Rover Land Discovery Specifications Page 1

DISCOVERYWorkshop Manual

01INTRODUCTION8INFORMATIONTRANSPORTING THE VEHICLE BY TRAILERLashing eyes are provided on front and rear of thechassis side members, to facilitate the

Tdi19REPAIROIL TEMPERATURE CONTROL VALVEService repair no - 12.60.69Remove1. Disconnect oil cooler pipes.2. Remove two bolts and carefully withdrawthe

12ENGINE20REPAIRCYLINDER HEAD GASKETService repair no - 12.29.02Remove1. Disconnect battery negative lead.2. Remove bonnet [Hood].See CHASSIS ANDBODY,

Tdi21REPAIR23. Remove rocker cover.24. Remove nuts and bolts and withdraw rockershaft assembly.25. Remove push rods, store as an identified set toallo

12ENGINE22REPAIRNOTE: Cylinder head retaining bolts canbe used up to a maximum of five times.34. Lubricate threads of bolts with light oil and fit top

Tdi23REPAIRVACUUM PUMPService repair no - 70.50.19RemoveNOTE: To ease pump removal set engineto T.D.C. on No.1 cylinder.1. Disconnect battery negative

Tdi1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the c

12ENGINE2SPECIFICATIONS, TORQUECylinder headCylinder head to cylinder block See repair section...St

Tdi3SPECIFICATIONS, TORQUETurbo charger oil drain adaptor to block 42...Oil drain pipe to turbocharge

12ENGINE4SPECIFICATIONS, TORQUEMETRIC NmM5 6...M6 9

V8i1DESCRIPTION AND OPERATIONDESCRIPTIONThe V8i engine has cast aluminium cylinder headsand cylinder block. The two banks of steel cylinderliners whic

INTRODUCTION9INFORMATIOND. Connect other end of second jumper cable to agood earth point on the engine, NOT TONEGATIVE TERMINAL OF DISCHARGEDBATTERY.

12ENGINE2DESCRIPTION AND OPERATION1. Cylinder block2. Pistons and gudgeon pins (8)3. Connecting rods (8)4. Core plugs5. Camshaft6. Dipstick7. Camshaft

V8i3DESCRIPTION AND OPERATION1. Cylinder heads (2)2. Rocker covers (2)3. PCV filter4. Rocker shafts (2)5. Hydraulic tappets (8)6. Pushrods (8)7. Rocke

12ENGINE4DESCRIPTION AND OPERATIONLubrication systemThe V8i full flow lubrication system uses a gear type oil pump which is driven from the front of t

V8i5DESCRIPTION AND OPERATIONDistributor and timing chain lubricationThe distributor and timing chain are lubricated fromthe camshaft front bearing. T

V8i1FAULT DIAGNOSISENGINE OIL PRESSURE TESTService tools:LRT-12-052: Pressure test equipmentWARNING: Use suitable exhaustextraction equipment, if test

12ENGINE2FAULT DIAGNOSISENGINE NOISESExcessive or obtrusive noise from the enginecompartment originates from three main sources:A. The exhaust system,

V8i3FAULT DIAGNOSISENGINE STARTING PROBLEMSEngine fails to crank in park or neutral (AutomaticTransmission)1. Is battery in good state of charge?NO -S

12ENGINE4FAULT DIAGNOSIS3. Are fuel supply, tank, pump, ventilation andemission control systems in correct workingorder or the fuel contaminated?NO -S

V8i5FAULT DIAGNOSISEngine backfires into inlet system1. Is the Distributor, HT connections and routingcorrect?NO -See ELECTRICAL, Repair, Distributor-

V8i1REPAIRDRIVE BELTA single ’serpentine drive belt’ is introduced for 1995model year. This belt drives the water pump and allthe ancilliaries. It is

01INTRODUCTION10INFORMATIONABBREVIATIONS AND SYMBOLS USED IN THISMANUALAcross flats (bolt size) AF...After bo

12ENGINE2REPAIRRemove1. Remove fan cowl upper.2. Release drive belt tension by turning tensionerclockwise.3. With tension released, remove belt fromge

V8i3REPAIRDRIVE BELT TENSIONERService repair no - 86.10.09Remove1. Remove drive belt from tensioner.See DriveBelt Renew2. Loosen tensioner centre bolt

12ENGINE4REPAIRCYLINDER HEAD GASKETS - RENEWService repair no - 12.29.011. Drain cooling system.See COOLING SYSTEM,Adjustment, Coolant2. Remove inlet

V8i5REPAIRCYLINDER HEADS - RENEWService repair no - 12.29.151. Remove cylinder heads and gaskets.SeeCylinder Head Gaskets - Renew2. Remove spark plugs

12ENGINE6REPAIR11. Place one end of gasket into cover recess withedge firmly against recess wall, holdingremainder of gasket clear. Work around cover,

V8i7REPAIRROCKER SHAFT RENEWService repair no - 12.29.291. Remove rocker covers as required.SeeRocker Cover - Right Hand - Renewor.SeeRocker Cover - L

12ENGINE8REPAIRCRANKSHAFT PULLEY ASSEMBLYService repair no - 12.21.011. Remove viscous coupling.See COOLINGSYSTEM, Repair, Viscous Coupling, FanBlades

V8i9REPAIRFRONT COVER GASKETService repair no - 12.65.041. Remove crankshaft pulley.See CrankshaftPulley Assembly. Do not remove pulleys2. Remove wate

12ENGINE10REPAIRTIMING CHAIN AND CHAINWHEELSService repair no - 12.65.12Remove1. Remove front cover.See Front Cover Gasket2. Remove retaining bolt and

V8i11REPAIRFLEXIBLE DRIVE PLATE AND RING GEARService repair no - 12.53.13Remove1. Remove transmission.See AUTOMATICGEARBOX, Repair, LT230T Transfer Ge

INTRODUCTION11INFORMATIONCROSS REFERENCE OF EMISSION SYSTEMTERMINOLOGYNEW TERM (ACRONYM)Accelerator pedal (AP)...

12ENGINE12REPAIR12. Ensure service tools LRT-12-010 andLRT-12-091 are scrupulously clean. Coat sealguide and oil seal journal with clean engine oil.CA

V8i13REPAIRNOTE: Release bolts securing compressormounting bracket to engine and removebracket to enable temporary lifting eyeETC 5964 to be fitted. S

12ENGINE14REPAIR39. Remove remaining bell housing to cylinder blockbolts.40. Remove starter motor ground strap fromchassis.41. Remove stands and lower

V8i15REPAIROIL SUMPService repair no - 12.60.44Remove1. Drain engine oilSee SECTION 10,Maintenance, Under Vehicle Maintenance2. Fit drain plug. Tighte

V8i1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the c

V8i1SERVICE TOOLSENGINELRT-12-034 Spring compressorMS1519ALRT-12-010 Crankshaft rear seal guideRO1014LRT-12-052 Oil pressure test kit

4.0 V81DESCRIPTION AND OPERATIONDESCRIPTIONFor description and operation refer to overhaulmanual 4.0/4.6 V8 engine.CONTENT OF THIS SECTIONOnly service

4.0 V81REPAIRCRANKSHAFT PULLEYService repair no - 12.21.01 - Crankshaft PulleyRemove1. Disconnect battery negative lead.2. Remove cooling fan.See COOL

12ENGINE2REPAIRCRANKSHAFT FRONT OIL SEALService repair no - 12.21.14 - Crankshaft Front OilSealRemove1. Remove crankshaft pulley.See ENGINE 3.9 V8,Rep

4.0 V83REPAIRENGINE ASSEMBLYService repair no - 12.41.01/99Remove1. Position vehicle on ramp.2. Remove bonnet.See CHASSIS AND BODY,Repair, Bonnet [Hoo

01INTRODUCTION12INFORMATIONVEHICLE IDENTIFICATION NUMBER (VIN)The Vehicle Identification Number and therecommended maximum vehicle weights are stamped

12ENGINE4REPAIR39. Release battery positive lead terminal cover.40. Remove terminal nut41. Release terminal from battery.42. Release fusebox main feed

4.0 V85REPAIR77. Release sensor/shield and remove.78. Disconnect sensor multiplug.79. Remove sensor.80. Remove starter motor heatshield.SeeELECTRICAL,

12ENGINE6REPAIR106. Remove top starter bolt securing engine earthcable.107. Remove nut securing kick-down cable clip to LHcylinder head.108. With assi

4.0 V87REPAIR171. Route drive belt around pulleys.172. Pivot tensioner downwards.173. Align belt to tensioner and release tensioner.174. Connect batte

12ENGINE8REPAIR9. Disconnect multiplug from camshaft sensor.See FUEL SYSTEM SFI, Repair, CamshaftPosition Sensor (CMP Sensor)10. Remove 9 bolts securi

4.0 V89REPAIR28. Remove alignment tool LRT-12-090.29. Apply a small amount of Loctite 242 to threadsand refit front cover bolts. Tighten to22 Nm.30. F

12ENGINE10REPAIRROCKER COVER GASKET - LEFT HANDService repair no - 12.29.40 - LH Cover GasketService repair no - 12.29.41 - RH Cover GasketRemove1. Di

4.0 V811REPAIRROCKER COVER GASKET - RIGHT HANDService repair no - 12.29.41 - RH Cover Gasket1. Depressurise fuel system.See FUEL SYSTEMSFI, Repair, Fu

12ENGINE12REPAIR12. Remove 4 bolts securing rocker cover to cylinderhead.13. Remove rocker cover.14. Remove and discard rocker cover gasket.Refit15. C

4.0 V813REPAIRCRANKSHAFT REAR OIL SEALService repair no - 12.21.20Remove1. Manual vehicles: Remove flywheel.SeeENGINE 3.9 V8, Repair, Flywheel2. Autom

INTRODUCTION13INFORMATIONEuropean vehicle identification number (VIN)Stamped on the right hand side chassis forward ofrear wheel.Federal (USA) vehicle

12ENGINE14REPAIRDRIVE PLATE - AUTOMATICService repair no - 12.53.13Remove1. Remove automatic gearbox and torqueconverter.See AUTOMATIC GEARBOX,Repair,

Mpi1DESCRIPTION AND OPERATIONDESCRIPTIONThe ’T’ Series engine is a four cylinder, water cooledunit comprising a cast iron cylinder block, aluminiumall

12ENGINE2DESCRIPTION AND OPERATIONThe aluminium alloy, tin coated pistons have twocompression and an oil control ring and are securedto the connecting

Mpi3DESCRIPTION AND OPERATIONLubricationOil is drawn from the pressed steel sump through astrainer (1) and into the oil pump (2); excess pressurebeing

12ENGINE4DESCRIPTION AND OPERATIONCYLINDER BLOCK COMPONENTS1. Cylinder block2. Knock sensor3. Crankshaft sensor4. Bolt - crankshaft sensor5. Locating

Mpi5DESCRIPTION AND OPERATION

12ENGINE6DESCRIPTION AND OPERATIONCYLINDER HEAD COMPONENTS1. Engine oil filler cap2. Filler cap seal3. Screw - spark plug cover4. Spark plug cover5. h

Mpi7DESCRIPTION AND OPERATION

12ENGINE8DESCRIPTION AND OPERATIONTIMING BELT COMPONENTS1. Bolt - timing belt upper cover2. Timing belt upper cover3. Bolt - camshaft timing gear4. Pl

Mpi1REPAIRCAMSHAFT FRONT OIL SEALService repair no - 12.13.07 - ExhaustService repair no - 12.13.09 - InletRemove1. Disconnect battery negative lead.2

01INTRODUCTION14INFORMATIONLOCATION OF IDENTIFICATION NUMBERSEngine serial number - 300Tdi EngineThe 300Tdi engine number is stamped on the cylinderbl

12ENGINE2REPAIR13. Remove 2 bolts securing camshaft gears tocamshafts.14. Remove tool LRT-12-060.CAUTION: Do not rotate camshafts.15. Remove gears not

Mpi3REPAIRFor torque values.See Specifications, torque,Torque Values3. Fit timing belt upper backplate and tighten boltsto the correct torque.4. Fit c

12ENGINE4REPAIRCRANKSHAFT FRONT OIL SEALService repair no - 12.21.14Remove1. Remove timing belt.See Camshaft Drive Belt2. Slide timing gear off cranks

Mpi5REPAIRCRANKSHAFT REAR OIL SEALService repair no - 12.21.20Remove1. Remove gearbox.2. Remove clutch assembly.3. Remove flywheel.4. Drain engine oil

12ENGINE6REPAIRENGINEService repair no - 12.41.01Remove1. Site vehicle onto ramp [hoist].2. Remove the drive belt.See SECTION 10,Maintenance, Under Bo

Mpi7REPAIRNOTE: On current models the generatorcover is omitted.9. Remove 3 nuts securing generator rear cover.10. Remove rear cover.11. Remove 3 nuts

12ENGINE8REPAIR21. Release clip and disconnect inlet hose frompower steering pump.22. Disconnect outlet pipe union at power steeringpump, discard ’O’

Mpi9REPAIR29. Disconnect oil pressure switch multiplug.30. Disconnect air conditioning compressormultiplug.31. Remove 3 bolts securing engine harness

12ENGINE10REPAIR38. Disconnect 2 ignition coil multiplugs.39. Disconnect 3 vacuum hoses from manifold.40. Release cover and remove bolt securing earth

Mpi11REPAIR43. Remove engine mounting heat shield. Removeupper nuts from engine L.H. and R.H.mountings.44. Release 4 screws and remove spark plug cove

INTRODUCTION15INFORMATIONAutomatic gearboxStamped on a plate riveted to the bottom left handside of the gearbox casing.

12ENGINE12REPAIR51. Remove engine L.H. and R.H. mounting lowernuts.52. Lower vehicle.53. Raise engine.54. Remove engine mountings.55. Lower engine.56.

Mpi13REPAIR19. Connect crankshaft sensor, knock sensor, airconditioning compressor, fuel injector harness,inlet manifold air temperature and fueltempe

12ENGINE14REPAIRRefit1. Clean sump, remove all traces of gasket frommating faces of sump and cylinder block.Visually check sump for damage.2. Apply be

Mpi15REPAIR4. Release clip and disconnect hose from heaterrail.5. Disconnect 2 coolant temperature sensormultiplugs.6. Release clips and disconnect th

12ENGINE16REPAIR14. Release clip and disconnect brake servo hosefrom manifold.15. Disconnect fuel temperature sensor multiplug.16. Remove 3 bolts secu

Mpi17REPAIR22. Raise vehicle23. Remove 4 nuts securing downpipe to exhaustmanifold.24. Release downpipe from exhaust manifold.25. Collect gasket.26. R

12ENGINE18REPAIRRefit1. Fit location dowels to cylinder head.2. Fit cylinder head gasket to cylinder block.3. Using assistance fit cylinder head to cy

Mpi19REPAIRCAMSHAFT COVER GASKETService repair no - 12.29.40 - ExhaustService repair no - 12.29.41 - InletRemove1. Release 4 screws from spark plug co

12ENGINE20REPAIRExhaust only13. Fit bolts finger tight.14. Working from the centre outwards, progressivelytighten bolts to the correct torque.10NmInle

Mpi21REPAIRCAUTION: Never use the camshaft gears,gear retaining bolts or timing belt to rotatecrankshaft.7. Fit tool LRT-12-058 to lock flywheel.8. Po

01INTRODUCTION16INFORMATIONFAULT DIAGNOSTIC EQUIPMENTTESTBOOKTodays Land Rover Vehicles are equipped with alarge amount of electronics to provide the

12ENGINE22REPAIRCAUTION: Ease timing belt off gears usingfingers only. Metal levers may damage thebelt and gears. Do not rotate engine withtiming belt

Mpi23REPAIRCHECK CAMSHAFT DRIVE BELTService repair no - 12.65.17CAUTION: This check must be carried outat the service intervals specified andwhenever

Mpi1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the c

Mpi1SERVICE TOOLSENGINELRT-12-056 Engine lifting bracket18G 1644LRT-12-058 Location pin valve timing18G 1523LRT-12-059 Crankshaft pulley locking tool1

12ENGINE2SERVICE TOOLSLRT-12-061 Protection sleeve crankshaft rear oil18G 1108 sealLRT-12-063 Remover camshaft oil seals18G 1476LRT-12-064 Replacer pi

Mpi3SERVICE TOOLSLRT-12-070 Sleeve crankshaft front oil seal18G 1510LRT-12-072 Replacer drift camshaft front oil sealsLRT-12-073 Remover crankshaft fr

12ENGINE4SERVICE TOOLSLRT-12-076 Replacer needle crankshaft bearing

EMISSION CONTROL1DESCRIPTION AND OPERATIONREV: 09/95EMISSION CONTROLThree systems are used to control the vehicleatmospheric emissions these are:Engin

17EMISSION CONTROL2DESCRIPTION AND OPERATION REV: 09/95Exhaust emission control.The fuel injection system provides accurately meteredquantities of fue

EMISSION CONTROL3DESCRIPTION AND OPERATIONREV: 09/95EXHAUST SYSTEM1. Manifold to front pipe connection.2. Heated oxygen sensor - pre-catalytic convert

GENERAL SPECIFICATION DATA1INFORMATIONENGINE 3.9 V8iType V8i...Number of

17EMISSION CONTROL4DESCRIPTION AND OPERATION REV: 09/95Evaporative emission control system - preadvanced EVAPS.The system is designed to prevent harmf

EMISSION CONTROL5DESCRIPTION AND OPERATIONREV: 09/95EVAPORATIVE CONTROL SYSTEM - PREADVANCED EVAPS1. Adsorption canister and purge valve.2. Location o

17EMISSION CONTROL6DESCRIPTION AND OPERATION ADD: 09/95EVAPORATIVE EMISSION CONTROL SYSTEM -ADVANCED EVAPSComponent location1. EVAP canister2. EVAP ca

EMISSION CONTROL7DESCRIPTION AND OPERATIONADD: 09/95Fuel filler neck componentsA Anti-trickle fill valveB Liquid/Vapour SeparatorC Vent line to pressu

17EMISSION CONTROL8DESCRIPTION AND OPERATION ADD: 09/95System operationThe system is designed to prevent fuel vapourescaping to atmosphere, and consis

EMISSION CONTROL1FAULT DIAGNOSISREV: 09/95TESTING EVAPORATIVE EMISSION CONTROL -PRE ADVANCED EVAPSThe following pressure test procedure is intended to

17EMISSION CONTROL2FAULT DIAGNOSIS ADD: 09/95DRIVE CYCLE - ADVANCED EVAPS1. Switch on ignition for 30 seconds.2. Ensure that coolant temperature is le

EMISSION CONTROL1REPAIRPOSITIVE CRANKCASE VENTILATION AIRINTAKE FILTERService repair no - 17.10.02The PCV air intake filter is located at the rear of

17EMISSION CONTROL2REPAIRHEATED OXYGEN SENSOR (HO2S)Service repair no - 19.26.16CAUTION: The removal of the sensorsfrom the exhaust system must only b

EMISSION CONTROL3REPAIRCHARCOAL CANISTERService repair no - 17.15.13Remove1. Disconnect battery negative lead.2. Pry out purge valve.3. Disconnect pip

0104050709101217192630333741444751545760647470757680828486Workshop manualDISCOVERYThis manual covers vehicles from1995 model year01 INTRODUCTION04 GEN

04GENERAL SPECIFICATION DATA2INFORMATIONPistonsClearance in bore, measured at bottomof skirt at right angles to piston pin 0,018-0,041 mm...

