Discovery Series II

Workshop Manual

Discovery Series II WORKSHOP MANUAL - 1999MY ON

Publication Part No. VDR 100330 NAS (6) Land Rover 2003All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission from Land Rover.

CONTENTSINTRODUCTION ...................................................................................... 01-1How To Use This Manual................................................................................................................ Repairs and Replacements............................................................................................................. Specifications .................................................................................................................................. Abbreviations and Symbols ............................................................................................................ 01-1 01-2 01-2 01-3

GENERAL INFORMATION ...................................................................... 03-1General Precautions ....................................................................................................................... Safety Instructions .......................................................................................................................... Environmental Precautions ............................................................................................................. General Fitting Instructions ............................................................................................................. Ball and Roller Bearings ................................................................................................................. Oil Seals.......................................................................................................................................... Joints and Joint Faces .................................................................................................................... Locking Devices .............................................................................................................................. Screw Threads ................................................................................................................................ Bolt and Nut Identification ............................................................................................................... Flexible Pipes and Hoses ............................................................................................................... Rolling Road Testing....................................................................................................................... Fuel Handling Precautions .............................................................................................................. Electrical Precautions ..................................................................................................................... Supplementary Restraint System Precautions ............................................................................... SRS Component Replacement Policy ............................................................................................ Air Conditioning System Precautions.............................................................................................. Air Conditioning Compressor Replacement .................................................................................... Body Repairs .................................................................................................................................. 03-1 03-2 03-3 03-6 03-7 03-8 03-9 03-9 03-10 03-11 03-13 03-15 03-16 03-17 03-18 03-23 03-24 03-26 03-27

GENERAL DATA ..................................................................................... 04-1Engine - Td5 ................................................................................................................................... Engine - V8 ..................................................................................................................................... Fuel system - Td5 ........................................................................................................................... Fuel system - V8 ............................................................................................................................. Cooling system - Td5 ...................................................................................................................... Cooling system - V8 ........................................................................................................................ Clutch - Td5 .................................................................................................................................... Clutch - V8 ...................................................................................................................................... Manual gearbox - R380 .................................................................................................................. Transfer box - LT230SE.................................................................................................................. Automatic gearbox - ZF4HP22/24 .................................................................................................. Rear axle......................................................................................................................................... Front axle ........................................................................................................................................ Steering........................................................................................................................................... Suspension ..................................................................................................................................... Brakes ............................................................................................................................................. Wheels and tyres ............................................................................................................................ Air conditioning ............................................................................................................................... Electrical - Td5 ................................................................................................................................ Electrical - V8.................................................................................................................................. Dimensions ..................................................................................................................................... Weights ........................................................................................................................................... 04-1 04-4 04-8 04-8 04-9 04-10 04-11 04-12 04-13 04-14 04-15 04-16 04-16 04-17 04-18 04-19 04-20 04-21 04-22 04-22 04-23 04-24

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CONTENTSIDENTIFICATION NUMBERS .................................................................. 05-1Vehicle Identification Number ......................................................................................................... 05-1 Identification Number Locations ..................................................................................................... 05-3

TORQUE WRENCH SETTINGS .............................................................. 06-1Maintenance ................................................................................................................................... Engine Td5 ..................................................................................................................................... Engine V8 ....................................................................................................................................... Emission control - Td5 .................................................................................................................... Emission control - V8...................................................................................................................... Engine management system - Td5................................................................................................. Engine management system - V8................................................................................................... Cooling system ............................................................................................................................... Manifolds and exhaust systems - Td5 ............................................................................................ Manifolds and exhaust systems - V8 .............................................................................................. Clutch.............................................................................................................................................. Manual gearbox - R380 .................................................................................................................. Transfer box - LT230SE ................................................................................................................. Automatic gearbox - ZF4HP22 ....................................................................................................... Propeller shafts............................................................................................................................... Axles ............................................................................................................................................... Steering .......................................................................................................................................... Front suspension ............................................................................................................................ Rear suspension............................................................................................................................. Brakes............................................................................................................................................. Restraint systems ........................................................................................................................... Body................................................................................................................................................ Heating and air conditioning ........................................................................................................... Wipers and washers ....................................................................................................................... Electrical ......................................................................................................................................... 06-1 06-2 06-4 06-5 06-5 06-6 06-6 06-7 06-8 06-8 06-9 06-10 06-11 06-12 06-13 06-13 06-14 06-15 06-16 06-17 06-18 06-19 06-20 06-20 06-21

LIFTING AND TOWING ........................................................................... 08-1LIFTING .......................................................................................................................................... 08-1 TOWING ......................................................................................................................................... 08-2 TRANSPORTING ........................................................................................................................... 08-4

