WSM Range Rover Sport 2014 - 5 - Body

Workshop Service Manual for Range Rover Sport 2014 Sec.
5
5: Body and Paint
501: Body and Paint
501-00: Body System - General Information
General Procedures
Thread Repair Insert
501-02: Front End Body Panels
Specification
Removal and Installation
Cowl Panel Grille
Engine Undershield (76.10.50)
Fender (76.10.24)
Fender Splash Shield (76.10.48)
Hood
Hood Latch Panel (76.16.22)
Secondary Bulkhead Center Panel (76.11.35) - TDV6 3.0L Diesel
Secondary Bulkhead Center Panel (76.11.35) - V6 S/C 3.0L Petrol
Secondary Bulkhead Center Panel (76.11.35) - V8 S/C 5.0L Petrol
Secondary Bulkhead Panel LH - TDV6 3.0L Diesel
Secondary Bulkhead Panel LH - V6 S/C 3.0L Petrol /V8 S/C 5.0L Petrol
Secondary Bulkhead Panel RH - TDV6 3.0L Diesel
Secondary Bulkhead Panel RH - V6 S/C 3.0L Petrol /V8 S/C 5.0L Petrol
501-03: Body Closures
Specification
Description and Operation
Body Closures
General Procedures
Liftgate Alignment (76.28.31)
Front Door (76.28.01/99)
Front Door Check Arm
Fuel Filler Door Assembly
Fuel Filler Door
Liftgate (76.28.29/99)
Power Liftgate Switch (86.65.04)
Rear Door (76.28.02/99)
Rear Door Check Arm
Front Door Weatherstrip
Rear Door Weatherstrip
501-05: Interior Trim and Ornamentation
Specification
A-Pillar Trim Panel (76.13.26)
B-Pillar Trim Panel
C-Pillar Lower Trim Panel
C-Pillar Upper Trim Panel (76.13.35)
Cowl Side Trim Panel (76.13.27)
D-Pillar Trim Panel (76.13.73)
Engine Cover (12.30.50) - TDV6 3.0L Diesel
Engine Cover (12.30.50) - V6 S/C 3.0L Petrol /V8 S/C 5.0L Petrol
Front Door Trim Panel (76.34.01)
Front Scuff Plate Trim Panel (76.49.17)
Headliner (76.64.15)
Tailgate Trim Panel
Loadspace Trim Panel LH
Loadspace Trim Panel RH
Rear Door Trim Panel (76.34.04)
Rear Scuff Plate Trim Panel
Sun Visor
Luggage Compartment Upper Trim Panel
501-08: Exterior Trim and Ornamentation
Diagnosis and Testing
Retractable Running Board
Front Fender Moulding
Front Door Lower Moulding
Radiator Grille
Rear Door Lower Moulding
Rear Fender Splash Shield
Roof Moulding
Rear Quarter Panel Moulding (76.43.32)
Rear Spoiler
Rear Rocker Panel Moulding
Tailgate Moulding
Towbar
Towbar
501-09: Rear View Mirrors
Specification
Rear View Mirrors
Rear View Mirrors
Exterior Mirror (76.11.10)
Exterior Mirror Glass (76.11.08)
Exterior Mirror Motor (76.11.09)
Exterior Mirror Cover
Interior Rear View Mirror (76.10.51)
501-10: Seating
Seats
Driver Seat Cushion - Vehicles With: Power Seats
Driver Seat Cushion - Vehicles Without: Power Seats
Driver Seat Cushion Heater Mat
Front Seat (78.10.44/99) - Vehicles With: Power Seats
Front Seat (78.10.44/99) - Vehicles Without: Power Seats
Front Seat Armrest
Front Seat Backrest Blower Motor
Front Seat Backrest Cushion - Vehicles With: Power Seats
Front Seat Backrest Cushion - Vehicles Without: Power Seats
Front Seat Backrest Cover (78.90.08) - Vehicles With: Power Seats
Front Seat Backrest Cover (78.90.08) - Vehicles Without: Power Seats
Front Seat Backrest Heater Mat (78.90.36)
Front Seat Control Switch (78.70.89)
Front Seat Cushion Blower Motor
Front Seat Cushion Cover (78.30.01) - Vehicles With: Power Seats
Front Seat Cushion Cover (78.30.01) - Vehicles Without: Power Seats
Front Seat Head Restraint - Vehicles With: Power Seats
Front Seat Head Restraint - Vehicles Without: Power Seats
Front Seat Height Adjustment Motor (78.70.27)
Front Seat Recliner Motor (78.70.34)
Front Seat Track - Vehicles Without: Power Seats
Front Seat Track Motor (78.70.25)
Lumbar Assembly (78.60.01)
Massaging Lumbar Assembly
Memory Seat Position Switch
Passenger Seat Cushion - Vehicles With: Power Seats
Passenger Seat Cushion - Vehicles Without: Power Seats
Passenger Seat Cushion Heater Mat
Rear Seat Armrest
Rear Seat Backrest
Rear Seat Backrest Blower Motor
Rear Seat Backrest Cover (78.90.12)
Rear Seat Backrest Heater Mat
Rear Seat Control Switch
Rear Seat Cushion (78.40.54)
Rear Seat Cushion Blower Motor
Rear Seat Cushion Cover (78.40.70)
Rear Seat Cushion Heater Mat
Rear Seat Forward/Rearward Motor
Rear Seat Head Restraint Motor
Rear Seat Lumbar Support
Rear Seat Massaging Lumbar Assembly
Rear Seat Recliner Motor
Seat Base
Third Row Seat Cushion Cover
Third Row Seat Backrest Cover
Third Row Seat Head Restraint Motor
Third Row Seat
501-11: Glass, Frames and Mechanisms
Glass, Frames and Mechanisms
Glass, Frames and Mechanisms
Fixed Window Glass
General Procedures
Door Window Motor Initialization
Driver Door Window Control Switch
Front Door Window Regulator
Front Door Window Glass
Front Glass Roof Panel
Liftgate Window Glass
Passenger Door Window Control Switch
Rear Door Window Glass
Rear Door Window Regulator Motor
Rear Glass Roof Panel
Rear Quarter Window Glass
Windshield Glass
Windshield Moulding
501-12: Instrument Panel and Console
Specification
Floor Console (76.25.01)
Floor Console Cup Holder
Floor Console Stowage Compartment
Floor Console Stowage Compartment Lid
Floor Console Upper Section
In-Vehicle Crossbeam
Instrument Panel Center Reinforcement
Instrument Panel Lower Section
Instrument Panel Upper Section (76.46.04)
Glove Compartment (76.52.03)
Overhead Console (76.25.02)
501-14: Handles, Locks, Latches and Entry Systems
Handles, Locks, Latches and Entry Systems
Locks, Latches and Entry Systems
General Procedures
Tailgate Striker Adjustment (76.28.03)
Liftgate Striker Adjustment (76.37.28)
Door Lock Cylinder
Exterior Front Door Handle
Exterior Rear Door Handle
Front Door Latch
Liftgate Latch
Rear Door Latch
501-16: Wipers and Washers
Specification
Wipers and Washers
Wipers and Washers
Headlamp Washer Jet
Rain Sensor
Rear Window Wiper Motor
Rear Window Wiper Pivot Arm
Windshield Washer Pump
Windshield Washer Reservoir
Windshield Washer Fluid Level Sensor
Windshield Wiper Pivot Arm
Wiper Linkage Assembly
501-17: Roof Opening Panel
Roof Opening Panel
Roof Opening Panel
General Procedures
Roof Opening Panel Alignment (76.84.82)
Air Deflector
Roof Opening Panel
Roof Opening Panel Blind
Roof Opening Panel Frame
Roof Opening Panel Motor
Roof Opening Panel Seal
501-19: Bumpers
Specification
Front Bumper
Front Bumper Cover
Front Bumper Lower Cover
Rear Bumper
Rear Bumper Cover
501-20A: Safety Belt System
Specification
Safety Belt System
Safety Belt System
Safety Belt System
Front Safety Belt Buckle - Vehicles With: Power Seats
Front Safety Belt Buckle - Vehicles Without: Power Seats
Front Safety Belt Retractor
Rear Center Safety Belt Buckle
Rear Center Safety Belt Retractor
Rear Safety Belt Retractor
Rear Safety Belt Buckle
Third Row Safety Belt Retractor
Third Row Safety Belt Buckle
Third Row Center Safety Belt Buckle
501-20B: Supplemental Restraint System
Specification
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Air Bag Supplemental Restraint System (SRS)
General Procedures
Air Bag Disposal
B-Pillar Side Impact Sensor
Clockspring
Driver Air Bag Module
Occupant Detection Sensor - Vehicles With: Power Seats
Occupant Detection Sensor - Vehicles Without: Power Seats
Passenger Air Bag Module
Side Air Bag Module
Side Air Curtain Module
Restraints Control Module (RCM)
501-25A: Body Repairs - General Information
Body Construction
Corrosion Prevention
Sealer, Underbody Protection Material and Adhesives
501-25B: Body Repairs - Water Leaks
Water Leaks
501-26: Body Repairs - Vehicle Specific Information and Tolerance Checks
Body and Frame
501-27: Front End Sheet Metal Repairs
Front End Sheet Metal
Front Side Member Section (77.30.20/21)
Fender Apron Panel
Fender Apron Panel Closing Panel
Suspension Top Mount
Front Side Member and Suspension Top Mount Assembly
Front Fender Mounting Panel
Front Fender Lower Mounting Bracket
Hood Latch Panel (76.16.22)
Hood Latch Panel Mounting Bracket
501-28: Roof Sheet Metal Repairs
Roof
Roof Panel
Roof Front Panel
Roof Rear Panel
501-29: Side Panel Sheet Metal Repairs
Side Panel Sheet Metal
Side Panel (77.40.01)
Side Panel Front Section
A-Pillar Reinforcement
Rocker Panel (77.40.60)
Rocker Panel Inner Reinforcement
Rocker Panel Section
Rocker Panel and B Pillar Inner
B-Pillar Outer Panel
B-Pillar Reinforcement
501-30: Rear End Sheet Metal Repairs
Rear End Sheet Metal
Quarter Panel (77.40.09)
Quarter Panel Reinforcement
Inner Quarter Panel Upper - Vehicles With: Glass Roof Panel
Inner Quarter Panel Upper - Vehicles Without: Glass Roof Panel
Inner Quarter Panel Lower
Rear Side Member Section (77.70.07)
Back Panel Inner
Back Panel Outer
Back Panel Assembly
Rear Floor Panel Section (77.70.02)
Rear Lamp Panel Inner
Rear Lamp Panel Outer
Rear Wheelhouse Outer (77.40.36)
Rear Floor Side Extension
Rear Wheelhouse Extension
Water Drain Panel Lower
502: Frame and Mounting
502-00: Uni-Body, Subframe and Mounting System
Specification
General Procedures
Thread Repair Insert
Front Subframe - TDV6 3.0L Diesel
Front Subframe - V6 S/C 3.0L Petrol
Front Subframe - V8 S/C 5.0L Petrol
Front Subframe - TDV8 4.4L Diesel
Front Subframe - SDV6 3.0L Diesel - Hybrid Electric Vehicle
Rear Subframe
Rear Subframe Bushing
502-02: Full Frame and Body Mounting
Specification
Transmission Support Crossmember - TDV6 3.0L Diesel
Transmission Support Crossmember - V6 S/C 3.0L Petrol /V8 S/C 5.0L
Petrol
Transmission Support Crossmember - TDV8 4.4L Diesel
502-03: Towbar
Specification
Deployable Towbar Control Module (DTCM)
Deployable Towbar Control Module (DTCM)
Published: 13-Apr-2013
Body System - General Information - Thread Repair Insert
General Procedures
Special Tool(s)
JLR-501-169
Steel Insert Kit
Repair
CAUTIONS:
If one hole/thread is damaged, all remaining holes/threads must have a steel insert installed.
Make sure that the drill speed is not at maximum when repairing the damaged hole/thread. Use a suitable
electric drill with a slow speed setting.
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
1. WARNING: Prior to carrying out this procedure,

make sure that the chassis is not already installed
with an insert. Using a suitable extended magnet,
check the damaged hole for a steel insert. Do not
drill if there is a steel insert located already. Failure
to follow this instruction may result in permanent
damage to the vehicle..
Using compressed air make sure the hole is clean

and free of debris.
2. CAUTION: Make sure that the depth of the drill does not
exceed 100 mm
NOTE: Apply a suitable cutting lubricate to the drill bit

prior to drilling.
Drill the hole to a depth of 100mm using a 14mm drill.

3. Using compressed air make sure the hole is clean and free of
debris.
exceed 75 mm

prior to drilling.
Drill the hole to a depth of 75mm using a 15mm drill.

debris.
exceed 75 mm

prior to drilling.
Drill the hole to a depth of 75mm using a 16.5mm drill.

debris.
8. NOTE: Apply a suitable cutting lubricate to the tap

prior to cutting the thread.
Tap the hole using a M18 x 1.5 flute tap.
Special Tool(s): JLR-501-169

9. CAUTION: Make sure that the inside of the drilled hole is
clean and free of oil residue.
Using compressed air make sure the hole is clean and free of
debris.
10. CAUTION: Make sure that the threaded steel

insert is clean and free of oil residue before applying
Loctite.
Apply four beads of Loctite 243 to the outside of the

threaded steel insert as shown.
11. Thread the steel insert on to the special tool.
12. Using the special tool, install the threaded insert into the body.
Note the position of the machined cut on the special tool in
relation to the body.

13. CAUTION: Allow the Loctite to cure before
installing any of the sub-frame fixings.
Using a suitable tool measure the seated depth of

the steel insert, if the depth isn't as shown repeat
step 12.
14. Repeat steps 1-11 for any sub-frame fixings shown that may be
damaged.
Published: 02-May-2013
Front End Body Panels -
Torque Specifications
Item Nm lb-ft lb-in
Engine undershield retaining bolts 60 44 -
Fender retaining bolts 10 7 -
Hood safety latch to hood bolts 9 - 80
Hood to hinge retaining nuts 24 17 -
Engine bay support brace retaining bolts 55 41 -
Secondary bulkhead panel retaining bolts 6 4 -
Windshield washer reservoir bolts 7 - 62
Headlamp bolts 5 - 44
Active grille air shutter bolts 5 - 44
Hood latch panel to the charge air cooler bolts 5 - 44
Hood latch panel to body bolts 25 18 -
Front bumper mounting bracket bolts 5 - 44
Hood latches to hood latch panel bolts 10 7 -
Hood safety latch guide bolts 10 7 -
Front impact sensor bolt 11 8 -
Published: 06-Aug-2012
Front End Body Panels - Cowl Panel Grille
Removal
NOTE: Removal steps in this procedure may contain installation details.
1. NOTE: Repeat the procedure for the other side.
Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and

Washers, Removal and Installation).
2.
3.
4.
Installation
1. CAUTION: Make sure that the clip is correctly

located.
2. To install, reverse the removal procedure.

Published: 31-Jul-2012
Front End Body Panels - Engine Undershield
Removal
1. WARNING: Make sure to support the vehicle with axle

stands.
Raise and support the vehicle.
2.
3.
Installation
1. Torque: 60 Nm
2.
Front End Body Panels - Fender
Removal
NOTES:
Removal steps in this procedure may contain installation details.
LH illustration shown, RH is similar.

stands.
2. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal

and Installation).
3. NOTE: RH side only.
Refer to: Windshield Washer Reservoir (501-16 Wipers and

4.
5.
6. CAUTION: Make sure to protect the paintwork.
7. Torque: 10 Nm
8. Torque: 10 Nm
9. Torque: 10 Nm
10. NOTE: Make sure that the component is installed to the
position noted on removal.
Torque: 10 Nm
11. CAUTION: Carefully release either side of the

component to avoid damage.
NOTE: Do not disassemble further if the

component is removed for access only.
Installation
2. Refer to: Body and Frame (501-26 Body Repairs - Vehicle

Specific Information and Tolerance Checks, Description and
Operation).
Front End Body Panels - Fender Splash Shield
Removal
NOTES:
Some variation in the illustrations may occur, but the essential information is always correct.
1. WARNING: Do not work on or under a vehicle supported

only by a jack. Always support the vehicle on safety stands.
2. Remove the front wheel.
Refer to: Wheel and Tire - TDV6 3.0L Diesel /TDV8 4.4L
Diesel/V6 S/C 3.0L Petrol /V8 S/C 5.0L Petrol (204-04 Wheels
and Tires, Removal and Installation).
3.
4.
5.
6.
7.
8. NOTE: Do not disassemble further if the
Installation
1. To install reverse the removal procedure.

Front End Body Panels - Hood
Removal
NOTES:
The hood is manufactured from aluminium.
1. Refer to: Corrosion Prevention (501-25A Body Repairs - General

Information, Description and Operation).
2.
3.
4. WARNING: This step requires the aid of another technician.

6.
7.
8.
9. CAUTION: Protect the surrounding paintwork to
avoid damage.
10. CAUTION: Protect the surrounding paintwork to

avoid damage.
Installation
1. NOTES:
Install new retaining clips.
Make sure that the adhesive strip is removed

before installation.
2. NOTE: Install new retaining clips.
3.
4. Torque: 9 Nm
5.
6.
NOTE: Do not tighten at this stage.

8.
Lower the hood and check for alignment.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks, Description
and Operation).
If necessary adjust the hood buffers.
Check the operation and if necessary adjust the hood
latches.
9. Torque: 24 Nm
Front End Body Panels - Hood Latch Panel
Removal
NOTES:
1. Disconnect the battery ground cable.
Refer to: Specifications (414-00 Battery and Charging System -

General Information, Specifications).

stands.
3.
4. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and

Installation).
5.
6. NOTE: If equipped.
Torque: 7 Nm
7. NOTE: The step must be carried out on both

sides.

sides.
9. NOTE: The step must be carried out on both sides.
Torque: 5 Nm

sides.
Torque: 5 Nm
12. Torque: 7 Nm
13.
14.
15. NOTES:
The step must be carried out on both sides.
16. NOTES:
Torque: 5 Nm
17. NOTES:
Make sure that the locking tangs are installed

correctly.
Make sure that new components are installed.
18. NOTE: RH Shown.
19. NOTE: LH shown.

sides.
Torque: 25 Nm
21. CAUTION: Make sure the component is aligned as shown.
NOTE: This step requires the aid of another technician.
Torque: 25 Nm
Torque: 5 Nm
23.
24.
25. NOTE: Note the orientation of the components.
Torque: 10 Nm
26. Torque: 10 Nm
27.
28. CAUTION: Make the components are aligned as
shown.
Torque: 11 Nm
29.
Installation
2.
Lower the hood and check for alignment.
Refer to: Body and Frame (501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks, Description
and Operation).
Check the operation and if necessary adjust the hood
latches.
Front End Body Panels - Secondary Bulkhead Center Panel TDV6 3.0L
Diesel
Removal
NOTES:
1. Refer to: Cowl Panel Grille (501-02 Front End Body Panels,
Removal and Installation).
2. Torque: 55 Nm
3. Torque: 55 Nm
4. Torque: 6 Nm
5. Torque: 6 Nm
Torque: 6 Nm
Installation

Front End Body Panels - Secondary Bulkhead Center Panel V6 S/C 3.0L
Petrol
Removal
NOTES:
2. Torque: 55 Nm
3. Torque: 55 Nm
4. Torque: 6 Nm
5. Torque: 6 Nm
Torque: 6 Nm
Installation

Front End Body Panels - Secondary Bulkhead Center Panel V8 S/C 5.0L
Petrol
Removal
NOTES:
2. Torque: 55 Nm
3. Torque: 55 Nm
4. Torque: 6 Nm
5. Torque: 6 Nm
Torque: 6 Nm
Installation

Front End Body Panels - Secondary Bulkhead Panel LH TDV6 3.0L Diesel
Removal
NOTES:
1. Refer to: Secondary Bulkhead Center Panel - TDV6 3.0L Diesel

(501-02 Front End Body Panels, Removal and Installation).
2. Torque: 6 Nm
3. Torque: 6 Nm
Installation

Front End Body Panels - Secondary Bulkhead Panel LH V6 S/C 3.0L Petrol
/V8 S/C 5.0L Petrol
Removal
NOTES:
1. Refer to: Secondary Bulkhead Center Panel - V6 S/C 3.0L

Petrol (501-02 Front End Body Panels, Removal and
Installation).
Refer to: Secondary Bulkhead Center Panel - V8 S/C 5.0L
Installation).
2. Torque: 6 Nm
3. Torque: 6 Nm
Installation

Front End Body Panels - Secondary Bulkhead Panel RH TDV6 3.0L Diesel
Removal
NOTES:
1. Refer to: Secondary Bulkhead Center Panel - TDV6 3.0L Diesel

(501-02 Front End Body Panels, Removal and Installation).
2. Torque: 6 Nm
3. Torque: 6 Nm
4. Torque: 6 Nm
Installation

Front End Body Panels - Secondary Bulkhead Panel RH V6 S/C 3.0L
Petrol /V8 S/C 5.0L Petrol
Removal
NOTES:
1. Refer to: Secondary Bulkhead Center Panel - V6 S/C 3.0L

Installation).
Refer to: Secondary Bulkhead Center Panel - V8 S/C 5.0L
Installation).
2. Torque: 6 Nm
3. Torque: 6 Nm
4. Torque: 6 Nm
Installation

Body Closures -
Item Nm ib-ft lb-in

Front door hinge pivot bolt 13 10 -
Front door hinge to body bolts 35 26 -
Front door hinge to door bolts 35 26 -
Front door check arm nuts 10 7 -
Front door check arm to body bolt 24 18 -
Front door waist seal trim retaining screws 1.2 1 12
Front door trim panel handle retaining screw 1.5 1.5 18
Front door trim panel retaining bolts 3.5 3 36
Front door trim panel upper retaining screw 1.5 1.5 18
Front door trim panel lower retaining screw 1 1 12
Front door lower exterior trim retaining screw 1.2 1 12
Front door exterior handle retaining screw 3.5 3 36
Front door latch bolts 7 5 60
Rear door hinge pivot bolt 13 10 -
Rear door hinge to body bolts 35 26 -
Rear door hinge to door bolts 35 26 -
Rear door check arm nuts 10 7 -
Rear door check arm to body bolt 24 18 -
Rear door waist seal trim retaining screws 1.2 1 12
Rear door trim panel handle retaining screw 1.5 1.5 18
Rear door trim panel retaining bolts 3.5 3 36
Rear door trim panel upper retaining screw 1.5 1 12
Rear door trim panel lower retaining screw 1 1 12
Rear door lower exterior trim retaining screw 1.2 2 24
Rear door exterior handle retaining screw 3.5 3 36
Rear door latch bolts 7 5 -
Lift gate hinge to body bolts 25 18 -
Lift gate hinge to lift gate bolts 24 18 -
Lift gate trim panel handle bolts 3.5 3 36
Lift gate latch bolts 11 8 -
Body Closures - Body Closures
Component Location - Powered Tailgate
Item Part Number Description

1 - Right tailgate actuator
2 - Right tailgate anti-trap
3 - Tailgate Control Module (TGCM)
4 - Tailgate ajar switch
5 - Tailgate latch
6 - Tailgate soft close actuator
7 - Left tailgate actuator
8 - Left tailgate anti-trap
OVERVIEW
Powered tailgate
The powered tailgate is opened and closed by two electrically driven tailgate actuators mounted in place of the gas
struts as used on the manual tailgate.
The tailgate actuator assembly has ball joints at either end allowing it to articulate between the fixed mounts on the
vehicle. The nominal opening and closing time of the system is 5 seconds (+/2.0 seconds).
The tailgate operates using electronic latches with the addition of a soft-close closing motors to pull the latch closed
for the last 6 mm of travel (soft close). The latches and soft closing motor are located in the tailgate. The latch and
soft closing motor are located in the lower loadspace. The closing motos pulls the latch closed at the end of the
tailgates’ travel, once the latches’ secondary switch is reached.
Control Diagram
NOTE: A = Hardwired; F = RF (radio frequency) Transmission; N = Medium-Speed CAN (controller area

network)
Powered Tailgate

1 - Battery Junction Box 2 (BJB2)
2 - Battery Junction Box (BJB)
3 - Rear Junction Box (RJB)
4 - Right tailgate actuator
5 - Left tailgate actuator
6 - Tailgate global close switch
7 - Tailgate latch
9 - Tailgate exterior open/close switch
10 - Tailgate interior open/close switch
11 - RF filter
12 - Central Junction Box (CJB)
13 - Tailgate open/close switch - Smartkey
14 - RF receiver
15 - Keyless Vehicle Module (KVM)
16 - TGCM
17 - Left tailgate anti-trap
18 - Right tailgate anti-trap
19 - Battery
System Operation
Powered Tailgate
NOTES:
DO NOT CLOSE THE TAILGATE IF THE VEHICLE BATTERY IS DISCONNECTED. It is advisable to close the latch
claws when working on a vehicle with the battery disconnected to prevent accidental closure.
If required, the tailgate can be opened and closed manually.
The powered opening and closing actions are controlled by the tailgate modules. The modules receive permanent
battery power supply from the RJB (rear junction box) and they are connected with each other via medium speed
CAN and hardwired connection (anti-trap detection).
Tailgate Open/Close Sequence
To initiate the tailgate opening sequence a 'tailgate release-request' is received by the CJB (central junction box)
from one of the following:
KVM - signal originates from the smart key tailgate open/close switch
IC, internal tailgate open/close switch
Rear license-plate-plinth, external tailgate open/close switch.
The CJB responds with the following simultaneous actions:
A hardwire power release to the latch actuator mechanism

A powered opening request-signal and latch status transmitted to the tailgate module via the medium speed
CAN (controller area network) bus.
The processing of the opening signal by the CJB is influenced by a number of factors:
Source of 'opening signal'

Vehicle status: locked or unlocked
Vehicle equipped with or without passive entry
Vehicle speed and Transmission Control Switch (TCS) position.
Once the latch is released, the TGCM actuates the motors located in tailgate actuator to raise the tailgate to its fully
open or pre-set position. When the tailgate is in its opening cycle the automatic stop-position of the tailgate is
functioned by a hall-sensor located in the motor. The hall-sensor signal transmitted to the TGCM is synchronized with
the pre-set memory indicating the stop position of the tailgate.
To close the tailgate a hardwired signal is transmitted directly to the TGCM when the switch closing edge is pressed
and then released. The module operates the tailgate actuators in the opposite direction to close the tailgate to the
secondary latched position. (The tailgate can be closed via the Smartkey/interior/exterior tailgate release switch
also.)
When the latch engages with the striker plate a signal transmitted from the latches’ secondary switch, located in the
latch mechanism, to the TGCM confirms the latch is engaged. The module de-activates the tailgate actuators and
activates the tailgate soft close actuator to pull the latch closed through the last 6mm of travel. This is the latches'
primary fully-closed position. The tailgate soft close actuator then reverses to allow the latch to be opened upon the
next release request. Mechanical Bowden cables connection between the motors and latch assemblies are used to
complete the closing process of claw contraction and then reverse.
If the battery is disconnected when the tailgate is closed, the stored and calibrated tailgate opening heights will
remain stored when the battery is reconnected. However, if power supply to the TGCM is disconnected when the
tailgate is open, the system will not recognize the tailgate’s position, and subsequently will not function to any switch
commands when power is reinstated. To reset the system the tailgate must be moved manually to the closed position
where it will perform a soft-close and reset the hall-sensor counters to zero.
Component Description
Tailgate Actuators
Tailgate actuator components (reference only)

1 - Inner tube
2 - Outer tube
3 - Ball joint
4 - Outer tube spindle nut
5 - Spindle
6 - Springs
7 - Gear
8 - Motor
9 - Ball joint
The tailgate actuators open and close the tailgate using an electrically driven spindle located in the actuators' internal
electric motor. Ball-joints positioned at each end of the actuator allow it to articulate between a fixed mount on the
vehicle and the moveable tailgate. The tailgate opening operation is also aided by spring assistance.
The spindle drive comprises an inner and outer tube where the motor and gears in the inner tube drive a threaded
spindle which runs on a threaded nut fixed to the inside of the outer tube.
The spindle drive incorporates an object detection function controlled by the TGCM. The function is similar to the anti-
trap function of a closing electric window but operates in both directions. If the object detection feature is activated
while the tailgate is closing, the spindle motor(s) stop and then reverse for a preset period. If the object detection
feature is activated while a tailgate is opening, the spindle motor is stopped and held at that position.
NOTE: The spindle motor(s) on the tailgate experiencing an object/pinch condition whilst closing, will reverse to
the fully open state.
A hall sensor, located in the spindle motor, monitors the speed of the motor. If the speed decreases below a set
threshold, indicating an obstruction and increasing the motor current draw, the power feed to the motor is reversed
causing the tailgate to move in the opposite direction of travel.
The amount of travel in the opposite direction, before stopping, is determined by the hall sensor count. An exception
to the object detection reverse travel function occurs when the tailgate is opening through its first few degrees of
travel from the latched position. In these circumstances, if an obstacle is detected, the tailgate stops in the position
of the obstruction and no travel in the opposite direction occurs, other than a recoil action of the strut vs. hinge. The
tailgate may recoil back onto the secondary latch but NO soft close shall occur.
Powered Tailgate
Tailgate – release switch
The tailgate can be opened or closed using the following:
The open/close switch on the Smartkey

Rear license-plate-plinth, external tailgate open/close switch provided that the doors are unlocked and Park
(P) is selected on the TCS.
IC, internal tailgate open/close switch, providing:
- the vehicle is not locked and alarmed
- the vehicle speed is not at 5 kilometer/hour (3 mile/hour) or above.

1 - Tailgate open/close switch
2 - Tailgate open/close switch - Smartkey
The powered tailgate can also be manually closed, to either the latches’ secondary or primary position, without
causing any damage to the power mechanism.
The tailgate (Global Close) close switch is located on the tailgate closing edge.


1 - Tailgate global close switch
The tailgate can be stopped at any time during the open or close cycle by a single press on any of the tailgate
control switches. Thereafter:
Pressing any ‘release’ control switch will authorize the tailgate to change the direction of movement (Toggle).
Pressing the ‘close’ control switch will authorize the tailgate to continue or start closing.
For further information, see chart below.
The tailgate has a 'Garage Position' setting, where it is possible to set the maximum height to which the tailgate will
open.
To set the required height:
Open the tailgate to the position of the required height and ensure the tailgate is stationary for at least three
seconds.
Press and hold, the tailgate close switch.
Successful height programming will be indicated by a long beep heard from the tailgate.
Close the tailgate manually, or via the close switch, then open again to check that it opens to the
programmed height.
The maximum opening height is now set. To reset the maximum opening height to full, repeat the process, but fully
open the tailgate before pressing and holding the close switch.
The opening and closing control strategies of the tailgate are listed in the following chart:
Start from stopped Start from stopped Garage position

Strategy Opening Closing Stop position after opening position after closing - set/reset
Smartkey One One One One push for toggle closing One push for toggle X
push push push opening
Interior tailgate One One One One push for toggle closing One push for toggle X
release push push push opening
Exterior tailgate One One One One push for toggle closing One push for toggle X
release push push push opening
Global X One One One push for closing One push for closing One push until
open/close push push long beep
switch
Tailgate One One One One push for toggle closing One push for toggle X
open/close push push push opening
switch
If any object is detected that would interfere with the closing of either tailgate, the tailgate will stop and reverse to
the fully open position. An audible mislock warning, that is 2 beeps from the security sounder, will indicate either a
failed closing action or object or pinch detection. Any obstructions must be removed before pressing the close switch
again.
The powered tailgate may lose its position memory if:
there are multiple object detections

there are inadvertent loads on the tailgate while it is moving; for example a person leaning against the
tailgate
the battery voltage is low
any latch is manually closed.
The above may also inhibit the powered operation of the tailgate.
To reset the tailgate:
Manually close the tailgate.

Press a tailgate release switch.
Allow the tailgate to power fully open or to the previously set position.
Press and release the close switch.
Allow the tailgate to power close fully.
The tailgate programmed position memory will now be restored.
NOTE: if the vehicle is locked and the alarm is armed, if the tailgate is opened, and subsequently closed (via an
authorized user/key) with the valid Smartkey, that was used to open the tailgate, the tailgate will re-open and an
audible mislock warning, that is 2 beeps from the security sounder, will indicate a failed closing action. Please remove
key and reclose tailgate. The Smartkey will not be detected if it is any way covered/obstructed by metal
objects/laptops etc.
Published: 12-Sep-2012
Body Closures - Liftgate Alignment
General Procedures
Check
1. With the liftgate closed, check the alignment of the liftgate to the
roof panel and bodyside panel. The liftgate should be central in
its aperture.
Adjustment
1. Refer to: Rear Spoiler (501-08 Exterior Trim and Ornamentation,
2. NOTES:
Make sure that the tailgate is flush with the fender at point
1.
Make sure that the tailgate is recessed by 1.5 mm in

relation to the fender, at point 2.
Loosen, but do not remove the liftgate hinge bolts.

3. Tighten the liftgate hinge bolts.
Torque: 24 Nm
Body Closures - Front Door
Removal
CAUTIONS:
Make sure to protect the paintwork.
Refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
2.
3. NOTE: This step requires the aid of another technician.
Torque:

Stage 1:Check Arm Bolt 24 Nm
Stage 2:Hinge Bolt 13 Nm
4. Refer to: Front Door Lower Moulding (501-08 Exterior Trim and Ornamentation, Removal and Installation).
5. Refer to: Front Door Latch (501-14 Handles, Locks, Latches and Entry Systems, Removal and Installation).
6. Refer to: Front Door Check Arm (501-03 Body Closures, Removal and Installation).
7. Refer to: Front Door Window Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation).
8.
9.
10. NOTE: If a new door is to be installed the bolts shown should be replaced with plain shank bolts to allow
for correct door alignment.
Torque: 35 Nm
11. Torque: 8 Nm
12.
13.
14.
15.
16. Torque: 3.5 Nm

17.
18.
19.
20.
Installation

Body Closures - Front Door Check Arm
Removal
NOTE: Left hand shown, right hand similar.

2. Refer to: Front Door Speaker (415-01 Information and

Entertainment System, Removal and Installation).
3. Torque: 25 Nm
4.
5. Torque: 10.5 Nm
6.
Installation

Body Closures - Fuel Filler Door Assembly
Removal
All vehicles

stands.
2. Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and

Safety Precautions (100-00 General Information, Description
and Operation).
Refer to: Diesel Fuel System Health and Safety Precautions
(100-00 General Information, Description and Operation).
Vehicles with petrol engine

3. Refer to: Fuel System Pressure Release - V6 S/C 3.0L Petrol
/V8 S/C 5.0L Petrol (310-00 Fuel System - General Information,
General Procedures).
All vehicles
4. Remove the RH rear wheel arch liner.
Refer to: Rear Fender Splash Shield (501-08 Exterior Trim and
Ornamentation, Removal and Installation).
5. NOTE: Some variation in the illustrations may

occur, but the essential information is always
correct.
6.
7.
8.
9. CAUTION: Make sure to protect the

paintwork.
paintwork.
NOTE: Do not disassemble further if the

Installation

Body Closures - Fuel Filler Door
Removal
CAUTION: Make sure to protect the paintwork.
1.
Installation
1.
Published: 06-Jun-2013
Body Closures - Liftgate
Removal

2. Refer to: Headliner (501-05 Interior Trim and Ornamentation,

3. Refer to: Liftgate Window Glass (501-11 Glass, Frames and

Mechanisms, Removal and Installation).
4. Refer to: Power Liftgate Switch (501-03 Body Closures, Removal

and Installation).
5. Open the liftgate.
6.
7.
8. NOTE: Repeat the step for the other side.

9. Open the Liftgte.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Installation
1. Torque: 25 Nm
2.
3.
4.
5. Torque: 2.5 Nm
6.
7.
8.
9.
10. Install the Liftgte.
Torque: 25 Nm
12.
13.

15. NOTE: Make sure that the tailgate is flush with the fender
at point 1, and at point 2.
Torque: 24 Nm
Body Closures - Power Liftgate Switch
Removal
1.
Installation

Body Closures - Rear Door
Removal
NOTES:

2. Refer to: Rear Door Window Glass (501-11 Glass, Frames and
3. Refer to: Rear Door Latch (501-14 Handles, Locks, Latches and
Entry Systems, Removal and Installation).
4. Refer to: Rear Door Check Arm (501-03 Body Closures, Removal
and Installation).
5.
6. NOTE: This step requires the aid of another

technician.
Torque:

Stage 1:Check Arm Bolt 24 Nm
Stage 2:Hinge Bolt 13 Nm
7. NOTE: If a new door is to be installed the bolts
shown should be replaced with plain shank bolts to
allow for correct door alignment.
Torque: 35 Nm
8.
9.
10.
11.
Installation

Body Closures - Rear Door Check Arm
Removal
NOTE: Left hand shown, right hand similar.

2. Refer to: Rear Door Speaker (415-01 Information and

Entertainment System, Removal and Installation).
3. Torque: 25 Nm
4.
5. Torque: 10.5 Nm
6.
Installation

Published: 05-Dec-2013
Body Closures - Front Door Weatherstrip
Removal
NOTES:
Left Hand illustration shown, Right Hand is similar.
1. Refer to: Front Door Trim Panel (501-05 Interior Trim and
2.
3.
4.
5. Using a suitable non-permanent marker, mark the installed

position of existing seal.
6. NOTE: Discard the door seal.

Installation
1. CAUTIONS:
To aid the bonding process the ambient air temperature

must be above 20 degrees C.
The door seal must not be installed outward of the marked

outline.
Using a suitable clean agent, throughly clean the adhesive

contact area.
Install the door seal to the marked outline.
Press the door seal firmly into place.
2.
3.
4. Torque: 24 Nm
Body Closures - Rear Door Weatherstrip
Removal
NOTES:
Left Hand illustration shown, Right Hand is similar.
1. Refer to: Rear Door Trim Panel (501-05 Interior Trim and
2. Torque: 24 Nm
3.
4.
5. Using a suitable non-permanent marker, mark the installed

6. NOTE: Discard the door seal.

Installation
1. CAUTIONS:
To aid the bonding process the ambient air temperature

must be above 20 degrees C.
The door seal must not be installed outward of the marked

outline.
Using a suitable clean agent, throughly clean the adhesive

contact area.
Install the door seal to the marked outline.
Press the door seal firmly into place.
2.
3.
Interior Trim and Ornamentation -
Item Nm lb-ft lb-in
A-pillar trim panel retaining bolt 6 - 53
Front seat safety belt anchor retaining bolt 40 29 -
B-pillar trim panel retaining bolt 6 - 53
C-pillar lower trim panel retaining bolt 5 - 44
D-pillar trim panel retaining bolt 6 - 53
Front door trim panel handle center retaining screw 1.5 - 13
Front door handle retaining screw 1.6 - 14
Front door trim panel M6 bolts 3.2 - 28
Front door trim panel lower retaining screws 1 - 9
Front door trim panel upper retaining screws 1.5 - 13
Front door trim panel storage compartment retaining screws 1.5 - 13
Front door trim panel door window switch retaining screws 1 - 9
Front door trim panel speaker retaining screws 1.9 - 17
Front door trim panel speaker grille screws 1.6 - 14
Luggage compartment upper trim panel safety belt retaining bolts 6 - 53
C-pillar upper trim panel retaining bolt 5.9 - 53
Rear seat safety belt anchor retaining bolt 45 33 -
Rear seat retaining bolts 50 37 -
Rear door trim panel handle center retaining screw 1.5 - 13
Rear door trim panel center retaining screws 3.5 - 31
Rear door trim panel lower retaining screws 1 - 8
Rear door trim panel upper retaining screws 1.5 - 13
Rear door trim panel handle retaining screws 1.5 - 13
Rear door trim panel tweeter speaker retaining screws 1.5 - 13
Rear door trim panel speaker retaining screws 1.5 - 13
Sun visor retaining screws 6 - 53
Grab handle bolts 6 - 53
Headliner bolts 6 - 53
Headliner speaker bolts 1.9 - 17
Headliner speaker bracket to headliner bolts 1.9 - 17
Interior Trim and Ornamentation - A-Pillar Trim Panel
Removal
1. CAUTION: Apply heatshrink or protective tape

to the end of a suitable tool to protect the interior
components.
2.
3. Torque: 6 Nm
4.
Installation

Interior Trim and Ornamentation - B-Pillar Trim Panel
Removal
NOTES:
Make sure that new plastic clips are installed and the original metal clips are installed to the trim if detached on
removal.

components.
2.
3. Make the SRS system safe.
Refer to: Standard Workshop Practices (100-00 General

4.
5. Torque: 40 Nm
6.
7.
8.

Installation
1.
Interior Trim and Ornamentation - C-Pillar Lower Trim Panel
Removal
NOTES:
RH illustration shown, LH is similar.

components.
3. Refer to: Luggage Compartment Upper Trim Panel (501-05

Interior Trim and Ornamentation, Removal and Installation).
4.
Installation

Interior Trim and Ornamentation - C-Pillar Upper Trim Panel
Removal
NOTES:

components.
2.
3. Torque: 6 Nm
4.
5.
Installation
2.
Interior Trim and Ornamentation - Cowl Side Trim Panel
Removal
NOTES:
Make sure that new plastic clips are installed and the original metal clips are installed to the trim if detached on
removal.
1.
2.
3.
4.
Installation

Interior Trim and Ornamentation - D-Pillar Trim Panel
Removal
NOTES:

components.
2.
3.
4. Torque: 6 Nm
5. NOTES:
This step is only required if third row seat is

not fitted to the vehicle.
Install new retaining clips.

7.
8.
Installation
1.

Interior Trim and Ornamentation - Engine Cover TDV6 3.0L Diesel
Removal
1.
Installation

Interior Trim and Ornamentation - Engine Cover V6 S/C 3.0L Petrol /V8
S/C 5.0L Petrol
Removal
1.
Installation

Interior Trim and Ornamentation - Front Door Trim Panel
Removal
NOTES:

components.
2. Torque: 1.5 Nm
3.
4. Torque:
M6 screw 3.2 Nm
M4 upper screw 1.5 Nm
M4 lower screw 1 Nm
5.
6.

8. Torque: 1.0 Nm
9. Torque: 1.0 Nm
10. Torque: 1.9 Nm

11.
12. Torque: 1.6 Nm
13. Torque: 1.6 Nm

Installation

Interior Trim and Ornamentation - Front Scuff Plate Trim Panel
Removal
CAUTION: Make sure that new plastic clips are installed and the original metal clips are installed to the trim if
detached on removal.
1. Refer to: Cowl Side Trim Panel (501-05 Interior Trim and
2. Refer to: B-Pillar Trim Panel (501-05 Interior Trim and

3.
4.
5.
Installation

Interior Trim and Ornamentation - Headliner
Removal
NOTES:
Some variation in the illustration may occur, but the essential information is always correct.

components.
2. Refer to: Windshield Glass (501-11 Glass, Frames and


4. Refer to: C-Pillar Upper Trim Panel (501-05 Interior Trim and
5. Refer to: D-Pillar Trim Panel (501-05 Interior Trim and

6. Refer to: Sun Visor (501-05 Interior Trim and Ornamentation,

7. Refer to: Overhead Console (501-12 Instrument Panel and

Console, Removal and Installation).
8. NOTE: Note the orientation of the seal prior to detaching.

sides.
Torque: 6 Nm

sides.
Torque: 6 Nm
sides.
Torque: 6 Nm

sides.
sides.
Torque: 6 Nm
14. NOTES:
If equipped.
15. NOTES:
If equipped.
Torque: 6 Nm
16.
17.
18. CAUTIONS:
Take extra care not to damage the component.
Using a suitable plastic trim tool, release the magnetic

fixings.
NOTE: Make sure that there is at least 50mm clearance

between the magnetic fixings and the headliner during the
removal procedure. The fixings will engage if too close to each
other.
19. CAUTION: Take extra care not to damage the component.
NOTE: The step must be carried out on both sides.
20. CAUTIONS:

fixings.

other.

22. NOTES:
If equipped.
23. NOTES:
If equipped.

25. NOTE: This step requires the aid of another
technician.
26.
27. NOTE: Do not disassemble further if the component is

removed for access only.
sides.
29. NOTES:
If equipped.

Torque: 1.9 Nm
31. NOTES:
If equipped.
Torque: 1.9 Nm
Torque: 1.9 Nm
Installation
1. NOTE: Install a new retaining clip.
3. CAUTION: Make sure that the seal is installed to the correct

orientation as noted in the removal procedure. Failure the follow
this instruction may result in damage to the headliner.
Interior Trim and Ornamentation - Tailgate Trim Panel
Removal

components.
2.
3.
Installation
1.
Interior Trim and Ornamentation - Loadspace Trim Panel LH
Removal

components.
2. CAUTION: Take extra care not to damage the

component.
NOTES:
If equipped.

component.
NOTES:
If equipped.

4.
5.
Installation

Interior Trim and Ornamentation - Loadspace Trim Panel RH
Removal

components.

component.
NOTE: If equipped.

component.
NOTE: If equipped.
4.
5.
6.

Installation

Interior Trim and Ornamentation - Rear Door Trim Panel
Removal

components.
2. Torque: 1.5 Nm
3.
4. Torque: 3.5 Nm
5.
6.
7.
9.
10.
11.
12.
13.
Installation

Interior Trim and Ornamentation - Rear Scuff Plate Trim Panel
Removal
CAUTION: Take extra care not to damage the component.
NOTES:


5.
Installation

Interior Trim and Ornamentation - Sun Visor
Removal
CAUTION: Take extra care not to damage the edges of the component.
NOTES:
1.
2.
3. CAUTION: Make sure the wiring harness and

electrical connectors are not damaged during this
operation.
Torque: 6 Nm
Installation

Interior Trim and Ornamentation - Luggage Compartment Upper Trim
Panel
Removal
NOTES:

components.
2. Refer to: Loadspace Trim Panel RH (501-05 Interior Trim and


5.
6. Torque: 45 Nm
7. Torque: 6 Nm
8. Torque: 6 Nm
Installation

Exterior Trim and Ornamentation - Retractable Running Board
Principles of Operation - Deployable Sidestep Control Module (DSCM)
For a detailed description of the retractable running board system and operation, refer to the relevant description
and operation section of the workshop manual
Inspection and Verification
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or
the donor vehicle
1. Verify the customer concern
2. Visually inspect for obvious signs of mechanical or electrical damage

Visual Inspection
Mechanical Electrical
Deployable sidestep switch condition and installation Battery condition and state of charge
Deployable sidestep hinges condition and installation Fuses
Deployable sidestep motor(s) condition and installation Harnesses and connectors
Deployable sidestep switch
Deployable sidestep motor(s)
Ignition switch
Battery junction box
Central junction box
CAN circuit(s)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step
4. If the cause is not visually evident, check for diagnostic trouble codes (DTCs) and refer to the DTC index
DTC Index
For a list of diagnostic trouble codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - DTC: Module Name: Deployable Sidestep Control Module (100-00,
Description and Operation).
Exterior Trim and Ornamentation - Front Fender Moulding
Removal

stands.
2.

paintwork.
Installation

Exterior Trim and Ornamentation - Front Door Lower Moulding
Removal
CAUTIONS:
Make sure to protect the paintwork.
1. CAUTION: Protect the paintwork during this

operation.
Open the front door for access.
2. CAUTION: Do not use tools during this

operation, removal of the component(s) must be
carried out by hand.
NOTE: Open the front door for access.
3.
Installation

Exterior Trim and Ornamentation - Radiator Grille
Removal
1.
Installation

Exterior Trim and Ornamentation - Rear Door Lower Moulding
Removal
CAUTIONS:
Protect the paintwork during this operation.
1. NOTE: Open the rear door for access.
2. CAUTION: Do not use tools during this

operation, removal of the component(s) must be
carried out by hand.
NOTE: Open the rear door for access.
3.
Installation

Exterior Trim and Ornamentation - Rear Fender Splash Shield
Removal
NOTES:

stands.
2. Refer to: Wheel and Tire - TDV6 3.0L Diesel /TDV8 4.4L
3.
4.
5.
6.
7.

Installation

Exterior Trim and Ornamentation - Roof Moulding
Removal
CAUTION: Protect the paintwork during this operation.
1. NOTE: Use a screw driver with heat shrink

protection fitted.
2.
Installation

Published: 24-Oct-2013
Exterior Trim and Ornamentation - Rear Quarter Panel Moulding
Removal
1.
2. CAUTIONS:
Discard the component.
Make sure that a new component is installed.
Installation
Exterior Trim and Ornamentation - Rear Spoiler
Removal
CAUTION: Protect the paintwork during this operation.
NOTE: The audio unit antenna is an integral part of the rear spoiler and cannot be removed.
1. NOTE: Open the liftgate.
3.
5. NOTE: Take extra care not to damage the

component.
6.
Installation
1. Torque: 7 Nm
2. Torque: 3.5 Nm
3.
4. CAUTION: Only tighten the nuts finger-tight at this stage.
5. NOTE: Adjust the rear spoiler by rotating the adjustment

studs clockwise and counter clockwise as necessary.
6. CAUTION: Make sure that the gap is even
between the rear spoiler and the rear quarter panel
moulding and the rear spoiler is flush with the roof
panel (use a suitable plastic straight edge).
7. Torque: 7 Nm
Exterior Trim and Ornamentation - Rear Rocker Panel Moulding
Removal
NOTES:
Left-hand shown, right-hand similar.

stands.
2. Refer to: Front Fender Trim Panel (501-08, Removal and

Installation).
3.
4.
Installation

Exterior Trim and Ornamentation - Tailgate Moulding
Removal
CAUTION: Make sure to always protect the paintwork during this procedure.
1. NOTE: Using a suitable plastic tool to release

the fixings.
Installation
1.
2. CAUTION: Make sure that the retaining clips

are correctly installed.
NOTE: To install the clips a tapping force

required by hand.
Exterior Trim and Ornamentation - Towbar
Removal

stands.
2. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and

Installation).
3.
4.
5. Torque:

Stage 1:M12: 80 Nm
Stage 2:90° Nm

Stage 1:M10: 70 Nm
Stage 2:60° Nm
6.
Installation

This section contains no data
Rear View Mirrors -
Description Nm lb-ft
Exterior mirror Torx screws 8 6
Rear View Mirrors - Rear View Mirrors
COMPONENT LOCATION
NOTE: Right Hand Drive (RHD) shown, Left Hand Drive (LHD) similar

1 - Driver door mirror
2 - Driver door switchpack
3 - Interior rear view mirror
4 - Passenger Door Module (PDM)
5 - Passenger door mirror
6 - Driver Door Module (DDM)
OVERVIEW
Rear view mirrors
Rear view mirrors consist of an interior mirror on the windshield, an exterior mirror on each front door cheater.
Interior mirror
The interior rear view mirror is provided as an electrically operated automatic dimming type.
The automatic dimming mirror comprises an electro-chromatic glass housed within a surrounding case that is
attached with a ball joint connector to the mirror stem.
Light sensors are mounted on the front and rear of the mirror surround case. The sensors control the automatic
dimming feature to reduce glare from the headlights of following vehicles.
Exterior mirrors
The exterior mirrors are bolted to the front door structure and incorporate the following features:
Convex mirror glass.
Electric adjustment.
Mirror heating.
Automatic dimming (model and market dependent).

Memory recall and reverse dipping (model and market dependent).
Mirror fold back function (model and market dependent).
Approach lighting (model dependent).