17EMISSION CONTROL4REPAIRHEATED OXYGEN SENSOR (HO2S) - 4.0 V8WARNING: Do not attempt HO2S removalwhen the exhaust is hot.RemoveFor all sensors:1. Rais

EMISSION CONTROL5REPAIRRear sensors9. Release sensor cable from clips.10. Release multiplug from bracket and disconnect.11. Unscrew and remove sensor

17EMISSION CONTROL6REPAIRCATALYTIC CONVERTER/FRONT PIPE - 4.0 V8Service repair no - 17.50.09WARNING: The removal of the exhaustsystem must only be car

EMISSION CONTROL7REPAIREVAP CANISTER AND PURGE VALVE - 4.0 V8Service repair no - 17.15.13Remove1. Disconnect battery negative lead.2. Disconnect multi

17EMISSION CONTROL8REPAIR ADD: 09/95EVAP CANISTER - ADVANCED EVAPSService repair no - 17.15.13Remove1. Disconnect battery negative lead.2. Release cli

EMISSION CONTROL9REPAIRADD: 09/95EVAP CANISTER VENT SOLENOID - ADVANCEDEVAPSService repair no - 17.15.43Remove1. Disconnect battery negative lead.2. R

Tdi1DESCRIPTION AND OPERATIONDESCRIPTIONAir intakeThe air cleaner is positioned to the right of the engineand connected by hoses to a cold air intake

19FUEL SYSTEM2DESCRIPTION AND OPERATIONFUEL SYSTEM LAYOUT1. Fuel tank2. Fuel lift pump3. Fuel filter4. Fuel injection pump5. Spill return line6. Fuel

Tdi3DESCRIPTION AND OPERATION

19FUEL SYSTEM4DESCRIPTION AND OPERATIONOPERATIONDiesel engines operate by compression ignition. Therapid compression of air in the cylinder during the

GENERAL SPECIFICATION DATA3INFORMATIONENGINE 4.0 V8Type 4.0 litre V8...N

Tdi5DESCRIPTION AND OPERATIONExhaust Gas Recirculation (EGR)Operation of the EGR system is dependent on thefollowing:a. Engine temperature - must be b

19FUEL SYSTEM6DESCRIPTION AND OPERATIONDESCRIPTION ELECTRONIC DIESEL CONTROLThe Electronic Diesel Control (EDC) ’drive by wire’system derives its from

Tdi7DESCRIPTION AND OPERATION

19FUEL SYSTEM8DESCRIPTION AND OPERATIONFUEL SYSTEM LAYOUT EDC1. Fuel injection pump2. Fuel temperature sensor3. Air temperature sensor4. Water tempera

Tdi9DESCRIPTION AND OPERATIONOPERATION EDCUnder start up conditions, signals from the crankspeed and water temperature sensors are relayed tothe ECM t

19FUEL SYSTEM10DESCRIPTION AND OPERATIONVehicle speed sensorThe vehicle speed sensor is located on the transferbox behind the transmission brake. The

Tdi1ADJUSTMENTTHROTTLE CABLEAdjust1. Loosen throttle cable adjustment ferrule.2. Hold throttle lever in fully closed position.3. Adjust outer cable, b

19FUEL SYSTEM2ADJUSTMENTLOW AND HIGH IDLE SPEEDAdjustThe high idle speed (cold start idle) isautomatically set by the setting of the low idlespeed and

Tdi1REPAIRTANK SENDER UNITService repair no - 88.25.32WARNING: Ensure that the WARNINGSand FUEL HANDLING PRECAUTIONSgiven in Section 01 are adhered to

19FUEL SYSTEM2REPAIRTHROTTLE CABLEService repair no - 19.20.06Remove1. Disconnect battery negative lead.2. Remove pin and clevis pin securing throttle

04GENERAL SPECIFICATION DATA4INFORMATIONPiston ringsNumber of compression rings 2...Number of control rings 1..

Tdi3REPAIRTURBOCHARGER OIL FEED PIPEService repair no - 19.42.14Remove1. Disconnect battery negative lead.2. Remove exhaust front pipe.See MANIFOLDAND

19FUEL SYSTEM4REPAIRTURBOCHARGER ACTUATORService repair no - 19.42.31Remove1. Remove exhaust manifold and turbocharger.See MANIFOLD AND EXHAUST SYSTEM

Tdi5REPAIRFUEL LIFT PUMPService repair no - 19.45.09Remove1. Loosen unions securing fuel injection pipes toinjectors and injector pump. Remove injecti

19FUEL SYSTEM6REPAIRFUEL FILTER ELEMENTService repair no - 19.25.07Remove1. Disconnect battery negative lead.2. Clean area around filter head.3. Place

Tdi7REPAIR9. Move intercooler upwards and clear of fan cowl.Refit10. Ensure locatiing lug grommets are fitted and ingood condition.11. Ensure foam pad

19FUEL SYSTEM8REPAIRAll glow plugs5. Remove terminal nut from glow plug, disconnectwire from glow plug terminal.6. Remove glow plug.Refit7. Clean glow

Tdi9REPAIRGLOW PLUG CONTROL UNITService repair no - 19.60.33Remove1. Disconnect battery negative lead.2. Remove nut and bolt securing control unit tom

19FUEL SYSTEM10REPAIREGR THROTTLE POSITION SENSORService repair no - 19.30.14Remove1. Remove 2 screws securing sensor mountingplate to injection pump.

Tdi11REPAIRFUEL INJECTION PUMP AND TIMINGService repair no - 19.30.07NOTE: The following text refers to a Tdivehicle with a manual gearbox withoutelec

19FUEL SYSTEM12REPAIR12. Remove pin from pump gear.13. Fit gear retaining tool LRT-12-045 with an 8 mmwasher, 1.5 to 2 mm thick, under each bolt headi

GENERAL SPECIFICATION DATA5INFORMATIONFUEL SYSTEM 3.9 V8iFuel system type Lucas 14CUX hot wire system electronically controlled...

Tdi13REPAIRRefit21. 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

19FUEL SYSTEM14REPAIRENGINE CONTROL MODULE (ECM)Service repair no - 18.30.03NOTE: The ECM is not a serviceable item,in the event of failure it must be

Tdi15REPAIRBOOST PRESSURE SENSORService repair no - 18.30.63Remove1. Disconnect battery negative lead.2. Disconnect sensor multi-plug.3. Disconnect pr

19FUEL SYSTEM16REPAIRENGINE SPEED SENSORService repair no - 18.30.65Remove1. Disconnect battery negative lead.2. Disconnect sensor multi-plug.3. Place

Tdi17REPAIRVEHICLE SPEED SENSORService repair no - 18.30.22RemoveNOTE: The following procedure is carriedout with the ramp still raised.1. Disconnect

19FUEL SYSTEM18REPAIRBRAKE PEDAL SWITCHService repair no - 18.30.66Remove1. Disconnect battery negative lead.2. Disconnect switch wiring Lucars.3. Loo

Tdi19REPAIRTHROTTLE POSITION SENSORService repair no - 18.30.17NOTE: The throttle position sensor is not aserviceable item, in the event of failure it

MFI1DESCRIPTION AND OPERATIONDESCRIPTIONHot Wire Multiport Fuel InjectionThe ’Hot Wire’ Multiport fuel injection system derivesits name from the mass

19FUEL SYSTEM2DESCRIPTION AND OPERATIONFuel pressure regulatorThe fuel pressure regulator is mounted in the fuel railat the rear of the plenum chamber

MFI3DESCRIPTION AND OPERATIONTune select resistor -To suit individual market requirements a tune selectresistor is connected across pins 5 and 27 of t

04GENERAL SPECIFICATION DATA6INFORMATIONFUEL SYSTEM (GEMS) 4.0 V8 ENGINEType Sagem - Lucas Gems 8 hot wire system electronically...

19FUEL SYSTEM4DESCRIPTION AND OPERATIONENGINE MOUNTED COMPONENTS1. By-pass air valve (stepper motor).2. Fuel pressure regulator.3. Air flow meter.4. T

MFI5DESCRIPTION AND OPERATIONCHASSIS MOUNTED COMPONENTS1. Fuel filter.2. Fuel pump (in fuel tank).

19FUEL SYSTEM6DESCRIPTION AND OPERATIONBODY MOUNTED COMPONENTS1. Engine control module (ECM).2. Main relay and fuel pump relay.3. Inertia switch.4. Ig

MFI7DESCRIPTION AND OPERATIONMICRO PROCESSOR POWER CHECK(Instrument binnacle - Service use only)As part of the engine starting procedure, this symbolw

MFI1FAULT DIAGNOSISENGINE TUNINGCircuit fault diagnosis may be carried out on all V8ivehicles, using Testbook. Testbook will guide theoperator by visu

19FUEL SYSTEM2FAULT DIAGNOSISBASE IDLE SPEED SETTINGNOTE: Base idle speed is set at factory. Itshould not require further adjustmentunless plenum cham

MFI3FAULT DIAGNOSISFUEL PRESSURE CHECKIn order to check the fuel pressure it is necessary tofirst depressurise the fuel system as follows:WARNING: Und

MFI1REPAIRAIR CLEANER ASSEMBLYService repair no - 19.10.01Remove3.9 V8 vehicle illustrated1. Release 2 clips securing air cleaner to air flowsensor.2.

19FUEL SYSTEM2REPAIRAIR FLOW SENSORService repair no - 19.22.25RemoveNOTE: The air flow sensor is not aserviceable item. In event of failure ordamage

MFI3REPAIRIDLE AIR CONTROL VALVEService repair no - 19.22.54Remove1. Disconnect battery negative lead.2. Disconnect multi-plug.3. Unscrew valve from r

GENERAL SPECIFICATION DATA7INFORMATIONSHIFT SPEED AUTOMATIC ZF ON 3.9 V8iOPERATION SELECTOR VEHICLE SPEED ENGINE SPEEDPOSITON APPROX APPROX (RPM)KICKD

19FUEL SYSTEM4REPAIRMULTIPORT FUEL INJECTION RELAYSService repair no - 19.22.08The two Multiport fuel injection relays are located inthe RH footwell a

MFI5REPAIRINERTIA FUEL SHUTOFF SWITCHService repair no - 18.30.35The inertia fuel shutoff switch is located on thebulkhead next to the washer reservoi

19FUEL SYSTEM6REPAIRENGINE COOLANT TEMPERATURE SENSORService repair no - 19.22.18Remove1. Position drain tray to collect coolant spillage.2. Disconnec

MFI7REPAIRFUEL PRESSURE REGULATORService repair no - 19.45.06Remove1. Depressurise fuel system.See DepressurisingFuel System2. Disconnect battery nega

19FUEL SYSTEM8REPAIR10. Remove fuel rail and injectors.11. Remove injector retaining clips, ease injectorsfrom rail. Remove and discard ’O’ rings from

MFI9REPAIR15. Remove distributor vacuum hose.16. Release two screws and remove throttle positionsensor.17. Remove six screws securing plenum chamber.R

19FUEL SYSTEM10REPAIRKEY1. Spherical bush/housing2. Retaining clips (2)3. Countershaft assembly4. Overtravel spring5. Throttle shaft nut6. Throttle re

MFI11REPAIR25. Remove three bolts securing throttle bracket toplenum chamber, withdraw bracket assembly.26. Remove tab washer and throttle stop lever

19FUEL SYSTEM12REPAIRThrottle disc - inspect and overhaul36. Examine throttle shaft for excessive wearbetween bushes in plenum chamber and shaft.A sma

MFI13REPAIR44. Grease new air seal with Admax L3 orEnergrease LS3. Push seal down shaft, intocounterbore until seal is 6.0 mm (0.236 in) belowface of

04GENERAL SPECIFICATION DATA8INFORMATIONSHIFT SPEED AUTOMATIC ZF ON Tdi ENGINEOPERATION SELECTOR VEHICLE SPEED ENGINE SPEEDPOSITON APPROX APPROX (RPM)

19FUEL SYSTEM14REPAIRRAM HOUSINGService repair no - 19.70.04Remove1. Disconnect battery negative lead.2. Remove plenum chamber.See PlenumChamber3. Rel

MFI15REPAIR11. Loosen clip and disconnect top hose fromthermostat housing.12. Disconnect multiplug from distributor amplifiermodule.13. Loosen clip an

19FUEL SYSTEM16REPAIRRefit1. Clean mating faces of cylinder heads, cylinderblock and intake manifold.2. Locate NEW seals in position with endsengaged

MFI17REPAIRFUEL FILTERService repair no - 19.25.02RemoveWARNING: Spilling of fuel is unavoidableduring this operation. Ensure allnecessary precautions

19FUEL SYSTEM18REPAIRFUEL PIPESService repair no - 19.40.92WARNING: Depressurise fuel system.SeeDepressurise Fuel Systembeforedisconnecting any fuel p

MFI19REPAIRTHROTTLE CABLEService repair no - 19.20.06Remove1. Remove clevis pin securing cable to lever.2. Carefully pry throttle cable adjustment nut

19FUEL SYSTEM20REPAIRACCELERATOR PEDALService repair no - 18.30.35Remove1. Remove lower dash panel.2. Remove clevis pin securing throttle cable toacce

MFI21REPAIR6. Remove access panel from floor.7. Disconnect multi-plug from fuel sender unit.8. Disconnect two fuel line unions from fuel pump.9. Using

19FUEL SYSTEM22REPAIRFUEL TANKService repair no - 19.55.01WARNING: Ensure that fuel handlingprecautions given in Section 01 -introduction are strictly

MFI23REPAIR13. Remove back two bolts and nut plates securingfuel tank cradle.14. Remove front nuts, bolts and washers. Removefuel tank cradle.15. With

GENERAL SPECIFICATION DATA9INFORMATIONTRANSMISSION 3.9 V8iManual gearboxType R380 Single helical constant mesh...

MFI1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the c

MFI1SERVICE TOOLSFUEL SYSTEMLRT-19-004 Test equipment fuel pressure18G 500LRT-19-003 MFI pressure test adaptorLST 143LRT-19-002 Connector splitterLST

SFI1DESCRIPTION AND OPERATIONENGINE MANAGEMENT SYSTEMDescriptionThe engine management system (EMS) maintainsoptimum engine performance over the entire

19FUEL SYSTEM2DESCRIPTION AND OPERATION REV: 09/95ENGINE MANAGEMENT SYSTEM COMPONENTLOCATION - PRE ADVANCED EVAPS1. Engine control module2. Ignition c

SFI3DESCRIPTION AND OPERATION1. EVAP purge valve2. Inertia switch3. Engine fuel temperature sensor4. Crankshaft position sensor5. Oxygen sensor (4 off

19FUEL SYSTEM4DESCRIPTION AND OPERATIONThrottle position sensor (TP Sensor)The throttle position sensor is mounted on the plenumchamber and connected

SFI5DESCRIPTION AND OPERATIONREV: 09/95Engine fuel temperature sensor (EFT Sensor)This is another resistive sensor. Located on the fuelrail it measure

19FUEL SYSTEM6DESCRIPTION AND OPERATION REV: 09/95Idle air control (IAC)Idle speed is controlled by a stepper motor whichconsists of two coils. When e

SFI7DESCRIPTION AND OPERATIONREV: 09/95Fuel pressure regulatorThe fuel pressure regulator is located at the rear ofthe engine in the fuel rail. It con

19FUEL SYSTEM8DESCRIPTION AND OPERATION ADD: 09/95ENGINE MANAGEMENT SYSTEM COMPONENTLOCATION - ADVANCED EVAPS1. Engine control module (ECM)2. Ignition

04GENERAL SPECIFICATION DATA10INFORMATIONCOOLING SYSTEM 3.9 V8iSystem type Pressurised, spill return, thermostatically controlled...

SFI9DESCRIPTION AND OPERATIONADD: 09/951. EVAP canister purge valve2. EVAP canister vent solenoid (ECVS)3. Inertia fuel shut-off (IFS)4. Engine fuel t

19FUEL SYSTEM10DESCRIPTION AND OPERATION ADD: 09/95DESCRIPTION AND OPERATION - ADVANCEDEVAPS1. Fuel filter2. Fuel pump and gauge sender unit3. Fuel fe

SFI11DESCRIPTION AND OPERATIONADD: 09/95Fuel Filler Neck AssemblyThe filler neck consists of a stainless steel uppersection and a convolute nylon lowe

SFI1ADJUSTMENTENGINE TUNINGService repair no - 19.22.13The position of the Idle Air Control (IAC) valve can bechecked using TestBook and adjusted if n

SFI1REPAIRCAMSHAFT POSITION SENSOR (CMP SENSOR)Service repair no - 19.22.07Remove1. Disconnect battery negative lead.2. Raise vehicle on a ramp.3. Rel

19FUEL SYSTEM2REPAIRENGINE COOLANT TEMPERATURE SENSOR (ECTSENSOR)Service repair no - 18.30.10Remove1. Disconnect battery negative lead.2. Remove sprin

SFI3REPAIRFUEL SYSTEM - DEPRESSURISEWARNING: Fuel pressure of up to 2.5 barwill be present in the system, even if theengine has not been run for some

19FUEL SYSTEM4REPAIRENGINE CONTROL MODULE (ECM)Service repair no - 18.30.01Remove1. Disconnect battery negative lead.2. Release and move washer reserv

SFI5REPAIRFUEL RAIL AND INJECTORSService repair no - 19.60.04 - Fuel RailService repair no - 19.60.12 - InjectorsRemove1. Disconnect battery negative

19FUEL SYSTEM6REPAIR15. Disconnect hose, plug return hose and rail.Remove cloth.16. Remove 6 nuts securing fuel rail and ignition coilbracket to inlet

GENERAL SPECIFICATION DATA11INFORMATIONSUSPENSIONType Coil springs controlled by telescopic dampers front...

SFI7REPAIRFUEL TEMPERATURE SENSORService repair no - 19.22.08RemoveNOTE: Because fuel leakage will not occurwhen sensor is removed, it is notnecessary

19FUEL SYSTEM8REPAIRIGNITION COILSService repair no - 18.20.45 - SetService repair no - 18.20.43 - EachService repair no - 18.20.44 - Extra - EachRemo

SFI9REPAIRINTAKE AIR TEMPERATURE SENSOR (IATSENSOR)Service repair no - 18.30.09Remove1. Disconnect multiplug from IAT sensor.2. Remove IAT sensor from

19FUEL SYSTEM10REPAIRKNOCK SENSORService repair no - 18.30.28 - Sensor - LHService repair no - 18.30.30 - Sensor - RHCAUTION: Due to the sensitivity o

SFI11REPAIRFUEL PRESSURE REGULATORService repair no - 19.45.06Remove1. Disconnect battery negative lead.2. Depressurise fuel system.See Fuel System -D

19FUEL SYSTEM12REPAIRRefit15. Ensure locations on fuel pressure regulator andfuel rail are clean.16. Fit new spacer ring and ’O’ ring to fuel pressure

SFI13REPAIRPLENUM CHAMBERService repair no - 19.22.46Remove1. Disconnect battery negative lead.2. Slacken clip securing intake hose to plenumchamber a

19FUEL SYSTEM14REPAIR19. Disconnect hoses and remove plenum chamber.20. Place cloth over ram pipes to prevent ingress offoreign matter.21. Remove 4 bo

SFI15REPAIRREV: 09/95Refit25. Ensure all mating surfaces are clean.26. Fit TP sensor. Ensure drive engages correctlywith throttle spindle.27. Position

19FUEL SYSTEM16REPAIR ADD: 09/95RELAY MODULE - ADVANCED EVAPSService repair no - 18.30.71Remove1. Release module from bracket.2. Disconnect 2 multiplu

INTRODUCTION1INFORMATIONINTRODUCTIONThis workshop manual covers vehicles from 1995model year onwards. Amendments and additionalpages will be issued to

04GENERAL SPECIFICATION DATA12INFORMATIONSHOCK ABSORBERSType Telescopic, double-acting non-adjustable...