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1Capacities ....................................................................................................................................... Fluids .............................................................................................................................................. Anti-Freeze Concentration.............................................................................................................. Lubrication ...................................................................................................................................... Sealants.......................................................................................................................................... 09-1 09-2 09-2 09-3 09-4

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CONTENTSMAINTENANCE ........................................................................................ 10-1PROCEDURESV8 engine underbonnet view .......................................................................................................... Diesel underbonnet view................................................................................................................. Seats and seat belts ...................................................................................................................... Lamps, horns and warning indicators ............................................................................................. Wipers and washers ...................................................................................................................... Handbrake .................................................................................................................................. Alarm handset battery ..................................................................................................................... Road wheels ................................................................................................................................... Tyres .............................................................................................................................................. Brake pads, discs and calipers ....................................................................................................... Road wheel speed sensors............................................................................................................. Brake fluid ....................................................................................................................................... Fuel filter - diesel engine ................................................................................................................. Fuel filter sedimenter ...................................................................................................................... Road wheels ................................................................................................................................... Radiator/Intercooler ........................................................................................................................ Ambient air Temperature and pressure sensor .............................................................................. Doors, bonnet and fuel filler flap ..................................................................................................... Air suspension intake filter .............................................................................................................. Anti-freeze....................................................................................................................................... Cooling system ............................................................................................................................... Spark plugs - V8 engine.................................................................................................................. Air cleaner - V8 engine ................................................................................................................... Air cleaner and dump valve - diesel engine .................................................................................... Auxiliary drive belt ........................................................................................................................... Auxiliary drive belt - V8 engine ....................................................................................................... Auxiliary drive belt - diesel engine .................................................................................................. Fluid reservoirs ............................................................................................................................... Steering box .................................................................................................................................... Battery............................................................................................................................................. Intercooler - diesel engine............................................................................................................... Engine oil - V8 engine..................................................................................................................... Engine oil - diesel engine ................................................................................................................ Centrifuge rotor diesel engine ...................................................................................................... Engine oil filter - diesel engine ........................................................................................................ Engine oil filter V8 engine ............................................................................................................ Manual gearbox .............................................................................................................................. Automatic gearbox ......................................................................................................................... Transfer box .................................................................................................................................... Front and rear axle.......................................................................................................................... Propeller shafts ............................................................................................................................... Anti-roll bar links ............................................................................................................................. ACE actuators ................................................................................................................................. ACE filter ......................................................................................................................................... 10-1 10-2 10-3 10-5 10-5 10-6 10-6 10-6 10-6 10-6 10-7 10-7 10-7 10-7 10-8 10-8 10-8 10-8 10-9 10-9 10-9 10-10 10-10 10-10 10-11 10-11 10-11 10-12 10-13 10-13 10-14 10-14 10-15 10-15 10-16 10-16 10-17 10-18 10-19 10-20 10-20 10-22 10-23 10-23

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CONTENTSBrake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ Engine, gearbox, transfer box and axles ........................................................................................ Exhaust system .............................................................................................................................. Steering box and front suspension ................................................................................................. Steering rod ball joints ................................................................................................................... Dampers and SLS height sensors .................................................................................................. Front and rear axle suspension links .............................................................................................. Towing bracket ............................................................................................................................... Engine mountings - V8 engine........................................................................................................ Road/roller test ............................................................................................................................... 10-24 10-25 10-25 10-25 10-27 10-27 10-28 10-29 10-30 10-31

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CONTENTSENGINE - V8 ............................................................................................. 12-2-1DESCRIPTION AND OPERATIONV8 Engine ....................................................................................................................................... Cylinder head components ............................................................................................................. Cylinder block components ............................................................................................................. Description ...................................................................................................................................... 12-2-1 12-2-2 12-2-4 12-2-6

ADJUSTMENTSEngine oil pressure check .............................................................................................................. 12-2-11

REPAIRSSeal - crankshaft - rear .................................................................................................................. Gasket - cylinder head - LH ........................................................................................................... Gasket - cylinder head - RH............................................................................................................ Gasket - rocker cover - LH ............................................................................................................ Gasket - rocker cover - RH ............................................................................................................ Mounting - front - LH ...................................................................................................................... Mounting - front - RH ..................................................................................................................... Mounting - rear - LH ....................................................................................................................... Mounting - rear - RH ...................................................................................................................... Engine assembly............................................................................................................................. Flywheel ........................................................................................................................................ Plate - drive - automatic ................................................................................................................ Ring gear - starter ......................................................................................................................... Filter - oil ....................................................................................................................................... Strainer - oil pick-up ...................................................................................................................... Pump - oil ...................................................................................................................................... Gasket - sump ................................................................................................................................ Switch - oil pressure ....................................................................................................................... Cooler - engine oil .......................................................................................................................... Gasket - timing gear cover ............................................................................................................ Seal - cover - timing gears ............................................................................................................ 12-2-13 12-2-14 12-2-16 12-2-19 12-2-20 12-2-22 12-2-23 12-2-24 12-2-25 12-2-26 12-2-31 12-2-32 12-2-34 12-2-35 12-2-35 12-2-36 12-2-37 12-2-39 12-2-39 12-2-41 12-2-43 12-2-45 12-2-48 12-2-49 12-2-50 12-2-52 12-2-53 12-2-54 12-2-55 12-2-56 12-2-58 12-2-59 12-2-61 12-2-63 12-2-67 12-2-72 12-2-73 12-2-77

