Land Rover Discovery (1995) manual

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INTRODUCTION 1 INFORMATION INTRODUCTION This workshop manual covers vehicles from 1995 model year onwards. Amendments and additional pages will be issued to ensure that the manual covers latest models. Amendments and additions will be identified by the addition of a dated footer at the bottom of the page. This Workshop Manual is designed to assist [...]

01 INTRODUCTION 2 INFORMATION FUEL HANDLING PRECAUTIONS The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines the other areas of risk which must not be ignored. This information is issued for basic guidance only, and in any case of doubt, appropriate enquiries should be made of[...]

INTRODUCTION 3 INFORMATION SYNTHETIC RUBBER Many ’0’ ring seals, flexible pipes and other similar items which appear to be natural rubber are made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe, and does not present a health hazard. However, if the material is damaged by fire or excessive[...]

01 INTRODUCTION 4 INFORMATION ACCESSORIES AND CONVERSIONS DO NOT FIT unapproved accessories or conversions, as they could affect the safety of the vehicle. Land Rover will not accept liability for death, personal injury, or damage to property which may occur as a direct result of the fitting of non-approved conversions to the vehicle. WHEELS AND TY[...]

INTRODUCTION 5 INFORMATION JACKING The following instructions must be carried out before raising the vehicle off the ground. 1. Use a solid level ground surface. 2. Apply parking brake. 3. Select ’P’ or 1st gear in main gearbox. 4. Select Low range in transfer gearbox. CAUTION: To avoid damage occurring to the under body components of the vehic[...]

01 INTRODUCTION 6 INFORMATION 2. Raise front road wheels to enable an axle stand to be installed under left hand axle tube. 3. Position an axle stand under right hand axle tube, carefully lower jack until axle sits securely on both axle stands, remove trolley jack. 4. Before commencing work on underside of vehicle re-check security of vehicle on st[...]

INTRODUCTION 7 INFORMATION DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) WARNING: Do not attempt to test ABS function on a dynamometer Four wheel dynamometers NOTE: Before testing a vehicle on a four wheel dynamometer disconnect the valve relay. See Electrical Trouble Shooting Manual. The ABS function will not work, the ABS warning lig[...]

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GENERAL SPECIFICATION DATA 3 INFORMATION ENGINE 4.0 V8 Type 4.0 litre V8 ................................................................................. Number of cylinders Eight, two banks of four ......................................................... Bore 94.00 mm ..............................................................................[...]

04 GENERAL SPECIFICATION DATA 4 INFORMATION Piston rings Number of compression rings 2 .......................................... Number of control rings 1 .................................................... No 1 compression ring Nitrided steel barrel faced ..................................................... No 2 compression ring Tapered spheric[...]

GENERAL SPECIFICATION DATA 5 INFORMATION FUEL SYSTEM 3.9 V8i Fuel system type Lucas 14CUX hot wire system electronically controlled .............................................................. Fuel pump-make/type ACX delco high pressure electrical, immersed in the ...................................................... fuel tank Fuel pump delivery[...]

04 GENERAL SPECIFICATION DATA 6 INFORMATION FUEL SYSTEM (GEMS) 4.0 V8 ENGINE Type Sagem - Lucas Gems 8 hot wire system electronically ................................................................................. controlled Fuel pump-make/type High pressure electrical, immersed in the fuel tank ...................................................[...]

GENERAL SPECIFICATION DATA 7 INFORMATION SHIFT SPEED AUTOMATIC ZF ON 3.9 V8i OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED POSITON APPROX APPROX (RPM) KICKDOWN MPH KPH KD4 - 3 D 8 4 - 92 136 - 150 KD3 - 2 3(D) 57 - 62 91 - 99 KD2 - 1 2(D,3) 27 - 34 44 - 56 KD3 - 4 D N/A N/A KD2 - 3 D(3) 60 - 63 96 - 104 4750 - 5200 KD1 - 2 D(3,2) 34 - 40 56 - 64 46[...]

04 GENERAL SPECIFICATION DATA 8 INFORMATION SHIFT SPEED AUTOMATIC ZF ON Tdi ENGINE OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED POSITON APPROX APPROX (RPM) KICKDOWN MPH KPH KD4 - 3 D 6 2 - 72 99 - 115 KD3 - 2 3(D) 43 - 49 69 - 78 KD2 - 1 2(D,3) 23 - 36 37 - 58 KD3 - 4 D 6 4 - 76 102 - 122 3400 - 4000 KD2 - 3 D(3) 46 - 51 74 - 82 3600 - 3900 KD1 - [...]

GENERAL SPECIFICATION DATA 9 INFORMATION TRANSMISSION 3.9 V8i Manual gearbox Type R380 Single helical constant mesh ....................................................................... Speeds 5 forward 1 reverse all synchromesh ............................................................................. Clutch Make and type Borg and beck diaphr[...]

04 GENERAL SPECIFICATION DATA 10 INFORMATION COOLING SYSTEM 3.9 V8i System type Pressurised, spill return, thermostatically controlled ..................................................................... water and anti-freeze mixture. Pump assisted thermo syphon. Coolant radiator combined with oil cooler. Fan and viscous coupling assembly 11 blade[...]

GENERAL SPECIFICATION DATA 11 INFORMATION SUSPENSION Type Coil springs controlled by telescopic dampers front ................................................................................. and rear. Front Lateral location of axle by Panhard rod, and ................................................................................. longitudinal lo[...]

04 GENERAL SPECIFICATION DATA 12 INFORMATION SHOCK ABSORBERS Type Telescopic, double-acting non-adjustable ................................................................................. Bore diameter 35.47mm ................................................................... BRAKES Front service brake Type Outboard discs with four piston caliper[...]

GENERAL SPECIFICATION DATA 13 INFORMATION AIR CONDITIONING System Nippon Denso ............................................................................. Compressor Nippon Denso 10 PA 17 ..................................................................... Refrigerant R134a ....................................................................... [...]

04 GENERAL SPECIFICATION DATA 14 INFORMATION Coil Make/type Bosch 0221 122 392 ........................................................................ Distributor Make/type Lucas 35 DLM8 ........................................................................ Firing angles 0 ° -4 5 ° -9 0 ° (every 45 ° ) ± 1 ° ...............................[...]

GENERAL SPECIFICATION DATA 15 INFORMATION BULBS REPLACEMENT BULBS TYPE Exterior lights Headlamps 12V 60/55W (Halogen) Headlamps - France amber 12V 60/55W (Halogen) Auxiliary driving lamps 12V 55W H3 (Halogen) Sidelamps 12V 5W bayonet Tail lamps 12V 5/21W bayonet Reverse lamps 12V 21W bayonet Stop lamps 12V 21W bayonet Direction indicator lamps 12V [...]

04 GENERAL SPECIFICATION DATA 16 INFORMATION VEHICLE WEIGHTS AND PAYLOAD When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the unladen vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values. It is the customer’s responsibility to limit t[...]

GENERAL SPECIFICATION DATA 17 INFORMATION TYRE PRESSURES Pressures: Check Normal on and off-road use. Off-road ’emergency’ soft use maximum with tyres cold All speeds and loads speed of 40 kph (25 mph) 205R16 Radial Front Rear Front Rear bars 1.9 2.6 1.2 1.8 lbf/in 2 28 38 17 25 kgf/cm 2 2.0 2.7 1.2 1.8 WARNING: Vehicles fitted with tubeless al[...]

04 GENERAL SPECIFICATION DATA 18 INFORMATION 300 Tdi ENGINE Type Direct injection, turbocharged, intercooled ................................................................................. Number of cylinders 4 ......................................................... Bore 90,47 mm .................................................................[...]

GENERAL SPECIFICATION DATA 19 INFORMATION Piston rings Type: - Top Barrel edge, chrome plated ........................................................................ - Second Taper faced .................................................................. - Oil control Expander and rails ..............................................................[...]

04 GENERAL SPECIFICATION DATA 20 INFORMATION Lubrication System Wet sump, pressure fed ............................................................................. Pressure, engine warm at normal operating speeds 25 - 55lbf/in 2 = 1,76 - 3,87Kgf cm 2 ........ Oil pump: - Type G-rotor integral with front cover. .....................................[...]

GENERAL SPECIFICATION DATA 21 INFORMATION TRANSMISSION - 300 Tdi Manual gearbox Type R380 Single helical constant mesh ....................................................................... Speeds 5 forward 1 reverse all synchromesh ............................................................................. Automatic gearbox Type ZF4HP Four spee[...]

04 GENERAL SPECIFICATION DATA 22 INFORMATION ENGINE - Mpi - 2.0 LITRE Type 20 T4 - 16 valve twin overhead camshaft ................................................................................. Cylinder arrangement 4 in line ....................................................... Bore 84.45 mm ....................................................[...]

GENERAL SPECIFICATION DATA 23 INFORMATION Valves Valve stem diameter: Inlet 7.09 to 7.10 mm ......................................................................... Exhaust 7.07 to 7.09 mm ................................................................... Valve head diameter: Inlet 31.7 to 31.95 mm ................................................[...]

04 GENERAL SPECIFICATION DATA 24 INFORMATION FUEL SYSTEM - Mpi Electronic fuel injection data See ENGINE TUNING DATA, Information, Engine ............................................ - Mpi - 2.0 Litre Fuel Pump: Make/Type A.C. Rochester/Electric immersible ....................................................................... Pump pressure 3.2 bar[...]

GENERAL SPECIFICATION DATA 25 INFORMATION VEHICLE DIMENSIONS Dimensions Overall length (including spare wheel) 4538 mm ............................. Overall length (including tow hitch) 4581 mm .................................. Overall width 2189 mm .................................................................... Overall height 1914 mm .......[...]

ENGINE TUNING DATA 1 INFORMATION ENGINE 3.9 V8i Type 3.9 Litre V8i ................................................................................. Firing order 1-8-4-3-6-5-7-2 ..................................................................... Cylinder Numbers Left bank 1-3-5-7 ...................................................................[...]

05 ENGINE TUNING DATA 2 INFORMATION Distributor Make/type Lucas 35DLM8 electronic ........................................................................ Rotation Clockwise ............................................................................ Air gap 0.20-0.35mm .............................................................................. [...]

ENGINE TUNING DATA 3 INFORMATION ENGINE 4.0 V8 Type 4.0 Litre V8 ................................................................................. Firing order 1-8-4-3-6-5-7-2 ..................................................................... Cylinder Numbers Left bank 1-3-5-7 .....................................................................[...]

05 ENGINE TUNING DATA 4 INFORMATION 300 Tdi ENGINE Type 2.5 Litre Turbo diesel intercooled ................................................................................. Firing order 1-3-4-2 ..................................................................... Injection timing 1,54 mm lift at T.D.C. ..............................................[...]

ENGINE TUNING DATA 5 INFORMATION GLOW PLUGS Make & type Probe type, No.0100226129A Beru 12 volts ..................................................................... Time to reach operating temperature of 850 ° C 8 seconds ................ INJECTORS Make & type - standard Bosch KBAL 90 P37 .................................................[...]

05 ENGINE TUNING DATA 6 INFORMATION ENGINE - Mpi - 2.0 LITRE Type/Capacity 20 T4/1994 cm 3 .................................................................. Firing order 1-3-4-2 ....................................................................... Compression ration 10 : 1 .......................................................... Idle speed: Co[...]

GENERAL FITTING REMINDERS 1 INFORMATION GENERAL FITTING REMINDERS WORKSHOP SAFETY IS YOUR RESPONSIBILITY! The suggestions, cautions and warnings in the section are intended to serve as reminders for trained and experienced mechanics. This manual is not a course in automotive mechanics or workshop safety. Shop equipment, shop environment, and the us[...]

07 GENERAL FITTING REMINDERS 2 INFORMATION PREPARATION 1. Before removing a component, clean it and its surrounding areas as thoroughly as possible. 2. Blank off any openings exposed by component removal, using greaseproof paper and masking tape. 3. Immediately seal fuel, oil or hydraulic lines when separated, using plastic caps or plugs, to preven[...]

GENERAL FITTING REMINDERS 3 INFORMATION BALL AND ROLLER BEARINGS CAUTION: Never refit a ball or roller bearing without first ensuring that it is in a fully serviceable condition. 1. Remove all traces of lubricant from bearing under inspection by washing in a suitable degreaser; maintain absolute cleanliness throughout operations. 2. Inspect visuall[...]

07 GENERAL FITTING REMINDERS 4 INFORMATION OIL SEALS NOTE: Ensure that the seal running track is free from pits, scores, corrosion and general damage prior to fitting replacement seal. 1. Always fit new oil seals when rebuilding an assembly. 2. Carefully examine seal before fitting to ensure that it is clean and undamaged. 3. Coat the sealing lips [...]

GENERAL FITTING REMINDERS 5 INFORMATION JOINTS AND JOINT FACES 1. Always use correct gaskets where they are specified. 2. Use jointing compound only when recommended. Otherwise fit joints dry. 3. When jointing compound is used, apply in a thin uniform film to metal surfaces; take great care to prevent it from entering oilways, pipes or blind tapped[...]

07 GENERAL FITTING REMINDERS 6 INFORMATION FUEL SYSTEM HOSES CAUTION: All fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core. If any of the fuel system hoses have been disconnected, it is imperative that the internal bore is inspected to ensure that the viton lining has not become separated from the a[...]

GENERAL FITTING REMINDERS 7 INFORMATION COTTER PINS 1. Fit new cotter pins throughout when replacing any unit. 2. Always fit cotter pins where cotter pins were originally used. Do not substitute spring washers: there is always a good reason for the use of a cotter pin. 3. All cotter pins should be fitted as shown unless otherwise stated. NUTS 1. Wh[...]

LUBRICANTS, FLUIDS AND CAPACITIES 1 INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS - USA VEHICLES AMBIENT TEMPERATURE ° C COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 4 0 50 Engine Use oils to API 5W/20 ) service level SGSH 5W/30 ) or 5W/40 ) RES.22.OL.G4 or CCMC G4 10W/30 10W/40 ) 10W/50 ) 15W/40 ) 15W/50 ) 20W/40 ) 20W/50 ) Automatic [...]

09 LUBRICANTS, FLUIDS AND CAPACITIES 2 INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS All climates and conditions AMBIENT TEMPERATURE ° C COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 4 0 50 Petrol models Oils must meet: 5W/30 Engine sump RES.22.OL.G-4 5W/40 or 5W/50 CCMC G-4 or 10W/30 API SG or SH 10W/40 10W/50 15W/40 15W/50 20W/40 20W/[...]

LUBRICANTS, FLUIDS AND CAPACITIES 3 INFORMATION Propeller shaft Front and Rear NLGI - 2 Multi-purpose Lithium based GREASE Lubrication nipples (hubs, ball joints etc.) Seat slides Door lock striker Brake and clutch reservoirs Brake fluids having a minimum boiling point of 260 ° C (500 ° F) and complying with FMVSS 116 DOT4 Engine coolant Use an e[...]

09 LUBRICANTS, FLUIDS AND CAPACITIES 4 INFORMATION CAPACITIES The following capacity figures are approximate and are provided as a guide only. Capacities (approx.)* Litres Imp.Unit US unit Engine sump oil - 300Tdi models 5,8 ...................................................... 10.20 pt 12.30 pt - V8i petrol models 3.9 6,1 ........................[...]

LUBRICANTS, FLUIDS AND CAPACITIES 5 INFORMATION ANTI-FREEZE ENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTION CONCENTRATION LOWER TEMPERATURE LIMIT V8i Engine One part anti-freeze Diesel Engine One part water 50% Complete protection -3 3 ° F Vehicle may be driven away immediately from cold - 36 ° C Safe limit protection -4 1 ° C Coolant in mush[...]

09 LUBRICANTS, FLUIDS AND CAPACITIES 6 INFORMATION RECOMMENDED FUEL Petrol engines - with catalytic converter unleaded only, 95 RON (USA 90 CLC or AKI) ................................................ - non catalytic, 9.35:1 compression ratio leaded 97 RON/unleaded 95 RON ....................... - non catalytic, 8.13:1 compression ratio leaded 90 R[...]

MAINTENANCE 1 MAINTENANCE SERVICE SCHEDULE This section gives information on the range of service procedures. Where required, instructions are given for carrying out each service procedure, or a cross reference is given, where the procedure can be found in this manual. Service Schedule sheets are published separately to reflect the maintenance need[...]

10 MAINTENANCE 2 MAINTENANCE CHECK SECURITY AND OPERATION OF PARK BRAKE Parking brake adjust 1. Select a gear or ’P’ in main gearbox. 2. Chock road wheels. 3. Release parkbrake lever. 4. Remove switch panel from centre console. 5. Underneath vehicle, rotate brake adjuster clockwise until brake shoes are fully expanded against drum. 6. Back off [...]

MAINTENANCE 3 MAINTENANCE VEHICLE EXTERIOR CHECK/ADJUST HEADLAMP ALIGNMENT Check/adjust headlamp and auxiliary alignment. CHECK FRONT WHEEL ALIGNMENT Use recognised wheel alignment equipment to perform this check and adjustment. See STEERING, Adjustment, Front Wheel Alignment REMOVE WHEELS, CHECK TYRES Check tyres (including spare) for compliance w[...]

10 MAINTENANCE 4 MAINTENANCE UNDER BONNET [HOOD] MAINTENANCE CHECK COOLING/HEATER SYSTEMS Check cooling/heater systems for leaks and hoses for security and condition. Cooling system hoses should be changed at first signs of deterioration. CHECK CONDITION OF ENGINE MOUNTING RUBBERS CHECK BRAKE SERVO HOSE FOR SECURITY AND CONDITION CHECK FUEL EVAPORA[...]

MAINTENANCE 5 MAINTENANCE 2. Clean or replace spark plugs as applicable. 3. It is essential that correct type of spark plugs are fitted. 4. Incorrect grade of plugs may lead to piston overheating and engine failure. Remove 5. Disconnect battery negative lead. Remove H.T. leads from spark plugs. 6. Remove plugs and washers. 7. When pushing leads ont[...]

10 MAINTENANCE 6 MAINTENANCE RENEW SPARK PLUGS - Mpi Spark plugs - Mpi Remove 1. Release 4 screws and remove spark plug cover. 2. Disconnect 4 plug leads. 3. Release plug leads from securing clips. 4. Remove spark plugs from cylinder head. Refit 5. Inspect spark plugs. 6. Set plug gaps. CAUTION: Use correct type and grade of plug. 7. Apply anti-sei[...]

MAINTENANCE 7 MAINTENANCE CHECK/ADJUST VALVE CLEARANCES. - Tdi Valve adjustment. See GENERAL SPECIFICATION DATA, Information, 300 Tdi Engine RENEW FUEL FILTER ELEMENT - Tdi Drain off water and sediment CAUTION: It is essential that any water and sediment in fuel filter is drained off, as water in fuel can result in damage to injection pump. 1. Hold[...]

10 MAINTENANCE 8 MAINTENANCE CLEAN PLENUM CHAMBER VENTILATION PASSAGEWAY - V8i Cleaning plenum chamber ventilation passageway can be carried out without removing plenum chamber from ram housing. CAUTION: Care must be taken to prevent debris from passageway passing beyond throttle butterfly disc. WARNING: Safety glasses must be worn when performing [...]

MAINTENANCE 9 MAINTENANCE CHECK CONDITION OF DRIVE BELT - V8i - Tdi - Mpi RENEW - V8i - Tdi Renew drive belt V8i. See ENGINE, Repair, Drive Belt Renew Renew drive belt Tdi. See ENGINE, Repair, Drive Belt Renew RENEW - Mpi 1. Check condition of drive belt, renew a belt that shows signs of wear, splitting or oil contamination. 2. Check belt length in[...]

10 MAINTENANCE 10 MAINTENANCE CHECK/TOP UP COOLING SYSTEM 1. To prevent corrosion of aluminium alloy engine parts it is imperative that cooling system is filled with a solution of water and phosphate free anti-freeze, winter or summer. Never fill or top up with plain water. WARNING: Do not remove filler cap when engine is hot because cooling system[...]

MAINTENANCE 11 MAINTENANCE CHECK/ADJUST ENGINE IDLE SPEED - Tdi For idle speed. See ENGINE TUNING DATA, Information, 300 Tdi Engine CHECK ENGINE IDLE SPEED - Mpi For idle speed. See ENGINE TUNING DATA, Information, Engine - Mpi - 2.0 Litre CHECK/ADJUST STEERING BOX V8i - Tdi - Mpi Check steering box for fluid leaks. Check that there is no backlash [...]

10 MAINTENANCE 12 MAINTENANCE EXTERNALLY CHECK INTERCOOLER FOR OBSTRUCTION - Tdi Clear any trapped dirt or flies from vanes of intercooler CLEAN INTERCOOLER ELEMENT - Tdi Remove 1. Remove intercooler element. 2. Flush intercooler with ICI ’GENKLENE’or ˆ oD-SOLVE’ propriety cleaner, following the manufacturer’s instructions. 3. Dry the inte[...]

MAINTENANCE 13 MAINTENANCE RENEW AUTOMATIC GEARBOX FLUID AND OIL SCREEN 1. Site vehicle on lift or level ground. Place container to drain gearbox fluid into. Disconnect battery negative lead. 2. Remove gearbox dipstick, located at rear of right hand rocker cover, to aid oil drainage. Release plug from bottom of sump and allow fluid to drain complet[...]

10 MAINTENANCE 14 MAINTENANCE RENEW TRANSFER GEARBOX OIL 1. Site vehicle on lift or level ground. 2. Disconnect battery negative lead. 3. Clean immediate area around filler/level and drain plugs. WARNING: When draining gearbox care should be taken to ensure that oil is not hot as personal scalding could result. 4. Place a container under gearbox to[...]

MAINTENANCE 15 MAINTENANCE RENEW FRONT AND REAR AXLE OIL 1. Site vehicle on lift or level ground. Place container under axle to be drained. 2. Using a 13mm square drive wrench, remove drain and filler/level plugs from axle. Allow oil to drain completely. Clean and refit drain plug. 3. Inject new oil of recommended make and grade until it reaches le[...]

10 MAINTENANCE 16 MAINTENANCE LUBRICATE PROPELLER SHAFT SLIDING , AND UNIVERSAL JOINTS 1. Clean all grease nipples on front and rear propeller shafts. 2. Using a low pressure hand grease gun, apply recommended grease, to grease nipples at front and rear propeller shaft universal and sliding joints. NOTE: The rear propeller shaft flexible coupling i[...]

MAINTENANCE 17 MAINTENANCE CHECK/TIGHTEN FRONT AND REAR AXLE SUSPENSION LINK FIXINGS, CHECK CONDITION OF MOUNTING RUBBERS DRAIN FUEL SEDIMENTER - Tdi Fuel sedimenter The sedimenter is attached to left-hand side of chassis frame near fuel tank. It increases the working life of the fuel filter by removing larger droplets of water and larger particles[...]

10 MAINTENANCE 18 MAINTENANCE ABS VEHICLES - CHECK ROAD WHEEL SPEED SENSOR ELECTRICAL HARNESS FOR DAMAGE RENEW OXYGEN SENSORS See EMISSION CONTROL, Repair, Heated Oxygen Sensor (HO2S) RENEW CATALYTIC CONVERTERS See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust System Complete REPORT ANY UNUSUAL FEATURES OF VEHICLE CONDITION AND ADDITIONAL WORK REQUI[...]

MAINTENANCE 19 MAINTENANCE RESET EMISSION MAINTENANCE REMINDER - USA The emission maintenance reminder is designed to activate at 52,500 and 105,000 miles respectively and will illuminate a ’Service Engine’ red warning light in instrument binnacle. The emission maintenance reminder must be reset after required maintenance has been carried out a[...]

Tdi 1 REPAIR DRIVE BELT INFORMATION A single ’serpentine drive belt’ drives all the ancilliaries bar the air conditioning compressor, which has a separate drive belt. It is essential that the belts are fitted exactly as shown. It should also be noted that the water pump/viscous fan is driven in a clockwise direction. A drive belt tensioner auto[...]

12 ENGINE 2 REPAIR DRIVE BELT RENEW Service repair no - 86.10.03 NOTE: If cast lines on tensioner arm and tensioner spring case are aligned, a new drive belt must be fitted. Remove 1. Remove fan cowl upper. 2. Apply ring spanner to tensioner pulley retaining bolt. 3. Turn spanner to release pulley tension from belt. 4. Detach belt from pulley. 5. R[...]

Tdi 3 REPAIR ENGINE Service repair no - 12.41.01 Remove CAUTION: Seal all exposed pipe ends against ingress of dirt after disconnection. 1. Park vehicle on level ground and apply park brake. 2. Disconnect battery negative lead. 3. Remove bonnet [hood]. See CHASSIS AND BODY, Repair, Bonnet [Hood] 4. If air conditioning is fitted, remove RH footwell [...]

12 ENGINE 4 REPAIR 22. Disconnect feed pipe and spill return pipe from injector pump. 23. Disconnect both pipes from fuel lift pump. 24. Disconnect servo hose from vacuum pump. 25. Remove three retaining nuts and disconnect exhaust down pipe. 26. Remove oil cooler pipes from oil filter adaptor. 27. If automatic transmission is fitted, disconnect fe[...]

Tdi 5 REPAIR 37. Remove nuts and plain washers securing front engine mountings to chassis,and lift both engine mounting bracket assemblies from vehicle. 38. Remove engine to bell housing fixings. Leave starter motor attached. 39. Raise engine to separate from transmission. 40. Check all connections to engine have been disconnected. 41. Remove engin[...]

12 ENGINE 6 REPAIR CRANKSHAFT PULLEY Service repair no - 12.21.01 Remove 1. Disconnect battery negative lead. 2. Drain coolant. 3. Remove top hose from radiator. 4. Remove intercooler to induction manifold hose. 5. Remove viscous fan and coupling. See COOLING SYSTEM, Repair, Viscous Coupling, Fan Blades, Pulley and Fan Cowl 6. Remove fan cowl. 7. R[...]

Tdi 7 REPAIR FRONT COVER PLATE Service repair no - 12.65.01 Remove 1. Disconnect battery negative lead. 2. Drain coolant. 3. Remove top hose from radiator. 4. Remove inter-cooler to induction manifold hose. 5. Remove viscous coupling and fan. See COOLING SYSTEM, Repair, Viscous Coupling, Fan Blades, Pulley and Fan Cowl 6. Remove fan cowl. 7. Remove[...]

12 ENGINE 8 REPAIR CAMSHAFT DRIVE BELT AND GEARS Service repair no - 12.65.18 TIMING BELT Remove 1. Remove front cover plate. See Front Cover Plate 2. Position engine at TDC on No. 1 cylinder. 3. If manual gearbox: Remove blanking plug from flywheel housing and insert timing tool LRT-12-044. If EDC - timing tool LRT-12-085 must be used. If automati[...]

