Discovery (2003) - Car LAND ROVER - Free user manual and instructions

Product Type	SUV (Sports Utility Vehicle)
Brand	Land Rover
Model	Discovery (2003)
Body Style	5-door wagon
Seating Capacity	5 or 7 (optional third row)
Engine Options	4.0L V8 petrol (185 hp) or 2.5L Td5 diesel (139 hp)
Fuel Type	Petrol or Diesel
Transmission	4-speed automatic or 5-speed manual
Drive Type	Permanent four-wheel drive with low-range
Length	4,705 mm (185.2 in)
Width (including mirrors)	2,190 mm (86.2 in)
Height	1,940 mm (76.4 in)
Wheelbase	2,545 mm (100.2 in)
Curb Weight	2,065 kg (4,553 lb)
Fuel Tank Capacity	93 L (24.6 US gal)
Cargo Volume (seats up)	1,290 L (45.6 cu ft)
Maximum Towing Capacity	3,500 kg (7,716 lb) braked
Safety Features	ABS, dual front airbags, traction control, stability control
Maintenance Interval	Oil change every 10,000 km or 12 months
Care and Cleaning	Use mild soap and water; avoid high-pressure washers on soft-top
Spare Parts and Repairability	Parts widely available; DIY friendly with basic tools

Frequently Asked Questions - Discovery (2003) LAND ROVER

How do I reset the service light on a 2003 Land Rover Discovery?

Turn the ignition off, press and hold the trip meter reset button, then turn the ignition to position II while holding the button. Wait for the service light to flash and go out.

What type of engine oil does the 2003 Discovery need?

For the 4.0L V8, use 5W-30 fully synthetic oil (API SL or higher). For the 2.5L Td5 diesel, use 10W-40 semi-synthetic (API CF or ACEA B3). Capacity is about 5.5 L with filter.

What is the towing capacity of the 2003 Discovery?

Maximum braked towing capacity is 3,500 kg (7,716 lb). Unbraked trailer capacity is 750 kg (1,654 lb). Always use a suitable tow hitch and check local regulations.

How do I engage low-range four-wheel drive on a Discovery?

Stop the vehicle, put the transmission in neutral (or park for automatic), then move the transfer case lever to the low-range position. You may need to press down on the lever.

What tire pressure is recommended for a 2003 Discovery?

For standard road use: front 2.4 bar (35 psi), rear 2.6 bar (38 psi) for normal loads. Adjust for heavy loads or off-road; refer to the driver's door placard.

How do I replace a headlight bulb on a 2003 Discovery?

Open the bonnet and locate the headlight assembly. Twist the bulb holder counterclockwise, remove the old bulb, and insert a new H7 bulb without touching the glass. Reinstall holder.

Why is my Discovery's air suspension not working?

Possible causes: blown fuse, faulty compressor, air leak in a bag or line, or height sensor issue. Check fuses first; if the compressor runs but no lift, look for leaks with soapy water.

How do I fold the rear seats on a 2003 Discovery?

For second row: lift the seat base forward, then pull the lever on top of the seatback to fold it flat. For third row (if equipped): pull the strap to release and fold seats into the footwell.

What is the recommended coolant for a 2003 Discovery?

Use OAT (Organic Acid Technology) coolant, typically a 50/50 mix with distilled water. Do not mix with traditional green coolant. Land Rover recommends specific OAT coolant; check manual.

How do I change the cabin air filter on a 2003 Discovery?

The cabin filter is located behind the glovebox. Remove the glovebox screws, lower the glovebox, and slide out the filter cover. Remove old filter and insert new one with airflow arrows pointing down.

USER MANUAL Discovery (2003) LAND ROVER

Workshop Manual

Discovery Series II

WORKSHOP MANUAL - 1999MY ON

Publication Part No. VDR 100330 NAS (6)

© Land Rover 2003

CONTENTS

INTRODUCTION 01-1

How To Use This Manual.... 01-1

Repairs and Replacements.... 01-2

Specifications 01-2

Abbreviations and Symbols 01-3

GENERAL INFORMATION 03-1

General Precautions 03-1

Safety Instructions 03-2

Environmental Precautions 03-3

General Fitting Instructions 03-6

Ball and Roller Bearings 03-7

Oil Seals 03-8

Joints and Joint Faces 03-9

Locking Devices 03-9

Screw Threads 03-10

Bolt and Nut Identification 03-11

Flexible Pipes and Hoses 03-13

Rolling Road Testing.... 03-15

Fuel Handling Precautions 03-16

Electrical Precautions 03-17

Supplementary Restraint System Precautions 03-18

SRS Component Replacement Policy 03-23

Air Conditioning System Precautions 03-24

Air Conditioning Compressor Replacement 03-26

Body Repairs 03-27

GENERAL DATA 04-1

Engine - Td5 04-1

Engine - V8 04-4

Fuel system - Td5 04-8

Fuel system - V8 04-8

Cooling system - Td5 04-9

Cooling system - V8 04-10

Clutch - Td5 04-11

Clutch - V8 04-12

Manual gearbox - R380 04-13

Transfer box - LT230SE 04-14

Automatic gearbox - ZF4HP22/24 04-15

Rear axle 04-16

Front axle 04-16

Steering 04-17

Suspension 04-18

Brakes 04-19

Wheels and tyres 04-20

Air conditioning 04-21

Electrical - Td5 04-22

Electrical - V8 04-22

Dimensions 04-23

Weights 04-24

CONTENTS

IDENTIFICATION NUMBERS 05-1

Vehicle Identification Number 05-1

Identification Number Locations 05-3

TORQUE WRENCH SETTINGS 06-1

Maintenance 06-1

Engine Td5 06-2

Engine V8 06-4

Emission control - Td5 06-5

Emission control - V8 06-5

Engine management system - Td5 06-6

Engine management system - V8 06-6

Cooling system 06-7

Manifolds and exhaust systems - Td5 06-8

Manifolds and exhaust systems - V8 06-8

Clutch 06-9

Manual gearbox - R380 06-10

Transfer box - LT230SE 06-11

Automatic gearbox-ZF4HP22 06-12

Propeller shafts 06-13

Axles 06-13

Steering 06-14

Front suspension 06-15

Rear suspension 06-16

Brakes 06-17

Restraint systems 06-18

Body 06-19

Heating and air conditioning 06-20

Wipers and washers 06-20

Electrical 06-21

LIFTING AND TOWING 08-1

LIFTING 08-1

TOWING 08-2

TRANSPORTING 08-4

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ....09-1

Capacities 09-1

Fluids 09-2

Anti-Freeze Concentration 09-2

Lubrication 09-3

Sealants.... 09-4

CONTENTS

MAINTENANCE 10-1

PROCEDURES

V8 engine underbonnet view 10-1

Diesel underbonnet view.... 10-2

Seats and seat belts 10-3

Lamps, horns and warning indicators 10-5

Wipers and washers 10-5

Handbrake 10-6

Alarm handset battery 10-6

Road wheels 10-6

Tyres 10-6

Brake pads, discs and calipers 10-6

Road wheel speed sensors.... 10-7

Brake fluid 10-7

Fuel filter - diesel engine 10-7

Fuel filter sedimenter 10-7

Road wheels 10-8

Radiator/Intercooler 10-8

Ambient air Temperature and pressure sensor 10-8

Doors, bonnet and fuel filler flap 10-8

Air suspension intake filter 10-9

Anti-freeze 10-9

Cooling system 10-9

Spark plugs - V8 engine 10-10

Air cleaner - V8 engine 10-10

Air cleaner and dump valve - diesel engine 10-10

Auxiliary drive belt 10-11

Auxiliary drive belt - V8 engine 10-11

Auxiliary drive belt - diesel engine 10-11

Fluid reservoirs 10-12

Steering box 10-13

Battery 10-13

Intercooler - diesel engine 10-14

Engine oil - V8 engine 10-14

Engine oil - diesel engine 10-15

Centrifuge rotor – diesel engine 10-15

Engine oil filter - diesel engine 10-16

Engine oil filter – V8 engine 10-16

Manual gearbox 10-17

Automatic gearbox 10-18

Transfer box 10-19

Front and rear axle.... 10-20

Propeller shafts 10-20

Anti-roll bar links 10-22

ACE actuators.... 10-23

ACE filter 10-23

CONTENTS

Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses.... 10-24

Engine, gearbox, transfer box and axles 10-25

Exhaust system 10-25

Steering box and front suspension 10-25

Steering rod ball joints 10-27

Dampers and SLS height sensors 10-27

Front and rear axle suspension links 10-28

Towing bracket 10-29

Engine mountings - V8 engine.... 10-30

Road/roller test 10-31

CONTENTS

ENGINE - V8 12-2-1

DESCRIPTION AND OPERATION

V8 Engine 12-2-1

Cylinder head components 12-2-2

Cylinder block components 12-2-4

Description 12-2-6

ADJUSTMENTS

Engine oil pressure check 12-2-11

REPAIRS

Seal - crankshaft - rear 12-2-13

Gasket - cylinder head - LH 12-2-14

Gasket - cylinder head - RH.... 12-2-16

Gasket - rocker cover - LH 12-2-19

Gasket - rocker cover - RH 12-2-20

Mounting - front - LH 12-2-22

Mounting-front-RH 12-2-23

Mounting - rear - LH 12-2-24

Mounting - rear - RH 12-2-25

Engine assembly.... 12-2-26

Flywheel 12-2-31

Plate - drive - automatic 12-2-32

Ring gear - starter 12-2-34

Filter - oil 12-2-35

Strainer - oil pick-up 12-2-35

Pump - oil 12-2-36

Gasket - sump 12-2-37

Switch - oil pressure 12-2-39

Cooler - engine oil 12-2-39

Gasket - timing gear cover 12-2-41

Seal - cover - timing gears 12-2-43

OVERHAUL

Gasket - inlet manifold 12-2-45

Gasket - exhaust manifold 12-2-48

Seal - crankshaft - rear - automatic models 12-2-49

Seal - crankshaft - rear - manual models 12-2-50

Bearing - spigot - crankshaft 12-2-52

Gasket - engine sump 12-2-53

Strainer - oil pick-up 12-2-54

Seal - timing gear cover 12-2-55

Gasket - timing gear cover 12-2-56

Timing chain and gears 12-2-58

Rocker shaft - overhaul 12-2-59

Gasket - cylinder head 12-2-61

Cylinder head - overhaul 12-2-63

Piston assemblies 12-2-67

Bearings - connecting rods 12-2-72

Crankshaft and main bearings 12-2-73

Camshaft 12-2-77

CONTENTS

EMISSION CONTROL - V8.... 17-2-1

DESCRIPTION AND OPERATION

Crankcase emission control system 17-2-1
Exhaust emission control 17-2-2
Evaporative emission system component layout 17-2-3
Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4
Evaporative emission system control diagram 17-2-5
Secondary air injection system component layout.... 17-2-6
Secondary air injection system control diagram 17-2-8
Emission Control Systems 17-2-9
Crankcase Emission Control System 17-2-10
Exhaust Emission Control System.... 17-2-11
Evaporative Emission Control System.... 17-2-15
Secondary Air Injection System.... 17-2-26
Crankcase Emission Control Operation.... 17-2-34
Exhaust Emission Control Operation 17-2-35
Evaporative Emission Control Operation.... 17-2-39
Secondary Air Injection System Operation 17-2-43
SAI System Fault Finding and Check Malfunctions 17-2-44