OVERHAULGasket - inlet manifold ................................................................................................................... Gasket - exhaust manifold ............................................................................................................. Seal - crankshaft - rear - automatic models .................................................................................... Seal - crankshaft - rear - manual models ........................................................................................ Bearing - spigot - crankshaft .......................................................................................................... Gasket - engine sump .................................................................................................................... Strainer - oil pick-up ....................................................................................................................... Seal - timing gear cover ................................................................................................................. Gasket - timing gear cover ............................................................................................................. Timing chain and gears .................................................................................................................. Rocker shaft - overhaul ................................................................................................................. Gasket - cylinder head .................................................................................................................... Cylinder head - overhaul ................................................................................................................ Piston assemblies ........................................................................................................................... Bearings - connecting rods ............................................................................................................ Crankshaft and main bearings ........................................................................................................ Camshaft .......................................................................................................................................

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CONTENTSEMISSION CONTROL - V8....................................................................... 17-2-1DESCRIPTION AND OPERATIONCrankcase emission control system ............................................................................................... 17-2-1 Exhaust emission control................................................................................................................ 17-2-2 Evaporative emission system component layout............................................................................ 17-2-3 Evaporative emission system (with positive pressure leak detection) component layout (NAS only) 17-2-4 Evaporative emission system control diagram ............................................................................... 17-2-5 Secondary air injection system component layout.......................................................................... 17-2-6 Secondary air injection system control diagram ............................................................................. 17-2-8 Emission Control Systems.............................................................................................................. 17-2-9 Crankcase Emission Control System ............................................................................................. 17-2-10 Exhaust Emission Control System.................................................................................................. 17-2-11 Evaporative Emission Control System............................................................................................ 17-2-15 Secondary Air Injection System...................................................................................................... 17-2-26 Crankcase Emission Control Operation.......................................................................................... 17-2-34 Exhaust Emission Control Operation.............................................................................................. 17-2-35 Evaporative Emission Control Operation........................................................................................ 17-2-39 Secondary Air Injection System Operation ..................................................................................... 17-2-43 SAI System Fault Finding and Check Malfunctions........................................................................ 17-2-44

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

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CONTENTSENGINE MANAGEMENT SYSTEM - V8 .................................................. 18-2-1DESCRIPTION AND OPERATIONEngine management component location - Passenger compartment ............................................ Engine management component location - Engine compartment .................................................. Engine management block diagram ............................................................................................... Description - engine management .................................................................................................. Operation - engine management .................................................................................................... 18-2-1 18-2-2 18-2-4 18-2-6 18-2-49 18-2-61 18-2-62 18-2-63 18-2-74

DESCRIPTION AND OPERATIONCruise control component layout .................................................................................................... Cruise control block diagram .......................................................................................................... Description - cruise control ............................................................................................................. Operation - cruise control................................................................................................................

ADJUSTMENTSCable - throttle ............................................................................................................................. 18-2-77 Cable - cruise control .................................................................................................................... 18-2-77

REPAIRSSpark plugs .................................................................................................................................. Coil - ignition ................................................................................................................................. Engine control module (ECM) ......................................................................................................... Sensor - engine coolant temperature (ECT) ................................................................................ Sensor - crankshaft position (CKP) ............................................................................................... Sensor - radiator temperature ....................................................................................................... Sensor - camshaft position (CMP) ................................................................................................. Knock sensor (KS) .......................................................................................................................... Air cleaner assembly ..................................................................................................................... Element - air filter .......................................................................................................................... Cable - throttle ................................................................................................................................ Sensor - Mass Air Flow (MAF) ...................................................................................................... Throttle Body................................................................................................................................... Plenum chamber ............................................................................................................................. Sensor - throttle position (TP) ....................................................................................................... Valve - idle air control (IACV) ........................................................................................................ Injectors ......................................................................................................................................... Actuator - cruise control ................................................................................................................ Vacuum control unit - up to 03MY................................................................................................... Vacuum control unit - from 03MY ................................................................................................... Cable - cruise control ..................................................................................................................... Switch - cruise control (on/off) ........................................................................................................ Switch - cruise control (set/resume)............................................................................................... Switch - clutch pedal - cruise control ............................................................................................ ECU - Cruise control ..................................................................................................................... 18-2-79 18-2-80 18-2-81 18-2-82 18-2-83 18-2-84 18-2-84 18-2-85 18-2-86 18-2-87 18-2-88 18-2-89 18-2-90 18-2-91 18-2-91 18-2-92 18-2-92 18-2-94 18-2-94 18-2-95 18-2-96 18-2-96 18-2-97 18-2-97 18-2-98

