Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual

							INTRODUCTION
01-6
SLABS Self Levelling and Anti-Lock 
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft 
SPE Single Point Entry
sp.gr Specific gravity
SRO Service Repair Operation
SRS Supplementary Restraint System
std. Standard
synchro Synchronizer or synchromesh
TA Traffic Announcement
TDC Top Dead Centre
TMAP Temperature, Manifold Absolute 
Pressure
TMC Traffic Management Channel
TP Throttle Position
TP Throttle Position 
TV Torsional Vibration
TWC Three-way Catalyst
TXV Thermostatic Expansion Valve
UK United Kingdom
US United States
US galls/h US gallons per hour
V Volt
Var. Variable
VDOP Velocity Dilation Of Precision
VICS Vehicle Information 
Communications System
VIN Vehicle Identification Number
VIS Variable Intake System
VRS Variable Reluctance Sensor
VSS Vehicle Speed Signal
VCC Variable Camshaft Control
WWatt
WOT Wide Open Throttle 
						

							GENERAL INFORMATION
03-1
GENERAL INFORMATION
General Precautions
Dangerous substances
Modern vehicles contain many materials and liquids 
which if not handled with care can be hazardous to 
both personal health and the environment.
WARNING: Many liquids and other substances 
used in motor vehicles are poisonous and should 
under no circumstances be consumed and 
should, as far as possible, be kept from contact 
with the skin. These liquids and substances 
include acid, anti-freeze, asbestos, brake fluid, 
fuel, windscreen washer additives, lubricants, 
refrigerants and various adhesives.
Always read carefully the instructions printed on 
labels or stamped on components and obey them 
implicitly. Such instructions are included for 
reasons of your health and personal safety. 
Never disregard them.
Synthetic rubber
Many O rings, seals, hoses, flexible pipes and other 
similar items which appear  to be natural rubber, are 
in fact, made of synthetic materials called 
Fluoroelastomers.  Under normal operating 
conditions this material is safe and does not present 
a health hazard. However, if the material is damaged 
by fire or excessive heating, it can break down and 
produce highly corrosive Hydrofluoric acid.
Contact with Hydrofluoric acid can cause serious 
burns on contact with skin. If skin contact does occur:
lRemove any contaminated clothing 
immediately.
lIrrigate effected area of skin with a copious 
amount of cold water or limewater for 15 to 60 
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or overheated 
condition, handle with extreme caution and wear 
protective clothing (seamless industrial gloves, 
protective apron etc.).
Decontaminate and dispose of gloves immediately 
after use.
Lubricating oils
Avoid excessive skin contact with used lubricating 
oils and always adhere to the health protection 
precautions.
WARNING: Avoid excessive skin contact with 
used engine oil. Used engine oil contains 
potentially harmful contaminants which may 
cause skin cancer or other serious skin 
disorders.
WARNING: Avoid excessive skin contact with 
mineral oil. Mineral oils remove the natural fats 
from the skin, leading to dryness, irritation and 
dermatitis.
Health protection precautions
The following precautions should be observed at all 
times.
lWear protective clothing, including impervious 
gloves where practicable.
lAvoid prolonged and repeated contact with oils, 
particularly used engine oils. 
lDo not put oily rags in pockets. 
lAvoid contaminating clothes (particularly those 
next to the skin) with oil. 
lOveralls must be cleaned regularly. Discard 
heavily soiled clothing and oil impregnated 
footwear. 
lFirst aid treatment should be obtained 
immediately for open cuts and wounds. 
lApply barrier creams before each work period to 
help prevent lubricating oil from contaminating 
the skin.
lWash with soap and water to ensure all oil is 
removed (proprietary skin cleansers and nail 
brushes will help).
lUse moisturisers after cleaning; preparations 
containing lanolin help replace the skins natural 
oils which have been removed. 
lDo not use petrol/gasoline, kerosene, diesel 
fuel, oil, thinners or solvents for cleaning skin. 
lWhere practicable, degrease components prior 
to handling.
lIf skin disorders develop, obtain medical advice 
without delay.
lWear eye protection (e.g. goggles or face 
shield) if there is a risk of eye contamination. 