SFI17REPAIRADD: 09/95Refit6. Fit a NEW filter to bracket.NOTE: Ensure direction of flow arrowstamped on canister is correct.7. Position filter mountin

19FUEL SYSTEM18REPAIR ADD: 09/956. Fold back loadspace carpet and soundinsulation to reveal access panel.7. Remove 6 screws securing fuel pump accessp

SFI19REPAIRADD: 09/9512. Using service tool LRT-19-009 loosen andremove the metal locking ring.13. Prise the pump from the tank opening using ablunt i

19FUEL SYSTEM20REPAIR ADD: 09/95FUEL SYSTEM - DEPRESSURISE - ADVANCEDEVAPSService repair no - 19.50.02WARNING: Fuel pressure of up to 2.5 barwill be p

SFI21REPAIRADD: 09/955. Fold back loadspace carpet and soundinsulation to reveal access panel.6. Remove 6 screws securing fuel pump accesspanel.7. Rem

19FUEL SYSTEM22REPAIR ADD: 09/9512. Mark location of anti-roll [sway] bar straps.13. Remove nuts and bolts securing anti-roll [sway]bar straps, and al

SFI23REPAIRADD: 09/9520. Remove nut and bolt securing RH side of upperfuel tank strap to chassis.21. Remove 4 nuts and bolts securing fuel tankcradle.

19FUEL SYSTEM24REPAIR ADD: 09/95Refit29. Fit NEW pump seal to tank opening.30. Carefully lower pump into tank opening, pressingfirmly on the pump top

SFI25REPAIRADD: 09/955. Fold back loadspace carpet and soundinsulation to reveal access panel.6. Remove 6 screws securing fuel pump accesspanel.7. Rem

19FUEL SYSTEM26REPAIR ADD: 09/95FUEL FILLER NECK - ADVANCED EVAPSService repair no - 19.55.07WARNING: Ensure that fuel handlingprecautions given in 1

GENERAL SPECIFICATION DATA13INFORMATIONAIR CONDITIONINGSystem Nippon Denso...

SFI27REPAIRADD: 09/9511. Disconnect vent line quickfit connector fromliquid/vapour separator.12. Remove torque screw cap from hose to tankfiller neck

19FUEL SYSTEM28REPAIR ADD: 09/95Refit26. Fit vent line to filler neck.27. Fit NEW clip to filler neck hose.28. Fit hose to filler neck.29. Position fi

SFI29REPAIRADD: 09/95ANTI-TRICKLE FILL VALVE - ADVANCED EVAPSService repair no - 19.55.31Remove1. Remove the fuel filler neck.See fuel filler neck- ad

Mpi1DESCRIPTION AND OPERATIONDESCRIPTIONThe Mpi Modular Engine Management System(MEMS) controls the fuel injection and programmedignition systems.The

19FUEL SYSTEM2DESCRIPTION AND OPERATIONBasic ignition timingMEMS provides the optimum ignition timing for therelevant engine speed and load. The speed

Mpi3DESCRIPTION AND OPERATIONFuel systemECMThe MEMS system is controlled by the ECM which islocated in the engine compartment.The ECM is an adaptive u

19FUEL SYSTEM4DESCRIPTION AND OPERATIONInjectorsThe four fuel injectors are fitted between thepressurised fuel rail and inlet manifold. Each injectorc

Mpi5DESCRIPTION AND OPERATIONFuel pumpThe electric fuel pump, located inside the fuel tank, isa self-priming centrifugal ’wet’ pump, the motor andpump

19FUEL SYSTEM6DESCRIPTION AND OPERATIONNon - evaporative loss equipment1. Throttle disc2. Fuel cut-off valve3. Two way valve4. Charcoal canister5. Pur

Mpi7DESCRIPTION AND OPERATIONMEMS COMPONENTS & LOCATION ON VEHICLEComponents Location1 Fuel pump Fuel tank...

04GENERAL SPECIFICATION DATA14INFORMATIONCoilMake/type Bosch 0221 122 392...Distr

19FUEL SYSTEM8DESCRIPTION AND OPERATIONMEMS COMPONENTS & LOCATION ON ENGINEComponents Location1 Fuel pressure regulator Engine rear...

Mpi9DESCRIPTION AND OPERATIONSYSTEM OPERATIONIgnition onWhen the ignition is switched on, voltage is applied toECM pin 11. The ECM then switches on th

19FUEL SYSTEM10DESCRIPTION AND OPERATIONDrivingWhen the throttle pedal is depressed, the ECMimplements the cruise air/fuel ratio map. Duringdriving th

Mpi1ADJUSTMENTTHROTTLE CABLEAdjustNOTE: Use diagnostic equipment toensure that the throttle potentiometer andstepper motor are synchronised beforeadju

Mpi1REPAIRKNOCK SENSORService repair no - 18.30.18Remove1. Disconnect multiplug from knock sensor.2. Remove knock sensor.Refit3. Clean mating face of

19FUEL SYSTEM2REPAIRCOOLANT TEMPERATURE SENSORService repair no - 18.30.10Remove1. Position drain tin below coolant pump hose.2. Disconnect sensor mul

Mpi3REPAIRFUEL TEMPERATURE SENSORService repair no - 18.30.08Remove1. Disconnect fuel temperature sensor multiplug.2. Remove fuel temperature sensor.3

19FUEL SYSTEM4REPAIRCHARCOAL CANISTERService repair no - 17.15.13Remove1. Disconnect multiplug from purge valve.2. Release clip and disconnect hose fr

Mpi5REPAIR6. Remove nut securing throttle cable bracket tobrake servo and release cable.7. Release grommet from bulkhead and withdrawcable.8. Locate c

19FUEL SYSTEM6REPAIRINTAKE AIR TEMPERATURE SENSORService repair no - 18.30.09Remove1. Disconnect multiplug from temperature sensor.2. Remove sensor fr

GENERAL SPECIFICATION DATA15INFORMATIONBULBSREPLACEMENT BULBS TYPEExterior lightsHeadlamps 12V 60/55W (Halogen)Headlamps - France amber 12V 60/55W (Ha

Mpi7REPAIRFUEL RAIL AND INJECTORSService repair no - 19.60.04 - RailService repair no - 19.60.10 - InjectorsRemove1. Remove inlet manifold chamber gas

19FUEL SYSTEM8REPAIRRefit17. Clean fuel rail, temperature sensor and pressureregulator mating surfaces.18. Fit fuel temperature sensor. Tighten to7Nm1

Mpi9REPAIRRefit9. Examine flexible mounting for splits or damage;renew as necessary.10. Thoroughly clean throttle housing and matingface of flexible m

19FUEL SYSTEM10REPAIRRefit9. Clean pressure regulator and mating surfaces.10. Fit new ’O’ ring to pressure regulator.11. Fit vacuum hose to pressure r

Mpi11REPAIRAIR CLEANERService repair no - 19.10.01Remove1. Release clip and remove intake hose from aircleaner.2. Ease air cleaner assembly bottom mou

CRUISE CONTROL1DESCRIPTION AND OPERATIONCRUISE CONTROL COMPONENT LOCATIONS -Tdi AUTO EDCCOMPONENT LOCATION1. Cruise control unit Under LH dash...

19FUEL SYSTEM2DESCRIPTION AND OPERATIONCRUISE CONTROL SYSTEM - V8i/Tdi AUTO EDCDescriptionThe cruise control system consists ofelectro-mechanical devi

CRUISE CONTROL1FAULT DIAGNOSISROAD TESTCAUTION: Do not engage cruise controlwhen vehicle is being used in low transfergear or reverse.WARNING: The use

CRUISE CONTROL1REPAIRBRAKE AND CLUTCH PEDAL SWITCHES/VENTVALVESService repair no - 19.75.34 - Clutch SwitchService repair no - 19.75.35 - Brake Switch

19FUEL SYSTEM2REPAIRENGAGEMENT (ON/OFF) SWITCHService repair no - 19.75.30Switch ReplacementRemove1. Disconnect battery negative lead.2. Carefully rel

04GENERAL SPECIFICATION DATA16INFORMATIONVEHICLE WEIGHTS AND PAYLOADWhen loading a vehicle to its maximum (Gross Vehicle Weight), consideration must b

CRUISE CONTROL3REPAIR5. Disconnect 2 Lucars from horn contacts.6. Remove 2 screws securing cruise control switchto steering wheel.7. Remove 3 bolts se

19FUEL SYSTEM4REPAIRNOTE: If rotary coupler is to be re-used apiece of adhesive tape should be placedaround the moulding in position A toprevent rotat

CRUISE CONTROL5REPAIRACTUATOR LINK-SETTING - V8iService repair no - 19.75.21NOTE: Setting procedure is carried out atminimum throttle condition only.1

19FUEL SYSTEM6REPAIRVACUUM PUMP - TDIService repair no - 19.75.06NOTE: The vacuum pump is nonserviceable, fit a new unit if failure ordamage occurs.Re

CRUISE CONTROL7REPAIRCRUISE CONTROL ECU - V8iService repair no - 19.75.49Remove1. Remove lower dash panel.2. Disconnect ECU multi-plug.3. Remove ECU f

19FUEL SYSTEM8REPAIRACTUATOR - TdiService repair no - 19.75.05NOTE: The actuator is non serviceable, fita new unit if failure or damage occurs.Remove1

CRUISE CONTROL9REPAIRCRUISE CONTROL ECU - TdiService repair no - 19.75.49Remove1. Remove 4 studs securing fascia left handclosing panel.2. Remove clos

Tdi1DESCRIPTION AND OPERATIONENGINE COOLINGDescriptionThe Tdi engine uses a pressurized cooling systemand cross flow radiator which is supplied from a

26COOLING SYSTEM2DESCRIPTION AND OPERATIONVISCOUS FANDescriptionThe viscous drive unit for the engine cooling fan,provides a means of controlling the

Tdi3DESCRIPTION AND OPERATIONViscous unit slipping (Engine at normal runningtemperature)1. Inner member (drive in fast)2. Outer member (drive out slow

GENERAL SPECIFICATION DATA17INFORMATIONTYRE PRESSURESPressures: Check Normal on and off-road use. Off-road ’emergency’ soft usemaximumwith tyres cold

Tdi1FAULT DIAGNOSISENGINE OVERHEATINGBefore conducting any cooling system diagnosis:SeeDescription and operation, Engine Cooling1. Is coolant level co

26COOLING SYSTEM2FAULT DIAGNOSISENGINE RUNS COLDBefore conducting any cooling system diagnosis:SeeDescription and operation, Engine Cooling1. Check op

Tdi1ADJUSTMENTCOOLANTService repair no - 26.10.01DrainingWARNING: Do not remove any caps orplugs when the engine is hot. The coolingsystem is pressuri

Tdi1REPAIRVISCOUS COUPLING, FAN BLADES, PULLEY ANDFAN COWLService repair no - 26.25.03/05Viscous coupling - Remove 1to3Fan blades - Remove 1to4Fan cow

26COOLING SYSTEM2REPAIRWATER PUMPService repair no - 26.50.01RemoveWARNING: Disconnect battery negativeterminal to prevent engine being startedbefore

V8i1DESCRIPTION AND OPERATIONENGINE COOLINGDescriptionThe V8i engine uses a pressurised cooling systemand cross flow radiator which is supplied from a

26COOLING SYSTEM2DESCRIPTION AND OPERATIONCOOLANT CIRCULATIONOperationWhen the engine is started from cold the thermostatprevents any coolant circulat

V8i3DESCRIPTION AND OPERATIONPlenum chamber heatingAir entering the plenum chamber is heated by a flowof coolant from the inlet manifold which returns

26COOLING SYSTEM4DESCRIPTION AND OPERATIONOperationThe viscous unit consists of two principal components:An inner member 1 which is secured to water p

V8i5DESCRIPTION AND OPERATIONHot conditionsWhen operating in high ambient temperatures orwhen stationary in traffic, the bi-metal thermostat willopera

04GENERAL SPECIFICATION DATA18INFORMATION300 Tdi ENGINEType Direct injection, turbocharged, intercooled...

V8i1FAULT DIAGNOSISENGINE OVERHEATINGBefore conducting any cooling system diagnosis:SeeDescription and operation, Engine Cooling1. Is coolant level co

26COOLING SYSTEM2FAULT DIAGNOSISENGINE RUNS COLDBefore conducting any cooling system diagnosis:SeeDescription and operation, Engine cooling1. Check op

V8i1ADJUSTMENTCOOLANT REQUIREMENTSFrost precautions and engine protection.Cooling system MUST ALWAYS be filled andtopped-up with solution of water and

26COOLING SYSTEM2ADJUSTMENT3. Disconnect bottom hose from radiator. Draincoolant into a clean container. Reconnect bottomhose, re-tighten hose clamp.N

V8i1REPAIREXPANSION TANKService repair no - 26.15.01RemoveWARNING: Do not remove expansion tankfiller cap when engine is hot. The coolingsystem is pre

26COOLING SYSTEM2REPAIR3. Use LRT-12-093 to prevent coolant pump pulleyfrom turning and using LRT-12-094, unscrewviscous coupling from water pump.NOTE

V8i3REPAIRTHERMOSTATService repair no - 26.45.01Remove1. Partially drain cooling system, until coolant levelis below thermostat housing.2. Disconnect

26COOLING SYSTEM4REPAIRRADIATORService repair no - 26.40.01Remove1. Drain cooling system.See Adjustment,Coolant2. Remove viscous coupling and fan asse

V8i5REPAIR

26COOLING SYSTEM6REPAIRWATER PUMPService repair no - 26.50.01RemoveWARNING: Disconnect battery negativeterminal to prevent engine being startedbefore

GENERAL SPECIFICATION DATA19INFORMATIONPiston ringsType:- Top Barrel edge, chrome plated...

V8i1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the c

Mpi1REPAIRCOOLANT PUMPService repair no - 26.50.01Remove1. Position drain tin below coolant pump hose.WARNING: Do not carry out the nextinstruction un

26COOLING SYSTEM2REPAIRRADIATORService repair no - 26.40.01Remove1. Disconnect battery negative lead.WARNING: Do not carry out the nextinstruction unt

Mpi3REPAIR12. With assistance lift out radiator assembly.Do not carry out further dismantling if componentis removed for access only.13. Remove 2 bolt

26COOLING SYSTEM4REPAIRTHERMOSTATIC SENSORService repair no - 19.22.18Remove1. Disconnect Lucar connector from sensor.2. Remove sensor.Refit3. Clean s

Mpi5REPAIR6. Remove clip securing thermostat in hose.7. Lubricate hose in front of thermostat andmanoeuvre thermostat from hose.Refit8. Lubricate insi

MANIFOLD AND EXHAUST SYSTEM1DESCRIPTION AND OPERATIONCATALYTIC CONVERTERS - V8iDescriptionCatalytic converters which form part of the engineemission c

MANIFOLD AND EXHAUST SYSTEM1REPAIREXHAUST SYSTEM COMPLETEService repair no - 30.11.01To improve sealing and accuracy of assembly, a twopiece exhaust s

30MANIFOLD AND EXHAUST SYSTEM2REPAIRRemoveCatalysts - remove and refit 1 to 51. Raise vehicle on a ramp [hoist].2. Catalyst vehicles only: Disconnect

MANIFOLD AND EXHAUST SYSTEM3REPAIRMANIFOLD AND EXHAUST SYSTEM - TdiRemove1. Raise vehicle on a ramp [hoist].2. Remove anti-roll[sway] bar bolts to cha

04GENERAL SPECIFICATION DATA20INFORMATIONLubricationSystem Wet sump, pressure fed...

30MANIFOLD AND EXHAUST SYSTEM4REPAIREXHAUST MANIFOLD - TdiService repair no - 30.15.10Remove1. Disconnect battery negative lead.2. Remove heat shield

MANIFOLD AND EXHAUST SYSTEM5REPAIRINLET MANIFOLD GASKET - MpiService repair no - 30.15.08Remove1. Disconnect battery negative lead.2. Position absorbe

30MANIFOLD AND EXHAUST SYSTEM6REPAIR10. Release clip and disconnect breather hose frommanifold.11. Release 2 bolts securing cam cover brackets tomanif

MANIFOLD AND EXHAUST SYSTEM7REPAIRRefit19. Ensure mating faces of inlet manifold andcylinder head are clean.20. Fit a new gasket, position inlet manif

30MANIFOLD AND EXHAUST SYSTEM8REPAIR6. Disconnect oxygen sensor multiplug.7. Release multiplug from bracket on thermostathousing.8. Release harness fr

MANIFOLD AND EXHAUST SYSTEM9REPAIRMANIFOLD CHAMBER GASKET - MpiService repair no - 30.15.37Remove1. Disconnect battery negative lead.2. Position absor

30MANIFOLD AND EXHAUST SYSTEM10REPAIR10. Release clip and disconnect breather hose frommanifold.11. Release 2 bolts securing camshaft coverbrackets to

MANIFOLD AND EXHAUST SYSTEM1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixin

CLUTCH1DESCRIPTION AND OPERATIONDESCRIPTIONThe clutch unit fitted with the manual transmission,comprises a single dry plate friction disc anddiaphragm

33CLUTCH2DESCRIPTION AND OPERATIONWhen the clutch pedal is depressed, hydraulic fluidtransmits the movement via the slave cylinder, releaselever 10, b

GENERAL SPECIFICATION DATA21INFORMATIONTRANSMISSION - 300 TdiManual gearboxType R380 Single helical constant mesh...

CLUTCH1FAULT DIAGNOSISCLUTCH ASSEMBLY CONDITIONSFor the clutch to operate correctly as described andillustrated in the "Description and Operation

33CLUTCH2FAULT DIAGNOSISFAULT/SYMPTOM CHARTSymptomsSlip Spin/Drag Judder/Fierce Fault Item* * * Worn or oil on clutch linings 2* * * Mechanical damage

CLUTCH1REPAIRCLUTCH ASSEMBLYService repair no - 33.10.01Clutch pressure plateRenew pressure plate if diaphragm spring fingers areworn or if pressure p

33CLUTCH2REPAIRBLEED HYDRAULIC SYSTEMService repair no - 33.15.01ProcedureNOTE: During bleed procedure, keep fluidreservoir topped up to avoid introdu

CLUTCH3REPAIRRefit7. Fit the master cylinder and fixings.8. Fit push-rod to pedal and retain with clevis pinand washer.9. Raise fasica fuse box panel.

33CLUTCH4REPAIRSLAVE CYLINDERService repair no - 33.35.01NOTE: All flexible and pipe connectionsand joints should be tightened to15 Nm.Remove1. Evacua

CLUTCH5REPAIRRENEWING HYDRAULIC DAMPER - TdiService repair no - 33.15.05NOTE: All flexible and pipe connectionsand joints should be tightened to15 Nm.