Tdi 9 REPAIR Belt tensioner NOTE: The belt tensioner need only be removed if it is being replaced or for access purposes to remove front cover. 11. Remove securing bolt and withdraw tensioner complete with spacer. Crankshaft gear/front cover oil seal 12. If the crankshaft gear cannot be removed by hand, use special tool LRT-12-078 with main body an[...]

12 ENGINE 10 REPAIR 21. With lip side leading, drive-in seal squarely using special tool LRT-12-082. 22. Refit gear. FUEL INJECTION PUMP GEAR Service repair no - 19.30.06 Remove 23. Slacken the three bolts on front of gear. CAUTION: It is important to ensure that when the injection pump is locked no attempt must be made to rotate it. Take care not [...]

Tdi 11 REPAIR Timing belt fitting and tensioning NOTE: It is important that belt tensioning is carried out carefully and accurately. The following procedure involves tensioning the belt twice to ensure that it is equally tensioned between each gear. New and original belts are tensioned to different figures. 28. Ensure timing marks are correctly ali[...]

12 ENGINE 12 REPAIR FRONT COVER/TIMING GEAR HOUSING GASKET Service repair no - 12.65.10 Remove 1. Remove timing belt and gears. See Camshaft Drive Belt and Gears 2. Remove fuel injection pump. See FUEL SYSTEM, Repair, Fuel Injection Pump and Timing 3. Remove engine oil sump. See Oil Sump 4. Remove oil pick up strainer. See Oil Pick-Up Strainer 5. R[...]

Tdi 13 REPAIR OIL SUMP Service repair no - 12.60.44 Remove 1. Disconnect battery negative lead. 2. Drain engine oil. 3. Slacken sump securing bolts and, using a sharp knife, break sealant around sump flange. 4. Remove bolts and withdraw sump. Refit 5. Clean mating faces of sump, timing gear housing and cylinder block. 6. Apply a 2,0 mm bead of ’H[...]

12 ENGINE 14 REPAIR FLYWHEEL Service repair no - 12.53.07 Remove 1. Disconnect battery negative lead. 2. Remove gearbox. See MANUAL GEARBOX, Repair, R380 Manual Gearbox 3. Remove clutch. See CLUTCH, Repair, Clutch Assembly 4. Fit two long 8mm bolts into the clutch bolt holes, diametrically opposite, to use as handles when lifting the flywheel off t[...]

Tdi 15 REPAIR CRANKSHAFT REAR OIL SEAL Service repair no - 12.21.20 Remove NOTE: The crankshaft rear oil seal is retained in its own housing, if the seal requires replacing the housing and seal assembly (1) must be renewed complete with the housing seal (3). Housing and seal assemblies are supplied with their own former/seal guide (2) already fitte[...]

12 ENGINE 16 REPAIR 8. Ensure housing seal is correctly seated in its groove in new housing and seal assembly. 9. Fit new assembly, with former/guide in-situ, over crankshaft flange, this action will eject former/guide. 10. Secure assembly to cylinder block with five bolts tightened to correct torque, removing slave studs individually and inserting[...]

Tdi 17 REPAIR Method 2. Thread the bore of the existing bush and using a suitable bolt extract the bush. Thoroughly clean bush location ensuring all swarf is removed. Fitting 6. Fit new bush using a suitable shouldered drift, inserting bush flush with end of crankshaft. 7. Refit flywheel. See Flywheel 8. Refit clutch. See CLUTCH, Repair, Clutch Ass[...]

12 ENGINE 18 REPAIR 10. Apply sealant to flywheel housing mating face on cylinder block (Fig. J5944). 11. Fit housing to cylinder block and secure with bolts as removed. Tighten to 45 Nm. 12. Remove surplus sealant from block. 13. Refit starter motor. 14. Refit flywheel. See Flywheel 15. Refit clutch. See CLUTCH, Repair, Clutch Assembly 16. Refit g[...]

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

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Tdi 1 DESCRIPTION AND OPERATION DESCRIPTION Air intake The air cleaner is positioned to the right of the engine and connected by hoses to a cold air intake duct and the turbocharger inlet. A crankcase breather hose is fitted between the air cleaner and the separator. A single stage turbocharger, fitted between the exhaust manifold and exhaust pipe,[...]

19 FUEL SYSTEM 2 DESCRIPTION AND OPERATION FUEL SYSTEM LAYOUT 1. Fuel tank 2. Fuel lift pump 3. Fuel filter 4. Fuel injection pump 5. Spill return line 6. Fuel injectors 7. Sediment plug FUEL SYSTEM COMPONENT LOCATION 1. Fuel filter bleed screw 2. Fuel filter 3. Turbocharger 4. Wastegate 5. Air cleaner 6. Fuel injector 7. Glow plug 8. Glow plug con[...]

Tdi 3 DESCRIPTION AND OPERATION[...]

19 FUEL SYSTEM 4 DESCRIPTION AND OPERATION OPERATION Diesel engines operate by compression ignition. The rapid compression of air in the cylinder during the compression cycle heats the injected fuel, causing it to self ignite. During cold starting, automatically controlled glow plugs assist in raising the temperature of the compressed air to igniti[...]

Tdi 5 DESCRIPTION AND OPERATION Exhaust Gas Recirculation (EGR) Operation of the EGR system is dependent on the following: a. Engine temperature - must be between 20 ° C and 100 ° C approx. b. Engine speed - must be between 630 and 2850 rev/min. c. Engine load - calculated by throttle position sensor. d. EGR valve lift position. e. Duration of en[...]

19 FUEL SYSTEM 6 DESCRIPTION AND OPERATION DESCRIPTION ELECTRONIC DIESEL CONTROL The Electronic Diesel Control (EDC) ’drive by wire’ system derives its from the replacement of conventional mechanical controls by electronic components. The EDC system supplies the exact amount of fuel to the engine according to the prevailing engine operating con[...]

Tdi 7 DESCRIPTION AND OPERATION[...]

19 FUEL SYSTEM 8 DESCRIPTION AND OPERATION FUEL SYSTEM LAYOUT EDC 1. Fuel injection pump 2. Fuel temperature sensor 3. Air temperature sensor 4. Water temperature sensor 5. No. 4 injector sensor 6. Air flow sensor 7. Engine speed sensor 8. Boost pressure sensor 9. Vehicle speed sensor 10. Clutch switch 11. Brake switch 12. Throttle position sensor [...]

Tdi 9 DESCRIPTION AND OPERATION OPERATION EDC Under start up conditions, signals from the crank speed and water temperature sensors are relayed to the ECM to control starting fuel quantity and injection timing. Once the engine has started the ECM initiates a ’closed loop’ monitoring system for fuel quantity, injector timing and EGR relative to [...]

19 FUEL SYSTEM 10 DESCRIPTION AND OPERATION Vehicle speed sensor The vehicle speed sensor is located on the transfer box behind the transmission brake. The unit has a multirole as the vehicle electronic speedometer sensor and as a sensor for ’surge damping’, (a function which smooths out engine response to sharp accelerator movement and reduces[...]

Tdi 1 ADJUSTMENT THROTTLE CABLE Adjust 1. Loosen throttle cable adjustment ferrule. 2. Hold throttle lever in fully closed position. 3. Adjust outer cable, by rotating ferrule, to give 1.57 mm (0.062 in) of free play in the inner cable. 4. Check that throttle opens fully when the throttle is depressed. EGR THROTTLE POSITION SENSOR Check 1. Run engi[...]

19 FUEL SYSTEM 2 ADJUSTMENT LOW AND HIGH IDLE SPEED Adjust The high idle speed (cold start idle) is automatically set by the setting of the low idle speed and can not be adjusted individually. 1. Check and adjust throttle cable. 2. Start engine and run it until normal operating temperature is reached. 3. Using a suitable tachometer, check the engin[...]

Tdi 1 REPAIR TANK SENDER UNIT Service repair no - 88.25.32 WARNING: Ensure that the WARNINGS and FUEL HANDLING PRECAUTIONS given in Section 01 are adhered to before carrying out the following operations. Special tool - LST131 Remove 1. Disconnect battery negative lead. 2. Remove the rear carpet retainer. 3. Ease the carpet from under the lower trim[...]

19 FUEL SYSTEM 2 REPAIR THROTTLE CABLE Service repair no - 19.20.06 Remove 1. Disconnect battery negative lead. 2. Remove pin and clevis pin securing throttle cable to throttle lever. 3. Pull ferrule from abutment bracket and withdraw throttle cable. 4. Release throttle cable from clip on bulkhead. 5. Remove pin and clevis pin securing throttle cab[...]

Tdi 3 REPAIR TURBOCHARGER OIL FEED PIPE Service repair no - 19.42.14 Remove 1. Disconnect battery negative lead. 2. Remove exhaust front pipe. See MANIFOLD AND EXHAUST SYSTEM, Repair, Manifold and Exhaust System - Tdi 3. Remove banjo bolt securing oil feed pipe to turbocharger, discard 2 sealing washers. 4. Unscrew union, disconnect oil feed pipe f[...]

19 FUEL SYSTEM 4 REPAIR TURBOCHARGER ACTUATOR Service repair no - 19.42.31 Remove 1. Remove exhaust manifold and turbocharger. See MANIFOLD AND EXHAUST SYSTEM, Repair, Exhaust Manifold - Tdi 2. Remove 2 nuts securing the actuator to the turbocharger bracket. 3. Release clip and disconnect hose from actuator. 4. Remove and discard clip securing cont[...]

Tdi 5 REPAIR FUEL LIFT PUMP Service repair no - 19.45.09 Remove 1. Loosen unions securing fuel injection pipes to injectors and injector pump. Remove injection pipes. 2. Plug the connections to prevent the ingress of foreign material. 3. Loosen unions and disconnect fuel supply and feed hoses from fuel lift pump. 4. Plug the connections to prevent [...]

19 FUEL SYSTEM 6 REPAIR FUEL FILTER ELEMENT Service repair no - 19.25.07 Remove 1. Disconnect battery negative lead. 2. Clean area around filter head. 3. Place a suitable container beneath filter bowl to collect any spillage. 4. Loosen bleed screw. 5. Loosen drain tap, allow fuel to drain into container. 6. Unscrew filter element, discard element. [...]

Tdi 7 REPAIR 9. Move intercooler upwards and clear of fan cowl. Refit 10. Ensure locatiing lug grommets are fitted and in good condition. 11. Ensure foam pad is in good condition and attached to intercooler. 12. Move intercooler into position. 13. Reverse removal procedure. GLOW PLUGS Service repair no - 19.60.31 Remove 1. Disconnect battery negati[...]

19 FUEL SYSTEM 8 REPAIR All glow plugs 5. Remove terminal nut from glow plug, disconnect wire from glow plug terminal. 6. Remove glow plug. Refit 7. Clean glow plug and seating. 8. Coat threads of glow plug with suitable anti-seize compound operational to a temperature of 1000 ° C. 9. Fit glow plug. Tighten to 23 Nm. 10. Connect wire to glow plug [...]

Tdi 9 REPAIR GLOW PLUG CONTROL UNIT Service repair no - 19.60.33 Remove 1. Disconnect battery negative lead. 2. Remove nut and bolt securing control unit to mounting bracket. 3. Disconnect multiplug and remove control unit. Refit 4. Reverse removal procedure. EGR CONTROL UNIT Service repair no - 19.45.06 Remove 1. Release 2 glovebox stays from fasc[...]

19 FUEL SYSTEM 10 REPAIR EGR THROTTLE POSITION SENSOR Service repair no - 19.30.14 Remove 1. Remove 2 screws securing sensor mounting plate to injection pump. 2. Disconnect sensor multiplug from harness. 3. Remove sensor assembly. Refit 4. Position sensor assembly on injection pump and fit and tighten screws. 5. Connect multiplug. 6. Adjust sensor.[...]

Tdi 11 REPAIR FUEL INJECTION PUMP AND TIMING Service repair no - 19.30.07 NOTE: The following text refers to a Tdi vehicle with a manual gearbox without electronic diesel control. Where reference is made to the timing tool substitute the following information for automatic and EDC variants. If manual gearbox: Timing tool LRT-12-044 fits into the ba[...]

19 FUEL SYSTEM 12 REPAIR 12. Remove pin from pump gear. 13. Fit gear retaining tool LRT-12-045 with an 8 mm washer, 1.5 to 2 mm thick, under each bolt head in addition to the existing washer. 14. Remove throttle cable and hand throttle cable if fitted. 15. Disconnect stop control solenoid connector. 16. Remove banjo bolts securing spill return, mai[...]

Tdi 13 REPAIR Refit 21. Remove blanks from pump. 22. Remove special tool pin from pump. 23. Clean mating faces of pump and front cover. 24. Fit pump to cover with a new gasket and secure with nuts. Tighten to 25 Nm. 25. Attach pump to bracket and finger tighten nuts and bolts 26. First tighten bolts securing bracket to block and then bolts securing[...]

19 FUEL SYSTEM 14 REPAIR ENGINE CONTROL MODULE (ECM) Service repair no - 18.30.03 NOTE: The ECM is not a serviceable item, in the event of failure it must be renewed. Remove 1. Disconnect battery negative lead. 2. Remove ’A’ post trim pad. 3. Loosen multi-plug screw to ECM. 4. Disconnect multi-plug from ECM. 5. Secure multi-plug and harness asi[...]

Tdi 15 REPAIR BOOST PRESSURE SENSOR Service repair no - 18.30.63 Remove 1. Disconnect battery negative lead. 2. Disconnect sensor multi-plug. 3. Disconnect pressure tube union. 4. Retrieve and discard union copper washers. 5. Place pressure tube aside. 6. Remove sensor to mounting bracket bolts. 7. Remove sensor. Refit 8. Renew all copper washers. [...]

19 FUEL SYSTEM 16 REPAIR ENGINE SPEED SENSOR Service repair no - 18.30.65 Remove 1. Disconnect battery negative lead. 2. Disconnect sensor multi-plug. 3. Place vehicle on ramp and apply handbrake. 4. Raise ramp. 5. Remove sensor retaining nut. 6. Remove sensor from housing. 7. Clean housing mating faces. Refit 8. Reverse removal procedure.[...]

Tdi 17 REPAIR VEHICLE SPEED SENSOR Service repair no - 18.30.22 Remove NOTE: The following procedure is carried out with the ramp still raised. 1. Disconnect battery negative lead. 2. Disconnect sensor multi-plug. 3. Remove sensor retaining screw. 4. Remove sensor retaining plate. 5. Remove sensor from transfer box. Refit 6. Reverse removal procedu[...]

19 FUEL SYSTEM 18 REPAIR BRAKE PEDAL SWITCH Service repair no - 18.30.66 Remove 1. Disconnect battery negative lead. 2. Disconnect switch wiring Lucars. 3. Loosen rear locknut. 4. Remove front locknut. 5. Remove switch from mounting bracket. Refit 6. Reverse removal procedure. COOLANT TEMPERATURE SENSOR Service repair no - 18.30.68 Remove 1. Discon[...]

Tdi 19 REPAIR THROTTLE POSITION SENSOR Service repair no - 18.30.17 NOTE: The throttle position sensor is not a serviceable item, in the event of failure it must be renewed. Remove 1. Disconnect battery negative lead. 2. Disconnect multiplug from sensor. 3. Remove nut securing throttle pedal quadrant to sensor. Remove throttle pedal quadrant. 4. Re[...]

MFI 1 DESCRIPTION AND OPERATION DESCRIPTION Hot Wire Multiport Fuel Injection The ’Hot Wire’ Multiport fuel injection system derives its name from the mass air flow sensor which uses one cold wire and one electrically heated wire to measure the volume of air entering the engine. The function of the system is to supply the exact amount of fuel d[...]

19 FUEL SYSTEM 2 DESCRIPTION AND OPERATION Fuel pressure regulator The fuel pressure regulator is mounted in the fuel rail at the rear of the plenum chamber. The regulator is a mechanical device controlled by plenum chamber vacuum, it ensures that fuel rail pressure is maintained at a constant pressure difference of 2.5 bar above that of the manifo[...]

MFI 3 DESCRIPTION AND OPERATION Tune select resistor - To suit individual market requirements a tune select resistor is connected across pins 5 and 27 of the ECM. It is located adjacent to the ECM, and strapped to the MFI cable assembly. The value of the resistor is dependent on the market application: Red wire, 180 ohms, Australia, Rest of world. [...]

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

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

19 FUEL SYSTEM 6 DESCRIPTION AND OPERATION BODY MOUNTED COMPONENTS 1. Engine control module (ECM). 2. Main relay and fuel pump relay. 3. Inertia switch. 4. Ignition coil. 5. Charcoal canister. 6. Purge control valve.[...]

MFI 7 DESCRIPTION AND OPERATION MICRO PROCESSOR POWER CHECK (Instrument binnacle - Service use only) As part of the engine starting procedure, this symbol will illuminate momentarily. FUEL INJECTION SYSTEM CAUTION: The fuel system incorporates fine metering components that would be affected by any dirt in the system; therefore it is essential that [...]

MFI 1 FAULT DIAGNOSIS ENGINE TUNING Circuit fault diagnosis may be carried out on all V8i vehicles, using Testbook. Testbook will guide the operator by visual prompts through a series of diagnostic checks. Before commencing any fault diagnosis, the following preminary checks must be carried out. Preliminary checks CAUTION: Catalyst exhaust: If engi[...]

19 FUEL SYSTEM 2 FAULT DIAGNOSIS BASE IDLE SPEED SETTING NOTE: Base idle speed is set at factory. It should not require further adjustment unless plenum chamber is changed. The adjustment screw is sealed with a plug to prevent unauthorised alteration. Check ignition timing before attempting following procedure, since this will affect idle speed. Eq[...]

MFI 3 FAULT DIAGNOSIS FUEL PRESSURE CHECK In order to check the fuel pressure it is necessary to first depressurise the fuel system as follows: WARNING: Under normal operating conditions the multiport fuel injection system is pressurised by a high pressure fuel pump, operating at up to 2.3 to 2.5 bar. When engine is stationary pressure is maintaine[...]

MFI 1 REPAIR AIR CLEANER ASSEMBLY Service repair no - 19.10.01 Remove 3.9 V8 vehicle illustrated 1. Release 2 clips securing air cleaner to air flow sensor. 2. 3.9 V8 only: Release clip and disconnect hose from air cleaner. 4.0 V8 only: Release clip and disconnect multiplug from intake air temperature sensor. See FUEL SYSTEM SFI, Repair, Intake Air[...]

19 FUEL SYSTEM 2 REPAIR AIR FLOW SENSOR Service repair no - 19.22.25 Remove NOTE: The air flow sensor is not a serviceable item. In event of failure or damage the complete unit must be replaced. 1. Disconnect battery negative lead. 2. Release intake hose clamp, disconnect from sensor. 3. Disconnect multi-plug. 4. Release two clips securing air clea[...]

MFI 3 REPAIR IDLE AIR CONTROL VALVE Service repair no - 19.22.54 Remove 1. Disconnect battery negative lead. 2. Disconnect multi-plug. 3. Unscrew valve from rear plenum chamber. 4. Remove washer. Refit 5. Fit NEW sealing washer. NOTE: If same idle air control valve is being refitted clean sealing compounds from threads. Apply Loctite 241 to threads[...]

19 FUEL SYSTEM 4 REPAIR MULTIPORT FUEL INJECTION RELAYS Service repair no - 19.22.08 The two Multiport fuel injection relays are located in the RH footwell area behind the ’A’ post trim panel. The fuel injection relays can be identified as follows: A. Fuel pump relay - Blue base B. Main relay - Black base Remove 1. Release front door seal from [...]

MFI 5 REPAIR INERTIA FUEL SHUTOFF SWITCH Service repair no - 18.30.35 The inertia fuel shutoff switch is located on the bulkhead next to the washer reservoir under bonnet [hood]. Remove 1. Disconnect battery negative lead. 2. Disconnect multiplug from inertia switch. 3. Remove 2 screws securing inertia switch to mounting bracket. 4. Remove inertia [...]

19 FUEL SYSTEM 6 REPAIR ENGINE COOLANT TEMPERATURE SENSOR Service repair no - 19.22.18 Remove 1. Position drain tray to collect coolant spillage. 2. Disconnect multiplug from coolant sensor. 3. Remove sensor from thermostat housing. 4. Remove and discard copper washer. Refit 5. Fit a new copper washer. 6. Fit sensor and tigten securely. 7. Top-up c[...]

MFI 7 REPAIR FUEL PRESSURE REGULATOR Service repair no - 19.45.06 Remove 1. Depressurise fuel system. See Depressurising Fuel System 2. Disconnect battery negative lead. 3. Remove plenum chamber. See Plenum Chamber 4. Release clip and disconnect fuel return hose from regulator. 5. Disconnect vacuum hose from regulator. 6. Remove 2 bolts securing pr[...]

19 FUEL SYSTEM 8 REPAIR 10. Remove fuel rail and injectors. 11. Remove injector retaining clips, ease injectors from rail. Remove and discard ’O’ rings from injectors. 12. Remove fuel pressure regulator if required. Refit 13. Fit NEW ’O’ rings, to injectors. Lightly coat ’O’ rings with silicon grease 300. Insert injectors into fuel rail[...]

MFI 9 REPAIR 15. Remove distributor vacuum hose. 16. Release two screws and remove throttle position sensor. 17. Remove six screws securing plenum chamber. Remove plenum chamber. 18. Remove air idle air control valve hose. Throttle lever assembly - remove 19. If fitted - unclip cruise control actuator link. Hold throttle fully open, release link fr[...]

19 FUEL SYSTEM 10 REPAIR KEY 1. Spherical bush/housing 2. Retaining clips (2) 3. Countershaft assembly 4. Overtravel spring 5. Throttle shaft nut 6. Throttle return spring (2) 7. Tab washer 8. Throttle stop lever 9. Throttle bracket assembly 10. Pop rivets (2)[...]

MFI 11 REPAIR 25. Remove three bolts securing throttle bracket to plenum chamber, withdraw bracket assembly. 26. Remove tab washer and throttle stop lever from throttle shaft. Throttle lever assembly - inspect and overhaul 27. Remove two retaining clips from spherical bush. 28. Remove the countershaft assembly. 29. If spherical bush worn, drill out[...]

19 FUEL SYSTEM 12 REPAIR Throttle disc - inspect and overhaul 36. Examine throttle shaft for excessive wear between bushes in plenum chamber and shaft. A small amount of clearance is permissible. If excessive wear is evident fit new shaft and bushes as follows. 37. Remove two split screws securing throttle disc and withdraw disc. CAUTION: Take care[...]

MFI 13 REPAIR 44. Grease new air seal with Admax L3 or Energrease LS3. Push seal down shaft, into counterbore until seal is 6.0 mm (0.236 in) below face of plenum. Throttle levers and bracket - assemble 45. Fit stop lever to throttle shaft, a new tab washer and secure with throttle shaft nut. 46. Holding stop lever on stop, tighten throttle shaft n[...]

19 FUEL SYSTEM 14 REPAIR RAM HOUSING Service repair no - 19.70.04 Remove 1. Disconnect battery negative lead. 2. Remove plenum chamber. See Plenum Chamber 3. Release hoses from ram housing. 4. Remove six through bolts (with plain washers) securing ram housing to intake manifold. 5. Remove ram housing from intake manifold. 6. Place a protective cove[...]

MFI 15 REPAIR 11. Loosen clip and disconnect top hose from thermostat housing. 12. Disconnect multiplug from distributor amplifier module. 13. Loosen clip and disconnect hose from heater valve. 14. Remove injector harnesses from behind fuel rail and lay to one side. 15. Loosen union and disconnect fuel return hose from fuel rail. NOTE: The intake m[...]

19 FUEL SYSTEM 16 REPAIR Refit 1. Clean mating faces of cylinder heads, cylinder block and intake manifold. 2. Locate NEW seals in position with ends engaged in notches formed between the cylinder heads and block. 3. Apply RTV sealant between ends of seals, cylinder head and block. 4. Fit intake manifold gasket with the word ’FRONT’ to the fron[...]

MFI 17 REPAIR FUEL FILTER Service repair no - 19.25.02 Remove WARNING: Spilling of fuel is unavoidable during this operation. Ensure all necessary precautions are taken to prevent fire and explosion. WARNING: Ensure fuel handling precautions given in Section 01 - Introduction are strictly adhered to when carrying out following instructions. 1. Depr[...]

19 FUEL SYSTEM 18 REPAIR FUEL PIPES Service repair no - 19.40.92 WARNING: Depressurise fuel system. See Depressurise Fuel System before disconnecting any fuel pipes ensure that all necessary precautions are taken against fuel spillage WARNING: Ensure fuel handling precautions given in Section 01 - introduction are strictly adhered to when carrying [...]

MFI 19 REPAIR THROTTLE CABLE Service repair no - 19.20.06 Remove 1. Remove clevis pin securing cable to lever. 2. Carefully pry throttle cable adjustment nut out of mounting bracket. 3. Remove cable from mounting bracket. 4. Release outer cable from retaining clips in engine compartment. 5. Remove lower dash panel. 6. Disconnect cable from accelera[...]

19 FUEL SYSTEM 20 REPAIR ACCELERATOR PEDAL Service repair no - 18.30.35 Remove 1. Remove lower dash panel. 2. Remove clevis pin securing throttle cable to accelerator pedal. 3. Release tension from pedal return spring. 4. Remove circlip from pedal pivot pin. 5. Withdraw pivot pin. NOTE: It may be necessary to lower steering column to gain access to[...]

MFI 21 REPAIR 6. Remove access panel from floor. 7. Disconnect multi-plug from fuel sender unit. 8. Disconnect two fuel line unions from fuel pump. 9. Using service tool no. LRT-19-001, remove pump unit retaining ring. Withdraw unit from fuel tank. WARNING: A quantity of fuel will be retained in body of unit, care must be taken to prevent fuel spil[...]

19 FUEL SYSTEM 22 REPAIR FUEL TANK Service repair no - 19.55.01 WARNING: Ensure that fuel handling precautions given in Section 01 - introduction are strictly adhered to when carrying out following instructions. CAUTION: Before disconnecting any part of fuel system, it is imperative that all dust, dirt and debris is removed from around components t[...]

MFI 23 REPAIR 13. Remove back two bolts and nut plates securing fuel tank cradle. 14. Remove front nuts, bolts and washers. Remove fuel tank cradle. 15. With assistance, tilt right hand side of tank upwards and manoeuvre tank through chassis to remove. Refit 16. Reverse removal procedure. Ensuring sealing ring, fuel pipe and hose connections are se[...]

MFI 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Air-Bypass valve (stepper motor) 20 ............................................................... All flexible hose securing clamps 1,3 .......................................[...]

