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OWNER MANUAL
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Contents
Quick start USING SEAT BELTS DURING PREGNANCY.... 69
QUICK START ................................................... 7
Airbags
Filling station information PRINCIPLE OF OPERATION............................ 70
FILLING STATION INFORMATION................... 38 SIDE AIRBAGS ............................................... 72
CURTAIN AIRBAGS ........................................ 72
Introduction DISABLING THE PASSENGER AIRBAG........... 73
SYMBOLS GLOSSARY.................................... 40 AIRBAG WARNING LAMP .............................. 75
LABEL LOCATIONS ......................................... 40 AIRBAG SERVICE INFORMATION................... 75
HEALTH AND SAFETY..................................... 41
DATA RECORDING.......................................... 41 Child safety
PARTS AND ACCESSORIES ............................ 42 CHILD SEATS ................................................. 76
CHILD SEAT POSITIONING ............................ 78
Keys and remote controls ISOFIX ANCHOR POINTS................................ 80
PRINCIPLE OF OPERATION ............................ 44 CHILD SAFETY LOCKS ................................... 82
GENERAL INFORMATION ON RADIO
FREQUENCIES ................................................ 44 Steering wheel
USING THE KEY .............................................. 45 ADJUSTING THE STEERING WHEEL .............. 83
PROGRAMMING THE REMOTE CONTROL...... 45 HORN ............................................................. 83
AUDIO CONTROL ........................................... 83
Locks VOICE CONTROL ............................................ 84
LOCKING AND UNLOCKING............................ 47 CRUISE CONTROL.......................................... 84

Engine immobiliser Lighting

PRINCIPLE OF OPERATION ............................ 50
CODED KEYS .................................................. 50
Alarm
PRINCIPLE OF OPERATION ............................
ARMING THE ALARM .....................................
SWITCHING OFF THE ALARM.........................
TILT SENSOR..................................................
PANIC ALARM ................................................
Seats
SITTING IN THE CORRECT POSITION ............
MANUAL SEATS .............................................
ELECTRIC SEATS............................................
HEAD RESTRAINTS ........................................
REAR SEATS...................................................
HEATED SEATS...............................................
Seat belts
GENERAL INFORMATION ...............................
SEAT BELT REMINDER...................................
FASTENING THE SEAT BELTS ........................
SEAT BELT HEIGHT ADJUSTMENT.................
GENERAL INFORMATION ............................... 85
LIGHTING CONTROL ...................................... 86
FRONT FOG LAMPS........................................ 87
REAR FOG LAMPS.......................................... 87
51 ADJUSTING THE HEADLAMPS....................... 88
51 HEADLAMP LEVELLING ................................. 88
52 HAZARD WARNING FLASHERS...................... 89
53 ADAPTIVE FRONT LIGHTING SYSTEM (AFS). 89
53 DIRECTION INDICATORS ............................... 91
INTERIOR LAMPS .......................................... 92
REMOVING A HEADLAMP .............................. 93
54 REMOVING A REAR LAMP ............................. 94
55 CHANGING A BULB ........................................ 95
57 BULB SPECIFICATION CHART...................... 104
58
59 Wipers and washers
65 WINDSCREEN WIPERS ................................ 105
RAIN SENSOR .............................................. 106
WINDSCREEN WASHERS............................. 106
66 REAR WINDOW WIPER AND WASHERS...... 107
68 ADJUSTING THE WINDSCREEN WASHER JETS .
68 108
69 HEADLAMP WASHERS................................. 108

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Contents
CHECKING THE WIPER BLADES .................. 108 TRANSFER GEARBOX ................................... 148
CHANGING THE WIPER BLADES.................. 109
Brakes
Windows and mirrors PRINCIPLE OF OPERATION .......................... 152
ELECTRIC WINDOWS................................... 110 HINTS ON DRIVING WITH ABS..................... 154
EXTERIOR MIRRORS ................................... 111 ELECTRIC PARKING BRAKE (EPB) ............... 155
ELECTRIC EXTERIOR MIRRORS .................. 112
INTERIOR MIRROR ...................................... 114 Parking aid
PRINCIPLE OF OPERATION .......................... 159
Information displays USING THE PARKING AID............................. 159
TRIP COMPUTER ......................................... 115
PERSONALISED SETTINGS .......................... 116 Driving hints
INFORMATION MESSAGES .......................... 117 RUNNING-IN ................................................. 161
GENERAL DRIVING POINTS.......................... 161
Climate control REDUCED ENGINE PERFORMANCE .............. 163
AIR VENTS ................................................... 119 ECONOMICAL DRIVING ................................ 163
MANUAL CLIMATE CONTROL ...................... 121
AUTOMATIC CLIMATE CONTROL................. 123 Cruise control
REAR PASSENGER CLIMATE CONTROLS .... 126 PRINCIPLE OF OPERATION .......................... 164
HEATED WINDOWS AND MIRRORS ............ 126 USING CRUISE CONTROL............................. 164
AUXILIARY HEATER ..................................... 127
ELECTRIC SUNROOF .................................... 127 Stability control
PRINCIPLE OF OPERATION .......................... 166
Convenience features USING STABILITY CONTROL ........................ 166
SUN VISORS ................................................ 129
SUN BLINDS................................................. 129 Traction control
INSTRUMENT LIGHTING DIMMER............... 129 PRINCIPLE OF OPERATION .......................... 168
CLOCK .......................................................... 130
CIGAR LIGHTER ........................................... 132 Hill descent control (HDC)
ASHTRAY ..................................................... 132 PRINCIPLE OF OPERATION .......................... 169
AUXILIARY POWER SOCKETS ..................... 133 USING HDC ................................................... 169
CUP HOLDERS ............................................. 134
CENTRE CONSOLE ....................................... 135 Terrain response
COOL BOX .................................................... 136 PRINCIPLE OF OPERATION .......................... 172
STORAGE COMPARTMENTS ........................ 137 USING TERRAIN RESPONSE ........................ 172
MEMORY FUNCTION .................................... 138
Air suspension
Starting the engine PRINCIPLE OF OPERATION .......................... 179
GENERAL INFORMATION ............................. 139 ADJUSTING THE SUSPENSION .................... 180
STARTER SWITCH ....................................... 139 AIR SUSPENSION MESSAGES...................... 184
STEERING WHEEL LOCK.............................. 140
STARTING A PETROL ENGINE ..................... 140 Fuel and refuelling
STARTING A DIESEL ENGINE....................... 141 SAFETY PRECAUTIONS................................. 186
FUEL QUALITY .............................................. 186
Transmission RUNNING OUT OF FUEL................................ 188
MANUAL TRANSMISSION............................ 142 FUEL FILLER FLAP ........................................ 189
AUTOMATIC TRANSMISSION ...................... 142 REFUELLING ................................................. 190

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Contents
FUEL CUT-OFF .............................................. 191 TYRE PRESSURE MONITORING SYSTEM.... 248
CATALYTIC CONVERTER .............................. 191 TYRE GLOSSARY ......................................... 253
FUEL CONSUMPTION ................................... 192
Fuses
Load carrying FUSE BOX LOCATIONS................................. 254
GENERAL INFORMATION ............................. 193 CHANGING A FUSE....................................... 255
LUGGAGE ANCHOR POINTS......................... 193 FUSE SPECIFICATION CHART ...................... 257
REAR LOADSPACE HATCHES....................... 193
LUGGAGE COVERS ....................................... 194 Vehicle recovery
TOWING POINTS.......................................... 263
Towing LASHING POINTS......................................... 264
TOWING A TRAILER ..................................... 197 TRANSPORTING THE VEHICLE .................... 265
GEAR CHANGING.......................................... 198 TOWING THE VEHICLE ON FOUR WHEELS.. 265
LEVELLING ................................................... 198
ESSENTIAL TOWING CHECKS ...................... 199 Vehicle identification
RECOMMENDED TOWING WEIGHTS ........... 200 VEHICLE IDENTIFICATION NUMBER (VIN)... 267
DETACHABLE TOW BALL ............................. 200
TOW BAR DIMENSIONS ............................... 204 Technical specifications
TECHNICAL SPECIFICATIONS ...................... 268
Vehicle care
CLEANING THE EXTERIOR ........................... 207 Type approvals
CLEANING THE INTERIOR ............................ 208 TYPE APPROVALS ....................................... 274
REPAIRING MINOR PAINT DAMAGE ............ 209
Audio introduction
Maintenance RADIO RECEPTION....................................... 283
GENERAL INFORMATION ............................. 210
OPENING AND CLOSING THE BONNET ........ 212 Audio unit overview
ENGINE COMPARTMENT OVERVIEW ........... 213 AUDIO UNIT OVERVIEW............................... 284
UNDER BONNET COVERS............................. 219
ENGINE OIL CHECK ...................................... 219 Audio unit operation
ENGINE COOLANT CHECK ............................ 220 ON/OFF CONTROL ........................................ 286
BRAKE FLUID CHECK ................................... 222 VOLUME CONTROL...................................... 286
POWER STEERING FLUID CHECK ................ 223 BASS/TREBLE CONTROL ............................. 289
WASHER FLUID CHECK ................................ 224 BALANCE/FADE CONTROL ........................... 292
STATION PRESET BUTTONS ........................ 292
Vehicle battery WAVEBAND BUTTON ................................... 293
BATTERY WARNING SYMBOLS ................... 225 AUTOSTORE CONTROL................................ 293
BATTERY CARE ............................................ 225 RADIO DATA SYSTEM (RDS) ....................... 294
USING BOOSTER CABLES ............................ 226 TRAFFIC INFORMATION (TA) CONTROL ...... 295
CHARGING THE VEHICLE BATTERY ............. 228 PTY PROGRAMME TYPES............................ 297
CHANGING THE VEHICLE BATTERY ............. 229
Compact disc player
Wheels and tyres LOADING COMPACT DISCS ......................... 299
GENERAL INFORMATION ............................. 230 EJECTING COMPACT DISCS ........................ 301
CHANGING A ROAD WHEEL ......................... 231 EJECTING MULTIPLE COMPACT DISCS....... 301
TYRE CARE ................................................... 242 COMPACT DISC SELECTION ........................ 302
USING SNOW CHAINS.................................. 248 COMPACT DISC PLAYBACK ......................... 303

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Contents
TRACK SELECTION....................................... 304
COMPACT DISC PAUSE................................ 304
FAST FORWARD/REVERSE .......................... 304
COMPACT DISC FUNCTION MENU............... 305
SHUFFLE/RANDOM ...................................... 305
REPEAT COMPACT DISC TRACKS ............... 306
COMPACT DISC TRACK SCANNING ............. 306
MP3 FILE PLAYBACK ................................... 307

Rear passenger controls

REAR SEAT CONTROLS ............................... 308
HEADPHONES .............................................. 309

Auxiliary input (AUX IN) socket

AUXILIARY INPUT (AUX IN) SOCKET........... 310

Voice recognition
PRINCIPLE OF OPERATION.......................... 312
USING THE SYSTEM .................................... 312
AUDIO SYSTEM COMMANDS ...................... 314

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Quick start
QUICK START
Quick start
Remote control
Dependent upon specification and vehicle
configuration, the operation of the remote
control may differ from the following.
0604
Press once to lock all doors and arm
the alarm.
Press twice within three seconds to deactivate
the interior space protection and tilt sensor.
Press once to deactivate the alarm
and unlock the driver’s door (Single
point entry).
A second press will unlock all other doors.
Customer configurable button. Can
be programmed to remotely operate
one of the following functions:
• Headlamp on (default).
• Panic alarm.
• Air suspension.
See PROGRAMMING THE REMOTE CONTROL
(page 45).
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Single point entry
This is a security feature that unlocks only the
driver’s door. It can be disabled on individual
remote controls by simultaneously pressing
and holding the lock and unlock buttons for
three seconds. The vehicle will lock and then
unlock in the currently selected mode to
confirm the change.
You can now unlock all doors with a single
press. Repeating the procedure will re-enable
Single point entry.
Automatic relock
If the vehicle is unlocked with the remote
control, it will automatically relock and arm the
alarm if a door or the tailgate is not opened
within one minute.
Key blade
Press button (arrowed in illustration) to release
the key blade.
Remote control battery
The remote control battery is rechargeable and
should never need replacement. The battery is
recharged whenever the key is in the starter
switch and the engine running.
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Quick start
Central locking Tailgate

1
1 2

2
LAN0605

Master lock and unlock switches

1. Press to unlock all doors and tailgate.
2. Press to lock all doors and tailgate.
Speed-related locking
If enabled, the doors and tailgate will
automatically lock when the vehicle's speed
exceeds 8 km/h (5 mph).
This feature can be disabled or enabled in the
Settings option accessed via the trip computer.
LAN0606
Opening the upper tailgate
With all the doors unlocked, press the release
switch 1 on the underside of the exterior handle
and pull to open.
Opening the lower tailgate
With the upper tailgate open, press the touch
pad 2 on the lower tailgate waist moulding.

Operating note
If the tailgate is locked/unlocked 10 times
within a short period, the latch will be
disabled for approximately one minute, to
protect the battery and lock mechanism.

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Quick start
Bonnet Power operated seat adjustment
To adjust the seats the starter switch must be
in position I or II. On those vehicles equipped
with a memory driver’s seat, the seat has a 10
minute active period initiated when the driver’s
door is opened/closed or the starter key is
1 turned to the off position.

1 2

LAN0607

LAN0611

Opening
Pull the bonnet release lever 1 located on the 1. Seat foreward/backward, cushion height
left-hand side of the vehicle. and front tilt control switch.
Lift the bonnet safety catch lever 2, located on 2. Backrest adjustment switch.
the front edge of the hood beneath the centre 3. Lower backrest lumbar support
point of the words LAND ROVER, and raise the handwheel.
bonnet.
Closing
Lower the bonnet until the safety catch
engages. Using both hands, press the bonnet
down until the catches click.
Check that both catches 3 are engaged by
trying to lift the front edge of the bonnet.

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Quick start
Driving position memory (when fitted)
Once you have adjusted the power operated
driver's seat and exterior mirrors for your ideal
driving position, the vehicle can memorise
these settings for future use.
1 2
Lazy entry
When this feature is enabled, the vehicle stores
the seating and mirror positions for each
remote control. Next time the vehicle is
unlocked using a remote control, the position
of the seat and mirrors will adjust to the last
used position.
This feature can be disabled or enabled in the
Settings option accessed via the trip computer.
Manual seat adjustment

LAN0612

1. Press the memory store button 1 to

activate the memory function for five
seconds.
2. Press one of the preset buttons 2 within 4
five seconds to memorise the current
settings.
2
Memory Stored will be displayed on the 1
message centre accompanied by an
audible chime to confirm the settings have
been memorised. 3

Operating note
A seat position will only be memorised during
the five second active period.
LAN0613
Any existing settings will be over-written
when programming a memory position.
1. Forward/backward adjustment.
2. Height adjustment.
3. Backrest adjustment.
4. Lower backrest lumbar support.

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Quick start
Windows/Door mirrors
1 direction to adjust the position of the mirror
2 With the mirror adjustment switch knob in the
LAN0614
• To open a window, press and hold the
respective switch.
• To close the window, pull and hold the
switch.
• Window movement can be stopped at any
time by releasing the switch.
The driver’s window has a one touch facility
that allows it to be fully opened or closed with
a single operation of the switch. Firmly press
the switch and release. Movement can be
stopped by briefly pressing the switch again.
Press the right-hand side of switch 2 to inhibit
the operation of the rear window switches.
Door mirror adjustment
To adjust the mirrors, rotate the mirror
adjustment knob 1 left or right to select the
appropriate mirror. Move the knob in any
glass.
Power fold mirrors (when fitted)
Some vehicles are equipped with the facility
that allows the mirrors to be electrically folded
towards the door for better
clearance/protection.
central position, push the knob downwards to
fold/unfold the mirrors.
Reverse automatic mirror dip
With the feature enabled, when reverse gear is
selected the door mirrors will dip.
The dip position of the door mirrors can be
personalised. See ELECTRIC EXTERIOR
MIRRORS (page 112).
This feature can be disabled or enabled in the
Settings option accessed via the trip computer.
See TRIP COMPUTER (page 115).

Resonance with lowered windows

If a resonance/booming sound occurs when a
rear window is open, lowering an adjacent
front window about 25 mm (1 inch) will
eliminate the condition.

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Quick start
Steering column adjustment Overhead console

1 2

LAN0616

Courtesy lamps
If automatic mode is enabled, the front and rear
courtesy lamps will operate in conjunction with
the vehicle being unlocked/locked or when a
door is opened.
The courtesy lamps can be manually switched
on/off by pressing and releasing the centre
lamp switch (arrowed in illustration).
LAN0615

1. Move the lever located under the steering
wheel fully downward.
2. Adjust the height and reach of the steering
wheel to the desired position.
3. Move the lever fully up to lock the position
of the wheel.
Automatic mode
Automatic mode for the courtesy lamps can
be enabled/disabled by pressing and holding
the centre lamp switch for more than three
seconds.
A message will be displayed in the message
centre advising you of the currently set
mode.

Interior lamps
The interior lamps can be switched on/off by
pressing the switch adjacent to the lamp.

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Quick start
Sunroof
To open the sunroof:
• Press and release the rear of the switch 1
to open the roof to the tilt position.
• Press and release the rear of the switch
again to open the roof fully.
To close the sunroof:
• Press and release the front of the switch 2
to close the roof to the tilt position.
• Press and hold the front of the switch
again to close the roof fully.
If the sunroof is moving, it can be stopped by
pressing the switch again.
Operating note
The sunroof can be operated with the starter
key in position I or II and for 40 seconds after
position 0 has been selected, providing that
neither front door has been opened.
With the starter key in position I or 0, the
switch will need to be pressed and held until
the roof reaches the desired position.
Rear view mirror
Some rear view mirrors are fitted with a feature
that will automatically darken to counteract
glare from the headlamps of a following
vehicle.
This feature is temporarily switched off when
reverse gear is selected.
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Seat belts/Child restraints
The use of front and rear seat belts is
mandatory in most countries. Using seat belts
saves lives. They should be worn by all
occupants whenever the vehicle is in use.
A warning light on the instrument
pack will illuminate to alert you that
the driver's and/or front
passenger's seat belt is unbuckled. Dependent
upon specification this may be accompanied by
an intermittent chime.
Automatic Locking Reels (ALR)
The second and third row seat belts have ALR
fitted for use with child seats or securing large
items.
• To engage: Extend belt to maximum length
to enable locking mechanism.
• Allow seat belt to retract onto the child
seat/item (a clicking sound will be heard as
the belt retracts). Ensure there is no slack
by pressing the seat/item firmly into the
vehicle seat.
• To disengage: Unbuckle belt and allow belt
to fully retract.
With ALR enabled, as the seat belt retracts, it
will automatically lock preventing
re-extension.
Ensure passengers do not fully extend the
restraints and inadvertently engage this
feature during normal use.
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Quick start
Child Seats Passenger airbag deactivation
It is important to remember that the child's
weight, rather than age, determines the type of
seat that is required. See CHILD SEATS
(page 76).

Recommended child seat

Land Rover strongly recommends the use of
ISOFIX child seats.
ISOFIX child seats can only be fitted in the
second-row outer seating positions.

PASS
AIRB
AG
OFF

LAN0617

If it becomes necessary to fit a child restraint

on the front passenger seat, the passenger
airbag must be deactivated.
To deactivate the airbag, open the front
passenger door and use the starter key to turn
the PASS.AIRBAG switch (located on the end
of the fascia) to the OFF position.
With the airbag deactivated, the status
indicator (arrowed in illustration) will
illuminate whenever the starter key is turned to
position II.

Operating note
When an adult is seated in the front
passenger seat, ensure the PASS.AIRBAG
switch is turned to the ON position.

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Quick start
Heating and ventilation
These are the primary functions of the heating
and ventilation system. Dependent upon
specification, the control panel may differ from
those shown.

1 1

LAN0618

3 4

LAN0619

Air conditioning Air conditioning is automatically switched on

Air conditioning is an integral part of the and controlled whenever the system is not
heating and ventilation system, providing operating in economy mode.
cooled and dehumidified air for occupant
comfort. The dry airflow is effective in
preventing misting of windows and is also
beneficial at low external temperatures.

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Quick start
External water deposits
The air conditioning system removes
moisture from the air and deposits excess
water beneath the vehicle. Puddles may form,
but this is normal and no cause of concern.
AUTO mode (Automatic system only)
Press AUTO to select automatic
operation of the system, both LEDs in
the switch will illuminate.
The system will adjust the heat output, blower
speed, air intake and airflow distribution to
maintain the selected temperature(s) and
reduce misting without further adjustments.
The air distribution and blower controls can be
operated to override the automatic settings.
This will extinguish the appropriate LED in the
AUTO control.
Recommended mode
Select AUTO as the normal operating mode.
This will help prevent window misting and
odours from the climate control system.
Temperature selection (Automatic system
only)
Rotate the controls 1 to adjust the temperature
for the respective side of the passenger
compartment.
Operating note
On the automatic system, it is not possible to
achieve a temperature differential of more
than 4°C (7°F) between the left and right.
Blower speed (Automatic system only)
Rotate the blower control 2 to adjust airflow
through the vents. As the control is adjusted,
LEDs will illuminate to indicate which of the
eight possible speeds is currently selected.
16
Air distribution control (Automatic system
only)
Press to select the desired distribution setting.
An LED will illuminate in the switch.
Windscreen and side window vents
Face level vents
Foot level vents
More than one setting can be
selected to achieve the desired
distribution.
OFF (Automatic system only)
Press to switch the system off. An
LED will illuminate in the switch to
show this condition.
Press again to return the system to its previous
operating mode. The system will also be
reactivated by using the AUTO, blower speed,
air distribution or defrost controls.
Defrost mode (Automatic system only)
Press to remove frost or heavy
misting from the windscreen. The
system will automatically adjust the
blower output for maximum clearing, in
addition the rear window and windscreen
heaters will be activated.
Press again to switch off defrost mode. The
rear screen and windscreen heaters will remain
on.
Air recirculation
Press once to activate air
recirculation. An LED will illuminate
in the switch.
Press again to return to fresh air intake.
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Quick start
Economy mode Rear environment (when fitted)
Press button to put the system into Press once to activate automatic
economy mode. An LED will mode in which the comfort level for
illuminate in the switch to show this the rear passengers is controlled
condition. from the front. The upper LED will be
In economy mode air conditioning is switched illuminated.
off. This reduces the load on the engine, Press a second time to pass control of the rear
thereby improving fuel consumption. environment to the rear passengers control
panel. The lower LED will be illuminated.
Heated windscreen/rear window
Press a third time to switch this feature off.
Press to operate. An LED in the
Neither LED will be illuminated.
switch will illuminate whilst
operating.
The heaters will automatically
switch off after a preset interval.
Seat heaters
Press the relevant button to operate
the required seat heater at high level.
Both LEDs will illuminate.
Press a second time to heat the seat at a lower
level. One LED will extinguish.
Press a third time to switch off.
Temperature selection (Manual system only)
Rotate the control 3 to adjust the air
temperature entering the passenger
compartment.
Blower speed (Manual system only)
Rotate the blower control 4 to adjust airflow
through the vents. As the control is adjusted,
LEDs will illuminate to indicate which of the
eight possible speeds is currently selected.
Air distribution control (Manual system only)
Rotate the control 5 to achieve the desired air
distribution setting.
Windscreen and side window vents
Face level vents
Foot level vents

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Quick start
Facia - Left-hand drive vehicles

1 2 3 4 5 6 7 8 9 10 11

1 2 3
ABC DEF
6CD-465
4 5 6
GHI JKL MNO

CD 3 14 : 54
7 8 9
PQRS TUV WXYZ
Tr 1 5 2 : 43
0 1 2 3 4 5 6

12
22 21 20 19
13

18 14

17 15

16
LAN0636

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Quick start
1. Direction indicators/headlamps/trip
computer switch
2. Cruise control switches
3. Instrument pack/warning indicators and
message centre
4. Audio/telephone switches
5. Wiper/washer switch
6. Audio system
7. Dynamic stability control (DSC) switch
8. Touch screen
9. Hazard warning switch
10. Master locking switches
11. Passenger airbag status indicator
12. Heater/air conditioning controls
13. Gear selector
14. Terrain response control switch
15. Transfer gearbox switch
16. Hill Descent Control switch
17. Air suspension control
18. Electric Parking Brake (EPB)
19. Starter switch
20. Steering column adjustment
21. Bonnet release lever
22. Exterior lamps master switch

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Quick start
Facia - Right-hand drive vehicles

1 2 3 4 5 6 7 8 9 10 11

1 2 3
ABC DEF
6CD-465
4 5 6
GHI JKL MNO

CD 3 14 : 54
7 8 9
PQRS TUV WXYZ
Tr 1 5 2 : 43
0 1 2 3 4 5 6

15
14 13 12
16

21 17

20 18

19
LAN0635

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Quick start
1. Audio system
2. Dynamic stability control (DSC) switch
3. Touch screen
4. Hazard warning switch
5. Master locking switches
6. Passenger airbag status indicator
7. Direction indicators/headlamps/trip
computer switch
8. Cruise control switches
9. Instrument pack/warning indicators and
message centre
10. Audio/telephone switches
11. Wiper/washer switch
12. Exterior lamps master switch
13. Starter switch
14. Steering column adjustment
15. Heater/air conditioning controls
16. Gear selector
17. Electric Parking Brake (EPB)
18. Transfer gearbox switch
19. Hill Descent Control switch
20. Air suspension control
21. Terrain response control switch

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Quick start
Instrument pack

1 2 3 4

EXT 23 C

8 7 6 5
9
E80508

1. Tachometer 6. Trip recorder reset switch

2. Temperature gauge 7. Gear selector position display
3. Fuel gauge 8. Main message centre.
4. Speedometer 9. Warning indicators panel.
5. Total distance (odometer) and trip
recorder

22

Quick start
Tachometer
Indicates engine speed in revolutions per
minute (x 1 000). In normal driving conditions
the engine is most fuel efficient between 2 000
and 3 000 rev/min.
Temperature gauge
At normal operating temperature, the pointer is
positioned midway between the red and blue
segments of the gauge (the precise position
will vary according to climatic conditions).
E80509
If the pointer moves above the mid point, the
engine coolant is becoming too hot. Should the
pointer move into the red segment and the red
warning indicator (arrowed) illuminates,
severe engine damage could occur (under
these circumstances the air conditioning may
switch off and engine performance may reduce
to minimise engine load).
Stop the vehicle as soon as safety permits, and
allow the engine to idle until the warning
indicator extinguishes and the pointer moves
back to its normal position. If the problem
persists, seek qualified assistance
immediately.
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Fuel gauge
CAUTION
Never allow vehicles to run out of fuel as
the resultant misfire may destroy the
catalytic converter.
When the starter switch is turned to position II,
the pointer quickly rises to show the level of
fuel in the tank.
E80510
When the remaining fuel reaches a minimum of
12 litres (3 gallons), the amber low fuel
warning indicator( arrowed) illuminates.
The remaining fuel should give a range of
80 km (50 miles).
The small arrow alongside the fuel pump
symbol indicates the side of the vehicle on
which the fuel filler is located.
Total distance (odometer) and trip recorder
Indicates the total distance travelled, and also
shows the most recent individual journey
distance.
Trip recorder reset switch
With the starter switch in position II, press to
reset the trip recorder back to zero.
Selected gear display
The currently selected gear is displayed.
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Quick start
Warning indicators (attention) Warning indicators (information)
If any of the following illuminates whilst driving The following will illuminate during normal
a fault has been detected. Refer to Owner’s driving to indicate that a particular system or
Handbook for further information. feature is operating.
Battery charge indicator. Seat belt reminder.
See page 161. See page 68.
Low oil pressure. Door open.
See page 161. See page 47.
Electric parking brake. Low screen washer level.
See page 155. See page 224.
Brake systems. Diesel glow plugs active.
See page 152. See page 141.
Anti-lock Braking System. Lo gear range selected.
See page 154. See page 148.
Airbag system. Hill Descent Control (HDC) active.
See page 75. See page 169.
Engine management system. Cruise control active.
See page 163. See page 164.
Engine. Direction indicator.
See page 163. See page 91.
Suspension system. Trailer direction indicator.
See page 179. See page 197.
Transmission. Headlamp high beam on.
See page 142. See page 86.
Transmission temperature. Sidelamps on.
See page 142. See page 86.
Hill Descent Control (HDC). Rear fog lamps on.
See page 169. See page 87.
Low engine coolant level. Front fog lamps on.
See page 220. See page 87.
Dynamic Stability Control (DSC). Overspeed warning.
See page 166. See page 161.
Adaptive front lighting system.
See page 89.
Tyre Pressure Monitoring system.
See page 248.

24
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Quick start
Steering column levers Direction indicators/Headlamp high beam

5 3
2
1
0
4
A
LAN0640

Move the lever up or down to

B activate the direction indicators.
LAN0637

Windscreen wiper Moving the lever up or down against spring

pressure and then releasing will flash the
1. Intermittent wipe/rain sensor
indicators 3 times. Useful for lane changing.
2. Normal speed operation
Push the lever away from you to
3. High speed operation select headlamp high beam. A
4. Single wipe - press and release to operate. warning indicator will illuminate on
the instrument panel.
Rotate collar 5 to adjust speed of intermittent
Trip computer
wipe or sensitivity of the rain sensor.
Press the button on the end of the
Short delay/Most sensitive to rain.
lever to cycle through the trip
computer functions displayed on the
Long delay/Least sensitive to rain.
message centre.

Windscreen washer
Push the button on the end of the
lever to operate the windscreen
washer.
Rear wiper and washer
Pull the lever to position A for intermittent
operation of the rear wiper. Pull and hold the
lever in position B to operate the rear washer
and wiper.

25
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Quick start
Exterior lamps master switch Electric Parking Brake (EPB)

3 4
1 2

AUTO

LAN0643

A
B Applying
With the vehicle stationary, pull up the parking
brake lever and then release it. The red warning
LAN0642
indicator in the instrument panel will
illuminate.
1. Exterior lamps off
On manual tranmission vehicles, the parking
2. Sidelamps
brake will automatically apply when the starter
3. Headlamps key is removed.
4. Autolamps
Releasing
In AUTO mode and the starter switch in The starter switch must be in position I or II.
position II, a sensor monitors the exterior light Apply the foot brake and press down on the
levels and will automatically switch the side parking brake lever.
lamps and dipped headlamps on and off as
required. On automatic transmission vehicles, if the
vehicle is stationary with the parking brake
A. Front fog lamps (if fitted) applied and either D (Drive) or R (Reverse)
B. Rear fog lamps selected, pressing the accelerator will
If front fog lamps are not fitted, the rear fog automatically release the parkbrake.
lamps will come on at position A.

Operating note
Fog lamps can not be operated if the lamps
master switch is in AUTO.

26
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Quick start
Automatic transmission CommandShift ™
CommandShift gear selection can be used as
Gearshift interlock
an alternative to automatic gear selection and
The starter switch must be in position II, the is particularly effective when rapid acceleration
foot brake applied and the selector release or engine braking are required.
button pressed before the gear selector can be
moved from P (Park) to R (Reverse).
The gear selector must be in the P position
before the starter key can be removed.
Sport mode P

M +
R
N
S M
S D
-

P LAN0645

R
+
M
N 1. Select Sport mode. The transmission will
D
-
S
automatically select the gear most
appropriate to the vehicle’s road speed and
accelerator position.
LAN0644
2. Moving the selector lever forward (+) or
In Sport mode, automatic gear changing is backward (-) and then releasing will
maintained but the gearshift changes are manually select a higher or lower gear
modified to improve performance. (when available). The message
To select Sport mode, move the gear selector TRANSMISSION COMMANDSHIFT
from the D position towards the left hand side SELECTED will appear in the message
of the vehicle. centre.
The word SPORT will appear on the instrument 3. Subsequent gear selections will display the
pack display and the LED in the gear selector selected gear on the instrument pack
surround will illuminate. display.
4. To deselect CommandShift mode, move
When Sport is selected, the transmission will the selector lever back to the D position.
stay in lower gears for longer with downshifts
occurring more readily.
Fuel consumption will be adversely affected.
If Terrain Response is fitted, Sport mode is
only available when the General program is
selected.

27
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Quick start
Transfer gearbox Hill Descent Control (HDC)

LAN0649

HDC operates in conjunction with the anti-lock

LAN0646
braking system to provide greater control in
HIGH range should be used for all off-road situations particularly when
normal road driving and also for descending severe gradients.
off-road driving across dry level Press the switch (arrowed in
terrain. illustration) to select HDC. HDC can
LOW range should be used in be selected at speeds below
situations where low speed 80 km/h (50 mph) but will not be fully active
manoeuvring is necessary, or in until the vehicle speed reduces below 50 km/h
extreme off-road conditions. (30 mph), confirmed by a continuously
illuminated HDC indicator in the instrument
Range changing pack. Press the switch again to deselect HDC.
The recommended method for range changing
is with the vehicle stationary. With the engine
running, and the main gearbox in N (Neutral),
move the transfer gearbox lever to the required
position and then release. The indicators on the
switch and instrument pack display will flash
during range changing. When range changing
is complete a chime will sound and a message
will be displayed on the message centre.

28
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Quick start
Air suspension Terrain response system

1 2

3
4
5
6
LAN0651

7 The Terrain Response system, if fitted, is

LAN0650
Vehicle height can be manually adjusted via the
raise/lower lever 1. Height changes may only
be made when the engine is running and the
driver and passenger doors are closed.
Indicators 2 or 7 will illuminate to show the
direction of movement. They extinguish when
the height change movement is completed.
Off-road height 3, provides improved ground
clearance and approach, departure and
break-over angles.
On-road height 4, is the normal height for the
vehicle.
Access height 5, lowers the vehicle to provide
easier entry, exit and loading of the vehicle.
This position may be selected up to 40 seconds
after the starter switch is turned off.
Crawl (locked at Access height) 6, allows the
vehicle to be driven at low speeds at access
height, to give increased roof clearance.
always active and can not be switched off.
When the vehicle is started the system will
normally start in the General program.
Manual selection of a special program, by
rotating the knob, will provide benefits in how
the vehicle can be driven over different
surfaces or terrains by automatically adjusting
the vehicle’s drive and suspension systems.
It is recommended that a special program be
engaged whenever driving conditions could
become difficult, and cancelled once the
conditions for use are no longer present.
General
Suitable for surfaces that match
E80903
typical road surfaces.
Grass-Gravel-Snow
Suitable for surfaces which are firm
but have a slippery surface, e.g.
grass, snow, loose gravel, pebbles
or icy conditions.

Vehicle height will be automatically adjusted Mud-Ruts

according to road speed in order to maintain Suitable for soft, muddy, uneven or
driveability and handling. deeply rutted ground. It is
If Terrain Response is fitted, some of it’s recommended that LOW range is
programs will automatically adjust the selected on the Transfer gearbox.
suspension height.

29
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Quick start
Sand
Suitable for soft, predominantly dry,
yielding sandy ground, e.g. sand
dunes and deserts. If the sand is
damp or wet, the Mud-Ruts
program may be more beneficial.
Rock Crawl
Only selectable when the transfer
E80907
gearbox is in LOW range. Suitable
for crossing wet or dry, solid
unyielding ground requiring high
levels of wheel displacement, e.g.
clusters of boulders or rocky river
beds.
Wading
When driving through water less than
600 mm (24 inches) deep, select the
program suitable for the surface beneath the
water.
30
Cruise control
Cruise control enables the driver to maintain a
constant road speed without using the
accelerator pedal.
1
2
3
4
LAN0652
1. SET (+): to set a road speed or increase the
speed in 2 km/h (1 mph) steps when cruise
control is operating.
2. SET (-): to set a road speed or decrease the
speed in 2 km/h (1 mph) steps when cruise
control is operating.
3. RESUME: resumes a SET speed retained in
memory.
4. CANCEL: cancel cruise control but retains
the set speed in memory.
Cruise control will automatically disengage
when the brake/clutch pedal is used or when
the vehicle speed falls below 30 km/h
(18 mph).
 R

Quick start
Audio systems Sound settings

General operation

Bass

1
LAN0657

Press the knob 1 to switch on/off and rotate to

adjust volume.
LAN0659
Press the appropriate mode button to select
FM, AM, CD or AUX. Press the button repeatedly to scroll
Press the or buttons to skip CD tracks through the sound settings options. These
or to search for a radio station. Press the options vary depending on specification of
or buttons to search through a CD track or audio system, but will include: Bass, Treble,
to manually tune to a radio station. Balance, Fader and Reset Tone Settings.
Dependent upon audio system specification,
Steering wheel controls other options may be available.
With the desired sound setting displayed,
rotate knob to adjust. Confirm new setting
by pressing the button.
1
2
3
4

LAN0658

1. Press to switch between Radio, CD or

AUX.
2. Press to increase volume.
3. Press to decrease volume.
4. Press and release to scroll through preset
radio stations or CD tracks. Press and hold
for two seconds to search up or down for
the next or previous radio station/CD track.

31
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Quick start
Radio operation CD operation

Compatible disc types

The use of discs with paper labels or dual
format discs (CD/DVD) should be avoided as
FM 14 :54 they could become jammed.
2 98.2 Autostore
1 2 3 4 5 6

LAN0662

1 2
ABC
3
DEF 6CD-465

Press either the FM or AM button to select the 4

GHI
5
JKL
6
MNO
CD 3 14 : 54
required waveband. Repeated presses of either 7
PQRS
8
TUV
9
WXYZ
Tr 1 5
1 2 3 4 5 6
2 : 43
0
button will scroll through the FM and AM
waveband memory options.
Storing radio stations
To automatically store radio stations, press
and hold either the FM or AM button. Autostore LAN0664
will be shown on the information display and
the stations will be stored under the preset Standard audio
numbers in the selected waveband. The standard audio unit features a single-slot
To recall a preset station, press and release one CD player.
of the numbered preset buttons. See STATION Insert a disc, label side up, into the player. The
PRESET BUTTONS (page 292). disc will load and start to play.
To end CD playback, briefly press one of the
other mode buttons (FM, AM or AUX).
To eject the disc, press the button. The
display will show the message Remove Disc
when it is safe to do so.
Premium audio
The premium audio unit features an integral
6-disc autochanger.

32
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Quick start
Loading CDs
To insert a single disc, press the CD button,
then one of the number buttons 1-6. When
prompted by the information display, insert the
disc, label side up. The autochanger will load
the CD in the selected position.
To fully load the autochanger, press and hold
the CD button. The information display will
show Loading All. When prompted, insert a
disc, label side up. This process is repeated
until all six CD positions are occupied.
Playing CDs
When in CD mode, press the appropriate CD
number 1-6 to start playing the selected disc.
Playback commences and progresses
sequentially through all of the loaded discs.
Playback can be paused by briefly pressing one
of the other mode buttons (FM, AM or AUX).
Playback will resume when the CD button is
pressed again.
Ejecting CDs
To eject a single disc, select the required disc
by pressing one of the number buttons 1-6 and
then press the button.
To eject all loaded discs, press and hold the
button, the discs will be ejected one at a
time. Remove disc(s) only when the display
shows the message Remove Disc.

33
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Quick start
Navigation
The screen allows touch-control of the
navigation system. Only a light touch is Navigation Menu

required to operate the function, excess

pressure on the screen could result in damage. TMC
Destination Stored
On initial activation, ensure that both the Entry Locations RDS-TMC

correct country and area have been selected.

Setting a destination Navigation Route
Setup Options
To set a destination and start using the
navigation system, use the following LAN0668
procedure:
Touch the Destination Entry icon.

Destination Entry
1 2
A 3 4
1/8 mi

Address Point of Select from

Change Map

Memory Previous
AUSTIN PLACE, ABINGDON Change Postcode Point Dest

1 2 3 4 5

LAN0669

LAN0665
Touch the Address icon, then enter the Town,
Address and House Number (if known) using
Press the Navigation button on the
the on-screen keypad.
display surround, and when
prompted, touch Agree to access Touch OK to enter.
the initial Home menu.
Touch the Home icon on the screen
to access the navigation menu.

34
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Quick start

81 AUSTIN PLACE, ABINGDON, ABI

Route
Preference
A 34
1/8 mi

Destination Way Point

LAN0670

Once found, the screen displays the

destination. To change the route settings,
touch Route Preference, or touch Destination
to start the route calculation.

Route preferences
When set, route preferences are remembered
and used for calculating all new routes. If you
encounter problems with the type of routes
being selected or the guidance being given,
please check the route preferences.

Once calculated, the screen highlights the

route. Touch 3-Routes to select an alternate
route, or touch Start to start navigation. Drive
away, following the voice guidance.

Touch the audible repeat icon to

hear again the last voice
instruction.

When your destination is reached, voice and

visual confirmation is given.
Cancelling guidance
Touch the Home icon, select Route
options, Cancel guidance and
touch Confirm.

35
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Quick start
Telephone – Bluetooth system Pairing a handset to the vehicle’s system
Mobile phones with Bluetooth capability can Prepare the mobile phone for pairing to the
communicate with the vehicle’s inbuilt system. See the telephone manufacturer’s
telephone feature. instructions for further details, or follow the
table below for generic commands.
Mobile phone compatibility When the handset has been successfully paired
There are a number of mobile phones that to the system, Bluetooth will appear on the
have been tested for full functionality with the Phone menu screen.
Land Rover system, however not all phones
Note: If more than one paired Bluetooth phone
are compatible and some may only be
is in range, the system will automatically select
partially compatible. For the latest list of
the last phone used in Bluetooth mode.
compatible phones and software versions,
please refer to
www.ownerinfo.landrover.com.
Alternatively consult your Dealer.

Nokia Motorola Ericsson

1. Select menu Select menu Select menu
2. Select settings Select settings Select connectivity
3. Select Bluetooth OR Select Select Connection Select Bluetooth
Connectivity then
Bluetooth
4. Select On Select Bluetooth link Select My Devices
5. Select Search for Audio Select Hands-free With New Device highlighted,
devices select Add. Press OK to
confirm
6. After search select Land Select Look for devices After search select Land Rover
Rover
7. Enter pass code 2121. After search select Land Select Connect
Press OK to confirm Rover
8. No connection? Select Permission to bond? Enter pass code 2121 after
Bluetooth (Menu) then Select Yes and enter pass prompt
Paired devices Jaguar code 2121

36
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Quick start
Making a call Receiving a call

1 1
2 2

LAN0673 LAN0673

1. With a paired or docked handset, press the
button on the audio system, or operate
the answer call switch 1 on the steering
wheel controls.
2. Enter the required telephone number using
the numeric keypad.
3. Press the button, or operate the
answer call switch 1 on the steering wheel
to send.
To answer an incoming call, press the
button on the audio unit, or operate the answer
call switch 1 on the steering wheel controls.
To end, or reject an incoming call, press the C
button on the audio system, or operate the end
call switch 2 on the steering wheel.

37
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Filling station information

FILLING STATION INFORMATION Refuelling
Filling station information

Fuel filler flap

Fuel filler flap location
A small arrow on the fuel gauge
indicates which side the fuel filler
flap is located.
Fuel filler flap opening

LAN0680

The filler cap is secured to the vehicle by a

LAN0675
Press and release the centre of the left edge of
the fuel filler flap (where arrowed) to open.
strap. For your convenience a holder is
provided on the flap to store the cap whilst
refuelling.
Insert the pump nozzle into the filler neck,
pushing aside the spring-loaded cover.
When delivery is complete, withdraw the nozzle
and replace the cap. Tighten the cap clockwise
until you hear it click three times. Return the
fuel filler flap to its closed position.

Operating note Fuel specification

The fuel flap has a spring loaded release, do The correct fuel specification for your vehicle is
not force it open. shown on the inside of the fuel filler flap. See
FUEL QUALITY (page 186).

Land Rover petrol engines are not fitted with

equipment necessary for the use of fuels
containing more than 10 per cent ethanol.
Do not use E85 fuels (85 per cent ethanol
content). If E85 fuels are used serious engine
and fuel system damage will occur.

Incorrect fuelling

CAUTION
If the fuel tank is accidentally filled with
the wrong type of fuel, it is essential that
the engine is not started and you seek qualified
assistance.

38
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Filling station information

Tyre pressures Engine oil specification
Air pressure naturally increases in warm tyres;
if it is necessary to check the tyres when they Variant Specification
are warm (after the vehicle has been driven for Diesel vehicles SAE 5W-30 meeting
a while), you should expect the pressures to specification ACEA:B1 or
have increased by up to 30 - 40 kPa (0.3- 0.4 B3
bar) (4 - 6 lbf/in²). In this circumstance, Do not Petrol vehicles WSS-M2C913-B ¹
let air out of the tyres in order to match the
recommended cold tyre pressures. See TYRE
¹ If you are unable to find an oil that meets the
CARE (page 242).
specification defined by WSS-M2C913-B, you
Tyre pressures label must use an SAE 5W-30 oil meeting
specification ACEA:A3 or specification API SL
or SM. See ENGINE OIL CHECK (page 219).
DISCOVERY

XXX/XXRXX
MAX. XXX X.X XX XXX X.X XX Engine coolant specification
XXX/XXRXX (kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
XXX/XXRXX
Top-up to the upper level indicator mark
L7MTA

XXX/XXRXX XXX X.X XX XXX X.X XX

(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)

TXXX/XXRXX
MAX. XXX X.X XX XXX X.X XX
located above the COLD FILL RANGE text, on
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
the side of the expansion tank. Use only a 50%
RTC500XXX

XXX X.X XX XXX X.X XX

(kpa) (BAR) (PSI) (kpa) (BAR) (PSI) mix of water and Castrol SF antifreeze. See
ENGINE COOLANT CHECK (page 220).

A B

E80376

A Left-hand drive vehicle

B Right-hand drive vehicle
The correct tyre pressures are shown on a label
attached to the driver’s door.
Temporary spare wheel
The tyre pressure in the temporary spare
wheel/tyre should be maintained at 420 kPa
(4.2 bar/60 lbf/in²) for all loading conditions.

39
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Introduction
SYMBOLS GLOSSARY
Introduction
Warnings
WARNING
Safety warnings are included in this
handbook. These indicate either a
procedure which must be followed precisely,
or information that should be considered with
great care in order to avoid the possibility of
personal injury.
Cautions
CAUTION
Cautions are included in this handbook.
These indicate either a procedure which
must be followed precisely, or information that
should be considered with great care in order
to avoid the possibility of damage to your
vehicle.
Symbols
This recycling symbol identifies
those items that must be disposed
of safely in order to prevent
unnecessary damage to the environment.
This symbol identifies those
features that can be adjusted,
disabled or enabled by a Land Rover
Dealer/Authorised Repairer.
40
LABEL LOCATIONS
Warning labels attached to your
vehicle bearing this symbol mean: DO
NOT touch or adjust components until
you have read the relevant instructions
in the handbook.
Labels showing this symbol indicate
that the ignition system utilises very
high voltages. DO NOT touch any
ignition components while the starter
switch is turned on.
Warning labels
Labels are attached to your vehicle at several
positions. These are applied to draw your
attention to important subjects, e.g. tyre
pressures, tow bar use, airbags, roll-over risk,
engine compartment hazards, etc.
DISCOVERY
XXX/XXRXX
MAX. XXX X.X XX XXX X.X XX
XXX/XXRXX (kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
XXX/XXRXX
XXX/XXRXX XXX X.X XX XXX X.X XX L7MTA
MAX.
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
XXX X.X XX XXX X.X XX
TXXX/XXRXX
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
RTC500XXX
XXX X.X XX XXX X.X XX
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
A B
E80376
A Left-hand drive vehicle
B Right-hand drive vehicle
It is important that you are familiar with these
subjects to ensure that your vehicle and its
features are used safely. Using the index at the
back of this handbook, refer to the relevant
topic for more information.

Introduction
HEALTH AND SAFETY
WARNINGS
Your vehicle has a higher ground
clearance and hence, a higher centre of
gravity than ordinary passenger cars, to
enable the vehicle to perform in a wide variety
of off-road applications. An advantage of the
higher ground clearance is a better view of the
road allowing you to anticipate problems.
The vehicle is not designed for
cornering at the same speed as
conventional passenger cars any more than a
low-slung sports car is designed to perform
satisfactorily under off-road conditions. If at
all possible, avoid sharp turns or abrupt
manoeuvres. As with other vehicles of this
type, failure to operate the vehicle correctly
may result in loss of control or vehicle
roll-over.
41
R
DATA RECORDING
Service data recording
Service data recorders in your vehicle are
capable of collecting and storing diagnostic
information about your vehicle. This potentially
includes information about the performance or
status of various systems and modules in the
vehicle such as engine, throttle, steering or
brakes.
In order to properly diagnose and service your
vehicle, Land Rover and service and repair
facilities may access vehicle diagnostic
information through a direct connection to
your vehicle.
Event data recording
Event data recorders are capable of collecting
and storing data during a crash or near-crash
event. The recorded information may assist in
the investigation of such an event. The
modules may record information about both
the vehicle and the occupants, potentially
including information such as:
• How various systems in your vehicle were
operating.
• Whether or not the driver and passenger
seat belts were buckled.
• How far, if at all, the driver was depressing
the accelerator and/or the brake pedal.
• How fast the vehicle was travelling.
• Where the driver was positioning the
steering wheel.
To access this information special equipment
must be connected directly to the recording
modules. Land Rover do not access event data
recorder information without obtaining
consent, unless pursuant to court order or
where required by law enforcement, other
government authorities or third parties acting
with lawful authority.
L
Introduction
Other parties may seek to access the
information independently of Land Rover.
PARTS AND ACCESSORIES
WARNINGS
The fitting of non-approved parts and
accessories, or the carrying out of
non-approved alterations or conversions, may
be dangerous and could affect the safety of the
vehicle and occupants and also invalidate the
terms and conditions of the vehicle warranty.
Land Rover will not accept any liability
for death, personal injury or damage to
property which may occur as a direct result of
fitment on non-approved accessories or the
carrying out of non-approved conversions to
Land Rover vehicles.
Land Rover strongly advise against
making any modifications to the
suspension or steering system. This could
seriously affect the handling and stability of
the vehicle leading to loss of control or
roll-over.
The vehicle has been designed, built and tested
to cope with a variety of off-road driving
conditions, some of which can place the
severest possible demands on control systems
and components. As such, fitting replacement
parts and accessories that have been
developed and tested to the same stringent
standards as the original components will
safeguard the continued reliability, safety and
performance of your vehicle.
To augment the vehicle's already impressive
performance, a comprehensive range of Land
Rover-approved spare parts and accessories is
available, enabling the vehicle to fulfil a wide
variety of roles, and enhancing and protecting
the vehicle in the many tasks to which it can be
applied.
42
Land Rover parts are the only parts built to
original equipment specifications and
approved by Land Rover designers; this means
that every single part and accessory has been
rigorously tested by the same engineering
team that designed and built the vehicle and
can therefore be guaranteed for twelve months
with unlimited mileage.
A full list and description of all accessories is
available from your Land Rover Dealer/
Authorised Repairer.
Electrical equipment
WARNING
It is extremely hazardous to fit or
replace parts or accessories, the
installation of which requires the dismantling
of, or addition to, either the electrical or fuel
systems.
Always consult a Land Rover Dealer/
Authorised Repairer before fitting any
accessory.
Fitting inferior quality parts or accessories,
may be dangerous and could invalidate the
vehicle warranty.
It is recommended that you always consult a
Land Rover Dealer/Authorised Repairer for
advice regarding the approval, suitability,
installation and use of any parts or accessories
before fitting.
 R

Introduction
Airbag SRS Travelling abroad
In certain countries, it is illegal to fit parts
WARNING
which have not been made to the vehicle
The components that make up the manufacturers' specification.
airbag SRS are sensitive to electrical or
physical interference, either of which could Owners should ensure that any parts or
easily damage the system and cause accessories fitted to the vehicle while travelling
inadvertent operation or a malfunction of the abroad will also conform to the legal
airbag module. requirements of their own country when they
return home.
To prevent any airbag SRS malfunction, always
consult a Land Rover Dealer/
Authorised Repairer before fitting any of the
following:
• Electronic equipment such as a mobile
phone, two-way radio or in-car
entertainment system.
• Accessories attached to the front of the
vehicle.
• Any modification to the front of the vehicle.
• Any modification involving the removal or
repair of any wiring or component in the
vicinity of any of the SRS components,
including the steering wheel, steering
column, instrument or facia panels.
• Any modification to the facia panels or
steering wheel.
After-sales service
The After Sales Parts service is of paramount
importance, both in the UK and across the
world. In the UK there are over 100 authorised
Land Rover Dealer/Authorised Repairer, all
computer linked for rapid ordering of parts and
accessories.
In addition, with franchised representation in
over 100 countries worldwide, Land Rover are
able to support your vehicle wherever you go.

43
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Keys and remote controls
PRINCIPLE OF OPERATION
Keys and remote controls
E81023
You have been supplied with two remote
controls, with integral keys, to operate all the
vehicle’s locks.
The operation of all buttons on all remote
controls, will be inhibited while a key is in the
starter switch.
Note: Interference from other radio equipment,
operating on a similar frequency may affect the
remote control. If this happens, operate the
remote control as close as possible to the
vehicle or use the key.
Note: If the remote control fails to work even
when close to the vehicle, it may not be
synchronised with the system. Start and run
the engine for six minutes to synchronise. If
the remote control still fails to operate, unlock
the vehicle manually. See USING THE KEY
(page 45).
44
Remote control battery
CAUTION
The remote control contains delicate
electronic circuits and must be protected
from impact, water damage, high
temperatures and humidity, direct sunlight
and the effects of solvents, waxes and abrasive
cleaners.
The battery is rechargeable. If the battery needs
recharging the following will occur:
• KEY BATTERY LOW will be displayed in the
main message centre.
• A gradual deterioration in range and
performance will be noticed.
To recharge the battery, insert the key in the
ignition and start the engine.
GENERAL INFORMATION ON RADIO
FREQUENCIES
Note: The radio frequency used by your remote
control may be used by other devices. For
example, amateur radios, medical equipment,
wireless head phones or other remote control
devices. This may cause the frequency to be
jammed and prevent your remote control from
operating correctly.
Environmental conditions can affect the
operation of remote controls, and the operating
range may vary considerably depending on the
vehicle's location.
 R

Keys and remote controls

USING THE KEY PROGRAMMING THE REMOTE
Emergency locking and unlocking
CONTROL
The Land Rover button on the remote control
Under a removable cap on the left front door
can be programmed to operate one of the
outer handle, there is an emergency-use door
following functions:
lock.
• Panic alarm.
• Headlamp courtesy delay.
• Air suspension control.
The currently programmed feature will be
activated when the reprogramming sequence
is started.
The button is disabled when the key is in the
ignition switch.
Panic alarm

2
E80563 3

Press and hold the Land Rover button and

press the hazard warning switch. A chime will
confirm the feature is programmed.
E80586
The alarm will sound and the hazard warning
lamps will flash when the button is pressed.
1. Insert the key fully into the slot under the Press the lock or unlock buttons or insert the
cap and turn clockwise to release the key in the ignition switch, to switch off the
forward edge of the cap. alarm.
2. Remove the cap and withdraw the key.
3. Insert the key into the emergency lock, and
turn counterclockwise to unlock.
4. If the alarm is armed, it will sound when
the door is unlocked. Insert the key in the
starter switch to stop the alarm.
To emergency lock the vehicle, reverse the
above instructions.

45
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Keys and remote controls
Headlamp courtesy delay
E80564
Press and hold the Land Rover button and flash
the headlamps. A chime will confirm
successful programming.
A short press of the Land Rover button will turn
on the headlamps for the length of time
specified in Settings. See TRIP COMPUTER
(page 115).
A second press of the button after three
seconds, will deactivate the lamps.
Air suspension control
E80565
Press and hold the Land Rover button and
press the suspension raise/lower switch. A
chime will confirm the feature is programmed.
Programming of this function must be done
within one minute of switching off the engine.
Before attempting to raise or lower the
suspension, turn on the hazard warning lamps
and close all the doors.
To raise the suspension, press and hold the
Land Rover button and the lock button.
46
To lower the suspension, press and hold the
Land Rover button and the unlock button.
If any button is released during the raising or
lowering, all movement will stop, until the
buttons are pressed again.
Initially the height will change slowly, but will
increase after three seconds.
While the height is changing, a symbol on the
raise/lower switch will be lit, according to the
direction of movement. See ADJUSTING THE
SUSPENSION (page 180).
If the suspension is not set to On-road height,
all movement will stop when On-road height is
reached. Release the buttons and press again,
to continue. See ADJUSTING THE
SUSPENSION (page 180).
Single-point entry
This feature enables the driver's door to be
unlocked, while leaving the other doors in a
locked state.
Single-point entry can be disabled on individual
remote control keys, by pressing and holding
the lock and unlock buttons for three seconds.
All doors will now unlock with a single press.
Repeating the procedure will re-enable single
point entry.
Each time single-point entry is enabled or
disabled, the vehicle will lock then unlock into
the selected mode.
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Locks
LOCKING AND UNLOCKING
Locks

To operate, the remote control must be within

range of the vehicle when a button is pressed.
Note: If the remote control fails to work even
when close to the vehicle, it may not be
synchronised with the system. Start and run
the engine for six minutes to synchronise. If
the remote still fails to respond, unlock the
vehicle manually. See USING THE KEY
(page 45).
Note: If a key is in the starter switch, the
vehicle will not respond to remote control
commands.
Note: If any door or the tailgate is unlocked 10
times within a short period, the latch is
disabled for approximately one minute.
Superlocking
WARNING
For safety, never use superlocking if
passengers are to remain inside the
vehicle - in an emergency they would not be
able to escape, or be released by emergency
services. Also, any movement from within the
vehicle would activate the interior space
protection alarm.
Superlocking is activated by one press of the
lock button on the remote control.
When the vehicle is superlocked, the doors can
only be opened (from inside or outside of the
vehicle) with the correct key or remote control.
The interior door handles are immobilised.
Locking with the remote control
Remove the key from the starter switch and
shut all doors, the bonnet and the tailgate.
1
2
3
4
E80759
The four buttons on the remote control are
used as follows:
1. Key release button
2. Lock button
• Press to superlock all doors and to
activate the perimetric alarm, the interior
space protection and the tilt sensor.
• Press twice within three seconds to lock
all doors and activate the perimetric
alarm, but not activate interior space
protection or tilt sensor.
• The direction indicator lamps will flash
three times.
3. Unlock button
• Press once to disarm the alarm and
unlock the driver’s door. Press again to
unlock the remaining doors.
• In either case, the interior lamps
illuminate and the direction indicators
flash once.
4. Land Rover button. See PROGRAMMING
THE REMOTE CONTROL (page 45).

47
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Locks
Partial locking
If an aperture (door, bonnet or tailgate) is not
fully closed when the remote control lock
button is pressed, the horn will sound briefly to
signal that an aperture is still open. The alarm
will remain disarmed, but all of the closed
apertures will lock.
As soon as the open aperture is closed, the
system will automatically arm, signalled by
three flashes of the hazard warning lamps, with
interior space protection activating 30 seconds
later.
Note: The vehicle will not superlock if an
aperture (other than the bonnet) is open.
Master lock and unlock switches
Automatic re-lock
If the vehicle is unlocked using the remote
control and a door, the tailgate or the bonnet is
not opened within one minute, the vehicle will
re-lock and the alarm will re-arm.
Automatic unlocking
If the vehicle is involved in a collision which
causes a restraints device to deploy, all door
locks will automatically be unlocked, the
hazard warning lamps will flash and the interior
lamps will illuminate.
Interior door handles and door locking
levers

1 2

E80762

E80760 From inside the vehicle, each door can be

individually locked by depressing the
1. Press the unlock switch to unlock all the appropriate lever (arrowed).
doors.
To open and unlock a front door, pull the door
If the vehicle is superlocked, the switch is handle.
inhibited.
To open a rear door, first return the locking
2. Press the lock switch to lock all the doors. lever to its unlocked position, then pull the
Speed-related locking door handle.
This feature locks all the doors automatically When the master lock or unlock switch is used,
when the vehicle speed exceeds 8 km/h or speed related locking is activated, all door
(5 mph). locking levers will activate automatically.
Speed related locking can be disabled. See
TRIP COMPUTER (page 115).
Note: Pressing the master lock or unlock
switch will override the speed locking function
for the journey.

48
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Locks
Opening the tailgate

E80763

Upper tailgate
Unlock the vehicle and press the touch pad on
the underside of the exterior handle. Pull to
open.
Lower tailgate
With the upper tailgate open, press the touch
pad on the lower tailgate waist moulding.
Door open warning indicator
Illuminates when the tailgate or one
of the vehicle's doors is open. On
vehicles with a message centre, the
message DRIVER’S DOOR OPEN will be
displayed when the driver’s door is open or not
fully closed.

49
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Engine immobiliser
PRINCIPLE OF OPERATION
Engine immobiliser

Your vehicle is fitted with a sophisticated

electronic engine immobilisation system.
Engine immobilisation occurs automatically
five seconds after the key is removed from the
starter switch.
Note: The engine will be re-mobilised
automatically whenever the key is inserted into
the starter switch. When this happens, the
anti-theft alarm indicator will illuminate for one
second.

CODED KEYS
Note: A replacement remote control can only
be obtained from your Land Rover
Dealer/Authorised Repairer. The Dealer will
require proof of ownership.
Notify your Dealer immediately if a remote
control is lost or stolen.

50

Alarm
PRINCIPLE OF OPERATION
Alarm
E81206
Your vehicle is fitted with a sophisticated
electronic anti-theft alarm system. There are
also a number of additional security features,
some of which are selectable options and some
are standard features of the vehicle.
In order to ensure maximum security and
operating convenience, you are strongly
advised to gain a full understanding of the
features and alternatives available, by
thoroughly reading this section of the
handbook.
Vehicle security
The security system fitted to your vehicle is
Thatcham category one approved and meets
European regulation 97 and directive 95/56/EC.
Battery-backed sounder
In some markets a separate, battery-backed
sounder is fitted. This device will sound if the
alarm is activated, or if the vehicle battery or
the sounder are disconnected.
51
R
ARMING THE ALARM
Perimetric alarm
This feature is activated automatically
whenever the vehicle is locked using the
remote control and protects the doors, bonnet
and tailgate.
If any of these apertures are opened, or if an
unknown key is inserted into the starter switch,
the alarm will be triggered.
When the perimetric alarm is activated, the
direction indicators will flash three times, and
the anti-theft alarm indicator will flash.
Partial arming
If an aperture (door, bonnet or tailgate) is not
fully closed when the remote control lock
button is pressed, the horn will sound briefly to
signal that an aperture is still open. The alarm
will remain disarmed, but all of the closed
apertures will lock.
As soon as the open aperture is fully closed,
the system will automatically arm, signalled by
three flashes of the hazard warning lamps, with
interior space protection activating 30 seconds
later.
Note: The vehicle will not superlock if an
aperture (other than the bonnet) is open.
L

Alarm
Interior space protection Anti-theft alarm indicator
Interior space protection is activated whenever
the vehicle is superlocked.

E80560

The indicator provides information about the

status of the alarm and immobiliser systems,
as follows:

Alarm status Indicator

Armed with space Triple flash for 10
E80559
protection seconds, then single
Four roof-mounted sensors monitor the flash
interior space and activate the alarm if Armed without space Double flash for 10
movement of air is detected in the passenger protection seconds, then single
compartment. flash
Note: Interior space protection cannot be Disarmed, engine Single flash
activated if an aperture (other than the bonnet) immobilised
is open.
Disarmed, engine A one second flash
Disabling interior space protection mobilised
To disable interior space protection, press the
lock button on the remote control twice within SWITCHING OFF THE ALARM
three seconds. If the alarm is triggered, the alarm will sound
and the hazard warning lamps will flash for 30
seconds, before resetting to the same
protection status that existed prior to the alarm
being triggered.
To silence the alarm, press the lock or unlock
button on the remote control or insert the key
into the starter switch. Pressing the lock button
will keep the alarm armed.

52
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Alarm
If the alarm has been activated since it was last
armed, the hazard warning lights will flash
rapidly for eight seconds when the alarm is
disarmed.

TILT SENSOR
Your vehicle is fitted with a tilt sensor which
activates the alarm if the vehicle is tilted fore
and aft, or side to side, after it has been
superlocked.
The alarm will sound if theft is attempted by
hoisting onto another vehicle or if a side is
lifted to attempt wheel removal.
If you wish to have the doors locked but the tilt
sensor disabled (e.g. when aboard a ferry or
having the vehicle transported on a recovery
truck) press the lock button twice within three
seconds.

PANIC ALARM
The Land Rover button on the remote control
can be programmed to operate the panic alarm.
See PROGRAMMING THE REMOTE CONTROL
(page 45).
The alarm will sound and the hazard warning
lamps will flash when the button is pressed.
Press the lock or unlock buttons or insert the
key in the ignition switch, to switch off the
alarm.

53
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Seats
SITTING IN THE CORRECT POSITION 2. Adjust the position of the seat. A minimum
Seats

distance B of at least 254 mm (10 inches)

WARNINGS
Do not adjust the driver's seat while the
vehicle is in motion, this may cause
loss of control and personal injury.
Optimum benefit is obtained from the
seat belt with the backrest angle set to
no more than 30 degrees from the upright
(vertical). Failure to maintain the correct
backrest angle will reduce the effectiveness of
the seat belt and increase the risk of serious
injury or death in a crash.
A comfortable and enables you to maintain full
B
between the centre of the breastbone and
the steering wheel is recommended.
• The driver should hold the steering
wheel with their arms slightly bent.
• The legs should also be slightly bent so
that the pedals can fully be pressed to
the floor.
3. Position the seat belt across the centre of
your shoulder. Fit the lap strap tightly
across your hips and not across your
stomach.
Make sure that your driving position is
control of the vehicle.

E80441

The seat, head restraint, seat belt and airbags

all contribute to the protection of the user.
Correct use of these components will give you
more protection therefore observe the
following points:
1. Sit in an upright position with the base of
your spine as far back as possible and the
backrest reclined not more than 30
degrees A.

54
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Seats
MANUAL SEATS Backrest adjustment
Forward/backward adjustment WARNING
Travelling in a vehicle with the backrest
incorrectly adjusted will reduce the
effectiveness of the seat belt and increase the
risk of serious injury or death in a crash. See
SITTING IN THE CORRECT POSITION
(page 54).

E80435

Lift the bar at the front of the seat and slide the
seat to the desired position.
The seat should then be moved slightly
forwards and backwards, to ensure that the bar
has latched into position.
E80436

Adjust by turning the rotary wheel.

55
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Seats
Height adjustment Folding armrest

E80437

Pumping the lever upwards raises the seat;

downwards lowers the seat. E80439

Lumbar support adjustment The height of the armrest can be adjusted by

turning the knob clockwise to raise or
counterclockwise to lower. The armrest can be
stowed vertically alongside the backrest.

E80438

Turn the knob clockwise to increase lumbar

support or counterclockwise to reduce the
support.

56
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Seats
ELECTRIC SEATS
2

1
3

1
2

4 3

E80424

1. Forward/backward adjustment 3. Seat cushion height adjustment

2. Backrest adjustment 4. Seat cushion edge adjustment

In addition, the seats have a 15 minute (10

WARNING minutes for a driver's seat with seat memory)
Do not adjust any part of a seat while active period initiated when:
the vehicle is in motion. Vehicle • the vehicle is unlocked, or
movement may cause the seat to suddenly
• the starter key is turned to position 0.
shift, potentially causing injury.
The seat adjustment controls are situated on
the outboard side of the seat cushion. The
position of the seat can be adjusted when the
starter key is in position I or II.

57
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Seats
HEAD RESTRAINTS Rear head restraints
WARNINGS Adjustment
Head restraints are designed to support
the back of the head (not the neck), and
to restrain rearward movement in the event of
a collision. The restraint must be correctly
positioned to be effective.
Do not drive or carry passengers with
the head restraints removed from
occupied seats.
Do not adjust the head restraints while
the vehicle is in motion.
Failure to have the head restraints
installed and properly positioned will
E81310
increase the potential for serious injuries.
1. Press the collar button.
Front head restraints
2. Raise or lower the head restraint until the
Note: The front head restraints are an integral
top of the head restraint is level with the
part of the seat, and are not designed to be
top of the head.
removed or adjusted.
Removal
To remove the head restraint, press the collar
button whilst lifting the restraint clear of the
seat.
To replace the head restraint, engage the guide
posts into the collars and press the restraint
downwards until a click is heard.

58
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Seats
REAR SEATS 4. Lower the backrest until it locks into place.
Note: Only Land Rover-approved seat covers
WARNING
and accessories should be used on these seats.
Do not adjust any part of a seat while
the vehicle is in motion. Vehicle Raising the seats
movement may cause the seat to suddenly
shift, potentially causing injury. 1

Second-row seats - 5-seat vehicle

Note: Some 5-seat models are fitted with the
same type of seat as the 7-seat model.
2
Folding the seats
One or both parts of the seat can be folded.
Move the front seats forward and remove any
items from the seats and the rear footwell.

1
2

2 E80412

1. Pull the strap vertically on the back of the

seat to unlock the seat. Continue to pull to
raise the backrest(s) until they click into
3 position.
2. Push the seat cushion(s) firmly back into
position.
3. If the lever has not returned to its locked
position, red flags will be visible around
the lever.
4. Pull the headrest up into the correct
position.
4
4
E80411

1. Fully lower the head restraints.

2. Pull the strap on the required cushion(s),
to raise the cushion to the vertical position.
3. Pull the seat backrest release lever(s)
forward.

59
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Seats
Second row seats - 7-seat vehicle
1
WARNING
Do not adjust any part of a seat while
the vehicle is in motion. Vehicle
movement may cause the unlatched seat to
suddenly shift, potentially causing injury.
The seats can be used in a variety of
configurations:
• As a standard row of three seats. 2
• A backrest can be folded forwards to form
a table.
• One or all seats can be folded flat.
• An outer seat can be folded forwards for
access to the third row of seats. E80413

If the front seats are in their rearmost position,

move them forward prior to folding down the
seats.
Table fold position
WARNINGS
The latching mechanism should be
checked and physically tested to ensure
that both the cushion and backrest are secure
before driving.
Remove any items from the seats and rear
footwell. Fully lower the head restraint on the
seat(s) to be folded.
1. Pull the backrest release lever forwards.
2. Lower the backrest forwards into the
table-fold position.
Note: Only Land Rover-approved seat covers
and accessories should be used on these seats.
To return the seat-back to its upright position,
push the release lever forwards and pull the
backrest up until it clicks into place.
If it has not returned to its locked position, red
flags will be visible around the lever.
Pull the head restraint up to its correct
position.

60
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Seats
Extending the loadspace Raising the seat

CAUTION
1
Do not attempt to raise the seats from
the loadspace position while the
loadspace cover unit is stowed behind it as
2
damage to the unit or seats will result.
4
3

3 4
2

E80414

1. Pull the backrest release lever forwards.

2. Lower the backrest forwards into the
1
table-fold position.
3. Pull the strap at the front of the seat
4. Press down on the seat. E80415

Note: The centre seat must always be folded 1. To raise the seat, pull the strap at the front
first. of the cushion.
2. Grasp the top and bottom of the backrest,
lift the seat and return it to the table-fold
position.
3. Push the release lever forward.
4. Pull the backrest up and push until the
latching mechanism clicks into place.
If the lever has not returned to its locked
position, red flags will be visible around the
lever.
Note: If a combination of backrests, including
the centre backrest, is to be erected, the centre
E81904 backrest should be erected last.

Remove the luggage cover and stow it between

the folded seat rows.

61
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Seats
Access position
WARNING
The outer seat(s) must not be left in the
access position while the vehicle is
being driven. Motion of the vehicle could
cause the seat to drop back into its table-fold
position.
To enter the third-row seats, first ensure that
the head restraint on the second-row seat is
fully lowered.
1 checked and physically tested to ensure
2 Pull the seat down into the table-fold position.
Note: A second-row seat cannot be moved
from the loadspace position, to the access
position. Return the seat to the table-fold
position before attempting to move it to the
access position.
Raising the seat
WARNINGS
When lowering the seats from the
access position, ensure that nothing is
trapped by the returning seat.
The latching mechanism should be
that the cushion and backrest are secure
before driving.
The access lever will click into place. Check
around the lever, a red flag will be visible
behind the lever if the backrest is not correctly
located.

E80416

1. Pull the backrest release lever forwards.

2. Lower the backrest forwards into the
table-fold position.
3. Pull the access lever on the side of the
seat.
4. Tilt the seat forwards.
Once access to the third-row seat has been
gained, return the second-row seat to its fully
upright position.

62
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Seats
Third-row seats Folding the seat
Third row seats can be folded flat.
1
WARNINGS 2
Ensure that nothing has been left under
the seat or in the footwell when folding
down the seat as this could cause damage.
Beware of potential finger traps when 3
operating the seats.

CAUTION
Do not attempt to raise the seats from
the loadspace position while the
loadspace cover is in its floor level stowage 4
position as this may damage either the cover
or the seats.

E80417

1. Press the head restraint release button.

2. Fold the head restraint fully downwards.
3. Pull up the release strap at the rear corner
of the cushion; this lifts under spring
pressure.
4. Fold the cushion fully forwards until it
latches into position.
5. Pull up the backrest release lever.
6. Fold the backrest fully forwards until it
latches into position in the loadspace floor.

63
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Seats
Raising the seat 5. Raise the head restraint until it latches into
position.
WARNINGS
Note: When not in use, the head restraints
The head restraint must always be should be folded to improve rear vision.
raised when using the third-row seat.
Do not use the seat until it is fully
raised.

1 2

E80418

1. Pull lever to release backrest.

2. Raise the backrest into its upright position,
ensuring that it is fully latched into place.
3. Release catch and raise cushion.
4. Push the cushion into place, ensuring that
the cushion is latched to the backrest.

64
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Seats
HEATED SEATS
Front seat heaters

E80400

Rear seat heaters

E80401

With the starter switch turned on, the seat

cushion and backrest can be heated at two
different settings.
• Press once to operate at the high setting
(both indicators illuminate). As cabin
temperature rises, the heaters will switch
to the low setting and one light will
extinguish
• Press twice to operate at the low setting
(one indicator illuminates).
• Press a third time to turn off the heaters
(both indicators will extinguish).
The seat heaters are thermostatically
controlled and will maintain a factory-set
temperature.
Note: The seat heaters consume considerable
power from the battery. It is recommended that
they are only operated while the engine is
running.

65
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Seat belts
GENERAL INFORMATION
Seat belts
WARNINGS
Seat belts are life saving equipment. In
a collision, occupants not wearing a
seat belt can be thrown around inside or
possibly thrown out of the vehicle. This is
likely to result in more serious injuries than
would have been the case had a seat belt been
properly worn. It may even result in loss of life.
Make sure all occupants are securely
strapped in at all times - even for the
shortest journeys.
The airbag supplemental restraint
system (SRS) is designed to add to the
overall effectiveness of the seat belts. It does
not replace them. Seat belts must always be
worn.
Seat Belts are designed to bear upon
the bony structure of the body and
should be worn low across the pelvis, or pelvis
chest and shoulders, as applicable; wearing
the lap section of the belt across the
abdominal area must be avoided.
Do not wear seat belts over hard, sharp
or fragile items in clothing, such as
pens, keys, spectacles, etc.
Seat belts should be adjusted as firmly
as possible, consistent with comfort, to
provide the protection for which they have
been designed. A slack belt will greatly reduce
the protection afforded to the wearer.
Do not allow front seat occupants to
travel with the seat backs reclined
steeply rearwards. Optimum benefit is
obtained from the seat belt with the seat back
angle set to no more than 30 degrees from the
upright.
Belts should not be worn with the
straps twisted.
66
WARNINGS
Ensure that all seat belts are worn
correctly - an improperly worn seat belt
increases the risk of death or serious injury in
the event of a collision.
Each belt assembly must only be used
by one occupant; it is dangerous to put
a belt around a child being carried on the
occupant’s lap.
It is essential to replace the entire
assembly after it has been worn in a
severe impact, even if damage to the assembly
is not obvious.
No modifications or additions should
be made by the user, which will either
prevent the seat belt adjusting devices from
operating to remove slack, or prevent the seat
belt assembly from being adjusted to remove
slack.
Should the seat belt not retract and
remain at its static length, consult your
Land Rover Dealer/Authorised Repairer.
Care should be taken to avoid
contamination of the webbing with
polishes, oils and chemicals and particularly
battery acid. Cleaning may safely be carried
out using mild soap and water. The belt should
be replaced if webbing becomes frayed,
contaminated or damaged.
Where possible, use the seat belts to
secure large items of luggage that are
to be carried on the seats. In the event of an
accident, unsecured items become flying
missiles, capable of causing serious injury.
Never wear just the lap strap of a
lap/shoulder diagonal seat belt and
never sit on the lap strap using just the
shoulder strap. These actions are extremely
dangerous and increase your risk of serious
injury.

Seat belts
Seat belts
Lap/shoulder inertia reel seat belts are
provided for both front seat occupants and all
rear seat positions.
The inertia reel operating mechanism of the
seat belts, allows the wearers to move their
upper bodies to reach various controls.
The seat belts include a buckle sensor, to
detect when the buckle is latched.
Caring for seat belts
Regularly inspect the belt webbing for signs of
fraying, cuts and wear; also pay particular
attention to the condition of the fixing points
and adjusters.
Do not bleach or dye the webbing and avoid
contaminating the webbing with polish, oil or
chemicals. See FASTENING THE SEAT BELTS
(page 68).
Testing inertia reel belts
• With the seat belt fastened, give the
webbing near the buckle a quick upward
pull. The buckle must remain securely
locked.
• With the seat belt unfastened, reel out the
webbing to the limit of its travel. Check that
unreeling is free from snatches and snags
and then allow the belt to fully retract.
• Partially unreel the webbing, then hold the
tongue plate and give it a quick forward
pull. The mechanism must lock
automatically and prevent any further
unreeling.
If a seat belt should fail any of these tests, seek
qualified assistance.
Note: If the vehicle is parked on ground that is
not level, the seat belt mechanism may lock.
This is not a fault; gently ease the belt from the
upper anchorage to release.
67
R
Seat belt pre-tensioners
WARNINGS
The seat belt pre-tensioners will only be
activated once and then must be
replaced by a Land Rover Dealer/Authorised
Repairer. Failure to replace the pre-tensioners
will reduce the efficiency of the vehicle's front
restraint systems.
After any impact, always have the seat
belts and pre-tensioners checked and,
if necessary, replaced by a Land Rover Dealer/
Authorised Repairer.
In the interests of safety, it is
recommended that removal or
replacement of the front seats and seat belts
should only be carried out by a Land Rover
Dealer/Authorised Repairer.
The seat belt pre-tensioners activate in
conjunction with the airbag SRS and provide
additional protection in the event of a severe
frontal impact on the vehicle. The
pre-tensioners automatically retract the seat
belts fitted to the front seats. This reduces any
slack in both the lap and diagonal portions of
the belts, thereby reducing forward movement
of the belt wearer in the event of a severe
frontal collision.
The airbag SRS warning indicator on the
instrument pack, will alert you to any
malfunction of the seat belt pre-tensioners.
If the pre-tensioners have been activated, the
seat belts will still function as restraints and
must be worn in the event that the vehicle
remains in a driveable condition.
Note: The seat belt pre-tensioners will be
activated in major side and frontal impacts and
in rollovers.
L

Seat belts
SEAT BELT REMINDER FASTENING THE SEAT BELTS
Beltminder commences when the
starter switch is turned to position II
and the driver's belt is unbuckled.
Dependent on market, the warning indicator in
the instrument pack illuminates, the message
FASTEN SEAT BELTS appears in the message
centre and an audible chime sounds.
The visual and audible warnings applicable to
the Beltminder feature are market dependent to
meet individual market requirements. The
E80379
warning signals given may also change
depending on whether the vehicle is stationary Insert the metal tongue plate into the buckle
or when the vehicle speed exceeds a nearest the wearer. A click indicates that the
pre-determined threshold. belt is securely locked.
In certain markets, the Beltminder feature also The buckles on third row seats are
applies to the front passenger seat and will be spring-loaded allowing them to be stowed
activated if the seat is occupied and the within the seat. This is to prevent damage when
occupant's seat belt is unbuckled. the seats are folded flat. To fasten the belt, pull
Note: Objects placed on the passenger seat the buckle up from the seat before inserting the
may activate the seat belt warning system. tongue plate.
Although not advisable, it is Adjust the seat belt to eliminate any slack in the
possible to disable the Beltminder webbing.
function. Please see a Land Rover
Dealer/Authorised Repairer to disable or
Releasing the belt
reinstate the function. Press the red button on the seat belt buckle.

68

Seat belts
SEAT BELT HEIGHT ADJUSTMENT
WARNING
Maladjustment of the seat belt could
reduce its effectiveness in a crash.
Always ensure that the anchorage is correctly
located and properly locked in one of the
height positions before driving and do not
adjust the height once the vehicle is in motion.
E80375
Press down (solid arrow) to release the catch,
then lift or push down to adjust the height of
the anchorage.
Ensure the anchorage has clicked into one of
the locked positions before driving.
Where possible passengers should adjust their
position on the seat to enable the seat belt
webbing to cross the shoulder without
pressing on the neck.
69
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USING SEAT BELTS DURING
PREGNANCY
WARNINGS
Pregnant women must wear a correctly
positioned seat belt; it is safer for
mother and unborn child.
Never place anything between you and
the seat belt in an attempt to cushion
the impact in the event of an accident. It can be
dangerous and reduce the effectiveness of the
seat belt in preventing injury.
E80374
During pregnancy, Women should wear the
belt across the hips below the baby, with the
diagonal belt passing across the shoulder,
between the breasts and to one side of the baby
- if in doubt, consult a doctor.
L
Airbags
PRINCIPLE OF OPERATION
Airbags
5 4
E82231
WARNINGS
The airbag is a supplementary restraint
system that provides additional
protection in a severe impact only - it does not
replace the need to wear a seat belt. To reduce
the risk of injury or death in the event of a
crash, all occupants in all seating positions
should wear their seat belt.
An inflating airbag can cause facial
abrasions and other injuries. Minimise
the risk of injury by ensuring that the front seat
occupants are seated correctly, with the seat
as far back as is practical.
Ensure that a gap is maintained
between the side of the vehicle and the
head and torso, to enable unobstructed
inflation of the curtain and seat mounted side
airbags. Do not lean out of the window.
70
3 2 1
The airbag Supplementary Restraint System
(SRS) incorporates front airbags 1 and 2, seat
mounted side airbags 3 and curtain airbags 4
for the front seat occupants driver and curtain
airbags 5 for occupants in the rear seat
outboard positions (see illustration for airbag
locations). These are indicated by the word
AIRBAG on the trim.
Provided the occupants are correctly seated,
with the seat belts properly worn; in the event
of a severe frontal impact, the airbags will
provide additional protection to the chest and
face of the front seat occupants.
In the event of a severe side collision, airbags
provide additional protection to the side of the
head and body facing the impact for front seat
occupants and to the side of the head facing
the impact for outer rear seat occupants.
Note: Inflation and deflation of the front and
seat mounted side airbags takes place very
quickly and will not protect against the effects
of secondary impacts that may occur. Head
airbags deflate at a slower rate and therefore do
offer some additional protection in the event of
a secondary impact.
 R

Airbags
How the airbag SRS works Obstruction of airbags
Operation of the airbag SRS is dependent on WARNINGS
the rate at which the vehicle's passenger
compartment changes speed as a result of a Do not allow passengers to obstruct the
collision. The circumstances affecting different operation of the airbags by placing feet,
collisions (vehicle speed, angle of impact, type knees or any other part of the body, or any
and size of object hit, for example), vary other objects in contact with, or in close
considerably and will affect the rate of proximity to, an airbag module.
deceleration accordingly. Do not attach or position items on, or
close to the roof lining, A, B and C post
In the event of a collision, the airbag control
finishers, front seat backrests or to an airbag
unit monitors the rate of deceleration induced
cover, which could interfere with the inflation
by the collision, to determine whether the
of the airbag or be propelled inside the vehicle
airbags should be deployed.
causing injury to the occupants.
When deployed, inflation of the airbags is
virtually instantaneous and occurs with
C B A
considerable force, accompanied by a loud
noise. The inflated bag, together with the seat
belt restraint system, limit the movement of an
occupant, thereby reducing the risk of injury to
the head and upper torso.
The airbag SRS is not designed to operate as a
result of:
• Rear collisions.
• Minor front impacts. E80487

• Minor side impacts.

• Heavy braking.
• Driving over bumps or potholes.
It follows, therefore, that significant superficial
damage can occur without the airbags
deploying or, conversely, that a relatively small
amount of structural damage may cause the
airbags to be deployed.
Do not use non-approved seat
covers/accessory seat covers over a front seat;
in particular, seat covers that have not been
designed for use with side airbags. If in doubt,
consult your Land Rover Dealer/Authorised
Repairer.
Note: Unauthorised modification of the vehicle
or parts may invalidate the vehicle’s warranty.

71
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Airbags
Deployment effects
WARNINGS
Following inflation, some airbag SRS
components are hot - do not touch until
they have cooled.
Even with airbag SRS equipment fitted,
seat belts must always be worn.
An airbag will only provide additional
protection in certain types of frontal
collisions. No protection is afforded against
the effects of rear impacts, or minor frontal
impacts.
Inflation and deflation take place
instantaneously and will not provide
protection against the effects of secondary
impacts that can occur during multiple vehicle
collisions.
Activation of an airbag creates dust,
causing possible breathing difficulties
for asthma sufferers or other people with
respiratory problems. If an airbag is activated,
any occupant who suffers from breathing
difficulties should either leave the vehicle as
quickly as possible, or obtain fresh air by fully
opening the windows and doors.
When an airbag inflates, a fine powder is
released. The powder may cause irritation to
the skin and should be thoroughly flushed from
the eyes and any cuts or abrasions of the skin.
After inflation, the front and seat mounted side
airbags deflate immediately (curtain airbags
deflate slowly). This provides a gradual
cushioning effect for the occupants and also
ensures that the driver's forward vision is not
obscured.
Disability modifications
Occupants with disabilities that may require the
vehicle to be modified must contact a Land
Rover Dealer/Authorised Repairer before any
modifications are made.
72
SIDE AIRBAGS
WARNING
Ensure that a gap is maintained
between the side of the vehicle and the
torso, to enable unobstructed inflation of the
seat-mounted side airbags
Side airbags are designed to protect the thorax
region of the torso and will only deploy in the
event of a severe side impact. They will not
inflate as a result of frontal or rear impacts
only.
In the event of a severe side collision, the
airbags on the impacted side of the vehicle
deploy from the side of the seat-back, rapidly
inflating to form a cushion between the front
seat occupants and the side of the vehicle. The
airbags on the non-impacted side of the vehicle
will not be deployed.
CURTAIN AIRBAGS
WARNING
For the curtain airbags to deploy
correctly, the roof lining and A post trim
must be undamaged and fitted correctly. Any
damage or suspect fitting should be referred
to a Land Rover Dealer/Authorised Repairer
for examination.
Curtain airbags are designed to protect the
head in the event of a severe side impact or
rollover event. They will not inflate as a result
of frontal or rear impacts alone.
In the event of a severe side collision, the
airbag pushes out from behind the roof lining
and pillar finisher as it inflates.
 R

Airbags
DISABLING THE PASSENGER AIRBAG Passenger airbag status indicator
WARNINGS
Always check the status indicator with
the starter key in position ll.

2U5A-14B372-BA

E80936 6CD-465

2U5A-14B372-BA
E80935
Prior to fitting a child restraint on the front
passenger seat, open the passenger door and
using the starter key, turn the airbag disabling
switch to the OFF position.
When the airbag disabling switch is turned to
the OFF position, the passenger airbag status
indicator (arrowed) will illuminate whenever
the starter key is turned to position ll.
When switching the passenger airbag on or off,
check that the status indicator shows the
correct condition.

73
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Airbags
Airbag switched OFF
WARNINGS
To avoid the risk of injury, never use a
child restraint in the front of the vehicle
unless the passenger airbag has been
switched OFF.
E82245
In order to fit a child restraint to the front
passenger seat, use the starter key to turn the
passenger airbag disabling switch to the OFF
position.
Check that when the starter key is turned to
position II, the status indicator on the facia is
illuminated confirming that the passenger
airbag is not operational.
If the airbag SRS warning indicator in the
instrument pack illuminates continuously,
remove the child restraint from the front seat
and consult your Land Rover Dealer/
Authorised Repairer.
74
Airbag switched ON
WARNINGS
To ensure that the adult restraint
system performs as intended, make
sure that the passenger airbag is switched ON.
E82246
When an adult is seated in the front passenger
seat of your vehicle, ensure that the passenger
airbag disabling switch is turned to the ON
position.
This will ensure that the airbag will perform as
intended in the event of a crash.
Check that when the starter key is turned to
position II, the operational status lamp on the
facia is not illuminated, confirming that the
passenger airbag is operational.

Airbags
AIRBAG WARNING LAMP
A red warning indicator in the
instrument pack will alert you to any
malfunction of the airbag SRS. On
vehicles with a message centre, this will be
accompanied by the message AIRBAG FAULT.
Seek qualified assistance urgently if any of the
following symptoms occurs:
• The warning indicator fails to illuminate
when the starter switch is turned to
position ll.
• The warning indicator fails to extinguish
within approximately four seconds after
the starter switch is turned to position Il.
• The warning indicator illuminates after the
engine is started, or while the vehicle is
being driven.
75
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AIRBAG SERVICE INFORMATION
WARNING
For your safety a Land Rover Dealer/
Authorised Repairer must carry out any
of the following tasks.
Removal, replacement, repair, or modification,
of any wiring or component in the vicinity of
the SRS components, including the steering
wheel, steering column, door trim, roof lining,
instrument pack and instrument panel.
Installation of electronic equipment such as a
mobile phone, two-way radio or in-car
entertainment system.
Modification to the front or side of the vehicle,
including the bumper and chassis.
Attachment of accessories to the front or side
of the vehicle.
In addition, always contact your Land Rover
Dealer/Authorised Repairer if:
• An airbag inflates.
• A Pre-tensioner activates.
• The front or side of the vehicle is damaged,
even if the airbag has not inflated.
• Any part of an airbag module cover shows
signs of cracking or damage.
• Any trim containing airbags - front seat
back, headlining or pillar trims - becomes
damaged.
L
Child safety
CHILD SEATS
Child safety
WARNINGS
Do not use a child restraint on a seat
with an operational airbag in front of it.
There is a risk of death or serious injury when
the airbag deploys. The best place for a child,
is properly restrained in the rear seats.
Original text according to EEC R94.01.
Extreme Hazard! Do not use a rearward
facing child restraint on a seat protected by an
airbag in front of it.
Do not use a forward facing child seat,
until a child is above the minimum
weight of 9 kg (20 lb.) and able to sit up
unaided. Up to the age of two, a child's spine
and neck are not sufficiently developed to
avoid injury in a frontal impact.
Do not allow a baby or infant to be held
or carried on the lap. The force of a
crash can increase effective body weight by as
much as 30 times, making it impossible to
hold on to the child. Children typically require
the use of a booster seat appropriate to their
age and size, thereby enabling the seat belts to
be properly fitted, reducing the risk of injury in
a crash. Children could be endangered in a
crash, if their child restraints are not properly
secured in the vehicle.
Do not use a child seat that hooks over
the seat back. This type of seat cannot
be satisfactorily secured and is unlikely to be
safe for your child.
The seat belts fitted to your vehicle are
designed for adults and larger children. For
their safety, it is very important that all infants
and children under 12 are restrained in a
suitable child safety seat appropriate to their
age and size. See CHILD SEAT POSITIONING
(page 78).
76
Only fit a child seat that has been approved for
use in your vehicle, and ensure that the
manufacturer's fitting instructions are followed
exactly.
Note: Crash statistics show that children are
safer when properly restrained in the rear
seating positions than they are in the front.
If a child must travel in the front passenger
seat, Land Rover recommends the following:
1. Position the seat fully rearward.
2. Adjust the lumbar to its minimum.
3. Adjust the cushion to its highest position.
4. Set cushion rake to its lowest position.
5. Set seat belt upper anchorage to its lowest
position.
6. For markets other than Australia, disable
the airbag. See DISABLING THE
PASSENGER AIRBAG (page 73).
E80608
This symbol, affixed to the passenger side B
post of your vehicle, warns against the use of a
rear-facing child seat in the front passenger
seat when a passenger airbag is operational.
Child restraints for larger children
In a situation where a child is too large to fit
into a child safety seat, but is too small to safely
fit the three point seat belt properly, a booster
seat is recommended for maximum safety.
Follow the manufacturer’s fitting instructions
exactly, then adjust the seat belt to suit.

Child safety
Seat belt automatic locking mechanism
The second and third row seat belts have a
special locking mechanism which aids the
retention of child seats.
The procedure to install a child seat is as
follows:
1. Place the child seat in the vehicle, attach
the seat belt and secure the buckle in
accordance with the manufacturer’s fitting
instructions.
2. Pull on the shoulder section of the belt to
reel out all of the remaining webbing to the
limit of its travel. This will engage the
automatic locking feature, which then acts
as a ratchet, allowing the webbing only to
retract.
3. Allow the seat belt to retract onto the child
seat (a clicking sound will confirm that the
ratchet has engaged), while firmly pushing
the child seat into the vehicle seat.
4. Ensure that there is no slack in the seat belt
by pulling upwards on the shoulder belt
immediately above the child restraint. The
seat belt should now be locked and the
child seat held firmly in position.
When the child seat is removed and all of the
seat belt webbing is allowed to retract, the seat
belt locking mechanism reverts to normal
operation.
Note: Where possible, use the seat belt
automatic locking mechanism to secure large
items of luggage that are to be carried on the
seats. In the event of an accident, insecure
items become missiles capable of causing
serious injury.
77
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Child restraint checklist
Complete the check list every time a child
travels in the vehicle:
• Carefully follow the instructions provided
by the manufacturer of the restraint
system.
• Always use the appropriate child restraints
and adjust harnesses for every child, every
trip.
• Always attach the top tether when
installing the ISOFIX seat.
• Always give the ISOFIX seat a final pull to
ensure that the lower anchors are secure.
• Avoid dressing a child in bulky clothing
and do not place any objects between the
child and the restraint system.
• Regularly check the fit of a child seat and
replace seats or harnesses that show signs
of wear.
• Ensure that you have removed all slack
from the adult seat belt.
• Set children a good example - always wear
your seat belt.
L

Child safety
CHILD SEAT POSITIONING
The following table shows the suitability of
CAUTION each passenger seat position for carrying
Information given in the table was children up to 12 years of age or 1.5 m (5 feet)
correct at the time of going to press. tall and the installation of suitable child
However, availability of child restraints may restraint systems.
change. Please refer to your Land Rover
Dealer/Authorised Repairer for the latest
recommendation.
Seating position Mass group (with approximate age) As shown on child restraint
0 = Up to 10 kg 0+ = Up to 13 kg I = 9 to 18 kg (20 II and III =15 to 36
(22 lb) (0-10 (29 lb) (0-18 to 40 lb) (9 kg (33 to 80 lb)
months) months) months - 5 years) (4-12 years)
Front passenger U U U U
Rear seats - 5-seat L L L L
vehicle
Second row seats - U U U U
7-seat vehicles
Third row seats X X UF UF

• U = Suitable for universal category restraints approved for this mass group.
• UF = Suitable for forward-facing universal category restraints approved for this mass group.
• X = Not suitable for children in this mass group.
• L = Suitable for particular child restraints as listed in the Child seat usage table.
Recommended child seats

Child size/age Recommended seat

Groups 0 and O+ Britax Cosy-Tot or
Römer Baby Safe.
Group II and III Britax Evolva 23 Ultra.

