Range Rover Workshop Manual

Range Rover Workshop Manual
Workshop Manual
Werkplaatshandboek
Manual d'Atelier
Werkstatthandbuch
Manuale d'Officina
Manual de Taller
Manual de Oficina
Workshop manual
RANGE ROVER
VOLUME 1
01
04
05
07
09
10
12
This manual covers vehicles from
introduction 1995
01
04
05
06
07
09
10
12
12
17
19
19
19
26
26
30
33
37
INTRODUCTION
GENERAL SPECIFICATION DATA
ENGINE TUNING DATA
TORQUE VALUES
GENERAL FITTING REMINDERS
LUBRICANTS, FLUIDS AND CAPACITIES
MAINTENANCE
ENGINE BMW DIESEL
ENGINE LANDROVER V8
EMISSION CONTROL
FUEL SYSTEM BMW DIESEL
FUEL SYSTEM LANDROVER V8
CRUISE CONTROL
COOLING SYSTEM BMW DIESEL
COOLING SYSTEM LANDROVER V8
MANIFOLD AND EXHAUST SYSTEM
CLUTCH
MANUAL GEARBOX
This manual supersedes:
Workshop manual VDR100370
Body Repair Manual LRL0085
Published by Rover Technical Communication
 1999 Rover Group Limited
Publication part no. LRL0326ENG
17
19
26
30
33
37
01 - INTRODUCTION
CONTENTS
Page
INFORMATION
INTRODUCTION .................................................................................................. 1
DIMENSIONS ....................................................................................................... 1
REFERENCES ..................................................................................................... 1
REPAIRS AND REPLACEMENTS ....................................................................... 1
POISONOUS SUBSTANCES .............................................................................. 1
FUEL HANDLING PRECAUTIONS ...................................................................... 2
SYNTHETIC RUBBER ......................................................................................... 3
RECOMMENDED SEALANTS ............................................................................. 3
USED ENGINE OIL .............................................................................................. 3
ACCESSORIES AND CONVERSIONS ............................................................... 4
WHEELS AND TYRES ......................................................................................... 4
STEAM CLEANING .............................................................................................. 4
SPECIFICATION .................................................................................................. 4
SPECIAL SERVICE TOOLS ................................................................................ 5
COPYRIGHT ........................................................................................................ 5
JACKING .............................................................................................................. 6
HYDRAULIC VEHICLE RAMP (FOUR POST) ..................................................... 7
TWO POST VEHICLE RAMPS ............................................................................ 7
DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES
(ABS) .................................................................................................................... 7
JUMP STARTING ................................................................................................ 8
ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL ............................. 9
VEHICLE IDENTIFICATION NUMBER (VIN) ..................................................... 12
LOCATION OF IDENTIFICATION NUMBERS ................................................... 13
EMERGENCY TOWING .................................................................................... 15
TRANSPORTING THE VEHICLE BY TRAILER ................................................ 16
INTRODUCTION
INTRODUCTION
REFERENCES
This workshop manual covers the New Range
Rover vehicle from introduction in 1995, and is
designed to be used in conjunction with Electrical
Troubleshooting Manual LRL0329 and Electrical
Circuit Diagrams YVB101590 (2nd Edition).
Amendments and additional pages will be issued
to ensure that the manual covers latest models.
Amendments and additions will be identified by
the addition of a dated footer at the bottom of the
page.
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Range Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which could not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Range
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONS and NOTES are given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Range Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Range Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer’s specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are toxic and
should not be consumed under any circumstances,
and should be kept away from open wounds. These
substances amongst others include anti-freeze, brake
fluid, fuel, oil, windscreen washer additives, air
conditioning refrigerant, lubricants and various
adhesives.
INFORMATION
1
01
INTRODUCTION
NEW RANGE ROVER
FUEL HANDLING PRECAUTIONS
Hot fuel handling precautions
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines other potential risks which must not be
ignored.
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
This information is issued for basic guidance only; in
any case of doubt, seek advice from your local Fire
Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic.
1. Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2. Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
When fuel evaporates it produces 150 times its own
volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowest level.
It can readily be distributed throughout a workshop by
air currents, consequently, even a small spillage of
fuel is very dangerous.
Always have a fire extinguisher containing FOAM CO2
GAS, or POWDER close at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being
dismantled, all forms of ignition must be
extinguished or removed, any leadlamps used
must be flame proof and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.
2
INFORMATION
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
A FUEL VAPOUR warning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
INTRODUCTION
SYNTHETIC RUBBER
USED ENGINE OIL
Many ’O’ ring seals, flexible pipes and other similar
items which appear to be natural rubber are made of
synthetic materials called Fluoroelastomers. Under
normal operating conditions this material is safe, and
does not present a health hazard. However, if the
material is damaged by fire or excessive heat, it can
break down and produce highly corrosive Hydrofluoric
acid which can cause serious burns on contact with
skin. Should the material be in a burnt or overheated
condition, handle only with seamless industrial gloves.
Decontaminate and dispose of the gloves immediately
after use.
WARNING: Prolonged and repeated
contact with engine or motor oil will result
in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
If skin contact does occur, remove any contaminated
clothing immediately and obtain medical assistance
without delay. In the meantime, wash the affected
area with copious amounts of cold water or limewater
for fifteen to sixty minutes.
RECOMMENDED SEALANTS
A number of branded products are recommended in
this manual for use during maintenance and repair
work.
These items include:
HYLOMAR GASKET AND JOINTING COMPOUND
and
HYLOSIL RTV SILICON COMPOUND.
They should be available locally from garage
equipment suppliers. If there is any problem obtaining
supplies, contact the following company for advice
and the address of the nearest supplier.
MacDERMID LUBRICANTS LTD.
Hylo House,
Cale lane,
New Springs,
Wigan
WN2 1JR
United Kingdom
Tel: 01942 824242
Fax: 01942 501110
Used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities should be provided.
Handling precautions
1. Avoid prolonged and repeated contact with oils,
particularly used engine oils.
2. Wear protective clothing, including impervious
gloves where applicable.
3. Do not put oily rags in pockets.
4. Avoid contaminating clothes, particularly
underwear, with oil.
5. Overalls must be cleaned regularly. Discard
unwashable clothing and oil impregnated
footwear.
6. First aid treatment must be obtained immediately
for open cuts and wounds.
7. Use barrier creams, before each work period, to
help the removal of oil from the skin.
8. Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
9. Do not use gasoline, kerosene, diesel fuel,
petrol, thinners or solvents for washing the skin.
10. If skin disorders develop, obtain medical advice.
11. Where practicable, degrease components prior
to handling.
12. Where there is a risk of eye contact, eye
protection should be worn, for example, goggles
or face shields; in addition an eye wash facility
should be provided.
Disposing of used oils
Environmental protection precaution
It is illegal to pour used oil onto the ground, down
sewers or drains, or into waterways.
Dispose of used oil through authorised waste disposal
contractors. If in doubt, contact your Local Authority
for advice on disposal facilities.
INFORMATION
3
01
INTRODUCTION
NEW RANGE ROVER
ACCESSORIES AND CONVERSIONS
SPECIFICATION
DO NOT FIT unapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitment of non-approved
conversions to the Range Rover.
The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any particular one. For the specification of a
particular vehicle, purchasers should consult their
Dealer.
The Manufacturers reserve the right to vary their
specifications with or without notice, and at such times
and in such manner as they think fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer’s policy of constant product
improvement.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Range Rover wheels which are designed
for multi-purpose on and off road use and have
very important relationships with the proper
operation of the suspension system and vehicle
handling. Replacement tyres must be of the make
and sizes recommended for the vehicle, and all
tyres must be the same make, ply rating and tread
pattern.
CAUTION: When refitting a road wheel,
apply a suitable anti-seize compound such
as Raworth 33/04, to the spigot bore of the
wheel. This will prevent possible seizure of the
wheel to the hub spigot. Ensure that no
compound comes into contact with the braking
components.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bay MUST be followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine water pipes, hose clips and ignition
coil clamp.
4
INFORMATION
While every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer nor Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.
INTRODUCTION
SPECIAL SERVICE TOOLS
COPYRIGHT
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified, only these tools should be used
to avoid the possibility of personal injury or
damage to the components. Also the amount of time
which they save can be considerable.
 Land Rover 1995
All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Land Rover.
Every special tool is designed with the close
co-operation of Land Rover, and no tool is put into
production which has not been tested and approved
by us. New tools are only introduced where an
operation cannot be satisfactorily carried out using
existing tools or standard equipment. The user is
therefore assured that the tool is necessary and that it
will perform accurately, efficiently and safely.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to V. L. Churchill. Overseas
orders should be placed with the local V. L. Churchill
distributor, where one exists. Countries where there is
no distributor may order direct from:
V. L. Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN11 4NF.
The tools recommended in this Workshop Manual are
listed in a multi-language illustrated catalogue,
publication number LPA ST ML 95, which is
obtainable from V. L. Churchill Limited at the above
address.
INFORMATION
5
01
INTRODUCTION
NEW RANGE ROVER
JACKING
Vehicle jack
The following instructions must be carried out before
raising the vehicle off the ground.
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a wheel. Do
NOT use the jack for any other purpose. Refer to
Owner’s Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
1.
2.
3.
4.
Use a solid level ground surface.
Apply parking brake.
Select ’P’ or 1st gear in main gearbox.
Select Low range in transfer gearbox.
Hydraulic jack
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
axle.
Body structure
Bumpers
Brake lines
Panhard rod
Rear Trailing links
Engine sump
Air suspension pipes
Fuel lines
Front radius arms
Steering linkage
Fuel tank
Gearbox bell housing
CAUTION: If supporting vehicle by the
front crossmember, the safety stands
must be positioned carefully to avoid
damage to air suspension pipes.
6
INFORMATION
Raise the front of the vehicle
1. Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.
INTRODUCTION
2. Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3. Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1. Position cup of hydraulic arm under differential
casing.
2. Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3. Lower jack until axle sits securely on axle
stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay. See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
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.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a ’drive on’ type ramp which supports vehicle
by its own road wheels. If a ’wheel-free’ condition is
required, use a ’drive on’ ramp incorporating a
’wheel-free’ system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of RANGE ROVER VEHICLES
DOES NOT recommend using ’Two Post’ ramps
that employ four adjustable support arms. These
are NOT considered safe for Range Rover
vehicles.
If a vehicle is installed on a Two Post ramp,
responsibility for safety of the vehicle and
personnel performing service operations is
attributable to the Service Provider.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
WARNING: Vehicles from 99 MY are fitted
with 4 wheel traction control, which must
be disabled prior to testing on a single
axle dynamometer.
INFORMATION
7
01
INTRODUCTION
NEW RANGE ROVER
JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1. Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2. Ensure that ignition and all electrical accessories
are switched off; the parking brake must be
applied and neutral selected on a manual
gearbox; for an automatic gearbox select neutral
(N) or park (P). Connect the jump leads as
follows;
A. Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B. Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C. Connect one end of second jumper cable to
negative terminal of booster battery.
D. Connect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY. Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade
assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
8
INFORMATION
3. If booster battery is installed in another vehicle,
start engine and allow to idle.
4. Start engine of vehicle with discharged battery,
following starting procedure in Owners’ Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalysts.
5. Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6. Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
INTRODUCTION
ABBREVIATIONS AND SYMBOLS USED IN THIS
MANUAL
Across flats (bolt size) ............................................ AF
After bottom dead centre ................................... ABDC
Air Conditioning ..................................................... A/C
Air Fuel Ratio ....................................................... AFR
After top dead centre ......................................... ATDC
Air Temperature Control ....................................... ATC
Alternating current ................................................... ac
Ambient Air Pressure ........................................... AAP
Ambient Air Temperature ..................................... AAT
Ambient Pressure ................................................... AP
Ampere ........................................................ amp or A
Ampere hour .................................................... amp hr
Anti-lock Braking System ..................................... ABS
Anti-shunt Control ............................................... ASC
Automatic ............................................................ Auto
Automatic Volume Control .................................. AVC
Auxiliary .............................................................. AUX
Battery Backed-Up Sounder ............................. BBUS
Before bottom dead centre ................................ BBDC
Before top dead centre ...................................... BTDC
Body Electrical Control Module ......................... BeCM
Boost Pressure ...................................................... BP
Bottom dead centre ............................................. BDC
Brake horse power ................................................ bhp
Brake Pedal Positions .......................................... BPP
British Standards .................................................... BS
Camshaft Position ............................................... CMP
Calculated Load Value ......................................... CLV
Canister Vent Solenoid ....................................... CVS
Carbon Dioxide .................................................... CO2
Carbon monoxide .................................................. CO
Celsius ..................................................................... C
Centimetre ............................................................. cm
Central Door Locking ........................................... CDL
Centre Differential Control ................................... CDC
Centre High Mounted Stop Lamp ................... CHMSL
Chlorofluorocarbon .............................................. CFC
Clutch Pedal Position .......................................... CPP
Compact Disc ......................................................... CD
Compact Disc - Read Only Memory ............. CD-ROM
Controller Area Network ...................................... CAN
Crankshaft Position ............................................. CKP
Cubic centimetre ................................................... cm3
Cubic feet per minute ........................................ ft3/min
Cubic inch ............................................................... in3
dB .................................................................. Decibels
Degree (angle) ............................................... deg or °
Degree (temperature) ..................................... deg or °
Diagnostic Control Unit ....................................... DCU
Dial Test Indicator ................................................. DTI
Diameter ............................................................... dia.
Digital Diesel Electronics ..................................... DDE
Digital Signal Processing .................................... DSP
Digital Versatile Disc ........................................... DVD
Direct current ........................................................... dc
Direct Ignition System ........................................... DIS
Direct Injection ........................................................ DI
Directional Control Valve ..................................... DCV
Double Overhead Camshaft ............................. DOHC
Dual Mass Flywheel ............................................ DMF
Electronic Air Control Valve .............................. EACV
Electronic Air Suspension .................................... EAS
Electronic Automatic Transmission ...................... EAT
Electronic Brake pressure Distribution ................ EBD
Electronic Control Unit ........................................ ECU
Electronic Diesel Control ..................................... EDC
Electronic Erasable Programmable Read Only
Memory ....................................................... EEPROM
Electronic Fuel Injection ........................................ EFI
Electronic Traction Control ................................... ETC
Electronic Unit Injector .......................................... EUI
Electronic Vacuum Regulator .............................. EVR
Electrical Reference Library ................................. ERL
Emergency Key Access ....................................... EKA
Emergency Locking Retractor .............................. ELR
Engine Control Module ........................................ ECM
Engine Coolant Temperature ............................... ECT
Engine Fuel Temperature .................................... EFT
Engine Management System .............................. EMS
Enhanced Other Network .................................... EON
European Community Directive .......................... ECD
European Norm ...................................................... EN
European Economic Community ......................... EEC
European On Board Diagnostics ....................... EOBD
Evaporative Emission ........................................ EVAP
Exhaust Gas Recirculation .................................. EGR
Fahrenheit ................................................................. F
Fast Throttle Control ............................................ FTC
Feet ........................................................................... ft
Feet per minute .................................................. ft/min
Field Effect Transistor .......................................... FET
Fifth ........................................................................ 5th
First ........................................................................ 1st
Fluid ounce .......................................................... fl oz
Foot pounds (torque) ............................................ lbf.ft
Fourth ..................................................................... 4th
Fuel Burning Heater ............................................. FBH
Fuel Injection Pump .............................................. FIP
Gallons ................................................................... gal
Gallons (US) ..................................................... US gal
Gramme (force) ........................................................ gf
Gramme (mass) ........................................................ g
Greenwich Mean Time ........................................ GMT
Global Positioning System .................................. GPS
Gravity ....................................................................... g
INFORMATION
9
01
INTRODUCTION
Heated Front Screen ............................................ HFS
Heated oxygen sensor ....................................... HO2S
Heated Rear Window ......................................... HRW
Height Dilation Of Precision ............................. HDOP
High ......................................................................... HI
High compression ................................................... hc
High Density Polyethylene ................................ HDPE
High Molecular Weight ....................................... HMW
High Strength Low Alloy .................................... HSLA
High tension (electrical) .................................. HT or ht
Hill Descent Control ............................................ HDC
Hour .......................................................................... h
Hydrocarbons ......................................................... HC
Hydrofluorocarbon ............................................... HFC
Idle Air Control Valve ......................................... IACV
In Car Entertainment ............................................. ICE
Inches of mercury .............................................. in. Hg
Inches ...................................................................... in
Inertia-fuel Shut Off ............................................... IFS
Injector Pulse Width ............................................. IPW
Inlet Throttle ........................................................... ILT
Intake Air Temperature ......................................... IAT
Intermediate Frequency ........................................... IF
Internal diameter ....................................... I.D. or i.dia.
International Organisation for Standardisation ...... ISO
Kilogramme (force) ................................................. kgf
Kilogramme (mass.) ................................................ kg
Kilogramme centimetre (torque) ....................... kgf.cm
Kilogrammes per hour .......................................... kg/h
Kilogramme per square millimetre ................. kgf/mm2
Kilogramme per square centimetre ................. kgf/cm2
Kilogramme metres (torque) .............................. kgf.m
Kilometres .............................................................. km
Kilometres per hour ............................................. km/h
KiloPascal ............................................................. kPa
Kilowatts ................................................................. kW
Kilovolts ................................................................... kV
Knock Sensor ......................................................... KS
Left-hand ................................................................ LH
Left-hand Drive ..................................................... LHD
Left-hand thread ............................................... LHThd
Light Emitting Diode ............................................. LED
Litres .......................................................................... l
Liquid Crystal Display ........................................... LCD
Liquid Vapour Separator ...................................... LVS
Low ........................................................................ LO
Low compression ..................................................... lc
Low Emission Vehicle .......................................... LEV
Low tension ............................................................. l.t.
Malfunction Indicator Light .................................... MIL
Manifold Absolute Pressure ................................ MAP
Mass Air Flow ...................................................... MAF
Maximum ............................................................ max.
MegaPascal ........................................................ MPa
Metal Oxide Semiconductor Field Effect
Transistor ..................................................... MOSFET
10
INFORMATION
NEW RANGE ROVER
Metre ........................................................................ m
Millilitre .................................................................... ml
Millimetre ............................................................... mm
Miles per gallon .................................................... mpg
Miles per hour ...................................................... mph
Minus (of tolerance) ................................................... Minimum .............................................................. min.
Minute (angle) ............................................................ ’
Model Year ............................................................ MY
Modular Engine Management System ............. MEMS
Motorised Valve .................................................... MV
Multi-Function Logic ............................................. MFL
Multi-Function Unit .............................................. MFU
Multi-Point injection ............................................... MPi
Multiport Fuel Injection .......................................... MFI
Negative (electrical) ............................................... -ve
Negative Temperature Coefficient ...................... NTC
Newton metres (torque) ........................................ Nm
Nitrogen Dioxide ................................................... NO2
Non-Return Valve ................................................ NRV
North American Specification .............................. NAS
Number ................................................................. No.
Off-road Mode .................................................... ORM
Ohms ................................................................... ohm
On Board Diagnostics ......................................... OBD
On Board Monitoring ........................................... OBM
Organic Acid Technology .................................... OAT
Ounces (force) ....................................................... ozf
Ounces (mass) ........................................................ oz
Ounce inch (torque) .......................................... ozf.in.
Outside diameter .................................... O.D. or o.dia.
Overhead Cam .................................................... OHC
Oxides of Nitrogen ............................................... NOx
Part number ................................................... Part No.
Percentage ............................................................... %
Pints ......................................................................... pt
Pints (US) ........................................................... US pt
Plus or Minus .......................................................... ±
Plus (tolerance) ......................................................... +
Polytetrafluorethylene ........................................ PTFE
Position Dilation Of Position .............................. PDOP
Positive (electrical) ................................................ +ve
Positive Crankcase Ventilation ............................ PCV
Positive Temperature Coefficient ......................... PTC
Pound (force) .......................................................... lbf
Pounds force feet ................................................. lbf.ft
Pounds inch (torque) ........................................... lbf.in
Pound (mass) ....................................................... lb(s)
Pounds per square inch ......................................... psi
Pounds per square inch ..................................... lbf/in2
Power Assisted Steering ...................................... PAS
Pressure Conscious Reducing Valve ................ PCRV
Printed Circuit Board ........................................... PCB
Programme Information .......................................... PI
Pulses Per Second ............................................... PPS
Pulse Width Modulation ..................................... PWM
INTRODUCTION
Radio Data Service ............................................. RDS
Radio Frequency .................................................... RF
Radius ........................................................................ r
Ratio ........................................................................... :
Read Only Memory ............................................ ROM
Red/Green/Blue .................................................. RGB
Reference .............................................................. ref.
Regionalisation ................................................... REG
Research Octane Number .................................. RON
Rest Of World ..................................................... ROW
Revolution per minute ..................................... rev/min
Right-hand ............................................................. RH
Right-hand Drive ................................................. RHD
Roll Over Valve ................................................... ROV
Rover Engineering Standards ............................. RES
SCREW THREADS
American Standard Taper Pipe ......................... NPTF
British Standard Pipe ........................................... BSP
Unified Coarse .................................................... UNC
Unified Fine ......................................................... UNF
Second (angle) ........................................................... "
Second (numerical order) ...................................... 2nd
Secondary Air Injection ......................................... SAI
Self Levelling and Anti-Lock Brake System .... SLABS
Self Levelling Suspension .................................... SLS
Single Overhead Camshaft .............................. SOHC
Single Point Entry ................................................. SPE
Society of Automotive Engineers ......................... SAE
Specific gravity ................................................... sp.gr.
Square centimetres ............................................... cm2
Square inches ......................................................... in2
Standard ............................................................... std.
Standard wire gauge ......................................... s.w.g.
Supplementary Restraint System ........................ SRS
Synchroniser/Synchromesh .......................... synchro.
Temperature, Manifold Absolute Pressure ........ TMAP
Third ....................................................................... 3rd
Thermostsatic Expansion Valve ........................... TXV
Three Way Catalyst ............................................. TWC
Throttle Position ..................................................... TP
Top Dead Centre ................................................. TDC
Torsional Vibration ................................................. TV
Traffic Announcement ............................................ TA
Traffic Management Control ................................ TMC
United Kingdom ...................................................... UK
United States .......................................................... US
US gallons per hour .................................... US galls/h
Variable ................................................................ Var.
Variable Intake System ......................................... VIS
Variable Reluctance Sensor ................................ VRS
Vehicle Identification Number ............................... VIN
Vehicle Information Communications System .... VICS
Vehicle Speed Sensor .......................................... VSS
Velocity Dilation Of Precision ............................ VDOP
Volts ......................................................................... V
Watts ....................................................................... W
Wide Open Throttle ............................................ WOT
INFORMATION
11
01
INTRODUCTION
NEW RANGE ROVER
VEHICLE IDENTIFICATION NUMBER (VIN)
Federal (USA) vehicle identification number
An adhesive label containing the Vehicle Identification
Number and the recommended maximum vehicle
weights is located on the left hand side of the bonnet
locking platform.
The number is also stamped on the outside of the
chassis in the front RH wheel arch to the rear of the
anti-roll bar link.
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings.
NOTE: It may be necessary to remove
underseal in order to locate the number;
ensure underseal is restored on
completion.
Key to Vehicle Identification Number Plate
A.
B.
C.
D.
E.
VIN (17 digits)
Maximum permitted laden weight for vehicle
Maximum vehicle and trailer weight
Maximum road weight-front axle
Maximum road weight-rear axle
In addition, the VIN is stamped on a plate which is
visible through the left side of the windscreen.
12
INFORMATION
INTRODUCTION
LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - V8 engine
Main gearbox R380 - 5 speed
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
Stamped on a cast pad on the bottom right hand side
of the gearbox.
NOTE: The engine compression ratio is
stamped above the serial number.
Automatic gearbox ZF4HP22/ZF4HP24
Engine serial number - BMW Diesel engine
Stamped on a plate riveted to the bottom left hand
side of the gearbox casing.
Stamped on the LH side of the cylinder block above
the sump.
INFORMATION
13
01
INTRODUCTION
NEW RANGE ROVER
Transfer gearbox-Borg Warner
Vehicle identification number (VIN)
Stamped on a plate attached to the gearbox casing,
between filler/level and drain plug.
Made up of 17 digits, these numbers are used to
identify manufacturer, model range, specification,
body type, engine, transmission/steering, model year,
plant and build sequence number and serve to identify
the vehicle.
This example shows the sequence:
European code
S AL LP A M J 7 M A
S
AL
LP
A
M
J
7
M
A
Europe
UK
Range Rover
European Spec.
4 Door Station Wagon
4.6 Litre Fuel Injection
Manual right steering
1995 Model Year
Solihull
Front and rear axle
Federal (USA) code
Stamped on the left hand axle tubes.
S AL P V 1 2 4 2 S A
S
AL
P
V
1
2
4
2
S
A
14
INFORMATION
Europe
UK
Range Rover
North America Spec.
4 Door Station Wagon
4.0 Litre fuel injection
Automatic, Left Hand Steering
Check Digit
1995 Model Year
Solihull
INTRODUCTION
EMERGENCY TOWING
CAUTION: The New Range Rover has
permanent four-wheel drive. The following
instructions must be adhered to when
towing:Towing the vehicle on four wheels
If it is necessary to recover the vehicle by towing on
all four wheels, ’Transfer neutral’ MUST be selected.
1. With the starter key removed, insert a fuse of 5
amps or more in fuse position ’11’ in the RH seat
fuse box.
2. Turn the starter switch to position ’2’; the transfer
box will now automatically select neutral.
3. Wait until the message centre displays
’TRANSFER NEUTRAL’ and then turn the
starter switch off, position ’0’.
4. Turn the starter switch to position ’1’ to unlock
the steering and leave in this position while the
vehicle is being towed.
CAUTION: Power assistance for braking
and steering systems will not be provided
without the engine running. Greater pedal
pressure will be required to apply the brakes, the
steering wheel will require greater effort to turn
the front wheels.
The vehicle tow connection should be used only
in normal road conditions.
CAUTION: DO NOT remove the starter key
or turn the switch to position ’0’ when the
vehicle is in motion.
7. To reactivate the transfer box after towing, turn
the starter switch off to position ’0’ and remove
the fuse from position ’11’. On automatic
vehicles the transfer box will automatically
engage the Low or High gear range.
8. On manual vehicles, first press the range
change switch. The transfer box will then engage
the Low or High gear range.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST be
removed, dependant upon which axle is
being trailed.
9. To facilitate reassembly, first mark the propeller
shaft drive flanges at transfer box and axle.
10. Remove propeller shaft fixings and lift shaft from
vehicle.
11. If the front axle is to be trailed, turn ignition key
to position ’1’ to release the steering lock.
CAUTION: If the rear axle is to be raised,
the steering wheel and/or linkage MUST be
secured in a straight ahead position. DO
NOT use the steering lock for this purpose.
5. Secure tow rope to the front towing eye.
6. Release the parking brake.
INFORMATION
15
01
INTRODUCTION
TRANSPORTING THE VEHICLE BY TRAILER
If the vehicle should require transporting on a trailer or
the back of a lorry, the air suspension must be set to
’ACCESS’ before being lashed. See FRONT
SUSPENSION, Description and operation.
Lashing eyes are provided on the front and rear
chassis cross members to facilitate the securing of the
vehicle, as shown.
CAUTION: DO NOT secure lashing hooks
or trailer fixings to any other part of the
vehicle.
CAUTION: If the air suspension cannot be
set to the ’ACCESS’ position, then the
vehicle must be lashed by its wheels and
not the lashing eyes.
Install vehicle on the trailer and apply park brake.
Select neutral in main gearbox; this will prevent
damage to the parking pawl of the automatic gearbox.
16
INFORMATION
NEW RANGE ROVER
04 - GENERAL SPECIFICATION DATA
CONTENTS
Page
INFORMATION
ENGINE - 4.0 V8 .................................................................................................. 1
ENGINE - 4.6 V8 .................................................................................................. 4
ENGINE - BMW DIESEL ...................................................................................... 7
ENGINE MANAGEMENT SYSTEM (EMS) V8 ENGINE .................................... 10
FUEL SYSTEM - BMW DIESEL ENGINE .......................................................... 12
COOLING SYSTEM - V8 ENGINE ..................................................................... 12
COOLING SYSTEM - BMW DIESEL ENGINE ................................................... 12
MANUAL TRANSMISSION ................................................................................ 13
AUTOMATIC TRANSMISSION .......................................................................... 14
STEERING ......................................................................................................... 15
SUSPENSION .................................................................................................... 15
SHOCK ABSORBERS ....................................................................................... 15
AIR CONDITIONING .......................................................................................... 15
BRAKES ............................................................................................................. 16
ELECTRICAL ..................................................................................................... 17
REPLACEMENT BULBS .................................................................................... 18
VEHICLE WEIGHTS AND PAYLOAD ................................................................ 19
VEHICLE DIMENSIONS .................................................................................... 20
TYRE PRESSURES ........................................................................................... 20
WHEELS AND TYRES ....................................................................................... 20
GENERAL SPECIFICATION DATA
ENGINE - 4.0 V8
Type .................................................................................
Number of cylinders .........................................................
Bore .................................................................................
Stroke ...............................................................................
Capacity ...........................................................................
Valve operation ................................................................
Compression ratio
Up to 99MY .............................................................
From 99MY .............................................................
Maximum power (at 4750 rev/min)
Up to 99MY .............................................................
From 99MY
All except NAS ...............................................
NAS only ........................................................
4.0 litre V8
Eight, two banks of four
94.00 - 94.04 mm
71.04 - 71.20 mm
3950 cm3
Overhead by push-rod
High Compression
9.35:1
9.38:1
Low Compression
8.2:1
8.23:1
140 kW
132 kW
136 kW
140 kW
132 kW
-
3.7008 - 3.7024 in
2.7966 - 2.8031 in
241 in3
Crankshaft
Main journal diameter ....................................................... 63.500 - 63.487 mm
2.50 - 2.4995 in
Crankpin journal diameter ................................................ 55.513 - 55.500 mm
2.1856 - 2.1850 in
Crankshaft end thrust/end float ........................................ Taken on thrust washers of centre main bearing
0.10 - 0.20 mm
0.004 - 0.008 in
Main bearings
Number and type
Up to 99MY .............................................................
From 99MY .............................................................
Material ............................................................................
Diametrical clearance .......................................................
5, Vandervell shells
5, Glacier Vandervell / AS15
Lead bronze with lead-indium overlay
0.010 - 0.048 mm
0.0004 - 0.002 in
Connecting rods
Type ................................................................................. Horizontally split big-end, plain small-end
Length between centres ................................................... 155.12 - 155.22 mm
6.1071 - 6.1110 in
Big-end bearings
Type and material
Up to 99MY ............................................................. Vandervell VP Lead bronze with lead-indium overlay
From 99MY ............................................................. Glacier Vandervell GPL2120 / AS124A
Diametrical clearance ....................................................... 0.015 - 0.055 mm
0.0006 - 0.002 in
INFORMATION
1
04
GENERAL SPECIFICATION DATA
Piston pins
Length ..............................................................................
Diameter ..........................................................................
Fit-in connecting rod .........................................................
Clearance in piston ..........................................................
NEW RANGE ROVER
60.00 - 60.50 mm
23.995 - 24.000 mm
Press fit
0.015 - 0.006 mm
Pistons
Clearance in bore, measured 10 mm from
base of skirt at right angles to piston pin
Up to 99MY ............................................................. 0.020 - 0.050 mm
From 99MY ............................................................. 0.022 - 0.067 mm
Piston rings
Number of compression rings ..........................................
Number of oil control rings ...............................................
No 1 compression ring .....................................................
No 2 compression ring .....................................................
Width of compression rings
Bottom .....................................................................
Top
Up to 99MY ....................................................
From 99MY .....................................................
Compression ring gap
Bottom .....................................................................
Top ..........................................................................
Oil control ring type
Up to 99MY .............................................................
From 99MY .............................................................
Oil control ring width .........................................................
Oil control ring rail gap .....................................................
Camshaft
Location ...........................................................................
Bearings ...........................................................................
Number of bearings ..........................................................
Drive .................................................................................
Camshaft end float
Up to 99MY .............................................................
From 99MY .............................................................
INFORMATION
0.00059 - 0.00024 in
0.0008 - 0.0020 in
0.0009 - 0.0026 in
2
1
Nitrided steel barrel faced
Tapered spherical barrel marked ’TOP’
1.478 - 1.49 mm
0.0582 - 0.0587 in
1.21 - 1.23 mm
1.17 - 1.19 mm
0.0476 - 0.0484 in
0.0461 - 0.0479 in
0.40 - 0.65 mm
0.3 - 0.5 mm
0.0157 - 0.0256 in
0.0118 - 0.0197 in
Aclonoform
3 Piece Aeconoform
3.0 mm
0.38-1.40 mm
0.1181 in
0.0150 - 0.0551 in
Central
Non serviceable
5
Chain 9.52 mm pitch x 54 pitches.
0.076 - 0.355 mm
0.075 - 0.350 mm
Tappets ........................................................................... Hydraulic self-adjusting
2
2.3622 - 2.3819 in
0.9447 - 0.9449 in
0.003 - 0.014 in
0.002 - 0.013 in
GENERAL SPECIFICATION DATA
Valves
Length
Inlet .........................................................................
Exhaust ...................................................................
Seat angle
Inlet .........................................................................
Exhaust ...................................................................
Head diameter
Inlet .........................................................................
Exhaust ...................................................................
Stem diameter
Inlet .........................................................................
Exhaust ...................................................................
Stem to guide clearance
Inlet .........................................................................
Exhaust ...................................................................
Valve lift (inlet and exhaust) .............................................
Valve spring length fitted
Up to 99MY .............................................................
From 99MY .............................................................
116.59 - 117.35 mm
116.59 - 117.35 mm
Up to 99MY
46° - 46° 25’
46° - 46° 25’
4.590 - 4.620 in
4.590 - 4.620 in
From 99MY
45° - 45° 30’
45° - 45° 30’
39.75 - 40.00 mm
34.227 - 34.48 mm
1.565 - 1.575 in
1.3475 - 1.3575 in
8.664 - 8.679 mm
8.651 - 8.666 mm
0.3411 - 0.3417 in
0.3406 - 0.3412 in
0.025 - 0.066 mm
0.038 - 0.078 mm
9.94 mm
0.0010 - 0.0026 in
0.0015 - 0.0031 in
0.3913 in
40.40 mm (1.59 in) at pressure of 29.5 kg (65 lb)
40.93 mm (1.61 in) at pressure of 29.5 kg (65 lb)
Lubrication
System type ..................................................................... Wet sump, pressure fed
Oil pump type ................................................................... Crank driven rotor
Oil pressure
Up to 99MY ............................................................. 2.06 to 2.7 bar (30 to 40 lbf/in2) at 2400 rev/min with
engine warm
From 99MY ............................................................. 3.45 bar (50 lbf/in2) at 2000 rev/min with engine warm
Oil filter-internal ................................................................ Wire screen, pump intake filter in sump
Oil filter-external ............................................................... Full flow, self-contained cartridge
INFORMATION
3
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
ENGINE - 4.6 V8
Type .................................................................................
Number of cylinders .........................................................
Bore .................................................................................
Stroke ...............................................................................
Capacity ...........................................................................
Valve operation ................................................................
Compression ratio
Up to 99MY .............................................................
From 99MY .............................................................
Maximum power (at 4750 rev/min)
Up to 99MY .............................................................
From 99MY
All except NAS ...............................................
NAS only ........................................................
4.6 litre V8
Eight, two banks of four
94.00 - 94.04 mm
81.92 - 82.08 mm
4554 cm3
Overhead by push-rod
High Compression
9.35:1
9.37:1
Low Compression
8.36:1
8.37:1
165.5 kW
157 kW
160 kW
165.5 kW
150 kW
3.7008 - 3.7024 in
3.2252 - 3.2315 in
278 in3
Crankshaft
Main journal diameter ....................................................... 63.500 - 63.487 mm
2.50 - 2.4995 in
Crankpin journal diameter ................................................ 55.513 - 55.500 mm
2.21 - 2.20 in
Crankshaft end thrust/end float ........................................ Taken on thrust washers of centre main bearing
0.10 - 0.20 mm
0.004 - 0.008 in
Main bearings
Number and type
Up to 99MY .............................................................
From 99MY .............................................................
Material ............................................................................
Diametrical clearance .......................................................
5, Vandervell shells
5, Glacier Vandervell / AS15
Lead bronze with lead-indium overlay
0.010 - 0.048 mm
0.0004 - 0.002 in
Connecting rods
Type ................................................................................. Horizontally split big-end, plain small-end
Length between centres ................................................... 149.68 - 149.78 mm
5.893 - 5.897 in
Big-end bearings
Type and material
Up to 99MY ............................................................. Vandervell VP Lead bronze with lead-indium overlay
From 99MY ............................................................. Glacier Vandervell GPL2120/AS124A
Diametrical clearance ....................................................... 0.015 - 0.055 mm
0.0006 - 0.002 in
Piston pins
Length ..............................................................................
Diameter ..........................................................................
Fit-in connecting rod .........................................................
Clearance in piston ..........................................................
60.00 - 60.50 mm
23.995 - 24.000 mm
Press fit
0.015 - 0.006 mm
Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin
Up to 99MY ............................................................. 0.020 - 0.050 mm
From 99MY ............................................................. 0.022 - 0.067 mm
4
INFORMATION
2.3622 - 2.3819 in
0.9447 - 0.9449 in
0.0006 - 0.0002 in
0.0008 - 0.0020 in
0.0009 - 0.0026 in
GENERAL SPECIFICATION DATA
Piston rings
Number of compression rings ..........................................
Number of oil control rings ...............................................
No 1 compression ring .....................................................
No 2 compression ring .....................................................
Width of compression rings
Bottom .....................................................................
Top
Up to 99MY ....................................................
From 99MY .....................................................
Compression ring gap
Bottom .....................................................................
Top ..........................................................................
Oil control ring type
Up to 99MY .............................................................
From 99MY .............................................................
Oil control ring width .........................................................
Oil control ring rail gap .....................................................
Camshaft
Location ...........................................................................
Bearings ...........................................................................
Number of bearings ..........................................................
Drive .................................................................................
Camshaft end float
Up to 99MY .............................................................
From 99MY .............................................................
2
1
Nitrided steel barrel faced
Tapered spherical barrel marked ’TOP’
1.478 - 1.49 mm
0.0582 - 0.0587 in
1.21 - 1.23 mm
1.17 - 1.19 mm
0.0476 - 0.0484 in
0.0461 - 0.0479 in
0.40 - 0.65 mm
0.3 - 0.5 mm
0.0157 - 0.0256 in
0.0118 - 0.0197 in
Aclonoform
3 Piece Aeconoform
3.0 mm
0.38-1.40 mm
0.1181 in
0.0150 - 0.0551 in
Central
Non serviceable
5
Chain 9.52 mm pitch x 54 pitches.
0.076 - 0.355 mm
0.075 - 0.350 mm
0.003 - 0.014 in
0.002 - 0.013 in
Tappets ........................................................................... Hydraulic self-adjusting
Valves
Length
Inlet .........................................................................
Exhaust ...................................................................
Seat angle
Inlet .........................................................................
Exhaust ...................................................................
Head diameter
Inlet .........................................................................
Exhaust ...................................................................
Stem diameter
Inlet .........................................................................
Exhaust ...................................................................
Stem to guide clearance
Inlet .........................................................................
Exhaust ...................................................................
Valve lift (inlet and exhaust) .............................................
Valve spring length fitted
Up to 99MY .............................................................
From 99MY .............................................................
116.59 - 117.35 mm
116.59 - 117.35 mm
Up to 99MY
46° - 46° 25’
46° - 46° 25’
4.590 - 4.620 in
4.590 - 4.620 in
From 99MY
45° - 45° 30’
45° - 45° 30’
39.75 - 40.00 mm
34.227 - 34.48 mm
1.565 - 1.575 in
1.3475 - 1.3575 in
8.664 - 8.679 mm
8.651 - 8.666 mm
0.3411 - 0.3417 in
0.3406 - 0.3412 in
0.025 - 0.066 mm
0.038 - 0.078 mm
9.94 mm
0.0010 - 0.0026 in
0.0015 - 0.0031 in
0.3913 in
40.40 mm (1.59 in) at pressure of 29.5 kg (65 lb)
40.93 mm (1.61 in) at pressure of 29.5 kg (65 lb)
INFORMATION
5
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
Lubrication
System type ..................................................................... Wet sump, pressure fed
Oil pump type ................................................................... Crank driven rotor
Oil pressure
Up to 99MY ............................................................. 2.06 to 2.7 bar (30 to 40 lbf/in2) at 2400 rev/min with
engine warm
From 99MY ............................................................. 3.45 bar (50 lbf/in2) at 2000 rev/min with engine warm
Oil filter-internal ................................................................ Wire screen, pump intake filter in sump
Oil filter-external ............................................................... Full flow, self-contained cartridge
6
INFORMATION
GENERAL SPECIFICATION DATA
ENGINE - BMW DIESEL
Type .................................................................................
Number of cylinders .........................................................
Bore .................................................................................
Stroke ...............................................................................
Capacity ...........................................................................
Compression ratio ............................................................
Valve operation ................................................................
Turbo charger ..................................................................
Indirect injection, turbocharged, intercooled
6
80.00 mm
3.15 in
82.80 mm
3.26 in
152 in3
2497 cm3
22.5:1 ± 1:1
OHC chain driven
Mitsubishi TD04 - 11G4
Camshaft
Drive ................................................................................. Chain
Number of bearings .......................................................... 7
Cylinder head
Longitudinal warp ............................................................. 0.1 mm
Lateral warp ..................................................................... 0.05 mm
Valves and guides
Valve head diameter:
Inlet ..................................
Exhaust ...........................
Stem diameter - Standard:
Inlet ..................................
Service limit .....................
Exhaust ...........................
Service limit .....................
Stem diameter - 1st oversize: Inlet ..................................
Service limit .....................
Exhaust ...........................
Service limit .....................
Stem diameter - 2nd oversize: Inlet ..................................
Service limit .....................
Exhaust ...........................
Service limit .....................
Valve head stand-down:
Inlet ..................................
Exhaust ...........................
Valve head oversizes - increased thickness ....................
Valve tilt - inlet and exhaust .............................................
Valve seats:
Valve seat angle ...............................................................
Correction angle - outside ................................................
Correction angle - inside ..................................................
Seat face outside diameter
Inlet ..................................
Exhaust ...........................
Valve seat width
Inlet ..................................
Exhaust ...........................
Valve guides:
Inner diameter for reaming - inlet and exhaust
Standard ..........................................................................
1st oversize valve stem ....................................................
2nd oversize valve stem ...................................................
0.004 in
0.002 in
36.0 mm
31.0 mm
6.97 mm
6.95 mm
6.95 mm
6.93 mm
7.07 mm
7.05 mm
7.06 mm
7.04 mm
7.17 mm
7.15 mm
7.16 mm
7.14 mm
0.65 to 0.85 mm
0.85 to 1.05 mm
0.25 and 0.50 mm
0.5 mm
1.42 in
1.22 in
0.274 in
0.273 in
0.273 in
0.272 in
0.28 in
0.277 in
0.278 in
0.27 in
0.282 in
0.28 in
0.281 in
0.279 in
0.02 to 0.03 in
0.03 to 0.04 in
0.01 and 0.02 in
0.02 in
45° ± 10’
15°
60°
35.5 mm
30.6 mm
1.75 to 2.25 mm
2.60 to 2.90 mm
1.4 in
1.2 in
0.007 to 0.09 in
0.10 to 0.11 in
7.0 mm
7.1 mm
7.2 mm
0.275 in
0.28 in
0.283 in
INFORMATION
7
04
GENERAL SPECIFICATION DATA
Crankshaft
Main bearing bearing journal diameter
Yellow .....................................................................
Green ......................................................................
White .......................................................................
Oversize bearings ............................................................
Big-end journal diameter:
Standard ..........................................................................
1st undersize - Size 1 - 0.25 mm (0.01 in) .......................
2nd undersize - Size 2 - 0.50 mm (0.02 in) ......................
Oversize bearings ............................................................
Crankshaft end float .........................................................
NEW RANGE ROVER
59.984 to 59.990 mm
59.977 to 59.983 mm
59.971 to 59.976 mm
0.25 and 0.50 mm
2.3616 to 2.3618 in
2.3612 to 2.3615 in
2.3610 to 2.3611 in
0.01 and 0.02 in
44.975 to 45.00 mm
44.725 to 44.75 mm
44.475 to 44.50 mm
0.25 and 0.50 mm
0.080 to 0.163 mm
1.770 to 1.771 in
1.761 to 1.762 in
1.751 to 1.752 in
0.01 and 0.02 in
0.003 to 0.006 in
Main bearings
Number and type .............................................................. 7 halved shells with oil grooves
Diametrical clearance ....................................................... 0.020 to 0.058 mm
0.001 to 0.002 in
Connecting rods
Diametrical clearance (big-end bearings) ........................
Gudgeon pin bush bore ....................................................
Maximum deviation of connecting rod parallelism ............
Maximum distortion ..........................................................
Pistons
Type .................................................................................
Piston diameter measured 7 mm (0.27 in) from lower
edge and at right angles to gudgeon pin ..........................
Intermediate size ..............................................................
Oversize 1 ........................................................................
Piston running clearance ..................................................
Piston rings
Type:
Top ..........................................................................
Second ....................................................................
Oil control ................................................................
Gap in bore:
All ............................................................................
Clearance in piston grooves:
Top ..........................................................................
Second ....................................................................
Oil control ................................................................
Cylinder bores
Standard ..........................................................................
Intermediate .....................................................................
1st oversize ......................................................................
Maximum ovality ..............................................................
Maximum taper ................................................................
8
INFORMATION
0.010 to 0.055 mm
28.995 to 29.021 mm
0.05 mm
0.5 mm
0.0004 to 0.002 in
1.142 to 1.143 in
0.002 in
0.02 in
Aluminium alloy, combustion chamber in crown
79.96 ± 0.009 mm
80.04 ± 0.009 mm
80.21 ± 0.009 mm
0.031 to 0.63 mm
3.14 ± 0.004 in
3.15 ± 0.004 in
3.16 ± 0.004 in
0.0012 to 0.002 in
Double keystone
Taper faced
Bevelled ring with spring
0.2 to 0.4 mm
0.008 to 0.020 in
Not measured
0.040 to 0.072 mm
0.030 to 0.065 mm
0.002 to 0.004 in
0.001 to 0.003 in
80.00 to 80.04 mm
80.08 to 80.12 mm
80.25 to 80.29 mm
0.04 mm
0.04 mm
3.150 to 3.151 in
3.153 to 3.154 in
3.20 to 3.21 in
0.002 in
0.002 in
GENERAL SPECIFICATION DATA
Lubrication
System .............................................................................
Oil pressure, at idle ..........................................................
Regulated pressure ..........................................................
Oil pump:
Type ........................................................................
Drive ........................................................................
Radial clearance:
Inner rotor/bearing sleeve (max.) .....................................
Outer rotor/pump body (max.) ..........................................
Axial clearance:
Inner rotor/pump body ......................................................
Outer rotor/pump body .....................................................
Oil pressure relief valve ....................................................
Relief valve spring:
Length relaxed ........................................................
Oil filter .............................................................................
Engine oil cooler ...............................................................
Wet sump, pressure fed
2.0 bar
3.8 bar
29.0 lbf/in2
55.0 lbf/in2
Internal gear type pump, mounted on front of engine
Direct from crankshaft
0.065 mm
0.4 mm
0.003 in
0.02 in
0.065 mm
0.003 in
0.070 mm
0.004 in
piston operated, non-adjustable
84.10 mm
3.3 in
Disposable cartridge
Mounted on front of coolant radiator
INFORMATION
9
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
ENGINE MANAGEMENT SYSTEM (EMS) V8
ENGINE
Type
Up to 99MY ............................................................. Sagem - Lucas Gems 8 hot wire system, electronically
controlled
From 99MY ............................................................. Bosch Motronic M5.2.1, electronically controlled
Fuel pump ........................................................................ High pressure electrical, immersed in the fuel tank
Fuel pump delivery pressure
Up to 99MY ............................................................. 2.4-2.6 bar
34-37 lbf/in2
From 99MY ............................................................. 3.5 bar
50.75 lbf/in2
Fuel filter .......................................................................... Bosch in-line filter ’canister’ type
Mass airflow sensor
Make and type
Up to 99MY ............................................................. Lucas ’Hot Wire’ 20AM
From 99MY ............................................................. Bosch EH1174 (includes air intake temperature
sensor)
Injectors
Make and type
Up to 99MY ............................................................. Lucas D1000
From 99MY ............................................................. Bosch EV6C
Electronic Control Module
Make and type
Up to 99MY ............................................................. Lucas GEMS 8.2
From 99MY ............................................................. Bosch M5.2.1
Fuel pressure regulator
Make and type
Up to 99MY ............................................................. Lucas 8RV
From 99MY ............................................................. Rochester (part of fuel pump)
Coolant temperature sensor
Make and type ................................................................. Lucas 8TT
Bypass air valve (Stepper motor)
Make and type
Up to 99MY ............................................................. Lucas 3ACM
From 99MY ............................................................. Bosch
Throttle position sensor
Make and type
Up to 99MY ............................................................. Lucas 3TP
From 99MY ............................................................. Bosch DKG1
10
INFORMATION
GENERAL SPECIFICATION DATA
Heated oxygen sensor - catalyst vehicles
Make and type
Up to 99MY ............................................................. Lucas 4LS
From 99MY ............................................................. Bosch LSH
Camshaft position sensor
Make and Land Rover part no.
Up to 99MY ............................................................. Honeywell ERR2261
From 99MY ............................................................. Lucas ERR6170
Crankshaft position sensor
Make and type
Up to 99MY ............................................................. Lucas 4CS
From 99MY ............................................................. Bosch DG6
Knock sensor
Make and type
Up to 99MY ............................................................. Lucas 2KS
From 99MY ............................................................. Bosch KS1S
Intake air temperature sensor
Make and type
Up to 99MY ............................................................. Lucas 10TT
From 99MY ............................................................. Not applicable (combined with MAF sensor)
Ignition coils
Make and type
Up to 99MY ............................................................. Lucas 2DIS2
From 99MY ............................................................. Bosch 0 221 503 407
Fuel temperature sensor
Make and type
Up to 99MY ............................................................. Lucas 6TT
From 99MY ............................................................. Not applicable
INFORMATION
11
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
FUEL SYSTEM - BMW DIESEL ENGINE
Injection pump type ..........................................................
Injection pump timing .......................................................
Injectors ...........................................................................
Heater plugs .....................................................................
Fuel lift pump type ............................................................
Fuel filter ..........................................................................
Air cleaner ........................................................................
Turbocharger ...................................................................
Bosch rotary R515
0.95 ± 0.02 mm lift at TDC
See ENGINE TUNING DATA, Information.
See ENGINE TUNING DATA, Information.
Electric in tank fuel pump
Paper element type
Paper element type
Mitsubishi TD04 11G4
COOLING SYSTEM - V8 ENGINE
System type ..................................................................... Pressurized, spill return, thermostatically controlled
water and anti freeze mixture. Vertical flow radiator
with remote header tank and pump assisted.
Cooling fan ....................................................................... 9 blade axial flow. Viscous coupling.
Pump type ........................................................................ Centrifugal, impeller, belt driven.
Thermostat opening
Up to 99MY ............................................................. 88 °C
190 °F
From 99MY ............................................................. 85 ± 5 °C
185 ± 9 °F
Expansion tank cap pressure (system pressure) ............. 1.0 bar
15 lbf/in2
COOLING SYSTEM - BMW DIESEL ENGINE
System type ..................................................................... Pressurized, spill return, thermostatically controlled
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
Cooling fan ....................................................................... 11 blade axial flow 433 mm diameter. 1.44:1 drive
ratio. Viscous coupling.
Pump type ........................................................................ Centrifugal, impeller, belt driven.
Thermostat opening ......................................................... 80 °C
176 °F
Expansion tank cap pressure (system pressure) ............. 1.0 bar
15 lbf/in2
12
INFORMATION
GENERAL SPECIFICATION DATA
MANUAL TRANSMISSION
Clutch
Make and type - V8 engine ..............................................
Clutch plate diameter .......................................................
Make and type - Diesel engine .........................................
Clutch plate diameter .......................................................
AP Borg and Beck, diaphragm spring
265 mm (10,43 in.)
Valeo, diaphragm spring
242 mm (9.53 in.)
Transfer gearbox
Borg Warner ..................................................................... Two speed reduction on main gearbox output, front
and rear drive permanently engaged via a centre
differential controlled by a Viscous unit giving a 50/50
nominal front and rear torque split.
Transfer gearbox ratios
High .................................................................................. 1.216:1
Low .................................................................................. 3.271:1
Manual gearbox
Type R380 ....................................................................... 5 speed, single helical constant mesh with
synchromesh on all gears
Manual gearbox ratios:
5th ...........................................................................
4th ...........................................................................
3rd ...........................................................................
2nd ..........................................................................
1st ...........................................................................
Reverse ...................................................................
Diesel models low first gear ....................................
0.731:1
1.000:1
1.397:1
2.132:1
3.321:1
3.429:1
3.692:1
Overall ratio (final drive):
5th ...........................................................................
4th ...........................................................................
3rd ...........................................................................
2nd ..........................................................................
1st ...........................................................................
Reverse ...................................................................
Diesel models low 1st gear .....................................
High transfer
3.15:1
4.30:1
6.01:1
9.18:1
14.29:1
14.76:1
15.89:1
Low transfer
8.46:1
11.58:1
16.18:1
24.69:1
38.45:1
39.70:1
42.75:1
Propeller shafts
Type:
Front ........................................................................ Tubular 51mm diameter
Rear ........................................................................ Tubular 51mm diameter
Universal joints ................................................................. Open type Hooks O3EHD
Rear axle
Type ................................................................................. Spiral bevel
Ratio ................................................................................. 3.54:1
Front axle
Type ................................................................................. Spiral bevel
Ratio ................................................................................. 3.54:1
INFORMATION
13
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
AUTOMATIC TRANSMISSION
Automatic gearbox
Model
2.5 litre Diesel & 4.0 litre Petrol ............................... ZF4HP22
4.6 litre Petrol .......................................................... ZF4HP24
Type ................................................................................. Four speed and reverse epicyclic gears with fluid
torque converter and lock up.
Transfer gearbox
Borg Warner ..................................................................... Two speed reduction on main gearbox output, front
and rear drive permanently engaged via a centre
differential controlled by a Viscous unit giving a 50/50
nominal front and rear torque split.
Transfer gearbox ratios
High .................................................................................. 1.216:1
Low .................................................................................. 3.271:1
Automatic gearbox ratios
4th ...........................................................................
3rd ...........................................................................
2nd ..........................................................................
1st ...........................................................................
Reverse ...................................................................
0.728:1
1.000:1
1.480:1
2.480:1
2.086:1
Overall ratio (final drive):
4th ...........................................................................
3rd ...........................................................................
2nd ..........................................................................
1st ...........................................................................
Reverse ...................................................................
High transfer
3.13:1
4.30:1
6.37:1
10.67:1
8.98:1
Propeller shafts
Type:
Front ........................................................................ Tubular 51mm diameter
Rear ........................................................................ Tubular 51mm diameter
Universal joints ................................................................. Open type Hooks O3EHD
Rear axle
Type ................................................................................. Spiral bevel
Ratio ................................................................................. 3.54:1
Front axle
Type ................................................................................. Spiral bevel
Ratio ................................................................................. 3.54:1
14
INFORMATION
Low transfer
8.43:1
11.58:1
17.14:1
28.72:1
24.15:1
GENERAL SPECIFICATION DATA
STEERING
Power steering box
Make/type ........................................................................ ZF type 8055, recirculating ball steering gear
Steering wheel turns, lock-to-lock .................................... 3.2
Steering pump
Make/type:
V8 engine ................................................................ ZF type 7691, vane type
Diesel engine .......................................................... ZF type7681, vane type
Steering geometry
Steering wheel diameter ..................................................
Toe-out measurement ......................................................
Toe-out included angle .....................................................
Camber angle ..................................................................
Castor angle .....................................................................
Swivel pin inclination static ...............................................
406.4mm (16 in.)
0.6 to 1.80mm (0.02 - 0.07 in.)
0°5’ to 0°15’
0°
NOTE:
4°
Check at
8°
kerbweight
SUSPENSION
Type:
Air suspension ........................................................ Variable rate air springs controlled by an ECU giving 5
height profiles. Automatic self levelling. Automatic
standard and low profiles. Driver selected access, low
and high profiles.
Lateral location of axle by Panhard rod.
Front ................................................................................. Fore and aft location by two radius arms.
Lateral location of axle by a Panhard rod.
Rear ................................................................................. Fore and aft movement controlled by two trailing
arms.
Lateral location of axle by a Panhard rod.
SHOCK ABSORBERS
Type ................................................................................. Telescopic, double-acting non-adjustable
AIR CONDITIONING
System ............................................................................. CFC free expansion valve system
Compressor
V8 up to 99MY ........................................................ Sanden TRS105N
V8 from 99MY and diesel ........................................ Nippon Denso 10PA17
INFORMATION
15
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
BRAKES
Front service brake
Caliper ..............................................................................
Operation .........................................................................
Disc ..................................................................................
Disc diameter ...................................................................
Disc thickness ..................................................................
Wear limit .........................................................................
Disc run out maximum .....................................................
Pad area ..........................................................................
Total swept area ...............................................................
Pad minimum thickness ...................................................
Lucas Colette, single sided, two piston
Power hydraulic, self-adjusting
Reverse ventilated, outboard
297.2 mm (11.7 in.)
25 mm (1 in.)
22.0 mm (0.87 in.)
0.15 mm (0.006 in)
64.9 cm2 (10 in2) per pad
844 cm2 (130.8 in2) per disc
2 mm (0.08 in.)
Rear service brake
Caliper ..............................................................................
Operation .........................................................................
Disc ..................................................................................
Disc diameter ...................................................................
Disc thickness ..................................................................
Wear limit .........................................................................
Disc run out maximum .....................................................
Pad area ..........................................................................
Total swept area ...............................................................
Pad minimum thickness ...................................................
Lucas Colette,single sided, single piston
Power hydraulic, self-adjusting
Solid, outboard
304.0 mm (12 in.)
12.6 mm (0.5 in.)
11.7 mm (0.46 in.)
0.15 mm (0.006 in)
34.4 cm2 (5.33 in2) per pad
798 cm2 (123.7 in2) per disc
2 mm (0.08 in.)
Parking brake
Type ................................................................................. Mechanical-cable operated drum brake on the rear
of the transfer gearbox output shaft
Drum internal diameter ..................................................... 254 mm (10 in.)
Width ................................................................................ 70 mm (2.75 in)
Anti-lock brake system
Manufacturer/type ............................................................ Wabco/power hydraulic - 4 channel, 4 wheel sensed
integrated anti-lock brake system.
ABS control ...................................................................... Microprocessor based ECU
System split ...................................................................... Front/rear
Power source ................................................................... Electrically driven pump
Power storage .................................................................. Hydraulic accumulator
Maximum boost pressure ................................................. 180 bar
Reservoir .......................................................................... Built in low fluid warning. Supplies clutch hydraulic
system
Electronic traction control
Type ................................................................................. Integrated with ABS system
ETC control ...................................................................... Integrated with ABS ECU
16
INFORMATION
GENERAL SPECIFICATION DATA
ELECTRICAL
System ............................................................................ 12 volt, negative ground
Battery
Make: ............................................................................... Land Rover Parts and Equipment maintenance free
Type:
V8 ............................................................................ 072, 72 amp/hr
Diesel ...................................................................... 664, 107 amp/hr
Alternator
Make and type
V8 up to 99MY and diesel ....................................... Magnetti Marelli A133, 100A, 105A or 120A
V8 from 99MY ......................................................... Bosch NC90/150, 150A
Fuses
Type ................................................................................. Autofuse (blade type) blow ratings
to suit individual circuits
Horns
Make/type ........................................................................ Klamix (Mixo) TR99
Starter motor
Make and type:
V8 Engine ............................................................... Bosch 331.303.006.808 pre-engaged
Diesel Engine .......................................................... Bosch 0.001.362.092 pre-engaged
INFORMATION
17
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
REPLACEMENT BULBS
BULB LOCATION
TYPE
Exterior:
Dip/main headlamps ...............................................
Inboard main beam headlamps ...............................
Front fog lamps .......................................................
Sidelamps ...............................................................
Tail lamps ................................................................
Rear fog lamps ........................................................
Reverse lamps ........................................................
Stop lamps ..............................................................
Direction indicator lamps .........................................
Side repeater lamps ................................................
Number plate lamps ................................................
12V - 60/55W (Halogen)
12V - 55W (Halogen)
12V - 55W H3 (Halogen)
12V - 5W capless
12V - 5W capless
12V - 21W bayonet
12V - 21W bayonet
12V - 21W bayonet
12V - 21W bayonet
12V - 5W capless
12V - 5W capless
Interior:
Front interior roof lamps ..........................................
Map reading lamp ...................................................
Rear interior roof lamps ...........................................
Map reading lamp ...................................................
Puddle lamps ..........................................................
Glovebox lamp ........................................................
Vanity mirror lamp ...................................................
Rear footwell lamp ..................................................
Load space lamp .....................................................
Clock illumination ....................................................
Cigar lighter illumination ..........................................
Auxiliary switch illumination .....................................
Auxiliary switch warning lamp .................................
Heater/air conditioning graphics illumination ...........
12V - 10W ’Festoon’
12V - 5W capless
12V - 5W ’Festoon’
12V - 5W capless
12V - 3W capless
12V - 5W ’Festoon’
12V - 1.2W ’Festoon’
12V - 5W ’Festoon’
12V - 10W ’Festoon’
12V - 2W bayonet
12V - 1.2W capless
12V - 0.2W capless
12V - 0.2W capless
12V - 1.2W capless
Instrument panel:
Instrument panel illumination .................................. 14V - 3.4W T10 bulb/holder unit
Warning lamps ........................................................ 14V - 1.4W T5 bulb/holder unit
LCD background ..................................................... 14V - 1.4W T5 bulb/holder unit
NOTE: The correct specification Toshiba bulbs must be used in the instrument panel to ensure the
correct level of illumination.
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.
18
INFORMATION
GENERAL SPECIFICATION DATA
VEHICLE WEIGHTS AND PAYLOAD
When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the vehicle kerb
weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum
values. It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither
maximum axle loads nor Gross Vehicle Weight are exceeded.
GROSS VEHICLE WEIGHT
Front Axle ..............................
Rear Axle ..............................
Total ......................................
Maximum Payload .................
Petrol Models
Diesel Models
1320 kg (2910 lb) .............
1840 kg (4056 lb) .............
2780 kg (6129 lb) .............
603 kg (1329 lb) ...............
1320 kg (2910 lb)
1840 kg (4056 lb)
2780 kg (6129 lb)
596 kg (1314 lb)
EEC KERB WEIGHT AND DISTRIBUTION
4.0 Litre Manual
4.0 Litre Automatic
4.6 Litre Automatic
EEC Kerb Weight .................. 2090 kg (4607 lb) ............. 2100 kg (4629 lb) ............. 2220 kg (4894 lb)
Front Axle .............................. 1095 kg (2414 lb) ............. 1100 kg (2425 lb) ............. 1165 kg (2568 lb)
Rear Axle .............................. 995 kg (2193 lb) ............... 1000 kg (2204 lb) ............. 1055 kg (2325 lb)
2.5 Diesel Manual
2.5 Diesel Automatic
EEC Kerb Weight .................. 2115 kg (4662 lb) ............. 2130 kg (4695 lb)
Front Axle .............................. 1110 kg (2447 lb) ............. 1120 kg (2469 lb)
Rear Axle .............................. 1005 kg (2215 lb) ............. 1010 kg (2226 lb)
NOTE: EEC KERB WEIGHT is the minimum vehicle specification plus full fuel tank and 75 kg (165
lb) driver.
NOTE: GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver,
passengers, and equipment. This figure is liable to vary according to legal requirements in certain
countries.
NOTE: MAXIMUM ROOF RACK LOAD (including weight of rack) 75 kg (165 lb) must be included in
total vehicle weight.
INFORMATION
19
04
GENERAL SPECIFICATION DATA
NEW RANGE ROVER
VEHICLE DIMENSIONS
Overall length ...................................................................
Width excluding door mirrors ...........................................
Width including door mirrors ............................................
Overall height at standard profile .....................................
Wheelbase .......................................................................
Track:
Front ........................................................................
Rear ........................................................................
mm
4713
1853
2228
1817.5
2745
inches
185.6
73.0
87.7
71.6
108.1
1540
1530
60.6
60.2
Turning circle between kerbs ........................................... 11.9 m (39 ft)
TYRE PRESSURES
Normal on and off-road use. All speeds and loads
Front
bar ........................................................................... 1.9
lbf/in2 ....................................................................... 28
kgf/cm2 .................................................................... 2.0
Rear
2.6
38
2.7
NOTE: Check pressures with tyres cold
WARNING: After any off-road driving, tyres and wheels should be inspected for damage,
particularly if high cruising speeds are subsequently to be used.
WHEELS AND TYRES
Wheel type and size ......................................................... Alloy 7.00J X 16 (use with 235/70 tyres)
Alloy 8.00J X 16 (use with 255/65 tyres)
Alloy 8.00J X 18 (use with 255/55 tyres)
WARNING: All vehicles are fitted with tubeless alloy road wheels as original equipment. Note that
these wheels DO NOT accept inner tubes and tubed tyres MUST NOT be fitted.
20
INFORMATION
05 - ENGINE TUNING DATA
CONTENTS
Page
INFORMATION
ENGINE - 4.0 V8 .................................................................................................. 1
ENGINE - 4.6 V8 .................................................................................................. 2
ENGINE - BMW DIESEL ...................................................................................... 3
ENGINE TUNING DATA
ENGINE - 4.0 V8
Type ................................................................................. 4.0 Litre V8
Firing order ..................................................................... 1-8-4-3-6-5-7-2
Cylinder Numbers
Left bank .......................................................................... 1-3-5-7
Right bank ........................................................................ 2-4-6-8
No 1 Cylinder location ................................................... Pulley end of left bank
Spark plugs
Make and type
Up to 99MY .............................................................
From 99MY .............................................................
Gap
Up to 99MY .............................................................
From 99MY .............................................................
Champion RN11YCC
Champion RC11PYB4
0.90 - 1.00 mm
1.00 ± 0.05 mm
0.035 - 0.040 in
0.040 ± 0.002 in
NOTE: Do not attempt to adjust the gaps of RC11PYB4 spark plugs.
Valve timing
Inlet
Opens .............................................................................. 28°BTDC
Closes .............................................................................. 77°ABDC
Exhaust
66°BBDC
39°ATDC
Idle speed - controlled by Engine Management System
Up to 99MY ...................................................................... 700 ± 20 rev/min
From 99MY ...................................................................... 660 rev/min
Base idle setting ............................................................. Not adjustable (idle air control valve position checked
via TestBook)
CO at idle (vehicles without heated oxygen sensors)
Up to 99MY ...................................................................... 1.0 - 2.0 %
From 99MY ...................................................................... 0.5 - 1.0 %
Calculated Load Value (CLV) - Engine fully warm, in neutral gear, with all loads off
At Idle ............................................................................... 2.8 to 3.8%
At 2500 rev/min ................................................................ 10% ± 1%
Air mass flow at sea level - Engine fully warm, in neutral gear, with all loads off
At Idle ............................................................................... 20 ± 3 kg/hr
At 2500 rev/min ................................................................ 60 ± 3 kg/hr
INFORMATION
1
05
ENGINE TUNING DATA
NEW RANGE ROVER
ENGINE - 4.6 V8
Type ................................................................................. 4.6 Litre V8
Firing order ..................................................................... 1-8-4-3-6-5-7-2
Cylinder Numbers
Left bank .......................................................................... 1-3-5-7
Right bank ........................................................................ 2-4-6-8
No 1 Cylinder location ................................................... Pulley end of left bank
Spark plugs
Make and type
Up to 99MY .............................................................
From 99MY .............................................................
Gap
Up to 99MY .............................................................
From 99MY .............................................................
Champion RN11YCC
Champion RC11PYB4
0.90 - 1.00 mm
1.00 ± 0.05 mm
0.035 - 0.040 in
0.040 ± 0.002 in
NOTE: Do not attempt to adjust the gaps of RC11PYB4 spark plugs.
Valve Timing
Up to 99MY
Opens .....................................................................
Closes .....................................................................
From 99MY
Opens .....................................................................
Closes .....................................................................
Inlet
Exhaust
14°BTDC
70°ABDC
64°BBDC
20°ATDC
28°BTDC
64°ABDC
72°BBDC
20°ATDC
Idle speed - controlled by Engine Management System
Up to 99MY ...................................................................... 700 ± 20 rev/min
From 99MY ...................................................................... 660 rev/min
Base idle setting ............................................................. Not adjustable (idle air control valve position checked
via TestBook)
CO at idle (vehicles without heated oxygen sensors)
Up to 99MY ...................................................................... 1.0 - 2.0 %
From 99MY ...................................................................... 0.5 - 1.0 %
Calculated Load Value (CLV) - Engine fully warm, in neutral gear, with all loads off
At Idle ............................................................................... 2.8 to 3.8%
At 2500 rev/min ................................................................ 10% ± 1%
Air mass flow at sea level - Engine fully warm, in neutral gear, with all loads off
At Idle ............................................................................... 20 kg/hr ± 3 kg\hr
At 2500 rev/min ................................................................ 61 kg\hr ± 3 kg\hr
2
INFORMATION
ENGINE TUNING DATA
ENGINE - BMW DIESEL
ENGINE
Type ................................................................................. 2.5 Litre turbocharged diesel, indirect injection engine
with intercooler
Firing order ....................................................................... 1-5-3-6-2-4
Injection timing at TDC, No.1 cylinder .............................. 0.95 ± 0.02 mm lift
0.04 ± 0.0008 in lift
Timing marks:
Valve timing ............................................................. Slot for pin in flywheel
Injection timing ............................................................... Dial gauge inserted into pump
Maximum governed speeds:
Full load (speed cut-off starts) ................................. 4400 rev/min
No load (flight speed) .............................................. 4950 ± 150 rev/min
Idle speed ............................................................... 750 ± 50 rev/min
INJECTION PUMP
Make/type:
Digital Diesel Electronic Control - DDE ............................ Bosch rotary R515 type with electronic control of fuel
and timing. Constant pressure delivery valves.
Direction of rotation .......................................................... Clockwise, viewed from drive end
INJECTORS
Make/type
Standard .................................................................
Nozzle type ......................................................................
Opening (injection) pressure
Minimum pressure ...................................................
Maximum pressure ..................................................
Maximum pressure deviation ..................................
Needle lift sensor in no.4 injector .....................................
Bosch KCA 21 S 71
DN O SD 300
140 bar
160 bar
10 bar
Bosch KCA 21 S 76
2030 lbf/in2
2320 lbf/in2
145 lbf/in2
HEATER PLUGS
Make/type ........................................................................ Beru, probe type, 12 volts
Temperature after 5 seconds of operation ....................... 800°C
Resistance at 20 °C ......................................................... 0.4 - 0.6 Ohms
TURBOCHARGER
Make/type ........................................................................ Mitsubishi/TD04 - 11G4
INFORMATION
3
06 - TORQUE VALUES
CONTENTS
Page
INFORMATION
MAINTENANCE ................................................................................................... 1
ENGINE - BMW DIESEL ...................................................................................... 1
ENGINE - V8 PETROL ......................................................................................... 3
EMISSION CONTROL ......................................................................................... 4
FUEL SYSTEM - BMW DIESEL ........................................................................... 4
FUEL SYSTEM - V8 PETROL ............................................................................. 5
COOLING SYSTEM - BMW DIESEL ................................................................... 5
COOLING SYSTEM - V8 PETROL ...................................................................... 5
MANIFOLD AND EXHAUST SYSTEM - BMW DIESEL ....................................... 6
MANIFOLD AND EXHAUST SYSTEM - V8 PETROL .......................................... 6
CLUTCH - BMW DIESEL ..................................................................................... 7
CLUTCH - V8 PETROL ........................................................................................ 7
MANUAL GEARBOX - R380 ................................................................................ 7
TRANSFER GEARBOX ....................................................................................... 7
AUTOMATIC GEARBOX - ZF .............................................................................. 8
PROPELLER SHAFTS ......................................................................................... 8
REAR AXLE AND FINAL DRIVE ......................................................................... 8
FRONT AXLE AND FINAL DRIVE ....................................................................... 9
STEERING ........................................................................................................... 9
FRONT SUSPENSION ...................................................................................... 10
REAR SUSPENSION ......................................................................................... 11
BRAKES ............................................................................................................. 11
SUPPLEMENTARY RESTRAINT SYSTEM ...................................................... 12
CHASSIS AND BODY ........................................................................................ 12
SEATS ............................................................................................................... 13
AIR CONDITIONING .......................................................................................... 13
WIPERS AND WASHERS ................................................................................. 13
ELECTRICAL ..................................................................................................... 13
INSTRUMENTS ................................................................................................. 13
TORQUE VALUES
Description
10 - MAINTENANCE
Road wheels ....................................................................
Spark plugs ......................................................................
Air suspension air reservoir drain plug .............................
Sump drain plug - BMW diesel
- M12 ................................................................................
- M22 ................................................................................
Sump drain plug - V8 petrol up to 99MY ..........................
Sump drain plug - V8 petrol from 99MY ...........................
Automatic gearbox oil drain plug ......................................
Automatic gearbox oil filler / level plug .............................
Manual gearbox oil drain plug ..........................................
Manual gearbox oil filler/level plug ...................................
Transfer gearbox oil drain plug ........................................
Transfer gearbox oil filler/level plug .................................
12 - ENGINE - BMW DIESEL
Adaptor DA 102-85 to No. 1 glow plug location ...............
Glow plug to cylinder head ...............................................
Feed wires to glow plugs ..................................................
* Camshaft cover bolts .....................................................
+ Crankshaft pulley hub bolt:
- Stage 1 ..........................................................................
- Stage 2 - Tighten further ................................................
- Stage 3 - Tighten further ................................................
- Stage 4 - Tighten further ................................................
Damper and pulley to hub bolts .......................................
Pulley to water pump bolts ...............................................
Crankshaft rear oil seal to cylinder block:
- M6 bolts .........................................................................
- M8 bolts .........................................................................
Manual gearbox harness bracket bolt ..............................
+ Propeller shaft flanges nuts and bolts ...........................
Engine mounting nuts ......................................................
Manual gear lever bolts ....................................................
Pipes to air conditioning compressor bolts .......................
Pipes to air conditioning condenser .................................
Feed hose to PAS pump union ........................................
Pipes to gearbox oil cooler ...............................................
+ Flywheel to crankshaft bolts - manual gearbox .............
+ Drive plate to crankshaft bolts - automatic gearbox ......
Front cover to cylinder block bolts ....................................
Steering pump bracket to front cover / cylinder
block bolts ........................................................................
Nm
lbf.ft
108
20
70
80
15
52
25
60
45
32
15
30
30
30
30
30
18
44
33
24
11
22
22
22
22
22
20
20
4
15
15
15
3
11
100
60°
60°
30°
23
10
74
60°
60°
30°
17
7
10
22
6
48
45
25
23
15
30
30
105
120
10
7
16
4
35
33
18
17
11
22
22
77
88
7
22
16
DATA, TORQUE & TOOLS
1
06
TORQUE VALUES
+ * Cylinder head bolts:
- Stage 1 - Tighten to .......................................................
- Stage 2 - Slacken ...........................................................
- Stage 3 - Tighten to .......................................................
- Stage 4 - Tighten further ................................................
- Stage 5 - Tighten further ................................................
- Stage 6 - Run engine .....................................................
- Stage 7 - Allow to cool ...................................................
- Stage 8 - Tighten further ................................................
Cylinder head to timing cover nut and bolts:
- M6 ..................................................................................
- M7 ..................................................................................
- M8 ..................................................................................
Camshaft cover blanking plate bolts ................................
Drive belt tensioner plug ..................................................
+ Camshaft sprocket bolt:
- Stage 1 - Tighten to .......................................................
- Stage 2 - Tighten further ................................................
Turbocharger to exhaust manifold bolts ...........................
Pipes to engine oil cooler .................................................
Oil filter bolt ......................................................................
Oil filter head to cylinder block bolts .................................
Oil pump bolts ..................................................................
Oil pick-up strainer bolts ...................................................
Oil pressure switch ...........................................................
Oil sump to cylinder block bolts:
- M6 8.8 ............................................................................
- M6 10.9 ..........................................................................
- M8 ..................................................................................
Oil pump cover screws .....................................................
Oil sump drain plug:
- M12 ................................................................................
- M22 ................................................................................
Fuel injection pump sprocket nut .....................................
Timing chain tensioner access plug .................................
Camshaft bearing cap nuts:
- M6 ..................................................................................
- M7 ..................................................................................
- M8 ..................................................................................
+*Main bearing cap bolts:
- Stage 1 ..........................................................................
- Stage 2 - Tighten further ................................................
Oil cooling jets ..................................................................
+ Reinforcing plate bolts:
- M8 ..................................................................................
- M10 ................................................................................
2
DATA, TORQUE & TOOLS
NEW RANGE ROVER
80
180°
50
90°
90°
25 mins
90°
59
180°
37
90°
90°
25 mins
90°
10
15
20
22
20
7
11
15
16
15
20
35°
45
30
33
22
22
10
40
15
35°
33
22
24
16
16
7
30
10
12
20
20
7
9
15
15
25
60
50
40
18
44
37
30
10
15
20
7
11
15
20
50°
12
15
50°
9
22
43
16
32
TORQUE VALUES
Cylinder block coolant drain plug .....................................
+*Big-end bearing cap bolts:
- Stage 1 ..........................................................................
- Stage 2 ..........................................................................
- Stage 3 - Tighten further ................................................
25
18
5
20
70°
4
15
70°
40
50
22
270
22
30
37
16
200
16
85
45
80
6
48
45
25
23
15
16
30
63
33
59
4
35
33
18
17
11
12
22
18
30
16
8
15
22
22
22
13
22
12
6
11
16
16
16
20
90°
90°
15
50
45
50
18
13
8
25
45
45
15
90°
90°
11
37
33
37
13
9
6
18
33
33
+ New nuts/bolts must be fitted
* Tighten in sequence
12 - ENGINE - V8 PETROL
Alternator mounting bracket to engine bolts .....................
Camshaft drive gear bolt ..................................................
Coolant rail to inlet manifold bolt ......................................
Crankshaft pulley bolt .......................................................
Water pump pulley bolts ...................................................
Hub aligner to crankshaft Allen screws
- automatic gearbox .........................................................
Drive plate clamp ring bolts - automatic gearbox .............
Flywheel to crankshaft bolts - manual gearbox ................
Manual gearbox harness bracket bolt ..............................
+ Propeller shaft flanges nuts and bolts ...........................
Engine mounting nuts ......................................................
Manual gear lever bolts ....................................................
Pipes to air conditioning compressor bolts .......................
Pipes to air conditioning condenser .................................
Feed hose to PAS pump union ........................................
Pipes to engine oil cooler .................................................
Gearbox cooler pipes to LH engine mounting bracket
bolt ...................................................................................
Pipes to gearbox oil cooler ...............................................
Fuel pipe to fuel rail union ................................................
Camshaft position sensor to timing cover bolt ..................
Oil pressure switch to timing cover ..................................
Water pump to timing cover bolts .....................................
* Timing cover bolts ..........................................................
Camshaft position sensor multiplug bracket bolts ............
* Cylinder head bolts:
- Stage 1 ..........................................................................
- Stage 2 - Tighten further ................................................
- Stage 3 - Tighten further ................................................
Oil cooler pipes to front cover ..........................................
Auxiliary drive belt tensioner bolt - up to 99MY ................
Auxiliary drive belt tensioner bolt - from 99MY .................
Auxiliary drive belt idler pulley bolt ...................................
Auxiliary drive belt cover bolts ..........................................
Oil filter head adaptor .......................................................
Oil pick-up strainer bolts ...................................................
Oil pick-up strainer to main bearing cap nut .....................
+ Engine mounting flange nuts .........................................
Engine rear mounting to gearbox bolts ............................
DATA, TORQUE & TOOLS
3
06
TORQUE VALUES
Crossmember to chassis ..................................................
+ Gearbox mounting to crossmember nuts/bolts .............
Rear engine mounting to gearbox bolts ...........................
Rocker cover to cylinder head bolts - up to 99MY:
Stage 1 .............................................................................
Stage 2 .............................................................................
Stage 3 - re-torque to: ......................................................
+ Rocker cover to cylinder head bolts - from 99MY:
Stage 1 .............................................................................
Stage 2 .............................................................................
* Rocker shaft to cylinder head bolts ................................
* Oil sump to cylinder block nuts/bolts .............................
Oil sump to bell housing bolts ..........................................
Oil sump drain plug - up to 99MY .....................................
Oil sump drain plug - from 99MY .....................................
NEW RANGE ROVER
45
45
45
33
33
33
4
8
8
3
6
6
3
7
38
23
45
45
32
2.2
5.2
28
17
33
33
24
17 - EMISSION CONTROL
SAI control valve to engine manifold bracket bolts ...........
Vacuum reservoir to mounting bracket bolt ......................
SAI pump rubber mountings ............................................
SAI pump to mounting bracket nuts .................................
SAI air injection pipe unions .............................................
10
10
10
10
25
7
7
7
7
18
19 - FUEL SYSTEM - BMW DIESEL
Fuel injection pump flange nuts .......................................
Rear support bolt ..............................................................
Fuel injection pump access hole bolt ...............................
High pressure pipes to fuel injection pump unions ...........
High pressure pipes to injectors unions ...........................
Air suspension drier to air cleaner bolt .............................
Engine coolant temperature sensor .................................
Crankshaft position sensor to bracket bolt .......................
Fuel feed pipe to fuel injection pump and filter union .......
Glow plugs to cylinder head .............................................
Feed wires to glow plugs nuts ..........................................
+ Sprocket to fuel injection pump nut ...............................
Fuel return pipe to fuel injection pump .............................
Adaptor to fuel filter ..........................................................
Fuel filter hollow bolt ........................................................
Fuel injectors to cylinder head .........................................
Air intake sensor to inlet manifold ....................................
Throttle position sensor bolts ...........................................
Turbocharger to exhaust manifold bolts ...........................
Oil feed pipe to turbocharger banjo bolt ...........................
Fuel feed and return pipes to tank unit .............................
22
22
25
20
20
8
18
8
14
20
4
50
25
10
14
65
14
5
45
25
16
16
16
18
15
15
6
13
6
10
15
3
37
18
7
10
48
10
4
33
18
12
+ New nuts/bolts must be fitted
* Tighten in sequence
+ New nut must be fitted
4
DATA, TORQUE & TOOLS
TORQUE VALUES
19 - FUEL SYSTEM - V8 PETROL
Intake air temperature sensor to air cleaner .....................
Air suspension drier to air cleaner bolts ...........................
Camshaft position sensor to timing cover bolt ..................
Engine coolant temperature sensor to manifold ...............
Crankshaft position sensor to cylinder block
adaptor plate bolts ............................................................
Fuel pressure regulator to fuel rail bolts ...........................
Ignition coil bracket to inlet manifold nuts .........................
Fuel feed pipe to fuel rail union ........................................
Ram housing to inlet manifold bolts .................................
Fuel temperature sensor to fuel rail .................................
Heated oxygen sensor .....................................................
Spark plugs to cylinder head ............................................
Fuel rail/ignition coil bracket to manifold nuts ...................
Throttle position sensor clamp plate bolts ........................
RH knock sensor to cylinder block ...................................
Fuel pressure regulator bolts ...........................................
Stepper motor bolts ..........................................................
Idle air control bolts ..........................................................
Water jacket to plenum chamber bolts .............................
Throttle linkage bracket to plenum chamber bolts ............
Plenum chamber to ram pipe housing bolts .....................
Throttle potentiometer to stepper motor bolts ..................
Fuel hoses to filter ............................................................
Fuel feed and return pipes to tank unit .............................
Fuel spill return pipe to tank .............................................
Fuel feed pipe to filter .......................................................
8
8
8
20
6
6
6
15
6
10
8
16
24
17
20
20
8
2
16
10
2
2.3
13
8
24
2
20
16
16
20
4
7
6
12
18
13
15
15
6
1.5
12
7
1.5
2
10
6
18
1.5
15
12
12
15
26 - COOLING SYSTEM - BMW DIESEL
Radiator drain plug ...........................................................
Oil cooler pipes to radiator - manual gearbox ..................
Water pump bolts .............................................................
Pulley to water pump bolts ...............................................
Fan to coupling bolts ........................................................
Viscous coupling to water pump ......................................
Thermostat housing to front cover bolts ...........................
Coolant connecting pipe to front cover bolt ......................
6
30
10
10
10
40
10
10
4
22
7
7
7
30
7
7
26 - COOLING SYSTEM - V8 PETROL
Radiator drain plug ...........................................................
Fan to coupling bolts ........................................................
Fan assembly to water pump ...........................................
Water pump bolts .............................................................
Pulley to water pump bolts ...............................................
6
24
56
22
22
4
18
41
16
16
DATA, TORQUE & TOOLS
5
06
TORQUE VALUES
30 - MANIFOLD AND EXHAUST SYSTEM - BMW
DIESEL
* Exhaust manifold to cylinder head nuts .........................
Turbocharger to manifold bolts ........................................
Coolant connecting pipe to front cover bolt ......................
Front pipe to turbocharger nuts:
- Stage 1 ..........................................................................
- Stage 2 - Slacken 2.5 turns ............................................
* Inlet manifold to cylinder head nuts ...............................
Intermediate exhaust pipe flange nuts .............................
97MY on:
Tail pipe flange to intermediate pipe flange nuts ..............
NEW RANGE ROVER
22
45
10
16
33
7
14
22
25
10
16
18
25
18
55
8
85
50
30
25
45
45
40
6
63
37
22
18
33
33
8
16
6
12
0.7
10
50
17
0.5
7
37
12
20
65
25
65
15
48
18
48
* Tighten progressively working from centre outwards
30 - MANIFOLD AND EXHAUST SYSTEM - V8
PETROL
* Exhaust manifold to cylinder head bolts ........................
Outer heat shield bolts .....................................................
RH shock absorber top mounting bolt ..............................
Front exhaust pipe to manifold nuts - up to 99MY ............
Front exhaust pipe to manifold nuts - from 99MY ............
Front exhaust pipe to intermediate pipe nuts ...................
+ Gearbox cross member to chassis nuts and bolts ........
+ Gearbox mounting to cross member flange nuts ..........
* Inlet manifold to cylinder head bolts:
Ignition coil bracket to inlet manifold nuts .........................
Fuel feed pipe to fuel rail union ........................................
Inlet manifold to cylinder head bolts:
- Stage 1 - Tighten gasket clamp bolts .............................
- Stage 2 - Tighten manifold bolts ....................................
- Stage 3 - Tighten manifold bolts ....................................
- Stage 4 - Tighten gasket clamp bolts .............................
97 MY on:
Heated oxygen sensor to front pipe .................................
LH to RH tail pipe clamps .................................................
Tail pipe flange to intermediate pipe flange nuts ..............
RH tail pipe to LH tail pipe nut ..........................................
+ New nuts/bolts must be fitted
* Tighten in sequence
6
DATA, TORQUE & TOOLS
TORQUE VALUES
33 - CLUTCH - BMW DIESEL
Cover to flywheel bolts:
- M8 8.8 ............................................................................
- M8 10.9 ..........................................................................
Clutch housing bolts:
- M8 ..................................................................................
- M10 ................................................................................
- M12 ................................................................................
Slave cylinder to clutch housing bolts ..............................
24
34
18
25
27
51
86
45
20
38
63
33
33 - CLUTCH - V8 PETROL
Cover to flywheel bolts ..................................................... 40
Clutch housing bolts ......................................................... 40
Slave cylinder to clutch housing bolts .............................. 45
30
30
33
37 - MANUAL GEARBOX - R380
Bell housing extension to gearbox bolts ...........................
Clutch release bearing spigot bolts ..................................
Transfer gearbox to gearbox bolts ...................................
Gearbox to bell housing bolts ...........................................
+ Propeller shafts to transfer box drive flanges
nuts ..................................................................................
Gear lever bolts ................................................................
Selector remote housing to gearbox bolts ........................
Pipes to oil cooler unions .................................................
45
18
45
45
33
13
33
33
48
25
25
22
35
18
18
16
10
148
48
45
25
7
109
35
33
18
+ New nuts must be fitted
41 - TRANSFER GEARBOX
Ratio motor to transfer gearbox bolts ...............................
+ Front and rear output shaft flanges Nyloc nut ...............
+ Propeller shaft flanges nuts ...........................................
Transfer gearbox to gearbox bolts ...................................
Gear lever bolts ................................................................
+ New nuts must be fitted
DATA, TORQUE & TOOLS
7
06
TORQUE VALUES
44 - AUTOMATIC GEARBOX - ZF
Oil drain plug ....................................................................
Oil filler / level plug ...........................................................
Extension housing bolts ...................................................
Parking pawl guide Torx screw ........................................
Breather pipes to gearbox bolts .......................................
Intermediate plate Allen plugs (M14) ...............................
Intermediate plate Allen plugs (M20) ...............................
Fluid pump to intermediate plate bolts .............................
Oil cooler adaptors ...........................................................
Valve block to gearbox bolts ............................................
Lock-up solenoid valve, retaining fork Torx screw ...........
Lock-up solenoid valve assembly to valve body Torx
screws ..............................................................................
Pressure regulator to valve body Torx screws .................
Fluid filter to valve block bolts ..........................................
Oil pick-up tube bolt .........................................................
Fluid pan to gearbox bolts ................................................
Oil filler tube to fluid pan (up to 99MY) .............................
Snubber bar to crossmember (from 99MY) ......................
Transfer gearbox to gearbox bolts ...................................
Gearbox to engine bolts ...................................................
Fluid cooler pipe unions ...................................................
Gearbox mounting assembly bolts ...................................
+ Propeller shafts to transfer box output flanges nuts ......
Torque converter to drive plate bolts - from 99MY ...........
NEW RANGE ROVER
15
30
25
10
15
40
50
10
42
8
8
8
11
22
18
7
11
30
37
7
30
6
6
6
8
8
8
8
70
45
45
45
22
45
48
50
6
6
6
6
52
33
33
33
16
33
35
37
47 - PROPELLER SHAFTS
+ Front propeller shaft nuts .............................................. 48
+ Rear propeller shaft to differential drive flange nuts ...... 48
Rear propeller shaft to brake drum nuts ........................... 48
35
35
35
+ New nuts must be fitted
+ New nuts must be fitted
51 - REAR AXLE AND FINAL DRIVE
Axle to trailing arms:
- M12 nuts and bolts .........................................................
- M16 nuts and bolts - 8.8 Grade .....................................
- M16 nuts and bolts - 10.9 Grade ...................................
Trailing arms to chassis bolts ...........................................
Shock absorbers to axle nuts ...........................................
Panhard rod to axle bolt ...................................................
+ Propeller shaft to rear axle nuts ....................................
Differential to axle case nuts ............................................
Differential drive flange:
- Nut (to 1997.5 MY) .........................................................
- Bolt (1997.5 MY onwards) .............................................
Mass damper to rear axle bolts ........................................
+ New nuts must be fitted
8
DATA, TORQUE & TOOLS
125
160
240
160
45
200
48
40
92
118
177
118
33
148
35
30
135
100
45
100
74
33
TORQUE VALUES
54 - FRONT AXLE AND FINAL DRIVE
Differential to axle case nuts ............................................
+ Propeller shaft to differential nuts ..................................
Radius arms to axle nuts and bolts ..................................
Radius arms to chassis nuts ............................................
Shock absorbers to axle nuts ...........................................
Air spring securing pin retaining bolts ..............................
+ Propeller shaft to front axle nuts ...................................
Track rods to steering knuckles nuts ................................
Panhard rod to axle bolt ...................................................
Drag link to steering knuckle nut ......................................
Brake calipers to steering knuckles bolts .........................
Mass damper to front axle bolts .......................................
40
48
125
160
45
20
48
50
200
50
220
45
30
35
92
118
33
15
35
37
148
37
162
33
30
50
22
37
30
16
22
12
22
47
25
25
25
16
35
18
18
18
22
47
16
35
50
37
125
50
125
30
50
4
125
50
22
22
92
37
92
22
37
3
92
37
16
16
+ New nuts must be fitted
57 - STEERING
Fluid pipes to PAS pump:
- M14 ................................................................................
- M16 ................................................................................
Feed hose to PAS pump union:
- BMW diesel ....................................................................
- V8 petrol .........................................................................
Track rod adjuster clamps nuts and bolts:
- 8 mm ..............................................................................
- 10 mm ............................................................................
Steering column to bulkhead bolts ...................................
Steering column to pedal box nuts and bolts ...................
Steering column universal joints bolts ..............................
Drag link clamps nuts and bolts:
- 8 mm ..............................................................................
- 10 mm ............................................................................
Drag link to drop arm and swivel hubs
nuts and bolts ...................................................................
Damper to drag link nut and bolt:
- 95 & 96 MY ....................................................................
- 97 MY on .......................................................................
Damper to chassis fixing ..................................................
Feed hose to steering box banjo bolt ...............................
Return hose to steering box banjo bolt ............................
Bleed screw .....................................................................
Steering box to chassis nuts and bolts .............................
Drag link to drop arm nut ..................................................
PAS pump to bracket bolts ...............................................
PAS pulley to pump bolts .................................................
DATA, TORQUE & TOOLS
9
06
TORQUE VALUES
V8 petrol:
- PAS pump and compressor mounting bracket to
engine bolts ......................................................................
- PAS pump to mounting bracket bolts - up to 99MY .......
- PAS pump to mounting bracket bolts - from 99MY ........
- Pulley to PAS pump bolts ..............................................
Steering wheel bolt ...........................................................
Pad to steering wheel bolts ..............................................
Track rods to steering knuckles nuts ................................
Road wheel nuts ..............................................................
Composite link to axle nuts:
- M12 ................................................................................
- M16 ................................................................................
Composite link to chassis nut ...........................................
PAS reservoir to radiator bracket bolt ..............................
PAS pipes to steering box nut ..........................................
60 - FRONT SUSPENSION
Air hose to compressor union ..........................................
Compressor to air supply unit nuts ...................................
Air reservoir to air bracket bolts .......................................
Anti-roll bar rubber bush clamp bolts ...............................
Anti-roll bar link nuts .........................................................
Compressor air inlet filter .................................................
Air drier to bracket ............................................................
Height sensor retaining bolts:
- 95 & 96 MY ....................................................................
- 97 MY on .......................................................................
Height sensor link to radius arm nut .................................
Heat shield bracket/height sensor bolts ...........................
Heat shield to bracket bolts ..............................................
Hub and drive shaft assembly bolts .................................
Drive shaft nut ..................................................................
Panhard rod to chassis nut and bolt .................................
Panhard rod to axle bolt ...................................................
Panhard rod to axle securing bolt locking
plate screw .......................................................................
Radius arm to chassis ......................................................
Radius arm to axle nut and bolt .......................................
Shock absorber upper retaining bolt ................................
Shock absorber lower retaining bolt .................................
Road wheel nuts ..............................................................
Swivel hub upper joint to axle nut ....................................
Swivel hub lower joint to axle nut .....................................
Track and drag links to swivel hub nuts ...........................
Pressure switch to valve block .........................................
Solenoid coil to valve block screws ..................................
Front air spring to axle bolt ...............................................
Air distribution box to body bolt ........................................
Air drier to air cleaner bolt ................................................
10
DATA, TORQUE & TOOLS
NEW RANGE ROVER
40
18
22
25
33
8
50
108
30
13
16
18
24
6
37
80
125
160
160
10
25
92
118
118
7
18
7
2
25
125
125
1
12
5
1.5
18
92
92
0.75
9
12
6
8
6
6
135
260
200
200
9
4
6
4
4
100
192
148
148
20
160
125
125
45
108
110
160
80
23
1.5
20
6
3
15
118
92
92
33
80
81
118
59
17
1
15
4
2
TORQUE VALUES
64 - REAR SUSPENSION
Height sensor to chassis bolts:
- 95 & 96 MY ....................................................................
- 97 MY on .......................................................................
Hub to axle case bolts ......................................................
Drive shaft nut ..................................................................
Panhard rod to chassis nut and bolt .................................
Panhard rod to axle bolt ...................................................
Panhard rod to axle locking plate screw ..........................
Shock absorber top mounting bolt ...................................
Shock absorber lower mounting nut .................................
Road wheel nuts ..............................................................
Trailing arm to chassis nuts and bolts:
- M12 ................................................................................
- M16 ................................................................................
70 - BRAKES
Parking brake shoe adjusting bolt ....................................
High pressure hose to pump banjo bolt ...........................
Pump/motor to mounting nuts ..........................................
High pressure hose to booster unit banjo bolt ..................
Booster unit to pedal box bolts .........................................
Brake pipes to booster unit unions ...................................
Front caliper to hub bolts ..................................................
Flexible hose to front caliper banjo bolt ............................
Rear caliper to hub bolts ..................................................
Flexible hose to rear caliper banjo bolt ............................
ECU to bracket bolts ........................................................
Front brake disc shield bolts ............................................
Brake disc screw ..............................................................
Rear brake disc shield strap bolts ....................................
Rear brake disc shield bolts .............................................
Rear brake disc screw ......................................................
Rear caliper bolts .............................................................
Front brake pads guide pin bolt ........................................
Road wheel nuts ..............................................................
Rear brake pads guide pin bolts ......................................
Propeller shaft to parking brake drum bolts ......................
PCRV valve to valance bolts ............................................
Pipes to PCRV unions ......................................................
Pump motor to valance nuts ............................................
High pressure hose to pump banjo bolt ...........................
Reservoir bracket bolt ......................................................
12
6
65
260
200
200
20
125
45
108
9
4
48
192
148
148
15
92
33
80
125
160
92
118
25
24
8
24
45
14
165
32
100
32
6
8
25
8
8
25
100
30
108
30
48
8
14
8
24
10
18
18
6
18
33
10
122
24
74
24
4
6
18
6
6
18
74
22
80
22
35
6
10
6
18
7
DATA, TORQUE & TOOLS
11
06
TORQUE VALUES
75 - SUPPLEMENTARY RESTRAINT SYSTEM
Crash sensor bolts ...........................................................
DCU bolts .........................................................................
Driver’s air bag module to steering wheel bolts ................
Passenger’s air bag module to fascia Torx screws ..........
Side impact airbag nuts ....................................................
76 - CHASSIS AND BODY
Front door hinge bolts ......................................................
Striker bolts ......................................................................
Rear door hinge bolts .......................................................
Chassis crossmember to chassis nuts and bolts .............
Gearbox mounting to crossmember nuts .........................
Front bumper valance bolts ..............................................
Rear bumper and support bracket bolts ...........................
Rear bumper valance mounting bolts ..............................
Road wheel nuts ..............................................................
Pedal box to fascia bolt ....................................................
Fascia to base of ’A’ post nuts .........................................
Fascia to scuttle panel bolts .............................................
Fascia to tunnel brackets nuts .........................................
Gear lever to gearbox remote bolts ..................................
Air conditioning pipes to TXV clamp bolt ..........................
Seat belt top mountings - ’B’ and ’D’ posts bolts ..............
Front seat belt stalk bolt ...................................................
Front seat belt reel bolts - up to 99MY .............................
Front seat belt reel bolts - from 99MY ..............................
Front seat belt upper anchorage bolt - up to 99MY ..........
Front seat belt upper anchorage bolt - from 99MY ...........
Front seat belt to seat mounting bolt - from 99MY ...........
Seat belt adjustable mounting to ’B’ post bolts .................
Seat belt adjustable mounting to ’D’ post bolts ................
Rear seat belt to seat pan bolt .........................................
Rear seat stalk to squab hinge bolt ..................................
Rear seat belt to upper anchorage point nut ....................
Rear seat belt reel bolt .....................................................
Rear seat squab to cushion bolts .....................................
Tailgate hinge bolts ..........................................................
Tailgate support stays to body bolt ..................................
Tailgate striker bolts .........................................................
Wind deflector Torx screws ..............................................
Sunroof guide assembly screws:
Front .................................................................................
Rear .................................................................................
Sunroof motor screws ......................................................
Sunroof cable locator screws ...........................................
Sunroof to body bolts .......................................................
Sunroof tilt mechanism screws ........................................
Sunroof panel nuts ...........................................................
12
DATA, TORQUE & TOOLS
NEW RANGE ROVER
9
9
9
9
5.5
7
7
7
7
4
30
22
25
45
45
70
29
70
108
25
25
25
25
25
6
25
35
35
32
25
22
32
25
25
35
35
25
35
45
25
22
8
2
22
16
18
33
33
52
22
52
80
18
18
18
18
18
4
18
26
26
24
18
16
24
18
18
26
26
18
26
33
18
16
6
1.5
3
1.5
2
3
6
5
5
2.2
1.1
1.5
2.2
4.5
4
4
TORQUE VALUES
78 - SEATS
Front seat fixing bolts .......................................................
Front seat slides to cushion frames bolts .........................
Rear seat squab latch securing screws ...........................
Rear seat front and rear retaining bolts ............................
Seat outstation - cushion pan to frame bolts ....................
Rear seat belt stalk to latch bolt .......................................
Rear seat latch to cushion and squab bolt .......................
29
30
14
29
29
35
30
21
22
10
22
21
26
22
82 - AIR CONDITIONING
Compressor to mounting bracket bolts - V8 from 99MY .. 22
Pipes to condenser .......................................................... 15
Pipes to compressor bolt .................................................. 23
16
11
17
84 - WIPERS AND WASHERS
Headlamp wiper arm to spindle nut ..................................
Headlamp wiper motor securing nut ................................
Screen wiper spindle housing to scuttle nuts ...................
Screen wiper motor securing bolts ...................................
Rear wiper arm to spindle nut ..........................................
Rear wiper motor mounting bolts .....................................
Rear wiper motor spindle seal retaining nut .....................
Front wiper arm to spindle nut ..........................................
9
9
11
7
17
7
4
19
7
7
8
5
12
5
3
14
50
48
86
37
35
63
18
13
18
5
20
20
10
40
25
39
50
45
13
3.5
15
15
7
30
18
29
37
33
10
8
7
6
86 - ELECTRICAL
BMW diesel:
- Pulley to alternator nut ...................................................
- Starter motor securing nuts and bolts ............................
- Clutch fluid pipe bracket lower bolt ................................
V8 petrol:
- Battery lead to starter solenoid nut - from 99MY ............
- Engine harness to alternator nuts - from 99MY
B+ terminal ..............................................................
D+ terminal ..............................................................
- Engine harness to cylinder head bolt - from 99MY ........
- Earth lead to alternator bracket bolt - from 99MY ..........
- Earth lead to RH front wing valance nut - from 99MY ....
- Pulley to alternator nut ...................................................
- Alternator to mounting bracket bolts ..............................
- Tensioner securing bolt ..................................................
- Tensioner pulley bolt ......................................................
- Starter motor securing bolts ...........................................
All vehicles:
Headlamp wiper arm to spindle nut ..................................
Temperature gauge sensor ..............................................
88 - INSTRUMENTS
BMW diesel - Coolant temperature sensor ...................... 20
V8 petrol - Coolant temperature sensor ........................... 10
15
7
DATA, TORQUE & TOOLS
13
06
TORQUE VALUES
NEW RANGE ROVER
NOTE: Torque values given below are for all screws
and bolts not listed.
METRIC
M5 ....................................................................................
M6 ....................................................................................
M8 ....................................................................................
M10 ..................................................................................
M12 ..................................................................................
M14 ..................................................................................
M16 ..................................................................................
Nm
6
10
25
45
90
105
180
lbf.ft
4
7
18
33
66
77
132
UNC/UNF
1/4 ....................................................................................
5/16 ..................................................................................
3/8 ....................................................................................
7/16 ..................................................................................
1/2 ....................................................................................
5/8 ....................................................................................
10
24
39
78
90
136
7
18
29
58
66
100
14
DATA, TORQUE & TOOLS
07 - GENERAL FITTING REMINDERS
CONTENTS
Page
INFORMATION
GENERAL FITTING REMINDERS .......................................................................
PRECAUTIONS AGAINST DAMAGE ..................................................................
SAFETY PRECAUTIONS ....................................................................................
PREPARATION ....................................................................................................
DISMANTLING .....................................................................................................
INSPECTION-GENERAL .....................................................................................
BALL AND ROLLER BEARINGS .........................................................................
OIL SEALS ...........................................................................................................
JOINTS AND JOINT FACES ................................................................................
FLEXIBLE HYDRAULIC PIPES, HOSES .............................................................
FUEL SYSTEM HOSES .......................................................................................
COOLING SYSTEM HOSES ...............................................................................
METRIC BOLT IDENTIFICATION ........................................................................
METRIC NUT IDENTIFICATION ..........................................................................
KEYS AND KEYWAYS ........................................................................................
TAB WASHERS ...................................................................................................
SPLIT PINS ..........................................................................................................
NUTS ...................................................................................................................
LOCKING WIRE ...................................................................................................
SCREW THREADS ..............................................................................................
UNIFIED THREAD IDENTIFICATION ..................................................................
1
1
1
2
2
2
3
4
5
5
6
6
7
8
8
8
8
9
9
9
9
GENERAL FITTING REMINDERS
GENERAL FITTING REMINDERS
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a course in automotive mechanics or
workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.
PRECAUTIONS AGAINST DAMAGE
1. Always fit covers to protect wings before
commencing work in engine compartment.
2. Cover seats and carpets, wear clean overalls
and wash hands or wear gloves before working
inside vehicle.
3. Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.
4. Always use a recommended Service Tool, or a
satisfactory equivalent, where specified.
5. Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.
SAFETY PRECAUTIONS
1. Whenever possible use a ramp or pit when
working beneath vehicle, in preference to
jacking. Chock wheels as well as applying
parking brake.
WARNING: Do not use a pit when
removing fuel system components.
2. Never rely on a jack alone to support vehicle.
Use axle stands carefully placed at jacking
points to provide rigid support.
3. Ensure that a suitable form of fire extinguisher is
conveniently located.
4. Check that any lifting equipment used has
adequate capacity and is fully serviceable.
5. Disconnect negative (grounded) terminal of
vehicle battery.
WARNING: Do not disconnect any pipes in
air conditioning refrigeration system,
unless trained and instructed to do so. A
refrigerant is used which can cause blindness if
allowed to contact eyes.
6. Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
7. Do not apply heat in an attempt to free stiff nuts
or fittings; as well as causing damage to
protective coatings, there is a risk of damage to
electronic equipment and brake linings from
stray heat.
INFORMATION
1
07
GENERAL FITTING REMINDERS
PREPARATION
1. Before removing a component, clean it and its
surrounding areas as thoroughly as possible.
2. Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3. Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4. Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5. Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6. Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7. Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1. Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2. Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3. Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4. Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5. Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6. Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.
2
INFORMATION
NEW RANGE ROVER
INSPECTION-GENERAL
1. Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2. When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3. Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4. Use ’Plastigauge’ 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.
GENERAL FITTING REMINDERS
BALL AND ROLLER BEARINGS
CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.
1. Remove all traces of lubricant from bearing
under inspection by washing in a suitable
degreaser; maintain absolute cleanliness
throughout operations.
2. Inspect visually for markings of any form on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any bearings found to be marked, since any
marking in these areas indicates onset of wear.
3. Holding inner race between finger and thumb of
one hand, spin outer race and check that it
revolves absolutely smoothly. Repeat, holding
outer race and spinning inner race.
4. Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation, and reject
bearing if action is not perfectly smooth.
5. Lubricate bearing generously with lubricant
appropriate to installation.
6. Inspect shaft and bearing housing for
discoloration or other marking suggesting that
movement has taken place between bearing and
seatings. (This is particularly to be expected if
related markings were found in operation 2).
7. Ensure that shaft and housing are clean and free
from burrs before fitting bearing.
8. If one bearing assembly of a pair shows an
imperfection it is generally advisable to replace
both with new bearings; an exception could be
made if the faulty bearing had covered a low
mileage, and it could be established that
damage was confined to it only.
9. When fitting bearing to shaft, apply force only to
inner ring of bearing, and only to outer ring when
fitting into housing. (Refer to ST1042M).
10. In the case of grease lubricated bearings (e.g.
hub bearings) fill space between bearing and
outer seal with recommended grade of grease
before fitting seal.
11. Always mark components of separable bearings
(e.g. taper roller bearings) when dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring, always fit a complete new
bearing assembly.
INFORMATION
3
07
GENERAL FITTING REMINDERS
NEW RANGE ROVER
OIL SEALS
NOTE: Ensure that the seal running track
is free from pits, scores, corrosion and
general damage prior to fitting
replacement seal.
1. Always fit new oil seals when rebuilding an
assembly.
2. Carefully examine seal before fitting to ensure
that it is clean and undamaged.
3. Coat the sealing lips with clean grease; pack
dust excluder seals with grease, and heavily
grease duplex seals in cavity between sealing
lips.
4. Ensure that seal spring, if provided, is correctly
fitted.
5. Place lip of seal towards fluid to be sealed and
slide into position on shaft, using fitting sleeve
when possible to protect sealing lip from damage
by sharp corners, threads or splines. If fitting
sleeve is not available, use plastic tube or tape
to prevent damage to sealing lip.
7. If correct service tool is not available, use a
suitable drift approximately 0.4mm (0.015 in)
smaller than outside diameter of seal. Use a
hammer VERY GENTLY on drift if a suitable
press is not available.
8. Press or drift seal in to depth of housing if
housing is shouldered, or flush with face of
housing where no shoulder is provided. Ensure
that the seal does not enter the housing in a
tilted position.
NOTE: Most cases of failure or leakage of
oil seals are due to careless fitting, and
resulting damage to both seals and
sealing surfaces. Care in fitting is essential if
good results are to be obtained. NEVER use a seal
which has been improperly stored or handled,
such as hung on a hook or nail.
6. Grease outside diameter of seal, place square to
housing recess and press into position, using
great care and if possible a ’bell piece’ to ensure
that seal is not tilted. (In some cases it may be
preferable to fit seal to housing before fitting to
shaft). Never let weight of unsupported shaft rest
in seal.
4
INFORMATION
GENERAL FITTING REMINDERS
JOINTS AND JOINT FACES
1. Always use correct gaskets where they are
specified.
2. Use jointing compound only when
recommended. Otherwise fit joints dry.
3. When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4. Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5. Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
removed material or dirt to enter tapped holes or
enclosed parts.
6. Blow out any pipes, channels or crevices with
compressed air, fit new ’O’ rings or seals
displaced by air blast.
FLEXIBLE HYDRAULIC PIPES, HOSES
1. Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
2. Obtain appropriate plugs or caps before
detaching hose end fittings, so that ports can be
immediately covered to exclude dirt.
3. Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any hose found faulty.
4. When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not
twisted before or during tightening of union nuts.
5. Containers for hydraulic fluid must be kept
absolutely clean.
6. Do not store brake fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7. Do not allow brake fluid to be contaminated with
mineral oil, or use a container which has
previously contained mineral oil.
8. Do not re-use brake fluid bled from system.
9. Always use clean brake fluid to clean hydraulic
components.
10. Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
11. Absolute cleanliness must be observed with
hydraulic components at all times.
12. After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to
the brakes (engine running) and operates the
steering.
INFORMATION
5
07
GENERAL FITTING REMINDERS
NEW RANGE ROVER
FUEL SYSTEM HOSES
COOLING SYSTEM HOSES
CAUTION: 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 amoured outer sleeve. A new
hose must be fitted if separation is evident.
CAUTION: The following precautions
MUST be followed to ensure that integrity
of cooling hoses and their connections to
system components are maintained.
6
INFORMATION
Hose orientation and connection
1. Correct orientation of cooling hoses is important
in ensuring that the hose does not become
fatigued or damaged through contact with
adjacent components.
2. Where ’timing’ marks are provided on the hose
and corresponding connection, these must be
used to ensure correct orientation.
3. Hoses must be pushed fully onto their
connection points. Usually, a moulded form on
the stub pipe provides a positive indicator.
GENERAL FITTING REMINDERS
Hose clips
4. Markings are usually provided on the hose to
indicate the 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.
5. 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.
METRIC BOLT IDENTIFICATION
1. 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 head.
2. In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm2.
3. Zinc plated ISO metric bolts and nuts are
chromate passivated, a gold-bronze colour.
6. Worm drive clips should be tightened to 3 Nm (2
lbf.ft) unless otherwise stated.
CAUTION: Ensure that hose clips do not
foul adjacent components.
Heat protection
7. Always ensure that heatshields and protective
sheathing are in good condition. Replace if
damage is evident.
8. 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.
CAUTION: Hoses will relax and deflect
slightly when hot; ensure this movement
is taken into account when routing and
securing hoses.
INFORMATION
7
07
GENERAL FITTING REMINDERS
METRIC NUT IDENTIFICATION
1. 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 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.
2. A clock face system is 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.
3. A dot is used to locate the 12 o’clock position
and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
o’clock position.
KEYS AND KEYWAYS
1. Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
2. Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
TAB WASHERS
1. Fit new washers in all places where they are
used. Always fit a new tab washer.
2. Ensure that the new tab washer is of the same
design as that replaced.
8
INFORMATION
NEW RANGE ROVER
SPLIT PINS
1. Fit new split pins throughout when replacing any
unit.
2. Always fit split pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a split pin.
3. All split pins should be fitted as shown unless
otherwise stated.
GENERAL FITTING REMINDERS
NUTS
UNIFIED THREAD IDENTIFICATION
1. When tightening a slotted or castellated nut
never loosen it back to insert split pin or locking
wire except in those recommended cases where
this forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2. Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1. Fit new locking wire of the correct type for all
assemblies incorporating it.
2. Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.
SCREW THREADS
1. Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2. Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3. Always ensure that replacement bolts are at
least equal in strength to those replaced.
4. Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5. Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6. To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7. 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.
INFORMATION
9
09 - LUBRICANTS, FLUIDS AND CAPACITIES
CONTENTS
Page
INFORMATION
RECOMMENDED LUBRICANTS AND FLUIDS - NAS VEHICLES .....................
RECOMMENDED LUBRICANTS AND FLUIDS - ALL EXCEPT NAS
VEHICLES ...........................................................................................................
LUBRICATION PRACTICE ..................................................................................
CAPACITIES ........................................................................................................
ANTI-FREEZE ......................................................................................................
FUEL REQUIREMENTS ......................................................................................
RECOMMENDED FUEL ......................................................................................
1
2
3
4
5
6
6
LUBRICANTS, FLUIDS AND CAPACITIES
RECOMMENDED LUBRICANTS AND FLUIDS NAS VEHICLES
AMBIENT TEMPERATURE °C
COMPONENT
SPECIFICATION
VISCOSITY
Engine
Use oils to API
service level
SG, SH or SJ
or
ILSAC GF2
or
ACEA A2:96
5W/20
-30
-20
-10
0
10
20
30
40
50
5W/30
5W/40
5W/50
10W/30
10W/40
10W/50
10W/60
15W/40
15W/50
20W/40
20W/50
Final drive units
Texaco Multigear
75W 90R
Main Gearbox
Automatic
ATF Dexron III
Main Gearbox
Manual
Texaco MTF 94
Transfer box
ATF Dexron III
Power steering
ATF Dexron III or Texamatic 9226
See page 3 for remaining vehicle fluids
INFORMATION
1
09
LUBRICANTS, FLUIDS AND CAPACITIES
NEW RANGE ROVER
RECOMMENDED LUBRICANTS AND FLUIDS - ALL
EXCEPT NAS VEHICLES
All climates and conditions
AMBIENT TEMPERATURE °C
COMPONENT
SPECIFICATION
VISCOSITY
Petrol models
Engine sump
Oil can
Use oils to API
service level
SG or SH
or
ACEA A2:96
5W/30
5W/40
5W/50
10W/30
10W/40
10W/50
10W/60
15W/40
15W/50
20W/40
20W/50
25W/40
25W/50
Diesel models
Engine sump
ACEA A3:96
ACEA B3:96
5W/30
5W/40
5W/50
10W/30
10W/40
10W/50
Final drive units
Texaco Multigear
Main Gearbox
Automatic
ATF Dexron III
Main Gearbox
Manual
Texaco MTF 94
Transfer box
ATF Dexron III
Power steering
ATF Dexron III or Texamatic 9226
2
INFORMATION
75W 90R
-30
-20
-10
0
10
20
30
40
50
LUBRICANTS, FLUIDS AND CAPACITIES
Propeller shaft Front and Rear Lubrication nipples .......... NLGI - 2 Multi-purpose Lithium based GREASE
Door check straps ............................................................ Rocol SM500 molygrease
Door locks ........................................................................ Fuchs Renocal FN745
Brake and clutch reservoirs .............................................. Brake fluids having a minimum boiling point of 260°C
(500 °F) and complying with FMVSS 116 DOT4
Engine cooling system ..................................................... Use an ethylene glycol based anti-freeze (containing
no methanol) with non-phosphate corrosion inhibitors
suitable for use in aluminium engines to ensure the
protection of the cooling system against frost and
corrosion in all seasons.
