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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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Workshop Manual Service Procedures NRRWM 21/11/01 11:22 am Page 15
WORKSHOP MANUAL - SERVICE PROCEDURES LR L0 477NAS (6 th Ed it ion) © 2003 Land Rover All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without written prior permission from Land Rover.
CONTENTS CONTENTS 1 INTRODUCTION ...................................................................................... 01-1 How To Use This Manual................................................................................................................ 01-1 Testbook - Fault Diagnostic Equipment .......................................................................................... 01-2 Repairs and Replacements ............................................................................................................. 01-2 Specifications .................................................................................................................................. 01-3 Abbreviations and Symbols ............................................................................................................ 01-4 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 .............................................................................................................................. 03-10 Screw Threads ................................................................................................................................ 03-11 Bolt and Nut Identification ............................................................................................................... 03-11 Flexible Pipes and Hoses ............................................................................................................... 03-14 Service Tools .................................................................................................................................. 03-16 Rolling Road Testing....................................................................................................................... 03-17 Fuel Handling Precautions .............................................................................................................. 03-18 Electrical Precautions ..................................................................................................................... 03-19 Supplementary Restraint System (SRS) Precautions ..................................................................... 03-21 SRS Component Replacement Policy ........................................................................................... 03-28 Air Conditioning System Precautions .............................................................................................. 03-29 Body Repairs .................................................................................................................................. 03-32 GENERAL DATA ..................................................................................... 04-1 Engine - Td6 ................................................................................................................................... 04-1 Engine - V8 ..................................................................................................................................... 04-5 Fuel system - Td6 ........................................................................................................................... 04-8 Fuel system - V8 ............................................................................................................................. 04-8 Cooling system - Td6 ...................................................................................................................... 04-9 Cooling system - V8 ........................................................................................................................ 04-9 Transfer box ................................................................................................................................... 04-10 Automatic gearbox - Td6 engine ..................................................................................................... 04-11 Automatic gearbox - V8 engine ....................................................................................................... 04-11 Propeller and drive shafts ............................................................................................................... 04-12 Front differential .............................................................................................................................. 04-12 Rear differential ............................................................................................................................... 04-12 Steering........................................................................................................................................... 04-13 Front and rear suspension .............................................................................................................. 04-14 Brakes ............................................................................................................................................. 04-15 Wheels and tyres ............................................................................................................................ 04-16 Air conditioning ............................................................................................................................... 04-17 Electrical - Td6 ................................................................................................................................ 04-18 Electrical - V8 .................................................................................................................................. 04-18 Dimensions ..................................................................................................................................... 04-19 Weights ........................................................................................................................................... 04-19
CONTENTS 2CONTENTS IDENTIFICATION NUMBERS .................................................................. 05-1 Vehicle Identification Number ......................................................................................................... 05-1 Identification Number Locations ..................................................................................................... 05-3 TORQUE WRENCH SETTINGS .............................................................. 06-1 Maintenance ................................................................................................................................... 06-1 Engine Td6 ..................................................................................................................................... 06-2 Engine V8 ....................................................................................................................................... 06-4 Emission control - Td6 .................................................................................................................... 06-6 Emission control - V8 ...................................................................................................................... 06-6 Engine management system - Td6 ................................................................................................. 06-7 Engine management system - V8................................................................................................... 06-8 Fuel Delivery System - Td6 ............................................................................................................ 06-9 Fuel Delivery System - V8 ............................................................................................................. 06-9 Cooling System - Td6 ..................................................................................................................... 06-10 Cooling System - V8 ....................................................................................................................... 06-10 Manifold and Exhaust System - Td6 .............................................................................................. 06-11 Manifold and Exhaust System - V8................................................................................................. 06-11 Transfer Box ................................................................................................................................... 06-12 Automatic Gearbox - Td6............................................................................................................... 06-13 Automatic Gearbox - V8 ................................................................................................................. 