Eye wash facilities should be provided in close 
vicinity of the work area. 
						

							GENERAL INFORMATION
03-2
Safety Instructions
Whenever possible, use a lift or pit when working 
beneath vehicle, in preference to jacking. Chock 
wheels as well as applying parking brake.
Jacking
Always refer to Lifting and Towing Section of this 
manual, prior to jacking vehicle.
Always use the recommended jacking points.
Always ensure that any lifting apparatus has 
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior 
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle 
supported only by a jack. Always support the 
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc. 
around or on the work bench area. Always keep a 
clean and tidy work area.
Brake pads
Always fit the correct grade and specification of 
brake pads. When renewing brake pads, always 
replace as complete axle sets.Brake hydraulics
Observe the following recommendations when 
working on the brake system:
lAlways use two spanners when loosening or 
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are 
not kinked or twisted.
lFit brake pipes securely in their retaining clips 
and ensure that the pipe cannot contact a 
potential chafing point.
lContainers used for brake fluid must be kept 
absolutely clean.
lDo not store brake fluid in an unsealed 
container, it will absorb water and in this 
condition would be dangerous to use due to a 
lowering of its boiling point.
lDo not allow brake fluid to be contaminated with 
mineral oil, or put new brake fluid in a container 
which has previously contained mineral oil.
lDo not re-use brake fluid removed from the 
system.
lAlways use clean brake fluid or a recommended 
alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses, 
immediately fit suitable blanking caps or plugs to 
prevent the ingress of dirt.
lOnly use the correct brake fittings with 
compatible threads.
lObserve absolute cleanliness when working 
with hydraulic components.
Cooling system caps and plugs
Extreme care is necessary when removing 
expansion tank caps and coolant drain or bleed 
screws when the engine is hot, especially if it is 
overheated. To avoid the possibility of scalding, 
allow the engine to cool before attempting removal.
Air suspension
Whenever working on the air suspension system, 
suitable eye protection must always be worn. 
						

							GENERAL INFORMATION
03-3
Environmental Precautions
General
This section provides general information  which  can 
help to reduce the environmental  impacts from the 
activities carried out in workshops.
Emissions to air  
Many of the activities that are carried out in 
workshops emit gases and fumes which contribute to 
global warming, depletion of the ozone layer and/or 
the formation of  photochemical smog at ground 
level. By considering how the workshop activities are 
carried out,  these gases and fumes can be 
minimised, thus reducing the impact on the 
environment.
Exhaust fumes
Running car engines is an essential part of workshop 
activities and exhaust fumes need to be  ventilated to 
atmosphere.  However, the amount of time engines 
are running and the position of the  vehicle should be 
carefully considered at all times, to reduce the 
release of poisonous gases and minimise the 
inconvenience to people living nearby.
Solvents 
Some of the cleaning agents used are solvent based 
and will evaporate to atmosphere if used  carelessly, 
or if cans are left unsealed.  All solvent containers 
should be firmly closed when not  needed and 
solvent should be used sparingly. Suitable 
alternative materials may be available  to replace 
some of the commonly used solvents.  Similarly, 
many paints are solvent based and  the spray should 
be minimised to reduce solvent emissions.  
Refrigerant
It is illegal to release any refrigerants into the 
atmosphere. Discharge and replacement of these  
materials from air conditioning units should only be 
carried out using the correct equipment.  
Checklist 
Always adhere to the following.
Engines:
lDont leave engines running unnecessarily;
lMinimise testing times and check where the 
exhaust fumes are being blown.  Materials: 
lKeep lids on containers of solvents; 
lOnly use the minimum quantity; 
lConsider alternative materials;
lMinimise over-spray when painting. 
Gases:
lUse the correct equipment for collecting 
refrigerants;
lDont burn rubbish on site. 
