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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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CONTENTS 8CONTENTS DRIVESHAFTS ......................................................................................... 47-1 REPAIRS Drive shaft - front - LH ................................................................................................................... 47-1 Drive shaft - front - RH .................................................................................................................. 47-4 Gaiter - bell & joint - outer - front .................................................................................................... 47-8 Gaiter - inner joint ........................................................................................................................... 47-9 Seal - drive shaft - front - RH ........................................................................................................ 47-10 Bearing driveshaft support ............................................................................................................ 47-14 O Ring - driveshaft housing ......................................................................................................... 47-15 Drive shaft - rear ............................................................................................................................ 47-15 Gaiter - bell & joint - outer - rear ..................................................................................................... 47-17 Gaiter - inner joint .......................................................................................................................... 47-18 Propeller shaft - front .................................................................................................................... 47-20 Propeller shaft - rear ...................................................................................................................... 47-21 Support bearing - rear ................................................................................................................... 47-23 FINAL DRIVE ............................................................................................ 51-1 ADJUSTMENTS Rear differential - drain and refill .................................................................................................... 51-1 REPAIRS Differential assembly ..................................................................................................................... 51-3 Gasket - cover - rear - differential .................................................................................................. 51-6 Bush - differential mounting - each ................................................................................................ 51-6 Bush - differential mounting - rear ................................................................................................. 51-8 Oil seal - pinion .............................................................................................................................. 51-10 Oil seal - differential housing ......................................................................................................... 51-12 FRONT DIFFERENTIAL ........................................................................... 54-1 ADJUSTMENTS Front differential - drain and refill ................................................................................................... 54-1 REPAIRS Differential assembly - Td6 ............................................................................................................ 54-3 Differential assembly - V8 .............................................................................................................. 54-6 Oil seal - differential housing ......................................................................................................... 54-9
CONTENTS CONTENTS 9 STEERING ................................................................................................ 57-1 ADJUSTMENTS Power assisted steering (PAS) system - bleed .............................................................................. 57-1 Front wheel alignment - check & adjust ......................................................................................... 57-2 Steering geometry ......................................................................................................................... 57-2 Power steering pressure test - Td6 ................................................................................................ 57-4 Power steering pressure test - V8 .................................................................................................. 57-5 REPAIRS Power steering rack - left hand drive - Td6 .................................................................................... 57-7 Power steering rack - left hand drive - V8 ....................................................................................... 57-10 Power steering rack - right hand drive - V8 .................................................................................... 57-14 Power steering rack - right hand drive - Td6 .................................................................................. 57-19 Oil cooler - power steering - Td6 .................................................................................................... 57-24 Oil cooler - power steering - V8 ..................................................................................................... 57-25 Pump - power steering - Td6 ......................................................................................................... 57-26 Pump - power steering - V8 ........................................................................................................... 57-28 Column assembly - inner & outer ................................................................................................... 57-29 Sensor- steering angle/column ...................................................................................................... 57-32 Nacelle - column - complete .......................................................................................................... 57-32 Switch - column adjustment - control ............................................................................................. 57-33 Ball joint - track rod ........................................................................................................................ 57-33 Steering wheel ............................................................................................................................... 57-34 Switch unit - steering wheel ........................................................................................................... 57-36 Electronic control unit (ECU) - heated steering wheel ................................................................... 57-36 FRONT SUSPENSION.............................................................................. 60-1 ADJUSTMENTS Air suspension system - depressurise and repressurise................................................................. 60-1 Calibrate - air suspension ............................................................................................................... 60-1 REPAIRS Anti-roll bar ..................................................................................................................................... 60-3 Link - anti roll bar .......................................................................................................................... 60-4 Ball joint - tie rod ............................................................................................................................. 60-5 Air spring assembly ....................................................................................................................... 60-7 Hub ............................................................................................................................................... 60-10 Bearings - hub ................................................................................................................................ 60-13 Lower arm ...................................................................................................................................... 60-15 Bush - lower arm ............................................................................................................................ 60-16 Height sensor ................................................................................................................................. 60-17 Tie rod ............................................................................................................................................ 60-18 Bushes - tie rods ............................................................................................................................. 60-20 Air reservoir .................................................................................................................................... 60-20 Electronic Control Unit (ECU) - air suspension ............................................................................... 60-22 Air supply unit ................................................................................................................................ 60-22 Valve block assembly .................................................................................................................... 60-23 Valve assembly - cross link ............................................................................................................. 60-25