06-14 Driveshafts ..................................................................................................................................... 06-15 Final Drive....................................................................................................................................... 06-15 Front Differential ............................................................................................................................. 06-15 Steering ......................................................................................................................................... 06-16 Front Suspension........................................................................................................................... 06-17 Rear Suspension ............................................................................................................................ 06-18 Brakes............................................................................................................................................ 06-19 Restraint Systems.......................................................................................................................... 06-20 Body................................................................................................................................................ 06-21 Heating and Ventilation.................................................................................................................. 06-22 Air Conditioning ............................................................................................................................. 06-22 Wipers and Washers ..................................................................................................................... 06-22 Electrical ........................................................................................................................................ 06-23 LIFTING AND TOWING ........................................................................... 08-1 Lifting .............................................................................................................................................. 08-1 Towing ............................................................................................................................................ 08-4 Transporting.................................................................................................................................... 08-5 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 CONTENTS 3 MAINTENANCE ........................................................................................ 10-1 PROCEDURES Td6 Diesel engine underbonnet view .............................................................................................. 10-1 V8 Engine 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 Road wheels ................................................................................................................................... 10-6 Tyres .............................................................................................................................................. 10-7 Brake pads, discs and calipers ....................................................................................................... 10-7 Brake fluid ....................................................................................................................................... 10-8 Fuel filter element - Td6 engine ...................................................................................................... 10-8 Anti-freeze....................................................................................................................................... 10-9 Cooling system ............................................................................................................................... 10-9 Spark plugs - V8 engine.................................................................................................................. 10-10 Air cleaner element - Td6 engine .................................................................................................... 10-10 Air cleaner element - V8 engine ...................................................................................................... 10-10 Ancillary drive belt ........................................................................................................................... 10-11 Fluid reservoirs ............................................................................................................................... 10-11 Battery ............................................................................................................................................. 10-12 Engine oil and filter - Td6 engine .................................................................................................... 10-13 Engine oil and filter - V8 engine ...................................................................................................... 10-14 Gearbox fluid - Td6 ........................................................................................................................ 10-15 Gearbox fluid - V8 .......................................................................................................................... 10-16 Brake hose, brake pipes, fuel pipes, hydraulic pipes and unions/electrical harnesses.................. 10-17 Engine, automatic gearbox, transfer box, front and rear and differentials ...................................... 10-17 Exhaust system............................................................................................................................... 10-18 Underbody ...................................................................................................................................... 10-18 Body ................................................................................................................................................ 10-18 Steering rod ball joints and dust covers .......................................................................................... 10-18 Road/roller test................................................................................................................................ 10-19
CONTENTS 4CONTENTS Engine - V8 ............................................................................................... 12-2-1 ADJUSTMENTS Engine oil pressure check .............................................................................................................. 12-2-1 REPAIRS Pulley - crankshaft ......................................................................................................................... 12-2-3 Oil seal - crankshaft - front ............................................................................................................. 12-2-3 Oil seal - crankshaft - rear ............................................................................................................. 12-2-4 Gasket - cylinder head - LH ........................................................................................................... 12-2-6 Gasket - cylinder head - RH .......................................................................................................... 12-2-9 Gasket - camshaft cover - LH ......................................................................................................... 12-2-13 Gasket - camshaft cover - RH ....................................................................................................... 12-2-15 Acoustic cover - engine ................................................................................................................. 12-2-17 Control solenoid - variable camshaft control (VCC) - LH ................................................................ 12-2-18 Control solenoid - variable camshaft control (VCC) - RH ............................................................... 12-2-19 Variable camshaft unit - variable camshaft control (VCC) - LH ...................................................... 12-2-20 Variable camshaft unit - variable camshaft control (VCC) - RH ..................................................... 12-2-26 Engine & ancillaries - remove for access & refit ............................................................................ 12-2-32 Mounting - rear ............................................................................................................................. 12-2-45 Engine mounting - LH .................................................................................................................... 12-2-47 Engine mounting - RH ................................................................................................................... 