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

							GENERAL INFORMATION
03-10
Locking Devices
General
Always replace locking devices with one of the same 
design.
Tab washers
Always release locking tabs and fit new locking 
washers. Do not re-use locking tabs.
Locking nuts
Always use a backing spanner when loosening or 
tightening locking nuts, brake and fuel pipe unions.
Roll pins
Always fit new roll pins of an interference fit in the 
hole.
Circlips
Always fit new circlips of the correct size for the 
groove.
Keys and keyways
Remove burrs from edges of keyways with a fine file 
and clean thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for 
refitting only if indistinguishable from new, as any 
indentation may indicate the onset of wear.Split pins
Always fit new split-pins of the correct size for the 
hole in the bolt or stud. 
						

							GENERAL INFORMATION
03-11
Screw Threads
General
Metric threads to ISO standards are used. 
Damaged nuts, bolts and screws must always be 
discarded. Cleaning damaged threads with a die or 
tap impairs the strength and fit of the threads and is 
not recommended.
Always ensure that replacement bolts are at least 
equal in strength to those replaced. Castellated nuts 
must not be loosened to accept a split-pin, except in 
recommended cases when this forms part of an 
adjustment.
Do not allow oil or grease to enter blind threaded 
holes. The hydraulic action on screwing in the bolt or 
stud could split the housing.
Always tighten a nut or bolt to the recommended 
torque figure. Damaged or corroded threads can 
affect the torque reading.
To check or re-tighten a bolt or screw to a specified 
torque figure, first loosen a quarter of a turn, then re-
tighten to the correct torque figure. 
Oil thread lightly before tightening to ensure a free 
running thread, except in the case of threads treated 
with sealant/lubricant, and self-locking nuts.
Bolt and Nut Identification
Bolt identification
A large number of the nuts and bolts used on New 
Range Rover must be discarded after removing or 
loosening them. Refer to the repair sections in this 
Manual for further information.
CAUTION: All rear suspension fixings must be 
replaced whenever they are removed.
An ISO metric bolt or screw made of steel and larger 
than 6 mm in diameter can be identified by either of 
the symbols ISO M or M embossed or indented on 
top of the bolt head.
In addition to marks identifying the manufacturer, the 
top of the bolt head is also marked with symbols 
indicating the strength grade, e.g. 8.8; 10.9; 12.9;  
14.9. As an alternative, some bolts and screws have 
the M and strength grade symbol stamped on the 
flats of the hexagon. 
						

							GENERAL INFORMATION
03-12
Encapsulated bolts and screws
Encapsulated bolts and screws have a micro-
encapsulated locking agent pre-applied to the 
thread. They are identified by a coloured section 
which extends 360° around the thread. The locking 
agent is released and activated by the assembly 
process and is then chemically cured to provide the 
locking action.
Unless a specific repair procedure states otherwise, 
encapsulated bolts may be re-used providing the 
threads are undamaged and the following procedure 
is adopted:
lRemove loose adhesive from the bolt and 
housing threads.
lEnsure threads are clean and free of oil and 
grease.
lApply an approved locking agent.
An encapsulated bolt may be replaced with a bolt of 
equivalent specification provided it is treated with an 
approved locking agent.Self-locking bolts and screws
Self-locking bolts and screws, i.e. nylon patched or 
trilobular thread can be re-used providing resistance 
can be felt when the locking portion enters the female 
thread.
Nylon patched bolts and screws have a locking agent 
pre-applied to the threads. They are identified by the 
presence of a coloured section of thread which 
extends for up to 180° around the thread.
Trilobular bolts (i.e. Powerlok) have a special thread 
form which creates a slight interference with the 
thread of the hole or nut into which it is screwed.
DO NOT  re-use self-locking fasteners in critical 
locations (e.g. engine bearings, flywheel). Always 
use the correct replacement self-locking nut, bolt or 
screw. 
DO NOT  fit non self-locking fasteners in applications 
where a self-locking nut, bolt or screw is specified. 
						

