Land Rover Range Rover Classic Workshop Manual
Range Rover Classic (LH code chassis for Range Rover or LJ for discovery) uses one of the following engines as a standard engine: 300Tdi (code F) or V8i Petrol (code V) with a R380 Borg-Warner transfer case, engine capacity are informed as the following:
3.9 Litre: 35D. - 9.35:1 compression, manual transmission; 36D. - 9.35:1 compression, automatic transmission; 37D. - 8.13:1 compression, manual transmission; 38D. - 8.13: 1 compression, automatic transmission
4.2 Litre: 40D. - 8.94:1 compression, automatic transmission
This workshop manual covers vehicles from 1995 model year onwards. Amendments and additional pages will be issued to ensure that the manual covers latest models. Amendments and additions will be identified by the addition of a dated footer at the bottom of the page.
Contents:
01 INTRODUCTION [ INFORMATION INTRODUCTION DIMENSIONS REFERENCES REPAIRS AND REPLACEMENTS POISONOUS SUBSTANCES FUEL HANDLING PRECAUTIONS SYNTHETIC RUBBER RECOMMENDED SEALANTS USED ENGINE OIL ACCESSORIES AND CONVERSIONS WHEELS AND TYRES STEAM CLEANING SPECIFICATION SPECIAL SERVICE TOOLS COPYRIGHT JACKING HYDRAULIC VEHICLE RAMP (FOUR POST) TWO POST VEHICLE RAMPS DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) TOWING TRANSPORTING THE VEHICLE BY TRAILER JUMP STARTING ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION OF IDENTIFICATION NUMBERS FAULT DIAGNOSTIC EQUIPMENT READING THIS MANUAL ]
04 - GENERAL SPECIFICATION DATA [ INFORMATION ENGINE - V8 ENGINE - 300Tdi FUEL SYSTEM - V8 Engine FUEL SYSTEM - 300Tdi Engine COOLING SYSTEM - V8 ENGINE COOLING SYSTEM - 300Tdi ENGINE TRANSMISSION SHIFT SPEED SPECIFICATION - AUTOMATIC ZF4HP22 GEARBOX STEERING SUSPENSION SHOCK ABSORBERS ROAD SPRING DATA BRAKES WHEELS AND TYRES AIR CONDITIONING WIPER MOTORS ELECTRICAL REPLACEMENT BULBS VEHICLE WEIGHTS AND PAYLOAD VEHICLE DIMENSIONS TYRE PRESSURES ]
05 - ENGINE TUNING DATA [ INFORMATION ENGINE - 3.9 V8 ENGINE - 4.2 V8 ENGINE - 300Tdi ]
06 - TORQUE WRENCH SETTINGS [ INFORMATION ENGINE - 300Tdi ENGINE - 3.9 V8 ENGINE - 4.2 V8 ]
07 - GENERAL FITTING REMINDERS [ INFORMATION GENERAL FITTING REMINDERS PRECAUTIONS AGAINST DAMAGE SAFETY PRECAUTIONS PREPARATION DISMANTLING INSPECTION-GENERAL BALL AND ROLLER BEARINGS OIL SEALS JOINTS AND JOINT FACES FLEXIBLE HYDRAULIC PIPES, HOSES FUEL SYSTEM HOSES METRIC BOLT IDENTIFICATION METRIC NUT IDENTIFICATION KEYS AND KEYWAYS TAB WASHERS SPLIT PINS NUTS LOCKING WIRE SCREW THREADS UNIFIED THREAD IDENTIFICATION ]
09 - LUBRICANTS, FLUIDS AND CAPACITIES [ INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS - USA VEHICLES RECOMMENDED LUBRICANTS AND FLUIDS LUBRICATION PRACTICE CAPACITIES ANTI-FREEZE FUEL REQUIREMENTS RECOMMENDED FUEL ]
10 - MAINTENANCE [ MAINTENANCE SERVICE SCHEDULE VEHICLE INTERIOR VEHICLE EXTERIOR UNDER BONNET [HOOD] MAINTENANCE UNDER VEHICLE MAINTENANCE RECOMMENDED SERVICE ITEMS ]
12 - ENGINE - Tdi [ REPAIR DRIVE BELT INFORMATION DRIVE BELT RENEW COMPRESSOR DRIVE BELT ENGINE CRANKSHAFT PULLEY FRONT COVER PLATE CAMSHAFT DRIVE BELT AND GEARS FRONT COVER/TIMING GEAR HOUSING GASKET OIL SUMP OIL PICK-UP STRAINER FLYWHEEL CRANKSHAFT REAR OIL SEAL CRANKSHAFT BEARING BUSH FLYWHEEL HOUSING OIL FILTER OIL TEMPERATURE CONTROL VALVE OIL FILTER HEAD GASKET CYLINDER HEAD GASKET VACUUM PUMP GENERATOR SPECIFICATIONS, TORQUE TORQUE VALUES ]
12 - ENGINE - V8i [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS ENGINE OIL PRESSURE TEST CYLINDER COMPRESSION - TEST ENGINE NOISES ENGINE STARTING PROBLEMS ENGINE RUNNING PROBLEMS REPAIR DRIVE BELT DRIVE BELT RENEW DRIVE BELT - CHECK TENSION DRIVE BELT TENSIONER CYLINDER HEAD GASKETS - RENEW CYLINDER HEADS - RENEW ROCKER COVER - RIGHT HAND - RENEW ROCKER COVER - LEFT HAND - RENEW ROCKER SHAFT RENEW HYDRAULIC TAPPETS RENEW CRANKSHAFT PULLEY ASSEMBLY FRONT COVER OIL SEAL - RENEW FRONT COVER GASKET TIMING CHAIN AND CHAINWHEELS FLYWHEEL FLEXIBLE DRIVE PLATE AND RING GEAR CRANKSHAFT REAR OIL SEAL ENGINE OIL SUMP SPECIFICATIONS, TORQUE TORQUE VALUES SERVICE TOOLS ENGINE ]
17 - EMISSION CONTROL [ DESCRIPTION AND OPERATION EMISSION CONTROL EXHAUST SYSTEM EVAPORATIVE CONTROL SYSTEM FAULT DIAGNOSIS TESTING EVAPORATIVE EMISSION CONTROL REPAIR POSITIVE CRANKCASE VENTILATION AIR INTAKE FILTER POSITIVE CRANKCASE VENTILATION BREATHER FILTER LAMBDA (OXYGEN) SENSOR PURGE CONTROL VALVE CHARCOAL CANISTER ]
19 - FUEL SYSTEM - Tdi [ DESCRIPTION AND OPERATION DESCRIPTION FUEL SYSTEM LAYOUT FUEL SYSTEM COMPONENT LOCATION OPERATION ADJUSTMENT THROTTLE CABLE EGR THROTTLE POSITION SENSOR LOW AND HIGH IDLE SPEED CHECK TURBOCHARGER BOOST PRESSURE REPAIR TANK SENDER UNIT THROTTLE CABLE INTAKE HOSE TURBOCHARGER TURBOCHARGER OIL FEED PIPE TURBOCHARGER OIL DRAIN PIPE TURBOCHARGER ACTUATOR TURBOCHARGER AND GASKET FUEL LIFT PUMP FUEL FILTER ELEMENT INTERCOOLER GLOW PLUGS EGR VALVE GLOW PLUG CONTROL UNIT EGR CONTROL UNIT EGR THROTTLE POSITION SENSOR INJECTORS FUEL INJECTION PUMP AND TIMING VEHICLE SPEED SENSOR COOLANT TEMPERATURE SENSOR ]