Battery lugs, earthing surfaces where paint ..................... Petroleum jelly.
has been removed
NOTE: Do not use Silicone Grease
Air conditioning system refrigerant ................................... Refrigerant R134a
CAUTION: DO NOT use any other type of
refrigerant.
Air conditioning compressor oil
V8 up to 99MY ........................................................ Sanden SP10
V8 from 99MY and diesel ........................................ Nippon Denso ND-OIL 8
ABS sensor bush ............................................................. Silicone grease: Staborags NBU - Wabco 830
502,0634
Wacker chemie 704 - Wabco 830 502,0164
Kluber GL301
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze windscreen washer additives, lubricants and various adhesives.
INFORMATION
3
09
LUBRICANTS, FLUIDS AND CAPACITIES
NEW RANGE ROVER
CAPACITIES
The following capacity figures are approximate and provided as a guide only. Refer to Section 10 for correct
checking procedure for powertrain oil levels.
Engine sump and filter - Petrol
From dry ..................................................................
Refill ........................................................................
Engine sump and filter - Diesel
From dry ..................................................................
Refill ........................................................................
Manual gearbox
From dry ..................................................................
Refill ........................................................................
Automatic gearbox
4.6 V8 up to ’99MY ..................................................
4.0 V8 (& 4.6 V8 from ’99MY) .................................
Diesel ......................................................................
Transfer box
From dry ..................................................................
Refill ........................................................................
Front axle
From dry ..................................................................
Refill ........................................................................
Rear axle
From dry ..................................................................
Refill ........................................................................
Power steering box and reservoir ....................................
Cooling system ................................................................
Fuel tank
Petrol .......................................................................
Diesel ......................................................................
Air conditioning system
Refrigerant charge weight
V8 up to 99MY ................................................
V8 from 99MY ................................................
Diesel .............................................................
Refrigerant oil in system
V8 up to 99MY ................................................
V8 from 99MY ................................................
Diesel .............................................................
4
INFORMATION
6.6 litres
5.8 litres
14.0 US pints
12.3 US pints
9.5 litres
8.7 litres
20 US pints
18.4 US pints
2.7 litres
2.2 litres
5.7 US pints
4.6 US pints
11 litres
9.7 litres
9.7 litres
23.2 US pints
20.5 US pints
20.5 US pints
2.4 litres
2.0 litres
5.0 US pints
4.2 US pints
1.7 litres
1.6 litres
3.6 US pints
3.4 US pints
1.7 litres
1.6 litres
1.7 litres
11.3 litres
3.6 US pints
3.4 US pints
3.6 US pints
24 US pints
100 litres
90 litres
26.4 US gallons
24 US gallons
1250 grammes
1380 ± 25 grammes
1100 grammes
44 oz
49 ± 1 oz
39 oz
150 cm3
180 cm3
140 cm3
0.32 US pint
0.38 US pint
0.30 US pint
LUBRICANTS, FLUIDS AND CAPACITIES
ANTI-FREEZE
ENGINE TYPE
MIXTURE STRENGTH
V8 Engine
Diesel Engine
One part anti-freeze
One part water
PERCENTAGE
CONCENTRATION
PROTECTION
LOWER
TEMPERATURE
LIMIT
50%
Complete protection
Vehicle may be driven away immediately from cold
- 33°F
- 36°C
Safe limit protection
Coolant in mushy state. Engine may be started and driven away after warm-up
period
- 41°C
- 42°F
Lower protection
Prevents frost damage to cylinder head, block and radiator. Thaw out before
starting engine
- 47°C
- 53°F
CAUTION: Anti-freeze content must never be allowed to fall below 25% otherwise damage to the
engine is liable to occur. Also, anti-freeze content should not exceed 60% as this will greatly
reduce the cooling effect of the coolant.
INFORMATION
5
09
LUBRICANTS, FLUIDS AND CAPACITIES
NEW RANGE ROVER
FUEL REQUIREMENTS
Catalyst vehicles
Vehicles equipped with catalytic converter are designed to use ONLY unleaded fuel. Unleaded fuel must be used
for the emission control system to operate properly. Its use will also reduce spark plug fouling, exhaust system
corrosion and engine oil deterioration.
Using fuel that contains lead will result in damage to the emission control system and could result in loss of
warranty coverage. The effectiveness of the catalysts in the catalytic converters will be seriously impaired if leaded
fuel is used. The vehicle is equipped with an electronic fuel injection system, which includes two oxygen sensors
(4 oxygen sensors on NAS vehicles). Leaded fuel will damage the sensors, and will deteriorate the emission
control system.
Regulations require that pumps delivering unleaded fuel be labelled UNLEADED. Only these pumps have nozzles
which fit the filler neck of the vehicle fuel tank.
RECOMMENDED FUEL
Petrol engines
Use petrol conforming to European standard EN228
Low compression engines
With catalytic converter ........................................... 91 RON minimum unleaded
Without catalytic converter
4.0 litre ............................................................ 91 RON minimum unleaded or 91 RON minimum
leaded
4.6 litre ............................................................ 91 RON minimum unleaded or 91 RON minimum
leaded
High compression engines ............................................... 95 RON minimum unleaded
NOTE: It is possible to use unleaded fuel with a 91 RON minimum octane rating for high
compression engines, but performance will be adversely affected.
Using fuel with an octane rating lower than stated above could seriously impair vehicle performance.
Diesel engines
Diesel fuel to European standard EN 590; minimum
................................................................ Cetane No. 45
In the interests of optimum vehicle performance, the use of oxygenated fuels such as blends of methanol/gasoline
or ethanol/gasoline (e.g. ’Gasohol’) is not recommended. If oxygenated fuels are to be used, be aware of the
following maximum limits for the percentage of fuel additive that is allowed in the relevant markets:
NAS specification:
Methyl Tertiary Butyl Ether (MTBE) ................................. 15%
Ethyl Tertiary Butyl Ether (ETBE) ..................................... 15%
Ethanol (Ethyl or grain alcohol) ........................................ 10%
CAUTION: Wherever possible, avoid using fuel containing Methanol
6
INFORMATION
LUBRICANTS, FLUIDS AND CAPACITIES
European specification (EN 228):
Methyl Tertiary Butyl Ether (MTBE) .................................
Ethyl Tertiary Butyl Ether (ETBE) .....................................
Ethanol (Ethanol (Ethyl or grain alcohol) ..........................
Methanol with co-solvents ................................................
15%
15%
5%
3%
CAUTION: Take care not to spill fuel during refuelling.
INFORMATION
7
10 - MAINTENANCE
CONTENTS
Page
MAINTENANCE
SERVICE SCHEDULE .........................................................................................
VEHICLE INTERIOR ............................................................................................
VEHICLE EXTERIOR ...........................................................................................
UNDER BONNET MAINTENANCE .....................................................................
UNDER VEHICLE MAINTENANCE .....................................................................
1
2
2
3
7
MAINTENANCE
SERVICE SCHEDULE
The following section describes the items detailed in
the vehicle Service Schedule. Where required,
instructions are given for carrying out the service
procedure, or a cross reference is given to where the
procedure may be found in the manual.
Service schedule sheets are published separately to
reflect the needs and intervals for each vehicle
variant. Procedures given in the workshop manual
must be used in conjunction with the service schedule
sheets.
Service schedule sheets are available in pads from:
Land Rover Merchandising
PO Box 534
Erdington
Birmingham B24 0QS
England
MAINTENANCE
1
10
MAINTENANCE
NEW RANGE ROVER
VEHICLE INTERIOR
VEHICLE EXTERIOR
CHECK CONDITION AND SECURITY OF SEATS,
SEAT BELT MOUNTINGS AND BELTS, BUCKLES
AND OPERATION OF INERTIA SEAT BELTS.
CHECK/ADJUST HEADLAMP AND AUXILIARY
LAMP ALIGNMENT.
REMOVE ROAD WHEELS. CHECK TYRES.
CHECK CONDITION/OPERATION OF
FRONT/REAR/HEADLAMP WASHERS AND WIPER
BLADES.
CHECK OPERATION OF PARK BRAKE, ADJUST
IF NECESSARY.
The park brake should be fully operational on third
notch of ratchet. If adjustment is required. See
BRAKES, Adjustment.
Check tyres (including spare) for compliance with
manufacturers’ specification. Check visually for cuts,
lumps, bulges, uneven tread wear and tread depth.
Check tyre pressures.
INSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND DISCS FOR CONDITION
Fit new pads if minimum thickness is less than 3.0
mm (1/8 in.)
For front brake pad renewal. See BRAKES, Repair.
For rear brake pad renewal. See BRAKES, Repair.
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads in axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
REFIT ROAD WHEELS
Fit road wheels in original hub position. Secure in
position with wheel nuts, do not fully tighten wheel
nuts at this stage, lower vehicle and finally tighten
wheel nuts. Tighten to 108 Nm (80 lbf.ft)
CAUTION: When refitting a road wheel,
apply a suitable anti-seize compound such
as Raworth 33/04, to the spigot bore of the
wheel. This will prevent possible seizure of the
wheel to the hub spigot. Ensure that no
compound comes into contact with the braking
components.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to
perform this check. See STEERING, Adjustment.
LUBRICATE DOOR LOCKS, CHECK STRAPS,
BONNET CATCHES AND FUEL FLAP.
2
MAINTENANCE
MAINTENANCE
UNDER BONNET MAINTENANCE
RENEW SPARK PLUGS
CHECK COOLING, INTERCOOLER AND HEATER
SYSTEMS FOR LEAKS, HOSES FOR SECURITY
AND CONDITION. TOP UP AS NECESSARY.
CAUTION: Take great care when fitting
spark plugs not to cross-thread plug,
otherwise costly damage to cylinder head
will result. It is essential that correct type of spark
plugs is fitted. Incorrect grade of plugs may lead
to piston overheating and engine failure. Only use
approved spark plugs, use of unapproved spark
plugs may cause the misfire detection system to
malfunction.
CAUTION: Cooling system hoses should
be changed at first signs of deterioration.
Remove
1. Disconnect battery negative lead.
2. Remove H.T. leads from spark plugs.
NOTE: Note lead connections to ensure
correct re-assembly.
CAUTION: To avoid damage to H.T. leads,
remove them by pulling the rubber boot
NOT the lead.
3. Remove plugs and washers.
4. Ensure plugs are set to correct gap: 1.0 ± 0.05
mm (0.040 ± 0.002 in). See FUEL SYSTEM,
Repair.
NOTE: Do not attempt to clean or adjust
gaps on spark plugs fitted after 99MY. If a
spark plug problem exists, try substituting
the defective spark plug with a new one.
5. Fit new spark plugs and washers. Tighten to 20
Nm (15 lbf ft)
6. Ensure H.T. leads are correctly refitted. See
FUEL SYSTEM, Repair.
7. Reconnect battery negative lead.
MAINTENANCE
3
10
MAINTENANCE
RENEW FUEL FILTER ELEMENT (DIESEL)
NEW RANGE ROVER
CHECK/TOP UP AUTOMATIC TRANSMISSION
FLUID - up to 99MY
Renew fuel filter. See FUEL SYSTEM, Repair.
DRAIN WATER FROM FUEL FILTER (DIESEL)
RENEW AIR FILTER ELEMENT AND CLEAN
DRAIN HOLE (DIESEL)
RENEW AIR FILTER ELEMENT AND CLEAN
DRAIN HOLE (V8)
CAUTION: When replacing the dipstick,
ensure that the handle lugs fully engage
with tube.
NOTE: Check the fluid level only when the
engine and gearbox are cold.
1. Ensure vehicle is level, then select ’P’ (park) and
start the engine.
2. With the engine running at idle speed and both
footbrake and hand brake applied, move the
selector lever to position ’1’ and then back to
position ’P’.
3. Still with the engine running remove dipstick,
wipe using lint free cloth.
4. Reinsert the dipstick fully and withdraw again to
check the level.
1. Release 4 clips, lift air cleaner cover.
2. Remove air filter element.
3. Fit new element ensuring it locates correctly in
air cleaner body.
RENEW POLLEN FILTERS
Renew pollen filters. See HEATING AND
VENTILATION, Repair.
RENEW EVAP CANISTER, CHECK EVAPORATIVE
LOSS SYSTEM AND FILLER CAP SEAL (V8)
Renew EVAP canister. See EMISSION CONTROL,
Repair.
CHECK CONDITION OF ANCILLARY DRIVE
BELT/S (poly V)
Renew drive belts if damaged.
RENEW ANCILLARY DRIVE BELT (POLY V)
Alternator Drive Belt - Renew. See ELECTRICAL,
Repair.
4
MAINTENANCE
5. Check fluid level registers between MAX and
MIN marking on dipstick. For fluid
recommendations. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
CHECK/TOP UP AUTOMATIC TRANSMISSION
FLUID - from 99MY
1. Refer to gearbox drain and refill procedure. See
AUTOMATIC GEARBOX, Repair.
MAINTENANCE
CHECK/TOP UP POWER STEERING FLUID
RESERVOIR
NOTE: Power steering fluid level is
checked when fluid is cold with engine
switched off.
1. Clean filler cap.
2. Remove dipstick, wipe using lint free cloth.
CHECK/TOP UP WASHER RESERVOIR
Top up washer reservoir to within 25 mm of bottom of
filler neck. Use the correct quantity of screen washer
additive to assist removing mud, flies and road film
and protect against freezing.
LUBRICATE ACCELERATOR AND CRUISE
CONTROL LINKAGES
REMOVE BATTERY CONNECTIONS
Clean, coat with petroleum jelly and refit terminals.
The exterior of the battery should be wiped clean to
remove any dirt or grease.
NOTE: From ’96 MY, the alarm sounder
may be fitted with a back-up battery, the
purpose of which is to power the anti-theft
alarm if the main battery is disconnected. On
these vehicles it is essential to adopt the following
procedure before disconnecting the terminals in
order to prevent the alarm from sounding:
3. Fit cap fully, remove cap, check fluid level
registers between the two markings on the
dipstick. For fluid recommendations. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
CHECK/TOP UP BRAKE/CLUTCH FLUID
RESERVOIR
WARNING: Clean reservoir body and filler
cap before removing cap. Use only fluid
from a sealed container.
NOTE: Clutch master cylinder is supplied
by the brake fluid reservoir. Use following
procedure if topping up is required.
1. Turn ignition ON, to activate hydraulic pump. If
pump does not activate, depress brake pedal
several times until it is heard to operate.
2. When pump stops, check that level is between
’MIN’ and ’MAX’ marks.
3. If level is below ’MIN’ mark on reservoir, top up,
using correct fluid. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
1. Turn starter switch ’on’ and then ’off’.
2. Disconnect the battery WITHIN 17 SECONDS
(if the battery is not disconnected within 17
seconds, the alarm will sound).
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Batteries contain sulphuric acid. Avoid contact
with skin, eyes, or clothing. Also, shield your eyes
when working near battery to protect against
possible splashing of acid solution. In case of
acid contact with skin, eyes, or clothing, flush
immediately with water for a minimum of fifteen
minutes. If acid is swallowed, drink large
quantities of milk or water, followed by milk of
magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
A low maintenance battery is installed in the vehicle.
Dependent upon climate conditions electrolyte levels
should be checked as follows:
Temperate climates every three years.
Hot climates every year.
MAINTENANCE
5
10
MAINTENANCE
CHECK INTERCOOLER/RADIATOR FOR
EXTERNAL OBSTRUCTIONS
NEW RANGE ROVER
DEPRESSURISE ELECTRONIC AIR SUSPENSION.
Depressurise air suspension system using TestBook.
FLUSH DIESEL INTERCOOLER ELEMENT
Remove intercooler. See FUEL SYSTEM, Repair.
Flush the intercooler using Intercooler flushing solvent
following the manufacturer’s instructions. Dry the
intercooler completely and check for damage or
deterioration. Fit a new intercooler if necessary.
CHECK CONDITION OF STEERING
INTERMEDIATE SHAFT
RENEW ELECTRONIC AIR SUSPENSION
COMPRESSOR INTAKE AND EXHAUST FILTERS.
Compressor inlet filter. See FRONT SUSPENSION,
Repair.
REMOVE/REFIT AIR RESERVOIR DRAIN PLUG.
1. Clean area around reservoir drain plug.
2. Partially open drain plug, allow residual air to
escape.
The intermediate shaft has a red indicator clip fitted
which must be inspected at service, or after the
vehicle has been subjected to an impact. If the clip is
not present, or is not fully seated against the clamp
plate, a new intermediate shaft must be fitted. See
STEERING, Repair.
3. Remove drain plug.
4. Renew air dryer if there is evidence of water in
the system. See FRONT SUSPENSION,
Repair.
5. Fit drain plug. Tighten to 70 Nm (52 lbf.ft)
REPRESSURISE AIR SUSPENSION SYSTEM.
6
MAINTENANCE
MAINTENANCE
UNDER VEHICLE MAINTENANCE
RENEW ENGINE OIL AND FILTER - V8
This section covers renewal of lubricating oils for
vehicle major units and other components requiring
lubrication, as detailed in the Service Schedule. For
lubricant recommendations. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
If possible drain oil when it is warm. Always clean
drain and filler/level plugs before removing.
Disconnect vehicle battery to prevent engine being
started and vehicle moved inadvertently, while oil
changing is taking place.
Allow oil to drain completely, except where blown
sand or dirt can enter drain holes. In these conditions
clean and refit drain plugs immediately main bulk of oil
has drained.
Always refill with oil of correct make and specification
recommended in lubrication charts and from sealed
containers.
1.
2.
3.
4.
RENEW ENGINE OIL AND FILTER - DIESEL
5. Remove drain plug from sump. Allow oil to drain
completely.
6. Fit new copper washer and refit plug. Tighten to:
Up to 99MY - 45 Nm (33 lbf.ft).
From 99MY - 32 Nm (24 lbf.ft).
7. Place drain tray under oil filter.
1.
2.
3.
4.
Ensure vehicle is level.
Run engine to warm oil, switch off ignition.
Disconnect battery negative lead.
Place a suitable drain tray under drain plug.
Ensure vehicle is level.
Run engine to warm oil, switch off ignition.
Disconnect battery negative lead.
Place suitable drain tray under drain plug.
5. Remove drain plug from sump. Allow oil to drain
completely.
6. Fit new sealing washer, fit plug and tighten to:M12 plug - 25 Nm (18 lbf.ft)
M22 plug - 60 Nm (44 lbf.ft)
7. Fit new oil filter. See ENGINE, Repair.
8. Fill engine with correct quantity of new oil, check
level.
9. Reconnect battery negative lead.
10. Start engine and run at 2500 rpm until oil
warning lamp extinguishes (approximately 5
seconds).
11. Stop engine, check for oil leaks, check oil level.
Top-up if necessary.
MAINTENANCE
7
10
MAINTENANCE
8. Unscrew filter anti-clockwise.
9. Clean oil cooler adaptor mating face. Coat
rubber washer of new filter with clean engine oil.
Screw filter on clockwise until rubber sealing ring
touches machined face, tighten a further half
turn by hand only. DO NOT overtighten.
10. Clean outside of oil filler cap, remove from filler
neck. Clean inside cap.
11. Pour in correct quantity of new oil of correct
grade from a sealed container to high mark on
dipstick and firmly replace filler cap. DO NOT
FILL ABOVE ’HIGH’ MARK.
12. Reconnect battery negative lead.
13. Run engine and check for leaks from filter. Stop
engine, allow oil to run back into sump for a few
minutes, check oil level again and top up if
necessary.
NOTE: When checking oil level, ensure
that the oil can symbol on dipstick is
correct way up when viewed from left hand
side of vehicle.
NEW RANGE ROVER
CHECK/TOP UP GEARBOX OIL
1. Ensure vehicle is level.
2. Remove oil filler level plug. If necessary, inject
new oil into the gearbox until it runs out of filler
hole. Fit and tighten plug to 30 Nm (22 lbf.ft)
RENEW AUTOMATIC GEARBOX FLUID AND
FILTER
For procedure. See AUTOMATIC GEARBOX,
Repair.
RENEW TRANSFER BOX OIL
1. Ensure vehicle is level. Place a suitable drain
tray under gearbox. Disconnect battery negative
lead.
2. Clean area around filler/level plug. Remove
filler/level plug.
3. Clean area around drain plug. Remove drain
plug. Allow oil to drain completely.
RENEW MANUAL GEARBOX OIL.
1. Ensure vehicle is level. Place a suitable drain
tray under gearbox.
2. Disconnect battery negative lead.
3. Clean area around filler/level and drain plugs.
Remove both plugs. Allow oil to drain
completely.
4. Thoroughly clean drain plug threads, apply
Hylomar sealant. Fit drain plug. Tighten to
30 Nm (22 lbf.ft)
5. Inject new oil into the gearbox until it runs out of
filler hole.
6. Thoroughly clean filler/level plug threads, apply
Hylomar sealant. Fit plug. Tighten to 30 Nm
(22 lbf.ft)
7. Reconnect battery negative lead.
4. Fit and tighten drain plug to 30 Nm (22 lbf.ft)
5. Inject new oil into the gearbox until it runs out of
filler hole. Fit and tighten plug to 30 Nm
(22 lbf.ft)
6. Reconnect battery negative lead.
8
MAINTENANCE
MAINTENANCE
CHECK TRANSFER BOX OIL LEVEL
1. Ensure vehicle is level. Place a suitable drain
tray under gearbox.
2. Disconnect battery negative lead.
3. Clean area around filler/level plug.
4. Remove plug. If required, inject new oil into the
gearbox until it runs out of filler hole.
5. Thoroughly clean filler/level plug threads, apply
Hylomar sealant. Fit plug to 30 Nm (22 lbf.ft)
6. Reconnect battery negative lead.
CHECK FRONT AND REAR AXLE OIL LEVEL
NOTE: To ensure correct oil level the
vehicle must be in ’STANDARD’ ride
height when checking/topping up axle oil.
1. Place vehicle on lift or level ground.
2. Clean area around filler plug. Remove filler plug.
3. If necessary, inject new oil into the axle until it
runs out of filler hole.
4. Clean and fit filler/level plug. Wipe away surplus
oil.
RENEW FRONT AND REAR AXLE OIL
NOTE: To ensure correct oil level the
vehicle must be in ’STANDARD’ ride
height when checking/topping up axle oil.
1. Ensure vehicle is level. Place a suitable drain
tray under axle to be drained.
2. Clean area around filler/level and drain plugs.
Remove both plugs. Allow oil to drain
completely.
LUBRICATE PROPELLER SHAFT SLIDING AND
UNIVERSAL JOINTS
1. Clean all grease nipples on front and rear
propeller shafts.
2. Using a low pressure hand grease gun, apply
recommended grease to grease nipples on
propeller shaft universal and sliding joints.
3. Clean and fit drain plug. Inject new oil into the
axle until it runs out of filler hole.
4. Clean and fit filler/level plug. Wipe away surplus
oil.
REPLACE FUEL FILTER (V8)
To renew fuel filter. See FUEL SYSTEM, Repair.
CHECK VISUALLY HEATSHIELDS, BRAKE, FUEL,
CLUTCH PIPES/UNIONS FOR CHAFING, LEAKS
AND CORROSION. INVESTIGATE IF NECESSARY.
MAINTENANCE
9
10
MAINTENANCE
NEW RANGE ROVER
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE.
CARRY OUT ROAD TEST, CHECK FOR CORRECT
FUNCTION OF ALL VEHICLE SYSTEMS.
RENEW HEATED OXYGEN SENSORS (HO2S)
(CATALYST VEHICLES).
ENDORSE THE SERVICE RECORD.
To renew oxygen sensors. See FUEL SYSTEM,
Repair.
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIRED.
IMPORTANT
RENEW CATALYTIC CONVERTERS (V8)
Antifreeze
To renew catalytic converters. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
CHECK FOR CHAFING, CORROSION AND FLUID
LEAKS FROM STEERING AND SUSPENSION
SYSTEMS, HYDRAULIC PIPES AND UNIONS.
At three yearly intervals, or at the onset of the third
winter, the cooling system must be drained, flushed
and refilled with the correct water and antifreeze
solution
Air bags
CHECK/TIGHTEN SUSPENSION, STEERING UNIT
AND STEERING ROD BALL JOINT FIXINGS,
CHECK CONDITION OF BALL JOINTS AND DUST
COVERS.
Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. Joints
should be checked at specified intervals but more
frequently if the vehicle is used continuously under
arduous conditions. Any ball joints exhibiting wear or
dislodged/damaged dust covers will require the entire
joint to be replaced.
CHECK AIR SUSPENSION PIPES AND SPRINGS
FOR SECURITY AND DAMAGE.
CHECK SHOCK ABSORBERS/HEIGHT SENSORS
AND HARNESS ASSEMBLY FOR LEAKAGE AND
DAMAGE.
CHECK ROAD WHEEL SPEED SENSOR HARNESS
FOR DAMAGE.
The front air bags on SRS vehicles must be renewed
every 10 years. The side air bags must be renewed
every 15 years.
IT IS RECOMMENDED THAT:
At 20,000 km (12,000 miles) intervals, clean sunroof
drain tubes and channels, lubricate guide rails and
slides.
At 60,000 km (36,000 miles) intervals or every 3
years, whichever is the earlier, the hydraulic brake
fluid should be completely renewed.
At 120,000 km (72,000 miles) intervals or 6 years,
whichever is earlier, all hydraulic brake fluid seals and
flexible brake hoses should be renewed. All working
surfaces of the caliper cylinders should be examined
and components renewed where necessary.
Vehicles used extensively in arduous/off road
operating conditions will require the road wheel speed
sensors, brake pads, calipers, hoses and pipes to be
checked at 1600 km (1000 mile) intervals.
Vehicles used extensively in arduous/off road
operating conditions will require the air suspension
compressor inlet and exhaust filters to be replaced at
more frequent intervals.
Every 3 years the vehicle locking handset batteries
should be renewed.
When the vehicle is used in dusty or field conditions or
deep wading, frequent attention to the air cleaner may
be required.
WARNING: Two wheel roller tests must not
be carried out. Four wheel roller tests
must be restricted to 5 km/h (3 mph).
10
MAINTENANCE
12 - ENGINE
CONTENTS
Page
BMW DIESEL
DESCRIPTION AND OPERATION
DESCRIPTION ..................................................................................................... 1
REPAIR
CYLINDER PRESSURE CHECK - DIESEL ......................................................... 1
CAMSHAFT COVER GASKET - NON EGR ........................................................ 2
CAMSHAFT COVER GASKET - WITH EGR ....................................................... 4
CRANKSHAFT PULLEY AND FRONT COVER OIL SEAL .................................. 5
CRANKSHAFT REAR OIL SEAL ......................................................................... 6
ENGINE AND GEARBOX .................................................................................... 6
FLYWHEEL/DRIVE PLATE ................................................................................ 18
FRONT COVER GASKET .................................................................................. 19
CAMSHAFT ....................................................................................................... 21
CYLINDER HEAD GASKET ............................................................................... 24
VALVES AND TAPPETS ................................................................................... 30
OIL COOLER ..................................................................................................... 35
OIL FILTER - UP TO 1998MY ............................................................................ 37
OIL FILTER 1998MY ONWARDS ...................................................................... 38
OIL PUMP .......................................................................................................... 38
OIL PUMP AND OIL PRESSURE RELIEF VALVE - OVERHAUL ..................... 40
OIL PRESSURE SWITCH .................................................................................. 43
SUMP ................................................................................................................. 43
BIG-END BEARINGS ......................................................................................... 45
PISTONS, CONNECTING RODS AND CYLINDER BORES ............................. 49
CRANKSHAFT AND MAIN BEARINGS ............................................................. 54
CRANKSHAFT SPIGOT BEARING ................................................................... 59
TIMING CHAINS AND SPROCKETS ................................................................ 59
BMW DIESEL
DESCRIPTION
Pistons
The diesel engine fitted to New Range Rover is a 2.5
litre, liquid cooled, 6 cylinder, in-line unit. It has an
electronically regulated fuel injection system and is
turbocharged. Power output is increased by the
turbocharger which delivers compressed air to the
combustion chambers via an intercooler.
Each piston is manufactured from aluminium and has
three grooves to accommodate piston rings. The top
ring is a 15°keystone ring, the centre ring is a tapered
compression ring and the lower ring is spring-loaded
oil ring. The piston skirt is phosphated and graphited
while the piston crown has a V-patterned groove
machined into it. The V-patterned groove forms part of
the combustion chamber, which is designed on a swirl
chamber principle. This reduces fuel consumption,
exhaust emission and smoke produced at full load.
Piston cooling is by oil which is directed to the
underside of each piston through crankcase-mounted
spray jets; drillings in the piston allow oil to circulate
thoroughly.
The engine develops 100 kW (134 hp) at 4400 RPM.
Engine performance is managed by a Digital Diesel
Electronics (DDE) system. This system monitors and
controls all engine functions such as the injection
timing, delivery volume and charge-air intercooling.
For full description of the DDE system, See FUEL
SYSTEM, Description and operation.
The flywheel is a dual-mass unit and is hydraulically
damped to prevent transmission rattle in all operating
conditions. Attached to the flywheel, around its
circumference at 60 degree intervals, are six position
pins. These are used by the DDE system to determine
engine speed and crankshaft position.
The engine comprises the following main systems and
components:
Crankcase
Cylinder head
Air intake system
Forced aspiration system
Injection system - See FUEL SYSTEM, Description
and operation.
Lubrication system
Cooling system - See COOLING SYSTEM,
Description and operation.
Auxiliary driven assemblies
Pistons have a stroke of 82.8 mm and are attached to
the connecting rods by 27 mm diameter gudgeon pins
Connecting rods
Power is transmitted to the crankshaft through the
forged steel connecting rods.
Crankshaft
The crankshaft is forged from high-tensile steel and
has seven main bearing journals. Journals are
supported in bearing shells fitted to the crankcase;
dynamic balancing of the crankshaft is achieved by
the use of 12 balance weights. An axially decoupled
torsional vibration damper suppresses longitudinal
vibration of the crankshaft to reduce noise.
Crankshafts are available in three sizes which have
different journal sizes - standard size, undersize 1 and
undersize 2. A colour code, yellow, green or white
denotes the actual size of the journals.
Crankcase
The cast steel crankcase, which incorporates a
cooling water jacket, is machined and bored to form a
cylinder block (cylinder bore 80 mm) and a crankshaft
housing. These contain the pistons, connecting rods
and the crankshaft. Bolted to the underside of the
crankcase is an aluminium reinforcement plate with an
integrated oil deflector. The reinforcement plate
increases crankcase stability and prevents oil foaming
and ventilation losses.
At its front end, the crankshaft drives a close coupled
oil pump for the engine lubrication system and the fuel
injection pump timing chain. The timing chain
connects the crankshaft mounted sprocket and
injector pump drive sprocket. A second timing chain
takes drive from the injector pump sprocket to the
overhead camshaft in the cylinder head.
DESCRIPTION AND OPERATION
1
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
2
ENGINE
Charge air collector
Oil dipstick
Oil filter
Fuel injection pump chain drive
Tensioner rail - chain drive
Crankshaft
Oil sump
Reinforcement plate
Piston cooling jet
Cooling water jacket
DESCRIPTION AND OPERATION
NEW RANGE ROVER
11.
12.
13.
14.
15.
16.
17.
18.
19.
Oil return from turbocharger
Turbocharger
Exhaust manifold
Camshaft drive chain
Camshaft
Hydraulic tappet
Fuel injector
Swirl chamber
Glow plug
BMW DIESEL
1.
2.
3.
4.
5.
6.
7.
8.
Charge air collector
Connection from intercooler
Intake air temperature sensor groove
Hydraulic damper - tensioner roller
Radiator fan and viscous coupling
Torsional vibration damper
Oil pump
Water pump
9.
10.
11.
12.
13.
14.
15.
Vacuum cell for turbocharger
Turbocharger air intake
Piston crown, V-pattern
Exhaust pipe from turbocharger
Exhaust manifold
Overhead camshaft
Hydraulic tappet
DESCRIPTION AND OPERATION
3
12
ENGINE
NEW RANGE ROVER
Cylinder head
The aluminium cylinder head houses the chain driven
overhead camshaft, the valve gear and fuel injectors.
Coolant enters the cylinder head from the crankcase.
The coolant flow is across the cylinder head and out
to the heater matrix and radiator.
An oil separator with wire mesh filter is installed in the
camshaft cover.
1.
2.
3.
4.
5.
6.
7.
8.
Oil separator
Camshaft cover bolts
Fuel injector
Glow plug
Outlet valve
Oil supply duct
Hydraulic tappet
Camshaft
Camshaft
Seven bearings support the camshaft in the cylinder
head. The camshaft is chain driven from the fuel
injection pump drive sprocket, which itself is chain
driven from the crankshaft. Both the injection pump
timing chain and the camshaft timing chain run within
guide rails and are tensioned automatically by tension
rails and a chain adjuster mechanism.
4
DESCRIPTION AND OPERATION
1.
2.
3.
4.
5.
6.
7.
Guide rail
Camshaft drive chain
Guide rail
Injection pump drive chain
Tension rail
Chain adjuster
Tension rail
Valve gear
The camshaft operates the inlet and exhaust valves
through bucket-type tappets with hydraulic valve
clearance adjustment. The hydraulic tappets are
leakproof, eliminating rattle during the first few
revolutions of the engine. Valves are available in
standard size or oversize and are identified by a
number stamped on the stem. Valves are coated
during manufacture and DO NOT need to be lapped
when they are renewed.
BMW DIESEL
Fuel injectors
Turbocharger
Fuel is delivered to each cylinder through fuel injector
nozzles. An injector is screwed into a pre-combustion
chamber (swirl chamber) at each cylinder position.
The turbocharger consists of a compressor housing
and a turbine housing bolted to the exhaust manifold.
The compressor housing has an ambient air inlet and
a compressed air outlet. The turbine housing has an
exhaust gas inlet and an exhaust gas outlet. Both
compressor and turbine housings are bolted to a
central bearing housing. The bearing housing contains
two pressure lubricated bearings which provide
support for the rotor shaft. An exhaust-gas driven
turbine mounted at one end of the rotor shaft, drives a
centrifugal compressor mounted at the other.
The precombustion chambers are also fitted with glow
plugs. Each injector comprises a nozzle holder and
contains a spring-loaded needle valve; the nozzle
holder of cylinder No 4 incorporates a sender which
senses the time of fuel ejection by recognising needle
movement. This information is utilised by the DDE
system - See ENGINE MANAGEMENT, Description.
To regulate charge air pressure, a by-pass plate is
installed on the exhaust side of the turbocharger. The
by-pass plate is connected to a pneumatic pressure
actuator.
1.
2.
3.
4.
Fuel injector
Glow plug
Pre-combustion chamber
Piston crown, V-patterned groove
Air intake
Fresh air is drawn in through an air cleaner assembly
secured to the left hand inner wing of the vehicle. The
air cleaner assembly comprises a housing which
contains a paper filter element. The rectangular,
two-part housing is constructed from moulded plastic
and incorporates an air inlet and an air outlet.
The air cleaner delivers filtered air to the turbocharger.
Forced aspiration system
Forced aspiration is by an exhaust driven
turbocharger. Compressed air, from the turbocharger,
passes through an intercooler to the charge air
collector mounted on the cylinder head.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Charge air outlet
Pressurised oil from engine
Turbine housing
Turbine
Exhaust gas outlet
Exhaust gas inlet
Bearing housing
Rotor shaft
Compressor housing
Compressor
Air intake
DESCRIPTION AND OPERATION
5
12
ENGINE
NEW RANGE ROVER
Intercooler
Operation
To lower the temperature of the charge air, and
therefore increase its density, an intercooler is fitted
between the turbocharger and the charge air collector.
When the engine is running, exhaust gas impinges on
the turbine vanes of the turbocharger causing the
turbine to rotate. The rotor shaft transmits drive from
the turbine to the inlet centrifugal compressor. Air is
drawn into the compressor from the air cleaner and
compressed air is discharged to the charge air
collector via the intercooler.
Charge air collector
The charge air collector is bolted to the cylinder head
and consists of a manifold having a single inlet and six
individual outlets, one to each cylinder. Intake charge
air pressure and charge air temperature sensors
mounted on the collector are linked to the control unit
of the DDE system. The air temperature sensor has a
black connector and is fitted at the front of the air
collector. The pressure sensor is a small, black plastic
sensor mounted on the fuel filter bracket. It is
connected to the air collector through a tube.
1.
2.
3.
4.
6
By-pass plate actuator
Charge air pressure sensor
Intake air (charge air) temperature sensor
DDE system control unit
DESCRIPTION AND OPERATION
Charge air pressure is regulated by operation of the
by-pass plate.
BMW DIESEL
Lubrication system
Oil pump
The lubrication system comprises the sump, pump, oil
filter and oil ducts.
An internal gear-type pump is mounted on the front
end of the crankshaft. It is directly driven by the
crankshaft. The pump consists of a body which
houses a driven rotor and a stator. Pump pressure is
regulated by a piston operated pressure relief valve
housed within the body of the pump.
Sump
This is a one-piece, rigid, aluminium, die-cast unit
bolted to underside of the crankcase. An oil deflector
plate is attached to the crankcase reinforcing shell
above the sump. The sump incorporates a drain plug
and a dip-stick guide pipe.
1. Camshaft bearing
2. Camshaft bearings
3. Oil duct
4. Main oil duct
5. Big end bearing
6. Main crankshaft bearing
DESCRIPTION AND OPERATION
7
12
ENGINE
NEW RANGE ROVER
Oil ducts
Oil circulates around the engine, and is delivered to
the turbocharger bearings, through ducts and oilways.
A longitudinal main oil duct allows oil to be delivered
to the crankshaft bearings. Vertical ducts from the
main duct allow oil to the piston cooling jets and to the
camshaft bearings.
Operation
Refer to the lubrication system circuit diagrams for
lubrication system operating details.
Auxiliary driven assemblies
The auxiliary driven assemblies consist of the
following:
Water pump
Power steering pump
Alternator
The water pump, alternator and power steering pump
are driven from the crankshaft by means of a
decoupled pulley and a 5-rib, automatically tensioned,
V-belt.
1.
2.
3.
4.
5.
6.
Camshaft timing chain drive
Upper tension rail
Chain adjuster
Injection timing
Lower tension rail
Oil return
Oil filter
The oil filter is vertically-mounted below the charge air
collector. It consists of a filter element contained
within a housing which is screwed to a filter head. A
filter by-pass valve is installed in the housing, while
the filter head holds a thermostat. The thermostat
promotes quick warm up of the engine by preventing
oil circulating through the oil cooler when the oil
temperature is low. The thermostat operates at 80°C.
8
DESCRIPTION AND OPERATION
BMW DIESEL
1.
2.
3.
4.
5.
Belt tensioning element
Alternator drive
Power steering pump drive
Torsional vibration damper with decoupled pulley
Water pump drive
DESCRIPTION AND OPERATION
9
BMW DIESEL
CYLINDER PRESSURE CHECK - DIESEL
Service repair no - 19.60.31
NOTE: Test must only be carried out with
battery in good condition. Compression
tests should not be used as the sole
means of assessing the state of an engine. They
must only be used to support other symptoms or
the results of other tests.
1. Disconnect battery negative lead.
2. Remove glow plugs. See FUEL SYSTEM,
Repair.
3. Release cover and disconnect lead from stop
solenoid.
4. Remove 2 screws securing harness trunking to
cylinder block and position trunking aside.
5. Reconnect battery negative lead.
6. Using kit LRT-19-007 fit adaptor DA 102-85 to
number 1 glow plug location. Tighten to 20 Nm
(15 lbf.ft).
7. Connect gauge to adaptor and tighten securely.
9. Repeat operations 6 to 8 on remaining cylinders.
10. All readings should be at least 20 bar and within
approximately 3 bar of each other.
11. If any reading is low, inject 4 shots of clean
engine oil into glowplug hole and repeat test.
Low readings on both wet and dry tests indicate
a badly seating valve or leaking cylinder head
gasket. Low readings on a dry test and
satisfactory wet test results indicate piston ring
and/or cylinder bore problems.
12. Disconnect battery negative lead.
13. Remove test equipment.
14. Connect stop solenoid.
15. Align harness trunking and secure with screws.
16. Fit glow plugs, See FUEL SYSTEM, Repair.
17. Reconnect battery negative lead.
8. Operate the starter motor until the gauge needle
reaches its highest reading and mark with the
pointer.
REPAIR
1
12
ENGINE
NEW RANGE ROVER
CAMSHAFT COVER GASKET - NON EGR
Service repair no - 12.29.40
Remove
1. Disconnect battery negative lead.
2. Remove 4 screws securing injector covers.
Remove covers.
3. Release intake hose from ducting.
4. Release turbocharger intake hose from ducting.
5. Release breather valve from intake ducting
grommet.
NOTE: Collect grommet. Refit to ducting.
6. Disengage 2 clips. Remove intake ducting.
7. Remove 3 bolts securing intake ducting bracket
and exhaust manifold heat shield to camshaft
cover. Collect bracket.
2
REPAIR
BMW DIESEL
8. Remove 10 bolts securing camshaft cover to
cylinder head.
9. Remove camshaft cover. Collect gasket and
discard.
Refit
10. Ensure mating faces are clean.
11. Fit gasket to camshaft cover.
12. Position camshaft cover on cylinder head.
Ensure gasket is correctly seated.
NOTE: Protrusion on rear of gasket can
snag on bearing cap during positioning of
cover.
13. Fit camshaft cover bolts. Tighten in diagonal
sequence, working from centre outwards to 15
Nm (11 lbf.ft)
14. Align exhaust manifold heat shield. Position
intake ducting bracket.
15. Secure ducting bracket and heat shield with
bolts.
16. Position intake ducting. Engage clips.
17. Engage breather valve into ducting grommet.
18. Connect ducting to turbocharger intake hose.
Secure clip.
19. Connect intake hose to ducting. Secure clip.
20. Fit injector covers. Secure with screws.
21. Reconnect battery negative lead.
REPAIR
3
12
ENGINE
CAMSHAFT COVER GASKET - WITH EGR
Service repair no - 12.29.40
Remove
1. Disconnect battery negative terminal.
2. Remove air intake ducting. See FUEL
SYSTEM, Repair.
Refit
8.
9.
10.
11.
Inspect sealing washers, renew as necessary.
Ensure mating faces are clean.
Fit gasket to camshaft cover.
Position camshaft cover on cylinder head.
Ensure gasket is correctly seated.
NOTE: Protrusion on rear of gasket can
snag on bearing cap during positioning of
cover.
12. Fit camshaft cover bolts. Tighten in diagonal
sequence, working from centre outwards to 15
Nm (11 lbf.ft).
4
REPAIR
NEW RANGE ROVER
3. Remove 2 bolts securing harness trunking and
position trunking aside.
4. Remove 3 bolts securing intake ducting bracket
and exhaust manifold heat shield to camshaft
cover. Collect bracket.
5. Remove 10 bolts securing camshaft cover to
cylinder head.
6. Collect sealing washers.
7. Remove camshaft cover. Collect gasket and
discard.
13. Align exhaust manifold heat shield. Position
intake ducting bracket.
14. Secure ducting bracket and heat shield with
bolts.
15. Fit air intake ducting. See FUEL SYSTEM,
Repair.
16. Connect battery negative terminal.
BMW DIESEL
CRANKSHAFT PULLEY AND FRONT COVER OIL
SEAL
Service repair no - 12.21.01 - Crankshaft Pulley
Service repair no - 12.65.05 - Timing Gear Cover
Oil Seal
Remove
1. Disconnect battery negative lead.
2. Remove radiator. See COOLING SYSTEM,
Repair.
3. Remove cover from air conditioning drive belt
tensioner.
4. Release drive belt tension. Remove drive belt.
5. Slacken 4 water pump pulley bolts.
10. Secure LRT-12-105 to hub with 3 bolts. Remove
and discard hub retaining bolt.
11. Note orientation of shouldered washer. Remove
hub and tool.
12. Remove seal from front cover.
Refit
13.
14.
15.
16.
17.
18.
6. Release auxiliary drive belt tension. Remove
belt.
7. Remove water pump pulley bolts. Remove
pulley.
8. Remove bolt from auxiliary drive belt tensioner
pulley. Remove pulley.
9. Remove 6 bolts securing vibration damper and
air conditioning pulley to vibration damper hub.
Remove damper and pulley.
19.
20.
21.
22.
23.
24.
25.
Ensure mating faces are clean.
Lubricate outer face of seal.
Locate seal in timing cover.
Using LRT-12-111, push seal home until flush
with face of timing cover.
Lubricate lip of oil seal. Fit crankshaft pulley hub.
Hold hub using LRT-12-105. Secure with new
bolt and tighten to 100 Nm (74 lbf.ft) plus 150 °
torque angle.
Fit damper and pulley to hub. Secure with bolts.
Tighten to 23 Nm (17 lbf.ft)
Fit auxiliary belt tensioner pulley. Secure with
bolt.
Fit pulley to water pump. Secure with bolts.
Tighten to 10 Nm (7 lbf.ft)
Rotate auxiliary drive belt tensioner. Fit drive
belt.
Fit and tension air conditioning drive belt. See
AIR CONDITIONING, Repair.
Fit radiator. See COOLING SYSTEM, Repair.
Reconnect battery negative lead.
REPAIR
5
12
ENGINE
NEW RANGE ROVER
CRANKSHAFT REAR OIL SEAL
ENGINE AND GEARBOX
Service repair no - 12.21.20
Service repair no - 12.37.01.99
NOTE: Seal and carrier are supplied as an
assembly.
Remove
1.
2.
3.
4.
Disconnect battery negative lead.
Remove flywheel. See this section.
Remove sump. See this section.
Remove 6 bolts securing seal carrier to cylinder
block.
5. Remove seal carrier from location dowels.
6. Collect gasket and discard.
Refit
7. Ensure mating faces are clean.
8. Position new gasket.
9. Lubricate seal guide LRT-12-107 with engine oil.
Position over crankshaft boss.
10. Lubricate oil seal lip. Position seal carrier
squarely over guide. Locate carrier onto dowels.
11. Remove guide.
12. Secure carrier with bolts.
M6, Tighten to 10 Nm (7 lbf.ft)
M8, Tighten to 22 Nm (16 lbf.ft)
13. Fit sump. See this section.
14. Fit flywheel. See this section.
15. Reconnect battery negative lead.
6
REPAIR
Remove
1. Position vehicle on four post lift.
2. Remove battery. See ELECTRICAL, Repair.
3. With assistance, release bonnet struts from body
locations. Retain bonnet in vertical position using
stay clips.
WARNING: Only open the bonnet to the
vertical position with the vehicle on a
horizontal surface in the workshop. This
position is not intended to be used outdoors
where the bonnet could be affected by winds.
4. Remove inlet manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
5. Remove ECM. See FUEL SYSTEM, Repair.
6. Remove 2 screws securing engine harness
clamp to battery tray. Collect harness clamp.
BMW DIESEL
7. Release starter feed wire and glow plug relay
feed from battery terminal clamp.
8. Remove 4 bolts securing battery tray. Remove
battery tray.
10. Remove 3 bolts securing fuse box. Lift fuse box
for access.
11. Disconnect engine harness multiplug from base
of fuse box.
12. Release earth wire from valance stud.
13. Disconnect engine harness multiplug from main
harness.
9. Release earth lead from shock absorber turret.
14. Release engine harness clip from valance. Tie
harness aside over engine.
15. Disconnect fuel feed line from fuel heater/filter
head. Remove ’O’ rings and discard.
REPAIR
7
12
ENGINE
NEW RANGE ROVER
23. Disconnect gearbox oil cooler. Remove ’O’ rings
and discard. Tie pipes aside on engine.
16. Release clip. Disconnect fuel return hose from
Fuel Injection Pump (FIP).
17. Disconnect multiplugs from fuel heater and turbo
boost sensor.
18. Position harness aside over engine.
19. Drain cooling system. See COOLING SYSTEM,
Repair.
20. Discharge air conditioning system. See AIR
CONDITIONING, Adjustment.
21. Remove cooling fan. See COOLING SYSTEM,
Repair.
22. Remove engine oil cooler. See this section.
CAUTION: Where pipes are disconnected,
plug pipes and ports to prevent ingress of
dirt.
24. Disconnect bottom hose from radiator.
25. Disconnect coolant bleed hose from radiator.
8
REPAIR
BMW DIESEL
26. Release 2 fog lamp breather hoses from clips on
either side of radiator.
27. Disconnect 2 heater hoses from engine coolant
pipes.
28. Position container beneath power steering
reservoir to catch spillage.
29. Disconnect return pipe from reservoir. Tie
reservoir aside to engine.
30. Disconnect feed pipe from power steering pump.
Remove sealing washers and discard. Tie pipe
aside to chassis.
31. Remove bolt and screw securing washer bottle
filler neck. Remove filler neck.
REPAIR
9
12
ENGINE
NEW RANGE ROVER
32. Disconnect 2 pipes from air conditioning
condenser. Remove ’O’ rings and discard.
34. Remove 2 nuts and bolts securing radiator
mountings to chassis.
33. Disconnect 2 pipes from air conditioning
compressor. Remove ’O’ rings and discard.
Place pipes aside.
35. Disconnect 2 condenser cooling fan multiplugs.
36. Remove 2 nuts securing air conditioning pipe to
condenser fans. Release pipe.
10
REPAIR
BMW DIESEL
43. Remove 2 bolts securing gear lever. Remove
lever.
37. With assistance, remove radiator/condenser
assembly.
Manual Vehicles:
38. Clamp clutch flexible hose using approved brake
hose clamp.
Automatic Vehicles:
44. Remove window switch pack. See
ELECTRICAL, Repair.
39. Remove clip securing flexible hose to gearbox
bracket.
40. Disconnect clutch flexible hose at gearbox pipe.
Position hose aside.
41. Remove centre console. See CHASSIS AND
BODY, Repair.
42. Remove 6 nuts securing gaiter ring. Remove
ring and gaiter.
REPAIR
11
12
ENGINE
NEW RANGE ROVER
All Vehicles:
45. Release handbrake. Remove handbrake cable
clevis pin.
46. Raise lift. Drain gearbox, transfer box and
engine fluids. See SECTION 10, Maintenance.
47. Using a transmission jack, support transmission
under brake drum.
48. Remove chassis cross member. See CHASSIS
AND BODY, Repair.
Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
49. Release hand brake cable from grommet in
tunnel.
50. Remove 4 bolts securing rear propeller shaft
guard. Remove guard.
12
REPAIR
51. Mark positions of propeller shafts and transfer
box flanges to aid reassembly.
52. Raise one wheel on each axle to allow rotation
of propeller shafts.
53. Remove 4 nuts from rear flange and 4 nuts and
bolts from front flange. Disconnect propeller
shafts. Tie aside.
54. Lower gearbox for access.
BMW DIESEL
Automatic Vehicles:
55. Disconnect gear selector cable trunnion from
gearbox lever. Remove 2 bolts securing selector
cable abutment bracket to gearbox.
56. Place selector cable aside.
All Vehicles:
58. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
57. Disconnect multiplugs from gear selection
position switch and gearbox speed sensor.
59. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
REPAIR
13
12
ENGINE
Manual Vehicles:
60. Disconnect multiplugs from reverse and neutral
switches. Remove bolt securing harness bracket
to gearbox. Release harness from clips on
gearbox brackets.
All Vehicles:
61. Disconnect engine harness to gearbox harness
multiplug. Position harness aside.
14
REPAIR
NEW RANGE ROVER
62. Remove 4 nuts securing each engine mount to
engine bracket.
BMW DIESEL
63. Remove 4 nuts securing each engine mount to
chassis. Discard nuts.
64. Fit lifting bracket to engine lifting eyes. Attach
suitable hoist.
65. Raise engine slightly. Ensure that lifting bracket
does not foul bulkhead. Remove both engine
mountings.
NOTE: It may be necessary to lower
gearbox support slightly during above
operation.
66. Raise power unit and draw forward.
67. Lower support from transmission.
NOTE: Power unit must be tilted at an
angle of approximately 45 degrees before
it can be withdrawn from engine
compartment.
68. Remove engine/transmission assembly.
REPAIR
15
12
ENGINE
Refit
69. Raise power unit. Guide into engine bay.
70. Position transmission jack beneath transmission
brake drum.
71. With assistance, raise transmission and lower
engine until engine mountings can be fitted.
72. Attach mountings to chassis with new flange
nuts. Do not tighten at this stage.
NEW RANGE ROVER
74. Attach engine to mountings with new flange
nuts. Do not tighten at this stage.
75. Release lifting bracket from engine lifting eyes.
Remove hoist.
76. Route gearbox harness. Secure with clips.
77. Connect multiplug to engine harness
78. Connect multiplugs to High/Low motor and
output shaft speed sensor.
Manual Vehicles:
CAUTION: Engine mountings must be
fitted with centre bolt head facing
outboard as shown.
79. Secure gearbox harness bracket with bolt.
Tighten to 6 Nm (4 lbf.ft).
80. Connect multiplugs to reverse and neutral
switches.
81. Secure harness to gearbox bracket with clips.
82. Connect Lucars to transfer box fluid temperature
sensor.
83. Raise transmission on jack.
84. Align harness bracket to gearbox.
Automatic Vehicles:
85. Connect multiplugs to gear selection position
switch and gearbox speed sensor.
86. Position selector cable abutment bracket to
gearbox. Secure with bolts.
87. Adjust gear selector cable. See AUTOMATIC
GEARBOX, Adjustment.
All Vehicles:
88. Raise one wheel on each axle to allow rotation
of propeller shafts.
89. Position shafts to transfer box flanges. Align
marks.
90. Secure propeller shaft flanges with nuts and
bolts. Tighten to 48 Nm (35 lbf.ft)
91. Fit propeller shaft guard. Tighten bolts.
92. Guide hand brake cable through grommet in
transmission tunnel.
93. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
94. Fit chassis cross member. See CHASSIS AND
BODY, Repair.
95. Remove support from under transmission.
96. Tighten engine mounting nuts to 45 Nm (33
lbf.ft)
97. Lower lift.
98. Connect handbrake cable to lever, secure with
clevis pin and clip.
73. Lower and guide engine onto mounting studs.
16
REPAIR
BMW DIESEL
Manual Vehicles:
99. Fit seal around gearbox remote housing to
transmission tunnel aperture.
100. Fit gear lever bolts. Tighten to 25 Nm. (18 lbf.ft)
101. Fit gaiter and ring. Secure with nuts.
102. Fit centre console. See CHASSIS AND BODY,
Repair.
Automatic Vehicles:
103. Fit window switch pack. See ELECTRICAL,
Repair.
Manual Vehicles:
104. Connect clutch flexible hose. Remove hose
clamp.
105. Secure flexible hose union to gearbox bracket
with clip.
106. Bleed clutch hydraulic system. See CLUTCH,
Repair.
All Vehicles:
107. With assistance, position radiator/condenser
assembly.
108. Connect multiplugs to condenser cooling fans.
109. Engage radiator in lower mounting rubbers.
Secure with nuts and bolts.
110. Align air conditioning pipe to condenser fans.
Secure with nuts.
111. Remove plugs from air conditioning compressor
and pipes.
112. Fit new ’O’ rings to compressor pipes. Lubricate
’O’ rings with compressor oil. Connect to
compressor.
113. Fit compressor connection bolts. Tighten to 23
Nm (17 lbs.ft)
114. Remove plugs from air conditioning condenser
and pipes.
115. Fit new ’O’ rings to condenser pipes. Lubricate
’O’ rings with compressor oil. Secure pipes to
condenser. Tighten to 15 Nm (11 lbf.ft)
116. Fit washer bottle filler neck. Secure with bolt and
screw.
117. Remove plugs from power steering pump and
pipes.
118. Using new sealing washers, secure feed pipe to
power steering pump. Tighten to 30 Nm (22
lbf.ft)
119. Untie power steering reservoir from engine.
Remove plugs. Connect return pipe. Secure
return pipe to reservoir with clip.
120. Secure fog lamp breather hoses to clips on
either side of radiator.
121. Connect heater hoses to engine coolant pipes.
Secure with clips.
122. Connect coolant bleed hose to radiator. Secure
with clip.
123. Connect bottom hose to radiator. Secure with
clip.
124. Remove plugs from transmission oil cooler and
pipes.
125. Lubricate pipes with transmission fluid, fit new
’O’ rings. Connect to oil cooler. Tighten to 30
Nm (22 lbf.ft)
126. Replenish transmission fluids. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
127. Fit engine oil cooler. See this section.
128. Fit cooling fan. See COOLING SYSTEM,
Repair.
129. Evacuate and recharge air conditioning system.
See AIR CONDITIONING, Adjustment.
130. Refill cooling system. See COOLING SYSTEM,
Repair.
131. Refill engine oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
132. Connect multiplugs to fuel heater and turbo
boost sensor.
133. Connect fuel return hose to FIP. Secure with
clip.
134. Using new ’O’ rings, connect fuel feed hose to
fuel heater/filter head.
135. Route engine harness along valance. Secure
clip.
136. Connect engine harness multiplug to main
harness. Secure earth terminal to valance stud.
137. Connect engine harness multiplug to base of
fuse box.
138. Position fuse box. Secure with bolts.
139. Position earth lead to shock absorber turret.
Secure with bolt.
140. Fit battery tray. Secure with bolts.
141. Fit starter feed wire to battery positive terminal
clamp. Secure with nut.
142. Position engine harness to battery tray. Secure
harness grommets.
143. Secure harness clamp to battery tray with
screws.
REPAIR
17
12
ENGINE
144. Fit ECM. See FUEL SYSTEM, Repair.
145. Fit inlet manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
146. Refit battery. See ELECTRICAL, Repair.
147. With assistance, release bonnet stay clips.
Engage bonnet struts.
CAUTION: Ensure bonnet stay clips are
returned to their original positions as
shown.
NEW RANGE ROVER
FLYWHEEL/DRIVE PLATE
Service repair no - 12.53.07
Remove
1. Disconnect battery negative lead.
2. Manual gearbox: Remove clutch assembly. See
CLUTCH, Repair.
3. Automatic gearbox: Remove gearbox. See
AUTOMATIC GEARBOX, Repair.
4. Lock flywheel/drive plate using LRT-12-106.
5. Remove and discard 8 bolts securing
flywheel/drive plate.
6. Remove flywheel/drive plate.
148. Start engine. Check for fuel, coolant and oil
leaks.
NOTE: Flywheel illustrated
Inspection
7. Inspect flywheel clutch face/drive plate for
cracks, scores or overheating.
8. Inspect ring gear for worn, chipped or broken
teeth.
9. Replace defective parts as necessary.
18
REPAIR
BMW DIESEL
Refit
10. Ensure mating faces, dowel and dowel locations
are clean.
11. Position flywheel/drive plate to crankshaft, locate
dowel.
12. Secure flywheel/drive plate with new bolts.
Tighten bolts to:
Flywheel - 105 Nm (77 lbf.ft)
Drive plate - 120 Nm (88 lbf.ft)
13. Manual gearbox: Fit clutch assembly. See
CLUTCH, Repair.
14. Automatic gearbox: Fit gearbox. See
AUTOMATIC GEARBOX, Repair.
15. Reconnect battery negative lead.
FRONT COVER GASKET
Service repair no - 12.65.04
Remove
1. Disconnect battery negative lead.
2. Remove cylinder head gasket. See this
section.
3. Remove sump. See this section.
4. Remove alternator. See ELECTRICAL, Repair.
5. Remove crankshaft pulley. See this section.
6. Remove 4 bolts securing air conditioning
compressor to bracket. Tie compressor aside.
7. Remove 6 bolts securing compressor bracket to
cylinder block and front cover. Remove
compressor bracket.
REPAIR
19
12
ENGINE
8. Remove 2 bolts securing power steering pump
bracket to front cover and cylinder block.
9. Release bracket/pump assembly. Tie aside.
NEW RANGE ROVER
12. Remove and discard gasket.
NOTE: Front cover gasket is integral with
oil pump gasket. When removing front
cover only, separate gaskets by cutting at
points shown.
Refit
10. Remove 15 bolts securing front cover to cylinder
block.
11. Remove front cover from 2 cylinder block ring
dowels.
20
REPAIR
13. Ensure mating faces are clean.
14. Position new gasket on cylinder block.
15. Align front cover to cylinder block dowels.
Secure with bolts. Tighten to 10 Nm (7 lbf.ft)
16. Position power steering pump on cylinder block
dowel.
17. Secure steering pump bracket to front cover and
cylinder block with bolts. Tighten to 22 Nm (16
lbf.ft)
18. Position air conditioning compressor bracket to
cylinder block. Secure with bolts.
19. Position compressor on mounting bracket ring
dowels. Secure with bolts.
20. Fit crankshaft pulley. See this section.
21. Fit alternator. See ELECTRICAL, Repair.
22. Fit sump. See this section.
23. Fit cylinder head gasket. See this section.
24. Reconnect battery negative lead.
BMW DIESEL
CAMSHAFT
4. Remove plastic plug from flywheel/drive plate
timing pin access hole.
Service repair no - 12.13.02
Remove
1. Remove camshaft cover. See this section.
Vehicles with EGR: Remove EGR vacuum
pump. See EMISSION CONTROL, Repair.
2. Remove bolt securing harness trunking, recover
nut plate.
3. Vehicles without EGR: Remove 2 bolts securing
camshaft front cover plate, remove cover plate;
remove and discard ’O’ ring. Lay harness
trunking aside.
5. Rotate crankshaft clockwise until No.1 piston is
at top dead centre (TDC) on its compression
stroke. Insert timing pin LRT-12-108 into hole in
flywheel/drive plate.
NOTE: TDC No. 1 is indicated when
camshaft lobes of No. 1 cylinder are
positioned as shown.
REPAIR
21
12
ENGINE
NEW RANGE ROVER
11. Locate tool LRT-12-113 on cylinder head,
secure with tool with camshaft cover bolts.
12. Rotate shaft of tool LRT-12-113 to load camshaft
bearing caps.
13. Ensure camshaft bearing caps are suitably
identified to their fitted positions.
6. Fit camshaft holding tool LRT-12-112.
7. Remove timing chain tensioner access plug,
remove and discard sealing washer.
8. Using tool LRT-12-115, retract timing chain
tensioner and insert tensioner pin LRT-12-114 to
retain tensioner plunger.
CAUTION: Ensure eye of tensioner pin
LRT-12-114 is vertical not horizontal.
NOTE: Caps should be numbered from 1
to 7 and are read from the front of the
engine.
14. Remove nuts securing camshaft bearing caps.
15. Rotate shaft of tool LRT-12-113 until loading is
removed from camshaft bearing caps, remove
tool.
16. Remove camshaft bearing caps.
17. Remove camshaft.
Inspection
9. Remove bolt securing camshaft sprocket,
remove sprocket.
NOTE: Do not discard bolt at this stage.
10. Remove camshaft holding tool LRT-12-112.
18. Clean camshaft, bearing caps and journals in
cylinder head.
19. Check cam lobes for signs of wear, pitting or
scoring.
20. Check journals on camshaft, bearing caps and
cylinder head for signs of wear, overheating and
scoring.
21. Lubricate cam followers, camshaft bearing caps
and journals with engine oil.
22. Clean sealant from threads of front cover plate
bolt and bolt hole.
CAUTION: Do not use a tap.
22
REPAIR
BMW DIESEL
Refit
23. Remove timing pin LRT-12-108 from
flywheel/drive plate.
24. Rotate crankshaft anti-clockwise approximately
30° .
25. Fit camshaft with lobes of No.1 cylinder facing
upwards.
26. Fit camshaft bearing caps ensuring No.1 cap is
at front of engine and cap identification marks
are on exhaust manifold side.
27. Locate tool LRT-12-113 on cylinder head,
secure tool with camshaft cover bolts.
28. Rotate shaft of tool LRT-12-113 to load camshaft
bearing caps.
29. Fit camshaft bearing cap nuts and tighten to:
M6 - 10 Nm (7 lbf.ft)
M7 - 15 Nm (11 lbf/ft)
M8 - 20 Nm (15 lbf/ft)
30. Rotate shaft of tool LRT-12-113 until loading is
removed from camshaft bearing caps, remove
tool.
31. Rotate crankshaft clockwise until No.1 piston is
at top dead centre (TDC) and timing pin
LRT-12-108 can be inserted in flywheel/drive
plate; fit camshaft holding tool LRT-12-112.
NOTE: If camshaft is not positioned
correctly, rotate camshaft using spanner
on cast hexagon until tool can be fitted.
32. Engines with recorded mileage in excess of
20,000 km (12,500 miles): Insert a 4.61 mm
(0.18 in) thickness of feeler gauges between
camshaft holding tool LRT-12-112 and inlet
manifold side of cylinder head.
33. All engines: Fit camshaft sprocket.
34. Fit new camshaft sprocket bolt and tighten to:
Stage 1 - 20 Nm (15 lbf.ft).
Stage 2 - Further 35°
NOTE: Use angular torque wrench.
35. Using tool LRT-12-115, retract timing chain
tensioner rail slightly and remove tensioner pin
LRT-12-114.
36. Fit new sealing washer to timing chain tensioner
access plug, fit plug and tighten to 20 Nm (15
lbf.ft) .
37. Remove timing pin LRT-12-108 from
flywheel/drive plate.
38. Fit plastic plug in timing pin access hole.
CAUTION: The tappets expand when
camshaft is removed. To avoid pistons
contacting valves, observe the following
wait times before rotating pistons back to top
dead centre (TDC).
Above 20° C - 4 minutes
10° C to 20° C - 11 minutes
0° C to 10° C - 30 minutes
Below 0° C - 75 minutes
REPAIR
23
12
ENGINE
39. Apply STC 3373 sealant to camshaft front cover
plate dowel bolt.
40. Lubricate new ’O’ ring with engine oil.
41. Position harness trunking.
42. Vehicles without EGR: Fit ’O’ ring and camshaft
front cover plate, fit bolts and tighten to 22 Nm
(16 lbf.ft) .
CAUTION: Ensure dowel bolt passes
through timing chain guide rail.
43. Position nut plate to bracket, fit and tighten
harness trunking bolt.
44. Fit camshaft cover. See this section.
45. Vehicles with EGR: Fit EGR vacuum pump. See
EMISSION CONTROL, Repair.
NEW RANGE ROVER
CYLINDER HEAD GASKET
Service repair no - 12.29.02
Remove
1. Disconnect battery negative lead.
2. Remove fan cowl. See COOLING SYSTEM,
Repair.
3. Remove high pressure fuel pipe assembly. See
FUEL SYSTEM, Repair.
4. Remove camshaft cover. See this section.
5. Vehicles with EGR: Remove EGR vacuum
pump. See EMISSION CONTROL, Repair.
6. Remove exhaust manifold heat shield. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
7. Remove 3 bolts securing turbocharger to
exhaust manifold. Collect gasket and discard.
8. Remove turbocharger intake hose. Plug
turbocharger intake.
24
REPAIR
BMW DIESEL
All vehicles
15. Release alternator belt tension using a suitable
lever beneath tensioner damper as shown.
Release drive belt from alternator pulley.
9. Disconnect leak-off pipe from No. 1 injector. Plug
injector and pipe.
10. Disconnect engine coolant temperature sensor
(ECT) Sensor and temperature gauge sensor.
11. Disconnect leads from 6 glowplugs.
12. Disconnect No. 4 injector needle lift sensor.
Vehicles without EGR
13. Remove 2 bolts securing harness trunking to
cylinder head. Tie trunking aside.
16. Remove bolt securing damper to drive belt
tensioner.
17. Release hoses from thermostat housing and
cylinder head.
18. Disconnect heater hose from cylinder head.
19. Remove plastic plug from flywheel timing pin
access hole. Insert timing pin LRT-12-108.
14. Remove remaining bolt securing camshaft end
cover. Remove cover. Discard ’O’ ring.
NOTE: LH cover bolt also serves as
retaining pin for timing chain guide rail.
REPAIR
25
12
ENGINE
20. Turn crankshaft clockwise until No. 1 piston is at
Top Dead Centre (TDC) on its compression
stroke. Locate timing pin into flywheel.
NEW RANGE ROVER
24. Remove bolt securing camshaft sprocket.
Remove sprocket.
NOTE: TDC No. 1 indicated by camshaft
lobes of No. 1 cylinder pointing upwards.
21. Fit camshaft holding tool LRT-12-112.
22. Remove timing chain tensioner access plug.
Collect sealing washer and discard.
23. Using tool LRT-12-115, lever timing chain
tensioner rail to slack position. Insert tool
LRT-12-114 to retain tensioner plunger.
25. Remove timing chain tensioner and guide rail
pins. Remove ’O’ rings and discard.
26. Remove timing chain tensioner rail.
27. Remove 5 bolts and 1 nut securing cylinder
head to timing cover.
28. Remove camshaft holding tool.
CAUTION: Do not rotate camshaft.
29. Using sequence shown, progressively slacken
and remove 14 cylinder head bolts. Discard
bolts.
NOTE: LH rear bolt cannot be removed
due to proximity of bulkhead.
26
REPAIR
BMW DIESEL
30. Attach suitable lifting eye to upper rear inlet
manifold stud.
31. Attach hoist to lifting eyes. Remove cylinder
head, remove and discard LH rear cylinder head
bolt.
NOTE: 2 ring dowels locate cylinder head
to block.
CAUTION: To avoid damaging timing chain
guide, ensure cylinder head is lifted as
squarely as possible.
32. Remove cylinder head gasket.
33. Check number of thickness identification holes
before discarding gasket.
CAUTION: Check cylinder head for
warping, see Cylinder head warp check.
If crankshaft, pistons or connecting rods
have been renewed, new cylinder head gasket
thickness must be determined using the following
Piston Protrusion Check procedure. If above items
have not been disturbed, continue at Refit using
gasket with same thickness identification as
original.
REPAIR
27
12
ENGINE
Piston Protrusion - Check
34. Ensure cylinder block face and piston crowns
are clean.
35. Position a dial gauge with suitable base to
cylinder block.
NEW RANGE ROVER
NOTE: Top Dead Centre must be located
using dial gauge.
41. Calculate average piston protrusion to determine
required gasket thickness:
Up to 0.76 mm = 2 identification holes
Over 0.76 mm = 3 identification holes
NOTE: If any piston protrudes more then
0.81mm, a gasket with 3 identification
holes must be fitted.
Cylinder head warp - check
42. Remove all traces of carbon and gasket material
from cylinder head.
43. Using a straight edge and feeler gauges, check
cylinder head for distortion along lines shown in
illustration and compare with figures given:
Longitudinal warp A = 0.1 mm (0.004 in)
Lateral warp B = 0.05 mm (0.002 in)
44. Replace cylinder head if figures obtained exceed
those given.
NOTE: Cylinder heads may not be refaced.
36. Preload and zero gauge on cylinder block face.
37. Move gauge onto piston crown. Measure
protrusion of No. 1 piston in two positions as
shown. Take average of readings. Record
results.
38. Repeat protrusion check on piston No. 6.
39. Remove timing pin LRT-12-108 from flywheel.
40. Record protrusion of remaining pistons. Ensure
that readings are taken at exactly TDC.
28
REPAIR
BMW DIESEL
Refit
CAUTION: If crankshaft timing pin
LRT-12-108 has been removed, ensure that
FIP is on correct stroke, with dimple on
FIP sprocket visible, before refitting pin.
45. Ensure all mating faces are clean.
46. Check cylinder block ring dowels for condition
and correct location.
47. Apply 1.5mm bead of Unipart sealant STC 3373
to joint lines of cylinder block and timing cover.
48. Fit cylinder head gasket of correct thickness.
49. Fit tool LRT-12-112 to ensure camshaft is in
correct position. If necessary, turn camshaft
using spanner on cast hexagon.
CAUTION: Do not turn camshaft if cylinder
head is fitted to cylinder block.
NOTE: Fit a lightly oiled, new cylinder
head bolt in LH rear location.
50. Position cylinder head on cylinder block. Ensure
timing chain guide is not fouled and rear LH bolt
enters bolt hole in cylinder block. Locate cylinder
head on ring dowels.
51. Disconnect lifting chains. Remove lifting eye.
52. Lightly lubricate new cylinder head bolts. Fit
bolts. Tighten, in sequence shown, in the
following stages.
Stage 1 = 80 Nm (59 lbf.ft)
Stage 2 = Loosen by 180°
Stage 3 = 50 Nm (37 lbf.ft)
Stage 4 = Tighten 90°
Stage 5 = Tighten 90°
Stage 6 = Run engine for 25 minutes
Stage 7 = Stop engine, allow to cool
Stage 8 = Tighten 90°
53. Secure cylinder head to timing cover with bolts
and nut.
M7 -15 Nm (11 lbf.ft)
M8 -20 Nm (15 lbf.ft)
54. Fit camshaft timing chain tensioner rail.
55. Using new ’O’ rings, fit tensioner and guide rail
pins.
56. Engage timing chain with camshaft sprocket.
Position sprocket on camshaft.
57. Fit NEW camshaft sprocket bolt.
NOTE: Important; if engine has covered
more than 20,000 km (12,500 miles), insert
a feeler gauge of 4.61 mm (0.18 in)
thickness between cylinder head face and inlet
manifold side of LRT-12-112 prior to tightening
bolt.
58. With LRT-12-112 fitted to camshaft, tighten
camshaft sprocket bolt to 20 Nm (15 lbf.ft).
59. Using a suitable torque angle gauge, further
tighten bolt by 35°.
60. Remove LRT-12-112.
61. Using tool LRT-12-115, lever tensioner rail to
slack position. Remove LRT-12-114 from
tensioner plunger.
62. Using a new sealing washer, refit access plug.
NOTE: Tighten using angular torque
wrench.
REPAIR
29
12
ENGINE
63. Remove LRT-12-108 from flywheel. Fit plastic
plug.
64. Connect cooling hoses. Secure with clips.
65. Align damper to tensioner. Secure with bolt.
66. Lever tensioner to slack position. Engage drive
belt over alternator pulley.
Vehicles without EGR
67. Using a new ’O’ ring, fit camshaft end cover.
NOTE: Apply Loctite 577 sealant to
threads of LH camshaft end cover bolt.
68. Align harness trunking to cylinder head. Secure
camshaft end cover and harness trunking with
bolts.
NEW RANGE ROVER
VALVES AND TAPPETS
Service repair no - 12.29.59
Remove
1. Remove camshaft. See this section.
2. Remove inlet manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
3. Remove exhaust manifold. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
4. Remove injectors. See FUEL SYSTEM, Repair.
5. Remove glow plugs. See FUEL SYSTEM,
Repair.
6. Remove cylinder head. See this section.
7. Remove tappets and store in their fitted order.
All Vehicles
69. Connect No. 4 injector needle lift sensor.
70. Connect leads to glowplugs.
71. Connect ECT sensor and temperature gauge
sensor.
72. Remove plugs. Connect leak-off pipe to No. 1
injector.
73. Remove plug, fit intake hose to turbocharger.
Secure with clip.
74. Position new gasket on exhaust manifold. Fit
turbocharger.
75. Secure with bolts. 45 Nm (33 lbf.ft)
76. Fit exhaust manifold heat shield. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
77. Fit camshaft cover. See this section.
78. Vehicles with EGR: Fit EGR vacuum pump. See
EMISSION CONTROL, Repair.
79. Fit high pressure fuel pipes. See FUEL
SYSTEM, Repair.
80. Fit fan cowl. See COOLING SYSTEM, Repair.
81. Reconnect battery negative lead.
30
REPAIR
8. Insert protective sleeve LRT-12-101 in tappet
bore.
BMW DIESEL
13. Remove valve stem oil seal using LRT-12-071,
discard seal.
14. Remove valve.
CAUTION: Store valve components in their
fitted order.
15. Repeat above procedures for remaining valves.
16. Clean all components.
9.
10.
11.
12.
Position tool LRT-12-034 on valve.
Compress valve spring.
Remove 2 collets using a stick magnet.
Release tool LRT-12-034, collect valve spring
cup, valve spring and spring seat, discard valve
spring.
REPAIR
31
12
ENGINE
NEW RANGE ROVER
Valve guides
Inspection
Valves
CAUTION: Prior to checking/reaming valve
guides, check cylinder head for warping.
See Cylinder head gasket.
17. Remove carbon from valves, valve guides and
seats.
18. Check valves for signs of burning, cracking and
pitting of valve seats.
19. Check head diameter of each valve:
Inlet = 36.0 mm (1.42 in)
Exhaust = 31.0 mm (1.22 in)
20. Check stem diameter of each valve, half-way
along stem and compare diameters with
dimensions given to determine stem sizes of
valves fitted and valve stem wear.
Standard:
Inlet = 6.97 mm (0.274 in)
Service limit = 6.95 mm (0.273 in)
Exhaust = 6.95 mm (0.273 in)
Service limit = 6.93 mm (0.272 in)
1st oversize:
Inlet = 7.07 mm (0.28 in)
Service limit = 7.05 mm (0.277 in)
Exhaust = 7.06 mm (0.278 in)
Service limit = 7.04 mm (0.27 in)
2nd oversize:
Inlet = 7.17 mm (0.282 in)
Service limit = 7.15 mm (0.28 in)
Exhaust = 7.16 mm (0.281 in)
Service limit = 7.14 mm (0.279 in)
21. If valve stems are worn in excess of service
limits, valves with next oversize stems must be
fitted and valve guides reamed to correct size.
22. Position a suitable DTI to cylinder head adjacent
to No.1 valve seat.
23. Insert a new valve with same stem diameter as
the original in the valve guide.
24. Position end of valve stem flush with spring end
of guide.
25. Move valve away from DTI, pre-load gauge and
note pre-load reading.
26. Move valve towards DTI, note gauge reading
and subtract pre-load from this figure. Compare
final figure obtained with tilt figure:
Valve tilt - inlet and exhaust = 0.5 mm (0.02 in).
27. If tilt figure exceeds above dimension, original
valve must be replaced with next oversize valve
and valve guide reamed to next oversize.
Valve guide inside diameter - inlet and exhaust:
Standard = 7.0 mm (0.275 in)
For 1st oversize valve stem = 7.1 mm (0.28 in)
For 2nd oversize valve stem = 7.2 mm (0.283 in)
NOTE: Valve guides may not be replaced.
32
REPAIR
BMW DIESEL
28. Dry ream valve guides using BMW tool 004210
and appropriate size reamer from those supplied
with tool.
29. Ream valve guide from combustion chamber
side, rotate tool once only in a downwards
direction; remove all traces of swarf on
completion.
Check valve head stand-down
30. Original valves: Lap valves to their seats,
remove all traces of grinding paste on
completion.
31. Replacement valves: Do not lap valves to their
seats.
32. Insert No.1 valve into its guide.
34. Position DTI to centre of valve, measure valve
head stand-down and compare with figures
given:
Inlet = 0.65 to 0.85 mm (0.02 to 0.03 in)
Exhaust = 0.85 to 1.05 mm (0.03 to 0.04 in)
35. Replace any valve having stand-down in excess
of figures given with a valve having an increased
head thickness.
36. Refer to the following to determine thickness of
valve head required ensuring that valves with
correct size stem diameter are obtained.
NOTE: It will be necessary to re-cut valve
seats when fitting valves with increased
head thickness.
Standard valve stem diameter:
Head thickness increase - 0.25 mm (0.01 in)
Identification marks - RO
33. Position suitable DTI to cylinder head, pre-load
then zero gauge.
REPAIR
33
12
ENGINE
NEW RANGE ROVER
1st oversize valve stem:
Head thickness increase - 0.25 mm (0.01 in)
Identification marks - R1
Head thickness increase - 0.50 mm (0.02 in)
Identification marks - R2
2nd oversize stem:
Head thickness increase - 0.50 mm (0.02 in)
Identification marks - R3
NOTE: Identification marks will be found
adjacent to cotter grooves.
Valve seat - recut
38. Use BMW tool 003580 to obtain specified valve
seat dimensions:
Valve seat angle A = 45° ± 10’
Correction angle - outside B = 15°
Correction angle - inside C = 60°
Seat face outside diameter D:
Inlet valve = 35.5 mm (1.4 in)
Exhaust valve = 30.6 mm (1.2 in)
Valve seat width E:
Inlet valve = 1.75 to 2.25 mm (0.07 to 0.09 in)
Exhaust valve = 2.60 to 2.90 mm (0.10 to 0.11
in)
39. Remove all traces of swarf on completion.
37. Recut valve seats using BMW tool 003520.
Head thickness:
0.25 mm (0.01 in) - Increase depth by 0.25 mm
(0.01 in)
0.50 mm (0.02 in) - Increase depth by 0.50 mm
(0.02 in)
34
REPAIR
CAUTION: Do not lap replacement valves
to their seats.
Refit
40. Lubricate all components including valve guides
and new valve stem oil seals with engine oil.
41. Insert protective sleeve LRT-12-101 in tappet
bore.
BMW DIESEL
OIL COOLER
Service repair no - 12.60.68
Remove
1. Remove intercooler. See FUEL SYSTEM,
Repair.
2. Remove 2 trim fixing studs securing LH deflector
panel. Remove panel.
42. Fit protection sleeve LRT-12-104 on valve stem.
43. Fit new valve stem oil seal.
NOTE: Inlet valve stem oil seals are
coloured RED whilst exhaust valve stem
oil seals are coloured GREEN.
44. Press valve stem oil seal into position using tool
LRT-12-071, remove protection sleeve
LRT-12-104.
45. Fit valve spring seat, new valve spring and
spring cup.
46. Compress valve spring using tool LRT-12-034, fit
2 collets.
47. Remove protection sleeve LRT-12-101.
48. Repeat procedures for remaining valves.
49. Lubricate tappet bores and tappets with engine
oil, fit tappets to their original locations.
50. Fit cylinder head. See this section.
51. Fit exhaust manifolds. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
52. Fit glow plugs. See FUEL SYSTEM, Repair.
53. Fit injectors. See FUEL SYSTEM, Repair.
54. Fit inlet manifolds. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
55. Fit camshaft. See this section.
3. Position container to catch oil spillage.
4. Disconnect oil cooler upper hose. Remove ’O’
ring and discard.
5. Plug hose and cooler.
6. Release left hand fog lamp breather tubes from
radiator bracket clips.
REPAIR
35
12
ENGINE
NEW RANGE ROVER
8. Raise oil cooler for access.
9. Disconnect lower hose. Remove ’O’ ring and
discard.
7. Remove 2 bolts securing oil cooler to radiator
bracket.
10. Plug hose and cooler.
11. Remove oil cooler.
Refit
12. Position oil cooler. Remove plugs.
13. Using new ’O’ ring, connect lower hose to oil
cooler. Tighten to 30 Nm (22 lbf.ft).
14. Lower cooler to radiator bracket.
15. Apply Loctite 270 Stud Lock to threads of RH
fixing.
16. Assemble spacers to fixing and secure fixing to
radiator bracket, finger tight.
17. Engage slot in RH side of cooler to spacers.
18. RH fixing Tighten to 5 Nm (4 lbf.ft).
LH fixing Tighten to 25 Nm (19 lbf.ft).
19. Using new ’O’ ring, connect upper pipe to oil
cooler. Tighten to 30 Nm (22 lbf.ft)
20. Remove container.
21. Secure fog lamp breather tubes to radiator
bracket clips.
22. Fit deflector panel. Secure with studs.
23. Fit intercooler. See FUEL SYSTEM, Repair.
24. Check engine oil level. Top-up if necessary.
CAUTION: The RH side of the oil cooler
has a sliding mount which allows the
cooler to expand and contact with
changes in temperature. Incorrect tightening
torque of the RH fixing will lead to cooler damage.
36
REPAIR
BMW DIESEL
OIL FILTER - UP TO 1998MY
Service repair no - 12.60.02
Remove
1. Drain engine oil. See SECTION 10,
Maintenance.
2. Position cloth beneath oil filter casing to catch
spillage.
3. Remove bolt securing cover to filter casing.
Collect ’O’ ring and discard .
4. Remove cap. Collect ’O’ ring and discard.
5. Remove filter element and discard.
Refit
6. Clean filter casing and cap.
7. Fit filter element.
8. Using new ’O’ rings, position cap. Secure with
bolt. Tighten to 33 Nm (24 lbf.ft)
9. Replenish engine oil. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
10. Start engine. Run at 2500 rev/min until oil
pressure warning light extinguishes.
NOTE: Oil pressure warning light will
extinguish after approximately 5 seconds.
11. Stop engine. Recheck oil level.
NOTE: Oil in filter casing will run back into
sump once cover is removed.
REPAIR
37
12
ENGINE
NEW RANGE ROVER
OIL FILTER 1998MY ONWARDS
OIL PUMP
Service repair no - 12.60.02
Service repair no - 12.60.26
Remove
Remove
1. Drain engine oil. See SECTION 10,
Maintenance.
2. Position cloth beneath oil filter casing to catch
spillage.
3. Using a socket wrench, carefully loosen cap and
allow oil to drain back into sump.
4. Remove cap and collect 3 ’O’ ring seals. Discard
seals.
5. Remove filter element and discard.
1. Remove timing chains and sprockets. See this
section.
2. Remove sump. See this section.
3. Remove 3 bolts securing oil pick-up strainer to
oil pump and deflector plate.
Refit
6.
7.
8.
9.
10.
Clean filter casing and cap.
Fit filter element.
Lubricate new ’O’ ring seals using engine oil.
Fit cap and tighten to 25 Nm (18 lbf.ft)
Replenish engine oil. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
11. Start engine. Run at 2500 rev/min until oil
pressure warning light extinguishes.
NOTE: Oil pressure warning light will
extinguish after approximately 5 seconds.
12. Stop engine. Recheck oil level.
38
REPAIR
4. Remove pick-up strainer. Collect gasket.
BMW DIESEL
5. Remove lower chain guide.
6. Remove Woodruff key from crankshaft.
Refit
9. Ensure mating faces are clean.
10. Position new oil pump/front cover gasket to
cylinder block.
11. Refit oil pump. Fit bolts, finger tight.
12. Fit tool LRT-12-116 over crankshaft. Tighten
centre screw by hand to centralise oil pump.
7. Remove 8 bolts securing oil pump to cylinder
block.
8. Remove pump. Collect gasket.
Tighten oil pump bolts to 22 Nm (16 lbf.ft)
Remove tool from crankshaft.
Fit woodruff key to crankshaft.
Fit lower chain guide.
Using a new gasket, position oil pick-up strainer.
Secure with bolts. Tighten to 10 Nm (7 lbf.ft)
18. Fit timing chains and sprockets. See this
section.
19. Reconnect battery negative lead.
13.
14.
15.
16.
17.
REPAIR
39
12
ENGINE
NEW RANGE ROVER
OIL PUMP AND OIL PRESSURE RELIEF VALVE OVERHAUL
Service repair no - 12.60.32
1. Remove oil pump. See this section.
Oil pump
NOTE: Oil pump is only supplied as an
assembly but the following dimensional
checks checks may be carried out to
determine serviceability.
4. Press flanged bush out from front of oil pump.
2. If fitted : Remove 2 bolts securing oil pick-up
pipe, remove pipe.
3. Remove and discard seal.
40
REPAIR
5. Make suitable alignment marks between cover
plate and pump housing.
6. Noting fitted position of special screw, remove 4
screws securing cover plate, remove plate.
BMW DIESEL
7. Make suitable alignment marks between inner
and outer rotors and pump housing.
8. Clean rotors and recess in pump housing, fit
rotors ensuring square identification marks face
towards cover plate and reference marks are
aligned.
11. Remove flanged bush, position a straight edge
across both rotors and the pump body.
12. Using feeler gauges inserted between straight
edge and on each side of inner and outer rotors,
measure axial clearance between rotors and
pump body and compare with figures given:
Outer rotor to pump body axial clearance =
0.070 mm (0.004 in) - maximum
Inner rotor to pump body axial clearance = 0.065
mm (0.003 in) - maximum
13. If any of the clearances obtained exceed figures
given, pump assembly must be replaced.
9. Insert flanged bush into inner rotor with flange on
rotor side of pump.
10. Using feeler gauges, check clearance between
outer rotor to pump body and inner rotor to
flanged bush and compare with figures given:
Outer rotor to pump housing = 0.4 mm (0.02 in) maximum
Inner rotor to flanged bush = 0.065 mm (0.003
in) - maximum
REPAIR
41
12
ENGINE
NEW RANGE ROVER
Oil pressure relief valve
Oil pump and oil pressure relief valve assembling
20. Lubricate all components with engine oil.
21. Fit a new ’O’ ring to sleeve.
22. Insert piston, spring and sleeve into relief valve
bore, depress sleeve and fit circlip.
WARNING: Suitable eye protection must
be worn.
14. Using a suitable mandrel, depress sleeve and
remove circlip.
WARNING: Sleeve is under strong spring
pressure, suitable eye protection must be
worn.
15. Gradually release spring pressure, remove
sleeve, spring and piston.
16. Remove and discard ’O’ ring.
17. Clean all components, check piston, sleeve and
relief valve bore for damage, scoring and signs
of wear.
18. Check relief valve spring free length:
Free length = 84.1 mm (3.3 in)
19. Renew relief valve as an assembly.
42
REPAIR
23. Check that circlip is correctly seated in groove.
24. Insert rotors into pump ensuring that square
identification marks are toward cover.
25. Fit cover plate ensuring reference marks are
aligned.
26. Fit 4 screws ensuring special screw is in its
original location, tighten screws to 20 Nm (15
lbf.ft).
27. Fit flanged bush ensuring that flange is on cover
plate side of pump.
28. Position new seal to oil pick-up pipe, fit pipe.
29. Fit 2 bolts and tighten to 10 Nm (7 lbf.ft).
30. Fit oil pump. See this section.
BMW DIESEL
OIL PRESSURE SWITCH
SUMP
Service repair no - 12.60.50
Service repair no - 12.60.44
Remove
Remove
1. Disconnect switch multiplug.
2. Remove switch. Collect sealing washer and
discard.
1. Raise vehicle on four post lift.
2. Disconnect battery negative lead.
3. Remove nut and bolt securing dipstick tube.
Remove tube. Remove and discard ’O’ ring.
4. Raise lift.
5. Position support under chassis front cross
member.
Refit
3. Ensure mating faces are clean.
4. Fit a new sealing washer, oil threads of switch
and fit switch. Tighten to 40 Nm (30 lbf.ft)
5. Connect multiplug.
REPAIR
43
12
ENGINE
NEW RANGE ROVER
9. Remove 29 bolts securing sump. Remove sump
and gasket.
6. Lower lift to give clearance between front axle
and sump.
CAUTION: Do not lower axle from chassis
if front shock absorbers are disconnected.
7. Drain oil from sump. Refit sump plug.
8. Remove bolt securing power steering pump
bracket to sump.
44
REPAIR
BMW DIESEL
Refit
10. Ensure mating faces are clean.
11. Clean sump.
12. Fit gasket to sump. Fill front and rear openings in
gasket with STC 3373 sealant.
13. Position sump to cylinder block.
14. Secure sump with bolts.
M6 - 10 Nm (7 lbf.ft)
M6 - 12 Nm (9 lbf.ft)
M8 - 20 Nm (15 lbf.ft)
15. Tighten sump plug to:M12 - 25 Nm (18 lbf.ft)
M22 - 60 Nm (44 lbf.ft)
16. Position power steering pump bracket on sump.
Secure with bolt.
17. Raise lift. Remove chassis support.
18. Lower lift.
19. Lubricate new dipstick tube ’O’ ring with clean
engine oil.
20. Fit ’O’ ring to dipstick tube. Fit tube. Secure with
nut and bolt.
21. Refill engine oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
22. Reconnect battery negative lead.
BIG-END BEARINGS
Service repair no - 12.17.16
Remove
1. Remove sump. See this section.
2. Remove 3 bolts securing oil pick-up pipe.
3. Remove oil pick-up pipe, remove and discard
seal.
REPAIR
45
12
ENGINE
NEW RANGE ROVER
10. Remove and discard big-end bearing shells from
connecting rods.
CAUTION: Take care when carrying out
above operation that piston does not
contact valves. Keep big-end bearing caps
and bolts in their fitted order.
Inspection
4. Progressively slacken then remove and discard
10 bolts securing reinforcing plate,
5. Remove reinforcing plate.
6. Carefully rotate crankshaft to gain access to
connecting rod bolts.
11. Measure and record crankshaft big-end journal
diameter, take 4 measurements at 90° intervals.
7. Ensure that connecting rods and big-end bearing
caps are suitably identified to each other.
8. Remove big-end bearing cap bolts.
NOTE: Do not discard bolts at this stage.
9. Remove big-end bearing caps, remove and
discard big-end bearing shells.
CAUTION: Dowel located, do not tap
bearing caps sideways.
46
REPAIR
NOTE: There are 3 sizes of crankshaft
big-end journals, Standard, Size 1 and Size
2. Crankshafts with either Standard or Size
1 journals may be ground to the next undersize
and the appropriate oversize big-end bearing
shells fitted.
Standard = 44.975 to 45.00 mm (1.770 to 1.771 in)
Size 1 - 0.25 (0.01 in) undersize = 44.725 to 44.75
mm (1.761 to 1.762 in)
Size 2 - 0.50 mm (0.02 in) undersize = 44.475 to
44.50 mm (1.751 to 1.752 in)
12. Repeat above procedures for remaining big-end
journals.
BMW DIESEL
Check big-end bearing clearances
14. Fit a new BLUE colour coded big-end bearing
shell of the appropriate size in the big-end
bearing cap.
CAUTION: Do not fit a ’sputter’ bearing to
bearing cap.
15. Place a strip of Plastigage across crankshaft
big-end journal.
16. Pull connecting rod on to journal.
17. Fit big-end bearing cap ensuring reference
marks on connecting rod and cap are aligned.
18. Fit original big-end bearing cap bolts and tighten
to:
Stage 1 - 5 Nm (4 lbf.ft)
Stage 2 - 20 Nm (15 lbf.ft)
Stage 3 - Use angular torque wrench and tighten
further 70°
NOTE: Big-end bearing shells are available
in 3 sizes - Standard, 0.25 (0.01 in) and
0.50 (0.02 in) oversize and are colour
coded RED or BLUE. Additionally, the connecting
rod bearing shell is of the ’sputter’ type and can
be identified by a letter S or a series of XXX on the
outside of the shell. Sputter bearings must be
fitted to the connecting rod.
13. Fit a new RED colour coded big-end bearing
shell of the appropriate size in connecting rod.
CAUTION: Ensure bearing shell is of the
’sputter’ type.
CAUTION: Do not rotate crankshaft.
19. Remove big-end bearing cap.
20. Using scale provided, measure width of
Plastigage on bearing journal and compare with
bearing clearance:
Big-end bearing clearance = 0.010 to 0.055 mm
(0.0004 to 0.002 in)
21. If correct clearance cannot be obtained with
bearing shells available, crankshaft journals
must be ground to next undersize and the
appropriate oversize big-end bearing shells
fitted.
REPAIR
47
12
ENGINE
NEW RANGE ROVER
22. Retain selected bearing shell with connecting
rod and bearing cap.
23. Remove all traces of Plastigage using an oily
rag.
24. Repeat above procedures for remaining big-end
bearings.
25. Discard original big-end bearing cap bolts.
Refit
26. Lubricate crankshaft journals and selected
big-end bearing shells with engine oil.
27. Fit selected big-end bearing shells to connecting
rod and big-end bearing cap ensuring that
’sputter’ bearing is fitted to connecting rod.
31. Position reinforcing plate to crankcase ensuring
that arrows on plate are pointing towards front of
engine.
32. Fit 10 new bolts and tighten from centre
outwards to :
M4 - 22 Nm (16 lbf.ft)
M10 - 43 Nm (32 lbf.ft)
28. Pull connecting rod down on to crankshaft
journal.
29. Fit big-end bearing cap ensuring that reference
marks on cap and rod are aligned.
30. Fit new big-end bearing cap bolts and tighten to:
Stage 1 - 5 Nm (4 lbf.ft)
Stage 2 - 20 Nm (15 lbf.ft)
Stage 3 - Use angular torque wrench and tighten
further 70°.
48
REPAIR
BMW DIESEL
PISTONS, CONNECTING RODS AND CYLINDER
BORES
Service repair no - 12.17.03
Remove
1. Remove cylinder head. See this section.
2. Remove big-end bearings. See this section.
3. Push piston and connecting rod to top of cylinder
bore, remove piston and connecting rod.
4. Suitably identify piston and connecting rod to its
cylinder bore.
5. Repeat above procedure for remaining pistons
and connecting rods.
Pistons and connecting rods - dismantling
6. Remove and discard piston rings.
33. Position new seal to oil pump.
34. Fit oil pick-up pipe, fit 3 bolts and tighten to 10
Nm (7 lbf.ft)
35. Fit sump. See this section.
7. Remove and discard snap rings retaining
gudgeon pin.
8. Remove gudgeon pin, remove piston from
connecting rod.
CAUTION: Keep each piston, gudgeon pin
and connecting rod together as a set.
REPAIR
49
12
ENGINE
9. Remove carbon from piston crowns, and piston
ring grooves.
CAUTION: Do not attempt to remove
carbon or deposits from piston skirts as
graphite coating will be destroyed.
Pistons - inspection
10. Check piston for signs of burning and skirt for
scoring or damage.
NEW RANGE ROVER
Connecting rods - inspection
14. Check that oil feed passages are clear.
15. Check dowels in connecting rods and big-end
bearing caps for security, replace as necessary.
16. Check gudgeon pin bush in connecting rod for
wear:
Gudgeon pin bush bore = 28.995 to 29.021 mm
(1.142 to 1.143 in)
17. Replace worn bushes as necessary.
CAUTION: When fitting new bushes,
ensure oil holes in bush and connecting
rod are aligned.
11. Measure and record piston diameter at a point
7.0 mm (0.27 in) from bottom of skirt and at right
angles to gudgeon pin holes.
NOTE: Three sizes of piston may be fitted:
Standard = 79.96 ± 0.009 mm (3.14 ±
0.0004 in)
Intermediate = 80.04 ± 0.009 mm ( 3.15 ± 0.0004
in)
1st oversize = 80.21 ± 0.009 mm (3.16 ± 0.0004 in)
12. Check gudgeon pin holes in piston for signs of
ovality.
13. Repeat above procedures for remaining pistons.
18. Check connecting rods for distortion, fit a new
BLUE colour coded ’sputter’ big-end bearing
shell to the connecting rod and a new RED
colour coded shell to the big-end bearing cap.
19. Fit original big-end bearing cap bolts and tighten
to 5 Nm (4 lbf.ft).
20. Check parallelism of connecting rods on both
sides of rod.
Maximum deviation A = 0.05 mm (0.002 in)
NOTE: Measurement must be taken
approximately 150 mm (6.0 in) from centre
line of rod:
21. Check for distortion on both sides of connecting
rod:
Maximum distortion B = 0.5 mm (0.02 in)
22. Repeat above procedures for remaining
connecting rods.
50
REPAIR
BMW DIESEL
23. Replace connecting rods as necessary, do not
attempt to straighten distorted rods.
CAUTION: replacement connecting rods
must be of the same weight classification,
the classification is embossed on the main
bearing caps.
Cylinder bores - inspection
24. De-glaze cylinder bores, check bores for scoring.
25. Remove all traces of cylinder head gasket and
carbon deposits from cylinder block.
28. Repeat procedure at angle shown and from the
2 sets of measurements obtained, calculate
cylinder bore ovality and taper:
Maximum ovality = 0.04 mm (0.002 in)
Maximum taper = 0.04 mm (0.002 in)
29. Compare piston diameter with cylinder bore size
and determine piston to bore clearance:
Piston to bore clearance = 0.031 to 0.063 mm
(0.0012 to 0.002 in)
NOTE: For engines which have been ’run
in,’ the above clearance may be increased
to 0.213 mm (0.008 in).
30. Standard and intermediate size cylinder bores
which are worn in excess of limits given may be
rebored to next oversize and the appropriate
oversize pistons fitted.
26. Check and record cylinder bore diameter at
bottom, centre and top of bore ensuring that
measurements are taken at the angle shown.
27. Compare figures obtained with the following and
determine cylinder bore size:
Standard = 80.00 to 80.04 mm (3.150 to 3.151
in)
Intermediate = 80.08 to 80.12 mm (3.153 to
3.154 in)
1st oversize = 80.25 to 80.29 mm (3.20 to 3.21
in)
REPAIR
51
12
ENGINE
NEW RANGE ROVER
Piston rings - check
CAUTION: Ensure that replacement piston
rings are the correct size for the pistons to
be fitted.
31. Lubricate cylinder bores and new piston rings
with engine oil.
37. Fit oil control, 2nd and 1st compression rings to
piston.
NOTE: 1st and 2nd rings are marked TOP.
32. Insert 1 set of piston rings in turn into No. 1
cylinder bore.
33. Check piston ring gaps using feeler gauges:
Piston ring gap - 1st, 2nd and oil control rings =
0.2 to 0.4 mm (0.008 to 0.020 in)
CAUTION: If ring gaps are too wide, it will
be necessary to rebore cylinder(s) to next
size and fit appropriate size pistons and
rings.
34. Suitably identify the piston rings with No.1
cylinder and retain with the piston and
connecting rod for that cylinder.
35. Repeat above procedures for remaining
cylinders.
36. Lubricate pistons and ring grooves with engine
oil.
52
REPAIR
38. Using feeler gauges, measure clearance
between piston ring groove and 2nd
compression and oil control rings.
Ring to groove clearance:
1st compression - not checked
2nd compression = 0.040 to 0.072 mm ( 0.002
to0.004 in)
Oil control = 0.030 to 0.065 mm (0.001 to 0.003
in)
39. Check that 1st compression ring is free to move
in groove.
40. Repeat above procedures for remaining pistons
and rings.
BMW DIESEL
Pistons and connecting rods - assembling
Pistons and connecting rods - refit
43. Lubricate pistons, rings and cylinder bores with
engine oil.
44. Position piston ring gaps at 120° to each other
ensuring that they are not over gudgeon pin.
41. Assemble each piston to its connecting rod
ensuring that the number on the rod is
positioned relative to the arrow on the piston
crown as shown.
45. Compress piston rings using LRT-12-519.
46. Fit each piston and connecting rod to its
respective cylinder in turn ensuring that arrow on
piston crown is pointing towards front of engine.
CAUTION: Fit pistons using hand pressure
only.
47. Fit big-end bearings. See this section.
48. Fit cylinder head. See this section.
42. Lubricate gudgeon pins and bushes with engine
oil, fit pins and retain with new snap rings.
NOTE: Position snap ring gaps opposite
recess in piston.
REPAIR
53
12
ENGINE
NEW RANGE ROVER
CRANKSHAFT AND MAIN BEARINGS
Service repair no - 12.21.33/01
Remove
1. Remove engine and gearbox. See this section.
2. Remove oil pump. See this section.
3. Remove crankshaft rear oil seal. See this
section.
4. Remove pistons and connecting rods. See this
section.
6. Ensure that main bearing caps 1 to 5 are
suitably identified on the exhaust manifold side
of the engine.
NOTE: Main bearing caps 6 and 7 are not
marked on production, ensure that they
are suitably identified to their fitted
positions. Bearing cap 6 carries the integral
thrust/main bearing shell.
5. Using sequence shown, progressively slacken
then remove main bearing cap bolts.
NOTE: Do not discard bolts at this stage.
54
REPAIR
7. Remove main bearing caps.
8. Remove and discard main bearing shells from
caps.
9. Lift out crankshaft.
10. Remove and discard main bearing shells from
cylinder block.
11. Clean crankshaft, ensure all oilways are clear.
12. Clean main bearing caps and bearing shell
locations in cylinder block; ensure bearing cap
bolt holes are clean and dry.
13. Clean original bearing cap bolts and lightly oil
threads.
BMW DIESEL
Inspection
14. Check front web of crankshaft to determine if
main bearing journals have been ground
undersize.
No paint mark - Standard journals
1 paint mark - Journals are 0.25 mm (0.01 in)
undersize
2 paint marks - Journals are 0.50 mm (0.02 in)
undersize
NOTE: Each of the three main journal sizes
has a triple colour classification which
corresponds to the colour code of the
main bearing cap shells, a colour code on the
edge of the balance webs will indicate the actual
size.
15. Measure and record main journal diameters and
compare with the sizes given below. Take 4
measurements of each journal at 90° intervals to
check for appropriate specified size and ovality.
Standard:
Yellow = 59.984 to 59.990 mm (2.3616 to 2.3618
in)
Green = 59.977 to 59.983 mm (2.3612 to 2.3615
in)
White = 59.971 to 59.976 mm (2.3610 to 2.3611
in)
Undersize 1 - 0.25 mm (0.01 in):
Yellow = 59.734 to 59.740 mm (3.3522 to 2.3526
in)
Green = 59.727 to 59.733 mm (2.3514 to 2.3520
in)
White = 59.721 to 50.726 mm (2.3512 to 2.3514
in)
Undersize 2 - 0.50 mm (0.02 in):
Yellow = 59.484 to 59.490 mm (2.3418 to 2.3420
in)
Green = 59.477 to 59.483 mm (2.3414 to 2.3417
in)
White = 59.471 to 59.476 mm (2.3413 to 2.3415
in)
16. If standard or undersize 1 journals are found to
be oval, the crankshaft may be ground to the
next undersize.
17. If journals are worn below the original colour
code size but ovality is within limits, then the
next size main bearing shells should be fitted in
the main bearing caps and cylinder block when
carrying out the Plastigage check.
NOTE: If journals are worn below the
lowest colour size for standard or
undersize 1 journals, crankshaft may be
ground to the next undersize. Ensure that paint
stripe(s) to denote that grinding has been carried
out are marked on the crankshaft front web.
REPAIR
55
12
ENGINE
NEW RANGE ROVER
Check crankshaft main bearing clearances
18. Fit new, appropriate size yellow main bearing
shells in cylinder block at positions 1 to 5 and 7.
19. Fit new, appropriate yellow thrust/main bearing
shell in cylinder block at position 6.
NOTE: Thrust portion of bearing shells
fitted in cylinder block and main bearing
cap should be the thinnest of the range
available - See crankshaft end-float - check.
27. Using sequence shown, tighten main bearing
cap bolts to 20 Nm (15 lbf.ft).
28. Using a suitable angular torque wrench, tighten
bolts in sequence a further 50°
CAUTION: Do not rotate crankshaft.
20. Position crankshaft in cylinder block.
21. Check colour coding on crankshaft webs and fit
new, appropriate size main bearing shells of the
same colour coding in main bearing caps
numbers 1 to 5 and 7.
22. Fit new, appropriate size thrust/main bearing
shell of the same colour coding in number 6
main bearing cap.
23. Place a strip of Plastigage across each main
bearing journal.
24. Fit main bearing caps ensuring that identification
marks are on exhaust manifold side of engine.
25. Fit original main bearing cap bolts.
26. Align main bearing caps to crankcase.
29. Using sequence shown, progressively slacken
then remove main bearing cap bolts.
30. Remove main bearing caps and shells.
56
REPAIR
BMW DIESEL
Crankshaft end float - check
36. Fit crankshaft, fit main bearing caps ensuring
that reference marks are on exhaust manifold
side of engine.
37. Align main bearing caps to crankcase.
31. Using scale provided, measure width of
Plastigage on each main bearing journal and
compare with specified bearing clearances:
Main bearing clearance = 0.020 to 0.058 mm
(0.001 to 0.002 in)
32. If clearances are incorrect, select alternative
main bearing cap shell(s) from the range
available and repeat check.
NOTE: If colour coding of selected bearing
shell(s) differs from colour marked on
adjacent crankshaft web, ensure correct
colour is marked on web on completion.
38. Fit original main bearing cap bolts and tighten in
sequence shown to 20 Nm (15 lbf.ft) then using
an angular torque wrench, tighten in sequence a
further 50° .
33. Remove all traces of Plastigage using an oily
rag.
34. Fit selected main bearing shells to main bearing
caps.
35. Remove crankshaft, lubricate journals and main
bearing shells with engine oil.
39. Position a suitable DTI to front of crankshaft.
40. Move crankshaft fully rearwards and zero gauge.
41. Move crankshaft fully forwards and note
end-float reading on gauge.
Crankshaft end-float = 0.080 to 0.163 mm (0.003
to 0.006 in)
REPAIR
57
12
ENGINE
Crankshaft end-float incorrect:
42. Remove crankshaft.
43. Select combined thrust/main bearing shells from
the range available to give correct end-float
ensuring that correct colour coding/size of
bearing shell is maintained.
NEW RANGE ROVER
Refit
48. Lightly oil threads of new main bearing cap bolts.
49. Fit main bearing cap bolts, align main bearing
caps to crankcase.
NOTE: Each of the thrust/main bearing
shell sizes has three widths of shell
available:
Standard = 25.0 mm (0.94 in)
Size 1 = 25.2 mm (0.992 in)
Size 2 = 25.4 mm (1.00 in)
44. Fit selected thrust/main bearing shells in cylinder
block and main bearing caps.
45. Fit crankshaft and main bearing caps ensuring
that identification marks are on exhaust manifold
side of engine and repeat check as necessary
until end-float is correct.
46. Discard original main bearing cap bolts on
completion.
Crankshaft end-float correct:
47. Using sequence shown, progressively slacken
then remove main bearing cap bolts; discard
bolts.
58
REPAIR
50. Tighten main bearing cap bolts in sequence
shown using the following procedure:
Stage 1 - Tighten in sequence shown to 20 Nm
(15 lbf.ft).
Stage 2 - Slacken bolts on number 6 main
bearing cap.
Stage 3 - Using a hide mallet, strike each end of
crankshaft to centralise thrust/main bearing
shells.
Stage 4 - Tighten number 6 main bearing cap
bolts to 20 Nm (15 lbf.ft)
Stage 5 - Using an angular torque wrench,
tighten all main bearing cap bolts in sequence a
further 50° .
51. Fit pistons and connecting rods. See this
section.
52. Fit crankshaft rear oil seal. See this section.
53. Fit oil pump. See this section.
54. Fit engine and gearbox. See this section.
BMW DIESEL
CRANKSHAFT SPIGOT BEARING
TIMING CHAINS AND SPROCKETS
Service repair no - 12.21.45/01
Service repair no - 12.65.12
Remove
Remove
1. Remove flywheel/drive plate. See this section.
1. Disconnect battery negative lead.
2. Remove front cover. See this section.
3. Remove upper timing chain guide rail.
2. Remove spigot bearing using LRT-12-109,
discard bearing.
Refit
3. Clean spigot bearing recess in crankshaft.
4. Position new spigot bearing to crankshaft.
5. Drift bearing fully into crankshaft using
LRT-12-110.
6. Fit flywheel/drive plate. See this section.
4. Using a suitable lever, retract lower chain
tensioner plunger. Insert retaining pin
LRT-12-114.
5. Remove lower timing chain tensioner rail.
6. Ensure timing pin LRT-12-108 is still located in
flywheel.
REPAIR
59
12
ENGINE
7. Remove nut from Fuel Injection Pump (FIP)
sprocket.
8. Remove centre bolt from tool LRT-12-119.
Screw body of tool onto FIP sprocket.
9. Fit centre bolt to tool. Pull sprocket from FIP.
10. Withdraw sprockets and chains as an assembly.
11. Remove tool from FIP sprocket.
12. Remove lower timing chain guide rail.
NEW RANGE ROVER
Refit
13.
14.
15.
16.
Ensure mating faces are clean.
Lubricate timing chains with clean engine oil.
Fit lower chain guide.
Assemble sprockets to lower timing chain.
Ensure dimples on sprockets align with chain
’bright’ links.
17. Engage upper timing chain over rear sprocket.
18. Engage sprockets over crankshaft and FIP shaft.
Ensure sprockets/bright links remain aligned.
NOTE: Align FIP shaft to sprocket keyways
using tool LRT-12-118 prior to fully
engaging sprockets.
19. Secure FIP sprocket with nut. Tighten to 50 Nm
(37 lbf.ft)
20. Fit lower timing chain tensioner rail.
21. Depress tensioner plunger using a suitable lever.
Remove retaining pin LRT-12-114.
22. Fit upper timing chain guide rail.
23. Refit front cover. See this section.
24. Check and adjust fuel injection pump timing.
See FUEL SYSTEM, Adjustment.
25. Reconnect battery negative lead.
60
REPAIR
12 - ENGINE
CONTENTS
Page
LAND ROVER V8
DESCRIPTION AND OPERATION
V8 ENGINE - from 99MY .....................................................................................
CYLINDER HEAD COMPONENTS - from 99MY .................................................
CYLINDER BLOCK COMPONENTS - from 99MY ...............................................
DESCRIPTION - up to 99MY ...............................................................................
DESCRIPTION - from 99MY ................................................................................
1
2
4
6
6
REPAIR
CRANKSHAFT PULLEY AND FRONT COVER OIL SEAL - up to 99MY ............ 1
CRANKSHAFT PULLEY AND FRONT COVER OIL SEAL - from 99MY ............. 2
CRANKSHAFT REAR OIL SEAL ......................................................................... 3
DRIVE PLATE - AUTOMATIC - up to 99MY ........................................................ 4
DRIVE PLATE - AUTOMATIC - from 99MY ......................................................... 5
ENGINE AND GEARBOX - up to 99MY ............................................................... 7
ENGINE AND ANCILLARIES - from 99MY ........................................................ 16
FLYWHEEL ........................................................................................................ 25
FRONT COVER GASKET AND OIL PUMP - up to 99MY ................................. 26
GASKET - FRONT COVER - from 99MY ........................................................... 29
FRONT COVER AND OIL PUMP ASSEMBLY .................................................. 32
ENGINE MOUNTINGS - up to 99MY ................................................................. 33
ENGINE MOUNTINGS - from 99MY .................................................................. 35
REAR ENGINE MOUNTING .............................................................................. 36
OIL FILTER ........................................................................................................ 38
OIL COOLER ..................................................................................................... 38
OIL PRESSURE SWITCH - up to 99MY ............................................................ 40
OIL PRESSURE SWITCH - from 99MY ............................................................. 40
STRAINER - OIL PICK-UP ................................................................................. 41
ROCKER COVER GASKET - up to 99MY ......................................................... 42
ROCKER COVER GASKET (LH) - from 99MY .................................................. 44
ROCKER COVER GASKET (RH) - from 99MY ................................................. 45
ROCKER SHAFT - OVERHAUL ........................................................................ 46
SUMP - up to 99MY ........................................................................................... 47
SUMP GASKET - from 99MY ............................................................................. 49
TAPPETS - ENGINE SET .................................................................................. 50
CYLINDER HEAD GASKET (LH) - from 99MY .................................................. 51
CYLINDER HEAD GASKET (RH) - from 99MY ................................................. 53
TIMING CHAIN AND GEARS - from 99MY ........................................................ 55
LAND ROVER V8
V8 ENGINE - from 99MY
DESCRIPTION AND OPERATION
1
12
ENGINE
CYLINDER HEAD COMPONENTS - from 99MY
2
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Rocker cover - right hand
Engine oil filler cap
Oil filler dust cap seal
’O’ ring - oil filler cap
Bolt - rocker cover (4 off; 2 x short, 2 x long)
Rocker cover - left hand
Gasket - rocker cover
Cylinder head - left hand
Valve spring cap (16 off)
Valve stem oil seals (16 off)
Collets (16 pairs)
Valve spring (16 off)
Valve seat insert (16 off)
Exhaust valve (8 off)
Inlet valve (8 off)
Seal - inlet manifold gasket (2 off)
Gasket - cylinder head (2 off)
Gasket - exhaust manifold
Cylinder head - right hand
Spark plug (8 off)
Bolt - cylinder head (3 x long & 7 x short per
cylinder head)
Valve guide (16 off)
Split pin (4 off)
Washers - plain (4 off)
Washers - spring (4 off)
Spring - rocker shaft (6 off)
Rocker arm
Pedestal bolt
Pedestal
Push rod
Hydraulic tappet
Rocker shaft
Screw/washer - inlet manifold gasket clamp (2
off)
Clamp - inlet manifold gasket (2 off)
Gasket - inlet manifold
DESCRIPTION AND OPERATION
3
12
ENGINE
CYLINDER BLOCK COMPONENTS - from 99MY
4
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
Bolt - Rear lifting eye (2 off)
Rear lifting eye
Camshaft
Dipstick, dipstick tube, clamp and bolt
Timing chain
Camshaft sprocket
Front lifting eye
Bolt - Front lifting eye (2 off)
Washer
Bolt - camshaft timing gear
Thrust plate - camshaft end-float
Bolt - camshaft thrust plate
Gasket - front cover
Front cover
Oil pressure switch
Circlip
Plunger - oil pressure relief valve
Plug - oil pressure relief valve
Spring - oil pressure relief valve
Bolt
Crankshaft front oil seal
Oil filter element
Crankshaft front pulley
Washer
Bolt - crankshaft front pulley
Upper main bearing seal
Upper centre main bearing shell and thrust
washer
Crankshaft
Woodruff key
Crankshaft timing gear
Lower main bearing shells
Numbers 1, 2 and 3 main bearings
Bolt - main bearing caps
Oil pick-up pipe and strainer
’O’ ring
Screw - oil pick-up pipe (2 off)
Gasket - sump
Sump
Bolt - sump
Oil sump drain plug
Sealing washer
Baffle plate - oil sump
Screws - baffle plate (4 off)
Stiffener and nut - oil pick-up pipe to main
bearing cap
Spacer - oil pick-up pipe to main bearing cap
Number 4 main bearing cap
Bolt - connecting rod big-end bearing cap
Connecting rod big-end bearing shell - lower
Connecting rod big-end bearing cap
Number 5 - rear main bearing cap
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
Cruciform seal - rear main bearing cap
Number 5 - rear main bearing seal
Crankshaft rear oil seal
Crankshaft knock sensor
Side bolt - main bearing cap
Dowty washers
Side Allen bolt - main bearing cap
Connecting rod big-end bearing shell - upper
Connecting rod
Piston
Gudgeon pin
Oil control ring
Top compression ring
2nd compression ring
Flywheel / drive plate and starter ring gear
Bolt - flywheel / drive plate
Core plugs
Tappet oil gallery plugs (2 off)
Plug - Camshaft rear bore
Cylinder block
DESCRIPTION AND OPERATION
5
12
ENGINE
DESCRIPTION - up to 99MY
For description and operation of V8 engine before
99MY, refer to 4.0/4.6 V8 Engine Overhaul Manual.