In many countries, legislation governs how and

where children should be carried when
travelling in a vehicle.
It is the responsibility of the driver to comply
with all regulations in force in the country
where the vehicle is being used.

78
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Child safety
ISOFIX child seat positions
Note:
ISOFIX anchorages are provided for second row outer seating positions. ISOFIX child restraints
should be securely attached following the manufacturers instructions at these locations only.

Mass group as shown on child Size Classes Fixtures Vehicle ISOFIX

restraint. positions
Carrycot F/ G ISO L1/L2 X
0 = Up to 10 kg (22 lb) E ISO R1 IL
0+ = Up to 13 kg (29 lb) C/ D/ E ISO R1/R2/R3 IL
I = 9 to 18 kg (20 to 40 lb) C/ D ISO R2/R3 IL
A/ B1/ B ISO F2/ F2X/ F3 IUF
II = 15 to 25 kg (33 to 55 lb) - - -
III = 22 to 36 kg (48 to 79 lb) - - -

• IUF = suitable for ISOFIX forward child restraints systems of universal category approved for
use in the mass group.
• IL = suitable for particular ISOFIX child restraint systems (CRS) in the table below. These
ISOFIX CRS are those of the "specific vehicle", "restricted" or "semi-universal" categories.
• X = ISOFIX position not suitable for ISOFIX child restraint systems in this mass group and/or
this size class.
Recommended ISOFIX child seats

ISOFIX position Recommended seat

IL Britax Cosy-Tot ISOFIX or
Römer Baby Safe ISOFIX.

79
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Child safety
ISOFIX ANCHOR POINTS
A
WARNINGS
Do not attempt to fit an ISOFIX child
seat to the centre seating position - the
anchor bars are not designed to hold an
ISOFIX child seat in this position. If the child
seat is not correctly anchored, there is a
significant risk of injury to the child in the
event of a collision or emergency braking.
Always follow the child seat or restraint
system manufacturer's instructions
when fitting tether straps.
Note: ISOFIX child restraints are only fitted to
B
the second row seats.

E80614

A. 5-seat vehicles
B. 7-seat vehicles
Both second row outer seating positions, are
equipped to accept ISOFIX restraints.

80
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Child safety
Once the ISOFIX child seat is installed, test the
security of the installation, before seating a
child. Attempt to twist the child seat from side
to side and to pull it away from the vehicle seat,
then check that the anchors are still securely in
place.
Tether strap anchorages (Australia only)
WARNING
E80615
Child restraint anchorages are designed
to withstand only those loads imposed
To install your child seat with an ISOFIX by correctly fitted child restraints. Under no
restraint system: circumstances are they to be used for adult
1. Raise or remove the head restraint. seat belts, harnesses or for attaching other
items or equipment to the vehicle.
2. Lift the velcro strap, exposing the ISOFIX
When fitting a child seat or restraint
locking mechanism.
system, always pass the tether strap
3. Slide the child seat into the locking over the top of the seat back and beneath the
mechanism. underside of the head restraint.
Child seat upper tether anchorage
(5-seat vehicles)

FRONT OF
VEHICLE

E80616

Upper tether anchorages are provided at each

seating position equipped to accept ISOFIX
child restraints (shown in the illustrations).
Note: Always ensure that if an upper tether is E81521
provided, it is secured and tightened properly,
as this provides maximum protection for a
child.

81
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Child safety
Child seat upper tether anchorage CHILD SAFETY LOCKS
(7-seat vehicles)
WARNING
To avoid injury or death, never leave
children unsupervised in the vehicle.

FRONT OF
VEHICLE

E80631

E81522
Child safety locks are fitted to the rear doors.
Provision is made in the second row seats for
Insert the starter key into the keyhole and turn
the fitting of up to three child seats of the type
outwards to activate the child safety lock.
that requires tether strap anchorage points.
With the child safety locks engaged, the rear
Your vehicle is equipped with anchorage points
doors cannot be opened from inside the
on the back of the second row seat frames.
vehicle.
These should be used to attach straps from
child seats or restraint systems. Turn the key inwards to disengage the child
safety lock.

82
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Steering wheel
ADJUSTING THE STEERING WHEEL HORN
Steering wheel

WARNINGS
Do not adjust the steering wheel
position while the vehicle is moving.
This is extremely dangerous!
Ensure that the lever is fully up.
Inadvertent movement of the wheel
may occur if the lever is not locked. E80445

To operate, press either of the horn switches.

AUDIO CONTROL

2
3
4
5
E80450

1. Mode select.
2. Volume up.
E80511 3. Volume down.
The steering wheel position can be adjusted in 4. Channel up.
two directions. 5. Channel down.
Move the lever, located under the steering
wheel, fully downwards (see inset).
Adjust the steering wheel up or down, in or out.
Move the lever fully up to lock.

83
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Steering wheel
VOICE CONTROL CRUISE CONTROL
Cruise control is operated via the switches on
Activating the voice control system
the steering wheel and enables the driver to
maintain a constant road speed without using
the accelerator pedal. See USING CRUISE
CONTROL (page 164).

1
2

3
E80446
4
To activate voice control:
• Briefly pull the control paddle (your Audio
will mute at this point). An audible alert will E80444

be heard, and LISTENING will be displayed
on the main message centre to indicate
that the system is now waiting for a voice
command.
Note: It is only necessary to use the steering
wheel voice control paddle at the beginning of
each voice session.
1. Set + : Set or increase the speed
2. Set - : Set or decrease the speed
3. Resume: Resume set speed
4. Cancel: Cancels without erasing
memorised speed

84
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Lighting
GENERAL INFORMATION Daytime running lamps
Lighting

There are three types of headlamp systems: In certain markets, the side lamps, licence plate
• Halogen high/low beam main lamp with a lamps and headlamp low beams will illuminate
fill-in high beam halogen lamp alongside. with the engine running and the lamps master
switch turned off. The instrument pack
• Bi-xenon high/low beam main lamps with
illumination remains off.
fill-in high beam halogen lamp alongside.
• An Adaptive Front Lighting System (AFS). Unless they are required or
See ADAPTIVE FRONT LIGHTING SYSTEM prohibited by law, daytime running
(AFS) (page 89). lamps can be disabled or enabled by
a Land Rover Dealer/Authorised Repairer.
Halogen headlamps
Stop lamps
Halogen bulbs are very similar to the standard
light bulbs fitted to side or tail lights. Added The stop lamps will illuminate while the brake
traces of halogen inside the bulb make it 10 to pedal is pressed.
20% more efficient than a standard light bulb The stop lamps also illuminate when Hill
of similar voltage and wattage. Halogen bulbs Descent Control is braking the vehicle or
have an operating life of two to three times during Electric parking brake dynamic
longer than a standard bulb. operation. See ELECTRIC PARKING BRAKE
(EPB) (page 155).
Bi-Xenon headlamps
Some vehicles are fitted with Xenon low/high Reversing lamps
beam headlamp units. Xenon lamps provide Selection of reverse gear will operate the
significantly improved visibility, especially reversing lamps.
during adverse weather and driving conditions.
Bi-Xenon units use a Xenon bulb for both high
beam and low beam, whilst a halogen bulb is
used for high beam fill-in. A shutter, operated
by a solenoid, changes the direction of the
Xenon light beam, to give either low or high
beam.
The operational life of a Bi-Xenon light is
significantly longer than that of a conventional
or halogen bulb.

85
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Lighting
LIGHTING CONTROL High beam headlamps
Lamps master switch

E81026

With the lamps master switch in position 3 and

2 3 starter switch in position II, push the column
1
4 stalk away from the steering wheel to select
high beam.
The blue warning indicator in the
AUTO
instrument pack will illuminate
when high beam is selected.
To cancel high beam, pull the stalk towards the
steering wheel.
E81025 To flash the headlamps on high beam, pull the
1. Off stalk towards the steering wheel and release it.
2. Side lamps Headlamp courtesy delay
3. Low beam headlamps The headlamps can be kept on for a short time
4. Automatic control lamps after the vehicle is parked. Turn the starter
switch off with the lamps master switch in
Side lamps positions 2, or 3.
The side lamps and licence plate lamps, Remove the key from the starter switch and
illuminate when the lamps master switch is turn the lamps master switch to position 1. The
turned to positions 2 or 3, regardless of the headlamps will remain illuminated for up to
position of the starter switch. 240 seconds. This time delay is configurable.
A green warning indicator in the See TRIP COMPUTER (page 115).
instrument pack will illuminate The courtesy delay may be cancelled at any
when side lamps are on. time by turning the starter switch to position I
or II or the lamps master switch to positions 1
Low beam headlamps
or 2.
The low beam headlamps, illuminate when the
lamps master switch is turned to position 3, Note: If Automatic Control Lamps are switched
and the starter switch is in position II. on, the headlamp courtesy delay will operate
automatically.

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Lighting
Automatic control lamps REAR FOG LAMPS
With the lamps master switch in position 4 and
starter switch in position II, the side lamps, low
beam headlamps and licence plate lamps will
illuminate automatically when the ambient light AUTO
falls below a pre-defined level.
All of the lamps will go out when the ambient
light rises above that level.

FRONT FOG LAMPS

E81029
1 2 3

With the side lamps or low beam headlamps

AUTO switched on, pull the switch to position 3 to
switch on the rear fog lamps.
If front fog lamps are not fitted, the rear fog
lamps illuminate with the switch in position 2.
An amber warning indicator will
illuminate in the instrument pack
E81028
1 2 when the rear fog lamps are
switched on.
With the side lamps or low beam headlamps To switch off the fog lamps, return the switch
switched on, pull the switch to position 2 to to position 1.
switch on the front fog lamps.
Note: Fog lamps should only be used when
A green warning indicator will visibility is severely restricted.
illuminate in the instrument pack
when the front fog lamps are
switched on.
To switch off the fog lamps, return the switch
to position 1.
Note: Fog lamps should only be used when
visibility is severely restricted.

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Lighting
ADJUSTING THE HEADLAMPS HEADLAMP LEVELLING
Vehicles with coil suspension have manual
Headlamp beam adjustment - Halogen
headlamp levelling to compensate for uneven
It will be necessary to attach blanking decals to loading of the vehicle. If, for instance, the rear
the headlamp lenses to alter the beam pattern. is heavily laden, the resulting tilt of the vehicle
Seek qualified assistance for further may bring the low headlamps beam up to a
information. level unacceptable to other road users.
Headlamp beam adjustment - Xenon
Position of the lever illustrated will vary
depending on the side of vehicle. It may be on
either side of the headlamp bulb aperture.
AUTO
When travelling in countries which drive on the
opposite side of the road, use the lever within
each headlamp unit to alter the beam pattern.

E81502

With the headlamps turned on, rotate the

thumbnail up or down to adjust the vertical aim
of the beams.

Switch position Setting

0 Driver only or driver and
E81158 front seat passenger.
You will need to gain access to the inside of the 0.5 All seats occupied in a
headlamp unit. See REMOVING A HEADLAMP 5-seat vehicle or all seats in
(page 93).Move the lever down for when front and third rows for a
driving in left-hand drive countries and up for 7-seat vehicle.
right-hand drive countries. 1 All seats occupied in a
7-seat vehicle.
1.5 All seats occupied in a
vehicle loaded to its Gross
Vehicle Weight.
2 Driver only in a vehicle
loaded to its Gross Vehicle
Weight.

88

Lighting
HAZARD WARNING FLASHERS
2
E80817 3 The headlamp units can swivel left or right to
Press the switch to operate the hazard warning
lamps. All of the direction indicator lamps will
flash together.
Use only in an emergency to warn other road
users when the stationary vehicle is causing an
obstruction, or is in a hazardous situation.
Remember to switch off before moving away.
89
R
ADAPTIVE FRONT LIGHTING SYSTEM
(AFS)
Adaptive front lighting system (AFS) is a new
lighting system, designed to give the driver
improved visibility. It has two main
components: A swivelling headlamp unit and a
static bending lamp, with a beam set to 45
degrees from the centre line of the vehicle.
improve light spread on bends in the road and
they operate throughout the vehicle speed
range. They also react to braking or
acceleration in the vertical plane, to maximise
headlamp performance. Additional lighting is
supplied by the static bending lamps at speeds
between 30 km/h (18 mph) and 70 km/h (44
mph). If the higher speed is exceeded, the
static bending lamps will only reactivate when
speed reduces to 60 km/h (37 mph). These
headlamps broaden the beam of the headlamps
when cornering.
The system takes inputs from the vehicle's
road speed and steering angle, to determine
the amount of horizontal swivel. The amount of
swivel is highest at low manoeuvring speeds
and movement reduces as speed increases.
Static bending lights operate when the system
detects a steering wheel rotation of 70 degrees
or more.
If reverse gear is selected, the lamps return to
the central position and the unit's swivelling
capability is disabled.
An amber warning indicator will
illuminate in the instrument pack if a
fault is detected with the AFS. Seek
qualified assistance.
L

Lighting
The AFS advantage Cornering lamps
These lamps broaden the beam of the
1 headlamps when cornering during normal
night driving.
Additional lighting comes from the static
bending lamps which have a beam set to 45
degrees outward from the centre line of the
vehicle.
The system switches on the lamp, if it has
received an input from the vehicle's direction
indicator. As the system is ignition-based, the
lamps will not stay on even if the vehicle is
parked with the direction indicator lever in the
operating position.
Only the lamp on the same side as the
operating direction indicator comes on.
2
Operating the direction indicators will also
activate the relevant lamp.
If reverse gear is selected, the lamps return to
the central position and the unit's swivelling
capability is disabled unless the direction
indicators are operating.

E80820

1. Shows the light spread of a vehicle not

fitted with AFS.
2. Shows the light spread of a vehicle fitted
with AFS.

90
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Lighting
DIRECTION INDICATORS
1

2
E80816

With the starter switch in position II, move the

E80821
1. Shows the light spread of a vehicle not
fitted with cornering lamps.
2. Shows the light spread of a vehicle fitted
with cornering lamps.
lever up or down to operate the direction
indicators.
A green left or right warning
indicator in the instrument pack will
flash when the direction indicator
lamps are operating.
When the lever is held momentarily up or down
against spring pressure and then released, the
indicators will flash three times to indicate a
lane change.
Note: The indicators will continue to flash if the
lever is held against spring pressure.
This feature can be enabled or
disabled by a Land Rover
Dealer/Authorised Repairer.
If the warning indicator fails to flash or flashes
rapidly, this may indicate a bulb failure in one
of the direction indicator lamps.

91
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Lighting
INTERIOR LAMPS
Front interior lamps
E81079
The interior lamps can be switched on
individually by pressing the switch adjacent to
the lamp required.
It is possible to de-activate the courtesy lamps
automatic mode by pressing the centre switch.
The message INTERIOR LIGHTS OFF will flash
in the message centre.
To switch the lamps off without disabling
automatic mode briefly press the centre
switch.
To enable automatic mode press the front
centre switch for more than three seconds. The
message INTERIOR LIGHTS AUTOMATIC will
flash in the message centre.
Map lamp operation
Press the required map lamp switch (outer
lamps) to turn on and off.
Glovebox lamp
Illuminates automatically (with headlamps on)
whenever the glovebox is opened and
extinguishes when the glovebox is closed.
92
Rear interior lamps
E81080
The rear interior lamps are grouped together in
the roof above the second row of seats. This
fitment may include the rear air conditioning
controls.
Vanity mirror lamps
The vanity mirror lamps are turned on when the
corresponding vanity mirror cover is opened
and turned off when it is closed.
Note: Map lamps, glovebox lamps and vanity
mirror lamps will extinguish automatically after
15 minutes to prevent battery drain provided
that the starter switch is in position 0.
Low-level night-time illumination
With the main lighting switch turned to
sidelamps or headlamps, LEDs in the front
interior lamps provides very low level
illumination. The level of illumination can be
adjusted using the instrument pack
illumination dimmer switch.
Low level lighting provides very limited
illumination for the interior of the vehicle,
whilst the vehicle is being driven, without
affecting the driver’s night vision.
 R

Lighting
REMOVING A HEADLAMP Removal of headlamp unit
Removing the grille

E80618

1. Remove the grille by pressing down on the

four upper clips, and up on the bottom
two, securing the grille to the vehicle body. E80619

2. Lift the grille clear of the vehicle and place
it where it will not sustain any damage.
1. Carefully lever up the two locking bars.
2. Disconnect the wiring plug from the back
of the unit and remove the unit from the
vehicle.
3. Place face down on a flat surface covered
in a soft material to prevent damage to the
unit's lenses.

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Lighting
Refitting the headlamp unit REMOVING A REAR LAMP

E80591

Note: If accessory lamp guards are fitted, refer

E80628
1. Reconnect the wiring plug.
2. Offer up the unit into position.
3. Push down on the two locking slides.
Refitting the grille
1. Refit the grille, aligning the upper and
lower clips with their respective slots, and
press into place.
2. Ensure the clips have sprung into place
securing the grille
to the separate accessory user instructions for
removal.
The rear lamp unit contains five lamps and it is
necessary to completely remove the unit from
the vehicle in order to change any of the bulbs.
Removal of rear lamp unit
1. With the tailgate open, remove two screws
from the edge of the unit nearer the rear
door aperture.
2. Pull the unit away from the vehicle.
3. Disconnect the wiring multi-plug and
remove the unit from the vehicle. Place
face down on a flat surface covered in a
soft material to prevent damage.

94

Lighting
1 SPECIFICATION CHART (page 104).
2
3 Halogen bulbs
4 beam and front fog lamps. Take care not to
5 touch this type of bulb with your fingers;
E80592
Each bulb is now accessible by twisting off its
electrical connection cap. See BULB
SPECIFICATION CHART (page 104).
1. Stop/tail lamp
2. Direction indicator
3. Tail lamp
4. Reversing lamp
5. Rear fog lamp
Note: Tail lamp 3 uses the same twin-filament
bulb as stop/tail lamp 1.
Refitting the rear lamp unit
1. Reconnect the electrical multi-plug.
2. Locate the unit’s two studs in the sockets
at the outer side of the mounting face.
3. Insert and tighten the two screws on the
side of the unit nearer the door aperture.
4. Check that all of the bulbs work.
95
R
CHANGING A BULB
CAUTION
Before replacing a bulb, always turn off
the starter switch and appropriate
lighting switch to prevent any possibility of a
short circuit. Only replace bulbs with the same
type and specification. See BULB
Check the operation of all exterior lamps before
you drive the vehicle.
Halogen bulbs are used for high beam, low
always use a cloth to handle them. If
necessary, clean the bulb with methylated
spirits to remove fingerprints.
Xenon lamp units
WARNINGS
Bi-Xenon lamp units operate at very
high temperature. If they have recently
been in use allow sufficient time for them to
cool down before touching them.
Xenon lamp units contain Mercury
which is hazardous.
The Xenon system generates up to
28,000 volts. Contact with this voltage
could lead to a fatality. Ensure that the
headlamps and starter switch are turned off
before working on the system.
Replacement or maintenance of Xenon
lamps should only be carried out by
qualified personnel.
Seek advice about the proper
disposal of Xenon lamp units from a
Land Rover Dealer/Authorised
Repairer or your local authority.
L

Lighting
Headlamp unit To change a high or low beam bulb
(Halogen only)
WARNING
Do not attempt to change any bulb with High beam
the lighting switched on. If the lighting
has just been switched off, give the bulbs time
to cool down. Handling them in a hot condition
may cause personal injury.
The headlamp unit contains five lamps and it is
necessary to completely remove the unit from
the vehicle in order to change any of the bulbs.
See REMOVING A HEADLAMP (page 93).
Bulb access

1 2

E80622

Low beam

4 3
E80620

The five bulbs within the headlamp unit,

accessible under domed caps are:
1. Direction indicator.
2. Low beam/Xenon.
3. High beam. E80623

4. Side lamp and static bending lamp. 1. Twist and lift off the domed cap.
2. Pull off the electrical connector.
3. Release the spring clip holding the bulb in
place and lift out the bulb.

96
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Lighting
4. Insert the new bulb and repeat the above To change a static bending bulb
procedure in reverse order. When
replacing the cap, align the arrowheads on
the cap and the body of the unit.
Note: After the replacement of any high or low
beam bulb, the alignment of the headlamps
should be checked, seek qualified assistance.
To change a Xenon bulb

E80625

1. Twist and lift off the domed cap.

2. Twist the bulb holder to unlock, then pull
out the bulb complete with electrical
connector.
3. To release the bulb, squeeze the two
catches, then pull to remove the electrical
E80624
connector.
1. Twist and lift off the domed cap. 4. Insert the new bulb and repeat the above
2. Twist the connector cap anticlockwise to procedure in reverse order. When
unlock it. Pull clear of the bulb. replacing the cap, align the arrowheads on
the cap and the body of the unit.
3. Release the spring clip holding the bulb in
place and lift out the bulb.
4. Insert the new bulb and repeat the above
procedure in reverse order. When
replacing the cap, ensure that the lugs are
in contact with the bulb base.
Note: After the replacement of any high or low
beam bulb, the alignment of the headlamps
should be checked, seek qualified assistance.

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Lighting
To change a front side lamp bulb To change a front indicator lamp bulb

E80626

1. Twist and lift off the domed cap.

2. Pull out the bulb complete with electrical
connector.
3. Pull the bulb out of the electrical E80621

connector.
To access the direction indicator, the headlamp
4. Insert the new bulb and repeat the above unit locking slide must be completely removed
procedure in reverse order. When from the unit.
replacing the cap, align the arrowheads on
the cap and the body of the unit.

E80627

1. Twist and lift off the domed cap.

98
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Lighting
2. Pull out the bulb complete with electrical Replacing the bulb
connector.
3. Pull the bulb out of the electrical
connector.
4. Insert the new bulb and repeat the above
procedure in reverse order. When
replacing the cap, align the arrowheads on
the cap and the body of the unit.
To change a front fog lamp bulb
Removing the fog lamp

E80595

1. Twist the bulb holder counterclockwise to

unlock, then pull out the bulb, complete
with electrical connector.
2. To release the bulb, depress the two
catches (solid arrows in inset), then pull to
remove the bulb from the holder.
3. Replace bulb. See BULB SPECIFICATION
CHART (page 104).
E80594
• Before fitting the replacement bulb, note
the flat and the tab on the otherwise
1. Using the finger slot at the top of the fog circular shape of the bulb mounting
lamp surround, pull to remove. flange. The tab acts as a key to enable
2. Remove the three securing screws to correct positioning of the bulb in the
release the lamp unit. Ease the unit out of bulb holder.
the front bumper. • Do not touch the bulb glass with your
fingers. If necessary, clean the bulb with
methylated spirits.
4. Insert the new bulb and repeat the above
procedure in reverse order to reassemble.

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Lighting
Note: After the replacement of a fog lamp bulb,
the alignment of the lamp should be checked,
seek qualified assistance.
Refitting the fog lamp
E80596
1. Align fog lamp to front bumper and secure
with screws.
2. Align the spring clip above the finger slot
with the upper receiver shape in the
bumper and push into place.
3. Push the lower part of fog lamp surround
into place, applying some upward
pressure.
Note: The fog lamp surround is uniquely
shaped and will only fit in one position.
100
To change a number plate lamp bulb
E81086
1. With the upper tailgate open, use a suitable
tool to lever the lens from the tailgate (see
inset).
2. Twist the bulb holder counterclockwise to
unlock, then pull out the bulb, complete
with electrical connector.
3. Pull the bulb to remove it from the
connector.
4. Insert a new bulb and refit the
components. See BULB SPECIFICATION
CHART (page 104).
 R

Lighting
To change a side repeater lamp bulb To change a stepwell lamp bulb

E80597

1. With the relevant door open, insert a small

E81087 flat-bladed screwdriver under the forward
edge of the lens, to carefully lever the lamp
1. Push the lens firmly towards the front of
unit out.
the vehicle and withdraw the lamp unit
from the wing. 2. Pull the bulb out of the electrical
connector.
2. Twist to release the bulb holder from the
lens unit, then pull the bulb from its socket. 3. Insert a new bulb and refit the
components. See BULB SPECIFICATION
3. Insert a new bulb and refit the
CHART (page 104).
components. See BULB SPECIFICATION
CHART (page 104).

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Lighting
To change a courtesy lamp bulb To change a tailgate lamp bulb

E80597

1. Insert a small flat-bladed screwdriver

E81088
1. Insert a small flat-bladed screwdriver into
the indent on the side of the lens and
carefully prise the lens from the lamp unit.
2. Pull the bulb out of the electrical
connector.
3. Insert a new bulb and refit the
components. See BULB SPECIFICATION
CHART (page 104).
under the lens and carefully prise the lens
from the lamp unit.
2. Pull the bulb out of the electrical
connector.
3. Insert a new bulb and refit the
components. See BULB SPECIFICATION
CHART (page 104).

102

Lighting
To change a map lamp bulb
E81089
1. Insert a small flat-bladed screwdriver into
the indent on the side of the lens and
carefully prise the lens from the lamp unit.
2. Pull the bulb out of the electrical
connector.
3. Insert a new bulb and refit the
components. See BULB SPECIFICATION
CHART (page 104).
103
R
To change a vanity mirror lamp bulb
E81090
1. With the vanity mirror cover open, use a
small flat-bladed screwdriver to carefully
lever the relevant lens from the
mirror/lamp unit.
2. Pull the bulb out of the electrical
connector.
3. Insert a new bulb and refit the
components. See BULB SPECIFICATION
CHART (page 104).
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Lighting
BULB SPECIFICATION CHART
Note: All bulbs must be rated at 12 volts.

Bulb Watts
Headlamps, low and high beam 55 (H7)
(Halogen)
Headlamps, low and high beam 55 (D2S)
(Xenon)
Cornering lamps (Halogen) 35 (H8)
Front side lamps W5W
Front direction indicators S8
Rear direction indicators P21
Front fog lamps (Halogen) 55 (H11)
Side marker lamps W5W
Reverse lamps P21
Rear fog guard lamps P21
Stop/tail lamps P21/5
Number plate lamps W5W
Door/puddle lamps W5W
Interior lamps W5W
Luggage/footwell lamps W5W
Luggage/tailgate lamps W5W
Glovebox lamp W5W
Vanity mirror lamp 1.2

Note: In certain territories it is a legal

requirement to carry spare bulbs, in case of
bulb failure. A replacement bulb kit is available
as an approved accessory from your Land
Rover Dealer/Authorised Repairer.

104
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Wipers and washers

WINDSCREEN WIPERS Single wipe
Wipers and washers

The wipers and washers will only operate when Pull the lever down to position 4 and release
the starter switch is turned to position I or II. immediately.
Note: With the lever held down, the wipers will
CAUTIONS
operate at fast speed until the lever is released.
Do not operate the windscreen wipers on
a dry screen. The drag on the wiper Intermittent variable delay
mechanism may cause damage.
In freezing or very hot conditions ensure
that the wipers have not stuck to the
windscreen before operating. The drag on the
wiper mechanism may cause damage.
Remove any snow, ice or frost, from the
windscreen, around the wiper arms and
blades, and the screen scuttle before operating
the wipers. Snow and ice can cause damage to
the wiper mechanism if left uncleared.
E80469
Note: If the wiper blades do become stuck, or
jammed, an electronic cut out may temporarily With the lever in position 1, rotate the collar
halt the operation of the wipers. If this clockwise to decrease the interval between
happens, switch off the wipers and the ignition. wipes. Rotate the collar counterclockwise to
Clear any obstructions, and free the wiper increase the interval between wipes.
blades before attempting to switch on the Speed dependent mode
ignition
When speed dependent mode is configured,
3 the operation of all wiper modes will be
affected by vehicle speed.
2 If the vehicle’s speed drops below 8 km/h
(5 mph) with the wipers operating, the wiper
1 frequency automatically reduces. The wipers
will switch to the next lowest speed. When the
0 vehicle’s speed increases to over 8 km/h
(5 mph), the original wiper speed setting is
4 restored automatically.
E80468 This feature can be enabled or
disabled by a Land Rover
1. Rain sensor or intermittent variable delay Dealer/Authorised Repairer.
2. Normal speed wipe
3. Fast speed wipe

105
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Wipers and washers

Speed dependent intermittent mode WINDSCREEN WASHERS
The frequency of intermittent variable delay is
WARNING
adjusted automatically according to road speed
on vehicles not equipped with a rain sensor. If the vehicle operates in temperatures
below 41°F (5°C), use washer fluid with
The intermittent period can be adjusted for
antifreeze protection. In cold weather, failure
each of the speed dependent modes by rotating
to use washer fluid with antifreeze protection
the delay switch either clockwise or
could result in impaired vision and increase
counterclockwise.
the risk of an accident.
This feature can be enabled or
disabled by a Land Rover
Dealer/Authorised Repairer.

RAIN SENSOR
Rain sensor variable delay
CAUTION
Before entering an automatic car wash,
ensure that the wipers are switched off,
they could operate during the car wash
programme and be damaged.
E80469
With the wiper switch in position 1, wiper
operation is adjusted automatically according
to information supplied by the rain sensor.
E80471
Push the button to operate the windscreen
washer. The front wipers will operate if the
button is pressed for more than half a second.
When the button is released, the wipers will
complete the current stroke and then complete
two further strokes before parking
automatically.
If the button is pressed for less than half a
second, only the washer will operate.
Note: National or local regulations may restrict
the use of Volatile Organic Compounds
(VOCs), which are commonly used as
antifreeze agents in washer fluid. A washer
fluid with limited VOC content should be used
only if it provides adequate freeze resistance
for all climates in which the vehicle will be
operated.

Rotate the collar clockwise to increase (a wipe

will occur immediately) or counterclockwise to
decrease the sensitivity of the rain sensor, and
therefore the frequency of wiper operation.

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Wipers and washers

REAR WINDOW WIPER AND Tailgate open disable
WASHERS If the tailgate is opened while the rear wiper is
operating, the wiper will:
• Stop immediately.
• Not start to move if it is already stationary.
If the tailgate is subsequently closed, the wiper
will resume operation after three seconds.
If the tailgate is open and the vehicle's speed is
above 3 km/h (2 mph), the wiper will operate as
if the tailgate were closed.
1
E80472 2

Wiper - intermittent operation

Pull the lever to position 1. The intermittent
delay period will vary according to the delay
switch setting.
Wiper - continuous operation
The rear wiper can be configured to operate
continuously.
This setting can be configured by a
Land Rover Dealer/Authorised
Repairer.
Washer
Pull the lever to position 2 and hold it. The
wiper and washer will operate. When the lever
is released, the washer will stop and the wiper
will complete a further two wipe cycles and
then return to intermittent operation.
Reverse gear input
If reverse gear is selected while the front
wipers are operating, the rear wiper will
operate automatically.

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Wipers and washers

ADJUSTING THE WINDSCREEN HEADLAMP WASHERS
WASHER JETS If the headlamps are on, operating the screen
washer will also power wash the headlamps.
Front
Note: If the fluid level sensor detects a low
level, the headlamp power wash is inhibited.

CHECKING THE WIPER BLADES

CAUTION
Only use cleaning products which have
been approved for use on automotive
glass and rubber. Inappropriate products can
have unpredictable effects.

E80473

The windscreen washer jets are set during

manufacture and should not need adjusting.
However, if adjustment is ever necessary,
insert a needle into the jet orifice and lever
gently to position each jet, so that the spray is
directed towards the centre of the front screen.
Rear
E80573
The wiping edge of the blades should be
checked and cleaned periodically. Check the
blade rubber for cracks, splits and roughness.
If any damage, wear or roughness is detected
the blade should be replaced immediately to
prevent damage to the glass.
Clean the blade edge by wiping with a soft cloth
or sponge, using warm soapy water.

E80474

Should any jet become obstructed, insert a

needle or thin strand of wire into the orifice to
clear the blockage.

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Wipers and washers

CHANGING THE WIPER BLADES Rear
Only fit replacement wiper blades that are
identical to the original specification.
Front

E80476

1. Lift the wiper arm away from the rear

window.
E80475 2. Press the tab (arrowed in inset), to release
the blade assembly
1. Lift the wiper arm away from the screen
and pivot the blade assembly away from 3. Slide the blade assembly off the end of the
the arm. wiper arm.

2. Press the tab (arrowed in inset), to release 4. Carefully replace the arm to its stowed
the blade assembly position.

3. Slide the blade assembly off the end of the To replace, position the blade assembly onto
wiper arm. the inside of the wiper arm and push firmly into
position until the blade clips into place.
4. Carefully replace the arm to its stowed
position.
To replace, position the wiper arm into the
aperture in the middle of the blade assembly
and push firmly into position until the blade
clips into place.

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Windows and mirrors
ELECTRIC WINDOWS
Windows and mirrors
WARNINGS
Closing a window on fingers, hands or
any vulnerable part of the body, can
result in serious injury.
Ensure that all adult passengers are
familiar with the controls and the
potential dangers of electric windows.
For their safety, when leaving children
unattended in the vehicle always
remove the key from the starter switch.
Ensure that children are kept clear
whilst raising or lowering windows.
Isolate the rear window switches when
carrying children.
Do not allow passengers to extend any
part of their bodies through a window
aperture while the vehicle is moving - injury
from flying debris, branches of trees or other
obstructions could occur.
Operating the windows
5 4 2 recalibrate the window position, close the
E80395 3 1
1. Right-hand front window
2. Left-hand front window
3. Right-hand rear window
4. Left-hand rear window
5. Rear window isolation switch
110
The windows can be operated when the starter
switch is at position I or II and for up to 40
seconds after the starter switch is turned to
position 0 (provided a front door is not
opened).
Press and hold the front of the respective
switch to lower a window. Lift and hold the
front of the switch to close a window. The
window will stop moving as soon as the switch
is released.
One touch operation (front windows
only)
The front windows have a one touch facility
that allows them to be fully opened or closed
with a single operation of the switch. Firmly
press or lift (and then release) the front of the
switch, to open or close the window. Window
movement can be stopped at any time by
operating the switch again.
Resetting one touch operation
If the power is disconnected when the window
is open, one touch operation will be disabled
until the window position is recalibrated. To
window and keep the switch pressed for one
second.
Anti-trap mechanism (front windows
only)
If the anti-trap sensor detects an obstruction
during window closing, the window will stop
and then open slightly. This will prevent a
window trapping vulnerable parts of the body
or other obstructions.
The anti-trap feature can be overridden by
attempting to close the window at intervals of
less than 10 seconds. On the fourth attempt the
window will move up a short distance with
increased force to try and move the
obstruction.
 R

Windows and mirrors

If this fails to move the obstruction, anti-trap EXTERIOR MIRRORS
will be disabled until reset.
Proximity mirror (Japan only)
Resetting anti-trap
To reset anti-trap, close the window and keep
the switch pressed for one second.
Rear window isolation switch

E80397

Press the right-hand side of the switch to

isolate the window switches on the rear doors.
Press the left-hand side to restore independent
control.
Rear window operation
E80440
The proximity mirror has a split lens, providing
views along the left side and immediately
ahead of the vehicle. Correct adjustment of the
mirror will reduce blind spots.
Adjust the mirror by rotating the head to the left
or right. The mirror should be adjusted a few
degrees at a time and the view checked from
the driver's seat before making further
adjustments.

E80396
Note: Alignment marks on the mirror head and
arm, indicate the initial position the mirror was
The rear windows can be operated from the set to during manufacture.
switches on the rear doors if the rear window
isolation switch has not been activated.

111
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Windows and mirrors

ELECTRIC EXTERIOR MIRRORS Note: On vehicles fitted with the driver's seat
memory facility, up to three exterior mirror
CAUTION positions for each starter key can be stored.
Objects viewed in exterior mirrors may See MEMORY FUNCTION (page 138).
appear further away than they actually
Folding the mirror body
are.
Mirror glass adjustment

A B

E81039

The door mirrors are designed to fold forwards

or rearwards on impact. They can also be
folded towards the side windows into a park
E81037 position.

A. Right-hand drive vehicles Manual operation

B. Left-hand drive vehicles On some vehicles this operation can be carried
out by physically pushing the mirror bodies
With the starter switch turned to position I or II,
towards the side windows.
rotate the knob to select either the left or right
mirror.

E81038

Push the knob in the appropriate direction to

tilt the mirror glass up, down, left or right.

112

Windows and mirrors
Electric operation
E81040
With the rotary knob in the central position,
push the knob downwards to fold the mirrors.
Push the knob downwards again to unfold the
mirrors.
If the mirrors are accidentally knocked out of
position (i.e. with one mirror folded and the
other in the normal position), an additional
operation of the switch will re-synchronise
them.
113
R
Reverse mirror dipping
Vehicles with driver’s seat memory have a
function which dips the exterior mirrors
whenever reverse gear is selected, giving the
driver a view of the kerb.
When this feature is first used, the mirrors will
dip to a preset position. The degree of dipping
can be programmed using the following
sequence:
1. Turn the starter key to position I or II. Do
not start the engine.
2. Select or store a driver’s seat memory
position. See MEMORY FUNCTION
(page 138).
3. Select reverse gear, the exterior mirrors
will adjust to a preset position.
4. Adjust the mirrors to the required dipped
position.
5. Perform a memory store procedure on the
currently selected driving seat position.
6. DOOR MIRROR DIP STORED will be
displayed on the message centre
accompanied by a single chime.
This feature can be enabled or disabled. See
TRIP COMPUTER (page 115).
L

Windows and mirrors

INTERIOR MIRROR
Manual mirror

E80447

Manually adjust the position of the mirror to

provide the best rear view.
Move the lever (forwards or backwards) to
change the angle of the mirror glass. This
allows the mirror to be dimmed to counteract
the glare from the headlamps of a following
vehicle.
Automatic dimming mirror

E81427

Some rear-view mirrors are fitted with a feature

that will automatically darken the mirror to
counteract the glare from the headlamps of a
following vehicle.
This feature is temporarily switched off when
reverse gear is selected.

114
 R

Information displays
TRIP COMPUTER
Information displays

RANGE 246 MILES

AV.
EXT 73 F FUEL 17.4 MPG
AV.
TRIP 134.5 MILES SPEED 45 MPH
OVERSPEED WARNING
65 MPH

EXT 72 F

E81031 TRIP 134.5 MILES

The trip computer can be set to give a wide E81032

range of information. The units used can be

selected by the driver. See PERSONALISED
SETTINGS (page 116).
At engine start-up, the display shows SYSTEM
CHECK IN PROGRESS. When this check is
completed, the outside temperature is shown.
If the vehicle is moving, the display will also
show the current trip distance.
Trip computer statistics can be viewed by
pressing the i button.
A long press (over two seconds) will zero the
trip distance recorder and then start to record
distance from that point.
A series of short presses (less than two
seconds) will scroll through the following:
• Range (with current fuel tank contents).
• Average fuel consumption.
• Average speed.
• Overspeed warning function (a long press
turns the function on or off).
• A review of active warning messages.
• Outside temperature.
• Trip distance.
• Clock (24 hour time format).
Note: The clock is set via the audio system.
See CLOCK (page 130).

115
L

Information displays
PERSONALISED SETTINGS When selections are complete, a short press
Various trip computer settings can be selected, (less than two seconds) on the i button will
by the driver, to suit personal requirements. All save the settings and return to the trip
of the selections made are associated with the computer display.
remote control that was used during the Note: If the vehicle is moved while changes are
process. These choices are recalled when the being made, the system will prevent any further
vehicle is next unlocked using that remote input until the vehicle is stationary again.
control. See MEMORY FUNCTION (page 138).
With the starter key in any position, the vehicle TRIP COMPUTER SELECTION
stationary and a blank display, a short press SETTINGS
(less than two seconds) on the I button brings TRIP DISTANCE MILES/KM
up the SETTINGS display. UNITS (odometer)
FUEL USAGE UNITS MPG
l/100km
Km/l
SETTINGS
EXTERNAL °C or °F
ENTER TEMPERATURE
EXIT
OVERSPEED Off
WARNING 20 - 250 km/h or 15 to
3 140 mph in 5-unit
steps
4
HEADLAMP OFF 30/60/120/240
1 DELAY seconds
AUTO DOOR LOCK ON/OFF
2
(speed related
locking)
REVERSE MIRROR ON/OFF
TRIP DISTANCE DIP†
UNITS
KM
LAZY ENTRY† ON/OFF
NEXT
EXIT BACK RESTORE DEFAULT YES/NO
E81030
SETTINGS

Press button 1 to access the settings that can † Vehicles with driver’s seat memory.
be personalised.
Move through the menu, by pressing buttons 1
or 2, and make selections by pressing buttons
3 or 4.

116

Information displays
INFORMATION MESSAGES
LOW WASHER FLUID
E81033
Driver warning and information messages are
displayed in the main message centre.
They are displayed when a fault is detected and
also when the starter switch is turned off.
Messages have different priority levels and are
grouped into the following categories.
Critical warning messages
Critical warning messages are accompanied by
an audible warning and the message may have
the handbook symbol next to it.
Do not ignore these messages - Take
corrective action immediately!
Warnings messages
Warning messages are non-critical, but must
be treated with some urgency. They may also
be accompanied by an audible warning when
the message is displayed.
Do not ignore these messages - Take
corrective action as soon as possible.
All warning messages are displayed
for approximately four seconds,
after which this symbol is displayed
in the main message centre, indicating that
there are messages to be reviewed. Review the
messages by pressing the i button on the
direction indicator lever until the list of
messages appear.
The message centre will cycle through the
messages until the i button is pressed again.
117
R
Information messages
Information messages will be displayed as and
when applicable, and also when the starter
switch is turned on or off. Where the message
requires action by the driver - Take corrective
action as soon as possible.
Messages are displayed in order of importance
with critical warnings taking priority.
Languages
The language displayed in the main message
centre is a Dealer configurable feature.
If navigation is fitted, the language selected for
navigation display will also be displayed in the
main message centre. If the main message
centre does not support the selected navigation
language, English will be displayed.
Service interval indicator
E81053
The display will activate when a pre-determined
distance or time before service is reached.
When the starter switch is turned to position II,
and the pre-determined value is reached, a
distance countdown to the next service
appears in the display. A minus sign preceding
the distance indicates that the service interval
point has been exceeded by that distance.
After approximately five seconds, the display
reverts to total distance travelled.
Note: After the completion of each service, the
repairer will reset the distance display for the
countdown to the next service.
L

Information displays
Gear selector display

E81054

Vehicles with automatic transmission: the

display shows the current gear selector
position and indicates when SPORT has been
selected.
Vehicles with manual transmission: the display
shows the gear engaged.

118
 R

Climate control
AIR VENTS
Climate control

3
2

5 4

E81929

119
L
Climate control
1. Face level vents
• Direct the air flow by moving the control
in the centre of the louvres. Rotate the
thumbwheel to open, or close the vents.
• To ensure best ventilation and minimum
noise, the vents should be fully open
when the air distribution control is set to
face level.
2. Driver’s lap vent
• Airflow can be directed to the driver’s lap
via an outlet located below the steering
wheel. Control the airflow by adjusting
the louvres.
3. Centre console rear vent controls
• Move the louvres to adjust the direction
and volume of airflow. Rotate the bezel
to direct the air flow.
• The temperature cannot be set by the
rear occupants.
4. Rear upper vent controls
• Press the ridged portion of the louvres
to open and adjust the volume of air.
• Rotate the louvres to direct the air flow.
5. Rear pillar vent controls
• Direct the airflow by moving the control
in the centre of the louvres.
120
Third row seats vent
E81008
A fixed louvre outlet on the left-hand side rear
quarter panel provides airflow to the third-row
seat lower area.
Intake air
The ventilation system provides fresh,
conditioned and/or heated air to the interior of
the vehicle from the air intake grille in front of
the windscreen.
Note: Always keep the air intake grille clear of
obstructions such as leaves, snow or ice.
Particulate air filter
The ventilation system is fitted with a
particulate air filter to remove most potentially
harmful particles such as pollen, industrial
fall-out and road dust from the air entering the
vehicle's interior.
Combined filter
Vehicles fitted with automatic temperature
control have a combined carbon and
particulate air filter.
The carbon layer reduces the level of odours
coming through the heater system from
outside.
 R

Climate control
MANUAL CLIMATE CONTROL
1 2 3

7 6 5 4
4
E80976

1. Temperature control 5. Heated windscreen

2. Air distribution control 6. Economy mode
3. Blower control 7. Air recirculation control
4. Heated rear screen

The manual air conditioning system provides
air at a variable temperature, direction and flow
with selectable air recirculation, economy
mode and rear screen heating.
The system may be fitted with windscreen
heating.
Note: The indicator in a switch illuminates if
the feature is operating.
Operation of controls
Temperature controls
Rotate the controls 1 to set the required
temperature for the corresponding side of the
passenger compartment.
Temperatures within the range 16°C (60°F) to
28°C (83°F) can be set. The blue dot gives
maximum cooling and the red dot maximum
heating.
Note: The system will not achieve a
temperature differential from left to right of
more than 4°C (7°F).
To obtain maximum air conditioning, rotate the
temperature controls fully counterclockwise.
This activates the air conditioning and air
recirculation, and sets the blower speed at
maximum and the air distribution to face-level.
Note: Rotating the temperature controls fully
clockwise provides maximum heating to the
foot/screen vents.
When in stationary traffic, select P or N
(automatic transmission) to maximise air
conditioning efficiency.

121
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Climate control
Air distribution control General notes
Rotate to select the desired distribution setting: • For optimum operating efficiency, ensure
Windscreen and side window vents all air vents (including those in the rear of
E80977
the vehicle) are open.
Face level vents • For the automatic temperature control
system to function efficiently, all windows
Foot level vents and the sunroof should be closed, and the
E80979
air intake vents free from ice, snow, leaves
or other debris.
Position the control 2 between two symbols to • In very humid conditions, slight screen
obtain air flow from both sets of vents. misting may be experienced when the air
Blower control conditioning system is turned on. This is a
natural occurrence and will clear after a
Rotate the blower control 3 to adjust airflow
few seconds.
through the vents.
• The air conditioning compressor will not
Economy mode function unless the engine is running.
Press the button to select Economy • Surplus water produced by the
mode. An LED in this switch dehumidifying process is expelled from
illuminates. The air conditioning is the system via drain tubes beneath the
switched off. This reduces the load on the vehicle. This may result in a small pool of
engine, thereby improving fuel consumption. water forming on the road when the
Air recirculation vehicle is stationary.
Press the button once to activate air
recirculation. Press the button a
second time to deactivate air
recirculation.
Air recirculation prevents air entering from
outside, and recirculates the air inside the
vehicle. This prevents the entry of traffic
fumes.
Air recirculation also significantly influences
the dehumidifying and cooling performance of
the air-conditioning system.
Note: Prolonged recirculation at low ambient
temperatures may cause the windows to mist.

122
 R

Climate control
AUTOMATIC CLIMATE CONTROL
3 1 2 3

12
4 11
10

5 8 7 9
6
E80975

1. Auto mode 7. Off

2. Blower control 8. Economy mode
3. Temperature control 9. Rear environment
4. Air distribution control 10. Heated rear screen
5. Air recirculation control - manual 11. Heated windscreen
6. Air recirculation control - with pollution 12. Defrost mode
sensor

The air conditioning system features automatic Operation of controls

temperature and air distribution control and is
programmed to maintain optimum levels of
comfort within the vehicle in all but the most
severe climatic conditions.
The configuration of controls may vary
depending on the specification of your system.
The variants are shown as insets to the main
illustration.
The system may include windscreen heating.
Note: The indicator in a switch illuminates if
the feature is operating.
Auto mode
Allowing the system to function automatically
is preferable in most operating conditions.
• Press AUTO for fully automatic operation.
• Rotate the temperature controls 3 to select
the required temperature.
In Auto mode, air conditioning, air distribution,
blower speeds and air recirculation are
adjusted automatically to maintain, a
comfortable environment irrespective of
prevailing conditions.
The air distribution and blower controls can be
operated independently to override the
automatic setting.

123
L
Climate control
In this case, the appropriate indicator in the
AUTO switch extinguishes. The circular
indicator represents the blower, the
rectangular indicator represents air
distribution.
Press AUTO again to re-establish automatic
operation.
Note: If the air distribution and blower controls
are operated independently, the system may
not be able to maintain the required
temperature settings.
Blower control
Rotate the blower control 2 to adjust airflow
through the vents.
Temperature controls
Rotate the controls 3 to set the required
temperature for the corresponding side of the
passenger compartment.
Temperatures within the range 16°C (60°F) to
28°C (83°F) can be set. The blue dot gives
maximum cooling and the red dot maximum
heating.
Note: The system will not achieve a
temperature differential from left to right of
more than 4°C (7°F).
To obtain maximum air conditioning, rotate the
temperature controls fully counterclockwise.
This mode automatically activates the air
conditioning and air recirculation, and sets the
blower speed at maximum and the air
distribution to the face-level vents.
Note: Rotating the temperature controls fully
clockwise provides maximum heating to the
foot/screen vents.
When in stationary traffic, select P or N in an
automatic transmission vehicle to maximise air
conditioning efficiency.
124
Air distribution control
Press to select the desired distribution setting:
Windscreen and side window vents
E80977
Face level vents
Foot level vents
E80979
More than one setting can be selected to
achieve the desired distribution.
Air recirculation - manual
Press the button once to activate air
recirculation. Press the button a
second time to deactivate air
recirculation.
Air recirculation prevents air entering from
outside, and recirculates the air inside the
vehicle. This prevents the entry of traffic
fumes.
Air recirculation also significantly influences
the dehumidifying and cooling performance of
the air-conditioning system.
Note: Prolonged recirculation at low ambient
temperatures may cause the windows to mist.
Air recirculation - with pollution sensor
Press the button once to activate air
recirculation. Press the button a
second time to activate automatic
air recirculation. Press the button a third time
to switch the system off.
In Auto mode, air recirculation is regulated
automatically to enable the air-conditioning
system to achieve its optimum performance.
Air recirculation prohibits the entry of air from
outside the vehicle, recirculating the air inside
the vehicle instead. This is useful to prevent the
entry of traffic fumes.

Climate control
Air recirculation also significantly influences
the dehumidifying and cooling performance of
the air-conditioning system.
Note: Prolonged recirculation at low ambient
temperatures may cause the windows to mist.
Off
Press to switch the system off; the
indicator in the switch will illuminate
to show this condition. Pressing the
button again returns the system to its previous
mode.
Economy mode
Press the button to select economy
mode. An LED in this switch
illuminates. The air conditioning is
switched off. This reduces the load on the
engine, thereby improving fuel consumption.
Rear environment
The rear environment unit is located
E80983
behind the left-hand side rear
quarter panel and provides heating
and air conditioning to the rear passengers. Do
not obstruct the louvres on the side of the
quarter panel.
• Automatic: press the button once to
control the rear heating and air
conditioning using the front controls. The
upper amber light will be illuminated.
• Manual: press the button a second time to
pass control to the rear passengers. The
lower amber light will be illuminated.
• Off: press the button a third time to switch
the rear heating and air conditioning off.
125
R
Defrost mode
If the windscreen is misting or
E80986 covered in ice, press button, the
system will immediately direct its
output to achieve maximum screen clearing by:
• Setting the blower speed to an appropriate
level.
• Distributing air flow to the screen only.
• Deactivating air recirculation (in certain
circumstances).
• The windscreen and rear screen heaters
will be switched on (or their timed
operating cycle will recommence if they
are already switched on).
Press the button a second time (or select AUTO
or any air distribution control) to switch off the
defrost mode. Heated screens will remain on
until their time-out period has expired.
General notes
• For optimum operating efficiency, ensure
all air vents (including those in the rear of
the vehicle) are open.
• For the automatic temperature control
system to function efficiently, all windows
and the sunroof should be closed, and the
air intake vents free from ice, snow, leaves
or other debris.
• In very humid conditions, slight screen
misting may be experienced when the air
conditioning system is turned on. This is a
natural occurrence and will clear after a
few seconds.
• The air conditioning compressor will not
function unless the engine is running.
• Surplus water produced by the
dehumidifying process is expelled beneath
the vehicle. This may result in a small pool
of water forming when the vehicle is
stationary.
L

Climate control
REAR PASSENGER CLIMATE HEATED WINDOWS AND MIRRORS
CONTROLS Note: The heated windscreen and rear screen
only operate while engine is running.
Heated windscreen
Press to operate. The screen heater
will operate for a timed period
before automatically switching off.
Heated rear screen
CAUTION
1 2 3 To avoid damage to the heating
elements, do not attach labels to the rear
screen. Also, do not scrape or use abrasive
materials to clean the inside of the rear screen.
Press to operate. The screen heater
will operate for a timed period
before automatically switching off

E81009 Exterior mirrors

The exterior mirrors have integral heating
1. Temperature control: turn the control elements which disperse ice or mist. These
clockwise (red dot) to increase the operate automatically when the starter switch
temperature of the incoming air. is in position II and are controlled according to
2. Distribution control: the external temperature and wiper status.
• turn the control fully counterclockwise,
to direct incoming air to the third row
seats vent
• turn the control fully clockwise to direct
air to the rear seat upper vents and the
rear pillar vents.
3. Blower control: turn the control clockwise,
to increase the blower speed.
Note: The panel is only active when the rear
environment button on the front control panel
is set to manual mode.

126

Climate control
AUXILIARY HEATER
WARNINGS
If the fuel-burning heater has been used
recently, do not touch the unit’s
exhaust when working in the engine
compartment.
Turn the starter switch off, to ensure
that the fuel-burning heater is switched
off when refuelling the vehicle.
When the engine is started in very cold
weather, the auxiliary heater is automatically
switched on to provide extra heat to help warm
up the engine.
During this period, exhaust fumes from the
heater may be seen coming from under the
bonnet.
ELECTRIC SUNROOF
WARNINGS
Accidental closure of a sunroof on any
part of the body, can result in serious
personal injury.
Ensure that children are kept clear and
that the sunroof is not obstructed when
opening or closing.
For their safety, when leaving children
unattended in the vehicle always
remove the key from the starter switch.
Ensure that all adult passengers are
familiar with the controls and the
potential dangers of operating an electrically
operated sunroof.
Do not allow passengers to extend any
part of their bodies through the sunroof
aperture while the vehicle is moving - injury
from flying debris, branches of trees or other
obstructions could occur.
127
R
CAUTION
Always close the roof when the vehicle is
unattended.
E81042
The sunroof can be operated when the starter
switch is in positions I or II and for 40 seconds
after position 0 has been selected, provided
that a front door is not opened.
• To open the sunroof to the tilted position,
briefly press the rear of the switch. The
roof will move to its tilted position.
• To fully open the sunroof from the tilted
position, briefly press the rear of the
switch again.
• To close the sunroof to the tilted position,
briefly press the front of the switch.
• To fully close the sunroof, press and hold
the front of the switch. Releasing the
switch before the roof is fully closed will
stop movement.
Note: While the sunroof is moving, a further
press of the switch will stop the movement.
Note: If the starter key is not in position II, the
switch has to be pressed and held to operate
the sunroof.
L

Climate control
Anti-trap mechanism
CAUTION
It is possible to override the anti-trap
mechanism when movement is
restricted by ice or dirt, by pressing and
holding the front of the switch whilst the roof
is closing.
If the sunroof encounters resistance while
closing, the operation is interrupted and the
roof opens slightly, to prevent the sunroof
trapping vulnerable parts of the body or other
obstructions..
This anti-trap feature does not apply when the
roof is being closed from the tilted position.
Sunroof calibration
Under some circumstances (i.e. if the battery is
disconnected), the sunroof position may need
to be recalibrated. The sunroof position is
recalibrated as follows:
1. With the battery connected, turn the starter
switch to position ll.
2. Press and hold the front of the switch for
20 seconds. The sunroof will start to
move. Continue to hold the switch until the
sunroof completes one full open and
closing cycle. When the sunroof stops
moving, release the switch.
The sunroof can then be operated as normal.
Note: Calibration will not function if the battery
voltage is low.

128
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Convenience features
SUN VISORS INSTRUMENT LIGHTING DIMMER
Convenience features

AUTO

E80434

The sun visor can be pivoted downwards, or to

the side as required to reduce glare. E80432

The sun visor is fitted with illuminated mirrors. Rotate the dimmer control to vary the level of
Lifting the cover of the vanity mirror will switch instrument pack illumination.
on the lamp. Closing the cover switches off the
lamp.

SUN BLINDS

E80433

Pull the sunroof blind, against spring pressure,

across the sunroof aperture to deploy it. When
it is pressed against the edge of the aperture, it
will lock into place.
To open, push vertically on the textured part of
the blind handle. Allow the blind to return
under spring pressure.
The blinds retract into the panel between the
sunroofs.

129
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Convenience features
CLOCK To adjust the hours, rotate the control
clockwise to increase or counterclockwise to
Setting the time - standard audio system decrease. Pressing the rotary control to accept
the hours setting moves the highlight on to the
Clock Cancel minutes setting.
Set Repeat the exercise for minutes and press the
rotary control to accept the value shown. The
highlight moves on to OK and a further press of
the rotary control accepts the settings.
Clock Cancel Set 12-24 hour display
Set

Clock Cancel
Set

Clock PM
Set 06 : 15 OK
Clock Set
12/24

Clock
Set AM 09 : 15 OK

Clock Set
12/24 24h r

Clock
Set AM 09 : 43 OK E80429

To set the clock display to 12 or 24 hour

E80428
To access the Clock Set menu, press the MENU
OK button, turn the right-hand rotary control to
scroll to the clock menu, then press the rotary
control to select Set.
format, enter the Clock Set menu by pressing
the MENU OK button. Turn the rotary control
until Clock Set is highlighted, and press the
control again to adjust the format. Rotate the
control to scroll between 12 and 24, then press
the control to select the required format.

130
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Convenience features
Setting the time - premium audio system

09
Cancel
PTY Seek Time
FM Scan Set AM 09
1 2 3 4 5 6

1 2 3 4 5 6

32
News
Clock
1 2 3 4 5 6
Time
Set AM 09 32
1 2 3 4 5 6

12 24
E80431

Time
To adjust the hours, rotate the control
12/24 12 clockwise to increase, or counterclockwise to
1 2 3 4 5 6 decrease. Press the rotary control to accept the
value shown.
E80430
Once the hours have been set and accepted,
the minutes will be highlighted and are set in
Access the clock set menu by pressing the the same way. Having set both hours and
MENU OK button. Use the rotary control to minutes, the display will return to the main
scroll to Clock, then press the control to select. menu.
Rotate the control to scroll between 12 and 24,
then press the control to select the required
format.

131
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Convenience features
CIGAR LIGHTER ASHTRAY
CAUTION
Do not use the ashtrays for disposing of
waste paper or other combustible items.
A fire may result.

E80426

Push the centre of the faceplate and it will

lower to reveal the lighter.
With the starter switch turned on, press the
lighter in to heat up. When it has reached the
correct temperature it will partially eject and
can then be withdrawn for use.
• Only hold the cigar lighter by the handle. E80423

• Do not plug accessories into the cigar
lighter socket. Use the auxiliary power
sockets provided.
After use, push the lighter back in to the first
position and lift up the faceplate.
Push the bottom edge of the ashtray cover to
open (left inset).
To remove the ashtray, open fully, then pull the
ashtray forwards.

132
 R

Convenience features
AUXILIARY POWER SOCKETS Rear auxiliary power sockets
CAUTIONS
Never plug non-approved accessories
into a power socket - damage to the
vehicle's electrical systems could occur.
Always run the engine during prolonged
use of electrical accessories, otherwise
the battery may become discharged.
Note: Power sockets can be used to power
approved accessories that use a maximum of
E80421
180 Watts.
Raise cover to access the auxiliary power
Front auxiliary power socket
socket in the rear of the centre console.

1 2
ABC
3
DEF 6CD-465

4
GHI
5
JKL
6
MNO
CD 3 14 : 54
7 8 9
PQRS TUV WXYZ
Tr 1 5 2 : 43
1 2 3 4 5 6
0

E80422

On 7-seat vehicles, a third power socket is

E80420
fitted in the left-hand side trim in the loadspace
Pull down the hinged cover to access the area.
socket. When released, the cover will return to
its closed position.

133
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Convenience features
CUP HOLDERS

1
5 5
2 2

2
3 3

5 5

4 4 3

5 4

E80419

1. Front passenger's cup holder Note: The inner cores of the cup holders can be
2. Front seat cup holders removed for cleaning or to make a holder for a
larger drinks container.
3. Second-row seats cup holders
4. Rear compartment cup holders
5. Door bottle holders

134
 R

Convenience features
CENTRE CONSOLE
WARNINGS
The driver should not drink or use the
cup holder while driving.
If the cup holder is retractable, it should
be kept closed when not in use.
Do not carry open-top drink containers
in the cup/bottle holders while the
vehicle is in motion; a spilled hot drink could
cause personal injury. Spilled drinks can also
damage upholstery, carpeting and electrical
components. E80541

Use only for soft containers. Do not use Lift the catch at the front of the lid to access the
to hold cups or bottles made of glass, storage area.
china or hard plastic, as these may cause
injury in the event of an accident or emergency Card holder
manoeuvre. Unopened, sealed containers
(cans of drink, for example) are hard objects
and may also cause injury.

E80542

On the front inside face of the centre console is

a feature to hold a credit/toll card.
CD storage
A rubber mat in the bottom of the centre
console is designed to hold CD cases and is
removable for cleaning.

135
L

Convenience features
COOL BOX The cool box is most effective when filled with
When fitted, the cool box replaces the centre cold or pre-chilled items.
console storage area. The cool box must be cleaned regularly to
remove any condensation or contamination
that could lead to odours.
Note: The cool box will continue to operate for
a short period after the starter switch is turned
to position 0.

E80549

The cool box is switched on/off using the

switch on the inside front lip of the cool box.
This switch has a built-in indicator which will
illuminate to show that the cool box is
operating. There is a short delay (one or two
seconds) between pressing the switch, and
illumination of the indicator. During this period
the control system checks the battery voltage.
If the indicator does not illuminate when the
cool box is switched on, or it goes out while the
cool box is operating, this means that the
battery voltage is low and the cool box has
switched itself off. This will only happen when
the engine is not running.
If the engine is started, the indicator will
illuminate and the cool box will continue to
operate.
The cool box should be left switched off when
it is not needed to protect the vehicle's battery.
The tray on top of the cool box should always
be in place to ensure maximum cooling
performance. This tray can be inverted to allow
for the storage of taller bottles while still
maintaining the sealing.
The tray can be clipped onto the inside of the
main lid when not required.

136
 R

Convenience features
STORAGE COMPARTMENTS

1
2

4 4

4 3

E80534

1. Glovebox
WARNING
2. Lower glovebox
Do not wedge the lids of the rear
3. Centre console storage bins open as this may restrict
4. Rear storage bins the deployment of the rear airbags.

137
L

Convenience features
MEMORY FUNCTION 5. Memory Stored will be displayed on the
message centre to confirm the action. A
WARNING single chime will sound to confirm.
Before activating the seat memory,
Recalling a stored seat position
ensure that the area immediately
surrounding the seat is clear of obstructions Press the pre-set button associated with the
and that all occupants are clear of moving desired driving position. The seat and mirrors
parts. will move to the position stored on that pre-set.
A confirmation message will display in the
2 1 message centre and a double chime will sound
when adjustments are complete.
Note: To stop seat movement at any time,
press any seat adjustment control.
Lazy entry
When this feature is enabled, the vehicle stores
the seating and mirror positions for each
remote control. Next time the vehicle is
E80425
3 unlocked using a remote control, the position
of the seat and mirrors will adjust to the last
1. Memory store button. used position.
2. Memory pre-set buttons. This feature can be disabled or enabled in the
3. Seat adjustment controls. See ELECTRIC Settings option accessed via the trip computer.
SEATS (page 57). See TRIP COMPUTER (page 115).
Up to three different driver seat and exterior
mirror positions can be stored in the memory,
one for each of three possible remote controls.
Your preferred setting for the reverse mirror
dipping feature can also be stored. See
EXTERIOR MIRRORS (page 111).
Setting a memory pre-set
1. Insert the starter key and turn it to position
I or II.
2. Adjust the seat and exterior mirrors to the
desired position.
3. Press the memory store button 1 to
activate the memory function.
4. Within five seconds, press the desired
pre-set button 2.

138
 R

Starting the engine

GENERAL INFORMATION STARTER SWITCH
Starting the engine

WARNING
Never start or leave the engine running
in an unventilated building - exhaust
gases are poisonous.

CAUTION
Do not run the diesel engine above idle
speed until the oil pressure warning light
extinguishes. This will ensure that the engine
and turbo-charger bearings are properly E80362

lubricated before being run at speed.

Similarly, always allow the engine to idle for 10
seconds before switching off.
Continued use of the starter will not only
discharge the battery, but may cause
damage to the starter motor.
Before starting the engine and driving
1. Check that the electric parking brake is
applied and that the gear selector is in the
P (Park) or N (Neutral) position (automatic
transmission vehicles) or Neutral (manual
transmission vehicles).
2. Switch off all non-essential electrical
equipment.
3. Insert the starter key and turn the switch to
position II. For diesel models, wait until the
glow plug warning light extinguishes.
4. Turn the key to position III and
immediately release it. The starter will
automatically switch off when the engine
starts. Do not press the accelerator pedal
while starting.
In temperate climates do not operate the
starter for longer than 10 seconds. If the
engine fails to start, switch off and wait 10
seconds before re-using the starter.
Note: The battery charging and oil pressure
warning lights should extinguish as soon as
the engine is running.
The starter switch uses the following sequence
of key positions to operate the steering lock,
electrical circuits and starter motor.
Position 0
• Steering locked.
• Some lighting circuits are operational,
including sidelamps and hazard warning
lamps.
• With the driver’s door open, seat memory
facility operational.
Position I
• Steering unlocked.
• Clock, audio system and cigar lighter can
now be operated.
• Wipers/washers are operational.
Position II
• All instruments, warning indicators and
electrical circuits are operational.
Position III
• The starting sequence is initiated. Note
that operation of position I electrical
functions will be interrupted during engine
cranking.
Note: On vehicles with automatic
transmission, gear selector position P or N
must be selected before the engine can be
started.

139
L
Starting the engine
STEERING WHEEL LOCK
WARNING
It is impossible to steer the vehicle
when the steering lock is engaged. Do
not remove the key, or turn it to position 0,
while the vehicle is in motion.
E80361
To unlock the steering column
Insert the key into the starter switch and rotate
key to position I. If the key will not rotate, turn
the steering wheel left or right while rotating
the key.
To lock the steering column
Remove the key from the starter switch and
turn the steering wheel until the lock engages.
STARTING A PETROL ENGINE
• Do not continue to operate the starter after
a few failed attempts (unburnt fuel may be
drawn into the exhaust system, thereby
poisoning the catalyst), seek qualified
assistance.
• When starting the engine, Do not drive if a
misfire is suspected and do not attempt to
clear a misfire by pressing the accelerator,
seek qualified assistance.
140
Cold climates
In very cold climates the oil pressure warning
light may take several seconds to extinguish.
Similarly, engine cranking times will also
increase. At -25°C (-13°F) the starter motor
may require continuous operation for as long
as 30 seconds before the engine will start. For
this reason, ensure that all non-essential
electrical equipment is switched off to
maximise the available battery power for
starting.
After starting
On automatic transmission vehicles ensure
that the electric parking brake and foot brake
are firmly applied and the accelerator pedal is
not depressed while moving the gear selector
lever from N or P. An interlock will prevent this
movement if the footbrake is not applied.
Warming-up
In the interests of fuel economy and of
reducing engine wear, it is advisable to drive
the vehicle straight away, remembering that
harsh acceleration or labouring the engine
before normal operating temperature has been
reached can damage the engine.
Driving
Seek qualified assistance, if your vehicle is
burning excessive oil (blue smoke from the
exhaust), as this will progressively reduce
catalyst efficiency.
 R

Starting the engine

STARTING A DIESEL ENGINE Warming-up
• Do not continue to operate the starter after In the interests of fuel economy and of
a few failed attempts (unburnt fuel may be reducing engine wear, it is advisable to drive
drawn into the exhaust system, thereby the vehicle straight away, remembering that
poisoning the catalyst), seek qualified harsh acceleration or labouring the engine
assistance. before normal operating temperature has been
• When starting the engine, do not drive if a reached can damage the engine.
misfire is suspected and do not attempt to Driving
clear a misfire by pressing the accelerator,
Seek qualified assistance, if your vehicle is
seek qualified assistance.
burning excessive oil (blue smoke from the
The glow plug warning indicator in exhaust), as this will progressively reduce
the instrument pack illuminates catalyst efficiency.
when the starter switch is turned to
position II. When the engine is cold, wait for
the light to extinguish before starting. If the
engine is warm, the light will not illuminate.
Cold climates
In very cold climates the oil pressure warning
light may take several seconds to extinguish.
Similarly, engine cranking times will also
increase. At -25°C (-13°F) the starter motor
may require continuous operation for as long
as 30 seconds before the engine will start. For
this reason, ensure that all non-essential
electrical equipment is switched off to
maximise the available battery power for
starting.
After starting
On automatic transmission vehicles ensure
that the electric parking brake and foot brake
are firmly applied and the accelerator pedal is
not depressed while moving the gear selector
lever from N or P. An interlock will prevent this
movement if the footbrake is not applied.

141
L

Transmission
MANUAL TRANSMISSION Starting
Transmission

The engine can only be started with the selector

CAUTION
Do not select reverse gear unless the
vehicle is stationary. This may cause
damage to the transmission.
lever in the P (Park) or N (Neutral) positions.
• Always apply the electric parking brake and
foot brake before starting the engine.
• Keep the brakes applied while moving the
selector lever into a drive position (the
selector lever cannot be moved from P or
N unless the foot brake is applied).
Note: If pressure is applied to the selector lever
before the footbrake is applied any gear
selected may not be available irrespective of
the lever position. In this situation, remove
pressure from the selector lever, ensure that
the foot brake is applied, and select the
required gear.

E80496

When the gearbox is in neutral, the gear lever

is spring-loaded to lie naturally between 3 and
4 gear positions.
A spring loaded inhibitor prevents the
accidental selection of reverse gear. To select
reverse gear, use a knock-over action to
overcome the inhibitor.

AUTOMATIC TRANSMISSION
WARNINGS
Do not leave children unattended in the
vehicle, especially with the keys in the
starter switch.
Always select P and turn the starter
E80498
switch to position O before leaving the
vehicle. • The selector release button must be
pressed while selecting P and R and also to
enable the lever to be moved between the
P and R positions.

142

Transmission
• Do not rev the engine or allow it to run
above normal idle speed while selecting D
or R , or while the vehicle is stationary with
any gear selected.
• Always keep the brakes applied until you
are ready to move off - remember, once a
drive gear has been selected, an automatic
vehicle will tend to creep forward (or
backward if reverse is selected).
• Do not allow the vehicle to remain
stationary for any length of time with a
drive gear selected and the engine running
(always select N if the engine is to idle for
a prolonged period).
Note: The gear selector lever must be in the P
position before the starter key can be removed.
Selector lever positions
CAUTIONS
Do not select P or R if the vehicle is
moving. This may cause damage to the
transmission.
Do not select a forward drive gear when
the vehicle is moving backwards.
Do not select reverse gear when the
vehicle is moving forwards.
143
R
P
P
P
R R
++ N
M
D N
-
S
D
E80497
An illuminated indicator on the selector panel
and a number or letter on the gear selector
display in the instrument pack, identify the
selected gear position.
P - Park
This position locks the transmission and
should be selected before switching the engine
off. To avoid transmission damage, ensure that
the vehicle is completely stationary, with the
parking brake applied, before selecting P.
The selector release button must be pressed
before moving the selector lever into P.
With the starter key in position II, press the
selector release button and the footbrake to
move the selector lever out of P.
Note: The selector lever cannot be moved out
of P unless the starter key is in position II.
R - Reverse
Before selecting R, ensure that the vehicle is
stationary, with the brakes applied. The
selector release button must be pressed before
moving the selector lever into Reverse
position.
L
Transmission
N - Neutral
Select N when the vehicle is stationary and the
engine is required to idle for a brief period (at
traffic lights, for example). In N, the
transmission is not locked, so the electric
parking brake must be applied.
If the vehicle remains stationary, the selector
lever becomes locked in Neutral and it is then
necessary to depress the brake pedal in order
to release the selector lever.
Press the selector release button and foot
brake to move from N to R or D.
D - Drive
Before selecting drive ensure that the brakes
are applied. Select D for all normal driving; full
automatic gear changing occurs on all six
forward gears, according to road speed and
accelerator position.
Kick-down in automatic mode
To provide rapid acceleration for overtaking,
push the accelerator pedal to the full extent of
its travel (this is known as kick-down), a click
will be felt through the accelerator pedal. Up to
a certain speed, this will cause an immediate
downshift to the lowest appropriate gear,
followed by rapid acceleration. Once the pedal
is relaxed, normal gear change speeds will
resume (dependent upon road speed and
accelerator pedal position).
Note: Moderate accelerator pressure may also
result in a downshift in the transmission,
depending on vehicle speed.
144
Sport mode
In Sport mode, full automatic progression
through the gear ratios is retained and the
transmission will stay in the lower gears for
longer. This improves mid-range performance
with downshifts occurring more readily.
P
P
M R
S ++ N
M
S D
-
E80499
To select Sport mode, move the gear lever
from the D position towards the left hand side
of the vehicle. The word SPORT will appear in
the gear selector display in the instrument pack
(for approximately six seconds) and the LED in
the selector display to the side of the selector
lever illuminates.
Sport mode can be deselected at any time, by
returning the lever to the D position.
To return to Sport mode after CommandShift
has been selected move the selector into the D
position. Then move it back into Sport mode.
Note: On vehicles fitted with the terrain
response system, Sport mode is only available
when the Terrain Response General program is
selected.

Transmission
CommandShift™
CommandShift gear selection can be used as
an alternative to fully automatic transmission
and is particularly effective when rapid
acceleration or engine braking are required.
P
P Normal sequential gear changing can be
M utilised once the vehicle is moving.
R
S ++ N
M
S D
- If CommandShift is selected in low range, the
E80500
1. With D selected, move the gear selector
from the D position towards the left-hand
side of the vehicle.
2. The transmission then automatically
selects the ratio most appropriate to the
vehicle's road speed and accelerator
depression. Move the selector forward (+)
or backward (-) and release will manually
select a higher or lower gear (when
available). The message TRANSMISSION
COMMANDSHIFT SELECTED appears in
the main message centre.
3. A single forward (+) movement and release
of the selector lever will change the
transmission to a higher gear, while
rearward (-) movement and release of the
lever will change down to a lower gear. The
selected gear will be indicated in the digital
display in the instrument pack (see inset).
145
R
4. To deselect CommandShift, simply move
the selector lever sideways, back to the D
position. Automatic gear changing will
then resume.
Note: In CommandShift, kick-down is still
available for increased acceleration.
Note: If a Terrain Response special program is
active, the automatic transmission will go
straight into CommandShift when the lever is
moved to the Sport/CommandShift position.
Using CommandShift in High range
If CommandShift is selected in high range, gear
1 must be selected to move off from stationary.
Using CommandShift in Low range
vehicle can move off from stationary in gears 1,
2 or 3 - this is particularly useful to improve
traction when driving off-road.
Kick-down in CommandShift
When in CommandShift, kick-down overrides
the manual gear selection, to provide increased
acceleration.
In high range, with CommandShift selected,
kick-down will cause a downshift to the lowest
gear possible for the current speed.
Electronically selected automatic
models
In fully automatic mode or Sport mode (not
available in CommandShift), the transmission
control system will electronically adjust gear
change points to suit a variety of driving
conditions.
L
Transmission
Hill ascent, trailer and high altitude mode
A gear change pattern is selected to retain
lower gears for longer. This is to counter
momentum lost by more frequent gear
changing during hill ascents or towing. This
gear change pattern is also selected at high
altitudes to combat reduced engine torque.
Hill descent mode
When in manual CommandShift™ mode, with
the optimum gear for engine braking selected,
the selector lever can then be moved across to
the D position. The transmission will retain the
previously selected manual gear until the
descent is completed, then the transmission
will automatically change to D .
High coolant temperature mode
In high ambient temperatures during extreme
load conditions, it is possible for the engine
and the gearbox to overheat. The transmission
will select a gear change pattern designed to
aid the cooling process.
Note: On vehicles fitted with the Terrain
Response system, automatic transmission
change points/patterns will change depending
on which mode has been selected.
Limp-home mode
Should the transmission develop a fault, F is
displayed in the gear position display and only
limited gears are available. Seek immediate
assistance from your Land Rover Dealer/
Authorised Repairer.
146
Transmission warning indicators and
messages
If a fault occurs within the transmission,
depending on the vehicle specification, either a
lamp will illuminate in the instrument pack or a
message will be displayed in the main message
centre.
The transmission warning lamp
illuminates amber when the
operation of the transmission is
limited. Seek qualified assistance as soon as
possible.
The transmission warning lamp illuminates red
when the transmission is unable to function
properly. Stop as soon as safety permits and
turn off the engine. Leave the vehicle with the
starter switch turned off for five minutes and
then turn the starter switch back on. If the red
light is still on, do not use the vehicle.
Note: This warning indicator is not fitted to
vehicles with a message centre.
The transmission temperature
warning lamp Illuminates red when
the transmission oil temperature
reaches a pre-determined limit. Stop the
vehicle where safety permits and switch off the
engine. Allow the transmission to cool for one
hour before continuing.
Note: This warning indicator is not fitted to
vehicles with a message centre.
 R

Transmission
Messages
The following table lists the messages relating
to automatic transmission that could appear in
the message centre. Market criteria mean that
some messages will not apply to your vehicle
and will therefore not appear.
Message Meaning What to do?
TRANSMISSION Advises driver that automatic Seek qualified assistance
FAULT transmission has a fault. immediately.
TRANSMISSION Advises driver that an Seek qualified assistance
FAULT AND automatic transmission fault immediately.
OVERHEAT has occurred and the
temperature is too high.
TRANSMISSION Advises driver that automatic Seek qualified assistance
FAULT LIMITED transmission has a fault and immediately.
GEARS AVAILABLE performance may be affected.

147
L

Transmission
TRANSFER GEARBOX
CAUTION
Do not use auxiliary equipment, such as
roller generators, that are driven by only
one or two wheels of the vehicle, as they will
cause failure of the transfer gearbox.
Range changing
The recommended method of changing range
is with the vehicle stationary. For vehicles
equipped with a message centre, the messages
displayed will assist the experienced driver in
carrying out a range change on-the-move.
Range change indicators
When the vehicle is in Hi, the Hi range indicator
lamp at the switch is illuminated.
When the vehicle is in Lo, the green
warning indicator in the instrument
pack and the Lo range indicator
lamp at the switch are illuminated.

E80493

Your vehicle is equipped with an electronically

controlled transfer gearbox allowing the driver
to select high or low range driving gears.
HIGH range (Hi)
Hi should be used for all normal road driving
and also for off-road driving across dry, level
terrain.
LOW range (Lo)
Lo should only be used in situations where low
speed manoeuvring is necessary, such as
reversing a trailer or negotiating a
boulder-strewn river bed, or when moving off E80494
while heavily loaded or towing. On vehicles
with manual transmission, this will prevent While a Hi to Lo change is in progress, the Lo
prolonged slipping of the clutch. range indicator lamps at the switch and
Also use Lo for more extreme off-road instrument pack display will flash.
conditions, such as steep ascents and When the range change is complete, the high
descents. Do not attempt to use the Lo for range indicator lamp at the switch
normal road driving. extinguishes. The Lo range indicator lamps at
both the switch and the instrument pack
display will illuminate constantly.

148

Transmission
A warning chime will sound, and LOW RANGE
ENGAGED is displayed in the message centre
for a few seconds.
E80495
While a Lo to Hi range change is in progress,
the high range indicator lamp at the switch and
the Lo range indicator in the instrument pack
display will flash.
When the range change is complete, the Lo
range indicator lamp at the switch and in the
instrument pack will extinguish. The Hi range
indicator lamp at the switch will illuminate
constantly.
A warning chime will sound, and HIGH RANGE
ENGAGED is displayed in the message centre
for a few seconds.
149
R
Stationary range changing
With the vehicle stationary and the engine
running select the neutral position.
Move the transfer gear switch towards the
range required (Hi or Lo) and then release.
When the switch is released, it returns to the
default position. Range change status will be
confirmed after a couple of seconds by the
instrument pack and message centre at which
point any manual gear can be selected
normally using the clutch.
Range changing on the move
Note: If the vehicle speed is too high when a
range change is requested, a warning chime
sounds and SPEED TOO HIGH FOR RANGE
CHANGE appears in the message centre.
Note: If the vehicle speed is too high for a
range change and the shift lever is not in
neutral, there will be no message or warning
chime.
Automatic Transmission - High to Low
If N is not selected before using the transfer
gear switch, the message SELECT NEUTRAL
FOR RANGE CHANGE is displayed and a
warning chime sounds.
Note: Do not attempt to make moving range
changes at speeds of 3 km/h (2 mph) or less.
With the vehicle slowing down and travelling
no faster than 40 km/h (24 mph), select N.
Pull the transfer gear switch fully rearwards to
the Lo position and release it.
Indication of the range change status is the
same as for the Stationary method.
When the range change is confirmed by the
indicators, select D.
An interlock prevents selection of a drive gear
until the range change is complete.
L
Transmission
Manual transmission - High to Low
If neutral is not selected before using the
transfer gear switch, the message SELECT
NEUTRAL FOR RANGE CHANGE is displayed
and a warning chime sounds.
Note: Do not attempt to make moving range
changes at speeds of 3 km/h (2 mph) or less.
With the vehicle slowing down and travelling
no faster than 20 km/h (12 mph), depress the
clutch and select neutral.
Pull the transfer gear switch fully rearwards to
the Lo position and release it.
Indication of the range change status is the
same as for the Stationary method.
When the range change is confirmed by the
indicators, select the most appropriate manual
gear for the vehicle speed.
if a gear is selected before the range change is
complete, the change will cancel and may leave
the transfer box in neutral. An audible warning
will be given if this happens.
A failed range change condition produces loss
of drive, and attempting to move the vehicle in
this state is not possible. After a failed range
change, it will be necessary to reselect neutral
in the main gearbox and request the range
change again in the normal way.
Changing from Low to High
With the vehicle travelling no faster than
60 km/h (38 mph), select N or neutral. Press
the front of the transfer gear switch to the Hi
position and release it.
Indication of the range change status is the
same as for the stationary method.
Now select D or the most appropriate manual
gear for the vehicle speed.
150
Transmission warning indicators and
messages
If a fault occurs within the transmission,
depending on the vehicle specification, either a
lamp will illuminate in the instrument pack or a
message will be displayed in the main message
centre.
The transmission warning lamp
illuminates amber when the
operation of the transmission is
limited. Seek qualified assistance as soon as
possible.
The transmission warning lamp illuminates red
when the transmission is unable to function
properly. Stop as soon as safety permits and
turn off the engine. Leave the vehicle with the
starter switch turned off for five minutes and
then turn the starter switch back on. If the red
light is still on, do not use the vehicle.
Note: This warning indicator is not fitted to
vehicles with a message centre.
The transmission temperature
warning lamp Illuminates red when
the transmission oil temperature
reaches a pre-determined limit. Stop the
vehicle where safety permits and switch off the
engine. Allow the transmission to cool for one
hour before continuing.
Note: This warning indicator is not fitted to
vehicles with a message centre.
 R

Transmission
Messages
The following table lists the messages relating
to transfer box that could appear in the
message centre. Market criteria mean that
some messages will not apply to your vehicle
and will therefore not appear.
Message Meaning What to do?
TRANSMISSION Advises driver that a fault has Stop the vehicle as soon as it is
FAULT occurred with the electronic safe to do so.
STOP SAFELY rear differential.
TRANSMISSION Advises driver that a fault has Reduce speed and seek
FAULT occurred with the transfer box qualified assistance
TRACTION REDUCED control system. immediately.
Off-road performance will be
reduced.
TRANSMISSION Rear differential temperature Reduce speed and seek
OVERHEAT has reached or is approaching qualified assistance
SLOW DOWN the overheat threshold. immediately.
TRANSMISSION Advises driver that a fault has Reduce speed and seek
RANGE CHANGE occurred which prevents the qualified assistance
NOT AVAILABLE transfer box from changing immediately.
range.
TRANSMISSION Transfer box control module Reduce speed and seek
TRACTION fault. qualified assistance
REDUCED immediately.
SELECT NEUTRAL Alerts driver that range change Select neutral.
FOR RANGE will not occur until neutral is
CHANGE selected on the transmission.
SPEED TOO HIGH Driver has requested range Reduce speed to 40 km/h
FOR RANGE change when vehicle speed is (25mph) on automatic
CHANGE too high. transmission or 20 km/h (12
mph) on manual transmission.

151
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Brakes
PRINCIPLE OF OPERATION
Brakes
Foot brake
WARNINGS
Do not rest your foot on the brake pedal
while travelling as this may overheat
the brakes, reduce their efficiency and cause
excessive wear.
Never allow the vehicle to freewheel
with the engine turned off as full
braking assistance will not be available.
If the red brake warning indicator
illuminates while the vehicle is in
motion, bring the vehicle to a halt as quickly as
traffic conditions and safety allow and seek
qualified assistance before continuing.
Never place non-approved floor
matting or any other obstructions
under the brake pedal. This restricts pedal
travel and braking efficiency.
The brake system warning indicator
illuminates amber and red briefly in
the instrument pack as a bulb check
when the starter switch is turned to position II,
and monitors five separate brake functions.
• Emergency Brake Assist (EBA) - amber.
• Brake pad wear - amber.
• Electric Parking Brake (EPB) - amber.
• Electronic Brake Distribution (EBD) - red.
• Brake fluid level - red.
If the indicator remains amber after starting, or
illuminates whilst driving, suspect a fault with
the Emergency Brake Assist (EBA) system or
worn brake pads. Drive with care and seek
qualified assistance urgently.
152
If the indicator illuminates red while the vehicle
is being driven, suspect low brake fluid level or
a fault with the Electronic Brake Distribution
(EBD) system. Stop the vehicle gently, as soon
as safety permits and check and top up brake
fluid if necessary. If the indicator remains
illuminated, seek qualified assistance before
continuing.
Emergency Brake Assist (EBA)
If rapid full brake application is made,
Emergency Brake Assist (EBA) automatically
boosts the braking force to the maximum and
helps to stop the vehicle. Also, if the driver
brakes more slowly, but with sufficient brake
pressure to activate Anti-lock Braking System
(ABS) on both front wheels, the system
automatically increases the braking force so
that all four wheels are in ABS control,
optimising the performance of the ABS system.
If the brake pedal is released, EBD will cease
operation.
A fault with the EBD system is indicated by
illumination of the amber brake warning
indicator.
Electronic Brake Distribution (EBD)
Electronic Brake Distribution (EBD), balances
braking forces between front and rear axles to
maintain maximum braking efficiency.
For example, under light loads EBD applies less
effort to the rear brakes to maintain vehicle
stability; conversely allowing full braking effort
to the rear wheels when the vehicle is towing or
is heavily laden.
A fault with the EBD system is indicated by
illumination of the red brake warning indicator.
 R

Brakes
Servo assistance
The braking system is servo assisted, but only
when the engine is running. Without this
assistance greater braking effort is necessary
to safely control the vehicle, resulting in longer
stopping distances. Always observe the
following precautions:
• Always take particular care when being
towed with the engine turned off.
• If the engine should stop for any reason
while the vehicle is in motion, bring the
vehicle to a halt as quickly as traffic
conditions safely allow, and do not pump
the brake pedal as the braking system may
lose any remaining assistance available.
Brake pads
Brake pads require a period of bedding in. For
the first 800 km (500 miles), you should avoid
situations where heavy braking is required.
Wet conditions
Driving through water or even very heavy rain
may adversely affect braking efficiency. Always
dry the braking surfaces by intermittent light
application of the brakes.
Messages
The following table lists the messages relating
to brakes that could appear in the message
centre. Market criteria mean that some
messages will not apply to your vehicle and will
therefore not appear.

Message Meaning What to do?

CHECK Brake fluid in reservoir below Seek qualified assistance
BRAKE FLUID recommended level. immediately.
CHECK Brake pads worn beyond the Seek qualified assistance
BRAKE PADS service limit. immediately.
PRESS FOOTBRAKE A switch release has been Follow the instructions to
AND PARKBRAKE detected without brake pedal achieve a manual release.
SWITCH contact.
TO RELEASE
PRESS FOOTBRAKE A switch release has been Follow the instructions to
OR CLUTCH detected without brake or achieve a manual release.
AND PARKBRAKE clutch pedal contact.
SWITCH
TO RELEASE

153
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Brakes
HINTS ON DRIVING WITH ABS
CAUTIONS
Anti-lock Braking System (ABS) cannot
overcome the physical limitations of
braking distance, or the danger of
aquaplaning, i.e. where a layer of water
prevents adequate contact between the tyres
and the road surface.
The fact that a vehicle is fitted with ABS
must never tempt the driver into taking
risks that could affect safety. In all cases, it
remains the driver's responsibility to drive
within normal safety margins, having due
consideration for prevailing weather and traffic
conditions.
The driver should always take account
of the surface to be travelled over and
the fact that brake pedal reactions will be
different to those experienced on a non-ABS
vehicle.
If the wheels begin to lock under braking, ABS
will automatically come into operation to allow
efficient braking without wheels locking. This
will be recognisable by a rapid pulsation felt
through the brake pedal.
No matter how hard you brake, dependent
upon road conditions, you should be able to
continue steering the vehicle as normal.
In an emergency situation, ABS functions most
effectively when full braking effort is applied
even when the road surface is slippery. The
ABS system constantly monitors the speed of
each wheel and varies the brake pressure to
each, according to the available grip.
• Do not pump the brake pedal at any time;
this will interrupt operation of the system
and may increase the stopping distance.
154
• Never place additional floor matting or any
other obstruction under the brake pedal.
This restricts pedal travel and may impair
brake efficiency.
The ABS warning indicator
illuminates amber in the instrument
pack as a bulb check when the
starter switch is turned to position II. If the ABS
warning indicator remains on or illuminates
whilst driving, a fault with the ABS system is
indicated. Drive with care, avoiding heavy
brake application, and seek qualified assistance
urgently.
Cornering Brake Control (CBC)
Cornering Brake Control (CBC) is an advanced
form of ABS, which maintains vehicle stability
and steering control during braking whilst
cornering or changing lanes at speed.
Off-road driving
Anti-lock braking will operate in off-road
driving conditions, but on certain surfaces
reliance on the system is unwise. ABS cannot
compensate for driver error or inexperience on
difficult off-road surfaces.
Note: On soft, deep surfaces such as powdery
snow, sand or gravel, and on rough ground,
the ABS may require a greater braking distance
than a brake system without ABS. The natural
action of locked wheels on soft surfaces builds
a wedge of surface material in front of the
wheels which assists them to stop.
Note: If the vehicle is stopped on a very steep
slope where little traction is available, it may
slide with the wheels locked as there is no
wheel rotation signal for the ABS. Briefly
release the brakes to permit some wheel
movement, then re-apply the brakes to allow
ABS to gain control.