19 - FUEL SYSTEM - MFI [ DESCRIPTION AND OPERATION DESCRIPTION ENGINE MOUNTED COMPONENTS CHASSIS MOUNTED COMPONENTS BODY MOUNTED COMPONENTS MICRO PROCESSOR POWER CHECK FUEL INJECTION SYSTEM ENGINE SETTING PROCEDURE FAULT DIAGNOSIS ENGINE TUNING INJECTOR TESTS BASE IDLE SPEED SETTING FUEL PRESSURE CHECK REPAIR AIR CLEANER ASSEMBLY AIR CLEANER ELEMENT AIR FLOW SENSOR THROTTLE POSITION SENSOR IDLE AIR CONTROL VALVE VEHICLE SPEED SENSOR MULTIPORT FUEL INJECTION RELAYS ENGINE CONTROL MODULE (ECM)-14 CUX INERTIA FUEL SHUTOFF SWITCH ENGINE FUEL TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR DEPRESSURISING FUEL SYSTEM FUEL PRESSURE REGULATOR FUEL RAIL-INJECTORS R/H AND L/H PLENUM CHAMBER RAM HOUSING INTAKE MANIFOLD FUEL FILTER FUEL PIPES THROTTLE CABLE ACCELERATOR PEDAL FUEL PUMP AND SENDER UNIT FUEL TANK FUEL FILLER FLAP RELEASE BUTTON FUEL FILLER FLAP RELEASE ACTUATOR SPECIFICATIONS, TORQUE TORQUE VALUES SERVICE TOOLS FUEL SYSTEM ]
19 - FUEL SYSTEM - Cruise Control [ DESCRIPTION AND OPERATION CRUISE CONTROL SYSTEM-HELLA GR66 FAULT DIAGNOSIS ROAD TEST REPAIR BRAKE AND CLUTCH PEDAL SWITCHES/VENT VALVES MAIN CONTROL SWITCH CRUISE CONTROL SWITCH ROTARY COUPLER ACTUATOR ACTUATOR LINK-SETTING VACUUM PUMP CRUISE CONTROL ECU SPEED TRIP ECU - MANUAL ]
26 - COOLING SYSTEM - Tdi [ DESCRIPTION AND OPERATION ENGINE COOLING COOLANT CIRCULATION VISCOUS FAN FAULT DIAGNOSIS ENGINE OVERHEATING ENGINE RUNS COLD ADJUSTMENT COOLANT REPAIR VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL THERMOSTAT WATER PUMP RADIATOR ]
26 - COOLING SYSTEM - V8i [ DESCRIPTION AND OPERATION ENGINE COOLING COOLANT CIRCULATION VISCOUS FAN FAULT DIAGNOSIS ENGINE OVERHEATING ENGINE RUNS COLD ADJUSTMENT COOLANT REQUIREMENTS COOLANT REPAIR EXPANSION TANK VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL THERMOSTAT WATER PUMP RADIATOR SPECIFICATIONS, TORQUE TORQUE VALUES ]
30 - MANIFOLD AND EXHAUST SYSTEM [ DESCRIPTION AND OPERATION CATALYTIC CONVERTERS - V8i REPAIR EXHAUST SYSTEM COMPLETE EXHAUST MANIFOLD - V8i MANIFOLD AND EXHAUST SYSTEM - Tdi EXHAUST MANIFOLD - Tdi SPECIFICATIONS, TORQUE TORQUE VALUES ]
33 - CLUTCH [ DESCRIPTION AND OPERATION DESCRIPTION OPERATION FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS CLUTCH SPIN - DRAG CLUTCH SLIP CLUTCH JUDDER - FIERCE FAULT/SYMPTOM CHART CLUTCH NOISE - MECHANICAL FAULTS HYDRAULIC FAULTS REPAIR CLUTCH ASSEMBLY BLEED HYDRAULIC SYSTEM MASTER CYLINDER RELEASE BEARING ASSEMBLY SLAVE CYLINDER RENEWING HYDRAULIC DAMPER - Tdi OVERHAUL MASTER CYLINDER SLAVE CYLINDER SPECIFICATIONS, TORQUE TORQUE VALUES ]
37 - MANUAL GEARBOX - R380 [ DESCRIPTION AND OPERATION MANUAL TRANSMISSION FAULT DIAGNOSIS MANUAL GEARBOX REPAIR R380 GEARBOX SPECIFICATIONS, TORQUE TORQUE VALUES ]
41 - TRANSFER GEARBOX - BORG WARNER [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS BORG WARNER - SYMPTOMS REPAIR REAR OUTPUT SHAFT OIL SEAL FRONT OUTPUT SHAFT OIL SEAL BORG WARNER TRANSFER GEARBOX OVERHAUL BORG WARNER GEARBOX ILLUSTRATED ASSEMBLIES BORG WARNER TRANSFER GEARBOX DISMANTLE, INSPECTION AND OVERHAUL SPECIFICATIONS, TORQUE TORQUE VALUES SERVICE TOOLS ADAPTER PLATE TRANSFER BOX ]
44 - AUTOMATIC GEARBOX - ZF [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS ZF AUTOMATIC GEARBOX ROAD TEST PROCEDURE AUTOMATIC GEARBOX ASSEMBLY ILLUSTRATED FAULT SYMPTOMS REPAIR ZF AUTO WITH BORG WARNER TRANSFER GEARBOX INHIBITOR SWITCH SELECTOR SHAFT OIL SEAL OIL SUMP GASKET KICKDOWN CABLE LEAK EXTENSION HOUSING OIL SCREEN CONTROL UNIT OIL INLET SEALING RINGS MANUAL VALVE OPERATING MECHANISM GOVERNOR HOUSING GOVERNOR HUB PARKING PAWL MECHANISM REPLACING TORQUE CONVERTER ELIMINATING LEAKS ON PUMP HOUSING ELIMINATING LEAKS BETWEEN GEARBOX HOUSING AND INTERMEDIATE PLATE REPLACING BELLHOUSING REPLACING PUMP REPLACING INTERMEDIATE PLATE SPECIFICATIONS, TORQUE TORQUE VALUES ZF GEARBOX DATA SERVICE TOOLS AUTOMATIC GEARBOX HOLDING FIXTURE AUTOMATIC GEARBOX AND BORG WARNER TRANSFER GEARBOX AUTOMATIC GEARBOX ]
47 - PROPELLER SHAFTS [ DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT FAULT DIAGNOSIS VIBRATION HARSHNESS REPAIR FRONT PROPELLER SHAFT SPIDER ASSEMBLY COMPONENTS REAR PROPELLER SHAFT FLEXIBLE COUPLING ]
51 - REAR AXLE AND FINAL DRIVE [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS REPAIR REAR AXLE REAR BRAKE DISC NON ABS REAR BRAKE DISCS ABS REAR HUB ASSEMBLY OVERHAUL AXLE DIFFERENTIAL ASSEMBLY CROWN WHEEL/PINION BACKLASH ADJUSTMENT REAR HUB ASSEMBLY REAR STUB AXLE SPECIFICATIONS, TORQUE AXLE DIFFERENTIAL DATA REAR HUB TORQUE VALUES SERVICE TOOLS AXLE DIFFERENTIAL REAR HUB ]
54 - FRONT AXLE AND FINAL DRIVE [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS REPAIR FRONT AXLE ASSEMBLY FRONT BRAKE DISCS FRONT HUB ASSEMBLY OVERHAUL FRONT DIFFERENTIAL FRONT HUB FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING NON ABS FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING ABS SPECIFICATIONS, TORQUE TORQUE VALUES FRONT HUB AND SWIVEL DATA SERVICE TOOLS FRONT HUB ]
57 - STEERING [ DESCRIPTION AND OPERATION DESCRIPTION ]
FAULT DIAGNOSIS [ INSUFFICIENT POWER ASSISTANCE POWER STEERING SYSTEM - TEST STEERING DAMPER STEERING FAULTS STEERING STABILITY AND VEER UNDER BRAKING 1. GENERAL STEERING 2. STEERING VEER 3. VEER UNDER BRAKING 4. DIRECTIONAL STABILITY POWER STEERING FLUID LEAKS POWER STEERING SYSTEM - EXCESSIVE NOISE POWER STEERING SYSTEM - GRUNT VISUAL AND SAFETY CHECKS ROAD TEST PROCEDURE STIFF STEERING CHECKLIST VISUAL CHECK AND BASIC ADJUSTMENTS STEERING LINKAGE INSPECT ADJUSTMENT POWER STEERING BOX CENTRALISE STEERING BOX STEERING LOCK STOPS FRONT WHEEL ALIGNMENT POWER STEERING PUMP DRIVE BELT REPAIR POWER STEERING FLUID PIPES POWER STEERING BOX POWER STEERING SYSTEM - BLEED POWER STEERING FLUID RESERVOIR POWER STEERING PUMP DRIVE BELT POWER STEERING PUMP - V8i POWER STEERING PUMP - Tdi LOWER STEERING SHAFT AND UNIVERSAL JOINTS STEERING COLUMN SHROUD STEERING WHEEL UPPER STEERING COLUMN STEERING COLUMN LOCK ASSEMBLY DROP ARM STEERING DAMPER TRACK ROD AND LINKAGE DRAG LINK AND DRAG LINK ENDS OVERHAUL POWER STEERING BOX SPECIFICATIONS, TORQUE STEERING PUMP TORQUE VALUES SERVICE TOOLS POWER STEERING BOX ]
