. Remove spacer from sensor.30. Tighten to 20 Nm. 13. 2 REPAIR . 9. Clean mating faces. Clean sealing washer. 10. Remove 2 bolts securing sensor/shield to engine backplate. Disconnect battery negative lead. Fit bolts. Fit spring clip to multiplug and connect multiplug to ECT sensor. 7. Reconnect battery negative lead. Position cloth around ECT sensor to absorb coolant spillage. Disconnect sensor multiplug and remove sensor. Disconnect battery negative lead. 9.10 CRANKSHAFT POSITION SENSOR (CKP SENSOR) Service repair no . Remove shield. Remove spring clip and disconnect ECT sensor multiplug. Lower ramp. 5. Coat sensor threads with Loctite 577 and fit new sealing washer. 14. 2. Fit spacer to sensor. Top up cooling system.18. sensor threads and sensor location. 12.12 Remove Remove 1.30. 3. 6. Refit 6. Tighten to 6 Nm. Remove sealing washer and discard. 1. 3.

Carefully slacken union. even if the engine has not been run for some time. Tighten union to correct torque once pressure has relieved. 3.DEPRESSURISE WARNING: Fuel pressure of up to 2. Always depressurise the system before disconnecting any components in the fuel feed line (between fuel pump and pressure regulator). 1. REPAIR 3 .5 bar will be present in the system.SFI FUEL SYSTEM . Ensure that all necessary precautions are taken to prevent fire and explosion. Position cloth around relevant union to protect against fuel spray. 2. NOTE: Fuel pressure can be relieved at fuel rail feed union or fuel filter unions. The spilling of fuel is unavoidable during this operation.

Ensure mating faces of air cleaner. Reverse removal procedure. Refit 9. 10. 4 REPAIR . 7. Disconnect battery negative lead. Collect ’O’ ring seal. Reconnect battery negative lead.25 Remove 1. Disconnect battery negative lead.18. 6. Release ECM from 2 lower retainers. 11. Washer Reservoir 3.19 FUEL SYSTEM ENGINE CONTROL MODULE (ECM) Service repair no . MAF sensor and intake hose are clean. Disconnect 3 ECM multiplugs. Remove 2 studs securing ECM cover. causing running problems. 3. Fit MAF sensor to air cleaner and secure with clips. 5. Remove ECM. 2. See WIPERS AND WASHERS. Release and move washer reservoir aside. CAUTION: Failure to connect intake hose securely will allow unmetered air to enter the engine. NOTE: Ensure ECM is correctly located by lower retainers.30. Release 2 clips and remove MAF sensor from air cleaner. MASS AIR FLOW SENSOR (MAF SENSOR) Service repair no .01 Remove 1. 2. Refit 6. 5.22. 8. Repair. Loosen clip and disconnect intake hose from MAF sensor. Fit ’O’ ring to MAF sensor. Remove cover. Disconnect multiplug from MAF sensor. 4.19. Connect multiplug to MAF sensor. 9. 8. 4. Connect intake hose and secure with clip. Remove 2 bolts securing ECM. 7.

10.04 . Remove 6 bolts securing ram housing to inlet manifold.Injectors Remove 1. 14. Disconnect fuel temperature sensor multiplug. Lever between packing block and ram pipe housing to break seal. See Plenum Chamber 6. Disconnect purge hose. REPAIR 5 . Plug fuel pipe and rail.SFI FUEL RAIL AND INJECTORS Service repair no . Release plenum chamber and place aside. Depressurise fuel system. Place small packing block on inlet manifold. 7. 12. 2. crankcase breather hose. See Fuel System Depressurise 3.19. Position cloth around fuel feed pipe union to absorb fuel spillage. Slacken clip securing fuel return hose.60. CAUTION: Do not lever against fuel rail. 4. 9.60.Fuel Rail Service repair no . servo vacuum hose and fuel regulator hose from ram housing. 8. 13. 5.19. Remove ram housing.12 . Disconnect 8 injector multiplugs. Place cloth over inlet manifold to prevent ingress of foreign matter. Disconnect battery negative lead. 11. Disconnect fuel feed pipe from fuel rail.

Reconnect battery negative lead. Position ignition coil bracket on inlet manifold studs. Fit fuel pressure regulator to fuel rail. Disconnect hose. Secure with bolts. Remove injectors from fuel rail. 29. Remove fuel rail and injectors. Remove pressure regulator assembly. 20. 39. 22. Remove 8 clips securing injectors to fuel rail. 37. 24. Tighten to 8 Nm. Connect hose and tighten clip.19 FUEL SYSTEM 15. Ensure all locations in fuel rail and inlet manifold are clean. Remove plugs from fuel feed and return pipes and rail. 19. 17. Place aside. 30. Position fuel rail to inlet manifold. 32. See Plenum Chamber 43. 16. 44. 27. Secure ignition coil bracket and fuel rail to inlet manifold with nuts. Release fuel rail and injectors from inlet manifold. 35. Remove ’O’ ring from fuel pressure regulator and discard. Release ignition coil bracket from inlet manifold studs. Clean feed pipe union and connect fuel feed pipe to fuel rail. Remove cloth. Connect purge hose. Check for leaks around fuel rail and injectors. Ensure mating surfaces between inlet manifold and ram pipe housing are clean. Fit plenum chamber. Remove 2 bolts securing fuel pressure regulator to fuel rail. Start engine. crankcase breather hose. 34. 18. 31. 42. Apply a thin. servo and pressure regulator vacuum hoses to ram housing. one bank at a time. 25. Tighten to 24 Nm. Refit 26. 21. 38. Lubricate and fit new ’O’ rings to injectors and fuel pressure regulator. Do not carry out further dismantling if component is removed for access only. Connect multiplugs to fuel injectors and fuel temperature sensor. Fit ram housing to inlet manifold. 23. Remove 2 ’O’ rings from each injector and discard. 40. Tighten to 10 Nm. Fit injectors to fuel rail. Secure with bolts. plug return hose and rail. 41. Remove cloth from inlet manifold. Secure with clips. Remove 6 nuts securing fuel rail and ignition coil bracket to inlet manifold. 33. uniform coating of Loctite 577 sealant to mating face of inlet manifold. 6 REPAIR . 28. Engage injectors. Tighten union to 16 Nm. 36.

1. Reconnect battery negative lead. Refit 4. 6. 7. Disconnect battery negative lead. Fit sensor.22.08 Remove NOTE: Because fuel leakage will not occur when sensor is removed. 5. REPAIR 7 . Ensure sensor and location in fuel rail are clean. Connect multiplug.SFI FUEL TEMPERATURE SENSOR Service repair no . Tighten to 17 Nm. 2.19. 3. Remove sensor from fuel rail. it is not necessary to depressurise the fuel system for this operation. Disconnect multiplug from fuel temperature sensor.

45 .18.T. Fit ignition coil to bracket.19 FUEL SYSTEM Refit IGNITION COILS Service repair no . Reconnect battery negative lead.44 . 9.Each Service repair no . 2. Connect H. Connect multiplug. REPAIR 8 . 16. 18. 7. 4. Secure fuel rail and ignition coil bracket with nuts. 3. leads from ignition coils. Remove terminal cover. Manoeuvre coil/bracket assembly from behind plenum chamber and remove. Remove 2 nuts securing leads to coil terminals. 17. Disconnect battery negative lead. 15.Set Service repair no . 5. Secure with nuts. 19.18. Remove 3 Torx screws securing ignition coil to bracket and remove coil. 12. leads aside.43 .20.T. Tighten to 8 Nm. Fit terminal cover. Disconnect H. Remove leads from terminals.Extra . Connect leads to terminals.T. 13.20. 11. Note positions of leads.20. Position ignition coil bracket on inlet manifold studs. 8. 6. 14. Note lead positions.Each Remove 1. Release ignition coil bracket from inlet manifold studs. 10.18. Disconnect ignition coil multiplug. Secure with screws. Place H. Remove 4 nuts securing coil bracket. leads to respective coil towers.

19. Ensure drive engages correctly with throttle spindle. Clean sensor and mating face. Refit 1.49 Remove Remove 1.SFI INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) Service repair no .09 THROTTLE POSITION SENSOR (TP SENSOR) Service repair no . Clean mating faces.30.18. Remove 2 Torx screws securing TP sensor. 5. Disconnect multiplug from TP sensor. Secure TP sensor with Torx screws.22. 7. Refit 3. Connect multiplug. 4. Position clamp plate. REPAIR 9 . Fit TP sensor. 4. Tighten to 2 Nm. Collect clamp plate. Remove TP sensor. Remove IAT sensor from air cleaner. 2. Fit IAT sensor. 3. 6. Disconnect multiplug from IAT sensor. 2. Connect multiplug. 5. Tighten to 8 Nm.

RH CAUTION: Due to the sensitivity of the sensors. 3. 6. RH Sensor only: Remove bolt securing starter motor heatshield to RH engine mounting.30. Remove 1. 9. 11. do not apply tape or sealant to sensor threads.Sensor . Release heatshield clip from starter solenoid. Lower ramp. Tighten to 16 Nm. Clean sensor and mating face. Both sensors: Disconnect sensor multiplug. Fit and tighten bolt.28 . RH Sensor only: Manoeuvre heatshield into position.30.19 FUEL SYSTEM KNOCK SENSOR Service repair no . 13.Sensor .18. 10 REPAIR . 12. CAUTION: Failure to tighten sensor to correct torque will result in malfunction or sensor damage.LH Service repair no . 4. Refit 7.18. Connect sensor multiplug. 8. Align bracket to mounting and fit bolt. Raise vehicle on ramp. Remove sensor. Fit sensor. 2.30 . 5. Move heatshield aside for access to knock sensor. 10. Secure clip to solenoid.

Remove fuel pressure regulator assembly. Release fuel return hose clip. Remove 2 bolts securing fuel pressure regulator to fuel rail. 7. See Fuel System Depressurise 9. Depressurise fuel system. slacken union to release fuel pressure. then re-tighten union. Release clip and remove connecting pipe from regulator. Release ignition coil bracket from inlet manifold studs and place aside. Release regulator connecting pipe from clip. Disconnect vacuum hose from fuel pressure regulator. 13. 12. 10. Remove ’O’ ring and spacer ring from fuel pressure regulator. 6. 3. 4. 8. Position cloth over fuel feed union. 5.06 Remove 1. 14. 2. Plug connections. 11.45. Discard ’O’ ring. Fit plugs to regulator and rail. Disconnect battery negative lead.SFI FUEL PRESSURE REGULATOR Service repair no . Remove 4 nuts ignition coil bracket to inlet manifold. Remove fuel return hose from regulator connecting pipe. REPAIR 11 .19.

22. 22. Remove plugs. 9. Secure with bolts. Check for leaks around fuel pressure regulator.3 Nm. fuel feed and fuel return unions. 7.19. Ensure locations on fuel pressure regulator and fuel rail are clean. Remove 2 bolts securing IAC to plenum. 25. 6. 15. Tighten to 2. Secure ignition coil bracket and fuel rail to inlet manifold with nuts. 19. Disconnect battery negative lead. Align ignition coil bracket to inlet manifold studs. Secure regulator connecting pipe in clip. Lubricate ’O’ ring with silicone grease. Start engine. 5. Refit Disconnect IAC multiplug. 12 REPAIR .54 Remove 1. 27. Connect return pipe to regulator connecting pipe. 23. 24. Fit pressure regulator assembly to fuel rail. 3. 16. 4. Fit new spacer ring and ’O’ ring to fuel pressure regulator. Remove cloth. 26. 18. Tighten to 8 Nm. 2. Reconnect battery negative lead. Remove gasket and discard. Ensure all mating faces are clean. Remove IAC. Using a new gasket. Connect vacuum hose to fuel pressure regulator. 21. 8.19 Refit FUEL SYSTEM IDLE AIR CONTROL (IAC) Service repair no . fit IAC to plenum. 17. Reconnect battery negative lead. Tighten to 10 Nm. Connect multiplug. Secure with clip. 20. Secure with bolts.

2. Disconnect multiplug from idle air control (IAC). 18. Disconnect vacuum hose from cruise actuator. 8.19. 11.22. 4. 13. Slacken clip securing intake hose to plenum chamber and release hose. 17. 14. Remove front locknut from kick down cable. 3. Remove split pin from throttle cable clevis pin. 7. Remove clevis pin. Tighten clamp. Release cable from bracket. 15. 6. Release plenum chamber from ram pipe housing.46 Remove 1. Slacken clips securing coolant hoses to plenum.SFI PLENUM CHAMBER Service repair no . 5. Position cloth to absorb coolant spillage. Disconnect breather hose from plenum. Disconnect battery negative lead. Fit approved hose clamp to water jacket coolant hoses. Do not carry out further dismantling if component is removed for access only. Release and remove kick down cable clevis pin. 12. Remove 6 bolts securing plenum chamber. Release throttle cable from abutment bracket. REPAIR 13 . 10. 16. 9. Release clip and disconnect multiplug from throttle position sensor (TP Sensor).

Remove water jacket. Remove bracket. Remove 4 bolts securing water jacket to plenum chamber. Remove TP sensor. 22. Collect clamp plate. 23. Disconnect hoses and remove plenum chamber. Remove gasket and discard. Remove 2 bolts securing IAC. Remove 2 Torx bolts securing TP sensor.19 FUEL SYSTEM 19. 21. Collect return spring. Remove gasket and discard. Place cloth over ram pipes to prevent ingress of foreign matter. Remove 3 bolts securing throttle linkage bracket to plenum chamber. 20. Remove motor. 14 REPAIR . 24.

71 Remove 1. 49. Fit clevis pin. 39. Using a new gasket. 2. Connect throttle cable to abutment bracket. Secure with bolts. Tighten to 8 Nm. 37. Secure linkage bracket to plenum chamber with bolts. 3. Fit clevis pin and secure clip.30. Tighten to 2. Release module from bracket. Fit TP sensor. 48. Ensure all mating surfaces are clean. 31. Top up cooling system. Using a new gasket. Reverse removal procedure. fit and engage return spring. Tighten to 2 Nm. 45. 36. 27. 30.PRE ADVANCED EVAPS Service repair no . Tighten to 24 Nm. Fit plenum chamber bolts. Fit plenum chamber. Connect intake hose and secure with clip. Tighten to 13 Nm. 26. 35. Secure with clips. Align throttle cable to lever. RELAY MODULE . 41. Fit kick down cable to abutment bracket and fit locknut. Remove module. 46. 47. 28. Remove clamp from coolant pipes. Remove cloth. 42.3 Nm. Apply a thin. Disconnect 2 multiplugs. 32. Secure clevis pin with split pin. REV: 09/95 REPAIR 15 . Position clamp plate. Connect breather hose to plenum chamber. Position throttle linkage bracket. Connect coolant hoses to water jacket. fit IAC. Remove cloth from ram housing.18. 33.SFI Refit 25. uniform coating of Loctite 577 sealant to sealing face of plenum chamber. Ensure mating faces of water jacket and plenum chamber are clean. Connect vacuum hose to actuator. Reconnect battery negative lead. Connect multiplugs to TP sensor and IAC. 38. Align kick down cable to lever. 34. Position plenum chamber. Ensure drive engages correctly with throttle spindle. 43. Secure with bolts. Ensure mating faces of plenum chamber and ram pipe housing are clean. 44. fit water jacket. 29. 40. Refit 4. 50. Secure TP sensor with bolts.

Remove module. CAUTION: Use two spanners when loosening or tightening unions. Refit 4. 16 REPAIR ADD: 09/95 .ADVANCED EVAPS Service repair no .02 Remove WARNING: Spilling of fuel is unavoidable during this operation. Remove nut and bolt securing fuel filter bracket to chassis and remove filter from bracket.19. 4.18. Depressurise fuel system. Raise rear of vehicle. WARNING: Ensure fuel handling precautions given in section 1 Introduction are strictly adhered to when carrying out following instructions. Clean area around hose connections to prevent ingress of foreign matter into fuel system. 2. Remove and discard ’O’ rings. Disconnect 2 multiplugs from module. Plug ends of hoses to prevent ingress of dirt.ADVANCED EVAPS Service repair no .25. 3. Position module. Ensure all necessary precautions are taken to prevent fire and explosion. 5. 1.71 Remove FUEL FILTER . Release module from bracket.advanced evaps 2. Loosen 2 fuel line unions and disconnect hoses. 1. Clamp inlet and outlet hoses to prevent fuel spillage when disconnecting hoses. connect multiplugs and secure to bracket.30. See fuel system depressurise . 3. WARNING: Support on safety stands.19 FUEL SYSTEM RELAY MODULE .

Lubricate NEW ’O’ rings with clean fuel and fit to fuel hoses. 4. 10.SFI Refit 6. The fuel pump is accessed through a panel in the load space floor. 3. Repair. Remove stand(s) and lower vehicle. Remove RH luggage compartment side panel. drain 2.03 NOTE: Ensure direction of flow arrow stamped on canister is correct. Remove plugs from fuel hose ends. CAUTION: Before disconnecting any part of fuel system. FUEL PUMP AND GAUGE SENDER UNIT ADVANCED EVAPS Service repair no .advanced evaps 7. it is imperative that all dust. Fit a NEW filter to bracket. See CHASSIS AND BODY.draining . Position filter mounting bracket to chassis and secure with nut and bolt. CAUTION: Use two spanners when loosening or tightening unions.19. 12. WARNING: Ensure that fuel handling precautions given in 01 . A plastic fuel tank with a combined fuel pump and gauge sender unit is fitted. Depressurise fuel system.advanced evaps 2.45. The top flange of the pump also houses a pressure sensor which is not removable from the pump. Check the amount of fuel in the tank.4 US gallons (9 litres) minimum. If the tank is full. Remove 6 screws securing tail door tread strip and remove tread strip. Disconnect battery negative lead. Remove 1. 11. Run the engine to check for any fuel leaks. rear compartment lower trim panels ADD: 09/95 REPAIR 17 . 9.Introduction are strictly adhered to when carrying out following instructions. 8. See fuel system depressurise . Connect fuel hoses to filter and tighten unions to 18 Nm . dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system. 5. See fuel tank .

Care must be taken to catch any excess fuel which may spill from the fuel lines once removed. Release vent hose from pressure sensor body. 10. Remove 6 screws securing fuel pump access panel. Noting their fitted positions. 9. 18 REPAIR ADD: 09/95 .19 FUEL SYSTEM 6. 11. 8. 7. Disconnect multiplugs from fuel pump and pressure sensor. Remove access panel. Fold back loadspace carpet and sound insulation to reveal access panel. disconnect both fuel connections by pressing the black release latches on each connector and pushing the connector back down the line.

Connect vent hose to pressure sensor body. Fit NEW pump seal to tank opening. Fit RH luggage compartment side panel. Connect multiplugs to fuel pump and pressure sensor.SFI Refit 15. ADD: 09/95 REPAIR 19 . 19. pressing firmly on the pump top flange to allow correct positioning. 26. 21. 23. Remove and discard seal. See CHASSIS AND BODY. tip the pump to the right to allow fuel contained in the body of the pump to drain into the tank. Prise the pump from the tank opening using a blunt instrument under the edge of the pump flange. 24. 14. 18. Using service tool LRT-19-009 loosen and remove the metal locking ring. 16. Fit access panel and secure with screws. Once clear of the seal. 20. Fit locking ring and tighten to 35 Nm using service tool LRT-19-009. 13. Run the engine to check for any fuel leaks. 25. Connect both fuel lines to the pump by pushing the connectors down each line square to the pump connection until the connectors positively latch. Reposition loadspace sound insulation and carpet. CAUTION: Do not lift the pump from the tank using the feed and return stubs. rear compartment lower trim panels 27. Fit tail door tread strip and secure with screws. 12. Repair. 22. NOTE: Ensure location tag on pump top flange is engaged correctly to tank opening lip. Carefully lower pump into tank opening. 17. Refill tank with drained fuel. Reconnect battery negative lead.

02 WARNING: Fuel pressure of up to 2.19 FUEL SYSTEM FUEL SYSTEM .DEPRESSURISE . Always depressurise the system before disconnecting any components in the fuel feed line (between fuel pump and pressure regulator). FUEL TANK . The spilling of fuel is unavoidable during this operation. Position cloth around relevant union to protect against fuel spray. 4.50. even if the engine has not been run for some time. Repair. See CHASSIS AND BODY. Remove 6 screws securing tail door tread strip and remove tread strip. 2. Remove RH luggage compartment side panel. 2.01 WARNING: Ensure fuel handling precautions given in section 01 Introduction are strictly adhered to when carrying out following instructions. 4. Disconnect battery negative lead. it imperative that all dust. dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system. NOTE: Fuel pressure can be relieved at fuel filter unions. Drain fuel tank completely. CAUTION: Use two spanners when loosening or tightening unions. Remove cloth.5 bar will be present in the system.19.ADVANCED EVAPS Service repair no . 3. See fuel tank draining . Carefully loosen union. Tighten union once fuel pressure is relieved. Ensure that all necessary precautions are taken to prevent fire and explosion.ADVANCED EVAPS Service repair no .19.advanced evaps 3. Remove 1. 1. rear compartment lower trim panels 20 REPAIR ADD: 09/95 . CAUTION: Before disconnecting any part of fuel system.55.

10. Raise rear of vehicle. Fold back loadspace carpet and sound insulation to reveal access panel. disconnect both fuel connections by pressing the black release latches on each connector and pushing the connector back down the line. 6. WARNING: Support on safety stands.SFI 5. Disconnect multiplugs from fuel pump and pressure sensor 9. Remove access panel. 11. 8. Remove 6 screws securing fuel pump access panel. Care must be taken to catch any excess fuel which may spill from the fuel lines once removed. 7. ADD: 09/95 REPAIR 21 . Noting their fitted positions.

Remove and discard fuel filler neck clip. and allow bar to swing down clear of tank. 14. 16. 13. Disconnect pressure sensor breather pipe connection. Remove torque screw cap from hose to tank filler neck clip. 15. 18. Release hose from filler neck and internal filler neck breather hose from fuel tank. Loosen clip screw securing hose to tank filler neck. Mark location of anti-roll [sway] bar straps. 17. Disconnect vent line quickfit connector from liquid/vapour separator. 22 REPAIR ADD: 09/95 .19 FUEL SYSTEM 12. Remove nuts and bolts securing anti-roll [sway] bar straps. 19.

With assistance. ADD: 09/95 REPAIR 23 . tilt right hand side of tank upwards and manoeuvre through chassis to remove. 27. 21. 28. Remove and discard seal. 23. 24. Using service tool LRT-19-009 loosen and remove the metal locking ring. Prise the pump from the tank opening using a blunt instrument under the edge of the lip of the pump flange. Do not carry out further dismantling if component is removed for access only. Remove 4 nuts and bolts securing fuel tank cradle. Remove nut and bolt securing RH side of upper fuel tank strap to chassis. Remove fuel tank cradle. CAUTION: Do not lift the pump from the tank using the feed and return stubs.SFI 20. Release vent hose from tank pressure sensor. 22. 25. 26. Remove vent hose from 3 fuel tank clips.

rear compartment trim panels 52.55. 48. Depressurise fuel system. 43. 46. dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system. 51. Repair. See CHASSIS AND BODY. 33. 32. 47. Fit fuel tank cradle and secure with nuts and bolts. Remove 6 screws securing tail door tread strip and remove tread strip. 42. With assistance. See fuel system depressurise . Reposition loadspace sound insulation and carpet. Position anti-roll [sway] bar straps and secure with nuts and bolts. Fit locking ring and tighten to 35 Nm using service tool LRT-19-009. Disconnect battery negative lead. Connect multiplugs to fuel pump and pressure sensor.advanced evaps 2. Refill tank with drained fuel. CO2. NOTE: Assuming the fuel tank is FULL drain the following quantities: Renew Fuel pump = 9 Litres (2. Run the engine to check for any fuel leaks. Fit NEW pump seal to tank opening. 24 REPAIR ADD: 09/95 . Connect vent line quickfit connector to liquid/vapour separator. 29. GAS or POWDER close at hand when handling or draining fuel. 3. WARNING: Petrol/gasoline vapour is highly flammable and in confined spaces is also explosive and toxic. 4. Carefully lower pump into tank opening. Align upper fuel tank strap and secure with nut and bolt. Fit access panel and secure with screws. Fit tail door tread strip and secure with screws. Remove stand(s) and lower vehicle. Fit RH luggage compartment side panel. fit fuel tank into position. 41. 35. Always have a fire extinguisher containing FOAM. 50. pressing firmly on the pump top flange to allow correct positioning. 38. Connect fuel filler neck hose to tank.19. Connect fuel filler neck internal breather to tank. 49. Remove RH luggage compartment side panel.19 Refit FUEL SYSTEM FUEL TANK . See Introduction CAUTION: Before disconnecting any part of fuel system. 34. 36.02 WARNING: Before removing the fuel tank it must be drained. Fit vent hose to fuel tank clips and connect to pressure sensor. Position fuel filler neck hose clip and tighten until head shears.ADVANCED EVAPS Service repair no . Connect vent line hose connection. 40. Reconnect battery negative lead.DRAINING . 45. 37. 30. 44. 31. Connect both fuel lines to the pump by pushing the connectors down each line square to the pump connection until the connectors positively latches. it is imperative that all dust. 39. Repair. See CHASSIS AND BODY. NOTE: Ensure location tag on pump top flange is engaged correctly to tank opening lip.4 US Gallons) Renew Fuel filler neck = 22 Litres (6 US Gallons) Renew Fuel tank = COMPLETE DRAIN 1. Fit NEW clip to fuel filler neck hose.

Continue draining until air bubbles appear and fuel ceases to flow. Care must be taken to catch any excess fuel which may spill from the fuel line once removed. Disconnect the fuel return connection by pressing the black release latch on connector and pushing the connector back down the line. Follow the manufacturers instructions for the connection and safe use of the bowser. Fit tail door tread strip and secure with screws. 8. Repair. ADD: 09/95 REPAIR 25 . Fold back loadspace carpet and sound insulation to reveal access panel. Disconnect bowser from fuel pump return stub. Reposition loadspace sound insulation and carpet. 14. Remove access panel. Remove 6 screws securing fuel pump access panel.SFI 5. 13. 10. Fit RH luggage compartment side panel. 9. 6. 11. rear compartment trim panels 16. 7. Reconnect battery negative lead. drain fuel into a sealed container. Connect fuel return line to pump by pushing the connector down line square to the pump connection until the connector positively latches. Using a bowser. 17. 15. See CHASSIS AND BODY. with a 7 mm inside diameter hose connection attach to fuel pump return stub. 12. Fit access panel and secure with screws.

draining.55. See fuel system depressurise . 7.advanced evaps 2. Check the amount of fuel in the tank. 26 REPAIR ADD: 09/95 . it is imperative that all dust.07 WARNING: Ensure that fuel handling precautions given in 1 . 10. Remove nut and bolt securing filler neck support bracket to mud flap bracket. Remove 1. Raise rear of vehicle. Remove mud flap.19 FUEL SYSTEM FUEL FILLER NECK . See fuel tank . WARNING: Support on safety stands. 9. 8. Remove RH luggage compartment side panel. Remove 5 nuts and bolts securing mud flap to body. dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system. 5. Fold back loadspace carpet and sound insulation to gain access to RH mudflap fixing. Remove 6 screws securing tail door tread strip and remove tread strip. 3. 4.Introduction are strictly adhered to when carrying out following instructions. If the tank is full drain 6 US gallons (22 litres) minimum. rear compartment trim panels 6. Disconnect battery negative lead. Repair. See CHASSIS AND BODY. Depressurise fuel system.ADVANCED EVAPS Service repair no . CAUTION: Before disconnecting any part of fuel system.19. NOTE: This fixing also retains the filler neck earth strap.

Release fuel filler cap from filler neck. 25. Fit ignition key to fuel filler flap lock and open flap. Remove filler neck assembly from vehicle.SFI 11. Remove hose from filler neck. 18. 14. 15. 13. Disconnect the pressure sensor breather pipe connection. 19. 24. 22. Release hose from filler neck and internal filler neck breather hose from fuel tank. 23. ADD: 09/95 REPAIR 27 . Do not carry out further dismantling if component is removed for access only. Remove torque screw cap from hose to tank filler neck clip. Loosen clip screw securing hose to filler neck. Disconnect the vent line hose connection. Remove vent line from filler neck. Remove and discard fuel filler hose clip. Remove and discard fuel filler neck clip. Loosen clip screw securing hose to tank filler neck. 12. 21. 17. Remove torque screw cap from hose to filler neck clip. Disconnect vent line quickfit connector from liquid/vapour separator. 16. 20.

lock with ignition key and remove key. Reposition loadspace sound insulation and carpet. 3. Remove fuel filler cap. 38. 33. 40. lock with ignition key and remove key. FUEL SYSTEM FUEL TANK FILLER CAP . 29. 42. Connect fuel filler neck hose to tank. 35. 6. Remove stand(s) and lower vehicle. NOTE: To aid fitment of filler neck through body grommet apply a soap solution to lip of grommet. Position cap retaining strap to body and secure with screw. Fit NEW clip to filler neck hose. 32. Fit fuel filler cap to filler neck.19. Refit 4. 31. Fit RH luggage compartment side panel. Fit mud flap and secure with nuts and bolts. Fit hose to filler neck. Position filler neck hose clip and tighten until head shears.19 Refit 26. 39. 34. Close filler flap.ADVANCED EVAPS Service repair no . Fit tail door tread strip and secure with screws. Connect vent line quickfit connector to liquid/vapour separator. 28. Fit NEW clip to fuel filler neck hose. 30. Fit fuel filler cap. 43. Connect fuel filler neck internal breather to tank. 44. 2. Connect the vent line hose connection. Fit ignition key to fuel filler flap lock and open flap. Remove screw securing cap retaining strap to body. 36. 45. Close filler flap. Fit filler neck assembly to vehicle. Refill tank with drained fuel.08 Remove Fit vent line to filler neck. 5. Position fuel filler neck hose clip and tighten until head shears. 47. 46. 27.55. 28 REPAIR ADD: 09/95 . Repair. Connect the pressure sensor breather pipe connection. See CHASSIS AND BODY. Position filler neck support bracket and earth strap to mud flap bracket and secure with nut and bolt. Reconnect battery negative lead. 41. 37. 1.

Carefully remove the valve and hose assembly from the filler neck ADD: 09/95 REPAIR 29 . 9. two complete turns. Release the cobra clip securing the hose to the liquid/vapour separator and disconnect the hose. 5.19.55. 10. Fit the valve and hose assembly to the filler neck stub pipe.advanced evaps Refit 6.refit 2. then tighten to 3 Nm. 7. See fuel filler neck advanced evaps. Remove the fuel filler neck. Hand tighten the nut. 8. Connect the hose to the liquid/vapour separator and secure with the cobra clip. 11. Fit a new ’O’ ring to the recess in the stub pipe. ensuring that the ’O’ ring is fitted around the body of the valve as it is pushed into the filler neck stub pipe. Tighten the grub screw to 2 Nm.31 Remove 1. Loosen the grub screw on the valve nut. 3. See fuel filler neck .SFI ANTI-TRICKLE FILL VALVE . 4. Fit the fuel filler neck. NOTE: The nut is held captive by the stub pipe on the filler neck.ADVANCED EVAPS Service repair no . Loosen the valve nut completely.

The ECM incorporates short circuit protection and can store intermittent faults on certain inputs. Spark distribution is achieved by 2 coils mounted at the rear of the engine and controlled by the ECM.Engine noise and vibration. within the relay module.Engine load 3. DESCRIPTION AND OPERATION 1 . Manifold absolute pressure sensor . • A separate diagnostic connector allows engine tuning or fault diagnosis to be carried out using Testbook without disconnecting the ECM harness connector. Knock sensor . Manifold absolute pressure sensor . MEMS uses no centrifugal or vacuum advance. Crankshaft sensor . • The ECM uses the speed/density method of air flow measurement to calculate fuel delivery.Mpi DESCRIPTION The Mpi Modular Engine Management System (MEMS) controls the fuel injection and programmed ignition systems. 5. timing being controlled by the ECM which is energised by the main relay.Engine speed and crankshaft position.Engine temperature. This method measures the inlet air temperature and inlet manifold pressure and assumes that the engine is a calibrated vacuum pump with its characteristics stored in the ECM • If certain system inputs fail. Coolant temperature sensor . • The ECM harness multiplug incorporates specially plated pins to minimise oxidation and give improved reliability. 4. although at a reduced level of performance. The main features are as follows: • The Engine Control Module (ECM) controls programmed ignition and fuel injection.Throttle closed. the ECM implements a back-up facility to enable the system to continue functioning. Testbook can interrogate the ECM for these stored faults. 2. The following components supply data for both fuelling and ignition: Ignition system The ECM determines the optimum ignition timing based on the signals it receives from the following sensors: 1. • The throttle potentiometer requires no adjustment in service.

NOTE: Due to the sensitivity of this system the ignition timing will be constantly changing at idle speed. the insert consisting of 34 poles spaced at 10 °intervals. The sensor ’reads’ these poles to provide a constant up-date of engine speed and crankshaft position to the ECM The load signal is provided by the manifold absolute pressure sensor mounted inside the ECM casing which detects manifold pressure via a hose connected to the manifold chamber. The sensor converts pressure variations into graduated electrical signals which can be read by the ECM Ignition timing compensation Coolant temperature sensor When the ECM receives a low engine temperature signal from the coolant sensor. it provides optimum driveability and emissions by advancing or retarding the ignition timing. 2 DESCRIPTION AND OPERATION . The speed and position of the engine is detected by the crankshaft sensor which is bolted to. Knock sensor The knock sensor is a capacitive device mounted in the cylinder block between nos. The sensor incorporates an armature which runs adjacent to a reluctor insert in the flywheel. When loads are placed on.19 FUEL SYSTEM Basic ignition timing MEMS provides the optimum ignition timing for the relevant engine speed and load. Idle speed control When the throttle pedal is released and the engine is at idle. the ignition timing returns to the idle setting.C. When load is removed from the engine and the stepper motor returns to it’s original position. the ECM uses the fast response of ignition timing to assist idle speed control. advances or retards the ignition timing to maintain the specified idle speed. and projects through the engine adapter plate. positions. with two missing poles 180 °apart to identify the T.D. 2 and 3 cylinders below the inlet manifold. or removed from the engine the ECM senses the change in engine speed and in conjuction with the opening of the throttle disc by the stepper motor. The sensor monitors noise and vibration in the engine and passes this information to the ECM which is able to identify the characteristics of the knocking and make the necessary corrections to the ignition timing of individual cylinders.

NOTE: After fitting a different ECM. The fuelling offset is required to enable the system when not in closed loop control to provide the correct fuelling and while in closed loop control to prevent having to apply excessive adjustments to the fuelling which can adversely affect the emissions and driveability. The idle stepper position required to achieve the specified idle speed. DESCRIPTION AND OPERATION 3 . 2. The ECM is an adaptive unit and can learn the load and wear characteristics of a particular engine. The fuelling change or offset required to achieve a set oxygen sensor voltage. a full tune procedure must be carried out using Testbook.Mpi Fuel system INPUTS TO MEMS ECM Crankshaft sensor Manifold absolute pressure Coolant temperature sensor Inlet air temperature sensor Knock sensor Oxygen sensor Throttle potentiometer Throttle closed Battery supply Ignition supply Diagnostic input Power earth Sensor earth Fuel temperature sensor Oxygen sensor Air conditioning switch OUTPUTS FROM MEMS ECM Ignition coil Injectors Aircon relays Stepper motor Temperature gauge Fuel pump relay (inside relay module) Main relay (inside relay module) Diagnostic output ECM The MEMS system is controlled by the ECM which is located in the engine compartment. The ECM inputs and outputs are shown in the table. The stepper position is used as a reference to update the amount of stepper motor movement required to achieve the specified idle speed under all conditions. The ECM remembers and updates two main engine requirements when the engine is fully warm: 1.

Also incorporated in the throttle housing are the throttle potentiometer and stepper motor. Three wires connect the throttle potentiometer to the ECM. The stepper motor maximum movement is 3. The sensor is a resistive device in which the resistance varies with temperature Throttle housing The throttle housing is attached to the inlet manifold via a rubber sandwich plate and incorporates a throttle disc which is connected to the throttle pedal via the throttle lever and a cable. There are two breather pipes.5°. If it is identified as being outside this range it can be adjusted to within range by turning the throttle air bypass bleed screw.75 revolutions accomplished in steps of 7. The reduction gear converts this into 180°of cam movement. When the engine is running with the throttle disc open. This pipe incorporates a restrictor to prevent engine oil being drawn into the engine by the substantially greater manifold depression. Engine coolant temperature sensor The coolant temperature sensor is mounted in the thermostat housing and is immersed in the engine coolant. only the pipe on the inlet manifold side of the disc is subject to manifold depression. The throttle lever has a throttle position setting screw which rests on the stepper motor operating pin when the throttle pedal is released and is used to set the relationship between engine speed and stepper motor position. It is important to follow Testbook setting procedure when adjusting this screw to prevent mismatching of throttle body settings. an earth return to the ECM and an output voltage to the ECM which indicates the rate of throttle disc movement. In the side of the throttle housing is a throttle air bypass bleed screw to provide easier and more sensitive setting of the stepper motor position at idle. a 5 volt supply to the potentiometer. The push rod is in direct contact with the throttle lever and moves the throttle disc to control idle and fast idle speed. When the throttle disc is closed. The stepper motor position is checked using Testbook and should be within the range of 20 to 40 steps when the engine is run in. Throttle potentiometer The throttle potentiometer is mounted in front of the throttle housing and is directly coupled to the throttle disc shaft. both pipes are subject to manifold depression and draw crankcase fumes into the manifold. one either side of the throttle disc.19 FUEL SYSTEM Injectors The four fuel injectors are fitted between the pressurised fuel rail and inlet manifold. 4 DESCRIPTION AND OPERATION . This ensures that the stepper motor is at the optimum position within its range for providing further movement to compensate for changes in engine load or temperature in accordance with signals from the ECM NOTE: The stepper motor and throttle position setting screws must only be adjusted when Testbook identifies the requirement. Each injector comprises of a solenoid operated needle valve and a specially designed nozzle to ensure good fuel atomisation. Stepper motor The stepper motor is contained within the throttle housing and operates a cam and push rod via a reduction gear.

and adjusts the injector duration to maintain the ratio necessary for efficient gas conversion by the catalyst. The electrical supply for the heater element is controlled by the oxygen sensor relay. DESCRIPTION AND OPERATION 5 . during cranking and while the engine is running. This oxygen sensor relay is energised when the ignition is switched on and supplies current to the ECM Intake air temperature sensor The intake air temperature sensor is fitted in the side of the inlet manifold and sends the ECM a signal relating to air temperature. Inertia switch The fuel pump circuit incorporates an inertia switch which in the event of sudden deceleration isolates the power supply to the fuel pump. is a self-priming centrifugal ’wet’ pump. Diagnostic connector A diagnostic connector is provided to enable diagnosis to be carried out without disturbing the system electrical connections and to allow the ECM’s ability to store certain faults to be utilised. Fuel pressure regulator The pressure regulator is a mechanical device controlled by manifold depression and is mounted in the fuel rail. The main relay is energised when the ignition is switched on and supplies current to the ECM The fuel pump relay is energised by the ECM for a short period when the ignition is switched on. if tripped. fuel pump relay. so that pressure in the fuel system can be maintained under all conditions. If the mixture becomes richer so the oxygen content decreases and the voltage increases. as manifold depression increases the regulated fuel pressure is reduced in direct proportion. and opens the throttle disc via the stepper motor to aid hot starting. Relay module The relay module contains the main relay. The ECM uses this signal in its calculations on air flow. WARNING: Check the integrity of the fuel system before the inertia switch is reset. located inside the fuel tank. The starter relay is energised by the cranking signal from the ignition switch. The inertia switch is situated in the engine compartment on the bulkhead and can.Closed-loop emission control The MEMS Mpi system operates a closed loop emission system to ensure the most efficient level of exhaust gas conversion. the motor and pump are filled with fuel. It then supplies a small voltage proportional to exhaust oxygen content to the ECM As the air/fuel mixture weakens. When pressure exceeds the regulator setting excess fuel is spill returned to the fuel tank swirl pot which contains the fuel pick-up strainer. The ECM uses this signal voltage to determine the air/fuel mixture being delivered to the engine. the ECM increases fuel supply. Oxygen sensor . During engine cranking at high temperatures. An oxygen sensor fitted in the exhaust manifold monitors the exhaust gases. Fuel temperature sensor The fuel temperature sensor is inserted in the fuel rail and measures fuel and fuel rail temperatures. the exhaust oxygen content increases and so the voltage to the ECM decreases. The fuel pump supplies more fuel than the maximum load requirement for the engine. The regulator ensures that fuel rail pressure is maintained at a constant pressure difference to that in the inlet manifold. starter relay and oxygen sensor relay and is mounted on the ECM mounting bracket. be reset by depressing the central plunger.Mpi Fuel pump The electric fuel pump. The oxygen sensor has an integral heating element to ensure an efficient operating temperature is quickly reached from cold.

Throttle disc 2. When the purge valve is opened. Two way valve 4. The charcoal canister is purged when the purge control valve is open. ECM 8. the purge control valve will be operational (modulated ON and OFF) whenever the engine speed is above approximately 1600 rev/min. Charcoal canister 5. the additional enrichment in fuel mixture would delay catalyst light off time and cause erratic idle. through the charcoal canister and into a port in the inlet manifold.19 FUEL SYSTEM Non . fresh air is drawn through the purge air hose. One way valve Charcoal canister A charcoal canister is used for the temporary storage of fuel vapour from the fuel tank until the vapour can be purged from the canister into the engine and burned. fuel vapour from the charcoal canister is drawn into the inlet manifold for combustion. If the charcoal canister was purged during cold running or at idling speed. Purge control valve A purge control valve is operated by the ECM The valve remains closed when the engine is cold and at idling speed to protect engine tune and catalyst performance. Fuel filler cap 7. 6 DESCRIPTION AND OPERATION . Purge control valve 6.evaporative loss equipment 1. Fuel cut-off valve 3. When the engine temperature is above 75°C.

...................................... Diagnostic connector .......................Mpi MEMS COMPONENTS & LOCATION ON VEHICLE Components 1 2 3 4 5 6 7 Fuel pump ........................... ........... Relay module ......... Fuel filter ................................................ Purge control valve .................... Location Fuel tank Right chassis rear Bulkhead Under bonnet [hood] On charcoal canister Right inner wing [fender] Right inner wing [fender] DESCRIPTION AND OPERATION 7 ........................................................................................................................................... Fuel inertia switch ......................................... MEMS ECM......................................

..................................... Twin ignition coils ................................................................................................................................................................... Knock sensor .....................................................................................................19 FUEL SYSTEM MEMS COMPONENTS & LOCATION ON ENGINE Components 1 2 3 4 5 6 7 8 9 10 11 Fuel pressure regulator ......... Location Engine rear Inlet manifold Under starter motor on flywheel housing Engine rear Exhaust manifold Coolant chamber Fuel rail Engine block 8 DESCRIPTION AND OPERATION ........ Coolant temperature sensor ........ Intake air temperature sensor ..................... Oxygen sensor ............... Injectors Stepper motor Throttle potentiometer Fuel temperature sensor ....... Crankshaft sensor ..

to the four injectors and through the ignition coil to ECM pin 25. During cranking.Mpi SYSTEM OPERATION Ignition on When the ignition is switched on. • Ignition signal at pin 11. • Manifold absolute pressure data (via pipe from manifold). The ECM activates a unipolar stepper motor acting directly on the throttle lever. Voltage is applied through the inertia switch to the fuel pump. battery voltage is applied to the starter motor solenoid. the ECM will substitute the back-up values shown to maintain driveability. 24 on then 8 pulses off. it increases the injector pulse widths to compensate. • Throttle potentiometer data at pin 8. injector pulses are intermittent i. the fuel pump relay is switched on by the ECM supplying an earth path on pin 20. 60°C at speeds above idle. 23. 26 and 1 for the period the injectors are required to be open. Inlet air temperature Derived from engine speed and engine load. Manifold absolute pressure DESCRIPTION AND OPERATION 9 . when the engine speed is below approx. • Engine speed data at pins 31 and 32. Ignition is controlled by the ECM switching the low tension circuit via pin 25. The fuel pressure regulator will open at its maximum setting and excess fuel is spill returned to the tank. • Inlet air temperature data at pin 16. the ECM increases the injector pulse width to aid starting. the ECM will implement a slightly higher idle speed to prevent the engine stalling. On return to idle. Finally the ignition timing is retarded to its nominal value. In addition. 400 rev/min. The ECM carefully meters the amount of fuel injected by adjusting the injector opening period (pulse width). The ECM controls the enrichment by increasing injector pulse width. To prevent flooding. The ECM then switches on the main relay by supplying an earth path at pin 4. voltage is applied to ECM pin 11. • Battery voltage at pin 28. The ECM determines the amount of stepper motor movement from the following signals: • Engine coolant temperature data at pin 33. if voltage falls sufficiently to cause fluctuations in injector pulse widths. Derived from engine speed and throttle position. The ECM monitors battery voltage and. The enrichment decays in relation to the rising coolant temperature. the load on the engine is increased sufficiently to cause engine speed to fall. The ECM provides an earth signal on pins 24. Idle speed response is improved by the ignition system advancing or retarding the timing when load is placed on. The amount of increase depends upon coolant temperature. Input Back-up value Starter operation Whilst the starter relay is energised. If. Idling After start enrichment is provided at all temperatures immediately cranking ceases. This allows battery voltage to pass to ECM pin 28. The solenoid also energises and supplies battery voltage directly to the starter motor. or removed from the engine. the ECM will sense this via the crankshaft sensor and instantly advance the ignition timing to increase idle speed and then energise the stepper motor to open the throttle disc thus maintaining the idle speed. The pump runs for a short period to pressurise the fuel rail.e. If one or more of the following inputs fail. Provided the ECM is receiving a signal that the engine speed is close to the idle speed set point. during engine idle. the injector solenoids are energised (simultaneously on naturally aspirated models) and fuel is sprayed into the manifold onto the back of the inlet valves. the ECM will implement idle speed control. Coolant temperature Idle Speed controlled until engine is fully warm.

• Throttle disc closed. • Engine speed is above 2000 rev/min . cutting off injection. 10 DESCRIPTION AND OPERATION .engine at normal operating temperature. Over-run fuel cut-off The ECM implements over-run fuel cut-off when the following signals are received. During driving the ECM continually monitors inlet air temperature and engine speed and load for it’s air flow calculations. Additional inputs are throttle potentiometer for acceleration and throttle pedal switch for cruise/idle fuel map selection and over-run fuel cut-off.19 FUEL SYSTEM Driving When the throttle pedal is depressed. together with coolant temperature for any temperature corrections. the ECM implements the cruise air/fuel ratio map. Over-speed fuel cut-off To prevent damage at high engine speeds the ECM inhibits the earth path for the injectors. 30 seconds while it drives the stepper motor to the 35 step position for the next engine start. The ECM provides additional fuel by increasing the normal injector pulse width and also provides a small number of extra injector pulses on rapid throttle openings. As engine speed falls. the ECM receives a rising voltage from the throttle potentiometer and detects a rise in manifold pressure from the manifold absolute pressure sensor. Ignition switch off When the ignition is switched off. injection is reinstated. the ECM will keep the main relay energised for approx. Fuel is reinstated progressively when any of the above signals cease. Acceleration enrichment When the throttle pedal is depressed.

Loosen throttle cable adjustment nut and locknut from abutment bracket. Tighten cable locknut to contact abutment bracket. Using two wrenches tighten nuts onto abutment bracket. Ensure that the cable is correctly routed and located. 6.Mpi THROTTLE CABLE Adjust NOTE: Use diagnostic equipment to ensure that the throttle potentiometer and stepper motor are synchronised before adjusting the throttle cable. 3. ADJUSTMENT 1 . 1. 5. 4. Switch ignition on. Hold cam in "throttle closed" position and rotate cable adjustment nut until a gap of 2mm exists between the nut and abutment bracket. Operate throttle pedal and ensure throttle opens fully. wait 5 seconds and switch ignition off to ensure stepper motor is in setting position. 2.

Fit 3 bolts and tighten to the correct torque. REPAIR 1 .30. Tighten to 15 Nm 5. 5.18 Remove IGNITION COILS Service repair no . leads to ensure correct refitment. 13. Remove 3 bolts securing coil bracket to bell housing. 7.t. 2.41 . 4. Refit 3. Remove knock sensor. 12. 6. Disconnect 4 h. Position coil assembly to bell housing. 3.20. 10. 4. Connect multiplug. Disconnect crankshaft sensor multiplug.18.Mpi KNOCK SENSOR Service repair no . Disconnect multiplug from knock sensor. NOTE: Mark the position of the h.20.40 . Connect multiplugs and h.2 & 3 Cylinders Remove 1. leads to coils.1 & 4 Cylinders Service repair no . 11. 9. 2. leads from coils. Remove coil assembly. Secure crankshaft sensor multiplug to coil bracket with screw. Connect crankshaft sensor multiplug.t. Remove screw securing crankshaft sensor multiplug to coil bracket. Fit knock sensor. 1.18. Refit 8.t. Reconnect battery negative lead. Disconnect 2 multiplugs from coils.18. NOTE: Access to the rear bolts is from under the vehicle. Clean mating face of cylinder block. Disconnect battery negative lead.

30. Disconnect sensor multiplug. 6. release lead from bracket. 2. Remove sensor.18.12 Remove 1.18. 10. 4. Remove crankshaft sensor. Top-up cooling system. Fit sensor and tighten to the correct torque. Clean sensor. Connect multiplug 2 REPAIR . Tighten to 7 Nm 9. Refit 7.10 Remove 1. 3. Position lead to bracket. Lower vehicle. 4. Remove 2 bolts securing crankshaft sensor. Position harness and secure with clip. Disconnect multiplug from crankshaft sensor flylead. 11. Release harness clip and harness. fit and tighten screw. 5. 2. CRANKSHAFT SENSOR Service repair no . 6. Position drain tin below coolant pump hose. Fit crankshaft sensor. Position vehicle on ramp [hoist]. 9. Refit 5. 8. 8. Connect multiplug. 3. Raise ramp [hoist]. Clean crankshaft sensor and mating surface of backplate.30. 7.19 FUEL SYSTEM COOLANT TEMPERATURE SENSOR Service repair no . Remove screw. fit bolts.

08 Remove 1. 5. 2. 5. 6. Position ECM to mounting. REPAIR 3 .30. 2. Remove 3 bolts securing ECM. Connect multiplugs to ECM. Connect vacuum hose to ECM. Tighten to 7 Nm Connect fuel temperature sensor multiplug. Fit bolts and tighten. 3.Mpi FUEL TEMPERATURE SENSOR Service repair no . Disconnect 2 multiplugs from ECM. MEMS ENGINE CONTROL MODULE (ECM) Service repair no . Remove fuel temperature sensor.18. Fit temperature sensor.18. Fit a new sealing washer to sensor. Remove ECM. 7. Discard sealing washer. Clean mating face of fuel rail.30. 10.01 Remove 1. Disconnect fuel temperature sensor multiplug. Disconnect vacuum hose from ECM. Position ECM and spacers to wing [fender]. Collect ECM spacers (LHD only) Refit 4. Refit 6. 8. 4. 9. 3. 7.

19. 5. Remove footwell closing panel. Fit charcoal canister and secure strap. Connect fuel tank hose to charcoal canister and secure clip. 2. Release clip and disconnect fuel tank hose from charcoal canister.15. Loosen 2 nuts securing throttle cable to abutment bracket. Remove clevis pin and release cable from throttle pedal. Connect multiplug to purge valve. 3. 4. 2.13 Remove 1. Release split [cotter] pin from throttle pedal clevis pin. 8.06 Remove 1.20. 4 REPAIR . Refit 5. 3.17. Connect hose to purge valve and secure clip. 7. Unscrew bolt to release securing strap and remove charcoal canister. THROTTLE CABLE Service repair no . Disconnect multiplug from purge valve. 4. Release throttle cable from throttle lever. Release clip and disconnect hose from purge valve. 6.19 FUEL SYSTEM CHARCOAL CANISTER Service repair no .

CAUTION: Ensure throttle potentiometer is correctly engaged with throttle cam and that wiring outlet faces downwards. remove potentiometer. Adjust throttle cable. Connect cable to throttle pedal. 10. 6. fit and tighten screws. 2.22. Connect multiplug. Connect cable to cam. Locate cable in bulkhead. Disconnect throttle potentiometer multiplug. Remove 2 screws securing throttle potentiometer.19. Check with diagnostic equipment. Clean mating faces of throttle potentiometer and throttle housing.49 Remove 1.Mpi 6. 7. 4. 11. Remove nut securing throttle cable bracket to brake servo and release cable. Refit 3. 5. THROTTLE POTENTIOMETER Service repair no . 9. 8. Fit throttle potentiometer. Release grommet from bulkhead and withdraw cable. REPAIR 5 .

3. 2. Refit 3. 4.15. Connect multiplug to valve. 7. Connect multiplug to sensor. 8. Tighten to 7 Nm 5. Clean valve and valve location. Release valve from charcoal canister. 2. 9. Refit 6. Discard ’O’ ring. Position and secure valve to charcoal canister. Release clip and disconnect hose from valve.17. 6 REPAIR . Remove valve.19 FUEL SYSTEM INTAKE AIR TEMPERATURE SENSOR Service repair no . 5. Disconnect multiplug from purge control valve. Remove sensor from inlet manifold. PURGE CONTROL VALVE Service repair no . Connect hose to purge valve and secure with clip.30. Disconnect multiplug from temperature sensor.18. Clean sensor threads and mating face. Fit sensor to inlet manifold. 4.39 Remove 1.09 Remove 1.

See MANIFOLD AND EXHAUST SYSTEM. Remove fuel rail complete with injectors. 12. Do not carry out further dismantling if component is removed for access only. 4. 13. Release fuel feed hose from fuel rail. 15.60.Mpi FUEL RAIL AND INJECTORS Service repair no . 7. Remove injector(s). Disconnect 4 injector multiplugs. 16. 6. Remove pressure regulator. Move injector harness aside. Repair. Remove inlet manifold chamber gasket.19. 14. REPAIR 7 . 8. 10.Mpi 2.19. 5.Rail Service repair no . 11. Remove 2 bolts securing fuel rail to inlet manifold.10 . Discard ’O’ ring.Injectors Remove 1. Release 4 injectors from inlet manifold. Fix protective cap to each injector. Discard inlet ’O’ ring(s) from injector(s). 9.04 . Remove 4 bolts securing fuel feed hose flange stiffening bracket. Manifold Chamber Gasket . 3. Remove fuel temperature sensor. remove stiffening bracket. Discard outlet ’O’ rings from injectors.60. Remove clip(s) securing injector(s) to fuel rail.

4. Fit inlet manifold chamber.19 Refit FUEL SYSTEM THROTTLE HOUSING Service repair no . Remove plugs from fuel feed hose and fuel rail. 27.22. Fit stiffening bracket. 30. Disconnect breather hose from throttle housing. 18. 29. Tighten stiffening bracket and feed hose bolts. Clean injectors and injector recesses in fuel rail and inlet manifold. Fit pressure regulator. 28. 21. Fit injector(s) to fuel rail.19. Fit fuel rail securing bolts. 7. 8 REPAIR . 5. Clean fuel rail. Release throttle cable from cam. 22. fit and secure clip(s). disconnect hose from throttle housing. 31. Fit new ’O’ rings to outlet ends of injectors. 8. 24. Release throttle housing from studs. Disconnect multiplug from stepper motor. Tighten to 10 Nm 25. 32. 17. Remove 4 nuts securing throttle housing to flexible mounting.45 Remove 1. 3. 23. Fit new ’O’ ring to fuel feed hose. Fit new ’O’ ring(s) to inlet end of injector(s). Disconnect multiplug from throttle potentiometer. 6. Connect injector multiplugs. Align injectors to inlet manifold and push fuel rail into position. 2. Fit fuel temperature sensor. Tighten to 7 Nm 19. 20. temperature sensor and pressure regulator mating surfaces. Loosen 2 nuts securing throttle cable to abutment bracket and release cable. 26. Loosen clip. Connect fuel feed hose to fuel rail.

Connect hose to throttle housing. Remove 4 bolts securing pressure regulator steady bracket to fuel rail and manifold.45. 5. 15. REPAIR 9 . fit nuts. Position throttle housing to mounting studs. tighten clip. Adjust throttle cable. Examine flexible mounting for splits or damage. Re-tighten bolt. 3.06 Remove 1. 13. 17. remove steady bracket. Connect breather hose to throttle housing. Connect multiplug to stepper motor. 4. 16. Loosen bolt to relieve pressure.Mpi FUEL PRESSURE REGULATOR Service repair no . Refit 9. 2. renew as necessary. Connect throttle cable to cam. Connect multiplug to throttle potentiometer. Release clip and disconnect fuel hose from pressure regulator.19. 11. Discard ’O’ ring. Disconnect vacuum hose from pressure regulator. Tighten to 7 Nm. Position absorbant cloth around fuel pipe to fuel rail union. CAUTION: Plug the connectors. 8. 12. 6. 14. Manoeuvre pressure regulator from fuel rail. Disconnect battery negative lead. Disconnect intake air temperature sensor multiplug. 10. 7. Thoroughly clean throttle housing and mating face of flexible mounting.

Fit new ’O’ ring to pressure regulator. Refit 9.41 . Reconnect battery negative lead. 10 REPAIR . Fit oxygen sensor.R. Release multiplug from bracket. Fit vacuum hose to pressure regulator.18. 3.42 . 13. Disconnect oxygen sensor multiplug. 15. 14. Refit 5. 4. 7.H Service repair no . Fit sealing washer to oxygen sensor.30. 17. 16. Secure multiplug to bracket. 8.30. 10. fit fuel hose to regulator and secure with clip. 2. Fit steady bracket. 12.19 FUEL SYSTEM OXYGEN SENSOR Service repair no . Remove oxygen sensor. Release harness lead from cable tie. 11. Position pressure regulator. connect multiplug. Connect multiplug to air temperature sensor. recover sealing washer. Tighten to 55 Nm. Clean pressure regulator and mating surfaces. 6.H Remove 1. Remove plugs. Fit bolts and tighten.18. Secure harness lead with cable tie.L.

9.Mpi AIR CLEANER Service repair no . REPAIR 11 . Position air cleaner assembly to body ensuring front spigots locate securely in wing [fender] mounting rubbers and bottom mounting rubbers are located in the body. Raise top cover. Remove air cleaner. 11.10. 6. 12. Refit 8. 2. 7. Fit intake hose and secure with clip. Do not carry out further dismantling if component is removed for access only. Ease air cleaner from inner wing [fender] mounting rubber 4. Fit air cleaner element. 10. Release clip and remove intake hose from air cleaner. Remove air cleaner element. Release 4 clips securing top cover. Clean assembly body and top cover.19.01 Remove 1. Ease air cleaner assembly bottom mounting rubbers from body. 3. 5. Position top cover and secure with clips.

..... Cruise control switch ........ Engagement (on/off) switch .................. 8..... Brake/vent switch ........ Vacuum pump ........................... 4................ LOCATION Under LH dash Dash panel Steering wheel Steering wheel Box section under jack Brake pedal Transfer box behind transmission brake Behind RH lower ’A’ post trim casing RH engine compartment DESCRIPTION AND OPERATION 1 ...................................................................................................... 2....... Rotary coupler .............CRUISE CONTROL CRUISE CONTROL COMPONENT LOCATIONS Tdi AUTO EDC COMPONENT 1........................................... Actuator .. Cruise control unit .............. 5.......................... Vehicle speed sensor .................................. 9........ Neutral lock-out relay ...... 3......................................................................... 7...................................... 6................

Clutch pedal switch The clutch pedal switch is located under the lower dash attached to the clutch pedal mounting bracket. Brake pedal switch The brake pedal switch is located under the lower dash attached to the brake pedal mounting bracket. accessible by removing the trim casing. The switch provides for fast disengagement of the cruise control system and rapid return of the throttle levers to the idle position when the brake pedal is applied. A control valve in the pump provides for steady increase of road speed or purge of the system when the brake pedal is applied.V8i/Tdi AUTO EDC Description The cruise control system consists of electro-mechanical devices.19 FUEL SYSTEM CRUISE CONTROL SYSTEM . or park.Manual vehicles This unit is located in the right hand side footwell. The switch provides for fast disengagement of the cruise control system and rapid return of the throttle levers to the idle position when the clutch pedal is applied. Engine speed trip ECU . accessible by removing the trim casing. Actuator The actuator provides the servo mechanism link between the cruise control system and throttle linkage and is operated by vacuum from the vacuum pump. The function of the relay module is to disengage the cruise control system if neutral. clutch pedal switch on manual models. Driver operated switches The main cruise control switch is located in the auxiliary switch panel and activates the cruise control system. is selected in the main gearbox. Vehicle speed sensor The vehicle speed sensor is located on the side of the transfer box adjacent to park brake. The pump provides a vacuum source to the cruise control actuator. and comprises of the following components. Neutral lockout relay . 2 DESCRIPTION AND OPERATION . and is actuated by the steering wheel and brake pedal switches. The sensor provides road speed data to the ECU. Vacuum pump The vacuum pump is energised when the main cruise control switch is operated. The function of the unit is to disengage cruise control if engine speed exceeds 5000 rev/min. The cruise control system cannot be engaged until the road speed exceeds 45 km/h. when the system is engaged. The ECU also has a memory function for set speed storage. (28 mph) the system will automatically disengage at a road speed of 42 km/h (26 mph). ELECTRONIC CONTROL UNIT (ECU) The microprocessor based ECU evaluates the signals provided by the driver controls. These switches provide the interface between driver and cruise control system. The ECU activates the vacuum pump as required. brake pedal switch. and the vehicle speed sensor.automatic vehicles The relay module is located in the right hand side footwell. The steering wheel switches provide ’set/accelerate’ and ’resume/decelerate’ features.

See Electrical Trouble Shooting Manual. remove foot from accelerator pedal. (30 mph). 4. declutch. 5. 11. Accelerate to approximately 50 km/h. Therefore. Operate ’res/decel’ switch. vehicle should return to previously set speed. Momentarily touch and release ’set/acc’ switch. Operate ’res/decel’ switch. Depress main control switch in control system should immediately disengage and erase previously set speed from ECU memory. vehicle should accelerate smoothly until switch is released. Adjustment. cruise control system should remain disengaged. Operate ’set/acc’ switch and hold at that position. vehicle should accelerate to previously set speed without driver operation of accelerator pedal. select neutral. 7. (28 mph). FAULT DIAGNOSIS 1 . operate ’set/acc’ switch. 3. system should disengage. system should disengage. depress main control switch to actuate cruise control system. Operate ’set/acc’ switch below 40 km/h. Apply ’res/decel’ switch while vehicle is in cruise control mode. Engine should rev to 5000 rev/min. Vehicle should now maintain new speed at which ’set/acc’ switch was released. Engage forward gear. Slow to approximately 55 km/h. An incorrectly adjusted kickdown cable can prevent correct operation of the cruise control system. 2. 6. 1. engine returns to idle. NOTE: The cruise control system fitted to the diesel engine is not as responsive as that fitted to the petrol engine. operate ’res/decel’ switch. vehicle speed should increase 1. Manual vehicles . vehicle should smoothly adjust to previously memorised speed. and remove foot from accelerator pedal. due to the characteristics of diesel engines. (26 mph). Vehicle should maintain speed at which ’set/acc’ switch was operated. 9.select neutral. kickdown cable adjustment. ELECTRICAL TESTS Electrical functionality can be checked using TestBook. 8. cruise control system should immediately disengage returning vehicle to driver control at accelerator pedal.depress clutch. (28 mph). immediately release switch. Operate brake pedal. Automatic vehicles . cruise control system should remain disengaged. 65 km/h (40 mph). vehicle should smoothly accelerate to previously set speed. immediately release switch and remove foot from accelerator. Operate ’res/decel’ switch. Operate ’res/decel’ switch. cruise control should disengage. WARNING: The use of cruise control is not recommended on winding. (35 mph) operate ’res/decel’ switch.CRUISE CONTROL ROAD TEST CAUTION: Do not engage cruise control when vehicle is being used in low transfer gear or reverse.6 km/h (1 mph) for each touch. Accelerate. snow covered or slippery roads or in heavy traffic conditions where a constant speed cannot be maintained. using accelerator pedal to above 45 km/h. remove foot from clutch. CABLE SETTING . Note that five touches will increase speed 8 km/h (5 mph). Operate ’res/decel’ switch and allow vehicle to decelerate to below 42 km/h. Increase speed using accelerator pedal. Cruise at 80 km/h (50 mph). Speed should accelerate to previous set speed. at speeds below approx. the vehicle speed may drop when cruise is selected and then slowly regain the ’set’ speed. 10. Remove foot from accelerator. release pedal. cruise control disengages. Start engine. See AUTOMATIC GEARBOX.TDi AUTOMATIC MODELS 1.

3. REPAIR 1 . NOTE: Ensure locking sleeve is correctly positioned.19. 2. Release and move closing panel aside. Reverse removal procedure. Disconnect vacuum hose and harness connector from switch. Release switch/vent valve from pedal bracket. 4. Remove 3 studs securing driver’s side fascia closing panel. Remove switch.75.Brake Switch Remove 1. Locate and release locking sleeve.19. 5.34 .75.CRUISE CONTROL BRAKE AND CLUTCH PEDAL SWITCHES/VENT VALVES Service repair no .35 . Refit 7. 6.Clutch Switch Service repair no .

4. Models fitted with airbags: Remove driver’s airbag module. 2 REPAIR . 3. Repair.30 Switch Replacement Remove 1. Disconnect battery negative lead. Disconnect cruise control switch multiplug from main harness. Rotate bulb holder 90°and withdraw it from switch. Position switch to facilitate removal of bulb.36 Remove 1. Carefully release auxiliary switch panel from fascia. Disconnect multiplug from switch. Remove 2 Torx screws securing pad to steering wheel and remove steering wheel pad. Bulb replacement 5. Depress retaining lugs on switch.19. See SUPPLEMENTARY RESTRAINT SYSTEM. CRUISE CONTROL SWITCH Service repair no .75. remove switch from panel. 2.75. Disconnect battery negative lead.19 FUEL SYSTEM ENGAGEMENT (ON/OFF) SWITCH Service repair no . 4. Driver’s Airbag Module 2. Models without airbags: Turn steering wheel through 90°. 3. 6.19.

Remove steering wheel.CRUISE CONTROL ROTARY COUPLER Service repair no . Access is gained by removing the steering wheel and steering column shroud. Refit 9. Models fitted with airbags: Refit driver’s airbag module and follow all safety precautions. Repair. 7. Disconnect 2 Lucars from horn contacts. Disconnect battery negative lead. 10. See SUPPLEMENTARY RESTRAINT SYSTEM.54 The rotary coupler is located behind the steering wheel. See STEERING.19. Remove 2 screws securing cruise control switch to steering wheel.75. Ensuring wiring harness is routed correctly. Repair. Driver’s Airbag Module 5. 2. 8. See SUPPLEMENTARY RESTRAINT SYSTEM. Reverse removal procedure. Remove 3 screws securing lower half of shroud to steering column. 6. Remove cruise control switch from steering wheel. Remove 3 bolts securing mounting bracket to steering wheel and remove mounting bracket. 4. Rotary Coupler Remove 1. Repair. Release 2 turnbuckles securing lower dash closing panel and lower. 5. Steering Wheel 3. NOTE: On vehicles fitted with airbags. Disconnect rotary coupler multiplug from steering column harness. REPAIR 3 .