Discharges to water
Most sites will have two systems for discharging 
water: storm drains and foul drains. Storm drains 
should only receive clean water, foul drains will take 
dirty water.     
The foul drain will accept many of the normal waste 
waters such as washing water, detergents  and 
domestic type wastes, but oil, petrol, solvent, acids, 
hydraulic oil, antifreeze and other such  substances 
should never be poured down the drain.  If in any 
doubt speak to the Water  Company first. 
Every precaution must be taken to prevent spillage of 
oil, fuel, solvents etc. reaching the drains.   All 
handling of such materials must take place well away 
from the drains and preferably in an  area with a kerb 
or wall around it, to prevent discharge into the drain. 
If a spillage occurs it  should be soaked up 
immediately.  Having a spill kit available will make 
this easier. 
Additional precautions 
Check whether the surface water drains are 
connected to an oil water separator, this could  
reduce the pollution if an incident was to occur. Oil 
water separators do need regular maintenance to  
ensure effectiveness.   
						

							GENERAL INFORMATION
03-4
Checklist
Always adhere to the following.
Disposal:
lNever pour anything down a drain without first 
checking  that it is environmentally safe to do so, 
and that it does not contravene any local 
regulations or bye-laws;
l Have oil traps emptied regularly.
Spillage prevention:
lStore liquids in a walled area;
lMake sure that taps on liquid containers are 
secure and cannot be accidentally turned on;
lProtect bulk storage tanks from vandalism by 
locking the valves;
lTransfer liquids from one container to another in 
an area away from open drains;
lEnsure lids are replaced securely on containers;
lHave spill kits available near to points of storage 
and handling of liquids.
Spill kits
Special materials are available to absorb a number of 
different substances.   They can be in granular form, 
ready to use and bought in convenient  containers for 
storage.  Disposal of used spill-absorbing material is 
dealt with in Waste Management section.
Land contamination 
Oils, fuels and solvents etc. can contaminate any soil 
that they are allowed to contact.  Such materials 
should never be disposed of by pouring onto soil and  
every precaution must be taken to prevent spillage 
reaching soil. Waste materials stored on open 
ground could also leak, or have polluting substances 
washed  off them that would contaminate the land. 
Always store these materials in suitable skips or  
other similarly robust containers.  
Checklist 
Always adhere to the following.
lDont pour or spill anything onto the soil or bare 
ground;
lDont store waste materials on bare ground, see 
Spillage prevention list.
Legal compliance  
Some sites may have a discharge consent for 
effluent discharge to the foul drain for a car  wash etc. 
It is important to know what materials are allowed in 
the drain and to check the  results of any monitoring 
carried out by the Water Company. Where paint-spraying operations are carried out it 
may be necessary to apply to the Local  Authority for 
an air emissions licence to operate the plant.  If such 
a licence is in operation, additional precautions will 
be necessary to comply with the requirements, and 
the results of  any air quality monitoring must be 
checked regularly.  
Checklist
Always adhere to the following.
lKnow what legal consents and licences apply to 
the operations;
lCheck that the emissions and discharges 
comply with legal requirements.
Local issues  
A number of environmental issues will be of 
particular concern to residents and other  neighbours 
close to the site.  The sensitivity of these issues will 
depend on the proximity of the site and the layout 
and amount of activity carried on at the site.
 Noise is a major concern and therefore  
consideration should be given to the time spent  
carrying out noisy activities and the location of those 
activities that can cause excessive noise.   
Car alarm testing, panel beating, hammering and 
other such noisy activities should, whenever 
possible, be carried  out  indoors with doors and 
windows shut or as far away from houses as  
possible.
Running vehicle engines may  be an outside activity 
which could cause nuisance to  neighbours because 
of both noise and smell.
Be sensitive to the time of day when these  activities 
are carried out and minimise the  time of the noisy 
operation, particularly in  the early morning and late 
evening. 
Another local concern will be the smell from the 
various materials used.  Using less solvent,  paint 
and petrol could help prevent this annoyance.