Brakes
ELECTRIC PARKING BRAKE (EPB)
WARNING
Do not rely on the Electric Parking
Brake (EPB) to hold the vehicle
stationary if the brake system warning
indicator is illuminated or the EPB warning
indicator is flashing. Seek qualified assistance
urgently.
Note: If the vehicle is used in severe off-road
conditions such as wading, deep mud, etc.,
additional maintenance and adjustment of the
parking brake will be required. Consult your
Land Rover Dealer/Authorised Repairer.
Applying the electric parking brake
1 2
E81356
1 Right-hand drive vehicles
2 Left-hand drive vehicles
With the vehicle stationary, pull up the lever
(arrowed) and release it. The lever will return to
the neutral position and the red EPB warning
indicator in the instrument pack will illuminate.
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If the lever is operated while the vehicle is
travelling at less than 3 km/h (2 mph), the
vehicle will be brought to a stop abruptly. The
stop lamps will not illuminate.
Applying the electric parking brake
automatically
On manual transmission vehicles the electric
parking brake will be applied automatically
when the starter key is removed. This operation
must only be carried out when the vehicle is
stationary.
This feature can be inhibited by turning the
starter switch on and off, then pressing down
on the lever while removing the starter key.
Dynamic operation
CAUTION
Driving the vehicle with the electric
parking brake applied or repeated use of
the parking brake to decelerate the vehicle may
cause serious damage to the brake system.
In an emergency, the electric parking brake can
be applied dynamically, i.e. with the vehicle
travelling at more than 3 km/h (2 mph). Pulling
up on the lever and holding it up gives a
gradual reduction in speed. The brake warning
indicator will illuminate accompanied by a
harsh sound and CAUTION PARKBRAKE
APPLIED appears in the message centre. The
stop lamps will illuminate.
Releasing or depressing the lever will cancel
the electric parking brake application.
L
Brakes
Releasing the electric parking brake
CAUTIONS
The electric parking brake operates on
the rear wheels of the vehicle and hence
secure parking of the vehicle is dependent on
being on a hard and stable surface.
Do not rely on the electric parking brake
to operate effectively if the wheels have
been immersed in mud and water.
To disengage the electric parking brake, the
starter switch must be in position II. Apply
pressure to the foot brake on automatic
transmission vehicles, (clutch pedal in vehicles
with a manual transmission) while pressing
down on the parking brake lever.
Electric parking brake automatic release -
manual tranmission models
If the vehicle is stationary with the electric
parking brake applied, press the accelerator
and release the clutch to drive away. The
parking brake will release automatically.
Automatic release will operate in first, second
and reverse in high range and first, second,
third and reverse in low range
To delay automatic release, hold the electric
parking brake lever in the applied position, and
release at the desired point.
The parking brake system gradually reduces
the system load (depending on gradient), to
assist a smooth drive away. If the reduction in
system load causes the vehicle to move after a
valid gear is selected, full load will be
automatically re-applied to the electric parking
brake.
To override the load reducing feature of the
electric parking brake, apply the parking brake
after selecting a gear.
156
In the event of a failure, the message
PARKBRAKE FAULT. AUTO RELEASE NOT
FUNCTIONAL will be displayed in the message
centre.
Electric parking brake automatic release -
automatic transmission models
If the vehicle is stationary with the electric
parking brake applied and D or R selected,
press the accelerator and drive away. The
parking brake will release automatically.
To delay automatic release, hold the electric
parking brake lever in the applied position, and
release at the desired point.
The parking brake system gradually reduces
the system load (depending on gradient), to
assist a smooth drive away. If the reduction in
system load causes the vehicle to move after a
valid gear is selected, full load will be
automatically re-applied to the electric parking
brake.
To override the load reducing feature of the
electric parking brake, apply the parking brake
after selecting a gear.
In the event of a failure, the message
PARKBRAKE FAULT. AUTO RELEASE NOT
FUNCTIONAL will be displayed in the message
centre.
At the start of a journey, electric parking brake
release times may be extended when changing
from P or N. This is to allow for increased gear
engagement times.
 R

Brakes
EPB warning indicators
The EPB warning indicator illuminates in the
instrument pack for three seconds as a bulb
check when the starter switch is turned to
position II.
If the system detects a fault with the
electric parking brake, the amber
brake system warning indicator will
illuminate and the message PARKBRAKE
FAULT will appear in the message centre.
If the system detects a fault while
EPB is operated, the red warning
indicator will flash and the message
PARKBRAKE FAULT. SYSTEM NOT
FUNCTIONAL will appear in the message
centre.
Note: The red indicator will continue to be
illuminated for at least ten seconds after the
starter switch has been turned off.
When parking a vehicle with an EPB fault,
ensure that it is parked on a level surface and is
secured stationary without reliance on the EPB.
Releasing the electric parking brake in an
emergency
E81357
WARNINGS
To prevent the vehicle moving, chocks 1. Using a suitable lever, remove the
must be placed on both sides of one of following:
the wheels or the foot brake must be applied • left-hand drive vehicles, the coin tray on
before releasing the cable. the opposite side of the gear shift lever
Emergency release of the electric from the EPB lever.
parking brake takes considerable • right-hand drive vehicles, the cover
physical effort. If the tools slip, break or are behind the EPB lever.
used incorrectly a serious injury may occur. 2. Attach the jack handle to the cable loop
Whenever possible, this operation should be (arrowed) and insert the screwdriver shaft
carried out by Roadside Assistance. through the jack handle.
If the electric parking brake is applied and the 3. Pull cable to release the EPB.
system develops a fault, the following The electric parking brake must be applied
procedure can be used to manually release the using the lever for the system to operate again.
parking brake.

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Brakes
Messages
The following table lists the messages relating
to electric parking brake (EPB) that could
appear in the message centre. Market criteria
mean that some messages will not apply to
your vehicle and will therefore not appear.
Message Meaning What to do?
PRESS FOOTBRAKE A switch release has been Follow the instructions to
AND PARKBRAKE detected without brake pedal achieve a manual release.
SWITCH contact.
TO RELEASE
PRESS FOOTBRAKE A switch release has been Follow the instructions to
OR CLUTCH detected without brake or achieve a manual release.
AND PARKBRAKE clutch pedal contact.
SWITCH
TO RELEASE
PARKBRAKE A garage technician has If not required, an ignition reset
BEDDING CYCLE requested a bedding cycle. will cancel the function.
ACTIVE
PARKBRAKE FAULT Electric parking brake Seek qualified assistance.
functions may not be available.
PARKBRAKE FAULT Drive-away release function is Use manual release.
AUTO RELEASE not available.
NOT FUNCTIONAL
PARKBRAKE FAULT Supports the red warning Seek qualified assistance
SYSTEM indicator - electric parking immediately.
NOT FUNCTIONAL brake functions are not
available.
PARKBRAKE FAULT Electric parking brake has lost Follow the instructions to park
TO HOLD VEHICLE vehicle speed information. the vehicle.
REMOVE KEY THEN
APPLY PARKBRAKE
PARKBRAKE OFF An emergency release Once original faults have been
LIFT SWITCH operation is detected. corrected, apply the switch to
TO APPLY reinstate electric park brake.
CAUTION Electric parking brake has been Only use this function in an
PARKBRAKE applied while the vehicle is emergency.
APPLIED moving.

158

Parking aid
PRINCIPLE OF OPERATION
Parking aid
CAUTIONS
The front parking aid may emit tones if it
detects a frequency tone using the same
band as the sensors.
Keep the sensors clean. If the sensors
are dirty their performance may be
impaired. When washing the vehicle, avoid
aiming high pressure jets directly at the
sensors.
E80443
The parking aid alerts the driver to any
obstructions that need to be avoided whilst
manoeuvring. When the parking aid is active,
an indicator in the switch on the centre console
illuminates.
The vehicle is fitted with four ultrasonic
sensors on each of the bumpers (some
vehicles are fitted with sensors only in the rear
bumpers).
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R
The driver is made aware of any obstruction
within range by an intermittent tone. As the
vehicle moves closer to an obstruction, the
frequency of the intermittent tone increases.
The range of the front sensors, and the two
sensors on the corner of the rear bumper is
approximately 60 cm (2 feet). The two sensors
in the centre of the rear bumper have a range of
approximately 1.5 metres (5 feet).
USING THE PARKING AID
WARNING
Parking aids may not detect moving
objects such as children and animals,
until they are dangerously close. Always
manoeuvre with caution.
CAUTION
The parking aid is for guidance only. The
sensors may not be able to detect certain
types of obstruction (narrow posts or small
narrow objects, small objects close to the
ground and some objects with dark,
non-reflective surfaces, for example).
With the starter switch in position II, the front
and rear parking aid are activated whenever
Reverse is selected. A short confirmation tone
will sound after one second.
If an obstruction is detected by the sensors
while manoeuvring the vehicle, an intermittent
tone will sound. As the vehicle moves closer to
the obstruction, the intermittent tone increases
in frequency.
When the distance between the sensor and the
obstruction is less than approximately 30 cm
(1 foot), the tone becomes continuous.
If Neutral is selected from Reverse, both sets of
sensors will remain active.
L

Parking aid
The parking aid is automatically switched off
when the vehicles forward speed exceeds
16 km/h (10 mph).
Selecting P, or activating the electric parking
brake while the vehicle is stationary, will switch
off the parking aid.
Front parking aid - manual operation

2
E80442 3

When driving into a limited space, the front

parking aid can be manually activated.
To activate the front parking aid, press the
switch on the centre console (arrowed). The
indicator in the switch will illuminate and a
short confirmation tone will sound.
Press the switch again to deactivate the
parking aid.
Towing
The rear sensors are automatically switched off
when a trailer is attached to the vehicle.
System fault
If a system fault is detected, a long high pitched
tone will sound and the switch indicator light
will flash. Check that the sensors are not
obscured by dirt, ice or snow and clean if
necessary. If the problem persists, seek
qualified assistance.

160

Driving hints
RUNNING-IN
Driving hints
Proper running-in will have a direct bearing on
the reliability and smooth running of your
vehicle throughout its life.
In particular, the engine, gearbox, brakes and
tyres need time to bed-in and adjust to the
demands of everyday motoring. During the
first 800 km (500 miles), it is essential to drive
with consideration for the running-in process
and heed the following advice:
• Limit maximum road speed to 110 km/h
(70 mph) or 3,000 rev/min. Initially, drive
the vehicle on a light throttle and only
increase engine speeds gradually once the
running-in distance has been completed.
• Do not operate at full throttle or allow the
engine to labour in any gear.
• Avoid fast acceleration and heavy braking
except in emergencies.
• Remember! Regular servicing is vital to
ensure that the brake pads are examined
for wear and changed periodically to
ensure long term safety and optimum
performance.
GENERAL DRIVING POINTS
Warning indicators
Battery charging - red
Illuminates as a bulb check when
the starter switch is turned to
position II and extinguishes once
the engine is running. If it remains on, or
illuminates whilst driving, a fault with the
battery charging system is indicated. Seek
qualified assistance urgently.
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R
Low oil pressure - red
Illuminates as a bulb check when
the starter switch is turned to
position II and extinguishes when
the engine is started. If the indicator remains
on, flashes on and off, or illuminates whilst
driving, stop the vehicle as soon as safety
permits and switch off the engine immediately.
Seek qualified assistance before driving.
Always check the oil level when this indicator
illuminates.
Overspeed warning - amber
Illuminates when the vehicle speed
is exceeding the limit set by the
driver. See PERSONALISED
SETTINGS (page 116).
Breakdown safety
If a breakdown occurs while travelling:
• Wherever possible, consistent with road
safety and traffic conditions, the vehicle
should be moved off the main highway,
preferably onto the shoulder as far as
possible.
• Switch on hazard warning lamps.
• If possible, position a warning triangle or a
flashing amber light at an appropriate
distance from the vehicle to warn other
traffic of the breakdown, (note the legal
requirements of some countries).
• Consider evacuating passengers through
the doors facing away from traffic, to a
safe area away from the vehicle, as a
precaution in case your vehicle is
accidentally struck by another one.
L
Driving hints
Servicing requirements
Vehicles which operate in arduous conditions,
particularly on dusty, muddy, or wet terrain,
and vehicles which undergo frequent, or deep
wading conditions will require more frequent
servicing. Contact a Land Rover
Dealer/Authorised Repairer for advice.
After wading in salt water, or driving on sandy
beaches, wash the underbody components and
exposed panels with fresh water. This will help
to protect the vehicle's cosmetic appearance
and prevent impairment of electric parking
brake efficiency.
Vehicle stability
WARNING
Many vehicle rollovers occur when a
driver attempts to bring a vehicle back
onto the road after some or all of the wheels
drift onto the shoulder of the road, especially
when the shoulder is unpaved. If you find
yourself in such a situation, do not initiate any
sharp or abrupt steering and/or braking
manoeuvres to re-enter the roadway. Instead,
let the vehicle slow down as much as safely
possible before attempting to re-enter the
roadway and keep your wheels as straight as
possible while re-entering the roadway.
Measures that can reduce the risk of injury and
death from vehicle crashes and roll-over are:
• Limit your speed. Posted speed limits
should never be exceeded.
• Take curves at reasonable speeds,
avoiding unnecessary braking.
• Drive defensively. Be aware of road and
weather conditions. Avoid risk-taking
behaviour such as following too close,
rapid lane changing or abrupt
manoeuvres.
162
• Assume that pedestrians and other drivers
are going to make mistakes. Anticipate
what they might do. Be ready for their
mistakes.
• Avoid distractions.
• Before changing lanes, check your mirrors
and use the direction indicators.
• Never operate your vehicle when you have
consumed alcohol, are sleepy or fatigued
or have taken any medication that affects
judgement, reflexes or alertness.
Wading
CAUTIONS
The maximum advisable wading depth is
normally 600 mm (24 in). This can be
increased to 700 mm (27 in) if the air
suspension is set to off-road height. Wading at
greater depths may cause damage.
If the vehicle remains stationary for any
length of time in water above the level of
the door sills, severe electrical damage may
occur.
Do not switch off the engine during
wading. If the engine stalls during
wading re-start immediately. Should the
engine stall, have it checked by qualified
technician as soon as possible.
If during wading water enters the engine
air intake, switch off immediately. The
vehicle should be towed from the water and
recovered to a Land Rover Dealer/Authorised
Repairer.

Driving hints
REDUCED ENGINE PERFORMANCE
Engine Management System (EMS) fault
Illuminates amber in the instrument
pack when the engine management
system registers a serious fault -
reduced performance may be experienced.
Avoid high speeds and consult your Land
Rover Dealer/Authorised Repairer as soon as
possible.
Check engine - petrol models only
Illuminates amber in the instrument
pack as a bulb and system check
when the starter switch is turned on
and extinguishes as soon as the engine is
started. Illumination at any other time indicates
that the emission performance of the engine
management system is impaired - seek
qualified assistance.
If the indicator flashes while driving,
immediately reduce engine power to avoid
catalytic converter damage.
163
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ECONOMICAL DRIVING
Fuel consumption is influenced by two major
factors:
• How your vehicle is maintained.
• How you drive your vehicle.
To obtain optimum fuel economy, it is essential
that your vehicle is maintained in accordance
with the manufacturer's service schedule.
Items such as the condition of the air cleaner
element, tyre pressures and wheel alignment
will have a significant effect on fuel
consumption. But, above all, the way in which
you drive is most important. The following
hints may help you to obtain better value from
your motoring:
• Avoid unnecessary, short, start-stop
journeys.
• Avoid fast starts by accelerating gently and
smoothly from rest.
• Do not drive in the lower gears for longer
than necessary.
• Decelerate gently and avoid sudden and
heavy braking.
• Anticipate obstructions and adjust your
speed accordingly well in advance.
• When stationary in traffic, select neutral to
improve fuel economy and air conditioning
performance.
• Turn off air conditioning when not
required.
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Cruise control
PRINCIPLE OF OPERATION USING CRUISE CONTROL
Cruise control

CAUTIONS
Do not use cruise control in traffic
conditions where a constant speed
cannot easily be maintained.
Do not use cruise control on winding or
slippery road surfaces, or in off-road
conditions.
Do not use Sport mode when cruise
control is selected.
Cruise control is operated via switches on the
steering wheel and enables the driver to
maintain a constant road speed without using
the accelerator pedal.
1
2 Suspending cruise control
3 press of switch 4. The warning indicator in the
4 instrument pack extinguishes.
E80444
The steering wheel switches operate as
follows:
1. Set + : Set or increase the speed.
2. Set - : Set or decrease the speed.
3. Resume: Resume set speed.
4. Cancel: Cancels without erasing
memorised speed.
Note: Cruise control is not available when the
vehicle is being driven in low range gears or if
a Terrain Response special program is
selected.
To operate
Accelerate until the desired cruising speed is
reached. This must be above the system's
operational minimum speed of 30 km/h
(18 mph).
Press switch 1 to maintain that road speed.
An amber warning indicator in the
instrument pack will illuminate
when cruise control is operating.
The speed can be increased by normal use of
the accelerator e.g. for overtaking. When the
accelerator is released, road speed will return
to the previously set cruising speed.
Note: If the accelerator pedal is pressed for
more than 60 seconds, cruise control will be
cancelled.
Cruise control can be suspended by a single
Cruise control will also suspend when the
brake or clutch pedal is pressed, when the gear
selector is moved into neutral or if HDC or DSC
becomes active.
To resume cruise control at the previously set
speed, press switch 3.
Note: The set speed will not be erased by
pressing switch 4. The set speed will only be
erased when the starter switch is turned to
position 0 or the gear selector is moved to P or
R.

164
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Cruise control
To reduce the cruising speed
Press and hold switch 2; the vehicle will
decelerate. Release the switch as soon as the
desired speed is reached. The vehicle speed at
the point of switch release becomes the new
set speed.
Alternatively, the set speed can be decreased
incrementally by tapping the (-) switch. Each
press of the switch will decrease the speed by
2 km/h (1 mph).
To increase the cruising speed
WARNINGS
It is important to remember that when
travelling downhill the vehicle may
exceed the set speed.
The driver must always ensure that a
safe speed is maintained within the
speed limit, taking account of traffic and road
conditions.
Press and hold switch 1; the vehicle will
accelerate. Release the switch as soon as the
desired speed is reached.
The vehicle speed at the point of switch release
becomes the new set speed.
Alternatively, the set speed can be increased
incrementally by tapping the (+) switch. Each
press of the switch will increase the speed by
2 km/h (1 mph).
A further alternative is to increase speed by
normal use of the accelerator. When the
desired speed is reached, press switch 1 to set
the cruise control.

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Stability control
PRINCIPLE OF OPERATION • To rock the vehicle out of a hollow or out
Stability control

of a soft surface.
WARNING • Starting in deep snow or on a loose
Dynamic Stability Control (DSC) cannot surface.
compensate for driver misjudgement. It • Driving in deep sand.
is the driver's responsibility to drive
• Driving on tracks with deep longitudinal
appropriately in every situation. Do not take
ruts.
risks that could endanger yourself and
passengers. • Driving through deep mud.

The system controls dynamic stability when

accelerating. Additionally, it identifies unstable
driving behaviour, such as understeering and
oversteering and helps to keep the vehicle
under control by manipulating the engine
output and applying the brakes at individual
wheels. The system is ready to operate each
2 3
time the engine is started. E81084

An amber warning indicator in the
instrument pack illuminates briefly
as a bulb and system check when
the starter switch is turned to position II.
If the warning indicator flashes, the system is
active, regulating engine output and brake
forces.
If the warning indicator illuminates constantly,
and does not extinguish when the DSC switch
is pressed, a fault has been detected in the
system. Any fault will deactivate DSC. Drive
with care and seek qualified assistance as soon
as possible.
USING STABILITY CONTROL
Deactivating Dynamic Stability Control
(DSC)
Land Rover recommend that DSC is
operational in all normal driving conditions.
In some driving conditions, to maximise
traction, it may be beneficial to deactivate DSC.
Such conditions include:
To deactivate DSC, press and briefly hold the
DSC switch on the instrument panel (the DSC
warning indicator will illuminate continuously).
Deactivating DSC has no effect on traction
control operation.
Note: Driving with DSC deactivated, may add
additional loads on the brakes - always drive
with DSC switched on if possible.
Reactivating Dynamic Stability Control
(DSC)
To reactivate DSC, press and briefly hold the
DSC switch on the instrument panel. DSC will
automatically reactivate when the engine is
started.
DSC is reactivated automatically when the
program is changed on vehicles fitted with the
Terrain Response system.

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Stability control
Messages
The following table lists a message relating to
dynamic stability control that could appear in
the message centre. Market criteria mean that
some messages will not apply to your vehicle
and will therefore not appear.
Message Meaning What to do?
DSC SWITCHED OFF System not available - To reselect, press DSC switch.
switched off by driver.

167
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Traction control
PRINCIPLE OF OPERATION
Traction control

Electronic Traction Control (ETC) improves

vehicle traction when one or more wheels has
a tendency to spin. It operates in conjunction
with the Dynamic Stability Control (DSC)
system.
If a wheel is spinning, ETC automatically brakes
that wheel until it regains grip.
An amber warning indicator in the
instrument pack illuminates briefly
as a bulb check when the starter
switch is turned to position II.
If ETC or DSC is activated by the system, the
warning indicator will flash and continue to
flash until the vehicle regains traction and or
stability.
The indicator will be constantly illuminated if
DSC is manually deactivated. Deactivating DSC
has no effect on traction control.
If the warning indicator illuminates constantly,
and does not extinguish when the DSC switch
is pressed, a fault has been detected in the
system. Any fault will deactivate the system.
Drive with care and seek qualified assistance
urgently.

168

Hill descent control (HDC)
PRINCIPLE OF OPERATION
Hill descent control (HDC)
Hill Descent Control (HDC) operates in
conjunction with the anti-lock braking system
to provide greater control in off-road situations
particularly when descending severe gradients.
During a hill descent, if engine braking is
insufficient to control the vehicle speed, HDC
automatically operates the brakes to slow the
vehicle and maintain a speed relative to the
selected gear range and the accelerator pedal
position.
In vehicles with manual transmission, HDC
should only be used in first and reverse gears
in high range and all gears in low range. Once
the vehicle is moving, the clutch pedal should
be fully released.
In vehicles with automatic transmission, HDC
should only be used in D, R and CommandShift
1 in high range and in D, R and all
CommandShift gears in low range. When in D,
the vehicle will automatically select the most
appropriate gear.
Note: If Terrain Response is fitted, some of the
program and range combinations will activate
or deactivate HDC automatically.
USING HDC
E81081
HDC should be used in conjunction with an
appropriate gear.
169
R
Press and release the switch (arrowed) to
select HDC. To deselect, press and release
again.
HDC can be selected at speeds below 80 km/h
(50 mph), but full HDC function is not active
until the vehicle speed falls below 50 km/h
(30 mph). The green HDC indicator will
illuminate.
If the vehicle speed exceeds 80 km/h (50 mph),
HDC will deselect and the green HDC indicator
will extinguish.
If HDC is selected and vehicle speed rises
above 50 km/h (30 mph) in high range, HDC
function is suspended and the green HDC
indicator will flash. A message will also appear
in the message centre.
If HDC is deselected when HDC is operating,
the system fades out, allowing the vehicle to
gradually increase speed.
In low range, HDC controls the vehicle speed
more aggressively. Use low range when
descending steep slopes.
When driving off-road, HDC can be
permanently selected to ensure that control is
maintained. ABS and traction control are still
operational.
Note: HDC is automatically deselected if the
starter switch is turned off for more than 6
hours.
Hill Descent Control (HDC) in action
The green warning indicator
illuminates briefly as a bulb and
system check when the starter
switch is turned to position II.
If HDC is selected and all operating conditions
are met, the indicator will illuminate. If all
operating conditions are not met (vehicle in
neutral, clutch pedal pressed, vehicle speed
above HDC operating range) the indicator will
flash.
L
Hill descent control (HDC)
If an HDC fault occurs, HDC will fade-out and
then deselect, or deselect immediately
(depending on the type of fault and whether or
not HDC is in operation). The indicator will
extinguish and the message SYSTEM NOT
AVAILABLE will appear in the message centre
or the HDC fault amber indicator will illuminate.
1 indicator.
2 More information on the messages that may be
E81082
While HDC is controlling the vehicle speed,
descent speeds can be varied using the
steering-wheel-mounted cruise control
switches. To reduce the descent speed, press
and hold switch 2. Release the switch when the
desired speed is reached.
To increase the descent speed, press and hold
switch 1. Release the switch when the desired
speed is reached.
Alternatively, the descent speed can be
adjusted by tapping switch 1 or 2. Each press
of the switch will adjust the descent speed by
approximately 0.5 km/h (0.3 mph).
Note: Each gear has a pre-defined minimum
descent speed.
The descent speed will only increase if the
gradient is sufficiently steep to cause the
vehicle to accelerate as the braking effect is
reduced. On a shallow slope, pressing switch 1
may result in no speed increase.
Note: With HDC selected, gear changes can be
carried out in the normal way.
170
If the brake pedal is depressed when HDC is
active, HDC is overridden and the brakes will
perform as normal (a pulsation might be felt
through the brake pedal). If the brake pedal is
then released, HDC will start operating at the
reduced speed.
Hill Descent Control (HDC) faults
Faults in the HDC system can be displayed by
the message centre or by the amber warning
displayed is given later in this section.
The HDC amber indicator is fitted to
models without a message centre
and has two functions.
1. Illuminate continuously if there is a fault in
the HDC system. If the fault is detected
while the system is active, HDC will fade
out. Do not attempt a steep descent when
HDC is unavailable, alternatively use a very
low gear and/or the foot brake. Consult
your Land Rover Dealer/Authorised
Repairer at the earliest opportunity.
2. Flash if the brake temperatures reach a
pre-defined limit. HDC will fade out and
become temporarily inactive. HDC will not
be available until the brakes reach an
acceptable temperature.
HDC fade-out
HDC fade-out gradually decreases the HDC
function with the effect that the rate of hill
descent will increase. HDC will be disabled
completely once the descent is complete.
 R

Hill descent control (HDC)

Messages
The following table lists the messages relating
to Hill Descent Control (HDC) that could appear
in the message centre. Market criteria mean
that some messages will not apply to your
vehicle and will therefore not appear.
Message Meaning What to do?
HDC FAULT Hill Descent Control system Drive with care and do not
SYSTEM fault. attempt to descend steep
NOT AVAILABLE slopes. Seek qualified
assistance immediately.
HDC HDC not operative because of Select correct gear if HDC is
NOT AVAILABLE incorrect gear selection. HDC is required. In Low range, HDC
IN THIS GEAR fully functional in 1st and operates in all gears for manual
Reverse gears in manual and automatic transmissions.
transmissions and 1, R and D
in automatic in High range. It
operates in all gears in Low
range.
HDC HDC unavailable, speed Reduce vehicle speed.
NOT AVAILABLE threshold exceeded. Maximum
SPEED TOO HIGH HDC operating speed is
50 km/h (30 mph), maximum
speed for HDC selection is
80 km/h (50 mph).
HDC TEMPORARILY HDC switched off while brake Wait until message disappears
NOT AVAILABLE system is cooling. before attempting to descend
SYSTEM COOLING steep slopes.

171
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Terrain response
PRINCIPLE OF OPERATION
Terrain response
E80899
The Terrain Response™ system is a
permanently active system, continuously
providing benefits in traction and driveability.
These benefits can be further enhanced for
specific off-road driving conditions by the
selection of one of the four special programs.
Dependant on the selected special program,
the system optimises the vehicle set-up for the
prevailing conditions, providing the maximum
in traction, driveability and vehicle response.
The systems comprising Terrain Response are:
• Engine management.
• Gearbox management.
• Intelligent differential control.
• Dynamic stability, traction control and Hill
Descent Control (HDC) systems.
• Air suspension.
The system will provide a variable throttle
response, ranging from very cautious (large
pedal movement has a minimum effect on
engine power) when driving in slippery
conditions, to very responsive (engine power is
allowed to rise more quickly) when driving over
sand.
172
Note: Changing from one special program to
another will result in the system adopting a
different set of criteria for the systems it
controls. For instance, the engine revs
produced by the current throttle position might
increase or decrease slightly in the new
program, or the suspension could change
height. The changes are not dramatic, but are
noticeable.
To obtain the maximum benefits from the
system, it is suggested that you experiment
with the different features in an environment
that will not affect other road users.
USING TERRAIN RESPONSE
E80901
Rotate the control to select the required special
program. When the selector reaches either end
of its range, it can be turned further, but doing
so has no effect.
In addition to General, four special programs
are available:
• Grass/gravel/snow (also includes ice).
• Mud/ruts.
• Sand.
• Rock Crawl.
When the starter switch is turned on, the
indicators around the control are illuminated,
with the active program highlighted in amber.

Terrain response
If a special program is active, the special
program indicator will also be displayed on the
message centre.
E80902
If the starter switch is turned off when a special
program is selected, the program will remain in
the system memory for approximately six
hours. The system will return to that program
when the starter switch is turned back on.
The message centre will confirm that the
previously selected special program is still
selected. After six hours, the system will
automatically revert back to the General
program.
General
Select as soon as a special program
E80903
is not required.
All systems, except Hill Descent
Control (HDC), will adopt settings based on the
conditions sensed. HDC will remain active if it
was manually selected. The suspension will
also change from raised to normal ride height
when the vehicle starts moving.
The General setting is suitable for surfaces that
match typical road surfaces, including dry
cobbles, Tarmac or wooden planks.
173
R
Grass-Gravel-Snow
Use this special program for
surfaces which are firm, but have a
coating of loose material. This could
be grass, snow or loose gravel, pebbles or
sand. This program should also be selected in
icy conditions.
HDC will engage automatically in low range,
but can be manually de-selected. See USING
HDC (page 169).
Start off in a higher gear than usual, second
gear in high range or third gear in low range.
Manual transmission vehicles: when
Grass/Gravel/Snow program is selected,
confirmation will be given in the message
centre. This message will appear only once per
ignition cycle.
Using the vehicle with snow chains fitted could
affect operation of Terrain Response. See
USING SNOW CHAINS (page 248).
Note: If the vehicle cannot obtain forward
traction in deep snow, switch off Dynamic
Stability Control (DSC). DSC must be switched
on as soon as conditions permit. See USING
STABILITY CONTROL (page 166).
Mud-Ruts
Use this special program when
traversing muddy or deeply rutted
ground that is soft and uneven and
demands maximum axle displacement.
Unevenness of the ground could be caused by
roots, brushwood or small logs.
System settings are similar to
Grass-Gravel-Snow, except for the individual
systems that optimise traction and driveability
in muddy/rutted driving conditions. Low range
is recommended for this program.
L
Terrain response
If low range is not selected, the message centre
will prompt the driver. If the Mud-Ruts
program and low range are selected together,
the vehicle ride height will be raised
automatically.
Sand
Use this special program on soft
and predominantly dry, yielding
sandy ground, such as dry beaches
and sand deserts. Also use for deep gravel.
Where the sand is damp or wet, select
Mud-Ruts special program.
Note: If the sand is extremely soft and dry and
of a depth that allows the wheels to sink, switch
off Dynamic Stability Control (DSC). DSC must
be switched on as soon as conditions permit.
See USING STABILITY CONTROL (page 166).
Rock Crawl
Use this special program on solid,
E80907
unyielding ground, which demands
high levels of wheel displacement
and careful vehicle control, such as clusters of
boulders. This program would also be used for
crossing river beds strewn with submerged
rocks.
Rock Crawl is only selectable in low range. If
selection is attempted in high range, the driver
will be prompted to select low range. This
special program will utilise system control
settings to optimise the vehicle suspension and
traction system for extreme suspension
articulation and good low-speed control.
Wading
When driving through water less than 600 mm
(24 inches) deep, select the Terrain Response
program suitable for the surface beneath the
water.
174
Increased suspension height
When a special program requires increased
suspension height, the system will
automatically raise the suspension, unless
there is electric load on the trailer socket,
indicating that a trailer is attached to the
vehicle.
A message will be displayed on the message
centre.
Driver override options
The following two systems controlled by
Terrain Response may also be operated by the
driver.
• Air Suspension
• Hill Descent Control
In some special programs, the Terrain
Response system will switch on HDC and, in
low range, the system will automatically raise
the suspension to off-road height.
Both the HDC and ride height selections can be
cancelled by the driver at any time. If HDC or a
specific ride height has not been selected by
the system, the driver can select them at any
time.
HDC and ride height selections will be
confirmed through the message centre and by
the individual system information indicators,
irrespective of whether the system or driver
selected them. Use of special programs,
particularly in low range, may prompt some
driving advice and warnings as well as
additional information on the message centre.
Note: Use the CommandShift function on the
gearbox to lock the vehicle in a particular gear.
 R

Terrain response
Inappropriate special program selection
CAUTION
Selecting an inappropriate special
program will not endanger the driver or
damage the vehicle. It will, however, impair the
vehicle's response to the conditions and
reduce the durability of the suspension and
drive systems.
If selection of an inappropriate special program
is attempted, such as choosing Rock Crawl
while in high range - the symbol of that
program will flash amber and an audible chime
will sound. The message centre will advise that
the special program is unavailable and suggest
corrective action.
If the requirements have not been met after 60
seconds, the warnings will cease and the
message centre will show the active program.
If the system becomes partly inoperable, it may
not be possible to select some special
programs. A warning will be given when
selection of an affected program is attempted.
If the system becomes totally inoperable, all of
the special program indicators will be switched
off and the message centre will display a
message.
The suspension system provides an automatic
levelling function. See ADJUSTING THE
SUSPENSION (page 180).If low range is
needed, it is likely that mobility and vehicle
composure would benefit from increased
ground clearance.

175
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Terrain response
Messages
The following table lists the messages relating
to Terrain Response that could appear in the
message centre. Market criteria mean that
some messages will not apply to your vehicle
and will therefore not appear.
Message Meaning What to do?
CAUTION! Terrain Response system Raise suspension manually to
RISK OF would have selected off-road off-road height if possible and
GROUNDING WITH height but the driver has appropriate.
SUSPENSION AT manually lowered the vehicle
NORMAL HEIGHT (or the system cannot raise the
vehicle).
HDC FAULT HDC system fault. Drive with care and do not
SYSTEM attempt to descend steep
NOT AVAILABLE slopes. Seek qualified
assistance immediately.
HDC HDC not operative because of Select correct gear if HDC is
NOT AVAILABLE incorrect gear selection. See required.
IN THIS GEAR USING HDC (page 169).
HDC HDC unavailable, speed Reduce vehicle speed.
NOT AVAILABLE threshold exceeded. Max HDC
SPEED TOO HIGH operating speed is 50 km/h (30
mph), max speed for HDC
selection is 80 km/h (50 mph).
HDC TEMPORARILY HDC switched off while brake Wait until message disappears
NOT AVAILABLE system is cooling. before attempting to descend
SYSTEM COOLING steep slopes.
PROGRAM CHANGE It is temporarily impossible to If conditions change within 60
IN PROGRESS select a new program. This can seconds, the chosen program
be due to ABS or DSC activity will be selected.
or the overheating of the If the message is prompted by
electronic differentials. electronic differential overheat,
then it will take longer but there
will be separate advice about
this.
Once the differentials have
cooled, try to reselect the
special program.

176
 R

Terrain response

Message Meaning What to do?

RECOMMEND Low range is recommended for Select low range.
LOW RANGE Mud-Ruts special program.
IS SELECTED
FOR MUD-RUTS
PROGRAM
RECOMMEND RAISING Mud-Ruts program is being Raise suspension manually to
SUSPENSION TO used in high range. Suspension off-road height or select low
OFF ROAD HEIGHT raised automatically in low range.
IN DEEP MUD-RUTS range.
RECOMMEND STARTING IN In slippery conditions start off Select second/third gear.
2ND/3RD GEAR in a higher gear than usual.
FOR SLIPPERY
CONDITIONS
RESET SUSPENSION Suspension still in extended Check if vehicle is clear of
HEIGHT IF CLEAR mode. obstacle. If clear, select
OF OBSTACLE required suspension.
SELECT LOW RANGE Vehicle is not in low range, so Select low range if Rock Crawl
TO ACTIVATE Rock Crawl cannot be is required.
ROCK CRAWL activated.
SELECT NEUTRAL Range change will not occur Select neutral.
FOR RANGE until neutral is selected.
CHANGE
SLOW DOWN OR VEHICLE Vehicle will automatically Choose to slow down or accept
WILL LOWER/RAISE lower/raise if vehicle speed height change.
increases.
SPEED TOO HIGH Vehicle speed is too high for Reduce speed to 40 km/h
FOR RANGE requested range change. (25mph) on automatic
CHANGE transmission or 20 km/h (12
mph) on manual transmission.
SYSTEM FAULT There is a fault on the Terrain Be careful off-road as full
SOME PROGRAMS Response system. Terrain Response programs
NOT AVAILABLE are not available.
Seek qualified assistance
immediately.
SYSTEM FAULT There is a fault on the Terrain Be careful off-road as Terrain
SPECIAL PROGRAMS Response system. Response programs are not
NOT AVAILABLE available
Seek qualified assistance
immediately.

177
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Terrain response

Message Meaning What to do?

TRAILER CONNECTED Vehicle has not achieved If a trailer is connected, do
OFF ROAD HEIGHT off-road height as trailer socket nothing.
NOT SELECTED is being used. If no trailer is connected but
AUTOMATICALLY something else, such as a bike
rack, is connected, raise to
off-road height manually.
If nothing is connected, check
socket for faults.

178

Air suspension
PRINCIPLE OF OPERATION
Air suspension
+70mm
55mm
0mm
50mm
E80695
The air suspension system maintains the
correct vehicle height by controlling the
quantity of air in the vehicle's air springs.
Unless stated otherwise, height changes may
only be made while the engine is running and
the driver and passenger doors are closed.
When the air suspension system lifts the
vehicle, it normally uses compressed air stored
in its reservoir. The suspension will rise much
more slowly if this reservoir is depleted due to
repeated raising and lowering of the
suspension.
On-road height
The normal height for the vehicle.
Off-road height
This is 55 mm (2.2 in.) higher than on-road
height. It provides improved ground clearance
and approach, departure and break-over
angles. See TECHNICAL SPECIFICATIONS
(page 268).
Off-road height can be selected at any speed up
to 40 km/h (24 mph). When the system is at
off-road height, the system will automatically
select on-road height if the vehicle speed
exceeds 50 km/h (30 mph).
179
R
Note: If Terrain Response is in use, some of its
programs/range combinations will adjust
suspension height automatically.
Note: If the trailer socket is in use, increased
supension height control will be inhibited.
Extended mode
If the vehicle is grounded while at off-road
height and traction control is induced, the
system provides additional lift to clear the
obstruction. Extended mode is activated
automatically and cannot be selected manually.
Access height
WARNING
Ensure that the vehicle is clear of
people and obstacles before lowering
the suspension. Remember that the difference
between off-road height and access height is
105 mm (4.1 in.).
This is 50 mm (2.0 in.) lower than On-road
height. It provides easier entry, exit and loading
of the vehicle.
The suspension will automatically rise from
access height when the vehicle speed exceeds
10 km/h (6 mph).
If access height was selected directly from
off-road height, the system will return to
off-road height when the vehicle speed exceeds
10 km/h (6 mph). Otherwise the system will lift
the suspension to on-road height.
High speed height
This feature lowers the suspension ride height
by 20 mm (0.75 in), if the vehicle exceeds 160
km/h (100 mph) for longer than five seconds.
This action is automatic and cannot be
over-ridden. Ride height will return to normal
when vehicle speed remains below 130 km/h
(80 mph) for 30 seconds.
L

Air suspension
Locked at access height (crawl mode) ADJUSTING THE SUSPENSION
This mode enables the vehicle to be driven at
low speeds at access height, to give increased 1 2
roof clearance in multi-storey car parks, etc.
Locked at access height can be selected when 3
the vehicle speed is below 10 km/h (6 mph).
When the vehicle is in this mode, On-road
4
height will be selected automatically if the
vehicle speed exceeds 40 km/h (24 mph). 5
Suspension warning indicator
6
The suspension warning indicator in
the instrument pack illuminates
both red and amber briefly as a bulb 7
E80690
check when the starter is turned to position II.
If the indicator illuminates amber, a 1. Raise/lower switch
suspension fault has been detected, but the 2. Raising indicator
vehicle can still be driven normally.
3. Off-road indicator
If the indicator flashes red, a serious
4. On-road indicator
suspension fault has been detected and the
vehicle should be driven slowly until qualified 5. Access indicator
assistance can be obtained. 6. Lock indicator
The first illumination of the indicator will be 7. Lowering indicator
accompanied by a warning chime.
Suspension height indicators
Indicators 2 or 7 will illuminate to show the
direction of movement. They extinguish when
the height change is completed.
If a height change is requested that is not
allowed, such as attempting to raise the height
of the vehicle with the engine not running,
indicators 2 and 7 will flash twice and a chime
will sound. A message will be displayed on the
message centre.
A flashing indicator 2 or 7 indicates that the
system is in a waiting state or shows that it will
automatically override the driver's choice if
speed criteria are exceeded.

180

Air suspension
Access height
If access height is selected while vehicle speed
is above 20 km/h (12 mph), indicators 5 and 7
will flash while the system waits for the vehicle
to slow down. The system will cancel the
access height request if the vehicle does not
slow sufficiently within one minute.
When the vehicle slows down to 20 km/h
(12 mph), indicator 4 will extinguish as the
system goes to the part-lowered height.
Indicator 5 will be lit and indicator 7 will
continue to flash.
The vehicle must slow down to 8 km/h
(5 mph), within one minute to prevent access
height cancellation. Indicators 5 and 7 will be
lit. When access height is reached, indicator 7
will extinguish.
Access height may be selected up to
40 seconds after the starter switch is turned
off, provided that the driver's door has not
been opened within this time.
181
R
Locked at access height crawl mode
1
5
6
E80691
When the suspension is at on-road or access
height and the vehicle speed is below 35 km/h
(22 mph), press the raise/lower switch 1 in the
down direction for one second. Indicators 5
and 6 will illuminate to confirm the selection,
and a chime will sound.
Locked at access height can be cancelled by
pressing the raise/lower switch in the up
direction for one second. Indicator 6 will
extinguish.
Note: When locked at access height is
cancelled, the suspension will rise to on-road
height if the vehicle speed is greater than 10
km/h (6 mph).
Access height from off-road height
When the suspension is at off-road height,
press switch 1 down, then press it again before
indicator 7 goes out.
The system will remember to return the
suspension to off-road height automatically if
the vehicle is driven above 10 km/h (6 mph).
L

Air suspension
Automatic height change warnings
2

3
2
4
4

7 5

E80692

When the suspension is at off-road height, E80693 7

access or locked at access height, the
suspension height will change automatically
when vehicle speed exceeds predetermined
levels.
When the suspension is at off-road height or
locked at access height, it warns the driver that
the vehicle is approaching a speed threshold. A
chime will sound, a message will be displayed
on the message centre and the on-road
indicator 4 and either 2 or 7 will flash.
The off-road height speed warning is shown
above. If the vehicle slows down, the warning
will disappear.
The indicator for the target height 3, 4 or 5 will
remain lit and the lifting indicator 2 or the
lowering indicator 7 will flash.
The height change will resume if all of the
doors are closed within 90 seconds.
If the doors are not closed within this time, the
raising indicator 2 or the lowering indicator 7
will extinguish and the indicators showing the
heights above and below the current position
will be illuminated.
Selecting a new height using the raise/lower
switch 1, or driving off will reset the system.

Door open override Extended mode

If a door is opened during a height change If the vehicle is grounded and traction control
while the vehicle is at rest, the height change is induced, the system raises the vehicle clear
will be restricted. of the obstruction. Extended mode is activated
automatically and cannot be selected manually.

182

Air suspension
1 If the system is attempting to change the
3 system will freeze all movements.
E80694
When extended mode is activated, indicator 3
will flash. A message will be displayed on the
message centre.
To exit extended mode, either press the
raise/lower switch 1 briefly up or down or drive
the vehicle at a speed greater than 5 km/h (3
mph) for 30 seconds.
Additional lift whilst in extended mode
When extended mode is invoked and the
automatic lifting of the vehicle has been
completed, the driver can select an additional
lift in order to clear the obstacle. This can be
particularly useful when extended mode has
been invoked on soft surfaces.
To request additional lifting, wait for the raising
indicator 2 to extinguish then press and hold
the switch 1 for three seconds whilst pressing
the brake pedal. A chime will sound to confirm
that the request has been accepted. Indicator 2
will be illuminated while the vehicle is being
lifted.
To exit extended mode briefly press either the
raise or lower switch. Alternatively, the vehicle
will automatically lower if driven at a speed
greater than 5 km/h (3 mph) for 30 seconds.
183
R
Suspension freeze
suspension height and it detects that the
suspension is prevented from moving, the
This can be caused by attempting to lower the
vehicle on to an obstacle or attempting to lift
the vehicle against an obstruction.
The indicators operate in the same way as
described in extended mode and the same
message will be displayed on the message
centre. As in extended mode, to exit this freeze
state, either press the switch 1 up or down, or
drive the vehicle at a speed greater than 20
km/h (12 mph).
Remote operation
WARNINGS
The remote control will operate
normally from inside the vehicle. It is
therefore important to keep it out of reach of
children at all times.
When operating the remote control
from inside the vehicle, ensure that a
responsible adult checks for obstructions
under the vehicle and and supervises the
lowering process.
Care should be taken with all
suspension height changes when a
trailer is attached to the vehicle.
The remote control can be programmed to
operate the air suspension.
L

Air suspension
AIR SUSPENSION MESSAGES
When a message centre is fitted to the vehicle,
messages relating to the air suspension
system may be displayed. For an explanation of
those messages, refer to the following table.
Message Meaning What to do?
CAUTION! RISK OF Displayed when the Terrain Raise suspension manually to
GROUNDING WITH Response system would off-road height if possible and
SUSPENSION AT NORMAL normally have provided appropriate.
HEIGHT off-road height but the driver
has manually lowered the
vehicle (or the system cannot
raise the vehicle).
RECOMMEND RAISING In deep ruts it is beneficial to Raise suspension manually to
SUSPENSION TO OFF ROAD raise the vehicle to off-road off-road height.
HEIGHT IN DEEP MUD-RUTS height. This is done
automatically in low range but
has to be done manually if
mud/ruts program is used in
high range.
RESET SUSPENSION HEIGHT Suspension still in extended Check if vehicle is clear of
IF CLEAR OF OBSTACLE mode. obstacle. If clear, select
required suspension.
SLOW DOWN OR VEHICLE Vehicle will automatically Choose to slow down or accept
WILL LOWER/RAISE lower/raise if vehicle speed height change.
increases.
SUSPENSION CLOSE DOOR Air suspension height change Close all doors.
TO CHANGE HEIGHT is prevented because a door is
open.
SUSPENSION FAULT A fault has been detected in the Seek qualified assistance
air suspension system. System immediately.
may still operate normally.
SUSPENSION FAULT MAX A major fault has been detected Drive slowly until fault can be
SPEED 50 km/h (MAX SPEED in the air suspension system. rectified.
30 mph) Height cannot be controlled.
SUSPENSION FAULT NORMAL A fault has been detected in the Seek qualified assistance
HEIGHT ONLY air suspension system. Only immediately.
normal height is available.

184
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Air suspension

Message Meaning What to do?

SUSPENSION FAULT STOP Major component failure. Stop vehicle immediately and
SAFELY STOP ENGINE seek qualified assistance.
SUSPENSION SPEED TOO A height change has been Reduce vehicle speed.
HIGH TO CHANGE HEIGHT requested but is prevented
because speed is too high.
SUSPENSION START ENGINE Vehicle height can only be Start the engine.
TO RAISE VEHICLE raised with the engine running.
SUSPENSION WILL RAISE Air suspension compressor is Wait for suspension to carry
WHEN SYSTEM COOLED cooling. Lifting will resume out lifting sequence.
when compressor has cooled.

185
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Fuel and refuelling
SAFETY PRECAUTIONS
Fuel and refuelling
WARNINGS
Fuel vapour is highly flammable, and in
confined spaces is explosive and toxic.
In the event of spillage, and before refuelling,
always switch off the engine. Do not use
exposed flame or light. Do not smoke. Do not
inhale fumes.
To avoid fuel spillage that could be
hazardous to other road users, always
stop refuelling when the fuel nozzle shuts off
for the second time. Additional fuel will fill the
expansion space in the tank which could lead
to fuel overflowing.
CAUTION
Never use additives of any kind in the
fuel tank. Additives could reduce engine
life or affect exhaust emissions.
Note: Do not leave the remote handset in the
vehicle while refuelling. Always lock the vehicle
if it is to be left unattended.
186
FUEL QUALITY
D
Pb
DIESEL
TIGHTEN UNTIL CAP CLICKS
OR ENGINE LIGHT MAY COME ON
SEE OWNERS GUIDE
E80367
The correct fuel specification for your vehicle is
shown on the inside of the fuel filler flap.
Fuel specification - petrol engines
CAUTION
On vehicles fitted with a catalytic
converter, serious damage to the
catalyst will occur if leaded fuel is used.
Only use Unleaded 95 RON fuel to EN 228
specification. Unleaded fuel no lower than 90
RON may also be used.
The RON value (octane rating) and type of
petroleum available at garage forecourts will
vary in different parts of the world.
During manufacture, engines are tuned to suit
the fuel supplies commonly available in the
country for which the vehicle is destined.
However, if a vehicle is later exported to a
different country, or is used to travel between
different territories, the owner should be aware
that the available fuel supplies may not be
compatible with the engine specification.

Fuel and refuelling
Using petrol with a lower octane rating than 91
RON, however, can cause persistent, heavy
engine knock (a metallic rapping noise). If
severe, this can lead to engine damage.
If heavy engine knock is detected when using
the recommended octane rated fuel, or if
constant engine knocking is present while
maintaining a steady speed on level roads,
contact your Land Rover Dealer/Authorised
Repairer for advice.
Note: An occasional, light, engine knock while
accelerating or climbing hills is acceptable.
Ethanol fuels
CAUTIONS
This vehicle is not fitted with the
equipment necessary for the use of fuels
containing more than 10% ethanol.
Do not use E85 fuels (85 per cent ethanol
content). Equipment necessary for the
use of fuels containing more than 10% ethanol
is not fitted to this vehicle. If E85 fuels are
used, serious engine and fuel system damage
will occur.
Fuels containing up to 10% ethanol (grain
alcohol) may be used. Ensure the fuel has
octane ratings no lower than those
recommended for unleaded fuel. Most drivers
will not notice any operating difference with
fuel containing ethanol. If a difference is
detected, the use of conventional unleaded fuel
should be resumed.
187
R
Methanol
Some fuels contain methanol (methyl or wood
alcohol). If you use fuels containing methanol
the fuels must also contain co-solvents and
corrosion inhibitors for methanol. Also, do not
use fuels that contain more than 3% methanol
even if they contain co-solvents and corrosion
inhibitors. Fuel system damage or vehicle
performance problems resulting from the use
of such fuels is not the responsibility of Land
Rover, and may not be covered under the
warranty.
Methyl Tertiary Butyl Ether (MTBE)
Unleaded fuel containing an oxygenate known
as MTBE can be used provided the ratio of
MTBE to conventional fuel does not exceed
15%. MTBE is an ether based compound,
derived from petroleum, which has been
specified by several refiners as the substance
to enhance the octane rating of fuel.
Reformulated gasoline
Several petroleum companies have announced
the availability of reformulated fuels. These
fuels are specially designed to further reduce
vehicle emissions. Land Rover fully supports
all efforts to protect and maintain ambient air
quality and encourages the use of reformulated
gasoline where available.
L

Fuel and refuelling

Fuel specification - diesel engines
CAUTION
The maximum allowable Bio-diesel mix
is 5%, meeting EN 590 specification.
Only use Diesel or Automotive Gas Oil (AGO) to
EN 590 specification.
The quality of diesel fuel (Derv) can vary in
different countries and only clean, good quality
fuel should be used. It is important that the
sulphur content of diesel fuel does not exceed
0.3%. In Europe all supplies should be within
this limit, but in other parts of the world, you
should check with your supplier.
In markets where the sulphur content exceeds
0.3%, more frequent engine oil and filter
changes will be required.
RUNNING OUT OF FUEL
CAUTION
Do not run the fuel tank dry. This could
create an engine misfire capable of
damaging the engine, the catalytic converter
or the fuel pump.
Note: Should the vehicle run out of fuel it will
be necessary to add a minimum of 4 litres
(0.8 gallons) of fuel in order to restart the
engine. In some circumstances it will be
necessary to drive a short distance, typically
1.6 - 5 kilometres (1 - 3 miles) in order for the
vehicles monitoring systems to register the
additional fuel.

CAUTION
If the fuel tank is accidentally filled with
petrol, it is essential that you seek
qualified assistance before attempting to start
the engine.
Note: The use of commercial vehicle diesel
pumps with a higher fill rate, may result in E80510
premature pump cut-off and fuel spillage.
When the remaining fuel reaches a minimum of
12 litres (three gallons), the amber low fuel
warning indicator illuminates. The remaining
fuel should give a range of 80 km (50 miles).

188
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Fuel and refuelling

FUEL FILLER FLAP
CAUTIONS
The fuel filler flap has a spring loaded
release, do not force it open. If the flap
has been forced open, it may fail to close
properly. Seek qualified assistance.
When replacing the fuel filler cap make
sure that it is tightened until it clicks
three times. Failure to do so may result in the
engine warning light illuminating due to
evaporative emission levels increasing.

E80364

With the vehicle fully unlocked (all doors and

the tailgate), press the left side of the fuel filler
flap to open.
The fuel filler flap springs open revealing the
filler cap.
E80363

The fuel filler is located behind the rear

right-hand wheel arch. An arrow on the fuel
gauge points to that side of the vehicle.

E80365

The filler cap is secured to the vehicle by a

strap. For your convenience a holder is
provided on the flap to store the cap whilst
refuelling.

189
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Fuel and refuelling

REFUELLING
WARNINGS
To avoid any sudden discharge of fuel
caused by excessive fuel vapour
pressure, do not fully remove the filler cap
until any captive tank pressure has been
released.
Take careful note of warning labels
located around the filler cap.
Do not attempt to fill the tank beyond its
maximum capacity. If the vehicle is to 1 2
be parked on a slope, in direct sunlight, or high
ambient temperature, expansion of the fuel
could cause spillage.

CAUTION
When refitting the fuel filler cap, ensure E82173

that it is tightened until it clicks. Failure

to do so may result in the engine warning
indicator illuminating due to evaporative
emission levels increasing.
Insert the pump nozzle 1 into the filler neck,
pushing the spring-loaded cover 2 aside.
When delivery is complete, withdraw the nozzle
and replace the cap. Turn the cap clockwise
until it clicks three times.

190
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Fuel and refuelling

FUEL CUT-OFF
If the Supplementary Restraint System is
activated during an accident, the fuel supply to
the engine may be stopped. If this happens, the
system must be reset before attempting to
restart the engine.
Resetting the fuel cut-off system
WARNING
To avoid the possibility of fire or
personal injury, do not reset the fuel
cut-off system if you see or smell fuel.
If no fuel leak is apparent, reset the system as
follows:
1. Turn the starter switch to position 0 and
wait for one minute.
2. Turn the starter switch to position II and
wait for 30 seconds.
3. Make a further check for fuel leaks.
4. If no leak is found, start the engine as
normal.

CATALYTIC CONVERTER
WARNING
Exhaust system temperatures can be
extremely high - do not park on ground
where combustible materials such as dry
grass or leaves could come into contact with
the exhaust system.

CAUTION
Catalytic converters can be easily
damaged through improper use,
particularly if the wrong fuel is used, or if an
engine misfire occurs.

191
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Fuel and refuelling

FUEL CONSUMPTION
Fuel consumption figures
The fuel consumption figures shown below have been calculated using a standard testing
procedure (the new EC test procedure from Directive 99/100/EC), and produced in accordance with
The Passenger Car Fuel Consumption (Amendment) Order 1996.
Under normal use, a vehicle’s actual fuel consumption figures may differ from those achieved
through the test procedure, depending on driving technique, road and traffic conditions,
environmental factors, vehicle load and condition.

Variant Urban Extra-urban Combined CO2 emissions

l/100km (mpg) l/100km (mpg) l/100km (mpg) g/km
V6 Diesel (manual) 11.1 (25.4) 8.1 (34.9) 9.2 (30.7) 244
V6 Diesel (automatic) 13.1 (21.6) 8.5 (33.2) 10.2 (27.7) 270
V8 Petrol 20.9 (13.5) 12.1 (22.3) 15.0 (18.8) 354

Urban cycle
The urban test cycle is carried out from a cold start and consists of a series of accelerations,
decelerations and periods of steady speed driving and engine idling. The maximum speed attained
during the test is 50 km/h (30 mph) with an average speed of 19 km/h (12 mph).
Extra-urban cycle
The extra-urban cycle test is carried out immediately after the urban test. Approximately half of the
test comprises steady-speed driving, while the remainder consists of a series of accelerations,
decelerations and engine idling. The maximum test speed is 120 km/h (75 mph) and the average
speed 63 km/h (40 mph). The test is carried out over a distance of 7 km (4.4 miles).
Combined
The combined figure is an average of the urban and extra-urban test cycle results, which has been
weighted to take account of the different distances covered during the two tests.
Note:
These figures should not be compared with the figures produced using the ECE/EEC procedure
previously required by The Passenger Car Fuel Consumption Order 1983. Because of the changes
in test procedure, even the urban figures would differ if the same car were subjected to both tests.

192
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Load carrying
GENERAL INFORMATION REAR LOADSPACE HATCHES
Load carrying

WARNINGS
Do not carry loose items of luggage on
top of the luggage cover - these may
damage the cover or obscure vision, and could
become dangerous projectiles in the event of a
sudden stop or collision.
All equipment, luggage or tools carried
in the loadspace should be secured to
minimise the risk of injury to the driver and E80967
passengers in the event of an accident or
emergency manoeuvre. There are access hatches on both sides of the
rear loadspace. On 7-seater models the
LUGGAGE ANCHOR POINTS right-hand side hatch gives access to the
toolkit and the left-hand hatch gives access to
the tow bar.
Pull down the catch (upper inset) and pull the
hatch away from the side of the vehicle.
When refitting the hatch, ensure that it is
securely and correctly fitted before driving.

E80966

Four fixing points are provided in the rear

loadspace floor, to assist in safely securing
large items of luggage. Land Rover provide a
range of approved luggage retention
accessories.

193
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Load carrying
LUGGAGE COVERS
CAUTIONS
When retracting the cover ensure that
nothing is left on top. If any items are left
on top, including paper or fabrics, they may be
drawn into the mechanism and cause it to jam.
If the cover is damaged in any way it
should not be used as the damaged area
may prevent the cover from operating
correctly.
Operating the luggage cover
1. Pull the rigid portion of the blind to unroll
the cover.
2. Engage the end pieces into the recessed
features moulded into the loadspace sides.
Stowing the luggage cover
WARNING
When fitting the cartridge in position
ensure that the paddle returns to the
flush (horizontal) position. Failure to do so
may allow the cartridge to move when the
vehicle is in motion.

E80969

The luggage cover is a tray unit with a

roller-blind type of cover which can be
extended to cover the rear loadspace.
The luggage cover cartridge can be placed at
either end of the loadspace. The foremost
fitting is close behind the second row of seats;
the rearmost is behind where the third row of
seats are in a 7-seat vehicle.
E80970
1. Disengage the ends from the recess and
fully retract the cover into the tray unit.
2. Fold the rigid portion of the blind back
under the unit and press until the edge
engages and is retained.

194

Load carrying
Removal and refitting of luggage cover
Note: It is easier to do this if the second row
seat backs have been tipped forward.
E80971
1. Pull up the paddle at the right-hand end of
the cartridge; this disengages the locking
bolt. Lift the right-hand end of the unit and
pull it away from the opposite loadspace
side.
2. Installation of the cartridge is the reverse
of the removal procedure above.
195
R
5-seat vehicle
WARNING
Do not store the loadspace cover loose
in the vehicle.
When the luggage cover is removed, it must be
stored away from the vehicle.
7-seat vehicle
WARNING
Never fit the luggage cover behind the
second row of seats if the third row is to
be occupied.
CAUTIONS
Remove the stowed unit before moving
the seats.
Do not attempt to raise the second-row
seats into the upright position, or tip
them forward for third-row access, while the
luggage cover is in this stowed position as
damage will result.
In order to fit the blind into position the third
row seats must be folded down.
Once fitted into position in the loadspace sides,
the third row seats must be deployed.
If the luggage cover is removed from a 7-seat
vehicle in order to maximise the loadspace area
by folding down both second and third rows of
seats, the unit can be stowed in the gap
between the folded-flat second and third row
seats.
L

Load carrying

E81919

This is done by lowering the unit into the gap

between the rows of seats and engaging the
unit’s receivers onto the studs protruding from
the outboard portions of the outboard
second-row seat-backs.

196

Towing
TOWING A TRAILER
Towing
E80894
WARNINGS
To preserve vehicle handling and
stability, only fit towing accessories
that have been designed and approved by
Land Rover.
Do not use lashing points or vehicle
recovery towing points to tow a trailer.
Use of the towing eyes for purposes other than
their designed intention could result in
damage or injury.
CAUTION
An equalising or other form of weight
distributing hitch should not be used
with your vehicle.
The torque ranges of Land Rover engines allow
maximum-weight loads to be pulled smoothly
from standstill and reduce gear changing on
hills or rough terrain. To avoid excessive clutch
wear, the use of low range is recommended for
manual transmission vehicles when
manoeuvring heavy trailers or performing hill
starts.
It is the driver's responsibility to ensure that
the towing vehicle and trailer are loaded and
balanced, so that the combination is stable
when in motion. When preparing your vehicle
for towing, pay attention to any instructions
provided by the trailer manufacturer as well as
to the information that follows.
197
R
The trailer warning indicator
illuminates as a bulb check when
the starter switch is turned to
position II and extinguishes when the engine is
started.
If a trailer is attached and the direction
indicators are used, this indicator will flash in
time with the direction indicator lamps. If it
does not flash, a faulty trailer bulb is indicated.
Points to remember
• When calculating the laden weight of the
trailer, remember to include the weight of
the trailer plus the load.
• Vehicles with air suspension: To ensure
that the towing hitch is at the correct
height before balancing the combination
ensure that:
• All doors are closed.
• The engine is running.
• On-road ride height is selected.
• Where the load can be divided between
trailer and tow vehicle, loading more
weight into the vehicle will generally
improve the stability of the combination.
• Towing regulations vary from country to
country. Always ensure national
regulations governing towing weights and
speed limits are observed (refer to the
relevant national motoring organisation for
information).
L

Towing
Note: When towing do not exceed 100 km/h All towing circuits are independently fused in
(60 mph), or 80 km/h (50 mph) when the the tow hitch fusebox. See FUSE BOX
temporary spare wheel is in use. LOCATIONS (page 254).
Towing weights - Australia only GEAR CHANGING
Australian regulations specify that the weight
To avoid overheating the gearbox, and the
of a trailer must not exceed 1.5 times the
clutch in manual gearbox vehicles, it is not
towing vehicle’s weight.
advisable to tow heavy trailer loads at speeds
Never exceed the towing weights specified in of less than 32 km/h (21 mph) using the main
this section. gearbox in high range. Select low range
instead.
Vehicle weights
WARNING LEVELLING
In the interest of safety, the gross To ensure optimum stability, it is essential that
vehicle weight, maximum rear axle the trailer is level with the ground, with the
weight, maximum trailer weight and tow hitch towing hitch and trailer drawbar set at the same
load (nose weight) must not be exceeded. height (note the illustration at the start of the
Exceeding allowable vehicle and axle loads will section).
increase the risk of tyre and suspension This is particularly important when towing twin
failure, increase vehicle brake stopping axle trailers.
distance and adversely affect vehicle handling • The trailer should be level with the ground
and stability. This may result in a crash or when loaded.
rollover. • The height of the drawbar hitch point
Nose weight should be set so that the trailer is level
when connected to the loaded vehicle.
WARNING
The nose weight, plus the combined
weight of the vehicle's load carrying
area and rear seat passengers, must never
exceed the specified maximum rear axle load.
Trailer socket
The trailer socket is located alongside the rear
towing point and behind the towing point
cover.
The vehicle's electrical system is configured to
support all towing requirements and the
electrical socket fitted will comply with legal
requirements for the specific territory.

198
 R

ESSENTIAL TOWING CHECKS
Markets except Australia
Tyre pressures
Nose weight
Breakaway cable or secondary
coupling
Towing
Increase rear pressures of towing vehicle to those for
Maximum Gross Vehicle Weight conditions.
If the vehicle is loaded to the Gross Vehicle Weight (GVW), the
nose weight is limited to 150 kg (330 lb). If a greater nose
weight is necessary (up to 250 kg (550 lb) maximum), vehicle
load should be reduced to ensure the GVW and rear axle
weights are not exceeded.
A breakaway cable or secondary coupling must be attached. If
the trailer/caravan is fitted with brakes, it is usual for an
attached breakaway cable to operate the brakes in the event of
the coupling becoming detached. See your trailer
manufacturer's literature. If your trailer does not have a
breakaway cable, a secondary coupling must be attached. Use
a suitable point on the towing bracket to securely attach the
coupling. It is not advisable to loop cables or couplings around
the neck of the tow ball as they could slide off.

Australia only
Tyre pressures Increase rear pressures of towing vehicle to those for
Maximum Gross Vehicle Weight conditions.
Nose weight Must be a minimum of 7% of gross caravan/trailer weight, up
to a maximum of 350 kg (772 lb).
Hitch height Must be set with the engine running, so that the caravan/trailer
is level when connected to the vehicle.

199
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Towing
RECOMMENDED TOWING WEIGHTS
Towing weights
Maximum permissible towed weights On-road Off-road
Unbraked trailers 750 kg (1 654 lb) 750 kg (1 654 lb)
Trailers with overrun brakes 3 500 kg (7 716 lb) 1,000 kg (2 205 lb)
Nose weight 150 kg (330 lb) -

Maximum towing/load limits

Gross Train Weight (Weight of Vehicle 6 680 - 6, 30 kg 14 727 - 14 837 lb
plus Trailer with Overrun Brakes)
Roof load (including the weight of roof 75 kg 165 lb
rack)

Note: The gross vehicle weight must not be

exceeded.

DETACHABLE TOW BALL

Stowage
WARNING
The tow ball is heavy. Care must be
taken when handling it.
When handling the tow ball, hold the bottom of
the component. Locking into position occurs
automatically and causes the locking lever to
rotate under spring pressure.
Your vehicle is fitted with a towing housing
which will accept a detachable tow ball.
The following illustrations show a UK and Rest
of the World tow ball. An Australian tow ball is
visually different, but is stowed in exactly the
same place.

200
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Towing
5-seat models

E82305

7-seat models

E82306

The tow ball is stowed under an access cover

in the loadspace floor (5-seat models) or
behind an access cover on the left-hand side of
the loadspace (7-seat models).

201
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Towing
Fitting the tow ball

1 4

2 3

E82307

1. Remove the protective cover from the tow 5. Turn the key counterclockwise to lock the
ball mounting and stow it in the tow ball tow ball. Remove the key and store in a
stowage area. safe place.
2. The tow ball can only be installed when the The tow ball must be locked in position before
green locking lever is in the unlocked towing.
position.
3. Insert the tow ball into the mounting and
push firmly upwards until the tow ball
locks into position.
4. The red marker should be completely
covered by the green locking lever.

202
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Towing
Removing the tow ball

2
3

E82308

1. Insert the key and turn it clockwise to

unlock the tow ball.
2. Pull the handle outwards and rotate
counterclockwise until a click is heard. The
marker on the handle should show red.
3. Carefully lower the tow ball and place it in
its stowage area and fully secure it.
4. Replace the protective towing cover in the
tow ball mounting. Press the bottom of the
cover to fix it in position.
Store the tow ball in the stowage area when not
in use.

203
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Towing
TOW BAR DIMENSIONS
Fixed - tow ball

E81325

Tow ball dimensions

Ref. Dimension Metric Imperial
A Wheel centre to centre of tow ball 1,190 mm 46.9 in.
B Ground to centre of tow ball 409 mm 16.1 in.
C Centre of tow ball to tow bar attachment 170 mm 6.7 in.
D Centre of tow ball to tow bar attachment 124 mm 4.9 in.

Note: Dimensions refer to towing equipment

officially released by Land Rover.

204
 R

Towing
Multi-height drop plate - tow bar

H I

D F E
G

B
A

J K

E81326

Tow ball dimensions

Ref. Dimension Metric Imperial
A Wheel centre to centre of tow ball 1,210 mm 47.64 in.
(horizontal)
B Centre of outer attachment points to 403,6 mm 15.89 in.
centre of tow ball (horizontal)
C Centre line of housing bayonet slot tip 192,4 mm 7.57 in.
radius to centre of tow ball (horizontal)
D Centre of inner attachment points to 108 mm 4.25 in.
centre of tow ball (horizontal)

205
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Towing

Ref. Dimension Metric Imperial

E Centre of inner attachment points to 20 mm 0.79 in.
centre of tow ball (vertical)
F Centre of upper tow ball plate bolt to 36 mm 1.42 in.
centre of tow ball (vertical)
G Centre of lower tow ball plate bolt to 70 mm 2.76 in.
centre of tow ball (vertical)
H Centre of outer attachment points to 167.3 mm 6.59 in.
centre of tow ball (horizontal)
I Centre line of housing bayonet slot tip 174.3 mm 6.86 in.
radius to centre of tow ball (vertical)
J Distance between inner attachment 180.5 mm 7.10 in.
point centres
K Distance between outer attachment 822.5 mm 32.38 in.
point centres

206

Vehicle care
CLEANING THE EXTERIOR
Vehicle care
CAUTIONS
Some high pressure cleaning systems
are sufficiently powerful to penetrate
door/window seals and damage trim and door
locks.
Never aim the water jet directly at the engine
air intake, heater air intakes, body seals (door,
sunroof, windows etc.), or at any components
which may be damaged (lights, mirrors,
exterior trim etc.).
Do not use a power wash system in the
engine bay area as it may damage fragile
components, electrical systems etc.
Ensure that you read and comply with all
warnings and product instructions
supplied with any cleaning products.
Never use cleaning products that are not
approved for use on vehicles.
E79400
Washing the vehicle
CAUTION
Substances that are corrosive, such as
bird droppings, tree resin, dead insects,
tar spots, road salt and industrial fall out can
damage the vehicle's paintwork. Any such
deposits should be removed as soon as
possible to prevent damage to the vehicle's
paintwork.
207
R
Remove heavy deposits of mud and dirt with a
hose before washing the vehicle.
Wash the vehicle frequently using a sponge
and generous quantities of cold or lukewarm
water containing a suitable car shampoo. Rinse
thoroughly and dry with a chamois leather, or
synthetic substitute.
Note: In hot weather, do not wash the vehicle
in direct sunlight.
Cleaning after off-road driving
Ensure that the vehicle and underside is
cleaned soon after off-road driving, taking
particular care to clean areas where mud and
debris may have compacted.
E81976
Using a hose pipe, direct clean water through
the front bumper (where arrowed) to remove
any build up of mud on the radiator and air
conditioning condenser.
Removing tar spots
Use white spirit to remove tar spots and
stubborn grease stains from paintwork. Ensure
that after using white spirit, the area is washed
immediately with soapy water to remove all
traces of spirit.
L
Vehicle care
Underbody maintenance
Corrosive materials used on highways to
control snow and ice, as well as accumulations
from off-road driving or wading in salt water
can collect on the vehicle's underbody. If these
materials are not removed, accelerated
corrosion can occur. Regularly flush the
underbody with plain water, and pay particular
attention to areas where mud and debris
collect.
If damage or corrosion is detected, please have
the vehicle checked by a Land Rover
Dealer/Authorised Repairer as soon as
possible.
Polishing
Occasionally treat the paint surface with an
approved polish containing the following
properties:
• Very mild abrasives to remove surface
contamination without removing or
damaging the paint.
• Filling compounds that will fill scratches
and reduce their visibility.
• Wax to provide a protective coating
between the paint and the elements.
Note: Do not apply car polish to the unpainted
areas of the bumper mouldings - polish will
become ingrained in the textured finished.
Glass and mirrors
The rear screens and mirror glass should only
be cleaned using soapy water and a soft cloth.
This will avoid damaging the reflective surface
of the mirror and the heating elements and
antenna in the rear screen.
Never use abrasive cleaning products or metal
ice scrapers on the mirrors or the front/rear
screens.
208
CLEANING THE INTERIOR
CAUTION
Ensure that you read all of the
information, and instructions for use,
provided with cleaning products.
Plastic and cloth
Clean plastic or cloth faced surfaces with warm
water and a non-detergent soap then wipe
clean with a soft cloth.
CAUTION
Do not polish instrument panel. Polished
surfaces are reflective, and may interfere
with the driver's view.
Leather
CAUTION
Only use cleaning products specifically
designed for use on leather. The use of
products which are not approved will
invalidate your warranty.
Leather should be cleaned and protected at
least every six months.
Land Rover recommend the use of leather
cleaning kit BAC500490. Use only in
accordance with the instructions.
Note: Some materials/fabrics are prone to
dye-transfer which can cause unsightly
discolouration of lighter coloured leathers.
Affected areas should be cleaned and
re-protected as soon as possible.
Carpet and fabrics
Only clean with a dilute solution of an approved
upholstery cleaner. It is advisable to test all
cleaners on a concealed area before use.
 R

Vehicle care
Instrument pack, clock and radio REPAIRING MINOR PAINT DAMAGE
Only use a soft dry cloth to clean the Regularly inspect the paintwork for damage.
instrument panel, clock, and audio equipment. Any stone chips, fractures or deep scratches in
Do not use cleaning fluids or sprays. the bodywork should be repaired promptly.
Seat belts Bare metal will corrode quickly and, if left
untreated can result in expensive repairs.
WARNING Some exterior panels of your vehicle are made
Do not allow any water, cleaners, or of aluminium which will not corrode in the
fabric from cloths to enter the seat belt same manner as steel. However, any damage
mechanism. Any substance which enters the should still receive prompt attention.
mechanism may affect the performance of the Minor chips and scratches can be repaired with
seat belt in an impact. touch-up materials available from your Land
Extend the seat belts fully, then use warm Rover Dealer/Authorised Repairer. Larger
water and a non-detergent soap to clean. Allow areas of damage will require professional
the seat belts to dry naturally whilst fully repair.
extended.
Note: Whilst cleaning the seat belt, take the
opportunity to examine the webbing for
damage/wear. Any wear or damage should be
reported to, and rectified by a Land Rover
Dealer/Approved Repairer.
Airbag module covers
WARNINGS
Do not allow the airbag covers, or
surrounding areas, to become
contaminated with liquids. Any substance
which enters the mechanism can prevent
correct deployment of an airbag during an
impact.

CAUTION
Airbag covers should only be cleaned
using a slightly dampened cloth, and a
small amount of upholstery cleaner.

209
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Maintenance
GENERAL INFORMATION
Maintenance
Regular systematic maintenance is the key to
ensuring the continued reliability and efficiency
of your vehicle.
Maintenance is the owner's responsibility and
you must ensure that owner maintenance
operations, oil services, inspections and brake
fluid and coolant changes are carried out when
required and according to the manufacturer's
recommendations.
The routine maintenance requirements for your
vehicle are shown in the Service Portfolio book.
Most of this necessary workshop maintenance
requires specialised knowledge and
equipment, and should preferably be entrusted
to a Land Rover Dealer/Authorised Repairer.
Service Portfolio
The Service Portfolio book includes a Service
Record section, which enables a record to be
kept of all the servicing and inspections that are
carried out on the vehicle. This section of the
book also has an area for brake fluid changes
to be recorded.
Ensure your service provider signs and stamps
the book after each service and inspection.
210
Owner Maintenance
CAUTION
Any significant or sudden drop in fluid
levels, or uneven tyre wear, should be
reported to a qualified technician without
delay.
In addition to the routine maintenance, a
number of simple checks must be carried out
more frequently. Advice is given on the pages
that follow.
Daily checks
• Operation of lamps, horn, direction
indicators, wipers, washers and warning
indicators.
• Operation of seat belts and brakes.
• Look for fluid deposits underneath the
vehicle that might indicate a leak.
Weekly checks
• Engine oil level. See ENGINE OIL CHECK
(page 219).
• Brake fluid level. See BRAKE FLUID CHECK
(page 222).
• Power steering fluid level. See POWER
STEERING FLUID CHECK (page 223).
• Screen washer fluid level. See WASHER
FLUID CHECK (page 224).
• Tyre pressures and condition.
• Operate air conditioning.
Note: The engine oil level should be checked
more frequently if the vehicle is driven for
prolonged periods at high speeds.

Maintenance
Driving in arduous conditions
When a vehicle is operated in extremely
arduous conditions, more frequent attention
must be paid to servicing requirements.
For example: If your vehicle experiences deep
wading conditions, even daily servicing could
be necessary to ensure the continued safe and
reliable operation of the vehicle.
Arduous driving conditions include:
• Driving in dusty and/or sandy conditions.
• Driving on rough and/or muddy roads
and/or wading.
• Driving in extremely hot conditions.
• Towing a trailer or driving in mountainous
conditions.
Contact a Land Rover Dealer/Authorised
Repairer for advice.
Emission control
Your vehicle is fitted with various items of
emission and evaporative control equipment,
designed to meet specific territorial
requirements. You should be aware that
unauthorised replacement, modification or
tampering with this equipment by an owner or
repair shop, may be unlawful and subject to
legal penalties.
In addition, engine settings must not be
tampered with. These have been established to
ensure that your vehicle complies with
stringent exhaust emission regulations.
Incorrect engine settings may adversely affect
exhaust emissions, engine performance and
fuel consumption, as well as causing high
temperatures, which will result in damage to
the catalytic converter and the vehicle.
211
R
Road testing dynamometers (rolling
roads)
Because your vehicle is equipped with anti-lock
brakes and permanent four-wheel drive, it is
essential that any dynamometer testing is
carried out only by a qualified person, familiar
with the dynamometer testing and safety
procedures practised by Land Rover
Dealers/Authorised Repairers.
Safety in the garage
WARNINGS
If the vehicle has been driven recently,
do not touch exhaust and cooling
system components until the engine has
cooled.
Never leave the engine running in an
unventilated area - exhaust gases are
poisonous and extremely dangerous.
Do not work beneath the vehicle with
the wheel changing jack as the only
means of support.
Keep your hands and clothing away
from drive belts and pulleys.
Remove metal wrist bands and
jewellery, before working in the engine
compartment.
Do not touch electrical leads or
components while the engine is
running, or with the starter switch turned on.
Do not allow tools or metal parts of the
vehicle to make contact with the battery
leads or terminals.
L

Maintenance
Fuel system OPENING AND CLOSING THE
WARNINGS BONNET
Under no circumstances should any Opening the bonnet
part of the fuel system be dismantled or
replaced by anyone other than a suitably
qualified vehicle technician. Failure to comply
with this instruction, may result in fuel spillage
with a consequent serious risk of fire.
Ensure sparks and naked lights are kept
away from the engine compartment.
Wear protective clothing, including,
where practicable, gloves made from
an impervious material.
Poisonous fluids
Fluids used in motor vehicles are poisonous
and should not be consumed or brought into
contact with open wounds. These include;
battery acid, antifreeze, brake, clutch and E80332
power steering fluid, petrol, diesel, engine oil
and windscreen washer additives. 1. Pull the bonnet release handle located on
the left-hand side of the vehicle.
For your own safety, always read and obey all
instructions printed on labels and containers. 2. Lift the bonnet safety catch lever located
below the centre point of the words LAND
Used engine oil ROVER, and raise the bonnet.
Prolonged contact with engine oil may cause
serious skin disorders, including dermatitis Closing the bonnet
and cancer of the skin. Always wash WARNING
thoroughly after contact.
Do not drive with the bonnet retained by
It is illegal to pollute drains, water the safety catch alone.
courses or soil. Use authorised
waste disposal sites to dispose of Lower the bonnet until the safety catch
used oil and toxic chemicals. engages. Using both hands, press the bonnet
down until the catches click.
Check that both catches are fully engaged by
attempting to lift the front edge of the bonnet.
This should be free from all movement.

212
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Maintenance
ENGINE COMPARTMENT OVERVIEW
V8 Petrol engine, left-hand drive
vehicles

2 1 3

4 5 6

E80380

1. Engine oil filler cap

2. Engine oil dipstick
3. Brake fluid reservoir
4. Power steering reservoir
5. Cooling system reservoir
6. Washer reservoir
WARNING
While working in the engine
compartment, always observe the
safety precautions listed under Safety in the
garage. See GENERAL INFORMATION
(page 210).

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Maintenance
V8 Petrol engine, right-hand drive
vehicles

3 1 2

4 5 6

E80381

1. Engine oil filler cap

2. Engine oil dipstick
3. Brake fluid reservoir
4. Power steering reservoir
5. Cooling system reservoir
6. Washer reservoir
WARNING
While working in the engine
compartment, always observe the
safety precautions listed under Safety in the
garage. See GENERAL INFORMATION
(page 210).

214
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Maintenance
V6 Petrol engine, left-hand drive
vehicles

1 2 3

4 5 6

E80382

1. Engine oil filler cap

2. Engine oil dipstick
3. Brake fluid reservoir
4. Power steering reservoir
5. Cooling system reservoir
6. Washer reservoir
WARNING
While working in the engine
compartment, always observe the
safety precautions listed under Safety in the
garage. See GENERAL INFORMATION
(page 210).

215
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Maintenance
V6 Petrol engine, right-hand drive
vehicles

3 2 1

4 5 6

E80383

1. Engine oil filler cap

2. Engine oil dipstick
3. Brake fluid reservoir
4. Power steering reservoir
5. Cooling system reservoir
6. Washer reservoir
WARNING
While working in the engine
compartment, always observe the
safety precautions listed under Safety in the
garage. See GENERAL INFORMATION
(page 210).

216
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Maintenance
V6 Diesel engine, left-hand drive
vehicles

1 2 3

4 5 6

E80384

1. Engine oil filler cap

2. Engine oil dipstick
3. Brake fluid reservoir
4. Power steering reservoir
5. Cooling system reservoir
6. Washer reservoir
WARNING
While working in the engine
compartment, always observe the
safety precautions listed under Safety in the
garage. See GENERAL INFORMATION
(page 210).

217
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Maintenance
V6 Diesel engine, right-hand drive
vehicles

3 1 2

4 5 6

E80385

1. Engine oil filler cap

2. Engine oil dipstick
3. Brake fluid reservoir
4. Power steering reservoir
5. Cooling system reservoir
6. Washer reservoir
WARNING
While working in the engine
compartment, always observe the
safety precautions listed under Safety in the
garage. See GENERAL INFORMATION
(page 210).

218
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Maintenance
UNDER BONNET COVERS ENGINE OIL CHECK
The oil consumption of an engine is influenced
Removal
by many factors. Under high loads an engine
will consume more oil than usual. Diesel
engines consume slightly more oil than petrol
engines.
Check the oil level weekly, when the engine is
cold and with the vehicle resting on level
ground.
Checking the oil level
Note: If it is necessary to check the oil level
when the engine is hot, switch off the engine
and let the vehicle stand for five minutes to
allow the oil to drain back into the sump. Do not
start the engine.

E80386

1. Press the two tabs to release the front edge

of the cover.
MAX
2. Lift the front of the cover and slide towards
the front of the vehicle to remove. MIN
Fitting
CAUTION
Ensure that no pipes, cables, or other
items have been trapped between the MAX
cover and casing.
MIN
1. Slide the rear edge of the cover under the
rubber trim fitted to the scuttle panel. E80357

2. Align front edge of cover to casing and
press down until the two tabs click into
place.
1. Withdraw the dipstick and wipe the blade
clean with a lint free cloth.
2. Fully re-insert the dipstick and withdraw
again to check the oil level. Never allow the
oil level to fall below the lower mark or hole
on the dipstick.

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Maintenance
As a general guide, if the level on the dipstick: Engine oil specification
• Is nearer to the upper mark or hole than
the lower, add no oil. Variant Specification
• Is nearer to the lower mark or hole than the Diesel vehicles SAE 5W-30 meeting
upper, add half a litre (one pint) of oil. specification ACEA:B1 or
• Is below the lower mark or hole, add one B3
litre (two pints) of oil and re-check the level Petrol vehicles WSS-M2C913-B ¹
after a further five minutes.
Topping up the oil ¹ If you are unable to find an oil that meets the
specification defined by WSS-M2C913-B, you
CAUTIONS must use an SAE 5W-30 oil meeting
Your vehicle warranty may be invalidated specification ACEA:A3 or specification API SL
if damage is caused by using oil that or SM.
does not meet the required specification.
Failure to use an oil that meets the
ENGINE COOLANT CHECK
required specification could cause If the quantity of fluid in the coolant
excessive engine wear, a build up of sludge reservoir drops below the
and deposits, and increase pollution. It could recommended level, an amber
also lead to engine failure. warning indicator in the instrument pack will
illuminate. Stop the vehicle and check the
Overfilling with oil could result in severe
coolant level.
engine damage. Oil should be added in
small quantities and the level re-checked to On vehicles with a message centre, the
ensure that the engine is not overfilled. message LOW COOLANT LEVEL or COOLING
SYSTEM FAULT MONITOR GAUGE will be
1. Unscrew the oil filler cap.
displayed in place of the warning indicator.
2. Add oil to maintain the level between the
MIN and MAX marks or holes on the Checking the coolant level
dipstick. Clean up any oil spilled during
CAUTION
topping-up.
Running the engine without coolant will
3. Check the oil level again after 5 minutes.
cause serious engine damage.
It is essential to use the correct specification
The coolant level in the expansion tank should
oil, and to ensure it is suitable for the climatic
be checked at least weekly (more frequently in
conditions in which the vehicle is to be
high mileage or arduous operating conditions).
operated.
Always check the level when the system is
Note: The approximate quantity of oil required cold.
to raise the level from MIN to MAX on the
dipstick is 1.5 litres (2.64 pints).

220

Maintenance
E80387
Ensure the coolant level is maintained between
the level indicator marks located above and
below COLD FILL RANGE, on the side of the
expansion tank. This should be viewed by
standing in front of the vehicle. Ignore any
coolant visible in the top section of the tank.
If the level has fallen appreciably, suspect
leakage or overheating and arrange for the
vehicle to be examined by a qualified
technician.
Topping up the coolant
WARNINGS
Never remove the filler cap when the
engine is hot - escaping steam or
scalding water could cause serious personal
injury.
Avoid spilling antifreeze onto a hot
engine - a fire may result.
Unscrew the filler cap slowly, allowing
the pressure to escape before removing
completely.
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R
CAUTION
When travelling in territories where the
water supply contains salt, always
ensure you carry a supply of fresh (rain or
distilled) water. Topping up with salt water will
cause serious engine damage.
Top-up to the upper level indicator mark
located above the COLD FILL RANGE text, on
the side of the expansion tank. Use only a 50%
mix of water and Castrol SF antifreeze.
Note: In an emergency - and only if the
approved antifreeze is unavailable - top-up the
cooling system with clean water, but be aware
of the resultant reduction in frost protection.
Do not top-up or refill with conventional
antifreeze formulations. If in doubt consult a
qualified technician.
Ensure the cap is tightened fully after top-up is
completed by turning the cap until the ratchet
cap clicks.
Antifreeze
WARNINGS
Antifreeze is poisonous and can be fatal
if swallowed - keep containers sealed
and out of the reach of children. If accidental
consumption is suspected, seek medical
attention immediately.
If the fluid comes into contact with the
skin or eyes, rinse immediately with
plenty of water.
CAUTIONS
The use of non-approved antifreeze will
have an adverse effect on the engine
cooling system and therefore engine
durability.
L

Maintenance

CAUTIONS Note: If the warning indicator illuminates, or

Antifreeze will damage painted surfaces;
soak up any spillage with an absorbent
cloth immediately and wash the area with a
mixture of car shampoo and water.
Antifreeze contains important corrosion
inhibitors. The antifreeze content of the coolant
must be maintained at 50% ± 5% all year round
(not just in cold conditions). To ensure that the
anti-corrosion properties of the coolant are
retained, the antifreeze content should be
checked once a year and completely renewed
every ten years, regardless of distance
travelled. Failure to do so may cause corrosion
of the radiator and engine components.
The specific gravity of a 50% antifreeze
solution at 20°C (68°F) is 1.068 and protects
against frost down to -40°C (-40°F).
the message is displayed while the vehicle is
being driven, stop the vehicle as soon as safety
permits by gently applying the brakes.
Check and top-up the fluid level if necessary.
Checking the fluid level
WARNING
Seek qualified assistance immediately if
brake pedal travel is unusually long or if
there is any significant loss of brake fluid.
Driving under such conditions could result in
extended stopping distances or complete
brake failure.
With the vehicle on level ground, check the
fluid level at least every week (more frequently
in high mileage or arduous operating
conditions).

BRAKE FLUID CHECK

WARNINGS
Brake fluid is highly toxic - keep
containers sealed and out of the reach
of children. If accidental consumption of fluid
is suspected, seek medical attention
immediately.
If the fluid comes into contact with the
skin or eyes, rinse immediately with
plenty of water.
Take care not to spill the fluid onto a hot E80388
engine - a fire may result.
Do not drive the vehicle with the fluid Check the level visually through the side of the
level below the MIN mark. transparent reservoir without removing the
filler cap.
If the quantity of fluid in the brake
The brake fluid level should be between the
reservoir drops below the
MIN and the MAX marks.
recommended level, a red warning
indicator in the instrument pack will illuminate The fluid level may fall slightly during normal
or the message CHECK BRAKE FLUID will be use as a result of brake pad wear but should
displayed in the message centre. not be allowed to fall below the MIN mark.

222
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Maintenance
Topping up the fluid
CAUTIONS
Brake fluid will damage painted surfaces.
Soak up any spillage with an absorbent
cloth immediately and wash the area with a
mixture of car shampoo and water.
Only use new fluid from an airtight
container (fluid from opened containers
or fluid previously bled from the system will
have absorbed moisture, which will adversely
affect performance, and must not be used).
1. Clean the filler cap before removing to
prevent dirt from entering the reservoir.
2. Disconnect the electrical lead.
3. Unscrew the cap (1/8 turn) and remove.
4. Top-up the reservoir to the MAX mark
using Shell DOT4 ESL brake fluid. If Shell
DOT4 ESL is not available, a low viscosity
DOT4 brake fluid that meets ISO 4925
class 6 and Land Rover LRES22BF03
requirements may be used.
5. Replace the cap and reconnect the
electrical lead, ensuring that the lead
points to the centre-line of the vehicle.
Checking the fluid level
CAUTIONS
The engine must not be started if the
fluid level has dropped below the MIN
mark - severe damage to the steering pump
could result.
Seek qualified assistance immediately if
there is a large or sudden drop in the
fluid level.
If it can be established that fluid loss is slow,
then the reservoir may be topped-up to the
upper level mark to enable the vehicle to be
driven to a repair facility for examination.
Do not drive the vehicle if there is a possibility
that the leaked fluid will come into contact with
a hot surface, such as the exhaust.
Check and top-up the fluid level only with the
engine switched off and the system cold, and
ensure that the steering wheel is not turned
after stopping the engine.

POWER STEERING FLUID CHECK

WARNINGS
Power steering fluid is highly toxic -
keep containers sealed and out of reach
of children. If accidental consumption of fluid
is suspected, seek medical attention
immediately. E80389

If the fluid comes into contact with the

The level of fluid can be seen through the
skin or eyes, rinse immediately with
translucent body of the reservoir.
plenty of water.
The fluid level should be between the MIN and
Do not spill the fluid onto a hot engine -
the MAX marks.
a fire may result.

223
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Maintenance
Topping up the fluid CAUTIONS
CAUTIONS Body panels may suffer discolouration
as a result of screen wash spillage. Take
Power steering fluid will damage painted
care to avoid spillage, particularly if an
surfaces. Soak up any spillage with an
undiluted or high concentration is being used.
absorbent cloth immediately and wash the
If spillage occurs, wash the affected area
area with a mixture of car shampoo and water.
immediately with water.
Do not fill the reservoir above the MAX
If the quantity of fluid remaining in
mark.
the washer reservoir drops to less
1. Clean the filler cap before removing to than one litre, an amber warning
prevent dirt from entering the reservoir. indicator in the instrument pack will illuminate
2. Remove filler cap. or the message LOW WASHER FLUID will be
3. Top-up the reservoir until the fluid level is displayed in the message centre.
between the MIN and MAX marks using
Texaco Cold Climate PAS fluid.
4. Replace filler cap.

WASHER FLUID CHECK

WARNINGS
Some screen wash products are
inflammable, particularly if high or
undiluted concentrations are exposed to
sparking. Do not allow screen wash fluid to
come into contact with naked flames or
sources of ignition. E80390

If the vehicle is operated in

temperatures below 40°C (40°F), use a
washer fluid with frost protection. In cold
weather, failure to use a washer fluid with frost
protection, could result in impaired vision and
increase the risk of a vehicle crash.
CAUTIONS
Do not use an antifreeze or vinegar/water
solution in the washer reservoir -
antifreeze will damage painted surfaces, while
vinegar can damage the windscreen washer
pump.
The washer reservoir supplies both front and
rear screen washer jets and headlamp washer
jets.
Check and top-up the reservoir level at least
every week. Always top-up with screen washer
fluid to prevent freezing.
Operate the washer switches periodically to
check that the nozzles are clear and properly
directed.

224
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Vehicle battery
BATTERY WARNING SYMBOLS
Vehicle battery

WARNINGS
There is a label on the battery depicting a Battery posts, terminals and related
number of warning signs. The warning signs accessories contain harmful lead and
are as follows: lead compounds. Wash hands after handling.
No smoking, no naked flames, no A low maintenance battery specifically
sparks. designed for use with this vehicle is fitted in the
Keep away from children. engine compartment.
The exterior of the battery should be
Shield eyes. occasionally wiped clean to remove any dirt or
grease.
Battery acid. If a new battery is to be fitted, it must be the
same type as the original. The use of
unapproved batteries is not recommended and
Explosive gas.
could invalidate the vehicle warranty.
We recommend that the battery charge is
checked frequently if the vehicle is used mostly
BATTERY CARE for short distance trips or if it is not used for
WARNINGS long periods of time.
Batteries contain acid, which is both Note: The service life of the battery is
corrosive and poisonous. If spillage dependent on its condition of charge. It must
occurs: always be sufficiently charged for the battery to
last an optimum length of time.
On clothing or the skin - remove any
contaminated clothing immediately, flush the
skin with large amounts of water, and seek
medical attention urgently.
In the eyes - flush with clean water
immediately for at least 15 minutes. Seek
medical attention urgently.
Swallowing battery acid can be fatal
unless immediate action is taken - seek
medical attention urgently.
Always wear eye protection when
working around batteries.
For your safety, remove all metal wrist
bands and jewellery before working in
the engine compartment and never allow the
battery terminals or vehicle leads to make
contact with tools or metal parts of the vehicle.

225
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Vehicle battery
Check and replenish battery electrolyte
WARNING
Do not allow naked lights near the
battery (batteries generate hydrogen
gas which is highly flammable).
E81572
Unscrew the six cell plugs.
Check that the electrolyte is level with the
plastic level indicator 1. If necessary, top up
with distilled water, but do not overfill.
Note: In normal climates this must be carried
out at least once a year. During hot weather or
in hot climates the electrolyte level must be
checked at least every three months.
Note: If illumination is required, use a hand
held flashlight to inspect the electrolyte level.
Refit the six cell plugs.
USING BOOSTER CABLES
WARNINGS
During normal operation batteries emit
explosive hydrogen gas - ensure sparks
and naked lights are kept away from the engine
compartment.
Make sure both batteries are of the
same voltage (12 volts), and that the
booster cables have insulated clamps and are
approved for use with 12 volt batteries.
226
WARNINGS
Do not connect positive (+) terminals to
negative (-) terminals, and ensure
booster cables are kept away from any moving
parts in the engine compartment.
Do not attempt to start the vehicle if the
electrolyte in the battery is suspected of
being frozen.
Do not disconnect the discharged
battery.
Take care when working near rotating
parts of the engine.
CAUTION
Do not push or tow start a vehicle with a
discharged battery.
Using booster cables (jump leads) from a
donor battery, or a battery fitted to a donor
vehicle, is the only approved method of starting
a vehicle with a discharged battery.
Boosting from another vehicle
CAUTION
Do not use a 24 volt booster start
system. These produce excessive
voltage and can damage the vehicles electrical
system.
If a donor vehicle is to be used, both vehicles
should be parked with their battery locations
adjacent to each other. Ensure that the two
vehicles do not touch.
Apply the electric parking brake and ensure
that the transmission of both vehicles is set in
neutral (P or Park for vehicles with automatic
transmission).
Turn off the starter switch and all electrical
equipment of both vehicles.