REPAIRS

Canister - EVAP 17-2-51
Canister - EVAP - Models with Fuel Leak Detection Pump - up to 03MY 17-2-52
Canister - EVAP - Models with Fuel Leak Detection Pump - from 03MY 17-2-53
Valve - purge control 17-2-54
Solenoid - evap canister vent solenoid (CVS) valve 17-2-55
Sensor - heated oxygen (HO2S) - pre-catalytic converter 17-2-56
Sensor - heated oxygen (HO2S) - post-catalytic converter 17-2-57
Control Valve - Secondary Air Injection (SAI) 17-2-58
Reservoir - Vacuum - Secondary Air Injection (SAI) - up to 03MY 17-2-58
Reservoir - vacuum - Secondary Air Injection (SAI) - from 03MY 17-2-59
Pump - Air - Secondary Air Injection (SAI) 17-2-59
Air Manifold - LH - Secondary Air Injection (SAI) 17-2-60
Air Manifold - RH - Secondary Air Injection (SAI) 17-2-61
Solenoid - Vacuum - Secondary Air Injection (SAI) 17-2-62
Pipe - Secondary Air Injection (SAI) 17-2-62
Pump - Fuel Leak Detection - up to 03MY 17-2-64
Pump - fuel leak detection - from 03MY 17-2-64
Filter - fuel leak detection pump - up to 03MY 17-2-65
Filter - fuel leak detection pump - from 03MY 17-2-65