DESCRIPTION - from 99MY
General
The V8 petrol engine is an eight cylinder, water cooled
unit having two banks of four cylinders positioned at
90 degrees to each other. The engine comprises five
main castings - two cylinder heads, cylinder block,
front cover and the oil sump, all of which are
manufactured from aluminium alloy. The engine is
available in 4.0 litre and 4.6 litre versions and each
type can be supplied as high compression or low
compression variants, dependent on market
requirements.
Cylinder heads
The cylinder heads are fitted with replaceable valve
guides and valve seat inserts with the combustion
chambers formed in the head. Each cylinder head is
sealed to the cylinder block with a multi-layer gasket.
The exhaust manifolds are bolted to the outside of
each cylinder head whilst the inlet manifolds are
located in the centre of the ’Vee’ and are bolted to the
inside face of each head. Inlet and exhaust manifolds
are sealed to the cylinder heads by means of gaskets.
Each cylinder has a single inlet and exhaust valve.
The exhaust valves are of the ’carbon break’ type, a
recess on the valve stem prevents a build-up of
carbon in the valve guide by dislodging particles of
carbon as the valve stem moves up and down the
guide. Inlet and exhaust valve stem oil seals are fitted
at the top of each valve guide. Valve operation is by
means of rocker arms, push rods and hydraulic
tappets. Each of the rocker arms is located on a
rocker shaft which is supported by means of pedestals
bolted to the cylinder heads. A spring, positioned on
either side of each rocker arm, maintains the correct
relative position of the arm to its valve stem. The
rocker arms are operated directly by the push rods
which pass through drillings in the cylinder heads and
cylinder block. The bottom end of each push rod
locates in a hydraulic tappet operated by the single,
chain driven camshaft.
6
DESCRIPTION AND OPERATION
NEW RANGE ROVER
The rocker covers are bolted to the cylinder heads
and are sealed to the heads by a rubber gasket. Stub
pipes for crankcase ventilation hose connections are
fitted to each rocker cover, the pipe in the right hand
rocker cover incorporates an oil separator. The engine
oil filler cap is situated in the right hand cover.
Cylinder block and camshaft
The cylinder block is fitted with cast iron cylinder liners
which are shrink-fitted and locate on stops in the
block. The camshaft is positioned in the centre of the
cylinder block and runs in one-piece bearing shells
which are line bored after fitting. Camshaft end-float is
controlled by a thrust plate bolted to the front of the
cylinder block. A timing gear, chain driven by the
crankshaft timing gear is bolted to the front of the
camshaft.
Crankshaft and main bearings
The crankshaft is carried in five main bearings. The
upper main bearing shell locations are an integral part
of the cylinder block casting. The lower main bearing
caps are bolted to the cylinder block on either side of
the upper bearing shell locations with an additional
bolt being inserted into each cap from either side of
the cylinder block. The rear main bearing cap carries
the crankshaft rear oil seal and is sealed to the
cylinder block by means of cruciform shaped seals in
each side of the cap. Number four main bearing cap
carries the stud fixing for the oil pick-up pipe. Lower
main bearing shells are plain whilst the upper shells
have an oil feed hole and are grooved. Crankshaft
end-float is controlled by the thrust faces of the upper
centre shell. The crankshaft timing gear is located on
the front of the crankshaft by means of a Woodruff key
which is also used to drive the gear type oil pump.
The drive plate incorporates the crankshaft position
sensor reluctor ring, and the assembly is dowel
located and bolted to the crankshaft.
LAND ROVER V8
Front cover
The front cover is bolted to the front of the cylinder
block and is sealed to the block with a gasket. The
disposable, full-flow oil filter canister is screwed to the
front cover, which also carries the oil pressure switch,
oil pressure relief valve and crankshaft front oil seal.
The gear type oil pump is integral with the front cover
which also has an internal oilway to direct oil from the
oil cooler to the filter.
Oil sump
The oil sump is bolted to the bottom of the cylinder
block and the front cover and is sealed to both
components with a one-piece gasket. A removable
baffle to prevent oil surge is fitted in the sump. The oil
pick-up pipe and strainer assembly is positioned
within the sump. The assembly is attached at the
pick-up end to a stud screwed into number four main
bearing cap and at the delivery end to the oil pump.
The oil drain plug is located in the bottom of the sump
and is sealed with a washer.
Pistons and connecting rods
Each of the aluminium alloy pistons has two
compression rings and an oil control ring. The pistons
are secured to the connecting rods by semi-floating
gudgeon pins. Each gudgeon pin is offset by 0.5 mm
(0.02 in). The top of each piston is recessed, the
depth of recess determining the compression ratio of
the engine. Plain big-end bearing shells are fitted to
each connecting rod and cap.
DESCRIPTION AND OPERATION
7
12
ENGINE
Lubrication
1.
2.
3.
4.
5.
6.
7.
A.
B.
8
Rocker shaft assembly
Hydraulic tappet
Oil pump
Oil filter element
Oil pick-up pipe and strainer
Oil pressure switch
Oil pressure relief valve
- to oil cooler
- from oil cooler
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
Oil is drawn from the sump through a strainer and into
the oil pump via the oil pick-up pipe. Pressurised oil
from the pump passes through the oil cooler mounted
in front of the radiator and returns to the full-flow oil
filter element. Oil from the filter passes into the main
oil gallery and through internal drillings to the
crankshaft where it is directed to each main bearing
and to the big-end bearings via numbers 1, 3 and 5
main bearings. Excess oil pressure is relieved by the
oil pressure relief valve. An internal drilling in the
cylinder block directs oil to the camshaft where it
passes through further internal drillings to the
hydraulic tappets, camshaft bearing journals and
rocker shafts. Lubrication to the pistons, small ends
and cylinder bores is by oil grooves machined in the
connecting rods and by splash.
Oil pressure switch
The oil pressure warning light switch registers low oil
pressure in the main oil gallery on the outflow side of
the filter. Whilst the engine is running and oil pressure
is correct, the switch is open. When the ignition is
switched on or if oil pressure drops below the
pressure setting of the switch, the switch closes and
the low oil pressure warning lamp located in the
instrument pack will illuminate.
Hydraulic tappets
1.
2.
3.
4.
5.
6.
7.
8.
The hydraulic tappet provides maintenance free, quiet
operation of the valves. This is achieved by utilizing
engine oil pressure to eliminate the clearance
between the rocker arms and valve stems. When the
valve is closed, engine oil pressure present in the
upper chamber, passes through the non-return ball
valve and into the lower chamber. When the cam
begins to lift the outer sleeve, the resistance of the
valve spring, felt through the push rod and seat,
causes the tappet inner sleeve to move downwards
inside the outer sleeve. This downwards movement
closes the non-return ball valve and increases the
pressure in the lower chamber sufficiently to ensure
that the valve is fully opened by the push rod. As the
tappet moves off the peak of the cam, the non-return
ball valve opens thereby allowing the pressure in both
chambers to equalize. This ensures that the valve will
be fully closed when the tappet is on the back of the
cam.
Crankcase ventilation
A positive crankcase ventilation system is used to
vent crankcase gases to the air induction system.
Gases are drawn from the left hand rocker cover to a
tapping in the throttle body. An oil separator is
incorporated in the hose connection stub pipe in the
right hand rocker cover, gases from this connection
are drawn to a tapping in the inlet manifold.
Clip
Pushrod seat
Inner sleeve
Upper chamber
Non-return ball valve
Spring
Outer sleeve
Lower chamber
DESCRIPTION AND OPERATION
9
LAND ROVER V8
CRANKSHAFT PULLEY AND FRONT COVER OIL
SEAL - up to 99MY
Service repair no - 12.21.01 - Crankshaft Pulley
Service repair no - 12.21.14 - Front Cover Oil Seal
Remove
1. Disconnect battery negative lead.
2. Remove cooling fan. See COOLING SYSTEM,
Repair.
8. Remove crankshaft pulley bolt. Collect pulley
and tool.
3. Slacken 3 water pump pulley securing bolts.
4. Remove alternator drive belt.
5. Remove water pump pulley bolts. Remove
pulley.
6. Raise vehicle on four post lift.Remove acoustic
cover if applicable. See CHASSIS AND BODY,
Repair.
7. Secure LRT-12-080 to crankshaft pulley with 4
bolts.
9. Using LRT-12-088, remove oil seal from front
cover.
CAUTION: Do not damage front cover.
REPAIR
1
12
ENGINE
Refit
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
NEW RANGE ROVER
CRANKSHAFT PULLEY AND FRONT COVER OIL
SEAL - from 99MY
Clean seal register and crankshaft pulley.
Lubricate outer face of seal.
Using LRT-12-089, fit seal to cover.
Lubricate oil seal lip. Fit crankshaft pulley.
Refit crankshaft pulley bolt. Tighten to 270 Nm
(200 lbf.ft)
Ensure mating faces between flywheel access
cover and gearbox are clean.
Lower vehicle.
Ensure mating faces between water pump pulley
and pump are clean.
Refit water pump pulley. Tighten to 22 Nm (16
lbf.ft)
Refit alternator drive belt.
Refit cooling fan. See COOLING SYSTEM,
Repair.
Reconnect battery negative lead.
Service repair no - 12.21.01 Crankshaft pulley
Service repair no - 12.21.14 Front cover oil seal
Remove
1. Remove auxiliary drive belt. See ELECTRICAL,
Repair.
2. Secure LRT-12-080 to crankshaft pulley with 2
bolts.
3. Remove crankshaft pulley bolt.
4. Remove crankshaft pulley.
5. Using LRT-12-088, remove oil seal from front
cover.
Refit
6. Clean seal register in front cover and crankshaft
pulley.
2
REPAIR
LAND ROVER V8
CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
1. Manual Vehicles: Remove flywheel. See this
section.
2. Automatic Vehicles: Remove drive plate. See
this section.
7. Lubricate outer face of seal and fit seal to front
cover using LRT-12-089
8. Fit crankshaft pulley and tighten bolt to 270 Nm
(200 lbf.ft.).
9. Remove LRT-12-080 from crankshaft pulley.
10. Fit auxiliary drive belt. See ELECTRICAL,
Repair.
3. Remove oil seal from location.
CAUTION: Do not damage seal location or
running surface on crankshaft.
Refit
4. Ensure both seal location and running surface
on crankshaft are clean.
5. Ensure mating faces of flywheel and crankshaft
are clean.
6. Lubricate seal guide LRT-12-095 with clean
engine oil. Position over crankshaft boss.
REPAIR
3
12
ENGINE
NEW RANGE ROVER
DRIVE PLATE - AUTOMATIC - up to 99MY
Service repair no - 12.53.13
Remove
1. Remove automatic gearbox and torque
converter. See AUTOMATIC GEARBOX,
Repair.
7.
8.
9.
10.
Lubricate oil seal lip.
Position seal squarely. Remove guide.
Drift seal into location using LRT-12-091.
Manual Vehicles: Fit flywheel. See this
section.
11. Automatic Vehicles: Fit drive plate. See this
section.
2. Remove 4 clamp ring bolts. Collect clamp ring.
3. Remove flexible drive plate/starter ring gear
assembly from hub aligner.
4. Remove 6 screws from hub aligner. Remove hub
aligner from crankshaft. Collect spacer.
5. Check drive plate for distortion or cracks. Check
starter ring gear for chipped or broken teeth. If
either component shows signs of damage, fit a
new assembly.
4
REPAIR
LAND ROVER V8
Refit
6. Ensure all mating surfaces are clean.
7. Fit spacer and hub aligner to crankshaft.
8. Fit hub aligner screws. Tighten to 85 Nm (63
lbf.ft)
9. Fit drive plate and clamp ring.
10. Fit clamp ring bolts. Tighten to 45 Nm (33 lbf.ft)
11. Fit automatic gearbox and converter assembly.
See AUTOMATIC GEARBOX, Repair.
DRIVE PLATE - AUTOMATIC - from 99MY
Service repair no - 12.53.13
Remove
1. Remove gearbox. See AUTOMATIC
GEARBOX, Repair.
2. Remove CKP sensor. See FUEL SYSTEM,
Repair.
3. Remove Lucar from starter solenoid.
4. Remove nut securing battery lead to starter
solenoid and disconnect lead.
5. Remove 2 Allen screws securing starter motor
and remove starter motor.
6. Remove 4 bolts securing drive plate clamp ring
and remove ring.
7. Remove drive plate from hub.
8. Remove spacer.
9. Remove starter ring gear.
REPAIR
5
12
ENGINE
Refit
10. Clean starter ring gear and hub, clean dowel and
dowel hole.
11. Fit starter ring gear to hub.
12. Clean spacer, clamp ring and mating face on
hub.
13. Clean drive plate and check for cracks and
distortion.
14. Fit spacer to hub, fit drive plate and clamp ring.
Tighten bolts to 45 Nm (33 lbf.ft).
15. Clean starter motor and mating face.
16. Fit starter motor and tighten Allen screws to 45
Nm (33 lbf.ft).
17. Connect battery lead to starter solenoid and
secure with nut.
18. Connect lucar to starter solenoid.
19. Fit CKP sensor. See FUEL SYSTEM, Repair.
20. Fit gearbox. See AUTOMATIC GEARBOX,
Repair.
6
REPAIR
NEW RANGE ROVER
LAND ROVER V8
ENGINE AND GEARBOX - up to 99MY
Service repair no - 12.37.01/99
Remove
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Position vehicle on four post lift.
Remove battery. See ELECTRICAL, Repair.
Remove ECM. See FUEL SYSTEM, Repair.
Remove 2 screws securing engine harness
clamp to battery tray. Collect clamp.
Release starter feed wire from battery terminal
clamp.
Release earth lead from alternator bracket.
Release fuel return hose clip. Release fuel return
hose from regulator connecting pipe.
Release fuel feed pipe from fuel rail.
Disconnect multiplug from purge valve.
Release purge hose from ram pipe housing.
11. Remove purge valve securing bolt from shock
absorber turret. Place valve aside.
12. Disconnect multiplug from air flow meter.
13. Release harness from intake hose.
14. Slacken clip securing intake hose to plenum
chamber.
15. Remove intake hose/air flow meter assembly.
16. Position harness across engine.
17. Disconnect throttle and cruise control cables
from throttle linkage.
18. Release cables from abutment bracket.
19. Disconnect top hose from inlet manifold.
20. Disconnect heater hose from inlet manifold.
Release hose from clip. Place hose aside.
21. Disconnect coolant hose from plenum chamber
water jacket. Release hose from 2 clips. Place
hose aside on valance.
22. Remove 4 bolts securing battery tray. Remove
battery tray.
REPAIR
7
12
ENGINE
23. Remove 2 bolts securing fuse box. Pivot fuse
box for access.
24. Disconnect engine harness multiplug from base
of fuse box.
25. Release earth wire from valance stud.
26. Disconnect 2 engine harness multiplugs from
main harness.
27. Release engine harness clip from valance. Tie
harness aside over engine.
28. With assistance, release bonnet struts from body
locations. Retain bonnet in vertical position using
stay clips.
NEW RANGE ROVER
29. Depressurise fuel system. See FUEL SYSTEM,
Repair.
30. Remove air cleaner. See FUEL SYSTEM,
Repair.
31. Drain cooling system. See COOLING SYSTEM,
Repair.
32. Discharge air conditioning system. See AIR
CONDITIONING, Adjustment.
33. Remove cooling fan and viscous coupling. See
COOLING SYSTEM, Repair.
34. Remove front grille. See CHASSIS AND BODY,
Repair.
35. Remove 4 bolts securing bonnet platform.
WARNING: Only open the bonnet to the
vertical position with the vehicle on a
horizontal surface in the workshop. This
position is not intended to be used outdoors
where the bonnet could be affected by winds.
36. Release straps securing bonnet release cable to
platform. Remove platform.
37. Remove 2 studs securing each radiator air
deflector. Remove both deflectors.
8
REPAIR
LAND ROVER V8
38. Remove bolt and screw securing washer bottle
filler neck. Remove filler neck.
41. Release 2 fog lamp breather hoses from clips on
either side of radiator.
42. Disconnect 3 coolant hoses from thermostat
housing.
43. Remove 2 bolts securing power steering fluid
reservoir to radiator.
CAUTION: Where pipes are disconnected,
plug pipes and ports to prevent ingress of
dirt.
39. Disconnect engine and gearbox oil coolers.
Remove ’O’ rings and discard. Tie pipes aside
on engine.
NOTE: Position container beneath power
steering reservoir to catch spillage.
44. Disconnect return pipe from reservoir. Tie
reservoir aside to engine.
45. Disconnect feed pipe from power steering pump.
Remove ’O’ rings and discard.
40. Disconnect coolant bleed hose from radiator.
REPAIR
9
12
ENGINE
46. Release feed pipe clip from bracket. Place pipe
aside.
47. Disconnect multiplug from gearbox oil
temperature sensor.
48. Disconnect 2 pipes from air conditioning
condenser. Remove ’O’ rings and discard.
49. Disconnect 2 pipes from air conditioning
compressor. Remove ’O’ rings and discard.
Place pipes aside.
50. Remove 2 nuts and bolts securing radiator
mountings to chassis.
51. With assistance, raise radiator assembly for
access to condenser cooling fan connections.
NEW RANGE ROVER
Manual Vehicles:
58. Remove centre console. See CHASSIS AND
BODY, Repair.
59. Remove 6 nuts securing gaiter ring. Remove
ring and gaiter.
60. Remove 2 bolts securing gear lever. Remove
lever.
52. Disconnect 2 condenser cooling fan multiplugs.
53. With assistance, remove radiator/condenser/oil
cooler assembly.
Manual Vehicles:
54. Clamp clutch flexible hose using an approved
brake hose clamp.
55. Remove clip securing flexible hose to gearbox
bracket.
56. Disconnect clutch flexible hose at gearbox pipe.
Position hose aside.
Automatic Vehicles:
57. Remove window switch pack. See
ELECTRICAL, Repair.
10
REPAIR
All Vehicles:
61. Release handbrake. Release handbrake cable
clevis pin.
LAND ROVER V8
62. Raise lift. Drain gearbox, transfer box and
engine fluids. See SECTION 10, Maintenance.
63. Using a transmission jack, support transmission
under brake drum.
64. Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
65. Release hand brake cable from grommet in
tunnel.
66. Remove 4 bolts securing rear propeller shaft
guard. Remove guard.
67. Mark transfer box and propeller shaft flanges to
aid reassembly.
68. Raise one wheel on each axle to allow rotation
of propeller shafts.
69. Remove 4 nuts and bolts from each flange.
Disconnect propeller shafts. Tie aside.
70. Automatic Vehicles: Disconnect gear selector
cable trunnion from gearbox lever. Remove 2
bolts securing selector cable abutment bracket
to gearbox. Place selector cable aside.
REPAIR
11
12
ENGINE
NEW RANGE ROVER
75. Manual Vehicles: Disconnect multiplugs from
reverse and neutral switches. Remove bolt
securing harness bracket to gearbox. Release
harness from clips on gearbox brackets.
71. Lower gearbox for access.
72. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
73. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
74. Automatic Vehicles: Disconnect multiplugs
from gear selection position switch and gearbox
speed sensor.
12
REPAIR
76. Disconnect engine harness to gearbox harness
multiplug. Position harness aside.
77. Remove 4 nuts securing each engine mount to
chassis and engine brackets. Discard nuts.
LAND ROVER V8
78. Remove oil filler cap.
79. Place cloth over plenum chamber to protect from
damage during lifting.
80. Shorten front chain of lifting bracket to 2 links as
shown.
83. Raise power unit and draw forward. Lower
support from transmission.
NOTE: Power unit must be tilted at an
angle of approximately 45 degrees before
it can be withdrawn from engine
compartment.
84. Remove engine/transmission assembly.
Refit
85. Raise power unit. Guide into engine bay.
86. Position transmission jack beneath transmission
brake drum.
87. With assistance, raise transmission and lower
engine until engine mountings can be fitted.
CAUTION: Ensure all under body wax is
removed from mating surfaces of fixings
before fitting.
81. Fit lifting bracket to engine lifting eyes. Attach
suitable hoist.
82. Raise engine slightly. Ensure that lifting bracket
does not foul bulkhead. Remove both engine
mountings.
NOTE: It may be necessary to lower
gearbox support slightly during above
operation.
REPAIR
13
12
ENGINE
88. Attach mountings to chassis with new flange
nuts. Do not tighten at this stage.
CAUTION: Engine mountings must be
fitted with centre bolt head facing
outboard as shown.
NEW RANGE ROVER
89. Lower and guide engine onto mounting studs.
90. Attach engine to mountings with new flange
nuts. Do not tighten at this stage.
91. Release lifting bracket from engine lifting eyes.
Remove hoist.
92. Route gearbox harness. Secure with clips.
93. Connect multiplug to engine harness.
94. Connect multiplugs to High/Low motor and
output shaft speed sensor.
Manual Vehicles:
95. Secure gearbox harness bracket with bolt.
Tighten to 6 Nm (4 lbf.ft).
96. Connect multiplugs to reverse and neutral
switches.
97. Secure harness to gearbox bracket with clips.
Automatic Vehicles:
98. Connect multiplugs to gear selection position
switch and gearbox speed sensor.
99. Position selector cable abutment bracket to
gearbox. Secure with bolts.
100. Adjust gear selector cable. See AUTOMATIC
GEARBOX, Adjustment.
All Vehicles:
101. Connect Lucars to transfer box fluid temperature
sensor.
102. Raise gearbox on transmission jack.
103. Align harness bracket to gearbox.
104. Raise one wheel on each axle to allow rotation
of propeller shafts.
105. Position shafts to transfer box flanges. Align
marks.
106. Secure propeller shaft flanges with nuts and
bolts. Tighten to 48 Nm (35 lbf.ft)
107. Fit propeller shaft guard. Tighten bolts.
108. Guide hand brake cable through grommet in
transmission tunnel.
109. Fit exhaust front pipe and chassis cross
member. See MANIFOLD AND EXHAUST
SYSTEM, Repair.
110. Remove support from under transmission.
111. Tighten engine mounting nuts to 45 Nm (33
lbf.ft)
14
REPAIR
LAND ROVER V8
112. Lower lift.
113. Connect handbrake cable to lever, secure with
clevis pin and clip.
Manual Vehicles:
114. Fit seal around gearbox remote housing to
transmission tunnel aperture.
115. Position gear lever. Secure with bolts. Tighten
to 25 Nm (18 lbf.ft)
116. Fit gaiter and ring. Secure with bolts.
117. Fit centre console. See CHASSIS AND BODY,
Repair.
118. Connect clutch flexible hose. Remove hose
clamp.
119. Secure flexible hose union to gearbox bracket
with clip.
120. Bleed clutch hydraulic system. See CLUTCH,
Repair.
Automatic Vehicles:
121. Fit window switch pack. See ELECTRICAL,
Repair.
All Vehicles:
122. With assistance, position radiator/condenser/oil
cooler assembly.
123. Connect multiplugs to condenser cooling fans.
124. Engage radiator in lower mounting rubbers.
Secure with nuts and bolts.
125. Remove plugs from air conditioning compressor
and pipes.
126. Fit new ’O’ rings to compressor pipes. Lubricate
’O’ rings with compressor oil. Connect to
compressor.
127. Fit compressor connection bolts. Tighten to 23
Nm (17 lbf.ft)
128. Remove plugs from air conditioning condenser
and pipes.
129. Fit new ’O’ rings to condenser pipes. Lubricate
’O’ rings with compressor oil. Secure pipes to
condenser. Tighten to 15 Nm (11 lbf.ft)
130. Connect gearbox oil temperature multiplug.
131. Remove plugs from power steering pump and
pipes.
132. Fit new ’O’ rings to power steering pipes.
Lubricate ’O’ rings with power steering fluid.
Secure to power steering pump. Tighten to 16
Nm (12 lbf.ft)
133. Untie power steering reservoir from engine.
Remove plugs. Connect return pipe. Secure
return pipe to reservoir with clip.
134. Position reservoir to radiator. Secure with bolts.
135. Secure fog lamp breather hoses to clips on
either side of radiator.
136. Route plenum chamber hose along front of
engine. Secure in clips.
137. Connect hose to plenum chamber water jacket.
Secure with clip.
138. Connect coolant hoses to radiator, thermostat
housing and inlet manifold. Secure hoses with
clips.
139. Remove plugs from oil coolers and pipes.
140. Lubricate pipes with clean fluid. Fit new ’O’ rings.
Connect to oil coolers. Tighten to 30 Nm (22
lbf.ft)
141. Fit washer bottle filler neck. Secure with bolt and
screw.
142. Fit radiator deflector panels. Secure with studs.
143. Position bonnet platform. Secure bonnet release
cable to platform with clips.
144. Secure bonnet platform with bolts.
145. Fit front grille. See CHASSIS AND BODY,
Repair.
146. Fit cooling fan and viscous coupling. See
COOLING SYSTEM, Repair.
147. Evacuate and recharge air conditioning system.
See AIR CONDITIONING, Adjustment.
148. Refill cooling system. See COOLING SYSTEM,
Repair.
149. Replenish transmission fluids. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
150. Replenish engine oil. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
151. Fit oil filler cap.
152. Route engine harness along valance. Secure
clip.
153. Connect engine harness multiplugs to main
harness. Secure earth terminal to valance stud.
154. Connect engine harness multiplug to base of
fuse box.
155. Position fuse box. Secure with bolts.
156. Position earth lead to alternator bracket. Secure
with bolt.
157. Fit battery tray. Secure with bolts.
158. Fit starter feed wire to battery positive terminal
clamp. Secure with nut.
159. Position engine harness to battery tray. Secure
harness grommets.
160. Secure harness clamp to battery tray with
screws.
REPAIR
15
12
ENGINE
161. Fit ECM. See FUEL SYSTEM, Repair.
162. Fit throttle and cruise control cables to abutment
bracket. Secure cruise control cable with ’C’ clip.
163. Position cable trunnions to throttle linkage.
Secure with clevis and split pins.
164. Adjust throttle cable free-play. See FUEL
SYSTEM, Adjustment.
165. Adjust cruise control cable. See CRUISE
CONTROL, Adjustment.
166. Fit intake hose and air flow meter assembly to
plenum chamber. Secure with clip. Connect
multiplug to air flow meter.
167. Connect multiplug to purge valve.
168. Position purge valve on shock absorber turret.
Secure with bolt.
169. Connect purge hose to ram pipe housing.
170. Secure harness to clip on intake hose.
171. Fit air cleaner. See FUEL SYSTEM, Repair.
172. Remove plugs from fuel hoses and fuel rail
connections.
173. Connect fuel feed pipe to fuel rail. Tighten to 16
Nm (12 lbf.ft)
174. Connect return hose to pressure regulator pipe.
Secure with clip.
175. Refit battery. See ELECTRICAL, Repair.
176. With assistance, release bonnet stay clips.
Engage bonnet struts.
NEW RANGE ROVER
ENGINE AND ANCILLARIES - from 99MY
Service repair no - 12.41.01.99
Remove
1. Drain engine oil and remove oil filter.
2. Remove radiator. See COOLING SYSTEM,
Repair.
3. Remove ignition coils. See FUEL SYSTEM,
Repair.
4. Position absorbent material to catch any fuel
spillage and disconnect fuel pipe from rail.
CAUTION: Plug the connections.
CAUTION: Ensure bonnet stay clips are
returned to their original positions as
shown.
5. Disconnect MAF sensor multiplug.
177. Start engine. Check for fuel, coolant and oil
leaks.
16
REPAIR
LAND ROVER V8
6. Release clip and remove top hose from adaptor
on inlet manifold.
7. Remove 2 bolts securing auxiliary drive belt
cover, remove cover and collect spacers.
9. Disconnect A/C compressor multiplug.
10. Remove 4 bolts securing A/C compressor,
release compressor and tie aside.
8. Using a 15 mm spanner, release auxiliary drive
belt tension and remove drive belt.
11. Remove 2 bolts securing PAS pump to mounting
bracket, release pump and tie pump aside.
REPAIR
17
12
ENGINE
NEW RANGE ROVER
14. Release 2 clips securing heater hoses to coolant
rails and disconnect hoses from rails.
15. Disconnect multiplug from purge valve and
position EVAP pipe aside.
12. Release clip and disconnect coolant hose from
water pump.
16. Remove bolt securing engine oil cooler return
pipe to alternator mounting bracket.
13. Release 2 clips securing coolant hoses to
coolant rails, release hoses and remove hoses
and thermostat housing.
17. Loosen engine oil cooler feed and return pipe
unions from oil pump.
18. Release feed and return pipes, remove and
discard ’O’ rings.
CAUTION: Plug the connections.
18
REPAIR
LAND ROVER V8
19. Remove bolt securing gearbox fluid cooler pipes
clamp to engine LH mounting bracket and
remove clamp and spacer.
20. Disconnect multiplug from LH KS.
21. Remove bolt securing harness ’P’ clip to cylinder
block.
22. Disconnect multiplug from RH KS.
23. Remove nut securing battery lead to starter
solenoid, release lead and disconnect lucar from
solenoid.
24. Release clip securing harness to engine RH
mounting bracket.
25. Disconnect multiplug from CMP sensor.
26. Disconnect Lucar from oil pressure switch.
27. Release clip securing harness to coolant rail.
28. Remove bolt securing engine earth lead and
position lead aside.
29. Release cover from battery positive terminal.
30. Remove nut securing positive lead to battery
terminal, release fuse box feed lead, and
disconnect positive lead from battery terminal.
31. Release positive lead from battery carrier.
32. Remove 2 screws and remove harness clamp
from battery carrier.
REPAIR
19
12
ENGINE
NEW RANGE ROVER
33. Remove 3 bolts securing under bonnet fuse box.
36. Disconnect engine harness multiplug from main
harness.
37. Disconnect multiplug from Canister Vent
Solenoid (CVS) unit.
38. Release clip securing harness to RH wing
valance.
34. Disconnect engine harness multiplug from fuse
box.
35. Remove nut and disconnect 2 earth leads from
RH wing valance.
20
REPAIR
39. Release harness clips from fuel rail and heater
coolant pipe.
40. Disconnect multiplug from ECT sensor.
41. Disconnect multiplugs from fuel injectors.
LAND ROVER V8
44. Remove bolt securing engine harness ’P’ clip to
rear of LH cylinder head.
42. Disconnect multiplug from CKP sensor.
45. Remove cable tie securing purge pipe to engine
rear lifting eye.
46. Move harness clear of engine.
47. Raise vehicle on ramp.
43. Remove 2 nuts securing engine harness to
alternator.
REPAIR
21
12
ENGINE
NEW RANGE ROVER
51. Remove access plug and remove 4 bolts
securing torque converter to drive plate.
48. Remove 6 nuts securing exhaust front pipes to
exhaust manifolds and collect gaskets.
52. Using hoist and LRT-12-138 connected to
engine lifting eyes provided, support engine
weight.
49. Remove 2 nuts securing exhaust front pipe to
intermediate pipe.
50. Release exhaust front pipe from intermediate
pipe.
22
REPAIR
LAND ROVER V8
53. Remove 8 nuts securing engine mountings,
raise engine and remove engine mountings.
56. Remove 12 bolts securing engine to gearbox
and remove crash bracket.
57. Support gearbox on a jack.
58. Remove 2 remaining bolts securing engine to
gearbox and with assistance, remove engine
from gearbox dowels and remove engine from
engine bay.
59. Care must be taken when releasing engine from
dowels to ensure torque convertor remains fully
engaged with gearbox.
Refit
60. Clean mating faces of engine and gearbox,
dowel and dowel holes.
61. Ensure drive plate and convertor mating faces
are clean.
54. Remove bolt securing earth strap to RH cylinder
head.
55. Release 3 breather hoses from RH lifting eye.
REPAIR
23
12
ENGINE
62. With assistance position engine in engine bay,
align to gearbox and locate on dowels.
63. Fit crash bracket to gearbox flange and fit and
tighten engine to gearbox bolts to 45 Nm (33
lbf.ft).
64. Lower and remove support from gearbox.
65. Fit breather hoses to clip on engine RH lifting
eye.
66. Position earth strap to RH cylinder head and
secure with bolt.
67. Fit engine mountings, lower engine onto
mountings and tighten nuts to 45 Nm (33 lbf.ft).
68. Lower lifting equipment and remove from engine.
69. Align torque converter and drive plate. Fit bolts
and tighten to 50 Nm (37 lbf.ft).
70. Fit access plug.
71. Ensure mating face of exhaust front pipe ,
intermediate pipe and exhaust manifolds are
clean.
72. Use new gaskets, fit front pipe to exhaust
manifolds and tighten nuts to 30 Nm (22 lbf.ft).
73. Fit intermediate pipe to front pipe, align clamp
and tighten nuts to 25 Nm (18 lbf.ft).
74. Secure purge pipe to rear engine lift eye with
cable tie.
75. Fit bolt to secure harness ’P’ clip to LH cylinder
head.
76. Connect harness to alternator and tighten B +
terminal nut to 18 Nm (13 lbf.ft) and D +
terminal nut to 5 Nm (3.5 lbf.ft).
77. Connect multiplug to CKP sensor.
78. Connect multiplugs to fuel injectors and ECT
sensor.
79. Fit harness clips to fuel rail and heater coolant
pipe.
80. Connect multiplug to Canister Vent Solenoid
(CVS) unit.
81. Connect engine harness multiplug to main
harness.
82. Connect earth leads to stud on RH wing valance
and tighten nut to 10 Nm (7 lbf.ft).
83. Connect engine harness multiplug to fuse box.
84. Secure harness clip to RH wing valance.
85. Fit bolts to secure fuse box.
86. Fit harness clamp to battery carrier and secure
with screws.
87. Fit battery positive lead to battery carrier and
connect cable to battery terminal. Connect fuse
box positive feed to terminal clamp bolt and
secure with nut. Fit terminal cover.
88. Fit engine earth lead to alternator bracket and
tighten bolt to 20 Nm (15 lbf.ft).
89. Secure harness to coolant rail.
24
REPAIR
NEW RANGE ROVER
90. Connect Lucar to oil pressure switch.
91. Connect multiplug to CMP sensor.
92. Connect battery lead to starter solenoid and
tighten nut to 18 Nm (13 lbf.ft).
93. Connect Lucar to starter solenoid.
94. Connect multiplug to RH KS and secure harness
clip to engine RH mounting bracket.
95. Connect multiplug to LH KS, align harness ’P’
clip to cylinder block and tighten bolt to 20 Nm
(15 lbf.ft).
96. Align gearbox oil cooler pipes, fit spacer and
clamp and tighten bolt to 18 Nm (13 lbf.ft).
97. Ensure engine oil cooler pipe unions are clean.
Fit new ’O’ rings, connect pipes to oil pump and
tighten unions to 15 Nm (11 lbf.ft).
98. Align engine oil cooler return pipe to alternator
mounting bracket and secure with bolt.
99. Align EVAP pipe and connect multiplug to purge
valve.
100. Connect and secure heater hoses to coolant
rails.
101. Fit thermostat housing and hose assembly.
Connect and secure hoses to coolant rails.
102. Connect and secure coolant hose to water
pump.
103. Ensure PAS pump and mating face is clean . Fit
PAS pump to mounting bracket and tighten bolts
to 22 Nm (16 lbf.ft).
104. Ensure compressor and mating face is clean. Fit
compressor to mounting bracket and tighten
bolts to 22 Nm (16 lbf.ft).
105. Connect multiplug to compressor.
106. Ensure auxiliary drive belt pulley grooves are
clean and free from damage.
107. Fit new drive belt to pulleys, and ensure belt is
correctly aligned in pulley grooves.
108. With assistance, hold tensioner fully clockwise
and fit drive belt to remaining pulley.
109. Fit auxiliary drive belt cover and spacers and
tighten bolts to 18 Nm (13 lbf.ft).
110. Connect and secure coolant top hose to adaptor
on inlet manifold.
111. Connect multiplug to MAF sensor.
112. Ensure connection is clean and connect fuel
pipe to fuel rail.
113. Fit ignition coils. See FUEL SYSTEM, Repair.
114. Fit radiator. See COOLING SYSTEM, Repair.
115. Fit engine oil filter and fill engine with engine oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
116. Check and if necessary top up gearbox oil.
LAND ROVER V8
FLYWHEEL
Service repair no - 12.53.07
Remove
1. Remove clutch assembly. See CLUTCH,
Repair.
2. Rotate flywheel until location dowel is opposite
starter motor.
3. Remove 6 flywheel securing bolts. Remove
flywheel.
Refit
6. Ensure mating surfaces, dowel and dowel
locations in both flywheel and crankshaft are
clean.
7. Offer flywheel up to crankshaft. Locate on dowel.
8. Refit flywheel bolts. Tighten to 80 Nm (59 lbf.ft)
9. Refit clutch assembly. See CLUTCH, Repair.
4. Inspect flywheel clutch face for cracks, scores or
overheating.
5. Inspect ring gear for worn, chipped or broken
teeth.
REPAIR
25
12
ENGINE
FRONT COVER GASKET AND OIL PUMP - up to
99MY
Service repair no - 12.65.04 - Front Cover Gasket
Service repair no - 12.60.26 - Oil Pump
NEW RANGE ROVER
13. Disconnect oil cooler hoses from front cover.
Plug hoses and connections.
14. Disconnect Lucar from oil pressure switch.
15. Disconnect multiplug from camshaft sensor.
Remove
1.
2.
3.
4.
Raise vehicle on four post lift.
Disconnect battery negative lead.
Raise lift.
Drain cooling system. See COOLING SYSTEM,
Repair.
5. Remove oil sump. See this section.
6. Remove 2 bolts and nut securing oil pick up
strainer.
7. Remove strainer and ’O’ ring.
8. Remove oil filter. See SECTION 10,
Maintenance.
9. Remove stand from under front cross member.
Lower vehicle.
10. Remove crankshaft pulley. See this section.
11. Remove auxiliary drive belt tensioner.
12. Slacken bottom hose clip. Remove hose from
water pump.
26
REPAIR
16.
17.
18.
19.
Remove 9 bolts securing front cover.
Release cover from 2 dowels. Remove cover.
Remove gasket.
Remove seal from cover.
Do not carry out further dismantling if
component is removed for access only.
LAND ROVER V8
20. Remove 6 remaining bolts securing water pump
to cover. Remove water pump and gasket.
21. Remove oil pressure switch.
22. Remove bolt securing camshaft sensor. Remove
sensor from front cover.
23. Ensure mating faces of camshaft sensor and
front cover are clean.
24. Refit sensor.
25. Refit sensor bolt. Tighten to 8 Nm (6 lbf.ft)
26. Ensure thread of oil pressure switch is clean.
27. Refit switch to front cover. Tighten to 15 Nm (11
lbf.ft)
28. Ensure water pump, its mating face, dowel and
dowel hole are clean.
29. Refit water pump and new gasket.
30. Refit water pump bolts. Tighten to 22 Nm (16
lbf.ft)
A- Early type seal
B- Later type seal - use as replacement for all
covers
34. Lubricate new front cover oil seal with Shell
Retinax LX grease ensuring that space between
seal lips is filled with grease.
CAUTION: Do not use any other type of
grease.
35. Using LRT-12-089, fit seal to cover.
Refit
31. Ensure cover, its mating face, dowels and dowel
holes are clean.
32. Ensure crankshaft and oil pump mating faces
are clean.
33. Ensure oil seal register in cover is clean.
REPAIR
27
12
ENGINE
NEW RANGE ROVER
42. Remove plugs from oil cooler hoses and cover.
CAUTION: Over tightening of oil cooler
hose unions can crack front cover.
36. Fit alignment tool LRT-12-090 to end of
crankshaft.
37. Position front cover gasket on engine.
38. Position front cover on engine, align pump drive
gear with key in crankshaft. Fit cover onto
dowels.
39. Refit front cover bolts, tighten in sequence
shown to 22 Nm (16 lbf.ft).
40. Align camshaft sensor multiplug bracket. Refit
bolts. Tighten to 22 Nm (16 lbf.ft)
41. Connect camshaft sensor multiplug. Connect
Lucar to oil pressure switch terminal.
28
REPAIR
43. Fit new ’O’ ring seals, reconnect hoses to cover.
Tighten to 15 Nm (11 lbf.ft)
44. Reposition engine harness under auxiliary drive
belt tensioner.
45. Refit tensioner and bolt. Tighten to 50 Nm (37
lbf.ft)
46. Refit bottom hose to water pump. Tighten clip.
47. Fit engine oil filter. See SECTION 10,
Maintenance.
48. Refit crankshaft pulley. See this section.
49. Ensure oil pick up strainer is clean.
50. Refit strainer and new ’O’ ring to engine.
51. Refit strainer bolts. Tighten to 8 Nm (6 lbf.ft)
52. Refit strainer nut to main bearing cap. Tighten to
25 Nm (18 lbf.ft)
53. Refit sump. See this section.
54. Refill cooling system. See COOLING SYSTEM,
Repair.
55. Reconnect battery negative lead.
LAND ROVER V8
GASKET - FRONT COVER - from 99MY
Service repair no - 12.65.04
Remove
1. Remove oil pick-up strainer. See this section.
2. Remove front cover oil seal. See this section.
3. Drain cooling system. See COOLING SYSTEM,
Repair.
4. Remove bolt securing auxiliary belt jockey pulley
and remove pulley.
5. Remove 3 bolts securing water pump pulley and
remove pulley.
6. Release clip and disconnect bottom hose from
radiator.
7. Release clip and disconnect top hose from
radiator.
8. Release clip and disconnect coolant hose from
water pump.
9. Release thermostat housing from radiator cowl
and move hoses clear of front cover.
REPAIR
29
12
ENGINE
NEW RANGE ROVER
12. Remove engine oil filter.
13. Disconnect Lucar from oil pressure switch.
14. Disconnect multiplug from CMP sensor.
10. Position cloth to collect spillage and loosen both
gearbox fluid cooler pipe unions and engine oil
cooler inlet pipe union.
15. Remove bolt securing engine oil cooler return
pipe to alternator bracket.
11. Remove 2 clips securing radiator cowl and
remove cowl.
30
REPAIR
LAND ROVER V8
16. Loosen unions and disconnect oil cooler feed
and return pipes from front cover , remove and
discard ’O’ rings.
CAUTION: Plug the connections.
17. Remove 9 bolts securing front gear cover and
remove cover. Remove and discard gasket.
Refit
21. Fit new ’O’ rings to oil cooler pipes, connect
pipes to front cover and tighten unions to 15 Nm
(11 lbf.ft).
22. Fit bolt securing oil cooler return pipe to
alternator mounting bracket.
23. Connect Lucar to oil pressure switch.
24. Connect multiplug to CMP sensor.
25. Ensure oil filter seal and mating face on front
cover is clean.
26. Lubricate seal with clean engine oil and fit
engine oil filter.
27. Fit radiator cowl and secure with clips.
28. Fit oil cooler pipes into recesses in radiator cowl
and tighten pipe unions to 30 Nm (22 lbf.ft).
29. Fit thermostat housing to radiator cowl.
30. Connect bottom coolant hose to radiator and
secure with clip.
31. Connect hose to water pump and secure with
clip.
32. Connect top hose to radiator and secure with
clip.
33. Ensure mating faces of water pump pulley and
drive flange are clean, fit pulley and tighten bolts
to 22 Nm (16 lbf.ft).
34. Fit auxiliary belt jockey pulley and tighten bolt to
50 Nm (37 lbf.ft).
35. Fit front cover oil seal. See this section.
36. Fit oil pick-up strainer. See this section.
37. Refill cooling system. See COOLING SYSTEM,
Repair.
18. Clean mating faces of front cover and cylinder
block. Clean dowels and dowel holes.
19. Fit new gasket onto dowels in cylinder block.
20. Fit front cover to cylinder block and tighten bolts
in sequence shown to 22 Nm (16 lbf.ft). Ensure
CMP sensor multiplug bracket is secured by bolt.
REPAIR
31
12
ENGINE
FRONT COVER AND OIL PUMP ASSEMBLY
Service repair no - 12.60.26
Remove
1. Remove front cover gasket See this section.
2. Remove bolt securing CMP sensor, remove
clamp and sensor. Discard ’O’ ring.
3. Remove 6 bolts securing water pump, remove
pump and discard gasket.
4. Remove oil pressure switch and discard ’O’ ring.
5. Remove oil filter cartridge. See this section.
32
REPAIR
NEW RANGE ROVER
Refit
6. Ensure oil filter cartridge adaptor thread is clean
and apply Loctite 577 sealant to thread.
7. Ensure oil pressure switch and mating face is
clean.
8. Fit new ’O’ ring and tighten switch to 15 Nm (11
lbf.ft).
9. Clean water pump and mating face.
10. Use a new gasket and fit water pump. Tighten
bolts securing water pump to 22 Nm (16 lbf.ft).
11. Ensure CMP sensor is clean, fit new ’O’ ring and
fit sensor to cover.
12. Fit clamp to CMP sensor and tighten bolt to 8
Nm (6 lbf.ft).
13. Fit front cover gasket. See this section.
LAND ROVER V8
ENGINE MOUNTINGS - up to 99MY
Service repair no - 12.45.01 - LH
Service repair no - 12.45.02 - RH
Remove
1. Disconnect battery negative lead.
2. With assistance, release bonnet struts from body
locations. Retain bonnet in vertical position using
stay clips.
WARNING: Only open the bonnet to the
vertical position with the vehicle on a
horizontal surface in the workshop. This
position is not intended to be used outdoors
where the bonnet could be affected by winds.
3. Right Hand Mounting Only: Fit lifting eye to
alternator bracket.
4. RHD - Right Hand Mounting Only: Remove
steering column intermediate shaft. See
STEERING, Repair.
5. Left Hand Mounting Only: To prevent strain on
cruise control cable, disconnect from abutment
and actuator diaphragm.
7. Remove 4 nuts securing mounting to chassis
and engine. Discard nuts.
6. Raise vehicle on four post lift.
REPAIR
33
12
ENGINE
NEW RANGE ROVER
8. Connect hoist to lifting eye. Raise relevant side
of engine.
CAUTION: Raise engine by minimum
necessary to remove mounting. Ensure
ignition coils do not foul bulkhead.
9. Remove engine mounting.
Refit
10. Fit engine mounting. Ensure domed head of
centre bolt faces toward chassis.
11. Align mounting studs. Lower engine. Disconnect
hoist.
12. Fit new engine mounting flange nuts. Tighten to
45 Nm (33 lbf.ft)
13. Lower vehicle.
14. Left Hand Mounting Only: Connect cruise
control cable to abutment bracket and actuator
diaphragm.
15. Adjust cable free-play if necessary. See
CRUISE CONTROL, Adjustment.
16. RHD - Right Hand Mounting Only: Fit steering
column intermediate shaft. See STEERING,
Repair.
17. Right Hand Mounting Only: Remove lifting eye
from alternator bracket.
18. With assistance, release bonnet stay clips.
Engage bonnet struts.
CAUTION: Ensure bonnet stay clips are
returned to their original positions as
shown.
19. Reconnect battery negative lead.
34
REPAIR
LAND ROVER V8
ENGINE MOUNTINGS - from 99MY
Service repair no - 12.45.11 - LH
Service repair no - 12.45.12 - RH
Remove
1. With assistance, release bonnet struts and retain
bonnet in vertical position with stay clips.
2. Release fixings and remove battery cover.
3. Disconnect battery earth lead.
6. Remove ties securing harness to support
bracket at rear of engine and move harness
clear of bracket.
7. Remove bolt securing harness support bracket
and remove bracket.
8. Right hand engine mounting: Fit suitable lifting
eye to alternator fixing bolt.
9. RHD - Right hand engine mounting: Remove
steering column intermediate shaft. See
STEERING, Repair.
10. Raise vehicle on 4 post ramp.
4. Remove bolt securing screen washer filler tube.
5. Release 2 clips and remove cooling fan cowl.
11. Remove and discard 4 nuts securing engine
mounting.
12. Connect hoist to lifting eye and raise relevant
side of engine.
13. Remove engine mounting.
REPAIR
35
12
ENGINE
Refit
NEW RANGE ROVER
REAR ENGINE MOUNTING
14. Fit engine mounting. Ensure domed head of
centre bolt faces towards chassis.
15. Carefully lower engine onto mounting and
disconnect hoist.
16. Fit new engine mounting nuts and tighten to 45
Nm (33 lbf.ft).
17. Lower vehicle.
18. RHD - Right hand engine mounting: Fit
steering column intermediate shaft See
STEERING, Repair.
19. Right hand mounting: Remove lifting eye from
alternator fixing bolt.
20. Fit harness support bracket and secure with bolt.
21. Lay harness onto bracket and secure with cable
ties.
22. Fit cooling fan cowl and secure with clips.
23. Fit bolt to secure screen washer reservoir filler
tube.
24. Connect battery earth lead.
25. Fit battery cover and secure with fixings.
26. With assistance, release bonnet stay clips and
engage bonnet struts.
Service repair no - 12.45.08
Remove
1. Raise vehicle on 4 post ramp.
2. Support transmission using a suitable stand.
3. Remove 4 nuts and 2 bolts securing mounting to
crossmember and discard nuts.
4. Remove transmission snubber bar.
5. If applicable, remove 2 bolts securing rear of
gearbox side acoustic covers to crossmember.
36
REPAIR
LAND ROVER V8
Refit
CAUTION: Ensure all under body wax is
removed from mating surfaces of fixings
before fitting.
10. Fit mounting to gearbox, fit bolts and tighten to
45 Nm (33 lbf.ft)
11. Using assistance, fit crossmember to chassis.
12. Fit nuts and bolts and tighten to 45 Nm (33
lbf.ft)
13. Fit transmission snubber bar.
14. Fit NEW flange nuts and bolts securing
transmission mount to crossmember and tighten
to 45 Nm (33 lbf.ft)
15. Remove transmission stand.
16. If applicable, align rear of side acoustic covers to
crossmember and secure with bolts.
6. Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
7. With assistance, remove remaining bolt securing
crossmember and remove crossmember.
8. Remove 4 bolts securing mounting to gearbox.
9. Remove mounting assembly.
REPAIR
37
12
ENGINE
NEW RANGE ROVER
OIL FILTER
OIL COOLER
Service repair no - 12.60.04
Service repair no - 12.60.68
Remove
Remove
1. Raise front of vehicle.
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
WARNING: Support on safety stands.
2. Remove engine acoustic cover (if applicable).
See CHASSIS AND BODY, Repair.
3. Position drain tray to catch spillage.
3. Remove front grille. See CHASSIS AND BODY,
Repair.
4. Release 2 clips securing bonnet release cable to
bonnet platform.
4. Remove oil filter cartridge.
Refit
5. Clean mating face of oil pump.
6. Lubricate oil filter seal with clean engine oil.
7. Fit oil filter and tighten until rubber seal contacts
machined face. Tighten a further half turn by
hand.
CAUTION: DO NOT overtighten oil filter.
8. Run engine to allow oil to fill filter.
9. Stop engine, check and top up oil level. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
10. Fit engine acoustic cover (if applicable). See
CHASSIS AND BODY, Repair.
11. Remove stand(s) and lower vehicle.
38
REPAIR
5. Remove 4 bolts securing bonnet platform.
Remove platform.
6. Remove 4 bolts from condenser mounting
brackets. Collect 2 brackets.
LAND ROVER V8
Refit
11. Position oil cooler to radiator bracket. Secure
with bolts.
12. Using new ’O’ rings, connect pipes to oil cooler.
Tighten unions to 30 Nm (22 lbf.ft)
13. Remove container.
14. Position condenser brackets. Secure with bolts.
15. Fit bonnet platform. Secure with bolts.
16. Secure release cable to bonnet platform with
clips.
17. Fit front grille. See CHASSIS AND BODY,
Repair.
18. Remove safety stands. Lower vehicle.
19. Reconnect battery negative lead.
20. Check engine oil level. Top-up if necessary.
7. Position container to catch oil spillage.
8. Disconnect pipes from oil cooler. Remove ’O’
rings and discard.
9. Remove 2 bolts securing oil cooler to radiator
bracket.
10. Remove oil cooler.
REPAIR
39
12
ENGINE
NEW RANGE ROVER
OIL PRESSURE SWITCH - up to 99MY
OIL PRESSURE SWITCH - from 99MY
Service repair no - 12.60.50
Service repair no - 12.60.50
Remove
Remove
1. Disconnect battery negative lead.
Remove cooling fan. See COOLING SYSTEM,
Repair.
2. Remove alternator drive belt tensioner. See
ELECTRICAL, Repair.
3. Disconnect Lucar from oil pressure switch.
4. Remove switch and discard ’O’ ring.
1.
2.
3.
4.
Release fixings and remove battery cover.
Disconnect battery earth lead.
Raise vehicle on 4 post ramp.
Remove oil filter. See this section.
5. Remove bolt securing engine oil cooler return
pipe to alternator support bracket.
Refit
5. Ensure switch thread and seating in front cover
are clean.
6. Lubricate new ’O’ ring with clean engine oil. Fit
to switch.
7. Fit switch. Tighten to 15 Nm (11 lbf.ft)
8. Refit alternator drive belt tensioner. See
ELECTRICAL, Repair.
9. Fit cooling fan. See COOLING SYSTEM,
Repair.
10. Reconnect battery negative lead.
40
REPAIR
6. Loosen union and remove oil cooler return pipe.
LAND ROVER V8
STRAINER - OIL PICK-UP
Service repair no - 12.60.20
Remove
1. Remove sump gasket. See this section.
7. Disconnect Lucar from oil pressure switch.
8. Position container below switch to catch oil
spillage.
9. Remove oil pressure switch and discard ’O’ ring.
Refit
10. Clean oil pressure switch threads.
11. Fit new ’O’ ring to switch.
12. Fit oil pressure switch and tighten to 15 Nm (11
lbf.ft).
13. Connect Lucar.
14. Ensure oil cooler return pipe union is clean and
fit new ’O’ ring to pipe.
15. Align oil cooler return pipe to alternator support
bracket and fit but do not tighten bolt at this
stage.
16. Tighten oil cooler return pipe union to 15 Nm (11
lbf.ft).
17. Tighten bolt securing oil cooler return pipe to
alternator support bracket.
18. Fit oil filter. See this section.
19. Connect battery earth lead.
20. Fit battery cover and secure with fixings.
21. Top up engine oil.
2. Remove 2 bolts and 1 nut securing oil pick-up
strainer.
3. Remove oil pick-up strainer.
4. Collect spacer from stud.
5. Remove and discard ’O’ring.
Refit
6.
7.
8.
9.
Clean oil pick-up strainer and ’O’ ring recess.
Lubricate and fit new ’O’ ring.
Locate spacer on stud.
Position oil pick-up strainer, fit and tighten, bolts
to 10 Nm (7 lbf.ft) and, nut to 22 Nm (17 lbf.ft).
10. Fit new sump gasket. See this section.
REPAIR
41
12
ENGINE
ROCKER COVER GASKET - up to 99MY
Service repair no - 12.29.39 - Gaskets - Pair
Service repair no - 12.29.40 - LH Cover Gasket
Service repair no - 12.29.41 - RH Cover Gasket
Remove
1. Disconnect battery negative lead.
2. Disconnect crankcase breather hose from cover.
NOTE: Instructions 3,4,5 & 6 apply to RH
Cover Only.
42
REPAIR
NEW RANGE ROVER
3. Depressurise fuel system. See FUEL SYSTEM,
Repair.
4. Remove fuel feed pipe from fuel rail.
5. Release fuel pressure regulator return pipe from
clip.
6. Release heater hose from clip on inlet manifold.
NOTE: Instructions 7,8 & 9 apply to LH
Cover Only.
7. Release plenum chamber. Place aside for
access. See FUEL SYSTEM, Repair.
8. Release purge hose from ram pipe housing.
Place hose aside.
LAND ROVER V8
9. Remove screw securing dipstick tube to rocker
cover.
10. Remove H.T. leads from spark plugs and guide
clips on rocker covers.
12. Remove rocker cover.
13. Remove and discard rocker cover gasket.
Refit
14. Clean mating faces between rocker cover and
cylinder head.
15. Refit rocker cover to cylinder head using a new
gasket.
16. Fit rocker cover bolts and tighten by diagonal
selection to :
Stage 1 - 4 Nm (3 lbf.ft)
Stage 2 - 8 Nm (6 lbf.ft)
Stage 3 - Re-torque to 8 Nm (6 lbf.ft)
17. Refit H.T. leads to spark plugs. Secure leads to
rocker cover clips.
18. Align dipstick tube. Secure to rocker cover with
screw.
19. Reconnect purge hose to ram pipe housing.
20. Refit plenum chamber. See FUEL SYSTEM,
Repair.
21. Secure heater hose to clip on inlet manifold.
22. Secure fuel pressure regulator return pipe in clip.
23. Reconnect fuel feed pipe to fuel rail.
24. Reconnect breather hose to rocker cover.
25. Reconnect battery negative lead.
11. Remove 4 bolts securing rocker cover to cylinder
head.
REPAIR
43
12
ENGINE
ROCKER COVER GASKET (LH) - from 99MY
Service repair no - 12.29.40
Remove
1. Remove upper inlet manifold gasket See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2. Release HT leads from clips on rocker cover.
3. Remove screw securing dip stick tube.
4. Remove and discard 4 bolts securing rocker
cover.
5. Remove rocker cover and gasket.
44
REPAIR
NEW RANGE ROVER
Refit
6. Clean mating faces of rocker cover and cylinder
head.
7. Position new gasket on cylinder head.
8. Locate rocker cover on gasket and install
securing bolts.
9. Ensure gasket outer rim is correctly located
around periphery of rocker cover, then tighten
bolts in diagonally opposite sequence to:
Stage 1 - 3 Nm (2.2 lbf.ft).
Stage 2 - 7 Nm (5.2 lbf.ft).
10. Fit and tighten screw securing dip stick tube.
11. Fit plug leads to clips on rocker cover.
12. Fit upper inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
LAND ROVER V8
ROCKER COVER GASKET (RH) - from 99MY
Service repair no - 12.29.41
Remove
1. Drain cooling system. See COOLING SYSTEM,
Repair.
2. Remove upper inlet manifold gasket. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
9. Remove and discard 4 bolts securing rocker
cover.
10. Remove rocker cover and gasket.
Refit
3. Release engine harness clip from coolant rail
and move harness clear of rocker cover.
4. Release clips and disconnect coolant hoses
from heater.
5. Remove 2 bolts securing coolant rails and move
outer rail clear of rocker cover.
6. Remove bolt securing inner coolant rail to inlet
manifold, remove rail and discard ’O’ ring.
7. Release HT leads from clips on rocker cover.
11. Clean mating faces of rocker cover and cylinder
head.
12. Position new gasket on cylinder head.
13. Locate rocker cover on gasket and install
securing bolts.
14. Ensure gasket outer rim is correctly located
around periphery of rocker cover, then tighten
bolts in diagonally opposite sequence to:
Stage 1 - 3 Nm (2.2 lbf.ft).
Stage 2 - 7 Nm (5.2 lbf.ft).
15. Connect HT leads to spark plugs and fit leads to
clips on rocker cover.
16. Clean coolant rail ’O’ ring recess.
17. Lubricate and fit new ’O’ ring to coolant rail, fit
rail to inlet manifold and tighten bolt to 22 Nm
(16 lbf.ft).
18. Align outer coolant rail and fit and tighten bolts.
19. Connect coolant hoses to heater and secure
with clips.
20. Reposition engine harness and secure with clip
to coolant rail.
21. Fit upper inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
22. Refill cooling system. See COOLING SYSTEM,
Repair.
8. Disconnect HT leads from spark plugs and move
clear of rocker cover.
REPAIR
45
12
ENGINE
ROCKER SHAFT - OVERHAUL
Service repair no - 12.29.49 - LH Shaft
Service repair no - 12.29.50 - RH Shaft
Service repair no - 12.29.55 - Both Shafts
NEW RANGE ROVER
4. Remove rocker shaft assembly. Ensure
pushrods remain seated in tappets.
Do not carry out further dismantling if
component is removed for access only.
5. Remove and discard split pin from one end of
rocker shaft.
Remove
1. Disconnect battery negative lead.
2. Remove relevant rocker cover. See this
section.
NOTE: If both shafts are to be removed,
identify each assembly to ensure refitment
on original cylinder bank.
3. Remove 4 bolts securing rocker shaft assembly.
6. Remove the following components:
NOTE: Retain components in correct
sequence for re-assembly.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Plain washer.
Wave washer.
Rocker arms.
Rocker pillars.
Springs.
Clean all components.
Inspect all components for wear.
Inspect rocker shaft and bores in rocker arms. If
excessively worn or scored, fit new components.
Replace all weak or broken springs.
Lubricate all moving parts with clean engine oil.
Re-assemble rocker shafts. Ensure that
components are returned to their original
positions, use new split pins to retain
components.
Ensure shaft identification groove is positioned
at one o’clock, with pushrod locations of rocker
arms to the right.
CAUTION: Oil feed restriction will result if
rocker shafts are incorrectly assembled.
46
REPAIR
LAND ROVER V8
Refit
19. Refit rocker shaft to original cylinder bank.
20. Engage push-rods in rocker arm locations.
21. Refit rocker shaft securing bolts. Tighten working
from centre outwards to 38 Nm (28 lbf.ft).
22. Refit rocker cover. See this section.
23. Reconnect battery negative lead.
SUMP - up to 99MY
Service repair no - 12.60.44
Remove
1. Disconnect battery earth lead.
2. Raise vehicle on 4 post ramp.
3. Remove engine acoustic cover (if applicable).
See CHASSIS AND BODY, Repair.
4. Remove gearbox acoustic cover (if applicable).
See CHASSIS AND BODY, Repair.
5. Remove engine oil dip stick.
6. Drain engine oil from sump. Refit sump plug.
7. Position support under chassis front
crossmember.
8. Lower ramp to give clearance between front axle
and sump.
REPAIR
47
12
ENGINE
NEW RANGE ROVER
14. Position sump to cylinder block taking care not to
disturb sealant bead.
9. Release 2 heated oxygen sensor multiplugs
from sump brackets.
10. Remove 3 nuts and 14 bolts securing sump to
cylinder block.
11. Remove sump.
Refit
12. Clean sealant from mating faces of sump and
cylinder block.
13. Apply a bead of Hylosil type 101 or 106 sealant
to joint face of sump as shown.
Bead width - areas A, B, C and D = 12 mm (0.5
in)
Bead width - remaining areas = 5 mm (0.20 in)
Bead length - areas A and B = 32 mm (1.23 in)
Bead length - remaining areas = 19 mm (0.75 in)
CAUTION: Do not spread sealant bead.
Sump must be fitted immediately after
applying sealant bead.
48
REPAIR
15. Fit nuts and bolts securing sump to cylinder
block and tighten in the sequence shown to 23
Nm (17 lbf.ft) .
16. Fit sump plug and tighten to 45 Nm (33 lbf.ft).
17. Engage oxygen sensor multiplugs to sump
brackets.
18. Fit engine acoustic cover (if applicable). See
CHASSIS AND BODY, Repair.
19. Fit gearbox acoustic cover (if applicable). See
CHASSIS AND BODY, Repair.
20. Raise ramp and remove support.
21. Lower vehicle.
22. Fill engine oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
23. Fit dip stick.
LAND ROVER V8
SUMP GASKET - from 99MY
Service repair no - 12.60.38
Remove
Refit
13. Clean all traces of RTV sealant from sump and
sump mating faces using a wide, flat-bladed
implement or solvent.
1.
2.
3.
4.
5.
Release fixings and remove battery cover.
Disconnect battery earth lead.
Remove dipstick.
Raise vehicle on ramp
Drain engine oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
6. Raise front of vehicle under body to increase
clearance between engine and front axle.
14. Apply a bead of RTV sealant 5mm wide across
the cylinder block to front cover joint and across
the cylinder block to rear main bearing joint.
Apply a globule of RTV to cover end of cruciform
seal, (see illustration).
15. Fit new gasket to sump, ensuring that locating
tags are correctly positioned.
7. Remove 2 forward facing and 4 rearward facing
bolts securing sump to bell housing.
8. Remove 2 bolts in sump recess.
9. Remove 3 nuts securing front of sump.
10. Remove 12 bolts securing sump flange to
engine.
11. Manoeuvre sump over front axle and remove
sump.
12. Discard sump gasket.
REPAIR
49
12
ENGINE
NEW RANGE ROVER
TAPPETS - ENGINE SET
Service repair no - 12.29.57
Remove
1. Disconnect battery negative lead.
2. Remove inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
3. Remove both rocker shaft assemblies. See this
section.
NOTE: Identify each rocker shaft assembly
to ensure refitment on original cylinder
bank.
4. Remove pushrods, retain in fitted order.
5. Remove tappets.
16. Fit sump and tighten sump bolts and nuts in
sequence illustrated to 23 Nm (17 lbf.ft).
17. Fit and tighten bolts securing sump to bell
housing to 45 Nm (33 lbf.ft).
18. Lower vehicle.
19. Refill engine oil and fit dip stick.
20. Connect battery earth lead.
21. Fit battery cover and secure with fixings.
NOTE: If tappets are to be refitted, retain
with respective pushrods.
6. Clean tappets.
7. Check for even, circular wear patterns on
camshaft contact area.
NOTE: If contact area is pitted, or square
wear patterns have developed, renew
tappets. Inspect camshaft lobes for
excessive wear.
50
REPAIR
LAND ROVER V8
8. Inspect tappet body for excessive wear or
scoring.
CYLINDER HEAD GASKET (LH) - from 99MY
Service repair no - 12.29.02
NOTE: If scoring or deep wear patterns
extend up to oil feed area, replace tappet.
9. Inspect pushrod seats in tappets. If surface is
rough or pitted, replace tappet.
10. Clean and inspect tappet bores in engine block.
11. Ensure that tappets rotate freely in their
respective bores.
12. Inspect pushrods for straightness.
13. Inspect pushrod contact surfaces. If surfaces are
rough or pitted, replace pushrod.
14. Inspect pushrod seats in valve rocker arms. If
surfaces are rough or pitted, replace rocker arm.
Remove
1. Remove inlet manifold gasket See MANIFOLD
AND EXHAUST SYSTEM, Repair.
2. Remove exhaust manifold gasket See
MANIFOLD AND EXHAUST SYSTEM, Repair.
Refit
15.
16.
17.
18.
19.
20.
Immerse tappets in clean engine oil.
Lubricate tappet bores with clean engine oil.
Refit tappets in removed order.
Refit pushrods in removed order.
Refit rocker shaft assemblies. See this section.
Refit inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
21. Reconnect battery negative lead.
3. Remove dipstick and dipstick tube. Remove four
screws securing rocker cover and remove rocker
cover.
4. Remove bolt securing engine harness to rear of
cylinder head.
REPAIR
51
12
ENGINE
5. Progressively remove 4 bolts securing rocker
shaft and remove rocker shaft.
6. Remove push rods.
NOTE: Store push rods in their fitted
order.
NEW RANGE ROVER
9. Remove cylinder head gasket.
Refit
10. Clean mating faces of cylinder block and head
using suitable gasket removal spray and a
plastic scraper, ensure that bolt holes in block
are clean and dry.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
11. Check head and block faces for warping and
pitting.
12. Fit cylinder head gasket with the word TOP
uppermost.
NOTE: Gasket must be fitted dry.
7. In the sequence shown remove 10 bolts
securing the cylinder head to block.
8. Remove cylinder head.
52
REPAIR
13. Carefully fit cylinder head and locate on dowels.
14. Lightly lubricate new cylinder head bolt threads
with clean engine oil.
LAND ROVER V8
NOTE: Long bolts: 1, 3, 5.
CYLINDER HEAD GASKET (RH) - from 99MY
Service repair no - 12.29.03
Remove
1. Remove inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
2. Remove RH exhaust manifold gasket. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
NOTE: RHD models: Exhaust manifold will
remain captive in engine bay but clear of
cylinder head.
15. Fit bolts and tighten in the sequence shown to
20 Nm (15 lbf.ft) then 90 ° , then a further 90 ° .
16. Clean push rods.
17. Lubricate ends of push rods with clean engine
oil.
18. Fit push rods in their removed order.
19. Clean base of rocker pillars and mating faces on
cylinder head.
20. Clean contact surface on rockers, valves and
push rods.
21. Lubricate contact surfaces and rocker shaft with
clean engine oil.
22. Fit rocker shaft assembly and engage push rods.
23. Tighten rocker shaft securing bolts progressively
to 38 Nm (28 lbf.ft).
24. Fit and tighten engine harness bolt to 20 Nm (15
lbf.ft).
25. Refit rocker cover.
26. Ensure dipstick tube and mating face on cylinder
block is clean.
27. Apply Loctite 638 to end of dipstick tube and fit
tube and dipstick to cylinder block.
28. Fit exhaust manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
29. Fit inlet manifold gasket. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
3. Remove bolt securing auxiliary drive belt
tensioner and remove tensioner.
REPAIR
53
12
ENGINE
NEW RANGE ROVER
4. Remove bolt securing engine earth lead.
5. Remove bolt securing engine oil cooler pipe to
alternator mounting bracket.
9. Progressively remove 4 bolts securing the rocker
shaft and remove rocker shaft assembly.
10. Remove push rods.
6. Remove 4 bolts securing alternator mounting
bracket and remove bracket.
7. Disconnect HT leads from spark plugs.
8. Remove rocker cover.
NOTE: Store push rods in their fitted
order.
11. In the sequence shown remove 10 bolts
securing the cylinder head.
12. Remove cylinder head.
13. Remove cylinder head gasket.
54
REPAIR
LAND ROVER V8
Refit
TIMING CHAIN AND GEARS - from 99MY
14. Use a suitable gasket removal spray and plastic
scraper to clean cylinder head and cylinder block
mating faces. Ensure bolt holes are left clean
and dry.
Service repair no - 12.65.12
Remove
1. Remove front cover gasket. See this section.
CAUTION: Do not use metal scraper or
machined surfaces may be damaged.
15. Check head and block faces for warping and
pitting.
16. Fit cylinder head gasket with the word TOP
uppermost.
NOTE: Gasket must be fitted dry.
17. Carefully fit cylinder head and locate on dowels.
18. Lightly lubricate new cylinder head bolt threads
with clean engine oil.
NOTE: Long bolts: 1, 3, 5. short bolts: 2, 4,
6, 7, 8, 9, 10.
19. Fit bolts and tighten in the sequence shown to
20 Nm (15 lbf.ft) then 90 ° , then a further 90 ° .
20. Clean push rods.
21. Lubricate ends of push rods with clean engine
oil.
22. Fit push rods in their removed order.
23. Clean base of rocker pillars and mating face on
cylinder head.
24. Clean contact surface on rockers, valves and
push rods.
25. Lubricate contact surface and rocker shaft with
clean engine oil.
26. Fit rocker shaft assembly and engage push rods.
Tighten bolts progressively to 38 Nm (28 lbf.ft).
27. Fit rocker cover.
28. Position alternator mounting bracket, fit and
tighten bolts to 40 Nm (30 lbf.ft).
29. Position engine harness, align oil cooler pipe
and secure with bolt.
30. Position auxiliary drive belt tensioner, fit bolt and
tighten to 45 Nm (33 lbf.ft).
31. Position engine earth lead, fit bolt and tighten to
22 Nm (16 lbf.ft).
32. Connect HT leads to spark plugs.
33. Fit exhaust manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
34. Fit inlet manifold gasket. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
35. Remove stand(s) and lower vehicle.
2. Fit crankshaft pulley bolt and rotate engine to
align timing marks. Remove crankshaft pulley
bolt.
REPAIR
55
12
ENGINE
NEW RANGE ROVER
Refit
7. Clean timing chain, gears and gear locations.
8. Fit key to crankshaft.
9. Temporarily fit gears to camshaft and crankshaft.
If necessary, rotate shafts to align timing marks.
NOTE: When aligned correctly, the timing
marks will face each other: the crankshaft
gear with its timing mark at twelve 0’clock
position and the camshaft with its timing mark at
six 0’clock position.
3. Restrain camshaft gear and remove gear
retaining bolt.
4. Remove camshaft drive chain and gears as an
assembly.
5. Remove gears from chain.
6. If necessary remove key from crankshaft.
56
REPAIR
10. Remove gears from shafts and fit to timing
chain.
11. With timing marks aligned, fit timing chain and
gears as an assembly.
12. Restrain the camshaft gear and tighten retaining
bolt to 50 Nm (37 lbf.ft).
13. Fit front cover gasket See this section.
14. Reconnect battery negative lead.
17 - EMISSION CONTROL
CONTENTS
Page
DESCRIPTION AND OPERATION
EMISSION CONTROL - BMW DIESEL ................................................................ 1
EMISSION CONTROL - LAND ROVER V8 ......................................................... 5
SECONDARY AIR INJECTION SYSTEM .......................................................... 12
EVAPORATIVE CONTROL SYSTEM - PRE ADVANCED EVAPS ................... 16
EVAPORATIVE EMISSION CONTROL SYSTEM - ADVANCED EVAPS
(up to 99MY) ....................................................................................................... 18
EVAPORATIVE EMISSION CONTROL SYSTEM - ADVANCED EVAPS
(from 99MY) ....................................................................................................... 19
EXHAUST EMISSION CONTROL COMPONENTS - (from 99MY) ................... 23
SECONDARY AIR INJECTION SYSTEM COMPONENTS ............................... 26
EVAPORATIVE EMISSION SYSTEM CONTROL COMPONENTS - (from
99MY) ................................................................................................................. 31
FAULT DIAGNOSIS
TESTING EVAPORATIVE EMISSION CONTROL - PRE ADVANCED
EVAPS .................................................................................................................
LEAK DETECTION PROCEDURE - ADVANCED EVAPS ..................................
DRIVE CYCLES - up to 99MY .............................................................................
DRIVE CYCLES - from 99MY ..............................................................................
1
1
2
2
REPAIR
CATALYST HEAT SHIELDS ................................................................................ 1
EVAP CANISTER - PRE-ADVANCED EVAPS .................................................... 1
EVAP CANISTER - ADVANCED EVAPS (up to 99MY) ....................................... 2
EVAP CANISTER - from 99MY ............................................................................ 3
EVAP CANISTER - LEVS .................................................................................... 4
PURGE VALVE - up to 97MY .............................................................................. 5
PURGE VALVE - 97MY to 99MY ......................................................................... 5
PURGE VALVE - from 99MY ............................................................................... 6
EVAP CANISTER VENT SOLENOID - up to 99MY ............................................. 6
EVAP CANISTER VENT SOLENOID - from 99MY .............................................. 7
EXHAUST GAS RECIRCULATION (EGR) VALVE - DIESEL .............................. 8
MODULATOR VALVE - EGR ............................................................................... 8
VACUUM PUMP - EGR SYSTEM ........................................................................ 9
SOLENOID - EVAP CANISTER VENT VALVE .................................................. 10
CONTROL VALVE - SECONDARY AIR INJECTION (SAI) ............................... 10
RESERVOIR - VACUUM - SECONDARY AIR INJECTION (SAI) ...................... 11
PUMP - SECONDARY AIR INJECTION (SAI) ................................................... 11
AIR MANIFOLD - LH - SECONDARY AIR INJECTION (SAI) ............................ 12
17 - EMISSION CONTROL
CONTENTS
Page
AIR MANIFOLD - RH - SECONDARY AIR INJECTION (SAI) ........................... 12
SOLENOID - VACUUM - SECONDARY AIR INJECTION (SAI) ........................ 13
PIPE - SECONDARY AIR INJECTION (SAI) ..................................................... 13
EMISSION CONTROL
EMISSION CONTROL - BMW DIESEL
Crankcase Ventilation Control
The purpose of the crankcase ventilation system is to
ensure that any gases entering the inside of the
engine are redirected into the air intake and do not
accumulate in the engine.
As the gases are drawn into the camshaft cover, they
pass through a wire mesh filter which separates oil
from the gases. A Mann Hummel type valve is located
in the pipe to the intake duct. The valve allows
crankcase ventilation at low engine speeds but closes
at high engine speeds to prevent excessive crankcase
depression.
Vehicles with EGR
Vehicles without EGR
The camshaft cover is connected via a pipe to the air
intake duct to the turbocharger. When the engine is
running, gases are drawn from the crankcase and the
camshaft cover into the air intake duct due to the
pressure difference between the air induction into the
turbocharger and the inside of the engine.
1.
2.
3.
4.
5.
6.
The Mann Hummel type valve is no longer used and
the camshaft cover is fitted with a pressure regulating
valve. The valve is located in the front of the cover
and is connected by a pipe to the air intake duct. The
purpose of the regulating valve is to maintain a
constant vacuum of 20 mbar inside the engine
crankcase, improving crankcase ventilation under all
operating conditions.
Camshaft cover
Blow-by pipe
Internal engine pressure
Atmospheric vent
Membrane
Spring
The pressure regulating valve comprises a membrane
held in the open position by a spring. The membrane
and spring are subject to engine crankcase pressure
and intake manifold depression on one side and
atmospheric pressure on the other side. When
crankcase pressure rises, gases are drawn from the
engine past the open membrane and into the air
intake manifold by the intake manifold depression.
When the intake manifold depression exceeds the
crankcase pressure, the membrane moves against
the spring pressure and engine crankcase pressure.
This causes the membrane to lower and cover the
port, preventing excessive depression in the
crankcase.
DESCRIPTION AND OPERATION
1
17
EMISSION CONTROL
NEW RANGE ROVER
Exhaust Gas Recirculation (EGR)
Component location
1.
2.
3.
4.
5.
6.
Intake Manifold
EGR Valve
EGR Modulator Valve
Mass Air Flow (MAF) Sensor
Pipe - Exhaust Manifold to EGR Valve
Vacuum Pump - EGR System
During certain running conditions, the EGR system
directs exhaust gases into the intake manifold to be
used in the combustion process. The principal affect
of this is to reduce combustion temperatures by
reducing the amount of oxygen fed into the
combustion chamber, which in turn reduces Oxides of
Nitrogen (NOX) emissions. Up to 50% of the intake air
can be replaced by exhaust gas.
Recirculating too much exhaust gas can result in
higher emissions of soot, HC and CO due to
insufficient air. The precise quantity of recirculated
gas is controlled by the ECM to ensure that optimum
conditions are maintained.
2
DESCRIPTION AND OPERATION
The ECM controls an EGR modulator valve mounted
on the LH inner wing. This valve, when modulated,
opens an EGR valve on the inlet manifold and directs
exhaust gases into the inlet manifold. The EGR
modulator valve controls the supply of vacuum from a
vacuum pump located at the front of the cylinder
head.
Exhaust gases are fed from a metal pipe on the
exhaust manifold to the EGR valve on the inlet
manifold. The pipe is secured at each end by a
flanged connection secured by two bolts.
In operation, the ECM monitors engine conditions and
signals the EGR modulator to supply a vacuum to the
EGR valve.
EMISSION CONTROL
The EGR valve opens allowing exhaust gases to be
drawn into the air intake manifold. The exhaust gas
replaces a proportion of the air drawn into the intake
manifold. Less air flows through the MAF sensor
which consequently requires a lower electrical current
to maintain its temperature. The change of current is
read by the ECM which calculates the amount of
exhaust gas being recirculated.
EGR Valve
The mapping in the ECM monitors the MAF sensor
current changes and alters the signal current supplied
to the EGR modulator, varying the vacuum to operate
the EGR valve. In this way, the ECM controls the
amount of exhaust gas recirculated to maintain the
engine at its optimum operating parameters.
The EGR system does not operate when starting the
engine, at engine overrun or when the engine is at full
load. The ECM may also prevent EGR system
operation if the electrical signal from the MAF sensor
is insufficient or if a given speed or injection volume is
exceeded.
Vacuum pump
1.
2.
3.
4.
5.
6.
7.
8.
Vacuum connection
Spring
Diaphragm
Housing
Air inlet connection
EGR pipe connection
Seal
Rod
The EGR valve is located on the forward end of the
intake manifold. The valve is sealed to the manifold
with an O-ring and secured with four bolts. The EGR
valve comprises a diaphragm, housing and valve.
The EGR valve is mounted on an aluminium housing
which also provides for the connection of the air intake
hose from the intercooler. The valve is positioned
opposite the exhaust gas pipe intake connection. The
valve is connected to the diaphragm by a rod and is
held in the closed position by a spring.
The vacuum pump is located at the front of the engine
on the cylinder head. The pump is sealed to the
cylinder head with a sealing ring and secured with two
bolts.
The pump is driven from the camshaft via two drive
dogs which engage with corresponding slots in the
end of the camshaft. Engine oil is supplied through a
nozzle in the end of the camshaft gear to lubricate the
vacuum pump. The pump is connected to the EGR
modulator valve via a pipe and hose.
DESCRIPTION AND OPERATION
3
17
EMISSION CONTROL
NEW RANGE ROVER
Vacuum supplied by the EGR modulator valve acts on
the diaphragm, overcoming the spring pressure and
pulling the valve open up to 2.5 mm (0.1 in.). This
exposes the exhaust gas pipe connection and allows
gases to be drawn into the intake manifold. When the
vacuum is removed the diaphragm moves under
spring pressure, closing the valve and sealing the
EGR pipe inlet with a seal on the valve. The extent to
which the valve opens is controlled by the vacuum
level supplied from the EGR modulator, which in turn
is controlled by the ECM.
The modulator valve receives full vacuum from the
pump and is also subjected to atmospheric pressure
supplied from an air filter attached to the side of the
EGR modulator valve. The vacuum and atmospheric
pressure are mixed inside the modulator valve by
electrical actuation of the solenoid creating a
controlled vacuum.
EGR Modulator valve
Mass Air Flow (MAF) Sensor
1.
2.
3.
4.
5.
Vacuum pipe to EGR valve
Vacuum pipe from vacuum pump
Modulator valve
Electrical connector
Air filter
The EGR modulator valve is located in the engine
compartment on the left inner wing near the bulkhead.
The EGR modulator is vacuum operated through a
solenoid valve. When the ECM determines that EGR
should take place, the solenoid valve is modulated
and vacuum, supplied from the vacuum pump, opens
the EGR valve. When EGR is not required, the ECM
switches the control solenoid to close the vacuum to
the EGR valve.
4
DESCRIPTION AND OPERATION
Failure of the EGR modulator valve may result in a
reduction of engine performance and the EGR may
shut down or operate at full EGR.
1.
2.
3.
4.
Electrical connector
Air cleaner outlet pipe
MAF sensor
Air cleaner housing
The MAF sensor, located in the air cleaner outlet pipe,
monitors the amount of air being drawn into the intake
manifold. This data is used by the ECM to calculate
the injected fuel volume, the intake air temperature
and the rate of EGR.
The MAF sensor is a hot film sensor which has a
heated surface maintained by an electrical current at a
constant temperature. With cool air flowing past the
sensor, the volume of air drawn into the intake
manifold is measured by the electrical current required
to keep the temperature of the hot film sensor
constant.
EMISSION CONTROL
EMISSION CONTROL - LAND ROVER V8
Engine design has evolved in order to minimise the
emission of harmful by-products. Emission control
systems are fitted to Land Rover vehicles which are
designed to maintain the emission levels within the
legal limits pertaining for the specified market.
Despite the utilisation of specialised emission control
equipment, it is still necessary to ensure that the
engine is correctly maintained and is in good
mechanical order so that it operates at its optimal
condition. In particular, ignition timing has an effect on
the production of HC and NOx emissions, with the
harmful emissions rising as the ignition timing is
advanced.
CAUTION: In many countries it is against
the law for a vehicle owner or an
unauthorised dealer to modify or tamper
with emission control equipment. In some cases,
the vehicle owner and/or the dealer may even be
liable for prosecution.
The following types of supplementary control system
are used to reduce harmful emissions released into
the atmosphere from the vehicle:
• Crankcase emission control - also known as
blow-by gas emissions from the engine
crankcase.
• Exhaust emission control - to limit the
undesirable by-products of combustion.
• Fuel vapour evaporative loss control - to
restrict the emission of fuel through evaporation
from the fuel system.
• Fuel leak detection system (NAS only) - an on
board diagnostic (OBD) test to check the
evaporative emission system for the presence of
fuel evaporation leaks from the fuel tank to the
purge valve.
• Secondary air injection system (NAS only) to reduce emissions experienced during cold
starting of the engine.
The engine management ECM is fundamental for
controlling the emission control systems. In addition to
controlling normal operation, the system complies with
On Board Diagnostic (OBD) system strategies. The
system monitors and reports on faults detected with
ignition, fuelling and exhaust systems which cause an
excessive increase in tailpipe emissions. This includes
component failures, engine misfires, catalyst damage,
catalyst efficiency, fuel evaporative loss and exhaust
leaks.
When an emission relevant fault is determined, the
fault condition is stored in the ECM memory. For NAS
vehicles, the MIL warning lamp on the instrument
pack will be illuminated when the fault is confirmed.
Confirmation of a fault condition occurs if the fault is
found to be present during the driving cycle
subsequent to the one when the fault was first
detected. See FUEL SYSTEM, Description and
operation.
DESCRIPTION AND OPERATION
5
17
EMISSION CONTROL
Crankcase ventilation system
The concentration of hydrocarbons in the crankcase
of an engine is much greater than that in the vehicle’s
exhaust system. In order to prevent the emission of
these hydrocarbons into the atmosphere, crankcase
emission control systems are employed and are a
standard legal requirement.
The crankcase ventilation system is an integral part of
the air supply to the engine combustion chambers and
it is often overlooked when diagnosing problems
associated with engine performance. A blocked
ventilation pipe, filter or excessive air leak into the
inlet system through a damaged pipe or leaking
gasket can affect the air:fuel mixture, performance
and economy of the engine. Periodically check the
ventilation hoses are not cracked and that they are
securely fitted to form airtight connections at their
relevant ports.
The purpose of the crankcase ventilation system is to
ensure that any noxious gas generated in the engine
crankcase is rendered harmless by burning them in
the combustion chambers. Burning the crankcase
vapours in a controlled manner decreases the HC
pollutants that could be emitted and helps to prevent
the development of sludge in the engine oil as well as
increasing fuel economy.
6
DESCRIPTION AND OPERATION
NEW RANGE ROVER
When the engine is running in cruise conditions, or at
idle, manifold pressure is low and the majority of
gasses are drawn into the inlet manifold through an
oil/vapour separator (1), located in the RH rocker
cover. At the same time, filtered air is drawn from the
throttle body (3) into the engine via the LH rocker
cover (2). The oil/vapour separator serves to prevent
oil mist being drawn into the engine.
During periods of driving at Wide Open Throttle
(WOT), pressure at either side of the throttle disc
equalizes (manifold depression collapses). The larger
ventilation opening (3), positioned in the fast moving
stream of intake air, now offers more ’pull’ than the
small opening (1) in the RH rocker cover, and the flow
of ventilation reverses. Gases are drawn from the LH
rocker cover into the throttle body (3).
EMISSION CONTROL
Crankcase ventilation system - from 99MY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hose - RH rocker cover to inlet manifold
Inlet manifold
Throttle body
Air intake
Hose - LH rocker cover to inlet manifold
LH rocker cover breather tube (without oil separator)
LH rocker cover baffle
RH rocker cover baffle
RH rocker cover breather tube
Oil separator (integral with breather tube)
A spiral oil separator is located in the stub pipe to the
ventilation hose on the right hand cylinder rocker
cover, where oil is separated and returned to the
cylinder head. The rubber ventilation hose from the
right hand rocker cover is routed to a port on the right
hand side of the inlet manifold plenum chamber,
where the returned gases mix with the fresh inlet air
passing through the throttle butterfly valve. The stub
pipe on the left hand rocker cover does not contain an
oil separator, and the ventilation hose is routed to the
throttle body housing at the air inlet side of the
butterfly valve. The ventilation hoses are attached to
the stub pipe by metal band clamps.
Oil laden noxious gas in the engine crankcase is
drawn through the spiral oil separator. The mass of
fresh air which is drawn in from the atmospheric side
of the throttle butterfly to mix with the returned
crankcase gas depends on the throttle position and
the engine speed.
DESCRIPTION AND OPERATION
7
17
EMISSION CONTROL
Exhaust emission control.
The fuel injection system provides accurately metered
quantities of fuel to the combustion chambers to
ensure the most efficient air to fuel ratio under all
operating conditions. A further improvement to
combustion is made by measuring the oxygen content
of the exhaust gases to enable the quantity of fuel
injected to be varied in accordance with the prevailing
engine operation and ambient conditions; any
unsatisfactory composition of the exhaust gas is then
corrected by adjustments made to the fuelling by the
ECM.
The main components of the exhaust emission
system are two catalytic converters which are an
integral part of the front exhaust pipe assembly. The
catalytic converters are included in the system to
reduce the emission, to atmosphere, of carbon
monoxide (CO), oxides of nitrogen (NOx), and
hydrocarbons (HC). The active constituents of the
converters are platinum (Pt), palladium (PD) and
rhodium (Rh). Catalytic converters for NAS low
emission vehicles (LEVs) from 2000MY have
active constituents of palladium and rhodium
only). The correct functioning of the converters is
dependent upon close control of the oxygen
concentration in the exhaust gas entering the
catalysts.
The basic control loop comprises the engine
(controlled system), the heated oxygen sensors
(measuring elements), the engine management ECM
(control) and the injectors and ignition (actuators).
Other factors also influence the calculations of the
ECM, such as air flow, air intake temperature and
throttle position. Additionally, special driving
conditions are compensated for such as starting,
acceleration, deceleration, overrun and full load. See
FUEL SYSTEM, Description and operation.
The reliability of the ignition system is critical for
efficient catalytic converter operation, since misfiring
will lead to irreparable damage of the catalytic
converter due to the overheating that occurs when
unburned combustion gases are burnt inside it.
CAUTION: If the engine is misfiring, it
should be shut down immediately and the
cause rectified. Failure to do so will result
in irreparable damage to the catalytic converter.
CAUTION: Ensure the exhaust system is
free from leaks. Exhaust leaks upstream of
the catalytic converter could cause
internal damage to the catalytic converter.
8
DESCRIPTION AND OPERATION
NEW RANGE ROVER
CAUTION: Serious damage to the engine
may occur if a lower octane number fuel
than that which is recommended is used.
CAUTION: Only unleaded fuel must be
used on vehicles fitted with catalytic
converters; serious damage to the
catalytic converter and oxygen sensors will occur
if leaded fuel is used. A reminder label is adhered
to the inside of the fuel filler flap. As a further
safeguard, the filler neck is designed to
accommodate only unleaded fuel pump nozzles.
The oxygen content of the exhaust gas is signalled to
the Engine Control Module (ECM) by two Heated
Oxygen Sensors (HO2S) located in the exhaust front
pipes, upstream of each catalytic converter. The ECM
can then make an appropriate adjustment to the fuel
supply to correct the composition of the exhaust
gases.
North American Specification (NAS) vehicles have
additional Heated Oxygen Sensors, positioned
downstream of each catalytic converter. The ECM
uses the signals from these sensors to determine
whether the catalysts are working efficiently.
EMISSION CONTROL
HO2S sensors and exhaust system - up to 99MY
Detail of front pipe showing location of oxygen
sensors. Only NAS vehicles have four sensors, Rest
of World vehicles have two sensors, one mounted
upstream (towards the exhaust manifold) of each
catalytic converter.
DESCRIPTION AND OPERATION
9
17
EMISSION CONTROL
NEW RANGE ROVER
HO2S sensors and exhaust system - from 99MY
1.
2.
3.
4.
RH catalytic converter
Heated oxygen (HO2S) sensors - post-catalytic converter (2 off - NAS only).
LH catalytic converter
Heated oxygen (HO2S) sensors - pre-catalytic converter (2 off).
The oxygen content of the exhaust gas is monitored
by heated oxygen (HO2S) sensors using either a four
sensor (NAS only) or two sensor setup, dependent on
market destination and legislative requirements.
Signals from the HO2S sensors are input to the engine
management ECM, which correspond to the level of
oxygen detected in the exhaust gas. From ECM
analysis of the data, necessary changes to the air:fuel
mixture and ignition timing can be made to bring the
emission levels back within acceptable limits under all
operating conditions.
Changes to the air:fuel ratio are needed when the
engine is operating under particular conditions such
as cold starting, idle, cruise, full throttle or high
altitude. In order to maintain an optimum air:fuel ratio
for differing conditions, the engine management
control system uses sensors to determine data which
enable it to select the ideal ratio by increasing or
decreasing the air to fuel ratio.
NOTE: Some markets do not legislate for
closed loop fuelling control and in this
instance no heated oxygen sensors will be
fitted to the exhaust system.
10
DESCRIPTION AND OPERATION
On open loop systems, improved fuel economy can
be arranged by increasing the quantity of air to fuel to
create a lean mixture during part-throttle conditions.
On closed loop systems, lean running conditions are
not implemented as the system automatically
optimises the air:fuel ratio to the stoichiometric ideal.
A higher proportion of fuel can be supplied to create a
rich mixture during idle and full-throttle operation. Rich
running at wide open throttle (WOT) is used for
improved performance and high load to keep the
exhaust temperature down and protect the catalysts
and exhaust valves.
The voltage of the HO2S sensors at the stoichiometric
point is 450 to 500mV. The voltage decreases to
between 100 and 500 mV if there is an increase in
oxygen content(i.e. lean mixture). The voltage
increases to between 500 and 1000mV if there is a
decrease in oxygen content, signifying a rich mixture.
EMISSION CONTROL
The HO2S sensor needs to operate at high
temperatures in order to function correctly (350°C
(662°F)). To achieve this, the sensors have integral
heater elements, controlled by a pulse width
modulated (PWM) signal from the ECM. The heater
element warms the sensor’s ceramic layer from the
inside so that the sensor is hot enough for operation.
The heater elements are supplied with current
immediately following engine start and are ready for
closed loop control within 20 to 30 seconds (longer at
cold ambient temperatures less than 0°C (32°F)).
Heating is also necessary during low load conditions
when the temperature of the exhaust gases is
insufficient to maintain the required sensor
temperatures. The maximum tip temperature is 930°C
(1706°F).
Failure of the closed loop control of the exhaust
emission system may be attributable to one of the
failure modes indicated below:
• Mechanical fitting and integrity of the sensor.
• Sensor open circuit / disconnected.
• Short circuit to vehicle supply or ground.
• Lambda ratio outside operating band.
• Crossed sensors.
• Contamination from leaded fuel or other sources.
• Change in sensor characteristic.
A non-functioning heater element will delay the
sensor’s readiness for closed loop control and
influences emissions. A diagnostic routine is utilised to
measure both sensor heater current and the heater
supply voltage so its resistance can be calculated.
The function is active once per drive cycle, as long as
the heater has been switched on for a pre-defined
period and the current has stabilised. The PWM duty
cycle is carefully controlled to prevent thermal shock
to cold sensors.
The heated oxygen sensors age with mileage,
causing an increase in the response time to switch
from rich to lean and lean to rich. This increase in
response time influences the closed loop control and
leads to progressively increased emissions. The
response time of the pre-catalytic converter sensors
are monitored by measuring the period of rich to lean
and lean to rich switching. The ECM monitors the
switching time, and if the threshold period is
exceeded, the fault will be detected and stored in the
ECM as a fault code (the MIL light will be illuminated
on NAS vehicles). NAS vehicle engine calibration
uses downstream sensors to compensate for aged
upstream sensors, thereby maintaining low emissions.
• Harness damage.
• Air leak into exhaust system (cracked pipe / weld
or loose fixings).
System failure will be indicated by the following
symptoms:
• MIL light on (NAS only).
• Default to open-loop fuelling for the defective
cylinder bank.
• If sensors are crossed, engine will run normally
after initial start and then become progressively
unstable with one bank going to its maximum
rich clamp and the other bank going to its
maximum lean clamp - the system will then
revert to open-loop fuelling.
• High CO reading.
• Strong smell of H2S (rotten eggs).
• Excessive emissions.
Diagnosis of electrical faults is continuously monitored
for both the pre-catalytic converter sensors and the
post-catalytic converter sensors (NAS only). This is
achieved by checking the signal against maximum
and minimum thresholds for open and short circuit
conditions. For NAS vehicles, if the pre- and
post-catalytic sensors are inadvertently transposed,
the lambda signals will go to maximum but opposite
extremes and the system will automatically revert to
open loop fuelling. The additional sensors for NAS
vehicles provide mandatory monitoring of catalyst
conversion efficiency and long term fuelling
adaptations.
See FUEL SYSTEM, Description and operation.
DESCRIPTION AND OPERATION
11
17
EMISSION CONTROL
SECONDARY AIR INJECTION SYSTEM COMPONENT LOCATION
12
DESCRIPTION AND OPERATION
NEW RANGE ROVER
EMISSION CONTROL
1.
2.
3.
4.
5.
6.
7.
8.
9.
Vacuum reservoir
SAI vacuum solenoid valve
Engine Control Module (ECM)
Fuse 26 - Engine Compartment Fusebox
Main relay - Engine Compartment Fusebox
SAI pump relay - Engine Compartment Fusebox
Fuselink 2 - Engine Compartment Fusebox
Secondary Air Injection (SAI) pump
SAI control valves (2 off)
DESCRIPTION AND OPERATION
13
17
EMISSION CONTROL
Secondary air injection system - description
The secondary air injection (SAI) system comprises
the following components:
• Secondary air injection pump
• SAI vacuum solenoid valve
• SAI control valves (2 off, 1 for each bank of
cylinders)
• SAI pump relay
• Vacuum reservoir
• Vacuum harness and pipes
The SAI system is used to limit the emission of carbon
monoxide (CO) and hydrocarbons (HCs) that are
prevalent in the exhaust during cold starting of a spark
ignition engine.
The concentration of hydrocarbons experienced
during cold starting at low temperatures are
particularly high until the engine and catalytic
converter reach normal operating temperature. The
lower the cold start temperature, the greater the
prevalence of hydrocarbons emitted from the engine.
There are several reasons for the increase of HC
emissions at low cold start temperatures, including the
tendancy for fuel to be deposited on the cylinder walls,
which is then displaced during the piston cycle and
expunged during the exhaust stroke. As the engine
warms up through operation, the cylinder walls no
longer retain a film of fuel and most of the
hydrocarbons will be burnt off during the combustion
process.
The SAI pump is used to provide a supply of air into
the exhaust ports in the cylinder head, onto the back
of the exhaust valves, during the cold start period. The
hot unburnt fuel particles leaving the combustion
chamber mix with the air injected into the exhaust
ports and immediately combust. This subsequent
combustion of the unburnt and partially burnt CO and
HC particles help to reduce the emission of these
pollutants from the exhaust system. The additional
heat generated in the exhaust manifold also provides
rapid heating of the exhaust system catalytic
converters. The additional oxygen which is delivered
to the catalytic converters also generate an
exothermic reaction which causes the catalytic
converters to ’light off’ quickly.
14
DESCRIPTION AND OPERATION
NEW RANGE ROVER
The catalytic converters only start to provide effective
treatment of emission pollutants when they reach an
operating temperature of approximately 250°C
(482°F) and need to be between temperatures of
400°C (752°F) and 800°C (1472°F) for optimum
efficiency. Consequently, the heat produced by the
secondary air injection "afterburning", reduces the
time delay before the catalysts reach an efficient
operating temperature.
The engine control module (ECM) checks the engine
coolant temperature when the engine is started, and if
it is below 55°C (131°F), the SAI pump is started.
Secondary air injection will remain operational for a
period controlled by the ECM and is dependent on the
starting temperature of the engine. This varies from
approximately 95 seconds for a start temperature of
8°C (46°F) to 30 seconds for a start temperature of
55°C (131°F). The SAI pump operation can be cut
short due to excessive engine speed or load.
Air from the SAI pump is supplied to the SAI control
valves via pipework and an intermediate T-piece
which splits the air flow evenly to each bank.
At the same time the SAI pump is started, the ECM
operates a SAI vacuum solenoid valve, which opens
to allow vacuum from the vacuum reservoir to be
applied to the vacuum operated SAI control valves on
each side of the engine. When the vacuum is applied
to the SAI control valves, they open simultaneously to
allow the air from the SAI pump through to the
exhaust ports. Secondary air is injected into the inner
most exhaust ports on each bank.
When the ECM breaks the ground circuit to
de-energise the SAI vacuum solenoid valve, the
vacuum supply to the SAI control valves is cut off and
the valves close to prevent further air being injected
into the exhaust manifold. At the same time as the SAI
vacuum solenoid valve is closed, the ECM opens the
ground circuit to the SAI pump relay, to stop the SAI
pump.
A vacuum reservoir is included in the vacuum line
between the intake manifold and the SAI vacuum
solenoid valve. This prevents changes in vacuum
pressure from the intake manifold being passed on to
cause fluctuations of the SAI vacuum solenoid valve.
The vacuum reservoir contains a one way valve and
ensures a constant vacuum is available for the SAI
solenoid valve operation. This is particularly important
when the vehicle is at high altitude.
EMISSION CONTROL
Secondary air injection system - operation
When the engine is started, the engine control module
(ECM) checks the engine coolant temperature and if it
is below 55°C (131°F), the ECM grounds the electrical
connection to the coil of the SAI pump relay.
The Main and Secondary Air Injection (SAI) pump
relays are located in the engine compartment fusebox.
A 12V battery supply is fed to the contacts of the SAI
pump relay via fuselink 2. When the ECM completes
the earth path, the coil energises and closes the
contacts of the SAI pump relay to supply 12V to the
SAI pump. The SAI pump starts to operate, and will
continue to do so until the ECM switches off the earth
connection to the coil of the SAI pump relay.
An earth connection from the Main relay coil is
connected to the ECM. When the ECM completes the
earth path, the coil energises and closes the contacts
of the Main relay. When the contacts of the Main relay
are closed, a 12V battery supply is fed to the SAI
vacuum solenoid valve via fuse 26 in the engine
compartment fusebox. The ECM grounds the
electrical connection to the SAI vacuum solenoid
valve at the same time as it switches on the SAI pump
motor.
The SAI pump remains operational for a period
determined by the ECM and depends on the starting
temperature of the engine, or for a maximum
operation period determined by the ECM if the target
engine coolant temperature has not been reached in
the usual time.
When a vacuum is applied to the control ports of the
SAI control valves, the valves open to allow
pressurised air from the SAI pump to pass through to
the exhaust ports in the cylinder heads for
combustion.
When the ECM has determined that the SAI pump
has operated for the desired duration, it switches off
the earth paths to the SAI pump relay and the SAI
vacuum solenoid valve. With the SAI vacuum solenoid
valve de-energised, the valve closes, cutting off the
vacuum supply to the SAI control valves. The SAI
control valves close immediately and completely to
prevent any further pressurised air from the SAI pump
entering the exhaust manifolds.
The engine coolant temperature sensor incurs a time
lag in respect of detecting a change in temperature
and the SAI pump automatically enters a ’soak period’
between operations to prevent the SAI pump
overheating. The ECM also compares the switch off
and start up temperatures, to determine whether it is
necessary to operate the SAI pump. This prevents the
pump running repeatedly and overheating on repeat
starts.
Other factors which may prevent or stop SAI pump
operation include the prevailing engine speed/load
conditions.
When the SAI vacuum solenoid valve is energised, a
vacuum is provided to the operation control ports on
both of the vacuum operated SAI control valves at the
exhaust manifolds. The control vacuum is sourced
from the intake manifold depression and routed to the
SAI control valves via a vacuum reservoir and the SAI
vacuum solenoid valve.
The vacuum reservoir is included in the vacuum
supply circuit to prevent vacuum fluctuations caused
by changes in the intake manifold depression affecting
the smooth operation of the SAI control valves.
DESCRIPTION AND OPERATION
15
17
EMISSION CONTROL
Evaporative emission control system - pre
advanced EVAPS.
The system is designed to prevent harmful fuel vapour
escaping to the atmosphere. The system comprises a
vapour separator (C) and a two way valve (D), both
located on the fuel filler neck (A), an Evaporative
Emissions (EVAP) canister and an EVAP canister
purge valve.
A
B
C
D
E
16
Fuel filler neck
External fill breather pipe
Fuel/vapour separator
Two way valve - fuel vapour to EVAP canister
Fuel vapour from fuel tank
DESCRIPTION AND OPERATION
NEW RANGE ROVER
During conditions of high ambient temperatures, fuel
in the tank vapourises, and pressure rises. Fuel
vapour enters the vapour separator and any liquid fuel
runs back to the tank. Three roll over valves (ROVs)
are fitted in the fuel tank vapour lines. These valves
prevent liquid fuel entering the vapour separator if the
vehicle rolls over. When pressure rises above 5 to 7
kPa (0.7 to 1.0 lbf/in2), the two way valve opens and
allows fuel vapour to flow to the EVAP canister where
it is stored in the canister’s activated charcoal
element. When the correct engine operating
conditions are met, the Engine Control Module (ECM)
opens the EVAP canister purge valve and vapour is
drawn from the canister, into the plenum chamber to
be burned in the engine. Fresh air is drawn into the
canister through a vent to take up the volume of
displaced vapour. If the two way valve should fail, or
the main vapour line becomes blocked, excess
pressure is vented to atmosphere through a valve in
the fuel filler cap. Similarly, the cap vent valve will
open to prevent the tank collapsing if excessive
vacuum is present.
When the temperature of fuel in the tank reduces,
pressure also reduces and vapour must be drawn
back into the tank. When tank pressure drops into
vacuum, the two way valve opens, allowing fuel
vapour to be drawn out of the EVAP canister into the
fuel tank. Again, fresh air is drawn into the canister to
take up the displaced volume.
EMISSION CONTROL
EVAPORATIVE CONTROL SYSTEM - PRE
ADVANCED EVAPS
1.
2.
3.
4.
5.
6.
7.
8.
EVAP canister
EVAP canister purge valve
Fuel filler neck assembly
Fuel/vapour separator
Fuel tank
Fuel pump and gauge sender unit
Roll over valves
Two way valve
DESCRIPTION AND OPERATION
17
17
EMISSION CONTROL
EVAPORATIVE EMISSION CONTROL SYSTEM ADVANCED EVAPS (up to 99MY)
Component location
1.
2.
3.
4.
5.
6.
7.
8.
EVAP canister
EVAP canister vent solenoid (ECVS)
EVAP canister purge valve
Anti-trickle fill valve
Liquid/vapour separator
Fuel filler neck assembly
Fuel tank
Fuel pump and gauge sender unit, incorporating
fuel tank pressure sensor
9. Roll over valves
18
DESCRIPTION AND OPERATION
NEW RANGE ROVER
EMISSION CONTROL
EVAPORATIVE EMISSION CONTROL SYSTEM ADVANCED EVAPS (from 99MY)
Component location
1.
2.
3.
4.
5.
6.
7.
8.
9.
Liquid/vapour separator
Anti-trickle fill valve
Fuel filler neck assembly
Roll over valves
Fuel pump and gauge sender unit, incorporating
fuel tank pressure sensor (NAS only)
EVAP canister purge valve
Fuel tank
Canister vent solenoid (CVS) unit
EVAP canister
DESCRIPTION AND OPERATION
19
17
EMISSION CONTROL
99MY component location continued:
1. Canister Vent Solenoid (CVS) unit - (NAS only)
2. Purge valve
20
DESCRIPTION AND OPERATION
NEW RANGE ROVER
EMISSION CONTROL
Identification
The system was introduced on all North American
specification vehicles from 1998 Model Year.
Advanced EVAP vehicles can be recognised by the
information contained in the EVAP. FAMILY entry on
the underbonnet Emission label (mounted on the
bonnet lock platform).
A - Vehicles without advanced EVAPS
VLR1095AYPBD
B - Vehicles with advanced EVAPS
WLRXEO124001
DESCRIPTION AND OPERATION
21
17
EMISSION CONTROL
Evaporative emission control system - Advanced
EVAPS.
The evaporation emission control system is used to
reduce the level of hydrocarbons emitted into the
atmosphere from the fuel system. The system
comprises a vapour separator (B) and an anti-trickle
valve (A), both located on the fuel filler neck (F), an
Evaporative Emissions (EVAP) canister and an EVAP
canister purge valve. A Canister vent solenoid (CVS)
unit is mounted in front of the EVAP canister on
vehicles up to 99MY. On vehicles from 99MY the CVS
unit is mounted near the bulkhead on the RHS of the
engine bay. The CVS unit is used by the ECM to
control fresh air supply to the canister.
On NAS vehicles, the fuel pump and gauge sender
unit incorporates a pressure sensor which is used by
the ECM, in conjunction with the CVS unit, to
determine the presence of leaks which may cause
vapour to escape. This system is added for
compliance with OBD measures.
A
B
C
D
E
F
G
22
Anti-trickle fill valve
Liquid/Vapour Separator
Vent line to pressure sensor
From fuel tank to liquid/vapour separator
From EVAP canister to anti-trickle fill valve
Fuel filler neck assembly
Internal fill breather hose
DESCRIPTION AND OPERATION
NEW RANGE ROVER
During conditions of high ambient temperatures, fuel
in the tank vapourises, and pressure rises. Fuel
vapour enters the vapour separator and any liquid fuel
runs back to the tank. Two roll over valves are fitted in
the fuel tank vapour lines. These valves prevent liquid
fuel entering the vapour separator if the vehicle rolls
over. The advanced EVAPS system has no two way
valve, so vapour is free to flow to the EVAP canister,
where it is stored in the canister’s activated charcoal
element. When the correct engine operating
conditions are met, the Engine Control Module (ECM)
opens the EVAP canister purge valve and vapour is
drawn from the canister, into the plenum chamber to
be burned in the engine. Fresh air is drawn into the
canister through the EVAP canister vent solenoid to
take up the volume of displaced vapour. During
normal operating conditions, and when the engine is
switched off, the vent solenoid remains open and the
fuel tank is free to breath through the EVAP canister.
If the vent solenoid should fail, or the main vapour line
becomes blocked, excess pressure is vented to
atmosphere through a valve in the fuel filler cap.
Similarly, the cap vent valve will open to prevent the
tank collapsing if excessive vacuum is present.
When the temperature of fuel in the tank reduces,
pressure also reduces and vapour must be drawn
back into the tank. Fresh air is drawn into the canister,
through the open vent solenoid, to take up the
displaced volume.
EMISSION CONTROL
An anti-trickle fill valve is fitted to the filler neck in the
line between the tank and EVAP canister. The
function of this valve is to prevent the user overfilling
the tank by trickling fuel into the neck, thereby
preserving the vapour space in the tank to allow for
fuel expansion during hot weather.
EXHAUST EMISSION CONTROL COMPONENTS (from 99MY)
Catalytic converters
The breather ports from the EVAP canister are
located high up in the engine bay (CVS unit on NAS
vehicles, snorkel tubes on ROW vehicles), to prevent
water ingress during vehicle wading.
The catalytic converters are located in each of the
front pipes from the exhaust manifolds. The catalytic
converter’s housings are fabricated from stainless
steel and are fully welded at all joints. Each catalytic
converter contains two elements of an extruded
ceramic substrate which is formed into a honeycomb
of small cells with a density of 62 cells / cm2. The
ceramic element is coated with a special surface
treatment called ’washcoat’ which increases the
surface area of the catalyst element by approximately
7000 times. A coating is applied to the washcoat
which contains the precious elements Platinum (Pt),
Palladium (PD) and Rhodium(Rh) in the following
relative concentrations: 1 Pt : 21.6 PD : 1 Rh.
The advanced evaporative loss control system used
on NAS vehicles is similar to the standard system, but
also includes a CVS unit and an in-tank pressure
sensor to monitor the pressure build-up for
determining whether leaks are present.
The metallic coating of platinum and palladium oxidize
the carbon monoxide and hydrocarbons and convert
them into water (H2O) and carbon dioxide (CO2). The
coating of rhodium removes the oxygen from nitrogen
oxide (NOx) and converts it into nitrogen (N2).
The function of the CVS unit is to block the
atmospheric vent side of the EVAP canister to enable
the ECM to carry out the EVAP system leak check.
The leak check is only carried out when the vehicle is
stationary and the engine is running at idle speed. The
test uses the natural rate of fuel evaporation and
engine manifold depression. Failure of the leak check
will result in illumination of the Malfunction Indicator
Lamp (MIL).
NOTE: Catalytic converters for NAS low
emission vehicles (LEVS) from 2000MY
have active constituents of Palladium and
Rhodium only. The proportion of active
constituents are 14 PD: 1 Rh, and the Palladium
coating is used to oxidise the carbon monoxide
and hydrocarbons in the exhaust gas.
The valve creates a blockage in the vent line during
the fuel filling process. The valve is operated by the
action of inserting the fuel filler gun. With the valve in
the closed position, air displaced during filling exits the
tank only through the internal fill breather. When the
fuel level reaches the level of the fill breather, the filler
neck fills with fuel, shutting off the filler gun.
The fuel evaporation leak detection is included as part
of the On-Board Diagnostics (OBD) strategy and
checks for leaks greater than 1mm (0.04 in.) in
diameter. During checking, the vent and purge lines
are closed for a reference check on system pressure
to be determined. Then the purge valve is opened,
exposing the fuel tank and vent lines to engine
vacuum. The ECM then checks the signal from the
fuel tank pressure sensor for any pressure increase
(i.e loss of vacuum) which would indicate a leakage.
Any fuel evaporation system leaks which occur
between the output of the purge valve and the
connection to the inlet manifold cannot be determined
using this test, but this type of fault will be detected
through the fuelling adaption diagnostics.
CAUTION: Catalytic converters contain
ceramic material which is very fragile.
Avoid heavy impacts on the converter
casing.
CAUTION: Serious damage to the catalytic
converter will occur if leaded fuel or a
lower octane number fuel than
recommended is used. The fuel tank filler neck is
designed to accomodate only unleaded fuel pump
nozzles.
WARNING: To prevent personal injury
from a hot exhaust system, do not attempt
to disconnect any components until the
exhaust system has cooled down.
DESCRIPTION AND OPERATION
23
17
EMISSION CONTROL
NEW RANGE ROVER
Heated oxygen (HO2S) sensors
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Connection cable
Disc spring
Ceramic support tube
Protective sleeve
Clamp connection for heating element
Heating element
Contact element
Sensor housing
Active sensor ceramic
Protective tube
Post-catalytic converter sensor (NAS spec. only)
Pre-catalytic converter sensor
The heated oxygen sensor is an integral part of the
exhaust emission control system and is used in
conjunction with the catalytic converters and the
engine management control ECM to ensure that the
air:fuel mixture ratio stays around the stoichiometric
ideal, where the catalytic converters are most
effective. Combinations of four (NAS only) or two
heated oxygen sensors are used in the exhaust
system, dependent on market legislation.
The heated oxygen sensors are screwed into
threaded mountings welded into the front exhaust
pipes at suitable locations. They are used to detect
the level of residual oxygen in the exhaust gas to
provide an instantaneous indication of whether
combustion is complete. By positioning sensors in the
stream of exhaust gases from each separate bank of
the exhaust manifold, the engine management system
is better able to control the fuelling requirements on
each bank independently of the other. This facilitates
much closer control of the air:fuel ratio and optimises
catalytic converter efficiency.
CAUTION: HO2S sensors are easily
damaged by dropping, excessive heat or
contamination. Care must be taken not to
damage the sensor tip or housing.