Reverse removal procedure. ACTUATOR . Ensuring that the column harnesses are not trapped by the column shroud.V8i Service repair no . CAUTION: Ensure front wheels are in the straight ahead position before removal and refitting. 3. 7. and manoeuvre actuator operating link off throttle lever. Remove rotary coupler from column stalk assembly. Fit a new actuator assembly if diaphragm is damaged. Inspect rubber diaphragm. Remove actuator. Remove nut securing actuator to throttle bracket. Disconnect vacuum hose from actuator. NOTE: If original rotary coupler is to be fitted and there is evidence of tampering.75. 4. 2. Refit 8.19 FUEL SYSTEM NOTE: If rotary coupler is to be re-used a piece of adhesive tape should be placed around the moulding in position A to prevent rotation. Repair. Remove 1. 6. Store in a plastic bag. Failure to do this may result in damage to the wires inside the coupler. Reverse removal procedure. Ensure rotary coupler lugs are correctly engaged in the rear of the steering wheel.19. Withdraw actuator. Fitting the hook uppermost. fit a new unit if failure or damage occurs. Release clips securing rotary coupler to column stalk assembly. 7. 4 REPAIR . 5.12 NOTE: The actuator is non serviceable. See SUPPLEMENTARY RESTRAINT SYSTEM. DO NOT rotate mechanism whilst removed. Rotary Coupler NOTE: If a new rotary coupler is to be fitted and the sealing tape is broken it MUST NOT be used. Refit 6. Disconnect battery negative lead. it is imperative that the coupler is centralised.

Link . Check clearance between inside edge of actuator link and recessed diameter of throttle lever. REPAIR 5 .75.0 mm. Remove link from actuator. check a gap of at least 3mm exists between side of link ("A" in illustration) and side of small spring ("B" in illustration).2 to 2. 4.adjust 3. With throttle fully open. Realign link by bending to achieve correct gap.19. Clearance should be 0. Ensure ignition is switched ’OFF’. Refit link to actuator and recheck clearance between link and lever. Recheck clearance at closed throttle/open throttle. 6.V8i Service repair no . 2. Rotate socket joint adjuster as necessary. Check link slides smoothly in groove of throttle lever. 5.21 NOTE: Setting procedure is carried out at minimum throttle condition only.CRUISE CONTROL ACTUATOR LINK-SETTING . 1.

19.TDI Service repair no . 6.06 NOTE: The vacuum pump is non serviceable. Release 3 pump mounting rubbers from vehicle body. fit a new unit if failure or damage occurs. 2. 6 REPAIR . Manoeuvre pump out of box section. Refit 8. Remove 5.19 FUEL SYSTEM VACUUM PUMP . 4.75. 1. 7. Release multiplug cover and disconnect multiplug from pump. Disconnect vacuum hose from pump. Reverse removal procedure. 3. Release strap securing jack and remove. Release turnbuckle securing wheel chock and remove. Remove pump. Ensure all hose and electrical connections are secure.

Repair. SPEED TRIP ECU . 5. Vehicle Speed Sensor For V8i See FUEL SYSTEM MFI.30. Disconnect ECU multi-plug. Remove ECU. NOTE: For further information.19. Release and move closing panel aside.22 For Tdi See FUEL SYSTEM Tdi. Remove 2 studs securing right hand side ’A’ post lower trim casing. Remove ECU fixing.V8i Service repair no . 6.75.49 Remove 1. 3. 2.28 1. To identify components.18.75. See Electrical Trouble Shooting Manual. Repair. 4. REPAIR 7 . 5. See Electrical Trouble Shooting Manual. Remove casing. Vehicle Speed Sensor Refit 7.CRUISE CONTROL CRUISE CONTROL ECU . Locate relay (neutral coloured base) and release base from bracket.19. Ensuring that electrical multi-plug is securely reconnected. NEUTRAL LOCK OUT RELAY Service repair no . Remove 3 studs securing fascia right hand side closing panel. Remove lower dash panel. Remove relay.MANUAL V8i NOTE: The neutral lock out relay module/speed trip ECU is mounted in the right hand side footwell. Reverse removal procedure. 2. 4. VEHICLE SPEED SENSOR Service repair no . 3. Reverse removal procedure.

12. Measure 16 mm from diaphragm collar and mark the position. fit a new unit if failure or damage occurs. Connect cable to lever and secure with clevis pin and split pin. Adjust cable position to remove any free play from link. Refit 7. 3. 5. Fit a new actuator assembly if diaphragm is damaged. Fit actuator and secure to bracket with nut. 8 REPAIR . 4.19 FUEL SYSTEM ACTUATOR . setting dimension ’B’ should be 103 mm. Connect vacuum hose. withdraw clevis pin and disconnect cable from lever. Disconnect vacuum hose from actuator. Disconnect link ball end from cable lever. proceed to paragraph 9. 6.Tdi Service repair no . Connect link ball end to cable lever. 13. Remove 1. Remove split pin.05 NOTE: The actuator is non serviceable. If dimension ’A’ is not correct. 10.19. Inspect rubber diaphragm. then turn retainer a further quarter turn to lock. If correct. proceed as follows: • 2. Position link and retainer to the mark and rotate retainer half a turn to secure. Remove nut securing actuator to bracket and remove actuator. Check measurement ’A’ is still 16 mm. 8. Disconnect battery negative lead. Check that link setting distance (dimension ’A’) equals 16 mm and that the retainer is locked in position. • • 9.75. 11.

2.Tdi Service repair no . 9. Remove top nut securing ECU to bracket. Open glove box. Move SRS harness aside. Remove nut securing ECU/relay bracket. 1.CRUISE CONTROL CRUISE CONTROL ECU . Reverse removal procedure.75. Remove bottom nut securing ECU to bracket.19. Ensure electrical multiplug is securely reconnected. 8. Refit 11. align stops with cut-outs in fascia panel and lower. 4. Remove ECU. Remove 4 studs securing fascia left hand closing panel.49 Remove 6. 7. REPAIR 9 . 5. 10. Remove closing panel. 3. Disconnect ECU multiplug. Lower bracket for access.

2. The largest section is for engine coolant and the other two sections which are cast in aluminium. pumps coolant towards the rear of the cylinder block around each of the cylinders. 6. to the header tank. Coolant circulation (engine cold) 1. Hot coolant is supplied to the heater through hoses. are the engine oil cooler and the turbo charger intercooler.The coolant flows forwards to the thermostat. During the engine warm up period. 4. Engine warm (thermostat open) When the engine reaches normal running temperature the thermostat closes off the by-pass and opens the flow to the top of the radiator. 7. COOLANT CIRCULATION Operation When the engine is started from cold the thermostat prevents any coolant circulation through the radiator by closing off the top hose. The radiator assembly is in three sections.Tdi ENGINE COOLING Description The Tdi engine uses a pressurized cooling system and cross flow radiator which is supplied from a separate header tank. 3. Cross flow radiator Header tank Viscous fan Heater hoses By pass hose and engine thermostat Air purge hoses Coolant pump DESCRIPTION AND OPERATION 1 . Two small diameter air purge hoses connect the top of the radiator and cylinder head water gallery. into the cylinder head. Coolant as it is heated rises through ports in the cylinder block and head gasket. 5. A belt driven viscous fan and centrifugal water pump is located in the front of the cylinder block. by-pass port and radiator top hose connection. coolant circulates around the cylinder block and cylinder head via the by-pass. the water pump. Start from cold (thermostat closed) While the thermostat is closed.

half filling chambers A and B. provides a means of controlling the speed of the fan relative to the running temperature of the engine. the fan speed and noise will decline indicating that the fluid is being centrifuged into chamber B (as seen in RR3757M) causing the drive to slip. as is evident by the initial noise of the fan. An outer member 2 which has the fan blades attached. However within a very short period of time. after starting the engine. The unit also contains a valve 5 which is controlled by an external bi-metal thermostat 6. Thus when the engine is first started sufficient fluid is present in chamber A to provide a positive drive between the members. 1.26 COOLING SYSTEM VISCOUS FAN Description The viscous drive unit for the engine cooling fan. The inner and outer members have interlocking annular grooves machined in each. Bi-metal 2 DESCRIPTION AND OPERATION . Drive out to fan blades 3. with a small running clearance 3 to allow the silicone fluid to circulate through the valve plate 4. houses the working parts and is driven through the medium of the viscous fluid. Operation The viscous unit consists of two principal components: An inner member 1 which is secured to water pump spindle and is driven by the fan belt. The viscous unit is a type of fluid coupling. which drives the fan blades through the medium of a special ’silicone fluid’ injected into the unit during manufacture. Drive in from water pump spindle 2. Starting engine from cold During the time the engine is at rest the silicone fluid drains down.

causing the unit to couple. Opening the valve (as shown in RR3758M) allows the fluid to circulate between the two members. thus increasing the fan speed and cooling effect. 3. 8. 2. 4. 5. DESCRIPTION AND OPERATION 3 . valve (open) If the engine speed is increased the degree of slip will also increase to limit the maximum fan speed. Viscous unit slipping (Engine at normal running temperature) 1. A B Inner member (drive in fast) Outer member (drive out slow) Running clearance Valve plate Valve (closed) Bi-metal Fluid seals Ball race Fluid chamber Fluid chamber Viscous unit coupled (Hot running conditions) Bi-metal expanded. 7. the bi-metel thermostat will operate and open the valve port between chambers A and B. 6.Tdi Hot conditions When operating in high ambient temperatures or when stationary in traffic.

If problem is not diagnosed. operation and correct fitting. 3. Carry out cylinder pressure test to determine if pressure is leaking into cooling system causing over pressurising and loss of coolant. Coolant NO . Is air flow through radiator restricted or blocked? YES . Are fan blades fitted correct way round. Is drive belt tension correct? NO . from water pump. Is viscous unit operating correctly? See Description and operation. go to check 10. Coolant NO . concave side towards engine? NO .Continue. If only the lubrication system is contaminated with coolant. Are there any external leaks. check the coolant system for engine oil contamination and engine lubrication system for coolant contamination. 4.Rectify. NO . Fan Blades. fast idle thermostat or the heater unit? YES . 2. Check thermostat type. suspect the radiator. 8. 5. YES .Continue.Continue. See Repair.Continue. See Adjustment. Engine Cooling 1. YES . Is temperature sender and gauge giving accurate readings? NO . engine gaskets. Compressor Drive Belt YES . If both systems are contaminated.Allow engine to cool.Carry out a pressure test on radiator cap and system. See Adjustment. otherwise: Continue. FAULT DIAGNOSIS 1 . Pulley and Fan Cowl YES . Is coolant in radiator frozen? YES .Investigate and rectify. 6. 10. Thermostat If pressure test leads you to suspect coolant leakage across gaskets. YES . suspect leakage past cylinder liner seals or cylinder head gasket. Is coolant level correct? NO .Apply air pressure from engine side of radiator to clear obstruction.Rectify.Continue.Continue 7. Viscous Coupling. Repair. YES .Sustitute parts and compare readings.Slowly thaw and drain system. 9. NO .Renew. Are the air conditioning fans operating correctly? See Electrical Trouble Shooting Manual.Tdi ENGINE OVERHEATING Before conducting any cooling system diagnosis: See Description and operation. Viscous Fan NO .Continue. If only the coolant system is contaminated suspect a cylinder head gasket. See Repair.See ENGINE.Continue. top up level to expansion tank seam.

See Electrical Trouble Shooting Manual. Engine Cooling 1. Check operation of viscous unit. starting at 1.Continue.Continue. Viscous Coupling. Thermostat If problem is not diagnosed: Continue. If problem is not diagnosed repeat tests. 4. Pulley and Fan Cowl YES . Is thermostat correct type and operating? See Repair. Are the air conditioning fans operating continuously? YES . 3.See Repair. Fan Blades. See Description and operation. 2.26 COOLING SYSTEM ENGINE RUNS COLD Before conducting any cooling system diagnosis: See Description and operation. NO . Is temperature sender and gauge giving accurate readings? Substitute parts and compare readings. 2 FAULT DIAGNOSIS . Viscous Fan Is viscous unit operating correctly? NO .

26. Information. Start engine and run for 5 minutes. remove radiator plug. Fit radiator plug.01 Draining WARNING: Do not remove any caps or plugs when the engine is hot. 5. The cooling system is pressurised and personal scalding could result. Add correct mix of coolant into expansion tank until radiator is full (as seen through plug hole on top of radiator). 11. check coolant level in expansion tank.Tdi COOLANT Service repair no . FLUIDS AND CAPACITIES. Add more coolant if necessary. CAUTION: Take care to avoid excess coolant spillage from thermostat housing. 9. 7. 10. 2. Similarly when coolant level is below top of radiator. ADJUSTMENT 1 .10. 4. Continue adding coolant into expansion tank until coolant appears in thermostat housing. Check coolant in expansion tank is level with indicator post. NOTE: Refill procedure is slow but can be accelerated by squeezing hoses to assist removal of air from the system. follow the procedures carefully. Ensure container is clean if reusing coolant. Disconnect bottom hose from radiator and allow coolant to drain into a container. Anti-Freeze CAUTION: Take care to avoid excess coolant spillage from radiator. 3. See LUBRICANTS. Reconnect hose after draining and tighten hose clamp. 6. top up to level indicator post if necessary. 8. remove thermostat housing plug to assist drainage. 1. Fit thermostat housing plug. Allow engine to cool. Refit CAUTION: In order to expel ALL air from the cooling system. Remove expansion tank filler cap. NOTE: When expansion tank has emptied. Fit expansion tank filler cap.

Slacken nut securing viscous coupling/fan blade assembly to pulley. 4. observe temperature at which thermostat begins to open. NOTE: Nut securing viscous unit to pulley has a left hand thread.Remove 1 to 3 .26. Test 6. NOTE: The serpentine belt is removed by using a hexagonal socket and tommy bar on the auto-tensioning pulley nut. 2. PULLEY AND FAN COWL Service repair no . 5.Remove 1 to 6 1. Remove outlet elbow. Thermostat is satisfactory if its open between 85°C and 89°C. 9. Remove serpentine drive belt and. Tighten to 30 Nm. Fit the outlet elbow and new joint washer. Reverse removal procedure. 8. Drop viscous unit and fan assembly into bottom of cowling 3. remove pulley. Withdraw thermostat. Refit drive belt. Check for coolant leaks around all connections and joint faces. 1. Refit 7. Disconnect electrical connections to water temperature switch. Release by turning clockwise when viewed from front of viscous unit.25. Heat water.03/05 THERMOSTAT Service repair no . 2. WARNING: Disconnect battery negative terminal to prevent engine being started before removing or adjusting drive belt. 10. Insert thermostat with jiggle pin/vent hole upper most (12 o’clock position) . air conditioning compressor belt. 5. Fan is marked ’front’ and should be fitted with word ’front’ closest to radiator. Remove fan blades from viscous coupling if necessary.45. Drive Belt 4.01 Remove Viscous coupling Fan blades Fan cowl Fan pulley Remove . Ensure fan blades are fitted correctly. Disconnect hose from thermostat housing. Reverse removal procedure. Whilst tensioning the device the belt can be removed. 6. REPAIR 1 . Repair. Remove two fixings clips from top of cowling and lift cowling complete with viscous unit and fan out of lower mountings. 8.Tdi VISCOUS COUPLING. 7. FAN BLADES. if fitted. Partially drain cooling system. See ENGINE.Remove 1 to 3 . 1 to 3. 3. until coolant level is below thermostat housing. Tighten to 28 Nm.Remove 1 to 4 .26. Note rating of thermostat is 88°C. Remove pulley fixings. Place thermostat in a container half full of water.

Coolant 2. 10. 4. 7.50. Remove top hose intercooler to induction manifold. 10. noting location of 3 through bolts. Remove centre nut from belt tensioner. Transfer oil cooler adaptors if fitting new radiator. 12. Check condition of rubber mounting pads.26. Slacken water pump and power steering pump pully retaining bolts. 11. Remove drive belt. 12.26 COOLING SYSTEM WATER PUMP Service repair no . Refit 13. 6. Remove 8 bolts securing water pump. 9. 1.01 Remove 1. Refit 9. Remove radiator securing brackets from each side. 2 REPAIR . 3. 8.01 Remove WARNING: Disconnect battery negative terminal to prevent engine being started before removing drive belts. 3. release hose from clip on water pump and move aside. Check all connections for leaks. Reverse removal procedure. 4. 7. 11.26. 5. Drain cooling system. Disconnect expansion tank bleed hose from radiator. Disconnect engine oil cooler connections and turbo intercooler connections from radiator ends. Disconnect hose thermostat to bottom hose. Remove water pump pulley. Withdraw pump and gasket. Remove top hose radiator to thermostat. Manoeuvre pulley upwards and withdraw tensioner from retaining stud. Check radiator sealing strips are securely located. See Adjustment. Remove power steering pump pulley. 6. Remove radiator unit by lifting from its location. Refit water pump in reverse order to removal using new gasket. Disconnect radiator top hose. clean all gasket material from mating surfaces. Drain engine cooling system. Remove cowl. 5. 8. Blank off exposed oil connections. See Adjustment. RADIATOR Service repair no . NOTE: Oil spillage will occur when connections are loosened. Coolant 2. Remove fan blade assembly. Tighten oil cooler connections to 30 Nm before fitting fan blades and cowl.40.

The belt driven viscous fan and centrifugal water pump is located in the engine front cover with ports for circulation of coolant to both banks of cylinders and cylinder heads. The coolant radiator also incorporates a section at the left hand end for cooling the transmission oil and a section at the other end for cooling the engine oil. 3. 4. 2. Coolant also circulates through the vehicle heating system and is used to heat air entering the inlet manifold plenum chamber. Coolant circulation (engine hot) 1. 5. Coolant returns to the top of the radiator via ports in the inlet manifold where the thermostat is mounted horizontally.V8i ENGINE COOLING Description The V8i engine uses a pressurised cooling system and cross flow radiator which is supplied from a separate header tank. 6. Cross flow radiator Header tank Viscous fan and water pump Heater pipes Plenum chamber connection Thermostat DESCRIPTION AND OPERATION 1 .

2 DESCRIPTION AND OPERATION . coolant flows through the top hose to the radiator where it is cooled and drawn back into the pump via the bottom hose. and then flows forward to connect with ports at the front of the inlet manifold. At the rear of the cylinder block the coolant rises through a large port in each cylinder head/block joint face.26 COOLING SYSTEM COOLANT CIRCULATION Operation When the engine is started from cold the thermostat prevents any coolant circulation through the radiator by closing off the top hose. But with the thermostat open. During the engine warm up period. the water pump. pumps coolant around the cylinders to the rear of the cylinder block along the main galleries in both cylinder banks. does not change when normal running temperature is reached and the thermostat opens. The coolant circulation through the cylinder block and heads. From the manifold the coolant is carried by an external pipe to the heater unit and from the heater through another external pipe to the pump inlet.

to the top right corner of the radiator. provides a means of controlling the speed of the fan relative to the running temperature of the engine. Hot water supply 2. 1. which drives the fan blades through the medium of a special ’silicone fluid’ injected into the unit during manufacture.V8i Plenum chamber heating Air entering the plenum chamber is heated by a flow of coolant from the inlet manifold which returns through a long hose. Drive out to fan blades 3. The viscous unit is a type of fluid coupling. VISCOUS FAN Description The viscous drive unit for the engine cooling fan. Drive in from water pump spindle 2. Cold return to radiator 1. Bi-metal DESCRIPTION AND OPERATION 3 .

26 Operation COOLING SYSTEM The viscous unit consists of two principal components: An inner member 1 which is secured to water pump spindle and is driven by the fan belt. 5. half filling chambers A and B. 3. as is evident by the initial noise of the fan. However within a very short period of time. Thus when the engine is first started sufficient fluid is present in chamber A to provide a positive drive between the members. The inner and outer members have interlocking annular grooves machined in each. An outer member 2 which has the fan blades attached. The unit also contains a valve 5 which is controlled by an external bi-metal thermostat 6. 4. 8. the fan speed and noise will decline indicating that the fluid is being centrifuged into chamber B (as seen in RR3757M) causing the drive to slip. B. 7. 2. 4 DESCRIPTION AND OPERATION . 6. A. Starting engine from cold During the time the engine is at rest the silicone fluid drains down. houses the working parts and is driven through the medium of the viscous fluid. Inner member (drive in fast) Outer member (drive out slow) Running clearance Valve plate Valve (closed) Bi-metal Fluid seals Ball race Fluid chamber Fluid chamber If the engine speed is increased the degree of slip will also increase to limit the maximum fan speed. with a small running clearance 3 to allow the silicone fluid to circulate through the valve plate 4. Viscous unit slipping (Engine at normal running temperature) 1. after starting the engine.

Viscous unit coupled (Hot running conditions) Bi-metal expanded. valve (open) DESCRIPTION AND OPERATION 5 . the bi-metal thermostat will operate and open the valve port between chambers A and B. causing the unit to couple.V8i Hot conditions When operating in high ambient temperatures or when stationary in traffic. Opening the valve (as shown in RR3758M) allows the fluid to circulate between the two members. thus increasing the fan speed and cooling effect.

4.Continue. 8. See Adjustment. Are there any external leaks.Rectify. YES . See Repair. Carry out cylinder pressure test to determine if pressure is leaking into cooling system causing over pressurising and loss of coolant. 10.Renew.Slowly thaw and drain system.Allow engine to cool.Substitute parts and compare readings.Apply air pressure from engine side of radiator to clear obstruction. Fan Blades. Is coolant level correct? NO . Thermostat If pressure test leads you to suspect coolant leakage across gaskets. 9. YES . 5.Investigate and rectify.Continue.Continue. engine gaskets or the heater unit? YES . Engine Cooling 1. YES . concave side towards engine? NO .Continue. Is drive belt tension correct? NO . Adjustment. Ignition Timing YES . check the coolant system for engine oil contamination and engine lubrication system for coolant contamination. Is coolant in radiator frozen? YES .Continue. See Adjustment. 6. 7. Are the air conditioning fans operating correctly? See Electrical Trouble Shooting Manual. Viscous Coupling. 11. top up level to expansion tank seam.Continue. Coolant Requirements NO . Is viscous unit operating correctly? See Description and operation. Viscous Fan NO . suspect cylinder head gaskets or radiator.Carry out a pressure test on radiator cap and system. NO . Is air flow through radiator restricted or blocked? YES . If problem is not diagnosed. from water pump.V8i ENGINE OVERHEATING Before conducting any cooling system diagnosis: See Description and operation. Is ignition timing correct? NO . Coolant Requirements NO .Rectify.Continue. or both systems are contaminated. If only the lubrication stystem is contaminated with coolant. If the coolant only. 3. Are fan blades fitted correct way round. 2. YES .See ENGINE. Drive Belt Check Tension YES .Continue. go to check 11. otherwise: Continue. operation and correct fitting See Repair. Pulley and Fan Cowl YES .Continue. FAULT DIAGNOSIS 1 . suspect inlet manifold or front cover gaskets. Repair. Is temperature sender and gauge giving accurate readings? NO .K5 NO .See ELECTRICAL. Check thermostat type.

Are the air conditioning fans operating continuously? YES . Viscous Fan Is viscous unit operating correctly? NO .26 COOLING SYSTEM ENGINE RUNS COLD Before conducting any cooling system diagnosis: See Description and operation.See Repair.Continue. 4.Continue.See Electrical Trouble Shooting Manual. 2 FAULT DIAGNOSIS . Engine cooling 1. NO . If problem is not diagnosed repeat tests. Thermostat If problem is not diagnosed: Continue. Check operation of viscous unit. 3. Is thermostat correct type and operating? See Repair. 2. starting at 1. fan blades. See Description and operation. pulley and fan cowl YES . Viscous coupling. Is temperature sender and gauge giving accurate readings? Substitute parts and compare readings.

After the second winter the system should be drained and thoroughly flushed. ADJUSTMENT 1 .10. Remove radiator filler plug and ’O’ ring to assist drainage. CAUTION: Do not use salt water otherwise corrosion will occur. containing a suitable inhibitor for aluminium engines and engine parts. this may corrode aluminium alloy. Fluids and Capacities in Section 09. Anti-freeze can remain in the cooling system and will provide adequate protection for two years provided that specific gravity of coolant is checked before onset of second winter and topped-up with new anti-freeze as required. pause to allow pressure to escape.26. Instructions in chart must be strictly adhered to before driving vehicle. Recommended Lubricants and Fluids COOLANT Service repair no . Vehicles so filled are identified by a label affixed to radiator. winter and summer. Recommended solutions Anti-freeze: Universal anti-freeze or permanent type ethylene base. The cooling system is pressurised and personal scalding could result. Before adding new anti-freeze examine all joints and replace defective hoses to make sure that the system is leakproof. Remove expansion tank filler cap by slowly turning it anti-clockwise. FLUIDS AND CAPACITIES.V8i COOLANT REQUIREMENTS Frost precautions and engine protection. without methanol. NOTE: Should ambient temperatures be below that stated above refer to Anti-Freeze Data in Recommended Lubricants. In certain territories where only available natural water supply has some salt content use only rain or distilled water. NEVER use water alone. This gives protection against frost down to minus 36°C (minus 33°F). Information. 1.01 Draining WARNING: Do not remove expansion tank filler cap when engine is hot. 2. Vehicles leaving factory have cooling system filled with 50% solution of anti-freeze and water. Use one part of anti-freeze to one part of water. Cooling system MUST ALWAYS be filled and topped-up with solution of water and anti-freeze. See the ’Recommended Lubricants Fluids and Capacities’ for protection quantities. Continue turning it in same direction and remove. See coolant requirements before refilling system. See LUBRICANTS.

Remove engine drain plugs. Allow engine to cool. Tighten to 6 Nm. Refit radiator filler plug and ’O’ ring. Pour correct solution of water and anti-freeze into expansion tank until radiator is full. with new ’O’ ring if required. 2 ADJUSTMENT . Finally top up expansion tank until level reaches seam of expansion tank. 9. run it until normal operating temperature is attained. Drain coolant into a clean container. Drain coolant. It is not desirable to flush through system. 4.26 COOLING SYSTEM 3. after draining. Reconnect bottom hose. Start engine. Disconnect bottom hose from radiator. topping up as necessary. check coolant level. refit and tighten plugs. NOTE: It is not possible to drain all coolant retained in heater system. 7. 6. beneath exhaust manifolds. 8. re-tighten hose clamp. 5. one each side of cylinder block. Fit expansion tank filler cap.

26.Water pump pulley Service repair no .15. The cooling system is pressurised and personal scalding could result.19 . Check for leaks around all hose connections.25. 6. Replenish cooling system. pause to allow pressure to escape.Fan blades Special tools: LRT-12-093 LRT-12-094 . Remove three fixing bolts. 1. 2.V8i EXPANSION TANK Service repair no . Refit 4. allowing coolant to drain into a suitable container.26.Viscous coupling removal Remove 1.26. Disconnect two hoses from bottom of expansion tank.25. Release 2 clips securing cooling fan upper cowl.05 . remove expansion tank. VISCOUS COUPLING. 3. FAN BLADES. Reverse removal procedure. Disconnect battery negative lead.0 V8 only: Release coolant hose from cooling fan upper cowl. NOTE: 4.26. 5. Remove expansion tank filler cap by first turning it slowly anti-clockwise.03 . Continue turning in same direction and lift off. REPAIR 1 . PULLEY AND COWL Service repair no .Viscous coupling and fan assembly Service repair no .01 Remove WARNING: Do not remove expansion tank filler cap when engine is hot. 2.25. Remove cowl.

remove pulley. 15. Do not carry out further dismantling if component is removed for access only. 11. 2 REPAIR . 7. 10. Remove serpentine drive belt. Using LRT-12-093 and LRT-12-094. Remove pulley fixings. Use LRT-12-093 to prevent coolant pump pulley from turning and using LRT-12-094. NOTE: Mark fan with reference to assist refitting. Fit fan blades to coupling. 4.0 V8 only:Fit coolant hose to cooling fan upper cowl. Clean fan blades and mating faces. Remove fan and coupling assembly. Secure with clips. unscrew viscous coupling from water pump. fit fan assembly to pump. 4. Fit cooling fan upper cowl. Secure with screws. 9. Release by turning anti-clockwise when viewed from front of viscous unit. Fit pulley fixings. Remove 4 Allen screws securing blades to coupling. 6. 12. 13. 5. 14. Reconnect battery negative lead.26 COOLING SYSTEM Refit 8. remove pulley. Remove coupling. Tighten to 24 Nm. Fit serpentine drive belt. Tighten to 56 Nm. NOTE: Nut securing viscous unit to water pump has a right hand thread. 3.

1 to 3.45. Thermostat is satisfactory if it opens between 85°C and 89°C. 2. Reverse removal procedure.26. Remove outlet elbow. Heat water. 5. until coolant level is below thermostat housing. 8. 3. Check for coolant leaks around all connections and joint faces. Note rating of thermostat is 88°C. Fit the outlet elbow and new joint washer. Place thermostat in a container half full of water. Refit 7. Withdraw thermostat. 9. 10. 4. Test 6. Insert thermostat with jiggle pin/vent hole uppermost (12 o’clock position).01 Remove 1. Disconnect electrical connections to water temperature switch. Disconnect hose from thermostat housing. Tighten to 28 Nm.V8i THERMOSTAT Service repair no . REPAIR 3 . Partially drain cooling system. observe temperature at which thermostat opens.

Drain cooling system. Reverse removal procedure.40. Disconnect radiator top hoses. 14. 4. See Adjustment. Coolant 2. Remove radiator unit by lifting from its location.26 RADIATOR COOLING SYSTEM Refit 9. 5. 8. Disconnect transmission oil temperature sensor. Remove radiator securing brackets from each side. Clean unions and apply sealant. Release 2 clips and remove fan cowl. before fitting fan blades and cowl. 12. 7. Service repair no . Lubricate new ’O’ rings before fitting. Fan Blades.01 Remove 1. 10. Disconnect four transmission and engine oil cooler connections to radiator end tanks. Remove viscous coupling and fan assembly. 13. See Viscous Coupling. 4 REPAIR . Note oil spillage will occur when connections are loosened. Check condition of rubber mounting pads. 15. 6. Blank off exposed oil connections.26. Clean coolant/oil spillage from vehicle. Check all connections for coolant/oil leaks. Pulley and Fan Cowl 3. 16. Check radiator sealing strips are securely located. Transfer oil cooler adaptors if fitting new radiator. 11. Ensure that oil cooler connections are tightened to 30 Nm.

V8i REPAIR 5 .

1. Fan Blades.50. 9.26. See Adjustment. Coolant 2. Refit 6. Lightly grease new joint washer. Locate water pump in position. Remove water pump and joint washer.26 COOLING SYSTEM WATER PUMP Service repair no .01 Remove WARNING: Disconnect battery negative terminal to prevent engine being started before removing or adjusting drive belts. 6 REPAIR . Check for coolant leaks around all hose connections and joint faces. Disconnect inlet hose from water pump. 5. 10. 7. Reverse removal procedure. 8. 1 to 3. 4. Remove water pump bolts. Tighten remaining water pump housing bolts evenly to 28 Nm. Pulley and Fan Cowl 3. See Viscous Coupling. Clean threads of all long bolts and coat with Loctite 572 thread lubricant-sealant. Remove fan blades and pulley. position on timing cover. Drain engine cooling system.

................................... TORQUE 1 ........... 6 SPECIFICATIONS...................................................................V8i TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque....... Nm Oil cooler pipes .......................... 30 Radiator filler plug (plastic) ....................

Mpi COOLANT PUMP Service repair no . Remove housing cover. 12. Remove coolant pump from housing. Position housing cover.50. Position drain tin below coolant pump hose. 8. Lubricate new sealing rings with Loctite 405 and fit to coolant pump. Fit coolant pump to housing. REPAIR 1 . 9. WARNING: Do not carry out the next instruction until the coolant is cool to avoid personal injury from scalding. Clean coolant pump housing and mating faces. 2. 5. Remove 5 bolts securing housing cover. fit 5 bolts. Connect hose to housing cover and tighten clip. Release clip and disconnect hose from coolant pump housing cover.26. 6. 4. 3. Refit 7. Discard 3 sealing rings.01 Remove 1. Refill cooling system. 10. Tighten to 25Nm 11.

support bracket aside. 2. Slacken clip and release heater hose from radiator rail. 2 REPAIR . support bracket and position R. 11. 5.26. Disconnect 2 multiplugs from cooling fan assemblies. 7. 6. WARNING: Do not carry out the next instruction until the coolant is cool to avoid personal injury from scalding.26 RADIATOR COOLING SYSTEM Service repair no . Release air cleaner to throttle housing hose from securing brackets. Disconnect battery negative lead. Remove 2 bolts securing radiator side support brackets.01 Remove 1.40. Collect L. 8. Slacken clip and release bypass hose from radiator.H. Slacken clip and release bottom hose from radiator. 10. 4.H. Slacken clip and release top expansion hose from radiator. Slacken clip and release bottom hose from radiator rail. Slacken clip and release top hose from radiator. 9. allow coolant to drain into a suitable container 3.

With assistance lift out radiator assembly. 12. Secure radiator to body with the side support brackets and retaining bolts. 24. NOTE: Vehicles without air conditioning have one cooling fan fitted. Secure air cleaner to throttle housing to brackets. Remove 2 bolts securing radiator rail to radiator. Fit and secure 6 hoses to radiator. 21. 18. 22. 15. Position fan assemblies to radiator and tighten nuts to 6Nm 17. Do not carry out further dismantling if component is removed for access only. Reconnect battery negative lead. Position radiator rail to radiator and secure with bolts. Position radiator to vehicle. Refill cooling system. REPAIR 3 . 23.Mpi Refit 16. Connect multiplugs to cooling fans. 20. Remove 8 nuts securing fan assemblies to radiator. Remove radiator rail. 14. 19. 13.

Disconnect Lucar connector from sensor. Remove sensor. 4.22. Release top hose from securing bracket. 2.26. Fit sensor and tighten to 15Nm Connect Lucar to sensor. 7. 4.01 Remove 1. 6. Slacken 2 clips and release radiator top hose. THERMOSTAT Service repair no .26 COOLING SYSTEM THERMOSTATIC SENSOR Service repair no . 4 REPAIR . Refit 3. Clean sensor.45. 5.19.18 Remove 1. Apply Loctite 405 to threads of sensor. 3. Remove top hose. Top-up cooling system. 5. Position suitable container to collect coolant. 2. Release bypass hose from securing bracket.

Lubricate inside of top hose with liquid soap. Refit radiator hose. 11. REPAIR 5 . Refit 8. Fit and tighten clip securing thermostat to top hose. 9. Top-up cooling system. 12. Remove clip securing thermostat in hose. 7. 10. Manoeuvre thermostat into hose to previous position.Mpi 6. Lubricate hose in front of thermostat and manoeuvre thermostat from hose.

are located in the exhaust down pipes. Should the engine be supplied with a rich mixture causing high CO in the exhaust gas.MANIFOLD AND EXHAUST SYSTEM CATALYTIC CONVERTERS . into Nitrogen (N). Catalysts 2. excess oxygen in the exhaust gas will cause the catalysts to burn out.V8i Description Catalytic converters which form part of the engine emission control system. the ceramic element will become coated and the useful life of the catalyst reduced. are designed to ’clean’ the exhaust gases. The Hydrocarbons (HC). The oxygen sensors which transmit information to the fuel ECU for control of the mixture. Nitogen oxides (NOx) and Carbon monoxide (CO) emitted by the engine react with the catalytic element and exhaust temperature to convert the toxic gas. by closely controlling the fuel air ratio delivered to the engine and converting the residual exhaust compounds into products more acceptable to the environment. Carbon dioxide (CO2) and water vapour. 1. If the mixture is too weak. The front section of the exhaust system to each cylinder bank contain the ceramic elements of the catalytic converters. Lambda oxygen sensors DESCRIPTION AND OPERATION 1 .

NOTE: Ensure no exhaust leaks are evident in either a new or old exhaust system.MANIFOLD AND EXHAUST SYSTEM EXHAUST SYSTEM COMPLETE Service repair no .30. a two piece exhaust system is fitted. REPAIR 1 . WARNING: To prevent personal injury occurring from a hot exhaust system.01 To improve sealing and accuracy of assembly. DO NOT attempt to disconnect any components until exhaust system has cooled down.11. as this will affect vehicle performance.

Reverse removal procedure. 7. 5. Rectify if necessary. 3. Twist assembly clockwise until it is in mounting position. Lower front exhaust assembly with catalysts (if fitted). 5. Refit 4. 16. 11. new lockplates and plain washers. as for removing. 15.15. retain olive. 8. Remove nuts and release front downpipes from manifolds. Reconnect front exhaust pipe. 2. 2 REPAIR . Examine system for leaks. twist assembly anti-clockwise clear of rear axle.30.30 Remove MANIFOLD AND EXHAUST SYSTEM EXHAUST MANIFOLD . Ensure that mating surfaces of cylinder head and exhaust manifold are clean and smooth. to 9. Raise vehicle on a ramp [hoist]. 2. Discard gaskets. Place extended axle stands underneath chassis. 1. 4. 6. Facing rear of vehicle. 6. Remove manifold(s) and old gaskets.15. using new exhaust flange gaskets. Evenly tighten manifold bolts to 20Nm bend over lockplate tabs. Catalysts . Remove bolts securing three hanger brackets to chassis.remove and refit 1 to 5 1. Detach rubbers from hanging brackets. 10. Remove rear exhaust assembly from vehicle.11 Remove 1. NOTE: NAS models have four heated oxygen sensors fitted.Left hand .V8i Service repair no . centre silencer to right of vehicle. Plain washers are fitted between manifold and lockplates. Place manifold and new gaskets in position on cylinder head and fit securing bolts. Coat threads of each bolt with anti-seize compound. Catalyst vehicles only: Disconnect two heated oxygen sensor wiring connectors. Position rear exhaust assembly over rear axle in a diagonal position. Lower ramp[hoist] until vehicle weight is supported securely on stands. 14. in front of chassis mounted rear towing brackets.Right hand . using new manifold gaskets and applying exhaust sealer to system joint. NOTE: Assistance is required for removing and refitting rear exhaust assembly. 9.10 Service repair no . Lower exhaust assembly onto rear axle.30. 8. Move rear exhaust to a diagonal position. 3. Remove two nuts securing rear exhaust assembly to front exhaust assembly. lock tabs and washers. Refit 13. 12. Disconnect front exhaust pipe(s) from manifold(s). Tap back bolt locking tabs and remove eight bolts. 7. Lower ramp [hoist] until rear shock absorbers are ALMOST fully extended. ensuring that system does not foul underbody components.

Anti-roll [sway] Bar Assembly Rear 3. Lower hoist until vehicle weight is supported securely on stands. 14. Disconnect exhaust at manifold. 11. REPAIR 3 . Fit axle stands in suitable place on chassis. twist assembly anti-clockwise clear of rear axle. Remove exhaust support bracket behind catalyst. See REAR SUSPENSION. Remove anti-roll[sway] bar bolts to chassis and allow to swing down clear of axle. Reverse removal procedure instructions 1 to 15 using a new manifold gasket and applying exhaust sealer to system joints. Examine system for leaks. centre silencer to right of vehicle. Remove bolts securing three hanger brackets to chassis. 4. 5. Rectify if necessary. Disconnect flange between rear and front exhaust. Facing rear of vehicle. 8. 15. 9.Tdi Remove 1. 12. Move rear exhaust to a diagonal position. Manoeuvre front exhaust section fron underneath vehicle. 6. Raise vehicle on a ramp [hoist]. 2. Lower rear exhaust assembly onto rear axle. 13. Position rear exhaust assembly over rear axle in a diagonal position. Repair. 19. Refit 16. Twist assembly clockwise until it is in mounting position. Lower hoist until rear suspension is almost fully extended. 7. Detach rubbers from hanging brackets.MANIFOLD AND EXHAUST SYSTEM MANIFOLD AND EXHAUST SYSTEM . ensuring that system does not foul under body components. as for removing. Place extended axle stands underneath chassis in front of chassis mounted rear towing brackets. Remove rear exhaust assembly from vehicle. 17. Allow hoist to lower until front suspension is fully extended. 10. 18.

Disconnect battery negative lead. 8. and remove turbo charger if necessary. Refit 14. Remove the turbo boost pipes. Use a new manifold and exhaust flange gaskets. 15.10 Remove 1. 6. 13. Release the turbo charger oil pipes from the cylinder block. 4 REPAIR . Remove four bolts and disconnect diaphragm rod from manifold. 7. Remove heat shield from rear of air intake manifold. Remove air filter inlet pipe to turbo unit. 2. 9. 3.30 MANIFOLD AND EXHAUST SYSTEM EXHAUST MANIFOLD . Disconnect the intake hose from the manifold. 11. Remove the three fixings at the exhaust pipe flange. Remove the two bolts and two nuts securing the intake manifold to the cylinder head and withdraw the inlet manifold. Reverse removal procedure. Reconnect battery negative lead. release the heater rail and remove the manifold gasket. Release dip stick tube from cylinder block. Remove seven bolts securing the exhaust manifold. Remove intercooler pipe from turbo to intercooler. 10.15. Disconnect the EGR pipe from the inlet manifold hose. 1 to 12. 5.Tdi Service repair no . Start engine and check for leaks. complete with turbo unit. 4.30. 12.

8. Disconnect stepper motor multiplug. Release throttle cable from cam. 5.15. Position absorbent cloth around fuel pipe to fuel rail union.30. Unscrew union to relieve fuel pressure. Remove coolant bypass hose. 4. Disconnect fuel temperature sensor multiplug. 7. Disconnect throttle potentiometer multiplug. Release throttle cable from abutment bracket.Mpi Service repair no . REPAIR 5 . Release clip and remove air cleaner to throttle housing hose. 9. 3. Re-tighten union.MANIFOLD AND EXHAUST SYSTEM INLET MANIFOLD GASKET .08 Remove 1. 6. 2. Release clip and disconnect brake servo hose from manifold. CAUTION: Plug connections. Disconnect battery negative lead.

Release clip and disconnect breather hose from manifold. 16. 14. 17.30 MANIFOLD AND EXHAUST SYSTEM 10. Disconnect 3 vacuum hoses from manifold. Remove 2 nuts and 7 bolts securing manifold to cylinder head 18. 6 REPAIR . Disconnect intake air temperature sensor multiplug. 13. Release clip and disconnect fuel hose from pressure regulator. 11. 12. Remove 3 bolts securing engine harness to manifold. Disconnect fuel injector harness multiplug. Release 2 bolts securing cam cover brackets to manifold. CAUTION: Plug the connections. Remove manifold assembly and collect gaskets. 15.

Adjust throttle cable. Ensure mating faces of inlet manifold and cylinder head are clean.MANIFOLD AND EXHAUST SYSTEM Refit 19. Raise vehicle. 24. Fit fuel pipe to fuel rail.Mpi Service repair no . REPAIR 7 . position inlet manifold to cylinder head. 27. Loosen 2 nuts securing downpipe to silencer box.12 Remove 1. 22.15. 3. 32. secure with bolts. Connect battery negative lead. Remove 4 nuts securing downpipe to exhaust manifold. Connect breather hose and brake servo hose to manifold. 4. Connect fuel hose to pressure regulator and secure with clip. 20. Connect breather hose to throttle housing and secure with clip. 23. 5. Connect throttle cable to cam and secure to abutment bracket. 34. Connect stepper motor and throttle potentiometer multiplugs. Connect air cleaner hose to throttle housing and secure with clip. 35. Connect vacuum hoses to manifold. Position engine harness and cam cover brackets to manifold. tighten in the order shown to the correct torque 25Nm EXHAUST MANIFOLD GASKET . 31. Release downpipe from exhaust manifold. Connect multiplug to fuel temperature sensor. Connect coolant bypass hose to throttle housing. 28. 21. 33. 29. 36. 25. Discard gasket. Fit nuts and bolts. Fit a new gasket. 30. secure with clips. Connect fuel injector harness and intake air temperature sensor multiplug. 2. Position engine breather hose to manifold and secure with bolts. tighten union to 10Nm 26.30.

30. 23. See Specifications. 7. Release multiplug from bracket on thermostat housing. Remove drive belt. Secure oxygen sensor multiplug to bracket. 25. 16. 28. 8 REPAIR . Remove 2 rear bolts securing generator to mounting bracket. Position coolant rail bracket to manifold studs. 18. 27. 24. Release coolant rail bracket from manifold studs. 11. 22. Fit manifold nuts and bolts. Remove 3 bolts and 2 nuts securing exhaust manifold to cylinder head. torque. 14. 13. Remove exhaust manifold heat shield. 26. Disconnect oxygen sensor multiplug. Position generator to mounting bracket. Remove exhaust manifold and discard gasket. Fit new manifold flange gasket and align exhaust front pipe to manifold. 9. 20. Clean mating faces of exhaust manifold and cylinder head. 17. 10. Remove dipstick tube from cylinder block. 12. Connect oxygen sensor multiplug. Torque Values 19. Release harness from cable tie. Refit NOTE: For torque values. Fit and tighten 4 generator securing bolts. 15. 29. 8. 21. Remove dipstick and bolt securing dipstick tube to coolant rail. Fit new manifold gasket and align exhaust manifold to cylinder head. Refit drive belt. tighten to the correct torque in the order shown. Tighten exhaust downpipe to silencer box nuts to the correct torque. Move generator from mounting bracket and place aside. Remove 2 front bolts securing generator to mounting bracket.30 MANIFOLD AND EXHAUST SYSTEM 6. Fit nuts and tighten diagonally to the correct torque.

9. Release clip and disconnect breather hose from throttle housing. 8.MANIFOLD AND EXHAUST SYSTEM MANIFOLD CHAMBER GASKET . Remove coolant bypass hose from throttle housing. Release throttle cable from abutment bracket.Mpi Service repair no . REPAIR 9 . Release clip and remove air cleaner to throttle housing hose. Release clip and disconnect brake servo hose from manifold. Disconnect battery negative lead. Disconnect fuel temperature sensor multiplug. Re-tighten union. Loosen union to relieve pressure. 4. 3. Position absorbent cloth around fuel pipe to fuel rail union. Disconnect stepper motor and throttle potentiometer multiplugs. Release throttle cable from cam.30. 2.15. 7.37 Remove 1. 5. 6.

Adjust throttle cable. 28. position manifold chamber to lower manifold. Connect throttle cable to cam and secure to abutment bracket. 10 REPAIR . Connect air cleaner hose to throttle housing and secure with clip. Connect breather hose and brake servo hose to manifold. 17. Release 2 bolts securing camshaft cover brackets to manifold. Fit bolts. 27. Remove 6 bolts securing manifold chamber to lower manifold. 16. torque. Fit a new gasket. Connect stepper motor and throttle potentiometer multiplugs. 11. 22. 20. See Specifications. 24. Refit NOTE: For torque values. Connect multiplug to fuel temperature sensor. Remove manifold chamber and collect gaskets. 21. 26.30 MANIFOLD AND EXHAUST SYSTEM 10. Release clip and disconnect breather hose from manifold. Ensure mating faces of manifold chamber and lower manifold are clean. Connect vacuum hoses to manifold. 13. Position camshaft cover brackets to manifold. 14. 23. 19. tighten to the correct torque. secure with bolts. Disconnect 4 vacuum hoses from manifold. Connect breather hose to throttle housing and secure with clip. Torque Values 15. 25. 18. secure with clips. 12. Reconnect battery negative lead. Connect coolant bypass hose to throttle housing.

MANIFOLD AND EXHAUST SYSTEM

TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm MANIFOLDS AND EXHAUSTS - Mpi Inlet manifold nuts and bolts ...................................................................... Fuel pipe to fuel rail .................................................................................... Exhaust manifold nuts ................................................................................ Exhaust frontpipe to manifold .................................................................... Exhaust downpipe to silencer box ............................................................. Manifold chamber gasket ........................................................................... 25 10 45 10 30 10

SPECIFICATIONS, TORQUE

1

CLUTCH

DESCRIPTION The clutch unit fitted with the manual transmission, comprises a single dry plate friction disc and diaphragm spring clutch unit, secured to the engine flywheel.

OPERATION The unit is operated hydraulically by the clutch master cylinder 12 and a slave cylinder 13 attached to the transmission bell housing.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Crankshaft and flywheel Friction plate Clutch cover Diaphragm spring Pressure plate Fulcrum posts (9) for diaphragm spring Bearing rings (2) for diaphragm spring Retraction links and bolts (3) for pressure plate Release bearing Release lever

11. 12. 13. 14. 15. 16. 17. 18. 19.

Release lever pivot post Master cylinder Slave cylinder Master cylinder pedal pushrod Primary shaft and taper bearing (in gearbox) Gearbox front cover Primary shaft flywheel bush Pedal pivot and return spring Hydraulic damper (Diesel only)

DESCRIPTION AND OPERATION

1

33

CLUTCH

When the clutch pedal is depressed, hydraulic fluid transmits the movement via the slave cylinder, release lever 10, bearing 9, to the inner fingers of the diaphragm spring 4. The diaphragm spring 4 pivots on the bearing rings 7 and fulcrum posts 6 causing the pressure plate 5 to release the clamping force on the friction plate and linings 2.

As the the clamping force is removed from the friction plate 2, the plate slides on the splines of the primary shaft 15 and takes up a neutral position between the flywheel 1 and the pressure plate 5 , thus breaking the drive between the engine and the gearbox. NOTE: Diesel engined vehicles have an hydraulic damper 19 fitted into the system. The damper contains a steel diaphragm which absorbs slight hydraulic pulses caused by cyclic variations of the diesel engine crankshaft at low rpm.

2

DESCRIPTION AND OPERATION

CLUTCH

CLUTCH ASSEMBLY CONDITIONS For the clutch to operate correctly as described and illustrated in the "Description and Operation", it is important the following conditions are satisfied:A. The primary shaft 15 must be free in the crankshaft spigot bush 17. B. The friction plate 2 must be able to slide easily on the splines on the primary shaft 15, to a position where it does not contact either the flywheel or the pressure plate. C. The friction plate must not be distorted or the linings contaminated with oil, which may cause it to stick or continue to run in contact with the flywheel or pressure plate. A number of faults can develop in the operation of the clutch for a variety of reasons and although most faults are due to normal wear at high mileage, problems can also occur if the unit has been renewed by an unskilled operator. Recognising and diagnosing a particular clutch fault is therefore of paramount importance in ensuring, that the problem is rectified at the first attempt. Problems which develop in the clutch are as follows:A. Clutch spin/drag B. Clutch slip C. Clutch judder/fierce

CLUTCH SPIN - DRAG Symptoms Clutch spin is that, with engine running and clutch pedal depressed, the gears cannot be immediately engaged without making a grinding noise. This indicates the clutch is not making a clean break. However, if the clutch pedal is held depressed for several seconds the friction plate will eventually break free from the engine and the gear will engage silently. Clutch spin as it becomes more severe develops into clutch drag, making the silent engagement of a gear impossible, regardless of how long the pedal is held depressed.

CLUTCH SLIP Symptoms Clutch slip is most evident climbing a hill or when the vehicle is moving off from stationary with a heavy load. As the clutch is released slip occurs between the engine and the transmission, allowing the engine speed to increase without a corresponding increase in vehicle speed. Clutch slip can develop to the stage where no power is transmitted through the clutch as the pedal is released.

CLUTCH JUDDER - FIERCE Symptoms Clutch judder or fierce engagement, like slip, is most likely to occur when the vehicle is moving off from stationary. As the clutch pedal is released the vehicle will move rapidly or in a series of jerks, which can not be controlled even by careful operation of the clutch by the driver. It should be noted that a vehicle may display all the symptoms or any combination of the symptoms described, depending on the driving conditions vehicle load and operating temperatures.

FAULT DIAGNOSIS

1

33

CLUTCH

FAULT/SYMPTOM CHART

Symptoms Slip * * Spin/Drag * * * * * * Judder/Fierce * * * * * * * Fault Worn or oil on clutch linings Mechanical damage Distorted clutch plate Failed or air in hydraulic system Primary shaft tight fit in crankshaft bush Clutch splines sticking Weak clutch plate springs or insecure/worn engine/gearbox mountings Insecure/worn propeller shafts Insecure/worn suspension components/rubber bushes Item 2 45678 2 12 13 15 17 2 15 6

For items refered to in this chart. See Description and operation, Description

CLUTCH NOISE - MECHANICAL FAULTS Noise from clutch or gearbox in neutral, which disappears when clutch is depressed. Suspect gearbox input/primary shaft bearings. See MANUAL GEARBOX, Fault diagnosis, Manual Gearbox - Noise from gearbox in neutral, which disappears when clutch is depressed Noise from clutch or gearbox in neutral, which changes tone or becomes worse when the clutch is depressed. Suspect worn release bearing. Knocking/rattling from clutch or gearbox in neutral, which is reduced or disappears when the clutch is depressed. Suspect worn/weak release lever retainer or clutch unit. Noise from clutch or gearbox in neutral, which disappears when clutch is depressed. Suspect gearbox fault. See MANUAL GEARBOX, Fault diagnosis, Manual Gearbox - Noise from gearbox in neutral, which disappears when clutch is depressed.

HYDRAULIC FAULTS Unable to dis-engage clutch, little or no pedal resistance. 1. Check condition, specification and level of fluid. 2. Check pipes and cylinders for leaks. 3. Check that air vent in reservoir lid is clear. Suspect faulty master cylinder if no fluid leaks present. See Repair, Master Cylinder Spongy pedal operation 1. Check condition, specification and level of fluid. 2. Check that air vent in reservoir lid is clear. Suspect air in fluid. See Repair, Bleed Hydraulic System Clutch is difficult to dis-engage and/or does not immediately re-engage when pedal is released. 1. Check condition, specification and level of fluid. 2. Check that air vent in reservoir lid is clear. Suspect pedal pivot, master cylinder or slave cylinder seizure. See Repair, Master Cylinder

2

FAULT DIAGNOSIS

CLUTCH

CLUTCH ASSEMBLY Service repair no - 33.10.01 Clutch pressure plate Renew pressure plate if diaphragm spring fingers are worn or if pressure plate shows signs of wear, cracks or burning. Clutch driven plate Renew driven plate if centre hub splines are worn or if lining is contaminated, burned or unevenly worn. Service tools: Clutch centralising tool LRT-12-001 - V8 LRT-12-040 - Tdi LRT-12-057 - Mpi Remove 1. Remove gearbox. See MANUAL GEARBOX, Repair, R380 Manual Gearbox 2. Mark position of clutch cover to flywheel for reassembly. 3. Remove clutch cover securing bolts, working evenly and diagonally. 4. Do not disturb three bolts in clutch cover. 5. Remove clutch assembly. 6. Withdraw clutch driven plate.

Refit NOTE: To prevent clutch plate sticking, lubricate splines using Rocol MV 3 or Rocol MTS 1000 grease. 7. Renew/refit clutch driver plate and clutch assembly using centralising tool, where applicable, align assembly marks. 8. Secure clutch assembly cover fixings evenly, working in a diagonal sequence. Tighten to 28 Nm. 9. Fit gearbox to engine.

REPAIR

1

33

CLUTCH

BLEED HYDRAULIC SYSTEM Service repair no - 33.15.01 Procedure NOTE: During bleed procedure, keep fluid reservoir topped up to avoid introducing air to system. For hydraulic fluid recommendations. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids 1. Attach suitable tubing to slave cylinder bleed screw. 2. Place free end of tube in a glass jar containing clutch fluid. 3. Loosen bleed screw.

MASTER CYLINDER Service repair no - 33.20.01/03 NOTE: All flexible and pipe connections and joints should be tightened to 15 Nm. Remove 1. Evacuate hydraulic fluid from system. 2. Disconnect fluid pipe at master cylinder. Plug master cylinder fluid port and seal end of hydraulic pipe to prevent ingress of foreign matter. 3. Lower fascia fuse box panel. 4. Remove master cylinder fixings. 5. Remove retaining washer and clevis pin from push rod and clutch pedal. 6. Remove master cylinder.

4. Pump clutch pedal, pausing at end of each stroke, until fluid from tubing is free of air. Keeping free end of tube below surface of fluid. 5. Hold clutch pedal down, tighten bleed screw. 6. Top up fluid reservoir.

2

REPAIR

CLUTCH

Refit 7. Fit the master cylinder and fixings. 8. Fit push-rod to pedal and retain with clevis pin and washer. 9. Raise fasica fuse box panel.

RELEASE BEARING ASSEMBLY Service repair no - 33.10.07 Remove 1. Remove gearbox. See MANUAL GEARBOX, Repair, R380 Manual Gearbox 2. Remove clutch slave cylinder. See Slave Cylinder 3. Withdraw retainer staple.

10. Fit fluid pipe to master cylinder. 11. Bleed system. See Bleed Hydraulic System

4. Withdraw bearing and sleeve. If required, press bearing off sleeve. Fit replacement bearing with domed face outwards from sleeve. 5. Remove spring clip and fixings. 6. Withdraw release lever assembly. Refit 7. Smear pivot with grease and fit release lever and retain with spring clip and bolt. 8. Smear release bearing sleeve inner diameter with molybdenum disulphide base grease. 9. Reverse removal procedure. 1 to 4.

REPAIR

3

33

CLUTCH

SLAVE CYLINDER Service repair no - 33.35.01 NOTE: All flexible and pipe connections and joints should be tightened to 15 Nm. Remove 1. Evacuate clutch system fluid at slave cylinder bleed valve. 2. Disconnect fluid pipe. 3. Remove two securing bolts and withdraw slave cylinder and backing plate. 4. If dust cover is not withdrawn with slave cylinder, withdraw it from bell housing.

9. Reconnect fluid pipe. 10. Replenish and bleed clutch hydraulic system. 11. Check for fluid leaks with pedal depressed and also with system at rest.

Refit 5. Withdraw dust cover and backing plate from slave cylinder. 6. Coat both sides of backing plate with Hylomar P232M waterproof jointing compound. 7. Locate backing plate and dust cover in position on slave cylinder. 8. Fit slave cylinder, engaging push-rod through centre of dust cover and with bleed screw uppermost.

4

REPAIR

CLUTCH

RENEWING HYDRAULIC DAMPER - Tdi Service repair no - 33.15.05 NOTE: All flexible and pipe connections and joints should be tightened to 15 Nm. Remove 1. Remove the pipe between the slave cylinder and damper. 2. Disconnect the hydraulic hose from the damper. 3. Remove the two bolts securing the damper to the bracket and remove the damper.

Refit 4. Fit the damper to the bracket and tighten the two bolts. 5. Connect the flexible hose to the damper. 6. Fit the pipe to the slave cylinder and to the damper and tighten the unions. 7. Bleed the hydraulic system.

REPAIR

5

CLUTCH

MASTER CYLINDER Service repair no - 30.20.07 1. Remove master cylinder. See Repair, Master Cylinder Disassemble 2. Pull back and remove rubber sealing boot from pushrod. 3. Depress push-rod and extract circlip. 4. Withdraw push-rod assembly. 5. Withdraw piston assembly. 6. Withdraw retainer and spring.

12. Ensure reservoir cap vent is clear. Assemble NOTE: Cleanliness is essential, ensure hands are free of grease or dirt. Lubricate cylinder bore and rubber seals with new hydraulic fluid before assembly. 13. Fit a new piston washer and thinner of two piston seals, lip last, over piston nose, up against drilled piston head. Fit thicker seal into piston groove with lip facing towards seal at opposite end. 14. Insert spring and retainer into master cylinder bore. 15. Insert piston and seal assembly, ensuring that seal lips do not bend back. 16. Reverse 3 and 4, correctly locating circlip. 17. Stretch new rubber boot over push-rod, pack with rubber grease. Fit securely into locating groove. 18. Operate push-rod several times to ensure free movement of internal components. 19. Fit master cylinder.

7. Remove two piston seals and piston washer. Inspecting 8. Clean all components thoroughly using new hydraulic fluid. Dry, using a lint-free cloth. 9. Examine cylinder bore and piston, ensure they are smooth to touch with no corrosion, score marks or ridges. If in doubt, fit new components. 10. Fit new seals and rubber boot. These items are all included in master cylinder overhaul kit. 11. Ensure that feed and by-pass ports are not obstructed.

OVERHAUL

1

33

CLUTCH

SLAVE CYLINDER Service repair no - 33.35.07 Overhaul 1. Remove slave cylinder. See Repair, Slave Cylinder Disassemble 2. 3. 4. 5. Withdraw rubber boot. Withdraw push-rod. Remove circlip. Extract piston and seal assembly, applying low pressure air to fluid inlet if necessary. 6. Withdraw spring. 7. Remove bleed valve.

Inspecting 8. Clean all components thoroughly using new hydraulic fluid, and dry using lint-free cloth. 9. Examine cylinder bore and piston which must be free from corrosion, scores and ridges. 10. Replace seal and rubber boot using appropriate repair kit. Assemble NOTE: Cleanliness is essential, ensure hands are free of grease or dirt. 11. Fit bleed valve. Do not overtighten. 12. Lubricate seals, piston and bore using new hydraulic fluid. 13. Fit seal into piston groove, lip of seal towards fluid inlet end of cylinder. 14. Enter piston assembly, spring first, into cylinder bore. Ensure that seal lip does not fold back. 15. Secure with circlip. 16. Fill rubber boot with rubber grease. 17. Reverse removal procedure. 1 to 3.

2

OVERHAUL

CLUTCH

TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Clutch pipes Master cylinder union ................................................................................. Pipe joint .................................................................................................... Pipe to damper ........................................................................................... Pipe out of damper ..................................................................................... Pipe to jump hose ...................................................................................... Jump hose to pipe ...................................................................................... Pipe to slave cylinder ................................................................................. 15 15 15 15 15 15 15

SPECIFICATIONS, TORQUE

1

R380

MANUAL TRANSMISSION Description The all synchromesh five speed manual gearbox unit, is married to a LT230T two speed transfer gearbox. All the gears including reverse run on needle roller bearings and the main, layshaft and primary shafts are supported by tapered roller bearings.

The whole of the geartrain is lubricated through drillings in the shafts, supplied by a low pressure pump driven from the rear of the layshaft. The gear change has a single rail selector and spool type interlock. The main and transfer gearboxes ventilate through nylon pipes, which terminate high up in the engine compartment to prevent water entry when the vehicle is operating in adverse conditions.

1. 2. 3. 4. 5. 6. 7. 8.

Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 3rd gear Primary input shaft Mainshaft 5th gear Layshaft Mainshaft Lubrication pump

9. 10. 11. 12. 13. 14. 15.

Drain plug Ventilation pipe Single rail gear shift 1st/2nd synchromesh Oil seals 3rd/4th synchromesh 5th gear synchromesh

DESCRIPTION AND OPERATION

1

R380

MANUAL GEARBOX Symptom - Gear jumps out of engagement (any forward gear) 1. Check condition and security of transmission and engine mountings. 2. Check in situ, gear lever and selector adjustments. 3. In situ, remove gearshift and check selector rail yoke security. Also check selector detent spring tension and both spool retainers. Suspect internal fault See remove and overhaul procedure. 4. Check action/operation of main selector rail and forks. 5. Check condition of synchromesh and gear dog teeth. 6. Check main and layshaft end floats bearings and adjustments. 7. Check condition of all gearbox components, ensure clearances and adjustments are correct on reassembly. Symptom - Reverse gear only jumps out of engagment 1. Check condition and security of transmission and engine mountings. 2. Check in situ, gear lever and selector adjustments. 3. In situ, remove gearshift and check selector rail yoke security. Also check selector detent spring tension and both spool retainers. Suspect internal fault See remove and overhaul procedure. 4. Check action/operation of main selector rail and reverse lever. 5. Check condition of reverse gear, angled bearings and shaft. 6. Check condition of all gearbox components, ensure clearances and adjustments are correct on reassembly.

Symptom - Excessive force required to engage or change gear, vehicle stationary or moving. 1. Check lubricant specification and level, if low do not top up at this stage. 2. In situ, lubricate gear mechanism, and check selector adjustments. 3. In situ, remove gearshift and check selector rail is free and that the yoke is secure. Also check selector detent spring tension and both spool retainers. 4. Drain lubricant and check for contamination or metal particles. Suspect worn synchromesh unit or baulk rings on affected gears. See remove and overhaul procedure. Symptom - Noisy gear engagement, vehicle stationary. See CLUTCH, Fault diagnosis, Clutch Noise - Mechanical Faults Symptom - Noisy gear selection, vehicle moving. 1. Confirm that clutch operation is satisfactory. 2. Establish which gear/gears is causing noise. 3. Check lubricant specification and level, if low do not top up at this stage. 4. Drain lubricant and check for contamination or metal particles. Suspect worn synchromesh. See remove and overhaul procedure. 5. Check condition of synchromesh unit, springs and cones for distortion and wear. Also check dog teeth for damage and cone mating surface on gear for signs of overheating. 6. Check condition of all gearbox components, ensure clearances and adjustments are correct on reassembly. Symptom - Noise from gearbox in neutral, which changes tone or becomes worse when clutch is depressed. See CLUTCH, Fault diagnosis, Clutch Noise - Mechanical Faults

FAULT DIAGNOSIS

1

37

MANUAL GEARBOX

Symptom - Noise from gearbox in neutral, which disappears when clutch is depressed. 1. Check lubricant specification and level, if low do not top up at this stage. 2. Drain lubricant and check for contamination or metal particles. Suspect worn bearings on layshaft, primary shaft or front of main shaft. See remove and overhaul procedure. Symptom - Noise from gearbox in one or more gears when being driven. 1. Check lubricant specification and level, if low do not top up at this stage. 2. Drain lubricant and check for contamination or metal particles. Suspect worn roller bearings on particular mainshaft gears. See remove and overhaul procedure.

2

FAULT DIAGNOSIS

R380

R380 MANUAL GEARBOX Service repair no - 37.20.02 Remove WARNING: Where the use of a transmission hoist is necessary, it is absolutely essential to follow the manufacturer’s instructions to ensure safe and effective use of equipment.

1. Install vehicle on a ramp [hoist]. 2. Disconnect battery earth lead. 3. Remove centre console. See CHASSIS AND BODY, Repair, Centre Console 4. Remove sound insulation from top of transmission tunnel. 5. Remove bolt and remove upper gear lever. 6. Remove screws securing gear selector lever and high/low selector lever draft excluders. 7. Remove draft excluder clamp rings.

8. Remove handbrake cable clevis pin clip and clevis pin. 9. Remove ’C’ clip and cable adjuster. 10. Select low range to prevent gear lever fouling tunnel when removing gearbox. 11. Remove bolt securing gearbox breather pipe clip to cylinder block. 12. Remove bolts securing fan cowl to radiator. 13. Release fan cowl from radiator and lay over fan blades. 14. Raise ramp [hoist]. 15. Drain oil from main gearbox and transfer gearbox. See SECTION 10, Maintenance, Under Vehicle Maintenance 16. Remove exhaust front pipe(s). See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust System Complete 17. Release intermediate exhaust pipe(s) from mountings and tie aside. 18. Remove bolts securing clutch slave cylinder. 19. Release slave cylinder from clutch housing and collect spacer. 20. Mark propeller shaft drive flange relationships for reassembly. 21. Disconnect front and rear propeller shafts from transfer gearbox. Tie shafts aside. 22. Remove clamp and disconnect speedometer cable from transfer gearbox. 23. Release handbrake cable from transmission tunnel. 24. Temporarily support transmission in a way which enables the crossmember to be removed and a hoist cradle to be fitted.

REPAIR

1

37 MANUAL GEARBOX 25. 30. Remove bell housing nuts. Remove cross-member. securing lever to high/low shaft. 38. Remove clips securing gearbox breather pipes to harness. 35. 26. 37. To achieve balance of the transmission unit when mounted to hoist. 2 REPAIR . Remove nut and 5 bolts securing transfer gearbox to extension housing. Lower hoist sufficiently to allow transfer gearbox selector lever to clear transmission tunnel aperture. Manufacture an adapter plate to dimensions given in service tool section and attach it to a transmission hoist. 39. 31. 36. Support engine under sump with a jack. Remove nuts and bolts securing cross-member mountings to transmission. it is essential that point A. 34. Disconnect differential lock switch connectors. Remove nuts and bolts securing transmission cross-member to chassis. 29. 33. Remove ’Nyloc’ nut. Remove lower locknut from high/low operating rod. 41. is situated over lifting hoist ram. 42. Withdraw transmission whilst ensuring all connections to engine and chassis are released. CAUTION: Use a wooden block to protect sump. Remove breather pipes. Withdraw transfer gearbox. and remove bolt. Remove 2 clips and remove differential lock lever link. Drill holes B to suit hoist table. Place a sling round transfer box and attach to hoist. 43. 32. Disconnect reverse lamp switch connectors. 44. Secure the transmission unit cradle at point C using the lower bolts retaining transfer gearbox rear cover. Discard pipe union sealing washers. 27. Remove transmission assembly from hoist cradle and position safely on a bench. Raise hoist just enough to take weight of transmission. 28. 40. Collect spacer washer.