CONTENTS

ENGINE MANAGEMENT SYSTEM - V8 18-2-1

DESCRIPTION AND OPERATION

Engine management component location - Passenger compartment 18-2-1

Engine management component location - Engine compartment 18-2-2

Engine management block diagram 18-2-4

Description - engine management 18-2-6

Operation - engine management 18-2-49

DESCRIPTION AND OPERATION

Cruise control component layout 18-2-61

Cruise control block diagram 18-2-62

Description - cruise control 18-2-63

Operation - cruise control.... 18-2-74

ADJUSTMENTS

Cable - throttle 18-2-77

Cable - cruise control 18-2-77

REPAIRS

Spark plugs 18-2-79

Coil - ignition 18-2-80

Engine control module (ECM) 18-2-81

Sensor - engine coolant temperature (ECT) 18-2-82

Sensor - crankshaft position (CKP) 18-2-83

Sensor - radiator temperature 18-2-84

Sensor - camshaft position (CMP) 18-2-84

Knock sensor (KS) 18-2-85

Air cleaner assembly 18-2-86

Element - air filter 18-2-87

Cable - throttle 18-2-88

Sensor - Mass Air Flow (MAF) 18-2-89

Throttle Body 18-2-90

Plenum chamber 18-2-91

Sensor - throttle position (TP) 18-2-91

Valve - idle air control (IACV) 18-2-92

Injectors 18-2-92

Actuator - cruise control 18-2-94

Vacuum control unit - up to 03MY 18-2-94

Vacuum control unit - from 03MY 18-2-95

Cable - cruise control 18-2-96

Switch - cruise control (on/off) 18-2-96

Switch - cruise control (set/resume).... 18-2-97

Switch - clutch pedal - cruise control 18-2-97

ECU - Cruise control 18-2-98

CONTENTS

FUEL DELIVERY SYSTEM - V8 19-2-1

DESCRIPTION AND OPERATION

Fuel delivery system.... 19-2-1

Fuel tank and breather components (all except NAS) 19-2-2

Fuel tank and breather components (NAS) 19-2-3

Description.... 19-2-4

Operation 19-2-10

ADJUSTMENTS

Fuel tank - drain.... 19-2-11

REPAIRS

Switch - inertia - fuel cut-off 19-2-13

Pump - fuel 19-2-13

Tank - fuel 19-2-15

Filler tube - fuel 19-2-16

Solenoid - fuel filler flap release.... 19-2-17

Switch - fuel filler flap release - up to 03MY 19-2-17

Switch - fuel filler flap release - from 03MY 19-2-18

COOLING SYSTEM - V8.... 26-2-1

DESCRIPTION AND OPERATION

Cooling system component layout.... 26-2-2

Cooling system coolant flow 26-2-4

Description.... 26-2-6

Operation 26-2-10

ADJUSTMENTS

Drain and refill.... 26-2-13

REPAIRS

Fan - viscous 26-2-15

Radiator 26-2-15

Thermostat.... 26-2-18

Gasket - coolant pump 26-2-19

MANIFOLDS AND EXHAUST SYSTEMS - V8.... 30-2-1

DESCRIPTION AND OPERATION

Exhaust manifold component layout.... 30-2-1

Inlet manifold component layout 30-2-2

Exhaust system component layout 30-2-4

Description.... 30-2-5

REPAIRS

Front pipe.... 30-2-7

Intermediate pipe/silencer 30-2-8

Tail pipe 30-2-9

Heat shield - brake servo - Without Secondary Air Injection 30-2-9

Heat shield - brake servo - With Secondary Air Injection 30-2-10

Gasket - inlet manifold - lower 30-2-10

Gasket - exhaust manifold 30-2-14

Gasket - inlet manifold - upper - Without Secondary Air Injection 30-2-15

Gasket - inlet manifold - upper - With Secondary Air Injection 30-2-18

CONTENTS

CLUTCH - V8 33-2-1

DESCRIPTION AND OPERATION

Clutch components 33-2-2

Hydraulic operation 33-2-4

Description 33-2-6

Operation 33-2-9

ADJUSTMENTS

Clutch hydraulic system - bleed 33-2-11

REPAIRS

Clutch assembly 33-2-13

Master cylinder 33-2-14

Bearing and lever - clutch release 33-2-15

Slave cylinder.... 33-2-15

CONTENTS

MANUAL GEARBOX - R380 37-1

DESCRIPTION AND OPERATION

R380 gearbox 37-1

Gearbox casings, gear change and oil pump 37-2

Selector shaft and forks, synchromesh assemblies and gear train 37-4

R380 gearbox cross section 37-6

Description.... 37-7

Operation 37-8

ADJUSTMENTS

Spring - gear lever bias 37-9

REPAIRS

Housing - gear selector 37-11

Gearbox - V8 37-12

Gearbox - Diesel 37-16

Seal - gearbox mainshaft 37-20

Seal - input shaft 37-21

Cooler - oil - gearbox - Diesel 37-23

Cooler - oil - gearbox - V8 37-24

Switch - Reverse light 37-25

OVERHAUL

Shaft - output 37-27

Synchroniser - gearbox - set 37-32

Fork - set - selector shaft 37-34

Shaft - gearbox - input 37-35

Extension - gearbox rear 37-38

Pump - gearbox oil 37-41

Filter - gearbox oil 37-41

Gear - 5th gear set 37-42

Synchronizer assembly - 5th/reverse 37-43

5th gear - layshaft 37-44

Bearing - layshaft rear support 37-46

Bearing - output shaft rear support 37-47

Shaft - reverse idler 37-48

Housing - gear selector mechanism 37-50

Lever - gear change 37-51

Housing - clutch 37-52

Cover-front 37-53

CONTENTS

TRANSFER BOX - LT230SE 41-1

DESCRIPTION AND OPERATION

LT230SE transfer box 41-1

Transfer box cross section 41-2

Main casing components – Vehicles up to 03 model year.... 41-4

Main casing components – Vehicles from 03 model year.... 41-5

Differential components – Vehicles up to 03 model year.... 41-6

Differential components – Vehicles from 03 model year.... 41-7

Front output housing components – Vehicles up to 03 model year 41-8

Front output housing components – Vehicles from 03 model year.... 41-10

Rear output housing components 41-12

Description 41-13

Operation 41-18

ADJUSTMENTS

Cable - selector - differential lock - adjust 41-21

Cable - high/low selector.... 41-21

REPAIRS

Bottom cover - transfer box 41-23

Cable - selector - differential lock 41-24

Transfer box - Diesel 41-25

Transfer box - V8 41-29

Gasket - rear cover plate 41-33

Switch - differential lock - Up to 03 MY 41-34

Cable - high/low selector.... 41-35

Oil seal - input shaft 41-36

Seal - front output shaft 41-36

Seal - rear output shaft 41-38

Gasket - rear output shaft housing 41-39

Solenoid - interlock - Up to 03 MY 41-40

Solenoid - interlock - from 03 MY 41-40

Sensor - neutral 41-41

Sensor - oil temperature - If fitted 41-41

Switch - high low - warning 41-42

Switch(es) - differential lock warning From 03 MY 41-42

OVERHAUL

Intermediate gear assembly 41-43

Differential assembly 41-46

Dog clutch - differential lock 41-64

Input gear/bearing 41-68

Low gear - differential 41-70

CONTENTS

AUTOMATIC GEARBOX - ZF4HP22 - 24 44-1

DESCRIPTION AND OPERATION

Automatic gearbox component layout 44-1

Control schematic 44-2

Description.... 44-4

Operation 44-17

ADJUSTMENTS

Cable - selector 44-21

Stall test 44-21

REPAIRS

Cable and lever assembly - selector 44-23

Selector indicator 44-24

Switch - starter inhibitor 44-25

Seal - selector shaft 44-26

Gearbox - convertor and transfer gearbox - Diesel 44-27

Gearbox - convertor and transfer gearbox - V8 44-32

Torque converter and oil seal 44-37

Housing - torque converter 44-38

Gasket - intermediate plate 44-39

Intermediate plate 44-41

Pump - fluid 44-43

Seal - rear extension housing 44-44

Gasket - rear extension housing. 44-45

Parking pawl assembly. 44-46

Gasket - oil sump 44-47

Filter - oil 44-48

Cooler - fluid - Td5 44-49

Cooler - fluid - V8 44-50

Valve body assembly 44-51

Seal - valve body 44-53

Pressure regulator 44-54

Lock-up solenoid valve (MV 3) 44-55

Solenoids - shift control valves

(MV 1 & 2) 44-56

Harness - solenoid valves 44-57

Electronic control unit - automatic transmission 44-58

PROPELLER SHAFTS 47-1

DESCRIPTION AND OPERATION

Propeller shaft component layout 47-1

Description.... 47-2

REPAIRS

Propeller shaft - front 47-5

Propeller shaft - rear 47-5

Bush - spigot - rear propeller shaft 47-6

Flexible coupling 47-7

OVERHAUL

Propeller shaft.... 47-9

CONTENTS

REAR AXLE 51-1

DESCRIPTION AND OPERATION

Rear axle component layout 51-1

Description 51-2

REPAIRS

Differential - assembly 51-5

Seal-differentialpinion 51-7

OVERHAUL

Differential assembly 51-9

FRONT AXLE 54-1

DESCRIPTION AND OPERATION

Front axle component layout.... 54-1

Description 54-2

REPAIRS

Differential - assembly 54-5

Seal-differentialpinion 54-7

Seal - oil - front axle casing 54-9

Constant velocity joint - drive shaft 54-11

CONTENTS

STEERING 57-1

DESCRIPTION AND OPERATION

Steering system component layout.... 57-1

Steering column assembly and intermediate shaft 57-2

Steering box.... 57-4

Description.... 57-5

Operation.... 57-16

ADJUSTMENTS

Steering box - check and adjust 57-17

Hydraulic system - bleed 57-18

Steering linkage - centralise 57-18

Wheel alignment - front 57-19

Power steering pressure check - diesel models 57-20

Power steering pressure check - V8 LHD models 57-22

Power steering pressure check - V8 RHD models 57-24

REPAIRS

Power steering box - V8 57-27

Power steering box - LHD - diesel 57-30

Steering box - RHD - diesel 57-34

Seal - input shaft - steering box 57-37

Seal - output shaft - steering box 57-38

Pump - power steering - V8 57-39

Pump - power steering - diesel 57-42

Steering column assembly and lock 57-43

Shaft - intermediate and universal joint - steering column 57-45

Nacelle - steering column 57-47

Drop arm - steering box 57-47

Ball joint - track rod 57-48

Ball joint - drag link 57-49

Drag link 57-50

Damper - steering 57-51

Steering wheel 57-52

CONTENTS

FRONT SUSPENSION.... 60-1

DESCRIPTION AND OPERATION

Front suspension component layout (ACE torsion bar shown).... 60-1

Front suspension components (ACE torsion bar shown).... 60-2

Description 60-4

DESCRIPTION AND OPERATION

ACE system component layout.... 60-7

ACE system control diagram 60-8

Description - ACE 60-9

Operation 60-22

ADJUSTMENTS

ACE hydraulic system bleeding 60-25

Fluid level check - ACE system 60-25

REPAIRS

Bushes - Panhard rod 60-27

Ball joint - upper - steering knuckle 60-28

Ball joint - lower - steering knuckle 60-29

Steering knuckle 60-30

Road spring - front 60-32

Wheel hub 60-33

Damper-front 60-35

Bushes - radius arm 60-37

ECU - ACE 60-39

Accelerometer - ACE - upper 60-40

Accelerometer - ACE - lower 60-40

Pump - ACE - V8 60-41

Pump - ACE - diesel 60-42

Valve block - ACE 60-44

Filter - high pressure - ACE 60-47

Pressure transducer - ACE 60-48

Solenoid - pressure control valve - ACE 60-49

Solenoid - directional control valve - ACE 60-49

Pipe assembly - valve block to front actuator - ACE 60-50

Pipe assembly - pump or reservoir to valve block - ACE - V8 60-52

Pipe assembly - pump or reservoir to valve block - ACE - diesel 60-55

Pipe assembly - valve block to rear actuator - ACE 60-59

Actuator - front - ACE 60-61

Bushes-front long arm-ACE 60-63

CONTENTS

REAR SUSPENSION.... 64-1

DESCRIPTION AND OPERATION

Rear suspension component layout (vehicles with SLS) 64-2

Rear suspension component layout (vehicles without SLS).... 64-3

Rear suspension components 64-4

Description.... 64-6

DESCRIPTION AND OPERATION

SLS component layout.... 64-9

SLS system control diagram.... 64-10

Description - SLS 64-12

Operation 64-21

ADJUSTMENTS

SLS calibration blocks 64-25

REPAIRS

Wheel hub 64-27

Road spring - rear 64-29

Air spring - SLS 64-30

Damper - rear 64-31

Bushes - radius arm 64-31

Bushes - Watts linkage 64-34

Sensor - height - SLS 64-35

Compressor unit - air - SLS 64-35

Filter - intake - SLS 64-37

Switch - ride height 64-37

Air valve - SLS 64-38

Actuator - rear - ACE 64-39

Bushes - rear long arm - ACE.... 64-41

CONTENTS

BRAKES 70-1

DESCRIPTION AND OPERATION

Brake system control component layout 70-1

Brake system control diagram 70-2

Brake system hydraulic component layout 70-4

Description 70-5

Operation 70-20

DESCRIPTION AND OPERATION

Handbrake component layout 70-25

Description 70-26

ADJUSTMENTS

Handbrake 70-29

Brake system bleeding 70-30

REPAIRS

Brake disc - front 70-33

Brake disc - rear 70-34

Master cylinder - brake 70-35

Cable - handbrake 70-36

Switch - brake light 70-37

Brake pads - front 70-38

Brake pads - rear 70-39

Brake shoes - handbrake 70-40

Servo - brake 70-42

Vacuum pump - servo 70-43

Housing - caliper - front 70-45

Housing - caliper - rear 70-46

ECU - Self levelling and anti locking brakes (SLABS) 70-47

Sensor - ABS - front 70-48

Sensor - ABS - rear 70-48

Modulator unit - ABS 70-49

Switch - Hill descent control 70-50

Switch - handbrake 70-50

CONTENTS

RESTRAINT SYSTEMS.... 75-1

DESCRIPTION AND OPERATION

SRS component layout 75-1

SRS block diagram 75-2

Description - SRS 75-3

Operation - SRS 75-9

DESCRIPTION AND OPERATION

Description - seat belts 75-11

REPAIRS

Seat belt - front 75-13

Seat belt - rear - centre 75-13

Seat belt - rear - side 75-15

Mounting - seat belt - 'B' post 75-16

Seat belts - third row 75-17

Pre-tensioner-frontseat belt 75-18

Pre-tensioner - seat belt - front - deployment - in vehicle 75-19

Pre-tensioner - seat belt - front - deployment - off vehicle 75-20

Airbag module - drivers 75-22

Airbag module - passenger 75-23

DCU 75-24

Air bag - steering wheel - deployment - off vehicle 75-25

Air bag - fascia - passenger - deployment - in vehicle 75-26

Air bag - fascia - passenger - deployment - off vehicle 75-27

Rotary coupler 75-29

DOORS....76-1-1

REPAIRS

Door - front 76-1-1

Door - rear 76-1-2

Door - tail 76-1-3

Glass - front or rear door 76-1-5