CONTENTS 10 CONTENTS REAR SUSPENSION ................................................................................ 64-1 ADJUSTMENTS Suspension - depressurise and repressurise ................................................................................ 64-1 REPAIRS Hub ............................................................................................................................................... 64-3 Ball joint - upper ............................................................................................................................. 64-5 Ball joint - lower ............................................................................................................................. 64-6 Bearing(s) - hub ............................................................................................................................. 64-7 Air spring ........................................................................................................................................ 64-10 Damper .......................................................................................................................................... 64-11 Anti-roll bar .................................................................................................................................... 64-13 Tie rod ............................................................................................................................................ 64-14 Bushes - upper arm ....................................................................................................................... 64-15 Bushes - lower arm - front ............................................................................................................. 64-16 Bushes - lower arm - rear .............................................................................................................. 64-17 Link - anti roll bar .......................................................................................................................... 64-17 Arm assembly - lower .................................................................................................................... 64-18 Arm assembly - upper .................................................................................................................... 64-19 Bushes - rear subframe ................................................................................................................. 64-21 Height sensor ................................................................................................................................. 64-25 Valve assembly - cross link ............................................................................................................ 64-26 Valve - safety - air pressure ........................................................................................................... 64-27 BRAKES.................................................................................................... 70-1 ADJUSTMENTS Thickness and run out check - brake disc - front ........................................................................... 70-1 Thickness and run out check - brake disc - rear ............................................................................ 70-2 Brake system bleeding .................................................................................................................. 70-4 Handbrake adjustment ................................................................................................................... 70-5 REPAIRS Brake disc - front ............................................................................................................................ 70-7 Brake disc - rear ............................................................................................................................ 70-8 Pump - pre-charge ......................................................................................................................... 70-9 Reservoir - brake fluid .................................................................................................................... 70-10 Cylinder - master - tandem ............................................................................................................ 70-11 Pedal box ....................................................................................................................................... 70-12 Lever assembly - handbrake .......................................................................................................... 70-13 Cable - handbrake ......................................................................................................................... 70-14 Switch - handbrake warning .......................................................................................................... 70-16 Pads - front ................................................................................................................................... 70-16 Pads - rear .................................................................................................................................... 70-18 Sensor - pad wear - front ............................................................................................................... 70-19 Sensor - pad wear - rear ................................................................................................................ 70-20 Shoes - rear set ............................................................................................................................ 70-21 Servo assembly ............................................................................................................................. 70-22 Vacuum pump - Td6 ....................................................................................................................... 70-23 ABS Electronic control unit (ECU) ................................................................................................. 70-23 ABS sensor - front wheel .............................................................................................................. 70-24 ABS sensor - rear wheel ................................................................................................................ 70-25 ABS Modulator unit ........................................................................................................................ 70-26 Sensor - pressure - ABS modulator ............................................................................................... 70-27 Sensor - dynamic stability control (DSC) ....................................................................................... 70-28