Vehicle battery
Boosting procedure
WARNINGS
Do not connect the black cable to the
negative terminal of the discharged
battery. If in doubt, seek qualified assistance.
Ensure that each connection is securely
made and that there is no risk of the
clips accidentally slipping or being pulled from
the connection points/battery terminal - this
could cause sparking, which could lead to fire
or explosion.
+
+ battery. Once both engines are running
+
+ them, i.e. disconnect the black cable from the
E80818
Always adopt the following procedure,
ensuring the cables are connected in the order
shown below
1. On the donor vehicle, connect one end of
the red booster cable to the positive (+)
terminal of the battery or the vehicle’s
positive (+) connection point.
227
R
2. On the disabled vehicle, connect the other
end of the red booster cable to the positive
(+) battery terminal.
3. On the donor vehicle, connect one end of
the black booster cable to the negative (-)
terminal of the battery or the vehicle’s
negative (-) connection point.
4. On the disabled vehicle, connect the other
end of the black booster cable to a good
earth point (e.g. an engine mounting or
other unpainted metal surface) at least
0.5m (20 in.) from the battery and well
away from fuel and brake lines.
Check that the cables are clear of any moving
parts of both engines, then start the engine of
the donor vehicle and allow it to idle for a few
minutes.
Now start the vehicle with the discharged
normally, allow them to idle for two minutes
before switching off the donor vehicle engine.
Do not switch on any electrical circuits on the
previously disabled vehicle until after the
booster cables have been removed.
Disconnecting the booster cables must be an
exact reversal of the procedure used to connect
negative (-) connection terminal on the donor
vehicle first.
L
Vehicle battery
CHARGING THE VEHICLE BATTERY
WARNINGS
Batteries generate explosive gases,
contain corrosive acid and produce
levels of electric current sufficient to cause
serious injury.
While charging, shield your eyes or
avoid leaning over the battery and keep
the area around the top of the battery well
ventilated.
While charging, always heed the precautions:
• Before charging, disconnect and remove
the battery from the vehicle - charging the
battery with the cables connected may
damage the vehicle’s electrical system.
• Make sure the battery charger leads are
securely clamped to the battery terminals
before switching on the battery charger.
Do not move the leads once the charger is
switched on.
• When charging is finished, switch off the
battery charger before disconnecting the
leads from the battery terminals.
Note: Be aware that a battery will take longer to
charge in a cold environment.
After charging, leave the battery for one hour
before reconnecting to the vehicle - this will
allow time for explosive gases to disperse,
thereby minimising the risk of fire or explosion.
Disconnecting the battery
If the vehicle is already locked and alarmed,
you will first have to unlock and disarm it using
the remote control. See LOCKING AND
UNLOCKING (page 47).
Note: If the battery is flat and the vehicle is
locked and alarmed, you will first have to
unlock the left-hand front door using the
starter key.
Insert the starter key and turn it to position II.
228
Engage the Electric Parking Brake (EPB) or fit
wheel chocks. See CHANGING A ROAD WHEEL
(page 231).
Remove the starter key and wait two minutes
for the engine management system to power
down.
Open the bonnet. See OPENING AND CLOSING
THE BONNET (page 212).
Disconnect only the negative (-) terminal of the
battery.
Reconnecting the battery
Ensure that everything requiring power from
the battery - lights, audio, etc - is switched off.
Reconnect the battery lead.
Note: If the battery was disconnected while it
had an insufficient charge to disarm the alarm,
the alarm could sound on reconnecting.
Operating the remote control or inserting the
key into the starter switch will disarm the
alarm.
Insert the starter key and turn to position II.
Operate the Electric Parking Brake (EPB) to
extinguish the amber warning lamp.
Effects of battery disconnection
After reconnecting the battery, a number of the
vehicle systems will be reset automatically.
This may take a few minutes. Some systems
have to detect certain conditions while the
vehicle is being driven before full operability
returns. This in no way affects the safe
operation of the vehicle.
 R

Vehicle battery
Battery warning indicator Replacement
The red warning indicator in the Ensure that the battery is fitted the right way
instrument pack illuminates as a round (terminal posts towards the rear of the
bulb check when the starter switch vehicle) and that the clamping plate is secure.
is turned to position II and extinguishes once Tighten the clamping plate nuts until the
the engine is running. If it remains on, or clamping plate is free from movement, but do
illuminates whilst driving, a fault with the not over tighten.
battery charging system is indicated. Seek
Replacement batteries
qualified assistance urgently.
Only fit a replacement battery of the same type
CHANGING THE VEHICLE BATTERY and specification as the original - other
batteries could cause a fire hazard when
WARNINGS connected to the vehicle’s electrical system.
Always remove the starter key before
disconnecting the battery. Failure to do Petrol vehicles H7 75 amp/hr
this may cause a failure of the airbag SRS. Diesel vehicles H8 90 amp/hr
Do not reverse the polarity of the
battery - the electrical system may be Battery disposal
damaged if the battery leads are connected to Used batteries should be recycled.
the wrong terminals. However, batteries are hazardous -
you should seek advice about
CAUTIONS disposal from your local authority.
Keep the battery upright at all times -
damage will be caused if the battery is
tilted more than 45 degrees.
Do not run the engine with the battery
disconnected; or disconnect the battery
with the engine running.
Disconnect the negative (-) cable first and then
the positive (+) cable. When reconnecting,
connect the positive cable first and then the
negative cable. Do not allow the battery
terminals to make contact with metal parts of
the vehicle.
Removal
To release the battery from the vehicle, undo
the nuts securing the battery clamping plate
and remove the clamping plate.

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Wheels and tyres

GENERAL INFORMATION
Wheels and tyres

Tyre markings

3 4 5 6
2 7 8
1
9

15
10
14

13 11
12

E80640

1. P indicates that the tyre is for passenger
use.
2. The width of the tyre from sidewall edge to
sidewall edge in millimetres.
3. The aspect ratio, also known as the profile,
gives the sidewall height as a percentage
of the tread width. So, if the tread width is
205 mm, and the aspect ratio is 50, the
sidewall height will be 102 mm.
4. R indicates that the tyre is of Radial ply
construction.
5. The diameter of the wheel rim given in
inches.
6. The load index for the tyre. This index is
not always shown.
7. The speed rating denotes the maximum
speed at which the tyre should be used for
extended periods. †
8. Tyre manufacturing standard information,
which can be used for tyre recalls and
other checking processes. Most of this
information relates to the manufacturer,
place of manufacture etc. The last four
numbers are the date of manufacture. For
example, if the number was 3105, the tyre
was made in the 31st week of 2005.
9. M+S or M/S indicates that the tyre has
been designed with some capability for
mud and snow.

230
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Wheels and tyres

10. The number of plies in both the tread area, CHANGING A ROAD WHEEL
and the sidewall area, indicates how many
layers of rubber coated material make up Tool kit location
the structure of the tyre. Information is 5-seat vehicles
also provided on the type of materials
used.
11. Wear rate indicator. A tyre rated at 400 for
example, will last twice as long as a tyre
rated at 200.
12. The traction rating grades a tyres
performance when stopping on a wet road
surface. The higher the grade the better the
braking performance. The grades from
highest to lowest are, AA, A, B, and C.
E80452
13. The maximum load which can be carried
by the tyre. On 5-seat vehicles, the tool kit is located under
14. Heat resistance grading. The tyres a panel set in the loadspace floor.
resistance to heat is grade A, B, or C, with Note: Tool types and positions, may vary from
A indicating the greatest resistance to heat. the illustrations.
This grading is provided for a correctly
inflated tyre, which is being used within it's 7-seat vehicles
speed and loading limits.
15. The maximum inflation pressure for the
tyre. This pressure should not be used for
normal driving. See TECHNICAL
SPECIFICATIONS (page 268).
† Speed ratings

Rating Speed (mph)

Q 99
R 106
S 112
E80453
T 118
U 124 On 7-seat vehicles, the tool kit is stowed
behind an access cover in the loadspace area.
H 130
Note: Take careful note of the stowage position
V 149
of each of the tools as it is important to return
W 168 them to their correct position after use.
Y 186

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Wheels and tyres

Tool kit content Care of the jack
Examine the jack occasionally, clean and
1 grease the moving parts, particularly the screw
2 thread, to prevent corrosion.
To avoid contamination, the jack should always
3 4 be stowed in its fully closed position.
Wheel changing safety
6 WARNINGS
5
If possible, choose a safe place to stop
7
away from the main road.
8 Ensure that the jack will be positioned
on firm, level ground; never on soft
ground, or over metal gratings or manhole
9 covers. Do not place additional material
between the jack and the ground; this may
jeopardise the safety of the jacking operation.
3 Never raise the vehicle with passengers
4 4
10 inside, or with a caravan or trailer
connected!

Note: Switch on the hazard warning lights to

E80454 alert other road users.
1. Screwdriver handle Before changing a wheel, ensure the following:
2. Screwdriver blade • Front wheels are in the straight-ahead
position.
3. Jack screw rotating hook
• Electric parking brake is applied.
4. Extension piece
• Select P (Park) on an automatic
5. Wheel nut brace transmission vehicle or any gear on a
6. Wheel chocks manual transmission vehicle.
7. Wheel change jack (air suspension) • Turn off the starter switch and remove the
8. Locking wheel nut adapter key.
• Engage the steering lock.
9. Jack adapter (coil suspension)
10. Wheel change jack (coil suspension)

232
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Wheels and tyres

Spare wheel Spare wheel access - 7-seat vehicle
WARNING
The wheels are extremely heavy. Take
care when manoeuvring the spare
wheel.
Always remove the spare wheel before jacking
up the vehicle.
Spare wheel access - 5-seat vehicle

E80457

Note: Before removing the spare wheel, make a

note of the position that it is stowed in. The
wheel which is to be removed from the vehicle
must be correctly stowed in its place.

E80456

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Wheels and tyres

Lowering the spare wheel Note: 7-seat vehicles: The wheel-hoist winch
nut is close to the back of the rear seats. Turn
the wheel nut brace as far as possible
counterclockwise and then rotate the handle
over the top of the nut and continue to turn it.
Releasing the wheel

E80458

E80467

1. Open the spare wheel access hatch in the E80459

loadspace area.
1. Hold the cable and tilt the lifting lug until it
• 5-seat vehicles, remove the jack from
can be lifted through the hole in the wheel,
the tool tray.
as shown in the illustration.
2. Lift the cap covering the spare wheel-hoist
winch nut.
3. Fit the wheel nut brace to the wheel-hoist
winch nut and rotate counterclockwise to
lower the spare wheel. The mechanism has
been designed for use with the wheel nut
brace. Do not use power tools.
4. Continue to turn the wheel-hoist winch nut
until the wheel is on the ground and the
cable is slack. Do not attempt to turn the
winch nut beyond the physical stop.

234

Wheels and tyres
Using wheel chocks
WARNING
As an additional safety precaution, it is
necessary to chock the road wheels in
two places before raising the vehicle.
The wheel chocks are stowed in the tool kit.
E80455
1. If possible, position the vehicle on level
ground, chocking both sides of the wheel
diagonally opposite the one to be removed.
Note: If jacking the vehicle on a slope is
unavoidable, place the chocks on the downhill
side of the two opposite wheels.
235
R
Raising the vehicle (Air suspension)
WARNINGS
Always remove the spare wheel before
jacking up the vehicle.
Never work beneath the vehicle with the
jack as the only means of support.
Always use the vehicle support stands before
putting any portion of your body beneath the
vehicle.
The jack is designed for wheel changing
only.
Always place the jack on firm, level
ground.
Always position the jack from the side
of the vehicle, in line with the
appropriate jacking point.
Always raise the jack so that the pin in
the head of the jack engages with a hole
in the chassis rail at the points shown in the
illustrations.
Always use the complete, two-piece,
jack lever throughout to minimise any
chance of accidental damage or injury.
Only jack the vehicle using the jacking
points described, or damage to the
vehicle could occur.
Note: Before positioning the jack under the
vehicle, ensure that the air suspension is set to
off-road height.
Note: Your vehicle is fitted with a tilt sensor
which activates the alarm if the vehicle is tilted
fore and aft, or side to side, after it has been
locked. If you wish to have the doors locked
while jacking up the vehicle, lock the doors by
pressing the lock button on the remote control
twice within three seconds.
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Wheels and tyres

Jacking points

E80460

236

Wheels and tyres
Operating the jack
E80462
1. Attach the jack cranking lever to the jack.
Fit the wheel nut brace onto the end of the
cranking lever.
Positioning the jack
1. Before raising the vehicle, use the wheel
nut brace to slacken the wheel nuts half a
turn counterclockwise.
2. Position the jack beneath the jacking point,
ensuring that the pin on the jack head
aligns with the hole in the chassis.
237
R
3. Turn the jack lever clockwise to raise the
jack cradle until it engages with the jacking
point. Ensure that the base of the jack is in
full contact with the road surface.
Raising the vehicle (Coil suspension)
WARNINGS
Always remove the spare wheel before
jacking up the vehicle.
Never work beneath the vehicle with the
jack as the only means of support.
Always use vehicle support stands before
putting any portion of your body beneath the
vehicle.
The jack is designed for wheel changing
only.
Do not attempt to raise the vehicle
using any position other than the
jacking points illustrated.
Due to the nature of coil suspension
systems, it is not possible to raise the
wheel clear of the road surface by jacking
under the chassis.
Always place the jack on firm, level
ground.
Always position the jack from the side
of the vehicle, in line with the
appropriate jacking point.
Always raise the jack so that the saddle
of the jack head locates securely onto
the jacking point on the suspension arm.
Note: Your vehicle is fitted with a tilt sensor
which activates the alarm if the vehicle is tilted
fore and aft, or side to side, after it has been
locked. If you wish to have the doors locked
while jacking up the vehicle, lock the doors by
pressing the lock button on the remote control
twice within three seconds.
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Wheels and tyres

Jacking points

E80463

238
 R

Wheels and tyres

Operating the jack Positioning the jack

E80464

1. Attach the jack cranking lever to the jack

using the adapter. Fit the wheel nut brace
onto the end of the cranking lever.
E80465
1. Before raising the vehicle, use the wheel
nut brace to slacken the wheel nuts half a
turn counterclockwise.
2. Position the jack beneath the relevant
suspension arm.
3. Turn the jack lever clockwise to raise the
jack cradle until it engages with the jacking
point. Ensure that the base of the jack is in
full contact with the road surface.

239
L
Wheels and tyres
Changing a wheel
WARNING
When fitting a wheel, ensure that the
mating faces of the hub and wheel are
clean and free from rust or anti-seize
compound - any accumulation of dirt or rust
could cause the wheel nuts to become loose.
1. Raise the vehicle until the tyre is clear of
the ground.
2. Remove the wheel nuts and place to one
side to prevent them from being lost.
3. Remove the road wheel. Do not damage
the style surface of the wheel by placing it
face down on the road.
4. On alloy wheels, use an approved
anti-seize compound to treat the wheel
mounting bore. This will minimise any
tendency for adhesion between the wheel
and the bore.
• Ensure that no compound comes into
contact with the brake components or
the flat mounting surfaces of the wheel.
• If, due to an emergency situation, this
treatment is not practicable fit the spare
wheel. Remove and treat the wheel at the
earliest opportunity.
5. Fit the spare wheel and lightly tighten the
wheel nuts, ensuring they are firmly
seated. Do not fully tighten whilst the tyre
is clear of the ground. Ensure that
directional tyres are fitted correctly.
6. Ensure that the space under and around
the vehicle is free from obstructions then
lower the vehicle and remove the jack and
wheel chocks.
240
7. Fully tighten the wheel nuts in an
alternating pattern until all are tightened.
• Do not overtighten by using foot
pressure or extension bars on the wheel
nut brace.
• Wheel nuts should be tightened to a
torque of 140 Nm ± 10 Nm.
8. Using a suitable blunt tool, apply light
pressure to the rear of the displaced wheel
centre cap and remove.
9. Using hand pressure only, fit the centre
cap into the newly fitted wheel.
10. Finally, check the tyre pressure at the
earliest opportunity.
Note: During jacking, the air suspension
system may enter an automatic freeze state.
See AIR SUSPENSION MESSAGES (page 184).
Temporary spare wheel
WARNINGS
Drive cautiously; the temporary spare
wheel tyre is smaller in size and higher
in pressure than a regular tyre. It will cause a
harsher ride and may have less traction on
some road surfaces. If driving off-road on a
temporary spare wheel, drive with extra
caution.
The temporary spare wheel is for
temporary use only. It must be replaced
by a normal-sized wheel and tyre as soon as
possible.
Only one temporary spare wheel is to
be used on the vehicle at any one time.
Do not drive at a speed exceeding 80
km/h (50 mph).
The tyre pressure in the temporary
spare wheel/tyre should be 420 kPa
(4.2 bar/60 lbf/in²).
 R

Wheels and tyres

WARNINGS Using the wheel nut brace, unscrew the wheel

nut and adapter.
The temporary spare wheel has a
shorter life than a regular tyre. Replace Be sure to return the locking wheel nut adapter
the tyre with one of the same type and to the correct storage position.
specification. Stowing the changed wheel
The use of snow chains is not permitted
on a temporary spare wheel. WARNING
After wheel changing, always secure Do not stow the wheel while the vehicle
tools, chocks, jack and replaced wheel is still raised on the jack.
in their correct storage positions. Such objects
if not properly stowed can become flying
missiles in a crash or roll-over, potentially
causing injury or death.
Locking wheel nuts
Vehicles may be equipped with a locking wheel
nut on each wheel. These can only be removed
using the special adapter provided in the tool
kit.
Note: A code number is stamped on the
underside of the adapter. Ensure the number is
recorded on the Security Information card
supplied with the literature pack. Quote this
number if a replacement is required. Do not
keep the Security Information card in the
vehicle.

E80459

1. Place the wheel under the rear of the

vehicle with its style surface uppermost.
2. Place the lifting lug through the wheel
aperture and locate it in position.
3. Winch up the wheel using the wheel-hoist
mechanism.
Do not use power tools on the wheel-hoist
E80466
winch.
Insert the adapter firmly onto the locking wheel
nut.

241
L
Wheels and tyres
4. Continue to wind up until the mechanism
clutches out. This is confirmed by a clear
physical feedback from the wheel nut
brace and an audible noise.
5. Check that the wheel has returned to the
same position as the spare wheel as
previously noted. If in any doubt, unwind
the winch slightly and repeat the previous
step.
The wheel must be securely retained in its
correct position by the winch mechanism
or it could become loose.
6. Replace the locking cap over the
wheel-hoist nut. As the underside of this
cap is exposed to the same conditions as
the underside of the vehicle, ensure that it
is firmly in place.
Note: If, for any reason, the spare wheel is not
to be fitted back in its hoist, the wheel hoist
should be rewound as follows.
Position the lifting lug level on the cable and
wind up the wheel hoist mechanism until it
clutches out.
TYRE CARE
WARNINGS
Defective tyres are dangerous. Do not
drive if any tyre is damaged, is
excessively worn, or is inflated to an incorrect
pressure.
If your vehicle loses traction, avoid
spinning the tyre. The forces created by
rapidly spinning a tyre can cause damage to,
and failure of, the tyre structure.
Never exceed the 50 km/h (30 mph) point
indicated on the speedometer.
Do not allow anyone to stand near to, or
directly behind, a tyre that might spin.
242
CAUTION
Avoid contaminating the tyres with
vehicle fluids as they may damage the
tyre.
Always drive with consideration for the
condition of the tyres, and regularly inspect the
tread and side walls for any sign of distortion
(bulges), cuts or wear.
The way you drive has a great influence on your
safety and on the life of your tyres. Cultivate
good habits for your own benefit:
• Observe posted speed limits.
• Avoid fast starts, stops and turns.
• Avoid potholes and objects in the road.
• Do not run over kerbs or hit the tyre
against the kerb when parking.
Tyre pressures
WARNINGS
If the vehicle has been parked in strong
sunlight or used in high ambient
temperatures, Do not reduce tyre pressures;
instead, move the vehicle into the shade and
allow the tyres to cool before checking.
Under-inflation causes excessive
flexing and uneven wear to the tyre.
This can lead to sudden tyre failure.
Over-inflation causes a harsh ride,
uneven tyre wear and poor handling.
A hot tyre at or below the
recommended cold inflation pressure,
is dangerously under-inflated.
Correctly inflated tyres will ensure that you
enjoy the best combination of tyre life, ride
comfort, fuel economy and road handling.
 R

Wheels and tyres

Under-inflated tyres wear more rapidly, can
seriously affect the vehicle's road handling
characteristics and fuel consumption, as well
as increasing the risk of tyre failure.
Over-inflated tyres give a harsher ride, wear
unevenly and are more prone to damage.
Tyre pressures should be checked at least once
a week with normal road use, but should be
checked daily if the vehicle is used off-road.
Check the pressures (including the spare
wheel) when the tyres are cold - be aware that
Checking tyre pressures
WARNING
Tyre pressures should be checked
regularly using an accurate pressure
gauge when cold. Failure to properly maintain
your pressures could increase the risk of tyre
failure, with consequential loss of vehicle
control and personal injury.

DISCOVERY
it only takes 1.5 km (1 mile) of driving to warm
MAX. XXX X.X XX XXX X.X XX
up the tyres sufficiently to affect the tyre XXX/XXRXX
XXX/XXRXX (kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
XXX/XXRXX
pressures.

L7MTA
XXX/XXRXX XXX X.X XX XXX X.X XX
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
MAX.
Air pressure naturally increases in warm tyres; TXXX/XXRXX XXX X.X XX XXX X.X XX
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)

RTC500XXX
if it is necessary to check the tyres when they XXX X.X XX XXX X.X XX
(kpa) (BAR) (PSI) (kpa) (BAR) (PSI)
are warm (after the vehicle has been driven for
a while), you should expect the pressures to
have increased by up to 30 - 40 kPa (0.3- 0.4
bar) (4 - 6 lbf/in²). In this circumstance, Do not A B
let air out of the tyres in order to match the
recommended cold tyre pressures.

E80376

A Left-hand drive vehicle

B Right-hand drive vehicle
The correct tyre pressures are shown on the
label attached to the drivers door sill.

243
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Wheels and tyres

The following procedure should be used to Tyre wear
check and adjust tyre pressures:
CAUTION
1. Remove the valve cap.
Tyre condition should be checked after
2. Firmly attach a tyre pressure gauge/inflator
off-road use, check to make sure there
to the valve.
are no cuts, bulges, or exposure of the
3. Read the tyre pressure from the gauge. If ply/cord structure.
required add air to the tyre.
4. If air is added to the tyre, remove the gauge
from the valve and re-attach it before
checking that the pressure is correct.
Failure to remove and re-attach the gauge
to the valve could cause the gauge to show E80377
an incorrect reading.
Tyres fitted as original equipment have wear
5. If too much air is added, remove the gauge
indicators moulded into the tread pattern.
from the valve and allow air out of the tyre
When the tread has been worn down to 1.6 mm
by pressing the centre of the valve.
(1/16 in.) the indicators start appearing at the
Reconnect the gauge to the valve and
surface of the tread pattern, producing the
check that the air pressure is correct. If the
effect of a continuous band of rubber across
pressure is still not correct, repeat this
the width of the tyre.
process and re-check.
A tyre must be replaced as soon as an indicator
6. Refit the valve cap.
band becomes visible or the tread depth
Note: It is an offence in certain countries to reaches the minimum permitted by legislation.
drive a vehicle with tyres that are not properly
Note: If tyre wear is uneven (on one side of the
inflated in accordance with the vehicle's proper
tyre only) or becomes abnormally excessive,
use.
the wheel alignment should be checked by your
Valves Land Rover Dealer/Authorised Repairer.
Keep the valve caps screwed down firmly - they Tread depth must be checked regularly (at
prevent dirt from entering the valve. Check the every maintenance service, or more
valve for leaks (listen for a tell-tale hissing) frequently). Always replace a tyre before the
when you check the tyre pressure. tread reaches a remaining depth of 1.6 mm
(1/16 in.). Do not drive with tyres worn to this
limit; the safety of the vehicle and occupants
will be adversely affected.

244

Wheels and tyres
Age degradation
Tyres degrade over time due to the effects of
ultraviolet light, extreme temperatures, high
loads, and environmental conditions. It is
recommended that tyres are replaced every six
years, or sooner id required.
Land Rover recommends that even if unused,
the spare tyre be replaced at the same time as
the four road tyres.
Punctured tyres
WARNING
Do not drive the vehicle with a
punctured tyre. Even if the punctured
tyre has not deflated, it is unsafe to use as the
tyre may deflate suddenly at any time.
Your vehicle is fitted with tubeless tyres, which
may not leak if penetrated by a sharp object,
provided the object remains in the tyre.
If, however, you feel a sudden vibration or ride
disturbance while driving, or you suspect your
tyre or vehicle has been damaged, immediately
reduce your speed. Drive slowly, while
avoiding heavy braking or sharp steering
inputs, to the closest safe area out of traffic.
This may further damage the flat tyre, but your
safety is more important.
Stop and inspect the tyres for damage. If a tyre
is under inflated or damaged, remove the tyre
and wheel and replace it with the spare wheel.
If you cannot detect a cause, have the vehicle
recovered to a tyre repair centre, or a Land
Rover Dealer/Authorised Repairer to have the
vehicle inspected.
A puncture will eventually cause the tyre to lose
pressure, which is why frequent checking of
tyre pressures is important. Punctured or
damaged tyres must be permanently repaired
or replaced as soon as possible.
245
R
Replacement tyres
WARNINGS
Always use the same make and type of
radial-ply tyres front and rear. Do not
use cross-ply tyres, or interchange tyres from
front to rear.
Your vehicle is fitted with road wheels
that will not accept inner tubes. Do not
fit a tubed tyre.
Do not replace wheels with any type
other than genuine Land Rover parts.
Wheels and tyres are designed for both
off-road and on-road use and have a very
important influence on vehicle handling.
Alternative wheels which do not meet original
equipment specifications should not be fitted.
When using tyres other than those
recommended by Land Rover, do not
exceed the speed rating recommended by the
manufacturer.
Wheel rims and tyres are matched to suit the
handling characteristics of the vehicle. For
safety, always check that replacement tyres
comply with the original specification and that
the load and speed ratings shown on the side
wall are the same as that of the original
equipment. Contact your Land Rover
Dealer/Authorised Repairer for further
information or assistance.
Tyres of the correct size and type, but of
different make have widely varying
characteristics. It is therefore recommended
that only Land Rover approved tyres are fitted
to all wheels.
Ideally, tyres should be replaced as sets of
four, but if this is not possible, replace the tyres
as axle sets.
Always have the wheels re-balanced after
replacing tyres.
L

Wheels and tyres

Original wheel and tyre combinations High performance wheel and tyre
combinations
Wheel size Tyre size Load index
CAUTIONS
7J x 17 235/70 R17 H 111
This vehicle may be fitted with a high
8J x 18 255/60 R18 H or V 112
performance wheel and low profile tyre
8J x 19 255/55 R19 H or V 111 combination designed to give enhanced dry
road performance with consideration for
Note: Consult your Land Rover Dealer/ aquaplaning resistance.
Authorised Repairer before fitting any Low profile, high speed rated tyres have
accessory wheels or tyres. a softer tread compound. If driven
Accessory wheels and tyres aggressively they may suffer increased tread
wear and a shorter life than can be expected
from other tyre types.
This wheel and tyre combination is
susceptible to damage if driven off road.
This combination has less performance in
snow or ice conditions than M and S tyres
(tires). High performance tyres must be
replaced with winter tyres when weather
1 2 conditions dictate.

3 Flat spots
If the vehicle is stationary for a long period
when the ambient temperature is high, the
E82330
tyres may form flat spots. When the vehicle is
driven these flat spots will cause a vibration
1. Front tyre pressure. which will steadily disappear as the tyres
2. Rear tyre pressure. regain their original shape.
3. Accessory wheel and tyre specification.

E80322

In order to minimise flat spotting, the tyre

pressures can be increased.
Tyre pressures should be increased by 0.14 bar
(14 kPa, 2 lbf/in²) for each 10°C (20°F)
temperature increase.

246

Wheels and tyres
Long term storage
Flat spotting can be minimised during long
term storage by increasing the tyre pressures
to the maximum indicated on the tyre sidewall.
Note: The tyre pressures should be reduced to
the correct pressure before the vehicle is
driven.
Directional tyres
E80378
Directional tyres must be fitted so that they
rotate in the direction that the arrow is pointing
when the vehicle is moving forward.
247
R
Pressure compensation for ambient
temperature changes
E80321
If the ambient temperature drops, the tyre
pressures will decrease, which may cause
under inflation. This should be taken into
consideration when travelling to, or through,
areas of lower temperature.
Under inflation causes the tyre side wall height
to reduce, which in turn results in uneven tyre
wear, and a risk of tyre failure.
Tyre pressures may be adjusted before setting
off on a journey to, or through, areas of low
temperature. Alternatively, the tyre pressures
can be adjusted when low temperature areas
are reached.
Note: If the tyre pressures are to be adjusted in
the lower temperature area, the vehicle should
be left standing for at least one hour prior to
adjustment.
Tyre pressures should be increased by 0.14 bar
(14 kPa, 2 lbf/in²) for each 10°C (20°F)
temperature decrease.
L
Wheels and tyres
USING SNOW CHAINS
WARNINGS
Do not fit unapproved snow chains -
this could damage tyres, wheels,
suspension and brake components and could
result in damage to the bodywork of the
vehicle.
Snow chains are designed for use on
hard-surface roads in extreme snow
conditions only, and are not recommended for
off-road use.
Snow chains must not be fitted to a
temporary spare wheel.
Never exceed 50 km/h (30 mph).
If it is necessary to fit snow chains to your
vehicle, always observe the following:
• Snow chains can only be fitted to the front
wheels of vehicles equipped with 17, 18 or
19 inch wheels.
• Snow chains must not be fitted to the rear
wheels of any vehicle.
• Only Land Rover approved chains should
be used. These have been tested to ensure
that they do not cause damage top the
vehicle. Contact your Land Rover
Dealer/Authorised Repairer for
information.
• Always adhere to the snow chain fitting
and retensioning instructions and the
speed limitations recommended for
varying road conditions.
• Only fit snow chains in pairs.
• Avoid tyre damage by removing the chains
as soon as the road is free from snow.
• In some driving conditions, it may be
beneficial to deactivate Dynamic Stability
Control (DSC) in order to maximise
traction.
248
TYRE PRESSURE MONITORING
SYSTEM
WARNINGS
The Tyre Pressure Monitoring (TPM)
system is not a substitute for manually
checking tyre pressures. The TPM system only
provides a low tyre pressure warning and does
not re-inflate the tyres.
The TPM system cannot register
damage to a tyre. Regularly check the
condition of your tyres, especially if the vehicle
is driven off-road.
CAUTION
When inflating tyres, care should be
taken to avoid bending or damaging the
TPM system valves. Always ensure correct
alignment of the inflation head to the valve
stem.
Note: Non-approved accessories may interfere
with the system. If this occurs, TYRE
PRESSURE MONITORING SYSTEM FAULT will
be displayed in the message centre.
Note: Different types of tyre may affect the
performance of the TPM system. Always
replace tyres in accordance with
recommendations.
Your vehicle may be equipped with a TPM
system which monitors pressure in each tyre,
including the full-size spare tyre. Temporary
spare tyres are not fitted with sensors and are
consequently not monitored.
Note: The TPM system only provides a low tyre
pressure warning and does not re-inflate the
tyres.

Wheels and tyres
1 inflate them to the recommended pressure. If
2 vehicle’s handling and stopping ability.
E82445
Wheels fitted with a TPM system can be
visually identified by the external metal lock nut
and valve 1. All Land Rover non-TPM system
wheels have a rubber valve fitted 2.
TPM system operation
The TPM system monitors the pressure of the
tyres via sensors located in each wheel and a
receiver located within the vehicle.
Communication between sensor and receiver
is via Radio Frequency (RF) signals.
The tyre pressure warning
comprises an amber warning
indicator (telltale) within the
instrument pack and an associated message
within the message centre.
Each tyre, including the spare (if provided),
should be checked regularly, when cold, and
inflated to the recommended pressure. When
the low tyre pressure warning is indicated, one
or more of your tyres is significantly
under-inflated.
249
R
If the telltale light illuminates, you should stop
and check your tyres as soon as possible and
low pressure warnings occur frequently, the
cause must be determined and rectified.
Driving on a significantly under-inflated tyre
causes the tyre to overheat and can lead to tyre
failure. Under-inflation also reduces fuel
efficiency and tyre tread life, and may affect the
The TPM system also monitors the full size
spare tyre pressure. If the pressure for the
spare tyre is incorrect, the message CHECK
SPARE TYRE PRESSURE will be displayed,
accompanied by illumination of the warning
telltale.
When driving through variable climatic
conditions, the TPM system warnings may be
intermittent.
TPM system malfunction
Your vehicle will also indicate a TPM system
malfunction by initial flashing and subsequent
continuous illumination of the warning telltale.
A text message will accompany the system
malfunction and will display TYRE PRESSURE
MONITORING SYSTEM FAULT. The TPM
system fault sequence will be activated at every
ignition cycle until the fault is rectified. When a
malfunction occurs, the system may not be
able to detect or signal low tyre pressure as
intended.
TPM system malfunctions may occur for a
variety of reasons which may include; other
radio frequency systems causing interference
or the installation of incompatible replacement
tyres on the vehicle.
Spare tyre pressure
The full size spare tyre should be inflated to the
highest pressure for the specified tyre size,
when not in use on the vehicle.
L
Wheels and tyres
Full size spare wheel and tyre change
Should it be necessary to change a wheel and
tyre with the spare then the system will
automatically recognise the change in wheel
positions. The vehicle needs to be stationary
for 15 minutes during the wheel and tyre
change, before the system is ready to detect
the change in positions. After driving above
25 km/h (18 mph) any deflation warning will
clear typically within 5 minutes.
Temporary spare wheel and tyre change
If the temporary spare wheel is fitted, the
system will automatically recognise the change
in wheel positions. After approximately ten
minutes of driving above 18 mph (25 km/h),
the message TYRE PRESSURE FRONT (REAR)
RIGHT (LEFT) NOT MONITORED will be
displayed, accompanied by illumination of the
warning telltale.
The warning telltale will initially flash and will
subsequently revert to continuous illumination.
Extended use of the temporary spare wheel,
will produce an additional text message TYRE
PRESSURE MONITORING SYSTEM FAULT.
This TPM system display sequence will be
activated at every ignition cycle until the
temporary spare wheel is replaced by a fully
operational full size wheel and tyre assembly.
Always replace the temporary spare wheel
before having TPM system faults investigated.
The fault may well be rectified with the fitment
of a fully operational full size running tyre in
lieu of the temporary spare wheel assembly.
Vehicle loading
It is possible to select different pressure levels
that correspond to the placard pressures for a
lightly laden and a heavily laden vehicle. The
indicator on the TPM system button will
display the system status.
250
If the indicator is illuminated, the system is in
lightly laden mode and if the indicator is not
illuminated then the system is in heavily laden
mode. If the vehicle is to be used heavily laden
or for towing, the tyre pressures must be
increased to cope with the additional load, and
the tyre pressure monitoring system must be
set into heavily laden mode.
E82387
This can be accomplished by pressing the TPM
system button on the facia for at least four
seconds with the ignition in position ll and the
engine not running.
To indicate that the system has switched to
heavily laden mode, the indicator in the switch
will extinguish and the message TYRE
PRESSURE MONITORING SET FOR HEAVY
LOAD will be displayed on the message centre.
When the vehicle load is returned to normal
and the tyre pressures are reset, the system
should be put back into lightly laden mode by
pressing the button as before. The indicator in
the switch will illuminate and the message
TYRE PRESSURE MONITORING SET FOR
LIGHT LOAD will be displayed on the message
centre. This change to and from heavily laden
mode can be operated only when the ignition is
in position ll and the engine is not running.
 R

Wheels and tyres

If a tyre needs to be changed Replacement sensor fitment procedure
Sensor replacement should be carried out by a
CAUTION
Land Rover Dealer/Authorised Repairer.
The valve stem seal, washer, nut, valve
A replacement sensor must be fitted to a
core and cap should be replaced at every
running wheel in order to be recognised by the
tyre change.
TPM system. Recognition only occurs when
The valve stem seal, washer and nut must be the vehicle is driven above 25 km/h (18 mph)
replaced if the valve retention nut is loosened. for approximately ten minutes.
Sensor units and nuts must be refitted using Should the TPM system warning for any wheel
correct torque figures and associated profile. not clear, even after ensuring correct inflation
Sensors can be removed from the wheel by and driving for more than ten minutes above
unscrewing the valve retention nut. 25 km/h (18 mph), consult your Land Rover
Damage to the vehicle may result if these Dealer/Authorised Repairer.
precautions are not taken.
It is recommended that you should always
have your tyres serviced by a dealer or qualified
technician. If a TPM system is fitted, each
wheel and tyre assembly, with the exception of
a temporary spare, is equipped with a tyre
pressure sensor connected to the tyre valve
stem.
In order to avoid damage to the sensor, the
tyres must be removed and refitted to the road
wheel in a specified manner. Care must be
taken to avoid contact between the bead of the
tyre and the sensor during removal and
refitting of the tyre, otherwise the sensor may
become damaged and/or inoperable.

251
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Wheels and tyres

Messages
The following table lists the messages relating
to tyre pressure monitoring that could appear
in the message centre. Market criteria mean
that some messages will not apply to your
vehicle and will therefore not appear.
Message Meaning What to do?
CHECK ALL Advisory message, pressure in Check tyre pressures.
TYRE PRESSURES a running tyre decreased to
first warning threshold.
CHECK Pressure in spare tyre Check pressure of spare tyre.
SPARE TYRE decreased to warning
PRESSURE threshold.
TYRE PRESSURE Possible loss of RF Seek assistance immediately.
NOT MONITORED transmission or defective
sensor battery.
TYRE PRESSURE Pressure in a running tyre too Adjust to correct pressure as
TOO HIGH high, threshold reached. soon as possible.
TYRE PRESSURE Pressure in a running tyre Adjust to correct pressure as
VERY LOW decreased to warning soon as possible.
threshold.
TYRE PRESSURE TPM system fault has Seek qualified assistance
MONITORING occurred. immediately.
SYSTEM FAULT
TYRE PRESSURES Adjust to correct pressure as
TOO HIGH soon as possible.
TYRE PRESSURES Adjust to correct pressure as
VERY LOW soon as possible.
TYRE PRESSURE Indicates the system is set to Ensure setting is correct for the
MONITORING SET FOR HEAVY monitor the tyre pressures for current tyre pressures and
LOAD a heavily laden condition. loading conditions.
TYRE PRESSURE Indicates the system is set to Ensure setting is correct for the
MONITORING SET FOR LIGHT monitor the tyre pressures for current tyre pressures and
LOAD normally laden conditions. loading conditions.

252
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Wheels and tyres

TYRE GLOSSARY Production options weight
The combined weight of options installed
Terms used which weigh in excess of 1.4 kg (3 lb) more
lbf/in² than the standard items that they replaced, and
Pounds per square inch, an imperial unit of are not already considered in kerb or accessory
measure for pressure. weights. Items such as heavy duty brakes, high
capacity battery, special trim etc.
kPa
Vehicle capacity weight
Kilo Pascal, a metric unit of measure for
pressure. The number of seats multiplied by 68 kg
(150 lb) plus the rated amount of load/luggage.
Cold tyre pressure
Maximum loaded vehicle weight
The air pressure in a tyre which has been
standing in excess of three hours, or driven for The sum of kerb weight, accessory weight,
less than one mile. vehicle capacity weight, and production
options weight.
Maximum inflation pressure
Rim
The maximum pressure to which the tyre
should be inflated. This pressure is given on The metal support for a tyre, or tyre and tube,
the tyre side wall in lbf/in² and kPa. upon which the tyre beads are seated.
Note: This pressure is the maximum allowed Bead
by the tyre manufacturer. It is not the pressure The inner edge of a tyre that is shaped to fit to
recommended for use. See TECHNICAL the rim and form an air tight seal. The bead is
SPECIFICATIONS (page 268). constructed of steel wires which are wrapped,
or reinforced, by the ply cords.
Kerb weight
The weight of a standard vehicle, including a
full tank of fuel, any optional equipment fitted,
and with the correct coolant and oil levels.
Gross vehicle weight
The maximum permissible weight of a vehicle
with driver, passengers, load, luggage,
equipment, and tow ball load.
Accessory weight
The combined weight (in excess of those items
replaced) of items available as factory installed
equipment.

253
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Fuses
FUSE BOX LOCATIONS Engine compartment fuse box
Fuses

E80810
2
Remove the plastic cover by pressing the tabs.
The fuse values and locations and the circuits
protected are shown on the plastic cover.

E82383

1. Engine compartment fuse box.

2. Passenger compartment fuse box.
3. Tow hitch fuse box.
Note: The engine and passenger compartment
fuse boxes are always fitted on the passenger
side of the vehicle.

254

Fuses
Passenger compartment fuse box
E80809
The passenger compartment fuse box is fitted
behind the glovebox. To access the fuses, open
the glovebox and then pinch the top of the
support stays (arrowed), and lower the
glovebox into the footwell.
A label on the rear of the glovebox shows the
circuits protected, the fuse values and their
locations.
255
R
Tow hitch fuse box
E80791
The supplementary fuse box that protects the
tow hitch circuits, is located behind the
left-hand panel in the luggage compartment.
CHANGING A FUSE
WARNINGS
Fit Land Rover approved replacement
fuses of the same rating and type.
Incorrect fuse ratings may overload a system
and cause a fire or malfunction. No attempt
should be made to repair a fuse that has
blown.
Always rectify the cause of the failure
before replacing a fuse. Seek qualified
assistance if necessary.
Fuses are simple circuit breaker devices which
protect electrical equipment against the effects
of excess current.
A blown fuse is indicated when the electrical
equipment it protects becomes inoperative.
Always turn the starter switch to position 0 and
switch off the affected electrical circuit before
removing a fuse.
L

Fuses

E81022

The fuse removal tweezers are located in the

passenger compartment fuse box. Place the
tweezers onto the head of the suspect fuse (as
shown), squeeze the middle (arrowed) and pull
to remove. A break in the wire inside the fuse
indicates that the fuse has blown.
Note: Owners are advised against removing or
replacing the relays (identified as R1-R19 on
the relays) and fusible links (identified as
FL1-FL20 on the fusible links) in the engine
compartment fuse box. Failure of any of these
items should be investigated by a qualified
technician.

256
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Fuses
FUSE SPECIFICATION CHART
Engine compartment fuse box

F1 XX XX F2

F3 XX XX F4

F5 XX XX F6

F7 XX XX F8

F9 XX XX F10

F11 XX XX F12

F13 XX XX F14

F15 XX XX F16

F17 XX XX F18

F19 XX F20

F21 XX F22

F23 XX XX F24

F25 XX XX F26

F27 XX XX F28

F29 XX XX F30
E81432

Fuse Ampere rating Colour Circuits protected

1 25 White Fuel pump
2 - - -
3 5 Tan Air suspension ECU
4 25 White Diesel EMS (ECM and fuel pump relay control)
5 10 Tan Petrol EMS (purge valve, EGR, inlet manifold tune valve),
E-box fan
6 15 Blue Petrol EMS (ignition coils)
6 15 Blue Diesel EMS (sensors and glow plug relay control)
7 25 White Front seat heater
8 25 White Rear seat heater
9 - - -
10 15 Blue Petrol EMS (throttle motor, MAF), cooling fan
10 15 Blue Diesel - cooling fan

257
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Fuses

Fuse Ampere rating Colour Circuits protected

11 15 Blue Petrol EMS (rear oxygen sensors)
12 10 Red Heated washer jets
13 10 Red Petrol EMS (ECM, VVTs and fuel pump relay control)
13 10 Red Diesel EMS (PCV, VCV)
14 20 Yellow Petrol EMS (front oxygen sensors)
15 30 Green Heated front screen
16 10 Red Heated door mirrors
17 15 Blue Petrol EMS (injectors)
17 15 Blue Diesel EMS (MAF, EGR), E-Box fan
18 30 Green Heated front screen
19 - - -
20 5 Tan Alternator
21 - - -
22 30 Green Rear blower
23 25 White Dynamic Stability Control system
24 20 Yellow Petrol - brake boost pump
25 10 Red Lighting switch
26 20 Yellow Air suspension ECU
27 5 Tan Engine Control Module (ECM)
28 20 Yellow Diesel - auxiliary heater
29 30 Green Front wipers
30 10 Red Auto transmission ECU

258
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Fuses
Passenger compartment fuse box

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

XX
XX

XX

XX

XX

XX

XX

XX
F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22

XX
XX

XX

XX

XX

XX

XX

XX

XX

XX

XX

XX
F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F34
XX

XX

XX

XX

XX

XX
XX

XX

XX

XX

XX
F35 F36 F37 F38 F39 F40 F41 F42 F43 F44 F45 F46 F47 F48
XX
XX

XX
XX

XX
XX

XX

XX

XX

XX
XX

XX

XX
F49 F50 F51 F52 F53 F54 F55

XX
XX

XX

XX

XX

XX
XX
F56 F57 F58 F59
XX

XX

XX

XX

F60 F61 F62 F63

XX

XX

XX
XX

F64 F65 F66

XX

XX

XX

F67 F68 F69

XX

XX

XX

XX XX
SPARES

XX XX

XX XX
E81433

Fuse Ampere rating Colour Circuits protected

1 10 Red Interior lamps - glovebox lamp, vanity mirror lamp, map
lamps, switchable roof lamps.
Electric seats (non memory)
2 10 Red Right-hand side lamps
3 - -
4 10 Red Left-hand side lamps
5 10 Red Reverse lamps
6 10 Red Trailer reverse lamp
7 25 White Driver’s window
8 30 Green Trailer pick-up (battery feed)

259
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Fuses

Fuse Ampere rating Colour Circuits protected

9 5 Tan Airbags
10 - - -
11 15 Blue Washer pump
12 15 Blue Horn
13 25 White Heated rear window
14 10 Red Trailer side lamp
15 15 Blue Brake lamps, Brake switch
16 10 Red Powerfold mirror
17 20 Yellow Rear right-hand window
18 5 Tan Rain sensor, ambient light sensor (auto lamps)
19 15 Blue Auxiliary power socket - 2nd row seats
20 15 Blue Sunroof
21 25 White Passenger window
22 10 Red Trailer pick-up (ignition feed)
23 - - -
24 5 Tan Transfer box - centre differential, Terrain Response
25 5 Tan Engine Control Module (ECM)
26 5 Tan Battery back-up sounder
27 10 Red Adaptive front lighting, Headlamp levelling
28 5 Tan Fuse box engine compartment - ignition
29 30 Green Passenger electric seat
30 - - -
31 20 Yellow Rear left-hand window
32 15 Blue Rear fog lamps
33 5 Tan Mirror adjust, Automatic transmission selector
34 15 Blue Auxiliary power socket - front seats
35 5 Tan Air suspension ECU
36 5 Tan Park Distance Control, Tyre Pressure Monitoring system
37 5 Tan Dynamic Stability Control
38 15 Blue Front fog lamps
39 5 Tan Instrument pack
40 5 Tan Key-in sense

260
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Fuses

Fuse Ampere rating Colour Circuits protected

41 5 Tan Electric Parking Brake (EPB)
42 30 Green Audio amplifier
43 10 Red Radio frequency receiver, Tyre Pressure Monitoring
system
44 5 Tan Automatic transmission selector
45 - - -
46 30 Green Drivers electric seat
47 15 Blue Auxiliary power socket - 3rd row seats
48 15 Blue Rear wiper
49 30 Green Central door locking
50 10 Red Electric fuel flap actuator
51 10 Red Climate control ECU
52 5 Tan Telephone, traffic message centre
53 15 Blue Multi-media module, audio unit, DVD player,
Video Display
54 5 Tan Electric seat - memory
55 15 Blue Cigar lighter
56 10 Red Adaptive front lighting (left-hand unit)
57 10 Red Rear seat entertainment module
58 10 Red Telephone, touch screen display, multi-media module, TV
tuner
59 10 Red Cubby box cooler
60 5 Tan Engine Control Module (ECM)
61 10 Red Adaptive front lighting (right-hand unit)
62 5 Tan Low beam, auto lamps
63 10 Red Diagnostic socket
64 5 Tan Automatic transmission ECU
65 - - -
66 5 Tan HDC switch, Brake switch, Steering angle sensor, DSC
switch
67 5 Tan Auto lamps
68 5 Tan Instrument pack
69 5 Tan Auto dimming interior mirror

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Fuses
Tow hitch fuse box

1
2
3
4
5
6
E81903

Fuse Ampere rating Colour Circuits protected

1 7.5 Brown Brake lamp
2 15 Blue Ignition feed
3 15 Blue Battery feed
4 7.5 Brown Rear fog lamps
5 5 Tan Right-hand tail lamp
6 5 Tan Number plate and left-hand tail lamp

262
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Vehicle recovery
TOWING POINTS Front towing point cover
Vehicle recovery

WARNINGS
The towing points at the front and rear
of the vehicle are designed for on-road
vehicle recovery purposes only and must not
be used to tow a trailer or caravan.
Use of the towing points for purposes
other than their designed intention
could result in damage or injury.
Front towing point
A front towing point, is set behind a removable
cover in the lower front bumper.
Before driving off-road, remove the cover as a
precaution against accidental loss.

E80776

1. Rotate each of the fasteners 90 degrees

counterclockwise with a coin (or
something similar).
2. Lower the top edge and then pull the cover
forward to remove it.
3. Offer up the cover and ensure that the two
lugs on the bottom edge engage with the
holes in the body panel.
4. Turn each fastener 90 degrees clockwise
to secure the cover.

263
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Vehicle recovery
Rear towing point
The towing point provided at the rear of the
vehicle can be used to tow your vehicle, or
another vehicle, in recovery situations.
Before driving off-road, remove the cover as a
precaution against accidental loss.
Rear towing point cover
4. Offer up the cover and ensure that the four
hooks on the top edge engage with the
holes in the body panel.
5. Turn each fastener 90 degrees clockwise
to secure the cover.
LASHING POINTS
CAUTION
If the vehicle electronics are operational,
the air suspension must be set to access
height before securing the vehicle to a trailer.
See ADJUSTING THE SUSPENSION
(page 180).
Note: The front and rear lashing points are for
lashing only and must not be used for towing.
Front lashing points

E80777

1. Rotate each of the fasteners 90 degrees E80779

counterclockwise with a coin (or
something similar) to release the lower
edge.
2. Rotate the cover to release the hooks at the
top.
3. Remove the cover.

264

Vehicle recovery
Rear lashing points
E80780
Two pairs of lashing points for insertion of
appropriate hooks are fixed to the underside of
the vehicle. Do not secure lashing hooks to any
other part of the vehicle.
TRANSPORTING THE VEHICLE
Recovery by trailer is the recommended
method. Most vehicle recovery specialists will
load the vehicle onto a trailer, or have a
combined wheel lift and towing dolly
arrangement to lift it clear of the ground.
TOWING THE VEHICLE ON FOUR
WHEELS
WARNINGS
Do not remove the starter key or turn
the starter switch to position 0 while the
vehicle is moving as this will lock the steering.
Without the engine running, greater
effort will be required to operate the
brake pedal and steering wheel. Longer
stopping distances will also be experienced.
265
R
CAUTIONS
Under no circumstances can the vehicle
be towed with only two wheels on the
ground. It must be towed with all four wheels
on the ground, recovered onto a trailer, or
have a combined wheel lift and dolly
arrangement, to lift it clear of the ground.
When preparing to tow the vehicle on
four wheels, ensure that neutral N is
selected and the parking brake is applied.
The vehicle can be towed for a maximum
distance of only 50 km (30 miles) at a
maximum speed of 50 km/h (30 mph). If the
stated distance or speed is exceeded,
transmission damage may occur.
Do not be tow the vehicle if the gearbox
cannot be set in neutral or the rear
electronic differential has failed in the locked
position.
Your vehicle has permanent four-wheel drive
and is fitted with a steering lock. The following
procedure must be carried out carefully to
prevent damage to the vehicle:
1. Secure the towing attachment from the
recovery vehicle to the front towing point.
2. With the parking brake applied, insert the
starter key and turn it to position II.
3. Apply the foot brake and place the gear
lever into neutral.
4. Turn the starter switch to position I. Do not
turn the starter switch to position O.
5. The starter switch may be turned to
position II, to operate the brake lamps and
direction indicators. Leaving the starter
switch in position I or II may drain the
vehicle battery.
6. Release the parking brake before towing
the vehicle.
L

Vehicle recovery
After towing on four wheels
1. Apply the parking brake.
2. Turn the starter switch to position II and
apply the foot brake.
3. Place the auto selector lever in the Park
position.
4. Turn the starter switch to position O.
5. Remove the towing attachment and fit the
cover to the front towing point.

266
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Vehicle identification
VEHICLE IDENTIFICATION NUMBER
Vehicle identification

(VIN)
If you need to communicate with a Land Rover
Dealer/Authorised Repairer, you may be asked
to quote the Vehicle Identification Number
(VIN).

E82503

The VIN is stamped on a plate which is visible

through the lowest part of the left side of the
windscreen (this should match the VIN
recorded in the Service Portfolio book). VIN
information may also be found in areas such
as: Bonnet locking platform, Suspension tower
and Door shut faces.

267
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Technical specifications
TECHNICAL SPECIFICATIONS
Technical specifications

V6 Diesel

Capacity 2 720 cm³

Firing order 1-4-2-5-3-6
Bore 81.0 mm
Stroke 88.0 mm
Number of cylinders 6
Compression ratio 17.3:1

V8 Petrol

Capacity 4 394 cm³

Firing order 1-5-4-2-6-3-7-8
Bore 88.0 mm
Stroke 90.3 mm
Number of cylinders 8
Compression ratio 10.5:1
Spark plugs NGK IFR5N10
Spark plug gap Non-adjustable

V6 Petrol

Capacity 4 009 cm³

Firing order 1-4-2-5-3-6
Bore 100.4 mm
Stroke 84.4 mm
Number of cylinders 6
Compression ratio 9.7:1
Spark plugs Motorcraft AGSF 24 PM
Spark plug gap Non-adjustable

268
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Technical specifications
Weights

Approximate EEC kerb weights (full fuel Metric Imperial

tank)
- Petrol engine vehicles 2 486 - 2 704 kg 5 315 - 5 796 lb
- Diesel engine vehicles 2 494 - 2 718 kg 5,498 - 5 992 lb
Maximum gross vehicle weight 3 180 - 3 230 kg 7 011 - 7 121 lb
Maximum front axle load 1 450 kg 3 197 lb
Maximum rear axle load 1 840 - 1 855 kg 4 056 - 4 090 lb

Note: Axle weights are non-additive. The

individual maximum axle weights and gross
vehicle weight must not be exceeded.

269
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Technical specifications
Dimensions - Air suspension vehicles

C D H
G E
E81324
A F

Ref. Dimension Metric Imperial

A Overall width 2 191 mm 86.26 in.
Overall width (mirrors folded) 2 009 mm 79.09 in.
B Overall height
- Access height 1 887 mm 72.32 in.
- Standard height 1 837 mm 74.29 in.
- Off-road height 1 942 mm 76.46 in.
C Approach angle (at EEC kerb weight and 37.2°
off-road height)
D Ramp breakover angle (at EEC kerb 124.2°
weight and off-road height)
E Wheelbase 2 885 mm 113.6 in.
F Overall length 4 848 mm 190.9 in.
Overall length (including tow hitch - to 4 913 mm 193.4 in.
centre of tow ball)
G Track:
- Front 1 605 mm 63.2 in.
- Rear 1 612.5 mm 63.5 in.
H Departure angle without tow hitch (at 29.6°
EEC kerb weight and off-road height)
Departure angle with tow hitch (at EEC
kerb weight):
- Standard ride height 15.7°
- Off-road ride height 18.5°

270
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Technical specifications

Ref. Dimension Metric Imperial

Wading depth
- Standard height 600 mm 24 in.
- Off-road height 700 mm 28 in.
Minimum ground clearance (off-road 240 mm 9.44 in.
height)
Maximum gradient, nose up/down
- Continuous operation 35°
- Drive-through 45°
Turning circle 11.45 metres 37.56 ft
Wheel alignment (total)
- Front -0.16° ± 0.2° -10' ± 12'
- Rear 0.16° ± 0.2° 10' ± 12'
Brake pedal free travel Not adjustable
Clutch pedal free travel Not adjustable

271
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Technical specifications
Dimensions - Coil spring suspension
vehicles

C D H
G E
E81324
A F

Ref. Dimension Metric Imperial

A Overall width 2 191 mm 86.26 in.
Overall width (mirrors folded) 2 009 mm 79.09 in.
B Overall height 1 887 mm 74.29 in.
C Approach angle (at EEC kerb weight) 32.2°
D Ramp breakover angle (at EEC kerb 157.2°
weight)
E Wheelbase 2 885 mm 113.6 in.
F Overall length 4 848 mm 190.9 in.
Overall length (including tow hitch - to 4 913 mm 193.4 in.
centre of tow ball)
G Track:
- Front 1 605 mm 63.2 in.
- Rear 1 612.5 mm 63.5 in.
H Departure angle without tow hitch (at 24.9°
EEC kerb weight)
Departure angle with tow hitch (at EEC 15.7°
kerb weight)
Wading depth 600 mm 24 in.
Minimum ground clearance (off-road 240 mm 7.3 in.
height)
Maximum gradient, nose up/down
- Continuous operation 35°
- Drive-through 45°

272
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Technical specifications

Ref. Dimension Metric Imperial

Turning circle 11.45 metres 37.56 ft
Wheel alignment (total)
- Front -0.16° ± 0.2° -10' ± 12'
- Rear 0.16° ± 0.2° 10' ± 12'
Brake pedal free travel Not adjustable
Clutch pedal free travel Not adjustable

273
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Type approvals
TYPE APPROVALS
Type approvals

The Declarations of Conformity are from

manufacturers of RF (Radio Frequency)
equipment, whose components are used in the
manufacture of your Discovery 3.
These manufacturers state that their
components comply with relevant rules of the
R and TTE (Radio and Telecommunication
Terminal Equipment) directive.
The directive requires the manufacturer of
short range radio devices to self-certify that RF
parts fitted to Land Rover vehicles are fit for
use and that the declarations are supplied with
the vehicle documentation. If at a future date a
technical inspection is required, the
declarations will provide all necessary
information.
Note: The Declarations of Conformity are
published in the native language of the RF
equipment manufacturer, in compliance with
the R and TTE Directive.

274
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Type approvals

E81268

275
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Type approvals

DECLARATION OF CONFORMITY
Trade Name: Model No:
Connaught Electronics Ltd. LQN5752
Canadian 2306A-5752
Tested to comply Model 5752 by Connaught Electronics
FCC Standards 15B Operation is subject to the following two conditions: (1) this
device may not cause interference, and (2) this device must accept
any interference, including interference that may cause undesired
FOR HOME OR OFFICE USE operation of the device.

This declaration is the responsibility of the manufacturer / authorised representative within the
Community:

Supplier
Connaught Electronics Ltd.
Supplier Address
Dunmore Road,
Tuam
Co. Galway,
Ireland

This certifies that the following designated product

T5 RECEIVER 315MHZ PART NO. 5752
...................................
(Product identification)

complies with the essential protection requirements of R&TTE Directive 1999/5/ EC on the
approximation of the laws of the Member States relating to Radio Spectrum Matters, EMC
and Electrical Safety.
This declaration applies to all specimens manufactured in accordance with the technical
documentation described in the annex II. Connaught Electronics Ltd. keep this documentation
at the proposal of the relevant national authorities of any Member State for inspection
purpose.
Assessment of compliance of the product with the requirements relating to the essential
requirements acc. to Article 3 R&TTE was based on Annex IV of the Directive 1999/5/ EC
and the following standards:

Radio Spectrum : ................EN 300 220-1.....................................................................................

(Identification of regulations / standards)

EMC : .................EN 300 683 .............................................................

(Identification of regulations / standards)

Safety : .................EN 60950............................................................................................

(Identification of regulations / standards)

(Place, date) (Signature)

Tuam, Ireland

16/03/2004

E81269

276
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Type approvals

DECLARATION OF CONFORMITY

0682
This declaration is the responsibility of the manufacturer / authorised representative within the
Community:

Supplier
Connaught Electronics Ltd.
Supplier Address
Dunmore Road,
Tuam
Co. Galway,
Ireland

This certifies that the following designated product

T5 RECEIVER 433MHZ PART NO. 5751
...................................
(Product identification)

complies with the essential protection requirements of R&TTE Directive 1999/5/ EC on the
approximation of the laws of the Member States relating to Radio Spectrum Matters, EMC
and Electrical Safety.
This declaration applies to all specimens manufactured in accordance with the technical
documentation described in the annex II. Connaught Electronics Ltd. keep this documentation
at the proposal of the relevant national authorities of any Member State for inspection
purpose.
Assessment of compliance of the product with the requirements relating to the essential
requirements acc. to Article 3 R&TTE was based on Annex IV of the Directive 1999/5/ EC
and the following standards:

Radio Spectrum : ................EN 300 220-1.....................................................................................

(Identification of regulations / standards)

EMC : .................EN 300 683 .............................................................

(Identification of regulations / standards)

Safety : .................EN 60950............................................................................................

(Identification of regulations / standards)

(Place, date) (Signature)

Tuam, Ireland

16/03/2004

E81270

277
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Type approvals

E82488

278
 R

Type approvals

E82489

279
L

Type approvals

E82490

280
 R

Type approvals

E82491

281
L

Type approvals

E82492

282
 R

Audio introduction
RADIO RECEPTION
Audio introduction

E81779

Your audio unit receives signals whilst on the
move, and may experience widely differing
reception characteristics. Because of this,
some interference is to be expected from time
to time during a journey.
FM transmitters can only broadcast over a
limited range, and good clear signals will only
be received in the immediate area of the
transmitter. When travelling, occasionally it
may be necessary to re-tune the audio unit to
offset the effects of moving from one
transmitter area to another.
While RDS automatic retuning helps to reduce
the effects of signal changes, some manual
retuning may still be required (especially for
local stations) in areas of weak reception.
The broadcast range for good stereo reception
is within approximately 48 - 64 km (30 - 40
miles) of the transmitter.
FM Signals travel in a straight line, so large
obstacles, such as tall buildings, can shield the
vehicle from the signal causing distortion or
loss of reception (known as dead spots).
Distortion can also occur if FM signals received
directly from the transmitter, mix with signals
deflected by obstructions such as mountains,
hills, and tall buildings. This is known as
multi-path distortion.
Note: Although distortion, interference and
lack of signal clarity are sometimes attributed
to a fault in the radio, this is rarely the case.

283
L

Audio unit overview

AUDIO UNIT OVERVIEW
Audio unit overview

Standard audio unit

1 2

18
FM1 14 : 54
17 2 BBC R4
TA PTY NEWS

16
15

14 3

13 4

E81803 12 11 10 9 8 7 6 5
1. Radio station pre-sets 10. Manual tuning/scan down button
2. Information display screen • Radio station manual rearward search
3. Audio menu button: • Compact disc scan down
• Access 11. Automatic rearward tuning/search button
• Save • Radio station automatic rearward search
• Close • Compact disc rearward search
4. Audio menu button: 12. On/off and volume control
• Back • Press to switch on/off
• Exit • Rotate to change volume
5. Audio menu control 13. Traffic information (TA) or News button
• Rotate to scroll through options • Short press for Traffic announcements
• Press to enable or disable the function • Long press for News announcements
6. Automatic forward tuning/search button 14. Tone and volume settings button
• Radio station automatic forward search • Short press for tone settings menu
• Compact disc forward search • Long press for volume settings menu
7. Manual tuning/scan up button 15. Auxiliary input mode button
• Radio station manual forward search 16. Compact disc player mode button
• Compact disc scan up 17. AM waveband button
8. Compact disc slot 18. FM waveband button
9. Compact disc eject button

284
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Audio unit overview

Premium audio unit

1 2

19 1 2
ABC
3
DEF 6CD-465

18 4
GHI
5
JKL
6
MNO
FM A 14 : 54
17 7 8 9
PQRS TUV WXYZ 2 97.9 Radio 1
1 2 3 4 5 6 TA PTY NEWS
16 0 3

15 4

14 5

E81804 13 12 11 10 9 8 7 6
1. Input keypad 9. Compact disc slot
• Function (frequency, track number, 10. Compact disc eject button
telephone numbers, text etc.) 11. Manual tuning/scan down button
2. Information display screen • Radio station manual rearward search
3. Telephone mode button • Compact disc scan down
4. Audio menu button: 12. Automatic rearward tuning/search button
• Access • Radio station automatic rearward search
• Save • Compact disc rearward search
• Close 13. On/off and volume control
5. Audio menu button: • Press to switch on/off
• Back • Rotate to change volume
• Exit 14. Traffic information (TA) or News button
6. Audio menu control • Short press for Traffic announcements
• Rotate to scroll through options • Long press for News announcements
• Press to enable or disable the function 15. Tone and volume settings button
7. Automatic forward tuning/search button • Short press for tone settings menu
• Radio station automatic forward search • Long press for volume settings menu
• Compact disc forward search 16. Auxiliary input mode button
8. Manual tuning/scan up button 17. Compact disc player mode button
• Radio station manual forward search 18. AM waveband button
• Compact disc scan up
19. FM waveband button

285
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Audio unit operation

ON/OFF CONTROL VOLUME CONTROL
Audio unit operation

FM A 14 : 54 Audio Volume
2 97.9 Radio 1 16
1 2 3 4 5 6 TA PTY NEWS 1 2 3 4 5 6

E81870 E81863

Press the volume control to switch the audio
unit on. Press again to switch off.
With the engine running, rotate the volume
control to increase or decrease the audio unit
volume. The volume can be set between 0 and
35. The audio unit can be used with the engine
switched off, but the volume available is
restricted.
When the audio unit is turned on, the
previously set volume level will be
implemented, provided that it is suitable for the
prevailing conditions. If the previously set
volume is too quite or too loud, a suitable level
will be implemented automatically.
In addition to setting the volume of the audio,
the volume control is used to adjust the
following features:
• Automatic Volume control (AVC)
• Information volume offset
• Navigation volume offset
• Phone volume
• Voice volume
• Reset volume settings

286
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Audio unit operation

Automatic Volume control (AVC) Information volume offset

OFF Info Vol Offset

INFO
+6
1 2 3 4 5 6

AVC Level
4
1 2 3 4 5 6

E81865

The information volume offset allows an

E81864 increased volume level to be set for news and
traffic announcements.
The automatic volume control adjusts the
volume level to compensate for the changes in The figure set determines the number of steps
road noise as the vehicle speed increases or above the current volume. For example the
decreases. information volume offset is 6, and the audio
output is 14, the announcement will be made at
Note: The AVC value (0-9) represents the
a volume level of 20.
volume increase, and not the volume level.
To access the information volume offset
If the AVC level is set to zero, there will be no
setting, press the Tone button for
volume increase. An AVC setting of 1 will
approximately five seconds until the AVC Level
increase the volume by a small amount. An
setting is displayed. Repeatedly press the Tone
AVC setting of 9 will increase the volume by a
button to scroll through the menu until Info Vol
large amount.
Offset is displayed.
The AVC setting required will depend upon the
The current information volume offset value
expected speed and the expected road
will be displayed. Rotate the volume control to
conditions.
increase or decrease the value.
To access the AVC Level settings, press the
Note: If an announcement is received during a
Tone button for approximately five seconds
phone call, the phone call will be terminated.
until the current AVC Level setting is displayed.
Rotate the volume control to increase or
decrease the value.

287
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Audio unit operation

Navigation volume offset To access the phone volume setting, press the
Tone button for approximately five seconds
until the AVC Level setting is displayed.
Nav. Vol Offset Repeatedly press the Tone button to scroll
1 2
+6
3 4 5 6
through the menu until Phone Volume is
displayed.
The current phone volume value will be
displayed. Rotate the volume control to
increase or decrease the value.
Voice volume
E81866

The navigation volume offset allows you to set Voice Volume

an independent level for the volume of 22
1 2 3 4 5 6

Navigation announcements.
To access the navigation volume offset
settings, press the Tone button for
approximately five seconds until the AVC Level
setting is displayed. Repeatedly press the Tone
button to scroll through the menu until Nav Vol
Offset is displayed. E81868

The current navigation volume offset value will The voice volume allows you to set an
be displayed. Rotate the volume control to independent level for the volume of the unit’s
increase or decrease the value. voice output.
Phone volume To access the voice volume settings, press the
Tone button for approximately five seconds
until the AVC Level setting is displayed.
Phone Volume Repeatedly press the Tone button to scroll
8 through the menu until Voice Volume is
1 2 3 4 5 6

displayed.
The current voice volume value will be
displayed. Rotate the volume control to
increase or decrease the value.

E81867

The phone volume allows you to set an

independent level for the volume of the
telephone.

288
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Audio unit operation

Reset volume settings BASS/TREBLE CONTROL
Bass response adjustment

Reset Vol. Settings

No Bass
1 2 3 4 5 6

1 2 3 4 5 6

E81840

Press the Tone button briefly. When the current

Reset Vol. Settings
Yes Bass setting is displayed, rotate the volume
1 2 3 4 5 6
control to increase or decrease the level.
Press the Tone button to confirm the setting.
Treble response adjustment

E81869
Treble
This feature resets all of the volume settings to
the original factory values. 1 2 3 4 5 6

Press the Tone button for approximately five

seconds until the AVC Level setting is
displayed. Repeatedly press the Tone button to
scroll through the menu until Reset Vol
Settings is displayed. Rotate the volume
control to highlight Yes or No as required. E81841
Press the Tone button to confirm your choice
and exit the menu. Press the Tone button repeatedly until the
current Treble setting is displayed. Rotate the
volume control to increase or decrease the
level.
Press the Tone button to confirm your choice.

289
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Audio unit operation

Subwoofer settings Logic 7 settings

Subwoofer
LOGIC7
1 2 3 4 5 6
No
1 2 3 4 5 6

E81842

Press the Tone button repeatedly until the

current Subwoofer setting is displayed. Rotate
the volume control to increase or decrease the LOGIC7
setting. Yes
1 2 3 4 5 6

Press the Tone button to confirm your choice.

E81843

Press the Tone button repeatedly until the

current LOGIC7 setting is displayed. Rotate the
volume control to highlight Yes or No as
required.
Press the Tone button to confirm your choice.

290
 R

Audio unit operation

Source tone memory Resetting tone values

Source Tone Memory Reset Tone Settings

No No
1 2 3 4 5 6 1 2 3 4 5 6

Source Tone Memory Reset Tone Settings

Yes Yes
1 2 3 4 5 6 1 2 3 4 5 6

E81844 E81845

Press the Tone button repeatedly until the
current Source Tone Memory setting is
displayed. Rotate the volume control to
highlight Yes or No as required.
Press the Tone button to confirm your choice.
To return the tone settings to the factory
defaults, press the Tone button repeatedly until
Reset Tone Settings is displayed. Rotate the
volume control to highlight Yes or No as
required.
Premium audio: Press the Tone button to
confirm your choice.
Standard audio: Press the MENU/OK button to
confirm your choice.
All settings will be reset to the neutral (central)
value.

291
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Audio unit operation

BALANCE/FADE CONTROL STATION PRESET BUTTONS
Balance adjustment
FM1 14 : 54
Balance 87. 50

1 2 3 4 5 6

E81838

Press the Tone button repeatedly until the

current Balance setting is displayed. Rotate
the volume control to increase or decrease the
left or right sound level. FM1 14 : 54
2 BBC R4
Fader adjustment

Fader

1 2 3 4 5 6

E81885

To store a station, press either of the search

E81839
Press the Tone button repeatedly until the
current Fader setting is displayed. Rotate the
volume control to increase or decrease the
front or rear sound level.
buttons to scan up or down to the next
available station. Having tuned to the desired
station, press and hold the preset number
under which you would like the station stored.
Note: For information on radio reception
quality. See RADIO RECEPTION (page 283).
The audio output will be muted when the
button is pressed. When the audio output can
be heard again, the station has been stored.
To access the stored stations, press the
required preset number briefly.

292
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Audio unit operation

WAVEBAND BUTTON AUTOSTORE CONTROL

FM1 FM2 FMa

FMa 14 : 54
Autostore

FM1 14 : 54
2 BBC R4
E81884

To autostore FM stations, press and hold the

E81886
To select the FM waveband, press the FM
button briefly. Repeated presses will scroll
through FM1, FM2 and FMa. The selections
will be shown in the top left-hand corner of the
information display.
FM button. Autostore will be shown in the
information display and the stations will be
stored under the preset numbers in the order in
which they are found.
To access the stored stations, press the
required preset number briefly.

MW1 MWa LW1 LWa

MW1 14 : 54
4 531

E81887

To select the AM waveband (includes MW and

LW), press the AM button briefly. Repeated
presses will scroll through MW1, MWa, LW1
and LWa. The selections will be shown in the
top left-hand corner of the information display.

293
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Audio unit operation

RADIO DATA SYSTEM (RDS) ON or OFF will now be displayed. Rotate the
Your audio is equipped withRDS (Radio Data menu control to select one of these and press
System) RDSRDS (Radio Data System), either the menu control or the MENU/OK
which enables the audio unit to receive button to confirm your selection.
additional information with the normal radio The RDS status will be shown briefly on the
signals. information display.
On the FM waveband, RDS enables the audio to
receive traffic and news information
broadcasts. RDS also allows the audio to
automatically re-tune to stations that are linked
to the same network if that network allows this.
Note: Not all FM radio stations broadcast
RDSRDS. If a non-RDSRDS station is selected,
RDS RDS features will not be available.
Selecting RDS

Cancel
PTY Seek
FM Scan
1 2 3 4 5 6

FM Scan
RDS
AF Switch
1 2 3 4 5 6

Cancel
On
Off
1 2 3 4 5 6

E82210

To turn RDS on or off, press the MENU/OK

button to display the menu. Rotate the menu
control until RDS is displayed. Press the
control to accept this setting.

294
 R

Audio unit operation

TRAFFIC INFORMATION (TA)
CONTROL FM A 14 : 54
2 97.9 Radio 1
1 2 3 4 5 6 TA

News ON
TA OFF

TA

FM1 14 : 54 TA 14 : 54
2 BBC R4 95.2 BBC Oxfd
TA
1 2 3 4 5 6 TA

E81879

To switch Traffic information on or off, briefly

press the INFO button
TA If the audio unit is tuned to a weak FM signal (in
remote areas, for example) or a station that
cannot provide traffic information, when the
INFO button is pressed, the display will show
Tr a f f i c 14 : 54 No TA/TP.
BBC R2
TA
If a traffic information station cannot be found,
No Station will be displayed. The audio unit will
return to the previously tuned frequency.
E81878 If the signal from a traffic information station
weakens, the TP indicator in the left-hand side
Press the MENU/OK button to display the of the display will flash. Press either of the
menu. Rotate the menu control to select TA. search controls to search for another station. If
Press the menu control to change the status to the traffic information signal weakens during
ON or OFF. CD play, the audio unit will attempt to re-tune
As soon as a traffic announcement is received, to a traffic information station with a stronger
radio reception or CD play is interrupted and signal.
TRAFFIC appears briefly in the information Note: If a non-traffic information station is
display, followed by the name of the station stored on a preset button, and is selected while
providing the information. traffic information is switched on, the audio
At the end of the traffic announcement, radio or unit will remain on the selected station unless
CD play, will resume. TA is turned off and on again.

295
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Audio unit operation

Selecting news information Note: Both traffic and news information can be
selected at the same time. However, the audio
unit will always give priority to traffic
Regional ON information.
News OFF
Cancelling an announcement

TA 14 : 54
95.2 BBC Oxfd
1 2 3 4 5 6 TA

FM1 14 : 54
2 BBC R2
NEWS

E81881

To cancel an announcement, briefly press the C

NEWS button.
Note: Cancelling an announcement in this way
will not prevent further announcements when
News 14 : 54 they become available.
BBC R4
NEWS

E81880

Press the MENU/OK button to display the

menu. Rotate the menu control to select
NEWS. Press the MENU/OK button to change
the status to ON or OFF.
Alternatively, press and hold the INFO button to
switch news announcements on or off.
When a news announcement is received,
normal radio reception or CD play is
interrupted and the display flashes NEWS
alternately with the name of the station
providing the news information.
The display will alternatively flash the station
name and NEWS. At the end of each
announcement, radio or CD play will resume.

296
 R

Audio unit operation

PTY PROGRAMME TYPES Having entered the PTY menu, use the rotary
The RDS (Radio Data System) allows control to scroll through the programme types
programmes to be categorised by the until your choice is highlighted. Press either
broadcast type (rock music, current affairs, the rotary control or the MENU/OK button to
news etc.). select the programme type and start the
search.
This in turn, allows you to search for a station
by choosing the type of broadcast that you Once a matching station is found, it will
wish to listen to. continue to play. If you wish to continue
searching, press the Search up or Search
PTY search down button within thirty seconds. To continue
To search for a station by programme type, listening to the station, no action is required as
RDS must be set to ON. Press the MENU/OK to it will remain tuned, and can be stored as a
enter the menu. pre-set if required.
To abort a PTY search, press the C button.
PTY programme types
Cancel
PTY Seek
FM Scan NEWS News services
1 2 3 4 5 6

AFFAIRS Current affairs

INFO Information
SPORT Sport
Cancel
News EDUCATE Educational
Affairs
1 2 3 4 5 6 DRAMA Drama
CULTURE Cultural
SCIENCE Scientific
No PTY VARIED Varied programming
POP M Pop music
FM A 14 : 54 ROCK M Rock music
2 94.1 Radio 4 EASY M Easy listening music
1 2 3 4 5 6 PTY LIGHT M Light music
CLASSICS Classical music
OTHER M Other music
PTY WEATHER Weather information
E82211

FINANCE Financial information

Use the rotary control to scroll through the
menu until PTY Seek is highlighted, then press CHILDREN Children’s programming
the rotary control. SOCIAL Religious music
RELIGION Religious talk/music

297
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Audio unit operation

PHONE IN Phone-in
TRAVEL Travel
LEISURE Leisure
JAZZ Jazz music
COUNTRY Country music
NATION M National music
OLDIES Older music
FOLK M Folk music
DOCUMENT Documentaries

298
 R

Compact disc player

LOADING COMPACT DISCS Inserting a single disc - Premium audio
Compact disc player

Inserting a disc - Standard audio CAUTION

Do not force a disc into the slot.
CAUTION
Do not force a disc into the slot.

CD No Discs 14 : 54
FM1 14 : 54 Press 1-6
2 BBC R4

1 2
ABC
3
DEF

4
GHI
5
JKL
6
MNO
CD 3 14 : 54
7
PQRS
8
TUV
9
WXYZ Please Wait
0
E82442

A compact disc can be loaded during any mode

3
of play.
Ensure that the label side of the disc is facing CD 3 14 : 54
upwards then partially insert the disc; the Insert Disc
player mechanism will draw the disc in 3

automatically.

E81783

Press the CD mode button, then press the

numbered button of the position in which the
compact disc is to be stored. Please Wait will
appear in the information display, followed by
the instruction Insert Disc.
Note: The six circles at the bottom left-hand
side of the information display represent the
six available CD positions. As soon as a CD is
loaded, its number will appear in the circle.

299
L

Compact disc player

Ensure that the label side of the disc is facing Note: If a compact disc fails to be drawn in,
upwards then partially insert the disc; the and the message CD Error is displayed, press
player mechanism will draw the disc in the eject button to clear the error.
automatically. If the error fails to clear, contact your Land
Inserting multiple discs Rover Dealer/Authorised repairer.
This process is repeated until all six compact
disc positions are occupied. If one or more of
the disc positions is already occupied, that
CD 1 14 : 54
Please Wait
position will be skipped in the loading process.
Note: To stop the loading process, either press
and hold the CD mode button or press the C
button.
Note: If there is a problem with a disc that has
CD 1 14 : 54
been loaded (inserted upside down, wrong
Insert Disc
format etc.), Disc Error will appear in the
information display, and the disc in question
will be ejected. If the problem can be corrected
(disc upside down for example), then re-insert
the disc in the correct manner. If the problem
cannot be rectified, do not re-insert the disc.

CD 1 14 : 54
Loading All
1

CD 2 14 : 54
Please Wait
1
E81784

To insert more than one disc, briefly press the

CD mode button. Then press and hold the CD
mode button. The information display will
show Loading All, followed by Please Wait.
When the message Insert Disc is displayed, the
first disc can be inserted. The disc's position
number will be highlighted on the information
display screen both during and after loading.

300
 R

Compact disc player

EJECTING COMPACT DISCS EJECTING MULTIPLE COMPACT
DISCS
CAUTION
Do not pull the disc from the player
before it has stopped moving, this will CD 1 14 : 54
damage the player mechanism. Ejecting All
1 2 3 4 5 6

CD 5 14 : 54
Ejecting
1 2 3 4 5 6

CD 1 14 : 54
Remove Disc
2 3 4 5 6

CD 5 14 : 54
Remove Disc
1 2 3 4 6

CD 2 14 : 54
Ejecting All
2 3 4 5 6

E81785
It is only possible to eject a single disc, if it is
currently selected or playing.
To eject a disc, press the eject button briefly.
Ejecting will be shown on the information
display and, after a short pause, the disc will be
presented. When the disc has stopped moving
Remove Disc is displayed. The disc should
now be removed.
Note: If the disc is not removed from the slot
within fifteen seconds, it will be drawn back
into the player.
CD 6 14 : 54
Loading
E81786
All the discs loaded in the player can be ejected
in sequence. To eject all of the discs, press and
hold the eject button. Ejecting All will be
shown on the information display and, after a
short pause, the first disc will be presented.
When the disc has stopped moving Remove
Disc is displayed. The disc should now be
removed.

301
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Compact disc player

The discs will be ejected one at a time with a COMPACT DISC SELECTION
short pause in between each. Following the
removal of the last disc, Loading will be shown
1 2 3
in the information display. ABC DEF

4 5 6
To stop the process, press any number button. GHI JKL MNO
CD 1 14 : 54
7 8 9 Tr 12 2 : 43
Note: If a disc is not removed from the slot PQRS TUV WXYZ

1 2 3 5 6
within fifteen seconds, it will be drawn back 0
into the player.

CD 4 14 : 54
Please Wait
1 2 3 5 6

CD 4 14 : 54
Insert Disc
1 2 3 5 6

CD 4 14 : 54
Tr 01 0 : 01
1 2 3 4 5 6
E81788

To start compact disc playback, briefly press

the disc number required. If the position
selected does not contain a disc, there will be a
pause and the message Insert Disc will appear
on the information display.
Once a disc has been inserted, there will be a
pause whilst the player reads the disc
information. Playback will then begin at the
start of track one.

302
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Compact disc player

COMPACT DISC PLAYBACK Premium audio
Standard audio

CD 1 14 : 54
CD No Disc Tr 12
1 2 3 4 5 6
3 : 15

CD 14 : 54 1 2 3
Tr 01 0 : 01 ABC DEF

4
GHI
5
JKL
6
MNO
CD 3 14 : 54
7
PQRS
8
TUV
9
WXYZ Loading
1 2 3 4 5 6
E82443 0

To start compact disc playback, briefly press 6CD-465

the CD mode button.
Note: If no disc is inserted, NO Disc will appear CD 3 14 : 54
in the display . Playback will start as soon as a
dsic is inserted. Tr 01 0 : 01
1 2 3 4 5 6

E81789

To start compact disc playback, briefly press

the CD mode button, followed by the disc
number required. If no disc number is selected,
playback will begin at one of two places.
• If the discs have not been removed since
their last use, playback will begin from the
point at which it was stopped previously.
• If the discs have not been used since they
were inserted, playback will begin at the
start of disc one.

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Compact disc player

TRACK SELECTION FAST FORWARD/REVERSE

CD 4 14 : 54 CD 4 14 : 54
Tr 04 2 : 16 Tr 03 0 : 00
1 2 3 4 5 6 1 2 3 4 5 6

E81790 E81792

To search forwards or backwards through the To return to the start of a track during playback,
current track, briefly press the relevant button. briefly press the button arrowed.

COMPACT DISC PAUSE CD 4 14 : 54

Tr 04 0 : 00
1 2 3 4 5 6

CD 1 14 : 54
Tr 03 2 : 13
1 2 3 4 5 6

E81791

To pause or stop compact disc playback,

briefly press one of the other mode buttons,
E81793
AM or FM for example.
To fast forward to the beginning of the next
track, briefly press the button arrowed.

304
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Compact disc player

COMPACT DISC FUNCTION MENU SHUFFLE/RANDOM

CD 2 14 : 54 Cancel
Tr 06 1 : 27 Random
1 2 3 4 5 6
CD Scan

6CD-465

E81794
CD 3 14 : 54
The following additional functions are available :
Tr 17 0 00 Random
using the compact disc function menu:
1 2 3 4 5 6
• Random.
• CD scan. E81795

• Repeat.
Select compact disc mode, then briefly press
the MENU/OK button. Rotate the menu control
to select the required function. Press the
control to enable or disable the function.
Shuffle/random alters the playback sequence
for the current disc. The tracks are selected
randomly by the player.
Rotate the menu control to select Random and
press the control to enable the function.
To disable the function, rotate the menu control
to select Random and press the control.
Pressing the C button will also disable the
function.

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Compact disc player

REPEAT COMPACT DISC TRACKS COMPACT DISC TRACK SCANNING

CD Scan Random
Repeat CD Scan
Load All Repeat

6CD-465 6CD-465

CD 1 14 : 54 CD 1 Scan 14 : 54
Tr 06 :
0 27 Repeat Tr 01 0 : 08
1 2 3 4 5 6 1 2 3 4 5 6

E81796 E81797

Repeat allows the current track to play
repeatedly until it is stopped/ cancelled.
Rotate the menu control to select Repeat and
press the control to enable the function.
To disable the function, rotate the menu control
to select Repeat and press the control.
Pressing the C button, or the skip forward/next
track or return to start/previous buttons, will
also disable the function.
Compact disc track scan allows you to sample
the music on a compact disc. This feature plays
the first ten seconds of each track in numerical
order. Play will then begin at the start of track
one.
Rotate the menu control to select CD scan and
press the control to enable the function.
To disable the function, rotate the menu control
to select CD scan and press the control.
Pressing the C button, or the skip forward/next
track or return to start/previous buttons, will
also disable the function.

306
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Compact disc player

MP3 FILE PLAYBACK To ensure that the best sound quality is
achieved the instructions/information provided
6CD-465 with the recording software should be read
carefully and adhered to.
CD 3 Data 14 : 54
Tr 01 1 : 37
Fd 03 16 Tr 01 14
1 2 3 4 5 6

E81798

When a data disc (containing MP3 encrypted

music data) is inserted into the compact disc
slot, the information display will show
additional folder and track information.
The first line of the information display shows
that a data disc is inserted. The second line
shows which track is being played and the play
time of that track.
The third line shows which folder out of the
total number of folders (03/16) and which track
out of the total number of tracks available
(01/14) is currently playing
A short press on the # or * keys selects the next
or previous folder respectively. The number of
that folder will change accordingly
When a new folder is selected, play will
commence at the first track in that folder.
Within the current folder, track selection can be
changed by use of the return to start/previous
and skip forward/next track buttons. Track
number in the display will change accordingly.
Note: Blank or empty folders may be listed on
screen, but they will be skipped when moving
through the available folders.
If an MP3 recording is made with a
compression rate lower than 128k some Digital
Signal Processing (DSP) functionality may be
lost.

307
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Rear passenger controls
REAR SEAT CONTROLS
Rear passenger controls
2 5 7 frequency band for the next station with
1 3 4 6
E81893
1. 3.5 mm headphone jack
2. Preset/CD select
• During radio play, a short press will
select the next preset radio station.
• During CD play, a short press will select
the next CD.
3. Mode control
• A long press will select AUX.
• With AUX selected, press to return to the
previous mode.
• When rear seat entertainment is
selected, all adjustments are made
through the remote control.
4. Search down
• During radio play, press to search down
the frequency band for the next station
with a good signal strength.
• During CD play, a short press will start
the current track again. A second press
will start the previous track.
• During CD play, a long press will search
back through the track being played,
until the button is released.
308
5. Search up
• During radio play, press to search up the
a good signal strength.
• During CD play, a short press will start
the next track.
• During CD play, a long press will search
forward through the track being played,
until the button is released.
6. Volume decrease
• Press to decrease headphone volume
7. Volume increase
• Press to increase headphone volume
With the starter switch in position I or II, the
rear seat controls can operate, regardless of
whether the audio system is switched on or
not. However, the output can only be heard
through the headphones.
If rear seat passengers are listening to the
same source as the front seat passengers, only
the volume can be adjusted via the rear seat
controls.
For example, if a music CD is playing on the
audio unit, rear seat passengers can listen to
that music and adjust the volume to suit their
requirement. No other functions will be
available.
If however, the audio unit is switched to
another source, all CD related rear seat
controls become operable. If the audio source
is subsequently switched back to CD, the rear
seat controls will again be limited to volume
control only.
The same logic applies to radio functions.
Adjustments can be made to other functions of
the audio system.
 R

Rear passenger controls

For example, if a music CD is selected on the
audio unit, radio can be selected and controlled
using the rear seat controls. All radio related
rear seat controls become operable.

HEADPHONES
The maximum volume available to this type of
headphones is limited to the volume set at the
rear seat controls.
Note: Only headphones compatible with a 3.5
mm jack plug socket can be used. To obtain
optimum sound quality, use headphones with
an impedance of 32 ohms.
Note: When the headphones are not
connected, the rear seat controls remain
operational. It is still possible to select CD,
whilst the radio is playing on the audio unit. CD
play will remain operational until the mode
control is pressed again.
Note: The mode in use when the starter key is
removed will resume if the starter switch is
turned on again (position I or II) within two
minutes. If the starter switch is turned off for
longer than two minutes AUX mode will be
selected when the starter switch is next turned
on. For example, a CD is playing when the key
is removed, play will recommence when the
starter switch is next turned to position I, or the
engine is started, whether the headphones are
in use or not.
Note: Adjusting the volume on the audio unit,
does not alter the headphone volume. The
volume of each controller can be adjusted
independently.

309
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Auxiliary input (AUX IN) socket

AUXILIARY INPUT (AUX IN) SOCKET
Auxiliary input (AUX IN) socket

WARNINGS
Ensure that any auxiliary devices are
stored securely whilst the vehicle is in
motion. Any loose objects can present a
serious hazard during sudden manoeuvres,
emergency braking, or an accident.
Do not place any item connected to the
auxiliary input socket, or the auxiliary
power socket, on the vehicle’s seats, carpets,
or other upholstery. The heat generated by
these devices may cause damage to the
upholstery, or in extreme cases, a vehicle fire.
Do not leave any auxiliary input devices
connected whilst the vehicle is left
unattended. There is a risk of heat damage or
fire, in addition to the risk of theft. E80550

CAUTION AUX (Auxiliary Input) mode allows additional

Read the manufacturer's instructions for
any device before it is connected to the
vehicle's audio system. Ensure that the device
is suitable, and comply with any instructions
regarding connection and operation. Failure to
do so may result in damage to the vehicle's
audio system or the auxiliary device.
equipment to be connected to the vehicle's
audio system. Items such as a personal stereo,
MP3 player, hand-held navigation unit etc. can
be plugged in to the vehicle's audio system.
The auxiliary connector is situated at the rear of
the centre console. To gain access, lift the
lower edge of the cover.
Auxiliary audio devices are connected via the
3.5 mm stereo jack plug marked AUX.
The auxiliary power socket, situated next to the
auxiliary input connector, can be used to power
or charge any suitable device.
Note: On vehicles fitted with rear seat
entertainment, additional Audio Visual sockets
(AV1 and AV2) are provided. This allows
auxiliary equipment (such as a video games
console) to be linked up to the rear DVD
screens. For information on the installation of
such equipment, please refer to the installation
guide supplied with the auxiliary equipment.

310
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Auxiliary input (AUX IN) socket

Auxiliary mode

AUX

AUX 14 : 54

1 2 3 4 5 6

E80551

To listen to an auxiliary input source, connect

the device and briefly press the AUX button.
The unit will playback audio via the 3.5 mm
stereo jack plug.
Alternatively, press and hold the MODE button
on the steering wheel or the rear audio
controls.
Volume is controlled using the left rotary
control. Tone and balance can also be adjusted.
Note: The volume levels and sound quality
available from devices connected to the
auxiliary inputs may vary widely.

311
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Voice recognition
PRINCIPLE OF OPERATION • Avoid causing background noise in the
Voice recognition

Voice recognition enables operation of the vehicle while you are speaking, and ask
audio system without the need to divert your your passengers not to talk while you are
attention from the road ahead in order to issuing voice commands.
change settings, or receive feedback from the • The hands-free microphone is positioned
system. to pick up the driver’s voice. Commands
made by other occupants may be picked
Whenever you issue one of the defined
up, but clarity and accuracy will be
commands with the system active, the voice
reduced.
recognition system converts your command
into a control signal for the audio system. Your Activating the system
inputs take the form of dialogues or
commands. You are guided through these
dialogues by announcements or questions.
Please familiarise yourself with the functions of
the audio system before using voice
recognition.

USING THE SYSTEM

The voice recognition system includes a
hands-free microphone mounted in the roof of
your vehicle. There are a few points to observe
to ensure that the system understands your
commands:
• Speak continuously and at normal volume,
avoiding unnatural emphasis and pauses
between words.
• Do not speak while the voice recognition
system is giving an output. The voice
system displays LISTENING on the
message centre, and gives a beep when it
is waiting for a voice command.
• It is possible that noise from outside the
E82207

vehicle could affect commands. Keep the To activate voice control:

doors, windows, and sunroof closed.
• If a command is not heard, or is
misunderstood, the voice system
responds with
>Sorry, Command not recognised< or
>No speech detected<.
If this happens, repeat the command.
• Briefly pull the control (the audio will
mute). A tone will be heard, and
LISTENING will be displayed on the main
message centre to indicate that the system
is waiting for a voice command.
Note: It is only necessary to operate the
control at the beginning of each voice session.