Quarter light 76-1-6

Regulator and motor - front and rear door glass 76-1-7

Trim casing-front door 76-1-8

Trim casing - rear door 76-1-9

Trim casing - tail door 76-1-10

Latch and motor - front door 76-1-11

Latch and motor - rear door 76-1-12

Latch and motor - tail door 76-1-13

Handle - exterior - rear door 76-1-13

Handle - exterior - tail door 76-1-14

Handle - exterior - front door 76-1-14

CONTENTS

EXTERIOR FITTINGS.... 76-2-1

REPAIRS

Wing - front - up to 03MY 76-2-1

Wing - front - from 03MY 76-2-2

Rear folding step 76-2-4

Liner - wheel arch - front 76-2-5

Liner - wheel arch - rear 76-2-6

Panel - underbelly 76-2-7

Mirror - exterior - electric 76-2-7

Roof bars 76-2-8

Bonnet 76-2-9

Cable - bonnet release - up to 03MY 76-2-9

Cable - bonnet release - from 03MY 76-2-11

Bumper assembly - front 76-2-12

Bumper assembly - rear - from 03MY 76-2-13

Trim finisher - bumper - front - from 03MY 76-2-14

Bumper assembly - rear - up to 03MY 76-2-15

Side finisher - windscreen 76-2-16

Grille - front - up to 03MY 76-2-16

Grille - front - from 03MY 76-2-17

INTERIOR TRIM COMPONENTS.... 76-3-1

REPAIRS

Trim casing - tail door speaker 76-3-1

Trim casing - side - loadspace 76-3-2

Trim casing - upper - 'B' post 76-3-3

Trim casing - lower - 'B' post 76-3-3

Trim casing - 'D' post 76-3-4

Console-centre-automatic models 76-3-5

Console-centre-manual models 76-3-7

Fascia 76-3-10

Panel - auxiliary switch 76-3-14

Panel - fascia access - driver's side 76-3-15

Drink tray assembly - centre fascia 76-3-15

Louvre panel assembly - centre fascia 76-3-16

Carpet - front 76-3-18

Carpet - rear 76-3-19

Carpet - loadspace 76-3-20

Headlining 76-3-20

Stowage pocket - front 76-3-24

CONTENTS

SCREENS 76-4-1

REPAIRS

Glass/sealing rubber - tail door 76-4-1

Windscreen 76-4-2

Glass - body side - rear 76-4-4

Glass - alpine light 76-4-6

SEATS....76-5-1

DESCRIPTION AND OPERATION

Electric seat component location 76-5-1

Electric seat block diagram.... 76-5-2

Description - electric seats.... 76-5-4

Operation - electric seats.... 76-5-8

DESCRIPTION AND OPERATION

Heated seat component location 76-5-9

Heated seat block diagram (electric seats).... 76-5-10

Description - heated seats.... 76-5-11

Operation - heated seats 76-5-13

REPAIRS

Seat - front 76-5-15

Seat - third row 76-5-16

Seat - rear 76-5-18

Bolster assembly - rear armrest 76-5-19

Cover - cushion - front seat 76-5-20

Heating element - cushion - front seat 76-5-21

Cover - cushion - rear seat 76-5-22

Bladder - lumbar support 76-5-23

Motor - fore and aft - front seat 76-5-23

Motor - rise and fall - front seat 76-5-24

Motor - tilt - front seat 76-5-24

Motor - recline 76-5-25

Switch - electric seats 76-5-25

Cable - rear squab latch 76-5-26

Latch - rear seat 76-5-26

Cover - squab - front seat 76-5-28

Cover - squab - RH rear seat 76-5-31

Heating element - squab - front seat 76-5-33

Head restraint - third row seat 76-5-33

CONTENTS

SUNROOF 76-6-1

DESCRIPTION AND OPERATION

Electric sunroof component location 76-6-1

Sunroof components.... 76-6-2

System block diagram.... 76-6-4

Description 76-6-5

Operation 76-6-13

REPAIRS

Sunroof-front 76-6-15

Sunroof - rear 76-6-16

Glass panel - sunroof 76-6-17

Motor - sunroof 76-6-18

Drive cable assembly 76-6-19

Switch pack - sunroof 76-6-20

ECU - sunroof 76-6-20

CHASSIS AND BODY DIMENSIONS.... 77-1-1

CHASSIS DIMENSIONS

Chassis body mounting points - front end.... 77-1-1

Chassis body mounting points - rear end 77-1-2

Chassis dimensions - front end 77-1-3

Chassis dimensions - rear end 77-1-4

BODY DIMENSIONS

Body Dimensions 77-1-5

Gaps and profiles 77-1-13

CONTENTS

PANEL REPAIRS.... 77-2-1

REPLACEMENT PANELS

Replacement panels 77-2-1

Front end inner panels.... 77-2-2

Valance panels 77-2-3

Body side panels 77-2-4

Body side assembly 77-2-5

'D'-post assembly.... 77-2-6

Rear floor assembly.... 77-2-7

Rear end panels 77-2-8

Front and rear doors 77-2-9

Taildoor 77-2-10

Roof panels.... 77-2-11

Replacement panels 77-2-12

PROCEDURES

General welding precautions 77-2-13

Electronic control units.... 77-2-14

PROCEDURES

Panel replacement procedure.... 77-2-15

REPAIRS

Front bulkhead assembly.... 77-2-21

Bonnet locking platform 77-2-23

Front cross member 77-2-24

Headlamp mounting panel - RH 77-2-25

Headlamp mounting panel - LH 77-2-26

Valance upper assembly - LH 77-2-28

Valance upper assembly - RH 77-2-29

Valance upper assembly (front section) - LH 77-2-30

Valance upper assembly (front section) - RH 77-2-32

Front valance assembly - RH 77-2-33

Front valance assembly - LH 77-2-34

'A' post assembly 77-2-35

Dash side assembly.... 77-2-37

Sill outer assembly.... 77-2-38

Sill inner assembly 77-2-39

'B/C' post assembly 77-2-40

Panel body side assembly 77-2-41

Body side inner rear assembly 77-2-43

'D' post outer assembly.... 77-2-44

Wheelarch rear outer assembly 77-2-45

'E' post assembly 77-2-46

'E' post closing assembly.... 77-2-47

Cross member outer rear panel 77-2-47

Cross member outer rear panel (centre section) 77-2-48

Cross member outer rear panel (RH/LH section) 77-2-49

Cross member closing rear panel 77-2-49

Cross member rear assembly 77-2-50

Cross member rear assembly (RH/LH section) 77-2-50

Rear floor complete assembly 77-2-51

Rear floor (rear section).... 77-2-52

Rear floor (RH/LH section) 77-2-53

Roof assembly 77-2-53

TIMES

TIME SCHEDULES 77-2-55

CONTENTS

BODY SEALING MATERIALS 77-3-1

MATERIALS AND APPLICATIONS

Materials applications 77-3-1

Approved materials 77-3-2

Application equipment.... 77-3-4

CORROSION PREVENTION AND SEALING 77-4-1

CORROSION PREVENTION

Cavity wax treatment areas and injection holes - 'A' post and sill 77-4-1

Cavity wax treatment area and injection hole - fuel filler neck 77-4-2

Cavity wax treatment areas and injection holes - rear cross member 77-4-3

Cavity wax treatment areas and injection holes - front door, rear door and tail door.... 77-4-4

Corrosion prevention.... 77-4-6

SEALING

Body Sealing 77-4-9

Water leaks 77-4-22

PAINTING 77-5-1

PROCEDURES

Panel preparation.... 77-5-1

Paint preparation.... 77-5-2

HEATING AND VENTILATION.... 80-1

DESCRIPTION AND OPERATION

Heating and ventilation component layout 80-1

Fuel burning heater component layout 80-2

Description 80-3

Operation 80-13

REPAIRS

Heater control and fan switch 80-15

Cables - heater control 80-15

Servo - recirculation flap 80-17

Switch - recirculation control 80-18

Servo - air distribution control 80-19

Servo - air temperature control 80-20

Plenum Air Intake 80-21

Heater assembly - models without air conditioning.... 80-22

Heater assembly - models with air conditioning.... 80-24

Blower assembly 80-26

Motor - blower 80-27

Resistor pack - power resistor A/C 80-28

Heater matrix 80-29

Pipe - Heater - Feed 80-29

Pipe - Heater - Return 80-30

Fuel burning heater - (FBH) - Td5 80-31

CONTENTS

AIR CONDITIONING 82-1

DESCRIPTION AND OPERATION

A/C refrigerant system component layout.... 82-1

A/C control system component layout 82-2

Description.... 82-3

Operation 82-16

DESCRIPTION AND OPERATION

Rear A/C refrigerant system component layout.... 82-21

Rear A/C distribution and control component layout 82-22

Description.... 82-23

Operation 82-26

REFRIGERANT RECOVERY, RECYCLING AND RECHARGING

Refrigerant recovery, recycling and recharging.... 82-27

REPAIRS

Compressor - diesel.... 82-29

Compressor - V8.... 82-30

Fan - condenser 82-31

Condenser 82-31

Receiver drier and dual pressure switch.... 82-33

ECU - air temperature control.... 82-35

Sensor - ambient air temperature 82-35

Sensor - solar light 82-36

Sensor - air temperature 82-37

Evaporator, evaporator thermistor and thermal expansion valve (TXV) 82-38

Expansion valve - (TXV) - rear 82-41

Evaporator - rear.... 82-42

Evaporator and motor assembly - rear 82-43

Blower motor assembly - rear 82-44

Resistor - blower motor 82-45

Duct - centre - rear 82-45

CONTENTS

WIPERS AND WASHERS 84-1

DESCRIPTION AND OPERATION

Wipers and washers component layout 84-1

Front wiper components 84-2

Rear wiper components 84-3

Washer components 84-4

Wipers and washers block diagram 84-6

Description 84-8

Operation 84-17

REPAIRS

Reservoir - washer - up to 03MY 84-21

Reservoir - washer - from 03MY 84-22

Jet - washer - windscreen 84-23

Pump - washer - screen and headlamp 84-24

Motor and linkage - wiper - windscreen 84-25

Switch - wiper and washer - windscreen 84-26

Jet - washer - headlamp 84-27

Jet - washer - rear screen 84-27

Switch - rear wash 84-28

Motor - wiper - rear screen 84-29

Switch - wiper - rear - up to 03MY 84-30

Switch - wiper - rear - from 03MY 84-30

CHARGING AND STARTING.... 86-1-1

REPAIRS

Alternator - diesel 86-1-1

Alternator - V8 86-1-3

Belt - auxiliary drive.... 86-1-4

Battery 86-1-4

Battery carrier 86-1-5

Starter motor - diesel 86-1-6

Starter motor - V8 86-1-7

CONTENTS

LIGHTING.... 86-2-1

ADJUSTMENTS

Headlamps beam alignment - up to 03MY 86-2-1

Headlamps beam alignment - from 03MY 86-2-2

REPAIRS

Lamp - front repeater - up to 03MY 86-2-3

Headlamp - up to 03MY 86-2-4

Headlamp - from 03MY 86-2-5

Lamp - tail 86-2-6

Lamp - front fog up to 03MY 86-2-6

Lamp - front fog from 03MY 86-2-7

Housing - number plate lamp 86-2-8

Motor - headlamp levelling 86-2-9

Lamp - stop - centre high mounted (CHMSL) 86-2-10

Lamp - tail/flasher - bumper 86-2-10

Lamp - interior - front 86-2-11

Lamp - interior - rear 86-2-11

Rheostat - panel lights dimmer 86-2-12

Switch - hazard warning 86-2-13

Switch - indicator and exterior lighting - combined 86-2-13

Socket - accessory 86-2-14

Switch - front/rear fog lamps 86-2-14

BODY CONTROL UNIT 86-3-1

DESCRIPTION AND OPERATION

Description.... 86-3-1

Operation 86-3-19

REPAIRS

Body control unit (BCU) 86-3-35

ALARM SYSTEM AND HORN.... 86-4-1

DESCRIPTION AND OPERATION

Alarm system component layout.... 86-4-2

Alarm system block diagram.... 86-4-4

Description.... 86-4-5

Operation 86-4-17

REPAIR

Switch - central door locking 86-4-25

Switches - horn 86-4-25

Vehicle horn 86-4-26

Sounder - alarm 86-4-26

Sounder - battery backed-up (BBUS) 86-4-27

Switch - bonnet 86-4-27

Receiver - alarm system - models with sunroof 86-4-28

Receiver - alarm system - models without sunroof 86-4-28

Coil - passive immobilisation 86-4-29

CONTENTS

WINDOWS 86-5-1

DESCRIPTION AND OPERATION

Electric windows block diagram 86-5-1

Electric windows component layout 86-5-2

Description 86-5-4

Operation 86-5-11

REPAIRS

Switch - rear door 86-5-13

Switch - console 86-5-13

Switch - heated rear screen 86-5-14

IN CAR ENTERTAINMENT 86-6-1

DESCRIPTION AND OPERATION

ICE System Component layout 86-6-1

Base and mid line ICE system control diagram 86-6-2

High line ICE system control diagram 86-6-3

Description 86-6-4

DESCRIPTION AND OPERATION

DVD Player Component Layout 86-6-12

DVD Player Control Diagram 86-6-14

Description 86-6-16

Operation 86-6-27

REPAIRS

Radio 86-6-31

Speaker - low/full range - front door 86-6-32

Speaker - low range - rear door 86-6-32

Switches - remote control - ICE 86-6-33

Amplifier - aerial 86-6-33

Speaker - mid range - front door 86-6-34

Speaker - high range - rear door 86-6-34

Amplifier - power 86-6-35

Speaker - tail door 86-6-36

CD autochanger 86-6-36

DVD screen/player unit 86-6-37

Switch box - CD/DVD player 86-6-38

HARNESSES 86-7-1

REPAIRS

Harness - injectors - diesel 86-7-1

Harness - body 86-7-1

Harness - engine - V8 86-7-8

Harness - engine - diesel 86-7-12

Harness - main 86-7-15

Harness - main - DVD unit 86-7-28

Harness - link - CD/DVD switch box 86-7-32

CONTENTS

DRIVING AIDS 86-8-1

DESCRIPTION AND OPERATION

Park Distance Control – Component Location.... 86-8-1

Park Distance Control – Control Diagram.... 86-8-2

Description.... 86-8-4

Operation 86-8-11

REPAIRS

Control unit (ECU) - park distance control (PDC) 86-8-13

Sounder - parking aid rear 86-8-14

Sensor - parking aid - rear - inner 86-8-15

Sensor - parking aid - rear - outer 86-8-16

NAVIGATION SYSTEM 87-1

DESCRIPTION AND OPERATION

Harman/Becker Navigation System Component Location.... 87-1

Description.... 87-2

DESCRIPTION AND OPERATION

CARiN III Navigation and Trafficmaster System Component Location.... 87-12

Description.... 87-14

Operation 87-20

REPAIRS

Interface electronic control unit (ECU) - remote control 87-29

Display unit 87-30

INSTRUMENTS.... 88-1

DESCRIPTION AND OPERATION

Instrument pack 88-1

Instrument component location - Engine compartment / underneath vehicle.... 88-2

Instrument component location - Passenger compartment 88-3

Instrument block diagram 88-4

Interior rear view mirror with compass (where fitted) 88-42

REPAIRS

Clock 88-45

Instrument pack 88-45

How To Use This Manual

Introduction

This Manual is designed to assist skilled technicians in the efficient repair and maintenance of Discovery vehicles.