Local residents and other business users will also be 
concerned about traffic congestion, noise  and 
exhaust fumes, be sensitive to these concerns and 
try to minimise inconvenience from  deliveries, 
customers and servicing operations. 
						

							GENERAL INFORMATION
03-5
Checklist
Always adhere to the following.
lIdentify where the neighbours who are likely to 
be affected are situated;
lMinimise noise, smells and traffic nuisance;
lPrevent litter by putting waste in the correct  
containers;
lHave waste skips emptied regularly.
Use of resource 
Another environmental concern is the waste of 
materials and energy that can occur in day to  day 
activities.
Electricity for heating, lighting and compressed air 
uses resources and releases pollution during its 
generation.
Fuel used for heating, running cars or vans and 
mobile plant  is another limited resource which  
consumes large amounts of energy during its 
extraction and refining processes.
Water has to be cleaned, piped to site and disposed 
of; all of which creates more potential pollution.
Oil, spares, paint etc., have all produced pollution in 
the process of manufacture and they become a  
waste disposal problem if discarded.
Checklist
Always adhere to the following.
Electricity and heating:
lKeep doors and windows closed in the winter;
lSwitch off machinery or lights when not needed;
lUse energy efficient heating systems;
lSwitch off computers and photocopiers when 
not needed.
Fuel:
lDont run engines unnecessarily;
lThink about whether journeys are necessary 
and drive to conserve fuel.
Water:
lDont leave taps and hose pipes running;
lMend leaks quickly, dont be wasteful.
Compressed air:
lDont leave valves open;
lMend leaks quickly;
lDont leave the compressor running when not 
needed.
Use of environmentally damaging materials:
lCheck whether a less toxic material is available.Handling and storage of materials: 
lHave the correct facilities available for handling 
liquids to prevent spillage and wastage as  listed 
above;
lProvide suitable locations for storage to prevent 
frost damage or other  deterioration.
Waste Management 
One of the major ways that pollution can be reduced 
is by the careful handling, storage and  disposal of all 
waste materials that occur on sites. Legislation  
makes it illegal to dispose of waste materials other 
than to licensed  waste carriers and disposal sites.  
This means that it is necessary to not only know what 
the  waste materials are, but also to have the 
necessary documentation and licenses.
Handling and storage of waste
Ensure that waste materials are not poured down the 
drain or onto soils. They should be stored in such a 
way as to prevent the escape of the material to land, 
water or air.
They must also be segregated into  different types of 
waste e.g. oil, metals, batteries, used vehicle 
components. This will prevent any reaction between 
different materials and assist in disposal.
Disposal of waste
Disposal of waste materials must only be to waste 
carriers who are licensed to carry  those particular 
waste materials and all the necessary 
documentation must be completed.   The waste 
carrier is responsible for ensuring that the waste is 
taken to the correct  disposal sites. 
						

							GENERAL INFORMATION
03-6
Dispose of waste in accordance with the following 
guidelines.
lFuel, hydraulic fluid, anti-freeze and oil: keep 
separate and dispose of to specialist  contractor. 
lRefrigerant: collect in specialist equipment and 
reuse.
lDetergents: safe to pour down the foul drain if 
diluted.
lPaint, thinners: keep separate and dispose of 
to specialist contractor.
lComponents: send back to supplier for 
refurbishment, or disassemble and reuse any 
suitable parts. Dispose of the remainder in 
ordinary waste.
lSmall parts: reuse any suitable parts, dispose 
of the remainder in ordinary waste.
lMetals: can be sold if kept separate from 
general waste.
lTyres: keep separate and dispose of to 
specialist contractor.
lPackaging: compact as much as possible and 
dispose of in ordinary waste.
lAsbestos-containing: keep separate and 
dispose  of to specialist contractor.
lOily and fuel wastes (e.g. rags, used spill kit 
material): keep separate and dispose of to 
specialist contractor.
lAir filters: keep separate and dispose of to 
specialist contractor.
lRubber/plastics: dispose of in ordinary waste.
lHoses: dispose of in ordinary waste.