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

SFI 1 DESCRIPTION AND OPERATION ENGINE MANAGEMENT SYSTEM Description The engine management system (EMS) maintains optimum engine performance over the entire operating range. The correct amount of fuel is metered into each cylinder inlet tract and the ignition timing is adjusted at each spark plug. The system is controlled by the ENGINE CONTROL MODU[...]

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

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

19 FUEL SYSTEM 4 DESCRIPTION AND OPERATION Throttle position sensor (TP Sensor) The throttle position sensor is mounted on the plenum chamber and connected directly to the throttle shaft. The sensor is a variable resistor, the signal from which (0 - 5V) informs the ECM of the actual position of the throttle disc. As there is no default strategy, fa[...]

SFI 5 DESCRIPTION AND OPERATION REV: 09/95 Engine fuel temperature sensor (EFT Sensor) This is another resistive sensor. Located on the fuel rail it measures temperature of the rail rather than the fuel. The resistance varies with changes in temperature. The signal is used to increase the injection pulse time when undergoing hot restarts. When the [...]

19 FUEL SYSTEM 6 DESCRIPTION AND OPERATION REV: 09/95 Idle air control (IAC) Idle speed is controlled by a stepper motor which consists of two coils. When energised in the correct sequence the coils move a plunger which opens and closes the throttle bypass controlling the quantity of idle air. The stepper motor controls idle speed by moving the plu[...]

SFI 7 DESCRIPTION AND OPERATION REV: 09/95 Fuel pressure regulator The fuel pressure regulator is located at the rear of the engine in the fuel rail. It consists of a fuel inlet, outlet, vacuum port and internal diaphragm. When the engine is under high manifold depression, the applied vacuum sucks the diaphragm of its seat, allowing fuel to return [...]

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

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

19 FUEL SYSTEM 10 DESCRIPTION AND OPERATION ADD: 09/95 DESCRIPTION AND OPERATION - ADVANCED EVAPS 1. Fuel filter 2. Fuel pump and gauge sender unit 3. Fuel feed hose 4. Fuel return hose 5. Fuel filler neck assembly Fuel Tank Assembly The fuel tank consists of a moulded High Density Polyethylene (HDPE) fuel cell into which is fitted an electric fuel[...]

SFI 11 DESCRIPTION AND OPERATION ADD: 09/95 Fuel Filler Neck Assembly The filler neck consists of a stainless steel upper section and a convolute nylon lower section. The nylon lower is joined at one end to the tank and at the other to the stainless upper section where both joints utilise a short piece of rubber hose. The joint at the fuel tank is [...]

SFI 1 ADJUSTMENT ENGINE TUNING Service repair no - 19.22.13 The position of the Idle Air Control (IAC) valve can be checked using TestBook and adjusted if necessary through the by-pass screw in the plenum chamber. The bypass screw is covered by a tamper proof plug which can be extracted using a self tapping screw. All vehicles: 1. Ensure air condit[...]

SFI 1 REPAIR CAMSHAFT POSITION SENSOR (CMP SENSOR) Service repair no - 19.22.07 Remove 1. Disconnect battery negative lead. 2. Raise vehicle on a ramp. 3. Release sensor mutiplug from clip located on front cover. 4. Disconnect multiplug. 5. Remove bolt securing sensor. 6. Remove sensor from front cover. 7. Remove ’O’ ring from sensor and discar[...]

19 FUEL SYSTEM 2 REPAIR ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) Service repair no - 18.30.10 Remove 1. Disconnect battery negative lead. 2. Remove spring clip and disconnect ECT sensor multiplug. 3. Position cloth around ECT sensor to absorb coolant spillage. 4. Remove ECT sensor. 5. Remove sealing washer and discard. Refit 6. Clean sealing [...]

SFI 3 REPAIR FUEL SYSTEM - DEPRESSURISE WARNING: Fuel pressure of up to 2.5 bar will be present in the system, even if the engine has not been run for some time. Always depressurise the system before disconnecting any components in the fuel feed line (between fuel pump and pressure regulator). The spilling of fuel is unavoidable during this operati[...]

19 FUEL SYSTEM 4 REPAIR ENGINE CONTROL MODULE (ECM) Service repair no - 18.30.01 Remove 1. Disconnect battery negative lead. 2. Release and move washer reservoir aside. See WIPERS AND WASHERS, Repair, Washer Reservoir 3. Remove 2 studs securing ECM cover. 4. Remove cover. 5. Disconnect 3 ECM multiplugs. 6. Remove 2 bolts securing ECM. 7. Release EC[...]

SFI 5 REPAIR FUEL RAIL AND INJECTORS Service repair no - 19.60.04 - Fuel Rail Service repair no - 19.60.12 - Injectors Remove 1. Disconnect battery negative lead. 2. Depressurise fuel system. See Fuel System - Depressurise 3. Release plenum chamber and place aside. See Plenum Chamber 4. Disconnect purge hose, crankcase breather hose, servo vacuum h[...]

19 FUEL SYSTEM 6 REPAIR 15. Disconnect hose, plug return hose and rail. Remove cloth. 16. Remove 6 nuts securing fuel rail and ignition coil bracket to inlet manifold. 17. Release ignition coil bracket from inlet manifold studs. Place aside. 18. Release fuel rail and injectors from inlet manifold. Do not carry out further dismantling if component i[...]

SFI 7 REPAIR FUEL TEMPERATURE SENSOR Service repair no - 19.22.08 Remove NOTE: Because fuel leakage will not occur when sensor is removed, it is not necessary to depressurise the fuel system for this operation. 1. Disconnect battery negative lead. 2. Disconnect multiplug from fuel temperature sensor. 3. Remove sensor from fuel rail. Refit 4. Ensure[...]

19 FUEL SYSTEM 8 REPAIR IGNITION COILS Service repair no - 18.20.45 - Set Service repair no - 18.20.43 - Each Service repair no - 18.20.44 - Extra - Each Remove 1. Disconnect battery negative lead. 2. Disconnect H.T. leads from ignition coils. Note positions of leads. 3. Place H.T. leads aside. 4. Disconnect ignition coil multiplug. 5. Remove 4 nut[...]

SFI 9 REPAIR INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) Service repair no - 18.30.09 Remove 1. Disconnect multiplug from IAT sensor. 2. Remove IAT sensor from air cleaner. Refit 3. Clean sensor and mating face. 4. Fit IAT sensor. Tighten to 8 Nm. 5. Connect multiplug. THROTTLE POSITION SENSOR (TP SENSOR) Service repair no - 19.22.49 Remove 1. Disco[...]

19 FUEL SYSTEM 10 REPAIR KNOCK SENSOR Service repair no - 18.30.28 - Sensor - LH Service repair no - 18.30.30 - Sensor - RH CAUTION: Due to the sensitivity of the sensors, do not apply tape or sealant to sensor threads. Remove 1. Raise vehicle on ramp. 2. RH Sensor only: Remove bolt securing starter motor heatshield to RH engine mounting. 3. Releas[...]

SFI 11 REPAIR FUEL PRESSURE REGULATOR Service repair no - 19.45.06 Remove 1. Disconnect battery negative lead. 2. Depressurise fuel system. See Fuel System - Depressurise 3. Position cloth over fuel feed union, slacken union to release fuel pressure, then re-tighten union. 4. Release fuel return hose clip. Remove fuel return hose from regulator con[...]

19 FUEL SYSTEM 12 REPAIR Refit 15. Ensure locations on fuel pressure regulator and fuel rail are clean. 16. Fit new spacer ring and ’O’ ring to fuel pressure regulator. Lubricate ’O’ ring with silicone grease. 17. Fit pressure regulator assembly to fuel rail. 18. Secure regulator connecting pipe in clip. 19. Secure with bolts. Tighten to 10[...]

SFI 13 REPAIR PLENUM CHAMBER Service repair no - 19.22.46 Remove 1. Disconnect battery negative lead. 2. Slacken clip securing intake hose to plenum chamber and release hose. 3. Remove split pin from throttle cable clevis pin. 4. Remove clevis pin. 5. Release and remove kick down cable clevis pin. 6. Disconnect vacuum hose from cruise actuator. 7. [...]

19 FUEL SYSTEM 14 REPAIR 19. Disconnect hoses and remove plenum chamber. 20. Place cloth over ram pipes to prevent ingress of foreign matter. 21. Remove 4 bolts securing water jacket to plenum chamber. Remove water jacket. Remove gasket and discard. 22. Remove 3 bolts securing throttle linkage bracket to plenum chamber. Remove bracket. Collect retu[...]

SFI 15 REPAIR REV: 09/95 Refit 25. Ensure all mating surfaces are clean. 26. Fit TP sensor. Ensure drive engages correctly with throttle spindle. 27. Position clamp plate. Secure TP sensor with bolts. Tighten to 2 Nm. 28. Using a new gasket, fit IAC. Secure with bolts. Tighten to 2.3 Nm. 29. Ensure mating faces of water jacket and plenum chamber ar[...]

19 FUEL SYSTEM 16 REPAIR ADD: 09/95 RELAY MODULE - ADVANCED EVAPS Service repair no - 18.30.71 Remove 1. Release module from bracket. 2. Disconnect 2 multiplugs from module. 3. Remove module. Refit 4. Position module, connect multiplugs and secure to bracket. FUEL FILTER - ADVANCED EVAPS Service repair no - 19.25.02 Remove WARNING: Spilling of fuel[...]

SFI 17 REPAIR ADD: 09/95 Refit 6. Fit a NEW filter to bracket. NOTE: Ensure direction of flow arrow stamped on canister is correct. 7. Position filter mounting bracket to chassis and secure with nut and bolt. 8. Remove plugs from fuel hose ends. 9. Lubricate NEW ’O’ rings with clean fuel and fit to fuel hoses. 10. Connect fuel hoses to filter a[...]

19 FUEL SYSTEM 18 REPAIR ADD: 09/95 6. Fold back loadspace carpet and sound insulation to reveal access panel. 7. Remove 6 screws securing fuel pump access panel. 8. Remove access panel. 9. Disconnect multiplugs from fuel pump and pressure sensor. 10. Release vent hose from pressure sensor body. 11. Noting their fitted positions, disconnect both fu[...]

SFI 19 REPAIR ADD: 09/95 12. Using service tool LRT-19-009 loosen and remove the metal locking ring. 13. Prise the pump from the tank opening using a blunt instrument under the edge of the pump flange. Once clear of the seal, tip the pump to the right to allow fuel contained in the body of the pump to drain into the tank. CAUTION: Do not lift the p[...]

19 FUEL SYSTEM 20 REPAIR ADD: 09/95 FUEL SYSTEM - DEPRESSURISE - ADVANCED EVAPS Service repair no - 19.50.02 WARNING: Fuel pressure of up to 2.5 bar will be present in the system, even if the engine has not been run for some time. Always depressurise the system before disconnecting any components in the fuel feed line (between fuel pump and pressur[...]

SFI 21 REPAIR ADD: 09/95 5. Fold back loadspace carpet and sound insulation to reveal access panel. 6. Remove 6 screws securing fuel pump access panel. 7. Remove access panel. 8. Disconnect multiplugs from fuel pump and pressure sensor 9. Noting their fitted positions, disconnect both fuel connections by pressing the black release latches on each c[...]

19 FUEL SYSTEM 22 REPAIR ADD: 09/95 12. Mark location of anti-roll [sway] bar straps. 13. Remove nuts and bolts securing anti-roll [sway] bar straps, and allow bar to swing down clear of tank. 14. Disconnect pressure sensor breather pipe connection. 15. Disconnect vent line quickfit connector from liquid/vapour separator. 16. Remove torque screw ca[...]

SFI 23 REPAIR ADD: 09/95 20. Remove nut and bolt securing RH side of upper fuel tank strap to chassis. 21. Remove 4 nuts and bolts securing fuel tank cradle. 22. Remove fuel tank cradle. 23. With assistance, tilt right hand side of tank upwards and manoeuvre through chassis to remove. Do not carry out further dismantling if component is removed for[...]

19 FUEL SYSTEM 24 REPAIR ADD: 09/95 Refit 29. Fit NEW pump seal to tank opening. 30. Carefully lower pump into tank opening, pressing firmly on the pump top flange to allow correct positioning. NOTE: Ensure location tag on pump top flange is engaged correctly to tank opening lip. 31. Fit locking ring and tighten to 35 Nm using service tool LRT-19-0[...]

SFI 25 REPAIR ADD: 09/95 5. Fold back loadspace carpet and sound insulation to reveal access panel. 6. Remove 6 screws securing fuel pump access panel. 7. Remove access panel. 8. Disconnect the fuel return connection by pressing the black release latch on connector and pushing the connector back down the line. Care must be taken to catch any excess[...]

19 FUEL SYSTEM 26 REPAIR ADD: 09/95 FUEL FILLER NECK - ADVANCED EVAPS Service repair no - 19.55.07 WARNING: Ensure that fuel handling precautions given in 1 - Introduction are strictly adhered to when carrying out following instructions. CAUTION: Before disconnecting any part of fuel system, it is imperative that all dust, dirt and debris is remove[...]

SFI 27 REPAIR ADD: 09/95 11. Disconnect vent line quickfit connector from liquid/vapour separator. 12. Remove torque screw cap from hose to tank filler neck clip. 13. Loosen clip screw securing hose to tank filler neck. 14. Release hose from filler neck and internal filler neck breather hose from fuel tank. 15. Remove and discard fuel filler neck c[...]

19 FUEL SYSTEM 28 REPAIR ADD: 09/95 Refit 26. Fit vent line to filler neck. 27. Fit NEW clip to filler neck hose. 28. Fit hose to filler neck. 29. Position filler neck hose clip and tighten until head shears. 30. Fit filler neck assembly to vehicle. NOTE: To aid fitment of filler neck through body grommet apply a soap solution to lip of grommet. 31[...]

SFI 29 REPAIR ADD: 09/95 ANTI-TRICKLE FILL VALVE - ADVANCED EVAPS Service repair no - 19.55.31 Remove 1. Remove the fuel filler neck. See fuel filler neck - advanced evaps 2. Release the cobra clip securing the hose to the liquid/vapour separator and disconnect the hose. 3. Loosen the grub screw on the valve nut, two complete turns. 4. Loosen the v[...]

Mpi 1 DESCRIPTION AND OPERATION DESCRIPTION The Mpi Modular Engine Management System (MEMS) controls the fuel injection and programmed ignition systems. The main features are as follows: • The Engine Control Module (ECM) controls programmed ignition and fuel injection. The ECM incorporates short circuit protection and can store intermittent fault[...]

19 FUEL SYSTEM 2 DESCRIPTION AND OPERATION Basic ignition timing MEMS provides the optimum ignition timing for the relevant engine speed and load. The speed and position of the engine is detected by the crankshaft sensor which is bolted to, and projects through the engine adapter plate. The sensor incorporates an armature which runs adjacent to a r[...]

Mpi 3 DESCRIPTION AND OPERATION Fuel system ECM The MEMS system is controlled by the ECM which is located in the engine compartment. The ECM is an adaptive unit and can learn the load and wear characteristics of a particular engine. The ECM remembers and updates two main engine requirements when the engine is fully warm: 1. The idle stepper positio[...]

19 FUEL SYSTEM 4 DESCRIPTION AND OPERATION Injectors The four fuel injectors are fitted between the pressurised fuel rail and inlet manifold. Each injector comprises of a solenoid operated needle valve and a specially designed nozzle to ensure good fuel atomisation. Engine coolant temperature sensor The coolant temperature sensor is mounted in the [...]

Mpi 5 DESCRIPTION AND OPERATION Fuel pump The electric fuel pump, located inside the fuel tank, is a self-priming centrifugal ’wet’ pump, the motor and pump are filled with fuel. The fuel pump supplies more fuel than the maximum load requirement for the engine, so that pressure in the fuel system can be maintained under all conditions. Fuel pre[...]

19 FUEL SYSTEM 6 DESCRIPTION AND OPERATION Non - evaporative loss equipment 1. Throttle disc 2. Fuel cut-off valve 3. Two way valve 4. Charcoal canister 5. Purge control valve 6. Fuel filler cap 7. ECM 8. One way valve Charcoal canister A charcoal canister is used for the temporary storage of fuel vapour from the fuel tank until the vapour can be p[...]

Mpi 7 DESCRIPTION AND OPERATION MEMS COMPONENTS & LOCATION ON VEHICLE Components Location 1 Fuel pump Fuel tank ............................................................... 2 Fuel filter Right chassis rear ................................................................. 3 Fuel inertia switch Bulkhead ........................................[...]

19 FUEL SYSTEM 8 DESCRIPTION AND OPERATION MEMS COMPONENTS & LOCATION ON ENGINE Components Location 1 Fuel pressure regulator Engine rear ........................................... 2 Intake air temperature sensor Inlet manifold ................................. 3 Crankshaft sensor Under starter motor on flywheel housing .......................[...]

Mpi 9 DESCRIPTION AND OPERATION SYSTEM OPERATION Ignition on When the ignition is switched on, voltage is applied to ECM pin 11. The ECM then switches on the main relay by supplying an earth path at pin 4. This allows battery voltage to pass to ECM pin 28, to the four injectors and through the ignition coil to ECM pin 25. In addition, the fuel pump[...]

19 FUEL SYSTEM 10 DESCRIPTION AND OPERATION Driving When the throttle pedal is depressed, the ECM implements the cruise air/fuel ratio map. During driving the ECM continually monitors inlet air temperature and engine speed and load for it’s air flow calculations, together with coolant temperature for any temperature corrections. Additional inputs[...]

Mpi 1 ADJUSTMENT THROTTLE CABLE Adjust NOTE: Use diagnostic equipment to ensure that the throttle potentiometer and stepper motor are synchronised before adjusting the throttle cable. Ensure that the cable is correctly routed and located. 1. Switch ignition on, wait 5 seconds and switch ignition off to ensure stepper motor is in setting position. 2[...]

Mpi 1 REPAIR KNOCK SENSOR Service repair no - 18.30.18 Remove 1. Disconnect multiplug from knock sensor. 2. Remove knock sensor. Refit 3. Clean mating face of cylinder block. 4. Fit knock sensor. Tighten to 15 Nm 5. Connect multiplug. IGNITION COILS Service repair no - 18.20.40 - 1 & 4 Cylinders Service repair no - 18.20.41 - 2 & 3 Cylinder[...]

19 FUEL SYSTEM 2 REPAIR COOLANT TEMPERATURE SENSOR Service repair no - 18.30.10 Remove 1. Position drain tin below coolant pump hose. 2. Disconnect sensor multiplug. 3. Release harness clip and harness. 4. Remove sensor. Refit 5. Clean sensor. 6. Fit sensor and tighten to the correct torque. 7. Position harness and secure with clip. 8. Connect mult[...]

Mpi 3 REPAIR FUEL TEMPERATURE SENSOR Service repair no - 18.30.08 Remove 1. Disconnect fuel temperature sensor multiplug. 2. Remove fuel temperature sensor. 3. Discard sealing washer. Refit 4. Clean mating face of fuel rail. 5. Fit a new sealing washer to sensor. 6. Fit temperature sensor. Tighten to 7N m 7. Connect fuel temperature sensor multiplu[...]

19 FUEL SYSTEM 4 REPAIR CHARCOAL CANISTER Service repair no - 17.15.13 Remove 1. Disconnect multiplug from purge valve. 2. Release clip and disconnect hose from purge valve. 3. Release clip and disconnect fuel tank hose from charcoal canister. 4. Unscrew bolt to release securing strap and remove charcoal canister. Refit 5. Fit charcoal canister and[...]

Mpi 5 REPAIR 6. Remove nut securing throttle cable bracket to brake servo and release cable. 7. Release grommet from bulkhead and withdraw cable. 8. Locate cable in bulkhead. 9. Connect cable to throttle pedal. 10. Connect cable to cam. 11. Adjust throttle cable. THROTTLE POTENTIOMETER Service repair no - 19.22.49 Remove 1. Disconnect throttle pote[...]

19 FUEL SYSTEM 6 REPAIR INTAKE AIR TEMPERATURE SENSOR Service repair no - 18.30.09 Remove 1. Disconnect multiplug from temperature sensor. 2. Remove sensor from inlet manifold. Refit 3. Clean sensor threads and mating face. 4. Fit sensor to inlet manifold. Tighten to 7N m 5. Connect multiplug to sensor. PURGE CONTROL VALVE Service repair no - 17.15[...]

Mpi 7 REPAIR FUEL RAIL AND INJECTORS Service repair no - 19.60.04 - Rail Service repair no - 19.60.10 - Injectors Remove 1. Remove inlet manifold chamber gasket. See MANIFOLD AND EXHAUST SYSTEM, Repair, Manifold Chamber Gasket - Mpi 2. Remove pressure regulator. 3. Remove 4 bolts securing fuel feed hose flange stiffening bracket, remove stiffening [...]

19 FUEL SYSTEM 8 REPAIR Refit 17. Clean fuel rail, temperature sensor and pressure regulator mating surfaces. 18. Fit fuel temperature sensor. Tighten to 7N m 19. Clean injectors and injector recesses in fuel rail and inlet manifold. 20. Fit new ’O’ ring(s) to inlet end of injector(s). 21. Fit injector(s) to fuel rail, fit and secure clip(s). 2[...]

Mpi 9 REPAIR Refit 9. Examine flexible mounting for splits or damage; renew as necessary. 10. Thoroughly clean throttle housing and mating face of flexible mounting. 11. Connect breather hose to throttle housing. 12. Position throttle housing to mounting studs, fit nuts. Tighten to 7 Nm. 13. Connect throttle cable to cam. 14. Adjust throttle cable.[...]

19 FUEL SYSTEM 10 REPAIR Refit 9. Clean pressure regulator and mating surfaces. 10. Fit new ’O’ ring to pressure regulator. 11. Fit vacuum hose to pressure regulator. 12. Position pressure regulator. 13. Fit steady bracket. 14. Fit bolts and tighten. 15. Connect multiplug to air temperature sensor. 16. Remove plugs, fit fuel hose to regulator a[...]

Mpi 11 REPAIR AIR CLEANER Service repair no - 19.10.01 Remove 1. Release clip and remove intake hose from air cleaner. 2. Ease air cleaner assembly bottom mounting rubbers from body. 3. Ease air cleaner from inner wing [fender] mounting rubber 4. Remove air cleaner. Do not carry out further dismantling if component is removed for access only. 5. Re[...]

CRUISE CONTROL 1 DESCRIPTION AND OPERATION CRUISE CONTROL COMPONENT LOCATIONS - Tdi AUTO EDC COMPONENT LOCATION 1. Cruise control unit Under LH dash ................................................... 2. Engagement (on/off) switch Dash panel .................................... 3. Cruise control switch Steering wheel ...............................[...]

19 FUEL SYSTEM 2 DESCRIPTION AND OPERATION CRUISE CONTROL SYSTEM - V8i/Tdi AUTO EDC Description The cruise control system consists of electro-mechanical devices, and comprises of the following components. ELECTRONIC CONTROL UNIT (ECU) The microprocessor based ECU evaluates the signals provided by the driver controls, brake pedal switch, clutch peda[...]

CRUISE CONTROL 1 FAULT DIAGNOSIS ROAD TEST CAUTION: Do not engage cruise control when vehicle is being used in low transfer gear or reverse. WARNING: The use of cruise control is not recommended on winding, snow covered or slippery roads or in heavy traffic conditions where a constant speed cannot be maintained. 1. Start engine, depress main contro[...]

CRUISE CONTROL 1 REPAIR BRAKE AND CLUTCH PEDAL SWITCHES/VENT VALVES Service repair no - 19.75.34 - Clutch Switch Service repair no - 19.75.35 - Brake Switch Remove 1. Remove 3 studs securing driver’s side fascia closing panel. 2. Release and move closing panel aside. 3. Locate and release locking sleeve. 4. Release switch/vent valve from pedal br[...]

19 FUEL SYSTEM 2 REPAIR ENGAGEMENT (ON/OFF) SWITCH Service repair no - 19.75.30 Switch Replacement Remove 1. Disconnect battery negative lead. 2. Carefully release auxiliary switch panel from fascia. 3. Disconnect multiplug from switch. 4. Depress retaining lugs on switch, remove switch from panel. Bulb replacement 5. Position switch to facilitate [...]

CRUISE CONTROL 3 REPAIR 5. Disconnect 2 Lucars from horn contacts. 6. Remove 2 screws securing cruise control switch to steering wheel. 7. Remove 3 bolts securing mounting bracket to steering wheel and remove mounting bracket. 8. Remove cruise control switch from steering wheel. Refit 9. Reverse removal procedure. Ensuring wiring harness is routed [...]

19 FUEL SYSTEM 4 REPAIR NOTE: If rotary coupler is to be re-used a piece of adhesive tape should be placed around the moulding in position A to prevent rotation. Failure to do this may result in damage to the wires inside the coupler. 6. Release clips securing rotary coupler to column stalk assembly. 7. Remove rotary coupler from column stalk assem[...]

CRUISE CONTROL 5 REPAIR ACTUATOR LINK-SETTING - V8i Service repair no - 19.75.21 NOTE: Setting procedure is carried out at minimum throttle condition only. 1. Ensure ignition is switched ’OFF’. 2. Check clearance between inside edge of actuator link and recessed diameter of throttle lever. Clearance should be 0.2 to 2.0 mm. Link - adjust 3. Rem[...]

19 FUEL SYSTEM 6 REPAIR VACUUM PUMP - TDI Service repair no - 19.75.06 NOTE: The vacuum pump is non serviceable, fit a new unit if failure or damage occurs. Remove 1. Release turnbuckle securing wheel chock and remove. 2. Release strap securing jack and remove. 3. Release 3 pump mounting rubbers from vehicle body. 4. Manoeuvre pump out of box secti[...]

CRUISE CONTROL 7 REPAIR CRUISE CONTROL ECU - V8i Service repair no - 19.75.49 Remove 1. Remove lower dash panel. 2. Disconnect ECU multi-plug. 3. Remove ECU fixing. 4. Remove ECU. 5. Reverse removal procedure. Ensuring that electrical multi-plug is securely reconnected. SPEED TRIP ECU - MANUAL V8i NOTE: The neutral lock out relay module/speed trip [...]

19 FUEL SYSTEM 8 REPAIR ACTUATOR - Tdi Service repair no - 19.75.05 NOTE: The actuator is non serviceable, fit a new unit if failure or damage occurs. Remove 1. Disconnect battery negative lead. 2. Remove split pin, withdraw clevis pin and disconnect cable from lever. 3. Disconnect link ball end from cable lever. 4. Disconnect vacuum hose from actu[...]