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CONTENTSFUEL DELIVERY SYSTEM - V8 ............................................................... 19-2-1DESCRIPTION AND OPERATIONFuel delivery system ....................................................................................................................... Fuel tank and breather components (all except NAS) .................................................................... Fuel tank and breather components (NAS) .................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................ 19-2-1 19-2-2 19-2-3 19-2-4 19-2-10

ADJUSTMENTSFuel tank - drain.............................................................................................................................. 19-2-11

REPAIRSSwitch - inertia - fuel cut-off ............................................................................................................ Pump - fuel .................................................................................................................................... Tank - fuel ...................................................................................................................................... Filler tube - fuel ............................................................................................................................. Solenoid - fuel filler flap release...................................................................................................... Switch - fuel filler flap release - up to 03MY ................................................................................... Switch - fuel filler flap release - from 03MY .................................................................................... 19-2-13 19-2-13 19-2-15 19-2-16 19-2-17 19-2-17 19-2-18

COOLING SYSTEM - V8........................................................................... 26-2-1DESCRIPTION AND OPERATIONCooling system component layout.................................................................................................. Cooling system coolant flow ........................................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................ 26-2-2 26-2-4 26-2-6 26-2-10

ADJUSTMENTSDrain and refill................................................................................................................................. 26-2-13

REPAIRSFan - viscous .................................................................................................................................. Radiator ......................................................................................................................................... Thermostat...................................................................................................................................... Gasket - coolant pump .................................................................................................................. 26-2-15 26-2-15 26-2-18 26-2-19

MANIFOLDS AND EXHAUST SYSTEMS - V8......................................... 30-2-1DESCRIPTION AND OPERATIONExhaust manifold component layout............................................................................................... Inlet manifold component layout ..................................................................................................... Exhaust system component layout ................................................................................................. Description...................................................................................................................................... 30-2-1 30-2-2 30-2-4 30-2-5 30-2-7 30-2-8 30-2-9 30-2-9 30-2-10 30-2-10 30-2-14 30-2-15 30-2-18

REPAIRSFront pipe........................................................................................................................................ Intermediate pipe/silencer .............................................................................................................. Tail pipe .......................................................................................................................................... Heat shield - brake servo - Without Secondary Air Injection .......................................................... Heat shield - brake servo - With Secondary Air Injection .............................................................. Gasket - inlet manifold - lower ........................................................................................................ Gasket - exhaust manifold ........................................................................................................... Gasket - inlet manifold - upper - Without Secondary Air Injection .................................................. Gasket - inlet manifold - upper - With Secondary Air Injection .....................................................

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CONTENTSCLUTCH - V8 ............................................................................................ 33-2-1DESCRIPTION AND OPERATIONClutch components ......................................................................................................................... Hydraulic operation ......................................................................................................................... Description ...................................................................................................................................... Operation ........................................................................................................................................ 33-2-2 33-2-4 33-2-6 33-2-9

ADJUSTMENTSClutch hydraulic system - bleed ...................................................................................................... 33-2-11

REPAIRSClutch assembly ............................................................................................................................. Master cylinder................................................................................................................................ Bearing and lever - clutch release ................................................................................................ Slave cylinder.................................................................................................................................. 33-2-13 33-2-14 33-2-15 33-2-15

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CONTENTSMANUAL GEARBOX - R380 .................................................................... 37-1DESCRIPTION AND OPERATIONR380 gearbox ................................................................................................................................. Gearbox casings, gear change and oil pump ................................................................................ Selector shaft and forks, synchromesh assemblies and gear train ............................................... R380 gearbox cross section ........................................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................ 37-1 37-2 37-4 37-6 37-7 37-8

ADJUSTMENTSSpring - gear lever bias .................................................................................................................. 37-9