Individuals who undertake their own repairs should have some skill and training, and limit repairs to components which could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as steering, brakes, suspension or supplementary restraint system should be carried out by a Land Rover Dealer. Repairs to such items should NEVER be attempted by untrained individuals.

General

To assist in the use of this Manual, it is divided into sections and sub-sections. The section title is given at the top of each page and the relevant sub-section is given at the bottom.

There is a single contents section at the front of the Manual, which is divided by section and sub-section. Each section is numbered from page 1.

The individual items comprising repair operations are to be followed in the sequence in which they appear. Items numbers in the illustration are referred to in the text.

Adjustment and Repair operations include reference to Service tool numbers and the associated illustration depicts the tool in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, and specialist information and useful assembly details. Each adjustment or repair operation is given its Service Repair Operation number.

WARNINGS, CAUTIONS and NOTES have the following meanings:

WARNING: Procedures which must be followed precisely to avoid the possibility of injury.

CAUTION: Calls attention to procedures which must be followed to avoid damage to components.

NOTE: Gives helpful information.

References

References to the LH or RH side given in this Manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the crankshaft pulley end of the engine is referred to as the front.

Operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned.

Dimensions

The dimensions quoted are to design engineering specification with Service limits where applicable.

Repairs and Replacements

When replacement parts are required it is essential that only Land Rover recommended parts are used.

Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories.

Safety features and corrosion prevention treatments embodied in the vehicle may be impaired if other than Land Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification. Torque wrench setting figures given in this Manual must be used. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed.

Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the car conform to legal requirements.

The Terms of the vehicle Warranty may be invalidated by the fitting of parts other than Land Rover recommended parts.

All Land Rover recommended parts have the full backing of the vehicle Warranty.

Land Rover Dealers are obliged to supply only Land Rover recommended parts.

Specifications

Land Rover are constantly seeking to improve the specification, design and production of their vehicles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular vehicle.

This Manual does not constitute an offer for sale of any particular vehicle. Land Rover Dealers are not agents of Land Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.

Abbreviations and Symbols

A Amperes

AAP Ambient Air Pressure

ABDC After Bottom Dead Centre

ABS Anti-Lock Brake System

ac Alternating current

A/C Air Conditioning

ACE Active Cornering Enhancement

ACEA Association of Constructors of

European Automobiles

AFR Air Fuel Ratio

AP Ambient Pressure

ASC Anti-shunt Control

ATC Air Temperature Control

ATDC After Top Dead Centre

BBDC Before Bottom Dead Centre

BBUS Battery Backed Up Sounder

BCU Body Control Unit

BDC Bottom Dead Centre

bhp Brake Horse Power

BP Boost Pressure

BPP Brake Pedal Position

BS British Standard

BTDC Before Top Dead Centre

C Celsius

CAN Controller Area Network

CD Compact Disc

CDC Centre Differential Control

CDL Central Door Locking

CD - ROM Compact Disc - Read Only

Memory

CFC Chlorofluorocarbon

CHMSL Centre High Mounted Stop Lamp

CKP Crankshaft Position

CLV Calculated Load Value

cm Centimetre

cm² Square centimetre

cm ³ Cubic centimetre

CMP Camshaft Position

CPP Clutch Pedal Position

CO Carbon Monoxide

CO₂ Carbon Dioxide

CR Common Rail

CVS Canister Vent Solenoid

deg. Degree, angle or temperature

dia. Diameter

DIN Deutsche Industrie Normen

(German Industrial Standards)

dc Direct current

DCV Directional Control Valve

DOHC Double Overhead Camshaft

DTI Dial Test Indicator

DFM Dual Mass Flywheel

DVD Digital Versatile Disc

EACV Electronic Air Control Valve

EAT Electronic Automatic

Transmission

EBD Electronic Brake pressure

Distribution

ECD European Community Directive

ECM Engine Control Module

ECT Engine Coolant Temperature

ECU Electronic Control Unit

EDC Electronic Diesel Control

EEPROM Electronic Erasable

Programmable Read Only

Memory

EGR Exhaust Gas Recirculation

EKA Emergency Key Access

EN European Norm

EOBD European On Board Diagnostics

ETC Electronic Traction Control

EUI Electronic Unit Injector

EVAP Evaporative Emission

EVR Electronic Vacuum Regulator

F Fahrenheit

FBH Fuel Burning Heater

FIP Fuel Injection Pump

FTC Fast Throttle Control

g Gramme or Gravity

h Hour

hc High compression

HC Hydro Carbons

HDC Hill Descent Control

HDPE High Density Polyethylene

HFS Heated Front Screen

Hg Mercury

HO2S Heated Oxygen Sensor

HMW High Molecular Weight

HRW Heated Rear Window

ht/HT High tension

IACV Idle Air Control Valve

IAT Intake Air Temperature

ICE In-Car Entertainment

i.dia. Internal diameter

IDM Intelligent Driver Module

in ³ Cubic inch

ILT Inlet Throttle

ISO International Organisation for

Standardisation

k Thousand

kg Kilogramme

km Kilometre

km/h Kilometres per hour

kPa KiloPascal

KS Knock Sensor

I Litre

lbf.in Pounds force inches

lbf/in ² Pounds per square inch

lbf.ft Pounds force feet

λ Lambda

Ic Low compression

LCD Liquid Crystal Display

LED Light Emitting Diode

LH Left-Hand

LHD Left-Hand Drive

LVS Liquid Vapour Separator

m M e

μMicro

MAF Mass Air Flow

MAP Manifold Absolute Pressure

MFU Multi-Function Unit

MFL Multi-Function Logic

max. Maximum

MEMS Modular Engine Management

System

MIL Malfunction Indicator Lamp

min. Minimum

MPa MegaPascal

- Minus (tolerance)

Minute (angle)

mm Millimetre

mph Miles per hour

MPi Multi-Point injection

MY Model Year

NAS North American Specification

(-) Negative (electrical)

Nm Newton metre

No. Number

NO₂ Nitrogen Dioxide

NO_x Oxides of Nitrogen

NTC Negative Temperature

Coefficient

OBD On Board Diagnostics

o.dia. Outside diameter

ORM Off-road Mode

Ω Ohm

PAS Power Assisted Steering

PCV Positive Crankcase Ventilation

PDC Parking Distance Control

% Percentage

+ Plus (tolerance) or Positive

(electrical)

±Plus or minus (tolerance)

PTC Positive Temperature Coefficient

PTFE Polytetrafluorethylene

PWM Pulse Width Modulation

r Radius

: Ratio

ref Reference

RES Rover Engineering Standards

rev/min Revolutions per minute

RF Radio Frequency

RH Right-Hand

RHD Right-Hand Drive

ROM Read Only Memory

RON Research Octane Number

ROV Roll Over Valve

ROW Rest Of World

SAE Society of Automotive Engineers

" Second (angle)

SLABS Self Levelling and Anti-Lock

Brake System

SLS Self Levelling Suspension

SOHC Single Overhead Camshaft

sp.gr r Specific gravity

SRS Supplementary Restraint System

std. Standard

synchro Synchronizer or synchromesh

TDC Top Dead Centre

TMAP Temperature, Manifold Absolute

Pressure

TP Throttle Position

TPS Throttle Position Sensor

TV Torsional Vibration

TXV Thermostatic Expansion Valve

UK United Kingdom

US United States

V Volt

Var. Variable

VIN Vehicle Identification Number

VIS Variable Intake System

VRS Variable Reluctance Sensor

VSS Vehicle Speed Signal

W Watt

General Precautions

Dangerous substances

Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal health and the environment.

WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin. These liquids and substances include acid, anti-freeze, asbestos, brake fluid, fuel, windscreen washer additives, lubricants, refrigerants and various adhesives.

Always read carefully the instructions printed on labels or stamped on components and obey them implicitly. Such instructions are included for reasons of your health and personal safety. Never disregard them.

Synthetic rubber

Many 'O' rings, seals, hoses, flexible pipes and other similar items which appear to be natural rubber, are in fact, made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe and does not present a health hazard. However, if the material is damaged by fire or excessive heating, it can break down and produce highly corrosive Hydrofluoric acid.

Contact with Hydrofluoric acid can cause serious burns on contact with skin. If skin contact does occur:

• Remove any contaminated clothing immediately.
• Irrigate effected area of skin with a copious amount of cold water or limewater for 15 to 60 minutes.
• Obtain medical assistance immediately.

Should any material be in a burnt or overheated condition, handle with extreme caution and wear protective clothing (seamless industrial gloves, protective apron etc.).

Decontaminate and dispose of gloves immediately after use.

Lubricating oils

Avoid excessive skin contact with used lubricating oils and always adhere to the health protection precautions.

WARNING: Avoid excessive skin contact with used engine oil. Used engine oil contains potentially harmful contaminants which may cause skin cancer or other serious skin disorders.

WARNING: Avoid excessive skin contact with mineral oil. Mineral oils remove the natural fats from the skin, leading to dryness, irritation and dermatitis.

Health protection precautions

The following precautions should be observed at all times.

●Wear protective clothing, including impervious gloves where practicable.
●Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Do not put oily rags in pockets.
●Avoid contaminating clothes (particularly those next to the skin) with oil.
●Overalls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear.
●First aid treatment should be obtained immediately for open cuts and wounds.
- Apply barrier creams before each work period to help prevent lubricating oil from contaminating the skin.
●Wash with soap and water to ensure all oil is removed (proprietary skin cleansers and nail brushes will help).
- Use moisturisers after cleaning; preparations containing lanolin help replace the skin's natural oils which have been removed.
- Do not use petrol/gasoline, kerosene, diesel fuel, oil, thinners or solvents for cleaning skin.
- Where practicable, degrease components prior to handling.
- If skin disorders develop, obtain medical advice without delay.
●Wear eye protection (e.g. goggles or face shield) if there is a risk of eye contamination. Eye wash facilities should be provided in close vicinity of the work area.

Safety Instructions

Whenever possible, use a lift or pit when working beneath vehicle, in preference to jacking. Chock wheels as well as applying parking brake.

Jacking

Always use the recommended jacking points.

Always ensure that any lifting apparatus has sufficient load capacity for the weight to be lifted.

Ensure the vehicle is standing on level ground prior to lifting or jacking.

Apply the handbrake and chock the wheels.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Do not leave tools, lifting equipment, spilt oil, etc. around or on the work bench area. Always keep a clean and tidy work area.

Brake shoes and pads

Always fit the correct grade and specification of brake linings. When renewing brake pads and brake shoes, always replace as complete axle sets.