CRUISE CONTROL 9 REPAIR CRUISE CONTROL ECU - Tdi Service repair no - 19.75.49 Remove 1. Remove 4 studs securing fascia left hand closing panel. 2. Remove closing panel. 3. Remove nut securing ECU/relay bracket. 4. Lower bracket for access. 5. Remove bottom nut securing ECU to bracket. 6. Open glove box, align stops with cut-outs in fascia panel and[...]

Tdi 1 DESCRIPTION AND OPERATION ENGINE COOLING Description The Tdi engine uses a pressurized cooling system and cross flow radiator which is supplied from a separate header tank. The radiator assembly is in three sections. The largest section is for engine coolant and the other two sections which are cast in aluminium, are the engine oil cooler and[...]

26 COOLING SYSTEM 2 DESCRIPTION AND OPERATION VISCOUS FAN Description The viscous drive unit for the engine cooling fan, provides a means of controlling the speed of the fan relative to the running temperature of the engine. The viscous unit is a type of fluid coupling, which drives the fan blades through the medium of a special ’silicone fluid?[...]

Tdi 3 DESCRIPTION AND OPERATION Viscous unit slipping (Engine at normal running temperature) 1. Inner member (drive in fast) 2. Outer member (drive out slow) 3. Running clearance 4. Valve plate 5. Valve (closed) 6. Bi-metal 7. Fluid seals 8. Ball race A Fluid chamber B Fluid chamber If the engine speed is increased the degree of slip will also incr[...]

Tdi 1 FAULT DIAGNOSIS ENGINE OVERHEATING Before conducting any cooling system diagnosis: See Description and operation, Engine Cooling 1. Is coolant level correct? NO - Allow engine to cool, top up level to expansion tank seam. YES - Continue. 2. Is drive belt tension correct? NO - See ENGINE, Repair, Compressor Drive Belt YES - Continue. 3. Is coo[...]

26 COOLING SYSTEM 2 FAULT DIAGNOSIS ENGINE RUNS COLD Before conducting any cooling system diagnosis: See Description and operation, Engine Cooling 1. Check operation of viscous unit. See Description and operation, Viscous Fan Is viscous unit operating correctly? NO - See Repair, Viscous Coupling, Fan Blades, Pulley and Fan Cowl YES - Continue. 2. I[...]

Tdi 1 ADJUSTMENT COOLANT Service repair no - 26.10.01 Draining WARNING: Do not remove any caps or plugs when the engine is hot. The cooling system is pressurised and personal scalding could result. 1. Remove expansion tank filler cap. 2. Disconnect bottom hose from radiator and allow coolant to drain into a container. Ensure container is clean if r[...]

Tdi 1 REPAIR VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL Service repair no - 26.25.03/05 Viscous coupling - Remove 1t o3 Fan blades - Remove 1t o4 Fan cowl - Remove 1t o3 Fan pulley - Remove 1t o6 Remove WARNING: Disconnect battery negative terminal to prevent engine being started before removing or adjusting drive belt. 1. Slacken nut securi[...]

26 COOLING SYSTEM 2 REPAIR WATER PUMP Service repair no - 26.50.01 Remove WARNING: Disconnect battery negative terminal to prevent engine being started before removing drive belts. 1. Drain engine cooling system. See Adjustment, Coolant 2. Remove top hose radiator to thermostat. 3. Remove top hose intercooler to induction manifold. 4. Slacken water[...]

V8i 1 DESCRIPTION AND OPERATION ENGINE COOLING Description The V8i engine uses a pressurised cooling system and cross flow radiator which is supplied from a separate header tank. The coolant radiator also incorporates a section at the left hand end for cooling the transmission oil and a section at the other end for cooling the engine oil. The belt [...]

26 COOLING SYSTEM 2 DESCRIPTION AND OPERATION COOLANT CIRCULATION Operation When the engine is started from cold the thermostat prevents any coolant circulation through the radiator by closing off the top hose. During the engine warm up period, the water pump, pumps coolant around the cylinders to the rear of the cylinder block along the main galle[...]

V8i 3 DESCRIPTION AND OPERATION Plenum chamber heating Air entering the plenum chamber is heated by a flow of coolant from the inlet manifold which returns through a long hose, to the top right corner of the radiator. 1. Hot water supply 2. Cold return to radiator VISCOUS FAN Description The viscous drive unit for the engine cooling fan, provides a[...]

26 COOLING SYSTEM 4 DESCRIPTION AND OPERATION Operation The viscous unit consists of two principal components: An inner member 1 which is secured to water pump spindle and is driven by the fan belt. An outer member 2 which has the fan blades attached, houses the working parts and is driven through the medium of the viscous fluid. The inner and oute[...]

V8i 5 DESCRIPTION AND OPERATION Hot conditions When operating in high ambient temperatures or when stationary in traffic, the bi-metal thermostat will operate and open the valve port between chambers A and B. Opening the valve (as shown in RR3758M) allows the fluid to circulate between the two members, causing the unit to couple, thus increasing th[...]

V8i 1 FAULT DIAGNOSIS ENGINE OVERHEATING Before conducting any cooling system diagnosis: See Description and operation, Engine Cooling 1. Is coolant level correct? NO - Allow engine to cool, top up level to expansion tank seam. YES - Continue. 2. Is drive belt tension correct? NO - See ENGINE, Repair, Drive Belt - Check Tension YES - Continue. 3. I[...]

26 COOLING SYSTEM 2 FAULT DIAGNOSIS ENGINE RUNS COLD Before conducting any cooling system diagnosis: See Description and operation, Engine cooling 1. Check operation of viscous unit. See Description and operation, Viscous Fan Is viscous unit operating correctly? NO - See Repair, Viscous coupling, fan blades, pulley and fan cowl YES - Continue. 2. I[...]

V8i 1 ADJUSTMENT COOLANT REQUIREMENTS Frost precautions and engine protection. Cooling system MUST ALWAYS be filled and topped-up with solution of water and anti-freeze, winter and summer. NEVER use water alone, this may corrode aluminium alloy. CAUTION: Do not use salt water otherwise corrosion will occur. In certain territories where only availab[...]

26 COOLING SYSTEM 2 ADJUSTMENT 3. Disconnect bottom hose from radiator. Drain coolant into a clean container. Reconnect bottom hose, re-tighten hose clamp. NOTE: It is not possible to drain all coolant retained in heater system. It is not desirable to flush through system, after draining. 4. Remove engine drain plugs, one each side of cylinder bloc[...]

V8i 1 REPAIR EXPANSION TANK Service repair no - 26.15.01 Remove WARNING: Do not remove expansion tank filler cap when engine is hot. The cooling system is pressurised and personal scalding could result. 1. Remove expansion tank filler cap by first turning it slowly anti-clockwise, pause to allow pressure to escape. Continue turning in same directio[...]

26 COOLING SYSTEM 2 REPAIR 3. Use LRT-12-093 to prevent coolant pump pulley from turning and using LRT-12-094, unscrew viscous coupling from water pump. NOTE: Nut securing viscous unit to water pump has a right hand thread. Release by turning anti-clockwise when viewed from front of viscous unit. 4. Remove fan and coupling assembly. Do not carry ou[...]

V8i 3 REPAIR THERMOSTAT Service repair no - 26.45.01 Remove 1. Partially drain cooling system, until coolant level is below thermostat housing. 2. Disconnect hose from thermostat housing. 3. Disconnect electrical connections to water temperature switch. 4. Remove outlet elbow. 5. Withdraw thermostat. Test 6. Note rating of thermostat is 88 ° C. Pl[...]

26 COOLING SYSTEM 4 REPAIR RADIATOR Service repair no - 26.40.01 Remove 1. Drain cooling system. See Adjustment, Coolant 2. Remove viscous coupling and fan assembly. See Viscous Coupling, Fan Blades, Pulley and Fan Cowl 3. Release 2 clips and remove fan cowl. 4. Disconnect radiator top hoses. 5. Disconnect four transmission and engine oil cooler co[...]

V8i 5 REPAIR[...]

26 COOLING SYSTEM 6 REPAIR WATER PUMP Service repair no - 26.50.01 Remove WARNING: Disconnect battery negative terminal to prevent engine being started before removing or adjusting drive belts. 1. Drain engine cooling system. See Adjustment, Coolant 2. Remove fan blades and pulley. See Viscous Coupling, Fan Blades, Pulley and Fan Cowl 3. Disconnect[...]

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

Mpi 1 REPAIR COOLANT PUMP Service repair no - 26.50.01 Remove 1. Position drain tin below coolant pump hose. WARNING: Do not carry out the next instruction until the coolant is cool to avoid personal injury from scalding. 2. Release clip and disconnect hose from coolant pump housing cover. 3. Remove 5 bolts securing housing cover. 4. Remove housing[...]

26 COOLING SYSTEM 2 REPAIR RADIATOR Service repair no - 26.40.01 Remove 1. Disconnect battery negative lead. WARNING: Do not carry out the next instruction until the coolant is cool to avoid personal injury from scalding. 2. Slacken clip and release bottom hose from radiator, allow coolant to drain into a suitable container 3. Slacken clip and rele[...]

Mpi 3 REPAIR 12. With assistance lift out radiator assembly. Do not carry out further dismantling if component is removed for access only. 13. Remove 2 bolts securing radiator rail to radiator. 14. Remove radiator rail. 15. Remove 8 nuts securing fan assemblies to radiator. NOTE: Vehicles without air conditioning have one cooling fan fitted. Refit [...]

26 COOLING SYSTEM 4 REPAIR THERMOSTATIC SENSOR Service repair no - 19.22.18 Remove 1. Disconnect Lucar connector from sensor. 2. Remove sensor. Refit 3. Clean sensor. 4. Apply Loctite 405 to threads of sensor. 5. Fit sensor and tighten to 15Nm 6. Connect Lucar to sensor. 7. Top-up cooling system. THERMOSTAT Service repair no - 26.45.01 Remove 1. Po[...]

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

MANIFOLD AND EXHAUST SYSTEM 1 DESCRIPTION AND OPERATION CATALYTIC CONVERTERS - V8i Description Catalytic converters which form part of the engine emission control system, are designed to ’clean’ the exhaust gases, by closely controlling the fuel air ratio delivered to the engine and converting the residual exhaust compounds into products more a[...]

MANIFOLD AND EXHAUST SYSTEM 1 REPAIR EXHAUST SYSTEM COMPLETE Service repair no - 30.11.01 To improve sealing and accuracy of assembly, a two piece exhaust system is fitted. NOTE: Ensure no exhaust leaks are evident in either a new or old exhaust system, as this will affect vehicle performance. WARNING: To prevent personal injury occurring from a ho[...]

30 MANIFOLD AND EXHAUST SYSTEM 2 REPAIR Remove Catalysts - remove and refit 1 to 5 1. Raise vehicle on a ramp [hoist]. 2. Catalyst vehicles only: Disconnect two heated oxygen sensor wiring connectors. NOTE: NAS models have four heated oxygen sensors fitted. 3. Remove two nuts securing rear exhaust assembly to front exhaust assembly. 4. Remove nuts [...]

MANIFOLD AND EXHAUST SYSTEM 3 REPAIR MANIFOLD AND EXHAUST SYSTEM - Tdi Remove 1. Raise vehicle on a ramp [hoist]. 2. Remove anti-roll[sway] bar bolts to chassis and allow to swing down clear of axle. See REAR SUSPENSION, Repair, Anti-roll [sway] Bar Assembly Rear 3. Remove exhaust support bracket behind catalyst. 4. Disconnect exhaust at manifold. [...]

30 MANIFOLD AND EXHAUST SYSTEM 4 REPAIR EXHAUST MANIFOLD - Tdi Service repair no - 30.15.10 Remove 1. Disconnect battery negative lead. 2. Remove heat shield from rear of air intake manifold. 3. Release dip stick tube from cylinder block. 4. Disconnect the intake hose from the manifold. 5. Remove the two bolts and two nuts securing the intake manif[...]

MANIFOLD AND EXHAUST SYSTEM 5 REPAIR INLET MANIFOLD GASKET - Mpi Service repair no - 30.15.08 Remove 1. Disconnect battery negative lead. 2. Position absorbent cloth around fuel pipe to fuel rail union. Unscrew union to relieve fuel pressure. Re-tighten union. CAUTION: Plug connections. 3. Release clip and remove air cleaner to throttle housing hos[...]

30 MANIFOLD AND EXHAUST SYSTEM 6 REPAIR 10. Release clip and disconnect breather hose from manifold. 11. Release 2 bolts securing cam cover brackets to manifold. 12. Remove 3 bolts securing engine harness to manifold. 13. Disconnect 3 vacuum hoses from manifold. 14. Release clip and disconnect fuel hose from pressure regulator. CAUTION: Plug the co[...]

MANIFOLD AND EXHAUST SYSTEM 7 REPAIR Refit 19. Ensure mating faces of inlet manifold and cylinder head are clean. 20. Fit a new gasket, position inlet manifold to cylinder head. 21. Fit nuts and bolts, tighten in the order shown to the correct torque 25Nm 22. Position engine breather hose to manifold and secure with bolts. 23. Connect fuel injector[...]

30 MANIFOLD AND EXHAUST SYSTEM 8 REPAIR 6. Disconnect oxygen sensor multiplug. 7. Release multiplug from bracket on thermostat housing. 8. Release harness from cable tie. 9. Remove drive belt. 10. Remove 2 front bolts securing generator to mounting bracket. 11. Remove 2 rear bolts securing generator to mounting bracket. 12. Move generator from moun[...]

MANIFOLD AND EXHAUST SYSTEM 9 REPAIR MANIFOLD CHAMBER GASKET - Mpi Service repair no - 30.15.37 Remove 1. Disconnect battery negative lead. 2. Position absorbent cloth around fuel pipe to fuel rail union. Loosen union to relieve pressure. Re-tighten union. 3. Release clip and remove air cleaner to throttle housing hose. 4. Disconnect stepper motor [...]

30 MANIFOLD AND EXHAUST SYSTEM 10 REPAIR 10. Release clip and disconnect breather hose from manifold. 11. Release 2 bolts securing camshaft cover brackets to manifold. 12. Disconnect 4 vacuum hoses from manifold. 13. Remove 6 bolts securing manifold chamber to lower manifold. 14. Remove manifold chamber and collect gaskets. Refit NOTE: For torque v[...]

MANIFOLD AND EXHAUST SYSTEM 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm MANIFOLDS AND EXHAUSTS - Mpi Inlet manifold nuts and bolts 25 ...................................................................... Fuel pipe to fuel ra[...]

CLUTCH 1 DESCRIPTION AND OPERATION DESCRIPTION The clutch unit fitted with the manual transmission, comprises a single dry plate friction disc and diaphragm spring clutch unit, secured to the engine flywheel. OPERATION The unit is operated hydraulically by the clutch master cylinder 12 and a slave cylinder 13 attached to the transmission bell housi[...]

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

CLUTCH 1 FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS For the clutch to operate correctly as described and illustrated in the "Description and Operation", it is important the following conditions are satisfied:- A. The primary shaft 15 must be free in the crankshaft spigot bush 17. B. The friction plate 2 must be able to slide easily on the[...]

33 CLUTCH 2 FAULT DIAGNOSIS FAULT/SYMPTOM CHART Symptoms Slip Spin/Drag Judder/Fierce Fault Item * * * Worn or oil on clutch linings 2 * * * Mechanical damage 45678 * * Distorted clutch plate 2 * Failed or air in hydraulic system 12 13 * * Primary shaft tight fit in crankshaft bush 15 17 * Clutch splines sticking 2 15 * Weak clutch plate springs or[...]

CLUTCH 1 REPAIR CLUTCH ASSEMBLY Service repair no - 33.10.01 Clutch pressure plate Renew pressure plate if diaphragm spring fingers are worn or if pressure plate shows signs of wear, cracks or burning. Clutch driven plate Renew driven plate if centre hub splines are worn or if lining is contaminated, burned or unevenly worn. Service tools: Clutch c[...]

33 CLUTCH 2 REPAIR BLEED HYDRAULIC SYSTEM Service repair no - 33.15.01 Procedure NOTE: During bleed procedure, keep fluid reservoir topped up to avoid introducing air to system. For hydraulic fluid recommendations. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids 1. Attach suitable tubing to slave cylinder bleed[...]

CLUTCH 3 REPAIR Refit 7. Fit the master cylinder and fixings. 8. Fit push-rod to pedal and retain with clevis pin and washer. 9. Raise fasica fuse box panel. 10. Fit fluid pipe to master cylinder. 11. Bleed system. See Bleed Hydraulic System RELEASE BEARING ASSEMBLY Service repair no - 33.10.07 Remove 1. Remove gearbox. See MANUAL GEARBOX, Repair, [...]

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

CLUTCH 5 REPAIR RENEWING HYDRAULIC DAMPER - Tdi Service repair no - 33.15.05 NOTE: All flexible and pipe connections and joints should be tightened to 15 Nm. Remove 1. Remove the pipe between the slave cylinder and damper. 2. Disconnect the hydraulic hose from the damper. 3. Remove the two bolts securing the damper to the bracket and remove the dam[...]

CLUTCH 1 OVERHAUL MASTER CYLINDER Service repair no - 30.20.07 1. Remove master cylinder. See Repair, Master Cylinder Disassemble 2. Pull back and remove rubber sealing boot from pushrod. 3. Depress push-rod and extract circlip. 4. Withdraw push-rod assembly. 5. Withdraw piston assembly. 6. Withdraw retainer and spring. 7. Remove two piston seals a[...]

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

CLUTCH 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Clutch pipes Master cylinder union 15 ................................................................................. Pipe joint 15 ........................................[...]

R380 1 DESCRIPTION AND OPERATION MANUAL TRANSMISSION Description The all synchromesh five speed manual gearbox unit, is married to a LT230T two speed transfer gearbox. All the gears including reverse run on needle roller bearings and the main, layshaft and primary shafts are supported by tapered roller bearings. The whole of the geartrain is lubric[...]

R380 1 FAULT DIAGNOSIS MANUAL GEARBOX Symptom - Gear jumps out of engagement (any forward gear) 1. Check condition and security of transmission and engine mountings. 2. Check in situ, gear lever and selector adjustments. 3. In situ, remove gearshift and check selector rail yoke security. Also check selector detent spring tension and both spool reta[...]

37 MANUAL GEARBOX 2 FAULT DIAGNOSIS Symptom - Noise from gearbox in neutral, which disappears when clutch is depressed. 1. Check lubricant specification and level, if low do not top up at this stage. 2. Drain lubricant and check for contamination or metal particles. Suspect worn bearings on layshaft, primary shaft or front of main shaft. See remove[...]

R380 1 REPAIR R380 MANUAL GEARBOX Service repair no - 37.20.02 Remove WARNING: Where the use of a transmission hoist is necessary, it is absolutely essential to follow the manufacturer’s instructions to ensure safe and effective use of equipment. 1. Install vehicle on a ramp [hoist]. 2. Disconnect battery earth lead. 3. Remove centre console. See[...]

37 MANUAL GEARBOX 2 REPAIR 25. Remove nuts and bolts securing transmission cross-member to chassis. 26. Remove nuts and bolts securing cross-member mountings to transmission. 27. Remove cross-member. 28. Manufacture an adapter plate to dimensions given in service tool section and attach it to a transmission hoist. To achieve balance of the transmis[...]

R380 3 REPAIR Assembling transfer gearbox to main gearbox 45. Clean extension housing and transfer gearbox mating faces. 46. Ensuring loose upper dowel is fitted, hoist transfer gearbox into position. 47. Fit and tighten nut and bolts to 34Nm. 48. Connect high/low operating rod, fit and tighten locknut. 49. Fit link to differential lock lever and s[...]

R380 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Slave cylinder to bell housing 25 .................................................................... Breather 15 .............................................................[...]

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

TRANSFER GEARBOX 1 DESCRIPTION AND OPERATION LT230T TRANSFER BOX The LT230T transfer box is a permanent 4 wheel drive, two speed ratio reducing gearbox incorporating high and low range outputs with mechanically lockable centre differential (diff-lock). High/low range and diff-lock selection are made via a single lever located forward of the main ge[...]

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

TRANSFER GEARBOX 3 DESCRIPTION AND OPERATION DIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY 1. Differential selector assembly 2. Front output housing 3. High-low ratio cross shaft assembly 4. High-low selector shaft and lever 5. High-low selector fork and shaft 6. High-low selector finger 7. Differential lock selector shaft 8. Differential lock selector fo[...]

41 TRANSFER GEARBOX 4 DESCRIPTION AND OPERATION INTERMEDIATE GEAR AND POWER TAKE OFF ASSEMBLY 1. Transfer case assembly 2. Transfer case bottom cover 3. Intermediate shaft and ’O’ ring 4. Oil seal 5. Retaining plate and anchor screw 6. Intermediate shaft nut 7. Bearing 8. Transfer mainshaft gear 9. Selective shim 10. Mainshaft transfer bearing [...]

TRANSFER GEARBOX 5 DESCRIPTION AND OPERATION TRANSFER GEAR SELECTOR COMPONENTS 1. Gaiter retaining screw - 4 off 2. Gaiter 3. Gaiter support plate 4. Gate plate 5. Gasket 6. Clip 7. Pin 8. Circlip, retaining nylon seat 9. Gear lever ball 10. Nylon seat 11. Cross shaft 12. Gear lever 13. Gear change housing 14. Non-metallic bushes 15. Countersunk sc[...]

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

41 TRANSFER GEARBOX 2 FAULT DIAGNOSIS PROCEDURE Prior to road test 1. Check oil level in transfer box is correct. 2. Check tightness of level and drain plugs. 3. Check breather system for blockage. To validate the system the pipe must be removed, inspected, rectified as necessary and refitted. 4. Remove all traces of oil from exterior of transfer b[...]

TRANSFER GEARBOX 1 REPAIR LT230T TRANSFER GEARBOX Service repair no - 41.10.25 Remove Adaptor plate for removing transfer gearbox The transfer gearbox is removed from underneath the vehicle. Using a transmission hoist with an adaptor plate for securing the transfer gearbox to the hoist. The adaptor can be manufactured locally to the drawing below. [...]

41 TRANSFER GEARBOX 2 REPAIR Remove 1. Site vehicle on a ramp [hoist]. 2. Disconnect battery negative lead. 3. Remove fan cowl from radiator. 4. Remove transfer gear lever knob and gaiter. 5. Raise vehicle on ramp [hoist]. 6. Drain oil and refit plug. 7. Detach heat shield at front exhaust pipe to manifold. 8. Disconnect electrics to Lambda sensors[...]

TRANSFER GEARBOX 3 REPAIR Refit 36. Select ’P’ in main gearbox, with low range and differential lock selected in transfer gearbox. 37. Secure transfer gearbox to adaptor plate on lifting hoist. 38. Ensure joint faces of transfer and main gearboxes are clean and guide studs 18G 1425 are fitted. 39. Raise hoist until transfer gearbox can be locat[...]

41 TRANSFER GEARBOX 4 REPAIR SHIFTLOCK SOLENOID/NEUTRAL SWITCH Service repair no - 41.10.63/64 This is sited on top of the transfer gearbox. Access to the component is gained through the transmission tunnel aperture. Remove 1. Disconnect battery negative lead. 2. Remove centre console. See CHASSIS AND BODY, Repair, Centre Console 3. Remove rear pas[...]

TRANSFER GEARBOX 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm LT230T Transfer gearbox Pinch bolt - operating arm to crank arm 9 ...................................................... End cover gear change housing 9 ...........[...]

41 TRANSFER GEARBOX 2 SPECIFICATIONS, TORQUE LT230T TRANSFER GEARBOX DATA High range gear end - float 0,05 to 0,15 mm .............................................. Front differential bearing pre - load 0.56 to 1.69 Nm .................................. Input gear bearing pre - load 0.56 to 2.25 Nm ............................................ Inter[...]

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

ZF 1 DESCRIPTION AND OPERATION DESCRIPTION The automatic transmission is specially tailored version of the ZF4 HP22, used by many manufacturer’s of high performance vehicles. A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third gears are reduction ratios but fourth is an overdrive gea[...]

44 AUTOMATIC GEARBOX 2 DESCRIPTION AND OPERATION Power flow 1st gear D selected With D selected 1st gear engaged, clutches 4 and 11 are operative. The front planet gear carrier of gear set 9 is locked against the housing through freewheel 15 when the engine is pulling but freewheels when the vehicle is coasting. Epicyclic gear set 10 rotates as a s[...]

ZF 3 DESCRIPTION AND OPERATION 3rd gear D selected Clutches 4, 5, 7 and 11 are engaged. Freewheel 15 and 16 are overrun. Epicyclic gear set 9 and 10 rotate as a solid unit at a ratio of 1:1. 4th gear D selected Clutches 4, 5, 7 and 12 are engaged. Freewheel 14, 15 and 16 are overrun. Epicyclic gear set 9 rotates as a solid unit. The hollow shaft wi[...]

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

ZF 1 FAULT DIAGNOSIS ZF AUTOMATIC GEARBOX Before referring to fault symptoms, carry out initial static checks first: INITIAL STATIC CHECKS Check start positions ’P’ & ’N’ only ........................................................ Reverse lights ’R’ only .................................................................. Gear engag[...]

44 AUTOMATIC GEARBOX 2 FAULT DIAGNOSIS ROAD TEST PROCEDURE Follow the procedure given commencing each test, from a standing start, on a level road, in good weather conditions. ROADTEST 1 = CHECKS 1-2-3-4-5-6-7-8 D SELECTED KICKDOWN START FROM REST CHECK 1 Check for clutch squeal and slip. Check pressure is 150lbf/in 2 CHECK 2 Check 1st to 2nd upshi[...]

ZF 3 FAULT DIAGNOSIS ROADTEST 3 = CHECKS 12-13-14-15-16-17-18-19-20-21-22-23 D SELECTED FROM REST LIGHT THROTTLE START CHECK 12 Check 1st 2nd upshift speed and quality. CHECK 13 Check 2nd 3rd upshift speed and quality. CHECK 14 Check 3rd 4th upshift speed and quality. NOTE: This shift is usually very difficult to detect but can be confirmed by a 20[...]

44 AUTOMATIC GEARBOX 4 FAULT DIAGNOSIS AUTOMATIC GEARBOX ASSEMBLY ILLUSTRATED 1. Gearbox assembly 2. Inhibitor switch assembly 3. Control unit assembly 4. Filter and sump assembly[...]

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

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

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

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

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

44 AUTOMATIC GEARBOX 10 FAULT DIAGNOSIS FAULT SYMPTOMS SYMPTOM 1 - Intermittent drive and high pitched noise FAULT - Low fluid level or restricted filter SYMPTOM 2 - No drive in reverse Select ’D’ œ No drive FAULT - Continue with Symptom 3 œ Drives forward FAULT - Reverse gear interlock valve seized Select ’1’ œ No engine braking FAULT -[...]