24
DESCRIPTION AND OPERATION
EMISSION CONTROL
The HO2S sensors consist of a ceramic body
(Galvanic cell) which is practically a pure oxygen-ion
conductor made from a mixed oxide of zirconium and
yttrium. The ceramic is then coated with
gas-permeable platinum, which when heated to a
sufficiently high temperature (above 350°C) generates
a voltage which is proportional to the oxygen content
in the exhaust gas stream.
The sensor is protected by an outer tube with a
restricted flow opening to prevent the sensor’s
ceramic from being cooled by low temperature gases
at start up. The pre-catalytic sensors are identified by
three slots in the protective tube, whereas the
post-catalytic sensors have four square indentations
and a hole in the end of the protective tube (NAS
only). The post-catalytic sensors have improved signal
quality, but a slower response rate. It is important
not to confuse the sensor signal pins; the signal
pins are gold plated, whilst the heater supply pins
are tinned, mixing them up will cause
contamination and adversely affect system
performance.
WARNING: Some types of anti-seize
compound used in service are a potential
health hazard. Avoid skin contact.
WARNING: To prevent personal injury
from a hot exhaust system, do not attempt
to disconnect any components until the
exhaust system has cooled down.
CAUTION: Do not allow anti-seize
compound to come into contact with the
tip of the sensor or enter the exhaust
system.
NOTE: A new HO2S sensor is supplied with
pre-treated anti-seize compound.
The HO2S sensors should be treated with extreme
care, since the ceramic material within them can be
easily cracked if they are dropped, banged or
over-torqued. The sensors should be torqued to the
recommended values indicated in the repair
procedures. Apply anti-seize compound to the
sensor’s threads when refitting.
DESCRIPTION AND OPERATION
25
17
EMISSION CONTROL
NEW RANGE ROVER
SECONDARY AIR INJECTION SYSTEM COMPONENTS
Secondary air injection (SAI) pump
1.
2.
3.
4.
SAI pump cover
Foam filter
SAI pump
Pressurised air to exhaust manifolds
The SAI pump is attached to a bracket at the RH side
of the engine compartment. The pump is electrically
powered from a 12V battery supply via a dedicated
relay and supplies approximately 35 kg/hr of air when
the vehicle is at idle in Neutral / Park on a start from
20°C (68°F).
Air is drawn into the pump through vents in its front
cover and is then passed through a foam filter to
remove particulates before air injection. The air is
delivered to the exhaust manifold on each side of the
engine through a combination of plastic and metal
pipes.
26
DESCRIPTION AND OPERATION
The air delivery pipe is a flexible plastic type, and is
connected to the air pump outlet via a plastic quick-fit
connector. The other end of the flexible plastic pipe
connects to the fixed metal pipework via a short
rubber hose. The metal delivery pipe has a fabricated
T-piece included where the air is split for delivery to
each exhaust manifold via the vacuum operated SAI
control valves.
The pipes from the T-piece to each of the SAI control
valves are approximately the same length, so that the
pressure and mass of the air delivered to each bank
will be equal. The ends of the pipes are connected to
the inlet port of each SAI control valve through short
rubber hose connections.
EMISSION CONTROL
The T-piece is mounted at the rear of the engine (by
the ignition coils) and features a welded mounting
bracket which is fixed to the engine by two studs and
nuts.
The foam filter in the air intake of the SAI pump
provides noise reduction and protects the pump from
damage due to particulate contamination. In addition,
the pump is fitted on rubber mountings to help prevent
noise generated by pump operation from being
transmitted through the vehicle body into the
passenger compartment.
Secondary air injection (SAI) pump relay
The secondary air injection pump relay is located in
the engine compartment fusebox. The engine control
module (ECM) is used to control the operation of the
SAI pump via the SAI pump relay. Power to the SAI
relay contacts is via fuselink 2 which is located in the
engine compartment fusebox.
The SAI pump has an integral thermal cut-out switch,
to stop pump operation when the pump overheats.
The pump automatically enters a ’soak period’
between operations, to allow the pump motor a
cooling off period.
DESCRIPTION AND OPERATION
27
17
EMISSION CONTROL
NEW RANGE ROVER
Secondary air injection (SAI) vacuum solenoid
valve
1.
2.
3.
4.
5.
6.
Vacuum port to intake manifold (via vacuum reservoir)
SAI vacuum solenoid valve
Electrical connector
Vacuum port to vacuum operated SAI control valves
Purge valve clip
Mounting bracket
The SAI vacuum solenoid valve is located at the rear
LH side of the engine, mounted on a bracket with the
EVAP system purge valve and electrically controlled
by the ECM.
Vacuum to the SAI vacuum solenoid valve is provided
from the intake manifold depression via a vacuum
reservoir. A small bore vacuum hose with rubber
elbow connections at each end provides the vacuum
route between the vacuum reservoir and SAI vacuum
solenoid valve. A similar hose with a larger size elbow
connector, connects the SAI vacuum solenoid valve to
the SAI control valves on each side of the engine via
an intermediate connection. The SAI vacuum solenoid
valve port to the SAI control valves is located at a right
angle to the port to the vacuum reservoir.
The intermediate connection in the vacuum supply
line splits the vacuum equally between the two SAI
control valves and is located midpoint in front of the
inlet manifold. All vacuum hose lines are protected by
flexible plastic sleeving.
28
DESCRIPTION AND OPERATION
Electrical connection to the SAI vacuum solenoid
valve is via a 2-pin connector. A 12V electrical power
supply to the valve is provided via the Main relay and
Fuse 26 in the engine compartment fusebox. The
ground connection is via the ECM which controls the
SAI vacuum solenoid valve operation. Note that the
harness connector to the SAI solenoid valve is
grey, and must not be confused with the harness
connector to the EVAP system purge valve which
is black.
The ECM switches on the SAI vacuum solenoid valve
at the same time as initiating SAI pump operation.
When the SAI vacuum solenoid valve is open, a
steady vacuum supply is allowed through to open the
two vacuum operated SAI control valves. When the
ECM breaks the earth path to the SAI vacuum
solenoid valve, the valve closes and immediately
shuts off the vacuum supply to the two SAI control
valves at the same time as SAI pump operation is
terminated.
EMISSION CONTROL
SAI control valves
1.
2.
3.
4.
5.
6.
Pressurised air from SAI pump
Vacuum operated SAI control valve
Vacuum hose from SAI vacuum solenoid valve
Pressurised air to exhaust manifold
Protective heat sleeving
Air delivery pipe to exhaust manifold
The SAI control valves are located on brackets at
each side of the engine.
The air injection supply pipes connect to a large bore
port on the side of each SAI control valve via a short
rubber connection hose. A small bore vacuum port is
located on each SAI control valve at the opposite side
to the air injection supply port. The vacuum supply to
each vacuum operated SAI control valve is through
small bore nylon hoses from the SAI vacuum solenoid
valve. An intermediate connector is included in the
vacuum supply line to split the vacuum applied to
each SAI control valve, so that both valves open and
close simultaneously.
When a vacuum is applied to the SAI control valves,
the valve opens to allow the pressurised air from the
SAI pump through to the exhaust manifolds. The
injection air is output from each SAI control valve
through a port in the bottom of each unit. A metal pipe
connects between the output port of each SAI control
valve and each exhaust manifold via an intermediate
T-piece. The T-piece splits the pressurised air
delivered to ports at the outer side of the two centre
exhaust ports on each cylinder head. The pipes
between the T-piece and the exhaust manifold are
enclosed in thermal sleeving to protect the
surrounding components from the very high heat of
the exhaust gas, particularly at high engine speeds
and loads.
When the SAI vacuum solenoid valve is de-energised,
the vacuum supply line opens to atmosphere, this
causes the vacuum operated valves to close
automatically and completely to prevent further air
injection.
DESCRIPTION AND OPERATION
29
17
EMISSION CONTROL
NEW RANGE ROVER
Vacuum reservoir
1. Vacuum port to SAI vacuum solenoid valve
2. Vacuum port to intake manifold (one-way valve end)
3. Vacuum reservoir
A vacuum reservoir is included in the vacuum supply
line between the intake manifold and the SAI vacuum
solenoid valve. The vacuum reservoir contains a
one-way valve, to stop depression leaking back
towards the intake manifold side. The reservoir holds
a constant vacuum so that the SAI control valves
open instantaneously as soon as the SAI vacuum
solenoid valve is energised.
The vacuum reservoir is a plastic canister construction
located on the SAI pump bracket at the RH side of the
engine compartment. It is important to ensure the
reservoir is fitted in the correct orientation, and the
correct vacuum hoses are attached to their
corresponding ports. The one-way valve end of the
reservoir is the cap end which connects to the inlet
manifold.
30
DESCRIPTION AND OPERATION
A small bore nylon hose is used to connect the
one-way valve end of the vacuum reservoir to a port
on the RH side of the inlet manifold. A further small
bore nylon hose connects between the other port on
the vacuum reservoir and a port on the front of the
SAI vacuum solenoid valve.
EMISSION CONTROL
EVAPORATIVE EMISSION SYSTEM CONTROL
COMPONENTS - (from 99MY)
Purge valve
The service port is used for pressure testing using
specialist nitrogen test equipment for localising the
source of leaks. A pipe/hose from the inlet side of the
service port connects to a quick-fit connector that
mates to the purge pipe leading to the EVAP canister
beneath the vehicle.
Purge valve operation is controlled by the engine
control module (ECM). The purge valve has a two-pin
electrical connector which links to the ECM via the
engine harness. Note that the harness connector to
the SAI solenoid valve is grey, and must not be
confused with the harness connector to the EVAP
system purge valve which is black.
One pin of the connector is the power supply source
and the other is the switched earth from the ECM
(pulse width modulated (PWM) signal) which is used
to control the purge valve operation time.
1.
2.
3.
4.
Direction of flow indicator
Inlet port - from EVAP canister
Outlet port - to inlet manifold
Harness connector
The EVAP canister purge valve is located in the
engine bay at the LH side of the engine intake
manifold. On NAS vehicles with secondary air
injection, the purge valve is fixed to a metal bracket
together with the SAI vacuum solenoid valve; the
purge valve is fixed to the bracket by two plastic clips.
The outlet side of the purge valve is connected to a
stub pipe on the back of the inlet manifold plenum
chamber (through a combination of rubber and nylon
pipes). The connector to the plenum chamber stub
pipe is a quick-release type, plastic 90°female elbow.
A short hose/pipe is connected between the inlet side
of the purge valve and a service port.
When the purge valve is earthed by the ECM, the
valve opens to allow hydrocarbons stored in the EVAP
canister to be purged to the engine inlet manifold for
combustion.
If the purge valve breaks or becomes stuck in the
open or closed position, the EVAP system will cease
to function and there are no default measures
available. The ECM will store the fault in memory and
illuminate the MIL warning lamp. If the purge valve is
stuck in the open position, a rich air:fuel mixture is
likely to result at the intake manifold, this could cause
the engine to misfire and fuelling adaptions will
change. The following failure modes are possible:
• Sticking valve
• Valve blocked
• Connector or harness wiring fault (open or short
circuit)
• Valve stuck open
The purge valve has a plastic housing, and a
directional arrow is moulded onto the side of the
casing to indicate the direction of flow. The head of
the arrow points to the outlet side of the valve which
connects to the plenum chamber.
A service port is connected in line between the EVAP
canister and the inlet side of the purge valve and is
rated at 1 psi maximum regulated pressure. The
service port must be mounted horizontally and is
located close to the bulkhead at the rear left hand side
of the engine bay.
DESCRIPTION AND OPERATION
31
17
EMISSION CONTROL
NEW RANGE ROVER
Canister Vent Solenoid (CVS) unit - (NAS only)
1.
2.
3.
4.
CVS unit
Mounting bracket
Spring clips to pipe from EVAP canister
Harness connector
The CVS unit is mounted at the rear right hand side of
the engine bay on a slide-on bracket. The vent pipe
from the EVAP canister is connected to a stub pipe on
the CVS unit via a short rubber hose. The rubber hose
is connected to the CVS unit and plastic pipe by two
metal band clips. A two-pin connector links to the
engine management ECM via the engine harness for
solenoid control. One wire is for the voltage feed, the
other is the valve drive line to the ECM. The solenoid
is operated when the ECM grounds the circuit.
The valve is normally open, allowing any build up of
air pressure within the evaporation system to escape,
whilst retaining the environmentally harmful
hydrocarbons in the EVAP canister.
When the ECM is required to run a fuel evaporation
system test, the CVS valve is energised and closes to
seal the system. The ECM is then able to measure the
pressure in the EVAP system using the fuel tank
pressure sensor. The ECM performs electrical
integrity checks on the CVS valve to determine wiring
or power supply faults. The ECM can also detect a
valve blockage if the signal from the fuel tank
pressure sensor indicates a depressurising fuel tank
while the CVS valve should be open to atmosphere.
The following failure modes are possible:
• Connector or wiring harness fault (open or short
circuit)
• Valve stuck open or shut
• Valve blocked
32
DESCRIPTION AND OPERATION
EMISSION CONTROL
EVAP canister
1.
2.
3.
4.
EVAP canister
Port to breather tube (CVS unit on NAS vehicles)
Port - vent line from fuel tank
Port - purge line
The EVAP canister is mounted on a bracket which is
fitted beneath the vehicle on the RH side of the
chassis. The ports of the EVAP canister face towards
the rear of the vehicle. Each EVAP canister port has a
moulded inscription next to it for identification of the
’purge’, ’tank’ and ’air’ connections.
The NAS and ROW EVAP canisters are of similar
appearance, but use charcoal of different consistency.
The ROW vehicles use granular charcoal of 11 bwc
(butane working capacity) and NAS vehicles use
pelletised charcoal with a higher absorption capacity
of 15 bwc. All canisters are of rectangular shape and
have purge foam retention.
The vent line from the fuel tank to the EVAP canister
connects to the vent port on the canister by means of
a straight quick-fit connector. The vent line terminates
in a quick-fit connector at the fuel filler.
The nylon pipe to atmosphere connects to a port on
the EVAP canister via a short rubber hose secured
with metal band clips. The atmosphere end of the pipe
terminates in a quick-fit connector to the pipe leading
to the CVS unit on NAS vehicles and a snorkel tube
situated behind the engine at the bulkhead on ROW
vehicles. The bore of the nylon breather pipe used on
NAS vehicles is larger than that used on ROW
vehicles.
The purge line from the EVAP canister is connected to
the inlet manifold plenum after the throttle body via a
purge valve and service port. The pipe between the
EVAP canister and the purge valve is routed over the
transmission and into the LH side of the engine bay.
The pipe clips to the purge port on the EVAP canister
by means of an elbowed quick-fit connector and the
connection is covered by a rubber seal which is held
in position on the port stub pipe.
The pipes are clipped at various points along the pipe
runs and tied together with tie straps at suitable points
along the runs.
DESCRIPTION AND OPERATION
33
17
EMISSION CONTROL
NEW RANGE ROVER
Fuel tank pressure sensor - (NAS only)
1. Ambient pressure
2. Tank pressure
3. Sensor cell
A fuel tank pressure sensor is fitted to NAS vehicles
with advanced EVAPS, it is used by the ECM during
an EVAP system leak test, in accordance with the on
board diagnostics (OBD) strategy.
The fuel tank pressure sensor is located in the top
flange of the fuel tank sender/ fuel pump module and
is a non-serviceable item (i.e. if the sensor becomes
defective, the entire fuel tank sender unit must be
replaced). The fuel tank pressure sensor connector is
accessible through the fuel pump access hatch in the
rear floor of the vehicle.
The pressure sensor is basically a piezo-resistive
sensor element with associated circuitry for signal
amplification and temperature compensation. The
active surface is exposed to ambient pressure by an
opening in the cap and by the reference port. It is
protected from humidity by a silicon gel. The tank
pressure is fed up to a pressure port at the rear side
of the diaphragm.
Fuel evaporation leaks are diagnosed by the ECM
monitoring the sensor for a drop in vacuum pressure
during test conditions. The EVAP system is sealed by
the CVS valve and purge valve after a vacuum has
been set up in the system from the intake manifold
while the purge valve is open and the CVS valve is
closed.
34
DESCRIPTION AND OPERATION
If any holes or leaks are present at the evaporation
system joints, the vacuum pressure will gradually drop
and this change in pressure will be detected by the
fuel tank pressure sensor. The system is sensitive
enough to detect leaks down to 1mm (0.04 in.) in
diameter.
The fuel tank pressure sensor is part of the NAS OBD
system, a component failure will not be noticed by the
driver, but if the ECM detects a fault, it will be stored in
the diagnostic memory and the MIL light will be
illuminated on the instrument pack. Possible failures
are listed below:
• Damaged or blocked sensor
• Harness/connector faulty
• Sensor earthing problem
• Open circuit
• Short circuit to battery voltage
• Short circuit to ground
• ECM fault
EMISSION CONTROL
Fuel vapour separator
The fuel vapour separator is located under the right
rear wheel arch next to the filler neck and protected by
the wheel arch lining. The connections to the
separator unit are quick release devices at the end of
the flexible hoses which connect the fuel tank to the
inlet side of the separator and the outlet of the
separator to the evaporation vent line.
DESCRIPTION AND OPERATION
35
EMISSION CONTROL
TESTING EVAPORATIVE EMISSION CONTROL PRE ADVANCED EVAPS
The following pressure test procedure is intended to
provide a method for ensuring that the system does
not leak excessively and will effectively control
evaporative emissions.
Equipment required.
Nitrogen cylinder (compressed air may be used to
pressure the system when there has NEVER been
fuel present in the fuel or evaporative control
systems).
Water manometer 0 - 100 cm (0 - 30" H2O or more).
Pipework and a "T" piece.
Method.
1. Ensure that there is at least two gallons of fuel in
the petrol tank unless there has never been any
fuel in the system.
2. Disconnect, at the EVAP canister, the pipe to the
fuel tank vapour separator.
3. Connect this pipe to the nitrogen cylinder and
the water manometer using the "T" piece.
4. Pressurize the system to between 67.3 and 70.0
cm (26.5 and 27.5 inches) of water, allow the
reading to stabilize, then turn off the nitrogen
supply.
5. Measure the pressure drop within a period of 2
minutes 30 seconds. If the drop is greater than
6.3 cm (2.5 inches) of water the system has
failed the test. Note that a fully sealed system
will show a slight increase in pressure.
6. Should the system fail the test, maintain the
pressure in the system and apply a soap
solution round all the joints and connections until
bubbles appear to reveal the source of the leak.
7. Repeat the test and if successful, dismantle the
test equipment and reconnect the pipe to the
EVAP canister.
LEAK DETECTION PROCEDURE - ADVANCED
EVAPS
1. Connect TestBook to the vehicle and confirm
that the fault code(s) displayed relate to an
EVAP system fault.
2. Examine components in fuel and EVAP system
for damage or poorly connected joints.
3. Repair or replace components to rectify any
faults found, then reset the Malfunction Indicator
Lamp (MIL) using TestBook.
4. Carry out Drive Cycle, See this section.
5. Using TestBook confirm that the Evaporative
Loss Control (ELC) Inspection and Maintenance
(IM) flag has cleared. This procedure should
confirm that the ELC test was carried out during
the drive cycle and that the fault was cured.
6. If the IM flag is still shown, use TestBook to
interrogate the engine management system to
ascertain which of the following situations exists:
• If a fault code is shown, then further investigation
is required, proceed to the next step.
• If the IM flag is still shown, but no faults are
indicated the conditions for the ELC check have
not been met and the drive cycle must be
repeated.
7. Connect the EVAP Diagnostic Station to the
service port and carry out the procedures given
in the operating instructions supplied with the
equipment.
8. Rectify faults indicated by the EVAP Diagnostic
Station and return to step 4.
FAULT DIAGNOSIS
1
17
EMISSION CONTROL
DRIVE CYCLES - up to 99MY
1. Switch on ignition for 30 seconds.
2. Ensure that coolant temperature is less than
30 °C (86 °F).
3. Start engine and allow to idle for 2 minutes.
4. Perform 2 light accelerations 0 to 35 mph (0 to
56 km/h) with light pedal pressure.
5. Perform 2 medium accelerations 0 to 45 mph (0
to 72 km/h) with moderate pedal pressure.
6. Perform 2 hard accelerations 0 to 55 mph (0 to
88 km/h) with heavy pedal pressure.
7. Cruise at 60 mph (96 km/h) for 5 minutes.
8. Cruise at 50 mph (80 km/h) for 5 minutes.
9. Cruise at 35 mph (56 km/h) for 5 minutes.
10. Allow engine to idle for 2 minutes.
11. Connect TestBook and check for fault codes.
NEW RANGE ROVER
DRIVE CYCLES - from 99MY
The following are the Testbook drive cycles
Drive cycle A:
1. Switch on the ignition for 30 seconds.
2. Ensure engine coolant temperature is less than
60°C (140°F).
3. Start the engine and allow to idle for 2 minutes.
4. Connect Testbook and check for fault codes.
Drive cycle B:
1. Switch ignition on for 30 seconds.
2. Ensure engine coolant temperature is less than
60°C (140°F).
3. Start the engine and allow to idle for 2 minutes.
4. Perform two light accelerations (0 to 35 mph) (0
to 60 km/h) with light pedal pressure).
5. Perform two medium accelerations (0 to 45 mph)
(0 to 70 km/h) with moderate pedal pressure).
6. Perform two hard accelerations (0 to 55 mph) (0
to 90 km/h) with heavy pedal pressure).
7. Allow engine to idle for two minutes.
8. Connect Testbook and check for fault codes.
Drive cycle C1 (vehicles without advanced
EVAPS):
1. Switch ignition on for 30 seconds.
2. Ensure engine coolant temperature is less than
60°C (140°F).
3. Start the engine and allow to idle for 2 minutes.
4. Perform two light accelerations (0 to 35 mph) (0
to 60 km/h) with light pedal pressure).
5. Perform two medium accelerations (0 to 45 mph)
(0 to 70 km/h) with moderate pedal pressure).
6. Perform two hard accelerations (0 to 55 mph) (0
to 90 km/h) with heavy pedal pressure).
7. Cruise at 60 mph (100 km/h) for 5 minutes.
8. Cruise at 50 mph (80 km/h) for 5 minutes.
9. Allow engine to idle for 2 minutes.
10. Connect Testbook and check for fault codes.
2
FAULT DIAGNOSIS
EMISSION CONTROL
Drive cycle C2 (vehicles with advanced EVAPS):
1. Switch ignition on for 30 seconds.
2. Ensure engine coolant temperature is less than
60°C (140°F).
3. Start the engine and allow to idle for 2 minutes.
4. Perform two light accelerations (0 to 35 mph) (0
to 60 km/h) with light pedal pressure).
5. Perform two medium accelerations (0 to 45 mph)
(0 to 70 km/h) with moderate pedal pressure).
6. Perform two hard accelerations (0 to 55 mph) (0
to 90 km/h) with heavy pedal pressure).
7. Cruise at 60 mph (100 km/h) for 8 minutes.
8. Cruise at 50 mph (80 km/h) for 3 minutes.
9. Allow engine to idle for 3 minutes.
10. Connect Testbook and check for fault codes.
Drive cycle E:
1.
2.
3.
4.
5.
6.
Ensure the fuel tank is more than a quarter full.
Carry out drive cycle A.
Switch off ignition.
Leave vehicle undisturbed for 20 minutes.
Switch on ignition.
Connect Testbook and check for fault codes.
NOTE: The following areas have an
associated readiness test which must be
flagged as complete, before a problem
resolution can be verified:
• Catalytic converter fault;
• Evaporative loss system fault;
• HO2S sensor fault;
• HO2S sensor heater fault.
When carrying out a drive cycle C to determine a
fault in the above areas, select the readiness
test icon to verify that the test has been flagged
as complete.
Drive cycle D:
1. Switch ignition on for 30 seconds.
2. Ensure engine coolant temperature is less than
35°C (95°F).
3. Start the engine and allow to idle for 2 minutes.
4. Perform two light accelerations (0 to 35 mph) (0
to 60 km/h) with light pedal pressure).
5. Perform two medium accelerations (0 to 45 mph)
(0 to 70 km/h) with moderate pedal pressure).
6. Perform two hard accelerations (0 to 55 mph) (0
to 90 km/h) with heavy pedal pressure).
7. Cruise at 60 mph (100 km/h) for 5 minutes.
8. Cruise at 50 mph (80 km/h) for 5 minutes.
9. Cruise at 35 mph (60 km/h) for 5 minutes.
10. Allow engine to idle for 2 minutes.
11. Connect Testbook and check for fault codes.
FAULT DIAGNOSIS
3
EMISSION CONTROL
CATALYST HEAT SHIELDS
EVAP CANISTER - PRE-ADVANCED EVAPS
Service repair no - 17.50.05
Service repair no - 17.15.13
Remove
Remove
1. Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
2. Remove 5 retaining washers securing heat
shield to floor pan studs.
1. Disconnect fuel tank vapour and purge valve
hoses from canister.
2. Remove bolt and clamp plate securing canister
to mounting plate.
3. Remove EVAP canister.
Refit
4. Reverse removal procedure.
3. Remove heat shield. Discard retaining washers.
Refit
4. Reverse removal procedure.
REPAIR
1
17
EMISSION CONTROL
NEW RANGE ROVER
EVAP CANISTER - ADVANCED EVAPS (up to
99MY)
Service repair no - 17.15.13
Remove
1. Disconnect battery earth lead.
4. Release clip securing vent solenoid hose to
cannister and disconnect hose.
5. Release vent and purge quickfit connectors from
canister.
6. Remove bolt securing canister to mounting
bracket and collect clamp plate.
7. Remove canister.
Refit
2. Remove 2 screws securing cruise control
actuator bracket to suspension control box.
3. Position cruise control actuator assembly aside.
2
REPAIR
8. Position canister to mounting bracket.
9. Position clamp plate and secure canister to
bracket with bolt.
10. Connect purge and vent hoses to cannister,
ensuring that quickfit connectors correctly
engage.
11. Connect vent solenoid hose to canister and
secure clip.
12. Align cruise control actuator bracket to
suspension control box and secure with screws.
13. Connect battery earth lead.
EMISSION CONTROL
EVAP CANISTER - from 99MY
Service repair no - 17.15.13
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise vehicle on lift.
Refit
9. Fit bracket to canister and secure with bolt.
10. Fit canister to chassis and secure with nuts and
bolts.
11. Ensure all connections are clean.
12. Connect purge and tank pipes to canister.
13. Connect air hose to canister and secure hose
with clip.
14. Lower vehicle.
15. Connect battery earth lead.
16. Fit battery cover and secure with fixings.
4. Release clip and disconnect air hose from
canister.
5. Release and remove purge and tank pipes from
canister.
6. Remove 2 nuts and 2 bolts securing EVAP
canister to chassis.
7. Remove EVAP canister.
8. Remove bolt securing bracket to canister and
remove canister.
CAUTION: Plug the connections.
REPAIR
3
17
EMISSION CONTROL
EVAP CANISTER - LEVS
Service repair no - 17.15.13
Remove
1. Raise vehicle on 4 post ramp.
NEW RANGE ROVER
4. Remove 2 bolts securing EVAP canister
mounting bracket to body.
5. Remove 2 nuts securing EVAP canister
mounting bracket to body.
6. Remove bolt securing EVAP canister to
mounting bracket. Collect nut and mounting
bracket.
7. Remove mounting bracket.
8. Position cloth to absorb any fuel spillage.
9. Release purge and tank vent pipes from EVAP
canister.
10. Remove clip securing CVS valve pipe to EVAP
canister.
11. Release pipe from EVAP canister and remove
canister.
CAUTION: Plug the connections.
Refit
2. Remove 3 bolts securing air suspension
reservoir to mounting brackets.
3. Release air suspension reservoir and carefully
move aside.
4
REPAIR
12. Remove plugs and ensure all connections are
clean.
13. Connect CVS valve pipe to EVAP canister and
secure with clip.
14. Connect purge and tank vent pipes to EVAP
canister.
15. Position mounting bracket to EVAP canister and
secure with bolt.
16. Position mounting bracket to body and secure
with nuts.
17. Fit and tighten bolts securing mounting bracket
to body.
18. Lower vehicle.
EMISSION CONTROL
PURGE VALVE - up to 97MY
PURGE VALVE - 97MY to 99MY
Service repair no - 17.15.39
Service repair no - 17.15.39
Remove
Remove
1. Disconnect multiplug from purge valve.
2. Disconnect hoses from EVAP canister and ram
pipe housing.
3. Remove bolt securing valve to shock absorber
turret. Remove purge valve.
Refit
1. Disconnect multiplug from purge valve.
2. Depress quick release connector tabs and
disconnect hose from throttle housing.
3. Depress quick release connector tabs and
disconnect hose from EVAP canister.
4. Remove bolt securing purge valve to shock
absorber turret.
5. Remove purge valve.
4. Reverse removal procedure.
Refit
6. Position purge valve to shock absorber turret.
7. Fit and tighten bolt securing purge valve to
shock absorber turret.
8. Clean hose connections.
9. Connect hoses to EVAP canister and throttle
housing.
NOTE: Ensure connections are correctly
engaged by gently pulling hose
connections.
10. Connect multiplug to purge valve.
REPAIR
5
17
EMISSION CONTROL
NEW RANGE ROVER
PURGE VALVE - from 99MY
EVAP CANISTER VENT SOLENOID - up to 99MY
Service repair no - 17.15.39
Service repair no - 17.15.47
Remove
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
1. Disconnect battery earth lead.
3. Disconnect multiplug from purge control valve.
4. Release purge control valve and hoses from
clips.
5. Disconnect hoses from purge control valve and
remove valve.
CAUTION: Plug the connections.
Refit
6. Position purge control valve, connect hoses and
secure with clips.
7. Fit purge control valve and hoses to clips.
8. Connect multiplug to purge control valve.
9. Connect battery earth lead.
10. Fit battery cover and secure with fixings.
6
REPAIR
2. Remove 2 screws securing cruise control
actuator bracket to suspension control box.
3. Position cruise control actuator assembly aside.
EMISSION CONTROL
EVAP CANISTER VENT SOLENOID - from 99MY
Service repair no - 17.15.47
Remove
4. Release vent solenoid from EVAP canister
bracket for access to hose clip and connector.
5. Disconnect multiplug from vent solenoid.
6. Release clip and remove vent solenoid from
hose.
Refit
7. Fit vent solenoid to hose and secure hose clip.
8. Connect multiplug to vent solenoid.
9. Position vent solenoid to bracket and engage
clip.
10. Align cruise control actuator bracket to
suspension control box and secure with screws.
11. Connect battery earth lead.
1. Disconnect multiplug from vent solenoid.
2. Remove clip securing hose to vent solenoid.
3. Disconnect hose from vent solenoid.
CAUTION: Plug the connections.
4. Release clip and remove vent solenoid from
bracket.
Refit
5.
6.
7.
8.
Fit vent solenoid to bracket.
Connect hose to vent solenoid.
Fit clip to secure hose to vent solenoid.
Connect multiplug to vent solenoid.
REPAIR
7
17
EMISSION CONTROL
EXHAUST GAS RECIRCULATION (EGR) VALVE DIESEL
NEW RANGE ROVER
MODULATOR VALVE - EGR
Service repair no - 17.45.04
Service repair no - 17.45.01
Remove
Remove
1. Disconnect vent hose from solenoid valve.
1. Disconnect battery negative terminal.
2. Disconnect vacuum hose from EGR valve.
3. Slacken clip and disconnect intercooler hose
from EGR valve.
4. Remove 2 bolts securing EGR pipe to EGR
valve.
5. Remove 4 bolts securing EGR valve to intake
manifold.
6. Remove EGR valve and collect seal from intake
manifold.
CAUTION: Care must be taken when
extracting seal to ensure recess in intake
manifold is not damaged.
NOTE: Record hose positions to aid
connection.
2. Disconnect EGR valve and vacuum pump hoses
from solenoid valve.
CAUTION: Plug the connections.
3. Disconnect multiplug from solenoid valve.
4. Remove 2 nuts securing solenoid valve to
mounting and remove valve.
Refit
7. Clean sealing faces of manifold, EGR valve and
EGR pipe.
Refit
8. Fit new seal to intake manifold recess.
9. Position EGR valve to intake manifold and
secure with bolts. Tighten bolts to 10 Nm (7
lbf.in).
10. Engage EGR pipe to valve, align flange and
secure with bolts. Tighten bolts to 22 Nm (16
lbf.in).
11. Connect intercooler hose to EGR valve and
secure with clip.
12. Connect vacuum hose to EGR valve.
13. Connect battery negative terminal.
8
REPAIR
5. Fit solenoid valve to mounting and secure with
nuts.
6. Connect multiplug to valve.
7. Connect vent hose and vacuum hoses to
solenoid valve.
EMISSION CONTROL
VACUUM PUMP - EGR SYSTEM
Service repair no - 17.45.30
Remove
1.
2.
3.
4.
Disconnect battery negative terminal.
Remove camshaft cover. See ENGINE, Repair.
Position harness trunking aside.
Release clip and disconnect pipe from vacuum
pump.
5. Remove 2 bolts securing vacuum pump.
NOTE: Dowel bolt is used to secure inlet
manifold side of vacuum pump.
6. Remove vacuum pump and discard ’O’ ring seal.
Refit
8. Fit new ’O’ ring seal to vacuum pump.
9. Apply STC 3373 to threads of dowel bolt.
10. Position vacuum pump and engage drive dog
with camshaft slot.
11. Secure vacuum pump with bolts. Tighten to 22
Nm (16 lbf.ft).
CAUTION: Ensure that dowel bolt passes
through timing chain guide rail bolt.
12. Connect pipe to vacuum pump and secure with
clip.
13. Align harness trunking.
14. Fit camshaft cover. See ENGINE, Repair.
15. Connect battery negative terminal.
7. Clean sealing faces of vacuum pump and
cylinder head.
REPAIR
9
17
EMISSION CONTROL
NEW RANGE ROVER
SOLENOID - EVAP CANNISTER VENT VALVE
(CVS)
CONTROL VALVE - SECONDARY AIR INJECTION
(SAI)
Service repair no - 17.15.47
Service repair no - 17.25.02
Remove
Remove
1. Disconnect multiplug from CVS unit.
2. Remove clip securing hose to CVS unit.
3. Disconnect hose from CVS unit.
1.
2.
3.
4.
Release clip and disconnect air hose from valve.
Disconnect vacuum hose from valve.
Remove 2 bolts securing valve to air manifold.
Remove valve and discard gasket.
CAUTION: Plug the connections.
Refit
4. Remove CVS unit from bracket.
Refit
5.
6.
7.
8.
10
Fit CVS unit to bracket.
Connect hose to CVS unit.
Fit clip to secure hose to CVS unit.
Connect multiplug to CVS unit.
REPAIR
5. Clean air valve and mating face on manifold.
6. Fit new gasket and fit valve. Tighten bolts to 10
Nm (7 lbf.ft) .
7. Connect vacuum hose.
8. Connect air hose and secure with clip.
EMISSION CONTROL
RESERVOIR - VACUUM - SECONDARY AIR
INJECTION (SAI)
PUMP - SECONDARY AIR INJECTION (SAI)
Service repair no - 17.25.07
Service repair no - 17.25.04
Remove
Remove
1. Disconnect 2 vacuum hoses from reservoir.
2. Remove bolt securing reservoir to mounting
bracket and collect reservoir.
Refit
3. Position reservoir to mounting bracket and
tighten bolt to 10 Nm (7 lbf.ft) .
4. Connect vacuum hoses to reservoir.
1. Disconnect multiplug from air pump.
2. Release clip and disconnect air hose from air
pump.
3. Remove 3 nuts securing air pump to mounting
bracket and remove pump.
4. Remove 3 mountings from air pump.
Refit
5. Fit mountings to air pump and tighten to 10 Nm
(7 lbf.ft) .
6. Fit air pump to mounting bracket and tighten
nuts to 10 Nm (7 lbf.ft) .
7. Connect air hose and secure with clip.
8. Connect multiplug to air pump.
REPAIR
11
17
EMISSION CONTROL
NEW RANGE ROVER
AIR MANIFOLD - LH - SECONDARY AIR
INJECTION (SAI)
AIR MANIFOLD - RH - SECONDARY AIR
INJECTION (SAI)
Service repair no - 17.25.17
Service repair no - 17.25.18
Remove
Remove
1. Remove SAI control valve. See this section.
2. Loosen 2 union nuts securing air manifold to
cylinder head adaptors.
3. Remove 2 nuts securing air manifold bracket to
inlet manifold.
4. Remove air manifold.
Refit
5.
6.
7.
8.
9.
12
Clean air manifold and cylinder head adaptors.
Fit air manifold and start union nuts.
Fit nuts securing air manifold to inlet manifold.
Tighten air manifold unions to 25 Nm (18 lbf.ft) .
Fit SAI control valve. See this section.
REPAIR
1. Remove SAI control valve. See this section.
2. Remove heater feed and return pipes. See
HEATING AND VENTILATION, Repair.
3. Loosen 2 union nuts securing air manifold to
cylinder head adaptors.
4. Remove nut securing air manifold bracket to inlet
manifold.
5. Remove air manifold.
Refit
6.
7.
8.
9.
10.
Clean air manifold and cylinder head adaptors.
Fit air manifold and start union nuts.
Fit nut securing air manifold to inlet manifold.
Tighten air manifold unions to 25 Nm .
Fit heater return and feed pipes. See HEATING
AND VENTILATION, Repair.
11. Fit SAI control valve. See this section.
EMISSION CONTROL
SOLENOID - VACUUM - SECONDARY AIR
INJECTION (SAI)
PIPE - SECONDARY AIR INJECTION (SAI)
Service repair no - 17.25.59
Service repair no - 17.25.47
Remove
Remove
1. Release multiplug from solenoid.
2. Disconnect 2 vacuum hoses from solenoid.
3. Release solenoid from mounting bracket and
remove.
1. Loosen clip securing RH SAI control valve hose
to air injection pipe.
2. Release hose from air injection pipe.
Refit
4. Secure solenoid to mounting bracket.
5. Connect vacuum hoses and multiplug to
solenoid.
3. Loosen clip securing SAI pump hose to air
injection pipe.
4. Release hose from air injection pipe.
5. Loosen clip securing LH SAI control valve hose
to air injection pipe.
6. Release hose from air injection pipe.
REPAIR
13
17
EMISSION CONTROL
7. Remove 2 nuts securing air injection pipe to air
intake plenum.
8.
9.
10.
11.
Position drain tin to collect any coolant spillage.
Release clips securing heater hoses to heater.
Release hoses from heater.
Remove air injection pipe.
Refit
12. Fit air injection pipe to rear of air intake plenum
and tighten nuts.
13. Connect heater hoses to heater and secure with
clips.
14. Connect SAI pump hose to air injection pipe and
secure with clip.
15. Connect LH and RH SAI control valve hoses to
air injection pipe and secure with clips.
16. Remove drain tin.
17. Top up engine coolant.
14
REPAIR
NEW RANGE ROVER
19 - FUEL SYSTEM
CONTENTS
Page
BMW DIESEL
DESCRIPTION AND OPERATION
DESCRIPTION ..................................................................................................... 1
OPERATION ...................................................................................................... 10
ADJUSTMENT
FUEL INJECTION PUMP TIMING - CHECK AND ADJUST ................................ 1
REPAIR
GLOW PLUG CONTROL UNIT ............................................................................ 1
AIR CLEANER ASSEMBLY ................................................................................. 2
ENGINE COOLANT TEMPERATURE SENSOR (ECT SENSOR) ...................... 2
CRANKSHAFT POSITION SENSOR (CKP SENSOR) ........................................ 3
ENGINE CONTROL MODULE (ECM) ................................................................. 4
FUEL FILTER ....................................................................................................... 5
FUEL HEATER/FILTER HEAD ............................................................................ 6
GLOW PLUGS ..................................................................................................... 6
FUEL INJECTION PUMP (FIP) ............................................................................ 7
FUEL INJECTORS ............................................................................................... 9
HIGH PRESSURE PIPES .................................................................................. 10
INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) - VEHICLES
WITHOUT EGR .................................................................................................. 11
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ..................................... 11
THROTTLE POSITION SENSOR (TP SENSOR) .............................................. 12
TURBOCHARGER ............................................................................................. 13
INTERCOOLER ................................................................................................. 14
FILLER NECK ASSEMBLY ................................................................................ 16
FUEL TANK, PUMP AND GAUGE SENDER UNIT ........................................... 17
MASS AIR FLOW (MAF) SENSOR - DIESEL WITH EGR ................................. 19
DUCTING - AIR INTAKE - DIESEL WITH EGR ................................................. 20
BMW DIESEL
DESCRIPTION
Fault diagnosis
Operation of the engine is monitored and controlled by
a Digital Diesel Electronics (DDE) system. The DDE
system electronically regulates injection timing and
fuel delivery rate under all operating conditions.
Operating faults are registered by the ECM and held
within a defect code memory. TestBook connected
into the diagnostic socket beneath the fascia, can be
used to interrogate the ECM for stored faults and
perform diagnostic routines. The ECM is also
connected to a warning lamp on the instrument panel.
The system comprises:
- An engine control module
- Output devices
- Input devices
- An injection pump
Engine Control Module (ECM)
The 55-pin engine control module (ECM) is located
under the bonnet, in a compartment of the battery
tray. It consists of an input section, two
microprocessors, No. 1 and No. 2, and an output
section. The microprocessors receive input signals
from the various input devices and calculate the
necessary response to the output devices.
Calculations are based on fixed, pre-programmed
data. Data is manipulated within function blocks:
Microprocessor function blocks
The following function blocks are provided in
microprocessor 1:
- Injection timing (start of injection) control
- Output of self-diagnosis results
The following function blocks are provided in
microprocessor 2:
- Injection quantity control with special start quantity
control and full load quantity limitation
- Engine speed control
- Running stability control and vibration damping
- Exhaust emission limitation and overheating
protection
- Cruise control
DESCRIPTION AND OPERATION
1
19
FUEL SYSTEM
NEW RANGE ROVER
Fuel system inputs/outputs - Vehicles without
EGR
1. Vehicle speed signal
2. Throttle position sensor - linked to accelerator
pedal
3. Cruise control selector (optional)
4. Brake switch
5. Clutch switch
6. Engine speed signal
7. Diagnostic lamp
8. Glow plug lamp
9. Heater time relay
10. Injection timing device
2
DESCRIPTION AND OPERATION
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Fuel injection pump
Stop solenoid
Quantity servo control unit
Quantity servo control unit potentiometer
Fuel temperature sensor
Crankshaft position sensor
Start of injection sensor
Coolant temperature sensor
Intake air temperature sensor
Manifold absolute pressure sensor
Engine Control Module (ECM)
BMW DIESEL
Fuel system inputs/outputs - Vehicles with EGR
1. Vehicle speed signal
2. Throttle position sensor - linked to accelerator
pedal
3. Cruise control selector (optional)
4. Brake switch
5. Clutch switch
6. Engine speed signal
7. Diagnostic lamp
8. Glow plug lamp
9. Heater time relay
10. Injection timing device
11. Fuel injection pump
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Stop solenoid
Quantity servo control unit
Quantity servo control unit potentiometer
Fuel temperature sensor
Crankshaft position sensor
Start of injection sensor
Coolant temperature sensor
Manifold Absolute Pressure (MAP) sensor
Mass Air Flow (MAF) sensor
EGR Modulator valve
Engine Control Module (ECM)
DESCRIPTION AND OPERATION
3
19
FUEL SYSTEM
Input devices
Input devices of the DDE system comprise the
following:
Crankshaft position sensor
Start of injection sensor
Fuel temperature sensor
Coolant temperature sensor
Intake air temperature sensor
Manifold absolute pressure sensor
Vehicle speed signal
Throttle position sensor
Servo unit potentiometer (drive potentiometer) on
quantity servo control unit
Clutch switch
Brake switches
Cruise control selector (if fitted)
NEW RANGE ROVER
As the flywheel rotates, position pins pass the CKP
sensor and disturb the magnetic field, inducing
voltage pulses in the coil. The pulses are transmitted
to the ECM.
When the flywheel rotates one complete revolution,
six pulses are transmitted to the ECM. The ECM
determines engine speed by calculating how many
pulses occur within a given time. The output from the
CKP sensor is also used, in conjunction with the start
of injection sensor, to determine and control ignition
timing.
Crankshaft position sensor (CKP sensor)
Attached to the flywheel of the engine are six position
pins. These are equally spaced around the crankshaft
circumference at 60 degree intervals.
To determine engine speed and crankshaft position,
an inductive CKP sensor is mounted on the crankcase
adjacent to the flywheel. The CKP sensor consists of
a body containing a coil and a permanent magnet
which provides a magnetic field. The CKP sensor is
situated so that an air gap exists between it and the
position pins. Air gap distance is critical for correct
operation.
The flywheel position pins are spaced so that at TDC,
one pin is 40 degrees before TDC while the other is
20 degrees after TDC as shown. To determine which
pulse represents 40 degrees before, or 20 degrees
after TDC, the control unit requires additional
information from the start of injection sensor.
1. Sensor
2. Flywheel
4
DESCRIPTION AND OPERATION
BMW DIESEL
Start of injection sensor
Fuel temperature sensor
The start of fuel injection is registered by this sensor
which is incorporated in No 4 injector.
Fuel temperature is monitored by a sensor located in
the fuel injection pump. This sensor is of the negative
temperature coefficient (NTC) type, designed to
reduce its resistance with increasing temperature.
The sensor consists of a coil which surrounds the
shaft of an extended injection needle.The coil is fed a
DC supply from the ECM which produces a magnetic
field.
When the needle is moved under the influence of fuel
pressure, the magnetic field is disturbed which
induces an AC voltage in the coil. The induced voltage
is registered in the ECM as a reference point for the
start of injection.
When the system is operating, the ECM regularly
checks the sensor resistance. As fuel density varies
with temperature, the information received is used to
calculate the correct quantity of fuel to inject.
Engine coolant temperature sensor (ECT sensor)
The temperature of the engine coolant is monitored by
a ECT sensor located on the cylinder head.
The ECT sensor is of the NTC type and is similar in
operation to the fuel temperature sensor previously
described.
The ECM uses this information to adjust the basic
injection timing and quantity values for all operating
conditions.
1. Coil
2. Injector needle
The ECM uses the input signals from the start of
injection sensor, together with signals from the
crankshaft position sensor, to detect the actual start of
injection angle. The detected actual value is adjusted
by the ECM to a nominal value via the injection timing
solenoid.
DESCRIPTION AND OPERATION
5
19
FUEL SYSTEM
Intake air temperature sensor (IAT sensor) Vehicles without EGR
Intake air temperature is monitored by a IAT sensor in
the intake manifold. The IAT sensor is of the NTC type
and is similar in operation to the fuel temperature
sensor previously described.
The ECM uses the information received from the IAT
sensor, in conjunction with the manifold absolute
pressure sensor, to determine the volume of air being
be drawn in to the engine.
NEW RANGE ROVER
Manifold absolute pressure sensor (MAP sensor)
Inlet air pressure is monitored by a silicon diaphragm
type sensor mounted on top of the fuel filter and
connected, via a pressure tube to the intake manifold.
The MAP sensor is connected electrically to the ECM.
When inlet air pressure changes, pressure in the
detection chamber causes the diaphragms to deflect.
This alters the length of each resistor, changing their
resistance value. The change is detected by
electronics within the MAP sensor which varies the
output voltage. This is converted to a pressure
reading in the ECM.
Manifold absolute pressure, when linked to inlet air
temperature, gives an accurate measurement of the
charge volume. The ECM adjusts fuelling as
necessary.
Mass air flow sensor (MAF sensor) - Vehicles with
EGR
The MAF sensor is located in the air inlet pipe from
the air cleaner and is connected electrically to the
ECM. The sensor replaces the Air Intake Temperature
(IAT) sensor previously used on Pre-EGR vehicles.
1. Intake manifold
2. IAT sensor
The MAF sensor comprises a hot film sensor which
has a heated surface maintained by an electrical
current at a constant temperature. With cool air
flowing past the sensor, the volume of air drawn into
the intake manifold is measured by the electrical
current required to keep the temperature of the hot
film sensor constant.
EGR Modulator valve - Vehicles with EGR
The EGR modulator valve is located in the engine
compartment on the left inner wing near the bulkhead.
The EGR modulator valve is used to control the EGR
valve and is controlled by the ECM. See EMISSION
CONTROL, Description and operation.
6
DESCRIPTION AND OPERATION
The MAF sensor records the amount of incoming air
being drawn into the engine. The ECM uses this
information to control the Exhaust Gas Recirculation
(EGR) process. See EMISSION CONTROL,
Description and operation.
BMW DIESEL
Vehicle speed signal
Clutch switch
Vehicle speed is monitored by the ECM from the ABS
ECU.
A switch fitted at the clutch pedal position is
connected to the ECM.
The ECM uses vehicle speed data when adjusting idle
stabilisation, cruise control and fuel delivery.
The switch detects when the clutch is depressed. This
input is used to deactivate the cruise control and
various driveability strategies.
Throttle position sensor (TP sensor)
Brake switch
The position, selected by the driver, of the accelerator
pedal is signalled to the ECM by the TP sensor. This
is linked, mechanically to the pedal and electrically to
the ECM.
The sender consists of a thick film TP sensor together
with a sender switch (9 degree switch). With the
accelerator pedal at rest the switch is open. When the
pedal is moved past the 9 degree position the switch
closes.
When the ignition is switched ON, pedal position is
signalled to the ECM. Pedal movement causes
voltage through the TP sensor to vary and the ECM
uses this to measure:
- Required engine speed
- Rate of acceleration
- Rate of deceleration
The brake pedal is fitted with a twin contact switch
which provides two outputs. Both outputs send signals
to the ECM. Both signals are used by the system to
test the operation of the brake circuit, and to
deactivate the cruise control.
Output devices
Output devices of the DDE system comprise the
following:
Quantity servo control unit
Stop solenoid
Injection timing device
Heater time relay
Diagnosis and preheater lamps
Fuel consumption indicator in instrument pack
Quantity servo control unit
The ECM calculates the rate of change of the voltage
signal in a positive (accelerate) or negative
(decelerate) direction. From this, acceleration
enrichment, deceleration fuel metering or overrun fuel
cut-off can be carried out by the system.
The servo is used to accurately control the amount of
fuel delivered to the injectors. It is housed within the
fuel injection pump. See Injection pump.
The sender switch is used together with the voltage
from the TP sensor to check the operation of the
circuit. When the pedal is moved, the switch signals a
logic input to the ECM. The ECM then checks the
voltage signal from the TP sensor. This voltage is
compared with a pre-programmed value to check that
the TP sensor is working correctly.
The unit consists of a rotary magnet mounted on an
eccentric shaft; the shaft engages with the control
spool of the pump. The rotary magnet is fitted with a
return spring and moves under the influence of a
control coil. The magnet rotates through an arc of
about 60 degrees which moves the control spool from
zero to maximum fuel delivery position. The eccentric
shaft engages with the control spool at one end, while
the opposite end operates a rotary potentiometer.
Servo unit potentiometer (drive potentiometer) on
quantity servo control unit
This potentiometer signals a voltage to the ECM. The
voltage value is used to calculate the position of the
control spool in the injection pump quantity servo
control unit - See description of this item.
DESCRIPTION AND OPERATION
7
19
FUEL SYSTEM
NEW RANGE ROVER
Injection timing device
This injection timing device is housed within the fuel
injection pump. It consists of a spring-loaded plunger
and a solenoid. The spring loaded plunger moves
under the influence of pump working pressure. The
solenoid is controlled by a pulsed frequency signal
from the control unit.
When the pump is operating the solenoid regulates
the speed dependent, internal pump pressure into
working pressure. This moves the plunger against
spring tension.
1.
2.
3.
4.
Rotary potentiometer
Control coil
Control spool
Return spring
When the control coil is energised the rotary magnet
and eccentric shaft move against spring pressure.
Rotary movement of the eccentric shaft is converted
into linear movement of the control spool. This allows
more fuel to be delivered to the injectors.
When the control coil is de-energised the return spring
causes the rotary magnet and eccentric shaft to
resume their original position. The control spool is
moved to the zero position.
The control unit accurately controls the position of the
control spool to achieve the desired engine
performance.
Stop solenoid
This is a solenoid operated valve located on the high
pressure section of the injection pump. When the
ignition is switched ON it receives voltage supply and
the valve opens allowing fuel to flow.
When the ignition is switched OFF the valve closes
and the fuel supply is cut.
8
DESCRIPTION AND OPERATION
1.
2.
3.
4.
5.
Plunger
Solenoid
Spring
Pump feed pressure
Pump internal pressure
Injection is retarded with an energised solenoid and
the resultant pressure drop. The beginning of injection
is advanced with a de-energised solenoid and the
resultant pressure rise.
Heater time relay
Glow plug preheating time is regulated by the heater
timer relay in the heating time control unit. This
connects to the glow plugs in the cylinder head and to
the ECM.
The control unit monitors and operates the glow plugs;
operating time for the glow plugs is dependent on
engine temperature.
BMW DIESEL
Fuel injection pump (FIP)
Injection timing device
The FIP is of the vane-type and is chain driven from
the front end of the crankshaft. Fuel delivery from the
FIP to the injectors is regulated by the movement of a
control spool. Movement of the control spool
increases or decreases the fuel delivery rate to meet
engine operating requirements.
Regulates pump speed dependent on internal pump
pressure.
The FIP houses the following items that either send
signals to the ECM, or responds to signals sent from
the ECM:
Stop solenoid
Fuel quantity servo unit
These items have been previously described in this
section - See Input devices or Output devices as
applicable.
Moves the control spool to regulate the amount of fuel
delivered to injectors.
Fuel temperature sensor
Monitors fuel temperature.
Cuts fuel delivery to the injectors when de-energised.
Servo unit potentiometer
Used by the control unit to calculate the position of the
control spool.
1.
2.
3.
4.
Rotary potentiometer
Quantity control servo unit
Stop solenoid
Injection timing device solenoid valve
5.
6.
7.
8.
Control spool
Timing device plunger
Drive shaft
Fuel temperature sensor
DESCRIPTION AND OPERATION
9
19
FUEL SYSTEM
NEW RANGE ROVER
OPERATION
Start control
General
To determine the quantity of fuel to inject during
starting, the ECM uses signals from the coolant
temperature sensor, fuel temperature sensor,
crankshaft position sensor and throttle position
sensor.
The digital diesel electronics system (DDE) facilitates
exact control of injection quantity and injection timing
under all operating conditions. As a result, fuel
consumption and exhaust emissions are kept to a
minimum.
Malfunctions
If a fault occurs in any of the following circuits:
manifold absolute pressure sensor, fuel temperature
sensor or coolant temperature sensor, the ECM will
provide substitute values. In the case of a faulty
throttle position sensor, start of injection sensor or
injection timing device, the engine will run at a
reduced performance level.
Engine speed control
After starting, an idle speed control function cuts in
after a certain engine speed threshold has been
exceeded. This is calculated by the ECM dependent
on the coolant temperature and the active loads. The
idle speed can be adjusted by means of TestBook.
The maximum engine speed is limited by the ECM by
reducing the injection quantity.
Running stability control and jolt damping
If the servo unit potentiometer or servo unit fails, the
injection system is deactivated. The engine shuts
down as a result.
Injection timing (Start of Injection) control
The start of injection is controlled by the injection
timing device in the injection pump. A solenoid valve
modulates the internal pump pressure on one side of
the system so that a defined start of injection is set.
When no power is applied, the solenoid valve is
closed, resulting in advanced injection timing (start of
injection).
Injection quantity control
Injection quantity control is achieved by the quantity
servo control unit in the injection pump. The servo
acts on the pump control spool to vary the effective
stroke of the pump piston (injection quantity). The
position of the control spool is signalled back via the
servo potentiometer to the ECM. The ECM compares
the actual value with the nominal value and, if
necessary, adjustment is carried out until the nominal
injection quantity value is achieved. The servo control
unit is set to zero delivery when no power is applied.
10
DESCRIPTION AND OPERATION
The running stability control system is used for engine
speed stabilization when idling. Controlled injection
quantity correction counteracts the irregularities which
occur in the individual cylinders as the result of
dispersion of the injected fuel quantity.
In the case of spontaneous change in the position of
the accelerator pedal or a sudden change in the
driving resistance, vibrations occur which, in
conjunction with the control frequency of the injection
hydraulics, can result in jolts and jerks.
On the basis of segment-by-segment angle evaluation
in the input sequence, the engine speed signals
provide the information which is used for corrective
control (rotation irregularities) in the quantity servo
control unit. The prerequisite for this function is the
input of the vehicle speed signal.
Exhaust emission limitation and overheating
protection
At high ambient air temperatures and at increasing
altitude, the full load quantity is reduced in order to
limit exhaust emission. The full load fuel quantity is
also reduced when the permissible water temperature
is exceeded in the high speed range.
BMW DIESEL
Cruise control
The required driving statuses: acceleration or resume
driving speed can be set or selected using the
steering wheel switches. These functions are active
with a vehicle speed of more than 40 km/h (25 mph).
Air conditioning compressor cut-out
The ECM switches off the air conditioning compressor
during driving conditions demanding high torque
requirements (starting off, accelerating). The
compressor is also cut-out at high water temperatures
(more than 110°C) in order to protect the engine.
Self-diagnosis
The task of the self-diagnosis function is to detect
malfunctions in the DDE system and to make
available substitute values and emergency programs.
The ECM stores a record of faults, including
intermittent faults which can be interrogated using
TestBook.
DESCRIPTION AND OPERATION
11
BMW DIESEL
FUEL INJECTION PUMP TIMING - CHECK AND
ADJUST
5. Remove oil filler cap.
6. Observe No. 1 camshaft lobe. Turn engine
clockwise until lobe points vertically upwards.
Service repair no - 19.30.01
Check
1. Disconnect battery negative lead.
2. Remove intake manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
3. Remove cooling fan cowl. See COOLING
SYSTEM, Repair.
4. Loosen high pressure pipe unions at injectors
and Fuel Injection Pump (FIP) using
LRT-12-117.
NOTE: This indicates that the engine is
approximately 90° Before Top Dead Centre
(BTDC) with No. 1 cylinder on its
compression stroke.
7. Remove bolt from timing access hole in FIP.
Collect sealing washer.
CAUTION: Hold delivery valves against
rotation as pipe unions are loosened.
ADJUSTMENT
1
19
FUEL SYSTEM
NEW RANGE ROVER
11. Rotate engine slowly clockwise until dial gauge
needle reaches its lowest point. Zero gauge.
12. Continue turning crankshaft in a clockwise
direction until timing pin locates into flywheel.
Check reading:
Engines with less than
20,000 km = 0.95 mm ± 0.02 mm (0.4 ± 0.001
in)
Engines with more than
20,000 km = 0.90 mm ± 0.02 mm (0.035 ±
0.001 in)
If in tolerance, continue at Assemble.
If out of tolerance, carry out adjustment as follows:
Adjust
8. Fit injection pump timing gauge holder
LRT-12-121 into access hole.
9. Fit dial gauge and preload by approximately 2
mm. Secure dial gauge in holder.
13. Slacken 2 flange nuts and 1 support bolt
securing FIP.
CAUTION: Slacken flange nuts by
minimum amount. Timing chain tension
will deflect pump if bolts are over loose,
leading to false readings.
14. Rotate pump on mounting until correct reading is
achieved.
NOTE: Ensure final movement of pump
head is made towards the engine.
CAUTION: If final movement of pump head
is away from engine, backlash will be left
in pump mechanism, leading to false
readings.
15.
16.
17.
18.
19.
10. Remove plastic plug from flywheel timing pin
access hole. Insert timing pin LRT-12-108.
2
ADJUSTMENT
Tighten pump flange nuts to 22 Nm (16 lbf.ft)
Remove flywheel timing pin.
Repeat from operation 6 to verify timing.
Refit plastic plug to flywheel timing pin hole.
Tighten rear support bolt to 22 Nm (16 lbf.ft)
BMW DIESEL
Assemble
20. Remove dial gauge and holder.
21. Fit bolt to FIP timing access hole, use a new
sealing washer if necessary. Tighten to 25 Nm
(18 lbf.ft)
22. Using LRT-12-117, tighten high pressure pipe
unions on injection pump to 20 Nm (15 lbf.ft).
Do not tighten pipes at injectors.
CAUTION: Hold delivery valves against
rotation as pipe unions are tightened.
23. Fit oil filler cap.
24. Fit cooling fan cowl. See COOLING SYSTEM,
Repair.
25. Fit intake manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
26. Reconnect battery negative lead.
27. With assistance, crank engine. As fuel emerges
at injector connections, secure each pipe union
using tool LRT-12-117. Tighten to 20 Nm (15
lbf.ft)
WARNING: Engine will start during high
pressure pipe bleeding procedure.
ADJUSTMENT
3
BMW DIESEL
GLOW PLUG CONTROL UNIT
Service repair no - 19.60.33
Remove
1. Disconnect battery negative lead.
2. Remove 2 screws securing ECM housing cover.
Remove cover.
6. Disconnect multiplug. Remove control unit.
Refit
7. Reverse removal procedure.
3. Remove 2 harness clamp screws. Remove
harness clamp.
4. Lift ECM and control unit from housing.
5. Remove nut securing battery cable to control
unit. Release cable.
REPAIR
1
19
FUEL SYSTEM
AIR CLEANER ASSEMBLY
NEW RANGE ROVER
ENGINE COOLANT TEMPERATURE SENSOR (ECT
SENSOR)
Service repair no - 19.10.01
Service repair no - 18.30.10
Remove
Remove
1. Release intake hose from air cleaner.
1. Partially drain cooling system. See COOLING
SYSTEM, Repair.
2. Disconnect ECT sensor multiplug.
3. Remove ECT sensor. Collect sealing washer
and discard.
2. Remove bolt securing air suspension dryer to air
cleaner.
3. Release dryer pipes from air cleaner. Position
dryer aside.
4. Remove 2 bolts securing air cleaner to valance.
5. Release air cleaner lug from valance grommet.
Remove air cleaner.
6. If necessary, remove seal.
Refit
7. If removed, refit seal to air cleaner.
8. Position air cleaner assembly. Engage lug to
valance grommet. Secure with bolts.
9. Position air suspension dryer to air cleaner.
Secure with bolt. Tighten to 8 Nm (6 lbf.ft)
10. Engage dryer pipes to clips.
11. Connect intake hose to air cleaner. Secure with
clip.
2
REPAIR
Refit
4. Ensure mating faces are clean.
5. Using a new sealing washer, fit ECT sensor.
Tighten to 18 Nm (13 lbf.ft)
6. Connect multiplug to ECT sensor.
7. Refill cooling system. See COOLING SYSTEM,
Repair.
8. Run engine to normal operating temperature.
Check for leaks around ECT sensor.
BMW DIESEL
CRANKSHAFT POSITION SENSOR (CKP SENSOR)
CKP Sensor Bracket - Adjust
Service repair no - 18.30.12
CAUTION: CKP Sensor bracket must be
correctly positioned. CKP sensor damage
or failure will result from mis-aligned
bracket.
Remove
1. Disconnect battery negative lead.
2. Remove cooling fan cowl. See COOLING
SYSTEM, Repair.
5. Rotate crankshaft until flywheel TDC pole is
central to CKP sensor aperture.
NOTE: Cowl removed to give access to
crankshaft pulley for manual cranking of
engine.
3. Disconnect CKP sensor multiplug.
NOTE: Use mirror and lamp to view
flywheel poles.
6. Slacken bolt securing CKP sensor bracket to
cylinder block.
7. Position LRT-12-122 to CKP sensor bracket.
Secure with bolt.
8. Push CKP sensor bracket rearwards until tool
contacts flywheel pole.
NOTE: Tool positions bracket allowing for
correct air gap between CKP sensor nose
and flywheel poles.
9. Tighten bolt securing bracket to cylinder block.
10. Remove bolt securing tool to bracket. Remove
tool.
Refit
11. Fit CKP sensor to bracket. Secure with bolt.
Tighten to Max 8 Nm (6 lbf.ft)
12. Connect CKP sensor multiplug.
13. Fit cooling fan cowl. See COOLING SYSTEM,
Repair.
14. Reconnect battery negative lead.
4. Remove bolt securing CKP sensor to bracket.
Remove CKP sensor.
REPAIR
3
19
FUEL SYSTEM
ENGINE CONTROL MODULE (ECM)
Service repair no - 18.30.03
Remove
1. Disconnect battery negative lead.
2. Remove 2 screws securing ECM housing cover.
Remove cover
3. Slacken 2 harness clamp screws.
4. Lift ECM slightly for access. Disconnect
multiplug.
5. Remove ECM from housing.
6. Remove carrier plate from ECM.
4
REPAIR
NEW RANGE ROVER
Refit
7. Reverse removal procedure.
BMW DIESEL
FUEL FILTER
Service repair no - 19.25.07
Remove
1. Disconnect battery negative lead.
2. Position container beneath fuel filter to catch
spillage.
Refit
4.
5.
6.
7.
8.
Ensure mating faces are clean.
Lubricate seal on new filter with clean diesel fuel.
Fit filter to filter head. Tighten securely by hand.
Remove container.
Slacken fuel feed union at fuel injection pump
using LRT-12-117.
NOTE: Position cloth over feed union to
catch any fuel spillage.
9. Reconnect battery negative lead.
10. With assistance, turn on ignition switch to
operate fuel lift pump.
11. When all air is bled from filter, secure feed pipe
at injection pump. Tighten to 14 Nm (10 lbf.ft)
3. Remove filter using strap wrench.
REPAIR
5
19
FUEL SYSTEM
NEW RANGE ROVER
FUEL HEATER/FILTER HEAD
GLOW PLUGS
Service repair no - 19.25.20
Service repair no - 19.60.31
Remove
Remove
1. Disconnect battery negative lead.
2. Remove fuel filter. See this section.
3. Disconnect multiplug from fuel heater.
4. Disconnect fuel lines from filter head. Remove 2
’O’ rings from each connection and discard.
NOTE: Fuel line connections are of quick
release type. Press retainer, pull fuel line
to remove.
5. Remove 2 bolts securing fuel heater to bracket.
6. Position Manifold Absolute Pressure (MAP)
sensor aside. Remove fuel heater.
Refit
7. Align fuel heater to bracket. Position MAP
sensor.
8. Secure fuel heater and MAP sensor to bracket
with bolts.
9. Fit new ’O’ rings to fuel connections. Lubricate
with diesel fuel.
10. Connect fuel lines and multiplug to fuel heater.
11. Fit fuel filter. See this section.
12. Reconnect battery negative lead.
6
REPAIR
1. Disconnect battery negative lead.
2. Remove injector high pressure pipe assembly.
See this section.
3. Remove nuts and disconnect feed wires from
glow plugs.
4. Using a deep 12 mm socket, remove glow plugs.
Refit
5. Ensure glow plug threads and locations in
cylinder head are clean.
6. Fit glow plugs. Tighten to 20Nm (15lbf.ft).
7. Connect feed wires and tighten nuts to 4Nm
(3lbf.ft).
8. Fit injector pipe assembly. See this section.
9. Reconnect battery negative lead.
BMW DIESEL
FUEL INJECTION PUMP (FIP)
NOTE: Position cloth beneath FIP to catch
fuel spillage.
Service repair no - 19.30.07
Remove
1. Disconnect battery negative lead.
2. Remove high pressure pipes. See this section.
3. Remove cooling fan cowl. See COOLING
SYSTEM, Repair.
4. Disconnect lead from stop solenoid terminal.
5. Disconnect FIP harness multiplug.
6. Disconnect oil pressure switch.
7. Disconnect FIP cycle valve multiplug.
8. Disconnect fuel return pipe. Collect sealing
washers.
9. Using tool LRT-12-117, disconnect fuel feed pipe
at FIP.
10. Plug pipes and connections.
11. Remove plastic plug from flywheel timing pin
access hole.
12. Remove oil filler cap. Observe No. 1 camshaft
lobe.
13. Rotate crankshaft clockwise until camshaft lobe
points towards inlet side of engine.
14. Insert timing pin LRT-12-108 into access hole.
Locate into flywheel timing hole.
NOTE: No. 1 Piston is now at Top Dead
Centre (TDC) on its compression stroke.
REPAIR
7
19
FUEL SYSTEM
NEW RANGE ROVER
15. Remove end cap from auxiliary belt tensioner
fulcrum. Collect ’O’ ring and discard.
19. Fit centre bolt to LRT-12-119. Press FIP from
sprocket.
16. Remove nut from FIP sprocket.
17. Remove centre bolt from LRT-12-119. Screw
body of tool onto FIP sprocket to retain sprocket
in position when pump is removed.
18. Remove 2 flange nuts and 1 support bolt
securing FIP to timing case.
8
REPAIR
BMW DIESEL
20. Remove FIP from timing case.
21. Remove FIP. Collect ’O’ ring and discard.
22. Remove centre bolt from LRT-12-119.
CAUTION: If body of tool is removed, FIP
sprocket will drop into timing case.
Refit
23. Ensure mating faces are clean.
24. Ensure Woodruff key on FIP drive shaft aligns
with sprocket keyway. If necessary, turn pump
shaft using tool LRT-12-118.
25. Fit new ’O’ ring. Position pump to timing case.
26. Secure pump to timing case with nuts and bolts.
Do not tighten at this stage.
27. Remove body of LRT-12-119 from injection
pump sprocket.
28. Fit nut to injection pump shaft. Tighten to 50 Nm
(37 lbf.ft)
29. Using a new ’O’ ring, fit end cap to auxiliary belt
tensioner fulcrum.
30. Adjust injection timing. See Adjustment.
31. Remove plugs from FIP connections and pipes.
32. Connect fuel feed pipe to FIP using LRT-12-117.
Tighten to 14 Nm (10 lbf.ft)
33. Using new sealing washers, connect fuel return
pipe. Tighten to 25 Nm (18 lbf.ft)
34. Connect FIP harness and cycle valve multiplugs.
35. Connect oil pressure switch.
36. Connect lead to stop solenoid terminal.
37. Fit cooling fan cowl. See COOLING SYSTEM,
Repair.
38. Fit high pressure pipes. See this section.
39. Reconnect battery negative lead.
FUEL INJECTORS
Service repair no - 19.60.10 - Injectors - each
Service repair no - 19.60.12 - Injectors - set
Remove
1. Disconnect battery negative lead.
2. Remove high pressure pipes. See this section.
3. Disconnect leak-off pipes from injector. Plug
connections.
4. No. 4 injector only: Disconnect needle lift
sensor multiplug.
REPAIR
9
19
FUEL SYSTEM
NEW RANGE ROVER
HIGH PRESSURE PIPES
Service repair no - 19.60.14
Remove
1. Disconnect battery negative lead.
2. Remove inlet manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
3. Using LRT-12-117, disconnect high pressure
pipes at Fuel Injection Pump (FIP) and injectors.
CAUTION: Hold delivery valves against
rotation as pipe unions are loosened.
5. Remove injector using tool LRT-12-120.
NOTE: Special tool has cut-out for needle
lift sensor multiplug. Thread flylead
through tool. Ensure lead and connector
are not damaged during injector removal or
refitting.
6. Collect sealing washer and discard.
4. Remove clip securing leak-off pipe to No. 1 high
pressure pipe.
5. Remove high pressure pipe assembly.
6. Plug high pressure pipes and connections.
Refit
7. Ensure all pipes and connections are clean,
8. Remove plugs. Position pipe assembly.
9. Using LRT-12-117, secure high pressure pipes
to injection pump. Tighten to 22 Nm (16 lbf.ft)
CAUTION: Hold delivery valves against
rotation as pipe unions are tightened.
Refit
7. Ensure injector nozzle and cylinder head bore
are clean.
8. Apply anti-seize compound to injector threads.
9. Position injector with new sealing washer to
cylinder head. Using LRT-12-120. Tighten to 65
Nm (48 lbf.ft)
10. No. 4 injector only: Connect needle lift sensor
multiplug.
11. Remove plugs. Connect leak-off pipes.
12. Fit high pressure pipe assembly. See this
section.
13. Reconnect battery negative lead.
10. Connect pipes to injectors. Do not tighten.
11. Secure leak-off pipe to No. 1 high pressure pipe
with clip.
12. Fit inlet manifold. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
13. Reconnect battery negative lead.
14. With assistance, crank engine. As fuel emerges
at injector connections, secure each pipe union
using tool LRT-12-117. Tighten to 22 Nm (16
lbf.ft)
CAUTION: Engine will start during high
pressure pipe bleeding procedure.
10
REPAIR
BMW DIESEL
INTAKE AIR TEMPERATURE SENSOR (IAT
SENSOR) - VEHICLES WITHOUT EGR
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR
Service repair no - 18.30.09
Service repair no - 19.42.34
Remove
Remove
1. Disconnect multiplug.
2. Remove sensor from intake manifold. Discard
sealing washer.
1. Disconnect multiplug from sensor.
2. Remove nut and bolt. Release sensor from
bracket.
3. Release clip. Remove sensor from hose.
Refit
3. Ensure mating faces are clean.
4. Using a new sealing washer, fit sensor to intake
manifold. Tighten to 14 Nm (10 lbf.ft)
5. Connect multiplug.
Refit
4. Reverse removal procedure.
REPAIR
11
19
FUEL SYSTEM
THROTTLE POSITION SENSOR (TP SENSOR)
Service repair no - 19.22.49
NEW RANGE ROVER
7. Remove 2 bolts securing TP sensor to pedal
box.
8. Release TP sensor harness from pedal box.
Remove TP sensor.
Remove
Refit
1. Disconnect battery negative lead.
2. Remove drivers side fascia closing panel. See
CHASSIS AND BODY, Repair.
3. Remove 3 scrivet fasteners securing lower
closing panel. Release panel to gain access to
blower motor ducting.
4. Release ducting from blower motor housing and
heater. Remove blower motor ducting.
5. Release linkage from ball joint on TP sensor
lever.
6. Disconnect multiplug.
12
REPAIR
9. Position TP sensor. Route harness correctly
over pedal box.
10. Secure TP sensor with bolts. Tighten to 5 Nm (4
lbf.ft)
11. Connect linkage to TP sensor lever ball joint.
12. Connect multiplug.
13. Fit blower ducting. Engage to heater and blower
motor housing.
14. Align lower closing panel. Secure with scrivet
fasteners.
15. Fit drivers side fascia closing panel. See
CHASSIS AND BODY, Repair.
16. Reconnect battery negative lead.
BMW DIESEL
TURBOCHARGER
Service repair no - 19.42.01
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Remove exhaust system front pipe. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
4. Remove heat shield. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
5. Disconnect intake hose from turbocharger.
Refit
10. Ensure all mating faces are clean.
11. Remove plugs. Position new gasket on manifold.
Position turbocharger.
12. Secure turbocharger with bolts. Tighten to 45
Nm (33 lbf.ft)
13. Connect oil drain hose to turbocharger. Secure
with clip.
14. Position oil feed pipe with new washers. Secure
with banjo bolt. Tighten to 25 Nm (18 lbf.ft)
15. Connect intake hose to turbocharger. Secure
with clip.
16. Fit exhaust system front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
17. Fit heat shield. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
18. Remove safety stands. Lower vehicle.
19. Reconnect battery negative lead.
6. Disconnect oil feed pipe from turbocharger.
Collect sealing washers and discard.
7. Disconnect oil drain hose from turbocharger.
8. Remove 3 bolts securing turbocharger to
exhaust manifold.
9. Remove turbocharger. Collect gasket and
discard.
NOTE: Plug all connections to prevent
ingress of dirt.
REPAIR
13
19
FUEL SYSTEM
NEW RANGE ROVER
INTERCOOLER
Service repair no - 19.42.15
Remove
1. Remove battery. See ELECTRICAL, Repair.
5. Remove 4 bolts securing battery box. Remove
battery box.
6. Remove front grille. See CHASSIS AND BODY,
Repair.
7. Remove 4 bolts securing bonnet platform.
2. Remove 2 screws securing fuel ECM cover.
Remove cover.
3. Remove 2 screws securing ECM harness clamp.
Remove clamp.
4. Remove ECM from battery box. Position ECM
and battery harness aside.
8. Release bonnet release cable clips from
platform. Remove platform.
14
REPAIR
BMW DIESEL
10. Remove 2 bolts securing intercooler to air
conditioning condenser.
11. Remove 4 bolts securing intercooler to radiator
bracket.
9. Disconnect hoses from intercooler.
12. Remove intercooler.
Refit
13. Reverse removal procedure.
REPAIR
15
19
FUEL SYSTEM
FILLER NECK ASSEMBLY
Service repair no - 19.55.07
WARNING: If fuel tank is full, fuel level will
be above filler neck aperture in the tank. If
gauge indicates over 75%, drain a
minimum 10 litres of fuel from tank.
Remove
1. Disconnect battery negative lead.
2. Remove rear wheel arch liner. See CHASSIS
AND BODY, Repair.
3. Remove fuel filler cap.
4. Slacken clips securing hoses to filler neck.
5. Release fill breather hose from filler neck.
6. Petrol Models Only: Disconnect fuel tank and
charcoal canister hoses from vapour separator.
7. Diesel Models Only: Release cap from quick
release connector. Disconnect breather hose.
8. Remove nut securing filler neck to wheel arch.
16
REPAIR
NEW RANGE ROVER
9. Release filler neck from fuel tank hose and
grommet in body aperture.
10. Remove filler neck assembly.
Refit
11. Apply liquid soap to grommet and mating surface
of filler neck.
12. Reverse removal procedure.
BMW DIESEL
FUEL TANK, PUMP AND GAUGE SENDER UNIT
Service repair no - 19.55.01 - Fuel Tank
Service repair no - 19.45.08 - Fuel Pump
Service repair no - 88.25.32 - Fuel gauge Tank Unit
Remove
1. Disconnect battery negative lead.
2. Petrol Models Only: Depressurise fuel system.
See this section.
3. Remove contents of fuel tank into an approved
closed container.
4. Remove fuel filler neck. See this section.
5. Raise vehicle on four post lift.
6. Position container beneath fuel filter to catch
spillage.
7. Petrol Models Only: Disconnect feed pipe from
fuel filter.
8. Diesel Models Only: Disconnect feed pipe at
connection, forward of fuel tank.
9.
10.
11.
12.
Disconnect return pipe, forward of tank.
Plug pipes and connections.
Support tank with jack.
Remove 3 nuts and 2 bolts securing tank cradle
to floor pan.
13. Lower tank by 150mm. Disconnect multiplug
from fuel tank unit.
REPAIR
17
19
FUEL SYSTEM
NEW RANGE ROVER
14. Lower tank assembly. Remove from jack.
Do not carry out further dismantling if
component is removed for access only.
Disassemble
15. Remove tank from cradle.
16. Slacken clip. Remove fill breather pipe from tank
unit.
WARNING: A quantity of fuel will be
retained in the unit, care must be taken to
avoid excessive spillage during removal.
19. Remove tank unit sealing rubber and discard.
Reassemble
17. Disconnect feed and return pipes from tank unit.
Remove each pipe from 2 fuel tank clips.
18. Remove tank unit retaining ring using
LRT-19-001. Remove assembly from tank.
18
REPAIR
20.
21.
22.
23.
Fit new sealing rubber.
Fit tank unit. Align location marks.
Fit retaining ring using LRT-19-001.
Connect fuel feed and return pipes to tank unit.
Tighten to 16 Nm (12 lbf.ft)
24. Secure pipes to fuel tank clips.
25. Position fill breather pipe to tank unit. Secure
with clip.
26. Position tank in cradle.
BMW DIESEL
Refit
27. Raise fuel tank assembly on jack until multiplug
can be connected to tank unit.
28. Raise tank. Align cradle mounting points. Secure
with nuts and bolts.
29. Remove plugs from pipes and connections.
30. Petrol Models Only: Using new ’O’ ring,
connect fuel spill return pipe. Tighten to 16 Nm
(12 lbf.ft)
31. Petrol Models Only: Using new ’O’ ring,
connect fuel feed pipe to filter. Tighten to 20 Nm
(15 lbf.ft)
32. Diesel Models Only: Connect fuel feed and
return pipes.
33. Lower vehicle.
34. Refit fuel filler neck. See this section.
35. Refill fuel tank.
36. Reconnect battery negative lead.
MASS AIR FLOW (MAF) SENSOR - DIESEL WITH
EGR
Service repair no - 19.22.25
Remove
1. Disconnect multiplug from MAF sensor.
2. Slacken clip and disconnect intake hose from
MAF sensor.
3. Remove 2 bolts securing MAF sensor to air
cleaner.
4. Remove MAF sensor and collect ’O’ ring seal.
NOTE: Discard ’O’ ring seal.
Refit
5. Position new ’O’ ring seal to MAF sensor.
6. Engage MAF sensor to air cleaner and secure
with bolts. Tighten bolts to 10Nm (7 lbf.in).
7. Connect intake hose and secure with clip.
8. Connect multiplug to MAF sensor.
REPAIR
19
19
FUEL SYSTEM
DUCTING - AIR INTAKE - DIESEL WITH EGR
Service repair no - 19.10.27
Remove
1. Disconnect battery negative terminal.
2. Remove 4 bolts securing injector cover and
remove cover.
3. Slacken clip securing intake hose to intake
ducting and disconnect hose.
Refit
8. Position intake duct. Engage turbo duct and
breather hose.
9. Carefully engage intake duct clips to camshaft
cover and inlet manifold locations.
CAUTION: Ensure that manifold clips are
correctly engaged before pushing duct
downwards or clips may be damaged.
20
REPAIR
NEW RANGE ROVER
4. Release clip securing breather hose to intake
ducting.
5. Slacken clip securing intake duct to turbo duct.
6. Carefully release intake duct from clips on intake
manifold and camshaft cover.
CAUTION: Care must be taken to ensure
clips do not become damaged.
7. Disengage duct from breather hose and turbo
duct. Remove intake duct assembly.
10. Connect intake hose to intake duct.
11. Secure clips on intake turbo duct, intake hose
and breather hose.
12. Position injector cover and secure with bolts.
Tighten bolts to Tighten to 10 Nm (7 lbf.in).
13. Connect battery negative terminal.
19 - FUEL SYSTEM
CONTENTS
Page
LAND ROVER V8
DESCRIPTION AND OPERATION
ENGINE MANAGEMENT SYSTEM - up to 99MY ................................................ 1
ENGINE MANAGEMENT SYSTEM COMPONENT LOCATION - up to
99MY .................................................................................................................... 2
ENGINE MANAGEMENT SYSTEM SCHEMATIC - up to 99MY ......................... 4
ENGINE MANAGEMENT SYSTEM - from 99MY ................................................ 7
ENGINE MANAGEMENT SYSTEM COMPONENT LOCATION - from
99MY .................................................................................................................... 8
ENGINE MANAGEMENT SYSTEM COMPONENT LOCATION - from
99MY (Continued) .............................................................................................. 10
ENGINE MANAGEMENT SYSTEM SCHEMATIC - from 99MY ........................ 12
COMPONENT DESCRIPTIONS - up to 99MY ................................................... 14
COMPONENT DESCRIPTIONS - from 99MY ................................................... 31
ADJUSTMENT
FUEL TANK - DRAIN ...........................................................................................
THROTTLE CABLE - up to 99MY ........................................................................
THROTTLE CABLE - from 99MY .........................................................................
ENGINE TUNING - up to 99MY ...........................................................................
1
2
2
3
REPAIR
AIR CLEANER ASSEMBLY - up to 97MY ............................................................ 1
AIR CLEANER ASSEMBLY - from 97MY ............................................................ 2
ELEMENT - AIR CLEANER - from 99MY ............................................................. 3
AIR INTAKE HOSE - up to 99MY ......................................................................... 3
CAMSHAFT POSITION (CMP) SENSOR - up to 99MY ...................................... 4
CAMSHAFT POSITION (CMP) SENSOR - from 99MY ....................................... 5
ENGINE COOLANT TEMPERATURE (ECT) SENSOR - up to 99MY ................. 5
ENGINE COOLANT TEMPERATURE (ECT) SENSOR - from 99MY .................. 6
CRANKSHAFT POSITION (CKP) SENSOR - up to 97MY .................................. 7
CRANKSHAFT POSITION (CKP) SENSOR - 97MY to 99MY ............................. 8
CRANKSHAFT POSITION (CKP) SENSOR - from 99MY ................................... 9
FUEL SYSTEM - DEPRESSURISE ................................................................... 10
ENGINE CONTROL MODULE (ECM) - up to 99MY .......................................... 10
ENGINE CONTROL MODULE (ECM) - from 99MY ........................................... 11
FAN - ECM COOLING - from 99MY ................................................................... 12
MASS AIR FLOW (MAF) SENSOR - up to 99MY .............................................. 13
MASS AIR FLOW (MAF) SENSOR - from 99MY ............................................... 13
FUEL RAIL AND INJECTORS - up to 99MY ...................................................... 14
FUEL RAIL AND INJECTORS - from 99MY ....................................................... 16
19 - FUEL SYSTEM
CONTENTS
Page
ENGINE FUEL TEMPERATURE (EFT) SENSOR .............................................
HEATED OXYGEN SENSOR (HO2S) - FRONT (up to 99MY) AND REAR ......
HEATED OXYGEN SENSOR (HO2S) - FRONT - from 99MY ...........................
SPARK PLUGS ..................................................................................................
H.T. LEADS .......................................................................................................
IGNITION COILS - up to 99MY ..........................................................................
IGNITION COILS - from 99MY ...........................................................................
INERTIA FUEL SHUT OFF (IFS) SWITCH ........................................................
INTAKE AIR TEMPERATURE (IAT) SENSOR ..................................................
THROTTLE POSITION (TP) SENSOR - up to 99MY ........................................
THROTTLE POSITION (TP) SENSOR - from 99MY .........................................
KNOCK SENSOR (KS) - up to 99MY ................................................................
KNOCK SENSOR (KS) - from 99MY .................................................................
FUEL PRESSURE REGULATOR ......................................................................
IDLE AIR CONTROL (IAC) VALVE - up to 99MY ..............................................
IDLE AIR CONTROL (IAC) VALVE - from 99MY ...............................................
PLENUM CHAMBER - up to 97MY ....................................................................
PLENUM CHAMBER - 97MY to 99MY ..............................................................
PLENUM CHAMBER - from 99MY ....................................................................
FUEL FILTER ....................................................................................................
THROTTLE CABLE - up to 99MY ......................................................................
THROTTLE CABLE - from 99MY .......................................................................
FILLER NECK ASSEMBLY - PRE-ADVANCED EVAPS ...................................
FUEL FILLER NECK - ADVANCED EVAPS ......................................................
ANTI-TRICKLE FILL VALVE - ADVANCED EVAPS ..........................................
FUEL TANK, PUMP AND GAUGE SENDER UNIT - PRE-ADVANCED
EVAPS ...............................................................................................................
FUEL TANK, PUMP AND GAUGE SENDER UNIT - ADVANCED EVAPS .......
FUEL TANK FILLER CAP - ADVANCED EVAPS ..............................................
THROTTLE BODY - from 99MY ........................................................................
18
18
19
20
21
22
23
24
25
26
26
27
28
28
30
30
31
33
35
36
37
38
40
41
42
43
46
48
49
LAND ROVER V8
ENGINE MANAGEMENT SYSTEM - up to 99MY
Description
The V8 engine for models prior to 99MY is controlled
by a Sagem GEMS engine management system. The
ECM uses sensors to determine ambient conditions
and operating data and uses this data and the
information stored in an internal memory map to
control the electronic ignition and fuel injection. The
system features idle speed control, fault monitoring,
security immobilisation and engine load management
functions. GEMS can be interrogated via the
diagnostic socket to access fault codes and other
diagnostic information using Testbook.
The engine management system (EMS) maintains
optimum engine performance over the entire
operating range. The correct amount of fuel is
metered into each cylinder inlet tract and the ignition
timing is adjusted at each spark plug.
The system incorporates certain default strategies to
enable the vehicle to be driven in case of sensor
failure. This may mean that a fault is not detected by
the driver. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.
A further feature of the system is ’robust
immobilisation’, fitted to European specification
vehicles. Upon arming the alarm, the EMS ECM
disables the injectors and the Body electrical Control
Module (BeCM) inhibits the crank relay (the vehicle
cannot be started until the alarm is disarmed).
CAUTION: System sensor connectors can
be contaminated by oil or coolant when
disconnected during repair or testing. Use
a suitable cap to prevent dirt or fluid ingress.
The system is controlled by the engine control module
(ECM) which receives data from sensors located on
and around the engine. From this information it
provides the correct fuel requirements and ignition
timing at all engine loads and speeds.
The fuel injection system uses a hot wire mass air
flow (MAF) sensor to calculate the quantity of air
flowing into the engine.
The ignition system does not use a distributor. It is a
direct ignition system (DIS), using four double ended
coils. The circuit to each coil is completed by
switching inside the ECM.
The on-board diagnostic system detects any faults
which may occur within the EMS. Fault diagnosis
includes failure of any EMS sensors and actuators,
emissions related items, fuel supply and exhaust
systems.
DESCRIPTION AND OPERATION
1
19
FUEL SYSTEM
ENGINE MANAGEMENT SYSTEM COMPONENT
LOCATION - up to 99MY
2
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
1. Engine Control Module (ECM)
2. Relays in underbonnet fuse/relay box
- Main relay
- Ignition relay
- Starter motor relay
- Fuel pump relay
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Engine Fuel Temperature (EFT) sensor
Inertia Fuel Shut-off (IFS) switch
Heated Oxygen Sensor (HO2S)
Fuel pump and gauge sensor (Advanced
EVAPS unit also incorporates tank pressure
sensor)
Knock Sensors (KS) (2 off)
Ignition coils
Fuel injectors
Crankshaft position (CKP) sensor (early type
shown)
EVAP Canister Vent Solenoid (ECVS) Advanced EVAPS only
EVAP canister purge valve
Mass air flow (MAF) sensor
Intake Air Temperature (IAT) sensor
Idle Air Control (IAC) Valve
Throttle Position (TP) sensor
Camshaft Position (CMP) sensor
Engine coolant temperature (ECT) sensor
DESCRIPTION AND OPERATION
3
19
FUEL SYSTEM
ENGINE MANAGEMENT SYSTEM SCHEMATIC up to 99MY
4
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
1. Body electrical Control Module (BeCM)- (Inputs and Outputs)
- Engine speed signal - (Output)
- Engine immobilisation security signal - (Input)
- Road speed signal - (Input from ABS ECU via BeCM)
- Check engine / Service engine soon (NAS) warning lamp - (Output)
- Fuel level signal - (Input)
2. Electronic Automatic Transmission (EAT) ECU - (Inputs and Outputs)
- Engine torque signal - (Output)
- Throttle angle signal - (Output)
- Ignition retard - (Input)
- Engine speed signal - (Output via BeCM)
3. Throttle Position (TP) sensor - (Input)
4. Ignition coils (4 off) - (Output)
5. Crankshaft speed and position (CKP) sensor - (Input)
6. Mass air flow (MAF) sensor - (Input)
7. Camshaft position (CMP) sensor - (Input)
8. Canister vent solenoid (CVS) unit - (Output- NAS Advanced EVAPs system only)
9. Purge valve - (Output)
10. Fuel tank pressure sensor - (Input - NAS Advanced EVAPs system only)
11. HO2S sensors (0, 2 or 4 off dependent on market legislation)
- (Input signal and HO2S sensor heater supply output)
12. HEVAC unit - (Inputs and Outputs)
- Air Con Request - (Output)
- Air Con Grant - (Output)
- Condenser Fan Request - (Input)
- Heated Front Screen - (Input via BeCM for idle speed compensation)
13. Condenser Fan Relay - (Output)
14. Instrument pack - (Fuel used signal output)
15. Engine coolant temperature (ECT) sensor - (Input)
16. Intake air temperature (IAT) sensor - (Input)
17. Idle Air Control Valve (IACV) - (Output)
18. Fuel temperature sensor - (Input)
19. ABS ECU (Rough road signal) - (Input via BeCM)
20. Fuel injectors (8 off) - (Output)
21. Fuel pump relay - (Output)
22. Park / Neutral Switch - (Input)
23. Main power relay - (Input)
24. Ignition supply (Ignition sense) - (Input)
25. Diagnostic connector - (bi-directional)
26. Transfer box ECU - (MIL request input)
27. Knock (KS) sensors (2 off) - (Input)
DESCRIPTION AND OPERATION
5
19
FUEL SYSTEM
NEW RANGE ROVER
This page is intentionally left blank
6
DESCRIPTION AND OPERATION
LAND ROVER V8
ENGINE MANAGEMENT SYSTEM - from 99MY
Description
The V8 engine for models from 99MY is controlled by
a Bosch Motronic 5.2.1 engine management system.
The ECM uses sensors to determine ambient
conditions and operating data and uses this data and
the information stored in an internal memory map to
control the electronic ignition and fuel injection. The
system features:
The ECM software program processes these signals
and determines what actions to implement based on
these signals and the internal mapped data settings.
The on-board diagnostic system detects any faults
which may occur within the EMS. The system
monitors and reports on any ignition, fuelling or
exhaust faults which cause an excessive increase in
emissions. Fault diagnosis includes failure of any
EMS sensors and actuators, as well as misfire,
catalyst damage, catalyst efficiency, fuel evaporative
loss control and exhaust leaks.
• Idle speed control (ISC)
• Adherance to regulatory emissions standards
• Adherance to OBDII legislation for NAS vehicles
• Security immobilisation
• Fuelling quantity
• Exhaust emission control using HO2S sensors
and closed loop fuelling
• Knock control
• Ignition timing
• Interfaces with other electronic systems
including Electronic Automatic Transmission
(EAT) ECU, Transfer Box ECU, ABS ECU,
BeCM and instrument pack.
The engine management system controls the engine
fuelling by providing full sequential injection to all
cylinders. Ignition is controlled by a direct ignition
system which is provided by two quad ignition coils
operating on the wasted spark principle.
The system incorporates certain default strategies to
enable the vehicle to be driven in case of sensor
failure. This may mean that a fault is not detected by
the driver. The fault is indicated by illumination of the
malfunction indicator lamp (MIL) on North American
specification vehicles.
The ECM also communicates with the EAT ECU using
a CAN data link for the transmission of OBD
information.
A further feature of the system is ’robust
immobilisation’, (fitted to vehicles in most markets).
Upon arming the alarm, the EMS ECM disables the
injectors and the Body electrical Control Module
(BeCM) inhibits the crank relay (the vehicle cannot be
started until the alarm is disarmed).
CAUTION: System sensor connectors can
be contaminated by oil or coolant when
disconnected during repair or testing. Use
a suitable cap to prevent dirt or fluid ingress.
Sensors used in the engine management system
include:
• Mass air flow sensor - to determine the mass of
air entering the engine
• Throttle position sensor - to detect the current
throttle angle
• Coolant temperature sensor - to detect current
engine coolant temperature
• Exhaust gas sensors (HO2S) sensors - to
determine the exhaust emission levels
DESCRIPTION AND OPERATION
7
19
FUEL SYSTEM
ENGINE MANAGEMENT SYSTEM COMPONENT
LOCATION - from 99MY
8
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Ignition coils
Idle Air Control Valve (IACV)
Purge valve
Engine Control Module (ECM)
"E-box" cooling fan
MAF Sensor & IAT Sensor
Throttle Position Sensor
Engine Coolant Temperature (ECT) Sensor
Camshaft Position (CMP) Sensor
Engine Compartment Relay and Fusebox
A - Main Relay
B - Ignition Relay
C - Air Conditioning On/Off Relay
D - Battery supply fuse (30A)
E - Ignition relay supply fuse (30A)
F - Main relay output fuse (20A)
G - Main relay output fuse (30A)
11. Canister Vent Solenoid (CVS) Valve
NOTE: For component locations of
secondary air injection system
components fitted to NAS vehicles from
2000MY, refer to the EMISSION CONTROL section
of this manual.
DESCRIPTION AND OPERATION
9
19
FUEL SYSTEM
ENGINE MANAGEMENT SYSTEM COMPONENT
LOCATION - from 99MY (Continued)
10
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
1. Diagnostic connector
2. Instrument pack
- Check engine / Service engine soon (NAS only) warning lamp
- Tachometer
- Fuel used
3. Fuel tank pressure sensor
4. Electronic Automatic Transmission (EAT) ECU
5. Transfer Box ECU
6. HO2S sensors
7. Crankshaft position sensor
8. Spark plugs and HT leads
9. Knock sensor
10. Fuel injectors
11. ABS ECU
12. Body electronic Control Module (BeCM)
DESCRIPTION AND OPERATION
11
19
FUEL SYSTEM
ENGINE MANAGEMENT SYSTEM SCHEMATIC from 99MY
12
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
ECM engine interface inputs:
1.
2.
3.
4.
5.
6.
7.
Knock sensor (2 off)
Engine coolant temperature (ECT) sensor
Throttle position (TP) sensor
Camshaft position (CMP) sensor
Crankshaft speed and position sensor
Engine control module (ECM)
Mass air flow (MAF) / Inlet air temperature (IAT)
sensor
Fuel system:
8. Canister vent solenoid (CVS) valve (output)
9. Purge valve (output)
10. Fuel tank pressure sensor (input)
Emissions:
11. Heated oxygen sensors (0, 2 or 4 dependent on
market destination)
- HO2S sensor signal inputs
- HO2S sensor heater supply outputs
Air Conditioning System:
12. - Air conditioning compressor (output)
- Air conditioning condenser fan relay (output)
- Air conditioning request (input)
- Condenser fan request (input)
ECM engine interface outputs:
18.
19.
20.
21.
Ignition coils (4 off)
Idle air control (IAC) actuator
Fuel injectors (8 off)
Fuel pump relay
Diagnostics:
22. Diagnostic connector (bi-directional)
Power supply:
23. Main relay (input)
Electronic Control Unit interfaces:
24. Electronic Automatic Transmission (EAT) ECU
(via bi-directional CAN link)
25. Transfer Box ECU (MIL request)
26. ABS ECU (Rough road signal)
Ignition switched power supply:
27. Ignition switch - position II (input)
NOTE: Additional components for
secondary air injection are fitted to some
NAS vehicles from 2000MY, refer to the
EMISSION CONTROL section in this manual for
details.
BeCM:
13. BeCM
- Immobilisation signal (input)
- Fuel tank level signal (input)
Instrument pack:
14. Check Engine / Service Engine Soon (NAS)
warning lamp (output)
15. Fuel used signal - display (output)
16. Tachometer (output)
E-box:
17. E-box cooling fan control (output)
DESCRIPTION AND OPERATION
13
19
FUEL SYSTEM
COMPONENT DESCRIPTIONS - up to 99MY
Engine Control Module (ECM) - (up to 99MY)
The engine control module (ECM) prior to 99MY is a
GEMS (Generic Engine Management System), it is
located in a plastic moulded box behind the battery in
the engine compartment.
The ECM has various sensors fitted to the engine to
allow it to monitor engine condition. The ECM
processes these signals and decides what actions to
carry out to maintain driveability, after comparing the
information from these signals to mapped data within
its memory.
Input / Output
C509:18-pin black connector
C507:36-pin red connector
C505:36-pin black connector
14
DESCRIPTION AND OPERATION
NEW RANGE ROVER
The black plastic case which houses the ECM
protects it from sources of contamination including
heat. The ECM itself is contained in a cast aluminium
case. The ECM has 3 independent connectors
totalling 90 pins, of which up to 66 are used,
dependent on market variations.
LAND ROVER V8
18-pin black connector (C509):
This connector is used primarily for ECM power and earth connections.
NOTE: Voltages and other measurements given are approximations only. Actual values will
depend on particular specification and will be affected by accuracy and calibration of the
measurement tool used and impedances caused by harness wiring etc.
ECM pin details for Connector C509:
Pin No.
Description
Input/Output
Voltage
1
Coil driver - Cylinders 5 & 8
Output
0 - 12V
2
Not used
-
-
3
Not used
-
-
4
Throttle Position Sensor
Output
5V supply
5
ECM to chassis ground
Ground
0V
6
Not used
-
-
7
Main relay supply
Input
0 - 12V
8
Ignition sense
Input
0 - 12V
9
ECM to chassis ground
Ground
0V
10
ECM to chassis ground
Ground
0V
11
Crankshaft (CKP) sensor -ve
Ground
0V
12
Crankshaft (CKP) sensor +ve
Analogue input
18V (average)
at 480Hz
13
Coil driver - Cylinders 2 & 3
Output
0 - 12V
14
Coil driver - Cylinders 1 & 6
Output
0 - 12V
15
Coil driver - Cylinders 4 & 7
Output
0 - 12V
16
ECM to chassis ground
Ground
0V
17
Main relay control
Output
switched to
ground
18
Not used
-
-
DESCRIPTION AND OPERATION
15
19
FUEL SYSTEM
NEW RANGE ROVER
36-pin red connector (C507):
This connector is used primarily for sensor inputs to the ECM.
NOTE: Voltages and other measurements given are approximations only. Actual values will
depend on particular specification and will be affected by accuracy and calibration of the
measurement tool used and impedances caused by harness wiring etc.
ECM pin details for Connector C507:
16
Pin No.
Description
Input/Output
Voltage
1
Rough road detected
Input
0 -12V
2
Camshaft position (CMP) sensor
Input (2 pulses per
engine revolution)
12V (average)
3
Not used
-
-
4
Transfer box (Low range detected)
Input
0 - 12V
5
Not used
-
-
6
Not used
-
-
7
Fuel level
Input (out of range and
validity check only)
0 - 12V
8
HO2S Bank B Upstream
Input
0V (Rich) - 5V
(Lean)
9
Not used
-
-
10
Knock sensor ground
Ground
0V
11
Knock sensor A
Input
Voltage signal
proportional to
level of knock
detected
12
Knock sensor B
Input
Voltage signal
proportional to
level of knock
detected
13
Air temperature sensor
Input
1 k-ohm to 1.3
k-ohm at 40°C
(140°F)
14
Coolant temperature sensor
Input
4.7V at -30°C
(-22°F) to
0.25V at 130°C
(266°F); 2.0V
at 40°C (104°F)
15
Throttle position sensor
Input
0 to 5V (0.6V at
idle; 4.5V
typical max.)
16
Mass air flow (MAF) Sensor
Analogue input
0 to 5V (1.4V at
idle)
17
HO2S sensor Bank A Downstream
Input
0V (Rich) - 5V
(Lean)
DESCRIPTION AND OPERATION
LAND ROVER V8
ECM pin details for Connector C507 continued:
Pin No.
Description
Input/Output
Units
18
Park / Neutral Switch
Input
0V
(Park/Neutral) 12V (Drive)
19
Not used
-
-
20
Diagnostic ’L’ Line
Bi-directional
Serial 0 - 12V
21
Heated front windshield
Output
0V or 12V
22
Not used
-
-
23
Diagnostic ’K’ Line
Bi-directional
Serial 0 - 12V
24
Not used
-
-
25
Not used
-
-
26
Immobilization
Input
Serial 0 - 12V
(366 baud)
27
Vehicle speed
Input
PWM 0 - 12V
(8000 pulses /
mile)
28
A/C request
Output
0V or 12V
29
Condenser cooling fan request
Input
0V or 12V
30
Fuel Pressure sensor (from 97.5 MY)
Input
1 k-ohm to 1.3
k-ohm at 40°C
(140°F)
31
Ignition Retard Request (EAT ECU)
Input
12V PWM
32
HO2S sensor
Ground
0V
33
HO2S sensor Bank B Downstream
Input
0V (Rich) - 5V
(Lean)
34
HO2S sensor Bank A Upstream
Input
0V (Rich) - 5V
(Lean)
35
Fuel temperature sensor
Input
1 k-ohm to 1.3
k-ohm at 40°C
(140°F)
36
Sensor ground
Ground
0V
DESCRIPTION AND OPERATION
17
19
FUEL SYSTEM
NEW RANGE ROVER
36-pin black connector (C505):
This connector is used primarily for outputs to actuators and sensors driven by the ECM.
NOTE: Voltages and other measurements given are approximations only. Actual values will
depend on particular specification and will be affected by accuracy and calibration of the
measurement tool used and impedances caused by harness wiring etc.
ECM pin details for Connector C505:
18
Pin No.
Description
Input/Output
Units
1
A/C grant
Output
0V or 12V
2
Fuel used
Output
Serial 0 - 12V
(12000 pulses
per litre)
3
Condenser cooling fan
Output drive
Switch to
ground
4
Not used
-
-
5
Not used
-
-
6
Canister vent solenoid (from 97.5 MY)
Output
0 - 12V
7
Not used
-
-
8
Not used
-
-
9
Not used
-
-
10
Not used
-
-
11
Injector - Cylinder 3
Output
0 - 12V
12
Not used
-
-
13
Injector - Cylinder 1
Output
0 - 12V
14
Not used
-
-
15
IACV-D Stepper motor
Output
stepped by
sequentially
changing
voltage polarity
16
IACV-B Stepper motor
Output
stepped by
sequentially
changing
voltage polarity
17
Injector - Cylinder 6
Output
0 - 12V
18
Injector - Cylinder 8
Output
0 - 12V
19
Purge valve
Output
0 - 12V (100
Hz)
20
Not used
-
-
DESCRIPTION AND OPERATION
LAND ROVER V8
ECM pin details for Connector C505 continued:
Pin No.
Description
Input/Output
Voltage
21
HO2S sensor Upstream - Heater supply
Output
Heater
resistance =
5.7 ohms
22
Malfunction Indicator Lamp (MIL)
Output drive
Switch to
ground
23
Engine speed output
Output
12V square
wave (4 pulses
per revolution)
24
Fuel pump relay
Output drive
Switch to
ground
25
Not used
-
-
26
Not used
-
-
27
Throttle position
Analogue input
0 - 5V (1.4V at
idle)
28
HO2S sensor Upstream - Heater supply
Output
Heater
resistance =
5.7 ohms
29
Engine torque
Output
12V PWM
30
Injector - Cylinder 4
Output
0 - 12V
31
Not used
-
-
32
Injector - Cylinder 7
Output
0 - 12V
33
Injector - Cylinder 5
Output
0 - 12V
34
IACV-C Stepper motor
Output
stepped by
sequentially
changing
voltage polarity
35
IACV-A Stepper motor
Output
stepped by
sequentially
changing
voltage polarity
36
Injector - Cylinder 2
Output
0 - 12V
DESCRIPTION AND OPERATION
19
19
FUEL SYSTEM
NEW RANGE ROVER
Crankshaft position (CKP) sensor - (up to 99MY)
Camshaft position (CMP) sensor - (up to 99MY)
The crankshaft position sensor is the most important
sensor on the engine. It is located in the left hand side
of the flywheel housing and uses a different thickness
of spacer for manual and automatic gearboxes. The
signal it produces informs the ECM:
- the engine is turning
- how fast the engine is turning
- which stage the engine is at in the cycle
The camshaft sensor is located in the engine front
cover, between the belt pulleys. It is a Hall Effect
device which produces four pulses for every two
revolutions of the engine. The signal is used for two
purposes, injector timing corrections for fully
sequential fuelling and active knock control. The CMP
sensor signal pulses are generated from four gaps on
the cam wheel, one gap is smaller than the other
three, consequently one of the pulses is longer than
the others.
As there is no default strategy, failure of the CKP
sensor will result in the engine failing to start. The fault
is indicated by illumination of the malfunction indicator
light (MIL) on North American specification vehicles.
The output signal from the CKP sensor is obtained
from the magnetic path being made and broken as the
reluctor ring teeth pass the sensor tip. The reluctor
ring has 35 teeth and one missing tooth spaced at
10°intervals. The missing tooth is positioned at
20°after TDC.
If the camshaft sensor fails, default operation is to
continue normal ignition timing. The fuel injectors will
be actuated sequentially, timing the injection with
respect to top dead centre. Injection will either be
correct or one revolution out of synchronisation. The
fault is not easily detected by the driver. The fault is
indicated by illumination of the malfunction indicator
light (MIL) on North American specification vehicles.
Fault codes:
Fault codes:
• P0335 -Crankshaft sensor circuit fault - no signal
• P0336 -Crankshaft sensor generating poor
quality signal
20
DESCRIPTION AND OPERATION
• P0340 - Camshaft sensor circuit fault or signal
timing different from crankshaft sensor signal.
NOTE: It is physically possible to
interchange the camshaft gear wheel fitted
to pre-99MY and post-99MY vehicles.
However, because the GEMS and Motronic
systems are incompatible, an incorrect camshaft
signal will be received by the ECM and a P0340
fault code will result.
LAND ROVER V8
Mass air flow (MAF) sensor - (up to 99MY)
Throttle Position (TP) sensor - (up to 99MY)
The ’hot wire’ type mass air flow sensor is mounted
rigidly to the air filter and is connected by flexible hose
to the plenum chamber inlet. The MAF sensor is a hot
wire anenometer. The main sensing element of the
sensor is a heated wire, positioned in the stream of
intake air. Changes in intake air flow changes the
temperature, and hence resistance, of the wire. The
ECM measures this change in resistance and
calculates the amount of air flowing into the engine.
The throttle position sensor is mounted on the throttle
body in line with the throttle plate shaft. The sensor is
a variable resistor, the signal from which (0 - 5V)
informs the ECM of the actual position of the throttle
disc and the rate of change of throttle position. This
information is used by the ECM for regulation of
acceleration enrichment fuelling. Sensor failure will
adversely affect the acceleration performance. The
closed throttle voltage is continuously monitored and
updated when engine conditions indicate that the
throttle is closed.
As there is no default strategy, failure will result in the
engine starting, and dying when it reaches 550
rev/min, when the ECM detects no MAF sensor
signal. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.
Intake Air Temperature (IAT) sensor - (up to 99MY)
The IAT sensor is another resistive sensor, located in
the body of the air cleaner. The sensor resistance
varies with changes in air temperature. The signal
from the IAT sensor is used to retard the ignition
timing if the air temperature rises above 55°C. If the
sensor is disconnected or failure occurs, a default
value will be used by the system. The default value
selected will represent nominal operating conditions.
The fault may not be evident to the driver, there may
be slight power loss in high ambient temperatures.
The fault is indicated by illumination of the malfunction
indicator light (MIL) on North American specification
vehicles.
The GEMS ECM performs a throttle potentiometer
range check by cross checking with the measured air
flow. If the two values do not correlate and fuelling
feedback indicates that fuelling and therefore airflow is
correct, the potentiometer is assumed to have failed.
In the event that a fault is detected, GEMS supplies a
default value dependent on air flow.
The throttle angle is also supplied to the gearbox
ECM, the loss of this signal will result in poor gear
change quality and loss of kickdown.
WARNING: If the throttle potentiometer is
changed, it is necessary to reset the
closed throttle voltage.
Fault codes:
• P0121 - Throttle potentiometer signal
inconsistent with MAF, IACV, air temperature
and engine rpm.
• P0122 - Throttle potentiometer circuit low input
• P0123 - Throttle potentiometer circuit high input
DESCRIPTION AND OPERATION
21
19
FUEL SYSTEM
NEW RANGE ROVER
Engine Coolant Temperature (ECT) sensor - (up to
99MY)
Engine Fuel Temperature (EFT) sensor - (up to
99MY)
The sensor is located at the top front of the engine, to
the right of the alternator and in front of the plenum
chamber.
The EFT sensor is located on the fuel rail by cylinders
3 and 5. The sensor measures the temperature of the
rail rather than the fuel. The resistance varies with
changes in temperature. The signal is used to
increase the injection pulse time when undergoing hot
restarts. When the fuel is hot, vapourisation can occur
in the fuel rail and bubbles form in the injectors.
Increasing the pulse time helps flush the fuel vapour
away. An EFT sensor fault may not be evident to the
driver, there may be a hot restart problem. The fault is
indicated by illumination of the malfunction indicator
light (MIL) on North American specification vehicles.
The sensor comprises a temperature dependant
resistive metal strip. The resistance of the strip varies
considerably with coolant temperature, i.e. from 28K
ohms at - 30°C to 90 ohms at 130°C. At 85°C the
resistance is 300 ohms. The ECT sensor signal is vital
to engine running, as the correct fuelling is dependant
upon engine temperature i.e. richer mixture at low
temperatures.
If the sensor is disconnected or failure occurs, a
default value will be supplied to the system. The initial
default value selected will be based on the value of
the air intake temperature. This will increase to a
nominal warmed up value over a given time,
programmed for each default value. The fault may not
be evident to the driver, there may be a hot restart
problem. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.
Fault codes:
• P0116 - Coolant temperature sensor - falling
temperature fault
• P0117 - Coolant temperature sensor circuit low
range fault
• P0118 - Coolant temperature sensor circuit high
range fault
• P0125 - Coolant temperature sensor - no
warm-up fault
22
DESCRIPTION AND OPERATION
Fault codes:
• P0181 - Fuel temperature sensor fault - reading
invalid compared with water temperature
• P0182 - Fuel temperature sensor circuit low
range fault
• P0183 - Fuel temperature sensor circuit high
range fault
LAND ROVER V8
Knock Sensors (KS) - up to 99MY
Ignition coils - up to 99MY
The knock sensor produces an output voltage which is
proportional to mechanical vibration caused by the
engine. A sensor is located in each cylinder bank
between 2/4 and 3/5 cylinders. The ECM calculates if
the engine is knocking by taking camshaft and
crankshaft sensor signals to determine the position of
the engine in the combustion cycle.
The electronic ignition system uses four double ended
coils. The ignition coils are mounted on a bracket
fitted to the rear of the engine. The circuit to each coil
is completed by switching within the ECM, allowing
each coil to charge. When the ECM determines the
correct ignition point, it switches off current supply to
the coil which in turn causes the magnetic field around
the coil’s primary winding to collapse, inducing ht
voltage in the secondary winding and in the iron core
of the coil. High tension voltage, of different polarities,
is produced at either end of the coil’s core and is
transmitted to two cylinders simultaneously, one on
compression stroke, the other on exhaust stroke. This
is called the wasted spark principle.
The ECM can also work out exactly which cylinder is
knocking and progressively retards the ignition on that
particular cylinder until the knock disappears. It then
advances the ignition to find the optimum ignition
timing for that cylinder.
The ECM can simultaneously adjust the timing of
each cylinder for knock. It is possible that all eight
cylinders could have different advance angles at the
same time. If the camshaft sensor fails, the knock
control will be disabled.
Fault codes:
• P0331 - Continuous knock on bank B
• P0332 - Knock background noise low, bank B
Note that coil 1 feeds cylinders 1 and 6, coil 2 feeds
cylinders 5 and 8, coil 3 feeds cylinders 4 and 7, and
coil 4 feeds cylinders 2 and 3. The resistance of the
spark plug in the compression cylinder is higher than
that in the exhaust cylinder and hence more spark
energy is dissipated in the compression cylinder. Coil
failure will result in a lack of ignition, resulting in a
misfire in the related cylinders. The fault is indicated
by illumination of the malfunction indicator light (MIL)
on North American specification vehicles.
• P0333 - Knock background noise high, bank B
• P0326 - Continuous knock on bank A
• P0327 - Knock background noise low, bank A
• P0328 - Knock background noise high, bank A
DESCRIPTION AND OPERATION
23
19
FUEL SYSTEM
Fuel injectors - (up to 99MY)
A multiport Sequential Fuel Injection (SFI) system is
used which utilises one injector per cylinder. Each
injector comprises a small solenoid which is activated
by the ECM to allow a metered quantity of fuel to pass
into the combustion chamber. Due to the pressure in
the fuel rail and the shape of the injector orifice, the
fuel is injected into the cylinder in a fine spray which
aids combustion. In the unlikely event of total injector
failure or leakage which will cause a rich mixture, a
misfire will occur in the affected cylinder. The fault is
indicated by illumination of the malfunction indicator
light (MIL) on North American specification vehicles.
Fault codes:
• P0201 - Injector circuit fault, cylinder 1
• P0202 - Injector circuit fault, cylinder 2
• P0203 - Injector circuit fault, cylinder 3
• P0204 - Injector circuit fault, cylinder 4
• P0205 - Injector circuit fault, cylinder 5
• P0206 - Injector circuit fault, cylinder 6
• P0207 - Injector circuit fault, cylinder 7
• P0208 - Injector circuit fault, cylinder 8
• P1201 - Injector circuit open or ground short,
cylinder 1
• P1202 - Injector circuit open or ground short,
cylinder 2
• P1203 - Injector circuit open or ground short,
cylinder 3
• P1204 - Injector circuit open or ground short,
cylinder 4
• P1205 - Injector circuit open or ground short,
cylinder 5
• P1206 - Injector circuit open or ground short,
cylinder 6
• P1207 - Injector circuit open or ground short,
cylinder 7
• P1208 - Injector circuit open or ground short,
cylinder 8
24
DESCRIPTION AND OPERATION
NEW RANGE ROVER
CAUTION: The injectors are extremely
sensitive, they must not be dropped or
contaminated.
CAUTION: When assembling the injector
to the fuel rail, only use clean engine oil to
aid assembly. DO NOT use petroleum jelly
or other forms of grease, as this will contaminate
the injector.