312

Voice recognition
Defined voice commands
The voice control system understands
predefined commands which need to be
quoted word for word.
An audio feedback of voice commands is
available. To activate the feedback, pull the
control briefly and give one of the following
commands:
• Voice help - to list all commands.
• Radio help - to list Radio commands.
• CD help - to list CD commands.
• Navigation help - to list Navigation
commands.
Please refer to the Navigation Handbook
for operating instructions.
• Notepad Help - to list Notepad commands.
Please refer to the Owner’s Handbook for
operating instructions.
313
R
Interrupting voice control
A command can be interrupted by saying the
word Cancel or by pressing the control until the
system responds by saying >Command
cancelled<.
If you receive a telephone call (or Navigation
route guidance instruction/TA announcement)
while conducting a dialogue, the dialogue is
interrupted.
Command not recognised
If a command is not recognised, the system
responds with:
>Sorry. Please say your command again<.
L

Voice recognition
AUDIO SYSTEM COMMANDS
Starting a dialogue
Hold the control until the tone is heard. Any
audio sources in the vehicle are muted.
Radio stations
Frequencies are said as in the following
examples:
• Radio Tune five thirty one AM, or Radio
Tune five thirty one (531).
• Radio Tune nine hundred (900).
• Radio Tune fourteen forty (1440).
• Radio Tune fifteen oh three AM (1503).
• Radio Tune fifteen ten AM (1510).
• Radio Tune ten eighty (1080).
• Radio Tune eighty nine point nine FM or
Radio Tune eighty nine point nine (89.9).
• Radio Tune eighty seven point nine FM
or Radio Tune eighty seven point nine
(87.9)
• Radio Tune ninety point zero or Radio
Tune ninety (90.0).
• Radio Tune ninety point one (90.1).
• Radio Tune one hundred point five
(100.5).
• Radio Tune one oh one point one FM
(101.1).
• Radio Tune one oh eight point oh, Radio
Tune one oh eight point zero, or Radio
Tune one oh eight (108.0).
• Radio Tune one oh seven point nine
(107.9).
Note: The word Select can be used in place of
the word Tune if preferred.

Command System response Message centre display

“Radio play” >Radio play< RADIO PLAY
“Radio tune ninety six point nine >Radio tune 96.9 FM (or AM 96.9 FM
(96.9) FM” (or AM or Medium or Medium Wave)
Wave)
“Radio tune” <nametag> >Radio tune <nametag>< Station frequency

Nametags Radio tune <nametag> is used to select a

Nametags are a unique name or phrase of your station that has been previously stored.
choice which can be used to recall a radio
station. The nametags used can be the station
name, or a completely separate name of your
choosing.
The names are stored in a directory by using
the Radio store name command. The system
responds with >Name please<. You say the
name that you have chosen (e.g. Radio 1).
The system will read out a list of current
nametags when given the command Radio
directory.

314
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Voice recognition
Storing radio stations via voice The command
command Radio store preset <say number (1-9)>
Once you have tuned to a radio station, it is calls up the dialogue for storing a pre-set
possible to store that station for future use as a station.
pre-set. The following commands apply to the The command
currently tuned station. Radio autostore
enters the autostore function for the selected
frequency band (e.g. FM).

Command System response Message centre display

“Radio store preset” <preset
number (1-9)>
1. “Radio store” name
3. “Name”
“Radio autostore”
“Radio tune” <name>
>Radio store preset RADIO STORE PRESET (1-9).
<preset number (1-9)>
2. >Radio store name, RADIO STORE NAME, NAME
name please< PLEASE
>Name<
STORED
>Radio autostore< RADIO AUTOSTORE
>Radio tune <name>< RADIO TUNE

315
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Voice recognition
Tune/Delete from the radio directory
The commands Radio play directory or Radio
directory prompt the system to read aloud the
entire list of nametag entries in the radio
directory.
The nametag list is read out in stored order,
and commands can be entered during the
system response.
Replay
After a nametag has been read out by the
system, give the command Replay and the
nametag will be repeated.
Tune
After a nametag has been read out by the
system, give the command Tune and the radio
tunes to the station saved under that nametag.
Delete
After a nametag has been read out by the
system, give the command Delete and the
nametag will be removed from the directory.
After a nametag has been read out by the
system, give the command Cancel and the
current Voice session will end.

Command System response Message centre display

Radio play directory >Radio play directory< RADIO DIRECTORY
You can say “Replay”, Reads out directory. Station frequency
“Tune”, “Delete” or “Cancel”
after each name.

316
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Voice recognition
Deleting the directory
The command Radio delete directory deletes
all entries in the radio directory.

Command System response Message centre display

1. “Radio delete directory” 1. >Radio delete 1. DELETE DIRECTORY SAY YES OR
directory, confirm yes NO
or no
2. “Yes” 1. >Are you sure that 2. SAY YES OR NO
you want to delete the
whole directory?<
3. “Yes” 1. >Directory deleted< 3. DIRECTORY DELETED

317
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Voice recognition
Selecting disc and track numbers
For CD player commands, say disc and track
numbers as in the following examples:
• CD play disc one.
• CD play disc six track ten.
• CD play track twenty five.
• CD play track forty seven.

Command System response Message centre display

“CD help”
“CD play
“CD play disc” <say number
(1-6)>
“CD play next disc”
“CD play previous disc”
“CD play track” <say number
(1-99)>
“CD play disc” <say number
(1-6)> track <say number
(1-99)>
>List of CD commands< CD HELP
>CD play< CD PLAY
>CD play disc <say number DISC <disc number (1-6)>
(1-6)><
>CD play next disc< NEXT DISC
>CD play previous disc< PREVIOUS DISC
>CD play track <say number TRACK <track number
(1-99)>< (1-99)>
>CD play disc <say number DISC <disc number (1-6)>
(1-6) track <say number TRACK <track number
(1-99)>< (1-99)>

318
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Voice recognition
Rear seat entertainment operation
When rear seat entertainment is fitted, it can be
controlled by the following voice commands.

Command System response Message centre display

“Radio auxiliary on” or “Radio
auxilliary play”
“Headphones on” or
“Headphones play”
“Headphones off”
“Rear entertainment on” or
“Rear entertainment play”
“Rear entertainment off’”
Selects auxiliary input to allow AUXILIARY PLAY
an external device, such as a
portable CD/MD player plugged
into the Aux socket, to be
played through the cabin
speakers
Switches on both headphone HEADPHONES PLAY
outputs
Switches off both headphone HEADPHONES OFF
outputs
Switches on rear seat RSE PLAY
entertainment system
Switches off rear seat RSE OFF
entertainment system

319
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Voice recognition
Using Notepad Briefly pull the voice control (the audio will
Notepad allows you to record short messages mute). A tone will be heard, and LISTENING
as memory aids or reminders. will be displayed on the main message centre.
A notepad command can now be given.
You can record a maximum of 10 notes, each
with a maximum duration of 30 seconds.

Command System response Action

“Record note” or “Notepad Notepad gives a beep to
record” indicate the start of recording.
“Play notepad” or “Rear Notepad will recite each note in
notepad” turn. You can say Replay,
Delete or Cancel after each
beep or remain silent to hear
the next note.
“Clear notepad” or “Notepad Do you want to clear the
delete” notepad?
“Notepad help” The system will recite notepad
information and all the
commonly used commands
You may start your
recording after the beep. To
stop recording, hold the
voice recognition control.
Saying Replay will replay the
previous message.
Saying Delete will delete the
previous message.
Saying Cancel will cancel the
previous message.
Say Yes to delete all stored
notes. Say No to cancel the
command

320

Index
A Alarm
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ABS driving hints. . . . . . . . . . . . . . . . . . . 154
Accessories . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting the windscreen washer jets
Front . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Air conditioning . . . . . . . . . . . . . . . . . . . . 119
Air suspension
Access height . . . . . . . . . . . . . . . . . . . 179
Crawl. . . . . . . . . . . . . . . . . . . . . . . . . . 180
Door open override . . . . . . . . . . . . . . . 182
Extended mode . . . . . . . . . . . . . . . . . . 179
Height change warnings . . . . . . . . . . . 182
Height indicators. . . . . . . . . . . . . . . . . 180
High speed height . . . . . . . . . . . . . . . . 179
Messages . . . . . . . . . . . . . . . . . . . . . . 184
Off-road height . . . . . . . . . . . . . . . . . . 179
On-road height . . . . . . . . . . . . . . . . . . 179
Operating . . . . . . . . . . . . . . . . . . . . . . 180
Principle of operation . . . . . . . . . . . . . 179
Remote operation . . . . . . . . . . . . . . . . 183
System freeze . . . . . . . . . . . . . . . . . . . 183
Warning indicator . . . . . . . . . . . . . . . . 180
Air vents . . . . . . . . . . . . . . . . . . . . . . . . . 119
Intake air filters . . . . . . . . . . . . . . . . . . 120
User adjustable vents . . . . . . . . . . . . . 119
Airbags
Curtain airbags . . . . . . . . . . . . . . . . . . . 72
Deployment. . . . . . . . . . . . . . . . . . . . . . 72
Disabling the passenger airbag . . . . . . . 73
Obstructions . . . . . . . . . . . . . . . . . . . . . 71
Operation . . . . . . . . . . . . . . . . . . . . . . . 71
Principle of operation . . . . . . . . . . . . . . 70
Service information. . . . . . . . . . . . . . . . 75
Side airbags . . . . . . . . . . . . . . . . . . . . . 72
Status indicator. . . . . . . . . . . . . . . . . . . 73
Warning indicator . . . . . . . . . . . . . . . . . 75
321
R
Anti-theft alarm indicator . . . . . . . . . . . . 52
Arming the alarm . . . . . . . . . . . . . . . . . . 51
Interior space protection . . . . . . . . . . . . 52
Partial arming. . . . . . . . . . . . . . . . . . . . . 51
Perimetric alarm. . . . . . . . . . . . . . . . . . . 51
Principle of operation . . . . . . . . . . . . . . . 51
Switching off the alarm . . . . . . . . . . . . . 52
Tilt sensor . . . . . . . . . . . . . . . . . . . . . . . 53
Anti-lock Braking System (ABS) . . . . . . . . 154
Driving hints. . . . . . . . . . . . . . . . . . . . . 154
Anti-theft alarm indicator . . . . . . . . . . . . . . 52
Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Audio unit overview
Premium audio unit . . . . . . . . . . . . . . . 285
Standard audio unit . . . . . . . . . . . . . . . 284
Automatic climate control. . . . . . . . . . . . . 123
General notes . . . . . . . . . . . . . . . . . . . . 125
Operation of controls . . . . . . . . . . . . . . 123
Automatic transmission . . . . . . . . . . . . . . 142
CommandShift™ . . . . . . . . . . . . . . . . . 145
Kick-down in automatic mode . . . . . . . 144
Messages . . . . . . . . . . . . . . . . . . . . . . . 147
Selector lever positions . . . . . . . . . . . . 143
Sport mode . . . . . . . . . . . . . . . . . . . . . 144
Warning indicators and messages . . . . 146
Autostore stations . . . . . . . . . . . . . . . . . . 293
Auxiliary heater. . . . . . . . . . . . . . . . . . . . . 127
Auxiliary input (AUX IN) socket . . . . . . . . 310
Auxiliary mode . . . . . . . . . . . . . . . . . . . 311
B
Balance/fade control . . . . . . . . . . . . . . . . . 292
Bass/treble control . . . . . . . . . . . . . . . . . . 289
Battery care . . . . . . . . . . . . . . . . . . . . . . . 225
Battery charging . . . . . . . . . . . . . . . . . . . . 228
Battery warning symbols . . . . . . . . . . . . . 225
Bonnet lock. . . . . . . . . . . . . . . . . . . . . . . . 212
Booster cables . . . . . . . . . . . . . . . . . . . . . 226
Booster seats . . . . . . . . . . . . . . . . . . . . . . . 76
Brake fluid check . . . . . . . . . . . . . . . . . . . 222
Checking the fluid level . . . . . . . . . . . . 222
Topping up the fluid . . . . . . . . . . . . . . . 223
L
Brakes
Anti-lock Braking System (ABS) . . . . .
Electric parking brake (EPB) . . . . . . . .
Foot brake . . . . . . . . . . . . . . . . . . . . . .
Messages . . . . . . . . . . . . . . . . . . . . . .
Principle of operation . . . . . . . . . . . . .
C Halogen bulbs . . . . . . . . . . . . . . . . . . . . 95
Car wash . . . . . . . . . . . . . . . . . . . . . . . . .
Catalytic converter. . . . . . . . . . . . . . . . . .
CD
Disc selection . . . . . . . . . . . . . . . . . . .
Ejecting compact discs . . . . . . . . . . . .
Ejecting multiple compact discs . . . . .
Fast forward/reverse . . . . . . . . . . . . . .
Function menu . . . . . . . . . . . . . . . . . .
Inserting a single disc . . . . . . . . . . . . .
Inserting multiple discs. . . . . . . . . . . .
Loading compact discs . . . . . . . . . . . .
MP3 file playback . . . . . . . . . . . . . . . .
Pause . . . . . . . . . . . . . . . . . . . . . . . . .
Playback . . . . . . . . . . . . . . . . . . . . . . .
Repeat track . . . . . . . . . . . . . . . . . . . .
Shuffle/random . . . . . . . . . . . . . . . . . .
Track scanning . . . . . . . . . . . . . . . . . .
Track selection . . . . . . . . . . . . . . . . . .
Centre console. . . . . . . . . . . . . . . . . . . . .
Card holder . . . . . . . . . . . . . . . . . . . . .
CD storage . . . . . . . . . . . . . . . . . . . . .
Index
Changing a bulb . . . . . . . . . . . . . . . . . . . . . 95
154 Bulb specification chart . . . . . . . . . . . . 104
155 Courtesy lamp . . . . . . . . . . . . . . . . . . . 102
152 Front direction indicator lamp . . . . . . . . 98
153 Front fog lamp . . . . . . . . . . . . . . . . . . . . 99
152 Front side lamp . . . . . . . . . . . . . . . . . . . 98
207 Halogen headlamps - high or low beam . 96
191 Headlamp unit . . . . . . . . . . . . . . . . . . . . 96
Map lamp . . . . . . . . . . . . . . . . . . . . . . . 103
302 Number plate lamp. . . . . . . . . . . . . . . . 100
301 Rear direction indicator lamp . . . . . . . . . 94
301 Rear fog lamp. . . . . . . . . . . . . . . . . . . . . 94
304 Reversing lamp . . . . . . . . . . . . . . . . . . . 94
305 Side repeater lamp . . . . . . . . . . . . . . . . 101
299 Static bending lamp . . . . . . . . . . . . . . . . 97
300 Stepwell lamp. . . . . . . . . . . . . . . . . . . . 101
299 Stop/tail lamp . . . . . . . . . . . . . . . . . . . . . 94
307 Tail lamp. . . . . . . . . . . . . . . . . . . . . . . . . 94
304 Tailgate lamp . . . . . . . . . . . . . . . . . . . . 102
303 Vanity mirror lamp . . . . . . . . . . . . . . . . 103
306 Xenon headlamps. . . . . . . . . . . . . . . . . . 97
305 Xenon lamp units . . . . . . . . . . . . . . . . . . 95
306 Changing a fuse . . . . . . . . . . . . . . . . . . . . 255
304 Changing a road wheel . . . . . . . . . . . . . . . 231
135 Changing a wheel . . . . . . . . . . . . . . . . . 240
135 Raising the vehicle (Air suspension) . . 235
135 Raising the vehicle (Coil suspension). . 237
Spare wheel . . . . . . . . . . . . . . . . . . . . . 233
Stowing the changed wheel . . . . . . . . . 241
Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . 231
Using wheel chocks . . . . . . . . . . . . . . . 235
Wheel changing safety . . . . . . . . . . . . . 232
Changing the vehicle battery. . . . . . . . . . . 229
Battery disposal . . . . . . . . . . . . . . . . . . 229
Removal . . . . . . . . . . . . . . . . . . . . . . . . 229
Replacement . . . . . . . . . . . . . . . . . . . . 229
Charging the vehicle battery . . . . . . . . . . . 228
Battery warning indicator . . . . . . . . . . . 229
Disconnecting the battery. . . . . . . . . . . 228
Effects of battery disconnection . . . . . . 228
Reconnecting the battery . . . . . . . . . . . 228
Checking the wiper blades . . . . . . . . . . . . 108
Child safety locks . . . . . . . . . . . . . . . . . . . . 82
322

Index
Child seats. . . . . . . . . . . . . . . . . . . . . . . . . 76
Checklist . . . . . . . . . . . . . . . . . . . . . . . . 77
ISOFIX. . . . . . . . . . . . . . . . . . . . . . . . . . 80
Positioning . . . . . . . . . . . . . . . . . . . . . . 78
Recommended restraints . . . . . . . . . . . 78
Seat belt automatic locking mechanism 77
Cigar lighter. . . . . . . . . . . . . . . . . . . . . . . 132
Cleaning the exterior . . . . . . . . . . . . . . . . 207
Cleaning after off-road driving . . . . . . 207
Glass and mirrors . . . . . . . . . . . . . . . . 208
Polishing. . . . . . . . . . . . . . . . . . . . . . . 208
Removing tar spots. . . . . . . . . . . . . . . 207
Underbody maintenance . . . . . . . . . . . 208
Washing the vehicle . . . . . . . . . . . . . . 207
Cleaning the interior . . . . . . . . . . . . . . . . 208
Airbag module covers . . . . . . . . . . . . . 209
Carpet and fabrics. . . . . . . . . . . . . . . . 208
Instrument pack, clock and radio . . . . 209
Leather . . . . . . . . . . . . . . . . . . . . . . . . 208
Plastic and cloth . . . . . . . . . . . . . . . . . 208
Seat belts . . . . . . . . . . . . . . . . . . . . . . 209
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Premium audio . . . . . . . . . . . . . . . . . . 131
Standard audio . . . . . . . . . . . . . . . . . . 130
Coded keys . . . . . . . . . . . . . . . . . . . . . . . . 50
Cool box . . . . . . . . . . . . . . . . . . . . . . . . . 136
Coolant check . . . . . . . . . . . . . . . . . . . . . 220
Cruise control . . . . . . . . . . . . . . . . . . . . . 164
Increasing the cruising speed . . . . . . . 165
Operating . . . . . . . . . . . . . . . . . . . . . . 164
Principle of operation . . . . . . . . . . . . . 164
Reducing the cruising speed. . . . . . . . 165
Cup holders . . . . . . . . . . . . . . . . . . . . . . . 134
D F
Data recording. . . . . . . . . . . . . . . . . . . . . . 41
Event data . . . . . . . . . . . . . . . . . . . . . . . 41
Service . . . . . . . . . . . . . . . . . . . . . . . . . 41
Detachable tow ball . . . . . . . . . . . . . . . . . 200
Fitting the tow ball . . . . . . . . . . . . . . . 202
Removing the tow ball . . . . . . . . . . . . 203
Dimensions
Air suspension vehicles . . . . . . . . . . . 270
Coil spring suspension vehicles . . . . . 272
Direction indicators . . . . . . . . . . . . . . . . . . 91
323
R
E
Economical driving . . . . . . . . . . . . . . . . . . 163
Electric exterior mirrors . . . . . . . . . . . . . . 112
Folding the mirror body . . . . . . . . . . . . 112
Mirror glass adjustment . . . . . . . . . . . . 112
Reverse mirror dipping . . . . . . . . . . . . 113
Electric parking brake (EPB) . . . . . . . . . . . 155
Applying the electric parking brake . . . 155
Dynamic operation . . . . . . . . . . . . . . . . 155
Messages . . . . . . . . . . . . . . . . . . . . . . . 158
Releasing the electric parking brake. . . 156
Electric sunroof . . . . . . . . . . . . . . . . . . . . 127
Anti-trap mechanism . . . . . . . . . . . . . . 128
Calibration . . . . . . . . . . . . . . . . . . . . . . 128
Electric windows. . . . . . . . . . . . . . . . . . . . 110
Anti-trap mechanism . . . . . . . . . . . . . . 110
One touch operation. . . . . . . . . . . . . . . 110
Operating . . . . . . . . . . . . . . . . . . . . . . . 110
Rear window isolation switch. . . . . . . . 111
Rear window operation . . . . . . . . . . . . 111
Engine compartment overview . . . . . . . . . 213
Engine coolant check . . . . . . . . . . . . . . . . 220
Checking the coolant level . . . . . . . . . . 220
Topping up the coolant . . . . . . . . . . . . 221
Engine immobiliser
Coded keys. . . . . . . . . . . . . . . . . . . . . . . 50
Principle of operation . . . . . . . . . . . . . . . 50
Engine oil check . . . . . . . . . . . . . . . . . . . . 219
Checking the oil level . . . . . . . . . . . . . . 219
Engine oil specification. . . . . . . . . . 39, 220
Topping up the oil . . . . . . . . . . . . . . . . 220
Essential towing checks . . . . . . . . . . . . . . 199
Event data recording. . . . . . . . . . . . . . . . . . 41
Filling station information . . . . . . . . . . . . . . 38
Fog lamps
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
L

Fuel
Consumption . . . . . . . . . . . . . . . . . . .
Cut-off system . . . . . . . . . . . . . . . . . .
Filler flap . . . . . . . . . . . . . . . . . . . . . . .
Filling . . . . . . . . . . . . . . . . . . . . . . . . .
Quality. . . . . . . . . . . . . . . . . . . . . . . . .
Running dry . . . . . . . . . . . . . . . . . . . .
Safety precautions . . . . . . . . . . . . . . .
Specification - diesel engines . . . . . . .
Specification - petrol engines . . . . . . .
Fuel burning heater . . . . . . . . . . . . . . . . .
Fuse box locations. . . . . . . . . . . . . . . . . .
Engine compartment fuse box . . . . . .
Passenger compartment fuse box. . . .
Tow hitch fuse box . . . . . . . . . . . . . . .
Fuse specification chart . . . . . . . . . . . . . .
Engine compartment fuse box . . . . . .
Passenger compartment fuse box. . . .
Tow hitch fuse box . . . . . . . . . . . . . . .
G Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Gear changing . . . . . . . . . . . . . . . . . . . . .
Gear selector display . . . . . . . . . . . . . . . .
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . .
General driving points . . . . . . . . . . . . . . .
Breakdown safety . . . . . . . . . . . . . . . .
Servicing requirements . . . . . . . . . . . .
Vehicle stability . . . . . . . . . . . . . . . . . .
Wading . . . . . . . . . . . . . . . . . . . . . . . .
H
Hazard warning flashers . . . . . . . . . . . . . .
Head restraints . . . . . . . . . . . . . . . . . . . . .
Front head restraints . . . . . . . . . . . . . . .
Rear head restraints . . . . . . . . . . . . . . .
Headlamp
Bi-Xenon . . . . . . . . . . . . . . . . . . . . . . . .
Index
Headlamps
192 Adaptive front lighting system (AFS) . . . 89
191 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . 88
189 Automatic control lamps . . . . . . . . . . . . 87
190 Bulb replacement . . . . . . . . . . . . . . . . . . 96
186 Cornering lamps. . . . . . . . . . . . . . . . . . . 90
188 Courtesy delay . . . . . . . . . . . . . . . . . . . . 86
186 Halogen . . . . . . . . . . . . . . . . . . . . . . . . . 85
188 High beam . . . . . . . . . . . . . . . . . . . . . . . 86
186 Levelling. . . . . . . . . . . . . . . . . . . . . . . . . 88
127 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . 94
254 Removing. . . . . . . . . . . . . . . . . . . . . . . . 93
254 washers . . . . . . . . . . . . . . . . . . . . . . . . 108
255 Headphones . . . . . . . . . . . . . . . . . . . . . . . 309
255 Heated seats . . . . . . . . . . . . . . . . . . . . . . . . 65
257 Heated windows and mirrors . . . . . . . . . . 126
257 Exterior mirrors . . . . . . . . . . . . . . . . . . 126
259 Heated rear screen . . . . . . . . . . . . . . . . 126
262 Heated windscreen . . . . . . . . . . . . . . . . 126
198 Hill Descent Control (HDC)
118 Fade out . . . . . . . . . . . . . . . . . . . . . . . . 170
142 Messages . . . . . . . . . . . . . . . . . . . . . . . 171
161 Operating . . . . . . . . . . . . . . . . . . . . . . . 169
161 Principle of operation . . . . . . . . . . . . . . 169
162 System fault . . . . . . . . . . . . . . . . . . . . . 170
162 Warning indicator. . . . . . . . . . . . . 169, 170
162 Hints on driving with ABS
Cornering Brake Control (CBC). . . . . . . 154
Off-road driving . . . . . . . . . . . . . . . . . . 154
89
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
58
58 I
58 Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . 50
Information labels. . . . . . . . . . . . . . . . . . . . 40
85 Information messages . . . . . . . . . . . . . . . 117
Critical . . . . . . . . . . . . . . . . . . . . . . . . . 117
Gear selector display . . . . . . . . . . . . . . 118
Information . . . . . . . . . . . . . . . . . . . . . 117
Languages . . . . . . . . . . . . . . . . . . . . . . 117
Warnings . . . . . . . . . . . . . . . . . . . . . . . 117
Instrument lighting dimmer . . . . . . . . . . . 129

324

Instrument panel overview . . . . . . . . . . . . 22
Fuel gauge. . . . . . . . . . . . . . . . . . . . . . . 23
Selected gear display . . . . . . . . . . . . . . 23
Tachometer. . . . . . . . . . . . . . . . . . . . . . 23
Temperature gauge . . . . . . . . . . . . . . . . 23
Total distance (odometer). . . . . . . . . . . 23
Trip recorder . . . . . . . . . . . . . . . . . . . . . 23
Trip recorder reset switch . . . . . . . . . . . 23
Interior lamps . . . . . . . . . . . . . . . . . . . . . . 92
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Glovebox. . . . . . . . . . . . . . . . . . . . . . . . 92
Low-level illumination . . . . . . . . . . . . . . 92
Map lamps . . . . . . . . . . . . . . . . . . . . . . 92
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Vanity mirror. . . . . . . . . . . . . . . . . . . . . 92
Interior mirror
Automatic dimming mirror . . . . . . . . . 114
Manual mirror . . . . . . . . . . . . . . . . . . . 114
Interior space protection . . . . . . . . . . . . . . 52
ISOFIX anchor points . . . . . . . . . . . . . . . . 80
J Lighting
Jacking point locations
Air suspension . . . . . . . . . . . . . . . . . . 236
Coil suspension. . . . . . . . . . . . . . . . . . 238
Jump starting . . . . . . . . . . . . . . . . . . . . . 226
K
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency locking and unlocking. . . . .
Keys and remote controls
Information on radio frequencies . . . . .
Principle of operation . . . . . . . . . . . . . .
Remote control battery . . . . . . . . . . . . .
L Speed-related locking. . . . . . . . . . . . . . . 48
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
R
Index
Lamps
Adaptive front lighting system (AFS) . . . 89
Adjusting the headlamps . . . . . . . . . . . . 88
Automatic control lamps . . . . . . . . . . . . 87
Bi-Xenon headlamps . . . . . . . . . . . . . . . 85
Cornering lamps. . . . . . . . . . . . . . . . . . . 90
Daytime running lamps . . . . . . . . . . . . . 85
Direction indicators . . . . . . . . . . . . . . . . 91
Front fog lamps . . . . . . . . . . . . . . . . . . . 87
Halogen headlamps . . . . . . . . . . . . . . . . 85
Hazard warning . . . . . . . . . . . . . . . . . . . 89
Headlamp courtesy delay . . . . . . . . . . . . 86
Headlamp levelling . . . . . . . . . . . . . . . . . 88
High beam headlamps . . . . . . . . . . . . . . 86
Interior lamps. . . . . . . . . . . . . . . . . . . . . 92
Low beam headlamps . . . . . . . . . . . . . . 86
Rear fog lamps. . . . . . . . . . . . . . . . . . . . 87
Reversing lamps . . . . . . . . . . . . . . . . . . 85
Side lamps . . . . . . . . . . . . . . . . . . . . . . . 86
Stop lamps. . . . . . . . . . . . . . . . . . . . . . . 85
General information . . . . . . . . . . . . . . . . 85
Master switch. . . . . . . . . . . . . . . . . . . . . 86
Load carrying
General information . . . . . . . . . . . . . . . 193
Locking and unlocking . . . . . . . . . . . . . . . . 47
Automatic re-lock. . . . . . . . . . . . . . . . . . 48
45
Automatic unlocking . . . . . . . . . . . . . . . 48
45
Interior door handles . . . . . . . . . . . . . . . 48
Locking with the remote control. . . . . . . 47
44
Master lock and unlock switches . . . . . . 48
44
Opening the tailgate . . . . . . . . . . . . . . . . 49
44
Partial locking . . . . . . . . . . . . . . . . . . . . 48
Superlocking . . . . . . . . . . . . . . . . . . . . . 47
Luggage anchor points . . . . . . . . . . . . . . . 193
Luggage covers . . . . . . . . . . . . . . . . . . . . 194
5-seat vehicle . . . . . . . . . . . . . . . . . . . . 195
7-seat vehicle . . . . . . . . . . . . . . . . . . . . 195
Operating the luggage cover . . . . . . . . 194
M
Maintenance
General information . . . . . . . . . . . . . . . 210
325
L
Manual climate control . . . . . . . . . . . . . . 121
General notes . . . . . . . . . . . . . . . . . . . 122
Operation of controls . . . . . . . . . . . . . 121
Manual transmission . . . . . . . . . . . . . . . . 142
Memory function
Recalling a stored seat position . . . . . 138
Setting a memory pre-set . . . . . . . . . . 138
Message centre . . . . . . . . . . . . . . . . . . . . 115
Messages . . . . . . . . . . . . . . . . . . . . . . . . 117
Airbags . . . . . . . . . . . . . . . . . . . . . . . . . 75
Automatic transmission . . . . . . . . . . . 147
Brake fluid. . . . . . . . . . . . . . . . . . . . . . 222
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 153
Electric parking brake (EPB) . . . . . . . . 158
Engine coolant . . . . . . . . . . . . . . . . . . 220
Hill Descent Control (HDC) . . . . . . . . . 171
Seat belts . . . . . . . . . . . . . . . . . . . . . . . 68
Stability control. . . . . . . . . . . . . . . . . . 167
Terrain Response . . . . . . . . . . . . . . . . 176
Transfer gearbox. . . . . . . . . . . . . . . . . 151
Tyre pressure monitoring system . . . . 252
Washer fluid . . . . . . . . . . . . . . . . . . . . 224
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . 110
MP3 file playback . . . . . . . . . . . . . . . . . . 307
O Rear passenger climate controls. . . . . . . . 126
Oil check . . . . . . . . . . . . . . . . . . . . . . . . .
Opening and closing the bonnet . . . . . . .
Closing the bonnet . . . . . . . . . . . . . . .
Opening the bonnet. . . . . . . . . . . . . . .
P Second-row seats - 5-seat vehicle . . . . . 59
Panic alarm . . . . . . . . . . . . . . . . . . . . . . . . 53
Parking aid
Manual operation . . . . . . . . . . . . . . . . 160
Principle of operation . . . . . . . . . . . . . 159
System fault . . . . . . . . . . . . . . . . . . . . 160
Towing . . . . . . . . . . . . . . . . . . . . . . . . 160
Parts and accessories . . . . . . . . . . . . . . . . 42
Power sockets . . . . . . . . . . . . . . . . . . . . . 133
Power steering fluid check . . . . . . . . . . . 223
Checking the fluid level . . . . . . . . . . . . 223
Topping up the fluid . . . . . . . . . . . . . . 224
Programme Type (PTY). . . . . . . . . . . . . . 297
Index
Programming the remote control . . . . . . . . 45
Air suspension control . . . . . . . . . . . . . . 46
Headlamp courtesy delay . . . . . . . . . . . . 46
Panic alarm . . . . . . . . . . . . . . . . . . . . . . 45
Single-point entry. . . . . . . . . . . . . . . . . . 46
Proximity mirror (Japan only). . . . . . . . . . 111
Q
Quick start . . . . . . . . . . . . . . . . . . . . . . . . . . 7
R
Radio controls
Premium audio unit . . . . . . . . . . . . . . . 285
Standard audio unit . . . . . . . . . . . . . . . 284
Radio Data System (RDS). . . . . . . . . . . . . 294
Radio reception. . . . . . . . . . . . . . . . . . . . . 283
Radio startion
Waveband button . . . . . . . . . . . . . . . . . 293
Radio station
Autostore . . . . . . . . . . . . . . . . . . . . . . . 293
Preset buttons . . . . . . . . . . . . . . . . . . . 292
Rear lamps
Bulb replacment . . . . . . . . . . . . . . . . . . . 94
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . 95
Removing. . . . . . . . . . . . . . . . . . . . . . . . 94
Rear loadspace hatches . . . . . . . . . . . . . . 193
219 Rear seat audio controls . . . . . . . . . . . . . . 308
212 Rear seat entertainment commands . . . . . 319
212 Rear seats. . . . . . . . . . . . . . . . . . . . . . . . . . 59
212 Second row seats - 7-seat vehicle . . . . . 60
Third-row seats . . . . . . . . . . . . . . . . . . . 63
Rear window wiper and washers . . . . . . . 107
Tailgate open disable . . . . . . . . . . . . . . 107
Washer. . . . . . . . . . . . . . . . . . . . . . . . . 107
Wiper - intermittent operation . . . . . . . 107
Recommended towing weights. . . . . . . . . 200
Reduced engine performance . . . . . . . . . . 163
Remote control battery . . . . . . . . . . . . . . . . 44
Remote control programming . . . . . . . . . . 45
Repairing minor paint damage . . . . . . . . . 209
Running-in . . . . . . . . . . . . . . . . . . . . . . . . 161
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
326

Index
Seat adjustment
Backrest adjustment . . . . . . . . . . . . 55, 57
Folding armrest. . . . . . . . . . . . . . . . . . . 56
Forward/backward adjustment . . . . 55, 57
Head restraints . . . . . . . . . . . . . . . . . . . 58
Height adjustment. . . . . . . . . . . . . . 56, 57
Lazy entry . . . . . . . . . . . . . . . . . . . . . . 138
Lumbar support adjustment . . . . . . . . . 56
Seat belt reminder . . . . . . . . . . . . . . . . . . . 68
Seat belts
Automatic locking mechanism . . . . . . . 77
Caring for . . . . . . . . . . . . . . . . . . . . . . . 67
During pregnancy . . . . . . . . . . . . . . . . . 69
Fastening . . . . . . . . . . . . . . . . . . . . . . . 68
Height adjustment. . . . . . . . . . . . . . . . . 69
Pre-tensioners . . . . . . . . . . . . . . . . . . . 67
Releasing . . . . . . . . . . . . . . . . . . . . . . . 68
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Testing . . . . . . . . . . . . . . . . . . . . . . . . . 67
Seats
Electric adjustment . . . . . . . . . . . . . . . . 57
Heated seats . . . . . . . . . . . . . . . . . . . . . 65
Manual adustment . . . . . . . . . . . . . . . . 55
Seat memory facility . . . . . . . . . . . . . . 138
Sitting in the correct position . . . . . . . . 54
Service data recording. . . . . . . . . . . . . . . . 41
Service interval indicator . . . . . . . . . . . . . 117
Snow chains . . . . . . . . . . . . . . . . . . . . . . 248
Sound settings
Balance . . . . . . . . . . . . . . . . . . . . . . . . 292
Bass response adjustment . . . . . . . . . 289
Fader. . . . . . . . . . . . . . . . . . . . . . . . . . 292
Logic 7 . . . . . . . . . . . . . . . . . . . . . . . . 290
Resetting tone values . . . . . . . . . . . . . 291
Source tone memory . . . . . . . . . . . . . 291
Subwoofer . . . . . . . . . . . . . . . . . . . . . 290
Treble response adjustment . . . . . . . . 289
Speed control . . . . . . . . . . . . . . . . . . . . . 164
Stability Control
Warning indicator . . . . . . . . . . . . . . . . 166
Stability control
Messages . . . . . . . . . . . . . . . . . . . . . . 167
Principle of operation . . . . . . . . . . . . . 166
Using stability control . . . . . . . . . . . . . 166
Starter switch . . . . . . . . . . . . . . . . . . . . . 139
327
R
Starting a diesel engine . . . . . . . . . . . . . . 141
After starting . . . . . . . . . . . . . . . . . . . . 141
Cold climates . . . . . . . . . . . . . . . . . . . . 141
Driving . . . . . . . . . . . . . . . . . . . . . . . . . 141
General information . . . . . . . . . . . . . . . 139
Warming-up . . . . . . . . . . . . . . . . . . . . . 141
Starting a petrol engine . . . . . . . . . . . . . . 140
After starting . . . . . . . . . . . . . . . . . . . . 140
Cold climates . . . . . . . . . . . . . . . . . . . . 140
Driving . . . . . . . . . . . . . . . . . . . . . . . . . 140
General information . . . . . . . . . . . . . . . 139
Warming-up . . . . . . . . . . . . . . . . . . . . . 140
Steering wheel
Adjustment. . . . . . . . . . . . . . . . . . . . . . . 83
Audio controls . . . . . . . . . . . . . . . . . . . . 83
Cruise control switches . . . . . . . . . . . . . 84
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Voice control switch. . . . . . . . . . . . . . . . 84
Storage compartments . . . . . . . . . . . . . . . 137
Sun blinds . . . . . . . . . . . . . . . . . . . . . . . . 129
Sun visors . . . . . . . . . . . . . . . . . . . . . . . . 129
Sunroof. . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Superlocking. . . . . . . . . . . . . . . . . . . . . . . . 47
T
Technical specifications . . . . . . . . . . . . . . 268
Dimensions . . . . . . . . . . . . . . . . . 270, 272
V6 Diesel . . . . . . . . . . . . . . . . . . . . . . . 268
V6 Petrol . . . . . . . . . . . . . . . . . . . . . . . 268
V8 Petrol . . . . . . . . . . . . . . . . . . . . . . . 268
Weights . . . . . . . . . . . . . . . . . . . . . . . . 269
Temporary spare wheel . . . . . . . . . . . . . . 240
Terrain Response
Driver override options. . . . . . . . . . . . . 174
Messages . . . . . . . . . . . . . . . . . . . . . . . 176
Operating . . . . . . . . . . . . . . . . . . . . . . . 172
Principle of operation . . . . . . . . . . . . . . 172
Special programs . . . . . . . . . . . . . . . . . 172
Wading. . . . . . . . . . . . . . . . . . . . . . . . . 174
Tilt sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tone settings
Bass . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Resetting tone values . . . . . . . . . . . . . . 291
Source tone memory . . . . . . . . . . . . . . 291
Treble . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Tow ball stowage . . . . . . . . . . . . . . . . . . . 200
L

Index
Towing a trailer . . . . . . . . . . . . . . . . . . . . 197 Tyre glossary . . . . . . . . . . . . . . . . . . . . . . 253
Fixed - tow ball . . . . . . . . . . . . . . . . . . 204 Terms used . . . . . . . . . . . . . . . . . . . . . 253
Multi-height drop plate - tow bar . . . . 205 Tyre pressure monitoring system . . . . . . . 248
Nose weight . . . . . . . . . . . . . . . . . . . . 198 Messages . . . . . . . . . . . . . . . . . . . . . . . 252
Points to remember . . . . . . . . . . . . . . 197 Vehicle loading . . . . . . . . . . . . . . . . . . . 250
Trailer socket . . . . . . . . . . . . . . . . . . . 198 Warning indicator. . . . . . . . . . . . . . . . . 249
Vehicle weights . . . . . . . . . . . . . . . . . . 198 Tyre pressures . . . . . . . . . . . . . . . . . . . . . 243
Towing points . . . . . . . . . . . . . . . . . . . . . 263 Tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Front towing point. . . . . . . . . . . . . . . . 263 TPM system . . . . . . . . . . . . . . . . . . . . . 248
Rear towing point . . . . . . . . . . . . . . . . 264 U
Towing the vehicle on four wheels . . . . . 265 Under bonnet covers . . . . . . . . . . . . . . . . 219
Towing weights - Australia only . . . . . . . 198 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Traction control Removal . . . . . . . . . . . . . . . . . . . . . . . . 219
Principle of operation . . . . . . . . . . . . . 168 Using booster cables . . . . . . . . . . . . . . . . 226
Traffic information (TA) . . . . . . . . . . . . . . 295 Boosting from another vehicle . . . . . . . 226
Traffic information (TA) control Boosting procedure . . . . . . . . . . . . . . . 227
Selecting news information. . . . . . . . . 296 Using cruise control
Transfer gearbox . . . . . . . . . . . . . . . . . . . 148 To operate . . . . . . . . . . . . . . . . . . . . . . 164
HIGH range (Hi) . . . . . . . . . . . . . . . . . 148 Using snow chains . . . . . . . . . . . . . . . . . . 248
LOW range (Lo) . . . . . . . . . . . . . . . . . 148 Using terrain response
Messages . . . . . . . . . . . . . . . . . . . . . . 151 Rock Crawl . . . . . . . . . . . . . . . . . . . . . . 174
Range changing . . . . . . . . . . . . . . . . . 148
V
Range changing on the move . . . . . . . 149
Vehicle identification number (VIN) . . . . . 267
Stationary range changing . . . . . . . . . 149
Vehicle recovery
Warning indicator . . . . . . . . . . . . . . . . 148
Lashing points . . . . . . . . . . . . . . . . . . . 264
Warning indicators and messages . . . 150
Vehicle security. . . . . . . . . . . . . . . . . . . . . . 51
Transporting the vehicle . . . . . . . . . . . . . 265
Vehicle weights. . . . . . . . . . . . . . . . . . . . . 269
Trip computer . . . . . . . . . . . . . . . . . . . . . 115
Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . 119
Personalised settings . . . . . . . . . . . . . 116
Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Type approvals . . . . . . . . . . . . . . . . . . . . 274
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Tyre care . . . . . . . . . . . . . . . . . . . . . . . . . 242
Voice recognition
Age degradation . . . . . . . . . . . . . . . . . 245
Activating the system . . . . . . . . . . . . . . 312
Checking tyre pressures . . . . . . . . . . . 243
Audio system commands. . . . . . . . . . . 314
Directional tyres . . . . . . . . . . . . . . . . . 247
CD commands . . . . . . . . . . . . . . . . . . . 318
Flat spots . . . . . . . . . . . . . . . . . . . . . . 246
Defined commands . . . . . . . . . . . . . . . 313
High performance wheel and tyre
important information . . . . . . . . . . . . . 312
combinations . . . . . . . . . . . . . . . . . 246
Making yourself understood. . . . . . . . . 312
Pressure compensation for ambient
Notepad facility. . . . . . . . . . . . . . . . . . . 320
temperature changes . . . . . . . . . . . 247
Principle of operation . . . . . . . . . . . . . . 312
Punctured tyres. . . . . . . . . . . . . . . . . . 245
Using the system . . . . . . . . . . . . . . . . . 312
Replacement tyres . . . . . . . . . . . . . . . 245
Tyre pressures . . . . . . . . . . . . . . . . . . 242
Tyre wear . . . . . . . . . . . . . . . . . . . . . . 244
Valves . . . . . . . . . . . . . . . . . . . . . . . . . 244

328
 R

Index
Volume control Washers . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Audio unit . . . . . . . . . . . . . . . . . . . . . . 286 Rear screen . . . . . . . . . . . . . . . . . . . . . 107
Automatic Volume control (AVC) . . . . 287 Windscreen . . . . . . . . . . . . . . . . . . . . . 106
Information volume offset. . . . . . . . . . 287 Washing . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Navigation volume offset . . . . . . . . . . 288 Weights
Phone volume . . . . . . . . . . . . . . . . . . . 288 Axle loads. . . . . . . . . . . . . . . . . . . . . . . 269
Reset volume settings. . . . . . . . . . . . . 289 Gross . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Voice volume . . . . . . . . . . . . . . . . . . . 288 Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 269
W Wheels and tyres
Wading . . . . . . . . . . . . . . . . . . . . . . . . . . 162 General information . . . . . . . . . . . . . . . 230
Warning indicators Windows. . . . . . . . . . . . . . . . . . . . . . . . . . 110
Adaptive front lighting system (AFS) . . 89 Windscreen washers . . . . . . . . . . . . . . . . 105
Air suspension . . . . . . . . . . . . . . . . . . 180 Jet adjustment . . . . . . . . . . . . . . . . . . . 108
Airbags . . . . . . . . . . . . . . . . . . . . . . . . . 75 Operation . . . . . . . . . . . . . . . . . . . . . . . 106
Anti-lock Braking System (ABS) . . . . . 154 Windscreen wipers . . . . . . . . . . . . . . . . . . 105
Battery charging . . . . . . . . . . . . . . . . . 161 Intermittent variable delay . . . . . . . . . . 105
Brake fluid. . . . . . . . . . . . . . . . . . . . . . 222 Rain sensor . . . . . . . . . . . . . . . . . . . . . 106
Brake system . . . . . . . . . . . . . . . . . . . 152 Single wipe. . . . . . . . . . . . . . . . . . . . . . 105
Check engine. . . . . . . . . . . . . . . . . . . . 163 Speed dependent intermittent mode . . 106
Direction indicators. . . . . . . . . . . . . . . . 91 Speed dependent mode . . . . . . . . . . . . 105
Door open . . . . . . . . . . . . . . . . . . . . . . . 49 Wiper blade replacement
Dynamic Stability Control (DSC) . . . . . 166 Front. . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Electric Parking Brake (EPB) . . . . . . . . 157 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Engine Management System (EMS) . . 163
Front fog lamps. . . . . . . . . . . . . . . . . . . 87
Glow plugs . . . . . . . . . . . . . . . . . . . . . 141
Headlamp high beam . . . . . . . . . . . . . . 86
Hill Descent Control (HDC) . . . . . 169, 170
Low coolant . . . . . . . . . . . . . . . . . . . . 220
Low gear range . . . . . . . . . . . . . . . . . . 148
Low oil pressure . . . . . . . . . . . . . . . . . 161
Overspeed. . . . . . . . . . . . . . . . . . . . . . 161
Rear fog lamps . . . . . . . . . . . . . . . . . . . 87
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 68
Side lamps . . . . . . . . . . . . . . . . . . . . . . 86
Traction control. . . . . . . . . . . . . . . . . . 168
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 197
Transmission . . . . . . . . . . . . . . . . . . . 146
Transmission temperature . . . . . . . . . 146
Tyre Pressure Monitoring system . . . . 249
Washer fluid . . . . . . . . . . . . . . . . . . . . 224
Warning labels. . . . . . . . . . . . . . . . . . . . . . 40
Washer fluid check . . . . . . . . . . . . . . . . . 224

329
 Workshop Manual - Discovery 3 (L319) 2005-2009MY

Published: 11-May-2011
General Information - About This Manual
Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective
is to use common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with
tested and effective techniques. Following them will help to ensure reliability.

Important Safet Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles as well as the personal safety of the individual carrying out the work.

Anyone who departs from the instructions provided in this manual must first establish that personal safety or vehicle
integrity is not compromised by the choice of method, tools or components.

Warnings, Cautions and Notes in This Manual

WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal
injury.

C AUTION: C autions are used to indicate that failure to follow a procedure correctly may result in damage to the
vehicle or equipment being used.

NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory
repair.

Generic warnings or cautions are in their relevant description and operation procedure within section 100-00. If the
generic warnings or cautions are required for a procedure, there will be a referral to the appropriate description and
operation procedure.

If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.

Trustmark Authoring Standards (TAS) Removal and Installation Procedures

NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta color
of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed
when removing/disassembling or installing/assembling a component.

Many of the TAS procedures will have the installation information within the removal steps. These procedures will
have the following note at the beginning of the procedure:

NOTE: Removal steps in this procedure may contain installation details.

Items such as O-ring seals, gaskets, seals, self-locking nuts and bolts are to be discarded and new components
installed unless otherwise stated within the procedure. C oated nuts or bolts are to be reused, unless damaged or
otherwise stated within the procedure.

Specification procedures will contain all technical data that are not part of a repair procedure.

TAS Graphics

C olors used in the graphic are as follows:

Blue - Indicates the target item, item to be removed/installed or disassembled/assembled

Green and Brown - Indicates a secondary item that needs to be detached, removed/installed or
disassembled/assembled prior to the target item
Magenta - Indicates electrical connectors and fasteners such as nuts, bolts, clamps or clips
Pale Blue - is for the special tool(s) and general equipment.

There may be multiple steps assigned to one illustration.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps
or clips.

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I ( ).

TAS S

S .T
.

P .

H S
.

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Warning s mbols are used to indicate potential risks resulting from a certain component or area.

Instruction s mbols are used to appl sealer, lubricant, weight, tape or cleaning detergent to a component.

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Location s mbols are used to show the location of a component or s stem within the vehicle.

Gearshift lever or selector lever position s mbols are used to show which gearshift lever or selector lever position is
to be set.

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Pointer s mbols are used to draw the attention to components and give special instructions such as a required
sequence or number of components. The number of components is reflected b the value inside the lut arrow. A
sequence number is located inside the circle. Numbers inside circles are also used to allocate special information such
as tightening torques or chemicals to a particular component.

Movement arrows are used to show three dimensional or rotational movements. These movements can include
specific values inside the s mbol if required.

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Standard tool s mbols recommend the use of certain standard tools. These tools can include dimension values if
required.

The following graphic illustrates a set of s mbols that are used to provide detailed information on where to appl a
material.

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15.12.2011 TOPIx - WSM-4479 - Workshop Manual - Discovery 3 (L319) 2005-2009MY

Mea e e b ide de ai ed i f ai he e ca a ecific ea e e . The e b

ca i c de ecific a e if e i ed.

S ecia T a dT e Fig e( )

S ecia i be h i h he be i he i a i . The ecia be ( ), ge e a e i e ,

a e ia ( ) a d e fig e( ) ed f he ced e e i be h i he e c .

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15.12.2011 TOPIx - WSM-4479 - Workshop Manual - Discovery 3 (L319) 2005-2009MY

Published: 11 May 2011

How to use This Manual

This manual covers all aspects necessary in order to service the vehicle effectively.

The manual is structured into five main sections, General Information, C hassis, Powertrain, Electrical and Body and
Paint with each section dealing with a specific part of a vehicle system.

Each of the five main sections contain sub-sections dealing with items which form a part of that specific system.

Pages at the start of the manual list all sections available. Each section has a contents list detailing, where applicable,
Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair Procedures.

Where components need to be removed or disassembled in sequence, each operation in the sequence will be
identified numerically and also graphically in an accompanying illustration.

• NOTE: Dimensions quoted are to design engineering specifications with service limits quoted, where applicable.

Workshop Manual Organi ation

The five main sections, together with the areas which they cover are given below:

Section 1 - General Information.

Section 2 - C hassis.
Section 3 - Powertrain.
Section 4 - Electrical.
Section 5 - Body and Paint.

Sub-section numbers appear after the initial section number, for example, Section 412-03 covers air conditioning,
which is part of the electrical section.

In the number given above, the first digit of the number '4' indicates the section i.e. Electrical.

The second and third digits '12' of the number indicate the vehicle system i.e. Air Conditioning.

The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e. Air
Conditioning Compressor.

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Published: 11-Ma -2011

General Information - Important Safet Instructions
Description and Operation

Safet Notice

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles, as well as the safet of the person doing the work. This manual provides general directions for
accomplishing service and repair work with tested effective techniques. Following them will help assure reliabilit .

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill
of the person doing the work. This manual cannot possibl anticipate all such variations and provide advice or
cautions as to each. Accordingl , an one who departs from the instructions provided in the manual must first
establish that neither personal safet or vehicle integrit is compromised from choices of methods, tools or parts.

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Published: 11-Ma -2011

General Information - General Service Information
Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of Land Rover technicians worldwide and
to assist them in the efficient repair and maintenance of Land Rover vehicles.

This manual provides descriptions and methods for accomplishing adjustment, service and repair work using tested
and effective procedures. Following these procedures will help ensure product reliabilit .

Special Tools

The Special Tool(s) Table provided at the beginning of each procedure lists the special tool(s) required to carr out
repair operations within that specific procedure. Wherever possible, illustrations are provided which will assist
technicians in identif ing the special tool(s) required and also showing such tool(s) in use.

Special tools ma be obtained from the manufacturer, SPX Tools, the addresses of their branches will be found in the
Special Tools Glossar contained within this Section.

Important Safet Instructions

Appropriate service methods and correct repair procedures are essential for the safe and reliable operation of all
motor vehicles as well as ensuring the personal safet of the individual carr ing out the work.

This manual cannot possibl anticipate all such variations and provide advice or cautions as to each. An person who
departs from the instructions provided in this manual must first establish that the compromise neither their personal
safet nor the vehicle integrit b their choice of methods, tools or parts.

Individuals who undertake their own repairs should have some skill or training and limit repairs to components which
could not affect the safet of the vehicle or its passengers. An repairs required to safet critical items such as
steering, brakes, suspension or supplemental restraint s stem should be carried out b a Land Rover Dealer. Repairs
to such items should NEVER be attempted b untrained individuals.

Warnings, Cautions and Notes which appear in this manual

As ou read through this manual, ou will come across Warnings, C autions and Notes. A Warning, C aution or Note is
placed at the beginning of a series of steps. If the warning, caution or note onl applies to one step, it is placed at the
beginning of the specific step after the step number.

Warnings, Cautions and Notes have the following meanings:

Warning: Procedures which must be followed to avoid the possibilit of personal injur .

Caution: C alls attention to procedures which must be followed to avoid damage to components.

Note: Gives helpful information.

References

References to the Left Hand (LH) or Right Hand (RH) side given in this manual are made when viewing the vehicle or
unit from the rear.

Fault Diagnostic Equipment

The vehicle is equipped with a number of electronic control s stems to provide optimum performance of the vehicle's
s stems.

Diagnostic Equipment (T4) is available and must be used where specified. The use of this equipment will assist with
the fault diagnostic abilities of the Dealer workshop. In particular, the equipment can be used to interrogate the
electronic s stems for diagnosis of faults which ma become evident during the life of the vehicle.

This manual is produced as a reference source to supplement T4.

Features of the equipment include:

a. Full upgradeable support for the technician

b. Structured diagnostics to accommodate all skill levels

c. Direct print-out of screen information and test results

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Testing the ehicle

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 Replacement Parts

Land Rover parts are manufactured to the same exacting standards as the original factory fitted components. For this
reason, it is essential that only genuine Land Rover parts are used during maintenance or repair.

Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and
accessories.

Safety features and corrosion prevention treatments embodied in the vehicle may be impaired if other than Land
Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to
manufacturer's specification. Torque wrench setting figures, where given, must be adhered to and locking devices,
where specified must be used. If the efficiency of a locking device is impaired during removal it must be replaced.

Owners purchasing accessories whilst travelling abroad must ensure that the accessory and its fitted location on the
vehicle conform to legal requirements.

The terms of the vehicle warranty may be invalidated by the fitting of parts other than those recommended by Land
Rover.

NOTE: The fitting of non-approved Land Rover parts and accessories or the carrying out of non-approved alterations
or conversions may be dangerous. Any of the foregoing could affect the safety of the vehicle and occupants; also, the
terms and conditions of the vehicle warranty may also be invalidated .

All Land Rover recommended parts have the full backing of the vehicle warranty.

Land Rover Dealers are obliged to supply only Land Rover recommended parts.

Specifications

Land Rover are constantly seeking to improve the specification, design and production of their vehicles and
alterations take place accordingly. Whilst every effort is made to ensure the accuracy of this Manual, it should not be
regarded as an infallible guide to current specifications of any particular vehicle.

This Manual does not constitute an offer for sale of any particular vehicle. Land Rover dealers are not agents of Land
Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.

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Published: 11-May-2011
General Information - Standard Workshop Practices
Description and Operation

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle
moving forwards or backwards.
Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust
fumes.
There is adequate room to raise the vehicle and remove the wheels, if necessary.
Fender covers are always installed if any work is to be carried out in the engine compartment.
Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the
vehicle is raised.

Caution: Prior to disconnecting the batter , refer to the Electrical Section of this manual - Batter
disconnection/connection and the following paragraphs.For additional information, refer to:
Specifications (414-00 Battery and C harging System - General Information, Specifications).

C AUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the
possibility of a surge of current causing damage to the internal components of the generator.

If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Batter - General

WARNING: It is essential that a period of 2 minutes elapses after the batter is disconnected before
an work is undertaken on an part of the SRS s stem.

C AUTION: A discharged battery condition may have been caused by an electrical short circuit. If this condition
exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can
cause arcing when the jumper cables are connected.

Caution: Prior to carr ing out an procedures which involve disconnecting/ or connecting the
batter , refer to the Electrical Section of this manual - Batter disconnection/connection.For
additional information, refer to: Specifications (414-00 Battery and C harging System - General Information,
Specifications).

Jump Starting a Vehicle

C AUTIONS:

While it is not recommended that a vehicle is jump started, it is recognized that this may occasionally be the
only practical way to mobilize a vehicle. Reference should be made to the following and also to the Electrical Section
of this manual - Jump Starting.

It is advisable not to use starter/charger sets for jump starting but if this is unavoidable, make sure that the
sets are not used in the 'START' mode.

Always make sure that the jumper cables are adequate for the task.
Always make sure that the slave battery is of the same voltage (12 volts) as the vehicle battery. The batteries
must be connected in parallel.
Make sure that the battery terminals of both batteries are fully tightened.
Where another vehicle is used to jump start a disabled vehicle, make sure that the two vehicles are not
touching.
It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to make sure
that the battery of the donor vehicle does not also become discharged.
Always make sure that switchable electric circuits are OFF before connecting jump cables. This reduces the risk
of arcing occurring when the final connection is made.

Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged
as soon as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in
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.

T ( <16 ) .M
.

C AUTION: B .

To ing he Vehicle

WARNING: W , J ,L T S
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Componen emo al

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Bearing journal clearances should be checked where necessary using Plastigage.
Gaskets, seals and O-ring seals are to be re-used unless damaged.

Joints and Joint Faces

All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install
O-rings using the fingers only.

Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.

C AUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.

Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together with
its part number will be found listed in the relevant repair operation and also in the sealants table.

C AUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified
solvents where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may damage the
sealing surfaces. Make sure that sealing surfaces are free from oil or grease as sealants will not adhere properly to
contaminated surfaces.

Do not allow sealant to enter tapped holes or oilways.

Locking Devices

Always replace locking devices with one of the same design and of the correct size.

Tab washers

Always release locking tabs before loosening fixings, do not re-use tab washers.

Locknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always install new roll pins of the correct size.

Circlips

Always install new circlips ensuring that they are of the correct size for the groove.

Woodruff ke s

Woodruff keys may be re-used provided there is no indication of wear or distortion.

Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and re-use a split pin, always make sure that replacement pins are of the correct size for
the hole in which they are to be installed.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads
with a tap or die impairs the strength and fit of the threads and is not recommended.

NOTE: During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap.
Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of
the correct size and thread is used.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be re-used. New
bolts having the same part number as the original must always be installed. When nuts or bolts are to be
discarded, the repair operation and relevant torque chart will include an instruction to that effect. Do not use
proprietary thread locking agents as they may not meet the specification required. See also Encapsulated
('Patched') Bolts and Screws.
Always make sure that replacement nuts and bolts are at least equal in strength to those that they are
replacing. C astellated nuts must not be loosened to accept a split pin except in recommended cases when this
forms part of an adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud

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can split the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a
false torque reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of
components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is
given to tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly
where certain stages involve tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the
specified torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.

Where it is stated that bolts and screws may be re-used, the following procedures must be carried out:

C heck that threads are undamaged.

Remove all traces of locking agent from the threads.

C AUTION: DO NOT use a wire brush; take care that threads are not damaged.

Make sure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

Bolt and Nut Identification

An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the
symbols ISO M or M embossed or indented on top of the bolt head.

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the
strength grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade symbol
stamped on the flats of the hexagon.

Encapsulated ('Patched') bolts and scre s

Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during manufacture.
Most thread locking agents are colored, the band of color extending for 360 around the thread. Some locking agents
however, are neutral in color and may not be so easily identified apart from a slightly darker area of thread where
the locking agent has been applied. The locking agent is released and activated by the tightening process and is then
chemically cured to provide the locking action.
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Self-locking bolts and scre s

Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread can
be re-used provided that resistance is felt when the locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion. They are
identified by the presence of a colored section of thread extending approximately 180 around the thread or by a
colored plug inserted into the bolt.

Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut into
which it is screwed.

C AUTION: Do Not re-use self-locking fasteners in critical locations e.g. drive plates/flywheel or engine bearings.
Do not install non self-locking fasteners where a self-locking fastener is specified.

Trilobular bolts should not be used as a substitute for patched bolts.

Nut identification

A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol
8, 12, 14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the
hexagonal flat opposite the strength grade marking.

A clock face system is sometimes used as an alternative method of indicating the strength grade. The external
chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate
the strength grade.

A dot is used to locate the 12 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.

When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part of an
adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or nuts should
be selected.

Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.

Self-locking nuts

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Unle a ed o he i e, elf-locking n once emo ed m be di ca ded and ne n of he ame pe and
eng h g ade in alled.

Air S spension

Al a make e ha i able e e p o ec ion i o n hen o king on he ai pen ion em.

Ball and Roller Bearings

When emo ing and in alling bea ing , make e ha he follo ing p ac ice a e ob e ed o make e componen
e iceabili :

C AUTION: Se ice ool ha e been de eloped fo emo ing he majo i of bea ing ; he e m al a be
ed he e pecified.

Remo e all ace f om bea ing nde in pec ion b cleaning i h a i able deg ea an ; main ain ab ol e
cleanline h o gho ope a ion .
C ond c a i al in pec ion fo ma king on olling elemen , ace a , o e face of o e o inne
face of inne ing . Rejec an bea ing fo nd o be ma ked ince ma king in he e a ea indica e on e
of ea .
Hold inne ace of bea ing be een finge and h mb of one hand and o a e o e ace o check ha i
e ol e ab ol el moo hl . Repea holding o e ace and o a ing inne ace. DO NOT pin he bea ing.
Ro a e o e ing gen l ing a ecip oca ing mo emen hil holding inne ing; feel fo an check o
ob c ion o o a ion. Rejec bea ing if mo emen i no ab ol el moo h.
C heck bea ing fo bl eing o ign of o e hea ing.
L b ica e bea ing i h he pecified l b ican .
In pec bea ing face of haf and bea ing ho ing fo di colo a ion o o he ma king hich indica e
o e hea ing of bea ing o mo emen be een bea ing and ea ing.
Befo e in alling bea ing, make e ha haf and bea ing ho ing a e clean and f ee f om b .
If one bea ing of a pai ho ign of ea , o e hea ing e c., i i ad i able o eplace bea ing a a pai
nle i i pec ed ha one bea ing ma ha e been fa l hen in alled, a in alled inco ec l o he
fa l a o e d e o oil eal fail e.
Ne e ein all a bea ing nle i i in a f ll e iceable condi ion.

When in alling a bea ing o a haf , onl appl fo ce o he inne ing of he bea ing. When in alling a bea ing
in o a ho ing, onl appl fo ce o he o e ing of he bea ing.

C AUTION: Se ice ool ha e been de eloped fo in alling he majo i of bea ing ; he e m al a be ed

he e pecified.

In he ca e of g ea e l b ica ed bea ing , fill he pace be een he bea ing and o e eal i h he
ecommended g ade of g ea e befo e in alling he eal.

C AUTION: When a a ed oil eal (in alled d ) pe of oil eal i o be in alled, ake g ea ca e ha g ea e
doe no con amina e he nning face of he eal.

Al a make i able efe ence ma k be een he componen of epa able bea ing e.g. ape olle
bea ing hen di a embling o make e co ec loca ion of componen hen a embling. Ne e in all ne
olle in an o e ing, al a in all a ne bea ing a embl .

Brake Pads and Linings

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A .W ,
.

Brake H draulics

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WARNING: N ' - ' .T

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C ' - '
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M .I ,
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Electrical Precautions

General

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Polarit

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High voltage circuits

Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to
contact other components, particularly EC U's.

Vehicles installed with Bi-Xenon headlamp bulbs

WARNING: The following precautions must be observed as failure to comply may result in exposure to ultra-
violet rays, severe electric shock, burns or risk of an explosion.

Safety goggles and gloves must be worn.

Make sure that headlamps are switched off before removing bulbs.
Do not touch the glass portion of the bulb.
On no account should headlamps be switched on with the bulb removed from the headlamp.
Bulb testing may only be carried out with the bulb installed in the headlamp.
Bulbs must be disposed of in accordance with the local authority bye-laws.

Connectors and harnesses

The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors.
Always observe the following:

Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
Make sure that disconnected multiplugs and sensors are protected from any possible oil, coolant or other liquid
contamination. Any such contamination could impair performance or lead to component failure.
Never force connectors apart or pull on the wiring harness.
Always make sure locking tabs are disengaged before disconnecting multiplugs etc. and make sure that
correct orientation is achieved before connection.
Make sure that any protection covers, insulation etc. are replaced if disturbed.

Having confirmed that a component is faulty, carry out the following:

Switch off the ignition and disconnect the battery.

Remove the component and support the disconnected harness.
When replacing electrical components, keep oily hands away from electrical connections and make sure that
locking tabs on connectors are fully engaged.

Batter Disconnection/Connection

Always refer to the Electrical Section of this manual - Battery C onnection/Disconnection prior to attempting to connect
or disconnect the battery.
For additional information, refer to: Specifications (414-00 Battery and C harging System - General Information,
Specifications).

Fuel Handling Precautions

The following information lists basic precautions which must be observed if fuel is to be handled safely. It also outlines
other areas of risk which must not be ignored. As this information is issued for basic guidance only, consult your local
Fire Department where any doubt as to personal and environmental safety exists - See also Health and Safety
Precautions.

General precautions

Always have the correct type of fire extinguisher containing Foam, C O2, Gas or powder accessible when handling or
draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.

Make sure that suitable warning signs are exhibited.

Keep all sources of ignition well away from areas where fuel is being handled.

Make sure that any leadlamps are flameproof and kept clear of spillage.

WARNINGS:

Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.

No one should be permitted to repair components associated with fuel without first having specialist training.

Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel
system.

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Fuel tank and system draining

Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this
manual.

WARNINGS:

Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel must be
carried out in a well ventilated area.

Never switch on or operate mobile (cellular) phones in the vicinity of vehicles when operations are being carried
out on the fuel system.

Always attach fuel vapor warning labels to fuel tanks immediately after draining.

C ontainers used for storing fuel must be clearly marked with the contents and placed in a safe storage area
which meets the requirements of the local authority.

C AUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged, no
attempt must be made to repair the connector, a new fuel line and connector(s) assembly must be installed.

Always release pipe clips fully before attempting to disconnect fuel pipes.

F el ank epai

C AUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a
new tank must be installed.

Oil eal

Never use a seal which has been improperly stored or handled.

Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
C arefully examine seal before installing to make sure that it is clean and undamaged.
Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs or
scratches. Renew the component if the sealing surface cannot be restored.
Special tools and protection sleeves are provided for installing the majority of seals and must be used when
specified.
Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing. Always
check the relevant repair procedure which will state if a seal must be installed dry. Never touch these seals
with oily hands as the oil will contaminate the protective coating and affect the sealing properties of the seal;
also, make sure that installing tools and protection sleeves are free from oil and grease. Seals which must be
lubricated prior to installing should have the recommended lubricant applied to the areas specified in the repair
procedure.
Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards the
lubricant which it is sealing.
When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to be
installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported shaft
to rest on the seal.

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Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified, use
a suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use
adhesive tape on the shaft to protect the sealing lip of the seal.

Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the
housing where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.

S pplemen a Re ain S em (SRS) P eca ion

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The
following guidelines and precautions are intended to alert personnel to potential sources of danger and emphasise the
importance of ensuring the integrity of the SRS components installed to the vehicle.

WARNING: The following precautions MUST be adhered to when working on the SRS system:

The co ec p oced e m al a be ed hen o king on SRS componen .

Pe on o king on he SRS em m be f ll ained and ha e been i ed i h he afe
g ideline .
The ai bag mod le con ain e emel flammable and ha a do compo nd . Con ac i h a e ,
acid o hea me al ma p od ce ha mf l o e plo i e e l . Do no di man le, incine a e o
b ing in o con ac i h elec ici befo e he ni ha been deplo ed.
Al a eplace a ea bel a embl ha ha i h ood he ain of a e e e ehicle impac o if
he ebbing ho ign of f a ing.
Allo a pe iod of 2 min e o elap e af e di connec ing he ba e befo e nde aking an
o k on he SRS em.
Al a di connec he ehicle ba e befo e ca ing o an elec ic elding on a ehicle
in alled i h an SRS em.

C AUTION: Do not expose airbag modules or seat belt pre-tensioners to temperatures exceeding 85° C (185° F).

It should be noted that these precautions are not restricted to operations performed when servicing the SRS system.
The same care should be exercised when working on ancillary systems and components located in the vicinity of SRS
components; these include but are not limited to:

Steering wheel airbag, clock spring.

Passenger front airbag.
Head airbag modules - front and rear.
Seat belt pre-tensioners.
SRS harnesses, link leads and connectors.
Side curtain air bags.

Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the
following operations:

Remove the ignition key.

Disconnect the battery, earth lead first.
Wait 2 minutes for the SRS power circuit to discharge before commencing work.

NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure
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under crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in order to
avoid the risk of accidental deployment.

Installation

In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained so
that it is ready for effective operation in the event of a collision. C arefully inspect SRS components before installation.
Do not install a part that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.

WARNING: The integrity of the SRS systems is critical for safety reasons. Make sure the following precautions
are always adhered to:

Do not install accessories or other objects to trim panels which cover airbags.
Never install used SRS components from another vehicle or attempt to repair an SRS component.
When repairing an SRS system, only use genuine new parts.
Never apply electrical power to an SRS component unless instructed to do so as part of an
approved test procedure.
Special fixings are necessary for installing an airbag module do not use other fixings and make
sure that all fixings are tightened to the correct torque.
Always use new fixings when replacing an SRS component.

C AUTIONS:

Take care not to trap airbag modules when installing interior trim components.

Make sure SRS components are not contaminated by oil or grease.

NOTE: Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but
will need to be replaced as soon as possible to make sure full SRS protection.

NOTE: If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following :

WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only T4 to
diagnose system faults.

WARNING: Do not use electrical test equipment on the SRS harness while it is connected to any of the SRS
components, it may cause accidental deployment and injury.

Handling and storage

Always observe the following precautions when handling SRS components:

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Never drop an SRS component. The airbag diagnostic control unit is a particularly shock sensitive device and
must be handled with extreme care. Airbag modules and seat belt pre-tensioners could deploy if subjected to a
strong shock.
Never wrap your arms around an airbag module. If a module has to be carried, hold it by the cover with the
cover uppermost and the base away from your body.
Never transport airbag modules or seat belt pre-tensioners in the passenger compartment of a vehicle. Always
use the luggage compartment of the vehicle for carrying airbag modules and seat belt pre-tensioner units.
Never attach anything to an airbag cover or any trim component covering an airbag module. Do not allow
anything to rest on top of an airbag module.
Always keep components cool, dry and free from contamination.
Never apply grease or cleaning solvents to seat belt pre-tensioner units, component failure could result.
Always store an airbag module with the deployment side uppermost. If it is stored deployment side down,
accidental deployment will propel the airbag module with sufficient force to cause serious injury.
Keep new airbag modules in their original packaging until just prior to installing. Place the old module in the
empty packaging for carriage.

WARNINGS:

When handling any SRS component, hold by the gas generator housing, DO NOT hold by the airbag. Do not
wrap the thumb around the gas generator while holding. Do not drape airbag over shoulder or around neck. For seat
buckle type pre-tensioners, hold by the piston tube, with the open end of the piston tube pointing towards the ground
and the buckle facing away from your body. Do not cover the end of the piston tube. DO NOT hold buckle type pre-
tensioners by the bracket assembly or cable. Never point the piston tube towards your body or other people.

Airbag modules and seat belt pre-tensioners are classed as explosive devices. For overnight and longer term
storage, they must be stored in a secure steel cabinet which has been approved as suitable for the purpose and has
been registered with the local authority.

Store airbag modules or seat belt pre-tensioners in a designated storage area. If there is no designated storage
area available, store in the locked luggage compartment of the vehicle and inform the workshop supervisor.

C AUTION: Improper handling or storage can internally damage the airbag module making it inoperative. If you
suspect the airbag module has been damaged, install a new module and refer to the deployment/disposal procedures

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for disposal of the damaged module.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:

Never attempt to modify, splice or repair SRS wiring.

Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system in
such a way that it could generate electrical interference in the airbag harness. Seek specialist advice when
installing such equipment.

NOTE: SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe
protective coverings are sometimes used).

WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS
wiring.

WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses.
Look for possible chafing points.
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Impact crash sensors - inspection

After any degree of side or frontal body damage, inspect the impact crash sensors. Replace a crash sensor if there is
any sign of damage.

C AUTION: Take extra care when painting or carrying out bodywork repairs in the vicinity of the crash sensors.
Avoid direct exposure of the crash sensors or link harnesses to heat guns, welding or spraying equipment. Take care
not to damage sensor or harness when reinstalling components.

C lock spring

C AUTION: Always follow the procedure for installing and checking the clock spring as instructed in the SRS
repairs section. C omply with all safety and installation procedures to make sure the system functions correctly.
Observe the following precautions:

Do not unlock and rotate the clock spring when it is removed from the vehicle.
Do not turn the road wheels when the clock spring is removed from the vehicle.
Always make sure the clock spring is removed and installed in its central position and with the front road
wheels in the straight ahead position - refer to SRS repair section for the correct removal and installation
procedure.
If a new clock spring is being installed, make sure the locking tab holding the spring's rotational position is not
broken; units with a broken locking tab must not be used.

Ai bag and p e- en ione deplo men

WARNING: During deployment parts of the airbag module become hot enough to burn you. Wait 30 minutes
after deployment before touching the airbag module.

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who
have undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules. The
following precautions must be complied with:

Only use deployment equipment approved for the intended purpose.

Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been
designated for the purpose.
Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.
Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner
units.
When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet) away
from the deployment zone.
Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS
section of this manual. In particular, make sure deployment tool is NOT connected to battery supply before
connecting to airbag module connector.
When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
When removing deployed airbag modules and pre-tensioner units, wear protective clothing. Use gloves and
seal deployed units in a plastic bag.
Following deployment of any component of the SRS system within the vehicle, all SRS components must be
replaced. DO NOT re-use or salvage any parts of the SRS system.
Do not lean over an airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pre-tensioner units must be manually deployed. In this
case airbags can be deployed in the vehicle. Before deployment, make sure the airbag module is secure within its
correct mounting position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the
vehicle is not being scrapped, deploy the module outside of the vehicle.

SRS Componen Replacemen Polic

C AUTIONS:

The Restraints C ontrol Module (RC M) will log a crash fault after every impact which is severe enough to cause
airbag deployment. I i po ible o ha e h ee c a he /impac logged af e one e en he e, fo
e ample, a f on , ide and ollo e ha occ ed. Af e he hi d fa l i logged, he SRS a ning lamp
ill be ill mina ed and he e ain con ol mod le (RCM) m be eplaced.

The SRS side/front impact sensor(s) must be replaced if there are any signs of physical damage or if the
restraints control module (RC M) is registering a fault.

The following information details the policy for replacement of SRS components as a result of a vehicle accident.
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Impacts which do not deplo the airbags or pre-tensioners

C heck fo c al damage in he a ea of he impac pa ing pa ic la a en ion o b mpe a ma e , longi dinal

and b acke .

Impacts which deplo the airbags or pre-tensioners

The eplacemen and in pec ion polic i dependen on he pe and e e i of he c a h condi ion. The follo ing
g ideline a e he minim m ha ho ld be e e ci ed a a e l of he deplo men of pecific SRS componen .

Check for structural damage in the area of impact pa ing particular attention to bumper armatures,
longitudinals and bracketr .

Front Airbag Deplo ment - Driver and Passenger

C AUTION: If he f on ai bag a e deplo ed, he follo ing componen m be eplaced:

D i e ai bag mod le
Pa enge ai bag mod le
Fl lead ( he e applicable) connec ing f on ai bag mod le o SRS ha ne
F on ea bel b ckle p e- en ione
Rea ea bel p e- en ione - if in alled
D i e ' ea bel e ac o - if in alled
C lock p ing
An f on impac en o ha ha e been ph icall damaged o if a fa l i being egi e ed
Re ain con ol mod le (RC M) if he h ee c a he /impac ha e been o ed

Additionall , the following items must be inspected for damage and replaced as necessar :

F on pa enge ' ea bel e ac o and ebbing, ong e la ching f nc ion, 'D' loop and bod ancho age poin
Rea ea bel b ckle , ebbing, b ckle co e , bod ancho age poin and ong e la ching f nc ion
In men panel mo lding adjacen o pa enge ai bag mod le
S ee ing heel
F on ea f ame and head e ain
S ee ing col mn - if adj men i lo o if he e a e ign of collap e
Sea bel heigh adj e
Rea ea bel

Side Ai Bag

C AUTION: If he ide c ain ai bag a e deplo ed, he follo ing componen m be eplaced on he ide of
he ehicle on hich he deplo men occ ed:

Side c ain ai bag

An ide impac en o ha ha e been ph icall damaged o if a fa l i being egi e ed
Re ain C on ol Mod le (RC M) if he h ee c a he /impac ha e been o ed

Additionall , the following items must be inspected for damage and replaced as necessar :

F on ea bel , e ac o and ebbing, ong e la ching f nc ion, 'D' loop and bod ancho age poin
Rea ea bel b ckle , ebbing, b ckle co e , ong e la ching f nc ion, and bod ancho age poin
F on ea f ame and head e ain
Doo im ca ing
Sea bel heigh adj e
Rea ea bel

Head ai bag mod le

C AUTION: If he head ai bag mod le a e deplo ed, he follo ing componen m be eplaced on he ide of
he ehicle on hich he deplo men occ ed:

Head ai bag mod le

Link lead be een ai bag ga gene a o and e ain con ol mod le (RC M) ha ne
Ai bag e aining clip
In e nal im fini he
F on ea bel b ckle p e- en ione
An ide impac en o ha ha e been ph icall damaged o if a fa l i being egi e ed
Re ain C on ol Mod le (RC M) if he h ee c a he /impac ha e been o ed

Additionall , the following items must be inspected for damage and replaced as necessar :

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Headlining
C omponent mounting brackets
Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Adjacent trim components
Seat belt height adjusters

Rear impacts

C AUTION: If the seat belt pre-tensioners are deployed during a rear impact, the following components must be
replaced:

Seat belt pre-tensioners

Front and rear seat belt retractors used during the impact
Restraints C ontrol Module (RC M) if the three crashes/impacts have been stored

Additionall , the following items must be inspected for damage and replaced as necessar :

Seat belt height adjusters

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

(A/C) S stem Precautions

The A/C system contains fluids and components which could be potentially hazardous to the service engineer or the
environment if not serviced and handled correctly. The following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance of ensuring the integrity of the A/C operating conditions
and components installed to the vehicle.

Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the
Health and Safety Section. These precautions must be referred to prior to commencing repair operations.

The refrigerant used in the A/C system is HC -134a (Hydrofluorocarbon) R134a.

WARNINGS:

Servicing must only be carried out by personnel familiar with both the vehicle system and the charging and
testing equipment. All operations must be carried out in a well ventilated area away from open flame and heat
sources.

R134a is a hazardous liquid and when handled incorrectly can cause serious injury. Suitable protective clothing,
consisting of face protection, heat proof gloves, rubber boots and rubber apron or waterproof overalls, must be worn
when carrying out operations on the A/C system.

Remedial actions

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed on any
part of the body will cause immediate freezing of that area. Also, refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if contact is made.

If an accident involving R134a should occur, conduct the following remedial actions:

If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise
the temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing,
cover the eye with a clean pad and seek immediate medical attention.
If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the
temperature. Implement the same action if the skin comes in contact with discharging cylinders. Wrap the
contaminated body parts in blankets (or similar materials) and seek immediate medical attention.
If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or
oxygen and seek immediate medical attention.

Service precautions

Observe the following precautions when handling components used in the system:

A/C units must not be lifted by their hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by
kinks or restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make sure
that all clips and supports are utilised.
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Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected
by heat shielding.
C ompleted assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of
components and panels may transmit noise and so must be eliminated.
The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value.
An additional spanner must be used to hold the union to prevent twisting of the pipe when tightening
connections.
Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings,
B NO to the threads of the connection.
All protective plugs or caps must remain in place in the component until immediately prior to connection.
Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of
moisture from the air that enters it.
When disconnecting, immediately plug or cap all pipes to prevent ingress of dirt and moisture into the system.
C omponents must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 24
hours or longer, a new receiver/drier must be installed.
The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A
receiver/drier that has been left uncapped for longer than 24 hours must not be used; install a new unit.
The receiver/drier should be the last component connected to the system to make sure optimum dehydration
and maximum moisture protection of the system.
Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new
receiver/drier unit.
Use alcohol and a clean lint-free cloth to clean dirty connections.
Make sure that all new parts installed are marked for use with R134a.
When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this
manual for the correct procedure.

Refrigerant oil

C AUTION: Refrigerant oil (ND-8 PAG) easily absorbs water and must not be stored for long periods. Do not pour
unused refrigerant oil back into the container. Always use an approved refrigerant oil.

When replacing components in the system, drain the refrigerant oil from the component being replaced into a
graduated container. On assembly, add the quantity of refrigerant oil drained to the new component - See
C ompressor Replacement in this Section.

A/C C ompressor

A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release the
sealing cap; gas pressure should be heard to vent as the seal is broken.

C AUTION: A new compressor should always be sealed and could be pressurised with nitrogen gas. To avoid
possible oil loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to connecting the
pipes to the compressor.

Rapid refrigerant discharge

If the A/C system is damaged as a result of an accident and the system is punctured, the refrigerant will discharge
rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The
compressor must be removed and all the remaining oil in the compressor drained and refilled as instructed in the air
conditioning section of this manual.

Precautions for refrigerant recovery, recycling and recharging

When the A/C system is recharged, any existing refrigerant is first recovered from the system and recycled. The
system is then charged with the required weight of refrigerant and volume of refrigerant oil.

WARNING: Refrigerant must always be recycled before re-use to make sure that the purity of the refrigerant is
high enough for safe use in the system. Recycling should always be carried out with equipment which is design
certified by Underwriter Laboratory Inc. for compliance with SAE J1991. Other equipment may not recycle refrigerant
to the required level of purity.

C AUTIONS:

A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of
refrigerant. Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle systems.

The system must be evacuated immediately before recharging commences. Delay between evacuation and
recharging is not permitted.

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A/C C ompressor Replacement

A new compressor is supplied filled with a full charge (X cm ) of refrigerant oil.

A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of oil
to be drained:

Remove the drain plug from the old compressor.

Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor
clutch to make sure the compressor is completely drained.
Note the quantity of oil drained (Y cm ).
C alculate the quantity of oil to be drained from the new compressor using the following formula:X cm — (Y
cm + 20 cm ) = Q cm
Remove the drain plug from the new compressor and drain Q cm of oil. install and tighten the compressor
drain plug.

Vehicle Weights

Item kg lb
Maximum Gross Vehicle Weight (GVW) - All models* 3230 7106
Maximum weight of unbraked trailer:
On-road 750 1650
Off-road 750 1650
Maximum towable weight (mass) - Trailers with overrun brakes
On-road 3500 7700
Off-road 1000 2205
Maximum roof rack load (Including the mass of the roof rack):
On-road 75 110
Off-road 75 110
* Weight quoted is the maximum weight possible for vehicles in this model range; weights may be less
for certain variants depending upon trim level, territorial requirements etc.

Vehicle Dimensions
Item mm in
Length - including number plate plinth - All models 4842 190.6
Width - All models:
Mirrors extended 2189 86.2
Mirrors folded 2009 79.1
Coil Suspension - Maximum height - At EEC kerb weight - All models:
With roof rack and rails 1891 74.4
With roof antenna module 1938 76.3
Air Suspension - Maximum height - At normal ride height - All models:
With roof rack and rails 1891 74.4
With roof antenna module 1938 76.3
Wheelbase - All models 2885 113.5
Front overhang - All models 820 32.3
Rear overhang - All models 1130 44.5
Maximum roof load 75 kg 165 lb
Track - All models:
Front 1601 63.0
Rear 1601 63.0
Coil Suspension:
Underbody - Running clearance to exhaust - Minimum - Kerb weight 185 7.3
Front axle to axle undertray clearance 203 7.9
Rear axle to differential casing clearance 214 8.4
Air Suspension:
Underbody - Running clearance to exhaust - Minimum - Kerb weight 185 7.3
Front axle to axle undertray clearance 203 7.9
Rear axle to differential casing clearance 214 8.4
Suspension articulation - All models:
Front 255 10.03
Rear 330 12.9
Coil Suspension:
Wading depth 600 23.6

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Approach angle 32.2 32.2
Depa e angle - To ba NOT in alled:
With full size spare wheel 24.9 24.9
With space saver wheel 26.7 26.7
Depa e angle - To ba in alled - NOT NAS ehicle 15.7 15.7
Depa e angle - To ba in alled - NAS ehicle 18 18
Depa e angle - Adj able heigh o ba in alled 14 14
Ai S pen ion:
Wading depth - Off-road height 700 27.5
App oach angle:
Standard ride height 32.2 32.2
Off-road ride height 37.2 37.2
Depa e angle - To ba NOT in alled - S anda d ide heigh :
With full size spare wheel 24.9 24.9
With space saver wheel 26.7 26.7
Depa e angle - To ba NOT in alled - Off- oad ide heigh :
With full size spare wheel 27.9 27.9
With space saver wheel 29.5 29.5 .
Depa e angle - To ba in alled - NOT NAS ehicle :
Standard ride height 15.7 15.7
Off-road ride height 18.5 18.5
Depa e angle - To ba in alled - NAS ehicle :
Standard ride height 18 18
Off-road ride height 21 21
Depa e angle - Adj able heigh o ba in alled:
Standard ride height 14 14
Off-road ride height 16.6 16.6
Ramp angle - Coil S pen ion 22.8
Ramp angle - Ai S pen ion
Standard ride height 22.8 22.8
Off-road ride height 27.9 27.9

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Published: 11-May-2011
General Information - Health and Safet Precautions
Description and Operation

Introduction

Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal
health and the environment. Also, many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health.

This subsection lists some of these hazardous operations and the materials and equipment associated with them.
Precautions necessary to avoid these hazards are identified.

The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with
health and safety in mind.

Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be
consulted.

WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no
circumstances be consumed and should, as far as possible, be kept from contact with the skin. These liquids and
substances include acid, anti-freeze, brake fluid, fuel, windscreen washer additives, lubricants, refrigerants and
various adhesives.

Acids and Alkalis

For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in batteries.

Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can destroy
ordinary protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not
breath mists.

Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.

Display Eye Hazard sign.

Air Bags

Highly flammable, explosive observe No Smoking policy.

Used within the vehicle as safety restraints.

The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C ).

The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air bag
module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as
this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical
waste site.

Following an direct contact with Sodium A ide:

Wash affected areas thoroughly with water.

SEEK IMMEDIATE MEDICAL ASSISTANCE.

Air Bags - Do's

Do store modules in an upright position.

Do keep modules dry.
Do carry modules with the cover side pointing away from the body.
Do place modules with their cover side upwards.
Do carefully inspect modules for damage.
Do stand to one side when connecting modules.
Do make sure all test equipment is properly calibrated and maintained.
Do wash hands after handling deployed air bags.

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Air Bags - Do Not

Do Not store highly flammable material together with modules or gas generators.
Do Not store gas generators at temperatures exceeding 80°C .
Do Not store modules upside down.
Do Not attempt to open a gas generator housing.
Do Not expose gas generators to open flame or sources of heat.
Do Not place anything on top of a module cover.
Do Not use damaged modules.
Do Not touch a fired module or gas generator for at least 10 minutes after firing.
Do Not use any electrical probes on the wiring circuit.

Air Suspension

Whenever work is being undertaken on the air suspension system, suitable eye protection must be worn.

Air Conditioning Refrigerant

Highly flammable, combustible observe No Smoking policy.

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and
goggles.

If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should
also be rinsed with an appropriate irrigation solution such as a solution of 9% Sodium C hloride and Purified Water. DO
NOT RUB THE EYES AND SEEK IMMEDIATE MEDICAL ATTENTION.

Air Conditioning Refrigerant

Do Not

Do Not expose refrigerant bottles to sunlight or heat.

Do Not expose refrigerant bottles to frost.
Do Not drop refrigerant bottles.
Do Not vent refrigerant to atmosphere under any circumstance.
Do Not mix refrigerants.

Adhesives and Sealants

Many adhesives and sealants are highly flammable OBSERVE NO SMOKING POLIC Y. These items, should be stored
in flameproof cabinets in No Smoking areas. C leanliness and tidiness in use should be observed, for example
disposable paper covering benches. All adhesives and sealants should be dispensed from applicators where possible;
containers, including secondary containers, should be labelled appropriately.

Anaerobic, C anoacr late (super-glues) and other Acr lic Adhesives

Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturer's instructions followed.

C yanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover
with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull skin tissue apart. Use
in well ventilated areas as vapors can cause irritation to the nose and eyes.

For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Solvent-based Adhesives/Sealers - See Solvents

Follow manufacturers instructions.

Water-based Adhesives/Sealers

Those based on polymer emulsions and rubber/latex may contain small amounts of volatile, toxic and harmful
chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives

In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the
inhalation of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate

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e ac i .

Resin-based Adhesives/Sealers, for e ample Epo ide and Formaldeh de Resin-based

Mi i g h d be ca ied i e e i a ed a ea a ha f ic a i e che ica a be e ea ed.

S i c ac ih c ed e i a d ha de e ca e i i iai , de a i i , a d ab i f ic ha f
che ica h gh he i . S a he ca da age he e e .

P ide ade ae e ia i a da id i a de e c ac .

Isoc anate (Pol urethane) Adhesives/Sealers

See a Re i -ba ed Adhe i e

I di id a ffe i g f a h a e i a a e gie h d ih ea he e a e ia a e ii i
eac i ca cc .

O e e e i i iai g he e e a d e i a e . E ce i e c ce a i a d ce effec he
e e i c di g d i e . I e e e ca e , fc ci e a e .L g e e e
a c ce a i a e i ad e e hea h effec .

P ged c ac i h he i a ead i i iai a di e ca e , de aii .

S a he e e i g he e e i ca e di c f a d ib e da age.

A a i g h d efe ab be ca ied i e i a ed b h hich i c a e faci i ie f e i g a

a d a d e f he b ea hi g e.

Wea a ia e g e ,e e a d e i a ec i .

Antifree e

Ma be f a ab e he di ed.

Va a be gi e ff f c a a if ee e he hea ed. A id b ea hi g he e a .

A if ee e a be ab bed h gh he i i ic ha f a i ie . A if ee e, if a ed, ca be fa a ;
SEEK IMMEDIATE MEDICAL ATTENTION.

Batter Acids

See a A a i a d Acid .

Ga e e ea ed d i g ba e cha gi g a e e i e. A a e e he ba e f he ehic e i cha gi g.

Ne e e a ed f a e a a ea cha gi g ece cha ged ba e ie . NEVER add acid a ba e ,
he che ica eac i d ced i be i e a d e i e. I ca e fe e c ac , a h affec ed a ea i h c i
a f a e a d SEEK IMMEDIATE MEDICAL ATTENTION.

Ma e e he e i ade ae e ia i d i g ba e cha gi g, b e e NO SMOKING POLIC Y.

Brake Pads and Linings

A a fi he c ec g ade a d ecifica i fb a e ad a d i i g . Whe e e i g ad a d i i g , a a

e ace a c e e a e e .

Brake and Clutch Fluid

S a he he i a d e e a e i i a i g a d i he g e ca be da agi g, a id ged i c ac . I
ca e fe e c ac , a h affec ed a ea i h c i a f a e a d SEEK IMMEDIATE MEDIC AL ATTENTION.

Chemical Materials

A che ica a e ia h da a be ed i h ca i a d ed a d ha d ed i h ca e. The a be ic,

ha f , c i e, i i a high fa ab e a d gi e i e ha a d f e a dd .

The effec f e ce i e e e che ica a be i edia e de a ed; b ief e e ie ced e a e ;

c a i e; e ficia ; ife h ea e i g; a ed ce ife e ec a c .

Chemical Materials - Do's

D ca ef ead a d b e e ha a d a d eca i a i g gi e a e ia c ai e ( abe ) a d i

a acc a i g eaf e , e he i ci . Ma e ia hea h a d afe da a hee ca be
b ai ed f a fac e .
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Do remove chemical materials from the skin and clothing as soon as practicable after soiling. C hange heavily
soiled clothing and have it cleaned.
Do organise work practices and protective clothing to avoid soiling of the skin and eyes.
Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and explosion
hazards.
Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical
materials.
Do keep work areas clean, uncluttered and free of spills.
Do store chemical materials according to national and local regulations.
Do keep chemical materials out of the reach of children.

Che ica Ma e ia -D N

Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other
toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.
Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example when
people are inside a vehicle.
Do Not apply heat or flame to chemical materials except under the manufacturers instructions. Some are
highly flammable and some may release toxic or harmful fumes.
Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations.
Some fumes are heavier than air and will accumulate in confined areas such as pits.
Do Not transfer chemical materials to unlabelled containers.
Do Not clean hands or clothing with chemicals. C hemicals, particularly solvents and fuels, will dry skin and
may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
Do Not use emptied containers for other materials except when they have been cleaned under supervised
conditions.
Do Not sniff or smell chemical materials, even brief exposure to high concentrations of fumes can be toxic or
harmful.

C i P ec i Ma e ia

Some corrosion protection materials are highly flammable observe NO SMOKING POLIC Y.

These materials are varied and the manufacturers instructions must always be followed. The materials may contain
solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces.

Dust or powder produced during repair operations may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is
inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.

E ec ica E i e

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good
condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be
labelled and preferably removed from the work station.

Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. If using
cable reel extension equipment, ALWAYS ensure that the cable is fully unwound from the reel.

Make sure that electrical equipment and flexes do not come into contact with water.

Make sure that electrical equipment is protected by the correct rated fuse.

Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.

Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.

Make sure that the designated electrical workers are trained in basic First Aid.

I ca e f e ec c i :

Switch off the power supply before approaching the victim.

If this is not possible, DO NOT TOUCH THE VICTIM but push or drag the person from the source of electricity
using dry, non-conductive material.
C ommence resuscitation if trained to do so.
SEEK IMMEDIATE MEDICAL ATTENTION.
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E haust Fumes

The e c ai a h ia i g, ha f a d ic che ica a d a ic e ch a ca b ide , i ge ide ,

a deh de , ead a d a a ic h d ca b . E gi e h d be de c di i f ade a e e ha
e ac i ge e a e i a i a d i c fi ed ace .

Gasoline (Petrol) engine

The e a be ade ae a i g f d fi iai bef e ic ha f effec a i e. The e a be

i edia e de a ed.

Gas Oil (Diesel engine)

S , di c f a di iai a gi e ade ae a i g f ha a d f e c ce ai .

Fibre Insulation

The fib a e f face a d c edge ca ca e i i iai . Thi i a a h ica a d a che ica

effec .

P eca i h d be a e a id e ce i e i c ac h gh ca ef ga i a i f ac ice a d he
e fg e .

Fire

Ma f he a e ia f d a cia ed i h he e ai f ehic e a e high f a ab e. S e gi e ff ic

ha f f e if b ; he ch a f ea e he b da aged b e ce i e hea ca b ea d
a d d ce high c i e h d f ic acid - See F ea e .