REPAIRSHousing - gear selector .................................................................................................................. Gearbox - V8 .................................................................................................................................. Gearbox - Diesel............................................................................................................................. Seal - gearbox mainshaft ............................................................................................................... Seal - input shaft ............................................................................................................................ Cooler - oil - gearbox - Diesel ......................................................................................................... Cooler - oil - gearbox - V8............................................................................................................... Switch - Reverse light ................................................................................................................... 37-11 37-12 37-16 37-20 37-21 37-23 37-24 37-25 37-27 37-32 37-34 37-35 37-38 37-41 37-41 37-42 37-43 37-44 37-46 37-47 37-48 37-50 37-51 37-52 37-53

OVERHAULShaft - output ................................................................................................................................. Synchroniser - gearbox - set ......................................................................................................... Fork - set - selector shaft .............................................................................................................. Shaft - gearbox - input .................................................................................................................. Extension - gearbox rear ............................................................................................................... Pump - gearbox oil ......................................................................................................................... Filter - gearbox oil ......................................................................................................................... Gear - 5th gear set ........................................................................................................................ Synchronizer assembly - 5th/reverse ........................................................................................... 5th gear - layshaft ......................................................................................................................... Bearing - layshaft rear support ..................................................................................................... Bearing - output shaft rear support ............................................................................................... Shaft - reverse idler ...................................................................................................................... Housing - gear selector mechanism ............................................................................................. Lever - gear change ...................................................................................................................... Housing - clutch ............................................................................................................................ Cover - front ...................................................................................................................................

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CONTENTSTRANSFER BOX - LT230SE .................................................................... 41-1DESCRIPTION AND OPERATIONLT230SE transfer box ..................................................................................................................... Transfer box cross section .............................................................................................................. Main casing components Vehicles up to 03 model year .............................................................. Main casing components Vehicles from 03 model year............................................................... Differential components Vehicles up to 03 model year ................................................................ Differential components Vehicles from 03 model year................................................................. Front output housing components Vehicles up to 03 model year ................................................ Front output housing components Vehicles from 03 model year ................................................. Rear output housing components ................................................................................................... Description ...................................................................................................................................... Operation ........................................................................................................................................ 41-1 41-2 41-4 41-5 41-6 41-7 41-8 41-10 41-12 41-13 41-18

ADJUSTMENTSCable - selector - differential lock - adjust ...................................................................................... 41-21 Cable - high/low selector................................................................................................................. 41-21

REPAIRSBottom cover - transfer box .......................................................................................................... Cable - selector - differential lock.................................................................................................... Transfer box - Diesel....................................................................................................................... Transfer box - V8 ............................................................................................................................ Gasket - rear cover plate ................................................................................................................ Switch - differential lock - Up to 03 MY ........................................................................................... Cable - high/low selector................................................................................................................. Oil seal - input shaft ...................................................................................................................... Seal - front output shaft................................................................................................................... Seal - rear output shaft ................................................................................................................... Gasket - rear output shaft housing.................................................................................................. Solenoid - interlock - Up to 03 MY .................................................................................................. Solenoid - interlock - from 03 MY.................................................................................................... Sensor - neutral ........................................................................................................................... Sensor - oil temperature - If fitted ................................................................................................... Switch - high low - warning ........................................................................................................... Switch(es) - differential lock warning From 03 MY.......................................................................... 41-23 41-24 41-25 41-29 41-33 41-34 41-35 41-36 41-36 41-38 41-39 41-40 41-40 41-41 41-41 41-42 41-42 41-43 41-46 41-64 41-68 41-70

OVERHAULIntermediate gear assembly .......................................................................................................... Differential assembly .................................................................................................................... Dog clutch - differential lock .......................................................................................................... Input gear/bearing .......................................................................................................................... Low gear - differential ...................................................................................................................

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CONTENTSAUTOMATIC GEARBOX - ZF4HP22 - 24 ................................................ 44-1DESCRIPTION AND OPERATIONAutomatic gearbox component layout ............................................................................................ Control schematic ........................................................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................ 44-1 44-2 44-4 44-17

ADJUSTMENTSCable - selector ............................................................................................................................. 44-21 Stall test .......................................................................................................................................... 44-21

REPAIRSCable and lever assembly - selector .............................................................................................. Selector indicator .......................................................................................................................... Switch - starter inhibitor ................................................................................................................. Seal - selector shaft ........................................................................................................................ Gearbox - convertor and transfer gearbox - Diesel ....................................................................... Gearbox - convertor and transfer gearbox - V8 ............................................................................ Torque converter and oil seal ......................................................................................................... Housing - torque converter ............................................................................................................ Gasket - intermediate plate ............................................................................................................ Intermediate plate .......................................................................................................................... Pump - fluid .................................................................................................................................... Seal - rear extension housing ......................................................................................................... Gasket - rear extension housing. .................................................................................................. Parking pawl assembly. ................................................................................................................ Gasket - oil sump ........................................................................................................................... Filter - oil ........................................................................................................................................ Cooler - fluid - Td5 .......................................................................................................................... Cooler - fluid - V8 ........................................................................................................................... Valve body assembly ..................................................................................................................... Seal - valve body ........................................................................................................................... Pressure regulator ......................................................................................................................... Lock-up solenoid valve (MV 3) ...................................................................................................... Solenoids - shift control valves (MV 1 & 2) 44-56 Harness - solenoid valves .............................................................................................................. Electronic control unit - automatic transmission ............................................................................. 44-23 44-24 44-25 44-26 44-27 44-32 44-37 44-38 44-39 44-41 44-43 44-44 44-45 44-46 44-47 44-48 44-49 44-50 44-51 44-53 44-54 44-55