The injectors can be checked using a multimeter to
test the resistance values:
• Injector resistance at 20°C = 16.2 ohms ± 0.5
ohms
LAND ROVER V8
Idle Air Control (IAC) valve - up to 99MY
Heated Oxygen Sensor (HO2S) - up to 99MY
The idle speed control stepper motor is located on the
side of the inlet manifold. Idle speed is controlled by
the stepper motor, which comprises two coils,
mounted to the throttle housing. When energised in
the correct sequence, the coils move a plunger which
opens or closes the throttle bypass valve controlling
the quantity of idle air. The stepper motor controls idle
speed by moving the plunger a set distance called a
step. Fully open is 200 steps (180 steps for vehicles
up to 97MY) and fully closed 0 steps. Failure of the
stepper motor will result in low or high idle speed,
poor idle, engine stall or non start. If the number of
recorded steps changes beyond a set threshold
(opening or closing) without a corresponding change
in airflow, then a fault code will be stored. The GEMS
diagnostics also check for short circuit conditions
during normal stepper operation and open circuit
during power down. Detected faults are indicated by
illumination of the malfunction indicator light (MIL) on
North American specification vehicles.
The heated oxygen sensors consist of a titanium
metal sensor surrounded by a gas permeable ceramic
coating. Oxygen in the exhaust gas diffuses through
the ceramic coating on the sensor, and reacts with the
titanium wire altering the resistance of the wire. From
this resistance change the ECM calculates the
amount of oxygen in the exhaust gas. The injected
fuel quantity is then adjusted to achieve the correct
air:fuel ratio, thus reducing the emissions of carbon
monoxide (CO), hydrocarbons (HC), and oxides of
nitrogen (NOx). Two HO2S sensors are fitted, one in
each exhaust front pipe and positioned in front of the
catalytic convertor. On North American specification
vehicles, an additional HO2S sensor is fitted behind
each catalytic converter. These additional sensors are
used to monitor the operating efficiency of the
catalysts. Note that if the wiring to these sensors is
crossed, the vehicle will start and idle correctly until
the sensors reach operating temperature. Then the
ECM will read the signals from them and send one
bank of cylinders very rich and the other very weak.
The engine will misfire, have a rough idle and emit
black smoke, with possible catalyst damage.
The stepper motor coil resistance is 53 ohms ± 2
ohms.
CAUTION: The pintle must not be moved
by force.
Fault codes:
• P0506 - Low idle speed
• P0507 - High idle speed
• P1508 - IACV stepper motor open circuit
• P1509 - IACV stepper motor short circuit
The oxygen sensors are heated to ensure rapid warm
up and continued operation when the exhaust
temperature may be below the working temperature of
the sensor. Both the upstream sensor heaters and the
downstream sensor heaters are connected in parallel.
The heaters are directly driven from the GEMS ECM
by a pulse width modulated (PWM) signal to enable
temperature control of the heater to be achieved.
When the sensor is powered up, the duty ratio of the
PWM signal to the heater is started low and then
increased over a period of approximately 30 seconds.
This is to ensure the sensor is not heated up too
quickly, which might cause the ceramic interior of the
sensor to crack. The duty ratio of the heater signal
may be altered during normal operation to maintain
sensor temperature.
In the event of sensor failure, the system will default to
’open loop’ operation. Fuelling will be calculated using
signals from the remaining ECM inputs.
On North American Specification vehicles, a fault with
any of the HO2S sensors is indicated by illumination of
the malfunction indicator light (MIL). ECM diagnostics
also use the Heated Oxygen Sensors to detect
catalyst damage, misfire and fuel system faults.
DESCRIPTION AND OPERATION
25
19
FUEL SYSTEM
CAUTION: Although robust within the
vehicle environment, Heated Oxygen
Sensors are easily damaged by dropping,
excessive heat and contamination. Care must be
exercised when working on the exhaust system
not to damage the sensor housing or tip.
Fault codes:
NEW RANGE ROVER
• P0159 - Oxygen sensor circuit slow response,
downstream sensor bank B
• P1138 - Oxygen sensor problem with switching
lean, sensor(s) for bank A
• P1158 - Oxygen sensor problem with switching
lean, sensor(s) for bank B
• P0130 - Oxygen sensor circuit slow response,
upstream sensor bank A
• P1137 - Oxygen sensor problem with switching
rich, sensor(s) for bank A
• P0136 - Oxygen sensor circuit slow response,
upstream sensor bank A
• P1157 - Oxygen sensor problem with switching
rich, sensor(s) for bank B
• P0150 - Oxygen sensor circuit slow response,
upstream sensor bank B
• P1139 - Oxygen sensor circuit switching period
too long bank A
• P0156 - Oxygen sensor circuit slow response,
upstream sensor bank B
• P1159 - Oxygen sensor circuit switching period
too long bank B
• P0131 - Oxygen sensor circuit low voltage,
upstream sensor bank A
• P1171 - System too lean bank A and bank B
• P1172 - System too rich bank A and bank B
• P0151 - Oxygen sensor circuit low voltage,
upstream sensor bank B
• P0137 - Oxygen sensor circuit low voltage,
downstream sensor bank A
• P0171 - System too lean bank A
• P0174 - System too lean bank B
• P0172 - System too rich bank A
• P0157 - Oxygen sensor circuit low voltage,
downstream sensor bank B
• P0175 - System too rich bank B
• P0132 - Oxygen sensor circuit high voltage,
upstream sensor bank A
• P1185 - Oxygen sensor heater circuit open
circuit, upstream sensors
• P0152 - Oxygen sensor circuit high voltage,
upstream sensor bank B
• P1186 - Oxygen sensor heater circuit short
circuit, upstream sensors
• P0138 - Oxygen sensor circuit high voltage,
downstream sensor bank A
• P1187 - Oxygen sensor heater circuit inferred
open circuit, upstream sensors
• P0158 - Oxygen sensor circuit high voltage,
downstream sensor bank B
• P1188 - Oxygen sensor heater circuit high
resistance, upstream sensors
• P0133 - Oxygen sensor circuit slow response,
upstream sensor bank A
• P1189 - Oxygen sensor heater circuit inferred
low resistance, upstream sensors
• P0153 - Oxygen sensor circuit slow response,
upstream sensor bank B
• P1190 - Oxygen sensor heater circuit low
resistance, upstream sensors
• P0139 - Oxygen sensor circuit slow response,
downstream sensor bank A
26
DESCRIPTION AND OPERATION
LAND ROVER V8
• P1191 - Oxygen sensor heater circuit open
circuit, downstream sensors
• P1192 - Oxygen sensor heater circuit short
circuit, downstream sensors
• P1193 - Oxygen sensor heater circuit inferred
open circuit, downstream sensors
• P1194 - Oxygen sensor heater circuit high
resistance, downstream sensors
• P1195 - Oxygen sensor heater circuit inferred
low resistance, downstream sensors
• P1196 - Oxygen sensor heater circuit low
resistance, downstream sensors
Fuel pressure regulator - (up to 99MY only)
The fuel pressure regulator is a mechanical device
controlled by manifold depression and is mounted at
the rear of the engine in the fuel rail. The regulator
ensures that fuel pressure is maintained at a constant
pressure difference to that in the inlet manifold. As
manifold depression increases, the regulated fuel
pressure is reduced in direct proportion. When
pressure exceeds the regulator setting, excess fuel is
spill returned to the fuel tank swirl pot which contains
the fuel pick up strainer.
Failure of the regulator will result in a rich mixture at
idle but normal at full load, or a rich mixture resulting
in engine flooding, or a weak mixture. Although the
fault will not illuminate the MIL, faults caused by the
failure may be indicated.
• P0420 - Catalyst efficiency is low, bank A
Accumulator - (up to 99MY only)
• P0430 - Catalyst efficiency is low, bank B
Certain derivatives have an accumulator fitted into the
feed line connection at the fuel rail. The purpose of
this device is to damp out pulsations in the fuel
system caused by the normal opening and closing of
the injectors. These pulsations, called injector knock,
may otherwise be detected inside the vehicle.
Relays - (up to 99MY)
The engine management system employs four relays,
which are all located in the main under bonnet
fusebox.
Main Relay:
The main relay supplies the power feed to the ECM to
feed the fuel injectors (8 amps)and air flow meter (4
amps). This relay is controlled by the GEMS ECM
which has a second power feed. This enables the
ECM to remain powered up after ignition is switched
off. During this ’ECM power down routine’ the ECM
records all temperature readings and powers the
stepper motor to the cold start position. Failure of this
relay will result in the engine management ECM not
being powered up, resulting in engine not starting due
to absence of fuel and ignition.
Starter Motor Relay:
The starter motor relay is ignition key controlled and
activated with the key in position 3 only. Releasing the
key after cranking cuts supply to the relay and
switches off the starter motor. Failure of this relay will
result in the starter motor not working.
DESCRIPTION AND OPERATION
27
19
FUEL SYSTEM
Ignition Relay:
The ignition relay supplies the power feed to the coils
(6.5 amps), purge valve (1 amp, non-continuous) and
heating elements of the HO2S sensors (8 amps,
non-continuous). The relay is ignition key controlled,
when the key is turned off, supply to the coils is
immediately cut. Failure of this relay will result in no
ignition.
NEW RANGE ROVER
Advanced Evaporative Emissions System - 98MY
to 99MY (NAS only)
The Advanced evaporative emissions system is
included on NAS vehicles from 98MY in compliance
with OBD strategies. The system has the capability of
detecting holes in the fuel system down to 1 mm (0.04
in.). The leak tests are performed by the ECM,
allowing the tank to be depressurised and measuring
the pressure over a period of time.
Ignition switch sense:
This is used to initiate the power up and power down
routines within GEMS. The input is supplied from the
ignition relay. When the ignition is turned on, the
ignition relay is energised and the GEMS ECM starts
its power up routines and turns on the ECM main
relay, the main power to GEMS and its associated
system components. When the ignition is turned off,
GEMS will usually maintain its powered up state for
several seconds (up to 20 minutes in extreme cases
when cooling fans are required) while it initiates its
power down routine. On completion of the power
down routine, the ECM main relay is turned off.
Fuel Pump Relay:
The fuel pump relay is fed from the ignition relay and
controlled by the ECM. The relay is activated in
ignition key position 2 to prime the fuel system for a
period of time controlled by the ECM. Failure of this
relay will result in no fuel pressure.
See EMISSION CONTROL, Description and
operation.
Fault codes:
• P1440 - Purge valve stuck open.
• P0442 - Evaporative loss control system - small
leak
• P0448 - Evaporative loss control system - major
leak
• P0496 - Evaporative loss control system - major
leak
• P0446 - Purge canister closure valve information
• P1447 - Purge canister closure valve - poor
performance
Fuel Tank Pressure Sensor
This sensor is used on NAS vehicles with advanced
evaporative emissions systems. The sensor is located
in the fuel tank sender unit and is not a serviceable
item. The GEMS ECM checks for any fuel system
leaks through joints and holes, by measuring the
pressure drop after the vent seal valve is shut. The
diagnostic system performs out of range and validity
checks.
The following failure modes are possible:
• Connector or harness open circuit
• Sensor earthing problem
• Blocked sensor
28
DESCRIPTION AND OPERATION
LAND ROVER V8
Certain failure modes may cause the 5V supply
voltage which is shared with the throttle position
sensor to be reduced to less than 1V.
Fault codes:
• P0451 - Fuel tank pressure sensor poor
performance fault
• P0452 - Fuel tank pressure sensor low range
fault
• P0453 - Fuel tank pressure sensor high range
fault
See EMISSION CONTROL, Description and
operation.
EVAP Canister Vent Solenoid (CVS) Valve
The CVS unit is located at the left hand side of the
engine bay. The vent seal valve is normally open.
When the GEMS ECM is required to run a fuel system
test, the vent valve is closed to seal the system. The
ECM is then able to measure the pressure in the fuel
system using the fuel tank pressure sensor. Electrical
integrity checks are performed on the CVS valve and
a valve blockage can be determined from a
depressurising fuel tank.
The following failure modes are possible:
• Connector or harness wiring fault (open or short
circuit)
• Valve stuck open or shut
EVAP Canister Purge Valve
• Valve blocked
The purge valve is controlled by the GEMS ECM and
allows hydrocarbons stored in the EVAP canister to
be purged to the engine inlet manifold for burning.
Electrical circuit integrity and system flow checks are
performed.
See EMISSION CONTROL, Description and
operation.
If a purge valve breaks or becomes stuck, the purge
system will cease to function, and there is no default
operation measures. GEMS will store the fault if the
correct monitoring conditions have been achieved (45
seconds after 15 minutes running). If a valve is stuck
open, the engine may misfire and the fuelling
adaptions will change.
The following failure modes are possible:
• Sticking valve
• Valve blocked
• Connector or harness wiring fault (open or short
circuit)
• Valve stuck open
Fault codes:
• P0441 - Purge valve flow fault
• P0443 - Purge valve open or short circuit
See EMISSION CONTROL, Description and
operation.
DESCRIPTION AND OPERATION
29
19
FUEL SYSTEM
Inertia Fuel Shut-off (IFS) Switch
The inertia switch isolates the power supply to the fuel
pump in the event of sudden deceleration, as
encountered during an accident. The inertia switch is
located in the right hand side footwell behind an
access flap. It is reset by depressing the central
plunger at the top of the switch.
NEW RANGE ROVER
The following fault modes are possible:
• Harness wiring or connector faulty
• Power up problems
• Faulty gearbox ECU
Fault codes:
Electronic Automatic Gearbox Interface - up to
99MY
• P1775 - Gearbox has signalled a fault condition
to the ECM
Engine Torque Signal
The engine torque signal is calculated by the GEMS
ECM and output to the gearbox ECU in a 12 volt
PWM signal format. Warm up status of GEMS is
passed on start-up for OBDII purposes.
Throttle Angle Signal
The throttle signal is output by the GEMS ECM to the
gearbox ECU in a 12 volt PWM signal format. The
signal is used to calculate when a gear change is
necessary. If a fault occurs with this signal, then the
gearbox ECU assumes a default throttle angle. The
signal is also used to indicate engine temperature at
starting.
Ignition Retard (Torque Reduction)
The gearbox ECU calculates the optimum shift point
and in order to produce a smooth gear change, sends
a torque reduction signal to the GEMS ECM which
retards the ignition so reducing the engine torque to
allow a smooth shift.
Engine Speed Signal
The engine speed signal is output to the gearbox ECU
via the Body electronic control module (BeCM). The
signal comprises a 12 volt square wave with 4 pulses
for every engine revolution.
30
DESCRIPTION AND OPERATION
• P1776 - Gearbox ignition retard request duration
fault
• P1777 - Gearbox ignition retard request line fault
See AUTOMATIC GEARBOX, Description
and operation.
LAND ROVER V8
COMPONENT DESCRIPTIONS - from 99MY
Engine Control Module (ECM) - (from 99MY)
From 99MY the Engine Control Module (ECM) is a
Bosch Motronic 5.2.1. which is mounted in a plastic
"E-box" located on the LH side of the engine bay
bulkhead. The ECM is cooled by a dedicated fan,
which supplies cabin air into the plastic E-box to
provide a suitable temperature environment for the
ECM. The working temperature of the ECM is
monitored by an internal temperature sensor.
A.
B.
C.
D.
E.
The E-box is a moulded black plastic case which
houses the ECM and protects it from sources of
contamination. The ECM itself is contained in a cast
aluminium case. The ECM has 5 independent
connectors totalling 134 pins, of which up to 79 are
used, dependent on market variations. The ECM and
connectors can be accessed by positioning the cruise
control pneumatic actuator and pump assembly aside,
lifting the two plastic clips at the top of the e-box and
pulling the E-box lid upwards and out. The ECM is
held in position in the lid of the box by two plastic
brackets. The ECM connectors have to be
disengaged sequentially to release them from the unit.
Similarly, when the connectors are reconnected to the
ECM, the correct sequence must be observed.
9-pin connector (C0634)
24-pin connector (C0635)
52-pin connector (C0636)
40-pin connector (C0637)
9-pin connector (C0638)
Connectors C0634 and C0638 are square type and
have release buttons on their front face which have to
be pressed to enable them to be removed.
DESCRIPTION AND OPERATION
31
19
FUEL SYSTEM
NEW RANGE ROVER
The ECM memorises the positions of the crankshaft
and the camshaft when the engine has stopped via
the CKP and CMP sensors. This allows immediate
sequential fuel injection and ignition timing during
cranking. This information is lost if battery voltage is
too low (i.e. flat battery). So the facility will be disabled
for the first engine start after battery reconnection.
The ECM has various sensors fitted to the engine to
allow it to monitor engine condition. The ECM
processes these signals and decides what actions to
carry out to maintain driveability, after comparing the
information from these signals to mapped data within
its memory.
CAUTION: Do not connect test probes
connected to battery positive supply to
any ground pins on the ECM. THIS MAY
DESTROY THE ECM.
Connectors C0635, C0636 and C0637 are angled and
have release buttons located on the top face. The
release buttons have to be pressed and the locking
levers pulled back to enable the connectors to be
disconnected from the ECM. Each of the connectors
have two integral blocks, one grey and one black,
which can be removed from the connector housing to
enable access to the back of the plugs. Block removal
is achieved by pressing the locking tags and sliding
the connector blocks outwards.
The E-box lid has two location tags on the bottom
edge which have to be aligned with the corresponding
holes in the E-box case before clipping the top of the
lid into position. Care should be taken not to trap any
wires when closing the E-box lid.
The ECM uses a ’flash’ electronic erasable
programmable read only memory (EEPROM). This
enables the ECM to be externally configured, to
ensure that the ECM can be updated with any new
information; this also allows the ECM to be configured
as many times as is necessary to meet changing
specifications and legislation.
32
DESCRIPTION AND OPERATION
LAND ROVER V8
Input / Output
C0634: 9-pin connector
C0635: 24-pin connector
C0636: 52-pin connector
C0637: 40-pin connector
C0638: 9-pin connector
Connector 1 (C0634):
This connector contains 9 pins and is used primarily for ECM power input and earth. The ECM requires a
permanent battery supply, if this permanent feed is lost i.e. the battery discharges or is disconnected, the ECM will
lose its adapted values and its Diagnostic Trouble Codes (DTC). These adapted values are a vital part of the
engine management’s rolling adaptive strategy. Without an adaptive strategy, driveability, performance, emission
control and fuel consumption are adversely affected. The ECM can be affected by high voltage inputs, so care
must be taken when removing and replacing the ECM.
ECM pin details for Connector C0634:
Pin No.
Description
Input/Output
Voltage
1
Ignition position "II"
Input
12V
2
Not used
-
-
3
Not used
-
-
4
Chassis ground
Ground
0V
5
Fuel injector ground
Ground
0V
6
Power stage ground
Ground
0V
7
Battery supply
Input
12V
8
Main relay switched supply
Input switched
0 - 12V
9
Not used
-
-
DESCRIPTION AND OPERATION
33
19
FUEL SYSTEM
NEW RANGE ROVER
Connector 2 (C0635):
This connector contains 24 pins and is primarily used for the Heated Oxygen (HO2S) Sensor’s control and earth.
An output to a heater circuit in each HO2S sensor is also required; this is to assist in heating the tip of the sensors
to enable closed loop fuelling to be implemented quickly after cold starting.
ECM pin details for Connector C0635:
34
Pin No.
Description
Input/Output
Voltage
1
HO2S sensor heater RH bank downstream
Output drive
PWM 12 - 0V
2
Not used
-
-
3
Not used
-
-
4
Not used
-
-
5
Not used
-
-
6
Not used
-
-
7
HO2S sensor heater LH bank downstream
Output drive
PWM 12 - 0V
8
HO2S sensor RH bank - downstream
Ground signal
0V
9
HO2S sensor LH bank - upstream
Ground signal
0V
10
HO2S sensor RH bank - upstream
Ground signal
0V
11
HO2S sensor LH bank - downstream
Ground signal
0V
12
Not used
-
-
13
HO2S sensor heater RH bank upstream
Output drive
PWM 12 - 0V
14
HO2S sensor RH bank - downstream
Input signal
Analogue 0 5V
15
HO2S sensor LH bank - upstream
Input signal
Analogue 0 5V
16
HO2S sensor RH bank - upstream
Input signal
Analogue 0 5V
17
HO2S sensor LH bank - downstream
Input signal
Analogue 0 5V
18
Fuel pump relay
Output drive
Switch to
ground
19
HO2S sensor heater LH bank - upstream
Output drive
PWM 12 - 0V
20
Not used
-
-
21
Not used
-
-
22
Not used
-
-
23
Main relay output
Output drive
Switch to
ground
24
Not used
-
-
DESCRIPTION AND OPERATION
LAND ROVER V8
Connector 3 (C0636):
This connector contains 52 pins and is used for most sensor and actuator inputs and outputs. Sensor and actuator
control is vital to ensure that the ECM maintains adaptive strategy.
ECM pin details for Connector C0636:
Pin No.
Description
Input/Output
Voltage
1
Fuel injector cylinder number 2
Output drive
Switch to
ground
2
Fuel injector cylinder number 5
Output drive
Switch to
ground
3
Purge valve drive
Output signal
PWM 12 - 0V
4
SAI vacuum solenoid valve (NAS
vehicles from 2000MY only)
Output drive
Switch to
ground
5
Not used
-
-
6
Fuel tank pressure sensor (NAS
vehicles with Advanced EVAPS only)
Ground
0V
7
MAF sensor 5V supply
Output, reference
5V
8
Not used
-
-
9
MAF sensor earth
Ground
0V
10
Throttle pot sensor 5V supply
Output reference
5V
11
Not used
-
-
12
Not used
-
-
13
Not used
-
-
14
Fuel injector cylinder number 7
Output drive
Switch to
ground
15
Fuel injector cylinder number 6
Output drive
Switch to
ground
16
SAI pump relay (NAS vehicles from
2000MY only)
Output drive
Switch to
ground
17
Camshaft (CMP) sensor screen
Ground
0V
18
Not used
-
-
19
Not used
-
-
20
Camshaft (CMP) sensor signal
Input signal
Digital switch 0
- 12V
21
Coolant temperature (ECT) sensor
Ground
0V
22
Coolant temperature (ECT) sensor
signal
Input signal
Analogue 0 5V
23
MAF sensor signal
Input signal
Analogue 0 5V
24
Throttle potentiometer signal
Input signal
Analogue 0 5V
DESCRIPTION AND OPERATION
35
19
FUEL SYSTEM
NEW RANGE ROVER
ECM pin details for Connector C0636 continued:
36
Pin No.
Description
Input/Output
Voltage
25
Throttle potentiometer
Ground
0V
26
Not used
-
-
27
Fuel injector cylinder number 3
Output drive
Switch to
ground
28
Fuel injector cylinder number 8
Output drive
Switch to
ground
29
Not used
-
-
30
Canister vent solenoid (CVS) shut-off
valve (NAS vehicles with Advanced
EVAPs only)
Output drive
Switch to
ground
31
Air conditioner condenser fan drive
Output drive
Switch to
ground
32
Crankshaft (CKP) sensor signal
Input signal
Analogue 0 300V pk.
33
Not used
-
-
34
Intake air temperature (IAT) sensor
Input signal
Analogue 0 5V
35
Knock sensor RH bank
Ground
0V
36
Knock sensor RH bank
Input signal
Analogue 0V
37
Not used
-
-
38
Not used
-
-
39
Not used
-
-
40
Fuel injector cylinder number 4
Output drive
Switch to
ground
41
Fuel injector cylinder number 1
Output drive
Switch to
ground
42
Idle speed actuator open
Output signal
PWM 12 - 0V
43
Idle speed actuator close
Output signal
PWM 12 - 0V
44
Instrument Pack - Coolant sensor output
Output signal
PWM 0 - 12V
45
Crankshaft position (CKP) sensor
screen ground
Ground
0V
46
Crankshaft position (CKP) sensor
reference ground
Ground
0V
47
Not used
-
-
48
Knock sensor LH bank
Ground
0V
DESCRIPTION AND OPERATION
LAND ROVER V8
ECM pin details for Connector C0636 continued:
Pin No.
Description
Input/Output
Voltage
49
Knock sensor LH bank
Input signal
Analogue 0V
50
Not used
-
-
51
Not used
-
-
52
Not used
-
-
Connector 4 (C0637):
This connector contains 40 pins and facilitates the use of Testbook via the Diagnostic connector. Also contained in
this connector is the Malfunction Indicator Lamp (MIL), this instrument panel lamp informs the driver of concerns
within the engine management system.
ECM pin details for Connector C0637:
Pin No.
Description
Input/Output
Voltage
1
Not used
-
-
2
Not used
-
-
3
Not used
-
-
4
Not used
-
-
5
Not used
-
-
6
Not used
-
-
7
Not used
-
-
8
Low fuel level
Input signal
Active high
9
Fuel tank pressure sensor (NAS
vehicles with Advanced EVAPs only)
Output reference
5V
10
ECM E-box cooling fan
Output drive
Switch to
ground
11
Not used
-
-
12
BeCM Low fuel level signal
Ground
12V - 0V (when
fuel level low)
13
Not used
-
-
14
Fuel tank pressure sensor (NAS
vehicles with Advanced EVAPs only)
Input signal
Analogue 0 5V
15
Not used
-
-
16
Air conditioning compressor
Input signal
Active low
17
Engine speed output
Output signal
PWM 0 - 5V
18
Not used
-
-
DESCRIPTION AND OPERATION
37
19
FUEL SYSTEM
NEW RANGE ROVER
ECM pin details for Connector C0637 continued:
38
Pin No.
Description
Input/Output
Voltage
19
Not used
-
-
20
MIL "ON"
Output drive
Switch to
ground
21
Not used
-
-
22
Road speed sensor
Input signal
PWM 0 - 12V
23
Not used
-
-
24
Not used
-
-
25
Not used
-
-
26
Not used
-
-
27
Not used
-
-
28
Not used
-
-
29
Air con compressor relay
Output drive
Switch to
ground
30
Not used
-
-
31
Not used
-
-
32
Diagnostic K-line
Bi-directional
Serial 0 - 12V
33
Immobiliser serial W link
Input signal
Serial 0 - 12V
34
Rough road signal
Input signal
PWM 0 -12V
35
Not used
-
-
36
CAN bus ’high line’
Bi-directional
5 - 2.5V
37
CAN bus ’low-line’
Bi-directional
0 - 2.5V
38
Air conditioning stand by relay
Input signal
Active low
39
Not used
-
-
40
Not used
-
-
DESCRIPTION AND OPERATION
LAND ROVER V8
Connector 5 (C0638):
This connector contains 9 pins and is used to control the ignition system. The ignition coils are supplied with
power and a switching earth completes the circuit.
ECM pin details for Connector C0638:
Pin No.
Description
Input/Output
Voltage
1
Not used
-
-
2
Ignition coil cylinders 2+3
Output drive
Switch to
ground
3
Not used
-
-
4
Not used
-
-
5
Ignition screen
Ground
0V
6
Ignition coil cylinders 4 + 7
Output drive
Switch to
ground
7
Ignition coil cylinders 1 + 6
Output drive
Switch to
ground
8
Ignition coil cylinders 5 + 8
Output drive
Switch to
ground
9
Not used
-
-
DESCRIPTION AND OPERATION
39
19
FUEL SYSTEM
Crankshaft speed and position (CKP) sensor (from 99MY)
NEW RANGE ROVER
The ECM uses the signal produced at the CKP sensor
to determine the position of the crankshaft to enable
accurate ignition and fuel injection timing. The ECM
also determines the engine speed at any particular
instance through analysis of the frequency of
fluctuations induced in the CKP sensor as the teeth of
the reluctor ring pass by the sensor tip.
The CKP sensor is a variable reluctance sensor, and
contains a permanent magnet and soft iron core
surrounded by a copper winding. As the reluctor ring
passes by the sensor tip it causes a voltage to be
induced in the sensor, consequently the CKP sensor
does not need a power supply for operation. The
signal wires of the CKP sensor are surrounded by a
grounded screen to prevent noise being induced in
the signal wires and causing a spurious interference
signal being passed to the ECM.
NOTE: When fitting a CKP sensor, ensure
no ferrous metal has been attracted to it
by its magnet. Ensure the sensor pin is
straight and undamaged.
1.
2.
3.
4.
Multiplug
Aperture to reluctor ring
CKP sensor
Heatshield
The CKP sensor is located at the lower, rear LH side
of the engine below cylinder number 7. The CKP
sensor is protected by a heatshield which is attached
to the rear flange of the engine block by two M5 bolts.
The CKP sensor itself is located on two studs and
fixed in position by two M5 nuts and 18mm spacers.
The sensor has a flying lead which terminates in a
3-pin multiplug that connects to the engine harness
and is mounted to a bracket to the rear of the left hand
cylinder head.
The tip of the CKP sensor protrudes through an
aperture in the engine block rear flange, adjacent to
the outer circumference of the flywheel. A 60-tooth
reluctor ring is included on the flywheel which
provides the reference signal to the crankshaft
position sensor.
40
DESCRIPTION AND OPERATION
The reluctor ring teeth are spaced at 6° intervals and
are 3° wide. Two of the reluctor ring teeth are
removed, to provide a reference mark which indicates
when the crankshaft is at 60°BTDC for number 1
cylinder. The remaining 58 teeth cause an AC voltage
to be induced in the sensor pick-up, with the
amplitude of the signal increasing with rising engine
speed. The voltage generated is an analogue signal
capable of peak amplitude voltages of up to 300V.
The distance of the tip from the top of the reluctor ring
teeth is important as the amplitude of the detected
signal will be reduced in proportion to an increase in
the gap between the sensor tip and the top of the
reluctor ring teeth. If the air gap becomes too wide,
the CKP signal could become too weak and possible
misfires could occur. Spacers are included in the CKP
sensor kit which are used to ensure the correct gap
between the sensor tip and reluctor ring teeth.
The ECM uses the falling edge of the signal waveform
as its reference for each reluctor ring tooth.
Consequently, if the input signal wire and reference
ground wire are inadvertently reversed, the ECM will
react by providing a 3° advance in ignition timing.
LAND ROVER V8
If the crankshaft sensor fails, the engine will stop and
fail to restart. There is no back-up strategy or limp
home facility programmed into the ECM. If a fault
occurs whilst the engine is running, the engine will
stall and a fault code will be stored in ECM memory. If
the fault develops while the engine is not running, the
engine may not be capable of starting and no fault
code will be available. In this case, the MIL light will
still be illuminated.
In the event of a CKP sensor signal failure, the
following symptoms may be observed:
• Engine cranks but fails to start
Whenever a new CKP sensor is fitted or the flywheel
is removed, the adaptive values have to be reset
using Testbook.
Should a malfunction of the component occur, the
following fault codes may be evident and can be
retrieved by Testbook:
• P0335 - (reference mark is outside search
window with engine speed above 500 rev/min for
more than 2 revolutions.
• P0336 - (incorrect number of teeth detected ± 1
tooth between reference marks with engine
speed above 500 rev/min.
• MIL remains on at all times
• Engine misfires (CKP incorrectly fitted)
• Engine runs roughly or stalls (CKP incorrectly
fitted)
• Tachometer fails to work
In addition to crankshaft position, the ECM also uses
the CKP sensor signal to determine engine speed.
The ECM shares the engine speed information with
the electronic automatic transmission (EAT) ECU by
transmitting the data via the CAN link. Engine speed
output is also provided to the instrument pack
(tachometer), for which the output signal is scaled
down to 4 pulses per crankshaft revolution.
• Flywheel adaption reset -- ferrous contamination
Possible causes of CKP sensor failure include the
following:
• CKP sensor not fitted correctly (or assembly
loose)
The ECM also has a quick start facility, where the
position of the crankshaft and camshaft are
memorised when the engine is stopped. This stored
information is used to facilitate immediate sequential
fuelling during cranking.
• Incorrect length spacers fitted
• Sensor/wiring open or short circuit
• Sensor bent or damaged by reluctor ring
• Water ingress at sensor connector
• ECM unable to detect the software reference
point.
• Ferrous contamination of crank sensor
pin/reluctor.
DESCRIPTION AND OPERATION
41
19
FUEL SYSTEM
Camshaft Position (CMP) sensor - (from 99MY)
NEW RANGE ROVER
The CMP sensor uses the Hall effect to act as a
magnetic switch for switching battery voltage on or off
depending on the position of the camshaft gear wheel
in relationship to the sensor. This results in a square
wave input between 0 and 12V at the ECM input pin.
Symptoms of a CMP sensor failure include the
following:
• Ignition timing reverts to default values from
ECM memory with loss of cylinder correction.
• Loss of active knock control and diagnostics.
The CMP sensor is located at the front of the engine
block, above and behind the crankshaft pulley. The
sensor is clamped into position by means of a single
bolt. An ’O’ring is used to seal the interface between
the sensor and the aperture in the engine front cover.
• Loss of cylinder identification for misfire
diagnostics.
The sensor has three wires which terminate in a
multiplug secured to a bracket on the left of the
crankshaft pulley. A short link lead is used to connect
the sensor to the engine harness. The wires to the
sensor have the following functions:
• Fuel injection could be 360°out of phase at
engine restart.
• Power supply from engine compartment fusebox
• Camshaft input signal to ECM
• Screen to chassis ground connection
The CMP sensor is a Hall effect sensor which
produces four pulses for every two engine revolutions.
The sensing element is positioned less than 2mm
from the side of the camshaft gear wheel. The
camshaft gear wheel has four slots machined at
90°intervals which allows the identification of four
cylinder positions every camshaft revolution. Cylinder
recognition is used to enable sequential fuel injection
and knock control and is also used for diagnostic
purposes. The slots in the camshaft gear wheel are
shaped to provide unequal timing pulses for
determining TDC on No.1 cylinder. The camshaft and
crankshaft drives must also be correctly aligned, since
the ECM uses the crankshaft "missing teeth" marker
to determine crankshaft and camshaft position and
provide a reference mark which is 60°BTDC on No.1
cylinder.
42
DESCRIPTION AND OPERATION
• Loss of quick synchronisation of crankshaft and
camshaft for cranking/start up.
• Front HO2S sensor ageing period diagnostic
could become disabled (NAS only).
The cause of CMP sensor failure may be attributable
to one of the following conditions:
• Sensor open circuit.
• Sensor signal line short circuit to vehicle battery
supply.
• Sensor signal line or voltage supply line short
circuit to vehicle ground.
• Incorrect fitting of the sensor.
• Excessive camshaft gear wheel tolerance.
• Excessive camshaft endfloat.
• Camshaft and crankshaft misalignment.
• Speed signal correlation with CKP sensor signal.
• Cam wheel magnetised / residual magnetism.
LAND ROVER V8
Should a malfunction of the component occur the
following fault codes may be evident and can be
retrieved by Testbook:
Mass Air Flow (MAF) and Intake Air Temperature
(IAT) sensor - (from 99MY)
• P0340 - (Signal open & short circuit to vehicle
supply or ground).
The fault condition has to be detected for more than
100 cam pulses (25 revolutions) when the engine
speed is greater than 500 rev/min.
NOTE: It is physically possible to
interchange the camshaft gear wheel fitted
to pre-99MY and post-99MY vehicles.
However, because the GEMS and Motronic
systems are incompatible, an incorrect camshaft
signal will be received by the ECM and a P0340
fault code will result.
The MAF/IAT sensor is located at the RHS of the
engine compartment, in the air intake duct between
the air filter housing and the inlet manifold. The
complete assembly forms part of the air intake tube,
but the sensor itself is attached by two torx screws
and can be removed from the intake tube if
necessary.
The upper section of the intake tube containing the
MAF/IAT sensor is embossed with an arrow indicating
the direction of air flow, always ensure the unit is fitted
in the correct orientation.
CAUTION: Take care handling the sensor
unit, it should not be dropped or roughly
handled, ensure that the unit remains free
of contamination.
The sensor has a five pin connector which connects to
the ECM via the engine harness. The connector has
silver plated terminals for low current signals and
corrosion protection. The harness is clipped to prevent
vibration of the terminals.
MAF SENSOR
The Mass Air Flow sensor utilises a "hot film" element
contained in the air intake tube to monitor the mass
flow of the air stream being drawn into the engine.
The MAF sensor contains two sensing elements, one
element is controlled at ambient temperature (e.g.
25°C (77°F), while the other is heated to 200°C
(360°F) above the ambient temperature (e.g. 225°C
(437°F)).
DESCRIPTION AND OPERATION
43
19
FUEL SYSTEM
When the intake air passes the heated element, it
cools it down, so lowering the resistance of the hot
film element. In order to maintain the same
temperature, the circuit to the heated element has to
supply more current. The change in current causes a
corresponding change in potential difference to be
detected in the monitoring circuit. This change is
supplied to the ECM as a voltage between 0 and 5V,
where it is processed by the ECM’s internal mapping
to interpret the data as a measure of the mass of air
flow.
NEW RANGE ROVER
A MAF sensor failure is likely to occur for the following
reasons:
• Sensor open circuit of voltage supply, signal or
ground lines.
• Short circuit of signal line to vehicle supply or
ground.
• Contaminated / damaged sensor element.
• Air leak after the MAF sensor.
The measured air mass flow is used by the ECM to
determine the fuel quantity to be injected in order to
maintain the stoichiometric air:fuel mixture for
optimum engine performance and low emissions.
The MAF sensor receives a power supply via the
engine compartment fusebox, and a 5V reference
signal from the ECM. The MAF sensor and the IAT
sensor share a common ground connection and each
provide a separate signal input to the ECM.
CAUTION: Do not apply 12 V directly to the
5 V supply terminal, this will destroy the
internal circuitry. The connector terminals
are silver plated - avoid probing with multimeter
test leads.
If the MAF sensor fails, the ECM implements a
backup strategy which is based on throttle angle, air
temperature and engine speed. A MAF sensor failure
may result in the following symptoms being
experienced:
• The engine rpm may relapse slightly during
driving and then recover.
• Difficulty in starting and/or frequent stalling of
engine.
• Poor throttle response
• Degraded engine performance.
• Emissions control and idle speed control
inoperative.
• MAF sensor signal offset.
44
DESCRIPTION AND OPERATION
• Inlet air restriction.
• Poor connection or resistance in wiring harness
causing signal offset.
If the MAF sensor should fail, the following fault codes
will be generated by the ECM diagnostics, which can
be retrieved by Testbook:
• P0102 - (MAF signal less than the speed
dependent minimum threshold).
• P0103 - (MAF signal greater than the speed
dependent maximum threshold).
Intake-air density varies with temperature, the ECM
needs to be aware of these changes so that corrective
calculations can be incorporated into the ECM’s
fuelling and ignition timing strategies. The intake air
temperature value is also used by the ECM as a
reference when implementing compensation for an
ECT failure.
LAND ROVER V8
IAT SENSOR
Throttle Position (TP) sensor - (from 99MY)
The intake air temperature sensor utilises a thermistor
with a negative temperature co-efficient (as
temperature rises, thermistor resistance decreases).
The change in resistance causes a change in input
voltage at the ECM. The ECM converts the voltage
value it receives to provide an indication of the
temperature of the inlet air.
If the IAT sensor fails, the ECM substitutes a default
value for air temperature of 45°C (113°F). An IAT
sensor failure may result in the following symptoms
being experienced:
• Catalyst monitoring affected due to exhaust
temperature model.
• Warm-up ignition angle affected.
The TP sensor is located on the rear of the throttle
body assembly in the engine compartment and fixed
to its mounting studs by two screws.
• ISC speed adaption disabled
• ISC actuator blocked test disabled
• Fuelling adaptions disabled.
• Condenser fan hot restart inhibited
An IAT sensor failure is likely to occur for the following
reasons:
• Sensor open circuit.
• Sensor signal line short circuit to vehicle 12V
supply or ground.
• Damaged sensor element
• Bad connection or increased resistance in wiring
harness.
If the IAT sensor should fail, the following fault codes
will be generated by the ECM diagnostics, which can
be retrieved by Testbook:
• P0112 - (air temperature signal is less than the
minimum threshold - after a sufficient time (more
than three minutes) for exhaust warm-up has
been allowed).
The TP sensor is a potentiometer having a resistance
track that is connected to a stabilized 5V supply at
one end of its track and ground at the other end of the
track. The potentiometer wiper arm is connected to
the throttle plate assembly and provides a signal to
the ECM which is an analogue voltage between 0.3V
(closed throttle) and 4.5V (wide open throttle),
corresponding to the throttle valve angle. The TP
sensor connector terminals are gold plated for good
conductivity and corrosion resistance; care should be
exercised if it is necessary to probe the connector and
sensor terminals.
The TP sensor enables the ECM to determine the
throttle valve’s position and angular velocity. The ECM
uses the data from the throttle valve position for
determining intake-air volume, which it uses for
calculating the necessary fuel injection duration under
various operating conditions. The data from the
throttle valve’s angular velocity is used mainly for
acceleration/deceleration compensation. The ECM
also uses closed throttle position for idle speed control
in conjunction with road speed.
The TP sensor also supplies the ECM with information
to enable the overrun fuel shut off strategy to be
implemented. When the ECM receives closed throttle
information from the TP sensor, it closes the injectors
for the duration of the closed throttle time.
• P0113 - (air temperature signal greater than the
maximum threshold).
DESCRIPTION AND OPERATION
45
19
FUEL SYSTEM
A software strategy within the ECM enables the
closed throttle position to be learnt, so that the sensor
can be fitted without the need for adjustment.
NEW RANGE ROVER
Engine Coolant Temperature (ECT) sensor - (from
99MY)
The throttle position signal is also supplied to the EAT
ECU from the ECM using the CAN communication
link. The EAT ECU uses the throttle position data to
determine the correct point for gear shifts and
acceleration kickdown.
If the TP sensor signal fails, the ECM uses a default
value derived from engine load and speed. A TP
sensor failure may result in the following symptoms
being experienced:
• Poor throttle response and degraded engine
performance
• Emission control failure.
• Closed loop idle speed control inoperative.
• Automatic gearbox kickdown inoperative.
• Incorrect altitude adaption
• MIL illuminated (NAS only)
A TP sensor failure is likely to occur for the following
reasons:
• Sensor open circuit
• Short circuit of signal line to vehicle supply, 5V
supply or ground.
• Bad connection or increased resistance in wiring
harness causing signal offset.
• Blocked air filter (load monitoring, ratio of the TP
sensor to air flow).
• Restricted air inlet (load monitoring, ratio of the
TP sensor to air flow).
If the TP sensor should fail, the following fault codes
will be generated by the ECM diagnostics, which can
be retrieved by Testbook:
• P0101 - (load monitoring, the ratio of throttle
position to air flow).
• P0122 - (signal less than the minimum
threshold).
• P0123 - (signal greater than the maximum
threshold).
46
DESCRIPTION AND OPERATION
The ECT sensor is located at the top front of the
engine, adjacent to the coolant outlet pipe. The sensor
screws into a thread in the inlet manifold and
incorporates a sealing ring between the faces of the
sensor and manifold.
The ECT sensor multiplug has four wires; two are the
signal and ground connections used by the ECM, the
other two are used by the body control module
(BeCM) for control of the temperature warning lamp
operation on the instrument pack.
The sensor contains two thermistors with negative
temperature co-efficients; as temperature increases,
the thermistor’s resistance decreases. The ECM
receives a corresponding analogue input voltage
between 0 and 5V.
NOTE: The temperature / resistance
characteristics of the two thermistors
differ, and so it is important to maintain
the correct pin-outs.
The ECM uses the information received from the ECT
sensor to make adjustments to the engine operating
conditions. The ECM ensures a richer air:fuel mixture
is available at lower block temperatures for good
quality starts and smooth running. The mixture is then
made leaner as the engine temperature rises to
maintain low emissions and good performance.
For NAS vehicles with secondary air injection, the
signal from the ECT sensor is monitored at engine
start, to determine whether the conditions are cold
enough to warrant secondary air injection to be
employed. The ECT sensor is then monitored to
switch off the secondary air injection when the
required engine coolant temperature has been
attained.
LAND ROVER V8
If the sensor fails, the ECM uses a substitute software
routine that changes default value during warm up,
based on the signal from the inlet air temperature
sensor. When the software model reaches a coolant
temperature of 60°C (140°F) the ECM implements a
fixed default value of 85°C (185°F). The ECM coolant
model also forms part of the diagnostics that is
performed for detecting a temperature sensor fault, as
well as open and short circuit tests.
The ECT sensor can fail in the following ways, or
supply an incorrect signal:
• Sensor open circuit.
• Short circuit to vehicle supply.
• Short circuit to earth.
• Incorrect mechanical fitting.
Temperature
Voltage
-50°C
5V
-20°C
4.8V
10°C
4.2V
40°C
2.8V
70°C
1.4V
100°C
0.6V
130°C
0.2V
• Signal fixed above 40°C (140°F) will not be
detected.
• Signal fixed below 40°C (140°F) not detected.
Should a malfunction of the component occur, the
following fault codes may be evident and can be
retrieved by Testbook:
• P0116 - (Signal differs too much from
temperature model for longer than 2.54s)
• P0117 - (Open circuit or short circuit to battery
supply)
• P0118 - (Short circuit to ground)
NOTE: All voltages listed are approximate.
A coolant temperature circuit failure may result in the
following symptoms:
• Poor cold and warm/hot starting and driveability.
• Instrument pack temperature warning lamp will
illuminate.
• MIL will be illuminated.
• Temperature gauge reads excessively hot or
cold.
• Cooling fan will not run
• SAI pump will operate at engine start up even
when engine is hot (NAS with secondary air
injection system only).
DESCRIPTION AND OPERATION
47
19
FUEL SYSTEM
Knock Sensors (KS) - from 99MY
NEW RANGE ROVER
The ignition system is calibrated to run on 95 RON
Premium fuel for optimum fuel economy and
performance characteristics. The system can also
function satisfactorily with 91 RON Regular fuel. If the
vehicle is refuelled with a lower grade of fuel some
audible detonation may be heard until the system
adaptions are complete for the new fuel grade.
If a knock sensor should fail, the following symptoms
may be observed:
• Possible rough running
• Reduction in engine performance
A knock sensor failure is likely to occur for the
following reasons:
• Sensor open circuit
The ECM utilises active knock control, which serves to
prevent engine damage through pre-ignition or
detonation. Knock control is effective under all
operating conditions, enabling the engine to operate
without additional safety margins.
Two knock sensors are used, one mounted each side
of the cylinder block between the two centre cylinders
of each bank. Each sensor has two wires; a signal
wire providing input to the ECM and a ground
(screen). Each of the sensors monitor the ’knock’ from
four cylinders (Cylinder No’s: 1, 3, 5 & 7 and Cylinder
No’s: 2, 4, 6 & 8).
CAUTION: The connector and sensor
terminals are gold plated to provide good
conductivity and resistance to corrosion
and high temperatures. Be careful not to damage
terminals if probing with test equipment.
The knock sensors consist of piezo-ceramic crystals
that oscillate to create a voltage signal. During
pre-ignition, the frequency of crystal oscillation
increases which alters the signal output to the ECM.
The signal is processed by comparing it to signal
profiles contained in memory which indicate a
pre-ignition condition. If pre-ignition conditions are
evident, the ECM retards the ignition on that cylinder
for a number of cycles. The ignition timing gradually
reverts to its original setting.
48
DESCRIPTION AND OPERATION
• Short circuit to vehicle supply or ground
• Faulty component
• Loose sensor - incorrectly torqued
If knock control is disabled, a default "safe ignition
map" is used.
If a knock sensor should fail, the following fault codes
will be generated by the ECM diagnostics, which can
be retrieved by Testbook:
• P0327 - (LH bank signal less than the threshold
value determined from the ECM model above
2200 rpm)
• P0328 - (LH bank signal greater than the
threshold value determined from the ECM model
above 2200 rpm)
• P0332 - (RH bank signal less than the threshold
value determined from the ECM model above
2200 rpm)
• P0333 - (RH bank signal greater than the
threshold value determined from the ECM model
above 2200 rpm)
Noise induced on the battery supply line could be
misinterpreted as a knock signal and cause a
maximum knock fault. A maximum fault could be
caused by a short circuit to the battery supply or in the
case of extreme mechanical engine noise / piston
slap. A minimum fault is usually due to an open circuit.
LAND ROVER V8
Ignition coils
The positive supply to the coils is fed via a common
fuse and ignition relay located in the engine
compartment fusebox. Each coil supply feed has an
RFI suppression capacitor fitted adjacent to the coil
mounting bracket. The ignition primary wires are
screened to suppress the emission of radio frequency
interference, with the screens being grounded at a
connection on the ECM.
WARNING: The ignition coils operate at
very high voltages, do not attempt repair
operations and procedures on the ignition
high tension / secondary system when the engine
is running.
The ECM calculates the dwell timing from battery
voltage and engine speed data to ensure sufficient
secondary (spark) energy is always available without
excessive primary current flow, thus avoiding
overheating or damage to the ignition coils.
The spark timing for each individual cylinder is
calculated by the ECM using an internal memory map
under consideration of the following inputs:
The electronic ignition system is fitted with two quad
coils which are directly driven by the ECM. The
ignition coils are mounted on a bracket fitted to the
rear of the engine. The circuit to each coil is
completed by switching within the ECM, allowing each
coil to charge. When the ECM determines the correct
ignition point, it switches off current supply to the coil
which in turn causes the magnetic field around the
coil’s primary winding to collapse, inducing ht voltage
in the secondary winding and in the iron core of the
coil. High tension voltage, of different polarities, is
produced at either end of the coil’s core and is
transmitted to two cylinders simultaneously, one on
compression stroke, the other on exhaust stroke. This
is called the wasted spark principle.
Note that coil 1 feeds cylinders 1 and 6, coil 2 feeds
cylinders 5 and 8, coil 3 feeds cylinders 4 and 7, and
coil 4 feeds cylinders 2 and 3. The resistance of the
spark plug in the compression cylinder is higher than
that in the exhaust cylinder and hence more spark
energy is dissipated in the compression cylinder. Coil
failure will result in a lack of ignition, resulting in a
misfire in the related cylinders. The fault is indicated
by illumination of the malfunction indicator light (MIL)
on North American specification vehicles.
• Engine speed
• Engine load
• Engine temperature
• Knock control
• Automatic gearbox shift control
• Idle speed control
The nominal value for a warm engine at idle is
12°BTDC
CAUTION: Avoid running the engine if
there is a possibility of the secondary (ht)
becoming open circuit. This condition
could damage the ignition power stages and / or
the ignition coils through excessive energy being
reflected back into the primary circuit.
NOTE: Testbook is not able to perform
diagnostics to the primary power stage
coils. Ignition related faults are monitored
indirectly via the misfire detection system and its
fault codes (NAS vehicles only).
DESCRIPTION AND OPERATION
49
19
FUEL SYSTEM
Resistance measurements of the primary and
secondary sides of the ignition coils can be performed
using a suitable multimeter. Default values are:
NEW RANGE ROVER
Fuel injectors - from 99MY
• Nominal primary coil resistance (up to 99MY) =
0.8 ohms
• Nominal primary coil resistance (from 99MY) =
0.5 ohms ± 0.05 ohms at 20°C (68°F)
• Nominal secondary coil resistance = 13.3
k-ohms ± 1.3 k-ohms at 20°C (68°F)
If an ignition coil should fail, the following symptoms
may be observed:
• Engine will not start - loss of spark
• Engine misfire on specific cylinders
An ignition coil failure is likely to occur for the following
reasons:
• Connector or harness fault
• Coil open circuit
• Short circuit to vehicle battery supply or ground
• Faulty component
The fuel injectors are located beneath the air inlet
manifold. They utilise an electrical solenoid which lifts
an injector needle off its seat to allow fuel injection to
take place. The fuel injectors provide excellent fuel
atomisation in the lower portion of the inlet manifold,
the air:fuel mixture is then drawn into the cylinders to
provide optimum combustion characteristics and
excellent driveability.
A fuel pressure test point is provided by means of a
Schrader valve positioned between the rear of the
engine and the bulkhead, above the coil packs.
There are eight fuel injectors, one per cylinder which
the ECM operates sequentially. All the injectors are
fed from a common fuel rail as part of the returnless
fuel system. Fuel pressure is maintained at a constant
3.5 bar (52 lbf.in2) by a regulator that is integral with
the fuel pump.
CAUTION: The injectors are extremely
sensitive, they must not be dropped or
contaminated.
CAUTION: When assembling the injector
to the fuel rail, only use clean engine oil to
aid assembly. DO NOT use petroleum jelly
or other forms of grease, as this will contaminate
the injector.
The injectors can be checked using a multimeter to
test the resistance values:
• Injector resistance at 20°C = 14.5 ohms ± 0.7
ohms
50
DESCRIPTION AND OPERATION
LAND ROVER V8
If an injector should fail, the following symptoms may
be observed:
Injector 4
• P0204 - Open circuit
• Rough running
• P0270 - Short circuit to ground
• Difficult starting
• P0271 - Short circuit to battery supply
• Engine misfire
Injector 5
• Possible catalyst damage
• P0205 - Open circuit
• High emissions
• P0273 - Short circuit to ground
• Fuelling and idle speed control adaptations
disabled
A fuel injector failure is likely to occur for the following
reasons:
• P0274 - Short circuit to battery supply
Injector 6
• P0206 - Open circuit
• Actuator open circuit
• P0276 - Short circuit to ground
• Short circuit to vehicle 12V supply or ground
• P0277 - Short circuit to battery supply
• Blocked or restricted injector
Injector 7
• Low fuel pressure
• P0207 - Open circuit
If a fuel injector should fail, the following fault codes
will be generated by the ECM diagnostics, which can
be retrieved by Testbook:
• P0279 - Short circuit to ground
• P0280 - Short circuit to battery supply
Injector 1
Injector 8
• P0201 - Open circuit
• P0208 - Open circuit
• P0261 - Short circuit to ground
• P0282 - Short circuit to ground
• P0262 - Short circuit to battery supply
• P0283 - Short circuit to battery supply
Injector 2
All injectors
• P0202 - Open circuit
• P0170 - High leak rate detection
• P0264 - Short circuit to ground
• P0265 - Short circuit to battery supply
Injector 3
• P0300 to P0308 - Misfire detected excess
emissions - blocked or restricted injector
• P0300 to P0308 - Misfire detected catalyst
damage - blocked or restricted injector
• P0203 - Open circuit
• P0267 - Short circuit to ground
Specific P-code number depends on which cylinder(s)
is experiencing the fault.
• P0268 - Short circuit to battery supply
DESCRIPTION AND OPERATION
51
19
FUEL SYSTEM
Idle Air Control Valve (IACV) - from 99MY
NEW RANGE ROVER
During cold start conditions, the idle speed is held at
1200 rpm in neutral for 20 seconds. Ignition timing is
retarded as a catalyst heating strategy.
If the IACV should fail, the following symptoms may
be observed:
• Either low or high idle speed
• Engine stalls
• Difficult starting
• Raised idle speed in default condition.
An IACV failure is likely to occur for the following
reasons:
The idle air control valve is positioned at the top rear
of the engine, on the side of the air inlet pipe. The unit
is clamped to the inlet manifold by two bolts passing
through ’P’ clips.
A grey three-pin connector is provided at the back of
the unit. One wire supplies the voltage feed from the
engine compartment fusebox, while the other two
wires carry the valve positioning control signals.
The IACV is used to make adjustments to optimise the
engine idle speed under all operating conditions.
Engine load at idle will vary in reaction to a
combination of conditions and influences such as
engine friction, water pump , air conditioning, altitude
etc. The IACV utilises closed loop control to
compensate for the changing conditions by regulating
the air flow into the engine.
• Rotary valve seized
• Faulty actuator
• Connector or harness fault
• Intake system air leak
• Actuator port or hoses blocked, restricted or
crimped
If the IACV should fail, the following fault codes will be
generated by the ECM diagnostics, which can be
retrieved by Testbook:
• P0505 - Blocked IACV valve - rpm error high or
low
The IACV utilises two electromagnetic coils which use
opposing PWM signals to control the positioning of a
rotary valve. The rotary valve position determines how
much air is allowed to flow through the bypass route.
• P1510 - Short circuit to battery supply - opening
winding
CAUTION: Do not try to forcibly set the
valve position, the actuator cannot be
serviced. In the event of failure the IACV
must be replaced as a unit.
• P1514 - Open circuit - opening winding
If one of the electrical circuits supplying the PWM
signals fails, the ECM switches off the other circuit to
prevent the valve from biasing towards a maximum or
minimum setting. Under these conditions, a default
position for the valve is provided by a permanent
magnet, which sets the valve position to maintain the
idle speed at a fixed value of approximately 1200 rpm
with no load applied.
• P1552 - Short circuit to ground - closing winding
52
DESCRIPTION AND OPERATION
• P1513 - Short circuit to ground - opening winding
• P1553 - Short circuit to battery supply - closing
windings
• P1551 - Open circuit - closing winding
LAND ROVER V8
Heated Oxygen Sensors (HO2S) - from 99MY
1.
2.
3.
4.
RH catalytic converter
Heated oxygen sensors - post-catalytic converters (2 off - NAS only)
LH catalytic converter
Heated oxygen sensors - pre-catalytic converters (2 off)
The number of heated oxygen (HO2S) sensors fitted
to a vehicle is dependent on the particular market
requirements:
• 4 - HO2S sensors (NAS vehicles)
• 2 - HO2S (UK, European, Australia & Japan
vehicles)
• 0 - HO2S (Gulf & ROW vehicles)
The HO2S sensors monitor the level of oxygen in the
exhaust gases and the resulting data is used by the
ECM to control the air:fuel mixture to provide the most
efficient mix under all operating conditions. By
positioning a sensor in the stream of exhaust gases
from each bank of cylinders of the V8 engine enables
the ECM to control the fuelling on each bank
independently. This allows the ECM to provide more
accurate control of the air:fuel ratio and monitor
catalytic converter efficiency.
NAS vehicles utilise four HO2S sensors, one upstream
of each catalyst and one downstream of each catalyst.
This arrangement is used to monitor catalytic
converter efficiency and so determine when a catalyst
is no longer working effectively. Obtaining catalytic
converter efficiency data is a mandatory requirement
of the ECM OBD strategy. The downstream sensors
also provide for long term fuelling adaptions.
The basic closed control loop comprises the engine
(controlled system), the heated oxygen sensors
(measuring elements) and the engine management
ECM (control) and the injectors and ignition
(actuators). Although other factors also influence the
calculations of the ECM, such as air flow, air intake
temperature and throttle position. Additionally, special
driving conditions are compensated for such as
starting, acceleration and full load.
From cold start the ECM runs an open loop strategy,
which is kept in place until the sensor’s working
temperature has been reached.
Two upstream sensors are utilised in markets where
closed loop fuelling is the only mandatory
requirement. For markets where closed loop fuelling
control is not mandatory, HO2S sensors are not
included.
DESCRIPTION AND OPERATION
53
19
FUEL SYSTEM
The heated oxygen sensors age with mileage, which
will cause an increase in their response time for
switching from rich to lean and lean to rich. The
increase in response time influences the closed loop
control and leads to progressively increased
emissions. If the response rate is diagnosed to be
exceeding a preset threshold, an error code will be
stored in the ECM and the MIL warning lamp will be
illuminated (NAS only).
The heated oxygen sensor is protected by an outer
tube with a restricted flow opening to prevent the
sensor’s ceramics from being cooled by low
temperature exhaust gases at start up. The
pre-catalytic sensors are identified by three slots in
the protective tube, whereas the post-catalytic
sensors have four square indentations and a hole in
the end of the protective tube (NAS only).
NOTE: The maximum working temperature
of the tip of the HO2S sensor is 930 °C
(1706°F); temperatures higher than this
will damage the sensor.
The heater elements are controlled by a PWM signal
from the ECM. The heater elements are operated
immediately following engine start and also during low
load conditions when the temperature of the exhaust
gases is insufficient to maintain the required sensor
temperatures. The heater element warms the sensor’s
ceramic layer from the inside so that the sensor is hot
enough for operation. After start up, the sensors are
ready for closed loop control within about 20 to 30
seconds.
NEW RANGE ROVER
It is important not to confuse the sensor signal pins;
the signal pins are gold plated, whilst the heater
supply pins are tinned, mixing them up will cause
contamination and effect system performance with
time.
NOTE: Sensor voltage is most easily
monitored using "Testbook".
If a heated oxygen sensor should fail, the following
symptoms may be observed:
• Default to open loop fuelling on the catalyst bank
with the failed sensor.
• If sensor get crossed, the engine will run
normally after the initial start, but then become
progressively unstable. One bank will clamp at
the maximum rich level, and the other bank will
clamp at maximum lean. The system will then
revert to open loop fuelling.
• High CO reading
• Excess emissions
• Strong smell of hydrogen sulphide (H2S) until the
ECM defaults to open loop fuelling
• MIL lamp illuminated (NAS only)
A heated oxygen sensor failure is likely to occur for
the following reasons:
• Damaged or incorrectly fitted sensor
If the heater element fails, the ECM will not allow
closed loop fuelling to be implemented until the sensor
has achieved the required temperature. A diagnostic
routine is utilised to measure both sensor heater
current and the heater supply voltage, so its
resistance can be calculated. The function is active
once per drive cycle, as long as the heater has been
switched on for a pre-defined period and the current
has stabilised. The PWM duty cycle is carefully
controlled to prevent thermal shock to cold sensors.
The pre-catalytic and post-catalytic converters are not
interchangeable, and although it is possible to mount
them in transposed positions, their harness
connections are of different gender and colour:
• Upstream sensors have orange connectors.
• Downstream sensors have grey connectors.
54
DESCRIPTION AND OPERATION
• Sensor open circuit or disconnected
• Short circuit to vehicle supply or ground
• Stoichiometric ratio outside the correct operating
band
• Contamination from leaded fuel or other sources
• Change in sensor characteristics - Chemical
Shift Down (CSD)
• Sensors from LH and RH banks crossed
• Air leak into exhaust system (cracked pipe / weld
or loose fixings)
LAND ROVER V8
Diagnosis of electrical faults is continually monitored
by the ECM in both the upstream sensors and
downstream sensors (NAS only). The sensor signal is
checked against stored minimum and maximum
threshold values equating to short and open circuit
conditions.
If an HO2S sensor should fail, the following fault codes
will be generated by the ECM diagnostics, which can
be retrieved by Testbook:
• P1129 - Front heated oxygen sensors
transposed
Upstream sensor LH bank - electrical (NAS only)
• P0130 - Stoichiometric ratio outside operating
band
Upstream sensors aged (NAS only)
• P0133 - Upstream sensor aged - Period time too
short LH bank
• P0133 - Upstream sensor aged - Period time too
long LH bank
• P0153 - Upstream sensor aged - Period time too
short RH bank
• P0153 - Upstream sensor aged - Period time too
long RH bank
• P1170 - Upstream sensor aged - ATV adaption
too lean LH bank
• P1170 - Upstream sensor aged - ATV adaption
too rich LH bank
• P0132 - Short circuit to battery supply
• P0134 - Open circuit
Downstream sensor LH bank - electrical
• P0136 - Stoichiometric ratio outside operating
band
• P0137 - Short circuit to battery supply
• P0138 - Short circuit to ground or chemical shift
down
• P1173 - Upstream sensor aged - ATV adaption
too lean RH bank
• P1173 - Upstream sensor aged - ATV adaption
too rich RH bank
Sensor Heater faults
• P0135 - Upstream heater LH bank - Short circuit
(NAS only)
• P0135 - Upstream heater LH bank - Open circuit
(NAS only)
• P0140 - Open circuit
Upstream sensor RH bank - electrical (NAS only)
• P0141 - Downstream heater LH bank - Short
circuit
• P0150 - Stoichiometric ratio outside operating
band
• P0141 - Downstream heater LH bank - Open
circuit
• P0152 - Short circuit to battery supply
• P0155 - Upstream heater RH bank - Short circuit
(NAS only)
• P0154 - Open circuit
Downstream sensor RH bank - electrical
• P0155 - Upstream heater RH bank - Open circuit
(NAS only)
• P0156 - Stoichiometric ratio outside operating
band
• P0161 - Downstream heater LH bank - Short
circuit
• P0157 - Short circuit to ground
• P0161 - Downstream heater LH bank - Open
circuit
• P0158 - Short circuit to battery voltage
• P0160 - Open circuit
DESCRIPTION AND OPERATION
55
19
FUEL SYSTEM
NEW RANGE ROVER
A diagnostic routine is used to measure both sensor
heater current and the heater supply voltage so its
resistance can be calculated. The function is active
once per drive cycle as long as the heater has been
switched on for a pre-defined period and the current
has stabilised. The PWM duty cycle is carefully
controlled to prevent thermal shock to cold sensors.
Fuel pump relay - from 99MY
On NAS vehicles, the catalysts are monitored to
determine emission pollutant conversion efficiency;
the following fault codes will be generated by the ECM
diagnostics, which can be retrieved by Testbook:
The fuel supplied to the injectors from the in-tank fuel
pump is controlled by the ECM via the fuel pump
relay. During engine cranking, the fuel pump relay is
activated by the ECM allowing the fuel system to be
pressurised to 3.5 bar (52 lbf.in2). The pump relay is
then deactivated until engine start has been achieved.
• P0420 - Catalyst efficiency deteriorated LH bank
• P0430 - Catalyst efficiency deteriorated RH bank
See EMISSION CONTROL, Description and
operation.
The fuel pump relay is fitted in the engine
compartment fusebox which is situated at the front
right hand side of the engine compartment. The relay
is a four-pin normally open type, encapsulated in a
yellow plastic housing.
Battery voltage is supplied via the engine
compartment fusebox and relay activation is achieved
by ground path switching through the ECM.
If the fuel pump relay should fail, the following
symptoms may be observed:
• Engine stalls or will not start
• No fuel pressure at the fuel injectors
A fuel pump relay failure is likely to occur for the
following reasons:
• Relay drive open circuit
• Short circuit to vehicle supply or ground
• Component failure
If the fuel pump relay should fail, the following fault
codes will be generated by the ECM diagnostics,
which can be retrieved by Testbook:
• P1230 - Fuel pump relay open circuit - not the
fuel pump itself
• P1231 - Fuel pump relay short circuit to battery
supply - not the fuel pump itself
• P1232 - Fuel pump relay short circuit to ground not the fuel pump itself
56
DESCRIPTION AND OPERATION
LAND ROVER V8
Advanced Evaporative Emissions System - from
99MY (NAS only)
The Bosch Motronic 5.2.1 ECM includes control for
the evaporative emissions system components, its
purpose is to minimise the evaporative loss of fuel
vapour from the fuel system to the atmosphere. This
is achieved by venting the system through an EVAP
canister filled with vapour absorbing charcoal. The
charcoal acts like a sponge and stores the vapour
until the canister is purged under the control of the
ECM.
Fuel vapour is stored in the activated charcoal
canister for retention when the vehicle is not
operating. When the vehicle is operating, fuel vapour
is drawn from the canister into the engine via a purge
control valve. The vapour is then delivered to the
intake plenum chamber to be supplied to the engine
cylinders where it is burned in the combustion
process.
See EMISSION CONTROL, Description and
operation.
Fuel Filling
During fuel filling, the fuel vapour displaced from the
fuel tank is allowed to escape to atmosphere; valves
within the fuel filler prevent any vapour escaping
through the EVAP canister as this can adversely
effect the fuel cut-off height. Only fuel vapour
generated whilst driving is prevented from escaping to
atmosphere by absorption into the EVAP canister.
The fuel filler shuts off to leave the tank approximately
10% empty to ensure the roll over valves (ROVs) are
always above the fuel level and so vapour can escape
to the EVAP canister and the tank can breathe. The
back pressures normally generated during fuel filling
are too low to open the pressure relief valve, but
vapour pressures accumulated during driving are
higher and can open the pressure relief valve. Should
the vehicle be overturned, the ROVs shut off to
prevent any fuel spillage.
Liquid fuel must not be allowed to contaminate the
charcoal in the EVAP canister. To prevent this, the
fuel vapour separator fitted to the fuel filler neck
allows fuel to drain back into the tank. As the fuel
vapour cools, it condenses and is allowed to flow back
into the fuel tank from the vent line by way of the
two-way valve.
The EVAP canister contains charcoal pellets which
absorbs and stores the fuel vapour from the fuel tank
while the engine is not running. When the canister is
not being purged, the fuel vapour remains in the
canister and clean air exits the canister via the air inlet
port.
ECM Purge Control
The engine management ECM controls the output
signals to the purge valve and the canister vent
solenoid (CVS) valve, and receives an input from the
fuel tank pressure sensor. The system will not work
properly if there is a leakage or clogging within the
system, or if the purge valve cannot be controlled.
When the engine is running, the ECM decides when
conditions are correct for the vapour to be purged
from the canister and opens the canister purge valve.
This connects a manifold vacuum line to the canister
and fuel vapour containing the hydrocarbons is drawn
from the canister’s charcoal element to be burned in
the engine. Clean air is drawn into the canister
through the air inlet port to fill the displaced volume of
vapour.
The purge valve remains closed below preset coolant
and engine speed values to protect the engine tune
and catalytic converter performance. If the EVAP
canister was purged during cold running or at idling
speed the additional enrichment in the fuel mixture
would delay the catalytic converter light off time and
cause erratic idle. When the purge valve is opened,
fuel vapour from the EVAP canister is drawn into the
plenum chamber downside of the throttle housing, to
be delivered to the combustion chambers for burning.
Fuel Tank Venting
Fuel vapour generated from within the fuel tank as the
fuel heats up is stored in the tank until the pressure
exceeds the operating pressure of the two-way valve.
When the two-way valve opens, the fuel vapour
passes along the vent line from the fuel tank via the
fuel tank vapour separator to the evaporation inlet port
of the EVAP canister.
DESCRIPTION AND OPERATION
57
19
FUEL SYSTEM
The purge valve is opened and closed in accordance
with a PWM signal supplied from the ECM. Possible
failure modes associated with the purge valve failure
are listed below:
• Valve drive open circuit
NEW RANGE ROVER
Leak Test
The evaporative emission system used on NAS
vehicles includes a fuel pressure sensor and a
canister vent solenoid (CVS) valve. The system is
capable of detecting holes in the fuel system down to
1 mm (0.04 in.).
• Short circuit to vehicle supply or ground
The test is carried out in three parts:
• Purge valve or pipework blocked or restricted
• Purge valve stuck open
• Pipework joints leaking or disconnected.
Possible symptoms associated with purge valve or
associated pipework failure is listed below:
• Engine may stall on return to idle if purge valve
is stuck open
• Poor idling quality if the purge valve is stuck
open
• Fuelling adaptions forced excessively lean if the
EVAP canister is clear and the purge valve is
stuck open.
• Fuelling adaptions forced excessively rich if the
EVAP canister is saturated and the purge valve
is stuck open.
• Saturation of the EVAP canister if the purge
valve is stuck closed.
First the purge valve and the CVS valve closes off the
storage system and the vent pressure increases due
to the fuel vapour pressure level in the tank. If the
pressure level is greater than the acceptable limit, the
test will abort because a false leak test response will
result. In part two of the test, the purge valve is
opened (preferably with the engine idling) and the fuel
tank pressure will decrease due to purge operation. In
part three of the test, the leak measurement test is
performed. The pressure response of the tests
determines the level of the leak, and if greater than
the limit on two consecutive tests, the ECM stores the
fault in diagnostic memory and the MIL light on the
instrument pack is illuminated. The test is only carried
out at idle with the vehicle stationary. Following the
test, the system returns to normal purge operation
after the CVS valve opens. The in-tank pressure
sensor monitors the pressure build-up to determine
whether leaks are present.
Possible reasons for a test failure are listed below:
• Fuel filler not tightened or cap missing
• Sensor or actuator open circuit
To maintain driveability and effective emission control,
purging control must be closely controlled by the
ECM, as a 1% concentration of fuel vapour from the
EVAP canister in the air intake may shift the air:fuel
ratio by as much as 20%. The ECM must purge the
fuel vapour from the EVAP canister at regular
intervals as its storage capacity is limited and an
excessive build-up of fuel pressure in the system
could increase the likelihood of vapour leaks. Canister
purging is cycled with the fuelling adaption as both
cannot be active at the same time. The ECM alters
the PWM signal to the purge valve to control the rate
of purging of the canister to maintain the optimum
stoichiometric air:fuel mixture for the engine.
See EMISSION CONTROL, Description and
operation.
58
DESCRIPTION AND OPERATION
• Short circuit to vehicle supply or ground
• Either purge or CVS valve stuck open
• Either purge or CVS valve stuck closed or
blocked pipe
• Piping broken or not connected
• Loose or leaking connection
If the piping is broken forward of the purge valve or is
not connected, the engine may run rough and fuelling
adaptions will drift. The fault will not be detected by
the test, but by the engine management ECM
detecting that the fuelling adaption is suspended. The
evaluation of the leakage is dependent on the
differential pressure between the fuel tank and the
ambient atmospheric pressure. The diagnostic test is
disabled at altitudes above 2,800 metres (9,500 ft).
LAND ROVER V8
The fuel tank pressure sensor is included as part of
the OBD system. A failure of the fuel tank pressure
sensor will not be noticed by the driver, but if the ECM
detects a fault, it will be stored in the diagnostic
memory and the MIL warning lamp will be illuminated
on the instrument pack
• P0174 - Additive fuelling adaption (Max.)
exceeded lean limit - RH bank
• P0175 - Additive fuelling adaption (Min.)
exceeded lean limit - RH bank
• P0440 - Purge valve not sealing
Possible fuel tank pressure sensor failures are listed
below:
• Damaged sensor
• P0442 - Small leak within system
• P0443 - Purge valve power stage short circuit to
battery voltage
• Harness wiring or connector faulty
• P0444 - Purge valve power stage open circuit
• Open circuit
• Short circuit to battery voltage or ground
• P0445 - Purge valve power stage short circuit to
ground
• ECM fault
• P0445 - Large leak within system
Possible symptoms of a fuel tank pressure sensor
failure are listed below:
• P0446 - CVS valve / filter / pipe blocked
• P0447 - CVS valve open circuit
• Fuel tank pressure sensor poor performance
• P0448 - CVS valve short circuit to ground
• Fuel tank pressure sensor low range fault
• Fuel tank pressure sensor high range fault
Fault codes associated with the evaporative emission
control system are listed below:
• P0449 - CVS valve short circuit to battery
voltage
• P0451 - Fuel tank pressure signal stuck high
within range
• P0171 - Multiplication fuelling adaption (Max.)
exceeded lean limit - LH bank
• P0452 - Fuel tank pressure signal short circuit to
battery voltage (out of range - high)
• P0172 - Multiplication fuelling adaption (Min.)
exceeded lean limit - LH bank
• P0453 - Fuel tank pressure sensor signal short
circuit to ground or open circuit (out of range low)
• P0174 - Multiplication fuelling adaption (Max.)
exceeded lean limit - RH bank
• P0175 - Multiplication fuelling adaption (Min.)
exceeded lean limit - RH bank
• P0171 - Additive fuelling adaption (Max.)
exceeded lean limit - LH bank
• P0172 - Additive fuelling adaption (Min.)
exceeded lean limit - LH bank
DESCRIPTION AND OPERATION
59
19
FUEL SYSTEM
Secondary air injection system (NAS only from
2000MY)
Refer to EMISSION CONTROL section for description
of the secondary air injection system components.
Inertia Fuel Shut-off (IFS) Switch
The inertia switch isolates the power supply to the fuel
pump in the event of sudden deceleration, as
encountered during an accident. The inertia switch is
located in the right hand side footwell behind an
access flap. It is reset by depressing the central
plunger at the top of the switch.
NEW RANGE ROVER
High tension (ht) leads
The ht leads are routed from the ignition coils at the
back of the engine to four spark plugs on each bank of
the engine block.
An ht lead failure will result in a misfire condition on a
specific cylinder.
An ht lead failure may occur for the following reasons:
• Connector / wiring fault
• Faulty lead causing spark tracking to chassis
earth
E-box Cooling Fan control - from 99MY only
• Damage to ht lead during gearbox removal
The cooling fan is utilised to provide a cool
temperature environment for the Bosch Motronic 5.2.1
ECM in the under bonnet mounted E-box. The fan
provides cabin air into the E-box and operation is
controlled by the ECM. The ECM contains an internal
temperature sensor which it uses to determine when
cooling fan operation is necessary.
Spark plugs - from 99MY
The spark plugs are platinum tipped on both centre
and earth electrodes to provide a long maintenance
free life and exceptional cold starting performance.
CAUTION: Do not clean the spark plugs or
attempt to reset the spark plug gap.
CAUTION: If the wrong specification spark
plugs are used, the misfire detection
system is likely to malfunction and
corresponding error codes will be stored in the
ECM diagnostic memory. Only use the
recommended spark plugs.
In the event of a spark plug failure, a misfire on a
specific cylinder may be observed.
A spark plug failure may occur for the following
reasons:
• Connector or wiring fault
• Faulty plug (e.g. wrong gap, damaged
electrodes etc.)
• Incorrect spark plugs fitted
• Breakdown of high tension lead causing tracking
to chassis earth
60
DESCRIPTION AND OPERATION
Electronic Automatic Gearbox Interface - from
99MY
The ECM communicates with the EAT ECU via a
Controller Area Network (CAN). This is used for the
gearshift torque interface and as a means for
transmitting OBD information between the two control
units. The EAT ECU passes OBD data and requests
to the ECM which controls the storage of diagnostics
data and MIL activation. Unlike the GEMS ECM, the
Bosch M5.2.1 does not store gearbox faults. The MIL
activation request can be checked with Testbook.
The CAN network is a high speed serial interface
operating at 500 k-baud. The system is a differential
bus using a twisted pair. If either or both wires of the
twisted pair CAN bus is open or short circuited, a CAN
time out fault will occur and the EAT ECU defaults to
third gear.
See AUTOMATIC GEARBOX, Description and
operation.
LAND ROVER V8
Transfer Box ECU (MIL input) - from 99MY (NAS only)
The input from the transfer box ECU to the ECM indicates that there is an OBD relevant error detected within the
transfer box ECU and requests activation of the MIL. In addition, the ECM carries out an integrity check on the
signal following an "ignition ON" condition.
See TRANSFER BOX, Description and operation.
Engine Speed Output - from 99MY
The ECM supplies engine speed information to various vehicle systems (instrument pack etc.). The system uses
an output frequency of 4 pulses per engine revolution.
HeVAC system interface - from 99MY
The diagnostics for the condenser fans and A/C grant signal is disabled and so it is not possible to detect open
and short circuit conditions on these lines.
The condenser fans can be switched on by either the HeVAC ECU or the engine management ECM (to assist
engine cooling) or by the fan control logic.
See HEATING AND VENTILATION, Description and operation.
See AIR CONDITIONING, Description and operation.
Fuel used signal - from 99MY
This output is required to provide fuel consumption information to the trip computer.
Fuel level input - from 99MY
This input is required by the ECM as part of the misfire detection strategy, in order to record a "low fuel" situation
was present when misfire was detected and logged as a fault. The signal is received as an analogue signal from
the fuel tank sender unit.
Fuel Level State
Sender Resistance
Fuel Level Signal
Voltage
Full
19 ohm
1.00 V
Empty
270 ohm
3.16 V
Low Fuel Lamp
ON threshold
above 175 ohm
2.77 V
Low Fuel Lamp
OFF threshold
less than 117 ohm
2.40 V
DESCRIPTION AND OPERATION
61
LAND ROVER V8
FUEL TANK - DRAIN
Service repair no - 19.55.02
WARNING: Fuel must be drained through
the tank fill stub, with the filler neck
removed. In some circumstances, the fuel
level could be above the level of the stub. If the
fuel gauge indicates more than 75% full prior to
draining, a minimum of 10 litres of fuel must first
be removed through the fuel return line as
detailed below.
Fuel gauge indicated over 75% full:
3. Using a bowser, with a suitable hose connection
into the fuel return line, either at the fuel rail, or
at the under floor connection, forward of the fuel
tank, drain a minimum 10 litres (2.6 US Gallons)
from fuel tank.
WARNING: The fuel tank must be
completely drained before it is removed.
WARNING: Petrol/gasoline vapour is
highly flammable and in confined spaces
is also explosive and toxic. Always have a
fire extinguisher containing FOAM, CO2 GAS or
POWDER close to hand when handling or draining
fuel. See 01 Introduction.
CAUTION: Before disconnecting any part
of the fuel system, it is imperative that all
dust, dirt and debris is removed from
around components to prevent ingress of foreign
matter into the fuel system.
WARNING: Follow manufacturer’s
instructions for connection and safe use
of equipment.
NOTE: Assuming the fuel tank is FULL,
drain the following quantities:
Renew fuel pump = COMPLETE DRAIN
Fuel level at least 10 litres (2.6 US gallons) from full:
4. Remove fuel filler neck. See Repair.
5. Using a suitable length of plastic tube, inserted
through the fuel tank fill stub, drain contents of
tank into a closed container.
Renew fuel filler neck = 10 litres (2.6 US Gallons)
Renew Fuel Tank = COMPLETE DRAIN
1. Depressurise fuel system. See Repair.
2. Disconnect battery earth lead.
6. Fit filler neck. See Repair.
7. Connect battery earth lead.
ADJUSTMENT
1
19
FUEL SYSTEM
NEW RANGE ROVER
THROTTLE CABLE - up to 99MY
THROTTLE CABLE - from 99MY
Service repair no - 19.20.05
Service repair no - 19.20.05
Adjust
Adjust
NOTE: Accurate setting of this cable is
critical to correct operation of automatic
transmission.
1. Ensure throttle lever is against stop in closed
position.
1. Loosen outer cable locknuts.
2. Adjust the rear locknut until it is in contact with
the back of the abutment bracket and the throttle
lever is in contact with the inner driven lever.
3. Ensure that the driven lever remains in contact
with the throttle stop screw, (throttle closed).
4. Tighten cable front nut to lock cable to abutment
bracket and tighten lock nut.
2. Rotate thumb-wheel clockwise until all slack is
removed from cable. (Throttle lever is about to
lift from stop)
3. Back off thumb-wheel anti-clockwise by one
quarter of a turn.
4. Check cruise control cable adjustment.
5. If necessary, adjust cruise control cable. See
CRUISE CONTROL, Adjustment.
2
ADJUSTMENT
LAND ROVER V8
ENGINE TUNING - up to 99MY
Service repair no - 19.22.13
The position of the Idle Air Control (IAC) valve can be
checked using TestBook and adjusted if necessary
through the by-pass screw in the plenum chamber.
The bypass screw is covered by a tamper proof plug
which can be extracted using a self tapping screw.
Vehicles in certain markets are not fitted with oxygen
sensors or active catalytic converters. Certain
specification vehicles may have active catalytic
converters fitted, but do not use oxygen sensors. This
is referred to as an open loop catalyst system. All
vehicles without oxygen sensors must have the
exhaust CO content checked periodically using an
approved CO meter and adjusted if necessary using
TestBook.
On vehicles with open loop catalyst systems, exhaust
CO content must be checked upstream of the catalyst,
NOT at the tailpipe.
Preliminary Checks
1. Ensure that air filter and fuel filter elements are
in a serviceable condition.
2. Check air intake system, including vacuum pipes
and hoses for correct routing and freedom from
leaks and restriction.
3. Electrical connections must be secure and leads
correctly routed.
4. Check ignition system integrity using an
approved Engine Analyser.
Procedure
Open loop catalyst vehicles:
8. Remove blanking plug from RH exhaust front
pipe, forward of the catalyst.
9. Fit sampling pipe and tighten securely.
CAUTION: Air leaks at the sampling pipe
will cause incorrect readings.
10. Connect exhaust gas analyser to sampling pipe.
NOTE: When refitting the blanking plug
apply nickel based grease to the thread.
Vehicles without oxygen sensors:
5. Ensure exhaust gas analyser is warmed and
calibrated ready for use.
6. Non catalyst vehicles: Connect exhaust gas
analyser to tailpipe.
7. Disconnect purge valve pipe at charcoal
canister.
CAUTION: Do not disconnect purge valve
electrical multiplug.
ADJUSTMENT
3
19
FUEL SYSTEM
All vehicles:
11. Ensure air conditioning and all electrical loads
are off. Vehicle must be in neutral or park with
air suspension in kneel and disabled.
12. Carry out tuning or base idle setting procedure
as applicable using TestBook.
4
ADJUSTMENT
NEW RANGE ROVER
LAND ROVER V8
AIR CLEANER ASSEMBLY - up to 97MY
Service repair no - 19.10.01
Remove
1. Release 2 clips securing air flow meter to air
cleaner.
2. Release air flow meter. Remove ’O’ ring and
discard.
3. Disconnect intake air temperature sensor.
Refit
10. If removed, refit intake air temperature sensor
with seal to air cleaner. Tighten to 8 Nm (6
lbf.ft)
11. Position air cleaner assembly. Engage lug to
valance grommet. Secure with bolts.
12. Position air suspension dryer to air cleaner.
Secure with bolt. Tighten to 8 Nm (6 lbf.ft)
13. Engage dryer pipes to clips.
14. Connect multiplug to intake air temperature
sensor.
15. Fit new ’O’ ring to air flow meter.
16. Secure air flow meter to air cleaner with clips.
4. Remove bolt securing air suspension dryer to air
cleaner.
5. Release dryer pipes from 2 clips. Position dryer
aside.
6. Remove 2 bolts securing air cleaner to valance.
7. Release air cleaner lug from valance grommet.
Remove air cleaner.
8. If necessary, remove intake air temperature
sensor.
9. Remove seal.
REPAIR
1
19
FUEL SYSTEM
NEW RANGE ROVER
AIR CLEANER ASSEMBLY - from 97MY
Service repair no - 19.10.01
Remove
8. Remove air temperature sensor from air cleaner.
9. Remove and discard air temperature sensor
seal.
10. Fit new seal to air cleaner.
11. Fit air temperature sensor to air cleaner and
tighten to 8 Nm (6 lbf.ft)
1. Release 2 clips securing mass air flow (MAF)
meter to air cleaner.
2. Release MAF meter from air cleaner. Remove
and discard ’O’ ring from MAF sensor.
3. Disconnect multiplug from air temperature
sensor.
4. Remove bolt securing air suspension air dryer to
air cleaner.
5. Release air dryer from air cleaner and position
aside.
6. Release air cleaner from 2 valance grommets.
7. Remove air cleaner from inner wing grommet.
Do not carry out further dismantling if
component is removed for access only.
2
REPAIR
Refit
12. Fit air cleaner lugs to inner wing and valance
grommets. Ensure lugs are fully engaged to
grommets.
13. Position air dryer to air cleaner, fit bolt and
tighten to 8 Nm (6 lbf.ft)
14. Connect multiplug to air temperature sensor.
15. Fit new ’O’ ring seal to MAF meter.
16. Engage MAF meter to air cleaner and secure
with clips.
LAND ROVER V8
ELEMENT - AIR CLEANER - from 99MY
AIR INTAKE HOSE - up to 99MY
Service repair no - 19.10.10
Service repair no - 19.10.17
Remove
Remove
1. Release 3 fixings and remove battery cover.
2. Disconnect battery earth lead.
1. Loosen 2 clips securing intake hose to plenum
chamber and mass air flow sensor.
2. Release harness from intake hose clip.
3. Release intake hose from plenum chamber.
4. Remove intake hose from mass air flow sensor.
5. Remove 2 clips from intake hose.
Refit
3. Release 2 clips securing air flow meter to air
cleaner assembly.
4. Release air flow meter and position aside.
5. Release 2 clips securing air cleaner top cover
and remove cover.
6. Remove air cleaner element.
6.
7.
8.
9.
Fit clips to intake hose.
Fit intake hose to mass air flow sensor.
Connect intake hose to plenum chamber.
Tighten clips securing intake hose to plenum
and MAF sensor.
10. Engage harness to intake hose clip.
Refit
7.
8.
9.
10.
Clean inside of air cleaner case and cover.
Fit new air cleaner element.
Fit air cleaner cover and secure with clips.
Connect air flow meter to air cleaner assembly
and secure with clips.
11. Connect battery earth lead.
12. Fit battery cover and secure with fixings.
REPAIR
3
19
FUEL SYSTEM
NEW RANGE ROVER
CAMSHAFT POSITION (CMP) SENSOR - up to
99MY
Service repair no - 18.30.24
Remove
1. Disconnect battery negative lead.
2. Release 2 clips securing upper fan cowl.
Remove cowl.
4. Release CMP sensor connector from bracket.
Disconnect multiplug.
5. Remove bolt securing CMP sensor to front
cover.
6. Remove CMP sensor.
3. Release tension from auxiliary belt. Remove belt
from crankshaft pulley.
Refit
7. Ensure mating surfaces are clean.
8. Engage CMP sensor in front cover location.
Secure with bolt. Tighten to 8 Nm (6 lbf.ft)
9. Secure CMP sensor connector to bracket.
Connect multiplug.
10. Turn auxiliary belt tensioner. Refit belt to
crankshaft pulley.
11. Fit upper fan cowl. Secure with clips.
12. Reconnect battery negative lead.
4
REPAIR
LAND ROVER V8
CAMSHAFT POSITION (CMP) SENSOR - from
99MY
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR - up to 99MY
Service repair no - 18.30.24
Service repair no - 18.30.10
Remove
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
WARNING: Support on safety stands.
1. Partially drain cooling system. See COOLING
SYSTEM, Repair.
2. Disconnect ECT sensor multiplug.
3. Position rag around ECT sensor to catch
spillage.
4. Remove ECT sensor. Collect and discard
copper washer.
4. Disconnect engine harness from CMP sensor.
5. Disconnect CMP sensor multiplug from bracket.
6. Remove bolt from clamp securing CMP sensor
to front cover.
7. Remove clamp and sensor. Discard ’O’ ring from
CMP sensor.
Refit
8. Ensure CMP sensor is clean, fit new ’O’ ring and
sensor to cover.
9. Fit clamp to CMP sensor and tighten bolt to 8
Nm (6 lbf.ft).
10. Fit sensor multiplug to bracket and connect
engine harness to multiplug.
11. Lower vehicle.
12. Connect battery earth lead.
13. Fit battery cover and secure with fixings.
Refit
5. Ensure ECT sensor seat in manifold is clean.
6. Coat sensor threads with Loctite 577 and fit a
new copper washer.
7. Fit ECT sensor. Tighten to 20 Nm (15 lbf.ft).
8. Connect multiplug to ECT sensor.
9. Refill cooling system. See COOLING SYSTEM,
Repair.
10. Run engine to normal operating temperature.
Check for leaks around ECT sensor.
REPAIR
5
19
FUEL SYSTEM
NEW RANGE ROVER
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR - from 99MY
Service repair no - 18.30.10
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Drain sufficient coolant to ensure no spillage
during removal of ECT sensor. See COOLING
SYSTEM, Repair.
4. Remove alternator drive belt. See
ELECTRICAL, Repair.
6. Disconnect multiplug from ECT sensor.
7. Remove sensor from inlet manifold and discard
sealing washer.
Refit
5. Remove 2 bolts securing alternator, release
alternator from support bracket and position
aside.
6
REPAIR
8. Clean sealant from threads in manifold.
9. Apply Loctite 577 to sensor threads.
10. Fit new sealing washer to coolant sensor and
tighten sensor to 10 Nm (8 lbf. ft). Connect
multiplug.
11. Position alternator, fit bolts and tighten to 45 Nm
(33 lbf.ft).
12. Fit alternator drive belt. See ELECTRICAL,
Repair.
13. Top up cooling system. See COOLING
SYSTEM, Repair.
14. Connect battery earth lead.
15. Fit battery cover and secure with fixings.
LAND ROVER V8
CRANKSHAFT POSITION (CKP) SENSOR - up to
97MY
Service repair no - 18.30.12
Remove
CAUTION: 4.6 litre automatic vehicles have
a spacer fitted to the engine speed sensor.
1. Disconnect battery negative lead.
2. Disconnect multiplug from CKP sensor fly-lead.
3. Remove bolt securing CKP sensor connector to
bracket.
6. Remove CKP sensor.
7. 4.6 litre Automatic Only: Collect spacer from
sensor.
Refit
4. Raise the vehicle.
8. 4.6 litre Automatic Only: Fit spacer to CKP
sensor.
9. Fit CKP sensor to adaptor plate. Secure with
bolts. Tighten to 6 Nm (4 lbf.ft)
10. Remove safety stands. Lower vehicle.
11. Secure CKP sensor connector to bracket with
bolt.
12. Connect CKP sensor multiplug.
13. Reconnect battery negative lead.
WARNING: Support on safety stands.
5. Remove 2 bolts securing CKP sensor to cylinder
block adaptor plate.
REPAIR
7
19
FUEL SYSTEM
CRANKSHAFT POSITION (CKP) SENSOR - 97MY
to 99MY
Service repair no - 18.30.12
CAUTION: System sensor connectors can
be contaminated by oil or coolant when
disconnected during repair or testing. Use
a suitable cap to prevent dirt or fluid ingress.
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove gearbox LH acoustic cover. See
CHASSIS AND BODY, Repair.
4. Disconnect multiplug from CKP sensor.
5. Remove bolt securing CKP sensor to cylinder
block adaptor plate.
6. Remove CKP sensor.
7. Collect spacer from sensor.
8
REPAIR
NEW RANGE ROVER
Refit
8. Fit spacer to CKP sensor.
9. Fit CKP sensor to adaptor plate.
10. Fit bolt securing sensor to adaptor plate and
tighten to 6 Nm (4 lbf.ft)
11. Connect multiplug to CKP sensor.
12. Fit gearbox LH acoustic cover. See CHASSIS
AND BODY, Repair.
13. Remove stand(s) and lower vehicle.
LAND ROVER V8
CRANKSHAFT POSITION (CKP) SENSOR - from
99MY
Service repair no - 18.30.12
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
WARNING: Support on safety stands.
Refit
8. Ensure all components are clean.
9. Fit sensor mounting, CKP sensor, 2 spacers and
tighten sensor retaining nuts to 6 Nm (5 lbf.ft).
10. Fit CKP sensor heat shield and secure with
bolts.
11. Connect sensor multiplug to engine harness and
fit multiplug to bracket.
12. Remove stand(s) and lower vehicle.
13. Connect battery earth lead.
14. Fit and secure battery cover.
4. Release CKP sensor multiplug from bracket and
disconnect multiplug from engine harness.
5. Remove 2 bolts securing CKP sensor heat
shield.
6. Remove heat shield.
7. Remove 2 nuts securing CKP sensor, remove 2
spacers, sensor and sensor mounting.
REPAIR
9
19
FUEL SYSTEM
NEW RANGE ROVER
FUEL SYSTEM - DEPRESSURISE
ENGINE CONTROL MODULE (ECM) - up to 99MY
WARNING: Fuel pressure of up to 2.5 bar
will be present in the system, even if the
engine has not been run for some time.
Always depressurise the system before
disconnecting any components in the fuel feed
line (between fuel pump and pressure regulator).
The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions
are taken to prevent fire and explosion.
Service repair no - 18.30.01
Remove
1. Disconnect battery negative lead.
NOTE: Fuel pressure can be relieved at
fuel rail feed union or fuel filter unions.
1. Position cloth around relevant union to protect
against fuel spray.
2. Carefully slacken union.
3. Tighten union to correct torque once pressure
has relieved.
2. Remove 2 screws securing ECM housing cover.
Remove cover
3. Slacken 2 harness clamp screws.
4. Lift ECM slightly for access. Disconnect 3
multiplugs.
5. Remove ECM from housing.
6. Remove carrier plate from ECM.
Refit
7. Reverse removal procedure.
10
REPAIR
LAND ROVER V8
ENGINE CONTROL MODULE (ECM) - from 99MY
Service repair no - 18.30.01
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
6. Release ECM from housing cover, disconnect
multiplugs and remove ECM.
Refit
3. Remove 2 screws securing cruise control
assembly to EAS housing cover and position
aside.
4. Release 2 fixings securing ECM housing cover
and release cover.
7. Position ECM and connect multiplugs.
8. Fit ECM to housing cover and connect ECM
cooling fan multiplug.
9. Fit ECM housing cover to main housing and
secure with fixings.
10. Position cruise control assembly to EAS housing
cover and secure with screws.
11. Connect battery earth lead.
12. Fit battery cover and secure with fixings.
5. Disconnect ECM cooling fan multiplug.
REPAIR
11
19
FUEL SYSTEM
NEW RANGE ROVER
FAN - ECM COOLING - from 99MY
Service repair no - 18.30.80
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove 2 screws securing cruise control
assembly to EAS housing cover and position
aside.
4. Release 2 fixings securing ECM housing cover
and release cover.
7. Release ECM cooling fan from cooling fan cowl
and remove cooling fan.
8. Remove 2 screws securing cooling fan cowl to
ECM housing and remove cowl.
Refit
9. Remove cooling fan cowl from new cooling fan.
10. Fit cooling fan cowl to ECM housing and secure
with screws.
11. Fit cooling fan to cooling fan cowl and fit
multiplug to bracket.
12. Position ECM housing cover and connect ECM
cooling fan multiplug.
13. Fit ECM housing cover to main housing and
secure with fixings.
14. Position cruise control assembly to EAS housing
cover and secure with screws.
15. Connect battery earth lead.
16. Fit battery cover and secure with fixings.
5. Disconnect ECM cooling fan multiplug and
position ECM housing cover aside.
6. Release ECM cooling fan multiplug from bracket.
12
REPAIR
LAND ROVER V8
MASS AIR FLOW (MAF) SENSOR - up to 99MY
MASS AIR FLOW (MAF) SENSOR - from 99MY
Service repair no - 19.22.25
Service repair no - 19.22.25
Remove
Remove
1. Disconnect battery negative lead.
2. Loosen hose clip. Release intake hose from
MAF sensor.
3. Disconnect multiplug from MAF sensor.
4. Release 2 clips and remove MAF sensor from air
cleaner.
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Disconnect multiplug from MAF sensor.
4. Loosen clip screw and release air intake hose
from MAF sensor.
5. Release 2 clips and remove sensor from air
cleaner.
Refit
5. Collect ’O’ ring seal.
Refit
6. Ensure mating faces of air cleaner, MAF sensor
and intake hose are clean.
7. Fit ’O’ ring to MAF sensor.
8. Fit MAF Sensor to air cleaner. Secure with clips.
9. Connect multiplug to MAF sensor.
10. Connect intake hose. Secure with clip.
6.
7.
8.
9.
10.
Position sensor to air cleaner and secure clips.
Position air intake hose and tighten clip screw.
Connect multiplug.
Connect battery earth lead.
Fit battery cover and secure with fixings.
CAUTION: Failure to connect intake hose
securely will allow unmetered air to enter
the engine, causing running problems.
11. Reconnect battery negative lead.
REPAIR
13
19
FUEL SYSTEM
FUEL RAIL AND INJECTORS - up to 99MY
Service repair no - 19.60.04 - Fuel Rail
Service repair no - 19.60.12 - Injectors
NEW RANGE ROVER
5. Remove 6 bolts securing ram housing to inlet
manifold.
6. Place small packing block on inlet manifold.
Lever between packing block and ram pipe
housing to break seal.
Remove
CAUTION: Do not lever against fuel rail.
1. Disconnect battery negative lead.
2. Depressurise fuel system. See this section.
3. Release plenum chamber and place aside. See
this section.
4. Release purge hose, crankcase breather hose
and pressure regulator vacuum hose from ram
housing.
14
REPAIR
7. Remove ram housing from 2 dowels.
8. Place cloth over inlet manifold to prevent ingress
of debris.
LAND ROVER V8
9. Disconnect 8 injector multiplugs.
10. Disconnect fuel temperature sensor multiplug.
11. Disconnect fuel feed hose from fuel rail.
12. Disconnect fuel return hose from pressure
regulator pipe.
14. Release ignition coil bracket from inlet manifold
studs. Place aside.
15. Release injectors from inlet manifold and remove
fuel rail assembly.
Do not carry out further dismantling if
component is removed for access only.
16. Remove 8 clips securing injectors to fuel rail.
Remove injectors.
17. Remove 2 ’O’ rings from each injector and
discard.
18. Remove 2 screws securing fuel pressure
regulator to fuel rail.
19. Release return pipe from clip. Remove pressure
regulator assembly.
20. Remove ’O’ ring from fuel pressure regulator and
discard.
NOTE: Advanced EVAPS vehicles have a
threaded connection to the return hose.
13. Remove 6 nuts securing fuel rail and ignition coil
bracket to inlet manifold.
REPAIR
15
19
FUEL SYSTEM
Refit
NEW RANGE ROVER
FUEL RAIL AND INJECTORS - from 99MY
21. Ensure mating surfaces between inlet manifold
and ram pipe housing are clean.
22. Ensure all locations in fuel rail and inlet manifold
are clean.
23. Fit new ’O’ rings to injectors and fuel pressure
regulator.
24. Lubricate ’O’ rings with silicone grease.
25. Fit fuel pressure regulator to fuel rail. Secure
with bolts. Tighten to 10 Nm (7 lbf.ft)
26. Engage regulator return pipe in clip.
27. Fit injectors to fuel rail. Secure with clips.
28. Position fuel rail to inlet manifold. Engage
injectors, one bank at a time.
29. Position ignition coil bracket on inlet manifold
studs.
30. Secure ignition coil bracket and fuel rail to inlet
manifold with nuts. Tighten to 8 Nm (6 lbf.ft)
31. Connect return hose to pressure regulator pipe.
Secure with clip.
32. Connect fuel feed pipe to fuel rail. Tighten union
to 16 Nm (12 lbf.ft)
33. Connect multiplugs to fuel injectors and fuel
temperature sensor.
34. Remove cloth from inlet manifold.
35. Apply a thin, uniform coating of Loctite 577
sealant to mating face of inlet manifold.
36. Fit ram pipe housing to inlet manifold. Secure
with bolts. Tighten to 24 Nm (18 lbf.ft)
37. Connect purge hose, crankcase breather hose
and pressure regulator vacuum hose to ram pipe
housing.
38. Fit plenum chamber. See this section.
39. Reconnect battery negative lead.
40. Start engine. Check for leaks around fuel rail and
injectors.
Service repair no - 19.60.04 - Fuel Rail
Service repair no - 19.60.12 - Injectors
Remove
1. Remove upper inlet manifold gasket. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2. Release HT leads from clips on rocker covers
and from spark plugs.
3. Disconnect multiplugs from coils.
4. Remove 2 lower coil fixing bolts and remove coil
assembly.
5. Position absorbent cloth beneath fuel pipe to
catch spillage.
6. Disconnect fuel feed hose from fuel rail
CAUTION: Plug the connections.
7. Release injector harness clips from fuel rail and
disconnect injector multiplugs.
16
REPAIR
LAND ROVER V8
Refit
13. Clean injectors and recesses in fuel rail and inlet
manifold.
14. Lubricate new ’O’ rings with silicone grease and
fit to each end of injectors.
15. Fit injectors to fuel rail.
16. Secure injectors to fuel rail with spring clips.
17. Position fuel rail assembly and push-fit each
injector into inlet manifold.
18. Fit bolts securing fuel rail to inlet manifold and
tighten to 9 Nm (6 lbf.ft).
19. Connect fuel feed hose to fuel rail.
20. Connect injector harness multiplugs and secure
to fuel rail.
21. Carefully position coil assembly, fit 2 lower fixing
bolts but do not tighten at this stage.
22. Connect multiplugs to coils.
23. Fit HT leads to spark plugs and clips on rocker
covers.
24. Fit upper inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
8. Remove 4 bolts securing fuel rail to inlet
manifold.
9. Release injectors from inlet manifold and remove
fuel rail and injectors.
10. Release spring clips securing injectors to fuel rail
and remove fuel injectors.
11. Remove and discard 2 ’O’ rings from each
injector.
12. Fit protective caps to each end of injectors.
REPAIR
17
19
FUEL SYSTEM
ENGINE FUEL TEMPERATURE (EFT) SENSOR
NEW RANGE ROVER
HEATED OXYGEN SENSOR (HO2S)- FRONT (up to
99MY) AND REAR
Service repair no - 19.22.08
Remove
NOTE: Because fuel leakage will not occur
when sensor is removed, it is not
necessary to depressurise the fuel system
for this operation.
1. Disconnect battery negative lead.
2. Disconnect multiplug from fuel temperature
sensor.
3. Remove sensor from fuel rail.
Service repair no - 19.22.16 - Front
Service repair no - 19.22.17 - Rear (NAS Spec.
only)
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove clip securing HO2S lead.
Refit
4.
5.
6.
7.
18
Ensure sensor and location in fuel rail are clean.
Fit sensor. Tighten to 17 Nm (13 lbf.ft)
Connect multiplug.
Reconnect battery negative lead.
REPAIR
3. Release HO2S multiplug from bracket on sump
or transfer gearbox. Disconnect multiplug from
engine harness.
LAND ROVER V8
HEATED OXYGEN SENSOR (HO2S) - FRONT from 99MY
Service repair no - 19.22.16
Remove
1. Raise vehicle on ramp.
CAUTION: Although robust within the
vehicle environment, HO2S sensors are
easily damaged by dropping, excessive
heat and contamination. Care must be exercised
when working on the exhaust system not to
damage the sensor housing or tip.
4. Remove sensor from exhaust front pipe.
Remove sealing washer and discard.
2. Release HO2S harness from clip if fitted, and
disconnect HO2S multiplug.
3. Remove HO2S from exhaust front pipe.
Refit
5. Ensure mating faces are clean.
Refit
NOTE: New HO2S is supplied pre-treated
with anti-seize compound.
6. If refitting existing HO2S, coat threads with
anti-seize compound.
CAUTION: Do not allow anti-seize
compound to come into contact with HO2S
nose or enter exhaust system.
4. If refitting existing HO2S apply anti-seize
compound to threads.
5. Fit new sealing washer to HO2S.
6. Fit HO2S and tighten to 45 Nm (33 lbf.ft).
7. Connect HO2S multiplug and secure harness to
clip.
8. Lower vehicle.
7. Position HO2S with new sealing washer on
exhaust pipe. Tighten to 20 Nm (15 lbf.ft)
8. Connect multiplug to engine harness. Secure to
bracket.
9. Secure lead in clip.
10. Remove stands. Lower vehicle.
REPAIR
19
19
FUEL SYSTEM
NEW RANGE ROVER
SPARK PLUGS
Refit
Service repair no - 18.20.02
CAUTION: Take care not to cross-thread
spark plugs when fitting as costly damage
to the cylinder head will result. It is
essential that correct type of spark plug is fitted.
Incorrect grade of spark plugs may lead to piston
overheating and engine failure.
Remove
1. Remove air intake hose. See this section.
4. Ensure spark plug gaps are between 0.89 - 1.01
mm and set gap if necessary.
5. Fit spark plugs to cylinder heads and tighten to
20 Nm (15 lbf.ft)
6. Connect h.t. leads to spark plugs.
7. Fit air intake hose. See this section.
2. Disconnect 8 h.t. leads from spark plugs.
CAUTION: To avoid damage to h.t. leads,
disconnect them by pulling the rubber
boot NOT the lead.
3. Remove 8 spark plugs and washers from
cylinder heads.
20
REPAIR
LAND ROVER V8
H.T. LEADS
Service repair no - 18.20.11
Remove
Refit
9.
10.
11.
12.
Position h.t. leads and connect to ignition coils.
Connect h.t. leads to spark plugs.
Engage h.t. leads to camshaft cover clips.
Fit clips securing h.t. leads to each other.
1. Remove air intake hose. See this section.
2. Disconnect 4 h.t. leads from LH cylinder head
spark plugs.
CAUTION: To avoid damage to h.t. leads,
disconnect them by pulling on the rubber
boot, NOT the lead.
3. Release h.t. leads from 8 camshaft cover clips.
4. Disconnect 8 h.t. leads from ignition coils.
5. Disconnect 4 h.t. leads from RH cylinder head
spark plugs.
6. Release h.t. leads from 8 camshaft cover clips.
7. Remove 8 h.t. leads
8. Remove 4 clips securing h.t. leads to each other.
REPAIR
21
19
FUEL SYSTEM
IGNITION COILS - up to 99MY
Service repair no - 18.20.45 - Set
Service repair no - 18.20.43 - Each
Service repair no - 18.20.44 - Extra - Each
Remove
1. Disconnect battery negative lead.
2. Disconnect H.T. leads from ignition coils. Note
positions of leads.
3. Place H.T. leads aside.
NEW RANGE ROVER
4. Disconnect ignition coil multiplug.
5. Remove 6 nuts securing fuel rail and ignition coil
bracket to inlet manifold.
6. Lift fuel rail slightly for access. Release ignition
coil bracket from inlet manifold studs.
CAUTION: Do not completely withdraw
injectors from fitted locations.
7. Remove ignition coils assembly.
8. Remove terminal cover.
9. Remove 2 nuts securing wires to coil terminals.
10. Remove wires from terminals. Note wire
positions.
11. Remove 3 screws securing ignition coil to
bracket. Remove coil.
22
REPAIR
LAND ROVER V8
Refit
12.
13.
14.
15.
16.
17.
18.
19.
IGNITION COILS - from 99MY
Fit ignition coil to bracket. Secure with screws.
Connect wires to terminals. Secure with nuts.
Fit terminal cover.
Position ignition coil bracket on inlet manifold
studs.
Secure fuel rail and ignition coil bracket with
nuts. Tighten to 8 Nm (6 lbf.ft)
Connect multiplug.
Connect H.T. leads to respective coil towers.
Reconnect battery negative lead.
Service repair no - 18.20.45
Remove
1. Remove upper inlet manifold gasket. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2. Remove 2 lower coil fixing bolts.
3. Disconnect multiplugs from coils.
4. Release HT leads from rocker covers and
disconnect HT leads from plugs.
5. Carefully manoeuvre coil assembly from
between engine and bulkhead.
REPAIR
23
19
FUEL SYSTEM
NEW RANGE ROVER
INERTIA FUEL SHUT OFF (IFS) SWITCH
Service repair no - 19.22.09
Remove
1. Release 300mm of door seal from base of RH
’A’ post.
6. Noting their fitted position disconnect HT leads
from coils.
7. Remove 6 screws securing coils to support
bracket and remove coils.
Refit
8. Position coils to support bracket, fit and tighten
screws.
9. Connect HT leads to coils ensuring they are in
the correct position.
10. Carefully position coil assembly between engine
and bulkhead.
11. Connect HT leads to plugs and secure HT leads
to rocker covers.
12. Connect multiplugs to coils.
13. Fit 2 lower coil fixing bolts but do not tighten at
this stage.
14. Fit upper inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
2. Remove ’A’ post lower finisher securing screw.
Remove finisher from sprag clip.
3. Remove RH lower ’A’ post finisher.
24
REPAIR
LAND ROVER V8
4. Disconnect multiplug. Remove 2 screws
securing IFS switch to ’A’ post.
5. Remove IFS switch.
INTAKE AIR TEMPERATURE (IAT) SENSOR
Service repair no - 18.30.09
Remove
1. Disconnect multiplug from IAT sensor.
2. Remove IAT sensor from air cleaner.
Refit
3. Fit IAT sensor. Tighten to 8 Nm (6 lbf.ft)
4. Connect multiplug.
Refit
6. Reverse removal procedure.
REPAIR
25
19
FUEL SYSTEM
NEW RANGE ROVER
THROTTLE POSITION (TP) SENSOR - up to 99MY
THROTTLE POSITION (TP) SENSOR - from 99MY
Service repair no - 19.22.49
Service repair no - 19.22.49
Remove
Remove
1. Disconnect multiplug from TP sensor.
2. Remove 2 bolts securing TP sensor. Collect
clamp plate.
3. Remove TP sensor.
1. Disconnect TP sensor multiplug.
2. Remove 2 bolts securing TP sensor to throttle
body.
3. Remove TP sensor and discard ’O’ ring.
Refit
4. Clean TP sensor and throttle body mating faces.
5. Using a new ’O’ ring, position TP sensor, fit bolts
and tighten to 2.2 Nm (1.5 lbf.ft).
6. Connect TP sensor multiplug.
7. If fitting new TP sensor, connect Testbook to
check for correct operation.
Refit
4. Fit TP sensor. Ensure drive engages correctly
with throttle spindle.
5. Position clamp plate. Secure TP sensor with
bolts. Tighten to 2 Nm (1.5 lbf.ft)
6. Connect multiplug.
26
REPAIR
LAND ROVER V8
KNOCK SENSOR (KS) - up to 99MY
Service repair no - 18.30.28 - Sensor - LH
Service repair no - 18.30.30 - Sensor - RH
CAUTION: Due to the sensitivity of the
sensors, do not apply tape or sealant to
sensor threads.
Remove
1. Raise the vehicle.
Refit
5. Ensure sensor location in cylinder block is clean.
6. Fit sensor. Tighten to 16 Nm (12 lbf.ft)
CAUTION: Failure to tighten sensor to
correct torque will result in malfunction or
sensor damage.
7. Connect sensor multiplug.
8. RH Sensor Only: Fit starter motor. See
ELECTRICAL, Repair.
9. Remove safety stands. Lower vehicle.
WARNING: Support on safety stands.
2. RH Sensor Only: Remove starter motor. See
ELECTRICAL, Repair.
3. Disconnect sensor multiplug.
4. Remove sensor from cylinder block.
REPAIR
27
19
FUEL SYSTEM
NEW RANGE ROVER
KNOCK SENSOR (KS) - from 99MY
FUEL PRESSURE REGULATOR
Service repair no - 18.30.28 - Sensor - LH
Service repair no - 18.30.30 - Sensor - RH
Service repair no - 19.45.06
Remove
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
WARNING: Support on safety stands.
1. Disconnect battery negative lead.
2. Depressurise fuel system. See this section.
3. Release fuel return pipe clip. Remove fuel return
pipe from regulator connecting pipe.
NOTE: Advanced EVAPS vehicles have a
threaded connection to the return hose.
4. Disconnect multiplug from KS.
5. Remove nut securing KS to cylinder block and
remove KS.
Refit
6. Clean mating faces of KS and block.
7. Fit KS to block and tighten nut to 22 Nm (17
lbf.ft).
8. Connect multiplug to KS.
9. Remove stand(s) and lower vehicle.
10. Connect battery earth lead.
11. Fit and secure battery cover.
4. Release regulator connecting pipe from clip.
5. Disconnect vacuum hose from fuel pressure
regulator.
28
REPAIR
LAND ROVER V8
11. Remove ’O’ ring and spacer ring from fuel
pressure regulator. Discard ’O’ ring.
6. Remove 6 nuts securing fuel rail and ignition coil
bracket to inlet manifold.
7. Lift fuel rail slightly for access. Release ignition
coil bracket from inlet manifold studs. Place
aside.
CAUTION: Do not completely withdraw
injectors from fitted locations.
8. Remove bolts securing fuel pressure regulator to
fuel rail.
9. Remove fuel pressure regulator assembly.
10. Release connecting pipe and hose assembly
from regulator.
Refit
12. Ensure locations on fuel pressure regulator and
fuel rail are clean.
13. Fit new spacer ring and ’O’ ring to fuel pressure
regulator. Lubricate ’O’ ring with silicone grease.
14. Fit connecting pipe assembly to fuel pressure
regulator. Secure clip.
15. Fit pressure regulator assembly to fuel rail.
Secure with bolts. Tighten to 10 Nm (7 lbf.ft)
16. Secure regulator connecting pipe in clip.
17. Align ignition coil bracket to inlet manifold studs.
18. Secure ignition coil bracket and fuel rail to inlet
manifold with nuts. Tighten to 8 Nm (6 lbf.ft)
19. Connect return pipe to regulator connecting pipe.
Secure with clip.
NOTE: Advanced EVAPS vehicles have a
threaded connection to the return hose.
20. Connect vacuum hose to fuel pressure regulator.
21. Reconnect battery negative lead.
22. Start engine. Check for leaks around fuel
pressure regulator, fuel feed and fuel return
unions.
REPAIR
29
19
FUEL SYSTEM
NEW RANGE ROVER
IDLE AIR CONTROL (IAC) VALVE - up to 99MY
IDLE AIR CONTROL (IAC) VALVE - from 99MY
Service repair no - 19.22.54
Service repair no - 19.22.54
Remove
Remove
1. Disconnect battery negative lead.
2. Disconnect IAC multiplug.
3. Remove 2 bolts, remove IAC. Discard gasket.
1. Disconnect IAC valve multiplug.
2. Release and remove 2 clips securing air hoses
and release hoses.
3. Remove 2 screws securing IAC valve to inlet
manifold.
4. Collect IAC valve clamps and remove IAC valve.
Refit
5. Position IAC valve, locate clamps, fit screws and
tighten to 8.5 Nm (6 lbf.ft).
6. Position air hoses and secure clips.
7. Connect IAC valve multiplug.
8. Connect Testbook to clear any fault codes.
Refit
4. Ensure all mating faces are clean.
5. Using a new gasket, fit IAC. Secure with bolts.
Tighten to 2.3 Nm (2 lbf.ft)
6. Connect multiplug.
7. Reconnect battery negative lead.
30
REPAIR
LAND ROVER V8
PLENUM CHAMBER - up to 97MY
Service repair no - 19.22.46
Remove
1. Disconnect battery negative lead.
2. Slacken clip securing intake hose to plenum
chamber. Release hose.