CONTENTS CONTENTS 11 RESTRAINT SYSTEMS ............................................................................ 75-1 REPAIRS Seat belt - front .............................................................................................................................. 75-1 Seat belt - centre - rear .................................................................................................................. 75-2 Seat belt - rear ............................................................................................................................... 75-4 Pre-tensioner - front seat belt ......................................................................................................... 75-5 Airbag module - steering wheel ...................................................................................................... 75-6 Airbag module - passenger ............................................................................................................ 75-7 Airbag module - head - rear ........................................................................................................... 75-8 Crash sensor - side ........................................................................................................................ 75-9 Battery - disconnect unit (SRS) ...................................................................................................... 75-10 Rotary coupler ................................................................................................................................ 75-11 Airbag module - side impact - front door ......................................................................................... 75-12 Airbag module - head - front ......................................................................................................... 75-13 Diagnostic control unit (DCU) ........................................................................................................ 75-15 Pre-tensioner - seat belt - front - deployment - in vehicle .............................................................. 75-17 Pre-tensioner - front seat belt - deployment - off vehicle ............................................................... 75-18 Airbag module - steering wheel - deployment - off vehicle ............................................................ 75-20 Airbag module - passenger - deployment - in vehicle ..................................................................... 75-22 Airbag module - passenger - deployment - off vehicle .................................................................... 75-24 Battery - disconnect unit (SRS) - deployment - in vehicle .............................................................. 75-26 Battery - disconnect (SRS) - deployment - off vehicle ................................................................... 75-27 Airbag module - side impact front door - deployment - in vehicle .................................................. 75-29 Airbag module - side impact - front door - deployment - off vehicle ............................................... 75-31 Airbag module - head - front - deployment - in vehicle ................................................................... 75-33 Airbag module - head - front - deployment - off vehicle .................................................................. 75-34 Airbag module - head - rear - deployment - in vehicle .................................................................... 75-36 Airbag module - head - rear - deployment - off vehicle .................................................................. 75-37
CONTENTS 12 CONTENTS DOORS...................................................................................................... 76-1-1 ADJUSTMENTS Tailgate lower - adjust on striker ..................................................................................................... 76-1-1 Tailgate upper - adjust on striker(s) ................................................................................................ 76-1-1 REPAIRS Glass - front door ........................................................................................................................... 76-1-3 Glass - rear door ............................................................................................................................. 76-1-3 Quarter light - fixed - rear door ...................................................................................................... 76-1-4 Glass regulator - front door ............................................................................................................ 76-1-6 Glass regulator - rear door ............................................................................................................. 76-1-7 Seal - waist outer - front door ........................................................................................................ 76-1-7 Seal - waist inner - front door ......................................................................................................... 76-1-8 Trim casing - front door ................................................................................................................. 76-1-8 Trim casing - rear door ................................................................................................................. 76-1-11 Trim casing - tailgate upper ........................................................................................................... 76-1-13 Trim finisher - tailgate - upper ......................................................................................................... 76-1-13 Capping - front door arm rest ......................................................................................................... 76-1-14 Plastic sheet - front door ................................................................................................................. 76-1-14 Plastic sheet - rear door.................................................................................................................. 76-1-15 Finisher - door frame - front .......................................................................................................... 76-1-15 Finisher - upper - tailgate lower .................................................................................................... 76-1-16 Latch - front door ........................................................................................................................... 76-1-16 Latch - tailgate ............................................................................................................................... 76-1-17 Latch - outer - tailgate .................................................................................................................... 76-1-18 Finisher - front door ....................................................................................................................... 76-1-19 Finisher - rear door ........................................................................................................................ 76-1-19 Handle - outside - front door .......................................................................................................... 76-1-20 EXTERIOR FITTINGS ............................................................................... 76-2-1 REPAIRS Panel - extension - front wing ........................................................................................................ 76-2-1 Wing - front .................................................................................................................................... 76-2-2 Liner - front wheel arch ................................................................................................................. 76-2-3 Liner - rear wheel arch - single ...................................................................................................... 76-2-4 Spoiler - tailgate .............................................................................................................................. 76-2-4 Mirror glass - exterior ...................................................................................................................... 76-2-5 Motor - exterior mirror ................................................................................................................... 76-2-5 Mirror - exterior ............................................................................................................................... 76-2-6 Tow bar .......................................................................................................................................... 76-2-7 Undertray - front ............................................................................................................................ 76-2-8 Bumper armature - rear ................................................................................................................. 76-2-9 Bumper - assembly - front ........................................................................................................... 76-2-11 Bumper - rear ................................................................................................................................ 76-2-13 Extension - spoiler - front bumper .................................................................................................. 76-2-14 Finisher - sill ................................................................................................................................... 76-2-15 Finisher - E post ........................................................................................................................... 76-2-16 Side finisher - windscreen .............................................................................................................. 76-2-16 Lower finisher - windscreen ........................................................................................................... 76-2-17 Roof moulding................................................................................................................................. 76-2-18 Finisher - tailgate - lower ............................................................................................................... 76-2-18 Front grille ...................................................................................................................................... 76-2-19