44-57 44-58

PROPELLER SHAFTS ............................................................................. 47-1DESCRIPTION AND OPERATIONPropeller shaft component layout ................................................................................................... 47-1 Description...................................................................................................................................... 47-2

REPAIRSPropeller shaft - front ..................................................................................................................... Propeller shaft - rear ...................................................................................................................... Bush - spigot - rear propeller shaft ................................................................................................ Flexible coupling ............................................................................................................................ 47-5 47-5 47-6 47-7

OVERHAULPropeller shaft................................................................................................................................. 47-9

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CONTENTSREAR AXLE.............................................................................................. 51-1DESCRIPTION AND OPERATIONRear axle component layout ........................................................................................................... 51-1 Description ...................................................................................................................................... 51-2

REPAIRSDifferential - assembly .................................................................................................................... 51-5 Seal - differential pinion ................................................................................................................. 51-7

OVERHAULDifferential assembly ...................................................................................................................... 51-9

FRONT AXLE............................................................................................ 54-1DESCRIPTION AND OPERATIONFront axle component layout........................................................................................................... 54-1 Description ...................................................................................................................................... 54-2

REPAIRSDifferential - assembly .................................................................................................................... Seal - differential pinion ................................................................................................................ Seal - oil - front axle casing ........................................................................................................... Constant velocity joint - drive shaft ................................................................................................ 54-5 54-7 54-9 54-11

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CONTENTSSTEERING ................................................................................................ 57-1DESCRIPTION AND OPERATIONSteering system component layout................................................................................................. Steering column assembly and intermediate shaft ......................................................................... Steering box.................................................................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................ 57-1 57-2 57-4 57-5 57-16 57-17 57-18 57-18 57-19 57-20 57-22 57-24 57-27 57-30 57-34 57-37 57-38 57-39 57-42 57-43 57-45 57-47 57-47 57-48 57-49 57-50 57-51 57-52

ADJUSTMENTSSteering box - check and adjust ..................................................................................................... Hydraulic system - bleed ................................................................................................................ Steering linkage - centralise ......................................................................................................... Wheel alignment - front ................................................................................................................. Power steering pressure check - diesel models ............................................................................. Power steering pressure check - V8 LHD models .......................................................................... Power steering pressure check - V8 RHD models .........................................................................

REPAIRSPower steering box - V8 ................................................................................................................. Power steering box - LHD - diesel .................................................................................................. Steering box - RHD - diesel ............................................................................................................ Seal - input shaft - steering box ..................................................................................................... Seal - output shaft - steering box ................................................................................................... Pump - power steering - V8 ............................................................................................................ Pump - power steering - diesel ....................................................................................................... Steering column assembly and lock ............................................................................................... Shaft - intermediate and universal joint - steering column ............................................................ Nacelle - steering column ............................................................................................................... Drop arm - steering box ................................................................................................................ Ball joint - track rod ....................................................................................................................... Ball joint - drag link ....................................................................................................................... Drag link ........................................................................................................................................ Damper - steering ......................................................................................................................... Steering wheel ...............................................................................................................................

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CONTENTSFRONT SUSPENSION.............................................................................. 60-1DESCRIPTION AND OPERATIONFront suspension component layout (ACE torsion bar shown) ....................................................... 60-1 Front suspension components (ACE torsion bar shown)................................................................ 60-2 Description ...................................................................................................................................... 60-4

DESCRIPTION AND OPERATIONACE system component layout ....................................................................................................... ACE system control diagram .......................................................................................................... Description - ACE ........................................................................................................................... Operation ........................................................................................................................................ 60-7 60-8 60-9 60-22

ADJUSTMENTSACE hydraulic system bleeding ..................................................................................................... 60-25 Fluid level check - ACE system ...................................................................................................... 60-25