12-2-51 Torque converter drive plate .......................................................................................................... 12-2-53 Filter - engine oil ............................................................................................................................ 12-2-54 Tube - dipstick ............................................................................................................................... 12-2-54 Strainer - oil pick up ...................................................................................................................... 12-2-55 Pump - oil ....................................................................................................................................... 12-2-56 Gasket - lower oil sump ................................................................................................................. 12-2-57 Gasket - oil sump ........................................................................................................................... 12-2-58 Baffle Plate .................................................................................................................................... 12-2-60 Switch - oil pressure ....................................................................................................................... 12-2-60 Timing chain - includes align gears ............................................................................................... 12-2-61 Cover - timing gear - upper - RH ................................................................................................... 12-2-62 Cover - timing gear - upper - LH .................................................................................................... 12-2-66 Cover - timing gear - lower ............................................................................................................ 12-2-69 OVERHAUL Piston assemblies - engine set ...................................................................................................... 12-2-73 Bearings - connecting rods - engine set ........................................................................................ 12-2-76 Pulley - crankshaft ......................................................................................................................... 12-2-78 Oil seal - crankshaft - front ............................................................................................................ 12-2-79 Crankshaft and main bearings ....................................................................................................... 12-2-80 Oil seal - crankshaft - rear ............................................................................................................. 12-2-84 Gasket - cylinder head ................................................................................................................... 12-2-85 Cylinder head - overhaul ............................................................................................................... 12-2-89 Gasket - covers - camshaft ............................................................................................................. 12-2-93 Variable camshaft unit - variable camshaft control (VCC) .............................................................. 12-2-95 Strainer - oil pick up ....................................................................................................................... 12-2-101 Pump - engine oil ........................................................................................................................... 12-2-101 Gasket - sump bottom plate ........................................................................................................... 12-2-103 Gasket - oil sump ............................................................................................................................ 12-2-104 Cover - timing gear - upper ............................................................................................................. 12-2-106 Cover - timing gear - lower ............................................................................................................ 12-2-110 Timing chain & guides ................................................................................................................... 12-2-113 Pipe(s) - water pump to coolant manifold ...................................................................................... 12-2-114 Gasket(s) - induction manifold ....................................................................................................... 12-2-115
CONTENTS CONTENTS 5 EMISSION CONTROL - V8....................................................................... 17-2-1 ADJUSTMENTS Evaporative loss control system (EVAPS) - leak test - NAS ........................................................... 17-2-1 REPAIRS Solenoid - canister purge ............................................................................................................... 17-2-3 Charcoal canister ........................................................................................................................... 17-2-4 Valve - vacuum activation - secondary air injection (SAI) ............................................................... 17-2-5 Relay - secondary air injection pump (SAI) ..................................................................................... 17-2-6 Pump - secondary air injection (SAI) .............................................................................................. 17-2-6 Module - Tank Leakage Diagnostic (DMTL) .................................................................................. 17-2-8 Catalytic converter ......................................................................................................................... 17-2-9 Sensor - heated oxygen (HO2S) - pre-catalyst ............................................................................... 17-2-10 Sensor - heated oxygen (HO2S) - post catalyst ............................................................................. 17-2-10 ENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1 REPAIRS Spark plugs .................................................................................................................................... 18-2-1 Relay - ignition coils ....................................................................................................................... 18-2-1 Ignition coils - multiple - set ............................................................................................................ 18-2-2 Cover - Ignition coils - LH ............................................................................................................... 18-2-3 Cover - Ignition coils - RH .............................................................................................................. 18-2-4 Engine control module (ECM) ........................................................................................................ 18-2-5 Relay - combined ignition & fuel ECU ............................................................................................ 18-2-6 Sensor - engine coolant temperature (ECT) ................................................................................. 18-2-6 Sensor - crankshaft position (CKP) ............................................................................................... 18-2-7 Sensor - camshaft position (CMP) - LH ......................................................................................... 18-2-9 Sensor - camshaft position (CMP) - RH ......................................................................................... 18-2-10 Sensor - knock (KS) - LH ............................................................................................................... 18-2-11 Sensor - knock (KS) - RH .............................................................................................................. 18-2-11 Sensor - temperature - E box ....................................................................................................... 18-2-12 Housing - air cleaner ....................................................................................................................... 18-2-13 Element - air cleaner ...................................................................................................................... 18-2-14 Hose - air flow meter to throttle body ............................................................................................. 18-2-15 Sensor - accelerator pedal position (APP) ...................................................................................... 18-2-16 Sensor - combined mass air flow (MAFS) & intake air temperature (IAT) ..................................... 18-2-16 Throttle body .................................................................................................................................. 18-2-17 Fuel rail - remove for access & refit ............................................................................................... 18-2-18 Injectors - set ................................................................................................................................. 18-2-22 Sensor - brake pedal position ......................................................................................................... 18-2-23