3. Remove throttle and cruise control cables from
throttle linkage.
4. Remove throttle and cruise control cable from
abutment bracket.
5. Release harness clip from throttle linkage
bracket.
6. Disconnect breather hose from plenum chamber.
7. Disconnect multiplugs from idle air control (IAC)
and throttle position sensor (TP Sensor).
8. Remove 6 bolts securing plenum chamber.
Remove plenum chamber from ram pipe
housing.
9. Place cloth over ram pipes to prevent ingress of
foreign matter.
Do not carry out further dismantling if
component is removed for access only.
10. Clamp coolant hoses with an approved hose
clamp.
11. Disconnect coolant hoses from water jacket.
Remove plenum chamber.
12. Remove 4 bolts securing water jacket to plenum
chamber. Remove water jacket. Remove gasket
and discard.
REPAIR
31
19
FUEL SYSTEM
13. Remove 3 bolts securing throttle linkage bracket
to plenum chamber. Remove bracket. Collect
return spring.
14. Remove 2 bolts securing TP sensor. Collect
clamp plate. Remove TP sensor.
15. Remove 2 bolts securing IAC. Remove motor.
Remove gasket and discard.
NEW RANGE ROVER
Refit
16. Ensure all mating surfaces are clean.
17. Fit TP sensor. Ensure drive engages correctly
with throttle spindle.
18. Position clamp plate. Secure TP sensor with
bolts. Tighten to 2 Nm (2 lbf.ft)
19. Using a new gasket, fit IAC. Secure with bolts.
Tighten to 2.3 Nm (1.8 lbf.ft)
20. Ensure mating faces of water jacket and plenum
chamber are clean.
21. Using a new gasket, fit water jacket. Secure with
bolts. Tighten to 13 Nm (10 lbf.ft)
22. Position throttle linkage bracket, fit and engage
return spring.
23. Secure linkage bracket to plenum chamber with
bolts. Tighten to 8 Nm (6 lbf.ft)
24. Ensure mating faces of plenum chamber and
ram pipe housing are clean.
25. Position plenum chamber. Connect coolant
hoses to water jacket. Secure with clips.
26. Remove clamp from coolant pipes.
27. Apply a thin, uniform coating of Loctite 577
sealant to sealing face of plenum chamber.
28. Fit plenum chamber.
29. Fit plenum chamber bolts. Tighten to 24 Nm (18
lbf.ft)
30. Connect multiplugs to TP sensor and IAC.
31. Connect breather hose to plenum chamber.
32. Secure harness clip to throttle linkage bracket.
33. Engage throttle cable and cruise control cable to
abutment. Secure cruise control cable with ’C’
clip.
34. Align cables to throttle linkage. Fit clevis pins.
Secure clevis pins with split pins.
35. Adjust throttle cable. See Adjustment.
36. Connect intake hose. Secure with clip.
37. Reconnect battery negative lead.
38. Top up cooling system.
39. Check base idle speed. Adjust if necessary.
If 4.6 See ENGINE TUNING DATA, Information.
If 4.0 See ENGINE TUNING DATA, Information.
32
REPAIR
LAND ROVER V8
PLENUM CHAMBER - 97MY to 99MY
Service repair no - 19.22.46
Remove
1. Remove battery cover and disconnect battery.
2. Loosen clip securing air intake hose to plenum
chamber.
3. Disconnect air intake hose from plenum
chamber.
4. Remove split pin and clevis pin securing throttle
cable to throttle linkage.
5. Remove split pin and clevis pin securing cruise
control cable to throttle linkage and release
cable adjuster from abutment bracket.
6. Remove ’C’ clip securing cruise control cable
abutment to bracket and position cable aside.
7. Release clip securing throttle cable abutment to
bracket and position cable aside.
8. Release clip securing harness to cable abutment
bracket and position aside.
9. Disconnect breather hose from plenum chamber.
10. Release clip and disconnect purge hose from
plenum chamber.
11. Disconnect multiplug from throttle potentiometer.
12. Disconnect multiplug from stepper motor.
13. Remove 6 bolts securing plenum chamber to
ram housing.
14. Release plenum chamber from ram housing.
15. Fit hose clamp to 2 plenum chamber coolant
hoses.
16. Position cloth to catch spillage.
REPAIR
33
19
FUEL SYSTEM
17. Release clip securing coolant hose to plenum
water jacket and disconnect hose.
18. Loosen clip securing coolant hose to plenum
water jacket and disconnect hose.
19. Remove plenum chamber assembly.
20. Place clean cloth over intake pipes to prevent
dirt ingress.
Do not carry out further dismantling if
component is removed for access only.
21. Remove 4 bolts securing water jacket to plenum
chamber.
22. Remove water jacket and sealing gasket.
23. Position throttle linkage to gain access to bolt.
24. Remove 3 bolts securing throttle linkage to
plenum chamber.
25. Remove throttle linkage and bracket.
26. Collect spring.
34
REPAIR
NEW RANGE ROVER
27. Remove 2 bolts securing throttle potentiometer
to plenum chamber.
28. Collect clamp plate.
29. Remove throttle potentiometer.
30. Remove 2 bolts securing stepper motor to
plenum chamber.
31. Remove stepper motor and collect gasket.
32. Position throttle linkage bracket and spring to
plenum chamber.
33. Engage spring to linkage.
34. Fit bolts securing throttle linkage to plenum and
tighten to 8 Nm (6 lbf.ft)
35. Clean mating faces of throttle potentiometer and
stepper motor.
36. Fit throttle potentiometer, ensuring spindle is
correctly engaged.
37. Fit retaining plate and bolts and tighten to 2 N.
(1.5 lbf.ft)
38. Fit NEW stepper motor gasket to plenum
chamber.
39. Fit stepper motor.
40. Fit bolts securing stepper motor to plenum
chamber and tighten to 2 Nm (1.5 lbf.ft)
41. Clean mating faces of water jacket and plenum
chamber.
42. Fit NEW water jacket gasket to plenum chamber.
43. Fit water jacket to plenum chamber.
44. Fit bolts securing water jacket to plenum
chamber and tighten to 13 Nm (10 lbf.ft)
LAND ROVER V8
Refit
45. Clean mating faces of plenum chamber and ram
housing.
46. Connect coolant hose to water jacket and secure
with clip.
47. Connect second coolant hose to water jacket
and secure with clip.
48. Remove hose clamps.
49. Apply a thin, uniform coating of Loctite 577
sealant to mating face of plenum chamber.
50. Fit plenum chamber to ram housing.
51. Fit bolts securing plenum chamber to ram
housing and tighten to 24 Nm (18 lbf.ft)
52. Connect multiplugs to stepper motor and throttle
potentiometer.
53. Connect purge hose to plenum chamber. Ensure
connector is securely mated.
54. Connect breather hose to plenum chamber.
55. Position harness to throttle linkage bracket and
secure clip.
56. Engage throttle cable abutment clip to bracket.
57. Align throttle cable to throttle linkage, fit clevis
pin and split pin.
58. Position cruise control cable abutment to bracket
and secure with ’C’ clip.
59. Align cruise control cable to throttle linkage, fit
clevis pin and split pin.
60. Adjust throttle cable. See Adjustment.
61. Connect air intake hose to plenum chamber and
secure with clip.
62. Connect battery and fit cover.
63. Top up cooling system.
64. Check base idle speed. Adjust if necessary.
If 4.6 See ENGINE TUNING DATA, Information.
If 4.0 See ENGINE TUNING DATA, Information.
PLENUM CHAMBER - from 99MY
Service repair no - 19.22.46
Remove
1. Remove upper inlet manifold gasket. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
2. Remove 4 bolts securing throttle body to plenum
chamber, remove throttle body and collect
gasket.
3. Remove breather hose adaptor.
4. Remove 4 bolts securing plenum chamber to
upper manifold and remove plenum chamber.
5. Collect plenum chamber gaskets.
Refit
6. Clean plenum chamber and upper manifold
mating faces.
7. Using new gaskets, position plenum chamber, fit
bolts and tighten to 22 Nm (16 lbf.ft).
8. Fit and tighten breather adaptor to 6 Nm (4.5
lbf.ft).
9. Clean plenum chamber and throttle body mating
faces.
10. Using a new gasket, position throttle body, fit
bolts and tighten to 9 Nm (6 lbf.ft).
11. Fit upper inlet manifold gasket. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
REPAIR
35
19
FUEL SYSTEM
FUEL FILTER
Service repair no - 19.25.02
Remove
1. Disconnect battery negative lead.
2. Depressurise fuel system. See this section.
3. Raise the vehicle.
WARNING: Support on safety stands.
4. Position container beneath fuel filter to catch
spillage.
5. Disconnect fuel hoses from filter.
6. Remove ’O’ rings and discard.
7. Remove bolt securing filter and strap assembly.
Remove assembly.
36
REPAIR
NEW RANGE ROVER
Refit
8. Transfer strap to new fuel filter.
9. Position filter and strap assembly to floor pan.
Ensure that flow arrow points toward front of
vehicle.
10. Secure filter strap with bolt.
11. Using new ’O’ rings, connect fuel hoses to filter.
Tighten to 20 Nm (15 lbf.ft)
12. Remove container beneath filter.
13. Remove safety stands. Lower vehicle.
14. Reconnect battery negative lead.
LAND ROVER V8
THROTTLE CABLE - up to 99MY
Service repair no - 19.20.06
Remove
1. Remove split pin and clevis pin securing cable to
throttle linkage.
2. Release cable adjuster from abutment bracket.
3. Release cable from 3 clips along bulkhead and
single clip on brake booster bracket.
4. Remove driver’s side fascia closing panel. See
CHASSIS AND BODY, Repair.
5. Remove 3 scrivet fasteners securing lower
closing panel.
6. Release panel for access to blower motor
ducting.
REPAIR
37
19
FUEL SYSTEM
7. Release ducting from blower motor housing and
heater. Remove blower motor ducting.
8. Release cable from throttle pedal.
9. Release cable outer from bulkhead location.
Remove throttle cable assembly.
NEW RANGE ROVER
THROTTLE CABLE - from 99MY
Service repair no - 19.20.06
1. Remove closing panel from fascia. See
CHASSIS AND BODY, Repair.
2. Remove screw and remove heater outlet duct.
Refit
10. Lubricate bulkhead end of outer cable with liquid
soap to aid fitment.
11. Fully engage cable outer into bulkhead location.
Connect cable to throttle pedal.
12. Position blower ducting. Engage onto heater and
blower motor housing locations.
13. Position lower closing panel. Secure with scrivet
fasteners.
14. Fit driver’s side fascia closing panel. See
CHASSIS AND BODY, Repair.
15. Route cable along bulkhead. Secure to clips
16. Engage cable adjuster to abutment bracket.
17. Align cable trunnion to throttle linkage. Secure
with clevis pin and split pin.
18. Check and adjust throttle cable free-play. See
Adjustment.
38
REPAIR
3. Remove 4 scrivets and remove access panel
from fascia.
4. Release and remove heater air duct for access
to throttle pedal lever.
LAND ROVER V8
5. Disconnect inner cable from throttle cam.
6. Release cable gaiter.
7. Loosen locknuts and disconnect throttle cable
from abutment bracket.
9. Release and disconnect inner cable from throttle
lever.
10. Release throttle cable from bulkhead and
remove from vehicle.
Refit
8. Release throttle cable from 3 clips.
11. Apply liquid soap to bulkhead end of outer cable.
12. Fit throttle cable to bulkhead, connect and
secure inner cable to pedal lever.
13. Fit throttle cable to abutment bracket and
connect inner cable to throttle cam.
14. Fit throttle cable to clips.
15. Adjust throttle cable. See Adjustment.
16. Secure gaiter to outer cable.
17. Refit heater air duct.
18. Fit closing panel and secure with scrivets.
19. Fit heater outlet duct and secure with screw.
20. Fit closing panel to fascia. See CHASSIS AND
BODY, Repair.
REPAIR
39
19
FUEL SYSTEM
FILLER NECK ASSEMBLY - PRE-ADVANCED
EVAPS
Service repair no - 19.55.07
WARNING: If fuel tank is full, fuel level will
be above filler neck aperture in the tank. If
gauge indicates over 75%, drain a
minimum of 10 litres of fuel from tank.
Remove
1. Disconnect battery negative lead.
2. Remove rear wheel arch liner. See CHASSIS
AND BODY, Repair.
3. Remove fuel filler cap.
4. Slacken clips securing hoses to filler neck.
40
REPAIR
NEW RANGE ROVER
5. Release fill breather hose from filler neck.
6. Petrol Models Only: Disconnect fuel tank and
charcoal canister hoses from vapour separator.
7. Diesel Models Only: Release cap from quick
release connector. Disconnect breather hose.
8. Remove nut securing filler neck to wheel arch.
9. Release filler neck from fuel tank hose and
grommet in body aperture.
10. Remove filler neck assembly.
Refit
11. Apply liquid soap to grommet and mating surface
of filler neck.
12. Reverse removal procedure.
LAND ROVER V8
FUEL FILLER NECK - ADVANCED EVAPS
Service repair no - 19.55.07
Remove
WARNING: Ensure that fuel handling
precautions given in 01 - Introduction are
strictly adhered to when carrying out
following instructions.
7. Remove shear cap from clip securing neck
assembly to tank.
8. Slacken clip securing neck assembly to tank.
9. Release filler neck bracket from body stud. Push
filler neck down then forwards to release from
aperture grommet.
10. Remove filler neck assembly.
WARNING: If the fuel tank is full, the fuel
level may be close to the filler neck
aperture. If gauge indicates over 75%,
drain a minimum of 10 litres (2.6 US Gallons) from
fuel tank. See Adjustment.
CAUTION: before disconnecting any part
of the system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1. Open fuel filler flap and remove filler cap.
2. Disconnect battery earth lead.
3. Remove RH rear wheel arch liner. See
CHASSIS AND BODY, Repair.
4. Remove nut securing filler neck bracket to stud.
5. Disconnect vent line quickfit connectors at
fuel/vapour separator and under body
connection.
6. Disconnect pressure sensor breather pipe
connection.
REPAIR
41
19
FUEL SYSTEM
NEW RANGE ROVER
Refit
ANTI-TRICKLE FILL VALVE - ADVANCED EVAPS
CAUTION: Hose clips used on the filler
neck of advanced EVAPS vehicles have a
special ’shear’ cap to ensure the correct
tightening torque is achieved. Always use NEW
clips of the correct type.
Service repair no - 19.55.31
Remove
1. Remove the fuel filler neck. See this section.
11. Loosely position new clip to filler neck hose.
12. Position filler neck assembly to fuel tank stub,
rotated anti-clockwise as shown.
13. Engage internal breather hose to fuel tank inner
stub.
14. Engage filler neck hose with fuel tank stub.
15. Manoeuvre filler neck into position and engage
with grommet.
16. Engage filler neck bracket with body stud and
secure with nut.
17. Tighten clip securing hose to fuel tank stub until
cap shears off.
18. Connect vent lines to fuel/vapour separator and
under floor connection, ensuring that quickfit
connections fully engage.
19. Connect pressure sensor breather line.
20. Replenish fuel if necessary.
21. Fit filler cap and tighten in accordance with
instructions.
22. Close filler flap.
23. Connect battery earth lead.
2. Release the cobra clip securing the hose to the
liquid/vapour separator and disconnect the hose.
3. Loosen the grub screw on the valve nut, two
complete turns.
4. Loosen the valve nut completely.
NOTE: The nut is held captive by the stub
pipe on the filler neck.
5. Carefully remove the valve and hose assembly
from the filler neck
42
REPAIR
LAND ROVER V8
Refit
6. Fit a new ’O’ ring to the recess in the stub pipe.
7. Fit the valve and hose assembly to the filler neck
stub pipe, ensuring that the ’O’ ring is fitted
around the body of the valve as it is pushed into
the filler neck stub pipe.
8. Hand tighten the nut, then tighten to 3 Nm
9. Tighten the grub screw to 2 Nm
10. Connect the hose to the liquid/vapour separator
and secure with the cobra clip.
11. Fit the fuel filler neck. See this section.
FUEL TANK, PUMP AND GAUGE SENDER UNIT PRE-ADVANCED EVAPS
Service repair no - 19.55.01 - Fuel Tank
Service repair no - 19.45.08 - Fuel Pump
Service repair no - 88.25.32 - Fuel gauge Tank Unit
Remove
1. Disconnect battery negative lead.
2. Petrol Models Only: Depressurise fuel system.
See this section.
3. Remove contents of fuel tank into an approved
closed container.
4. Remove fuel filler neck. See this section.
5. Raise vehicle on four post lift.
6. Position container beneath fuel filter to catch
spillage.
7. Petrol Models Only: Disconnect feed pipe from
fuel filter.
8. Diesel Models Only: Disconnect feed pipe at
connection, forward of fuel tank.
9.
10.
11.
12.
Disconnect return pipe, forward of tank.
Plug pipes and connections.
Support tank with jack.
Remove 3 nuts and 2 bolts securing tank cradle
to floor pan.
REPAIR
43
19
FUEL SYSTEM
NEW RANGE ROVER
14. Lower tank assembly. Remove from jack.
Do not carry out further dismantling if
component is removed for access only.
Disassemble
15. Remove tank from cradle.
16. Slacken clip. Remove fill breather pipe from tank
unit.
13. Lower tank by 150mm. Disconnect multiplug
from fuel tank unit.
44
REPAIR
17. Disconnect feed and return pipes from tank unit.
Remove each pipe from 2 fuel tank clips.
18. Remove tank unit retaining ring using
LRT-19-001. Remove assembly from tank.
LAND ROVER V8
Refit
27. Raise fuel tank assembly on jack until multiplug
can be connected to tank unit.
28. Raise tank. Align cradle mounting points. Secure
with nuts and bolts.
29. Remove plugs from pipes and connections.
30. Petrol Models Only: Using new ’O’ ring,
connect fuel spill return pipe. Tighten to 16 Nm
(12 lbf.ft)
31. Petrol Models Only: Using new ’O’ ring,
connect fuel feed pipe to filter. Tighten to 20 Nm
(15 lbf.ft)
32. Diesel Models Only: Connect fuel feed and
return pipes.
33. Lower vehicle.
34. Refit fuel filler neck. See this section.
35. Refill fuel tank.
36. Reconnect battery negative lead.
WARNING: A quantity of fuel will be
retained in the unit, care must be taken to
avoid excessive spillage during removal.
19. Remove tank unit sealing rubber and discard.
Reassemble
20.
21.
22.
23.
Fit new sealing rubber.
Fit tank unit. Align location marks.
Fit retaining ring using LRT-19-001.
Connect fuel feed and return pipes to tank unit.
Tighten to 16 Nm (12 lbf.ft)
24. Secure pipes to fuel tank clips.
25. Position fill breather pipe to tank unit. Secure
with clip.
26. Position tank in cradle.
REPAIR
45
19
FUEL SYSTEM
NEW RANGE ROVER
FUEL TANK, PUMP AND GAUGE SENDER UNIT ADVANCED EVAPS
Service repair no - 19.55.01 - Fuel Tank
Service repair no - 19.45.08 - Fuel Pump
Service repair no - 88.25.32 - Fuel Gauge Tank Unit
Remove
WARNING: Ensure that fuel handling
precautions given in 01 - Introduction are
strictly adhered to when carrying out
following instructions.
CAUTION: before disconnecting any part
of the system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign matter
into fuel system.
Remove
1.
2.
3.
4.
Raise vehicle on 4 post ramp.
Disconnect battery earth lead.
Depressurise fuel system. See this section.
Drain fuel tank completely. See this section.
NOTE: Fuel tank draining includes removal
of fuel filler neck.
5. Position container beneath fuel filter to catch
spillage.
6. Disconnect fuel feed pipe at rear of filter.
7. Disconnect fuel return pipe.
8. Remove and discard ’O’ rings. Plug all pipes and
connections.
9. Support tank with jack.
10. Remove 3 nuts and 2 bolts securing tank cradle
to floor pan.
46
REPAIR
11. Lower tank by 150mm (6in) and disconnect 2
multiplugs from tank unit.
12. Lower tank assembly and remove from jack.
LAND ROVER V8
Disassemble
13. Remove tank from cradle.
14. Disconnect and remove breather hose from
pressure sensor.
15. Disconnect feed and return pipes at tank unit
and remove pipes.
16. Remove tank unit locking ring using LRT-19-009.
WARNING: A quantity of fuel will be
retained in the unit. Care must be taken to
avoid excessive spillage during removal.
17. Remove tank unit using the lifting eye provided.
CAUTION: Do not lift the unit using the
feed and return stubs as this may damage
the stubs.
18. Remove tank unit sealing rubber and discard.
Reassemble
19. Fit new sealing rubber to tank unit.
20. Carefully fit tank unit and align aperture tab.
21. Tighten retaining ring to 35Nm (26lbf.ft) using
tool LRT-19-009.
22. Fit fuel pipes and engage to tank clips.
23. Fit breather hose to pressure sensor.
24. Position tank in cradle.
25. Position tank assembly to jack.
REPAIR
47
19
FUEL SYSTEM
Refit
NEW RANGE ROVER
FUEL TANK FILLER CAP - ADVANCED EVAPS
26. Raise fuel tank assembly on jack until multiplugs
can be connected.
27. Connect multiplugs to tank unit.
28. Raise tank and align to mountings. Secure tank
with nuts and bolts.
29. Remove plugs from pipes and connections.
30. Connect and tighten fuel feed and return unions
using new ’O’ rings.
31. Lower vehicle.
32. Fit fuel filler neck. See this section.
33. Refill fuel tank.
34. Connect battery earth lead.
Service repair no - 19.55.08
Remove
1. Open filler flap.
2. Remove nut securing retaining strap to body.
3. Remove cap.
Refit
4. Fit cap, ensuring that it is tightened in
accordance with instruction label.
5. Position cap retaining strap to stud and secure
with nut.
6. Close fuel filler flap.
48
REPAIR
LAND ROVER V8
THROTTLE BODY - from 99MY
Service repair no - 19.22.45
Remove
1. Drain sufficient coolant to allow for removal of
throttle body.
4. Loosen clip securing breather hose and release
hose.
5. Remove TP sensor. See this section.
2. Loosen 3 clips securing air intake hose, release
air intake hose and position aside.
6. Release 2 clips securing coolant hoses to
throttle body and release hoses.
7. Remove 4 bolts securing throttle body to plenum
chamber and remove throttle body.
8. Remove and discard gasket.
Refit
3. Disconnect throttle and cruise control cables
from throttle body cams.
9. Clean plenum chamber and throttle body mating
faces.
10. Using a new gasket, position throttle body, fit
bolts and tighten to 9 Nm (7 lbf.ft).
11. Fit coolant hoses and secure clips.
12. Fit breather hose and secure clip.
13. Fit TP sensor. See this section.
14. Connect throttle and cruise control cables.
15. Position air intake hose and secure clips.
16. Refill cooling system.
REPAIR
49
19 - FUEL SYSTEM
CONTENTS
Page
CRUISE CONTROL
DESCRIPTION AND OPERATION
DESCRIPTION - V8 ............................................................................................. 1
DESCRIPTION - DIESEL ..................................................................................... 1
ADJUSTMENT
CABLE - CRUISE CONTROL - ADJUST - UP TO 99MY ..................................... 1
CABLE - CRUISE CONTROL - ADJUST - FROM 99MY ..................................... 1
REPAIR
CRUISE CONTROL ECU .....................................................................................
CRUISE CONTROL ACTUATOR ........................................................................
SET AND RESUME SWITCHES - CRUISE CONTROL ......................................
CRUISE CONTROL - VACUUM CONTROL UNIT ...............................................
BRAKE AND CLUTCH PEDAL SWITCHES/VENT VALVES - CRUISE
CONTROL ............................................................................................................
CRUISE CONTROL - SWITCH INVERTER/CONVERTER .................................
CABLE - CRUISE CONTROL - UP TO 99MY ......................................................
CABLE - CRUISE CONTROL - FROM 99MY ......................................................
1
1
2
2
3
4
5
5
CRUISE CONTROL
DESCRIPTION - V8
The cruise control system consists of
electro-mechanical devices and comprises of the
following components.
Electronic Control Unit (ECU)
The microprocessor based ECU evaluates the signals
received from the driver controls, BeCM (vehicle
speed signal), brake pedal switch and clutch pedal
switch on manual vehicles. The ECU activates a
vacuum pump as required. The ECU has a memory
function to store desired cruise speed. The memory is
cleared when power to the cruise ECU is cut, i.e.
when the main cruise control switch is turned off.
Driver operated switches
The driver controls cruise operation from 3 switches.
The main cruise control switch is located on the centre
switch pack and activates the cruise control system. 2
further switches are located in the steering wheel.
’Set/+’ informs the ECU of the required cruise speed.
’Res’ temporarily switches cruise control off but
retains the previously set cruise speed. Pressing ’Res’
a second time resumes the previously selected cruise
speed.
Vehicle speed signal
The cruise control ECU receives a road speed signal
from the BeCM, which in turn receives the signal from
the ABS ECU. The cruise control ECU compares the
road speed signal with the required cruise speed and
adjusts the output to the vacuum pump as necessary.
Cruise control will not operate below the low speed
threshold of 28 mph or above the high speed
threshold of 125 mph.
Brake pedal switch
The vehicle utilised 2 brake pedal switches, mounted
on the pedal box. One switch is normally closed with
the brake pedal released while the other is normally
open. The normally closed switch also incorporates a
vent valve to rapidly deplete actuator vacuum when
cruise control is disengaged. When the brake pedal is
pressed, the signal from each brake switch is
monitored by the cruise control ECU which switches
the vacuum pump off.
Clutch pedal switch
The clutch pedal switch is located on the pedal box
and is identical to the previously described brake
pedal switch with vent valve.
Vacuum pump
When cruise control is active and cruise ECU inputs
are acceptable, the ECU energises the vacuum pump
motor. The vacuum pump creates a vacuum in the
actuator which operates the throttle linkage. When the
required speed has been achieved, the ECU switches
off the vacuum pump. The ECU also controls a dump
valve which allows system vacuum to vent to
atmosphere.
Actuator
The actuator provides the servo mechanical link
between the cruise control system and the throttle
linkage.
Neutral lock-out - automatic vehicles
Cruise control is disengaged when neutral or park is
selected in the main gearbox. The cruise control ECU
receives a signal from the BeCM.
Engine overspeed - manual vehicles
Cruise control is disengaged if the engine speed
exceeds 5000 rpm. The cruise control ECU receives
the engine speed signal from the BeCM.
DESCRIPTION - DIESEL
Diesel vehicles utilise the electronic diesel control
(EDC) system for cruise control. As the EDC has
complete control of the fuelling system, the only
additional inputs required for cruise control are, driver
controls, vehicle speed, brake and clutch signals. The
individual components are as previously described by
V8 vehicles.
DESCRIPTION AND OPERATION
1
CRUISE CONTROL
CABLE - CRUISE CONTROL - ADJUST - UP TO
99MY
CABLE - CRUISE CONTROL - ADJUST - FROM
99MY
Service repair no - 19.75.09
Service repair no - 19.75.11
1. Ensure throttle cable is adjusted correctly. See
this section.
2. Using light finger pressure only, push cruise
control lever towards plenum chamber to remove
all free play from cruise control cable.
Check
1. Ensure that the throttle cable is correctly
adjusted. See this section.
2. Check for a 0.5 - 1.5mm gap between cruise
control cable cam and throttle cable driven lever.
Adjust
3. Adjust cable outer length by turning plastic
thumb screw to achieve a clearance of between
0.5 mm and 1.5 mm.
3. Rotate cruise control cable adjusting nut to give
a 0.5 - 1.5mm gap between the cruise control
cable cam and throttle cable driven lever.
ADJUSTMENT
1
CRUISE CONTROL
CRUISE CONTROL ECU
CRUISE CONTROL ACTUATOR
Service repair no - 19.75.49
Service repair no - 19.75.05
Remove
Remove
1. Remove fascia closing panel. See CHASSIS
AND BODY, Repair.
2. Remove 2 bolts securing ECU bracket to fascia.
Release bracket to gain access to fixings.
3. Disconnect multiplug from ECU.
4. Remove 2 bolts securing ECU. Remove ECU.
1. Disconnect vacuum hose from actuator.
2. Disconnect control cable from ball joint on
actuator diaphragm.
3. Remove nut securing actuator to bracket.
Remove actuator.
Refit
Refit
5. Reverse removal procedure.
4. Position actuator to bracket. Secure with nut.
5. Connect vacuum hose. Secure cable to actuator
ball joint.
6. Adjust cruise control cable. See CRUISE
CONTROL, Adjustment.
REPAIR
1
19
FUEL SYSTEM
SET AND RESUME SWITCHES - CRUISE
CONTROL
NEW RANGE ROVER
CRUISE CONTROL - VACUUM CONTROL UNIT
Service repair no - 19.75.06
Service repair no - 19.75.36 - Set Switch
Service repair no - 19.75.37 - Resume Switch
Remove
Remove
1. Remove steering wheel switch pack assembly.
See ELECTRICAL, Repair.
Refit
2. Reverse removal procedure.
1. Remove 2 screws securing actuator bracket.
2. Release cover and disconnect multiplug from
vacuum control unit.
2
REPAIR
CRUISE CONTROL
BRAKE AND CLUTCH PEDAL SWITCHES/VENT
VALVES - CRUISE CONTROL
Service repair no - 19.75.34 - Clutch Switch
Service repair no - 19.75.35 - Brake Switch (not
fitted to diesel variants)
Remove
1. Remove drivers side fascia closing panel. See
CHASSIS AND BODY, Repair.
2. Remove 3 scrivet fasteners securing lower
closing panel. Release panel to gain access to
blower motor ducting.
3. Remove vacuum hose from control unit.
4. Release 3 rubber mountings and remove control
unit.
5. Remove 3 rubber mountings from control unit.
Refit
6.
7.
8.
9.
10.
Fit rubber mountings to control unit.
Position control unit and secure mountings.
Connect vacuum hose to control unit.
Connect multiplug and fit cover.
Position actuator bracket and secure with
screws.
3. Release ducting from blower motor housing and
heater. Remove blower motor ducting.
4. Release switch/vent valve from pedal bracket.
REPAIR
3
19
FUEL SYSTEM
NEW RANGE ROVER
CRUISE CONTROL - SWITCH
INVERTER/CONVERTER
Service repair no - 19.75.22
NOTE: Inverter is used on petrol, converter
on diesel. Units are in same position and
are visually similar. Illustration 19M7054
shows petrol condition, diesel vehicles do not
have the cruise control ECU.
Remove
1. Remove fascia closing panel. See CHASSIS
AND BODY, Repair.
2. Release inverter/converter multiplug from
bracket.
5. Disconnect vacuum hose and multiplug from
switch.
NOTE: Vacuum hose fitted to petrol
variants only.
6. Remove switch/vent valve.
Refit
7. Reverse removal procedure.
NOTE: The switch/vent valve is factory set
and does not require adjustment in
service.
3. Remove inverter/converter from multiplug.
Refit
4. Reverse removal procedure.
4
REPAIR
CRUISE CONTROL
CABLE - CRUISE CONTROL - UP TO 99MY
CABLE - CRUISE CONTROL - FROM 99MY
Service repair no - 19.75.10
Service repair no - 19.75.10
Remove
Remove
1. Release cable from actuator. Disengage adjuster
from actuator abutment bracket.
2. Remove split pin and clevis pin from cable
trunnion.
3. Remove ’C’ clip securing cable to abutment
bracket. Remove cable.
1. Disconnect inner cable from actuator.
2. Release cable from actuator mounting bracket.
Refit
4. Position cable through abutment bracket. Secure
with ’C’ clip.
5. Position cable trunnion to throttle linkage.
Secure with clevis pin and split pin.
6. Engage cable adjuster to actuator abutment
bracket. Connect cable to actuator diaphragm.
7. Adjust cruise control cable. See CRUISE
CONTROL, Adjustment.
3. Release cable from 2 support clips.
REPAIR
5
19
FUEL SYSTEM
4. Loosen cable locknuts, release cable from
abutment bracket.
5. Release inner cable from operating lever and
remove cable.
Refit
6.
7.
8.
9.
Position cable and connect to operating lever.
Position cable to abutment bracket.
Fit cable to support clips.
Fit cable to actuator mounting bracket and
connect inner cable to actuator.
10. Adjust cruise control cable. See Adjustment.
6
REPAIR
NEW RANGE ROVER
26 - COOLING SYSTEM
CONTENTS
Page
BMW DIESEL
DESCRIPTION AND OPERATION
DIESEL COOLING SYSTEM ...............................................................................
ENGINE COOLING ..............................................................................................
COOLANT CIRCULATION ...................................................................................
INTERCOOLER ...................................................................................................
ENGINE OIL COOLER .........................................................................................
GEARBOX OIL COOLER - MANUAL ..................................................................
GEARBOX OIL COOLER - AUTOMATIC ............................................................
1
2
3
4
5
6
7
FAULT DIAGNOSIS
COOLING SYSTEM FAULTS .............................................................................. 1
REPAIR
COOLANT - DRAIN AND REFILL ........................................................................
RADIATOR ...........................................................................................................
WATER PUMP .....................................................................................................
VISCOUS COUPLING AND FAN ASSEMBLY ....................................................
THERMOSTAT .....................................................................................................
COOLING FAN COWL .........................................................................................
1
2
4
5
6
7
BMW DIESEL
DIESEL COOLING SYSTEM
The complete cooling system installed in vehicles with
diesel engines incorporates four independent cooling
functions:- Engine (coolant) cooling; Turbo (charge
air) intercooling; Engine oil cooling; Gearbox oil
cooling.
Both intercooler and engine oil cooler are mounted in
front of the radiator while the gearbox oil cooler on
manual vehicles is an integral part of the radiator.
Pre-formed pipes/hoses are used to link the
components within the separate systems, as shown in
26M7029.
Engine cooling system
1.
2.
3.
4.
5.
6.
7.
8.
9.
Radiator
Thermostat housing
Radiator return hose
Viscous fan and water pump
Radiator top hose
Radiator bleed pipe
Heater feed pipe
Heater matrix
Heater return pipe
10.
11.
12.
13.
14.
15.
16.
17.
18.
Expansion tank
Overflow/breather pipe
Crankcase
Intercooler
Cross-over duct
Link hose
Turbocharger
Inlet pipe
Feed hose
19.
20.
21.
22.
23.
Engine oil cooler
Oil filter
Feed pipe, engine oil cooler
Return pipe, engine oil cooler
Gearbox oil cooler (manual
gearbox, oil cooler shown)
24. Feed pipe, gearbox oil cooler
25. Return pipe, gearbox oil
cooler
DESCRIPTION AND OPERATION
1
26
COOLING SYSTEM
NEW RANGE ROVER
ENGINE COOLING
Description
The 2.5 litre diesel engine uses a pressurized cooling
system and a vertical flow, two row matrix radiator. An
expansion tank, mounted on the RH side of the
engine compartment, provides a fluid reservoir for the
coolant system.
A belt driven centrifugal water pump, complete with
viscous fan, is fitted to the engine front timing cover
and pumps coolant to the engine crankcase and
cylinder head. The thermostat housing, located at the
front of the crankcase, see 26M7030, is fitted with a
separate vent valve.
Engine cooling system
1.
2.
3.
4.
5.
6.
2
Radiator
Thermostat/housing
Radiator return hose
Viscous fan and water pump
Radiator top hose
Radiator bleed pipe
DESCRIPTION AND OPERATION
7.
8.
9.
10.
11.
12.
Heater feed pipe
Heater matrix
Heater return pipe
Expansion tank
Overflow/breather pipe
Crankcase
BMW DIESEL
COOLANT CIRCULATION
Operation
When the engine is started from cold, the thermostat,
integral in the housing (2), prevents any coolant
circulation through the radiator by closing off the
supply from the radiator. During the engine warm up,
the water pump (4) pumps coolant around the
cylinders in the crankcase (12) and through separate
galleries to the cylinder head. At the rear LH side of
the cylinder head, a proportion of the flow is diverted
through a heater feed pipe (7). The heater feed pipe is
connected to the heater matrix (8), which is housed in
the distribution unit of the heating and ventilation
system. This coolant is then carried, via the heater
return pipe (9) back to the water pump. The remaining
coolant flows through a bypass port at the front of the
cylinder head back to the water pump to complete the
cycle.
When normal engine running temperature is reached,
the thermostat opens and a secondary valve closes
the bypass port. With the thermostat open, coolant is
circulated through the top hose (5) to the radiator.
Coolant is drawn from the base of the radiator by the
water pump. Coolant circulation through the
crankcase and cylinder head to the heater matrix
remains the same.
An integral bleed pipe (6), connects the top of the
radiator to the expansion tank and aids bleeding of air
from the coolant system. The expansion tank cap
contains a pressure valve which allows excessive
pressure and coolant to vent to the overflow pipe (11)
if the system has been overfilled.
VISCOUS FAN
The viscous drive unit for the cooling fan on diesel
engines work on the same principal as that fitted on
V8 engines but is of slightly different size. See this
section.
DESCRIPTION AND OPERATION
3
26
COOLING SYSTEM
NEW RANGE ROVER
INTERCOOLER
Description
Operation
The intercooler (1) is an aluminium heat exchanger,
with integral side tanks, comprising a single row
matrix incorporating fifteen internal cooling tubes. A
cross-over duct (2) directs air from the air cleaner,
through a link hose (3) to the turbocharger (4). Air is
directed under pressure from the turbocharger to the
intercooler via the pre-formed inlet pipe (5). The
cooled air is fed to the inlet manifold through the feed
hose (6), see 26M 7031.
The 2.5 litre diesel has a high power output and is
subject to high running temperatures. Compression in
the turbocharger heats the air considerably, so that it
expands. As a result the air charge mass per cylinder
is reduced, having a negative effect on power output.
The charge-air intercooler cools the air before it
reaches the cylinders, thus increasing its density. This
increases power output through increased mass of
oxygen in the combustion process as well as
maximising engine durability through maintaining
lower piston and head temperatures.
Intercooler
1.
2.
3.
4.
5.
6.
4
Intercooler
Cross-over duct
Link hose
Turbocharger
Inlet pipe
Feed hose
DESCRIPTION AND OPERATION
BMW DIESEL
ENGINE OIL COOLER
Description
Operation
The engine oil cooler is located in front of the radiator,
below the intercooler, and comprises a two pass,
single row matrix with twelve internal cooling tubes.
Pre-formed feed and return pipes/hoses are used to
link the oil filter housing and oil cooler, as shown in
26M7032.
When the engine reaches its normal operating
temperature, oil, drawn through a steel strainer in the
sump, is pumped under pressure from the filter
housing (2) to the oil cooler (1) via the feed pipe (3).
Ambient air, forced through the front grille of the
vehicle and assisted by the pull of the viscous fan, is
dispersed across the oil cooler. The cooled oil then
passes through a return pipe (4) to the filter housing
before being distributed by the oil pump to the various
internal engine components.
Engine oil cooler
1.
2.
3.
4.
Engine oil cooler
Oil filter
Feed pipe
Return pipe
DESCRIPTION AND OPERATION
5
26
COOLING SYSTEM
NEW RANGE ROVER
GEARBOX OIL COOLER - MANUAL
Description
Operation
The gearbox oil cooler on manual vehicles is an
integral part of the radiator and is a brass concentric
tube type. The cooler is immersed in a separate water
tank at the base of the radiator. The inner core, which
has its own water jacket within the cooling tube,
carries the transmission oil via feed and return pipes,
see 26M7033.
Oil is pumped under pressure from the gearbox
through the feed pipe (3) into the tube (2) of the oil
cooler tank. With a combination of water and ram air
cooling, through the front grille of the vehicle and
assisted by the pull of the viscous fan, the cooled
transmission oil is routed back to the gearbox via the
return pipe (4), to repeat the cycle.
Gearbox oil cooler, manual transmission
1.
2.
3.
4.
6
Gearbox oil cooler tank
Coolant tube
Feed pipe, oil cooler
Return pipe, oil cooler
DESCRIPTION AND OPERATION
BMW DIESEL
GEARBOX OIL COOLER - AUTOMATIC
Description
Operation
On diesel models with automatic transmission an
independent oil cooler is used and is mounted on the
LH side of the vehicle behind the front bumper. The oil
cooler comprises a cast aluminium radiator, two pass,
single row matrix with sixteen internal cooling tubes.
Pre-formed feed and return pipes/hoses are used to
link the automatic transmission and oil cooler.
On automatic vehicles the coolant process relies on
ram air only through an aperture in the LH side of the
bumper moulding. Air is dispersed over the oil cooler,
the cooled oil then being fed back,via the return pipe
(3), to run parallel with the feed pipe to the LH side of
the transmission.
Gearbox oil cooler, automatic transmission
1.
2.
3.
4.
Gearbox oil cooler
Feed pipe, oil cooler
Return pipe, oil cooler
Mounting brackets
DESCRIPTION AND OPERATION
7
BMW DIESEL
COOLING SYSTEM FAULTS
This section covers mechanical faults that could occur
in the complete cooling system :- 1 Engine (coolant)
cooling; 2 Turbo intercooling; 3. Engine oil cooling; 4.
Gearbox oil cooling.
Before conducting any visual checks within the
separate systems and undertaking detailed diagnosis
procedures. See Description and operation.
1. ENGINE (COOLANT) COOLING SYSTEM
Symptom - Engine Overheating
POSSIBLE CAUSE
REMEDY
1. Engine coolant low.
1. Allow engine to cool. Top up expansion tank to correct level, with
engine running at idle. Check cooling system for leaks and rectify if
necessary.
2. Loose drive belt.
2. Check/renew drive belt tensioner or renew drive belt. See
ELECTRICAL, Repair.
3. Coolant in radiator frozen.
3. Slowly thaw and drain cooling system. See Repair.
4. Air flow through radiator
restricted or blocked.
4. Apply air pressure to engine side of radiator to clear obstruction. If
mud or dirt is evident, carefully use a hose.
5. External leaks from water
pump, engine gaskets,
thermostat housing or
pipe/hoses.
5. Check for visual causes and rectify.
6. Viscous fan not operating
correctly or inoperative.
6. Renew viscous fan unit. See Repair.
7. Thermostat seized in closed
position.
7. Check radiator bottom hose for coolant flow through radiator. If cold
a faulty thermostat is confirmed. Renew thermostat. See Repair.
FAULT DIAGNOSIS
1
26
COOLING SYSTEM
NEW RANGE ROVER
Symptom - Engine Overheating Continued
POSSIBLE CAUSE
REMEDY
8. Air in cooling system.
8. Check coolant level. Run engine at fast idle (approximately 2,000
rpm) with expansion tank cap off. Top up coolant level with engine
at idle and refit expansion tank cap.
9. Air conditioning condenser fans
not operating correctly or
inoperative.
9. See AIR CONDITIONING, Fault diagnosis.
10. Temperature gauge or sender
unit giving inaccurate readings.
10. Refer to TestBook .
11. Coolant leakage across
cylinder head gasket.
11. Carry out cylinder pressure test to determine if pressure is leaking
into cooling system, causing over pressurising and loss of coolant.
Renew cylinder head gasket.
12. Engine oil contamination of
cooling system due to leaking.
12. Renew cylinder head gasket. See ENGINE, Repair.
13. Coolant contamination of
lubrication system.
13. Renew inlet manifold or front cover gaskets. See MANIFOLD AND
EXHAUST SYSTEM, Repair. or See ENGINE, Repair.
Symptom - Engine Runs Cold
POSSIBLE CAUSE
REMEDY
1. Thermostat seized in open or
partially open position.
1. Remove thermostat housing and check operation of thermostat.
Renew, if necessary. See Repair.
2. Temperature gauge or sender
unit giving inaccurate readings.
2. Refer to TestBook .
3. Viscous fan not operating
correctly.
3. Renew viscous fan unit. See Repair.
4. Air conditioning condenser fans
operating continuously.
4. Refer to TestBook .
2
FAULT DIAGNOSIS
BMW DIESEL
2. TURBO INTERCOOLING SYSTEM
Symptom - Loss of Performance
POSSIBLE CAUSE
REMEDY
1. Cooling air flow through
intercooler matrix restricted or
blocked.
1. Apply air pressure to engine side of radiator to clear obstruction. If
mud or dirt is evident, carefully use a hose.
2. Charge-air flow through
intercooler matrix restricted.
2. Check for blocked air cleaner element and renew, if necessary.
See SECTION 10, Maintenance.
3. Blocked air cleaner.
3. Renew air cleaner element. See SECTION 10, Maintenance.
4. Pipe/hose leaks in intercooler
system.
4. Tighten all joint connections or renew components as necessary.
5. Turbocharger not operating
correctly or inoperative.
5. Substitute parts and recheck. See FUEL SYSTEM, Repair.
6. Customer fitted grille blind
restricting cooling air flow.
6. Remove blind or advise accordingly.
3. ENGINE OIL COOLING SYSTEM
Symptom - Engine Oil Overheating
POSSIBLE CAUSE
REMEDY
1. Air flow through oil cooler
matrix restricted or blocked.
1. Apply air pressure to engine side of radiator to clear obstruction. If
mud or dirt is evident carefully use a hose.
2. Blocked or damaged oil cooler
or pipe/hoses, restricting
engine oil flow.
2. Check for visual damage and renew components where necessary.
3. Oil cooler relief valve seized in
closed position.
3. Remove and check relief valve. Renew if necessary.
FAULT DIAGNOSIS
3
26
COOLING SYSTEM
NEW RANGE ROVER
4. GEARBOX OIL COOLING SYSTEM
Symptom - Gearbox Oil Overheating
POSSIBLE CAUSE
REMEDY
1. Blocked or damaged oil cooler
or pipe/hoses restricting
gearbox oil flow.
1. Check for visual damage and renew components where necessary.
2. Leaking coolant from oil cooler
water tank.
2. Remove radiator, inspect for source of leak and repair. See Repair.
3. Vehicle being driven in wrong
gear.
3. Advise owner/driver accordingly.
NOTE: Critical warning messages relating
to the complete cooling system are
displayed on the message centre of the
instrument pack, should a fault occur in any of the
separate systems.
4
FAULT DIAGNOSIS
BMW DIESEL
COOLANT - DRAIN AND REFILL
Service repair no - 26.10.01
5. If system is only being partially drained, continue
at Refill.
6. Reposition container. Remove cylinder block
drain plug. Allow coolant to drain.
Drain
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised. Personal scalding
could result.
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove expansion tank filler cap to assist
draining.
7. Clean drain plug threads. Apply a coating of
’Loctite 577’. Refit plug to block. Tighten
securely.
3. Position container beneath radiator.
4. Remove plug from base of radiator. Allow
coolant to drain.
REPAIR
1
26
COOLING SYSTEM
Refill
NEW RANGE ROVER
RADIATOR
8. Ensure sufficient coolant solution is available.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
9. Inspect radiator drain plug ’O’ ring, renew if
required.
10. Fit drain plug to radiator. Tighten to Max 6 Nm
(4 lbf.ft)
11. Remove safety stands. Lower vehicle.
12. Disconnect radiator bleed hose at the radiator.
13. Blow through hose to clear any residual coolant.
Reconnect hose.
14. Fill expansion tank until coolant is level with
base of neck.
15. Start engine, continue filling at expansion tank
until coolant level stabilises at the ’COLD
LEVEL’ marking.
16. Run the engine until the thermostat opens (top
hose becomes warm).
17. Stop engine, allow to cool.
18. Check coolant level, top-up as necessary.
19. Refit expansion tank filler cap.
Service repair no - 26.40.04
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3.
4.
5.
6.
Drain cooling system. See this section.
Remove viscous coupling. See this section.
Release bottom hose from radiator.
Release expansion tank hose from radiator.
7. Manual Vehicles:Disconnect gearbox oil cooler
pipes from radiator. Remove ’O’ rings and
discard.
8. Manual Vehicles:Plug oil cooler pipes and
connections.
9. Remove 2 bolts securing radiator to bracket.
Remove radiator assembly.
2
REPAIR
BMW DIESEL
Refit
11. Ensure that lower mounting rubbers are
positioned.
12. With assistance, position radiator. Engage
mountings. Secure with bolts.
13. Manual Vehicles:Remove plugs from oil cooler
pipes and connections.
14. Manual Vehicles:Using new ’O’ rings, connect
gearbox oil cooler pipes. Tighten to 30 Nm
(22 lbf.ft)
15. Fit viscous coupling. See this section.
16. Connect cooling hoses to radiator. Secure with
clips.
17. Refill cooling system. See this section.
18. Remove safety stands. Lower vehicle.
19. Reconnect battery negative lead.
20. Manual Vehicles:Top-up gearbox fluid. See
SECTION 10, Maintenance.
10. If necessary, remove 2 clips securing cowl to
radiator. Remove cowl.
REPAIR
3
26
COOLING SYSTEM
WATER PUMP
Service repair no - 26.50.01
Remove
1. Remove radiator assembly. See this section.
2. Slacken 4 water pump pulley bolts.
3.
4.
5.
6.
Release tension from auxiliary drive belt.
Release belt from water pump pulley.
Remove pulley bolts. Remove pulley.
Remove 4 bolts securing water pump.
7. Fit 2 M6 bolts into tapped holes of water pump.
Extract pump.
8. Remove ’O’ ring and extraction bolts.
4
REPAIR
NEW RANGE ROVER
Refit
9. Ensure mating faces are clean.
10. Lubricate ’O’ ring with petroleum jelly. Fit to
water pump.
11. Fit water pump. Secure with bolts. Tighten to
10 Nm (7 lbf.ft)
12. Fit water pump pulley. Secure with bolts. Tighten
to 10 Nm (7 lbf.ft)
13. Rotate tensioner. Fit auxiliary drive belt.
14. Fit radiator assembly. See this section.
BMW DIESEL
VISCOUS COUPLING AND FAN ASSEMBLY
NOTE: Viscous coupling is fitted with a LH
thread.
Service repair no - 26.25.19
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
9. Remove viscous coupling assembly from LH
side of radiator.
10. Do not carry out further dismantling if
component is removed for access only.
11. Remove 4 bolts securing fan to coupling.
Remove coupling.
WARNING: Support on safety stands.
3. Drain cooling system. See this section.
4. Remove 3 bolts securing upper fan cowl.
Remove cowl.
Refit
5. Release top hose from radiator. Position hose
aside.
6. Release outlet hose from intercooler. Position
hose aside.
7. Remove 2 bolts securing power steering
reservoir to radiator bracket. Position reservoir
aside.
8. Using special tools LRT-12-093 and LRT-12-094
unscrew viscous coupling.
12. Ensure mating faces are clean.
13. Fit fan to coupling. Secure with bolts. Tighten to
10 Nm (7 lbf.ft)
14. Position viscous coupling assembly.
15. Engage to pump. Using special tools
LRT-12-093 and LRT-12-094. Tighten to
40 Nm (29 lbf.ft)
16. Connect hoses to intercooler and radiator.
Secure with clips.
17. Position power steering fluid reservoir to radiator
bracket. Secure with bolts.
18. Position upper fan cowl. Secure with bolts.
19. Refill cooling system. See this section.
20. Remove safety stands. Lower vehicle.
21. Reconnect battery negative lead.
REPAIR
5
26
COOLING SYSTEM
THERMOSTAT
NEW RANGE ROVER
NOTE: Collect grommet. Refit to ducting.
Service repair no - 26.45.01
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
7. Disengage 2 clips securing intake ducting.
Remove ducting.
8. Remove 3 bolts securing intake ducting bracket
and exhaust manifold heat shield to camshaft
cover. Collect bracket.
WARNING: Support on safety stands.
3. Remove cooling fan cowl. See this section.
4. Release intake hose from ducting.
9. Disconnect heater hose from coolant connecting
pipe.
10. Remove bolt securing coolant connecting pipe to
engine front cover.
5. Release turbocharger intake hose from ducting.
6. Release breather valve from intake ducting
grommet.
6
REPAIR
BMW DIESEL
11. Remove coolant pipe. Remove ’O’ ring and
discard.
12. Remove top hose from thermostat housing.
13. Remove 3 bolts securing thermostat housing to
engine front cover.
14. Remove thermostat housing.
15. Collect thermostat. Remove ’O’ ring and discard.
COOLING FAN COWL
Service repair no - 26.25.11
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
Refit
WARNING: Support on safety stands.
16. Lubricate new ’O’ ring with clean coolant
solution. Fit to thermostat.
17. Locate thermostat in housing.
3. Remove viscous coupling and fan assembly.
See this section.
4. Disconnect bottom hose from radiator.
5. Remove 2 clips securing cowl to radiator.
6. Remove cooling fan cowl from radiator.
Refit
7. Reverse removal procedure.
CAUTION: Ensure that ball valve is
correctly located.
18. Position thermostat and housing assembly.
Secure with bolts. Tighten to 10 Nm (7 lbf.ft)
19. Fit top hose to thermostat. Secure with clip.
20. Using a new ’O’ ring, position coolant pipe.
Engage to engine front cover.
21. Secure connecting pipe to front cover with bolt.
Tighten to 10 Nm (7 lbf.ft)
22. Connect heater hose. Secure with clip.
23. Align exhaust manifold heat shield. Position
intake ducting bracket.
24. Secure ducting bracket and heat shield with
bolts.
25. Position intake ducting. Engage clips.
26. Engage breather valve into ducting grommet.
27. Connect ducting to turbocharger intake hose.
Secure with clip.
28. Connect intake hose to ducting. Secure with clip.
29. Fit cooling fan cowl. See this section.
30. Remove safety stands. Lower vehicle.
31. Reconnect battery negative lead.
REPAIR
7
26 - COOLING SYSTEM
CONTENTS
Page
LAND ROVER V8
DESCRIPTION AND OPERATION
ENGINE COOLING - DESCRIPTION .................................................................. 3
ENGINE COOLING - OPERATION ...................................................................... 9
FAULT DIAGNOSIS
COOLING SYSTEM FAULTS .............................................................................. 1
REPAIR
COOLANT - DRAIN AND REFILL ........................................................................
RADIATOR ...........................................................................................................
VISCOUS COUPLING AND FAN ASSEMBLY - UP TO 99MY ............................
VISCOUS COUPLING AND FAN ASSEMBLY - FROM 99MY ............................
WATER PUMP - UP TO 99MY ............................................................................
WATER PUMP - FROM 99MY .............................................................................
THERMOSTAT - UP TO 99MY ............................................................................
THERMOSTAT - FROM 99MY ............................................................................
EXPANSION TANK ..............................................................................................
1
2
4
5
6
7
8
8
9
LAND ROVER V8
V8 cooling system component layout - up to 99MY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Radiator
Thermostat housing
Bottom hose
Bypass hose
Viscous fan and water pump
Radiator top hose
Radiator bleed pipe
Plenum chamber feed pipe
Plenum chamber bleed pipe
Heater feed hose
Heater matrix
Heater return hose
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Expansion tank
Overflow/Breather pipe
Cylinder banks
Plenum chamber
Engine oil cooler
Engine oil filter
Feed pipe, engine oil cooler
Return pipe, engine oil cooler
Gearbox oil cooler
Feed pipe, gearbox oil cooler
Return pipe, gearbox oil cooler
DESCRIPTION AND OPERATION
1
26
COOLING SYSTEM
NEW RANGE ROVER
V8 cooling system component layout - from 99MY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
2
Heater matrix
Throttle housing
Throttle housing inlet hose
Throttle housing return pipe
Radiator top hose
Coolant pump
Manifold outlet pipe
Viscous fan
Radiator
Engine oil cooler
Gearbox oil cooler
DESCRIPTION AND OPERATION
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Radiator bottom hose
Thermostat housing
By-pass hose
Coolant pump feed hose
Radiator bleed pipe
Overflow/breather pipe
Expansion tank
Pressure cap
Expansion hose
Heater inlet hose/pipe
Heater return hose/pipe
LAND ROVER V8
ENGINE COOLING - DESCRIPTION
General
The complete cooling system installed in vehicles with
V8 engines incorporates three independent functions:Engine (coolant) cooling; Engine oil cooling; Gearbox
oil cooling.
Engine and gearbox oil coolers are mounted in front of
the radiator and linked to their separate systems by
pre-formed pipes and hoses.
The cooling system used on the V8 engine is a
pressurised, by-pass type system which allows
coolant to circulate around the engine block and
heater matrix when the thermostat is closed. With
coolant not passing through the radiator, faster heater
warm-up is promoted which in turn improves
passenger comfort.
A coolant pump is located in a housing at the front of
the engine and is driven by a drive belt. The water
pump is connected into the coolant passages cast into
the cylinder block and pumps coolant from the radiator
through the cylinder block and heater circuit.
The plastic housing contains a wax element
thermostat. The thermostat and housing are a sealed
unit and cannot be replaced individually. The
thermostat is used to maintain the coolant at the
optimum temperature for efficient combustion and to
aid engine warm-up.
The thermostat is closed at temperatures below
approximately 80 °C (176 °F). When the coolant
temperature reaches between 80 to 84 °C
(176 to 183 °F) the thermostat starts to open and is
fully open at approximately 96 °C (204 °F). In this
condition the full flow of coolant is directed through the
radiator.
Inlet manifold cooling connections
With the thermostat open, coolant leaves the cylinder
block via an outlet pipe and top hose attached to the
front of the inlet manifold. The top hose is connected
to the top of the radiator.
Hot coolant from the cylinder block is also directed
from the inlet manifold via pipes and hoses to the
heater matrix. Coolant is circulated through the heater
matrix at all times when the engine is running.
Plenum chamber - up to 99MY
A viscous fan is attached to the water pump drive
pulley. The fan is secured by a left hand threaded nut
to the pulley spindle. The fan draws air through the
radiator to assist in cooling when the vehicle is
stationary. The fan rotational speed is controlled
relative to the running temperature of the engine by a
thermostatic valve regulated by a bi-metallic coil.
The cooling system uses a 50/50 mix of anti-freeze
and water.
Thermostat housing
A ’four way’ thermostat housing, located at the bottom
of the fan cowling behind the radiator, is used to link
the main components within the engine cooling
system. The four connections locate the radiator
bottom hose, top hose, by-pass hose and coolant
pump feed hose.
The plenum chamber is heated with a supply of
coolant from a supply pipe from the inlet manifold to a
plate on the underside of the throttle on the plenum.
The hot coolant prevents the air intake and throttle
linkage from icing. A bleed pipe returns coolant from
the plenum chamber to the expansion tank.
Throttle housing - from 99MY
A tapping from the inlet manifold supplies coolant to
the throttle housing via a hose. The coolant circulates
through a plate attached to the bottom of the throttle
housing and is returned through a plastic bleed pipe to
the expansion tank. The hot coolant heats the throttle
housing preventing ice from forming.
DESCRIPTION AND OPERATION
3
26
COOLING SYSTEM
ECT sensor and temperature gauge sender unit up to 99MY
An Engine Coolant Temperature (ECT) sensor and a
temperature gauge sender unit are located on the inlet
manifold adjacent to the outlet pipe. The ECT sensor
monitors coolant temperature emerging from the
engine and sends signals relating to coolant
temperature to the ECM for engine management. The
temperature gauge sender unit operates the warning
lamp and temperature gauge in the instrument pack.
See FUEL SYSTEM - Engine Management,
Description and operation.
ECT sensor - from 99MY
An Engine Coolant Temperature (ECT) sensor is
located on the inlet manifold adjacent to the outlet
pipe. The ECT sensor monitors coolant temperature
emerging from the engine and sends signals relating
to coolant temperature to the ECM for engine
management and to the instrument pack for
temperature gauge operation. See FUEL SYSTEM Engine Management, Description and operation.
Expansion tank
The expansion tank is located in the engine
compartment and attached to the right hand inner
wing. The tank is made from moulded plastic and has
a maximum coolant level when cold mark moulded on
the side.
Excess coolant created by heat expansion is returned
to the expansion tank from the bleed pipe at the top of
the radiator. An outlet pipe is connected into the
thermostat housing and replaces coolant displaced by
heat expansion into the system when the engine is
cool.
The tank is fitted with a sealed pressure cap. The cap
contains a pressure relief valve which opens to allow
excessive pressure and coolant to vent through the
overflow pipe. The relief valve opens at a pressure of
1.4 bar (20 lbf.in) and above.
Heater matrix
The heater matrix is fitted in the distribution unit of the
heating and ventilation system inside the passenger
compartment. Two pipes pass through the bulkhead
and provide coolant flow to and from the matrix.
4
DESCRIPTION AND OPERATION
NEW RANGE ROVER
The matrix is constructed from aluminium with two
end tanks interconnected with tubes. Aluminium fins
are located between the tubes and conduct heat away
from the hot coolant flowing through the tubes. Air
from the heater assembly is warmed as it passes
through the matrix fins. The warm air is then
distributed into the passenger compartment as
required. See HEATING AND VENTILATION,
Description and operation.
Radiator
The radiator is located at the front of the vehicle. The
vertical flow radiator is manufactured from aluminium
with moulded plastic tanks at the top and bottom,
interconnected with tubes. Aluminium fins are located
between the tubes and conduct heat from the hot
coolant flowing through the tubes, reducing the
coolant temperature as it passes through the radiator.
Air intake from the front of the vehicle when moving
carries heat away from the fins. When the vehicle is
stationary, the viscous fan draws air through the fins
to prevent the engine from overheating.
Two connections at the top of the radiator provide for
the attachment of the top hose and bleed pipe. A
connection at the bottom of the radiator allows for the
attachment of the bottom hose to the thermostat
housing.
Two coolers are located in front of the cooling
radiator. The upper cooler provides cooling of the
engine oil and the lower cooler provides cooling for
the gearbox oil.
See MANUAL GEARBOX, Description and
operation.
See AUTOMATIC GEARBOX, Description and
operation.
See ENGINE, Description and operation.
Pipes and hoses
The coolant circuit comprises flexible hoses and metal
formed pipes which direct coolant into and out of the
engine, radiator and heater matrix. Plastic pipes are
used for the bleed and overflow pipes to the
expansion tank.
A drain plug is fitted to each cylinder bank in the
cylinder block. These are used to drain the block of
coolant.
LAND ROVER V8
Coolant pump
1. Pulley flange
2. Body
3. Impeller
The coolant pump is attached to the front of the
cylinder block with nine bolts and sealed between the
pump housing and the cylinder block with a gasket.
The pump comprises a shaft which passes through an
alloy housing.
The outer end of the shaft has a flange which allows
for the attachment of the pump drive pulley which is
secured with three bolts. The drive pulley is driven by
the grooved auxiliary drive belt and rotates at the
same speed as the crankshaft. The inner end of the
shaft is fitted with an impeller which draws coolant
from the thermostat housing and circulates it through
galleries in the cylinder block and through the heater
matrix.
4. Gallery
5. Inlet connection
The shaft is supported on bearings in the housing
which are packed with grease and sealed for life. A
seal is positioned in the housing to further protect the
bearings from the ingress of coolant. The seal is
manufactured from a synthetic material which will
allow for the expansion of the casing when hot coolant
is present.
The cast alloy housing has a hose connection which
provides the attachment for the coolant pump feed
hose. The housing connects with galleries in the
cylinder block and distributes coolant from the pump
impeller into the galleries and water jackets.
DESCRIPTION AND OPERATION
5
26
COOLING SYSTEM
Viscous fan
The viscous drive unit for the engine cooling fan
provides a means of controlling the speed of the fan
relative to the temperature of the engine. The viscous
fan unit is a type of fluid coupling, which drives the fan
blades by means of ’silicon fluid’.
1. Input (drive) member
2. Output (driven) member
3. Sensing mechanism (bi-metal coil)
6
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
Cooling system coolant flow - up to 99MY
1.
2.
3.
4.
5.
6.
7.
8.
Radiator
Thermostat housing
Bottom hose
Bypass hose
Viscous fan and water pump
Radiator top hose
Radiator bleed pipe
Plenum chamber feed pipe
9.
10.
11.
12.
13.
14.
15.
16.
Plenum chamber bleed pipe
Heater feed hose
Heater matrix
Heater return hose
Expansion tank
Overflow/breather pipe
Cylinder banks
Plenum chamber
DESCRIPTION AND OPERATION
7
26
COOLING SYSTEM
NEW RANGE ROVER
Cooling system coolant flow - from 99MY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
8
Heater matrix
Throttle housing
Throttle housing inlet hose
Throttle housing return pipe
Radiator top hose
Coolant pump
Manifold outlet pipe
Viscous fan
Radiator
Engine oil cooler
Gearbox oil cooler
DESCRIPTION AND OPERATION
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Radiator bottom hose
Thermostat housing
By-pass hose
Coolant pump feed hose
Radiator bleed pipe
Overflow/breather pipe
Expansion tank
Pressure cap
Expansion hose
Heater inlet hose/pipe
Heater return hose/pipe
LAND ROVER V8
ENGINE COOLING - OPERATION
Coolant flow
Engine warm up - up to 99MY
When the engine is started from cold, the thermostat,
integral in the housing, prevents any coolant
circulation through the radiator by closing off the
supply from the radiator bottom hose.
During engine warm up, the water pump moves
coolant around the cylinders to the rear of the engine
block and along the galleries in both cylinder banks.
At the rear of the cylinder block the coolant rises
through a large port in both cylinder head/block joint
faces to the inlet manifold.
From the manifold, the coolant flow is divided between
the by-pass hose, the heater feed hose and the
plenum chamber feed pipe. The heater feed hose
supplies the heater matrix, located within the
distribution unit of the heating and ventilation system.
The coolant is then carried, via the heater return hose,
back to the thermostat housing to complete the cycle.
The heater matrix acts as a heat exchanger reducing
coolant temperature as it passes through the matrix.
With the thermostat closed and coolant flowing around
the by-pass circuit, the cooling system is operating at
maximum heater performance.
The plenum chamber is heated by a flow of coolant
through the feed pipe from the inlet manifold. A bleed
pipe returns the coolant from the plenum chamber
across the engine to the expansion tank.
Coolant is drawn from the base of the radiator,
through the bottom hose, by the water pump. Coolant
circulation through the cylinder block and cylinder
heads to the heater matrix and plenum chamber
remains the same.
An integral bleed pipe connects the top of the radiator
to the expansion tank and aids bleeding of air from the
coolant system. The expansion tank cap contains a
pressure valve which allows excessive pressure and
coolant to vent to the overflow pipe if the system has
been overfilled.
Engine warm up - from 99MY
When the engine is started from cold, the thermostat,
integral in the housing, prevents any coolant
circulation through the radiator by closing off the
supply from the radiator bottom hose.
During engine warm up, the water pump moves
coolant around the cylinders to the rear of the engine
block and along the galleries in both cylinder banks.
At the rear of the cylinder block the coolant rises
through a large port in both cylinder head/block joint
faces to the inlet manifold.
From the manifold, the coolant flow is divided between
the outlet pipe and the top hose by-pass connection to
the thermostat housing, the heater inlet pipe and hose
and the throttle housing inlet hose.
The heater inlet pipe and hose supply the heater
matrix, located within the distribution unit of the
heating and ventilation system. The coolant is then
carried, via the heater return hose and pipe, back to
the thermostat housing to complete the cycle.
Engine hot - up to 99MY
When normal engine running temperature is reached,
the main valve of the thermostat opens and a
secondary valve closes the bypass port. With the
thermostat open, coolant is circulated through the top
hose to the radiator.
The air flowing between the tubes cools the coolant as
it passes through the radiator. A controlled flow of the
lower temperature coolant is drawn from the base of
the radiator, through the bottom hose, by the water
pump and blended with hot coolant returning from the
heater matrix. Coolant circulation through cylinder
block and cylinder heads to the heater matrix and
plenum chamber remains the same.
The heater matrix acts as a heat exchanger reducing
coolant temperature as it passes through the matrix.
With the thermostat closed and coolant flowing around
the by-pass circuit, the cooling system is operating at
maximum heater performance.
The throttle housing inlet hose allows coolant to flow
from the inlet manifold to the plate attached to the
bottom of the throttle housing. A return pipe directs
coolant flow from the throttle housing to the expansion
tank.
DESCRIPTION AND OPERATION
9
26
COOLING SYSTEM
Engine hot - from 99MY
NEW RANGE ROVER
Viscous unit disengaged (engine at normal
operating temperature)
When normal engine running temperature is reached,
the main valve of the thermostat opens and a
secondary valve closes the bypass port from the top
hose. With the thermostat open, coolant is circulated
through the top hose to the radiator.
The air flowing between the tubes cools the coolant as
it passes through the radiator. A controlled flow of the
lower temperature coolant is drawn from the base of
the radiator, through the bottom hose, by the water
pump and blended with hot coolant returning from the
heater matrix. Coolant circulation through the cylinder
block and cylinder heads to the heater matrix and
throttle housing remains the same.
A bleed pipe connects the top of the radiator to the
expansion tank and aids bleeding of air from the
coolant system. The expansion tank cap contains a
pressure valve which allows excessive pressure and
coolant to vent to the overflow pipe if the system has
been overfilled.
Viscous fan
There are two main components of the viscous fan
drive : An input (drive) member consisting of a
threaded shaft passing through a bearing into the
clutch plate and secured to the water pump. An output
(driven) member comprises the main body to which
the fan attaches, with the temperature sensing
mechanism (bi-metal coil) and pump plates.
The fan drive only has to be engaged periodically,
between 5% and 10% of the time during normal
driving conditions, because usually the vehicle is
cooled by ram air.
A bi-metal coil senses air temperature behind the
radiator. When a pre-determined temperature is
reached, the coil opens a valve which allows fluid to
enter the drive area. Centrifugal force circulates the
fluid to the annular drive area. There are two sets of
annular grooves, one in the drive clutch and the other
in the drive body, a specific clearance being provided
between the two sets of grooves. When this clearance
is filled with viscous fluid a shearing action, caused by
the speed differential between the two drive
components, transmits torque to the fan. The fluid is
thrown to the outside of the unit by centrifugal force
from where it is then re-circulated to the reservoir via
the pump plate adjacent to the drive member.
If the engine speed is increased, the amount of slip
will also increase to limit the maximum fan speed.
10
DESCRIPTION AND OPERATION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Input (drive) member
Output (driven) member
Running clearance
Pump plate
Valve (closed)
Sensing mechanism (bi-metal coil)
Fluid seal
Bearing,input member
Fluid chamber
Fluid reservoir
LAND ROVER V8
Viscous unit engaged (hot running temperature)
Engine oil cooler - up to 99MY shown
Bi-metal coil expanded, valve open.
When the air temperature from the radiator drops
sufficiently, the bi-metal coil closes the valve and
prevents fluid entering the drive area, see 26M7026.
The fluid that is in the drive area will gradually pump
out into the reservoir and the fan will return to an idle
condition.
Engine oil cooler
1.
2.
3.
4.
5.
6.
Engine oil cooler
Feed pipe
Return pipe
Oil filter
Radiator
Gearbox oil cooler
The engine oil cooler is located in front of the radiator
above the gearbox oil cooler and comprises a single
row matrix; on 4.0 litre models three internal cooling
tubes are used; 4.6 litre models use a larger matrix
incorporating six cooling tubes. Pre-formed feed and
return pipes/hoses are used to link the cylinder block,
oil filter and oil cooler. The oil cooler is mounted
above the gearbox oil cooler, fixed to the radiator side
frame.
Oil drawn through a steel gauze strainer in the sump,
is pumped under pressure through the feed pipe into
the oil cooler. Ambient air, forced through the front
grille of the vehicle and assisted by the pull of the
viscous fan, is dispersed across the oil cooler. The
cooled oil then passes through the return pipe to the
filter, before being distributed from the cylinder block
to the various internal engine components.
DESCRIPTION AND OPERATION
11
26
COOLING SYSTEM
Gearbox oil cooler
The gearbox oil cooler is located below the engine oil
cooler in front of the radiator and comprises a single
row matrix. On vehicles fitted with manual gearboxes
three internal cooling tubes are used, on vehicles with
automatic transmission a larger matrix, incorporating
twelve coolant tubes is fitted. Pre-formed feed and
return pipes/hoses are used to link the gearbox and oil
cooler.
Oil is pumped under pressure from the gearbox
through the feed pipe into the oil cooler. Ambient air,
forced through the front grille of the vehicle and
assisted by the pull of the viscous fan, is dispersed
over the oil cooler. The cooled oil then passes through
the return pipe, which is routed under the engine to
run parallel with the feed pipe back to the LH side of
the gearbox.
Gearbox oil cooler - up to 99MY shown
1.
2.
3.
4.
5.
12
Gearbox oil cooler
Feed pipe
Return pipe
Radiator
Engine oil cooler
DESCRIPTION AND OPERATION
NEW RANGE ROVER
LAND ROVER V8
COOLING SYSTEM FAULTS
This section covers mechanical faults that could occur
in the complete cooling system :
Before conducting any visual checks within the
separate systems and undertaking detailed diagnosis
procedures. See Description and operation.
1. Engine (coolant) cooling;
2. Engine oil cooling;
3. Gearbox oil cooling.
1. ENGINE (COOLANT) COOLING SYSTEM
Symptom - Engine Overheating
POSSIBLE CAUSE
REMEDY
1. Engine coolant low.
1. Allow engine to cool. Top up expansion tank to correct level, with
engine running at idle. Check cooling system for leaks and rectify, if
necessary.
2. Loose drive belt.
2. Check/renew drive belt tensioner or renew drive belt. See
ELECTRICAL, Repair.
3. Coolant in radiator frozen.
3. Slowly thaw and drain cooling system. See Repair.
4. Air flow through radiator
restricted or blocked.
4. Apply air pressure to engine side of radiator to clear obstruction. If
mud or dirt is evident, carefully use a hose.
5. External leaks from water
pump, engine gaskets,
thermostat housing or
pipe/hoses.
5. Check for visual causes and rectify.
6. Viscous fan not operating
correctly or inoperative.
6. Renew viscous fan unit. See Repair.
7. Thermostat seized in closed
position.
7. Check radiator bottom hose for coolant flow through radiator. If cold
a faulty thermostat is confirmed. Renew thermostat housing
assembly. See Repair.
FAULT DIAGNOSIS
1
26
COOLING SYSTEM
NEW RANGE ROVER
Symptom - Engine Overheating, continued
POSSIBLE CAUSE
REMEDY
8. Air in cooling system.
8. Check coolant level. Run engine at fast idle (approximately 2,000
rpm) with expansion tank cap off. Top up coolant level with engine
at idle and refit expansion tank cap.
9. Air conditioning condenser fans
not operating correctly or
inoperative.
9. See AIR CONDITIONING, Fault diagnosis.
10. Temperature gauge or sender
unit giving inaccurate readings.
10. Substitute parts and compare new readings.
11. Coolant leakage across
cylinder head gasket.
11. Carry out cylinder pressure test to determine if pressure is leaking
into cooling system, causing over pressurising and loss of coolant.
Renew cylinder head gasket.
12. Engine oil contamination of
cooling system due to leaking.
12. Renew cylinder head gasket. See ENGINE, Repair.
13. Coolant contamination of
lubrication system.
13. Renew inlet manifold or front cover gaskets. See MANIFOLD AND
EXHAUST SYSTEM, Repair. or See ENGINE, Repair.
Symptom - Engine Runs Cold
POSSIBLE CAUSE
REMEDY
1. Thermostat seized in open or
partially open position.
1. Remove thermostat housing and check operation of thermostat.
Renew, if necessary. See Repair.
2. Temperature gauge or sender
unit giving inaccurate readings.
2. Substitute parts and compare new readings.
3. Viscous fan not operating
correctly.
3. Renew viscous fan unit. See Repair.
4. Air conditioning condenser fans
operating continuously.
4. Refer to TestBook .
2
FAULT DIAGNOSIS
LAND ROVER V8
2. ENGINE OIL COOLING SYSTEM
Symptom - Engine Oil Overheating
POSSIBLE CAUSE
REMEDY
1. Air flow through oil cooler
matrix restricted or blocked.
1. Apply air pressure to engine side of radiator to clear obstruction. If
mud or dirt is evident, carefully use a hose.
2. Blocked or damaged oil cooler
or pipe/hoses restricting engine
oil flow.
2. Check for visual damage and renew components where necessary.
3. Oil cooler relief valve seized in
closed position.
3. Remove and check relief valve. Renew, if necessary.
3. GEARBOX OIL COOLING SYSTEM
SYMPTOM - Gearbox Oil Overheating
POSSIBLE CAUSE
REMEDY
1. Air flow through oil cooler
matrix restricted or blocked.
1. Apply air pressure to engine side of radiator to clear obstruction. If
mud or dirt is evident, carefully use a hose.
2. Damaged oil cooler or
pipe/hoses restricting gearbox
oil flow.
2. Check for visual damage and renew components where necessary.
3. Vehicle being driven in wrong
gear.
3. Advise owner/driver accordingly.
NOTE: Critical warning messages relating
to the complete cooling system are
displayed on the message centre in the
lower section of the instrument pack, should a
fault occur in any of the separate systems.
FAULT DIAGNOSIS
3
LAND ROVER V8
COOLANT - DRAIN AND REFILL
Service repair no - 26.10.01
5. If system is only being partially drained, continue
at Refill.
6. Reposition container. Remove LH cylinder block
drain plug. Allow coolant to drain.
Drain
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised. Personal scalding
could result.
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove expansion tank filler cap to assist
draining.
NOTE: Do not remove RH cylinder block
drain plug.
7. Clean drain plug threads. Apply a coating of
’Loctite 577’. Refit plug to block. Tighten
securely.
3. Position container beneath radiator.
4. Remove plug from base of radiator. Allow
coolant to drain.
REPAIR
1
26
COOLING SYSTEM
Refill
NEW RANGE ROVER
RADIATOR
8. Ensure sufficient coolant solution is available.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
9. Inspect radiator drain plug ’O’ ring, renew if
required.
10. Fit drain plug to radiator. Tighten to Max 6 Nm
(4 lbf.ft)
11. Remove safety stands. Lower vehicle.
12. Disconnect radiator bleed hose at the radiator.
13. Blow through hose to clear any residual coolant.
Reconnect hose.
CAUTION: If radiator bleed hose is not
cleared of coolant, air may become
trapped at top of radiator during refill,
leading to subsequent engine overheating.
Service repair no - 26.40.04
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Drain cooling system. See this section.
4. Release clips securing upper cooling fan cowl.
Remove cowl.
14. Fill expansion tank until coolant is level with
base of neck.
15. Start engine, continue filling at expansion tank
until coolant level stabilises at the ’COLD
LEVEL’ marking.
16. Run the engine until the thermostat opens (top
hose becomes warm).
17. Stop engine, allow to cool.
18. Check coolant level, top-up as necessary.
19. Refit expansion tank filler cap.
5. Release top hose from radiator.
6. Release expansion tank hose from radiator.
2
REPAIR
LAND ROVER V8
7. Remove clips securing radiator to cooling fan
cowl.
11. Release radiator from upper and lower
mountings.
12. Remove radiator. Collect lower mounting
rubbers.
Refit
13. Reverse removal procedure.
14. Refill cooling system. See this section.
8. Slacken bottom hose clips at radiator and
thermostat housing.
9. Release thermostat housing from fan cowl.
Remove bottom hose.
10. Remove 2 bolts securing radiator to mounting
bracket.
REPAIR
3
26
COOLING SYSTEM
VISCOUS COUPLING AND FAN ASSEMBLY - UP
TO 99MY
NEW RANGE ROVER
3. Using LRT-12-093 and LRT-12-094 unscrew
viscous coupling from water pump.
NOTE: Viscous coupling is secured with a
RH thread.
Service repair no - 26.25.19
Special tools:
LRT-12-093
LRT-12-094 - Viscous coupling removal
4. Remove fan and coupling assembly.
Remove
1. Disconnect battery negative lead.
Do not carry out further dismantling if component
is removed for access only.
5. Remove 4 bolts securing coupling to fan.
Remove coupling.
Refit
2. Release 2 clips securing cooling fan upper cowl.
Remove cowl.
4
REPAIR
6. Ensure mating faces are clean.
7. Fit fan to coupling. Secure with bolts. Tighten to
24 Nm (18 lbf.ft)
8. Using LRT-12-093 and LRT-12-094, fit fan
assembly to pump. Tighten to 56 Nm
(41 lbf.ft.)
9. Fit cooling fan upper cowl. Secure with clips.
10. Reconnect battery negative lead.
LAND ROVER V8
VISCOUS COUPLING AND FAN ASSEMBLY FROM 99MY
Service repair no - 26.25.19
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
4. Release 2 clips securing fan cowl and remove
fan cowl.
3. Remove bolt securing washer reservoir filler tube
support bracket to radiator bracket.
5. Remove cooling fan using LRT-12-093
andLRT-12-094.
Refit
6. Position cooling fan and tighten using
LRT-12-093 andLRT-12-094.
7. Fit fan cowl and secure with clips.
8. Align washer reservoir filler tube bracket and
secure with bolt.
9. Connect battery earth lead.
10. Fit battery cover and secure with fixings.
REPAIR
5
26
COOLING SYSTEM
NEW RANGE ROVER
WATER PUMP - UP TO 99MY
Service repair no - 26.50.01
Remove
1. Drain cooling system. See this section.
2. Remove cooling fan. See this section.
3. Slacken water pump pulley bolts.
6. Remove 9 bolts securing water pump.
7. Remove water pump and gasket.
Refit
4. Release tension from water pump drive belt.
Remove belt.
5. Remove water pump pulley.
6
REPAIR
8. Ensure mating faces are clean.
9. Fit water pump with new gasket.
10. Position water pump. Secure with bolts. Tighten
to 22 Nm (16 lbf.ft)
11. Fit water pump pulley. Secure with bolts.
Tighten to 22 Nm (16 lbf.ft)
12. Fit water pump drive belt.
13. Fit cooling fan. See this section.
14. Fill cooling system. See this section.
LAND ROVER V8
WATER PUMP - FROM 99MY
Service repair no - 26.50.01
Remove
1. Drain cooling system. See this section.
5. Release clip and disconnect coolant hose from
water pump.
6. Remove 9 bolts securing water pump, remove
water pump and discard gasket.
Refit
2. Loosen 3 bolts securing water pump pulley to
water pump.
3. Remove auxiliary drive belt. See ELECTRICAL,
Repair.
4. Remove 3 bolts securing pulley to water pump
and remove pulley.
7. Clean water pump and mating face.
8. Fit new gasket and water pump, tighten bolts to
24 Nm (18 lbf.ft).
9. Connect coolant hose to water pump and secure
with clip.
10. Ensure mating faces of water pump pulley and
flange are clean, fit pulley and tighten bolts to
22 Nm (17 lbf.ft).
11. Fit auxiliary drive belt. See ELECTRICAL,
Repair.
12. Refill cooling system. See this section.
REPAIR
7
26
COOLING SYSTEM
NEW RANGE ROVER
THERMOSTAT - UP TO 99MY
THERMOSTAT - FROM 99MY
Service repair no - 26.45.01
Service repair no - 26.45.09
Remove
Remove
1. Disconnect battery earth lead.
2. Raise vehicle on 4 post ramp.
3. Remove engine acoustic cover (if applicable).
See CHASSIS AND BODY, Repair.
4. Drain cooling system. See this section.
5. Loosen 3 upper hose clips and disconnect 3
hoses from top of thermostat housing.
6. Loosen lower hose clip and disconnect hose
from bottom of thermostat housing.
7. Release 2 clips securing thermostat to housing
radiator cowl and remove thermostat housing.
1. Drain cooling system. See this section.
2. Remove cooling fan. See this section.
3. Release 3 clips and disconnect coolant hoses
from thermostat.
4. Release clip securing thermostat to fan cowl and
remove thermostat.
Refit
Refit
8. Position thermostat housing and connect to
radiator hose.
9. Connect hoses to top of thermostat housing.
10. Tighten clips securing hoses to thermostat
housing.
11. Engage thermostat housing to radiator cowl
clips.
12. Fill coolant system. See this section.
13. Fit engine acoustic cover (if applicable). See
CHASSIS AND BODY, Repair.
8
REPAIR
5.
6.
7.
8.
Position thermostat and secure to cowl.
Fit hoses to thermostat and secure with clips.
Fit cooling fan. See this section.
Fill cooling system. See this section.
LAND ROVER V8
EXPANSION TANK
Service repair no - 26.15.01
NOTE: This operation covers all models
Remove
1. Position container to collect coolant spillage.
2. Disconnect heater hose and radiator bleed hose
from expansion tank.
3. Release expansion tank from clips.
4. Petrol only: Disconnect throttle housing coolant
bleed hose from expansion tank.
5. Remove expansion tank.
Refit
6. Reverse removal procedure.
7. Check and top up cooling system.
REPAIR
9
30 - MANIFOLD AND EXHAUST SYSTEM
CONTENTS
Page
REPAIR
EXHAUST MANIFOLD GASKETS - V8 - UP TO 99MY ....................................... 1
EXHAUST MANIFOLD GASKETS - V8 - FROM 99MY ....................................... 4
EXHAUST MANIFOLD GASKETS - DIESEL ....................................................... 6
EXHAUST MANIFOLD HEAT SHIELD - DIESEL ................................................ 7
EXHAUST FRONT PIPE - V8 .............................................................................. 9
EXHAUST FRONT PIPE - V8 - FROM 97MY UP TO 99MY .............................. 10
EXHAUST FRONT PIPE - V8 - FROM 99MY .................................................... 11
EXHAUST FRONT PIPE - DIESEL .................................................................... 12
INLET MANIFOLD GASKET - V8 - UP TO 99MY .............................................. 14
GASKET - INLET MANIFOLD - LOWER- FROM 99MY .................................... 16
GASKET - INLET MANIFOLD - UPPER - FROM 99MY .................................... 20
INLET MANIFOLD GASKETS - DIESEL - VEHICLES WITHOUT EGR ............ 23
INTAKE MANIFOLD GASKETS - DIESEL WITH EGR ...................................... 25
INTERMEDIATE AND REAR PIPES ................................................................. 27
TAIL PIPE - LH - FROM 97MY ........................................................................... 28
TAIL PIPE - RH - FROM 97MY .......................................................................... 29
MANIFOLD AND EXHAUST SYSTEM
EXHAUST MANIFOLD GASKETS - V8 - UP TO
99MY
Service repair no - 30.15.16 - Right Hand
Service repair no - 30.15.17 - Left Hand
1. Disconnect battery negative lead.
2. Raise vehicle on four post lift.
3. Remove 3 nuts securing each front pipe flange
to exhaust manifold.
7. Release harness from intake hose clip.
8. Release 2 clips securing air flow meter to air
cleaner. Release meter. Collect ’O’ ring.
9. Disconnect multiplug from air flow meter.
Remove meter.
10. Release purge hose from ram pipe housing.
11. Remove purge valve securing bolt from shock
absorber turret. Place valve aside.
NOTE: Instructions 12,13 & 14 apply to
Right Hand Manifold Only.
12. Release spark plug caps. Release H.T. leads
from clips on rocker cover. Place leads aside.
4. Release front pipe from exhaust manifolds.
Collect gaskets.
5. Lower lift.
NOTE: Instructions 6 to 11 apply to Left
Hand Manifold Only
6. Release intake hose from plenum chamber.
REPAIR
1
30
MANIFOLD AND EXHAUST SYSTEM
13. Remove screw securing H.T. lead clip to rocker
cover. Remove clip.
14. Unscrew RH shock absorber top mounting bolt
to provide additional clearance for heat shield
removal.
NOTE: Do not remove bolt.
15. Right Hand Drive - Right Hand Manifold Only.
Remove intermediate steering shaft. See
STEERING, Repair.
16. Remove 8 bolts (RH manifold) or 7 bolts (LH
manifold) securing outer heat shield to manifold.
Remove heat shield.
2
REPAIR
NEW RANGE ROVER
17. Remove 8 bolts securing exhaust manifold to
cylinder head. Remove manifold. Collect
gaskets.
MANIFOLD AND EXHAUST SYSTEM
Refit
18. Ensure mating faces are clean.
19. Position manifold on cylinder head. Align new
gaskets.
20. Secure manifold with bolts. Tighten to 55 Nm
(40 lbf.ft) in sequence shown.
30. Route H.T. leads. Secure in clips. Connect plug
caps.
31. If removed, fit intermediate steering shaft. See
STEERING, Repair.
32. Raise lift.
33. Fit new gasket to front pipe. Position pipe to
exhaust manifold. Secure with nuts. Tighten to
50 Nm (37 lbf.ft)
34. Reconnect battery negative lead.
21. Fit outer heat shield. Secure with bolts. Tighten
to 8 Nm (6 lbf.ft)
22. Position purge valve on shock absorber turret.
Secure with bolt.
23. Connect purge hose to ram pipe housing.
24. Fit air flow meter/hose assembly to plenum
chamber. Secure with clip.
25. Connect multiplug to air flow meter.
26. Fit ’O’ ring to air flow meter. Secure meter to air
cleaner with clips.
27. Engage harness in intake hose clip.
28. Tighten RH shock absorber top mounting bolt to
85 Nm (63 lbf.ft)
29. Position H.T. lead clip on rocker cover. Secure
with screw.
REPAIR
3
30
MANIFOLD AND EXHAUST SYSTEM
EXHAUST MANIFOLD GASKETS - V8 - FROM
99MY
Service repair no - 30.15.16 - Right Hand
Service repair no - 30.15.17 - Left Hand
1. Release 3 fixings and remove battery cover.
2. Disconnect battery negative lead.
3. Raise vehicle on four post lift.
NEW RANGE ROVER
8. Release clip and disconnect hose from IAC
valve.
9. Loosen clip and disconnect air intake hose from
throttle body.
10. Release two clips securing MAF sensor to air
cleaner.
11. Remove MAF sensor and hose assembly.
Collect ’O’ ring.
4. Remove 3 nuts securing each front pipe flange
to exhaust manifold.
5. Release front pipe from exhaust manifold.
Collect gaskets.
6. Lower lift.
12. Release spark plug caps. Release H.T. leads
from clips on rocker cover. Place leads aside.
7. Disconnect multiplug from MAF sensor and
release harness from clip on air intake hose.
4
REPAIR
MANIFOLD AND EXHAUST SYSTEM
13. RH Manifold Only. Loosen RH shock absorber
top mounting bolt (to provide clearance for heat
shield removal).
NOTE: Do not remove bolt.
14. RHD, RH Manifold Only. Remove steering
column intermediate shaft. See STEERING,
Repair.
16. Remove 8 bolts securing exhaust manifold to
cylinder head. Remove exhaust manifold and
collect gaskets.
Refit
17. Ensure mating faces are clean.
18. Position manifold on cylinder head. Align new
gaskets.
15. Remove 8 (RH exhaust manifold) or 7 (LH
exhaust manifold) bolts securing outer heat
shield to manifold. Remove heat shield.
19. Secure manifold with bolts. Tighten to 55 Nm
(40 lbf.ft) in sequence shown.
REPAIR
5
30
MANIFOLD AND EXHAUST SYSTEM
20. Fit outer heat shield. Secure with bolts. Tighten
to 8 Nm (6 lbf.ft).
21. Fit MAF sensor and hose assembly to throttle
body. Secure with clip.
22. Fit ’O’ ring to MAF sensor. Secure MAF sensor
to air cleaner with clips.
23. Connect multiplug to MAF sensor. Engage
harness in clip on air intake hose.
24. RH Manifold Only. Tighten RH shock absorber
top mounting bolt to 85 Nm (63 lbf.ft).
25. Route H.T. leads. Secure in clips. Connect plug
caps.
26. RHD, RH Manifold Only. Fit steering column
intermediate shaft. See STEERING, Repair.
27. Raise lift.
28. Fit new gasket to front pipe. Position pipe to
exhaust manifold. Secure with nuts. Tighten to
50 Nm (37 lbf.ft).
29. Reconnect battery negative lead.
30. Fit battery cover and secure with fixings.
NEW RANGE ROVER
EXHAUST MANIFOLD GASKETS - DIESEL
Service repair no - 30.15.12
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Remove heat shield. See this section.
4. Remove 3 bolts securing turbocharger to
exhaust manifold. Collect gasket and discard.
5. Remove 12 nuts and flat washers securing
exhaust manifold to cylinder head. Vehicles with
EGR: Remove 2 bolts securing EGR pipe flange
to manifold. Position pipe aside.
6
REPAIR
MANIFOLD AND EXHAUST SYSTEM
6. Remove exhaust manifold. Collect gaskets and
discard.
EXHAUST MANIFOLD HEAT SHIELD - DIESEL
Service repair no - 30.15.09
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Remove cooling fan cowl. See COOLING
SYSTEM, Repair.
4. Release intake hose from ducting.
5. Release turbocharger intake hose from ducting.
6. Release breather valve from intake ducting
grommet.
NOTE: The gasket fitted to No. 1 & 2
exhaust ports acts as a turbocharger heat
shield.
Refit
7. Ensure mating faces are clean.
8. Position new gaskets and turbocharger heat
shield to cylinder head studs. Ensure tabs face
outwards.
9. Position exhaust manifold. Secure with nuts and
flat washers. Working from centre outwards,
progressively tighten to 22 Nm (16 lbf.ft).
10. Vehicles with EGR: Secure EGR pipe flange to
manifold with bolts. Tighten to 22 Nm
(16 lbf.ft).
11. Position turbocharger with new gasket to
exhaust manifold. Secure with bolts. Tighten to
45 Nm (33 lbf.ft).
12. Fit heat shield. See this section.
13. Remove safety stands. Lower vehicle.
14. Reconnect battery negative lead.
REPAIR
7
30
MANIFOLD AND EXHAUST SYSTEM
NOTE: Collect grommet. Refit to ducting.
7. Disengage 2 clips securing intake ducting.
Remove ducting.
8. Remove 3 bolts securing intake ducting bracket
and exhaust manifold heat shield to camshaft
cover. Collect bracket.
9. Disconnect heater hose from coolant connecting
pipe.
10. Remove bolt securing coolant connecting pipe to
engine front cover.
11. Remove coolant pipe. Remove ’O’ ring and
discard.
12. Slacken clips securing turbocharger outlet hose
to turbocharger and intercooler.
13. Remove turbocharger outlet hose assembly.
14. Release harness from 2 heat shield clips.
15. Remove heat shield.
8
REPAIR
NEW RANGE ROVER
Refit
16. Position heat shield.
17. Secure harness to heat shield clips.
18. Position outlet hose to turbocharger and
intercooler. Secure with clips.
19. Using a new ’O’ ring, position coolant pipe.
Engage to engine front cover.
20. Secure connecting pipe to front cover with bolt.
Tighten to 10 Nm (7 lbf.ft)
21. Connect heater hose. Secure with clip.
22. Align exhaust manifold heat shield. Position
intake ducting bracket.
23. Secure ducting bracket and heat shield with
bolts.
24. Position intake ducting. Engage clips.
25. Engage breather valve into ducting grommet.
26. Connect ducting to turbocharger intake hose.
Secure with clip.
27. Connect intake hose to ducting. Secure with clip.
28. Fit cooling fan cowl. See COOLING SYSTEM,
Repair.
29. Remove safety stands. Lower vehicle.
30. Reconnect battery negative lead.
MANIFOLD AND EXHAUST SYSTEM
EXHAUST FRONT PIPE - V8
Service repair no - 30.10.09
Remove
1. Raise vehicle on four post lift.
2. Support transmission with a suitable stand.
3. Remove 6 nuts securing transmission mount to
crossmember. Remove snubber bar. Discard
nuts.
4. Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
5. With assistance, remove remaining bolt securing
crossmember. Remove crossmember.
6. Disconnect heated oxygen sensor (HO2S)
harnesses. Release multiplugs from sump
brackets.
7. Remove cable tie securing L.H. HO2S harness
to gearbox bracket.
8. Remove 2 nuts securing front pipe to
intermediate pipe flanges.
9. Remove 6 nuts securing front pipe to exhaust
manifold flanges.
10. Remove front pipe. Collect front pipe to manifold
gaskets.
11. If necessary, remove HO2S. See FUEL
SYSTEM, Repair.
Refit
12. Ensure mating faces are clean.
13. If removed, fit HO2S. See FUEL SYSTEM,
Repair.
14. Position front pipe assembly with gaskets to
manifolds. Secure with nuts. Tighten to 50 Nm
(37 lbf.ft)
15. Secure front pipe to intermediate pipe flange
with nuts. Tighten to 25 Nm (18 lbf.ft)
16. Secure LH HO2S harness to gearbox bracket
with cable tie.
17. Connect HO2S harnesses. Secure multiplugs to
sump brackets.
18. With assistance, position transmission
crossmember on chassis. Secure with nuts and
bolts. Tighten to 45 Nm (33 lbf.ft)
19. Fit snubber bar. Secure transmission mount to
crossmember with new flange nuts. Tighten to
45 Nm (33 lbf.ft)
20. Remove support from transmission.
21. Lower vehicle.
REPAIR
9
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
EXHAUST FRONT PIPE - V8 - FROM 97MY UP TO
99MY
Service repair no - 30.10.09
Remove
1. Raise vehicle on 4 post ramp.
2. Support transmission using a suitable stand.
3. Remove 4 nuts and 2 bolts securing
transmission mount to crossmember and discard
nuts.
4. Remove transmission snubber bar.
5. Remove 2 bolts securing rear of side acoustic
covers to crossmember.
6. Remove 3 of 4 nuts and bolts securing each side
of crossmember to chassis.
7. With assistance, remove remaining bolt securing
crossmember and remove crossmember.
8. Disconnect 2 oxygen sensor harness multiplugs
from oxygen sensor flylead.
9. Release 2 oxygen sensor flylead multiplugs from
brackets.
10. Release flyleads from 2 clips.
11. Remove 2 nuts securing front pipe to
intermediate pipe flange.
12. Remove 6 nuts securing front pipe to exhaust
manifold down pipe flanges
13. Using assistance, remove front pipe and collect
2 front pipe to manifold gaskets.
Do not carry out further dismantling if
component is removed for access only.
10
REPAIR
14. Remove 2 heated oxygen sensors from front
pipe and discard sealing washers.
15. Fit NEW sealing washers to heated oxygen
sensors.
16. Fit heated oxygen sensors to front pipe and
tighten to 20 Nm (15 lbf.ft)
MANIFOLD AND EXHAUST SYSTEM
Refit
17. Ensure all mating faces are clean.
18. Using assistance, position front pipe and NEW
gaskets to manifold.
19. Fit but do not tighten nuts securing front pipe to
manifolds.
20. Align front pipe to intermediate pipe, fit nuts and
tighten to 25 Nm (18 lbf.ft)
21. Tighten front pipe to manifold nuts to 50 Nm
(37 lbf.ft)
22. Connect heated oxygen sensor multiplugs to
brackets.
23. Connect oxygen sensor multiplugs.
24. Connect oxygen sensor fly leads to clips.
25. Using assistance, fit crossmember to chassis.
26. Fit nuts and bolts and tighten to 45 Nm
(33 lbf.ft)
27. Fit transmission snubber bar.
28. Fit bolts and NEW flange nuts securing
transmission mount to crossmember and tighten
to 45 Nm (33 lbf.ft)
29. Remove transmission stand.
30. Align rear of side acoustic covers to
crossmember and secure with threaded
fasteners.
EXHAUST FRONT PIPE - V8 - FROM 99MY
Service repair no - 30.10.09
Remove
1. Release fixings and remove battery cover.
2. Disconnect battery earth lead.
3. Remove chassis crossmember. See CHASSIS
AND BODY, Repair.
4. Disconnect 2 front HO2S multiplugs and release
RH HO2S harness from clip on sump.
5. Release 2 rear HO2S multiplugs from brackets,
disconnect from harness and release harness
from 2 clips.
6. Remove 2 nuts securing exhaust front pipe to
intermediate flange.
7. Remove 6 nuts securing front exhaust pipe to
exhaust manifold down pipe flanges.
REPAIR
11
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
EXHAUST FRONT PIPE - DIESEL
Service repair no - 30.10.09
Remove
1. Raise vehicle on four post lift.
2. Remove 2 nuts and bolts securing front pipe to
intermediate pipe flange.
8. With assistance, remove exhaust front pipe and
collect 2 front pipe to manifold gaskets.
9. Remove 4 HO2S from exhaust manifold and
discard sealing washers.
Refit
10. Clean mating faces of exhaust front pipe,
manifolds and intermediate pipe.
11. Use new sealing washers and fit and tighten
HO2S to 20 Nm (15 lbf.ft).
12. Use new flange gaskets and with assistance, fit
exhaust front pipe to manifolds. Fit nuts but do
not tighten at this stage.
13. Align intermediate pipe to front pipe and tighten
clamp nuts to 25 Nm (18 lbf.ft)
14. Tighten front pipe to manifold nuts to 50 Nm
(37 lbf.ft).
15. Connect HO2S multiplugs to harness and
secure multiplugs to brackets.
16. Secure RH front and rear HO2S harness to clips.
17. Fit chassis crossmember. See CHASSIS AND
BODY, Repair.
18. Connect battery earth lead.
19. Fit battery cover and secure with fixings.
3. Remove 2 nuts securing front pipe flange to
turbocharger oulet. Collect springs and flat
washers.
12
REPAIR
MANIFOLD AND EXHAUST SYSTEM
4. With assistance, manoeuvre front pipe
rearwards over chassis crossmember.
5. Remove front pipe.
6. Collect olive.
Refit
7. Ensure mating faces are clean.
8. With assistance, manoeuvre pipe forwards over
chassis crossmember into position.
9. Position olive. Fit front pipe flange over
turbocharger studs. Secure with nuts, springs
and washers.
10. Tighten nuts to 14 Nm (10 lbf.ft). Back off by
2.5 turns.
11. Position rear flange to intermediate pipe. Secure
with nuts. Tighten to 25 Nm (18 lbf.ft)
12. Lower lift.
REPAIR
13
30
MANIFOLD AND EXHAUST SYSTEM
INLET MANIFOLD GASKET - V8 - UP TO 99MY
Service repair no - 30.15.08
Remove
1. Depressurise fuel system. See FUEL SYSTEM,
Repair.
2. Drain cooling system. See COOLING SYSTEM,
Repair.
3. Remove alternator. See ELECTRICAL, Repair.
4. Remove plenum chamber. See FUEL SYSTEM,
Repair.
5. Release purge and crankcase breather hoses
from ram pipe housing.
6. Disconnect coolant temperature and
temperature gauge sensors.
7. Disconnect 8 injector multiplugs.
8. Disconnect fuel temperature sensor multiplug.
9. Disconnect fuel feed hose from fuel rail.
10. Disconnect fuel return hose from pressure
regulator pipe.
11. Remove 6 nuts securing fuel rail and ignition coil
bracket to inlet manifold.
12. Lift fuel rail slightly for access. Release ignition
coil bracket from inlet manifold studs. Place
aside.
13. Disconnect coolant hoses from inlet manifold
14. Disconnect plenum chamber coolant hose from
inlet manifold.
15. Remove 2 bolts securing harness to RH side of
inlet manifold.
16. Place harness and heater hose aside.
17. Remove bolt securing harness to LH side of inlet
manifold.
14
REPAIR
NEW RANGE ROVER
MANIFOLD AND EXHAUST SYSTEM
18. Using sequence shown, remove 12 bolts
securing inlet manifold to cylinder heads
36. Connect fuel feed pipe to fuel rail. Tighten to
16 Nm (12 lbf.ft).
37. Connect return hose to pressure regulator pipe.
Secure with clip.
38. Connect multiplugs to fuel injectors and fuel
temperature sensor.
39. Connect coolant temperature sensor and
temperature gauge sensor.
40. Connect purge and crankcase breather hose to
ram pipe housing.
41. Fit plenum chamber. See FUEL SYSTEM,
Repair.
42. Refill cooling system. See COOLING SYSTEM,
Repair.
43. Fit alternator. See ELECTRICAL, Repair.
44. Start engine. Check for leaks around fuel rail and
injectors.
19. Remove inlet manifold assembly.
20. Remove bolts and clamps securing manifold
gasket to cylinder block.
21. Remove inlet manifold gasket and discard.
22. Remove gasket seals and discard.
Refit
23. Ensure mating faces are clean.
24. Apply a thin bead of Loctite Superflex (black)
sealant to 4 notches between cylinder head and
block.
25. Position new gasket seals. Ensure ends engage
correctly in notches.
26. Fit new inlet manifold gasket.
27. Position manifold gasket clamps. Fit bolts and
tighten to 0.7 Nm (0.5 lbf.ft) .
28. With assistance to hold harness and ignition
coils aside, position inlet manifold assembly.
NOTE: When fitting inlet manifold bolts,
tighten in reverse of removal sequence.
29. Fit inlet manifold bolts. Initially tighten to 10 Nm
(7 lbf.ft)
30. Finally tighten bolts to 50 Nm (37 lbf.ft).
31. Tighten gasket clamp bolts to 17 Nm (13 lbf.ft).
32. Position RH injector harness and heater hose
bracket on inlet manifold. Secure with bolts.
33. Fit plenum chamber coolant hose to inlet
manifold. Secure with clip.
34. Connect 3 cooling hoses to inlet manifold.
Secure with clips.
35. Position ignition coil bracket on inlet manifold
studs. Secure with nuts. Tighten to 8 Nm
(6 lbf.ft).
REPAIR
15
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
GASKET - INLET MANIFOLD - LOWER- FROM
99MY
Service repair no - 30.15.08
Remove
1. Remove RH and LH rocker cover gaskets. See
ENGINE, Repair.
7. Remove 2 nuts securing leads to alternator and
release leads.
2. Disconnect multiplugs from coils.
3. Remove 2 bolts securing coils and remove coils.
4. Release leads from fuel rails and disconnect LH
and RH injector multiplugs.
5. Position absorbent cloth to catch any fuel
spillage and disconnect fuel pipe.
CAUTION: Plug the connections.
6. Remove auxiliary drive belt. See ELECTRICAL,
Repair.
16
REPAIR
8. Release clip securing top hose to outlet pipe and
release hose.
9. Remove 2 bolts securing alternator and remove
alternator.
MANIFOLD AND EXHAUST SYSTEM
10. Disconnect multiplug from compressor.
11. Remove 4 bolts securing compressor to
mounting bracket and position compressor
aside.
13. Remove bolt securing jockey pulley to mounting
bracket and remove pulley.
14. Remove 4 bolts and one nut securing mounting
bracket and remove mounting bracket .
12. Remove 2 bolts securing PAS pump to mounting
bracket and position aside.
15. Remove 4 bolts securing top hose outlet pipe
and remove outlet pipe.
16. Remove and discard ’O’ ring.
17. Disconnect ECT sensor multiplug.
REPAIR
17
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
18. Using the sequence shown, remove 12 bolts
securing inlet manifold.
19. Remove inlet manifold assembly.
20. Remove 2 bolts securing manifold gasket
clamps and collect gasket clamps.
21. Remove inlet manifold gasket.
22. Remove gasket seals.
Refit
23. Clean RTV from head and block notches.
24. Clean mating faces of block, head and manifold.
25. Apply RTV silicone sealant in the four ’V’ shaped
notches between the ends of the cylinder head
and the cylinder block joint.
26. Fit new gasket seals, ensure ends engage
correctly in notches.
27. Fit new manifold gasket.
28. Position gasket clamps, fit bolts but do not
tighten at this stage.
29. Position inlet manifold assembly.
NOTE: When fitting inlet manifold bolts,
tighten in reverse of removal sequence.
18
REPAIR
MANIFOLD AND EXHAUST SYSTEM
40. Position PAS pump to mounting bracket, locate
on dowels and fit and tighten bolts to 40 Nm
(30 lbf.ft).
41. Clean compressor dowels and dowel holes.
42. Position compressor, locate on dowels and fit
and tighten bolts to 25 Nm (18 lbf.ft).
43. Connect multiplug to compressor.
44. Position alternator, fit and tighten bolts to 45 Nm
(34 lbf.ft).
45. Position top hose and secure clip.
46. Connect alternator cables, fit nuts and tighten B+
nut to 18 Nm (13 lbf.ft) max and D+ nut to 5 Nm
(3.5 lbf.ft) max. B+ and D+ are marked on the
rear of the alternator, adjacent ot each cable
connector. Fit leads to alternator and tighten
nuts.
47. Fit auxiliary drive belt. See ELECTRICAL,
Repair.
48. Connect injector multiplugs and secure leads to
fuel rail.
49. Position coils and fit bolts but do not tighten at
this stage.
50. Connect multiplugs to coils.
51. Fit rocker cover gaskets. See ENGINE, Repair.
30. Fit manifold bolts and in the sequence shown
tighten bolts initially to 10 Nm (8 lbf.ft) , then
tighten to 51 Nm (38 lbf.ft).
31. Tighten gasket clamp bolts to 18 Nm (14 lbf.ft).
32. Connect fuel pipe.
33. Connect multiplug to ECT sensor.
34. Clean top hose outlet pipe mating faces.
35. Lubricate and fit new ’O’ ring to outlet pipe.
36. Position outlet pipe, fit and tighten bolts to
22 Nm (16 lbf.ft).
37. Position mounting bracket, fit and tighten, bolts
to40 Nm (30 lbf.ft) , and nut to 10 Nm (7 lbf.ft).
38. Fit jockey pulley and tighten bolt to 50 Nm
(37 lbf.ft).
39. Clean PAS pump dowels and dowel holes.
REPAIR
19
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
GASKET - INLET MANIFOLD - UPPER - FROM
99MY
Service repair no - 30.15.24
Remove
1.
2.
3.
4.
Release 3 fixings and remove battery cover.
Disconnect battery earth lead.
Remove gas struts from bonnet.
With assistance support bonnet on hinge
extension arms.
7. Remove 2 bolts securing abutment bracket to
plenum chamber and position aside.
8. Release throttle and cruise control cables from
clips and throttle cams and position aside.
5. Loosen 2 clips securing air intake hose, release
air intake hose and disconnect harness from clip
on hose.
6. Release clip securing IAC hose to air intake
hose and remove air intake hose.
9. Disconnect EVAP pipe from plenum chamber
and clip on upper manifold.
10. Disconnect multiplug from TP sensor.
11. Release clip securing breather hose to throttle
body and release breather hose.
12. Release clip and disconnect IAC hose from
plenum chamber.
20
REPAIR
MANIFOLD AND EXHAUST SYSTEM
13. Position a container below throttle body to collect
coolant.
14. Release clips securing coolant hoses to throttle
body and release hoses.
17. Remove 2 cable ties securing engine harness to
clip on upper manifold.
15. Release clip and disconnect engine breather
hose from plenum chamber.
16. Remove bolt securing coolant rails.
18. Release HT leads from clips on upper inlet
manifold.
19. Disconnect multiplug from IAC valve.
REPAIR
21
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
Refit
20. Remove 2 bolts securing top of coils.
21. Loosen 2 bolts securing bottom of coils to block
but do not remove bolts.
22. Remove 6 bolts securing upper manifold and
remove upper manifold.
23. Collect upper manifold gasket.
22
REPAIR
24. Clean inlet manifold and upper manifold mating
faces, dowels and dowel holes.
25. Using a new gasket, position upper manifold. Fit
bolts, and working in a diagonal sequence,
tighten to 22 Nm (16 lbf.ft).
26. Fit 2 top bolts securing coils to manifold and
tighten all coil fixing bolts to 8 Nm (6 lbf.ft).
27. Connect IAC valve multiplug.
28. Secure HT leads to upper manifold clips.
29. Connect multiplug to TP sensor.
30. Position engine harness in manifold clip and
secure with new cable ties.
31. Fit and tighten coolant rail bolt to 22 Nm
(16 lbf.ft).
32. Connect breather hose to plenum and secure
with clip.
33. Connect IAC hose to plenum chamber and
secure with clip.
34. Position coolant hoses to throttle body and
secure hose clips.
35. Fit breather hose to throttle body and secure
clip.
36. Connect multiplug to TP sensor.
37. Connect EVAP pipe to plenum chamber and clip
on upper manifold.
38. Connect throttle and cruise control cables to
clips and secure in throttle body cams.
39. Position abutment bracket to upper manifold, fit
and tighten bolts.
40. Fit air intake hose, tighten 2 clips and connect
harness to clip on hose.
41. Connect IAC hose to air intake hose and secure
with clip.
42. Top-up cooling system.
43. Lower bonnet and connect gas struts.
44. Connect battery earth lead.
45. Fit battery cover and secure fixings.
MANIFOLD AND EXHAUST SYSTEM
INLET MANIFOLD GASKETS - DIESEL - VEHICLES
WITHOUT EGR
4. Release turbocharger intake hose from ducting.
5. Release breather valve from grommet in intake
ducting.
Service repair no - 30.15.08
Remove
1. Disconnect battery negative lead.
2. Remove 4 screws securing injector covers.
Remove covers.
NOTE: Collect grommet. Refit to ducting.
6. Disengage 2 clips. Remove intake ducting.
7. Disconnect intake hose from manifold.
8. Disconnect multiplug from intake temperature
sensor.
9. Release fuel return hose from inlet manifold clip.
3. Release intake hose from ducting.
REPAIR
23
30
MANIFOLD AND EXHAUST SYSTEM
NEW RANGE ROVER
10. Remove 2 nuts and bolts securing stays to inlet
manifold.
11. Slacken 2 nuts securing manifold stays to oil
filter casing.
12. Release clip securing manifold pressure sensing
pipe to stay.
24
REPAIR
13. Remove 12 nuts securing intake manifold to
cylinder head.
14. Release gearbox breather hose bracket from
rearmost manifold stud.
15. Release manifold from studs. Ensure that
injector leak off pipes do not foul on manifold
flanges.
16. Place manifold aside. Do not strain manifold
pressure sensing hose.
MANIFOLD AND EXHAUST SYSTEM
17. Collect 6 inlet manifold gaskets.
18. Position cloth over inlet ports to prevent dirt
ingress.
INTAKE MANIFOLD GASKETS - DIESEL WITH
EGR
Service repair no - 30.15.08
Refit
Remove
19. Ensure mating faces are clean.
20. Position intake manifold with gaskets on studs.
Ensure injector leak off pipes are not fouled.
21. Position gearbox breather hose bracket on
rearmost manifold stud.
22. Secure manifold with nuts. Progressively tighten
to 22 Nm (16 lbf.ft)
23. Position manifold stays. Secure with nuts and
bolts.
24. Secure manifold pressure sensing hose to stay
with clip.
25. Connect multiplug to intake temperature sensor.
26. Engage fuel return hose into inlet manifold clip.
27. Connect intake hose. Secure with clip.
28. Position intake ducting. Engage clips.
29. Engage breather valve into ducting grommet.
30. Connect ducting to turbocharger intake hose.
Secure with clip.
31. Connect intake hose to ducting. Secure with clip.
32. Fit injector covers. Secure with screws.
33. Reconnect battery negative lead.
1.
2.
3.
4.
Disconnect battery negative terminal.
Remove air intake ducting. See this section.
Disconnect vacuum hose from EGR valve.
Slacken clip and disconnect intercooler hose
from EGR valve.
5. Remove 2 bolts securing EGR pipe to EGR
valve.
REPAIR
25
30
MANIFOLD AND EXHAUST SYSTEM
6. Disengage clip on underside of intake manifold.
Release wiring harness and vacuum hoses.
7. Release fuel return hose and EGR vacuum pipe
from clips on underside of manifold.
8. Remove 12 nuts securing intake manifold to
cylinder head.
9. Release gearbox breather hoses from rearmost
manifold stud.
10. Release manifold from from studs. Ensure that
injector leak off pipes do not foul on manifold
flanges.
11. Position manifold aside.
CAUTION: Ensure manifold pressure
sensing hose is not strained.
12. Remove 6 seals from intake manifold ports.
CAUTION: Care must be taken when
extracting seals to ensure recesses in
intake manifold are not damaged.
13. Clean mating faces of intake manifold and
cylinder head.
14. Position cloth over inlet ports to prevent dirt
ingress.
26
REPAIR
NEW RANGE ROVER
Refit
15. Fit new seals to recesses in intake manifold.
16. Position intake manifold to studs, ensuring that
leak off pipes do not become trapped beneath
flanges.
17. Position gearbox breather hose bracket to
rearmost stud.
18. Secure manifold with nuts and progressively
tighten to 22Nm (16 lbf.in).
19. Position and secure fuel return hose, harnesses
and vacuum hoses to clips on underside of
manifold.
20. Engage EGR pipe to valve, align flange and
secure with bolts. Tighten bolts to 22 Nm
(16 lbf.in).
21. Connect intercooler hose to EGR valve and
secure with clip.
22. Connect vacuum hose to EGR valve.
23. Fit air intake ducting. See this section.
24. Connect battery negative terminal.
MANIFOLD AND EXHAUST SYSTEM
INTERMEDIATE AND REAR PIPES
Service repair no - 30.10.11 - Intermediate Pipe
Service repair no - 30.10.22 - Rear Pipe
Remove
1. Raise vehicle on four post lift.
2. Remove 4 nuts securing intermediate pipe
flanges to front and rear pipes.