							GENERAL INFORMATION
03-13
Nut identification
A nut with an ISO metric thread is marked on one 
face or on one of the flats of the hexagon with the 
strength grade symbol 8, 12, or 14. Some nuts with a 
strength grade 4, 5 or 6 are also marked and some 
have the metric symbol M on the flat opposite the 
strength grade marking.
A clock face system is sometimes used as an 
alternative method of indicating the strength grade. 
The external chamfers or a face of the nut is marked 
in a position relative to the appropriate hour mark on 
a clock face to indicate the strength grade.
A dot is used to locate the 12 oclock position and a 
dash to indicate the strength grade. If the grade is 
above 12, two dots identify the 12 oclock position.
When tightening a slotted or castellated nut, never 
loosen it to insert a split pin except where 
recommended as part of an adjustment. If difficulty is 
experienced, alternative washers or nuts should be 
selected, or the washer thickness reduced.
Where bearing pre-load is involved, nuts should be 
tightened in accordance with special instructions.Self-locking nuts
Self-locking nuts, i.e. nylon insert or deferred thread 
nuts can be re-used providing resistance can be felt 
when the locking portion of the nut passes over the 
thread of the bolt or stud.
Where self-locking nuts have been removed, it is 
advisable to replace them with new ones of the same 
type.  
						

							GENERAL INFORMATION
03-14
Flexible Pipes and Hoses
General
When removing and installing flexible hydraulic pipes 
and hoses, ensure that the following practices are 
observed to ensure component serviceability.
lBefore removing any brake or power steering 
hose, clean end fittings and area surrounding 
them as thoroughly as possible.
lObtain appropriate plugs or caps before 
detaching hose end fittings, so that the ports can 
be immediately covered to prevent the ingress 
of dirt.
lClean hose externally and blow through with 
airline. Examine carefully for cracks, separation 
of plies, security of end fittings and external 
damage. Reject any faulty hoses.
lWhen refitting a hose, ensure that no 
unnecessary bends are introduced, and that 
hose is not twisted before or during tightening of 
union nuts.
lFit a cap to seal a hydraulic union and a plug to 
its socket after removal to prevent ingress of 
dirt.
lAbsolute cleanliness must be observed with 
hydraulic components at all times.
lAfter any work on hydraulic systems, carefully 
inspect for leaks underneath the vehicle while a 
second operator applies maximum brake 
pressure to the brakes (engine running) and 
operates the steering.Fuel system hoses
All fuel hoses are made up of two laminations, an 
armoured rubber outer sleeve and an inner viton 
core. If any of the fuel system hoses have been 
disconnected, it is imperative that the internal bore is 
inspected to ensure that the viton lining has not 
become separated from the armoured outer sleeve. 
A new hose must be fitted if separation is evident.
 Fuel system hose clips
Certain fuel system hoses are of the break-off head 
type, where a portion of the slot in the screw head 
shears off when the clip is tightened to a pre-
determined torque. These clips may be removed 
using a screwdriver and must be replaced with a new 
clip of the same type. Clips must be tightened until 
the portion of the slot shears off. Do not attempt to 
tighten clips by any other method. 
						

							GENERAL INFORMATION
03-15
Cooling system hoses
The following precautions MUST be followed to 
ensure that integrity of cooling hoses and their 
connections to system components are 
maintained.  
Hose orientation and connection
Correct orientation of cooling hoses is important in 
ensuring that the hose does not become fatigued or 
damaged through contact with adjacent 
components. Where timing marks are provided on 
the hose and corresponding connection, these must 
be used to ensure correct orientation. Hoses must be 
pushed fully onto their connection points. Usually, a 
moulded form on the stub pipe provides a positive 
indicator.
Hose clips
Markings are usually provided on the hose to indicate 
the correct clip position. If no markings are provided, 
position the clip directly behind the retaining lip at the 
end of the stub as shown. Worm drive clips should be 
oriented with the crimped side of the drive  housing 
facing towards the end of the hose, or the hose may 
become pinched between the clip and the stub pipe 
retaining lip.  Worm drive clips should be tightened to 
3 Nm (2 lbf.ft) unless otherwise stated. Ensure that 
hose clips do not foul adjacent components.
Oetiker clips may be removed by bending the tag 
(arrowed) and releasing the free end of the clip. Clips 
must not be re-used. When fitting new clips, ensure 
clip is correctly positioned on hose before tightening 
and ensure that when clip is tightened, the tag is 
located in longitudinal slot in free end of clip (arrowed 
in illustration). 
						