CLUTCH1OVERHAULMASTER CYLINDERService repair no - 30.20.071. Remove master cylinder.See Repair, MasterCylinderDisassemble2. Pull back and remove rubbe

33CLUTCH2OVERHAULSLAVE CYLINDERService repair no - 33.35.07Overhaul1. Remove slave cylinder.See Repair, SlaveCylinderDisassemble2. Withdraw rubber boo

CLUTCH1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to th

01INTRODUCTION2INFORMATIONFUEL HANDLING PRECAUTIONSThe following information provides basic precautionswhich must be observed if fuel is to be handled

04GENERAL SPECIFICATION DATA22INFORMATIONENGINE - Mpi - 2.0 LITREType 20 T4 - 16 valve twin overhead camshaft...

R3801DESCRIPTION AND OPERATIONMANUAL TRANSMISSIONDescriptionThe all synchromesh five speed manual gearbox unit,is married to a LT230T two speed transf

R3801FAULT DIAGNOSISMANUAL GEARBOXSymptom - Gear jumps out of engagement (anyforward gear)1. Check condition and security of transmissionand engine mo

37MANUAL GEARBOX2FAULT DIAGNOSISSymptom - Noise from gearbox in neutral, whichdisappears when clutch is depressed.1. Check lubricant specification and

R3801REPAIRR380 MANUAL GEARBOXService repair no - 37.20.02RemoveWARNING: Where the use of atransmission hoist is necessary, it isabsolutely essential

37MANUAL GEARBOX2REPAIR25. Remove nuts and bolts securing transmissioncross-member to chassis.26. Remove nuts and bolts securing cross-membermountings

R3803REPAIRAssembling transfer gearbox to main gearbox45. Clean extension housing and transfer gearboxmating faces.46. Ensuring loose upper dowel is f

R3801SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the

R3801SERVICE TOOLSADAPTER PLATE GEARBOXAdapter plate for removing gearbox. This can bemanufactured locally to drawing shown.MATERIAL AND WELDING SPECI

TRANSFER GEARBOX1DESCRIPTION AND OPERATIONLT230T TRANSFER BOXThe LT230T transfer box is a permanent 4 wheeldrive, two speed ratio reducing gearbox inc

41TRANSFER GEARBOX2DESCRIPTION AND OPERATIONREAR OUTPUT DRIVE ASSEMBLY1. Rear output shaft2. Joint sealant3. Speedometer drive housing4. Speedometer d

GENERAL SPECIFICATION DATA23INFORMATIONValvesValve stem diameter:Inlet 7.09 to 7.10 mm...

TRANSFER GEARBOX3DESCRIPTION AND OPERATIONDIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY1. Differential selector assembly2. Front output housing3. High-low ra

41TRANSFER GEARBOX4DESCRIPTION AND OPERATIONINTERMEDIATE GEAR AND POWER TAKE OFFASSEMBLY1. Transfer case assembly2. Transfer case bottom cover3. Inter

TRANSFER GEARBOX5DESCRIPTION AND OPERATIONTRANSFER GEAR SELECTOR COMPONENTS1. Gaiter retaining screw - 4 off2. Gaiter3. Gaiter support plate4. Gate pl

TRANSFER GEARBOX1FAULT DIAGNOSISLT230T TRANSFER BOX - OIL LEAKSVerify that the leak is from the transfer box and not thegearbox before proceeding.1. I

41TRANSFER GEARBOX2FAULT DIAGNOSISPROCEDUREPrior to road test1. Check oil level in transfer box is correct.2. Check tightness of level and drain plugs

TRANSFER GEARBOX1REPAIRLT230T TRANSFER GEARBOXService repair no - 41.10.25RemoveAdaptor plate for removing transfer gearboxThe transfer gearbox is rem

41TRANSFER GEARBOX2REPAIRRemove1. Site vehicle on a ramp [hoist].2. Disconnect battery negative lead.3. Remove fan cowl from radiator.4. Remove transf

TRANSFER GEARBOX3REPAIRRefit36. Select ’P’ in main gearbox, with low range anddifferential lock selected in transfer gearbox.37. Secure transfer gearb

41TRANSFER GEARBOX4REPAIRSHIFTLOCK SOLENOID/NEUTRAL SWITCHService repair no - 41.10.63/64This is sited on top of the transfer gearbox. Access tothe co

TRANSFER GEARBOX1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretight

04GENERAL SPECIFICATION DATA24INFORMATIONFUEL SYSTEM - MpiElectronic fuel injection dataSee ENGINE TUNING DATA, Information, Engine...

41TRANSFER GEARBOX2SPECIFICATIONS, TORQUELT230T TRANSFER GEARBOX DATAHigh range gear end - float 0,05 to 0,15 mm...

TRANSFER GEARBOX1SERVICE TOOLSLT230T TRANSFER GEARBOXLRT-51-003 Drive flange wrench18G 120518G 1271 Oil seal remover18G 1271LRT-37-014 Mainshaft rear

ZF1DESCRIPTION AND OPERATIONDESCRIPTIONThe automatic transmission is specially tailored version of the ZF4 HP22, used by many manufacturer’s of highpe

44AUTOMATIC GEARBOX2DESCRIPTION AND OPERATIONPower flow1st gear D selectedWith D selected 1st gear engaged, clutches 4 and 11 are operative. The front

ZF3DESCRIPTION AND OPERATION3rd gear D selectedClutches 4, 5, 7 and 11 are engaged. Freewheel 15 and 16 are overrun. Epicyclic gear set 9 and 10 rotat

44AUTOMATIC GEARBOX4DESCRIPTION AND OPERATIONReverse gearClutches 5, 8 and 11 are engaged. Since the front planet gear carrier of epicyclic gear set 9

ZF1FAULT DIAGNOSISZF AUTOMATIC GEARBOXBefore referring to fault symptoms, carry out initialstatic checks first:INITIAL STATIC CHECKSCheck start positi

44AUTOMATIC GEARBOX2FAULT DIAGNOSISROAD TEST PROCEDUREFollow the procedure given commencing each test,from a standing start, on a level road, in good

ZF3FAULT DIAGNOSISROADTEST 3 = CHECKS12-13-14-15-16-17-18-19-20-21-22-23D SELECTED FROM RESTLIGHT THROTTLE STARTCHECK 12Check 1st 2nd upshift speed an

44AUTOMATIC GEARBOX4FAULT DIAGNOSISAUTOMATIC GEARBOX ASSEMBLY ILLUSTRATED1. Gearbox assembly2. Inhibitor switch assembly3. Control unit assembly4. Fil

GENERAL SPECIFICATION DATA25INFORMATIONVEHICLE DIMENSIONSDimensionsOverall length (including spare wheel) 4538 mm...Overall

ZF5FAULT DIAGNOSIS1. Torque converter housing assembly2. Gearbox pump and casing assembly3. Governor and adaptor housing assembly

44AUTOMATIC GEARBOX6FAULT DIAGNOSIS1. A Clutch assembly2. B Clutch assembly

ZF7FAULT DIAGNOSIS1. C,C’ and D Clutch assembly

44AUTOMATIC GEARBOX8FAULT DIAGNOSIS1. Freewheel and fourth gear assembly

ZF9FAULT DIAGNOSIS1. E and F Clutch assembly

44AUTOMATIC GEARBOX10FAULT DIAGNOSISFAULT SYMPTOMSSYMPTOM 1 - Intermittent drive and high pitchednoiseFAULT - Low fluid level or restricted filterSYMP

ZF11FAULT DIAGNOSISSYMPTOM 10 - None or harsh engagement ofdirect drive clutchNOTE: The direct drive clutch will onlyengage if 4th gear is engaged at

ZF1ADJUSTMENTADD: 09/95KICKDOWN CABLE ADJUSTMENT1. Remove split pin, withdraw clevis pin anddisconnect kickdown cable from lever.2. Remove split pin,

ZF1REPAIRLT230T TRANSFER GEARBOX WITH AUTOMATICGEARBOX ASSEMBLY - V8iService repair no - 44.20.04Removal from V8i engineThe assembled transfer gearbox

44AUTOMATIC GEARBOX2REPAIR1. Site vehicle on a four post ramp [hoist].2. Disconnect battery negative lead.3. Remove fan cowl securing screws and relea

ENGINE TUNING DATA1INFORMATIONENGINE 3.9 V8iType 3.9 Litre V8i...Firing

ZF3REPAIR19. Disconnect rear propeller shaft to output flange,and tie to one side.20. Repeat instructions 18 and 19 on front propellershaft to main ge

44AUTOMATIC GEARBOX4REPAIRLT230T TRANSFER GEARBOX WITH AUTOMATICGEARBOX ASSEMBLY - TdiService repair no - 44.20.04Removal from Tdi engineThe assembled

ZF5REPAIRRemove1. Select low range with transfer gear lever.2. Remove knob and gaiter from transfer gearlever.3. Disconnect battery terminals.4. Remov

44AUTOMATIC GEARBOX6REPAIR13. Remove starter.14. Working through starter aperture note position oftorque converter flexible drive plate to facilitater

ZF7REPAIRAccessories removal/fittingIf fitting a replacement transmission assembly to thevehicle, remove the following items from the existingassembly

44AUTOMATIC GEARBOX8REPAIRINHIBITOR SWITCHService repair no - 44.15.19Remove1. Site vehicle on a four post ramp [hoist].2. Disconnect battery negative

ZF9REPAIROIL SUMPService repair no - 44.24.05Remove1. Site vehicle on a four post ramp [hoist].2. Disconnect battery negative lead.3. Raise vehicle.4.

44AUTOMATIC GEARBOX10REPAIROIL SCREENService repair no - 44.24.07Renew1. Site vehicle on a four post ramp [hoist].2. Disconnect battery negative lead.

ZF11REPAIRCONTROL UNITRemove1. Site vehicle on a four post ramp [hoist].2. Disconnect battery negative lead.3. Raise vehicle.4. Drain oil and refit pl

44AUTOMATIC GEARBOX12REPAIROil seal replacement14. Remove circlips and springs from control unit.Note locations of long and short springs.15. Using se

05ENGINE TUNING DATA2INFORMATIONDistributorMake/type Lucas 35DLM8 electronic...Ro

ZF13REPAIRKICKDOWN CABLEService repair no - 44.15.01Remove1. Site vehicle on a four post ramp [hoist].2. Select neutral ’N’ gear lever.3. Disconnect b

44AUTOMATIC GEARBOX14REPAIREXTENSION HOUSINGService repair no - 44.20.18Remove1. Remove transfer gearbox.See TRANSFERGEARBOX, Repair, LT230T Transfer

ZF15REPAIRGOVERNOR ASSEMBLYService repair no - 44.22.01Remove1. Remove transfer gearbox.See TRANSFERGEARBOX, Repair, LT230T Transfer Gearbox2. Drain o

44AUTOMATIC GEARBOX16REPAIRGOVERNOR HUBService repair no - 44.22.04Remove1. Remove transfer box.See TRANSFERGEARBOX, Repair, LT230T Transfer Gearbox2.

ZF17REPAIRPARKING PAWL MECHANISMService repair no - 44.28.07Remove1. Remove transfer box.See TRANSFERGEARBOX, Repair, LT230T Transfer Gearbox2. Remove

44AUTOMATIC GEARBOX18REPAIRREPLACING TORQUE CONVERTER1. Remove gearbox and transfer box assembly.See LT230T Transfer Gearbox2. Place gearbox on bench.

ZF19REPAIR6. Screw in two bolts, diagonally opposite eachother. Tap lightly using a soft headed mallet toremove pump assembly from intermediate plate.

44AUTOMATIC GEARBOX20REPAIRELIMINATING LEAKS BETWEEN GEARBOXHOUSING AND INTERMEDIATE PLATE1. Remove gearbox and transfer box assembly.See LT230T Trans

ZF21REPAIRREPLACING PUMPService repair no - 44.32.011. Remove gearbox and transfer box assembly.See LT230T Transfer Gearbox2. Place gearbox on bench.

44AUTOMATIC GEARBOX22REPAIR13. Place end-float gauge LST111 onto pumphousing and check that axial play is between0.2-0.4 mm. Replace existing washer,

ENGINE TUNING DATA3INFORMATIONENGINE 4.0 V8Type 4.0 Litre V8...Firing or

ZF1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to the co

44AUTOMATIC GEARBOX2SPECIFICATIONS, TORQUEZF GEARBOX DATAAxial end float 0.2 to 0.4 mm.From torque converter boss to torque converterhousing face 50 m

ZF1SERVICE TOOLSAUTOMATIC GEARBOX HOLDING FIXTURENOTE: This fixture enables ZF gearbox to be held securely during bench sited repairs. It can bemanufa

44AUTOMATIC GEARBOX2SERVICE TOOLS

ZF3SERVICE TOOLSAUTOMATIC GEARBOXLRT-44-001 Front and rear oil seal replacer.LST 108LRT-44-002 Selector linkage setting gauge.LST 109LRT-44-003 Oil pu

44AUTOMATIC GEARBOX4SERVICE TOOLSLRT-44-005 Control unit oil seal remover/replacer.LST 113LRT-44-006 Selector shaft oil seal replacer.LST 114LRT-44-00

ZF5SERVICE TOOLSLRT-44-009 Adaptor pressure take off.LST 502-1LRT-44-010 Convertor lifting handles.18G.1501

PROPELLER SHAFTS1DESCRIPTION AND OPERATIONPROPELLER SHAFT ALIGNMENTDescriptionThe front and rear propeller shafts have non-constantvelocity ’Hooks’ ty

PROPELLER SHAFTS1FAULT DIAGNOSISVIBRATION HARSHNESS1. Check that the propeller shaft universal jointsand sliding splines are not siezed or worn andtha

PROPELLER SHAFTS1REPAIRFRONT PROPELLER SHAFTService repair no - 47.15.02 - FrontRemove1. Place vehicle over pit or on a ramp [hoist].2. Remove nuts fr

05ENGINE TUNING DATA4INFORMATION300 Tdi ENGINEType 2.5 Litre Turbo diesel intercooled...

47PROPELLER SHAFTS2REPAIR18. Press each cup into its respective yoke up tolower land of circlip grooves. Damage may becaused to cups and seals if cups

PROPELLER SHAFTS3REPAIRSPIDER ASSEMBLY COMPONENTS1. Circlip2. Bearing cup3. Nylatron washer4. Needle rollers (27 per cup)5. Seal retainer and seal

47PROPELLER SHAFTS4REPAIRREAR PROPELLER SHAFTService repair no - 47.15.03NOTE: SGF rubber coupling should be leftattached to propeller shaft. Only rem

REAR AXLE AND FINAL DRIVE1DESCRIPTION AND OPERATIONDESCRIPTIONThe welded steel rear axle casing houses a separatespiral bevel type differential unit,

REAR AXLE AND FINAL DRIVE1FAULT DIAGNOSISFAULT DIAGNOSISComplaint - Oil leaksAn external leak of lubrication from the hub seals canbe caused by a faul

REAR AXLE AND FINAL DRIVE1REPAIRREAR AXLEService repair no - 51.25.01RemoveWARNING: Remove and refit of axlerequires a further two persons to steadyth

51REAR AXLE AND FINAL DRIVE2REPAIRREAR BRAKE DISC NON ABSService repair no - 70.10.11.Remove1. Remove rear hub assembly.See Rear HubAssembly2. Remove

REAR AXLE AND FINAL DRIVE3REPAIRREAR HUB ASSEMBLYService repair no - 64.15.01Remove1. Place rear axle onto axle stands and removeroad wheel.2. Release

51REAR AXLE AND FINAL DRIVE4REPAIRRefit10. Clean stub axle. Retract ABS sensor slightlyfrom sensor sleeve, if applicable11. Fit hub assembly to stub a

REAR AXLE AND FINAL DRIVE1OVERHAULAXLE DIFFERENTIAL ASSEMBLYService repair no - 51.15.07.DISMANTLENOTE: Mark differential components sotheir original

ENGINE TUNING DATA5INFORMATIONGLOW PLUGSMake & type Probe type, No.0100226129A Beru 12 volts...

51REAR AXLE AND FINAL DRIVE2OVERHAUL12. Remove pinion head bearing with service toolLRT-99-002.13. Remove bolts and washers securing crownwheel to dif

REAR AXLE AND FINAL DRIVE3OVERHAUL23. Check gear for freedom of rotation and backlash.Nominal backlash should be present. Excessbacklash necessitates

51REAR AXLE AND FINAL DRIVE4OVERHAUL35. Fit pinion outer bearing track to pinion housing.Use service tools LRT-54-505 and LRT-54-507.36. Fit pinion he

REAR AXLE AND FINAL DRIVE5OVERHAUL43. Nominal setting dimension is represented bysetting gauge block LRT-54-503. Referencedfrom pinion end face to bot

51REAR AXLE AND FINAL DRIVE6OVERHAUL48. Repeat on other bearing bore. Add readingsthen halve sum to obtain mean reading. Notewhether trace pin has mov

REAR AXLE AND FINAL DRIVE7OVERHAULPINION PRELOAD SHIMSPART No. INCH MMFTC3869 .085 2.155FTC3870 .084 2.130FTC3871 .083 2.105FTC3872 .082 2.080FTC3873

51REAR AXLE AND FINAL DRIVE8OVERHAULCROWN WHEEL/PINION BACKLASHADJUSTMENT63. Place differential housing in pinion housing.64. Fit bearing caps and par

REAR AXLE AND FINAL DRIVE9OVERHAULREAR HUB ASSEMBLYService repair no - 61.15.13.Overhaul1. Remove rear hub assembly.See Repair, RearHub Assembly2. Rem

51REAR AXLE AND FINAL DRIVE10OVERHAULRefit8. Clean hub and fit inner and outer bearing tracks.9. Pack hub inner bearing with grease and fit tohub.10.

REAR AXLE AND FINAL DRIVE11OVERHAULREAR STUB AXLEService repair no - 64.15.22.STUB AXLE COMPONENTS1. Rear axle shaft.2. Stub axle to axle casing bolt.

05ENGINE TUNING DATA6INFORMATIONENGINE - Mpi - 2.0 LITREType/Capacity 20 T4/1994 cm3...

REAR AXLE AND FINAL DRIVE1SPECIFICATIONS, TORQUEAXLE DIFFERENTIAL DATAPinion bearing pre-load:(new bearings) 3 Nm...

51REAR AXLE AND FINAL DRIVE2SPECIFICATIONS, TORQUETorque values below cover all screws and bolts used, unless specified otherwise.METRIC NmM5 6...

REAR AXLE AND FINAL DRIVE1SERVICE TOOLSAXLE DIFFERENTIALLRT-51-003 Flange holder tool18G1205LRT-54-504 Universal setting block18G1914LRT-54-502 Pinion

51REAR AXLE AND FINAL DRIVE2SERVICE TOOLSLRT-51-001 Oil seal replacerLST106LRT-54-505 Extractor for pinion bearing racesRO262757ALRT-54-506 Replacer a

REAR AXLE AND FINAL DRIVE3SERVICE TOOLSLRT-54-508 Wrench flange and carrierRO530105 bearing nutsREAR HUBLRT-99-503 Bracket for dial gauge and indicato

51REAR AXLE AND FINAL DRIVE4SERVICE TOOLSLRT-54-002 Hub nut wrenchRO606435ALRT-54-003 Hub oil seal replacer ABSLST137LRT-54-004 Oil seal replacer ABSL

FRONT AXLE AND FINAL DRIVE1DESCRIPTION AND OPERATIONDESCRIPTIONThe welded steel front axle casing houses a separatespiral bevel type differential unit

54FRONT AXLE AND FINAL DRIVE2DESCRIPTION AND OPERATIONFront axle1. Axle casing2. Ventilation pipe3. Axle shaft4. Wheel studs and hub5. Stub axle6. Whe

FRONT AXLE AND FINAL DRIVE1FAULT DIAGNOSISFAULT DIAGNOSISComplaint - Oil leaksAn external leak of lubrication can be caused by afaulty internal seal.