CONTENTS 6CONTENTS FUEL DELIVERY SYSTEM - V8 ............................................................... 19-2-1 ADJUSTMENT Fuel system - depressurise ............................................................................................................ 19-2-1 Fuel system - pressure test ........................................................................................................... 19-2-2 Tank - drain ................................................................................................................................... 19-2-3 REPAIRS Filter - main .................................................................................................................................... 19-2-5 Vapour separator ........................................................................................................................... 19-2-6 Pump - fuel tank ............................................................................................................................. 19-2-7 Tank - fuel ....................................................................................................................................... 19-2-9 Filler neck ...................................................................................................................................... 19-2-13 Cover - tank module - LH ............................................................................................................... 19-2-15 COOLING SYSTEM - V8........................................................................... 26-2-1 ADJUSTMENTS Coolant - drain, flush & refill .......................................................................................................... 26-2-1 REPAIRS Coupling unit - viscous fan ............................................................................................................. 26-2-3 Manifold - coolant .......................................................................................................................... 26-2-4 Pipe(s) - coolant pump to coolant manifold ................................................................................... 26-2-6 Gasket - coolant gallery sealing plate ........................................................................................... 26-2-7 Radiator ......................................................................................................................................... 26-2-7 Thermostat ..................................................................................................................................... 26-2-8 Gasket - coolant pump ................................................................................................................... 26-2-9 MANIFOLD AND EXHAUST SYSTEM - V8 ............................................. 30-2-1 REPAIRS Exhaust system & mountings ........................................................................................................ 30-2-1 Front pipe ...................................................................................................................................... 30-2-3 Intermediate pipe ........................................................................................................................... 30-2-4 Tail pipe & silencer ........................................................................................................................ 30-2-5 Gasket(s) - inlet manifold .............................................................................................................. 30-2-6 Gasket(s) - exhaust manifold - RH ................................................................................................ 30-2-12 Gasket(s) - exhaust manifold - LH ................................................................................................. 30-2-14
CONTENTS CONTENTS 7 TRANSFER BOX ...................................................................................... 41-1 ADJUSTMENTS Drain and refill ................................................................................................................................. 41-1 REPAIRS Transfer gearbox - Td6 ................................................................................................................... 41-3 Transfer gearbox - V8 ..................................................................................................................... 41-6 Oil seal - input shaft ....................................................................................................................... 41-9 Oil seal - front output shaft ............................................................................................................ 41-10 Oil seal - rear output shaft ............................................................................................................ 41-11 Fuse - transfer gearbox - electronic control unit (ECU) .................................................................. 41-12 Damper - vibration - Td6 ................................................................................................................. 41-13 Electronic control unit (ECU) - transfer gearbox ............................................................................ 41-13 Actuator - ratio control .................................................................................................................... 41-14 AUTOMATIC TRANSMISSION - ZF 5HP24 ............................................. 44-2-1 ADJUSTMENTS Gearbox fluid - drain & refill ............................................................................................................ 44-2-1 Selector cable - check and adjust .................................................................................................. 44-2-2 REPAIRS Lever - gearshift selector assembly ............................................................................................... 44-2-3 Knob - selector lever ....................................................................................................................... 44-2-3 Rod/cable assembly - selector ....................................................................................................... 44-2-4 Switch - starter inhibitor ................................................................................................................. 44-2-5 Fluid seal - selector shaft ............................................................................................................... 44-2-6 Solenoid - shift ................................................................................................................................ 44-2-7 Electronic control unit (ECU) - Electronic automatic transmission (EAT) ....................................... 44-2-8 Harness - solenoid valve ................................................................................................................ 44-2-9 Pick up - speed sensor - countershaft ............................................................................................ 44-2-10 Fluid seal - torque converter .......................................................................................................... 44-2-11 Gearbox & converter ...................................................................................................................... 44-2-12 Gearbox/converter & transfer gearbox assembly - remove for access and refit ............................. 44-2-13 Fluid seal - rear ............................................................................................................................... 44-2-18 Gasket - fluid pan ............................................................................................................................ 44-2-18 Filter - fluid ..................................................................................................................................... 44-2-19 Fluid cooler ..................................................................................................................................... 44-2-20 Thermostat - fluid cooler ................................................................................................................ 44-2-21 Valve body assembly ..................................................................................................................... 44-2-21