51. Position breather pipes. 46.R380 Assembling transfer gearbox to main gearbox 45. Remove temporary support. Maintenance. clutch slave cylinder and gearbox mating faces. Fit handbrake cable through transmission tunnel and secure gaiter. 62. Fit handbrake cable adjuster and secure with ’C’ clip. 74. fit and tighten bolt. fit clevis pin and secure with clip. Secure breather pipes to harness with clips. Connect speedometer cable to transfer gearbox. and fit transmission to engine whilst keeping wires and pipes clear to prevent trapping. Fit upper gear lever. Position draft excluder clamp rings. 60. fit and tighten screws. Fitting transfer gearbox and main gearbox assembly to engine 52. Exhaust System Complete 71. 68. 77. 63. fit and tighten bolts. 58. 48. hoist transfer gearbox into position. Fit and tighten nuts securing transmission to engine. Position cross-member. Fit and tighten nut and bolts to 34Nm. secure pipe unions using new sealing washers. Align lever to high/low shaft. 66. Align breather pipe clip to cylinder block. Position spacer and slave cylinder. Tighten all securing nuts and bolts. 47. Under Vehicle Maintenance 72. Connect reverse lamp switch connectors and differential lock switch connectors. Repair. 54. Tighten to 2Nm. Tighten to 25Nm. 65. See CHASSIS AND BODY. See MANIFOLD AND EXHAUST SYSTEM. Connect battery earth lead. Lower ramp [hoist]. 55. Check handbrake adjustment. Untie intermediate exhaust pipe(s) and refit exhaust front pipe(s). Maintenance. 67. loosely fit nuts and bolts securing cross-member mountings to transmission. Ensuring loose upper dowel is fitted. Position temporary support. Position and raise hoist. REPAIR 3 . align cross-member and loosely fit nuts and bolts securing cross-member to chassis. 80. 76. Tighten unions to 15Nm. See SECTION 10. Refill main gearbox and transfer gearbox with oil. 64. Connect high/low operating rod. Remove supporting jack from under sump. Raise transmission. Refit centre console. fit and tighten locknut. Clean extension housing and transfer gearbox mating faces. Align cable trunnion to handbrake lever. 61. See SECTION 10. Line up marks and connect front and rear propeller shafts. 81. Temporarily fit gear lever and select any gear in main gearbox to facilitate entry of gearbox input shaft. 79. fit and tighten bolts. Repair. 69. position washer. Clean spacer. Fit fan cowl. 70. Refit sound insulation. fit bolts. 75. Fit gear selector lever and high/low selector lever draft excluders. Centre Console 83. 73. 53. fit bolt and new Nyloc nut. Remove 2 bolts securing lifting cradle to transmission and remove hoist. Apply Loctite 290 to bolts and refit bolts. 56. 49. Vehicle Interior 78. 59. Fit link to differential lock lever and secure with 2 clips 50. 82. Position transmission assembly to hoist cradle. Clean bell housing and engine mating faces. 57.

................. 25 Breather ................. M8 ........................................................... M16 ......................... M6 ........................................ M10 ............................................................................... 2 Transfer box to gearbox ...............................................................................R380 TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque..................... 3/8 ............ 7/16 ................ 40 High/low level to shaft ............................................................................................................................................................................................................................................. 5/16 .............................................................................................. TORQUE 1 ...................................... 9 24 39 78 90 136 SPECIFICATIONS....... 15 Bell housing to cylinder block .............................................................................................................................................................................................. M14 ................................................................................ Nm 6 9 25 45 90 105 180 UNC / UNF 1/4 ....................................................... M12 ..................................................................................................................... 5/8 .............................................................................. 1/2 ......................................... METRIC M5 ........ Nm Slave cylinder to bell housing .......................................... 45 NOTE: Torque values below apply to all screws and bolts used unless otherwise specified...........

MATERIAL AND WELDING SPECIFICATION Steel Plate Tube Arc Welding BS 1449 (Grade 4 or 14) BS 4848 (Part 2) BS 5135 SERVICE TOOLS 1 . This can be manufactured locally to drawing shown.R380 ADAPTER PLATE GEARBOX Adapter plate for removing gearbox.

High/low range and diff-lock selection are made via a single lever located forward of the main gear lever. two speed ratio reducing gearbox incorporating high and low range outputs with mechanically lockable centre differential (diff-lock). A shiftlock device is fitted in some territories. An audible neutral alarm is also fitted. DESCRIPTION AND OPERATION 1 . it is used as a park facility and prevents accidental gear disengagement when the ignition is switched off. This alerts the driver when parking to move the gear lever to the high or low position.TRANSFER GEARBOX LT230T TRANSFER BOX The LT230T transfer box is a permanent 4 wheel drive.

41 TRANSFER GEARBOX REAR OUTPUT DRIVE ASSEMBLY 1. 10. Ball bearing Circlip Oil seal Oil shield Rear output flange Sealing washer 2 DESCRIPTION AND OPERATION . 12. 8. 5. Rear output shaft Joint sealant Speedometer drive housing Speedometer drive pinion assembly Speedometer worm drive Spacer 7. 3. 11. 6. 9. 4. 2.

29. rear half Retaining ring Front output shaft Dog clutch. 6. 11. 15. 25. 2. 31. Differential selector assembly Front output housing High-low ratio cross shaft assembly High-low selector shaft and lever High-low selector fork and shaft High-low selector finger Differential lock selector shaft Differential lock selector fork Differential lock spring and clips Front output housing cover and housing Felt washer. 21. 30. steel washer and flange nut Front output flange Mud shield Oil seal Bearing Spacer Circlip Differential carrier. 28. 35. 33. 9. 8. 18. 3. 23. 27. Differential carrier. 10. 20. 7. 22. 12. 4. front half 19. front drive lock-up Selective shim Bearing Selective thrust washers Sun and planet gears Thrust washers Cross shafts Gear low Hub and sleeve assembly High output gear Bush Bearing Bearing retaining nut Differential lock switch Differential lock detent ball and spring DESCRIPTION AND OPERATION 3 . 13. 17. 24. 5. 14.TRANSFER GEARBOX DIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY 1. 32. 34. 36. 26. 16.

6. 3. 4. 13. 2. 15. 14. 9. 11. 16. Transfer case assembly Transfer case bottom cover Intermediate shaft and ’O’ ring Oil seal Retaining plate and anchor screw Intermediate shaft nut Bearing Transfer mainshaft gear Selective shim 10. Mainshaft transfer bearing housing Joint sealant Power take off cover High low detent ball and spring Intermediate gear cluster Bearings Collapsible spacer Circlip 4 DESCRIPTION AND OPERATION . 8. 7. 5. 17. 12.41 TRANSFER GEARBOX INTERMEDIATE GEAR AND POWER TAKE OFF ASSEMBLY 1.

12. 11. 9. Gaiter retaining screw . 5. 15.4 off Gaiter Gaiter support plate Gate plate Gasket Clip Pin Circlip. 2. 16. 17. 18. 3. retaining nylon seat Gear lever ball 10. 14. 8. Nylon seat Cross shaft Gear lever Gear change housing Non-metallic bushes Countersunk screws End cover Selector fork ’O’ ring seals DESCRIPTION AND OPERATION 5 . 4.TRANSFER GEARBOX TRANSFER GEAR SELECTOR COMPONENTS 1. 13. 7. 6.

Input seal. 1. Bearing plate joint. Cover plate joints.OIL LEAKS Verify that the leak is from the transfer box and not the gearbox before proceeding. Power take off cover plate joint. 5. 6. 2. Front and rear housing joint faces. Rear output seal.TRANSFER GEARBOX LT230T TRANSFER BOX . 3. 7. Front output seal. FAULT DIAGNOSIS 1 . 4.

4. Also ensure the new seal is not damaged when refitting the transfer gearbox. If red A.T.F type oil is seen leaking during the workshop test. 7. 3. If these areas require servicing. 5. Observe joint between the main and transfer boxes. 7. Apply thread sealant to the bolts which come into contact with gearbox oil. Drain the oil and remove the leaking cover plate. Remove all traces of oil from exterior of transfer box. the leak is originating from the transfer box. Recommended Lubricants and Fluids Cover plate gasket leaking. CAUTION: Care must be taken not to overtighten the fixings. 10. Check the two inner (main/transfer) bolts are oil tight. 4. Run engine at 2000 rpm with the clutch/drive engaged. 3. Fit the output flange and all the other parts. FLUIDS AND CAPACITIES. If damaged renew component. Detent plugs and electrical switches do not usually leak. Refit cover plate. Front or rear output seal leaking:1. to both joint faces. Drain the oil and remove the leaking output flange. investigate the main gearbox for cause of leak. 2. Identify source of leaks and rectify as follows. Fit new seal. inspected. 2. See LUBRICANTS. 5. Detent plug or electrical switch leaks. Leak between the main and transfer gearboxes. Site vehicle onto a ramp [hoist]. and the front face of the transfer case for porosity. To validate the system the pipe must be removed. Degrease all components and apply a thin film of Hylomar sealant. 4. Check oil level in transfer box is correct. Take vehicle for short road test. Select neutral in transfer box and select 4th gear in the main gearbox. If oil leak is found establish if it is gear oil. 3. 6.41 TRANSFER GEARBOX PROCEDURE Prior to road test 1. CAUTION: Avoid damaging the new seal lip and ensure the seal is fitted flush with the machined face. Remove and discard the oil seal. 2. Inspect the seal locating bore and remove any sharp edges which may damage the new oil seal. 6. 2 FAULT DIAGNOSIS . Inspect the seal track on the flange for surface damage. the transfer gearbox input seal must also be renewed. 4. If so. It must be noted that they fit into open tapped holes in the transfer case and therefore should be considered when looking for the source of the leak. Information. Remove all traces of joint sealant from both joint faces. as these holes are tapped through into the main transfer case. Add oil to correct level into the gearbox. 2. 8. 1. rectified as necessary and refitted. 3. See Repair. Check breather system for blockage. 5. 1. Remove the transfer box to inspect the mainshaft collar seal track condition. LT230T Transfer Gearbox 9. 1. 5. Check tightness of level and drain plugs.

TRANSFER GEARBOX LT230T TRANSFER GEARBOX Service repair no .10. The adaptor can be manufactured locally to the drawing below.25 Remove Adaptor plate for removing transfer gearbox The transfer gearbox is removed from underneath the vehicle. WARNING: When using a transmission hoist it is essential to follow the hoist manufacturer’s instructions. REPAIR 1 .41. Using a transmission hoist with an adaptor plate for securing the transfer gearbox to the hoist.

transfer gearbox to main gearbox. 5. Loosen park brake adjustment nut. Remove right side mounting bracket to flexible mounting rubber. Remove nuts and bolts securing right transfer gearbox mounting bracket to chassis. 23. 19. Remove upper and lower bolts securing transfer gearbox to main gearbox. 8. Disconnect electrics to Lambda sensors. Check engine does not crush any components while lowering. 17. tie to one side. 25. 35. Disconnect battery negative lead. Select low range transfer gearbox position. Remove fan cowl from radiator. 13. Remove bolts retaining silencer front and rear securing brackets and tie silencer to one side. 9. Adjust hoist to take weight of transfer gearbox. Detach heat shield at front exhaust pipe to manifold. Disconnect leads from transfer gearbox temperature sensor and differential lock warning light switch. 6. 21. Raise vehicle on ramp [hoist]. Remove four central bolts from transfer gearbox bottom cover. 28. 11. 16. Drain oil and refit plug. Remove banjo bolt from breather pipe. 24. 32. 30. 14. Fit guide studs 18G 1425 to main gearbox and move transfer gearbox rearwards to detach. Remove park brake drum. retrieve sealing washers and lay pipe aside. 27. Repeat for left mounting bracket. Remove transfer gear lever knob and gaiter. 2. 26. Removal of these fixings will also free speedometer transducer bracket.41 Remove 1. 22. 15. 10. Tie cable to one side. Remove clamp and disconnect speedometer cable from transfer gearbox. Place four 30mm long spacers between top of hoist and adaptor plate. Lower hoist until rear brake drum clears passenger footwell. 20. move hoist into position and secure adaptor plate to transfer gearbox. and secure adaptor plate to hoist. 34. 18. Using wooden block support the main gearbox and bell housing. 4. 3. 29. Remove tie bar. Remove catalytic converter assembly. Remove heat shield from speedometer cable at transfer gearbox. 7. at securing points. Mark for reassembly then disconnect propeller shaft to output flange. Repeat on front propeller shaft to output flange. Remove high/low rod lower lock nut and remove rod from yoke. 33. 31. Remove chassis crossmember from under gearbox. Remove split [cotter] pin and washers securing differential lock to connecting rod and disconnect rod from lever. Position hoist jack channel under bell housing. 2 REPAIR . 12. Remove park brake assembly complete from rear output flange. TRANSFER GEARBOX Site vehicle on a ramp [hoist].

Secure transfer gearbox to adaptor plate on lifting hoist. See SECTION 10. Select ’P’ in main gearbox. noting the following important points. Raise hoist until transfer gearbox can be located over guide studs to main gearbox. At the same time locate high/low lower link to yoke. Vehicle Interior REPAIR 3 . FLUIDS AND CAPACITIES. 39. 45. 41. Complete refitting by reversing removal procedure. Information. clean threads of four bottom cover bolts. Check main gearbox oil level. Ensure joint faces of transfer and main gearboxes are clean and guide studs 18G 1425 are fitted. Maintenance. Recommended Lubricants and Fluids 44. 42. 40. Tighten to 25Nm 43. After removal of adaptor plate from transfer gearbox. 38. Check operation of parking brake and adjust as necessary. See LUBRICANTS. 37. coat threads with Loctite 290 and fit together with spring washers. with low range and differential lock selected in transfer gearbox. Remove guide studs and secure transfer gearbox to main gearbox. Add correct grade of oil to transfer gearbox to oil level plug hole.TRANSFER GEARBOX Refit 36.

Refit 3. Apply Hylosil or equivalent sealant to mating faces. 2. Access to the component is gained through the transmission tunnel aperture. Remove solenoid and spring washer. 5. Remove Refit 1. 10. 2. 7. 3. Remove four retaining bolts and remove shiftlock solenoid cover. 5. Fit four solenoid bolts. Ensure solenoid plug lead is located in cover recess. Clean joint sealant from mating faces. Repair. Reverse removal procedure.Tighten to 25Nm. Remove insulation pad. Remove rear passenger heater air ducts. 3. KEY 1. Apply Hylomar PL32/L20 or SL500 sealant to neutral switch. 2. Disconnect battery negative lead. 4.63/64 This is sited on top of the transfer gearbox. See CHASSIS AND BODY. Remove neutral switch from transfer box. 4. Disconnect solenoid multiplug. Reverse removal procedure. 6. 7. Tighten to 9Nm. 2. 1. Drill out rivets and remove tunnel blanking plate. 8. Gearlever Transmission tunnel aperture Transfer gearbox Bolt Switch Solenoid Electrical connections 4 REPAIR . Remove centre console. 4. 6. Centre Console 3. Remove four screws and remove main gear lever assembly. Disconnect neutral switch electrical plug.10. Neutral switch. 4. 5. Switch .41. audible alarm 1. 9.41 TRANSFER GEARBOX SHIFTLOCK SOLENOID/NEUTRAL SWITCH Service repair no .

. 45 Rear output speedometer housing to transfer gearbox ................................................................................................................................................................................. 25 Anti-rotation plate intermediate shaft ....................................................................................................... 45 Transfer gearbox mounting brackets to chassis ...................................................... 25 Gear change housing ........................................................................................ 25 Pivot shaft to link arm ........ 30 Differential case (front to rear) ................................................................................. 45 Oil drain plug ...TRANSFER GEARBOX TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque......................................................................... 45 Selector finger to cross shaft high/low ............. 30 Mounting brackets to transfer gearbox ................................ 25 Front output housing to transfer case ............... 25 Front output housing cover .............. 25 Brake drum to coupling flange ................... 25 Cross shaft housing to front output housing ..................................................... 9 Gearbox to transfer case ........................................... 21 Shiftlock Shiftlock screws ................................................................................................... 25 Selector fork...................... 9 Bottom cover to transfer case ......................................... 25 Transmission brake to speedometer housing ...................... 45 Transfer box rear drive flange to drive shaft .......... 55 Mounting rubbers to mounting brackets ....................................................... 9 End cover gear change housing ..................... 25 Connecting rod to adjustable clevis .......................................................................... 25 Finger housing to front output housing ............................ high/low to shaft ................................... 9 Neutral switch ..................... 15 Transfer box front drive flange to drive shaft ...................................... 25 Pivot bracket to extension housing .........................................................................................................................................................................operating arm to crank arm ...................................................................................................................... TORQUE 1 .................................................................................................................................................................... 162 Differential case rear stake nut ................ 25 Bearing housing to transfer case ................... 30 Oil filler/level plug ............................................................................................. 60 Output flanges ........................ 25 Bearing housing cover to transfer gearbox .................................................................................................................................................. 72 Gate plate to grommet plate .... Nm LT230T Transfer gearbox Pinch bolt ................................................................................................................................................. 25 SPECIFICATIONS................................... 72 Transfer breather ................

.........05 to 0.... Input gear bearing pre ............ Intermediate shaft bearing pre ..................................load .load ....................................... HYLOSIL RTV Neutral switch ....... HYLOMAR 2 SPECIFICATIONS...............................15 mm 0.........69 Nm 0.....41 TRANSFER GEARBOX LT230T TRANSFER GEARBOX DATA High range gear end ...56 to 1.... TORQUE ...... 22SE03 TYPE 2 Shiftlock solenoid cover ...................56 to 1....................................... Front differential bearing pre .....56 to 2................25 Nm 0..float .............69 Nm JOINT SEALANT Joint faces use ...................... 0............................load .......... BLS...................................

TRANSFER GEARBOX LT230T TRANSFER GEARBOX LRT-51-003 18G 1205 Drive flange wrench 18G 1271 18G 1271 Oil seal remover LRT-37-014 18G 1422 Mainshaft rear oil seal replacer LRT-99-003 Oil seal replacer handle MS 550 or 18G 134 SERVICE TOOLS 1 .

N = Neutral. R = Reverse gear. First. 1 = Provides a 1st gear start with no up shifts. All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output shaft. DESCRIPTION AND OPERATION 1 . D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1. second and third gears are reduction ratios but fourth is an overdrive gear for high speed cruising. The gear selector has seven positions as follows: P = Park provides a mechanical lock on the output shaft. A direct drive clutch. A three element torque converter delivers the power to a four speed epicyclic transmission. or 3-2-1. used by many manufacturer’s of high performance vehicles. 3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1.ZF DESCRIPTION The automatic transmission is specially tailored version of the ZF4 HP22. 2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1. integral with the torque converter operates to engage fourth gear.

Epicyclic gear set 10 also rotates as a solid unit. 7 and 11 are engaged. 6. to provide engine braking. Epicyclic gear set 10 rotates as a solid unit with the front planet gear carrier. 2 DESCRIPTION AND OPERATION . The front planet gear carrier of gear set 9 is locked against the housing through freewheel 15 when the engine is pulling but freewheels when the vehicle is coasting. 2nd gear D selected Clutches 4.44 Power flow AUTOMATIC GEARBOX 1st gear D selected With D selected 1st gear engaged. In selector position 1 with 1st gear engaged. the hollow shaft with the sun wheel of epicyclic gear set 9 is locked. Freewheel 15 overruns. clutch 8 operates to prevent the loss of drive on the overrun through freewheel 15. clutches 4 and 11 are operative.

15 and 16 are overrun. Freewheel 14. Above a predetermined road speed. by-passing the torque converter. DESCRIPTION AND OPERATION 3 . Freewheel 15 and 16 are overrun. 5.ZF 3rd gear D selected Clutches 4. Epicyclic gear set 9 and 10 rotate as a solid unit at a ratio of 1:1. 7 and 11 are engaged. 5. The hollow shaft with the sun wheel of epicyclic gear set 10 is locked. 4th gear D selected Clutches 4. 7 and 12 are engaged. Epicyclic gear set 9 rotates as a solid unit. clutch 2 locks the gearbox power input direct to the engine.

4 DESCRIPTION AND OPERATION . the direction of output-shaft rotation is reversed. 8 and 11 are engaged. Since the front planet gear carrier of epicyclic gear set 9 is locked. Epicyclic gear set 10 also rotates as a solid block.44 AUTOMATIC GEARBOX Reverse gear Clutches 5.

.....N-2..... 4...... remove socket head plug (located 10cm from oil pipe) Fit hose adaptor LST502-1.......................................................... Carry out road test.........................................3 bar. 0 to 300 lbf/in2 Pressure gauge.... Flexible hose adaptor. Reverse removal procedure... ’N’ selected..............................3 bar........... engine running at normal running temperature......... 6..................... 10 ± 0......................9 ± 0..... Automatic Gearbox 0 to 20 bar................. 5..............N-1............. Reverse lights ...... Gear engagements ............ Fit gauge 18G502A to hose and route into vehicle.................... 1......... 3............. Full throttle .. ensuring hose is clear of rotating parts and exhaust pipes...... Remove pressure gauge 6............ Oil level ............ 100 ± 5 lbf/in2 at 665 to 735 rev/min...... Pressure test 2000 rev/min . check full travel at engine and at pedal..................... To fit pressure gauge Service tools: See Service tools. Fit hose to adaptor.................................... Site vehicle on a ramp [hoist]........ZF ZF AUTOMATIC GEARBOX Before referring to fault symptoms. ’P’ & ’N’ only ’R’ only N-D................................. carry out initial static checks first: INITIAL STATIC CHECKS Check start positions .. From under gearbox.. 150 ± 5 lbf/in2 Idle pressure ............N-3... 2.........N-R Engine switched off... See Road Test Procedure FAULT DIAGNOSIS 1 .

CHECK 8 Check downshift speed and quality 2nd to 1st. CHECK 6 Check down shift speed and quality 4th to 3rd. CHECK 7 Check downshift speed and quality 3rd to 2nd. Check shift quality and engine rpm drop of approximately 500 rpm. Check pressure is 150lbf/in2 CHECK 2 Check 1st to 2nd upshift speed and quality. CHECK 10 Check 2nd 3rd upshift speed and quality. NOTE: This shift is usually very smooth and difficult to detect. from a standing start. Also difficult to detect. on a level road. Pressure should fall to 120 lbf/in2. Pressure should fall to 100 lbf/in2 CHECK 4 Release throttle to allow simultaneous engagement 4th + DDC. in good weather conditions. CHECK 3 Check 2nd-3rd upshift speed and quality. CHECK 5 To proceed to Check 5 release throttle and check drop out speed of direct drive clutch to 4th. NOTE: 4th and the direct drive clutch engage simultaneously.44 AUTOMATIC GEARBOX ROAD TEST PROCEDURE Follow the procedure given commencing each test. END OF ROADTEST 2 2 FAULT DIAGNOSIS . CHECK 11 Check 3rd 4th and direct drive clutch upshift speed and quality. ROADTEST 1 = CHECKS 1-2-3-4-5-6-7-8 D SELECTED KICKDOWN START FROM REST CHECK 1 Check for clutch squeal and slip. END OF ROADTEST 1 ROADTEST 2 CHECKS = 9-10-11 D SELECTED FROM REST FULL THROTTLE START CHECK 9 Check 1st-2nd upshift speed and quality.

Release throttle. confirmed by 300 rpm drop in engine speed. CHECK 20 CHECK 14 Check 3rd 4th upshift speed and quality. Continue to de-accelerate. gearbox should change immediately down to 3rd.ZF ROADTEST 3 = CHECKS 12-13-14-15-16-17-18-19-20-21-22-23 D SELECTED FROM REST LIGHT THROTTLE START CHECK 18 At approximately 138 kph (85 mph) select 3rd. FAULT DIAGNOSIS 3 . continue accelerating at full throttle until 3rd gear is attained. To do this you will have repeated check 2 of Test 1. Release throttle. No downshift should occur. De-accelerate to approximately 47 kph (30 mph) depress throttle to kickdown . CHECK 23 With 1 selected 2nd gear engaged continue to de-accelerate and at 45 kph (28 mph) the box should automatically downshift to 1st gear after which no upshifts will occur in this selector position. NOTE: This shift is usually very difficult to detect but can be confirmed by a 200 rpm drop in engine speed. CHECK 13 Check 2nd 3rd upshift speed and quality. CHECK 21 At 104 kph (65 mph) an automatic downshift into 2nd gear should occur. CHECK 17 At approximately 128 kph (80 mph) depress throttle to kickdown .gearbox should change down to 3rd release throttle to re-engage 4th direct drive clutch and continue to accelerate gently. which is indicated by a fall of 500rpm in engine speed. CHECK 15 CHECK 22 Check speed and quality of shift into direct drive clutch.geabox should downshift to 1st gear. END OF ROADTEST At 128 kph (80 mph) select 2nd no downshift should occur. At 88 kph (55 mph) select 1st. Continue to de-accelerate. CHECK 19 CHECK 12 Check 1st 2nd upshift speed and quality.gearbox should change down to 2nd release throttle to re-engage 4th direct drive clutch continue to accelerate gently. CHECK 16 At approximately 88 kph (55 mph) depress throttle to kickdown . NOTE: An intermediate throttle position engagement of 4th and the direct drive clutch.

3. 4. 2.44 AUTOMATIC GEARBOX AUTOMATIC GEARBOX ASSEMBLY ILLUSTRATED 1. Gearbox assembly Inhibitor switch assembly Control unit assembly Filter and sump assembly 4 FAULT DIAGNOSIS .

ZF 1. Torque converter housing assembly 2. Governor and adaptor housing assembly FAULT DIAGNOSIS 5 . Gearbox pump and casing assembly 3.

44 AUTOMATIC GEARBOX 1. A Clutch assembly 2. B Clutch assembly 6 FAULT DIAGNOSIS .

C.ZF 1.C’ and D Clutch assembly FAULT DIAGNOSIS 7 .

Freewheel and fourth gear assembly 8 FAULT DIAGNOSIS .44 AUTOMATIC GEARBOX 1.

ZF 1. E and F Clutch assembly FAULT DIAGNOSIS 9 .

Clutch A œ No pressure FAULT .Continue with symptom 5 œ Normal pressure FAULT .Restricted filter or sticking primary regulator SYMPTOM 4 .Continue with symptom 5 œ Normal pressure FAULT .Clutch ’B’ SYMPTOM 8 .Reverse gear interlock valve seized Select ’1’ œ No engine braking FAULT .No drive from rest with ’D’ selected Select ’1’ œ Vehicle drives FAULT .No 4th gear ’D’ selected FAULT .Restricted filter or sticking primary regulator œ Normal pressure FAULT .Low fluid level or restricted filter SYMPTOM 2 .Clutch ’A’ SYMPTOM 5 .44 AUTOMATIC GEARBOX FAULT SYMPTOMS SYMPTOM 1 .No 2 freewheel œ No drive Carry out main line pressure check œ Normal pressure FAULT .4th to 3rd downshift valve stuck or 3rd to 4th upshift valve stuck FAULT .Continue with Symptom 3 œ Drives forward FAULT .Modulator valve or clutch ’B’ damper FAULT .Clutch brake CB1 and/or clutch brake CB2 SYMPTOM 7 .Clutch ’A’ or damper for clutch’A’ SYMPTOM 6 .Clutch ’B’ SYMPTOM 9 .Fierce shift or flare 1st to 2nd shift Check engine idle speed Carry out mainline pressure check œ High pressure FAULT .Blocked filter or pump failure œ Low pressure FAULT .Clutch brake 4 10 FAULT DIAGNOSIS .Clutch brake 3 SYMPTOM 3 .Harsh engagement ’N’ to ’D’ Check engine idle speed Carry out main line pressure check œ High pressure FAULT .2-3 shift valve FAULT .Intermittent drive and high pitched noise FAULT .Slip in all forward gears Carry out main line pressure check œ No pressure FAULT .Fierce shift or flare 2nd to 3rd Carry out mainline pressure check œ High pressure FAULT .Modulator valve or dampers for clutch brake CB1 and/or clutch brake CB2 FAULT .Blocked filter or pump failure œ Low pressure FAULT .No 3rd gear FAULT .No drive in reverse Select ’D’ œ No drive FAULT .Primary regulator stuck œ Normal pressure FAULT .

SYMPTOM 13 . SYMPTOM 21 .2nd to 3rd shift valve stuck.No upshifts at light throttle FAULTS POSSIBLE Governor valve sticking Shift valves sticking SYMPTOM 18 . Governor sleeve sticking.No engine braking ’3’ selected 3rd gear FAULT .Governor valve sticking œ Incorrect pressure FAULTS POSSIBLE Incorrect throttle valve adjustment Primary regulator sticking SYMPTOM 17 .’2’ Selected 2nd gear no engine braking FAULT .ZF SYMPTOM 10 . Governor valve sticking. SYMPTOM 20 . SYMPTOM 14 . SYMPTOM 12 . ’1’ Position interlock valve sticking. ’2’ Position interlock valve sticking.’1’ Selected 1st gear no engine braking FAULT . Governor sleeve sticking. œ Normal pressure FAULT .At speeds below 28 mph when making a manual selection from ’2’ to ’1’.Upshifts/downshifts and kickdown shifts at incorrect road speeds Check throttle kickdown cable adjustment Carry out main line pressure check œ Normal pressure FAULT . downshift is delayed or does not occur FAULTS POSSIBLE Governor sticking.Clutch ’C’ SYMPTOM 19 .Delayed or no downshift occurs when making a manual selection from ’3’ to ’2’ FAULTS POSSIBLE 2nd and 3rd upshift valve sticking.Failed direct drive clutch œ Pressures correct but remains high FAULTS POSSIBLE Direct drive clutch and torque converter control valve stuck Hysteresis valve stuck Direct drive clutch control valve stuck SYMPTOM 11 .Governor valve sticking œ Low or incorrect pressure FAULTS POSSIBLE Direct drive clutch and torque converter control valve sticking. SYMPTOM 16 .Clutch brake 3 SYMPTOM 22 .With ’D’ selected vehicle starts in 2nd FAULTS POSSIBLE 1st and 2nd shift valve stuck.Drives in ’D’ but immediately upshifts to 3rd FAULT . 1st to 2nd shift valve sticking.With ’D’ selected vehicle starts in 3rd FAULTS POSSIBLE 1st to 2nd and 2nd to 3rd shift valves stuck.No kickdown 4th to 3rd FAULT . Carry out road test pressure check with gauge connected to torque converter. SYMPTOM 15 .Vehicle drives forward in ’N’ FAULT .None or harsh engagement of direct drive clutch NOTE: The direct drive clutch will only engage if 4th gear is engaged at 40 to 45 mph. Direct drive clutch control valve stuck.Direct drive clutch shift point incorrect or at low speed NOTE: Direct drive clutch engagement at low speed will cause vibration in the torque converter Carry out mainline and torque converter pressure check œ Normal pressure FAULT . Hysteresis valve stuck.4th to 3rd kickdown valve stuck.Clutch brake 1 SYMPTOM 23 .Clutch ’A’ stuck FAULT DIAGNOSIS 11 .

5. (dimension ’B’). ADD: 09/95 ADJUSTMENT 1 . Refit the rubber boot. 3. Rotate the knurled plug on the throttle cable until the crimped nipple is 1 mm from the end of the threads. 2. Connect the throttle cable to the lever and secure with clevis pin and split pin. Adjust the position of the kickdown cable locknuts so that dimension ’A’ is 28 mm. withdraw clevis pin and disconnect throttle cable from lever. Pull back the rubber boot on the kickdown cable until the crimped nipple is visible. 6.ZF KICKDOWN CABLE ADJUSTMENT 1. Remove split pin. 7. 8. (dimension ’C’). With cable held in this position. Tighten both locknuts Connect the kickdown cable to the lever and secure with clevis pin and split pin. Remove split pin. 4. there should be 6 threads exposed to the rear of the bracket. withdraw clevis pin and disconnect kickdown cable from lever.

44.20. England. automatic gearbox and torque converter is removed from underneath the vehicle. Tel. REPAIR 1 . The adaptor can be manufactured locally to the drawing below or purchased from:. Use a transmission hoist with an adaptor plate for securing the assembly to the hoist.V8i Service repair no .01909 480055 WARNING: When using a transmission hoist it is essential to follow the hoist manufacturer’s instructions.04 Removal from V8i engine The assembled transfer gearbox.ZF LT230T TRANSFER GEARBOX WITH AUTOMATIC GEARBOX ASSEMBLY .Straight Set Engineering.

Remove drain plugs and drain oil from transfer gearbox and main gearbox. Loosen securing clip and disconnect air flow hose from plenum chamber.44 AUTOMATIC GEARBOX 1. Remove chassis cross-member from under gearbox. unscrew knob and withdraw gaiter and knob. 9. 2. Disconnect battery negative lead. 3. 8. Raise vehicle on ramp [hoist]. Disconnect electrics to Lambda sensors. 10. Disconnect stepper motor hose from top of plenum chamber. Remove clamp and disconnect speedometer cable from transfer gearbox. 6. 4. 5. 16. Site vehicle on a four post ramp [hoist]. Working inside vehicle detach transfer gear lever gaiter from console. Remove fan cowl securing screws and release cowl from radiator. 2 REPAIR . Release two gearbox breather pipes from clip located on lifting eye at rear of right hand cylinder head. Refit plugs. Disconnect kickdown cable from throttle linkage and release from clipping. 13. 15. 11. 12. 7. Mark for reassembly propeller shaft to transfer gearbox mating flanges. 18. Remove catalytic converter assembly. Detach heat shield at front exhaust pipe to manifold. Tie cable to one side. 14. 17. Remove dipstick from main gearbox oil filler tube. Remove heat shield from speedometer cable at transfer gearbox.

50. 46.ZF 19. 55. Attach adaptor plate to hoist. Identify an access hole and bolt hole to aid reassembly. 43. Disconnect leads from transfer gearbox temperature sensor and differential lock warning light switch. 32. 26. 54. Maintenance. Remove clip securing outer brake cable 38. and tie to one side. Remove bolts securing drive plate to convertor through access holes. also detach harness bracket from bell housing. Remove bolts retaining silencer front and rear securing brackets and tie silencer to one side. Position hoist jack channel under engine and support using a wooden block. FLUIDS AND CAPACITIES. 25. Check engine does not crush any components while lowering. 49. Ensure torque converter is retained in bell housing. Check operation of parking brake and adjust as necessary. 51. 40. 33. Release cooler pipes from clamp at engine sump and remove distance piece. Adjust hoist to take weight of transmission. 39. See LUBRICANTS. Move oil cooler pipes clear of transmission and tie aside. Secure transmission to adaptor plate on lifting hoist. Recommended Lubricants and Fluids 60. Repeat instructions 18 and 19 on front propeller shaft to main gearbox. using crankshaft pulley. Note the following important points. 30. Secure to transfer gearbox at rear cover with two bolts removed. Drive plate to torque converter bolts are to be coated with Loctite 290 prior to assembly. Removal of these fixings will also free speedometer transducer bracket 34. 27. Disconnect inhibitor switch at multiplug. Raise hoist and locate transmission with engine. Remove clip and clevis pin from park brake lever. 36. Remove bell housing access plate complete with gasket. 44. 56. Complete refitting by reversing removal procedure. 57. 59. 23. 20. 37. Rotate crankshaft half turn to access and remove remaining bolts. 47. Blank pipe ends and unions. Remove torque converter retainer. Information. Ease transmission rearwards to allow access to secure torque converter in bell housing. 53. Repeat for the left mounting bracket. until two access holes are visible in drive plate/ring gear assembly through bell housing bottom cover opening. 31. Remove right side mounting bracket to flexible mounting rubber retaining nut. Remove bolt at bell housing and detach dipstick tube. Raise hoist to align adaptor plate with transfer gearbox and transmission. Rotate engine. 22. 42. Disconnect selector cable from operating lever. 41. Refit 52. 28. Lower hoist until rear brake drum clears passenger footwell. 35. 24. Disconnect rear propeller shaft to output flange. 58. 21. Remove ties securing breather pipes to harness. Remove nuts and bolts securing right transfer gearbox mounting bracket to chassis. Remove two bolts from transfer gearbox rear cover. 29. Disconnect oil dipstick tube at main gearbox. Remove bell housing to engine securing bolts. Disconnect oil cooler feed and return pipes from bottom and side of main gearbox. The park brake cable is now free. Complete attachment of transmission to engine and fit bell housing bolts. Blank pipe end and union. Vehicle Interior REPAIR 3 . Lower hoist and complete removal of transmission. Refill transfer and main gearboxes with correct grade oil. 48. 45. Fit the dipstick tube bracket and harness bracket to their respective bolts. See SECTION 10.

automatic gearbox and torque converter is removed from underneath the vehicle. WARNING: When using a transmission hoist it is essential to follow the hoist manufacturer’s instructions. 4 REPAIR .04 Removal from Tdi engine The assembled transfer gearbox.44 AUTOMATIC GEARBOX LT230T TRANSFER GEARBOX WITH AUTOMATIC GEARBOX ASSEMBLY .Tdi Service repair no .20. Use a transmission hoist with an adaptor plate for securing the assembly to the hoist.44.

Disconnect top hose from radiator. Disconnect turbo charger hose from inter-cooler.ZF Remove 1. Disconnect battery terminals. 4. 8. 7. Select low range with transfer gear lever. 11. 6. disconnect multi-plug from top of brake fluid reservoir. 2. 5. Remove bolt securing transfer and main gearbox breather pipe clip to rear of cylinder head. Remove insulation pad from rocker cover and inlet manifold. Disconnect kick down cable at fuel injection pump. 3. On LH drive vehicles only. 9. Drain coolant from cooling system. Remove starter heat shield. Remove knob and gaiter from transfer gear lever. 12. REPAIR 5 . 10. Release electrical harness from clips along top of bulkhead and pull over to one side.

19. Disconnect inhibitor switch multi-plug. Disconnect gearbox mounting brackets from chassis cross member. 40. Remove two bolts securing top of bell housing to flywheel housing. 28. Release union nut at gearbox sump and remove filler/dipstick tube. Disconnect electrical connections from differential lock switch on transfer gearbox. Disconnect park brake cable from linkage to park brake lever. Fit a suitable torque converter retaining strap to the bell housing. 24. Remove bolts securing transmission cradle to transfer box and withdraw hoist complete with cradle. 43. 45. 39. 41. 49. 18. 30. See PROPELLER SHAFTS. 35. 48. Working through starter aperture note position of torque converter flexible drive plate to facilitate refitting. Fit blanking plugs. Using suitable chains and lifting tackle take weight of transmission assembly. 25. 46. 31.44 AUTOMATIC GEARBOX 13. 38. 34. 23. Disconnect front propeller shaft at transfer gearbox and tie to one side. Remove ties from breather pipes and harness. 36. 15. Remove nut securing gearbox oil filler/dip stick tube to bell housing. Disconnect selector cable from lever on side of gearbox. Disconnect speedometer cable from transfer gearbox and disconnect associated clipping. 22. Disconnect oil cooler pipes from gearbox. 16. Remove bolt securing retaining bracket to sump and move cooler pipes aside. 21. 14. Remove the four torque convertor to flexible drive securing bolts. Remove starter. Blank off pipes and union connections. 33. Drain lubrication oil from transfer and main gearboxes. Remove bolts securing front and centre silencer mounting brackets and tie silencer to one side. 29. Raise hoist and secure cradle to transfer gearbox input bearing support plate using bolts removed. 6 REPAIR . Remove hoist and transmission from under vehicle. Fit lifting eyes to transmission. 47. Support engine using a wooden block with a suitable ramp [hoist] jack. Remove left hand gearbox mounting bracket assembly. Lower transmission sufficiently to allow access to items attached to top of gearbox. Remove rear propeller shaft. 17. 44. Remove two lower bolts from transfer gearbox input bearing support plate. Raise vehicle on four post ramp [hoist]. Flexible Coupling 20. Overhaul. rotating engine to gain access to each individual bolt. 32. Assemble approved support cradle to transmission hoist. Remove exhaust front pipe. Refit bolts to cover plate. 27. 26. Remove nut securing kick down cable bracket to bell housing. 42. 37. Remove nuts securing bell housing to flywheel housing and withdraw transmission assembly from engine. Remove chassis cross member.

37. 3. Recommended Lubricants and Fluids REPAIR 7 . Remove ramp [hoist] jack. Secure breather pipe clip to rear of cylinder head. 8. 51. 12. 44. 27. See LUBRICANTS. Secure breather pipes and harness with ties. Refill transfer gearbox with correct grade of lubricating oil. Connect speedometer cable to transfer gearbox. 6. Reconnect kick down cable to fuel injection pump. connect multi-plug to top of brake fluid reservoir. Select high range gear. Recommended Lubricants and Fluids 36. Refill main gearbox with correct grade of lubricating oil. See LUBRICANTS. Information. lower hoist and remove from under vehicle. 9. Secure gearbox mounting brackets to chassis cross member. Overhaul. 17. 34. On left hand drive vehicles only. Refit starter and heatshield. 18. 21. Information. Refill cooling system with correct mixture of coolant. 15. Fit blanks to all apertures where unions have been removed and blank off pipe ends. Lower ramp [hoist] to ground level. Connect oil cooler pipes to gearbox and secure retaining bracket to gearbox sump. Refit 1. Connect inhibitor switch multi-plug. Ensure low range gear is engaged. Flexible Coupling 30. Recommended Lubricants and Fluids 32. 23. Fit left hand mounting bracket assembly to gearbox. CAUTION: It is important to remove the spacer from the extension shaft and fit onto the replacement unit. 39. Locate hoist under vehicle and remove torque convertor retaining strap. 31. 53. Fit nuts and bolts to secure transmission to engine. Reconnect turbo-charger hose to inter-cooler.ZF Accessories removal/fitting If fitting a replacement transmission assembly to the vehicle. Connect selector cable to lever on side of gearbox. 40. Reconnect top hose to radiator. 7. secure with oil filler cap. rotating crankshaft to gain access to bolt locations. Refit rear propeller shaft. 26. Information. 24. Reconnect battery terminals. Refit gaiter and knob to transfer gear lever. Working through starter aperture refit the four torque convertor to flexible drive securing bolts. 52. FLUIDS AND CAPACITIES. Breather pipe union and washers from main gearbox. 43. 42. 4. 50. Apply approved sealant to bell housing face. 29. Oil cooler pipe unions. Raise hoist sufficiently to take weight. Fit filler/dipstick tube to gearbox sump and secure bracket to bell housing. Remove two bolts securing transmission to cradle. 2. Raise transmission and support with a suitable ramp [hoist] jack. 11. 14. 22. FLUIDS AND CAPACITIES. union and washers from transfer gearbox. 54. See PROPELLER SHAFTS. remove the following items from the existing assembly and fit to the replacement. 55. Refit insulation pad to rocker cover and inlet manifold. 16. Locate electrical wiring and breather pipes to position. See LUBRICANTS. 35. Secure kick down cable clip to bell housing. 10. Apply Loctite to above bolts and fit to transfer gearbox input bearing support plate. 33. Carefully raise assembly. Connect electrical leads to differential lock switch. 19. 5. align bell housing with flywheel housing and bring mating faces together. Apply Loctite to torque convertor bolts 13. 28. 38. Remove block and jack from engine sump. RH mounting bracket assembly. 25. Refit front propeller shaft to transfer gearbox. Fit chassis cross member. Fit transmission to cradle and hoist. 20. Breather pipe. 41. Main gearbox selector lever. Engage harness with clips along top of bulkhead. FLUIDS AND CAPACITIES. Secure silencer to chassis and refit exhaust front pipe.

Remove catalytic converter assembly. Remove transfer gearbox chassis mounting bracket nuts and bolts. Remove inhibitor switch. Check/top up gearbox oil level. 7. Disconnect battery negative lead. Secure with retaining plate and bolt. Raise vehicle. Lubricate new oil seal and position seal on tool.19 Remove 4. Remove tool from shaft. Fit tool outer sleeve and screw on nut to drive seal into housing. Raise vehicle. 19. Remove selector lever from shaft. 10. Fit switch to casing. 22. Refit catalytic converter assembly. Refit chassis cross-member. 27. 6. 1. 2. Support transfer gearbox with a jack or transmission hoist. 20. 13. Site vehicle on a four post ramp [hoist]. 2. Site vehicle on a four post ramp [hoist]. 21. 18. 26. 6. Connect electrics to Lambda sensors. Lower transmission to allow access to selector shaft. Remove chassis cross-member from under gearbox. 13. Note location of speedometer cable bracket for refit. 7. Remove inhibitor switch retaining plate. Fit and lubricate new ’O’ ring seal to switch. 11. 3. 25. 9. SELECTOR SHAFT OIL SEAL Service repair no . 8. 10. Clean mating face on casing. Connect multiplug to harness. Clean selector shaft and seal mating faces.15. Raise transmission and secure mounting brackets to chassis. Clean inhibitor switch.44. Disconnect battery negative lead. Disconnect electrics from Lambda sensors. Refit selector lever to shaft. Fit centre section of special tool LST 114 over selector shaft. 9. 12. Remove support jack. 11. Reconnect battery and remove vehicle from ramp [hoist]. Ensure speedometer cable bracket is secured. Refit 8. Tighten bolts to 30Nm. 5.44 AUTOMATIC GEARBOX INHIBITOR SWITCH Service repair no . 8 REPAIR .34 Renew 1.15. 3.44. Remove ’O’ ring seal. 14. Disconnect inhibitor switch multi plug. 12. Connect battery. Engage low range gear in the transfer gearbox. 4. 17. 16. Remove selector shaft seal from casing. 15. 5. 23. 24. Connect heat shield front pipe to manifold. Detach heat shield at front exhaust pipe to manifold.

10. 6. Refit 12. Site vehicle on a four post ramp [hoist]. Connect battery. 11. 5. Remove catalytic converter assembly. Disconnect dipstick tube at oil sump. See LUBRICANTS. Refit chassis cross member. Disconnect electrics from Lambda sensors. FLUIDS AND CAPACITIES. 17.44. 13. Connect electrics to Lambda sensors. Refit catalytic converter assembly 16. 15. 4. Raise vehicle. 7. 14. 3.05 Remove 1. Refit oil sump using a new gasket. 18. Detach heat shield at front exhaust pipe to manifold.24.ZF OIL SUMP Service repair no . REPAIR 9 . Note their locations for refit and withdraw sump. Loosen securing bolt at bell housing and move dipstick aside. 8. Connect heat shield front pipe to manifold. Information. 2. Refill gearbox using correct grade of oil. Remove chassis cross-member from under gearbox. Connect dipstick tube to oil sump and tighten bolt at bell housing. Disconnect battery negative lead. 19. Recommended Lubricants and Fluids 9. Remove gasket and clean gasket mating faces. Remove clamps securing oil sump. Drain oil and refit plug with new seal.

Connect battery. Detach heat shield at front exhaust pipe to manifold.44. Drain oil and refit plug with new seal. Remove clamps securing oil sump. 20. Remove catalytic converter assembly. 16. FLUIDS AND CAPACITIES. 12. Remove gasket and clean gasket mating faces. Connect heat shield front pipe to manifold. Recommended Lubricants and Fluids 9. Information. Refit catalytic converter assembly 22.24. Refit oil sump using a new gasket. 14. Disconnect battery negative lead.44 AUTOMATIC GEARBOX OIL SCREEN Service repair no . discard ’O’ ring seal. 21. 10. Disconnect electrics from Lambda sensors. Disconnect dipstick tube at oil sump. 13. Connect dipstick tube to oil sump and tighten bolt at bell housing. taking care to retain suction pipe spacer. 5. Clean suction pipe. Connect electrics to Lambda sensors. Refit chassis cross-member. 7. 11. 2. See LUBRICANTS. Remove chassis cross-member from under gearbox. Detach suction pipe from oil screen. Refill gearbox oil system using correct grade of oil. Site vehicle on a four post ramp [hoist]. 15. Note their locations for refit and withdraw sump. 18. Fit oil screen and suction pipe with spacer and secure with three bolts. Fit new ’O’ ring seals to oil screen using light grease to aid assembly. 24.07 Renew 1. 8. Clean oil screen and blow out with airline. 17. 6. 3. Remove securing screws and detach oil screen and suction pipe. 10 REPAIR . Loosen securing bolt at bell housing and move dipstick aside. 25. 23. 19. discard ’O’ ring seal. 4. Raise vehicle.

13. Detach heat shield at front exhaust pipe to manifold. Disconnect electrics from Lambda sensors. Remove securing screws and detach oil screen and suction pipe. 2. 5. 6. REPAIR 11 . Remove clamps securing oil sump. Site vehicle on a four post ramp [hoist]. Remove securing screws and detach control unit from casing. Disconnect dipstick tube at oil sump. Remove chassis cross-member from under gearbox. Disconnect battery negative lead.ZF CONTROL UNIT Remove 1. taking care to retain suction pipe spacer. Remove catalytic converter assembly. 11. Remove gasket and clean gasket mating faces. 9. Raise vehicle. 12. Note their locations for refit and withdraw sump. Drain oil and refit plug with new seal. 8. discard ’O’ ring seal. 10. Loosen securing bolt at bell housing and move dipstick aside. 4. 3. 7.

Refill gearbox oil system using correct grade of oil. 25. locating throttle valve behind cam and engaging selector quadrant with manual valve. Connect heat shield front pipe to manifold. Note locations of long and short springs. Set correct distance between control unit and cam. 29. Refit oil pan using a new gasket. 17. springs and circlips and check that they are satisfactory for further use. 15. 30. Fit control unit to gearbox. Refit 19. Using seal replacer/remover LST113 remove and discard seals. 24. Information. 18. Recommended Lubricants and Fluids 12 REPAIR . Remove special tool and close throttle. Connect battery. See LUBRICANTS. 34. Refit catalytic converter assembly 31. ensure seals are fully seated. 20. 32. Fit oil screen and suction pipe with spacer and secure with three bolts. 23. 27. FLUIDS AND CAPACITIES. 33. Fit springs to locations noted during removal and secure with circlips. Manually open throttle linkage to full throttle position. 26. 22. 28. Refit chassis cross member. Connect electrics to Lambda sensors. Engage special tool LST 109 between control unit and throttle valve pin. Fit new seals to control unit using LST113. Loosely fit securing screws. Connect dipstick tube to oil sump and tighten bolt at bell housing. Clean control unit. 21. 16. Remove circlips and springs from control unit.44 AUTOMATIC GEARBOX Oil seal replacement 14. Fit new ’O’ ring seals to oil screen using light grease to aid assembly.

25.01 Remove 1. Remove catalytic converter assembly. Remove wedge from cam and ensure nipple remains engaged.44. 39. Using special tool LST112 compress cable tangs and remove cable from gearbox. Fit new ’O’ ring seal to cable and lubricate seal. 6. 9. 20. Disconnect dipstick tube at oil sump. Fit cable to throttle linkage. If cable is to be refitted remove ’O’ ring seal and clean cable assembly. 23. Lower vehicle on ramp [hoist]. 36. Loosen securing bolt at bell housing and move dipstick aside. 28. introduce a curve into the cable. Site vehicle on a four post ramp [hoist]. Refit chassis cross-member 29. 34. Fit inner cable nipple to its location on cam. 17. Feed cable through to underside of vehicle. 12. and withdraw sump. Refit catalytic converter assembly 30. Raise vehicle on ramp [hoist]. 27. 37. measure distance ’B’ on old cable. 3.15. 18. Connect electrics to Lambda sensors. 4. Disconnect kickdown cable at throttle linkage. Recommended Lubricants and Fluids REPAIR 13 . 10. Feed free end of cable assembly into engine compartment. Disconnect cable from mounting bracket. 16. Locate cable in mounting bracket. Ensure throttle linkage is fully closed. 33. NOTE: When a new cable is fitted. Select neutral ’N’ gear lever. See LUBRICANTS.25mm (dimension ’A’) between end of outer cable and crimped collar on inner cable. 7. 31. 40. Connect dipstick tube to oil sump and tighten bolt at bell housing. Detach heat shield at front exhaust pipe to manifold. Release cable from bracket attached to cylinder head. 32. Fit cable to gearbox casing ensuring it is correctly seated. 5. Refit oil pan using a new gasket. 22. NOTE: If fitting a new cable. 8. Information. and collar on inner cable is loose. Drain oil and refit plug with new seal. Disconnect battery negative lead. Remove chassis cross-member from under gearbox. Note their locations for refit. Release cable from cam by pushing inner cable into outer casing and detaching cable nipple from cam. 13. Remove clamps securing oil sump. Crimp collar on new cable to this dimension. Connect heat shield front pipe to manifold. Refill gearbox oil using correct grade of oil.ZF KICKDOWN CABLE Service repair no .25 to 1. Adjust outer cable to achieve a gap of 0. 26. Fit cable to bracket at cylinder head. Disconnect electrics from Lambda sensors. 14. 2. 15. FLUIDS AND CAPACITIES. Tighten locknuts and recheck gap. Reconnect battery negative lead. Refit 21. 24. Do not bend or kink cable. 38. Release outer cable locknut. Wedge cam in this position. Pull kickdown inner cable to fully open valve cam. 19. do not tighten locknut. to help locate nipple to cam. 35. 11.

Fit extension housing to gearbox. Remove and discard gasket. See LUBRICANTS. Remove transfer gear lever housing securing bolts and move housing aside. 14 REPAIR . Remove bolts securing left hand mounting bracket to extension housing and withdraw bracket.20. 4. 13. Tighten to 23 Nm. 11. Refit 9.44. FLUIDS AND CAPACITIES. LT230T Transfer Gearbox 2. Refill automatic gearbox lubrication system with correct grade of oil. If damage is found and housing has to be renewed remove dowels from face of existing housing and fit to new housing. Secure housing with nine bolts. Refit mounting bracket to extension housing. Refit transfer gear box. Information. 10. 6. 3. See TRANSFER GEARBOX. Place extension housing on bench and remove oil seal. 7. See TRANSFER GEARBOX. Recommended Lubricants and Fluids 5. Drain oil from automatic gearbox. LT230T Transfer Gearbox 14. with a new gasket. ensuring oil seal is not damaged by extension shaft. Ensure that all surfaces are clean and housing is free from damage. Tighten to 25 Nm. 8. 12. Using special tool LST108 fit new oil seal to housing.44 AUTOMATIC GEARBOX EXTENSION HOUSING Service repair no .18 Remove 1. Remove securing bolts and withdraw extension housing from over coupling shaft. Refit transfer gear lever housing to top of extension housing. Remove transfer gearbox. Tighten to 52 Nm. Repair. Repair.

19. Remove transfer gear lever housing securing bolts and move housing aside. Repair. Clean all components. 4. withdraw shaft and discard ’O’ ring seal.22. 6. avoid damaging seal. If Tdi vehicle remove spacer. Fit extension shaft with spacer if Tdi. Fit governor assembly to output shaft. 10. 11. 8. Fit extension housing. Remove transfer gearbox. Refit transfer gearbox. See TRANSFER GEARBOX. Fit and lubricate new seal rings to ’F’ clutch housing shaft. Drain oil from automatic gearbox. Remove bolts securing left hand mounting bracket to extension housing and withdraw bracket.01 Remove 1. 20. Refit mounting bracket to extension housing. Refit transfer gear lever housing to extension housing. 22. Fit to output shaft 17. If necessary detach parking pawl by removing guide plates and withdrawing mechanism. Apply petroleum jelly to a new ’O’ ring seal. 3. Refill automatic gearbox with correct grade of oil. Repair. Refit 14. 7. Refit parking pawl mechanism if removed. LT230T Transfer Gearbox 2. Remove extension shaft retaining bolt. 9. Detach governor housing. See LUBRICANTS. remove and discard gasket. ensure they are correctly seated. Tighten to 23 Nm. Remove park gear from governor assembly. 15. 23. 5. 18. 21. Remove extension housing ensuring seal is not damaged. 13. FLUIDS AND CAPACITIES. Remove governor assembly. Information. Tighten to 52 Nm.44. 12. Recommended Lubricants and Fluids REPAIR 15 .ZF GOVERNOR ASSEMBLY Service repair no . 16. Remove and discard ’O’ ring seal from output shaft and three seal rings from ’F’ clutch housing. Fit park gear to governor assembly tightening screws to correct torque. See TRANSFER GEARBOX. Fit new ’O’ ring under bolt head. Remove security clip and counter weight. LT230T Transfer Gearbox 24.

Repair. Using a new ’O’ ring. NOTE: To aid fitting of ’O’ ring apply petroleum jelly.22. Remove transfer gear selector housing. Discard governor hub. LT230T Transfer Gearbox 2. 12. 19. remove parking wheel. tighten three bolts to 25 Nm. Tighten to 10Nm.04 Remove 1. 21. 22. 17. Refit 13. 20. Remove extension housing ensuring that seal is not damaged. Remove transfer box. Fit extension shaft. Remove ’O’ ring from output shaft and discard. If Tdi vehicle remove spacer. Fit new gasket to rear of gearbox. NOTE: Apply petroleum jelly to ’O’ ring. replace if necessary.44. Fit transfer gear selector housing. 4. Tighten to 10 Nm. 9. 7. 3. Fit parking wheel to governor hub. apply Loctite 270 to retaining bolt. Inspect all parts for damage or wear. Remove two screws holding governor housing. 8. 16. 11. 14. See TRANSFER GEARBOX. Refit transfer box. Remove three seal rings from ’F’ clutch housing shaft. 16 REPAIR . Fit counterweight and security clip into new governor hub. Fit extension housing. Push governor assembly and parking wheel onto output shaft until seated. 5. Remove two bolts.44 AUTOMATIC GEARBOX GOVERNOR HUB Service repair no . Fit three new seal rings onto F clutch housing shaft. 10. 15. Tighten nine extension housing nine bolts to 23 Nm.and spacer if Tdi. fit ’O’ ring onto output shaft. Remove governor assembly with parking wheel. Ensure seal rings are snapped together and seated. avoid damaging seal. Secure governor housing to governor hub. 18. 6. Remove extension shaft and retaining bolt with ’O’ ring. tighten bolt to 42 Nm. Remove security clip and counter-weight. discard gasket. Loosen nine bolts holding extension housing.

44. Avoid damaging parts which could weaken spring tension. 4. Fit extension shaft with spacer if Tdi and retaining bolt with new ’O’ ring. 14. Refit transfer box. 10. 6.07 Remove 1. pawl and spring. Fit extension housing. Remove transfer gear selector housing. Push governor assembly with parking wheel onto output shaft until seated. tighten nine bolts to 23Nm. Refit 11. Remove governor assembly with parking wheel.ZF PARKING PAWL MECHANISM Service repair no . 7. Replace if necessary. Loosen nine bolts holding extension housing. Remove plate and guide plate from gearbox case. LT230T Transfer Gearbox 2. Fit pawl to pin. Fit new gasket to rear of gearbox. Fit extension housing. remove spacer. Repair. 18. Remove pin. NOTE: Apply petroleum jelly to ’O’ ring. 15. tighten three bolts to 25 Nm. 17. Remove transfer box. taking care not to damage seal or assembly. 13. Inspect all parts for wear or damage. Fit pin and leg spring. 19. Fit plate and guide plate. 5.28. Tighten to 10 Nm. Remove extension shaft and retaining bolt with ’O’ ring. Ensure seal rings are snapped together and seated. REPAIR 17 . If Tdi vehicle. Remove extension housing ensuring that seal is not damaged. 8. 3. 9. 12. See TRANSFER GEARBOX. 16. Remove guide plate bolt. CAUTION: When removing assembly. discard gasket. Locate spring leg into hole in pawl to create tension in spring. Fit transfer gear selector housing. locate spring correctly.

Remove gearbox and transfer box assembly. Remove gearbox and transfer box assembly. Remove eight hexagonal bolts on rear of pump. 3. 4. This shows converter is correctly seated in housing. Refit gearbox and transfer box assembly. See LT230T Transfer Gearbox ELIMINATING LEAKS ON PUMP HOUSING 1. taking care not to damage torque converter/oil pump housing oil seal. 18 REPAIR . See LT230T Transfer Gearbox 2. Fit new torque converter using torque converter handles 18G1501. Remove torque converter using torque converter handles 18G1501. Remove bell housing and pump assembly. Check dimension from converter fixing boss to converter housing face is 50 mm. discard gasket. taking care not to damage torque converter/oil pump housing oil seal. Remove torque converter using torque converter handles 18G1501. Place gearbox on bench. Remove twelve hexagonal bolts (inner ring pattern). See LT230T Transfer Gearbox 2.44 AUTOMATIC GEARBOX REPLACING TORQUE CONVERTER 1. 3. Place gearbox on bench. 4. 5.

Using oil pump rotation sleeve LST111. Before fitting intermediate plate and bell housing assembly.4 mm. 10. tighten eight bolts to 10 Nm. 12. 15. situated at rear of intermediate plate. 13. Remove shaft sealing ring and ’O’ ring from pump housing and discard. Refit gearbox/transfer box assembly. diagonally opposite each other. Replace existing washer. Fit bell housing and intermediate plate assembly to gearcase. with a suitable washer to give required end float. Place gasket and disc washer onto bell housing and intermediate plate assembly using Petroleum Jelly. See LT230T Transfer Gearbox REPAIR 19 .ZF 6. Using oil seal replacer LST108 fit shaft seal ring into pump housing. 7. 18. 14. Tap lightly using a soft headed mallet to remove pump assembly from intermediate plate. 17.2-0. Place bell housing and intermediate plate assembly on bench. 11. Place end float gauge LST111 onto pump housing and check that axial play is between 0. Fit pump housing to intermediate plate. Align dowel with hole in intermediate plate and press pump housing home. 9.check that thrust washer and axial cage are seated on A clutch housing. checking that dimension from converter fixing bolt boss to converter housing face is 50 mm. 8. This shows converter is properly seated in housing. Refit torque converter into housing using torque converter handles 18G1501. check that pump gears rotate freely. Screw in two bolts. front face up. Tighten twelve bolts to 46 Nm. Fit ’O’ ring onto circumference of pump housing. 16.

This dimension shows converter is properly seated. 8. with a suitable washer to give required end-float. Fit bell housing assembly with disc washer to gearcase. 10. 5. 7. Before fitting bell housing assembly check that thrust washer and axial cage are seated on A clutch housing. 6.4 mm. 9. Place gearbox on bench. Checking that dimension from converter fixing boss to converter housing case is 50mm. Place end-float gauge LST111 onto pump housing and check that axial play is between 0.2-0. Remove torque converter using torque converter handles 18G1501. Replace existing washer. Remove twelve hexagonal bolts (inner ring pattern). Remove gearbox and transfer box assembly.44 AUTOMATIC GEARBOX ELIMINATING LEAKS BETWEEN GEARBOX HOUSING AND INTERMEDIATE PLATE 1. Refit gearbox/transfer box assembly. Refit torque converter using torque converter handles 18G1501. Tighten twelve bolts to 46Nm. See LT230T Transfer Gearbox 2. 3. See LT230T Transfer Gearbox 20 REPAIR . 4. taking care not to damage torque converter/oil pump housing oil seal. Place new gasket onto intermediate plate using Petroleum Jelly. situated at rear of intermediate plate. Remove bell housing/intermediate plate assembly from gearbox case and discard gasket.

Secure pump housing to intermediate plate using eight hexagonal bolts. Remove twelve bolts (inner ring pattern).01 1.ZF REPLACING PUMP Service repair no . Screw in two bolts. tap lightly using a soft headed mallet to free pump assembly from intermediate plate. 10. tighten twelve bolts to 46 Nm. 5. Place new gasket and disc washer onto bell housing and intermediate plate assembly using a Petroleum Jelly. 12.diagonally opposite each other.44.32. Fit bell housing and intermediate plate assembly. 8. Using oil pump rotation sleeve LST111. See LT230T Transfer Gearbox 2. Remove eight bolts on rear of pump. 4. Place bell housing and intermediate plate assembly on bench. Tighten to 10 Nm. discard gasket. Remove bell housing and pump assembly from gearbox case. 11. Remove gearbox and transfer box assembly. 6. Before replacing intermediate plate/bell housing assembly check that thrust washer and axial cage are seated on A clutch housing. aligning dowel with hole in intermediate plate. check that pump gears rotate freely. front face up. REPAIR 21 . Remove torque converter using torque converter handles 18G1501. 3. Place gearbox on bench. press pump housing home. Fit new pump assembly. 9. taking care not to damage torque converter/oil pump housing oil seal. 7.

situated at rear of intermediate plate. See LT230T Transfer Gearbox GEAR SELECTOR-INTERLOCK For remove and refit of gear selector interlock.2-0.44 AUTOMATIC GEARBOX 13. with suitable washer to give required end-float. Refit torque converter into housing using torque converter handles 18G1501. Gear Selector-Interlock 22 REPAIR . NOTE: If damage is apparent to bolts they should be replaced. Refit gearbox/transfer box assembly.4 mm. Check dimension converter fixing boss to converter housing face is 50 mm. Repair. Place end-float gauge LST111 onto pump housing and check that axial play is between 0. Replace existing washer. This shows converter is properly seated in housing. 14. 15. See ELECTRICAL.

.......................parking pawl .......... Torque values below are for all screws and bolts used except for those that are specified otherwise.................................... 23 Control unit mounting bolts ........................................................................................................................................ 9 Drive plates to crankshaft adaptor ........................................................................................................ 90 5/8 ................................................................................................................... 84 NOTE: * These bolts must have threads coated with Loctite 270 prior to assembly............. 24 3/8 ..................................... 10 Intermediate plate plugs (M20) .......................................................................................converter housing ...................................................................................................................................................................... TORQUE 1 .......... 8 Drive plate to converter ......... 9 M8 ............................................................................ 40 Bell housing mounting bolts ............ 39* Gearbox to engine ................................................................................................. 136 SPECIFICATIONS..........................................................................................................................................................................................................................clutch F ............................................. 10 Extension housing bolts ....................................................................................................pump ............................. 46 Governor mounting screws ......................................................... 39 7/16 ..................................................................................................................................... 10 Securing screws ...........................................................................................ZF TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque.................................. 9 Cover ......... 105 M16 ............................................................................................................... 42 Strut (threaded end) .................................................................................... 42 Bottom cover to converter housing ....................................................................................................................... 45 M12 ................ 40* Adaptor to crankshaft ................... 78 1/2 .............. 8 Sump plug ........................................................................................................................................................... 10 Securing screw ........................... Nm Coupling shaft to mainshaft .............................................. 9 5/16 ............... 10 Mounting screws for sump ...................................................................... 50 Intermediate plate plugs (M14) ..................................... 25 M10 ..... 6 M6 ............................................................................................................................................................................................ 25 Cooler pipe adaptor to gearbox ................................................................................................................ METRIC Nm M5 ............ 42 Securing screws ............................................... 42* Filler tube to sump ............................................................... 180 UNC / UNF 1/4 ....................................... 90 M14 .............................................. 68 Gear change lever to gearbox ............................................................

00 mm A cylinder protrusion above gearbox front face not more than 8.5 mm 2 SPECIFICATIONS. TORQUE .2 to 0. minimum clearance 0.44 AUTOMATIC GEARBOX ZF GEARBOX DATA Axial end float 0. dimension 10.1 mm Output shaft above cylinder F assembly. From torque converter boss to torque converter housing face 50 mm Freewheel cage assembly to ring gear.4 mm.