FRONT AXLE AND FINAL DRIVE1REPAIRFRONT AXLE ASSEMBLYService repair no - 54.15.01RemoveWARNING: Remove and refit of axlerequires a further two persons

INTRODUCTION3INFORMATIONSYNTHETIC RUBBERMany ’0’ ring seals, flexible pipes and other similaritems which appear to be natural rubber are made ofsynthe

GENERAL FITTING REMINDERS1INFORMATIONGENERAL FITTING REMINDERSWORKSHOP SAFETY IS YOUR RESPONSIBILITY!The suggestions, cautions and warnings in thesect

54FRONT AXLE AND FINAL DRIVE2REPAIRFRONT BRAKE DISCSService repair no - 70.10.10.Remove1. Remove front hub assembly.See Front HubAssembly2. Remove fiv

FRONT AXLE AND FINAL DRIVE3REPAIRFRONT HUB ASSEMBLYService repair no - 60.25.01.Remove1. Loosen front wheel nuts, jack up vehicle andlower onto axle s

54FRONT AXLE AND FINAL DRIVE4REPAIRRefit11. Clean stub axle and drive shaft and fit hubassembly to axle.12. Fit spacing washer.13. Fit hub adjusting n

FRONT AXLE AND FINAL DRIVE1OVERHAULFRONT DIFFERENTIALService repair no - 54.10.07.OverhaulThe front and rear differentials are the same. Whenoverhauli

54FRONT AXLE AND FINAL DRIVE2OVERHAUL9. With lip side leading fit new seal to hub usingspecial tool LST 137 seal replacer and drift 18G134. Drive in s

FRONT AXLE AND FINAL DRIVE3OVERHAULFRONT STUB AXLE, CONSTANT VELOCITY JOINTAND SWIVEL PIN HOUSING NON ABSService repair no - 60.15.43.Remove stub axle

54FRONT AXLE AND FINAL DRIVE4OVERHAUL12. Examine all components in particular inner andouter track, cage balls and bearing surfaces fordamage and exce

FRONT AXLE AND FINAL DRIVE5OVERHAULSwivel pin housing22. Remove bolts securing oil seal retaining plateand joint washer. Release assembly from swivelp

54FRONT AXLE AND FINAL DRIVE6OVERHAULSwivel assembly components1. Swivel pin housing2. Top swivel pin and brake hose bracket3. Upper and lower swivel

FRONT AXLE AND FINAL DRIVE7OVERHAULFit driveshaft and stub axle59. Insert axle shaft, and when differential splinesare engaged, push assembly in fully

07GENERAL FITTING REMINDERS2INFORMATIONPREPARATION1. Before removing a component, clean it and itssurrounding areas as thoroughly as possible.2. Blank

54FRONT AXLE AND FINAL DRIVE8OVERHAULRemove constant velocity joint from axle shaft7. Hold axle shaft firmly in a soft jawed vice.8. Using a soft mall

FRONT AXLE AND FINAL DRIVE9OVERHAUL19. Lubricate seal and lip with EP90 oil and withcavity side leading press in a new oil seal usingspecial tool LRT-

54FRONT AXLE AND FINAL DRIVE10OVERHAUL40. With seal lips trailing press axle shaft oil sealflush into rear of housing. Grease lips.41. Fit new thrust

FRONT AXLE AND FINAL DRIVE11OVERHAULFit driveshaft and stub axle59. Insert axle shaft, and when differential splinesare engaged, push assembly in full

54FRONT AXLE AND FINAL DRIVE12OVERHAULFRONT HUB AND SWIVEL COMPONENTS1. Brake caliper.2. Mud shield.3. Stub axle.4. Joint washer.5. Oil seal.6. Bearin

FRONT AXLE AND FINAL DRIVE1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixing

54FRONT AXLE AND FINAL DRIVE2SPECIFICATIONS, TORQUETorque values below cover all screws and bolts used, unless specified otherwise.METRIC NmM5 6...

FRONT AXLE AND FINAL DRIVE1SERVICE TOOLSFRONT HUBLRT-54-001 Oil seal replacer non ABSLST550-5LRT-99-003 Drift18G134LRT-54-002 Hub nut wrenchRO606435AL

54FRONT AXLE AND FINAL DRIVE2SERVICE TOOLSLRT-99-503 Dial gauge bracketRO530106LRT-37-004 Extractor ABS18G284AAHLRT-54-005 Bearing installer ABSLST132

FRONT AXLE AND FINAL DRIVE3SERVICE TOOLSLRT-99-004 Impulse extractorMS284LRT-570-024 Torque test adaptor ABSLST141

GENERAL FITTING REMINDERS3INFORMATIONBALL AND ROLLER BEARINGSCAUTION: Never refit a ball or rollerbearing without first ensuring that it is in afully

STEERING1DESCRIPTION AND OPERATIONDESCRIPTIONThe power assisted steering system incorporates acompression joint in the lower shaft, designed tocollaps

57STEERING2DESCRIPTION AND OPERATION

STEERING3DESCRIPTION AND OPERATIONSteering column components1. Upper shroud2. Column harness3. Cruise control switch (if fitted)4. Steering wheel and

57STEERING4DESCRIPTION AND OPERATIONPower steering box components1. Housing complete with sector shaft bearings2. Cover plate complete with bearing3.

STEERING5DESCRIPTION AND OPERATIONRotary valve operationThe rotary valve assembly seen in RR3620Mcomprises the worm (1), the valve sleeve (2), the inp

57STEERING6DESCRIPTION AND OPERATIONDemand for assistance (Valve misaligned)When the steering wheel and input shaft is turned,steering resistance tran

STEERING7DESCRIPTION AND OPERATIONPump and regulator valve operationThe pump which is belt driven from the engine is aneccentric roller type and also

STEERING1FAULT DIAGNOSISINSUFFICIENT POWER ASSISTANCE1. Is fluid level correct?YES - go to 3.NO - Fill/bleed sytem2. Is problem a leak?YES - Diagnose.

57STEERING2FAULT DIAGNOSISPOWER STEERING SYSTEM - TESTNOTE: If steering lacks power assistance.Check pressure of hydraulic pump beforefitting new comp

STEERING3FAULT DIAGNOSISSTEERING DAMPERThe power steering system, as well as reducing theeffort required to manoeuvre the vehicle whenparking, also he

07GENERAL FITTING REMINDERS4INFORMATIONOIL SEALSNOTE: Ensure that the seal running trackis free from pits, scores, corrosion andgeneral damage prior t

57STEERING4FAULT DIAGNOSISSymptom:-Fluid leaks from steering box seals.CAUTION: The steering wheel must not beheld on full lock for more than 30 secon

STEERING5FAULT DIAGNOSISSymptom :-Steering excessively light/sensitive. Excessivefreeplay at steering wheel.1. Are steering box adjustments correct?NO

57STEERING6FAULT DIAGNOSISSTEERING STABILITY AND VEER UNDERBRAKINGPossible cause:Incorrectly set, swivel pin bearing preload. There arethree different

STEERING7FAULT DIAGNOSIS2. STEERING VEERFrom 1. GENERAL STEERING:1. Vehicle veers, not under braking, swap fronttyres side to side.2. Is problem resol

57STEERING8FAULT DIAGNOSIS4. DIRECTIONAL STABILITYFrom 1. GENERAL STEERING:1. Is directional stability concern when vehicle istowing?YES - Check towin

STEERING9FAULT DIAGNOSISPOWER STEERING SYSTEM - EXCESSIVE NOISE1. Is fluid level correct?YES - go to 3.NO - Refill or drain to correct level. Bleedsys

57STEERING10FAULT DIAGNOSISVISUAL AND SAFETY CHECKSWARNING: Before taking vehicle out onthe public highway for road test, it isimportant that the foll

STEERING11FAULT DIAGNOSISSTIFF STEERING CHECKLISTNOTE: Having completed visual checksand steering assessment and confirmedthat vehicle steering load i

57STEERING12FAULT DIAGNOSISSteering column alignment1. Place vehicle on level ground. Measure theangle of lower steering shaft using a Pernumeterplace

STEERING13FAULT DIAGNOSISSTEERING LINKAGE INSPECTNOTE: When inspecting steering linkagesand ball joints for wear the following itemsmust be checked.St

GENERAL FITTING REMINDERS5INFORMATIONJOINTS AND JOINT FACES1. Always use correct gaskets where they arespecified.2. Use jointing compound only whenrec

STEERING1ADJUSTMENTPOWER STEERING BOXService repair no - 57.10.13WARNING: Adjustments of steering boxshould not be required while in warrantyperiod. I

57STEERING2ADJUSTMENTSTEERING LOCK STOPSService repair no - 57.65.03Check1. Measure clearance between tyre wall and radiusarm at full lock. This must

STEERING3ADJUSTMENTFRONT WHEEL ALIGNMENTService repair no - 57.65.01Checking Toe-out dimensionsNOTE: No Adjustment is provided forcastor, camber or sw

STEERING1REPAIRPOWER STEERING FLUID PIPESService repair no - 57.15.21CAUTION: If any joints are disconnected, itis essential that open pipe and ports

57STEERING2REPAIRPOWER STEERING BOXService repair no - 57.10.01General precautions1. Whenever any part of system, is removed ordisconnected, utmost cl

STEERING3REPAIR8. Remove undertray9. Disconnect drag link from drop arm using asuitable extractor.10. Remove pinch bolt securing lower shaftuniversal

57STEERING4REPAIRRefit15. Position steering box to chassis side member,ensuring locating peg is engaged. Tighten boltsto81 Nm.16. Fit pinch bolt and n

STEERING5REPAIRPOWER STEERING SYSTEM - BLEEDService repair no - 57.15.021. Ensure fluid in reservoir reaches dipstickmaximum.2. Run engine to normal o

57STEERING6REPAIRRefit6. Position reservoir, connect feed and returnhoses and tighten clamps to3 Nm.7. Fit reservoir in clamp, tighten clamp bolt.8. F

STEERING7REPAIR7. Loosen clamp securing reservoir hose tosteering pump; disconnect hose.8. Disconnect high pressure pipe from steeringpump.CAUTION: Pl

07GENERAL FITTING REMINDERS6INFORMATIONFUEL SYSTEM HOSESCAUTION: All fuel hoses are made up oftwo laminations, an armoured rubber outersleeve and an i

57STEERING8REPAIR7. Loosen clamp securing reservoir hose tosteering pump, disconnect hose.8. Disconnect high pressure pipe from steeringpump.CAUTION:

STEERING9REPAIRLOWER STEERING SHAFT AND UNIVERSALJOINTSService repair no - 57.40.25CAUTION: Before removing any parts ofsteering linkage, it is impera

57STEERING10REPAIRSTEERING COLUMN SHROUDService repair no - 57.40.29Remove1. Disconnect battery negative lead.2. Remove 3 screws securing shroud.3. Ca

STEERING11REPAIRRemove1. Disconnect battery negative lead.2. Position road wheels straight ahead so steeringwheel can be correctly re-assembled.3. Air

57STEERING12REPAIRUPPER STEERING COLUMNService repair no - 57.40.01NOTE: Steering column assembly is not aserviceable component.CAUTION: Before removi

STEERING13REPAIR8. Disconnect ignition switch main feed multiplug.9. Remove 4 nuts securing upper column to lowermounting.10. Remove 2 nuts securing l

57STEERING14REPAIRRefit20. Manoeuvre upper column to position in footwell,ensure splines in column and universal joint arecorrectly engaged and rubber

STEERING15REPAIRSTEERING COLUMN LOCK ASSEMBLYService repair no - 57.40.31RemoveCAUTION: Before removing any parts ofsteering linkage, it is imperative

57STEERING16REPAIR7. Remove bulb holder from steering column lockshroud.8. Tap head of shear bolts anti-clockwise to releasethem.9. Remove and discard

STEERING17REPAIR3. Bend back tabs on locking washer and removedrop arm using extractor LRT-57-012. Loosendrop arm securing nut, but do not remove befo

GENERAL FITTING REMINDERS7INFORMATIONCOTTER PINS1. Fit new cotter pins throughout when replacingany unit.2. Always fit cotter pins where cotter pins w

57STEERING18REPAIRTRACK ROD AND LINKAGEService repair no - 57.55.09Remove track rod1. Site vehicle on a ramp [hoist].2. Disconnect steering damper at

STEERING19REPAIRDRAG LINK AND DRAG LINK ENDSService repair no - 57.55.17Remove drag link1. Check front wheel alignment.See Adjustment,Front Wheel Alig

STEERING1OVERHAULPOWER STEERING BOXService repair no - 57.10.07OverhaulNOTE: Overhaul of steering box shouldnot be carried out during the warrantyperi

57STEERING2OVERHAUL12. Remove piston, a bolt screwed into piston willassist removal.13. Remove input shaft dirt excluder.14. Remove worm adjuster lock

STEERING3OVERHAULCAUTION: Do not remove sector shaftbearings from casing. Replacement partsare not available. If sector shaft bearingsare worn fit a n

57STEERING4OVERHAULSector shaft cover assembly31. Inspect cover and bearing. If worn or damaged,replacement parts are not available, fit a newsteering

STEERING5OVERHAULRack thrust pad and adjuster43. Examine thrust pad for scores.44. Examine adjuster for wear in pad seat.45. Fit new sealing ring to r

57STEERING6OVERHAUL61. Fit new worm adjuster sealing ring.62. Loosely screw adjuster into casing.63. Fit locknut, do not tighten.64. Turn in worm adju

STEERING7OVERHAULFitting sector shaft cover73. Fit new sealing ring to cover.74. Align cover with casing.75. Screw cover assembly fully on to sector s

57STEERING8OVERHAUL83. Hold input shaft and rock drop arm to establishbacklash is present. Continue rocking and slowlyturn sector shaft adjusting scre

LUBRICANTS, FLUIDS AND CAPACITIES1INFORMATIONRECOMMENDED LUBRICANTS AND FLUIDS -USA VEHICLESAMBIENT TEMPERATURE °CCOMPONENT SPECIFICATION VISCOSITY -3

STEERING9OVERHAULInput shaft oil seal92. Fit seal, lip side first, into housing. Use sealsaver LRT-57-016 and seal installerLRT-57-026. Note that seal

STEERING1SPECIFICATIONS, TORQUESTEERING PUMPMake/type - V8i ZF ’Unicorn’...Make/type - Td

57STEERING2SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened t

STEERING1SERVICE TOOLSPOWER STEERING BOXLRT-57-012 Drop arm extractorLRT-57-007 ’C’ WrenchLRT-57-006 Worm adjusting wrenchLRT-57-019 Ring expander

57STEERING2SERVICE TOOLSLRT-57-020 Ring compressorLRT-57-021 Seal saver, sector shaftLRT-57-016 Seal saver, valve and wormLRT-57-017 Torque setting to

STEERING3SERVICE TOOLSLRT-57-018 Ball joint removerLRT-57-005 Pressure gaugeLRT-57-001 Test adaptorLRT-57-022 Pressure test adaptors

FRONT SUSPENSION1DESCRIPTION AND OPERATIONINTRODUCTIONSuspension design is a major factor in determining the comfort, safety and performance of any ve

60FRONT SUSPENSION2DESCRIPTION AND OPERATIONAXLE LOCATIONThe front axle is controlled longitudinally, by two forged steel radius arms and transversely

FRONT SUSPENSION1REPAIRSELF LOCKING NUTSWARNING: Where self locking nuts areremoved, they must be replaced with newnuts of same specification.PANHARD

60FRONT SUSPENSION2REPAIR8. Press out flexible bushes.Refit9. Press in replacement bushes.CAUTION: When pressing in new bushespress on outer edge of b

09LUBRICANTS, FLUIDS AND CAPACITIES2INFORMATIONRECOMMENDED LUBRICANTS AND FLUIDSAll climates and conditionsAMBIENT TEMPERATURE °CCOMPONENT SPECIFICATI

FRONT SUSPENSION3REPAIR7. Withdraw lower seating washer, rubber bush andcupwasher.8. Remove fixings, shock absorber to mountingbracket.9. Withdraw mou

60FRONT SUSPENSION4REPAIRBUMP STOPService repair no - 60.30.10.Remove1. Remove fixings.2. Remove bump stop.Refit3. Position bolts in slots in chassis

FRONT SUSPENSION5REPAIRANTI-ROLL[SWAY] BAR ASSEMBLY FRONTService repair no - 60.10.01KEY1. Anti-roll[sway] bar2. Rubber bush3. Strap4. Nut, bolt, wash

60FRONT SUSPENSION6REPAIRANTI-ROLL[SWAY] BAR BALL JOINT LINKSService repair no - 60.10.04.Remove1. Remove two nuts, bolts, washers and rubberbushes fr

FRONT SUSPENSION1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretight

REAR SUSPENSION1DESCRIPTION AND OPERATIONAXLE LOCATIONLongitudinal location of the rear axle is by solid round section steel link arms and a forged &q

REAR SUSPENSION1REPAIRREAR ROAD SPRINGService repair no - 64.20.01Remove1. Loosen rear road wheel retaining nuts.2. Support chassis on stands and remo

64REAR SUSPENSION2REPAIRBUMP STOPService repair no - 64.30.15.Remove1. Remove fixings.2. Remove bump stop.Refit3. Position bolts in slots in bracket.4

REAR SUSPENSION3REPAIRRenew bush7. Press out rubber bushes.8. Fit bush centrally in housing.CAUTION: Apply pressure to outer edge ofbush, and not rubb

64REAR SUSPENSION4REPAIRANTI-ROLL[SWAY] BAR ASSEMBLY REARService repair no - 64.35.08.KEY1. Anti-roll[sway] bar2. Rubber bush3. Strap4. Nut, bolt, was

LUBRICANTS, FLUIDS AND CAPACITIES3INFORMATIONPropeller shaft Frontand RearNLGI - 2 Multi-purpose Lithium based GREASELubrication nipples(hubs, ball jo

REAR SUSPENSION5REPAIRANTI-ROLL[SWAY] BAR BALL JOINT LINKSService repair no - 64.35.24.Remove1. Remove two nuts, bolts, washers and rubberbushes from

REAR SUSPENSION1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretighte

BRAKES1DESCRIPTION AND OPERATIONBRAKESDiscovery vehicles have servo assisted brakesystems and the option of an anti-lock brake system.Information in t

70BRAKES2DESCRIPTION AND OPERATIONABS COMPONENTSLocationKey to diagram1. ABS Modulator unit2. Servo/Master cylinder3. Pressure reducing valve4. Electr

BRAKES3DESCRIPTION AND OPERATIONDescription of components1. ABS Modulator unitTo provide the ABS function a Modulator is positionedwithin the system b

70BRAKES4DESCRIPTION AND OPERATIONSystem descriptionThe brake system consists of dual hydraulic circuits ina front - rear split. That is individual ci

BRAKES5DESCRIPTION AND OPERATIONBRAKE PIPE LAYOUT ABSLeft hand drive shown. On right hand drive vehicles the master cylinder and servo unit only movep

70BRAKES6DESCRIPTION AND OPERATIONBRAKE PIPE LAYOUT NON ABSLeft hand drive shown. On right hand drive vehicles the master cylinder and servo unit only