lBatteries: keep separate and dispose of to 
specialist contractor.
lAirbags  - explosives: keep separate and 
dispose of to specialist contractor.
lElectrical components: send back to supplier 
for refurbishment, or disassemble and reuse 
any suitable parts. Dispose of the remainder in 
ordinary waste.
lElectronic components: send back to supplier 
for refurbishment, or disassemble and reuse 
any suitable parts. Dispose of the remainder in 
ordinary waste.
lCatalysts: can be sold if kept separate from 
general waste 
lUsed spill-absorbing material: keep separate 
and dispose of to specialist contractor.
lOffice waste: recycle paper and toner and ink 
cartridges, dispose of the remainder in ordinary 
waste.
General Fitting Instructions
Component removal
Whenever possible, clean components and 
surrounding area before removal. 
lBlank off openings exposed by component 
removal. 
lImmediately seal fuel, oil or hydraulic lines when 
apertures are exposed; use plastic caps or 
plugs to prevent loss of fluid and ingress of dirt. 
lClose the open ends of oilways exposed by 
component removal with tapered hardwood 
plugs or conspicuous plastic plugs. 
lImmediately a component is removed, place it in 
a suitable container; use a separate container 
for each component and its associated parts. 
lClean bench and provide marking materials, 
labels and containers before dismantling a 
component.  
Dismantling 
Observe scrupulous cleanliness when dismantling 
components,  particularly when brake, fuel or 
hydraulic system parts are being worked on. A 
particle of dirt or a cloth fragment could cause a 
serious malfunction if trapped in these systems.
lBlow out all tapped holes, crevices, oilways and 
fluid passages with an air line. Ensure that any 
O rings used for sealing are correctly replaced 
or renewed, if disturbed during the process.
lUse marking ink to identify mating parts and 
ensure correct reassembly. Do not use a centre 
punch or scriber to mark parts, they could 
initiate cracks or distortion in marked 
components.
lWire together mating parts where necessary to 
prevent accidental interchange (e.g. roller 
bearing components).
lWire labels on to all parts which are to be 
renewed, and to parts requiring further 
inspection before being passed for reassembly; 
place these parts in separate containers from 
those containing parts for rebuild.
lDo not discard a part due for renewal until after 
comparing it with a new part, to ensure that its 
correct replacement has been obtained.
Cleaning components
Always use the recommended cleaning agent or 
equivalent. Ensure that adequate ventilation is 
provided when volatile degreasing agents are being 
used. Do not use degreasing equipment for 
components containing items which could be 
damaged by the use of this process. 
						

							GENERAL INFORMATION
03-7
General inspection
All components should be inspected for wear or 
damage before being reassembled.
lNever inspect a component for wear or 
dimensional check unless it is absolutely clean; 
a slight smear of grease can conceal an 
incipient failure.
lWhen a component is to be checked 
dimensionally against recommended values, 
use the appropriate measuring equipment 
(surface plates, micrometers, dial gauges etc.). 
Ensure the measuring equipment is calibrated 
and in good serviceable condition. 
lReject a component if its dimensions are 
outside the specified tolerances, or if it appears 
to be damaged.
lA part may be refitted if its critical dimension is 
exactly to its tolerance limit and it appears to be 
in satisfactory condition. Use Plastigauge 12 
Type PG-1 for checking bearing surface 
clearances.
Ball and Roller Bearings
General
When removing and installing bearings, ensure that 
the following practices are observed to ensure 
component serviceability.
lRemove all traces of lubricant from bearing 
under inspection by cleaning with a suitable 
degreasant; maintain absolute cleanliness 
throughout operations.
lConduct a visual inspection for markings on 
rolling elements, raceways, outer surface of 
outer rings or inner surface of inner rings. Reject 
any bearings found to be marked, since marking 
in these areas indicates onset of wear.
lHold inner race of bearing between finger and 
thumb of one hand and spin outer race to check 
that it revolves absolutely smoothly. Repeat, 
holding outer race and spinning inner race.