60 - FRONT SUSPENSION [ DESCRIPTION AND OPERATION INTRODUCTION AXLE LOCATION REPAIR SELF LOCKING NUTS PANHARD ROD RADIUS ARM FRONT SHOCK ABSORBER FRONT ROAD SPRING BUMP STOP ANTI-ROLL [SWAY] BAR FRONT ANTI-ROLL BAR BALL JOINT LINKS SPECIFICATIONS, TORQUE TORQUE VALUES ]
64 - REAR SUSPENSION [ DESCRIPTION AND OPERATION AXLE LOCATION SELF LEVELLING UNIT FAULT DIAGNOSIS SELF LEVELLING UNIT REPAIR REAR ROAD SPRING REAR SHOCK ABSORBER LEVELLING UNIT LEVELLING UNIT BALL JOINTS BUMP STOP SUSPENSION LINK UPPER SUSPENSION LINK LOWER ANTI-ROLL BAR REAR ANTI-ROLL BAR BALL JOINT LINKS SPECIFICATIONS, TORQUE TORQUE VALUES ]
68 - AIR SUSPENSION [ DESCRIPTION AND OPERATION ELECTRONIC AIR SUSPENSION - (EAS) LOCATION OF COMPONENTS DESCRIPTION OF COMPONENTS PNEUMATIC SYSTEM DIAGRAM AIR PIPE COLOUR CODES SYSTEM OPERATION - see RR3858M ECU INPUTS SYSTEM FUNCTION FAULT DIAGNOSIS DIAGNOSTICS AND FAULT RECOVERY AIR SUSPENSION CIRCUIT DIAGRAM ADJUSTMENT DEPRESSURISE SYSTEM SYSTEM CALIBRATION - HEIGHT SENSOR DATUM AIR RESERVOIR - DRAIN AIR SPRINGS/HEIGHT SENSORS - INSPECT AIR HARNESS INSPECT LEAK TEST PROCEDURE REPAIR SUSPENSION COMPONENTS OPERATING SWITCHES AND BULBS DISCONNECT/CONNECT AIR PIPE AIR PIPE CONNECTION COLLET AND âOâ RINGS FRONT DAMPER REAR DAMPER FRONT AIR SPRING REAR AIR SPRING ASSEMBLY BUMP STOP HEIGHT SENSOR PRESSURE RELIEF VALVE COMPRESSOR INLET FILTER AIR SUPPLY UNIT AIR DRIER AIR COMPRESSOR VALVE BLOCK RESERVOIR PRESSURE SWITCH AIR RESERVOIR ELECTRONIC CONTROL UNIT AIR HARNESS SERVICE TOOLS RECOMMENDED EQUIPMENT ]
70 - BRAKES - NON ABS [ DESCRIPTION AND OPERATION BRAKE SERVO UNIT BRAKE SYSTEM BRAKE PIPE LAYOUT - LHD BRAKE PIPE LAYOUT - RHD REPAIR BRAKE SYSTEM BLEED (NON ABS) MASTER CYLINDER MASTER CYLINDER ASSEMBLY SERVO ASSEMBLY FRONT BRAKE PADS REAR BRAKE PADS FRONT BRAKE CALIPER ASSEMBLY FRONT BRAKE CALIPERS REAR BRAKE CALIPERS PARKING BRAKE LEVER STOP LIGHT SWITCH - NON ABS REAR BRAKE CALIPER ASSEMBLY ]
70 - BRAKES - ABS [ DESCRIPTION AND OPERATION ANTI-LOCK BRAKE SYSTEM - ABS SYSTEM DESCRIPTION HYDRAULIC COMPONENTS LOCATION OF COMPONENTS BRAKE PIPE LAYOUT - LEFT HAND DRIVE BRAKE PIPE LAYOUT - RIGHT HAND DRIVE WARNING LIGHTS DRIVING VEHICLE BRAKE APPLICATION WITH PARTIAL FAILURE FAULT DIAGNOSIS ACCUMULATOR PRECHARGE ABS FAULT DIAGNOSIS FAULT DIAGNOSIS PROCEDURE ABS FAULT AND REMEDY CHART REPAIR GENERAL SERVICE INFORMATION FLUID LEVEL CHECK / TOP UP DEPRESSURISE SYSTEM BRAKE SYSTEM BLEED (ABS) HYDRAULIC BOOSTER UNIT RESERVOIR (INCLUDE SEALS) HYDRAULIC POWER UNIT ACCUMULATOR ELECTRONIC CONTROL UNIT - ECU SENSORS - FRONT SENSORS - REAR STOP LIGHT SWITCH EXCITER RINGS SERVICE TOOLS ABS BRAKES SERVICE TOOLS ]
70 - BRAKES - ETC [ DESCRIPTION AND OPERATION ELECTRONIC TRACTION CONTROL - ETC COMPONENTS ETC HYDRAULIC COMPONENTS ETC OPERATION FAULT DIAGNOSIS REPAIR ETC VALVE BLOCK ]
74 - WHEELS AND TYRES [ DESCRIPTION AND OPERATION TYPES OF WHEEL RIMS AND TYRES FAULT DIAGNOSIS TYRE WEAR CHART FAULT - SYMPTOMS REPAIR GENERAL INFORMATION TYRE INSPECTION WHEELS INSPECTION VALVES INSPECTION TYRE PRESSURES WHEEL BALANCING TYRE FITTING WHEELS WHEEL STUD ]
75 - SUPPLEMENTARY RESTRAINT SYSTEM [ DESCRIPTION AND OPERATION SYSTEM COMPONENTS OPERATION GENERAL PRECAUTIONS VEHICLE RECOVERY AIRBAG STORAGE FAULT DIAGNOSIS CRASH SENSOR INSPECTION AIRBAG HARNESS WARNING LABELS REPAIR SYSTEM PRECAUTIONS DRIVERâS AIRBAG MODULE STEERING WHEEL ROTARY COUPLER ROTARY COUPLER CENTRALISE COLUMN SWITCH ASSEMBLY PASSENGERâS AIRBAG MODULE CRASH SENSOR AIRBAG DIAGNOSTIC CONTROL UNIT SRS WARNING LIGHT BULBS AIRBAG HARNESS AIRBAG MANUAL DEPLOYMENT SPECIFICATIONS, TORQUE TORQUE VALUES ]
76 - CHASSIS AND BODY [ DESCRIPTION AND OPERATION BODY CONSTRUCTION PAINT CODES - 1995 REPAIR BODY REPAIRS, GENERAL INFORMATION PAINTWORK BODY WELDING PREPARATION INNER BODY SHELL ASSEMBLY HEADLINING ROOF PANEL BONNET DECKER PANEL FRONT WING ASSISTED BONNET LIFT FUEL FILLER FLAP REAR CORNER PANEL AND WING REAR QUARTER PANEL-INTERIOR REAR QUARTER PANEL-EXTERIOR TAILGATE UPPER TAILGATE UPPER LOCK TAILGATE UPPER GLASS TAILGATE LOWER STRIKER TAILGATE LOWER TAILGATE LOWER RELEASE MECHANISM RADIATOR GRILLE FRONT DOOR FRONT DOOR GLASS AND REGULATOR FRONT DOOR TRIM PANEL FRONT DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES FRONT DOOR HEATED LOCK ASSEMBLY ADJUSTMENT - FRONT DOOR LOCK AND HANDLE ASSEMBLY FRONT WHEEL ARCH LINER SILL FINISHER REAR DOOR REAR DOOR - TRIM PANEL REAR DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES REAR DOOR LOCK AND HANDLE ASSEMBLY REAR DOOR GLASS AND REGULATOR REAR QUARTER LIGHT GLASS FRONT SEAT ELECTRICAL FRONT SEAT MANUAL ASYMMETRIC SPLIT REAR SEAT ASYMMETRIC SPLIT REAR SEAT - LOCKING MECHANISM FRONT SEAT HEATED CUSHION AND SQUAB SEAT BELTS FRONT SEAT BELT REAR SEAT BELT CENTRE CONSOLE DRINKS TRAY DASH PANEL CENTRAL LOUVRE PANEL DASH PANEL ASSEMBLY FRONT SPOILER FRONT BUMPER METAL SUNROOF ASSEMBLY OPERATING MOTOR, MICRO-SWITCH AND RELAY SUNROOF PANEL SEALS SUNROOF ASSEMBLY SUNROOF HEADLINER ASSEMBLY GLASS SUNROOF GLASS PANEL ASSEMBLY WIND DEFLECTOR ASSEMBLY MANUAL OPERATION MOTOR DRIVE ASSEMBLY AND CONTROL UNIT GLASS SUNROOF COMPLETE ASSEMBLY SLIDE AND GUIDE CHANNEL ASSEMBLIES OR SUNSHADE PANEL TIMING OF CONTROL UNIT TO SUNROOF OPERATION CHASSIS AMERICA ONLY - 1990 ONWARDS CHASSIS NON AMERICAN - 1990 ONWARDS CHASSIS - AMERICAN COUNTY LWB (108) MODELS CHASSIS - LSE (108) AIR SUSPENSION MODELS WINDSCREEN GLASS ]