For additional information, refer to: Interior Lighting (417-02 Interior Lighting, Description and Operation).
Proximity cameras (model dependent).
Ambient air temperature sensor.
Operation of the exterior mirrors is controlled by the 2 front door modules and the CJB. The door modules and the
CJB communicate with each other. The door modules interpret the signals and control switch inputs into appropriate
outputs for the exterior mirrors. For operation of the various exterior mirror functions the 2 door modules are
powered by a permanent battery feed from the CJB.
CONTROL DIAGRAM
NOTE: A= Hardwired;AO = Medium Speed Body CAN;O= LIN Bus

1 - Battery
3 - Interior rear view mirror
SYSTEM OPERATION
Automatic Dimming Interior Mirror
The automatic dimming function is permanently active when the ignition is in power mode 4 (Accessory) and power
mode 6 (Ignition). The forward facing light sensor monitors the ambient light level at the front of the vehicle; the
rearward facing light sensor monitors the light level coming from the rear of the vehicle. When light from the rear of
the vehicle exceeds the ambient light level from the front of the vehicle, the automatic dimming circuit darkens the
interior mirror surface.
Automatic dimming is inhibited when reverse gear is selected to provide the driver with maximum vision. On vehicles
with automatic transmission, the reverse gear signal is provided by the Transmission Control Module (TCM) via the
High speed CAN bus to the CJB. The CJB then provides a power feed to the mirror. On vehicles with manual
transmission, the reverse gear signal is provided by a transmission switch that is hardwired to the CJB.
Automatic dimming interior mirrors are connected to the vehicle wiring by an electrical connector in the mounting
stem. The electrochromic mirror circuits and, where fitted, the universal transmitter, are powered by a feed from the
central junction box (CJB) when the ignition is in power mode 6.
Universal Transmitter
WARNING: The universal transmitter must not be used with any garage door that lacks safety 'stop' and
'reverse' features, as required by federal safety standards (this includes any garage or door opener model
manufactured before April 1 1982). A garage door opener which cannot 'detect' an object in the path of a closing
door and then automatically 'stop' and 'reverse' the door, does not meet current federal safety standards. Using a
garage door opener without these features increases the risk of serious injury or death.
NOTES:
Universal transmitter is market dependent
HomeLink is a registered trademark owned by Johnson Controls Inc.
The universal transmitter can operate up to 3 home or office remotely operated systems (e.g. garage door/gate
openers, lighting and security systems), replacing the individual hand held transmitters required for each system.
The universal transmitter can learn the radio frequency codes of most current transmitters.
NOTE: Universal transmitter frequencies vary across markets
The universal transmitter incorporates 3 buttons, one for each channel, and an amber LED installed on the underside
of the interior mirror. When one of the buttons is pressed the universal transmitter outputs the radio signal
programmed for the related channel (if any) and illuminates the LED to confirm transmission.
For information on programming the universal transmitter, refer to the 'Owners Handbook'.
Auto High Beam
The Auto High Beam (AHB) system is controlled by a Auto High Beam Control Module (AHBCM) which is located in
the interior rear view mirror body. The module and the CJB are connected via the medium speed CAN bus.
The AHBCM receives a power supply from the CJB when the ignition is in power mode 6 (ignition on). The rear view
mirror also includes a low resolution camera (image) sensor which detects headlamps and tail lamps of preceding
vehicles. The sensor is connected to the control module which evaluates the image data, checking for light intensity
and location.
If conditions are correct and AHB has been activated, the control module will activate the AHB by sending a high or
low beam request message to the CJB via the medium speed CAN bus. The CJB then controls the shutter in the
Xenon projector module together with the high beam fill-in lamp.
For additional information, refer to: Exterior Lighting (417-01 Exterior Lighting, Description and Operation).
COMPONENT DESCRIPTION
Interior Mirrors


1 - Rear light sensor
2 - Front light sensor
3 - Universal Transmitter Light Emitting Diode (LED) (market dependent)
4 - Universal Transmitter channel switch
The interior rear view mirror is provided as a electrically operated automatic dimming type.
The automatic dimming mirror comprises an electro-chromatic glass housed within a surrounding case that is
attached with a ball joint connector to the mirror stem.
Light sensors are mounted on the front and rear of the mirror surround case. The sensors control the automatic
dimming feature to reduce glare from the headlights of following vehicles.
Exterior Mirrors

1 - Passenger door mirror adjustment
2 - Driver door mirror adjustment
3 - Press both switches together to fold/unfold the mirrors.
Heating
Heating of the exterior mirrors is controlled by the CJB and the respective door modules, and is active while the
ignition is in power mode 6 or 7.
The CJB receives the ambient air temperature value from the Instrument Cluster (IC) via the CAN (controller area
network) bus. The CJB converts the ambient air temperature value to an on-time percentage and transmits it on the
Medium speed CAN bus to the two door modules, which then energize the exterior mirror heating elements
accordingly. The on-time percentage is increased while the windshield wipers are on.
Exterior Mirror Heating Times
Ambient Air Temperature in < -10 -10 to 0 (14 to 0 to 15 (32 to 15 to 25 (59 to 25 to 35 (77 to > 35
°C (°F) (<14) 32) 59) 77) 95) (>95)
On-time Percentage 100% 75% 50% 25% 0% 0%
On-time Percentage With 100% 100% 75% 50% 25% 0%
Wipers On
On vehicles with the parked heating function, exterior mirror heating may also operate when the parked heating
function is active, depending on the ambient air temperature.
For additional information, refer to: Auxiliary Climate Control (412-02A Auxiliary Climate Control, Description and
Operation).
Dimming
Exterior mirrors with automatic dimming are slaved to the interior mirror. The interior mirror determines the amount
of dimming required and energizes the electrochromic elements in the exterior mirrors accordingly. Feed and ground
wires from the interior mirror, for the electrochromic elements in the exterior mirrors, bypass the door modules and
connect directly to the exterior mirrors.
Mirror Memory
The seat, exterior mirrors and steering column memory functions are integrated into the CJB.
The driver and front passenger door modules control the mirror memory while the driver seat module controls the
seat and the CJB controls the steering column memory.
Located on the outboard side of the driver seat plinth, the memory switch and memory pre-set buttons can be used
to store 3 different mirror positions. When a position is stored or recalled, the information is transmitted to the CJB
via the medium speed CAN. It is then relayed to the door modules. Each door module evaluates the recalling and
storage commands transmitted via the Medium speed CAN for positions 1 to 3 and performs the necessary
adjustments.
If a manual adjustment is selected while the mirror memory is operating, it will over-ride the memory recall function.
For mirror memory to operate, the mirror adjustment potentiometers must deliver a voltage value in the range of
80mV - 4.8V. Should a voltage applied be outside of this range the mirror will not operate when memory is selected.
Reverse Dipping
If the customer has activated reverse dipping when reverse gear is selected and the vehicle is in power mode 6 or 7,
the driver and passenger exterior mirrors dip to provide a better view of the kerb. The mirrors return to their original
position immediately upon reverse gear being disengaged.
The kerb view mirror position can be adjusted using the mirror adjustment multi-directional switch while reverse gear
is selected and the vehicle in power mode 6 or 7.
Blindspot Monitoring System


1 - Warning alert icon
2 - System status warning indicator
Blindspot monitoring function alerts the driver to a vehicle located in the vehicle blindspot. A warning indicator is
located in each exterior mirror towards the outer edge.
For additional information, refer to: Blindspot Monitoring System (413-09 Warning Devices, Description and
Operation).
Electrochromic Mirror
The electrochromic mirrors automatically dim to reduce glare from the headlights of following vehicles in dark or low
light conditions. In addition to dimming the interior mirror, the electrochromic mirror circuits also control the
dimming of the two exterior mirrors, via power feed and ground connections with the 2 exterior mirrors.
A light sensor on the front of the interior mirror monitors ambient light at the front of the vehicle and a light sensor
in the interior mirror glass monitors the light coming from behind the vehicle. When the light from behind the vehicle
exceeds the ambient light level, the electrochromic circuits simultaneously dim the interior and exterior mirrors.
Dimming is inhibited when reverse gear is selected. The interior mirror is provided with a reverse gear signal by the
lighting control switch.
Rear View Mirrors - Rear View Mirrors
Principle of Operation
For information on the description and operation of the mirrors, refer to the relevant section of the workshop
manual. REFER to: Rear View Mirrors (501-09 Rear View Mirrors, Description and Operation).
the donor vehicle
NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty,
refer to the warranty policy and procedures manual (section B1.2), or determine if any prior approval programme is
in operation, prior to the installation of a new module/component
2. Visually inspect for obvious mechanical or electrical faults

Visual inspection
Door mirror switch condition and installation Battery condition and state of charge
Door mirror condition and installation Fuses
Harnesses and connectors
Washer jet and mirror heater relay
Memory control module(s)
Door mirror switch(es)
Door mirror motor(s)
Ignition switch
Automatic temperature control module
LIN circuit(s)
4. Use the approved diagnostic system or a scan tool to retrieve any DTCs before moving onto the symptom
chart or DTC index
Because the DTCs are stored in more than one module, a complete vehicle read is recommended
Make sure that all DTCs are cleared following rectification
Symptom chart
Symptom Possible causes Action

Mirrors do not Fuse fault Check the fuses. Check the operation of the washer jet and mirror heater relay
defrost/washer Washer jet (see the visual inspection). Check the washer jet and mirror heater circuits.
jets freeze and mirror Refer to the electrical guides
heater relay
fault
Circuit fault:
high
resistance
Circuit fault:
short circuit
to ground
Automatic
temperature
control
module fault
Mirrors Mechanical Operate the mirror switch and listen for the motor(s). If the motor(s) can be
inoperative in fault heard, check the mechanical condition of the mirror and linkages. Rectify as
one or more Switch fault necessary. Check for DTCs indicating a switch, motor or circuit fault
directions Motor fault
Circuit fault:
high
resistance
Circuit fault:
short circuit
to ground
Memorized Battery Before condemning a memory component, check the function from the switch
mirror position voltage below and refer to the symptoms above. Make sure the battery voltage is adequate.
is not resumed 10.5 volts Make sure that the desired position is correctly stored. Make sure that the
Position not memory store/recall procedure is being followed. Refer to the relevant section
stored of the workshop manual
Switch
operated
during "one-
touch"
memory
recall
EEPROM fault
'Lazy entry' Remote Check that the remote transmitter operates the central locking, etc. If it does,
function transmitter the fault is not with the transmitter. Refer to symptom "mirror position is not
inoperative fault (battery, resumed" (above)
transmitter
programming,
etc)
See list for
"position is
not resumed"
DTC index
For a complete list of all diagnostic trouble codes (DTCs) that could be logged on this vehicle, please refer to Section
100-00. REFER to:
Diagnostic Trouble Code (DTC) Index - DTC: Driver/Passenger Door Module (100-00, Description and
Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Central Junction Box (CJB) (100-00 General Information,
Rear View Mirrors - Exterior Mirror
Removal
CAUTION: Take extra care not to damage the component.
NOTES:
2.
3. CAUTION: Make the components are aligned

as shown.
Torque: 9 Nm
4. CAUTION: Discard the seal.
Installation
1. CAUTIONS:
Make sure that the component is aligned and

attached as shown.
Install a new seal.
NOTE: Make sure that the adhesive strip is

removed before installation.
2. CAUTIONS:
Take extra care not to damage the seal.
Make sure that the component is aligned and

attached as shown.
Torque: 9 Nm

Rear View Mirrors - Exterior Mirror Glass
Removal
NOTES:
1. CAUTIONS:
Take extra care not to damage the

component.
Do not use tools during this operation,

removal of the component(s) must be carried out
by hand.
2.
Installation

Rear View Mirrors - Exterior Mirror Motor
Removal
NOTES:
1. Refer to: Exterior Mirror Glass (501-09 Rear View Mirrors,


component.
Torque: 1.2 Nm
Installation

Rear View Mirrors - Exterior Mirror Cover
Removal
CAUTION: Take extra care not to damage the edges of the component.
NOTES:
1. Refer to: Exterior Mirror Glass (501-09 Rear View Mirrors,

2.
3.
Installation

Rear View Mirrors - Interior Rear View Mirror
Removal
1.
2.
3.
4. NOTE: To install the rear view mirror, place in
the 4 or 8 o'clock position and rotate to the 6
o'clock position to lock.
Installation

Seating - Seats
For a detailed description of the seating systems and operation, refer to the relevant description and operation
section of the workshop manual. REFER to: Seats (501-10, Description and Operation).
the donor vehicle
NOTES:
If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to
the warranty policy and procedures manual (section B1.2), or determine if any prior approval programme is in
operation, prior to the installation of a new module/component
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests

Visual Inspection
Seat runners Battery condition and state of charge
Seat frames Fuses
Seat movement switch condition and installation Harnesses and connectors
Seat heater switch condition and installation Seat movement switch(es)
Seat motor(s) condition and installation Seat heater switch(es)
Seat heater elements
Seat motor(s)
Seat module(s)
Memory control module(s)
Ignition switch
LIN circuit
4. If the cause is not visually evident, verify the symptom and refer to the symptom chart, alternatively check
for diagnostic trouble codes (DTCs) and refer to the DTC Index.
Symptom Chart
Symptom Possible Causes Action

Front seat fore/aft movement not functioning Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test A.
Front seat excessive fore/aft free play Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test B.
Front seat fore/aft movement noisy Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test C.
Front seat height, tilt and/or seat extension motor Carry out the pinpoint test GO to Pinpoint
movement not functioning associated to this symptom Test D.
Front seat height, tilt and/or extension movement Carry out the pinpoint test GO to Pinpoint
noisy associated to this symptom Test E.
Heating And Cooling - Inoperative Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test F.
Heating And Cooling - Noisy operation Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test G.
Heating And Cooling - Poor heat or cool efficiency Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test H.
Heating And Cooling - Heat or cool operation slow Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test I.
Heating And Cooling - Intermittent operation Carry out the pinpoint test GO to Pinpoint
associated to this symptom Test J.
DTC Index
REFER to:
Diagnostic Trouble Code (DTC) Index - DTC: Driver/Passenger Seat Module (DSM/PSM) (100-00 General
Information, Description and Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Module Name: Seat Climate Control Module (100-00, Description
and Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Module Name: Automatic Temperature Control Module (100-00,
Pinpoint Tests
PINPOINT TEST A : FRONT SEAT FORE/AFT MOVEMENT NOT FUNCTIONING

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: CHECK FOR FRONT SEAT FORWARD-REARWARD SEAT MOTOR OPERATION
WARNING: Before work is carried out, make the air bag supplemental restraint system safe. For
additional information, refer to Standard Workshop Practices section of workshop manual
1Set ignition status to ' ON'

2From the switch pack, operate the front seat forward-rearward seat motor switch and listen for
evidence of the motor operating
Does the motor operate?
Yes
GO to A2.
No
GO to A3.
A2: CHECK FRONT SEAT FORWARD-REARWARD SEAT MOTOR DRIVE BAR
1 Check front seat drive bar for correct installation and condition
Is the front seat drive bar correctly installed and in a serviceable condition?
Yes
Re-check for correct front seat forward-rearward movement. Remove seat to allow for further
investigation if required
No
Correctly install front seat forward-rearward seat motor drive bar, or replace if required
A3: CHECK FRONT SEAT FORWARD-REARWARD SEAT MOTOR
WARNING: When carrying out the following steps, stand clear of all moving parts and ensure link harness is
routed accordingly
1 Set ignition status to 'OFF'
2 Disconnect front seat forward-rearward seat motor connector
NOTE: It may be that the seat has been driven to the limit of travel along the relevant axis,
and when the link harness is connected, the seat will remain in the same position. If this is the case,
a jolt may be felt from the motor. To confirm the motor operation, swap the link harness to alternate
motor pin connections and the seat should travel in the opposite direction
3 Using a locally made fused link harness and power supply, connect power and ground to
forward-rearward seat motor
Battery positive terminal Battery negative terminal

forward-rearward seat motor pin 1 forward-rearward seat motor pin 2
Yes
Using manufacturer approved diagnostic system, check for related(DTCs and carry out the repair
operations specified. Alternatively, refer to the electrical circuit diagrams and check front seat
forward-rearward seat motor circuits
No
Replace front seat forward-rearward seat motor. Refer to relevant section of workshop manual
PINPOINT TEST B : FRONT SEAT EXCESSIVE FORWARD-REARWARD FREE PLAY

CONDITIONS
B1: CHECK FRONT SEAT FOR EXCESSIVE FORWARD-REARWARD FREE PLAY
1 Check all accessible front seat frame fixings are installed and to the correct torque
Are all accessible front seat frame fixings installed and to the correct torque?
Yes
GO to B2.
No
Install and tighten all accessible front seat frame fixings to correct torque and re-check for
excessive free play
B2: COMPARE THE FRONT SEAT FORWARD-REARWARD FREE PLAY AGAINST A SIMILAR SEAT
1 Compare the front seat forward-rearward free play against a similar seat
Is the front seat forward-rearward free play excessive when compared to a similar seat?
Yes
GO to B3.
No
The front seat frame is operating correctly. Submit Electronic Product Quality Report (EPQR) with
any further query
B3: CHECK REMAINING FRONT SEAT FRAME FIXINGS
1 Remove front seat and/or any seat covers/trim to allow access to check remaining front seat
frame fixings are all installed and to the correct torque
Are all remaining front seat frame fixings installed and to the correct torque?
Yes
Replace front seat frame. Refer to the relevant section of the workshop manual
No
Install and tighten all remaining front seat frame fixings to correct torque and re-check for
excessive free play
PINPOINT TEST C : FRONT SEAT FORWARD-REARWARD MOVEMENT NOISY

CONDITIONS
C1: COMPARE FRONT SEAT FORWARD-REARWARD MOVEMENT NOISE TO OTHER FRONT SEAT
1 Compare the front seat forward-rearward movement noise to other front seat
Is the front seat forward-rearward movement noise excessive when compared to other front seat?
Yes
GO to C2.
No
GO to C3.
C2: COMPARE FRONT SEAT FORWARD-REARWARD MOVEMENT NOISE TO FRONT SEAT IN OTHER
VEHICLE
1 Compare the front seat forward-rearward movement noise to front seat in other vehicle
Is the front seat forward-rearward movement noise excessive when compared to front seat in other
vehicle?
Yes
GO to C3.
No
any further query
C3: CHECK FOR DEBRIS OBSTRUCTING SEAT MOVEMENT
1 Check for debris obstructing seat movement
Is the front seat forward-rearward movement obstructed by debris?
Yes
Remove obstruction and re-check for noisy forward-rearward seat movement
No
GO to C4.
C4: RE-ALIGN FRONT SEAT FRAME
1 Loosen front seat frame fixings
2 Set ignition status to 'ON'
3 Using the front seat switch pack drive the front seat fully forward then fully rearward
4 Tighten front seat frame fixings to the correct torque
5 Re-check for noisy seat movement
Is the front seat forward-rearward movement still noisy?
Yes
GO to C5.
No
The front seat frame is now operating correctly
C5: CHECK FRONT SEAT FORWARD-REARWARD SEAT MOTOR DRIVE BAR
1 Check front seat drive bar for correct installation and condition
Is the front seat drive bar correctly installed and in a serviceable condition?
Yes
Replace front seat forward-rearward seat motor. Refer to relevant section of workshop manual
No
Correctly install front seat forward-rearward seat motor drive bar, or replace if required
PINPOINT TEST D : FRONT SEAT HEIGHT, TILT AND/OR SEAT EXTENSION MOTOR MOVEMENT
NOT FUNCTIONING
CONDITIONS
D1: CHECK FRONT SEAT HEIGHT, TILT OR EXTENSION MOTOR
WARNINGS:
Before work is carried out, make the air bag supplemental restraint system safe. For additional information,
refer to Standard Workshop Practices section of workshop manual
When carrying out the following steps, stand clear of all moving parts and ensure link harness is routed
accordingly
1 Set ignition status to ' OFF'
2 Disconnect front seat height, tilt or extension motor connector
NOTE: It may be that the seat has been driven to the limit of travel along the relevant axis,
and when the link harness is connected, the seat will remain in the same position. If this is the case,
a jolt may be felt from the motor. To confirm the motor operation, swap the link harness to alternate
motor pin connections and the seat should travel in the opposite direction
3 Using a locally made fused link harness and power supply, connect power and ground to relevant
motor
Battery positive terminal Battery negative terminal

motor pin 1 motor pin 2
Yes
Using manufacturer approved diagnostic system, check for related DTCs and carry out the repair
operations specified. Alternatively, refer to the electrical circuit diagrams and check relevant
motor circuits
No
Replace the relevant motor. Refer to relevant section of workshop manual
PINPOINT TEST E : FRONT SEAT HEIGHT, TILT AND/OR EXTENSION MOVEMENT NOISY
CONDITIONS
E1: COMPARE THE HEIGHT, TILT OR EXTENSION MOVEMENT NOISE WITH THE OTHER FRONT SEAT
1 Compare the front seat movement noise to other front seat

Is the front seat height, tilt or extension movement noise excessive when compared to other front
seat?
Yes
GO to E2.
No
GO to E3.
E2: COMPARE FRONT SEAT HEIGHT, TILT OR EXTENSION MOVEMENT NOISE TO FRONT SEAT IN OTHER
VEHICLE
1 Compare the front seat height, tilt or extension movement noise to front seat in other vehicle
Is the front seat height, tilt or extension movement noise excessive when compared to front seat in
other vehicle?
Yes
GO to E3.
No
any further query
E3: CHECK FOR DEBRIS OBSTRUCTING SEAT MOVEMENT
1 Check for debris obstructing seat movement
Is the front seat height, tilt or extension movement obstructed by debris?
Yes
Remove obstruction and re-check for noisy height, tilt or extension seat movement. If still noisy
GO to Pinpoint Test G.
No
GO to E4.
E4: CHECK FOR HEIGHT, TILT OR EXTENSION MOVEMENT MECHANISM LUBRICATION
1 Check and apply manufacturer approved lubrication to seat height, tilt or extension movement
mechanism and retest for noise
Is the front seat height, tilt or extension noise still apparent?
Yes
Replace the relevant motor. Refer to relevant section of workshop manual
No
The front seat height, tilt or extension motor is operating correctly
PINPOINT TEST F : HEATER AND COOLING - INOPERATIVE
CONDITIONS
F1: CHECK FOR STORED DTC
1 Check the seat climate control module for stored DTCs
Are there any stored DTCs?
Yes
For information on stored DTCs refer to the information in the seat climate control module DTC
index.
No
GO to F2.
F2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
WARNING: Before work is carried out, make the air bag supplemental restraint system safe. For additional
information, refer to Standard Workshop Practices section of workshop manual
NOTES:
The climate controlled seat's (heat and cool) functions will only operate when the vehicle's engine is running
If a fault is identified and repaired, check for correct operation of the driver and front-passenger climate
controlled seat (heat and cool) functions
1 Check the heat and cool function of the backrest
Does the backrest heat and cool function operate correctly?
Yes
GO to F3.
No
GO to F5.
F3: DRIVER OR FRONT PASSENGER SEAT CUSHION CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
1 Check the heat and cool function at the cushion
Does the cushion heat and cool function operate correctly?
Yes
If there are no faults evident, verify the customer concern
No
GO to F4.
F4: CUSHION BELLOWS
1 Check the condition of the bellows
Are the bellows obstructed, have they collapsed?
Yes
Remove the obstruction or replace collapsed bellows
No
Suspect an internal fault with the climate controlled seat assembly. Replace as required
F5: BACKREST BELLOWS DUCT
1 Check the security of the bellows duct
Is the bellows duct correctly installed?
Yes
GO to F6.
No
Securely reconnect the bellows duct
F6: BACKREST BELLOWS
1 Check the security of the bellows
Yes
No
Suspect an internal fault with the climate controlled seat. Replace as required. Follow the link
below to check operation of the driver or front passenger seat cushion climate assemblyGO to
F2.
PINPOINT TEST G : HEATING AND COOLING - NOISY OPERATION

CONDITIONS
G1: CHECK FOR STORED DTC
Yes
index
No
GO to G2.
G2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - NOISE
NOTES:
1 There is a known issue which effects a limited number of vehicles where under acceleration of
the vehicle the occupant of seat can deform the suspension mat (snake wire) which then presses
on the casing of the seat backrest climate assembly, this causes the casing to distort and the
noise issue to occur. If contact has occurred there will be a witness mark on the casing. Carry
out visual inspection of the seat backrest climate assembly that has been identified as noisy by
the customer
Is there a witness mark on the casing?
Yes
Contact the local in market support for further information
No
GO to G3.
G3: DRIVER OR FRONT PASSENGER SEAT CLIMATE ASSEMBLY - NOISE 2
1 Operate the heat and cool function of the seat. Listen for a 'WAH WAH' noise (the fan speeds up
and slows down repeatedly)
Does the fan speeds up and slow down repeatedly?
Yes
Confirm the latest Strategy and Calibration software is installed, using the manufacturer
approved diagnostic system carry out the new seat climate control module application and
update the seat climate control module software if requiredIf the noise is still evident after
software update follow link belowGO to G4.
No
GO to G4.
G4: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - NOISE LEVEL COMPARISON
1 Compare the noise level of the suspect climate seat assembly to another climate seat assembly
Is the noise level equal between the two seats?
Yes
The noise level is standard and comparable to the design intent
No
PINPOINT TEST H : HEATING AND COOLING - POOR HEAT OR COOL EFFICIENCY

CONDITIONS
H1: CHECK FOR STORED DTC
Yes
index
No
GO to H2.
H2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
NOTES:
1 Check the heat and cool function of the backrest
Yes
GO to H3.
No
GO to H5.
H3: DRIVER OR FRONT PASSENGER SEAT CUSHION CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
Yes
No
GO to H4.
H4: CUSHION BELLOWS
Yes
No
GO to H7.
H5: BACKREST BELLOWS DUCT
Yes
GO to H6.
No
H6: BACKREST BELLOWS
Yes
No
Suspect an internal fault with the climate controlled seat assembly. Replace as required. Follow
the link below to check operation of the driver or front passenger seat cushion climate
assembly.GO to H2.
H7: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY -EFFICIENCY COMPARISON
1 Compare the efficiency of the suspect climate seat assembly to another climate seat assembly
Is the efficiency equal between the two seats?
Yes
The efficiency is standard and comparable to the design intent
No
PINPOINT TEST I : HEATING AND COOLING - HEAT OR COOL OPERATION SLOW

CONDITIONS
I1: CHECK FOR STORED DTC
Yes
index
No
GO to I2.
I2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
NOTES:
1 Check the heat and cool function of the backrest?
Yes
GO to I3.
No
GO to I5.
I3: DRIVER OR FRONT PASSENGER SEAT CUSHION CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
Yes
No
GO to I4.
I4: CUSHION BELLOWS
Yes
No
GO to I7.
I5: BACKREST BELLOWS DUCT
Yes
GO to I6.
No
I6: BACKREST BELLOWS
Yes
No
Suspect an internal fault with the climate controlled seat assembly. Replace as required. Follow
the link below to check operation of the driver or front passenger seat cushion climate
assemblyGO to I2.
I7: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - OPERATION COMPARISON
1 Compare the operation of the suspect climate seat assembly to another climate seat assembly
Is the operation equal between the two seats?
Yes
The operation is standard and comparable to the design intent
No
PINPOINT TEST J : HEATING AND COOLING - INTERMITTENT OPERATION

CONDITIONS
J1: CHECK FOR STORED DTC
Yes
index
No
GO to J2.
J2: CABLE CONNECTION CHECK
NOTES:
1 Identify from customer concern or stored DTCs which Seat Climate Assembly is operating
intermittently and confirm the harness connector is fully connected
Is the harness connector is fully connected?
Yes
No
Disconnect the harness connector, inspect connector and terminals for damage. Repair or
replace if required. Reconnect connector and check operation
Seating - Driver Seat Cushion Vehicles With: Power Seats
Removal
All vehicles
1. Refer to: Front Seat Cushion Cover - Vehicles With: Power
Seats (501-10 Seating, Removal and Installation).
2.
Vehicles with heated front seats

3.
Installation
Seating - Driver Seat Cushion Vehicles Without: Power Seats
Removal
NOTES:
1. Refer to: Front Seat - Vehicles Without: Power Seats (501-10

Seating, Removal and Installation).
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15. NOTE: Make sure that new hog rings are installed.
Installation
1. NOTES:
Make sure that new hog rings are installed.
Use hog ring pliers to close the hog rings. Do

not use any other tool. The hog rings must be
closed to overlap as illustrated.
2. NOTE: Make sure that the hogrings are installed in the

sequence shown.
Seating - Driver Seat Cushion Heater Mat
Removal
NOTES:

2.
Installation

Seating - Front Seat Vehicles With: Power Seats
Removal
WARNINGS:
To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before
repairing or replacing any air bag supplemental restraint system (SRS) components. To deplete the backup power
supply energy, disconnect the battery ground cable and wait one minute. Failure to follow this instruction may result
in personal injury.
Always wear safety glasses when working on an air bag equipped vehicle and when handling an air bag module.
Failure to follow this instruction may result in personal injury.
To minimize the possibility of premature deployment, do not use radio key code savers when working on the
supplemental restraint system. Failure to follow this instruction may result in personal injury.
To minimize the possibility of injury in the event of premature deployment, always carry a live air bag module
with the bag and trim cover pointed away from the body. Failure to follow this instruction may result in personal
injury.
To minimize the possibility of premature deployment, live air bag modules must only be placed on work benches
which have been ground bonded and with the trim cover facing up. Failure to follow these instructions may result in
personal injury.
Never probe the electrical connectors of air bag modules or any other supplemental restraint system component.
Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim
cover and air bags. Do not for any reason attempt to paint discolored or damaged air bag module trim covers or
instrument panel. Install a new component. Failure to follow this instruction may result in personal injury.
NOTES:

2.
3.
4. Torque: 40 Nm
5.
6. Torque: 40 Nm
7. Torque: 47 Nm
8.
9. Torque: 47 Nm
10. Reposition the front seat to the central position.

12.
13.
14.
15. WARNING: This step requires the aid of

another technician.
CAUTIONS:
Protect the surrounding paintwork to avoid

damage.
Protect the surrounding trim to avoid damage.
Installation

Seating - Front Seat Vehicles Without: Power Seats
Removal
WARNINGS:
in personal injury.
Always wear safety glasses when working on an air bag equipped vehicle and when handling an air bag
module. Failure to follow this instruction may result in personal injury.
injury.
To minimize the possibility of premature deployment, live air bag modules must only be placed on work
benches which have been ground bonded and with the trim cover facing up. Failure to follow these instructions may
result in personal injury.
Never probe the electrical connectors of air bag modules or any other supplemental restraint system
component. Failure to follow this instruction may result in personal injury.
NOTES:

2.
3.
4.
5. Torque: 40 Nm
6. Torque: 47 Nm
7.
8. Torque: 47 Nm

10.
11.
12. WARNING: This step requires the aid of
another technician.
CAUTIONS:

damage.
Protect the surrounding trim to avoid damage.
Installation

Seating - Front Seat Armrest
Removal
1. CAUTION: Care must be taken to avoid

damaging the surrounding components.
Torque: 25 Nm
Installation

Seating - Front Seat Backrest Blower Motor
Removal
1. Refer to: Front Seat - Vehicles With: Power Seats (501-10

2.
3. NOTE: Make sure that the clips are installed in

the correct orientation.
4.
5.
6.
7.
8.
9.
10.
Installation

Published: 22-Jan-2014
Seating - Front Seat Backrest Cushion Vehicles With: Power Seats
Removal
All vehicles
1. Refer to: Front Seat Cushion Cover (501-10A, Removal and
Installation).

2.
All vehicles
3.
Installation

Seating - Front Seat Backrest Cushion Vehicles Without: Power Seats
Removal
NOTES:
1. Refer to: Front Seat Backrest Cover - Vehicles Without: Power

2.
Installation

Seating - Front Seat Backrest Cover Vehicles With: Power Seats
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
NOTES:
1. Refer to: Front Seat Head Restraint - Vehicles With: Power Seats
(501-10 Seating, Removal and Installation).
2.
3.
4.

Torque: 25 Nm
6.
7.
8.
9.
10.
11.
12.
13.
14. Torque: 7 Nm
15.
16.
17. NOTES:
Repeat the procedure for the other side.

18.
19.
20.
21.
22.
Installation
1. NOTES:

not use any other tool. The hog rings must be closed
to overlap as illustrated.

sequence shown.

Seating - Front Seat Backrest Cover Vehicles Without: Power Seats
Removal
WARNINGS:
To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any air bag supplemental restraint
system (SRS) components. To deplete the backup power supply energy, disconnect the battery ground cable and wait one minute. Failure to follow this instruction may result in
personal injury.
Always wear safety glasses when working on an air bag equipped vehicle and when handling an air bag module. Failure to follow this instruction may result in personal
injury.
To minimize the possibility of premature deployment, do not use radio key code savers when working on the supplemental restraint system. Failure to follow this instruction
may result in personal injury.
To minimize the possibility of injury in the event of premature deployment, always carry a live air bag module with the bag and trim cover pointed away from the body.
To minimize the possibility of premature deployment, live air bag modules must only be placed on work benches which have been ground bonded and with the trim cover
facing up. Failure to follow these instructions may result in personal injury.
Never probe the electrical connectors of air bag modules or any other supplemental restraint system component. Failure to follow this instruction may result in personal
injury.
Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim cover and air bags. Do not for any reason attempt to paint
discolored or damaged air bag module trim covers or instrument panel. Install a new component. Failure to follow this instruction may result in personal injury.
NOTES:
1. Refer to: Front Seat - Vehicles Without: Power Seats (501-10 Seating, Removal and Installation).
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12. NOTE: Note the orientation of the clips.

13.
14. Torque: 7 Nm
15.
16.
17.
18.
19.
20.
Installation
1. NOTES:
Use hog ring pliers to close the hog rings. Do not use any other tool. The hog rings must be closed to
overlap as illustrated.
2. NOTE: Make sure that the hogrings are installed in the sequence shown.
Seating - Front Seat Backrest Heater Mat
Removal
WARNINGS:
in personal injury.
injury.

2. Refer to: Front Seat Head Restraint - Vehicles With: Power


Torque: 25 Nm
4. NOTE: Make sure that the clips are installed
in the correct orientation.
5.
6.
7.
8.
9.
10.
11. Torque: 7 Nm
12.
13.
14. NOTES:

15.
16.
17.
18.
19.
Installation

Seating - Front Seat Control Switch
Removal
1.
2. NOTE: Make sure that the clips are installed

in the correct orientation.

Installation

Seating - Front Seat Cushion Blower Motor
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
All vehicles
1.


5.

7.
8.
9.
10.
11.
12.
13.
NAS vehicles
14.
All vehicles
15.
16.
Installation

Seating - Front Seat Cushion Cover Vehicles With: Power Seats
Removal
NOTES:
1.

3.
4.


7.
8.
9.
10.
11.
12.
13.
14.
Installation
1. NOTES:


sequence shown.
Seating - Front Seat Cushion Cover Vehicles Without: Power Seats
Removal
NOTES:

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
17.
Installation
1. NOTES:


sequence shown.
Seating - Front Seat Head Restraint Vehicles With: Power Seats
Removal
NOTES:
1.

3.
4.
5.
6.
7.
8. CAUTION: Take extra care not to damage the wiring

harnesses.
10.
11.
12.
Installation

Seating - Front Seat Head Restraint Vehicles Without: Power Seats
Removal
NOTES:
1.
Installation

Seating - Front Seat Height Adjustment Motor
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
All vehicles


3.
5.
6.
7.
8.
9.
10. CAUTION: Make sure the component is aligned
as shown.
11.
12.
All vehicles
13.

component.
Torque: 35 Nm

correct.
Torque: 28 Nm
16. NOTES:
Use a suitable tool to remove the circlips from

the seat cushion frame bolts.
Note the orientation of the components.
Right-hand shown, left-hand similar.
17. NOTES:

Torque: 20 Nm
18.
19. NOTES:
Note the orientation of the components.
20.
21. Torque: 10 Nm
Installation

Seating - Front Seat Recliner Motor
Removal
WARNINGS:
in personal injury.
injury.

2. Refer to: Massaging Lumbar Assembly (501-10 Seating,

Refer to: Lumbar Assembly (501-10 Seating, Removal and
Installation).
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14. NOTE: Repeat the procedure for the other
side.
15.
16. Torque: 35 Nm
Installation

Seating - Front Seat Track Vehicles Without: Power Seats
Removal
NOTES:
The front seat runners are not serviceable. They are supplied as part of the front cushion frame assembly.
1. Refer to: Driver Seat Cushion - Vehicles Without: Power Seats

(501-10 Seating, Removal and Installation).
2.
3.
4.
5. Torque: 40 Nm
6.
7.
8. Torque: 9 Nm
9. CAUTION: Make sure the wiring harness and

electrical connectors are not damaged during this
operation.
Torque: 50 Nm
10.
Installation

Seating - Front Seat Track Motor
Removal
WARNINGS:
To avoid accidental deployment, the restraints control module backup power supply must be depleted. Wait at
least two minutes after disconnecting the battery ground cable(s) before commencing any repair or adjustment to
the supplemental restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these
instructions may result in personal injury.
injury.
NOTES:


3.
4.
5. Torque: 10 Nm
6. NOTE: Install the rear reatining bolt first.
Torque: 28 Nm
7. NOTE: Note the orientation of the electrical
connetor and wiring harness.
8. NOTE: Make a note of the orientation of the

front seat track motor drive pin bar.
Torque: 10 Nm
9. NOTE: Make a note of the orientation of the
electrical connector.
Torque: 1.7 Nm
Installation
1. CAUTIONS:
Make sure that the front seat track motor is

correctly installed to the front seat track.
Make sure that these components are

installed to the noted removal position.
Seating - Lumbar Assembly
Removal
WARNINGS:
in personal injury.
injury.
All vehicles

2. Refer to: Front Seat Head Restraint - Vehicles With: Power


Torque: 25 Nm
4.
5.
6.
7.
8.
9.
10.
11.
12.
13. Torque: 7 Nm
14.
15.
16. NOTES:
17.

18.
All vehicles
19.
20.
21.
22.
23.
24.
Installation

Seating - Massaging Lumbar Assembly
Removal
WARNINGS:
in personal injury.
injury.
All vehicles

Torque: 25 Nm
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13. Torque: 7 Nm
14.
15.
16. NOTES:
17.

18.
All vehicles
19.
20.
21.
22.
23.
24. NOTES:

25.
26.
Installation

Seating - Memory Seat Position Switch
Removal
2.
3.
4.
5.
6.
7.
Installation

Seating - Passenger Seat Cushion Vehicles With: Power Seats
Removal
NOTES:
All vehicles
2.

3.
All vehicles
4.
Installation
1. CAUTIONS:
Make sure the component is aligned as

shown.
Make sure that the mating faces are clean

and free of foreign material.
NOTES:

Install the occupant detection sensor with the
adhesive side facing the cushion.
2. CAUTION: Make sure the component is

aligned as shown.

Seating - Passenger Seat Cushion Vehicles Without: Power Seats
Removal
NOTES:

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
16.
Installation
1. CAUTIONS:
Make sure the component is aligned as shown.
Make sure that the mating faces are clean and

free of foreign material.
NOTES:


2. NOTES:


sequence shown.
Seating - Passenger Seat Cushion Heater Mat
Removal

2.
Installation

Seating - Rear Seat Armrest
Removal
1.
2.
3.
4. Torque: 10 Nm
5.
6.
7.
Installation

Seating - Rear Seat Backrest
Removal
All vehicles
1. Refer to: Rear Seat Backrest Cover (501-10 Seating, Removal
and Installation).
2.
Vehicles with heated rear seat

Installation

Seating - Rear Seat Backrest Blower Motor
Removal
1.
2.
3. Torque: 50 Nm
4.
5.
6. NOTE: LH shown.
Torque: 45 Nm
7. NOTE: LH shown.
8.
9.
10.
11. NOTE: LH shown.
12.
13.
14.
15.
16.
Installation

Seating - Rear Seat Backrest Cover
Removal
NOTES:
1.
2.
3.
4.
5. Torque: 50 Nm
6.
7.
8. Torque: 50 Nm
9.
10.
11. NOTE: LH shown.
Torque: 45 Nm
12. NOTE: LH shown.

13.
14.
15. CAUTION: Carefully release either side of the component to
avoid damage.
16. CAUTION: Care must be taken not to damage

the component.
17.
18.
19.
20.
21. NOTE: LH shown.

22.
Installation
1. NOTES:

2. NOTES:
Make sure that the hogrings are installed in the sequence

shown.

Seating - Rear Seat Backrest Heater Mat
Removal
1. Refer to: Rear Seat Backrest Cover (501-10 Seating, Removal

and Installation).

Installation

Seating - Rear Seat Control Switch
Removal
All vehicles
1.

2.
3.
All vehicles
4.
5. Torque: 50 Nm
6.
7.
8.
9.
Installation

Seating - Rear Seat Cushion
Removal
All vehicles
1. Refer to: Rear Seat Cushion Cover (501-10 Seating, Removal
and Installation).
2.

Installation

Seating - Rear Seat Cushion Blower Motor
Removal
1.
2.
3. Torque: 50 Nm
4.
5.
Installation

Seating - Rear Seat Cushion Cover
Removal
NOTES:
1.
2.
3.
4.
5.
Installation
1. NOTES:
Use hog ring pliers to close the hog rings. Do not use any other tool. The hog rings must be closed to
overlap as illustrated.
2. NOTES:
Make sure that the hogrings are installed in

the sequence shown.
Some variation in the illustrations may

correct.

Seating - Rear Seat Cushion Heater Mat
Removal
1. Refer to: Rear Seat Cushion Cover (501-10 Seating, Removal

and Installation).

Installation

Seating - Rear Seat Forward/Rearward Motor
Removal
1. Refer to: Rear Seat Massaging Lumbar Assembly (501-10

2. NOTES:
Make sure the wiring harness is routed

correctly.
Some variation in the illustrations may occur,

but the essential information is always correct.
Torque: 40 Nm
3.
4.
5.

correct.
correct.
8.
9.
10.
11. Torque: 5 Nm
12.
13.
Installation

Seating - Rear Seat Head Restraint Motor
Removal
1.
2. Refer to: Rear Seat Head Restraint - Vehicles With: Rear

Business Seats (501-10, Removal and Installation).
3.

correct.
5.
6.
7.
8.
9.
10.
11.
Installation

Seating - Rear Seat Lumbar Support
Removal
1.
2. NOTE: RH illustration shown, LH is similar.
3. Torque: 50 Nm
4.
5.
6. Torque: 45 Nm
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Installation

Seating - Rear Seat Massaging Lumbar Assembly
Removal
1. Refer to: Rear Seat Backrest Blower Motor - Vehicles With:

Rear Business Seats (501-10, Removal and Installation).
2.
3.
Installation

Seating - Rear Seat Recliner Motor
Removal
1. Refer to: Rear Seat Massaging Lumbar Assembly (501-10

2. NOTES:

correctly.
Some variation in the illustrations may occur,

but the essential information is always correct.
Torque: 40 Nm
3.
4.
5.

correct.
correct.
8.
9.
10.
11. Torque: 5 Nm
12.
13.
Installation

Seating - Seat Base
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
All vehicles


3.
5.
6.
7.
8.
9.
10.
11.
All vehicles
12.
13.
14.
15.
16.
17.
NAS vehicles
18. CAUTIONS:
Note the fitted position of the component prior

to removal.
It is essential that the sensor is installed in the

correct orientation as shown.
Torque: 5 Nm
19. CAUTIONS:
Note the fitted position of the component prior

to removal.
It is essential that the hose is installed in the

correct orientation as shown.
All vehicles
20.
21.
22.
23.
24. NOTE: Note the position of the wiring harnesses to aid
installation.

component.
Torque: 35 Nm
26.
27.
NAS vehicles
28. CAUTION: Note the fitted position of the

component prior to removal.
Torque: 5 Nm
All vehicles
29.
Installation
Seating - Third Row Seat Cushion Cover
Removal
NOTES:
1.
2.

4.
5. CAUTION: Carefully release either side of the

component to avoid damage.
Installation
2.
Seating - Third Row Seat Backrest Cover
Removal
NOTES:
1.

the component.
4.
5.
6. Torque: 25 Nm
7.
8.
9.

11. CAUTION: Using two 3mm Allen keys, release
the safety belt.

13. NOTE: Discard the retaining nuts.
Torque: 45 Nm
14.
Torque:
M10 47 Nm
M6 3 Nm
15. Torque: 47 Nm
CAUTION: Care must be taken to avoid damaging the

surrounding components.

18.
19.
20.
21.
22. Torque: 10 Nm
23.
25. NOTES:
Note the orientation of the component prior to

removal.
Torque: 40 Nm
26. NOTE: LH illustration shown, RH is similar.
Torque: 40 Nm
27. Torque: 3 Nm
28.
30. Torque: 2 Nm
Installation
1. CAUTION: Tighten the front retaining bolts first. Failure to

follow this instruction may result in misalignment or damage to
the seat seat mechanisms.

Seating - Third Row Seat Head Restraint Motor
Removal
NOTES:
1.
2.
3.
4.
5.

8.
9.
10.
11.
12. Torque: 10 Nm
Installation

Published: 13-Feb-2014
Seating - Third Row Seat
Removal
NOTES:
1.

the component.
4.
5.
6. Torque: 25 Nm
7.
8.
9. NOTE: Discard the retaining nuts.
Torque: 45 Nm
10.


14.
Torque:
M10 47 Nm
M6 3 Nm
15. Torque: 47 Nm
CAUTION: Care must be taken to avoid damaging the

surrounding components.
Installation
1. CAUTION: Tighten the front retaining bolts first. Failure to
follow this instruction may result in misalignment or damage to
the seat seat mechanisms.

Glass, Frames and Mechanisms - Glass, Frames and Mechanisms
COMPONENT LOCATION
Fixed Glass

1 - Heated front windshield
2 - Heated front windshield connectors
3 - Rear window
4 - Finisher
Door Glass and Mechanisms


1 - Front right Door Glass Regulator and motor
3 - Driver Door Module
4 - Rear right door switchpack
5 - Rear right Door Glass Regulator and motor
6 - Rear right door module
7 - Rear left door switchpack
8 - Rear left door module
9 - Rear left Door Glass Regulator and motor
11 - Front left Door Glass Regulator and motor
12 - Front left door switchpack
OVERVIEW
Door Mechanisms
Operation of the window lift system is controlled by the CJB (central junction box) in conjunction with the DDM and
the PDM. The door modules are mounted in the door of their respective windows. Door modules are also mounted in
both rear doors, and communicate with the front door modules over the LIN (local interconnect network) bus.
The window lift system features one shot up and down operation, plus an anti-trap feature for all door windows.
ONE-SHOT WINDOW OPERATION RESET

If the battery is disconnected or discharged, or the power supply to a door module is interrupted, one-shot window
operation is disabled until the window position is learned by the affected door module(s). The door glass must be
programmed for one-shot and global close operation. To reset one-shot window operation:
1. Close the window fully. Release the switch, then lift it to the close position and hold for 2 seconds.
2. Repeat this process a total of 5 times, then test the window to ensure one-shot up is enabled.
3. Repeat this process for each window.
NOTE: The door modules require a minimum of 12 volts to learn the windows, therefore it is advised to have
the engine running or an external power supply connected.
Fixed Glass
The laminated windshield is bonded and sealed to the body aperture using PU (polyurethane) adhesive.
The toughened rear window is also bonded and sealed to the tailgate aperture using PU adhesive. A single heating
element is printed on the inner surface of the rear window.
DESCRIPTION
Window Switches
Driver door switchpack
Passenger door switchpack
Individual window switches are installed in each of the three passenger doors. Window switches for all of the
windows and a rear window isolation switch are installed in the driver door switchpack in the top surface of the door
trim.
All window switches are of the non-latching rocker type. The switches have two switching positions in each direction,
inch up/down and one-shot up/down. Operating the switch to the second detent position will activate the one-shot
feature.
The driver door switchpack is powered by a permanent battery feed from the CJB. When the switches in the driver
door switchpack are used, the switchpack translates the switch movement into a LIN (local interconnect network) bus
message. A LIN bus connects the driver door switchpack to the DDM and the driver side rear door module. Each
passenger window switch is hardwired into circuits with the related door module.
DOOR MODULES


2 - Right rear door module
3 - Left rear door module
In addition to controlling the window lift system, the front door modules also control:
Door locking.
For additional information, refer to: Handles, Locks, Latches and Entry Systems (501-14 Handles, Locks,
Latches and Entry Systems, Description and Operation).
Door mirror adjustment and heating.
For additional information, refer to: Rear View Mirrors (501-09 Rear View Mirrors, Description and Operation).
Door mirror lamps.
Mirror proximity cameras
For additional information, refer to: Parking Aid (413-13 Parking Aid, Description and Operation).
The rear door modules control window lift and door locking only.
The door modules are color coded for position on the vehicle. The DDM and both rear door modules are black. The
PDM is gray. The electrical wiring harness connectors are also color coded to match the door modules.
NOTE: Both rear door modules are identical.
If a front door module develops a fault, a DTC (diagnostic trouble code) is stored in its memory, DTC's can be read
using the Land Rover approved diagnostic equipment. If either of the rear door modules develops a fault, the DTC is
stored in the respective front door module.
Door Glass Regulator
Front Door Glass Regulator


1 - Door glass
2 - Door glass regulator motor
3 - Mounting frame
4 - Glass carrier
The front door glass regulator and motor are supplied as an assembly and are handed. Each assembly comprises a
front and rear runner, a continuous cable and a motor.
The runners are secured in the door frame with five bolts, the fifth bolt is in the motor drum housing. The door glass
is located in two carriers, which are located in tracks in the runners. The glass is retained in friction pads in each
carrier and secured with clamps.
Each carrier is attached to the cable which, in turn, is attached to a drum driven by the motor. When the motor is
operated the drum pulls the cable in the required direction to raise or lower the glass.
Rear Door Glass Regulators


1 - Door glass
2 - Glass carrier
3 - Door glass regulator motor
4 - Mounting frame
The Door glass regulator and motor are supplied as an assembly and are handed. Each assembly comprises a front
and rear runner, a continuous cable and a motor.
The runners are secured in the door frame with five bolts, the fifth bolt is in the motor drum housing. The door glass
is located in two carriers, which are located in tracks in the runners. The glass is retained in friction pads in each
carrier and secured with clamps.
Each carrier is attached to the cable which, in turn, is attached to a drum driven by the motor. When the motor is
operated the drum pulls the cable in the required direction to raise or lower the glass.
OPERATION
The electric door glasses will operate in power modes 6 (ignition on) and 7 (engine running), and for five minutes
after the ignition is switched off provided none of the doors are opened.
When a door glass open or closed selection is made, the related door module supplies power to the door glass
regulator motor to drive it in the appropriate direction. In the inch mode, the motor stops when the switch is
released or the door glass reaches the end of its travel. In the one-shot mode, the motor stops when if the switch is
operated again (either up or down) or the door glass reaches the end of its travel.
When the passenger door glass switches are used, they produce an open or close request by completing a circuit
with the related door module.
When the driver door switches are used, the driver door switchpack outputs a request message for the appropriate
door module on the LIN bus. If the message is for a door module on the opposite side of the vehicle to the driver,
the DDM relays the message to the PDM on the medium speed CAN (controller area network) bus. If necessary, the
PDM then sends a LIN bus message to the RDM on its side of the vehicle
If any of the passenger door glasses have opposing up and down requests from two separate switches, for example,
a passenger door switch and the related switch on the driver door switchpack, then the operation of that door glass
will cease, until one or both of the switches are released.
When the rear door glass isolator switch engaged, the switch tell-tale is illuminated and the rear door modules ignore
requests from their related passenger door switches.
Global opening and closing requests are output from the CJB on the medium speed CAN bus. The DDM and the PDM
then relay the request to their respective RDM.
One-shot Door Glass Operation Reset
If the battery is disconnected or discharged, or the power supply to a door module is interrupted, one-shot window
operation is disabled until the window position is learned by the affected door module(s). The door glass must be
programmed for one-shot and global close operation. To reset one-shot window operation:
1. Close the window fully. Release the switch, then lift it to the close position and hold for 2 seconds.
2. Repeat this process a total of 5 times, then test the window to ensure one-shot up is enabled.
3. Repeat this process for each window.
NOTE: The door modules require a minimum of 12 volts to learn the windows, therefore it is advised to have
the engine running or an external power supply connected.
ANTI-TRAP PROTECTION
The anti-trap feature is incorporated for the door glass in both the inching and one-shot modes. If the anti-trap
function is activated while a window is closing, the window will reverse by approximately 200 mm.
Each window motor has two Hall sensors to enable the related door module to monitor the motor speed. If the
motor speed decreases below a set threshold, indicating an obstruction, the power feed to the motor is reversed so
the window goes back down.
If it is still necessary to raise the window, the anti-trap protection can be overridden by attempting to close the
window at intervals of less than 10 seconds. On the third attempt the window will move up with anti-trap protection
disabled to overcome the obstruction.
Control Diagram
NOTE: A = Hardwired, AO= Medium speed Body CAN bus


1 - Battery
3 - Rear right door glass regulator motor
4 - Driver door glass regulator motor
5 - Rear door switch
6 - DDM
8 - PDM
10 - Rear door window lift switch
11 - Rear left door glass regulator motor
12 - Passenger door glass regulator motor
13 - Passenger door switch
14 - CJB
15 - BJB
16 - BJB2
Glass, Frames and Mechanisms - Glass, Frames and Mechanisms
For a detailed description of the glass, frames and mechanisms and operation, refer to the relevant Description and
Operation section of the workshop manual. REFER to: Glass, Frames and Mechanisms (501-11 Glass, Frames and
Mechanisms, Description and Operation).
the donor vehicle
NOTES:

Visual Inspection
Door switchpacks condition and installation Fuses
Door window motors/regulators Harnesses and connectors
Door window channels/runners Door window lift relay
Door window cables Door switchpacks
Door window motors
Symptom Chart

Door Fuse(s) Check the fuses. Check the suspect door window operation from the
window(s) Door individual door switchpack and from the driver door switchpack (it is
inoperative switchpack unlikely that both door switchpacks would fail at the same time, so if the
fault door window is inoperative from either door switchpack, suspect a fault
Isolator switch other than a door switchpack)
fault If the inoperative door window is a rear unit, check the function of the
Door window isolator switch at the driver door switchpack
motor/regulator If the concern persists and a noise cannot be heard when operating the
fault door window, GO to Pinpoint Test B.
Door window If the concern persists and a noise can be heard when operating the door
channel/runner window, GO to Pinpoint Test C.
fault
Door window
cable fault
Wiring harness
fault
Door Door window

window(s) regulator motor NOTE: Do not install a new door window regulator motor for this concern
'one-shot' initialization
function required If the battery has been disconnected, carry out the initialization procedure.
inoperative Door REFER to: Door Window Motor Initialization (501-11 Glass, Frames and
switchpack Mechanisms, General Procedures).
fault Check the door switchpack function after initialization
Door Door window GO to Pinpoint Test A.

window(s) channel/runner
noisy during fault
operation Door window
cable fault
Door window
motor/regulator
fault
Incorrect
adjustment of
door window
Rear Fuse Check fuse. Check the operation of the heated rear window switch and relay.
window Switch fault Check the element for continuity. Check the heated rear window circuit. Refer to
does not Relay fault the electrical guides
defrost Element fault
Circuit fault
Slow or Fuse GO to Pinpoint Test D.

partial door Switch fault
window Relay fault
operation Element fault
Circuit fault
Wind noise Incorrect GO to Pinpoint Test E.

between the adjustment of
door door window
window and Door window
seal channel/runner
fault
Door window
cable fault
Door window
motor/regulator
fault
Rear door Door window

window motor NOTE: Do not install a new door window regulator motor for this concern
bounce initialization
back required (using Refer to IDS/SDD.
IDS/SDD)
Front door Door window

window motor NOTE: Do not install a new door window regulator motor for this concern
bounce initialization
back required GO to Pinpoint Test F.
Door window
channel/runner
fault
DTC Index
REFER to: (100-00 General Information)
Diagnostic Trouble Code (DTC) Index - DTC: Driver/Passenger Door Module (DDM/PDM) (Description and
Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Central Junction Box (CJB) (Description and Operation).
Pinpoint Test
PINPOINT TEST A : WINDOW(S) NOISY DURING OPERATION

CONDITIONS
A1: CHECK THE DOOR WINDOW IS SECURE
1 Remove the door window outer waist seal
2 Check if the door window is installed correctly and secured to the door window regulator
Is the door window correctly installed and secure?
Yes
GO to A2.
No
Make sure that the door window retaining bracket(s) are secured to the door window (bonded),
if damaged, install a new door window as necessary. REFER to: (501-11 Glass, Frames and
Mechanisms)
Front Door Window Glass (Removal and Installation),
Rear Door Window Glass (Removal and Installation).
If the door window retaining bracket(s) are OK, adjust the door window referring to the door
window setting procedure in this procedure
A2: CHECK THE OPERATION OF THE DOOR WINDOW REGULATOR MOTOR
1 Remove the door window as necessary. REFER to: (501-11 Glass, Frames and Mechanisms)
2 Operate the door window regulator four times
Does the door window regulator operate correctly (without noise)?
Yes
Remove any foreign material from door window regulator and lubricate the window runners. Test
the system for normal operation. If the concern persists, GO to A3.
No
Install a new door window regulator as necessary. REFER to: (501-11 Glass, Frames and
Mechanisms)
Front Door Window Regulator (Removal and Installation),
Rear Door Window Regulator Motor (Removal and Installation).
A3: CHECK THAT THE DOOR WINDOW SEAL IS FREE FROM FOREIGN MATERIAL
1 Check for any foreign material or obstruction in the door window seal
Is the door window seal free from foreign material?
Yes
GO to A4.
No
Remove any foreign material from door window seal and lubricate the seal. Test the system for
normal operation
A4: CHECK THAT THE DOOR WINDOW SEAL IS INSTALLED CORRECTLY
1 Check that the door window seal is installed correctly
Is the door window seal installed correctly?
Yes
GO to A5.
No
Install the door window seal correctly. Test the system for normal operation
A5: CHECK THAT THE DOOR WINDOW SEAL IS NOT WORN IN THE CHANNELS
1 Visually check that the door window seal is not worn in the door channels
Is the door window seal worn in the channels?
Yes
Install a new door window seal as necessary. Test the system for normal operation
No
Install the door window. Adjust the door window referring to the door window setting procedure
in this procedure
PINPOINT TEST B : WINDOW(S) INOPERATIVE (MOTOR NOISE CANNOT BE HEARD)

CONDITIONS
B1: CHECK FOR DOOR WINDOW REGULATOR MOTOR NOISE
1 Operate the door window regulator motor as necessary
Is there a noise from the door window regulator motor when operated?
Yes
GO to B3.
No
GO to B2.
B2: CHECK THE VOLTAGE TO THE DOOR WINDOW REGULATOR MOTOR
1 Using a multimeter, check the voltage to the door window regulator motor
Is the voltage greater than 10 volts?
Yes
Install a new door window regulator motor as necessary. REFER to: (501-11 Glass, Frames and
Mechanisms)
No
Repair the wiring harness. Test the system for normal operation
B3: CHECK THAT THE DOOR WINDOW SEAL IS FREE FROM FOREIGN MATERIAL
Yes
GO to B4.
No
normal operation
B4: CHECK THAT THE DOOR WINDOW SEAL IS INSTALLED CORRECTLY
Yes
GO to B5.
No
B5: CHECK THAT THE DOOR WINDOW SEAL IS NOT WORN IN THE CHANNELS
Yes
Install a new door window seal as necessary. Adjust the door window referring to the door
window setting procedure in this procedure. Test the system for normal operation
No
Adjust the door window referring to the door window setting procedure in this procedure
PINPOINT TEST C : WINDOW(S) INOPERATIVE (MOTOR NOISE CAN BE HEARD)
CONDITIONS
C1: CHECK THE DOOR WINDOW IS SECURE
2 Check if the door window installed correctly and secured to the door window regulator
Yes
GO to C2.
No
Install a new door window as necessary. REFER to: (501-11 Glass, Frames and Mechanisms)
C2: CHECK THE DOOR WINDOW REGULATOR INTEGRITY
1 Visually inspect the cables, rollers and rail sliders for foreign material
Are the cables, rollers and rail sliders free from foreign material?
Yes
GO to C3.
No
Remove any foreign material. Test the system for normal operation. If the concern persists,
install a new door window regulator as necessary. REFER to: (501-11 Glass, Frames and
Mechanisms)
C3: CHECK THAT THE DOOR WINDOW SEAL IS FREE FROM FOREIGN MATERIAL
Yes
GO to C4.
No
normal operation
C4: CHECK THAT THE DOOR WINDOW SEAL IS INSTALLED CORRECTLY
Yes
GO to C5.
No
C5: CHECK THAT THE DOOR WINDOW SEAL IS NOT WORN IN THE CHANNELS
Yes
No
Adjust the door window referring to the door setting procedure in this procedure
PINPOINT TEST D : SLOW OR PARTIAL WINDOW OPERATION

CONDITIONS
D1: CHECK THE DOOR WINDOW IS SECURE
Yes
GO to D2.
No
Install a new door window as necessary. REFER to: (501-11 Glass, Frames and Mechanisms)
D2: CHECK THE OPERATION OF THE DOOR WINDOW REGULATOR
1 Remove the door window as necessary REFER to: (501-11 Glass, Frames and Mechanisms)
2 Operate the door window regulator as necessary
Does the door window regulator operate correctly?
Yes
GO to D3.
No
GO to D6.
D3: CHECK THAT THE DOOR WINDOW SEAL IS FREE FROM FOREIGN MATERIAL
Yes
GO to D4.
No
normal operation
D4: CHECK THAT THE DOOR WINDOW SEAL IS INSTALLED CORRECTLY
Yes
GO to D5.
No
D5: CHECK THAT THE DOOR WINDOW SEAL IS NOT WORN IN THE CHANNELS
Yes
No
Install the door window. Adjust the door window referring to the door window setting procedure
in this procedure. Test the system for normal operation
D6: CHECK THE DOOR WINDOW REGULATOR MOTOR INTEGRITY
Yes
GO to D7.
No
Mechanisms)
D7: CHECK THE VOLTAGE TO THE DOOR WINDOW REGULATOR MOTOR
Yes
Install a new door window regulator as necessary. REFER to: (501-11 Glass, Frames and
Mechanisms)
No
Repair the wiring harness. Test the system for normal operation. If the concern continues, install
a new door window regulator as necessary. REFER to: (501-11 Glass, Frames and Mechanisms)
PINPOINT TEST E : WIND NOISE BETWEEN THE DOOR WINDOW AND SEAL
CONDITIONS
E1: CHECK THAT THE DOOR WINDOW SEAL IS FREE FROM FOREIGN MATERIAL
Yes
GO to E2.
No
normal operation
E2: CHECK THAT THE DOOR WINDOW SEAL IS INSTALLED CORRECTLY
Yes
GO to E3.
No
E3: CHECK THAT THE DOOR WINDOW SEAL IS NOT WORN IN THE CHANNELS
Yes
No
GO to E4.
E4: CHECK THE DOOR WINDOW REGULATOR INTEGRITY
Yes
GO to E5.
No
Mechanisms)
E5: CHECK THE VOLTAGE TO THE DOOR WINDOW REGULATOR MOTOR
Yes
Adjust the door window referring to the door window setting procedure in this procedure
No
Repair the wiring harness. Test the system for normal operation
PINPOINT TEST F : FRONT DOOR WINDOW BOUNCE BACK

CONDITIONS
F1: CHECK WINDOW MOTOR INITIALIZATION
1 Initialize the door window motor.
REFER to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General
Procedures).
Did the initialization work?
Yes
Test the system for normal operation
No
GO to F2.
F2: CHECK THAT THE DOOR WINDOW SEAL IS FREE FROM FOREIGN MATERIAL
Yes
GO to F3.
No
normal operation.
F3: CHECK THAT THE DOOR WINDOW SEAL IS INSTALLED CORRECTLY
Yes
GO to F4.
No
F4: CHECK THAT THE DOOR WINDOW SEAL IS NOT WORN IN THE CHANNELS
Yes
No
GO to F5.
F5: CHECK THE DOOR WINDOW IS SECURE
Yes
Test the system for normal operation
No
Adjust the door window referring to the door window setting procedure in this procedure. Test
the system for normal operation. If the concern persists, install a new door window regulator as
necessary.
REFER to: Front Door Window Regulator (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
Door window setting procedure
NOTE: Make sure that this procedure is carried out if any concern is with noise or if directed by a pinpoint test
1. Remove the door trim panel as necessary. REFER to: (501-05 Interior Trim and Ornamentation)
Front Door Trim Panel (Removal and Installation),
Rear Door Trim Panel (Removal and Installation).
2. Release but do not remove the door window retaining clip(s) bolt(s)
3. Operate the window switch up and down seven times to make sure that the door window is correctly installed
to the door window seal
4. NOTE: Make sure that the retaining clips are installed as illustrated
Install the door window to the retaining clips, first to the front retaining clip and then to the rear
5. Push the door window to the rear of the door to make sure correct installation in to the door window seal
6. NOTE: Tighten the rear retaining clip bolt first then the front bolt
Tighten the door window retaining clip bolts to 10 Nm
7. NOTE: Make sure that there is a minimum of 5mm engagement of the door window to the rear door
channel when the door window is fully closed
Check the system for normal operation

Glass, Frames and Mechanisms - Fixed Window Glass
Principles of Operation
For a detailed description of the Glass, Frames and Mechanisms and operation, refer to the relevant Description and
Operation section of the workshop manual.
NOTES:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
Refer to Section 100-00 General Information for window glass health and safety precautions.
1. Verify the customer concern.
2. Visually inspect for obvious mechanical faults.