ZF 11 FAULT DIAGNOSIS SYMPTOM 10 - None or harsh engagement of direct drive clutch NOTE: The direct drive clutch will only engage if 4th gear is engaged at 40 to 45 mph. Carry out road test pressure check with gauge connected to torque converter. œ Normal pressure FAULT - Failed direct drive clutch œ Pressures correct but remains high FAULTS POSS[...]

ZF 1 ADJUSTMENT ADD: 09/95 KICKDOWN CABLE ADJUSTMENT 1. Remove split pin, withdraw clevis pin and disconnect kickdown cable from lever. 2. Remove split pin, withdraw clevis pin and disconnect throttle cable from lever. 3. Adjust the position of the kickdown cable locknuts so that dimension ’A’ is 28 mm. With cable held in this position, there s[...]

ZF 1 REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC GEARBOX ASSEMBLY - V8i Service repair no - 44.20.04 Removal from V8i engine The assembled transfer gearbox, automatic gearbox and torque converter is removed from underneath the vehicle. Use a transmission hoist with an adaptor plate for securing the assembly to the hoist. The adaptor can be manufa[...]

44 AUTOMATIC GEARBOX 2 REPAIR 1. Site vehicle on a four post ramp [hoist]. 2. Disconnect battery negative lead. 3. Remove fan cowl securing screws and release cowl from radiator. 4. Loosen securing clip and disconnect air flow hose from plenum chamber. 5. Disconnect stepper motor hose from top of plenum chamber. 6. Disconnect kickdown cable from th[...]

ZF 3 REPAIR 19. Disconnect rear propeller shaft to output flange, and tie to one side. 20. Repeat instructions 18 and 19 on front propeller shaft to main gearbox. 21. Remove bolts retaining silencer front and rear securing brackets and tie silencer to one side. 22. Disconnect oil cooler feed and return pipes from bottom and side of main gearbox. 23[...]

44 AUTOMATIC GEARBOX 4 REPAIR LT230T TRANSFER GEARBOX WITH AUTOMATIC GEARBOX ASSEMBLY - Tdi Service repair no - 44.20.04 Removal from Tdi engine The assembled transfer gearbox, automatic gearbox and torque converter is removed from underneath the vehicle. Use a transmission hoist with an adaptor plate for securing the assembly to the hoist. WARNING[...]

ZF 5 REPAIR Remove 1. Select low range with transfer gear lever. 2. Remove knob and gaiter from transfer gear lever. 3. Disconnect battery terminals. 4. Remove insulation pad from rocker cover and inlet manifold. 5. On LH drive vehicles only, disconnect multi-plug from top of brake fluid reservoir. 6. Release electrical harness from clips along top[...]

44 AUTOMATIC GEARBOX 6 REPAIR 13. Remove starter. 14. Working through starter aperture note position of torque converter flexible drive plate to facilitate refitting. 15. Remove the four torque convertor to flexible drive securing bolts, rotating engine to gain access to each individual bolt. 16. Raise vehicle on four post ramp [hoist]. 17. Drain l[...]

ZF 7 REPAIR Accessories removal/fitting If fitting a replacement transmission assembly to the vehicle, remove the following items from the existing assembly and fit to the replacement. CAUTION: It is important to remove the spacer from the extension shaft and fit onto the replacement unit. 50. Breather pipe union and washers from main gearbox. 51. [...]

44 AUTOMATIC GEARBOX 8 REPAIR INHIBITOR SWITCH Service repair no - 44.15.19 Remove 1. Site vehicle on a four post ramp [hoist]. 2. Disconnect battery negative lead. Raise vehicle. 3. Disconnect inhibitor switch multi plug. 4. Remove inhibitor switch retaining plate. 5. Remove inhibitor switch. 6. Remove ’O’ ring seal. 7. Clean inhibitor switch.[...]

ZF 9 REPAIR OIL SUMP Service repair no - 44.24.05 Remove 1. Site vehicle on a four post ramp [hoist]. 2. Disconnect battery negative lead. 3. Raise vehicle. 4. Drain oil and refit plug with new seal. 5. Detach heat shield at front exhaust pipe to manifold. 6. Disconnect electrics from Lambda sensors. 7. Remove catalytic converter assembly. 8. Remov[...]

44 AUTOMATIC GEARBOX 10 REPAIR OIL SCREEN Service repair no - 44.24.07 Renew 1. Site vehicle on a four post ramp [hoist]. 2. Disconnect battery negative lead. 3. Raise vehicle. 4. Drain oil and refit plug with new seal. 5. Detach heat shield at front exhaust pipe to manifold. 6. Disconnect electrics from Lambda sensors. 7. Remove catalytic converte[...]

ZF 11 REPAIR CONTROL UNIT Remove 1. Site vehicle on a four post ramp [hoist]. 2. Disconnect battery negative lead. 3. Raise vehicle. 4. Drain oil and refit plug with new seal. 5. Detach heat shield at front exhaust pipe to manifold. 6. Disconnect electrics from Lambda sensors. 7. Remove catalytic converter assembly. 8. Remove chassis cross-member f[...]

44 AUTOMATIC GEARBOX 12 REPAIR Oil seal replacement 14. Remove circlips and springs from control unit. Note locations of long and short springs. 15. Using seal replacer/remover LST113 remove and discard seals. 16. Clean control unit, springs and circlips and check that they are satisfactory for further use. 17. Fit new seals to control unit using L[...]

ZF 13 REPAIR KICKDOWN CABLE Service repair no - 44.15.01 Remove 1. Site vehicle on a four post ramp [hoist]. 2. Select neutral ’N’ gear lever. 3. Disconnect battery negative lead. 4. Disconnect kickdown cable at throttle linkage. 5. Release outer cable locknut. 6. Disconnect cable from mounting bracket. 7. Release cable from bracket attached to[...]

44 AUTOMATIC GEARBOX 14 REPAIR EXTENSION HOUSING Service repair no - 44.20.18 Remove 1. Remove transfer gearbox. See TRANSFER GEARBOX, Repair, LT230T Transfer Gearbox 2. Drain oil from automatic gearbox. 3. Remove bolts securing left hand mounting bracket to extension housing and withdraw bracket. 4. Remove transfer gear lever housing securing bolt[...]

ZF 15 REPAIR GOVERNOR ASSEMBLY Service repair no - 44.22.01 Remove 1. Remove transfer gearbox. See TRANSFER GEARBOX, Repair, LT230T Transfer Gearbox 2. Drain oil from automatic gearbox. 3. Remove bolts securing left hand mounting bracket to extension housing and withdraw bracket. 4. Remove transfer gear lever housing securing bolts and move housing[...]

44 AUTOMATIC GEARBOX 16 REPAIR GOVERNOR HUB Service repair no - 44.22.04 Remove 1. Remove transfer box. See TRANSFER GEARBOX, Repair, LT230T Transfer Gearbox 2. Remove transfer gear selector housing. 3. Loosen nine bolts holding extension housing. 4. Remove extension housing ensuring that seal is not damaged, discard gasket. 5. Remove extension sha[...]

ZF 17 REPAIR PARKING PAWL MECHANISM Service repair no - 44.28.07 Remove 1. Remove transfer box. See TRANSFER GEARBOX, Repair, LT230T Transfer Gearbox 2. Remove transfer gear selector housing. 3. Loosen nine bolts holding extension housing. 4. Remove extension housing ensuring that seal is not damaged, discard gasket. 5. Remove extension shaft and r[...]

44 AUTOMATIC GEARBOX 18 REPAIR REPLACING TORQUE CONVERTER 1. Remove gearbox and transfer box assembly. See LT230T Transfer Gearbox 2. Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3. Fit new torque converter using torque converter handles[...]

ZF 19 REPAIR 6. Screw in two bolts, diagonally opposite each other. Tap lightly using a soft headed mallet to remove pump assembly from intermediate plate. 7. Remove shaft sealing ring and ’O’ ring from pump housing and discard. 8. Using oil seal replacer LST108 fit shaft seal ring into pump housing. 9. Fit ’O’ ring onto circumference of pu[...]

44 AUTOMATIC GEARBOX 20 REPAIR ELIMINATING LEAKS BETWEEN GEARBOX HOUSING AND INTERMEDIATE PLATE 1. Remove gearbox and transfer box assembly. See LT230T Transfer Gearbox 2. Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3. Remove twelve hex[...]

ZF 21 REPAIR REPLACING PUMP Service repair no - 44.32.01 1. Remove gearbox and transfer box assembly. See LT230T Transfer Gearbox 2. Place gearbox on bench. Remove torque converter using torque converter handles 18G1501, taking care not to damage torque converter/oil pump housing oil seal. 3. Remove twelve bolts (inner ring pattern). 4. Remove bell[...]

44 AUTOMATIC GEARBOX 22 REPAIR 13. Place end-float gauge LST111 onto pump housing and check that axial play is between 0.2-0.4 mm. Replace existing washer, situated at rear of intermediate plate, with suitable washer to give required end-float. NOTE: If damage is apparent to bolts they should be replaced. 14. Refit torque converter into housing usi[...]

ZF 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Coupling shaft to mainshaft 42* ...................................................................... Filler tube to sump 68 ....................................................[...]

44 AUTOMATIC GEARBOX 2 SPECIFICATIONS, TORQUE ZF GEARBOX DATA Axial end float 0.2 to 0.4 mm. From torque converter boss to torque converter housing face 50 mm Freewheel cage assembly to ring gear; minimum clearance 0.1 mm Output shaft above cylinder F assembly; dimension 10.00 mm A cylinder protrusion above gearbox front face not more than 8.5 mm[...]

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

44 AUTOMATIC GEARBOX 2 SERVICE TOOLS[...]

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

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

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

PROPELLER SHAFTS 1 DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT Description The front and rear propeller shafts have non-constant velocity ’Hooks’ type universal joints, with needle roller bearings. The bearing cups are pre-packed with lubricant on assembly and a grease nipple is fitted for servicing as specified, in maintenance section.[...]

PROPELLER SHAFTS 1 FAULT DIAGNOSIS VIBRATION HARSHNESS 1. Check that the propeller shaft universal joints and sliding splines are not siezed or worn and that the shafts are correctly aligned. NOTE: In the event that both shafts are satisfactory, but the vibration/harshness is still present, the transfer box operation and balance of the road wheels [...]

PROPELLER SHAFTS 1 REPAIR FRONT PROPELLER SHAFT Service repair no - 47.15.02 - Front Remove 1. Place vehicle over pit or on a ramp [hoist]. 2. Remove nuts from each end of propeller shaft. Remove shaft. 3. Scribe alignment marks on flanges at both ends of propeller shaft to ensure correct refitting. Service repair no - 47.15.11 Overhaul 4. Thorough[...]

47 PROPELLER SHAFTS 2 REPAIR 18. Press each cup into its respective yoke up to lower land of circlip grooves. Damage may be caused to cups and seals if cups pass this point. 19. Fit circlips and check no end float exists. 20. Engage spider in yokes of sliding member. Fit bearing cups and circlips as described in instructions 14 to 19. 21. Fit greas[...]

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

47 PROPELLER SHAFTS 4 REPAIR REAR PROPELLER SHAFT Service repair no - 47.15.03 NOTE: SGF rubber coupling should be left attached to propeller shaft. Only remove coupling from propeller shaft if replacement is required. Remove 1. Scribe alignment marks on flanges at both ends of propeller shaft to ensure correct refitting. 2. Remove three nuts and b[...]

REAR AXLE AND FINAL DRIVE 1 DESCRIPTION AND OPERATION DESCRIPTION The welded steel rear axle casing houses a separate spiral bevel type differential unit, which is off set to the right of the vehicle centre line. The differential unit drives the rear wheels via the axle shafts and fully floating hubs which are mounted on tapered roller bearings. Lu[...]

REAR AXLE AND FINAL DRIVE 1 FAULT DIAGNOSIS FAULT DIAGNOSIS Complaint - Oil leaks An external leak of lubrication from the hub seals can be caused by a faulty internal seal. For example, if the internal seals which separate the differential from the hubs are faulty and the vehicle is operating or parked on an embankment. Oil from the differential m[...]

REAR AXLE AND FINAL DRIVE 1 REPAIR REAR AXLE Service repair no - 51.25.01 Remove WARNING: Remove and refit of axle requires a further two persons to steady the axle when lowering or repositioning axle. 1. Drain brake system. 2. Support chassis rear. 3. Remove road wheels. 4. Support axle weight with hydraulic jack. 5. Disconnect ABS wiring harness [...]

51 REAR AXLE AND FINAL DRIVE 2 REPAIR REAR BRAKE DISC NON ABS Service repair no - 70.10.11. Remove 1. Remove rear hub assembly. See Rear Hub Assembly 2. Remove disc bolts. 3. Remove disc from rear hub. Refit 4. Fit disc to rear hub. 5. Fit disc bolts. Tighten to 73 Nm. 6. Check total disc run out, this must not exceed 0,15 mm. If necessary repositi[...]

REAR AXLE AND FINAL DRIVE 3 REPAIR REAR HUB ASSEMBLY Service repair no - 64.15.01 Remove 1. Place rear axle onto axle stands and remove road wheel. 2. Release brake hose clips and remove brake caliper bolts. Secure to one side. WARNING: Take care not to kink brake hose. 3. Remove five bolts and withdraw axle shaft. 4. Remove joint washer. 5. Bend b[...]

51 REAR AXLE AND FINAL DRIVE 4 REPAIR Refit 10. Clean stub axle. Retract ABS sensor slightly from sensor sleeve, if applicable 11. Fit hub assembly to stub axle. 12. Fit spacing washer. 13. Fit hub adjusting nut. Tighten to 61 Nm. Back off adjusting nut 90 ° . Tighten to 4 Nm. This will give the required hub end float of 0,010mm 14. Fit a new lock[...]

REAR AXLE AND FINAL DRIVE 1 OVERHAUL AXLE DIFFERENTIAL ASSEMBLY Service repair no - 51.15.07. DISMANTLE NOTE: Mark differential components so their original positions relative to other components is maintained. Bearing caps must not be interchanged. 1. Remove axle shafts then differential assembly fom axle. 2. Remove roll pin securing bearing nut l[...]

51 REAR AXLE AND FINAL DRIVE 2 OVERHAUL 12. Remove pinion head bearing with service tool LRT-99-002. 13. Remove bolts and washers securing crown wheel to differential flange. Remove crown wheel. 14. Remove differential carrier bearings. 15. Remove circlips and extract differential cross shaft. 16. Withdraw differential gears and pinions. 17. Clean [...]

REAR AXLE AND FINAL DRIVE 3 OVERHAUL 23. Check gear for freedom of rotation and backlash. Nominal backlash should be present. Excess backlash necessitates replacement of gears or differential housing. 24. Check serial number marked on pinion end face matches that on crown wheel. 25. Clean and fit crown wheel. 26. Fit carrier bearings and assemble t[...]

51 REAR AXLE AND FINAL DRIVE 4 OVERHAUL 35. Fit pinion outer bearing track to pinion housing. Use service tools LRT-54-505 and LRT-54-507. 36. Fit pinion head bearing to pinion. Use service tool LRT-54-502. 37. Fit pinion into its location without shims for bearing pre-load. 38. Fit outer bearing, and spacer (front axle differential only). 39. Fit [...]

REAR AXLE AND FINAL DRIVE 5 OVERHAUL 43. Nominal setting dimension is represented by setting gauge block LRT-54-503. Referenced from pinion end face to bottom radius of differential bearing bore. Drive pinion adjustment 44. Ensure pinion end face is free of burrs around etched markings. 45. Remove keep disc from magnetized base of dial gauge tool. [...]

51 REAR AXLE AND FINAL DRIVE 6 OVERHAUL 48. Repeat on other bearing bore. Add readings then halve sum to obtain mean reading. Note whether trace pin has moved up or down from zero. A. Where trace pin moves down, reading is equal to thickness of shims to remove, to bring pinion to nominal. B. Where trace pin moves up, reading is equal to thickness o[...]

REAR AXLE AND FINAL DRIVE 7 OVERHAUL PINION PRELOAD SHIMS PART No. INCH MM FTC3869 .085 2.155 FTC3870 .084 2.130 FTC3871 .083 2.105 FTC3872 .082 2.080 FTC3873 .081 2.055 FTC3874 .080 2.030 FTC3875 .079 2.005 FTC3876 .078 1.980 FTC3877 .077 1.955 FTC3878 .076 1.930 FTC3879 .075 1.905 FTC3880 .074 1.880 FTC3881 .073 1.855 FTC3882 .072 1.830 FTC3883 .[...]

51 REAR AXLE AND FINAL DRIVE 8 OVERHAUL CROWN WHEEL/PINION BACKLASH ADJUSTMENT 63. Place differential housing in pinion housing. 64. Fit bearing caps and partly tighten bolts. 65. Fit bearing adjusting nuts. 66. Mesh crown wheel to pinion. Using service tool LRT-54-508 loosen left bearing adjuster nut. 67. Tighten right nut until crown wheel/pinion[...]

REAR AXLE AND FINAL DRIVE 9 OVERHAUL REAR HUB ASSEMBLY Service repair no - 61.15.13. Overhaul 1. Remove rear hub assembly. See Repair, Rear Hub Assembly 2. Remove outer bearing. 3. Remove five nyloc nuts and withdraw ABS sensor ring, if applicable. 4. Mark, for reassembly, position of hub to brake disc. 5. Remove five bolts and separate hub from br[...]

51 REAR AXLE AND FINAL DRIVE 10 OVERHAUL Refit 8. Clean hub and fit inner and outer bearing tracks. 9. Pack hub inner bearing with grease and fit to hub. 10. With lip side leading fit a new seal flush with rear face of hub. Using service tool LRT-54-003 seal replacer and drift. Apply grease between seal lips. 11. Assemble brake disc to the hub, lin[...]

REAR AXLE AND FINAL DRIVE 11 OVERHAUL REAR STUB AXLE Service repair no - 64.15.22. STUB AXLE COMPONENTS 1. Rear axle shaft. 2. Stub axle to axle casing bolt. 3. Mudshield. 4. Stub axle. 5. Stub axle joint washer. 6. Axle case. 7. Sensor ABS. Overhaul 1. Remove hub assembly. See Repair, Rear Hub Assembly 2. Remove six bolts from stub axle to axle ca[...]

REAR AXLE AND FINAL DRIVE 1 SPECIFICATIONS, TORQUE AXLE DIFFERENTIAL DATA Pinion bearing pre-load: (new bearings) 3 Nm ........................................................ (bearings bedded in) 1,5 Nm ............................................... Crown wheel run-out 0,10 mm ........................................................ Crown wheel/p[...]

51 REAR AXLE AND FINAL DRIVE 2 SPECIFICATIONS, TORQUE Torque values below cover all screws and bolts used, unless specified otherwise. METRIC Nm M5 6 ...................................................................................................... M6 9 ............................................................................................[...]

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

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

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

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

FRONT AXLE AND FINAL DRIVE 1 DESCRIPTION AND OPERATION DESCRIPTION The welded steel front axle casing houses a separate spiral bevel type differential unit, which is off set to the right of the vehicle centre line. The differential unit drives the front wheels via the axle shafts and constant velocity joints which are totally enclosed in the spheri[...]

54 FRONT AXLE AND FINAL DRIVE 2 DESCRIPTION AND OPERATION Front axle 1. Axle casing 2. Ventilation pipe 3. Axle shaft 4. Wheel studs and hub 5. Stub axle 6. Wheel bearings (2) 7. Inner and outer hub seals 8. Axle shaft seal 9. Hub lock plate, thrust washer and nuts (2) 10. Brake disc 11. Drive flange 12. Shim washer and circlip 13. Dust cap 14. Con[...]

FRONT AXLE AND FINAL DRIVE 1 FAULT DIAGNOSIS FAULT DIAGNOSIS Complaint - Oil leaks An external leak of lubrication can be caused by a faulty internal seal. For example, if the seals which separate the differential from the swivel housings are faulty and the vehicle is operating or parked on an embankment, oil may leak across the axle leaving one sw[...]

FRONT AXLE AND FINAL DRIVE 1 REPAIR FRONT AXLE ASSEMBLY Service repair no - 54.15.01 Remove WARNING: Remove and refit of axle requires a further two persons to steady axle when lowering or repositioning axle. 1. Support chassis front. 2. Remove road wheels. 3. Support axle weight with hydraulic jack. 4. Remove radius arms to chassis frame nuts. 5. [...]

54 FRONT AXLE AND FINAL DRIVE 2 REPAIR FRONT BRAKE DISCS Service repair no - 70.10.10. Remove 1. Remove front hub assembly. See Front Hub Assembly 2. Remove five hub to disc bolts. 3. Tap disc to separate from hub. Refit 4. Locate disc to hub. 5. Apply Loctite 270 to disc bolts. Tighten to 73 Nm. 6. Check total disc runout with a dial indicator, th[...]

FRONT AXLE AND FINAL DRIVE 3 REPAIR FRONT HUB ASSEMBLY Service repair no - 60.25.01. Remove 1. Loosen front wheel nuts, jack up vehicle and lower onto axle stands and remove road wheel. 2. Release brake hose clips and remove brake caliper. Secure to one side. 3. Lever off dust cap. 4. Remove circlip and drive shaft shim from driveshaft. 5. Remove f[...]

54 FRONT AXLE AND FINAL DRIVE 4 REPAIR Refit 11. Clean stub axle and drive shaft and fit hub assembly to axle. 12. Fit spacing washer. 13. Fit hub adjusting nut. Tighten to 61 Nm. 14. Back off adjusting nut 90 ° . Tighten to 4 Nm. This will give the required hub end float of 0,010mm 15. Fit a new lock washer. 16. Fit locknut. Tighten to 61 Nm. 17.[...]

FRONT AXLE AND FINAL DRIVE 1 OVERHAUL FRONT DIFFERENTIAL Service repair no - 54.10.07. Overhaul The front and rear differentials are the same. When overhauling front differential. See REAR AXLE AND FINAL DRIVE, Overhaul, Axle Differential Assembly FRONT HUB Service repair no - 60.26.14. Overhaul 1. Remove front hub assembly. See Repair, Front Hub A[...]

54 FRONT AXLE AND FINAL DRIVE 2 OVERHAUL 9. With lip side leading fit new seal to hub using special tool LST 137 seal replacer and drift 18G 134. Drive in seal flush with rear face of hub. Apply grease between seal lips. 10. Fit brake disc to hub, lining up to marks made during dismantling. apllying Loctite 270, fit five retaining bolts. Tighten to[...]

FRONT AXLE AND FINAL DRIVE 3 OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING NON ABS Service repair no - 60.15.43. Remove stub axle, axle shaft and constant velocity joint. 1. Remove front hub assembly. See Repair, Front Hub Assembly 2. Drain swivel pin housing and refit plug. 3. Remove six bolts retaining stub axle to swiv[...]

54 FRONT AXLE AND FINAL DRIVE 4 OVERHAUL 12. Examine all components in particular inner and outer track, cage balls and bearing surfaces for damage and excessive wear. 13. Maximum acceptable end-float on assembled joint 0,64mm. Renew if worn or damaged. Lubricate with a recommended oil during assembly. Fit constant velocity joint to axle 14. Fit co[...]

FRONT AXLE AND FINAL DRIVE 5 OVERHAUL Swivel pin housing 22. Remove bolts securing oil seal retaining plate and joint washer. Release assembly from swivel pin housing. NOTE: Removal of oil seal and retaining plate is achieved when swivel bearing housing is removed. 23. Remove two bolts, retaining lower swivel pin to housing. 24. Remove brake disc s[...]

54 FRONT AXLE AND FINAL DRIVE 6 OVERHAUL Swivel assembly components 1. Swivel pin housing 2. Top swivel pin and brake hose bracket 3. Upper and lower swivel pin bearings 4. Shim 5. Retaining plate and washer 6. Oil seal 7. Joint washer 8. Swivel bearing housing 9. Joint washer 10. Lower swivel pin 11. Mudshield bracket 12. Swivel housing inner oil [...]

FRONT AXLE AND FINAL DRIVE 7 OVERHAUL Fit driveshaft and stub axle 59. Insert axle shaft, and when differential splines are engaged, push assembly in fully. CAUTION: Take care not to damage axle shaft oil seals. 60. Place a new joint washer in position on swivelpin housing to stub axle mating face. Coat threads of stub axle bolts with Loctite 270. [...]

54 FRONT AXLE AND FINAL DRIVE 8 OVERHAUL Remove constant velocity joint from axle shaft 7. Hold axle shaft firmly in a soft jawed vice. 8. Using a soft mallet drive constant velocity joint from shaft. 9. Remove circlip and collar from axle shaft. Constant velocity joint 10. Mark positions of constant velocity joint, inner and outer race and cage fo[...]

FRONT AXLE AND FINAL DRIVE 9 OVERHAUL 19. Lubricate seal and lip with EP90 oil and with cavity side leading press in a new oil seal using special tool LRT-54-004. 20. Using special tool LRT-54-005, fit bearing with its part number visible when fitted, and flush with end face of stub axle. 21. Press fit a new thrust ring onto stub axle. Swivel pin h[...]

54 FRONT AXLE AND FINAL DRIVE 10 OVERHAUL 40. With seal lips trailing press axle shaft oil seal flush into rear of housing. Grease lips. 41. Fit new thrust washers and bearing into top swivel pin bush. 42. Hang swivel pin bearing housing oil seal and retainer plate over back of housing. Ensure they are in correct assembly order. 43. Fit a new joint[...]

FRONT AXLE AND FINAL DRIVE 11 OVERHAUL Fit driveshaft and stub axle 59. Insert axle shaft, and when differential splines are engaged, push assembly in fully. CAUTION: Take care not to damage axle shaft oil seals. 60. Place a new joint washer in position on swivelpin housing to stub axle mating face. Coat threads of stub axle bolts with Loctite 270.[...]

54 FRONT AXLE AND FINAL DRIVE 12 OVERHAUL FRONT HUB AND SWIVEL COMPONENTS 1. Brake caliper. 2. Mud shield. 3. Stub axle. 4. Joint washer. 5. Oil seal. 6. Bearing. 7. Brake disc shield. 8. Constant velocity joint. 9. Circlip. 10. Bush. 11. Inner driveshaft. 12. Top swivel pin and jump hose bracket. 13. Shim. 14. Swivel pin housing. 15. Joint washer.[...]

FRONT AXLE AND FINAL DRIVE 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm FRONT AXLE Hub driving member to hub 65 ........................................................................ * Brake disc to hub 73 ..................[...]

54 FRONT AXLE AND FINAL DRIVE 2 SPECIFICATIONS, TORQUE Torque values below cover all screws and bolts used, unless specified otherwise. METRIC Nm M5 6 ...................................................................................................... M6 9 ...........................................................................................[...]