80 - HEATING AND VENTILATION [ DESCRIPTION AND OPERATION HEATING AND VENTILATION UNIT FAULT DIAGNOSIS HEATER OUTPUT REPAIR HEATER BLOWER SWITCH AND ILLUMINATION BULB HEATER CONTROL UNIT CONTROL CABLES RESISTOR UNIT WATER VALVE VACUUM SWITCH - WATER VALVE RECIRCULATION SWITCH RECIRCULATION FLAP SOLENOID BLOWER MOTOR UNIT - HEATER AND AIR CONDITIONING BLOWER MOTOR HEATER MATRIX SPECIFICATIONS, TORQUE TORQUE VALUES ]
82 - AIR CONDITIONING [ DESCRIPTION AND OPERATION AIR CONDITIONING SYSTEM COMPONENTS SCHEMATIC LAYOUT OF THE AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM OPERATION AIR CONDITIONING CONTROL SYSTEM FAULT DIAGNOSIS AIR CONDITIONING - ELECTRICAL - MECHANICAL FAULTS REFRIGERATION SYSTEM FAULTS HEATER AND AIR CONDITIONING - CIRCUIT DIAGRAMS ADJUSTMENT GENERAL PRECAUTIONS REMEDIAL ACTIONS SERVICING PRECAUTIONS REFRIGERANT RECOVERY RECYCLING RECHARGING LEAK TEST SYSTEM AIR CONDITIONING SYSTEM - PERFORMANCE TEST SYSTEM TEST COMPRESSOR DRIVE BELT REPAIR PRECAUTIONS IN HANDLING REFRIGERANT LINES PERIODIC MAINTENANCE RECEIVER DRIER AIR CONDITIONING SWITCH DUAL PRESSURE SWITCH COMPRESSOR CONDENSER CONDENSER FANS AND MOTORS HEATER AND COOLER UNIT EVAPORATOR AND EXPANSION VALVE THERMOSTAT SPECIFICATIONS, TORQUE TORQUE VALUES AIR CONDITIONING CHARGE DATA ]
84 - WIPERS AND WASHERS [ FAULT DIAGNOSIS WIPER MOTOR CHECKING REPAIR WASHER RESERVOIR POWER WASH PUMP WASHER PUMP - WINDSCREEN OR TAILGATE HEATED WINDSCREEN WASHER JETS HEATED WINDSCREEN WASHER JETS THERMOSTAT WINDSCREEN WASHER TUBES WIPER ARMS - WINDSCREEN WIPER ARM - TAILGATE WIPER BLADES - WINDSCREEN AND TAILGATE WINDSCREEN WIPER MOTOR, LINKAGE AND WHEEL BOXES TAILGATE GLASS WIPER MOTOR TAILGATE GLASS WASHER JET HEADLAMP POWER WASH JET POWER WASH HOSE ]
86 - ELECTRICAL [ DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT A.C. GENERATOR - A127/100 ANTI THEFT ALARM SYSTEM ANTI-THEFT SYSTEM FUNCTION ALARM COMPONENTS BUILT IN TEST PROCEDURE FAULT DIAGNOSIS LUCAS CONSTANT ENERGY IGNITION SYSTEM - V8i ADJUSTMENT IGNITION TIMING REPAIR BATTERY A.C. GENERATOR - V8i ENGINE A.C. GENERATOR DRIVE BELT DISTRIBUTOR-LUCAS 35 DLM8 ELECTRONIC IGNITION - V8i DISTRIBUTOR - V8i IGNITION COIL BULB REPLACEMENT HEADLAMP ASSEMBLY / SEALED BEAM UNIT HEADLAMP ASSEMBLY/BULB REPLACEMENT HEADLAMP ALIGNMENT AUXILIARY DRIVING LAMP SIDELIGHT AND FLASHER LAMP ASSEMBLY AND BULB DIRECTION INDICATOR/SIDE REPEATER LAMP BULB REPLACEMENT TAIL LAMP ASSEMBLY REFLECTORS/SIDE MARKER LAMP ASSEMBLY AND BULB UNDER BONNET LAMP ASSEMBLY HEATER/VENTILATION AND AIR CONDITIONING CONTROL PANEL BULB HEATER/VENTILATION AND AIR CONDITIONING CONTROL PANEL MSWITCHES AND BULBS DOOR EDGE LAMPS / PUDDLE LAMPS DOOR EDGE LAMPS/PUDDLE LAMPS BULB AUTOMATIC GEAR SELECTOR-PANEL BULB NUMBER/LICENSE PLATE LAMP ASSEMBLY AND BULB INTERIOR ROOF LAMP STARTER MOTOR - V8i ENGINE AUXILIARY SWITCHES AND BULBS AIR SUSPENSION SWITCHES AND BULBS HEADLAMP/FLASHER SWITCH AND WINDSCREEN WASH/WIPE SWITCH HAZARD WARNING SWITCH AND BULB IGNITION/STARTER SWITCH - BULB REPLACEMENT DOOR PILLAR SWITCH IGNITION/STARTER SWITCH REAR TAILGATE SWITCH UNDER BONNET/HOOD ILLUMINATION SWITCH CIGAR LIGHTER AND BULB REVERSE LIGHT SWITCH START INHIBIT / REVERSE LIGHT SWITCH OIL PRESSURE WARNING SWITCH - V8i PARK BRAKE WARNING SWITCH EXTERIOR DRIVING MIRRORS MOTOR CONTROL SWITCHES INSTRUMENT ILLUMINATION ELECTRONIC DIMMER / RHEOSTAT WINDOW LIFT/HEATED SEAT CUSHION SWITCHES AND BULBS WINDOW LIFT MOTOR - FRONT DOORS WINDOW LIFT MOTOR - REAR DOORS CENTRAL DOOR LOCKING HANDSET INITIALISATION FRONT DOOR ACTUATOR UNIT REAR DOOR ACTUATOR UNITS UPPER TAILGATE ACTUATOR UNIT FUEL FILLER FLAP ACTUATOR UNIT TRAILER SOCKET FRONT SEAT - MOTORS FRONT SEAT - SWITCHES MAP LIGHT BULB RENEWAL ELECTRICAL SEAT FAILURE DRIVE CABLE - ELECTRIC SEAT MEMORY SEAT - SWITCH MEMORY SEAT SWITCH - CLEAN ECU - MEMORY SEAT RADIO ANTENNA AMPLIFIER MEMORY SEAT - HARNESS LAYOUT A.C. GENERATOR HEAT SHIELD HIGH LEVEL STOP LAMP ALARM HORN GEAR SELECTOR-INTERLOCK SUBWOOFER BOX HEATED FRONT SCREEN RADIO COOLANT TEMPERATURE TRANSMITTER - V8i CLOCK AND BULB INSTRUMENT PANEL FINISHER INSTRUMENT BINNACLE INSTRUMENT ILLUMINATION AND WARNING LIGHT BULBS MAIN PRINTED CIRCUIT CIRCUIT BOARD INSTRUMENT BINNACLE COMPONENTS PRINTED CIRCUIT AND WARNING LIGHTS INSTRUMENT COWL AND ILLUMINATION BOARD SPEEDOMETER TACHOMETER COOLANT TEMPERATURE AND FUEL GAUGES SPEEDOMETER TRANSDUCER ALARM ECU OVERHAUL DISTRIBUTOR-LUCAS 35DLM8 DISTRIBUTOR CAP ROTOR ARM INSULATION COVER (FLASH SHIELD) VACUUM UNIT AMPLIFIER MODULE PICK-UP AND BASE PLATE ASSEMBLY LUBRICATION SPECIFICATIONS, TORQUE TORQUE VALUES ]
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3.9 Litre: 35D. - 9.35:1 compression, manual transmission; 36D. - 9.35:1 compression, automatic transmission; 37D. - 8.13:1 compression, manual transmission; 38D. - 8.13: 1 compression, automatic transmission
4.2 Litre: 40D. - 8.94:1 compression, automatic transmission
This workshop manual covers vehicles from 1995 model year onwards. Amendments and additional pages will be issued to ensure that the manual covers latest models. Amendments and additions will be identified by the addition of a dated footer at the bottom of the page.