Brake hydraulics

Observe the following recommendations when working on the brake system:

●Always use two spanners when loosening or tightening brake pipe or hose connections
● Ensure that hoses run in a natural curve and are not kinked or twisted.
●Fit brake pipes securely in their retaining clips and ensure that the pipe cannot contact a potential chafing point.
- Containers used for brake fluid must be kept absolutely clean.
- Do not store brake fluid in an unsealed container, it will absorb water and in this condition would be dangerous to use due to a lowering of its boiling point.
- Do not allow brake fluid to be contaminated with mineral oil, or put new brake fluid in a container which has previously contained mineral oil.
- Do not re-use brake fluid removed from the system.
●Always use clean brake fluid or a recommended alternative to clean hydraulic components.
● After disconnection of brake pipes and hoses, immediately fit suitable blanking caps or plugs to prevent the ingress of dirt.
●Only use the correct brake fittings with compatible threads.
- Observe absolute cleanliness when working with hydraulic components.

Cooling system caps and plugs

Extreme care is necessary when removing expansion tank caps and coolant drain or bleed screws when the engine is hot, especially if it is overheated. To avoid the possibility of scalding, allow the engine to cool before attempting removal.

Air suspension system

Whilst working on the air suspension system, eye protection must be worn at all times.

Environmental Precautions

General

This section provides general information which can help to reduce the environmental impacts from the activities carried out in workshops.

Emissions to air

Many of the activities that are carried out in workshops emit gases and fumes which contribute to global warming, depletion of the ozone layer and/or the formation of photochemical smog at ground level. By considering how the workshop activities are carried out, these gases and fumes can be minimised, thus reducing the impact on the environment.

Exhaust fumes

Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to atmosphere. However, the amount of time engines are running and the position of the vehicle should be carefully considered at all times, to reduce the release of poisonous gases and minimise the inconvenience to people living nearby.

Solvents

Some of the cleaning agents used are solvent based and will evaporate to atmosphere if used carelessly, or if cans are left unsealed. All solvent containers should be firmly closed when not needed and solvent should be used sparingly. Suitable alternative materials may be available to replace some of the commonly used solvents. Similarly, many paints are solvent based and the spray should be minimised to reduce solvent emissions.

Refrigerant

It is illegal to release any refrigerants into the atmosphere. Discharge and replacement of these materials from air conditioning units should only be carried out using the correct equipment.

Checklist

Always adhere to the following.

Engines:

●don't leave engines running unnecessarily;
- minimise testing times and check where the exhaust fumes are being blown.

Materials:

• keep lids on containers of solvents;
  ●only use the minimum quantity;
  ●consider alternative materials;
• minimise over-spray when painting.

Gases:

●use the correct equipment for collecting refrigerants;
●don't burn rubbish on site.

Discharges to water

Most sites will have two systems for discharging water: storm drains and foul drains. Storm drains should only receive clean water, foul drains will take dirty water.

The foul drain will accept many of the normal waste waters such as washing water, detergents and domestic type wastes, but oil, petrol, solvent, acids, hydraulic oil, antifreeze and other such substances should never be poured down the drain. If in any doubt speak to the Water Company first.

Every precaution must be taken to prevent spillage of oil, fuel, solvents etc. reaching the drains. All handling of such materials must take place well away from the drains and preferably in an area with a kerb or wall around it, to prevent discharge into the drain. If a spillage occurs it should be soaked up immediately. Having a spill kit available will make this easier.

Additional precautions

Check whether the surface water drains are connected to an oil water separator, this could reduce the pollution if an incident was to occur. Oil water separators do need regular maintenance to ensure effectiveness.

Checklist

Always adhere to the following.

Disposal:

●never pour anything down a drain without first checking that it is environmentally safe to do so, and that it does not contravene any local regulations or bye-laws;
● have oil traps emptied regularly.

Spillage prevention:

●store liquids in a walled area;
●make sure that taps on liquid containers are secure and cannot be accidentally turned on;
●protect bulk storage tanks from vandalism by locking the valves;
●transfer liquids from one container to another in an area away from open drains;
●ensure lids are replaced securely on containers;
●have spill kits available near to points of storage and handling of liquids.

Spill kits

Special materials are available to absorb a number of different substances. They can be in granular form, ready to use and bought in convenient containers for storage. Disposal of used spill-absorbing material is dealt with in 'Waste Management' section.

Land contamination

Oils, fuels and solvents etc. can contaminate any soil that they are allowed to contact. Such materials should never be disposed of by pouring onto soil and every precaution must be taken to prevent spillage reaching soil. Waste materials stored on open ground could also leak, or have polluting substances washed off them that would contaminate the land. Always store these materials in suitable skips or other similarly robust containers.

Checklist

Always adhere to the following.

• Don't pour or spill anything onto the soil or bare ground;
• don't store waste materials on bare ground, see 'Spillage prevention' list.

Legal compliance

Some sites may have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is important to know what materials are allowed in the drain and to check the results of any monitoring carried out by the Water Company.

Where paint-spraying operations are carried out it may be necessary to apply to the Local Authority for an air emissions licence to operate the plant. If such a licence is in operation, additional precautions will be necessary to comply with the requirements, and the results of any air quality monitoring must be checked regularly.

Checklist

Always adhere to the following.

●Know what legal consents and licences apply to the operations;
- check that the emissions and discharges comply with legal requirements.

Local issues

A number of environmental issues will be of particular concern to residents and other neighbours close to the site. The sensitivity of these issues will depend on the proximity of the site and the layout and amount of activity carried on at the site.

Noise is a major concern and therefore consideration should be given to the time spent carrying out noisy activities and the location of those activities that can cause excessive noise.

Car alarm testing, panel beating, hammering and other such noisy activities should, whenever possible, be carried out indoors with doors and windows shut or as far away from houses as possible.

Running vehicle engines may be an outside activity which could cause nuisance to neighbours because of both noise and smell.

Be sensitive to the time of day when these activities are carried out and minimise the time of the noisy operation, particularly in the early morning and late evening.

Another local concern will be the smell from the various materials used. Using less solvent, paint and petrol could help prevent this annoyance.

Local residents and other business users will also be concerned about traffic congestion, noise and exhaust fumes, be sensitive to these concerns and try to minimise inconvenience from deliveries, customers and servicing operations.

Checklist

Always adhere to the following.

• Identify where the neighbours who are likely to be affected are situated;
• minimise noise, smells and traffic nuisance;
  ●prevent litter by putting waste in the correct containers;
  ●have waste skips emptied regularly.

Use of resource

Another environmental concern is the waste of materials and energy that can occur in day to day activities.

Electricity for heating, lighting and compressed air uses resources and releases pollution during its generation.

Fuel used for heating, running cars or vans and mobile plant is another limited resource which consumes large amounts of energy during its extraction and refining processes.

Water has to be cleaned, piped to site and disposed of; all of which creates more potential pollution.

Oil, spares, paint etc., have all produced pollution in the process of manufacture and they become a waste disposal problem if discarded.

Checklist

Always adhere to the following.

Electricity and heating:

• keep doors and windows closed in the winter;
  ●switch off machinery or lights when not needed;
  ●use energy efficient heating systems;
• switch off computers and photocopiers when not needed.

Fuel:

●don't run engines unnecessarily;
●think about whether journeys are necessary and drive to conserve fuel.

Water:

●don't leave taps and hose pipes running;
●mend leaks quickly, don't be wasteful.

Compressed air:

●don't leave valves open;
●mend leaks quickly;
●don't leave the compressor running when not needed.

Use of environmentally damaging materials:

- check whether a less toxic material is available.

Handling and storage of materials:

●have the correct facilities available for handling liquids to prevent spillage and wastage as listed above;
●provide suitable locations for storage to prevent frost damage or other deterioration.

Waste Management

One of the major ways that pollution can be reduced is by the careful handling, storage and disposal of all waste materials that occur on sites. Legislation makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites. This means that it is necessary to not only know what the waste materials are, but also to have the necessary documentation and licenses.

Handling and storage of waste

Ensure that waste materials are not poured down the drain or onto soils. They should be stored in such a way as to prevent the escape of the material to land, water or air.

They must also be segregated into different types of waste e.g. oil, metals, batteries, used vehicle components. This will prevent any reaction between different materials and assist in disposal.

Disposal of waste

Disposal of waste materials must only be to waste carriers who are licensed to carry those particular waste materials and all the necessary documentation must be completed. The waste carrier is responsible for ensuring that the waste is taken to the correct disposal sites.

Dispose of waste in accordance with the following guidelines.

●Fuel, hydraulic fluid, anti-freeze and oil: keep separate and dispose of to specialist contractor.

●Refrigerant: collect in specialist equipment and reuse.

●Detergents: safe to pour down the foul drain if diluted.

●Paint, thinners: keep separate and dispose of to specialist contractor.

- Components: send back to supplier for refurbishment, or disassemble and reuse any suitable parts. Dispose of the remainder in ordinary waste.

●Small parts: reuse any suitable parts, dispose of the remainder in ordinary waste.

●Metals: can be sold if kept separate from general waste.

●Tyres: keep separate and dispose of to specialist contractor.

●Packaging: compact as much as possible and dispose of in ordinary waste.

●Asbestos-containing: keep separate and dispose of to specialist contractor.

- Oily and fuel wastes (e.g. rags, used spill kit material): keep separate and dispose of to specialist contractor.

●Air filters: keep separate and dispose of to specialist contractor.

●Rubber/plastics: dispose of in ordinary waste.

●Hoses: dispose of in ordinary waste.

●Batteries: keep separate and dispose of to specialist contractor.

●Airbags - explosives: keep separate and dispose of to specialist contractor.

●Electrical components: send back to supplier for refurbishment, or disassemble and reuse any suitable parts. Dispose of the remainder in ordinary waste.

●Electronic components: send back to supplier for refurbishment, or disassemble and reuse any suitable parts. Dispose of the remainder in ordinary waste.

● Catalysts: can be sold if kept separate from general waste

●Used spill-absorbing material: keep separate and dispose of to specialist contractor.

●Office waste: recycle paper and toner and ink cartridges, dispose of the remainder in ordinary waste.

General Fitting Instructions

Component removal

Whenever possible, clean components and surrounding area before removal.

• Blank off openings exposed by component removal.
• Immediately seal fuel, oil or hydraulic lines when apertures are exposed; use plastic caps or plugs to prevent loss of fluid and ingress of dirt.
• Close the open ends of oilways exposed by component removal with tapered hardwood plugs or conspicuous plastic plugs.
• Immediately a component is removed, place it in a suitable container; use a separate container for each component and its associated parts.
  ●Clean bench and provide marking materials, labels and containers before dismantling a component.

Dismantling

Observe scrupulous cleanliness when dismantling components, particularly when brake, fuel or hydraulic system parts are being worked on. A particle of dirt or a cloth fragment could cause a serious malfunction if trapped in these systems.