Visual Inspection
Mechanical
Physical damage to the windshield
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Warranty Repairs
NOTES:
The warranty period for the windshield is twelve months with the exception of delamination and electrical
faults.
Warranty repairs should be completed using genuine parts, in accordance with the Warranty Policy and
Procedures Manual.
1. Draw a line around the windshield damage using a marker pen.
2. Photograph the entire windshield. If the damage extends behind any trim, remove the trim and take further
photographs.
3. Photograph the trademark logo and code to validate the windshield as factory fitment.
Symptom Chart
Symptom Possible Cause Action

Scratches Debris trapped under a wiper blade GO to Pinpoint Test A.
Foreign object damage
Fouling by trim
Chips Foreign object damage GO to Pinpoint Test B.
Cracks Foreign object damage GO to Pinpoint Test C.

Impact damage during assembly
Delamination Manufacturing defect GO to Pinpoint Test D.
PINPOINT TEST A : SCRATCH TEST

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: IDENTIFY SCRATCH
NOTE: A scratch will usually be regular in shape, following the line of the object that caused it.
1 Probe using the tip of a pencil to identify a groove in the windshield surface.
Is there a groove?
Yes
Windshield scratched. GO to A2.
No
Defect not valid.
A2: CAUSE OF SCRATCH
1 Check for trim, body panels, or foreign objects that may have caused the scratch.
Was the scratch caused by a foreign object?
Yes
The damage is not due to a defect or an assembly error.
No
Rectify as appropriate.
PINPOINT TEST B : CHIP TEST

B1: CHIP TEST
NOTE: Impact damage may cause a crack to form.

1 Assess the damage by probing with the tip of a pencil.
Is the damaged area rough (indicating a breach of the windshield surface)?
Yes
Damage caused by the impact of a foreign object. Not a manufacturing defect.
No
Install a new windshield.
PINPOINT TEST C : CRACK TEST

C1: IDENTIFY CRACK
NOTE: A crack will be detectable as a step in the glass.
1 Confirm the presence of a crack by probing with the tip of a pencil.

Is the windshield cracked?
Yes
Windshield cracked. GO to C2.
No
Windshield not cracked. GO to Pinpoint Test A.
C2: CAUSE OF CRACK
NOTE: Multiple cracks will radiate out from the source.

1 Assess the source of the crack by probing with the tip of a pencil.
Is there evidence of impact damage being the source of the crack?
Yes
GO to Pinpoint Test B.
No
PINPOINT TEST D : DELAMINATION TEST

D1: DELAMINATION TEST
1 Visually assess the windshield for delamination.
Have the glass laminates separated?

Yes
No
No further action.
DTC Index
For a complete list of all Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to
Section 100-00.
Glass, Frames and Mechanisms - Door Window Motor Initialization
General Procedures
1. NOTES:
After the battery has been disconnected it is necessary to

initialize each door window motor separately to operate the
"one-touch" up function.
Make sure a minimum of 2 minutes from initial disconnect

of battery has elapse prior to reconnecting the battery. The
initialising of the window glass motor must be conducted with
the engine running.
Operate the window control switch until the door window glass
is in the fully closed position, continue to operate the window
control switch for a further two seconds.
2. Release the window control switch.
3. Operate the window control switch in the closed position and

continue to operate the window control switch for a further two
seconds.
4. Operate the window control switch until the door window glass
is in the fully open position ("one-touch" down).
5. NOTES:
If the door window motor initialization has been completed

correctly, when the window control switch is operated, the door
window glass should move to the fully closed position ("one-
touch" up) automatically.
If the door window glass does not fully close automatically

("one-touch" up), repeat the complete procedure.
Operate the window control switch once to the close position.
6. Repeat the door window motor initialization for each door

window motor.
Glass, Frames and Mechanisms - Driver Door Window Control Switch
Removal
NOTES:
LHD illustration shown, RHD is similar.
The ignition must be switched off.
2.
3.
Installation

Glass, Frames and Mechanisms - Front Door Window Regulator
Removal
WARNING: To avoid accidental deployment, the restraints control module backup power supply must be
depleted. Wait at least two minutes after disconnecting the battery ground cable(s) before commencing any repair or
adjustment to the supplemental restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to
follow these instructions may result in personal injury.
1.

4.
5. CAUTION: Inspect the regulator cable clips for
signs of damage. Renew if necessary.

retaining clips.
NOTE: Some variation in the illustrations may

correct.
Raise the glass and secure it at the top of the

door frame.
Secure with adhesive tape.
7. Torque: 8 Nm
Installation
1. NOTE: An audible click is heard when the clips are fully

latched.
To install, reverse the removal procedure.

Glass, Frames and Mechanisms - Front Door Window Glass
Special Tool(s)
501-114
Release Lever, Door Glass
Removal
NOTES:
1. Refer to: Exterior Mirror (501-09 Rear View Mirrors, Removal

and Installation).
2. CAUTION: Care must be taken not to damage the

component.
3.
retaining clips.
Special Tool(s): 501-114
5.
Installation

latched.

Glass, Frames and Mechanisms - Front Glass Roof Panel
Removal
1. Operate the opening roof panel fully rearwards.
2. Refer to: Air Deflector (501-17 Roof Opening Panel, Removal and
Installation).
3. Remove the glass panel rear seal.
4. CAUTION: Use suitable tape to protect the roof opening

panel weather strip.
5. CAUTION: A metal strip should be installed between the
bottom of the blade and the taped-down components. This will
reduce friction and allow the blade to cut easier.
Cut the sealant in the area shown, use a WK1S blade, and
set the controller arm set to a 110mm cut depth.
6.
Installation
1. NOTE: Remove the tape.
2. CAUTIONS:
Make sure that the mating faces are clean and free of
foreign material.
Correct preparation of body apertures “post painting” to

ensure satisfactory glass adhesion, must be carried out in line
with industry practise.
Prepare the window glass, window glass flange and

trimmed PU adhesive in accordance with the instructions
included with the PU adhesive kit.
3. CAUTION: Touching the adhesive surface will impair

rebonding.
NOTE: Install new spacers.
4.
Make sure the component is aligned with the
measurements taken prior to removal. Failure to follow
this instruction may result in damage to the glass panels
during operation of the roof opening panel.
Use suitable weights or straps, apply a downward pressure
to the glass to achieve the correct curvature of the glass.
Allow up to 1 hour, depending on temperature and
humidity, to allow the adhesive to set before continuing
with the procedure.
5.
6. NOTE: With the roof opening panel closed, check the

alignment of the glass to the roof panel. The glass should be
central in its aperture. Profile of rear glass panel to body: front
edge, set flush or up to 1.0 mm (0.040") low; rear edge, set
flush or up to 1.0 mm (0.040") high.
7. CAUTION: Make sure that no excess sealant residue is
evident.
If water is used as a means for the leak check, then allow

sealant to dry before testing.
Spray water around the windshield glass, mark any area
that leaks. Dry the windshield glass and sealant before
applying additional sealant.
Glass, Frames and Mechanisms - Liftgate Window Glass
Removal
1. Refer to: Rear Window Wiper Pivot Arm (501-16 Wipers and

sides.
3. CAUTIONS:
Protect the surrounding components.

damage.
Use a glazing cutting wire to cut the sealant.
4.
Installation
1. CAUTIONS:

Correct preparation of body apertures “post

painting” to ensure satisfactory glass adhesion,
must be carried out in line with industry practise.
2. NOTE: Make sure that a Hi-modulus sealer

(for example, Wurth Ultimate adhesive) is used
when bonding the component to the vehicle.

trimmed PU adhesive in accordance with the
instructions included with the PU adhesive kit.
3.
4. Test the sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around the glass and
check for leaks. Mark any area that leaks. Dry the
glass and sealer then apply additional sealer.

Glass, Frames and Mechanisms - Passenger Door Window Control Switch
Removal
NOTES:

components.
2. Torque: 1.5 Nm
3.
4.
5.
6.
7.
8.
Installation

Glass, Frames and Mechanisms - Rear Door Window Glass
Removal
1. Refer to: Rear Door Window Regulator Motor (501-11 Glass,

Frames and Mechanisms, Removal and Installation).
2.
Lower the rear door glass to the bottom of
the door.
4.
5.
6.
component.
8. Torque: 1.2 Nm
9.
Installation

Glass, Frames and Mechanisms - Rear Door Window Regulator Motor
Removal
WARNING: To avoid accidental deployment, the restraints control module backup power supply must be
depleted. Wait at least two minutes after disconnecting the battery ground cable(s) before commencing any repair or
adjustment to the supplemental restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure
to follow these instructions may result in personal injury.
1.

4.
5. CAUTION: Inspect the regulator cable clips for

signs of damage. Renew if necessary.
retaining clips.
Raise the glass and secure it at the top of

the door frame.
7. Torque: 8 Nm
Installation

latched.
Glass, Frames and Mechanisms - Rear Glass Roof Panel
Removal
3. NOTE: The procedure must be carried out on both sides.
Refer to: Roof Opening Panel Blind (501-17 Roof Opening Panel, Removal and
Installation).
4. CAUTION: A metal strip should be installed between the bottom of the blade and the
taped-down components. This will reduce friction and allow the blade to cut easier.
Cut the sealant in the area shown, use a WK1S blade, and set the controller arm
set to a 40mm cut depth.
5. CAUTION: Protect the surrounding paintwork and body from the

movement of the cutting blades, using WK11PP.
Cut the sealant in the area shown, use a WK1S blade.
6. CAUTION:
A metal strip
should be
installed
between the
bottom of the
blade and the
taped-down
components.
This will reduce
friction and
allow the blade
to cut easier.
Cut the
sealant
in the
area
shown,
use a
WK1S
blade,
and set
the
controller
arm set
to a
70mm
cut
depth.
7. CAUTION: A metal strip should be installed between the bottom of the
blade and the taped-down components. This will reduce friction and allow
the blade to cut easier.
8.
Cut the
sealant
in the
area
shown,
use a
WK1S
blade.
9.
Cut the
sealant
in the
area
shown,
use a
WK1S
blade.
Cut the
sealant
in the
area
shown,
use a
WK1S
blade,
and set
the
controller
arm set
to a
200mm
cut
depth.
10. CAUTION: A metal strip should be installed between the bottom of the
blade and the taped-down components. This will reduce friction and allow
the blade to cut easier.
11. CAUTION:
A metal strip
should be
installed
between the
bottom of the
blade and the
taped-down
components.
This will reduce
friction and
allow the blade
to cut easier.
Cut the
sealant
in the
area
shown,
use a
WK1S
blade,
and set
the
controller
arm set
to a
70mm
cut
depth.
12.
Installation
1. CAUTIONS:
Make sure that the mating faces are clean and free of foreign material.
Correct preparation of body apertures “post painting” to ensure satisfactory glass

adhesion, must be carried out in line with industry practise.
Using a suitable spirit wipe clean the component surfaces.

3. CAUTIONS:
Make sure that the mating faces are clean and free of foreign material.

4. NOTE: Make sure that the sealant follows the orientation and dimensions as
illustrated to allow correct installation of the component.
Prepare the window glass, window glass flange and trimmed PU adhesive in accordance
with the instructions included with the PU adhesive kit.
5. CAUTION: Touching the adhesive surface will impair rebonding.
Apply the sealant with the indicated bead dimensions.

6.
Make sure the component is aligned with the measurements taken prior to
removal. Failure to follow this instruction may result in damage to the glass panels
during operation of the roof opening panel.
Apply a downward pressure to the glass to achieve the correct glass position.
Refer to step 6.
Allow up to 1 hour, depending on temperature and humidity, to allow the adhesive
to set before continuing with the procedure.
7. NOTE: With the roof opening panel closed, check the alignment of the glass to the
roof panel. The glass should be central in its aperture. Profile of rear glass panel to body:
front edge, set flush or up to 1.0 mm (0.040") low; rear edge, set flush or up to 2.0 mm
(0.080") high.
9. Refer to: Roof Opening Panel Blind (501-17 Roof Opening Panel, Removal and
Installation).
Glass, Frames and Mechanisms - Rear Quarter Window Glass
Removal

3. Refer to: Rear Quarter Panel Moulding (501-08 Exterior Trim

and Ornamentation, Removal and Installation).
4.
5. CAUTIONS:

damage.
Pull glazing wire through windshield sealant to the

inside of the vehicle.
6.
Installation
1. CAUTIONS:

Correct preparation of body apertures “post

painting” to ensure satisfactory glass adhesion,
must be carried out in line with industry practise.
2. NOTE: Make sure that a Hi-modulus sealer

(for example, Wurth Ultimate adhesive) is used
when bonding the component to the vehicle.

trimmed PU adhesive in accordance with the
instructions included with the PU adhesive kit.
3.
4. Test the sealer for leaks, apply additional sealer if

necessary. If water is used, allow sealer to dry
before testing. Spray water around the glass and
check for leaks. Mark any area that leaks. Dry the
glass and sealer then apply additional sealer.

Glass, Frames and Mechanisms - Windshield Glass
Removal
CAUTIONS:
Always protect paintwork and glass when removing exterior components.
Always protect the interior components when removing body glass.
Lay the glass on felt covered supports. Do not stand on edge as this can cause chips which subsequently develop
into cracks.
NOTES:
The cutting blades used in this procedure are from the standard BTB glass removal kit.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and

3. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors,
4.
5.
6. NOTE: The procedure must be carried out on
both sides.
7. NOTE: The procedure must be carried out on

both sides.
8. WARNING: Wear safety goggles and protective gloves.
CAUTIONS:
Protect the surrounding paintwork to avoid damage.
NOTE: Windshield glass shown removed for clarity.
Cut between points 3 and 4, use a WK1S blade, reverse

cut with the flat side against the body.
Cut the bottom corner at points 3 and 4, use a WK1S
blade.
Cut between points 4 and 1, use a WK24ZRS blade
against the body and a WK11B controller arm set to
26mm cut depth.
Cut between points 3 and 2, use a WK24ZRS blade
against the body and a WK11B controller arm set to
26mm cut depth.
Cut between points 5 and 6, use a WK24RS.
Cut between points 1 and 2, use a WK1S blade, reverse
cut with the flat side against the windshield glass and a
WK11B controller arm set to 26mm cut depth.
Cut the top corner at points 1 and 2, use a WK1S blade.
Cut any adhesive from the windshield to allow removal,
use a WK1S blade.
9.
Installation
1. CAUTION: Make sure that the mating faces are

clean and free of foreign material.
2. Prepare the window glass, window glass flange and trimmed PU

adhesive in accordance with the instructions included with the PU
adhesive kit.
3. CAUTION: Touching the adhesive surface will impair

rebonding.
NOTE: Make sure that the standard approved sealing kit is

used when bonding the component to the vehicle.
Apply a continuous bead of sealant to the windshield

glass.
CAUTIONS:
Make sure that the component is correctly located on the

locating dowels.
Make sure that equal pressure is applied to the full length of

the component.
With assistance, install the window glass.

Lightly press the window glass to seat the sealer.
If the ambient temperature falls below 10 degrees C,
apply warm air (25 degrees C) continuously for 15
minutes.
5. CAUTION: Make sure that no excess sealant
residue is evident.
If water is used as a means for the leak

check, then allow sealant to dry before
testing.
Spray water around the windshield glass,
mark any area that leaks. Dry the windshield
glass and sealant before applying additional
sealant.

Glass, Frames and Mechanisms - Windshield Moulding
Removal
NOTES:
1. Open the hood.
2. Torque: 2.5 Nm
3. CAUTION: Protect the paintwork during this

operation.
Installation
1. CAUTION: Make sure that the mating faces are clean and
NOTE: The new adhesive seal must be installed between

the alignment lines marked on the frame.
Prepare the PU adhesive in accordance with the instructions

included with the PU adhesive kit.

Instrument Panel and Console -
Description Nm lb-ft lb-in
Floor console lid bolts 9 - 80
Floor console bolts 9 - 80
In-vehicle crossbeam bolts 9 - 80
In-vehicle crossbeam electrical harness bolts 12 9 -
Instrument Panel center reinforcement bolts 9 - 80
Rear Integrated Control Panel bolts 1.7 - 15
Audio Video Input/Output panel bolts 9 - 80
Steering column upper cowl bolts 1.7 - 15
Instrument panel upper section M6 bolts 2.5 - 22
Instrument panel upper section Torx bolts 9 - 80
Glove box bolts 9 - 80
Instrument Panel and Console - Floor Console
Removal
NOTES:
Some components shown removed for clarity.
1. Refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
2. Refer to: Floor Console Upper Section (501-12 Instrument Panel and Console, Removal and Installation).
3.
4.
5.
6.
8.
9. Torque: 3 Nm
10. Torque: 9 Nm
11. NOTE: Do not disassemble further if the component is removed for access only.
12.
13.
14.
15.
16.
17.
Installation
1.

Instrument Panel and Console - Floor Console Cup Holder
Removal
NOTES:
1. Refer to: Specifications (414-00 Battery and Charging System -

2. Refer to: Floor Console Upper Section (501-12 Instrument Panel

and Console, Removal and Installation).
3.
4.
Installation

Instrument Panel and Console - Floor Console Stowage Compartment
Removal
NOTES:

2. Refer to: Floor Console Upper Section (501-12 Instrument

Panel and Console, Removal and Installation).
3.
4.
5.
6.
7.
8.
Installation

Instrument Panel and Console - Floor Console Stowage Compartment
Lid
Removal
NOTES:
All vehicles
2.
3. Torque: 9 Nm
4.
Vehicles with rear air conditioning
5.
All vehicles
6.
Installation
Instrument Panel and Console - Floor Console Upper Section
Removal
NOTES:

2. Refer to: Climate Control Assembly (412-01A Climate Control,

3.
4.

6.
Installation

Instrument Panel and Console - In-Vehicle Crossbeam
Removal
NOTES:
All vehicles
1. Refer to: Standard Workshop Practices (100-00 General
2. Refer to: Heater Core and Evaporator Core Housing (412-01A

Climate Control, Removal and Installation).
Refer to: Heater Core and Evaporator Core Housing (412-01A
Climate Control, Removal and Installation).
All vehicles

stands.
4. Torque: 2.2 Nm
5.
6.
7.
8.
9.
10.
11.
12. Torque: 25 Nm
13. CAUTION: Install all the bolts finger tight before final
tightening.
Torque: 9 Nm
14. NOTE: Install the bolt finger tight before final tightening.
Torque: 12 Nm
15. CAUTION: Install all the bolts finger tight before final
tightening.
Torque: 9 Nm
16.
17. CAUTION: Install all the bolts finger tight before

final tightening.
Torque: 9 Nm
18.

final tightening.
Torque: 9 Nm
NAS vehicles
20. Torque: 9 Nm
All vehicles

final tightening.
Torque: 12 Nm
22.
23.
Installation
Torque: 1.1 Nm
2. NOTE: Install the trim retaining clips in the

moulding prior to installing the components.
Instrument Panel and Console - Instrument Panel Center Reinforcement
Removal
NOTES:
1. Refer to: Instrument Panel Upper Section (501-12 Instrument

2. Torque: 9 Nm
Installation

Instrument Panel and Console - Instrument Panel Lower Section
Removal
NOTES:

components.

3.
4.
5. Torque: 9 Nm
6. Torque: 1.7 Nm
7.
8. Torque: 9 Nm
9.
10.
11.
12.
13. NOTE: The steering wheel is shown removed

for clarity.
14. NOTE: The steering wheel is shown removed for clarity.
Torque: 1.7 Nm

for clarity.
16.
17. CAUTION: LH illustration shown, RH is similar.
Torque:
M8 2.5 Nm
T27 9 Nm
18.
Installation


Instrument Panel and Console - Instrument Panel Upper Section
Removal
NOTES:

components.

3. Refer to: Glove Compartment (501-12 Instrument Panel and

4. Refer to: Information and Entertainment Display (415-01

Information and Entertainment System, Removal and
Installation).
5. Refer to: Audio Unit (415-01 Information and Entertainment

System, Removal and Installation).
6. Refer to: Floor Console (501-12 Instrument Panel and Console,

Torque: 6 Nm
9.
10.
for clarity.
12. Torque: 1.7 Nm

13.
14. Torque: 1.7 Nm

15.
Torque: 1.1 Nm
Torque: 1.7 Nm
16.
17.
Torque:
M6 9 Nm
M6 2.5 Nm
19.
20.
21. Torque: 9 Nm
22.
23. Torque: 9 Nm
24. Torque: 9 Nm
25. Torque: 9 Nm
26. Torque: 9 Nm
27. NOTE: Discard the retaining clips.

30.
31.
32. Torque: 1.7 Nm
33.
34. Torque: 9 Nm
Installation

Instrument Panel and Console - Glove Compartment
Removal
NOTES:
1. NOTE: Some illustrations may show Right hand

drive. Left hand drive is similar, but the essential
information shown is always correct.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14. NOTE: RHD illustration shown, LHD is similar.

final tightening.
Torque: 9 Nm
16.

Installation

Instrument Panel and Console - Overhead Console
Removal
NOTES:
All vehicles

components.
Vehicles without telematics
2. CAUTION: Care must be taken when caring out this

operation. Do not use excessive force or the headliner may
distort and a new component will need to be installed.

Vehicles with telematics
4. CAUTION: Care must be taken when caring out

this operation. Do not use excessive force or the
headliner may distort and a new component will
need to be installed.

6.
Installation

Handles, Locks, Latches and Entry Systems - Handles, Locks, Latches and
Entry Systems
COMPONENT LOCATION - SHEET 1 of 2

2 - Driver door Central Locking (CL) switch
3 - Driver door latch
5 - Rear right door latch
6 - Right tail lamp
7 - Radio Frequency (RF) receiver
9 - Left tail lamp
10 - Rear left door latch
12 - Passenger door latch
14 - Smartkey
15 - Left headlamp
16 - Right headlamp
17 - Instrument Cluster (IC)
COMPONENT LOCATION - SHEET 2 of 2

2 - Fuel flap release motor
5 - Tailgate latch
7 - Hood release cable
8 - Left hood latch
9 - Left hood safety latch guide
10 - Hood release lever
11 - Right hood safety latch guide
12 - Right hood latch
OVERVIEW
All the vehicle hinged panels are secured by latches with mating strikers. The latches incorporate panel ajar switches
that will inform the driver of an open access point.
The Central Locking (CL) system is operated by either the Smartkey or the front door CL's. The CL system controls
the automatic locking and unlocking of the vehicle entry points. The software used to control the CL system is
incorporated within the Central Junction Box (CJB).
The CL system is also integrated with the interior lighting function. The interior lights and exterior mirror lamps are
illuminated via the RF receiver and CJB following a valid unlock request from the Smartkey.
If configured by the dealer, the exterior door mirror power fold function is also operated by the CL system.
A concealed mechanical door lock is provided in the driver door door exterior handle, and is used to gain access to
the vehicle if the battery is discharged or the CL system fails.
CONTROL DIAGRAM
NOTE: A = Hardwired; F= RF transmission;AP = Medium speed Comfort Controller Area Network (CAN)
bus;AO = Medium speed Body Controller Area Network (CAN) bus;O = Local Interconnect Network (LIN) bus.


2 - Gateway Module (GWM)
4 - Radio Frequency (RF) receiver
6 - Smartkey
7 - Right tail lamp
8 - Left tail lamp
9 - Right headlamp
10 - Left headlamp
11 - Left hood latch
12 - Right hood latch
13 - Tailgate ajar switch Left tailgate latch
14 - Fuel flap release motor
15 - Driver door Central Locking (CL) switch
16 - Rear right door latch
17 - Driver door latch
18 - Rear left door latch
19 - Passenger door latch
28 - Battery
30 - Tailgate latch
SYSTEM OPERATION
Central Locking System - Manual Operation
The CL system provides the option of 2 or 3 manual locking modes, dependent on the vehicle specification. The
locking modes are activated using the front door central lock/unlock switches, or the Smartkey lock/unlock switches:
Internally locked mode
Externally locked mode
Double locked mode (all except NAS, Japan vehicles).
When the vehicle is externally locked, the CJB flashes the direction indicators once for 250 milliseconds. When the
vehicle is double locked, the CJB flashes the direction indicators twice for 250 milliseconds with a 250 millisecond
pause between flashes. When the vehicle is unlocked with the Smartkey, the CJB flashes the direction indicator lamps
twice for 250 milliseconds with a 250 millisecond pause between flashes.
The Smartkey may be configured by the driver for single point entry or global entry, by simultaneously pressing the
Smartkey lock and unlock switches for 4 seconds. The vehicle must initially be in an unlocked state. The direction
indicators will flash twice for 250 milliseconds with a 250 millisecond pause between flashes to confirm the mode
change. The vehicle will also lock and then unlock in the selected mode
When single point entry is enabled, an unlock command from the Smartkey will only unlock the driver's door, tailgate
and the fuel filler door. To unlock the remaining entry points, a second unlock command from the Smartkey is
required.
Additional options for speed dependent locking and automatic relocking modes may be configured by the dealer. All
vehicles incorporate an automatically operated crash unlocking mode.
Internally Locked Mode
The internally locked mode is activated by a single press of a front door central lock/unlock switch.
When in the internally locked mode:
The exterior door release handles are disengaged from the door latches to prevent opening of the doors from
outside the vehicle.
The CJB disregards an open request from the tailgate exterior handle to prevent opening of the tailgate from
The vehicle may be unlocked by either a single press a front door central lock/unlock switch or a single press
of the Smartkey unlock switch. The vehicle will also unlock if the driver or front passenger door is opened.
Externally Locked Mode
The externally locked mode is activated by a single press of the Smartkey lock switch. When in the externally locked
mode:
The exterior door release handles are disengaged from the door latches to prevent opening of the doors from
The CJB disregards an open request from the tailgate exterior handle to prevent exterior opening of the
tailgate and doors.
The fuel filler door actuator is energized to lock the fuel filler door.
The vehicle may be unlocked by a single press of the Smartkey unlock switch.
For all UK, Europe and ROW specification vehicles, a single press of the Smartkey lock switch will externally lock the
vehicle to disengage the exterior handles, and will arm the active anti-theft system.
For additional information, refer to: Anti-Theft - Active (419-01A Anti-Theft - Active, Description and Operation).
For NAS and Japan specification vehicles, a single press of the Smartkey lock switch will externally lock the vehicle to
disengage the exterior handles, and will arm the active and passive anti-theft system.
For additional information, refer to: Anti-Theft - Active (419-01A Anti-Theft - Active, Description and Operation) /
Anti-Theft - Passive (419-01B Anti-Theft - Passive, Description and Operation).
For all vehicles except NAS, and Japan specifications, pressing the Smartkey lock switch twice within 3 seconds will
double lock the vehicle to disengage the interior and exterior handles, and will arm the active and passive anti-theft
system.
For additional information, refer to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Description and Operation).
Central Locking System - Automatic Modes
The CL system features automatic modes to control the vehicle entry points, and provide protection for the system
components.
The CL system incorporates the following automatic modes:
Mislock mode
Speed dependent locking mode (if programmed)
Crash unlocking mode
Repetition blocking mode
Lockout protection mode
Automatic relock mode (if programmed)
Transport mode.
Mislock Mode
A mislock occurs if the CJB receives an external lock or double lock request when a hinged panel is ajar. To indicate a
mislock the CJB sounds the horns to produce a 100 millisecond 'chirp'.
If a mislock occurs due to an external lock request when a hinged panel is ajar, the CJB will not carry out a lock
request on any access points.
Speed Dependent Locking Mode
When speed dependent locking is enabled the CJB will internally lock all the doors when the vehicle speed exceeds 8
km/h (5 mph) with all the doors closed and the engine running. If the driver or front passenger door is opened and
then closed, when the vehicle slows down or stops and then increases to more than 8 km/h (5 mph) again, the CJB
will internally lock the doors.
Speed dependent locking may be enabled or disabled by the dealer using the Land Rover approved diagnostic
system.
Crash Unlocking Mode
With the ignition in power mode 6 (Ignition), if a crash occurs that triggers deployment of the air bags, then the CJB
will unlock all of the doors. The CJB is informed of the crash by a status message from the Restraints Control Module
(RCM) on the medium speed CAN bus that changes from 'no crash' to 'crash'.
The CL system will also perform crash unlocking mode if a 'no crash' status message is not received from the RCM
every 500 milliseconds.
For additional information, refer to: Safety Belt System (501-20A Safety Belt System, Description and Operation).
Repetition Blocking Mode
To protect the CL system motors and actuators against system misuse, the CJB incorporates repetition blocking to
limit the maximum operating rate of each motor and actuator. The lock motor in each door latch also incorporates
thermal protection.
Central Locking System Motor and Actuator Operating Parameters
Motor or Current On Time Maximum Operations (per Nominal Operating Stall Current
Actuator (ms) minute) Current (A) (A)
Tailgate latch 600 ± 10 10 3.6 to 5.2 7.5
Fuel filler door 400 ± 10 5 2.7 8
Door double lock 100 to 110 10 0.28 1.14
Door lock 100 to 110 10 0.54 3.31
Lockout Protection Mode
The vehicle is not able to be locked using a front door CL switch if any door is open.
If an internal lock request is received from either of the front door CL switches, the CJB will centrally lock the vehicle
and then centrally unlock the vehicle if any door is open.
If a front door is open and the open door CL switch is pressed and held in the locked position, the open front door
may remain in the locked state. When the open door is subsequently closed, the CJB will centrally unlock all doors.
Automatic Relock Mode
Automatic relock prevents accidental operation of the Smartkey switches that will unlock and disarm the vehicle.
When the CL system is unlocked using the Smartkey, and a door or tailgate is not opened or the Smartkey is not
placed in the start control unit within 1 minute, the CJB will automatically lock or double lock the vehicle again,
depending on the previously locked mode.
Transport Mode
All new vehicles are delivered from the factory in transport mode. Transport mode replaces the traditional transit
relay and inhibits a number of electrical systems and features to reduce quiescent drain from the battery during
delivery. When the vehicle is in transport mode 'transp' is displayed in the IC odometer. Single point entry is enabled
and global locking and unlocking using the Smartkey is disabled.
The speed locking mode is also disabled, but crash unlocking mode remains enabled.
To remove the vehicle from transport mode, the Land Rover approved diagnostic system must be connected during
the Pre-Delivery Inspection (PDI). For further information, refer to the PDI manual.
DOOR LATCHES

1 - Emergency key blade
2 - Driver door emergency key barrel cover
3 - Emergency key barrel
4 - Driver door exterior door handle
5 - Door lock interior release cable
6 - Door latch
7 - Electrical connection to Driver Door Module (DDM)
8 - Door interior release handle
9 - Central lock/unlock switches
The door latches are installed at the rear edge of each door and engage with corresponding strikers mounted to the
'B' and 'C' pillars. Each interior and exterior door handle is connected with a release cable to the corresponding door
latch. In the driver door a third release cable is connected between the door latch and the concealed emergency
mechanical door lock.
Each door latch is a sealed unit that comprises the following:
Lock motor
Double lock motor (all except North American Specification (NAS), and Japan vehicles)
Door ajar switch.
An electrical connector is incorporated in each door latch and provides the interface with the door control module and
CJB. The front door control modules are connected to the CJB on the medium speed CAN bus; the rear door control
modules are connected via the LIN bus to the front door control modules.
The lock and double lock motors control the engagement of the door latches with the release cables to lock and
unlock the vehicle. When the vehicle is locked, the lock motors disengage the door latches from the exterior release
cables. When the vehicle is double locked, the double lock motors also disengage the door latches from the interior
release cables. When the vehicle is subsequently unlocked, the interior and exterior release cables are re-engaged
with the door latches.
All the door interior release handles incorporate a locking switch. When a front door central locking switch is pressed,
all the vehicle doors will centrally lock/unlock. When a rear door locking switch is pressed, the locking switch will only
lock/unlock the activated rear door.
When the door locking switch is pressed, the interior release cable is pushed and causes the exterior release cable to
be disengaged from the door latch. On the rear doors, pressing the locking switch will also disengage the interior
handle from the interior release cable.
When the door locking switch is pulled away from the door, the door interior release handle is re-engaged with the
interior release cable. As the interior release cable is re-engaged it is pulled, causing the door latch to re-engage with
the exterior release cable.
Rear Door Child Locks
The rear door latches incorporate child locks that provide additional rear occupancy safety. The child locks are
manually operated using the emergency key blade within the Smartkey. Setting the child lock to the locked position
will disengage the door latch interior release cable from the door latch, and prevent opening of the rear door using
the interior release handle.
For further information on child locks, refer to the Owner's Handbook.
Door Ajar Switch
An ajar switch is installed in each door latch and is hardwired to the CJB. If the ignition is in power modes 4
(Accessory) or 6 (Ignition) and a door is opened or is not fully closed, the corresponding door ajar switch is opened
to disconnect the ground from the CJB. A message is transmitted by the CJB via the medium speed CAN bus to the
IC, to inform the driver that a door is ajar.
On vehicles with a low-line IC the door ajar symbol is illuminated.

For additional information, refer to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).
On vehicles with a high-line IC, the door ajar symbol is illuminated and a message is also displayed in the message
center.
The door ajar switch is also integrated with the vehicle security system and is used as the detection device for
unauthorized vehicle entry.
The hood is secured in the closed position by 2 latches located on each side of the hood latch panel. The hood
release lever is located below the IP on the left 'A' pillar and is connected with a cable to the hood latches. Operation
of the hood release lever will open the 2 hood latches and release the hood.
A mechanically operated safety latch guide is installed at the front center of the hood. The safety latch guide
prevents the hood from fully opening in the event that the hood latches are open, and the vehicle is in motion. The
safety latch guide is spring operated to bias the latch guide to the latched position, and is formed with a lever plate.
The lever must be pressed to release the safety latch guide from the mating latch plate when the hood is to be fully
opened.
Hood Ajar Switch
The right hood latch incorporates the hood ajar switch that is hardwired to the CJB. If the ignition is in power modes
4 (Accessory) or 6 (Ignition) and the hood is opened or is not fully closed, the hood ajar switch is opened to
disconnect the ground from the CJB. A message is transmitted by the CJB via the Medium speed CAN bus to the IC,
to inform the driver that the hood is ajar.
On vehicles with a low-line instrument cluster the hood ajar symbol is illuminated.
On vehicles with a high-line instrument cluster, the hood ajar symbol is illuminated and a message is also displayed
in the message center.
For additional information, refer to: Information and Message Center (413-08 Information and Message Center,
The hood ajar switch is also integrated with the vehicle security system and is used as the detection device for
Tailgate Ajar Switch
The tailgate latches are also incorporating the tailgate ajar switch that is hardwired to the CJB. If the ignition is in
power modes 4 (Accessory) or 6 (Ignition) and the tailgate is opened or is not fully closed, the tailgate ajar switch is
opened to disconnect the ground from the CJB. A message is transmitted by the CJB via the medium speed CAN bus
to the IC, to inform the driver that the tailgate is ajar.
On vehicles with a low-line instrument cluster the tailgate ajar symbol is illuminated.
On vehicles with a high-line instrument cluster, the tailgate ajar symbol is illuminated and a message is also
displayed in the message center.
The tailgate ajar switch is also integrated with the vehicle security system and is used as the detection device for
FUEL FILLER DOOR ACTUATOR
The fuel filler door is electrically locked and unlocked with an actuator and plastic pin. The actuator is located behind
the fuel filler door housing, and operates the pin to engage or release a spigot on the door mounting hinge arm.
NOTE: Locking feature is not available on NAS spec cars.
The fuel filler door actuator is hardwired to the CJB and is operated by the vehicle CL system. The CJB reverses the
polarity of the actuator power and ground connections, allowing the pin to move in both directions for locking and
unlocking. When unlocked, the fuel filler door is manually opened to gain access to the fuel tank filler cap.
CENTRAL LOCKING SYSTEM CONTROLS
The CL system provides the driver with control over the locking and unlocking of the vehicle entry points, from inside
or outside the vehicle. Manual operation of the CL system is achieved using the following:
Smartkey and RF receiver
Front door CL switch.
Smartkey and Emergency Mechanical Door Lock


1 - Vehicle lock switch
2 - Vehicle unlock switch
3 - Tailgate unlock swith
4 - Panic alarm switch
5 - Headlamp delay function switch
6 - Emergency key blade cover
7 - Emergency key blade
8 - Emergency key barrel
9 - Front door handle
The Smartkey contains an emergency key blade, concealed in the key fob. The driver door exterior handle
incorporates a mechanical operated door lock that is concealed behind a removable plastic cover. The door lock
allows the door to be mechanically unlocked and locked using the emergency key blade in the event that the remote
CL operation fails, or a vehicle power failure occurs.
When the mechanical door lock is used the CL system will not operate, and if already armed the vehicle alarm will
sound when the door is opened. The vehicle is not able to be double locked, or the alarm system armed using the
emergency key blade.
The Smartkey contains a Printed Circuit Board (PCB), transponder and a battery.
The Smartkey contains an emergency key blade, concealed in the key fob. The emergency key blade is used to
access the vehicle through the driver door if the CL system fails. The emergency key blade is also used to enable or
disable the rear door child locks, and to disable the passenger airbag.
For additional information, refer to: Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (501-
20B Supplemental Restraint System, Description and Operation).
The Smartkey is identical for all vehicle specifications, but differs in the preset frequency and power that the
Smartkey operates. The Smartkey for each vehicle specification is identified by a suffix change to the base part
number as follows:
Part No. Suffix Operating Frequency Vehicle Specification

A# 315 MHz NAS, Japan and Korea
B# 433 MHz Europe and ROW
Each Smartkey features a unique identification code that is programmed within the integral transponder. The RF
signal produced by the Smartkey contains the unique identification code and also a rolling code. During vehicle
production, the unique identification codes of the valid Smartkeys are programmed into the RFA, and the rolling
codes are also synchronized with the RFA.
When the Smartkey is operated, the RFA checks the unique identification and rolling code. The RFA will only respond
if the RF signal produced is from a valid Smartkey for the vehicle.
A total of 8 'slots' are available in the RFA software to allow for replacement and the addition of Smartkeys. In
service, the Land Rover approved diagnostic system may be used to communicate with the RFA for the following:
Identification of Smartkey allocation within the RFA.
Enabling of new Smartkeys
Disabling of existing Smartkeys.
If the Smartkey rolling code loses synchronization with the RFA, the Smartkey functions will not operate.
Synchronization between the Smartkey and RFA is restored automatically when switches are pressed.
Additional switches are located on the Smartkey to provide convenience operation of the tailgate release, headlamp
delay and panic alarm functions.
RF Receiver
The RF receiver is installed on the headlining on center between pillar 'C' and 'D'. The receiver provides functionality
for the remote CL system.
NOTE: Tire Pressure Monitoring System (TPMS) is provided by a separate receiver
The RF receiver is identical for all vehicle specifications, but differs in the preset frequency that the receiver operates.
The RF receiver for each vehicle specification is identified by a suffix change to the base part number as follows:
Part No. Suffix Operating Frequency Vehicle Specification

A# 315 MHz NAS, Japan and Korea
B# 433 MHz Europe and ROW
The RF receiver converts the signals transmitted by the Smartkey into digital messages, and then transmits the
message via the ISO9141 bus to the RFA.
A permanent power feed is supplied to the RF receiver by the CJB.
Front Door Central Locking Switch

Both the front door interior locking switches will activate the CL function. When a front door CL switch is pressed, all
the vehicle doors will centrally lock/unlock.
When a front door CL switch is pressed, the door control module on the activated door transmits the central
lock/unlock request to the CJB. The CJB then transmits the central lock/unlock command to all the vehicle door
control modules to lock/unlock all the vehicle doors.
The CL feature using the front door CL switch is inhibited if either of the front doors is ajar. If a front door is ajar
when a front door CL switch is pressed to lock the doors, the doors will lock and then instantly unlock.
Handles, Locks, Latches and Entry Systems - Locks, Latches and Entry
Systems
For a detailed description of the locks, latches and entry systems and operation, refer to the relevant Description
and Operation section of the workshop manual. Refer to (501-14)
the donor vehicle
NOTES:

Visual Inspection
Incorrectly aligned door(s), hood or tailgate Fuses
Fuel filler door lock actuator Wiring harness
Hood release handle Wiring connector(s)
Hood release cables Door lock actuator(s)
Hood latch(es) Soft close actuator(s)
Exterior door handle(s) Remote transmitter (key-fob or smart key)
Interior door handle(s) Central locking switches
Cable(s) Micro switch(s)
Tailgate release switch CAN circuits
Rear window release switch Radio frequency receiver
Soft close actuator(s) Central junction box
Obstruction within door aperture or door latch Loose or corroded connections
5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the
specific customer complaint and carry out the recommendations as required
Symptom Chart

Door(s) will not Exterior door handle Check the exterior door handle condition and installation
open from outside condition/installation Check the condition and security of the exterior release
Exterior release cable cable
disconnected from
exterior door handle
or door latch
Door latch failure
Door(s) will not Child lock(s) engaged Check that the child locks are disengaged
open from inside Interior door handle Check the interior door handle condition and installation
condition/installation Check the condition and security of the interior release
Interior release cable cable
disconnected from
interior door handle
or door latch
Door latch failure
Vehicle indicates a Ajar switch circuit Refer to the electrical circuit diagrams and check the ajar
miss-lock when the short circuit to switch circuit for short circuit to ground
hood, tailgate and ground Check for DTCs indicating an ajar switch fault. Refer to the
doors appear to be Ajar switch failure DTC index
closed
Fuel flap does not Fuel flap cable Check the condition and installation of the fuel flap cable
lock/unlock detached from body Check the security of the fuel flap actuator and bracket
Fuel flap actuator Check the security of the actuator electrical connector
detached from Check for DTCs indicating a fuel flap actuator fault. Refer to
mounting bracket the DTC index
Fuel flap actuator
disconnected
Fuel flap actuator
failure
Door latching and Door latch

locking function Cable fault NOTE: Complete the diagnostic steps below to confirm any
test Door handle concern prior replacing the component
Door lock switch
Wiring harness Check for relevant stored DTCs
Central junction box Once any DTC related faults have been rectified continue
(CJB) with the diagnostic steps below
The first component that should be checked when
experiencing locking or latching issues are the door latch
release cables, then the door latch. These can be tested as
a discrete components to confirm if the specific component
is working as designed or is demonstrating a fault
Vehicle electrical Fuses Check for relevant stored DTCs

system test Wiring harness Refer to the electrical circuit diagrams to locate the fault
Wiring connector(s) Carry out continuity test to confirm circuit integrity
Soft close Door is closed with Close the door with less force to secondary latched position
inoperative on force/slammed and only
individual door the soft close
initiation switch (pawl
switch) first activation
process is missed
Soft close Fuse failure Check and install a new fuse as required
inoperative on Soft close door latch - Refer to the electrical circuit diagrams and check the soft
individual door - Ground circuit open close door latch ground circuit for open circuit, high
Actuator not circuit, high resistance
audible resistance Refer to the electrical circuit diagrams and check the soft
Soft close door latch close door latch initiation switch (pawl switch) signal circuit
initiation switch (pawl for open circuit, high resistance
switch) - Signal Refer to the electrical circuit diagrams and check the soft
circuit open circuit, close door latch position switch (claw switch) signal circuit
high resistance for open circuit, high resistance
Soft close door latch Refer to the electrical circuit diagrams and check the soft
position switch (claw close actuator power and ground circuits for open circuit,
switch) - Signal high resistance
circuit open circuit, Check and install a new soft close door latch as required
high resistance Check and install a new soft close actuator as required
Soft close actuator -
Power or ground
circuit open circuit,
high resistance
Soft close door latch -
Internal failure
Internal failure
Soft close Obstruction within Remove obstruction

inoperative on door aperture or door Check/adjust the door striker as necessary
individual door - latch Check and install a new soft close actuator and cable
Actuator audible Incorrect door assembly as required
striker- Check and install a new soft close actuator as required
Alignment/adjustment Relocate the door latch soft close mechanism spring
Soft close actuator - Check and install a new soft close door latch as required
Cable failure
Mechanism failure
Mechanism spring is
dislocated
Mechanism failure
Soft close Megafuse failure Check and install a megafuse as required

inoperative on all Central junction box - Refer to the electrical circuit diagrams and check the
doors and tailgate Power circuit short central junction box power circuit for short circuit to
circuit to ground, ground, open circuit, high resistance
open circuit, high Using the manufacturer approved diagnostic system, check
resistance the central junction box for related DTCs and refer to the
Central junction box relevant DTC index
fault

operation door aperture or door Check/adjust the door striker as necessary
intermittent on latch
individual door Incorrect door
striker-
Alignment/adjustment

inoperative on door aperture or door Check/adjust the door striker as necessary
individual door - latch
Door will not close Incorrect door
fully striker-
Alignment/adjustment
DTC Index
For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00.
REFER to: (100-00 General Information)
Diagnostic Trouble Code (DTC) Index - DTC: Driver/Passenger Door Module (DDM/PDM) (Description and
Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Central Junction Box (CJB) (Description and Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Keyless Vehicle Module (KVM) (Description and Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Tailgate Control Module (Description and Operation).
Handles, Locks, Latches and Entry Systems - Tailgate Striker
Adjustment
General Procedures
1. Check for an equal gap and alignment to the adjacent panels.

If incorrect, follow the adjust procedure below.
2. Loosen the 2 tailgate striker bolts.
3. Close the tailgate and check for an equal gap and alignment to
the adjacent panels.
4. Secure the tailgate striker.

Tighten the screws to 25 Nm (18 lb.ft).
Handles, Locks, Latches and Entry Systems - Liftgate Striker
Adjustment
General Procedures
1. Check for an equal gap and alignment to the adjacent panels.

If incorrect, follow the adjust procedure below.
2. Remove the tailgate upper trim panel.

Remove the 6 screw covers.
Remove the 6 screws.
3. Loosen the 2 screws securing the liftgate striker.
4. Close the liftgate and check for an equal gap and alignment to
the adjacent panels.

Tighten the screws to 10 Nm (7 lb.ft).
6. Install the tailgate upper trim panel.

Install the screws.
Install the screw covers.
Handles, Locks, Latches and Entry Systems - Door Lock Cylinder
Removal
1.
2. NOTE: Loosen the bolt, but do not fully

remove.
Torque: 4.1 Nm
3.
Installation

Handles, Locks, Latches and Entry Systems - Exterior Front Door Handle
Removal
CAUTION: Protect the surrounding paintwork to avoid damage.
NOTES:
Make sure the door window glass is in the fully closed position.
2. WARNING: To avoid accidental deployment, the restraints

control module backup power supply must be depleted. Wait at
least two minutes after disconnecting the battery ground cable(s)
before commencing any repair or adjustment to the
supplemental restraint system (SRS), or any component(s)
adjacent to the SRS sensors. Failure to follow these instructions
Make the SRS system safe.

3.
4.
5.
6. NOTE: LH shown.
7. NOTES:
Loosen the bolt, but do not fully remove.
LH shown.
Torque: 4.1 Nm
8. NOTE: LH shown.
9. NOTE: LH shown.
10. NOTE: RH Shown.

11. NOTE: RH Shown.
Installation
2. NOTE: LH shown.
Install the door lock cover.

Published: 24-Mar-2013
Handles, Locks, Latches and Entry Systems - Exterior Rear Door Handle
Removal
CAUTION: Protect the surrounding paintwork to avoid damage.
NOTES:
Make sure the door window glass is in the fully closed position.

5. NOTES:
Loosen the bolt, but do not fully remove.
Torque: 4.1 Nm

Installation

Handles, Locks, Latches and Entry Systems - Front Door Latch
Removal
NOTES:
Right hand shown, left hand similar.
1. WARNING: To avoid accidental deployment, the restraints

control module backup power supply must be depleted. Wait at
least two minutes after disconnecting the battery ground cable(s)
before commencing any repair or adjustment to the
supplemental restraint system (SRS), or any component(s)
adjacent to the SRS sensors. Failure to follow these instructions
Make the SRS system safe.
2. Refer to: Exterior Front Door Handle (501-14 Handles, Locks,

Latches and Entry Systems, Removal and Installation).
3.
4. Torque: 7 Nm
5.
6.
7. Torque: 3.2 Nm
8.

10.
11.
12.
Installation

Handles, Locks, Latches and Entry Systems - Liftgate Latch
Removal
NOTES:

2.
3.
4. Torque: 10 Nm
5.
Installation

Published: 27-Nov-2013
Handles, Locks, Latches and Entry Systems - Rear Door Latch
Removal
NOTES:
1. Refer to: Exterior Rear Door Handle (501-14 Handles, Locks,

Latches and Entry Systems, Removal and Installation).
2. NOTE: Loosen the bolt, but do not fully

remove.
Torque: 3.2 Nm
3.
4. Torque: 7 Nm
5.
6.
8.
9.
10.
Installation

Wipers and Washers -
Front wiper arms to linkage nut 34 25
Wiper linkage to front wiper motor:
Nut 25 18
Bolts 10 7
Rear window wiper motor bolts 10 7
Rear wiper arm to motor nut 13 10
Washer reservoir to body bolts 3 2.2
Wipers and Washers - Wipers and Washers
Component Location

1 - Windshield wiper assembly
2 - Right steering column multifunction switch
3 - Rain/light sensor
4 - Rear window wiper arm
5 - Rear window washer jet
6 - Radio Frequency (RF) filter
7 - Left heated windshieldwasher jet
8 - Right heated windshield washer jet
9 - Left heated headlamp washer jet
10 - Windshield washer reservoir (cold climate markets only)
11 - Right heated headlamp washer jet
12 - Windshield washer reservoir
Overview
The wipers and washers system functions on receipt of requests made by the driver or the rain/light sensor. All
wiper functions for the front and tailgate wipers are controlled from the right steering column multifunction switch.
The wiper and washer system comprises:
Windshield and rear window wiper motors

A windshield wiper linkage
Two front and one rear window wiper arms and blades
Two front heated washer jets and one rear washer jet
Two headlamp washer jets
A windshield washer reservoir, a front/rear washer pump and a headlamp washer pump
A wiper control switch
A rain/light sensor.
The wiper system is equipped with a rain/light sensor, which controls the automatic wiper functions and also the
automatic lighting functions. The sensor, located below the interior rear view mirror, detects rain drops on the
windshield and automatically operates the wipers in the intermittent mode. The column stalk switch must be in the
intermittent position for rain sensor controlled wiper operation.
The windshield wiper system has 4 wiper stages of operation and 4 intermittent wiper delay periods. The 4 wiper
stages are as follows:
Flick wipe
Intermittent
Normal (slow) speed continuous
Fast speed continuous.
The intermittent, normal and fast speeds are affected by road speed. The intermittent wiper delay periods change
with the road speed, with the delay decreasing as the road speed increases. The normal continuous operation
changes to intermittent operation when the vehicle is stationary.
The wipers and washers operate with the ignition switch in positions I or II (aux or ign). Wiper functions are
suspended during engine cranking to reduce battery power consumption under high load conditions.
Diagnostic information for the wiper system is available and can be retrieved using the Land Rover approved
diagnostic system.
Control Diagram
NOTE: A = Hardwired; AN = High speed PowertrainCAN (controller area network) bus;O = LIN (local
interconnect network) bus.