Contents:
01 INTRODUCTION [ INFORMATION INTRODUCTION DIMENSIONS REFERENCES REPAIRS AND REPLACEMENTS POISONOUS SUBSTANCES FUEL HANDLING PRECAUTIONS SYNTHETIC RUBBER RECOMMENDED SEALANTS USED ENGINE OIL ACCESSORIES AND CONVERSIONS WHEELS AND TYRES STEAM CLEANING SPECIFICATION SPECIAL SERVICE TOOLS COPYRIGHT JACKING HYDRAULIC VEHICLE RAMP (FOUR POST) TWO POST VEHICLE RAMPS DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) TOWING TRANSPORTING THE VEHICLE BY TRAILER JUMP STARTING ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION OF IDENTIFICATION NUMBERS FAULT DIAGNOSTIC EQUIPMENT READING THIS MANUAL ]
04 - GENERAL SPECIFICATION DATA [ INFORMATION ENGINE - V8 ENGINE - 300Tdi FUEL SYSTEM - V8 Engine FUEL SYSTEM - 300Tdi Engine COOLING SYSTEM - V8 ENGINE COOLING SYSTEM - 300Tdi ENGINE TRANSMISSION SHIFT SPEED SPECIFICATION - AUTOMATIC ZF4HP22 GEARBOX STEERING SUSPENSION SHOCK ABSORBERS ROAD SPRING DATA BRAKES WHEELS AND TYRES AIR CONDITIONING WIPER MOTORS ELECTRICAL REPLACEMENT BULBS VEHICLE WEIGHTS AND PAYLOAD VEHICLE DIMENSIONS TYRE PRESSURES ]
05 - ENGINE TUNING DATA [ INFORMATION ENGINE - 3.9 V8 ENGINE - 4.2 V8 ENGINE - 300Tdi ]
06 - TORQUE WRENCH SETTINGS [ INFORMATION ENGINE - 300Tdi ENGINE - 3.9 V8 ENGINE - 4.2 V8 ]
07 - GENERAL FITTING REMINDERS [ INFORMATION GENERAL FITTING REMINDERS PRECAUTIONS AGAINST DAMAGE SAFETY PRECAUTIONS PREPARATION DISMANTLING INSPECTION-GENERAL BALL AND ROLLER BEARINGS OIL SEALS JOINTS AND JOINT FACES FLEXIBLE HYDRAULIC PIPES, HOSES FUEL SYSTEM HOSES METRIC BOLT IDENTIFICATION METRIC NUT IDENTIFICATION KEYS AND KEYWAYS TAB WASHERS SPLIT PINS NUTS LOCKING WIRE SCREW THREADS UNIFIED THREAD IDENTIFICATION ]
09 - LUBRICANTS, FLUIDS AND CAPACITIES [ INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS - USA VEHICLES RECOMMENDED LUBRICANTS AND FLUIDS LUBRICATION PRACTICE CAPACITIES ANTI-FREEZE FUEL REQUIREMENTS RECOMMENDED FUEL ]
10 - MAINTENANCE [ MAINTENANCE SERVICE SCHEDULE VEHICLE INTERIOR VEHICLE EXTERIOR UNDER BONNET [HOOD] MAINTENANCE UNDER VEHICLE MAINTENANCE RECOMMENDED SERVICE ITEMS ]
12 - ENGINE - Tdi [ REPAIR DRIVE BELT INFORMATION DRIVE BELT RENEW COMPRESSOR DRIVE BELT ENGINE CRANKSHAFT PULLEY FRONT COVER PLATE CAMSHAFT DRIVE BELT AND GEARS FRONT COVER/TIMING GEAR HOUSING GASKET OIL SUMP OIL PICK-UP STRAINER FLYWHEEL CRANKSHAFT REAR OIL SEAL CRANKSHAFT BEARING BUSH FLYWHEEL HOUSING OIL FILTER OIL TEMPERATURE CONTROL VALVE OIL FILTER HEAD GASKET CYLINDER HEAD GASKET VACUUM PUMP GENERATOR SPECIFICATIONS, TORQUE TORQUE VALUES ]
12 - ENGINE - V8i [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS ENGINE OIL PRESSURE TEST CYLINDER COMPRESSION - TEST ENGINE NOISES ENGINE STARTING PROBLEMS ENGINE RUNNING PROBLEMS REPAIR DRIVE BELT DRIVE BELT RENEW DRIVE BELT - CHECK TENSION DRIVE BELT TENSIONER CYLINDER HEAD GASKETS - RENEW CYLINDER HEADS - RENEW ROCKER COVER - RIGHT HAND - RENEW ROCKER COVER - LEFT HAND - RENEW ROCKER SHAFT RENEW HYDRAULIC TAPPETS RENEW CRANKSHAFT PULLEY ASSEMBLY FRONT COVER OIL SEAL - RENEW FRONT COVER GASKET TIMING CHAIN AND CHAINWHEELS FLYWHEEL FLEXIBLE DRIVE PLATE AND RING GEAR CRANKSHAFT REAR OIL SEAL ENGINE OIL SUMP SPECIFICATIONS, TORQUE TORQUE VALUES SERVICE TOOLS ENGINE ]
17 - EMISSION CONTROL [ DESCRIPTION AND OPERATION EMISSION CONTROL EXHAUST SYSTEM EVAPORATIVE CONTROL SYSTEM FAULT DIAGNOSIS TESTING EVAPORATIVE EMISSION CONTROL REPAIR POSITIVE CRANKCASE VENTILATION AIR INTAKE FILTER POSITIVE CRANKCASE VENTILATION BREATHER FILTER LAMBDA (OXYGEN) SENSOR PURGE CONTROL VALVE CHARCOAL CANISTER ]
19 - FUEL SYSTEM - Tdi [ DESCRIPTION AND OPERATION DESCRIPTION FUEL SYSTEM LAYOUT FUEL SYSTEM COMPONENT LOCATION OPERATION ADJUSTMENT THROTTLE CABLE EGR THROTTLE POSITION SENSOR LOW AND HIGH IDLE SPEED CHECK TURBOCHARGER BOOST PRESSURE REPAIR TANK SENDER UNIT THROTTLE CABLE INTAKE HOSE TURBOCHARGER TURBOCHARGER OIL FEED PIPE TURBOCHARGER OIL DRAIN PIPE TURBOCHARGER ACTUATOR TURBOCHARGER AND GASKET FUEL LIFT PUMP FUEL FILTER ELEMENT INTERCOOLER GLOW PLUGS EGR VALVE GLOW PLUG CONTROL UNIT EGR CONTROL UNIT EGR THROTTLE POSITION SENSOR INJECTORS FUEL INJECTION PUMP AND TIMING VEHICLE SPEED SENSOR COOLANT TEMPERATURE SENSOR ]
19 - FUEL SYSTEM - MFI [ DESCRIPTION AND OPERATION DESCRIPTION ENGINE MOUNTED COMPONENTS CHASSIS MOUNTED COMPONENTS BODY MOUNTED COMPONENTS MICRO PROCESSOR POWER CHECK FUEL INJECTION SYSTEM ENGINE SETTING PROCEDURE FAULT DIAGNOSIS ENGINE TUNING INJECTOR TESTS BASE IDLE SPEED SETTING FUEL PRESSURE CHECK REPAIR AIR CLEANER ASSEMBLY AIR CLEANER ELEMENT AIR FLOW SENSOR THROTTLE POSITION SENSOR IDLE AIR CONTROL VALVE VEHICLE SPEED SENSOR MULTIPORT FUEL INJECTION RELAYS ENGINE CONTROL MODULE (ECM)-14 CUX INERTIA FUEL SHUTOFF SWITCH ENGINE FUEL TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR DEPRESSURISING FUEL SYSTEM FUEL PRESSURE REGULATOR FUEL RAIL-INJECTORS R/H AND L/H PLENUM CHAMBER RAM HOUSING INTAKE MANIFOLD FUEL FILTER FUEL PIPES THROTTLE CABLE ACCELERATOR PEDAL FUEL PUMP AND SENDER UNIT FUEL TANK FUEL FILLER FLAP RELEASE BUTTON FUEL FILLER FLAP RELEASE ACTUATOR SPECIFICATIONS, TORQUE TORQUE VALUES SERVICE TOOLS FUEL SYSTEM ]