3. Release 2 mounting rubbers. Remove rear pipe.
4. With assistance, release 2 mounting rubbers.
Remove intermediate pipe.
7. Position rear pipe. Secure with mounting
rubbers.
8. Position intermediate pipe flanges. Secure with
nuts. Tighten to 25 Nm (18 lbf.ft).
Refit
5. Ensure mating faces are clean.
6. With assistance, position intermediate pipe.
Secure with mounting rubbers.
REPAIR
27
30
MANIFOLD AND EXHAUST SYSTEM
TAIL PIPE - LH - FROM 97MY
Service repair no - 30.10.22
Remove
1. Raise vehicle on 4 post ramp.
2. Loosen clamp securing LH tail pipe to RH tail
pipe.
3. Release LH tail pipe from 2 mounting rubbers.
4. Release LH tail pipe from RH tail pipe and
remove tail pipe.
Refit
5. Clean tail pipe mating faces.
6. Position LH tail pipe to vehicle and fit to
mounting rubbers.
7. Engage LH tail pipe to RH tail pipe and tighten
clamp to 65 Nm (48 lbf.ft)
28
REPAIR
NEW RANGE ROVER
MANIFOLD AND EXHAUST SYSTEM
TAIL PIPE - RH - FROM 97MY
Service repair no - 30.10.52
Remove
1. Raise vehicle on 4 post ramp.
2. Loosen clamp securing LH tail pipe to RH tail
pipe.
3. Remove 2 nuts securing tail pipe flange to
intermediate pipe flange.
4. Release RH tail pipe from 2 mounting rubbers.
5. With assistance, release RH tail pipe from LH tail
pipe and remove tail pipe.
Refit
6. Clean tail pipe mating faces.
7. With assistance, position RH tail pipe to vehicle
and fit to mounting rubbers.
8. Engage RH tail pipe to LH tail pipe.
9. Align tail pipe flange to intermediate pipe flange
and fit nuts. Tighten nuts to 25 Nm (18 lbf.ft)
10. Tighten nut securing RH tail pipe to LH tail pipe
to 65 Nm (48 lbf.ft) .
REPAIR
29
33 - CLUTCH
CONTENTS
Page
REPAIR
HYDRAULIC SYSTEM BLEED ............................................................................
CLUTCH ASSEMBLY - V8 ...................................................................................
CLUTCH ASSEMBLY - DIESEL ..........................................................................
MASTER CYLINDER ...........................................................................................
SLAVE CYLINDER ...............................................................................................
SLAVE CYLINDER - FROM 97MY ......................................................................
1
1
4
6
7
8
CLUTCH
HYDRAULIC SYSTEM BLEED
CLUTCH ASSEMBLY - V8
Service repair no - 33.15.01
Service repair no - 33.10.07
1. Top-up clutch master cylinder. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
CAUTION: Do not allow brake fluid to
contact painted surfaces. Paint damage
will occur. If spilled, remove fluid. Wash
area with clean warm water.
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX, Repair.
2. Release push rod gaiter from clutch lever.
3. Remove 2 bolts securing clutch slave cylinder.
Tie cylinder aside.
2. Clean area around slave cylinder bleed screw.
3. Connect bleed tube to bleed screw. Immerse
free end of tube into container of brake fluid.
4. Remove 9 bolts securing flywheel access cover
to clutch housing. Remove cover.
4. Hold clutch pedal down. Slacken bleed screw.
5. Release clutch pedal, allow it to return
unassisted. Depress pedal again.
CAUTION: Ensure master cylinder is
topped up at frequent intervals. Use only
fresh fluid.
6. Repeat procedure until fluid issuing from bleed
tube is free from air bubbles.
7. Tighten bleed screw. Remove bleed tube.
8. Top-up master cylinder.
5. Remove 8 bolts securing clutch housing.
Disengage release lever from release bearing.
Remove clutch housing.
REPAIR
1
33
CLUTCH
NEW RANGE ROVER
9. Remove cover assembly. Collect friction plate.
6. If clutch cover is to be refitted, mark cover and
flywheel to aid re-assembly.
7. Restrain flywheel.
8. Working diagonally, sequentially slacken 6 bolts
securing clutch cover to flywheel. Remove bolts.
Check
10. Check linings of friction plate for excessive or
uneven wear, burning or contamination.
11. Check splines of friction plate for excessive
wear.
12. Check friction surface of cover for burning
distortion or scoring.
13. Check fingers of cover for cracks and distortion.
14. Check release bearing for smooth operation.
15. Renew components as necessary.
CAUTION: Bearing is packed with grease,
do not wash in solvent.
2
REPAIR
CLUTCH
Refit
19. Position cover. Locate on dowels.
16. Ensure mating faces are clean.
NOTE: New friction plates are supplied
with splines pre-greased.
17. If refitting existing friction plate, smear splines
with ’Molycote FB180’.
18. Position friction plate on flywheel. Fit
LRT-12-001 to align plate.
NOTE: If original cover is refitted, align
marks.
20. Secure cover with bolts. Tighten progressively,
in a diagonal sequence to 40 Nm (30 lbf.ft).
Remove LRT-12-001.
21. Position clutch housing onto dowels. Ensure
release fork engages with release bearing.
22. Secure clutch housing with bolts. Tighten to
40 Nm (30 lbf.ft)
23. Position flywheel access cover. Secure with
bolts.
24. Smear release lever push rod socket with
’Molycote FB180’.
25. Position slave cylinder on clutch housing.
Ensure pushrod is engaged with lever. Secure
cylinder with bolts. Tighten to 45 Nm (33 lbf.ft)
26. Secure push rod gaiter to clutch lever.
27. Fit gearbox assembly. See MANUAL
GEARBOX, Repair.
REPAIR
3
33
CLUTCH
NEW RANGE ROVER
CLUTCH ASSEMBLY - DIESEL
Service repair no - 33.10.07
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX, Repair.
2. Remove starter motor. See ELECTRICAL,
Repair.
3. Release push rod gaiter from clutch lever.
4. Remove 2 bolts securing clutch slave cylinder.
Tie cylinder aside.
5. Release clutch fluid pipe from clips. Move pipe
bracket clear of clutch housing.
6. Remove 7 remaining bolts securing clutch
housing. Disengage release lever from release
bearing. Remove clutch housing.
4
REPAIR
NOTE: Spacer plate may become detached
from dowels but remain captive behind
flywheel.
7. If clutch cover is to be refitted, mark cover and
flywheel to aid re-assembly.
8. Fit LRT-12-106 to flywheel. Secure tool to
cylinder block with bolts.
CLUTCH
Refit
17. Ensure mating faces are clean.
NOTE: New friction plates are supplied
with splines pre-greased.
18. Smear friction plate splines with ’Molycote BR2’.
19. Position friction plate on flywheel. Fit
LRT-12-123 to align plate.
20. Position cover, locate on dowels.
NOTE: If original cover is refitted, align
marks.
9. Working diagonally, sequentially slacken 6 bolts
securing clutch cover to flywheel. Remove bolts.
10. Remove cover assembly. Collect friction plate.
Check
11. Check linings of friction plate for excessive or
uneven wear, burning or contamination.
12. Check splines of friction plate for excessive
wear.
13. Check friction surface of cover for burning,
distortion or scoring.
14. Check fingers of cover for cracks and distortion.
15. Check release bearing for smooth operation.
16. Renew components as necessary.
21. Secure cover with bolts. Tighten progressively,
in a diagonal sequence, to:
M8 8.8 - 24 Nm (18 lbf.ft)
M8 10.9 - 34 Nm (25 lbf.ft)
22. Remove LRT-12-123 and LRT-12-106.
23. Position spacer plate onto dowels.
24. Position clutch housing onto dowels. Ensure
release fork engages with release bearing.
25. Align clutch fluid pipe bracket and coolant pipe
with clutch housing.
26. Secure clutch housing with bolts.
M8 - Tighten to 27 Nm (20 lbf .ft)
M10 - Tighten to 51 Nm (38 lbf.ft)
M12 - Tighten to 86 Nm (63 lbf.ft)
27. Smear push rod socket of release lever with
’Molycote FB180’.
28. Position slave cylinder on clutch housing.
Ensure push rod has engaged with lever. Secure
cylinder with bolts. Tighten to 45 Nm (33 lbf.ft)
29. Secure push rod gaiter to clutch lever.
30. Secure fluid pipe to clips.
31. Fit starter motor. See ELECTRICAL, Repair.
32. Fit gearbox assembly. See MANUAL
GEARBOX, Repair.
CAUTION: Release bearing is packed with
grease, do not wash in solvent.
REPAIR
5
33
CLUTCH
MASTER CYLINDER
NEW RANGE ROVER
4. Position cloth beneath master cylinder to absorb
fluid spillage.
Service repair no - 33.20.01
Remove
1. Remove fascia closing panel. See CHASSIS
AND BODY, Repair.
2. Remove 4 scrivets securing lower closing panel.
Disconnect multiplug from footwell lamp.
Remove panel.
CAUTION: Do not allow brake fluid to
contact painted surfaces. Paint damage
will occur. If spilled, remove fluid. Wash
area with clean warm water.
5. Disconnect reservoir hose from master cylinder.
Plug hose and connection.
6. Disconnect pressure pipe from master cylinder.
Plug pipe and connection.
7. Remove 2 nuts securing master cylinder to
bulkhead. Remove master cylinder.
3. Remove spring clip and clevis pin from master
cylinder push rod.
6
REPAIR
Refit
8. Ensure mating faces are clean.
9. Reverse removal procedure.
10. Bleed clutch system. See this section.
CLUTCH
SLAVE CYLINDER
Service repair no - 33.35.01
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Position container to collect fluid spillage.
CAUTION: Do not allow brake fluid to
contact painted surfaces. Paint damage
will occur. If spilled, remove fluid. Wash
area with clean warm water.
Refit
6. Ensure mating faces are clean.
7. Position cylinder to clutch housing and push rod.
Secure with bolts. Tighten to 45 Nm (33 lbf.ft)
8. Remove plugs from pipe and cylinder. Connect
pipe to cylinder. Tighten union.
9. Secure pipe to clip.
10. Bleed hydraulic system. See this section.
11. Remove safety stands. Lower vehicle.
3. Disconnect fluid pipe. Release pipe from clip.
Plug pipe and connection.
4. Remove 2 bolts securing cylinder.
5. Remove cylinder from clutch housing and push
rod.
REPAIR
7
33
CLUTCH
SLAVE CYLINDER - FROM 97MY
Service repair no - 33.35.01
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove gearbox RH acoustic cover. See
CHASSIS AND BODY, Repair.
3. Position container to collect fluid spillage.
CAUTION: Do not allow brake fluid to
contact painted surfaces. Paint damage
will occur. Thoroughly clean spillages with
clean, warm water.
4. Release pipe from clip.
5. Remove pipe union from slave cylinder.
CAUTION: Plug the connections.
6. Remove 2 bolts securing slave cylinder to clutch
housing.
7. Remove slave cylinder from push rod.
8
REPAIR
NEW RANGE ROVER
Refit
8. Ensure mating surfaces of slave cylinder and
clutch housing are clean.
9. Clean pushrod.
10. Fit slave cylinder to push rod and align to clutch
housing.
11. Fit bolts securing slave cylinder to clutch housing
and tighten to 25 Nm (18lbf.ft)
12. Remove plugs from slave cylinder and pipe
union.
13. Clean pipe union and slave cylinder.
14. Connect and tighten pipe union to slave cylinder.
15. Secure pipe to clip.
16. Bleed clutch system. See this section.
17. Fit gearbox RH acoustic cover. See CHASSIS
AND BODY, Repair.
37 - MANUAL GEARBOX
CONTENTS
Page
R380 GEARBOX
REPAIR
GEARBOX ...........................................................................................................
OUTPUT SHAFT SEAL ........................................................................................
SELECTOR REMOTE HOUSING ........................................................................
FLUID COOLER - PETROL .................................................................................
FLUID COOLER - DIESEL ...................................................................................
1
6
6
9
9
R380 GEARBOX
GEARBOX
Service repair no - 37.20.02 - Gearbox Renew
Service repair no - 37.20.02/99 - Gearbox Remove
for Access
Remove
1. Raise vehicle on four post lift.
2. Disconnect battery negative lead.
3. Petrol Vehicles: Release 2 clips securing
cooling fan cowling to radiator. Remove cowl.
4. Remove centre console. See CHASSIS AND
BODY, Repair.
6. Remove 2 bolts securing gear lever. Remove
lever.
7. Remove handbrake cable clevis pin.
8. Release handbrake cable from grommet in
tunnel. Refit cable grommet to tunnel.
5. Remove 6 nuts securing gaiter ring. Remove
ring and gaiter
9. Raise lift. Drain gearbox and transfer box oil.
See SECTION 10, Maintenance.
10. Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
11. Diesel Vehicles: Remove chassis
crossmember. See CHASSIS AND BODY,
Repair.
12. Remove 4 bolts securing rear propeller shaft
guard. Remove guard.
REPAIR
1
37
MANUAL GEARBOX
NEW RANGE ROVER
16. Disconnect 2 Lucars from transfer box oil
temperature sensor.
17. Disconnect multiplugs from high/low motor and
output shaft speed sensor.
13. Mark transfer box and propeller shaft flanges to
aid re-assembly.
14. Raise one wheel on each axle to allow rotation
of propeller shafts.
15. Remove 4 nuts and bolts from each flange.
Disconnect propeller shafts. Tie aside.
2
REPAIR
R380 GEARBOX
18. Disconnect multiplugs from reverse and neutral
switches.
19. Release harness from clips.
20. Remove 3 bolts securing oil cooler pipe adaptor
to gearbox.
21. Release adaptor, collect 2 ’O’ rings and discard.
Plug connections.
22. Remove banjo bolts securing breather pipes to
gearbox and transfer box.
23. Collect 2 sealing washers from each union and
discard. Plug pipes and connections.
24. Tie breather and oil cooler pipes aside.
25. Position adaptor plate to transmission lift. Secure
with bolts.
26. Raise transmission lift into position. Secure
adaptor plate to gearbox mounting bracket holes
with 4 bolts.
27. Remove transmission stand.
28. Lower transmission for access.
CAUTION: Place a wooden block between
axle case and sump to support engine.
29. Remove bolt securing harness bracket to
gearbox.
30. Remove 8 bolts securing gearbox to bell
housing.
CAUTION: Do not allow the weight of the
gearbox to be supported by the clutch.
REPAIR
3
37
MANUAL GEARBOX
NEW RANGE ROVER
31. With assistance, release gearbox from clutch
plate splines.
32. Lower transmission assembly away from vehicle.
33. Do not carry out further dismantling if
component is removed for access only.
34. Attach lifting eyes to transmission.
35. Attach hoist to lifting eyes. Take weight of
transmission.
36. Remove lift adaptor. Hoist transmission
assembly onto bench.
37. Fit lifting eye to transmission brake drum. Raise
gearbox on end.
CAUTION: Position packers beneath bell
housing extension to provide clearance for
input shaft.
38. Remove 6 bolts securing transfer box to
gearbox. Release from 2 ring dowels. Remove
transfer box.
39. Remove 2 bolts securing clutch release bearing
spigot. Remove spigot.
4
REPAIR
40. Lay gearbox on side. Position bell housing
extension over edge of bench.
41. Remove 6 bolts securing bell housing extension.
Release from 2 ring dowels. Remove from
gearbox.
42. Ensure mating faces are clean.
43. Clean release bearing spigot. Lightly coat
running surface with grease. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
44. Position bell housing extension to gearbox.
Engage ring dowels. Secure with bolts. Tighten
to 45 Nm (33 lbf.ft)
45. Position clutch release bearing spigot. Secure
with bolts. Tighten to 18 Nm (13 lbf.ft)
R380 GEARBOX
46. Place gearbox on end. Position transfer box.
47. Engage transfer box to ring dowels. Secure to
gearbox with bolts. Tighten to 45 Nm (33 lbf.ft)
48. Place transmission on side. Fit lifting eyes.
49. Raise transmission to lift adaptor. Secure to
adaptor plate with bolts.
50. Detach hoist. Remove lifting eyes.
Refit
51. With assistance, depress clutch pedal. Align
clutch friction plate with either:
LRT-12-001 Petrol models or
LRT-12-123 Diesel models.
52. Release clutch pedal. Remove aligning tool.
53. Select gear to aid input shaft alignment.
54. Position transmission to engine. Engage input
shaft to friction plate splines.
CAUTION: Do not allow the weight of the
gearbox to be supported by the clutch.
55. Engage bell housing ring dowels. Secure
gearbox to bell housing with bolts. Tighten to
45 Nm (33 lbf.ft)
CAUTION: Ensure that gearbox is located
on both dowels, or transmission damage
may occur.
67. Connect Lucar terminals to transfer box oil
temperature sensor.
68. Raise one wheel on each axle to allow rotation
of propeller shafts.
69. Position propeller shafts to transfer box flanges.
Align marks.
70. Secure shafts with nuts and bolts. Tighten to
48 Nm (35 lbf.ft)
71. Fit rear propeller shaft guard. Secure with bolts.
72. Route handbrake cable through grommet in
transmission tunnel.
73. Diesel Vehicles. Fit chassis cross member.
See CHASSIS AND BODY, Repair.
74. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
75. Refill gearbox and transfer box fluids. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
76. Fit seal around gearbox remote housing to
transmission tunnel aperture.
77. Connect handbrake cable to lever. Secure with
clevis pin and clip.
78. Position gear lever. Secure with bolts. Tighten
to 25 Nm (18 lbf.ft)
79. Fit gaiter and ring. secure with nuts.
80. Fit centre console. See CHASSIS AND BODY,
Repair.
81. Petrol Vehicles. Position radiator cooling fan
cowling. Secure with clips.
82. Reconnect battery negative lead.
56. Select neutral.
57. Raise transmission. Support under brake drum
with transmission jack.
58. Remove transmission lift adaptor. Remove lift.
59. Untie breather and oil cooler pipes.
60. Remove plugs from pipes pipes and
connections.
61. Fit new ’O’ rings to oil cooler pipe adaptor.
Position adaptor to gearbox. Secure with bolts.
62. Fit new sealing washers to breather pipes.
Position pipes. Secure with banjo bolts.
63. Position harness bracket to gearbox and secure
with bolt.
64. Secure harness to clips.
65. Connect multiplugs to reverse and neutral
switches.
66. Connect multiplugs to high/low motor and output
shaft speed sensor.
REPAIR
5
37
MANUAL GEARBOX
NEW RANGE ROVER
OUTPUT SHAFT SEAL
SELECTOR REMOTE HOUSING
Service repair no - 37.23.01
Service repair no - 37.16.29
Remove
Remove
1. Disconnect battery negative lead.
2. Remove transfer box. See TRANSFER BOX,
Repair.
3. Lever seal from extension housing.
CAUTION: Ensure seal location does not
become damaged.
Refit
4.
5.
6.
7.
8.
6
Ensure mating faces are clean.
Lubricate seal lip with transmission oil.
Using LRT-37-014, fit seal to extension housing.
Fit transfer box. See TRANSFER BOX, Repair.
Reconnect battery negative lead.
REPAIR
1. Raise vehicle on four post lift.
2. Disconnect battery negative lead.
3. Remove centre console. See CHASSIS AND
BODY, Repair.
4. Remove 6 nuts securing gaiter ring. Remove
ring and gaiter.
5. Remove 2 bolts securing gear lever. Remove
lever.
R380 GEARBOX
6. Remove handbrake cable clevis pin.
7. Raise lift.
8. Support gearbox using transmission jack.
9. Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
10. Diesel Vehicles. Remove chassis cross
member. See CHASSIS AND BODY, Repair.
11. Release hand brake cable from grommet in
tunnel. Refit grommet to tunnel.
12. Remove 4 bolts securing propeller shaft guard.
Remove guard.
13. Disconnect 2 Lucars from transfer box oil
temperature sensor.
REPAIR
7
37
MANUAL GEARBOX
14. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
15. Release harness from 2 clips on transfer
gearbox brackets.
16. Lower gearbox for access.
CAUTION: Ensure engine does not foul
bulkhead.
17. Disconnect neutral switch multiplug.
18. Remove 4 bolts securing remote housing to
gearbox. Position harness bracket aside.
19. Remove selector remote housing from 2 location
dowels.
8
REPAIR
NEW RANGE ROVER
Refit
20. Ensure all mating faces are clean.
21. Apply a uniform bead of Hylogrip 2000 to sealing
face of remote housing as shown.
22. Position remote housing. Engage remote spigot
into selector yoke.
23. Engage housing to location dowels. Align
harness bracket.
24. Secure remote housing with bolts. Tighten to
25 Nm (18 lbf.ft)
25. Connect neutral switch multiplug.
26. Connect multiplugs to High/Low motor and
output shaft speed sensor.
27. Connect Lucars to transfer box fluid temperature
sensor.
28. Secure harness in clips.
29. Position propeller shaft guard. Secure with bolts.
30. Route hand brake cable through grommet in
transmission tunnel.
31. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
32. Diesel Vehicles. Fit chassis cross member.
See CHASSIS AND BODY, Repair.
33. Remove jack. Lower lift.
34. Connect handbrake cable to lever. Secure with
clevis pin and clip.
35. Fit seal around gearbox remote housing to
transmission tunnel aperture.
36. Position gear lever. Secure with bolts. Tighten
to 25 Nm (18 lbf.ft)
37. Fit gaiter and ring. Secure with nuts.
38. Fit centre console. See CHASSIS AND BODY,
Repair.
39. Reconnect battery negative lead.
R380 GEARBOX
FLUID COOLER - PETROL
FLUID COOLER - DIESEL
Service repair no - 37.12.52
Service repair no - 37.12.52
Remove
Remove
1. Disconnect battery negative lead.
2. Remove engine oil cooler. See ENGINE,
Repair.
3. Remove 4 trim studs securing air deflectors.
Remove deflectors.
4. Position container to collect fluid spillage.
5. Unscrew fluid pipe union nuts. Collect ’O’ rings
and discard.
1. Remove radiator. See COOLING SYSTEM,
Repair.
Refit
2. Reverse removal procedure.
6. Plug pipes and connections.
7. Remove 4 bolts securing cooler to radiator
bracket.
8. Remove cooler.
Refit
9. Fit cooler.
10. Fit and tighten 4 bolts securing cooler to
mounting bracket.
11. Remove plugs from cooler and pipes.
12. Ensure pipe unions are clean.
13. Lubricate new ’O’ rings seals with clean fluid. Fit
seals to pipes.
14. Connect pipes to cooler. Tighten to 30 Nm (22
lbf.ft)
15. Remove container.
16. Fit air deflectors and secure with studs.
17. Fit engine oil cooler. See ENGINE, Repair.
18. Reconnect battery negative lead.
19. Top up gearbox fluid. See SECTION 10,
Maintenance.
REPAIR
9
Workshop manual
RANGE ROVER
VOLUME 2
41
44
47
51
54
57
This manual covers vehicles from
introduction 1995
41
44
47
51
54
57
60
64
70
75
76
77
78
80
82
84
86
87
88
TRANSFER BOX
AUTOMATIC GEARBOX
PROPELLER SHAFTS
REAR AXLE AND FINAL DRIVE
FRONT AXLE AND FINAL DRIVE
STEERING
FRONT SUSPENSION
REAR SUSPENSION
BRAKES
SUPPLEMENTARY RESTRAINT SYSTEM
CHASSIS AND BODY
PANEL REPAIRS
SEATS
HEATING AND VENTILATION
AIR CONDITIONING
WIPERS AND WASHERS
ELECTRICAL
NAVIGATION SYSTEM
INSTRUMENTS
This manual supersedes:
Workshop manual VDR100370
Body Repair Manual LRL0085
Published by Rover Technical Communication
 1999 Rover Group Limited
Publication part no. LRL0326ENG
60
64
70
75
76
77
78
80
82
84
86
87
88
41 - TRANSFER BOX
CONTENTS
Page
DESCRIPTION AND OPERATION
TRANSFER BOX - DESCRIPTION ...................................................................... 4
TRANSFER BOX - OPERATION ....................................................................... 12
REPAIR
ELECTRONIC CONTROL UNIT .......................................................................... 1
RATIO CONTROL MOTOR ................................................................................. 2
INPUT SHAFT OIL SEAL ..................................................................................... 2
OUTPUT SHAFT OIL SEAL - FRONT ................................................................. 3
OUTPUT SHAFT OIL SEAL - REAR .................................................................... 5
TRANSFER BOX - UP TO 99MY ......................................................................... 6
TRANSFER BOX - FROM 99MY ....................................................................... 10
TRANSFER BOX
Transfer box component layout
1.
2.
3.
4.
5.
6.
7.
High/low switch (Manual vehicles only)
BeCM
Selector lever assembly (Automatic transmission vehicles only)
EAT ECU (Automatic transmission vehicles only)
Transfer box ECU
Transfer box
Gearbox (Automatic transmission shown)
DESCRIPTION AND OPERATION
1
41
TRANSFER BOX
Transfer box control schematic
2
DESCRIPTION AND OPERATION
NEW RANGE ROVER
TRANSFER BOX
1.
2.
3.
4.
5.
6.
7.
8.
Automatic transmission and transfer box selector
Speed sensor
Ratio control motor
Transfer Box ECU
ECM (NAS vehicles only)
EAT ECU (Automatic transmission only)
Neutral switch (Manual transmission only)
High/Low fascia switch (Manual transmission
only)
9. BeCM Fuse 4 Battery supply to Transfer Box
ECU and ratio control motor
10. BeCM Fuse 6 Ignition supply to Transfer Box
ECU
11. BeCM
12. Diagnostic socket
13. Instrument pack
DESCRIPTION AND OPERATION
3
41
TRANSFER BOX
TRANSFER BOX - DESCRIPTION
General
All models are fitted with a Borg Warner transfer box.
The transfer box is a four wheel drive, two speed ratio
reducing gearbox with high and low range outputs
selected electrically by the driver.
A differential is fitted between the front and rear output
shafts to allow the propeller shafts to rotate at different
speeds when the vehicle is cornering. Drive to the
front propeller shaft is through a viscous coupling,
which eliminates the requirement for a differential
lock.
NEW RANGE ROVER
The base has an ’H’ pattern for the lever to move in.
The lever is hinged to the base and is moved across
the ’H’ pattern to select HI or LO range operating a
microswitch located in the base. The driver’s side of
the ’H’ pattern is the high range selection in all
markets.
The cover incorporates LED lever position indicators
for high and low range gear selection. Operation of
the LED indicators are controlled by the BeCM. The
selected range is displayed by the LED’s being
illuminated brightly, with the unused range LED’s
dimmed. An electrical connector at the rear of the
cover connects the selector lever assembly to the
vehicle wiring.
The high and low ranges are selected by the driver.
On manual transmission vehicles a switch is located
on the fascia and when pressed selects low range. On
automatic transmission vehicles high and low ranges
are selected by moving the auto transmission selector
lever across the H-gate to the required position.
On all vehicles, when the transfer box has changed to
high range, ’HIGH’ is displayed momentarily in the
instrument pack message centre. On automatic
transmission vehicles, if low range is selected, the
message centre momentarily displays ’LOW’ and then
permanently displays ’L’. On manual transmission
vehicles the message centre permanently displays
’LOW’.
The high and low range selection is performed by a
ratio control motor located on the transfer box. The
motor is controlled by a Transfer Box ECU located
below the LH front seat. The ECU is connected
electrically to other ECU’s to ensure that all conditions
for a successful range change are correct. The
transfer box ECU receives inputs and provides
outputs to/from the following ECU’s:
• Body electrical Control Module (BeCM)
• Electronic Automatic Transmission (EAT) ECU
• Engine Control Module (ECM) (NAS only).
High/low range selection - Automatic transmission
vehicles
On automatic transmission vehicles, high and low
range selection is performed using the transmission
selector lever. The selector lever assembly consists of
a lever and a cover attached to a cast base. The base
is located on a gasket and secured to the
transmission tunnel.
4
DESCRIPTION AND OPERATION
High/low range selection - Manual transmission
vehicles
On manual transmission vehicles, high and low range
selection is performed using a latching pushbutton
switch on the fascia. The switch has an indicator lamp
which flashes when the transfer box is changing range
and is permanently illuminated in low range.
TRANSFER BOX
Transfer Box
1.
2.
3.
4.
5.
6.
7.
8.
9.
Epicyclic gear set
Reduction hub
Drive gear
Selector fork
Oil pump
Morse chain
Bolt
Speed sensor
’O’ ring
10.
11.
12.
13.
14.
15.
16.
17.
Ratio control motor
Temperature sensor
Sealing washer
Rear output shaft
Differential unit
Viscous coupling unit
Front output shaft
Selector spool
DESCRIPTION AND OPERATION
5
41
TRANSFER BOX
NOTE: For a detailed description of the
transfer gearbox refer to the Borg Warner
Overhaul Manual.
The transfer box comprises:
- a front and rear casing
- an epicyclic gear set
- a viscous coupling
- a differential unit
- a ratio control motor
- a lubrication pump.
NEW RANGE ROVER
Viscous coupling unit
The viscous coupling operates in conjunction with the
differential unit to control the proportion of drive torque
transferred to the front and rear drive shafts. The
viscous coupling is a sealed unit filled with a silicon
jelly which surrounds discs within the unit. The silicon
jelly has properties which increase its viscosity and
resistance to flow when agitated and heated.
The epicyclic gear set is located in the front casing
and comprises a sun gear and four planet gears. The
sun gear receives the drive from the gearbox output
shaft and transfers the drive directly to a reduction
hub. The reduction hub is located on a splined
intermediate shaft which rotates at the same speed.
The reduction hub is moved along the intermediate
shaft by the selector spool and the ratio control motor
to one of three positions; high, low and neutral.
In the high position, the reduction hub is driven
directly from the sun gear and rotates the intermediate
shaft at the same speed as the gearbox output shaft.
In the low position, the reduction hub is engaged with
the planet carrier and rotates at a lower speed than
the gearbox output shaft.
In the neutral position, the reduction hub is not
engaged with either the sun gear or the planet carrier
and no drive is passed from the gearbox output shaft
to the intermediate shaft.
Differential unit
Drive from the intermediate shaft is transferred by a
morse chain to the differential unit. The differential unit
comprises sun and planet gears. The rear output
passes through the differential unit sun gear shaft and
engages with the planet carrier. The splined forward
end of the rear output shaft provides location for the
viscous coupling unit inner spline. The outer diameter
of the sun gear shaft engages with the outer splines of
the viscous coupling unit.
6
DESCRIPTION AND OPERATION
During normal driving conditions, slight variations in
the relative speed of each drive shaft is insufficient to
increase the viscosity of the silicon jelly. Therefore the
resistance within the viscous coupling is low.
In off-road conditions, when the wheels lose grip on
loose or muddy surfaces, a greater difference in the
rotational speeds of the front and rear drive shafts
exists. The slippage, due to the difference in rotational
speeds of the drive shafts, within the viscous coupling
agitates the silicon jelly causing heat which increases
the viscosity. The increased viscosity increases the
drag between the discs forcing both sets of discs to
rotate at similar speeds, reducing axle slippage and
increasing traction. The viscous coupling removes the
need for a manually controlled differential lock.
TRANSFER BOX
Selector mechanism
The selector mechanism comprises a selector fork
and an interlock spool. The selector fork is mounted
on a shaft between the front and rear casings. The
interlock spool is mounted on a spindle through the
rear casing and is positively connected to the ratio
control motor. The selector fork is engaged in a cam
track on the spool. When the ratio control motor
rotates the spool, the rotational movement of the
spool is converted to linear movement of the selector
along the shaft.
The selector is engaged with the reduction hub. The
linear movement of the selector moves the reduction
hub in the epicyclic gear set changing the ratio
between high, low or neutral.
Lubrication
Lubrication is provided by a low geroter plunger type
oil pump which is driven from the epicyclic gear set.
The oil pump passes oil through oil ways in the
components to lubricate the epicyclic gear set. The
differential unit and morse chain are partially
immersed in oil and are lubricated as the components
rotate.
DESCRIPTION AND OPERATION
7
41
TRANSFER BOX
NEW RANGE ROVER
Transfer Box Electrical Components
The transfer box ECU reads the motor position in the
form of a binary code with each switch either open or
closed circuit. The ECU measures between the
switches and an encoder ground on connector pin 19.
Ratio control motor
The ratio control motor is located on the rear casing of
the transfer box and secured with four bolts. The
motor comprises a conventional single speed
permanent magnet type motor. The motor spindle has
a worm which engages with a worm wheel in a
housing at the end of the motor. The worm wheel is
attached to the spindle of the selector interlock spool
inside the transfer box.
The worm wheel also drives a motor encoder which
comprises four position switches. The transfer box
ECU provides a 5 V signal to each switch and
interprets the transfer box range by monitoring the
condition of each switch.
The table below shows the motor switch states and
the corresponding motor position for each state.
Switch 1
Switch 2
Switch 3
Switch 4
Pin 17
Pin 32
Pin 31
Pin 7
Open
Open
Open
Closed
Left stop
Open
Closed
Open
Closed
Left of high
Closed
Closed
Open
Closed
High range
Closed
Closed
Closed
Closed
Right of high
Open
Closed
Closed
Closed
Zone 1
Open
Closed
Closed
Open
Neutral
Closed
Closed
Closed
Open
Zone 2
Closed
Open
Closed
Open
Low range
Closed
Open
Closed
Closed
Right stop
Speed sensor
The speed sensor is located in the rear casing and
secured with a screw. A toothed reluctor ring is
integrated on the rear output shaft. The inductive
speed sensor senses the reluctor ring and produces a
sine wave, impulse type signal as each tooth on the
reluctor ring passes the sensor.
The transfer box ECU processes the signal from the
speed sensor and compares this to a stored speed
value in the memory to determine if a range change is
allowed.
8
By using the combinations of the switches, the
transfer box ECU can calculate the transfer box
position and how the motor should operate to select
the desired range. If the transfer box should move to a
position outside the normal condition, i.e. left of high
range, the ECU can move the motor to the correct
position.
DESCRIPTION AND OPERATION
Motor position
NOTE: The speed sensor is dedicated to
the transfer box ECU to determine if a
range change can be permitted.
TRANSFER BOX
Temperature sensor
The temperature sensor is screwed into the rear
casing. The sensor has two Lucar connectors. One
connector is attached to an earth eyelet connector,
the other is connected to the BeCM.
When the transfer box oil reaches a temperature of
between 140 and 150 °C (284 and 302 °F), contacts
in the switch close, completing an earth path to the
BeCM. The BeCM uses the completed earth path as a
signal to generate a ’TRANSFER OVRHEAT’
message in the message centre. The ’TRANSFER
OVRHEAT’ message is displayed alternately with a
’REFER HANDBOOK’ message. When the transfer
box oil cools to between 126 and 134 °C
(258 and 273 °F), the switch contacts open and the
’TRANSFER OVRHEAT’ message is extinguished.
Transfer box ECU
The BeCM, located below the right hand front seat,
contains its own integral fusebox. The transfer box
ECU receives a battery power supply from the BeCM
via fuse number 4. An ignition on signal is also
supplied from the BeCM via fuse 6. The ignition on
signal is supplied to different ECU connector pins for
manual and automatic transmission vehicles.
On NAS only vehicles, if a fault occurs which prevents
the transfer box moving from low to high range, the
transfer box ECU outputs a signal to the ECM which is
interpreted as an OBDII fault flag.
The transfer box ECU provides feed and return paths
to the ratio control motor to operate the motor in the
required direction. Two pins are used to supply power
to the motor in each direction. The feed is supplied
from two pins to avoid overload and heat generation
which would occur if one pin was used. A 5 V signal
current is supplied to the four motor encoder switches
which are used by the ratio control motor to determine
motor position.
Speed signals from the transfer box speed sensor are
received as an input to the transfer box ECU which
calculates whether the speed is below the threshold to
allow a range change.
Range change request signals are received from the
H-gate selector switch on automatic transmission
vehicles or the high/low switch on manual vehicles.
Transfer box ECU
The transfer box ECU is located below the front LH
seat and is identified from the other ECU’s located
under the seat by its single 36 pin harness connector.
The connector supplies power, earth, signal and
sensor information to/from the ECU and other ECU’s
for transmission operation.
On automatic transmission vehicles, a park/neutral
signal is transmitted from the BeCM to the transfer
box ECU. On manual transmission vehicles, a neutral
switch located in the transmission provides an earth
signal which is used by the ECU and BeCM to
determine that the transmission is in neutral. The
park/neutral and neutral signal are used by the ECU
to allow a range change only when the transmission is
in neutral.
Outputs are provided by the transfer box ECU to the
BeCM for high and low range status. The BeCM uses
the signals for instrument pack message centre
display of range status.
DESCRIPTION AND OPERATION
9
41
TRANSFER BOX
NEW RANGE ROVER
Transfer box ECU connector face view
Transfer box ECU connector pin details
10
Pin No.
Description
Input/Output
1
Motor drive - Counter clockwise
Output
2
Motor drive - Counter clockwise
Output
3
Not used
-
4
Ignition - Manual vehicles only
Input
5
Power earth
Input
6
Not used
-
7
Motor position switch 4
Input
8 to 12
Not used
-
13
Vehicle speed signal
Input
14
Low range status
Output
15
Transfer box neutral select
Input
16
Not used
-
17
Motor position switch 1
Input
18
Not used
-
19
Motor encoder earth
Output
20
Not used
-
21
Ignition - Automatic vehicles only
Input
22
Not used
-
23
Battery supply
Input
24
Battery supply
Input
25
Motor drive - Clockwise
Output
DESCRIPTION AND OPERATION
TRANSFER BOX
Pin No.
Description
Input/Output
26
Motor drive - Clockwise
Output
27
Not used
-
28
Transfer box OBDII link
Output
29
Power earth
Input
30
Vehicle speed signal earth
Input
31
Motor position switch 3
Input
32
Motor switch position 2
Input
33
High/Low range select
Input
34
Park/Neutral (Auto) Neutral (Manual) Signal
Input
35
High range status line
Output
36
Neutral range status line
Output
DESCRIPTION AND OPERATION
11
41
TRANSFER BOX
TRANSFER BOX - OPERATION
Transfer Box
Drive is transmitted to the transfer box from the
gearbox output shaft which is permanently engaged in
the sun gear of the epicyclic gear set. In high range
the sun gear transmits drive directly to the selector
sleeve. In low range, when the selector spool has
moved the selector sleeve, the sun gear transmits
drive through the planet carrier.
The rotation of the selector sleeve is transferred to the
intermediate shaft. A gear attached to the
intermediate shaft carries the morse chain which
transfers the drive to the differential unit.
The rear output shaft passes through the differential
unit and rotates at the same speed. The viscous
coupling passes drive from the rear output shaft to the
front output shaft. When the silicon fluid in the viscous
coupling becomes warm its resistance to shear
increases passing more drive to the front drive shaft
increasing traction.
NEW RANGE ROVER
If the vehicle is moving above 5 mph (8 km/h) or the
selector lever is moved into gear before the range
change is complete, the change will not occur and a
’SLOW DOWN’ or ’SELECT NEUTRAL’ message will
be displayed in the message centre.
NOTE: The ’SLOW DOWN’ message is
generated by the BeCM, not the transfer
box ECU.
The transfer box can be placed in the ’Neutral’
position by moving the selector lever into the ’PARK’
position. Insert a spare fuse (minimum 5 Amp) into
fuse position 11 on the BeCM. After 5 seconds the
transfer box moves to the neutral position, an audible
warning will sound, a ’TRANSFER NEUTRAL’
message is displayed in the message centre and the
high and low LED illumination on the selector cover
will extinguish.
Manual transmission
To change from high to low the vehicle speed must be
below 5 mph (8 km/h) or from low to high the vehicle
speed must be below 15 mph (24 Km/h).
Electrical Operation
Range change
NOTE: Range changes should be
performed with the vehicle stationary and
although range changes are possible at
very low speeds, this practice is not
recommended.
Select neutral with the gear lever and press the
high/low switch on the fascia. The indicator lamp on
the switch will flash as the range change takes place.
If the change is from high to low the lamp will
continuously illuminate when the change is
successfully completed. If the change is from low to
high the lamp will extinguish when the change is
complete. The message centre displays the selected
range.
Automatic transmission
To change range the vehicle speed must be reduced
to below 5 mph (8 km/h). Move the gear selector to
neutral and then across the H-gate into the neutral
position in the selected range. The appropriate LED
illuminations on the selected range side of the selector
cover will flash and an audible warning will sound. The
flashing LED’s and the audible warning will continue
while the ratio control motor is moving the transfer box
to the selected range.
When the ratio control motor has moved the transfer
box into the selected range the LED’s will stop
flashing, the audible warning will stop and a message
is displayed in the message centre. The desired gear
can be selected and the vehicle can be driven as
required.
12
DESCRIPTION AND OPERATION
If a range change is requested and the vehicle is
moving too fast or neutral has not been selected, the
indicator lamp on the switch will flash and a ’SLOW
DOWN’ or ’SELECT NEUTRAL’ message will appear
in the message centre.
NOTE: The ’SLOW DOWN’ message is
generated by the BeCM, not the transfer
box ECU.
The transfer box can be placed in the ’Neutral’
position by placing the gear lever in neutral and
inserting a spare fuse (minimum 5 Amp) into fuse
position 11 on the BeCM. After 5 seconds the transfer
box moves to neutral, an audible warning will sound
and a ’TRANSFER NEUTRAL’ message is displayed
in the message centre.
TRANSFER BOX
Range information - Automatic transmission
High range
When the transfer box is in high range the message
centre only displays the selected gear and the high
range side of the selector lever cover is illuminated in
green.
When the range change is complete:
• The high range selector cover LED’s are
continuously illuminated in green
• The low range selector cover orange LED
illumination goes off
• The transfer box warning lamp goes off
High to low range
When a change from high to low range is requested:
• The message centre displays ’HIGH’ for several
seconds, then ’HIGH’ is removed and only the
selected gear is displayed.
• The low range selector cover LED’s flash in
orange
Range selection parameters incorrect
• The high range selector cover LED’s remain
illuminated in green
If a range change is requested and the vehicle speed
is too high:
• The transfer box amber warning lamp in the
instrument pack flashes while the range change
is taking place.
When the range change is complete:
• The low range selector cover LED’s are
continuously illuminated in orange
• The high range selector cover green LED
illumination goes off
• The transfer box warning lamp goes off
• The message centre displays ’LOW’ and after
several seconds displays ’L’ in front of the
selected gear.
• The LED illumination on the selected side of the
cover will flash
• A ’SLOW DOWN’ message is displayed in the
message centre
• The transfer box warning lamp in the instrument
pack flashes.
If a range change is requested and the selector lever
is moved before the range change is complete:
• The LED illumination on the selected side of the
cover will flash
• A ’SELECT NEUTRAL’ message is displayed in
the message centre
Low to high range
• The BeCM will initiate an audible warning
When a change from low to high range is requested:
• The transfer box warning lamp in the instrument
pack flashes.
• The high range selector cover LED’s flash in
green
Transfer box to neutral
• The low range selector cover LED’s remain
illuminated in orange
When a spare fuse (5 Amp minimum) is inserted in
BeCM fuse position 11 to select transfer box neutral:
• The transfer box warning lamp in the instrument
pack flashes while the range change is taking
place.
• A five second delay is initiated before the
transfer box moves to neutral
• The BeCM initiates an audible warning
• A ’TRANSFER NEUTRAL’ message is displayed
in the message centre.
DESCRIPTION AND OPERATION
13
41
TRANSFER BOX
NEW RANGE ROVER
Range information - Manual transmission
Range selection parameters incorrect
High range
If a range change is requested and the vehicle speed
is too high:
When the transfer box is in high range, the message
centre does not display any transmission information
and the high/low request switch indicator lamp is off.
High to low range
When a change from high to low is requested:
• The high/low switch indicator lamp will flash
• The transfer box warning lamp in the instrument
pack will flash
• A ’SLOW DOWN’ message is displayed in the
message centre.
• The high/low switch indicator lamp flashes
• The transfer box warning lamp in the instrument
pack flashes.
When the range change is complete:
If a range change is requested and the transmission is
in gear or a gear selected before range change is
complete:
• The high/low switch indicator lamp will flash
• The high/low switch indicator lamp is illuminated
continuously
• The transfer box warning lamp in the instrument
pack will flash
• The transfer box warning lamp goes off
• A ’SELECT NEUTRAL’ message is displayed in
the message centre for several seconds. If the
vehicle remains in gear the message will not be
repeated.
• A ’LOW’ message is continuously displayed in
the message centre.
Low to high range
Transfer box to neutral
When a change from low to high range is requested:
When a spare fuse (5 Amp minimum) is inserted in
BeCM fuse position 11 to select transfer box neutral:
• The high/low switch indicator lamp flashes
• The transfer box warning lamp in the instrument
pack flashes.
• A five second delay is initiated before the
transfer box moves to neutral
• The BeCM initiates an audible warning
When the range change is complete:
• The high/low switch indicator lamp goes off
• The transfer box warning lamp goes off
• The message centre displays ’HIGH’ for several
seconds.
14
DESCRIPTION AND OPERATION
• A ’TRANSFER NEUTRAL’ message is displayed
in the message centre.
TRANSFER BOX
ELECTRONIC CONTROL UNIT
Service repair no - 41.30.01
Remove
1. Position left hand front seat fully up and forward.
2. Disconnect battery negative lead.
3. Remove 2 screws securing heater air duct.
Remove duct.
Refit
8. Position ECU. Connect multiplug. Secure with
screws.
9. Position heater duct mounting. Secure with
screws.
10. Position underlay and carpet.
11. Position heater air duct. Secure with screws.
12. Reposition front seat.
13. Reconnect battery negative lead.
4. Raise carpet and underlay for access.
5. Remove 2 screws securing heater duct
mounting. Remove mounting.
6. Remove 2 screws securing ECU.
7. Disconnect multiplug. Remove ECU.
REPAIR
1
41
TRANSFER BOX
NEW RANGE ROVER
RATIO CONTROL MOTOR
INPUT SHAFT OIL SEAL
Service repair no - 41.30.03
Service repair no - 41.20.50
Remove
1.
2.
3.
4.
5.
Raise vehicle on four post lift.
Disconnect battery negative lead.
Disconnect temperature sensor.
Disconnect motor multiplug.
Remove 4 bolts securing motor to transfer
gearbox.
6. Remove motor.
1. Disconnect battery negative lead.
2. Remove transfer box. See this section.
3. Lever seal from location in transfer box.
CAUTION: Ensure seal location does not
become damaged.
Refit
Refit
7.
8.
9.
10.
11.
2
Fit motor and engage to drive spindle.
Tighten bolts to 10Nm (7 lbf.ft).
Connect motor and temperature sensor.
Reconnect battery negative lead.
Lower vehicle.
REPAIR
4.
5.
6.
7.
8.
Ensure mating faces are clean.
Lubricate seal lip with transmission fluid.
Using LRT-41-011, fit seal to transfer box.
Fit transfer box. See this section.
Reconnect battery negative lead.
TRANSFER BOX
OUTPUT SHAFT OIL SEAL - FRONT
Service repair no - 41.20.51
Remove
1. Remove chassis cross member. See CHASSIS
AND BODY, Repair.
2. Mark propeller shaft and transfer gearbox
flanges to aid assembly.
3. Remove 4 nuts and bolts securing propeller
shaft flange. Tie shaft aside.
5. Using LRT-99-500 if necessary, withdraw flange
from transfer box. Collect sealing washer.
4. Use LRT-51-003 to restrain transfer box drive
flange. Remove nut and discard. Collect washer.
6. Lever seal from location in transfer box.
REPAIR
3
41
TRANSFER BOX
NEW RANGE ROVER
Refit
7. Ensure mating faces are clean.
8. Lubricate seal lip with transmission fluid.
9. Fit seal using LRT-41-011.
CAUTION: Ensure seal location does not
become damaged.
10. Position flange. Fit sealing washer.
11. Use LRT-51-003 to restrain flange.
12. Secure flange with washer and new Nyloc nut.
Tighten to 148 Nm. (109 lbf.ft)
13. Position propeller shaft to output flange. Align
marks.
14. Secure propeller shaft with nuts and bolts.
Tighten to 48 Nm. (35 lbf.ft)
15. Fit chassis cross member. See CHASSIS AND
BODY, Repair.
16. Replenish transfer box oil. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
4
REPAIR
TRANSFER BOX
OUTPUT SHAFT OIL SEAL - REAR
Service repair no - 41.20.54
Remove
1.
2.
3.
4.
5.
Raise vehicle on four post lift.
Disconnect battery negative lead.
Release handbrake.
Raise lift.
Remove 4 bolts securing propeller shaft guard to
floor pan. Remove guard.
8. Apply handbrake.
9. Remove screw securing brake drum to flange.
10. Remove nut and washer securing flange to
output shaft, discard nut.
11. Release handbrake. Slacken park brake drum
adjusting screw.
12. Remove park brake drum.
13. Using LRT-99-500 if necessary, withdraw flange
from transfer box. Collect sealing washer.
6. Mark propeller shaft flange and brake drum to
aid assembly.
7. Remove 4 nuts securing propeller shaft flange to
brake drum. Release shaft. Tie aside.
14. Remove dust shield.
15. Lever seal from location in casing.
REPAIR
5
41
TRANSFER BOX
NEW RANGE ROVER
TRANSFER BOX - UP TO 99MY
Service repair no - 41.20.25
Remove
1. Position vehicle on four post lift.
2. Disconnect battery negative lead.
3. Automatic Vehicles.Remove window switch
pack. See ELECTRICAL, Repair.
Manual Vehicles:
CAUTION: Ensure seal location does not
become damaged.
4. Remove centre console. See CHASSIS AND
BODY, Repair.
5. Remove 6 nuts securing gaiter ring. Remove
ring and gaiter.
Refit
16. Ensure mating faces are clean.
17. Lubricate seal lip with transmission fluid.
18. Fit seal using LRT-41-011.
6. Remove 2 bolts securing gear lever. Remove
lever.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Position dust shield.
Position flange. Fit sealing washer.
Fit flat washer and new Nyloc nut, finger tight.
Position brake drum. Secure to flange with
screw.
Adjust park brake shoes. See BRAKES,
Adjustment.
Apply handbrake.
Tighten flange nut to 148 Nm. (109 lbf.ft)
Position propeller shaft flange on brake drum.
Align marks.
Secure propeller shaft with bolts. Tighten to
48 Nm. (35 lbf.ft)
Fit propeller shaft guard. Secure with bolts.
Replenish transfer box oil. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
Lower lift.
Reconnect battery negative lead.
All Vehicles:
7. Release handbrake.
8. Remove handbrake cable clevis pin.
6
REPAIR
TRANSFER BOX
9. Raise lift. Drain gearbox and transfer box oil.
See SECTION 10, Maintenance.
10. Support transmission with cross beam.
11. Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
12. Diesel Vehicles. Remove chassis cross
member. See CHASSIS AND BODY, Repair.
13. Release hand brake cable from grommet in
tunnel.
14. Remove 4 bolts securing rear propeller shaft
guard. Remove guard.
15. Mark flanges on propeller shafts and transfer
box to aid reassembly.
16. Raise one wheel on each axle to allow rotation
of propeller shafts.
17. Remove fixings securing shafts to transfer box.
Release shafts. Tie aside.
18. Automatic Vehicles.Disconnect gear selector
cable trunnion from gearbox lever. Remove 2
bolts securing selector cable abutment bracket
to gearbox. Place selector cable aside.
REPAIR
7
41
TRANSFER BOX
NEW RANGE ROVER
19. Lower gearbox for access.
20. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
21. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
22. Release harness from 2 clips on transfer box
brackets.
23. Position adaptor plate LRT-99-012 to
transmission lift. Secure with bolts.
24. Raise transmission lift. Secure adaptor plate to
transfer gearbox.
25. Remove 6 bolts securing transfer box.
26. Adjusting tilt as necessary, release transfer box
from gearbox. Lower transmission lift.
8
REPAIR
TRANSFER BOX
Refit
27. Manual Vehicles: Renew gearbox output shaft
seal. See MANUAL GEARBOX, Repair.
28. Automatic Vehicles: Renew gearbox output
shaft seal. See AUTOMATIC GEARBOX,
Repair.
29. Ensure mating faces are clean.
30. Lubricate input shaft with transmission fluid.
31. Raise transfer box on lift. Adjust tilt as necessary
to align shafts.
32. Engage shafts. Locate transfer box dowels to
gearbox.
33. Secure transfer box to gearbox with bolts.
Tighten to 45 Nm. (33 lbf.ft)
34. Remove transmission lift.
35. Connect multiplugs to High/Low motor and
output shaft speed sensor.
36. Connect Lucars to transfer box fluid temperature
sensor.
37. Secure harness in clips.
38. Raise gearbox on cross beam.
39. Automatic vehicles. Position selector cable
abutment bracket to gearbox. Secure with bolts.
40. Raise one wheel on each axle to allow rotation
of propeller shafts.
41. Position propeller shafts to transfer box flanges.
Align marks.
42. Secure shafts with nuts and bolts. Tighten to
48 Nm. (35 lbf.ft)
43. Fit propeller shaft guard. Tighten bolts.
44. Guide hand brake cable through grommet in
transmission tunnel.
45. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
46. Diesel Vehicles. Fit chassis cross member.
See CHASSIS AND BODY, Repair.
47. Automatic Vehicles: Adjust gear selector cable.
See AUTOMATIC GEARBOX, Adjustment.
48. Replenish gearbox and transfer box fluids. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
49. Lower lift.
50. Connect handbrake cable to lever, secure with
clevis pin and clip.
Manual Vehicles:
51. Fit seal around gearbox remote housing to
transmission tunnel aperture.
52. Position gear lever. Secure with bolts. Tighten
to 25 Nm. (18 lbf.ft)
53. Fit gaiter and ring. Secure with nuts.
54. Fit centre console. See CHASSIS AND BODY,
Repair.
55. Automatic Vehicles:Fit window switch pack.
See ELECTRICAL, Repair.
56. Reconnect battery negative lead.
REPAIR
9
41
TRANSFER BOX
TRANSFER BOX - FROM 99MY
NEW RANGE ROVER
ring and remove gaiter ring and gaiter. Remove
2 bolts securing gear lever and remove lever.
Service repair no - 41.20.25.
Remove
1. Position vehicle on a four post lift.
2. Release fixings and remove battery cover.
3. Disconnect battery earth lead.
4. Release clips securing cooling fan cowl and
remove cowl.
5. Automatic models: Remove window switch
pack. See ELECTRICAL, Repair.
6. Manual models: Remove centre console. See
CHASSIS AND BODY, Repair.
7. Manual models: Remove 6 nuts securing gaiter
10
REPAIR
8. With the handbrake released, remove clip and
clevis pin securing handbrake cable to
handbrake.
9. Raise vehicle and release handbrake cable and
grommet from tunnel.
10. Drain gearbox fluid. See AUTOMATIC
GEARBOX, Repair.
11. Drain transfer box oil. See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
12. Petrol models: Remove exhaust front pipe. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
13. Diesel models: Remove chassis crossmember.
See CHASSIS AND BODY, Repair.
TRANSFER BOX
14. Remove 4 bolts securing transmission mounting
assembly and remove assembly.
15. Support engine and gearbox with transmission
jack.
19. Remove 4 nuts from each propeller shaft flange.
20. Release propeller shafts and tie aside.
21. Lower transmission for access.
16. Remove 4 bolts securing rear propeller shaft
guard and remove guard.
17. Mark transfer box and propeller shaft flanges to
aid re-assembly.
18. Raise one wheel on each axle to allow rotation
of propeller shafts.
22. Automatic models: Remove split pin securing
gear selector cable trunnion to gearbox lever
and release trunnion.
REPAIR
11
41
TRANSFER BOX
NEW RANGE ROVER
23. Remove 2 bolts securing gear selector cable
abutment bracket and harness support bracket
to gearbox, and position selector cable and
brackets aside.
28. Remove bolt securing fuel pipe and purge pipe
retaining bracket to transfer box and release
bracket.
24. Remove banjo bolt securing breather pipe to
transfer box, remove and discard sealing
washer.
CAUTION: Plug the connections.
25. Disconnect 2 Lucars from transfer box oil
temperature sensor.
26. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
27. Release harness from 2 clips.
12
REPAIR
29. Position adaptor plate LRT-99-012 to
transmission lift and secure with nuts and bolts.
30. Raise and adjust transmission lift so that
LRT-99-012 is correctly located to transfer box.
TRANSFER BOX
Refit
31. Remove 6 bolts securing transfer box to gearbox
and release 2 harness clip mounting brackets.
32. Adjust transmission lift as necessary, release
and remove transfer box.
33. Remove seal from transfer box casing using a
suitable lever.
35. Ensure seal location faces on gearbox are clean.
36. Lubricate oil seal lip with transmission fluid
37. Automatic models: Using LRT-44-001 fit seal
to gearbox casing.
38. Manual models: Using LRT-37-014 fit seal to
extension housing.
39. Ensure seal location faces on transfer box are
clean.
40. Lubricate oil seal lip with transfer box oil.
41. Using LRT-41-011 fit seal to transfer box.
42. Clean transfer and gearbox mating faces and
dowel and dowel holes.
43. Lubricate transfer box input shaft with
transmission fluid.
44. Raise transfer box on lift and adjust angle of lift
as necessary to align shafts.
45. Engage shafts and locate transfer box dowels to
gearbox.
46. Fit bolts securing transfer box to gearbox and
tighten to 45 Nm (33 lbf.ft). Ensure that the 2
harness clip mounting brackets are correctly
fitted when fitting bolts.
47. Secure harness to clips.
48. Align bracket securing fuel pipe and purge pipe
to transfer box and secure with bolt.
49. Connect multiplugs to High/Low motor and
output shaft speed sensor.
50. Connect 2 Lucars to transfer box fluid
temperature sensor.
51. Clean breather pipe bolt and banjo, fit new
sealing washers and tighten bolt to 15 Nm
(11 lbf.ft).
52. Align harness support bracket and gear selector
cable abutment bracket to gear box, and secure
with bolts.
53. Automatic models: Connect gear selector
cable trunnion to gearbox lever and secure with
split pin.
CAUTION: Ensure seal location does not
become damaged as seal is levered from
casing.
34. Remove seal from gearbox casing using a
suitable lever.
REPAIR
13
41
TRANSFER BOX
54. Adjust gear selector cable. See AUTOMATIC
GEARBOX, Repair.
55. Raise transmission.
56. Clean propeller shaft and transfer box flanges.
57. Fit propeller shafts to transfer box flanges and
align marks.
58. Fit nuts to propeller shafts and tighten to 48 Nm
(35 lbf.ft).
59. Fit rear propeller shaft guard and secure with
bolts.
60. Fit and engage handbrake cable grommet into
transmission tunnel.
61. Fit transmission mounting assembly and tighten
bolts to 44 Nm (33 lbf.ft).
62. Support transmission under brake drum.
63. Lower lift and remove adaptor plate LRT-99-012
from lift.
64. Petrol models: Fit exhaust front pipe. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
65. Diesel models: Fit chassis crossmember. See
CHASSIS AND BODY, Repair.
66. Connect handbrake cable to lever, fit clevis pin
and secure pin with clip.
67. Manual models: Position gear lever and tighten
bolts to 25 Nm (18 lbf.ft). Fit gaiter and gaiter
ring and secure with nuts.
68. Manual models: Fit centre console. See
CHASSIS AND BODY, Repair.
69. Automatic models: Fit window switch pack.
See ELECTRICAL, Repair.
70. Position fan cowl and secure with clips.
71. Connect battery earth lead.
72. Fit battery cover and secure with fixings.
73. Fill transfer box with oil. See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
74. Fill gearbox with fluid. See AUTOMATIC
GEARBOX, Repair.
14
REPAIR
NEW RANGE ROVER
44 - AUTOMATIC GEARBOX
CONTENTS
Page
ZF AUTO
DESCRIPTION AND OPERATION
AUTOMATIC TRANSMISSION - DESCRIPTION ................................................ 4
OPERATION ...................................................................................................... 19
ADJUSTMENT
SELECTOR CABLE ............................................................................................. 1
GEARBOX - DRAIN AND REFILL - FROM 99MY ............................................... 1
REPAIR
SELECTOR LEVER ASSEMBLY ......................................................................... 1
SELECTOR CABLE ............................................................................................. 3
SELECTOR INDICATOR & MODE SWITCH ....................................................... 4
SELECTOR POSITION SWITCH ......................................................................... 5
SEAL - SELECTOR SHAFT ................................................................................. 6
FLUID COOLER - V8 - UP TO 99MY ................................................................... 9
FLUID COOLER - V8 - FROM 99MY ................................................................. 10
FLUID COOLER - DIESEL ................................................................................. 11
AUTOMATIC GEARBOX - UP TO 99MY ........................................................... 12
AUTOMATIC GEARBOX - FROM 99MY ........................................................... 17
TORQUE CONVERTER OIL SEAL ................................................................... 22
HOUSING - TORQUE CONVERTER ................................................................ 23
GASKET - INTERMEDIATE PLATE .................................................................. 24
INTERMEDIATE PLATE .................................................................................... 26
PUMP - FLUID ................................................................................................... 27
OUTPUT SHAFT SEAL ...................................................................................... 28
GASKET - REAR EXTENSION HOUSING ........................................................ 29
PARKING PAWL ASSEMBLY ............................................................................ 29
FLUID PAN AND FILTER ................................................................................... 30
VALVE BODY ASSEMBLY ................................................................................ 32
SEAL - VALVE BLOCK - SET ............................................................................ 33
PRESSURE REGULATOR ................................................................................ 34
LOCK UP SOLENOID VALVE (MV3) ................................................................. 35
SOLENOIDS - SHIFT CONTROL VALVES (MV1and 2) .................................... 35
HARNESS SOLENOID VALVES ....................................................................... 36
ELECTRONIC CONTROL UNIT ........................................................................ 37
ZF AUTO
Electronic Automatic Transmission component layout
1.
2.
3.
4.
Selector lever assembly
Gearbox
Electronic Automatic Transmission (EAT) ECU
Selector position switch
5.
6.
7.
8.
Oil cooler
Fluid lines
Breather tube
Selector cable
DESCRIPTION AND OPERATION
1
44
AUTOMATIC GEARBOX
Electronic Automatic Transmission control schematic
2
DESCRIPTION AND OPERATION
NEW RANGE ROVER
ZF AUTO
1.
2.
3.
4.
5.
6.
Transmission high/low switch
Mode switch
Gear position switch connector
Solenoid valve/speed sensor connector
Electronic Automatic Transmission (EAT) ECU
Engine Control Module (ECM)
7.
8.
9.
10.
11.
12.
Diagnostic socket
Instrument pack
Transmission fluid temperature sensor
Body electrical Control Module (BeCM)
Battery power supply
Ignition power supply
DESCRIPTION AND OPERATION
3
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
AUTOMATIC TRANSMISSION - DESCRIPTION
General
The ZF4HP22 transmission is used on 2.5 litre Diesel
and 4.0 litre petrol models. 4.6 litre petrol models use
the ZF4HP24 transmission unit to accomodate the
increased power output of the larger engine. Both
units are of similar construction with the ZF4HP24 unit
being slightly longer. The operation of both units is the
same.
Automatic transmission vehicles are fitted with an
’H-gate’ selector mechanism. The selector mechanism
combines the operation of the transmission selector
lever and the transfer box high/low gear range
selection. Selections on the selector lever assembly
are transmitted by a selector cable to a gear position
switch.
The gear position switch on the transmission passes
gear selection signals to an Electronic Automatic
Transmission (EAT) ECU located below the LH front
seat, which outputs the appropriate control signals to
an electro-hydraulic valve block in the transmission. A
mode switch enables the driver to change the control
mode of the EAT ECU between manual, economy and
sport. The EAT ECU provides signals to the message
centre in the instrument pack to indicate the control
mode and system status.
The gearbox features a pressure lubrication system
and is cooled by pumping the lubricant through an oil
cooler located in front of the engine cooling radiator.
From 99MY onwards, petrol models feature a revised
EAT ECU with Controller Area Network (CAN) digital
communications between the EAT ECU and the ECM.
4
DESCRIPTION AND OPERATION
H-gate selector lever assembly
The selector lever assembly consists of a lever and a
cover attached to a cast base. The base is located on
a gasket and secured to the transmission tunnel and
has an ’H’ pattern for the lever to move in. The lever is
hinged to the base and a latch in the lever engages
with detents in the base to provide positive location for
the lever positions. The latch is disengaged by
pressing a release button on the lever knob as shown
in the lever illustration below.
ZF AUTO
Except for lever movement between positions D and 3
(high range) and 4 and 3 (low range), the button must
be pressed before the lever can be moved. In some
markets, vehicles incorporate an interlock solenoid at
the bottom of the lever, which prevents the lever being
moved from P unless the ignition switch is in position
II and the foot brake is applied.
The cover incorporates LED lever position indicators
and the mode switch. The lever position indicators
illuminate to show the position of the selector lever.
The driver’s side of the H-gate is labelled ’Hi’ and is
used to select the high range gears. The passenger
side of the H-gate is labelled ’Lo’ and is used to select
the low range gears. Movement of the selector lever
across the H-gate selects high and low transfer box
gear ranges.
Selector cable
The selector cable is a Bowden type cable that
connects the selector lever assembly to a selector
lever on the gearbox. ’C’ clips secure the ends of the
outer cable to brackets on the selector lever assembly
and the selector lever. The inner cable is adjustable at
the connection of the inner cable with the gearbox
selector lever.
The LED indicators are controlled by the Body
electrical Control Module (BeCM). A mode switch is
located on the driver’s side of the cover. The mode
switch is used by the driver to select sport mode used
in the high range gears and manual mode used in the
low range gears. The mode switch is a non-latching
hinged switch that, when pressed, connects an earth
to the EAT ECU to request a change of mode. Sport
and Manual indicator lamps on the cover illuminate to
show the mode selected. The message centre in the
instrument pack also displays ’S’ for sport mode and
’LM’ for manual mode along with the selected gear.
An electrical connector at the rear of the cover
connects the selector lever assembly to the vehicle
wiring.
DESCRIPTION AND OPERATION
5
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
Gearbox
Gearbox
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
6
Torque converter
Torque converter housing
Fluid pump
Breather tube
Intermediate plate
Gearbox housing
Rear extension housing
Electrical connector
Snubbing bar
Upper mounting bracket
Mounting rubber
Lower mounting bracket
DESCRIPTION AND OPERATION
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Gasket
Sump
’O’ ring
Drain plug
’O’ ring
Filler/level plug
Bolt
Clamp
Lower mounting bracket
Mounting rubber
Selector lever
Gear position switch
ZF AUTO
The gearbox consists of a torque converter housing,
an intermediate plate, a gearbox housing and a rear
extension housing, bolted together in series. The rear
of the gearbox is supported by a rubber mounting
installed between a mounting bracket on the gearbox
and the LH chassis rail. A heat shield is installed on
the mounting to protect it from the exhaust.
Sectioned view of gearbox
1.
2.
3.
4.
5.
6.
7.
8.
9.
Lock-up clutch
Impeller
Turbine
Forward drive clutch
Reverse drive clutch
Brake clutch
Brake clutch
Brake clutch
Epicyclic gear set
10.
11.
12.
13.
14.
15.
16.
17.
Epicyclic gear set
Clutch
Brake clutch
Output shaft
Freewheel (one way clutch)
Freewheel (one way clutch)
Freewheel (one way clutch)
Stator and one way clutch
DESCRIPTION AND OPERATION
7
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
Valve block
Valve block
1.
2.
3.
4.
5.
6.
7.
8.
8
Valve block
Pressure regulating solenoid valve (MV 4)
Shift control solenoid valve (MV 2)
Shift control solenoid valve (MV 1)
Lock-up solenoid valve (MV 3)
Output shaft speed sensor
Bolt
Sensor retaining clip
DESCRIPTION AND OPERATION
9.
10.
11.
12.
13.
14.
15.
16.
Manual valve
’O’ ring
Filter
’O’ ring
Suction pipe
Bolt
Bolt
Washer
ZF AUTO
Torque converter housing
Gear ratios
On 2.5 litre Diesel models a 260 mm (10.2 in)
diameter torque converter is used. On 4.0 and 4.6 litre
petrol models a 280 mm (11 in) diameter torque
converter is used. On 4.6 litre petrol models up to
99MY the torque converter is longer than the torque
converter used on 4.0 litre petrol models. From 99MY,
both the 4.0 and 4.6 litre petrol models use the shorter
torque converter previously used on up to 99MY 4.0
litre models.
The torque converter housing attaches the gearbox to
the engine and contains the torque converter. The
torque converter is connected to the engine drive
plate and transmits the drive from the engine to the
gearbox input shaft. When engaged, a hydraulic
lock-up clutch in the torque converter prevents
slippage, to give a direct drive from the engine to the
gearbox for improved efficiency.
Intermediate plate
The intermediate plate supports the gearbox input
shaft and provides the interface between the
transmission fluid pump and the lubrication circuit.
The pump attaches to the front of the intermediate
plate and is driven by an impeller in the torque
converter. The pump pressurises transmission fluid
drawn from the sump on the gearbox housing. The
pressurised fluid then circulates through the torque
converter and gearbox housing components for
cooling, lubrication and gear shift purposes. Ports
around the outer periphery of the intermediate plate
provide the inlet and outlet connections to the fluid
cooler and a pressure take-off point for servicing.
On ZF4HP24 gearboxes, the intermediate plate is
15 mm (0.6 in) thicker than fitted to the ZF4HP22
gearbox to accomodate a larger fluid pump unit. To
compensate for the increased length of the
intermediate plate, the rear extension housing is
15 mm (0.6 in) shorter than that fitted to the ZF4HP22
gearbox.
Gearbox housing
The gearbox housing contains two epicyclic gear sets
on input and output shafts. Hydraulic clutches on the
shafts control which elements of the gear sets are
engaged, and their direction of rotation, to produce the
P and N selections, four forward gear ratios and one
reverse gear ratio.
Gear
Ratio
1st
2.480:1
2nd
1.480:1
3rd
1.000:1
4th
0.728:1
Reverse
2.086:1
The lock-up and brake clutches are operated by
pressurised transmission fluid from the valve block in
the sump. A manual valve and four solenoid valves,
also known as Motorised Valves (MV), control the
supply of pressurised transmission fluid from the valve
block:
• The manual valve controls the fluid supply for P,
R, N and D selector positions. The four solenoid
valves operate accordingly to operate shift
control, lock-up and shift quality.
• Solenoid valves MV 1 and MV 2 control the
supplies that operate the brake clutches for shift
control. They are also used to prevent accidental
engagement of reverse when moving forwards
and a forward gear when moving backwards.
• Solenoid valve MV 3 controls the supply that
operates the lock-up clutch.
• Solenoid valve MV 4 modulates the pressure of
the supplies to the brake clutches, to control shift
quality.
Operation of the manual valve is controlled by the
selector lever assembly. In the gearbox, a selector
shaft engages with the manual valve. The selector
shaft is connected to the selector lever assembly via
the selector cable and a selector lever on the left side
of the gearbox. The selector shaft also operates a
mechanism that locks the output shaft when P is
selected.
Operation of the solenoid valves is controlled by the
EAT ECU.
DESCRIPTION AND OPERATION
9
44
AUTOMATIC GEARBOX
An output shaft speed sensor in the gearbox housing
outputs a signal to the EAT ECU. The EAT ECU
compares output shaft speed with engine speed to
determine the engaged gear and output shaft speed
with vehicle speed to confirm the range selected on
the transfer box. The speed sensor signal is a
diagnostic function and not essential for correct
gearbox operation.
A bayonet lock electrical connector in the gearbox
casing, to the rear of the selector lever, connects the
solenoid valves and the output shaft speed sensor to
the vehicle wiring.
A pressed steel sump encloses the valve block and
collects transmission fluid draining from the gearbox
housing. A suction pipe and filter on the underside of
the valve block connect to the inlet side of the fluid
pump. A magnet is installed in the sump to collect any
magnetic particles that may be present. A level plug
and a drain plug are installed in the sump for
servicing.
NEW RANGE ROVER
Rear extension housing
The rear extension housing provides the interface
between the gearbox housing and the transfer box. A
splined output shaft transmits the drive from the
gearbox to the transfer box. A seal in the rear of the
housing prevents leakage past the extension shaft. A
breather pipe, attached to the left side of the rear
extension housing, ventilates the interior of the
gearbox and rear extension housings to atmosphere.
The open end of the breather pipe is located in the
engine compartment at the right rear corner of the
engine, against the bulkhead. On 99MY V8 vehicles,
the breather pipe is also located against the bulkhead,
but the open end is routed down the bulkhead and
located below the converter housing.
Gearbox power flows
The following schematics show the power flow
through the gearbox for each forward gear when D is
selected, and for reverse. The key to the Item
numbers on the schematics, and in parenthesis in the
accompanying text, can be found on the illustration
’Sectioned view of gearbox’ shown earlier in this
section of the Workshop Manual.
1st Gear (D selected)
Clutches (4) and (11) are engaged. The front planet gear carrier of gear set (9) locks against the gearbox housing
through freewheel (15) when the engine powers the vehicle, and freewheels when the vehicle is coasting. Gear
set (10) rotates as a solid unit with the front planet gear carrier.
10
DESCRIPTION AND OPERATION
ZF AUTO
2nd Gear (D selected)
Clutches (4), (6), (7) and (11) are engaged. Freewheel (15) overruns. The hollow shaft with the sun wheel of gear
set (9) is locked. Gear set (10) also rotates as a solid unit.
3rd Gear (D selected)
Clutches (4), (5), (7) and (11) are engaged. Freewheels (15) and (16) are overrun. Gear sets (9) and (10) rotate as
a solid unit.
4th Gear (D selected)
Clutches (4), (5), (7) and (12) are engaged. Freewheels (14), (15) and (16) are overrun. Gear set (9) rotates as a
solid unit. The hollow shaft with the sun wheel of gear set (10) is locked.
DESCRIPTION AND OPERATION
11
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
Reverse gear
Clutches (5), (8) and (11) are engaged. Freewheels (14) and (16) are overrun. The front planet gear carrier of gear
set (9) is locked. Gear set (10) also rotates as a solid block.
Gear position switch
The gear position switch outputs signals that are
related to the position of the selector lever assembly.
The switch is installed on the selector shaft on the left
side of the gearbox. Slotted mounting holes allow the
switch to be turned relative to the shaft for adjustment.
A fly lead connects the switch to the vehicle wiring.
The signals are interpreted by the EAT ECU for the
correct gear selection. The ECM uses the signals to
control engine idle speed etc. The BeCM uses the
signals to illuminate the gear selection display on the
selector cover, operate the reverse lamps, wiper
reverse operation and message centre display etc.
Movement of the selector lever assembly turns the
selector shaft, which connects with three sliding
contacts in the switch. The contacts are identified as
the X, Y and Z. When closed:
• The X, Y and Z contacts output a combination of
earth signals to the EAT ECU as shown in the
table below.
• The outputs of the X, Y and Z contacts are
monitored by the EAT ECU, ECM and the BeCM
to determine the position of the selector lever
assembly.
Gear position switch X, Y, Z outputs
12
Position switch
ECU pin
P
R
N
D
3
2
1
Line 1 (X)
36
0V
0V
-
-
0V
0V
0V
Line 2 (Y)
8
-
0V
0V
0V
0V
-
-
Line 3 (Z)
37
-
-
-
0V
0V
0V
-
DESCRIPTION AND OPERATION
ZF AUTO
Fluid Cooler
1. Outlet connection
2. Fixing bracket
3. Inlet connection
Transmission fluid from the gearbox is circulated
through a cooler located at the front of the radiator.
Fluid lines from the transmission are connected to
each end tank of the fluid cooler. A temperature
sensor on the LH end tank provides the instrument
pack with an input of transmission fluid temperature. If
the temperature exceeds between 120 and 130 °C
(248°F and 266°F), the instrument pack message
centre displays ’GEARBOX OVRHEAT’. The message
remains displayed until the temperature of the fluid
returns to between 82 and 88 °C (180°F and 190°F).
EAT ECU
The EAT ECU operates the solenoid valves in the
gearbox to provide automatic control of gear shifts
and torque converter lock-up. The EAT ECU is
attached to a bracket which is secured to the cabin
floor below the LH front seat.
4. Fixing bracket
5. Temperature sensor
Diesel vehicles from 95MY and petrol vehicles up
to 99MY
A 55 pin connector links the EAT ECU to the vehicle
wiring. Software in the ECU monitors hard wired
inputs and exchanges information via hard wired
connections with the ECM, BeCM and instrument
pack.
Petrol vehicles from 99MY
A 75 pin connector links the EAT ECU to the vehicle
wiring. Software in the EAT ECU monitors hard wired
inputs and exchanges information with the ECM on a
Controller Area Network (CAN) bus to determine gear
shift and torque converter lock-up requirements.
Resultant control signals are then output to the
gearbox solenoid valves.
DESCRIPTION AND OPERATION
13
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
The CAN bus, introduced on 99MY petrol vehicles,
provides the communication link between the ECM
and the EAT ECU. Inputs and outputs to and from
each control unit are transmitted via two twisted wire
connections, CAN high and CAN low.
The additional engine data is used by the EAT ECU to
give improved transmission quality and allows the
EAT ECU to operate in a greater number of default
modes in the event of sensor failure. Inputs and
outputs on the CAN communication bus are listed in
the table that follows.
The CAN bus allows more engine data to be passed
to the EAT ECU which, on earlier vehicles, would
require a number of additional hardwired connections.
CAN communications between EAT ECU and ECM - Petrol vehicles from 99MY
Inputs from ECM
Outputs to ECM
CAN version identifier
Calculated gear
Emissions (OBDll) control
Diagnostic information
Engine air intake temperature
Emission (OBDll) fault status
Engine speed
Engine torque reduction request
Engine speed fault flag
Gear position switch information
Engine temperature
Output shaft speed
Engine torque
Mode information
Engine torque fault flag
Shift information
Friction torque
Torque converter lock-up solenoid
Maximum engine torque
Reduced engine torque
Road speed
Status of engine speed torque reduction
Throttle position
14
DESCRIPTION AND OPERATION
ZF AUTO
EAT ECU connector - Diesel vehicles from 95MY and petrol vehicles up to 99MY
EAT ECU connector pin details - Diesel vehicles from 95MY
and petrol vehicles up to 99MY
Pin No.
Description
Input/Output
1
Ignition supply
Input
2
Vehicle speed sensor (positive)
Input
3
Engine speed
Input
4
Not used
5
Shift control solenoid valve (MV1)
6
Pressure regulator solenoid valve (MV4)
-
7
Electronics earth
-
Not used
-
8 to 13
14
Gear position switch, Y contacts
15
Diagnostics, L line
16
MES 1 - message centre display
17/18
Not used
19
Solenoid valves power supply
20
Earth (screen)
21
Engine torque PWM
22/23
Not used
24
Shift control solenoid valve (MV2)
25
Not used
Output
Input
Input/Output
Output
Output
Input
Output
-
DESCRIPTION AND OPERATION
15
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
EAT ECU connector pin details - Diesel vehicles from 95MY
and petrol vehicles up to 99MY (continued)
Pin No.
26
27/28
Input/Output
Power earth
-
Not used
-
29
Mode switch
31
MES 2 - message centre display
30
Not used
32
Torque reduction request
33
Gear position switch, Z contacts
34 to 37
Not used
Input
Output
Output
Input
-
38
Vehicle speed sensor (negative)
Input
39
Battery supply
Input
40/41
42
43 to 45
Not used
Torque converter solenoid (MV3)
Not used
Output
-
46
Transmission high/low switch
Input
47
Throttle position PWM
Input
48/49
Not used
50
Gear position switch, X contacts
51
Diagnostics, K line
51 to 55
16
Description
Not used
DESCRIPTION AND OPERATION
Input
Input/Output
-
ZF AUTO
EAT ECU connector - Petrol vehicles from 99MY
EAT ECU connector pin details - Petrol vehicles from 99MY
Pin No.
1 to 4
Description
Not used
Input/Output
-
5
Pressure regulator solenoid valve (MV 4)
6
Power earth
-
7
Not used
-
8
Gear position switch, Y contacts
9 to 12
Not used
Output
Input
-
13
Transmission high/low switch
Input
14
Gearbox output shaft speed sensor, negative
Input
15
Gearbox output shaft speed sensor, cable screen
16
CAN high
Input/Output
17 to 24
Not used
-
-
25
MES 1 - message centre display
Output
26
Battery supply
27
Not used
-
28
Electronics earth
-
29
Not used
-
30
Shift control solenoid valve (MV 1)
Input
Output
DESCRIPTION AND OPERATION
17
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
EAT ECU connector pin details - From 99MY (continued)
Pin No.
Input/Output
31
Diagnostics, K line
32
Converter lock-up solenoid valve (MV 3)
Output
33
Shift control solenoid valve (MV 2)
Output
34/35
Not used
Input/Output
-
36
Gear position switch, X contacts
Input
37
Gear position switch, Z contacts
Input
38 to 41
Not used
-
42
Gearbox output shaft speed sensor, positive
43
Not used
-
44
CAN low
Input/Output
45
Mode switch
46 to 50
Not used
51
MES 2 - message centre display
52
Not used
53
Solenoid valves power supply
54
Ignition power supply
55 to 75
18
Description
Not used
DESCRIPTION AND OPERATION
Input
Input
Output
Output
Input
-
ZF AUTO
OPERATION
General
The gear position switch outputs are monitored by the
BeCM and the EAT ECU. The BeCM outputs gear
position signals to illuminate the position indicators
each side of the gear selector lever and on the
message centre in the instrument pack.
In D, 3, 2, and 1, the EAT ECU outputs control signals
to the gearbox to select the required gear.
In D, all forward gears are available for selection by
the EAT ECU. In 3, 2 and 1, a corresponding limit is
imposed on the highest gear available for selection.
When R is selected, reverse gear only engages if the
vehicle is stationary or moving at 5 mph (8 km/h) or
less.
Selector Lever Interlock (where fitted)
The interlock solenoid on the selector lever is
de-energised unless the foot brake is applied while
the ignition is on. While de-energised, the interlock
solenoid allows the selector lever to move through the
range unless P is selected.
On entering the P position, the interlock solenoid
engages a latch which locks the selector lever. When
the ignition is on and the foot brake is applied, the
BeCM energises the interlock solenoid, which
disengages the latch and allows the selector lever to
be moved out of P.
Economy, Sport and Manual Modes
During the power-up procedure after the ignition is
switched on, the EAT ECU defaults to an economy
mode. Pressing the mode switch causes the EAT
ECU to change between the economy mode and the
sport or the manual mode, depending on the range
selected on the transfer box:
• If the transfer box is in high range, the EAT ECU
changes to the sport mode and illuminates the
sport mode lamp on the selector cover and
displays ’S’ in the instrument pack message
centre. In the sport mode the gearbox is more
responsive to accelerator pedal movement.
Downshifts occur earlier and upshifts occur later.
• If the transfer box is in low range, the EAT ECU
changes to the manual mode and illuminates the
manual mode lamp on the selector cover and
displays ’LM’ in the instrument pack message
centre. Kickdown is disabled and the EAT ECU
maintains the gearbox in the gear selected on
the selector lever (D = 4th gear) to give
improved off road performance. Downshifts
occur only to prevent the engine stalling.
From a standing start, the vehicle pulls away in
1st gear and, if a higher gear is selected,
upshifts almost immediately to the selected gear
(shifts of more than one gear can occur).
• After a second press of the mode switch the EAT
ECU reverts to the economy mode, for the range
selected on the transfer box, and extinguishes
the related mode lamp on the selector cover and
removes the ’S’ or ’LM’ display in the instrument
pack message centre.
• When the vehicle is in the default mode (i.e. high
range and economy) and towing or driving up
steep gradients, the EAT ECU will select a shift
pattern appropriate to the driving conditions. If a
heavy trailer is being towed or a steep gradient
is encountered, the transmission will hold in the
gears longer than in normal operation.
Shift Control
To provide the different driving characteristics for each
mode of operation, the EAT ECU incorporates
different shift maps of throttle position/road speed.
Base shift points are derived from the appropriate shift
map. When a shift is required, the EAT ECU sends a
request to the ECM for a reduction in engine torque, in
order to produce a smoother shift. The percentage of
torque reduction requested varies according to the
operating conditions at the time of the request.
DESCRIPTION AND OPERATION
19
44
AUTOMATIC GEARBOX
When the EAT ECU receives confirmation of the
torque reduction from the ECM, it then signals the
shift solenoid valves in the gearbox to produce the
shift. To further improve shift quality, the EAT ECU
also signals the pressure regulating solenoid valve to
modulate the hydraulic pressure and so control the
rate of engagement and disengagement of the brake
clutches.
With time, the components in a gearbox wear and the
duration of the gear shifts tends to increase, which
has an adverse affect on the brake clutches. To
counteract this, the EAT ECU applies a pressure
adaptation to each shift. To calculate the adaptations,
the EAT ECU monitors the pressure modulation used,
and time taken, for each shift. If a subsequent shift of
the same type, in terms of throttle position and engine
speed, has a longer duration, the EAT ECU stores an
adaptation for that type of shift in a volatile memory.
The adaptation is then included in future pressure
calculations for that type of shift, to restore shift
duration to the nominal.
Kickdown
The EAT ECU monitors the input of the throttle
position sensor to determine when kickdown is
required and select a gear to give the best available
acceleration. When it detects a kickdown situation, the
EAT ECU immediately initiates a down shift of one or
two gears or will maintain the current gear to avoid
engine overspeed.
Torque Converter Lock-Up
The EAT ECU energises the lock-up solenoid valve to
engage the lock-up clutch. Lock-up clutch operation is
dependent on throttle position, engine speed,
operating mode and the range selected on the
transfer box.
High Range
Unique lock-up maps, similar to the shift maps, are
incorporated in the economy and sport modes for all
forward gears. Engagement and disengagement of
the lock-up clutch is dependent on throttle position
and engine speed.
Low Range
To enhance off road control, particularly when
manoeuvring at low speeds, torque converter lock-up
does not occur when there is any degree of throttle
opening. When the throttle is closed above a preset
engine speed, the lock-up clutch engages to provide
maximum engine braking.
20
DESCRIPTION AND OPERATION
NEW RANGE ROVER
Increased Load/Reduced Torque Compensation
To aid performance and driveability in the high range
economy mode, the EAT ECU has three adaptive shift
and lock-up maps. These maps delay upshifts and
torque converter lock-up similar to the sport mode if
the inputs from the engine indicate:
• A sustained high load on the engine, such as
occurs when the vehicle is ascending a steep
gradient or towing a trailer.
• The EAT ECU monitors the engine inputs and
selects the most appropriate adaptive map for
the prevailing conditions.
• On vehicles from 99MY, a lower than normal
engine torque, such as occurs at altitude or high
ambient temperatures.
Diagnostics
While the ignition is on, the EAT ECU diagnoses the
system for faults. The extent of the diagnostic
capability at any particular time depends on the
prevailing operating conditions, e.g. it is not possible
to check torque converter lock-up while the vehicle is
stationary, or to check for a short circuit to earth if the
circuit concerned is already at a low potential.
If a fault is detected, the EAT ECU immediately stores
a fault code and the values of three operating
parameters associated with the fault. Depending on
the fault, there are four possible effects:
• The fault has little effect on gearbox operation or
vehicle emissions. The driver will probably not
notice any change and the warning lamps
remain extinguished.
• All gears are available but kickdown does not
function. ’GEARBOX FAULT’ will be displayed
on the instrument pack message centre. The
MIL remains extinguished.
• Limp home mode is selected and vehicle
performance is greatly reduced. ’GEARBOX
FAULT’ will be displayed on the instrument pack
message centre. If the fault is detected on a
second consecutive drive cycle, the MIL
illuminates.
ZF AUTO
Fault effects and warning indications - Diesel vehicles from 95MY
and petrol vehicles up to 99MY
Fault code
Fault description
Effect
MIL
Warning
lamp
’GEARBOX
FAULT’
message
1
* Solenoid supply
malfunction
Limp home mode in third if
stationary, fourth if moving.
On
Yes
2
* EAT ECU data
corrupted (ROM and
checksum values
disagree)
Limp home mode in third if
stationary, fourth if moving.
On
†
Yes
5
* Throttle angle
malfunction
Substitute throttle angle of 30%
used.
On
Yes
6
* Shift solenoid MV1
malfunction
Limp home mode in third if
stationary, fourth if moving.
On
Yes
6
* Shift solenoid MV1
short
Limp home mode in third if
stationary, fourth if moving.
On
Yes
7
* Shift solenoid MV2
malfunction
Limp home mode in third if
stationary, fourth if moving.
On
Yes
7
* Shift solenoid MV2
short
Limp home mode in third if
stationary, fourth if moving.
On
Yes
9
* MES 1 fault
No default condition. BeCM
recognises sport mode as a fault,
economy as low range manual and
manual as economy.
No
No
10
* MES 2 fault
No default condition. BeCM
recognises sport mode as a fault,
economy as low range manual and
manual as economy.
No
No
12
* Throttle angle
electrical short
Substitute throttle angle of 30%
used.
On
Yes
13
* EAT ECU circuit
output state does not
match command state
Limp home mode in third if
stationary, fourth if moving.
On
Yes
20
* Solenoid supply
malfunction
Limp home mode in third if
stationary, fourth if moving.
On
†
Yes
21
* Engine speed signal
out of range
Limp home mode in third if
stationary, fourth if moving.
On
†
Yes
21
* Engine speed, no
signal
Limp home mode in third if
stationary, fourth if moving.
On
†
Yes
22
* Pressure control
regulator malfunction
Limp home mode in third if
stationary, fourth if moving.
On
Yes
*= Emissions (OBDll) relevant
†= MIL illuminates immediately (in all other faults, MIL on illuminates in the 2nd consecutive drive cycle if the fault
is still present)
DESCRIPTION AND OPERATION
21
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
Fault effects and warning indications - Diesel vehicles from 95MY
and petrol vehicles up to 99MY (continued)
Fault code
Fault description
Effect
MIL
Warning
lamp
’GEARBOX
FAULT’
message
22
* Pressure control
regulator electrical
short
Limp home mode in third if
stationary, fourth if moving.
On
Yes
23
* Engine torque
reduction
Shift pressure to maximum, no shift
ignition retard, harsh gear
shifts/engagement.
On
Yes
24
* Output speed sensor
signal out of range
Limp home mode in third if
stationary, fourth if moving.
On
Yes
26
* Engine torque signal
out of range
Shift pressure to maximum, harsh,
erratic or elongated shifts can
occur.
On
Yes
27
* Output speed
sensor, no signal
Limp home mode in third if
stationary, fourth if moving.
On
Yes
28
* EAT ECU data
corrupted (ROM and
EEPROM values
disagree)
Limp home mode in third if
stationary, fourth if moving.
On
†
Yes
30
* Gear position switch
status inaccurate with
engine running
Limp home mode in third if
stationary, fourth if moving.
On
Yes
31
* Gear position switch
status inaccurate
when starting engine
Limp home mode in third if
stationary, fourth if moving.
On
Yes
The following fault codes apply to Diesel vehicles from 97MY onwards
and petrol vehicles up to 99MY only
40
* First gear ratio
incorrect
Limp home mode in third if
stationary, fourth if moving.
On
Yes
41
* Second gear ratio
incorrect
Limp home mode in third if
stationary, fourth if moving.
On
Yes
42
* Third gear ratio
incorrect
Limp home mode in third if
stationary, fourth if moving.
On
Yes
43
* Fourth gear ratio
incorrect
Limp home mode in third if
stationary, fourth if moving.
On
Yes
44
* Torque converter
lock-up gear ratio
incorrect
Limp home mode in third if
stationary, fourth if moving.
On
Yes
*= Emissions (OBDll) relevant
†= MIL illuminates immediately (in all other faults, MIL on illuminates in the 2nd consecutive drive cycle if the fault
is still present)
22
DESCRIPTION AND OPERATION
ZF AUTO
Fault effects and warning indications - Petrol vehicles from 99MY
Fault code
OBDll
(TestBook)
Fault description
Effect
MIL
Warning
lamp
’GEARBOX
FAULT’
message
P0705
(14, 23)
* Gear position switch,
incorrect outputs
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
P7021
(21)
* Downshift safety
monitor prevented
downshift which would
have caused engine
overspeed
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
P0722
(22)
* Torque converter
slipping
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
P0731
(29)
* Ratio monitoring,
implausible 1st gear
ratio
No apparent effect.
On
No
P0732
(30)
* Ratio monitoring,
implausible 2nd gear
ratio
No apparent effect.
On
No
P0733
(31)
* Ratio monitoring,
implausible 3rd gear
ratio
No apparent effect.
On
No
P0734
(32)
* Ratio monitoring,
implausible 4th gear
ratio
No apparent effect.
On
No
P0741
(5)
* Torque converter
lock-up clutch fault
May affect driveability.
On
No
P0743
(7, 25)
* Torque converter
lock-up solenoid
(MV 3), open or short
circuit
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
P0748
(10, 28)
* Pressure regulating
solenoid (MV 4), open
or short circuit
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
P0753
(8, 26)
* Shift solenoid
(MV 1), open or short
circuit
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
*= Emissions (OBDll) relevant
†= MIL illuminates immediately (in all other faults, MIL on illuminates in the 2nd consecutive drive cycle if the fault
is still present)
DESCRIPTION AND OPERATION
23
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
Fault effects and warning indicators - Petrol vehicles from 99MY (continued)
Fault code
OBDll
(TestBook)
Fault description
Effect
MIL
Warning
lamp
’GEARBOX
FAULT’
message
P0758
(9, 27)
* Shift solenoid (MV
2), open or short
circuit
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
P1562
(24)
* Battery supply below
9 V while engine
running
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
Off
Yes
P1601
(4)
* ECU, EEPROM
checksum
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
On
P1602
(36)
* Transmission
calibration selection
incorrect or invalid
Default to 4.0 litre calibration.
On
Yes
P1606
(3)
* ECU fault, EEPROM
communication
No apparent effect.
On
†
No
P1606
(6)
* Watchdog check,
ECU fault
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
P1612
(2)
* Solenoid valves
power supply relay,
sticking closed or
open circuit
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
P1613
(1)
* Solenoid valves
power supply relay,
sticking open or short
circuit
Limp home mode in low and high
ranges. Shift pressure to maximum,
harsh gear shifts/engagement.
On
Yes
P1705
(39)
Transmission high/low
range, implausible
input
No apparent effect.
On
No
P1810
(12, 13)
BeCM to message
centre circuit fault
Message centre does not display ’S’
or ’LM’. No effect on gearbox
operation.
On
No
P1841
(16)
* CAN bus fault
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
P1842
(15)
* CAN level
monitoring
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
*= Emissions (OBDll) relevant
†= MIL illuminates immediately (in all other faults, MIL on illuminates in the 2nd consecutive drive cycle if the fault
is still present)
24
DESCRIPTION AND OPERATION
ZF AUTO
Fault effects and warning indicators - Petrol vehicles from 99MY (continued)
Fault code
OBDll
(TestBook)
Fault description
Effect
MIL
Warning
lamp
’GEARBOX
FAULT’
message
P1843
(17)
* CAN time-out
monitoring
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
P1884
(11)
* CAN message:
Engine friction invalid
No apparent effect.
On
No
P1884
(18)
* CAN message:
Throttle position
invalid
Substitute throttle angle of 50%
adopted. No kickdown. Operates in
Economy mode only.
On
Yes
P1884
(19)
CAN message:
Engine temperature
invalid
Substitute engine temperature
derived from other inputs. No
apparent effect.
On
No
P1884
(20)
CAN message: Road
speed invalid
No apparent effect.
On
No
P1884
(33, 34)
CAN message:
Engine torque invalid
Substitute engine torque derived
from other inputs. May affect shift
quality.
On
No
P1884
(35)
CAN message:
Engine speed invalid
Maintains current gear in low range,
limp home mode in high range. Shift
pressure to maximum, harsh gear
shifts/engagement.
On
Yes
P1884
(37)
CAN message:
Engine air intake
temperature invalid
No apparent effect
On
No
P1884
(38)
Altitude shift control
invalid
No reduced torque compensation,
possible reduction in
performance/driveability at altitude
or high ambient temperatures.
On
No
*= Emissions (OBDll) relevant
†= MIL illuminates immediately (in all other faults, MIL on illuminates in the 2nd consecutive drive cycle if the fault
is still present)
DESCRIPTION AND OPERATION
25
44
AUTOMATIC GEARBOX
The fault codes can be accessed using TestBook. On
vehicles up to 99MY the automatic transmission fault
codes are a numeric code recognised by TestBook.
On V8 vehicles from 99MY the automatic transmission
fault codes are both numeric and OBDII ’P’ codes
recognised by TestBook and other suitable scantools.
After the detection of a fault, the effects remain active
for the remainder of the drive cycle. In subsequent
drive cycles, as soon as the EAT ECU diagnoses the
fault is no longer present, it resumes normal control of
the gearbox. The conditions required to diagnose that
the fault is no longer present depend on the fault.
Some faults require the engine to be started, others
require only that the ignition is switched on.
After a fault has not recurred for forty warm-up cycles,
the fault is deleted from the EAT ECU memory. Only
five different faults can be stored in the memory at any
one time. If a further fault occurs, the fault with the
lowest priority will be replaced by the new fault.
Mechanical Limp Home
In the mechanical limp home mode in high range,
gear engagement is controlled by the manual valve.
The gearbox is fixed in 4th gear if the fault occurs
while the vehicle is moving, or 3rd gear if the fault
occurs while the vehicle is stationary. 3rd gear is also
engaged if a vehicle is brought to a stop and the
selector lever is moved out of, and back into, D.
Neutral and reverse gear are also available.
In the mechanical limp home mode in low range,
depending on the severity of the fault, the engaged
gear is held until the vehicle is brought to a stop. The
gearbox then selects and holds 3rd gear.
26
DESCRIPTION AND OPERATION
NEW RANGE ROVER
Calibration Selection
EAT ECU’s differ between NAS, UK/Europe and ROW
markets and are identified by differentiation between
the part numbers.
On V8 vehicles from 99MY, the ECU contains two
calibrations for 4.0 and 4.6 litre engines. When a
replacement ECU is fitted, the correct ECU calibration
must be selected or the ECU will store a gearbox fault
and ’GEARBOX FAULT’ will be displayed in the
message centre. The vehicle can still be driven and is
not in ’limp home mode’.
Removed EAT ECU’s remember their calibration
setting and if re-fitted to the same vehicle will not
require calibration. A new EAT ECU will require
calibration using TestBook.
If an ECU is fitted from another vehicle, the message
centre will not display the ’GEARBOX FAULT’
message. The correct calibration level must be
selected or premature gearbox failure will occur.
ZF AUTO
USING THE H-GATE
’N’ Neutral
To make a change from high to low or vice versa, the
vehicle must be stationary.
Use this position when the vehicle is stationary and
the engine is to idle for a short period.
• Apply the brakes and select ’N’
’D’ Drive
• Move the selector lever into the cross-piece of
the ’H-gate’ and select the new gear range, the
panel illumination will flash before becoming
constant and an audible warning will sound.
Select ’D’ for all normal driving on good road surfaces.
Fully automatic gear changing occurs on all forward
gears according to vehicle speed and accelerator
position.
• When the illumination is constant select the gear
required.
’3’
CAUTION: If a gear is selected before the
gear transfer is complete, a ’clunk’ or
grinding sound will be heard because the
electric shift motor has not completed the
operation.
If this occurs and the panel illumination continues
to flash, reselect neutral and try again when the
illumination becomes constant.
If the vehicle is moving when a transfer gear
change is attempted, the message centre will
display ’SLOW DOWN’.
If an attempt is made to change the gear range
with the gear selector out of neutral, ’SELECT
NEUTRAL’ will be displayed.
Automatic gear changing is limited to first, second and
third gears only. Use in congested traffic conditions
and for town driving.
’2’
Automatic gear changing is limited to first and second
gear ratios only. Use when driving up steep gradients
and for negotiating very narrow, twisting roads. This
position also provides moderate engine braking for
descending slopes.
’1’
High Range Gears
First gear should only be used on very severe
gradients, especially when towing or when maximum
engine braking is required.
Use the high range for all normal road driving and
off-road driving across dry, level terrain. An audible
warning will sound, the selector lever illumination will
flash and the transfer box warning lamp will flash
while the range change is taking place. The message
centre will momentarily display ’HIGH’ as soon as high
range is selected, and then display the gear selected.
NOTE: If position ’2’ or ’1’ is selected from
’D’ or ’3’ while the vehicle is travelling at
high speed, then third gear will
immediately engage. Progressive deceleration will
then cause downshifts into second and then first
gear when appropriately low road speeds are
reached.
Selector lever positions:
’P’ Park
In this position the wheels are locked to prevent the
vehicle from moving. Select only with the vehicle
stationary.
’R’ Reverse
Select only when the vehicle is stationary.
DESCRIPTION AND OPERATION
27
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
’Sport’ Mode
Low Range Gears
In ’Sport’ mode gear changing is delayed to make
optimum use of the engine’s power when increased
acceleration is required or when negotiating long
inclines or twisting roads. Press the mode switch, with
the gearbox in high range, to select ’Sport’ mode. The
message centre will momentarily display ’SPORT’ and
then ’S’ along with the selected gear. Pressing the
switch a second time returns the gearbox to its normal
operation within the high range.
Use low range gears in any situation where low speed
manoeuvring is necessary, such as reversing a trailer
or negotiating a boulder strewn river bed; also use low
range for extreme off-road conditions. An audible
warning will sound, the selector lever illumination will
flash and the transfer box warning lamp will flash
while the range change is taking place. The message
centre will momentarily display ’LOW’ when the low
range is selected, and then ’L’ along with the relevant
gear selected.
Selector lever positions:
’P’ Park
As high range.
’R’ Reverse
As high range
’N’ Neutral
As high range
’4’
Select ’4’ to optimize vehicle performance for good
off-road conditions; fully automatic gear changing
occurs on all forward gears according to vehicle
speed and accelerator position.
’3’
Automatic gear changing is limited to first, second and
third gears only and should be used for reasonable
off-road conditions and ascending gradients.
’2’
Automatic gear changing is limited to first and second
ratios only when maximum engine performance is
required to ascend steep gradients. This position also
provides moderate engine braking for descending
slopes.
’1’
Select ’1’ on very severe gradients, particularly when
towing, when maximum engine performance and
engine braking is required.
28
DESCRIPTION AND OPERATION
ZF AUTO
’Transfer Neutral’
’Manual’ Mode
This mode enables the transmission to function as a
manual gearbox in low range, providing maximum
vehicle control and engine braking - ideal for use in
severe off-road conditions. Press the mode switch, to
select ’Manual’ mode; the message centre
momentarily displays ’LOW’ and then ’LM’ along with
the selected gear. Pressing the switch a second time
returns the gearbox to its normal function within the
low range.
If it is necessary for the vehicle to be towed on all four
wheels, ’Transfer neutral’ MUST be selected. For full
details. See INTRODUCTION, Information.
WARNING: Always leave the vehicle with
the gear selector in ’P’ (Park) position
when parked, even when the starter key is
not removed. Failure to do so will result in the
battery discharging.
DESCRIPTION AND OPERATION
29
ZF AUTO
SELECTOR CABLE
GEARBOX - DRAIN AND REFILL - FROM 99MY
Service repair no - 44.30.04
Service repair no - 44.24.02
Adjust
Drain
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Slacken selector cable trunnion locknut. Remove
split pin. Release trunnion from gearbox lever.
3. Select ’P’. Position lever on transmission fully
forward.
4. Adjust trunnion until a sliding fit in transmission
lever is achieved.
5. Connect trunnion to lever. Fit split pin. Tighten
locknut.
6. Remove safety stands. Lower vehicle.
1. Position vehicle on ramp.
2. Apply handbrake and position chocks under
front and rear wheels.
3. Position container under gearbox.
4. Remove gearbox drain plug and discard sealing
washer.
5. Refit drain plug using new sealing washer and
tighten to 15 Nm (11 lbf.ft).
6. Remove filler/level plug and discard sealing
washer.
Refill
7. Refill gearbox to bottom of filler/level plug hole
with correct grade of fluid.
8. Ensure gear lever in the ’P’ position, start engine
and move selector lever through all gear
positions and back to ’P’ position.
9. With the engine idling, continue filling gearbox
until a small thread of fluid runs from filler/level
orifice.
10. Refit filler/level plug using a new sealing washer
and tighten to 30 Nm (22 lbf.ft).
11. Lower vehicle.
ADJUSTMENT
1
ZF AUTO
SELECTOR LEVER ASSEMBLY
Service repair no - 44.15.04
Remove
1. Select ’P’. Remove ignition key.
CAUTION: Do not attempt to start vehicle
with selector cable disconnected,
incorrectly adjusted, or selector interlock
solenoid overridden.
2. Remove centre console. See CHASSIS AND
BODY, Repair.
3. Remove sound deadener pad.
5. Remove ’C’ clip securing cable outer to selector
lever bracket.
4. Select ’1’. Disconnect selector cable from lever.
NOTE: North American and Japanese
vehicles are fitted with a gear selector
interlock mechanism. To move selector
lever from ’P’, activate interlock solenoid manually
with 3 mm screwdriver as shown.
REPAIR
1
44
AUTOMATIC GEARBOX
6. If selector lever assembly is to be refitted, mark
relationship of lever bracket to transmission
tunnel.
7. Disconnect multiplug.
8. Remove 6 bolts securing selector lever
assembly to transmission tunnel.
9. Remove selector lever assembly. Collect gasket.
14.
15.
16.
17.
18.
19.
20.
Refit
10. Ensure mating faces are clean.
11. Using a new gasket, position selector lever
assembly. Engage cable.
12. Fit bolts, finger tight. Align selector lever
assembly with marks.
13. New lever only. Temporarily fit selector knob.
Secure with screw. Select ’P’. Adjust position of
lever assembly to give dimension ’A’ as shown.
Dimension A= 100 mm (3.9 in)
Remove selector knob.
2
NEW RANGE ROVER
REPAIR
21.
Tighten selector lever assembly fixings.
Connect multiplug.
Secure cable lever bracket with ’C’ clip.
Align cable to lever. Secure with clevis and split
pins.
Fit sound deadener pad.
Fit centre console. See CHASSIS AND BODY,
Repair.
Engage cable in gearbox abutment bracket.
Secure with ’C’ clip.
Adjust selector cable. See this section.
ZF AUTO
SELECTOR CABLE
Service repair no - 44.15.08
Remove
1. Select ’P’. Remove ignition key.
CAUTION: Do not attempt to start vehicle
with selector cable disconnected,
incorrectly adjusted, or selector interlock
solenoid overridden.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Remove split pin and washer securing cable
trunnion to transmission lever.
7. Select ’1’. Disconnect selector cable to lever.
NOTE: North American and Japanese
vehicles are fitted with a gear selector
interlock mechanism. To move selector
lever from ’P’, activate interlock solenoid manually
with 3 mm screwdriver as shown.
4. Remove ’C’ clip securing cable to transmission
abutment bracket. Remove cable.
5. Remove centre console. See CHASSIS AND
BODY, Repair.
6. Remove sound deadener pad.
8. Remove ’C’ clip securing cable to underside of
vehicle. Remove cable.
REPAIR
3
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
SELECTOR INDICATOR & MODE SWITCH
Service repair no - 44.15.10 - Selector Indicator
NOTE: The EAT Mode switch is integral
with the selector indicator assembly and
cannot be serviced separately.
Remove
1. Remove electric window switch pack. See
ELECTRICAL, Repair.
2. Remove screw at rear of gear lever applique.
Raise rear of applique. Disengage 2 spring clips
at forward end.
Refit
9. Reverse removal procedure.
10. Adjust selector cable. See Adjustment.
3. Disconnect cigar lighter multiplug. Release cigar
lighter bulb. Remove selector lever applique.
4. Remove screw securing selector knob. Remove
knob.
4
REPAIR
ZF AUTO
SELECTOR POSITION SWITCH
Service repair no - 44.15.19
Remove
1. Raise vehicle on four post lift.Select ’P’. Raise
lift.
2. Remove nut securing selector lever to selector
shaft. Release lever.
5. Remove 3 screws securing selector indicator.
6. Raise selector indicator. Disconnect multiplug.
7. Remove selector indicator.
Refit
8. Reverse removal procedure.
3. Release switch multiplug from bracket.
Disconnect from vehicle harness.
4. Remove nut and bolt securing position switch.
5. Release switch from selector shaft. Remove
breather hose.
6. Remove switch.
REPAIR
5
44
AUTOMATIC GEARBOX
Refit
NEW RANGE ROVER
SEAL - SELECTOR SHAFT
7. Ensure ’P’ is selected by rotating selector shaft
fully clockwise.
8. Engage ’N’ by rotating selector shaft
anti-clockwise by 2 detents.
9. Connect breather hose to switch. Connect
multiplug to vehicle harness. Secure to bracket.
10. Engage switch on selector shaft. Fit nut to stud,
fit bolt. Do not tighten.
11. Fit setting tool LRT-44-011 to shaft.
12. Insert setting pin into tool. Rotate switch until
setting pin engages with hole in switch as
shown.
Service repair no - 44.15.34
Remove
1. Position vehicle on a four post lift.
2. Release fixings from battery cover and remove
cover.
3. Disconnect battery earth lead.
4. Petrol models: Release clips securing cooling
fan cowl and remove cowl.
13. Tighten nut and bolt. Remove setting tool.
14. Fit selector lever to shaft. Secure with nut.
15. Lower vehicle.
6
REPAIR
5. Petrol models: Remove 3 bolts securing engine
RH lifting eye to cylinder head and position earth
strap and lifting eye aside.
6. Remove window switch pack. See
ELECTRICAL, Repair.
ZF AUTO
7. With the handbrake released, remove clip and
clevis pin securing handbrake cable to
handbrake.
8. Raise vehicle and release handbrake cable and
grommet from tunnel.
9. Petrol models: Remove exhaust front pipe.
See MANIFOLD AND EXHAUST SYSTEM,
Repair.
10. Diesel models: Remove chassis crossmember.
See CHASSIS AND BODY, Repair.
12. Remove 4 bolts securing rear propeller shaft
guard and remove guard.
13. Raise one wheel on each axle to allow rotation
of propeller shafts.
14. Mark transfer box and propeller shaft flanges to
aid re-assembly.
11. Remove 4 bolts securing transmission mounting
assembly and remove assembly.
REPAIR
7
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
20. Position selector cable and bracket aside.
21. Lower gearbox support to gain access to
selector shaft.
22. Remove valve block. See this section.
23. Disconnect harness from gear selector switch
multiplug and release multiplug from bracket.
24. Remove nut securing selector shaft lever and
release lever from shaft.
25. Remove bolt and nut securing gear selector
switch to gearbox and remove switch.
15. Remove 4 bolts from each propeller shaft flange.
16. Release propeller shafts and tie aside.
17. Lower gearbox for access.
26. Drift out and discard selector quadrant roll pin.
Remove selector shaft.
27. Remove selector quadrant and connecting rod.
28. Remove oil seal taking care not to damage seal
housing.
18. Remove split pin securing gear selector cable
trunnion to gear selector lever and release
trunnion.
19. Remove 2 bolts securing gear selector cable
abutment bracket and harness support bracket
to gearbox.
8
REPAIR
ZF AUTO
Refit
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
FLUID COOLER - V8 - UP TO 99MY
Clean shaft and seal housing.
Using a suitable adapter, fit new seal.
Fit selector quadrant and connecting rod.
Fit selector shaft and secure to quadrant using
new roll pin.
Fit valve block. See this section.
Position selector switch and tighten nut and bolt.
Position selector shaft lever and tighten nut.
Fit selector switch multiplug to bracket and
connect harness to multiplug.
Align harness support bracket and gear selector
cable abutment bracket to gearbox and secure
with bolts.
Connect gear selector cable trunnion to lever
and fit split pin.
Adjust gear selector cable. See this section.
Raise gearbox on transmission jack.
Fit handbrake cable through transmission tunnel.
Clean propeller shaft and transfer box flanges.
Fit shafts to transfer box flanges, align marks
and tighten nuts and bolts to 48 Nm (35 lbf.ft).
Fit rear propeller shaft guard and secure with
bolts.
Fit transmission mounting assembly and tighten
bolts to 45 Nm (33 lbf.ft).
Diesel models: Fit chassis crossmember. See
CHASSIS AND BODY, Repair.
Petrol models: Fit exhaust front pipe. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
Connect handbrake cable to lever and fit clevis
pin and clip.
Fit window switch pack. See ELECTRICAL,
Repair.
Petrol models: Fit engine RH lifting eye, align
earth strap and secure with bolts.
Petrol models: Fit cooling fan cowl and secure
with clips.
Connect battery earth lead.
Fit and secure battery cover.
Service repair no - 44.24.10
Remove
1. Disconnect battery negative lead.
2. Remove engine oil cooler. See ENGINE,
Repair.
3. Remove 4 trim studs securing air deflectors.
Remove deflectors.
4. Position container to collect fluid spillage.
5. Unscrew fluid cooler pipe union nuts and discard
’O’ rings.
6. Plug cooler and pipes.
7. Remove 4 bolts securing fluid cooler to radiator
mounting bracket.
8. Remove fluid cooler.
Refit
9. Fit fluid cooler.
10. Fit and tighten 4 bolts securing cooler to
mounting bracket.
11. Remove plugs from cooler and pipes.
12. Ensure pipe unions are clean.
13. Lubricate new ’O’rings with clean fluid and fit to
pipes.
14. Connect pipes to cooler. Tighten union nuts to
22 Nm (16 lbf.ft)
15. Remove container.
16. Fit air deflectors and secure with studs.
17. Fit engine oil cooler. See ENGINE, Repair.
18. Reconnect battery negative lead.
19. Top up gearbox fluid. See SECTION 10,
Maintenance.
REPAIR
9
44
AUTOMATIC GEARBOX
FLUID COOLER - V8 - FROM 99MY
Service repair no - 44.24.10
Remove
1. Remove engine oil cooler. See ENGINE,
Repair.
2. Position absorbent cloth under each gearbox
cooler pipe connection to collect spillage.
3. Loosen unions and release pipes from cooler,
discard ’O’ rings.
CAUTION: Plug the connections.
4. Remove 2 screws securing fluid temperature
sensor to cooler.
5. Remove 4 bolts securing fluid cooler to radiator
mounting brackets and remove cooler.
10
REPAIR
NEW RANGE ROVER
Refit
6. Clean fluid cooler and pipe connections.
7. Fit new fluid cooler to radiator, engage in
locations, fit and tighten bolts.
8. Position fluid temperature sensor and secure
with screws.
9. Using new ’O’ rings connect pipes to cooler and
tighten unions to 22 Nm (16 lbf.ft).
10. Top up gearbox fluid.
11. Fit engine oil cooler. See ENGINE, Repair.
ZF AUTO
FLUID COOLER - DIESEL
Service repair no - 44.24.10
Remove
1.
2.
3.
4.
Disconnect battery negative lead.
Raise vehicle on four post lift.
Position container to collect fluid spillage.
Unscrew fluid pipe union nuts and discard ’O’
rings.
Refit
8. Fit fluid cooler.
9. Fit and tighten 3 bolts securing cooler to chassis
bracket.
10. Remove plugs from cooler and pipes.
11. Ensure pipe unions are clean.
12. Lubricate new ’O’ rings with clean fluid and fit to
pipes.
13. Connect pipes to cooler. Tighten union nuts to
22 Nm (16 lb.ft).
14. Remove container.
15. Lower vehicle.
16. Reconnect battery negative lead.
17. Top up gearbox fluid, See SECTION 10,
Maintenance.
5. Plug cooler and pipes.
6. Remove 3 bolts securing fluid cooler to chassis
bracket.
7. Remove fluid cooler.
REPAIR
11
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
AUTOMATIC GEARBOX - UP TO 99MY
Service repair no - 44.20.02/99
Remove
1. Position vehicle on four post lift.
2. Disconnect battery negative lead.
3. Petrol Vehicles: Release clips securing cooling
fan cowling. Remove cowling.
7. Release hand brake cable from grommet in
tunnel.
8. Raise lift. Drain gearbox and transfer box fluids.
See SECTION 10, Maintenance.
9. Remove exhaust front pipe. See MANIFOLD
AND EXHAUST SYSTEM, Repair.
Diesel Vehicles:Remove chassis cross
member. See CHASSIS AND BODY, Repair.
10. Remove 4 bolts securing transmission mounting
assembly. Remove assembly.
4. Remove bolt securing gearbox filler tube to
engine.
5. Remove window switch pack. See
ELECTRICAL, Repair.
6. Release handbrake. Remove handbrake cable
clevis pin.
12
REPAIR
11. Position transmission lift adaptor LRT-99-007.
Secure to transmission mounting bracket
location with bolts. Remove transmission jack
from under brake drum.