1 - Battery
6 - RF filter
7 - Headlamp washer pump
8 - Tailgate wiper motor
9 - Windshield/Rear window washer pump
10 - Left heated washer jet
11 - Right heated washer jet
12 - Automatic Temperature Control (ATC) module
13 - Rain/Light sensor
14 - Wiper control switch
15 - Washer fluid level sensor
17 - Anti-Lock Brake System (ABS) control module
18 - Windshield wiper motor
19 - Engine Junction Box (EJB)
System Operation
Windshield wipers
The windshield wiper system has the following functionality:
Intermittent wipe and delay adjustment or rain/light sensor

Normal (slow) speed wipe
Fast speed wipe
Program wash/wipe
Flick wipe
Headlamp power wash
Motor blocking protection.
Intermittent
Intermittent wiper operation is selected on the wiper control switch by moving the switch vertically to the first
position. The intermittent delay period is adjustable using the rotary switch on the wiper control switch. The delay
period is also subject to vehicle speed, with the selected delay period decreasing with an increase in road speed.
The rotary potentiometer selects differing resistance values for each position. The potentiometer is connected into a
voltage divider circuit, with a 6.8kohm resistor. The power supply to the voltage divider circuit is limited to 6.5V.
This reduced voltage is used to determine the position of the rotary switch as follows:
Rotary Switch Position Resistance Min. Voltage Max. Voltage Typical Voltage
Error - Ground <0.2kohm - - <0.18V
1 2kohm ± 750ohm 1.00V 1.89V 1.48V
2 4kohm ± 750ohm 2.08V 2.70V 2.41V
3 6kohm ± 750ohm 2.80V 3.27V 3.04V
4 8kohm ± 750ohm 3.32V 3.69V 3.51V
Error - Positive >20kohm - - 4.88V
The intermittent delay is also influenced by the road speed of the vehicle using a signal value derived from the Anti-
Lock Brake System (ABS) control module on the high speed CAN bus. The time delay periods for the vehicle
stationary and when moving at different speeds are shown in seconds in the following table:
Vehicle Speed mph (km/h)

Rotary Switch 4 4 - 19 (6 - 19 - 44 (30 - 44 - 62 (70 - 62 - 87 (100 - >87 >112
Position (6) 30) 70) 100) 140) (140) (180)
Error - Ground 20 6 5 4 3 3 3
1 26 19 17 15 15 13 13
2 17 12 11 10 9 7 7
3 10 6 6 5 4 3 3
4 5 3 3 2 2 2 2
Error - Positive 8 6 5 4 3 3 3
The wiper control switch positions also influence the operation of the rain/light sensor by adjusting its sensitivity.
Refer to the following rain/light sensor operation section for details.
Normal (Slow) Speed
The normal (slow) speed continuous wiper operation is selected by moving the switch vertically to the second
detente position. The wipers will operate continuously when the vehicle is moving. When the vehicle is stationary
(less than 4 mph (6 km/h)), the CJB (central junction box) operates the wipers in the intermittent mode, using a 3
second intermittent delay period.
Fast Speed
The fast speed continuous wiper operation is selected by moving the switch vertically to the third detente position.
The wipers will operate continuously at fast speed when the vehicle is moving. When the vehicle is stationary (less
than 4 mph (6 km/h)), the CJB operates the wipers in normal (slow) speed mode.
Rain/Light Sensor
The rain/light sensor is active when the wiper control switch is in the intermittent position. The rain/light sensor
suspends wiper operation when the area of the windscreen for the rain/light sensor is dry and operates the wipers
continuously (fast or slow speeds) when the windscreen is subject to heavy rainfall.
If the ignition is switched off and the wiper control switch remains in the intermittent position, the CJB will suspend
rain/light sensor operation until intermittent operation is reselected, an adjustment of the rotary switch is made or
programmed wash/wipe is selected.
The sensitivity of the rain/light sensor can be adjusted by the driver using the intermittent rotary switch on the wiper
control switch. Six sensitivity levels of the sensor can be selected which has the effect of increasing or decreasing
the wiper delay period, allow driver adjustment for the prevailing conditions. When several continuous wipe cycles
have taken place, the sensor will maintain the continuous operation to avoid switching back to intermittent from a
continuous wipe and back again.
The rain/light sensor receives vehicle speed information from the ABS (anti-lock brake system) control module on the
high speed CAN bus every 2 seconds. The sensor increases the sensitivity as the speed increases to optimize wiper
operation. When the vehicle speed is reduced to less than 5 mph (8 km/h), the sensitivity is automatically reduced.
Below this speed the wipers will only operate continuously in very heavy rain.
Wash/Wipe
Moving either the wiper control switch backwards selects front wash/wipe. This position is non-latching and the
windshield washer pump is operated for as long as the switch is active. If the switch is only momentarily operated
(less than 300 ms), only the washer pump operates. If the switch is activated for more than 300 ms, the CJB also
powers the wiper motor after a 0.5 second delay. The CJB monitors the wash/wipe switch operation and after the
switch is released, the CJB allows 3 full wipe cycles to clear the screen.
Washer Fluid Level Sensor
The sensor cannot determine the precise amount of fluid in the reservoir, but can detect when the fluid level has
fallen below a certain point. When the fluid level is low, the magnetic float closes the sensor contacts, completing a
circuit through the sensor. This completed circuit is sensed by the CJB to which the sensor is directly connected.
The fluid level sensor is monitored continuously by the CJB. The CJB checks the fluid level sensor when the ignition
is switched on to give the driver an early warning of the low fluid level. The CJB then monitors the sensor value over
a 25 second period when the ignition is on to prevent invalid messages due to fluid 'sloshing' in the reservoir.
When the CJB determines a low fluid level, a signal is transmitted on the high speed CAN bus to the IC to illuminate
the 'WASHER FLUID LOW' message in the IC message center. The first illumination of this message is accompanied
by a 'gong' sound to alert the driver to the low fluid level.
Heated Washer Jets
The heated washer jets are controlled by the ATC (automatic temperature control) system and a heated washer jet
relay in the CJB.
When the ignition is switched on and the ATC system detects an ambient temperature of less than 3°C (37°F), the
ATC system completes an earth path for the coil of the heated washer jet relay. This allows battery voltage to pass
through the relay contacts and operate the heater elements. The ATC maintains the power to the heater elements for
as long as the ignition remains on or the ambient temperature remains below 6°C (42°F). If the ambient
temperature increases to 6°C (42°F) or above, the ATC system removes the earth for the relay coil, de-energizing
the heater elements.
The ATC system will also prevent heated washer jet operation if the battery voltage falls to below 11.4V. This is to
relieve loads on the battery and alternator when electrical loads are high. Heated washer jet operation will be
resumed when the battery voltage exceeds 12.2V.
Wiper Motor Blocking Protection
The wiper park signal is also used by the CJB for blocking protection of the windshield wiper motor. This feature
protects the motor in the event of the wiper operation being obstructed.
If the CJB does not receive the wiper park signal for a period of 16 seconds, when the wiper motor is active, the CJB
removes the power supply to the motor. The motor is disabled for a period of 3 minutes or until the ignition is
switched off and on again. Even after the 3 minute period has elapsed, the CJB will not automatically switch the
motor on, to prevent the risk of injury. The wiper switch must be moved off and then on to reactivate the wiper
motor. The blocking protection is active in all wiper switch positions and can only be reset by turning the ignition off.
Tailgate wiper
The tailgate wiper has the following functionality:
Intermittent operation
Adjustable intermittent wipe period
Continuous reverse wipe function.
Wiper Operation
The tailgate wiper is operated by the wiper control switch. Rotating the outer ring of the switch the first position
switches on the tailgate wiper intermittent mode. Rotating the switch forward to the second position switches on the
tailgate wiper normal mode. Pressing the switch end selects the rear wash/wipe function.
When reverse gear is engaged and the tailgate wiper is on, the tailgate wiper is operated continuously. The
continuous wipe will continue until reverse gear is disengaged or the tailgate wiper is switched off.
When rear wash/wipe is selected, the EJB (engine junction box) powers the washer pump for as long as the switch is
held. When the switch is released, the EJB initiates 5 complete wipe cycles. The first 3 wipe cycles are each
accompanied by a 0.5 second operation of the rear washer pump. The final 2 cycles are to clear the tail door window
and do not have a washer pump operation. If intermittent remains selected, the tailgate wiper continues in
intermittent mode.
Intermittent Adjustment
The intermittent interval time of the tailgate wiper can be adjusted by the driver to wipe at between 1 and 30 second
delays. Adjustment is performed by switching the tailgate wiper on for a short time and then off again. The next
switching on of the tailgate wiper determines the delay period. The time lapse between the off and the next on signal
is sensed by the CJB which sets this period as the requested time interval between wipes. If the next on signal is
more than 30 seconds after the off signal, the CJB sets the time interval to the maximum 30 seconds.
tailgate wiper Motor Blocking Protection
The tailgate wiper motor is protected by the CJB in the event of the wiper operation being obstructed.
Headlamp Washer
The headlamp washers are only active when the headlamps are switched on and the ignition is on. The washers are
controlled by the CJB, which limits their operation to preserve washer fluid in the reservoir.
With the ignition and lights on, the headlamp wash is activated on the first operation of the wiper control switch in
the wash/wipe position. The CJB then suspends headlamp wash activation for the next 4 operations of the wash/wipe
switch, with the headlamp power washers activated on the fifth operation of the switch.
The CJB monitors the operation of the wash/wipe switch and maintains a counter to restrict headlamp power wash
operation to every fifth operation of the wash/wipe switch. The CJB also maintains a timer, which prevents a second
operation of the headlamp wash within a 3 minute period. The counter and timer are reset when the ignition is
switched off.
When headlamp power wash is active, the CJB energizes the wash pump twice per cycle. The headlamp wash pump
is powered for a 0.5 second period. The CJB then initiates a 2 second delay before powering the headlamp wash
pump for a second 0.5 second period.
If the washer fluid level becomes low, the CJB suspends headlamp power wash operation to preserve the remaining
washer fluid.
Wiper Control Column Switch


1 - Wiper control switch
2 - Intermittent delay rotary control or rain/light sensor sensitivity adjust
3 - Programme wash/wipe position
4 - Rear window wiper intermittent delay position
5 - Rear window wiper normal wipe position
6 - Fast wipe position
7 - Normal wipe position
8 - Intermittent wipe position or rain/light sensor position
9 - Rear window wash position
10 - Flick wipe position
The wiper control switch is located on the right hand side of the steering column and controls all front and tailgate
wiper functions.
Moving the switch up 1 position selects intermittent windshield wiper operation. The rotary potentiometer on the
stalk selects 1 of 6 delay periods. When a rain/light sensor is incorporated into the system, the intermittent position
also initiates wiper operation controlled by the rain/light sensor. The sensitivity of the rain/light sensor can be
adjusted by rotating the rotary potentiometer to 1 of the 6 positions. Moving the switch up 1 further position selects
normal (slow) continuous wiper operation. Moving the switch up to the last position selects fast continuous wiper
operation.
Moving the switch down selects the flick wipe function. The windshield wipers will operate at normal speed for as
long as the flick wipe switch position is operated and will stop at the park position when the switch is released.
Moving the switch rearwards, towards the driver, selects the front wash/wipe function. The washer pump will operate
for as long as the switch is held. A short operation operates the pump momentarily and the wipers complete 3 full
cycles before stopping. The headlamp washers will operate if programmed wash/wipe is selected and the headlamps
are on. The power wash function can also be selected by depressing the button on the end of the stalk.
Rotating the outer ring of the wiper control switch to the first position selects the tailgate wiper intermittent mode
on. Rotating the outer ring of the wiper control switch further on to the second position selects the tailgate wiper
normal mode on. In intermittent mode, the tailgate wiper will complete 1 full cycle and will then operate on an
intermittent function until selected off. The intermittent delay between wipes can be adjusted by selecting the wiper
on, then off and then on again. Moving the switch forward to the second position selects the programmed rear
wash/wipe function. The wiper completes 5 full cycles with 3 automatic, short operations of the rear washer pump.
The tailgate wiper then operates in the tailgate wiper on mode until selected off.
The tailgate wiper also operates continuously if reverse gear is selected and the windshield wipers are on.
The wiper control switch comprises 8 switch positions and two intermittent rotary controls. The inner rotary control
selects the intermittent delay between wipes. The outer rotary control selects the tailgate wiper positions.
The switch positions each complete a combination of earth paths to 3 connections on the CJB. The CJB interprets the
selected combination of switches and operates the respective function accordingly.
Windshield wipers
The windshield wiper system comprises:
Wiper motor and linkage assembly

Washer reservoir and pumps
Wiper arms and blades.
Wiper Linkage

1 - Bolt (2 off)
2 - Washer (2 off)
3 - Bush (2 off)
4 - Crank (2 off)
5 - Tube
6 - Motor crank
7 - Link rod
8 - Pivot housing assembly
9 - Tube
10 - Electrical connector
11 - Windshield wiper motor
12 - Self-locking nut (2 off)
The wiper linkage and motor assembly are available as separate components. The wiper linkage differs between LHD
(left-hand drive) and RHD (right-hand drive) models. The wiper motor is common to LHD and RHD drive models.
The assembly is located below the plenum grill in the engine compartment and is secured with bushes, sleeves and
bolts. The rubber bushes isolate the assembly from the body mountings.
The linkage assembly comprises a main tube, with a pivot housing at each end. A bracket is attached, offset along
the tube length, which locates the motor assembly. A motor crank is positively attached to the motor output shaft. A
link rod is connected to the motor crank and is connected at the opposite end to the right pivot housing, via a crank.
The right link rod has a pivot attachment for the left link rod, which is connected at its opposite end to the right
pivot housing, via a second crank.
The motor crank converts rotary motion from the motor output shaft into linear movement of the link rods. The
cranks, connected between the each link rod and pivot housing, convert the linear motion back to rotary motion of
the pivot housing. This rotary motion is passed to the wiper arms and blades causing the blades to wipe an arc
across the windscreen.
Wiper Motor
The motor assembly comprises a DC (direct current) motor, which drives a gear wheel via a worm drive attached to
the motor spindle. The gear wheel has a central spigot, which provides the attachment point for the motor crank.
The motor is connected electrically by a four-pin connector. The connector supplies 2 battery voltage feeds to the
motor. The motor has 3 sets of brushes with 1 brush connected to ground. One feed is direct to the motor brush
opposite the ground brush and operates the motor at normal (slow) speed. The second feed is connected to a motor
brush, which is offset from the ground brush and operates the motor at fast speed. With the power supplied through
this brush, the current flows through fewer coil windings. This results in a lower resistance to the current flow to the
ground brush and gives a higher motor rotational speed.
Output control of the wiper motor is through a double contact relay. The relay is located in the EJB. The relay is a
tan color for identification.
The motor has an internal track, which signals the CJB when the wipers have reached the park position. The park
signal is an open circuit when the wipers are in the park position. When the wipers are switched off and the CJB
receives the park position signal from the motor, the CJB shorts the motor via a relay bridge circuit. This short
circuit has the effect of applying a brake to the motor, giving precise positioning of the wiper blades in the park
position.
Wiper Arms


1 - Self-locking nut cover
2 - Self-locking nut cover
3 - Wiper blade
4 - Wiper blade
5 - Wiper arm
6 - Wiper arm
The wiper arms are positively located on tapered splines on the wiper linkage spindles. The arm is located on a
curved wiper angle adjuster, which mates with the curved underside of the arm attachment. A curved slot in the arm
attachment locates an adjustment shim and the 3 components are retained under compression on the spindle spline
by a self-locking nut.
The wiper angle adjuster and the angle adjust shim allow the approach angle of the wiper blade to be finely adjusted
to its optimum wiping angle. The adjustment allows the approach angle of the blade to be adjusted to 2° on each
side of the spindle axis. This adjustment provides precise adjustment of the blade approach angle for maximum wiper
performance. The wiper angle adjuster is pressed onto the spindle and requires a tool for removal. Once removed,
the wiper angle adjuster must be discarded and new one fitted on re-assembly.
The wiper arm has a pivot point, midway between the spindle attachment and the blade. Two tension springs are
connected to the wiper arm on each side of the pivot point and apply pressure to maintain the wiper blade in contact
with the windscreen.
The wiper blades are attached to the wiper arms with clips that allow the blade to pivot. Each blade comprises a
number of levers and yokes to which the rubber wiper blade is attached. The levers and yokes ensure that the
pressure applied by the arm tension spring is distributed evenly along the full length of the blade and also allow the
blade to adjust to the curvature and contour of the windscreen. The driver's side blade is fitted with an aerofoil,
which presses the blade onto the windscreen at high speed, improving the wiper performance.
Washer Reservoir and Pumps

1 - Windshield washer reservoir filler cap
2 - Windshield washer reservoir filler neck
3 - Windshield washer reservoir
4 - Washer fluid level sensor
5 - Headlamp washer pump
6 - Front/rear washer pump
The windshield washer system comprises a washer fluid reservoir, a washer pump, 2 washer jets and hoses.
The plastic, molded reservoir is located in the right wheel arch, behind the liner and has a capacity of 12.3 pints (7
litres). It is secured with bolts and washers.
The reservoir has 2 recessed holes on its rear face, which provide location for the front/rear and headlamp washer
pumps. The pumps are push fitted into grommets, which seal the pumps in their locations. A hole in the top of the
reservoir allows for the fitment of a flexible filler tube.
A hole in the base of the reservoir provides the location for the fluid level sensor. The hole provides access to an
internal tube inside the reservoir, into which the sensor is fitted. The sensor has 2 pegs, which positively locate the
sensor in the reservoir when turned through 90°.
The sensor reacts to the influence of a magnetic field. A float, with integral magnet, is located around the tube,
inside the reservoir. The sensor has 2 contacts inside a glass tube, which are normally open. When the fluid level
reduces, the magnetic float moves down the tube. When the magnet reaches the sensor contacts, the magnetic field
closes the contacts. This completed circuit is sensed by the CJB, which displays the low fluid level message in the IC.
Heated Washer Jets
Two windshield washer jets are located in the rear trim panel on the bonnet outer surface. The washer fluid feed
hose from the front screen pump is connected to a 'Y' piece connector located between the 2 jets. Two short lengths
of hose connect the jets to the 'Y' piece. Each jet contains a Non-Return Valve (NRV) to prevent washer fluid
draining back to the reservoir and also to limit the amount of washer fluid, which can be forced by gravity from the
jet during cornering.
Each washer jet has 2 ball nozzles, which can rotate in their housings to obtain the optimum fluid application onto
the windscreen. Each washer jet contains a heater element, which prevents the fluid freezing in the nozzles in very
cold conditions. The jet heater elements are controlled by the ATC system, which energizes the heater elements
when the ambient temperature falls below a predetermined temperature.
Wiper Blade Heating
The lower, black, portion of the windshield contains 6 heating elements, which run from one side of the shield to the
other. These elements are designed to heat the area of the windscreen where the wiper blades rest to prevent
freezing in cold conditions.
The blade heating elements are controlled by the ATC system, which energizes the blade heating elements when the
ambient temperature falls below a predetermined temperature. The operation of the blade heating elements is
activated simultaneously with the heated washer jets.
Rain/Light Sensor

1 - Connector
2 - Receiver diodes
3 - Heater element
4 - Retaining clip
5 - Transmitter diodes
6 - Rain/light sensor body
7 - Ambient light sensor
8 - Forward light sensor
The rain/light sensor is located at the upper edge of the windshield, behind the interior rear view mirror. The sensor
is mounted on an optical unit which is heat bonded to the inner surface of the windscreen during manufacture. If
damage occurs to the optical unit or the windshield, then a new windscreen will be required and fitment can only be
performed by an authorized Land Rover dealer.
The rain/light sensor unit attaches to the optical unit via 4 clips which latch onto formed tags on the optical unit.
Positive retention is achieved by 2 retaining clips which force the clips onto the tags. The retaining clips must be
withdrawn to facilitate sensor removal.
The sensor provides information to the CJB, via the LIN bus, for the optimum wiper operation for the prevailing
conditions to maintain the screen in a clear condition at all times. The rain/light sensor is an optical unit, which
operates on an infrared waveband. The sensor uses the principle of the laws of reflection on interfacing surfaces
between materials with differing refraction indices.
The sensor contains 4 transmitter and receiver diodes for increased sensitivity and also contains a light sensor for
operation of the automatic headlamp function.
Rain/light Sensor Functionality


1 - Windscreen - Outside surface
2 - Optical unit
3 - Transmitter diodes (100% light transmitted)
4 - Rain/light sensor unit
5 - Receiver diodes (100% received)
6 - Water droplets/film
7 - Receiver diodes (less than 100% light received)
8 - Lost light
The rain/light sensor contains transmitter and receiver diodes, which transmit and receive infrared light, which is
directed onto the windscreen via an optical unit. The light is directed at an angle so that the light is reflected 100%
on the outside surface of the screen and is transmitted back into the optical unit. To receive a 100% reflection, the
outer screen surface must be clean and dry.
The light is reflected 4 times from when it leaves the transmitter diodes to when it is picked up by the receiver
diodes. If the windscreen is wet or dirty in the area of the optical unit, the clean conditions for 100% reflection
means that some of the light reflected is lost. As the screen becomes dirtier or wetter, the received light is evaluated
by the rain/light sensor and translated into a signal value. A micro-controller within the sensor monitors the change
in signal and initiates the appropriate wipe cycle via LIN bus signals to the CJB.
The software can compensate for the long-term effects of scratches and stone chips in the area of the optical unit
and the short term effects of dirt or smears caused by worn wiper blades. A heater element is also contained within
the rain/light sensor and uses ambient temperature LIN bus signals from the IC to keep the optical unit clear of frost
or condensation.
The rain/light sensor incorporates a light guide. The light guide directs the ambient light and a proportion of the
forward light (from the driving direction) to a light sensitive diode. This is used for the rain sensor sensitivity in low
ambient light levels and is also used to control the automatic headlamp function.
Intermittent (single wipe), continuous slow, and continuous fast windshield wiper operations are controlled by the
rain/light sensor when enabled.
Tailgate wiper
The tailgate wiper system comprises:
Wiper motor and control module assembly

Rear washer pump
Wiper arm and blade.
Tailgate Wiper Assembly


1 - Tailgate wiper blade
2 - Electrical connector
3 - Tailgate wiper motor
4 - Pivot housing assembly
5 - Bolt (3 off)
6 - Bush
7 - Tailgate wiper arm
8 - Self-locking nut
9 - Bush (3 off)
The tailgate wiper and washer operation is controlled by the CJB. The tailgate wiper operation is remote from the
GEM control of the windshield wiper systems.
The tailgate wiper motor and control module assembly is located in the upper tail door, behind a trim panel. The
assembly is secured to a bracket on the upper tail door with 3, Torx head screws. Rubber bushes isolate the motor
assembly from the bracket, which help reduce the transmission of motor operating noise to the tail door.
The assembly comprises the motor and the mounting bracket and the control module. The motor is located on a
worm drive gearbox mechanism, which converts the rotary motion of the motor output spindle into the required arc
for the tailgate wiper blade. The control module is integral with the motor and has 2 plug sockets, which accept 2
multiplugs from the harness. One multiplug has 2.5 mm diameter wires. Two of the wires supply permanent battery
feed and ground connections for the motor and control module. The third wire in this plug supplies a power supply to
the rear washer pump. The second multiplug has 0.35 mm diameter wires and carries signal data from the
wash/wipe control stalk switch and the CJB. There is also a power input from the RJB (rear junction box).
The rear washer feed hose is located at the rear of the motor spindle. The hose is connected to a 90° connector
allowing the washer fluid to flow through the center of the motor spindle.
The motor spindle is a conventional design with a taper spline location for the wiper arm and a threaded shank to
secure the arm to the spindle.
Wiper Arm
The wiper arm is similar in design to the windshield wiper arms. The arm attachment hole has tapered splines, which
mate with the splines on the wiper spindle. The arm is secured to the wiper motor spindle with a spring washer and
nut. The wiper arm has a pivot point, close to the spindle attachment. A tension spring is connected to the wiper
arm on each side of the pivot point and applies pressure to maintain the wiper blade in contact with the windscreen.
The wiper blade is attached to the wiper arm with a clip that allows the blade to pivot. The blade comprises a
number of levers and yokes to which the rubber wiper blade is attached. The levers and yokes ensure that the
pressure applied by the arm tension spring is distributed evenly along the full length of the blade and also allow the
blade to adjust to the curvature and contour of the windscreen.
A plastic cap located on the arm pivot point, covers the spindle attachment nut. The cap also contains 2, adjustable
ball jets, which direct washer fluid onto the tail door window. The cap, when installed, connects with the hollow
motor spindle, through which the washer fluid flows to the jets.
Headlamp Washer System

1 - Right headlamp washer jet
2 - Washer fluid hose
3 - Left headlamp washer jet
A wash jet for each headlamp is located in a housing on the top surface of the front bumper. The jets are fed with
fluid at high pressure from the headlamp wash pump. A large diameter hose connects each jet to the pump. Each
connection is secured with a metal clip to secure the hose due to the high pressure from the pump. Each jet directs
the high-pressure fluid in a wide spray onto the headlamp lens.
Wipers and Washers - Wipers and Washers
The wiper and washer system is controlled by the central junction box. All wiper functions for the front and rear
wipers are controlled from a multi-function wash/wipe switch assembly located on the steering column
For a detailed description of the wipers and washers systems and operation, refer to the relevant description and
operation section of the workshop manual. REFER to: Wipers and Washers (501-16 Wipers and Washers, Description
and Operation).
the donor vehicle
NOTES:

Visual Inspection
Windshield and rear window for damage or contamination e.g. road film Battery condition and state
or general residue deposits of charge
Wiper blades, arms and linkage for wear, security, damage and freedom Fusible links
of movement Fuses
Windshield/rear window/headlamp washer fluid level Relays
Washer pipes and jets for leaks, restrictions and damage Electrical connections
Front and rear wiper
motors
Wiper switch
Washer pumps
Rain/light sensor
Heated front washer jets
Ignition switch
Light switch
Ambient air temperature
sensor
ABS control module
Automatic temperature
control module
Instrument cluster
CAN circuits
Symptom Chart

Wiper blade(s) Contamination Clean the windshield/rear window. Check for the correct installation and
drag/judder across of the tension of the wiper arm(s). Refer to the relevant section of the
the windshield/rear windshield/rear workshop manual. Rectify as necessary
window window
Incorrectly
installed wiper
arm(s)
Wiper arm(s)
incorrectly
aligned to the
screen
Wiper arm(s)
spring tension
inadequate
Very slow operation Low battery Check the battery condition and state of charge. Check the wiper linkage
of the wiper(s) voltage for fouling. Disconnect the motor from the linkage. Refer to the relevant
across the Front wiper section of the workshop manual. Check the linkage operation. Check for
windshield/rear linkage seized DTCs indicating a wiper circuit fault. Rectify as necessary
window or fouling
Wiper(s) inoperative Wiper circuit
fault
Wiper switch
fault, high
resistance
Noisy operation of Wiper Lift the wiper arm(s) from the windshield/rear window and recheck the
wiper(s) motor/linkage noise level during the wiper sweep operation
fault
Noisy operation of Washer Listen for washer motor operation. Check and top up washer fluid level.
washers motor(s) faulty Check and rectify blocked washer circuit. Check the wiper/washer circuit
Washer system for DTCs indicating a fault. Rectify as necessary
blocked or
partially
blocked
Washers do not Fluid level low

operate Washer circuit
blocked
Washer circuit
faulty
DTC Index
REFER to: Diagnostic Trouble Code (DTC) Index - DTC: Central Junction Box (CJB) (100-00 General Information,
Wipers and Washers - Headlamp Washer Jet
Removal
WARNING: Be prepared to collect escaping fluid.

stands.
2. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and

Installation).
3.
4.
Installation

Wipers and Washers - Rain Sensor
Removal
2.
Installation

Wipers and Washers - Rear Window Wiper Motor
Removal
1. Remove the battery ground cable.

2. Refer to: Rear Window Wiper Pivot Arm (501-16 Wipers and
3. Torque: 4.1 Nm
4. CAUTION: The seals are to be reused unless

damaged.
5. Torque: 8 Nm
Installation

Wipers and Washers - Rear Window Wiper Pivot Arm
Removal
NOTES:
To be carried out in the event that the vehicle has no electrical power.

2. Refer to: Rear Spoiler (501-08 Exterior Trim and

3. Torque: 14 Nm
4. Do not disassemble further if removed for access

only
Installation

Wipers and Washers - Windshield Washer Pump
Removal
Refer to: Specifications (414-00, Specifications).

stands.
3. Refer to: Windshield Washer Reservoir (501-16 Wipers and

4.
Installation
1. CAUTION: The seals are to be reused unless damaged.
To install reverse the removal procedure.

Wipers and Washers - Windshield Washer Reservoir
Removal
All vehicles

stands.
3. Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Cold climate vehicles

4.
5. Torque: 7 Nm
6.
All vehicles
7.
8. Torque: 4.1 Nm
9.
10.
11. Torque: 4.1 Nm

13.
Installation
All vehicles
1. CAUTION: The seals are to be reused unless damaged.
To install reverse the removal procedure.

Cold climate vehicles
2.
3. Torque: 7 Nm
4.
Wipers and Washers - Windshield Washer Fluid Level Sensor
Removal
1. Refer to: Low Washer Fluid Warning Indicator Switch (413-09

Warning Devices, Removal and Installation).
Installation

Wipers and Washers - Windshield Wiper Pivot Arm
Removal
1. Note the orientation of the front wiper pivot arm

prior the removal.
Torque: 30 Nm

Installation

Wipers and Washers - Wiper Linkage Assembly
Removal
NOTES:

3. CAUTION: Protect the surrounding

components.
Installation
1. CAUTIONS:

shown.
Torque: 8 Nm
2.
Connect the battery ground cable.
Refer to: Specifications (414-00 Battery and Charging

System - General Information, Specifications).
Set the ignition to the ON position and make sure the
windshield wiper motor is in the park position.
Set the ignition to the OFF position.
Roof Opening Panel - Roof Opening Panel
Component Location

1 - Anti-Lock Brake System (ABS) control module
2 - Front roof opening panel blind and roof opening panel switches (front overhead console)
3 - Roof opening panel blind motor
4 - Roof opening panel motor
5 - Rear roof opening panel blind switch
6 - Roof opening panel
Overview
The roof opening panel assembly is built into a steel roof opening panel frame and incorporates the:
fixed Roof panels

opening roof panel
electronic roller blind
electric operating motors and mechanisms, and
wiring harness.
The motors are located at the front of the assembly. One of them powers the roof opening panel blind while the other
powers the roof opening panel. The steel frame is bonded into an aperture extending the full width of the roof,
between the cant rails of the vehicle’s aluminum body and fixed with 4x M8 nuts and 2x M6 bolts.
The roof opening panel and roof opening panel blind are controlled by the switch pack in the front overhead console.
The roof opening panel blind can also be controlled by a switch in the rear floor console on business class vehicles.
The rear floor console switch function can be isolated by isolating the rear electric windows isolation switch on the
driver window switch pack.
Control Diagram
NOTE: A = Hardwired; AN= High speed Powertrain CAN (controller area network)bus; O = LIN Bus

5 - Anti-lock Brake System (ABS) control module
7 - Rear roof opening panel blind switch (rear floor console)
8 - Front roof opening panel blind and roof opening panel switches (front overhead console)
10 - Battery
System Operation
Roof Opening Panel Switches

1 - Rear roof opening panel blind switch (rear floor console)
2 - Front roof opening panel blind switch (front overhead console)
3 - Roof opening panel switch
5 - Isolator switch
A rocker switch in the front overhead console controls the opening and closing of the roof opening panel with a one-
touch function in the direction required:
Press the roof opening panel switch once to tilt the panel.
Once tilted, press the roof opening panel switch again to open the panel.
Press the roof opening panel switch to close the panel from tilt.
From the fully open position, press the roof opening panel switch once to close to the tilt position, then press
again to close fully.
Roof opening panel movement can be halted at any time by pressing the roof opening panel switch again.
Anti-trap mechanism
If the roof panel encounters resistance when closing, it will stop and then open a set distance in the opposite
direction. This is to prevent serious injury or damage to the mechanism. The anti-trap mechanism can be overridden
to allow the roof to be closed when movement is restricted by dirt. To override the anti-trap mechanism, press and
hold the front of the switch until the roof reaches the closed position.
CAUTION: To prevent damage to the roof blind mechanism the blinds must not be operated manually.
Roof opening panel blind
NOTE: Global open/close functionality is enabled on the roof module.
One push of the front roof opening panel blind switch will fully open or close the blind. The blind is either fully open
or closed and cannot be halted part way.
The front blind opens automatically as the roof panel is opened, preventing wind affecting the blind. The blind cannot
be closed fully when the roof is open.
Glass Panels

1 - Front fixed panel
3 - Rear fixed panel
The external surface of the roof opening panel comprises the following three glass elements:
Fixed front glass panel (5mm thick)

Roof opening panel (4mm thick)
Fixed rear glass panel (4mm thick).
All three panels are manufactured in a tinted toughened glass and the opening and the rear panel have with a Protec
safety film bonded onto the lower surface to prevent shards of glass entering the vehicle cabin in the event of a
breakage.
The tinted glass provides a high degree of solar protection allowing only 8.2 percent heat transmission into the
vehicle.
The roof opening panel features an electrically powered tilt and slide mechanism. On opening, the rear of the panel
tilts upwards before moving rearwards above the rear roof opening panel.
Roof Opening Panel Components

1 - Front roof opening panel panel - fixed
3 - Rear roof opening panel panel - fixed
4 - Roof opening panel frame
5 - Roof opening panel blind support bracket
6 - Roof opening panel blind assembly
7 - Guide rails
8 - Roof opening panel blind drive assembly
9 - Roof opening panel drive assembly
Roof Opening Panel Components - Interior View


1 - Roof opening panel blind
4 - Roof opening panel frame
5 - Guide rails
The roof opening panel assembly features an electrically powered blind. Guided by side rails, the blind rolls to-and-
from the rear of the aperture.
Control Module and Motor
The opening and closing function of the roof opening panel and the roller-blind are controlled by the roof module
which is integral with the roof opening panel blind motor. The module receives a permanent battery power supply
from the CJB (central junction box).
To open or close the roof opening panel and the blind the module receives hardwired 'open/close' inputs from the
switches located in the front overhead console and the rear floor console.
The control module has a non-volatile memory. If battery power to the module is lost, the roof opening panel and
blind positions are retained and the one-touch feature does not require re-initializing. However, due to the software
condition, if the battery power to the control module is interrupted, when the ignition is switched on, the one-touch
feature must be re-initialized.
Once the power supply is restored, reset the roof mechanism as follows:
Turn ignition on.

Roof opening panel and roof opening panel blind system must be in closed position. (If not, use overhead
switches to close both).
Press “Roof” close switch for 20+ seconds until the roof opening panel blind actuates rearwards and then
forwards about 10mm.
Release “Roof” close switch and re-press “Roof” close switch again within 5 sec and keep pressed until the
following sequence has completed.
Roof opening panel blind opens fully.
Roof opening panel opens fully.
Roof opening panel closes fully.
Roof opening panel blind closes fully.
Release switch, roof is now fully initialized.
The motor that operates the roof opening panel uses a drive gear which engages and drives two cables within a
sleeved tube. Each cable is linked to the roof opening panel’s open and close mechanism located either side of the
panel in the guide rails. The rotation of the motor drives the cables in the required direction. Signals from a Hall
effect sensor located in the motor enables the control module to calculate the exact position and operating speed of
the glass sliding panel.
The Hall effect sensor is also an operational component of the anti-trap function. The control module uses the
operating speed of the roof opening panel and the current draw of the motor to detect an obstruction. If the roof
opening panel closing speed decreases below a set threshold and the current draw from the motor increases, the
power feed to the motor is reversed. This will then open the roof opening panel a set distance in the opposite
direction of travel. In an emergency the anti-trap function can be overridden by holding the operating switch in the
close position.
Depending on vehicle speed, the closing threshold of the anti-trap function is adjusted to counteract the force of air
pressure acting upon the roof opening panel. Vehicle speed signal is transmitted from the ABS (anti-lock brake
system) control module via the high speed CAN bus to the CJB where the signal is processed and transmitted over a
LIN (local interconnect network) bus connection to the roof module. As vehicle speed increases, air pressure forces
acting upon the sliding panel simultaneously increase, affecting the anti-trap functionality. The vehicle speed signal is
used by the control module to re-calibrate the anti-trap algorithm, accounting for the extra force acting on the
sliding panel. This function adapts the sliding panel closing speed threshold of the anti-trap function, dependent on
vehicle speed.
Both the roof opening panel and the blind motors have a thermal protection device built into the control module
software to protect them from overheating. The operating parameters are as follows:
If the motor temperature is between 60 and 77 °C, the roof operation is restricted to a close only function.
If the motor temperature exceeds 77 °C during the closing function, the movement will not be interrupted.
If the motor temperature exceeds 77 °C when the roof is closed, movement will be inhibited.
If the anti-trap function is operational when closing, the reverse movement of the motor will complete its
movement regardless of motor temperature.
Thermal protection for the roof opening panel motor and the blind motor are functioned in unison, therefore if one
motor exceeds 60 or 77 °C, the same restrictions, as defined above, will apply to both motors. For example, if the
front blind cannot be opened due to thermal protection, the roof opening panel will also ignore the opening
command.
For a detailed description of the roof opening panel system and operation, refer to the relevant description and
operation section of the workshop manual. REFER to: Roof Opening Panel (501-17 Roof Opening Panel, Description
and Operation).
the donor vehicle
NOTES:

Visual Inspection
Glass panel assembly Fuses
Glass panel seal Battery junction box
Frame assembly Central junction box
Sunblind Wiring harness
Deflector Loose or corroded connector(s)
Access panel Roof opening panel motor and control module
Roof opening panel cables Roof opening panel switch
Drain tube(s)
Symptom Chart

Roof opening Fuse(s) blown Check the fuse(s). Check the roof opening panel circuits. Check the switch
panel Circuit fault and motor function. Refer to the electrical guides
inoperative Switch fault
Motor fault
Roof opening Debris in the Check for general debris. Inspect, clean and lubricate the cable(s) and
panel channels/guides guides. Check the roof opening panel alignment. Refer to the relevant section
sticking Cable(s) of the workshop manual. Check the switch and motor function. Refer to the
sticking/damaged electrical guides
Roof opening
panel not
correctly aligned
Switch fault
Motor fault
Roof opening Debris in the Check for general debris. Inspect, clean and lubricate the cable(s) and
panel channels/guides guides. Check the roof opening panel alignment. Refer to the relevant section
juddering Cable(s) of the workshop manual. Check the motor function
sticking/damaged
Roof opening
panel not
correctly aligned
Motor fault
Water Debris in the Check for general debris and blocked drain tube(s). Inspect, clean and
ingress from channels/guides lubricate the cable(s) and guides. Check the glass panel seal. Check the roof
roof opening Drain tube(s) opening panel alignment. Refer to the relevant section of the workshop
panel blocked manual
Damage to the
glass panel seal
Roof opening
panel not
correctly aligned
Wind noise Damage to the Check the glass panel seal. Inspect, clean and lubricate the cable(s) and
glass panel seal guides. Check the roof opening panel alignment. Refer to the relevant section
Cable(s) of the workshop manual
sticking/damaged
Roof opening
panel not
correctly aligned
DTC Index
REFER to: Diagnostic Trouble Code (DTC) Index - DTC: Central Junction Box (CJB) (100-00 General Information,
Roof Opening Panel - Roof Opening Panel Alignment
General Procedures
1. NOTES:
The roof opening panel must be closed
With the roof opening panel closed, check the alignment of

the glass to the roof panel. The glass should be central in its
aperture. Profile of rear glass panel to body: front edge, set
flush or up to 1.0 mm (0.040") low; rear edge, set flush or up
to 1.0 mm (0.040") high.
Check the alignment of the roof opening panel.

The roof opening panel should be central in the roof
opening.
2. Raise the roof opening panel glass.

Open the roof opening panel shield.
3. NOTES:
RH shown LH similar.
Release the upper edges of the RH and LH roof opening panel

side trims.
4. NOTES:
5. Close the roof opening panel.
6. NOTE: RH shown LH similar.
Loosen the 4 screws.

7. CAUTION: Make sure the glass laminate is not damaged
during remove and installation.
NOTE: With the roof opening panel closed, check the

alignment of the glass to the roof panel. The glass should be
central in its aperture. Profile of rear glass panel to body: front
edge, set flush or up to 1.0 mm (0.040") low; rear edge, set
flush or up to 1.0 mm (0.040") high.
Align the roof opening panel glass.
8. NOTE: Apply force to the top of the glass panel to aid

alignment.
Align the roof opening panel glass.

Tighten the screws to 5 Nm.
9. NOTES:
This step requires the aid of another technician.
With assistance position the moving panel and tighten the

fixings.
10. NOTES:
Secure the upper edges of the RH and LH roof opening panel
side trims.
11. NOTES:
Roof Opening Panel - Air Deflector
Removal
NOTES:
1.
2. Release the wind deflector.

3. CAUTION: Remove the wind deflector in the sequence
shown, failure to do this may result in damage to the
component.
Installation

Removal
NOTES:
1.
2.
3. CAUTION: Make sure that new bolts are installed.
Torque: 5 Nm
4. CAUTION: Make sure that new bolts are installed.
Torque: 5 Nm

Installation
2. Refer to: Roof Opening Panel Alignment (501-17 Roof Opening

Panel, General Procedures).
Roof Opening Panel - Roof Opening Panel Blind
Removal
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: C-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
Refer to: D-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).
5. Refer to: Overhead Console (501-12 Instrument Panel and Console, Removal and Installation).
6. Refer to: Sun Visor (501-05 Interior Trim and Ornamentation, Removal and Installation).
7.
8. WARNING: Be prepared to collect escaping fluid.
9.
10.
11. NOTES:
13. CAUTION: Make sure damage is not caused

to the headliner.
NOTE: This step requires the aid of another

technician.
14.
15. CAUTION: The headliner must be lowered as
a complete unit to gain access, partial lowering of
the headliner may cause damage.
NOTE: Lower and reposition the headliner to

aid access.
16.
17.
18. Manually initialize the roof opening panel motor.
19. Open the roof opening panel glass.
20. Using a suitable tool, rotate the opening roof panel blind motor to adjust the blind.
21. CAUTION: Do not allow the glass roof panel
blind to retract until the locking pin is secure in its
locator.
Release the opening roof panel blind.
22. CAUTION: Do not allow the glass roof panel

blind to retract until the locking pin is secure in its
locator.
Release the opening roof panel blind from the

guide rails.
23. Install the glass roof panel blind retaining pin.

24.
25. Remove the opening roof panel blind.
Installation

Roof Opening Panel - Roof Opening Panel Frame
Removal
1. Refer to: Roof Opening Panel (501-17 Roof Opening Panel,

2. Refer to: Rear Glass Roof Panel (501-11 Glass, Frames and
3. Refer to: Front Glass Roof Panel (501-11 Glass, Frames and

Use a WK24ZS blade, cutting with the flat side against the
body.

body.
body.

body.
8.

Installation
1. CAUTIONS:
corrosion and foreign material.
Correct preparation of body apertures “post painting” to

ensure satisfactory glass adhesion, must be carried out in line
with industry practise.
Prepare the glass roof cassette flange and trim the PU adhesive in
accordance with the instructions included with the PU adhesive
kit.
2.
3. CAUTIONS:
corrosion and foreign material.

Prepare the glass roof cassette flange and trim the PU adhesive in
accordance with the instructions included with the PU adhesive
kit.
4. Apply RTV sealant in the position shown.
Install the roof opening panel module.

6. Torque:
M6 bolts 9 Nm
M8 Nuts 22 Nm
7. CAUTION: Make sure that no excess sealant residue is

evident.
If water is used as a means for the leak check, then allow

sealant to dry before testing.
Spray water around the glass roof panel, mark any area
that leaks. Dry the glass roof panel and sealant before
applying additional sealant.
Spray water around the roof area and mark any area that
leaks. Dry the roof glass and sealant before applying
additional sealant.
Roof Opening Panel - Roof Opening Panel Motor
Removal
NOTES:

2. Refer to: Sun Visor (501-05 Interior Trim and Ornamentation,


Refer to: B-Pillar Trim Panel (501-05 Interior Trim and

Refer to: C-Pillar Upper Trim Panel (501-05 Interior Trim and
Refer to: D-Pillar Trim Panel (501-05 Interior Trim and

7. NOTES:
Torque: 6 Nm
8. NOTES:
Torque: 6 Nm
9. NOTES:

10. NOTES:
Torque: 6 Nm
11. NOTES:

12. NOTES:
If equipped.
13. NOTES:
If equipped.

Torque: 6 Nm
14. CAUTION: Make sure damage is not caused to

the headliner.
NOTE: This step requires the aid of another

technician.
15. CAUTION: Make sure damage is not caused to the

headliner.
headliner.

headliner.
18.

headliner.
20. CAUTION: The headliner must be lowered as a complete
unit to gain access, partial lowering of the headliner may cause
damage.
NOTE: Lower and reposition the headliner to aid access.

21. WARNING: If the roof opening panel motor is
being replaced, the one touch and anti-trap function
will become inoperative. Close the roof opening
panel and continue to hold the switch for a further
20 seconds to allow the sunroof to complete a full
cycle. This will complete the roof opening panel
calibration routine and reset these functions.
Torque: 3 Nm
Installation

Roof Opening Panel - Roof Opening Panel Seal
Removal
NOTES:

2. CAUTION: Note the fitted position of the seal.
Using a suitable non-permanent marker, mark the installed

3. Remove and discard the seal.

4. CAUTION: Make sure that the surface is clean and free of
foreign material.
Clean the adhesive contact area.
Installation
1. Position the roof opening panel seal seam in the center of the roof
opening panel, as shown in the illustration.
2. CAUTION: Do not stretch the roof opening panel closing seal

during installation.
Install the roof opening panel closing seal using the mark made
prior to removal.

Bumpers -
Front bumper retaining bolts 55 41
Rear bumper retaining bolts 55 41
Horn assembly bolt 20 15
Bumpers - Front Bumper
Removal

stands.
2. Refer to: Speed Control Sensor (310-03A Speed Control - TDV6

3.0L Diesel, Removal and Installation).
4.
6.
7. Torque:
M10 45 Nm
M12 90 Nm
8. CAUTION: Be prepared to collect escaping
coolant.
Torque: 9 Nm
9.
10. Torque: 30 Nm
11.
12. Torque: 30 Nm
13. Torque: 55 Nm
14. Torque: 55 Nm
Installation

Bumpers - Front Bumper Cover
Removal

stands.
2. Refer to: Front Bumper Lower Cover (501-19 Bumpers, Removal

and Installation).
3.

6.
fluids.
8.
10.

13. NOTES:
Do not disassemble further if the component is

Repeat the step for the other side.

14.
15.
16.
17.
18.
19.
20.

Torque: 2.5 Nm
Torque: 2.5 Nm
Installation

Bumpers - Front Bumper Lower Cover
Removal

stands.
2.
Installation

Bumpers - Rear Bumper
Removal

stands.
2. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and

Installation).
Torque: 63 Nm
4. Torque: 63 Nm
Installation

Bumpers - Rear Bumper Cover
Removal
CAUTION: Always protect paintwork and glass when removing exterior components.
Refer to: Rear Lamp Assembly (417-01 Exterior Lighting,


stands.
5.
6.
7.
9.
10.
11.
12.
13. NOTES:

14.
15.
16.
17.

19.
20. CAUTION: Take extra care when handling the

component.
NOTE: Repeat the step for the other side.

Installation

Safety Belt System -
Safety belt retractor bolt 31 23
Safety belt height adjuster nut 31 23
Front safety belt upper anchor bolt 50 37
Rear safety belt upper anchor bolt 31 23
Safety belt guide bolt 6 4.4
Front safety belt buckle bolt 40 30
Rear safety belt buckle bolt 25 18
Safety Belt System - Safety Belt System
COMPONENT LOCATION - SHEET 1 OF 2

1 - Center rear seatbelt
2 - Center rear seatbelt retractor
3 - Rear left seatbelt retractor
4 - Rear left seatbelt
5 - Front left seatbelt height adjuster
6 - Front left seatbelt
7 - Front left seatbelt retractor
8 - Front seatbelt buckles
9 - Front right seatbelt retractor
10 - Front right seatbelt
11 - Front right seatbelt height adjuster
12 - Rear right seatbelt
13 - Rear right seatbelt retractor
14 - Rear seatbelt buckles
COMPONENT LOCATION - SHEET 2 OF 2 - 3RD ROW SEATS

1 - Seatbelt buckle
2 - Right seatbelt mounting
3 - Left seatbelt mounting
4 - Seatbelt
5 - Left seatbelt retractor
6 - Seatbelt buckle
7 - Seatbelt buckle
8 - Seatbelt buckle
9 - Seatbelt buckle
10 - Seatbelt buckle
11 - Right seatbelt retractor
12 - Right rear seatbelt
13 - Right rear seatbelt retractor
14 - Rear seatbelt buckles
OVERVIEW
A three point seatbelt is installed at each seat position. The front seatbelts have automatic height adjusters installed
on the B pillars.
A pretensioner is incorporated into the retractor of each front seatbelt and of the two rear seatbelts (4 seat vehicles),
or the two outer rear seatbelts (5 and 7 seat vehicles). Depending on vehicle specification and market, the seatbelts
may also have:
A tension sensor incorporated into the anchor of the front passenger seatbelt.
An ALR (automatic locking retractor) fitted to all passenger carrying seats.
A load limiter actuator incorporated into the retractor of the front passenger seatbelt.
A pretensioner incorporated into the anchor of the driver seatbelt.
A retractor with an active seatbelt function, on the driver and front passenger seatbelts.
The pretensioners, in the retractors and the driver seatbelt anchor, and the load limiter actuator are pyrotechnic
devices that are controlled by the RCM (restraints control module) in the SRS (supplemental restraint system). The
tension sensor is part of the occupant classification system in the SRS.
A seatbelt reminder and a beltminder system warn the driver if the seatbelt of an occupied front seat is not fastened,
or if a front or rear seatbelt is unfastened during the journey.
DESCRIPTION
Retractors

1 - Outboard rear seatbelt retractor
2 - Center rear seatbelt retractor
3 - Front seatbelt pretensioner retractor - non-active seatbelt (all except NAS passenger)
4 - Front seatbelt pretensioner retractor - non-active seatbelt (NAS passenger only)
5 - Front seatbelt pretensioner retractor - active seatbelt (all except NAS passenger)
6 - Front seatbelt pretensioner retractor - active seatbelt (NAS passenger only)
All of the seatbelt retractors incorporate an emergency locking function and, except for the center rear seatbelt on 5
and 7 seat vehicles, a load limiter function. On NAS vehicles, the retractors of the front passenger and rear seatbelts
also incorporate an automatic locking function.
The emergency locking function locks the retractor if the seatbelt is pulled out of the retractor too quickly, or if the
vehicle is subjected to a sudden deceleration or severe tilt angle. The automatic locking function allows the seatbelt
to be tightened and locked, for the installation of a child seat.
The load limiter function progressively releases an amount of seatbelt when the belt tension exceeds a certain level,
to limit the chest loading of an occupant during an impact.
LOAD LIMITER ACTUATOR
On NAS vehicles, the retractor of the front passenger seatbelt incorporates an adaptive load limiter that has two
different load limits, the standard load limit and a lower load limit. The lower load limit is designed to reduce the
seatbelt chest loading on smaller seat occupants during an impact. The load limiter changes from the standard limit
to the lower limit when the load limiter actuator is fired by the RCM.
ACTIVE SEATBELTS
Where fitted, active seatbelts incorporate retractors that recognize when the vehicle is in an extreme cornering or
braking condition, and automatically retract the seatbelt to pull the occupants more securely into their seats. Each
active seatbelt retractor has a locking unit, a drive unit with an electric motor, a clutch and gearing system, and an
electronic control module. The control module controls the operation of the electric motor using stored algorithms.
The active seatbelt retractor is a non-serviceable unit.
Active seatbelt retractors are powered by an ignition feed from the ignition relay in the CJB (central junction box),
and a permanent battery feed from the RJB (rear junction box). High speed CAN (controller area network) bus
connections provide the electronic control modules in the active seatbelt retractors with vehicle dynamic behavior
from other system control modules.
Buckle Switches
The buckle of each seatbelt incorporates a switch to provide a seatbelt status signal, which is used for operation of
the seatbelt reminder and beltminder systems, and for the firing strategy of the SRS.
The switches of the front seatbelts have signal and ground connections with the RCM. The switches of the rear
seatbelts have connections to a vehicle ground point and to the CJB. The RCM and the CJB broadcast the status of
the switches on the high speed CAN bus.
Seatbelt Warning Indicator
The CJB controls the operation of the seatbelt warning indicator with a high speed CAN bus message to the
instrument cluster.
OPERATION
Seatbelt Reminder
The seatbelt warning indicator comes on if the driver seatbelt, or the seatbelt of an occupied front passenger seat, is
not fastened. The indicator goes off when the offending seatbelt is fastened.
Front passenger seat occupancy status is provide by a hardwired input from the occupant detection sensor (all except
NAS), or a high speed CAN bus message from the OCSCM (NAS only).
Beltminder System
Where fitted, the beltminder system augments the seatbelt reminder. At vehicle speeds above 10 mph (16 km/h), if
the seatbelt of the driver seat or an occupied front passenger seat has not been fastened, or if a front or rear
seatbelt is unfastened, the beltminder system activates an intermittent warning tone, flashes the seatbelt warning
indicator and displays a warning message indicating which seatbelt triggered the warning.
The CJB controls the operation of the beltminder system with a high speed CAN bus message to the instrument
cluster.
A graphic in the message center shows the status of the seatbelts. Each seating position is represented by a
passenger icon, the color of which indicates the seatbelt status:
No color - seatbelt not fastened.