19 - FUEL SYSTEM - Cruise Control [ DESCRIPTION AND OPERATION CRUISE CONTROL SYSTEM-HELLA GR66 FAULT DIAGNOSIS ROAD TEST REPAIR BRAKE AND CLUTCH PEDAL SWITCHES/VENT VALVES MAIN CONTROL SWITCH CRUISE CONTROL SWITCH ROTARY COUPLER ACTUATOR ACTUATOR LINK-SETTING VACUUM PUMP CRUISE CONTROL ECU SPEED TRIP ECU - MANUAL ]
26 - COOLING SYSTEM - Tdi [ DESCRIPTION AND OPERATION ENGINE COOLING COOLANT CIRCULATION VISCOUS FAN FAULT DIAGNOSIS ENGINE OVERHEATING ENGINE RUNS COLD ADJUSTMENT COOLANT REPAIR VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL THERMOSTAT WATER PUMP RADIATOR ]
26 - COOLING SYSTEM - V8i [ DESCRIPTION AND OPERATION ENGINE COOLING COOLANT CIRCULATION VISCOUS FAN FAULT DIAGNOSIS ENGINE OVERHEATING ENGINE RUNS COLD ADJUSTMENT COOLANT REQUIREMENTS COOLANT REPAIR EXPANSION TANK VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL THERMOSTAT WATER PUMP RADIATOR SPECIFICATIONS, TORQUE TORQUE VALUES ]
30 - MANIFOLD AND EXHAUST SYSTEM [ DESCRIPTION AND OPERATION CATALYTIC CONVERTERS - V8i REPAIR EXHAUST SYSTEM COMPLETE EXHAUST MANIFOLD - V8i MANIFOLD AND EXHAUST SYSTEM - Tdi EXHAUST MANIFOLD - Tdi SPECIFICATIONS, TORQUE TORQUE VALUES ]
33 - CLUTCH [ DESCRIPTION AND OPERATION DESCRIPTION OPERATION FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS CLUTCH SPIN - DRAG CLUTCH SLIP CLUTCH JUDDER - FIERCE FAULT/SYMPTOM CHART CLUTCH NOISE - MECHANICAL FAULTS HYDRAULIC FAULTS REPAIR CLUTCH ASSEMBLY BLEED HYDRAULIC SYSTEM MASTER CYLINDER RELEASE BEARING ASSEMBLY SLAVE CYLINDER RENEWING HYDRAULIC DAMPER - Tdi OVERHAUL MASTER CYLINDER SLAVE CYLINDER SPECIFICATIONS, TORQUE TORQUE VALUES ]
37 - MANUAL GEARBOX - R380 [ DESCRIPTION AND OPERATION MANUAL TRANSMISSION FAULT DIAGNOSIS MANUAL GEARBOX REPAIR R380 GEARBOX SPECIFICATIONS, TORQUE TORQUE VALUES ]
41 - TRANSFER GEARBOX - BORG WARNER [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS BORG WARNER - SYMPTOMS REPAIR REAR OUTPUT SHAFT OIL SEAL FRONT OUTPUT SHAFT OIL SEAL BORG WARNER TRANSFER GEARBOX OVERHAUL BORG WARNER GEARBOX ILLUSTRATED ASSEMBLIES BORG WARNER TRANSFER GEARBOX DISMANTLE, INSPECTION AND OVERHAUL SPECIFICATIONS, TORQUE TORQUE VALUES SERVICE TOOLS ADAPTER PLATE TRANSFER BOX ]
44 - AUTOMATIC GEARBOX - ZF [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS ZF AUTOMATIC GEARBOX ROAD TEST PROCEDURE AUTOMATIC GEARBOX ASSEMBLY ILLUSTRATED FAULT SYMPTOMS REPAIR ZF AUTO WITH BORG WARNER TRANSFER GEARBOX INHIBITOR SWITCH SELECTOR SHAFT OIL SEAL OIL SUMP GASKET KICKDOWN CABLE LEAK EXTENSION HOUSING OIL SCREEN CONTROL UNIT OIL INLET SEALING RINGS MANUAL VALVE OPERATING MECHANISM GOVERNOR HOUSING GOVERNOR HUB PARKING PAWL MECHANISM REPLACING TORQUE CONVERTER ELIMINATING LEAKS ON PUMP HOUSING ELIMINATING LEAKS BETWEEN GEARBOX HOUSING AND INTERMEDIATE PLATE REPLACING BELLHOUSING REPLACING PUMP REPLACING INTERMEDIATE PLATE SPECIFICATIONS, TORQUE TORQUE VALUES ZF GEARBOX DATA SERVICE TOOLS AUTOMATIC GEARBOX HOLDING FIXTURE AUTOMATIC GEARBOX AND BORG WARNER TRANSFER GEARBOX AUTOMATIC GEARBOX ]
47 - PROPELLER SHAFTS [ DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT FAULT DIAGNOSIS VIBRATION HARSHNESS REPAIR FRONT PROPELLER SHAFT SPIDER ASSEMBLY COMPONENTS REAR PROPELLER SHAFT FLEXIBLE COUPLING ]
51 - REAR AXLE AND FINAL DRIVE [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS REPAIR REAR AXLE REAR BRAKE DISC NON ABS REAR BRAKE DISCS ABS REAR HUB ASSEMBLY OVERHAUL AXLE DIFFERENTIAL ASSEMBLY CROWN WHEEL/PINION BACKLASH ADJUSTMENT REAR HUB ASSEMBLY REAR STUB AXLE SPECIFICATIONS, TORQUE AXLE DIFFERENTIAL DATA REAR HUB TORQUE VALUES SERVICE TOOLS AXLE DIFFERENTIAL REAR HUB ]
54 - FRONT AXLE AND FINAL DRIVE [ DESCRIPTION AND OPERATION DESCRIPTION FAULT DIAGNOSIS REPAIR FRONT AXLE ASSEMBLY FRONT BRAKE DISCS FRONT HUB ASSEMBLY OVERHAUL FRONT DIFFERENTIAL FRONT HUB FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING NON ABS FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING ABS SPECIFICATIONS, TORQUE TORQUE VALUES FRONT HUB AND SWIVEL DATA SERVICE TOOLS FRONT HUB ]
57 - STEERING [ DESCRIPTION AND OPERATION DESCRIPTION ]
FAULT DIAGNOSIS [ INSUFFICIENT POWER ASSISTANCE POWER STEERING SYSTEM - TEST STEERING DAMPER STEERING FAULTS STEERING STABILITY AND VEER UNDER BRAKING 1. GENERAL STEERING 2. STEERING VEER 3. VEER UNDER BRAKING 4. DIRECTIONAL STABILITY POWER STEERING FLUID LEAKS POWER STEERING SYSTEM - EXCESSIVE NOISE POWER STEERING SYSTEM - GRUNT VISUAL AND SAFETY CHECKS ROAD TEST PROCEDURE STIFF STEERING CHECKLIST VISUAL CHECK AND BASIC ADJUSTMENTS STEERING LINKAGE INSPECT ADJUSTMENT POWER STEERING BOX CENTRALISE STEERING BOX STEERING LOCK STOPS FRONT WHEEL ALIGNMENT POWER STEERING PUMP DRIVE BELT REPAIR POWER STEERING FLUID PIPES POWER STEERING BOX POWER STEERING SYSTEM - BLEED POWER STEERING FLUID RESERVOIR POWER STEERING PUMP DRIVE BELT POWER STEERING PUMP - V8i POWER STEERING PUMP - Tdi LOWER STEERING SHAFT AND UNIVERSAL JOINTS STEERING COLUMN SHROUD STEERING WHEEL UPPER STEERING COLUMN STEERING COLUMN LOCK ASSEMBLY DROP ARM STEERING DAMPER TRACK ROD AND LINKAGE DRAG LINK AND DRAG LINK ENDS OVERHAUL POWER STEERING BOX SPECIFICATIONS, TORQUE STEERING PUMP TORQUE VALUES SERVICE TOOLS POWER STEERING BOX ]