ZF AUTO
12. Remove 4 bolts securing rear propeller shaft
guard. Remove guard.
16. Lower gearbox for access.
CAUTION: Place wooden block between
axle case and sump to support engine.
17. Disconnect gear selector cable trunnion from
gearbox lever. Remove 2 bolts securing selector
cable abutment bracket to gearbox. Place
selector cable aside.
13. Mark transfer box and propeller shaft flanges to
aid re-assembly.
14. Raise one wheel on each axle to allow rotation
of propeller shafts.
15. Remove 4 bolts from each flange. Disconnect
propeller shafts. Tie aside.
18. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
REPAIR
13
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
19. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
24. Release fluid filler pipe from gearbox. Remove
’O’ ring and discard. Plug pipe and connection.
25. Disconnect breather pipes from gearbox and
transfer box. Plug Pipes and connections.
26. Remove 3 bolts securing converter housing
lower access cover. Remove cover. Collect
gasket.
27. Remove 9 bolts securing converter drive plate
access cover. Remove cover.
20. Disconnect multiplugs from gear selection
position switch and gearbox speed sensor.
21. Release harness from clips.
22. Remove bolt from clamp securing gearbox
cooler pipes to engine.
23. Disconnect transmission cooler pipes. Remove
’O’ rings and discard. Plug pipes and
connections.
28. Mark drive plate and converter to aid
re-assembly.
29. Remove 4 bolts securing drive plate to
converter.
14
REPAIR
ZF AUTO
35. Attach hoist to lifting eyes. Take weight of
transmission.
36. Remove lift adaptor. Hoist transmission
assembly onto bench.
37. Fit lifting eye to transmission brake drum. Raise
gearbox on end.
CAUTION: Position packers beneath bell
housing extension to provide clearance for
input shaft.
38. Remove 6 bolts securing transfer box to
gearbox. Release from 2 ring dowels. Remove
transfer box.
30. Remove 8 bolts securing converter housing to
engine.
31. Remove transmission assembly.
CAUTION: Ensure converter does not
become detached from gearbox.
32. Fit retaining strap to converter. Secure with 2
nuts and bolts.
Do not carry out further dismantling if
component is removed for access only.
33. Lower transmission assembly from vehicle.
34. Attach lifting eyes to transmission.
39. Ensure mating faces are clean.
40. Place gearbox on end. Position transfer box.
41. Engage transfer box to ring dowels. Secure to
gearbox with bolts. Tighten to 45 Nm (33 lbf.ft)
CAUTION: Ensure that gearbox is located
on both dowels, or transmission damage
may occur.
42. Place transmission on side. Fit lifting eyes.
43. Attach transmission to lift adaptor. Secure with
bolts.
44. Detach hoist. Remove lifting eyes.
REPAIR
15
44
AUTOMATIC GEARBOX
Refit
45. Ensure converter spigot and mating faces are
clean.
46. Remove converter retaining strap.
47. Position transmission to engine. Secure with
bolts. Tighten to 45 Nm (33 lbf.ft)
48. Position drive plate to converter. Align marks.
Secure with bolts. Tighten to 50 Nm (37 lbf.ft)
49. Position converter access panels. Use a new
gasket with lower panel. Secure panels with
bolts.
50. Remove plugs from breather pipes and
connections.
51. Using new sealing washers, secure breather
pipes to gearbox and transfer box with banjo
bolts.
52. Fit new seals to fluid filler and cooler pipes.
Connect pipes to transmission. Tighten to
22 Nm (16 lbf.ft)
53. Fit clamp to cooler pipes. Secure to engine with
bolt.
54. Route gearbox harness. Secure with clips.
55. Connect multiplugs to High/Low motor and
output shaft speed sensor.
56. Connect multiplugs to gear selection position
switch and gearbox speed sensor.
57. Connect Lucars to transfer box fluid temperature
sensor.
58. Align harness bracket to gearbox.
59. Position selector cable abutment bracket to
gearbox. Secure with bolts.
60. Raise transmission. Support under brake drum
with transmission jack.
61. Remove transmission lift adaptor. Remove lift.
62. Position transmission mounting assembly.
Secure with bolts. Tighten to 45 Nm (33 lbf.ft)
63. Adjust gear selector cable. See Adjustment.
16
REPAIR
NEW RANGE ROVER
64. Raise one wheel on each axle to allow rotation
of propeller shafts.
65. Position shafts to transfer box flanges. Align
marks.
66. Secure shafts with nuts and bolts. Tighten to
48 Nm (35 lbf.ft)
67. Fit propeller shaft guard. Secure with bolts.
68. Guide hand brake cable through grommet in
transmission tunnel.
69. Diesel Vehicles:Fit chassis cross member. See
CHASSIS AND BODY, Repair.
70. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
71. Fill transfer box with oil. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
72. Lower Vehicle
73. Connect handbrake cable to lever.
74. Fit window switch pack. See ELECTRICAL,
Repair.
75. Position gearbox filler tube to engine. Secure
with bolt.
76. Petrol Engines:Position cooling fan cowl.
Secure with clips.
77. Fill gearbox with fluid. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
78. Reconnect battery negative lead.
ZF AUTO
AUTOMATIC GEARBOX - FROM 99MY
Service repair no - 44.20.04.99
Remove
1. Position vehicle on a four post lift.
2. Release fixings from battery cover and remove
cover.
3. Disconnect battery earth lead.
4. Petrol models: Release clips securing cooling
fan cowl and remove cowl.
8. With the handbrake released, remove clip and
clevis pin securing handbrake cable to
handbrake.
9. Raise vehicle and release handbrake cable and
grommet from tunnel.
10. Drain gearbox See this section. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
11. Drain transfer gearbox fluid. See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
12. Petrol models: Remove exhaust front pipe.
See MANIFOLD AND EXHAUST SYSTEM,
Repair.
13. Diesel models: Remove chassis crossmember.
See CHASSIS AND BODY, Repair.
5. Petrol models: Remove 3 bolts securing engine
RH lifting eye to cylinder head and position earth
strap and lifting eye aside.
6. Diesel Models: Remove starter motor. See
ELECTRICAL, Repair.
7. Remove window switch pack. See
ELECTRICAL, Repair.
REPAIR
17
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
14. Remove 4 bolts securing transmission mounting
assembly and remove assembly.
17. Remove 4 bolts securing rear propeller shaft
guard and remove guard.
18. Raise one wheel on each axle to allow rotation
of propeller shafts.
19. Mark transfer box and propeller shaft flanges to
aid re-assembly.
15. Fit LRT-99-007, to transmission jack and secure
to transmission mounting bracket location holes
with bolts.
16. Remove transmission jack from under brake
drum.
18
REPAIR
ZF AUTO
20. Remove 4 nuts from each propeller shaft flange.
21. Release propeller shafts and tie aside.
22. Lower gearbox for access.
CAUTION: Position jack and wooden block
under sump to support engine.
23. Remove split pin securing gear selector cable
trunnion to gearbox lever and release trunnion.
24. Remove 2 bolts securing gear selector cable
abutment bracket and harness support bracket
to gearbox, and position selector cable and
brackets aside.
25. Disconnect multiplugs from gear selection
position switch and gearbox speed sensor.
26. Disconnect 2 Lucars from transfer box fluid
temperature sensor.
27. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
28. Release harness from 3 clips.
29. Remove 2 banjo bolts securing breather pipes to
gearbox and transfer box, remove and discard
sealing washers.
CAUTION: Plug the connections.
REPAIR
19
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
gasket.
34. Remove access plug and mark drive plate and
torque convertor to aid re-assembly.
35. Rotate engine to gain access and remove 4
bolts securing drive plate to convertor.
30. Remove 2 bolts and release 1 clip securing fuel
and purge pipe retaining brackets to gearbox
and transfer box.
36. Remove 14 bolts securing gearbox to engine
and collect crash bracket.
37. With assistance remove transmission assembly.
CAUTION: Ensure converter does not
become detached from gearbox.
38. Fit retaining strap to converter and secure with 2
nuts and bolts.
31. Remove bolt from clamp securing gearbox fluid
cooler pipes to engine.
32. Loosen unions and release gearbox oil cooler
pipes, discard ’O’ rings.
CAUTION: Plug the connections.
33. Remove 3 bolts securing converter housing
lower access cover, remove cover and discard
20
REPAIR
ZF AUTO
Refit
39. Clean mating faces of engine and gearbox,
dowel and dowel holes.
40. Ensure drive plate and convertor mating faces
are clean.
41. Remove 2 nuts and bolts and remove convertor
retaining strap.
42. With assistance, fit transmission assembly to
engine.
CAUTION: Ensure that gearbox is located
on both dowels, or transmission damage
may occur.
43. Fit crash bracket to gearbox flange and fit and
tighten engine to gearbox bolts to 45 Nm
(33 lbf.ft).
44. Align drive plate to convertor and tighten bolts to
50 Nm (37 lbf.ft).
45. Fit access plug.
46. Fit new gasket and lower access cover. Secure
cover with bolts.
47. Clean gearbox fluid cooler pipe unions, fit new
’O’ rings and tighten union nuts to 22 Nm
(16 lbf.ft).
48. Clean breather pipe bolts and banjos, fit new
sealing washers and tighten bolts to 15 Nm
(11 lbf.ft).
49. Fit gearbox fluid cooler pipe clamp and secure
with bolt.
50. Align fuel and purge pipe brackets to gearbox
and transfer box and secure with 2 bolts and
1 clip.
51. Connect multiplugs to output shaft speed sensor
and High/Low motor.
52. Connect Lucars to transfer box temperature
sensor.
53. Connect multiplugs to gearbox selection position
switch and gearbox speed sensor.
54. Secure harness to clips.
55. Align harness support bracket and gear selector
cable abutment bracket to gearbox and secure
with bolts.
56. Connect gear selector cable trunnion to lever
and fit split pin.
57. Adjust gear selector cable. See this section.
58. Raise gearbox on transmission jack.
59. Fit and engage handbrake cable grommet in
transmission tunnel.
60. Clean propeller shaft and transfer box flanges.
61. Fit shafts to transfer box flanges, align marks
and tighten nuts to 48 Nm (35 lbf.ft).
62. Fit rear propeller shaft guard and secure with
bolts.
63. Position transmission jack under brake drum.
64. Remove 4 bolts securing LRT-99-007 to
transmission and remove support.
65. Fit transmission mounting assembly and tighten
bolts to 45 Nm (33 lbf.ft).
66. Diesel models: Fit chassis crossmember. See
CHASSIS AND BODY, Repair.
67. Petrol models: Fit exhaust front pipe. See
MANIFOLD AND EXHAUST SYSTEM, Repair.
68. Connect handbrake cable to lever, fit clevis pin
and secure pin with clip.
69. Fit window switch pack. See ELECTRICAL,
Repair.
70. Diesel models: Fit starter motor. See
ELECTRICAL, Repair.
71. Petrol models: Fit engine RH lifting eye, align
earth strap and secure with bolts.
72. Petrol models: Fit cooling fan cowl and secure
with clips.
73. Connect battery earth lead.
74. Fit and secure battery cover.
75. Fill transfer box with oil. See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
76. Fill gearbox with fluid. See this section.
REPAIR
21
44
AUTOMATIC GEARBOX
TORQUE CONVERTER OIL SEAL
Service repair no - 44.17.07 Torque Convertor
Service repair no - 44.17.11 Oil Seal
Remove
1. Remove gearbox. See this section.
2. Remove retaining strap.
3. Fit LRT-44-010 to torque converter and remove
torque converter from gearbox. Remove
LRT-44-010 from torque converter.
4. Position container beneath torque converter
housing to catch fluid spillage.
5. Remove oil seal from torque converter housing.
22
REPAIR
NEW RANGE ROVER
Refit
6. Clean oil seal running surfaces.
7. Lubricate oil seal with transmission fluid.
8. Fit new seal using LRT-44-001 into converter
housing.
9. Fit LRT-44-010 to torque converter.
10. Align oil pump drive and fit torque converter to
gearbox.
11. Remove LRT-44-010 from torque converter.
12. Fit torque converter retaining strap.
13. Fit gearbox. See this section.
ZF AUTO
HOUSING - TORQUE CONVERTER
Service repair no - 44.17.01
Remove
1. Remove torque converter oil seal. See this
section.
2. Remove 18 bolts and plain washers securing
torque converter and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads and
6 bolts, (outer ring), which are shorter.
3. Hold input shaft in position and carefully remove
the converter housing and intermediate plate
from gearbox casing. Note
Refit
8. Clean converter housing, intermediate plate and
gearbox casing mating faces.
9. Clean bolts and plain washers and sealant from
4 bolt threads.
10. Apply Petroleum Jelly to new gasket and
position on gearbox casing.
11. Apply Petroleum Jelly to thrust washer and
torrington race.
12. Correctly position Torrington race and thrust
washer to forward clutch hub.
13. Position intermediate plate and converter
housing to gearbox casing.
14. Apply High Formula Hylomar sealant to 4 longer
bolt threads and fit bolts in the positions shown.
15. Fit remaining bolts and tighten progressively in a
diagonal sequence to 50 Nm (37 lbf. ft).
4. Note the position of the Torrington race on the
forward clutch hub and the thrust washer which
will stay attached to the intermediate plate by
fluid adhesion.
5. Remove and discard intermediate plate gasket.
6. Remove thrust washer from intermediate plate.
7. Separate converter housing from intermediate
plate.
REPAIR
23
44
AUTOMATIC GEARBOX
16. Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
17. Clamp a suitable steel base to converter housing
flange.
18. Mount DTI gauge and position gauge probe onto
LRT-44-003/1 and zero gauge.
19. Check that the axial end-float is between 0.2 to
0.4 mm. If end-float is not within limits, replace
existing thrust washer, positioned at rear of
intermediate plate, with a suitable thickness
thrust washer to give the required end-float.
20. Remove DTI gauge and base plate.
21. Fit torque converter oil seal. See this section.
NEW RANGE ROVER
GASKET - INTERMEDIATE PLATE
Service repair no - 44.20.11
Remove
1. Remove torque converter oil seal. See this
section.
2. Remove 12 bolts and plain washers securing
converter housing and intermediate plate to
gearbox casing. Note the position of the 4 bolts
that have sealant applied to the bolt threads.
3. Hold input shaft in position and carefully lift off
converter housing and intermediate plate as an
assembly.
4. Note the position of the torrington race on the
forward clutch hub, and the thrust washer which
will stay attached to the intermediate plate by
fluid adhesion.
5. Remove and discard intermediate plate gasket.
6. Remove thrust washer from intermediate plate.
24
REPAIR
ZF AUTO
Refit
7. Clean intermediate plate and mating face on
gearbox casing.
8. Apply Petroleum Jelly to new gasket and
position on gearbox casing.
9. Apply Petroleum Jelly to thrust washer and
torrington race.
10. Correctly position torrington race and thrust
washer to forward clutch hub.
11. Position converter housing and intermediate
plate assembly to gearbox casing.
12. Clean bolts and plain washers and old sealant
from 4 bolt threads.
15. Place LRT-44-003/1 into pump housing, tighten
screws to secure LRT-44-003/1 to input shaft.
16. Clamp a suitable steel base to converter housing
flange.
17. Mount DTI gauge and position gauge probe onto
LRT-44-003/1 and zero gauge.
18. Check that the axial end-float is between 0.2 to
0.4 mm. If end-float in not within limits, replace
existing thrust washer, positioned at rear of
intermediate plate, with a suitable thickness
thrust washer to give the required end-float.
19. Remove DTI gauge and base plate.
20. Fit torque converter oil seal. See this section.
13. Apply High Formular Hylomar sealant to 4 longer
bolt threads and fit bolts in position shown.
14. Fit remaining bolts and tighten progressively in a
diagonal sequence to 45 Nm (33 lbf. ft).
REPAIR
25
44
AUTOMATIC GEARBOX
NEW RANGE ROVER
INTERMEDIATE PLATE
Service repair no - 44.17.20
Remove
1. Remove intermediate plate gasket. See this
section.
2. Remove selective thrust washer from
intermediate plate.
7. Note position and remove pump locating dowel.
8. Remove and discard ’O’ ring from pump
housing.
3. Remove 2 M14 Allen plugs from intermediate
plate, remove and discard sealing washers.
4. Remove 2 M20 plugs from intermediate plate,
remove and discard sealing washers.
5. Remove 2 oil cooler pipe adaptors from
intermediate plate.
9. Remove 6 bolts securing converter housing to
intermediate plate, and release intermediate
plate from converter housing.
6. Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.
26
REPAIR
ZF AUTO
Refit
10. Clean intermediate plate and mating faces with a
lint free cloth.
11. Position intermediate plate to converter housing,
fit bolts and tighten evenly to 50 Nm (37 lbf.ft)
12. Fit new sealing washers to M14 allen plugs, fit
plugs and tighten to 40 Nm (30lbf. ft).
13. Fit new sealing washers to M20 plugs, fit plugs
and tighten to 50 Nm (37lbf. ft).
14. Fit oil cooler adaptors and tighten to 42 Nm
(30lbf.ft).
15. Clean pump housing and mating face on
intermediate plate with lint free cloth.
16. Lubricate new ’O’ ring with transmission fluid and
fit to pump housing.
17. Position pump locating dowel into intermediate
plate.
18. Align pump to dowel and position in intermediate
plate.
19. Fit bolts and tighten in a diagonal sequence to
10 Nm (7lbf.ft).
PUMP - FLUID
Service repair no - 44.32.01
Remove
1. Remove intermediate plate gasket. See this
section.
2. Remove 8 bolts securing fluid pump to
intermediate plate and carefully remove pump
from intermediate plate.
20. Position LRT-44-003/1 into pump and check that
the pump rotors turn freely.
21. Fit intermediate plate gasket. See this section.
3. Note position and remove pump locating dowel.
4. Remove and discard ’O’ ring from pump
housing.
REPAIR
27
44
AUTOMATIC GEARBOX
Refit
NEW RANGE ROVER
OUTPUT SHAFT SEAL
5. Clean pump housing and mating face on
intermediate plate with lint free cloth.
6. Lubricate new ’O’ ring with transmission fluid and
fit to pump housing.
7. Position pump locating dowel into intermediate
plate.
8. Align fluid pump to dowel and position in
intermediate plate.
9. Fit bolts and tighten in a diagonal sequence to
10 Nm (7lbf.ft).
Service repair no - 44.20.18
Remove
1. Disconnect battery negative lead.
2. Remove transfer box. See TRANSFER BOX,
Repair.
3. Drain fluid from gearbox. See SECTION 10,
Maintenance.
4. Remove seal from gearbox casing using a
suitable lever.
CAUTION: Ensure location does not
become damaged as seal is levered from
casing.
10. Position LRT-44-003/1 into pump and check that
the pump rotors turn freely.
11. Fit intermediate plate gasket. See this section.
Refit
5. Clean seal location and running surface on
transfer gearbox input shaft.
6. Lubricate seal lip with clean transmission fluid.
7. Fit seal to gearbox casing using LRT-44-001
8. Fit transfer box. See TRANSFER BOX, Repair.
9. Reconnect battery negative lead.
10. Replenish transmission fluids. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
28
REPAIR
ZF AUTO
GASKET - REAR EXTENSION HOUSING
PARKING PAWL ASSEMBLY
Service repair no - 44.20.19
Service repair no - 44.28.07
Remove
Remove
1. Remove transfer gearbox. See TRANSFER
BOX, Repair.
1. Remove rear extension housing gasket. See
this section.
2. Remove Torx screw and discard, lift off parking
pawl guide and guide plate.
3. Remove ratchet, spring and pivot pin.
2. Remove 9 bolts securing rear extension housing
to gearbox case and remove housing.
3. Remove and discard gasket.
4. Diesel and 4.6 models:Remove circlip and
bearing track from output shaft.
5. Remove park lock gear.
6. Remove and discard ’O’ ring from output shaft.
Refit
4. Clean rear extension and mating face, dowel
and dowel holes.
5. Fit new gasket to gearbox case.
6. Fit rear extension housing and tighten bolts to 25
Nm (18 lbf.ft).
7. Fit transfer gearbox. See TRANSFER BOX,
Repair.
REPAIR
29
44
AUTOMATIC GEARBOX
Refit
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
NEW RANGE ROVER
FLUID PAN AND FILTER
Clean park lock components.
Lubricate and fit new ’O’ ring to output shaft.
Fit park lock gear to output shaft.
Diesel and 4.6 models: Fit bearing track and a
new circlip.
Position pivot pin, spring and ratchet.
Position parking pawl guide and guide plate,
tighten Torx screw to 10 Nm (7 lbf.ft).
Clean extension housing and gearbox case.
Position new gasket to gearbox case.
Position extension housing and tighten bolts to
25 Nm (18 lbf.ft).
Fit rear extension housing gasket. See this
section.
Service repair no - 44.24.04 - Fluid Pan
Service repair no - 44.24.05 - Gasket
Service repair no - 44.24.07 - Fluid Filter
Remove
1. Raise vehicle on four post lift.
2. Drain transmission fluid.
3. Up to 99MY: Release fluid filler tube from pan.
From 99MY: Loosen forward bolt securing
snubber bar to cross member.
30
REPAIR
ZF AUTO
4. Remove 6 bolts securing fluid pan to
transmission. Remove fluid pan. Collect retaining
plates.
5. Remove gasket and discard.
NOTE:
Do not carry out further dismantling if
component is removed for access only.
6. Remove bolt securing oil pick-up tube. Remove
pick-up tube. Collect spacer.
Refit
9. Ensure mating faces are clean.
10. Fit new ’O’ rings to fluid filter. Lubricate with
clean transmission fluid.
11. Position fluid filter. Secure with bolts. Tighten to
8 Nm (6 lbf.ft).
12. Position oil pick-up tube and spacer. Secure with
bolt. Tighten to 8 Nm (6 lbf.ft).
13. Fit new gasket to fluid pan. Position pan on
gearbox. Secure with bolts and retaining plates.
Tighten to 8 Nm (6 lbf.ft).
14. Up to 99MY: Fit oil filler tube. Tighten to 70 Nm
(52 lbf.ft).
From 99MY: Tighten forward bolt securing
snubber bar to cross member to 45 Nm
(33 lbf.ft).
15. Lower vehicle.
16. Refill transmission fluid. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information.
7. Remove remaining 2 bolts securing filter to valve
block. Remove filter.
8. Remove ’O’ rings and discard.
REPAIR
31
44
AUTOMATIC GEARBOX
VALVE BODY ASSEMBLY
Service repair no - 44.40.01
Remove
1. Remove gearbox fluid filter. See this section.
2. Remove 2 bolts securing speed sensor harness
bracket to valve block.
3. Disconnect multiplug from gearbox housing.
4. Using a 30 mm socket, remove nut securing
multiplug connector block from gearbox housing.
5. Remove 6 long bolts securing valve block to
gearbox.
6. Remove 5 short bolts securing valve block to
gearbox.
7. Release speed sensor and remove valve block.
8. Remove and discard ’O’ ring from multiplug
connector.
32
REPAIR
NEW RANGE ROVER
Refit
9. Clean valve block and mating faces.
10. Fit new ’O’ ring to multiplug connector block.
11. With assistance, position multiplug to gearbox
housing and tighten nut.
12. Align valve block to gearbox, ensure manual
valve is correctly located. Position speed sensor
retaining bracket, and tighten screws to 8 Nm
(6 lbf.ft).
13. Connect multiplug to gearbox connector.
14. Fit gearbox fluid filter. See this section.
ZF AUTO
SEAL - VALVE BLOCK - SET
Service repair no - 44.20.13
Remove
1. Remove valve body assembly. See this
section.
2. Remove circlips and springs from gearbox
casing noting location of long and short springs.
3. Remove and discard seals using LRT-44-005
from gearbox casing.
6. Position springs in their correct locations and
secure with circlips.
7. Fit valve body assembly. See this section.
Refit
4. Clean gearbox casing, springs and circlips.
5. Fit new seals using LRT-44-005, ensure seals
are fully seated.
REPAIR
33
44
AUTOMATIC GEARBOX
PRESSURE REGULATOR
Service repair no - 44.40.22
Remove
1. Remove valve body assembly. See this
section.
2. Release and remove clip securing pressure
regulator solenoid valve harness to valve body.
3. Disconnect multiplug from pressure regulator
solenoid valve.
4. Remove 5 Torx screws securing pressure
regulator to valve body and remove pressure
regulator.
34
REPAIR
NEW RANGE ROVER
Refit
5. Clean pressure regulator and mating face with a
lint free cloth.
6. Position pressure regulator to valve body, fit
Torx screws and tighten to 8 Nm (6lbf. ft).
7. Connect multiplug to pressure regulator solenoid
valve, fit clip and secure harness to valve body.
ZF AUTO
LOCK-UP SOLENOID VALVE (MV 3)
SOLENOIDS - SHIFT CONTROL VALVES (MV 1
and 2)
Service repair no - 44.15.35
Service repair no - 44.15.45
Remove
Remove
1. Remove valve body assembly. See this
section.
2. Disconnect multiplug from lock-up solenoid valve
and release harness from clip.
3. Remove Torx screw and retaining fork securing
solenoid valve to valve body.
4. Remove solenoid valve from valve body.
Refit
1. Remove valve body assembly. See this
section.
2. Remove 3 Torx screws securing lock-up
solenoid valve assembly to valve body and
move solenoid aside.
NOTE: This is to gain access to remove
Torx screw and MV2 shift control valve.
5. Clean lock-up solenoid valve with lint free cloth.
6. Position solenoid valve in valve body.
7. Position retaining fork, fit and tighten Torx screw
to 8 Nm (6lbf. ft).
8. Connect multiplug to lock-up solenoid valve and
secure harness in clip.
9. Fit valve body assembly. See this section.
3. Note their fitted position and disconnect
multiplugs from shift control valves MV 1 and MV
2.
4. Remove Torx screw and retaining fork securing
MV2 shift control solenoid valve to valve body.
Note that the tag on the retaining fork faces
towards the valve body.
5. Remove shift control valve from valve body.
REPAIR
35
44
AUTOMATIC GEARBOX
Refit
NEW RANGE ROVER
HARNESS - SOLENOID VALVES
6. Clean MV2 shift control solenoid valve with lint
free cloth.
7. Position MV2 shift control solenoid valve to valve
body.
8. Position retaining fork, fit Torx screw and tighten
to 8 Nm (6lbf. ft).
9. Connect multiplugs to both shift control solenoid
valves.
10. Clean lock-up solenoid valve assembly with a
lint-free cloth.
11. Position lock-up valve assembly, assembly,fit
and tighten Torx screws to 8 Nm (6lbf. ft).
12. Fit valve body assembly. See this section.
Service repair no - 44.15.52
Remove
1. Remove valve body assembly. See this
section.
2. Release and remove clip securing pressure
regulator solenoid harness to valve body.
3. Disconnect multiplug from pressure regulator
solenoid valve.
4. Disconnect multiplugs from lock-up solenoid
valve, shift control solenoid valves MV 1 and MV
2.
5. Release harness from 5 clips on valve body and
remove harness.
36
REPAIR
ZF AUTO
ELECTRONIC CONTROL UNIT
Service repair no - 44.15.46
Remove
1. Move left hand front seat fully rearwards. Raise
cushion for access.
6. Disconnect and remove speed sensor from
harness.
Refit
7. Connect speed sensor to harness multiplug.
8. Position harness to valve body.
9. Connect multiplugs to shift control solenoid
valves MV 1 and MV 2 and lock-up solenoid
valve.
10. Connect multiplug to pressure regulator solenoid
valve and secure solenoid valve harness with
clip to valve body.
11. Position and secure harness in clips on valve
body.
12. Fit valve body assembly. See this section.
2. Disconnect battery negative lead.
3. Remove 3 fixings securing trim to seat base.
Remove trim.
4. Remove 2 screws securing cover to ECU.
Remove cover.
5. Release multiplug from ECU.
REPAIR
37
44
AUTOMATIC GEARBOX
6. Remove screw securing ECU. Remove ECU.
Refit
7. Reverse removal procedure.
38
REPAIR
NEW RANGE ROVER
47 - PROPELLER SHAFTS
CONTENTS
Page
REPAIR
PROPELLER SHAFT - FRONT ........................................................................... 1
PROPELLER SHAFT - REAR .............................................................................. 2
PROPELLER SHAFTS
PROPELLER SHAFT - FRONT
Service repair no - 47.15.02
Remove
1. Raise vehicle on four post lift.
2. Mark propeller shaft and drive flanges for
reassembly.
3. With assistance, remove 4 nuts and bolts
securing each propeller shaft flange.
Refit
5. Clean mating faces of flanges.
6. Position propeller shaft. Align flange markings.
7. Fit bolts and new Nyloc nuts. Tighten to 48 Nm
(35 lbf.ft)
NOTE: Fit bolts with heads toward transfer
box and away from differential.
8. Lower vehicle.
NOTE: Raise 1 front road wheel and rotate
propeller shaft as necessary to gain
access to all fixings.
CAUTION: Assistance is necessary to
support propeller shaft when fixings are
removed.
4. Remove propeller shaft.
REPAIR
1
47
PROPELLER SHAFTS
PROPELLER SHAFT - REAR
Service repair no - 47.15.03
Remove
1. Raise vehicle on four post lift.
NOTE: Raise road wheel to allow rotation
of propeller shaft.
2. Mark propeller shaft and drive flanges to aid
re-assembly.
3. Remove 4 bolts securing propeller shaft guard to
floor pan. Remove guard.
4. Remove 4 nuts securing propeller shaft to brake
drum.
5. With assistance, remove 4 nuts and bolts
securing propeller shaft to differential drive
flange. Remove shaft.
Refit
6. Ensure mating faces are clean.
7. Position shaft to differential drive flange. Align
marks.
8. Secure with bolts new Nyloc nuts. Tighten to
48 Nm. (35 lbf.ft)
NOTE: Bolts fitted with heads away from
differential.
9. Position shaft to brake drum. Align marks.
Secure with nuts. Tighten to 48 Nm. (35 lbf.ft)
10. Position propeller shaft guard. Secure with bolts.
11. Lower lift.
2
REPAIR
NEW RANGE ROVER
51 - REAR AXLE AND FINAL DRIVE
CONTENTS
Page
REPAIR
REAR AXLE .........................................................................................................
DIFFERENTIAL ASSEMBLY ...............................................................................
OIL SEAL - PINION ..............................................................................................
MASS DAMPER ...................................................................................................
1
4
5
6
REAR AXLE AND FINAL DRIVE
REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: When lowering or
repositioning axle, an additional two
persons are required.
WARNING: Before commencing work,
depressurise air suspension. See FRONT
SUSPENSION, Repair.
6. Remove 2 nuts securing shock absorbers to
axle.
7. Remove ’R’ clips retaining air springs to axle.
8. Remove bolt securing Panhard rod to axle.
Release rod. Tie aside.
Up to 97MY:
9. Release ABS sensor multiplug from body
bracket. Disconnect multiplug. Release lead
from body clips.
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Support axle with hydraulic jack.
3. Remove rear road wheels.
4. Mark differential and propeller shaft flanges to
aid reassembly.
5. Remove 4 nuts and bolts securing propeller
shaft to differential. Release shaft and tie aside;
discard nuts.
10. Disconnect brake pipes from body bracket. Plug
pipes and connections.
11. Remove 2 clips securing brake pipes to body
bracket.
REPAIR
1
51
REAR AXLE AND FINAL DRIVE
NEW RANGE ROVER
From 97MY:
12. At LH and RH ends of axle, release ABS sensor
multiplug from chassis rail upper bracket.
Disconnect multiplug and release ABS sensor
lead from chassis rail lower bracket.
13. At LH and RH ends of axle, disconnect brake
pipe from brake hose at chassis rail lower
bracket. Remove clip and release brake hose
from chassis rail lower bracket. Plug open
connections.
All models:
14. Remove banjo bolt and strap securing breather
hose to axle. Plug hose and connection.
15. Release height sensors from trailing arms.
16. Slacken 2 nuts and bolts securing trailing arms
to chassis.
2
REPAIR
17. Remove 4 nuts and bolts securing trailing arms
to axle.
18. With assistance lower axle. Release suspension
units.
19. Remove axle from vehicle.
REAR AXLE AND FINAL DRIVE
Refit
From 97MY:
20. With assistance, position axle and align
suspension units.
21. Raise axle up to trailing arms.
22. Secure axle to trailing arms with nuts and bolts.
M16 with 8.8 strength grade - Tighten to
160 Nm (118 lbf.ft),
M16 with 10.9 strength grade - Tighten to
240 Nm (177 lbf.ft),
M12 - Tighten to 125 Nm (92 lbf.ft)
23. Remove safety stands. Lower vehicle.
24. Tighten bolts securing trailing arms to chassis.
Tighten to 160 Nm. (118 lbf.ft)
25. Retain air springs with ’R’ clips.
26. Secure height sensors to trailing arms.
27. Position shock absorbers on axle. Secure with
nuts. Tighten to 45 Nm. (33 lbf.ft)
28. Ensure all pipes and connections are clean.
29. Using new sealing washers, connect breather
hose to axle with banjo bolt.
30. Secure hose to axle with strap.
34. At LH and RH ends of axle, locate brake hose in
chassis rail lower bracket and secure with clip.
Remove plugs and connect brake pipe to brake
hose.
35. At LH and RH ends of axle, connect ABS sensor
multiplug and secure to chassis rail upper
bracket. Secure ABS sensor lead to chassis rail
lower bracket. Ensure ABS sensor lead is
retained in clips on brake hose.
All models:
36. Position panhard rod to axle. Secure with bolt.
Tighten to 200 Nm. (148 lbf.ft)
37. Position propeller shaft. Align marks on flanges.
38. Secure shaft with bolts and new nuts. Tighten to
48 Nm (35 lbf.ft)
39. Replenish axle oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
40. Bleed brakes. See BRAKES, Repair.
Up to 97MY:
31. Position brake pipes to body bracket. Remove
plugs. Connect pipes.
32. Secure pipes with clips.
33. Connect ABS sensor multiplug. Secure multiplug
to body bracket. Secure lead to body clips.
REPAIR
3
51
REAR AXLE AND FINAL DRIVE
DIFFERENTIAL ASSEMBLY
Service repair no - 51.15.01
Remove
1. Remove hubs and half shafts. See REAR
SUSPENSION, Repair.
2. Drain axle oil.
3. Mark differential and propeller shaft flanges to
aid reassembly.
4. Remove 4 nuts and bolts securing propeller
shaft to differential. Release shaft and tie aside;
discard nuts.
5. Remove 10 nuts securing differential to axle
case.
6. Remove differential.
4
REPAIR
NEW RANGE ROVER
Refit
7. Ensure mating faces are clean.
8. Apply a bead of RTV sealant to axle case.
9. Position differential. Secure with nuts. Tighten to
40 Nm. (30 lbf.ft)
10. Position propeller shaft. Align marks on flanges.
11. Secure shaft with bolts and new nuts. Tighten to
48 Nm. (35 lbf.ft)
12. Refit hubs and half shafts. See REAR
SUSPENSION, Repair.
13. Replenish axle oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
REAR AXLE AND FINAL DRIVE
OIL SEAL - PINION
Service repair no - 51.20.01
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Mark propeller shaft and differential flanges to
aid reassembly.
3. Remove 4 nuts and bolts securing propeller
shaft to differential. Release shaft and tie aside;
discard nuts.
5. Remove flange. Remove oil seal.
4. Hold differential flange with LRT-51-003.
Remove nut or bolt securing drive flange to
differential pinion.
CAUTION: Vehicles up to 1997.5 Model
Year have pinion flanges secured with a
nut. Later vehicles use a flange bolt. It is
important that each fixing type is tightened to the
correct torque.
Refit
6.
7.
8.
9.
10.
11.
12.
13.
Ensure mating surfaces are clean.
Lubricate oil seal lips with axle oil.
Using LRT-51-009, fit seal to differential.
Position flange. Hold with LRT-51-003. Tighten
nut to 135 Nm (100 lbf.ft). Tighten bolt to
100 Nm (74 lbf.ft).
Position propeller shaft. Align marks on flanges.
Secure shaft with bolts and new nuts. Tighten to
48 Nm. (35 lbf.ft)
Replenish axle oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
Remove safety stands. Lower vehicle.
REPAIR
5
51
REAR AXLE AND FINAL DRIVE
MASS DAMPER
Service repair no - 51.25.10
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove 2 bolts securing mass damper to rear
axle.
3. Remove rear mass damper.
Refit
4. Position mass damper to rear axle, fit bolts and
tighten to 45 Nm. (33 lbf.ft)
5. Remove stand(s) and lower vehicle.
6
REPAIR
NEW RANGE ROVER
54 - FRONT AXLE AND FINAL DRIVE
CONTENTS
Page
REPAIR
DIFFERENTIAL ASSEMBLY ...............................................................................
FRONT AXLE .......................................................................................................
MASS DAMPER ...................................................................................................
FRONT AXLE CASE OIL SEAL ...........................................................................
1
2
5
5
FRONT AXLE AND FINAL DRIVE
DIFFERENTIAL ASSEMBLY
Service repair no - 54.10.01
Remove
1. Remove track rod. See STEERING, Repair.
2. Drain axle oil.
3. Remove hub assemblies. See FRONT
SUSPENSION, Repair.
4. Mark differential and propeller shaft flanges to
aid reassembly.
5. Remove 4 nuts and bolts securing propeller
shaft to differential; discard nuts. Release shaft,
tie aside.
Refit
7. Ensure mating faces are clean.
8. Apply a bead of RTV sealant to axle case.
9. Position differential. Secure with nuts. Tighten to
40 Nm (30 lbf.ft)
10. Position propeller shaft. Align marks on flanges.
11. Secure shaft with bolts and new nuts. Tighten to
48 Nm (35 lbf.ft)
12. Refit hub assemblies. See FRONT
SUSPENSION, Repair.
13. Refit track rod. See STEERING, Repair.
14. Replenish axle oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
6. Remove 10 nuts securing differential to axle
case. Remove differential.
REPAIR
1
54
FRONT AXLE AND FINAL DRIVE
FRONT AXLE
Service repair no - 54.15.01
NEW RANGE ROVER
1. Remove brake pads. See BRAKES, Repair.
2. Remove 2 bolts securing each brake caliper
assembly to steering knuckles. Release caliper.
Tie aside.
Remove
WARNING: When lowering or
repositioning axle, an additional two
persons are required.
WARNING: Before commencing work,
depressurise air suspension. See FRONT
SUSPENSION, Repair.
2
REPAIR
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush must be fitted.
3. Remove ABS sensors and brake hoses from
steering knuckles.
4. Remove nut securing drag link to steering
knuckle. Release taper joint.
FRONT AXLE AND FINAL DRIVE
5. Remove bolt securing Panhard rod to axle.
Release panhard rod. Tie aside.
6. Remove anti roll bar. See FRONT
SUSPENSION, Repair.
7. Remove 2 nuts securing track rod ball joints to
steering knuckles. Release taper joints. Remove
track rod.
8. Mark differential and propeller shaft flanges to
aid reassembly.
9. Remove 4 nuts and bolts securing propeller
shaft to differential; discard nuts. Release shaft
and tie aside.
12. Support front axle.
13. Remove bolts securing air spring retaining pins.
Remove pins.
10. Release height sensors from radius arms.
14. Release air springs from axle.
15. Remove 2 nuts securing shock absorbers to
axle. Release shock absorbers. Collect
mounting rubbers.
11. Remove banjo bolt securing breather hose to
axle case. Collect sealing washers. Plug hose
and connection.
REPAIR
3
54
FRONT AXLE AND FINAL DRIVE
NEW RANGE ROVER
Refit
16. Remove 2 nuts securing radius arms to chassis
brackets.
17. With assistance, lower and move axle forward.
Release radius arms from chassis brackets.
Collect rubber bushes.
18. Remove axle from vehicle.
19. Remove 2 nuts and bolts securing each radius
arm. Remove radius arms.
4
REPAIR
20. Ensure mating faces are clean.
21. Position radius arms to axle. Secure with nuts
and bolts. Tighten to 125 Nm (92 lbf.ft)
22. Position axle under vehicle.
23. With assistance, raise axle, locating radius arms
and rubber bushes into chassis locations.
24. Secure radius arms with nuts.
Tighten to 160 Nm (118 lbf.ft)
25. Position shock absorbers with mounting rubbers
to axle. Secure with nuts.
Tighten to 45 Nm (33 lbf.ft)
26. Align air springs. Fit securing pins. Fit pin
retaining bolts. Tighten to 20 Nm (15 lbf.ft)
27. Remove plugs from breather hose and
connections. Secure to axle with banjo bolt and
new sealing washers.
28. Connect height sensor links to radius arms.
29. Position propeller shaft to differential flange.
Align marks.
30. Secure propeller shaft with bolts and new nuts.
Tighten to 48 Nm (35 lbf.ft)
31. Position track rod to steering knuckles. Secure
with nuts. Tighten to 50 Nm (37 lbf.ft)
32. Fit anti roll bar. See FRONT SUSPENSION,
Repair.
33. Position panhard rod. Secure with bolt. Tighten
to 200 Nm (148 lbf.ft)
34. Position drag link on steering knuckle. Secure
with nut. Tighten to 50 Nm (37 lbf.ft)
35. Lightly coat ABS sensors with silicone grease.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
36. Fit ABS sensors, new bushes and brake hoses
to steering knuckles.
37. Position caliper assemblies to steering knuckles.
Secure with bolts. Tighten to 220 Nm
(162 lbf.ft)
38. Fit brake pads. See BRAKES, Repair.
39. Replenish axle oil. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
FRONT AXLE AND FINAL DRIVE
MASS DAMPER
FRONT AXLE CASE OIL SEAL
Service repair no - 54.15.10
Service repair no - 54.15.04
Remove
Remove
1. Raise front of vehicle.
As front hub. See FRONT SUSPENSION, Repair.
WARNING: Support on safety stands.
2. Remove 2 bolts securing mass damper to front
axle.
3. Remove front mass damper.
Refit
4. Position mass damper to front axle, fit bolts and
tighten to 45 Nm (33 lbf.ft)
5. Remove stand(s) and lower vehicle.
REPAIR
5
57 - STEERING
CONTENTS
Page
DESCRIPTION AND OPERATION
STEERING SYSTEM ........................................................................................... 1
POWER STEERING SYSTEM OPERATION ....................................................... 3
FAULT DIAGNOSIS
STEERING SYSTEM FAULTS ............................................................................ 1
POWER STEERING SYSTEM - TEST ................................................................ 6
ADJUSTMENT
FRONT WHEEL ALIGNMENT ............................................................................. 1
STEERING BOX CENTRALISATION .................................................................. 1
LOCK STOP ADJUST .......................................................................................... 2
REPAIR
STEERING COLUMN .......................................................................................... 1
STEERING COLUMN INTERMEDIATE SHAFT .................................................. 3
DRAG LINK .......................................................................................................... 4
STEERING DAMPER ........................................................................................... 5
PUMP FEED HOSE ............................................................................................. 5
STEERING BOX FEED HOSE ............................................................................. 6
STEERING BOX RETURN HOSE ....................................................................... 7
COLUMN NACELLE ............................................................................................ 9
OIL RESERVOIR ................................................................................................. 9
POWER STEERING SYSTEM - BLEED ............................................................ 10
STEERING BOX ................................................................................................ 10
POWER STEERING PUMP - V8 - UP TO 99MY ............................................... 12
POWER STEERING PUMP - V8 - FROM 99MY ............................................... 13
POWER STEERING PUMP - DIESEL ............................................................... 14
STEERING WHEEL ........................................................................................... 15
STEERING WHEEL PAD ................................................................................... 17
TRACK ROD ...................................................................................................... 17
STEERING
STEERING SYSTEM
Description
Power steering
The steering system incorporates a safety steering
column, designed to collapse on impact. The tilt and
axial position of the column are adjustable, operated
by a single column mounted control. The range of tilt
and axial adjustment available depends on Model
Year and market.
The power steering system consists of an hydraulic
pump, a power steering box and a fluid reservoir.
The fluid reservoir supplies fluid to the hydraulic
pump. This vane type pump is belt driven from the
front of the engine. Pressurised fluid flows via a
pressure and flow limiting valve to the power steering
box. In the steering box, valve spools operated by
movement of the steering wheel direct fluid pressure
to the appropriate side of the piston to provide power
assistance.
The design of the intermediate steering shaft prevents
a frontal impact moving the upper column towards the
driver. The intermediate shaft has a red indicator clip
fitted which must be inspected at service, and after
the vehicle has been subjected to an impact. If the clip
is not present, or is not fully seated against the clamp
plate, a new assembly must be fitted. The steering
box is connected to the road wheels by the drag link
and track rod. A hydraulic steering damper connected
between the drag link and chassis absorbs shocks in
the steering caused by road wheel deflections when
operating on rough terrain.
Steering column adjustment range
Model year
Up to 97.5
From 97.5
Market
All except Japan and
NAS
Japan
NAS
All except Japan and
NAS
Japan
NAS
Tilt positions
Axial movement,
mm (in)
5
64 (2.5)
3
3
64 (2.5)
64 (2.5)
5
64 (2.5)
5
8
64 (2.5)
34 (1.3)
DESCRIPTION AND OPERATION
1
57
STEERING
Power steering system
1.
2.
3.
4.
5.
6.
7.
2
Steering column
Steering column intermediate shaft
Steering box
Hydraulic pump (pump for V8 up to 99MY shown - other pumps similar)
Oil reservoir
Drop arm
Hydraulic pipes
DESCRIPTION AND OPERATION
NEW RANGE ROVER
STEERING
POWER STEERING SYSTEM OPERATION
ZF recirculating ball power steering gear with ZF vane type pump
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Steering housing
Piston
Sector shaft
Worm
Recirculating balls
Recirculating tube
Radial groove
Radial groove
Input shaft
Torsion bar
Valve spool
12.
13.
14.
15.
16.
17.
18.
19.
Valve spool
Inlet grooves
Inlet grooves
Return grooves
Return grooves
Fluid reservoir
Hydraulic pump
Pressure and flow limiting valve
DESCRIPTION AND OPERATION
3
57
STEERING
NEW RANGE ROVER
20. Hydraulic flow steering wheel turned clockwise
NOTE: The illustrations show a sectional
view of the steering box with a section
through the valve spools directly above to
demonstrate valve spool movement and fluid flow.
Illustration 57M7022 shows steering wheel in the
straight ahead position, valve spools in the neutral
position.
Illustration 57M7023 shows hydraulic flow when
steering wheel is turned clockwise.
The steering housing (1) contains a complete
mechanical steering gear box and the steering control
valve. It also forms the power cylinder.
Steering wheel rotation is converted into axial
movement of the piston (2) by a chain of balls (5)
running in the worm (4). When the worm is rotated,
the balls enter the recirculating tube (6) and pass to
the other end to form an endless chain. The sector
shaft (3), which is at right angles to the piston axis, is
rotated by meshing teeth. The steering drop arm,
fitted to the sector shaft, transmits steering movement
via the steering linkage to the road wheels.
4
DESCRIPTION AND OPERATION
The worm is connected to the input shaft (9) by the
torsion bar (10). The worm head contains two valve
spools (11 and 12), which are at right angles to the
axis of the worm. Two pins on the input shaft engage,
without play, in the valve spools. When the steering
wheel is turned, there is relative rotation between the
input shaft and the worm which is made possible by
the torsion bar. The valve spools follow the movement
of the steering column, when the torsion bar twists the
pistons are moved from the neutral position into their
working position. When the steering wheel is
released, the torsion bar and the valve pistons return
to the neutral position. The force required at the
steering wheel to overcome the torsion bar and
therefore move the valves from the neutral position
provides the driver with good steering feel.
STEERING
Hydraulic fluid flow
Steering limit valve
Fluid from the hydraulic pump (18) flows into an
annular chamber and surrounds the part of the valve
body which houses the two valve spools. When the
valve is in the neutral position, see illustration
57M7022, the fluid flows through the inlet grooves
(13) and (14) to the radial grooves (7) and (8). The
radial grooves are connected via oilways to the right
and left hand cylinder chambers. Fluid also flows back
to the fluid reservoir (17) through the open return
grooves (15) and (16). When the steering wheel is
turned clockwise, see illustration 57M7023, the piston
(2) moves to the right in the power cylinder. At the
same time the valve spools are moved into their
working position. Valve spool (11) moves to the right,
inlet groove (13) is opened. Valve spool (12) moves to
the left, closing inlet groove (14). Pressure fluid now
flows via radial groove (8) to the left hand side of the
cylinder, assisting movement of the steering wheel.
The fluid in the right hand cylinder is pushed out by
the piston, and flows back to the fluid reservoir via
radial groove (7) and return groove (15). When the
steering wheel is turned anti-clockwise the valve
operation is reversed, pressure fluid flowing to the
right hand side of the cylinder.
A steering limit valve is incorporated in the piston
head (2) as a safeguard against overloading the
steering linkage, lock stops and hydraulic pump. This
ball valve is always shut by pressure in the left or right
hand cylinder. However shortly before the piston
reaches full travel in either direction, the valve is
opened by a pin, resulting in pressure drop. Hydraulic
assistance is greatly reduced, and full lock can only
be achieved with increased manual effort by the
driver.
Adjustment
The shape of the sector shaft gearing makes axial
adjustment of the shaft possible. This allows any play
between the two gears, which might occur after a long
period in service, to be eliminated using the sector
shaft adjuster screw.
The quantity of fluid required for the system is
adjusted by the pressure and flow limiting valve (19) in
the PAS pump. The flow limiting valve ensures that
maximum demand for pressure fluid is met regardless
of engine speed.
DESCRIPTION AND OPERATION
5
STEERING
STEERING SYSTEM FAULTS
This section covers possible mechanical and hydraulic
faults that could occur in the steering system
components. Visual checks of components within the
system should be carried out before undertaking
detailed fault diagnosis procedures.
Symptom - Insufficient Power Steering Assistance.
POSSIBLE CAUSE
REMEDY
1. Low fluid level in oil reservoir.
1. Top up reservoir to correct level.
2. Leaking oil from steering
system caused by loose
pipe/hose connections or
worn/damaged steering
components.
2. Tighten all relevant connections or check for visual/damage etc and
renew if necessary.
3. Loose drive belt.
3. Check/renew drive belt tensioner or renew drive belt.
Refer to Drive belt tensioner. See ELECTRICAL, Repair. or
Refer to Alternator drive belt. See ELECTRICAL, Repair.
4. Faulty PAS pump or steering
box.
4. Carry out PAS Test to check hydraulic pressures. If necessary,
renew steering box or pump.
Refer to Power steering box. See Repair. or
Refer to Power steering pump. See Repair.
5. Engine idle speed too low.
5. Refer to TestBook .
Symptom - Excessive Kick Back Through Steering Wheel - When Driven On Rough Terrain.
POSSIBLE CAUSE
REMEDY
1. Worn/damaged steering
damper.
1. Renew steering damper. See Repair.
2. Free play in steering ball joints
and linkage.
2. Check components for wear and renew as necessary. See Repair.
3. Free play in front hub
assembly.
3. Check components for wear and renew as necessary. See FRONT
SUSPENSION, Repair.
4. Worn front suspension
component bushes.
4. Check component bushes for wear and renew as necessary. See
FRONT SUSPENSION, Repair.
FAULT DIAGNOSIS
1
57
STEERING
NEW RANGE ROVER
Symptom - Heavy Steering
POSSIBLE CAUSE
REMEDY
1. Insufficient power assistance
1. Carry out PAS Test to check cause and rectify as necessary.
2. Front tyres under inflated.
2. Inflate tyres to correct pressures. See GENERAL SPECIFICATION
DATA, Information.
3. Incorrect tyres fitted.
3. Fit tyres of correct specification. See GENERAL SPECIFICATION
DATA, Information.
4. Seized steering ball joints and
linkage.
4. Check components for wear and renew as necessary. See Repair.
5. Seized front hub assembly
components.
5. Check components for wear and renew as necessary. See FRONT
SUSPENSION, Repair.
6. Seized or worn steering box
internal components.
6. Check components and renew as necessary. See Repair.
7. Steering column intermediate
shaft universal joint stiff or
seized.
7. Inspect universal joints and lubricate if joints are okay. Renew
intermediate shaft if universal joint is badly seized. See Repair.
8. Steering column bearings
and/or universal joint stiff or
seized.
8. Inspect universal joint and lubricate if joint is okay. If universal joint
is okay this would indicate seized column bearings. Renew steering
column. See Repair.
2
FAULT DIAGNOSIS
STEERING
Symptom - Light Steering or Free Play At Steering Wheel.
POSSIBLE CAUSE
REMEDY
1. Front tyres over inflated.
1. Inflate tyres to correct pressure. See GENERAL SPECIFICATION
DATA, Information.
2. Incorrect tyres fitted.
2. Fit tyres of correct specification. See GENERAL SPECIFICATION
DATA, Information.
3. Worn front suspension
component bushes.
3. Check component bushes for wear and renew as necessary. See
FRONT SUSPENSION, Repair.
4. Excessive free play in steering
linkage.
4. Check steering linkage components and adjust or renew as
necessary See Repair.
5. Excessive free play in swivel
pin.
5. Check swivel pin components and adjust or renew as necessary.
6. Steering box alignment
incorrect causing excessive
back lash.
7. Excessive free play in steering
column intermediate shaft
universal joint.
6. Centralize steering box. See Repair.
8. Excessive free play in steering
column bearings or universal
joint.
8. Renew steering column. See Repair.
7. Check and renew intermediate shaft. See Repair.
Symptom - Steering Vibration, Road Wheel Shimmy - Wobble.
POSSIBLE CAUSE
REMEDY
1. Road wheel/s out of balance.
1. Rebalance road wheel/s.
2. Worn/damaged steering
damper.
2. Renew steering damper. See Repair.
3. Worn PAS components,
mountings and fixings.
3. Check and renew steering components, mountings and fixings as
necessary. See Repair.
4. Worn front suspension
components, mountings and
fixings.
4. Check and renew suspension components, mountings and fixings.
See FRONT SUSPENSION, Repair.
5. Incorrect steering geometry.
5. Carry out full steering geometry check. See Adjustment.
FAULT DIAGNOSIS
3
57
STEERING
NEW RANGE ROVER
Symptom - Steering Stablity and Veer Under Braking.
POSSIBLE CAUSE
REMEDY
1. Unbalanced front tyre
pressures, side to side.
1. Ensure that front tyres are inflated to correct pressure. See
GENERAL SPECIFICATION DATA, Information.
2. Oil contamination of brake
discs and pads.
2. Thoroughly clean brake discs and renew brake pads, in axle sets.
See BRAKES, Repair. Check cause of contamination and rectify
as necessary.
3. Seized front brake caliper
pistons or damaged brake
discs.
3. Renew brake caliper.
Refer to Front caliper. See BRAKES, Repair. or
Refer to Brake disc and shield. See BRAKES, Repair.
Symptom - Steering Veer - General
POSSIBLE CAUSE
REMEDY
1. Front tyre construction
different, side to side
1. Swap front tyres side to side. If vehicle now veers in other direction,
fit new tyres. See GENERAL SPECIFICATION DATA,
Information.
2. Steering box set off centre.
2. Centralize steering box. See Adjustment.
Symptom - Poor Directional Stability
POSSIBLE CAUSE
REMEDY
1. Worn/damaged steering
damper.
1. Renew steering damper. See Repair.
2. Road wheel/s out of balance.
2. Rebalance road wheels.
3. Front or/and rear tyres inflated
to different pressures.
3. Ensure that all tyres are inflated to specified pressures. See
GENERAL SPECIFICATION DATA, Information.
4. Faulty component/s in front
suspension system.
4. Check front suspension components. See FRONT SUSPENSION,
Fault diagnosis.
5. Faulty component/s in rear
suspension system.
5. Check rear suspension components. See REAR SUSPENSION,
Fault diagnosis.
4
FAULT DIAGNOSIS
STEERING
Symptom - Power Steering System - Excessive Noise.
POSSIBLE CAUSE
REMEDY
1. Incorrect fluid level in oil
reservoir.
1. Top up or drain fluid to correct level and bleed PAS system. See
Repair.
2. High pressure hose from
steering pump to box in foul
condition with chassis or body.
2. Check that hose is correctly routed and secured.
3. Excessive lock angle, giving
loud ’hiss’.
3. Adjust steering lock to correct position. See Adjustment.
4. Insufficient lock angle, giving
squeal on full lock.
4. Adjust steering lock to correct position. See Adjustment.
5. Air in the PAS system, giving a
continuous moan.
5. Bleed the PAS system. See Repair.
6. Seized steering pump
bearings.
6. Renew pump. See Repair.
7. Start up noise from PAS in
excessive cold climate.
7. Use optional Cold Climate PAS Fluid.
FAULT DIAGNOSIS
5
57
STEERING
POWER STEERING SYSTEM - TEST
NEW RANGE ROVER
NOTE: The high pressure pipe and hose D,
could be transposed depending on hand
of drive.
Service repair no - 57.90.10/01
7. Fit hose G to adaptor block C.
8. Connect pressure gauge F to test valve E.
Connect hoses D and G to test valve E.
9. Ensure steering system is free from leaks.
Maintain maximum fluid level during test.
Test Procedure
NOTE: If power steering lacks assistance,
check pressure of hydraulic pump before
fitting new components. Use fault finding
chart to assist tracing faults.
A
B
C
D
E
F
G
Steering box
Steering pump
Adaptor block LRT-57-031
Hose LRT-57-031
Test valve LRT-57-001
Pressure gauge LRT-57-005
Hose LRT-57-030
Test Equipment - Assembly
1. Remove nut securing existing high and low
pressure pipes to steering box A.
2. Remove both banjo bolts from steering box.
Collect sealing washers.
3. Release existing pipes beneath radiator to allow
manipulation at steering box.
4. Connect existing low pressure pipe to steering
box. Secure with banjo bolt.
5. Fit hose D to adaptor block C. Fit assembly to
high pressure port of steering box. Secure with
banjo bolt.
6. Connect existing high pressure pipe to adaptor
block. Secure with banjo bolt.
6
FAULT DIAGNOSIS
1. A hydraulic pressure gauge and adaptor is used
to test the power steering system.
2. When testing the system, turn the steering wheel
gradually while reading the pressure gauge.
3. With the test valve open start the engine.
4. With the engine at 1500 rev/min, turn the
steering wheel. Hold on full lock.
5. Repeat pressure check in opposite lock.
6. The test pressure should be between
35 and 75 bar (507 and 1090 lbf/in2), depending
on the road surface. Pressure will drop back to
between 32 and 48 bar (464 and 696 lbf/in2),
when held in full lock.
7. With the engine idling, release the steering
wheel. Pressure should read below 7 bar
(102 lbf/in2).
8. Pressures outside the above tolerances indicate
a fault.
9. To determine if the fault is in the steering box or
steering pump. Close the test valve, for a
maximum of five seconds.
CAUTION: Pump damage will occur if test
valve is closed for longer periods.
10. If the gauge does not register between 100 and
110 bar (1450 and 1595 lnf/in2) (maximum pump
pressure), the pump is faulty.
11. If maximum pump pressure is correct, suspect
the steering box.
12. On completion, remove the test equipment and,
using new sealing washers, connect pipes to
pump with banjo bolts.
M16 bolts: Tighten to 50 Nm (37 lbf.ft).
M14 bolts: Tighten to 30 Nm (22 lbf.ft).
13. Check fluid level. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
14. Bleed power steering system. See Repair.
STEERING
FRONT WHEEL ALIGNMENT
STEERING BOX CENTRALISATION
Service repair no - 57.65.01
Check
NOTE: Markings on steering box and
pinion indicate when steering box is
centralised.
1. Ensure tyre pressures are correct, vehicle is at
kerbside weight and on a level surface.
2. Release handbrake.
3. Roll vehicle backwards and forwards to relieve
stresses in steering/front suspension.
NOTE: Ensure that alignment equipment is
properly calibrated. Take an average of
three readings. Use recommended
equipment only.
4. Check that front wheel alignment is within
tolerance. See GENERAL SPECIFICATION
DATA, Information.
Adjust
5. Slacken track rod adjuster clamping nuts and
bolts.
1. Move backward then forward by at least 2
vehicle lengths to ensure that road wheels are
pointing straight ahead.
2. Check for correct alignment of steering box
markings.
Adjust
3. Slacken drag link adjuster clamp nuts and bolts.
4. Rotate adjuster to align steering box.
6. Rotate adjuster to give correct alignment.
7. Roll vehicle backwards and forwards to relieve
stresses in steering/front suspension.
8. Recheck front wheel alignment, taking average
of three readings.
9. Repeat procedure as necessary to obtain correct
alignment.
CAUTION: Ensure adjuster clamp nuts and
bolts are positioned clear of drop arm.
CAUTION: Ensure that adjuster clamping
nuts and bolts are positioned as shown or
wheel rim foul will result.
10. Tighten track rod adjuster fixings to 8mm, 22Nm
(16 lbf.ft), 10mm, 47Nm, (35 lbf.ft).
ADJUSTMENT
1
57
STEERING
NEW RANGE ROVER
LOCK STOP ADJUST
Service repair no - 57.65.03
Adjust
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Slacken LH lock stop locknut. Screw stop bolt
clockwise, fully into hub.
5. Recheck steering box alignment.
6. Tighten adjuster clamps to 8mm,
22 Nm (16 lbf.ft), 10mm, 47 Nm, (35 lbf.ft).
7. Check steering wheel for correct alignment. If
necessary, remove wheel and centralise. See
Repair.
CAUTION: Repositioning of the steering
wheel on its splines cannot correct small
(less than 5 °) errors in steering wheel
alignment. Always rectify small errors in
alignment by adjusting the drag link as detailed
above, ensuring that steering box centralisation is
maintained.
Road Test
8. Carry out a short road test over an even surface.
Check for correct alignment of steering wheel.
Ensure that vehicle follows a straight track.
3. With assistance, start the engine, turn steering
onto right hand lock until resistance is felt.
NOTE: Resistance is created by hydraulic
limiter inside steering box.
4. With the steering held, unscrew anti-clockwise,
stop bolt until it contacts the axle. Screw bolt
back in clockwise, by 3 flats.
5. Tighten locknut.
6. Return steering to centre. Turn back to full right
hand lock to check adjustment.
NOTE: Resistance should be felt prior to
lock stop operation.
7. Repeat for RH lock stop.
8. Stop engine.
9. Remove safety stands. Lower vehicle.
2
ADJUSTMENT
STEERING
STEERING COLUMN
Service repair no - 57.40.01
WARNING: Under no circumstances must
any form of lubricant be applied to the
steering column. If noise or harshness is
present in the column a new unit must be fitted
Remove
1. Disconnect battery negative lead.
WARNING: If vehicle is fitted with SRS,
disconnect both battery terminals. Always
disconnect negative terminal first.
2. Remove intermediate steering shaft. See this
section.
3. Remove 4 scrivet fasteners securing closing
panel beneath steering column.
7. Remove screws securing wiper switch stalk to
column. Release stalk, remove from multiplug.
8. Disconnect ignition switch, ’key in’ sensor, rotary
coupler and SRS system multiplugs.
4. Release closing panel from fascia. Disconnect
footwell lamp multiplug, remove panel.
5. Remove steering column nacelle. See this
section.
6. Remove screws securing indicator switch stalk
to column. Release stalk, remove from multiplug.
REPAIR
1
57
STEERING
WARNING: The SRS connector beneath
the steering column must be disconnected
prior to removal of the air bag module.
9. Remove 2 clips securing SRS harness to
steering column harness.
10. Release clip securing harness to column.
11. Release illumination bulb from lock barrel.
Release bulb harness from clip.
12. Disconnect multiplug from key inhibit solenoid
(shift interlock).
13. Release duct from drivers blower motor housing,
remove duct from heater unit.
14. Remove 2 bolts securing column to bulkhead.
15. Remove 2 bolts and 2 nuts securing column to
pedal box.
16. Remove steering column assembly.
2
REPAIR
NEW RANGE ROVER
Refit
17. Position steering column assembly and engage
to pedal box studs.
NOTE: Tighten the steering column fixings
in the following sequence.
18. Fit bolts securing steering column to bulkhead.
Tighten to 25 Nm (18 lbf.ft)
19. Fit nuts securing steering column to pedal box.
Tighten to 25 Nm (18 lbf.ft)
20. Fit bolts securing steering column to pedal box.
Tighten to 25 Nm (18 lbf.ft)
21. Fit blower motor duct.
22. Connect column multiplugs. Secure ignition lock
illumination bulb in holder, position bulb harness
in clip.
23. Secure column harness clip to column bracket.
24. Connect SRS multiplug and secure SRS
harness to column harness with clips.
25. Connect wiper switch stalk to multiplug, and
secure stalk to column with Torx fixings.
26. Fit steering column nacelle. See this section.
27. Position closing panel. Connect footwell lamp.
Align and secure closing panel with scrivet
fasteners.
28. Fit intermediate steering shaft. See this
section.
29. Connect battery terminals, positive before
negative. Fit battery cover.
STEERING
STEERING COLUMN INTERMEDIATE SHAFT
Service repair no - 57.40.22
WARNING: The intermediate shaft has a
red indicator clip fitted which must be
inspected at service, and after the vehicle
has been subjected to an impact. If the clip is not
present, or is not fully seated against the clamp
plate, a new assembly must be fitted
Remove
1. Remove bolt securing intermediate shaft
universal joint to steering column.
2. Remove 2 bolts securing universal joint to
intermediate shaft and steering box.
3. Set front road wheels to the straight ahead
position. Remove key from ignition switch.
NOTE: To centralise steering, align the rib
incorporated in the input shaft with two
marks on steering box casing.
WARNING: Do not turn the steering wheel
with intermediate shaft removed. The
rotary coupler may be damaged, leading to
possible malfunction of SRS and steering wheel
mounted switches.
4. Disengage universal joint from steering box by
pushing the universal joint up the splines.
5. Remove intermediate shaft from steering
column.
Refit
WARNING: Clean and inspect splines, if
damaged fit new components.
6. Ensure that steering box is still centralised. Fit
intermediate shaft to steering column and
steering box. Do not use a hammer or other
implement on the intermediate shaft to aid spline
engagement.
WARNING: Ensure that universal joints are
fully engaged. The bolt holes must align
with grooves on steering box and column,
and flat on intermediate column.
7. Fit bolts to universal joints. Tighten to 25 Nm
(18 lbf.ft)
8. Ensure indicator clip is correctly installed. It must
be fully seated against the clamp plate.
REPAIR
3
57
STEERING
DRAG LINK
Service repair no - 57.15.17
Remove
NEW RANGE ROVER
3.
4.
5.
6.
7.
RHD Remove right hand front road wheel.
LHD Remove left hand front road wheel.
Remove nut securing drag link to drop arm.
Remove nut securing drag link to swivel hub.
Break taper joints using LRT-57-018. Remove
drag link.
1. Raise the vehicle.
Disassemble
WARNING: Support on safety stands.
2. Remove nut and bolt securing steering damper
to drag link. Release damper.
8. Slacken nut and bolt securing ball joint clamp.
Unscrew ball joint. Remove clamp.
9. Slacken nut and bolt securing adjuster clamp.
Unscrew adjuster. Remove clamp.
Assemble
10. Loosely fit adjuster clamp and adjuster.
11. Loosely fit ball joint clamp and ball joint.
12. Adjust drag link to nominal length of 1170 mm ±
10mm.
13. Orientate clamps as shown by illustration.
14. Secure clamps with nuts and bolts. Tighten to
8mm, 22 Nm (16 lbf.ft), 10mm, 47 Nm
(35 lbf.ft)
Refit
15. Use steering box centralising feature to
centralise box. Fit drag link.
16. Secure drag link to drop arm and swivel hubs
with nuts. Tighten to 50 Nm (37 lbf.ft)
17. Align damper to drag link. Secure with nut and
bolt, tighten to:Up to 97 MY - 125 Nm (92 lbf.ft)
97 MY on - 50 Nm (37 lbf.ft)
18. Remove safety stands. Lower vehicle.
19. Check front wheel alignment. See Adjustment.
4
REPAIR
STEERING
STEERING DAMPER
PUMP FEED HOSE
Service repair no - 57.55.21
Service repair no - 57.15.20
Remove
Remove
CAUTION: Seal all disconnected pipes and
ports to prevent ingress of dirt.
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove damper fixings at both ends.
1. Disconnect battery earth lead.
2. Remove strap securing coolant top hose to
engine lifting bracket.
3. Release feed hose clips. Remove hose.
Refit
4. Reverse removal procedure.
5. Bleed power steering. See this section.
3. Remove damper.
Refit
4. Fit damper to chassis. Fit, but do not tighten nut
and bolt.
5. Fit damper to drag link, fit nut and bolt, tighten
to:Up to 97 MY - 125 Nm (92 lbf.ft)
97 MY on - 50 Nm (37 lbf.ft)
6. Tighten damper to chassis fixing. Tighten to
125Nm. (92 lbf.ft)
7. Remove safety stands. Lower vehicle.
REPAIR
5
57
STEERING
NEW RANGE ROVER
STEERING BOX FEED HOSE
Service repair no - 57.15.21
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove nut securing PAS hose brackets to
steering box.
4. Release 2 hose brackets from steering box.
5. Position cloth to catch spillage.
6. Remove banjo bolt securing feed hose to
steering box. Remove and discard sealing
washers.
CAUTION: Plug the connections.
V8 from 99MY and diesel: Remove banjo bolt
securing feed hose to pump. Remove and
discard sealing washers.
CAUTION: Plug the connections.
7. Position container to catch spillage.
8. V8 up to 99MY: Loosen union and disconnect
feed hose from PAS pump.
6
REPAIR
9. Release PAS pipe from 2 radiator lower bracket
clips.
10. Remove pump feed hose.
STEERING
Refit
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
STEERING BOX RETURN HOSE
Position feed hose to vehicle.
Remove plugs from hose and PAS pump.
Clean hose and PAS pump union.
V8 up to 99MY: Connect feed hose union to
PAS pump and tighten to 16 Nm (12 lbf.ft).
V8 from 99MY and diesel: Connect feed hose
to pump using new sealing washers. Tighten
banjo bolt to 25 Nm (18 lbf.ft) (V8 models) or 30
Nm (22 lbf.ft) (diesel models).
Remove plugs from hose and steering box.
Clean hose and steering box union.
Position PAS hose brackets to steering box and
secure with nut.
Fit banjo bolt and new washers to feed hose and
fit to steering box. Tighten banjo bolt to 30 Nm
(22 lbf.ft)
Position feed hose and secure to radiator lower
bracket clips.
Bleed steering system. See this section.
Remove stand(s) and lower vehicle.
Service repair no - 57.15.22
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Position container to catch spillage.
4. Remove 2 bolts securing PAS fluid reservoir to
radiator bracket.
5. Remove clip securing return hose to PAS fluid
reservoir and disconnect return hose.
CAUTION: Plug the connections.
6. Position cloth to catch spillage.
REPAIR
7
57
STEERING
NEW RANGE ROVER
Refit
7. Remove banjo bolt securing pump return hose to
steering box and discard 2 washers.
CAUTION: Plug the connections.
8. Remove nut securing PAS hose brackets to
steering box.
9. Release PAS hose brackets from stud.
10. Release PAS pipe from 2 radiator lower bracket
clips.
11. Remove pump return hose.
8
REPAIR
12. Position return hose to vehicle.
13. Remove plugs from hose and PAS fluid
reservoir.
14. Clean hose and PAS pump union.
15. Connect return hose union to PAS fluid reservoir
and secure with clip.
16. Remove plugs from hose and steering box.
17. Clean hose and steering box union.
18. Position PAS hose brackets to steering box and
secure with nut.
19. Fit banjo bolt and NEW washers to return hose
and fit to steering box. Tighten banjo bolt to 50
Nm (37 lbf.ft)
20. Position return hose and secure to radiator lower
bracket clips.
21. Bleed steering system. See this section.
22. Remove stand(s) and lower vehicle.
STEERING
COLUMN NACELLE
OIL RESERVOIR
Service repair no - 57.40.29
Service repair no - 57.15.08.
Remove
Remove
1. Remove ignition key.
2. Remove instrument binnacle. See
INSTRUMENTS, Repair.
3. Release steering column tilt lever, fully extend
and tilt column down.
4. Remove 2 screws securing upper column
nacelle.
5. Release upper column nacelle from side fillet
clips and remove upper nacelle.
6. Remove 4 screws securing lower nacelle,
disengage from side fillet clips and remove
nacelle.
1. Place tray to catch fluid.
CAUTION: Power steering fluid damages
paintwork. Any spillage must be cleaned
immediately.
2. Disconnect battery negative lead.
3. Remove clips securing hoses to reservoir.
Release hoses.
4. Slacken clamp screw securing reservoir.
Remove reservoir.
Refit
7. Collect side fillets.
Refit
8. Position upper and lower nacelles, loosely fit
screws.
9. Position side fillets, engage clips.
10. Tighten nacelle screws.
11. Fit instrument binnacle. See INSTRUMENTS,
Repair.
12. Return steering column to original position.
13. Fit ignition key.
5. Position reservoir. Tighten clamp screw.
6. Connect hoses to reservoir. Secure with new
clips.
7. Fill reservoir. See LUBRICANTS, FLUIDS AND
CAPACITIES, Information.
8. Reconnect battery negative lead.
9. Bleed power steering. See this section.
REPAIR
9
57
STEERING
NEW RANGE ROVER
POWER STEERING SYSTEM - BLEED
STEERING BOX
Service repair no - 57.15.02
Service repair no - 57.30.01
1. Fill reservoir to upper mark on dipstick. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
2. Turn steering wheel 45°in both directions to
open valves inside steering box.
3. Top up steering reservoir fluid level.
CAUTION: Do not run engine with less
than minimum fluid level in reservoir. Top
up as necessary during bleed procedure.
4. Start engine. Allow to idle.
5. Turn steering wheel back and forth to open
valves inside steering box.
Remove
1. Disconnect battery negative lead.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Remove washer reservoir RHD only. See
WIPERS AND WASHERS, Repair.
4. Remove nut connecting drag link to drop arm.
Separate drag link from drop arm with
LRT-57-018.
WARNING: Fluid is under high pressure,
open bleed screw with caution.
6. With engine running, carefully open bleed screw
until fluid starts to flow. Tighten bleed screw to
4 Nm (3 lbf.ft)
7. Switch off engine. Top up reservoir.
CAUTION: To prevent damage to rotary
coupler, remove key from ignition switch.
Engage steering lock.
5. Remove bolts securing steering column lower
universal joint to steering box.
10
REPAIR
STEERING
Refit
10. Position steering box on chassis. Secure with
nuts and bolts. Tighten to 125 Nm (92 lbf.ft)
11. Remove plugs from pipes and connections.
12. Using new sealing washers, connect fluid pipes,
tighten banjo bolts to:
M16 - 50 Nm (37 lbf.ft)
M14 - 30 Nm (22 lbf.ft)
13. Ensure steering box is centralized and steering
wheel is in straight ahead position.
14. Engage steering column universal joint with
steering box pinion. Secure with bolts. Tighten
to 25 Nm (18 lbf.ft)
WARNING: Ensure universal joint is fully
engaged with pinion and lower securing
bolt interlocks with groove in pinion.
6. Slide universal joint up column to clear box
pinion. Release steering column.
7. Disconnect power steering pipes from steering
box. Collect sealing washers and discard.
15. Position drag link on drop arm. Secure with nut.
Tighten to 50 Nm (37 lbf.ft)
16. Fit washer reservoir. See WIPERS AND
WASHERS, Repair.
17. Remove safety stands. Lower vehicle.
18. Reconnect battery negative lead.
19. Fill power steering reservoir. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
20. Bleed power steering. See this section.
8. Plug pipes and connections.
9. Remove 4 nuts and bolts securing steering box.
Remove steering box.
REPAIR
11
57
STEERING
POWER STEERING PUMP - V8 - UP TO 99MY
Service repair no - 57.20.14
Remove
NEW RANGE ROVER
7. Remove 3 bolts securing mounting plate to
pump. Remove plate.
8. Remove pump assembly.
9. Remove 2 screws securing engine lifting bracket
to pump.
CAUTION: Seal all disconnected pipes and
ports to prevent ingress of dirt.
1. Remove alternator drive belt. See
ELECTRICAL, Repair.
2. Remove 3 bolts securing pump pulley. Remove
pulley.
Refit
3. Position container to catch fluid.
4. Release clip securing return hose to pump.
Release hose.
5. Disconnect high pressure pipe union from pump.
6. Remove 4 bolts securing pump and compressor
mounting bracket to engine.
12
REPAIR
10. Ensure mating faces are clean.
11. Position lifting bracket to pump. Secure with
screws. Tighten to 18 Nm (13 lbf.ft)
12. Position mounting plate to pump. Loosely fit
bolts.
13. Align pump assembly and compressor mounting
bracket to engine. Secure with bolts. Tighten to
40 Nm (30 lbf.ft)
14. Tighten pump to mounting bolts to 18 Nm
(13 lbf.ft)
15. Connect high pressure pipe to pump. Tighten to
16 Nm (12 lbf.ft)
16. Position return hose to pump. Secure with clip.
17. Position pulley to pump. Secure with bolts.
Tighten to 25 Nm (18 lbf.ft)
18. Secure coolant hose to lifting bracket.
19. Fit drive belt. See ELECTRICAL, Repair.
20. Reconnect battery negative lead.
21. Bleed power steering system. See this section.
STEERING
POWER STEERING PUMP - V8 - FROM 99MY
Service repair no - 57.20.14
Remove
CAUTION: Seal all disconnected pipes and
ports to prevent ingress of dirt.
1. Remove alternator drive belt. See
ELECTRICAL, Repair.
2. Position suitable container below vehicle to
catch oil spillage.
Refit
7. Clean pump and mounting bracket mating faces,
dowel and dowel holes.
8. Fit pump to mounting bracket and tighten bolts to
25 Nm (18 lbf.ft).
9. Connect feed hose to pump and secure with
new clip.
10. Clean high pressure pipe and banjo bolt.
11. Connect high pressure pipe to pump using new
sealing washers. Tighten banjo bolt to 25 Nm
(18 lbf.ft).
12. Fit alternator drive belt. See ELECTRICAL,
Repair.
13. Bleed power steering system. See this section.
3. Remove banjo bolt securing high pressure pipe
to pump. Remove and discard sealing washers.
4. Remove and discard clip securing feed hose to
pump and disconnect hose.
5. Plug open connections on pump, high pressure
pipe and feed hose.
6. Remove 2 bolts securing pump to mounting
bracket and remove pump.
REPAIR
13
57
STEERING
NEW RANGE ROVER
POWER STEERING PUMP - DIESEL
Service repair no - 57.20.15
Remove
1.
2.
3.
4.
Raise vehicle on four post lift.
Disconnect battery negative lead.
Raise lift.
Slacken 3 bolts securing pulley to steering
pump. Do not remove bolts.
6. Remove pulley bolts. Collect pulley.
7. Position container beneath power steering pump
to catch spillage.
8. Remove 4 bolts securing steering pump.
Release pump from bracket.
5. Release alternator belt tension using a suitable
lever beneath tensioner damper as shown.
Release drive belt from steering pump pulley.
9. Disconnect low pressure hose from pump.
10. Remove banjo bolt securing high pressure pipe
to pump. Discard sealing washers.
14
REPAIR
STEERING
STEERING WHEEL
Service repair no - 57.60.01
Remove
1. Remove steering wheel pad. See this section.
2. Vehicles with SRS: Remove drivers air bag
module. See SUPPLEMENTARY RESTRAINT
SYSTEM, Repair.
3. Disconnect steering wheel switch multiplug.
4. Release harnesses from clip.
11. Remove steering pump. Plug all hoses and
connections.
Refit
12. Remove plugs from hoses and connections.
13. Using new sealing washers, secure high
pressure pipe to steering pump with banjo bolt.
Tighten to 30 Nm (22 lbf.ft)
14. Connect low pressure hose to pump. Secure
with new clip.
15. Position steering pump on bracket. Secure with
bolts.
16. Position pulley on steering pump. Fit bolts, finger
tight.
17. Lever tensioner pulley to slack position. Engage
belt over power steering pump pulley.
18. Tighten steering pump pulley bolts.
19. Lower lift.
20. Reconnect battery negative lead.
21. Fill power steering reservoir. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
22. Bleed steering system. See this section.
5. Remove bolt securing steering wheel to column.
6. Remove steering wheel.
CAUTION: Ensure that air bag module and
steering wheel switch harnesses are
released during steering wheel removal.
REPAIR
15
57
STEERING
Disassemble
7. Remove 2 screws securing multiplug to horn
unit.
NEW RANGE ROVER
Assemble
10. Position switch pack assembly. Engage switches
to steering wheel.
CAUTION: Ensure switches are correctly
engaged.
11. Secure multiplug and printed circuit with screws.
Refit
12. Route harnesses through steering wheel
aperture.
13. Position steering wheel. Secure with bolt.
Tighten to 33 Nm (24 lbf.ft)
14. Connect steering wheel switch multiplug.
15. Secure harnesses in clip.
16. Fit steering wheel pad. See this section.
17. Vehicles with SRS: Fit drivers air bag module.
See SUPPLEMENTARY RESTRAINT SYSTEM,
Repair.
8. Remove 3 screws securing printed circuit to horn
unit.
WARNING: Take great care when removing
the 3 screws securing the printed circuit to
horn unit. The screws are non replaceable
and other fixings must not be used. If the screws
are damaged during removal, the steering wheel
must be renewed.
9. Lift 2 clips securing each switch pack. Remove
switch packs and printed circuit assembly.
16
REPAIR
STEERING
STEERING WHEEL PAD
TRACK ROD
Service repair no - 57.60.03
Service repair no - 57.55.09
NOTE: For vehicles fitted with
supplementary restraint system (SRS).
See SUPPLEMENTARY RESTRAINT
SYSTEM, Repair.
Remove
1. Raise the vehicle.
WARNING: Support on safety stands.
Remove
1. Position steering wheel for access to all fixings.
2. Unscrew 4 bolts securing pad to steering wheel.
2. Remove front wheels.
3. Remove 2 nuts securing track rod ball joints to
steering knuckles. Release taper joints. Remove
track rod.
NOTE: Bolts remain captive in steering
wheel.
3. Remove steering wheel pad.
Refit
4. Position pad to steering wheel. Secure with
bolts. Tighten to 8 Nm (6 lbf.ft)
REPAIR
17
57
STEERING
Disassemble
4. Slacken nuts and bolts clamping ball joints and
adjuster.
5. Remove ball joints, adjuster and clamps.
Assemble
6. Position ball joints, adjuster and clamps on track
rod.
7. Screw adjuster and ball joints in to full extent of
threads.
8. Using adjuster, set track rod to nominal length of
1340 mm ± 10mm.
9. Secure clamps with nuts and bolts.
Refit
10. Position track rod on steering knuckles. Secure
with nuts. Tighten to 50 Nm (37 lbf.ft)
11. Fit front wheels. Tighten to 108 Nm (80 lbf.ft)
12. Remove safety stands. Lower vehicle.
13. Set front wheel alignment. See Adjustment.
18
REPAIR
NEW RANGE ROVER
60 - FRONT SUSPENSION
CONTENTS
Page
ELECTRONIC AIR SUSPENSION
DESCRIPTION AND OPERATION
ELECTRONIC AIR SUSPENSION - EAS ............................................................
LOCATION OF COMPONENTS ..........................................................................
DESCRIPTION OF COMPONENTS ....................................................................
DRIVER CONTROLS ...........................................................................................
HEIGHT SETTINGS .............................................................................................
VEHICLE TRANSPORTATION ............................................................................
ELECTRICAL TROUBLESHOOTING ..................................................................
SYSTEM OPERATION ........................................................................................
FRONT SUSPENSION ........................................................................................
1
2
3
4
5
6
6
7
8
FAULT DIAGNOSIS
FRONT SUSPENSION FAULTS .......................................................................... 1
REPAIR
UNDERBODY WAX ............................................................................................. 1
DEPRESSURISE SYSTEM ................................................................................. 1
SYSTEM CALIBRATION ...................................................................................... 1
AIR SPRINGS/HEIGHT SENSORS - INSPECT .................................................. 2
AIR HARNESS INSPECT .................................................................................... 2
LEAK TEST PROCEDURE .................................................................................. 2
SUSPENSION COMPONENTS ........................................................................... 2
DISCONNECT AND CONNECT AIR PIPES ........................................................ 3
AIR PIPE CONNECTION COLLET AND ’O’ RINGS ............................................ 4
AIR COMPRESSOR ............................................................................................ 5
AIR RESERVOIR ................................................................................................. 6
AIR SPRING ......................................................................................................... 6
ANTI-ROLL BAR AND BUSHES .......................................................................... 8
BUMP STOP ........................................................................................................ 9
COMPRESSOR INLET FILTER ........................................................................... 9
DELAY TIMER UNIT .......................................................................................... 10
AIR DRIER ......................................................................................................... 10
ELECTRONIC CONTROL UNIT (ECU) ............................................................. 11
HEIGHT SENSOR .............................................................................................. 12
HEIGHT SENSOR - 97 MY ON .......................................................................... 13
DRIVE SHAFT AND HUB ASSEMBLY .............................................................. 14
ANTI-ROLL BAR LINK ....................................................................................... 16
PANHARD ROD AND BUSHES ........................................................................ 16
RADIUS ARM AND BUSHES ............................................................................ 17
SHOCK ABSORBER .......................................................................................... 18
60 - FRONT SUSPENSION
CONTENTS
Page
SWIVEL HUB .....................................................................................................
SWIVEL HUB - CHECK/ADJUST ......................................................................
BALL JOINT - UPPER .......................................................................................
BALL JOINT - LOWER .......................................................................................
SOLENOID VALVE BLOCK AND DRIVE PACK ................................................
SOLENOID COIL ...............................................................................................
19
21
22
23
24
26
ELECTRONIC AIR SUSPENSION
ELECTRONIC AIR SUSPENSION - EAS
Description
Self levelling
The Range Rover concept of air suspension is already
well established, the system fitted to the New Range
Rover is broadly similar. Progressive development
has resulted in added features to improve the control
and operation of the system.
Air springs provide a soft and comfortable feel to the
ride of the vehicle. The use of a microprocessor to
control the system exploits the advantages of air
suspension.
The system provides a near constant ride frequency
under all load conditions resulting in:
On a coil sprung vehicle the effect of adding weight is
for the vehicle to lean either from front to back or side
to side unless the increased weight is evenly spread.
With air suspension, the system detects this body lean
and automatically compensates for it. The vehicle will
self level to the lowest corner height for 20 seconds
each time the driver exits vehicle and closes the
doors.
The system will check vehicle height every 6 hours
and make minor corrections, not exceeding 8 mm,
(0.31 in) as necessary.
When unloading through the tailgate the system will
self level to compensate for the decreased load after
door closure.
•
Improved ride quality
•
Consistency of ride quality
•
Constant ride height
•
Improved headlamp levelling
The system provides five ride height settings plus self
levelling. Each setting is automatically maintained at
the correct height by the system logic with the
minimum of driver involvement. Vehicle height is
sensed by four rotary potentiometer type height
sensors. Height information from each sensor signals
the electronic control unit (ECU) to adjust each air
spring by switching the solenoid valves to hold, add or
release air.
The five height settings are as follows:
NOTE: If the vehicle is parked on uneven
ground or with a wheel or wheels on the
kerb, self levelling will lower the vehicle to
the lowest spring height.
CAUTION: The underside of the vehicle
must be kept clear of any obstacles while
the vehicle is parked, as self levelling may
result in a reduced trim height.
WARNING: Before commencing work
which requires access to the underside or
wheel arches of the vehicle, the
suspension must be allowed to relevel.
Relevelling is achieved by opening and closing of
any of the side doors, while all other doors and
tail gate remain closed, and the ignition off.
Standard: Profile
Low profile: 25 mm (1 in.) below standard.
Access: 65 mm (2.6 in.) below standard. Crawl: It is
possible to drive at the access ride height at speeds
less than 32 km/h (20 mph), where headroom is
restricted.
EAS must be set in ’high-lock’ using TestBook,
during any work which does not require chassis
to axle displacement. This will hold the
suspension in extended profile position, until
reset by TestBook.
High profile: 40 mm (1.6 in.) above standard.
Extended profile: 70 mm (2.75 in.) above standard.
This setting is not manually selectable.
DESCRIPTION AND OPERATION
1
60
FRONT SUSPENSION
NEW RANGE ROVER
LOCATION OF COMPONENTS
Key to location of components
1.
2.
3.
4.
5.
6.
2
Electrical control unit
Compressor
Air dryer
Valve block
Reservoir
Height sensors front
DESCRIPTION AND OPERATION
7.
8.
9.
10.
11.
Height sensors rear
Front air spring
Rear air spring
Relays, fuses
Driver controls
ELECTRONIC AIR SUSPENSION
DESCRIPTION OF COMPONENTS
Valve block
Electrical Control Unit - ECU
The valve block controls the direction of air flow. Air
flow to and from the air springs is controlled by seven
solenoid operated valves, one for each spring plus an
inlet, exhaust and outlet. In response to signals from
the ECU, the valves allow high pressure air to flow in
or out of the air springs according to the need to
increase or decrease pressure. A diaphragm valve
operated by the solenoid outlet valve ensures that all
exhausted air passes through the air dryer.
The ECU is located underneath the front left hand
seat. The ECU maintains the requested vehicle ride
height by adjusting the volume in each air spring. It is
connected to the cable assembly by a 35 way
connector. To ensure safe operation the ECU has
extensive on board diagnostic and safety features.
The ECU must be replaced in case of failure.
Air compressor
NOTE: The air compressor and valve block
are contained in the under bonnet unit
mounted on the left hand inner wing.
The air compressor provides system pressure. A
thermal switch is incorporated which cuts out
compressor operation at 120°C. An air filter is fitted to
the compressor head. The filter is renewed every
40,000 kms (24,000 miles), or every 30,000 miles in
NAS markets.
Mounted on the valve block is a pressure switch which
senses air pressure and signals the ECU to operate
the compressor when required.The compressor will
operate when the pressure falls between 7.2 and 8.0
bar (104 and 116 lbf/in2). It will cut out at a rising
pressure of between 9.5 and 10.5 bar (138 and 152
lbf/in2).
The valve block contains the following serviceable
components: solenoid coils 1 to 6, drive pack and
pressure switch.
The valve block must only be dismantled after the
correct diagnosis procedure.
Air dryer
Reservoir
The air dryer is connected into the air line between the
compressor and reservoir. It is mounted on the engine
air cleaner box. The dryer removes moisture from
pressurised air entering the system. All air exhausted
from the system passes through the dryer in the
opposite direction. The air dryer is regenerative in that
exhaust air absorbs moisture in the dryer and expels it
to atmosphere.
The air dryer is non-serviceable, designed to last the
life of the vehicle. However, if any water is found in
the system, the air dryer must be replaced.
CAUTION: If the air dryer is removed from
the vehicle the ports must be plugged to
prevent moisture ingress.
The 10 litre reservoir is mounted on the right hand
side of the chassis. One connection acts as air inlet
and outlet for the rest of the system. The reservoir
stores compressed air between set pressure levels.
The reservoir drain plug requires removing to check
for moisture in the system every 40,000 kms. (24,000
miles), or every 30,000 miles in NAS markets.
Height sensors
Four potentiometer type height sensors signal vehicle
height information to the ECU. The potentiometers are
mounted on the chassis and activated by links to the
front radius arms and rear trailing links. A height
sensor must be replaced in case of failure, and the
vehicle recalibrated using TestBook.
DESCRIPTION AND OPERATION
3
60
FRONT SUSPENSION
NEW RANGE ROVER
Air springs - front and rear
DRIVER CONTROLS
The air springs consist of the following components:
The driver controls are located in the centre of the
fascia. The controls consist of:
1. Top plate
2. Rolling rubber diaphragm
3. Piston
Front and rear air springs are of similar construction
but are NOT interchangeable. The diaphragm is not
repairable, if failure occurs the complete air spring
must be replaced
Driver controls
Mounted in the centre of the dashboard, the driver
controls consist of an UP/DOWN switch, an INHIBIT
switch and a height setting indicator. For full
description. See this section.
Relays, fuses
Located in the under bonnet fuse/relay box are 2
relays, plus 10, 20 and 30 amp fuses.
1. The HEIGHT CONTROL is a press and release
type rocker switch which is used to select the
required ride height. The vehicle will not respond
until switch is released. All movements selected
by operation of this switch are indicated by the
ride height indicator lights located next to the
switch.
2. The INHIBIT switch is a mechanically latching
switch. When selected it modifies the automatic
height changes of the system, for further details.
See Electrical Trouble Shooting Manual.
Selection of ’inhibit’ is indicated by illumination of
the switch tell-tale lamp, which is also bulb
tested with the ride height indicator.
3. High indicator light.
4. Standard indicator light.
5. Low indicator light.
6. Access indicator light.
7. Instrument pack warning light.
Indicator lights
When the ignition key is turned to position 2 all four
indicator lights, the air suspension warning light and
the inhibit switch will be illuminated continuously.
When the engine is started, the lights will remain
illuminated for 2 seconds, after which the current ride
height will be indicated. Two indicators will be
illuminated if the vehicle is between ride heights, with
the selected height flashing. When the new height is
achieved the indicator will be illuminated constantly
and the previous height indicator extinguished. The
inhibit switch indicator is illuminated while it is
activated. Both switches are illuminated with sidelights
switched on. Additional driver information is given by
the message centre in the instrument pack. For details
of the messages. See this section.
Air suspension warning lamp
This amber lamp is located in the instrument pack.
The lamp will be constantly illuminated when driving at
high ride height and will flash when vehicle is at
extended height. The lamp will also illuminate if a fault
within the system is detected. A bulb check is
provided when the ignition switch is turned to position
2 and for 2 seconds after vehicle start.
4
DESCRIPTION AND OPERATION
ELECTRONIC AIR SUSPENSION
HEIGHT SETTINGS
It is possible to select access up to 40 seconds after
switching engine off.
Standard ride height
With the Inhibit switch off (unlatched), at speeds
below 80 km/h (50 mph) the standard ride height
indicator will be illuminated.
Standard vehicle ride height is maintained under all
load conditions. This also maintains headlamp
levelling.
Low ride height
Low ride height is automatically selected when the
vehicle speed exceeds 80 km/h (50 mph) for at least
30 seconds with the inhibit switch off. Low ride height
indicator lamp will flash during height change and
standard ride height indicator will extinguish when low
ride height is attained.
NOTE: Opening a door or tailgate will
immediately stop vehicle height change.
When the door is closed, the height
change will be completed. If the door is open for
more than thirty seconds, the system will need
’reminding’ of the new height when the door is
closed.
Driving the vehicle will result in vehicle rising
automatically to standard ride height. Alternatively
standard ride height can be achieved by closing all
doors, starting engine and pressing the up switch. The
standard indicator will flash during the change. When
standard ride height is attained the indicator will
remain constantly illuminated and access indicator will
be extinguished.
Crawl mode
Standard ride height is automatically selected when
the vehicle speed drops below 56 km/h (35 mph) for
at least 30 seconds with the inhibit switch off.
The driver can select low ride height at any speed.
With the vehicle at low ride height, depressing the
inhibit switch (latched) will result in the vehicle
maintaining low ride height regardless of speed.
The height control switch can be used to change
between low and standard ride heights regardless of
speed.
In areas where height is restricted, the vehicle may be
driven in access mode. To achieve this, ensure the
inhibit switch is unlatched and select access mode.
When access height is achieved, press the inhibit
switch, the lamp will be illuminated. The message
centre in the instrument binnacle will beep three times
and display EAS MANUAL. The vehicle may now be
driven at speeds up to 32 km/h (20 mph).
If the vehicle is accelerated to 16 km/h (10 mph) the
message centre will beep three times and display
SLOW 20 MPH (32 KM/H) MAX.
Access mode
This position eases access to and from the vehicle.
With the vehicle stationary, doors and tailgate closed,
park brake applied, foot brake released and gearshift
in ’Park’ on automatic vehicles, press and release the
down switch. The vehicle will descend to access
mode. While the vehicle is descending, the access
indicator will flash. When access mode is attained, the
indicator will remain constantly illuminated, and
standard ride height lamp will be extinguished.
If speed exceeds 40 km/h (25 mph) the vehicle will
rise to low profile, with low warning flashing. On
slowing to 32 km/h (20 mph) the vehicle will lower to
access mode with access warning illuminated.
When speed falls below 8 km/h (5 mph) the message
centre will beep three times and display EAS
MANUAL.
To cancel crawl mode, release the inhibit switch or
depress the up switch.
Access mode can be selected up to 40 seconds
before stopping vehicle. On stopping, applying the
handbrake, releasing the foot brake and selecting
’Park’ on automatic vehicles, the vehicle will lower to
access mode.
DESCRIPTION AND OPERATION
5
60
FRONT SUSPENSION
NEW RANGE ROVER
High ride height
VEHICLE TRANSPORTATION
This position is used to improve approach and
departure angles and when wading. When at standard
ride height, pressing the up switch will select high ride
height provided the road speed is below 56 km/h (35
mph). The high ride height indicator will flash during
the height change. When the change is complete the
indicator will remain constantly illuminated, and
standard ride height indicator will be extinguished.
The indicator in the instrument pack will also be
illuminated. If speed exceeds 56 km/h (35 mph), the
vehicle will return to standard profile.
New vehicles are transported from the factory with the
EAS system electronically ’frozen’ in access mode.
When road speed exceeds 40 km/h (25 mph), the
vehicle will rise to low ride height. It will return to
access mode if speed falls below 38.4 km/h (24 mph).
This condition is cancelled at pre-delivery inspection,
by entering the appropriate command via TestBook.
Extended ride height
This position is achieved if chassis is grounded
leaving wheel or wheels unsupported. Initial ECU
reaction is to lower (deflate) affected springs. After a
timed period the ECU detects no height change, it
therefore reinflates springs to extended profile in an
attempt to regain traction. The position will be held for
10 minutes, after which time the vehicle will
automatically return to standard ride height.
Vehicle transportation/recovery
CAUTION: When an air suspension vehicle
is secured to a transporter using the
chassis lashing eyes, there is a possibility
due to air leakage, self levelling or operation of
ride height controls that the tension of the
securing straps will be lost. To prevent this the
ride height should be set to access mode before
securing to transporter.
If the engine cannot be run and the vehicle is not in
access mode, the vehicle can be transported, but it
must be secured to the transporter by the roadwheels,
not the chassis.
Pressing the down switch will lower vehicle 20 mm to
high profile.
If vehicle speed exceeds 56 km/h (35 mph) the
vehicle will immediately lower to standard ride height.
This speed could be achieved, for example, by
wheelspin.
6
DESCRIPTION AND OPERATION
ELECTRICAL TROUBLESHOOTING
For electrical details of the air suspension circuit. See
Electrical Trouble Shooting Manual.
ELECTRONIC AIR SUSPENSION
SYSTEM OPERATION
Numbers refer to pneumatic circuit diagram
Air is drawn through the inlet filter (1) to the
compressor (2), where it is compressed to 10 ± 0,5
bar (145 ± 7.25 lbf/in2).
Compressed air passes to the air dryer (3) where
moisture is removed as it flows through the dryer
dessicant. The dessicant in the lower portion of the
dryer becomes wet.
Dried air passes through a non-return valve NRV1 to
the reservoir (4).
The 3 non-return valves (6) ensure correct air flow.
They also prevent loss of spring pressure if total loss
of reservoir pressure occurs.
For air to be admitted to an air spring (10), the inlet
valve (7) must be energised together with the relevant
air spring solenoid valve (9).
For air to be exhausted from an air spring, the exhaust
valve (8) must be energised together with the relevant
air spring solenoid valve.
The solenoid diaphragm valve (12) ensures that all air
exhausted to atmosphere passses through the dryer.
Exhausted air passes vertically downwards through
the dryer. This action purges moisture from the
dessicant and regenerates the air dryer.
Air is finally exhausted through the system air
operated diaphragm valve (13) and to atmosphere
through a silencer (14) mounted below the valve
block.
The pressure switch (5) maintains system pressure
between set limits by switching on and off the
compressor via an ECU controlled relay.
DESCRIPTION AND OPERATION
7
60
FRONT SUSPENSION
NEW RANGE ROVER
FRONT SUSPENSION
Description
The front suspension design on the New Range Rover
allows maximum wheel travel and axle articulation,
providing good ground clearance without loss of
traction or directional stability.
Front axle suspension
1.
2.
3.
4.
5.
6.
7.
8
Radius arms
Panhard rod
Shock absorbers
Bump stops
Anti-roll bar
Air springs
Front axle
DESCRIPTION AND OPERATION
Near constant ride frequency under all load conditions
is achieved by utilizing advancements in suspension
geometry complemented to control and operation of
the air suspension system. See this section.
ELECTRONIC AIR SUSPENSION
Long front radius arms (1) are fitted to the front axle
(7) and provide maximum axle articulation which is
vital for off road performance. The radius arm,
comprising a forged steel link with twin front
mountings using ferrule rubber bushes, is secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arm to a mounting on
the chassis cross member as shown in 60M7040. The
vehicle height sensors are also linked to the front
radius arms; for full details of the height settings. See
this section.
A panhard rod (2), which ensures that the axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations. An anti-roll bar (5) is fitted to
the front axle to control body roll and directional
stability. Two rubber bearing bushes, with retaining
straps, secure the anti-roll bar to the front axle, while
ball jointed links, suspended from the chassis, support
the rear of the anti-roll bar.
Conventional telescopic shock absorbers (3), used to
control body movement, are secured to fabricated
towers which are welded to the chassis. The upper
fixing uses a single retaining bolt passing through a
flexible rubber bush. The lower fixing of the shock
absorber comprises of a stem type mounting with two
flexible rubber bushes and support washers secured
to an axle mounting by a single retaining nut. Cellular
foam bump stops (4) are fitted under the chassis
adjacent to the air springs (6) and prevent possible
damage that could occur should there be excessive
axle to chassis movement. Should there be a loss of
air pressure in the air springs the vehicle can still be
driven safely at a speed not exceeding 35 mph (56
km/h) with the bump stops resting on the axle,
although this will result in a hard ride. The loss of air
pressure should be investigated as soon as possible.
The bump stops are ’progressive’ and will reform from
a compressed state when the load is released.
DESCRIPTION AND OPERATION
9
ELECTRONIC AIR SUSPENSION
FRONT SUSPENSION FAULTS
This section covers possible mechanical, fuse and
relay faults that could occur in the front suspension
system, including air suspension components.
Visual checks of components within the system and
relevant fuses and relays should be carried out before
undertaking detailed fault diagnosis procedures, which
are covered on TestBook .
Symptom - Hard Ride.
POSSIBLE CAUSE
REMEDY
1. Seized or inoperable front
shock absorber/s.
1. Renew shock absorber. See Repair.
2. Loss of air pressure in the air
system resulting in the chassis
bump stops resting on the front
and rear axles.
2. Check air system components for faults and air harness for leaks
etc. See Repair.
Rectify or renew components where necessary.
3. Contaminated or fouled
suspension components with
off road debris.
3. Remove/clean off debris and check for damage. Renew
components where necessary.
4. Incorrect ride height calibration.
4. Re-calibrate air suspension system. Refer to TestBook .
Symptom - Vehicle Suspension Permanently In ’Standard Height’ Mode.
POSSIBLE CAUSE
REMEDY
1. Height sensor/s inoperative
due to loose or disconnected
multi-plug.
1. Reconnect multi-plug.
2. Height sensor linkage
disconnected or damaged.
2. Reconnect or renew sensor linkage.
3. Faulty height sensor/s.
3. Renew height sensor/s. See Repair.
4. Leaking air supply to air
spring/s.
4. Check air harness connections and pipes for damage or scoring.
5. Faulty/leaking air spring
diaphragm.
5. Renew air spring assembly. See Repair.
6. Faulty ABS speed sensor in
ECU.
6. Refer to TestBook .
7. Faulty pressure switch.
7. Refer to TestBook .
FAULT DIAGNOSIS
1
60
FRONT SUSPENSION
NEW RANGE ROVER
Symptom - Excessive Body Roll At Front Of Vehicle.
POSSIBLE CAUSE
REMEDY
1. Anti-roll bar damaged or
broken.
1. Renew anti-roll bar. See Repair.
2. Worn anti-roll bar axle
mounting rubbers.
2. Renew mounting rubbers. See Repair.
3. Worn or broken anti-roll bar link
ball joints.
3. Renew link assembly. See Repair.
4. Loose anti-roll bar chassis and
axle fixings.
4. Check and tighten all relevant fixings.
5. Worn or leaking shock
absorber/s.
5. Renew shock absorber/s. See Repair.
6. Worn radius arm axle mounting
bushes.
6. Renew radius arm bushes. See Repair.
7. Loose radius arm fixings.
7. Check and tighten all relevant fixings.
8. Worn radius arm chassis
mounting bushes.
8. Renew radius arm bushes. See Repair.
9. Deflated air spring.
9. Check air system components for faults and air harness for leaks
etc. See Repair.
Rectify or renew components where necessary.
10. Faulty valve block.
10. Refer to TestBook .
11. Damaged or broken chassis or
axle mounting brackets.
11. Vehicle should be recovered and not driven.
12. Failed or loose body mountings
giving excessive body
movement to chassis.
12. Tighten fixings or renew rubber body mountings if failed.
Symptom - Suspension Knock.
POSSIBLE CAUSE
REMEDY
1. Loose or worn suspension
component mountings and
fixings.
1. Check, tighten or renew relevant components and fixings.
2. Missing bump stop/s.
2. Fit new bump stop/s. See Repair.
2
FAULT DIAGNOSIS
ELECTRONIC AIR SUSPENSION
Symptom - Air Suspension System Faulty Or Inoperative.
POSSIBLE CAUSE
REMEDY
1. Blown air suspension system
fuse.
1. Check and renew fuse F44.
2. Blown fuse covering dashboard
’height control’ or ’inhibit’
switch.
2. Check and renew fuse F17.
3. Faulty ’height control’ switch;
could result in vehicle height
remaining at last setting until
ignition switched off.
3. Refer to TestBook to confirm fault and renew ’height control’
switch. See ELECTRICAL, Repair.
4. Faulty ’inhibit’ switch; could
result in vehicle not operating
automatically between
standard and low modes.
4. Refer to TestBook to confirm fault and renew ’inhibit’ switch. See
ELECTRICAL, Repair.
5. Compressor inoperative; no air
pressure due to loose or
disconnected multi-plug.
5. Check and reconnect compressor multi-plug.
6. Blown compressor maxi fuse.
6. Check and renew maxi fuse 2.
7. Faulty compressor relay,
resulting in compressor running
continuously.
7. Renew relay RL20.
8. Loss of air pressure in the air
system.
8. Check air system components for faults and air harness for leaks.
See Repair.
9. Faulty delay relay. If the delay
relay fails with a closed circuit
the system will be powered,
resulting in a flat battery.
9. Renew relay AMR3284.
Symptom - Vehicle Leaning Side To Side Or Front To Rear With Air Suspension System Operative.
POSSIBLE CAUSE
REMEDY
1. Faulty height sensor.
1. Refer to TestBook to locate faulty height sensor. Renew height
sensor and re-calibrate air suspension system. Refer to TestBook .
2. Incorrect height sensor
calibration.
2. Re-calibrate air suspension system. Refer to TestBook .
NOTE: Critical warning messages relating to the air suspension system are displayed on the
message centre, should a fault occur.
FAULT DIAGNOSIS
3
ELECTRONIC AIR SUSPENSION
UNDERBODY WAX
CAUTION: Ensure all under body wax is
removed from mating surfaces of fixings
before fitting.
DEPRESSURISE SYSTEM
Service repair no - 60.50.38
Equipment required: TestBook
Depressurise
WARNING: Air suspension is pressurised
up to 10 bar (150 lbf/in2). Dirt or grease
must not enter the system. Wear hand, ear
and eye safety standard protection when servicing
system.
SYSTEM CALIBRATION
Equipment required: TestBook
NOTE: This procedure must be carried out
when a new ECU or height sensor has
been fitted.
Calibration will also be required if any part affecting
damper relationship to body is changed i.e. damper
mounts, axles, chassis unit and body panels. The
vehicle can be calibrated laden or unladen, but Gross
Vehicle Weight must not be exceeded. Tyres must all
be the same size and at the correct pressures.
IMPORTANT: The floor used for calibration must
be level and smooth in all directions to enable
procedure to be carried out successfully.
1. Connect TestBook and follow instructions to
depressurise complete system.
CAUTION: Depressurising system will
lower body on to bump stops.
2. Ensure system is completely depressurised:
Check that all air springs are deflated, and
vehicle has dropped evenly on to the bump
stops. If a spring, or springs, remains inflated
possibly due to a stuck solenoid valve, it will be
necessary to disconnect the pressurised pipe at
that air spring.
WARNING: Wear hand, ear and eye safety
standard protection. For extra protection
wrap a clean cloth around pipe to be
disconnected. Note that vehicle will lower to bump
stop when pipe is disconnected.
3. Disconnect air pipe. See this section.
Repressurise
4. Run engine to repressurise system.
REPAIR
1
60
FRONT SUSPENSION
NEW RANGE ROVER
AIR SPRINGS/HEIGHT SENSORS - INSPECT
SUSPENSION COMPONENTS
Visually check air springs for cuts, abrasions and
stone damage to alloy end plates. Check security of
retention clips. Check height sensors for damage to
housing, operating links and cable assembly.
CAUTION: It is essential to note that
repairs to other suspension and
transmission components are affected by
air suspension.
AIR HARNESS INSPECT
Check air harness (pipes) for damage and security
over its full length around vehicle.
LEAK TEST PROCEDURE
Service repair no - 60.50.35
If an air leak is suspected the use of a proprietary leak
detection spray is recommended. This procedure
should also be used where pneumatic components
have been disturbed.
The spray used must have a corrosion inhibitor, and
must not cause damage to paintwork, plastics, metals
and plastic pipes.
Recommended leak detection spray is GOTEC LDS.
This is available under part number STC1090.
1. Ensure system is fully pressurised.
2. Clean around area of suspected leak.
3. Using manufacturer’s instructions, spray around
all component joints and air springs, working
systematically until source of leak is found.
4. If a component eg: air spring, air drier is leaking,
rectify by fitting a new component.
5. If an air pipe connection is leaking cut 5 mm (0.2
in) off end of pipe. Fit new collet. See this
section.
6. Reinflate system, carry out leak test.
2
REPAIR
The air suspension must be DEPRESSURISED
before attempting to remove the following
components:
Radius arms, Front axle
Rear axle, Trailing arms
WARNING: Before inflation, the air spring
must be restricted by suspension and the
shock absorbers fitted. Unrestricted
movement of a pressurised air spring will result in
failure of the assembly, causing component and
possible personal injury.
ELECTRONIC AIR SUSPENSION
DISCONNECT AND CONNECT AIR PIPES
Remove
WARNING: Air suspension is pressurised
up to 10 bar (150 lbf/in2). Dirt or grease
must not enter the system. Wear hand, ear
and eye safety standard protection when servicing
system.
1. Depressurise complete system. See this
section.
CAUTION: Air pipes may be damaged if
not disconnected correctly, resulting in
possible leaks.
NOTE: Air pipe may be trimmed if
sufficient straight pipe remains. Ensure
pipe end is cut square, without distortion
or frays to obtain air tight seal. Use service tool
LRT-60-002. Lightly chamfer pipe using a pencil
sharpener after cutting. DO NOT CUT PIPES
MORE THAN TWICE.
Refit
6. Push pipe firmly through two ’O’ rings until it
contacts base of housing as shown. Gently pull
pipe to ensure connection. The collet will retain
some movement while depressurised. Refit
rubber boot.
7. Pressurise system. See this section.
8. Leak test connection. See this section.
2. Clean air pipe connection with stiff brush and
soapy water. Peel back rubber boot.
3. Apply equal downward pressure on collet flange
at ’A’ as shown.
4. Pull air pipe firmly out through centre of collet.
5. Inspect disconnected end of air pipe for damage
and scores. Rectify as necessary.
REPAIR
3
60
FRONT SUSPENSION
NEW RANGE ROVER
AIR PIPE CONNECTION COLLET AND ’O’ RINGS
CAUTION: Avoid scratching inside wall of
housing, creating possible leak path.
Remove
Refit
WARNING: Air suspension is pressurised
up to 10 bar (150 lbf/in2). Dirt or grease
must not enter the system. Wear hand, ear
and eye safety standard protection when servicing
system.
1. Clean area with stiff brush and soapy water.
2. Depressurise system. See this section.
6. Lightly grease new ’O’ rings.
7. Fit ’O’ rings into recess. Use a crochet hook to
avoid damage to ’O’ rings and housing.
8. Locate collet legs into housing, push fully home.
9. Inspect end of air pipe for damage and scores
rectify by trimming.
NOTE: Air pipe may be trimmed if
sufficient straight pipe remains. Ensure
pipe end is cut square, without distortion
or frays to obtain air tight seal. Use service tool
LRT-60-002. Lightly chamfer pipe using a pencil
sharpener after cutting. DO NOT CUT PIPES
MORE THAN TWICE.
10. Connect air pipe. See this section.
11. Pressurise system. See this section.
12. Leak test connection. See this section.
3. Disconnect air pipe. See this section.
4. Remove collet.
5. Carefully pry out two ’O’ rings, using a smooth
plastic hook, eg: a crochet hook.
4
REPAIR
ELECTRONIC AIR SUSPENSION
AIR COMPRESSOR
5. Remove compressor outlet pipe, seal exposed
ends.
Service repair no - 60.50.10
Remove
WARNING: The air suspension is
pressurised to 10 bar (150 lbf/in2) . Dirt or
grease must not enter the system. Wear
hand, ear and eye safety standard protection
when servicing system.
1. Depressurise system. See this section.
6. Remove compressor.
Refit
7. Remove seals from air hose and compressor.
Connect air hose to compressor and tighten
union nut to 7 Nm. (5 lbf.ft)
8. Fit compressor ensuring correct orientation of
dished washers. Tighten fixings to 2 Nm.
(1.5 lbf.ft)
NOTE: Ensure compressor is mounted
centrally on mountings. Failure to align
mountings may result in excessive noise
and premature mounting rubber wear.
2. Remove cover from air supply unit.
3. Release compressor multiplug from casing and
disconnect plug.
9. Connect compressor multiplug, secure to casing.
10. Leak test connection. See this section.
11. Fit cover to air supply unit.
4. Remove 3 nuts and dished washers securing
compressor. Note orientation of dished washers.
REPAIR
5
60
FRONT SUSPENSION
NEW RANGE ROVER
AIR RESERVOIR
AIR SPRING
Service repair no - 60.50.03
Service repair no - 60.21.01
WARNING: Air suspension is pressurised
to 10 bar (150 lbf/in2). Dirt or grease must
not enter the system. Wear hand, ear and
eye safety standard protection when servicing
system.
Remove
Remove
1. Depressurise system. See this section.
2. Raise the vehicle.
WARNING: Support on safety stands.
3. Clean air connection.
WARNING: Air suspension is pressurised
up to 10 bar (150 lbf/in2). Dirt and grease
must not enter the system. Wear hand, ear
and eye standard protection when servicing the
system.
WARNING: Shock absorbers must be fitted
before inflating air springs. Failure to
observe this warning could cause air
spring damage. DO NOT ATTEMPT TO
DISMANTLE AIR SPRINGS.
1. Raise the vehicle.
WARNING: Support on safety stands.
2. Remove wheel arch liner. See CHASSIS AND
BODY, Repair.
3. Support chassis under front cross member.
4. Depressurise system. See this section.
5. Clean area, disconnect hose from air spring.
Seal hose and spring.
6. Remove clips securing air spring.
4. Release air pipe from reservoir, seal hose and
reservoir.
5. Remove 3 bolts securing reservoir. Remove
reservoir.
Refit
6.
7.
8.
9.
10.
11.
6
Fit reservoir, tighten bolts to 25 Nm. (18 lbf.ft)
Remove seals from air pipe and reservoir.
Connect air hose to reservoir.
Leak test reservoir. See this section.
Fit rubber boot to connection.
Remove safety stands. Lower vehicle.
REPAIR
ELECTRONIC AIR SUSPENSION
7. Remove bolt securing air spring retaining pin to
axle. Remove pin.
8. Raise chassis on jack for clearance to remove
air spring.
WARNING: Support on safety stands.
CAUTION: When refitting the air spring, do
not allow the vehicle to rest on the
deflated air spring.
The chassis must be supported until the air spring
is inflated.
9. Remove air spring.
Refit
10. Clean mating faces of axles chassis and air
spring.
11. Fit air spring to axle,fit retaining pin and secure
pin with bolt.
12. Remove support from under chassis, lower
chassis onto air spring. Fit clips to secure spring
to chassis.
13. Remove seals from spring and air pipe. Clean
hose, connect to spring.
14. Fit wheel a