							GENERAL INFORMATION
03-16
Heat protection 
Always ensure that heatshields and protective 
sheathing are in good condition. Replace if damage 
is evident. Particular care must be taken when 
routing hoses close to hot engine components, such 
as the exhaust manifold and the Exhaust Gas 
Recirculation (EGR) pipe. Hoses will relax and 
deflect slightly when hot; ensure this movement is 
taken into account when routing and securing hoses.   Service Tools
Special service tools have been developed to 
facilitate removal, dismantling and assembly of 
mechanical components in a cost effective and time 
efficient manner. The use of such special tools also 
helps prevent the potential for damage to 
components. Service tools may be obtained from:
All orders and enquiries from the United Kingdom 
and European countries except Germany, Austria, 
Switzerland and Spain and countries not in the 
following list should be sent direct to :
SPX UK Ltd;
Genoa House,
Everdon Park,
Daventry,
Northants,
NN11 5YJ.
England,
( 00 44 (0) 1327 303467 / 303455
) 00 44 (0) 1327 706632
e-mail: [email protected]
Overseas orders for the following countries should 
be placed with the local SPX distributor.
Germany, Austria and Switzerland
SPX Europe GMBH,
Porchestrasse 4,
63512 Hainburg,
Germany
( 00 49 61829590
) 00 49 6182959299
Spain
SPX Iberica SA,
C/Francisco Aritio,
158 nave 72 (Nudo Oeste)
19004 Guadalajara,
Spain
( 00 34 949208381
) 00 34 949208327 
						

							GENERAL INFORMATION
03-17
North America
SPX Corporation,
665, Eisenhower Drive,
Owatonna,
MN 55060,
USA
( 00 18 772979110
) 00 18 005787375
Australia
SPX Australia,
28, Clayton Road,
Notting Hill,
Victoria 3168,
Australia
( 00 (61) 00395446222
) 00 (61) 00395445222
e-mail: [email protected]
Japan and East Asia
Jatek Ltd,
5 - 53, Minawacho 2-chome,
Kohoku-ku,
Yokohama,
Kanagawa 223-0051,
Japan
( 00 81 455627700
) 00 81 455627800
Rolling Road Testing
General
IMPORTANT: Use a four wheel rolling road for 
brake testing if possible.
Four wheel rolling road
Provided that front and rear rollers are rotating at 
identical speeds and that normal workshop safety 
standards are applied, there is no speed restriction 
during testing except any that may apply to the tyres.
CAUTION: Ensure that gearbox selector lever is 
at N, hill descent control is not selected and 
handbrake is released.
When checking brakes, run engine at idle speed to 
maintain servo vacuum.
Two wheel rolling road
If brake testing on a two wheel rolling road, then the 
following precautions must be taken:
lDisconnect propeller shaft from the transfer box 
shaft driving the axle whose wheels are NOT on 
the rolling road.
lNeutral selected in gearbox. 
						

							GENERAL INFORMATION
03-18
Fuel Handling Precautions
Fuel vapour is highly flammable and in confined 
spaces is also explosive and toxic. The vapour is 
heavier than air and will always fall to the lowest 
level. The vapour can  be easily distributed 
throughout a workshop by air currents; 
consequently, even a small spillage of fuel is 
potentially very dangerous.
The following information provides basic precautions 
which must be observed if fuel is to be handled 
safely. It also outlines other areas of risk which must 
not be ignored. This information is issued for basic 
guidance only, if in doubt consult your local Fire 
Officer.
General
Always have a fire extinguisher containing FOAM, 
CO
2, GAS or POWDER close at hand when handling 
or draining fuel or when dismantling fuel systems. 
Fire extinguishers should also be located in areas 
where fuel containers are stored.
Always disconnect the vehicle battery before 
carrying out dismantling or draining work on a fuel 
system.
CAUTION: To prevent damage to the navigation 
computer software, a waiting period of two 
minutes must elapse after the ignition is 
switched off before the battery leads are 
disconnected.
Whenever fuel is being handled, drained or stored, or 
when fuel systems are being  dismantled, all forms of 
ignition must be extinguished or removed; any 
leadlamps must be flameproof and kept clear of 
spillage.
WARNING: No one should be permitted to repair 
components associated with fuel without first 
having specialist training.
WARNING: Do not remove fuel system 
components while the vehicle is over a pit.
Fuel tank draining
Fuel tank draining should be carried out in 
accordance with the procedure outlined in the FUEL 
DELIVERY section of this manual and observing the 
following precautions.
WARNING: Fuel must not be extracted or drained 
from any vehicle while it is over a pit. Extraction 
or draining of fuel must be carried out in a well 
ventilated area.
The capacity of containers must be more than 
adequate for the amount of fuel to be extracted or 
drained. The container should be clearly marked 
with its contents and placed in a safe storage 
area which meets the requirements of local 
authority regulations.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet by 
a spring steel clip, the clip must be released before 
the fuel line is disconnected or the fuel tank is 
removed. This procedure will avoid the possibility of 
fumes in the fuel tank being ignited when the clip is 
released.
As an added precaution, fuel tanks should have a 
FUEL VAPOUR warning label attached to them as 
soon as they are removed from the vehicle.
Fuel tank repairs - plastic tank
No attempt should be made to repair a plastic fuel 
tank. If the structure of the tank is damaged, a new 
tank must be fitted.
Body repairs
Plastic fuel pipes are particularly susceptible to heat, 
even at relatively low temperature, and can be 
melted by heat conducted from some distance away. 
When body repairs involve the use of heat, all fuel 
pipes which run in the vicinity of the repair area must 
be removed, and the tank outlet plugged.
WARNING: If welding is to be carried out in the 
vicinity of the fuel tank, the fuel system must be 
drained and the tank removed before welding 
commences. 
						