60 - FRONT SUSPENSION [ DESCRIPTION AND OPERATION INTRODUCTION AXLE LOCATION REPAIR SELF LOCKING NUTS PANHARD ROD RADIUS ARM FRONT SHOCK ABSORBER FRONT ROAD SPRING BUMP STOP ANTI-ROLL [SWAY] BAR FRONT ANTI-ROLL BAR BALL JOINT LINKS SPECIFICATIONS, TORQUE TORQUE VALUES ]
64 - REAR SUSPENSION [ DESCRIPTION AND OPERATION AXLE LOCATION SELF LEVELLING UNIT FAULT DIAGNOSIS SELF LEVELLING UNIT REPAIR REAR ROAD SPRING REAR SHOCK ABSORBER LEVELLING UNIT LEVELLING UNIT BALL JOINTS BUMP STOP SUSPENSION LINK UPPER SUSPENSION LINK LOWER ANTI-ROLL BAR REAR ANTI-ROLL BAR BALL JOINT LINKS SPECIFICATIONS, TORQUE TORQUE VALUES ]
68 - AIR SUSPENSION [ DESCRIPTION AND OPERATION ELECTRONIC AIR SUSPENSION - (EAS) LOCATION OF COMPONENTS DESCRIPTION OF COMPONENTS PNEUMATIC SYSTEM DIAGRAM AIR PIPE COLOUR CODES SYSTEM OPERATION - see RR3858M ECU INPUTS SYSTEM FUNCTION FAULT DIAGNOSIS DIAGNOSTICS AND FAULT RECOVERY AIR SUSPENSION CIRCUIT DIAGRAM ADJUSTMENT DEPRESSURISE SYSTEM SYSTEM CALIBRATION - HEIGHT SENSOR DATUM AIR RESERVOIR - DRAIN AIR SPRINGS/HEIGHT SENSORS - INSPECT AIR HARNESS INSPECT LEAK TEST PROCEDURE REPAIR SUSPENSION COMPONENTS OPERATING SWITCHES AND BULBS DISCONNECT/CONNECT AIR PIPE AIR PIPE CONNECTION COLLET AND âOâ RINGS FRONT DAMPER REAR DAMPER FRONT AIR SPRING REAR AIR SPRING ASSEMBLY BUMP STOP HEIGHT SENSOR PRESSURE RELIEF VALVE COMPRESSOR INLET FILTER AIR SUPPLY UNIT AIR DRIER AIR COMPRESSOR VALVE BLOCK RESERVOIR PRESSURE SWITCH AIR RESERVOIR ELECTRONIC CONTROL UNIT AIR HARNESS SERVICE TOOLS RECOMMENDED EQUIPMENT ]
70 - BRAKES - NON ABS [ DESCRIPTION AND OPERATION BRAKE SERVO UNIT BRAKE SYSTEM BRAKE PIPE LAYOUT - LHD BRAKE PIPE LAYOUT - RHD REPAIR BRAKE SYSTEM BLEED (NON ABS) MASTER CYLINDER MASTER CYLINDER ASSEMBLY SERVO ASSEMBLY FRONT BRAKE PADS REAR BRAKE PADS FRONT BRAKE CALIPER ASSEMBLY FRONT BRAKE CALIPERS REAR BRAKE CALIPERS PARKING BRAKE LEVER STOP LIGHT SWITCH - NON ABS REAR BRAKE CALIPER ASSEMBLY ]
70 - BRAKES - ABS [ DESCRIPTION AND OPERATION ANTI-LOCK BRAKE SYSTEM - ABS SYSTEM DESCRIPTION HYDRAULIC COMPONENTS LOCATION OF COMPONENTS BRAKE PIPE LAYOUT - LEFT HAND DRIVE BRAKE PIPE LAYOUT - RIGHT HAND DRIVE WARNING LIGHTS DRIVING VEHICLE BRAKE APPLICATION WITH PARTIAL FAILURE FAULT DIAGNOSIS ACCUMULATOR PRECHARGE ABS FAULT DIAGNOSIS FAULT DIAGNOSIS PROCEDURE ABS FAULT AND REMEDY CHART REPAIR GENERAL SERVICE INFORMATION FLUID LEVEL CHECK / TOP UP DEPRESSURISE SYSTEM BRAKE SYSTEM BLEED (ABS) HYDRAULIC BOOSTER UNIT RESERVOIR (INCLUDE SEALS) HYDRAULIC POWER UNIT ACCUMULATOR ELECTRONIC CONTROL UNIT - ECU SENSORS - FRONT SENSORS - REAR STOP LIGHT SWITCH EXCITER RINGS SERVICE TOOLS ABS BRAKES SERVICE TOOLS ]
70 - BRAKES - ETC [ DESCRIPTION AND OPERATION ELECTRONIC TRACTION CONTROL - ETC COMPONENTS ETC HYDRAULIC COMPONENTS ETC OPERATION FAULT DIAGNOSIS REPAIR ETC VALVE BLOCK ]
74 - WHEELS AND TYRES [ DESCRIPTION AND OPERATION TYPES OF WHEEL RIMS AND TYRES FAULT DIAGNOSIS TYRE WEAR CHART FAULT - SYMPTOMS REPAIR GENERAL INFORMATION TYRE INSPECTION WHEELS INSPECTION VALVES INSPECTION TYRE PRESSURES WHEEL BALANCING TYRE FITTING WHEELS WHEEL STUD ]
75 - SUPPLEMENTARY RESTRAINT SYSTEM [ DESCRIPTION AND OPERATION SYSTEM COMPONENTS OPERATION GENERAL PRECAUTIONS VEHICLE RECOVERY AIRBAG STORAGE FAULT DIAGNOSIS CRASH SENSOR INSPECTION AIRBAG HARNESS WARNING LABELS REPAIR SYSTEM PRECAUTIONS DRIVERâS AIRBAG MODULE STEERING WHEEL ROTARY COUPLER ROTARY COUPLER CENTRALISE COLUMN SWITCH ASSEMBLY PASSENGERâS AIRBAG MODULE CRASH SENSOR AIRBAG DIAGNOSTIC CONTROL UNIT SRS WARNING LIGHT BULBS AIRBAG HARNESS AIRBAG MANUAL DEPLOYMENT SPECIFICATIONS, TORQUE TORQUE VALUES ]
76 - CHASSIS AND BODY [ DESCRIPTION AND OPERATION BODY CONSTRUCTION PAINT CODES - 1995 REPAIR BODY REPAIRS, GENERAL INFORMATION PAINTWORK BODY WELDING PREPARATION INNER BODY SHELL ASSEMBLY HEADLINING ROOF PANEL BONNET DECKER PANEL FRONT WING ASSISTED BONNET LIFT FUEL FILLER FLAP REAR CORNER PANEL AND WING REAR QUARTER PANEL-INTERIOR REAR QUARTER PANEL-EXTERIOR TAILGATE UPPER TAILGATE UPPER LOCK TAILGATE UPPER GLASS TAILGATE LOWER STRIKER TAILGATE LOWER TAILGATE LOWER RELEASE MECHANISM RADIATOR GRILLE FRONT DOOR FRONT DOOR GLASS AND REGULATOR FRONT DOOR TRIM PANEL FRONT DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES FRONT DOOR HEATED LOCK ASSEMBLY ADJUSTMENT - FRONT DOOR LOCK AND HANDLE ASSEMBLY FRONT WHEEL ARCH LINER SILL FINISHER REAR DOOR REAR DOOR - TRIM PANEL REAR DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES REAR DOOR LOCK AND HANDLE ASSEMBLY REAR DOOR GLASS AND REGULATOR REAR QUARTER LIGHT GLASS FRONT SEAT ELECTRICAL FRONT SEAT MANUAL ASYMMETRIC SPLIT REAR SEAT ASYMMETRIC SPLIT REAR SEAT - LOCKING MECHANISM FRONT SEAT HEATED CUSHION AND SQUAB SEAT BELTS FRONT SEAT BELT REAR SEAT BELT CENTRE CONSOLE DRINKS TRAY DASH PANEL CENTRAL LOUVRE PANEL DASH PANEL ASSEMBLY FRONT SPOILER FRONT BUMPER METAL SUNROOF ASSEMBLY OPERATING MOTOR, MICRO-SWITCH AND RELAY SUNROOF PANEL SEALS SUNROOF ASSEMBLY SUNROOF HEADLINER ASSEMBLY GLASS SUNROOF GLASS PANEL ASSEMBLY WIND DEFLECTOR ASSEMBLY MANUAL OPERATION MOTOR DRIVE ASSEMBLY AND CONTROL UNIT GLASS SUNROOF COMPLETE ASSEMBLY SLIDE AND GUIDE CHANNEL ASSEMBLIES OR SUNSHADE PANEL TIMING OF CONTROL UNIT TO SUNROOF OPERATION CHASSIS AMERICA ONLY - 1990 ONWARDS CHASSIS NON AMERICAN - 1990 ONWARDS CHASSIS - AMERICAN COUNTY LWB (108) MODELS CHASSIS - LSE (108) AIR SUSPENSION MODELS WINDSCREEN GLASS ]