Green - seatbelt fastened.
Red - seatbelt status changed from fastened to unfastened.
A beltminder warning triggered by one of the rear seatbelts can be cancelled by pressing the information button on
the steering wheel.
Although not advisable, it is possible to disable the beltminder system using Land Rover approved diagnostic
equipment.
NOTE: If a heavy object is placed on the front passenger seat, it may trigger a beltminder warning.
Active Seatbelts
The active seatbelt function is scenario based, with arbitration taking place between the active scenarios to determine
the required system response. The system covers the following four scenarios:
CMbB (collision mitigation by braking) and AEBA (advanced emergency brake assist), associated with the
forward alert function of the adaptive speed control system.
Braking.
Cornering.
Stability (oversteer/understeer).
The active seatbelt system recognizes activation of the AEBA function, heavy braking, hard cornering and the onset
of either understeer or oversteer, as unusual states. The system receives the unusual state signals from several
network modules which broadcast the information on the high speed CAN bus.
The signals are detected by each retractor’s integrated control module, compared against the algorithm database
and, if appropriate, the module instructs the electric motor to activate the retractor.
If the unusual state continues to develop into an accident, the seatbelt pretensioners and load limiters are activated
in the normal way, over and above the function of the retractor. If the unusual state returns to a usual state, the
control module sends a further signal to the electric motor and the retractor is released until required again.
Conditions which activate the system include high lateral cornering forces, exceeding pre-determined understeer or
oversteer thresholds and exceeding pre-determined brake pressure thresholds. In each case the force and speed of
the seatbelt retraction will be proportional to the severity of the manoeuver.
The system activates the retractor at lower thresholds with correspondingly lower forces and on-set rates, while
increasing both force and the on-set rate in proportion to more severe inputs.
The system is also used to alert the driver to the AEBA function. If the threat of a collision increases beyond a set
threshold, the system will retract the seatbelt.
TENSION PROFILES
The operation of the system is linear and progressive in nature. Low level tensioning is introduced as the vehicle
enters a manoeuver that is deemed to offer a customer benefit by tensioning the seatbelt, thus providing occupant
support. If the vehicle increases the severity of its manoeuver, the level of tension will increase, until a pre-
determined high level combination of force and speed is reached, at which point 'maximum' output tension will be a
response to a critical driving manoeuver.
Once tension in the seatbelt is achieved (and the seatbelt has stopped pulling in), further increases in manoeuver
severity will not result in an increased tension. This is to prevent the occupant feeling repeated 'jerking' of the
seatbelt through a manoeuver. However, if a critical driving manoeuver is detected this logic is overruled and the
retractor will attempt to pull in at maximum force and speed.
NETWORK SIGNALS
The active seatbelt control modules use a combination of information from other system modules. Using this
information the module applies algorithms to control the active seatbelt operating conditions.
The active seatbelt control modules receive signals on the high speed CAN bus from the following system
components:
Signal Signal Supplier

Brake pressure ABS (anti-lock brake system) control module
Wheel speed sensors ABS control module
Steering wheel angle ABS control module
Steering wheel angle speed ABS control module
Steering wheel angle status ABS control module
Lateral acceleration RCM
Yaw rate RCM
Driver and passenger seatbelt buckle status RCM
Passenger seat occupant status (NAS only) RCM
Crash status RCM
Passenger seat occupant status (all except NAS) CJB
Vehicle information parameter CJB
CCF (car configuration files) CJB
Battery voltage CJB
Menu setting request Instrument cluster
Dynamic or Winter mode selected Transmission control switch
Advanced emergency brake assist Adaptive speed control module
The active seatbelt control modules communicate with each other to confirm the sensitivity mode request from the
instrument pack (selected by the vehicle user) and/or the dynamic or winter mode request from the transmission
control switch (selected by the vehicle user).
Acknowledgment signals are broadcast on the high speed CAN to confirm active seatbelt status in reply to the input
signals listed above. Fault warnings to the instrument pack message center activate an Active Seat Belt Unavailable
message, which is accompanied by the triangular amber warning indicator.
DRIVER SETTING
The vehicle user can access the active seatbelt setting menu via the vehicle Set-up menu of the instrument cluster:
Dynamic Mode On – the active seatbelt system is set to activate during enthusiastic driving and critical driving
maneuvers.
Dynamic Mode Off – the active seatbelt system is set to activate only during critical driving maneuvers with a
maximum level output.
The user selection remains locked during and after ignition cycling.
WINTER AND DYNAMIC MODES
The selection of the transmission dynamic mode or winter mode activates alternative mapping in the active seatbelt
control modules providing different levels of force and speed sensitivity of the system.
If the active seatbelt sensitivity is set to Dynamic Mode On (as selected in the instrument cluster menu) and the
vehicle user selects transmission dynamic mode, the active seatbelt will tension gently and then release. This will
occur at all vehicle speeds unless the active seatbelt is inhibited or Dynamic Mode Off is selected.
INHIBITED AND DISABLED FUNCTIONS
The following references to active seatbelt inhibited or disabled are defined as follows:
Active seatbelt has been inhibited but the control module is operating normally. For example, all scenarios are
inhibited because the seatbelt is not fastened.
Active seatbelt has been disabled due to an internal or external fault. For example, active seatbelt control
module internal memory fault or a fault discovered with the ABS module information.
The relevant active seatbelt control module is inhibited if any of the normal operating conditions listed below occurs
during a given ignition cycle. As soon as the condition no longer applies in the same ignition cycle, the active seatbelt
control module is re-enabled:
RCM indicates that the driver or passenger seatbelt is not fastened for the relevant active seatbelt control
module.
Ignition is off and no messages are being received or transmitted on the high speed CAN bus as a result.
NAS vehicles only - the active seatbelt functionality is inhibited on the passenger side if the Occupant
Classification Sensor Control Module (OCSCM) indicates that the passenger seat status is occupied inhibit. For
example, a small person is occupying the passenger seat.
RCM is transmitting a crash signal before the start of any retraction.
Active seatbelt is in the middle of a retraction or is already holding a retraction and the RCM has indicated that
a crash has occurred.
NOTE: No DTC (diagnostic trouble code) is recorded during the inhibited condition.
The relevant active seatbelt control module is disabled if any of the fault conditions listed below occur during a given
ignition cycle:
A fault occurs in high speed CAN message transmission or other system components transmitting operating
information.
Failure of critical parts within the active seatbelt unit, including software, that will not be resolved during a
given ignition cycle.
Battery voltage below 9 V or above 16 V continuously for two seconds (the system will differentiate between
genuine low battery voltage and low voltage due to engine cranking).
NAS vehicles only - the functionality is disabled on the passenger side only because the OCSCM indicates a
fault.
The active seatbelt motor has overheated and no retractions are available in the current cycle.
The active seatbelt unit has exceeded its cycle requirements for lower functions and safety activation is
unavailable (see below).
NOTE: If the active seatbelt motor exceeds a certain heat threshold and is on a hold cycle, the tension is still
released when the manoeuver has been completed.
The active seatbelt has been designed to exceed 10 years operating life in normal driving conditions. However, it has
a limited life cycle. The lower output functions are disabled in the unlikely event that the unit exceeds its cycle
requirement due to repeated overuse. In this case the lower output retractions are not operational. If this condition
occurs the unit only operates with a maximum output and a DTC is recorded. The DTC remains active even if a
complete re-programming procedure of the active seatbelt control module is attempted. The maximum output will
operate in all activation scenarios under critical maneuvers previously described except for cornering, which does not
include a maximum output activation.
DIAGNOSTICS
In the event of a system fault DTC's are stored in the control modules. In certain circumstances the system will
attempt to maintain an operational state utilizing the most appropriate default strategy, reducing its functionality
depending on the type of fault. The message Active Seat Belt Unavailable is displayed in the instrument cluster
message center, accompanied by the triangular amber warning indicator.
The active seatbelt control modules contain a self-test function, which can be activated by Land Rover approved
diagnostic equipment.
The self-test operates in the following sequence:
1. With the seatbelt buckled and the engine running, a maximum retraction is implemented.
2. Retraction held for 3 seconds.
3. Retraction released.
Control Diagram - Seatbelt Reminder/Beltminder System
NOTE: A = Hardwired; AN = High speed PowertrainCAN bus.


1 - Battery
4 - Occupant detection sensor (where fitted)
5 - Seatbelt tension sensor (where fitted)
6 - Occupant Classification Sensor Control Module (OCSCM) (where fitted)
8 - Restraints Control Module (RCM)
9 - Front left buckle switch
10 - Front right buckle switch
11 - Right rear buckle switch
12 - Rear center buckle switch (where fitted)
14 - Left rear buckle switch
Control Diagram - Active Seatbelts
NOTE: A = Hardwired; AN = High speed PowertrainCAN bus.


1 - Battery
5 - Left seatbelt retractor
6 - Right seatbelt retractor
7 - Occupant Classification Sensor Control Module (OCSCM) (where fitted)
9 - Transmission Control Switch (TCS) (dynamic and winter mode switches)
11 - Adaptive Speed Control Module (ASCM)
12 - Anti-lock Brake System (ABS) control module
14 - Occupant detection sensor (where fitted)
For a detailed description of the safety belt system and operation, refer to the relevant Description and Operation
section of the workshop manual. REFER to: Safety Belt System (501-20A Safety Belt System, Description and
Operation).
Safety Information
WARNINGS:
To avoid accidental deployment the back-up power supply must be depleted before beginning any work on the
SRS system or its components. Failure to follow this instruction may result in personal injury.
Do not use a multimeter to probe an SRS module. It is possible for the power from the meter battery to trigger
the activation of the module. Failure to follow this instruction may result in personal injury.
NOTE: It is advisable not to use a cellular phone or to have a cellular phone in close proximity when working
on the SRS system or components.
Power supply depletion
Before beginning any work on the SRS system or related components:
1. Remove the ignition key.
2. Disconnect the battery leads, ground first.
3. Wait 2 minutes for the power circuit to discharge.
There are comprehensive instructions on the correct procedures for SRS system repairs in the manual. Refer to the
relevant section of the workshop manual.
the donor vehicle.
NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
1. Verify the customer concern by operating the safety belt.
2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection
Check for the installation of non-standard accessories which may affect or Fuses
obstruct the function of the safety belt system Wiring harness
Frayed or damaged webbing Warning lamp
Buckles/Stalks, etc bulb(s)
Reels Impact sensor(s)
Retractors Buckle sensor(s)
Sensor(s) Pretensioner(s)
Pretensioner(s) Restraints control
module (RCM)
proceeding to the next step.
4. If the cause is not visually evident, carry out the test methods described below, alternatively check for
Diagnostic Trouble Codes (DTCs) and refer to the relevant DTC Index.
Symptom Chart

Seatbelt - Jammed (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Webbing guide incorrect location
Foreign object in webbing route
Safety belt reel is incorrectly installed
Seatbelt - Not retracting (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Seatbelt - Not working (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Seatbelt - Slow retraction (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Seatbelt - Binding (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Seatbelt - Inoperative (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Seatbelt - Intermittent (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Seatbelt - Jamming (ALR) automatic locking retractor in use (normal operation) GO to Pinpoint Test A.
Twist in webbing
Component Tests
Poor Retraction
If a safety belt does not retract correctly, check that the anchor covers and trim bezels are correctly installed and not
rubbing against the safety belt webbing. Where necessary, check the safety belt webbing is not rubbing at one end
of the retractor cover slot and if so, correct by loosening the retaining bolt, aligning the retractor to centralize the
safety belt webbing and re-tighten the bolt.
The vehicle is equipped with two front and three rear inertia reel safety belts. These safety belts are "dual sensitive"
which means that they have:
a vehicle motion sensor, which locks the safety belt webbing under braking, cornering, on steep hills and in
adverse camber conditions.
a webbing motion sensor, which locks when the safety belt webbing is quickly extracted.
Both systems should be fully operational and can be checked by the tests below:
Dynamic Tests
Either of the following two procedures may be used to check the correct operation of the safety belts. Both methods
require two people but note that people of larger than average size should not be asked to conduct these tests. This
is to avoid the possibility of a fully unrolled safety belt webbing being mistaken for a correctly locked safety belt
retractor.
Test Method 1 (braking)
WARNING: It is important that during this test, the wearer allows the safety belt to provide the restraint, the
wearer should not attempt to anticipate the sudden deceleration and the driver should not brace themselves against
the steering wheel. However, both the driver and the passenger must prepare themselves for the possibility that the
safety belt will not lock. The passenger should hold their hands in front of them, just clear of the instrument panel or
front seat backrest, depending on which belt is being tested. Failure to follow these instructions may result in
personal injury.
Select a quiet or private stretch of road. Make sure that the road is clear and that full visibility is maintained
at all times.
Both driver and passenger should adopt a normal, comfortable seating position. Both occupants should wear
the safety belts and the safety belt webbing should be correctly adjusted.
Proceed at a speed of approximately 10 km/h (6 miles/hour).
- Do not exceed 10 km/h (6 miles/hour) for this test
Apply the foot brake sharply to stop the vehicle. If the vehicle motion sensitive lock mechanism is operating
correctly, the safety belt webbing will lock and restrain the wearer.
Conduct the test twice in each front and rear passenger seat position.
Any safety belt retractor which does not restrain the wearer during this test must not be reused. A new safety
belt should be installed.
Test Method 2 (Turning circle)
This method requires a flat open area of private road, sufficient for the vehicle to be driven in a continuous circle on
full lock.
The driver should wear the safety belt provided and the belt webbing should be correctly adjusted.
The passenger should occupy a rear seat with the safety belt correctly adjusted.
Start the engine and, with the steering on full right-hand lock, drive the vehicle in a continuous circle at 16
km/h (10 miles/hour).
- Do not exceed 16 km/h (10 miles/hour) for this test
When the speed is stable, the passenger should attempt to slowly extract the safety belt webbing from each
safety belt retractor in turn. If the vehicle motion sensitive lock mechanism is operating correctly, it will not
be possible to extract the webbing.
Any safety belt retractor from which it is possible to extract the webbing during this test must not be used. A
new safety belt should be installed.
Safety Belt Webbing Sensor Test
With the vehicle stationary and on level ground take firm hold of the safety belt webbing (on the tongue side of the
upper safety belt anchor) and pull out quickly. The retractor should lock within 0.25m (10 inches), preventing further
webbing release. Any safety belt retractor from which it is possible to extract further webbing must not be used. A
new safety belt should be installed.
DTC Index
For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00.
Pinpoint Test
PINPOINT TEST A : DIAGNOSTIC GUIDE FOR THE SECOND AND THIRD ROW SAFETY BELTS
CONDITIONS
A1: SAFETY BELT
NOTE: During normal conditions the (ALR) automatic locking retractor can operate giving the impression of a
jammed safety belt this can be overcome by drawing 20mm of webbing from the belt reel with moderate force, the
belt reel should then operate correctly. Check the operation, if the webbing moves freely then retracts correctly no
further action required, do not replace safety belt.
1 Visually inspect the condition of the safety belt.
Is the safety belt fully retracted?
Yes
The safety belt is fully retracted, no slack in the webbing.GO to A2.
No
Not fully retracted, the webbing is slack.GO to A3.
A2: REQUIRED FORCE
1 Draw the webbing from the safety belt reel with moderate force then release the webbing. Carry
out this operation twice.
Does the webbing move freely then retract correctly?
Yes
No further action required, do not replace safety belt.
No
GO to A3.
A3: WEBBING SLACK - NOT FULLY RETRACTED
1 Remove any trim panels to expose the D loop (anchor point) and safety belt reel. Check the
webbing is not trapped or twisted.
Yes
While refitting the trim panels, ensure there are no obstruction and the webbing does not catch
or rub. Check the operation, if the webbing moves freely then retracts correctly no further action
required, do not replace safety belt.
No
GO to A4.
A4: TRAPPED OR TWISTED SAFETY BELT WEBBING
1 If the webbing is twisted due to a fold passing through the anchor point (do not remove the
safety belt reel) feed the twist back through the anchor point to remove. If the webbing is
trapped, release and inspect for damage, if the webbing is damaged replace the safety belt.
Yes
If the webbing moves freely then retracts correctly no further action required, do not replace
safety belt. While refitting the trim panels, ensure there are no obstruction and the webbing does
not catch or rub.
No
GO to A5.
A5: SAFETY BELT WEBBING GUIDE LOCATION
NOTE: The safety belt reel has a guide installed that can cause the safety belt reel to operate poorly if
incorrectly located.
1 Visually and manually inspect the safety belt reel webbing guide for location and installation.
Is the safety belt reel webbing guide for location and installation correct and secure?
Yes
GO to A6.
No
Refit the safety belt reel webbing guide ensure the fixing lug is properly located in the retractor
frame. When correct draw the full length of the webbing from the reel then allow the belt to
retract, the webbing will now be central on the spindle. Check the operation, if the webbing
moves freely then retracts correctly, no further action required, do not replace safety belt. While
replacing the trim panels, ensure there are no obstruction and the webbing does not catch or
rub.
A6: SAFETY BELT REEL LOCATION
NOTE: Incorrect installation / location of the safety belt reel can affect operation.
1 Confirm that the safety belt reel is correctly installed, check for correct location of both anti
rotational pins if present.
Is the safety belt reel is correctly installed?
Yes
Check the operation, if the webbing moves freely then retracts correctly, no further action
required, do not replace safety belt. While replacing the trim panels, ensure there are no
obstruction and the webbing does not catch or rub.
No
Correctly install the safety belt reel ensuring correct location of both anti rotational pins if
present. Check the operation, if the webbing moves freely then retracts correctly, no further
action required, do not replace safety belt. While replacing the trim panels, ensure there are no
obstruction and the webbing does not catch or rub.
For a detailed description of the seatbelt system and operation, refer to the relevant description and operation
section of the workshop manual
REFER to: Safety Belt System (501-20A Safety Belt System, Description and Operation).
Safety Information
WARNINGS:
To avoid accidental deployment the back-up power supply must be depleted before beginning any work on the
SRS system or its components. Failure to follow this instruction may result in personal injury
Do not use a multimeter to probe an SRS module. It is possible for the power from the multimeter battery to
trigger the activation of the module. Failure to follow this instruction may result in personal injury
NOTE: Do not to use a cellular phone or to have a cellular phone in close proximity when working on the SRS
system or components
Power supply depletion
Before beginning any work on the SRS system or related components:
1. Remove the ignition key
2. Disconnect the battery leads, ground first
3. Wait 2 minutes for the power circuit to discharge
There are comprehensive instructions on the correct procedures for SRS system repairs, refer to the relevant section
of the workshop manual
the donor vehicle
NOTE: Check and rectify basic faults before beginning diagnostic routines including pinpoint tests
1. Verify the customer concern by operating the seatbelt

Visual Inspection
Check for the installation of non-standard accessories which may affect or Fuses
obstruct the function of the seatbelt system Wiring harness fault
Frayed or damaged webbing Correct engagement of
Missing or damaged button stop electrical connectors
Pretensioner(s) Buckles/Stalks Loose or corroded
connections
Warning lamp bulb(s)
Impact sensor(s)
Buckle sensor(s)
Pretensioner(s)
Belt tension sensor(s)
Restraints control module
4. If the cause is not visually evident, carry out the test methods described below, alternatively check for
diagnostic trouble codes and refer to the relevant diagnostic trouble code index
For a complete list of all diagnostic trouble codes that could be logged on this vehicle, please refer to section 100-
00.
REFER to: Diagnostic Trouble Code (DTC) Index - DTC: Restraints Control Module (100-00 General Information,
Symptom Chart for Seatbelt Rows 1, 2 and 3

Seatbelt jammed - Backlock effect-in action (webbing retracted quickly GO to Pinpoint Test A.
Webbing tight and came to sudden stop) GO to Pinpoint Test F.
Seatbelt retractor not installed correctly GO to Pinpoint Test H.
Rear centre seatbelt only. Mini-button (webbing travel See the automatic locking
limit stop) missing and seat squab has been moved retractor description below
causing tight fit
Automatic locking retractor activated (clicking – during
retraction only)
Seat squab will GO to Pinpoint Test H.

not fold/jammed NOTE: Rear centre seatbelt only
Mini-button (webbing travel limit stop) missing and

seat squab has been moved causing excessive tension
Seatbelt jammed - Seatbelt webbing trapped in seat GO to Pinpoint Test B.

Webbing loose Seatbelt retractor webbing guide loose GO to Pinpoint Test C.
Twist in webbing GO to Pinpoint Test D.
Interference in webbing routing GO to Pinpoint Test E.
D-loop not rotating correctly GO to Pinpoint Test G.
Seatbelt - Seatbelt retractor not installed correctly GO to Pinpoint Test F.

Intermittent
jamming
Seatbelt - Slow Seatbelt retractor webbing guide loose GO to Pinpoint Test C.
retraction Twist in seatbelt webbing GO to Pinpoint Test D.
Seatbelt retractor not installed correctly GO to Pinpoint Test F.
Foreign object/debris GO to Pinpoint Test E.
Seatbelt - Not Seatbelt retractor webbing guide loose GO to Pinpoint Test C.

retracting Twist in seatbelt webbing GO to Pinpoint Test D.
Foreign object/debris GO to Pinpoint Test E.
Seatbelt - Not Backlock effect-in action (webbing retracted quickly GO to Pinpoint Test A.
extracting and came to sudden stop) GO to Pinpoint Test F.
Seatbelt retractor not installed correctly GO to Pinpoint Test C.
Seatbelt retractor webbing guide loose GO to Pinpoint Test D.
Twist in seatbelt webbing GO to Pinpoint Test G.
D-loop not rotating correctly GO to Pinpoint Test E.
Foreign object/debris See the automatic locking
Automatic locking retractor activated (clicking – during retractor description below
retraction only)
Seatbelt - Noisy Automatic locking retractor activated (clicking–during GO to Pinpoint Test B.

during operation retraction only) GO to Pinpoint Test E.
Interference in webbing routing (rubbing)
Seatbelt buckle - Foreign object/debris

Not latching / CAUTION: Do not insert any
jammed objects or tools into the buckle
head
GO to Pinpoint Test I.
Inertia Reel Seatbelts
The vehicle is equipped with (two row one), (three row two), and (two row three (seven seat versions only)) inertia
reel seatbelts
These seatbelts are "dual sensitive" which means that they have:
Car sense system - A vehicle motion sensor, which locks the seatbelt webbing under braking,
cornering, on steep hills and in adverse camber conditions, when parked on a steep incline or
driveway or two wheels on a high curb
Webb sense system - A webbing motion sensor, which locks when the seatbelt webbing is
extracted suddenly
The seatbelts in the following positions are equipped with an automatic locking retractor function:
Seat Automatic Locking Retractor From Model

Carline Market position Installed Year
Defender (L316) All All No 2007
Discovery / Range Rover Sport All Driver No 2008
(L319/L320)
Discovery / Range Rover Sport US Passenger Yes 2005
(L319/L320)
Discovery / Range Rover Sport All Driver No 2005
(L319/L320)
Discovery / Range Rover Sport ROW Passenger No 2005
(L319/L320)
Discovery (L319) All Row 2 Yes 2005
Discovery (L319) All Row 3 Yes 2005
Range Rover Sport (L320) All Row 2 Yes 2006
Freelander (L359) All Driver No 2007
Freelander (L359) ROW Passenger No 2007
Freelander (L359) US Passenger Yes 2007
Freelander (L359) ROW Row 2 No 2007
Freelander (L359) US Row 2 Yes 2007
Range Rover Evoque (L538) All Driver No 2011
Range Rover Evoque (L538) ROW Passenger No 2011
Range Rover Evoque (L538) US Passenger Yes 2011
Range Rover Evoque (L538) ROW Row 2 No 2011
Range Rover Evoque (L538) US Row 2 Yes 2011
Range Rover (L322) All Driver No 2003
Range Rover (L322) ROW Passenger No 2003
Range Rover (L322) US Passenger Yes 2003
Range Rover (L322) ROW Row 2 No 2003
Range Rover (L322) US Row 2 Yes 2003
Range Rover Sport (L494) All Driver No 2014
Range Rover Sport (L494) ROW Passenger No 2014
Range Rover Sport (L494) US Passenger Yes 2014
Range Rover Sport (L494) ROW Row 2 No 2014
Range Rover Sport (L494) US Row 2 Yes 2014
Range Rover Sport (L494) ROW Row 3 No 2014
Range Rover Sport (L494) US Row 3 Yes 2014
Range Rover (L405) All Driver No 2013
Range Rover (L405) ROW Passenger No 2013
Range Rover (L405) US Passenger Yes 2013
Range Rover (L405) ROW Row 2 No 2013
Range Rover (L405) US Row 2 Yes 2013
Range Rover (L405) All Row 3 No 2013
The automatic locking retractor function is a feature to secure a child seat or heavy load to the seat
Activation Deactivation
Automatic locking retractor is deactivated
NOTE: When automatic locking retractor is activated, no further by allowing the webbing to retract until
webbing can be drawn from the seatbelt retractor, prior to disengagement the clicking stops (close to park position)
of the automatic locking. This can be mistaken as a jammed seatbelt
retractor
Activated by total extraction of the webbing

When activated the automatic locking retractor is identified by a clicking When deactivated the automatic locking
noise during webbing retraction retractor seatbelt changes state, from a
static seatbelt to an automatic seatbelt
Seatbelt Locking Test
With the vehicle stationary and on level ground take firm hold of the seatbelt webbing (on the tongue side of the
upper seatbelt anchor) and withdraw sharply, the retractor should lock. Preventing further webbing release
(repeat this test 3 times). Any seatbelt retractor which fails to lock must not be used and a new seatbelt
must be installed.
DTC Index
For a list of diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00 or for
removal and installation/description and operation see Section 501-20
Diagnostic Guide Inertia Reel Seatbelts
PINPOINT TEST A : BACKLOCK

CONDITIONS
A1: BACKLOCK
1 Visually inspect the condition of the suspect seatbelt
2 Draw a maximum of 20mm of the webbing from the seatbelt retractor with moderate force.
Then release the webbing
3 Check for correct operation twice
Yes
No further action required
No
For first row seatbelt GO to Pinpoint Test C. For second and third row seatbelts GO to Pinpoint
Test B.
PINPOINT TEST B : WEBBING - TRAPPED IN SEAT

CONDITIONS
B1: WEBBING - TRAPPED IN SEAT
1 Visually inspect the condition of the suspect seatbelt
2 Lift the seat base or release the seat backrest as required
3 Free the trapped webbing, allow the webbing to retract Note: If the automatic locking
retractor is activated, allow the webbing to retract until the clicking stops
Yes
No further action required
No
GO to Pinpoint Test C.
PINPOINT TEST C : SEATBELT RETRACTOR - WEBBING GUIDE LOOSE

CONDITIONS
C1: SEATBELT RETRACTOR - WEBBING GUIDE LOOSE
1 Refer to 501-20 removal and installation section of the workshop manual, remove any trim
panels required to expose the D loop (anchor point) and seatbelt retractor
2 Check the webbing is not trapped or twisted and is centrally located on the seatbelt retractor
spindle
3 Attempt to withdraw the webbing from the seatbelt retractor NOTE: If the seatbelt webbing
is jammed, the automatic locking retractor could be engaged
4 To release the automatic locking retractor, manually wind the webbing onto the spindle until the
automatic locking retractor deactivates (clicking stops)
5 Fully extract webbing
6 Confirm webbing guide location is correct , Confirm the fixing lugs are correctly located in the
retractor frame
7 Allow webbing to retract
Yes
Refer to the 501-20 removal and installation section of the workshop manual, reinstall any trim
panels, ensure there are no obstructions and the webbing does not catch or rub. No further
action required
No
GO to Pinpoint Test D.
PINPOINT TEST D : TWIST IN WEBBING

CONDITIONS
D1: TWIST IN WEBBING
1 Refer to section 501-20 removal and installation section of the workshop manual, remove any
trim panels required to expose the D loop (anchor point)
2 Twist the webbing back the correct way in the loop
3 Pass the twist through the pillar loop or escutcheon as required
Yes
action required
No
GO to Pinpoint Test E.
PINPOINT TEST E : INTERFERENCE - WEBBING ROUTING

CONDITIONS
E1: INTERFERENCE - WEBBING ROUTING
1 Refer to the 501-20 removal and installation section of the workshop manual, remove any trim
panels required to expose the D loop (anchor point)
2 Remove obstructions and foreign objects ensure the webbing does not catch or rub
3 Confirm the seatbelt does not contact the wiring harness
Yes
action required
No
GO to Pinpoint Test F.
PINPOINT TEST F : SEATBELT RETRACTOR - INCORRECT INSTALLATION

CONDITIONS
F1: SEATBELT RETRACTOR - INCORRECT INSTALLATION
panels required to expose the D loop (anchor point) and the seatbelt retractor
2 Refer to the 501-20 removal and installation section of the workshop manual, correctly reinstall
the seatbelt retractor ensure that the locating "T bar" and "anti rotation pins" are correctly
located
Yes
action required
No
Replace as required. Refer to the warranty policy and procedures manual, or determine if any
prior approval programme is in operation, prior to the installation of a new module/component
PINPOINT TEST G : D-LOOP NOT ROTATING CORRECTLY

CONDITIONS
G1: D-LOOP NOT ROTATING CORRECTLY
panels required to expose the D loop (anchor point) and the seatbelt retractor
2 Ensure there are no obstructions and the webbing does not catch or rub, the D loop (anchor
point) rotates correctly and if installed the confirm the height adjuster operates correctly
Yes
action required
No
PINPOINT TEST H : MINI BUTTON - MISSING/DAMAGED

CONDITIONS
H1: MINI BUTTON - MISSING/DAMAGED
NOTE: This test applies to the rear centre seatbelt retractor installed in the seat back
1 Refer to the 501-20 removal and installation section of the workshop manual, remove the seat
cushion and the plastic escutcheon at the top of the seat back (where the webbing exits to
expose the lower anchor fixing point of the center seatbelt)
2 Remove the lower anchorage of the seatbelt
3 With the seat back correctly latched, allow up to 20mm webbing to retract, then extract the
webbing
Is the mini-button (webbing travel limit stop) correctly installed to the webbing and in good
condition?
Yes
Feed the mini-button back through the plastic escutcheon if required. Correctly reinstall the
escutcheon to the seat back, extract the webbing then allow to retract, ensure the mini-button
comes to rest outside the escutcheon stop
No
PINPOINT TEST I : SEATBELT BUCKLE - NOT LATCHING/JAMMED

CONDITIONS
I1: SEATBELT BUCKLE - NOT LATCHING/JAMMED
CAUTION: Do not insert any objects or tools into the buckle head
1 Visually inspect the buckle head for evidence of damage. If damaged replace as required
2 Depress the buckle release (red button) and (Using a torch) carry out visual inspection for any
evidence of debris/material or foreign objects in the buckle head
3 If required remove the pretensioner from the vehicle. Remove the seat. Remove the pretensioner
from the seat frame
4 Do not insert any objects or tools buckle head With the buckle removed invert and attempt
to shake out any debris
5 Attempt to latch the tongue in the buckle
Does the seatbelt buckle operate correctly
Yes
Reinstall any components, no further action required
No
Replace the pretensioner, Refer to section 501 20
Safety Belt System - Front Safety Belt Buckle Vehicles With: Power
Seats
Removal
WARNINGS:
in personal injury.
injury.


3.
4.
5. NOTE: Make sure the wiring harness is routed

correctly.
Torque: 40 Nm
Installation

Safety Belt System - Front Safety Belt Buckle Vehicles Without: Power
Seats
Removal
NOTES:

2.
3. Torque: 40 Nm
Installation

Safety Belt System - Front Safety Belt Retractor
Removal
WARNINGS:
in personal injury.
injury.
personal injury.

2.
3.
4. Torque: 40 Nm
5. Torque: 8 Nm
6.
7.

9. Torque:
M12 40 Nm
M6 10 Nm
10. Torque:
M10 40 Nm
M6 10 Nm
Installation

Safety Belt System - Rear Center Safety Belt Buckle
Removal
All vehicles
1.

2.
3.
All vehicles
4.
5. Torque: 50 Nm
6.

7.
8.
All vehicles
9.
10.
correctly.
Torque: 40 Nm
Installation

Safety Belt System - Rear Center Safety Belt Retractor
Removal
All vehicles
1.

2.
3.
All vehicles
5. Torque: 50 Nm
6.
7.
8. Torque: 45 Nm
9.
10.
11.
12.
All vehicles
13.
14.
15. Torque: 45 Nm
Installation

Safety Belt System - Rear Safety Belt Retractor
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
All vehicles

2.

3.
4.
Vehicles without business seats

5.
6. Torque: 50 Nm
Vehicles with business seats
7.
8. Torque: 50 Nm
9.
10. Torque: 50 Nm
11.
All vehicles
12. Torque: 45 Nm
13. Torque: 8 Nm
14.
15. Torque: 8 Nm
16.
17. NOTE: LH shown.

18. NOTE: LH shown.
19. NOTE: LH shown.

20.
21. Torque: 6 Nm
22. Torque: 9 Nm
23. Torque: 8 Nm
24. Torque: 45 Nm
Installation

Safety Belt System - Rear Safety Belt Buckle
Removal
All vehicles
1.

2.
3.
All vehicles

correctly.
Torque: 40 Nm
Installation

Safety Belt System - Third Row Safety Belt Retractor
Removal
NOTES:
1.

component.
3.
4.

components.
6.
7.
8.
9.
10.
Torque: 9 Nm
12.
13. Torque: 9 Nm

Torque: 9 Nm
18. Torque: 2.5 Nm

Torque: 25 Nm
21.
22. Torque: 9 Nm
23. Torque: 9 Nm
24. Torque: 2.5 Nm
25.
26. Torque: 9 Nm
27.
28.
29.
Torque:
M10 40 Nm
M8 24 Nm
Installation

Safety Belt System - Third Row Safety Belt Buckle
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
NOTES:
1.
2.

4.
5.
6.
7. Using two 3mm Allen keys, release the safety belt.
8. NOTES:

correctly.
Torque: 40 Nm
Installation
2.
Safety Belt System - Third Row Center Safety Belt Buckle
Removal
WARNINGS:
in personal injury.
injury.
personal injury.
NOTES:
1.
2.


5.
6. NOTES:
Note the orientation of the component prior to

removal.
Torque: 40 Nm
Installation
2.
Supplemental Restraint System -
Column switchgear and clockspring housing to steering column screws 6 4
* Passenger air bag to in-vehicle crossbeam bolts 19 14
* Passenger air bag to instrument panel upper section nuts 7 5
* Driver lower air bag to driver lower air bag trim panel nuts 7 5
* Front seat side air bag module nut 7 5
* Side air curtain module screw 7 5
* B-pillar side impact sensor bracket bolts 8 6
* Side air bag module bolts 9 7
* Front side air curtain module screw 10 7
* Front side air curtain module to the A-pillar screws 10 7
* Indicates a new bolt, nut or screw must be installed.
Supplemental Restraint System - Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS)

1 - Right side air curtain
2 - Left side air curtain
3 - Passenger side airbag
4 - Passenger airbag
5 - Driver airbag
6 - Driver side airbag


1 - Seatbelt tension sensor (NAS only)
2 - Pressure pad (NAS only)
3 - Occupant Classification Sensor Control Module (OCSCM) (NAS only)
4 - Right side impact sensors
5 - Left side impact sensors
6 - Left impact pressure sensor
7 - Front impact sensors
8 - Right impact pressure sensor
OVERVIEW
WARNING: All pyrotechnic devices are dangerous. Before performing any procedures on any pyrotechnic device,
read all information contained within the Standard Workshop Practices section of this manual.
For additional information, refer to: Standard Workshop Practices (100-00 General Information, Description and
Operation).
The SRS (supplemental restraint system) provides additional protection for vehicle occupants in certain impact
conditions by selective activation of driver and passenger airbags, side airbags, side air curtains and seatbelt
pretensioners. Operation of the system is controlled by a RCM (restraints control module).
The RCM receives inputs from various sensors around the vehicle to determine which devices, if any, should be
activated during an accident. The inputs include those from an occupant classification system for the front passenger
seat (NAS vehicles only), front and side impact sensors and side impact pressure sensors.
On all except NAS, Australia and Japan market vehicles, the passenger airbag can be enabled and disabled using the
vehicle Set-up menu in the IC.
The activation status of the passenger airbag is given by an indicator in the front overhead console. The status of the
SRS is given by an airbag warning indicator in the IC.
The airbags and air curtains feature hybrid inflators, which use a self-contained pyrotechnic device to heat a cylinder
of compressed inert gas within the inflator. Above a calibrated pressure, the cylinder bursts and releases the gas into
the airbag. The benefits of hybrid inflators are a cooler inflation gas, resulting in lower airbag surface temperatures,
and elimination of the post-deployment effluent associated with solid pyrotechnic inflators.
DESCRIPTION
Restraints Control Module
The RCM is installed on top of the floor tunnel, under the floor console, and controls operation of the SRS. The main
functions of the RCM include:
Crash detection and recording.

Airbag, air curtain and pretensioner firing.
Self test and system monitoring, with status indication via the airbag warning indicator, and non volatile
storage of fault information.
Supply of yaw rate and lateral acceleration data for the ABS (anti-lock brake system) control module.
The RCM determines which elements of the SRS are to be deployed by using two internal areas:
Crash severity evaluation.

Deployment handler.
Crash severity evaluation uses data from the RCM internal accelerometer, the front impact sensors and the seatbelt
buckle switches. Based on this data, the RCM decides which level of airbag module deployment is required and
forwards the information to the second area, the deployment handler.
The deployment handler evaluates the status of the seat position sensor(s), seatbelt buckle switches and, on NAS
vehicles, the occupant classification system, before a final decision is made about which restraints should be
deployed.
Data from the side impact and pressure sensors is used by the RCM in conjunction with acceleration data from the
RCM internal accelerometer to make a deployment decision. The RCM processes the acceleration data and, subject to
an impact being of high enough severity, decides whether the side airbag and air curtain should be deployed.
Yaw rate and lateral acceleration data for the ABS control module is derived from the internal accelerometer and
transmitted on the high speed CAN (controller area network) bus.
On board testing of the airbag, air curtain and pretensioner firing circuits, the warning indicator circuits and the RCM
status is performed by the RCM, together with the storing of fault codes. The impact and pressure sensors perform
basic self-tests.
The RCM drives the airbag warning indicator via a high speed CAN signal. If the warning indicator fails, a fault code is
recorded and a warning tone is sounded in place of the indicator if a further fault occurs. In the event of a crash, the
RCM records certain data which can be accessed via the diagnostic connector.
A safing sensor in the RCM provides confirmation of an impact to verify if airbag, air curtain and pretensioner
activation is necessary. A roll-over sensor monitors the lateral attitude of the vehicle. Various firing strategies are
employed by the RCM to ensure that during an accident only the appropriate airbags, air curtains and pretensioners
are fired. The firing strategy used also depends on the inputs from the seatbelt buckle switches and, on NAS vehicles,
the occupant classification system.
An energy reserve in the RCM ensures there is always a minimum of 150 milliseconds of stored energy available if
the power supply from the ignition circuit is disrupted during a crash. The stored energy is sufficient to produce firing
signals for the driver airbag, the passenger airbag and the seatbelt pretensioners.
When the ignition is switched on the RCM performs a self test and then performs cyclical monitoring of the system. If
a fault is detected the RCM stores a related fault code and illuminates the airbag warning indicator. The faults can be
retrieved by Land Rover approved diagnostic equipment over the high speed CAN bus. If a fault that could cause a
false fire signal is detected, the RCM disables the respective firing circuit, and keeps it disabled during a crash event.
Driver Airbag
The driver airbag forms the center pad of the steering wheel. It provides head and chest protection for the drive
when deployed during a front or rear impact.
Lines, molded into the inner surface of the airbag cover, provide weak points that split open in a controlled manner
when the airbag deploys. The driver airbag has a two stage inflator, with separate electrical connectors on each
stage.
Passenger Airbag
The passenger airbag is located in the instrument panel, behind the upper glovebox. It provides head and chest
protection when deployed during a front or rear impact.
The top of the passenger airbag is attached to a channel chute underneath the top pad of the instrument panel.
Doors in the top of the channel chute are forced open, and split the top pad, when the airbag deploys.
The passenger airbag has a two stage inflator, with separate electrical connectors on each stage.
Side Airbags
The side airbags are attached to the outside of each front seat backrest frame, under the backrest cover. They
provide protection for the thorax, rib and pelvis when deployed during a side impact.
The side airbags are handed and each consists of a folded airbag and an inflator in a soft cover / wrapper. When the
airbag deploys it fills within a deployment chute integrated into the seat trim, and splits open the airbag deployment
seam in the backrest cover.
Side Air Curtains
The side air curtains are installed along both sides of the car, under the edges of the headliner. They provide head
protection and roll-over ejection protection for outer seat occupants, in both the front and rear of the vehicle, when
deployed during a side impact.
The front and rear ends of the side air curtains are anchored to the body, to maintain tension across their lower
edges of the air curtains when they deploy. Their deployment area extends between the A and C pillar trims, passing
over the upper B pillar trim.
Pretensioners


1 - Front pretensioner retractor - non-active seatbelt (all except NAS passenger)
2 - Front pretensioner retractor - non-active seatbelt (NAS passenger only)
3 - Rear pretensioner retractor
4 - Front pretensioner retractor - active seatbelt (all except NAS passenger)
5 - Driver seatbelt pretensioner
6 - Front pretensioner retractor - active seatbelt (NAS passenger)
A pyrotechnic pretensioner is integrated into each seatbelt retractor and, in some markets, the anchor point of the
driver seatbelt. The pretensioners are used to tighten the seatbelts during a collision to ensure the occupants are
securely held in their seats.
When operated by the RCM. the pretensioners rotate the spool holding the end of the webbing to tighten the
seatbelt.
Load Limiter Actuator (NAS Front Passenger Seatbelt Only)

1 - Front pretensioner retractor - non-active seatbelt
2 - Front pretensioner retractor - active seatbelt
On NAS vehicles, a pyrotechnic load limiter actuator is incorporated into the retractor of the front passenger seatbelt
to provide an adaptive load limiter. The adaptive load limiter has two different load limits, the standard load limit
and a lower load limit. The lower load limit is designed to reduce the chest loading for smaller seat occupants during
an impact, and is engaged when the RCM fires the load limiter actuator.
Impact Sensors
Impact sensors are installed in the front and both sides of the vehicle. The two front impact sensors are attached to
the front end carrier, behind the inboard edge of each headlamp. The side impact sensors are attached to the base of
each C/D pillar and to the inner panel of each rear quarter wheel housing, adjacent to the rear door latch strikers.
The impact sensors are accelerometers that allow the RCM to detect the sudden vehicle acceleration that occurs
during an impact.
Impact Pressure Sensors
An impact pressure sensor is installed in each front door, attached to the door closing panels. The pressure sensors
allow the RCM to detect any sudden pressure pulse that occurs in the front door during a side impact.
Seat Position Sensors

The seat position sensors allow the RCM to detect when a seat is forward of a given point on the seat track. On all
vehicles except NAS, a seat position sensor is installed for the driver seat only. On NAS vehicles, a seat position
sensor is installed for both the driver and front passenger seats.
The seat position sensors consist of a Hall effect sensor attached to the seat frame. While the ignition is on, the RCM
supplies the sensor with power, and monitors the return current. When the seat frame moves forwards, the sensor
moves over the edge of the seat track, which changes the reluctance of the sensor. The change of current is detected
by the RCM and used as a switching point. The switching point is when the center of the sensor is 3 ± 4 mm from
the leading edge of the seat track.
Occupant Monitoring
There are two types of occupant monitoring:
In all markets except NAS, vehicles have an occupant detection sensor.

In NAS markets, vehicles have an occupant classification system.
OCCUPANT DETECTION SENSOR
The occupant detection sensor is installed in the cushion of the front passenger seat, between the foam padding and
the cover. The sensor consists of a foil contact circuit, embedded in a plastic sheet. Weight on the sensor reduces the
resistance of the circuit, which is detected by the CJB (central junction box).
The occupant detection sensor has no interface with the SRS. It only provides an input to the CJB for the seatbelt
reminder function.
For additional information, refer to: Safety Belt System (501-20A Safety Belt System, Description and Operation).
OCCUPANT CLASSIFICATION SYSTEM
Pressure Pad
Occupant Classification Sensor Control Module
Seatbelt Tension Sensor
The occupant classification system provides the RCM with the occupancy status of the front passenger seat. The RCM
uses this and the seat buckle status in the evaluation of the firing strategy for the passenger airbag, the passenger
side airbag and the pretensioner retractor of the front passenger seatbelt.
The occupant classification system can determine if the front passenger seat is unoccupied, occupied by a small
person, or occupied by a large person. The occupant classification system consists of:
An occupant classification sensor control module, installed under the front passenger seat.
A pressure pad, installed under the cushion of the front passenger seat, with a hose connecting it to the
occupant classification sensor control module.
A seatbelt tension sensor, integrated into the anchor point of the front passenger seatbelt.
CAUTION: The occupant classification sensor control module, hose and pressure pad form a sealed assembly
and must not be disassembled. The assembly can only be replaced as part of the occupant classification system
service kit. The service kit includes the seat cushion pad, because the assembly is specifically calibrated to the pad,
and each pad has a unique calibration.
The pressure pad is a silicone filled bladder, with a hose connecting it to the occupant classification sensor control
module. Any load on the pressure pad is detected by the occupant classification sensor control module.
The seatbelt tension sensor is a strain gauge that measures the load applied by the seatbelt anchor to the anchor
bolt.
The occupant classification sensor control module supplies a reference voltage to the seatbelt tension sensor and,
from the return signal, measures the load acting on the seatbelt anchor. The measurement is used to produce a
correction factor for the load acting on the pressure pad. The tightness of the seatbelt affects the load acting on the
pressure pad, so without the correction factor the occupant classification sensor control module cannot derive an
accurate occupancy status.
The occupant classification sensor control module translates the load readings into a seat occupancy status and
transmits the result to the RCM, on the high speed CAN bus. The occupant classification sensor control module
incorporates two load limits for the seat cushion: When the load is less than the lower limit, the seat is classified as
unoccupied; when the load exceeds the lower limit, but is less than the upper limit, the seat is classified as occupied
by a small person; when the upper limit is exceeded, the seat is classified as occupied by a large person.
The occupant classification system has four possible states as detailed in the following table:
Airbag
Indicator
Classification Seat Status Passenger Airbag Status Status
Empty Empty Disabled Off
Occupied The seat is occupied by a small person or a Passenger airbag and passenger side On
inhibit child restraint is being used airbag operation is disabled
Occupied The seat is occupied by a large person Passenger airbag and passenger side Off
allow airbag operation is enabled
Error - Passenger airbag and passenger side On
airbag operation is disabled
Passenger Airbag Deactivation Indicator
The PAD indicator is installed in the front overhead console. When appropriate, the indicator illuminates to advise
front seat occupants that the passenger airbag is disabled. Operation of the indicator is controlled by the RCM
connecting/ disconnecting a ground signal from the indicator. The RCM illuminates the indicator when:
There is a fault with the passenger airbag firing circuit(s).

The passenger airbag is disabled in the IC Set-up menu and the front passenger seat is occupied (all except
NAS, Australia and Japan).
Required by the occupant classification system (NAS only).
Airbag Warning Indicator

Operation of the airbag warning indicator in the instrument pack is controlled by a high speed CAN bus message from
the RCM. The RCM sends the signal to illuminate the airbag warning indicator if a fault is detected, and for
approximately 6 seconds during the bulb check at the beginning of each ignition cycle.
OPERATION
In a collision, the force of the impact is measured by the impact sensors, impact pressure sensors and the RCM
internal accelerometer. The RCM evaluates the readings to determine the impact point on the vehicle and whether
the readings exceed the limits for firing any of the airbags and pretensioners. During a collision, the RCM only fires
the airbags, air curtains and pretensioners if the safing function confirms that the data from the impact sensor(s)
indicates an impact limit has been exceeded.
The RCM incorporates the following impact thresholds to cater for different accident scenarios:
Front impact, pretensioners.

Front impact, driver and passenger airbags stage 1, belt unfastened.
Front impact, driver and passenger airbags stage 1, belt fastened.
Front impact, driver and passenger airbags stage 2, belt unfastened.
Front impact, driver and passenger airbags stage 2, belt fastened.
Rear impact.
Driver side impact.
Passenger side impact.
Firing Strategies
The seatbelt pretensioners are fired when the pretensioner impact limit is exceeded. The RCM only fires the
pretensioners if the related seatbelt is fastened.
The driver and passenger airbags are only fired in a frontal impact. If an impact exceeds a stage 1 limit, but is less
than the corresponding stage 2 limit, only one inflator in each airbag is fired (stage 2 is still fired, for airbag disposal
purposes, after a delay of 100 ms). If an impact exceeds the stage 2 limit, the two inflators in each airbag are fired
simultaneously. When the driver seat is forward of the seat position sensor switching point, the RCM introduces a
time delay between firing the two inflators of the driver airbag.
On NAS vehicles, the passenger airbag is disabled unless the front passenger seat is occupied by a large person. In
all markets except NAS, Australia and Japan, the passenger airbag can be selected off in the vehicle Set-up menu of
the IC.
The stage 2 inflator of the driver airbag is disabled if the driver seat is forward of the switching point of the seat
position sensor.
On NAS vehicles, the load limiter actuator, in the retractor of the front passenger seatbelt, is fired if the stage 2 front
impact threshold is exceeded and the passenger seat is forward of the seat position sensor switching point.
If there is a fault with a seatbelt buckle switch, the RCM assumes the related seatbelt is fastened for the pretensioner
firing strategy and unfastened for the driver and passenger airbag firing strategies. If there is a fault with the
occupant classification sensor, the RCM disables the passenger airbag. If there is a fault with the passenger airbag
deactivation switch, the RCM disables the passenger airbag.
If a side impact limit is exceeded, the RCM fires the side airbag and the side head airbag on that side of the vehicle.
If the side impact limit on the front passenger side of the vehicle is exceeded, the RCM also evaluates the input from
the occupant classification sensor, and fires the side airbag only if the front passenger seat is occupied by a large
person (NAS only).
If multiple impacts occur during a crash event, after responding to the primary impact the RCM will output the
appropriate fire signals in response to any further impacts if unfired units are available.
Front and Rear Impact Firing Strategy (All Except NAS)
Seatbelt Status Strategy
Front
Driver Passenger Applicable Pretensioner Driver Airbag Passenger Airbag
Fastened - Fired at pretensioner Fired at belt fastened -
threshold threshold
Unfastened - Not fired Fired at belt unfastened -
threshold
- Fastened Fired at pretensioner - Fired at belt fastened
threshold threshold
- Unfastened Not fired - Fired at belt unfastened
threshold
Front and Rear Impact Firing Strategy (NAS)
Seatbelt Status Strategy
Passenger Seat Applicable
Driver Passenger Classification Pretensioner Driver Airbag Passenger Airbag
Fastened - - Fired at pretensioner Fired at belt fastened -
threshold threshold
Unfastened - - Not fired Fired at belt unfastened -
threshold
- Fastened Occupied allow Fired at pretensioner - Fired at belt fastened
threshold threshold
- Fastened Occupied inhibit or Fired at pretensioner - Not fired
empty threshold
- Unfastened Occupied allow Not fired - Fired at belt unfastened
threshold
- Unfastened Occupied inhibit or Not fired - Not fired
empty
Crash Signal
When the RCM outputs any of the fire signals it also outputs a crash signal to the CJB and the ECM (engine control
module) on the high speed CAN. The crash signal is also hardwired to the ECM and the CJB. On receipt of the crash
signal, the ECM cuts the power supply to the fuel pump relay and the CJB goes into crash mode. In the crash mode,
the CJB:
Activates all of the unlock signals of the vehicle locking system, even if the vehicle is already unlocked.
Ignores all locking/superlocking inputs until it receives an unlock input, when it returns the locking system to
normal operation.
Activates the interior lamps. The interior lamps remain on permanently until they are manually switched off at
the lamp unit, or the CJB crash mode is switched off and they return to normal operation.
Disables the rear window child lock input until the crash mode is switched off.
Activates the hazard flashers. The hazard flashers remain on until cancelled by the hazard warning switch or
the crash mode is switched off.
The CJB crash mode is switched off by a valid locking and unlocking cycle of the locking system.
Control Diagram - Sheet 1 of 2
NOTE: A= Hardwired; O =LIN (local interconnect network)AO = MS CAN (controller area network) Body
bus;AN = HS CAN (controller area network) Powertrain bus;AP = MS CAN (controller area network) Comfort bus;


1 - Battery
5 - Gateway Module (GWM) IC and message center
6 - Instrument Cluster (IC) and message center
7 - Clockspring
8 - Occupant Classification Sensor Control Module (OCSCM) (NAS only)
9 - Right steering wheel switchpack
10 - Seatbelt tension sensor (NAS only)
11 - Left steering wheel switchpack
12 - Passenger seat position sensor (NAS only)
13 - Driver seat position sensor
14 - Passenger seatbelt buckle switch
15 - Driver seatbelt buckle switch
16 - Rear seatbelt buckle switch - 2 off
17 - Rear center seatbelt buckle switch
18 - Rear seatbelt buckle switch - 2 off
19 - Rear left side impact sensor
20 - Front left side impact sensor
21 - Left impact pressure sensor
22 - Front left impact sensor
23 - Front right impact sensor
24 - Restraints control module
25 - Front left side impact sensor
26 - Front right side impact sensor
27 - Right impact pressure sensor
Control Diagram - Sheet 2 of 2
NOTE: A= Hardwired; AN = HS CAN (controller area network) Powertrain bus.