Sh da a e ia be i a b e hea ed c di i , ha d e i h e e e ca i a d ea ec i e c hi g
he ha d i g ch i e . Di e f ch a e ia i acc da ce i h ca eg a i .

Dec a i a e a d di e f ec i e c hi g i edia e af e e.

Ob e e ic fi e afe he i g a d ha d i g f a ab e a e ia e , a ic a ea e ec ica
e i e e di g ce e .

Ma e e, bef e i g e ec ica e di g e i e , ha he e i fi e ha a d e e .

Ha e a i ab e fi e e i g i he a ai ab e he i g e di g hea i g e i e .

First Aid

A a f ee i g a ega e i e e i i de i ab e f e e i he h be ai ed i Fi Aid
ced e .

S a he i he e e h d be f hed ca ef i h c ea ae f a ea e i e .

S i ed i h d be a hed ih a a d ae .

I ca e fc db ,f a e ai e f e , ace affec ed a ea i c c d ae .

I di id a affec ed b i ha a i f ga e a d f e h d be e ed f e h ai i edia e . If effec e i ,

c ad c .

If i id a e a ed i ad e e ,c ad c gi i g hi he i f ai he c ai e abe . D
i d ce ii g e hi ac i i i dica ed he abe .

Fluoroelastomers (S nthetic Rubber)

Ma 'O' i g , ea , h e , f e ib e i e a d he i i a hich a ea be a fac ed f a a bbe

a e, i fac , ade f he ic a e ia ca ed F ea e .

U de a e a i g c di i , he e a e ia a e afe a d d c i e a hea h ha a d. H e e , if he
a e ia a e da aged b b i g e e e ce i e hea , he ca b ea d a d d ce high c i e
h d f ic acid.

WARNING: C ac ihh d f ic acid ca ca e e i b c ac i h he i . If i c ac d e

cc , ca he f i g e i edia e :

Re e a c a i a ed c hi g.

SEEK IMMEDIATE MEDICAL ATTENTION

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I iga e affec ed a ea f i ihc i a fc d ae i e ae f 15 60 i e .

Foams - Pol urethane

U ed i da d i e i ai .C ed f a ed i ea a d i c hi i g.

U eac ed c e a e i iai ga d a be ha f he i a d e e . Wea g e a d g gg e .

I di id a i h ch ic e i a di ea e , a h a, b chia edica be , hi ie f a e gic di ea e

h d i ea c ed a e ia .

The c e , a a i ca ca e di ec i i a i , e ii i eac i a d a be ic ha f .

Va a d a i be i ha ed. The e a e ia be a ied i h ade a e e ia i a d

e i a ec i . D e e he e i a i edia e af e a i g, ai i he a / i ha e
c ea ed.

B i g f he c ed c e a d he c ed f a ca ge e a e ic a d ha f f e .S i g, a ed
fa e he e f e ec ica e i e d i gf a i g e ai a d i a / i ha e c ea ed h d
be a ed. A hea c i g f c ed f a a ia c ed f a h d be ca ied i a ea ha i g i ab e
f e e ac i e i e .

Fuels

A id i c ac ihf e he e ib e. Sh dc ac cc , a h he affec ed i ih a a d ae .

Gasoline (Petrol)

High fa ab e - OBSERVE NO SMOKING POLIC Y.

S a i g ga i e ( e ) ca e i ha d h a i iai a d ab i f he ach ca e i
d i e a d c ci e .S a a ca be fa a chi d e . I ha a i i he g , h gh i i g,
i a e e i ha a d.

Ga i e ( e ) d ie he i a d ca ca e i i a i a d ged e ea ed c ac a ca e de a i i ; if i
i a ed e e he e e , i i ca e e e e a i g. Wa h affec ed a ea i h c i a f ae a d
SEEK IMMEDIATE MEDICAL ATTENTION.

Ga i e ( e ) a c ai a eciab e a i ie f be e e, hich i ic i ha a i a d he c ce a i
f a be e e . High c ce a i i ca e e e, e a d h a i i a i , a ea, headache,
de e i a d fd e e . Ve high c ce a i i e i a id fc ci e .

Ma e e he e i ade a e e i a i he ha d i g a d i g ga i e ( e ). G ea ca e be a e a id
he e i c e e ce f i ha a i i he e e f a b id a i i gf i age i c fi ed ace .

S ecia eca i a c ea i g a d ai e a ce e ai ga i e ( e ) age a .

Ga i e ( e ) h d be ed a a c ea i g age .I be i h ed b h.

Gas-oil (Diesel Fuel)

C b ib e.

P ged i c ac i h high b i i g i ga i (die e f e ) a ca e e i i di de i c di g i

ca ce .

I ha a i i he g i ca e i e a b eedi g - SEEK IMMEDIATE MEDICAL ATTENTION.

If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.

Kerosene (Paraffin)

U ed a a hea i g f e , e a d c ea i g age .

Fa ab e - OBSERVE NO SMOKING POLIC Y.

I iai f he ha d h a a e f a i g. The ai ha a d f a i g a i e if i id
a i ai i he g cc .

Li id c ac d ie he i a d ca ca e i iai de a i i . S a he i he e e a be igh i i a i g.

I a ci c a ce he a ii d e gi e i e ha f a .E e i a d a f
e e e a e e a ed e e a e h d be a ided ( i a a i e i de a i g). A id i a de e c ac a d
a e e he e i ade a e e ia i .

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If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.

Gas C linders

Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138 bar
(13800 kPa) (2000 lbf/in ) and great care should be taken in handling these cylinders to avoid mechanical damage to
them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings.

C ylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel
gases, for example acetylene and propane should not be stored in close proximity to oxygen cylinders.

C are should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.

Only trained personnel should undertake work involving gas cylinders.

General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used
where required.

Never use tools or equipment for any purpose other than that for which they were designed. Never overload
equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not
always immediately apparent and may result in a fatal failure the next time that the equipment is used.

Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.

Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipment

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.

Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the
underlying tissue and cause serious injury.

Jacking

Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.

When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is
applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has
sufficient load capacity for the weight of the vehicle.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety
stands.

Ensure that hoists have sufficient load capacity for the weight of the vehicle.

Legal Aspects

There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment
in a workshop.

For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and local authorities.

Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes
and skin.

Used Engine Oil

Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities must be provided.

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D e ed e gi e i a b ica f a a ica i he e a eciab e i c ac i i e cc .

Heal h P o ec ion P eca ion

A id ged a d e ea ed c ac i h i , a ic a ed e gi e i .
Wea ec i e c hi g, i c di g i e i g e he e ac icab e.
D i ag i c e .
A id c a i a i g c he , a ic a de a , i h i.
Hea i i ed c hi g a d i -i eg a ed f ea h d be .O e a be c ea ed eg a .
Fi Aid ea e h d be b ai ed i edia e f e c a d d .
U e ba ie c ea ,a i g he bef e each e i d, he he e a f i f he i .
Wa h i h a a d ae a e e a i i e ed ( i c ea e a d ai b he i he ).
P e a ai c ai i g a i e e ace he a a i i hich ha e bee e ed.
D e ga i e ( e ), e e e ( a affi ), die e f e (ga i ), hi e e f c ea i g i .
If i di de de e , b ai edica ad ice i h de a .
Whe e ac icab e, deg ea e c e i ha d i g.
Whe e he e i a i fe e c ac , e e ec i h d be ,f e a e che ica g gg e face
hie d ; i addi i a e e a h faci i h d be ided.

En i onmen al P eca ion

Thi ec i ide ge e a i f ai hich ca he ed ce he e i e a i ac f he ac i i ie

ca ied i h .

E i i ai

Ma f he ac i i ie ha a e ca ied i h e i ga e a d f e hich ca c ib e g ba a i g,
de e i f he e a e a d/ he f ai f h che ica ga g d e e.B c ide i g h he
h ac i i ie a e ca ied , he e ga e a d f e ca be i i i ed, h ed ci g he i ac he
e i e .

E ha f e

R i g ca e gi e i a e e ia a f h ac i i ie a d e ha f e eed be e i a ed
a he e. H e e , he a f i e e gi e a e i g a d he ii f he ehic e h d be ca ef
c ide ed a a i e , ed ce he e ea e f i ga e a d i i i e he i c e ie ce e e i i g
ea b .

S e

S e f he c ea i g age ed a e e ba ed a d i e a a e a id a he e if ed ca e e , if
c ai e a e ef ea ed. A c ai e be fi c ed he e i ed a d e h d be ed
a i g . Whe e e ib e, e ha i g a ici a d f a abi i h d be e ec ed. A a f he
i ci ied b he e a fac e . Si i a , a ai a e e ba ed a d he a h d be
ed i ch a a a ed ce e i i a i i .

Ref ige a

I i i ega e ea e a ef ige a i he a he e. Di cha ge a d e ace e f he e a e ia f ai

c di i i g i h d be ca ied i g he a ia e e i e .

Di cha ge ae

M h i ha e e f di cha gi g a e a e - d ai a df d ai . S d ai
h d ecei e c ea a e i.e. ai a e . F d ai i acce a f he a a e a e i.e. a hi g
a e , de e ge a dd e ic e a e BUT NOT i , e , e , acid , h d a ic f id, a if ee e a d i i a
f id . If i d b , a a c he ca a h i ae c a .

S i age

E e eca i be a e e e i age f i , f e , e e c., eachi g he d ai . A ha d i g f ch

a e ia a e ace e a a f d ai a d efe ab i a a ea i h a i ab e c ai i g a e e
di cha ge i d ai ae c e . If a i age cc ,i be a ed i edia e i ga i i he e
ided.

C hec i

Spillage p e en ion:

S e i id i a ec e a ea.

Ma e e ha a i id c ai e a e ec e a d ca be accide a ed .

P ec b age a f a da i b c i g he a e .

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Transfer liquids from one container to another in an area awa from open drains.

Ensure lids are replaced securel on containers.

Have spill kits available near to points of storage and liquid handling areas.

Spill Kits

Special materials are available to absorb a number of different substances. The can be in granular form, read to
use and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste
management.

Land contamination

Oils, fuels and solvents etc. can contaminate an soil with which the come into contact. Such materials MUST never
be disposed of b pouring on to soil and ever precaution must be taken to avoid spillage reaching soil. Waste
materials stored on open ground could either leak or have contaminating substances washed off them that would
contaminate the land. Alwa s store these materials in suitable skips or similarl robust containers.

Legal compliance

Some sites ma have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is essential to
know the t pes of effluent which are allowed to be discharged into the drain and to check the results of an
monitoring carried out b the Water C ompan .

Where paint spra ing operations are carried out it ma be necessar to appl to the Local Authorit for an air
emissions licence to operate the plant. If such a licence is necessar , additional precautions will be necessar to
compl with the requirements and the results of an air qualit monitoring must be checked regularl .

C hecklist

Alwa s adhere to the following:

Know what legal consents and licences appl to the operations.

C heck that the emissions and discharges compl with legal requirements.

Waste Management

Pollution can be reduced b careful handling, storage and disposal of all waste materials that occur on sites.
Legislation makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites.

This means that it is necessar to not onl know what the waste materials are but also to have the necessar
documentation and licences.

Handling and storage of waste

Ensure that waste materials are not poured down the drain or on to soil and are stored in such a wa that the do not
escape on to land or soil.

All waste must be segregated into individual t pes e.g. oils, metals, batteries, scrap components etc. This will prevent
an reaction between different materials and assist in disposal.

Disposal of waste

Dispose of waste in accordance with the following guidelines:

Fuel, h draulic fluid, anti-free e and oil: Keep separate and dispose of to specialist contractors.

Refrigerant: C ollect in specialist equipment and reuse.

Detergents: Safe to pour down the foul drain if diluted.

Paint, thinners: Keep separate and dispose of to specialist contractor.

Components: Return to supplier for refurbishment or disassemble and reuse an suitable parts. Dispose of
remainder in ordinar waste.

Small parts: Reuse an suitable parts, dispose of the remainder in ordinar waste.

Metals: C an be sold if separate from general waste.

T res: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of t res b burning.

Components/materials containing asbestos: Keep separate and dispose of to specialist contractor.

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Oil and fuel wastes (e.g. rags, used spill kit material): Kee e a a e a d di e f ecia i
c ac .

Air filters: Kee e a a e a d di e f ecia i c ac .

Rubber/plastics: Di e fi di a a e.

Hoses: Di e fi di a a e.

Batteries: Kee e a a e a d di e f ecia i c ac .

Air bags - DANGER EXPLOSIVES: Kee e a a e a d di e f ecia i c ac .

Electrical components: Re ie f ef bi h e di a e be a d e e a i ab e
c e . Di e f e ai de i di a a e.

Catal tic converters: Ma be d if e e a ae f ge e a a e.

Packaging: C ac / ec c e a ch a ib e a d di e fi di a a e.

Office/paper waste: Rec c e a e a d e a di ca idge , di e f e ai de i di a a e.

Noise

Ca a a e i g, a e bea i g, i g e gi e , i g ai e c. a e e ai hich i a iab d ce a a ge

a f i e. The ca i f ch ac i i ie a d a he i e f da be ca ef c ide ed ha i g ega d
he i i fh e ch e c.

S e e ai a d ce high i e e e hich c d, i i e, da age hea i g. I he e ca e , i ab e ea

ec i be .

Solder

S de a e i e f e a ch ha he e i g i f he i e i be ha f he c i e e a
( a ead a d i ). S de a ica i d e a gi e i e ic ead f e , ided a ga /ai f a e i
ed. O -ace e e f a e h d be ed, a he a e ch h e a d i ca e ead f e be d ced.

S e f e a be d ced b he a ica i fa fa e face c a ed i h g ea e, a d i ha a i f he e

h d be a ided.

Re a f e ce de h d be de a e i h ca e, a e e ha fi e ead d i d ced, hich

ca gi e ic effec if i ha ed. Re i a ec i a be ece a .

S de i age a d fi i g h d be c ec ed a d e ed e e ge e a ai c a i ai b ead.

High a da d f e a h gie e a e ece a i de a id i ge i f ead i ha a i f de d f

c hi g.

Solvents

F e a e ace e, hi e i i, e e, e e, ich e ha e.

U ed i c ea i g a d de a i g a e ia , ai , a ic , e i a d hi e .

S e a be high fa ab e fa ab e.

S i c ac i deg ea e he i a d a e i i iai a d de aii f i g e ea ed ged c ac .

S e ca be ab bed h gh he i i ic ha f a i ie .

S a he i he e e a ca e e e e i iai a dc d ead f i i .

B ief e e f high c ce ai f a i i ca e e e a d h a i iai ,d i e , di i e ,

headache a d, i he ci c a ce , c ci e .

Re ea ed ged e e e ce i e b e c ce ai f a i ,f hich he e igh

be ade a e a i g i dica i , ca ca e e e i ic ha f effec .

A i ai i he g ,f e a e h gh i i g, i he e i c e e ce f a i g.

A id a he he i ,e e a dc hi g. Wea ec i e g e , g gg e a d c hi g if ece a .

Ma e e he e i g d e ia i he i e, a id b ea hi g f e , a a d a i a d ee c ai e
igh ea ed. D e i c fi ed ace .

Whe a i g a e ia c ai i g e ,f e a e ai , adhe i e , a d e a c a i g , e e ac i
e ia i e a e i a ec i i he ab e ce f ade a e ge e a e i a i .
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Do not apply heat or flame except under specific and detailed manufacturers instructions.

S pended Load

C AUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised
load, for example a suspended engine.

Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for
the job, in good condition and regularly maintained.

Vi on

In common with many other manufacturers vehicles, some components installed to Land Rover vehicles have seals,
'O' rings or gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. Although Viton is the most well
known fluoroelastomer, there are others, including Fluorel and Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to
temperatures in excess of 400 C , the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid.

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.
WHERE CASES OF SKIN CONTACT OCCUR, SEEK IMMEDIATE MEDICAL HELP.

O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black
sticky substance.

DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-
ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material
may be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the
commencement of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue
and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Re i ance Welding

This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be
protected.

A c Welding

This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and
to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal
protection must be worn, and screens used to shield other people.

C ONTAC T LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPEC TAC LES WHEN ARC WELDING as the arc
spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in
blindness when the lens is removed from the eye.

Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any
applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and
inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators
may be necessary.

C AUTION: Some of the components installed to the vehicle e.g. the interior cross beam and underbonnet cross
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e be a e a fac ed f ag e i a .O acc h da e di g e ai be a e ed
he e c e .

Gas Welding (and Cutting)

O -ace e e che a be ed f e di g a d c i g, a d ecia ca e be a e e e ea age f

he e ga e , i h c e e i f fi e a d e i .

The ce i d ce e a a e a de e a d i ec i i ece a .

The f a e i b igh , a d e e ec i h d be ed, b he a- i e e i i i ch e ha ha f a c

e di g, a d igh e fi e a be ed.

The ce i ef d ce fe ic f e ,b ch f e a d ga e a be d ced f c ai g he ,
a ic a d i gc i ga a f da aged b d a , a d i ha a i f he f e h d be a ided.

I b a i g, ic f e a be d ced f he e a i he b a i g d, a d a e e e ha a d a a i e if
b a i g d c ai i g cad i a e ed. I hi e e a ic a ca e be a e a id i ha a i ff e
a d e e ad ice a be e i ed.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS
WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING OUT OF FUEL
TANKS.

Warning S mbols on Vehicles

Deca h i g a i g b i be f d a i ehic e c e .

The e deca be e ed. The a i g a e f he a e i f e / e a a d e ca i g

e ice e ai e ai he ehic e.

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P b i hed: 11-Ma -2011

General Information - Sol ents, Sealants and Adhesi es
De c i i a dO e ai

Sol ents

WARNING: A a ha d e a e , ea e a d adhe i e ihe e e ca e. S e c ai che ica

gi e ff f e hich ca be da ge hea h. A a f he a fac e i ci . If i d b ab a
b a ce, a ic a a e , DO NOT e i.

C AUTION: If i d b ab he i abi i fa ie a e ea e f a a ic a a ica i ,

c ac he a fac e f he d c f i f ai .

The Hea h a d Safe P eca i b ec i efe e c ed che ica a d a e ia , ha a d

a cia ed i h hei e, a d afe ea e be a e . S e f he e che ica a be i c ded a a
i g edie i a ea e adhe i e.

Sealers

C e ai ced e i hi a a i e he e f ea a d i gi a ai fc e . Whe e a ea a i
e i ed, he a ica i , ge he i h he La d R e a be i gi e i he Ge e a S ecifica i a he a
f each ec i a da i ci ha a ea a be ed a ea i he e e a e ai ced e.

I i e e ia ha he ea a ( ) ecified f a a ic a ced e a e ed, DO NOT e a he ea a .

A a e e ace f d ea a i ga a ic c a e i ab e e , e e e e e c h e a
c a e .

Adhesi es

Whe e e a ced e i e he e f a adhe i e, he adhe i e ecified be ed a d he a fac e '

i ci ega di g a ica i ge he iha hea h a d afe eca i be f ed.

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Published: 11-May-2011
General Information - Road/Roller Testing
Description and Operation

Road or rolling road testing may be carried out for various reasons and a procedure detailing pre-test checks,
through engine starting and stopping, pre-driving checks, on-test checks to final checks on completion of the test are
given.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead,
those items particularly relevant to the system(s) being checked can be extracted.

Pre-Test Checks

WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found,
do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak
is found and rectified.

It is suggested that pre-test and functional tests of those systems/circuits which affect the safe and legal operations of
the vehicle, such as brakes, lights and steering, should always be carried out before the road or rolling road test.

Engine oil level

Engine coolant level
Tires, for correct pressure, compatible types and tread patterns, and wear within limits.
There is sufficient fuel in the tank to complete the test.
C heck all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make
a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the
leak on completion of the test.

Starting the Engine

NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond
half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine
speed or with the accelerator pedal at full travel whilst the engine is cold.

With the ignition s itched off, check:

The parking brake is applied.

Manual gearbo : The gear lever is in neutral.
Automatic gearbo : The selector lever is in 'P' - Park
Transfer bo : 'H' - High is selected
All instrument gauges read zero.

With the ignition s itched on, check:

Ignition controlled warning lights come on.

Engine temperature gauge registers a reading compatible with the engine temperature.
Fuel gauge registers a reading appropriate to the fuel level in the tank.
The operation of the parking brake warning light and fluid level warning indicator light.

On Road Test Check:

C AUTION: At commencement of road testing, check the brake operation while still travelling at low speed before
continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road
test until the fault has been found and rectified.

Manual gearbo : C lutch pedal operation is not stiff or heavy.

Manual gearbo : Initial gear engagement is smooth and there is no evidence of clutch drag.
The parking brake releases completely.
Manual gearbo : C lutch takes up the drive smoothly, without slip or judder.
Gear changing is smooth, and there are no abnormal noises or vibrations from the gearbox.
The engine power output is satisfactory, acceleration is smooth and accelerator pedal operation is not stiff or
heavy, and engine speed returns to idle correctly.
There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or
overrun conditions.
Steering operation is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does
not pull to one side and self centres smoothly after cornering.
All instruments register the correct readings and operate correctly.
Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the
direction indicator control self cancels when the steering is returned to the straight ahead position.
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Hea ing and en ila ion em o k co ec l and effec i el .
B ake ope a e efficien l .

Brake Testing

A oid b ake e ing on b oad he e i can ca e incon enience o dange o o he oad e .

C AUTION: B ake e ing hich incl de hea b ake applica ion ho ld no be ca ied o i h ne b ake
pad /di c n il he componen ha e bedded-in. Ne b ake f ic ion componen ill no each f ll efficienc n il he
bedding-in p oce i comple e. No e ha hen ne pa king b ake hoe o ea b ake di c ha e been fi ed, i i
e en ial ha he 'bedding-in' p oced e gi en in Sec ion 206-05 - Pa king B ake Remo al and In alla ion i ca ied
o .

Te he b ake a e e al peed i hin he no mal ope a ing ange ing bo h ligh and hea pedal p e e. No e
an endenc o na ch, p ll o d ag, and an nd e dela in applica ion o elea e.

Allo he ehicle o coa and no e an endenc o p ll o one ide, o e idence ha he b ake a e binding.

Af e opping he ehicle (no immedia el af e a pe iod of hea b aking), ca ef ll check he b ake empe a e.
A di c hich feel app eciabl ho e han he o he , co ld indica e ha he pad on ha di c a e binding.

Af e comple ion of he e , check fo :

Oil, coolan , h d a lic, ai and f el leak .

Abno mal empe a e of an mo ing componen o a emblie , e.g. heel h b , an mi ion e c., hich
migh indica e o e igh ne o lack of l b ica ion.

Rolling Road Testing

Four-Wheel Rolling Road

WARNING: Do no ope a e he foo b ake o pa king b ake hil he olle a e d i ing he oad heel . En e
ha once di connec ed, p opelle haf a e p ope l ec ed and clea of all mo ing componen .

P o ided ha f on and ea olle a e o a ing a iden ical peed and ha no mal o k hop afe anda d a e
applied, he e i no peed e ic ion d ing e ing e cep an ha ma appl o he i e .

En e ha he pa king b ake i elea ed p io o engaging olle d i ing mechani m.

T o-Wheel Rolling Road

C AUTION: On no acco n ho ld an a emp be made o ca o an fo m of e ing on a o- heel olling

oad.

T o- heel olling oad e ing m no be pe fo med on hi ehicle.

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P : 11-M -2011
General Information - Special Tool Glossar
D O

Service Tools

S ,
.T
.

S .

A U K E G ,A ,S
S :

SPX UK Ltd.,

G H ,

E P ,

D ,

N ,

NN11 5YJ

Tel: 0044 (0) 1327 303467/303455

Fa : 0044 (0) 1327 706632

e-mail: @ . .

O .

G ,A S

SPX Europe GMBH,

P 4,

63512 H ,

Tel: 0049 61829590

Fa : 0049 6182959299

SPX Iberica SA,

C /F A ,

158 72 (N O ),

19004 G ,

Tel: 0034 949208381

Fa : 0034 949208327

N A

SPX Corporation

665, E D ,

O ,

MN 55060,

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USA

Tel: 0018 772979110

Fa : 0018 005787375

Australia

SPX Australia,

28, C la ton Road,

Notting Hill,

Victoria 3168,

Australia

Tel: 0061 00395446222

Fa : 0061 00395445222

e-mail: sales@sp .com.au

Japan and East Asia

Jatek Ltd.,

5 - 53, Mina acho 2-chome,

Kohoku-ku,

Yokohama,

Kanaga a 223-0051,

Japan

Tel: 0081 455627700

Fa : 0081 455627800

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Published: 05-Jul-2011
Iden ifica ion Code - Iden ifica ion Code
Description and Operation

VIN Number

The VIN number will be found in three locations:

1. Stamped on the side of the RH longitudinal member, rearward of the bod front mounting.
2. At the bottom of the windshield glass on the LH side of the vehicle and visible from the outside.
3. UK, E ope and ROW - No NAS/Canada -On the VIN plate attached to the bonnet locking platform.
4. NAS/Canada - On the Tire Data/Specification label attached to the front of the LH B-pillar.

Longitudinal Member VIN

Windscreen VIN

VIN number - UK, EU and ROW

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VIN Po i ion Cha ac e Iden ifie

1 - 3 - World identifier SAL Land Rover (UK)
4,5 - Vehicle t pe LA Discover 3
6 - C lass A Standard
7 - Bod st le A 4 Door
8 - Engine 1 276DT - V6 2.7 Diesel
8 - Engine 4 406 PN - V6 4.0 Petrol
8 - Engine 5 448PN - AJV8 4.4 Petrol
9 - Transmission and steering 3 RHD Automatic
9- Transmission and steering 4 LHD Automatic
9 - Transmission and steering 7 RHD Manual
9 - Transmission and steering 8 LHD Manual
10 - Model ear 5 2005
10 - Model ear 6 2006
10 - Model ear 7 2007
10- Model ear 8 2008
11 - Plant A Solihull
12 - 17 - Serial number 123456 Unique si digit serial number
VIN number - NAS and C anada

VIN Po i ion Cha ac e Iden ifie

1 - 3 - World identifier SAL Land Rover (UK)
4 - Model range A Discover 3
5 - C lass A Standard
6 - Bod st le 2 4 Door
7 - Engine 4 406 PN - V6 4.0 Petrol
7 - Engine 5 448PN - AJV8 4.4 Petrol
8- Transmission and steering 4 LHD Automatic
9 - C heck digit * Derived b calculation
10 - Model ear 5 2005
10 - Model ear 6 2006
10 - Model ear 7 2007
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10- M de ea 8 2008
11 - P a A S ih
12 -17 - Se ia be 123456 U i e i digi e ia be
B e c i g af VIN ae -N NAS/C a ada

The VIN ae c ai he f i gi f ai :

- Re e ed
- E gi e De c i i
- C
- Die e I dica
- Re e ed
- Head a C de/i i ia ai a e - If h
- C c de/g
- T e/A a N be - If h
- VIN N be
- G Vehic e Weigh
- G T ai Weigh
- F A e Weigh
- Rea A e Weigh

VIN/C e ifica i /Ti e Da a Labe - NAS

The C e ifica i Labe c ai he f i g VIN i f ai :

- * Vehic e VIN N be
- Ba c de ide ifica i

VIN/Ti e P e e S ecifica i Labe - C a ada

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The Tire Pressure C ertification Label contains the following VIN information:

- Vehicle VIN Number

- Vehicle T pe

Unit/Assembl Serial Number Locations

2.7 Litre V6 Diesel Engine Serial Number

The 2.7 Litre V6 Diesel Engine Serial Number is stamped on the RH side of the c linder block.

4.0 Litre V6 Petrol Engine Serial Number

The 4.0 Litre V6 Petrol Engine Serial Number is stamped on the LH side of the c linder block.

4.4 Litre V8 Petrol Engine Serial Number

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The 4.4 Litre V8 Petrol Engine Serial Number is stamped on the RH side of the starter ring gear housing.

Manual Gearbo Serial Number

The Manual Gearbo Serial Number is stamped on the rear LH side of the gearbo casing.

Automatic Gearbo Serial Number

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Tha Automatic Gearbo Serial Number is stamped on the rear LH side of the gearbo casing.

Front Differential Serial Number

The Front Differential Serial Number is stamped on the underside of the differential casing and is located above the
removable cross member.

Rear Differential Serial Number

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The Rea Diffe en ial Se ial N mbe i amped on he nde ide of he diffe en ial ca ing adjacen o he f on
mo n ing.

T an fe C a e Se ial N mbe

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The Transfer C ase serial number is stamped on the RH side of the transfer case and ma also be on a bar coded self-
adhesive label attached to the case.

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Published: 11-May-2011
Jacking and Lifting - Jacking
Description and Operation

General

WARNING: The following instructions must be adhered to before raising the vehicle off the ground:

Position vehicle on a solid, level surface.

Apply the parking brake.
Select 'P' - PARK on automatic transmission selector or 1st gear on manual transmission and 'H' High on
transfer case.

WARNING: If the drive shaft(s) are to be disconnected, it will be necessary to raise all four wheels off the
ground in order that the shaft(s) can be rotated. DO NOT use the customer jack and ensure that the vehicle is
adequately supported on axle stands. With the vehicle raised, it will be necessary to release the park brake and
select Neutral - 'N' in the main transmission to enable the drive shaft(s) to be rotated

C AUTIONS:

To avoid damage to the underbody components of the vehicle, the following instructions must be adhered to:

Do not position jacks or axle stands under the following components:

Body structure other than any approved jacking or lifting points

Bumpers

Fuel lines

Fuel tank

Brake lines

Front or rear suspension arms

Steering linkage

Transfer case

Front or rear differential units

Transmission

Engine oil pan - See note below

NOTE: For certain repair operations, it may be necessary to support the engine under the oil pan. In this case, a
block of hardwood or a rubber pad must be positioned on the jack lifting pad to protect the oil pan.

Vehicle jack

The jack provided with the vehicle is only intended for use in an emergency such as changing a tire. DO NOT use the
jack for any other purpose. Refer to the Owner's Handbook for the vehicle jack location points and jacking
procedures.

WARNING: Never work under a vehicle supported solely by the vehicle jack.

H draulic jack

A hydraulic jack with a minimum lifting capacity of 1500 kg, (3,300 lbs) must be used.

WARNINGS:

Do not commence work on the underside of the vehicle until suitable axle stands have been placed in the
correct position.

Always chock the wheels when jacking. The parking brake may be ineffective when the wheel(s) are off the

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ground.

Rai ing and S ppo ing he Vehicle

To assist in raising the vehicle, jacking points are provided as shown in the following illustrations.

Rai ing he F on of he Vehicle

Apply the parking brake.

Select 'P' - PARK on automatic transmission selector.

WARNING: Always chock the rear wheels when jacking the front of the vehicle.

Position the lifting pad of the hydraulic jack in the centre of the recess in the engine undershield.

NOTE: If the engine undershield has been removed, position the jack lifting pad in the centre of the front cross
beam.

With the vehicle raised to the desired height, position axle stands at positions shown.

C AUTION: Position suitable material between axle stands and longitudinal members to prevent damage to the
longitudinal members.

C arefully lower jack until vehicle rests on axle stands.

WARNING: Before commencing work on the underside of the vehicle, ensure that axle stands are correctly
positioned and vehicle is securely supported.

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Re e e p oced e hen emo ing ehicle f om and .

Rai ing he Rea of he Vehicle

Selec 'P' - PARK on a oma ic an mi ion elec o .

WARNING: Al a chock he f on heel hen jacking he ea of he ehicle.

Po i ion he lif ing pad of he h d a lic jack nde he cen e of he ea c o membe a ho n.

C AUTION: Take ca e ha he lif ing pad of he jack i of a i able i e o a oid damaging he hea hield. I i
no ad i able o e a pace block be een he lif ing pad and he ea c o membe a hi ma e l in ome
ehicle in abili .

Wi h ehicle ai ed o de i ed heigh , po i ion a le and a po i ion ho n.

C AUTION: Po i ion i able ma e ial be een a le and and longi dinal membe o p e en damage o he
longi dinal membe .

C a ef ll lo e jack n il ehicle e on a le and .

WARNING: Befo e commencing o k on nde ide of ehicle, en e ha a le and a e co ec l po i ioned

and ehicle i ec el ppo ed.

Re e e p oced e hen emo ing ehicle f om and .

Rai ing Vehicle - One Wheel/ ide

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Apply the parking brake.

Select 'P' - PARK on automatic transmission selector.

WARNING: Always chock the wheels which are not to be raised.

One front heel - position lifting pad of hydraulic jack beneath longitudinal member on the side to be raised
at Point 'A'
One rear heel - position lifting pad of jack beneath longitudinal member on the side to be raised at Point 'B'
Front and rear heels - ONE SIDE - position lifting pad of jack beneath longitudinal member on the side to
be raised at Point 'C '

NOTE: Point 'C ' is in line with number 3 body mounting.

With vehicle at desired height, position axle stand(s) beneath longitudinal members and adjacent to the lifting pad of
the jack at appropriate point(s) D.

C AUTION: Position suitable material between axle stands and longitudinal members to prevent damage to the
longitudinal members.

C arefully lower jack until vehicle rests on axle stands.

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WARNING: Befo e commencing o k on nde ide of ehicle, en e ha a le and a e co ec l po i ioned

and ehicle i ec el ppo ed.

Re e e p oced e hen emo ing ehicle f om and .

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Published: 11-May-2011
Jacking and Lif ing - Lif ing
Description and Operation

Vehicle on Wheel - Fo Po Ramp

WARNING: If the drive shaft(s) are to be disconnected, it will be necessary to raise all four wheels off the ramp
in order that the shaft(s) can be rotated. If the wheel free facility is not to be used, raise the vehicle off the ramp
using suitable equipment. With the vehicle raised, position axle stands in the positions shown for the front and rear
support blocks - see illustration in Jacking. With the axle stands positioned, release the parking brake and select
NEUTRAL 'N' in the transmission.

WARNING: Do not push the vehicle backwards and forwards along the ramp in order to gain access to the drive
shaft fixings.

Position the vehicle on the ramp with the front and rear of the vehicle equidistant from the ends of the ramp. C hock
the wheels, select NEUTRAL in the transmission and where practicable, apply the parking brake.

Wheel F ee Lif - Fo Po Ramp

NOTE: To enable the vehicle to be supported correctly on the wheel free longitudinals, it will be necessary to
produce 2 off each of the support blocks to the dimensions given in the accompanying illustrations. The supporting
part of each block must be manufactured from suitable hardwood or metal and the 'U' shaped base of each block
must be manufactured from metal. Note that it is essential to ensure that the 'U' shaped base of each block is wide
enough to fit over the wheel free longitudinals.

F on S ppo Block Dimen ion

'A' = 127.0 mm (5.0 in)

'B' = 146.0 mm (5.75 in)
'C' = 89.0 mm (3.5 in)

Rea ppo block dimen ion

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'A' = 152.0 mm (6.0 in)
'B' = 101.0 mm (4.0 in)
'C' = 76.0 mm (3.0 in)

Rai ing and S ppo ing he Vehicle

1. Position vehicle on ramp.

2. Position suspension in 'off-road' height.

3. Apply parking brake.

4. Raise ramp to desired height.

5. Align the wheel free longitudinals beneath the body frame longitudinals and position the support blocks beneath the
longitudinals in the positions shown.

C AUTION: Ensure that the front and rear support blocks are correctly oriented to front and rear of vehicle.

6. Engage wheel free and lower ramp slowly until weight of vehicle rests on support blocks and road wheels are just
clear of ramp.

7. Ensure that the vehicle is correctly supported on all four support blocks, that blocks are still correctly positioned
and are in full contact with the body frame longitudinals.

8. Lower the ramp.

WARNING: Make sure that the vehicle is stable before commencing work.

NOTE: Return the suspension to 'normal ride height' when the vehicle is removed from the ramp.

Two Post Lift

C AUTION: If the drive shaft(s) are to be removed, release the parking brake and select NEUTRAL 'N' in the
transmission in order that the shaft(s) can be rotated when the vehicle is raised to the desired height.

1. Position the vehicle with the centre of the lift pillars aligned approximately with the front of the driver/passenger
seat cushions.

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2. E end he lif ing a m and po i ion he pad of each lif ing a m benea h he bod f ame longi dinal lif ing poin .

3. Rai e he ehicle n il he heel a e j clea of he g o nd and check ha he pad of each lif ing a m a e ill
co ec l po i ioned.

4. Rai e he ehicle o he de i ed heigh .

5. En e ha ehicle i co ec l ppo ed on all fo lif ing pad , ha pad a e ill co ec l po i ioned and a e in
f ll con ac i h he bod f ame longi dinal .

WARNING: Make e ha he ehicle i able befo e commencing o k.

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Published: 11-May-2011
Jacking and Lifting - Vehicle Recover
Description and Operation

Towing/Lashing e es

C AUTION: The single towing/lashing eyes at the front and rear of the vehicle are designed for vehicle recovery
purposes only and MUST not be used to tow a trailer or caravan.

The front towing/lashing eye is accessible after releasing the 9 toggle fasteners securing the towing eye access panel
and removing the panel.

C AUTION: Ensure that during towing, the towing attachment does not contact the bumper.

The rear towing/lashing eye 'A' is accessible after releasing the 2 fasteners securing the access panel to the bumper
and removing the panel.

C AUTION: This towing/lashing eye should only be used for towing another vehicle or for recovery purposes to
enable this vehicle to be positioned in order that the front towing eye may be used for recovery/towing.

4 Wheel Towing

C AUTIONS:

Suspended towing of this vehicle MUST NOT be attempted, if 4 wheel towing is not possible, vehicle must be
recovered on a suitable trailer.

The vehicle may be towed for a maximum of 3 hours or 90 miles (150 km) at a maximum speed of 30 mph (50
km/h), these limits MUST NOT be exceeded.

The following procedures must be followed to ensure that the vehicle is towed in a safe condition and damage to
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the vehicle transmission system is prevented.

1. Remove the front towing/lashing eye access panel.

2. Secure the towing attachment from the recovery vehicle to the towing/lashing eye.

C AUTION: Ensure that the towing attachment will not contact the front bumper during towing.

3. Apply the parking brake.

4. Insert ignition key and turn the ignition switch to position 'II'.

5. Manual gearbo : Apply the footbrake and position the gear lever in 'N' - Neutral.

C AUTION: If 'N' - Neutral cannot be selected, front and rear propeller shafts must be removed before vehicle is
towed.

6. Automatic gearbo : Apply the footbrake and move the selector lever to the 'N' Neutral position.

NOTE: If electrical power is not available, use the manual interlock release tab on the selector lever to move the
selector lever to the Neutral position.

All vehicles

7. Select 'H' - HIGH on the transfer box.

C AUTION: If electrical power is not available, and 'H' - HIGH cannot be selected, the vehicle may not be towed
but must be recovered on a suitable trailer. If, however, transfer box was in 'H' - HIGH when electrical power was
lost, vehicle may still be towed.

8. Release the parking brake.

NOTE: If electrical power is not available, it will be necessary to release the parking brake manually using the
following procedures:

NOTE: Left hand drive illustrated, right hand drive on opposite side of centre console.

9. Lift out the coin tray from the centre console

10. Remove the access panel from the centre console.

11. Locate the electric parking brake release cable, insert a suitable tool through the cable eye and pull the cable
upwards to release the parking brake.

C AUTION: The electric parking brake will not function until electrical power is restored it will, therefore, be
necessary to chock the wheels when vehicle is at a standstill.

WARNING: Do not release the parking brake until towing is about to commence. Whilst towing, do not attempt to
remove the ignition key and do not turn the key to any position other than 'II'. With the engine switched off, the
power assisted steering system and brake booster will be inoperative thereby resulting in an increase in the effort
required to turn the steering wheel and apply the brakes.

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C AUTION: The ehic e c ec i h d be ed i a ad c di i ,' a ch' ec e be

a ided.

On completion of 4 wheel towing

1. A he a i gb a e if e ec ica e i a ai ab e, ec e ch c he hee .

2. De ach i ge i e f i g/ a hi g e e .

3. Fi he i g e e acce a e a d ec e he gg e fa e e .

Transporting b trailer

C AUTION: U e he i g/ a hi g e e a he f a d ea f he ehic e, DO NOT ec e a hi g h

e ai a he a f he ehic e.

P ii he ehic e, a he a i g b a e a d e ec 'N' - Ne a he a a a a ic gea b e ec

e e

C AUTION: If e ec ica e i a ai ab e a d he a i g b a e i e ea ed, i i be ib e e-a

he a i g b a e. I i , he ef e be ece a e ec 1 gea - a a gea b 'P' Pa - a a ic gea b
a de e ha he ehic e hee a e ade a e ch c ed e e ehic e e e .

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P bli hed: 11-Ma -2011

Maintenance Schedules - Maintenance Schedules - Gasoline Engines
De c ip ion and Ope a ion

Torque Specif ications

Description Nm lb-ft
Sea f ame fi ing To c e 40 30
Sea bel fi ing To c e 40 30
Road heel n 140 103
M12 ie od end n 76 56

C AUTION: Unle a ed o he i e, he follo ing ope a ion m be ca ied o a e e e ice in e al. No e

ha he 'A' and 'B' Se ice In e al li ed on he 'Main enance C heck Shee ' fo ehicle ope a ing nde a d o
condi ion , a f om ho e pecified fo ehicle ope a ing nde no mal condi ion . Refe ence m he efo e,
al a be made o he 'A d o C ondi ion Main enance C heck Shee ' fo ehicle ope a ing nde he e condi ion .

Underbonnet Vie - 4.0 Litre

1. Engine oil le el indica o

2. Engine oil fille cap
3. Po e ee ing fl id e e oi
4. B ake fl id e e oi (LH d i e ill a ed - RH d i e on oppo i e ide)
5. C oolan e pan ion ank
6. Wind c een a he e e oi

Underbonnet Vie - 4.4 Litre

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1. Engine oil fille cap

2. Engine oil le el indica o
3. Po e ee ing fl id e e oi
4. B ake fl id e e oi (LH d i e ill a ed - RH d i e on oppo i e ide)
5. C oolan e pan ion ank
6. Wind hield a he e e oi

Main enance Ope a ion

Sea and Safe Bel

F on ea f ame fi ing - E e 2 ea o 30,000 mile (48,000 km)

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. C a ef ll emo e he im panel co e ing he ea f ame fi ing To c e .

. C heck ha he f on ea f ame fi ing To c e a e ec e and ha he ea f ame ho no ign of

mo emen .

.In all he im panel on comple ion.

Rea ea f ame f on fi ing - E e 2 ea o 30,000 mile (48,000 km)

. C heck ha he ea ea f ame f on fi ing a e ec e and ha he ea f ame ho no ign of mo emen .

Rea ea f ame ea fi ing - E e 2 ea o 30,000 mile (48,000 km)

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. Fold he ea c hion fo a d and check ha he ea ea f ame ea fi ing a e ec e and ha he ea

f ame ho no ign of mo emen .

. Fold he ea c hion back on comple ion.

F on ea con ol

. C heck ope a ion of all ea con ol .

Safe bel -E e 2 ea o 30,000 mile (48,000 km)

. F ll e end each Safe bel and check ha i e n na i ed; epea fo all bel .

. C heck en i e leng h of afe bel ebbing fo ign of f a ing o damage; epea fo all bel .

10. C onnec each afe bel o he co ec b ckle, check afe bel b ckle and ong e a e ec e; check ha b ckle
elea e ong e co ec l .

11. C heck all afe bel and b ckle mo n ing and fi ing fo ec i .

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12. C heck f on afe bel heigh adj e fo co ec ope a ion.

Lamps, Horns and Warning Indicators

1. C heck ide, head, fog, e e ing and ail lamp fo co ec ope a ion.

2. C heck ope a ion of headlamp a oma ic le elling em - if in alled.

3. C heck n ignal and ha a d a ning lamp fo co ec ope a ion.

4. C heck b ake ( op) lamp fo co ec ope a ion.

5. C heck all e e io lamp len e fo cla i and condi ion; pa pa ic la a en ion o headlamp and fog lamp len e
fo one chip o damage.

6. C heck ho n fo lo d, clea o nd.

7. S i ch on headlamp and check ha ide/headlamp eminde a ning o nd hen doo i opened.

8. C heck ope a ion of in e io co e lamp .

9. C heck ope a ion of all in men pack a ning and indica o lamp .

Washers and Wipers

1. C heck all ipe blade fo condi ion and ign of pli o damage.

2. C heck ec i of ipe a m .

3. Ope a e f on and ea ind hield a he , check ha je a e clea and co ec l aimed.

4. Ope a e f on and ea ipe a all peed and check fo moo h, mea f ee ope a ion.

Check High/Lo Gear Engagement

1. Selec LOW ange gea , d i e ehicle fo a d 3 o4 ehicle leng h , op ehicle and elec HIGH ange gea -
gea m engage moo hl .

Pollen Filter
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1. Replace pollen filter.
For additional information, refer to: Pollen Filter (412-01 Air Distribution and Filtering, Removal and Installation).

Corrosion/Cosmetic Inspection

1. C arry out the annual corrosion/cosmetic inspection using the Annual C orrosion Inspection Sheet.

Wheels and Tires

1. C heck that tires comply with manufacturer's specification.

For additional information, refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).

2. C heck/adjust tire pressures including spare.

For additional information, refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).

3. Vehicle with Uni-directional tires installed: Mark the wheel to stud relationship of each road wheel and note
location of each road wheel to its respective hub.

4. Loosen road wheel nuts. Raise vehicle to a wheel free condition.

For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

5. Remove the road wheels.

6. Visually check tires for condition, lumps or bulges. C heck tread depth across the width of the tire and around the
circumference; make sure that remaining tread depth does not contravene local legislative requirements.

NOTE: Do not install wheels at this stage.

Braking S stem

C AUTION: When vehicles are operating under arduous conditions, the following service items must
be carried out ever 3 months or 3,750 miles (6,000 km)

1. Inspect front brake pads for wear.

For additional information, refer to: Specifications (206-03 Front Disc Brake, Specifications).

2. Inspect rear brake pads for wear.

For additional information, refer to: Specifications (206-04 Rear Disc Brake, Specifications).

3. C heck brake calipers for signs of fluid leaks.

4. C heck brake discs for condition.

5. C heck all brake booster and brake system pipes and hoses for condition, chafing and leaks.

6. C lean road wheel hub spigots and apply grease, Land Rover Part Number RYL 105020 to the wheel mating surface
of each spigot.

7. Vehicles with Uni-directional tires installed: Install road wheels on their respective hubs ensuring that stud to
wheel relationship is maintained.

8. Vehicles with NON uni-directional tires installed: Install wheels on the opposite side of the vehicle but make
sure that they are the same axle as they were originally installed.

9. Install road wheel nuts and tighten to 140 Nm (103 lb-ft).

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C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 2 ears or 30,000 miles (48,000 km).

10. Ever 3 ears or 45,000 miles (72,000 km): Replace brake fluid.
For additional information, refer to: Brake System Bleeding (206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).

11. Ever 6 ears or 90,000 miles (144,000 km): Replace all flexible brake hoses.

Electric Parking Brake

C AUTION: When vehicles are operating under arduous conditions, the following service items must
be carried out ever 3 months or 3,750 miles (6,000 km)

1.C heck the adjustment of the electric parking brake.

For additional information, refer to: Parking Brake Shoe and Lining Adjustment (206-05 Parking Brake and Actuation,
General Procedures).

2. Vehicles operating under arduous conditions: C heck the condition of the electric parking brake system.

Road Wheel Speed Sensors

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 3 months or 3,750 miles (6,000 km).

1. Inspect the road wheel speed sensor harnesses for damage.

Radiator and Cooling Fan

1. Vehicles operating under arduous conditions: Visually check radiator for external obstructions, check cooling
fan blades for damage.

Air Suspension

1. Ever 5 ears or 75,000 miles (120,000 km) - Vehicles operating under arduous conditions: Replace
air suspension compressor filter.
For additional information, refer to: Air Suspension Air Filter (204-05 Vehicle Dynamic Suspension, Removal and
Installation).

Door Locks and Hinges

1. C heck operation of all door locks, bonnet lock and fuel filler flap.

2. Lubricate all door check straps, bonnet catch and fuel filler flap catch.

Cooling S stem

1. C heck specific gravity of coolant using a hydrometer.

NOTE: A suitable hydrometer is available from the Equipment Programme under Part Number 511 3302 001 00.

2. Top-up cooling system if necessary.

For additional information, refer to: Specifications (303-03B Engine C ooling - V8 4.4L Petrol, Specifications).

C AUTION: Anti-free e concentration must be maintained at 50%.

C ooling system - C heck/Top-up

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WARNING: Since inj ch a calding co ld be ca ed b e caping eam o coolan , do no

emo e he fille cap f om he coolan e pan ion ank hil he em i ho .

C AUTION: Engine coolan ill damage he pain fini hed face . If coolan i pilled, immedia el
emo e he coolan and a h he a ea i h a e .

1. C hec he e e f c a i he e a i a . Wi h he e gi e c d, he c a e e be he 'UPPER
LEVEL' i dica a ab e he 'COLD FILL RANGE' e he ide f he e a i a . Ig e a c a
hich a be i ib e i he ec i f he a .

2. If i g- i e i ed, e e e a i a fi e ca a d - c a e e he 'UPPER LEVEL'

i dica a .
F addi i a i f a i , efe : S ecifica i (303-03A E gi e C i g - V6 4.0L Pe , S ecifica i )/
S ecifica i (303-03B E gi e C i g - V8 4.4L Pe , S ecifica i ).

C AUTION: Al a op- p i h a 50% mi e of an i-f ee e and a e .

3. I a e a i a fi e ca , igh e ca i a che i hea d 'c ic '.

C a - Re ace

1. E e 10 ea o 150,000 mile (240,000 km):F addi i a i f a i , efe :C i gS e D ai i g,

Fi i g a d B eedi g (303-03A E gi e C i g - V6 4.0L Pe , Ge e a P ced e ).Re ace he c a .
F addi i a i f a i , efe :C i gS e D ai i g, Fi i g a d B eedi g (303-03B E gi e C i g - V8 4.4L
Pe , Ge e a P ced e ).

Igni ion S em

1. * E e 12 mon h o 15,000 mile (24,000 km) Vehicle ing LEADED f el o ho e fi ed i h

COPPER pa k pl g : Re ace a g .
F addi i a i f a i , efe : S ecifica i (303-07A E gi e Ig i i - V6 4.0L Pe , S ecifica i )/
S ecifica i (303-07B E gi e Ig i i - V8 4.4L Pe , S ecifica i )/
S a P g (303-07A E gi e Ig i i - V6 4.0L Pe , Re a a dI a ai )/
S a P g (303-07B E gi e Ig i i - V8 4.4L Pe , Re a a dI a a i ).

2. E e 3 ea o 45,000 mile (72,000 km) - Vehicle ope a ing nde a d o condi ion : Re ace
a g .
F addi i a i f a i , efe : S ecifica i (303-07A E gi e Ig i i - V6 4.0L Pe , S ecifica i )/
S ecifica i (303-07B E gi e Ig i i - V8 4.4L Pe , S ecifica i )/
S a P g (303-07A E gi e Ig i i - V6 4.0L Pe , Re a a dI a ai )/
S a P g (303-07B E gi e Ig i i - V8 4.4L Pe , Re a a dI a a i ).

3. E e 6 ea o 90,000 mile (144,000 km) - 4.0 li e V6 and 4.4 li e V8 engine - NAS Vehicle :
Re ace a g .
F addi i a i f a i , efe : S ecifica i (303-07A E gi e Ig i i - V6 4.0L Pe , S ecifica i )/
S ecifica i (303-07B E gi e Ig i i - V8 4.4L Pe , S ecifica i )/
S a P g (303-07A E gi e Ig i i - V6 4.0L Pe , Re a a dI a ai )/
S a P g (303-07B E gi e Ig i i - V8 4.4L Pe , Re a a dI a a i ).

4.E e 6 ea o 90,000 mile (144,000 km) - 4.0 li e V6 engine - Re of Wo ld and ehicle ing
UNLEADED f el b no ho e ope a ing nde a d o condi ion : Re ace a g .
F addi i a i f a i , efe : S ecifica i (303-07A E gi e Ig i i - V6 4.0L Pe , S ecifica i )/

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Spark Plugs (303-07A Engine Ignition - V6 4.0L Petrol, Removal and Installation).

5. Ever 7 ears or 105,000 miles (168,000 km) - 4.4 litre V8 engines - Not NAS vehicles: Replace spark
plugs.
For additional information, refer to: Specifications (303-07B Engine Ignition - V8 4.4L Petrol, Specifications) /
Spark Plugs (303-07B Engine Ignition - V8 4.4L Petrol, Removal and Installation).

NOTE: * 4.0 litre V6 engines ma have either copper or platinum spark plugs installed.

Air Filtering

1. Ever 4 ears or 60,000 miles (96,000 km): Replace the air filter element.
For additional information, refer to: Air C leaner Element (303-12B Intake Air Distribution and Filtering - V8 4.4L
Petrol, Removal and Installation).

Ancillar Drive Belt

1. C heck the condition of the ancillary drive belt.

2. Remove all traces of mud and dirt from the drive belt and pulleys.

3. C heck the drive belt for signs of splitting and wear.

C AUTION: When vehicles are operating under arduous conditions, the following service items must
be carried out ever 5 ears or 75,000 miles (120,000 km).

4. Ever 7 ears or 105,000 miles (168,000 km) - 4.0 Litre engine: Replace the ancillary drive belt.
For additional information, refer to: Accessory Drive Belt (303-05A Accessory Drive - V6 4.0L Petrol, Removal and
Installation).

5. Ever 10 ears or 150,000 miles (240,000 km) - 4.4 Litre engine: Replace the ancillary drive belt.
For additional information, refer to: Accessory Drive Belt (303-05B Accessory Drive - V8 4.4L Petrol, Removal and
Installation).

Fluid Levels

Brake fluid reservoir

1. Remove the auxiliary battery box cover.

2. C heck the fluid level in the brake fluid reservoir, the level must be to the 'MAX' mark on the reservoir; top-up if
necessary.

3. C lean the area around the reservoir filler cap, remove cap.

4. If necessary, top-up using the recommended fluid to the 'MAX' mark on the reservoir.
For additional information, refer to: Specifications (206-00 Brake System - General Information, Specifications).

5. Install the reservoir filler cap.

6. Install the auxiliary battery box cover.

Power steering fluid reservoir

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C AUTION: To prevent over filling, check/top-up the s stem with the engine switched off and the
s stem cold. Make sure that the steering wheel is in the straight ahead position, do not turn the
steering wheel prior to checking the fluid level.

1. C heck that the fluid level is to the mid-way mark between the 'MAX' and 'MIN' marks on the fluid reservoir, top-
up if necessary.

2. C lean the area around the reservoir filler cap, remove cap.

3. If necessary, top-up using the recommended fluid to the mid-way mark on the reservoir.
For additional information, refer to: Specifications (211-02 Power Steering, Specifications).
.

C AUTION: Do not fill reservoir above the 'MAX' mark.

4. Install the reservoir filler cap.

Windshield washer reservoir

1. Remove the windshield washer reservoir filler cap.

2. Top-up the reservoir using a mixture of an approved windshield washer fluid and water until the level is to the
bottom of the gauze filter in the reservoir filler neck.

3. Install the reservoir filler cap.

Engine Oil and Filter

C AUTIONS:

NAS and Rest of World Vehicles - Not UK and Europe: The following service items must be carried
out ever 6 months or 7,500 miles (12,000 km).

When vehicles are operating under arduous conditions, the following service items must be
carried out ever 3 months or 3,750 miles (6,000 km).
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1. R - 4.0 .
F , :S (303-01A E - V6 4.0L P ,S )/
E O D F (303-01A E - V6 4.0L P ,G P ).

2. R - 4.4 .
F , :S (303-01B E - V8 4.4L P ,S )/
E O D F (303-01B E - V8 4.4L P ,G P ).

A oma ic T an mi ion

1. E e 10 ea o 150,000 mile (240,000 km): R - 4.0 .

F , :S (307-01A A T /T - V6 4.0L P ,
S )/
T F D R (307-01A A T /T - V6 4.0L P ,G
P ).

2. E e 10 ea o 150,000 mile (240,000 km): R - 4.4 .

F , :S (307-01C A T /T - TDV6 2.7L D ,
S )/
T F D R (307-01B A T /T - V8 4.4L P ,G
P ).

T an fe Ca e

1. E e 5 ea o 75,000 mile (120,000 km): R .

F , :S (308-07B T C ,S )/
T C D F (308-07B T C ,G P ).

Diffe en ial A emblie

1. E e 10 ea o 150,000 mile (240,000 km): R .

F , :S (205-03 F D A /D ,S )/
D D F (205-03 F D A /D ,G P ).

2. E e 5 ea o 75,000 mile (120,000 km): R 'E T M (ETM)' .

F , :S (205-02 R D A /D ,S )/
D D F (205-03 F D A /D ,G P ).

3. E e 10 ea o 150,000 mile (240,000 km): R 'OPEN' .

F , :S (205-02 R D A /D ,S )/
D D F (205-02 R D A /D ,G P ).

S pen ion and Bod Mo n ing

1. C .

2. C .

3.L / ( . . 1200
). C / ,
.A
.I ( ) , .

F el S em

1. C , , .

Elec ical Ha ne e

1. C .

Oil/Fl id Leak

1. C / .

E ha S em

1. C , .

Po e S ee ing

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1. C heck power steering rod ball joint fixings, gaiters and condition of ball joints and dust covers.

2. C heck power steering pipes, hoses and unions for chafing, leaks and corrosion.

NOTE: M14 tie rod end nuts do not require checking.

3. C heck torque of the tie rod end nuts - M12 nuts tighten to 76 Nm (56 lb.ft).

Fault Lamp(s)

1. If fault lamp(s) are illuminated, test the associated system using approved Land Rover diagnositc equipment and
report findings.

Road Test

1. C arry out road test of vehicle.

For additional information, refer to: Road/Roller Testing (100-00 General Information, Description and Operation).

General

1. Endorse Service Record.

2. Report any unusual features of vehicle condition and any additional work required.

ADDITIONAL ITEMS THAT MAY REQUIRE ATTENTION

It is recommended that:

1. Ever 6 ears: All brake fluid hydraulic seals are replaced.

NOTE: This is in addition to the maintenance requirement that flexible brake hoses MUST be replaced at this service
interval.

2. After 50 miles (80 km) continuous use in severe off-road conditions i.e. wading, deep mud and
abrasive grit/slurr : The electric parking brake should be cleaned and inspected.

3. After 50 miles (80 km) continuous use in severe off-road conditions i.e. wading, deep mud and
abrasive grit/slurr : The ancillary drive belt should be cleaned and inspected.

4. Vehicles with air suspension installed: Vehicles used extensively in arduous or off road conditions will require
the compressor air inlet filter to be renewed more frequently.

5. Vehicles used in dust or field conditions or deep wading: More frequent attention to the air cleaner will be
required.

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P bli hed: 11-Ma -2011

Maintenance Schedules - Maintenance Schedules - Diesel Engines
De c ip ion and Ope a ion

Torque Specif ications

Description Nm lb-ft
Sea f ame fi ing To c e 40 30
Sea bel fi ing To c e 40 30
Road heel n 140 103
M12 ie od end n 76 56

C AUTION: Unle a ed o he i e, he follo ing ope a ion m be ca ied o a e e e ice in e al. No e

ha he A and B Se ice li ed on he Main enance C heck Shee , applicable o ehicle ope a ing nde a d o
condi ion , a bo h in pe iod and mileage (kilome e ) o he in e al pecified fo ho e ehicle ope a ing nde
no mal condi ion . Refe ence m he efo e, al a be made o he 'A d o C ondi ion Main enance C heck Shee '
fo ehicle ope a ing nde he e condi ion .

Underbonnet Vie - 2.7 Litre

1. Engine oil le el indica o

2. Engine oil fille cap
3. Po e ee ing fl id e e oi
4. B ake/cl ch fl id e e oi (LH d i e ill a ed - RH d i e on oppo i e ide)
5. C oolan e pan ion ank
6. Wind hield a he e e oi

Maintenance Operations

Sea and Safe Bel

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F on ea f ame fi ing - E e 2 ea o 30,000 mile (48,000 km)

. C a ef ll emo e he im panel co e ing he ea f ame fi ing To c e .

. C heck ha he f on ea f ame fi ing To c e a e ec e and ha he ea f ame ho no ign of

mo emen .

. Rein all he im panel on comple ion.

Rea ea f ame f on fi ing - E e 2 ea o 30,000 mile (48,000 km)

. C heck ha he ea ea f ame f on fi ing a e ec e and ha he ea f ame ho no ign of mo emen .

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Rea ea f ame ea fi ing - E e 2 ea o 30,000 mile (48,000 km)

. Fold he ea c hion fo a d and check ha he ea ea f ame ea fi ing a e ec e and ha he ea

f ame ho no ign of mo emen .

. Fold he ea c hion back on comple ion.

F on ea con ol

. C heck ope a ion of all ea con ol .

Sea bel -E e 2 ea o 30,000 mile (48,000 km)

. F ll e end each afe bel and check ha i e n na i ed; epea fo all bel .

. C heck en i e leng h of afe bel ebbing fo ign of f a ing o damage; epea fo all bel .

10. C onnec each afe bel o he co ec b ckle, check afe bel b ckle and ong e a e ec e; check ha b ckle
elea e ong e co ec l .

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11. C heck all afe bel and b ckle mo n ing and fi ing fo ec i .

12. C heck f on afe bel heigh adj e fo co ec ope a ion.

Lamps, Horns and Warning Indicators

1. C heck ide, head, fog, e e ing and ail lamp fo co ec ope a ion.

2. C heck ope a ion of headlamp a oma ic le elling em - if in alled.

3. C heck n ignal and ha a d a ning lamp fo co ec ope a ion.

4. C heck b ake ( op) lamp fo co ec ope a ion.

5. C heck all e e io lamp len e fo cla i and condi ion; pa pa ic la a en ion o headlamp and fog lamp len e
fo one chip o damage.

6. C heck ho n fo lo d, clea o nd.

7. S i ch on headlamp and check ha ide/headlamp eminde a ning o nd hen doo i opened.

8. C heck ope a ion of in e io co e lamp .

9. C heck ope a ion of all in men pack a ning and indica o lamp .

Washers and Wipers

1. C heck all ipe blade fo condi ion and ign of pli o damage.

2. C heck ec i of ipe a m .

3. Ope a e f on and ea ind hield a he , check ha je a e clea and co ec l aimed.

4. Ope a e f on and ea ipe a all peed and check fo moo h, mea f ee ope a ion.

Check High/Lo Gear Engagement

1. Selec LOW ange gea , d i e ehicle fo a d 3 o4 ehicle leng h , op ehicle and elec HIGH ange gea -
gea m engage moo hl .
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Pollen Filter

1. Replace pollen filter.

For additional information, refer to: Pollen Filter (412-01 Air Distribution and Filtering, Removal and Installation).

Corrosion/Cosmetic Inspection

1. C arry out the annual corrosion/cosmetic inspection using the Annual C orrosion Inspection Sheet.

Wheels and Tires

1. C heck that tires comply with manufacturer's specification.

For additional information, refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).

2. C heck/adjust tire pressures including spare.

For additional information, refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).

3. Vehicles with Uni-directional tires installed: Mark the wheel to stud relationship of each road wheel and note
location of each road wheel to its respective hub.

4. Loosen road wheel nuts. Raise vehicle to a wheel free condition.

For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

5. Remove the road wheels.

6. Visually check tires for condition, lumps or bulges. C heck tread depth across the width of the tire and around the
circumference; make sure that remaining tread depth does not contravene local legislative requirements.

NOTE: Do not install wheels at this stage.

Braking S stem

C AUTION: When vehicles are operating under arduous conditions, the following service items must
be carried out ever 3 months or 3,750 miles (6,000 km).

1. Inspect front brake pads for wear.

For additional information, refer to: Specifications (206-03 Front Disc Brake, Specifications).

2. Inspect rear brake pads for wear.

For additional information, refer to: Specifications (206-04 Rear Disc Brake, Specifications).

3. C heck brake calipers for signs of fluid leaks.

4. C heck brake discs for condition.

5. C heck all brake booster and brake system pipes and hoses for condition, chafing and leaks.

6. C lean road wheel hub spigots and apply grease, Land Rover Part Number RYL 105020 to the wheel mating surface
of each spigot.

7. Vehicles with Uni-directional tires installed: Install road wheels to their respective hubs ensuring that stud to
wheel relationship is maintained.

8. Vehicles with NON uni-directional tires installed: Install wheels on the opposite side of the vehicle but make
sure that they on the same axle as they were originally installed.

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9. In all oad heel n and igh en o 140 Nm (103 lb-f ).

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 2 ears or 30,000 miles (48,000 km).

10. Ever 3 ears or 45,000 miles (72,000 km): Replace b ake fl id.
Fo addi ional info ma ion, efe o: B ake S em Bleeding (206-00 B ake S em - Gene al Info ma ion, Gene al
P oced e ) /
B ake S em P e e Bleeding (206-00 B ake S em - Gene al Info ma ion, Gene al P oced e ).

11. Ever 6 ears or 90,000 miles (144,000 km): Replace all fle ible b ake ho e .

Elec ic Pa king B ake

C AUTION: When vehicles are operating under arduous conditions, the following service items must
be carried out ever 3 months or 3,750 miles (6,000 km)

1.C heck he adj men of he elec ic pa king b ake.

Fo addi ional info ma ion, efe o: Pa king B ake Shoe and Lining Adj men (206-05 Pa king B ake and Ac a ion,
Gene al P oced e ).

2. Vehicles operating under arduous conditions: C heck he condi ion of he elec ic pa king b ake em.

Road Wheel Speed Sensors

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 3 months or 3,750 miles (6,000 km).

1. In pec he oad heel peed en o ha ne e fo damage.

Fuel Filter Element

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 12 months or 15,000 miles (24,000 km).

1. Ever 2 ears or 30,000 miles (48,000 km): Replace f el fil e elemen . Fo addi ional info ma ion, efe o:
(310-01C F el Tank and Line - TDV6 2.7L Die el)

F el Fil e Elemen - VIN Range: SALLA000304->END OF 06MY (Remo al and In alla ion),
F el Fil e Elemen - VIN Range: 07 MODEL YEAR->C URRENT (Remo al and In alla ion).

Fuel Sedimentor

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 3 months or 3,750 miles (6,000 km).

1. D ain he f el edimen o .
Fo addi ional info ma ion, efe o: Die el Fil e Wa e D ain-Off (310-00 F el S em - Gene al Info ma ion, Gene al
P oced e ).

Radiator/intercooler and Cooling Fan

C AUTION: Vehicles operating under arduous conditions:

1. Vi all check he adia o /in e coole fo e e nal ob c ion , check cooling fan blade fo damage.

2. Remo e an deb i f om he in e coole ing a lo p e e ho e.

Air Suspension

1. Ever 5 ears or 75,000 miles (120,000 km) - Vehicles operating under arduous conditions: Replace
he ai pen ion comp e o fil e .
Fo addi ional info ma ion, efe o: Ai S pen ion Ai Fil e (204-05 Vehicle D namic S pen ion, Remo al and
In alla ion).

Door Locks and Hinges

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1. C heck operation of all door locks, bonnet lock and fuel filler flap.

2. Lubricate all door check straps, bonnet catch and fuel filler flap catch.

Cooling S em

1. C heck specific gravity of coolant using a hydrometer.

NOTE: A suitable hydrometer is available from the Equipment Programme under Part Number 511 3302 001 00.

2. Top-up cooling system if necessary.

For additional information, refer to: Specifications (303-03B Engine C ooling - V8 4.4L Petrol, Specifications).

C AUTION: An i-f ee e concen a ion m be main ained a 50%.

C ooling system - C heck/Top-up

WARNING: Since inj ch a calding co ld be ca ed b e caping eam o coolan , do no

emo e he fille cap f om he coolan e pan ion ank hil he em i ho .

C AUTION: Engine coolan ill damage he pain fini hed face . If coolan i pilled, immedia el
emo e he coolan and a h he a ea i h a e .

1. C heck the level of coolant in the expansion tank. With the engine cold, the coolant level must be to the'UPPER
LEVEL' indicator mark above the 'COLD FILL RANGE' text on the side of the expansion tank. Ignore any coolant
which may be visible in the top section of the tank.

2. If topping-up is required, remove expansion tank filler cap and top-up coolant level to the 'UPPER LEVEL'
indicator mark.
For additional information, refer to: Specifications (303-03C Engine C ooling - TDV6 2.7L Diesel, Specifications).

C AUTION: Al a op- p i h a 50% mi e of an i-f ee e and a e .

3. Fit expansion tank filler cap, tighten cap until ratchet is heard to 'click'.

C oolant - Replace

1. E e 10 ea o 150,000 mile (240,000 km): Replace the coolant.

For additional information, refer to: C ooling System Draining, Filling and Bleeding (303-03C Engine C ooling - TDV6
2.7L Diesel, General Procedures).

Ai Fil e ing

C AUTION: When ehicle a e ope a ing nde a d o condi ion , he follo ing e ice i em m
be ca ied o e e 3 mon h o 3,750 mile (6,000 km).

1. E e 3 ea o 45,000 mile (72,000 km): Replace the air filter element.

For additional information, refer to: Air C leaner Element (303-12C Intake Air Distribution and Filtering - TDV6 2.7L
Diesel, Removal and Installation).

Ancilla D i e Bel

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1. C heck he condi ion of he ancilla d i e bel .

2. Remo e all ace of m d and di f om he d i e bel and p lle .

3. C heck he d i e bel fo ign of pli ing and ea .

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 3 ears or 45,000 miles (72,000 km).

2. Ever 7 ears or 105,000 miles (168,000 km): Replace he ancilla d i e bel .

Fo addi ional info ma ion, efe o: Acce o D i e Bel (303-05C Acce o D i e - TDV6 2.7L Die el, Remo al and
In alla ion).

Camshaft Timing Belt and High Pressure Fuel Pump Drive Belt

C AUTION: When vehicles are operating under arduous conditions, the following service item must
be carried out ever 4 ears or 60,000 miles (96,000 km).

3. Ever 7 ears or 105,000 miles (168,000 km): Replace cam haf iming bel .
Fo addi ional info ma ion, efe o: Timing Bel (303-01C Engine - TDV6 2.7L Die el, In- ehicle Repai ).
Replace he High p e e f el p mp d i e bel .
Fo addi ional info ma ion, efe o: F el Injec ion P mp Bel - VIN Range: SALLA000304->END OF 06 MY (303-05C
Acce o D i e - TDV6 2.7L Die el, Remo al and In alla ion).

Fluid Levels

B ake/cl ch fl id e e oi

1. Remo e he a ilia ba e bo co e .

2. C heck he fl id le el in he b ake/cl ch fl id e e oi , he le el m be o he 'MAX' ma k on he e e oi ; op-

p if nece a .

3. C lean he a ea a o nd he e e oi fille cap, emo e he cap.

4. If nece a , op- p ing he ecommended fl id o he 'MAX' ma k on he e e oi .

Fo addi ional info ma ion, efe o: Specifica ion (206-00 B ake S em - Gene al Info ma ion, Specifica ion ).

5. Rein all he e e oi fille cap.

6. In all he a ilia ba e bo co e .

Po e ee ing fl id e e oi

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C AUTION: To prevent over filling, check/top-up the system with the engine switched off and the system cold.
Make sure that the steering wheel is in the straight ahead position, do not turn the steering wheel prior to checking
the fluid level.

1. C heck that the fluid level is to the mid-way mark between the 'MAX' and 'MIN' marks on the fluid reservoir, top-
up if necessary.

2. C lean the area around the reservoir filler cap, remove the cap.

3. If necessary, top-up using the recommended fluid to the mid-way mark on the reservoir.
For additional information, refer to: Specifications (211-02 Power Steering, Specifications).
.

C AUTION: Do no fill e e oi abo e he 'MAX' ma k.

4. Reinstall the reservoir filler cap.

Windshield washer reservoir

1. Remove the windshield washer reservoir filler cap.

2. Top-up the reservoir using a mixture of an approved windshield washer fluid and water until the level is to the
bottom of the gauze filter in the reservoir filler neck.

3. Reinstall the reservoir filler cap.

Engine Oil and Fil e

C AUTIONS:

When ehicle a e ope a ing nde a d o condi ion , he follo ing e ice i em m be ca ied
o e e 3 mon h o 3,750 mile (6,000 km).

Vehicle ope a ing on high lph con en f el - abo e 0.7%, he oil and fil e change pe iod
MUST NOT e ceed 3 mon h o 3,750 mile (6,000 km).
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Vehicle ope a ing on mode a e lph con en f el - 0.3 o 0.7%, he oil and fil e change pe iod
MUST NOT e ceed 6 mon h o 7,500 mile (12,000 km).

1. Renew engine oil and filter.

For additional information, refer to: Engine Oil Draining and Filling (303-01C Engine - TDV6 2.7L Diesel, General
Procedures).

A oma ic T an mi ion

1. E e 10 ea o 150,000 mile (240,000 km): Renew automatic transmission fluid.

For additional information, refer to: Specifications (307-01C Automatic Transmission/Transaxle - TDV6 2.7L Diesel,
Specifications) /
Transmission Fluid Drain and Refill (307-01C Automatic Transmission/Transaxle - TDV6 2.7L Diesel, General
Procedures).

T an fe Ca e

1. E e 5 ea o 75,000 mile (120,000 km): Renew transfer case fluid.

For additional information, refer to: Specifications (308-07B Transfer C ase, Specifications) /
Transfer C ase Draining and Filling (308-07B Transfer C ase, General Procedures).

Diffe en ial A emblie

1. E e 10 ea o 150,000 mile (240,000 km): Renew front differential oil.

For additional information, refer to: Specifications (205-03 Front Drive Axle/Differential, Specifications) /
Differential Draining and Filling (205-03 Front Drive Axle/Differential, General Procedures).

2. E e 5 ea o 75,000 mile (120,000 km): Renew rear 'Electronic Torque Managed (ETM)' differential oil.
For additional information, refer to: Specifications (205-02 Rear Drive Axle/Differential, Specifications) /
Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General Procedures).

3. E e 10 ea o 150,000 mile (240,000 km): Renew rear 'OPEN' differential oil.

For additional information, refer to: Specifications (205-02 Rear Drive Axle/Differential, Specifications) /
Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General Procedures).

S pen ion and Bod Mo n ing

1. C heck for free play in all suspension and body mounting rubbers.

2. C heck condition of suspension rubber boots and gaiters.

3.Lift the vehicle so that front wheels are clear of ground/ramp to enable insertion of a suitable lever (e.g. a 1200mm
long steel tube). C heck the lower ball joints for free play by placing the lever between the ground/ramp and the tire,
and lifting the wheel assembly with the lever. A second person will be required to check simultaneously for any ball
joint lift. If free play (knock) is noted in the ball joint, replacement is required.

F el S em

1. C heck fuel system pipes, hoses and unions for chafing, leaks and corrosion.

Elec ical Ha ne e

1. C heck all electrical harnesses for chafing.

Oil/Fl id Leak

1. C heck for oil/fluid leaks.

E ha S em

1. C heck exhaust system for leaks, security and damage.

Po e S ee ing

1. C heck power steering rod ball joint fixings, gaiters and condition of ball joints and dust covers.

2. C heck power steering pipes, hoses and unions for chafing, leaks and corrosion.

NOTE: M14 tie rod end nuts do no require checking.

3. C heck torque of the tie rod end nuts - M12 nuts tighten to 76 Nm (56 lb.ft).
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Clutch

1. C heck clutch pipes and unions for chafing, leaks and corrosion.

Fault Lamp(s)

1. If fault lamp(s) are illuminated, test the associated system using approved Land Rover diagnositc equipment and
report findings.

Road Test

1. C arry out road test of vehicle.

For additional information, refer to: Road/Roller Testing (100-00 General Information, Description and Operation).

General

1. Endorse Service Record.

2. Report any unusual features of vehicle condition and any additional work required.

ADDITIONAL ITEMS THAT MAY REQUIRE ATTENTION

It is recommended that:

1. Ever 6 ears: All brake fluid hydraulic seals are replaced.

NOTE: This is in addition to the maintenance requirement that flexible brake hoses MUST be replaced at this service
interval.

2. After 50 miles (80 km) continuous use in severe off-road conditions i.e. wading, deep mud and
abrasive grit/slurr : The electric parking brake should be cleaned and inspected.

3. After 50 miles (80 km) continuous use in severe off-road conditions i.e. wading, deep mud and
abrasive grit/slurr : The ancillary drive belt should be cleaned and inspected.

4. Vehicles with air suspension installed: Vehicles used extensively in arduous or off road conditions will require
the compressor air inlet filter to be renewed more frequently.

5. Vehicles used in dust or field conditions or deep wading: More frequent attention to the air cleaner will be
required.

6. Vehicles used in areas where fuel qualit is poor: Where vehicles are used in these areas, the fuel
sedimentor may require draining at more frequent intervals.

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Published: 11-May-2011
Suspension S stem - General Information -
Coil Spring Suspension
Item Specification
T pe:
Front Independent with single rate coil spring, twin tube damper and high stress anti-roll bar
Rear Independent with dual rated coil spring, twin tube damper and anti-roll bar
A ir Spring Suspension
Item Specification
Type Independent with twin tube damper, anti-roll bars and air springs with multiple, driver selectable ride heights -
Standard, off-road and access.
Steering Geometr - Front

C AUTION: When checking or adjusting front or rear steering geometry, the vehicle must either have a full fuel
tank or have sufficient weight placed in the vehicle's load space to give the equivalent weight of a full fuel tank. The
weight must be evenly distributed at the front and the right hand side of the load space. The fuel tank capacity is 86.3
litres (18.9 Imperial gallons) (22.7 US gallons). Depending on the amount of fuel in the tank, calculate the amount of
weight which must be added:

1 litre of fuel weighs 0.8 kg (1.7 pounds)

1 Imperial gallon of fuel weighs 3.6 kg (8.0 pounds)
1 US gallon of fuel weighs 3.0 kg (6.7 pounds)

Suspension at Standard Ride Height Coil Spring Suspension D namic (Air) Suspension
C astor 4 01' ± 45' 4 01' ± 45'
(4.02 ± 0.75 ) (4.02 ± 0.75 )
C ross C astor 0 ± 45' - Maximum 0 ± 45' - Maximum
(0 ± 0.75 - Maximum) (0 ± 0.75 - Maximum)
C amber - 30' ± 45' - 30' ± 45'
(- 0.50 ± 0.75 ) (- 0.50 ± 0.75 )
C ross C amber 0° ± 45' - Maximum 0 ± 45' - Maximum
(0 ± 0.75 - Maximum) (0 ± 0.75 - Maximum)
King Pin Inclination (KPI) 13 54' 13 54'
(13.90 ) (13.90 )
Total Toe + 0 10' ± 12' + 0 10' ± 12'
(+ 0.16 ± 0.20 ) (+ 0.16 ± 0.20 )
Steering Geometr - Rear
Suspension at Standard Ride Height Coil Spring Suspension D namic (Air) Suspension
C amber - 30' ± 45' -45' ± 45'
(- 0.50 ± 0.75 ) (-0.75° ± 0.75°)
C ross C amber 0° ± 45' - Maximum 0° ± 45' - Maximum
(0 ± 0.75 - Maximum) (0 ± 0.75 - Maximum)
Total Toe 0 14' ± 8' 0 14' ± 8'
(0.24 ± 0.14 ) (0.24 ± 0.14 )
Thrust Angle 0 ± 8' - Maximum 0 ± 8' - Maximum
(0 ± 0.14 - Maximum) (0 ± 0.14 - Maximum)

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Published: 27-Jun-2011
Suspension S stem - General Information - Four-Wheel Alignment
General Procedures

Special Tool(s)

204-805

C AUTIONS:

Make sure the vehicle is on a flat level surface.

Make sure the tire pressures are within specification.

Make sure that only the manufacturers' recommended four wheel alignment equipment is used.

Make sure the vehicles fuel tank is full, if not distribute extra weight evenly over the fuel tank area to represent
a full tank of fuel.

Make sure there are no heavy objects in the vehicle.

Make sure the air suspension is set to NORMAL ride height.

Make sure the steering is in the straight ahead position.

Make sure the slip plates (turntables) are free to move before adjusting the geometry.

NOTE: This procedure can be used for vehicles with either air or coil spring suspension.

1. C heck the tie rod ends, suspension joints, wheel bearings

and wheels and tires for damage, wear and free play.

Adjust or repair any worn, damaged or incorrectly

adjusted components.

2. C heck and adjust tire pressures.

3. Position the vehicle on a calibrated, level, vehicle lift.
4. Release the vehicle parking brake.
5. Vehicles with dynamic suspension: Using the approved
diagnostic tool, check the air suspension control module for
fault codes and clear as required.
6. Vehicles with dynamic suspension: Using the diagnostic
tool, set vehicle to 'Geometry Set Mode', using the
instructions below. Putting the vehicle into this mode will
make sure that the ride heights are controlled more
accurately.

1. Select the 'C onfiguration' tab

2. Select 'Set up and C onfigure'.

3. Select 'Air Suspension'.

4. Select 'Suspension Geometry Set Up'.

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5. Select 'Tight Tolerance Mode'.

6. Follow the on-screen instructions until the set up

process has finished.

. NOTE: If rear camber adjustment is required, loosen the

rear camber adjustment bolts enough to allow adjustment
before starting any other wheel alignment adjustments. Do not
fully loosen the rear camber adjustment bolts.

Using only four wheel alignment equipment approved by

Land Rover, check and adjust the wheel alignment.

. C AUTION: Make sure the toe link anti-rotation tang

is fully seated in the integrated body frame before
tightening the toe link retaining nut. Failure to follow this
instruction will result in damage to the toe link or integrated
body frame.

NOTE: This step is only required if the toe links have been
removed or replaced.

Adjust the rear bump steer.

Loosen the toe link inner ball joint retaining nut.

Set the gap, between the underside of the toe link

rubber boot and the integrated body frame bracket,
to 10 mm (0.473 in).

Tighten the toe link inner ball joint retaining nut to

133 Nm (98 lb.ft)

Repeat the above procedure for the other side.

. Adjust the rear camber.

Loosen the rear camber adjusting bolts.

Rotate the rear camber adjusting bolt until the

correct value is obtained.

Repeat the above procedure for the other side.

Tighten the rear camber adjusting bolts.

10. Install the special tool and a suitable socket to the rear
camber adjusting bolt retaining nut.

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11. NOTE: The torque wrench must be installed in a direct

line with the special tool, as shown.

NOTE: Calculate the torque rench setting using

the formula belo .

NOTE: Key to letters:

A = Effective length of the torque wrench, measured

in mm.

Formula:

Torque rench setting (Nm) =

(133 A)/(A+100)

Using the special tool, a suitable extension bar and a

torque wrench, fully tighten the camber adjusting bolt
retaining nut.

Use the torque wrench setting calculated above.

Repeat the above procedure for the other side.

12. Adjust the rear toe.

Loosen the toe link adjustment locking nut.

Rotate the toe link inner ball joint until the correct
rear toe value is obtained.

Tighten the toe link adjustment locking nut to 130

Nm (96 lb.ft).

Repeat the above procedure for the other side.

Repeat the rear toe measurement.

13. C AUTION: Make sure the slip plates (turntables)

are free to move before adjusting the geometry.

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A .

L .

R
.

T
275 N (203 . ).

R .

1 .A .

L .

R
.

T .

R .

R .

R
.

T
275 N (203 . ).

1 .A .

M
.

I
:

S :L .

S :R
.

S :T .

S :R
.

1 .A .
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Loosen the track rod end locking nuts.

Rotate the track rods to adjust each individual front

toe to the correct value.

Tighten the track rod end locking nuts to 53 Nm (39

lb.ft).

1 . Vehicles with d namic suspension: Using the diagnostic

tool, return the vehicle to 'Normal Mode'.

1. Select the 'C onfiguration' tab

2. Select 'Set up and C onfigure'.

3. Select 'Air Suspension'.

4. Select 'Suspension Geometr Set Up'.

5. Select 'Normal Mode'.

6. Follow the on-screen instructions until the normal

mode process has finished.

1 . C alibrate the steering angle sensor using the diagnostic

tool.

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Published: 11-Ma -2011

Front Suspension -
Coil Spring Suspension
Item Specification
Road spring color coding:
YELLOW/BLUE
YELLOW/GREY
YELLOW
Note: The first color indicates the fitted position of the spring on the vehicle i.e. front. The secondar
color identifies the thickness of the isolator which is fitted to a particular spring to ensure that the
vehicle ride height is maintained within specified limits. Replacement springs will be supplied with the
appropriate isolator fitted.
Torque Specif ications
Description Nm lb-ft
* Stabili er bar link nuts 115 85
Stabili er bar clamp nuts 115 85
Front a le crossmember bolts 115 85
Shock absorber and spring assembl to lo er arm bolt 300 221
Shock absorber top mounting nuts 70 52
* Shock absorber upper bush rebound plate nut 98 72
Heat shield bolts 10 7
* Upper arm and heel knuckle nut 70 52
* Tie-rod end ball joint nut 76 56
Brake hose retaining bracket to heel knuckle bolt 22 16
*+ Halfshaft retaining nut 230 169
Brake hose to upper arm bolt 22 16
Upper arm nuts and bolts 175 129
Radiator access panel bolts 10 7
Wheel hub bolts 115 85
Brake disc dust shield bolts 10 7
Lo er arm bolts 275 203
Lo er arm ball joint retaining nut 115 85
Lo er arm front camber adjusting bolt 275 203
Lo er arm rear castor adjusting bolts 275 203
Toe link inner ball joint retaining nut 133 98
Rear camber adjusting bolts 133 98
Track rod end locking nuts 53 39
Wheel speed sensor bolt 10 7
A le carrier bushing bolt - M14 105 77
A le carrier bracket bolts 80 59
Road heel nuts 140 103
* New nut/bolts must be fitted

+ Stake nut on completion

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Published: 11-May-2011
F on S pen ion - F on S pen ion
Description and Operation

Front Suspension C omponent Layout

NOTE: Air suspension version shown

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I em Pa N mbe De c ip ion
1 - Flanged bolt (Upper control arm for ard bush)
2 - Bush - for ard (Upper control arm)
3 - Nut (Upper control arm for ard bush)

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4
5 -- Flanged
B h - ea bol (Uppe con con
a d (Uppe ol a ol
m afom)a d b h)
6 - N (Uppe con ol a m ea a d b h)
7 - N (An i- oll ba link o ppe con ol a m)
8 - Uppe con ol a m
9 - Ball join (Uppe con ol a m o i el h b)
10 - N (Ball join o i el h b a achmen )
11 - N (Lo e con ol a m ea a d b h)
12 - Fla a he
13 - C am a he (Lo e con ol a m ea a d b h)
14 - B h - ea a d (lo e con ol a m)
15 - Wheel kn ckle
16 - Wheel h b and bea ing a embl
17 - S ee ing ack a achmen
18 - Wheel h b bol (4 off)
19 - N (Dampe a embl lo e a achmen )
20 - Ball join (Lo e con ol a m o i el h b)
21 - N (Ball join o i el h b a achmen )
22 - Lo e con ol a m (ai pen ion e ion ho n)
23 - Bol (Dampe a embl lo e a achmen )
24 - N (Lo e con ol a m fo a d b h)
25 - Fla a he
26 - C am a he (Lo e con ol a m fo a d b h)
27 - Lo e con ol a m fo a d b h
28 - Bol (Lo e con ol a m fo a d b h)
29 - Bol (Lo e con ol a m ea a d b h)
30 - An i- oll ba link
31 - An i- oll ba
32 - An i- oll ba b h
33 - N (an i- oll ba b acke )
34 - An i- oll ba b acke
35 - N (an i- oll ba link o an i- oll ba )
36 - Dampe a embl (ai )
37 - Dampe a embl (coil p ing)

GENERAL

The f on pen ion i a f ll independen de ign hich offe a ed c ion in n p ng eigh o e he beam a le
de ign fi ed o p e io Land Ro e model . The f on pen ion comp i e an ppe con ol a m, a lo e con ol
a m, a heel kn ckle and h b, an an i- oll ba and link a embl and a dampe a embl . The dampe can ha e a coil
p ing o ai p ing, bo h dampe pe e a imila de ign. The pen ion componen a e common o bo h coil and
ai p ing e ion .

The pen ion con ol a m ha e been de igned fo ma im m g o nd clea ance and al o allo fo adj men of he
cambe and ca o ing cam adj e .

DAMPER MOD LE - AIR S SPENSION

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I em Pa N mbe De c ip ion
1 - Rebound washer*
2 - O-ring - damper rod (2 off)*
3 - Self-locking nut*
4 - Spacer - damper rod*
5 - Bump washer
6 - Spring aid*
7 - O-ring - air spring sleeve support (2 off)*
8 - Damper assembly*
9 - Voss air fitting
10 - Damper rod
11 - Self-locking nut (3 off)
12 - Top mount
13 - Bush
14 - Retaining pin - air spring assembly*
15 - Air spring assembly*
NOTE: * shows service items

The damper module comprises an air spring assembly, top mount and a damper assembly. The damper and air spring
are only serviceable as complete assemblies.

Dampe

The damper assembly is a twin tube design with the conventional coil spring replaced by the air spring. The lower end
of the damper is fitted with a bush and is attached to the lower control arm with a bolt and nut.

The damper functions by restricting the flow of hydraulic fluid through internal galleries within the damper. The damper
rod moves axially within the damper, its movement limited by the flow of fluid through the galleries, providing damping
of undulations in the terrain. The damper rod is sealed at its exit point from the damper body to maintain the fluid within
the unit and to prevent the ingress of dirt and moisture. The seal also incorporates a wiper to keep the rod clean.

Ai Sp ing

The air spring comprises an aluminium restraining cylinder, top mount, spring aid, air sleeve and an inner support
sleeve.
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The ai lee e i made f om a fle ible bbe ma e ial hich allo he lee e o oll p and do n he ai p ing pi on
a he ehicle change heigh . The ai lee e i a ached o he e aining c linde and ppo lee e b c imp ing
hich p o ide an ai igh eal. The ppo lee e con ain a eal ca ie hich ha o O- ing ealing he ppo
lee e and o O- ing ealing o he dampe bod . The op of he ai lee e i c imped o he op mo n hich
a ache o he cha i f ame i h 3 in eg al d and elf-locking n .

A p ing aid i fi ed o he dampe od and p e en he op mo n con ac ing he op of he dampe d ing f ll

pen ion comp e ion and a i he pen ion ne. The lo e end of he ai p ing i loca ed o e he dampe
bod and ea on a fab ica ed ea on he dampe bod . The ai lee e i po i i el a ached o he ea iha
e aining pin. The dampe od i loca ed h o gh a cen al hole in he op mo n . The od i h eaded a i o e end. A
elf-locking n ec e he ai p ing o he dampe od.

The op mo n i an in eg al pa of he ai p ing and i fi ed i h a b h and ebo nd a he . A b mp a he i

loca ed be een he op mo n pla e and he dampe od. The op mo n i ec ed o he dampe od i h a elf-
locking n . The op mo n a ache o a ho ing on he cha i i h 3 in eg al d and elf-locking n . The op
mo n al o inco po a e a 6 mm Vo ai fi ing hich allo fo he a achmen of he ai ha ne .

A gai o i a ailable a a deale fi componen . The gai o i imila o he one fi ed o he ea ai dampe mod le and
i a ailable if a c ome e pe ience di and deb i becoming apped be een he ai lee e and he e aining
c linde nde ce ain e ain condi ion .

DAMPER MOD LE - COIL SPRING S SPENSION

I em Pa N mbe De c ip ion
1 - Self locking n
2 - Rebo nd a he
3 - Top mo n a embl
4 - Sp ing pace ( elec i e)
5 - Sp ing i ola o
6 - B mp a he
7 - Sp ing aid
8 - D be
9 - B mp c p
10 - C oil p ing
11 - Dampe

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12 - Da e d
13 - Se f c i g (3 ff)
14 - B h
The c i i g da e d e c i e a da e ,c i i ga d .

Damper

The da e a e b i a i be de ig i h he c e i a c i i g ca ed a e ded i g ea he
da e be. The e e d f he da e i fi ed i h a b h a d i a ached he e c a ihab a d
.

The da e f ci b e ic i g he f f h d a ic f id h gh i e a ga e ie i hi he da e . The da e
d e a ia i hi he da e ,i e e i i ed b he f f f id h gh he ga e ie , idi g da i g
f d ai i he e ai . The da e d i ea ed a i e i i f he da e b d ai ai he f id i hi
he i a d e e he i g e f di a d i e. The ea a i c ae a i e ee he d c ea .

The da e di ca ed h gh a ce a h e i he . The di h eaded a i e e d. A e f- c i g

ec e he he da e d.

A i g aid i fi ed he da e da d e e he c ac i g he f he da e d i gf
e i c e i a da a i he e i e.

Spring and Top Mo n

The c i i g fi ed diffe ih ehic e ecifica i . Each i gi c c ded ide if i a i g a d fi e

e i e e .

The c i i gi ca ed i a i g ea hich i a i eg a a f he da e b d . The de ig f he i g ea

e e he i g a i g. The ie e d f he c i i gi ca ed i a i gi a hich i fi ed i he
. The i gi a i ade f bbe a d e e a i e d ced d i g da e a d i g
c e i /e e i f bei g a i ed he ehic e b d .

The i fi ed i h a b h a d eb d a he hich a e ca ed be ee he a e a d he da e
d, a e f c i g ec e he da e d he . The a ache ah i g he cha i
i h 3 i eg a d a d e f- c i g .

The i g i fi ed i h i g ace hich a e ca ed be ee he i gi a a d he . The i g

ace c he e g h f he i g ai ai he c ec i heigh . The i g ace a e c c ded a d a e
ied i h a e ace e i g.

ANTI-ROLL BAR

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I em Pa N mbe De c ip ion
1 - Nut - link to anti-roll bar (2 off)
2 - Link (2 off)
3 - Nut - link to upper control arm (2 off)
4 - RH upper control arm
5 - Nut (4 off)
6 - Bracket (2 off)
7 - Bush (2 off)
8 - LH upper control arm
9 - Anti-roll bar
The anti-roll bar is fabricated from induction hardened, solid spring steel bar. The anti-roll bar operates, via a pair of
links, from their attachment to the upper control arm.

The anti-roll bar is attached to the forward face of the chassis front cross member. The anti-roll bar is attached to the
cross member with two, Teflon lined bushes. Brackets, which are pressed onto the bushes, are attached to the cross
member with nuts, screwed onto studs in the cross member. The anti-roll bar has crimped, 'anti-shuffle' collars pressed
in position on the inside edges of the bushes. The collars prevent sidewa s movement of the anti-roll bar.