80 - HEATING AND VENTILATION [ DESCRIPTION AND OPERATION HEATING AND VENTILATION UNIT FAULT DIAGNOSIS HEATER OUTPUT REPAIR HEATER BLOWER SWITCH AND ILLUMINATION BULB HEATER CONTROL UNIT CONTROL CABLES RESISTOR UNIT WATER VALVE VACUUM SWITCH - WATER VALVE RECIRCULATION SWITCH RECIRCULATION FLAP SOLENOID BLOWER MOTOR UNIT - HEATER AND AIR CONDITIONING BLOWER MOTOR HEATER MATRIX SPECIFICATIONS, TORQUE TORQUE VALUES ]
82 - AIR CONDITIONING [ DESCRIPTION AND OPERATION AIR CONDITIONING SYSTEM COMPONENTS SCHEMATIC LAYOUT OF THE AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM OPERATION AIR CONDITIONING CONTROL SYSTEM FAULT DIAGNOSIS AIR CONDITIONING - ELECTRICAL - MECHANICAL FAULTS REFRIGERATION SYSTEM FAULTS HEATER AND AIR CONDITIONING - CIRCUIT DIAGRAMS ADJUSTMENT GENERAL PRECAUTIONS REMEDIAL ACTIONS SERVICING PRECAUTIONS REFRIGERANT RECOVERY RECYCLING RECHARGING LEAK TEST SYSTEM AIR CONDITIONING SYSTEM - PERFORMANCE TEST SYSTEM TEST COMPRESSOR DRIVE BELT REPAIR PRECAUTIONS IN HANDLING REFRIGERANT LINES PERIODIC MAINTENANCE RECEIVER DRIER AIR CONDITIONING SWITCH DUAL PRESSURE SWITCH COMPRESSOR CONDENSER CONDENSER FANS AND MOTORS HEATER AND COOLER UNIT EVAPORATOR AND EXPANSION VALVE THERMOSTAT SPECIFICATIONS, TORQUE TORQUE VALUES AIR CONDITIONING CHARGE DATA ]
84 - WIPERS AND WASHERS [ FAULT DIAGNOSIS WIPER MOTOR CHECKING REPAIR WASHER RESERVOIR POWER WASH PUMP WASHER PUMP - WINDSCREEN OR TAILGATE HEATED WINDSCREEN WASHER JETS HEATED WINDSCREEN WASHER JETS THERMOSTAT WINDSCREEN WASHER TUBES WIPER ARMS - WINDSCREEN WIPER ARM - TAILGATE WIPER BLADES - WINDSCREEN AND TAILGATE WINDSCREEN WIPER MOTOR, LINKAGE AND WHEEL BOXES TAILGATE GLASS WIPER MOTOR TAILGATE GLASS WASHER JET HEADLAMP POWER WASH JET POWER WASH HOSE ]
86 - ELECTRICAL [ DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT A.C. GENERATOR - A127/100 ANTI THEFT ALARM SYSTEM ANTI-THEFT SYSTEM FUNCTION ALARM COMPONENTS BUILT IN TEST PROCEDURE FAULT DIAGNOSIS LUCAS CONSTANT ENERGY IGNITION SYSTEM - V8i ADJUSTMENT IGNITION TIMING REPAIR BATTERY A.C. GENERATOR - V8i ENGINE A.C. GENERATOR DRIVE BELT DISTRIBUTOR-LUCAS 35 DLM8 ELECTRONIC IGNITION - V8i DISTRIBUTOR - V8i IGNITION COIL BULB REPLACEMENT HEADLAMP ASSEMBLY / SEALED BEAM UNIT HEADLAMP ASSEMBLY/BULB REPLACEMENT HEADLAMP ALIGNMENT AUXILIARY DRIVING LAMP SIDELIGHT AND FLASHER LAMP ASSEMBLY AND BULB DIRECTION INDICATOR/SIDE REPEATER LAMP BULB REPLACEMENT TAIL LAMP ASSEMBLY REFLECTORS/SIDE MARKER LAMP ASSEMBLY AND BULB UNDER BONNET LAMP ASSEMBLY HEATER/VENTILATION AND AIR CONDITIONING CONTROL PANEL BULB HEATER/VENTILATION AND AIR CONDITIONING CONTROL PANEL MSWITCHES AND BULBS DOOR EDGE LAMPS / PUDDLE LAMPS DOOR EDGE LAMPS/PUDDLE LAMPS BULB AUTOMATIC GEAR SELECTOR-PANEL BULB NUMBER/LICENSE PLATE LAMP ASSEMBLY AND BULB INTERIOR ROOF LAMP STARTER MOTOR - V8i ENGINE AUXILIARY SWITCHES AND BULBS AIR SUSPENSION SWITCHES AND BULBS HEADLAMP/FLASHER SWITCH AND WINDSCREEN WASH/WIPE SWITCH HAZARD WARNING SWITCH AND BULB IGNITION/STARTER SWITCH - BULB REPLACEMENT DOOR PILLAR SWITCH IGNITION/STARTER SWITCH REAR TAILGATE SWITCH UNDER BONNET/HOOD ILLUMINATION SWITCH CIGAR LIGHTER AND BULB REVERSE LIGHT SWITCH START INHIBIT / REVERSE LIGHT SWITCH OIL PRESSURE WARNING SWITCH - V8i PARK BRAKE WARNING SWITCH EXTERIOR DRIVING MIRRORS MOTOR CONTROL SWITCHES INSTRUMENT ILLUMINATION ELECTRONIC DIMMER / RHEOSTAT WINDOW LIFT/HEATED SEAT CUSHION SWITCHES AND BULBS WINDOW LIFT MOTOR - FRONT DOORS WINDOW LIFT MOTOR - REAR DOORS CENTRAL DOOR LOCKING HANDSET INITIALISATION FRONT DOOR ACTUATOR UNIT REAR DOOR ACTUATOR UNITS UPPER TAILGATE ACTUATOR UNIT FUEL FILLER FLAP ACTUATOR UNIT TRAILER SOCKET FRONT SEAT - MOTORS FRONT SEAT - SWITCHES MAP LIGHT BULB RENEWAL ELECTRICAL SEAT FAILURE DRIVE CABLE - ELECTRIC SEAT MEMORY SEAT - SWITCH MEMORY SEAT SWITCH - CLEAN ECU - MEMORY SEAT RADIO ANTENNA AMPLIFIER MEMORY SEAT - HARNESS LAYOUT A.C. GENERATOR HEAT SHIELD HIGH LEVEL STOP LAMP ALARM HORN GEAR SELECTOR-INTERLOCK SUBWOOFER BOX HEATED FRONT SCREEN RADIO COOLANT TEMPERATURE TRANSMITTER - V8i CLOCK AND BULB INSTRUMENT PANEL FINISHER INSTRUMENT BINNACLE INSTRUMENT ILLUMINATION AND WARNING LIGHT BULBS MAIN PRINTED CIRCUIT CIRCUIT BOARD INSTRUMENT BINNACLE COMPONENTS PRINTED CIRCUIT AND WARNING LIGHTS INSTRUMENT COWL AND ILLUMINATION BOARD SPEEDOMETER TACHOMETER COOLANT TEMPERATURE AND FUEL GAUGES SPEEDOMETER TRANSDUCER ALARM ECU OVERHAUL DISTRIBUTOR-LUCAS 35DLM8 DISTRIBUTOR CAP ROTOR ARM INSULATION COVER (FLASH SHIELD) VACUUM UNIT AMPLIFIER MODULE PICK-UP AND BASE PLATE ASSEMBLY LUBRICATION SPECIFICATIONS, TORQUE TORQUE VALUES ]