1 - Battery
5 - Engine Control Module (ECM)
7 - Passenger airbag
8 - Clockspring
9 - Driver airbag
10 - Passenger airbag deactivation indicator
11 - Rear left retractor pretensioner
12 - Rear right retractor pretensioner
13 - Driver seatbelt pretensioner (where fitted)
14 - Passenger retractor pretensioner (NAS non-active seatbelt version shown)
15 - Driver retractor pretensioner (non-active seatbelt version shown)
16 - Driver side airbag
17 - Passenger side airbag
19 - Right side air curtain
20 - Left side air curtain
Supplemental Restraint System - Air Bag Supplemental Restraint System
(SRS)
For a detailed description of the supplemental restraints system and operation, refer to the relevant Description and
Operation section in the workshop manual. REFER to: Air Bag and Safety Belt Pretensioner Supplemental Restraint
System (SRS) (501-20B Supplemental Restraint System, Description and Operation).
Safety Information
WARNINGS:
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST
BE DEPLETED BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND
WAIT ONE MINUTE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY
Do not use a multimeter to probe the restraints control module. It is possible for the power from the meter
battery to trigger the activation of the airbags. Failure to follow this instruction may result in personal injury
NOTES:
It is advisable not to use a cellular phone or to have a cellular phone in close proximity when working on the
restraints control module or associated systems
Given the legal implications of a restraints system failure, harness repairs to air bag module circuits are not
acceptable. Where the text refers to "REPAIR the circuit", this will normally mean the replacement of a harness
Power Supply Depletion
Before beginning any work on the restraints control module/supplemental restraints system or related components:
1. Remove the ignition key
2. Disconnect the battery leads, ground first
3. Wait 2 minutes for the power circuit to discharge
There are comprehensive instructions on the correct procedures for supplemental restraints system repairs in the
manual. Refer to the relevant section of the workshop manual
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or
the donor vehicle
NOTES:

1. Confirm the function of the warning lamp (if the warning lamp is inoperative, system faults will be
signalled by an audible chime)
2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Check for the installation of non-standard accessories which may Fuse(s)
affect or obstruct the function of the supplemental restraint Wiring harness
system Battery condition, state of charge
Check the condition of trim, etc at the supplemental restraint Ensure all electrical connector(s) are
system components engaged correctly on the air bag
Sensor(s) circuits
Pretensioner(s) Ensure the restraints control module
Air bag module(s) is correctly installed
Occupant classification sensor control module Warning lamp bulb(s)
Seat position sensor Impact sensor(s)
Buckle sensor(s)
Pretensioner(s)
Air bag module(s)
Air bag deactivation switch
Air bag deactivation warning lamp
Occupant classification sensor
control module
Seat position sensor
Clockspring
proceeding to the next step. Faults in supplemental restraint system harnesses would normally mean
replacement of the relevant harness. Supplemental restraint system harness repairs are not
recommended
4. If the cause is not visually evident, check for DTCs and refer to the DTC index
DTC Index
For a list of diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00. REFER to:
(100-00 General Information)
Diagnostic Trouble Code (DTC) Index - DTC: Occupant Classification Sensor Control Module (Description and
Operation),
Diagnostic Trouble Code (DTC) Index - DTC: Restraints Control Module (Description and Operation).
Supplemental Restraint System - Air Bag Disposal
General Procedures
Special Tool(s)
LRT-86-007-02
LRT-86-007-05
LRT-86-007-08
LRT-86-003
LRT-86-003-05
LRT-86-003-08
LRT-86-003-03
Deployed Air Bag
1. WARNING: Always wear safety glasses when repairing an

air bag supplemental restraint system (SRS) vehicle and when
handling an air bag module. Failure to follow this instruction
Deployed air bag modules are to be disposed of as special

waste and must comply with local environmental requirements,
if in doubt, contact the Authority for disposal requirements.
2. WARNING: The storage, transportation, disposal, and/or

recycling of air bag module components must be carried out in
accordance with all applicable federal, state and local
regulations including, but not limited to, those governing
building and fire codes, environmental protection, occupational
health and safety, and transportation.
Air bag modules removed and deployed by Land Rover service

are to be returned to the importer for disposal.
Undeployed Air Bag — Inoperative
1. WARNINGS:
Carry a live air bag module with the air bag and trim
cover or deployment door pointed away from your body. This
will reduce the risk of injury in the event of an accidental
deployment. Failure to follow this instruction may result in
personal injury.
All inoperative air bag modules should be placed on the

Mandatory Return List. All discoloured or damaged air bag
modules must be treated the same as any inoperative live air
bag being returned. Failure to follow this instruction may result
in personal injury.
Remove the inoperative driver air bag module or passenger air

bag module. For additional information, refer to: (501-20)
Driver Air Bag Module (Removal and Installation),
Passenger Air Bag Module (Removal and Installation),
Driver Lower Air Bag Module (Removal and Installation),
Front Side Air Curtain Module (Removal and Installation),
Side Air Curtain Module (Removal and Installation),
Side Air Bag Module (Removal and Installation),
Front Seat Side Air Bag Module (Removal and
Installation),
Front Safety Belt Buckle (Removal and Installation).
Undeployed Air Bag — Preparation of vehicle for disposal
NOTE: Remote Deployment
1. WARNINGS:
Always wear safety glasses when repairing an air bag

supplemental restraint system (SRS) vehicle and when handling
an air bag module. Failure to follow this instruction may result
in personal injury.
Carry a live air bag module with the air bag and trim
cover or deployment door pointed away from your body. This
will reduce the risk of injury in the event of an accidental
deployment. Failure to follow this instruction may result in
personal injury.
Before proceeding, make sure precautions have been

taken to warn personnel of a possible loud noise upon
activation. Do not allow anybody to approach closer to SRS
device than 15 Metres (50 Feet). Failure to follow this
instruction may result in personal injury.
Do not place the driver or passenger air bag module with

the trim cover or deployment door facing down, as the forces
of the deploying air bag module can cause it to ricochet and
cause personal injury. Failure to follow this instruction may
Remove any loose debris from around air bag module. Make
sure that no flammable liquids are present.
3. Disconnect the air bag module electrical connector.
4. Connect the special tool adaptor lead to the air bag module.
5. Connect the special tool lead to the air bag deployment tool
adaptor lead. Pass the special tool lead through the window,
close all doors, leave the window with the special tool lead
open.
6. WARNING: Make sure all personnel are a minimum of 15

Metres (50 Feet) away from the SRS component. Failure to
follow this instruction may result in personal injury.
Connect the special tool to a 12V battery.
7. WARNING: Do not handle the deployed air bag module

immediately after activation - it may be hot. Allow the air bag
module to cool. Cooling air bag modules should be continuously
monitored to make sure the heat does not create a fire with
spilled liquids or other debris. Failure to follow this instruction
Deploy the air bag module by operating both of the switches on

the special tool. If deployment does not occur, disconnect the
special tool from the battery and seek advice from Land Rover.
8. Repeat the procedure for all of the air bag modules in the
vehicle.
9. The vehicle can now be disposed of in the normal manner with

the air bag modules installed.
Disposal of the driver air bag module, passenger air bag module, side air bag
modules and driver lower air bag module
NOTE: Equipment required: Air bag deployment tools, LRT-86-003, LRT-86-007/02, LRT-86-007/05, LRT-86-
007/08, LRT-86-003/05 and LRT-86-003/08, Battery (12V), Safety goggles to BS2092 grade 2, Rubber gloves to
PrEN 374 class 2, Ear protectors that have been measured to BS.EN 24869, Particulate respirator to EN 149 grade
FFP2S, Suitable vice.
1. Using a suitable vice, secure the special tool bracket.
2. Secure the air bag module to the special tool bracket.
3. WARNING: Power must not be connected during this step.

CAUTION: Make sure the connector is not in contact with

the inflator or it will be damaged during the test.
Connect the special tool adaptor lead to the air bag module.
4. Make sure the special tool battery connections are 15 Metres

(50 Feet) away from the air bag module.
5. Remove any loose parts from around the air bag module. Make
6. WARNING: Before proceeding, make sure precautions
have been taken to warn personnel of a possible loud noise
upon activation. Do not allow anybody to approach closer to the
restraint device than 15 Metres (50 Feet). Failure to follow this


8. Allow the air bag module to cool.
9. Remove the air bag module from the special tool bracket and
seal it in a plastic bag, ready for disposal.
10. In the event of any problems or queries arising from this

procedure, contact Land Rover.
Disposal of the front side curtain air bag module and side curtain air bag
modules
NOTE: Equipment required: Air bag deployment tools LRT-86-003 and LRT-86-003/08, Battery (12V), Safety
goggles to BS2092 grade 2, Rubber gloves to PrEN 374 class 2, Ear protectors that have been measured to BS.EN
24869, Particulate respirator to EN 149 grade FFP2S.
2. Secure the air bag module to the special tool bracket.


Connect the special tool adaptor lead to the air bag module.

(50 Feet) away from the air bag module.
5. Remove any loose parts from around the air bag module. Make



8. Allow the air bag module to cool.
9. Remove the air bag module from the special tool bracket and
seal in a plastic bag, ready for disposal.

Disposal of the safety belt pretensioner.
NOTE: Equipment required: Air bag deployment tools LRT-86-003, LRT-86-003/08 and LRT-86-007/02 ,
Battery (12V), Safety goggles to BS2092 grade 2, Rubber gloves to PrEN 374 class 2, Ear protectors that have been
measured to BS.EN 24869, Particulate respirator to EN 149 grade FFP2S.
2. Secure the safety belt pretensioner to the special tool bracket.


Connect the special tool adaptor lead to the safety belt

pretensioner.

(50 Feet) away from the safety belt pretensioner.
5. Remove any loose parts from around the safety belt

pretensioner. Make sure that no flammable liquids are present.

7. WARNING: Do not handle the deployed device immediately

after activation - it may be hot. Allow the unit to cool for at
least 20 minutes. Cooling modules should be continuously
monitored to make sure heat does not create a fire with spilled
liquids or other debris. Failure to follow this instruction may
Deploy the safety belt pretensioner by operating both of the

switches on the special tool. If deployment does not occur,
disconnect the battery from the special tool and seek advice
from Land Rover.
8. Allow the safety belt pretensioner to cool for at least 20

minutes. Cooling SRS modules should be continuously
monitored to make sure the heat does not generate a fire with
spilt liquids or other debris.
9. Remove the safety belt pretensioner from the air bag

deployment tool bracket and seal in a plastic bag, ready for
disposal.

Supplemental Restraint System - B-Pillar Side Impact Sensor
Removal
WARNINGS:
Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work on the
SRS.
Do not probe supplemental restraint system (SRS) electrical connectors.
in personal injury.
Always use new fixings when replacing an SRS component.
Persons working on the supplemental restraint system (SRS) must be fully trained and have been issued with
the safety guidelines.
When repairing an SRS system, only use genuine new parts.
NOTES:
2. Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and
3. NOTE: Push down the carpet to allow access

to the component.
4.
5. Torque: 11 Nm
Installation

Supplemental Restraint System - Clockspring
Removal
WARNINGS:
Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work on the SRS.
Persons working on the supplemental restraint system (SRS) must be fully trained and have been issued with the
safety guidelines.
It is imperative that before any work is undertaken on the SRS system, the appropriate information is read
thoroughly.
The correct procedures must always be used when working on SRS components.
Always disconnect both battery cables before beginning work on the SRS system. Disconnect the ground cable
first. Never reverse connect the battery.
The SRS electrical connectors are unique. DO NOT force, or attempt to connect electrical connectors to the
wrong sockets.
Take extra care when handling supplemental restraint system (SRS) components.
NOTES:
Refer to: Specifications (414-02A Generator and Regulator -

TDV6 3.0L Diesel, Specifications).
2. Refer to: Steering Wheel (211-04 Steering Column, Removal and

Installation).
3.
4.
5.
6.
7.
Installation
1.
2.
3.
4.
5.
6.
7. Refer to: Steering Wheel (211-04 Steering Column, Removal and

Installation).
8. Connect the battery ground cable.
Refer to: Specifications (414-02A Generator and Regulator -

TDV6 3.0L Diesel, Specifications).
9. If a new component is installed, the soft lock stop reset routine

should be completed on the power steering system, using the
approved diagnostic tool.
Supplemental Restraint System - Driver Air Bag Module
Removal
WARNINGS:
Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when
handling an air bag module.
Take extra care when handling supplemental restraint system (SRS) components.
repairing or replacing any air bag supplementary restraints system (SRS) components. To deplete the backup power
supply energy, disconnect the battery ground cable and wait for one minute. Failure to follow this instruction may
Make sure all personnel are a minimum of 15 Meters (50 Feet) away from the SRS component. Failure to follow
this instruction may result in personal injury.
When repairing an SRS system, only use genuine new parts.
CAUTION: Make sure the wires are not twisted before connecting them to the airbag module. Once connected do
not rotate the airbag as this will cause the wires to twist, which can lead to harness damage and SRS faults.
NOTES:
If the SRS component is to be replaced, the bar code of the new unit must be recorded.
1. Refer to: Specifications (414-01, Specifications).
2. NOTE: The steering wheel is shown removed for clarity.

3. NOTE: Component shown removed for clarity.
4.
5.

wiring harnesses.
Installation

wiring harnesses.
2. WARNING: Driver air bag module installation

can be confirmed by hearing 3 audible clicks, 1 for
each clip.
CAUTION: Take extra care not to damage the

wiring harnesses.
3. If a new component has been installed, configure using Land
Rover approved diagnostic equipment.
Supplemental Restraint System - Occupant Detection Sensor Vehicles
With: Power Seats
Removal
WARNINGS:
in personal injury.
injury.
NOTES:
All vehicles


3.
4.
All vehicles
5.
Installation
1. CAUTIONS:

shown.

NOTES:


2. CAUTION: Make sure the component is

aligned as shown.

Supplemental Restraint System - Occupant Detection Sensor Vehicles
Without: Power Seats
Removal
WARNINGS:
in personal injury.
injury.
NOTES:
1. Refer to: Passenger Seat Cushion - Vehicles Without: Power

2.
Installation
1. CAUTIONS:

shown.

NOTES:


2. CAUTIONS:
Make sure that the wiring harness is correctly

routed.
Make sure that the electrical harness is not

trapped during installation.
Make sure that the wires are installed to align

with the corresponding coloured wire on the
opposite connector.
Check for correct operation of the front seat

after completion of the procedure to make sure
that the wiring harness has not become trapped or
stretched.

Supplemental Restraint System - Passenger Air Bag Module
Removal
WARNINGS:
To avoid accidental deployment, the restraints control module backup power supply must be depleted. Wait at
least two minutes after disconnecting the battery ground cable(s) before commencing any repair or adjustment to the
supplemental restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these
instructions may result in personal injury.
Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail
for deformation. If damaged, replace the sensor whether or not the air bag is deployed.
NOTES:
2. Remove the instrument panel upper section.
Refer to: Instrument Panel Upper Section (501-12 Instrument

4. Torque: 4.5 Nm
Installation

Supplemental Restraint System - Side Air Bag Module
Removal
WARNINGS:
in personal injury.
injury.
personal injury.


3.

5.
6.
7.
8.
9. Torque: 7 Nm
10.
Installation

Supplemental Restraint System - Side Air Curtain Module
Removal
WARNING: Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work
on the SRS.
NOTES:
Vehicles without roof opening panel
All vehicles



components.

Refer to: B-Pillar Trim Panel (501-05, Removal and Installation).
Refer to: C-Pillar Upper Trim Panel (501-05, Removal and

Installation).
Refer to: D-Pillar Trim Panel (501-05, Removal and Installation).
Refer to: Sun Visor (501-05 Interior Trim and Ornamentation,


12. WARNING: Be prepared to collect escaping

fluid.
13.

sides.
Torque: 6 Nm
sides.
Torque: 6 Nm
16. NOTES:
If equipped.
Torque: 6 Nm
17. NOTES:
If equipped.
18. NOTES:
If equipped.
Torque: 6 Nm
19. NOTES:
If equipped.
20. NOTES:
If equipped.
Torque: 6 Nm
21. NOTES:
If equipped.
22. NOTES:
If equipped.
Torque: 6 Nm
23.
24. NOTE: Note the orientation of the seal prior to

detaching.

sides.
Remove the rear seat head restraint(s).
26.

Vehicles with roof opening panel
29. CAUTIONS:

fixings.

other.
NOTE: The step must be carried out on both sides.
31. CAUTIONS:

fixings.

other.
All vehicles
32.
33. NOTES:
If equipped.
34. NOTES:
If equipped.
35. NOTES:
If equipped.
36. NOTES:
If equipped.

damage.

damage.

All vehicles
39.
40. NOTES:

Right illustration shown, Left is similar
If equipped.
41. NOTES:
42. NOTES:
Torque: 10 Nm
43. NOTES:
Torque: 10 Nm
Standard wheelbase
44. NOTES:
Torque: 10 Nm
Long wheelbase
45. NOTES:
Torque: 10 Nm
Installation
1. NOTE: Install a new retaining clip.
3. CAUTION: Make sure that the seal is installed

to the correct orientation as noted in the removal
procedure. Failure the follow this instruction may
result in damage to the headliner.
Supplemental Restraint System - Restraints Control Module (RCM)
Removal
NOTES:
The RCM must be replaced after every time any SRS component has been deployed.


3. Refer to: Floor Console (501-12 Instrument Panel and Console,

4.
5.
Installation
1. WARNING: Make sure that new nuts are
installed.
CAUTION: Make sure that all the RCM

retaining nuts are tighten to the correct torque
value prior to connecting the electrical connectors.
Failure to follow this instruction may result in
damage to the vehicle.
Torque: 10 Nm
2.
3. CAUTION: If a new component has been installed,

configure using Land Rover approved diagnostic equipment.

Body Repairs - General Information - Body Construction
Introduction
The body plays a significant role in the increasing trend of ever more rapidly changing model variants. The different
customer groups are strongly influenced by the design and shape of the body. At the same time the stability of the
body plays the most important part in ensuring passenger and driver safety. Lightweight construction, alternative
materials, composite materials, plastics and appropriate joining processes are all design features that characterize
modern Land Rover vehicle bodies.
In terms of manufacturing technology, modern safety cell bodies can be produced almost without any problems.
Land Rover guarantee high quality standards by ensuring that mechanical strength properties are tried and tested in
numerous computer simulations, crash tests, by testing materials and by employing sophisticated manufacturing
technologies. In the event of repairs it is vital that the production quality standards are upheld. This requires a well-
equipped workshop, and places particular emphasis on the qualifications of the workshop technicians. Up-to-date
knowledge of current manufacturing technologies and continuous training on new repair methods and techniques are
vital for high-quality body repairs. The model-specific repair manuals and the general repair techniques provide
valuable support when undertaking body repairs.
Always follow the repair instructions published in this manual. Failure to observe this instruction can result in serious
impairment of vehicle safety. All specified safety requirements must be met after the work has been carried out.
Accident damage and diagnosis
General notes:
Exact diagnosis of the extent of the damage enables proper repair planning
All body repairs must be carried out in accordance with the guidelines in this Body Repair Manual
The stability and strength properties of the body must be taken into account during body repairs. The body
has exact defined deformation patterns that must not be affected by any repair work
For instance, the crumple zones absorb the bulk of the impact energy. If any unprofessional repair techniques
or methods are used in these areas then this can pose a fundamental threat to vehicle safety
Hidden damage:
As well as looking at external indicators like flaked off paint, it is vital to check for hidden body damage or
deformation that is not visible from the outside. Large attached parts like bumpers and inner fenders often
need to be removed to allow accurate assessment of damage to underlying body parts
Gap dimensions offer another alternative for diagnosis by visual inspection. If any changes or misaligned
edges are apparent, then this usually indicates that the dimensions of the affected part are incorrect
Impact effects on the body
It is possible to deduce the overall extent of damage from the direction and magnitude of the impact forces. This
does however require extensive body-specific knowledge.
If, for instance, an impact occurs at the front left-hand side member, then the right-hand side member is usually
also affected as a result of the rigid body-shell design (crossmember). Often the length of this side member will not
have changed, but because of the rigid body-shell design it may have moved from its original position (often only by
a very small amount). If any deviations are present this can usually be detected by checking the gap dimensions
between door and fender or by checking for changes in dimension.
In the case of more severe impacts, the front part of the body cannot absorb all of the impact energy, and the
passenger cell is also deformed. Here the impact energy is transferred via the side member to the A-pillar. This
results in deformations in the area of the roof and the door rocker panel.
Planning a repair
The following decisions have to be made before the repairs are started
Does the vehicle need to be put on a body repair jig?

Does the body need to be measured?
Do aggregates like engine or axles need to be removed?
Which body parts need to be renewed?
Which body parts can be repaired?
Estimating
The authorized repair network is divided into category A and B. This section describes the process required to
identify category A or B damage. Should damage be identified as category A, the vehicle should be referred to the
nearest category A facility.
In line with the Land Rover continuous improvement program, information and data contained in this manual will be
updated through Land Rover technical bulletins.
The estimating process
Step 1:
Visual inspection, assess overall vehicle condition. Has damage travelled, distorting internal structural panels?
This is a visual check of the complete vehicle.
Possible indicators:
Panel misalignment
Panel gaps no longer uniform
Hinged panels catch on locks
Exterior cosmetic panels show signs of stress distortion
Customer describes unusual driving characteristics post incident
If structural distortion is visible, vehicle body alignment should be checked/corrected on a body repair jig, refer to
category A facility.
If no visual indications of damage transfer, go to Step 2.
Step 2:
If no visual signs indicate distortion to internal structural panels, but the customer is concerned with unusual driving
characteristics post incident, and there is no damage to the suspension. Vehicle body alignment should be checked
using four-wheel alignment geometry equipment.
If structural distortion is identified refer to category A facility.
Step 3:
If there is no sign or concern regarding vehicle body alignment, focus on the local area of damage.
Do any of the panels require replacement?
If no, go to Step 4.
If yes, are any of the panels secured with:
Bonding adhesive?
Fixings?
Weld?
If yes, refer to category A facility.
Step 4:
Do any of the panels require welding i.e. ripped or torn aluminum panel?
If no, go to Step 5.
If yes, refer to category A facility.
Step 5:
Can the damage be repaired by hand using serrated spoon, dolly, file and/or hot air?
If no, refer to category A facility.
Identifying the correct Land Rover Approved Body Centres
Through extensive research, Land Rover has identified the most appropriate method to rectify aftermarket damage.
It is key to safety and vehicle integrity that only the approved methods, materials and equipment are used.
Issues that could arise from the use of non-approved methods, materials and equipment include:
Warranty invalidation
Safety
Galvanic corrosion
Therefore, category A damage should always be referred to a category A Land Rover Approved Body Centres.
Obtaining spare parts
The availability of spare parts often determines how easily the body repairs can be carried out. The following
procedure is recommended:
Obtain all the data for the vehicle, including type, vehicle identification number, trim code, engine
identification letters, initial registration etc.
Establish all of the metal parts that need to be renewed
Establish all of the attached parts that need to be renewed, including small parts like rivets, clips etc.
Equipment
Land Rover Approved Body Centres are expected to be equipped in line with the Body Centre Tools and Equipment
standards.
The approved body equipment for the all new Range Rover aluminum range is listed as either:
Category A
Category B
Body centre approved equipment is also available to order on a global basis from SPX Service Solutions:
Country Name Phone Fax
UK Christine Gibson +44 1327 303 400 + 44 1327 303 499
France Sophie Leger +33 2 52 84 00 40 + 33 2 43 60 43 62
Spain Azucena Granado +34 949 208 329 +34 949 208 327
Non EU Markets Oliver Lehnasch +49 6182 959 345 +49 6182 959 245
Benelux Sonja Visschers +31 455 678 870 +31 455 678 871
Italy Sonia lanelli +39 0521 338 170 +39 0521 837 370
All other EU Markets Theodor Gardocki +49 6182 959 375 +49 6182 959 246
Nordic Sirpa Kulmala +49 6182 959 495 +49 6182 959 245
A copy of the approved equipment standards for category 'A' and 'B' repair facilities is available on request from and
the Global Body Centre Standards have been published on the HUB, along with the personal protective equipment
requirements, at the following locations:
https://jaguarhub.hub.tagworldwide.com/index.cfm?brand=42701
https://landroverhub.hub.tagworldwide.com/index.cfm?brand=42701
aluminum Information
The design of the modern motor vehicle attempts to overcome two conflicting needs:
Fuel economy - lighter, aerodynamic and fuel sensitive technology

High levels of comfort - this often equates to higher specifications and more accessories
aluminum alloy is the ideal material to meet these demands; it provides a lighter vehicle body with improved rigidity.
aluminum is different from traditional Steel, with the correct knowledge and suitable tools it is easily repaired.
There are two aluminum alloys discussed in this manual, the attributes detailed in the following table should be
considered when deciding to repair or replace:
6xxx 5754
Material 6xxx Series is a Magnesium/Silicon 5000 Series is an aluminum alloy with Magnesium content
Description aluminum alloy
Location on This alloy is used mainly in the outer Internal structural panels Thickness: 1.0 - 3.0mm
Vehicle body panels. Thickness: 0.9 - 2.0mm
Attributes High dent resistance Strength and durability
Reparability Yes - Light damage only
NOTE: All repairs to 5754 are restricted to Category A
Land Rover approved Body Repair Centres only.
Yes - Light damage only. Limited straightening is acceptable

Heat Yes - must be heated to maintain original alloy properties.
During CAUTION: material sensitive to Maximum Temperature range: 250°C.
Repair heat. Maximum temperature range:
140°C.
Notes
WARNING: DO NOT USE AN OPEN WARNING: DO NOT USE AN OPEN FLAME e.g. Oxygen
FLAME e.g. Oxygen Acetylene Acetylene Equipment.
Equipment.
Equipment: Induction heater. Use panel temperature indicator
Equipment: Hot air gun. Use panel strips. Heat crayons and digital thermometers to identify
temperature indicator strips. Heat temperature. Heat must be applied and maintained during the
crayons and digital thermometers to straightening process.
identify temperature.
Fixings
There are two groups of fixings used on the Range Rover Sport, other than conventional nuts and bolts. It is
important that the correct procedures are followed for the removal and replacement of these fixings and, where
applicable, the correct tools are used.
Self-Piercing Rivet (SPR)

Breakstem Fastener (BSF)
Self-Piercing Rivet (SPR)
CAUTION: Operating the SPR installation tool with no SPR or material in position will damage the tool die.
Self-Piercing Rivets are available in various sizes dependent on the size of the stack of panels to which they are
fitted. A stack refers to the combined gauge of the panels being riveted.
NOTE: It is important to identify and select the correct size fixing by referencing this table prior to installation.
SPR Type LR Part Rivet Rivet Application Die Die (SPX / Avdel Part
No. Number Length Force Description No)
1a LR043550 5 mm 25 kN Flat Bottom 78230-050809
1b LR043550 5 mm 30 kN Flat Bottom 78230-050809
2 LR043556 5 mm 45 kN Pip 78230-050088
4a LR043552 6.5 mm 35 kN Pip 78230-050088
4b LR043552 6.5 mm 30 kN Flat Bottom 78230-050809
4c LR043552 6.5 mm 30 kN Pip 78230-050088
5b LR043553 7 mm 40 kN Pip 78230-050088
5c LR043553 7 mm 35 kN Flat Bottom 78230-050809
5d LR043553 7 mm 50 kN Flat Bottom 78230-050809
5e LR043553 7 mm 40 kN Flat Bottom 78230-050809
6 LR043559 7 mm 50 kN Flat Bottom 78230-050809
7b LR043554 8 mm 45 kN Pip 78230-050088
7c LR043554 8 mm 35 kN Flat Bottom 78230-050809
7d LR043554 8 mm 45 kN Flat Bottom 78230-050809
7e LR043554 8mm 50 kN Pip 78230-050088
"Pip die" - Jaguar/Land Rover SPR repair kit, SPX/Avdel part number 78230-050088.
"Flat Bottom die"- Jaguar/Land Rover SPR repair kit, SPX/Avdel part number 78230-050809.
Removal
The ESN50 is the approved removal tool for Self Piercing Fixings. The ESN50 can be used with an optional, larger,
200mm C frame for improved access. Where tool access is impossible, drill out the remnant using a 5.3mm Cryobit
drill bit. Remove all debris.
Installation
The ESN50 is the approved installation tool for Self Piercing Fixings. Where the original panel is being refitted, the
new fixings should be placed adjacent to the original. Only where the ESN50 cannot be used, or there is insufficient
space on the panel, should the fixings be replaced with Breakstem Fastener Type As, unless the repair method
dictates otherwise.
Using the ESN50
Make sure there is access for the ESN50 on both sides of the fixing to be removed/installed, including the optional C
frame if required.
Removal: Align the plunger and anvil over the fixing and depress the trigger. Depressing the trigger will allow the
plunger to act on the fixing and remove it from the panel.
NOTE: Prior to replacing a self-piercing fixing, a test, using identical materials from waste panels, should be
performed, to make sure that all settings are correct and an acceptable joint has been achieved.
Installation: Load new fixing into ESN50. Align the ESN50 over the fixing position and depress the trigger. As the
trigger is depressed the ESN50 will clamp itself onto the work piece and install the fixing.
Removal of service SPR
Service SPR's will require the service anvil to have an internal diameter of 9mm, as shown in graphic E152490.
Item Description
A 9mm
BREAKSTEM FASTENERS
Breakstem Fasteners are used in repair if the joint/stack cannot be accessed from both sides or require a greater
load.
Breakstem fasteners will cope with joint/stack sizes of 1.5mm to 10.8mm.

A pre-drilled 6.5mm hole will be required before fitment.
To identify the correct size and part number of structural breakstem fasteners to be used in repair always
refer to TOPlx.
Where original rivet holes cannot be used replacement rivets should be positioned close to the original rivet
location/hole location.
When riveting, the first location of the first replacement panel is close to the original rivet placement, not in the
centre. The same process is followed by the next replacement, again not in the centre between the rivets.
Breakstem Fastener
Breakstem Fasteners have the following benefits:
Exceptional shear and tensile strength

Large blind side bearing area against the rear sheet
Interference lock formed by a splined stem
Spreads the tail bearing/clamp load on the rear sheet
Provides strong, vibration resistant joints
No loose stems
When the repair procedure requires the fitment of a breakstem fastener the stack size is identified within the repair
procedures (millimetres).
Removal
Breakstem Fastener used in production are removed by removing the centre of the fixing using a 4mm punch. Once
the centre has been removed, drill out the remnant using a 6.5mm Cryobit drill bit. Remove all debris. Aftermarket
Breakstem Fastener are removed in the same way as Breakstem Fastener used in production.
Installation
The Genesis G4 is the approved installation tool for Breakstem Fastener . Prior to replacement make sure the fixing
hole has been drilled to 6.5mm, using a Cryobit drill bit and all debris has been removed.
Using the Genesis G4
Make sure the fixing hole has been drilled to 6.5mm and all debris has been removed. Check that you have the
correct size Breakstem Fastener for replacement and insert it into the Genesis G4. Use the weight of the Genesis G4
to apply light pressure as the Breakstem Fastener is inserted into its hole. Depress the trigger which will tighten the
Breakstem Fastener in the hole, the wasted stud will be ejected into the Genesis G4 once a pre-determined pressure
is reached.
Breakstem Fastener Type Part Number Grip Range

BSF A LR044284 1.5 mm to 3.5 mm
BSF B LR044283 2.8 mm to 4.8 mm
BSF C LR044286 4.8 mm to 6.8 mm
BSF D LR043912 6.8 mm to 8.8 mm
BSF E LR044287 6.8-7.5mm to 9.5mm
BSF F LR044285 8.8 mm to 10.8 mm
BSF G TBC Alu Countersunk
Torx Screw and Rivnut
A Torx Screw and Rivnut are used where the fitment of a Breakstem Fastener Type A would give a poor cosmetic
appearance. There are also occasions where the Torx Screw and Rivnut replaces a Breakstem Fastener Type B,
where there is no access for the Genesis G4. The Rivnut acts as the thread.
Description Land Rover Service Number

Rivnut (G) TBC
Torx Screw (J) TBC
Removal
The removal of the Torx Screw is carried out using a T30 Torx Driver. The Rivnut is not an original fixing.
Installation
The Torx Screw is installed using a T30 Torx Driver. The Rivnut is installed using the Wurth HES412 Rivet Nut Thread
Setter, (Part No: 964948900).
Aluminum Welding
Health and Safety
Refer to Land Rover Global Tools and Equipment Standards and Equipment Manufactures Manual.
Set Up/Equipment Check
Refer to equipment manufacturers operators' manual.
Weld Process
This section provides information on aftermarket aluminum welding for the all new Range Rover aluminum range. It
covers the following areas:
Equipment: Metal Inert Gas (MIG)

Materials: Extruded and pressed aluminum sheet alloy.
Weld Structure: Fusion welding process: Metal Inert Gas (MIG).
Weld Procedures: Pre-weld, test weld, weld and post weld checks.
Weld Variants: Lap weld, Butt weld, Plug weld.
Equipment
NOTE: The Global Body Centre Standards have been published on the HUB, along with the personal protective
equipment requirements, at the following locations:
https://jaguarhub.hub.tagworldwide.com/index.cfm?brand=42701
https://landroverhub.hub.tagworldwide.com/index.cfm?brand=42701
Only equipment that meets or exceeds the minimum welder standard in the Global Body Centre Tools and Equipment
standards should be used in the repair of Land Rover products.
The accuracy of the approved equipment enables the delivery of one droplet of wire per pulse. This enables welding
of incredibly thin parent material, i.e. 0.6mm sheet can be welded using a 1.2mm filler wire.
The approved MIG welder uses Direct Current, (DC) and does not produce High Frequency, (HF), at start up, (initial
arc).
Welder Set Up
NOTE: The user should always refer to the operators' manual for detailed instructions.
The following provides an overview of the set-up procedure:
Health and Safety - read operators' manual

Check correct power supply
Check gas supply
Check all equipment parts - safety check
Attach power cables, connect to supply
Purge gas bottle, attach
Attach clamp
Approved equipment obtained from the Land Rover Equipment Program :
Speedglas with Adflo face shield/weld mask

Approved fume extractor
Stainless Steel Brush
Personal Protection Equipment (PPE)
Materials
Prior to any welding activity, it is necessary to identify the type of material to be welded. The all new aluminum
range is constructed from a number of aluminum alloys, each has different attributes that should be considered prior
to the weld process.
Body Materials
The repair methods shown focus on the replacement of:
Pressed aluminum Alloy sheet - 6xxx series - Used in skin-panels

Extruded aluminum Alloy - 5754 - Used in structural panels
Weld Wire
The approved weld wires for these alloys are:
6xxx series - 4043 or 4047 filler wire

5754 - 5554 filler wire
Weld Structure
The approved aftermarkets weld process is based on Fusion Welding:
Metal Inert Gas (MIG) Welding
The approved MIG welder uses DC (direct current). The Electrode, (filler wire), is Positive Pole and the work piece is
Negative Pole. The arc burns between a melting electrode, (which also acts as the filler wire) and the work piece.
The shielding gas is Argon, Helium or a mixture of these, (MIG).
Successful aluminum welding is partly dependent on the removal of surface Oxidization. Oxide MUST be removed
prior to welding. The oxide melts at a different temperature:
aluminum melting temperature - approximately 660°C

aluminum Oxide melting temperature - approximately 2040°C
Weld Procedures
Pre-Weld
Prior to starting any weld procedure, the following safety precautions should always be implemented:
Disconnect the vehicle battery

Disconnect the generator electrical connectors
Remove any ECM (engine control module)'s within 500mm of the weld area
Remove the battery before carrying out welding work in its vicinity
Utmost care must be taken when welding near the fuel tank or other components that contain fuel. If the
tank filler neck or a fuel line must be detached to allow access for welding work, then the fuel tank must be
drained and removed
Adjacent vehicle parts and adjacent vehicles must be shielded against flying sparks and heat
The aluminum surfaces MUST be cleaned prior to welding. Cleaning will aid penetration and avoid contamination.
There are three steps to this process:
1. Clean surface:
To remove wax and any other contaminants use a chemical surface cleaner:
Land Rover approved product: DuPont 3608S

Alternatively, an Isopropyl based product
2. Remove Oxide
This can be achieved through a number of processes:
NOTE: Items used to remove oxide should not be contaminated by use on a steel vehicle.
Stainless Steel brush

80 Grit abrasive paper
Non-Metallic scuff pad
3. Remove Oxide Dust
Remove dust with a lint free cloth
NOTE: Oxide builds up very quickly, therefore, perform steps 2 and 3 immediately prior to welding. If left for a
period of time, steps 2 and 3 should be repeated.
Materials
The materials listed in this section are those approved to be used on the all new Range Rover aluminum range in
conjunction with the repairs shown in this manual.
Approved Materials
Consumable Material Supplier
Weld Crack Penetrant Rocol Land Rover Equipment Program
Weld Crack Developer Rocol Land Rover Equipment Program
Weld Crack Cleaner Rocol Land Rover Equipment Program
Pyrosil coupling agent (primer) SurAlink GP15 Land Rover Equipment Program
Pyrosil refill cartridge Sura - Pyrosil Land Rover Equipment Program
Bonding Adhesive Structural Adhesive DP490 3M
Bonding Adhesive Structural Adhesive 8115 3M
Cavity Foam DM4330 Foam 3M
Semi Rigid Sealer 0893-2251 Wurth
Seam Sealer Terostat 1K PUR 11272C (4500010) Teroson
Cleaner/De-greaser 08984 3M
Cleaner/De-greaser 3608S DuPont
MIG Weld Wire (5754) 5554 Filler Wire Source Locally
MIG Weld Wire (6xxx) 4043 / 4047 Filler Wire Source Locally
Abrasive Discs Roloc Bristle Discs 07528 3M
Self Piercing Fixings (all variants) Microcat Land Rover Dealer Network
Breakstem Fasteners Fixings (all variants) Microcat Land Rover Dealer Network
Weld Variants
The following identifies the three types of weld variants used in Category A panel replacement. It is not a guide to
welding, as all Category A repairers will have staff who have attended and completed the Jaguar Land Rover
aluminum welding accreditation.
This section highlights the key points for each weld variant.
Lap Weld
Key points:
Run-In/Out distance of 5mm

Minimum overall length of 20mm
Must use Start/Finish weld tabs
Butt Weld
Key points:
Run-In/Out distance of 5mm

Minimum overall length of 20mm
Must use Start/Finish weld tabs
Backing plate required
Plug Weld
Key Points:
Hole size 10mm

Position of MIG nozzle - vertical
Backing Plates
Backing plates are required for all butt-weld joints. Backing plate fabrication is made from waste material and have a
width of 50mm. Securing backing plates is by either an interference fit, lap-weld, plug-weld or self-tapping screws.
Backing plate thickness is determined by work piece thickness, for example; (3mm work piece will require a 3mm
backing plate). Backing plates are used to avoid excess penetration, dissipate the heat and supports the molten weld
pool while cooling.
Weld Tabs
Weld tabs are manufactured from waste material and placed at the start and end of the effective weld length.
Test Weld
A test weld using identical coupons from waste panels should take place prior to working on the vehicle. The test
piece is then visually checked and destructively tested to make sure all settings are correct and an acceptable weld
has been achieved.
Prior to starting, the following should be checked:
Gas - Correct for the type of job

Filler Wire - Correct for the type of material to be welded
An effective weld should demonstrate the following qualities:
All visible weld surfaces shall be clean, bright and of a uniform profile
The weld seam should show uniform height and width over its entire length
There shall be complete fusion between the surfaces of the work piece and the weld metal deposit
Correct level of penetration will be visible at the rear of the coupon as a fine continuous line.
Effective Weld Length
The effective weld length is the weld seam as described in the Body Repair Sections. The effective weld length does
not include allowances for the run-in/run-out, or termination defects, (start/stop), of the weld seam. It is permissible
that the overall weld length is longer than detailed in the repair section, as the overall weld will include a minimum
of 5mm at both the start and the stop of the weld seam, provided the function of the part is not affected, or the weld
finishes on the edge of a panel.
Post Weld Checks
Weld inspections take the form of a visual examination, non-destructive and destructive testing.
Visual Examination
A visual examination of fusion welds should be carried out in accordance with the acceptance criteria detailed in the
following Imperfections/Defect Levels table.
Imperfection/Defect Levels Table
Defect/Imperfection
Type Details Limits
Burn-through Burn holes Not permitted
Seam offset, sides Incomplete fusion Not permitted within effective weld length
melted away
Cracks Any form of cracking is Not permitted
not permitted at any
position along the entire
length of the weld seam
Fused weld spatter Limited acceptance. Not permitted on visible surfaces or in areas
where functional performance of the part is affected, e.g. mating
surfaces, sealing surfaces, etc. In such instances spatter is to be
removed. All loosely adherent spatters must be removed
Visible ignition marks Local melting of parent Permitted provided functional performance of the component is not
metal due to arc affected.
Open end crater Reduces the cross Not permitted
sectional area of the
weld seam
Visual pores Not permitted
Weld skip Discontinuity/interruption Not permitted at any position along the entire length of the weld
in weld seam seam
Non Destructive
Dye penetrate testing MUST be used for detection of discontinuities, such as cracks, laps, folds, porosity and lack of
fusion that are open to the surface of the material. Typical defects include start, (cold start/incomplete fusion) and
stop, (crater cracking), defects within a fusion weld run. In addition to this lack of fusion/coalescence at the weld
toe, solidification cracks in the weld bead may also be detected.
Non Destructive Crack Inspection Process
Use the product as listed in the Approved Materials Section, this product is supplied within the Category A tool kit.
The product is an aerosol applied dye system. It is designed to penetrate the finest cracks and flaws to facilitate
detection, the system includes: Cleaner, Penetrant and Developer.
The process is as follows:
1. Use the cleaner to de-grease/clean the test area, then wipe with a lint free cloth.
2. When the surface is completely dry, apply the penetrant. Cover the test area and allow a minimum contact
time of 10 minutes.
3. Remove excess penetrant from the surface with a lint free cloth wetted with the cleaner.
4. Apply a THIN film of the developer and leave for a minimum of 10 minutes to draw up the retained dye
from flaws or cracks.
5. Suspect areas should then be examined under natural or electric light for signs of flaws and/or cracks.
Cracks will show up as lines whilst porosity will appear as pin holes.
Destructive Testing
Each test weld should be pulled apart to check the quality and penetration of the weld.
Body Repairs - General Information - Corrosion Prevention
Corrosion Protection
General
The application of additional corrosion protection following body repair is not necessary and not recommended.
However, it is important to be aware of galvanic corrosion and take steps to prevent its occurrence.
Galvanic Corrosion
Galvanic corrosion is the cross-contamination of dissimilar metals, in this case aluminium and steel. Avoidance of
galvanic corrosion is an important issue to be considered in the repair of aluminium bodied vehicles.
Precautions to prevent the contamination of exposed bare aluminium surfaces should be taken. Good housekeeping
and cleanliness should be adopted throughout repairs and especially prior to welding, pre-treatment, (Pyrosil), and
adhesive bonding.
The repair environment requires control and protection from dust and debris from conventional steel body repairs.
All equipment must be clearly identified and used solely on aluminium.
Tools should be kept clean and in good order. Steel fastenings are coated to prevent galvanic corrosion. Fastenings
should be examined during repairs and where damaged or suspect must be renewed.
The use of graphite, penetrating oil, or copper based anti-seize compounds upon the steel fixings is not
recommended.
Where the original equipment surface protection (paint), is removed it must be repainted to the recommended
standard.
Only Land Rover Cars Ltd original bodywork components and Land Rover Cars Ltd approved repair materials,
(sealer, paint, etc.), are to be used for bodywork repairs.
Body Repairs - General Information - Sealer, Underbody Protection
Material and Adhesives
General Information
Bonding
This section provides information on the bonded joints used in repair throughout the all new Range Rover Sport
aluminium body. The following topics are covered:
Equipment
Materials
Bonding Pre Treatment
Bonding Application
It is a pre-requisite that any person undertaking any repairs which involve panel bonding has attended Land Rover
Approved Training and has achieved the correct skill level to undertake these processes. Bonding is classed as a
Category 'A' repair.
Equipment
The approved bonding equipment consists of:
Pyrosil gas applicator kit

Approved two-pack adhesive applicator
Bonding Pre-treatment
Pre-treating the panels to be bonded, as described in this section, promotes the improved adhesion of the bonding
adhesive.
The pre-treatment is carried out using the approved "Pyrosil kit". The kit contains all of the equipment required to
perform the pre-treatment process.
CAUTION: Bonding without pre-treatment will reduce the performance of the joint.
The pre-treatment application is a two stage process:
Chemical application via a flame

Coupling Agent
Performing the Pre-treatment Application

CAUTION: Apply caution when using a naked flame. Remove all risk of combustion. Do not overheat the alloy.
Move the flame over the work piece at a constant velocity.
The application is colorless and has no visual indication.
Remove any original adhesive, or E-Coat from new panels

Clean surface to be treated using approved pre-cleaner/degreaser
Using the Pyrosil torch, pass the flame, (use the blue tip which is the oxidization flame), across the surface of
the joint
Immediately brush coupling agent (primer) onto panel surface and allow to dry
CAUTION: Apply the bonding adhesive immediately after the pre-treatment process.
Bonding Application
The approved bonding adhesive is supplied in a two pack cartridge.
A two-pack cartridge gun with a disposable mixing nozzle is used for the application of the adhesive.
NOTE: The curing process of the adhesive begins once mixed and has a working time of approximately 30
minutes.
Apply a 5mm "zig zag" bead directly to either the replacement panel or vehicle structure.
Make sure a continuous bead of adhesive surrounds fixing holes.
On completion the mixing nozzle must be discarded. Make sure an air tight seal is provided for the cartridges.
Body Repairs - Water Leaks - Water Leaks
General
If water leaks occur after bodywork repairs, the cause can be established using the checks described below. A
systematic and logical procedure is required to locate water leaks. Before beginning extensive checks, a
thorough visual inspection must be carried out.
Visual Inspection
- The following characteristics may indicate existing water leaks:
- Check the clearance and accurate fit of ancillary components such as the hood, tailgate, doors, and so
on.
- Check for correct fit and possible damage to sealing elements such as blanking plugs, rubber door
weather strips, and so on.
- Check water drain holes for unhindered flow.
Various tests can be used to provide further information on possible leaks:
- Water test
- Washer test
- Road test
- Chalk (powder) test
Practical execution of tests and checks
Water test
NOTE: Never aim a jet of water directly at a door weather strip or rubber seals.
Carry out the water test with a second person present (in the passenger compartment).
Use variable washer nozzles (concentrated water jet to fine spray mist).
Start in the lower section and spray the whole area, working upwards in stages.
Washer test
Further tests can be carried out in the washer system.

Some leaks originate here, or only occur here.
The relevant passenger compartment should be checked using a torch during the wash procedure.
Road test
If no leaks are located during the tests above, road tests should be carried out on wet roads.
Road tests under various conditions:
- At various speeds.
- On various road surfaces (asphalt to cobbles).
- With loaded or unloaded vehicle.
- Driving through puddles (splash water).
Chalk test (powder test)
In this test, the clamping load and the bearing surface of the seal are checked.
Performing the test:
- Dust the door seal with powder or coat with chalk.
- Coat the bearing surface of the seal with a thin film of petroleum jelly.
- Slowly close the door and open it again.
- Check the width and continuity of the imprint on the door seal.
Other test equipment
Other equipment such as stethoscopes, UV (ultraviolet) lamps, special mirrors or ultrasound measuring
instruments can be used to locate leaks.
Rectifying the leak using recommended tools, auxiliary equipment and materials
Tools and auxiliary equipment:

- Dry, absorbent cloths
- Variable washer nozzle
- Torch, fluorescent tube
- Mirror
- Compressed air
- Seal lip installer
- Wet/dry vacuum cleaner
- Sealing compound compressor
- Remover for interior trim
- Cutter blade or pocket knife
- Wedge (wood or plastic)
- Hot air blower
- Special mirror for concealed leaks
- Air flow checker
- Sealing compound (tape and plastic compound)
- Multi-purpose sticker
- Clinched flange sealer
- Window sealing compound
- Water shield PVC (polyvinyl chloride)
- Double-sided adhesive tape for water shield
- Methylated spirit (available from trade outlets)
- PU (polyurethane) adhesive
- Silicone remover
- Tar remover
Water leaks according to mileage or running time
Increasing mileage has an effect on the problem of leaks in a vehicle. Possible influencing factors are:
Servicing and maintenance of seals:

- No maintenance, lack of maintenance or incorrect maintenance
- Using an incorrect agent
Damaged seals:
- As a result of aging, wear or incorrect handling/assembly.
Heavy soiling of the vehicle:
- Heavy soiling of a vehicle can seriously impair the function of water drainage channels in particular,
and also of rubber seals.
Age-related factors:
- Environmental factors
- UV radiation
- Extreme climatic conditions
Corrosion can have a serious impact on bodywork, in particular as a result of:
- Lightly or heavily rusted seal carriers
- Rusted body seal welds
- Perforation corrosion
Water leaks after body repairs
If a vehicle develops a leak after body repairs, the following points must be taken into consideration in particular:
The correct seating of ancillary components and their seals must be checked.
The correct alignment of doors/tailgate and tailgate must be checked. The associated seals must not be
damaged and must be installed correctly.
Check that panel seams are correctly sealed.
The correct seating of rubber grommets must be checked.
Directly-glazed windows must have correct and complete bonding.
Water drainage system
If a vehicle develops water leaks, then areas into which water is routed or drained should be checked first.
Water drainage system (illustration for reference only)


1 - Water drainage, front
2 - Water drainage, side and rear
3 - Engine compartment drainage
4 - Roof drainage
Water leaks, diagnosis and corrective action: Front passenger compartment
Windscreen
Diagnosis:
- Ingress of water into A-pillar area or instrument cluster area and rocker panel area.
Cause:
- Breaks in adhesive beads.
- The breaks in adhesive beads can be located from inside by using compressed air. The leak can be
identified from outside by the escaping air.
- The second test method is by means of a water test. The outer trims must be raised carefully using a
plastic wedge. The leak should be located from inside by a second assistant.
Corrective action:
- Remove the windscreen. Remove the existing adhesive bead and reapply using the correct bonding
procedure.
Side windows
In the case of side windows, the same problems can arise as for a windscreen. The same corrective actions must
therefore be used.
Door seal
Diagnosis:
- Water ingress in the lower part of the interior door trim or in the rocker panel area.
Cause:
- The water shield fitted behind the interior door trim exists to drain off water that has entered the door
via the drainage holes, either downwards or outwards. If the water shield seal is damaged or has been
fitted incorrectly, then water can get into the passenger compartment.
- In addition to this, the drainage holes can become clogged with leaves, dirt or excess cavity protection
agents. Water gathers in the door and ingresses into the passenger compartment.
- Check water shield for damage or correct fitting.
- If the water shield needs to be re-bonded, then approved seam sealer should be used.
- Before the water shield is installed, the drainage holes must be checked for unhindered flow.
Door seals
Diagnosis:
- Ingress of water into the rocker panel area
Cause:
- Insufficient clamping load between seal and door.
Corrective action:
- Check clamping load:
- The easiest way to check the clamping load of a seal to the respective bearing surface is by means of
a paper strip test. This consists of trapping strips of paper at various points between the door and the
seal, and fully closing the door. If it is possible to pull out the paper with no great resistance, then the
clamping load is too low.
-
NOTE: When adjusting the clamping load, the profile alignment of the relevant components must
always be taken into consideration.
Adjust the clamping load:

- The clamping load is normally adjusted using the striker. When doing so, the edge alignment from the
door to the side panel, or from the front door to the rear door must be taken into account.
- Another setting method is to realign the panel flange for the seal mounting. The clamping load is
increased by moving the flange towards the door.
-
NOTE: Do not realign the flange too far in the direction of the door, as this can reduce the bearing
surface of the seal to the door.
Check the bearing surface:

- Apply chalk evenly to the surface of the seal. Evenly coat the bearing surface of the door with
petroleum jelly.
- Close the door fully, the lock must engage. Open the door. The imprint of the chalk (bearing surface)
can be identified in the film of petroleum jelly.
- The bearing surface should be at least 5mm across at all points.
Other causes:
- The door seal must completely seal the door where it meets the bodywork.
- Water can ingress directly or indirectly into the interior of the vehicle if the seal is damaged at any
point.
Corrective action:
- A damaged or worn door seal must always be installed in full.
- When installing the seal, the following must be taken into account:
- Always fit the seal first in the area of the narrow radii (corner points).
- Next, secure the seal to the flange evenly by tapping lightly with a rubber hammer. The installed seal
must not be kinked at any point.
NOTE: The prescribed length of a seal must not be shortened.
Other cause:
- The door seal is attached to the welded flange all the way round. If this welded flange is uneven or
damaged at any point (usually in areas with small radii) then this point could be subject to leaks.
- A stretched seal carrier can also cause a leak.
- In both cases, water gets into the vehicle interior under the seal carrier.
Corrective action:
- Align the deformed welded flange using a hammer and anvil block, prevent and, if necessary, repair
any paint damage.
Roof opening panel - front and rear fixed glass panels
In the case of the roof opening panel - front and rear fixed glass panels, the same problems can arise as for a
windscreen. The same corrective actions must therefore be used.
Roof opening panel - sliding central glass panel
NOTE: In the case of the sliding central glass panel, the rubber seals and the lock actuator or latch mechanism
must be checked first of all.
Diagnosis:
- Ingress of water at the roof opening panel.
Cause:
- The roof opening panel frame incorporates drain holes in each front corner allowing water to drain via
the A-pillars and each rear corner allowing water to drain via the roof panel channels.
- Damaged, worn, or incorrectly fitted seals on the sliding central glass panel.
- Incorrect alignment of the sliding central glass panel.
- Damaged, worn, or incorrectly fitted seals on the roof opening panel frame.
- Water drain channels or water drain holes blocked.
Corrective action:
- Check the seals on the sliding central glass panel, install as necessary.
- Check the correct adjustment of the sliding central glass panel, adjust as necessary, replace any worn
or damaged components as necessary.
- Check the internal seal of the roof opening panel frame, realign or install as necessary.
- Check the water drain channels and holes for blockages, clear blockages as necessary.
- Check the drainage system for unhindered flow.
Luggage compartment lid
Diagnosis:
- Ingress of water into the luggage area.
Cause:
- The leak problems of the luggage compartment lid correspond to those of the doors.
- In addition to this, the area to be sealed is much bigger. The routing holes for cables and hoses must
also be sealed.
- The rubber grommets for the routing holes must be checked for damage and correct seating (fully
unhooked).
- The grommets around the luggage compartment lid hinges may leak.
Corrective action:
- Check the rubber grommets and re-position, reseal or install new, if necessary.
Forced air extraction
Diagnosis:
- Ingress of water into side luggage compartment area
Cause:
- The forced air extraction for the vehicle interior is located in the quarter panel lower extension.
- The rubber flap of the forced air extraction must be able to move freely.
Corrective action:
- Remove the forced air extraction.
- Check the seal area between the bodywork and housing, as well as the rubber flap.
- Install a new seal if necessary.
Rear window
Diagnosis:
- Ingress of water into the passenger compartment area.
Cause:
- Rear window leaking via breaks in the adhesive bead.
- Check for leaks in the same way as for a leaking windscreen.
Corrective action:
- In the case of the rear window, the same problems can arise as for a windscreen. The same corrective
actions must therefore be used.
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body
and Frame
Dimensional Illustrations
Front End Body Dimensions
Item From To Dimension

A Right front fender, front fixing hole Left front fender, front fixing hole 1692.60
B Right front fender, front fixing hole Left front fender, rear fixing hole 1866.13
C Left front fender, front fixing hole Right front fender, rear fixing hole 1866.24
D Right front fender, middle fixing hole Left front fender, middle fixing hole 1765.80
A Left shock absorber mounting, left outboard fixing Right shock absorber, right outboard fixing 1043.31
B Right shock absorber, right outboard fixing Left front fender, rear fixing hole 1521.80
C Left shock absorber mounting, left outboard fixing Right front fender, rear fixing hole 1521.80
Item From To Length
A Windshield molding, top left fixing hole Windshield molding, top right fixing hole 1284.15
B Left side member deformation element, top Right side member deformation element, top 822.00
inboard fixing hole inboard fixing hole
Side Panel Dimensions
Item From To Length
A Body side, top hinge top fixing hole - front door Body side, top hinge top fixing hole - rear door 1149.62
B Body side, bottom hinge top fixing hole - front door Body side, top hinge top fixing hole - rear door 1242.56
C Body side, top hinge top fixing hole - front door Body side, bottom hinge top fixing hole - rear door 1182.39
D Body side, bottom hinge top fixing hole - front door Body side, bottom hinge top fixing hole - rear door 1129.35
E Body side, top hinge top fixing hole - rear door Body side, striker top fixing hole - rear door 1001.02
F Body side, bottom hinge top fixing hole - rear door Body side, striker top fixing hole - rear door 940.28
NOTE: Opposite side similar (From front right seat belt adjuster, top fixing hole To front left seat belt retractor,
mounting hole).
A Front left seat belt adjuster, top fixing hole Front right seat belt retractor, upper mounting hole 1697.58
A Instrument panel carrier top left fixing hole Instrument panel carrier top right fixing hole 1540.00
B Instrument panel carrier bottom left fixing hole Instrument panel carrier bottom right fixing hole 1540.00
Rear End Body Dimensions
Item From To Length
A Upper tailgate - left inboard hinge fixing hole Upper tailgate - right inboard hinge fixing hole 875.00
B Left rear panel - tooling hole Right rear panel - tooling hole 1440.00
C Rear armature - outboard top left fixing hole Rear armature - outboard top right fixing hole 1268.00
D Rear armature - outboard bottom left fixing hole Rear armature - outboard bottom right fixing hole 1273.00
Item From To Length
A Rear floor side member, left tooling hole Rear floor side member, right tooling hole 1070.00
Under Body Dimensions
Item From To Length
A Rear subframe, rear right fixing hole Rear subframe, rear left fixing hole 1028.00
B Rear subframe, front right fixing hole Rear subframe, front left fixing hole 1028.00
C Front side member, right tooling hole Front side member, left tooling hole 975.00
D Front subframe, center right fixing hole Front subframe, center left fixing hole 861.00
E Front subframe, front right fixing hole Front subframe, front left fixing hole 861.00
F Front subframe, front right fixing hole Front subframe, center right fixing hole 603.00
G Front subframe, front right fixing hole Front side member, right tooling hole 1191.36
H Front subframe, front right fixing hole Rear subframe, front right fixing hole 3063.14
I Front subframe, front right fixing hole Rear subframe, rear right fixing hole 3751.03
Item From To Length