CONTENTS CONTENTS 13 INTERIOR FITTINGS ................................................................................ 76-3-1 REPAIRS Sun visor ........................................................................................................................................ 76-3-1 Mirror - interior ............................................................................................................................... 76-3-1 Trim casing - rear quarter - lower ................................................................................................... 76-3-2 Foot rest finisher - LHD .................................................................................................................. 76-3-3 Trim finisher - A post - upper ....................................................................................................... 76-3-3 Trim finisher - A post - lower ......................................................................................................... 76-3-4 Trim finisher - B post - upper ....................................................................................................... 76-3-4 Trim finisher - D post - upper ....................................................................................................... 76-3-5 Trim finisher - D post - lower ........................................................................................................ 76-3-5 Trim finisher - E post .................................................................................................................... 76-3-6 Centre console ................................................................................................................................ 76-3-6 Console - headlining - front ........................................................................................................... 76-3-8 Finisher - console .......................................................................................................................... 76-3-9 Console - headlining - rear ............................................................................................................. 76-3-10 Cover - automatic transmission selector ........................................................................................ 76-3-11 Closing panel - centre console ........................................................................................................ 76-3-11 Switch panel - air suspension ....................................................................................................... 76-3-12 Top rail - fascia .............................................................................................................................. 76-3-12 Shroud - lower - fascia ................................................................................................................... 76-3-13 Closing panel - fascia end .............................................................................................................. 76-3-14 Finisher - upper - drivers side ........................................................................................................ 76-3-15 Finisher - upper - passengers side ............................................................................................... 76-3-16 Finisher - lower - passengers side ................................................................................................. 76-3-17 Finisher - lower - drivers side ......................................................................................................... 76-3-17 Fascia - carrier ............................................................................................................................... 76-3-18 Fascia - remove for access & refit ................................................................................................. 76-3-21 Closing panel - passenger side ...................................................................................................... 76-3-29 Closing panel - drivers side .......................................................................................................... 76-3-30 Carpet - front .................................................................................................................................. 76-3-30 Retainer - front carpet .................................................................................................................... 76-3-31 Finisher - tailgate carpet ................................................................................................................ 76-3-31 Glove box ....................................................................................................................................... 76-3-32 Latch - glove box ............................................................................................................................ 76-3-33 Handle - grab ................................................................................................................................. 76-3-34 Headlining ...................................................................................................................................... 76-3-34 SCREENS ................................................................................................. 76-4-1 REPAIRS Glass - tailgate upper ...................................................................................................................... 76-4-1 Windscreen ..................................................................................................................................... 76-4-3 Glass - quarter light - rear ............................................................................................................... 76-4-6
CONTENTS 14 CONTENTS SEATS ....................................................................................................... 76-5-1 REPAIRS Arm rest - rear seat ........................................................................................................................ 76-5-1 Front seat ....................................................................................................................................... 76-5-2 Rear seat ........................................................................................................................................ 76-5-3 Cover - one piece - front seat cushion ........................................................................................... 76-5-3 Cover - one piece - front seat cushion - models with adjustable upper squab ............................... 76-5-6 Cover - rear seat cushion - RH ...................................................................................................... 76-5-9 Cover - rear seat cushion - LH........................................................................................................ 76-5-10 Finisher - rear seat squab .............................................................................................................. 76-5-11 Finisher - seat base rear ................................................................................................................ 76-5-12 Finisher - arm rest - rear seat - front ............................................................................................... 76-5-13 Backboard - front seat - models with adjustable upper squab ....................................................... 76-5-14 Bladder - lumbar support - front seat ............................................................................................. 76-5-16 Bladder - lumbar support - front seat - models with adjustable upper squab ................................. 76-5-18 Switch - lumbar support ................................................................................................................. 76-5-21 Motor - squab ................................................................................................................................. 76-5-22 Motor - fore & aft - front seat .......................................................................................................... 76-5-24 Motor - rise & fall - front seat ......................................................................................................... 76-5-25 Motor - rise & fall - head rest - front seat ....................................................................................... 