lRotate outer ring gently with a reciprocating 
motion, while holding inner ring; feel for any 
check or obstruction to rotation. Reject bearing 
if action is not perfectly smooth.
lLubricate bearing with generous amounts of 
lubricant appropriate to installation.
lInspect shaft and bearing housing for 
discoloration or other markings which indicate 
movement between bearing and seatings.
lEnsure that shaft and housing are clean and 
free from burrs before fitting bearing.
lIf one bearing of a pair shows an imperfection, it 
is advisable to replace both with new bearings; 
an exception could be if the faulty bearing had 
covered a low mileage, and it can be 
established that damage is confined to only one 
bearing.
lNever refit a ball or roller bearing without first 
ensuring that it is in a fully serviceable condition.
lWhen hub bearings are removed or displaced, 
new bearings must be fitted; do not attempt to 
refit the old hub bearings. 
						

							GENERAL INFORMATION
03-8
lWhen fitting a bearing to a shaft, only apply 
force to the inner ring of the bearing. When 
fitting a bearing into a housing, only apply force 
to the outer ring of the bearing.
lIn the case of grease lubricated bearings (e.g. 
hub bearings) fill the space between bearing 
and outer seal with the recommended grade of 
grease before fitting seal.
lAlways mark components of separable bearings 
(e.g. taper roller bearings) when dismantling, to 
ensure correct reassembly. Never fit new rollers 
in a used outer ring; always fit a complete new 
bearing assembly.
Oil Seals
General
Always renew oil seals which have been removed 
from their working location (whether as an individual 
component or as part of an assembly). NEVER use 
a seal which has been improperly stored or handled, 
such as hung on a hook or nail.
lCarefully examine seal before fitting to ensure 
that it is clean and undamaged.
lEnsure the surface on which the new seal is to 
run is free of burrs or scratches. Renew the 
component if the original sealing surface cannot 
be completely restored.
lProtect the seal from any surface which it has to 
pass when being fitted. Use a protective sleeve 
or tape to cover the relevant surface.
lLubricate the sealing lips with a recommended 
lubricant before use to prevent damage during 
initial use. On dual lipped seals, smear the area 
between the lips with grease.
lIf a seal spring is provided, ensure that it is fitted 
correctly. Place lip of seal towards fluid to be 
sealed and slide into position on shaft. Use 
fitting sleeve where possible to protect sealing 
lip from damage by sharp corners, threads or 
splines. If a fitting sleeve is not available, use 
plastic tube or tape to prevent damage to the 
sealing lip.
lGrease outside diameter of seal, place square 
to housing recess and press into position using 
great care, and if possible a bell piece to 
ensure that seal is not tilted. In some cases it 
may be preferable to fit seal to housing before 
fitting to shaft. Never let weight of unsupported 
shaft rest in seal. 
						

							GENERAL INFORMATION
03-9
lUse the recommended service tool to fit an oil 
seal. If the correct service tool is not available, 
use a suitable tube approximately 0.4 mm 
(0.015 in.) smaller than the outside diameter of 
the seal. Use a hammer VERY GENTLY  on 
drift, if a suitable press is not  available.
lPress or drift the seal in to the depth of its 
housing with the sealing lip facing the lubricant 
to be retained if the housing is shouldered, or 
flush with the face of the housing where no 
shoulder is provided. Ensure that the seal does 
not enter the housing in a tilted position. 
Joints and Joint Faces
General
Fit joints dry unless specified otherwise.
lAlways use the correct gaskets as specified.
lWhen jointing compound is used, apply in a thin 
uniform film to metal surfaces; take care to 
prevent jointing compound from entering 
oilways, pipes or blind tapped holes.
lIf gaskets and/or jointing compound is 
recommended for use; remove all traces of old 
jointing material prior to reassembly. Do not use 
a tool which will damage the joint faces and 
smooth out any scratches or burrs using an oil 
stone. Do not allow dirt or jointing material to 
enter any tapped holes or enclosed parts.
lPrior to reassembly, blow through any pipes, 
channels or crevices with compressed air.