A Rear subframe, rear left fixing hole Rear subframe, front right fixing hole 1237.03
B Front subframe, front left fixing hole Front side member, right tooling hole 1506.86
C Front subframe, front left fixing hole Front subframe, center right fixing hole 1051.16
Description
Gap and Profile Measurements

The following information is to be used as a guide to assist the technician when fitting exterior body panels and trim
items so as to achieve a correctly aligned and cosmetically acceptable vehicle.
NOTE: All dimensions shown are in millimeters, (mm).
Section Description Gap Profile

A-A Hood to bumper cover gap N/A N/A
B-B Front bumper cover to headlamp 3.0 +/- 2.1 0.5 +/-1.6
C-C Bumper cover to headlamp gap 1.5 +1.75 -1.45 N/A
D-D Headlamp to hood N/A N/A
E-E Fender to bumper cover 0 +/- 0.25 0 +/- 0.5
F-F Fender to hood 6 +1.1 -1 N/A
G-G Fender to front door 4 +/-1 0.5 +/-1
H-H Front door to sill panel 0.2 +0.6 -0 N/A
I-I Front door to Rear door 5 +/-1.5 0.5 +/-1.5
J-J Front door to Rear door 4 +/-1 0.5 +/-1
K-K Rear door to sill panel 0.2 +0.6 -0 N/A
Section Description Gap Profile
A-A Rear door to roof panel 6.5 +/-1.5 -2 +/-1.5
B-B Rear door to quarter glass 6.5 +/-1.5 0 +/-1.5
C-C Rear door to quarter panel 4 +/-1 0 +/-1
D-D Quarter panel to bumper cover 0 +0.5 -0 0 +/-1
E-E Quarter panel to tail lamp 1.5 +/-1.48 1 +/-0.51
F-F Quarter panel to tail lamp 1.5 +/-1.34 1 +/-0.64
G-G Quarter panel to tail lamp 1.5 +/-0.91 1 +/-0.70
H-H D-Pillar trim panel to rear window 5 +/-1.7 6 +/-1.7
I-I Tail lamp to bumper cover 1.5 +/-1.5 N/A
J-J Tail lamp to tailgate 4.5 +/-1.95 5 +/-1.6
Front End Sheet Metal Repairs - Front End Sheet Metal
Front end service panels
NOTES:
The illustration may indicate either hand of the service panel, the opposite hand will be similar.
RHD (right-hand drive) shown, LHD (left-hand drive) similar.
Item Description Material

1 Front Fender Mounting Panel 5 Series Aluminium
2 Fender Apron Panel Closing Panel 5 Series Aluminium
3 Suspension Top Mount Cast Aluminium
4 Front Side Member and Suspension Top Mount Assembly 5 Series, AC Series and Cast Aluminium
5 Front Side Member AC Series Aluminium
6 Fender Apron Panel 5 Series Aluminium
7 Front Fender Lower Mounting Bracket 5 Series Aluminium
8 Hood Latch Panel Mounting Bracket 6 Series Aluminium
9 Hood Latch Panel Cast Magnesium
Front End Sheet Metal - Single Panel Times
The following information shows the total time taken to install single panels. These times do not include removal of
mechanical, electrical and trim, (MET), items or paint times.
The times shown are to be used as a guide only.
Panel Description Hours

Front Fender Mounting Panel 0.20
Fender Apron Panel Closing Panel 4.20
Suspension Top Mount 1.60
Front Side Member and Suspension Top Mount Assembly 6.80
Front Side Member Section 3.70
Fender Apron Panel 3.30
Front Fender Lower Mounting Bracket 0.70
Hood Latch Panel Mounting Bracket 1.30
Hood Latch Panel 1.10
Front End Sheet Metal Repairs - Front Side Member Section
Removal
NOTE: The front side member section is installed in conjunction with:
Front bumper cover
Front bumper
Front fender
Fender splash shield
Hood latch panel
Air cleaners
Radiators
Charge air cooler
Front suspension
Front subframe
Anti-lock brake system (ABS) module
Engine
1. The front side member section is serviced as indicated.
2. Before commencing this procedure make sure that you are

aware of all Health and Safety requirements.For additional
information, refer to: Health and Safety Precautions (100-00
General Information, Description and Operation).
3. For further information on the methods, tools and fixings used in

this procedure refer to the body repairs - general information
section.
4. To make sure the vehicle is correctly aligned. It must be

placed on a Land Rover approved alignment jig.
NOTES:
Where breakstem fasteners (BSF) removal is instructed remove fastener shaft with a 4mm punch and remove
the head with a 6.5mm drill bit. Make sure all the drilled holes are free from debris.
Where self piercing rivets (SPR) removal is instructed use either the approved SPR tool or 5.3mm drill bit.
Any joints sealed as part of vehicle manufacture must be sealed as part of the repair.
5. For additional information, refer to: Front Bumper Cover (501-

19 Bumpers, Removal and Installation).
6. For additional information, refer to: Front Bumper (501-19

Bumpers, Removal and Installation).
7. For additional information, refer to: Fender (501-02 Front End

Body Panels, Removal and Installation).
8. For additional information, refer to: Fender Splash Shield (501-

02 Front End Body Panels, Removal and Installation).
9. h
For additional information, refer to: Hood Latch Panel (501-27
Front End Sheet Metal Repairs, Removal and Installation).
10. NOTE: Left hand only.
For additional information, refer to: Air Cleaner LH (303-12A

Intake Air Distribution and Filtering - TDV6 3.0L Diesel, Removal
and Installation).
11. NOTE: Right hand only.
For additional information, refer to: Air Cleaner RH (303-12A

Intake Air Distribution and Filtering - TDV6 3.0L Diesel, Removal
and Installation).
12. For additional information, refer to: Radiator (303-03A Engine

Cooling - TDV6 3.0L Diesel, Removal and Installation).
13. For additional information, refer to: Condenser - TDV6 3.0L

Diesel (412-01A Climate Control, Removal and Installation) /
Condenser - TDV8 4.4L Diesel (412-01A Climate Control,
Removal and Installation) / Condenser - V6 S/C 3.0L Petrol /V8
S/C 5.0L Petrol (412-01A Climate Control, Removal and
Installation).
14. For additional information, refer to: Shock Absorber and Spring
Assembly (204-01 Front Suspension, Removal and Installation).
15. Front subframe

For additional information, refer to: Front Subframe - TDV6 3.0L
Diesel (502-00 Uni-Body, Subframe and Mounting System,
Removal and Installation) /
Front Subframe - V6 S/C 3.0L Petrol (502-00 Uni-Body,
Subframe and Mounting System, Removal and Installation) /
Front Subframe - V8 S/C 5.0L Petrol (502-00 Uni-Body,
Subframe and Mounting System, Removal and Installation).
For additional information, refer to: Anti-Lock Brake System

(ABS) Module - RHD (206-09 Anti-Lock Control - Traction
Control, Removal and Installation).
17. For additional information, refer to: Engine (303-01A Engine -

TDV6 3.0L Diesel, Removal).
18. Release the front side member wiring harness and position to
one side.
19. Remove the brake pipe retaining bracket as indicated.
20. CAUTION: The front side member and front side member
closing panel joints are staggered.
Mark out the position where the front side member closing panel
section MIG (metal inert gas) butt joint is to be made. Cut
through the front side member closing panel at this point, as
indicated.
21. CAUTION: Care should be taken not to cut through into the
front side member closing panel, as this section of the front side
member closing panel remains in place.
Mark out the position where the front side member section MIG
butt joint is to be made. Cut through the front side member at
this point, as indicated.
22. Remove the SPR's from the front side member as indicated.
23. Remove the SPR's from the front side member as indicated.
24. Separate the joints and remove the front side member section.
Installation
CAUTION: Where structural adhesive is to be applied between surfaces it is essential compression is applied to
the joints during the curing period.
NOTES:
BSF installation involves using the Land Rover approved BSF installation tool and requires a hole diameter of
6.5mm.
SPR installation requires using the Land Rover approved SPR tool.
1. Remove the rivet remnants.
2. Dress the flanges where necessary.
3. Mark out the position on the front side member service panel
where the MIG butt joint is to be made and cut the panel at this
point.
4. Mark out the position on the front side member closing panel
where the MIG butt joint is to be made and cut the panel at this
point.
5. Offer up the new front side member service panel and clamp
into position. Check alignment, if correct , proceed to the next
step, if not rectify and recheck before proceeding.
6. Offer up the new front side member closing panel and clamp
into position. Check alignment, if correct, proceed to next step,
if not rectify and recheck before proceeding.
7. Drill holes at the points where BSF's are to be installed as

indicated.
8. Drill holes at the points where BSF's are to be installed as

indicated.
9. Deburr the drilled holes.
10. Using a fine bristle disc, clean and prepare the panel surfaces,
including the inner surfaces where backing plates are to be
installed.
11. Measure and cut two 50mm wide backing plates, to be placed
25mm each side of the MIG butt joint, from the discarded part
of the new front side member panel.
12. Cut four run on/run off tabs from the discarded part of the new
front side member remnant.
13. Using a fine bristle disc clean and prepare the backing plates the
new front side member closing panel and new front side
member panel.
14. Drill holes in the vehicle assembly for the backing plates that
are MIG plug welded as indicated.
16. Using a fine bristle disc clean and prepare the panel surfaces,
including the inner panel surfaces where backing plates are to
be welded.
17. Offer up the backing plates, align and clamp into position. Check
alignment, if correct proceed to the next step, if not rectify and
recheck before proceeding.
18. MIG plug weld the backing plates to the vehicle assembly as
indicated.
19. Drill holes for the MIG plug welds for the installation of the
backing plate to the front side member outer section as
indicated.
20. Drill holes for MIG plug welds for the installation of the backing
plate to the front side member inner section as indicated.
21. Offer up the new front side member closing panel to the vehicle,
align and clamp into position. Check alignment, if correct,
proceed to next step, if not rectify and recheck before
proceeding.
22. Tack weld the run-on/run-off tabs to the front side member
section.
23. MIG plug weld the backing plates and MIG butt weld the front
side member outer panel as indicated.
24. Apply the coupling agent where the Land Rover recommended
bonding material is to be applied and allow to dry.
25. NOTE: Make sure a continuous bead of adhesive surrounds

fixing holes.
Apply a 5mm zig zag bead of Land Rover recommended bonding

material to the front side member section.
26. Offer up the new front side member closing panel to the vehicle,
align and clamp into position. Check alignment, if correct,
proceeding.
27. Tack weld the run-on/run-off tabs to the front side member
closing panel.
28. MIG plug weld the backing plates and MIG butt weld the front
side member closing panel as indicated.
29. Cut off the run on/run off tabs.
30. Carry out a non destructive crack inspection on theMIGbutt

joints. If correct proceed to next step, if not, rectify and recheck
before proceeding.
31. Dress the welded joints.
32. Install the SPR's and BSF's as indicated.

33. Install the BSF's as indicated.
34. Make sure corrosion protection is applied to all areas affected by

repair.
35. The installation of associated panels and components is the

reversal of the removal procedure.
Front End Sheet Metal Repairs - Fender Apron Panel
Removal
NOTES:
The fender apron panel is installed in conjunction with:
Front fender
Fender mounting panel
Hood latch panel mounting bracket
Front door
Cowl panel grill
Hood
Windshield moulding
Right side indicated, left side similar.
1. The fender apron panel is serviced as indicated.


section.
NOTES:


6. For additional information, refer to: Front Fender Mounting Panel

(501-27 Front End Sheet Metal Repairs, Removal and
Installation).
7. For additional information, refer to: Hood Latch Panel Mounting

Bracket (501-27 Front End Sheet Metal Repairs, Removal and
Installation).
8. For additional information, refer to: Front Door (501-03 Body

Closures, Removal and Installation).
9. For additional information, refer to: Cowl Panel Grille (501-02

Front End Body Panels, Removal and Installation).
10. For additional information, refer to: Hood (501-02 Front End
11. For additional information, refer to: Windshield Moulding (501-

11 Glass, Frames and Mechanisms, Removal and Installation).
12. Remove the SPR's from the hood latch panel mounting bracket
as indicated.
13. Remove the SPR's as indicated.

14. Separate the panels.
Installation
NOTES:
6.5mm.
SPR installation requires using the Jaguar approved SPR tool.
1. Remove rivet remnants.
2. Dress flanges where necessary.
3. Offer up the new fender apron panel and clamp into position.
Check alignment, if correct proceed to next step, if not, rectify
and recheck before proceeding.
4. Using a fine bristle disc, clean and prepare the panel surfaces.
5. Offer up the original hood strut mounting panel to the new

fender apron panel, align and clamp into position.
6. NOTE: The hood strut mounting panel bracket is

manufactured from mild steel. Make sure the mating surfaces
are correctly sealed prior to installation to avoid galvanic
corrosion.
Drill holes through the old hood latch panel mounting bracket
into the new fender apron panel at the points where BSF's are to
be installed.
7. Offer up the new fender apron panel, clamp into position. Check
alignment, if correct, proceed to next step, if not rectify and
8. Drill holes through the old panel into the new panel, at the
points where BSF's are to be installed.
9. Remove the new panel.


fixing holes.
Apply a 5mm zig zag bead of the Land Rover recommended

bonding material to the fender apron panel as indicated.
13. Offer up the new fender apron panel, clamp into position. Check
14. NOTE: Make sure the BSF's are installed from the outside.
Install the BSF's as indicated.

15. Remove any excess adhesive.
16. NOTES:
The hood strut mounting panel bracket is manufactured

from mild steel. Make sure the mating surfaces are correctly
sealed prior to installation to avoid galvanic corrosion.
Make sure the BSF's are installed from the outside.

17. 18 Make sure corrosion protection is applied to all areas affected
by repair.

reversal of removal procedure.
Front End Sheet Metal Repairs - Fender Apron Panel Closing Panel
Removal
NOTE: The fender apron panel closing panel is installed in conjunction with:
Fender apron panel
1. The fender apron panel closing panel is serviced as

indicated.

aware of all Health and Safety requirements. For additional

section.
NOTES:
4. For additional information, refer to: Fender Apron Panel (501-27

5. Release the wiring harness attached to the fender apron panel

closing panel and position to one side.
6. Make sure that the position of the fender apron panel is marked
in relation to the adjacent panels. This will aid the alignment of
the fender apron closing panel on installation.

inner panel.
Mark out the position where the fender apron panel closing panel
section MIG (metal inert gas) butt joint is to be made. Cut
through the fender apron panel closing panel at this point as
indicated.
9. Remove the fender apron panel closing panel as indicated.

Installation
NOTES:
6.5mm.
3. Offer up the new fender apron closing panel and clamp into
position. Check alignment, if correct proceed to next step, if not,
rectify and recheck before proceeding.
4. Drill holes where BSF's are to be installed as indicated.


9. NOTES:
Make sure the Land Rover recommended bonding material

is 30mm away from the MIG welded butt joint.
Make sure a continuous bead of adhesive surrounds fixing

holes.

bonding material as indicated.
10. Offer up the new fender apron closing panel, clamp into position.
Check alignment, if correct, proceed to next step, if not rectify
12. Fabricate a 25mm backing plate from the new fender apron
panel closing panel remnant. Deburr the backing plate and offer
up to the fender apron panel closing panel as indicated.
13. MIG weld the backing plate on to the fender apron panel closing
panel using 20mm runs as indicated.
14. MIGweld the fender apron panel closing panel section butt joint
as indicated.
16. Dress the MIG welded butt joints.
18. 18 Make sure corrosion protection is applied to all areas affected

by repair.
Front End Sheet Metal Repairs - Suspension Top Mount
Removal
NOTE: The suspension top mount is installed in conjunction with:
Fender apron panel
Fender apron closing panel
1. NOTE: The right-hand suspension top mount

contains the stamped Vehicle Identification Number
(VIN). When a new right hand suspension top mount
is requested it will be supplied stamped with the VIN
number. This operation is carried out within the Land
Rover parts supply process.
The suspension top mount is serviced as indicated.


section.
NOTES:
Before carrying out this repair the vehicle must be correctly aligned using a Land Rover approved alignment jig.

5. For additional information, refer to: Fender Apron Panel Closing

Panel (501-27 Front End Sheet Metal Repairs, Removal and
Installation).
6. Remove the front side member heat shield.

8. NOTE: Retain the old panel to use as a template during the
install process.
Separate the joints and remove the suspension top mount.
9. Cut two sections from the old suspension top mount as

indicated. These are to be used as a template to mark the BSF
locations on the new suspension top mount.
Installation
NOTES:
6.5mm.
3. Offer up the new suspension top mount and clamp into position.
5. Drill holes through the template into the new panel for the
installation of the BSF's as indicated.
7. Offer up the new suspension top mount, clamp into position.



fixing holes.

material to the suspension top mount as indicated.
14. Offer up the new suspension top mount, clamp into position.

repair.

Front End Sheet Metal Repairs - Front Side Member and Suspension Top
Mount Assembly
Removal
NOTES:
Right hand indicated left hand similar.
The front side member and suspension top mount assembly are installed in conjunction with:
Front bumper cover
Front bumper
Front fender
Fender apron panel
Fender apron closing panel
Hood
Hood latch panel
Anti-lock brake system (ABS) module
Radiator
Condenser
Front subframe
Front suspension
Engine
Transmission
1. The front side member and suspension top mount assembly is

serviced as indicated.
NOTE: The assembly includes the deformation element,

front side member to deformation element bracket, front side
member, front side member closing panel, suspension top
mount and the inner apron and wheelhouse panels.
The right-hand front side member and suspension top mount

assembly contains the stamped Vehicle Identification Number
(VIN). When a new right hand front side member and
suspension top mount assembly is requested it will be supplied
stamped with the VIN. This operation is carried out within the
Land Rover parts supply process.

section.
NOTES:
To make sure that the vehicle is correctly aligned, it must be placed on a Land Rover approved alignment
jig.

5. For additional information, refer to: Front Bumper (501-19




9. For additional information, refer to: Fender Apron Panel Closing

Panel (501-27 Front End Sheet Metal Repairs, Removal and
Installation).
10. For additional information, refer to: Hood (501-02 Front End
11. For additional information, refer to: Hood Latch Panel (501-27
12. For additional information, refer to: Anti-Lock Brake System

(ABS) Module - RHD (206-09 Anti-Lock Control - Traction
Control, Removal and Installation).
13. For additional information, refer to: Radiator (303-03A Engine

Cooling - TDV6 3.0L Diesel, Removal and Installation).
14. For additional information, refer to: Air Conditioning (A/C)

System Recovery, Evacuation and Charging (412-00 Climate
Control System - General Information, General Procedures).
15. For additional information, refer to: Front Subframe - TDV6 3.0L
Diesel (502-00 Uni-Body, Subframe and Mounting System,
Removal and Installation) / Front Subframe - V6 S/C 3.0L Petrol
(502-00 Uni-Body, Subframe and Mounting System, Removal
and Installation) / Front Subframe - V8 S/C 5.0L Petrol (502-00
Uni-Body, Subframe and Mounting System, Removal and
Installation).
16. For additional information, refer to: Shock Absorber and Spring
Assembly (204-01 Front Suspension, Removal and Installation).
17. For additional information, refer to: Engine (303-01A Engine -

TDV6 3.0L Diesel, Removal).
18. For additional information, refer to: Transmission - TDV6 3.0L

Diesel (307-01A Automatic Transmission/Transaxle - Vehicles
With: 8HP70 8-Speed Automatic Transmission AWD, Removal) /
Transmission - TDV8 4.4L Diesel (307-01A Automatic
Transmission/Transaxle - Vehicles With: 8HP70 8-Speed
Automatic Transmission AWD, Removal) / Transmission - V6 S/C
3.0L Petrol /V8 S/C 5.0L Petrol (307-01A Automatic
Transmission/Transaxle - Vehicles With: 8HP70 8-Speed
Automatic Transmission AWD, Removal).
19. For additional information, refer to: Front Seat - Vehicles With:
Power Seats (501-10 Seating, Removal and Installation).
20. Remove the front floor carpet.
For additional information, refer to: Brake Pedal and Bracket

(206-06 Hydraulic Brake Actuation, Removal and Installation).
Remove the front to rear brake pipes.
Remove the brake pipes at the bulkhead.
Remove the fuel supply and return pipes.
For additional information, refer to: Fuel Fired Booster Heater

(412-02A Auxiliary Climate Control, Removal and Installation).
26. NOTE: Right hand and left hand

Release and position the front side member and suspension top
mount wiring harness to one side.
27. Prior to removal, mark the position of the front side member
and suspension top mount assembly in relation to adjacent
panels for ease of alignment on installation.


32. Remove the SPR's and the reinforcement as indicated.
33. Remove the SPR's and the retaining screws as indicated.

34. CAUTION: This step requires the aid of another technician
as the front side member and suspension top mount assembly is
heavy.
NOTE: Retain the old panel as it will be required for

reference on installation.
Separate the joints and remove the front side member and
suspension top mount assembly.
Installation
NOTES:
6.5mm.
4. NOTE: Where there is limited or no access to drill through

both the old and the new front side member and suspension top
mount assembly when they are offered up to the vehicle
assembly use the old front side member and suspension top
mount assembly for reference. Measure and mark the locations
for the installation of the BSF's on the new front side member
and suspension top mount assembly.
Drill holes where BSF's are to be installed prior to offering up

the replacement panel.

as the front side member and suspension top mount assembly is
heavy
NOTE: Make sure the alignment for the rivet nuts and
drilled holes for the BSF's are correct.
Offer up the new front side member and suspension top mount
assembly and clamp into position. Check alignment, if correct
proceed to next step, if not, rectify and recheck before
proceeding.
7. Drill holes through the old panel into the new panel where BSF's
are to be installed as indicated.
8. Drill holes where the BSF's are to be installed as indicated.

9. Drill holes through the old panel into the new panel where the
BSF's are to be installed as indicated.
15. Apply the coupling agent where the Land Rover approved

fixing holes.
Apply a 5mm zig zag bead of Land Rover approved bonding

material to the body joints in the area of the contact surface of
the front side member and suspension top mount assembly.
17. Offer up the new front side member and suspension top mount
assembly, clamp into position. Check alignment, if correct,
proceeding.
18. NOTE: Do not fully tighten at this stage.
Install the retaining screws as indicated.


23. Install the BSF's and tighten the retaining screws to 24Nm.
25. Make sure that any open or exposed panel joints are suitably
sealed.

repair.

Front End Sheet Metal Repairs - Front Fender Mounting Panel
Removal
NOTE: The front fender mounting panel is installed in conjunction with:
Front fender
1. The front fender mounting panel is serviced as

indicated.

aware of all Health and Safety requirements.
For additional information, refer to: Health and Safety
Precautions (100-00 General Information, Description and
Operation).
3. For further information on the methods, tools and fixings used

in this procedure refer to the body repairs - general information
section

5. Remove the front fender mounting panel bolts as

indicated.
Installation
1. Install the front fender mounting panel and tighten the bolts to
11Nm.
2. Make sure corrosion protection is applied to all areas affected

by repair.
Front End Sheet Metal Repairs - Front Fender Lower Mounting Bracket
Removal
NOTE: The front fender lower mounting bracket is installed in conjunction with:
Front fender
1. The front fender lower mounting bracket is serviced as

indicated.

Operation).

section.
NOTES:
Right hand indicated, left hand similar.

6. Remove the BSF's as indicated.
7. Separate the joints and remove the front fender lower mounting
bracket.
Installation
NOTES:
6.5mm.
3. Offer up the new front fender lower mounting bracket and clamp
into position. Check alignment, if correct proceed to next step, if
not, rectify and recheck before proceeding.
4. Using a combination of the old front fender mounting bracket

and the new front fender lower mounting bracket, mark and drill
holes for BSF's as indicated.
5. Remove the new front fender mounting bracket.


fixing holes.
Apply a 5mm zig zag bead of the Land Rover approved bonding
material as indicated.
9. Offer up the new panel and clamp into position. Check
alignment, if correct proceed to next step, if not, rectify and

repair.

Front End Sheet Metal Repairs - Hood Latch Panel
Removal
NOTES:
The hood latch panel is installed in conjunction with:
Front bumper cover
Headlamp assembly
1. The hood latch panel is serviced as indicated.


section.

5. For additional information, refer to: Headlamp Assembly (417-01

Exterior Lighting, Removal and Installation).
6. Release the windshield washer reservoir and position to one side

as indicated.
7. Remove both air deflectors.
8. Remove the active vanes as indicated.
9. Release the hood latch panel wiring harness and position to one
side.
10. Remove both front impact sensors as indicated.
11. Release the front bonnet seal in the area of the hood latch
panel.
12. Disconnect the hood latch panel release cable as indicated.
13. Remove both hood latches as indicated.
14. Remove the front bumper cover retaining strip as indicated.

15. Remove the hood latch panel retaining bolts as indicated.
16. Remove the hood latch panel retaining bolts as indicated.
17. CAUTION: Protect the front fender paintwork to avoid

damaging the front fenders.
Remove the hood latch panel and disconnect the radiator splash
shield.
Installation
1. Offer up the new hood latch panel. Check alignment, if correct,
proceeding.
2. CAUTION: The hood latch panel bolts are coated to

inhibit galvanic corrosion and can be reused only if the
coating is not damaged.
Install the hood latch panel and tighten the bolts to 25Nm.
3. Install the hood latches and tighten the bolts to 10Nm.
4. Install the front impact sensors and tighten the bolts to 10Nm.

repair.
Front End Sheet Metal Repairs - Hood Latch Panel Mounting Bracket
Removal
NOTE: The hood latch mounting panel is installed in conjunction with:
Front fender
Hood latch panel
1. The hood latch panel mounting bracket is serviced as

indicated.

Operation).
3. For further information on the methods, tools and fixings used

in this procedure refer to the body repairs - general information
section.
NOTES:

5. For additional information, refer to: Hood Latch Panel (501-27


7. Remove the hood latch panel mounting bracket.
Installation
NOTES:
6.5mm.
3. Offer up the hood latch panel mounting bracket and clamp into
position. Check alignment, if correct, proceed to next step, if
not rectify and recheck before proceeding.
4. Install the SPR's as indicated.
5. Make sure corrosion protection is applied to all areas affected

by repair.

Roof Sheet Metal Repairs - Roof
Roof Service Panels (Fixed Roof)

1 Roof panel AC Series Aluminium
Roof Service Panels (Roof Opening Panel)

1 Roof Front Panel AC Series Aluminium
2 Roof Rear Panel AC Series Aluminium
Time schedules, roof panels

Single panel times (Fixed Roof)
Roof panel TBC
Single panel times (Roof Opening Panel)
Roof Front Panel 4.20
Roof Rear Panel TBC
Roof Sheet Metal Repairs - Roof Panel
Removal
NOTE: In this procedure the roof panel is installed in conjunction with:
Windshield
Liftgate
Headliner
Side air curtain module
Roof moulding
1. The roof panel is serviced as indicated.


section.
NOTES:
4. For additional information, refer to: Windshield Glass (501-11

Glass, Frames and Mechanisms, Removal and Installation).
5. For additional information, refer to: Liftgate (501-03 Body
6. For additional information, refer to: Headliner (501-05 Interior

Trim and Ornamentation, Removal and Installation).
7. For additional information, refer to: Side Air Curtain Module

(501-20B Supplemental Restraint System, Removal and
Installation).
8. For additional information, refer to: Roof Moulding (501-08

Exterior Trim and Ornamentation, Removal and Installation).
9. For additional information, refer to: Antenna (415-01

Information and Entertainment System, Description and
Operation).
10. Remove the bolts as indicated.
11. Remove any electrical components in the local area of repair to

prevent damage.
12. Release and position the roof panel wiring harness to one side.

14. Separate the joints and remove the old panel.
Installation
NOTES:
6.5mm.
3. Using a fine bristle disc, clean and prepare the panel surfaces,
removing any adhesive residue.
4. Offer up the new panel and clamp into position. Check

5. Drill holes through the old panels into the new panel, at the
points where BSF's are to be installed as indicated.
6. Drill holes through the old panels into the new panel, at the
points where BSF's are to be installed as indicated.
10. Apply the coupling agent where Land Rover recommended

fixing holes.
Apply a 5mm bead of Land Rover recommended bonding

material to the body joints as indicated.
12. NOTE: Make sure the areas highlighted have a sealer

thickness of 8mm.
Apply a 8mm bead of Land Rover recommended semi-rigid

sealer to the body joints as indicated.
13. Offer up the new roof panel, clamp into position. Check

16. NOTE: Make sure that the BSF's are installed from inside
outwards.
Install the SPR's and the BSF's as indicated.
18. Make sure that sealer is applied over the rivet heads including
the remnants of the rivet stem and the surrounding hole.
sealed.
20. Install the new bolts and tighten to 23Nm.

the repair.

Roof Sheet Metal Repairs - Roof Front Panel
Removal
NOTE: The roof front panel is installed in conjunction with:
Roof opening panel
Roof moulding
Windshield glass
Headliner
1. The roof front panel is serviced as indicated.

Operation).

section.
NOTES:

5. For additional information, refer to: Roof Opening Panel Frame

(501-17 Roof Opening Panel, Removal and Installation).


8. Release and position the roof opening panel wiring harness to

one side.

10. Separate the joints and remove the roof front panel.
Installation
NOTES:
6.5mm.
4. Offer up the new roof front panel and clamp into position. Check
5. Drill holes through the old roof front panel into the new roof
front panel where BSF's are to be installed as indicated.

10. Apply the Land Rover approved semi rigid sealer to the body
assembly as indicated.
fixing holes.
Apply a 5mm zig zag bead (1) and a straight bead (2) of the
Land Rover recommended bonding material as indicated.
12. Offer up the new roof front panel and clamp into position. Check
13. Install the BSF's and the SPR's as indicated.
15. Make sure that any open or exposed panel joints are sealed with
a Land Rover recommended sealer.

repair.

Roof Sheet Metal Repairs - Roof Rear Panel
Removal
NOTE: The roof rear panel is installed in conjunction with:
Liftgate
Rear glass roof panel
Headliner
Antenna
1. The roof rear panel is serviced as indicated.


section.
NOTES:
4. For additional information, refer to: Liftgate (501-03 Body


7. For additional information, refer to: Roof Opening Panel Frame

(501-17 Roof Opening Panel, Removal and Installation).

Installation).
9. For additional information, refer to: Antenna (415-01

Information and Entertainment System, Description and
Operation).
10. Remove the rear roof panel bolts as indicated.
11. Release and position the roof panel wiring harness to one side.

13. Separate the joints and remove the old roof rear panel.
Installation
NOTES:
6.5mm.
4. Offer up the new roof rear panel and clamp into position. Check
5. Drill holes through the old roof rear panel into the new roof rear
panel where BSF's are to be installed as indicated.
6. Remove the new roof rear panel.

10. NOTE: Make sure that the areas highlighted have a sealer
thickness of 8mm.
Apply a 5mm zig zag bead (1) and a straight bead (2) of Land
Rover recommended bonding material to the body joints.
fixing holes.
Apply a bead of Land Rover recommended semi-rigid sealer to

the body assembly as indicated.
12. Offer up the new roof rear panel and clamp into position. Check
13. NOTE: Make sure that the two BSF's at the rear of the roof
rear panel are installed from the inside.
Install the BSF's and the SPR's as indicated.
15. Make sure that sealer is applied over the rivet heads including
the remnants of the rivet stem and the surrounding hole.
16. Install the roof rear panel fixing bolts and tighten to 23Nm.
17. Make sure that any open or exposed panel joints are correctly
sealed.

repair.

Side Panel Sheet Metal Repairs - Side Panel Sheet Metal
Side service panels
NOTE: The illustration may indicate either hand of the service panel, the opposite hand will be similar.

1 B-Pillar Inner Panel 6 Series Aluminium
2 B-Pillar Reinforcement 6 Series Aluminium
3 B-Pillar Outer Panel AC Series Aluminium
4 Side Panel AC Series Aluminium
5 Rocker Panel AC Series Aluminium
6 Rocker Panel Inner Reinforcement 6 Series Aluminium
7 A-Pillar Reinforcement 6 Series Aluminium
Time schedules, side panels

Single panel times
B-Pillar Inner Panel TBC
B-Pillar Reinforcement TBC
B-Pillar Outer Panel TBC
Side Panel TBC
Rear quarter panel front wheel housing TBC
Rocker Panel 8.00
A-Pillar Reinforcement 8.70
Side Panel Front Section TBC
Rocker Panel Section 0.90
Side Panel Sheet Metal Repairs - Side Panel
Removal
All vehicles
NOTES:
The side panel is installed in conjunction with:
Fender
Fender apron panel
Front fender lower mounting bracket
Windshield
Front door
Rear door
Rocker panel moulding
Roof moulding
Headliner
Roof panel
Rear quarter window glass
Rear fender splash shield
Rear bumper cover
Rear lamp assembly
Fuel tank filler pipe
Front seat
Rear seat cushion
Instrument panel
Right hand indicated, left hand similar
1. The side panel is serviced as indicated.

2. Before commencing this procedure make sure that you are aware of all
Health and Safety requirements. For additional information, refer to: Health
and Safety Precautions (100-00 General Information, Description and
Operation).
3. For further information on the methods, tools and fixings used in this
procedure refer to the body repairs - general information section.
NOTES:
Where breakstem fasteners (BSF) removal is instructed remove fastener shaft with a 4mm punch and remove the head with
a 6.5mm drill bit. Make sure all the drilled holes are free from debris.
4. For additional information, refer to: Fender (501-02 Front End Body Panels,
5. For additional information, refer to: Fender Splash Shield (501-02 Front End
6. For additional information, refer to: Front Fender Lower Mounting Bracket
(501-27 Front End Sheet Metal Repairs, Removal and Installation).
7. For additional information, refer to: Fender Apron Panel (501-27 Front End
Sheet Metal Repairs, Removal and Installation).
8. For additional information, refer to: Windshield Glass (501-11 Glass, Frames
and Mechanisms, Removal and Installation).
9. For additional information, refer to: Front Door (501-03 Body Closures,
10. For additional information, refer to: Rear Door (501-03 Body Closures,
11. For additional information, refer to: Rear Rocker Panel Moulding (501-08
12. For additional information, refer to: Roof Moulding (501-08 Exterior Trim and
13. For additional information, refer to: Headliner (501-05 Interior Trim and
14. For additional information, refer to: Side Air Curtain Module (501-20B
Supplemental Restraint System, Removal and Installation).
15. For additional information, refer to: Rear Quarter Window Glass (501-11
16. For additional information, refer to: Rear Fender Splash Shield (501-08
17. For additional information, refer to: Rear Bumper Cover (501-19 Bumpers,
For additional information, refer to: Fuel Tank Filler Pipe (310-01E Fuel Tank
and Lines - SDV6 3.0L Diesel - Hybrid Electric Vehicle, Removal and
Installation).
19. For additional information, refer to: Rear Lamp Assembly (417-01 Exterior
Lighting, Removal and Installation).
20. For additional information, refer to: Front Seat - Vehicles Without: Power
21. For additional information, refer to: Rear Seat Cushion (501-10 Seating,
22. For additional information, refer to: Instrument Panel Lower Section (501-12
Instrument Panel and Console, Removal and Installation).
23. For additional information, refer to: Instrument Panel Upper Section (501-12
Instrument Panel and Console, Removal and Installation).
24. For additional information, refer to: Roof Front Panel (501-28 Roof Sheet
Metal Repairs, Removal and Installation).
25. For additional information, refer to: Roof Rear Panel (501-28 Roof Sheet
26. For additional information, refer to: Roof Opening Panel Frame (501-17 Roof
Opening Panel, Removal and Installation).

27. For additional information, refer to: Roof Panel (501-28 Roof Sheet Metal
Repairs, Removal and Installation).
All vehicles
28. Release the floor carpet and position to one side.
29. Lift edge of rear header rail to reveal hidden SPR as indicated.
30. Remove the SPR as indicated.





39. CAUTION: Avoid where possible damaging the noise, vibration and
harshness (NVH) components located behind the side panel.
Carefully separate the adhesive from the rear wheelhouse outer, rear lamp
panel outer, right hand quarter panel and the fuel filler neck housing as
indicated.
40. Separate the panels.
Installation
CAUTION: Where structural adhesive is to be applied between surfaces it is essential compression is applied to the joints
during the curing period.
NOTES:
BSF installation involves using the Land Rover approved BSF installation tool and requires a hole diameter of 6.5mm.
4. Offer up the new side panel and clamp into position. Check alignment, if
correct proceed to next step, if not, rectify and recheck before proceeding.




13. Remove the new side panel.
16. Apply the coupling agent where the Land Rover recommended bonding
material is to be applied and allow to dry.
17. NOTE: Make sure a continuous bead of adhesive surrounds fixing holes.
Apply a 5mm zig zag bead of Land Rover recommended bonding material to
the vehicle assembly at points where the new side panel is in contact.
18. Install the NVH components and apply a bead of Land Rover recommended
semi-rigid sealer to the NVH components as indicated.
21. Offer up the new side panel and clamp into position. Check alignment, if


25. Install the SPR's and the BSF's as indicated.


30. Fold back the edge of rear roof header rail as indicated..
31. Install the BSF as indicated.
33. Make sure that any open or exposed panel joints are correctly sealed.
34. Make sure corrosion protection is applied to all areas affected by repair.
35. The installation of associated panels and components is the reversal of

removal procedure.
Side Panel Sheet Metal Repairs - Side Panel Front Section
Removal
All vehicles
NOTES:
The side panel front section is installed in conjunction with:
Front fender
Fender apron panel
Windshield
Instrument panel
Front door
1. The side panel front section is serviced as indicated.


section.
NOTES:

5. For additional information, refer to: Front Fender Lower

Mounting Bracket (501-27 Front End Sheet Metal Repairs,



9. For additional information, refer to: Instrument Panel Lower

Section (501-12 Instrument Panel and Console, Removal and
Installation).
10. For additional information, refer to: Instrument Panel Upper

Section (501-12 Instrument Panel and Console, Removal and
Installation).
Installation).

13. For additional information, refer to: Roof Front Panel (501-28
Roof Sheet Metal Repairs, Removal and Installation).

14. For additional information, refer to: Roof Panel (501-28 Roof
All vehicles
15. Release the side panel front section wiring harness and position
it to one side.

inner panel.
Mark out the position where the side panel front section metal
inert gas (MIG) butt joint is to be made. Cut through the side
panel front section as indicated.
inner panel.
Mark out the position where the side panel front section MIG
butt joint is to be made. Cut through the side panel front
section as indicated
20. Separate the joints and remove the side panel front section.
Installation
NOTES:
6.5mm.
4. Offer up the new side panel front section and clamp into
5. Drill holes through the old side panel front section panel into the
new side panel front section where BSF's are to be installed as
indicated.
6. Drill holes through the old side panel front section into the new
side panel front section where BSF's are to be installed as
indicated.
7. Remove the new side panel front section.
8. Using a 10mm drill bit, drill holes for the MIG plug welds ready
for the installation of the backing plate as indicated.
11. Measure and cut two 50mm wide backing plate, (25mm each
side of the MIG butt joint) from the side panel front section
remnant.
12. Cut four run on/run off tab from the side panel front section
remnant.
14. Install and MIG plug weld the backing plate as indicated.

fixing holes.
18. Offer up the new side panel front section and clamp into

22. Install and tack weld the run-on/run-off tabs to the side panel
front section.
23. Install and MIG plug weld the backing plate and MIG weld the
side panel front section butt joint as indicated.
24. Install and MIG plug weld the backing plate and MIG weld the
side panel front section butt joint as indicated.
26. Carry out a non destructive crack inspection on the MIG welded
butt joints. If correct proceed to next step, if not, rectify and
sealed.

repair.

Side Panel Sheet Metal Repairs - A-Pillar Reinforcement
Removal
NOTE: The A-pillar reinforcement is installed in conjunction with:
Side panel front section
Front fender apron panel
1. The A-pillar reinforcement is serviced as indicated.
2. Before commencing this procedure make sure that you are aware of all Health and
Safety requirements.
For additional information, refer to: Health and Safety Precautions (100-00 General
3. For further information on the methods, tools and fixings used in this procedure refer
to the body repairs - general information section.
NOTES:
Where breakstem fasteners (BSF) removal is instructed remove fastener shaft with a 4mm punch and remove the head with a 6.5mm
drill bit. Make sure all the drilled holes are free from debris.
4. For additional information, refer to: Fender Apron Panel (501-27 Front End Sheet Metal
5. For additional information, refer to: Side Panel Front Section (501-29 Side Panel Sheet
6. For additional information, refer to: Front Fender Lower Mounting Bracket (501-27
7. Remove the retaining bolts as indicated.

8. Remove SPR's as indicated.
9. Remove SPR's as indicated.

10. CAUTION: Avoid where possible damaging the noise, vibration and harshness
(NVH) components located behind the A-pillar reinforcement.
Separate the joints and remove the A-pillar reinforcement also releasing the NVH
components.
Installation
CAUTION: Where structural adhesive is to be applied between surfaces it is essential compression is applied to the joints during the
curing period.
NOTES:

4. Offer up the new A-pillar reinforcement and clamp into position. Check alignment, if
5. Drill holes through the old panels into the new panel where BSF's are to be installed as
indicated.
6. Drill holes
through the
old A-pillar
reinforcement
panel into the
new A-pillar
reinforcement
panel where
BSF's are to
be installed
as indicated.
7. Remove the new A-pillar reinforcement.
10. Apply the coupling agent where the Land Rover recommended bonding material is to
be applied and allow to dry.
11. Install the NVH (noise, vibration and harshness) component and apply a bead of the
Land Rover recommended semi-rigid sealer to the NVH component.
Apply a 5mm zig zag bead of the Land Rover recommended bonding material to the A-
pillar reinforcement as indicated.
13. Offer up the new A-pillar reinforcement and clamp into position. Check alignment, if

16. Install the retaining bolts as indicated and tighten to 24Nm.

18. Make sure that any open or exposed panel joints are correctly sealed.
20. The installation of associated panels and components is the reversal of removal
procedure.
Side Panel Sheet Metal Repairs - Rocker Panel
Removal
NOTES:
The rocker panel is installed in conjunction with:
Front door
Rear door
Front fender
Right side indicated, left side similar.
1. The rocker panel is serviced as indicated.

aware of all Health and Safety requirementsFor additional

section.
NOTES:
4. For additional information, refer to: Rear Rocker Panel Moulding
(501-08 Exterior Trim and Ornamentation, Removal and
Installation).

6. For additional information, refer to: Rear Door (501-03 Body


8. For additional information, refer to: Front Fender Lower

Mounting Bracket (501-27 Front End Sheet Metal Repairs,

10. For additional information, refer to: Rear Seat Cushion (501-10
11. For additional information, refer to: Wheel and Tire - TDV6 3.0L
Diesel /TDV8 4.4L Diesel/V6 S/C 3.0L Petrol /V8 S/C 5.0L Petrol
(204-04 Wheels and Tires, Removal and Installation).
12. For additional information, refer to: Rear Fender Splash Shield
Installation).
13. For additional information, refer to: Rear Scuff Plate Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
14. For additional information, refer to: A-Pillar Trim Panel (501-05
15. For additional information, refer to: B-Pillar Trim Panel (501-05
16. seat belt

For additional information, refer to: Front Safety Belt Retractor
(501-20A Safety Belt System, Removal and Installation).
17. For additional information, refer to: C-Pillar Lower Trim Panel
Installation).
18. Release the floor carpet and position to one side.
19. NOTE: If the front fender lower mounting bracket is

undamaged retain it for use on installation.
Remove the front fender lower mounting bracket,
20. Release the rocker panel wiring harness and position it to one
side.

23. CAUTION: Care should be taken not to cut through into

inner panels or reinforcements.
Mark out the positions where the rocker panel MIG (metal inert
gas) butt joint are to be made. Cut through the rocker panel as
indicated.
24. NOTE: Care should be taken not to cut through into inner
panels or reinforcements.
Mark out the position where the rocker panel MIG butt joint is to
be made. Cut through the rocker panel as indicated.
25. Separate the joints and remove the rocker panel.

26. Release the noise, vibration and harshness (NVH) components
as indicated.
Installation
NOTES:
6.5mm.
4. Offer up the new rocker panel and clamp into position. Check
5. Drill holes through the old rocker panel into the new rocker
panel where BSF's are to be installed as indicated.
6. Remove the new rocker panel.
7. Using a 10mm drill bit, drill holes for MIG plug welds ready for
the installation of the backing plate as indicated.
11. Measure and cut three 50mm wide backing plates, 25mm each
side of the MIG butt joint, from the rocker panel remnant.
12. Cut six run on/run off tabs from the rocker panel remnant.
17. Using a 10mm drill bit, drill holes for MIG plug welds as
indicated.
18. Using a 10mm drill bit, drill holes for MIG plug welds as
indicated.
20. Install the NVH components and apply a bead of Land Rover
recommended semi-rigid sealer to the NVH component as
indicated.

fixing holes. Do not apply adhesive in the vicinity of the MIG
welds.

22. Offer up the new rocker panel and clamp into position. Check

26. Tack weld the run-on/run-off tabs to the rocker panel.
27. MIG plug weld the rocker panel to the backing plate as indicated
and MIG weld the rocker panel butt joint as indicated.
31. Carry out a non destructive crack inspection on the MIG butt
before proceeding.
sealed.

repair.

Side Panel Sheet Metal Repairs - Rocker Panel Inner Reinforcement
Removal
NOTE: The rocker panel inner reinforcement is installed in conjunction with:
Rocker panel
A-pillar reinforcement
1. The rocker panel inner reinforcement is serviced as indicated.


section.
NOTES:
4. For additional information, refer to: Rocker Panel (501-29 Side

Panel Sheet Metal Repairs, Removal and Installation).
5. For additional information, refer to: A-Pillar Reinforcement (501-

29 Side Panel Sheet Metal Repairs, Removal and Installation).
6. Remove the SPR's and the BSF's as indicated.

8. Separate the joints and remove the rocker panel inner

reinforcement.
Installation
the joints during the curing period
NOTES:
6.5mm.
4. Offer up the new rocker panel inner reinforcement and clamp

5. Drill holes through the old rocker panel inner reinforcement into
the new rocker panel inner reinforcement where BSF's are to be
installed as indicated.
6. Drill holes through the old rocker panel inner reinforcement into
the new rocker panel inner reinforcement where BSF's are to be
7. Remove the new rocker panel inner reinforcement.

fixing holes.


sealed.

repair.

Side Panel Sheet Metal Repairs - Rocker Panel Section
Removal
NOTE: The rocker panel section is installed in conjunction with:
Rear scuff plate trim panel
Front seat
1. The rocker panel section is serviced as indicated.


section.
NOTES:

Installation).
5. For additional information, refer to: Rear Scuff Plate Trim Panel
Installation).

7. Release the floor carpet and position it to one side.
8. Release the rocker panel wiring harness and position to one

side.
10. NOTE: Care should be taken not to cut through into inner
panels or reinforcements.
Mark out the positions where the rocker panel section MIG
(metal inert gas) butt joint are to be made. Cut through the
rocker panel at these points as indicated.
11. Separate the joints and remove the rocker panel section.
Installation
NOTES:
6.5mm.
4. Mark out the positions on the new rocker panel section where
the MIG butt joint are to be made and cut through the rocker
panel at these points.
5. Offer up the new rocker panel section and clamp into position.
6. Drill holes through the old rocker panel section into the new
rocker panel section panel where BSF's are to be installed as
indicated.
7. Remove the new rocker panel section.
11. Measure and cut two 50mm wide backing plates, 25mm each
side of the MIG butt joint, from the new rocker panel remnant.
12. Cut four run on/run off tab from the new rocker panel remnant.
14. Install and MIG plug weld the backing plates as indicated.
16. CAUTION: Do not apply the Land Rover approved bonding

material in the vicinity of the MIG welds.
NOTE: Make sure a continuous bead of adhesive surrounds

fixing holes.
Apply a 5mm zig zag bead of the Land Rover approved bonding
17. Offer up the new rocker panel section and clamp into position.
20. Install and tack weld the run-on/run-off tabs to the rocker
panel.
21. MIG plug weld the backing plates and MIG weld the rocker panel
section butt joints as indicated.
before proceeding.
sealed.

repair.

Side Panel Sheet Metal Repairs - Rocker Panel and B Pillar Inner
Removal
NOTE: The rocker panel and B-pillar inner are installed in conjunction with:
Rocker panel
Front door
Rear door
B-pillar outer panel
B-pillar inner reinforcement
Rocker panel inner reinforcement
1. The B-pillar inner is serviced as indicated.


section.
NOTES:


6. For additional information, refer to: B-Pillar Outer Panel (501-29

Side Panel Sheet Metal Repairs, Removal and Installation).
7. For additional information, refer to: Rocker Panel (501-29 Side

8. For additional information, refer to: Rocker Panel Inner

Reinforcement (501-29 Side Panel Sheet Metal Repairs, Removal
and Installation).
9. For additional information, refer to: B-Pillar Reinforcement (501-

29 Side Panel Sheet Metal Repairs, Removal and Installation).

12. Separate the joints and remove the B-pillar inner.
Installation
NOTES:
6.5mm.
4. Offer up the new B-pillar inner and clamp into position. Check
5. Drill holes through the old B-pillar inner into the new B-pillar
inner where BSF's are to be installed as indicated.
6. Drill holes through the old B-pillar inner into the new B-pillar
inner where BSF's are to be installed as indicated.
7. Remove the new B-pillar inner.

fixing holes.

12. Offer up the new B-pillar inner and clamp into position. Check
13. NOTE: Make sure that the BSF's indicated in green are
installed from the inside.
Install the SPR's and BSF's as indicated.

14. NOTE: Make sure that the BSF indicated in green is
sealed.

repair.

Side Panel Sheet Metal Repairs - B-Pillar Outer Panel
Removal
NOTES:
The B-pillar outer panel is installed in conjunction with:
Rear door
Front seat
Front safety belt retractor
Front scuff plate trim panel
1. The B-pillar outer panel is serviced as indicated.


section.
NOTES:

5. For additional information, refer to: Front Seat - Vehicles

Without: Power Seats (501-10 Seating, Removal and
Installation).
6. For additional information, refer to: Front Safety Belt Retractor



Installation).

Installation).
10. For additional information, refer to: Front Scuff Plate Trim Panel
Installation).

12. Release the floor carpet and position it to one side.
13. Release the B-pillar outer panel wiring harness and position it to
one side.
15. CAUTION: Care should be taken to avoid cutting through

the inner panels and reinforcements.
Mark out the positions where the metal inert gas (MIG) butt
joints are to be made and cut through the B-pillar outer as
indicated.
16. CAUTION: Care should be taken to avoid cutting through

the inner panels and reinforcements.
Mark out the positions where the MIG butt joints are to be made
and cut through the B-pillar outer as indicated.
17. CAUTION: Avoid damaging the noise, vibration and
harshness (NVH) components that are located behind the B-
pillar.
Separate the joints, remove the B-pillar outer panel and the
NVH components.
Installation
NOTES:
6.5mm.
4. Offer up the new B-pillar outer panel and clamp into position.
6. Remove the new B-pillar outer panel.
for the installation of the backing plates as indicated.
9. Using a 10mm drill bit, drill holes in the new B-pillar outer for
the MIG plug welds ready for the installation of the backing
plate as indicated.
11. Measure and cut three 50mm wide backing plates, (25mm each
side of the MIG butt joint) from the B-pillar outer panel
remnant.
12. Cut six run on/run off tabs from the B-pillar outer panel
remnant.
14. Install and MIG plug weld the backing plates as indicated.
17. Install the NVH components and apply a bead of Land Rover
recommended semi-rigid sealer to the NVH components.
fixing holes.

19. Offer up the new B-pillar outer panel and clamp into position.
22. Install and tack weld the run-on/run-off tab's to the B-pillar
outer panel.
23. MIG plug weld the backing plate and MIG seam weld the B-pillar
outer panel butt joint as indicated.
24. MIG plug weld the backing plates and MIG seam weld the B-
pillar outer panel butt joints as indicated.
before proceeding.
sealed.

repair.

Side Panel Sheet Metal Repairs - B-Pillar Reinforcement
Removal
NOTE: The B-pillar reinforcement is installed in conjunction with:
B-pillar outer panel
Rocker panel
Rocker panel reinforcement
1. The B-pillar
reinforcement
is serviced as
indicated.
2. Before commencing this procedure make sure that you are aware of all Health and
Safety requirements. For additional information, refer to: Health and Safety
Precautions (100-00 General Information, Description and Operation).
3. For further information on the methods, tools and fixings used in this procedure refer
to the body repairs - general information section.
NOTES:
Where breakstem fasteners (BSF) removal is instructed remove fastener shaft with a 4mm punch and remove the head with a 6.5mm
drill bit. Make sure all the drilled holes are free from debris.
4. For additional information, refer to: B-Pillar Outer Panel (501-29 Side Panel Sheet
5. For additional information, refer to: Rocker Panel (501-29 Side Panel Sheet Metal
6. For additional information, refer to: Rocker Panel Inner Reinforcement (501-29 Side

8. Separate the joints and remove the B-pillar reinforcement also releasing the noise,
vibration and harshness (NVH) components.
Installation
CAUTION: Where structural adhesive is to be applied between surfaces it is essential compression is applied to the joints during the
curing period.
NOTES:
4. Offer up the new B-pillar reinforcement and clamp into position. Check alignment, if
5. Drill holes through the old B-pillar reinforcement into the new B-pillar reinforcement
where BSF's are to be installed as indicated.
6. Remove the new B-pillar reinforcement.
9. Apply the coupling agent where the Land Rover approved bonding material is to be
applied and allow to dry.
10. Install the NVH (noise, vibration and harshness) components and apply a bead of Land
Rover recommended semi-rigid sealer to the NVH components as indicated.
Apply a 5mm zig zag bead of the Land Rover recommended bonding material as
indicated.
12. Offer up the new B-pillar reinforcement and clamp into position. Check alignment, if
15. Make sure that any open or exposed panel joints are suitably sealed.
17. The installation of associated panels and components is the reversal of removal
procedure.
Rear End Sheet Metal Repairs - Rear End Sheet Metal
Rear end service panels

1 Quarter Panel AC Series Aluminium
2 Rear Side Member Section AD Series, AC Series Aluminium
3 Inner Quarter Panel Upper 5 Series Aluminium
4 Rear Wheelhouse Outer 5 Series Aluminium
5 Quarter Panel Reinforcement 5 Series Aluminium
6 Rear Lamp Panel Outer 5 Series Aluminium
7 Rear Wheelhouse Extension 5 Series Aluminium
8 Inner Quarter Panel Lower 5 Series Aluminium
9 Rear Lamp Panel Inner 5 Series Aluminium
10 Rear Floor Side Extension 5 Series Aluminium
11 Rear Bumper Steel
12 Back Panel Outer 5 Series Aluminium
13 Back Panel Inner 5 Series Aluminium
14 Water Drain Panel Lower 5 Series Aluminium
15 Rear Floor Panel Section 5 Series Aluminium
Rear End Sheet Metal - Single Panel Times

Item Description
Quarter Panel TBC
Rear Side Member Section TBC
Inner Quarter Panel Upper TBC
Rear Wheelhouse Outer TBC
Quarter Panel Reinforcement TBC
Rear Lamp Panel Outer TBC
Rear Wheelhouse Extension TBC
Inner Quarter Panel Lower TBC
Rear Lamp Panel Inner TBC
Rear Floor Side Extension TBC
Rear Crossmember TBC
Back Panel Outer TBC
Back Panel Inner TBC
Water Drain Panel Lower TBC
Rear Floor Panel Section TBC
Rear End Sheet Metal Repairs - Quarter Panel
Removal
NOTES:
The quarter panel is installed in conjunction with:
Rear bumper
Loadspace trim panel
C-pillar lower trim panel
D-pillar trim panel
Rear quarter window glass
Fuel tank filler pipe
Rear safety belt retractor
Right hand indicated, left hand similar
1. The quarter panel is serviced as indicated.


section.
NOTES:
4. For additional information, refer to: Rear Bumper (501-19

5. For additional information, refer to: Loadspace Trim Panel RH

Installation).
6. For additional information, refer to: C-Pillar Lower Trim Panel

Installation).
7. For additional information, refer to: D-Pillar Trim Panel (501-05

8. For additional information, refer to: Rear Quarter Window Glass

(501-11 Glass, Frames and Mechanisms, Removal and
Installation).
9. For additional information, refer to: Rear Safety Belt Retractor

For additional information, refer to: Fuel Tank Filler Pipe (310-
01E Fuel Tank and Lines - SDV6 3.0L Diesel - Hybrid Electric
Vehicle, Removal and Installation).
11. Release the load space wiring harness and position to one side.
12. Remove the C-pillar side impact sensor as indicated.
13. Remove the rear bumper cover side retaining bracket as

indicated.