BRAKES7DESCRIPTION AND OPERATIONBRAKE SERVO UNITDescriptionThe power assistance for the brake system isprovided by a twin diaphragm suspended vacuumse

70BRAKES8DESCRIPTION AND OPERATIONBrakes appliedWhen the brake pedal is depressed the pedal pushrodoperates valve C situated in the plastic diaphragm

01INTRODUCTION4INFORMATIONACCESSORIES AND CONVERSIONSDO NOT FIT unapproved accessories or conversions,as they could affect the safety of the vehicle.L

09LUBRICANTS, FLUIDS AND CAPACITIES4INFORMATIONCAPACITIESThe following capacity figures are approximate and are provided as a guide only.Capacities (a

BRAKES9DESCRIPTION AND OPERATIONPetrol engine vacuum systemThe vacuum necessary to operate the brake servo onpetrol engine vehicles is provided by the

BRAKES1FAULT DIAGNOSISABS FAULT DIAGNOSISIf a fault has occurred, or has been identified by ECUself diagnostic function and ABS warning light isillumi

70BRAKES2FAULT DIAGNOSISABS FAULT AND REMEDY CHARTSYMPTOM POSSIBLE CAUSE CHECK REMEDYABS warning light on ABS electrical fault Check ABS electricalcir

BRAKES1REPAIRGENERAL BRAKE SERVICE PRACTICEBrake fluid precautionsWARNING: Do not allow brake fluid tocome into contact with eyes or skin.CAUTION: Bra

70BRAKES2REPAIRBRAKE SYSTEM BLEEDService repair no - 70.25.02The following method for bleeding the hydraulic brakesystem applies to both ABS and NON A

BRAKES3REPAIRMASTER CYLINDER ABSService repair no - 70.30.08- Lucas Girling - Type 25.4mm CV/CVNOTE: This master cylinder is identified bya 3rd plugge

70BRAKES4REPAIRMASTER CYLINDER NON ABSService repair no - 70.30.08 - RemoveService repair no - 70.30.09 - Repair- Lucas Girling - Type 25.4mm AS/ASWAR

BRAKES5REPAIR10. Ease reservoir out of master cylinder taking careto ensure that two outlet ports on bottom ofreservoir do not become damaged during t

70BRAKES6REPAIRNOTE: The primary plunger assemblycannot be broken down any further and isserviced as a complete unit. Discardassembly.15. The secondar

BRAKES7REPAIR19. Coat new seals in unused brake fluid. Fit ’L’ sealto plunger.20. Fit washer followed by recuperating seal. Fit sealretainer and sprin

LUBRICANTS, FLUIDS AND CAPACITIES5INFORMATIONANTI-FREEZEENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTIONCONCENTRATION LOWERTEMPERATURELIMITV8i Engin

70BRAKES8REPAIRMASTER CYLINDER ASSEMBLY NON ABSKey to master cylinder1. Water ingress seal2. Transfer housing3. Vacuum seal4. Guide ring5. Retaining r

BRAKES9REPAIRSERVO ASSEMBLYService repair no - 70.50.01RemoveBefore starting repair refer to general brake servicepractice.See General Brake Service P

70BRAKES10REPAIRFRONT BRAKE PADSService repair no - 70.40.02Service tool:LRT.70-500 - Piston clampRemove1. Remove front road wheels.See WHEELS ANDTYRE

BRAKES11REPAIRREAR BRAKE PADSService repair no - 70.40.03Service tool:LRT-70-500 - Piston clampRemove1. Remove rear road wheels.See WHEELS ANDTYRES, R

70BRAKES12REPAIRFRONT BRAKE CALIPER ASSEMBLYKey to caliper1. Caliper2. Bleedscrew3. Antirattle springs4. Pad retaining pins5. Split [cotter] pin6. Fri

BRAKES13REPAIRFRONT BRAKE CALIPERSService repair no - 70.55.03Service repair no - 70.55.16Service tool:LRT-70-500 - Piston clampBefore starting repair

70BRAKES14REPAIRAssemble outboard pistons13. Coat new fluid seal with brake fluid. Ease sealinto groove in bore using only fingers, ensuring itis prop

BRAKES15REPAIRREAR BRAKE CALIPERSService repair no - 70.55.06Service repair no - 70.55.17Service tool:LRT-50-700 - Piston clampBefore starting repair

70BRAKES16REPAIR13. Apply brake fluid to new seal. Fit seal intogroove in bore. When seal is seated it feelsraised to touch at edge furthest away from

BRAKES17REPAIRREAR BRAKE CALIPER ASSEMBLYLH Rear Caliper illustratedKey to caliper1. Caliper2. Bleed screw3. Pad retaining springs4. Brake pads5. Pist

09LUBRICANTS, FLUIDS AND CAPACITIES6INFORMATIONRECOMMENDED FUELPetrol engines- with catalytic converter unleaded only, 95 RON (USA 90 CLC or AKI)...

70BRAKES18REPAIRSENSORS - FRONTService repair no - 70.65.32CAUTION: If a sensor is removed for anyreason, a NEW sensor bush and seal mustbe fitted.Rem

BRAKES19REPAIRSENSORS - REARService repair no - 70.65.31CAUTION: If a sensor is removed for anyreason, a NEW sensor bush must be fitted.Remove1. Disco

70BRAKES20REPAIRSTOP LIGHT SWITCH - NON ABSService repair no - 86.65.51Remove1. Disconnect battery negative lead.2. Remove lower dash panel.3. Depress

BRAKES21REPAIRBRAKE COMPONENTS ABSLeft hand drive shown. On right hand drive vehicles the master cylinder and servo unit only moveposition.KEY1. Conne

70BRAKES22REPAIRMODULATOR UNITService repair no - 70.65.45WARNING: New modulator units aresupplied in a shock absorbing packmarked with a use by date.

BRAKES1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened to th

BRAKES1SERVICE TOOLSBRAKE SERVICE TOOLSLRT-70-500 Brake piston compressor18G 672

WHEELS AND TYRES1DESCRIPTION AND OPERATIONTYPES OF WHEEL RIMS AND TYRESDescriptionDependent on specification, the vehicle is equippedwith alloy or pre

WHEELS AND TYRES1FAULT DIAGNOSISTYRE WEAR CHARTFAULT CAUSE REMEDYRapid wear at Tyres under-inflated Inflate to correct pressureshoulders Worn suspensi

74WHEELS AND TYRES2FAULT DIAGNOSISFAULT - SYMPTOMSVibration through steering wheel1. Check tyre pressures.See Repair, TyrePressures2. Check condition

MAINTENANCE1MAINTENANCESERVICE SCHEDULEThis section gives information on the range of serviceprocedures.Where required, instructions are given for car

WHEELS AND TYRES1REPAIRGENERAL INFORMATIONWARNING: This is a multi- purpose vehiclewith wheels and tyres designed for bothon and off road usage. Only

74WHEELS AND TYRES2REPAIRWhen the indicators appear in two or more adjacentgrooves, at three locations around the tyre, a new tyremust be fitted.NOTE:

WHEELS AND TYRES3REPAIRWHEEL BALANCINGCAUTION: It is essential that all wheelbalancing is carried out off the vehicle.The use of on the vehicle balanc

74WHEELS AND TYRES4REPAIRStatic balanceWheel trampA. Heavy spot.B. Add balance weights here.C. Centre line of spindle.Static balance is the equal dist

WHEELS AND TYRES5REPAIROff vehicle balancingBalance wheel assembly referring to equipmentmanufacturer’s instructions.It is essential that the wheel is

74WHEELS AND TYRES6REPAIRWHEELSRemoveWARNING: The parking brake acts ontransmission, not rear wheels, and maynot hold vehicle when jacking unlessfollo

WHEELS AND TYRES7REPAIRWHEEL STUDRemove1. Remove wheel.See Wheels2. Drive stud out of driveshaft flange.Refit3. Position stud in flange.4. Install a s

SUPPLEMENTARY RESTRAINT SYSTEM1DESCRIPTION AND OPERATIONSYSTEM COMPONENTS1. Airbag crash sensors (distributed SRS)2. SRS warning light (airbag)3. Rota

75SUPPLEMENTARY RESTRAINT SYSTEM2DESCRIPTION AND OPERATIONOPERATIONThe airbag supplementary restraint system (SRS) is asafety device which, when used

SUPPLEMENTARY RESTRAINT SYSTEM3DESCRIPTION AND OPERATIONSRS warning light (airbag)Distributed SRSThe warning light in the instrument pack illuminatesa

10MAINTENANCE2MAINTENANCECHECK SECURITY AND OPERATION OF PARKBRAKEParking brake adjust1. Select a gear or ’P’ in main gearbox.2. Chock road wheels.3.

75SUPPLEMENTARY RESTRAINT SYSTEM4DESCRIPTION AND OPERATIONGENERAL PRECAUTIONSImpacts which do not deploy airbagsCAUTION: Check for structural damage i

SUPPLEMENTARY RESTRAINT SYSTEM5DESCRIPTION AND OPERATION7. Do not use electrical test equipment on theairbag harness or connectors. Tampering with ord

75SUPPLEMENTARY RESTRAINT SYSTEM6DESCRIPTION AND OPERATIONAIRBAG STORAGETemporary storageFor temporary storage of the airbag module duringservice, obs

SUPPLEMENTARY RESTRAINT SYSTEM1FAULT DIAGNOSISCRASH SENSOR INSPECTION - DISTRIBUTEDSRS1. After any degree of front body damage, inspectboth front cras

75SUPPLEMENTARY RESTRAINT SYSTEM2FAULT DIAGNOSISWARNING LABELS1. Bonnet locking platformRefer to the Owner’s Handbook for information on theairbag sys

SUPPLEMENTARY RESTRAINT SYSTEM3FAULT DIAGNOSIS4. Airbag modulesA - If defective, replace and dispose of the entire unitas directed in the instructions

SUPPLEMENTARY RESTRAINT SYSTEM1REPAIRSYSTEM PRECAUTIONSCAUTION: Before and during any removaloperations within the SRS section, noterouting and positi

75SUPPLEMENTARY RESTRAINT SYSTEM2REPAIR5. Disconnect airbag harness connector fromyellow airbag column harness.6. Use special socket, unscrew 2 tamper

SUPPLEMENTARY RESTRAINT SYSTEM3REPAIR8. Disconnect harness connector from airbagmodule.9. Remove airbag module.CAUTION: Store the airbag module inacco

75SUPPLEMENTARY RESTRAINT SYSTEM4REPAIRRefit9. Reverse removal procedure.CAUTION: Ensure road wheels are straightahead before fitting steering wheel.1

MAINTENANCE3MAINTENANCEVEHICLE EXTERIORCHECK/ADJUST HEADLAMP ALIGNMENTCheck/adjust headlamp and auxiliary alignment.CHECK FRONT WHEEL ALIGNMENTUse rec

SUPPLEMENTARY RESTRAINT SYSTEM5REPAIR5. Remove 3 screws securing lower half of nacelleto steering column.6. Separate the 2 halves of the nacelle and r

75SUPPLEMENTARY RESTRAINT SYSTEM6REPAIR11. If rotary coupler is being re-used, place a pieceof adhesive tape around moulding in position Ato prevent r

SUPPLEMENTARY RESTRAINT SYSTEM7REPAIRROTARY COUPLER CENTRALISEFitting a rotary coupler which has not been centralisedcould result in tape breakage. If

75SUPPLEMENTARY RESTRAINT SYSTEM8REPAIR3. Remove 3 screws securing lower half of nacelleto steering column.4. Separate the halves of the nacelle and r

SUPPLEMENTARY RESTRAINT SYSTEM9REPAIRPASSENGER’S AIRBAG MODULEService repair no - 76.74.02WARNING: All the airbag systemcomponents, including the wiri

75SUPPLEMENTARY RESTRAINT SYSTEM10REPAIRCRASH SENSOR - DISTRIBUTED SRSService repair no - 76.74.04Remove1. Disconnect battery negative lead.2. LH sens

SUPPLEMENTARY RESTRAINT SYSTEM11REPAIRAIRBAG DIAGNOSTIC CONTROL UNIT -DISTRIBUTED SRSService repair no - 76.74.03Remove1. Disconnect battery negative

75SUPPLEMENTARY RESTRAINT SYSTEM12REPAIRSRS WARNING LIGHT BULBSService repair no - 76.73.74Remove1. Remove instrument binnacle.SeeELECTRICAL, Repair,

SUPPLEMENTARY RESTRAINT SYSTEM13REPAIR9. Carefully remove 2 screws securing face plate totachometer.10. Release warning light housing from tachometerc

75SUPPLEMENTARY RESTRAINT SYSTEM14REPAIRAIRBAG HARNESSService repair no - 86.70.63Remove1. Remove driver’s airbag.See driver’s airbagmodule.2. Remove

10MAINTENANCE4MAINTENANCEUNDER BONNET [HOOD] MAINTENANCECHECK COOLING/HEATER SYSTEMSCheck cooling/heater systems for leaks and hoses forsecurity and c

SUPPLEMENTARY RESTRAINT SYSTEM15REPAIRAIRBAG MANUAL DEPLOYMENTCAUTION: Deployment in the vehicle willdamage the steering wheel; if the vehicleis not b

75SUPPLEMENTARY RESTRAINT SYSTEM16REPAIR3. Knee bolster (where fitted); Remove 4 screwsand withdraw kneebolster.4. Release airbag harness to column ha

SUPPLEMENTARY RESTRAINT SYSTEM17REPAIR9. Press both operating buttons to deploy airbagmodule.10. DO NOT return to airbag module for 30 minutes.11. Usi

75SUPPLEMENTARY RESTRAINT SYSTEM18REPAIRWARNING: Ensure tool SMD 4082/1 is notconnected to battery.4. Secure airbag module to tool SMD 4082/2.Ensure m

SUPPLEMENTARY RESTRAINT SYSTEM19REPAIR9. Press both operating buttons to deploy airbagmodule.10. DO NOT return to airbag module for 30 minutes.11. Usi

75SUPPLEMENTARY RESTRAINT SYSTEM20REPAIR5. Position airbag module to tool SMD 4082/6.Ensure module is correctly secured using allfixings.6. Ensure air

SUPPLEMENTARY RESTRAINT SYSTEM21REPAIR10. Press both operating buttons to deploy airbagmodule.11. DO NOT return to airbag module for 30 minutes.12. Us

SUPPLEMENTARY RESTRAINT SYSTEM1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fi

CHASSIS AND BODY1REPAIRFRONT DOORService repair no - 76.28.01Remove1. Disconnect battery negative lead.2. Detach the door seal at the lower section of

76CHASSIS AND BODY2REPAIRFRONT DOOR TRIM PANELService repair no - 76.34.01Remove1. Remove the two securing screws and detach thedoor pull from its mou

MAINTENANCE5MAINTENANCE2. Clean or replace spark plugs as applicable.3. It is essential that correct type of spark plugs arefitted.4. Incorrect grade

CHASSIS AND BODY3REPAIR8. Disengage the lifting arm stud from the upperlifting channel, manoeuvre the window regulatorand remove it from the lower cen

76CHASSIS AND BODY4REPAIRFRONT DOOR LOCK, OUTSIDE AND INSIDEDOOR RELEASE HANDLESService repair no - 76.37.12/31Remove1. Disconnect battery negative le

CHASSIS AND BODY5REPAIR11. Withdraw the lock through the lower rear cut-outon the inner door panel.12. Remove the two nuts, shakeproof washers andreta

76CHASSIS AND BODY6REPAIRADJUSTMENT-FRONT DOOR LOCK AND HANDLEASSEMBLYService repair no - 76.37.47Inside door release handle to lock1. Refit the insid

CHASSIS AND BODY7REPAIRREAR SIDE DOORSService repair no - 76.28.02Remove1. Disconnect battery negative lead.2. Detach the convoluted grommet from the

76CHASSIS AND BODY8REPAIRREAR SIDE DOOR - TRIM PANELService repair no - 76.34.04Remove1. Disconnect battery negative lead.2. Remove the two securing s

CHASSIS AND BODY9REPAIRREAR SIDE DOOR LOCK, INSIDE AND OUTSIDERELEASE HANDLESService repair no - 76.37.13/32Remove1. Ensure that the window is in the

76CHASSIS AND BODY10REPAIRADJUSTMENT-REAR SIDE DOOR LOCK ANDHANDLEService repair no - 76.37.47Outside door release handle to lock1. Disconnect the sho

CHASSIS AND BODY11REPAIR11. Remove the two bolts, spring and plain washerssecuring the door frame to the edge of the door.12. Lift out the door frame

76CHASSIS AND BODY12REPAIRREAR DOOR TRIM PANELService repair no - 76.34.09Remove1. Remove the two screws securing the door pulland remove it from the

10MAINTENANCE6MAINTENANCERENEW SPARK PLUGS - MpiSpark plugs - MpiRemove1. Release 4 screws and remove spark plug cover.2. Disconnect 4 plug leads.3. R

CHASSIS AND BODY13REPAIR8. Remove the screws securing the lock controlmechanism pivot bracket and the door pullmounting bracket, ease the bracket from

76CHASSIS AND BODY14REPAIRLock barrel and number plate light housingDisassembleNOTE: The lock barrel can only beremoved from its housing when the lock

CHASSIS AND BODY15REPAIRREAR DOOR CHECK STAYService repair no - 76.40.30Remove1. Remove the rear door from the vehicle.Seerear door.2. Invert the door

76CHASSIS AND BODY16REPAIRALPINE LIGHT TRIM CASINGService repair no - 76.13.20Remove1. Remove RH ’E’ post trim casing.See ’E’ posttrim casing - rh.2.

CHASSIS AND BODY17REPAIRFRONT BODYSIDE TRIM CASINGService repair no - 76.13.01Remove1. Remove the grab handle.2. Remove the rear compartment lower tri

76CHASSIS AND BODY18REPAIRHEADLININGService repair no - 76.64.01/14Remove1. Disconnect battery negative lead.2. Remove the lower trim panels from the

CHASSIS AND BODY19REPAIR’D’ POST TRIM CASINGService repair no - 76.13.73Remove1. Remove the rear compartment lower trim panel.See rear compartment low

76CHASSIS AND BODY20REPAIRBODY SIDE WINDOW HINGESService repair no - 76.81.47Remove1. Remove the window.See body side openingwindows.2. Remove the pas

CHASSIS AND BODY21REPAIRREAR DOOR GLASSService repair no - 76.31.21Remove1. Remove the spare wheel from the rear door.2. Remove the rear door wiper ar

76CHASSIS AND BODY22REPAIRFRONT FOLDING SEATS 3 DOOR VEHICLESService repair no - 76.70.01WARNING: Care must be taken if the seatlifting mechanism is o

MAINTENANCE7MAINTENANCECHECK/ADJUST VALVE CLEARANCES. - TdiValve adjustment.See GENERAL SPECIFICATIONDATA, Information, 300 Tdi EngineRENEW FUEL FILTE

CHASSIS AND BODY23REPAIRSEAT BASEService repair no - 76.70.06/25WARNING: Care must be taken if the seatlifting mechanism is operated when theseat is r

76CHASSIS AND BODY24REPAIRSEAT BASE TORSION BARSService repair no - 76.71.34Remove1. Tilt the seat assembly forward.2. Remove the torsion bar clamps.3

CHASSIS AND BODY25REPAIRFRONT SEAT COVERSService repair no - 76.70.14CushionRemove1. Remove the seat from the base.2. Invert the seat on a suitable cl

76CHASSIS AND BODY26REPAIRREAR SEAT SQUABService repair no - 76.70.38Remove1. Fold the rear seat down.2. Remove the two seat squab securing bolts.3. W

CHASSIS AND BODY27REPAIRREAR SEAT CUSHION COVERService repair no - 76.70.88/89RemoveNOTE: The procedure for removing bothleft and right hand seat cush

76CHASSIS AND BODY28REPAIRREAR FOLD DOWN SEATSService repair no - 76.71.23Seat and squabRemove1. Locate the seat in the down position, release theseat

CHASSIS AND BODY29REPAIR10. Remove the pivot bolts and washers securingthe hinge links to the seat squab.11. If necessary remove the clips securing th

76CHASSIS AND BODY30REPAIR8. Release the Torx bolt to allow removal of theseat belt stalk assembly.Refit9. Reverse removal procedure.NOTE: Ensure the

CHASSIS AND BODY31REPAIRREAR CENTRE SEAT BELTService repair no - 76.73.20Remove1. Pull both halves of the seat belt through to therear of the seat.2.