• Blow out all tapped holes, crevices, oilways and fluid passages with an air line. Ensure that any 'O' rings used for sealing are correctly replaced or renewed, if disturbed during the process.
• Use marking ink to identify mating parts and ensure correct reassembly. Do not use a centre punch or scriber to mark parts, they could initiate cracks or distortion in marked components.
  ● Wire together mating parts where necessary to prevent accidental interchange (e.g. roller bearing components).
  ●Wire labels on to all parts which are to be renewed, and to parts requiring further inspection before being passed for reassembly; place these parts in separate containers from those containing parts for rebuild.
• Do not discard a part due for renewal until after comparing it with a new part, to ensure that its correct replacement has been obtained.

Cleaning components

Always use the recommended cleaning agent or equivalent. Ensure that adequate ventilation is provided when volatile degreasing agents are being used. Do not use degreasing equipment for components containing items which could be damaged by the use of this process.

General inspection

All components should be inspected for wear or damage before being reassembled.

●Never inspect a component for wear or dimensional check unless it is absolutely clean; a slight smear of grease can conceal an incipient failure.

- When a component is to be checked dimensionally against recommended values, use the appropriate measuring equipment (surface plates, micrometers, dial gauges etc.). Ensure the measuring equipment is calibrated and in good serviceable condition.

- Reject a component if its dimensions are outside the specified tolerances, or if it appears to be damaged.

●A part may be refitted if its critical dimension is exactly to its tolerance limit and it appears to be in satisfactory condition. Use 'Plastigauge' 12 Type PG-1 for checking bearing surface clearances.

Ball and Roller Bearings

General

When removing and installing bearings, ensure that the following practices are observed to ensure component serviceability.

• Remove all traces of lubricant from bearing under inspection by cleaning with a suitable degreasant; maintain absolute cleanliness throughout operations.
  ●Conduct a visual inspection for markings on rolling elements, raceways, outer surface of outer rings or inner surface of inner rings. Reject any bearings found to be marked, since marking in these areas indicates onset of wear.
  ●Hold inner race of bearing between finger and thumb of one hand and spin outer race to check that it revolves absolutely smoothly. Repeat, holding outer race and spinning inner race.
• Rotate outer ring gently with a reciprocating motion, while holding inner ring; feel for any check or obstruction to rotation. Reject bearing if action is not perfectly smooth.
  ●Lubricate bearing with generous amounts of lubricant appropriate to installation.
  ●Inspect shaft and bearing housing for discoloration or other markings which indicate movement between bearing and seatings.
  ●Ensure that shaft and housing are clean and free from burrs before fitting bearing.
• If one bearing of a pair shows an imperfection, it is advisable to replace both with new bearings; an exception could be if the faulty bearing had covered a low mileage, and it can be established that damage is confined to only one bearing.
  ●Never refit a ball or roller bearing without first ensuring that it is in a fully serviceable condition.
• When hub bearings are removed or displaced, new bearings must be fitted; do not attempt to refit the old hub bearings.

• When fitting a bearing to a shaft, only apply force to the inner ring of the bearing. When fitting a bearing into a housing, only apply force to the outer ring of the bearing.
  ●In the case of grease lubricated bearings (e.g. hub bearings) fill the space between bearing and outer seal with the recommended grade of grease before fitting seal.
  ●Always mark components of separable bearings (e.g. taper roller bearings) when dismantling, to ensure correct reassembly. Never fit new rollers in a used outer ring; always fit a complete new bearing assembly.

Oil Seals

General

Always renew oil seals which have been removed from their working location (whether as an individual component or as part of an assembly). NEVER use a seal which has been improperly stored or handled, such as hung on a hook or nail.

● Carefully examine seal before fitting to ensure that it is clean and undamaged.
- Ensure the surface on which the new seal is to run is free of burrs or scratches. Renew the component if the original sealing surface cannot be completely restored.
- Protect the seal from any surface which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface.
● Lubricate the sealing lips with a recommended lubricant before use to prevent damage during initial use. On dual lipped seals, smear the area between the lips with grease.
- If a seal spring is provided, ensure that it is fitted correctly. Place lip of seal towards fluid to be sealed and slide into position on shaft. Use fitting sleeve where possible to protect sealing lip from damage by sharp corners, threads or splines. If a fitting sleeve is not available, use plastic tube or tape to prevent damage to the sealing lip.

●Grease outside diameter of seal, place square to housing recess and press into position using great care, and if possible a 'bell piece' to ensure that seal is not tilted. In some cases it may be preferable to fit seal to housing before fitting to shaft. Never let weight of unsupported shaft rest in seal.

M010093

• Use the recommended service tool to fit an oil seal. If the correct service tool is not available, use a suitable tube approximately 0.4 mm (0.015 in.) smaller than the outside diameter of the seal. Use a hammer VERY GENTLY on drift if a suitable press is not available.
• Press or drift the seal in to the depth of its housing with the sealing lip facing the lubricant to be retained if the housing is shouldered, or flush with the face of the housing where no shoulder is provided. Ensure that the seal does not enter the housing in a tilted position.

Joints and Joint Faces

General

Fit joints dry unless specified otherwise.

●Always use the correct gaskets as specified.
- When jointing compound is used, apply in a thin uniform film to metal surfaces; take care to prevent jointing compound from entering oilways, pipes or blind tapped holes.
- If gaskets and/or jointing compound is recommended for use; remove all traces of old jointing material prior to reassembly. Do not use a tool which will damage the joint faces and smooth out any scratches or burrs using an oil stone. Do not allow dirt or jointing material to enter any tapped holes or enclosed parts.
●Prior to reassembly, blow through any pipes, channels or crevices with compressed air.

Locking Devices

General

Always replace locking devices with one of the same design.

Tab washers

Always release locking tabs and fit new locking washers. Do not re-use locking tabs.

Locking nuts

Always use a backing spanner when loosening or tightening locking nuts, brake and fuel pipe unions.

Roll pins

Always fit new roll pins of an interference fit in the hole.

Circlips

Always fit new circlips of the correct size for the groove.

Keys and keyways

Remove burrs from edges of keyways with a fine file and clean thoroughly before attempting to refit key.

Clean and inspect key closely; keys are suitable for refitting only if indistinguishable from new, as any indentation may indicate the onset of wear.

Split pins

M010102

Always fit new split-pins of the correct size for the hole in the bolt or stud.

Screw Threads

General

Metric threads to ISO standards are used.

Damaged nuts, bolts and screws must always be discarded. Cleaning damaged threads with a die or tap impairs the strength and fit of the threads and is not recommended.

Always ensure that replacement bolts are at least equal in strength to those replaced. Castellated nuts must not be loosened to accept a split-pin, except in recommended cases when this forms part of an adjustment.

Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or stud could split the housing.

Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads can affect the torque reading.

To check or re-tighten a bolt or screw to a specified torque figure, first loosen a quarter of a turn, then retighten to the correct torque figure.

Oil thread lightly before tightening to ensure a free running thread, except in the case of threads treated with sealant/lubricant, and self-locking nuts.

Bolt and Nut Identification

Bolt identification

M010087

An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M or M embossed or indented on top of the bolt head.

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the strength grade, e.g. 8.8; 10.9; 12.9; 14.9. As an alternative, some bolts and screws have the M and strength grade symbol stamped on the flats of the hexagon.

Encapsulated bolts and screws

M010091

Encapsulated bolts and screws have a micro-encapsulated locking agent pre-applied to the thread. They are identified by a coloured section which extends 360° around the thread. The locking agent is released and activated by the assembly process and is then chemically cured to provide the locking action.

Unless a specific repair procedure states otherwise, encapsulated bolts may be re-used providing the threads are undamaged and the following procedure is adopted:

• Remove loose adhesive from the bolt and housing threads.
  ●Ensure threads are clean and free of oil and grease.
  ●Apply an approved locking agent.

An encapsulated bolt may be replaced with a bolt of equivalent specification provided it is treated with an approved locking agent.

Self-locking bolts and screws

M010090

Self-locking bolts and screws, i.e. nylon patched or trilobular thread can be re-used providing resistance can be felt when the locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent pre-applied to the threads. They are identified by the presence of a coloured section of thread which extends for up to 180° around the thread.

Trilobular bolts (i.e. Powerlok) have a special thread form which creates a slight interference with the thread of the hole or nut into which it is screwed.

DO NOT re-use self-locking fasteners in critical locations (e.g. engine bearings, flywheel). Always use the correct replacement self-locking nut, bolt or screw.

DO NOT fit non self-locking fasteners in applications where a self-locking nut, bolt or screw is specified.

Nut identification

M010088

A nut with an ISO metric thread is marked on one face or on one of the flats of the hexagon with the strength grade symbol 8, 12, or 14. Some nuts with a strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking.

A clock face system is sometimes used as an alternative method of indicating the strength grade. The external chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two dots identify the 12 o'clock position.

When tightening a slotted or castellated nut, never loosen it to insert a split pin except where recommended as part of an adjustment. If difficulty is experienced, alternative washers or nuts should be selected, or the washer thickness reduced.

Where bearing pre-load is involved, nuts should be tightened in accordance with special instructions.

Self-locking nuts

M010089

Self-locking nuts, i.e. nylon insert or deferred thread nuts can be re-used providing resistance can be felt when the locking portion of the nut passes over the thread of the bolt or stud.

Where self-locking nuts have been removed, it is advisable to replace them with new ones of the same type.

Flexible Pipes and Hoses

General

When removing and installing flexible hydraulic pipes and hoses, ensure that the following practices are observed to ensure component serviceability.

●Before removing any brake or power steering hose, clean end fittings and area surrounding them as thoroughly as possible.
- Obtain appropriate plugs or caps before detaching hose end fittings, so that the ports can be immediately covered to prevent the ingress of dirt.
●Clean hose externally and blow through with airline. Examine carefully for cracks, separation of plies, security of end fittings and external damage. Reject any faulty hoses.
- When refitting a hose, ensure that no unnecessary bends are introduced, and that hose is not twisted before or during tightening of union nuts.
●Fit a cap to seal a hydraulic union and a plug to its socket after removal to prevent ingress of dirt.
●Absolute cleanliness must be observed with hydraulic components at all times.
●After any work on hydraulic systems, carefully inspect for leaks underneath the vehicle while a second operator applies maximum brake pressure to the brakes (engine running) and operates the steering.

Fuel system hoses

M010103

All fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core. If any of the fuel system hoses have been disconnected, it is imperative that the internal bore is inspected to ensure that the viton lining has not become separated from the armoured outer sleeve. A new hose must be fitted if separation is evident.

Cooling system hoses

The following precautions MUST be followed to ensure that integrity of cooling hoses and their connections to system components are maintained.

Hose orientation and connection

Correct orientation of cooling hoses is important in ensuring that the hose does not become fatigued or damaged through contact with adjacent components. Where 'timing' marks (2) are provided on the hose and corresponding connection, these must be used to ensure correct orientation. Hoses must be pushed fully onto their connection points. Usually, a moulded form (3) on the stub pipe provides a positive indicator.