REPAIRSBushes - Panhard rod ................................................................................................................... Ball joint - upper - steering knuckle ............................................................................................... Ball joint - lower - steering knuckle ................................................................................................. Steering knuckle ........................................................................................................................... Road spring - front ........................................................................................................................ Wheel hub ....................................................................................................................................... Damper - front ............................................................................................................................... Bushes - radius arm ...................................................................................................................... ECU - ACE ..................................................................................................................................... Accelerometer - ACE - upper ........................................................................................................ Accelerometer - ACE - lower ........................................................................................................ Pump - ACE - V8 ............................................................................................................................ Pump - ACE - diesel ....................................................................................................................... Valve block - ACE ......................................................................................................................... Filter - high pressure - ACE .......................................................................................................... Pressure transducer - ACE ........................................................................................................... Solenoid - pressure control valve - ACE ....................................................................................... Solenoid - directional control valve - ACE ..................................................................................... Pipe assembly - valve block to front actuator - ACE ...................................................................... Pipe assembly - pump or reservoir to valve block - ACE - V8 ....................................................... Pipe assembly - pump or reservoir to valve block - ACE - diesel .................................................. Pipe assembly - valve block to rear actuator - ACE........................................................................ Actuator - front - ACE .................................................................................................................... Bushes - front long arm - ACE ........................................................................................................ 60-27 60-28 60-29 60-30 60-32 60-33 60-35 60-37 60-39 60-40 60-40 60-41 60-42 60-44 60-47 60-48 60-49 60-49 60-50 60-52 60-55 60-59 60-61 60-63

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CONTENTSREAR SUSPENSION ................................................................................ 64-1DESCRIPTION AND OPERATIONRear suspension component layout (vehicles with SLS)............................................................... Rear suspension component layout (vehicles without SLS).......................................................... Rear suspension components ........................................................................................................ Description...................................................................................................................................... 64-2 64-3 64-4 64-6 64-9 64-10 64-12 64-21

DESCRIPTION AND OPERATIONSLS component layout.................................................................................................................... SLS system control diagram........................................................................................................... Description - SLS............................................................................................................................ Operation ........................................................................................................................................

ADJUSTMENTSSLS calibration blocks .................................................................................................................... 64-25

REPAIRSWheel hub....................................................................................................................................... Road spring - rear........................................................................................................................... Air spring - SLS............................................................................................................................... Damper - rear ............................................................................................................................... Bushes - radius arm ....................................................................................................................... Bushes - Watts linkage ................................................................................................................. Sensor - height - SLS ..................................................................................................................... Compressor unit - air - SLS ............................................................................................................ Filter - intake - SLS ......................................................................................................................... Switch - ride height ......................................................................................................................... Air valve - SLS ................................................................................................................................ Actuator - rear - ACE ...................................................................................................................... Bushes - rear long arm - ACE......................................................................................................... 64-27 64-29 64-30 64-31 64-31 64-34 64-35 64-35 64-37 64-37 64-38 64-39 64-41

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CONTENTSBRAKES ................................................................................................... 70-1DESCRIPTION AND OPERATIONBrake system control component layout ......................................................................................... Brake system control diagram ........................................................................................................ Brake system hydraulic component layout ..................................................................................... Description ...................................................................................................................................... Operation ........................................................................................................................................ 70-1 70-2 70-4 70-5 70-20

DESCRIPTION AND OPERATIONHandbrake component layout ......................................................................................................... 70-25 Description ...................................................................................................................................... 70-26

ADJUSTMENTSHandbrake .................................................................................................................................... 70-29 Brake system bleeding ................................................................................................................... 70-30

REPAIRSBrake disc - front .......................................................................................................................... Brake disc - rear ............................................................................................................................ Master cylinder - brake ................................................................................................................. Cable - handbrake ........................................................................................................................ Switch - brake light ........................................................................................................................ Brake pads - front ......................................................................................................................... Brake pads - rear .......................................................................................................................... Brake shoes - handbrake ................................................................................................................ Servo - brake .................................................................................................................................. Vacuum pump - servo ..................................................................................................................... Housing - caliper - front ................................................................................................................. Housing - caliper - rear ................................................................................................................. ECU - Self levelling and anti locking brakes (SLABS) ................................................................. Sensor ABS front ..................................................................................................................... Sensor ABS rear ....................................................................................................................... Modulator unit - ABS ...................................................................................................................... Switch - Hill descent control ............................................................................................................ Switch - handbrake ....................................................................................................................... 70-33 70-34 70-35 70-36 70-37 70-38 70-39 70-40 70-42 70-43 70-45 70-46 70-47 70-48 70-48 70-49 70-50 70-50

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CONTENTSRESTRAINT SYSTEMS ............................................................................ 75-1DESCRIPTION AND OPERATIONSRS component layout ................................................................................................................... SRS block diagram ......................................................................................................................... Description - SRS ........................................................................................................................... Operation - SRS ............................................................................................................................. 75-1 75-2 75-3 75-9