ZF AUTOMATIC GEARBOX HOLDING FIXTURE NOTE: This fixture enables ZF gearbox to be held securely during bench sited repairs. SERVICE TOOLS 1 . It can be manufactured to details given. or purchased under service tool number LST 118.

44 AUTOMATIC GEARBOX 2 SERVICE TOOLS .

LRT-44-002 LST 109 Selector linkage setting gauge.ZF AUTOMATIC GEARBOX LRT-44-001 LST 108 Front and rear oil seal replacer. LRT-44-003 LST 111 Oil pump rotation sleeve and end float gauge. SERVICE TOOLS 3 . LRT-44-004 LST 112 Kickdown cable remover.

502K Hose and adaptor.502A Line pressure test gauge. 4 SERVICE TOOLS . LRT-44-008 18G. LRT-44-006 LST 114 Selector shaft oil seal replacer. LRT-44-007 18G.44 AUTOMATIC GEARBOX LRT-44-005 LST 113 Control unit oil seal remover/replacer.

SERVICE TOOLS 5 . LRT-44-010 18G.1501 Convertor lifting handles.ZF LRT-44-009 LST 502-1 Adaptor pressure take off.

The splines are pre-packed with lubricant and sealed.PROPELLER SHAFTS PROPELLER SHAFT ALIGNMENT Description The front and rear propeller shafts have non-constant velocity ’Hooks’ type universal joints. The bearing cups are pre-packed with lubricant on assembly and a grease nipple is fitted for servicing as specified. The front shaft which is shorter than the rear is ’Phased’. The phasing is necessary on the front shaft only to allow for greater variation in angular changes. Catalyst vehicles The front shaft is ’phased’ as above but is of solid bar construction. The rear shaft is fitted with a conventional joint at gearbox end and the sliding joint sealed with a rubber gaiter. with needle roller bearings. An SGF rubber coupling is fitted at the differential end of the shaft. in maintenance section. with the joints at each end. DESCRIPTION AND OPERATION 1 . Both shafts have Rilsan coated sliding splines to accommodate the variation in distance between the axles and transmission. A and B mis-aligned as shown in RR4199.

NOTE: In the event that both shafts are satisfactory.Oil Leaks For balance of road wheels. Wheel Balancing FAULT DIAGNOSIS 1 . Fault diagnosis. Repair.PROPELLER SHAFTS VIBRATION HARSHNESS 1. LT230T Transfer Box . For transfer box operation. Check that the propeller shaft universal joints and sliding splines are not siezed or worn and that the shafts are correctly aligned. See WHEELS AND TYRES. See TRANSFER GEARBOX. but the vibration/harshness is still present. the transfer box operation and balance of the road wheels should be checked.

Remove bearing cups from new spider. Scribe alignment marks on flanges at both ends of propeller shaft to ensure correct refitting. Remove nuts from each end of propeller shaft. 7.PROPELLER SHAFTS FRONT PROPELLER SHAFT Service repair no . FLUIDS AND CAPACITIES. Remove circlips.11 Overhaul 4.Front Remove 1. 9. 5. Ensure bearing cups are one-third full of lubricant. Enter new spider with seals into yokes of sliding member flange. 10. Assemble 11. 13. Place vehicle over pit or on a ramp [hoist].47. Check all needle rollers are present and positioned in bearing cups. Remove bearing cups and spider.15. See LUBRICANTS. Thoroughly examine universal joint for signs of damage or wear. CAUTION: To ensure correct assembly and reduce possibility of imbalance. 2. Recommended Lubricants and Fluids 14. Press both cups into place. Clean universal joint bearing cups and circlips. Clean yokes and bearing cup locations. 8. 16.15. 3. 6. Tap yokes to eject bearing cups. 17. Service repair no . Insert opposite bearing cup into flange yoke. Information.02 . REPAIR 1 . Remove shaft. 12. Mark position of spider pin lubricator relative to journal yoke ears. Partially insert one bearing cup into flange yoke and enter spider trunnion into bearing cup.47. and grease nipple. Repeat instructions 4 to 7 for opposite end of propeller shaft if necessary. Before removing propeller shaft joint. Replace if necessary. 15.

Refit 24. 19. 20. 2 REPAIR . Fit bearing cups and circlips as described in instructions 14 to 19. 21. Engage spider in yokes of sliding member. Press each cup into its respective yoke up to lower land of circlip grooves. Fit grease nipple and lubricate. Fit grease nipples to spider and sliding member. Apply instructions 14 to 19 to opposite end of propeller shaft. 23. 22.47 PROPELLER SHAFTS 18. Fit propeller shafts to vehicle and tighten nuts to 47Nm Refit FRONT propeller shaft so sliding joint end of shaft is fitted to transfer gearbox. Damage may be caused to cups and seals if cups pass this point. Fit circlips and check no end float exists.

PROPELLER SHAFTS SPIDER ASSEMBLY COMPONENTS 1. 4. 3. 5. Circlip Bearing cup Nylatron washer Needle rollers (27 per cup) Seal retainer and seal REPAIR 3 . 2.

3. 6. Tighten to 78 Nm. 4. Refit 5. 2. Raise propeller shaft at gearbox end detach coupling from spigot at differential and withdraw shaft. The SGF rubber coupling is a non-serviceable item. Overhaul. See Rear Propeller Shaft.15.12 NOTE: Refer to front propeller shaft overhaul procedure for gearbox end of shaft. Only remove coupling from propeller shaft if replacement is required.03 NOTE: SGF rubber coupling should be left attached to propeller shaft.47. Remove rear propeller shaft.47. Locate flexible coupling over spigot. 4 REPAIR . 2. Refit 3.47 PROPELLER SHAFTS REAR PROPELLER SHAFT Service repair no . Remove 1. See REAR AXLE AND FINAL DRIVE.15. FLEXIBLE COUPLING NOTE: Flexible coupling should only be removed if a new coupling is to be fitted. Reverse removal procedure. NOTE: For replacement of spigot (pinion flange centralising peg). Secure flexible coupling to axle flange with three nuts and bolts and Tighten to 78 Nm. Fit nuts and bolts. Remove nuts securing propeller shaft flange to transfer gearbox. Remove nuts and bolts securing flexible coupling to propeller shaft. Scribe alignment marks on flanges at both ends of propeller shaft to ensure correct refitting. Remove three nuts and bolts securing flexible coupling to axle flange. align scribed marks and secure at transfer gearbox. Axle Differential Assembly Overhaul Service repair no . Remove 1. Tighten to 47 Nm.

REAR AXLE AND FINAL DRIVE DESCRIPTION The welded steel rear axle casing houses a separate spiral bevel type differential unit. The differential unit drives the rear wheels via the axle shafts and fully floating hubs which are mounted on tapered roller bearings. 4. Lubrication The differential is lubricated with oil and the hub bearings with grease. Rear axle hub 1. Ventilation Ventilation of the hub bearings is through the outer oil seals and the differential ventilation pipe. The hub bearings are fitted with inner and outer seals. 2. Inner hub seal Outer hub/axle shaft seal Hub lock plate. ABS DESCRIPTION AND OPERATION 1 . 10. 6. which terminates at a high level. 9. 8. thrust washer and nuts (2) Brake disc Sensor ring. 5. Axle casing Ventilation pipe Axle shaft Wheel studs and hub Wheel bearing stub axle Wheel bearings (2) 7. 11. 3. which is off set to the right of the vehicle centre line. The wheel hubs on axles with ABS brakes share the same construction to non ABS axles except for the addition of a sensor ring 11 on the brake disc 10. The outer seals prevent the differential oil mixing with the hub grease and the inner seals prevent dirt ingress into the hub.

When investigating hub seal leaks check the grease for dilution with oil. For example. Check also the differential level and oil for metal particles and the condition of internal seals.REAR AXLE AND FINAL DRIVE FAULT DIAGNOSIS Complaint . Do not assume that a high oil level in the differential is due to over filling or. that a low level is because of an external leak. FAULT DIAGNOSIS 1 . If the vehicle is driven in deep water with defective oil seals. water may contaminate the lubricants and raise the differential level giving a false impression that the housing has been overfilled with oil. Oil from the differential may flood one hub causing a leak and leave the differential lacking lubrication. as a blockage can cause internal pressure to force oil past the seals.Oil leaks An external leak of lubrication from the hub seals can be caused by a faulty internal seal. When a seal is found to be leaking check the axle ventilation system. See ’Description and Operation’ for illustrations of oil seal locations. if the internal seals which separate the differential from the hubs are faulty and the vehicle is operating or parked on an embankment.

Remove axle assembly. Release bolts and remove coil spring retaining plates. if applicable. Bleed brake system. 12. 11. Lower axle and remove road springs. 15. Drain brake system. 5. 4. Reverse removal procedure. Lower propeller shaft and tie to one side. Disconnect shock absorbers. Disconnect pivot bracket ball joint at axle bracket. 6. Anti-Roll[Sway] Bar Ball Joint Links 14. 2. 7. See REAR SUSPENSION. 17. Disconnect lower links at axle. Brake System Bleed REPAIR 1 . 18. Repair.01 Remove WARNING: Remove and refit of axle requires a further two persons to steady the axle when lowering or repositioning axle. 10. Position axle and fit lower links. 13. Repair. Remove four nuts and bolts. 8. Mark differential and propeller shaft flanges with identification marks for assembly. See BRAKES. 3.REAR AXLE AND FINAL DRIVE REAR AXLE Service repair no . Support chassis rear. Refit 1. Support axle weight with hydraulic jack. Disconnect flexible brake hose at connection under floor. Remove road wheels. Tighten propeller shaft to differential drive flange to 47 Nm 19. Tighten pivot bracket ball joint to axle to 176 Nm. 9.51. Disconnect ABS wiring harness multi-plug at jump hose bracket. Tighten to 176 Nm 16. Disconnect anti-roll[sway] bar links to axle.25.

Machine equal amounts off each face. If necessary reposition disc. Remove rear hub assembly.51 REAR AXLE AND FINAL DRIVE REAR BRAKE DISC NON ABS Service repair no . Fit hub assembly. Remove 1. 3. Remove disc from rear hub. See Rear Hub Assembly 2. Machine equal amounts off each face. 2 REPAIR .15 mm. Fit disc bolts.70. See Rear Hub Assembly Disc reclamation 11. Refit 4. this must not exceed 0. REAR BRAKE DISCS ABS Service repair no . Remove disc from hub. Using new nyloc nuts fit sensor ring. Remove disc bolts. Tighten to 73 Nm.70. Fit rear hub assembly.10. Check total disc run out. Remove five hub to disc retaining bolts. 7. this must not exceed 0. Remove five nyloc nuts. 5. 9. 7. Tighten to 73 Nm. 4. Refit 6. 8. Check disc thickness.11. See Rear Hub Assembly 2. Check total disc run out. Check disc thickness. 3. Fit disc onto hub. See Rear Hub Assembly Disc reclamation 8. Fit disc to rear hub. Remove 1. This dimension may be reduced to minimum thickness of 12 mm.11.11. 10. Remove sensor ring. 6. Remove rear hub assembly. Apply loctite 270 and fit hub to disc retaining bolts.15 mm. This dimension may be reduced to a minimum thickness of 12 mm. 5. If necessary reposition disc.

8. 6. 13. Bend back lock washer tabs. Remove joint washer. 6. WARNING: Take care not to kink brake hose. Sensor ring ABS. 14. Sensor ring retaining nut ABS. 7. Remove hub and brake disc assembly complete with bearings. Release brake hose clips and remove brake caliper bolts. Grease seal. 12. 5. 3.01 Remove 1. 5. 2. 4.64. 2. Hub. Brake disc. Axle shaft joint washer. Secure to one side. 10. 11. Remove spacing washer. Lock nut. 8. Remove five bolts and withdraw axle shaft. REAR HUB COMPONENTS 1. Remove locknut and lock washer. Place rear axle onto axle stands and remove road wheel. Lock washer. 9.15. Inner bearing. REPAIR 3 . 15. Axle shaft. 7. 3.REAR AXLE AND FINAL DRIVE REAR HUB ASSEMBLY Service repair no . Axle shaft retaining bolt (five off). 4. Outer bearing. 9. Disc retaining bolt (five off). Spacing washer. Hub adjusting nut. Remove hub adjusting nut.

Tighten to 61 Nm. Back off adjusting nut 90°. 17. Clean stub axle. This will give the required hub end float of 0.010mm 14. Fit a new lock washer. Tighten to 65 Nm. Push sensor in until it touches sensor ring then rotate hub to set sensor. if applicable 11. Using a new joint washer fit axle shaft to hub. remove axle stands and final tighten road wheel nuts to 126 Nm. Operate footbrake to locate brake pads before driving vehicle. Tab over lock washer to secure adjusting nut and locknut. 18. 13. Fit locknut. 21. Retract ABS sensor slightly from sensor sleeve. 12. Fit hub assembly to stub axle. set ABS brakes sensor. Tighten to 4 Nm. 4 REPAIR . 19. Fit spacing washer. 16. 20. Fit hub adjusting nut. Tighten to 61 Nm. Tighten to 82 Nm. secure with five bolts. Fit road wheel. Fit brake caliper. Secure brake pipes to axle casing. 15.51 Refit REAR AXLE AND FINAL DRIVE 10. If applicable.

Remove pinion flange nut using service tool LRT-51-003 to restrain flange. Remove pinion FRONT AXLE DIFFERENTIAL ONLY 7. Remove pinion flange oil seal. 10. Remove washer and pinion drive flange. Remove locking fingers. Remove pinion complete with bearing and outer bearing shims. Remove pinion flange oil seal and bearing. Remove pinion complete with bearing and outer bearing shims. Remove bearing cap bolts and bearing caps. 5. 1. 11. Using service tool LRT-54-508. 6.07. remove pinion head bearing track and shim and drive out outer bearing of differential housing. 9. OVERHAUL 1 . 2. 8. Loosen bearing cap bolts and mark caps for assembly. remove bearing adjusting nuts. 4. 9. 10. Remove roll pin securing bearing nut locking fingers to bearing caps.REAR AXLE AND FINAL DRIVE AXLE DIFFERENTIAL ASSEMBLY Service repair no . Using service tool LRT-54-505. Remove pinion flange centralizing peg using service tool LRT-51-008. DISMANTLE NOTE: Mark differential components so their original positions relative to other components is maintained.15. Remove crown wheel differential unit and bearings. Bearing caps must not be interchanged. spacer and bearing. Remove pinion REAR AXLE DIFFERENTIAL ONLY 7. 3.51. Remove axle shafts then differential assembly fom axle. 8. Remove pinion flange nut using service tool LRT-51-003 to restrain flange.

14. 22. ASSEMBLE Differential gears 21. 12. 2 OVERHAUL . Remove circlips and extract differential cross shaft. Withdraw differential gears and pinions. 19. Clean all components. scuffing. Remove bolts and washers securing crown wheel to differential flange. Remove crown wheel. pinion housing and bearing caps. Supplied as matched sets are: crown wheel and pinion. 20. 16. 17. Remove differential carrier bearings. Remove pinion head bearing with service tool LRT-99-002.51 REAR AXLE AND FINAL DRIVE INSPECTION 18. pitting and damaged teeth. Check all bearings for wear and pitting. Fit differential gears to differential housing. Check all gears for wear. 15. 13. Fit differential cross shaft and circlips.

Do not tighten bolts. After checking run out remove differential housing from pinion housing. 31. Clean and fit crown wheel. Tighten bearing cap bolts to 90 Nm. OVERHAUL 3 . Fit carrier bearings and assemble tracks to bearings. Nominal backlash should be present. Place differential housing with crown wheel and bearings in pinion housing.REAR AXLE AND FINAL DRIVE 23.10 mm. Tighten to 58 Nm. 25. If fitting a new shim use minimum 1. Fit pinion head bearing track and original shim to pinion housing. Remove crown wheel bolts and refit using Loctite ’Studlock’. 33. Use service tools LRT-54-505 and LRT-54-506. Check serial number marked on pinion end face matches that on crown wheel. A buckled or damaged differential housing flange is corrected by replacing differential gear housing. Fit bearing adjusting nuts and adjust to obtain zero end float. If exceeded examine crown wheel and mounting flange for burrs. Check crown wheel for run-out. Fit bearing caps and bolts. Excess backlash necessitates replacement of gears or differential housing. 29. 24. 34. Check gear for freedom of rotation and backlash. 27. 28.27 mm thickness. This should not exceed 0. etc. Refit and recheck. 32. 30. 26. grit.

Fit pinion into its location without shims for bearing pre-load. 4 OVERHAUL . 37. 36. pre-load figure is 1. This will pre-load bearings to check pinion height dimension.51 REAR AXLE AND FINAL DRIVE 35. Tighten pinion flange nut until force required to rotate pinion is 3 Nm if new bearings are fitted. required to set pinion. Use service tool LRT-54-502.5 Nm. Pinions marked minus (-) must be set above nominal. 41. Fit outer bearing. 42. 39. Unmarked pinions must be set at nominal. and spacer (front axle differential only). Do not fit oil seal at this stage. Fit pinion head bearing to pinion. deviation from nominal. Fit pinion outer bearing track to pinion housing. washer and nut. 40. Fit driving flange. Pinions marked plus (+) must be set below nominal. NOTE: If using original bearings. Figures marked on end face opposite to serial number show in thousandths of an inch. Drive pinion markings NOTE: Markings on end face adjacent to serial number are of no relevance to servicing. 38. Use service tools LRT-54-505 and LRT-54-507.

498 1. FTC3853 FTC3854 FTC3855 FTC3856 FTC3857 FTC3858 FTC3859 FTC3860 FTC3861 FTC3862 FTC3863 FTC3864 FTC3865 FTC3866 FTC3867 FTC3868 INCH . NOTE: Setting block has three height settings heights.047 .060 .548 1. Note dial gauge measurement from zeroed setting.048 . Position dial gauge centrally on pinion end face.052 . Zero dial gauge trace pin on setting block.198 1. 47.348 1.50mm setting mark for this differential.398 1.049 .248 1. 45.058 . Place dial gauge and setting block on surface plate.059 . register on lowest point on one differential bearing bore.523 1. Drive pinion adjustment 44.448 1.053 .REAR AXLE AND FINAL DRIVE Pinion height shims PART No.423 1.050 . Referenced from pinion end face to bottom radius of differential bearing bore.046 MM 1.223 1.298 1.061 .051 . OVERHAUL 5 .373 1.057 . 46.173 43. Ensure pinion end face is free of burrs around etched markings.054 .273 1. Nominal setting dimension is represented by setting gauge block LRT-54-503. Remove keep disc from magnetized base of dial gauge tool.055 .473 1. Use 39.323 1.056 .

025 .010 = = = = = = = = = = MM . Before adjusting shim thickness: check pinion face marking. Note whether trace pin has moved up or down from zero. For example. mean reading of dial gauge will agree with figure marked on pinion end face. Change shim as necessary to obtain reading. Tighten pinion flange nut to 130 Nm. Do not fit oil seal at this stage. of same thickness as original (bearing pre-load) into position on pinion shaft.008 . 49. INCH . reading is equal to thickness of shims to remove.10 . B. reading is equal to thickness of shims to add. Force to rotate pinion shaft is 3Nm using new bearings. 57.075 .125 . add amount to shim thickness figure.009 . 56. Fit pinion to pinion housing and fit outer bearing and spacer (front differential only). 51.005 . NOTE: Where dial indicator is metric conversion must be made to inches when measuring and selecting shims. NOTE: If using original bedded in bearings. 54. to bring pinion to nominal. 6 OVERHAUL . Thicker shim will reduce pre-load. dial gauge reading should indicate pinion is +0.25 Bearing pre-load adjustment 52.006 .20 .001 .225 .003 . Add readings then halve sum to obtain mean reading. If pinion has a minus (-) figure.003 in.002 . Adjust shim thickness under pinion head bearing track as necessary. Where trace pin moves up. Recheck pinion height setting. Where trace pin moves down. washer and nut. 53. pinion. with end face marking of +3.15 . If setting is correct. to bring pinion to nominal.5 Nm.155 mm. Repeat on other bearing bore. Slide new shim. outer bearing and spacer. subtract in thousandths of an inch from shim thickness figure.05 .004 . If fitting a new shim use thickest shim 2. 50. Fit driving flange. Thinner shim will increase pre-load. A.007 . 58. pre-load figure is 1. If a plus (+) figure. Remove pinion flange.175 .51 REAR AXLE AND FINAL DRIVE 48. 55. Remove the pinion flange.

Fit pinion drive flange to differential and secure with washer and nylon nut.068 .955 1.065 . Lubricate seal lips with axle oil.079 . Tighten to 130 Nm.830 1. FTC3869 FTC3870 FTC3871 FTC3872 FTC3873 FTC3874 FTC3875 FTC3876 FTC3877 FTC3878 FTC3879 FTC3880 FTC3881 FTC3882 FTC3883 FTC3884 FTC3885 FTC3886 FTC3887 FTC3888 FTC3889 FTC3890 FTC3891 FTC3892 FTC3893 FTC3894 FTC3895 FTC3896 Fitting Pinion Oil Seal 59.505 1.083 .080 2.059 . Coat centralizing peg with Loctite 601 or 638 and fit over pinion retaining nut in drive flange.069 .080 . Secure flange with washer and nylon nut.rear axle differential 60.755 1.071 .062 . Fit spacer and pinion drive flange to differential.075 . INCH .705 1.680 1. Coat outer diameter of seal with grease. 61.074 .855 1.066 . OVERHAUL 7 . 61.081 .060 .061 .805 1.005 1.067 . 62.580 1.REAR AXLE AND FINAL DRIVE PINION PRELOAD SHIMS PART No.480 Fit pinion drive flange .084 .780 1.078 .605 1.880 1.530 1.076 .063 .055 2.905 1. Fit seal lip side leading flush with end face of housing using tool LRT-51-001.655 1.105 2.030 2.front axle differential 60.730 1.155 2.064 .077 .130 2.058 MM 2. 62.082 .073 . Tighten to 130 Nm.980 1.930 1.630 1.070 .555 1. Fit pinion drive flange . Lubricate seal lips with axle oil.085 .072 .

Fit bearing adjusting nuts.51 REAR AXLE AND FINAL DRIVE CROWN WHEEL/PINION BACKLASH ADJUSTMENT 63. 8 OVERHAUL . Align locking finger with a slot. Lubricate bearings and gears. Recheck crown wheel/pinion backlash. DO NOT loosen right nut otherwise bearing preload will be affected. 71. 67.17 mm is met. Using service tool LRT-54-508 loosen left bearing adjuster nut. Evenly tighten bearing cap bolts to 90 Nm. 70. Place differential housing in pinion housing. 69. Mesh crown wheel to pinion. Tighten left nut until it contacts bearing. 65. 72. 66. 64. 68. Fit locking fingers and roll pins. Continue turning until a backlash of 0. Tighten right nut until crown wheel/pinion backlash is just removed. Fit bearing caps and partly tighten bolts.10 to 0.

Rear Hub Assembly 2. REAR HUB COMPONENTS 1. Overhaul 1. 8. Disc retaining bolt (five off). 4. Should more studs be unserviceable fit new hub with studs. 7. Brake disc. Remove rear hub assembly. Mark. Inner bearing. 15. 4. position of hub to brake disc. 3. Remove five nyloc nuts and withdraw ABS sensor ring. Remove grease seal and inner bearing from hub. 14. 7. Sensor ring retaining nut ABS. Sensor ring ABS.13. 10. Remove outer bearing.REAR AXLE AND FINAL DRIVE REAR HUB ASSEMBLY Service repair no . Lock washer. 3. Axle shaft joint washer. 5. WARNING: A maximum of two road wheel retaining studs can be renewed. 6.15. 13. Axle shaft. Grease seal. Lock nut. if applicable. 9. Spacing washer. 2. 5. Hub.61. 6. 11. OVERHAUL 9 . Remove five bolts and separate hub from brake disc. for reassembly. Axle shaft retaining bolt (five off). See Repair. Hub adjusting nut. 12. Remove inner and outer bearing tracks. Outer bearing.

Tighten to 9 Nm. Clean hub and fit inner and outer bearing tracks. See Repair.51 Refit REAR AXLE AND FINAL DRIVE 8. Pack hub outer bearing with grease and fit to hub. 14. 13. where applicable. Apply grease between seal lips. Rear Hub Assembly 9. If necessary. 10 OVERHAUL . With lip side leading fit a new seal flush with rear face of hub. line up reassembly marks. Fit sensor ring using new nyloc nuts. Using service tool LRT-54-003 seal replacer and drift. Assemble brake disc to the hub. Pack hub inner bearing with grease and fit to hub. Ensuring it is correctly fitted to avoid tooth run out. 11. Applying Loctite 270. renew sensor ring studs applying Loctite 270 to threads. fit and tighten retaining bolts to 73 Nm. 12. 10. Fit rear hub assembly.

Refit rear hub assembly. Rear Hub Assembly OVERHAUL 11 . 4. Rear axle shaft. Remove stub axle and joint washer. Fit rear axle shaft avoid damaging stub axle seal. Remove mudshield. Mudshield. Rear Hub Assembly 2. Fit new joint washer. Remove hub assembly.REAR AXLE AND FINAL DRIVE REAR STUB AXLE Service repair no . 8. 6. 3. Tighten to 65 Nm. STUB AXLE COMPONENTS 1. Overhaul 1. Using special tool LST 138 fit new oil seal lipside trailing so that seal is flush with rear face of stub axle. Stub axle to axle casing bolt. stub axle and mudshield with bolts. Refit 7. Lubricate seal and lip with EP90 oil. Axle case.15. 4. 2.64. 3. 5. 5. See Repair. Remove rear axle shaft from axle casing. Remove six bolts from stub axle to axle casing. Sensor ABS. Stub axle joint washer. See Repair. Remove and discard oil seal. Stub axle. 7.22. Renew rear stub axle oil seal 6. 9.

.................. SPECIFICATIONS.......... (bearings bedded in) ..................................... Nm REAR AXLE Pinion housing to axle case .................... 129 Lower link to axle ...... 11 Sensor ring to brake disc ABS ...............................................10 to 0.......... 0.......................................................................................................................................................................................... 41 Crown wheel to differential case ................ 73 * Stub axle rear to axle case .............17 mm REAR HUB Rear hub end float ......... 58 Differential bearing cap to pinion housing ......................... 65 * Brake disc to hub ....... Crown wheel run-out .......... 82 Disc shield to axle case ........................... 65 Brake caliper to axle case .......................................................................... Crown wheel/pinion backlash ..........................................................................REAR AXLE AND FINAL DRIVE AXLE DIFFERENTIAL DATA Pinion bearing pre-load: (new bearings) ........................................................................................................... 176 REAR HUB ABS VEHICLES Hub driving member to hub .................. 176 Pivot bracket ball joint to axle ... 47 Bevel pinion nut ................ TORQUE 1 ......................................................................................... 3 Nm 1............................................................. 9 * Apply loctite 270 prior to assembly..................10 mm 0................................................................................................................5 Nm 0.............................................................................................010 mm TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque...... 90 Differential drive flange to drive shaft ..........................................................................................

.......51 REAR AXLE AND FINAL DRIVE Torque values below cover all screws and bolts used............ 90 M14 .................................................................. 180 UNC / UNF 1/4 ............ TORQUE .................................... 9 5/16 ... 78 1/2 .. unless specified otherwise............................................................. 9 M8 ............................................................................ 45 M12 ............................................. 6 M6 ........................................................................................... 90 5/8 ................... 105 M16 ...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... METRIC Nm M5 ............................................................................................. 25 M10 ............................................................................................................................................................. 24 3/8 ........................................................... 39 7/16 .................................................................. 136 2 SPECIFICATIONS..............

REAR AXLE AND FINAL DRIVE AXLE DIFFERENTIAL LRT-51-003 18G1205 Flange holder tool LRT-54-504 18G1914 Universal setting block LRT-54-502 18G476 Pinion head bearing remover/replacer LRT-99-002 MS47 Press SERVICE TOOLS 1 .

51 REAR AXLE AND FINAL DRIVE LRT-51-001 LST106 Oil seal replacer LRT-54-505 RO262757A Extractor for pinion bearing races LRT-54-506 RO2627571 Replacer adapter pinion head bearing cup LRT-54-507 RO2627572 Adaptor pinion tail bearing cup replacer 2 SERVICE TOOLS .

REAR AXLE AND FINAL DRIVE LRT-54-508 RO530105 Wrench flange and carrier bearing nuts REAR HUB LRT-99-503 RO530106 Bracket for dial gauge and indicator LRT-54-001 LST550-5 Oil seal replacer non ABS LRT-99-003 18G134 Drift SERVICE TOOLS 3 .

51 REAR AXLE AND FINAL DRIVE LRT-54-002 RO606435A Hub nut wrench LRT-54-003 LST137 Hub oil seal replacer ABS LRT-54-004 LST138 Oil seal replacer ABS 4 SERVICE TOOLS .

The wheel hubs on all axles are supported by two taper bearings and driven by drive flanges which are splined to the one piece. swivel pin housing and wheel hubs are indiviudally lubricated and separated by oil seals 7 and 8 to prevent oil transfer across the axle when the vehicle is traversing steep inclines. Lubrication The differential. The top swivel pin also houses the ABS pickup (electrical connection) as shown in the main illustration. The wheel bearings are lubricated with grease and the swivel housing and differential with oil. The swivel housings ventilate through axle shaft oil seals 8 into the differential and the hub bearings vent via the oil seals into swivel housing.non ABS The front wheels are pivoted on tape roller bearings at the top (see insert) and bottom of the swivel housing. which is off set to the right of the vehicle centre line. The differential unit drives the front wheels via the axle shafts and constant velocity joints which are totally enclosed in the spherical and swivel housings. Front axle .FRONT AXLE AND FINAL DRIVE DESCRIPTION The welded steel front axle casing houses a separate spiral bevel type differential unit. DESCRIPTION AND OPERATION 1 .ABS The front wheels are pivoted on taper roller bearings 19 at the bottom of the swivel housing and a ’Rialco bush’ 25 at the top. The front axles fitted with ABS brakes or non ABS brakes are of the same construction except for different top swivel pins in the swivel housing and a sensor on the constant velocity joint. Front axle . Ventilation Ventilation of the differential is through a plastic pipe 2 which terminates at a high level in the vehicle on both ABS and non ABS axles. stub shaft/constant velocity joint. J5367.

seal and retainer Swivel housing Constant velocity shaft seal ABS pickup (electrical connection) ’Rialco’ bush ABS 2 DESCRIPTION AND OPERATION . thrust washer and nuts (2) Brake disc Drive flange Shim washer and circlip Dust cap 14. 13. 18. 7. 6. 17. 23. 22. 9. 8. 5. 20. 19. 24. 12. 21. Constant velocity joint/shaft Thrust collar for CV joint Roller bearing Spacer Circlip Bottom swivel taper bearing Top and bottom swivel pins Spherical housing. 3. 25. 2. 11. 4. 10. Axle casing Ventilation pipe Axle shaft Wheel studs and hub Stub axle Wheel bearings (2) Inner and outer hub seals Axle shaft seal Hub lock plate. 16.54 FRONT AXLE AND FINAL DRIVE Front axle 1. 15.

Swivel oil should be checked for signs of grease leaking from the hub bearings and the hub grease should not contain oil. Check that the axle ventilation system is clear. For example. When investigating leaks or checking oil levels. it is essential that all the lubrication is drained from any housing with a high level and that the other levels are checked. Do not assume that a high oil level is due to over filling or. give a false impression that the housing has been overfilled with oil.Oil leaks An external leak of lubrication can be caused by a faulty internal seal. water may contaminate the lubricants and when checked. as a blockage can cause internal pressure to force oil past the seals. that a low level is because of an external leak. oil may leak across the axle leaving one swivel with a high level and the other swivel and differential lacking lubrication. If the vehicle is driven in deep water with defective oil seals. FAULT DIAGNOSIS 1 . See ’Description and Operation’ for illustrations of oil seal locations. if the seals which separate the differential from the swivel housings are faulty and the vehicle is operating or parked on an embankment.FRONT AXLE AND FINAL DRIVE FAULT DIAGNOSIS Complaint .

25. 5. See Specifications. REPAIR 1 . Remove nuts and washers securing shock absorbers to axle. Refit bolts to prevent oil leakage. 12. supporting left side of axle. 10. 6.54. Anti-Roll[Sway] Bar Ball Joint Links 17. Tighten propeller shaft bolts to 47 Nm. 8. Tighten drag link to hub arm to 40 Nm. Remove bolts from brake calipers and tie to one side. tie propeller shaft to one side. Lower axle assembly and remove road springs. 23. 9. Disconnect steering damper from track rod. 15. if applicable. torque. 26. Remove ABS sensor. Remove four nuts and bolts. 1. Position axle under vehicle. Tighten track rod end to 40 Nm. 22. Mark for reassembly drive shaft flanges. Reverse removal procedure. Tighten radius arms to axle bolts to 197 Nm. 16. Remove two nuts and bolts securing panhard rod to axle bracket. 2. 7. 11. Support axle weight with hydraulic jack. Remove road wheels. Remove bolts securing brake hose brackets. 4. Torque Values 24. Tighten radius arms to chassis side member nuts to 197 Nm.01 Remove WARNING: Remove and refit of axle requires a further two persons to steady axle when lowering or repositioning axle. Tighten upper swivel pin bolts.15. Using a extractor remove track rod links from swivel pin arms. Disconnect anti-roll[sway] bar link. 21.FRONT AXLE AND FINAL DRIVE FRONT AXLE ASSEMBLY Service repair no . Lift rod clear of axle. Refit 18. Remove axle assembly. 14. Fit new split [cotter] pin. Repair. Support chassis front. Disconnect drag link from swivel pin housing arm. Remove four nuts and bolts securing radius arms to axle bracket. 3. Tighten panhard rod to axle bracket to 88 Nm. See FRONT SUSPENSION. 13. 19. 20. Remove radius arms. Remove radius arms to chassis frame nuts.

15 mm. See Front Hub Assembly Disc reclamation 8. 3. If necessary reposition disc. Apply Loctite 270 to disc bolts. Remove 1. Remove front hub assembly. 6.54 FRONT AXLE AND FINAL DRIVE FRONT BRAKE DISCS Service repair no . Locate disc to hub. Refit 4. Tap disc to separate from hub.10. 2 REPAIR . Machine equal amount off each face. Tighten to 73 Nm. This dimension may be reduced to minimum thickness of 12 mm. Check disc thickness. Check total disc runout with a dial indicator. 5. Fit hub assembly.70. Remove five hub to disc bolts. this must not exceed 0. See Front Hub Assembly 2. 7.10.

jack up vehicle and lower onto axle stands and remove road wheel.FRONT AXLE AND FINAL DRIVE FRONT HUB ASSEMBLY Service repair no . Loosen front wheel nuts. Lock washer. 5. 4. Grease seal. 2. 10. Hub adjusting nut. Bend back lock washer tabs. Remove 1.60. 7. Remove hub and brake disc assembly complete with bearings. 8. 16. REPAIR 3 . Remove five bolts and withdraw driving member and joint washer. Spacing washer. 4. 6. 10. Drive shaft shim.01. Drive member. Remove circlip and drive shaft shim from driveshaft. 3. 14. 13. HUB COMPONENTS 1. Dust cap. Drive member joint washer. Remove locknut and lock washer. 15. 8.25. 12. Hub. Lever off dust cap. 2. Outer bearing. 7. 9. Drive member retaining bolt. Release brake hose clips and remove brake caliper. 11. Lock nut. Inner bearing. Remove spacing washer. 3. 9. Remove hub adjusting nut. 6. Secure to one side. Brake disc Disc retaining bolt. 5. Drive shaft circlip.

Move drive shaft in and out noting dial gauge reading. 12. Bleed brake system. Tighten to 4 Nm. 18. See BRAKES. Fit hub adjusting nut. Tighten to 65 Nm. Fit locknut. Clean stub axle and drive shaft and fit hub assembly to axle. Fit a new lock washer. Brake System Bleed 26.010mm 15. Fit road wheel. 22. Back off adjusting nut 90°. Tighten to 61 Nm. 4 REPAIR . Fit spacing washer. Fit a suitable bolt to threaded end of drive shaft. remove axle stands and tighten road wheel nuts to 126 Nm. End play should be between 0.25 mm. Fit a new joint washer to driving member and fit member to hub and secure with five bolts. 14. Tighten to 61 Nm. 17. If end play requires adjustment.54 Refit FRONT AXLE AND FINAL DRIVE 11. Tab over lock washer to secure adjusting nut and locknut. This will give the required hub end float of 0. remove circlip. 23. 27. 13. fit circlip and dust cap. 21. 19. To check drive shaft end play mount a dial gauge using bracket LRT-99-503 and rest pin in a loaded condition on end of drive shaft. measure shim thickness and fit an appropriate shim to give required end-play. Tighten to 82 Nm. 20.08 to 0. Operate footbrake to locate brake pads before taking vehicle on road. Repair. 24. 16. 25. Fit original drive shaft shim and secure with a circlip. Remove bolt from drive shaft. Fit brake caliper.

1. 4. Drive member joint washer. Lock washer. See Repair. 5. Disc retaining bolt. relationship between hub and brake disc. if original hub is to be refitted. Drive shaft circlip. Dust cap. 15. Hub adjusting nut. 16. for reassembly. 4. 7. Drift out grease seal and inner bearing from hub and discard seal. Outer bearing.10. Axle Differential Assembly 5. Inner bearing. 11. 8. Drive shaft shim. Drift out inner and outer bearing tracks. Hub. 2. 10. Grease seal. HUB COMPONENTS 8. See REAR AXLE AND FINAL DRIVE. 3. OVERHAUL 1 . Overhaul. Overhaul The front and rear differentials are the same. FRONT HUB Service repair no . Remove outer bearing. Remove front hub assembly. Drive member.26.07. Overhaul 1. 3. 14.54. 9. Remove five bolts and separate hub from brake disc. Front Hub Assembly 2.14. Clean hub and drift in inner and outer bearing tracks. Brake disc. 6. 13. When overhauling front differential. Pack hub inner bearing with recommended grease and fit to hub. Spacing washer. Drive member retaining bolt. 6.60. 7.FRONT AXLE AND FINAL DRIVE FRONT DIFFERENTIAL Service repair no . Mark. 12. Lock nut.

Fit front hub assembly. Apply grease between seal lips.54 FRONT AXLE AND FINAL DRIVE 9. 11. With lip side leading fit new seal to hub using special tool LST 137 seal replacer and drift 18G 134. Front Hub Assembly 2 OVERHAUL . apllying Loctite 270. fit five retaining bolts. Fit brake disc to hub. Tighten to 73 Nm. 10. 12. lining up to marks made during dismantling. Drive in seal flush with rear face of hub. Grease and fit outer bearing to hub. See Repair.

FRONT AXLE AND FINAL DRIVE FRONT STUB AXLE.60. 6. axle shaft and constant velocity joint. 8. Remove six bolts retaining stub axle to swivel housing. 1. 11. Drain swivel pin housing and refit plug. Hold axle shaft firmly in a soft jawed vice. Remove circlip and collar from axle shaft. Remove front hub assembly. 3. 4. Mark positions of constant velocity joint. inner and outer race and cage for reassembly. Remove constant velocity joint from axle shaft 7. Pull out axle shaft and constant velocity joint from axle casing. Using a soft mallet drive constant velocity joint from shaft. 5. OVERHAUL 3 . Front Hub Assembly 2.15. 9. Constant velocity joint 10. Remove stub axle and joint washer. Swivel cage and inner race to remove balls. Remove stub axle.43. CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING NON ABS Service repair no . See Repair. Remove mud shield.

13. Renew stub axle. Press fit a new thrust ring onto stub axle. Fit collar and a new circlip. 19.thrust ring. oil seal and bearing 16.54 FRONT AXLE AND FINAL DRIVE 12. 15. Lubricate with a recommended oil during assembly. Engage constant velocity joint on axle shaft splines and using a soft mallet. 20. and flush with end face of stub axle. Repeat instruction for removal of oil seal. Using special tool LRT-54-005. 21. Drill and chisel off thrust ring taking care to avoid damaging stub axle. 18. Renew if worn or damaged. Ensure lip of tool locates behind bearing to to drive it out. 17. Fit constant velocity joint to axle 14. fit bearing with its part number visible when fitted.64mm. cage balls and bearing surfaces for damage and excessive wear. 4 OVERHAUL . Maximum acceptable end-float on assembled joint 0. drive joint in fully. Remove bearing and oil seal using special tool LRT-37-004 and slide hammer LRT-99-004. Examine all components in particular inner and outer track. Lubricate seal and lip with EP90 oil and with cavity side leading press in a new oil seal using special tool LRT-54-004.

Tighten to 73 Nm. 40. Remove seven bolts retaining swivel bearing housing to axle case. 43. 34. 28. Tighten to 78 Nm bend over lock tabs. 27. Remove two bolts retainin brake hose bracket and top swivel pin. 38. Remove bolts securing oil seal retaining plate and joint washer. 42. 25. NOTE: Use upper bearing opening to gain access to lower bearing track. 33. Remove top bearing track from swivel bearing housing. 32. 44. Apply Loctite 270 or equivalent to lower swivel pin bolts. Grease and fit upper and lower swivel pin taper roller bearings. 35. Release assembly from swivel pin housing. 37. Coat joint washer both sides with sealing compound and position on lower swivel pin. Remove brake disc shield bracket. 23. Swivel bearing housing 29. Remove lower bearing track from swivel bearing housing. Coat swivel bearing housing to axle casing bolts with Loctite 270 or equivalent. Remove inner oil seal from back of housing.FRONT AXLE AND FINAL DRIVE Swivel pin housing 22. 31. 30. Position swivel pin housing over swivel bearing housing. Remove bracket. NOTE: Removal of oil seal and retaining plate is achieved when swivel bearing housing is removed. renew housing. CAUTION: Ensure bearing tracks are fitted square or damage could occur. Loosely fit top swivel pin plus existing shims and brake hose bracket to swivel pin housing. If worn. Loosely fit brake shield bracket plus lower swivel pin with lug outboard to swivel pin housing. tap lug to remove lower swivel pin and joint washer. 45. 39. Remove swivel pin housing while retrieving lower and upper bearings. Fit upper and lower bearing tracks into swivel bearing housing. Coat both sides of joint washer with a sealing compound. Tighten top swivel pin bolts to 78 Nm. Remove two bolts. pitted or damaged. Grease seal lips. top swivel pin and shims. Fit swivel pin housing 36. 41. joint washer and oil seal over axle flange ready for assembly. retaining lower swivel pin to housing. Position swivel bearing housing to axle mating face. 46. OVERHAUL 5 . NOTE: Use lower bearing opening to gain access to upper bearing track. Fit swivel bearing housing to axle flange with seven bolts. 26. 24. With seal lips trailing. fit swivel housing inner oil seal into rear of housing. Place retaining plate.

and bend over lock tabs.46 kg. 1. 4. 3. once initial inertia has been overcome. Loosely fit lock stop bolt and nut. 55. 9. 58. Apply recommended grease between lips of swivel oil seal. Attach a spring balance to ball joint bore and pull balance to determine effort required to turn swivel pin housing.16 to 1. Tighten to 40 Nm. Fit oil seal. 47. Apply a recommended grease between lips of swivel housing oil seal.54 FRONT AXLE AND FINAL DRIVE Swivel assembly components Check and adjust preload on bearings NOTE: Swivel housing oil seal and axle should not be fitted. When setting is correct remove top swivel bolts. 57. 6. 7. Swivel pin housing Top swivel pin and brake hose bracket Upper and lower swivel pin bearings Shim Retaining plate and washer Oil seal Joint washer Swivel bearing housing Joint washer Lower swivel pin Mudshield bracket Swivel housing inner oil seal 48. joint washer and retaining plate with seven bolts and spring washers to 11 Nm. 52. Fit brake disc shield. 2. 6 OVERHAUL . 10. 8. 54. Tighten to 11 Nm. Adjust by removing or adding shims to top swivel pin. 51. should be 1. Fit tie rod and drag link and secure with new cotter pins. Secure oil seal with retaining plate and securing bolts. Fit track-rod and drag link and secure with new cotter pins. apply Loctite 270 or equivalent. 56. Loosely fit lock stop bolt for later adjustment. 11. 12. Fit brake disc shield. 53. 50. Resistance. Refit to 78 Nm. 49. 5.

62. Fit brake jump hoses to brake jump hose bracket. See SECTION 10. See Repair. Coat threads of stub axle bolts with Loctite 270. 64. Front Hub Assembly 2. 4. 6. Set steering lock stop bolts to provide a clearance of 20mm. 3. Steering Lock Stops FRONT STUB AXLE. Fit stub axle with flat at 12 o’clock position. See Repair. See STEERING. Remove stub axle. push assembly in fully. Under Vehicle Maintenance 67.FRONT AXLE AND FINAL DRIVE Fit driveshaft and stub axle 59. Maintenance. Remove six bolts retaining stub axle to swivel housing. OVERHAUL 7 . Remove front hub assembly. CAUTION: Take care not to damage axle shaft oil seals. 66. Drain swivel pin housing and refit plug. Check swivel pin housing oil drain plug is fitted. Front Hub Assembly 65. CAUTION: Ensure that constant velocity joint bearing journal is butted against thrust ring on stub axle. Insert axle shaft. Place a new joint washer in position on swivelpin housing to stub axle mating face. Place mud shield in position and secure stub axle to swivel pin housing with six bolts and tighten evenly to 65 Nm. axle shaft and constant velocity joint. 61. Remove stub axle and joint washer. 1. 5. and when differential splines are engaged.15. with new oil.60. Before stub axle is secured. 60. Remove mud shield. Fill swivel assembly to correct level. Adjustment. Pull out axle shaft and constant velocity joint from axle casing. Fit front hub complete assembly. CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING ABS Service repair no .43. 63.

drive joint in fully. Examine all components in particular inner and outer track. Using a soft mallet drive constant velocity joint from shaft. Remove circlip and collar from axle shaft. Maximum acceptable end-float on assembled joint 0. 8. 18. 8 OVERHAUL . Ensure lip of tool locates behind bearing to to drive it out. Engage constant velocity joint on axle shaft splines and using a soft mallet.54 FRONT AXLE AND FINAL DRIVE Remove constant velocity joint from axle shaft 7.64mm. 11. 17. 12. Fit collar and a new circlip. Mark positions of constant velocity joint.thrust ring. Drill and chisel off thrust ring taking care to avoid damaging stub axle. Renew if worn or damaged. Swivel cage and inner race to remove balls. Constant velocity joint 10. Remove bearing and oil seal using special tool LRT-37-004 and slide hammer LRT-99-004. Lubricate with a recommended oil during assembly. oil seal and bearing 16. Repeat instruction for removal of oil seal. cage balls and bearing surfaces for damage and excessive wear. 13. 15. 9. Renew stub axle. Hold axle shaft firmly in a soft jawed vice. inner and outer race and cage for reassembly. Fit constant velocity joint to axle 14.

FRONT AXLE AND FINAL DRIVE 19. Fit a new bush and bush housing. Remove top swivel pin retaining bolts complete with brake jump hose bracket. 30. Swivel pin bearing housing 33. fit bearing with its part number visible when fitted. Remove ABS brake sensor. 23. and flush with end face of stub axle. Prise seal from swivel pin housing. Withdraw lower swivel pin and joint washer by tapping protruding lug. Remove seven bolts securing swivel pin bearing housing to axle case. 31. 35. as shown. If worn. 38. 20. Ensure relieved lip of bush housing faces towards rear. Remove and discard oil seal and joint washer. Swivel pin housing assembly 22. 24. 36. 25. 37. Remove brake disc shield bracket. Remove top swivel pin and shims. Remove six bolts securing oil seal and retaining plate to swivel pin housing. 28. 21. Remove swivel pin housing while retrieving lower taper bearing. 27. Disconnect drag-link ball joint. Fit a new lower swivel pin bearing track. 39. Remove top swivel pin bush housing assembly. OVERHAUL 9 . 29. Lubricate seal and lip with EP90 oil and with cavity side leading press in a new oil seal using special tool LRT-54-004. Press fit a new thrust ring onto stub axle. Disconnect track-rod end ball joint from housing. renew swivel pin bearing housing. pitted or damaged. Disconnect jump hoses from brake jump hose bracket. Remove lower swivel pin bearing track. 32. Using special tool LRT-54-005. Remove two screws securing brake damper/shield bracket and lower swivel pin to housing. NOTE: Oil seal and retaining plate cannot be removed until swivel pin bearing housing is removed. 26. 34. Discard two thrust washers and bearing.

58. Fit a new sensor bush and new oil seal. 49. With seal lips trailing press axle shaft oil seal flush into rear of housing. and reading from centre of swivel pin.30 mm. 45. The torque required to turn swivel assembly from lock to lock to be 2. lip side leading to top swivel pin. 40. Tighten to 72Nm. Coat threads of top swivel pin bolts with Loctite 542.0 to 2. Lubricate with a recommended oil and fit top swivel pin with existing shims. 56. 41. Fit track-rod and drag link and secure with new cotter pins. Starting with top fixing dowel bolt. with a torque wrench and extension as shown.54 FRONT AXLE AND FINAL DRIVE 50. 46. 54. Tighten top swivel pin and brake jump hose bracket securing bolts to 65 Nm.8 Nm. without swivel housing oil seal and axle fitted. Check and adjust preload on bearings 52. Ensure they are in correct assembly order. Place swivel pin housing in position over swivel pin bearing housing. 53. Fit bolts and jump hose bracket (do not tighten).25 to 0. The preload on bearings to be 0. 51. 43. Fit new thrust washers and bearing into top swivel pin bush. 47. To take a reading use special tool LRT-57-024 torque test adaptor. Using a new joint washer. Hang swivel pin bearing housing oil seal and retainer plate over back of housing. Fit a new joint washer and secure swivel pin bearing housing to axle. Adjust by removing or adding shims as necessary. Grease and fit lower swivel pin bearing to bearing housing. 48. 10 OVERHAUL . fit lower swivel pin with lip outboard. Tighten to 11Nm. Grease lips. Fit brake disc shield. Loosely fit lock stop bolt for later adjustment. 42. Do not secure with screws at this stage. together with damper and shield bracket. 57. Apply a recommended grease between lips of swivel housing oil seal. Secure oil seal with retaining plate and securing bolts. Tighten to 25 Nm. 55. Coat threads of lower swivel pin screws with Loctite 270 and fit. Fit swivel pin housing 44.

Fit brake jump hoses to brake jump hose bracket. Coat threads of stub axle bolts with Loctite 270. 60. Fit front hub complete assembly. Place a new joint washer in position on swivelpin housing to stub axle mating face. Repair. Fill swivel assembly to correct level. Steering Lock Stops 68. push assembly in fully. Sensors . CAUTION: Take care not to damage axle shaft oil seals. Front Hub Assembly 65. Check swivel pin housing oil drain plug is fitted. 62. Set steering lock stop bolts to provide a clearance of 20mm. 66.FRONT AXLE AND FINAL DRIVE Fit driveshaft and stub axle 59. with new oil. CAUTION: Ensure that constant velocity joint bearing journal is butted against thrust ring on stub axle. Adjustment. 63. Before stub axle is secured. Under Vehicle Maintenance 67. See Repair. 61. See BRAKES. 64. Place mud shield in position and secure stub axle to swivel pin housing with six bolts and tighten evenly to 65 Nm. Maintenance.Front OVERHAUL 11 . See STEERING. Fit stub axle with flat at 12 o’clock position. Fit ABS brake sensor. See SECTION 10. Insert axle shaft. and when differential splines are engaged.

Damper and shield bracket. Swivel pin housing. Shim. Joint washer. Swivel pin bearing housing. 23. 19. ABS. Bush and housing. 21. 4. ABS. 12. Thrust washer. Bearing. 3. ABS. Mud shield. 10. Constant velocity joint. 18. 9. 13. Top swivel pin and jump hose bracket. Brake disc shield. Thrust bearing. 17. 2. 27. 20. 8. Lower swivel pin bearing (and upper bearing non ABS). Joint washer.54 FRONT AXLE AND FINAL DRIVE FRONT HUB AND SWIVEL COMPONENTS 1. Circlip. 16. Bush. 12 OVERHAUL . Inner driveshaft. 25. 22. ABS. 11. 5. Sensor bush. Stub axle. Joint washer. Oil seal retaining plate. ABS. 15. 6. Oil seal. 26. 14. Oil seal. Lower swivel pin. 24. Oil seal. 7. Brake caliper.

......................... 73 * Pinion housing to axle case .................................................................................................................................................................................................................................................................................................... 78 * Lower swivel pin to swivel pin housing ABS ....................... 190 NOTE: * These bolts to be coated with Loctite 270 prior to assembly.............................. 65 * Brake caliper to swivel pin housing ................................................................... 190 Radius arm to chassis side member ................................................................................. 82 Upper swivel pin to swivel pin housing ........................... 78 * Upper swivel pin to swivel pin housing ABS .................. SPECIFICATIONS............................................. 47 Mudshield to bracket lower swivel pin .................................. 25 * Oil seal retainer to swivel pin housing ..................................FRONT AXLE AND FINAL DRIVE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque.............................................................................................. Nm FRONT AXLE Hub driving member to hub ...................... 11 Swivel bearing housing to axle case ............... 88 Radius arm to axle ................................... 90 Differential drive flange to drive shaft ........ 58 Differential bearing cap to pinion housing ............................... 40 Panhard rod to axle bracket ................................ 130 Draglink to hub arm ........................................................ 9 Bevel pinion nut ............................................................................................................................... 65 Lower swivel pin to swivel pin housing ......................................... 41 Crown wheel to differential housing ................................. 73 Stub axle to swivel pin housing ... TORQUE 1 ............. 65 * Brake disc to hub ................................................. 11 Disc shield to bracket lower ABS .............................................................................................................

..................................................................... 25 M10 .................................... TORQUE ................................................................................... 9 M8 ......................46Kg 2 SPECIFICATIONS.....Resistance to turn .....................................................................010 mm Drive shaft end play .................................................................................................................................................................. Nm Non ABS vehicles .......................................................................... 2.............25 mm Swivel pin bearing preload ABS vehicles ............................... 90 5/8 ........................... 78 1/2 ....... 39 7/16 ...................... unless specified otherwise............... METRIC Nm M5 ..................................... 105 M16 ........................................................................................... 90 M14 ..................................................................................................................................................................................................... to 3.................................................................................... 24 3/8 ..............16 to 1...................... 45 M12 ...........Torque to turn ..................................................................... 9 5/16 ...... 1........................ 6 M6 .................................................................................................. 0...................................... 0....................................... 136 FRONT HUB AND SWIVEL DATA Front hub Front hub end float ........ 180 UNC / UNF 1/4 ...08 to 0....54 FRONT AXLE AND FINAL DRIVE Torque values below cover all screws and bolts used....................................................................................

FRONT AXLE AND FINAL DRIVE FRONT HUB LRT-54-001 LST550-5 Oil seal replacer non ABS LRT-99-003 18G134 Drift LRT-54-002 RO606435A Hub nut wrench LRT-54-003 LST137 Hub oil seal replacer ABS SERVICE TOOLS 1 .

54 FRONT AXLE AND FINAL DRIVE LRT-99-503 RO530106 Dial gauge bracket LRT-37-004 18G284AAH Extractor ABS LRT-54-005 LST132 Bearing installer ABS LRT-54-004 LST133 Seal installer ABS 2 SERVICE TOOLS .

FRONT AXLE AND FINAL DRIVE LRT-99-004 MS284 Impulse extractor LRT-570-024 LST141 Torque test adaptor ABS SERVICE TOOLS 3 .

Power steering system The power steering system comprises a hydraulic pump which is belt driven from the engine and supplied with fluid from a reservoir that also acts as a cooler. 5. 6. The rotary valve which is operated by movement of the steering wheel. The steering box houses a self neutralizing rotary valve which is part of the worm/valve assy and a hydraulic piston/rack to assist the mechanical operation. An hydraulic damper absorbs shocks in the steering. 8. an air bag located in the centre of the steering wheel.STEERING DESCRIPTION The power assisted steering system incorporates a compression joint in the lower shaft. is also designed to prevent frontal impact moving the column toward the driver. designed to collapse on impact and for certain countries. 4. The steering box is located behind the first cross member of the chassis and is connected to the road wheels by the drag link and track rod. The mis-alignment of the upper steering column with the steering box and the inclusion of two universal joints and a compression joint in the lower shaft. Hydraulic pump Fluid reservoir Steering box Upper column Universal joints Lower shaft Compression joint Drag link DESCRIPTION AND OPERATION 1 . directs fluid pressure to the appropriate side of the hydraulic piston/rack to provide assistance. 2. 7. caused by road wheel deflections when operating on rough terrain. Power steering system 1. 3.

57 STEERING 2 DESCRIPTION AND OPERATION .

22. 18. 3. 15. 20. 9. 12. 11. 6. 14. Lower shroud Column lock/ignition Air bag mounting bracket (if fitted) Air bag module Steering pad (non-airbag) Lower shaft Rubber coupling Compression joint Universal joint Universal joint bolt DESCRIPTION AND OPERATION 3 . 4.STEERING Steering column components 1. 17. 21. 16. 2. 8. 19. 5. 7. Upper shroud Column harness Cruise control switch (if fitted) Steering wheel and nut Rotary coupler Column switch Shear bolts Switch saddle Upper steering column Universal joint Universal joint bolt Steering column lock assembly 13. 10.

washer and backup seal Circlip and dust cover 4 DESCRIPTION AND OPERATION . 16. 7. 3. 12. ’Teflon’ and rubber seal for piston End cover seal and snap ring Adjustment components for piston/rack Hydraulic pipe Bleed screw Sector shaft adjustment lock nut with seal Cover plate bolts (4) Cover plate seal Seal.57 STEERING Power steering box components 1. circlip and dirt excluder 11. 9. 20. 18. 10. 15. locknut and seal Worm shaft pressure seal. 5. 13. 17. 2. 19. Housing complete with sector shaft bearings Cover plate complete with bearing Sector shaft Hydraulic piston/rack Worm/valve and torsion bar assembly Shims for centralizing worm/valve Ball race (2) ’Teflon’ seals for valve sleeve (3) Bearing adjuster. 6. 4. 8. 14.

The input shaft is attached to the steering wheel via the steering shaft and steering column and incorporates valve ports in its outer diameter to align with those in the sleeve. Any excess fluid flow from the pump returns to the reservoir via B. No demand for assistance (Valve at neutral) When there is no demand for assistance as seen in RR3620M. The torsion bar which is secured to the worm and input shaft with pins (6) at each end (later models use one pin at input shaft end). The valve sleeve is retained inside the worm by the trim screw (3). and incorporates valve ports in its inner bore.STEERING Rotary valve operation The rotary valve assembly seen in RR3620M comprises the worm (1). holds the valve ports in neutral alignment when there is no demand for assistance. Rotary valve at neutral DESCRIPTION AND OPERATION 5 . allowing equal pump pressure A to both sides of the piston/rack (9). the input shaft (4) and the torsion bar (5). the torsion bar holds the input shaft and sleeve valve ports in neutral relationship to one another. the valve sleeve (2).

causing the temperature of the fluid and the pump to rise rapidly. When demanding maximum assistance. ensures steering control is maintained sufficient to allow the vehicle to be recovered. To avoid excessive fluid temperatures which could damage the oil seals. In the unlikely event of mechanical failure of the torsion bar.57 STEERING Demand for assistance (Valve misaligned) When the steering wheel and input shaft is turned. any excessive fluid output from the pump due to high pump speed. will circulate through the regulator valve located in the pump unit. steering resistance transmitted to the worm causes the torsion bar to be twisted and the valve ports to be misaligned for a right or left turn. will the torsion bar return the valve to neutral. allowing the fluid to circulate through the reservoir where it is cooled. The misalignment of the valve ports directs all fluid pressure A to one side of the piston only and allows displaced fluid B on the other side. the steering must not be held on full lock for more that 30 seconds in one minute. Rotary valve misaligned 6 DESCRIPTION AND OPERATION . a coarse splined connection (7) between the input shaft and worm. Only when the steering wheel and the demand for assistance is released.

as seen in RR3569M. the rotary valve effectively stops all fluid flow through the steering box. The ball plug item 5 is pressed into the valve 4 during manufacture and determines the opening pressure of pressure relief valve 3. No flow. 6. No demand for assistance High flow through box Low pressure With no demand for assistance as illustrated in RR3568M the rotary valve in the steering box acts as a pressure relief valve.STEERING Pump and regulator valve operation The pump which is belt driven from the engine is an eccentric roller type and also houses the pressure regulator and flow control valve. which in turn allows pump output A to escape directly into the pump inlet B. the system reverts to the condition seen in RR3568M and the road wheels are returned to the straight ahead position by the mechanical steering geometry. No demand for assistance 1. The fall in pressure in the flow control spring chamber. In the event of any hydraulic failure steering control though heavy. Reservoir Pump Pressure control ball valve and spring Flow control valve and spring Press fit plug (ball bearing) Restrictor Assistance demanded As soon as the steering wheel is released after making a turn. at a pre-determined pressure the relief valve 3 will open and allow the pressure to escape. thus causing an increase in pressure A. DESCRIPTION AND OPERATION 7 . allows the flow control valve to move to the right. allowing fluid A to flow freely through the steering box and back to the reservoir and pump inlet B. The pressure is controlled by a spring loaded ball valve 3 which is housed inside the flow control valve piston 4. 4. 2. will be maintained through the mechanical components in the steering box. 5. 3.High pressure When the steering is turned. This increase in pressure is felt in the flow control valve spring chamber where. through box .

Fill/bleed sytem 2. See Power Steering System .9 V8i If Tdi See ENGINE TUNING DATA. Insufficient pressure in the system is usually caused by low fluid level or PAS pump drive belt slip.Test 6.continue 3. or one of the following: PAS system leaks.go to 5.end NO .9 See ENGINE TUNING DATA. Is drive belt tension correct? YES .end NO . worn components in PAS pump or box. NOTE: 1. See ENGINE. Is correct pressure achieved? YES .Mpi . Is correct pressure obtained? YES .retension. Excessive pressure in the system is almost always caused by a faulty relief valve in the PAS pump. Engine 3. Is problem a leak? YES . Bypass steering box using adaptor tap LRT-57-001 10. Engine . Drive Belt 4. See Power Steering Fluid Leaks NO . NO . Information.go to 3.Go to 8.0 Litre 8. Information. NOTE: 2. Is fluid level correct? YES . Carry out pressure test at idle and 1000 rev/min. NO . Is problem resolved? YES . 7.continue 5.Diagnose.defective steering box NO .Correct idle speed If 3. Is idle speed correct? YES . 300 Tdi Engine If Mpi See ENGINE TUNING DATA. NO . Is problem resolved? YES .2. leak at piston in steering box. 9. faulty PAS pump relief valve.steering box defective Not at any speed go to 9. Information. fault in steering box valve and worm assembly. Not at idle go to 7. FAULT DIAGNOSIS 1 .go to 9. Repair.STEERING INSUFFICIENT POWER ASSISTANCE 1.defective steering pump CAUTION: Do not hold steering wheel on full lock for more than 30 seconds in any one minute to avoid overheating fluid and possibly damaging seals.

Pressure gauge LRT-57-005. C. E. 9. Check and maintain maximum fluid level of reservoir. F. If pressures differ to those given a fault exists. Some fault conditions of hydraulic pump may obtain pressures up to 105 kgf/cm2. Thread adaptor LRT-57-022. turn steering wheel gradually while reading pressure gauge. take care not to overload pressure gauge. Assemble test equipment and fit to vehicle. steering box to pump. 12. D. Steering box.000 rev/min. Fit a new pump. as shown in RR3959M. If low pressure or a substantial imbalance exists. Steering wheel held on full lock and engine idling. Pressure should read below 7 kgf/cm2. Test adaptor LRT-57-001. Thread adaptor LRT-57-004. fault is in steering box valve and worm assembly.57 STEERING POWER STEERING SYSTEM . When testing. Release steering wheel and with engine idling. 3. B. Examine power steering units and connections for leaks. 70 to 77 kgf/cm2. Check steering pump drive belt tension. 5. 7. Hose LRT-57-030. 14. Drive Belt 6. With system in good condition. Open tap of adaptor.TEST NOTE: If steering lacks power assistance. 13. Procedure 1. pump is faulty. Existing hose. pressures should be: (A) (B) Steering wheel held on full lock and engine running at 1. 2 FAULT DIAGNOSIS . If gauge does not register specified pressure. 8. 2. The maximum power steering system pressure is 77 kgf/cm2. 10. CAUTION: Do not maintain this pressure for more than 30 seconds in any one minute to avoid overheating fluid and possibly damaging seals. This gauge is able to measure 140 kgf/cm2. To determine if fault is steering box or pump. 11. Close adaptor tap for a maximum five seconds. A hydraulic pressure gauge and test adaptor is used to test power steering system. G. Repair. H. 4. See ENGINE. Use fault diagnosis chart to assist in tracing faults. A. 28 kgf/cm2. Pressure on gauge is same pressure being exerted upon steering wheel. Bleed system. bleed system and repeat test. Check pressure of hydraulic pump before fitting new components. All leaks must be rectified before attempting to test the system. Steering pump. Checks should be carried out on both full lock positions.

as well as reducing the effort required to manoeuvre the vehicle when parking. Constant Velocity Joint and Swivel Pin Housing ABS FAULT DIAGNOSIS 3 . the road wheels are often deflected by ruts and boulders causing the steering wheel to turn left and right. This phenomenon is known as ’steering kickback’. Inspect damper for casing damage or leaks. Overhaul. 4. The damper. Clamp one end of the damper horizontally in a vice using soft jaws. See Repair. 2. a hydraulic damper is fitted in the steering linkage between the track rod and the differential casing. Front Stub Axle. When operating the vehicle off road. Steering damper check Check the condition operation of the hydraulic steering damper as follows: Check procedure 1.Steering excessively light/sensitive and freeplay at steering wheel. also helps to dampen any deflections of the road wheels. NO Continue. being transmitted back to the steering wheel. 3. fit a new steering damper STEERING FAULTS Symptom:Excessive kickback through steering wheel . which offers the same resistance in extension and compression. Check the resistance of the axle swivels. Steering Damper YES Continue. If it is felt that the unit is outside acceptable limits. NO Suspect axle swivel resistance. is sealed for life. Radius Arm NOTE: When replacing suspension bushes ALL bushes and fixings must be replaced. 2. Is the steering damper in good working order? See Steering Damper NO Renew unit. To subdue the effects of ’steering kickback’. Front Stub Axle. Is the steering exceptionally light/sensitive when driven on good road surface? YES See fault symptom . Constant Velocity Joint and Swivel Pin Housing Non ABS See FRONT AXLE AND FINAL DRIVE. Compress and extend the unit by hand. See FRONT AXLE AND FINAL DRIVE. 1.when driven on rough terrain. 3.STEERING STEERING DAMPER The power steering system. Resistance should be equal in both directions. Repair. Is there any looseness or free play in the steering ball joints and linkage? YES See Steering Linkage Inspect NO Continue. 5. Is there any looseness or worn bushes in front suspension? YES See FRONT SUSPENSION. Overhaul.