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

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

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

STEERING 1 DESCRIPTION AND OPERATION DESCRIPTION The power assisted steering system incorporates a compression joint in the lower shaft, designed to collapse on impact and for certain countries, an air bag located in the centre of the steering wheel. The mis-alignment of the upper steering column with the steering box and the inclusion of two unive[...]

57 STEERING 2 DESCRIPTION AND OPERATION[...]

STEERING 3 DESCRIPTION AND OPERATION Steering column components 1. Upper shroud 2. Column harness 3. Cruise control switch (if fitted) 4. Steering wheel and nut 5. Rotary coupler 6. Column switch 7. Shear bolts 8. Switch saddle 9. Upper steering column 10. Universal joint 11. Universal joint bolt 12. Steering column lock assembly 13. Lower shroud 1[...]

57 STEERING 4 DESCRIPTION AND OPERATION Power steering box components 1. Housing complete with sector shaft bearings 2. Cover plate complete with bearing 3. Sector shaft 4. Hydraulic piston/rack 5. Worm/valve and torsion bar assembly 6. Shims for centralizing worm/valve 7. Ball race (2) 8. ’Teflon’ seals for valve sleeve (3) 9. Bearing adjuster[...]

STEERING 5 DESCRIPTION AND OPERATION Rotary valve operation The rotary valve assembly seen in RR3620M comprises the worm (1), the valve sleeve (2), the input shaft (4) and the torsion bar (5). The valve sleeve is retained inside the worm by the trim screw (3), and incorporates valve ports in its inner bore. The input shaft is attached to the steeri[...]

57 STEERING 6 DESCRIPTION AND OPERATION Demand for assistance (Valve misaligned) When the steering wheel and input shaft is turned, steering resistance transmitted to the worm causes the torsion bar to be twisted and the valve ports to be misaligned for a right or left turn. The misalignment of the valve ports directs all fluid pressure A to one si[...]

STEERING 7 DESCRIPTION AND OPERATION Pump and regulator valve operation The pump which is belt driven from the engine is an eccentric roller type and also houses the pressure regulator and flow control valve. The pressure is controlled by a spring loaded ball valve 3 which is housed inside the flow control valve piston 4. No demand for assistance H[...]

STEERING 1 FAULT DIAGNOSIS INSUFFICIENT POWER ASSISTANCE 1. Is fluid level correct? YES - g o to 3. NO - Fill/bleed sytem 2. Is problem a leak? YES - Diagnose. See Power Steering Fluid Leaks NO - continue 3. Is drive belt tension correct? YES - g o to 5. NO - retension. See ENGINE, Repair, Drive Belt 4. Is problem resolved? YES - end NO - continue [...]

57 STEERING 2 FAULT DIAGNOSIS POWER STEERING SYSTEM - TEST NOTE: If steering lacks power assistance. Check pressure of hydraulic pump before fitting new components. Use fault diagnosis chart to assist in tracing faults. A. Steering box. B. Steering pump. C. Existing hose, steering box to pump. D. Hose LRT-57-030. E. Test adaptor LRT-57-001. F. Pres[...]

STEERING 3 FAULT DIAGNOSIS STEERING DAMPER The power steering system, as well as reducing the effort required to manoeuvre the vehicle when parking, also helps to dampen any deflections of the road wheels, being transmitted back to the steering wheel. When operating the vehicle off road, the road wheels are often deflected by ruts and boulders caus[...]

57 STEERING 4 FAULT DIAGNOSIS Symptom:- Fluid leaks from steering box seals. CAUTION: The steering wheel must not be held on full lock for more than 30 seconds in one minute, as this may overheat the fluid and cause damage to the oil seals. 1. Check fluid level. See Repair, Power Steering Fluid Reservoir Check fluid pressure. See Power Steering Sys[...]

STEERING 5 FAULT DIAGNOSIS Symptom :- Steering excessively light/sensitive. Excessive freeplay at steering wheel. 1. Are steering box adjustments correct? NO - See Adjustment, Power Steering Box WARNING: Adjustments of steering box should not be required while in warranty period. If box is within warranty, it must be returned to manufacturer. No at[...]

57 STEERING 6 FAULT DIAGNOSIS STEERING STABILITY AND VEER UNDER BRAKING Possible cause: Incorrectly set, swivel pin bearing preload. There are three different settings for these bearings dependant on model year and if fitted with ABS brakes. Remedy. 1. Establish model year of vehicle. 2. If fitted with or without antilock brakes. 3. Follow instruct[...]

STEERING 7 FAULT DIAGNOSIS 2. STEERING VEER From 1. GENERAL STEERING: 1. Vehicle veers, not under braking, swap front tyres side to side. 2. Is problem resolved? YES - end NO - continue. 3. Does vehicle now veer in other direction? YES - fit new tyres NO - continue. 4. Recentralise steering box. See Adjustment, Centralise Steering Box 5. Is problem[...]

57 STEERING 8 FAULT DIAGNOSIS 4. DIRECTIONAL STABILITY From 1. GENERAL STEERING: 1. Is directional stability concern when vehicle is towing? YES - Check towing/vehicle loading parameters in Owner’s Handbook. NO - go to 3. 2. Is problem resolved? YES - end NO - continue. 3. Check condition of rear trailing link/chassis bushes. 4. Is problem resolv[...]

STEERING 9 FAULT DIAGNOSIS POWER STEERING SYSTEM - EXCESSIVE NOISE 1. Is fluid level correct? YES - g o to 3. NO - Refill or drain to correct level. Bleed system, check for leaks. See Repair, Power Steering System - Bleed 2. Is problem resolved? YES - end NO - continue. 3. Is pressure hose from pump to box touching body in a hard foul condition? YE[...]

57 STEERING 10 FAULT DIAGNOSIS VISUAL AND SAFETY CHECKS WARNING: Before taking vehicle out on the public highway for road test, it is important that the following basic visual checks are carried out to ensure that the vehicle complies with legal requirements. Tyres and wheel rims 1. Check and adjust tyre pressures. See GENERAL SPECIFICATION DATA, I[...]

STEERING 11 FAULT DIAGNOSIS STIFF STEERING CHECKLIST NOTE: Having completed visual checks and steering assessment and confirmed that vehicle steering load is incorrect carry out the following procedure in order shown. Steering wheel ’torque to turn’ loads 1. Raise vehicle so both front wheels free. 2. With engine off, centralise steering wheel,[...]

57 STEERING 12 FAULT DIAGNOSIS Steering column alignment 1. Place vehicle on level ground. Measure the angle of lower steering shaft using a Pernumeter placed on the shaft between the universal joints. The angle should measure a minimum of 12˚. 2. If necessary, realign the shaft. Release the five fixings securing the steering column. Position colu[...]

STEERING 13 FAULT DIAGNOSIS STEERING LINKAGE INSPECT NOTE: When inspecting steering linkages and ball joints for wear the following items must be checked. Steering ball joints 1. Check ball joint rubber boots for security, signs of cracking or deterioration. 2. Check ball joint assemblies for seizure i.e. no movement on ball joint and associated as[...]

STEERING 1 ADJUSTMENT POWER STEERING BOX Service repair no - 57.10.13 WARNING: Adjustments of steering box should not be required while in warranty period. If box is stiff or tight and within warranty, it must be returned to manufacturer. No attempt must be made to introduce backlash. 1. Apply park brake, select ’P’ in automatic transmission an[...]

57 STEERING 2 ADJUSTMENT STEERING LOCK STOPS Service repair no - 57.65.03 Check 1. Measure clearance between tyre wall and radius arm at full lock. This must be 20 mm. Adjust 2. Loosen stop bolt locknut. 3. Turn stop bolt as required. 4. Tighten locknut. 5. Check clearance between tyre wall and radius arm on each lock. NOTE: Alternatively lock stop[...]

STEERING 3 ADJUSTMENT FRONT WHEEL ALIGNMENT Service repair no - 57.65.01 Checking Toe-out dimensions NOTE: No Adjustment is provided for castor, camber or swivel pin inclinations. 1. Set vehicle on level ground with road wheels positioned straight ahead. 2. Push vehicle back and forwards to settle linkage. 3. Measure toe-out at horizontal centre-li[...]

STEERING 1 REPAIR POWER STEERING FLUID PIPES Service repair no - 57.15.21 CAUTION: If any joints are disconnected, it is essential that open pipe and ports are plugged to prevent ingress of dirt. The following procedures must be followed when refitting fluid pipes: Power steering pump 1. Remove plugs, place clamp on feed hose. V8i Steering pump ill[...]

57 STEERING 2 REPAIR POWER STEERING BOX Service repair no - 57.10.01 General precautions 1. Whenever any part of system, is removed or disconnected, utmost cleanliness must be observed. 2. Disconnected ports and hoses must be plugged to prevent ingress of dirt. If metal sediment is found in system, establish cause rectify and flush system. 3. Do no[...]

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

57 STEERING 4 REPAIR Refit 15. Position steering box to chassis side member, ensuring locating peg is engaged. Tighten bolts to 81 Nm. 16. Fit pinch bolt and nut securing universal joint to power steering box. Tighten to 25 Nm. 17. Position tie bar, tighten bolts and nut to 81 Nm, starting with tie bar to mounting nut, then loosen nut and bolts by [...]

STEERING 5 REPAIR POWER STEERING SYSTEM - BLEED Service repair no - 57.15.02 1. Ensure fluid in reservoir reaches dipstick maximum. 2. Run engine to normal operating temperature. 3. Recheck and correct reservoir fluid level. NOTE: During instructions 4 to 6, maintain maximum fluid level in reservoir. Do not increase engine speed or move steering wh[...]

57 STEERING 6 REPAIR Refit 6. Position reservoir, connect feed and return hoses and tighten clamps to 3 Nm. 7. Fit reservoir in clamp, tighten clamp bolt. 8. Fill reservoir to ’MAX’ mark on dipstick with power steering fluid. See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids 9. Fit undertray. 10. Bleed power [...]

STEERING 7 REPAIR 7. Loosen clamp securing reservoir hose to steering pump; disconnect hose. 8. Disconnect high pressure pipe from steering pump. CAUTION: Plug the connections. 9. Release ht lead from clip 10. Remove 3 bolts securing steering pump. Remove pump and recover engine lifting bracket. NOTE: Do not carry out further dismantling if compone[...]

57 STEERING 8 REPAIR 7. Loosen clamp securing reservoir hose to steering pump, disconnect hose. 8. Disconnect high pressure pipe from steering pump. CAUTION: Plug the connections. 9. Remove 4 bolts securing steering pump to mounting bracket, remove pump. NOTE: Do not carry out further dismantling if component is removed for access only. 10. Remove [...]

STEERING 9 REPAIR LOWER STEERING SHAFT AND UNIVERSAL JOINTS Service repair no - 57.40.25 CAUTION: Before removing any parts of steering linkage, it is imperative that road wheels are positioned straight ahead. Then steering wheel removed to prevent rotary coupler being wound up or damaged. CAUTION: After refitting steering linkage parts follow corr[...]

57 STEERING 10 REPAIR STEERING COLUMN SHROUD Service repair no - 57.40.29 Remove 1. Disconnect battery negative lead. 2. Remove 3 screws securing shroud. 3. Carefully release upper shroud from lower. 4. Manoeuvre lower shroud clear of steering column. Refit 5. Position upper and lower shrouds to steering column ensuring plastic tags on lower shroud[...]

STEERING 11 REPAIR Remove 1. Disconnect battery negative lead. 2. Position road wheels straight ahead so steering wheel can be correctly re-assembled. 3. Airbag fitted: Remove air bag. See SUPPLEMENTARY RESTRAINT SYSTEM, Repair, Driver’s Airbag Module 4. Remove trim pad from steering wheel, disconnect Lucars from horn button. 5. Disconnect rotary[...]

57 STEERING 12 REPAIR UPPER STEERING COLUMN Service repair no - 57.40.01 NOTE: Steering column assembly is not a serviceable component. CAUTION: Before removing any parts of steering linkage, it is imperative that road wheels are positioned straight ahead. then steering wheel removed to prevent rotary coupler being wound up or damaged. CAUTION: Aft[...]

STEERING 13 REPAIR 8. Disconnect ignition switch main feed multiplug. 9. Remove 4 nuts securing upper column to lower mounting. 10. Remove 2 nuts securing lower mounting steady bracket, remove bracket. 11. Remove pinch bolt securing upper column to universal joint. 12. Remove 2 nuts and washes securing upper column to upper mounting bracket. 13. Ca[...]

57 STEERING 14 REPAIR Refit 20. Manoeuvre upper column to position in footwell, ensure splines in column and universal joint are correctly engaged and rubber boot is fitted. 21. Fit but do not tighten universal joint pinch bolt. 22. Position upper column to upper mounting, fit washers and nuts, do not tighten nuts. 23. Fit but do not tighten nuts a[...]

STEERING 15 REPAIR STEERING COLUMN LOCK ASSEMBLY Service repair no - 57.40.31 Remove CAUTION: Before removing any parts of steering linkage, it is imperative that road wheels are positioned straight ahead. Then steering wheel removed to prevent rotary coupler being wound up or damaged. CAUTION: After refitting steering linkage parts follow correct [...]

57 STEERING 16 REPAIR 7. Remove bulb holder from steering column lock shroud. 8. Tap head of shear bolts anti-clockwise to release them. 9. Remove and discard shear bolts. 10. Detach saddle. 11. Remove steering column lock assembly. Refit 12. Position steering lock saddle on column, locating spigot in hole provided. 13. Place lower lock assembly in[...]

STEERING 17 REPAIR 3. Bend back tabs on locking washer and remove drop arm using extractor LRT-57-012. Loosen drop arm securing nut, but do not remove before using extractor. 4. Remove nut, discard locking washer. Refit 5. Centralise steering box. See Adjustment, Centralise Steering Box 6. Fit drop arm, align master splines. 7. Fit a new tab washer[...]

57 STEERING 18 REPAIR TRACK ROD AND LINKAGE Service repair no - 57.55.09 Remove track rod 1. Site vehicle on a ramp [hoist]. 2. Disconnect steering damper at track rod. 3. Disconnect track rod at ball joints, using extractor LRT-57-018. 4. Remove track rod. Remove linkage 5. Loosen clamp bolts. 6. Unscrew ball joints. 7. Unscrew track rod adjuster.[...]

STEERING 19 REPAIR DRAG LINK AND DRAG LINK ENDS Service repair no - 57.55.17 Remove drag link 1. Check front wheel alignment. See Adjustment, Front Wheel Alignment 2. Ensure wheels are positioned straight ahead during following procedure. 3. Place vehicle on a hoist, or support front axle on axle stands. 4. Remove right front road wheel. 5. Disconn[...]

STEERING 1 OVERHAUL POWER STEERING BOX Service repair no - 57.10.07 Overhaul NOTE: Overhaul of steering box should not be carried out during the warranty period. WARNING: Wear safety glasses while removing and refitting circlips and retaining ring. CAUTION: Absolute cleanliness is essential when overhauling power steering box. 1. Remove steering bo[...]

57 STEERING 2 OVERHAUL 12. Remove piston, a bolt screwed into piston will assist removal. 13. Remove input shaft dirt excluder. 14. Remove worm adjuster locknut using ’C’ wrench LRT-57-007. 15. Remove worm adjuster using wrench LRT-57-006. 16. Tap splined end of shaft to free bearing. 17. Remove bearing cup and caged ball bearing assembly. 18. [...]

STEERING 3 OVERHAUL CAUTION: Do not remove sector shaft bearings from casing. Replacement parts are not available. If sector shaft bearings are worn fit a new steering box. 21. Remove dirt excluder, circlip and seal from input shaft housing bore. CAUTION: The use of a seal puller is recommended to prevent damage to casing, and possible oil leaks. I[...]

57 STEERING 4 OVERHAUL Sector shaft cover assembly 31. Inspect cover and bearing. If worn or damaged, replacement parts are not available, fit a new steering box. Sector shaft adjuster locknut 32. The locknut is also a fluid seal. Fit new nut at overhaul. Valve and worm assembly 33. Examine bearing areas for wear. The areas must be smooth and not i[...]

STEERING 5 OVERHAUL Rack thrust pad and adjuster 43. Examine thrust pad for scores. 44. Examine adjuster for wear in pad seat. 45. Fit new sealing ring to rack adjuster. Rack and piston 46. Examine for excessive wear on rack teeth. 47. Ensure thrust pad bearing surface is free from scores and wear. 48. Ensure piston outer diameters are free from bu[...]

57 STEERING 6 OVERHAUL 61. Fit new worm adjuster sealing ring. 62. Loosely screw adjuster into casing. 63. Fit locknut, do not tighten. 64. Turn in worm adjuster until end float is almost eliminated. Ensure bearing cages are seated correctly. 65. Measure maximum rolling torque of valve and worm assembly, using a torque wrench and spline socket LRT-[...]

STEERING 7 OVERHAUL Fitting sector shaft cover 73. Fit new sealing ring to cover. 74. Align cover with casing. 75. Screw cover assembly fully on to sector shaft adjuster screw. 76. If necessary back off sector shaft adjuster screw. Tap cover in place to allow cover to joint fully with casing. NOTE: Before tightening fixings, rotate input shaft to e[...]

57 STEERING 8 OVERHAUL 83. Hold input shaft and rock drop arm to establish backlash is present. Continue rocking and slowly turn sector shaft adjusting screw clockwise. Continue rotating adjuster screw until backlash has almost been eliminated. 84. Refit locknut and tighten. NOTE: It is important steering box is centralised before any adjustments a[...]

STEERING 9 OVERHAUL Input shaft oil seal 92. Fit seal, lip side first, into housing. Use seal saver LRT-57-016 and seal installer LRT-57-026. Note that seal is fitted to a depth of 4.75 - 5.00 mm from face of box. 93. Secure seal with circlip. 94. Smear inner lip of dirt excluder with PTFE grease. Fit dirt excluder using LRT-57-027. When fitted cor[...]

STEERING 1 SPECIFICATIONS, TORQUE STEERING PUMP Make/type - V8i ZF ’Unicorn’ ................................................................ Make/type - Tdi Hobourn Eaton 500 series ................................................................ Operating pressure - straight ahead position - at idle 7 bar, 100 lbf/in 2 maximum ...... Full loc[...]

57 STEERING 2 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Ball joint nuts 40 .............................................................................................. Clamp bolt nuts 14 ....................................[...]

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

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

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

FRONT SUSPENSION 1 DESCRIPTION AND OPERATION INTRODUCTION Suspension design is a major factor in determining the comfort, safety and performance of any vehicle, but is particularly significant to 4 wheel drive cross country vehicles. The ideal suspension must allow maximum wheel travel and axle articulation, and provide good ground clearance withou[...]

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

FRONT SUSPENSION 1 REPAIR SELF LOCKING NUTS WARNING: Where self locking nuts are removed, they must be replaced with new nuts of same specification. PANHARD ROD Service repair no - 60.10.07. Remove 1. Remove fixings at mounting arm. 2. Remove fixings at axle bracket. 3. Remove Panhard rod. 4. Press out flexible bushes. Ensure the steel tubing locat[...]

60 FRONT SUSPENSION 2 REPAIR 8. Press out flexible bushes. Refit 9. Press in replacement bushes. CAUTION: When pressing in new bushes press on outer edge of bush and not rubber inner. 10. Reverse removal procedure. 1 to 8. Tighten fixings to following torques: Radius arm to chassiss 176Nm Radius arm to axle 197Nm FRONT SHOCK ABSORBER Service repair[...]

FRONT SUSPENSION 3 REPAIR 7. Withdraw lower seating washer, rubber bush and cupwasher. 8. Remove fixings, shock absorber to mounting bracket. 9. Withdraw mounting bracket. 10. Lift off top seating washer, rubber bush and cupwasher. Refit 11. Reverse removal procedure. 1 to 10. FRONT ROAD SPRING Service repair no - 60.20.11. Remove 1. Remove front s[...]

60 FRONT SUSPENSION 4 REPAIR BUMP STOP Service repair no - 60.30.10. Remove 1. Remove fixings. 2. Remove bump stop. Refit 3. Position bolts in slots in chassis brackets. 4. Fit bump stop, secure with washers and nuts.[...]

FRONT SUSPENSION 5 REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY FRONT Service repair no - 60.10.01 KEY 1. Anti-roll[sway] bar 2. Rubber bush 3. Strap 4. Nut, bolt, washer 5. Nut and washer 6. Castellated nut and cotter pin 7. Ball joint link arm Remove 1. Mark for reassembly position of rubber bushes on anti- roll[sway] bar. 2. Remove four nuts, bolts and w[...]

60 FRONT SUSPENSION 6 REPAIR ANTI-ROLL[SWAY] BAR BALL JOINT LINKS Service repair no - 60.10.04. Remove 1. Remove two nuts, bolts, washers and rubber bushes from ball joint links. 2. Remove cotter pin and loosen castellated nut a few turns. 3. Release ball joint using special tool 18G 1063A as shown. 4. Remove castellated nut and ball joint link. Re[...]

FRONT SUSPENSION 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Anti-roll[sway] bar front - Strap nyloc nuts 30 .............................................................................. - Ball link self lock nut 68 ........[...]

REAR SUSPENSION 1 DESCRIPTION AND OPERATION AXLE LOCATION Longitudinal location of the rear axle is by solid round section steel link arms and a forged "A" frame, upper link assembly, which is secured to a chassis cross member and provides transverse control. Long travel coil springs and hydraulic shock absorbers provide the springing for[...]

REAR SUSPENSION 1 REPAIR REAR ROAD SPRING Service repair no - 64.20.01 Remove 1. Loosen rear road wheel retaining nuts. 2. Support chassis on stands and remove wheels. 3. Support rear axle weight with jack. 4. Disconnect shock absorbers at one end. 5. Position coil spring compressor correctly on road spring. 6. Compress spring evenly to facilitate [...]

64 REAR SUSPENSION 2 REPAIR BUMP STOP Service repair no - 64.30.15. Remove 1. Remove fixings. 2. Remove bump stop. Refit 3. Position bolts in slots in bracket. 4. Fit bump stop secure with washer and nuts. SUSPENSION LINK UPPER Service repair no - 64.35.44. Remove 1. Support rear of chassis on stands, allow axle to hang freely. 2. Remove fixings, u[...]

REAR SUSPENSION 3 REPAIR Renew bush 7. Press out rubber bushes. 8. Fit bush centrally in housing. CAUTION: Apply pressure to outer edge of bush, and not rubber inner. Refit 9. Reverse removal procedure. 1 to 6. Do not fully tighten fixings until all components are in position. 10. Tighten fixings to correct torque. See Specifications, torque, Torqu[...]

64 REAR SUSPENSION 4 REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY REAR Service repair no - 64.35.08. KEY 1. Anti-roll[sway] bar 2. Rubber bush 3. Strap 4. Nut, bolt, washer 5. Nut and washer 6. Ball joint link arm 7. Bolt and washer 8. Castellated nut and cotter pin Remove 1. Note for reassembly, position of rubber bushes on anti-roll bar. 2. Remove four nu[...]

REAR SUSPENSION 5 REPAIR ANTI-ROLL[SWAY] BAR BALL JOINT LINKS Service repair no - 64.35.24. Remove 1. Remove two nuts, bolts, washers and rubber bushes from ball joint links and lower anti-roll bar to clear links. 2. Remove cotter pin and loosen castellated nut a few turns. 3. Release ball joint using special tool 18G 1063A as shown. 4. Remove cast[...]

REAR SUSPENSION 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Anti-roll[sway] bar rear - Strap nyloc nuts 30 .............................................................................. - Ball link self lock nut 68 ..........[...]

BRAKES 1 DESCRIPTION AND OPERATION BRAKES Discovery vehicles have servo assisted brake systems and the option of an anti-lock brake system. Information in this section refers to components relevant to both brake systems. Where the system components are different they are referred to as ABS or NON ABS BRAKE SYSTEM NON ABS Description The servo assis[...]

70 BRAKES 2 DESCRIPTION AND OPERATION ABS COMPONENTS Location Key to diagram 1. ABS Modulator unit 2. Servo/Master cylinder 3. Pressure reducing valve 4. Electronic control unit 5. Rear sensors/exciter rings 6. Front sensors/exciter rings 7. Diagnostic plug connection[...]

BRAKES 3 DESCRIPTION AND OPERATION Description of components 1. ABS Modulator unit To provide the ABS function a Modulator is positioned within the system between the master cylinder and the calipers. On both LHD and RHD vehicles it is sited on the left inner wing [fender]. The Modulator has 8 solenoid valves, 2 for each wheel, 2 expanders and a re[...]

70 BRAKES 4 DESCRIPTION AND OPERATION System description The brake system consists of dual hydraulic circuits in a front - rear split. That is individual circuits to front and rear axles. Wheelspeed signals are provided by the fitting of exciter rings to axles and speed sensors. An ABS stop light switch is fitted to provide a braking signal to the [...]

BRAKES 5 DESCRIPTION AND OPERATION BRAKE PIPE LAYOUT ABS Left hand drive shown. On right hand drive vehicles the master cylinder and servo unit only move position. KEY 1. Connector double elbow 2. Rear left brake 3. Modulator to rear left brake 4. Modulator to master cylinder 5. Modulator to pressure reducing valve upper 6. Electrical connection 7.[...]

70 BRAKES 6 DESCRIPTION AND OPERATION BRAKE PIPE LAYOUT NON ABS Left hand drive shown. On right hand drive vehicles the master cylinder and servo unit only move position. KEY 1. T-Connector 2. Rear left brake 3. Master cylinder to pressure reducing valve lower 4. Front left brake to pressure reducing valve upper 5. Front left brake 6. Front right b[...]

BRAKES 7 DESCRIPTION AND OPERATION BRAKE SERVO UNIT Description The power assistance for the brake system is provided by a twin diaphragm suspended vacuum servo. A ’Suspended Vacuum’ servo is one where, with the engine running vacuum is present both sides of the diaphragm or diaphragms when the brakes are fully released or partially applied. Th[...]

70 BRAKES 8 DESCRIPTION AND OPERATION Brakes applied When the brake pedal is depressed the pedal pushrod operates valve C situated in the plastic diaphragm hub 9 and 10. Inital depression of the the brake pedal, push rod 6 and plunger 7 compress a rubber pad 8. This slight movement causes valve C to close port D sealing off the vacuum to chambers 2[...]

BRAKES 9 DESCRIPTION AND OPERATION Petrol engine vacuum system The vacuum necessary to operate the brake servo on petrol engine vehicles is provided by the engine inlet manifold. During normal operation of the brakes only a small volume of air is drawn from the servo and into the inlet manifold or plenum chamber. However any excessive air leaks due[...]