Hose clips

Markings (4) are usually provided on the hose to indicate the correct clip position. If no markings are provided, position the clip directly behind the retaining lip at the end of the stub as shown. Worm drive clips should be oriented with the crimped side of the drive housing (5) facing towards the end of the hose, or the hose may become pinched between the clip and the stub pipe retaining lip. Worm drive clips should be tightened to 3 Nm (2 lbf.ft) unless otherwise stated. Ensure that hose clips do not foul adjacent components.

Heat protection

Always ensure that heatshields and protective sheathing are in good condition. Replace if damage is evident. Particular care must be taken when routing hoses close to hot engine components, such as the exhaust manifold and the Exhaust Gas Recirculation (EGR) pipe. Hoses will relax and deflect slightly when hot; ensure this movement is taken into account when routing and securing hoses.

Rolling Road Testing

General

IMPORTANT: Use a four wheel rolling road for brake testing if possible.

WARNING: Do not attempt to test ABS function on a rolling road.

Four wheel rolling road

Provided that front and rear rollers are rotating at identical speeds and that normal workshop safety standards are applied, there is no speed restriction during testing except any that may apply to the tyres.

Before testing a vehicle with anti-lock brakes on a four wheel rolling road, disconnect the ABS modulator. The ABS function will not work, the ABS warning light will illuminate. Normal braking will be available.

Two wheel rolling road

Up to 03MY

ABS will not function on a two wheel rolling road. The ABS light will illuminate during testing. Normal braking will be available.

If brake testing on a two wheel rolling road is necessary, the following precautions should be taken:

●Propeller shaft to the rear axle is removed.

●Neutral selected in gearbox.

When checking brakes, run engine at idle speed to maintain servo vacuum.

From 03MY

The differential lock must be engaged for two wheel rolling road testing. It will also be necessary to disconnect the propeller shaft from the transfer box output shaft driving the axle whose wheels are NOT on the rolling road. Additionally, the ETC system must be deactivated by either removing the 10 amp fuse (Number 28, labelled ABS in the main fuse box) or disconnecting the ABS modulator pump. This must be done with the ignition OFF; a fault in the ABS system may still be recorded.

WARNING; VEHICLES NOT FITTED WITH A DIFFERENTIAL LOCK MUST NOT BE TESTED ON A ROLLING ROAD WHERE THE ROLLERS ARE DRIVEN BY THE VEHICLE.

Fuel Handling Precautions

Fuel vapour is highly flammable and in confined spaces is also explosive and toxic. The vapour is heavier than air and will always fall to the lowest level. The vapour can be easily distributed throughout a workshop by air currents; consequently, even a small spillage of fuel is potentially very dangerous.

The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only, if in doubt consult your local Fire Officer.

General

Always have a fire extinguisher containing FOAM, CO₂ , GAS or POWDER close at hand when handling or draining fuel or when dismantling fuel systems. Fire extinguishers should also be located in areas where fuel containers are stored.

Always disconnect the vehicle battery before carrying out dismantling or draining work on a fuel system.

Whenever fuel is being handled, drained or stored, or when fuel systems are being dismantled, all forms of ignition must be extinguished or removed; any leadlamps must be flameproof and kept clear of spillage.

WARNING: No one should be permitted to repair components associated with fuel without first having specialist training.

WARNING: Do not remove fuel system components while the vehicle is over a pit.

Fuel tank draining

Fuel tank draining should be carried out in accordance with the procedure outlined in the FUEL DELIVERY section of this manual and observing the following precautions.

WARNING: Fuel must not be extracted or drained from any vehicle while it is over a pit. Extraction or draining of fuel must be carried out in a well ventilated area.

The capacity of containers must be more than adequate for the amount of fuel to be extracted or drained. The container should be clearly marked with its contents and placed in a safe storage area which meets the requirements of local authority regulations.

Fuel tank removal

When the fuel line is secured to the fuel tank outlet by a spring steel clip, the clip must be released before the fuel line is disconnected or the fuel tank is removed. This procedure will avoid the possibility of fumes in the fuel tank being ignited when the clip is released.

As an added precaution, fuel tanks should have a 'FUEL VAPOUR' warning label attached to them as soon as they are removed from the vehicle.

Fuel tank repairs - plastic tank

No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a new tank must be fitted.

Body repairs

Plastic fuel pipes are particularly susceptible to heat, even at relatively low temperature, and can be melted by heat conducted from some distance away.

When body repairs involve the use of heat, all fuel pipes which run in the vicinity of the repair area must be removed, and the tank outlet plugged.

WARNING: If welding is to be carried out in the vicinity of the fuel tank, the fuel system must be drained and the tank removed before welding commences.

Electrical Precautions

General

The following guidelines are intended to ensure the safety of the operator while preventing damage to the electrical and electronic components fitted to the vehicle. Where necessary, specific precautions are detailed in the individual procedures of this manual.

Equipment

Prior to commencing any test procedure on the vehicle ensure that the relevant test equipment is working correctly and any harness or connectors are in good condition. It is particularly important to check the condition of the lead and plugs of mains operated equipment.

Polarity

Never reverse connect the vehicle battery and always ensure the correct polarity when connecting test equipment.

High voltage circuits

Whenever disconnecting live ht circuits always use insulated pliers and never allow the open end of the ht lead to contact other components, particularly ECU's. Exercise caution when measuring the voltage on the coil terminals while the engine is running, high voltage spikes can occur on these terminals.

Connectors and harnesses

The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors:

● Always ensure electrically related items are dry and oil free before disconnecting and connecting test equipment.
- Ensure disconnected multiplugs and sensors are protected from being contaminated with oil, coolant or other solutions. Contamination could impair performance or result in catastrophic failure.
●Never force connectors apart using tools to prise apart or by pulling on the wiring harness.
●Always ensure locking tabs are disengaged before disconnection, and match orientation to enable correct reconnection.
- Ensure that any protection (covers, insulation etc.) is replaced if disturbed.

Having confirmed a component to be faulty:

• Switch off the ignition and disconnect the battery.
• Remove the component and support the disconnected harness.
• When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking tabs fully engage.

Battery disconnection

Before disconnecting the battery, disable the alarm system and switch off all electrical equipment. If the radio is to be serviced, ensure the security code has been deactivated.

CAUTION: To prevent damage to electrical components, always disconnect the battery when working on the vehicle's electrical system. The ground lead must be disconnected first and reconnected last.

CAUTION: Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

Battery charging

Only recharge the battery with it removed from the vehicle. Always ensure any battery charging area is well ventilated and that every precaution is taken to avoid naked flames and sparks.

Ignition system safety precautions

The vehicle's ignition system produces high voltage and the following precautions should be observed before carrying out any work on the system.

WARNING: Before commencing work on an ignition system, ensure all high tension terminals, adapters and diagnostic equipment are adequately insulated and shielded to prevent accidental personal contacts and minimise the risk of shock. Wearers of surgically implanted pacemaker devices should not be in close proximity of ignition circuits or diagnostic equipment.

Disciplines

Switch off the ignition prior to making any connection or disconnection in the system to prevent electrical surges caused by disconnecting 'live' connections damaging electronic components.

Ensure hands and work surfaces are clean and free of grease, swarf, etc. Grease collects dirt which can cause electrical tracking (short-circuits) or high-resistance contacts.

When handling printed circuit boards, treat with care and hold by the edges only; note that some electronic components are susceptible to body static.

Connectors should never be subjected to forced removal or refit, especially inter-board connectors. Damaged contacts can cause short-circuit and open-circuit fault conditions.

Prior to commencing test, and periodically during a test, touch a good vehicle body earth to discharge static charge. Some electronic components are vulnerable to the static electricity that may be generated by the operator.

Grease for electrical connectors

Some under bonnet and under body connectors may be protected against corrosion by the application of a special grease during vehicle production. Should connectors be disturbed in service, repaired or replaced, additional grease should be applied: Part No. BAU 5811, available in 150 gm tubs.

NOTE: The use of greases other than BAU 5811 must be avoided as they can migrate into relays, switches etc. contaminating the contacts and leading to intermittent operation or failure.

Supplementary Restraint System Precautions

General

The Supplementary Restraint System (SRS) provides active protection for vehicle occupants in the event of a serious collision. The system components include airbags and pretensioner seat belts which are automatically deployed when a severe frontal crash condition is detected.

In order to assure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is ready for operation in the event of an accident.

The SRS system contains components which could be potentially hazardous to the service engineer if not serviced and handled correctly. The following guidelines are intended to alert the service engineer to potential sources of danger and emphasise the importance of ensuring integrity of the SRS components fitted to the vehicle.

Where necessary, additional specific precautions are detailed in the Restraint Systems section of this Manual which should be referred to prior to commencing repair operations.

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system. The same care should be exercised when working on ancillary systems and components located in the vicinity of SRS components; these include but are not limited to steering system (driver's airbag), body and trim components (passenger's airbag and seat belt pretensioners) and electrical system components (SRS harnesses etc.).

WARNING: Do not use rear facing child seats in the front passenger seat if the vehicle is fitted with a passenger airbag.

WARNING: It is imperative that before any work is undertaken on the SRS system the appropriate information is read thoroughly.

WARNING: Replace the airbag every 10 years.

Do not install used SRS parts from another car. When repairing an SRS system, always use approved new parts.

Carefully inspect the airbag module before installing it. Do not install an airbag module that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.

Do not try to disassemble or tamper with the airbag module.

Special bolts are necessary for installing the airbag module. Do not use other bolts.

Preliminary procedures

The SRS system uses energy reserve capacitors that keep the system active in the event of electrical supply failure under crash conditions. It is necessary to allow the capacitors sufficient time to discharge in order to avoid the risk of accidental deployment.

Always remove the ignition key from the starter switch, disconnect the vehicle battery and wait 10 minutes before commencing work on the SRS system.

Carefully inspect any SRS component before installation. Do not install any SRS component that shows signs of damage such as dents, cracks or deformity.

Component handling

M010095

The SRS components are sensitive and potentially hazardous if not handled correctly; always comply with the following handling precautions:

●Never drop an SRS component. The airbag Diagnostic Control Unit (DCU) is a particularly shock sensitive device and must be handled with extreme care. Airbag modules and seat belt pretensioner units could deploy if subjected to a strong shock.
●Never wrap your arms around an airbag module. If an airbag module has to be carried, hold it by the cover, with the cover uppermost and the base away from your body.
●Never transport airbag modules or seat belt pretensioners in the cabin of a vehicle. Always use the luggage compartment of the vehicle for carrying airbag modules and seat belt pretensioner units.

WARNING: The airbag module contains sodium azide which is poisonous and extremely flammable. Contact with water, acid or heavy metals may produce harmful or explosive compounds. Do not dismantle, incinerate or bring into contact with electricity, before the unit has been deployed.