Power Steering Box YES . Constant Velocity Joint and Swivel Pin Housing ABS YES . Power steering Pump If oil seal leaks persist after renewing the pump.See fault symptom Insufficient assistance.See Overhaul. See Power Steering System . Power Steering System .Check steering ball joints for seizure and axle swivels lubrication and resistance. Is the steering column stiff to turn when disconnected from the box? NO .See GENERAL SPECIFICATION DATA. Check fluid level. Wheels and Tyres YES . Information. Constant Velocity Joint and Swivel Pin Housing Non ABS See FRONT AXLE AND FINAL DRIVE. See Repair.Remove and overhaul box. CAUTION: The steering wheel must not be held on full lock for more than 30 seconds in one minute.See Overhaul. Power Steering Fluid Reservoir YES . YES . Overhaul.Test If pressure is not correct after bleeding the system.See GENERAL SPECIFICATION DATA. See Overhaul.stiff. Power Steering Pump YES .castor return action normal. Power Steering Box 4 FAULT DIAGNOSIS . Power Steering Box NO . See Repair. renew pump.57 Symptom:- STEERING Symptom:Steering heavy . Power Steering Box 2. See Repair. Drag Link and Drag Link Ends 3.Check universal joints for seizure and correct alignment.Adjust steering column. See Repair. See Repair. Lower Steering Shaft and Universal Joints 4. Power Steering Fluid Reservoir Check fluid pressure. Drag Link and Drag Link Ends See FRONT AXLE AND FINAL DRIVE. Is the power assistance satisfactory? NO . 2. See Stiff Steering Checklist Fluid leaks from steering box seals. Are tyres correct type and pressure? NO .Check fluid pressure. poor castor return action. See Repair. Front Stub Axle.Disconnect the lower steering shaft and check the column and box for stiffness. See Overhaul.Check fluid level See Repair. Lower Steering Shaft and Universal Joints Check power steering box adjustments. Are tyres correct type and pressure? NO .Bleed 3. Is pressure high? YES . Is the steering stiff with the drag link disconnected? NO . 1. (castor return action normal). See Overhaul. Information. Is fluid level correct? NO . Is pressure correct? NO . Power Steering Box Symptom:Insufficient power assistance . See Power Steering System .Renew pump. See Repair. Overhaul. as this may overheat the fluid and cause damage to the oil seals. Wheels and Tyres YES . 1.Test 2.Disconnect drag link from drop arm and check steering column and box for stiffness. 1. Front Stub Axle. See Repair.Continue.Check system for air locks.

Are steering box adjustments correct? NO . 1. Regardless of the terminology used by the owner/driver to describe the symptoms. See Steering Damper 3. Front Shock Absorber 6. Radius Arm See FRONT SUSPENSION. Check the steering hydraulic damper function. No attempt must be made to introduce backlash. is generally caused by out of balance road wheels. bolts and washers.Symptoms See WHEELS AND TYRES. Excessive freeplay at steering wheel. See Overhaul.Suspect worn panhard rod or radius arm bushes Check condition of ball joints and the lower steering column shaft universal joints for wear. See FRONT AXLE AND FINAL DRIVE. Road test vehicle. Information. See FRONT AXLE AND FINAL DRIVE. Anti-Roll[Sway] Bar Assembly See FRONT SUSPENSION.See Adjustment. Power Steering Box WARNING: Adjustments of steering box should not be required while in warranty period. Carry out a full steering geometry check. Fault . See INTRODUCTION.If problem persists fit damper kit STC 241 (2 off front) and STC 1474 (2 off rear). See GENERAL SPECIFICATION DATA. Lower Steering Shaft and Universal Joints Symptom :Steering vibration.STEERING Symptom :Steering excessively light/sensitive. Description and operation. Steering FAULT DIAGNOSIS 5 . Check the power steering box adjustments and operation. road wheel shimmy . As applicable. Repair. If box is within warranty. Check the hub bearing end floats and determine the condition of the hub bearings.wobble. Vibration through the steering linkage powerful enough to induce high frequency oscillation of the steering wheel. See Repair. Front Hub Assembly 10. 11. Panhard Rod See FRONT SUSPENSION. Check steering linkage ball joints for wear. However there are a number of other possible causes of this symptom which if severe. correct alignment and security. Repair. Fault diagnosis. Wheel Balancing 2. 7. See Steering Linkage Inspect 5. Description If problem is not diagnosed: Repeat checks starting at 1. may be described as shimmy or wobble. Fit new nuts. Check all front suspension rubbers for wear. including steering box and tie rod. Coil spring vehicles only . Check the tyres and balance of the road wheels. Check the resistance and condition of the swivels. See Repair. Check all fixing torques. Repair. YES . the following diagnostic checks should be carried out in the order presented. Lower Steering Shaft and Universal Joints 4. it must be returned to manufacturer. Power Steering Box 9. Fit harmonic damper if vehicle has air suspension. 8. Repair. panhard rod and anti-roll [sway] bar. Wheels and Tyres See WHEELS AND TYRES. Information. See FRONT SUSPENSION. Fit new radius arm bushes using NTC 6860. including radius arm bushes. Repair. Check steering column universal joints for wear and correct alignment. Repair. 1.

10. Is problem steering niggle ? YES . steering geometry. 2. Carry out visual and safety checks. Is problem resolved? YES . 12.Go to 6. Radius Arm NO .end NO . Overhaul. Overhaul. Is problem resolved? YES . Constant Velocity Joint and Swivel Pin Housing ABS 1. Remedy. Is problem stiff steering? YES . Is problem resolved? YES . See Adjustment. GENERAL STEERING 1. See FRONT AXLE AND FINAL DRIVE. If fitted with or without antilock brakes. arm and axle. adjust if necessary. 3.57 STEERING STEERING STABILITY AND VEER UNDER BRAKING Possible cause: Incorrectly set.continue.continue. 6. Veer Under Braking See 4.end NO . Directional Stability 6 FAULT DIAGNOSIS . Road test vehicle. See Road Test Procedure 3. 5. Is problem resolved? YES . There are three different settings for these bearings dependant on model year and if fitted with ABS brakes.end NO . 7. Check.Replace radius arm bushes.go to 8.end NO . or with ABS as appropriate. constant velocity joint and swivel pin non ABS. See FRONT SUSPENSION. Is problem resolved? YES . 8.See Stiff Steering Checklist NO . 11. 1. Follow instructions to overhaul front stub axle. swivel pin bearing preload. Constant Velocity Joint and Swivel Pin Housing Non ABS See FRONT AXLE AND FINAL DRIVE. Front Stub Axle. Establish model year of vehicle. Steering Veer See 3.continue 4. Front Stub Axle. Centralise steering box. Centralise Steering Box 9. Repair.go to 8.continue.end NO . See Visual and Safety Checks 2. Categorise the remaining problems into one or more of the following descriptions: See 2.

continue. Is problem resolved? YES . Check brake lines and hoses for deterioration.continue.contact local technical office. not under braking. 3.continue. GENERAL STEERING: 1. 3.STEERING 2. axles etc for contamination.continue. Is problem resolved? YES .end NO . 2. Is problem resolved? YES . swap front tyres side to side.end NO .end NO . bleed brake system. 3.end NO . Is problem resolved? YES . Centralise Steering Box 5. 4. 2. 4. Vehicle veers under braking. and discs. GENERAL STEERING: 1. 6. See Adjustment. 7.end NO . STEERING VEER From 1. Is problem resolved? YES . Vehicle veers. Contact local technical office. 5. Does vehicle now veer in other direction? YES . Check brake pads for glazing.continue.fit new tyres NO . VEER UNDER BRAKING From 1. Recentralise steering box. FAULT DIAGNOSIS 7 . Replace as necessary.

side to side. Does leak remain? YES . Is fluid level correct? YES . Power Steering System . YES . Is oil leaking from PAS box? YES .end.bleed system.go to 10. 3. Are hoses or joints leaking? Check on full lock with engine at 2000 rev/min.contact local technical office. Check and replace as necessary.Bleed 2. 3. GENERAL STEERING: 1.Bleed NO .continue.change PAS pipe. 8. 10. NO . Check condition of rear trailing link/chassis bushes. 4. 2. Check condition of front and rear shock absorbers. add tracer dye to system.continue.continue. 7.go to 10. Check wheel balance 10. NO .end NO .end. 8 FAULT DIAGNOSIS . Is problem resolved? YES . POWER STEERING FLUID LEAKS 1.end. 7. NO .end. Retest 11. Is problem resolved? YES .go to 6. 9.end NO .continue.57 STEERING 4.loosen and retorque joints. If in doubt change units in pairs. Is oil still escaping from filler cap? YES . See Repair. See Repair.Check towing/vehicle loading parameters in Owner’s Handbook. Is problem resolved? YES . Is oil still leaking? YES . Is oil escaping from filler cap? YES . DIRECTIONAL STABILITY From 1.end NO . NO .go back to 1.end NO .continue. NO . Bleed system.suspect seal in component. NO . Is problem resolved? YES . NO .end NO . Power Steering System . NO .go to 8. NO .go to 3.end. Does leak remain? YES . Is problem resolved? YES . 6.establish leak point.end NO .go to 3.continue. 5. 5. Is directional stability concern when vehicle is towing? YES . 9. check for leaks. Check steering damper. Is problem resolved? YES . Is oil leaking from PAS pump? YES . 4. See Steering Damper 8.Refill or drain to correct level. 6. Repair or replace unit as necessary. Clean unit.

3. Is correct low pressure hose ANR 3152.go to 13. Power Steering System . change belt. FAULT DIAGNOSIS 9 . Is pressure hose from pump to box touching body in a hard foul condition? YES . 15. Repair. 6.STEERING POWER STEERING SYSTEM . Does noise remain? YES . Is noise an intermittent "grunt"? YES . 11.end.continue.Fit correct hose. NO . Compare with other vehicles NO . Purge box by doing figure 8 manoeuvres e. NO . 10. See Repair.go to 3. Does moan remain? YES . 3. 12. Does grunt remain? YES . Bleed system. NO .reroute hose away from body. NO .end.end NO .continue NO .EXCESSIVE NOISE 1. NO . Repair.end. Does grunt remain? YES .end. NO . Is noise a continuous moan? YES .continue NO . Is fluid level correct? YES .continue.end.check/reset drive belt tension. Does noise remain? YES .Grunt NO . 7. Change steering box and/or pump. 4. 6.do figure 8 manoeuvres. 5.end. Bleed system. POWER STEERING SYSTEM . 13. See Repair. Is noise excessive? YES . See ENGINE.Contact local technical office NO .end.GRUNT Steering box grunts intermittently when turning from lock to lock: 1.drive belt contaminated.bleed PAS system.reset drive belt tension.go to 8.contact local technical office. on car park. 5.Refill or drain to correct level.end. Drive Belt NO . NO . See Repair.Bleed 2.go to 10.Bleed NO .noise is not a fault unless excessive. followed by 10 minutes normal road use. Is noise a whistle or hiss on full lock? YES . check for leaks. NO .go to 5. Does moan remain? YES . NO . Does grunt remain? YES . Power Steering System . Is noise a squeal on full lock? YES .continue NO . See ENGINE. 4.end.Suspect suspension or drive train. Power Steering System .go to 5.See Power Steering System . check for leaks.refill or drain to correct level.go to 3. 14. Does squeal remain? YES .g.continue. Is problem resolved? YES . Drive Belt NO .continue. Is it a clunking noise? YES .Bleed 2. 9. steering box to reservoir fitted? YES . Is fluid level correct? YES . 8.

check for steering veer. If the symptom described by the customer is stiff steering or steering niggle. if a veer is consistently noted carry out a braking efficiency test on a rolling road. 4. CONDITION AND USE OF THE VEHICLE. 3.drive at 64 km/h (40 mph) on a staight FLAT road (no camber). Carry out visual and safety checks. it is important that the following basic visual checks are carried out to ensure that the vehicle complies with legal requirements. damage and feathering. See Visual and Safety Checks Confirm general nature of complaint with customer. 3. noting any tendency to veer. Steering load assessment . 1. if a veer is consistently noted carry out a braking efficiency test on a rolling road. Information. type and general condition are common across each axle. A small amount of veer in direction of camber is acceptable. simulating where possible the conditions under which the problem occurs. carry out stiff steering procedure.drive at 96 km/h (60 mph) on a straight flat road. Vehicle should quickly settle into a new straight path. 2. See GENERAL SPECIFICATION DATA. Check tread depth. WARNING: Ensure that all road tests are conducted by suitably qualified drivers in a safe and legal manner. Carry out a normal lane change. and where local traffic conditions allow. 5. Apply full braking effort. Directional stability assessment .drive at 16 km/h (10 mph). Tyres and wheel rims 1. Carry out following road test procedure to establish the problem. The vehicle should follow a straight path with NO tendency to follow a curved path. vehicle may be ’camber sensitive’. 4. Braking assessment (full effort) . Check wheel rims for signs of damage and excessive run out. See Stiff Steering Checklist If not proceed with basic checks and adjustments. Tyre Pressures Note that this information refers to standard tyres fitted as original equipment. Steering assessment . 6. Braking assessment (medium effort) . Carry out road test.57 STEERING VISUAL AND SAFETY CHECKS WARNING: Before taking vehicle out on the public highway for road test. If vehicle veers towards the kerb. Apply steady medium braking effort.drive at 112 km/h (70 mph) or maximum legal speed on a straight flat road. Put 90°turn input into steering wheel. See Visual Check and Basic Adjustments ROAD TEST PROCEDURE General steering/handling problems can usually be classified into one of the categories listed and ARE GENERALLY RELATED TO THE AGE.drive at 96 km/h (60 mph) on a straight flat road. See Road Test Procedure 2. 5. The self centering should be equal on each lock BUT not necessarily return to exactly straight ahead without assistance from the driver. Carry out brake test three times. Inspect for signs of uneven wear. Carry out brake test three times. Ensure that the tyre make. check self centering. Check condition of tyres. Check and adjust tyre pressures. 10 FAULT DIAGNOSIS . noting any tendency to veer.

centralise steering wheel. Check lower steering shaft is correctly phased. 2. See Repair. Drive vehicle over speed bumps and include harsh braking if possible. 3. 2. FAULT DIAGNOSIS 11 . Lower steering shaft universal joint lubrication 1. Raise vehicle so both front wheels free. Lubricate universal joints with an anti-seizure type penetrating spray. If steering stiffness still persists carry out steering column alignment. Compare figures obtained with the specified figures: Without ABS 4. See Visual Check and Basic Adjustments Steering box tie bar reset 1. See FRONT AXLE AND FINAL DRIVE. Overhaul.40 Nm. Front Stub Axle. 3. 5. 81 Nm. if fitted or steering wheel pad. Lower Steering Shaft and Universal Joints 2. NON ABS vehicles. With engine off. 6. Work the joints to ensure full penetration of the spray by driving vehicle and steering from lock to lock. Swivel pin preload setting The swivel pin preload setting must be checked and set following the workshop manual procedure. See FRONT AXLE AND FINAL DRIVE. ABS vehicles.8 Nm is required after the axle shaft and swivel housing seal have been removed. WARNING: Do not drive on public highway. Record readings obtained in each direction. If torque reading is still greater than specified.2. Near end of 2. Tighten the two fixings tie bar to steering box. With ABS 4. Recheck steering wheel torque to turn. If figures are as specified. 1. 3. Overhaul. 4.STEERING STIFF STEERING CHECKLIST NOTE: Having completed visual checks and steering assessment and confirmed that vehicle steering load is incorrect carry out the following procedure in order shown. Constant Velocity Joint and Swivel Pin Housing Non ABS Note that a pull load of 1. Steering wheel ’torque to turn’ loads 1. and remove air bag. 2. Drive vehicle carefully a short distance (within the dealership) applying full lock in both directions in order to settle steering components. check torque required to turn the steering wheel one turn in each direction. Using torque wrench on column nut.0 . Constant Velocity Joint and Swivel Pin Housing ABS Note that a torque to turn of 2. NOTE: If figures are in excess of those specified carry out steering box tie bar reset below.16 . carry out steering shaft universal joint lubrication.65 Nm. 110 Nm. Tighten panhard rod mounting arm nut. Loosen the three tie bar fixings one complete turn. Front Stub Axle. 3.46 kg is required after the axle shaft and swivel housing seal have been removed. ensure vehicle is driven in a straight line on level ground and halted.1. If steering stiffness still persists carry out swivel pin preload setting.

Brake system . See Road Test Procedure Attempting to reproduce the symptoms established earlier. torque. it is permissible to set the front track to parallel. Record results on data sheet. 10. Tighten the fixings evenly. 4. If symptoms still exist refer to relevant Diagnostic Chart. Recheck steering column angle. If necessary. drag link and ball joints. pad wear/contamination. Track rod/drag link . Release the five fixings securing the steering column.examine all steering and suspension bushes for signs of wear and deterioration. check operation of steering damper and steering box for smoothness. Torque Values 7. Repair. Reposition shroud. Tighten to correct torque value. See FRONT SUSPENSION. Place vehicle on level ground. Drive Belt 12 FAULT DIAGNOSIS . tighten screws. Replace all damaged or worn components that impair the operation of the steering system. Ride height . road test vehicle. Having completed all the above checks and adjustments. 1. Vehicles displaying a tendency to veer more than considered allowable. disc wear/condition and ABS sensors for correct fitting.measure trim height from wheel centre to wheelarch eyebrow. 8. 11. Power Steering Fluid Reservoir 4. Position column as required. Drag Link and Drag Link Ends If either component is damaged. Road springs . VISUAL CHECK AND BASIC ADJUSTMENTS NOTE: It is important that the following instructions are carried out in the sequence shown and the results recorded. Information. Loosen the three screws securing lower steering column shroud to upper shroud ensure lower shroud is clipped to upper shroud. 3. Check tension and condition of drive belt. realign the shaft.check brake system for leaks.check front and rear axle hubs for leak and repair as necessary. Specifications.check condition of track rod. Check condition of steering damper See Steering Damper 5. See GENERAL SPECIFICATION DATA. Power Steering Box Steering damper check 1. See Repair. Oil leaks . Suspension bushes . See Adjustment. 9. Check front wheel alignment. See ENGINE. 6. Hub end float . The angle should measure a minimum of 12˚. pipe condition. Measure the angle of lower steering shaft using a Pernumeter placed on the shaft between the universal joints. 2. Also check all fixings for torque relaxation. Check steering box adjustment. Steering box adjustment 1. Check/top up power steering fluid See Repair. For spring specification. 3.check that road springs are correctly seated and are to correct specification for vehicle. 27 Nm.57 STEERING Steering column alignment 1.check movement in the hubs by rocking the wheels. Road Springs Data 2.

no movement on ball joint and associated assemblies. This will be evident as extreme movement on track rod and steering linkages. Check for excessive wear.e. Check ball joint rubber boots for security. Check all linkages for wear. Check ball joint assemblies for seizure i. Drag Link and Drag Link Ends Steering linkages 4.STEERING STEERING LINKAGE INSPECT NOTE: When inspecting steering linkages and ball joints for wear the following items must be checked. 3. Track Rod and Linkage See Repair. Track Rod and Linkage See Repair. 2. Renew parts as necessary. Steering ball joints 1. signs of cracking or deterioration. See Repair. Renew parts as necessary. See Repair. deterioration and damage. Drag Link and Drag Link Ends FAULT DIAGNOSIS 13 .

13. Turn steering wheel lock to lock and check no tightness exists. Left hand drive vehicles . Road Test Procedure NOTE: If steering wheel is not in straight ahead position when vehicle is travelling in a straight line. select ’P’ in automatic transmission and chock wheels.57. 9. CENTRALISE STEERING BOX 1. Steering Wheel The adjustment of the steering box ensures any preload or end float present on centre is removed. Right hand drive vehicles . 10. Centralise steering box. Support chassis front on axle stands. To centralise the box. it must be returned to manufacturer. NOTE: If steering wheel is not straight. The adjustment is obtained by rocking the drop arm about centre whilst an assistant slowly tightens the steering box adjuster screw. 8. drag link is too long. If steering wheel is to left drag link is too long. insert a suitable peg (hole size 8. Tighten the locknut when all backlash has been removed. Check torque to turn. 3. No attempt must be made to introduce backlash. If box is stiff or tight and within warranty. Drag link adjust 15. 16. 12. Disconnect drag link from steering drop arm. 4. 2.06 mm) into the rear of the drop arm and into the steering box casing to enable rapid and accurate setting on centre.if steering wheel is to right. See Centralise Steering Box NOTE: Only check for no backlash when steering box is in central position. Stiff Steering Checklist 5.if steering wheel is to right.10. 6. See Front Wheel Alignment 11.STEERING POWER STEERING BOX Service repair no . Ensure front wheels are aligned and in straight ahead position. 14.13 WARNING: Adjustments of steering box should not be required while in warranty period. See Fault diagnosis. Remove engine undertray. Repeat the check for backlash. Apply park brake. See Repair. drag link length is incorrect and is pushing drop arm away from central position. drag link is too short. Adjust drag link 924 mm between ball joint centres. See Fault diagnosis. Lower vehicle to ground level and remove chocks. Adjust drag link until steering wheel points straight ahead when vehicle is travelling in a straight line. Tighten to 40 Nm. ADJUSTMENT 1 . it should be repositioned. Connect drag link. 1. Road test vehicle. If steering wheel is to left drag link is too short. 7. If backlash exists loosen locknut and repeat adjustment procedure.

3. Check clearance between tyre wall and radius arm on each lock. This must be 40. Loosen stop bolt locknut. Loosen stop bolt locknut. Tighten locknut. 4. 3. 4.57. 5. 5. Turn stop bolt as required. Check wheel position at full lock. Measure stop bolt protrusion as shown in RR1697M.57 STEERING STEERING LOCK STOPS Service repair no . This must be 20 mm. Measure clearance between tyre wall and radius arm at full lock. 2 ADJUSTMENT . NOTE: Alternatively lock stop adjustment may be carried out using following procedure.65.03 Check Check 1. Turn stop bolt as required. 1. 2.5 mm. Adjust Adjust 2. Tighten locknut.

Check toe-out setting as instructions 1 to 4. When toe-out is correct. Loosen adjuster sleeve clamp.01 Adjust NOTE: For details of drive belt adjust procedure See ENGINE. Tighten to 14 Nm. POWER STEERING PUMP DRIVE BELT Service repair no . 7. 2. tap steering linkage ball joint. to maximum of their travel. Repair. 6. Tighten clamp bolts to 14 Nm.STEERING FRONT WHEEL ALIGNMENT Service repair no . Measure toe-out at horizontal centre-line of wheels.65. Check tightness of clamp bolt fixings.57. in directions of arrows shown. Set vehicle on level ground with road wheels positioned straight ahead. Push vehicle back and forwards to settle linkage.20.01 Checking Toe-out dimensions NOTE: No Adjustment is provided for castor.57. Rotate adjuster to lengthen or shorten track rod. 1. 3. 8. camber or swivel pin inclinations. Adjust 5. This ensures full unrestricted working travel. Drive Belt ADJUSTMENT 3 . 4.

Remove plugs and refit pipes to steering box.STEERING POWER STEERING FLUID PIPES Service repair no . Tighten to 20 Nm. Hold pipe in correct position. 14mm thread 15 Nm.15. Remove plugs and refit pipes and clamps. The following procedures must be followed when refitting fluid pipes: Power steering pump 1. 6. Tighten to 3 Nm. Remove plugs. Tighten clamps to 3 Nm. Fit high pressure union into pump. 3. 4. V8i Steering pump illustrated 2. Power steering reservoir 1. Tighten to torque: 16mm thread 20 Nm.21 CAUTION: If any joints are disconnected. 5. place clamp on feed hose. 2. REPAIR 1 .57. 7. leave fingertight. it is essential that open pipe and ports are plugged to prevent ingress of dirt. Hold clamp in position. Push hose onto pump.

2. parking brake is applied. 4.57. Follow normal ’O’ ring replacement procedure whenever pipes are disconnected. CAUTION: After refitting steering linkage parts follow correct procedure to ensure that road wheels. 6. utmost cleanliness must be observed. Open bonnet[hood]. 4. 2 REPAIR . Disconnect feed and return pipes from steering box.01 equal. Remove filler cap from power steering fluid reservoir. is removed or disconnected. tighten steering wheel securing nut and fit air bag . Metric pipe fittings are used with ’O’ ring pipe ends on fittings to steering box. Support chassis front on axle stands. Plug open pipes and steering box ports to prevent ingress of dirt. 5. CAUTION: Before removing any parts of steering linkage. establish cause rectify and flush system. Do not start engine until reservoir is full as pump will be damaged. 6. ensure that drive pegs on rotary coupler are correctly positioned before steering wheel is replaced. travel available at steering wheel to each full lock is not Remove 1. 7. 5. This ensures drive pegs locate in their holes in rear of steering wheel. WARNING: Ensure wheels are chocked. and low range selected. Disconnected ports and hoses must be plugged to prevent ingress of dirt. General precautions NOTE: When drag link is disconnected from steering box. steering box and steering wheel are correctly positioned relative to each other when in straight ahead condition.if fitted or steering wheel trim pad. Clean steering box. it is imperative that road wheels are positioned straight ahead. Site vehicle on level surface. 3. Or raise vehicle on a hoist. Then steering wheel removed to prevent rotary coupler being wound up or damaged. 2. After final alignment connect rotary coupler multiplug. Whenever any part of system. Ensure compatible metric components when fitting replacement pipes. 1. If steering wheel requires repositioning. If metal sediment is found in system. 3.57 STEERING POWER STEERING BOX Service repair no .10.

10. REPAIR 3 . 9. Remove undertray 12.STEERING 8. Remove bolts securing tie bar. Disconnect drag link from drop arm using a suitable extractor. 13. 14. Remove pinch bolt securing lower shaft universal joint to power steering box. Remove bolts securing power steering box to chassis side member. Withdraw power steering box. move tie bar aside. Loosen but do not remove nut securing tie bar to mounting. 11.

WARNING: Do not test drive vehicle on public highway. 14mm thread to 15 Nm. 31. 21. then loosen nut and bolts by one complete turn. Information. Tighten bolts to 81 Nm. Remove plugs and refit pipes to steering box. Tighten tie bar to mounting nut to 110 Nm. Tighten bolts securing tie bar to 81 Nm. 4 REPAIR . drive vehicle over speed bumps and include harsh braking. If necessary reposition steering wheel. Recheck fluid level and replace cap. Refit 15. Drive vehicle in a straight line on level ground and stop. Fit pinch bolt and nut securing universal joint to power steering box. 25. 18. See Steering Wheel 32. 30. Check steering box. test steering system for leaks by holding steering in both full lock directions. Use recommended fluid. Ensure steering wheel is correctly aligned when wheels are positioned straight ahead.57 STEERING CAUTION: Do not maintain this pressure for more than 30 seconds in any one minute. 17. 26. 27. With engine running. Remove filler cap. Power Steering Box 19. Lower vehicle to ground. See Adjustment.Bleed 24. FLUIDS AND CAPACITIES. 23. If possible. 20. to avoid oil overheating and possible seal damage. Fit undertray. Tighten 16mm thread to 20 Nm. 28. Recommended Lubricants and Fluids and bleed power steering system. See LUBRICANTS. Test drive vehicle: using both full lock directions. adjust if necessary. Position tie bar. See Power Steering System . 22. 16. 29. Refit drag link to drop arm tighten nut to 40 Nm. starting with tie bar to mounting nut. tighten bolts and nut to 81 Nm. Position steering box to chassis side member. ensuring locating peg is engaged. Tighten to 25 Nm. to settle steering components. Road test vehicle. Fill reservoir to oil level mark on dipstick.

5.57. Position drain tin beneath reservoir. Loosen clamps. Remove undertray.57. maintain maximum fluid level in reservoir. Run engine to normal operating temperature. With engine at idle speed. CAUTION: Plug the connections. Carry out road test. 8. remove fluid and clean area with warm water.02 1. Ensure fluid in reservoir reaches dipstick maximum. REPAIR 5 . allow fluid to drain. Loosen mounting bracket clamp bolt. Do not allow fluid to contact paintwork. When fluid seeps past bleed screw retighten screw. Remove reservoir. NOTE: During instructions 4 to 6.15. Clean away fluid around bleed screw. disconnect feed and return hoses from reservoir.STEERING POWER STEERING SYSTEM . pump and steering box for fluid leaks by holding steering on full lock in both directions. raise reservoir to gain access to pipe clamps. 3.15. 5. CAUTION: Discard fluid drained from system.08 Remove 1. Check fluid level. 4. loosen bleed screw. 7. 6. 2. 2. POWER STEERING FLUID RESERVOIR Service repair no . 3. CAUTION: Do not maintain this pressure for more than 30 seconds in any one minute to avoid overheating fluid and possibly damaging seals. Recheck and correct reservoir fluid level. 4. Check hose connections. Do not increase engine speed or move steering wheel. if spilled.BLEED Service repair no .

Disconnect battery negative lead. See COOLING SYSTEM.V8i Service repair no .20. See ENGINE. tighten clamp bolt. Drive Belt 6.57.14 NOTE: The power steering pump is not serviceable. remove 3 bolts securing pulley to pump. Fill reservoir to ’MAX’ mark on dipstick with power steering fluid. 6. Recommended Lubricants and Fluids 9. Position drain tin beneath steering pump. 7. Repair. 4. remove pulley. 8. See ENGINE. connect feed and return hoses and tighten clamps to 3 Nm. Fit reservoir in clamp. Drive Belt 3. Viscous Coupling. FLUIDS AND CAPACITIES. Using a 9 mm Allen key to restrain steering pump pulley.02 NOTE: For details of drive belt remove and refit. See LUBRICANTS. 6 REPAIR . Repair.57 Refit STEERING POWER STEERING PUMP . Fit new pump if worn or damaged.57. Remove fan blades and viscous coupling. Fit undertray. Pulley and Fan Cowl 5. See Power Steering System . Bleed power steering system.20. Repair. Remove drive belt from steering pump. Remove 1. 10. Fan Blades. Position reservoir. Remove undertray.Bleed POWER STEERING PUMP DRIVE BELT Service repair no . Information. 2.

Remove drive belt. Repair. Repair. Secure ht lead in clip. Remove 5 bolts securing front mounting plate. POWER STEERING PUMP . Connect high pressure pipe to steering pump. REPAIR 7 . 12.57. 6. Position drain tin beneath steering pump. Remove undertray. See COOLING SYSTEM. See COOLING SYSTEM.20. tighten union to 20 Nm. remove pulley. Tighten to 10 Nm. 8. Bleed power steering system.STEERING 7. Fan Blades. Fit undertray. disconnect hose. 21. fit bolts.Bleed 2. See ENGINE. CAUTION: Plug the connections. 14. Position pulley to pump. coat threads of bolts with Loctite 242. See Power Steering System . Remove fan blades and viscous coupling. NOTE: Do not carry out further dismantling if component is removed for access only. Reconnect battery negative lead. Drive Belt 19. Fit front mounting plate to replacement steering pump. Repair. Viscous Coupling. Tighten to 35 Nm. Restrain steering pump pulley. Disconnect high pressure pipe from steering pump. Pulley and Fan Cowl 9. Viscous Coupling. 5.Tdi Service repair no . Repair. See ENGINE. Fit drive belt. 3. Drive Belt 4. 17. 15. Position steering pump and engine lifting plate. fit bolts.14 Remove 1. 22. 18. Tighten clamp to 3 Nm. loosen but do not remove 3 bolts securing pulley. Fan Blades. Restrain pulley using a 9 mm Allen key. 11. Pulley and Fan Cowl 20. Connect reservoir hose to steering pump. 16. Loosen clamp securing reservoir hose to steering pump. Remove pump and recover engine lifting bracket. Remove 3 bolts securing steering pump pulley. Remove 3 bolts securing steering pump. Release ht lead from clip 10. Tighten bolts to 9 Nm. Fit fan blades and viscous coupling. Refit 13.

Fan Blades. tighten bolts to 10 Nm.Bleed 9. 11. Viscous Coupling. remove pump. Connect reservoir hose to steering pump. NOTE: Do not carry out further dismantling if component is removed for access only. fit but do not fully tighten 3 bolts. Tighten clamp to 3 Nm. See ENGINE.57 STEERING 7. 16. Fit mounting plate to replacement steering pump. disconnect hose. Tighten to 20 Nm. Restrain steering pump pulley. Remove 3 bolts securing mounting plate to pump. See COOLING SYSTEM. 10. Connect high pressure pipe to steering pump. 8 REPAIR . Tighten to 35 Nm. Tighten bolts to 9 Nm. Fit drive belt. 14. Refit 12. 8. Fit fan blades and viscous coupling. Position pulley to steering pump. 18. CAUTION: Plug the connections. Pulley and Fan Cowl 19. Repair. Repair. 20. Position steering pump. remove plate. Disconnect high pressure pipe from steering pump. fit 3 bolts. Fit undertray. Loosen clamp securing reservoir hose to steering pump. See Power Steering System . 15. Bleed power steering system. 13. Drive Belt 17. coat threads of bolts with Loctite 242. Remove 4 bolts securing steering pump to mounting bracket.

WARNING: If clip is displaced. Then steering wheel removed to prevent rotary coupler being wound up or damaged. Secure heat shield stud fasteners (if fitted). 8.STEERING LOWER STEERING SHAFT AND UNIVERSAL JOINTS Service repair no . Position lower universal joint on shaft.40. 14. rubber coupling and top universal joint is only available as an assembly. 13. 11. Remove universal joint from lower shaft. 5. 6. a new shaft assembly must be fitted. 2. ensure that drive pegs on rotary coupler are correctly positioned before steering wheel is replaced. 10. CAUTION: After refitting steering linkage parts follow correct procedure to ensure that road wheels. This ensures drive pegs locate in their holes in rear of steering wheel. Align bolt holes with grooves in splines. Fit pinch bolts. renew if necessary. Move lower shaft up to release lower universal joint from steering box splines. After final alignment connect rotary coupler. If steering wheel requires repositioning.if fitted or steering wheel trim pad. REPAIR 9 . Refit NOTE: Fit universal joints so pinch bolt holes line up with flat on shaft. Release stud fasteners securing heat shield (if fitted). NOTE: Do not dismantle upper coupling joint. Remove lower shaft. Move assembly up spline to enable lower universal joint to fit onto steering box splines. Tighten to 25 Nm. Remove 1. Ensure road wheels are straight ahead. tighten steering wheel securing nut and fit air bag module . lubricate if necessary.57. renew lower shaft as an assembly if necessary. Inspect top universal joint and rubber coupling. 4.25 CAUTION: Before removing any parts of steering linkage. Remove 2 pinch bolts securing lower universal joint. Inspect lower universal joint for wear and excessive play. NOTE: Prior to fitting a replacement steering shaft check the following: 9. Steering shaft. steering box and steering wheel are correctly positioned relative to each other when in straight ahead condition. Inspect universal joints for stiffness. 7. no attempt must be made to drive clip into engagement. it is imperative that road wheels are positioned straight ahead. 3. Check that indicator clip coloured red is fully inserted under head of compression joint bolt. Remove pinch bolt securing top universal joint to steering column. Position shaft assembly onto steering column. 12.

Description and operation. After final alignment connect rotary coupler multiplug. CAUTION: Before removing any parts of steering linkage. Disconnect battery negative lead. This ensures drive pegs locate in their holes in rear of steering wheel.57. steering box and steering wheel are correctly positioned relative to each other when in straight ahead condition. Fit and tighten 3 screws. tighten steering wheel securing nut and fit air bag . Then remove steering wheel to prevent rotary coupler being wound up or damaged. Refit 5. If steering wheel requires repositioning. 10 REPAIR .01 CAUTION: Prior to commencing work on vehicles fitted with an air bag.57.40. 4. ensure that drive pegs on rotary coupler are correctly positioned before steering wheel is replaced.57 STEERING STEERING COLUMN SHROUD Service repair no . Position upper and lower shrouds to steering column ensuring plastic tags on lower shroud are correctly located. Clip both halves of shroud together.29 Remove 1. See SUPPLEMENTARY RESTRAINT SYSTEM. Manoeuvre lower shroud clear of steering column. Carefully release upper shroud from lower. 6. STEERING WHEEL Service repair no . CAUTION: After refitting steering linkage parts follow correct procedure to ensure that road wheels.if fitted or steering wheel trim pad. it is imperative that road wheels are positioned straight ahead. 3. 2. Remove 3 screws securing shroud.60.

disconnect Lucars from horn button. Secure in position with adhesive tape. 12. Release harness from retaining clip. Non airbag module: Fit horn push assembly. 17. 13. 14. 9. Remove adhesive tape securing rotary coupler. Connect rotary coupler multiplug. NOTE: Do not carry out further dismantling if component is removed for access only. Position steering wheel to column. 8. remove retaining nut and washer. Fit airbag module . See SUPPLEMENTARY RESTRAINT SYSTEM. Reconnect battery negative lead. Airbag fitted: Remove air bag. 5. Remove trim pad from steering wheel. Repair.if fitted. Driver’s Airbag Module 4. 16. Repair. 6. 15. Tighten to 50 Nm. 11. REPAIR 11 . Driver’s Airbag Module 18. Loosen but do not remove retaining nut. 2.STEERING Remove 1. Disconnect rotary coupler multiplug. Withdraw steering wheel whilst at the same time feeding harness through wheel hub. secure harness in clip. See SUPPLEMENTARY RESTRAINT SYSTEM. CAUTION: Prevent rotation of rotary coupler once steering wheel is removed. connect Lucars to horn button. push wheel fully onto taper. Recheck road wheels are positioned straight ahead. Disconnect battery negative lead. 3. Fit steering wheel nut. 7. Locate rotary coupler drive pegs and indicator switch self-cancel pegs in steering wheel hub. Refit 10. feed harness through wheel hub. Position road wheels straight ahead so steering wheel can be correctly re-assembled. Release steering wheel from taper.

Remove steering wheel. This ensures drive pegs locate in their holes in rear of steering wheel. tighten steering wheel securing nut and fit airbag . Remove steering column shroud. ensure that drive pegs on rotary coupler are correctly positioned before steering wheel is replaced. CAUTION: After refitting steering linkage parts follow correct procedure to ensure that road wheels. remove knee bolster. After final alignment.57. Remove driver’s access panel. 12 REPAIR . 5. See SUPPLEMENTARY RESTRAINT SYSTEM.if fitted or steering wheel trim pad and horn push assembly. it is imperative that road wheels are positioned straight ahead. If fitted . Disconnect column switch multiplug.01 NOTE: Steering column assembly is not a serviceable component. Remove 1. CAUTION: Before removing any parts of steering linkage. Remove rotary coupler.57 STEERING UPPER STEERING COLUMN Service repair no . if steering wheel requires repositioning. Secure in position with adhesive tape. connect rotary coupler multiplug. Repair. Disconnect ignition switch multiplug from fuse box. Rotary Coupler 6. then steering wheel removed to prevent rotary coupler being wound up or damaged. steering box and steering wheel are correctly positioned relative to each other when in straight ahead condition. 7. See Steering Column Shroud 4. 3. See Steering Wheel CAUTION: Prevent rotation of rotary coupler once steering wheel is removed.remove 4 screws securing knee bolster. 2.40.

discard shear bolts. 11. 18. NOTE: Do not shear column lock bolts at this stage. Loosen but. 12. Remove 4 nuts securing upper column to lower mounting. 9.STEERING 13. 14. Disconnect ignition switch multiplug. 16. Remove 2 nuts and washes securing upper column to upper mounting bracket. Withdraw bulb holder from column lock shroud. Remove pinch bolt securing upper column to universal joint. connect multiplug. Disconnect column switch multiplugs. withdraw assembly to gain access to multiplugs. Carefully manoeuvre upper column out of footwell. remove column switch assembly. remove bracket. Remove 2 nuts securing lower mounting steady bracket. 15. 19. do not remove screw securing column switch assembly. Disconnect ignition switch main feed multiplug. NOTE: Do not carry out further dismantling if upper column is removed for access only. REPAIR 13 . Remove shear bolts securing steering column lock. Transfer components to new upper column. recover rubber boot. 8. remove lock and saddle. 17. 10.

23. fit and tighten screws. Connect column switch multiplug. See SUPPLEMENTARY RESTRAINT SYSTEM. Fit but do not tighten nuts and bolts securing upper column to lower mounting. 29. See Steering Wheel 32. 26. If fitted . See Steering Column Shroud 36. tighten shear bolts until heads shear off. Fit steering wheel. fit washers and nuts. 22. Reconnect battery negative lead. Manoeuvre upper column to position in footwell. Ensure upper column is aligned to mountings. Repair. Fit lower mounting steady bracket. do not tighten nuts. Rotary Coupler 31. Connect ignition switch multiplugs. Fit but do not tighten universal joint pinch bolt. 33. 24. 27. fit but do not tighten nuts and bolts. 21. Position upper column to upper mounting. Tighten all nuts and bolts to 22 Nm. 28. Check steering column lock for correct operation. Tighten universal joint pinch bolt to 25 Nm. 25.position knee bolster. Fit rotary coupler. ensure splines in column and universal joint are correctly engaged and rubber boot is fitted. 35. 34. Fit driver’s access panel. 30. 14 REPAIR .57 Refit STEERING 20. Fit steering column shroud.

ensure that drive pegs on rotary coupler are correctly positioned before steering wheel is replaced. CAUTION: After refitting steering linkage parts follow correct procedure to ensure that road wheels. tighten steering wheel securing nut and fit airbag module . If steering wheel requires repositioning. 4.31 Remove CAUTION: Before removing any parts of steering linkage. Disconnect ignition switch multiplug from fuse box. Disconnect battery negative lead. 2. See Steering Column Shroud 3. it is imperative that road wheels are positioned straight ahead.57. 5. lower driver’s access panel. REPAIR 15 . After final alignment connect rotary coupler multiplug. Then steering wheel removed to prevent rotary coupler being wound up or damaged.40. 6. This ensures drive pegs locate in their holes in rear of steering wheel.if fitted. Release turnbuckles. steering box and steering wheel are correctly positioned relative to each other when in straight ahead condition. remove 4 screws securing knee pad. remove bolster.STEERING STEERING COLUMN LOCK ASSEMBLY Service repair no . Disconnect ignition switch main feed multiplug. Remove steering column shroud. 1. If fitted.

11. See Steering Column Shroud 20. If fitted . Tap head of shear bolts anti-clockwise to release them. Place lower lock assembly into column. 15. Insert bulb holder into steering column lock shroud. 9. 8. 17. Remove steering column lock assembly. Fit steering column shroud. locating spigot in hole provided. secure turnbuckles. Place vehicle on a hoist. 7. Fit but do not fully tighten new shear bolts. Raise driver’s access panel. 13. fit and tighten screws. 16. using extractor LRT-57-018.50.57. Remove and discard shear bolts.14 Remove 1. 14. Reconnect battery negative lead. Position steering lock saddle on column. Detach saddle. 21. 10. or support front axle on axle stands.fit knee bolster. 2. Connect multiplugs. 16 REPAIR . Remove bulb holder from steering column lock shroud. tighten shear bolts until heads shear off. 18. Disconnect drag link ball joint from drop arm. Refit 12.57 STEERING DROP ARM Service repair no . 19. Check steering column lock for correct operation.

57. Tighten ball joint nut 40 Nm.55. discard locking washer. align master splines. STEERING DAMPER Service repair no . Remove fixings at differential case bracket. 4. 2. Centralise steering box. but do not remove before using extractor. 8. Fit drop arm. Loosen drop arm securing nut.STEERING 3. bend over tab. See Adjustment. 7. 4. Fit a new tab washer and drop arm fixing nut. Remove nut. REPAIR 17 . Tighten to 176 Nm. Refit 5. Refit 5. Remove fixings at track rod bracket. Site vehicle on a ramp [hoist]. Reverse removal procedure.21 Remove 1. Centralise Steering Box 6. Remove steering damper. 3. Fit drag link. Bend back tabs on locking washer and remove drop arm using extractor LRT-57-012. 1 to 4.

Unscrew track rod adjuster. Fit track rod and tighten ball joint nuts to 40 Nm.55. Remove linkage 5. using extractor LRT-57-018. Loosely fit clamp pinch bolts. Check front wheel alignment. 18 REPAIR . Screw in ball joint to full extent of threads.57. See Adjustment. Remove vehicle from hoist. 6.5mm as shown. 16. 11. Refit track rod CAUTION: Fit a new track rod if existing is damaged or bent. Site vehicle on a ramp [hoist]. 14. Unscrew ball joints. Set adjuster to track rod distance to 9mm as shown. 4. 2. Fit replacement parts. 10. 12. Refit linkage 8. Set adjuster end ball joint distance to 28. Track rod effective length of 1230. Disconnect track rod at ball joints. 9. Connect steering damper to track rod. No attempt should be made to repair it. 3. Loosen clamp bolts. (left hand thread).57 STEERING TRACK ROD AND LINKAGE Service repair no . or axle stands. Disconnect steering damper at track rod. Remove track rod. 7. Front Wheel Alignment 15. 13.09 Remove track rod 1.0mm is subject to adjustment during wheel alignment check.

Road test vehicle. 9. 14. Tighten clamp bolts to 14 Nm. Ensure full steering travel is obtained between lock stops. 23. Tighten ball-joint nuts to 40 Nm. Check front wheel alignment. Refit drag link ends 11. Place vehicle on a hoist. or support front axle on axle stands. using extractor LRT-57-018. Set ball joints to drag link distance to 28. Adjust ball pin centres to nominal length of 924. 13. 5. 20. See Adjustment. Steering Lock Stops 18. 10. Loosen clamp bolts. Remove drag link ends 21. Clean internal threads in drag link. 17. WARNING: To correct steering wheel deviations greater than ± 5°. Ensure wheels are positioned straight ahead during following procedure. Remedy by adjusting drag link length. Centralise Steering Box 15.55.0mm. Fit replacement ends.17 Remove drag link 1.57. 12. this length is adjusted during refit. Wheel REPAIR 19 . If driving straight ahead and steering wheel is offset by 0°to ± 5°in either direction. Remove and reposition steering wheel. Loosely fit clamp bolts. See Adjustment. Centralise steering box. See Steering Wheel Refit drag link CAUTION: Fit new drag link if existing drag link is damaged or bent. Reverse removal procedure. See Steering 8. See Adjustment. 3 and 4. Remove right front road wheel.5mm as shown. 19. Tap ball joints in direction shown. Adjust drag link length to suit. Remove drag link. 7. so both pins are in same angular plane. Check steering lock stops. if necessary. Front Wheel Alignment 2. No attempt should be made to repair it. Align steering wheel. 16. Disconnect drag link ball joint at drop arm using LRT-57-018. 4. 3. 6.STEERING DRAG LINK AND DRAG LINK ENDS Service repair no . Unscrew ball joints. Disconnect drag link ball joint at swivel housing arm. Fit drag link. 22.

9. WARNING: Wear safety glasses while removing and refitting circlips and retaining ring. 1. CAUTION: Absolute cleanliness is essential when overhauling power steering box. OVERHAUL 1 . See Repair. Screw in sector shaft adjuster until cover is removed. 7. but do not remove before using extractor. Hold steering box over suitable container. 10. 4. using a screwdriver. remove blanking plugs and bleed screw. Remove four bolts from sector shaft cover. 6. Drain oil. Loosen drop arm securing nut. Slide out sector shaft. Rotate retainer ring until one end is 12 mm from extractor hole. Using a drift through hole in cylinder. NOTE: Sealant is applied to hexagon socket to ’tamperproof’ sector shaft adjuster 11. turn input shaft from lock to lock.57. Turn input shaft fully in opposite direction.10. Power Steering Box Remove drop arm using extractor LRT-57-012. applying pressure to piston. 5. 3. until oil is drained. Remove set screw retaining rack pad adjuster. Refit bleed screw. Remove rack adjuster and pad. 8. 2. Remove sector shaft adjuster locknut. lift retaining ring from groove in cylinder bore. Turn input shaft (left lock on left hand drive. Remove dirt excluder from output shaft. right lock on right hand drive) until piston pushes out cover. Remove retainer ring.STEERING POWER STEERING BOX Service repair no . Remove steering box from vehicle.07 Overhaul NOTE: Overhaul of steering box should not be carried out during the warranty period.

Remove bearing cup and caged ball bearing assembly. Remove worm adjuster locknut using ’C’ wrench LRT-57-007. NOTE: Should difficulty be experienced warm casing and bearing assembly. 18. Tap splined end of shaft to free bearing. 17. 15. 13. a bolt screwed into piston will assist removal. Steering box seals 20. Cool bearing cup using a mandrel and tap steering box on a bench. Remove input shaft dirt excluder. Retain shims for reassembly. 2 OVERHAUL . 16. Remove valve and worm assembly. 19. Remove piston. Remove worm adjuster using wrench LRT-57-006.57 STEERING 12. Remove inner bearing cage. Remove circlip and seal from sector shaft housing bore. cup and shim washers. 14.

Fit a new feed tube if damaged. Replacement parts are not available. and possible oil leaks. Check there is no side play on roller. Steering box casing 23. INSPECTING Piston 22. Examine gear teeth for uneven or excessive wear. Examine feed tube.STEERING CAUTION: Do not remove sector shaft bearings from casing. Fit new adjuster if end float exceeds 0. Remove dirt excluder. Sector shaft assembly 26. 25. NOTE: A rubber seal is fitted behind plastic ring on rack piston.15 mm. 30. 21. Tighten to 22 Nm. CAUTION: The use of a seal puller is recommended to prevent damage to casing. Check condition of adjuster screw threads. 28. 24. If side play on roller exists fit a new sector shaft. Examine bearing areas on shaft for excessive wear. OVERHAUL 3 . 27. 29. Examine piston bore for scoring and wear. If sector shaft bearings are worn fit a new steering box. circlip and seal from input shaft housing bore. Discard all rubber seals and provide replacements. Discard seal and plastic ring. Check adjuster end float.

fit a new steering box. Check for wear on torsion bar assembly pin. Examine ball races and cups for wear and general condition. 34. Sector shaft adjuster locknut 32. 42. Examine worm track which must be smooth and not indented. Remove expander. replacement parts are not available. Ball bearing and cage assemblies 39. No free movement should exist between input shaft and torsion bar or between torsion bar and worm. replace all three rings. 40. 4 OVERHAUL . NOTE: Any sign of wear makes it essential to fit new valve and worm assembly. Examine bearing areas for wear. If worn or damaged. Examine valve rings for cuts. Inspect cover and bearing. If ball cage has worn against bearing cup. Bearing balls must be retained by cage. Bearing and cage repair is carried out by complete replacement of assembly. 41. The expander will not pass over rings already fitted. slide expander over valve and worm assembly. 38. The areas must be smooth and not indented. Warm rings and expander tool to aid assembly. If required. slide valve and worm assembly into ring compressor LRT-57-020 and allow to cool.57 STEERING Sector shaft cover assembly 31. 37. The locknut is also a fluid seal. Fit rings to expander. Remove rings to allow access without damaging seal grooves. scratches and grooves. using ring expander LRT-57-019. In turn fit rings to their grooves. 35. 36. The valve rings should be free to rotate in grooves. Fit new nut at overhaul. fit replacements. Valve and worm assembly 33.

Fit outer cage and bearings assembly. Fit new sealing ring to rack adjuster. lip side first.76 mm thickness. 59. 54. 55. Fit oil seal. 60. 48. 45. Rack and piston 46. NOTE: If original shims are not used. 53. 49. Examine thrust pad for scores. Warm nylon seal and fit to piston. lipped side last. OVERHAUL 5 . Refit original shims and inner bearing cup. Examine adjuster for wear in pad seat. Fit inner cage and bearings assembly. Slide piston assembly into cylinder with rack tube outwards. Examine for excessive wear on rack teeth. fit shims of 0. Fit outer bearing cup. 51. Fit dust seal. 57. 50. Ensure thrust pad bearing surface is free from scores and wear. Fitting valve and worm assembly 56. Reassemble NOTE: When fitting replacement oil seals lubricate with recommended fluid and ensure absolute cleanliness. 47. 44. Ensure piston outer diameters are free from burrs and damage. Examine seal and ring groove for scores and damage. Sector shaft oil seal 52.STEERING Rack thrust pad and adjuster 43. Fit extrusion washer. 58. Fit circlip. Use Petroleum Jelly to aid assembly. Fit new ring to piston. Fit valve and worm assembly.

Push in sector shaft while rotating input shaft to allow sector roller to engage worm. Fit locknut. 67. 66.56 Nm.34 Nm with locknut tight. Ensure bearing cages are seated correctly. 100 Nm. Fit new worm adjuster sealing ring. do not tighten. Align roller with cut out in casing . to 0. Fit rack adjuster and thrust pad to engage rack. 62. Fit sector shaft using seal saver LRT-57-021. Use worm adjusting wrench LRT-57-006 and locknut wrench LRT-57-028. 65. Back off worm adjuster 1/4 turn. 72.57 STEERING Fitting rack and piston 68. Screw slave bolt into piston to aid assembly. Turn in worm adjuster to increase reading at 65. Loosely fit new nylon pad and adjuster set screw assembly. Back off half turn on adjuster. 63. by 0. Turn in worm adjuster until end float is almost eliminated. Fit piston and rack so piston is 70 mm from outer end of bore. Fitting sector shaft 70. 6 OVERHAUL . 69. Loosely screw adjuster into casing.0. using a torque wrench and spline socket LRT-57-025. Turn in worm adjuster while rotating shaft to increase figure measured in instruction 65. 64. Fitting rack adjuster 71. Measure maximum rolling torque of valve and worm assembly.21 .see RR3934M. 61.

rotate input shaft to full inner-lock (full right lock for a left hand drive vehicle. 82. OVERHAUL 7 . Fit retaining ring to groove with one end of ring positioned 12 mm from extractor hole. Tighten to 75 Nm. turn adjuster screw approximately two turns in a clockwise direction. rotate input shaft to ensure sector shaft roller is free to move in valve worm. The box is now on centre and can be adjusted. 79. 74. If necessary back off sector shaft adjuster screw. Fitting cylinder cover 78. 77. Press cover into cylinder just to clear retainer ring groove. 81. Fit cover bolts. full left lock for a right hand drive vehicle). Tap cover in place to allow cover to joint fully with casing. Remove slave bolt fitted at instruction 68. Align cover with casing. 80. Adjusting sector shaft NOTE: Refit drop arm and tighten nut sufficiently to ensure that no backlash exists between drop arm and sector shaft. Fit new square section seal to cover.STEERING Fitting sector shaft cover 73. To set worm on centre. Fit new sealing ring to cover. 75. Screw cover assembly fully on to sector shaft adjuster screw. 76. NOTE: Before tightening fixings. Rotate input shaft back towards centre two full turns. If initial resistance is left.

0.24mm. rolling torque figures should be greatest across centre position and equally disposed about centre position. NOTE: Adjustment of 0. 86. Hold input shaft and rock drop arm to establish backlash is present. With input coupling shaft toward the operator.0. refer to fitting valve and worm assembly . turn shaft fully counter-clockwise. 0. extreme caution must be exercised to prevent seal damage during reassembly.34 Nm plus torque figure at one and a quarter turns. Adjustments 91. 87. Check maximum rolling torque one and a quarter turns either side of centre position. The final figure may be less. subtract from shim washer value. Procedure 88. The condition depends on value of shimming fitted between valve and worm assembly inner bearing cup and casing.07mm. 85. Check torque figures obtained from lock to lock using torque wrench and spline socket LRT-57-025. Note where greatest figures are recorded relative to steering position. Tighten to 5 Nm. by 0. Tighten adjuster locknut to 60 Nm. using a torque wrench and spline socket LRT-57-025.07mm to shim value will move torque peak area by 1/4 turn on the shaft. Torque peak check With input shaft rotated from lock to lock.35 Nm.12mm and 0. Adjusting rack adjuster. Continue rotating adjuster screw until backlash has almost been eliminated. Shim washers are available as follows: 0. add to shim washer value. Check also for equal engagement either side of centre. The original shim washer value will give correct torque peak position unless major components have been replaced.23 .If greatest figures are not recorded across centre of travel (steering straight-ahead). Continue rocking and slowly turn sector shaft adjusting screw clockwise. Turn in rack adjuster to increase figure measured in instruction 85. but must not exceed 1. 84. Rotate adjuster screw to obtain across centre torque of 0. adjust as follows: If torque peak occurs before centre position. if torque peak occurs after centre position. NOTE: It is important steering box is centralised before any adjustments are made.57 STEERING 83. Lock rack adjuster in position with grub screw. 8 OVERHAUL . Refit locknut and tighten.34 Nm.03mm. 90. CAUTION: When reshimming valve and worm. 89.

94. Fit steering box. Fit seal. dimension X in RR3941M. Smear inner lip of dirt excluder with PTFE grease. Note that seal is fitted to a depth of 4. 96. With input shaft on centre. Remove drop arm.00 mm from face of box.4.75 . When fitted correctly outer shoulder of excluder is 4. Use seal saver LRT-57-016 and seal installer LRT-57-026. 93. 97. line up centralising holes in drop arm and steering box see inset in RR3940M. Secure seal with circlip. into housing. Fit dirt excluder using LRT-57-027. Fit drop arm to steering box using a new tab washer. bend over tab.STEERING Input shaft oil seal 92.00 .50 mm from face of box. Tighten to 176 Nm. See Repair. OVERHAUL 9 . Smear inner lip of dirt excluder with PTFE grease and refit.5. Power Steering Box 95. ensuring outer lip is flush with casing. lip side first.

............ Operating pressure ....... Full lock (left or right) at idle .......straight ahead position ........at idle .......... TORQUE 1 ............................................................ ZF ’Unicorn’ Hobourn Eaton 500 series 7 bar...........V8i .....Tdi .......................STEERING STEERING PUMP Make/type .......... Make/type ......... 400 lbf/in2 minimum 70-77 bar.................... 1000-1100 lbf/in2 SPECIFICATIONS..... Full lock (left or right) 1000 rev/min ............................ 100 lbf/in2 maximum 28 bar.......

........... 45 M12 ............................................................................ 3 Front mounting plate bolts ..... 81 Steering box fluid pipes 14mm thread ................................................................................. 105 M16 .............................................................................................................................. 3 * Torque values below are for all screws and bolts used except for those that are specified otherwise...................... 35 Pulley bolts........... 22 Steering wheel nut .......... 60 Drop arm nut .................................................. METRIC Nm M5 .... 81 PAS pump High pressure fluid pipe .......................................................................................................................................... 9 5/16 .......................................................................................................................................................................... 90 5/8 .................................. 20 Tie bar ........... 15 Steering box fluid pipes 16mm thread ...................................................................... 176 Sector shaft cover to steering box ................ 25 PAS box Adjuster locknut ...................... 90 M14 ............................................................................................................................................................................................................................................................................... 24 3/8 ................................................................................................................................................................................................................................................................................. 9 M8 ...................................................................... 14 Steering column bracket nuts ............................................................................................................................... Nm Ball joint nuts ................ 6 M6 ............ 136 2 SPECIFICATIONS..............................................................57 STEERING TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque...................................................................................................... 20 Power steering pump mounting ......................... 39 7/16 ............................... 9 PAS reservoir Hose clamp ......................................... 78 1/2 ..................................... TORQUE ...................................................................................................................................................................................................................................................................... 75 Steering box to chassis .................................................................. 40 Clamp bolt nuts . 50 Tie bar to mounting nut ................................................... 180 UNC / UNF 1/4 .......................................................................................................................... 110 Universal joint pinch bolt ................. 10 Hose clamp .................. 25 M10 ......................................................................................................................................................... power steering pump ..............................................................................

STEERING POWER STEERING BOX LRT-57-012 Drop arm extractor LRT-57-007 ’C’ Wrench LRT-57-006 Worm adjusting wrench LRT-57-019 Ring expander SERVICE TOOLS 1 .

57 STEERING LRT-57-020 Ring compressor LRT-57-021 Seal saver. sector shaft LRT-57-016 Seal saver. valve and worm LRT-57-017 Torque setting tool 2 SERVICE TOOLS .

STEERING LRT-57-018 Ball joint remover LRT-57-005 Pressure gauge LRT-57-001 Test adaptor LRT-57-022 Pressure test adaptors SERVICE TOOLS 3 .

FRONT SUSPENSION INTRODUCTION Suspension design is a major factor in determining the comfort. safety and performance of any vehicle. but is particularly significant to 4 wheel drive cross country vehicles. Independent system DESCRIPTION AND OPERATION 1 . Suspension comparison 1. A well designed beam axle layout can embrace all of these qualities and also has the inherent advantage (over independent systems) of no variation in wheel track or camber angle. Beam axle system 2. and provide good ground clearance without loss of traction or directional stability. The ideal suspension must allow maximum wheel travel and axle articulation.

Front axle suspension 1.transverse location Radius arms . provide the springing for each wheel.longitudinal location Coil springs Shock absorber Long travel coil springs and hydraulic shock absorbers. 4. by two forged steel radius arms and transversely by a panhard rod. 3. 2. 2 DESCRIPTION AND OPERATION .60 FRONT SUSPENSION AXLE LOCATION The front axle is controlled longitudinally. Panhard rod .

Remove 1. Press out flexible bushes. 5. PANHARD ROD Service repair no . Raise front of vehicle.07. Support chassis on stands and remove wheel. CAUTION: Apply pressure to outer edge of bush. Disconnect track rod at ball joint. Lower radius arm front end to clear axle and remove from vehicle. Loosen road wheel retaining nuts. 2. Support front axle weight with jack. 1 to 4. Fit replacement bushes. 4. 7. 6. Remove fixings.10.10. 3. Remove radius arm to chassis side member fixings.60.60. Remove 1. Tighten to 88Nm REPAIR 1 . 3. Remove Panhard rod. RADIUS ARM Service repair no .FRONT SUSPENSION SELF LOCKING NUTS WARNING: Where self locking nuts are removed. Reverse removal procedure. Refit 5. they must be replaced with new nuts of same specification.16. Ensure the steel tubing locates on the outer edge of the bush and not on the rubber inner. radius arm to axle. 6. Remove fixings at mounting arm. 4. and not rubber inner. Remove fixings at axle bracket. 2.

30. Loosen road wheel retaining nuts. 2 REPAIR . Press out flexible bushes. 1 to 8. 3. Press in replacement bushes. 6. CAUTION: When pressing in new bushes press on outer edge of bush and not rubber inner. 5. Refit 9. 10. Withdraw shock absorber and bracket complete. Support axle weight with jack. Remove 1. Tighten fixings to following torques: Radius arm to chassiss 176Nm Radius arm to axle 197Nm 4.60. 8. rubber bush and seating washer. 2.60 FRONT SUSPENSION FRONT SHOCK ABSORBER Service repair no . Support chassis on stands and remove road wheel. Remove four shock absorber bracket fixings.02. Remove shock absorber lower fixing and withdraw cupwasher. Reverse removal procedure.

11. 3. Remove fixings. Reverse removal procedure. If necessary loosen hose connector locknuts to allow hoses to follow axle. Fit front shock absorber. 10. Retain in position with a nut. Withdraw mounting bracket. Fit shock absorber bracket retaining ring. Remove 1.20. 8. REPAIR 3 . Remove nut retaining securing ring. 2. 6. 7. Withdraw shock absorber bracket securing ring.FRONT SUSPENSION 7. Withdraw lower seating washer. rubber bush and cupwasher. Refit 11. shock absorber to mounting bracket. FRONT ROAD SPRING Service repair no . Lower axle sufficient to free road spring. Withdraw road spring. 1 to 10.60. Remove front shock absorber. See Front Shock Absorber CAUTION: Avoid over stretching brake hoses. 4. Lift off top seating washer. 9. Reverse 2 and 3. Refit 5. 8. rubber bush and cupwasher.

Remove bump stop. 4.10. Refit 3. Remove fixings. secure with washers and nuts. 2. 4 REPAIR . Position bolts in slots in chassis brackets.60 BUMP STOP FRONT SUSPENSION Service repair no . Fit bump stop.30.60. Remove 1.

bolt. Ensure split points towards axle on RH bush and away from axle on LH bush. Remove four nuts. Tighten to 68Nm. Fit bolt. bolts. Anti-roll[sway] bar Rubber bush Strap Nut. 3.FRONT SUSPENSION ANTI-ROLL[SWAY] BAR ASSEMBLY FRONT Service repair no . Position bushes on anti-roll[sway] bar. Mark for reassembly position of rubber bushes on anti. 2. washer 5. 3. 6.10.60. washers and rubber bushes from ball joint links and remove anti-roll[sway] bar. washers and rubber bushes. Loosely fit the bolts.roll[sway] bar. 4. washers and nyloc nuts. Using new nuts fit anti-roll[sway] bar to ball joint links. 2. Nut and washer 6. Refit 4. Fit anti-roll[sway] bar with two straps. 7. Ball joint link arm Remove 1. Remove nuts. 5. Tighten nuts securing straps to 30Nm REPAIR 5 . Castellated nut and cotter pin 7. bolts and washers securing two bush straps. To ensure correct fit angled sides of bar should point down as shown.01 KEY 1.

Fit bolts. Remove two nuts. Ensure ball joint link arm points up. Remove cotter pin and loosen castellated nut a few turns. Tighten to 68Nm. 6.04.60. washers and rubber bushes from ball joint links. bolts. Fit ball joint link and castellated nut. Refit 5. Align anti-roll bar to ball joint links. 3. Remove 1. 7. 4. 6 REPAIR .60 FRONT SUSPENSION ANTI-ROLL[SWAY] BAR BALL JOINT LINKS Service repair no . Tighten to 40Nm and fit new cotter pin.10. 2. Release ball joint using special tool 18G 1063A as shown. washers and rubber bushes using new self locking nuts secure anti-roll[sway] bar to ball joint links. Remove castellated nut and ball joint link.

.................................................... 40 Drag link to axle ....................... M8 ................................................................... 68 .................................. 3/8 ......................... M14 .............................................................................. 197 Torque values below are for all screws and bolts used except for those that are specified otherwise........... 88 Tie bar to Panhard rod ..................... 40 Securing ring for mounting turret .................................................... 110 Radius arm to axle (front only) .......................................... 88 Panhard rod to axle ................................................................................... TORQUE 1 ....................................................................... 1/2 ................................................................... Nm 6 9 25 45 90 105 180 UNC / UNF 1/4 ..................................................... M16 ............................................................... 7/16 .......................................... M12 ................................................................................................................................ 5/16 ...................................................................................... M6 ................................................................................................. 5/8 ..........................................................................................Castellated nut ................................................................................................ 30 ..................................................................Strap nyloc nuts ......................... 9 24 39 78 90 136 SPECIFICATIONS.............................................................................. METRIC M5 ................................................FRONT SUSPENSION TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque........ 88 Panhard rod to mounting bracket ..Ball link self lock nut ................................ 14 Radius arm to chassis ............................................... 176 Panhard rod mounting arm to chassis ............................ Nm Anti-roll[sway] bar front .......... M10 ........................................................................................................................................................

Long travel coil springs and hydraulic shock absorbers provide the springing for each wheel. "A" frame. Rear axle suspension 1. which is secured to a chassis cross member and provides transverse control.longitudinal location Coil springs Shock absorber DESCRIPTION AND OPERATION 1 . 3. upper link assembly.REAR SUSPENSION AXLE LOCATION Longitudinal location of the rear axle is by solid round section steel link arms and a forged "A" frame. upper link assembly .transverse location Lower link assembly . 4. 2.

Support rear axle weight with jack. 3. and spring isolator. CAUTION: Avoid lowering axle further than rear brake flexible hose will allow. Remove spring retainer plate. Refit 11. 6. Reverse removal procedure. If required remove mounting bracket If required remove mounting rubbers. 7. 8. Remove 1. Disconnect shock absorbers at one end. Refit Remove upper fixings. 5. 5. Reverse removal procedure.64. Lower axle to free road spring from upper seat.01 Remove 1. Loosen road wheel retaining nuts. Position coil spring compressor correctly on road spring.REAR SUSPENSION REAR ROAD SPRING Service repair no . Loosen rear road wheel retaining nuts. 3. Compress spring evenly to facilitate removal. 4. 2.64. 8. 2. 4. 7. Support chassis on stands and remove wheels. Withdraw shock absorber.30. REAR SHOCK ABSORBER Service repair no . 10.20. Lift off spring seat. REPAIR 1 . 9. Remove fixings and withdraw shock absorber from axle bracket.02. 6. Withdraw road spring. Remove road wheel and support rear axle weight with jack. Support chassis on stands.

Remove fixings. 2.44. Separate link from bracket. upper links to pivot bracket. 6. Fit bump stop secure with washer and nuts. Remove bump stop. 2. Remove upper link complete with frame bracket.64. allow axle to hang freely. 5. 4.35. 3. Remove 1.15. Refit 3.30.64 BUMP STOP REAR SUSPENSION SUSPENSION LINK UPPER Service repair no . Support rear of chassis on stands. Remove bolt. upper link bracket to frame.64. Remove fixings. 4. Remove 1. 2 REPAIR . Remove fixings. Position bolts in slots in bracket. Service repair no .