76-5-25 Switch - front seat control .............................................................................................................. 76-5-27 Switch pack - seat memory ............................................................................................................ 76-5-28 Lever assembly - rear squab release ............................................................................................ 76-5-28 Latch - rear squab .......................................................................................................................... 76-5-29 Cover - squab - front seat - models with adjustable upper squab .................................................. 76-5-29 Cover - squab - front seat .............................................................................................................. 76-5-33 Cover - squab - rear seat - side - LH .............................................................................................. 76-5-35 Cover - squab - rear seat - RH ...................................................................................................... 76-5-37 Hinge - rear seat - side .................................................................................................................. 76-5-38 SUNROOF ................................................................................................. 76-6-1 ADJUSTMENT Sun roof - align to roof panel & adjust ........................................................................................... 76-6-1 REPAIRS Sunroof .......................................................................................................................................... 76-6-3 Motor - sunroof ............................................................................................................................. 76-6-4 BODY DIMENSIONS................................................................................. 77-1-1 BODY DIMENSIONS Dimensional Information ................................................................................................................. 77-1-1 Dimensional Illustrations ................................................................................................................. 77-1-2 BODY GAPS AND PROFILES Gap and Profile Measurements ...................................................................................................... 77-1-11
CONTENTS CONTENTS 15 PANEL REPAIRS ..................................................................................... 77-2-1 REPLACEMENT PANELS Serviceable Panels ......................................................................................................................... 77-2-1 Inner front end panels ..................................................................................................................... 77-2-2 Outer body side panels .................................................................................................................. 77-2-3 Body side inner ............................................................................................................................... 77-2-4 Sunroof drain tubes ........................................................................................................................ 77-2-5 Rear inner body side panels .......................................................................................................... 77-2-6 Roof assemblies ............................................................................................................................ 77-2-7 Rear end panels.............................................................................................................................. 77-2-8 Door assemblies ............................................................................................................................. 77-2-9 Door assemblies ............................................................................................................................. 77-2-10 WELDING PROCEDURES General Welding Precautions ......................................................................................................... 77-2-11 PROCEDURES Panel replacement procedure ......................................................................................................... 77-2-13 REPAIRS Front bulkhead assembly ............................................................................................................... 77-2-19 Bonnet locking platform .................................................................................................................. 77-2-20 Headlamp mounting panel .............................................................................................................. 77-2-20 Radiator protection bar ................................................................................................................... 77-2-21 Front sidemember end panel .......................................................................................................... 77-2-21 Front sidemember (front section) ................................................................................................... 77-2-22 Front sidemember assembly ........................................................................................................... 77-2-24 Valance outer .................................................................................................................................. 77-2-26 Valance outer extension ................................................................................................................. 77-2-26 Valance inner closing panel ............................................................................................................ 77-2-27 Valance inner assembly .................................................................................................................. 77-2-27 Valance inner reinforcement ........................................................................................................... 77-2-29 Valance inner assembly - front section ........................................................................................... 77-2-30 Body side panel - A post................................................................................................................ 77-2-30 A post reinforcement...................................................................................................................... 77-2-32 Body side panel - sill section........................................................................................................... 77-2-34 Body side panel - sill and B/C post section.................................................................................... 77-2-35 B/C post reinforcement .................................................................................................................. 77-2-36 Sill reinforcement ............................................................................................................................ 77-2-37 Body side panel - rear section ........................................................................................................ 77-2-38 Rear wheel arch reinforcement - upper .......................................................................................... 77-2-40 D post reinforcement ..................................................................................................................... 77-2-40 Body side - rear extension .............................................................................................................. 77-2-41 Tail lamp mounting panel ................................................................................................................ 77-2-41 Body rear - outer panel ................................................................................................................... 77-2-42 Body rear assembly ........................................................................................................................ 77-2-43 Spare wheel well ............................................................................................................................. 77-2-44 Rear floor extension ........................................................................................................................ 77-2-44 Floor longitudinal............................................................................................................................. 77-2-45 Roof assembly ................................................................................................................................ 77-2-46 Doors .............................................................................................................................................. 77-2-47 TIMES TIME SCHEDULES ........................................................................................................................ 77-2-49