76CHASSIS AND BODY32REPAIRREAR GRAB HANDLEService repair no - 76.58.35Remove1. Remove speaker and rear quarter trim panel.2. Detach the foam strip.3.

INTRODUCTION5INFORMATIONJACKINGThe following instructions must be carried out beforeraising the vehicle off the ground.1. Use a solid level ground sur

10MAINTENANCE8MAINTENANCECLEAN PLENUM CHAMBER VENTILATIONPASSAGEWAY - V8iCleaning plenum chamber ventilation passagewaycan be carried out without remo

CHASSIS AND BODY33REPAIRWINGS [FENDERS]Service repair no - 76.10.24Remove1. Disconnect battery negative lead.2. Remove the headlamp surround.3. Remove

76CHASSIS AND BODY34REPAIRSILL FINISHERService repair no - 76.76.05Remove1. Remove the nut, bolt and washer securing thefront of the sill finisher to

CHASSIS AND BODY35REPAIRAIR INTAKE PLENUM COWLService repair no - 76.11.08Remove1. Remove the windscreen wiper arms.2. Remove the securing nuts and th

76CHASSIS AND BODY36REPAIRSUNROOF ELECTRIC/MANUALIntroductionTwin sunroofs are fitted to the vehicle, the open/closesequence for both electric and man

CHASSIS AND BODY37REPAIRSUNROOF GLASS FRONT AND REARService repair no - 76.82.64Remove1. Open sunroof to tilt position.2. Using a right angled screwdr

76CHASSIS AND BODY38REPAIRSUNROOF ASSEMBLY - ELECTRICAL, FRONTAND REARService repair no - 76.82.59RemoveRefer to sunroof components illustration J5483

CHASSIS AND BODY39REPAIRSUNROOF ELECTRIC MOTORSService repair no - 76.82.84/85FRONT MOTORRemove1. Disconnect battery negative lead.2. Ensure sunroof i

76CHASSIS AND BODY40REPAIRSUNROOF ELECTRIC CONTROL UNITService repair no - 76.82.73The control unit serves both front and rear sunroofsand is sited ab

CHASSIS AND BODY41REPAIRSUNROOF ASSEMBLY - MANUAL, FRONT ANDREARService repair no - 76.83.01Remove1. Close sunroof.2. Remove headlining.See headlining

76CHASSIS AND BODY42REPAIRSUNROOF REGULATOR MANUALService repair no - 76.83.03/04FRONTRemove1. Ensure sunroof is in normally closed position.2. Remove

MAINTENANCE9MAINTENANCECHECK CONDITION OF DRIVE BELT - V8i - Tdi -MpiRENEW - V8i - TdiRenew drive belt V8i.See ENGINE, Repair, DriveBelt RenewRenew dr

CHASSIS AND BODY43REPAIRSUN BLIND ASSEMBLYService repair no - 76.82.78Remove1. Open sunroof to the tilt position.2. Remove the trim finisher from the

76CHASSIS AND BODY44REPAIR7. Remove centre console switch pack cover.8. Remove 4 screws securing switch pack toconsole.9. Release switch pack from con

CHASSIS AND BODY45REPAIRRefit20. Position centre console assembly, ensuringharnesses and connectors are not trapped andare routed to their correct loc

76CHASSIS AND BODY46REPAIRDASH PANEL CENTRAL LOUVRE PANELService repair no - 76.46.42Remove1. Disconnect battery negative lead.2. Remove radio.See ELE

CHASSIS AND BODY47REPAIR14. Remove 2 screws securing louvre panel.15. Remove louvre panel from dash panel.Refit16. Position louvre panel, feed harness

76CHASSIS AND BODY48REPAIR20. Note position of levers, disconnect heater controlcables from levers and outer cable from retainingclips.21. Remove 4 bo

CHASSIS AND BODY49REPAIRRefitCAUTION: When refitting avoid trappingelectrical wiring.29. Reverse removal procedure.30. With assistance: Position dash

76CHASSIS AND BODY50REPAIRNOTE: If heated front screen: 2 electricalmultiplug connectors are located underthe decker [cowl] panel. To access releasede

CHASSIS AND BODY51REPAIR16. Cut through sealer between the supports.If heated front screen: Cut through the 2 wireseach side of the supports. Tape cut

76CHASSIS AND BODY52REPAIR24. Ensure body flanges and surfaces covered bythe finishers are clean.25. Shake the primer container for at least 30seconds

10MAINTENANCE10MAINTENANCECHECK/TOP UP COOLING SYSTEM1. To prevent corrosion of aluminium alloy engineparts it is imperative that cooling system is fi

CHASSIS AND BODY53REPAIR31. With assistance: Attach suction cups to glassand lift into position, carefully align the indicatorson the obscuration band

76CHASSIS AND BODY54REPAIR5. Remove Torx screw securing seat belt.6. Remove 2 Torx screws securing seat.7. Disconnect multiplug.8. Remove seat.Refit9.

CHASSIS AND BODY55REPAIRRefit7. Reverse removal procedure.8. Tighten Torx screws securing seat to29 Nm (21lbf ft).9. Tighten bolts securing seat slide

76CHASSIS AND BODY56REPAIRRefit10. Reverse removal procedure. Ensure harness iscorrectly routed in mirror base so it does notbecome trapped.

CHASSIS AND BODY57REPAIRSUN VISORService repair no - 76.10.47Remove1. Release sun visor from headlining retaining clip.2. Remove 3 screws securing sun

76CHASSIS AND BODY58REPAIRMUD FLAP - REAR - LHService repair no - 76.10.85Remove1. Remove rear compartment lower trim panel.See rear compartment lower

CHASSIS AND BODY59REPAIR9. Remove 5 trim studs securing trim panel.10. Remove trim panel.Refit11. Fit and align trim panel.12. Fit trim panel retainin

76CHASSIS AND BODY60REPAIR’E’ POST TRIM CASING - LH - WITH REAR AIRCONDITIONING FITTEDService repair no - 76.13.13/20Remove1. Remove rear speaker.See

CHASSIS AND BODY61REPAIRREAR DOOR UPPER TRIM PANEL - WITH REARAIR CONDITIONING FITTEDService repair no - 76.13.72/20Remove1. Remove alpine light trim

76CHASSIS AND BODY62REPAIR’D’ POST TRIM CASING - LH - WITH REAR AIRCONDITIONING FITTED - 5 DOORService repair no - 76.13.73/20Remove1. Remove rear com

MAINTENANCE11MAINTENANCECHECK/ADJUST ENGINE IDLE SPEED - TdiFor idle speed.See ENGINE TUNING DATA,Information, 300 Tdi EngineCHECK ENGINE IDLE SPEED -

CHASSIS AND BODY63REPAIRSWITCH PACK - DASH PANEL CENTRAL LOUVREPANELService repair no - 76.46.38Remove1. Release switch pack from louvre panel.2. Disc

76CHASSIS AND BODY64REPAIRGRAB HANDLE - TAIL DOOR - WITH REAR AIRCONDITIONING FITTEDService repair no - 76.58.35/20Remove1. Remove ’E’ post trim casin

CHASSIS AND BODY65REPAIR9. Remove front sun roof aperture seal.10. Release rear passenger interior lamp assemblyfrom headlining panel, disconnect mult

76CHASSIS AND BODY66REPAIR15. Release LH and RH, ’A’ post trim finishers fromuppermost retaining clips.16. With assistance, release headlining from LH

CHASSIS AND BODY67REPAIRASH TRAY - DASH PANEL CENTRAL LOUVREPANELService repair no - 76.67.26Remove1. Open ash tray.2. Press release catch and remove

76CHASSIS AND BODY68REPAIRDismantle4. Remove interior lamp lens.5. Remove 2 nuts securing lamp to stowage panel.6. Remove lamp.7. Remove alarm volumet

CHASSIS AND BODY69REPAIRFRONT SEAT BELTS - 5 DOOR (96 MODELS)Service repair no - 76.73.10Remove1. Move the seat to gain access to the seat beltmountin

76CHASSIS AND BODY70REPAIR8. Remove the securing bolt and detach the inertiareel from the bottom of the ’B’ post.9. Release the seat belt sensor conne

HEATING AND VENTILATION1DESCRIPTION AND OPERATIONHEATING AND VENTILATION UNITThe heating and ventilation and blower units arestandard on all models. A

80HEATING AND VENTILATION2DESCRIPTION AND OPERATIONThrough-flow ventilationThrough-flow ventilation is achieved by means ofone-way air extraction vent

10MAINTENANCE12MAINTENANCEEXTERNALLY CHECK INTERCOOLER FOROBSTRUCTION - TdiClear any trapped dirt or flies from vanes ofintercoolerCLEAN INTERCOOLER E

HEATING AND VENTILATION3DESCRIPTION AND OPERATIONControls set for unheated air to footwells and face level ventsHeater and ventilation operationThe he

80HEATING AND VENTILATION4DESCRIPTION AND OPERATIONAir direction flapFlap moves across mixing chamber to direct the airflow away from the heater matri

HEATING AND VENTILATION1FAULT DIAGNOSISHEATER OUTPUTSymptom:-Heater emits cold air.1. Engine running: Check coolant valve opens as atemperature contro

HEATING AND VENTILATION1REPAIRHEATER BLOWER SWITCH AND ILLUMINATIONBULBService repair no - 80.10.22 - SwitchService repair no - 86.48.73 - BulbRemove1

80HEATING AND VENTILATION2REPAIR8. Disconnect 4 multiplugs and position harnessaside.NOTE:Do not carry out furtherdismantling if component is removed

HEATING AND VENTILATION3REPAIRAir direction3. Set control fully clockwise4. Release outer cable from 2 clips on unit.5. Release cable from stud on fla

80HEATING AND VENTILATION4REPAIRWATER VALVEService repair no - 80.10.16Remove1. Disconnect vacuum pipe from water valve.2. Slacken 4 clips securing ho

HEATING AND VENTILATION5REPAIRRECIRCULATION SWITCHService repair no - 80.10.27Remove1. Release fascia centre louvre vent panel from itsfitted position

80HEATING AND VENTILATION6REPAIRBLOWER MOTOR UNIT - HEATER AND AIRCONDITIONINGService repair no - 80.20.17Service repair no - 82.25.54.Remove1. Move s

HEATING AND VENTILATION7REPAIR5. Remove fan retaining clip.6. Remove fan.7. Remove 2 screws securing motor to casing.8. Remove blower motor.Refit9. Re

MAINTENANCE13MAINTENANCERENEW AUTOMATIC GEARBOX FLUID AND OILSCREEN1. Site vehicle on lift or level ground. Placecontainer to drain gearbox fluid into

HEATING AND VENTILATION1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings a

AIR CONDITIONING1DESCRIPTION AND OPERATIONAIR CONDITIONING SYSTEM COMPONENTS1. Compressor2. Condenser3. Receiver/drier4. Evaporator5. High pressure se

82AIR CONDITIONING2DESCRIPTION AND OPERATIONSCHEMATIC LAYOUT OF THE AIR CONDITIONINGSYSTEM1. Compressor2. Condenser3. Receiver/drier4. Thermostatic ex

AIR CONDITIONING3DESCRIPTION AND OPERATIONAIR CONDITIONING SYSTEM OPERATIONThe air conditioning system provides the means ofsupplying cooled and dehum

82AIR CONDITIONING4DESCRIPTION AND OPERATION5. EvaporatorAs this change of state occurs, a large amount oflatent heat is absorbed. The evaporator is t

AIR CONDITIONING5DESCRIPTION AND OPERATIONCondenser cooling fansThe condenser cooling fans operate automaticallywhenever the air conditioning system i

AIR CONDITIONING1FAULT DIAGNOSISAIR CONDITIONING FAULTSFAULT CAUSE REMEDY1. Incorrect voltage. 1. Check voltage.A. 2. Open or defective fuse or relay.

82AIR CONDITIONING2FAULT DIAGNOSISREFRIGERATION SYSTEM FAULTSFor any refrigeration system to function properly allcomponents must be in good working o

AIR CONDITIONING3FAULT DIAGNOSISFAULT CAUSE REMEDY1. Overcharge of refrigerant. 1. Discharge, evacuate and chargesystem.A.HIGH HEAD 2. Air in system.

82AIR CONDITIONING4FAULT DIAGNOSISFAULT CAUSE REMEDYE.NOISYEXPANSIONVALVE(steady hissing) 1. Low refrigerant charge; evident bybubbles in sight glass.

10MAINTENANCE14MAINTENANCERENEW TRANSFER GEARBOX OIL1. Site vehicle on lift or level ground.2. Disconnect battery negative lead.3. Clean immediate are

AIR CONDITIONING1ADJUSTMENTGENERAL PRECAUTIONSThe refrigerant used in the air conditioning system isHFC (Hydrofluorocarbon) R134a.WARNING: R134a is a

82AIR CONDITIONING2ADJUSTMENTSERVICING PRECAUTIONSCare must be taken when handling refrigerationsystem components. Units must not be lifted by theirho

AIR CONDITIONING3ADJUSTMENTSERVICING EQUIPMENTThe following equipment is required for full servicingof the air conditioning system.Recovery, recycling

82AIR CONDITIONING4ADJUSTMENTEvacuation and recharging1. Add refrigerant oil to compressor if necessary.2. Renew the receiver/drier.CAUTION: When a ma

AIR CONDITIONING5ADJUSTMENTAIR CONDITIONING SYSTEM - PERFORMANCETESTWARNING: R134a is hazardous, refer tothe GENERAL PRECAUTIONS given at thebeginning

82AIR CONDITIONING6ADJUSTMENTSYSTEM TEST1. Place the vehicle in a ventilated, shaded areafree from excessive draught, with the doors andwindows open.2

AIR CONDITIONING1REPAIRPRECAUTIONS IN HANDLING REFRIGERANTLINESWARNING: Wear eye and hand protectionwhen disconnecting componentscontaining refrigeran

82AIR CONDITIONING2REPAIRPERIODIC MAINTENANCERoutine servicing, apart from visual checks, is notnecessary. The visual inspections are as follows:Conde

AIR CONDITIONING3REPAIR5. Disconnect 2 pipe unions from oil cooler. Use asecond wrench to support hose adapter.6. Remove transmission oil cooler. Seal

82AIR CONDITIONING4REPAIRAIR CONDITIONING SWITCHService repair no - 82.20.29Remove1. Remove fascia centre louvre vent panel.SeeCHASSIS AND BODY, Repai

MAINTENANCE15MAINTENANCERENEW FRONT AND REAR AXLE OIL1. Site vehicle on lift or level ground. Placecontainer under axle to be drained.2. Using a 13mm

AIR CONDITIONING5REPAIRCOMPRESSORService repair no - 82.10.20Remove1. Disconnect battery negative lead.2. Recover refrigerant from air conditioning sy

82AIR CONDITIONING6REPAIRCONDENSERService repair no - 82.15.07Remove1. Disconnect battery negative lead.WARNING: Wear eye and hand protectionwhen disc

AIR CONDITIONING7REPAIR12. Disconnect receiver/drier pipes at condenserunions.13. Remove retaining bracket from side pipe.14. Remove LH pipe from cond

82AIR CONDITIONING8REPAIRHEATER AND COOLER UNITService repair no - 86.25.21WARNING: All work involving the serviceand maintenance of air conditioningr

AIR CONDITIONING9REPAIR10. Disconnect multiplug connecting heater toblower unit, remove 3 screws and removeblower unit.11. Remove 5 screws securing ca

82AIR CONDITIONING10REPAIR2. Disconnect 2 Lucar connectors from thermostat.3. Position wiring aside.4. Remove 2 screws securing heater pipe bracketand

AIR CONDITIONING11REPAIRTHERMOSTATService repair no - 86.25.50Remove1. Remove heater and cooler unit.See Heaterand Cooler Unit2. Remove lower cover an

82AIR CONDITIONING12REPAIR7. Remove nut securing rear fold down seatmounting frame to wheel arch.8. Remove 5 bolts securing rear fold down seatmountin

AIR CONDITIONING13REPAIRBLOWER MOTOR - REARService repair no - 82.26.02Remove1. Remove evaporator/blower motor assembly.See evaporator/blower motor as

82AIR CONDITIONING14REPAIRSOLENOID - HIGH PRESSURE PIPE CONTROLVALVE - REARService repair no - 82.26.05Remove1. Remove evaporator/blower motor assembl

10MAINTENANCE16MAINTENANCELUBRICATE PROPELLER SHAFT SLIDING , ANDUNIVERSAL JOINTS1. Clean all grease nipples on front and rearpropeller shafts.2. Usin

AIR CONDITIONING15REPAIRRefit13. Fit solenoid to valve.14. Fit but do not tighten screw securing solenoid tocontrol valve.NOTE: Ensure arrow on contro

82AIR CONDITIONING16REPAIR9. Remove 2 screws securing mounting bracket tocontrol valve.10. Remove mounting bracket.11. Noting the direction arrow on c

AIR CONDITIONING17REPAIREXPANSION VALVE - REARService repair no - 82.26.07Remove1. Remove evaporator/blower motor assembly.See evaporator/blower motor

82AIR CONDITIONING18REPAIREVAPORATOR - REARService repair no - 82.26.08Remove1. Remove evaporator/blower motor assemblyharness.See harness - evaporato

AIR CONDITIONING19REPAIR11. Remove 6 screws securing evaporator/blowermotor casing halves.12. Remove 4 clips securing evaporator/blowermotor casing ha

82AIR CONDITIONING20REPAIRTHERMOSTAT - REARService repair no - 82.26.09Remove1. Remove evaporator/blower motor assemblyharness.See harness - evaporato

AIR CONDITIONING21REPAIRHARNESS - EVAPORATOR/BLOWER MOTORASSEMBLY - REARService repair no - 82.26.12Remove1. Remove evaporator/blower motor assembly.S

82AIR CONDITIONING22REPAIRREAR AIR CONDITIONING SWITCHService repair no - 82.26.14Remove1. Open rear door.2. Release switch pack from headlining panel

AIR CONDITIONING23REPAIRREAR BLOWER MOTOR SWITCHService repair no - 82.26.15Remove1. Open rear door.2. Release switch pack from headlining panel.3. Di

82AIR CONDITIONING24REPAIRBULB - REAR AIR CONDITIONING SWITCHService repair no - 82.26.16Remove1. Remove rear air conditioning switch.See rearair cond