							GENERAL INFORMATION
03-19
Electrical Precautions
General
The following guidelines are intended to ensure the 
safety of the operator while preventing damage to the 
electrical and electronic components fitted to the 
vehicle. Where necessary, specific precautions are 
detailed in the individual procedures of this manual.
Equipment
Prior to commencing any test procedure on the 
vehicle ensure that the relevant test equipment is 
working correctly and any harness or connectors are 
in good condition. It is particularly important to check 
the condition of the lead and plugs of mains operated 
equipment.
Polarity
Never reverse connect the vehicle battery and 
always ensure the correct polarity when connecting 
test equipment.
High voltage circuits
Whenever disconnecting live ht circuits always use 
insulated pliers and never allow the open end of the 
ht lead to contact other components, particularly  
ECUs. Exercise caution when measuring the voltage 
on the coil terminals while the engine is running, high 
voltage spikes can occur on these terminals.
WARNING: – VEHICLES FITTED WITH BI-XENON 
HEADLAMP BULBS:– The following precautions 
must be observed. Failure to comply may result 
in exposure to ultra violet rays, severe electric 
shock, burns or risk of explosion.
lSafety goggles and gloves must be worn.
lEnsure that headlamps are switched off before 
removing bulbs.
lDo not touch the glass portion of the bulb.
lOn no account should headlamps be switched 
on with the bulb removed from the headlamp.
lBulb testing may only be carried out with the 
bulb fitted in the headlamp.
lBulbs must be disposed of in accordance with 
local authority bye-laws.Connectors and harnesses 
The engine compartment of a vehicle is a particularly 
hostile environment for electrical components and 
connectors:
lAlways ensure electrically related items are dry 
and oil free before disconnecting and 
connecting test equipment.
lEnsure disconnected multiplugs and sensors 
are protected from being contaminated with oil, 
coolant or other solutions. Contamination could 
impair performance or result in catastrophic 
failure.
lNever force connectors apart using tools to 
prise apart or by pulling on the wiring harness.
lAlways ensure locking tabs are disengaged 
before disconnection, and match orientation to 
enable correct reconnection.
lEnsure that any protection (covers, insulation 
etc.) is replaced if disturbed.
Having confirmed a component to be faulty:
lSwitch off the ignition and disconnect the 
battery. 
lRemove the component and support the 
disconnected harness.
lWhen replacing the component keep oily hands 
away from electrical connection areas and push 
connectors home until any locking tabs fully 
engage.
Battery disconnection
It is imperative that the key is removed from the 
ignition before disconnecting the battery. A time of 2 
minutes must also elapse before disconnection. 
Failure to do so could result in: 
lNavigation computer hardware damage
lIncorrect fuel gauge reading
Before disconnecting the battery, disable the alarm 
system and switch off all electrical equipment. If the 
radio is to be serviced, ensure the security code has 
been deactivated. 
CAUTION: Never disconnect the battery with the 
ignition switched on.
CAUTION: To prevent damage to the navigation 
computer hardware, a waiting period of two 
minutes must elapse after the ignition is 
switched off before the battery leads are 
disconnected.
CAUTION: To prevent damage to electrical 
components, always disconnect the battery 
when working on the vehicles electrical system. 
The ground lead must be disconnected first and 
reconnected last.
CAUTION: Always ensure that battery leads are 
routed correctly and are not close to any 
potential chafing points.