BRAKES 1 FAULT DIAGNOSIS ABS FAULT DIAGNOSIS If a fault has occurred, or has been identified by ECU self diagnostic function and ABS warning light is illuminated. The system and components must be checked to locate and rectify fault, using Testbook diagnostics. NOTE: If warning lamp has indicated a fault in system, and no fault code has been stored[...]

70 BRAKES 2 FAULT DIAGNOSIS ABS FAULT AND REMEDY CHART SYMPTOM POSSIBLE CAUSE CHECK REMEDY ABS warning light on ABS electrical fault Check ABS electrical circuit with Testbook diagnostic equipment Change component if necessary High sensor air gaps Push in sensors Brake fluid warning light ON Fluid loss Check reservoir fluid level and inspect system[...]

BRAKES 1 REPAIR GENERAL BRAKE SERVICE PRACTICE Brake fluid precautions WARNING: Do not allow brake fluid to come into contact with eyes or skin. CAUTION: Brake fluid can damage paintwork, if spilled wash off immediately with plenty of clean water. CAUTION: Use only correct grade of brake fluid. If an assembly fluid is required use ONLY brake fluid.[...]

70 BRAKES 2 REPAIR BRAKE SYSTEM BLEED Service repair no - 70.25.02 The following method for bleeding the hydraulic brake system applies to both ABS and NON ABS vehicles. Preparation WARNING: Before bleeding the brake system refer to general brake service practice. See General Brake Service Practice • During bleed procedure, brake fluid level must[...]

BRAKES 3 REPAIR MASTER CYLINDER ABS Service repair no - 70.30.08 - Lucas Girling - Type 25.4mm CV/CV NOTE: This master cylinder is identified by a 3rd plugged outlet port protruding down from the master cylinder body. Before starting repair refer to general brake service practice. See General Brake Service Practice Remove 1. Disconnect battery nega[...]

70 BRAKES 4 REPAIR MASTER CYLINDER NON ABS Service repair no - 70.30.08 - Remove Service repair no - 70.30.09 - Repair - Lucas Girling - Type 25.4mm AS/AS WARNING: This master cylinder is not suitable to be fitted on vehicles with antilock brake systems. Before starting repair refer to general brake service practice. See General Brake Service Pract[...]

BRAKES 5 REPAIR 10. Ease reservoir out of master cylinder taking care to ensure that two outlet ports on bottom of reservoir do not become damaged during this process. 11. Withdraw two reservoir seals from master cylinder inlet ports. Note for reassembly these seals are different. Discard seals. 12. Remove retaining ring and ’O’ ring seal from [...]

70 BRAKES 6 REPAIR NOTE: The primary plunger assembly cannot be broken down any further and is serviced as a complete unit. Discard assembly. 15. The secondary plunger assembly will remain at bottom of master cylinder bore. Remove tapping assembly on a piece of wood until plunger appears at cylinder mouth, carefully pull plunger out of master cylin[...]

BRAKES 7 REPAIR 19. Coat new seals in unused brake fluid. Fit ’L’ seal to plunger. 20. Fit washer followed by recuperating seal. Fit seal retainer and springs, ensure springs are correctly seated. Assembling master cylinder CAUTION: It is important that following instructions are carried out precisely, otherwise damage could be caused to new se[...]

70 BRAKES 8 REPAIR MASTER CYLINDER ASSEMBLY NON ABS Key to master cylinder 1. Water ingress seal 2. Transfer housing 3. Vacuum seal 4. Guide ring 5. Retaining ring 6. ’O’ ring seal 7. Primary plunger assembly 8. ’L’ seal 9. Secondary plunger 10. Washer 11. Recuperating seal (primary cup) 12. Seal retainer 13. Springs (2 off) 14. Swirl tube [...]

BRAKES 9 REPAIR SERVO ASSEMBLY Service repair no - 70.50.01 Remove Before starting repair refer to general brake service practice. See General Brake Service Practice NOTE: The filter, non-return valve and grommet, are the only serviceable components, in event of failure or damage fit a new unit. 1. Disconnect battery negative lead. 2. Disconnect el[...]

70 BRAKES 10 REPAIR FRONT BRAKE PADS Service repair no - 70.40.02 Service tool: LRT.70-500 - Piston clamp Remove 1. Remove front road wheels. See WHEELS AND TYRES, Repair, Wheels 2. Clean exterior of calipers. 3. Remove split [cotter] pin from retaining pins. 4. Remove pad retaining pins and anti-rattle springs. 5. Remove brake pads. 6. Clean expos[...]

BRAKES 11 REPAIR REAR BRAKE PADS Service repair no - 70.40.03 Service tool: LRT-70-500 - Piston clamp Remove 1. Remove rear road wheels. See WHEELS AND TYRES, Repair, Wheels 2. Disconnect battery negative lead. 3. Clean exterior of calipers. 4. Remove pad retaining pins and springs. 5. Remove brake pads. 6. Clean exposed parts of pistons, using new[...]

70 BRAKES 12 REPAIR FRONT BRAKE CALIPER ASSEMBLY Key to caliper 1. Caliper 2. Bleedscrew 3. Antirattle springs 4. Pad retaining pins 5. Split [cotter] pin 6. Friction pads 7. Piston 8. Wiper seal retainer 9. Wiper seal 10. Fluid seal 11. Brake disc[...]

BRAKES 13 REPAIR FRONT BRAKE CALIPERS Service repair no - 70.55.03 Service repair no - 70.55.16 Service tool: LRT-70-500 - Piston clamp Before starting repair refer to general brake service practice. See General Brake Service Practice Remove caliper 1. Loosen front wheel retaining nuts, raise front of vehicle, lower onto axle stands, remove wheels.[...]

70 BRAKES 14 REPAIR Assemble outboard pistons 13. Coat new fluid seal with brake fluid. Ease seal into groove in bore using only fingers, ensuring it is properly seated. Fluid seal and groove are not same in section, so when seal is seated it feels raised to touch at edge furthest away from mouth of bore. 14. Coat appropriate piston with brake flui[...]

BRAKES 15 REPAIR REAR BRAKE CALIPERS Service repair no - 70.55.06 Service repair no - 70.55.17 Service tool: LRT-50-700 - Piston clamp Before starting repair refer to general brake service practice. See General Brake Service Practice Remove caliper 1. Loosen rear road wheel nuts. Jack up vehicle, lower onto axle stands, remove wheels. 2. Using a re[...]

70 BRAKES 16 REPAIR 13. Apply brake fluid to new seal. Fit seal into groove in bore. When seal is seated it feels raised to touch at edge furthest away from mouth of bore. 14. Coat piston with brake fluid. Insert it squarely into bore. Do not tilt piston during insertion and leave 8mm projecting from bore. 15. Coat a new wiper seal with brake fluid[...]

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

70 BRAKES 18 REPAIR SENSORS - FRONT Service repair no - 70.65.32 CAUTION: If a sensor is removed for any reason, a NEW sensor bush and seal must be fitted. Remove 1. Disconnect battery negative lead. 2. Disconnect required sensor electrical connection, located on inner wing [fender] panel. 3. Remove sensor lead from clips. 4. Clean area surrounding[...]

BRAKES 19 REPAIR SENSORS - REAR Service repair no - 70.65.31 CAUTION: If a sensor is removed for any reason, a NEW sensor bush must be fitted. Remove 1. Disconnect battery negative lead. 2. Disconnect sensor electrical connections, located above rear axle. 3. Remove sensor from its locating clip. 4. Remove bolts securing mudshield. 5. Using a suita[...]

70 BRAKES 20 REPAIR STOP LIGHT SWITCH - NON ABS Service repair no - 86.65.51 Remove 1. Disconnect battery negative lead. 2. Remove lower dash panel. 3. Depress foot brake. 4. Remove rubber protector from switch, if fitted. 5. Remove hexagon nut. 6. Withdraw switch. 7. Disconnect electrical leads. Adjust 8. With switch still in position and multiplu[...]

BRAKES 21 REPAIR BRAKE COMPONENTS ABS Left hand drive shown. On right hand drive vehicles the master cylinder and servo unit only move position. KEY 1. Connector-double elbow 2. Rear left brake 3. Modulator to rear left brake 4. Modulator to master cylinder 5. Modulator to pressure reducing valve upper 6. Electrical connection 7. Modulator unit 8. [...]

70 BRAKES 22 REPAIR MODULATOR UNIT Service repair no - 70.65.45 WARNING: New modulator units are supplied in a shock absorbing pack marked with a use by date. The new modulator will contain hydraulic brake fluid within the valve block and all ports plugged. Modulator units must be handled with care the following must be avoided:- any impact, use of[...]

BRAKES 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Brakes Brake pipe connections to: - Modulator unit 15 ................................................................................. - Brake calipers 15 ..................[...]

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

WHEELS AND TYRES 1 DESCRIPTION AND OPERATION TYPES OF WHEEL RIMS AND TYRES Description Dependent on specification, the vehicle is equipped with alloy or pressed steel wheel rims, both using tubeless radial ply tyres. Tyre codes The writing, codes and numbers moulded into the tyre wall vary between tyre manufacturers, however most tyres are marked w[...]

WHEELS AND TYRES 1 FAULT DIAGNOSIS TYRE WEAR CHART FAULT CAUSE REMEDY Rapid wear at Tyres under-inflated Inflate to correct pressure shoulders Worn suspension components Replace worn components i.e. ball joints, panhard rod bushes,steering damper Excessive cornering speeds Rapid wear at centre Tyres over-inflated Inflate to correct pressure of trea[...]

74 WHEELS AND TYRES 2 FAULT DIAGNOSIS FAULT - SYMPTOMS Vibration through steering wheel 1. Check tyre pressures. See Repair, Tyre Pressures 2. Check condition of tyres. See Tyre Wear Chart 3. Check front wheel alignment. See STEERING, Adjustment, Front Wheel Alignment 4. Check wheel balance. See Repair, Wheel Balancing NOTE: In the event that any a[...]

WHEELS AND TYRES 1 REPAIR GENERAL INFORMATION WARNING: This is a multi- purpose vehicle with wheels and tyres designed for both on and off road usage. Only use wheels and tyres specified for use on the vehicle. The vehicle is equipped with tubeless ’S’,’T’ or ’H’ rated radial ply tyres as standard equipment. The tyres are of European me[...]

74 WHEELS AND TYRES 2 REPAIR When the indicators appear in two or more adjacent grooves, at three locations around the tyre, a new tyre must be fitted. NOTE: Do not attempt to interchange tyres, e.g. from front to rear, as tyre wear produces characteristic patterns depending on their position. If tyre position is changed after wear has occured, the[...]

WHEELS AND TYRES 3 REPAIR WHEEL BALANCING CAUTION: It is essential that all wheel balancing is carried out off the vehicle. The use of on the vehicle balancing could cause component damage or personal injury and MUST NOT be attempted. NOTE: Before attempting to balance a wheel and tyre assembly clean all mud and dirt deposits from both inside and o[...]

74 WHEELS AND TYRES 4 REPAIR Static balance Wheel tramp A. Heavy spot. B. Add balance weights here. C. Centre line of spindle. Static balance is the equal distribution of weight around the wheel. A statically unbalanced wheel will cause a bouncing action called wheel tramp. This condition will eventually cause uneven tyre wear. Dynamic balance Whee[...]

WHEELS AND TYRES 5 REPAIR Off vehicle balancing Balance wheel assembly referring to equipment manufacturer’s instructions. It is essential that the wheel is located by the centre hole NOT the stud holes. To ensure positive wheel location the diameter of the locating collar on the machine shaft must be 112.80 to 112.85 mm (4.441 to 4.443 in). This[...]

74 WHEELS AND TYRES 6 REPAIR WHEELS Remove WARNING: The parking brake acts on transmission, not rear wheels, and may not hold vehicle when jacking unless following procedure is used. If one front wheel and one rear wheel is raised no vehicle holding or braking effect is possible. Wheels MUST be chocked in all circumstances. Apply parking brake, sel[...]

WHEELS AND TYRES 7 REPAIR WHEEL STUD Remove 1. Remove wheel. See Wheels 2. Drive stud out of driveshaft flange. Refit 3. Position stud in flange. 4. Install a suitable spacer over stud. 5. Using a M16 x 1.5P nut, a slave wheel nut is suitable, pull stud into flange until shoulder of stud abuts flange. 6. Refit wheel.[...]

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

75 SUPPLEMENTARY RESTRAINT SYSTEM 2 DESCRIPTION AND OPERATION OPERATION The airbag supplementary restraint system (SRS) is a safety device which, when used in conjunction with the seat belt, is designed to protect the driver and front passenger. Two different SRS systems are fitted to Discovery. The Distributed SRS which has two crash sensors locat[...]

SUPPLEMENTARY RESTRAINT SYSTEM 3 DESCRIPTION AND OPERATION SRS warning light (airbag) Distributed SRS The warning light in the instrument pack illuminates after the electrical circuits are switched on whilst a system check is carried out. After about 8 seconds the warning light will go out. The system checks airbag diagnostic control unit, airbag c[...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 4 DESCRIPTION AND OPERATION GENERAL PRECAUTIONS Impacts which do not deploy airbags CAUTION: Check for structural damage in the area of the impact, paying particular attention to bumper armatures, longitudinals, crash cans and bracketry. 1. Carefully inspect any airbag part before installing. Do not install any par[...]

SUPPLEMENTARY RESTRAINT SYSTEM 5 DESCRIPTION AND OPERATION 7. Do not use electrical test equipment on the airbag harness or connectors. Tampering with or disconnecting the harness could result in accidental firing of the airbag or make the system inoperative, which may result in serious injury. 8. An airbag system fault can only be diagnosed using [...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 6 DESCRIPTION AND OPERATION AIRBAG STORAGE Temporary storage For temporary storage of the airbag module during service, observe the following precautions: Store the airbag module with the pad surface up. Place the airbag module in designated storage area. If no designated storage area is available, the module may b[...]

SUPPLEMENTARY RESTRAINT SYSTEM 1 FAULT DIAGNOSIS CRASH SENSOR INSPECTION - DISTRIBUTED SRS 1. After any degree of front body damage, inspect both front crash sensors. Replace a sensor if there are any signs of dents, cracks or deformation. 2. Ensure the sensors are installed correctly. There must be no gap between the sensor and body of the vehicle[...]

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

SUPPLEMENTARY RESTRAINT SYSTEM 3 FAULT DIAGNOSIS 4. Airbag modules A - If defective, replace and dispose of the entire unit as directed in the instructions. Under no circumstances should a diagnosis be performed using electrically powered test equipment or probing devices. B - Tampering or mishandling can result in personal injury. For special hand[...]

SUPPLEMENTARY RESTRAINT SYSTEM 1 REPAIR SYSTEM PRECAUTIONS CAUTION: Before and during any removal operations within the SRS section, note routing and position of all harnesses to aid correct refitting and to avoid accidentally trapping cables. CAUTION: During refitting of any item within the SRS section, always ensure connectors are fully engaged a[...]

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

SUPPLEMENTARY RESTRAINT SYSTEM 3 REPAIR 8. Disconnect harness connector from airbag module. 9. Remove airbag module. CAUTION: Store the airbag module in accordance with the storage procedures outlined in Description and Operation. NOTE: If airbag module is to be replaced the serial numbers must be recorded in the vehicle service record. Refit 10. R[...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 4 REPAIR Refit 9. Reverse removal procedure. CAUTION: Ensure road wheels are straight ahead before fitting steering wheel. 10. Fit steering wheel ensuring the rotary coupler lugs are correctly engaged. 11. Fit steering wheel nut. Tighten to 50 Nm (37 lbf ft). 12. Refit driver’s airbag module. See driver’s airba[...]

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

75 SUPPLEMENTARY RESTRAINT SYSTEM 6 REPAIR 11. If rotary coupler is being re-used, place a piece of adhesive tape around moulding in position A to prevent rotation. Refit 12. Reverse removal procedure. CAUTION: Ensure indicator cancellation pegs correctly engage into back of steering wheel. 13. Align direction indicator cancellation bush. If origin[...]

SUPPLEMENTARY RESTRAINT SYSTEM 7 REPAIR ROTARY COUPLER CENTRALISE Fitting a rotary coupler which has not been centralised could result in tape breakage. If the tape is broken, a new rotary coupler must be fitted. Providing the removal procedure has been correctly followed this operation should not be necessary. If however there is evidence of tampe[...]

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

SUPPLEMENTARY RESTRAINT SYSTEM 9 REPAIR PASSENGER’S AIRBAG MODULE Service repair no - 76.74.02 WARNING: All the airbag system components, including the wiring harness, MUST be renewed after the airbags have deployed. Remove 1. Switch off ignition. 2. Disconnect battery negative lead and then positive lead. 3. Open glovebox and disconnect harness [...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 10 REPAIR CRASH SENSOR - DISTRIBUTED SRS Service repair no - 76.74.04 Remove 1. Disconnect battery negative lead. 2. LH sensor only: Slacken power steering reservoir clamp and lift reservoir to provide access. Diesel model only: Remove jack and mounting bracket. 3. Disconnect multiplug from sensor CAUTION: Ensure a[...]

SUPPLEMENTARY RESTRAINT SYSTEM 11 REPAIR AIRBAG DIAGNOSTIC CONTROL UNIT - DISTRIBUTED SRS Service repair no - 76.74.03 Remove 1. Disconnect battery negative lead. 2. Remove centre console assembly. See CHASSIS AND BODY, Repair, centre console. 3. Remove 4 screws and release the 2 rear passenger air ducts from their fitted position and remove centre[...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 12 REPAIR SRS WARNING LIGHT BULBS Service repair no - 76.73.74 Remove 1. Remove instrument binnacle. See ELECTRICAL, Repair, instrument binnacle. 2. Remove window and face plate from instrument panel. 3. Remove 3 screws securing ECU to instrument panel. 4. Release and remove small cover from ECU. 5. Disconnect mult[...]

SUPPLEMENTARY RESTRAINT SYSTEM 13 REPAIR 9. Carefully remove 2 screws securing face plate to tachometer. 10. Release warning light housing from tachometer circuit board. 11. Carefully (to avoid damage to tachometer needle and spindle), tilt and remove warning light housing. 12. Remove 2 warning light bulbs. Refit 13. Reverse removal procedure. 14. [...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 14 REPAIR AIRBAG HARNESS Service repair no - 86.70.63 Remove 1. Remove driver’s airbag. See driver’s airbag module. 2. Remove passenger’s airbag. See passenger’s airbag module. 3. Remove dash panel assembly. See CHASSIS AND BODY, Repair, dash panel assembly 4. Remove heater blower unit. See HEATING AND VENT[...]

SUPPLEMENTARY RESTRAINT SYSTEM 15 REPAIR AIRBAG MANUAL DEPLOYMENT CAUTION: Deployment in the vehicle will damage the steering wheel; if the vehicle is not being scrapped deploy the module away from the vehicle in accordance with the separate procedure. If a vehicle is to be scrapped and contains an undeployed airbag module, the module must be manua[...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 16 REPAIR 3. Knee bolster (where fitted); Remove 4 screws and withdraw kneebolster. 4. Release airbag harness to column harness connector from bracket. 5. Disconnect airbag harness connector from column harness. WARNING: Ensure tool is not connected to battery. 6. Connect flylead SMD 4082/5 to column harness connec[...]

SUPPLEMENTARY RESTRAINT SYSTEM 17 REPAIR 9. Press both operating buttons to deploy airbag module. 10. DO NOT return to airbag module for 30 minutes. 11. Using gloves and face mask, remove airbag module from steering wheel, place airbag module in plastic bag and seal bag. 12. Transport deployed airbag module to designated area for incineration. NOTE[...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 18 REPAIR WARNING: Ensure tool SMD 4082/1 is not connected to battery. 4. Secure airbag module to tool SMD 4082/2 . Ensure module is correctly secured using both fixings. 5. Ensure airbag module mounting brackets are secure. 6. Connect flylead SMD 4082/4 to airbag module. 7. Connect flylead SMD 4082/4 to tool SMD 4[...]

SUPPLEMENTARY RESTRAINT SYSTEM 19 REPAIR 9. Press both operating buttons to deploy airbag module. 10. DO NOT return to airbag module for 30 minutes. 11. Using gloves and face mask, remove airbag module from tool, place airbag module in plastic bag and seal bag. 12. Wipe down tool with damp cloth. 13. Transport deployed airbag module to designated a[...]

75 SUPPLEMENTARY RESTRAINT SYSTEM 20 REPAIR 5. Position airbag module to tool SMD 4082/6. Ensure module is correctly secured using all fixings. 6. Ensure airbag module mounting brackets are secure. WARNING: Ensure tool SMD 4082/1 is not connected to battery. 7. Connect flylead SMD 4082/5 to airbag module. 8. Connect flylead Smd 4082/5 to tool SMD 4[...]

SUPPLEMENTARY RESTRAINT SYSTEM 21 REPAIR 10. Press both operating buttons to deploy airbag module. 11. DO NOT return to airbag module for 30 minutes. 12. Using gloves and face mask, remove airbag module from tool, place airbag module in plastic bag and seal bag. 13. Wipe down tool with damp cloth. 14. Transport deployed airbag module to designated [...]

SUPPLEMENTARY RESTRAINT SYSTEM 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Airbag module screws 8 (6 lbf ft) ........................................................................... Steering wheel nut 50 (37 lbf ft) ......[...]

CHASSIS AND BODY 1 REPAIR FRONT DOOR Service repair no - 76.28.01 Remove 1. Disconnect battery negative lead. 2. Detach the door seal at the lower section of the ’A’ post. 3. Carefully remove the two retaining buttons from the trim panel on the side of the footwell and ease out the panel. 4. Disconnect the three multiplugs connecting the door h[...]

76 CHASSIS AND BODY 2 REPAIR FRONT DOOR TRIM PANEL Service repair no - 76.34.01 Remove 1. Remove the two securing screws and detach the door pull from its mounting brackets on the inner door panel. 2. Remove the interior door handle finisher button to reveal the screw retaining the handle surround. 3. Remove the screw and detach the handle surround[...]

CHASSIS AND BODY 3 REPAIR 8. Disengage the lifting arm stud from the upper lifting channel, manoeuvre the window regulator and remove it from the lower centre opening in the inner door panel. 9. Remove the exterior driving mirror. See ELECTRICAL, Repair, exterior driving mirrors. 10. Remove the waist rail seal from the top of the door panel. 11. Re[...]

76 CHASSIS AND BODY 4 REPAIR FRONT DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES Service repair no - 76.37.12/31 Remove 1. Disconnect battery negative lead. 2. Remove the door trim panel. See front door trim panel. 3. Remove the door glass and regulator. See front door glass and regulator. 4. Where applicable remove the door actuator unit. See[...]

CHASSIS AND BODY 5 REPAIR 11. Withdraw the lock through the lower rear cut-out on the inner door panel. 12. Remove the two nuts, shakeproof washers and retaining bracket securing the outer door release handle to the outer door panel, accessible through the upper rear cut-out on the inner door panel. 13. Carefully detach the door release handle from[...]

76 CHASSIS AND BODY 6 REPAIR ADJUSTMENT-FRONT DOOR LOCK AND HANDLE ASSEMBLY Service repair no - 76.37.47 Inside door release handle to lock 1. Refit the inside door release handle surround before any adjustment is made, allowing the handle to be set from the correct operating position. 2. At the lock end of the interior handle connecting rod, rotat[...]

CHASSIS AND BODY 7 REPAIR REAR SIDE DOORS Service repair no - 76.28.02 Remove 1. Disconnect battery negative lead. 2. Detach the convoluted grommet from the ’B’ post. 3. Withdraw the door harness multiplugs from the ’B’ post and disconnect them. 4. Remove the bolts and washers securing the check strap to the ’B’ post. WARNING: Instructi[...]

76 CHASSIS AND BODY 8 REPAIR REAR SIDE DOOR - TRIM PANEL Service repair no - 76.34.04 Remove 1. Disconnect battery negative lead. 2. Remove the two securing screws and detach the door pull from its mounting brackets. 3. Remove the securing screw and detach the interior door release handle surround. 4. Where applicable remove the window winder or re[...]

CHASSIS AND BODY 9 REPAIR REAR SIDE DOOR LOCK, INSIDE AND OUTSIDE RELEASE HANDLES Service repair no - 76.37.13/32 Remove 1. Ensure that the window is in the fully closed position. 2. Disconnect battery negative lead. 3. Remove the interior trim panel from the door. See rear side door - trim panel. 4. Remove the plastic vapour barrier sheet. 5. Disc[...]

76 CHASSIS AND BODY 10 REPAIR ADJUSTMENT-REAR SIDE DOOR LOCK AND HANDLE Service repair no - 76.37.47 Outside door release handle to lock 1. Disconnect the short off-set connecting rod at the rear of the outer release handle, rotate the rod clockwise or counter clockwise to shorten or extend the operating length of the rod as required. NOTE: Door re[...]

CHASSIS AND BODY 11 REPAIR 11. Remove the two bolts, spring and plain washers securing the door frame to the edge of the door. 12. Lift out the door frame complete with glass and remove to a suitable workbench. 13. Remove the tape and slide the glass out of the door frame channel. Refit 14. Reverse removal procedure. NOTE: When refitting the door g[...]

76 CHASSIS AND BODY 12 REPAIR REAR DOOR TRIM PANEL Service repair no - 76.34.09 Remove 1. Remove the two screws securing the door pull and remove it from the door. 2. Remove the finisher from the inner door handle. 3. Using a trim panel removing tool release the seventeen trim panel fasteners and withdraw the panel from the door. 4. If necessary re[...]

CHASSIS AND BODY 13 REPAIR 8. Remove the screws securing the lock control mechanism pivot bracket and the door pull mounting bracket, ease the bracket from the lock barrel stem and remove from the door. 9. Remove the two screws and withdraw the childproof lock actuator. 10. Disconnect the adjustable lock rod from the outer ’Y’ lever. 11. Remove[...]

76 CHASSIS AND BODY 14 REPAIR Lock barrel and number plate light housing Disassemble NOTE: The lock barrel can only be removed from its housing when the lock barrel and number plate light housing is removed from the door. 20. Remove the bolt securing the lock barrel mounting bracket to the housing and withdraw the assembled barrel and bracket. 21. [...]

CHASSIS AND BODY 15 REPAIR REAR DOOR CHECK STAY Service repair no - 76.40.30 Remove 1. Remove the rear door from the vehicle. See rear door. 2. Invert the door on a suitable protected area. 3. Remove the two securing bolts and withdraw the check stay assembly. Refit 4. Reverse removal procedure. REAR COMPARTMENT LOWER TRIM PANELS Service repair no [...]