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The end of he an i- oll ba a e a ached o he ppe con ol a m ia link . Thi allo he an i- oll ba o mo e i h
he heel a el p o iding ma im m effec i ene . Each link ha a ball join a each end. The op ball join i a ached
o he link, pa allel i h he link a i . The ball join i loca ed in a hole in he ppe con ol a m and ec ed i h a elf-
locking n . The bo om ball join i a ached o he link a 90 deg ee o he link a i . The ball join i loca ed in a hole
in he end of he an i- oll ba and ec ed i h a elf-locking n . The link a e no handed and he efo e can be fi ed
o ei he ide of he an i- oll ba .

PPER CON ROL ARM

I em Pa N mbe De c ip ion
1 - Flanged bol
2 - B h
3 - Self locking n
4 - Flanged bol
5 - B h
6 - Self locking n
7 - Self locking n
8 - C i clip
9 - Timing ma k
10 - Ball join
11 - An i- oll ba link a achmen hole
12 - Uppe con ol a m
The ppe con ol a m a embl comp i e , he con ol a m, o b he and a ball join . The ppe con ol a m i a
p e ed eel fab ica ion. I o e end ha a hole o accep he ball join . A mall inden a ion i loca ed adjacen o he
ball join hole and i ed o ob ain he co ec o ien a ion of he ball join . A malle hole nea he ball join p o ide fo
he a achmen of he an i- oll ba link. The nde ide of he ppe con ol a m ha a b acke fo a achmen of he
heigh en o link a m and o f he b acke hich ec e he b ake ho e, pad ea en o and heel peed en o
cable .

The inne end of he a m ha o fab ica ed b h ho ing hich a e elded o he a m p e ing. A b h i p e ed

in o each ho ing. The b he a e loca ed be een l g on he cha i and a e ec ed i h bol and elf-locking n
h o gh me al in e in he cen e of he b he .

The ball join in p e ed in o he ppe con ol a m. The ball join i an in e fe ence fi in he hole hich p e en he
ball join f om mo ing. A ci clip i fi ed o he ball join o e ain i in he hole. The op face of he ball join ha o
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semi-circular cut-outs. One of these cut-outs must be aligned with the small indentation in the upper control arm to
ensure the correct operation of the ball joint.

LO ER CONTROL ARM

I em Pa N mbe De c ip ion
1 - Self locking nut
2 - Flat washer
3 - C am washer
4 - Bush
5 - Special bolt
6 - Bolt
7 - H drobush
8 - C am washer
9 - Flat washer
10 - Self locking nut
11 - Self locking nut - damper lower attachment
12 - Ball joint
13 - C irclip
14 - Self locking nut
15 - Lower control arm
16 - Bolt - damper lower attachment
17 - Jacking bracket (Vehicles with coil springs onl )
The lower control arm assembl comprises, the control arm, two bushes and a ball joint. The lower control arm is a
pressed steel fabrication with a hole at its outer end to accept the ball joint.

The inner end of the arm has two fabricated bush housings which are welded to the arm pressing. A bush is pressed
into each housing. The rear bush is a h drobush which provides a progressive increase in the hardness of the bush as
the deflection of the wheel increases. The bushes are located between lugs on the chassis and are secured with bolts
and self-locking nuts through metal inserts in the centre of the bushes. The forward bush, self-locking nut, has a cam
washer located beneath it. The cam washer is located between lugs on the chassis bracket and its orientation can be
adjusted to set the front camber. The rear bush, self-locking nut, also has a cam washer located beneath it. The cam
washer is located between lugs on the chassis bracket and its orientation can be adjusted to set the front castor.

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On vehicles fitted with coil springs onl , a jacking bracket is located on the lower control arm.

A central aperture in the arm provides for the attachment of the damper module lower bush. The damper is secured
with a long bolt which is positioned through holes in the arm and secured with a self-locking nut.

The ball joint is pressed into the lower control arm. The ball joint is an interference fit in the hole which prevents the ball
joint from moving. A circlip is fitted to the ball joint to retain it in the hole.

WHEEL KNUCKLE, HUB AND BEARING ASSEMBL

I em Pa N mbe De c ip ion
1 - Upper control arm attachment
2 - Brake caliper attachment holes
3 - Brake hose bracket attachment point
4 - Wheel speed sensor location
5 - Wheels studs
6 - Wheel hub
7 - Brake disc dust shield attachment holes
8 - Lower control arm ball joint attachment
9 - Steering rack ball joint attachment
10 - Wheel hub bolts (4 off)
The wheel knuckle is a machined casting which is located between the ball joints of the upper and lower control arms.
The knuckle has four clearance holes which allow for the fitment of four bolts which secure the wheel hub housing. A
cast boss on the forward edge of the knuckle provides for attachment of the steering gear, tie rod ball joint.

The wheel hub and bearing assembl comprises the wheel hub housing, wheel hub and taper roller bearing. The wheel
hub and bearing assembl is a non-serviceable component. Five M14 studs are pressed into the wheel hub and provide
for the attachment of the road wheel with wheel nuts.

The wheel hub housing is a machined forging which houses a taper roller bearing. The housing has four threaded holes
which provide for the attachment to the wheel knuckle with four bolts.

The wheel hub has a splined centre bore which mates with corresponding splines on the half shaft. Rotation of the half
shaft is passed, via the splines, to the wheel hub which rotates on the taper roller bearing.

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Front Suspension - Front Stabili er Bar
Remo al and In alla ion

Removal

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e .
3. Di connec bo h he abili e ba link f om he abili e
ba .

Remo e he 2 n .

4. Remo e he engine nde hield.

Fo addi ional info ma ion, efe o: Engine Unde hield
(501-02 F on End Bod Panel , Remo al and In alla ion).
5. Remo e he f on a le c o membe .

Remo e he 4 bol .

6. Remo e he abili e ba b hing.

Remo e he 4 n .

Remo e he abili e ba clamp .

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7. Remo e he abili e ba .

Remo e he abili e ba o h o gh he LH ide

heel a ch.

In alla ion
1. In all he abili e ba .

In all he abili e ba h o gh he LH ide heel a ch.

2. In all he abili e ba b hing.

In all he abili e ba clamp .

Tigh en he n o 115 Nm (85 lb.f ).

3. In all he f on a le c o membe .

Tigh en he 4 bol o 115 Nm (85 lb.f ).

4. In all he engine nde hield.

Fo addi ional info ma ion, efe o: Engine Unde hield
(501-02 F on End Bod Panel , Remo al and In alla ion).
5. C onnec bo h abili e ba link o he abili e ba .

Tigh en he n o 115 Nm (85 lb.f ).

6. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

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Front Suspension - Front Stabili er Bar Link
Remo al and In alla ion

Removal

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.

3. C AUTION: U e a ench on he he agon p o ided

o p e en he ball join o a ing.

Remo e he abili e ba link.

Remo e and di ca d he 2 n .

Installation
1. In all he abili e ba link.

Tigh en he n o 115 Nm (85 lb.f ).

2. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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F on S pen ion - Uppe A m Ball Join
Removal and Installation

Special Tool( )
Ball joint remover

204-516/3 (LRT 64-026/3)

Ball joint remover

204-530-2

Ball joint installer

204-530-3

Ball joint installer

204-530-1

Remo al
NOTE: This procedures shows removal and installation of the upper arm ball joint.

1. Remove the upper arm.

For additional information, refer to: Upper Arm (204-01
Front Suspension, Removal and Installation).
2. Remove the dust seal.

Remove the seal retainer.

Remove the circlip.

3. Using the special tools, remove the ball joint.

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In alla ion

1. C AUTION: Make e he iming ma k a e aligned.

U ing he pecial ool , in all he ball join .

2. C AUTION: C i clip hole o be 90 deg ee o a ed

f om iming ma k .

In all he ci clip.

3. In all he ppe a m.
Fo addi ional info ma ion, efe o: Uppe A m (204-01
F on S pen ion, Remo al and In alla ion).

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F on S pen ion - Lo e A m Ball Join
Removal and Installation

Special Tool( )
Remover/installer front lower arm
ball joint

204-531/3

Remover/installer front lower arm

ball joint

204-531/2

Remover/installer front lower arm

ball joint

204-531/1

Remover/installer front lower arm

ball joint

204-753

Remover/installer front lower arm

ball joint

204-754

Remo al
All vehicles

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the lower arm.
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Fo addi ional info ma ion, efe o: Lo e A m (204-01
F on S pen ion, Remo al and In alla ion).
. Remo e he ci clip.

. In pec he in alled ball join o de e mine if a adi i

p e en .

Ball join i ho adi

. U ing he pecial ool , emo e he ball join .

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Ball join i h adi

7. U ing he pecial ool , emo e he ball join .

In alla ion
All ehicle
1. C lean he componen .
2. In pec he ne ball join o de e mine if a adi i
p e en .

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Ball joint ithout radius

. Using the special tools, install the ball joint.

Ball joint ith radius

. Using the special tools, install the ball joint.

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All ehicle
. In all he ci clip.
. In all he lo e a m.
Fo addi ional info ma ion, efe o: Lo e A m (204-01
F on S pen ion, Remo al and In alla ion).
. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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P bli hed: 05-Sep-2011

F on S pen ion - Wheel Kn ckle
Remo al and In alla ion

Special Tool( )
Half haf emo e / eplace

204-506/1 (LRT-60-030/1)

Half haf emo e / eplace

204-506/2(LRT-60-030/2)

Half haf emo e / eplace

204-506/3 (LRT-60-030/3)

Re aine - half haf

emo e / eplace

204-506/5 (LRT-60-030/5)

Half haf in alle adap e

204-506-01

Ball join epa a o

205-754 (LRT-54-027)

Remo al

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. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. Remove the wheel and tire.
. Loosen the halfshaft retaining nut.

. Remove the brake disc.

For additional information, refer to: Brake Disc (206-03
Front Disc Brake, Removal and Installation).
. Remove the halfshaft retaining nut.

Discard the nut.

. Loosen the tie-rod end ball joint retaining nut.

. Using the special tool, release the tie-rod end ball joint
from the wheel knuckle.

Discard the nut.

. Release the wheel speed sensor from the wheel knuckle.

Remove the bolt.

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. C AUTION: U e a ench on he he agon p o ided o

p e en he ball join o a ing.

Remo e and di ca d he abili e ba link n .

10. Loo en he ppe a m e aining n .
11. U ing he pecial ool, elea e he ppe a m ball join .

12. U ing he pecial ool , elea e he half haf f om he

d i e flange.

13. Remo e he lo e ball join e aining n .

14. U ing he pecial ool, elea e he lo e ball join f om
he ee ing kn ckle.

15. C AUTION: The lo e a m ball join can be damaged

b e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o hang
on he lo e a m. Fail e o follo hi in c ion ill e l in
damage o ehicle.

Remo e he ppe a m e aining n .

Di ca d he n .

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16. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he heel kn ckle.

17. Remo e he b ake di c d hield.

Remo e he fi e e aining bol .

18. Remo e he heel h b.

Remo e he 4 bol .

In alla ion
1. C lean he componen .
2. In all he heel h b.

Tigh en he 4 bol o 115 Nm (85 lb.f ).

3. In all he b ake di c d hield.

Tigh en he 5 bol o 10 Nm (7 lb.f ).

4. C AUTION: The lo e a m ball join can be damaged

b e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o hang
on he lo e a m. Fail e o follo hi in c ion ill e l in
damage o ehicle.

Wi h a i ance, in all he heel kn ckle.

5. U ing he pecial ool , in all he half haf in he heel
h b.

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. C onnect the upper arm and wheel knuckle.

Install a new nut and tighten to 70 Nm (52 lb.ft).

. Secure the stabili er bar link.

Install a new nut and tighten to 115 Nm (85 lb.ft).

. Tighten the lower arm ball joint retaining nut to 115 Nm (85
lb.ft).
. C onnect the tie-rod end ball joint.

Install a new nut and tighten to 76 Nm (56 lb.ft).

10. Install a new halfshaft retaining nut and lightl tighten.

11. Install the wheel speed sensor.

Tighten the bolt to 10 Nm (7 lb.ft).

12. Install the brake disc.

For additional information, refer to: Brake Disc (206-03
Front Disc Brake, Removal and Installation).

13. C AUTION: Do not use air tools to install the nut.

Failure to follow this instruction ma result in damage to the
component.

Tighten the new halfshaft retaining nut to 230 Nm (169 lb.ft).

Stake the nut to the halfshaft.

14. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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F on S pen ion - F on Wheel Bea ing and Wheel H b
Removal and Installation

Special Tool( )
Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Halfshaft remover/replacer

204-506/2(LRT-60-030/2)

Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Retainers - halfshaft
remover/replacer

204-506/5(LRT-60-030/5)

Halfshaft installer adapter

204-506-01(LRT-60-030/4)

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Loosen the halfshaft retaining nut.

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. Relea e he b ake ho e b acke f om he heel kn ckle.

Remo e he bol .

. Remo e he heel peed en o e aining bol .

. C AUTION: Do no allo he b ake calipe o hang on

he b ake ho e.

Relea e he b ake calipe ancho pla e f om he heel

kn ckle and ie he calipe a ide.

Tie a ide comple e i h he heel peed en o .

. Remo e he b ake di c.

Remo e he To c e .

. Remo e he half haf e aining n .

Di ca d he n .

. C AUTION: Do no e a hamme o de ach he

half haf f om he h b a embl , fail e o follo hi
in c ion ma e l in damage o he half haf .

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U ing he pecial ool , elea e he half haf f om he
heel h b.

10. Remo e he heel h b.

Remo e he 4 bol .

In alla ion
1. C lean he componen .
2. In all he heel h b.

U ing he pecial ool , in all he half haf in he

heel h b.

Tigh en he 4 bol o 115 Nm (85 lb.f ).

3. In all a ne half haf e aining n and ligh l igh en.

4. Make e he b ake di c and h b ma ing face a e
clean.
5. In all he b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

6. In all he b ake calipe and ancho pla e.

In all he heel peed en o .

Tigh en he bol o 275 Nm (203 lb.f ).

7. In all he heel peed en o e aining bol .

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. Secure the brake hose retaining bracket to the wheel
knuckle.

Tighten the bolt to 22 Nm (16 lb.ft).

. C AUTION: Do not use air tools to install the nut.

Failure to follow this instruction ma result in damage to the
component.

Tighten the new halfshaft retaining nut to 230 Nm (170 lb.ft).

Stake the nut to the halfshaft.

10. Depress the brake pedal several times, check the fluid
level in the brake fluid reservoir and top-up with brake fluid
if necessar .
11. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Front Suspension - Shock Absorber and Spring Assembl
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the fender splash shield.
For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
3. Disconnect the shock absorber and spring assembl from
the lower arm.

Remove the nut and bolt.

4. Release the heat shield for access to the shock absorber

and spring assembl upper mounting inner nut.

Remove the three retaining bolts.

5. Remove the shock absorber and spring assembl .

Remove the three retaining bolts.

Installation
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. Install the shock absorber and spring assembl .

Make sure the spring and shock absorber assembl top

mounting to bod mating faces are clean.

Fit the nuts and tighten to 70 Nm (52 lb.ft).

. Secure the heat shield.

Install the three retaining bolts and tighten to 10 Nm (7

lb.ft).

. C onnect the shock absorber and spring assembl to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

. Install the fender splash shield.

For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).

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F on S pen ion - Uppe A m
Remo al and In alla ion

Special Tool( )
Ball join epa a o

205-754(LRT-54-027)

Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.

3. C AUTION: Do no e e ce i e fo ce o di connec
he heigh en o link.

Di connec he heigh en o link a m.

4. Remo e he ppe a m and b ake line hea hield fo

acce .

Remo e he 3 n .

Remo e he 3 bol .

5. C AUTION: U e a ench on he he agon p o ided o

p e en he ball join o a ing.

Remo e he abili e ba link n .

Di ca d he n .

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. Relea e he b ake ho e and heel peed en o lead f om

he ppe a m.

Remo e he bol .

. C AUTION: To p e en he heel kn ckle falling

o a d and di connec ion of he half haf inne join ,
ppo he heel kn ckle.

Loo en he ppe a m e aining n .

. U ing he pecial ool, elea e he ppe a m ball join .

Remo e and di ca d he n .

. Remo e he ppe a m.

Remo e and di ca d he 2 n .

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In alla ion
1. Install the upper arm.

Fit the bolts but do not full tighten at this stage.

Install new nuts.

2. C onnect the upper arm and wheel knuckle.

Install a new nut and tighten to 70 Nm (52 lb.ft).

3. Secure the brake hose and wheel speed sensor leads to the
upper arm.

Tighten the bolt to 23 Nm (17 lb.ft).

4. Secure the stabili er bar link.

Install a new nut and tighten to 115 Nm (85 lb.ft).

5. Install the upper arm and brake line heat shields.

Install the 3 bolts.

Install the 3 nuts.

6. C onnect the height sensor link.

7. Set the height distance between the centre of the
halfshaft end and the edge of the fender trim to 466 mm
(18.34'').

8. Tighten the 2 upper arm nuts and bolts to 175 Nm (129

lb.ft).
9. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

10. Using the Land Rover approved diagnostic s stem,

calibrate the suspension ride height.

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For additional information, refer to: Ride Height Adjustments
(204-05 Vehicle D namic Suspension, General Procedures).

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F on S pen ion - Lo e A m
Removal and Installation

Special Tool( )
Ball joint separator

205-754(LRT-54-027)

Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Retainers - halfshaft
remover/replacer

204-506/5(LRT-60-030/5)

Halfshaft installer adapter

204-506-01(LRT-60-030/4)

Remo al
1. Place vehicle into access mode.

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. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. Remove the wheel and tire.
. Disconnect the shock absorber and spring assembl from
the lower arm.

Remove the nut and bolt.

. Mark the position of the bolts in relation to the chassis

brackets.

Remove the 2 bolts.

. Remove the halfshaft retaining nut.

Discard the nut.

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. C AUTION: Do no e a hamme o de ach he

half haf f om he h b a embl , fail e o follo hi
in c ion ma e l in damage o he half haf .

U ing he pecial ool , elea e he half haf f om he

heel h b.

. NOTE: The lo e a m ball join can be damaged b

e ce i e a ic la ion. Do no o e a ic la e he ball join .
Fail e o follo hi in c ion ill e l in damage o
ehicle.

Relea e he half haf f om he heel kn ckle.

. Sec e he half haf clea of he lo e a m.

10. Remo e he lo e ball join e aining n .
11. U ing he pecial ool, elea e he lo e ball join f om
he ee ing kn ckle.

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12. Remo e he lo e a m.

In alla ion
1. In all he lo e a m.

Fi he bol b do no f ll igh en a hi age.

2. NOTE: The lo e a m ball join can be damaged b

e ce i e a ic la ion. Do no o e a ic la e he ball join .
Fail e o follo hi in c ion ill e l in damage o
ehicle.

C onnec he lo e a m o he heel kn ckle.

Tigh en he lo e a m ball join e aining n o 115 Nm

(85 lb.f ).

3. Relea e he half haf .

4. U ing he pecial ool , in all he half haf in he heel
h b.

5. C AUTION: In all he half haf n finge igh .

In all a ne half haf e aining n .

Tigh en he ne half haf e aining n o 350 Nm (258

lb.f ).

S ake he n o he half haf .

6. Se he heigh di ance be een he cen e of he

half haf end and he edge of he fende im o 466 mm
(18.34'').

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. C AUTION: Do not use air tools to install the nut.

Failure to follow this instruction ma result in damage to the
component.

Tighten the lower arm bolts to 275 Nm (203 lb.ft).

Align the bolts to the marks made previousl .

. C onnect the shock absorber and spring assembl to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

10. C arr out the wheel alignment procedure.

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Published: 11-May-2011
F on S pen ion - Uppe A m B hing
Removal and Installation

Special Tool( )
Receiver cup upper arm bushes

204-532/1

Remover upper arm bushes

204-532/2

Installer upper arm front bush

204-532/3

Installer upper arm rear bush

204-532/4

Remo al
NOTE: The bushings must be replaced in pairs, LH and RH sides.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the front wheels and tires.
3. Remove the LH upper arm.
For additional information, refer to: Upper Arm (204-01
Front Suspension, Removal and Installation).
4. Release the heat shield for access to the upper arm
bolts.

Remove the nut.

Remove the forward bolt and loosen the rearward

bolt.

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. Loosen the upper arm bolts.

. Disconnect the height sensor link arm.

. C AUTION: Use a wrench on the hexagon provided to

prevent the ball joint rotating.

Remove the stabili er bar link nut.

Discard the nut.

. C AUTION: To prevent the wheel knuckle falling

outwards and disconnection of the halfshaft inner joint,
support the wheel knuckle.

Loosen the upper arm retaining nut.

. Using the special tool, release the upper arm ball joint.

Remove and discard the retaining nut.

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. Relea e he b ake ho e f om he ppe a m.

. Relea e he heel peed en o lead f om he ppe a m.
. Remo e he RH ppe a m.

. No e he po i ion of he b hing in ela ion o he ppe

a m.

. C AUTION: The b h flange need o be emo ed

o allo b h emo al.

U ing a i able ool, bend o e he b h flange .

. U ing a hack a , emo e he flange f om he b hing,

making e he ppe a m i no damaged.
. U ing he pecial ool , emo e and di ca d he ppe
a m b hing .

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In alla ion

1. C AUTION: Make sure the correct special tool is

used to install the bushings to the correct depth.

Using the special tools, install the upper arm rear

bushings.

Align the arrow on the bush with the mark,

previousl made on the upper arm.

2. Using the special tools, install the upper arm front

bushings.

Align the arrow on the bush with the mark,

previousl made on the upper arm.

3. Install the RH upper arm.

Fit the bolts but do not full tighten at this stage.

4. Secure the brake hose to the upper arm.

Tighten the bolt to 23 Nm (17 lb.ft).

5. Secure the wheel speed sensor lead to the upper arm.

6. C onnect the upper arm and wheel knuckle.

Install a new nut and tighten to 70 Nm (52 lb.ft).

7. Secure the stabili er bar link.

Install a new nut and tighten to 115 Nm (85 lb.ft).

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. C onnec he heigh en o link a m.

. Se he heigh di ance be een he cen e of he half haf
end and he edge of he fende im o 466 mm (18.34'').
10. Tigh en he 2 ppe a m n and bol o 175 Nm (129
lb.f ).
11. Sec e he hea hield.
12. In all he LH ppe a m.
Fo addi ional info ma ion, efe o: Uppe A m (204-01
F on S pen ion, Remo al and In alla ion).
13. In all he f on heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

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P bli hed: 03-Oc -2011

Front Suspension - Lo er Arm Bushing
Remo al and In alla ion

Special Tool(s)
Recei e f on lo e a m f on
b h

204-536/1

Remo e f on lo e a m f on
b h

204-536/2

In alle f on lo e a m f on b h

204-536/3

Ball join epa a o

205-754(LRT-54-027)

Half haf emo e / eplace

204-506/1(LRT-60-030/1)

Half haf emo e / eplace

204-506/3(LRT-60-030/3)

Re aine - half haf

emo e / eplace

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204-506/5(LRT-60-030/5)

Receiver lower arm rear bush

204-535/1

Remover lower arm rear bush

204-535/2

Remover plate lower arm rear

bush

204-535/4

Installer lower arm rear bush

204-535/3

Installer/depth setter lower arm

rear bush

204-535/5

Remo al
NOTE: The bushings must be replaced in pairs, LH and RH sides.

NOTE: Take note of the fitted position of the bush.

1. Make sure that the tire pressures are correct and that the
vehicle is at the correct ride height.
For additional information, refer to: Ride Height Adjustments

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(204-05 V D S ,G P ).
.M
.

1. U ,

2. A

3. A

( ).

4. M
- - .

. WARNING: D
.A
.

R .
.R .
.R RH .
F , :L A (204-01
F S ,R I ).
.R .

D .

. C AUTION: U
.

D LH .

R .

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. Relea e he b ake ho e b acke f om he heel kn ckle.

Remo e he bol .

. Loo en he ie- od end ball join e aining n .

10. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he ie- od end ball join

f om he heel kn ckle.

Di ca d he n .

11. C AUTION: To p e en he heel kn ckle falling

o a d and di connec ion of he half haf inne join ,
ppo he heel kn ckle.

Loo en he ppe a m e aining n .

12. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he ppe a m ball join .

Remo e and di ca d he e aining n .

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1 . C AUTION: Do not use a hammer to detach the

halfshaft from the hub assembl , failure to follow this
instruction ma result in damage to the halfshaft.

Using the special tools, release the halfshaft from the

wheel hub.

1 . Release the halfshaft from the wheel knuckle.

1 . Secure the halfshaft clear of the lower arm.

1 . Remove the lower ball joint retaining nut.
1 . Using the special tool, release the lower ball joint from
the steering knuckle.

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1 . Loosen the 2 lower arm bolts.

Mark the position of the bolts in relation to the chassis

brackets.

1 . Disconnect the shock absorber and spring assembl from

the lower arm.

Remove the LH retaining bolt.

20. Remove the LH lower arm.

21. Note the position of the bushing in relation to the lower

arm.

22. C AUTION: The bush flanges need to be removed

to allow bush removal.

Remove the lower arm front bushing flanges.

23. Using the special tools, remove and discard the lower
arm front bushings.

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2 . Appl alignment guide lines to installer tool (204-

535/3).

1. Mark center line on installer tool.

2. Mark line across top surface 3 degrees to the

left of center line.

3. Mark 'LH' on top surface.

4. Mark line across bottom surface 3 degrees to

the left of the center line.

5. Mark 'RH' on bottom surface.

2 . Using the special tools, remove and discard the lower

arm rear bushings.

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In alla ion

1. C AUTION: Make sure the bush is correctl aligned.

Mark the position of the bushing in relation to the lo er

arm.

1. Make sure the correct marked side line 'RH' or

'LH' on the special tool (204-535/3) is aligned
ith the scribed line on the RH or LH bush to be
installed.

2. E tend the line from the installer tool onto the

bush using a marker pen. Using the marked
line, align the bush to the lo er arm before
installing the bush.

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. C AUTION: Make sure the correct special tool is

used to install the bushings to the correct depth.

Using the special tools, install the lo er arm rear

bushings.

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. C AUTION: Make sure the bush is correctl aligned.

Using the special tools, install the lower arm front

bushings

. Install the LH lower arm.

Fit the bolts but do not full tighten at this stage.

. C onnect the shock absorber and spring assembl to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

. Release the halfshaft.

. Using the special tools, install the halfshaft in the wheel
hub.

. C onnect the upper arm and wheel knuckle.

Install a new nut and tighten to 70 Nm (52 lb.ft).

. Secure the stabili er bar link.

Tighten the nut to 115 Nm (85 lb.ft).

. C onnect the tie-rod end ball joint.

Install a new nut and tighten to 76 Nm (56 lb.ft).

. C AUTION: Install the halfshaft nut finger tight.

Install a new halfshaft retaining nut and lightl tighten.

. Secure the brake hose retaining bracket to the wheel
knuckle.

Tighten the bolt to 25 Nm (18 lb.ft).

. Secure the LH stabili er link.

Tighten the nut to 115 Nm (85 lb.ft).

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1 . C AUTION: Do not use air tools to install the nut.

Failure to follow this instruction ma result in damage to the
component.

Tighten the new halfshaft retaining nut to 230 Nm (170 lb.ft).

Stake the nut to the halfshaft.

1 . Set the height distance between the centre of the

halfshaft end and the edge of the fender trim to 466 mm
(18.34'').

1 . Tighten the lower arm bolts to 275 Nm (203 lb.ft).

Align the bolts to the marks made previousl .

1 . Install the RH lower arm.

For additional information, refer to: Lower Arm (204-01
Front Suspension, Removal and Installation).
1 . Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

1 . C arr out the wheel alignment procedure.

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Published: 11-May-2011
Front Suspension - Shock Absorber and Spring Assembl
Disassembly and Assembly

Disassembl
WARNINGS:

Ensure the spring compressor Safe Working Load (SWL) meets or exceeds the spring rating quoted in the
Specifcations section.
For additional information, refer to: Specifications (204-00 Suspension System - General Information, Specifications).

Always follow the spring compressor manufacturer's instructions.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the shock absorber and spring assembly.
For additional information, refer to: Shock Absorber and
Spring Assembly (204-01 Front Suspension, Removal and
Installation).
3. Install a suitable spring compressor in a vise.
4. Install the shock absorber and spring assembly in the
spring compressor.

C ompress the spring just sufficiently to relieve the

spring tension.

5. Remove the shock absorber.

Restrain the shock absorber spindle, remove and

discard the nut.

Remove the upper bush rebound plate and upper

bush.

Remove the upper mounting assembly.

Remove the dust tube and rebound plate assembly.

Remove the spring aid.

6. Remove the spring from the spring compressor.

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7. C lean and inspect the components for deterioration.

To aid reassembl , mark the position of the rubber

insulator in relation to the upper mounting plate.

Remove the rubber insulator.

Remove the spacer.

Remove the rebound plate from the dust tube.

Assembl
1. Install the spring in the spring compressor.

Make sure the spring is installed with the close coils

positioned towards the top of the shock absorber.

2. Install the spring aid.

3. Install the dust tube.

Install the rebound plate into the dust tube.

4. Install the shock absorber.

Make sure the spring is correctl located in the spring

seat.

5. Install the upper mounting.

Install the spacer and rubber insulator, making sure the

spacer drops over the stud heads and the insulator is
aligned with the mark made previousl .

Install the upper bush and upper bush rebound plate.

Install a new nut and tighten to 98 Nm (72 lb.ft).

6. Install the shock absorber and spring assembl .

For additional information, refer to: Shock Absorber and
Spring Assembl (204-01 Front Suspension, Removal and
Installation).

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Published: 11-Ma -2011

Rear Suspension -
Coil Spring Suspension
Item Specification
Road spring color coding - 5 Seat Model:
BROWN/WHITE
BROWN/GREEN
BROWN/ORANGE
BROWN
Road spring color coding - 7 Seat Model:
RED/WHITE
RED/GREEN
RED/ORANGE
RED
Note: The first color indicates the fitted position of the spring on the vehicle i.e. rear. The secondar
color identifies the thickness of the isolator which is fitted to a particular spring to ensure that the
vehicle ride height is maintained within specified limits. Replacement springs will be supplied with the
appropriate isolator fitted.
General Specif ications
Item Specification
Gap between underside of the toe link rubber boot and the integrated bod frame bracket 10.0 mm (0.394 in)
Height between the center of the halfshaft end and the edge of the fender trim 485 mm (19.10 in)
Torque Specif ications
Description Nm lb-ft
Toe link bolt 175 129
* Toe link inner ball joint retaining nut 133 98
* Stabili er bar link nuts 115 85
Stabili er bar clamp bolts 62 46
Bod mount retaining bolts 133 83
Shock absorber to the lower suspension arm nut and bolt 300 221
Shock absorber to suspension turret nuts 70 52
Lower arm to wheel knuckle bolt 175 129
Lower arm bolts 275 203
*+ Halfshaft retaining nut 350 258
Upper arm to wheel knuckle nut 133 98
Upper arm front bolt 175 129
Upper arm rear bolt 275 203
Brake tube unions 18 13
Rear camber adjusting bolts 133 98
Wheel speed sensor 9 7
Brake disc dust shield bolts 9 7
Parking brake cable coupling 8 6
Road wheel nuts 140 103
* New nut must be installed

+ Nut must be staked after tightening

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Rear S spension - Rear S spension
Description and Operation

Rear Suspension C omponent Location

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I em Pa N mbe De c ip ion
1 - Bolt (Upper control arm for ard bush)
2 - Bush - For ard (Upper control arm)

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3 - C aged n (Uppe con ol a m fo a d b h)
4 - Bol (Uppe con ol a m ea a d b h)
5 - B h - Rea a d (Uppe con ol a m)
6 - C aged n (Uppe con ol a m ea a d b h)
7 - Uppe con ol a m
8 - Eccen ic a he (Wheel kn ckle ppe ball join )
9 - N (Wheel kn ckle ppe ball join )
10 - Bol (Wheel kn ckle ppe ball join )
11 - Special n (Adj able an e e oe link)
12 - Adj able an e e oe link
13 - Wa he (Adj able an e e oe link)
14 - Dampe mod le a embl (Ai )
15 - Dampe mod le a embl (C oil)
16 - Bol (Adj able an e e oe link)
17 - Ball join (Wheel kn ckle ppe )
18 - Wheel kn ckle and bea ing a embl
19 - Wheel h b
20 - S ake n
21 - C i clip
22 - Wheel bea ing
23 - Ball join (Wheel kn ckle lo e )
24 - C i clip (Wheel kn ckle lo e ball join )
25 - Self-locking n (Wheel kn ckle lo e ball join )
26 - Self-locking n (Dampe a embl lo e a achmen )
27 - Bol (Wheel kn ckle lo e ball join )
28 - Bol (Dampe a embl lo e a achmen )
29 - Lo e con ol a m
30 - B mp op clip
31 - Self-locking n (Lo e con ol a m fo a d b h)
32 - B h - Fo a d (Lo e con ol a m)
33 - Bol (Lo e con ol a m fo a d b h)
34 - N and e aine (Lo e con ol a m ea a d b h)
35 - Self-locking n (An i- oll ba link o lo e con ol a m)
36 - Bol (Lo e con ol a m ea a d b h)
37 - B h - Rea a d (Lo e con ol a m)
38 - An i- oll ba link
39 - Self-locking n (An i- oll ba link o an i- oll ba )
40 - An i- oll ba b h
41 - Bol (An i- oll ba b acke )
42 - An i- oll ba
43 - An i- oll ba b acke
44 - B mp op clip

GENERAL

The independen ea pen ion offe a ed c ion in n p ng eigh o e he beam a le de ign fi ed o p e io

Land Ro e model . The ea pen ion comp i e an ppe con ol a m, a lo e con ol a m, a heel kn ckle and
heel h b, o p ing dampe mod le and an an i- oll ba and link a embl . The dampe mod le e a imila
de ign of dampe hich can be fi ed i h ei he a coil p ing o an ai p ing.

The ea pen ion con ol a m ha e been de igned o gi e ma im m g o nd clea ance and al o allo fo he
adj men of he cambe ing a cam bol and adj men of oe and b mp ee ia an adj able an e e link.

DAMPER MOD LE - AIR S SPENSION

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I em Pa N mbe De c ip ion
1 - Strap*
2 - Upper gaitor*
3 - Self-locking nut*
4 - Rebound washer*
5 - O-ring - Damper rod*
6 - Spacer - Damper rod*
7 - Air spring*
8 - Retaining pin - Air spring sleeve support*
9 - Bump washer*
10 - Spring aid*
11 - O-ring - Air sleeve support (2 off)*
12 - Damper rod
13 - Damper assembly
14 - Strap*
15 - Lower gaitor*
16 - Strap*
17 - Self-locking nut (3 off)
18 - Top mount assembly
19 - Bush
20 - Voss connector
NOTE: * Shows service items

The damper module comprises an air spring assembly, top mount and a damper assembly. The damper and air
spring are only serviceable as complete assemblies.

Dampe

The damper assembly is a twin tube design with the conventional coil spring replaced by the air spring. The lower end
of the damper is fitted with a bush and is attached to the lower control arm with a bolt and nut.

The damper functions by restricting the flow of hydraulic fluid through internal galleries within the damper. The
damper rod moves axially within the damper, its movement limited by the flow of fluid through the galleries,
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p o iding damping of nd la ion in he e ain. The dampe od i ealed a i e i poin f om he dampe bod o
main ain he fl id i hin he ni and o p e en he ing e of di and moi e. The eal al o inco po a e a ipe o
keep he od clean.

Ai Sp ing

The ai p ing i imila in de ign o he ai p ing ed on he f on pen ion.

The ai p ing comp i e an al mini m e aining c linde , op mo n , p ing aid, ai lee e and an inne ppo
lee e.

The ai lee e i made f om a fle ible bbe ma e ial hich allo he lee e o oll p and do n he ai p ing
pi on a he ehicle change heigh . The ai lee e i a ached o he e aining c linde and he ppo lee e i h
c imp ing hich p o ide an ai igh eal. The ppo lee e con ain a eal ca ie hich ha o O- ing ealing
he ppo lee e and o O- ing ealing o he dampe bod . The op of he ai lee e i c imped o he op mo n
hich a ache o a mo n ing on he cha i i h 3 in eg al d and elf-locking n .

A p ing aid i fi ed o he dampe od and p e en he op mo n con ac ing he op of he dampe d ing f ll

pen ion comp e ion and a i he pen ion ne. The lo e end of he ai p ing i loca ed o e he dampe
bod and ea on a fab ica ed ea on he dampe bod . The ai lee e i po i i el a ached o he ea iha
e aining pin. The dampe od i loca ed h o gh a cen al hole in he op mo n . The od i h eaded a i o e end
and accep a elf-locking n hich ec e he ai p ing o he dampe od.

The op mo n i an in eg al pa of he ai p ing and i fi ed i h a b h and ebo nd a he hich a e loca ed

be een he op mo n pla e and he dampe od. A elf locking n ec e he dampe od o he op mo n . The
op mo n a ache o a ho ing on he cha i i h 3 in eg al d and elf-locking n . The op mo n al o
inco po a e a 6 mm Vo ai fi ing hich allo fo he a achmen of he ai ha ne .

The ai p ing i fi ed i h o gai o . The ppe gai o i fi ed be een he op mo n and he ai p ing e aining
c linde . The lo e gai o i ec ed o he lo e end of he e aining c linde and he dampe bod i h me al
ap . The gai o p e en di and deb i becoming apped be een he ai lee e and he e aining c linde .

DAMPER MODULE - COIL SPRING SUSPENSION

I em Pa N mbe De c ip ion
1 - Self locking n

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2 - Reb d a he
3 - T a e b
4 - S i g ace ( e ec i e)
5 - S i gi a
6 - B a he
7 - S i g aid
8 - D be
9 - B c
10 - C i i g
11 - Da e
12 - Da e d
13 - Se f c i g (3 ff)
14 - B h
The c i i g da e d e c i e a da e ,ac i i ga da .

Damper

The da e a e b i a i i a de ig he f e i da e , iha i be de ig iha i g ea

a ached he da e b d . The e e d f he da e i fi ed i h a b h a d i a ached he e c
a ihab a d e f- c i g . The da e f ci b e ic i g he f f h d a ic f id h gh i e a
ga e ie i hi he da e .

The da e d e a ia i hi he da e ,i e e i i ed b he f f f id h gh he ga e ie ,
idi g da i g f d ai i he e ai . The da e d i ea ed a i e i i f he da e b d
ai ai he f id i hi he i a d e e he i g e f di a d i e. The ea a i c ae a i e
ee he d c ea .

The da e di ca ed h gh a ce a h e i he . The di h eaded a i e e d a d a e f-

c i g ec e he he da e d.

A i g aid i fi ed he da e da d e e he c ac i g he f he da e d i gf
e i c e i a da i he e i e.

Spring and Top Mo n

The c i i g fi ed diffe ih ehic e ecifica i . Each i gi c c ded ide if i a i g a d fi e

e i e e .

The c i i gi ca ed i a i g ea hich i a i eg a a f he da e b d . The de ig f he i g ea

e e he i g a i g. The ie e d f he c i i gi ca ed i a i g i a hich i fi ed i he
. The i gi a i ade f bbe a d e e a i e d ced d i g i g a d da e
c e i /e e i f bei g a i ed he ehic e b d . Th ee e f i gi a a e a ai ab e hich
a f diffe e ce i ehic e ecifica i .

The i fi ed i h a b h a d a eb d a he hich a e ca ed be ee he a e a d he
da e d. The i ec ed he da e d i h a e f- c i g . The a ache ah i g
he ehic e cha i i h h ee i eg a d a d e f- c i g .

The i g i fi ed i h i g ace hich a e ca ed be ee he i gi a a d he . The i g

ace c he e g h f he i g ai ai he c ec i heigh . The i g ace a e c c ded a d
a e ied i h a e ace e i g.

ANTI-ROLL BAR

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I em Pa N mbe De c ip ion
1 - RH lo e con ol a m
2 - N - link o lo e con ol a m (2 off)
3 - Link (2 off)
4 - N - link o an i- oll ba (2 off)
5 - LH lo e con ol a m
6 - B h (2 off)
7 - Bol (4 off)
8 - B acke (2 off)
The an i- oll ba i fab ica ed f om hea ea ed, olid, p ing eel ba . The an i- oll ba ope a e , ia a pai of link ,
f om i a achmen o he lo e con ol a m .

The an i- oll ba i loca ed on he ppe face of a combined bod mo n and an i- oll ba b acke hich i elded o
each cha i ide membe . The an i- oll ba i a ached o he b acke ih o, Teflon lined b he . The b he a e
fi ed i h b acke , hich a e p e ed on o he b he and ec ed o he cha i b acke i h bol .

The an i- oll ba ha c imped, 'an i- h ffle' colla p e ed in o po i ion on he in ide edge of he b he . The colla
p e en ide a mo emen of he an i- oll ba .

The end of he an i- oll ba a e a ached o he lo e con ol a m ia link . Thi allo he an i- oll ba o mo e i h

he heel a el p o iding ma im m effec i ene . Each link ha a ball join a each end. The op ball join i a ached
o he link a 90 deg ee o he link a i and i loca ed in a hole in he end of he an i- oll ba and ec ed i h a elf
locking n . The bo om ball join i al o a ached o he link a 90 deg ee o he a i of he link and i loca ed a hole
in a b acke on he lo e con ol and a m and ec ed i h a elf-locking n . The link a e no handed and he efo e
can be fi ed o ei he ide of he an i- oll ba .

PPER CON ROL ARM

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I em Pa N mbe De c ip ion
1 - Bolt
2 - Bumpstop clip
3 - Forward bush
4 - Bumpstop clip
5 - C aged nut
6 - Bolt
7 - Rearward bush
8 - C aged nut
9 - Self-locking nut - upper knuckle ball joint
10 - Eccentric washer - upper knuckle ball joint
11 - C am bolt - upper knuckle ball joint
12 - Upper control arm
The upper control arm locates in brackets on the upper surface of each chassis side member. The upper control arm
assembl comprises the control arm and two bushes. The upper control arm is a pressed steel fabrication. Its outer
end has two brackets with slotted holes which locate the upper ball joint of the knuckle. The ball joint is secured in the
upper control arm with a cam bolt, eccentric washer and a self-locking nut. The cam bolt and the eccentric washer
allow for the adjustment of the wheel camber.

Two fabricated tubular housings provide the location for the forward and rearward bushes. The bushes, which are
pressed into the housings, locate between brackets on the chassis side members and are secured with bolts and
caged nuts through metal inserts in the centre of the bushes.

LO ER CONTROL ARM

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I em Pa N mbe De c ip ion
1 - Self-locking nut
2 - C lip
3 - Forward bush
4 - C lip
5 - Bolt
6 - Nut and retainer
7 - Rearward bush
8 - Bolt
9 - Anti-roll bar link bracket
10 - Self-locking nut - damper lower attachment
11 - Self-locking nut - knuckle upper ball joint attachment
12 - Bolt - knuckle upper ball joint attachment
13 - Bolt - damper lower attachment
14 - Lower control arm
15 - Jacking bracket (Vehicles with coil springs onl )
The lower control arm locates in brackets on the lower surface of each chassis side member. The lower control arm
assembl comprises the control arm and two bushes. The lower control arm is a pressed steel fabrication. Its outer
end has two brackets which locate the lower ball joint of the knuckle. The ball joint is secured with a bolt and self-
locking nut. The lower control arm also provides for the attachment of the damper bush which is secured with a bolt
and a self-locking nut.

A bracket, welded to the upper surface of the lower control arm, allows for the attachment of the anti-roll bar link,
bottom ball joint which is secured with a self-locking nut.

Two fabricated tubular housings provide the location for the forward and rearward bushes. The bushes, which are
pressed into the housings, locate between brackets on the chassis side members. The forward bush is secured to the
chassis bracket with a bolt and self-locking nut. The rearward bush is secured to the chassis bracket with a bolt and a
nut and retainer. The nut and retainer allows for eas installation or removal of the bolt b removing the requirement
to hold the self-locking nut when installing or removing the bolt.

On vehicles fitted with coil springs onl , a jacking bracket is located on the lower control arm.

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WHEEL KNUCKLE, WHEEL HUB AND BEARING ASSEMBL

I em Pa N mbe De c ip ion
1 - C irclip - lower ball joint
2 - Ball joint - lower
3 - Park brake assembl attachment holes
4 - Wheel speed sensor location
5 - Wheel speed sensor cable bracket attachment
6 - Ball joint - upper
7 - Knuckle
8 - Brake caliper attachment holes
9 - Wheel bearing
10 - C irclip - wheel bearing retention
11 - Nut - halfshaft
12 - Wheel hub
13 - Wheel studs
The wheel knuckle is a machined forging which is located between the upper and lower control arms. The knuckle is
fitted with two ball joints which are pressed into the knuckle, with the lower ball joint being secured with a circlip. The
ball joints are positioned between brackets on the upper and lower control arms and secured to the arms with a bolt
and self-locking nut.

The wheel knuckle provides the location for the rear wheel taper roller bearing, which is pressed into a machined
bore and retained with a circlip. The wheel bearing is a serviceable item. The knuckle has a machined bore which
provides the location for the wheel speed sensor. Four threaded holes allow for the attachment of the park brake
assembl . A cast boss on the knuckle provides positive location for the park brake assembl . Two bosses on the
knuckle casting provide the attachment points for the rear brake caliper.

The wheel hub is a machined casting which is pressed into the wheel bearing in the knuckle. The hub has a splined
centre bore which mates with corresponding splines on the halfshaft. Five M14 studs are pressed into the wheel hub
and provide for the attachment of the road wheel with wheel nuts. Rotation of the halfshaft is passed, via the splines,
to the wheel hub which rotates on the taper roller bearing.

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Published: 11-Ma -2011

Rea S pen ion - Uppe A m Ball Join
Removal and Installation

Special Tool( )
Remover/installer rear upper arm
ball joint

204-525/3

Remover/installer rear upper arm

ball joint

204-525/2

Remover/installer rear upper arm

ball joint

204-525/1

Remo al
1. Remove the wheel knuckle.
For additional information, refer to: Wheel Knuckle (204-02
Rear Suspension, Removal and Installation).
2. Using the special tools, remove the ball joint.

Position machined face against the special tool.

In alla ion
1. C lean the components.

2. C AUTIONS:

Ensure the ball joint seal is not damaged. A damaged

seal will lead to the premature failure of the joint.

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If he p h in fo ce i le han 10 kN he heel
kn ckle m be eplaced.

U ing he pecial ool , in all he ball join .

Po i ion machined face again he pecial ool.

. In all he heel kn ckle.

Fo addi ional info ma ion, efe o: Wheel Kn ckle (204-02
Rea S pen ion, Remo al and In alla ion).

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Published: 11-Ma -2011

Rear Suspension - Lo er Arm Ball Joint
Removal and Installation

Special Tool(s)
Ball joint remover/installer

204-516/1 (LRT-64-026/1)

Ball joint remover/installer

204-516/2 (LRT-64-026/2)

Ball joint remover/installer

204-516/3 (LRT-64-026/3)

Ball joint remover/installer

204-516/4 (LRT-64-026/4)

Halfshaft remover/replacer

204-506/1 (LRT-60-030/1)

Halfshaft remover/replacer

204-506/3 (LRT-60-030/3)

Halfshaft installer adapter

204-506-01

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Retainers - halfshaft
remover/replacer

204-506/5 (LRT-60-030/5)

Remo al

C AUTION: The bolt securing the toe link to the wheel knuckle must not be used more than 5 times. Mark the bolt
head with a suitable centre punch.

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Loosen the halfshaft retaining nut.

4. Disconnect the toe link.

Remove the bolt.

5. Release the parking brake cable from the lower arm.

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. Remo e he half haf e aining n .

. Relea e he kn ckle f om he lo e a m.

Remo e he bol .

. U ing he pecial ool , elea e he half haf f om he

heel h b.

. U ing he pecial ool, emo e he lo e a m ball join .

S ppo he heel kn ckle o gi e acce o he

lo e ball join .

Remo e and di ca d he nap ing.

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In alla ion
1. C AUTIONS:

If the push in force is less than 17 kN the wheel

knuckle must be replaced.

Make sure the ball joint in installed from the

chamfered side of the wheel knuckle.

Using the special tool, install the lower arm ball joint.

Install the snap ring.

2. Using the special tools, install the halfshaft in the wheel

hub.

3. C AUTION: Ensure the ball joint seal is not damaged. A

damaged seal will lead to the premature failure of the joint.

C onnect the lower arm to the wheel knuckle.

Tighten the bolt to 175 Nm (129 lb.ft).

4. Install a new halfshaft retaining nut and lightl tighten.

5. Secure the parking brake cable.

6. C AUTION: Do not use a bolt that has been installed

more than 5 times. C heck the bolt head for centre punch
marks. A bolt head with 4 centre punch marks indicates the
bolt has been installed 5 times and must be replaced.

C onnect the toe link.

Tighten the bolt to 175 Nm (129 lb.ft).

Mark the bolt head with a centre punch, to indicate the

number of times it has been used.

7. Tighten the halfshaft retaining nut to 350 Nm (258 lb.ft).

Stake the nut to the halfshaft.

8. Install the wheel and tire.

9. C arr out the wheel alignment procedure.

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Published: 11-Ma -2011

Rear S spension - Wheel Bearing and Wheel H b
Removal and Installation

Special Tool(s)
Rear wheel bearing
remover/installer

204-509/10(LRT-60-033/10)

Rear wheel bearing

remover/installer

205-802/1

Rear wheel bearing

remover/installer

205-802/2

Rear wheel bearing

remover/installer

205-802/3

Rear wheel bearing

remover/installer

205-802/4

Rear wheel bearing

remover/installer

205-802/5

Remo al

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. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. Remove the wheel and tire.
. Remove the wheel knuckle.
For additional information, refer to: Wheel Knuckle (204-02
Rear Suspension, Removal and Installation).
. Remove the adjuster and return spring.

. Remove the primar brake shoe.

Remove the hold-down spring and retaining pin.

Pivot the shoe to release it from the spreader plate

and return spring.

. Remove the spreader plate and spring.

. Remove the return spring.

. Remove the secondar brake shoe.

Remove the hold-down spring and retaining pin.

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Di connec he pa king b ake cable e aining p ing
f om he b ake hoe le e .

. U ing he pecial ool , emo e he d i e flange.

10. Remo e he b ake di c d hield.

Remo e he 3 c e .

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11. C AUTION: Make sure that the circlip is removed

prior to the removal of the wheel bearing. Failure to follow
this instruction ma result in damage to the vehicle.

Using the special tools, remove the wheel bearing.

Remove and discard the circlip.

In alla ion
1. C lean the components.
2. Using the special tools, install the wheel bearing.

3. C AUTIONS:

Make sure that a new circlip is installed.

Make sure that the bearing seal is not damaged when

installing the circlip.

Install the circlip.

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. In all he b ake di c d hield.

Tigh en he bol o 9 Nm (7 lb.f ).

. WARNING: Do no e comp e ed ai o clean b ake

componen . D f om f ic ion ma e ial can be ha mf l if
inhaled.

C lean he backing pla e and appl g ea e o he b ake hoe

con ac .
. C lean he adj e and e i oi minim m e en ion.
. In all he econda b ake hoe.

C onnec he pa king b ake cable e aining p ing o he

b ake hoe le e , making e he p ing i no i ed.

In all he hold-do n p ing and e aining pin.

. In all he p ima b ake hoe.

In all he p eade pla e and he p ing.

In all he e n p ing.

In all he hold-do n p ing and e aining pin.

. In all he e n p ing.
10. In all he b ake hoe adj e .
11. U ing he pecial ool , in all he d i e flange.

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. In all he heel kn ckle.

Fo addi ional info ma ion, efe o: Wheel Kn ckle (204-02
Rea S pen ion, Remo al and In alla ion).

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Published: 11-Ma -2011

Rear Suspension - Shock Absorber and Spring Assembl
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Loosen the 3 spring and shock absorber retaining nuts.

4. Disconnect the shock absorber and spring assembl from

the lower arm.

Using a jack and a suitable block of wood, support

the base of the shock absorber.

Remove the nut and bolt.

5. Remove the shock absorber and spring assembl

retaining nuts.

6. Remove the shock absorber and spring assembl .

Installation
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. Install the shock absorber and spring assembl .

Make sure the spring and shock absorber assembl top

mounting to bod mating faces are clean.

Install the nuts but do not full tighten at this stage.

. C onnect the shock absorber and spring assembl to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

Tighten the three retaining nuts to 70 Nm (52 lb.ft).

. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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P bli hed: 11-Ma -2011

Rear Suspension - Rear Stabili er Bar
Remo al and In alla ion

Removal

C AUTION: I i po ible o in all he abili e ba inco ec l . No e he po i ion of he abili e ba befo e

emo al.

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he ea b mpe co e .
Fo addi ional info ma ion, efe o: Rea B mpe C o e
(501-19 B mpe , Remo al and In alla ion).
3. Remo e he pa e heel and i e.
4. Rai e he ehicle.
5. Remo e he ea heel and i e .

6. C AUTION: U e a ench on he he agon p o ided

o p e en he ball join o a ing.

Relea e bo h abili e ba link .

Remo e and di ca d he 2 n .

7. Remo e he bod mo n e aining bol .

Remo e he 8 bol .

8. C AUTION: Onl ai e he bod fficien l o emo e

he bod mo n .

C a ef ll ai e he bod .

U ing i able and , ai e he bod o elea e he

bod mo n .

9. Remo e he 2 ea bod mo n .

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10. Remove the stabili er bar bushing.

Remove the stabili er bar clamps.

Remove the 4 bolts.

11. C AUTION: Mark the position of the stabili er bar.

Remove the stabili er bar.

In alla ion

1. C AUTION: Make sure the stabili er bar is correctl

installed.

Install the stabili er bar.

2. Install the stabili er bar bushing.
3. Install the stabili er bar clamps.

Tighten the 4 retaining bolts to 62 Nm (46 lb.ft).

4. Install the bod mounts.

5. Lower the bod .

Remove the stands.

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. Install the bod mount retaining bolts.

Tighten the 8 retaining bolts to 133 Nm (98 lb.ft).

. Attach both stabili er bar links.

Tighten the nuts to 115 Nm (85 lb.ft).

. Install the wheels and tires.

. Lower the vehicle.
10. Install the spare wheel and tire.
11. Install the rear bumper cover.
For additional information, refer to: Rear Bumper C over
(501-19 Bumpers, Removal and Installation).

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Published: 25-Ma -2011

Rear S spension - Wheel Kn ckle
Removal and Installation

Special Tool(s)
Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Halfshaft remover/replacer

204-506/2(LRT-60-030/2)

Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Retainers - halfshaft
remover/replacer

204-506/5(LRT-60-030/5)

Halfshaft installer adapter

204-506-01(LRT-60-030/4)

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Loosen the halfshaft retaining nut.

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. Remo e he b ake di c.
Fo addi ional info ma ion, efe o: B ake Di c (206-04
Rea Di c B ake, Remo al and In alla ion).
. Relea e he pa king b ake cable.

Di connec he pa king b ake cable f om he b ake

hoe le e .

Di connec he pa king b ake cable f om he

backpla e.

Relea e he cable f om he lo e a m.

. Relea e he heel peed en o f om he heel kn ckle.

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. Disconnect the toe link.

Remove and discard the bolt.

. Remove the halfshaft retaining nut.

. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure
of the joint.

Release the knuckle from the lower arm.

Remove the bolt.

10. C AUTION: Do not use a hammer to detach the

halfshaft from the hub assembl , failure to follow this
instruction ma result in damage to the halfshaft.

Using the special tools, release the halfshaft from the

wheel hub.

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11. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure
of the joint.

Disconnect the upper arm from the wheel knuckle.

Mark the position of the bolt in relation to the upper

arm.

Remove the nut and bolt.

Discard the nut.

12. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure of
the joint.

Remove the wheel knuckle.

In alla ion
1. C lean the components.

2. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure of
the joint.

Install the wheel knuckle.

Locate the halfshaft.

3. C onnect the upper arm and wheel knuckle.

Align the bolt to the marks made previousl .

Install a new nut and tighten to 133 Nm (98 lb.ft).

4. Using the special tools, install the halfshaft in the wheel

hub.

5. C AUTION: Install the halfshaft nut finger tight.

Install a new halfshaft retaining nut and lightl tighten.

6. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure of
the joint.

C onnect the lower arm to the wheel knuckle.

Tighten the nut and bolt to 175 Nm (129 lb.ft).

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. C onnect the toe link.

Tighten the new bolt to 175 Nm (129 lb.ft).

. Install the wheel speed sensor.

Tighten the bolt to 9 Nm (7 lb.ft).

. Locate the parking brake cable to the backplate.

C onnect the cable to the brake shoe lever.

Tighten the coupling to 8 Nm (6 lb.ft).

Secure the parking brake cable to the lower arm.

10. Install the brake disc.

For additional information, refer to: Brake Disc (206-04
Rear Disc Brake, Removal and Installation).

11. C AUTION: Do not use air tools to install the nut.

Failure to follow this instruction ma result in damage to the
component.

Tighten the halfshaft retaining nut to 350 Nm (258 lb.ft).

Stake the nut to the halfshaft.

12. Install the wheel and tire.

13. C arr out the wheel alignment procedure.

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Rear S spension - Upper Arm B shing
Removal and Installation

Special Tool(s)
Remover/installer - rear
suspension upper arm front
bushing

204-528/1

Remover/installer - rear
suspension upper arm front
bushing

204-528/2

Remover/installer - rear
suspension upper arm front
bushing

204-528/3

Remover/installer rear suspension

upper arm rear bushing

204-527/1

Remover/installer rear suspension

upper arm rear bushing

204-527/2

Remover/installer rear suspension

upper arm rear bushing

204-527/3

Remo al
NOTE: If a bushing requires renewal always renew the opposite.
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. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. Remove the wheels and tires.

. C AUTION: Alwa s plug an open connections to

prevent contamination.

Remove the brake tube.

Disconnect the 2 brake tube unions.

Remove the brake hose clips and release the hoses.

Release the brake tube from the clip.

. Disconnect the height sensor link.

. Release the wheel speed sensor lead.

. Remove the LH upper arm.

Loosen the upper arm bolts.

Mark the position of the bolt in relation to the upper

arm.

Disconnect the upper arm from the wheel knuckle.

Remove the upper arm bolts.

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. Remo e he RH ppe a m.
Fo addi ional info ma ion, efe o: Uppe A m (204-02
Rea S pen ion, Remo al and In alla ion).
. Ma k he po i ion of he b hing in ela ion o he ppe
a m.
. U ing he pecial ool , emo e and di ca d he ea
ppe a m f on b hing.

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10. Using the special tools, remove and discard the rear
upper arm rear bushing.

In alla ion
1. C AUTIONS:

Make sure the bush is correctl aligned.

Make sure the correct special tool is used to install the

bushings to the correct depth.

Using the special tools, install the rear upper arm front
bushing.

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. C AUTION: Make sure the bush is correctl aligned.

Using the special tools, install the rear upper arm rear
bushing.

. Install the LH upper arm.

Fit the bolts but do not full tighten at this stage.

. Set the height bet een the center of the halfshaft end
and the edge of the fender trim to 485 mm (19.10'').

Support ith an a le stand.

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. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure of
the joint.

C onnect the upper arm and wheel knuckle.

Align the bolt to the marks made previousl .

Tighten the bolt to 133 Nm (98 lb.ft).

. Tighten the upper arm front bolt to 175 Nm (129 lb.ft).

. Tighten the upper arm rear bolt to 275 Nm (203 lb.ft).
. Secure the wheel speed sensor lead.
. Secure the brake pad wear indicator sensor lead.
10. C onnect the height sensor link.
11. Install the brake tube.

Tighten the brake tube unions to 18 Nm (13 lb.ft).

12. Install the RH upper arm.

For additional information, refer to: Upper Arm (204-02
Rear Suspension, Removal and Installation).
13. Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Rear Suspension - Rear Stabili er Bar Link
Remo al and In alla ion

Removal

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.

3. C AUTION: U e a ench on he he agon p o ided

o p e en he ball join o a ing.

Remo e he abili e ba link.

Remo e and di ca d he 2 n .

Installation
1. In all he abili e ba link.

Tigh en he n o 115 Nm (85 lb.f ).

2. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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Rea S pen ion - Lo e A m
Remo al and In alla ion

Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.

3. C AUTION: U e a ench on he he agon p o ided

o p e en he ball join o a ing.

Relea e he abili e ba link.

Remo e and di ca d he e aining n .

4. Loo en he 2 lo e a m bol .
5. Di connec he hock ab o be and p ing a embl f om
he lo e a m.

Remo e he n and bol .

6. Relea e he pa king b ake cable.

7. Remo e he 2 lo e a m bol .

8. C AUTION: En e he ball join eal i no damaged. A

damaged eal ill lead o he p ema e fail e of he join .

Relea e he kn ckle f om he lo e a m.

Remo e he bol .

9. Remo e he lo e a m.

In alla ion
1. In all he lo e a m.

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Fit the bolts but do not full tighten at this stage.

. C AUTION: Ensure the ball joint seal is not damaged. A

damaged seal will lead to the premature failure of the joint.

C onnect the lower arm to the wheel knuckle.

Tighten the bolt to 175 Nm (129 lb.ft).

. C onnect the shock absorber and spring assembl to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

. Set the height between the center of the halfshaft end

and the edge of the fender trim to 485 mm (19.10'').

. Tighten the lower arm bolts to 275 Nm (203 lb.ft).

. Secure the parking brake cable.
. C onnect the stabili er link.

Install a new nut and tighten to 115 Nm (85 lb.ft).

. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

. C arr out the wheel alignment procedure.

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Rear S spension - Upper Arm
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.

3. C AUTION: Alwa s plug an open connections to

prevent contamination.

Remove the brake tube.

Disconnect the 2 brake tube unions.

Remove the brake hose clips and release the hoses.

Release the brake tube from the clip.

4. Disconnect the height sensor link arm.

5. Release the wheel speed sensor lead.

6. RH side onl : Release the brake pad wear indicator

sensor lead.

7. Remove the upper arm.

Loosen the upper arm bolts.

Mark the position of the bolt in relation to the upper

arm.

Remove the nut and bolt, then release the upper

arm from the wheel knuckle.
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Remo e he ppe a m bol .

In alla ion
1. In all he ppe a m.

Fi he bol b do no f ll igh en a hi age.

2. Se he heigh be een he cen e of he half haf end

and he edge of he fende im o 485 mm (19.10'').

S ppo i h an a le and.

3. C AUTION: En e he ball join eal i no damaged. A

damaged eal ill lead o he p ema e fail e of he join .

C onnec he ppe a m and heel kn ckle.

Align he bol o he ma k made p e io l .

Tigh en he bol o 133 Nm (98 lb.f ).

4. Tigh en he ppe a m f on bol o 175 Nm (129 lb.f ).

5. Tigh en he ppe a m ea bol o 275 Nm (203 lb.f ).
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. Secure the wheel speed sensor lead.

. Secure the brake pad wear indicator sensor lead.
. C onnect the height sensor link arm.
. Install the brake tube.

Tighten the brake tube unions to 18 Nm (13 lb.ft).

10. Bleed the brake s stem.

For additional information, refer to: Brake S stem Bleeding
(206-00 Brake S stem - General Information, General
Procedures).
11. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

12. C arr out the wheel alignment procedure.

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Rea S pen ion - Toe Link
Remo al and In alla ion

Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.
3. Di connec he oe link.

Remo e and di ca d he bol .

4. Remo e he oe link.

Remo e and di ca d he n .

In alla ion

1. C AUTION: Make e he oe link an i- o a ion ang i

f ll ea ed in he in eg a ed bod f ame befo e igh ening he
oe link e aining n . Fail e o follo hi in c ion ill
e l in damage o he oe link o in eg a ed bod f ame.

In all he oe link.

In all a ne n and ligh l igh en.

2. C onnec he oe link.

U ing a M14 X 2 ap, cean he h ead of he kn ckle

fi ing hole. Blo o deb i i h an ai -line.

Tigh en he ne bol o 175 Nm (129 lb.f ).

3. Se he gap, be een he nde ide of he oe link bbe

boo and he in eg a ed bod f ame b acke , o 10 mm
(0.473 in).

Tigh en he oe link inne ball join e aining n o

133 Nm (98 lb.f )

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. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

. C arr out the wheel alignment procedure.

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Rear S spension - Lo er Arm B shing
Removal and Installation

Special Tool(s)
Receiver rear lower arm front bush

204-526/1

Remover rear lower arm front

bush

204-526/2

Installer rear lower arm front bush

204-526/3

Receiver rear lower arm rear bush

204-540/1

Remover rear lower arm rear bush

204-540/2

Installer rear lower arm rear bush

204-540/3

Remo al
NOTE: The bushings must be replaced in pairs, LH and RH sides.
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. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

. Remove the wheels and tires.
. Remove the LH lower arm.
For additional information, refer to: Lower Arm (204-02
Rear Suspension, Removal and Installation).
. Remove the RH lower arm.
. Note the position of the bushing in relation to the lower
arm.

. C AUTION: The bush flanges need to be removed to

allow bush removal.

NOTE: Take note of the fitted position of the bush.

Using a suitable tool, bend over the bush flanges.

. Using a hacksaw, remove the flange from the bushing,
making sure the upper arm is not damaged.

. Using the special tools, remove and discard the lower

arm rear bushings.

. Using the special tools, remove and discard the lower

arm front bushings.

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In alla ion
1. C AUTIONS:

Make sure the bush is correctl aligned.

Make sure the correct special tool is used to install the

bushings to the correct depth.

Using the special tools, install the lower arm front

bushings

2. C AUTION: Make sure the bush is correctl aligned.

Using the special tools, install the lower arm rear

bushings.

3. Install the LH lower arm.

For additional information, refer to: Lower Arm (204-02
Rear Suspension, Removal and Installation).
4. Install the RH lower arm.
5. Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

6. C heck the wheel alignment.

For additional information, refer to: Four-Wheel Alignment
(204-00 Suspension S stem - General Information, General
Procedures).

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P : 11-M -2011
Rear Suspension - Shock Absorber and Spring Assembl
D A

Disassembl

WARNING: E S W L (SWL)
S .

1. R .
2. R .
3. R .
F , :S A
S A (204-02 R S ,R
I ).
4. I .
5. I
.

C
.

6. R .

R ,
.

R
.

R .

R .

R .

7. R .

Assembl
1. C .

R .

R .

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Remove the rebound plate from the dust tube.

. Install the spring in the spring compressor.

Make sure the spring is installed with the close coils

positioned towards the top of the shock absorber.

. Install the spring aid.

. Install the dust tube.

Install the rebound plate into the dust tube.

. Install the shock absorber.

Make sure the spring is correctl located in the spring

seat.

. Install the upper mounting.

Install the spacer and rubber insulator, making sure

the spacer drops over the stud heads.

Install the upper bush and upper bush rebound plate.

Install a new nut and tighten to 98 Nm (72 lb.ft).

. Install the shock absorber and spring assembl .

For additional information, refer to: Shock Absorber and
Spring Assembl (204-02 Rear Suspension, Removal and
Installation).
. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Wheels and Tires -
Wheels
Wheel type Wheel size
Alloy wheel 7J x 17
Alloy wheel 8J x 18
Alloy wheel 8J x 19
Reduced size spare wheel - Steel 5.5J x 19
C AUTIONS:

With reduced size spare wheel fitted, do not exceed 50 mph (80 kph) and replace with standard size wheel at
earliest opportunity.

Do not use power tools when operating the spare wheel winch, raise and lower winch manually using hand tools
only.
Tire Sizes - Standard Fit
Wheel size Tire size Tire load index
7J x 17 - Alloy 235/70 R17H - All terrain 111
8J x 18 - Alloy 255/60 R18H or V - All terrain 112
8J x 19 - Alloy 255/55 R19H or V - All terrain 111

C AUTION: Inner tubes must not be fitted with any of these tires.

Tire Sizes - A ccessory Fit

Wheel size Tire size Tire load index
8J x 19 - Alloy 255/55 R19 - Mud terrain 111
8J x 19 - Alloy 255/55 R19 - Sand 111

C AUTION: Inner tubes must not be fitted with any of these tires.
Tire Pressures - Not NA S Vehicles
Loading condition bars lbf/in kPa
Normal operating conditions - Up to 4 people:
Front 2.3 33 230
Rear 2.5 36 250
Vehicle loaded to maximum gross vehicle weight:
Front 2.3 33 230
Rear 2.9 42 290
Reduced size spare wheel 4.2 60 420
* Standard size spare wheel 2.9 42 290

C AUTION: * The standard size spare wheel tire should be inflated to the maximum gross vehicle weight
pressure and the pressure for the front or rear wheel locations must be adjusted accordingly if the wheel is to be
used under conditions other than with the vehicle loaded to maximum gross vehicle weight.

Tire Pressures - NA S Vehicles

Loading condition bars lbf/in kPa
All conditions - Vehicle loaded up to maximum gross vehicle weight:
Front 2.3 33 230
Rear 2.9 42 290
Reduced size spare wheel 4.2 60 420
* Standard size spare wheel 2.9 42 290

C AUTION: * The standard size spare wheel tire should always be inflated to the highest loading condition
pressure which must be adjusted accordingly if the wheel is to be fitted to the front wheel locations.
General Specif ication
Item Make Location
Tire low pressure sensor Siemens On inside of wheel rim
Tire pressure sensor
initiator:

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Front Siemens Attached to the fender splash shield adjacent to the front bumper
Rear Siemens Attached to the fender splash shield adjacent to the rear bumper
Module Siemens Attached to the roof panel bet een the sun roofs, on the left hand side of the
interior light
Recommended Lubricant
Application Land Rover Part No.
Wheel hub spigot RYL 105020
Torque Specif ications
Description Nm lb-ft
* Road heel nuts 140 103
Tire lo pressure sensor 6 4
* Wheel nuts must be tightened b diagonal selection

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Wheels and Tires - Wheels and Tires
De c ip ion and Ope a ion

GENERAL

A n mbe of allo heel and i e i e combina ion a e a ailable. A Ti e P e e Moni o ing S em (TPMS) i al o
a ailable. Thi em moni o he p e e in each i e and info m he d i e if he p e e i o ide
p ede e mined h e hold .

WHEELS (2009 MY on ards)

I em Pa N mbe De c ip ion
A - 7JX17 (5 2 Spoke)
B - 8JX18 (5 Spoke)
C - 8JX18 (10 Spoke)
D - 8JX19 (6 Spoke)
E - 8JX19 (Slo Machine)
F - 5.5JX19 (Space Sa e Spa e)

WHEELS (up to 2009 MY)

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I em Pa N mbe De c ip ion
A - 7JX17
B - 8JX18 - Style 1
C - 8JX18 - Style 2
D - 8JX19
E - 5.5JX19 - Space saver
The spare wheel fitted to all vehicles is a steel space saver wheel. The wheel size is 5.5J X 19 and uses a T175/80R19
tire. The space saver wheel is a standard fitment for all markets except Gulf states. A full size spare is offered as an
optional fitment.

TIRES

Tires are available in a number of sizes and tread patterns dependent on the vehicle usage. Tire sizes are as follows:

235/70R17
255/60R18
255/55R19.

The following tires are available; All Season (AS), All Terrain (AT) and All Terrain - Sport (AT-S).

NOTE: Tires should be inflated to the recommended pressures (as given in the owners handbook) only when the
tires are cold (ambient temperature). If the tires have been subjected to use or exposed to direct sunlight, move the
vehicle into a shaded position and allow the tires to cool before checking and/or adjusting the pressures.

Ti e Changing

C are must be taken when removing and refitting tires to ensure that the tire pressure sensor is not damaged.

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I em Pa N mbe De c ip ion
1 - Tire valve and pressure sensor
2 - Tire fitting/removal tool initial start position
3 - High tire and bead tension area
4 - Low tire and bead tension area
When removing the tire, the bead breaker must not be used within 90 degrees of the tire valve in each direction.

When using the tire removal machine, the fitting arm start position must be positioned as shown in the tire changing
illustration. The wheel can then be rotated through 180 degrees in a counterclockwise direction. This will relieve the
high tension from the tire bead allowing the remaining 180 degrees of the tire to be manually pulled from the rim.

When refitting the tire, position the fitting arm as shown. Rotate the tire and take care that the bead on the low
tension side of the tire does not damage the sensor.

Tread Act - NAS Onl

Vehicles supplied to the North American markets must comply with the legislation of the Transport Recall
Enhancement, Accountability and Documentation (TREAD) act. Part of the requirement of the TREAD act is for the
vehicle to display a label, positioned on the driver's side B-pillar, which defines the recommended tire inflation
pressure, load limits and maximum load of passengers and luggage weight the vehicle can safely carry. This label will
be specific to each individual vehicle and will be installed on the production line.

This label must not be removed from the vehicle. The label information will only define the specification of the vehicle
as it came off the production line. It will not include dealer or owner fitted accessory wheels and tires of differing size
from the original fitment.

NOTE: If tires and wheels of a non-standard size are fitted to the vehicle, the car configuration file must be updated
using T4.

If the label is damaged or removed for body repair, it must be replaced with a new label specific to that vehicle. A
new label is requested from Land Rover parts and will be printed specifically for the supplied VIN of the vehicle.

TIRE PRESSURE MONITORING SYSTEM (TPMS)

Tire Pressure Monitoring System - C omponent Location

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I em Pa N mbe De c ip ion
1 - Ini ia o
2 - Ti e p e e en o

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3 - Instrument cluster
4 - TPMS module
5 - TPMS switch (Not available on NAS vehicles)
The purpose of the Tire Pressure Monitoring System (TPMS) is to assist the driver in maintaining the vehicle s tire
pressures at the optimum level in order to:

improve fuel consumption

maintain ride and handling characteristics
reduce the risk of rapid tire deflation – which may be caused by under inflated tires
comply with legislation in relevant markets.

The TPMS measures the pressure in each of the tires on the vehicle (including the spare, if required) and issues
warnings to the driver if any of the pressures deviate from defined tolerances.

• NOTE: During a blow out a very rapid reduction in pressure is experienced. The system is not intended to warn the
driver of a blow out , since it is not possible to give the driver sufficient warning that such an event is occurring, due
to its short duration. The design of the TPMS is to assist the driver in keeping the tires at the correct pressure, which
will tend to reduce the likelihood of a tire blow out occurring.

A single TPMS hardware configuration is used. Two levels of instrument cluster are available; low-line with two
warning indicator LEDs and high-line with text message center display and one warning indicator LED.

A TPMS fitted with a high-line instrument cluster provides the driver with additional functionality of the identification of
tire position on the vehicle and a more sophisticated driver interface.

TPMS Mod le

The TPMS module is located above the headlining of the vehicle, mounted directly to the central roof cross-beam,
behind the sunroof. The module is retained in position with two screws which secure into weldnuts on the cross beam.
The three connectors of the module point towards the front of the vehicle.

The TPMS module s main function is to detect the following:

the tire pressure is below the recommended low tolerance value – under inflated tire
the tire pressure is below the recommended lower tolerance value – significantly under inflated tire
the position of the tire on the vehicle.

The TPMS module also communicates with the vehicle instrument cluster to provide the driver with appropriate
warnings that show the importance of the condition detected and indicate the status/failure of TPMS components.

Tire Loca ion

Because of the requirement for different pressure targets and thresholds for the front and rear tires, the TPMS
module can identify the position of the tires on the vehicle, and assign a received tire pressure sensor identification to
a specific position on the vehicle (i.e. FL (front left), FR (front right), RL (rear left) or RR (rear right)).

Tire location is performed automatically by the module using an auto-location function. This function requires no
manual intervention by the driver. The TPMS module can automatically learn the position of tires on the vehicle if the

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tire pressure sensors or their positions are changed on the vehicle.

The TPMS module can automatically detect, under all operating conditions, the following:

one or more tire pressure sensors have been replaced

one or more tire pressure sensor identifications are missing
one or more ‘alien’ identifications are being received, i.e. the module can reject identifications from tire
pressure sensors that do not belong to the vehicle
the spare tire and one of the tires in use on the vehicle have exchanged position on the vehicle.

If the tire pressure sensors fitted to the vehicle are changed, the module can learn the new sensor identifications
automatically. The learn function requires no manual intervention by the driver.

Spare Tire Identification

Depending on the vehicle specification, the spare tire may or may not be fitted with a tire pressure sensor.

If the spare tire is fitted with a tire pressure sensor, the TPMS module can detect it, determine that it is the spare tire
and monitor its pressure and issue warnings to the driver accordingly. If the TPMS module expects the spare tire to
be fitted with a tire pressure sensor and it does not, the module will not show a fault to the driver, however a fault
code will be stored in the TPMS module.

If the spare tire is being monitored and the driver replaces a flat ‘running’ tire with the spare tire, the module will not
continually warn the driver that the original flat tire (now in the spare position) is flat. This prevents distraction of the
driver by constant pressure warnings being issued.

S stem Operation

Each time the vehicle is driven, the TPMS module commands each initiator to transmit a LF (125 KHz) signal to each
pressure sensor in turn. This is received by the tire pressure sensor which passes its identification code and tire
information to the TPMS module log. The senosr then transmits an RF (315 or 433 MHz depending on market) signal
to the module. This signal contains coded data which corresponds to sensor identification, tire pressure, tire
temperature and acceleration data.

The system enters 'parking mode' after the vehicle speed has been less than 12.5 mph (20km/h) for 12 minutes. In
parking mode the tire pressure sensors transmit transmit a coded signal to the module once every 13 hours. If the
tire pressure decreases by more than 1 lbf/in (0.6 bar) the sensor will transmit more often if pressure is being lost.

The spare tire sensor transmits a signal every 132 hours in the same manner as the road wheels when in parking
mode. If the tire pressure decreases by more than 1 lbf/in (0.6 bar) the sensor will transmit more often if pressure
is being lost.

As each wheel responds to the LF signal from the TPMS module, it is assigned a position on the vehicle and is
monitored for the remainder of that drive cycle in that position.

When the vehicle has been parked for more than 15 minutes and then driven at a speed of more than 12.5 mph (20
km/h), the initiators fire in turn for 6 seconds on all except NAS vehicles or for 18 seconds on NAS only vehicles in
the following order:

Front left
6 second pause (for the TPMS module to detect a response from the tire pressure sensor)
Front right
6 second pause
Rear right
6 second pause
Rear left
6 second pause.

Each tire sensor responds in turn so the module can establish the sensor positions at the start of the drive cycle. This
process is repeated up to three times but less if the sensor positions are already known in the module. The process is
known as 'Auto Location' and takes 3 to 4 minutes on all except NAS vehicles and 7 to 8 minutes on NAS vehicles to
complete. During this period the tire sensors transmit at regular intervals, once every 5 seconds on all except NAS
vehicles and once every 15 seconds on NAS vehicles. For the remainder of the drive cycle the tire sensors transmit
once every 60 seconds or if a change in tire pressure is sensed until the vehicle stops and the system returns to
parking mode.

Once the wheel position is established, the initiators stop firing and do not fire again until the vehicle has been parked
for more than 15 minutes. The signal transmissions from each wheel sensor continue at 1 minute intervals whilst the
vehicle is being driven. This transmission is to monitor the tire pressure. There are two levels of warning; amber
warning indicator illuminated at 25% deflation and an appropriate message displayed in the instrument cluster
message centre at 35% deflation. The message centre will also display additional information about the position of the
affected wheel(s).

Initiator
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The initiators are located near the front of the front wheel arches and near the rear of the rear wheel arches and are
secured with two scrivets. The TPMS system has four initiators. Each initiator has a connector which connects with the
body harness.

The initiator is a passive, Low Frequency (LF) transmitter. Each initiator provides an auto-location feature to identify
tire positions on the vehicle and transmit that data to the TPMS module.

The TPMS module energises each initiator in turn using LF drivers. The corresponding tire pressure sensor detects the
resulting LF transmission and responds by initiating an RF transmission of its data. This data is received by the TPMS
module internal RF antenna. The module can then determine which sensor is transmitting and its location on the
vehicle.

Tire Press re Sensor

The TPMS system uses active tire pressure sensors which are mounted on each wheel, inside the tire cavity. The
sensor is retained in position by the valve attachment to the wheel structure. The sensors transmit their RF signals at
either 315 MHz or 433 MHz dependent on market requirements.

The sensors periodically measure the pressure and temperature of the air inside the tire. Pressure and temperature
measurements are transmitted periodically to the RF receiver in the vehicle.

The tire pressure sensors are self-contained units which have no electrical connections into or out of the sensor.

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The care points detailed in 'Tire C hanging' in this chapter must be followed to avoid damage to the sensor. If the
sensor is replaced, the nut, seal and washer must also be replaced and the sensor tightened to the correct torque
value as given in the Service Repair manual.

The RF transmission from the sensor contains a unique identification code in its transmission data, so that the TPMS
module can identify the tire on the vehicle. If the sensor is replaced on a 'running' wheel, the new sensor
identification will be learnt when the vehicle is first driven at a speed of more than 12.5 mph (20 km/h) for 15
minutes. If a new sensor is fitted to the spare wheel, the identification for that sensor must be programmed into the
TPMS module using T4 or that wheel will not be monitored. The code is provided on a label with the complete wheel
and tire assembly when new and is also printed on the casing of each sensor.

The replacement spare wheel may also be programmed to the vehicle by using it as a 'running' wheel for 12.5 mph
(20 km/h) for 15 minutes, then replacing it to the spare wheel position.

In order to conserve battery power, the tire sensor module uses different transmission rates when the wheel is
stationary or moving. The wheel speed required to change between the stationary and moving transmission rates is
very low to allow for the requirement for slow off-road driving.

TPMS S itch

• NOTE: The TPMS switch is not fitted to NAS market vehicles. NAS vehicles do not have the option to select target
pressure modes.

The TPMS switch is a non-latching push button switch which is located in the center console switch pack, adjacent to
the hazard warning switch.

The TPMS switch is used by the driver to set the required target pressures for the vehicle, i.e. normal load or high
load . The switch is used to toggle between the two modes.

The TPMS switch has a status LED, located in the face of the switch, which informs the driver when the normal load
or high load pressures are set. When 'normal load' mode is set, the LED is illuminated. When 'high load' mode is set,
the LED is extinguished.

The status LED has two-stage illumination, providing day or night time illumination levels. The illumination level is
determined by the TPMS module, based on data received via the vehicle C AN interface.

The switch is used to change between the modes as required. The ignition switch must be in position II. If the TPMS is
in the 'normal load' mode, pressing and holding the switch will change the target pressures to 'high load' mode. The
LED will be extinguished, the message center in the instrument cluster will flash 'Tire Pressures High Load C ondition'
for 5 seconds. This setting will remain until deselected by the driver.

To change from 'high load' mode to 'normal load' mode, the ignition switch must be in position II and the switch must
be pressed and held. This will change the target pressures from 'high load' mode to 'normal load' mode. The switch
LED will illuminate and the instrument cluster message center will display 'Tire Pressures Normal condition' for 5
seconds.

Instrument Cluster Indications

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I em Pa N mbe De c ip ion
A - Low line instrument cluster
B - High line instrument cluster
1 - Amber warning indicator
2 - Red warning indicator
3 - Message center
The warning indications to the driver differ between the specification of instrument cluster fitted to the vehicle. On
vehicles with a low line instrument cluster, tire pressure warnings are conveyed to the driver by amber and red LED
warning indicators. On high line instrument clusters, warnings are conveyed by an amber LED warning indicator and a
text message displayed in the message center.

The warning indicators on both cluster specifications are driven by C AN messages from the TPMS module. The
warning indicators are illuminated by the cluster software for 3 seconds when the ignition is switched to position II for
a bulb check.

NOTE: If the vehicle is not fitted with the TPMS, the warning indicators will not illuminate at any time.

When the TPMS module transmits a warning indicator on signal, this may also be accompanied by a chime from the
instrument cluster sounder.

The following table shows the warning indicator functionality for given events for both specifications of instrument
cluster.

E en Lo Line In men Cl e High Line In men Cl e

Minor warning threshold reached in any Amber LED illuminated
'running' tire
Minor warning threshold reached in spare Amber LED illuminated for 20
tire (if fitted) seconds then extinguished.
At next and subsequent ignition
cycles Amber LED illuminated for
20 seconds then extinguished.
Major warning threshold reached in any Red LED illuminated.
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Amber LED illuminated.
'C HEC K TIRE PRESSURES' message
displayed.
Amber LED illuminated for 20
seconds then extinguished.
At next and subsequent ignition
cycles Amber LED illuminated for 20
seconds then extinguished.
'C HEC K SPARE TYRE PRESSURE'
message displayed.
'XX TIRE PRESSURE VERY LOW'
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'running' tire
Major warning threshold reached in more
than one 'running tire'
Over-pressure threshold reached in any
'running' tire with 'normal load' mode set
Over-pressure threshold reached in more
than one 'running tire' with 'normal load'
mode set
Any 'running' or 'spare' tire pressure sensor No indication (Fault code stored on No indication (Fault code stored on
battery low
TPMS Fault
One TPMS wheel sensor fault
More than one TPMS wheel sensor fault
TPMS switch pressed for 4 seconds to set
'Normal Load' operation when engine is not illuminated
running and the ignition switch is in position
II (Not applicable to NAS vehicles)
TPMS switch pressed for 4 seconds to set
'High Load' operation when engine is not
running and the ignition switch is in position
II (Not applicable to NAS vehicles)
NOTE: 'XX' is the tire position on the vehicle, e.g. FL (front left), FR (front right), RL (rear left) or RR (rear right).
Inp and O p
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Sounder activated once when LED message displayed.
is illuminated. Sounder activated once when
message is displayed.
Amber and Red LEDs illuminated 'TYRE PRESSURES VERY LOW'
Sounder activated on detection of message displayed.
each major warning event. Sounder activated once when
Sounder activated once before message is displayed.
Amber and Red LEDs illuminated Sounder activated once before
and vehicle speed increased from Amber LED illuminated, message
0 to 37 mph (0 to 60 km/h). displayed and vehicle speed
increased from 0 to 37 mph (0 to 60
km/h).
No indication 'XX TYRE PRESSURE TOO HIGH'
message displayed
No indication 'TYRE PRESSURES TOO HIGH'
message displayed
TPMS module) TPMS module)
Amber LED illuminated. Amber LED illuminated.
Amber LED illuminated at next Amber LED illuminated at next and
and subsequent ignition on cycle. subsequent ignition on cycle.
Sounder activated on initial LED Sounder activated on initial LED
illumination. illumination.
'TYRE PRESSURE MONITORING
SYSTEM FAULT' message displayed.
Amber LED illuminated. Amber LED illuminated.
Amber LED illuminated at next Amber LED illuminated at next and
and subsequent ignition on cycle. subsequent ignition on cycle.
Sounder activated on initial LED Sounder activated on initial LED
illumination. illumination.
'XX TYRE PRESSURE NOT
MONITORED' message displayed.
Amber LED remains illuminated. Amber LED illuminated.
Amber LED illuminated at next Amber LED illuminated at next and
and subsequent ignition on cycle. subsequent ignition on cycle.
Sounder activated on detection of Sounder activated on detection of
each additional wheel sensor fault each additional wheel sensor fault
event. event.
'TYRE PRESSURE MONITORING
SYSTEM FAULT' message displayed.
TPMS switch status LED TPMS switch status LED illuminated.
'TYRE PRESSURE MONITORING
LIGHT LOAD MODE' message
displayed for 3 seconds.
TPMS switch status LED is TPMS switch status LED is
extinguished extinguished.
'TYRE PRESSURE MONITORING
HEAVY LOAD MODE' message is
displayed for 3 seconds.
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I em Pa
N mbe De c ip ion
1 - C ec C 2447
2 - C ec C 1537
3 - N ed
T c ec ide he i e face be ee he TPMS d e a d he e e a TPMS c e . The hi d
c ec a e e he TPMS d e i ed.

The f i g ab e h he de ai f he ig a e ec ica ie each c ec i .

Connector C1537
Pin No. Description Input/Output
1 N ed -
2 C AN LOW - IN I /O
3 C AN HIGH - IN I /O
4 N ed -
5 TPMS S i ch LED D i e O
6 N ed -
7 TPMS S i ch I
8 Ig i i 12V I
9 N ed -
10 C AN LOW - OUT I /O
11 C AN HIGH - OUT I /O
12 G d I
13 15 N ed -
16 12V Pe a e ba e I
Connector C2447
Pin No. Description Input/Output
1 4 N ed -
5 Rea LH i i ia - Sig a i i e (+) O
6 Rea LH i i ia - Sig a ega i e (-) O
7 Rea RH i i ia - Sig a i i e (+) O
8 Rea RH i i ia - Sig a ega i e (-) O
9 12 N ed -
13 F LH i i ia - Sig a i i e (+) O
14 F LH i i ia - Sig a ega i e (-) O
15 F RH i i ia - Sig a i i e (+) O
16 F RH i i ia - Sig a ega i e (-) O
Controller Area Net ork (CAN) Signals

The TPMS d e e d a d ecei e a be f digi a e age ia he edi eed C AN. The ecei ed
e age a e ed f he e ai f he TPMS. The a i ed e age c i e f TPMS a a d e e
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to the instrument cluster to illuminate warnings indicators and/or display messages in the message center.

Received Messages

The TPMS module receives the messages shown in the following table.

Message Transmitted B
Vehicle speed ABS module
External ambient temperature - corrected ATC module
Side lamp status C JB
Ignition switch status C JB
Odometer value Instrument cluster
Minute counter Instrument cluster
Vehicle voltage level Instrument cluster
Engine crank relay status EC M
Diagnostic physical request T4
Diagnostic functional request T4
Engine running status EC M
Master car configuration identification Instrument cluster
C ar configuration parameters Instrument cluster
Transmitted Messages

The TPMS module transmits the messages shown in the following table.

Message Received B
TPMS diagnostic response T4
TPMS Red warning indicator request at 35% tire deflation Instrument cluster
TPMS yellow warning indicator request at 25% tire deflation Instrument cluster
TPMS audible alert Instrument cluster
TPMS message display request Instrument cluster
Diagnostics

The TPMS module has a diagnostic connection via the medium speed C AN to enable system status and faults to be
retrieved using T4.

Additionally, an on-board diagnostic routine within the TPMS module constantly monitors the system and alerts the
driver to a system faults by illuminating the amber or red warning indicators, emitting a tone from the instrument
cluster sounder and/or displaying a message in the instrument cluster message center.

Fault Detection

If a sensor fails, the amber warning indicator in the instrument cluster will be illuminated. A message 'XX Tyre
Pressure Not Monitored' will be displayed in the message center in addition to the amber warning indicator.

If more than one sensor fails or the TPMS module develops a fault, the amber warning indicator will be illuminated. A
message 'Tyre Pressure Monitoring System Fault' will be displayed in the message center in addition to the amber
warning indicator. This fault could also be caused if RF interference near the vehicle affects the system signal
reception. When the interference has ceased, the fault will be automatically cancelled and the TPMS will operate
normally.

If a tire pressure sensor battery voltage becomes low, the sensor transmits a message to the TPMS module. The
module stores the low battery condition as a fault flag in its memory with no other visual warnings displayed. If the
battery fails, the sensor will stop transmitting and the TPMS module will transmit a message to display 'FL Tyre Not
Being Monitored' for example in the message center. The dealer should interrogate the TPMS module using T4 for the
fault flag to determine the cause of the message. If the battery has failed the sensor must be replaced and the stored
fault flags removed using T4. The TPMS module will learn the identification of the new sensor when the vehicle is
driven. If the replaced sensor is fitted to the spare wheel (if fitted), its identification must be manually programmed
into the module using T4 or by using it as a 'running' wheel for 15 minutes at more than 12.5 mph (20 km/h), then
replacing it to the spare wheel position.

CONTROL DIAGRAM

NOTE: A = Hardwired; F = RF Transmission; N = Medium Speed C AN Bus

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I em Pa N mbe De c ip ion
1 - Fusible link 17E (50A)
2 - Ignition s itch

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3 - Fuse 36P (5A)
4 - Fusible link 11E (30A)
5 - Fuse 32P (10A)
6 - TPMS module
7 - TPMS s itch and LED
8 - Instrument cluster
9 - Tire pressure sensor - spare (if fitted)
10 - Initiator - Rear right hand
11 - Initiator - Rear left hand
12 - Initiator - Front right hand
13 - Initiator - Front left hand
14 - Tire pressure sensor - Rear right hand
15 - Tire pressure sensor - Rear left hand
16 - Tire pressure sensor - Front right hand
17 - Tire pressure sensor - Front left hand

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Published: 14-Jul-2011
Wheel and Ti e - Wheel and Ti e VIN Range: 000304->412101
Diagnosis and Testing

O e ie

For information on the operation of the systems, refer to the relevant section of the workshop manual.

TPMS in pec ion and e ifica ion

C AUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the
donor vehicle.

1. 1. Verify the customer complaint. As much information as possible should be gathered from the driver to assist
in diagnosing the cause(s). C onfirm which of the following two warning types exist for the TPMS

Check i e p e e a ning . A low tire pressure warning will continuously illuminate the low tire
pressure warning lamp. This warning will generate a text message C HEC K TIRE PRESSURE. No
Diagnostic Trouble C odes (DTC s) are generated with this type of warning.
NOTE: Tire pressure adjustments are part of routine owner maintenance. Tire pressure adjustments
that are required due to a lack of owner maintenance are not to be claimed under vehicle warranty. To
extinguish this warning it is essential that, with the ignition 'ON', all vehicle tires are to be set to the
correct pressure as stated in the vehicle handbook or as indicated on the placard label in the
passenger/driver door aperture

S em fa l a ning . When a system fault is detected, the low tire pressure warning lamp will flash
for approximately 75 seconds prior to being continuously illuminated. This indicates the presence of a
system fault.

2. 2. Visually inspect for obvious signs of damage and system integrity.

Vi al in pec ion
Mechanical Elec ical
Tire pressures Fuses
Tire/Wheel damage Front antenna installation/damage
Tire low pressure sensor installation/damage Rear antenna installation/damage
Front antenna installation/damage External antenna installation/damage
Rear antenna installation/damage TPMS switch
Module antenna installation/damage TPMS module
C onnectors/Harnesses

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. 4. If the cause is not visually evident check for Diagnostic Trouble C odes (DTC s) and refer to the DTC Index.

5. 5. If the tester fails to communicate with the TPMS module, it is recommended that the TPMS power supply
fuse is removed from the Rear Junction Box (RJB) for approximately 10 seconds and re-installed.