MAINTENANCE17MAINTENANCECHECK/TIGHTEN FRONT AND REAR AXLESUSPENSION LINK FIXINGS, CHECK CONDITIONOF MOUNTING RUBBERSDRAIN FUEL SEDIMENTER - TdiFuel se

AIR CONDITIONING25REPAIRAIR DUCT - CENTRE - WITH REAR AIRCONDITIONING FITTED - 5 DOORService repair no - 82.26.18Remove1. Remove headlining.See CHASSI

82AIR CONDITIONING26REPAIRALPINE LIGHT DUCTService repair no - 82.26.21Remove1. Remove evaporator to alpine light duct.Seeevaporator to alpine light d

AIR CONDITIONING27REPAIRBLOWER MOTOR RESISTOR - REARService repair no - 82.26.23Remove1. Remove evaporator/blower motor assembly.See evaporator/blower

AIR CONDITIONING1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretight

WIPERS AND WASHERS1DESCRIPTION AND OPERATIONWINDSCREEN WIPER AND WASHER OPERATIONThe illustration below locates and identifies the maincomponents of t

84WIPERS AND WASHERS2DESCRIPTION AND OPERATIONWash wipe functionWith the ignition switched on, power is supplied via afuse to the multi-switch, a cont

WIPERS AND WASHERS1FAULT DIAGNOSISWIPER MOTOR CHECKINGNOTE: These instructions apply towindscreen and rear window wiper motor.If unsatisfactory operat

WIPERS AND WASHERS1REPAIRWASHER RESERVOIRService repair no - 84.10.03.Remove1. Remove two bolts securing top of reservoir.2. From underneath the wheel

84WIPERS AND WASHERS2REPAIRWINDSCREEN WASHER JETSService repair no - 84.10.09.Remove1. Disconnect washer tube from jet.2. Remove nut and washer securi

WIPERS AND WASHERS3REPAIRWIPER ARMS - WINDSCREENService repair no - 85.15.01.Remove1. Lift wiper arm end cap to gain access to securingnut.2. Remove n

01INTRODUCTION6INFORMATION2. Raise front road wheels to enable an axle standto be installed under left hand axle tube.3. Position an axle stand under

10MAINTENANCE18MAINTENANCEABS VEHICLES - CHECK ROAD WHEEL SPEEDSENSOR ELECTRICAL HARNESS FOR DAMAGERENEW OXYGEN SENSORSSee EMISSION CONTROL, Repair, H

84WIPERS AND WASHERS4REPAIRWIPER BLADESService repair no - 84.15.05Remove1. Pull wiper blade away from screen.2. Depress spring clip and withdraw blad

WIPERS AND WASHERS5REPAIRWINDSCREEN WIPER MOTOR AND LINKAGEService repair no - 84.15.12.Remove1. Disconnect battery negative lead.2. Remove windscreen

84WIPERS AND WASHERS6REPAIRRefit16. Reverse removal procedure.17. Fit wiper motor to support plate using newsealing bushes at the motor spindle asnece

WIPERS AND WASHERS7REPAIRHEADLAMP POWER WASH JETService repair no - 84.20.08Remove1. Disconnect hose from power wash jet.2. Remove nut securing jet to

ELECTRICAL1DESCRIPTION AND OPERATIONELECTRICAL EQUIPMENTDESCRIPTIONThe electrical system is Negative ground, and it ismost important to ensure correct

86ELECTRICAL2DESCRIPTION AND OPERATIONANTI-THEFT SYSTEM FUNCTIONPerimetric protectionUsing the key in the correct sequence will turn on andoff perimet

ELECTRICAL3DESCRIPTION AND OPERATIONRadio frequency systemThe RF system uses four frequencies according tomarket. If the coaxial aerial is not fitted

86ELECTRICAL4DESCRIPTION AND OPERATIONBUILT IN TEST PROCEDUREThe built in test procedure is accessed as follows:1. Starting conditions: ignition off,

ELECTRICAL5DESCRIPTION AND OPERATIONANTI THEFT ALARM SYSTEMThe main function of the system is to offer easy to useremote locking and unlocking of the

86ELECTRICAL6DESCRIPTION AND OPERATIONALARM COMPONENT LOCATIONS (96 MODELS)COMPONENT LOCATION1. Electronic control unit (ECU) and relays Under dash (p

MAINTENANCE19MAINTENANCERESET EMISSION MAINTENANCE REMINDER -USAThe emission maintenance reminder is designed toactivate at 52,500 and 105,000 miles r

ELECTRICAL7DESCRIPTION AND OPERATIONANTI-THEFT ALARM DESCRIPTION (96 MODELS)NOTE: The alarm system provides securityprotection under wide rangingcircu

86ELECTRICAL8DESCRIPTION AND OPERATIONDETECTION COMPONENTSSwitchesPerimetric protection for the vehicle is provided byECU inputs connected to the foll

ELECTRICAL9DESCRIPTION AND OPERATIONMobilisationThe vehicle can be mobilised using any one of thefollowing processes:1. Placing the handset in close p

86ELECTRICAL10DESCRIPTION AND OPERATIONRadio frequency systemThe RF system uses frequencies according to marketand both ECU and handset are colour cod

ELECTRICAL11DESCRIPTION AND OPERATIONANTI-THEFT ALARM BUILT-IN TEST (96 MODELS)NOTE: The handset should be detachedfrom the key to allow perimetric te

ELECTRICAL1FAULT DIAGNOSISGENERAL INFORMATIONThe electrical fault diagnostic tool on Discoveryvehicles is Testbook. Detailed information of electrical

86ELECTRICAL2FAULT DIAGNOSISLUCAS CONSTANT ENERGY IGNITION SYSTEM -V8iPreliminary checksInspect battery cables and connections to ensure theyare clean

ELECTRICAL3FAULT DIAGNOSIS1 2 3 4 SUSPECTL * * * DISCHARGED BATTERY* L L * IGN. SWITCH AND/ORWIRING* * L * COIL OR AMPLIFIER* * * H AMPLIFIER GROUNDKe

86ELECTRICAL4FAULT DIAGNOSISTEST 4:Pick-up Coil ResistanceRemove amplifier.Connect ohmmeter leads to two pick-up terminals inbody of distributor.The o

ELECTRICAL5FAULT DIAGNOSISTEST 6:Rotor ArmRemove distributor cover. Disconnect coil H.T. leadfrom cover, using insulated pliers hold about 3mmabove ro

Tdi1REPAIRDRIVE BELT INFORMATIONA single ’serpentine drive belt’ drives all theancilliaries bar the air conditioning compressor, whichhas a separate d

ELECTRICAL1ADJUSTMENTIGNITION TIMINGService repair no - 86.35.15Adjust1. It is essential that following procedures areadhered to. Inaccurate timing ca

ELECTRICAL1REPAIRFUSE BOX - INTERIORRight Hand Drive shownThe interior fusebox is fitted below the steering column, behind the trim panel. It comprise

86ELECTRICAL2REPAIRFUSE BOX - ENGINE COMPARTMENTThe fusebox is located on the right side of the engine compartment. The circuits protected and their l

ELECTRICAL3REPAIRBATTERYService repair no - 86.15.01NOTE: Some vehicles are fitted with abattery backed-up sounder. Disconnectingthe vehicle battery w

86ELECTRICAL4REPAIR

ELECTRICAL5REPAIRELECTRONIC IGNITION - V8iA Lucas 35DLM8 distributor is employed. This has aconventional vacuum advance unit and centrifugalautomatic

86ELECTRICAL6REPAIRRefitNOTE: If a new distributor is being fitted,mark body in same relative position asdistributor removed.8. Leads for distributor

ELECTRICAL7REPAIRAUTOMATIC GEAR SELECTOR-PANEL BULBService repair no - 86.45.401. Disconnect battery negative lead.2. Carefully prise quadrant finishe

86ELECTRICAL8REPAIRPARK BRAKE WARNING SWITCHService repair no - 86.65.45Remove1. Disconnect battery negative lead.2. Remove four screws and move aside

ELECTRICAL9REPAIR7. Disconnect wiring solenoid to multiplug.8. Remove circlip and retainer plate.9. Remove clip and centre sleeve.10. Refit clip into

12ENGINE2REPAIRDRIVE BELT RENEWService repair no - 86.10.03NOTE: If cast lines on tensioner arm andtensioner spring case are aligned, a newdrive belt

86ELECTRICAL10REPAIR8. Remove 3 clips as shown.9. Slide trunnion forward and remove gear selectorarm.10. Remove bolts securing coxcomb.11. Remove micr

ELECTRICAL11REPAIRHANDSET INITIALISATIONNOTE: New handsets are supplied in pairs.If a new handset is required, it will requireinitialisation to the EC

86ELECTRICAL12REPAIRFRONT DOOR ACTUATOR UNITService repair no - 86.26.08Remove1. Ensure that the window glass is in its fully closedposition.2. Discon

ELECTRICAL13REPAIREXTERIOR DRIVING MIRRORSService repair no - 76.11.10Replacing the mirror glass1. Press the outer end of the glass inwards to itsfull

86ELECTRICAL14REPAIRREAR DOOR ACTUATORService repair no - 86.26.09Remove1. Disconnect battery negative lead.2. Remove the door pull, trim panel and va

ELECTRICAL15REPAIRRefit9. If removed fit the mounting plate to the actuator.10. Engage the actuator operating rod with hookedend of the actuator link.

86ELECTRICAL16REPAIRSIDELIGHT BULBService repair no - 86.40.33Remove1. Remove headlight,See Headlight2. Disengage bulb holder by twisting a quarter tu

ELECTRICAL17REPAIRREAR LIGHT UNITService repair no - 86.40.74Remove1. Pull out side facing seat or pocket cover.2. Unscrew fastener and remove access

86ELECTRICAL18REPAIRREAR LIGHTS, BUMPER MOUNTEDService repair no - 86.41.42Remove1. From behind bumper disconnect light plugs.2. Unscrew two retaining

ELECTRICAL19REPAIRNUMBER PLATE LIGHTSService repair no - 86.40.86Remove1. Remove two screws and withdraw light unit.2. Disconnect wiring leads and rem

Tdi3REPAIRENGINEService repair no - 12.41.01RemoveCAUTION: Seal all exposed pipe endsagainst ingress of dirt after disconnection.1. Park vehicle on le

86ELECTRICAL20REPAIRHIGH MOUNTED STOP LIGHTService repair no - 86.41.35Remove1. Remove two screws and lift off light reflectorbody.2. Unscrew retainin

ELECTRICAL21REPAIRINTERIOR LIGHTService repair no - 86.35.14Remove1. Pry out light unit from roof location.2. Disconnect light switch plug.Refit3. Rev

86ELECTRICAL22REPAIRSIDE REPEATER LIGHTService repair no - 86.50.59Remove1. Push the lens to the right and then pull outwardto detach lens and bulb ho

ELECTRICAL23REPAIRRADIOService repair no - 86.50.03Remove1. Disconnect battery earth lead.2. Insert removal tools SMD 4091 to radio.3. Release radio a

86ELECTRICAL24REPAIRSPEAKERS AND AMPLIFIER PACK, REAR DOORService repair no - 86.50.36Remove1. Disconnect battery negative lead.2. Remove securing scr

ELECTRICAL25REPAIRSTARTER MOTOR - MpiService repair no - 86.60.01Remove1. Disconnect battery negative lead.2. Remove 2 nuts securing cables to starter

86ELECTRICAL26REPAIRTRAILER SOCKETRemove1. If fitted remove the RH side facing seatSeeCHASSIS AND BODY, Repair, Rear FoldDown Seats2. Remove the rear

ELECTRICAL27REPAIRWINDOW LIFT MOTOR - FRONTService repair no - 86.25.04Remove1. Ensure that the window glass is in its fully closedposition and secure

86ELECTRICAL28REPAIRINSTRUMENT PANEL FINISHERService repair no - 88.20.03Remove1. Position steering wheel for access.2. Remove 2 screws securing panel

ELECTRICAL29REPAIRINSTRUMENT BINNACLEService repair no - 88.20.13Remove1. Remove instrument panel finisher.SeeInstrument panel finisher2. Remove 4 scr

12ENGINE4REPAIR22. Disconnect feed pipe and spill return pipe frominjector pump.23. Disconnect both pipes from fuel lift pump.24. Disconnect servo hos

86ELECTRICAL30REPAIRINSTRUMENT ILLUMINATION AND WARNINGLIGHT BULBSService repair no - 86.45.48 - InstrumentService repair no - 86.45.61 - Warning ligh

ELECTRICAL31REPAIRMAIN PRINTED CIRCUITService repair no - 88.20.19Remove1. Remove instrument cowl.See Instrumentcowl and illumination board2. Remove c

86ELECTRICAL32REPAIRCIRCUIT BOARDService repair no - 88.20.25Remove1. Remove binnacle.See Instrument binnacle2. Remove screw, release lower cover from

ELECTRICAL33REPAIRINSTRUMENT BINNACLE COMPONENTS1. Instrument cowl2. Face plate3. Fuel gauge4. Speedometer5. Instrument binnacle6. Screw - securing ci

86ELECTRICAL34REPAIRPRINTED CIRCUIT AND WARNING LIGHTS1. Panel illumination bulbs2. Transmission oil temperature warning lamp bulb3. Hazard warning la

ELECTRICAL35REPAIRINSTRUMENT COWL AND ILLUMINATION BOARDService repair no - 88.20.06 - Instrument cowlService repair no - 88.20.22 - Illumination boar

86ELECTRICAL36REPAIRSPEEDOMETERService repair no - 88.30.01Remove1. Remove instrument cowl.See Instrumentcowl and illumination board2. Remove speedome

ELECTRICAL37REPAIRCOOLANT TEMPERATURE AND FUEL GAUGESService repair no - 88.25.14 - Coolant temperaturegaugeService repair no - 88.25.26 - Fuel gaugeR

86ELECTRICAL38REPAIRREVERSE LIGHT SWITCHService repair no - 37.27.01Manual GearboxRemoveReverse light switch is located at rear of selectorhousing, ac

ELECTRICAL39REPAIRCIGAR LIGHTER AND BULBService repair no - 86.65.60Service repair no - 86.45.55Cigar LighterRemove1. Remove centre console.See CHASSI

Tdi5REPAIR37. Remove nuts and plain washers securing frontengine mountings to chassis,and lift both enginemounting bracket assemblies from vehicle.38.

86ELECTRICAL40REPAIRINSTRUMENT ILLUMINATION ELECTRONICDIMMER/RHEOSTATService repair no - 86.65.07Electronic dimming control switch is located ininstru

ELECTRICAL41REPAIRCOOLANT TEMPERATURE TRANSMITTER - V8iService repair no - 26.10.02Remove1. Disconnect battery negative lead.2. Disconnect lead from t

86ELECTRICAL42REPAIRFOG LAMP - FRONTService repair no - 86.40.96Remove1. Locate and release lamp harness multiplug fromclip behind headlamp.2. Disconn

ELECTRICAL43REPAIRANTI-THEFT ALARM ECU (96 MODELS)Service repair no - 86.55.85Remove1. Remove 4 studs securing fascia left handclosing panel.2. Remove

86ELECTRICAL44REPAIRBONNET SWITCHService repair no - 86.55.89Remove1. Remove 2 bolts securing sounder, movesounder aside.2. Locate and disconnect bonn

ELECTRICAL45REPAIRSOUNDER (96 MODELS)Service repair no - 86.55.87RemoveNOTE: Failure to follow steps 1 and 2 willresult in sounder being activated.1.

86ELECTRICAL46REPAIRSTARTER MOTOR - 4.0 V8Service repair no - 86.60.01Remove1. Disconnect battery negative lead.2. Raise vehicle on ramp.3. Remove hea

ELECTRICAL47REPAIR10. From above, remove top bolt securing startermotor and position earth lead aside.NOTE: To assist removal, use 230 mmextension bar

86ELECTRICAL48REPAIRSTARTER MOTOR HEAT SHIELD - 4.0 V8Service repair no - 86.60.12Remove1. Disconnect battery negative lead.2. Raise vehicle on ramp.3

ELECTRICAL49REPAIRRefit8. Fit bulb to lens.9. Secure bulb retaining clip.10. Connect 2 Lucars to bulb.11. Position lamp lens to shroud.12. Position la

12ENGINE6REPAIRCRANKSHAFT PULLEYService repair no - 12.21.01Remove1. Disconnect battery negative lead.2. Drain coolant.3. Remove top hose from radiato

86ELECTRICAL50REPAIRDIGITAL DIESEL SHUT-OFF VALVE (DDS) - 97 MYService repair no - 86.77.00Remove1. Remove fuel injection pump.See FUELSYSTEM, Repair,

ELECTRICAL1OVERHAULDISTRIBUTOR-LUCAS 35DLM8OverhaulDISTRIBUTOR CAPService repair no - 86.35.101. Unclip and remove cap2. Fit a new cap if faulty.3. Cl

86ELECTRICAL2OVERHAULLUBRICATIONApply clean engine oil:a. A spot into rotor spindle before fitting rotorarm.Apply Omnilube 2 (or equivalent) grease.b.

ELECTRICAL1SPECIFICATIONS, TORQUETORQUE VALUESNOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings aretightened t

Tdi7REPAIRFRONT COVER PLATEService repair no - 12.65.01Remove1. Disconnect battery negative lead.2. Drain coolant.3. Remove top hose from radiator.4.

12ENGINE8REPAIRCAMSHAFT DRIVE BELT AND GEARSService repair no - 12.65.18TIMING BELTRemove1. Remove front cover plate.See Front CoverPlate2. Position e

INTRODUCTION7INFORMATIONDYNAMOMETER TESTING - VEHICLES WITHANTI-LOCK BRAKES (ABS)WARNING: Do not attempt to test ABSfunction on a dynamometerFour whee

Tdi9REPAIRBelt tensionerNOTE: The belt tensioner need only beremoved if it is being replaced or foraccess purposes to remove front cover.11. Remove se

12ENGINE10REPAIR21. With lip side leading, drive-in seal squarely usingspecial tool LRT-12-082.22. Refit gear.FUEL INJECTION PUMP GEARService repair n

Tdi11REPAIRTiming belt fitting and tensioningNOTE: It is important that belt tensioningis carried out carefully and accurately. Thefollowing procedure

12ENGINE12REPAIRFRONT COVER/TIMING GEAR HOUSING GASKETService repair no - 12.65.10Remove1. Remove timing belt and gears.See CamshaftDrive Belt and Gea

Tdi13REPAIROIL SUMPService repair no - 12.60.44Remove1. Disconnect battery negative lead.2. Drain engine oil.3. Slacken sump securing bolts and, using

12ENGINE14REPAIRFLYWHEELService repair no - 12.53.07Remove1. Disconnect battery negative lead.2. Remove gearbox.See MANUAL GEARBOX,Repair, R380 Manual

Tdi15REPAIRCRANKSHAFT REAR OIL SEALService repair no - 12.21.20RemoveNOTE: The crankshaft rear oil seal isretained in its own housing, if the sealrequ

12ENGINE16REPAIR8. Ensure housing seal is correctly seated in itsgroove in new housing and seal assembly.9. Fit new assembly, with former/guide in-sit

Tdi17REPAIRMethod 2.Thread the bore of the existing bush and using asuitable bolt extract the bush. Thoroughly clean bushlocation ensuring all swarf i

12ENGINE18REPAIR10. Apply sealant to flywheel housing mating face oncylinder block (Fig. J5944).11. Fit housing to cylinder block and secure withbolts