DESCRIPTION AND OPERATIONDescription - seat belts ................................................................................................................... 75-11

REPAIRSSeat belt - front .............................................................................................................................. Seat belt - rear - centre ................................................................................................................. Seat belt - rear - side .................................................................................................................... Mounting - seat belt - 'B' post ...................................................................................................... Seat belts - third row....................................................................................................................... Pre-tensioner - front seat belt ....................................................................................................... Pre-tensioner - seat belt - front - deployment - in vehicle ............................................................... Pre-tensioner - seat belt - front - deployment - off vehicle.............................................................. Airbag module - drivers .................................................................................................................. Airbag module - passenger ........................................................................................................... DCU ................................................................................................................................................ Air bag - steering wheel - deployment - off vehicle......................................................................... Air bag - fascia - passenger - deployment - in vehicle ................................................................... Air bag - fascia - passenger - deployment - off vehicle .................................................................. Rotary coupler ................................................................................................................................ 75-13 75-13 75-15 75-16 75-17 75-18 75-19 75-20 75-22 75-23 75-24 75-25 75-26 75-27 75-29

DOORS...................................................................................................... 76-1-1REPAIRSDoor - front .................................................................................................................................... Door - rear .................................................................................................................................... Door - tail ........................................................................................................................................ Glass - front or rear door .............................................................................................................. Quarter light ................................................................................................................................... Regulator and motor - front and rear door glass .......................................................................... Trim casing - front door .................................................................................................................. Trim casing - rear door .................................................................................................................. Trim casing - tail door .................................................................................................................... Latch and motor - front door .......................................................................................................... Latch and motor - rear door ........................................................................................................... Latch and motor - tail door ............................................................................................................ Handle - exterior - rear door ......................................................................................................... Handle - exterior - tail door ........................................................................................................... Handle - exterior - front door .......................................................................................................... 76-1-1 76-1-2 76-1-3 76-1-5 76-1-6 76-1-7 76-1-8 76-1-9 76-1-10 76-1-11 76-1-12 76-1-13 76-1-13 76-1-14 76-1-14

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CONTENTSEXTERIOR FITTINGS............................................................................... 76-2-1REPAIRSWing - front - up to 03MY ................................................................................................................ Wing - front - from 03MY................................................................................................................. Rear folding step ............................................................................................................................ Liner - wheel arch - front ................................................................................................................. Liner - wheel arch - rear ................................................................................................................. Panel - underbelly .......................................................................................................................... Mirror - exterior - electric ................................................................................................................ Roof bars ....................................................................................................................................... Bonnet ........................................................................................................................................... Cable - bonnet release - up to 03MY .............................................................................................. Cable - bonnet release - from 03MY ............................................................................................... Bumper assembly - front ............................................................................................................... Bumper assembly - rear - from 03MY ............................................................................................. Trim finisher - bumper - front - from 03MY...................................................................................... Bumper assembly - rear - up to 03MY ............................................................................................ Side finisher - windscreen .............................................................................................................. Grille - front - up to 03MY................................................................................................................ Grille - front - from 03MY ................................................................................................................ 76-2-1 76-2-2 76-2-4 76-2-5 76-2-6 76-2-7 76-2-7 76-2-8 76-2-9 76-2-9 76-2-11 76-2-12 76-2-13 76-2-14 76-2-15 76-2-16 76-2-16 76-2-17

INTERIOR TRIM COMPONENTS ............................................................. 76-3-1REPAIRSTrim casing - tail door speaker ...................................................................................................... Trim casing - side - loadspace ....................................................................................................... Trim casing - upper - 'B' post ......................................................................................................... Trim casing - lower - 'B' post ......................................................................................................... Trim casing - 'D' post ...................................................................................................................... Console - centre - automatic models .............................................................................................. Console - centre - manual models .................................................................................................. Fascia ............................................................................................................................................. Panel - auxiliary switch ................................................................................................................... Panel - fascia access - driver's side.............................................................................................. Drink tray assembly - centre fascia ................................................................................................. Louvre panel assembly - centre fascia ........................................................................................... Carpet - front................................................................................................................................... Carpet - rear .................................................................................................................................. Carpet - loadspace ......................................................................................................................... Headlining ...................................................................................................................................... Stowage pocket - front .................................................................................................................. 76-3-1 76-3-2 76-3-3 76-3-3 76-3-4 76-3-5 76-3-7 76-3-10 76-3-14 76-3-15 76-3-15 76-3-16 76-3-18 76-3-19 76-3-20 76-3-20 76-3-24

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CONTENTSSCREENS ................................................................................................. 76-4-1REPAIRSGlass/sealing rubber - tail door ..................................................................................................... Windscreen ......................................................................