CAUTION: Apply pressure to outer edge of bush. SUSPENSION LINK LOWER Renew bush Service repair no . support vehicle on stands under rear axle.REAR SUSPENSION Renew bush 7. Fit bush centrally in housing.64. Alternatively. Do not fully tighten fixings until all components are in position. 8. and not rubber inner. Reverse removal procedure. 11. 3. Tighten fixings to correct torque. Remove locknut. 6 and 7. 9. Reverse removal procedure. Torque Values 4. Remove 1. 12. 10. See Specifications. Reverse removal procedure. 7. CAUTION: Apply pressure to outer edge of bush. 2. allow axle to take up static laden position. Lower vehicle. Press out rubber bushes. Remove mounting bracket from lower link. torque.35. 1 to 6. Tighten to 176 Nm. Refit 9. 8.02. Site vehicle on a ramp [hoist]. Remove rear fixings. Fit bush centrally in housing. Press out rubber bushes. 5. Remove mounting bracket fixings at side member bracket. and not rubber inner. Remove lower link complete. Do not tighten locknut. 6. REPAIR 3 . Refit 10. 3 to 5.

7. Fit anti-roll bar with two straps. bolt. Tighten to 68Nm. washers and rubber bushes from the ball joint links and remove anti-roll bar. bolts.64 REAR SUSPENSION ANTI-ROLL[SWAY] BAR ASSEMBLY REAR Service repair no . Fit bolt. Fit anti-roll bar to ball joint links. 7. Anti-roll[sway] bar Rubber bush Strap Nut. Fit joint towards axle.64. Loosely fit. 6. Remove nuts. bolts. KEY 1. position of rubber bushes on anti-roll bar. Refit 4. 5. washers and new nyloc nuts. washer 5. 3. 3. washers and rubber bushes. Remove four nuts. 2. 2.08. 8. 4. Ensure ball joint link arms point down as shown. bolts and washers securing two bush straps. Nut and washer Ball joint link arm Bolt and washer Castellated nut and cotter pin Remove 1. 6. Tighten nuts securing straps to 30Nm. Position rubber bushes on anti-roll bar. 4 REPAIR . Note for reassembly.35.

Remove two nuts. 4.35. Fit ball joint link arm and castellated nut. washers and rubber bushes from ball joint links and lower anti-roll bar to clear links. Align anti-roll bar to ball joint links. washers and rubber bushes using new self locking nuts secure anti-roll bar to ball joint links. Remove castellated nut and ball joint link. Tighten to 68Nm. 6. Release ball joint using special tool 18G 1063A as shown. REPAIR 5 . Refit 5.24. Point ball joint link arm down as shown. Fit bolts. Remove 1. 7. 2.REAR SUSPENSION ANTI-ROLL[SWAY] BAR BALL JOINT LINKS Service repair no . bolts. Remove cotter pin and loosen castellated nut a few turns.64. Tighten to 40Nm and fit new cotter pin. 3.

.................................................. 9 M8 ................................................................................................................... 78 1/2 ....................... METRIC Nm M5 ...................Castellated nut ................................Ball link self lock nut ...................................................................... 6 M6 ............................................... 9 5/16 ............................................................... 39 7/16 ........................................................................................................................................................................................................... 176 Bottom link to chassis .............................................................................................................................................................................................................................................................................................. 90 5/8 ...............................................Strap nyloc nuts ................................................... 90 M14 .................. 45 M12 ............................................................................... 176 Bottom link to axle ................................................................... 30 .... 180 UNC / UNF 1/4 .......................................... 47 Shock absorber to axle ................................................ Nm Anti-roll[sway] bar rear ........................................................ 136 SPECIFICATIONS.................................................................................................... 40 Top link to mounting bracket .................... 25 M10 ........................................................................ 37 Torque values below are for all screws and bolts used except for those that are specified otherwise..... 176 Top link bracket to rear cross member ............. 24 3/8 ............................................................... 105 M16 ......................................................................................................................................................................................REAR SUSPENSION TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque................................................................... 68 ...................................................... TORQUE 1 .......

The brake pedal travel will be longer in the event of a half system failure. The brake fluid reservoir is divided. incorporating primary and secondary hydraulic circuits. If the secondary circuit fails the primary circuit will still function. these are fed by the primary hydraulic circuit via a pressure reducing valve. NOTE: References made to primary or secondary do not imply main service brakes or emergency brakes but denote hydraulic line identification. In the event of a failure in the primary circuit the secondary circuit will still function. A brake fluid level switch is incorporated into the reservoir cap assembly. The brake pedal is connected to a vacuum assisted mechanical servo which in turn operates a tandem master cylinder. Under normal operating conditions both the primary and secondary circuits operate simultaneously on brake pedal application. these pistons are fed by the secondary hydraulic circuit.BRAKES BRAKES Discovery vehicles have servo assisted brake systems and the option of an anti-lock brake system. The front disc brake calipers each house four pistons. The hand operated parking brake acts on a brake drum at the rear of the transfer gearbox and is completely independent of the hydraulic circuits. The rear disc brake calipers each house two pistons. Hydraulic circuit non ABS BRAKE SYSTEM NON ABS Description The servo assisted hydraulic braking system is the dual line type. Where the system components are different they are referred to as ABS or NON ABS If the servo should fail. the section closest to the servo feeds the primary circuit and the section furthest from the servo feeds the secondary circuit. Key A = Primary hydraulic circuit B = Secondary hydraulic circuit C = Pressure reducing valve DESCRIPTION AND OPERATION 1 . both hydraulic circuits will still function but would require greater pedal effort due to the lack of vacuum assistance. Information in this section refers to components relevant to both brake systems. the switch will immediately illuminate a warning light in the instrument binnacle indicating low fluid or sudden fluid loss.

Front sensors/exciter rings 7. Diagnostic plug connection 2 DESCRIPTION AND OPERATION . 3. 2. 4.70 BRAKES ABS COMPONENTS Location Key to diagram 1. Rear sensors/exciter rings 6. ABS Modulator unit Servo/Master cylinder Pressure reducing valve Electronic control unit 5.

Fuse Box . sensing a 60 tooth exciter ring. • The fitting of ABS does not imply that the vehicle will always stop in a shorter stopping distance. allowing full system pressure to the rear axle in the event of a front circuit failure. It is non serviceable. It is sited on the left inner wing [fender].ABS Manufactured by WABCO Introduction The purpose of ABS is to prevent vehicle wheels locking during brake application. This allows vehicle to be steered whilst brakes are applied. this provides pressure to opposed piston calipers at each brake pad Twin piston at the front axle. non serviceable. 5.BRAKES Description of components 1. For location and identification of ABS electrical fuses. The Modulator has 8 solenoid valves.4 off A sensor is sited at each wheel. Front and rear sensors/exciter rings . Details of how to access the ECU diagnostics are provided in the Electrical Troubleshooting Manual. Pressure reducing valve To maintain the braking balance. Diagnostic plug connection A diagnostic plug is located behind the dash. following another vehicle too closely or aquaplaning. is connected to the ABS harness by a 35 way connector. i. Repair. Fuse Box . 4. See ELECTRICAL. DESCRIPTION AND OPERATION 3 . and to avoid obstacles where there is sufficient space to redirect the vehicle. • The additional control provided by ABS must never be exploited in a dangerous or reckless manner which could jeopardise the safety of driver or other road users.Interior or. 3. The ECU continually monitors the brake system. Repair. On both LHD and RHD vehicles it is sited on the left inner wing [fender].ECU ABS control is provided by an electronic control unit which is positioned on the passenger side of the vehicle behind the dash panel/glove box.& 6. Servo/master cylinder Actuation of the system is provided by a combined master cylinder and servo assembly attached to the pedal box. • ABS will not prevent accidents resulting from excessive cornering speeds. thus maintaining vehicle steerability and stability. It is a 5 way blue connector. single piston at the rear. The location and identification of ABS electrical relays are given in the Electrical Troubleshooting Manual.e. 2 for each wheel. • ABS cannot defy the natural laws of physics acting on the vehicle.Engine Compartment ANTI-LOCK BRAKE SYSTEM . The rear exciter ring is bolted to the rear of each brake disc bell. Electronic control unit . which is non-serviceable. Front exciter ring is fitted to outside diameter of constant velocity joint inside each front hub assembly. To the right of the steering column on RHD vehicles. WARNING: ABS is an aid to retaining steering control and stability while braking. 2 expanders and a recirculation pump. When vehicle is in motion inductive sensors send signals to ECU. providing diagnostics in the event of a system malfunction. The ECU. ABS Modulator unit To provide the ABS function a Modulator is positioned within the system between the master cylinder and the calipers. even under emergency conditions. pressure to the rear axle is regulated by a Pressure Reducing Valve (PRV) This PRV is of the failure bypass type. See ELECTRICAL. 2. To the left of the steering column on LHD vehicles. where a layer of water prevents adequate contact between tyre and road surface. 7.

3-2 secs). Hydraulic circuit ABS ABS System operation During normal braking the feel of the brake pedal on vehicles equipped with ABS will be the same as that on non ABS vehicles. Key A = Primary hydraulic circuit B = Secondary hydraulic circuit C = Pressure reducing valve D = ABS Modulator 4 DESCRIPTION AND OPERATION . including a check of the solenoid valves/pump motor.then comes on again.70 BRAKES System description The brake system consists of dual hydraulic circuits in a front . and will only act when the ECU detects that ABS cycling is necessary. WARNING LIGHT The warning light will be on during the self check (1.rear split. The system is fully automatic in operation both on and off road. That is individual circuits to front and rear axles.5sec. This is the only time that the light will be on without indicating a problem. Discovery Electrical Troubleshooting Manual gives the location and wiring circuits of these components. It will then remain on until the vehicle is driven faster than 7 kph/5mph. Electrical wiring is provided as necessary with system relays and fuses. Wheelspeed signals are provided by the fitting of exciter rings to axles and speed sensors. The ECU continually monitors the operation of the system. When starting the ABS system will go through a series of self checks. During ABS cycling the driver will experience feedback in the form of a pulsating brake pedal and solenoid/pump motor noise from the Modulator. Visual warning of system malfunction is provided via a warning light in the instrument panel. An ABS stop light switch is fitted to provide a braking signal to the ECU as well as operate the stop lights. If no faults are stored in the memory the light goes out for 0. Any faults detected by the ECU will cause the warning light to illuminate indicating that the vehicle may not have full ABS control.

2. KEY 1. 22. Connector double elbow Rear left brake Modulator to rear left brake Modulator to master cylinder Modulator to pressure reducing valve upper Electrical connection Modulator unit Nut. 15. 19. 17. 11. 4. 10. On right hand drive vehicles the master cylinder and servo unit only move position. 16. 5. Modulator to front right brake Modulator to pressure reducing valve lower Master cylinder to pressure reducing valve lower Front right brake Bolt Pressure reducing valve Modulator to pressure reducing valve upper Master cylinder Servo unit Modulator to rear right brake Rear right brake DESCRIPTION AND OPERATION 5 . 9. 21. 13. mounting bush and cup Modulator to front left brake Front left brake Electrical connection 12. 8. 7. 3.BRAKES BRAKE PIPE LAYOUT ABS Left hand drive shown. 14. 18. 20. 6.

Master cylinder 11. Pressure reducing valve 9. 7. 5. T-Connector Rear left brake Master cylinder to pressure reducing valve lower Front left brake to pressure reducing valve upper Front left brake Front right brake Master cylinder to pressure reducing valve lower 8.70 BRAKES BRAKE PIPE LAYOUT NON ABS Left hand drive shown. Pressure reducing valve upper to both rear brakes 13. On right hand drive vehicles the master cylinder and servo unit only move position. 2. 6. Front right brake to pressure reducing valve upper 10. Servo unit 12. 3. KEY 1. 4. Rear right brake 6 DESCRIPTION AND OPERATION .

D via the valve C which is shown fully released in RR3640M.3 and 4. in chambers 1. vacuum is present in front of the diaphragm with atmospheric pressure on the rear. B. it provides very accurate control of the position of the diaphragm and therefore.BRAKES BRAKE SERVO UNIT Description The power assistance for the brake system is provided by a twin diaphragm suspended vacuum servo. The chambers comunicate by ports A. with the engine running vacuum is present both sides of the diaphragm or diaphragms when the brakes are fully released or partially applied. it ensures instantaneous servo response to the brake being applied or released and second. A ’Suspended Vacuum’ servo is one where. At full pedal depression. First. the degree of partial brake application. Operation Brakes released With the brakes released depression is present both sides of the diaphragms. The principal of having vacuum both sides of the diaphragm has two main advantages.2. DESCRIPTION AND OPERATION 7 .

when valve C comes to rest on the plunger 7. This slight movement causes valve C to close port D sealing off the vacuum to chambers 2/4 and allows atmospheric pressure to enter the chambers through the air filter E. diaphragms and master cylinder push rod will stop moving. Inital depression of the the brake pedal. 8 DESCRIPTION AND OPERATION . At this point the valve will balance the pressure in all the chambers. the servo hub. to provide the power assistance. the pressure in all chambers is equalised and the servo is returned to the rest position by spring 12. It is only when the brakes are fully applied that the valve does not balance the pressures in all the chambers. Atmospheric pressure over the large area of the diaphragms multiples the force applied to the master cylinder piston. If the brake pedal is only partially depressed. When the brake pedal is released.70 BRAKES Brakes applied When the brake pedal is depressed the pedal pushrod operates valve C situated in the plastic diaphragm hub 9 and 10. but ensures that maximum available depression is in chambers 1/3 and full atmospheric pressure enters chambers 2/4. With depression in chambers 1/3 and air pressure in chambers 2/4 the servo hub will apply the brakes via the master cylinder push rod 13. push rod 6 and plunger 7 compress a rubber pad 8. to the applied effort at the pedal and provide proportional braking.

However any excessive air leaks due to damage in the brake servo system or manifold hose connection.BRAKES Petrol engine vacuum system The vacuum necessary to operate the brake servo on petrol engine vehicles is provided by the engine inlet manifold. DESCRIPTION AND OPERATION 9 . During normal operation of the brakes only a small volume of air is drawn from the servo by the vacuum pump. Diesel engine vacuum system As the diesel engine inlet system does not produce depression sufficient to operate the brake servo. may cause excessive crankcase pressure. However as the pump exhausts air into the engine crankcase atmosphere. will effect the mixture strength and ECM fuelling calculations on engines equipped with an MFI system. During normal operation of the brakes only a small volume of air is drawn from the servo and into the inlet manifold or plenum chamber. an air leak due to damage in the brake servo system or pump hose connection. it is necessary to install an engine driven vacuum pump.

2. Inspect all exposed cables for damage or abrasion. or has been identified by ECU self diagnostic function and ABS warning light is illuminated. Battery . NOTE: If warning lamp has indicated a fault in system.BRAKES ABS FAULT DIAGNOSIS If a fault has occurred. 2. 4. NOTE: After any steering adjustment.state of charge. DO NOT attempt to open sealed 35 way connector to ECU. Fault rectification 1. Before commencing fault diagnosis procedure following items must be checked: 1. RELAYS AND FUSES ABS The location and identification of ABS electrical relays are given in the Electrical Troubleshooting Manual For location and identification of ABS electrical fuses. 3. Check hub end-float. 3. fault will be retained by the ECU memory. The ECU will indicate a fault that has been rectified. as this could jeopardise safe function of ABS. Repair. 5. All ABS fuses and electrical connections. Fuse Box . Complete harness should be replaced if faults are found in wiring harness. See ELECTRICAL. bearing replacement/adjustment. and no fault code has been stored in memory.Interior or. using Testbook diagnostics. See ELECTRICAL. The system and components must be checked to locate and rectify fault.Engine Compartment FAULT DIAGNOSIS 1 . Check ground on ABS system. Where wheel sensors have been pushed fully home prior to test. Fuse Box . cause of fault is: a) b) c) d) Failure in electrical supply Bad ECU ground Faulty warning light relay ECU not connected FAULT DIAGNOSIS PROCEDURE NOTE: If ABS warning light illuminates due to large sensor air gap. DO NOT use unspecified cables or connectors. Repair. brake disc replacement: Check hub end-float and sensor clearance.

70 BRAKES ABS FAULT AND REMEDY CHART SYMPTOM ABS warning light on POSSIBLE CAUSE ABS electrical fault CHECK Check ABS electrical circuit with Testbook diagnostic equipment REMEDY Change component if necessary Push in sensors High sensor air gaps Brake fluid warning light ON Fluid loss Check reservoir fluid level and inspect system for leaks Check fluid level switch Rectify leakage. refill reservoir Change reservoir cap/switch Rebleed brake system Change master cylinder Reservoir fluid level switch malfunction Pedal travel increased. foot pressure normal Air in system Master cylinder malfunction Pedal can be moved downwards under constant pressure Seal leaking in master cylinder Seal leaking in servo unit Inspect system for leaks Change master cylinder Change servo unit 2 FAULT DIAGNOSIS .

Park vehicle on level ground.e. 2. • DO NOT use brake fluid previously bled from the system. FLUIDS AND CAPACITIES. CAUTION: Thoroughly clean all brake calipers. if spilled wash off immediately with plenty of clean water. If an assembly fluid is required use ONLY brake fluid. Cover all electrical terminals carefully to make absolutely certain that no fluid enters the terminals and plugs. CAUTION: Use only correct grade of brake fluid. The brake system should be drained and flushed at the recommended service intervals. Do NOT use mineral oil. See LUBRICANTS. Check level is between ’MIN’ and ’MAX’ marks. Use only fluid from a sealed container. • To ensure the brake system efficiency is not impaired the following warnings must be adhered to :• DO NOT use any petroleum based cleaning fluids or any proprietary fluids containing petrol. Information. engine oil etc. Recommended Lubricants and Fluids Do not fill reservoir above maximum line REPAIR 1 . 3. 1. CAUTION: Brake fluid can damage paintwork. Failure to do so could cause foreign matter to enter the system and cause damage to seals and pistons which will seriously impair the efficiency of the brake system. using correct fluid. i. FLUID LEVEL CHECK / TOP UP WARNING: Clean reservoir body and filler cap before removing cap. pipes and fittings before commencing work on any part of the brake system. If level is below ’MIN’ mark top up fluid level to ’MAX’ mark on reservoir.BRAKES GENERAL BRAKE SERVICE PRACTICE Brake fluid precautions WARNING: Do not allow brake fluid to come into contact with eyes or skin. • DO NOT flush the brake system with any fluid other than the recommended brake fluid.

6. See Fluid Level Check / Top-Up 2 REPAIR . 9. 5. Preparation WARNING: Before bleeding the brake system refer to general brake service practice. Open bleed screw of caliper. The equipment manufacturer’s instructions must be followed and the pressure must not exceed 4. Disconnect battery negative lead. one at each caliper. Keeping pedal fully depressed. Air bubbles will rise into the reservoir during these instructions. Release the pedal and wait for ten seconds. brake fluid level must not be allowed to fall below the MIN level. PRESSURE BLEED PROCEDURE. Repeat the above procedure on remaining three calipers. Manual bleed procedure Equipment required • Clean glass receptacle • Bleed hose • Wrench • Approx 2 litres brake fluid.70. Repeat instructions until a firm resistance is felt at the pedal. Pressure bleed procedure Purpose designed equipment for pressure filling and bleeding of hydraulic systems may be used on Land Rover vehicles. 2. Fit all bleed screw protection caps. Fit bleed hose to any caliper bleed screw. See LUBRICANTS. Depress brake pedal fully and slowly 5 times. Check/top-up fluid level when bleeding is complete. Information. 2. then release pedal. Complete circuit bleed 1. 8. Disconnect battery negative lead. FLUIDS AND CAPACITIES.5 bar. 4. • To bleed the hydraulic circuits four bleed nipples are provided. Keep reservoir topped to the MAX level. See General Brake Service Practice • During bleed procedure.25. 5. 3.02 The following method for bleeding the hydraulic brake system applies to both ABS and NON ABS vehicles. MANUAL BLEED PROCEDURE. 7. Dip free end of bleed hose into brake fluid in bleed bottle.70 BRAKES BRAKE SYSTEM BLEED Service repair no . tighten bleed screw. Recommended Lubricants and Fluids Master cylinder bleed 1. 4. • There are two methods by which air can be removed from the braking system:1. 2. Depress brake pedal fully several times until fluid is clear of air bubbles. 3.

Bleed system.4mm CV/CV NOTE: This master cylinder is identified by a 3rd plugged outlet port protruding down from the master cylinder body. 5. Fit master cylinder to servo. REPAIR 3 . Secure in position with two nuts. Place a suitable container under master cylinder to catch brake fluid from cylinder when brake pipes are disconnected. 6. 2. Tighten to 26 Nm. Disconnect battery negative lead. Detach master cylinder from servo. Before starting repair refer to general brake service practice.Type 25. Fit cap. Remove each brake pipe. sealing each pipe and outlet port with suitable plugs to prevent ingress of foreign matter. Information. reconnect electrical lead to fluid level switch. 4.30. 7. Reconnect battery negative lead. Fit brake pipes to master cylinder. remove reservoir cap and drain brake fluid into a container. Recommended Lubricants and Fluids 10. See LUBRICANTS. Refit NOTE: Ensure O ring seal between master cylinder and servo unit is fitted correctly.08 . See Brake System Bleed 11.BRAKES MASTER CYLINDER ABS Service repair no . See General Brake Service Practice Remove 1. Thoroughly clean immediate area around all outlet ports.Lucas Girling .70. Remove two nuts securing master cylinder to servo unit remove also spring and plain washers. Tighten to 15Nm. 3. FLUIDS AND CAPACITIES. Top-up master cylinder with correct grade of brake fluid. Disconnect electrical plug from low fluid switch on reservoir cap. 8. plain and spring washers. 9.

Lucas Girling .Type 25. Thoroughly clean master cylinder and inspect outer surfaces for damage and condition. remove reservoir cap and drain brake fluid into a suitable container.70.70 BRAKES MASTER CYLINDER NON ABS Service repair no . Thoroughly clean immediate area around all outlet ports. See General Brake Service Practice Remove 1. Using two soft jaws. 6. sealing each pipe and outlet port with suitable plugs to prevent ingress of foreign matter. 9. 8. Remove water ingress ’O’ ring seal from master cylinder to servo flange and discard. Remove two nuts securing master cylinder to servo unit remove also spring and plain washers.4mm AS/AS WARNING: This master cylinder is not suitable to be fitted on vehicles with antilock brake systems. clamp master cylinder flange in a suitable vice.Remove Service repair no .09 . 2.30.30. Disconnect battery negative lead.70. 4.Repair . renew complete assembly if necessary. Grip outside of transfer housing with a suitable pair of pliers. working pliers in a backwards and forwards rocking motion to ease housing off master cylinder. 4 REPAIR . Remove each brake pipe. Detach master cylinder from servo. Before starting repair refer to general brake service practice. 3. Discard housing and vacuum seal. carefully pull. Place a suitable container under master cylinder to catch brake fluid from cylinder when brake pipes are disconnected. Repair 7. 5.08 . Disconnect electrical plug from low fluid switch on reservoir cap.

which supports primary plunger assembly. Discard seals. Note for reassembly these seals are different. Pull primary plunger assembly out of master cylinder. 14. Discard both seal and retaining ring. from mouth of master cylinder. REPAIR 5 . Ease reservoir out of master cylinder taking care to ensure that two outlet ports on bottom of reservoir do not become damaged during this process. 13. note this component is not part of service kit. 11. Place to one side for reassembly. 12. Withdraw two reservoir seals from master cylinder inlet ports.BRAKES 10. Remove retaining ring and ’O’ ring seal from machined outer surface of master cylinder. Remove guide ring.

new seals from a Girling Service repair kit may be used. Remove tapping assembly on a piece of wood until plunger appears at cylinder mouth. Clean all parts with unused brake fluid.70 BRAKES NOTE: The primary plunger assembly cannot be broken down any further and is serviced as a complete unit. carefully pull plunger out of master cylinder. Provided working surfaces are in perfect condition. 6 REPAIR . (A) (B) (C) (D) (E) Springs Seal retainer Recuperating seal (primary cup) Washer ’L’ seal 15. Renewing secondary plunger seals 18. Discard assembly. Remove following components from secondary plunger and discard: NOTE: A small screwdriver with end rounded off and polished is required to remove ’L’ seal. 16. Inspect cylinder bore and plungers for signs of corrosion. If swirl tube was not expelled at same time as secondary plunger. 17. repeat above operation to remove it from bottom of master cylinder bore and discard. ridges and score marks. The secondary plunger assembly will remain at bottom of master cylinder bore. Place cleaned parts onto a clean sheet of paper. DO NOT damage secondary plunger.

Fit transfer housing to master cylinder. Gently introduce plunger with a circular rocking motion. Refit NOTE: Ensure O ring seal between master cylinder and servo unit is fitted correctly. Fit washer followed by recuperating seal. Secure in position with two nuts. 24. ease seal into bore and slowly push plunger down bore in one continuous movement. 26. Offer plunger assembly to cylinder until recuperation seal is resting centrally in mouth of bore. otherwise damage could be caused to new seals when inserting plungers into cylinder bore. push housing fully up to cylinder mounting flange. FLUIDS AND CAPACITIES. 29. Fit new swirl tube to bottom of cylinder bore. 34. CAUTION: Do not roll ’O’ ring down outer location surface of master cylinder. ensure springs are correctly seated. Generous amounts of new brake fluid should be used to lubricate parts during assembly. 30. 22. Fit ’L’ seal to plunger. Fit two new reservoir seals in respective ports. Lubricate secondary plunger and cylinder bore.BRAKES 19. as illustrated. Fit seal retainer and springs. Coat new seals in unused brake fluid. Lubricate new water ingress seal with brake fluid. Tighten to 15Nm. Do not adjust transfer housing after fitting. 27. plain and spring washers. Fit brake pipes to master cylinder. Recommended Lubricants and Fluids 35. 23. Ensuring that seal does not become trapped. 31. 25. 32. Slightly stretch seal and ease down housing until it is in position between housing and flange. REPAIR 7 . Fit new primary plunger assembly using same method as for secondary plunger. Assembling master cylinder CAUTION: It is important that following instructions are carried out precisely. Coat a new ’O’ ring with brake fluid and fit to its respective groove on outer location surface of master cylinder. Do not over stretch seal. It should be slightly stretched and eased down cylinder and into its groove. Fit new retaining ring on outer surface of master cylinder ensuring that serrations of ring are facing mounting flange. 20. See LUBRICANTS. Bleed system. Information. Fit original guide ring to support primary plunger. 33. Roll reservoir into top of master cylinder. open face of seal towards primary plunger. reconnect electrical lead to fluid level switch. Top-up master cylinder with correct grade of brake fluid. Tighten to 26 Nm. 28. Lubricate vacuum seal with brake fluid. See Brake System Bleed 36. Fit a new vacuum seal to either primary plunger or to bottom of transfer housing bore. 21. reversing procedure described in instruction 10. Reconnect battery negative lead. Fit cap. Fit master cylinder to servo.

14. 3. 5. 8 REPAIR . 18. 2. 6. 10. 8. 15. Springs (2 off) Swirl tube Master cylinder body Reservoir seals Reservoir Low fluid level switch and cap NOTE: Thoroughly check that no debris is lodged in fluid passageways and drillings. If debris is found. Seal retainer 13.70 BRAKES MASTER CYLINDER ASSEMBLY NON ABS Key to master cylinder 1. re-clean cylinder and re-check. 17. 11. 16. Water ingress seal Transfer housing Vacuum seal Guide ring Retaining ring ’O’ ring seal 7. Primary plunger assembly ’L’ seal Secondary plunger Washer Recuperating seal (primary cup) 12. carefully remove. 4. 9.

Information. 9. 18. 17. sealing each pipe and outlet port to prevent ingress of foreign matter.01 Remove Before starting repair refer to general brake service practice. FLUIDS AND CAPACITIES. Disconnect battery negative lead. plain and spring washers. 6. Disconnect vacuum supply hose to servo. Tighten nuts to 26 Nm. NOTE: Retain spacer for reassembly. 2. Refit brake pipes to respective ports. are the only serviceable components. Refit 12. Detach spacer from pedal box mounting face of servo. Remove master cylinder from existing servo and refit to new servo. if fitting new unit. Drain brake fluid into a suitable container. Fit push rod to lower hole of brake pedal. Recommended Lubricants and Fluids 22. Remove lower dash panel to gain access to servo push rod to brake pedal. Remove all sealing plugs. non-return valve and grommet.BRAKES SERVO ASSEMBLY Service repair no . 11. 10. Fit clevis pin and clip. See General Brake Service Practice NOTE: The filter.70. Fit master cylinder to servo. 3. Fit servo to pedal box. 14. Remove two nuts and plain washers securing servo. 4. Secure servo with two nuts and plain washers. The spacer ensures stringent pedal to servo operating dimensions are maintained. Remove clevis pin securing servo push rod to brake pedal. 7. 20. 19. Fit spacer to servo. 16. See LUBRICANTS. in event of failure or damage fit a new unit. Tighten brake pipes to 15 Nm. Refit lower dash panel. 15. Remove each brake pipe. REPAIR 9 . 13. 5. 21. Remove servo and master cylinder assembly. Refit vacuum supply hose. Disconnect electrical plug to low fluid level switch.50. Thoroughly clean immediate area around all master cylinder outlet ports. refit nuts. 1. Fill master cylinder to correct level using correct grade of brake fluid. Tighten nuts to 26 Nm. (If master cylinder is kept horizontal it is not necessary to drain fluid). Lightly grease brake pedal around area servo push rod pivots. Bleed brake system. See Brake System Bleed 8.

Using piston clamp LRT-70-500 press each piston back into its bore. Fit brake pads. using correct grade of fluid. Refit 8. Recommended Lubricants and Fluids 4.40. 5. See LUBRICANTS. Secure with new split [cotter] pin. 6. Remove brake pads. Ensure that displaced brake fluid does not overflow from reservoir. Wipe away excess with a lint free cloth. 10. Check fluid reservoir.70-500 . Wheels 2. Information. using new brake fluid. 11. Top up if necessary.02 Service tool: LRT. 9. See WHEELS AND TYRES. Fit pad retaining pins and anti-rattle springs. 3. 7. FLUIDS AND CAPACITIES.70 BRAKES FRONT BRAKE PADS Service repair no . Remove front road wheels. Remove pad retaining pins and anti-rattle springs. Remove split [cotter] pin from retaining pins. Clean exterior of calipers. Apply service brake pedal several times to locate pads.Piston clamp Remove 1. 10 REPAIR . Repair. Clean exposed parts of pistons.70.

4. 11. 10. Wipe away excess with a lint free cloth.40. Refit 8. Apply service brake pedal several times to locate pads. Using piston clamp LRT-70-500 press each piston back into its bore. See WHEELS AND TYRES.03 Service tool: LRT-70-500 . using correct grade of fluid. REPAIR 11 .Piston clamp Remove 1. Insert brake pads.70. Ensure that displaced brake fluid does not overflow from reservoir. Disconnect battery negative lead. Wheels 2. top up if necessary.BRAKES REAR BRAKE PADS Service repair no . Remove rear road wheels. 9. using new brake fluid. Check fluid reservoir. fit new pins and spread ends. Position pad retaining springs. Clean exposed parts of pistons. Repair. 3. Remove brake pads. 7. Remove pad retaining pins and springs. Clean exterior of calipers. See LUBRICANTS. FLUIDS AND CAPACITIES. 5. Recommended Lubricants and Fluids 6. Information.

8. 5. 2. 4. 10. 6.70 BRAKES FRONT BRAKE CALIPER ASSEMBLY Key to caliper 1. 11. 9. 3. Caliper Bleedscrew Antirattle springs Pad retaining pins Split [cotter] pin Friction pads Piston Wiper seal retainer Wiper seal Fluid seal Brake disc 12 REPAIR . 7.

6. Disconnect rigid brake pipe from flexible hose. or their condition is not perfect. 8. Clean bores. identifying them with their respective bores. pistons and seal grooves using clean brake fluid only. 11. Taking care not to damage seal grooves. REPAIR 13 . See General Brake Service Practice Remove caliper 1. Finally remove pistons. 5. Using a recognised hose clamp.Piston clamp Before starting repair refer to general brake service practice. Expose flexible brake hose by moving coiled protective covering. Clean outer surfaces of caliper using aerosol brake cleaner. clamp hose to prevent loss of brake fluid. 10. 2.BRAKES FRONT BRAKE CALIPERS Service repair no . Loosen front wheel retaining nuts. identify them for assembly to original locations.70. If caliper or pistons are corroded. Remove wiper seal retainer by inserting a blunt screwdriver between retainer and seal. 4.03 Service repair no . Using special tool LRT-70-500. new parts must be fitted. Gently. and with CAUTION. It is unlikely that pistons will expel at same time.70. regulate rate with a suitable piece of wood between appropriate piston and caliper. seal exposed ends to prevent ingress of dirt. Loosen bolts and remove caliper. Repair Do not separate caliper halves 7. retaining pins and springs. 12. remove wheels. Remove split [cotter] pin.16 Service tool: LRT-70-500 . keeping fingers clear. Pry retainer carefully from mouth of bore.55. 9. extract wiper seal and fluid seal. lower onto axle stands. clamp pistons in inboard half of caliper. withdraw pads. raise front of vehicle. If refitting pads. 3.55. apply air pressure to fluid inlet port to expel pistons.

Finally tighten road wheel nuts to 130 Nm. this may take several hundred miles before brakes are at maximum efficiency. Use piston clamp to press home seal retainer and piston. Remove hose clamps. Fit caliper. secure using new split [cotter] pin. Insert pads. See Brake System Bleed 22. 14 REPAIR . Fit pins and springs. Coat appropriate piston with brake fluid. ensuring it is properly seated. Fit calipers and pads 17. instructions 8 to 15. 20. 18. Fit road wheels. over protruding piston and into bore recess. Slide assembly. 21. Clamp outboard pistons and carry out same procedure for removing and fitting outboard pistons and seals. Ease seal into groove in bore using only fingers. leave approximately 8mm projecting from bore. Press brake pedal firmly several times to locate friction pads. Connect brake flexible hoses to caliper. Bleed brake system. Coat new fluid seal with brake fluid. 15. 19. Mounting inboard pistons 16. 23. Fluid seal and groove are not same in section. Note that new friction pads require ’bedding-in’. Road test vehicle. 24. remove axle stands. tighten bolts evenly to 82 Nm. Coat new wiper seal with brake fluid and fit to new seal retainer.70 BRAKES Assemble outboard pistons 13. 14. Insert it squarely into bore by hand only. so when seal is seated it feels raised to touch at edge furthest away from mouth of bore. seal first. Tighten to 15 Nm. Do not tilt piston during insertion.

BRAKES REAR BRAKE CALIPERS Service repair no . extract wiper seal and fluid seal. Repair Do not separate caliper halves 7.17 Service tool: LRT-50-700 .70.06 Service repair no . identify them for assembly in original positions. Taking care not to damage seal grooves. Clean outer surfaces of caliper with aerosol brake cleaner. 8. 2. Remove brake pipe(s) from rear brake caliper(s). Finally. It is unlikely both pistons will expel at same time.70. Loosen rear road wheel nuts. 3. Using a recognised hose clamp. clamp flexible brake hose above rear axle. regulate rate with a suitable piece of wood inserted between two pistons.Piston clamp Before starting repair refer to general brake service practice. 9. 10. remove wheels. 12. Clean bores. 4.55. pistons and particularly seal grooves using clean brake fluid only. See General Brake Service Practice Remove caliper 1. Seal pipe ends to prevent ingress of dirt. REPAIR 15 .55. Remove wiper seal retainer by inserting a blunt screwdriver between retainer and seal and pry retainer carefully from mouth of bore. Jack up vehicle. 11. Remove two bolts. 5. If same pads are to be refitted. remove pistons keeping them identified with their respective bores. WITH CAUTION expel pistons from their bores by applying air pressure to fluid inlet port. withdraw caliper from axle. lower onto axle stands. Remove retaining pins and springs and withdraw pads. If caliper or pistons are corroded or their condition is not perfect new parts must be fitted. 6.

piston clamp. See Brake System Bleed 23. 15. Using special tool LRT-70-500 . Coat piston with brake fluid. Coat a new wiper seal with brake fluid and fit to new seal retainer. remove axle stands and finally tighten road wheel nuts. Insert it squarely into bore. Fit road wheels. 16. Slide assembly. Insert pads and retaining springs. over protruding piston into bore recess. 24. Note correct position of retaining springs. Fit seal into groove in bore. Fit caliper to axle. instructions 8 to 16. Carry out same procedure as for removing and fitting outboard piston and seals. When seal is seated it feels raised to touch at edge furthest away from mouth of bore.70 BRAKES 13. Note new brake pads require ’bedding-in’. Maintenance. 20. Tighten to 15Nm. Apply brake fluid to new seal. Remove clamp from flexible brake hose. tighten two bolts evenly to 82 Nm. Bleed brake system. Mounting inboard piston 17. Do not tilt piston during insertion and leave 8mm projecting from bore. 22. Connect brake pipe to caliper. 14. Press brake pedal firmly several times to locate pads. Road test vehicle. seal first. secure in position with new retaining pins and spread ends. PARKING BRAKE ADJUST See SECTION 10. 21. 19. for several hundred miles before brakes are at maximum efficiency. Vehicle Interior 16 REPAIR . 25. Fit calipers and pads to vehicle 18. press home seal retainer and piston.

9. Wiper seal retainer Wiper seal Fluid seal Retaining pins REPAIR 17 . 7. 4. 5. 3.BRAKES REAR BRAKE CALIPER ASSEMBLY LH Rear Caliper illustrated Key to caliper 1. 2. Caliper Bleed screw Pad retaining springs Brake pads Piston 6. 8.

located on inner wing [fender] panel. See FRONT AXLE AND FINAL DRIVE.FRONT Service repair no . Remove 1. Remove sensor lead from clips. 12. 3. Push sensor through bush until it contacts exciter ring. Disconnect battery negative lead. Repair.65.70 BRAKES SENSORS . Refit brake jump hose bracket. Front Stub Axle. SENSOR RINGS The rear sensor ring is assembled to the rear brake disc to form part of the rear hub assembly.70. Refit 7. 4. Lightly coat new sensor using EP 90 oil. Sensor will be ’knocked back’ to correct position when vehicle is driven. a NEW sensor bush and seal must be fitted. Constant Velocity Joint and Swivel Pin Housing ABS 18 REPAIR . Release harness cable ties. remove sensor lead from vehicle. coat bolts with Loctite 270. 9. 5. Remove top swivel retaining bolts complete with brake jump hose and sensor seal. Drive vehicle to ensure ABS warning light is extinguished. Reconnect sensor electrical connection. 10. Overhaul. 8. Secure sensor lead in original position. 2. 11. 6.32 CAUTION: If a sensor is removed for any reason. Clean area surrounding sensor to prevent ingress of dirt. See REAR AXLE AND FINAL DRIVE. Disconnect required sensor electrical connection. Using a suitable lever pry sensor from mounting bush. Rear Hub Assembly The front sensor ring is a toothed ring on the axle shaft which forms part of the front stub axle assembly. Remove sensor bush. Insert new sensor bush and seal.

Reconnect sensor electrical connection. 3. REPAIR 19 . pull brake pedal back fully to set switch. 12. 8. 12. 3.86. Check switch operation by slowly depressing brake pedal and checking that the switch clicks twice. located above rear axle.BRAKES SENSORS . Refit 7. Drive vehicle to ensure ABS warning light is extinguished. Ensure retaining clips are FULLY located. 4. Disconnect multiplug to switch.31 CAUTION: If a sensor is removed for any reason. Pull sleeve and plunger of switch FULLY forward. Secure harness in position. remove sensor lead from vehicle. Turn ignition off. Fit new sensor bush. 13. Remove sensor bush. Depress brake pedal access front of switch. Using a suitable lever. 4. Hold switch firmly in place. pry sensor from mounting bush. 11. Information.REAR Service repair no . See LUBRICANTS. STOP LIGHT SWITCH ABS Service repair no . 7. 2. Disconnect battery negative lead. Recheck switch is securely fitted.65. Operation may be checked using Testbook. 5. 5. Refit 8. Remove lower trim panel. 13. Reconnect battery and turn ignition on. 10. Sensor will be ’knocked back’ to correct position when vehicle is driven.51 Remove 1. Pull sleeve and plunger of switch fully forward. Disconnect sensor electrical connections. FLUIDS AND CAPACITIES. a NEW sensor bush must be fitted. 11. 6. Lightly grease new sensor using silicone grease. Release harness cable ties. Remove switch rearwards NOTE: If switch is difficult to release.70. Push sensor through bush until it touches exciter ring.65. Remove 1. Depress brake pedal. Recommended Lubricants and Fluids 10. 9. Remove sensor from its locating clip. 2. check sleeve is FULLY forward. fit switch. Remove bolts securing mudshield. Disconnect battery negative lead. Check stop lamps go off when pedal is released. 9. 14. 6.

Reverse removal procedure. Remove lower dash panel. Withdraw switch. Refit 11. 9. Depress foot brake. Remove hexagon nut. 20 REPAIR . 2. 7. With switch still in position and multiplug disconnected. Adjust 8.51 Remove 1. Disconnect electrical leads.86. Tighten locknut. Remove rubber protector from switch. Disconnect battery negative lead. CAUTION: Ensure switch does not prevent brake pedal returning fully. if fitted. 5. Screw switch in until open circuit exists across terminals with pedal released and continuity exists as soon as pedal is depressed. 10.65. connect an ohmmeter across switch terminals. 4.NON ABS Service repair no . 3. 6.70 BRAKES STOP LIGHT SWITCH .

17. 5. KEY 1. 13. 4. Connector-double elbow Rear left brake Modulator to rear left brake Modulator to master cylinder Modulator to pressure reducing valve upper Electrical connection Modulator unit Nut. 6. On right hand drive vehicles the master cylinder and servo unit only move position. mounting bush and cup Modulator to front left brake Front left brake Electrical connection 12. 16. 11. 8. Modulator to front right brake Modulator to pressure reducing valve lower Master cylinder to pressure reducing valve lower Front right brake Bolt Pressure reducing valve Modulator to pressure reducing valve upper Master cylinder Servo unit Modulator to rear right brake Rear right brake REPAIR 21 . 18. 19. 15. 7. 2. 20. 22. 9. 3. 21.BRAKES BRAKE COMPONENTS ABS Left hand drive shown. 14. 10.

Refer to general brake service practice. Release ECU plug retaining clip. Fit mounting bushes and cup to new modulator. 2. Check new modulator unit is packaged in accordance with the WARNING above. See Brake System Bleed 15. 12. Bleed the complete hydraulic system. removing plugs to connection ports before fitting unit.65. Refit 11. ABS Components 1. Identify 8 pipe to modulator connections for correct reassembly. Tighten to 15Nm. For details of modulator unit and hydraulic pipe connections to it. Remove nuts securing modulator to mounting bracket. 9. Test operation of brakes. 6. Fit modulator unit to mounting bracket. Move plug in direction of arrow and release hooked end of plug from retaining post. Remove the two electrical plugs. 7. 3. Remove two screws and detach ECU complete with harness plug from mounting bracket.45 WARNING: New modulator units are supplied in a shock absorbing pack marked with a use by date. 22 REPAIR . Disconnect 8 pipe unions. Refit 6. 4.70. 7. 8.any impact.65. Reconnect ECU harness plug ensuring that it is firmly located and retaining clip secures plug. 5. Remove modulator unit. ELECTRONIC CONTROL UNIT ABS Service repair no .70 BRAKES MODULATOR UNIT Service repair no . 10. 14. Remove 1. use of compressed air on any of the hydraulic ports. The new modulator will contain hydraulic brake fluid within the valve block and all ports plugged. 5. 13. 4. Check system function using the ’Testbook’ diagnostics 16. Fit 8 pipes to modulator connections. See Description and operation. Refer to the illustration of brake components ABS. Disconnect battery negative lead. See Brake Components ABS 2.01 Remove For location of the ECU. Pipes must be connected to correct port. Modulator units must be handled with care the following must be avoided:. Remove mounting bushes and cup. Reverse removal procedure.70. Disconnect battery negative lead. See General Brake Service Practice 3. Remove retaining bolt and lower alarm system ECU and relay mounting bracket into passenger footwell.

.................. Master cylinder to servo .................................................................................................................................................. Servo assembly to pedal box ...................................................... TORQUE 1 ..................................... Jump hoses to calipers ............................................................. 15 15 15 15 15 82 26 26 SPECIFICATIONS................................................................ Brake caliper to swivel pin housing ................................................................................................................ ................. .................................Master cylinder .............................. Bleed screws .............. Nm Brakes Brake pipe connections to: .....Modulator unit ..........Brake calipers ..........BRAKES TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque...............

BRAKES BRAKE SERVICE TOOLS LRT-70-500 18G 672 Brake piston compressor SERVICE TOOLS 1 .

SIDE WALL 2 PLIES RAYON. 4. See GENERAL SPECIFICATION DATA.TUBELESS Country of manufacture . 2. Wheels and Tyres DESCRIPTION AND OPERATION 1 . 12.S or T USA Tyre quality grading .205 16 ot 235/70 R16 Type of tyre . codes and numbers moulded into the tyre wall vary between tyre manufacturers. For specific tyre specifications. 14.WHEELS AND TYRES TYPES OF WHEEL RIMS AND TYRES Description Dependent on specification. Information. 9. however most tyres are marked with the information shown in the illustrated example. 6. 15. the vehicle is equipped with alloy or pressed steel wheel rims. 10. 5. 11. 13.Reinforced USA Load and pressure specification 900Kg(1984LBS) at 340KA (50PSI) MACS PRESS Tyre size .TRACTION PLUS mzx M NOTE: The illustration is an example of the type of markings moulded into tyres and is for guidance only.E66 103S6 Tyres with ’Mud Snow’ type tread pattern are marked .Radial Ply Load index . both using tubeless radial ply tyres. 8. 3. Tyre codes The writing. 1. 7.MADE IN GREAT BRITAIN USA Compliance symbol and identification DOT AB7C DOFF 267 European type approval identification .Tread wear 160 Traction A temperature B Tread wear indicators moulded into tread pattern are located at intervals around the tyre and marked by a code . Type of tyre construction .M&S Tyre reinforcing mark .104 Speed symbol . TREAD 2 RAYON 2 STEEL Manufacturer’s brand name/type .E11 01234 Tyre construction .

steering damper Excessive cornering speeds Inflate to correct pressure Replace worn components Rapid wear at centre of tread Tyres over-inflated Inflate to correct pressure Wear at one shoulder Track out of adjustment Bent panhard rod Adjust track to correct figure Check and replace worn or damaged components Bald spots or tyre cupping Wheel out of balance Balance wheel and tyre assembly Check runout and replace tyre if necessary Replace shock Excessive radial runout Shock absorber worn Excessive braking Tyre scalloped Track out of adjustment Worn suspension components Excessive cornering speeds Adjust toe to correct figure Replace as necessary CAUTION: This diagnosis chart is for general guidance only and does not necessarily include every cause of abnormal tyre wear. ball joints. panhard rod bushes. FAULT DIAGNOSIS 1 .e.WHEELS AND TYRES TYRE WEAR CHART FAULT CAUSE REMEDY Rapid wear at shoulders Tyres under-inflated Worn suspension components i.

74 WHEELS AND TYRES FAULT . Tread contact with road. Over-inflation. Fault diagnosis. See Repair. Tyre Pressures 2. See PROPELLER SHAFTS. 2 FAULT DIAGNOSIS . go to steering Fault Diagnosis. Check front wheel alignment. Adjustment. 4. Steering Faults NOTE: Radial ply tyres have a flexible sidewall.SYMPTOMS Vibration through steering wheel 1. which produces a sidewall bulge making the tyre appear under-inflated. This is a normal condition for radial ply tyres. Check wheel balance. Check condition of tyres. Check tyre pressures. 2. See STEERING. Under-inflation. See Tyre Wear Chart 3. Front Wheel Alignment 4. Fault diagnosis. Wheel Balancing NOTE: In the event that any apparent vibration is not eliminated at this stage. See Repair. Vibration Harshness NOTE: In the event that any apparent vibration is not eliminated at this stage. See STEERING. 3. Correct inflation. 1. road wheel shimmy/wobble). Do not attempt to reduce this bulge by over-inflating the tyre. Fault Symptom (Steering vibration.

Care must be taken when handling the wheel to avoid scratching or chipping the finish.WHEELS AND TYRES GENERAL INFORMATION WARNING: This is a multi. including spare wheel. bulges and for objects embedded in the tread. The tyres are of European metric size and must not be confused with the "P" size metric tyres available in North America. When the tread has worn to a remaining depth of 1. The alloy wheel rim is of the asymmetric hump type incorporating a safety hump to improve location of the tyre bead in its seat. If difficulty is experienced in fitting tyres to this type of rim. For tyre specification and pressures. Check tyres at least weekly for cuts. The vehicle is equipped with tubeless ’S’. as shown in the illustration below. TYRE INSPECTION Inspect tyres at weekly intervals to obtain maximum tyre life and performance and to ensure compliance with legal requirements.purpose vehicle with wheels and tyres designed for both on and off road usage. must be fitted with the same make and type of tyre to the correct specification and tread pattern. Wheels and Tyres Alloy Wheels Tubeless tyres are mounted on 7.6 mm the indicators appear at the surface as bars which connect the tread pattern across the width of the tread as shown in the illustration below. See Fault diagnosis. abrasions. Vehicle wheel sets. See GENERAL SPECIFICATION DATA. To assist tyre inspection. Check for signs of incorrect inflation and uneven wear.The surface has a paint finish covered with a clear polyurethane lacquer. Tyre Wear Chart if the tyres have abnormal or uneven wear patterns.0 inch wide by 16 inch diameter steel wheels. Steel wheels Tubeless tyres are mounted on 7. Under no circumstances must cross-ply or bias-belted tyres be used.0 inch wide by 16 inch diameter cast aluminium alloy wheels. See Tyre Fitting WARNING: Do not fit an inner tube to an alloy wheel.’T’ or ’H’ rated radial ply tyres as standard equipment. which may indicate a need for balancing or front wheel alignment. REPAIR 1 . More frequent inspections are recommended when the vehicle is regularly used in off road conditions. Information. tread wear indicators are moulded into the bottom of the tread grooves. Only use wheels and tyres specified for use on the vehicle.

g. or leaking air. the performance of the tyre will be adversely affected. as pressures can increase by 0. WHEELS INSPECTION Regularly check the condition of the wheels. at three locations around the tyre. Check and adjust tyre pressures ONLY when the tyres are cold. loose. If tyre position is changed after wear has occured. 2 REPAIR .74 WHEELS AND TYRES When the indicators appear in two or more adjacent grooves. as tyre wear produces characteristic patterns depending on their position. Tyre pressures must be checked at least once a month and at least once a week.A label attached to the inside edge of the driver’s door also provides tyre pressure information. See GENERAL SPECIFICATION DATA. Always check tyre inflation pressures using an accurate gauge and inflate tyres to the recommended pressures only. e. dented or has excessive runout. a new tyre must be fitted.s. For recommended tyre pressures in all conditions. The tyre inflation pressure is calculated to give the vehicle satisfactory ride and steering characteristics without compromising tyre tread life.i) over cold inflation pressures. TYRE PRESSURES Maximum tyre life and performance will be obtained only if tyres are maintained at the correct pressures. or driven for less than 3. cracked.41 bars (6 p. Wheels and Tyres American vehicles . vehicle parked for three hours or more. Refit the valve caps as they form a positive seal and keep dust out of the valve. from front to rear. Check ALL tyre pressures including the spare. cracked.2 km (2 miles) at speeds below 64 km/h (40 mph). Replace any wheel that is bent. Replace any valve that is worn. Do not reduce inflation pressures if the tyres are hot or the vehicle has been driven for more than 3. if the vehicle is used off road. NOTE: Do not attempt to interchange tyres. preferably daily. VALVES INSPECTION Check condition of inflation valve. NOTE: Territorial vehicle regulations governing tyre wear MUST be adhered to.2 km (2 miles) at speeds over 64 km/h (40 mph). Information.

Steel wheels Clean area of wheel rim and attach adhesive balance weights in position shown. DO NOT attempt to use a steel wheel weight on an aluminium wheel. Alloy wheels CAUTION: Use only correct adhesive balance weights to avoid damage to aluminium wheel rim. REPAIR 3 . Cut through rear face of weight strip to detach required weights. Clean area of wheel rim and attach balance weights in position shown. The use of on the vehicle balancing could cause component damage or personal injury and MUST NOT be attempted. NOTE: Before attempting to balance a wheel and tyre assembly clean all mud and dirt deposits from both inside and outside rims and remove existing balance weights.WHEELS AND TYRES WHEEL BALANCING CAUTION: It is essential that all wheel balancing is carried out off the vehicle. Remove stones from the tyre tread in order to avoid operator injury during dynamic balancing and to obtain the correct balance. Inspect tyres for damage and correct tyre pressures and balance according to the equipment manufacturer’s instructions.

B. Add balance weights here. This condition will eventually cause uneven tyre wear. A statically unbalanced wheel will cause a bouncing action called wheel tramp. B. Heavy spot. Dynamic balance is the equal distribution of weight on each side of the centre line so that when the wheel spins there is no tendency for side to side movement. C. Centre line of spindle. Add balance weights here. A dynamically unbalanced wheel will cause wheel shimmy. A. 4 REPAIR . C. Centre line of spindle. Heavy spot. Static balance is the equal distribution of weight around the wheel.74 WHEELS AND TYRES Static balance Wheel tramp Dynamic balance Wheel shimmy A.

WHEELS AND TYRES Off vehicle balancing Balance wheel assembly referring to equipment manufacturer’s instructions. and carry out following procedure. broken or cracked beads. Do not attempt to repair a tyre that has sustained the following: bulges or blisters. Inflate tyre to seat beads correctly. following the equipment manufacturer’s instructions. DO NOT attempt to repair punctures in tyre shoulders or sidewalls. to avoid damaging the wheel. as they may damage tyre beads or the aluminium wheel rim. Where possible always use the vehicle wheel retaining nuts to locate the wheel on the balancer. TYRE FITTING Alloy wheels 1.85 mm (4. 4. CAUTION: Do not use tyre sealants that are injected through valve stem to repair punctured tyres. This diameter will ensure that the collar fits correctly within the centre hole of the wheel. Puncture repair Remove punctured tyre from wheel and repair using a combination service plug and vulcanising patch. 3. Ensure wheel and tyre is adequately lubricated. It is essential that the wheel is located by the centre hole NOT the stud holes.80 to 112. Tyre changing Use only tyre changing equipment to mount or demount tyres. as they will destroy the lacquer finish. NOTE: Stop inflation immediately if tyre seats opposite valve. REPAIR 5 . If this is not possible. This part of beading having seated over hump previously will automatically seat first when tyre is re-inflated. To ensure positive wheel location the diameter of the locating collar on the machine shaft must be 112. DO NOT use abrasives or aluminium wheel cleaners containing acid. bead area should be well lubricated with a suitable tyre lubricant. Always follow manufacturer’s instructions when using a puncture repair kit. Aluminium wheel rim bead seats should be cleaned using a non-abrasive cleaner to remove the mounting lubricants and old rubber. making further inflation impossible. DO NOT use hand tools or tyre levers. Mount tyre in normal manner. Only punctures in tread area are repairable. they may produce wheel corrosion and tyre imbalance. Cleaning Wash the aluminium wheels using a suitable wash and wax concentrate correctly diluted and rinse with cold clear water. unseat and rotate it around the rim until valve is in line with that part of tyre which seated initially. ply separation. 5. as this will result in valve being blocked by tyre beading. Deflate tyre. Before mounting or demounting a tyre. Inflate tyre and at same time apply hand pressure to area around valve to aid seating over valve first. wear indicators visible and punctures larger than 6 mm diameter. finally inflate to correct pressure. the locating nuts must be of a similar pattern to the original wheel nuts. Install a new valve assembly. 2. The use of conical type wheel nuts for this purpose may damage the aluminium alloy.441 to 4.443 in).

Remove wheel nuts and carefully withdraw wheel over studs.74 WHEELS Remove WHEELS AND TYRES Refit 4. (Do not apply oil) 7. See INTRODUCTION. and may not hold vehicle when jacking unless following procedure is used. Jacking 3. Using a suitable trolley jack raise vehicle and place on axle stands. select ’P’ or a gear in main gearbox and engage low gear in transfer box. Information. WARNING: The parking brake acts on transmission. Loosen five wheel nuts. 8. Alloy wheels and steel wheels: 130Nm. Tighten nuts as much as possible using a suitable wrench. 6. 1. Fit wheel nuts and turn by hand for at least three full threads before using any form of wheel wrench. Lower vehicle and finally tighten nuts to correct torque sequence shown. 6 REPAIR . Wheels MUST be chocked in all circumstances. Refit wheel taking care not to damage stud threads. Alloy wheels: Lightly coat wheel mounting spigot face with a suitable anti-seize compound to minimise possibility of adhesion between wheel and spigot face. 5. 2. Apply parking brake. Ensure that retaining studs and nuts are clean. If one front wheel and one rear wheel is raised no vehicle holding or braking effect is possible. 9. not rear wheels.

pull stud into flange until shoulder of stud abuts flange. REPAIR 7 . See Wheels 2. Refit 3.WHEELS AND TYRES WHEEL STUD Remove 1. 4. Install a suitable spacer over stud. a slave wheel nut is suitable. Using a M16 x 1. Refit wheel. Drive stud out of driveshaft flange. 6. Remove wheel. 5. Position stud in flange.5P nut.

Airbag crash sensors (distributed SRS) SRS warning light (airbag) Rotary coupler Driver’s airbag module Passenger’s airbag module 6. 5. 10. 2. 9. Airbag diagnostic socket Airbag diagnostic control unit Airbag harness (distributed SRS) Knee bolsters (where fitted) Airbag harness DESCRIPTION AND OPERATION 1 .SUPPLEMENTARY RESTRAINT SYSTEM SYSTEM COMPONENTS 1. 4. 7. 3. 8.

including the wiring harness. is designed to protect the driver and front passenger. SPS SRS In the event of a frontal impact. As an occupant moves into the airbag it immediately discharges the gas to provide progressive occupant deceleration and reduce risk of injuries. the diagnostic control unit fires igniters. The change from distributed SRS to SPS SRS occurred at VINs 198222 and 528977. This in turn ignites tablets of sodium azide which generate a large amount of Nitrogen gas leading to airbag inflation in approximately 30 milli-seconds. The Distributed SRS which has two crash sensors located in the engine compartment on the chassis longitudinals and the Single Point Sensing (SPS) SRS which has a single crash sensor located in the Airbag diagnostic control unit. All Models When fully deployed the airbag offers additional protection to the front seat occupant.75 OPERATION SUPPLEMENTARY RESTRAINT SYSTEM The airbag supplementary restraint system (SRS) is a safety device which. 2 DESCRIPTION AND OPERATION .3 seconds. WARNING: All the airbag system components. The whole process is completed in approximately 0. when used in conjunction with the seat belt. when the airbag diagnostic control unit and one of the airbag crash sensors senses the impact. Distributed SRS In the event of a frontal impact. This in turn ignites tablets of sodium azide which generate a large amount of Nitrogen gas leading to airbag inflation in approximately 30 milli-seconds. MUST be renewed after the airbags have deployed. the diagnostic control unit fires igniters. when the airbag diagnostic control unit senses the impact. Two different SRS systems are fitted to Discovery.

The system checks airbag diagnostic control unit. SPS SRS The warning light in the instrument pack illuminates after the electrical circuits are switched on whilst a system check is carried out. driver and passenger modules. All Models In the event of a fault in the system the warning light will illuminate.SUPPLEMENTARY RESTRAINT SYSTEM SRS warning light (airbag) Distributed SRS The warning light in the instrument pack illuminates after the electrical circuits are switched on whilst a system check is carried out. airbag crash sensors. DESCRIPTION AND OPERATION 3 . The airbag diagnostic control unit logs the fault which can only be accessed using TestBook. After about 8 seconds the warning light will go out. The system checks airbag diagnostic control unit. After about 5 seconds the warning light will go out. driver and passenger modules. airbag harness. airbag harness.

Do not install any part that shows signs of being dropped or improperly handled. There are NO separately serviceable parts. 6. Carefully inspect any airbag part before installing. Disconnect the negative cable first. Always remove the key from the starter switch before beginning work. When repairing. crash cans and bracketry. CAUTION: The airbag system has sufficient stored energy to deploy airbags for up to 20 minutes. 2. cracks or deformation. it cannot be repaired or reused. 4. 4 DESCRIPTION AND OPERATION . disconnect the driver’s airbag and passenger’s airbag (where fitted). 3. paying particular attention to bumper armatures. 1. 5. Always disconnect both the negative ’-’ cable and positive ’+’ cable at the battery before removal of driver or passenger airbag modules. To continue work immediately.75 SUPPLEMENTARY RESTRAINT SYSTEM GENERAL PRECAUTIONS Impacts which do not deploy airbags CAUTION: Check for structural damage in the area of the impact. Do not install used airbag parts from another vehicle. such as dents. longitudinals. use only new airbag parts. Do not try to dismantle the airbag module. Once an airbag has been deployed.

as a precaution switch the ignition off and then disconnect both battery leads. However. Do not dismantle. acid or heavy metals may produce harmful or explosive compounds.airbag not deployed Normal towing procedures are unlikely to cause an airbag to deploy. Disconnect the negative ’-’ lead first. Do not use electrical test equipment on the airbag harness or connectors. Contact with water. 8. Disconnect the negative ’-’ lead first. 7. Tampering with or disconnecting the harness could result in accidental firing of the airbag or make the system inoperative. 9. Towing . DESCRIPTION AND OPERATION 5 . as a precaution switch the ignition off and then disconnect both battery leads. However. An airbag system fault can only be diagnosed using TestBook.airbag deployed Once the driver’s airbag has been deployed the vehicle must have a front suspended tow. which may result in serious injury.SUPPLEMENTARY RESTRAINT SYSTEM VEHICLE RECOVERY Towing . The airbag module contains Sodium Azide which is poisonous and extremely flammable. incinerate or bring into contact with electricity.

Always lock the boot when module is stored in it and inform workshop supervisor. the module may be stored in the boot of the vehicle from which it was removed. observe the following precautions: Store the airbag module with the pad surface up. detergent or water. making it inoperative. install a new unit. oil. 6 DESCRIPTION AND OPERATION .75 SUPPLEMENTARY RESTRAINT SYSTEM AIRBAG STORAGE Temporary storage For temporary storage of the airbag module during service. CAUTION: Improper handling or storage can internally damage the airbag module. accidental deployment could propel the unit with enough force to cause serious injury. Overnight storage Airbag modules are classed as an explosive article and as such they must be stored in a secure steel cabinet which has been approved by the local authority. grease. If you suspect the airbag module has been damaged. WARNING: If the airbag is improperly stored face down. Store the removed airbag module on a secure flat surface away from heat. If no designated storage area is available. Place the airbag module in designated storage area.

Ensure all airbag harness connectors are mated correctly and securely fastened. a mobile telephone. After any degree of front body damage. Tighten front sensor fixing before rear sensor fixing. two-way radio or in-car entertainment system in such a way that it interferes electrically with the airbag harness. CAUTION: Take extra care when painting or doing body work in the vicinity of the sensors. FAULT DIAGNOSIS 1 . Do not leave the connectors hanging loose. NOTE: The airbag harness can be identified by a special yellow outer protective covering. 2. inspect both front crash sensors. 3. 1. splice or repair the airbag harness. Never attempt to modify. Use the fixing screws supplied with the sensor and tighten to the correct torque.SUPPLEMENTARY RESTRAINT SYSTEM CRASH SENSOR INSPECTION . Never install electronic equipment such as.DISTRIBUTED SRS AIRBAG HARNESS 1. Make sure the airbag harness is installed correctly and not pinched or trapped. cracks or deformation. Replace a sensor if there are any signs of dents. There must be no gap between the sensor and body of the vehicle. Avoid direct exposure of the sensors or harness to heat guns. Ensure the sensors are installed correctly. welding or spraying equipment. 2.

Bonnet locking platform Refer to the Owner’s Handbook for information on the airbag system. 2 FAULT DIAGNOSIS . Driver’s sun visor Refer to the Owner’s Handbook for information on the airbag system.75 SUPPLEMENTARY RESTRAINT SYSTEM WARNING LABELS 2. 3. CAUTION: Ensure wheels are straight ahead before removal and installation. Rotary coupler 1.

The code number must be recorded if the airbag module is to be replaced. replace and dispose of the entire unit as directed in the instructions. C . FAULT DIAGNOSIS 3 . Steering wheel Refer to the Owner’s Handbook for information on the airbag system. Use diagnostic instructions to determine if the unit is defective. Airbag modules A . B .SUPPLEMENTARY RESTRAINT SYSTEM 4. Under no circumstances should a diagnosis be performed using electrically powered test equipment or probing devices. This airbag module cannot be repaired.Tampering or mishandling can result in personal injury. For special handling instruction refer to the Workshop manual.If defective. 5.ROVER Bar code .

MUST be renewed after the airbags have deployed. always ensure connectors are fully engaged and latched before proceeding to the next stage of the operation. Turn steering wheel 90˚ from horizontal. 4.01 WARNING: All the airbag system components. Remove 1.SUPPLEMENTARY RESTRAINT SYSTEM SYSTEM PRECAUTIONS CAUTION: Before and during any removal operations within the SRS section. CAUTION: During refitting of any item within the SRS section. DRIVER’S AIRBAG MODULE Service repair no .74. CAUTION: Always disconnect both leads. REPAIR 1 . Release 2 turnbuckles and remove dash lower panel. Switch off ignition.76. 3. Disconnect battery negative ’-’ and then the positive ’+’ lead. 2. note routing and position of all harnesses to aid correct refitting and to avoid accidentally trapping cables. including the wiring harness.

unscrew 2 tamper-proof Resistorx screws securing airbag module to steering wheel. 7. Use special socket. 6. 2 REPAIR .75 SUPPLEMENTARY RESTRAINT SYSTEM 5. Disconnect airbag harness connector from yellow airbag column harness. Release airbag module from steering wheel. CAUTION: Do not allow the airbag module to hang by the airbag harness.

CAUTION: Store the airbag module in accordance with the storage procedures outlined in Description and Operation. Position steering wheel so the road wheels are in the straight ahead position. Disconnect harness connector from airbag module. 5. See driver’s airbag module. Use special socket to tighten screws to 8Nm (6 lbf ft). Check Supplementary Restraint System using Testbook . Remove airbag module. Release steering wheel from column. 2. 9.60. Feed harnesses through hole in steering wheel. 3. Remove driver’s airbag module. 8. Position airbag module on steering wheel and engage retained screws. Refit 10. CAUTION: Prevent rotation of rotary coupler once steering wheel is removed. Remove steering wheel. Connect harness connector to airbag module with harness downwards (as shown at 8). Release harnesses from clip on steering wheel. Disconnect cruise control switch connector (where fitted) from rotary coupler harness. Remove steering wheel nut.01 Remove 1. CAUTION: Take care not to cross thread screws. Reverse removal procedure. 6. Secure in position with adhesive tape. REPAIR 3 . NOTE: If airbag module is to be replaced the serial numbers must be recorded in the vehicle service record. 7. 8. 11. 13. 4.57.SUPPLEMENTARY RESTRAINT SYSTEM STEERING WHEEL Service repair no . 12.