19. CAUTION: Where possible avoid damaging the inner panels

when cutting the quarter panel.
NOTE: The cut lines shown are the maximum range

allowed.
Mark and cut the quarter panel as indicated.
20. NOTE: Noise, vibration and harshness (NVH) components

are located behind the quarter panel.
Carefully separate and release the adhesive between the quarter

panel and the rear wheelhouse outer, rear outer lamp panel
outer and the fuel filler flap aperture as indicated.
21. Separate the joints and remove the quarter panel and release
the NVH components.
Installation
NOTES:
6.5mm.
1. Offer up the new quarter panel and mark the cut lines on the
new quarter panel.
2. Trim the excess material from the new quarter panel.
4. Using a fine bristle disc, remove the adhesive residue.
6. Offer up the new quarter panel and clamp into position. Check
7. Drill holes through the old quarter panel into the new quarter
14. Apply a bead of Land Rover recommended semi-rigid sealer to

the rear wheelhouse outer and the fuel tank filler pipe housing.
15. CAUTION: Make sure that adhesive is not applied within

30mm of the metal inert gas (MIG) welded butt joints.
NOTE: Make sure a continuous bead of adhesive surrounds

the fixing holes.

bonding material to the areas indicated apart from the rear
wheelhouse outer and the fuel tank filler pipe housing.
16. Offer up the new quarter panel and clamp into position. Check
17. NOTE: Make sure that the SPR highlighted in green is



23. MIG weld the quarter panel butt joints as indicated.

butt joints. If correct proceed to next step, if not, rectify and
26. Install the rear bumper side retaining bracket and tighten the
bolts to 10Nm.
sealed.

repair.

Rear End Sheet Metal Repairs - Quarter Panel Reinforcement
Removal
NOTE: The quarter panel reinforcement is installed in conjunction with:
Quarter panel
Rear lamp panel outer
Rear lamp panel inner
1. The quarter panel reinforcement is serviced as indicated.

Operation).

section.
NOTES:
4. For additional information, refer to: Quarter Panel (501-30 Rear

End Sheet Metal Repairs, Removal and Installation).
5. For additional information, refer to: Rear Lamp Panel Outer

(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
6. For additional information, refer to: Rear Lamp Panel Inner

Installation).
8. Separate the joints and remove the quarter panel reinforcement.
Installation
NOTES:
6.5mm.
3. Offer up the new quarter panel reinforcement, align and clamp


5. Remove the new quarter panel reinforcement panel.
8. Apply a coupling agent where the Land Rover recommended


fixing holes.

10. Offer up the new quarter panel reinforcement, clamp into
position. Check alignment, if correct, proceed to next step, if not
sealed.

repair.

Rear End Sheet Metal Repairs - Inner Quarter Panel Upper Vehicles With:
Glass Roof Panel
Removal
NOTE: The inner quarter panel upper is installed in conjunction with:
Roof rear panel
Side panel
Quarter panel
Quarter panel reinforcement
Rear wheelhouse outer
Rear wheelhouse extension
Inner quarter panel lower
Roof opening panel
1. The inner quarter panel upper is serviced as indicated.

Operation).

section.
NOTES:
To make sure that the vehicle is correctly aligned it must be placed on a Land Rover approved alignment jig.
4. For additional information, refer to: Side Panel (501-29 Side



Installation).

Installation).
8. For additional information, refer to: Quarter Panel Reinforcement

Installation).
9. For additional information, refer to: Rear Wheelhouse Outer

Installation).
10. For additional information, refer to: Rear Wheelhouse Extension

Installation).
11. For additional information, refer to: Inner Quarter Panel Lower
Installation).
12. For additional information, refer to: Roof Opening Panel (501-17
Roof Opening Panel, Removal and Installation).
13. For additional information, refer to: Roof Rear Panel (501-28
Roof Sheet Metal Repairs, Removal and Installation).
14. In this procedure the quarter panel requires a cut line on the C-
pillar as indicated.
16. Lift the edge of rear roof header rail to reveal hidden SPR's as
indicated.
17. In this procedure the quarter panel requires additional SPR's to
be removed as indicated.



24. Remove the SPR and the bolt as indicated.

25. CAUTION: Once the inner quarter panel upper has been
removed support is required to hold the upper panels in position
until the new inner quarter panel upper has been installed.
Make sure that the upper panels are supported.
Installation
NOTES:
Where structural adhesive is to be applied between surfaces it is essential compression is applied to the joints
during the curing period.
6.5mm.

as the panel will be heavy.
Offer up the new inner quarter panel upper and clamp into


9. Drill holes where the BSF's and the metal inert gas (MIG) plug
welds are to be installed as indicated.

11. NOTES:
Make sure that the holes indicated in green are drilled

from the inside.
Make sure that the holes indicated in red are drilled from
the outside.
Drill holes where BSF's are to be installed as indicated.

Remove the inner quarter panel upper.
13. Using a 10mm drill bit, drill holes in the new quarter panel for
plate as indicated.
14. Using a 10mm drill bit, drill holes in the vehicle assembly for the
MIG plug welds ready for the installation of the backing plate as
indicated.
side of the MIG butt joint, from the quarter panel remnant.
17. Cut four run on/run off tabs from the new quarter panel
remnant.
18. MIG plug weld the backing plate to the new quarter panel as
indicated.

fixing holes.

material to the new inner quarter panel as indicated.
fixing holes.

23. Apply a 5mm bead of Land Rover recommended bonding

material to the rear water drain panel as indicated.
25. Install the SPR's and the BSF's as indicated. MIG plug and seam
weld as indicated.


30. NOTES:
The green hole indicates that this BSF is installed from the
inside but not until the roof panel has been installed.
The crossed holes indicate that these two BSF's are not
fitted at this stage but are installed when the roof header rail is
installed.

31. NOTES:
Make sure that the BSF highlighted in red is installed from

the outside in.
Make sure that the bolt is renewed.
Install the BSF and the bolt and tighten to the new bolt to
40Nm as indicated.
32. Install quarter panel.
33. Install and tack weld the run-on/run-off tabs to the panel joints.
34. MIG plug weld the backing plate and MIG weld the quarter panel
section butt joint as indicated.
35. NOTE: Make sure that the BSF's that are highlighted with a
cross are not installed until the roof panel is installed.
37. Fold down the edge of the rear roof header rail as indicated.
38. Drill holes where the BSF is to be installed as indicated.

sealed.

repair.

Rear End Sheet Metal Repairs - Inner Quarter Panel Upper Vehicles
Without: Glass Roof Panel
Removal
NOTE: The inner quarter panel upper is installed in conjunction with:
Roof panel
Side panel
Quarter panel
Rear wheelhouse outer
Inner quarter panel lower
1. The inner quarter panel upper is serviced as indicated.

aware of all Health and Safety requirements
Operation).

section.
NOTES:
To make sure that the vehicle is correctly aligned it must be placed on a Land Rover approved alignment jig.
4. For additional information, refer to: Roof Panel (501-28 Roof

5. For additional information, refer to: Side Panel (501-29 Side



Installation).

Installation).

Installation).
10. For additional information, refer to: Rear Wheelhouse Outer

Installation).

Installation).
12. For additional information, refer to: Inner Quarter Panel Lower
Installation).
13. In this procedure the quarter panel requires a cut line on the C-
pillar as indicated.
15. Lift the edge of rear roof header rail to reveal hidden SPR's as
indicated.
16. In this procedure the quarter panel requires additional SPR's to
be removed as indicated.



23. Remove the SPR and the bolt as indicated.

24. CAUTION: Once the inner quarter panel upper has been
removed support is required to hold the upper panels in position
until the new inner quarter panel upper has been installed.
Make sure that the upper panels are supported.
Installation
NOTES:
6.5mm.



9. Drill holes where the BSF's and the metal inert gas (MIG) plug
welds are to be installed as indicated.

11. NOTES:
Make sure that the holes indicated in green are drilled

from the inside.
Make sure that the holes indicated in red are drilled from
the outside.
Drill holes where BSF's are to be installed as indicated.

Remove the inner quarter panel upper.
13. Using a 10mm drill bit, drill holes in the new quarter panel for
plate as indicated.
14. Using a 10mm drill bit, drill holes in the vehicle assembly for the
MIG plug welds ready for the installation of the backing plate as
indicated.
side of the MIG butt joint, from the quarter panel remnant.
17. Cut four run on/run off tabs from the new quarter panel
remnant.
18. MIG plug weld the backing plate to the new quarter panel as
indicated.

fixing holes.

fixing holes.

23. Apply a 5mm bead of Land Rover recommended bonding

material to the rear water drain panel as indicated.
position. Check alignment, if correct proceed to next step, if not
25. Install the SPR's and the BSF's as indicated. MIG plug and seam
weld as indicated.


30. NOTES:
The green hole indicates that this BSF is installed from the
inside but not until the roof panel has been installed.
The crossed holes indicate that these two BSF's are not
fitted at this stage but are installed when the roof header rail is
installed.

31. NOTES:
Make sure that the BSF highlighted in red is installed from

the outside in.
Make sure that the bolt is renewed.
Install the BSF and the bolt and tighten to the new bolt to
40Nm as indicated.
32. Install quarter panel.
33. Install and tack weld the run-on/run-off tabs to the panel joints.
34. MIG plug weld the backing plate and MIG weld the quarter panel
section butt joint as indicated.
35. NOTE: Make sure that the BSF's that are highlighted with a
cross are not installed until the roof panel is installed.
37. Fold down the edge of the rear roof header rail as indicated.
38. Drill holes where the BSF is to be installed as indicated.

sealed.

repair.

Rear End Sheet Metal Repairs - Inner Quarter Panel Lower
Removal
NOTES:
The inner quarter panel lower is installed in conjunction with:
Quarter panel
1. The inner quarter panel lower is serviced as indicated.


section.
NOTES:


Installation).

Installation).

Installation).

Installation).

11. Separate the joints and remove the inner quarter panel lower.
Installation
NOTES:
6.5mm.
3. Offer up the new inner quarter panel lower and clamp into
4. Drill holes through the old inner quarter panel lower into the
new inner quarter panel lower where BSF's are to be installed as
indicated.
5. Drill holes through the old inner quarter panel lower into the
new inner quarter panel lower where BSF's are to be installed as
indicated.
6. Remove the new inner quarter panel lower.

fixing holes.

bonding material to the inner quarter panel lower as indicated.
11. Offer up the new inner quarter panel lower and clamp into

sealed.

repair.
Rear End Sheet Metal Repairs - Rear Side Member Section
Removal
NOTE: The rear side member section is installed in conjunction with:
Rear bumper
Back panel outer
Back Panel Inner
Rear floor side extension
Rear floor panel section
1. The rear side member section is serviced as indicated. It

includes the rear bumper mounting and the rear side member
closing panel.
2. In this procedure, to make sure the vehicle is correctly aligned,

it must be placed on an approved alignment jig.

Operation).

section.
NOTES:
To make sure the vehicle is correctly aligned it must be placed a Land Rover approved alignment jig.

6. For additional information, refer to: Back Panel Outer (501-30

Rear End Sheet Metal Repairs, Removal and Installation).
7. For additional information, refer to: Back Panel Inner (501-30

8. For additional information, refer to: Rear Floor Side Extension

Installation).
9. For additional information, refer to: Rear Floor Panel Section

Installation).
10. Release the rear side member wiring harness and position it to
one side.

14. CAUTION: Care should be taken when cutting the rear side
member section joint to avoid damaging the inner panels.
Mark out and cut through the rear side member, separate the
joints and remove the rear side member section as indicated.
15. Remove the SPR's and separate the joints. Pull the rear side
member remnant to the outside to release it from the vehicle
assembly.
Installation
NOTES:
6.5mm.
3. Offer up the new rear side member section and clamp into

7. Remove the new rear side member section.

fixing holes.

material to the rear side member section as indicated.
12. Offer up the new rear side member section and clamp into


sealed.

repair.

Rear End Sheet Metal Repairs - Back Panel Inner
Removal
NOTE: The back panel inner is installed in conjunction with:
Rear bumper cover
Rear bumper
Back panel outer
1. The back panel inner is serviced as indicated.

Operation).

section.
NOTES:
the head with a 6.5mm drill bit. Make sure all the drilled holes are free from debris
4. For additional information, refer to: Rear Bumper Cover (501-19


9. Separate the joints and remove the back panel inner.

Installation
NOTES:
6.5mm.
2. Using a fine bristle disc clean and prepare the panel surfaces.
4. Offer up the new back panel inner and clamp into position.
5. Drill holes through the old back panel inner into the new back
panel inner where BSF's are to be installed as indicated.
6. Drill holes through the old back panel inner into the new back
panel inner where BSF's are to be installed as indicated.
7. Prepare the new back panel inner for the installation of new
weld studs. Using the old back panel inner measure the locations
of the weld studs and install new weld studs on the new back
panel inner. The components that are located/fixed to these
weld studs must be offered up and cross checked for alignment
prior to the installation of the weld studs to the new back panel
inner.
11. Apply a coupling agent where the Land Rover recommended


fixing holes.

bonding material to the areas as indicated.
13. Offer up the new back panel inner and clamp into position.
Check alignment, if correct, proceed to the next step, if not
rectify before proceeding.
15. Install the SPR's and the BSF's as indicated

sealed.

repair.

Rear End Sheet Metal Repairs - Back Panel Outer
Removal
NOTE: The back panel outer is installed in conjunction with:
Rear bumper
Rear muffler
1. The back panel outer is serviced as indicated.


section.
NOTES:

5. For additional information, refer to: Rear Muffler (309-00A

Exhaust System - TDV6 3.0L Diesel, Removal and Installation) /
Rear Muffler (309-00B Exhaust System - V6 S/C 3.0L Petrol,
Removal and Installation) / Rear Muffler (309-00C Exhaust
System - V8 S/C 5.0L Petrol, Removal and Installation).
6. Release the liftgate weatherstrip and position to one side.
7. Remove the liftgate latch striker.
8. Release the load space wiring harness and position it to one

side.
9. Remove the SPR's and remove the supporting panel as

indicated.

11. Carefully build an expansion space between the rear lamp panel
outer and the outer back panel as indicated.
12. Separate the joints and pull down on the back panel outer to
remove it as indicated.
Installation
NOTES:
6.5mm.
1. NOTES:
If the peg indicated by arrow one is broken or damaged

but no further damage is evident then this is acceptable as the
peg is only used in the original vehicle assembly process.
If the rear bumper mounting indicated by arrow two is

suspected to be damaged make sure a non destructive crack
test is carried out before installation the back panel outer is
carried out.
Check the assembly peg and the rear bumper mounting.

4. Offer up the new back panel outer and clamp into position.
5. Drill holes through the old back panel outer into the new back
panel outer panel where BSF's are to be installed as indicated.
6. Remove the new back panel outer.
8. Using a fine bristle disc clean and prepare the panel surfaces.


fixing holes.

bonding material to the back panel outer as indicated.
11. Offer up the new back panel outer and clamp into position.
12. NOTE: Make sure that the BSF's highlighted in red are

14. Offer up the new supporting panel and clamp into position.
15. Drill holes through the old supporting panel into the new
supporting panel and the back panel outer where the BSF's are
to be installed as indicated.
19. Offer up the new supporting panel, clamp into position. Check

sealed.

repair.

Rear End Sheet Metal Repairs - Rear Floor Panel Section
Removal
NOTE: The rear floor panel section is installed in conjunction with:
Rear bumper
Back panel outer
Back panel inner
Battery tray
1. The rear floor panel section is serviced as indicated.


section.
NOTES:
This procedure is for the replacement of the rear floor panel. However if there is damage to the rear floor panel
reinforcements this is also covered in step seventeen.

6. For additional information, refer to: Back Panel Inner (501-30

7. For additional information, refer to: Battery Tray (414-01,

8. Mark onto the rear floor panel section that is installed on the
vehicle the cut lines as indicated and remove the SPR's.

Installation
NOTES:
6.5mm
4. Mark onto the new rear floor panel the cut lines as indicated.
5. Slide the new rear floor panel underneath original floor panel
and create an overlap. Check alignment, if correct proceed to
next step, if not, rectify and recheck before proceeding.
6. Drill holes through the panels where BSF's are to be installed as

indicated.
7. Remove the new rear floor panel section.

11. NOTES:
Make sure a continuous bead of adhesive surrounds fixing.
Make sure that sealer is applied between the overlapped

joint of the new and the old rear floor panels.

bonding material adhesive as indicated.

fixing holes.

bonding material adhesive as indicated.
13. Offer up the new rear floor panel section and clamp into
15. Offer up the rear floor panel reinforcement and clamp into
18. Offer up the rear floor panel reinforcement and clamp into
rectify and recheck before proceeding
sealed.
repair.

Rear End Sheet Metal Repairs - Rear Lamp Panel Inner
Removal
NOTE: The rear lamp panel inner is installed in conjunction with:
Quarter panel
1. The rear lamp panel inner is serviced as indicated.


section.
NOTES:


Installation).

10. Release the noise, vibration and harshness (NVH) component as

indicated.
11. Separate the joints and pull down the rear lamp panel inner to
release and remove it from the vehicle assembly as indicated.
Installation
NOTES:
6.5mm.
3. Offer up the new rear lamp panel inner, clamp into position.
4. Drill holes through the old rear lamp panel inner into the new
rear lamp panel inner panel where BSF's are to be installed as
indicated.
5. Drill holes through the old rear lamp panel inner into the new
rear lamp panel inner panel where BSF's are to be installed as
indicated.
6. Remove the new rear lamp panel inner.


fixing holes.

bonding material to the area as indicated.
fixing holes.

12. Offer up the new rear lamp panel inner, clamp into position.

17. Install the NVH component as indicated.
sealed.

repair.
Rear End Sheet Metal Repairs - Rear Lamp Panel Outer
Removal
NOTE: The rear lamp outer panel is installed in conjunction with:
Quarter panel
1. The rear lamp panel outer is serviced as indicated.

Operation).

section.
NOTES:

5. Remove the rear lamp assembly mounting plate bolts as

indicated.

8. Remove the mounting bracket from the rear lamp panel outer as
indicated.
9. Separate the joints and remove the old rear lamp outer panel.
Installation
NOTES:
6.5mm.
3. Offer up the mounting bracket to the new rear lamp panel outer
and clamp into position. Check alignment, if correct proceed to
5. Offer up the new rear lamp panel outer and clamp into position.
6. Drill holes through the old rear lamp panel outer into the new
rear lamp panel outer panel where BSF's are to be installed as
indicated.
7. Drill holes through the old rear lamp panel outer into the new
rear lamp panel outer panel where BSF's are to be installed as
indicated.
8. Remove the new rear lamp panel outer.
11. Offer up the new rear lamp panel outer and clamp into position.

14. Offer up the mounting bracket to the new rear lamp panel outer
and clamp into position. Check alignment, if correct proceed to
16. Install the rear lamp assembly mounting bracket and tighten the
bolts to 10Nm.
sealed.

repair.

Rear End Sheet Metal Repairs - Rear Wheelhouse Outer
Removal
NOTES:
The rear wheelhouse outer is installed in conjunction with:
Quarter panel
1. The rear wheelhouse outer is serviced as indicated.


section.
NOTES:
4. Release the rear wheelhouse outer wiring harness and position it

to one side.

inner panel.
Release the noise, vibration and harshness (NVH) component

and mark out the position where the C-pillar reinforcement
metal inert gas (MIG) butt joint is to be made. Mark and cut
through the C-pillar reinforcement as indicated.


11. Separate the joints and remove the rear wheelhouse outer.
12. Release the NVH components.
Installation
NOTES:
6.5mm.
1. Remove the SPR's from the new rear wheelhouse front extension
as indicated.
5. Carefully build an expansion space between the quarter panel

inner and rear wheelhouse outer.
6. Make sure that the rear wheelhouse outer holes and the rear
wheelhouse front extension holes line up correctly as indicated.
7. Offer up the new rear wheelhouse outer and clamp into position.
8. Drill through the old rear wheelhouse outer panel holes into the
new rear wheelhouse outer panel where BSF's are to be
9. Remove the new rear wheelhouse outer.


fixing holes.

14. Offer up the new rear wheelhouse outer, clamp into position.
and recheck before proceeding..
15. NOTES:
Make sure that the BSF's indicated in green are installed

from the inside.
Make sure that the BSF's indicated in red are installed

from the outside.

17. Offer up the C-pillar reinforcement section, align and clamp into
18. Drill through the old C-pillar reinforcement where BSF's are to
be installed as indicated.
20. NOTES:
Make sure that the BSF's indicated in green are installed

from the inside.
Make sure that the BSF's indicated in red are installed

from the outside.
MIG weld the butt joint and install the BSF's as indicated.
butt joint. If correct proceed to next step, if not, rectify and
22. Dress the welded joint.
23. Drill holes through the old door striker plate mounting plate into
the new rear wheelhouse outer where BSF's are to be installed.
26. Drill holes through the old rear wheelhouse outer into the new
rear wheelhouse outer panel where BSF's are to be installed as
indicated.
29. Drill holes through the rear wheelhouse extension into the rear
wheelhouse outer where BSF's are to be installed as indicated.
33. Install the NVH components as indicated.

sealed.

repair.

Rear End Sheet Metal Repairs - Rear Floor Side Extension
Removal
NOTE: The rear floor side extension is installed in conjunction with:
Rear side member section
Battery tray
1. The rear floor side extension is serviced as indicated.


section.
NOTES:
4. For additional information, refer to: Rear Side Member Section

Installation).
5. For additional information, refer to: Battery Tray (414-01,

8. Separate the joints, pull down on the rear floor side extension
and remove it to the rear as indicated.
Installation
NOTES:
6.5mm.
3. Offer up the new rear floor side extension and clamp into
4. Drill holes through the old rear floor side extension into the new
rear floor side extension panel where BSF's are to be installed
as indicated.
5. Drill holes through the old rear floor side extension into the new
rear floor side extension panel where BSF's are to be installed
as indicated.
6. Remove the new rear floor side extension.

fixing holes.

11. Offer up the new rear floor side extension panel, clamp into

sealed.

repair.
Rear End Sheet Metal Repairs - Rear Wheelhouse Extension
Removal
NOTE: The rear wheelhouse extension is installed in conjunction with:
Quarter Panel
1. The rear wheelhouse extension is serviced as indicated.

Operation).

section.
NOTES:

End Sheet Metal Repairs, Removal and Installation).or side panel
depending on the repair required.
Installation).

Installation).

Installation).

10. Remove the rear wheelhouse extension and also release the
noise, vibration and harshness (NVH) components as indicated.
Installation
NOTES:
BSF installation involves using the Jaguar approved BSF installation tool and requires a hole diameter of 6.5mm.
3. Offer up the new rear wheelhouse extension and clamp into

4. Drill holes through the old rear wheelhouse extension into the
new rear wheelhouse extension where BSF's are to be installed
as indicated.
5. Drill holes through the old rear wheelhouse extension into the
new rear wheelhouse extension where BSF's are to be installed
as indicated.
6. Remove the new rear wheelhouse extension.


fixing holes.

bonding material to the new rear wheelhouse extension.
11. Offer up the new rear wheelhouse extension, clamp into


14. Install the NVH component as indicated.

sealed.

repair.

reversal of the removal procedure.
Uni-Body, Subframe and Mounting System -
Front subframe to body bolts
Front bolts *
Stage 1 100 74
Stage 2 Then a further 300 Then a further 300
degrees degrees
Centre bolts *
Stage 1 100 74
degrees degrees
Rear bolts *
Stage 1 70 52
degrees degrees
Front dynamic stabilizer bar support bracket to subframe
bolts *
M12 bolts
Stage 1 90 66
degrees degrees
M14 bolts
Stage 1 130 96
stage 2 Then a further 120 Then a further 120
degrees degrees
Rear subframe to body bolts
Front bolts
170 125
Rear bolts *
Stage 1 100 74
degrees degrees
Rear subframe support bracket to body bolts
60 44
* New nuts/bolts must be installed
Recommended Lubricant for subframe bushes

CIRCO Light rubber process oil
Uni-Body, Subframe and Mounting System - Thread Repair Insert
General Procedures
Check
CAUTIONS:
If one hole/thread is damaged, all remaining holes/threads must have a steel insert installed.
Make sure that the drill speed is not at maximum when repairing the damaged hole/thread. Use a suitable
electric drill with a slow speed setting.
1. WARNING: Prior to carrying out this procedure, make sure

that the sub-frame is not already installed with inserts. Using a
suitable magnet, check the damaged hole for a steel insert. Do
not drill if there is a steel insert located already. Failure to follow
this instruction may result in permanent damage to the vehicle.
The procedure requires tools from JLR-501-169 and JLR-501-

171.
2. CAUTIONS:
Make sure that the depth of the drill does not exceed 35
mm.
Apply a suitable cutting lubricate to the drill bit prior to

drilling.
Drill the hole to a depth of 35 mm using a 13mm drill.

debris.
4. CAUTIONS:
mm.

drilling.

debris.
6. NOTE: Apply a suitable cutting lubricate to

the tap prior to cutting the thread.

Loctite.

8. Using the special tool JLR-501-171, install the
threaded insert into the body. Note that the special
tool will stop against the sub-frame.

Make sure the steel insert is located flush with the

sub-frame as shown in the illustration.
10. CAUTIONS:
mm.

drilling.
Repeat steps 2-9 for any remaining M12 fixings.
11. CAUTIONS:
mm.

drilling.

debris.
13. CAUTIONS:
mm.

drilling.
Repeat steps 11 and 12 using a 15, 16, and 16.5mm drill bit.
14. NOTE: Apply a suitable cutting lubricate to
the tap prior to cutting the thread.

Loctite.

16. Using the special tool JLR-501-171, install the
threaded insert into the body. Note that the special
tool will stop against the sub-frame.

Make sure the steel insert is located flush with the

sub-frame as shown in the illustration.
18. CAUTIONS:
mm.

drilling.
Repeat steps 11-17 for any remaining M14 fixings.
Adjustment
1. Repeat the process for the remaining sub-frame fixings.
Uni-Body, Subframe and Mounting System - Front Subframe TDV6 3.0L
Diesel
Special Tool(s)
303-1129
Engine Lifting Brackets
JLR-204-794
Left Alignment Pin, Subframe
JLR-204-796
Right Alignment Pin, Subframe
JLR-204-802
Splitter, Damper
Removal
CAUTIONS:
Make sure that both the Transmission Undertray and Engine Undertray are correctly installed to the vehicle, as
they are structural components.
The final tightening of the suspension components must be carried out with the vehicle on its wheels.
NOTES:

stands.

3. Refer to: Radiator (303-03A Engine Cooling - TDV6 3.0L Diesel,

4. Refer to: Generator (414-02A Generator and Regulator - TDV6
5. CAUTION: Discard the bolt.
NOTE: LHD illustration shown, RHD is similar.
Align the steering wheel to straight ahead.
6.
7.
8.
9.

coolant.

coolant.
12.
13.
14. CAUTION: A new O-ring seal is to be installed.

15.
16. Refer to: Intake Air Shutoff Throttle (303-04A Fuel Charging and
Controls - TDV6 3.0L Diesel, Removal and Installation).
17.
18.
19. Special Tool(s): 303-1129
Torque: 22 Nm
20.
21.
22.
23. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts,

24. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts,


26. WARNING: Be prepared to catch escaping fluid.
CAUTION: Brake fluid will damage paint

finished surfaces. If spilled, immediately remove the
fluid and clean the area with water.
NOTE: LH illustration shown, RH is similar.
28. NOTES:
Discard the nuts and bolts.

32. Repeat the above 7 steps for the other side.
33.
34.
35.
36.
37.
38.
39.
41. CAUTION: The transmission must be kept supported while

the transmission support crossmember is removed.
Refer to: Front Driveshaft - TDV6 3.0L Diesel (205-01 Driveshaft,

42.
Refer to: Front Stabilizer Bar (204-06 Ride and Handling

Optimization, Removal and Installation).
Refer to: Rear Rocker Panel Moulding (501-08 Exterior Trim and
NOTE: Repeat the procedure for the other side.
46. Using a suitable hydraulic jack, support the front

subframe.
47. CAUTION: Discard the 6 bolts.
With assistance, remove the front subframe

assembly.
48. NOTES:
If equipped.

49. NOTE: Discard the bolts.

50.
51.
52.
Installation
1. CAUTION: Install the bolt finger tight.
2. Torque: 110 Nm
3. Torque: 60 Nm
4. Torque: 60 Nm
5. NOTE: Make sure that new bolts are installed.
Torque:
Stage 1:100 Nm
Stage 2:240°
During installation tighten the bolts in the following

sequence.
Torque:
Bolts 1 110 Nm
Bolts 2 110 Nm
Bolts 1 110 Nm
7. CAUTION: Make sure that 6 new bolts are

installed.
With assistance, install the front subframe.
Special Tool(s): JLR-204-794, JLR-204-796

Torque:
1
Stage 1:100 Nm
Stage 2:300°
2
Stage 1:100 Nm
Stage 2:240°
3
Stage 1:70 Nm
Stage 2:120°
8. Remove the special tools.
9.

Refer to: Front Stabilizer Bar (204-06 Ride and Handling

13.
14. Refer to: Front Driveshaft - TDV6 3.0L Diesel (205-01 Driveshaft,
Torque:
M8 22 Nm
M6 Nut 9 Nm
M6 Screw 12 Nm
16. Torque: 10 Nm
17.
18.
19. Torque: 25 Nm
20. Torque: 90 Nm
21. Torque:
M10 45 Nm
M12 90 Nm
22.

Torque: 90 Nm
26. CAUTION: Only tighten the nuts and bolts

when the suspension is in the normal drive position.
NOTES:
Make sure that new nuts and bolts are

installed.
Torque:
Front Lower Arm Bolt
Stage 1:80 Nm
Stage 2:300°
Rear Lower Arm Bolt
Stage 1:100 Nm
Stage 2:360°
28. CAUTION: Make sure that the area around the

component is clean and free of foreign material.
Torque: 16 Nm



33. Torque: 32 Nm
34. Torque: 32 Nm
35.
37. Torque: 8 Nm
38. Torque: 8 Nm
40. Torque: 25 Nm
41. CAUTION: A new O-ring seal is to be installed.
Torque: 18 Nm
42. Torque: 6 Nm
43.
44.
45. Torque: 6 Nm
46. Torque: 6 Nm
47. Torque: 6 Nm
48. NOTE: Make sure the retaining clips are

correctly installed and tightened.
49. NOTE: Make sure the retaining clips are
correctly installed and tightened.
50. CAUTION: Make sure that a new bolt is

installed.
Using a suitable tool, clean out the threads.
Torque: 30 Nm
51. Refer to: Generator (414-02A Generator and Regulator - TDV6


54. Refer to: Brake System Bleeding - Vehicles With: Standard

Brakes (206-00 Brake System - General Information, General
Procedures).
Refer to: Brake System Bleeding - Vehicles With: High
Performance Brakes (206-00 Brake System - General
Information, General Procedures).
55. Refer to: Four-Wheel Alignment (204-00 Suspension System -

General Information, General Procedures).
Uni-Body, Subframe and Mounting System - Front Subframe V8 S/C 5.0L
Petrol
Special Tool(s)
303-1436
Engine Lifting Bracket Front
JLR-204-794
JLR-204-796
JLR-204-802
Splitter, Damper
Removal
CAUTIONS:
NOTES:

stands.

3. Refer to: Radiator (303-03C Engine Cooling - V8 S/C 5.0L Petrol,

Refer to: Fender Splash Shield (501-02 Front End Body Panels,
6.

Torque: 40 Nm
8.
9.
10.
11.




22.
23.
24.
25.
Refer to: Front Driveshaft - V6 S/C 3.0L Petrol /V8 S/C 5.0L
Petrol (205-01 Driveshaft, Removal and Installation).
27.
28. Refer to: Front Stabilizer Bar (204-06 Ride and Handling

subframe.

assembly.
34.
35.
36.
Installation
2. Torque: 110 Nm
3. Torque: 60 Nm
4. Torque: 60 Nm
Torque:
Stage 1:100 Nm
Stage 2:240°

installed.

Torque:
1
Stage 1:100 Nm
Stage 2:300°
2
Stage 1:100 Nm
Stage 2:240°
3
Stage 1:70 Nm
Stage 2:120°
8.
12.
13. Refer to: Front Driveshaft - V6 S/C 3.0L Petrol /V8 S/C 5.0L
14. Torque:
M8 22 Nm
M6 Nut 9 Nm
M6 Screw 12 Nm
15. Torque: 10 Nm
16. Torque: 90 Nm
17. Torque:
M10 45 Nm
M12 90 Nm
Torque: 90 Nm

NOTES:

installed.
Torque:
Front Lower Arm Bolt.
Stage 1:80 Nm
Stage 2:300°
Rear Lower Arm
Stage 1:100 Nm
Stage 2:360°

Torque: 16 Nm



27. Torque: 32 Nm
28. Torque: 32 Nm
29. Torque: 25 Nm
30.
32. Torque: 45 Nm
installed.
Torque: 30 Nm
35. Refer to: Radiator (303-03C Engine Cooling - V8 S/C 5.0L Petrol,


Procedures).

Uni-Body, Subframe and Mounting System - Front Subframe TDV8 4.4L
Diesel
Special Tool(s)
JLR-204-794
JLR-204-796
JLR-204-802
Splitter, Damper
JLR-303-1569
Lifting Bracket, Engine
JLR-303-1570
Lifting Bracket, Engine
Removal
CAUTIONS:
NOTES:

stands.

3. Refer to: Radiator (303-03F Engine Cooling - TDV8 4.4L Diesel,

5. NOTES:
Discard the bolt.
6. Refer to: Accessory Drive Belt (303-05D Accessory Drive - TDV8

7.
8.
9.
10.
11. CAUTION: Take extra care when removing the

battery cable from the generator.
12. NOTE: The component cannot be removed at
this stage.
13. CAUTIONS:
Take extra care not to damage the battery

cable terminal when removing the wiring harness or
generator. Make sure that the terminal is not bent or
split.
Support the generator prior to disconencting

the electrical connectors.
NOTE: The component cannot be removed at

this stage.
14.
15.
16.
17.
18.
19.
20. Special Tool(s): JLR-303-1569

Torque: 40 Nm
21.
22.

Torque: 40 Nm
24.
25. CAUTION: Discard the bolts.



32. NOTES:


37.
38.
39.
40.
41.
42.
43.
44.

46.

subframe.

assembly.
53.
54.
55.
Installation
2. Torque: 110 Nm
3. Torque: 60 Nm
4. Torque: 60 Nm
Torque:
Stage 1:100 Nm
Stage 2:240°

installed.

Torque:
1
Stage 1:100 Nm
Stage 2:300°
2
Stage 1:100 Nm
Stage 2:240°
3
Stage 1:70 Nm
Stage 2:120°
8.
12.
14. Torque:
M8 22 Nm
M6 Nut 9 Nm
M6 Screw 12 Nm
15. Torque: 10 Nm
16.
17.
18. Torque: 25 Nm
19. Torque: 90 Nm
20. Torque:
M10 45 Nm
M12 90 Nm
21.

Torque: 90 Nm

NOTES:

installed.
Torque:
Stage 1:80 Nm
Stage 2:300°
Rear Lower Arm Bolt
Stage 1:100 Nm
Stage 2:360°

Torque: 16 Nm


32. CAUTIONS:
Make sure to install new bolts.
Tighten the bolts in the sequence shown
Torque: 40 Nm
33. CAUTIONS:
Make sure to install new bolts.
Tighten the bolts in the sequence shown
Torque: 40 Nm
34.

36. Torque: 10 Nm
37. Torque:
M8 25 Nm
M10 45 Nm

39. Torque: 10 Nm
40. Torque: 9 Nm
41. Torque:
M6 12 Nm
Clamp 3.5 Nm
42. Torque: 3.5 Nm
43.
44.
45. Torque: 47 Nm
46. Torque: 8 Nm
47. Torque: 12 Nm
48. Torque:
Clamp 3.5 Nm
Bolt 8 Nm
49. Torque: 3.5 Nm

50. Torque: 3.5 Nm
51.
52. Refer to: Accessory Drive Belt (303-05D Accessory Drive - TDV8

installed.
Torque: 30 Nm
55. Refer to: Radiator (303-03F Engine Cooling - TDV8 4.4L Diesel,

57. Refer to: Brake System Bleeding - Vehicles With: High

Refer to: Brake System Bleeding - Vehicles With: Standard
Procedures).

Uni-Body, Subframe and Mounting System - Front Subframe SDV6 3.0L
Diesel - Hybrid Electric Vehicle
Special Tool(s)
303-1129
Engine Lifting Brackets
JLR-204-794
JLR-204-796
JLR-204-802
Splitter, Damper
Removal
All vehicles
WARNING: This procedure can only be carried out after the vehicle has been decommissioned, by an approved
person.
CAUTIONS:
NOTES:

stands.


4. Refer to: Electric Air Conditioning (A/C) Compressor (412-01

Climate Control - TDV6 3.0L Diesel - Hybrid Electric Vehicle,
Right-hand drive vehicles
All vehicles
7.
8.

Torque: 22 Nm
10.
11.
12.



18. NOTES:

23.
24.
25.
26.
27.
28.
29.

31.

subframe.

assembly.
38.
39.
40.
Installation
All vehicles

2. Torque: 110 Nm
3. Torque: 60 Nm
4. Torque: 60 Nm
Torque:
Stage 1:100 Nm
Stage 2:240°
6. During installation tighten the bolts in the following

sequence.
Torque:
Bolts 1 110 Nm
Bolts 2 110 Nm
Bolts 1 110 Nm
installed.

Torque:
1
Stage 1:100 Nm
Stage 2:300°
2
Stage 1:100 Nm
Stage 2:240°
3
Stage 1:70 Nm
Stage 2:120°
9.

12.
14. Torque: 10 Nm
15.
16.
17. Torque: 25 Nm
18. Torque: 90 Nm
19. Torque:
M10 45 Nm
M12 90 Nm
20.

Torque: 90 Nm

NOTES:

installed.
Torque:
Stage 1:80 Nm
Stage 2:300°
Rear Lower Arm Bolt
Stage 1:100 Nm
Stage 2:360°

Torque: 16 Nm


31. Torque: 32 Nm
32. Torque: 32 Nm
33.

35. Torque: 8 Nm
36. Torque: 8 Nm
Right-hand drive vehicles

installed.
Torque: 30 Nm
All vehicles
39. Refer to: Electric Air Conditioning (A/C) Compressor (412-01
Climate Control - TDV6 3.0L Diesel - Hybrid Electric Vehicle,


Procedures).

Uni-Body, Subframe and Mounting System - Rear Subframe
Special Tool(s)
JLR-204-798
Alignment Pins, Subframe
Removal
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
NOTES:
1. CAUTION: This step must be carried out in order to

maintain the correct air suspension compressor/dryer
performance.
Using the approved diagnostic equipment, depressurize the rear

springs.
Refer to: Air Suspension System Depressurize and Pressurize

(204-05 Vehicle Dynamic Suspension, General Procedures).

3. Raise and support the vehicle.
4. Remove the rear wheels and tires.
5. Refer to: Rear Driveshaft - TDV6 3.0L Diesel (205-01 Driveshaft,

Refer to: Rear Driveshaft - SDV6 3.0L Diesel - Hybrid Electric
Vehicle (205-01 Driveshaft, Removal and Installation).
Refer to: Rear Driveshaft - V6 S/C 3.0L Petrol /V8 S/C 5.0L
Refer to: Rear Driveshaft - TDV8 4.4L Diesel (205-01 Driveshaft,
6. WARNING: A small amount of air maybe

released when removing the air line connector.
CAUTION: Before disconnecting or removing the

components, make sure the area around the joint
faces and connections are clean. Plug open
connections to prevent contamination.
NOTES:

Discard the air line connector.
CAUTION: Brake fluid will damage paint finished

surfaces. If spilled, immediately remove the fluid and
clean the area with water.
NOTES:
8.
9.
10.
11. NOTES:
12. CAUTION: Make sure that the component is not suspended

by the fluid hoses.
NOTE: If equipped.
Tie aside.
14.
16.
17.
18. CAUTION: Discard the nut and bolt.

NOTES:
21.
22. NOTES:
NOTES:
24.
25.

27.
28.
29.

32.
33. NOTES:
34. CAUTIONS:
Discard the lower control arm front retaining

nut and bolt.
Discard the lower control arm rear retaining nut

and bolt.
NOTES:

35.
36.
37.
Installation
1.
2. Torque: 110 Nm
3. Torque: 170 Nm
4. CAUTIONS:
Only tighten the nuts and bolts when the

suspension is in the normal drive position.
Make sure that a new lower control arm front

retaining nut and bolt is installed.
Make sure that a new lower control arm rear

retaining nut and bolt is installed.
NOTES:
Torque:
1
Stage 1:100 Nm
Stage 2:240°
2
Stage 1:100 Nm
Stage 2:240°
3
Stage 1:40 Nm
Stage 2:60°
5. CAUTION: Only tighten the nuts and bolts when

the suspension is in the normal drive position.
NOTES:
Torque:
Stage 1:50 Nm
Stage 2:60°
6.
9.
10. Torque: 10 Nm
11. Torque: 10 Nm
12.
13.
14.
15. CAUTION: Only tighten the bolts finger-tight at
this stage.
NOTES:

installed.
Torque:
Stage 1:100 Nm
Stage 2:300°

installed.
Torque:
Stage 1:100 Nm
Stage 2:300°
NOTES:
Torque:
M14 170 Nm
M10 60 Nm
20.
23. CAUTION: Make sure that a new nut and bolt is

installed.
NOTES:

Torque:
Stage 1:100 Nm
Stage 2:240°
24.
25.
27.
Torque: 110 Nm
Torque: 110 Nm
30. NOTES:
Torque: 185 Nm
31. Torque: 25 Nm
32.
33. Torque: 5 Nm

NOTES:

Torque:
M8 25 Nm
Union 16 Nm

NOTES:
Refer to: Air Line Connector (204-05 Vehicle

Dynamic Suspension, General Procedures).
Torque: 3.5 Nm
36. Refer to: Rear Driveshaft - TDV6 3.0L Diesel (205-01 Driveshaft,
Refer to: Rear Driveshaft - SDV6 3.0L Diesel - Hybrid Electric
Vehicle (205-01 Driveshaft, Removal and Installation).
Refer to: Rear Driveshaft - V6 S/C 3.0L Petrol /V8 S/C 5.0L
Refer to: Rear Driveshaft - TDV8 4.4L Diesel (205-01 Driveshaft,

38. Refer to: Brake System Bleeding - Vehicles With: High

Refer to: Brake System Bleeding - Vehicles With: Standard
Procedures).
39. CAUTION: This step must be carried out to prevent damage

to the air spring.
Refer to: Air Suspension - Manual Control Procedure (204-05

Vehicle Dynamic Suspension, General Procedures).
40. Install the rear wheels and tires.
41. CAUTION: This step must be carried out in order to

maintain the correct air suspension compressor/dryer
performance.
NOTE: This step must be carried out with the weight of the
vehicle on the suspension.
Using the approved diagnostic equipment, pressurize the rear

springs.
Refer to: Air Suspension System Depressurize and Pressurize

(204-05 Vehicle Dynamic Suspension, General Procedures).

Uni-Body, Subframe and Mounting System - Rear Subframe Bushing
Special Tool(s)
JLR-502-016
Remover, Bush
JLR-502-017
Remover Support, Bush
JLR-502-018
Installer, Bush
JLR-502-019
Remover Support, Bush
Removal
CAUTION: Take extra care not to damage the component surface, failure to follow this instruction may result in
corrosion.
1. Refer to: Rear Subframe (502-00 Uni-Body, Subframe and

Mounting System, Removal and Installation).
2. NOTE: Note the orientation of the bushing

before removal.
3. CAUTION: The bush flanges need to be
removed to allow bush removal.
4. CAUTION: Make sure that the special tool is

correctly located.
Installation
1. NOTE: Make sure the bushing is correctly

orientated.
2. CAUTIONS:
Use the recommended lubricant.
Make sure that the special tool is correctly

located.
Using the special tools, install the rear subframe

bush.
Refer to: Specifications (502-00 Uni-Body,

Subframe and Mounting System, Specifications).
3. Refer to: Rear Subframe (502-00 Uni-Body, Subframe and

Mounting System, Removal and Installation).
Full Frame and Body Mounting -
Transmission support crossmember to chassis bolts 110 81
Transmission support insulator through-bolt 175 129
Transmission support crossmember to support bracket bolt 24 18
Full Frame and Body Mounting - Transmission Support
Crossmember TDV6 3.0L Diesel
Removal
NOTES:
All vehicles

2. Using a transmission jack, support the transmission.
3. Torque:
M10 60 Nm
M6 10 Nm
Hybrid vehicles only

4. Torque:
M6 10 Nm
M8 25 Nm
Vehicles with 3.0L diesel engine

5. Torque: 24 Nm
All vehicles
6. NOTE: Note the orientation of the component

prior to removal.
7. Torque: 175 Nm
8. Torque: 110 Nm
Installation

Full Frame and Body Mounting - Transmission Support Crossmember V6
S/C 3.0L Petrol /V8 S/C 5.0L Petrol
Removal
NOTES:

3. Torque:
M6 10 Nm
M10 60 Nm
4. Torque: 24 Nm

prior to removal.
6. Torque: 175 Nm
7.
8. Torque: 110 Nm
Installation

Full Frame and Body Mounting - Transmission Support
Crossmember TDV8 4.4L Diesel
Removal
NOTES:

3. Torque: 60 Nm
4. Torque: 24 Nm

prior to removal.
6. Torque: 175 Nm
7. Torque: 110 Nm
Installation

Towbar -
Description Nm lb-ft lb-in

Deployable towbar control module (DTCM) retaining nut 2 - 18
Towbar - Deployable Towbar Control Module (DTCM)
Principles of Operation
the donor vehicle
NOTES:
the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in
When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal
places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the
DMM leads into account
For a detailed description of the deployable towbar control module system and operation, refer to the relevant
section of the workshop manual

Visual Inspection
Deployable towbar mechanism and motor Fuses
Deployable towbar calibration Battery junction box
Rear fuse box
Wiring harness
Loose or corroded connector(s)
Deployable towbar motor and control module
Deployable towbar switch
Deployable towbar status indicators
4. If the cause is not visually evident, verify the symptom and refer to the table below
Deployable Towbar - Diagnosis and Testing
Deployable Towbar Calibration
For details of the deployable towbar calibration procedure

REFER to: Deployable Towbar Control Module (DTCM) (502-03, Removal and Installation).
Deployable Towbar - Warning Indicators/Buzzer
The deployable towbar control module is a standalone unit and does not log any DTCs. However, the unit is able to
communicate various status and fault indicators via a buzzer and the LEDs on the towbar deploy switch. Details of
these status indicator codes are included in the table below
Deployable Towbar Status Indicators - Buzzer and LED codes
Green Red Buzzer
LED LED Noise Towbar State Action
OFF OFF OFF Towbar inactive No action required
Blinking Blinking OFF Towbar not initialized Start engine and run for longer than 2 seconds. Stop
(still in factory mode) engine. Switch ignition to ON. Switch ignition to OFF
Press the 'power on' button (the left side switch on the
deployable towbar switchpack) for 2 seconds until the
green LED illuminates on the 'deploy/stow' button
Press and hold the 'deploy/stow' button (the right side
switch on the deployable towbar switchpack). This will
cause the towbar to start its initialization. Keep the
'deploy/stow' button depressed until the towbar has
reached its fully deployed position (this will be indicated
by two beeps). This process should take no longer than
10 seconds
Release the 'deploy/stow' button
In the case of any difficulties or interruptions with the
initialization process, re-start the sequence from the
beginning
Blinking Blinking ON Towbar not initialized Start engine and run for longer than 2 seconds. Stop
continuously (previous initialization engine. Switch ignition to ON. Switch ignition to OFF
for 2 settings have been Press the 'power on' button (the left side switch on the
minutes lost) deployable towbar switchpack) for 2 seconds until the
green LED illuminates on the 'deploy/stow' button
Press and hold the 'deploy/stow' button (the right side
switch on the deployable towbar switchpack). This will
cause the towbar to start its initialization. Keep the
'deploy/stow' button depressed until the towbar has
reached its fully deployed position (this will be indicated
by two beeps). This process should take no longer than
10 seconds
Release the 'deploy/stow' button
In the case of any difficulties or interruptions with the
initialization process, re-start the sequence from the
beginning
On for OFF OFF Towbar active and

5 towbar switchpack is NOTE: The 'deploy/stow' button needs to be depressed
seconds enabled for longer than 1 second before the deploy/stow movement
starts. Once a deploy/stow movement is underway the button
may be released and the towbar will continue to move to its
deployed/stowed position automatically. If the 'deploy/stow'
button is held down for longer during the stow/deploy
movement, this will cause the control module to increase the
power to the deployable towbar motor. This function may be
required if the normal towbar movement is impeded in some
way, for example, by a build-up of snow, ice or other debris
Towbar is ready for deploy/stow command

Press the 'deploy/stow' button (the right side switch on
the deployable towbar switchpack). This will cause the
towbar to start its movement
Blinking OFF Repeated Towbar is performing a No remedial action required

prolonged deploy/stow movement The towbar movement may be halted by pressing the
beeps normally deploy/stow button again
Blinking ON Continuous Towbar is an Press the 'deploy/stow' button (the right side switch on
tone intermediate state. the deployable towbar switchpack). This will cause the
Towbar movement has towbar to re-start its movement
been stopped/has
stalled
OFF OFF Short Towbar is now locked No remedial action required
double beep in a stowed or
deployed position
OFF ON Continuous Engine is running and Switch off engine and ignition
tone towbar is an Note the status of the red/green LEDs on the deployable
intermediate state. towbar switchpack and refer to this table
Towbar movement has
been stopped/has
stalled or towbar had
detected an error
OFF Blinking Continuous Towbar signals Acknowledge/clear error alert by pressing the 'power on'
tone indicating system error button
If error alert clears successfully the towbar will revert
to an intermediate state (see above)
Press the 'deploy/stow' button (the right side switch on
the deployable towbar switchpack). This will cause the
towbar to re-start its movement
If error alert is NOT CLEARED, contact dealer technical
support
OFF ON Tone during Engine is running Deployable towbar switchpack buttons are locked while
(during button causing system lock- engine is running
button press out Switch off engine and ignition to activate deployable
press) towbar switchpack
- - - In the event that Ensure engine is not running/ignition is off, then

either a new towbar is perform the following sequence of operations:
fitted to an existing Press, then release, the towbar 'power on' button (the
vehicle and ECU, or left side switch on the deployable towbar switchpack)
that the towbar will Simultaneously hold down the 'power on' and
not completely stow or 'deploy/stow' buttons for 10 seconds until both LEDs
deploy fully and moves illuminate continuously
between incomplete Immediately start the engine and run for over 2
states, then the seconds before switching the engine off again
TOWBAR REQUIRES A The operations above will have led to the deletion of
COMPLETE RESET any previously stored initialization data and returned
the ECU to an un-initialized state (this will be indicated
by both LEDs blinking and the buzzer sounding
continuously)
Refer to the initialization procedures described under
"Towbar not initialized (previous initialization settings
have been lost)" above
Towbar - Deployable Towbar Control Module (DTCM)
Removal
NOTES:
The ignition must be switched off.
1.
2.
3.
4. Torque: 9 Nm
5.
6.

threads.
Torque: 2 Nm
Installation
2. Start the engine.
3.
Press and hold the brake pedal down.
Allow the engine to run for longer than 2 seconds.
4. Turn off the engine.
5. Set the ignition to the ON position.
6. Set the ignition to the OFF position.
7. Press ON button until the green led illuminates.

This will take approximately 2 seconds.
8.
Press and hold deploy/stow button until the
towbar moves to fully deployed position.
Listen for two beeps to confirm system is
calibrated.
Release button.

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Workshop Service Manual for Range Rover Sport 2014 Sec.

1. WARNING: Prior to carrying out this procedure,

Using compressed air make sure the hole is clean

NOTE: Apply a suitable cutting lubricate to the drill bit

Drill the hole to a depth of 100mm using a 14mm drill.

NOTE: Apply a suitable cutting lubricate to the drill bit

Drill the hole to a depth of 75mm using a 15mm drill.

NOTE: Apply a suitable cutting lubricate to the drill bit

Drill the hole to a depth of 75mm using a 16.5mm drill.

8. NOTE: Apply a suitable cutting lubricate to the tap

Tap the hole using a M18 x 1.5 flute tap.

Special Tool(s): JLR-501-169

10. CAUTION: Make sure that the threaded steel

Apply four beads of Loctite 243 to the outside of the

11. Thread the steel insert on to the special tool.

Special Tool(s): JLR-501-169

Using a suitable tool measure the seated depth of

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

1. NOTE: Repeat the procedure for the other side.

Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and

1. CAUTION: Make sure that the clip is correctly

2. To install, reverse the removal procedure.

1. WARNING: Make sure to support the vehicle with axle

Raise and support the vehicle.

Removal steps in this procedure may contain installation details.

LH illustration shown, RH is similar.

1. WARNING: Make sure to support the vehicle with axle

Raise and support the vehicle.

2. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal

3. NOTE: RH side only.

Refer to: Windshield Washer Reservoir (501-16 Wipers and

11. CAUTION: Carefully release either side of the

NOTE: Do not disassemble further if the

1. To install, reverse the removal procedure.

2. Refer to: Body and Frame (501-26 Body Repairs - Vehicle

Removal steps in this procedure may contain installation details.

LH illustration shown, RH is similar.

1. WARNING: Do not work on or under a vehicle supported

Raise and support the vehicle.

2. Remove the front wheel.

1. To install reverse the removal procedure.

The hood is manufactured from aluminium.

Removal steps in this procedure may contain installation details.

1. Refer to: Corrosion Prevention (501-25A Body Repairs - General

5. NOTE: Do not disassemble further if the

10. CAUTION: Protect the surrounding paintwork to

Install new retaining clips.

Make sure that the adhesive strip is removed

2. NOTE: Install new retaining clips.

7. WARNING: This step requires the aid of another technician.

NOTE: Do not tighten at this stage.

Removal steps in this procedure may contain installation details.

1. Disconnect the battery ground cable.

Refer to: Specifications (414-00 Battery and Charging System -

2. WARNING: Make sure to support the vehicle with axle

Raise and support the vehicle.

4. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and

7. NOTE: The step must be carried out on both

8. NOTE: The step must be carried out on both

10. NOTE: The step must be carried out on both

The step must be carried out on both sides.

LH illustration shown, RH is similar.

The step must be carried out on both sides.