CONTENTS 16 CONTENTS BODY SEALING MATERIALS ................................................................. 77-3-1 MATERIALS AND APPLICATIONS ........................................................................................................................................................ 77-3-1 APPROVED MATERIALS ........................................................................................................................................................ 77-3-3 APPLICATION EQUIPMENT Application Equipment .................................................................................................................... 77-3-5 CORROSION PREVENTION AND SEALING .......................................... 77-4-1 STRUCTURAL SEALING Structural adhesive on front sidemembers ..................................................................................... 77-4-1 Structural adhesive on front sidemembers ..................................................................................... 77-4-2 Structural adhesive on valance outer and body side panel ............................................................ 77-4-3 Structural adhesive on body side frame - inner .............................................................................. 77-4-4 Structural adhesive ......................................................................................................................... 77-4-4 SEALING Factory treatments .......................................................................................................................... 77-4-7 CAVITY WAX Cavity wax application areas and injection holes ........................................................................... 77-4-15 Front wing ....................................................................................................................................... 77-4-16 Body side ........................................................................................................................................ 77-4-17 Rear wheel arch.............................................................................................................................. 77-4-18 Rear end ......................................................................................................................................... 77-4-19 Cavity wax ...................................................................................................................................... 77-4-20 LEAK DETECTION Water Leaks.................................................................................................................................... 77-4-21 PAINTING.................................................................................................. 77-5-1 PANEL PROCEDURES Panel Preparation ........................................................................................................................... 77-5-1 PAINT PROCEDURES Paint preparation ............................................................................................................................ 77-5-3
CONTENTS CONTENTS 17 HEATING AND VENTILATION................................................................. 80-1 REPAIRS Controls - heater (ECU) .................................................................................................................. 80-1 Sensor - pollution detection .......................................................................................................... 80-2 Motor - windscreen air vent ............................................................................................................. 80-2 Fresh air vent - face level ............................................................................................................... 80-3 Ventilator(s) - centre ...................................................................................................................... 80-3 Filter - fresh air intake .................................................................................................................... 80-4 Plenum - air intake ......................................................................................................................... 80-4 Heater unit/HEVAC - remove for access & refit ............................................................................. 80-5 Motor assembly - select (air blend) control .................................................................................... 80-6 Motor assembly - fresh & recirculated air control - LH .................................................................... 80-7 Motor assembly - fresh & recirculated air control - RH .................................................................. 80-7 Motor - fan ...................................................................................................................................... 80-8 Resistor unit - fan motor - LHD ...................................................................................................... 80-9 Resistor unit - fan motor - RHD ...................................................................................................... 80-10 Motor - footwell air vent................................................................................................................... 80-11 Heater matrix ................................................................................................................................. 80-11 Fuel Burning Heater (FBH) - Td6 .................................................................................................... 80-13 Receiver - fuel burning heater (FBH) ............................................................................................. 80-14 Sensor - ambient temperature ........................................................................................................ 80-15 Fuel pump - Fuel Burning Heater (FBH) Td6 ................................................................................. 80-16 AIR CONDITIONING ................................................................................. 82-1 REFRIGERANT RECOVERY, RECYCLING AND RECHARGING Refrigerant recovery - recycling and recharge ............................................................................... 82-1 REPAIRS Drive belt - compressor - Td6 ......................................................................................................... 82-3 Drive belt - compressor - V8 ......................................................................................................... 82-3 Tensioner - compressor drive belt - Td6 ........................................................................................ 82-5 Tensioner - compressor drive belt - V8 ......................................................................................... 82-5 Compressor - Td6 .......................................................................................................................... 82-6 Compressor - V8 ............................................................................................................................ 82-8 Motor - condenser fan ................................................................................................................... 82-10 Condenser ..................................................................................................................................... 82-13 Drier desiccant bag ....................................................................................................................... 82-14 Sensor - refrigerant pressure ........................................................................................................ 82-16 Sensor - solar light - automatic temperature control ..................................................................... 82-17 Sensor - air temperature - automatic temperature control ............................................................. 82-17 Sensor - evaporator temperature - LHD ........................................................................................ 82-18 Sensor - evaporator temperature - RHD ........................................................................................ 82-18 Valve - thermostatic expansion (TXV) - LHD .................................................................................. 82-19 Valve - thermostatic expansion (TXV) - RHD.................................................................................. 82-21 Evaporator ..................................................................................................................................... 82-22