See driver’s airbag module. Release lever and lower steering column. Fit steering wheel ensuring the rotary coupler lugs are correctly engaged. 12. 9. Refit driver’s airbag module. 2. Store in plastic bag. See driver’s airbag module.76.75 Refit SUPPLEMENTARY RESTRAINT SYSTEM ROTARY COUPLER Service repair no . 4. DO NOT rotate mechanism whilst removing. See steering wheel.74. 10. Remove steering wheel. CAUTION: Ensure road wheels are straight ahead before fitting steering wheel.07 CAUTION: Ensure wheels are straight ahead before removal and refitting. Reverse removal procedure. 4 REPAIR . Release 2 turnbuckles and remove lower dash panel. 3. Remove driver’s airbag module. Fit steering wheel nut. Tighten to 50 Nm (37 lbf ft). Remove 1. 11.

Remove 3 screws securing lower half of nacelle to steering column. REPAIR 5 . 6. Release airbag harness connector from bracket and disconnect.SUPPLEMENTARY RESTRAINT SYSTEM 5. Separate the 2 halves of the nacelle and remove from steering column. 10. Disconnect rotary coupler connector from steering column harness. 9. Release 2 clips securing rotary coupler to column switch assembly. Remove rotary coupler from column switch assembly. 7. 8.

Refit driver’s airbag module. check alignment of indicator cancellation pegs. Refit 12. 17. it is imperative that the coupler is centralised. Refit steering wheel. If a new rotary coupler is being fitted and the sealing tape at position B is broken it MUST NOT be used.75 SUPPLEMENTARY RESTRAINT SYSTEM 13. See driver’s airbag module. 14. If original rotary coupler is being fitted remove adhesive tape and then fit rotary coupler to column switch assembly. 15. Turn steering wheel to both LH and RH lock 5 times. place a piece of adhesive tape around moulding in position A to prevent rotation. Align direction indicator cancellation bush. If rotary coupler is being re-used. If adverse noises can be heard. Reverse removal procedure. 16. 6 REPAIR . See steering wheel. NOTE: If original rotary coupler is to be fitted and there is evidence of tampering. 11. CAUTION: Ensure indicator cancellation pegs correctly engage into back of steering wheel. See rotary coupler centralise.

Release 2 turnbuckles and remove lower dash panel. See rotary coupler. Providing the removal procedure has been correctly followed this operation should not be necessary. proceed to turn coupler 2. See steering wheel.Indicator/lighting . Releasing peg will lock coupler in its current position. Having turned rotary coupler fully anti-clockwise to limit position.Wash/wipe . REPAIR 7 . 1. COLUMN SWITCH ASSEMBLY Service repair no . rotate coupler anti-clockwise as far as inner tape will allow. Refit driver’s airbag module. it is imperative that the coupler is centralised. tape has already broken and rotary coupler must be replaced. If no limit can be found. a new rotary coupler must be fitted. See steering wheel. See driver’s airbag module.55 Service repair no . Make necessary electrical connections and refit steering wheel. NOTE: Do not apply excessive force when limit is reached as this may result in tape breakage. If however there is evidence of tampering. 4. If the tape is broken.34 Remove 1. 2.15. 3. 5. Correctly fit rotary coupler to column switch assembly but do not fit steering wheel or make any electrical connections. Remove steering wheel.SUPPLEMENTARY RESTRAINT SYSTEM ROTARY COUPLER CENTRALISE Fitting a rotary coupler which has not been centralised could result in tape breakage. 2.65.84.5 turns clockwise to obtain central position. CAUTION: Ensure wheels are positioned straight ahead before fitting the rotary coupler.86. Depress rotary coupler locking peg and without using undue force. (Coupler will normally rotate a full five turns from anti-clockwise limit to clockwise limit).

Release rotary coupler. 5. 8 REPAIR . Refit 9. 7. 8. 6. Remove column switch assembly from steering column. Reverse removal procedure. CAUTION: Do not allow rotary coupler to hang on its harness. Release 2 clips securing rotary coupler to column switch assembly. Disconnect 4 connectors from column switch assembly.75 SUPPLEMENTARY RESTRAINT SYSTEM 3. 4. Separate the halves of the nacelle and remove from steering column. Remove 3 screws securing lower half of nacelle to steering column.

Use special socket. remove 2 torx head screws securing rear of airbag module to fascia panel. Refit 8. REPAIR 9 . Tighten airbag module securing screws to 8 Nm (6 lbf ft). Disconnect battery negative lead and then positive lead. Check Supplementary Restraint System using Testbook. MUST be renewed after the airbags have deployed.SUPPLEMENTARY RESTRAINT SYSTEM PASSENGER’S AIRBAG MODULE Service repair no . Carefully and without pulling on connector remove airbag module. Switch off ignition. CAUTION: Do not allow the airbag module to hang by the airbag harness. CAUTION: Store the airbag module in accordance with the storage procedures described in Description and Operation. Reverse removal procedure. 2. 10. 7. remove 2 torx head screws securing front of airbag module to fascia panel.76. Open glovebox and disconnect harness connector from airbag module.74. Remove 1. 9. 5. 3. 6. Use special socket and long extension. including the wiring harness.02 WARNING: All the airbag system components. Release airbag module from fascia panel. 4. CAUTION: Take care not to cross thread screws. NOTE: If airbag module is to be replaced the serial number must be recorded in the vehicle service record.

8. remove 2 screws securing crash sensor to body. 3. 7. LH sensor only: Slacken power steering reservoir clamp and lift reservoir to provide access. Tighten crash sensor securing screws to 10 Nm (7 lbf ft).76. Ensure multiplug is fully engaged on sensor and retained by its latch.DISTRIBUTED SRS Service repair no . Refit 6. 10 REPAIR . 4.75 SUPPLEMENTARY RESTRAINT SYSTEM CRASH SENSOR . Diesel model only: Remove jack and mounting bracket.04 Remove 1. Reverse removal procedure. Use special socket.74. Disconnect battery negative lead. Check Supplementary Restraint System using Testbook. 5. 2. Disconnect multiplug from sensor CAUTION: Ensure airbag harness connector seal and anti-backout DO NOT come adrift when disconnecting sensor. Remove crash sensor.

Reverse removal procedure. 5. 3. centre console. 6. Refit 7. Remove airbag diagnostic control unit.76. Disconnect battery negative lead. Use flat ended screwdriver and release YELLOW retainer. REPAIR 11 . 2. remove 2 screws securing airbag control unit to body bracket. Check Supplementary Restraint System using Testbook. Remove centre console assembly.03 Remove 1.74. Remove 4 screws and release the 2 rear passenger air ducts from their fitted position and remove centre console mounting bracket. Use special socket. 9. Repair. Tighten control unit securing screws to 10Nm (7 lbf ft). pull retainer 30mm (1 1/8 in) from multiplug and disconnect airbag harness multiplug from airbag control unit.SUPPLEMENTARY RESTRAINT SYSTEM AIRBAG DIAGNOSTIC CONTROL UNIT DISTRIBUTED SRS Service repair no . 4. See CHASSIS AND BODY. 8.

74 Remove 1. Repair. Remove window and face plate from instrument panel. See ELECTRICAL. Disconnect multiplug from ECU. 6. Remove tachometer. 3. Release and remove small cover from ECU. 8. Remove 4 screws securing tachometer. Remove ECU 7. 5. 2. Remove instrument binnacle. instrument binnacle. 4. Remove 3 screws securing ECU to instrument panel.73. 12 REPAIR .75 SUPPLEMENTARY RESTRAINT SYSTEM SRS WARNING LIGHT BULBS Service repair no .76.

Reverse removal procedure. Carefully remove 2 screws securing face plate to tachometer. Carefully (to avoid damage to tachometer needle and spindle). See ELECTRICAL. 17. 16. 11. tilt and remove warning light housing. Ensure that tachometer needle is on the correct side of its stop. Fit new warning light bulbs. 10. Fit instrument binnacle. REPAIR 13 . Carefully fit warning light housing. Remove 2 warning light bulbs. 14. Repair.SUPPLEMENTARY RESTRAINT SYSTEM Refit 13. 9. 15. instrument binnacle. Release warning light housing from tachometer circuit board. 12. ensuring that locating pegs engage correctly and that retaining clips lock housing into position.

63 Remove 1. 8. 3. Release airbag harness from driver’s side and remove.86. Remove dash panel assembly.75 SUPPLEMENTARY RESTRAINT SYSTEM AIRBAG HARNESS Service repair no .heater and air conditioning. Pre 97 MY 6. Disconnect steering wheel airbag multiplug. Displace airbag harness grommet to inside of bulkhead and feed harness through bulkhead. 14. 11. See driver’s airbag module. 9. Remove 3 screws securing expansion tank and position expansion tank aside. Release ties securing harness along toeboard. heater and cooler unit All Models 10. See HEATING AND VENTILATION. Reverse removal procedure. Repair. blower motor unit . Remove driver’s airbag. CAUTION: Ensure harness is correctly routed in harness protector and that all securing clips and ties are correctly engaged and harness is undamaged. See CHASSIS AND BODY. Disconnect multiplug from each crash sensor. Ensure all connections are fully engaged and retained by their latches. 2. 12.70. 7. 14 REPAIR . 5. Repair. Remove heater and cooler unit. Refit 15. 13. dash panel assembly 4. Release airbag harness from clips and ties along the bulkhead and each valance. Release airbag harness from under carpet. Disconnect multiplug from airbag control unit. Repair. Remove passenger’s airbag. See passenger’s airbag module. Remove heater blower unit. See AIR CONDITIONING.

8. Self test now complete. Connect crocodile clips of second tool lead to battery. Ensure airbag module is not damaged or ruptured before deploying. WARNING: Only use the LAND ROVER approved deployment equipment. 5. if the vehicle is not being scrapped deploy the module away from the vehicle in accordance with the separate procedure. Insert BLUE and YELLOW connectors of tool lead into corresponding sockets on face of tool. Deploy airbag module in a well ventilated designated area. Deployment with module fitted to vehicle These guidelines are written to aid authorised personnel to carry out the safe disposal of the airbag module when fitted to the vehicle. 2. Disconnect blue and yellow connectors from tool face sockets. the module must be manually deployed. remove lower panel. 4.SUPPLEMENTARY RESTRAINT SYSTEM AIRBAG MANUAL DEPLOYMENT CAUTION: Deployment in the vehicle will damage the steering wheel. RED to positive and BLACK to negative. Press and hold both operating buttons. 10. This operation should only be carried out using the following recommended manual deployment procedure. 7. RED "READY" light should illuminate. Deployment tool SMD 4082/1 self test procedure GREEN "DEFECTIVE" light should illuminate. Carry out deployment tool self test. 1. If a vehicle is to be scrapped and contains an undeployed airbag module. Release 2 turnbuckles securing lower panel to dash. 3. 6. Before deployment is started the deployment tool self test procedure should be carried out. Disconnect tool from battery. RED "READY" light should illuminate. 2. 9. Release both operating buttons. 1. REPAIR 15 .

Connect flylead SMD 4082/5 to column harness connector. 8.75 SUPPLEMENTARY RESTRAINT SYSTEM 3. Remove 4 screws and withdraw kneebolster. Release airbag harness to column harness connector from bracket. 7. Connect tool SMD 4082/1 to battery. Connect flylead SMD 4082/5 to tool SMD 4082/1. Knee bolster (where fitted). 4. WARNING: Ensure airbag module is secure within steering wheel. Disconnect airbag harness connector from column harness. 6. 5. 16 REPAIR . WARNING: Ensure all personnel are standing at least 15 metres (50 ft) away from vehicle. WARNING: Ensure tool is not connected to battery.

Remove airbag module from steering wheel. remove airbag module from steering wheel. 11. DO NOT re-use or salvage any parts of the airbag system including steering wheel. Position tool SMD 4082/2 in vice. Tighten vice. See driver’s airbag module. place airbag module in plastic bag and seal bag. 9. REPAIR 17 . 10. 1. Using gloves and face mask. Press both operating buttons to deploy airbag module. Ensure airbag module is not damaged or ruptured before deploying. Transport deployed airbag module to designated area for incineration. 13. Scrap all remaining parts of airbag system. NOTE: DO NOT transport airbag module in the vehicle passenger compartment. 3. WARNING: Only use the LAND ROVER approved deployment equipment. Driver’s Airbag Module These guidelines are written to aid authorised personnel to carry out the safe disposal of airbag modules when removed from the vehicle. 12. ensuring that vice jaws grip tool above bottom flange to prevent possibility of tool being forced upwards from vice. Carry out deployment tool self test. 2. Deploy airbag modules in a well ventilated designated area. DO NOT return to airbag module for 30 minutes.SUPPLEMENTARY RESTRAINT SYSTEM Deployment with module removed from vehicle.

WARNING: Ensure all personnel are standing at least 15 metres (50 ft) away from module. 6. Connect flylead SMD 4082/4 to airbag module. 5. WARNING: Do not lean over module whilst connecting.75 SUPPLEMENTARY RESTRAINT SYSTEM WARNING: Ensure tool SMD 4082/1 is not connected to battery. Connect flylead SMD 4082/4 to tool SMD 4082/1. 7. 18 REPAIR . Ensure module is correctly secured using both fixings. 4. 8. Ensure airbag module mounting brackets are secure. Connect tool SMD 4082/1 to battery. Secure airbag module to tool SMD 4082/2.

SUPPLEMENTARY RESTRAINT SYSTEM Passenger’s Airbag Module 1. 10. lightly tighten bolts. REPAIR 19 . ensuring that vice jaws grip tool above bottom flange to prevent possibility of tool being forced upwards from vice. 11. 12. Using gloves and face mask. Carry out deployment tool self test. place airbag module in plastic bag and seal bag. Tighten vice. NOTE: DO NOT transport airbag module in the vehicle passenger compartment. Press both operating buttons to deploy airbag module. See passenger’s airbag module. 3. DO NOT return to airbag module for 30 minutes. 13. Wipe down tool with damp cloth. Transport deployed airbag module to designated area for incineration. 2. 9. Position tool SMD 4082/6 in vice. 4. DO NOT re-use or salvage any parts of the airbag system including steering wheel or steering column. Position brackets SMD 4082/7 to tool. Remove airbag module from fascia. remove airbag module from tool.

Ensure airbag module mounting brackets are secure. 20 REPAIR . 9. 7. 8. WARNING: Ensure all personnel are standing at least 15 metres (50 ft) away from module. Position airbag module to tool SMD 4082/6. Connect flylead Smd 4082/5 to tool SMD 4082/1 WARNING: Do not lean over module whilst connecting. Connect tool SMD 4082/1 to battery.75 SUPPLEMENTARY RESTRAINT SYSTEM 5. 6. Ensure module is correctly secured using all fixings. WARNING: Ensure tool SMD 4082/1 is not connected to battery. Connect flylead SMD 4082/5 to airbag module.

03 Remove 1. Fit centre console. Disconnect connector from control unit. NOTE: DO NOT transport airbag module in the vehicle passenger compartment. 4. Transport deployed airbag module to designated area for incineration. Repair. centre console. 12. REPAIR 21 . Remove 2 Torx bolts securing control unit to body. 3. 7.76. 13. Position control unit to body. place airbag module in plastic bag and seal bag.SPS SRS Service repair no . DO NOT re-use or salvage any parts of the airbag system. 14. centre console. Remove centre console. Remove control unit. Connect control unit connector and secure. 6. Refit 5. Check supplementary restraint system using TestBook. See CHASSIS AND BODY. Repair. 8. fit Torx bolts and tighten to 10 Nm (7 lbf ft) .SUPPLEMENTARY RESTRAINT SYSTEM AIRBAG DIAGNOSTIC CONTROL UNIT . Press both operating buttons to deploy airbag module. remove airbag module from tool.74. DO NOT return to airbag module for 30 minutes. See CHASSIS AND BODY. 11. 2. Wipe down tool with damp cloth. 10. Using gloves and face mask.

.......................................................... Nm Airbag module screws ......................... 50 (37 lbf ft) Crash sensor screws (Distributed SRS) .......................................... TORQUE 1 ............................. 10 (7 lbf ft) Control unit ................................. 8 (6 lbf ft) Steering wheel nut ............................................................SUPPLEMENTARY RESTRAINT SYSTEM TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque........................ 10 (7 lbf ft) SPECIFICATIONS......................

Set the door in the open position without engaging the check stay. 14. Locate the check stay to the bracket on the ’A’ post and secure with a new roll pin. If necessary. take up the slack and refit the convoluted grommet to the ’A’ post. REPAIR 1 . WARNING: Instruction 7 MUST BE carried out with assistance.28. Disconnect battery negative lead. and by the addition or removal of shims between the hinge and door.76. 9. Feed the door harness and speaker leads through the aperture in the ’A’ post. 6. The door lock striker can be adjusted by loosening the striker and moving it in the appropriate direction or by adding and removing spacing washers between the striker and ’B’ post. 13. 10. 5. then remove the roll pin securing the check stay at the ’A’ post. Refit the door and secure the hinge posts with the ’C’ clips.CHASSIS AND BODY FRONT DOOR Service repair no .01 Remove 1. Carefully remove the two retaining buttons from the trim panel on the side of the footwell and ease out the panel. 12. fully open the door and reconnect the multiplugs in the footwell. Disconnect the three multiplugs connecting the door harness and speaker leads. 4. 11. Detach the door seal at the lower section of the ’A’ post. Check the location of the door and the operation of the door lock. Remove the door hinge ’C’ clips from the hinge posts and with assistance carefully lift the door from the vehicle. Refit the footwell side panel. Refit 8. adjust the door and striker. 2. 7. 3. Detach the convoluted grommet from the ’A’ post and withdraw the door harness and speaker leads. The door can be adjusted up and down or in and out of the opening by loosening the six screws securing the hinges to the door.

Remove the two screws and shakeproof washers retaining the lower window lift channel. Refit 8. remove the speaker. Remove the door trim panel. 3. 4. 6. Disconnect the two speaker connections from inside the door and remove the trim panel complete with speaker. See front door trim panel. FRONT DOOR GLASS AND REGULATOR Service repair no . window lift motor . 4. Reverse removal procedure.76. 6. Ensure the window is in the fully closed position and secure with adhesive tape to prevent the window from dropping down.34. and slide the channel off the stud.76. 5.01 Remove 1. 7. Remove the screw and detach the handle surround from the trim panel. Disconnect battery negative lead. Repair. See ELECTRICAL. 7. gently prise out the fourteen plastic securing clips from their respective holes in the inner door panel. door bin and remote button finisher from the existing trim panel and fit them to the new panel. 2 REPAIR . Remove the two securing screws and detach the door pull from its mounting brackets on the inner door panel. Where applicable remove the window lift motor. 3. 2. Detach the trim panel by inserting a trim panel removing tool between the trim panel and the inner door panel. and door bin.76 CHASSIS AND BODY FRONT DOOR TRIM PANEL Service repair no .31.front. If a new trim panel is to be fitted. 2. 5. Remove the interior door handle finisher button to reveal the screw retaining the handle surround.45 Remove 1. Remove the four window regulator retaining screws and shakeproof washers from the inner door panel. Where applicable remove the window winder. Remove the plastic vapour barrier.

Lift the door glass frame complete with glass out of the door panel and remove to a suitable bench. Reverse removal procedure. 17. Disengage the lifting arm stud from the upper lifting channel. 18. Slide the glass out of the door frame channel. REPAIR 3 . Remove the bolt and plain washer from the opening edge of the door which secures the rear of the door frame. 14. 10.CHASSIS AND BODY 8. Remove the bolt and plain washer from the recessed hole in the front of the inner door panel under the exterior driving mirror mounting plate. from inside the door. 11. 13. manoeuvre the window regulator and remove it from the lower centre opening in the inner door panel. Remove the screws and plain washers. ensure it is repositioned to suit the door opening before fully tightening the door frame securing bolts. 12. exterior driving mirrors. Remove the exterior driving mirror. 15. Remove the ’Torx’ bolt from the hinge face of the door which secures the front of the door frame. 16. securing the bottom of the front and rear glass channels. Remove the waist rail seal from the top of the door panel. Refit NOTE: When refitting the door glass frame. 9. See ELECTRICAL. Remove the adhesive tape securing the glass to the door frame. Repair.

Release the door lock by removing the two counter-sunk screws from the door edge and the single screw and shakeproof washer on the inner door panel.37. 4. Disconnect the lock barrel control rod from the lock by releasing the metal clip at the bottom of the rod. OUTSIDE AND INSIDE DOOR RELEASE HANDLES Service repair no .12/31 Remove 1. 9. From inside the door panel push out the small pin that secures the quadrant to the inner door panel. Push the quadrant out of the panel. front door actuator unit. 10. See front door trim panel. This is accessible through the small centre cut-out in the door panel. Disconnect the control rod connector between the inside door release handle and the door lock by releasing the metal clip and pulling one of the control rods out of the plastic connecting block.76. Repair. See front door glass and regulator. 2.76 CHASSIS AND BODY FRONT DOOR LOCK. Disconnect the control rod from the outside door release handle by pulling it out of the plastic ferrule. 3. 5. 8. The control rod also passes through a guide bracket in the inside of the inner door panel. 4 REPAIR . Disconnect battery negative lead. Where applicable remove the door actuator unit. 7. Remove the door glass and regulator. See ELECTRICAL. Disconnect the remote button control rod from the lock by releasing the metal clip at the bottom of the rod and withdraw the rod from the door. Remove the door trim panel. 6.

Remove the two screws securing the inside door release handle to the inner panel. 12.CHASSIS AND BODY 11. Reverse removal procedure. 14. shakeproof washers and retaining bracket securing the outer door release handle to the outer door panel. Refit 17. 13. 15. Withdraw the handle from its location with the connecting rod half still attached. accessible through the upper rear cut-out on the inner door panel. Remove the two nuts. REPAIR 5 . Carefully detach the door release handle from the outer panel. Withdraw the lock through the lower rear cut-out on the inner door panel. Unclip the end of the connecting rod from the handle. 16.

Disconnect the connecting rod from the plastic ferrule at the rear of the outer door release handle. Outside door release handle to lock 3. At the lock end of the interior handle connecting rod. 6 REPAIR . rotate the spring tensioned nyloc nut clockwise or counter-clockwise. 2.47 Inside door release handle to lock 1. Rotate the rod clockwise or counter-clockwise to shorten or extend the operating length as necessary. NOTE: Door release should be effective before the total handle movement is exhausted to provide a small overthrow movement. Refit the inside door release handle surround before any adjustment is made. as necessary to shorten or extend the operating length of the rod.37. allowing the handle to be set from the correct operating position.76 CHASSIS AND BODY ADJUSTMENT-FRONT DOOR LOCK AND HANDLE ASSEMBLY Service repair no .76.

Withdraw the door harness multiplugs from the ’B’ post and disconnect them. Fitting new ’C’ clips if the existing ones are worn or distorted. adjust the door and striker. Reverse removal procedure. To adjust the door up.02 Remove 1. using an equal thickness of shims to those removed. Adjust 8. Adjust the door by adding or removing shims between the hinge and the door to move the door forward or rearward in the opening. adjust as necessary and retighten the screws to the correct torque value. Disconnect battery negative lead. 9. NOTE: If it is necessary to remove the hinges from the ’B’ post they must be refitted in exactly the same position. loosen the screws securing the hinges to the door.28. Remove the door hinge ’C’ clips from the hinge posts and with assistance carefully lift the door from the vehicle. If necessary. 4. Adjustment of the door striker is identical to the procedure for front doors. REPAIR 7 . 5. 7. 10. 3. Remove the bolts and washers securing the check strap to the ’B’ post. WARNING: Instruction 5 MUST BE carried out with assistance. Detach the convoluted grommet from the ’B’ post. Check the operation of the door and lock. Refit 6.76. 2. down or in and out of the opening.CHASSIS AND BODY REAR SIDE DOORS Service repair no .

If a new trim panel is to be fitted. Reverse removal procedure. Remove the two securing screws and detach the door pull from its mounting brackets. 2. 4.76. Refit 8. 6.04 Remove 1.34. 8 REPAIR . Observe its correct location and withdraw from the door panel. 7.76 CHASSIS AND BODY REAR SIDE DOOR . 3. Where applicable remove the window winder or release electric switch and disconnect. Ensuring correct fitment of the sill button operating rod. Where applicable disconnect the electrical plug from the window lift switch and withdraw the panel. Remove the securing screw and detach the interior door release handle surround. 5. NOTE: With the trim panel removed the remote button and rod will fall from its location in the bellcrank. Lift the trim panel over the remote button and clear of the door. gently prise out the plastic securing clips from their respective holes in the inner panel. Disconnect battery negative lead. door bin and remote button finisher from the existing trim panel and fit them to the new panel. remove the window lift switch.TRIM PANEL Service repair no . Detach the trim panel by inserting a trim panel removing tool between the trim panel and the inner door panel.

Using a small screwdriver. Retrieve any spacing washers which may be fitted between the inner door panel and lock.trim panel. Sill locking bellcrank 14. 2. 7. Disconnect the outside release handle control rod by pulling it out of the plastic ferrule. NOTE: When refitting the bellcranks the locking pins are entered into the square insert from outside and pressed in flush. Remove the two nuts. Ensure that the window is in the fully closed position. 16. Disconnect the sill button connecting rod from the bellcrank and withdraw the rod complete with sill button. INSIDE AND OUTSIDE RELEASE HANDLES Service repair no . 4. 11.175 mm (1/8 in) diameter rod. Remove the plastic vapour barrier sheet. 15. See rear side door . 13. press the plastic locking pins through the respective square inserts in the inner door panel. 10. Disconnect the sill locking control rod from the lock by releasing the metal clip. 12. NOTE: If necessary the following items can be removed. Withdraw the lock through the upper rear opening in the inner door panel. Remove the two countersunk screws from the door edge and the single screw and shakeproof washer from the inner door panel. Disconnect battery negative lead. 6. Carefully detach the handle from the outer door panel. 3. REPAIR 9 . Remove the interior trim panel from the door.76. Disconnect the inside release handle control rod by pulling it from its location in the door lock.13/32 Remove 1. Release the bellcranks from the inner door panel and unhook the respective connecting rods. 8.CHASSIS AND BODY REAR SIDE DOOR LOCK. Remove the two screws and plain washers securing the inside release handle to the inner door panel and withdraw the handle complete with connecting rod. 9. or length of 3. 5.37. shakeproof washers and retaining bracket securing the outer release handle which are accessible through the upper rear cut-out on the inner door panel. Withdraw the bellcranks from inside the door panels.

Carefully disengage the lifting arm stud from the glass lifting channel and remove the window regulator from the lower opening in the inner door panel.76 CHASSIS AND BODY ADJUSTMENT-REAR SIDE DOOR LOCK AND HANDLE Service repair no . Remove the door trim panel. Where applicable remove the door actuator and window lift motor. spring and plain washers from inside the door.47 REAR SIDE DOOR GLASS AND REGULATOR Service repair no . 2. Remove the single bolt. 10. spring and plain washers from the hinge face of the door. See ELECTRICAL. securing the bottom of the short glass run channel. 5. rotate the rod clockwise or counter clockwise to shorten or extend the operating length of the rod as required. NOTE: Door release should occur before the total handle movement is achieved to provide a small overthrow movement. Remove the four window regulator securing screws and shakeproof washers from the inner door panel. 10 REPAIR . 9. Repair.76. Remove the two bolts. Remove the waist rail seal from the top of the door panel. 8. Disconnect battery negative lead.37. Ensure that the window is in the fully closed position and secure it with adhesive tape over the top of the door to prevent the glass from dropping down. 3. Remove the plastic vapour barrier. See rear side door .76.45 Remove Outside door release handle to lock 1. Repair.31. 6. 1. 4. rear side door actuator units.rear.trim panel. Disconnect the short off-set connecting rod at the rear of the outer release handle. 7. window lift motor . See ELECTRICAL.

28. Remove the spare wheel from the exterior of the door. Release the convoluted grommet from the door post. 5. Remove the circlip and washer from the check stay pivot on the body. Remove the tape and slide the glass out of the door frame channel. WARNING: Instruction 5 MUST BE carried out with assistance. spring and plain washers securing the door frame to the edge of the door. Lift out the door frame complete with glass and remove to a suitable workbench. See rear door trim panel. REPAIR 11 . 11. 2.19 Remove 1. Refit 14. 12. 4.CHASSIS AND BODY REAR DOOR Service repair no . Remove the trim panel from inside the rear door. NOTE: When refitting the door glass frame ensure that it is adjusted to suit the door opening before fully tightening the securing bolts. expose the door harness connectors and multiplugs and disconnect. Reverse removal procedure. 3. remove the four bolts securing the hinges to the door and with assistance slide the door off the hinges. Suitably support the door. Reverse removal procedure. Refit 6. Remove the two bolts. 13.76.

Disconnect the inner release handle connecting rod at the lock. Detach the lock and barrel connecting rods from the upper leg of the inner ’Y’ lever. 2.76 CHASSIS AND BODY REAR DOOR TRIM PANEL Service repair no . 7. If necessary remove the sixteen screws securing the stowage bins to the trim panel and detach the bins. remove the central locking actuator control rod link from the actuator and from the inner ’Y’ lever. 4. Using a trim panel removing tool release the seventeen trim panel fasteners and withdraw the panel from the door.09 REAR DOOR LOCK AND INNER AND OUTER RELEASE HANDLES Service repair no .76.76. Remove the finisher from the inner door handle.16/74/77/78 Remove Remove 1. 2.34. If fitted. 1. 3. NOTE: Two identical ’Y’ shaped levers (bellcranks) are fitted to the rear door lock mechanism and are referred to as inner and outer ’Y’ levers. 6. Remove the two screws securing the inner handle and withdraw the handle complete with connecting rod. Remove the door pull. Disconnect battery negative lead. to allow access to the door handles and lock mechanisms. Reverse removal procedure. the trim panel and the vapour protective sheet. 4. 3.37. Remove the two screws securing the door pull and remove it from the door. the inner one being the nearest to the inner door panel. 12 REPAIR . 5. Refit 5. Detach the remote button connecting rod at the inner ’Y’ lever and withdraw from inside the door.

13. 18. 17. 16. 14. remove the single bolt securing the housing. 9. 12. From inside the door panel remove the nuts and washers securing the lock barrel and number plate light housing. REPAIR 13 . 15. Remove the connecting rod from the outer door handle lever. Partially withdraw the housing and its rubber seal from the door. Disconnect the adjustable lock rod from the outer ’Y’ lever. Remove the screws securing the lock control mechanism pivot bracket and the door pull mounting bracket. Remove the two screws and withdraw the childproof lock actuator. Remove the centre pin from the outer ’Y’ lever pivot and release the pivot from the door. withdraw the number plate light leads and complete the removal of the housing and seal from the door. Remove the three lock securing screws and manoeuvre the lock and ’Y’ lever out of the door panels. Remove the logo from the housing and working through the logo aperture. 11. Remove the ’E’ clip securing the fulcrum to the barrel stem and withdraw the fulcrum and lock rod.CHASSIS AND BODY 8. 19. Disconnect the number plate light leads from the door harness. displace the rubber grommet from the door panel. 10. Remove the two nuts and washers securing the outer handle from inside the door panels and detach the handle and seal. ease the bracket from the lock barrel stem and remove from the door.

Locate the barrel stem in the insert on the bracket. 39. locate the ’Y’ lever pivot and secure with the pin. Insert the assembled bracket and barrel into its location in the housing. from the existing housing and fit them to the new housing. 30. 20. 34. Attach the remote button and the actuator connecting rods to the ’Y’ lever. Remove the ’O’ ring seal from inside the housing. Fit the lock and assembled outer ’Y’ lever. 37. Place a new ’O’ ring seal on the inner face of the barrel aperture in the housing. Position a new seal on the inner face of the barrel. 31. Fit the connecting rod from the outer handle lever to the outer ’Y’ lever. Insert the barrel stem through the door. 40. Fit the outer handle to the door and secure from the inside with the two nuts and washers. door trim panel and door pull. Fit the stem to the barrel and secure with the ’U’ clip. Fit the logo to the aperture in the housing. fitting the door pull mounting bracket under the heads of the top two screws. secure the lock with the three screws. If the lock barrel and number plate light housing is being renewed. harness and the housing mounting bracket. Refit 29. 32. and secure with the single bolt and washer through the logo aperture. ensure that the seal seats correctly. attach the barrel connecting rod to the top clip of the upper leg and the rod from the lock to the lower clip of the upper leg. 43. Remove the spring clip securing the barrel to the bracket and withdraw the barrel and stem assembly from the bracket complete with seal. Fit the lock barrel and number plate light housing by inserting the number plate light leads through the aperture in the door panel and locating the rubber grommet in the aperture. 14 REPAIR . 22. 24.76 CHASSIS AND BODY Lock barrel and number plate light housing Disassemble NOTE: The lock barrel can only be removed from its housing when the lock barrel and number plate light housing is removed from the door. locate the housing on the door panel. taking care not to disturb the seal. 36. 33. Secure the bracket with the four screws. Remove the ’U’ clip securing the stem to the barrel and detach the seal from the inner face of the barrel. 27. Refit the vapour protective sheet. Connect the number plate light leads to the door harness. and secure with the bolt. Fit the fulcrum and connecting rod to the barrel stem and secure with secure with the ’E’ clip. 21. Insert the remote button and rod to the location in the door. insert the stem and barrel into the mounting bracket and secure with the spring clip. Remove the bolt securing the lock barrel mounting bracket to the housing and withdraw the assembled barrel and bracket. 26. Reassemble 25. remove the number plate lights. 41. 35. 38. 23. Fit the childproof lock actuator and check that it is functioning. 28. Offer up the assembled inner ’Y’ lever and bracket. 42. Fit the inner release handle and attach the connecting rod to the lock.

Remove the two securing bolts and withdraw the check stay assembly. feed the seat belts through the apertures and withdraw the panel. REPAIR 15 . Remove the five trim panel retainers. whichever is applicable. 3. Reverse removal procedure. See rear fold down seats. Remove speaker by releasing screws and disconnecting Lucars. Refit 5.76. Withdraw rear quarter trim panel.03 Remove 1. Invert the door on a suitable protected area.30 Remove 1. Remove the rear door from the vehicle. 2. Ease the trim panel from its location.CHASSIS AND BODY REAR DOOR CHECK STAY Service repair no .40. Reverse removal procedure. 4. REAR COMPARTMENT LOWER TRIM PANELS Service repair no . 3. 2. Remove the fold down seat or pocket side panel. Refit 4.13.76. See rear door.

Fit and align trim casing and secure with studs. 8. 11.rh. Fit ’E’ post trim casing. 4. fit bolt and tighten to 32 Nm (24 lbf ft) . Fit cover to seat belt anchorage bolt. 6. Remove RH ’E’ post trim casing. Refit 7. See ’E’ post trim casing .76. See ’E’ post trim casing . 2. Remove trim casing. Remove bolt securing rear seat belt anchorage.20 Remove 1.76 CHASSIS AND BODY ALPINE LIGHT TRIM CASING Service repair no . Remove 2 trim studs securing trim casing. Release trim casing from 2 retaining studs. Fit 2 trim studs securing trim casing. 9. 3. 5. 16 REPAIR . Remove rear seat belt anchorage retaining bolt cover.rh. Position seat belt anchorage.13. 10.

4. Release the rear seat belt from the guide attached to the casing. 10. Tighten upper and lower seat belt fixings to 32 Nm (24 lbf ft) . Refit 13. Open the side window. Reverse removal procedure. Remove the finisher from its location over the seat belt inertia reel. 6. See alpine light trim casing. Remove the bolts securing the upper and lower seat belt mountings. Remove the alpine light trim casing. Release the casing from the window rubber. 9. 3. See rear compartment lower trim panels. Remove the rear compartment lower trim panel.13. 5. 14. 8. 7. Remove the grab handle.76.CHASSIS AND BODY FRONT BODYSIDE TRIM CASING Service repair no . 2. NOTE: Ensure that the trim material glued to the door post is not wrinkled when the door seal is fitted. 11. Fold down the rear seats and carefully ease the casing from the fastenings. Remove the front seat belt guide from the upper aperture in the casing. REPAIR 17 .01 Remove 1. Remove the side window hinge finishers. 12. Pass the front seat belt through the upper aperture and withdraw the casing from the vehicle. remove the catch securing screws and withdraw the catch trim.

10. 6. remove the passenger net pockets and fit them to the new headlining. Remove the front bodyside trim casing. if fitted. 4. See rear compartment lower trim panels. Release the headlining from the channel above the rear door and manoeuvre it from the vehicle through the rear door. Remove the roof lights from the headlining pocket and from the headlining. 3. Remove the finishers from the sun roof apertures. Remove the sun visors and their retaining clips. 2. Remove the front grab handles. Remove the lower trim panels from the rear compartment. Reverse removal procedure. Remove the alpine light trim casing. 11. Remove the front headlining pocket. See alpine light trim casing. 8.76. See front bodyside trim casing. 7. 5. Disconnect battery negative lead. If the existing headlining is being replaced. 9. 18 REPAIR .76 CHASSIS AND BODY HEADLINING Service repair no .01/14 Remove 1. Refit 12.64.

Remove the alpine light trim casing.73 Remove 1. 5.13. Reverse removal procedure. Remove the screws securing the catch to the body and detach the catch trim. 2. Refit 4. Fold down the rear seats. Remove the hinge finishers from the hinges. withdraw the glass and fixings taking care not to lose the joint washers. REPAIR 19 . 2. Reverse removal procedure. 4.81. 3. 3. Release the rear seat belt from the guide attached to the casing. Release the D’ post casing from the rear side window seal and carefully ease the casing from the fasteners.18 Remove 1. See rear compartment lower trim panels. Refit 6. Remove the rear compartment lower trim panel. See alpine light trim casing. BODY SIDE OPENING WINDOWS Service repair no .CHASSIS AND BODY ’D’ POST TRIM CASING Service repair no . Remove the screws securing the glass to the hinges.76.76.

4. 11. 10. 4. 2. 5. Do not fully tighten the screws at this stage. If fitted push out the glass and remove the mounting rubber.76. pushing the glass and mounting rubber into the opening. coat the flange in the bodyside with liquid soap. 8. To aid assembly. finally tighten the screws. Refit the top seat belt bracket and the grab handle. Thoroughly clean the opening to be glazed. Check the alignment and squareness of the glass. 9. Refit 6. 12.81. 2. Clean the glass and fit the mounting rubber.47 Remove 1. See body side opening windows.81. Ease the trim panel away from the door post to gain access to the window hinges.76. ensuring that the glass sits correctly in the groove. Fit a draw cord around the exterior of the mounting rubber. with the tails of the draw cord fed into the interior of the vehicle. Note the thickness and location of any packing washers fitted. adjust as necessary by adding or deleting washers and using the elongated slots in the hinges for adjustment. With assistance from a second operator. Remove the passenger grab handle. Position the assembled glass and rubber mounting to the opening in the body. REAR SIDE FIXED WINDOWS Service repair no .76 CHASSIS AND BODY BODY SIDE WINDOW HINGES Service repair no . Locate the window catch trim and secure the catch to the body. Reposition the trim panel and refit the hinge finishers. 20 REPAIR . 9. Remove the rear seat belt top fixing. Remove the window. Close the window and secure with the catch. Detach the front seat belt top mounting from the door post. 8. pull the draw cord from the mounting rubber enabling the seal to ride up over the retaining flange. 7. Remove the screws securing the window hinges. 5. 3. 6. taking care not to lose the the packing washers where fitted. Refit the glass to the hinges. Ease the inner section of the mounting rubber over the interior trim panel. 7.18 Remove 1. Fit the hinges with packing washers fitted to the locations and thickness noted during removal. Refit 3.

Repair. To aid assembly. 7. pull the draw cord from the mounting rubber enabling the seal to ride up over the retaining flange.CHASSIS AND BODY REAR DOOR GLASS Service repair no .76. 10. REPAIR 21 . wiper arm . 2. Clean the glass and fit the mounting rubber. disconnect the heater leads from the terminals. coat the glass opening in the door with liquid soap.31. Position the assembled glass and rubber mounting to the opening. 9. Thoroughly clean the opening to be glazed. 8.21 Remove 1. If the glass is fitted. 6. Remove the spare wheel from the rear door. Remove the rear door wiper arm. 3. Connect the heater leads to the terminals on the glass. Fit a draw cord around the exterior of the mounting rubber with the tails of the cord situated on the top corner of the bend at the bottom of the glass. ensuring that the glass sits correctly in the groove. push out the glass and remove the mounting rubber. Refit 4. 5. pushing the glass and mounting rubber into the opening. with the tails of the draw cord fed into the interior of the vehicle. With assistance from a second operator.rear window. See WIPERS AND WASHERS.

Lift the seat from the base and withdraw from the vehicle. 2. Slide the seat to the full extent rearwards and remove the rear seat to base securing bolts.76 CHASSIS AND BODY FRONT FOLDING SEATS 3 DOOR VEHICLES Service repair no .76.70. 22 REPAIR .01 WARNING: Care must be taken if the seat lifting mechanism is operated when the seat is removed from the base otherwise personal injury could occur. Slide the seat forward and remove the front seat to base securing bolts. Remove 1. Reverse removal procedure. 5. Refit 4. Tighten all securing bolts to 22 Nm (16 lbf ft) . 3.

5. 13. Reverse removal procedure.06/25 WARNING: Care must be taken if the seat lifting mechanism is operated when the seat is removed from the base otherwise personal injury could occur. 4.CHASSIS AND BODY SEAT BASE Service repair no . Refit 6. Carefully operate the seat mechanism to raise it to the tilt position. 10. 2. Remove the seat from the base. Pull the carpet flap forward to expose the front securing bolts. Return the seat mechanism to the upright position. Remove the seat from the base. REPAIR 23 . Remove the bolts and withdraw the runners. Remove the two bolts securing the rear of the base to the floor. Reverse removal procedure. 3. 12. 8. remove the bolts and lift out the seat base. Refit 11. Refit the seat to the base. Fit the runners and release handle. Slide the runners forward sufficient to gain access to the rear securing bolts and rearward for the front bolts. SEAT BASE RUNNERS Remove 7. Spring the release handle off its locations on the runners.70. 9.76. Remove 1.

Slide the seat forwards and remove the rear base to floor securing screw. FRONT SEATS 5 DOOR VEHICLES Service repair no .71. 6. 7.70. Refit 5. Tighten front base to floor securing screws to 22 Nm (16 lbf ft) .76. 24 REPAIR .76 CHASSIS AND BODY SEAT BASE TORSION BARS Service repair no . Lift the seat and base assembly and withdraw from the vehicle. Tilt the seat assembly forward. Extract the right angled ends of the torsion bars from the brackets on the seat base and withdraw.01 Remove 1. Refit 4.34 Remove 1. 3.76. Reverse removal procedure. Remove the finisher from the seat base. 4. 2. Remove the torsion bar clamps. Reverse removal procedure. Tighten rear base to floor securing screws to 29 Nm (21 lbf ft) . Slide the seat to the full extent rearwards and remove the front base to floor securing screws. 3. 2.

76. Release the four wire hooks securing the squab cover to the lower spring frame. 6. Reverse removal procedure. Remove the seat from the base. 5. REPAIR 25 .14 Cushion Remove 1. Reverse removal procedure. Release the cushion rear clip from the frame and detach the cushion complete with cover. REAR PASSENGER SEAT Service repair no .70. 2. 4. remove the bolts from the front of the hinges. Feed the seat belts through the seats into the rear compartment.70. Fold the seats forward. Detach the seat cover retaining clips from the frame.37 Remove 1. remove the bolts from the rear of the hinges and withdraw the seats from the vehicle. Refit 4. Refit 7. Invert the seat on a suitable clean bench. 3. 2.76.CHASSIS AND BODY FRONT SEAT COVERS Service repair no . Tighten fixing bolts to 8 Nm (6 lbf ft) . 5. With the seats in the upright position. 3. Remove the cover from the cushion.

Refit 4.70. Withdraw the seat squab from the seat assembly.38 Remove 1. Remove the squab striker plate. 4. 2.79/80 Remove 1. Remove the rear seat back finisher from the squab. Reverse removal procedure. Fold the rear seat down. 3. 2. Reverse removal procedure. Remove the securing clips and remove the cover from the squab. 5.76 CHASSIS AND BODY REAR SEAT SQUAB Service repair no .76. Remove the rear seat squab from the seat assembly and withdraw it from the vehicle. 26 REPAIR . Refit 6. See rear seat squab.70.76. Release the squab cover from the frame. REAR SEAT SQUAB COVER Service repair no . Remove the two seat squab securing bolts. 3.

2. REPAIR 27 .70. Remove the rear seat assembly from the vehicle.CHASSIS AND BODY REAR SEAT CUSHION COVER Service repair no . 1. The operating rod can be removed from the latch by releasing it at the plastic clip.76.51 Remove 1. Refit 7. 5. SPLIT REAR SEAT LOCKING MECHANISM Service repair no . Refit 5.5/16 in). 3. Remove the cushion base cover retaining screws and withdraw the cover. See front body side trim casing.8 mm (3/16 . Retrieve the latch from the opening at the rear of the tower. Reverse removal procedure. Remove the front body side trim casing. If necessary retrieve the single screw.88/89 Remove NOTE: The procedure for removing both left and right hand seat cushions is the same. Remove the seat squab. Remove the cover from the cushion. Reverse removal procedure. See rear passenger seat. noting that access to the single screw is gained through the hole in the front of the tower. 2. Release the seat cover securing clips at the frame and at the seat belt aperture. 4. Remove the three screws securing the latch to the tower. 3. Remove the seat cushion. 4.76.70. 6. Setting the release button to achieve a gap of 5 .

fit Torx screws and tighten to 13 Nm (10 lbf ft) . Secure the seat belt strap and buckle to their stowed positions. release the seat belt strap and buckle from their stowed positions. Collect 4 washers. 6. and secure with Torx screws tightened to 13 Nm (10 lbf ft) . Remove seat assembly. 7. 4. Fold the seat up and remove the 2 Torx screws from the upper brackets. 2.76. NOTE: The pivot bolts. 28 REPAIR . Locate the seat in the down position.71. Remove 4 Torx screws from the lower brackets. Position seat assembly. securing the seat squab and cushion. are fitted with a wavy washer under the head and a plain washer between the link or bracket.76 CHASSIS AND BODY REAR FOLD DOWN SEATS Service repair no . Remove the seat assembly from the vehicle. Refit 5. Remove the pivot bolts and washers securing the seat squab to the frame. align upper brackets. NOTE: Ensure washers are fitted in their correct positions. Seat squab Remove 8.23 Seat and squab Remove 3. 1. Align lower brackets. Ensure that these washers are fitted in the correct locations when reassembling the seat. 9.

7.CHASSIS AND BODY 10. 16. Move the front seat to the fully forward position or tilt the seat forward (3 door vehicles).73. Refit 12. 14. Remove the pivot bolts and washers securing the hinge bracket and detach the bracket. 18. REPAIR 29 . Seat cushion Remove 13. 11. to gain access to the stay pivot bolts. Remove the securing bolt and detach the inertia reel from the bottom of the ’B’ post. Remove the seat from the vehicle. 4.10 Remove 1. If necessary remove the clips securing the cover and detach the cover. 15. 2. Release the seat belt from the split section at the top of the trim panel and withdraw the panel. 17. FRONT SEAT BELTS Service repair no . Invert the seat base and remove the screws and rivets securing the base cover to the base. Remove the seat squab. Reverse removal procedure. NOTE: 3 door models have a non-adjustable. Remove the flanged securing bolt to release the upper mounting and spacer. Remove cover to gain access to the seat belt upper mounting bolt. Raise the seat base cover. remove the bolts and washers and withdraw the stay and seat base cover. If necessary remove the clips and detach the cushion cover. 3. Reverse removal procedure. Remove the cover and bolt securing the lower mounting to the floor. upper mounting. Remove the pivot bolts and washers securing the hinge links to the seat squab. Detach the door seals from the ’B’ post sufficiently to allow removal of the lower trim panel from the post.76. 5. 6. 5 door model illustrated Refit 19.

76

CHASSIS AND BODY

REAR OUTER SEATS BELT Service repair no - 76.73.18 Remove 1. Remove the rear fold down seat (if applicable). See rear fold down seats. 2. Remove the speaker by releasing the screws and disconnecting the Lucars. Withdraw the rear quarter trim panel. 3. Remove the rear bodyside lower trim panel. See rear compartment lower trim panels. 4. Remove the bolts securing the brackets to the wheel arch and upper bodyside. 5. Remove the bolt securing the inertia reel to the bodyside and withdraw the seat belt. 6. Remove the seat belt buckle strap from the floor mounted bracket. See rear centre seat belt.

8. Release the Torx bolt to allow removal of the seat belt stalk assembly. Refit 9. Reverse removal procedure. NOTE: Ensure the seat belt is not twisted.

10. Finally, tighten the seat belt bolts to 32 Nm (24 lbf ft) .

Refit 7. Reverse removal procedure. 8. Finally, tighten the seat belt bolts to 32 Nm (24 lbf ft) .

30

REPAIR

CHASSIS AND BODY

REAR CENTRE SEAT BELT Service repair no - 76.73.20 Remove 1. Pull both halves of the seat belt through to the rear of the seat.

REAR FOLD DOWN SEAT BELTS Service repair no - 76. 73.28 Remove 1. Remove the fold down seat or pocket side panel, whichever is applicable. See rear fold down seats. 2. Remove speaker by releasing screws and disconnecting Lucars. Withdraw rear quarter trim panel. 3. Remove the rear bodyside lower trim panel. See rear compartment lower trim panels. 4. Remove the bolts securing the seat belt halves to the body side.

2. Pull back the load space carpet to reveal the Torx bolt heads. 3. Remove the Torx bolt and plain washer securing the belt bracket to load space floor. 4. Remove belt complete with bracket. 5. Repeat steps 2 to 4 for other half of belt. Refit 6. Reverse removal procedure. 7. Finally, tighten the seat belt bolts to 32 Nm (24 lbf ft) . Refit 5. Reverse removal procedure. 6. Finally, tighten the seat belt bolts to 32 Nm (24 lbf ft) .

REPAIR

31

76

CHASSIS AND BODY

REAR GRAB HANDLE Service repair no - 76.58.35 Remove 1. Remove speaker and rear quarter trim panel. 2. Detach the foam strip. 3. Remove the four securing bolts and detach the handle.

Refit 4. Reverse removal procedure.

32

REPAIR

CHASSIS AND BODY

WINGS [FENDERS] Service repair no - 76.10.24 Remove 1. 2. 3. 4. 5. Disconnect battery negative lead. Remove the headlamp surround. Remove the front bumper assembly. Remove the indicator repeater light. Remove the four screws securing the wing [fender] at the ’A’ post. 6. Remove the bolts securing the bottom of the wing [fender] at the bumper retaining bracket and at the sill finisher. 7. If removing the RH wing [fender] loosen the radio aerial securing nut.

Cleaning/painting 10. Thoroughly clean all traces of existing sealant from the sealing faces of the valance and ’A’ post. 11. Paint the cleaned surfaces with etch primer. 12. If the existing wing [fender] is to be refitted repeat the cleaning and painting procedure on the wing [fender] sealing surfaces. Refit 13. Apply 3M 8572 Bolted Panel Sealer to the joint faces on the valance and ’A’ post and to the bracket face. 14. Refit the wing [fender], on RH wings [fenders] fit the radio aerial, and secure with the bolts and screws ensuring that the wing [fender] correctly aligns with the bonnet [hood].

8. Remove the seven bolts from the drain channel in the top of the wing [fender]. 9. Break the sealed joints at the valance and ’A’ post; then complete the removal of the wing [fender]. If removing a RH wing withdraw the wing [fender] sufficiently to allow removal of the aerial before completing the removal.

REPAIR

33

76

CHASSIS AND BODY

SILL FINISHER Service repair no - 76.76.05 Remove 1. Remove the nut, bolt and washer securing the front of the sill finisher to the wing [fender] support bracket. 2. Remove the screw securing the bracket at the rear end of the finisher to the sill. 3. Using a suitable punch, remove the inserts from the seven plastic retainers and withdraw the finisher from the sill.

BONNET [HOOD] Service repair no - 76.16.01 Remove 1. Open the bonnet [hood] and support with the stay. 2. Mark the position of the hinges to the bonnet [hood]. 3. With the assistance of a second operator, remove the hinge to bonnet [hood] securing screws, remove the support stay and lift bonnet [hood] from the vehicle. Note the quantity of shims fitted between the hinge and bonnet [hood]. Refit 4. Reverse removal procedure. Ensuring that it aligns with the wings [fenders], cowl panel and front grille before fully tightening the securing bolts.

Refit 4. Reverse removal procedure. Using new plastic retainers.

34

REPAIR

CHASSIS AND BODY

AIR INTAKE PLENUM COWL Service repair no - 76.11.08 Remove 1. Remove the windscreen wiper arms. 2. Remove the securing nuts and the steel and rubber washers from the wiper spindles. 3. Open the vehicle bonnet [hood]. 4. Remove the rubber seal from the cowl flange. 5. Release the screen washer tubes from the washer jets on the cowl. 6. Remove the centre bolt securing the cowl centre section. 7. Remove the retainers securing the centre section to the outer section. 8. Detach the centre section from the bulkhead. 9. Remove the nuts and bolts and detach the outer sections of the cowl. Refit 10. Reverse removal procedure.

REPAIR

35

76

CHASSIS AND BODY

SUNROOF ELECTRIC/MANUAL Introduction Twin sunroofs are fitted to the vehicle, the open/close sequence for both electric and manual versions sharing the same operation:A Closed position, B Tilt position, C Fully open position. When fully open the sunroof slides back in a tilt position over the vehicle roof. The electric front and rear sunroofs, operated by roof mounted switches are controlled by an electronic control unit. A roof mounted isolation switch is also fitted to cut off power to the rear sunroof. On manual sunroofs a pull down handle is used, incorporating a depress button that locks the handle after each sequence. Twin sun blinds are installed in the clamping frame of the sunroof and can be drawn forwards independently.

36

REPAIR

CHASSIS AND BODY

SUNROOF GLASS FRONT AND REAR Service repair no - 76.82.64 Remove 1. Open sunroof to tilt position. 2. Using a right angled screwdriver remove four retaining screws and detach sunroof glass from upper frame. Retain capnuts and washers. Refit 3. Locate sunroof glass in upper frame complete with capnuts and loosely fit retaining screws. 4. Close sunroof and move glass centrally in upper frame. 5. Open to tilt position and tighten retaining screws. CAUTION: Ensure washers under capnuts do not twist or spread out when tightening retaining screws.

Sunroof components

1. 2. 3. 4.

Glass panel Capnut and washer Screw Upper frame assembly

5. 6. 7. 8.

Clamping frame assembly Screw Edging trim Drain tube

REPAIR

37

76

CHASSIS AND BODY

SUNROOF ASSEMBLY - ELECTRICAL, FRONT AND REAR Service repair no - 76.82.59 Remove Refer to sunroof components illustration J5483 1. 2. 3. 4. 5. 6. 7. 8. Refit 9. Position upper frame assembly into roof aperture. 10. Locate clamping frame and reconnect drain tubes. 11. Loosely fit screws, centralise upper frame and clamping frame assemblies and then tighten screws. 12. Reverse removal procedure. Ensure sunroof is in normally closed position. Disconnect battery negative lead. Remove headlining. See headlining. Disconnect electric motor wiring plug. See sunroof electric motors. Remove screws and detach electric motor from clamping frame. Disconnect drain tubes from each side of clamping frame. Remove 13 fixings and remove clamping frame from upper frame. Remove upper frame assembly.

38

REPAIR

CHASSIS AND BODY

SUNROOF ELECTRIC MOTORS Service repair no - 76.82.84/85

FRONT MOTOR Remove 1. Disconnect battery negative lead. 2. Ensure sunroof is in normally closed position NOTE: If the electric motor has failed the sunroof can be closed manually using an allen key to turn motor spindle A. 3. Remove switch panel from stowage pocket panel 4. Remove interior lamp from stowage pocket panel 5. Remove alarm ultrasonic unit. 6. Unscrew ten fixings and remove stowage pocket from headlining. 7. Disconnect motor wiring multiplug. 8. Remove three screws and motor.

REAR MOTOR Remove 1. Disconnect battery negative lead. 2. Ensure sunroof is in normally closed position NOTE: If the electric motor has failed the sunroof can be closed manually using an allen key to turn motor spindle. 3. Remove headlining. See headlining. 4. Disconnect motor wiring multiplug. 5. Remove three screws and motor. Refit 6. Reverse removal procedure. CAUTION: Ensure the motor is aligned with fixing holes and the sunroof is in the normally closed position. DO NOT rotate the motor drive spindle in the rack - this may result in incorrect operation of the sunroof.

Refit 9. Reverse removal procedure. CAUTION: Ensure the motor is aligned with fixing holes and the sunroof is in the normally closed position. DO NOT rotate the motor drive spindle in the rack - this may result in incorrect operation of the sunroof.

REPAIR

39

76

CHASSIS AND BODY

SUNROOF ELECTRIC CONTROL UNIT Service repair no - 76.82.73 The control unit serves both front and rear sunroofs and is sited above the front switches behind headlining. Remove 1. Disconnect battery negative lead. 2. Ensure sunroof is in normally closed position. NOTE: If the electric motor has failed the sunroof can be closed manually using an allen key to turn motor spindle. 3. Remove switch panel from stowage pocket panel 4. Remove interior lamp from stowage pocket panel 5. Remove alarm ultrasonic unit. 6. Unscrew ten fixings and remove stowage pocket from headlining. 7. Disconnect electric plugs from control unit. 8. Remove two retaining screws and control unit.

Refit 9. Reverse removal procedure.

40

REPAIR

CHASSIS AND BODY

SUNROOF ASSEMBLY - MANUAL, FRONT AND REAR Service repair no - 76.83.01 Remove 1. Close sunroof. 2. Remove headlining. See headlining. 3. Remove screws and manual regulator from clamping frame. See sunroof regulator manual. 4. Disconnect drain tubes from each side of clamping frame. 5. Remove 13 screws and clamping frame from upper frame. 6. Remove upper frame assembly from roof aperture. Refit 7. Position upper frame assembly into roof aperture. 8. Locate clamping frame and reconnect drain tubes. 9. Loosely fit screws, centralise upper frame and clamping frame assemblies and then tighten screws. 10. Reverse removal procedure.

Sunroof components

1. 2. 3. 4.

Glass panel Capnut and washer Screw Upper frame assembly

5. 6. 7. 8.

Clamping frame assembly Screw Edging trim Drain tube

REPAIR

41

76

CHASSIS AND BODY

SUNROOF REGULATOR MANUAL Service repair no - 76.83.03/04

FRONT Remove 1. Ensure sunroof is in normally closed position. 2. Remove retaining screw and regulator handle. 3. Remove switch panel from stowage pocket panel 4. Remove interior lamp from stowage pocket panel 5. Remove alarm ultra sonic unit. 6. Unscrew ten fixings and remove stowage pocket from headlining. 7. Remove two retaining screws and regulator from clamping frame.

REAR Remove 1. 2. 3. 4. Ensure sunroof is in normally closed position. Remove retaining screw and regulator handle. Remove headlining. See headlining. Remove two retaining screws and regulator from clamping frame.

Refit 5. Reverse removal procedure. CAUTION: Ensure the regulator is aligned with fixing holes and the sunroof is in the normally closed position. DO NOT rotate the regulator spindle in the rack - this may result in incorrect operation of the sunroof.

Refit 8. Reverse removal procedure. CAUTION: Ensure the regulator is aligned with fixing holes and the sunroof is in the normally closed position. DO NOT rotate the regulator spindle in the rack - this may result in incorrect operation of the sunroof.

42

REPAIR

CHASSIS AND BODY

SUN BLIND ASSEMBLY Service repair no - 76.82.78 Remove 1. Open sunroof to the tilt position. 2. Remove the trim finisher from the sunroof surround. 3. Release the headlining locally to access under clamping frame of the sunroof. 4. Lever forward and upward the rear leg of 3 retaining clips to release sun blind roll assembly.

CENTRE CONSOLE Service repair no - 76.52.02 Remove 1. Disconnect battery earth lead.

Refit 5. Ensure front leg of retaining clips are located. 6. Push in rear leg of retaining clip. 7. Reverse removal procedure.

2. Release tranfer gear lever gaiter from console. 3. Remove transfer gear lever gaiter and knob assembly. 4. Release gear selector lever gaiter from centre console. 5. Remove gear selector lever gaiter and knob assembly. 6. Remove centre console rubber mat.

REPAIR

43

76

CHASSIS AND BODY

All models

7. Remove centre console switch pack cover. 8. Remove 4 screws securing switch pack to console. 9. Release switch pack from console and disconnect 7 multiplugs. NOTE: If the ’Cold Pack’ option is not fitted there will only be 5 switches in pack. 10. Remove switch pack. Models fitted with electric front seats

14. Release hand brake lever gaiter from centre console. 15. Remove clip and clevis pin securing cable to hand brake lever.

16. Remove 4 screws securing centre console to body. 17. Raise hand brake lever, pull centre console rearwards to gain access to cigar lighter multiplug and illumination bulb Lucar.

11. Release electric front seat switches from centre console. 12. Disconnect 2 multiplugs from each switch. 13. Remove switches.

18. Disconnect cigar lighter multiplug and illumination bulb Lucar. 19. Remove centre console assembly.

44

REPAIR

CHASSIS AND BODY

Refit 20. Position centre console assembly, ensuring harnesses and connectors are not trapped and are routed to their correct locations. 21. Connect cigar lighter multiplug and illumination bulb Lucar. 22. Align centre console to body fixings and fascia. 23. Fit and tighten screws securing centre console to body. 24. Lubricate hand brake lever to cable clevis pin. 25. Align hand brake cable to lever, fit clevis pin and secure with clip. 26. Secure hand brake lever gaiter to centre console. Models fitted with electric front seats 27. Position electric front seat switches,connect multiplugs and secure to centre console. All models 28. Position centre console switch pack and connect multiplugs to switches. 29. Align switch pack to centre console and secure with screws. 30. Fit centre console switch pack cover. 31. Fit centre console rubber mat. 32. Fit gear selector lever knob and secure gaiter. 33. Fit transfer gear lever knob and secure gaiter. 34. Reconnect battery earth lead.

DRINKS TRAY Service repair no - 76.46.41 Remove 1. Disconnect battery negative lead. 2. Remove ash tray. See ash tray - dash panel central louvre panel. 3. Remove switch pack. See switch pack - dash panel central louvre panel.

4. Remove 6 screws securing drinks tray to dash panel central louvre panel. 5. Remove drinks tray. Refit 6. Position drinks tray to dash panel central louvre panel and secure with screws. 7. Fit switch pack. See switch pack - dash panel central louvre panel. 8. Fit ash tray. See ash tray - dash panel central louvre panel. 9. Connect battery negative lead.

REPAIR

45

76

CHASSIS AND BODY

DASH PANEL CENTRAL LOUVRE PANEL Service repair no - 76.46.42 Remove 1. Disconnect battery negative lead. 2. Remove radio. See ELECTRICAL, Repair, radio.

3. Release tags securing radio cage to louvre panel and remove cage. 4. Remove clock. See ELECTRICAL, Repair, clock. 5. Release 4 coin tray securing tags.

7. Remove 3 heater control and blower switch knob. 8. Remove 2 screws securing heater graphic display panel and remove panel. 9. Remove 4 screws securing heater control unit to panel.

6. Remove coin tray.

10. Working through coin tray aperture, remove screw securing panel. 11. Working through clock aperture, remove screw securing panel. 12. Loosen 2 uppermost panel retaining screws. NOTE: On some models the panel is fitted with an LED. In this case, manoeuvre LED from panel and disconnect. 13. Remove panel retaining screw cover.

46

REPAIR

Remove centre console assembly. Repair. 19. See STEERING. Remove coin tray. Fit radio. 17. See SUPPLEMENTARY RESTRAINT SYSTEM. CAUTION: When refitting avoid trapping of electrical wiring. 21.and align to dash panel. 19. See ELECTRICAL. 7. 3. Remove louvre panel from dash panel. 16. feed harness connectors through their correct apertures. Remove instrument binnacle. clock. Remove steering wheel. Position louvre panel. Repair. 27. Repair. Remove passenger glove box. reference must be made to the Airbag Supplementary Restraint System section. See ELECTRICAL. 23. See SUPPLEMENTARY RESTRAINT SYSTEM. radio. 6. 20. REPAIR 47 . Set heater controls fully clockwise. driver’s airbag module. See centre console. Position heater control unit to panel and secure with screws. 2. See ELECTRICAL. CAUTION: When air bags are fitted. radio. 14. Fit clock. 24. Position coin tray and secure to tags. 11. Disconnect air bag multiplugs under dash panel. 15. Remove clock. Remove switch panel. Remove driver’s side access panel. 17.76. and position to panel. 25.23 Remove 1. Remove radio. 9. 8. 5. Repair. Move front seats to rearmost position. Fit heater graphic display panel and secure with screws. 18. See SUPPLEMENTARY RESTRAINT SYSTEM. feed electrical connectors and aerial through cage. 18. 10. Disconnect battery negative lead. Fit panel retaining screw cover. See ELECTRICAL. 15. Release clamp and lower steering column. Repair.46. Repair. 12. Connect battery negative lead. 4. Remove airbag from steering wheel. Repair. 13. Fit and tighten screws securing louvre panel. Remove passenger’s airbag from dash panel. 26. Remove column switch. Fit heater control and blower switch knobs. passenger’s airbag module. column switch assembly. steering wheel.CHASSIS AND BODY DASH PANEL ASSEMBLY Service repair no . Position radio cage. Remove 2 screws securing louvre panel. Bend back radio cage retaining tags. Undo screw securing mounting bracket and position passenger’s side relay assembly aside. Refit 16. Remove exterior mirrors switch panel. 22. instrument binnacle. 14. Repair.

Driver’s side: Disconnect 6 multiplugs connecting dash harness to main harness. Disconnect 3 multiplugs connecting dash harness to fusebox. disconnect heater control cables from levers and outer cable from retaining clips. 24. Note position of levers. Remove 4 bolts securing dash panel to centre lower mounting brackets. 23. 25. Remove 4 bolts securing dash panel to side lower mounting brackets. 28. With assistance: Manoeuvre dash panel partially rearward. 26. 27. 22. 48 REPAIR . With assistance: Lift dash panel rearward to clear fixings and remove from vehicle. 21. Undo 4 screws and remove 2 driver’s knee bolster pads from below steering column.76 CHASSIS AND BODY 20. Remove 4 nuts securing instrument mounting bracket to dash panel.

the exposed surfaces oxidises in approximately 90 minutes. • Body primer . With assistance: Position dash panel and connect dash harness multiplugs to fusebox and main harness. See Electrical Trouble Shooting Manual. to effect a satisfactory joint. The refit procedure must be completed within this time span to prevent the sealant oxidising. • Betaseal Adhesive sealant. The following materials are included in the windscreen repair kit: • Glass cleaning solvent . NOTE: The adhesive sealant cures in 6 to 8 hours CAUTION: Once existing sealant is cut. REPAIR 49 . Ensure dash panel upper bracket studs are located before the 4 lower brackets. Reverse removal procedure. Newly painted areas must then be left for 8 hours or more before applying adhesive sealant. 29.CHASSIS AND BODY Refit CAUTION: When refitting avoid trapping electrical wiring. Reverse removal procedure. 31. CAUTION: If the windscreen aperture body flange shows signs of corrosion it must be treated with anti corrosion primer and repainted. 30. Disconnect glovebox switch Lucars to ease fitting of relay bracket.Windscreen Glass Replacement.01 Information The following equipment is required: • Cutting wire and handles • Windscreen repair kit (see Technical Bulletin).81.’Betaprime’(green cap). Reverse removal procedure.’Betawipe’ Glass activator (yellow cap). • Glass primer . • Suction cup lifters.76. • Cotton buds. 32.’Betaprime’ paint/plastic primer (red cap). WINDSCREEN GLASS Service repair no . • Sealant applicator gun.