76 CHASSIS AND BODY 16 REPAIR ALPINE LIGHT TRIM CASING Service repair no - 76.13.20 Remove 1. Remove RH ’E’ post trim casing. See ’E’ post trim casing - rh. 2. Remove rear seat belt anchorage retaining bolt cover. 3. Remove bolt securing rear seat belt anchorage. 4. Remove 2 trim studs securing trim casing. 5. Release trim casing from 2 ret[...]

CHASSIS AND BODY 17 REPAIR FRONT BODYSIDE TRIM CASING Service repair no - 76.13.01 Remove 1. Remove the grab handle. 2. Remove the rear compartment lower trim panel. See rear compartment lower trim panels. 3. Remove the alpine light trim casing. See alpine light trim casing. 4. Remove the bolts securing the upper and lower seat belt mountings. 5. R[...]

76 CHASSIS AND BODY 18 REPAIR HEADLINING Service repair no - 76.64.01/14 Remove 1. Disconnect battery negative lead. 2. Remove the lower trim panels from the rear compartment. See rear compartment lower trim panels. 3. Remove the alpine light trim casing. See alpine light trim casing. 4. Remove the front bodyside trim casing. See front bodyside tri[...]

CHASSIS AND BODY 19 REPAIR ’D’ POST TRIM CASING Service repair no - 76.13.73 Remove 1. Remove the rear compartment lower trim panel. See rear compartment lower trim panels. 2. Remove the alpine light trim casing. See alpine light trim casing. 3. Release the rear seat belt from the guide attached to the casing. 4. Fold down the rear seats. 5. Re[...]

76 CHASSIS AND BODY 20 REPAIR BODY SIDE WINDOW HINGES Service repair no - 76.81.47 Remove 1. Remove the window. See body side opening windows. 2. Remove the passenger grab handle. 3. Detach the front seat belt top mounting from the door post. 4. Ease the trim panel away from the door post to gain access to the window hinges. 5. Remove the screws se[...]

CHASSIS AND BODY 21 REPAIR REAR DOOR GLASS Service repair no - 76.31.21 Remove 1. Remove the spare wheel from the rear door. 2. Remove the rear door wiper arm. See WIPERS AND WASHERS, Repair, wiper arm - rear window. 3. If the glass is fitted, disconnect the heater leads from the terminals, push out the glass and remove the mounting rubber. Refit 4[...]

76 CHASSIS AND BODY 22 REPAIR FRONT FOLDING SEATS 3 DOOR VEHICLES Service repair no - 76.70.01 WARNING: Care must be taken if the seat lifting mechanism is operated when the seat is removed from the base otherwise personal injury could occur. Remove 1. Slide the seat to the full extent rearwards and remove the rear seat to base securing bolts. 2. S[...]

CHASSIS AND BODY 23 REPAIR SEAT BASE Service repair no - 76.70.06/25 WARNING: Care must be taken if the seat lifting mechanism is operated when the seat is removed from the base otherwise personal injury could occur. Remove 1. Remove the seat from the base. 2. Carefully operate the seat mechanism to raise it to the tilt position. 3. Remove the two [...]

76 CHASSIS AND BODY 24 REPAIR SEAT BASE TORSION BARS Service repair no - 76.71.34 Remove 1. Tilt the seat assembly forward. 2. Remove the torsion bar clamps. 3. Extract the right angled ends of the torsion bars from the brackets on the seat base and withdraw. Refit 4. Reverse removal procedure. FRONT SEATS 5 DOOR VEHICLES Service repair no - 76.70.[...]

CHASSIS AND BODY 25 REPAIR FRONT SEAT COVERS Service repair no - 76.70.14 Cushion Remove 1. Remove the seat from the base. 2. Invert the seat on a suitable clean bench. 3. Detach the seat cover retaining clips from the frame. 4. Release the four wire hooks securing the squab cover to the lower spring frame. 5. Release the cushion rear clip from the[...]

76 CHASSIS AND BODY 26 REPAIR REAR SEAT SQUAB Service repair no - 76.70.38 Remove 1. Fold the rear seat down. 2. Remove the two seat squab securing bolts. 3. Withdraw the seat squab from the seat assembly. Refit 4. Reverse removal procedure. REAR SEAT SQUAB COVER Service repair no - 76.70.79/80 Remove 1. Remove the rear seat squab from the seat ass[...]

CHASSIS AND BODY 27 REPAIR REAR SEAT CUSHION COVER Service repair no - 76.70.88/89 Remove NOTE: The procedure for removing both left and right hand seat cushions is the same. 1. Remove the rear seat assembly from the vehicle. See rear passenger seat. 2. Remove the seat squab. 3. Remove the seat cushion. 4. Remove the cushion base cover retaining sc[...]

76 CHASSIS AND BODY 28 REPAIR REAR FOLD DOWN SEATS Service repair no - 76.71.23 Seat and squab Remove 1. Locate the seat in the down position, release the seat belt strap and buckle from their stowed positions. 2. Remove 4 Torx screws from the lower brackets. 3. Fold the seat up and remove the 2 Torx screws from the upper brackets. Collect 4 washer[...]

CHASSIS AND BODY 29 REPAIR 10. Remove the pivot bolts and washers securing the hinge links to the seat squab. 11. If necessary remove the clips securing the cover and detach the cover. Refit 12. Reverse removal procedure. Seat cushion Remove 13. Remove the seat from the vehicle. 14. Remove the seat squab. 15. Remove the pivot bolts and washers secu[...]

76 CHASSIS AND BODY 30 REPAIR 8. Release the Torx bolt to allow removal of the seat belt stalk assembly. Refit 9. Reverse removal procedure. NOTE: Ensure the seat belt is not twisted. 10. Finally, tighten the seat belt bolts to 32 Nm (24 lbf ft) . REAR OUTER SEATS BELT Service repair no - 76.73.18 Remove 1. Remove the rear fold down seat (if applic[...]

CHASSIS AND BODY 31 REPAIR REAR CENTRE SEAT BELT Service repair no - 76.73.20 Remove 1. Pull both halves of the seat belt through to the rear of the seat. 2. Pull back the load space carpet to reveal the Torx bolt heads. 3. Remove the Torx bolt and plain washer securing the belt bracket to load space floor. 4. Remove belt complete with bracket. 5. [...]

76 CHASSIS AND BODY 32 REPAIR REAR GRAB HANDLE Service repair no - 76.58.35 Remove 1. Remove speaker and rear quarter trim panel. 2. Detach the foam strip. 3. Remove the four securing bolts and detach the handle. Refit 4. Reverse removal procedure.[...]

CHASSIS AND BODY 33 REPAIR WINGS [FENDERS] Service repair no - 76.10.24 Remove 1. Disconnect battery negative lead. 2. Remove the headlamp surround. 3. Remove the front bumper assembly. 4. Remove the indicator repeater light. 5. Remove the four screws securing the wing [fender] at the ’A’ post. 6. Remove the bolts securing the bottom of the win[...]

76 CHASSIS AND BODY 34 REPAIR SILL FINISHER Service repair no - 76.76.05 Remove 1. Remove the nut, bolt and washer securing the front of the sill finisher to the wing [fender] support bracket. 2. Remove the screw securing the bracket at the rear end of the finisher to the sill. 3. Using a suitable punch, remove the inserts from the seven plastic re[...]

CHASSIS AND BODY 35 REPAIR AIR INTAKE PLENUM COWL Service repair no - 76.11.08 Remove 1. Remove the windscreen wiper arms. 2. Remove the securing nuts and the steel and rubber washers from the wiper spindles. 3. Open the vehicle bonnet [hood]. 4. Remove the rubber seal from the cowl flange. 5. Release the screen washer tubes from the washer jets on[...]

76 CHASSIS AND BODY 36 REPAIR SUNROOF ELECTRIC/MANUAL Introduction Twin sunroofs are fitted to the vehicle, the open/close sequence for both electric and manual versions sharing the same operation:- A Closed position, B Tilt position, C Fully open position. When fully open the sunroof slides back in a tilt position over the vehicle roof. The electr[...]

CHASSIS AND BODY 37 REPAIR SUNROOF GLASS FRONT AND REAR Service repair no - 76.82.64 Remove 1. Open sunroof to tilt position. 2. Using a right angled screwdriver remove four retaining screws and detach sunroof glass from upper frame. Retain capnuts and washers. Refit 3. Locate sunroof glass in upper frame complete with capnuts and loosely fit retai[...]

76 CHASSIS AND BODY 38 REPAIR SUNROOF ASSEMBLY - ELECTRICAL, FRONT AND REAR Service repair no - 76.82.59 Remove Refer to sunroof components illustration J5483 1. Ensure sunroof is in normally closed position. 2. Disconnect battery negative lead. 3. Remove headlining. See headlining. 4. Disconnect electric motor wiring plug. See sunroof electric mot[...]

CHASSIS AND BODY 39 REPAIR SUNROOF ELECTRIC MOTORS Service repair no - 76.82.84/85 FRONT MOTOR Remove 1. Disconnect battery negative lead. 2. Ensure sunroof is in normally closed position NOTE: If the electric motor has failed the sunroof can be closed manually using an allen key to turn motor spindle A. 3. Remove switch panel from stowage pocket p[...]

76 CHASSIS AND BODY 40 REPAIR SUNROOF ELECTRIC CONTROL UNIT Service repair no - 76.82.73 The control unit serves both front and rear sunroofs and is sited above the front switches behind headlining. Remove 1. Disconnect battery negative lead. 2. Ensure sunroof is in normally closed position. NOTE: If the electric motor has failed the sunroof can be[...]

CHASSIS AND BODY 41 REPAIR SUNROOF ASSEMBLY - MANUAL, FRONT AND REAR Service repair no - 76.83.01 Remove 1. Close sunroof. 2. Remove headlining. See headlining. 3. Remove screws and manual regulator from clamping frame. See sunroof regulator manual. 4. Disconnect drain tubes from each side of clamping frame. 5. Remove 13 screws and clamping frame f[...]

76 CHASSIS AND BODY 42 REPAIR SUNROOF REGULATOR MANUAL Service repair no - 76.83.03/04 FRONT Remove 1. Ensure sunroof is in normally closed position. 2. Remove retaining screw and regulator handle. 3. Remove switch panel from stowage pocket panel 4. Remove interior lamp from stowage pocket panel 5. Remove alarm ultra sonic unit. 6. Unscrew ten fixi[...]

CHASSIS AND BODY 43 REPAIR SUN BLIND ASSEMBLY Service repair no - 76.82.78 Remove 1. Open sunroof to the tilt position. 2. Remove the trim finisher from the sunroof surround. 3. Release the headlining locally to access under clamping frame of the sunroof. 4. Lever forward and upward the rear leg of 3 retaining clips to release sun blind roll assemb[...]

76 CHASSIS AND BODY 44 REPAIR 7. Remove centre console switch pack cover. 8. Remove 4 screws securing switch pack to console. 9. Release switch pack from console and disconnect 7 multiplugs. NOTE: If the ’Cold Pack’ option is not fitted there will only be 5 switches in pack. 10. Remove switch pack. Models fitted with electric front seats 11. Re[...]

CHASSIS AND BODY 45 REPAIR Refit 20. Position centre console assembly, ensuring harnesses and connectors are not trapped and are routed to their correct locations. 21. Connect cigar lighter multiplug and illumination bulb Lucar. 22. Align centre console to body fixings and fascia. 23. Fit and tighten screws securing centre console to body. 24. Lubr[...]

76 CHASSIS AND BODY 46 REPAIR DASH PANEL CENTRAL LOUVRE PANEL Service repair no - 76.46.42 Remove 1. Disconnect battery negative lead. 2. Remove radio. See ELECTRICAL, Repair, radio. 3. Release tags securing radio cage to louvre panel and remove cage. 4. Remove clock. See ELECTRICAL, Repair, clock. 5. Release 4 coin tray securing tags. 6. Remove co[...]

CHASSIS AND BODY 47 REPAIR 14. Remove 2 screws securing louvre panel. 15. Remove louvre panel from dash panel. Refit 16. Position louvre panel, feed harness connectors through their correct apertures,and align to dash panel. CAUTION: When refitting avoid trapping of electrical wiring. 17. Fit and tighten screws securing louvre panel. 18. Fit panel [...]

76 CHASSIS AND BODY 48 REPAIR 20. Note position of levers, disconnect heater control cables from levers and outer cable from retaining clips. 21. Remove 4 bolts securing dash panel to centre lower mounting brackets. 22. Remove 4 bolts securing dash panel to side lower mounting brackets. 23. Undo 4 screws and remove 2 driver’s knee bolster pads fr[...]

CHASSIS AND BODY 49 REPAIR Refit CAUTION: When refitting avoid trapping electrical wiring. 29. Reverse removal procedure. 30. With assistance: Position dash panel and connect dash harness multiplugs to fusebox and main harness. 31. Reverse removal procedure. Ensure dash panel upper bracket studs are located before the 4 lower brackets. 32. Reverse [...]

76 CHASSIS AND BODY 50 REPAIR NOTE: If heated front screen: 2 electrical multiplug connectors are located under the decker [cowl] panel. To access release decker panel. Remove 1. Remove windscreen wiper arms. See WIPERS AND WASHERS, Repair, wiper arms - windscreen. 2. Remove rear view mirror and stickers from glass. 3. Remove ’A’ post finishers[...]

CHASSIS AND BODY 51 REPAIR 16. Cut through sealer between the supports. If heated front screen: Cut through the 2 wires each side of the supports. Tape cut wires and panels to prevent damage to bodywork when screen is removed. 17. Attach suction cups to glass and lift glass from body flange, cut sealer free around supports as necessary. WARNING: If[...]

76 CHASSIS AND BODY 52 REPAIR 24. Ensure body flanges and surfaces covered by the finishers are clean. 25. Shake the primer container for at least 30 seconds. 26. Using a cotton bud, apply Glass Primer (green cap) to inside face of glass, 20mm (13/16 in) strip around inside of finishers and 30mm (1 1/8 in) wide along bottom edge. This must be touch[...]

CHASSIS AND BODY 53 REPAIR 31. With assistance: Attach suction cups to glass and lift into position, carefully align the indicators on the obscuration band with the supports. Lower screen onto body flange, check alignment and firmly press to seat glass in the aperture. NOTE: The finisher on later vehicles will not have cutouts, or supports fitted, [...]

76 CHASSIS AND BODY 54 REPAIR 5. Remove Torx screw securing seat belt. 6. Remove 2 Torx screws securing seat. 7. Disconnect multiplug. 8. Remove seat. Refit 9. Reverse removal procedure. 10. Tighten Torx screws securing seat to 29 Nm (21 lbf ft) . 11. Tighten bolts securing seat slides to 22 Nm (16 lbf ft) . 12. Tighten Torx screw securing seat bel[...]

CHASSIS AND BODY 55 REPAIR Refit 7. Reverse removal procedure. 8. Tighten Torx screws securing seat to 29 Nm (21 lbf ft) . 9. Tighten bolts securing seat slides to 22 Nm (16 lbf ft) . 10. Tighten Torx screw securing seat belt to 32 Nm (24 lbf ft) . INTERIOR MIRROR (96 MODELS) Service repair no - 76.10.51 - Manual Service repair no - 76.10.54 - Auto[...]

76 CHASSIS AND BODY 56 REPAIR Refit 10. Reverse removal procedure. Ensure harness is correctly routed in mirror base so it does not become trapped.[...]

CHASSIS AND BODY 57 REPAIR SUN VISOR Service repair no - 76.10.47 Remove 1. Release sun visor from headlining retaining clip. 2. Remove 3 screws securing sun visor to body. 3. Release sun visor and disconnect multiplug. 4. Remove sun visor. Refit 5. Position sun visor and connect muliplug. 6. Position sun visor to headlining and secure with screws.[...]

76 CHASSIS AND BODY 58 REPAIR MUD FLAP - REAR - LH Service repair no - 76.10.85 Remove 1. Remove rear compartment lower trim panel. See rear compartment lower trim panel - lh - with rear air conditioning fitted. 2. Remove 5 nuts and bolts securing mud flap to body and bumper valance. 3. Remove mud flap. Refit 4. Position mud flap to body, fit bolts[...]

CHASSIS AND BODY 59 REPAIR 9. Remove 5 trim studs securing trim panel. 10. Remove trim panel. Refit 11. Fit and align trim panel. 12. Fit trim panel retaining studs. 13. Position load space cover mounting bracket and secure with screws. 14. Fold rear seat squab back and secure to latch. 15. Position load space cover to mounting brackets and secure.[...]

76 CHASSIS AND BODY 60 REPAIR ’E’ POST TRIM CASING - LH - WITH REAR AIR CONDITIONING FITTED Service repair no - 76.13.13/20 Remove 1. Remove rear speaker. See ELECTRICAL, Repair, rear speaker. 2. Release 2 trim casing retaining screw covers. 3. Remove 2 screws securing trim casing. 4. Remove trim casing. Refit 5. Fit and align trim casing. 6. F[...]

CHASSIS AND BODY 61 REPAIR REAR DOOR UPPER TRIM PANEL - WITH REAR AIR CONDITIONING FITTED Service repair no - 76.13.72/20 Remove 1. Remove alpine light trim casing. See alpine light trim casing - lh - with rear air conditioning fitted. 2. Release 2 trim panel retaining screw covers. 3. Remove 2 trim panel retaining screws. 4. Release rear edge of t[...]

76 CHASSIS AND BODY 62 REPAIR ’D’ POST TRIM CASING - LH - WITH REAR AIR CONDITIONING FITTED - 5 DOOR Service repair no - 76.13.73/20 Remove 1. Remove rear compartment lower trim panel. See rear compartment lower trim panel - lh - with rear air conditioning fitted. 2. Remove the squab release button from control rod. 3. Release rear seat belt fr[...]

CHASSIS AND BODY 63 REPAIR SWITCH PACK - DASH PANEL CENTRAL LOUVRE PANEL Service repair no - 76.46.38 Remove 1. Release switch pack from louvre panel. 2. Disconnect 3 multiplugs from switch pack. 3. Remove switch pack. Refit 4. Position switch pack. 5. Connect multiplugs to switch pack. 6. Secure switch pack to louvre panel. GRAB HANDLE Service rep[...]

76 CHASSIS AND BODY 64 REPAIR GRAB HANDLE - TAIL DOOR - WITH REAR AIR CONDITIONING FITTED Service repair no - 76.58.35/20 Remove 1. Remove ’E’ post trim casing. See ’E’ post trim casing - lh - with rear air conditioning fitted. 2. Release foam strip from around grab handle retaining bolts. 3. Remove 4 bolts securing grab handle to body. 4. [...]

CHASSIS AND BODY 65 REPAIR 9. Remove front sun roof aperture seal. 10. Release rear passenger interior lamp assembly from headlining panel, disconnect multiplug and remove lamp. 11. Release rear sun roof switch from headlining panel, disconnect multiplug and remove switch. 12. Remove 3 vents from headlining. 13. Working through sun roof switch hous[...]

76 CHASSIS AND BODY 66 REPAIR 15. Release LH and RH, ’A’ post trim finishers from uppermost retaining clips. 16. With assistance, release headlining from LH and RH, ’A’, ’B’ and ’D’ post finishers. 17. Remove headlining assembly. Dismantle 18. Remove 22 nuts securing headlining stowage nets and rear headlining panel. 19. Remove stow[...]

CHASSIS AND BODY 67 REPAIR ASH TRAY - DASH PANEL CENTRAL LOUVRE PANEL Service repair no - 76.67.26 Remove 1. Open ash tray. 2. Press release catch and remove ash tray. Refit 3. Fit ash tray. HEADLINING STOWAGE PANEL - FRONT - WITH SUN ROOF FITTED Service repair no - 76.67.27 Remove 1. Remove 10 screws securing stowage panel to body. 2. Release pane[...]

76 CHASSIS AND BODY 68 REPAIR Dismantle 4. Remove interior lamp lens. 5. Remove 2 nuts securing lamp to stowage panel. 6. Remove lamp. 7. Remove alarm volumetric sensor/blanking plate. 8. Remove electric sun roof switch pack. 9. Remove electric sun roof manual opening plug. Rebuild 10. Fit electric sun roof manual opening plug to panel. 11. Fit ala[...]

CHASSIS AND BODY 69 REPAIR FRONT SEAT BELTS - 5 DOOR (96 MODELS) Service repair no - 76.73.10 Remove 1. Move the seat to gain access to the seat belt mountings. 2. Remove the cover and securing bolt to release the upper mounting and spacer from the ’B’ post adjustable mounting. 3. Electric seats only: Release fixings securing the seat side vala[...]

76 CHASSIS AND BODY 70 REPAIR 8. Remove the securing bolt and detach the inertia reel from the bottom of the ’B’ post. 9. Release the seat belt sensor connector (if fitted). 10. Release Torx bolt to allow removal of the seat belt stalk assembly. Refit 11. Reverse removal procedure. NOTE: Ensure the seat belt is not twisted. 12. Re-connect the s[...]

HEATING AND VENTILATION 1 DESCRIPTION AND OPERATION HEATING AND VENTILATION UNIT The heating and ventilation and blower units are standard on all models. Air conditioning system is an optional module, which when fitted provides fully integrated climate control for the vehicle interior. The heating and ventilation unit controls the air distribution [...]

80 HEATING AND VENTILATION 2 DESCRIPTION AND OPERATION Through-flow ventilation Through-flow ventilation is achieved by means of one-way air extraction vents incorporated in both rear quarter body panels. The vents open and close automatically dependent upon the heating and ventilation unit control settings and the volume of air entering the vehicl[...]

HEATING AND VENTILATION 3 DESCRIPTION AND OPERATION Controls set for unheated air to footwells and face level vents Heater and ventilation operation The heating and ventilation system contains a heater matrix, which is connected to the engine cooling system, and a 4 speed fan for air distribution. Engine coolant is circulated through the heater mat[...]

80 HEATING AND VENTILATION 4 DESCRIPTION AND OPERATION Air direction flap Flap moves across mixing chamber to direct the air flow away from the heater matrix. Air temperature flap Control at HOT, flaps fully closed. All air flow passes through heater matrix. As control is moved towards COLD the flaps progressively open directing air flow away from [...]

HEATING AND VENTILATION 1 FAULT DIAGNOSIS HEATER OUTPUT Symptom:- Heater emits cold air. 1. Engine running: Check coolant valve opens as a temperature control is moved from COLD. 2. Check for engine running cold. See COOLING SYSTEM, Fault diagnosis, Engine Runs Cold 3. Check heater pipes and hoses for blockage or restriction. 4. Check heater matrix[...]

HEATING AND VENTILATION 1 REPAIR HEATER BLOWER SWITCH AND ILLUMINATION BULB Service repair no - 80.10.22 - Switch Service repair no - 86.48.73 - Bulb Remove 1. Pull 3 knobs from rotary controls. 2. Pull knob from blower switch. 3. Remove 2 screws retaining graphics panel. 4. Remove graphics plate. 5. Remove capless bulb. 6. Remove 4 screws retainin[...]

80 HEATING AND VENTILATION 2 REPAIR 8. Disconnect 4 multiplugs and position harness aside. NOTE: Do not carry out further dismantling if component is removed for access only. 9. Fan speed switch: remove fan speed switch slide and push out fan speed switch. 10. Pull out light bulb disconnect terminals and remove fan speed light strip. 11. Unclip 3 h[...]

HEATING AND VENTILATION 3 REPAIR Air direction 3. Set control fully clockwise 4. Release outer cable from 2 clips on unit. 5. Release cable from stud on flap lever. 6. Remove control cable from control lever. Temperature 7. Set RH control fully clockwise, LH control fully anti-clockwise 8. Release outer cable from 2 clips on unit. 9. Release cable [...]

80 HEATING AND VENTILATION 4 REPAIR WATER VALVE Service repair no - 80.10.16 Remove 1. Disconnect vacuum pipe from water valve. 2. Slacken 4 clips securing hoses to water valve. 3. Use a thin blade to break seal between hoses and nozzles 4. Disconnect heater inlet hose from valve. NOTE: A quantity of coolant will be released. 5. Disconnect heater o[...]

HEATING AND VENTILATION 5 REPAIR RECIRCULATION SWITCH Service repair no - 80.10.27 Remove 1. Release fascia centre louvre vent panel from its fitted position to gain access to rear of panel. See CHASSIS AND BODY, Repair, Dash Panel Central Louvre Panel 2. Disconnect multiplug from switch 3. From the rear, push switch out of panel. Refit 4. Reverse [...]

80 HEATING AND VENTILATION 6 REPAIR BLOWER MOTOR UNIT - HEATER AND AIR CONDITIONING Service repair no - 80.20.17 Service repair no - 82.25.54. Remove 1. Move seats to rear most position. 2. Disconnect battery negative lead. 3. Remove fascia panel assembly. See CHASSIS AND BODY, Repair, Dash Panel Assembly 4. Remove 2 nuts securing lower brackets to[...]

HEATING AND VENTILATION 7 REPAIR 5. Remove fan retaining clip. 6. Remove fan. 7. Remove 2 screws securing motor to casing. 8. Remove blower motor. Refit 9. Reverse removal procedure. HEATER MATRIX Service repair no - 80.20.29 Remove 1. Remove heater unit. See AIR CONDITIONING, Repair, Heater and Cooler Unit 2. Remove evaporator. See AIR CONDITIONIN[...]

HEATING AND VENTILATION 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm METRIC M5 6 ...................................................................................................... M6 9 .....................................[...]

AIR CONDITIONING 1 DESCRIPTION AND OPERATION AIR CONDITIONING SYSTEM COMPONENTS 1. Compressor 2. Condenser 3. Receiver/drier 4. Evaporator 5. High pressure servicing connection 6. Low pressure servicing connection 7. Dual pressure switch 8. Sight glass 9. Rear evaporator/blower motor assembly[...]

82 AIR CONDITIONING 2 DESCRIPTION AND OPERATION SCHEMATIC LAYOUT OF THE AIR CONDITIONING SYSTEM 1. Compressor 2. Condenser 3. Receiver/drier 4. Thermostatic expansion valve 5. Evaporator 6. Capillary tube 7. Dual pressure switch 8. Cooling fans to maintain air flow 9. Compressor high pressure relief valve 10. Sight glass - refrigerant 11. Drying ag[...]

AIR CONDITIONING 3 DESCRIPTION AND OPERATION AIR CONDITIONING SYSTEM OPERATION The air conditioning system provides the means of supplying cooled and dehumidified, fresh or recirculated air to the interior of the vehicle. The cooling effect is obtained by blowing air through the matrix of an evaporator unit and when required, mixing that air with h[...]

82 AIR CONDITIONING 4 DESCRIPTION AND OPERATION 5. Evaporator As this change of state occurs, a large amount of latent heat is absorbed. The evaporator is therefore cooled and as a result heat is extracted from the air flowing across the evaporator. The air flow is controlled by the ventilation fan which can be operated at anyone of four speeds. To[...]