See WIPERS AND WASHERS. 8. Force cutting wire through sealer from inside and 100mm (3 7/8 in) from a top corner. Fit protective cover over dash panel and apply masking tape to protect ’A’ posts. Remove windscreen wiper arms. 9. Remove header finisher. Continue in 100mm (3 7/8 in) steps around the glass. Remove handle ’B’. 15. Allow 200mm (7 7/8 in) of wire between handles. 13. Repair. pull to disengage finisher flange from glass and remove. 6. use a sawing action at the corners. 11. Attach handle ’B’. 3. Use a needle if necessary to make a pilot hole. positions indicated on the obscuration band (See item 18). great care must be taken to cut up to the 2 supports. Remove 1. 50 REPAIR . From the outside: Carefully cut sealer from flange using a straight pull away from the glass. 14. wiper arms windscreen. Apply masking tape to protect paint finish around glass. 12. withdraw the cutting wire and insert it through the sealer between the supports. Ease one end of bottom finisher away from glass. With an assistant on the inside: Wedge the tube of the handle ’A’ between glass and body flange 100mm (3 7/8 in) ahead of hole in sealer. 4. 10. To access release decker panel. Bend end of wire to handle and tape over end. Prepare cutting wire in handle ’A’. 7. Remove RH ’A’ post finisher. CAUTION: Along the bottom edge. Remove rear view mirror and stickers from glass.76 CHASSIS AND BODY NOTE: If heated front screen: 2 electrical multiplug connectors are located under the decker [cowl] panel. tape over end of wire. pull to disengage finisher flange and remove. 5. Refit handle ’B’. 2. Remove ’A’ post finishers. Lift lip of LH ’A’ post finisher and release sealing strip along its length.

20. do not stand on edge. DO NOT cut down to glass surface. Carefully align each side finisher on edge of glass. Check condition of supports. CAUTION: Lay glass on felt covered supports. 19. 22. Using a cotton bud. If heated front screen: Cut through the 2 wires each side of the supports. apply glass cleaning solvent (yellow cap) to inside face of glass. Tape cut wires and panels to prevent damage to bodywork when screen is removed. Align header finisher on top edge of glass. 23. Cut back old sealant around glass to obtain a smooth surface 2mm (1/10 in) thick. push flange fully onto glass and use a wooden block and mallet to ensure fit. NOTE: The supports were fitted to early vehicles and now replaced with nylon sheaths. Any chipping of glass edge may develop into cracks. Refit 18. Immediately wipe off solvent with a clean cloth. 21. DO NOT cut down to flange. 20mm (13/16 in) strip around inside of finishers and 30mm (1 1/8 in) wide along bottom edge. Cut through sealer between the supports. push flange fully onto glass and use a wooden block and mallet to ensure fit.CHASSIS AND BODY 16. Locating studs must be at right angle to flange. 17. Use a vacuum cleaner to remove glass particles from inside the vehicle. CAUTION: Do not touch cleaned or primed surfaces with fingers. REPAIR 51 . Carefully cut back old sealant around body flange to obtain a smooth surface 2mm (1/10in) thick. If refitting original glass: It must be free from chips or cracks. Attach suction cups to glass and lift glass from body flange. WARNING: If glass has splintered: Protect eyes and operate demister blower at maximum speed to remove any glass from ducts. cut sealer free around supports as necessary. renew if necessary.

28. 26. This must be touch dry before applying adhesive. remove lid and shake out crystals and install cartridge in applicator gun. Remove protective covering (RED) from side finisher sealing strip. apply Glass Primer (green cap) to inside face of glass. Remove protective coverings and tape. Ensure body flanges and surfaces covered by the finishers are clean. 25. 52 REPAIR . Using a cotton bud. Vertical edge of sealer to abut finishers and to be 8mm (5/16 in) from bottom edge of glass. 30. Pierce top and pre-cut nozzle to sealer cartridge. 29. Apply a continuous bead of adhesive sealant around the glass as shown. 20mm (13/16 in) strip around inside of finishers and 30mm (1 1/8 in) wide along bottom edge.76 CHASSIS AND BODY 27. Shake the primer container for at least 30 seconds. 24.

as shown. 4. Operate controls to adjust seat fully backwards and remove 2 bolts securing seat slides. Operate controls to adjust seat fully forwards.CHASSIS AND BODY FRONT SEAT . 33. 32. 1. 3. Remove 3 studs securing seat side valance. Align cut outs with the supports and push finisher fully onto the glass. 2. carefully align the indicators on the obscuration band with the supports. REPAIR 53 . check alignment and firmly press to seat glass in the aperture. 34.01 Remove 31.ELECTRIC Service repair no . Remove side valance. Use a wooden block to ensure fit. With assistance: Attach suction cups to glass and lift into position.77.76. Lower screen onto body flange. NOTE: The finisher on later vehicles will not have cutouts. Refit wiper arms. or supports fitted. Refit ’A’ post finishers and interior mirror.

Raise adjusting bar and slide seat fully forwards. Tighten Torx screws securing seat to 29 Nm (21 lbf ft) .76 CHASSIS AND BODY FRONT SEAT .MANUAL . 3. Refit Remove Torx screw securing seat belt. Tighten bolts securing seat slides to 22 Nm (16 lbf ft) . Remove 2 Torx screws securing seat. 2. 9. 11.76. 7. 54 REPAIR . 6. 10.70. Raise adjusting bar and slide seat fully backwards. 1. Remove 2 Torx screws securing seat. 6. Remove Torx screw securing seat belt. Remove seat.01 Remove 5. Remove 2 bolts securing seat slides. 4. Reverse removal procedure. Disconnect multiplug. 8.5 DOOR (96 MODELS) Service repair no . 12. Remove seat. 5. Tighten Torx screw securing seat belt to 32 Nm (24 lbf ft) .

76. Tighten bolts securing seat slides to 22 Nm (16 lbf ft) . Tighten Torx screws securing seat to 29 Nm (21 lbf ft) . Remove headlining front pocket. Release left hand sun visor from clip and move aside. 4. CAUTION: Do not use tools to assist removal. 8. 3.Auto dimming Remove NOTE: To remove manual mirror. Locate mirror multiplug. parallel to windscreen. Remove tape securing harness (behind headlining). 7.10. Remove 2 screws securing sunroof ECU and move ECU aside. REPAIR 55 . 9. follow step 8 only. Tighten Torx screw securing seat belt to 32 Nm (24 lbf ft) .51 .54 . 6. Mirror base should be moved in direction of arrow. INTERIOR MIRROR (96 MODELS) Service repair no .76. 8.10. Reverse removal procedure. Release mirror from screen by applying sharp downward pressure to the base. Release harness from behind headlining and remove mirror. 5.Manual Service repair no . 1. 2. 9.CHASSIS AND BODY Refit 7. Remove clip securing screw and remove clip. 10. remove clip and disconnect multiplug. Release sun visor clip screw cover.

Ensure harness is correctly routed in mirror base so it does not become trapped. Reverse removal procedure. 56 REPAIR .76 Refit CHASSIS AND BODY 10.

Remove 3 screws securing sun visor to body. REPAIR 57 . 3. Remove stand and lower vehicle. 4. Remove front road wheel. Refit Release sun visor from headlining retaining clip. 3. Fit front road wheel and tighten nuts to 126 Nm (93 lbf ft) . Position sun visor and connect muliplug. Remove 4 wheel arch liner retainers. 2. Release sun visor and disconnect multiplug. 1. Position sun visor to headlining and secure with screws.76. 6. Secure sun visor to headlining clip.CHASSIS AND BODY SUN VISOR Service repair no . 4.76.10. 7. 6. Refit 5. 7.10. 2. Remove sun visor. Raise front of vehicle and support on safety stand.47 Remove WHEEL ARCH LINER . Remove wheel arch liner.48 Remove 1. 5.FRONT Service repair no . Fit wheel arch liner and secure with retainers.

LH . 58 REPAIR .LH Service repair no . Remove load space cover. 3.REAR .10. Refit 4. Remove mud flap. 4.lh . 6. See rear compartment lower trim panel . See ’E’ post trim casing .WITH REAR AIR CONDITIONING FITTED Service repair no . Remove rear fold down seat. See rear compartment lower trim panel . 2. Position mud flap to body. Remove rear compartment lower trim panel.with rear air conditioning fitted. Remove mounting bracket. 1. Remove 2 screws securing load space cover mounting bracket. Fit rear compartment lower trim panel.lh with rear air conditioning fitted.lh . Release load space cover end sleeve from mounting bracket.lh . 8.with rear air conditioning fitted. Remove ’E’ post trim casing.76 CHASSIS AND BODY MUD FLAP .03/20 Remove Remove 1.with rear air conditioning fitted.76. 2. Press rear seat squab release button and fold squab forward. 5.85 REAR COMPARTMENT LOWER TRIM PANEL . fit bolts and tighten nuts to 10 Nm (7 lbf ft) .13. 3. 7. Remove 5 nuts and bolts securing mud flap to body and bumper valance. 5. Remove fold down rear seat belts. See rear fold down seats. See rear fold down seat belts .76.

15. 17.lh . Fit rear speaker. Refit 5. 16. Refit 11.with rear air conditioning fitted. See rear fold down seat belts . See ’E’ post trim casing . Repair. Position load space cover to mounting brackets and secure.76. See rear fold down seats. 10. 18.lh . Fit fold down rear seat belts.13. Remove ’E’ post finisher. 14.with rear air conditioning fitted. Fit rear fold down seat. rear speaker. Position ’E’ post finisher clips to lower trim panel. rear speaker. Fold rear seat squab back and secure to latch. Remove 5 trim studs securing trim panel. Fit and align trim panel. Remove trim panel. 3. 4. Fit ’E’ post trim casing. See ELECTRICAL. 7. Secure ’E’ post finisher studs to alpine light trim. 12. REPAIR 59 .CHASSIS AND BODY ’E’ POST TRIM CASING . Position load space cover mounting bracket and secure with screws. Remove rear speaker.13/03 Remove 1. Release 2 ’E’ post finisher retaining clips from lower trim panel. 13. Release 2 ’E’ post finisher retaining studs from alpine light trim. Repair. 2. 6. See ELECTRICAL. 9. Fit trim panel retaining studs.RH Service repair no .

13. See ELECTRICAL. Fit and align trim casing and secure with studs. Refit 7. Repair. 6. ALPINE LIGHT TRIM CASING . fit bolt and tighten to 20 Nm (15 lbf ft) . 2. Remove 2 trim studs securing trim casing.76. Fit ’E’ post trim casing. Fit rear speaker. Fit cover to seat belt anchorage bolt.13/20 Remove 1. See ELECTRICAL. 2. Repair. 5.LH . 9. 8. 10.WITH REAR AIR CONDITIONING FITTED Service repair no . 7. rear speaker. Release 2 trim casing retaining screw covers. Remove rear speaker. 4. rear speaker. 11.with rear air conditioning fitted. 3. Position seat belt anchorage. Remove ’E’ post trim casing. Remove trim casing.with rear air conditioning fitted. Remove bolt securing rear seat belt anchorage. See ’E’ post trim casing .LH . Release trim casing from 2 retaining studs. Refit 5. 60 REPAIR .WITH REAR AIR CONDITIONING FITTED Service repair no . 6.lh .13. Fit 2 trim studs securing trim casing.20/20 Remove 1. Remove rear seat belt anchorage retaining bolt cover. 4. 3. Remove 2 screws securing trim casing. Remove trim casing. See ’E’ post trim casing .76 CHASSIS AND BODY ’E’ POST TRIM CASING . Fit and tighten screws securing trim casing and fit covers.lh .76. Fit and align trim casing.

with rear air conditioning fitted. Remove alpine light trim casing. 10.lh . 6. Secure trim panel retaining screw covers. Remove screw securing rear header duct to trim panel. 17. Fit rear header duct to new trim panel and secure with screw. See alpine light trim casing . REPAIR 61 . 14.72/20 Remove 1. Refit 13. Position trim panel and connect rear header duct to alpine light duct. Secure rear edge of trim panel to body. Dismantle 8. 18. Fit vents to trim panel. Release 2 trim panel retaining screw covers.76. Fit alpine light trim casing.WITH REAR AIR CONDITIONING FITTED Service repair no . 9. Release rear header duct from alpine light duct.with rear air conditioning fitted. 16. Rebuild 11. 3.lh . Release rear edge of trim panel from body. See alpine light trim casing . Fit and tighten screws securing trim panel. Remove 2 vents from trim panel. Fit and tighten screw securing rear header duct to alpine light duct.13. 2. 4.CHASSIS AND BODY REAR DOOR UPPER TRIM PANEL . Remove rear header duct. Remove 2 trim panel retaining screws. 7. 5. Remove trim panel assembly. 15. Remove screw securing rear header duct to alpine light duct. 12.

Position trim casing rear edge beneath sixth light seal flange. 3. Fit squab release button to control rod.WITH REAR AIR CONDITIONING FITTED .with rear air conditioning fitted. See rear compartment lower trim panel . 8. 4. Release trim casing from 2 retaining studs. 2. Remove the squab release button from control rod. 62 REPAIR . Refit 7. Fit trim casing under alpine light trim. Remove the trim casing retaining stud. Release rear seat belt from guide and remove guide.lh . Remove rear compartment lower trim panel.LH . Remove trim casing. 12. Fit trim casing retaining stud.13.76. 9.lh with rear air conditioning fitted. Fit seat belt to guide. 5.5 DOOR Service repair no . align squab release control rod and position guide to trim casing.73/20 Remove 1.76 CHASSIS AND BODY ’D’ POST TRIM CASING . 6. Fit rear compartment lower trim panel. align and secure retaining studs. 10. 11. See rear compartment lower trim panel .

Remove 4 screws securing grab handle to body. Position grab handle and washers.CHASSIS AND BODY SWITCH PACK . 3. 5. 4. Refit 2. 7.38 GRAB HANDLE Service repair no . 3. Remove switch pack. Position switch pack. REPAIR 63 . Fit and tighten screws securing grab handle to body. 2.58. Disconnect 3 multiplugs from switch pack. Secure grab handle retaining screw covers. Collect 2 washers. Release switch pack from louvre panel.DASH PANEL CENTRAL LOUVRE PANEL Service repair no . Secure switch pack to louvre panel. Connect multiplugs to switch pack.30 Remove Remove 1. Refit 4. Release 2 grab handle retaining screw covers.76.76. Remove grab handle. 1.46. 6. 6. 5.

76. 2.35/20 Remove 1. 4. Remove LH and RH clips. 8.5 DOOR Service repair no . Remove both sun visors.with rear air conditioning fitted. 6.58. Remove grab handle.with rear air conditioning fitted. 7.14/20 Remove 1. Remove LH and RH sun visor clip retaining screws.76 CHASSIS AND BODY GRAB HANDLE .front . 3. fit bolts and tighten to 10 Nm (7 lbf ft) . Release foam strip from around grab handle retaining bolts. Refit 5.lh . Release LH and RH sun visor clip retaining screw covers. See alpine light trim casing.TAIL DOOR . 3. See ’E’ post trim casing .lh . Remove LH alpine light trim casing. See headlining stowage panel . 6. 64 REPAIR . 7. Remove RH alpine light trim casing. Remove 4 bolts securing grab handle to body. Secure foam strip to body. Fit ’E’ post trim casing.76. 4.WITH SUN ROOF AND REAR AIR CONDITIONING FITTED . See alpine light trim casing . Remove 4 grab handles. Remove front headlining stowage panel.64. See grab handle.lh .WITH REAR AIR CONDITIONING FITTED Service repair no . Remove ’E’ post trim casing. See sun visor.with sun roof fitted. Position grab handle.with rear air conditioning fitted. HEADLINING . See ’E’ post trim casing . 5. 2.

REPAIR 65 . 11. Release rear sun roof switch from headlining panel. 14. Remove 3 vents from headlining. Remove front sun roof aperture seal. Remove rear sun roof aperture seal. 10. 13. Working through sun roof switch housing. remove screw securing headlining panel to body. Release rear passenger interior lamp assembly from headlining panel. disconnect multiplug and remove lamp.CHASSIS AND BODY 9. disconnect multiplug and remove switch. 12.

Position stowage nets and headlining panel. 25. 31.with sun roof fitted. 35. Release LH and RH. Fit grab handles. See sun visor. Secure LH and RH. See headlining stowage panel . 17.76 CHASSIS AND BODY Dismantle 18. fit headlining and position to LH and RH. ’A’ post trim finisher retaining clips. Fit LH and RH sun visor retaining clips to body. Rebuild 21. Fit RH alpine light trim casing. 20. 22.front . 29. Refit 15. See grab handle. 28. With assistance. Fit front sun roof aperture seal.lh . 19. Remove headlining assembly. Remove 22 nuts securing headlining stowage nets and rear headlining panel. ’A’. ’B’ and ’D’ post finishers. Position vents to headlining. Fit and tighten screws securing sun visor retaining clips and secure screw covers. fit mounting plates to studs and secure with nuts. 33. connect multiplug and secure to headlining panel. See alpine light trim casing. 26. ’A’ post trim finishers from uppermost retaining clips. 23. ’B’ and ’D’ post finishers. 24. Fit rear sun roof aperture seal. 34. 16. 36. Fit LH alpine light trim casing. Position rear sun roof switch. connect multiplug and secure to headlining panel. Collect 7 mounting plates. Fit sun visors. 32. 27. ’A’. Position rear passenger interior lamp. Fit front headlining stowage panel. release headlining from LH and RH.with rear air conditioning fitted. Remove stowage nets and headlining panel. Fit and tighten screw securing rear headlining panel to body. See alpine light trim casing . attach clips to vents and secure to headlining. With assistance. 30. 66 REPAIR .

FRONT .76.26 Remove 1. Press release catch and remove ash tray.76. 2.DASH PANEL CENTRAL LOUVRE PANEL Service repair no .WITH SUN ROOF FITTED Service repair no . Remove stowage panel assembly.27 Remove 2. HEADLINING STOWAGE PANEL . REPAIR 67 .67.67. Release panel and disconnect Lucar and 4 multiplugs. Fit ash tray. Refit 3. 1. Remove 10 screws securing stowage panel to body.CHASSIS AND BODY ASH TRAY . 3. Open ash tray.

6. Remove seat belt strap and buckle retaining bolt covers.28/20 Remove 1. Fit alarm volumetric sensor. Refit 5.LH WITH REAR AIR CONDITIONING FITTED Service repair no . Rebuild 10. 5. Refit 15. 16.73. Fit electric sun roof manual opening plug to panel. 6. 7. 68 REPAIR . remove the seat belt strap and buckle from their stowed positions. 4. Remove electric sun roof switch pack. Fit electric sun roof switch pack to panel. 13. 9. Locate the seat in the down position. Fit interior lamp lens. Secure seat belt strap and buckle to their stowed positions and position seat in the up position. position to fixings and tighten to 32 Nm (24 lbf ft) . 14. Remove bolts securing strap and buckle. Remove alarm volumetric sensor/blanking plate. 7. Remove electric sun roof manual opening plug. 4. Align panel to headlining and secure with screws.76. 11. 2. 3. Position stowage panel assembly and connect Lucar and multiplugs. 8. Remove 2 nuts securing lamp to stowage panel. Remove interior lamp lens.76 Dismantle CHASSIS AND BODY REAR FOLD DOWN SEAT BELTS . Remove seat belts and collect spacers. Remove lamp. Fit spacers to seat belt retaining bolts. 12. Fit seat belt retaining bolt covers. Fit interior lamp to panel and secure with nuts.

10 Remove 1.73.5 DOOR (96 MODELS) Service repair no . Detach the door seals from the ’B’ post sufficiently to allow removal of the lower trim panel from the post. Remove the Torx bolt securing the lower mounting to the seat. Remove the side valance. REPAIR 69 . 3. 2. Electric seats only: Release fixings securing the seat side valance.CHASSIS AND BODY FRONT SEAT BELTS . 7. Release the seat belt from the split section at the top of the trim panel and withdraw the panel. 6. 5.76. Move the seat to gain access to the seat belt mountings. Remove the cover and securing bolt to release the upper mounting and spacer from the ’B’ post adjustable mounting. 4.

8.76 CHASSIS AND BODY 9. Refit 11. Remove the securing bolt and detach the inertia reel from the bottom of the ’B’ post. Release Torx bolt to allow removal of the seat belt stalk assembly. tighten the seat belt fixings to 32 Nm (24 lbf ft) . Finally. Release the seat belt sensor connector (if fitted). Re-connect the seat belt sensor connector (if fitted). Reverse removal procedure. 12. 10. 70 REPAIR . NOTE: Ensure the seat belt is not twisted. 13.

DESCRIPTION AND OPERATION 1 . 2. 8. which when fitted provides fully integrated climate control for the vehicle interior. 10. 11. Fresh/recirculation air flap servo Blower motor relay Multiplug connector to main harness Multiplug connector. The heating and ventilation unit controls the air distribution and heating to the vehicle interior. while the air conditioning module (when fitted) provides refrigerated and dehumidified air. Fresh air inlet Recirculation air inlet Air outlets screen de-mist Air outlet face level vents Air outlets front footwells Air outlets to rear footwells 7. 5. 4. 6. blower to heater unit Resistor unit . 3.HEATING AND VENTILATION HEATING AND VENTILATION UNIT The heating and ventilation and blower units are standard on all models. The blower unit controls the volume of air supplied.blower speed. 1. Air conditioning system is an optional module. 9.

Fresh or recirculated air from blower unit Evaporator matrix .demist vents Control flap .air direction Control flap . 12. 9. 8. 5. 10. controls The Heating and Ventilation Unit is centrally located and concealed by the dash assembly. 2. 3. When air conditioning is fitted.80 HEATING AND VENTILATION Through-flow ventilation Through-flow ventilation is achieved by means of one-way air extraction vents incorporated in both rear quarter body panels. an evaporator is mounted in the heater unit forward of the heater matrix. Air outlets screen de-mist Control flap . Heating and ventilation unit. Controls set for maximum heat to footwells and face level vents Heating and ventilation flaps and air flow key 1. A single switch controls the air conditioning unit when fitted. 11.face level vents Control flap . The vents open and close automatically dependent upon the heating and ventilation unit control settings and the volume of air entering the vehicle. 4. The dash mounted central controls are used to operate both systems.air temperature Control flap .air direction 2 DESCRIPTION AND OPERATION . 6.air conditioning (when fitted) Heater matrix Air outlet front footwells Air outlet to rear footwells Air outlet face level vents 7.

DESCRIPTION AND OPERATION 3 . which is connected to the engine cooling system. Face level vent flap Control at face level. only fresh or re-circulated air is available from the face level vents. and a 4 speed fan for air distribution. Control at demist and foot level. Control at face and foot level. All other vents closed. an electrical servo operates and fully closes the fresh air intake flap. the coolant valve is turned off.HEATING AND VENTILATION Controls set for unheated air to footwells and face level vents Heater and ventilation operation The heating and ventilation system contains a heater matrix. flap fully open. flaps half open. Unless an air conditioning unit is fitted. Engine coolant is circulated through the heater matrix continuously. Demist vent flap Control at demist. the electrical servo returns and fully opens the fresh air intake flap. Heated air Temperature output is controlled by the temperature controls which move the air direction and temperature flaps independently to increase or decrease the volume of air flow through the heater matrix. flap fully open. Recirculated air When the recirculation switch is pressed. Fresh air When the recirculation switch is returned to the OFF position. except when the temperature controls are set to COLD. flaps half open. All other vents closed. V8 Engine: When both controls are in the cold position.

Control at COLD.80 HEATING AND VENTILATION Air direction flap Flap moves across mixing chamber to direct the air flow away from the heater matrix. 2 micro-switches are closed and operate a vacuum valve which closes the coolant valve. flaps fully closed. flaps fully open. As control is moved towards COLD the flaps progressively open directing air flow away from the heater matrix. Air temperature flap Control at HOT. 4 DESCRIPTION AND OPERATION . the mechanical operation of the heater controls remains unaltered. All air flow passes through heater matrix. Air conditioning When an air conditioning unit is fitted. V8 Engine: When both controls are at COLD. However the air conditioning evaporator is positioned in front of the mixing chamber through which all air flow passes.

Engine running: Check coolant valve opens as a temperature control is moved from COLD. Heater emits warm air. See COOLING SYSTEM. 1. Engine running: Check coolant valve closes when both temperature controls are moved to COLD. Check heater matrix for blockage or restriction. 2. Engine Runs Cold 3.HEATING AND VENTILATION HEATER OUTPUT Symptom:Heater emits cold air. Fault diagnosis. Check heater pipes and hoses for blockage or restriction. 4. flush system. FAULT DIAGNOSIS 1 . Check for engine running cold. 5.

6.42.22 . Pull 3 knobs from rotary controls. Remove 2 retaining screws and remove graphics panel. Release fascia centre louvre vent panel from its fitted position to gain access to rear of panel. Repair. 4. Disconnect multiplug and remove blower switch. Reverse removal procedure. 5. Pull 3 knobs from rotary controls. 9.86. Remove graphics plate.73 . Pull knob from blower switch. 3. 4. REPAIR 1 . 6.10. 3. 2. See CHASSIS AND BODY. 1.80. Remove switch panel. Remove 1.10.80. 7. 5. Remove 4 screws retaining switch. Remove capless bulb.HEATING AND VENTILATION HEATER BLOWER SWITCH AND ILLUMINATION BULB Service repair no . Remove 4 screws retaining switch. Dash Panel Central Louvre Panel Blower switch 8. Pull knob from blower switch. Pull blower switch from rear of panel. Use plastic tube to assist removal. 7.Bulb Remove HEATER CONTROL UNIT Service repair no . 2.48. Remove switch panel. Remove 2 screws retaining graphics panel.Switch Service repair no . Disconnect battery negative lead. Refit 10.

14.10. Remove heater control unit. Check the satisfactory function of the controls before fitting louvre vent panel. 13. Unclip 3 heater control cables from control unit.26 . 2 REPAIR .80 HEATING AND VENTILATION 8. Pull out light bulb disconnect terminals and remove fan speed light strip.Air flow Service repair no .Temperature control LH Remove 1. 9. Disconnect 4 multiplugs and position harness aside.Temperature control RH Service repair no . See CHASSIS AND BODY. 10. Reverse removal procedure. Open glove box. Repair.10. 12. 11.80.06 . manoeuvre side springs through cut-outs and lower lid. Fan speed switch: remove fan speed switch slide and push out fan speed switch. Dash Panel Central Louvre Panel 2. CONTROL CABLES Service repair no . Refit 15.80.10.80. Microswitch: Unclip 3 micro switches. Cut cable tie and release wiring harness from control unit.25 . NOTE: Do not carry out further dismantling if component is removed for access only. Release fascia centre louvre vent panel from its fitted position to gain access to rear of panel.

6. RESISTOR UNIT Service repair no . Reverse removal procedure. manoeuvre side springs through cut-outs and lower lid.80.HEATING AND VENTILATION Air direction 3. LH control fully anti-clockwise 8. Refit 4. Remove 2 screws securing resistor unit to trunking.20. REPAIR 3 . Temperature 7. Release cable from stud on flap lever. Refit 11. 5. Set control fully clockwise Release outer cable from 2 clips on unit.17 Remove 1. 10. Check the satisfactory function of the controls before fitting louvre vent panel. Remove control cable from control lever. Remove control cable from control lever. Reverse removal procedure. 3. 2. Release cable from stud on flap lever. 9. Set RH control fully clockwise. Release outer cable from 2 clips on unit. Open glove box. Disconnect multiplug and remove resistor unit. 4.

4. Disconnect 2 vacuum pipes and remove vacuum switch.16 Remove VACUUM SWITCH .10. Refit 5. NOTE: A quantity of coolant will be released. 5. Refit 7. Slacken 4 clips securing hoses to water valve. Release emission pipe from retaining clip.36 Remove 1.10. 8. Top-up engine coolant 1. Disconnect heater outlet hose from valve. 2. Reverse removal procedure. Remove bolt securing switch to bulkhead. Lightly lubricate water valve nozzles with petroleum jelly. 2. 3.WATER VALVE Service repair no . 4 REPAIR . 6. Disconnect multiplug from switch.80 HEATING AND VENTILATION WATER VALVE Service repair no . Reverse removal procedure.80. Disconnect vacuum pipe from water valve. Disconnect heater inlet hose from valve.80. Use a thin blade to break seal between hoses and nozzles 4. Reverse removal procedure. Lever valve from coolant pipe hoses. 3.

HEATING AND VENTILATION RECIRCULATION SWITCH Service repair no . From the rear. manoeuvre side springs through cut-outs and lower lid. 4. 1.10. Repair.27 Remove RECIRCULATION FLAP SOLENOID Service repair no . Position cruise control ECU aside. Release solenoid from lever. Refit 4.10.43 Remove 1. Reverse removal procedure. Disconnect multiplug from switch 3.80. Open glove box. 5. Refit 7. See CHASSIS AND BODY. 3. REPAIR 5 . 6. push switch out of panel. Disconnect multiplug and remove solenoid. Dash Panel Central Louvre Panel 2. Reverse removal procedure. Remove 2 locknuts securing cruise control ECU to bracket. 2.80. Remove 2 screws securing recirculation solenoid to casing. Release fascia centre louvre vent panel from its fitted position to gain access to rear of panel.

Ensure seal between blower and heater unit is tight.33.54.25. 2. See CHASSIS AND BODY.HEATER AND AIR CONDITIONING Service repair no . Refit 6. 4.20.80 HEATING AND VENTILATION BLOWER MOTOR UNIT . Remove 1. 4.82. 5. 3.Heater and Air Conditioning 2. Repair.82. See Blower Motor Unit .17 Service repair no . Remove fascia panel assembly. Remove 2 nuts securing lower brackets to toeboard. Remove 1. Dash Panel Assembly BLOWER MOTOR Service repair no . Move seats to rear most position. Release wiring harness retaining clip. Remove blower motor assembly. 3.80. Reverse removal procedure.20.80. Remove blower motor unit. 6 REPAIR . Manoeuvre blower unit from heater unit and remove. Remove 3 screws securing casing.25.17 Service repair no . Disconnect battery negative lead.

7. Remove 2 screws and remove RH side footwell outlet. See AIR CONDITIONING.80. Remove 2 screws securing motor to casing. Heater and Cooler Unit 2. Remove evaporator.29 Remove 1. Reverse removal procedure. Reverse removal procedure. 8. REPAIR 7 . Refit 7. Slide heater matrix from casing. 9. Repair. 3. Remove heater unit. 6. 4. Remove blower motor. Remove heater pipe clips. Remove fan. Repair.HEATING AND VENTILATION HEATER MATRIX Service repair no .20. Refit Remove fan retaining clip. 6. Release 2 clips and remove 2 heater pipes from matrix. 5. Evaporator and Expansion Valve 5. See AIR CONDITIONING.

.................................................... 180 UNC / UNF 1/4 ....................................................................... TORQUE 1 ................................................................................... 136 Torque values above apply to all screws and bolts used unless otherwise specified............................................... Nm METRIC M5 .............. 39 7/16 ........................... 9 5/16 .............................................................................................................................................................. 78 1/2 ............................................................................................................... 45 M12 .................................................................................................................................................................. 105 M16 ... 6 M6 ........................................................................................................ 90 M14 .......................................................... 90 5/8 ......HEATING AND VENTILATION TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque.......... 25 M10 ............................................................................................................................ 24 3/8 .................................................................. SPECIFICATIONS........................................................................ 9 M8 .........................................................................................................................................

5. 4. 2.AIR CONDITIONING AIR CONDITIONING SYSTEM COMPONENTS 1. Compressor Condenser Receiver/drier Evaporator High pressure servicing connection 6. 3. 7. 9. Low pressure servicing connection Dual pressure switch Sight glass Rear evaporator/blower motor assembly DESCRIPTION AND OPERATION 1 . 8.

2. 5. 10.refrigerant Drying agent .82 AIR CONDITIONING SCHEMATIC LAYOUT OF THE AIR CONDITIONING SYSTEM 1. 12.receiver/drier Blower motor A1 A2 A3 F1 F2 F3 F4 F5 Ambient air flow through condenser Ambient air flow through fan and evaporator Cooled air flow to vehicle interior High pressure high temperature refrigerant vapour High pressure slightly subcooled refrigerant liquid High pressure slightly subcooled refrigerant liquid with moisture. 3. 4. 9. 6. vapour bubbles and foreign matter removed Low pressure low temperature mixed liquid and vapour Low pressure slightly super heated refrigerant vapour 2 DESCRIPTION AND OPERATION . 11. 7. Compressor Condenser Receiver/drier Thermostatic expansion valve Evaporator Capillary tube Dual pressure switch Cooling fans to maintain air flow Compressor high pressure relief valve Sight glass . 8.

an electro-mechanical clutch maintains the correct temperature and pressure by engaging or disengaging to support the system’s requirements. NOTE: Vehicles fitted with rear air conditioning have an additional evaporator/blower motor assembly located behind the LH rear compartment lower trim panel. fresh or recirculated air to the interior of the vehicle. 2. supplemented by 2 cooling fans (8) mounted in front of the condenser. the evaporator is linked into the vehicle ventilation system. The cooling effect is obtained by blowing air through the matrix of an evaporator unit and when required. These units are interconnected by hoses and pipes carrying Refrigerant R134a. the thermostat disengages the clutch and also isolates the cooling fans relays. mixing that air with heated air by means of the heater distribution and blend unit. The cooling fans are controlled by engine temperature when the air conditioning is not switched on. Condenser From the compressor. Compressor The compressor (1). blend unit and control system combine to achieve the cooled air condition. 5. A sealed system. The compressor also has an emergency high pressure relief valve (9) fitted. signals the relay unit to disengage the clutch. 4. Description and operation. A condenser mounted in front of the radiator. belt driven from the crankshaft pulley. It acts as a reservoir and moisture extractor (11). 3. in the high pressure line. DESCRIPTION AND OPERATION 3 . Mounted on the compressor. the clutch is re-engaged. Thermostatic expansion valve mounted above the evaporator. The clutch action is normally controlled by a thermostat located at the evaporator (5). 2. A sight glass (10). Heating and ventilation unit The air conditioning system comprises five major units: 1. When the temperature at the evaporator (5) rises to the control temperature. cools the refrigerant vapour sufficiently to form a high pressure slightly subcooled liquid (F2). located in the high pressure line. Should the temperature at the evaporator (5) fall low enough for ice to begin to form on the fins. Receiver/drier This liquid then passes to a receiver/drier (3) which fulfils two functions. pressurises and circulates the refrigerant through the system. For air conditioning air distribution system. to provide the conditions required inside the vehicle. A receiver/drier unit located in front of the condenser.AIR CONDITIONING AIR CONDITIONING SYSTEM OPERATION The air conditioning system provides the means of supplying cooled and dehumidified. An evaporator unit mounted in front of the heater matrix. provides a method of determining the state of the refrigerant without breaking into the system. Refrigeration cycle 1. 3. The compressor is of the swashplate type having fixed displacement. Should the system pressure become excessive or drop sufficiently to cause damage to the compressor (1) a dual pressure switch (7). See HEATING AND VENTILATION. Expansion valve From the receiver/drier (3) the moisture free high pressure liquid refrigerant (F3) passes through a thermostatic expansion valve (4). 4. An engine-mounted compressor. A severe pressure drop occurs across the valve and as the refrigerant enters the evaporator space at a temperature of approximately -5°C it boils and vaporises. hot high pressure vaporised refrigerant (F1) passes to the condenser (2). which is mounted in front of the engine coolant radiator. charged with Refrigerant R134a. Ram air(A1) passing through the condenser (2). The volume of conditioned air being supplied is controlled by a variable speed blower. together with a blower unit.

Together these controls. Dual pressure switch This switch. AIR CONDITIONING CONTROL SYSTEM The air conditioning control system comprises relays. in conjunction with the cooling fans. pressure switches. 29 lbf/in2 the compressor’s clutch is re-engaged. due to a too cold condition. The air mix flap on the blend unit controls the temperature of the air being supplied. From the evaporator. A thermostat is fitted in the airflow out of the evaporator to sense the temperature of the exterior fins. Inputs from outside the air conditioning system comprise temperature information from the engine cooling system. The atomised refrigerant then passes through the evaporator (5). the compressor’s electro-mechanical clutch is dis-engaged.82 AIR CONDITIONING 5. Should ice begin to form. the compressor’s electro-mechanical clutch is dis-engaged. Fan blown air (A2) passes through the matrix (A3) of the evaporator and is cooled by absorption due to the low temperature refrigerant passing through the evaporator. The evaporator is therefore cooled and as a result heat is extracted from the air flowing across the evaporator. and a control panel. attached to the outlet pipe of the evaporator (5) and connected to the thermostatic expansion valve (4). To prevent liquid passing through to the compressor. it will signal to disengage the electro-mechanical clutch on the compressor (1). air is supplied by ram effect or blower to the areas selected by the controls. 2. When required a fully cold condition can be selected by turning the temperature controls to cold. Selecting air conditioning provides the added facility of cooled air available to be mixed as before.0 bar. 375 lbf/in2 the compressor clutch is re-engaged. a capillary tube (6). a large amount of latent heat is absorbed. low pressure slightly superheated refrigerant (F5) passes to the compressor to complete the cycle. located in the high pressure line between the receiver drier and the expansion valve. blower and heater distribution and blend unit enable minimal input to maintain the required environment inside the vehicle. When pressure rises above 2. and hot air can be selected to give required interior environmental conditions by selection at the control panel. Evaporator As this change of state occurs. Refrigerant pressure rises above 32 bar. When the pressure drops below 26 bar. fresh. When air conditioning is not selected. Mixtures of cooled. No cooled air is available. 4 DESCRIPTION AND OPERATION . thermostat. 455 lbf/in2 (due to possible blockage). Refrigerant pressure drops below 2. The air flow is controlled by the ventilation fan which can be operated at anyone of four speeds. controls the amount that the valve opens and closes in relation to the temperature of the low pressure high temperature refrigerant vapour (F4) at the outlet. compressor clutch. 29 lbf/in2 (due to possible leakage). even with cooling fan operation.0 bar. which automatically closes the heated coolant access to the heater matrix. monitors refrigerant pressure and by means of the relay module controls the following system functions: 1.

The temperature of the heated air flow into the vehicle interior is controlled by the blend flaps. As the temperature control is moved away from cold. Heater distribution and blend unit control Blower unit air flow. It is then directed into the vehicle interior in accordance with the flap positions designated by the air distribution control. the fans will operate for 10 minutes to reduce condenser and underbonnet temperature. When the temperature control is in the cold position. DESCRIPTION AND OPERATION 5 . having passed through the evaporator passes into the heater blend unit to be heated. Fan timer unit The thermostatically controlled timer will continue to operate the cooling fans after the air conditioning or ignition is switched off. the coolant valve is opened allowing heated engine coolant to flow throught the heater matrix. When the system temperature is excessive.AIR CONDITIONING Condenser cooling fans The condenser cooling fans operate automatically whenever the air conditioning system is switched on. In the other position they will cover the inlet from the inside of the vehicle leaving open the outside air inlet when fresh air is required. leaving open an inlet from the inside of the vehicle clear. The fresh air/recirculation flaps can move between two positions. The distribution control moves the flaps which control the direction of the air flow into the interior of the vehicle. Blower control The blower can be operated at any one of four speeds by sliding the blower switch to the required position. if required. These flaps are controlled individually by the driver’s and passenger’s temperature controls. when recirculated air is required. Heater flaps control the amount of air flowing through the heater matrix. One position covers the outside air inlet. a micro switch actuates a vacuum control to close the coolant valve on the engine. When the blower is switched off the air conditioning system will not operate.

D. Tight. 6. 5. Clutch will not spin freely. 9. 9. Defective resistors 1. Loose wire connection including ground. tighten all connections. Replace expansion valve if necessary. 5. 2.AIR CONDITIONING AIR CONDITIONING FAULTS FAULT CAUSE 1. Foreign matter build-up on blades. Worn motor brushes. Repair or replace as necessary. Clean blades with a suitable non-inflammable cleaner. Slipping clutch. Replace motor. 3. Shaft binding-blade misaligned. 1. 4. 2. Check and replace as necessary. 3. Compressor not mounted securely. CONDENSER VIBRATION 1. Check alignment. Low voltage to clutch. 10. 2. Replace thermostat or pressure switch. 4. Incorrect alignment. 7. Remove clutch and replace clutch pulley assembly. 1. repair as necessary. 5. Excessive wear of motor bearings. Replace coil. Bearing seized (clutch will not disengage). adjust as necessary. 5. Check and rectify. BLOWER MOTOR INOPERATIVE OR SLOW RUNNING B. Defective thermostat control or pressure switch. 8. Open or defective fuse or relay. 7. COMPRESSOR CLUTCH INOPERATIVE C. REMEDY 1. 6. Replace receiver/drier if necessary. Icing. Check alignment. Refer to B5 above. 4. Check compressor seals for leaks. 9. Check mountings. Check voltage. 9. Check connections and voltage. 8. Check voltage. 6. Overloaded or locked compressor. Check system wires. worn. Repair or replace compressor. Replace motor. Check and replace as necessary. 3. Open or defective fuse or relay. 2. 6. 8. Adjust to proper tension. Open rotor windings. 10. 7. 3. 3. 4. Shorted or open field coil. 6. Bearing in clutch-pulley assembly not pressed in. 5. Switch open or defective. Incorrect voltage. Refrigeration circuit problem causing heavy load and excessive drive torque. Then check air gap. 3. Replace motor. Rectify or replace. 3. Oil on clutch face. Refer to C5 above. Loose belt. 1. 5. 2. A. 2. Replace switch. 6. 4. 3. Replace clutch pulley assembly. 2. Check for suction line frosting. Repair as necessary. 2. Motor and/or blades improperly mounted. 7. 8. Incorrect voltage. 4. or burnt motor bearings. Replace motor. COMPRESSOR CLUTCH NOISY 1. FAULT DIAGNOSIS 1 .

The low and high side pressures at the compressor will vary with changing ambient temperature. any sudden increase in the length of the cooling cycle would be indicative of abnormal operation of the air conditioner. All low pressure lines should be cool to the touch. Compressor drive belt tension. 4.82 AIR CONDITIONING REFRIGERATION SYSTEM FAULTS For any refrigeration system to function properly all components must be in good working order. Condenser fins. 2. With these factors constant. etc. Inlet and outlet temperatures at the receiver/drier should be at the same temperature (warm). Any very noticeable temperature difference indicates a blocked receiver/drier. 5. in-car temperature and altitude. All high pressure lines and components should be hot to the touch. Compressor magnetic clutch operation. 4. The unit cooling cycle and the relationship between air discharge temperature and ambient temperature and the pressures at the compressor can help to determine proper operation of the system. As humidity increases the outlet temperature will be higher. thermostat setting. The following items should be checked before operating the system: 1. 2. The length of any cooling cycle is determined by such factors as ambient temperature and humidity. Heavy frost on the inlet to the expansion valve may indicate a defective valve or moisture in the system. humidity. The following conditions should be checked after operating the system for several minutes: 1. 2 FAULT DIAGNOSIS . Evaporation air temperature will vary with ambient temperature and humidity. compressor speed and air leakage into the cooled area. 3. 3. Condenser fan operation. dirt will cause poor cooling and higher operating temperatures.

Check voltage. Clean grilles as required. 2. evacuate and charge system. REMEDY 1. Undercharge of refrigerant. 1. Replace valves and/or gaskets. LOW SUCTION 3. 3. Refrigerant flooding through evaporator into suction line. 5. evident by temperature difference between input and output lines. evacuate and charge system. Valve outlet tube will frost while inlet hose tube will have little or no frost. Replace motor. Fit new drier. A. Bulb should be securely clamped to clean horizontal section of copper suction pipe. 5. Fit new drier. Condenser fan motor defective. evident by ice on suction line and suction service valve. 3. Leaking compressor valves. wiring. Receiver/drier blocked. Expansion valve stuck open. 1. 1. Expansion valve sticking closed. or blower switch. 2. Defective evaporator blower motor. Moisture freezing in expansion valve orifice. Incorrect voltage to fan motor. Refer to C-2 and C-3. 3. Warm thermobulb with hand. fit new drier. Dust. evacuate and charge system. 4. If not replace expansion valve. 4. Fit new drier. valve gaskets and/or service valves. Check thermobulb. LOW HEAD PRESSURE C. or other debris restricting evaporator blower grille 5. 1. Loose drive belt 2. Clean condenser of debris. 4. 1. Evacuate and charge system. 1. Defective compressor. 3. 3. Air in system. 4. System operates periodically. Suction should rise rapidly to 1. 5.AIR CONDITIONING FAULT CAUSE 1. Split compressor gasket or leaking valves. paper scraps. Check belt tension. Check for leakage. evacuate and charge system. Fit new drier evacuate and charge system. evacuate and charge system. HIGH SUCTION PRESSURE 2. Condenser air passage clogged with dirt or other foreign matter. Repair or replace compressor. 3. Clean if clogged. 5. Replace gasket and/or reed valve. HIGH HEAD PRESSURE 2. 5. B. 4.4 bar 20 lb/in2 or more. Discharge. 3. Expansion valve thermobulb not operating. 4. Discharge system. Refer to Fault Diagnosis Chart for blower motor. Check inlet side screen. evident by bubbles in sight glass while system is operating 2. D. 2. 2. FAULT DIAGNOSIS 3 . Replace expansion valve. Overcharge of refrigerant.

Loose flywheel or clutch retaining bolt. 9. 2. 1. 3. 9. Broken mounting bracket. Incorrect alignment of pulleys or worn belt not riding properly. COMPRESSOR BELT SLIPPING H. Repair as necessary. 3. Replace bearing. 7. 5. Excessive head pressure. ENGINE NOISE AND/OR VIBRATION 8. evident by bubbles in sight glass. Loose or missing mounting bolts. 1. 3. air filter. etc.82 AIR CONDITIONING FAULT CAUSE REMEDY E. Refer to C-2. HEATER AND AIR CONDITIONING . Seized compressor. Nicked or broken pulley. INSUFFICIENT COOLING G. Excessive head pressure. 6. A-3 A-4 and C-6. 4. generator. Refer to B-1 and E. 1. Repair or replace components as required. 4. 1. Refer to compressor Oil Level Check. 2. 3. 4 FAULT DIAGNOSIS . Belt tension. Refer to A-1. C-3. Refer to B-2 and B-3 1. 4. 3. 2. 4. Replace bearing. Rough idler pulley bearing. 3. F. Repair as needed. A-2. Low refrigerant charge. D-1 and E. 2. 1. 1. Insecure mountings of accessories. 2. Leak test. Refer to A-1 through A-4 and C-6. Repair as necessary. For details of heating and air conditioning electrics See Electrical Trouble Shooting Manual. Adjust belt tension. 2. Replace bracket. Bent. 5.CIRCUIT DIAGRAMS 1. Low refrigerant charge-evident by bubbles in sight glass. power steering. 6. Incorrect compressor oil level. NOISY EXPANSION VALVE (steady hissing) 1. or improperly mounted engine drive pulley. 5. Replace as needed. Replace compressor. Repair as necessary. 5. Compressor not pumping. Defective compressor bearing. Expansion valve not operating properly. 8. 7. loose. Repair as necessary.

WARNING: Do not allow a refrigerant container to be heated by a direct flame or to be placed near any heating appliance.AIR CONDITIONING GENERAL PRECAUTIONS The refrigerant used in the air conditioning system is HFC (Hydrofluorocarbon) R134a. especially in the boot of a car. 3. Inhalation of concentrations of the vapour can cause dizziness. WARNING: Do not allow fluids other than R134a or compressor lubricant to enter the air conditioning system. If liquid R134a strikes the eye. 2. Cover eye with clean pad and seek immediate medical attention. WARNING: Do not smoke or weld in areas where R134a is in use. Also refrigerant cylinders and replenishment trolleys when discharging will freeze skin to them if contact is made. Carry out the same actions if skin comes into contact with discharging cylinders. narcosis. rubber apron or waterproof overalls and rubber boots. Spontaneous combustion may occur. WARNING: Do not leave a container of refrigerant without its cap fitted. WARNING: R134a is a hazardous liquid and when handled incorrectly can cause serious injury. uncoordination. If suspected of being overcome by inhalation of R134a vapour seek fresh air. nausea or vomiting. R134a is not flammable but can form a highly toxic gas. R134a should be handled with care. NOTE: Due to its low evaporating temperature of -30°C. Do not handle or discharge in an enclosed area. If unconscious remove to fresh air. Do not transport a container of refrigerant that is unrestrained. REMEDIAL ACTIONS 1. If liquid R134a is splashed on the skin run large quantities of water over the area as soon as possible to raise the temperature. do not rub it. A refrigerant container must not be heated above 50°C. Apply artificial respiration and/or oxygen and seek immediate medical attention. WARNING: R134a splashed on any part of the body will cause immediate freezing of that area. clean water may be used. Wrap affected parts in blankets or similar material and seek immediate medical attention. disorientation. Suitable protective clothing must be worn when carrying out servicing operations on the air conditioning system. If eyewash is not available cool. ADJUSTMENT 1 . NOTE: Suitable protective clothing comprises: Wrap around safety glasses or helmet. Gently run large quantities of eyewash over the eye to raise the temperature. or in any area where the vapour or liquid can come in contact with naked flame or hot metal. WARNING: The refrigerant used in an air conditioning system must be reclaimed in accordance with the recommendations given with a Refrigerant Recovery Recycling Recharging Station. WARNING: R134a is odourless and colourless. heatproof gloves.

. The receiver/drier contains desiccant which absorbs moisture.. Refrigerant oil Use the approved refrigerant lubricating oil: Nippon Denso ND-OIL 8 Unipart R134a ND-OIL8 CAUTION: Do not use any other type of refrigerant oil....... The rapid discharged of refrigerant will also result in the loss of most of the oil from the system....... Remove sealing plugs from the OLD compressor 2.................. Before connecting any hose or pipe ensure that refrigerant oil is applied to the seat of the new ’0’ ring but not to the threads.. the receiver/drier must be renewed immediately before evacuating and recharging the system.... The compressor must be removed and all the remaining oil in the compressor drained and refilled as follows: 1...... To calculate the quantity of oil to be drained: 1.. Pipe or hose ...(Y + 20ml) = Q Rapid refrigerant discharge When the air conditioning system is involved in accident damage and the circuit is punctured................. the refrigerant is discharged rapidly. An additional wrench must be used to hold the union to prevent twisting of the pipe..... CAUTION: Whenever the refrigerant system is opened.. Ensure that hoses are positioned in their correct run before fully tightening the couplings...... add the following quantities of refrigerant oil: Condenser .................82 AIR CONDITIONING SERVICING PRECAUTIONS Care must be taken when handling refrigeration system components.... Invert compressor and gravity drain oil into measuring cylinder....... NOTE: A new compressor should always have its sealing caps in place and must not be removed until immediately prior to fitting Fitting a new compressor A new compressor is supplied with an oil fill (X) of: 180ml A calculated quantity of oil must be drained from a new compressor before fitting........ Check the oil trap for the amount of oil lost..... 3... Evaporator . Plug the inlet and outlet ports....... Do not pour unused oil back into the container. 2............ Total of refrigerant oil in system = 180ml = 6...... When renewing system components..... Refill the compressor with the following amount of new refrigerant oil: 130ml 3. Hoses and lines must not be subjected to any twist or stress............... Torque wrenches of the correct type must be used when tightening refrigerant connections to the stated value........................ It must be positively sealed at all times... Use alcohol and a clean cloth to clean dirty connections... and ensure that all clips and supports are used. Calculate the quantity (Q) of oil to be drained from the NEW compressor using the following formula: X ... Rotating the compressor clutch plate will assist complete draining. pipes or capillary lines.......... assist by rotating the clutch plate (not the pulley).. Note the quantity of oil drained (Y).. Receiver/drier . Units must not be lifted by their hoses...... slowly release the sealing cap. Ensure that all new parts fitted are marked for use with R134a... Gravity drain all the oil.. gas pressure should be heard to release as the seal is broken.......... All protective plugs on components must be left in place until immediately prior to connection.. Refrigerant oil easily absorbs water and must not be stored for long periods...... 4........... 40ml 80ml 20ml 20ml A new compressor is sealed and pressurised with Nitrogen gas...3 Fl oz 2 ADJUSTMENT .

WARNING: Refrigerant must always be recycled before reuse. recycling and charging station Leak detector Thermometer +20°C to -60°C Safety goggles and gloves Recovery and recycling REFRIGERANT RECOVERY RECYCLING RECHARGING WARNING: The air conditioning system is charged with a high pressure. Operate the refrigerant recovery system according to the manufacturer’s instructions. Other equipment may not recycle refrigerant to the required level of purity. Allow to bleed off slowly. An air conditioning portable Refrigerant Recovery Recycling Recharging Station for use with R134a refrigerant incorporates all the features necessary to recover refrigerant R134a from the air conditioning system. The operator must adhere to the equipment manufacturer’s instructions. Add an equal amount of new refrigerant oil to compressor before evacuation sequence. Repairs or servicing must only be carried out by an operator familiar with both the vehicle system and the charging and testing equipment. Low pressure servicing connection 1. Always wear safety goggles and gloves when opening refrigerant connections. potentially toxic refrigerant. Connect a Refrigerant Station to the high and low pressure servicing connections. Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle air conditioning systems. 1. to ensure that the purity of the refrigerant is high enough for safe use in the air conditioning system. High pressure servicing connection 2.AIR CONDITIONING SERVICING EQUIPMENT The following equipment is required for full servicing of the air conditioning system. ADJUSTMENT 3 . Open connections slowly in case liquid or pressure is present. WARNING: Wear eye and hand safety protection. Recovery. 2. Measure the amount of oil discharged from the system. to filter and remove moisture. The unit can also be used for performance testing and air conditioning system analysis. to evacuate and recharge with the reclaimed refrigerant. CAUTION: Overcharging air conditioning system will cause excessive head pressure. Recycling should always be carried out with equipment which is design certified by Underwriter Laboratory Inc. All operations must be carried out in a well-ventilated area away from open flame and heat sources. 3. for compliance with SAE-J1991. A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of refrigerant.

4. CAUTION: Whenever the refrigerant system is opened. a leak test should be carried out using inert gas. 2. Renew the receiver/drier. Commence searching for leaks by passing the detector probe around all joints and components. Switch the air conditioning blower on and off at intervals of ten seconds. If the full charge has not been accepted by the system. Pressurise system to 3 bar. set the temperature control to cold and switch the blower to maximum speed. Delay between evacuation and recharging is not permitted. CAUTION: When a major repair has been carried out. 4. head and base plate joints and back seal plate. LEAK TEST SYSTEM The following instructions refer to an electronic type Refrigerant Leak Detector for use with R134a. Insert the probe into an air outlet of the evaporator or into the evaporator drain tube. Partially recharge the system and check for leaks using an electronic leak tester. 3. Any leaking refrigerant will be gathered in by the blower and detected. suspect a leak in the system. 4 ADJUSTMENT . Carry out the air conditioning system performance test. NOTE: If the vacuum reading is below 700mmHg after 15 minutes. refrigerant gas is heavier than air. Switch on the air conditioning system. Operate the refrigerant recharging system according to the manufacturer’s instructions:Refrigerant required to charge system: Without rear air conditioning = 0. 8. 9. 7. the system must be discharged before rectification. Connect gas line to recharging station. Follow the instructions issued by the manufacturer of the particular leak detector being used. Check all service valve connections. Check suction lines first. 5. Operate the refrigerant evacuation system according to the manufacturer’s instructions. Rectify any leaks and recheck for leaks during evacuation prior to charging. which are the safest and most sensitive. 5. CAUTION: When a major repair has been carried out. as leakage from the system could be dissipated without detection. 3. then run the compressor for 5 minutes and then check the high pressure lines. Carry out leak test as above.90kg (32 fl/oz) With rear air conditioning = 1. Add refrigerant oil to compressor if necessary. 6. If any leaks are found. the receiver/drier must be renewed immediately before evacuating and recharging the system. a leak test should be carried out using an inert gas (see below). valve plate. Insert the probe between the magnetic clutch and compressor to check the shaft seal for leaks. 8. 3. Check the condenser for leaks at the pipe unions. CAUTION: The system must be evacuated immediately before recharging commences. Consult Refrigerant Station Manual for correct procedure to complete the charge. open the car windows. 1. 2.15kg (40 fl/oz) 6. Connect a Refrigerant Station to the high and low pressure servicing connections. 2. 1. Leak test using inert gas Use Nitrogen or Helium gas. 7.82 AIR CONDITIONING Evacuation and recharging 1. start the engine and run it at 1500 rev/min for a minimum of 2 minutes. Place the vehicle in a well ventilated area but free from draughts.

29°C 30 .23.6 .5 14.28 lbf/in2 1. 3.2 lbf/in2 100-150 140-190 180-225 215-250 ADJUSTMENT 5 .1-2.27°C 4. temperature control set to cold and blower at maximum speed.47 lbf/in2 2. Connect a Refrigerant Station to the high and low pressure servicing connections. Refrigeration System Faults. 1. 5.9-10. 8. refer to the GENERAL PRECAUTIONS given at the beginning of this section. stop engine.3.9 bar 27 .4-15.5 bar 299 . Do not spill water from the wet thermometer (psychrometer).6 bar 256 .2.6 .35°C Outlet temperature 4 .2 . Carry out this test with bonnet and doors or windows open.1 12.03-1.PERFORMANCE TEST WARNING: R134a is hazardous.2 bar High pressure 213 .384 lbf/in2 20. Check that sight glass is free of bubbles. See Fault diagnosis.20. Insert dry bulb thermometer into cold air outlet and position dry and wet bulb thermometer close to outside air inlet. 6.4-1.9 . Read both pressure gauges and thermometers.7 .4 lbf/in2 15-20 20-25 25-30 30-35 High Pressure Gauge Readings bar 6. 7.3 .341 lbf/in2 17. Low pressure 18 .5 bar Table 1 Ambient Temperature ˚C 16 26. Performance range Intake temperature 20 .1. Start engine and run it at 1500 rev/min for 10 minutes with air conditioning switched on.6 bar 33 .5 °F 60 80 100 110 Compound Gauge Readings bar 1.10°C 9 . 2.6-13.299 lbf/in2 14.19°C 20 . disconnect test equipment.AIR CONDITIONING AIR CONDITIONING SYSTEM . Check readings against table below with humidity between 60% and 80%.24°C 25 . Close high pressure valve on refrigerant station. Close low pressure valve on refrigerant station.7 38 43.72-2. If readings are incorrect. air conditioning switched on.3 9. Set the air supply control to supply fresh air. Switch off air conditioning.72 1.37 lbf/in2 1.8-17.1 2.4 1.26.

If oil is evident. Check that the evaporator condensate drain tubes are open and clear. leaves.82. Start the engine. Set the temperature controls to cold and switch the air conditioner blower control on and off several times. Switch on the ignition and the air conditioner air flow control.01. 2. 8. COMPRESSOR DRIVE BELT Service repair no . Compressor drive belt V8i and Mpi See ENGINE. The sight glass should be generally clear after five minutes running. Check that the surface of the condenser is not restricted with dirt. Tdi . check for leaks. Switch off the air conditioning blower and stop the engine. Repair. Check the sight glass for bubbles or foam. shaded area free from excessive draught. Check that the blower is operating efficiently at low. 10. 14. and adjust if necessary. Inspect all connections for the presence of refrigerant oil. and repair as necessary. flies. Repeat at 1800 rev/min. checking that the magnetic clutch on the compressor engages and releases each time. 11. Drive belt 6 ADJUSTMENT . Switch off the blower and the ignition. 7. medium and high speeds. Place the vehicle in a ventilated. and check the sight glass at intervals. Check the tension of the compressor driving belt. Clean as necessary. 5. 6. If the air conditioning equipment is still not satisfactory. Low temperature indicates a restriction or blockage at that point. 4. 3. Do not neglect to check the surface between the condenser and the radiator. carry out a pressure test as previously described in this section. 15. Gradually increase the engine speed to the high range. etc. With the temperature control at maximum cooling and the blower control at high speed.See ENGINE. Continuous bubbles may appear in a serviceable system on a cool day.10. 9.82 AIR CONDITIONING SYSTEM TEST 1. 12. Check for frosting on the service valves. warm up the engine and fast idle at 1000 rev/min. Repair. NOTE: The compressor oil is soluble in Refrigerant R134a and is deposited when the refrigerant evaporates from a leak. with the doors and windows open. 13. or if there is insufficient air flow over the condenser at a high ambient temperature. occasional bubbles being acceptable. Check the high pressure hoses and connections by hand for varying temperature.

Components must not remain uncapped for longer than fifteen minutes. Joints and ’O’ rings should be coated with refrigeration oil to aid correct seating. flexible end connections and components must be capped immediately they are opened to prevent the entrance of moisture and dirt. All replacement components and flexible end connections must be sealed. 2. grease or moisture cannot be removed from inside the hoses. Any dirt or grease on fittings must be wiped off with a clean alcohol dampened cloth. Proceed cautiously. Receiver/driers must never be left uncapped as they contain Silica Gel crystals which will absorb moisture from the atmosphere. one on each fitting when releasing and tightening refrigeration unions. Flexible hoses should not be bent to a radius less than 90mm. The compressor shaft must not be rotated until the system is entirely assembled and contains a charge of refrigerant. to prevent condensation of moisture from the air that enters. Open connections slowly. Slight damage could cause a leak with the high pressures used in the system. 10. allow it to bleed off slowly. Completed assemblies must be checked for refrigeration lines touching metal panels. 17. and only opened immediately prior to making the connection. Plug all exposed connections immediately. A receiver/ drier left uncapped must not be used. keeping hands and face well clear. Any direct contact of lines and panels transmits noise and must be eliminated. 4. 9. 6. 12. fit a new unit. 13. 5. REPAIR 1 . If dirt. Lines. A new compressor contains an initial charge of of refrigerant oil. 14. 16. Flexible hoses should not be within 100mm of the exhaust manifold. Fittings which are not lubricated with refrigerant oil are almost certain to leak. the caps must be fitted. 1. When disconnecting any hose or pipe connection the system must be discharged of all pressure. they must be replaced with new hoses. 15. All lines must be free of kinks. Ensure the components are at room temperature before uncapping. 8.AIR CONDITIONING PRECAUTIONS IN HANDLING REFRIGERANT LINES WARNING: Wear eye and hand protection when disconnecting components containing refrigerant. The receiver/drier should be the last component connected to the system to ensure optimum dehydration and maximum moisture protection of the system. The efficiency of the system is reduced by a single kink or restriction. If pressure is noticed. In the event of delay. The compressor also contains a holding charge of gas when received which should be retained by leaving the seals in place until the pipes are re-connected. Always use two wrenches of the correct size. 11. Do not use chlorinated solvents such as trichloroethylene. 7. regardless of gauge readings. All precautions must be taken to prevent damage to fittings and connections. 3. so that no injury occurs if there is liquid in the line.

82 AIR CONDITIONING PERIODIC MAINTENANCE Routine servicing. Check the pipe connections for signs of oil leakage. 3. Check flexible hoses for swelling. The visual inspections are as follows: Condenser With a water hose or air line. Compressor Check pipe connections for signs of oil leakage. Plug all exposed connections immediately. Evaporator Examine the refrigeration connections at the unit. Examine the compressor belt for tightness and condition. Sight glass and Receiver/Drier Examine the sight glass for bubbles with the system operating. leaves. See Fault diagnosis. Check connections for leakage. apart from visual checks. 2 REPAIR . 1. Automatic gearbox 4. clean the fins of the condenser to remove flies. Refrigerant Recovery Recycling Recharging WARNING: Wear eye and hand protection when disconnecting components containing refrigerant.17. Disconnect battery negative lead. 2. Remove 4 bolts securing transmission oil cooler to body.82. or if erratic operation is noticed. If the system should develop a fault. Refrigeration System Faults RECEIVER DRIER Service repair no . is not necessary. the ports must be blanked off immediately on disconnection. See Adjustment. Remove 3 screws from bonnet locking platform and remove radiator grille. etc.01 Remove CAUTION: If receiver/drier is to be refitted. Exposed life of unit is only 15 minutes. Recover refrigerant from system.

fit bolts in turn and tighten.AIR CONDITIONING 5. All models Refit 12. Disengage pipe flanges and withdraw receiver/drier from mounting bracket. Use a second wrench to support pipe unions. 14. 9. Automatic gearbox 16. Fit clamp bolt. 13. Seal connections. 11. lubricate with refrigerant oil. 17. 20. Remove ’O’ ring from each pipe flange. Move receiver/drier just sufficiently to gain access to pipe flange bolts without distorting the pipes. Remove bolt securing receiver/drier clamp. 8. Perform a leak test on disturbed joints. All models 18. Remove transmission oil cooler. Fit new ’O’ ring to each pipe flange. See Adjustment. REPAIR 3 . Plug all exposed connections immediately. Evacuate and recharge air conditioning system. Disconnect 2 pipe unions from oil cooler. Remove bolt securing each pipe flange to receiver/drier. Check gearbox fluid level. top-up if necessary. Refit transmission oil cooler. 10. 7. Engage pipe flanges. Carry out a functional check. WARNING: Wear eye and hand protection when disconnecting components containing refrigerant. Use a second wrench to support hose adapter. 15. 6. Refrigerant Recovery Recycling Recharging 19. Position receiver/drier in mounting bracket with inlet and outlet connections correctly aligned.

8. Screw switch into adapter and tighten to 11 Nm.20. 5. Disconnect multiplug from switch. From the rear.82. See Adjustment. Recover refrigerant from system. WARNING: Wear eye and hand protection when disconnecting components containing refrigerant. Disconnect battery negative lead. Evacuate and recharge air conditioning system. See Adjustment.82 AIR CONDITIONING AIR CONDITIONING SWITCH Service repair no . Remove ’O’ ring from switch. Use a second wrench to support adapter.82. push switch out of panel. Reverse removal procedure. Lubricate new ’O’ ring with refrigerant oil and fit to switch. 2. 4. Refit 4. 7. Dash Panel Central Louvre Panel DUAL PRESSURE SWITCH Service repair no . Disconnect multiplug from switch 3. Refrigerant Recovery Recycling Recharging 2. Refrigerant Recovery Recycling Recharging 4 REPAIR . Refit 6. Remove fascia centre louvre vent panel. Unscrew switch from adapter.20 Remove 1. Plug all exposed connections immediately. Repair. 3.29 Remove 1.20. Reverse removal procedure. See CHASSIS AND BODY.

Disconnect low pressure hose from compressor. 2. fit bolts. Remove compressor from mounting bracket. lubricate with refrigerant oil. 16.20 Remove 1. 15. Disconnect high pressure hose from compressor. Remove 2 bolts securing hose flanges to compressor. Fit compressor drive belt. Plug all exposed connections immediately. Drain and measure oil from old compressor. add 30 ml extra to this amount and refill new compressor through outlet port. Tighten to 25 Nm. Disconnect electrical lead from compressor clutch. Repair. Drive Belt 11. 12. Refrigerant Recovery Recycling Recharging 21.82. 20. REPAIR 5 . Connect electrical lead to compressor clutch. Remove 4 bolts securing compressor to mounting bracket. Fit centre panel to fan cowl. See Adjustment. WARNING: Wear eye and hand protection when disconnecting components containing refrigerant. fit bolts. Carry out a functional check. Measure new oil equal to amount drained from old compressor. 8. 22. Perform a leak test on disturbed joints. See ENGINE. Drive Belt 19. Recover refrigerant from air conditioning system. Tighten to 10 Nm. V8i engine illustrated 5. See Adjustment. See ENGINE. 9. 10.AIR CONDITIONING COMPRESSOR Service repair no . 6. Remove ’O’ ring from each flange. Refit 13.10. 18. Evacuate and recharge air conditioning system. Disconnect battery negative lead. Remove centre panel. 17. 7. Locate compressor in mounting bracket. Repair. Fit new ’O’ rings to high and low pressure hose flanges. 14. Engage hose flanges. Refrigerant Recovery Recycling Recharging 3. Release drive belt from compressor pulley. Remove screws retaining centre panel to fan cowl 4. New compressor to be fitted: Drain oil from new compressor outlet port.

82 AIR CONDITIONING CONDENSER Service repair no .07 Remove 1. Pull condenser into radiator area. Plug all exposed connections immediately. 8. 11. Disc