Drive C ycle

The vehicle must remain stationary for 15 minutes. C arry out a road test, for a minimum of 15 minutes at a speed
greater than 12.5 mph (20 kph) for at least 75% of the road test.

DTC Inde

C AUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the correct
adaptor kit.

NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer
to the Warranty Policy and Procedures manual, or determine if any prior approval Program is in operation prior to the
installation of a new module/component.

NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three
decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of
the DMM leads into account.

NOTE: C heck and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
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NOTE: If DTC s are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern
may be the cause. Always check for loose connections and corroded terminals.

NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. If this is the case, match
the five digits from the scan tool to the first five digits of the seven digit code listed to identify the fault (the last two
digits give extra information read by the manufacturer-approved diagnostic system).

DTC De c ip ion Po ible ca e Ac ion

C 1A0111 LED Switch LED Refer to the electrical guides and check the LED and circuits.
circuit short
circuit to
ground

C 1A0112 LED Switch LED Refer to the electrical guides and check the LED and circuits.
circuit short
circuit to
power

C 1A0113 LED Switch LED Refer to the electrical guides and check the LED and circuits.
circuit high
resistance

C 1A2992 Switch Switch C heck the switch operation. Refer to the electrical guides and check the
Activation Too performance switch circuit. Repair/renew as necessary.
Long Switch
operation
Switch held
for >2
minutes of
continuous
activation
Switch
circuit short
to ground or
power

C 1A5512 Ignition Switch Ignition C heck for DTC s indicating an ignition switch fault. Refer to the electrical
Input C ircuit switch input guides and check the ignition switch and circuits.
circuit short
circuit to
power

C 1A5514 Ignition Switch Ignition C heck for DTC s indicating an ignition switch fault. Refer to the electrical
Input C ircuit switch input guides and check the ignition switch and circuits.
circuit short
circuit to
ground
Ignition
switch input
circuit high
resistance

C 1A5616 Left Front Tire Low battery This DTC can be set if the vehicle is operating in an extreme
Pressure detected temperature environment, therefore the wheel unit must NOT be
Sensor and replaced if this is the ONLY wheel unit related DTC that is set. C heck for
Transmitter other DTC s. One wheel unit could be declared defective in multiple
Assembly positions on the vehicle, since the vehicle owner could re-position the
wheels in any of the five locations on the vehicle (FL, FR, RR, RL &
Spare). Therefore a wheel unit fault could be reported by the EC U at
several different positions on the vehicle. Therefore ensure that each
wheel unit is defective before replacing multiple wheel units - which
may require confirmatory drive cycles. C lear the DTC , road test and
recheck. If the problem persists, install a new tire pressure sensor.
Refer to the relevant section of the workshop manual.
C 1A5631 Left Front Tire No signal C heck for antenna faults. If no antenna faults are indicated, install a
Pressure Missing, new tire pressure sensor. Refer to the relevant section of the workshop
Sensor and incompatible manual.
Transmitter or defective
Assembly tire pressure
monitoring
system low
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e e
e
ecei e

C 1A5691 Lef F Ti e Da a f S ec he ef f i e e e e , chec a d i a a e

P e e a ge e a e i ed. Refe he e e a ec i f he h
Se a d Ti e a a.
T a i e e e
A e b e ha
e ed
f a ge
i f ai
f e e,
e e a e

acce e a i

C 1A5693 Lef F Ti e N e C hec f a e a fa . If a e a fa a e i dica ed, i a a

P e e ca be f d e i e e e e . Refe he e e a ec i f he h
Se a d a hi a a.
T a i e ca i
A e b Ti e
e e
i i g
e
i i ia
fai e
Ti e
e e
e
fai e

C 1A5711 Lef F Lef f C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i h
g d

C 1A5712 Lef F Lef f C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i h
e

C 1A5713 Lef F Lef f C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i e
ci c i

C 1A5816 Righ Ha d L ba e Thi DTC ca be e if he ehic e i e ai gi a e e e

F Ti e L de ec ed e e a e e i e , he ef e he hee i NOT be
P e e e aced if hi i he ONLY hee i e a ed DTC ha i e . C hec f
Se he DTC . O e hee i c d be dec a ed defec i e i i e
ii he ehic e, i ce he ehic e e c d e- ii he
hee i a f he fi e ca i he ehic e (FL, FR, RR, RL &
S a e). The ef e a hee i fa c d be e ed b he EC U a
e e a diffe e ii he ehic e. The ef e e e ha each
hee i i defec i e bef e e aci g i e hee i - hich
a e i e c fi a d i e c c e . C ea he DTC , ad e a d
echec . If he be e i ,i a a e i e e e e .
Refe he e e a ec i f he h a a.
C 1A5831 Righ F Ti e N ig a C hec f a e a fa . If a e a fa a e i dica ed, i a a
P e e Mi i g, e i e e e e . Refe he e e a ec i f he h
Se a d i c a ib e a a .
T a i e defec i e
A e b i e e e
i i g
e
e e
e
ecei e

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C 1A5891 Righ F Ti e Da a f S ec he igh f i e e e e , chec a d i a a e
P e e a ge e a e i ed. Refe he e e a ec i f he h
Se a d Ti e a a.
T a i e e e
A e b e ha
e ed
f a ge
i f ai
f e e,
e e a e

acce e a i

C 1A5893 Righ F Ti e N e C hec f a e a fa . If a e a fa a e i dica ed, i a a

P e e ca be f d e i e e e e . Refe he e e a ec i f he h
Se a d a hi a a.
T a i e ca i
A e b Ti e
e e
i i g
e
i i ia
fai e
Ti e
e e
e
fai e

C 1A5911 Righ F Righ f C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i h
g d

C 1A5912 Righ F Righ f C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i h
e

C 1A5913 Righ F Righ f C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i e
ci c i

C 1A6016 Lef Rea Ti e L ba e Thi DTC ca be e if he ehic e i e ai gi a e e e

P e e de ec ed e e a e e i e , he ef e he hee i NOT be
Se a d e aced if hi i he ONLY hee i e a ed DTC ha i e . C hec f
T a i e he DTC . O e hee i c d be dec a ed defec i e i i e
A e b ii he ehic e, i ce he ehic e e c d e- ii he
hee i a f he fi e ca i he ehic e (FL, FR, RR, RL &
S a e). The ef e a hee i fa c d be e ed b he EC U a
e e a diffe e ii he ehic e. The ef e e e ha each
hee i i defec i e bef e e aci g i e hee i - hich
a e i e c fi a d i e c c e . C ea he DTC , ad e a d
echec . If he be e i ,i a a e i e e e e .
Refe he e e a ec i f he h a a.
C 1A6031 Lef Rea Ti e N ig a C hec f a e a fa . If a e a fa a e i dica ed, i a a
P e e e i e e e e . Refe he e e a ec i f he h
Se a d a a.
T a i e
A e b
C 1A6091 Lef Rea Ti e Da a f S ec he ef ea i e e e e , chec a d i a a e
P e e a ge e a e i ed. Refe he e e a ec i f he h
Se a d Ti e a a.
T a i e e e
A e b e ha
e ed
f a ge
i f ai
f e e,
e e a e

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acce e a i

C 1A6093 Lef Rea Ti e N e C hec f a e a fa . If a e a fa a e i dica ed, i a a

P e e ca be f d e i e e e e . Refe he e e a ec i f he h
Se a d a hi a a.
T a i e ca i
A e b Ti e
e e
i i g
e
i i ia
fai e
Ti e
e e
e
fai e

C 1A6111 Lef Rea Lef ea C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i -
h
g d

C 1A6112 Lef Rea Lef ea C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i -
h
e

C 1A6113 Lef Rea Lef ea C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i -
e ci c i

C 1A6216 Righ Rea Ti e L ba e Thi DTC ca be e if he ehic e i e ai gi a e e e

P e e de ec ed e e a e e i e , he ef e he hee i NOT be
Se a d e aced if hi i he ONLY hee i e a ed DTC ha i e . C hec f
T a i e he DTC . O e hee i c d be dec a ed defec i e i i e
A e b ii he ehic e, i ce he ehic e e c d e- ii he
hee i a f he fi e ca i he ehic e (FL, FR, RR, RL &
S a e). The ef e a hee i fa c d be e ed b he EC U a
e e a diffe e ii he ehic e. The ef e e e ha each
hee i i defec i e bef e e aci g i e hee i - hich
a e i e c fi a d i e c c e . C ea he DTC , ad e a d
echec . If he be e i ,i a a e i e e e e .
Refe he e e a ec i f he h a a.
C 1A6231 Righ Rea Ti e N ig a C hec f a e a fa . If a e a fa a e i dica ed, i a a
P e e Mi i g, e i e e e e . Refe he e e a ec i f he h
Se a d i c a ib e a a .
T a i e defec i e
A e b i e e e
i i g
e
e e
e
ecei e

C 1A6291 Righ Rea Ti e Da a f S ec he igh ea i e e e e , chec a d i a a e

P e e a ge e a e i ed. Refe he e e a ec i f he h
Se a d Ti e a a.
T a i e e e
A e b e ha
e ed
f a ge
i f ai
f e e,
e e a e

acce e a i

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C 1A6293 Righ Rea Ti e N e C hec f a e a fa . If a e a fa a e i dica ed, i a a

P e e ca be f d e i e e e e . Refe he e e a ec i f he h
Se a d a hi a a.
T a i e ca i
A e b Ti e
e e
i i g
e
i i ia
fai e
Ti e
e e
e
fai e

C 1A6311 Righ Rea Righ ea C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i h
g d

C 1A6312 Righ Rea Righ ea C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i h
e

C 1A6313 Righ Rea Righ ea C hec he a e a ci c i . Refe he e ec ica g ide .

I i ia i i ia
ci c i e
ci c i

C 1A6416 S a e Whee L ba e Thi DTC ca be e if he ehic e i e ai gi a e e e

Ti e L de ec ed e e a e e i e , he ef e he hee i NOT be
P e e e aced if hi i he ONLY hee i e a ed DTC ha i e . C hec f
Se he DTC . O e hee i c d be dec a ed defec i e i i e
ii he ehic e, i ce he ehic e e c d e- ii he
hee i a f he fi e ca i he ehic e (FL, FR, RR, RL &
S a e). The ef e a hee i fa c d be e ed b he EC U a
e e a diffe e ii he ehic e. The ef e e e ha each
hee i i defec i e bef e e aci g i e hee i - hich
a e i e c fi a d i e c c e . C ea he DTC , ad e a d
echec . If he be e i ,i a a e i e e e e .
Refe he e e a ec i f he h a a.
C 1A6491 S a e Whee Da a f S ec he a e i e e e e , chec a d i a a e
Ti e P e e a ge e a e i ed. Refe he e e a ec i f he h
Se a d Ti e a a.
T a i e e e
A e b e ha
e ed
f a ge
i f ai
f e e,
e e a e

acce e a i

C 1A6493 S a e Whee N e If he ehic e i i a ed i h a e a a e hee a d i e a e

Ti e P e e ca be f d ac i . C hec f a e a fa . If a e a fa a e i dica ed,
Se a d a hi i a a e i e e e e . Refe he e e a ec i f he
T a i e ca i h a a.
A e b
U007388 C M d e B ff: Ti e The d e e i g hi c de ha di ab ed C AN a i i .E e
C ica i e e ha he a e a ch fi e i i a ed (a ai ab e GTR). C hec f he
B "A" Off i i g b ff c de . C hec he d e a d ci c i . Refe he e ec ica
e g ide . C ea a DTC a d a ad e he ehic e. If he c ce
(TPMS) e cc c ac Dea e Tech ica S f f he ad ice. U de
d e ci c a ce h da a be e aced e c e hi i e.
B ff:
B d c
d e
(BC M)
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U014087 L TPMS Refe he c ica i ae e a he a f he Ne

C ica i d e: C ica i ec i f he h a a.
Wi h B d Mi i g
C M d e e age

U015587 L C AN i e Refe he c ica i ae e a he a f he Ne

C ica i c e C ica i ec i f he h a a.
Wi h The ig a
I e ecei ed
Pa e C e f he
(IPC ) C i e
M d e a e c e
i he
ecified
i e

U016487 L A i ia Refe he c ica i ae e a he a f he Ne

C ica i hea e C ica i ec i f he h a a.
Wi h The ATC c
M d e d e
i i g
e age
BC M:
Mi i g
e age
IPK: Mi i g
e age
TPMS:
Mi i g
e age

U030055 S f a e I c ec C fig e he d e i g he a ed diag ic e . C hec he

I c a ibi i f a e C AN ci c i . Refe he e ec ica g ide .
aded
C AN b
c fig a i
fai e
C AN b
h ci c i
g d

U1A1449 C AN I e a S ec he i e e e i i g e d e, chec a di a
I i ia i a i e ec ic a e d e a e i ed, efe he e d e/c e
Fai e fai e i a ai e a he f he DTC I de

Wheels and tires inspection and erification

F ba ic i f ai he hee a d i e a ai ab e f hi de ea . Refe he e e a ec i f he
h a a.

F ecifica i f he hee a d i e ( e e , e , e c). Refe he e e a ec i f he h

a a.

Whe e aci g hee i e c ih ca egi a i ega di g hea h a d afe a dc ec

i a ai .

If he ehic e i i a ed i h TPMS, a ed hee a d i e h d be ed. If he hee a d i e i e i

cha ged (f e a e f R18 R20) he TPMS d e h d be da ed i h he c ec e e i f ai
a ia e he e hee a d i e e . U da e he TPMS d e i g he a ed diag ic e .

A a ge e a g ide i e, e e i e i ai a a e ,a d ih i e fe i ae i e a d ecifica i .

C fi he f he c e c ai .

A ch i f ai a ib e h d be ga he ed f he d i e a i i diag i g he ca e( ).

1. 1. Bef e a ad e , ca a ba ic i ec i a e e he ehic e i afe a d ega d i e.

Ba ic i ec i

C ec i e i fa i . Refe he ecifica i ec i f he h a a.

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Legal i e ead dep h.
C /B lge in i e ide all( ).
Ti e pl epa a ion.
Embedded objec .
Wheel im damage.
C o ec i e in alla ion ( pecifica ion, di ec ion of o a ion, e c).
An ob io di o ion of he i e (fla /high po ).
Wo n/Damaged ee ing o pen ion componen . Refe o he ele an ec ion of he o k hop man al.

Road e

If he e l of he ba ic in pec ion a e accep able, ca o a oad e o confi m he mp om .

To ep od ce he mp om , e he ehicle on imila oad o ho e on hich he fa l occ and a imila peed

(p o ided i i legal o do o).

If he ib a ion o noi e can be ep od ced, no e he peed a hich i occ and ee if i i po ible o d i e h o gh

he mp om, meaning, i i po ible o al e he fa l b d i ing fa e o lo e han he peed a hich i occ ?

If i i po ible, i i likel ha he fa l i ca ed b an imbalance in he heel o i e.

If he ib a ion o noi e ge o e a he ehicle peed inc ea e , i i likel ha he fa l i ca ed b di o ion in

he heel o i e, o o n o damaged componen .

Di o ion check

C heck fo di o ion b ai ing he ehicle o ha he heel a e f ee and placing an a le and o imila fi ed objec
ne o each heel in n.

If he and i placed a he ead of he i e, he i e can be checked fo o ali b ning he heel b hand and
checking fo high o lo po he e he gap be een he ead and he and inc ea e o ed ce .

If he and i placed ne o he heel im o i e ide all, he heel and i e can be checked fo n-o in a imila
a .

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Published: 02-Dec-2011
Wheel and Ti e - Wheel and Ti e VIN Range: 412102->ONWARDS
Diagnosis and Testing

P inciple of Ope a ion

For a detailed description of the wheels and tires, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (204-04 Wheels and Tires)

Wheels and Tires (Description and Operation),

Wheels and Tires (Description and Operation),
Wheels and Tires (Description and Operation).

In pec ion and Ve ifica ion

C AUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the
donor vehicle.

1. 1. Verify the customer complaint. As much information as possible should be gathered from the driver to assist
in diagnosing the cause(s). C onfirm which of the following two warning types (A or B) exist for the Tire
Pressure Monitoring System when the ignition status is switched from 'OFF' to 'ON'

(A) Check Ti e P e e Wa ning . A low tire pressure warning will con in o l illuminate the
low tire pressure warning lamp. This warning may be accompanied by a text message such as C HEC K
TIRE PRESSURE (refer to owner literature). The manufacturer approved diagnostic system does NOT
need to be used. Diagnostic Trouble C odes (DTC s) are not generated with this type of warning. To
extinguish this warning it is essential that, with the ignition 'ON', all vehicle tires (including the spare)
are to be set to the correct pressure as stated in the vehicle handbook or as indicated on the placard
label in the passenger/driver door aperture. I i no nece a o d i e he ehicle o clea
'check i e p e e' a ning - j changing he i e p e e ca e he i e lo
p e e en o o an mi ne da a.
NOTE: The tire pressures should be set by:

Using a calibrated tire pressure gauge

With 'cold' tires (vehicle parked in the ambient temperature for at least one hour, not in a garage
with an artificial ambient temperature)
NOTE: If the tire pressure warning does not clear within two minutes, it is likely that the gauge is not
correctly calibrated or the tires are 'warm'. C arry out the following steps until the warning has cleared:

Increase the tire pressures by 3psi

Wait a further two minutes
When the tires are at ambient temperature and a calib a ed gauge is available, reset the tire
pressures to the correct pressure.
NOTE: Tire pressure adjustments are part of routine owner maintenance. Tire pressure adjustments
that are required due to a lack of owner maintenance are not to be claimed under vehicle warranty.

(B) S em Fa l Wa ning . When a system fault is detected, the low tire pressure warning lamp will
flash for approximately 75 seconds prior to being continuously illuminated. Visually inspect for obvious
signs of damage and system integrity. C heck for the presence of tire low pressure sensors on all four
wheels (note: a tire low pressure sensor has a metal valve stem rather than a rubber one).

2. 2. C heck for Diagnostic Trouble C odes (DTC s) and refer to the DTC Index.

NOTE: If the tester fails to communicate with the Tire Pressure Monitoring System module, the following actions are
recommended:

Remove the Tire Pressure Monitoring System power supply fuse, inspect and re-install (if intact). Test to see if
communications have been re-established.

Remove the Tire Pressure Monitoring System ignition fuse (if applicable), inspect and re-install (if intact). Test
to see if communications have been re-established.
With ignition status set to 'ON', refer to the electrical circuit diagrams and check Tire Pressure Monitoring
System module for power, ignition and ground supplies.
C arry out C AN network integrity test using the manufacturer approved diagnostic system.

DTC Inde

NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer
to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in

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operation, prior to the installation of a new module/component.

NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. If this is the case, match
the five digits from the scan tool to the first five digits of the seven digit code listed to identify the fault (the last two
digits give extra information read by the manufacturer-approved diagnostic system).

NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three
decimal places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of
the DMM leads into account.

NOTE: C heck and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

NOTE: If DTC s are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern
may be the cause. Always check for loose connections and corroded terminals.

DTC De c ip ion Po ible Ca e Ac ion

C 1A0111 LED-circuit short to C enter facia switch Refer to the electrical wiring diagrams and check C enter
ground pack - tire pressure facia switch pack - tire pressure monitoring switch status
monitoring switch indicator LED circuit for short to ground. Repair as required.
status indicator LED C arry out On Demand Self Test (ODST) using manufacturer
circuit, short to approved diagnostic system to confirm rectification.
ground

C 1A0112 LED-circuit short to C enter facia switch Refer to the electrical wiring diagrams and check C enter
battery pack - tire pressure facia switch pack - tire pressure monitoring switch status
monitoring switch indicator LED circuit for short to power. Repair as required.
status indicator LED C arry out On Demand Self Test (ODST) using manufacturer
circuit, short to approved diagnostic system to confirm rectification.
power

C 1A0113 LED-circuit open
C enter facia switch Refer to the electrical wiring diagrams and check C enter
pack - tire pressure facia switch pack - tire pressure monitoring switch status
monitoring switch indicator LED circuit for open circuit. Repair as required.
status indicator LED C arry out On Demand Self Test (ODST) using manufacturer
circuit, open circuit approved diagnostic system to confirm rectification.

C 1A2992 Switch Activation
Too Long-
performance or
incorrect operation
C 1A5512 Ignition Switch
Input C ircuit-circuit
short to battery
C 1A5514 Ignition Switch
Input C ircuit-circuit
short to ground or
open
C enter facia switch C heck the switch for correct operation, the switch status
pack - tire pressure indicator LED will toggle state after each ignition on, if the
monitoring switch switch is constantly closed. Replace C enter facia switch pack
contact closed for as necessary. C arry out On Demand Self Test (ODST) using
excessive duration manufacturer approved diagnostic system to confirm
rectification.
Ignition switch input Refer to the electrical wiring diagrams and check the ignition
circuit short circuit switch and circuits for short to power. C arry out On Demand
to power Self Test (ODST) using manufacturer approved diagnostic
system to confirm rectification.
Ignition switch input Refer to the electrical wiring diagrams and check the ignition
circuit short circuit switch and circuits for short to ground, high resistance, open
to ground circuit. C arry out On Demand Self Test (ODST) using
Ignition switch input manufacturer approved diagnostic system to confirm
circuit high rectification.
resistance, open
circuit

C 1A5631 Left Front Tire Missing, GO to Pinpoint Test E.

Pressure Sensor incompatible or
and Transmitter defective tire low
Assembly-no signal pressure sensor or
radio frequency
receiver

C 1A5668 Left Front Tire Information only - No action required

Pressure Sensor vehicle exposed to
and Transmitter extreme
Assembly-event temperature
information environment and/or
tire low pressure
sensor low battery
voltage event

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C 1A5691 Lef F Ti e Ti e e e Re ace defec i e i e e e e . Refe he
P e e Se e ha e ed e e a ec i f he h a a
a dT a i e f a ge
A e b - i f ai f
a a e ic e e,
e e a e
acce e a i
C 1A5693 Lef F Ti e N i e e e GO Pi i Te F.
P e e Se e ca be
a dT a i e ca i ed a hi
A e b - ii d e a
e a i i i ia i e
e e e
af ci

C 1A5711 Lef F I i ia - Lef f i i ia GO Pi i Te A. Refe Pi i e A1

ci c i h ci c i i h
g d g d

C 1A5712 Lef F I i ia - Lef f i i ia GO Pi i Te A. Refe Pi i e A2

ci c i h ci c i i h
ba e e

C 1A5713 Lef F I i ia - Lef f i i ia GO Pi i Te A. Refe Pi i e A9

ci c i e ci c i e

C 1A5831 Righ F Ti e Mi i g, GO Pi i Te E.
P e e Se i c a ib e
a dT a i e defec i e i e
A e b - ig a e e e
adi f e e c
ecei e

C 1A5868 Righ F Ti e I f ai - N ac i e i ed
P e e Se ehic e e ed
a dT a i e e e e
A e b -e e e e a e
i f ai e i e a d/
i e e e
e ba e
age e e

C 1A5891 Righ F Ti e Ti e e e Re ace defec i e i e e e e . Refe he

P e e Se e ha e ed e e a ec i f he h a a.
a dT a i e f a ge
A e b - i f ai f
a a e ic e e,
e e a e
acce e a i

C 1A5893 Righ F Ti e N i e e e GO Pi i Te F.
P e e Se e ca be
a dT a i e ca i ed a hi
A e b - ii d e a
e ai i i ia i e
e e e
af ci

C 1A5911 Righ F Righ f i i ia GO Pi i Te B. Refe Pi i e B1

I i ia -ci c i ci c i i h
h g d g d

C 1A5912 Righ F Righ f i i ia GO Pi i Te B. Refe Pi i e B2

I i ia -ci c i ci c i i h
h ba e e

C 1A5913 Righ F Righ f i i ia GO Pi i Te B. Refe Pi i e B9

I i ia -ci c i ci c i e
e
C 1A6031 Lef Rea Ti e Mi i g, GO Pi i Te E.
P e e Se i c a ib e
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a dT a i e defec i e i e
A e b - ig a e e e
adi f e e c
ecei e

C 1A6068 Lef Rea Ti e I f ai - N ac i e i ed

P e e Se ehic e e ed
a dT a i e e e e
A e b -e e e e a e
i f ai e i e a d/
i e e e
e ba e
age e e

C 1A6091 Lef Rea Ti e Ti e e e Re ace defec i e i e e e e . Refe he

P e e Se e ha e ed e e a ec i f he h a a.
a dT a i e f a ge
A e b - i f ai f
a a e ic e e,
e e a e
acce e a i

C 1A6093 Lef Rea Ti e N i e e e GO Pi i Te F.

P e e Se e ca be
a dT a i e ca i ed a hi
A e b - ii d e a
e ai i i ia i e
e e e
af ci

C 1A6111 Lef Rea I i ia - Lef ea i i ia GO Pi i Te C . Refe Pi i e C1

ci c i h ci c i h
g d g d

C 1A6112 Lef Rea I i ia - Lef ea i i ia GO Pi i Te C . Refe Pi i e C2

ci c i h ci c i h
ba e e

C 1A6113 Lef Rea I i ia - Lef ea i i ia GO Pi i Te C . Refe Pi i e C9

ci c i e ci c i e

C 1A6231 Righ Rea Ti e Mi i g, GO Pi i Te E.

P e e Se i c a ib e
a dT a i e defec i e i e
A e b - ig a e e e
adi f e e c
ecei e

C 1A6268 Righ Rea Ti e I f ai - N ac i e i ed

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age e e

C 1A6291 Righ Rea Ti e Ti e e e Re ace defec i e i e e e e . Refe he

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P e e Se e ca be
a dT a i e ca i ed a hi
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e ai i i ia i e
e e e
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af ci
C 1A6311 Righ Rea Righ ea i i ia GO Pi i Te D. Refe Pi i e D1
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C 1A6312 Righ Rea Righ ea i i ia GO Pi i Te D. Refe Pi i e D2

I i ia -ci c i ci c i h
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C 1A6313 Righ Rea Righ ea i i ia GO Pi i Te D. Refe Pi i e D9

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C 1A6468 S a e Whee Ti e I f ai - N ac i e i ed
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C 1A6491 S a e Whee Ti e Ti e e e Re ace defec i e i e e e e . Refe he

P e e Se e ha e ed e e a ec i f he h a a.
a dT a i e f a ge
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C 1A6493 S a e Whee Ti e Mi i g, GO Pi i Te G.
P e e Se i c a ib e
a dT a i e defec i e i e
A e b - e e e
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ecei e

U001088 Medi S eed C AN b fa Ca C AN e i eg i e . Refe he e ec ica

C AN i i g diag a a d chec C AN e f h , e
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ihb d c B fa ci c i . C a C AN e i eg i e .
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U016400 L C AN b fa Refe he e ec ica i i g diag a a d chec c i a e
C ica i Ci ae c c d e e a dg d ie f h , e
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U030000 I e a C I c a ib e i e C hec c ec i e e e i i g e d e i
M d e S f a e e e i i gi a ed ehic e ecifica i , he i e ec he
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b e ehic e C AN
i f ai e

U041600 I a id Da a I a id da a C hec A i c B a i g S e d e a di e
Recei ed F ecei ed f A i c e f e a ed DTC a d efe he e e a DTC
Vehic e D a ic c B a i g I de . C a C AN e i eg i e i g
C M d e- S e d e a fac e a ed diag ic e .
b e C AN B fa
i f ai A i c B a i g
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System fault

U1A1449 C AN Initialisation Tire pressure Install a new tire pressure monitoring module. Refer to the
Failure-internal monitoring system new module/component installation note at the top of the
electronic failure module fault DTC Index

U300055 C ontrol Module-not Tire pressure C heck and amend the car configuration file.
configured monitoring system
configuration data is
invalid

U300087 C ontrol Module- Tire pressure C heck the instrument cluster for related DTC s and refer to
missing message monitoring system the relevant DTC Index. C arry out C AN network integrity
configuration data test.
not received

U300281 Vehicle Tire pressure NOTE: This DTC indicates that the tire pressure monitoring
Identification monitoring system system module is not the original part installed to the
Number - invalid module and vehicle vehicle at the factory/dealer and could have been
serial data VIN mis-match substituted. Refer to the note above the DTC index about
received replacing components which may remain under
manufacturer warranty.

Re-install the original or a new tire pressure monitoring

system control module

Componen Te

Wheel and Ti e

For wheel and tire specification information (pressures, torques, etc).

REFER to: Specifications (204-04 Wheels and Tires, Specifications).

When replacing wheels or tires, local legislation regarding health and safety must be complied with.

If the vehicle has a Tire Pressure Monitoring System installed, only Land Rover approved wheels and tires should be
used. If the wheel and tire size is changed (for example from R18 to R20) the Tire Pressure Monitoring System
module should be updated with the correct pressure information appropriate to the new wheel and tire set. Update the
Tire Pressure Monitoring System module using the Land Rover approved diagnostic system.

As a general guideline, only replace tires in pairs or as a set, and only with tires of equivalent size and specification.

C onfirm the symptoms of the customer complaint.

As much information as possible should be gathered from the driver to assist in diagnosing the cause(s).

1. 1. Before a road test, carry out a basic inspection to make sure the vehicle is safe and legal to drive.

Basic inspection

C orrect tire inflation.

REFER to: Specifications (204-04 Wheels and Tires, Specifications).
Legal tire tread depth
C uts/Bulges in tire sidewall(s)
Tire ply separation
Embedded objects
Wheel rim damage
C orrect tire installation (specification, direction of rotation, etc)
Any obvious distortion of the tire (flat/high spots)
Worn/Damaged steering or suspension components

Road e

If the results of the basic inspection are acceptable, carry out a road test to confirm the symptoms.

To reproduce the symptoms, test the vehicle on similar roads to those on which the fault occurs and at similar speeds
(provided it is legal to do so).

If the vibration or noise can be reproduced, note the speed at which it occurs and see if it is possible to drive through
the symptom, meaning, is it possible to alter the fault by driving faster or slower than the speed at which it occurs?

If it i possible, it is likely that the fault is caused by an imbalance in the wheel or tire.

If the vibration or noise gets worse as the vehicle speed increases, it is likely that the fault is caused by distortion in

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, .

Distortion checks

C
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.

Road test

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.

Pinpoint Tests

PINPOINT TEST A : LEFT FRONT LOW-FREQUENCY INITIATOR CIRCUIT

E CONDI ION DE AIL / E L /AC ION
A1: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 K .
2 D -
, C 2198.

3 M :
C2198, harness side Batter
P 2 N
I 10,000 ?
Yes
GO A5.
No
GO A3.

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A2: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2198, harness side Batter
Pin 2 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to A6.
No
GO to A4.
A3: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Measure the resistance between:
C2198, harness side Batter
Pin 1 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
GO to A7.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
A4: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2198, harness side Batter
Pin 1 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to A8.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
A5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.

2 Measure the resistance between:

C2198, harness side Batter
Pin 2 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2243 and C 2245. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
A6: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.

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2 Measure the resistance between:

C2198, harness side Batter
Pin 2 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2243 and C 2245. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
A7: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.

2 Measure the resistance between:

C2198, harness side Batter
Pin 1 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2243 and C 2245. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
A8: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.

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2 Measure the resistance between:

C2198, harness side Batter
Pin 1 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2243 and C 2245. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
A9: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, harness side C2198, harness side
Pin 14 Pin 2
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. This circuit contains
intermediate connectors, C 2243 and C 2245. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
GO to A10.
A10: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, harness side C2198, harness side
Pin 13 Pin 1
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. This circuit contains
intermediate connectors, C 2243 and C 2245. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
INSTALL a new left hand front low-frequenc initiator.
REFER to: Tire Pressure Monitoring S stem (TPMS) Front
Antenna (204-04 Wheels and Tires, Removal and
Installation).

PINPOINT TEST B : RIGHT FRONT LOW FREQUENCY INITIATOR CIRCUIT

E CONDI ION DE AIL / E L /AC ION
B1: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Ke off.
2 Disconnect the right hand front low-frequenc initiator
electrical connector, C 2199.
3 Measure the resistance between:
C2199, harness side Batter
Pin 2 Negative terminal

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Is the resistance less than 10,000 ohms?

Yes
GO to B5.
No
GO to B3.
B2: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2199, harness side Batter
Pin 2 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to B6.
No
GO to B4.
B3: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Measure the resistance between:
C2199, harness side Batter
Pin 1 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
GO to B7.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
B4: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2199, harness side Batter
Pin 1 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to B8.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
B5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2199, harness side Batter
Pin 2 Negative terminal

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Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2242 and C 2244. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.

B6: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2199, harness side Batter
Pin 2 Positive terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2242 and C 2244. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
B7: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2199, harness side Batter
Pin 1 Negative terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2242 and C 2244. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
B8: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.

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2 Measure the resistance between:
C2199, harness side Batter
Pin 1 Positive terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. This circuit contains intermediate
connectors, C 2242 and C 2244. For additional information,
refer to the wiring diagram. C lear the DTC and run an On
Demand Self Test (ODST) using the manufacturer
approved diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
B9: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, harness side C2199, harness side
Pin 16 Pin 2
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. This circuit contains
intermediate connectors, C 2242 and C 2244. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
GO to B10.
B10: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, harness side C2199, harness side
Pin 15 Pin 1
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. This circuit contains
intermediate connectors, C 2242 and C 2244. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
INSTALL a new right hand front low-frequenc initiator.
REFER to: Tire Pressure Monitoring S stem (TPMS) Front
Antenna (204-04 Wheels and Tires, Removal and
Installation).

PINPOINT TEST C : LEFT REAR LOW-FREQUENCY INITIATOR CIRCUIT

E CONDI ION DE AIL / E L /AC ION
C1: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Ke off.
2 Disconnect the left hand rear low-frequenc initiator
electrical connector, C 2200.
3 Measure the resistance between:
C2200, harness side Batter
Pin 2 Negative terminal

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Is the resistance less than 10,000 ohms?

Yes
GO to C 5.
No
GO to C 3.
C2: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2200, harness side Batter
Pin 2 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to C 6.
No
GO to C 4.
C3: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Measure the resistance between:
C2200, harness side Batter
Pin 1 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
GO to C 7.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
C4: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2200, harness side Batter
Pin 1 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to C 8.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
C5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2200, harness side Batter
Pin 2 Negative terminal

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Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
C6: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2200, harness side Batter
Pin 2 Positive terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
C7: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2200, harness side Batter
Pin 1 Negative terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
C8: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2200, harness side Batter
Pin 1 Positive terminal

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Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
C9: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, harness side C2200, harness side
Pin 6 Pin 2
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
GO to C 10.
C10: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, harness side C2200, harness side
Pin 5 Pin 1
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
INSTALL a new left hand rear low-frequenc initiator.
REFER to: Tire Pressure Monitoring S stem (TPMS) Rear
Antenna (204-04 Wheels and Tires, Removal and
Installation).

PINPOINT TEST D : RIGHT REAR LOW-FREQUENCY INITIATOR CIRCUIT

E CONDI ION DE AIL / E L /AC ION
D1: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Ke off.
2 Disconnect the right hand rear low-frequenc initiator
electrical connector, C 2201.
3 Measure the resistance between:
C2201, harness side Batter
Pin 2 Negative terminal

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Is the resistance less than 10,000 ohms?

Yes
GO to D5.
No
GO to D3.
D2: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2201, harness side Batter
Pin 2 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to D6.
No
GO to D4.
D3: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Measure the resistance between:
C2201, harness side Batter
Pin 1 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
GO to D7.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
D4: CHECK THE INITIATOR CIRCUIT FOR SHORT CIRCUIT TO POWER
1 Measure the resistance between:
C2201, harness side Batter
Pin 1 Positive terminal
Is the resistance less than 10,000 ohms?
Yes
GO to D8.
No
Fault not present run On Demand Self Test (ODST) to
confirm. Investigate cause of possible intermittent fault.
D5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2201, harness side Batter
Pin 2 Negative terminal

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Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
D6: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2201, harness side Batter
Pin 2 Positive terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
D7: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2201, harness side Batter
Pin 1 Negative terminal

Is the resistance less than 10,000 ohms?

Yes
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
D8: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the Tire Pressure Monitoring S stem module
connector, C 2447.
2 Measure the resistance between:
C2201, harness side Batter
Pin 1 Positive terminal

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Is the resistance less than 10,000 ohms?

Ye
REPAIR the short circuit. For additional information, refer to
the wiring diagram. C lear the DTC and run an On Demand
Self Test (ODST) using the manufacturer approved
diagnostic s stem to confirm rectification.
No
INSTALL a new Tire Pressure Monitoring S stem module.
D9: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, ha ne ide C2201, ha ne ide
Pin 8 Pin 2
Is the resistance greater than 5 ohms?
Ye
REPAIR the high resistance circuit. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
GO to D10.
D10: CHECK THE INITIATOR CIRCUIT FOR HIGH RESISTANCE
1 Measure the resistance between:
C2447, ha ne ide C2201, ha ne ide
Pin 7 Pin 1
Is the resistance greater than 5 ohms?
Ye
REPAIR the high resistance circuit. For additional
information, refer to the wiring diagram. C lear the DTC and
run an On Demand Self Test (ODST) using the
manufacturer approved diagnostic s stem to confirm
rectification.
No
INSTALL a new right hand rear low-frequenc initiator.
REFER to: Tire Pressure Monitoring S stem (TPMS) Rear
Antenna (204-04 Wheels and Tires, Removal and
Installation).

PINPOINT TEST E : MISSING, INCOMPATIBLE OR DEFECTIVE RUNNING TIRE LOW PRESSURE

SENSOR OR RECEIVER
E DE AIL / E L /AC ION
CONDI ION
E1: CHECK FOR CORRECT WHEEL AND TIRE ASSEMBLY AND TIRE LOW PRESSURE SENSOR
1 Establish that a full si e running wheel and tire assembl has a tire low pressure sensor installed.
As a visual confirmation, a tire low pressure sensor has a metal valve stem rather than a rubber
one and cannot be installed to a mini/space saver spare wheel.
Is a full si e wheel and tire assembl with tire low pressure sensor installed?
Ye

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GO to E2.
No
Install the correct wheel and tire assembly or tire low pressure sensor, of correct frequency, in
accordance with that defined in the manufacturer approved diagnostic system new tire low
pressure sensor application.
E2: CHECK FOR ADDITIONAL DTCS
1 Remove the Tire Pressure Monitoring System power supply fuse and re-install it. C lear DTC s and
leave the vehicle stationary for 15 minutes, then drive it at a speed greater than 15.5 mph (25
kph) continuously for at least 10 minutes.
(Note: If the vehicle speed drops below this value, the drive time to complete the test will need to be increased.)

The use of the manufacturer approved diagnostic system, and the datalogger signal Tire pressure
monitor system status – learn mode status will verify the completion of the test when the value
returns to Inactive .
2 C heck for additional DTC s C 1A5631, C 1A5831, C 1A6031, C 1A6231, with identical time stamps.
Have all four DTC s logged with identical time stamps in the tire pressure monitoring system module?
Ye
Replace the tire pressure monitoring system module.
No
GO to E3.
E3: VERIFY THE POSITION OF THE DEFECTIVE TIRE LOW PRESSURE SENSOR
1 C heck tire pressure monitoring system DTC s.
Are any C 1AXX31 DTC s logged?
Ye
Install the correct tire low pressure sensor, of correct frequency, in accordance with that defined
in the manufacturer approved diagnostic system new tire low pressure sensor application, to the
position identified by the logged DTC .
REFER to: Tire Low Pressure Sensor (204-04 Wheels and Tires, Removal and Installation).
No
No further action is required.
(Note: The use of the manufacturer approved diagnostic system, and the datalogger signal Tire pressure monitor system status – learn
completed successfully will verify the successful completion of the test.)

PINPOINT TEST F : LOCALIZATION FAILURE

E DE AIL / E L /AC ION
CONDI ION
F1: CHECK FOR ADDITIONAL DTCS
1 C heck for additional DTC s: C 1A5711, C 1A5712, C 1A5713. C 1A5911, C 1A5912, C 1A5913,
C 1A6111, C 1A6112, C 1A6113, C 1A6311, C 1A6312, C 1A6313.
Are any of the DTC s listed above also logged?
Ye
Refer to the DTC Index and remedial actions.
No
GO to F2.
F2: CHECK FOR ADDITIONAL DTCS
1 C heck for additional DTC s: C 1A5631, C 1A5831, C 1A6031 or C 1A6231
Is a C 1A5631, C 1A5831, C 1A6031 or C 1A6231 DTC also logged?
Ye
Refer to the DTC Index and remedial actions.
No
GO to F3.
F3: CHECK INITIATOR INSTALLATION
1 C heck for correct installation of Initiator. REFER to: (204-04 Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Front Antenna (Removal and Installation),
Tire Pressure Monitoring System (TPMS) Rear Antenna (Removal and Installation).
Is the Initiator correctly installed?
Ye
GO to F4.
No
Rectify as required. REFER to: (204-04 Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Front Antenna (Removal and Installation),
Tire Pressure Monitoring System (TPMS) Rear Antenna (Removal and Installation).
F4: CHECK FOR SHORT CIRCUIT IN INITIATOR HARNESS
1 Locate and remove module blue connector L.
2 Measure the resistance across the relevant initiator circuits within the blue connector.
Is the resistance less than 1 Ohm?
Ye
A value of less than 1 Ohm indicates a short circuit, rectify the short circuit as required.
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No
I a he c ec i e e e e , fc ec f e e c , i acc da ce i h ha defi ed
i he a fac e a ed diag ic e e i e e e e a ica i , he
ii ide ified b he gged DTC .
REFER : Ti e L P e e Se (204-04 Whee a d Ti e , Re a a dI a a i ).

PINPOINT TEST G : SPARE TIRE LOW PRESSURE SENSOR NO OPERATION

E DE AIL / E L /AC ION
CONDI ION
G1: ESTABLISH THE TYPE OF SPARE WHEEL AND TIRE ASSEMBLY INSTALLED
1 E ab i h he e f a e hee a d i e a e b i a ed.
I he a e hee a i i/ ace a e e?
Ye
Ti e e e e a e i a ed i i/ ace- a e a e hee . Ti e e e
e a e i a ed f i e a e hee . The DTC i be ig ed a d e ai ac i
i e i ed.
No
GO G2.
G2: ESTABLISH THAT THE SPARE WHEEL HAS A TIRE LOW PRESSURE SENSOR INSTALLED
1 E ab i h ha he a e hee ha a i e e e e i a ed, c ide i g he f i g
addi i a i f ai :

a) A a i a c fi ai , he i e e e e ha a e a a e e a he ha a
bbe e.

I a i e e e e i a ed?
Ye
GO G3.
No
A e a e i e e e e h d be i a ed. N e: Refe he e ab e he DTC
i de ab e aci g c e hich a e ai de a fac e a a . Refe he
ee a ec i f he h a a.
G3: CONFIRM OPERATION OF THE SPARE WHEEL PRESSURE SENSOR
1 Def a e he a e i e, i c e i i he ehic e, i i i c e e def a ed.
2 C e e a ig i i c ce ig i i a d e if ha he i e c e e a a e i e
e e a i gf a i a e 20 ec d .
3 Re-i f a e he a e i e, i c e i i he ehic e, he ec e ded a e i e
e e. Refe he I ec i a d Ve ifica i , C hec Ti e P e e Wa i g e .
4 C e e a ig i i c ce ig i i a d e if ha he i e c e ge e a
a e i e e e a i g.
D e he i e c e c i e e a a e i e e e a i g?
Ye
GO G4.
No
N e ai ac i i e i ed. I i ib e ha he c e a ha e aced i e i he
ehic e' ggage c a e ha e e ed c ec RF ece i .
G4: VERIFY THAT THE SPARE TIRE LOW PRESSURE SENSOR ID HAS BEEN CORRECTLY PROGRAMMED TO
THE MODULE
1 Re e i e e e e . Rec d he 8 cha ac e he adeci a ID i e he ca i g.
2 U e he a ed diag ic e ead he a e i e e ID f he d e. Refe
he e e a ced e i he h a a.
3 C a e he ID f e 1 & 2.
D he ID a ch?
Ye
Re ace he a e i e e e e . Refe he e e a i a ai ec i i he
h a a.
The ide ifica i f he e be g a ed i he i e e e i i g e
d e i g he a fac e a ed diag ic e . The ide ifica i c de i ided
a abe i h he c e e a e b a di a i ed he ca i g f each e .
No
P g a he a e i e e ID, ec ded i e 1, he d e i g he a ed diag ic
e . The ide ifica i c de i ided a abe i h he c e e a e b a di a
i ed he ca i g f each e .
Re ea e e e c ec e a i . GO G3.

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Published: 16-Aug-2011
Wheel and Ti e - Ti e Lo P e e Sen o
Removal and Installation

Remo al
NOTE: It is strongly recommended that the valve seal and steel washer is replaced each time a tire is changed to
avoid a seal failure. The seal and washer must be replaced if the sensor is removed. Removal of the sensor retaining
nut must be regarded as sensor removal. The valve cap must always be in place except when inflating, releasing
pressure or checking pressure.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.

3. C AUTION: To avoid damage to the tire low pressure

sensor, release the tire bead from the rim, 180 degrees from
the valve.

Remove the tire from the wheel.

4. C AUTIONS:

Do not push on the valve.

If the tire low pressure sensor is to be re-installed, a

new washer, seal and nut must be installed.

If the tire low pressure sensor is to be re-installed, a

new washer, seal, nut and silver coloured nickel valve core
must be installed.

Remove the tire low pressure sensor.

Remove the nut.

Release and withdraw the sensor along the valve

axis.

5. If necessary, install a new seal and washer.

Remove and discard the seal and washer.

Install a new washer and seal, making sure the

valve remains pressed fully onto its seat.

In alla ion

1. C AUTION: Do not use compressed air to clean the

sensor. Do not clean the sensor with solvents or cleaning
agents of any type, use a clean dry cloth.

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C lean the component mating faces.

. C AUTION: Do not apply any lubricant to the new

valve.

NOTE: If the sensor is replaced on a 'running' wheel, the

new sensor identification will be learnt when the vehicle is
first driven. If a new sensor is fitted to the spare wheel the
identification for that sensor must be programmed into the
Tire Pressure Monitoring System (TPMS) module using T4.
The identifcation code is provided on a label with the
complete assembly and is also printed on the casing of each
sensor.

Install the tire low pressure sensor.

Install and hand tighten the nut whilst keeping the

sensor in place.

Tighten the nut to 6.5 Nm (4.8 lb.ft).

. Install the tire and balance the wheel.

. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Published: 11-Ma -2011

Wheels and Tires - Tire Pressure Monitoring S stem (TPMS) Front Antenna
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the fender splash shield.
For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
3. Remove the tire pressure antenna.

Remove the 2 retainers.

Installation
1. To install, reverse the removal procedure.
2. Initiate a new tire pressure antenna using T4.

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P bli hed: 11-Ma -2011

Wheels and Tires - Tire Pressure Monitoring S stem (TPMS) Rear Antenna
Remo al and In alla ion

Removal
1. Remo e he fende mo lding.
Fo addi ional info ma ion, efe o: Rea Q a e Panel
Mo lding (501-08 E e io T im and O namen a ion,
Remo al and In alla ion).
2. Remo e he fende pla h hield.

Remo e he 2 c e .

Remo e he 6 e aine .

Di connec he elec ical connec o .

3. Remo e he i e p e e an enna.

Remo e he 2 e aine .

Installation
1. To in all, e e e he emo al p oced e.
2. Ini ia e a ne i e p e e an enna ing T4.

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Published: 11-May-2011
Vehicle D namic Suspension -
A ir Suspension - General Specif ication
Item Specification
Ride height:
Off road 55 mm (2.1 in) above standard
Access - reselectable whilst 50 mm (1.9 in) below standard
vehicle is moving
Trim height C onfigured using T4 plus special tools
Height sensors:
Location 4 per vehicle - one sensor for each wheel
Height sensor arm colour
coding:
Left hand side, front and rear WHITE
Right hand side, front and rear BLAC K
Height sensor operating
voltages:
Supply voltage 5 volts - supplied by air suspension EC U
Output voltage Left hand front and right hand rear - Decreases to 0.5 volts with bump travel.
Right hand front and left hand rear - Decreases to 4.5 volts with bump travel
Spring/damper modules:
Type Guided air spring surrounding twin tube damper
Pressures:
Normal - Front 800 to 1000 kPa (8.0 to 10.0 bar) (116.0 to 145.0 lbf/in )
Normal - Rear 500 to 800 kPa (5.0 to 8.0 bar) (72.5 to 116.0 lbf/in )
Burst pressure 3500 kPa (35 bar) (507.5 lbf/in )
Maximum spring pressure - Full Approximately 2700 kPa (27 bar) (391.5 lbf/in )
bump at gross vehicle weight
Air compressor: Supplied with air drier, electrically switched, pilot operated exhaust valve and double
temperature sensors
C ontrolled by EC U
Maximum pressure 1680 kPa (16.8 bar) (243.6 lbf/in )
Air reservoir:
Volume 9 litres (0.31 cu.ft)
Working pressure 1750 kPa (17.5 bar) (253.75 lbf/in )
Maximum operating pressure 2300 kPa (23 bar) (333.5 lbf/in )
Reservoir valve block Incorporates pressure sensor to monitor spring and air reservoir pressures
Valve blocks:
Front 2 corner valves, 1 cross link valve - all mounted on front bumper armature
Rear 2 corner valves, 1 cross link valve - all mounted on left hand rear spring tower
General Specif ications
Item Specification
Gap between underside of the toe link rubber boot and the chassis bracket 10.0 mm (0.393 in)
Torque Specif ications
Description Nm lb-ft
Air suspension compressor bolts 10 7
Air suspension compressor lower cover bolts 10 7
Voss connector to the front solenoid valve block 2.5 1.7
Voss connector to the front and rear air springs 3.5 2.6
Voss connector to the rear solenoid valve block 2.5 1.7
Voss connector to the air suspension reservoir 5 4
Voss connector to the air suspension reservoir solenoid valve block 2.5 1.7
Air suspension control module bolt 10 7
Air suspension reservoir bolts 23 17
* Stabilizer bar link nuts 115 85
Toe link bolt 175 129
Toe link inner ball joint retaining nut 133 98
Toe link nut 103 76
Toe link adjustment locking nut 130 96

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Lo er front arm camber adjusting bolt 275 203
Lo er arm rear castor adjusting bolts 275 203
Track rod end locking nuts 53 39
Rear camber adjusting bolts 133 98
Front and rear air spring/shock absorber to the suspension turret nuts 63 46
Front and rear air spring/shock absorber to the lo er suspension arm nut and bolt 300 221
* Front and rear air spring/shock absorber top nut 98 72
Heat shield bolts 10 7
*+ Halfshaft nut 350 258
Wheel speed sensor bolt 10 7
Brake disc dust shield bolts 10 7
Wheel hub bolts 115 85
* Lo er arm ball joint retaining nut 115 85
* Tie-rod end ball joint 76 56
Suspension height sensor Tor bolts 2.2 1.5
Road heel nuts 140 103
* Ne nut must be fitted

+ Stake nut on completion of tightening

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Published: 11-May-2011
Vehicle D namic Suspension - Vehicle D namic Suspension
Description and Operation

Dynamic Suspension - C omponent Location

NOTE: Right hand drive vehicle shown

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I em Pa N mbe De c ip ion
1 - Front RH air spring damper module
2 - Front RH height sensor
3 - Air suspension control module
4 - Air suspension control switch
5 - Rear RH height sensor
6 - Rear RH air spring damper module
7 - Air supply unit silencer
8 - Rear LH air spring damper module
9 - Air filter
10 - Rear valve block
11 - Rear LH height sensor
12 - Upper acoustic cover
13 - Lower acoustic cover
14 - Air supply unit
15 - Reservoir valve block
16 - Air reservoir
17 - Front LH height sensor
18 - Front LH air spring damper module
19 - Front valve block

GENE AL

• NOTE: This section covers the air suspension control system.

Front suspension is detailed in a separate section.

For additional information, refer to: Front Suspension (204-01 Front Suspension, Description and Operation).

Rear suspension is detailed in a separate section.

For additional information, refer to: Rear Suspension (204-02 Rear Suspension, Description and Operation).

Terrain Response is detailed in a separate section.

For additional information, refer to: Ride and Handling Optimization (204-06 Ride and Handling Optimization, Diagnosis and
Testing).

The dynamic suspension system is a four corner air suspension system which is fitted to higher specification vehicles in place
of the conventional damper and coil spring suspension used on non-air suspension models.

The dynamic suspension system is electronically controlled by an air suspension control module which controls the air supply
unit, reacts to inputs from four height sensors and distributes air around the system via valve blocks.

The main air suspension system components are:

Air suspension control module

Air supply unit
Four height sensors
Three valve block assemblies
Reservoir
Air harness
Four suspension air spring damper modules.

The four corner air suspension system maintains the vehicle height under all operating conditions by controlling the mass of
air in the air springs. The air suspension control module uses signals from the four height sensors to maintain the correct
suspension height. This is achieved by operating pneumatic control valves to increase or decrease the mass of air in the air
spring damper modules.

The air suspension system has three driver selectable, pre-determined ride heights. A driver interface indicates the selected
ride height and direction of movement. Additional information is also relayed to the driver via the instrument cluster message
center (where fitted) and by audible warnings also transmitted by the instrument cluster.

Height changes can only be made when the engine is running and the driver's and passenger doors are closed.

Access height can be selected with the engine not running, within 40 seconds of moving the ignition switch to the off position
provided the driver's door has not been opened in this time.

The air suspension can be controlled manually by the driver using a switch on the center console to select the required height
change.

Schematic Pneumatic C ircuit

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I em Pa N mbe De c ip ion
1 - C ompressor
2 - C ompressor temperature sensor
3 - Air dr er
4 - Reservoir
5 - Front LH air spring damper module
6 - Front valve block
7 - C ross link valve
8 - Front RH air spring damper module
9 - Front RH corner valve
10 - Front LH corner valve
11 - Reservoir control valve
12 - Pressure sensor
13 - Rear RH corner valve
14 - Rear RH air spring damper module
15 - C ross link valve
16 - Rear valve block
17 - Rear LH corner valve
18 - Rear LH air spring damper module
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19 - Inlet air filter

20 - Pilot exhaust valve
21 - Exhaust
22 - Air silencer
23 - Pressure relief and exhaust valve
24 - Motor temperature sensor
25 - Electric motor

OPE A ING MODE

Using the air suspension switch, the driver is able to manually select one of four ride states:

ON-ROAD - this height is the normal operating height of the vehicle

OFF-ROAD - this height is higher than the on-road height and provides improved ground clearance, approach,
departure and breakover angles
AC C ESS - this height is lower than the on-road height and makes entering and exiting the vehicle easier for the
occupants
C RAWL (Locked at access) - this height allows the vehicle to be driven at the access height at low speeds to provide
increased roof clearance in low car parks etc.

NOTE: Vehicle height changes are prevented if the air suspension control module receives a 'Door Open' signal from the
C entral Junction Box (C JB).

An additional 'TRANSPORTATION' mode is also available but is only selectable using the Land Rover approved diagnostic
equipment.

An additional function allows the vehicle to be raised or lowered from outside of the vehicle when the vehicle is stationary.
For example, this may assist with the attachment of a trailer and is achieved using the buttons on the remote handset and
the ignition switch in the off position. The remote handset can be programmed to perform a number of additional functions.
For additional information, refer to: Handles, Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry
Systems, Description and Operation).

If the air suspension control module senses that the vehicle has grounded and lost traction, the control module can
temporarily increase and/or redistribute the volume of air supplied to the affected air spring(s) to maximize the available
traction. This is known as extended mode and will be indicated to the driver by the lamps on the air suspension switch
flashing, and messages displayed in the instrument cluster message center.

If the air suspension control module senses that the vehicle is prevented from moving upwards or downwards during a height
change or leveling correction, the control module will adopt a safe state and further height changes will be suspended.

If a fault is detected by the air suspension control module, the control module will reduce the system functionality dependent
on the type and severity of the fault. The control module will also store a fault code which can be retrieved using the Land
Rover approved diagnostic equipment. If a severe fault occurs, the control module will attempt to put the vehicle in a safe
condition. A fault is relayed to the driver by the illumination of the air suspension warning indicator, the instrument cluster
message center and an audible warning emitted from the instrument cluster.

If the detected fault is minor and does not affect vehicle safety, the air suspension warning indicator in the instrument cluster
will illuminate in an amber color and the fault should be rectified at the earliest opportunity. If a more severe fault is
detected, the warning indicator will illuminate in a red color above 31 mph (50 km/h) vehicle speed, and the vehicle should
be driven with care until the fault is rectified. An audible warning is emitted by the instrument cluster sounder when the
warning indicator is illuminated. The indicator will change to an amber color and the audible warning will stop when the
vehicle speed is reduced.

Air Suspension Switch Mode Lamps

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I em Pa N mbe De c ip ion
1 - C rawl mode lamp
2 - Access mode lamp
3 - Lowering lamp
4 - On-road mode lamp
5 - Air suspension switch
6 - Raising lamp
7 - Off-road mode lamp
8 - Terrain Response rotary control
9 - Transfer box range switch
10 - Hill Descent C ontrol (HDC ) switch
On-Road Mode

This is the normal ride height for the vehicle.

Off-Road Mode

Off-road mode will only be activated if the vehicle speed is less than 25 mph (40 km/h). The vehicle will be raised 55 mm
(2.2 in) higher than the on-road mode to provide additional body clearance and improved approach, departure and
breakover angles. If the vehicle speed exceeds 31 mph (50 km/h), the air suspension control module will automatically lower
the vehicle to the on-road mode height. At 25 to 28 mph (40 to 45 km/h) a message is displayed in the message center to
warn the driver to slow down or the vehicle will lower.

• NOTE: The suspension can be automatically set to off-road mode when some Terrain Response programs and low range
are selected.

Acce Mode

Access mode lowers the vehicle body height by 50 mm (2 in) and provides easier entry, exit and loading of the vehicle.
Access mode can be pre-selected when the vehicle is moving. The vehicle will partly lower as the vehicle speed decreases,
lowering to the full access mode height when the vehicle reaches 5 mph (8 km/h). If the required road speed is not reached
within a predetermined time, the air suspension will return the vehicle to the previously selected height.

Access mode can be selected at any vehicle speed. When access mode is selected, the response of the air suspension
system will depend on the vehicle speed:

If the vehicle speed is more than 12.5 mph (20 km/h), the air suspension control module will wait for up to one minute
for the vehicle speed to be reduced. The access mode lamp and the lowering lamp will flash while the air suspension
control module waits for the vehicle speed to be reduced, the on-road mode lamp will remain illuminated. If the
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ehic e eed i ed ced fficie , he acce de e e i be ca ce ed af e 1 i e.
If he ehic e eed i e ha 12.5 h (20 /h), he ai e i c d e i e he e i a
a e ed heigh a d i e ai a hi heigh f e i e. The - ad de a i e i g i h a he
ai e i c d e e he e i he a e ed heigh . The acce de a a d he
e i g a i i i a e. Whe a e ed i eached, he ' e ' e a i f a h. If he ehic e eed i
ed ced e ha 5 h (8 /h) i he e i e e i d, he acce de e e i be ca ce ed.
If he ehic e eed i e ha 5 h (8 /h), he e i i be e ed acce de i edia e . The
acce de a a d he e i g a i i i a e. Whe he acce de heigh i eached, he e i g a
i be e i g i hed.

Acce heigh a be e ec ed 40 ec d af e he ig i i i ed ff, ided ha he d i e ' d ha bee

e ed i hi hi i e.

The e i i a a ica i e f acce de he he ehic e eed e ceed 6.2 h (10 /h). If acce
de a e ec ed di ec f ff- ad de he he e i e ff- ad de he he ehic e eed e ceed
6.2 h (10 /h). O he i e he e i if he e i O - ad heigh .

Selecting Access Mode Directl from Off-Road Mode

Whe he e i i i ff- ad de heigh , e i g he ai e i i ch ce a d he a ec d i e bef e he

e i g a i e i g i hed, he c d e i e he e i acce de heigh . The c d e i
e e be e he e i ff- ad heigh a a ica if he ehic e eed i c ea e ab e 6.2 h (10 /h).

Cra l (Locked at Access) Mode

C a de a he ehic e d i e a acce heigh . The ehic e i c ed i acce heigh a d ca be e ec ed a a

eed f e ha 21.7 h (35 /h) a d ca be d i e a eed i e c ea a ce i a ea i h e ic ed
head , i.e. ca a . If he ehic e e ceed 24.8 h (40 /h), c a de i be ca ce ed a d he ehic e i e
- ad heigh .

C a de a he ehic e be d i e a eed i h he e i c ed a he acce de heigh . Thi a

he ehic e be d i e i ca a e c. i h i c ea ed f c ea a ce.

C a de ca be e ec ed f N a Acce ide heigh 21.7 h (35 /h), i h a g e f he i ch i

he d di ec i . The acce de a a d he c a de a i be i i a ed. Whe he c d e i i c a
de, - ad de heigh i be e ec ed a a ica if he ehic e eed e ceed 25 h (40 /h). A 18.6 21.7
h (30 35 /h) a e age i di a ed i he e age ce e a he d i e d he ehic e i ai e.
C a de ca a be a a ca ce ed b i g he i ch i he di ec i f 1 ec d. The c a de a i
be e i g i hed.

Automatic Height Change Warnings

Whe he e i i i ff- ad de, acce de c a de heigh , he ai e i c d e i cha ge

he e i heigh a a ica he he ehic e eed e ceed ede e i ed h e h d .

Whe he e i i a ff- ad de c a de heigh , he c d e i e a a i g ad i e he d i e ha

he ehic e i a achi g he eed h e h d. The i e c e de i e i a chi e, a e age i be di a ed
i he e age ce e a d he - ad de a a d ei he he ai i g e i g a i f a h.

The ff- ad de c a de heigh eed a i gi e ed he he ehic e eed i ed ced.

SPECIAL MODES

Door Open Functionalit

If e e f he ehic e d a e e ed d i g a heigh cha ge he he ehic e i a i a , he ai e i

c d e i e ic f he heigh cha ge. The d e ig a i a i ed b he C JB he high eed C AN b
a d ecei ed b he ai e i c d e. Thi ee he ehic e e e he e heigh he a d e a
f cha ge i adi g c di i .

A ha d i ed d a ig a i a a i ed f he C JB he ai e i c d e. Thi ig a ide
d a i f ai he he high eed C AN b i ff, i.e.; d i g e i dic e- e e i g.

The a he ai e i i ch f he a ge de heigh i e ai i i a ed a d he ai i g e i g a i
f a h.

If a f he d a e c ed i hi 90 ec d , he heigh cha ge i e e. If he 90 ec d e i d i e ceeded a d a f

he d a e c ed, he heigh cha ge i be ca ce ed. The de a h i g he e i e ec ed heigh a d
he a ge heigh i be i i a ed. The de heigh cha ge ca be e e ec ed b e a i g he i ch, h e e , if he
ehic e i d i e a eed f e ha 5 h (8 /h) he c d e i c i e ai e e he ehic e he
a ge de heigh .

E tended Mode

If he ehic e bec e g ded a d he ac i c bec e e a i a , he ai e i c d e

a a ica i c ea e he a f ai i he ai i g ai e he ehic e c ea f he b ci .E e ded de i
ac i a ed a a ica a d ca be e ec ed a a .

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W , -
- .T - -
- - .T -
- .A .

T ,
2 (3 / ) 45 .

Additional Lift in E tended Mode

I .W
, .
T .

T .P 3
.A
.T .

Suspension Prevented From Moving

I
, .T ,
.

T
.T , ,
2 (3 / ) 45 .

High Speed Mode

I .H - ,
20 .T ' ' .

I 100 (160 / ) 5 ,
.W 80 (130 / ) 30 ,
' - ' .T .

Periodic Re-leveling

W , ' '
.T - ,
.

Transportation Mode

T
.T L R .

W , .T
.

W , , .
W , .A
.

AIR SUSPENSION CONTROL MODULE

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I em Pa N mbe De c ip ion
1 - A
2 - C C 2321
3 - C C 2320
4 - C C 2030
5 - C C 0867
T , ' 'A' .T
'A' .

Calibration

A L R
, EC U .O ,
,
.I ,
.

I , , , ,
.

Inputs and Outputs

T .

T C AN .T
, ,
.

T , ,
,
.

Air Suppl Unit Rela

T .T
10E (60A). T .T
.

W ,
, .T
.

T , ,
.

S stem Inhibits

A .T ,
.I ,
.

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Comp e o

The temperature sensors located within the compressor protect the compressor from overheating. If the compressor
temperature rises above set limits, the air suspension control module will inhibit the compressor operation. These limits are
shown in the following table:

Comp e o Head Tempe a e Sen o

Lif ing Filling Re e oi
S op 140 C (284 F) 130 C (266 F)
S a 120 C (248 F) 110 C (230 F)
Comp e o B h Tempe a e Sen o
Lif ing Filling Re e oi
S op 140 C (284 F) 130 C (266 F)
S a 120 C (248 F) 110 C (230 F)
Co ne ing

If the air suspension control module registers a cornering force greater than 0.2g it will inhibit all height changes and
corrections. The system will remain inhibited until the cornering force falls to less than 0.15g. The air suspension control
module receives a message from the lateral acceleration sensor (which is an integral part of the ABS yaw rate sensor) on the
high speed C AN bus for the cornering force.

Rapid Accele a ion

If the air suspension control module registers a rapid acceleration greater than 0.2g it will inhibit all height changes and
corrections. The system will remain inhibited until the rapid acceleration falls to less than 0.15g. Acceleration is calculated by
the air suspension control module from a vehicle speed signal received via the high speed C AN bus.

Rapid Decele a ion

If the air suspension control module registers a rapid deceleration smaller than -0.2g it will inhibit all height changes and
corrections. The system will remain inhibited until the rapid deceleration rises above -0.15g. Deceleration is calculated by the
air suspension control module from a vehicle speed signal received via the high speed C AN bus.

Vehicle Jack

The air suspension control module will inhibit all height changes and corrections if it detects a corner lowering too slowly for
more than 1.2 seconds. This is interpreted as the corner identified as moving too slowly being supported on a jack. In this
situation, the corner height will not change when air is released from the air spring because the jack acts as a mechanical
prop. The system will remain inhibited until any of the following conditions exist:

The air suspension switch is moved to the up or down position

Vehicle speed rises to more than 2 mph (3 km/h) for more than 45 seconds.

Doo Open

The air suspension control module will stop all height change requests while any of the doors are open. Vehicle leveling
continues with a door open by keeping the vehicle at the height when the door was opened if the vehicle load changes.

Diagno ic

The air suspension control module can store fault codes which can be retrieved using the Land Rover approved diagnostic
equipment. The diagnostic information is obtained via the diagnostic socket which is located in the lower instrument panel
closing panel, on the driver's side, below the steering column.

The diagnostic socket allows the exchange of information between the various control modules on the bus systems, and the
Land Rover approved diagnostic equipment. This allows the fast retrieval of diagnostic information and programming of
certain functions using the Land Rover approved diagnostic equipment.

Fa l De ec ion

The air suspension control module performs fault detection and plausibility checks. Fault detection is limited to faults that the
control module can directly measure as follows:

Sensor electrical hardware faults

Valve electrical hardware faults
Sensor and actuator supply faults
Bus failures
C ontrol module hardware errors.

Plausibility checks are checks on signal behavior, as follows:

Average height does not change correctly

- Height changes too slowly
Gallery pressure
- Does not increase fast enough when reservoir filling requested
- Increases when system is inactive
- Too low when lifting is requested

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-I
-D
-P .
C
-S - ( )
-T -
-D -
S
-S
-C

W ,
.

T .

Fa l

F ( 1. 5.
):

H ( )
-R ' ', . . - ,
.
P , ,
-R
-V -
-L ' ' .
R , - ,
-
-V -
-D ' ' .
F , - ,
-V .
ABS , C AN
-I ABS ABS
, ' ' , -
.O , .I
.W ,
.

F ' ' .T
.T
.

I - ,
.T C AN
. ' '
:

F -
I -
V - - -

S ( ).

I , . . - ,
.

I , .
D , , .

Fa l Me age

T ;
LED' .

W ' ' ,
LED' .

I , LED'
.

I -
, ' 30 (50 / )' ,
.

I , - ,

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lowered and the vehicle speed is too high, an air suspension fault message is displayed.

If the vehicle is restricted to on-road mode height an air suspension fault normal height only message is displayed.

AIR SUSPENSION S ITCH

I em Pa N mbe De c ip ion
1 - C rawl mode lamp
2 - Access mode lamp
3 - Lowering lamp
4 - On-road mode lamp
5 - Air suspension switch
6 - Raising lamp
7 - Off-road mode lamp
8 - Terrain Response rotary control
9 - Transfer box range switch
10 - Hill Descent C ontrol (HDC ) switch
The air suspension control switch is located in the center console, behind the manual or automatic transmission selector
lever. The switch is a three position, non-latching switch which allows selection of the following driver selectable modes:

Off-road mode
On-road mode
Access mode
C rawl (locked at access) mode.

The air suspension switch can be moved forwards or backwards from its central position. The switch is non-latching and
returns to the central position when released. The switch completes an earth path to the air suspension control module when
operated. This earth path is completed on separate wires for the raise and lower switch positions, allowing the control module
to determine which selection the driver has made.

The switch has six symbols which illuminate to show the current selected height and the direction of movement. The raise
and lower symbols will flash and a warning tone will be emitted from the instrument cluster sounder when a requested height
change is not allowed, i.e. vehicle speed too fast.

A flashing symbol indicates that the air suspension system is in a waiting state or that the system will override the driver's
selection because the speed threshold is too high.

The driver can also ignore the system's warnings signals and allow the height to change automatically. For example,
increasing the vehicle speed to more than 25 mph (40 km/h) will cause the control module to automatically change the ride

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height from off-road mode to on-road mode.

FRONT AND REAR AXLE VALVE BLOCKS

I em Pa N mbe De c ip ion
1 - Isolation rubber mounts (3 off)
2 - Location slots
3 - Front valve block, valves and solenoid assembly
4 - Front bumper armature
5 - Electrical connector
6 - LH air spring damper module air harness connection
7 - Air inlet/outlet connection
8 - RH air spring damper module air harness connection
9 - Rear valve block, valves and solenoid assembly
10 - RH air spring damper module air harness connection
11 - Air inlet/outlet connection
12 - LH air spring damper module air harness connection
13 - Rear suspension turret
The front and rear axle valve blocks are similar in their design and construction and control the air supply and distribution to
the front or rear pairs of air spring damper modules respectively. The difference between the two valves is the connections
from the valve block to the left and right hand air spring damper modules and the valve size. It is important that the correct
valve block is fitted to the correct axle. Fitting the incorrect valve block will not stop the air suspension system from
functioning but will result in slow raise and lower times and uneven raising and lowering between the front and rear axles.

The front valve block is attached to the right hand end of the front bumper armature assembly. The valve block has three
attachment lugs which are fitted with isolation rubber mounts. The rubber mounts locate in slots in the armature. The valve
lugs locate in the holes above the slots and are pushed downwards into positive location in the slots.

The rear valve block is located on the forward face of the left hand rear suspension turret. The valve block has three
attachment lugs which are fitted with isolation rubber mounts which locate in a bracket with three slotted holes. The bracket
is attached to the left hand side of the chassis. The isolation rubber mounts locate in the 'V' shaped slots and are pushed
downwards into positive location in the slots.

The front and rear valve blocks each have three air pipe connections which use 'Voss' type air fittings. One connection is an
air pressure inlet/outlet from the reservoir valve block. The remaining two connections provide the pressure connections to
the left and right hand air springs.

Each valve block contains three solenoid operated valves; two corner valves and one cross-link valve. Each of the valve
solenoids is individually controlled by the air suspension control module. The solenoids have a resistance value of 2 Ohms at
a temperature of 20 C (68 F).

Corner Val es

The corner valves control the flow of air into and out of the individual air springs. When the solenoid is de-energized, the
corner valves are held in a closed position by internal springs. When the solenoid is energized, the valve armature moves
and allows air to flow into or out of the air spring.

Cross Link Val es

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The cross-link valve provides a connection between the two air springs on the same axle. When de-energized, the cross-link
valve prevents air passing from one air spring to another. When the solenoid is energized, the valve spool moves and allows
air to pass from one air spring to the other. This increases wheel articulation and improves ride comfort at low vehicle
speeds.

RESERVOIR VALVE BLOCK

I em Pa N mbe De c ip ion
1 - C hassis mounting bracket
2 - Location slot
3 - Isolation rubber mounts (3 off)
4 - Electrical connector
5 - Reservoir valve block, valves and solenoid assembly
6 - Reservoir connection
7 - Rear valve block connection
8 - Front valve block connection
9 - Air supply unit connection
10 - Pressure sensor
The reservoir valve block controls the storage and distribution of air from the reservoir. The reservoir valve block also
contains the system pressure sensor.

The reservoir valve block is attached to a bracket on the outside of the left hand chassis rail, between the reservoir and the
air supply unit. The valve block is located within the air supply unit acoustic box to protect it from dirt ingress and damage
from stones. The valve block has three attachment lugs which are fitted with isolation rubber mounts which locate in the
chassis bracket which has three slotted holes. The isolation rubber mounts locate in the 'V' shaped slots and are pushed
downwards into positive location in the slots.

The valve block has four air pipe connections which use 'Voss' type air fittings. The connections provide for air supply from
the air supply unit, air supply to and from the reservoir and air supply to and from the front and rear valve blocks. The
connections from the air supply unit and the front and rear control valves are all connected via a common gallery within the
valve and therefore are all subject to the same air pressures.

The valve block contains a solenoid operated valve which is controlled by the air suspension control module. The solenoid
valve controls the pressure supply to and from the reservoir. The solenoid has a resistance value of 2 Ohms at a
temperature of 20 C (68 F). When energized, the valve spool moves allowing air to pass to or from the reservoir.

The valve block also contains a pressure sensor which can be used to measure the system air pressure in the air springs and
the reservoir. The pressure sensor is connected via a harness connector to the air suspension control module. The control
module provides a 5V reference voltage to the pressure sensor and monitors the return signal voltage from the sensor.

Using this sensor, the control module controls the air supply unit operation and therefore limits the nominal system operating
pressure to 244 lbf/in2 (16.8 bar gage).

AIR SUPPL UNIT

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I em Pa N mbe
1 -
2 -
3 -
4 -
5 -
6 -
De c ip ion
Mounting bracket
Air dr er
Pilot e haust valve solenoid and temperature sensors harness connector
Motor harness connector
Intake port
Pilot e haust valve

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7 - E
8 - I (2 )
9 - E
10 - I (1 )
11 - P
12 - H
13 - C
14 - C
T , .T
.

A B

I em Pa N mbe De c ip ion
1 - U
2 - L
3 - A
4 - R
T , ; , .T
.T
, .

T :

A
A 12V
A
A
A

T , ; ,
.

T .T
.

R .T
- ,
.
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There are a number of conditions that will inhibit operation of the air supply unit. It is vitally important that these system
inhibits are not confused with a system malfunction. A full list of air supply unit inhibits are given in the air suspension control
module section in this chapter.

Air Supply Unit - Sectional View

I em Pa N mbe De c ip ion
1 - Exhaust valve cap
2 - Plunger
3 - Valve seat
4 - Intake silencer port
5 - Delivery valve
6 - Valve guide
7 - C ylinder head
8 - Dryer case
9 - Desiccant
10 - Pilot exhaust line
11 - Isolation rubber mount
12 - Motor assembly
13 - C rankcase
14 - C rank
15 - C rankcase cover
16 - C onnecting rod
17 - Piston
18 - Pilot exhaust valve
19 - Spring - pressure relief
Pilot E haust Valve

A solenoid operated pilot exhaust valve is connected to the air delivery gallery, downstream of the air dryer. The pilot valve,
when opened, operates the main compressor exhaust valve. This allows the air springs to be deflated when required.

When the solenoid is energized, pilot air moves the exhaust valve plunger, allowing pressurized air from the air springs
and/or reservoir to pass via the reservoir control valve to the air supply unit.

The solenoid has a resistance value of 4 Ohms at a temperature of 20 C (68 F).

E haust Valve

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The e ha al e ha h ee f nc ion . I ope a e in conj nc ion i h he pilo e ha al e o allo ai o be e ha ed
f om he ai p ing and/o he e e oi a de c ibed p e io l .

The al e al o p o ec he em f om o e -p e e. The al e i connec ed in o he main p e e galle hich i

al a bjec o he em p e e a ailable in ei he he ai p ing o he e e oi . The al e i con olled b a p ing
hich e ic he ma im m ope a ing p e e o be een 333.5 o 370 lbf/in2 (23.0 o 25.5 ba ).

The minim m p e e in he em i al o con olled b he e ha al e o en e ha , e en hen defla ed, he ai

p ing con ain a po i i e p e e of app o ima el 14.5 lbf/in2 (1 ba gage) i h e pec o a mo phe e. Thi p o ec he
ai p ing b en ing i can ill ' oll' o e he pi on i ho c ea ing.

Electric Motor

The elec ic mo o i a 12V dc mo o i h a nominal ope a ing ol age of 13.5V. The mo o d i e a c ank hich ha an
eccen ic pin o hich he comp e o connec ing od i a ached.

The mo o i fi ed i h a empe a e en o on he b h PC B a embl . The en o i connec ed o he ai pen ion

con ol mod le hich moni o he empe a e and can pend mo o ope a ion if an o e hea condi ion occ .

Compressor

The comp e o comp i e a mo o d i en connec ing od and pi on hich ope a e in a c linde i h a c linde head. The
mo o o a e he c ank mo ing he pi on p and do n in he c linde bo e. The ai in he c linde i comp e ed i h he p
oke and i pa ed ia deli e al e, h o gh he ai d e in o he em.

Air Dr er

The ai d e i an in eg al pa of he ai ppl ni . The ai d e con ain a de iccan hich ab o b moi e. P e i ed

ai i pa ed h o gh he ai d e hich emo e an moi e in he comp e ed ai befo e i i pa ed o he e e oi
and/o he em

When he ai i e ha ed f om he em, he e ning ai i pa ed h o gh he ai d e , egene a ing he ai d e b

emo ing moi e f om he de iccan and e pelling i o a mo phe e ia he e ha .

The ai d e i an e en ial componen in he em en ing ha onl d ai i p e en in he em. If moi ai i

p e en in he em, f ee ing can occ , e l ing in poo em ope a ion o componen malf nc ion/fail e.

AIR RESERVOIR

I em Pa N mbe De c ip ion
1 - F on b acke
2 - Re e oi
3 - Ai ho e connec ion o e e oi al e block
4 - Rea b acke
The e e oi i an ai o age e el hich p o ide fa ai pen ion lif ime b he immedia e a ailabili of
p e i ed ai in o he em.

The e e oi i a eel fab ica ion and i loca ed on he o ide of he lef hand cha i ail, in f on of he ai ppl ni .
The e e oi ha a b acke a each end hich a ach o he bod mo n ing b acke on he cha i .

The ea a d end of he e e oi ha a 'Vo ' ai fi ing hich p o ide fo he connec ion of he ai ho e be een he

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e e oi and he e e oi al e block.

The e e oi ha a capaci of 550 in3 (9 li e ). The nominal o king p e e of he e e oi i 243.6 lbf/in2 (16.8 ba
gage), i h a ma im m p e e of 333.5 lbf/in2 (23 ba gage).

HEIGH EN O

F on Heigh Sen o

I em Pa N mbe De c ip ion
1 - Sen o bod
2 - Elec ical connec o
3 - Le e a m
4 - D op link
Rea Heigh Sen o

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I em Pa N mbe De c ip ion
1 - Drop link
2 - Electrical connector
3 - Sensor bod
4 - Lever arm
A height sensor is fitted in each corner of the vehicle to monitor the ride height of the vehicle. The sensor bodies are
attached with screws to brackets on the chassis rails.

Each sensor comprises a sensor bod which contains a single track rotar potentiometer, a lever arm and a drop link.

The sensor lever arm has a drop link which provides the connection between the sensor and the suspension control arm. The
drop link is a serviceable component and is a push fit to the lever arm and the suspension control arm.

The sensors are connected via their harness connector to the air suspension control module which receives the signal output
from each sensor and, using preprogrammed information, converts the signal to a height for each sensor position.

The front and rear sensors are handed and are colored coded for identification as follows:

Right hand front and rear - black colored lever

Left hand front and rear - white colored lever.

Calibra ion

A calibration routine is performed using the Land Rover approved diagnostic equipment to read the position of each corner of
the vehicle, and record the settings in the EC U memor . Once set, the calibration is not required to be performed unless the
air suspension control module is removed or replaced, a height sensor is removed or replaced or a suspension arm to which
the sensor is connected is removed or replaced. If the removed height sensor is subsequentl refitted, the calibration
procedure will have to be performed to ensure the integrit of the s stem.

If a replacement drop link is fitted, recalibration is not required providing the sensor bod is not removed from its mounting
bracket.

AIR SILENCER AND INLET AIR FILTER

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I em Pa N mbe De c ip ion
1 - E ha ( a he e)
2 - I e a d e ha i e ce
3 - Ai i e fi e
4 - E ha ai f ai i
5 - Ai i e ai i
The ai i e ce i e i ed i i a i e d ced f he ai i d i g i fa i def a i f he ai i g .

The i e ce c i e a ic ded ca b ded ge he a d c ai b c f i e ci g f a .A i e c ec i

i ded each e d f he i e ce a d ide f he a ach e f he e ha ai a he e i e a d he
e ha ai i e f he ai i.

A ec da cha be , ca ed a d he ide f he e ha cha be f he i e ce f he i e ai . Pi e

c ec i a e ded each e d f he i a e i e ce a d ide f he a ach e f he ai i e i e f he i e
ai fi e a d he ai i e i e he ai i . The i a e ai i e ce i a h cha be ih i e ed c i f a
fi i g.

The ai i a e fi e i c ec ed ia a i e he i a e i e ce cha be f he ai i e ce i . The fi e i ca ed i he

ea ef ha d c e f he b d , a a f ib e ce f di a d i e.

The fi e c ai af a ee e hich e e a ic a e a e f he i e ai bef e i eache he i e ce he ai

i.

AI HA NE

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I em Pa N mbe De c ip ion
1 - F on a le al e block
2 - Pipe - F on a le al e block o f on RH ai p ing dampe mod le
3 - F on RH ai p ing dampe mod le
4 - F on LH ai p ing dampe mod le
5 - Pipe - Re e oi al e block o f on a le al e block
6 - Pipe - Re e oi al e block o e e oi
7 - Pipe - E ha
8 - Rea RH ai p ing dampe mod le
9 - Pipe - Rea a le al e block o ea RH ai p ing dampe mod le
10 - Ai ilence a embl
11 - Ai inle fil e
12 - Pipe - Main inle
13 - Rea LH ai p ing dampe mod le
14 - Rea a le al e block
15 - Pipe - Re e oi al e block o ea a le al e block
16 - Pipe - C omp e o inle
17 - Pipe - C omp e o e ha
18 - Ai ppl ni
19 - Pipe - Ai ppl ni o e e oi al e block
20 - Re e oi al e block
21 - Re e oi
22 - Pipe - F on a le al e block o f on LH ai p ing dampe mod le
The ai ha ne comp i e en epa a e n lon pipe hich a e connec ed be een he em componen i h Vo
connec o . The pipe ha e he follo ing diame e :

Pipe Diame er
High p e e pipe 6 mm
C omp e o inle pipe 8 mm
Inle fil e o ilence 8 mm
C omp e o e ha pipe 10 mm
Silence e ha pipe 19 mm
If a pipe become damaged, an in-line connec o i a ailable fo epai p po e . The pipe a e ec ed o he bod and he
cha i i h a n mbe of pla ic clip .

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CON ROL DIAGRAM

NOTE: A = Hardwired

I em Pa N mbe De c ip ion
1 - Fuse 26E (20A)
2 - Fusible link 11E (30A)
3 - Ignition switch
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4 - F e 35P (5A)
5 - F ible link 10E (60A)
6 - Ai ppl ni ela
7 - F e 3E (5A)
8 - Ai ppl ni
9 - C omp e o empe a e en o
10 - Mo o
11 - Mo o empe a e en o
12 - E ha al e olenoid
13 - Ai pen ion con ol mod le
14 - C en al j nc ion bo
15 - Re e oi con ol al e
16 - Ai pen ion i ch
17 - F on con ol al e
18 - Rea con ol al e
19 - RH ea heigh en o
20 - LH ea heigh en o
21 - RH f on heigh en o
22 - LH f on heigh en o

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P bli hed: 11-Ma -2011

Vehicle D namic Suspension - Vehicle D namic Suspension
Diagno i and Te ing

Principle of Operation

Fo info ma ion on he ope a ion of he em, efe o ele an ec ion 204-05 - Vehicle D namic S pen ion of he
o k hop man al.

Inspection and Verification

1. 1. Ve if he c ome conce n.

2. 2. C onfi m hich, if an , a ning ligh and/o me age e e di pla ed on he in men cl e . Fo a li of

me age , Refe o he ele an ec ion of he o k hop man al.

3. 3. Vi all in pec fo ob io mechanical o elec ical fa l .

Visual inspection
Mechanical Electrical
Ai leakage Ba e
Ai p ing F e( )
Re e oi Wi ing ha ne ph ical damage o a e ing e
C omp e o Loo e o co oded elec ical connec o
C omp e o ai fil e Ai pen ion con ol i ch
Pipe o k and nion C on olle a ea ne o k (C AN) ci c i
Sen o in alla ion Sen o
Val e block( ) Val e block( )
Ai pen ion con ol mod le

4. 4. If an ob io ca e fo an ob e ed o epo ed conce n i fo nd, co ec he ca e (if po ible) befo e

p oceeding o he ne ep.

5. 5. U e he app o ed diagno ic em o a can ool o e ie e an diagno ic o ble code (DTC ) befo e

mo ing on o he mp om cha o DTC inde .

Make e ha all DTC a e clea ed follo ing ec ifica ion.

S mptom Chart

Possible Possible other

S mptom message warnings Possible causes Action
Vehicle on S pen ion T o chime Wa e ing e o Vi all in pec he i ing ha ne
b mp op fa l epea ed i ing ha ne o and connec o fo a e ing e .
eg la l connec o Vi all in pec he em fo ai
Red Ai leak( ) leakage. C heck he em mode
indica o Vehicle in and calib a ion ing he app o ed
pe manen l an po a ion diagno ic em. C heck fo
ill mina ed mode impla ible a ic la ion mp om ,
S em no i.e. heigh en o o linkage fa l ,
calib a ed o defla ed ai p ing, nde infla ed
calib a ion co p i e e c. No e impla ible a ic la ion
Impla ible mp om ma be ca ed b an n-
a ic la ion calib a ed heigh en o . C heck fo
mp om de ec ed heigh en o DTC and efe o he
Fail e of m l iple DTC inde . Refe o he a an
heigh en o polic and p oced e man al if a
Ai pen ion mod le i pec .
con ol mod le
fail e

Vehicle doe S pen ion T o chime Wa e ing e o Vi all in pec he i ing ha ne

no i le el fa l epea ed i ing ha ne o and connec o fo a e ing e .
eg la l connec o Vi all in pec he em fo ai
Red Ai leak( ) leakage and efe o he g ided
indica o C alib a ion co p diagno ic o ine on he app o ed
pe manen l c o -link al e diagno ic em. C heck he
ill mina ed fa l em calib a ion ing he
Heigh en o fa l app o ed diagno ic em. Fo
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Re e oi al e f on and ea c o link al e e
ck open efe o he g ided diagno ic o ine
E ha al e on he app o ed diagno ic em.
ck clo ed C heck fo heigh en o DTC and
C o ne al e efe o he DTC inde . Fo e e oi
ck open and e ha al e e efe o he
Ai pen ion g ided diagno ic o ine on he
con ol mod le app o ed diagno ic em. C heck
fail e fo co ne al e DTC and efe o
he DTC inde . Refe o he
a an polic and p oced e
man al if a mod le i pec .
Vehicle i S pen ion T o chime , Wa e ing e o Vi all in pec he i ing ha ne
oo lo fa l ambe i ing ha ne o and connec o fo a e ing e .
Hill de cen indica o connec o Vi all in pec he em fo ai
con ol pe manen l Ai leak( ) leakage. Fo ai comp e o
(HDC ) ill mina ed Ai pen ion empe a e en o , inle ai fil e ,
fa l , One chime comp e o e ha al e and ai comp e o
em no DSC ambe empe a e en o e efe o he g ided diagno ic
a ailable indica o fa l o ine on he app o ed diagno ic
D namic pe manen l Inle ai fil e em. Fo Ai pen ion con ol
abili ill mina ed blockage/ e ic ion mod le lo comm nica ion i h ABS
con ol ABS Ai pen ion mod le, efe o he lo
(DSC ) indica o comp e o fa l comm nica ion code a emen a
pe manen l E ha al e he end of hi able. C heck fo ABS
ill mina ed ck/ icking DTC , Refe o he ele an ec ion
Ai pen ion of he o k hop man al. Refe o
con ol mod le lo he a an polic and p oced e
comm nica ion i h man al if a mod le i pec .
ABS mod le
ABS fa l .
Ai pen ion
con ol mod le
fail e

Vehicle i S pen ion T o chime , Re e oi al e Fo e e oi al e and e ha

oo high fa l ambe ck open al e e efe o he g ided
indica o E ha al e diagno ic o ine on he app o ed
pe manen l ck clo ed diagno ic em. C heck fo co ne
ill mina ed C o ne al e al e DTC and efe o he DTC
ck open inde . Refe o he a an polic
Ai pen ion and p oced e man al if a mod le
con ol mod le i pec .
fail e

S em - - C o ed galle Refe o he g ided diagno ic

de ec and ai p ing pipe o ine on he app o ed diagno ic
e ended Inco ec al e em.
mode block in alled o
nnece a il f on o ea
hen lo e ing Damage o
blockage in ai
ha ne

Vehicle - - Leaking ai Refe o he g ided diagno ic

lean / il p ing( ) o ine on he app o ed diagno ic
af e being Leak f om co ne em.
lef o e -nigh al e o galle
o fo ome E ha al e
da ck open

Af e ehicle S pen ion - Leaking ai Refe o he g ided diagno ic

lef o e -nigh ehicle p ing( ) o ine on he app o ed diagno ic
o fo ome ai ing Leaking e e oi em.
da em lo l
eg la l
indica e
"S pen ion
ehicle ai ing
lo l " hen

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first driving
off
DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: Intermittent faults may cause DTC s to be logged, however some DTC s may be cleared during an ignition off,
ignition on cycle. C arry out a road test (if safe to do so), check the functionality of the system and retrieve any DTC s
before turning the ignition off.

DTC Description Possible causes Action

B1A8455 C ar Data does not match C onfigure the car configuration file (C C F) using the approved
C onfiguration that expected for diagnostic system. C lear the DTC and test for normal
Data VIN range/Air operation.
suspension
incorrectly
configured

C 112201 Steering Servotronic steering Refer to the guided diagnostic routine for this code on the
Isolation Valve valve disconnected approved diagnostic system.
Servotronic steering
valve circuit(s) high
resistance or short
circuit to ground
Servotronic steering
valve fault

C 11231C Steering Servotronic steering Refer to the guided diagnostic routine for this code on the
Isolation Valve valve supply circuit approved diagnostic system.
Supply C ircuit high resistance
Servotronic steering
valve supply circuit
short circuit to
ground
Servotronic steering
valve supply circuit
short circuit to power
Servotronic steering
valve fault

C 112F72 Air Spring Repeated or Refer to the approved diagnostic system for corner valve
Valve frequent level checks.
activity in the down
direction
C orner valve stuck
open
C orner valve leak to
gallery

C 113066 Air Spring Air Repeated or Visually inspect the system for air leakage. Refer to the guided
Supply frequent level diagnostic routine for this code on the approved diagnostic
activity in the up system.
direction
Air spring leak
Air harness leak
Exhaust valve stuck
open
C orner valve leak to
gallery

C 11307A Air Spring Sir Unable to lift vehicle Visually inspect the system for an excessive air leak. C heck
Supply Detached air pipe the height sensor linkage(s) for damage/restrictions. Visually
Loose or burst air inspect the air harness for evidence of melting, crushing,
pipe kinking or collapsing. Refer to the guided diagnostic routine for
Excessive air spring this code on the approved diagnostic system.
leak
Height sensor stuck
Height sensor failure

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Blockage in ai
ha ne

C 113192 Ai Sp ing Ai Unable o p e i e Vi all in pec he em fo ai leakage. C heck he

S ppl galle e e oi al e block pipe fo co ec o ing and in alla ion.
In fficien p e e
f om comp e o
De ached ai pipe
Loo e o b ai
pipe
Re e oi al e
block pipe
inco ec l in alled
( nion e e ed)
P e e en o fa l

C 1A001C C on ol Mod le A momen a lo C heck he ba e cha ge, condi ion and ci c i . Refe o he
ol age e en g ided diagno ic o ine fo hi code on he app o ed
occ ed diagno ic em.
Lo ba e ol age
One o mo e con ol
al e pplie
in e mi en ho
ci c i o g o nd

C 1A001D C on ol Mod le I ola ion i ch Refe o he g ided diagno ic o ine fo hi code on he

c en moni o app o ed diagno ic em. Refe o he a an polic and
One o mo e al e p oced e man al if a mod le i pec .
pplie ho ci c i
o g o nd
Rea al e block
di connec ed
Ai pen ion
con ol mod le
fail e

C 1A0049 C on ol Mod le Wa e ing e o Vi all in pec he i ing ha ne and connec o fo ae

al e i ing ha ne ing e . Refe o he g ided diagno ic o ine fo hi code on
o connec o ( ) he app o ed diagno ic em. Refe o he a an polic
Val e ppl and p oced e man al if a mod le i pec .
ci c i ( ) ho ci c i
o po e
Ai pen ion
con ol mod le
in e nal elec ical
fail e

C 1A0053 C on ol Mod le Thi i no a fa l , Ca o Ai pen ion defla ion e i o ine ing he

he em ha been app o ed diagno ic em o he o ine li ed a he end of
defla ed ing he hi ec ion.
diagno ic o ine

C 1A0054 C on ol Mod le Ai pen ion If he p oblem i fo nd d ing p e-deli e in pec ion, check
con ol mod le no ha he ai pen ion con ol mod le (RLM) i NOT in
calib a ed man fac ing mode, calib a ion mode o igh ole ance mode
Ai pen ion ing he app o ed diagno ic em. C onfig e he RLM o
con ol mod le ha c ome mode if nece a ( igh ole ance mode and
been e in o man fac ing mode can be e /clea ed b a ing hen
man fac ing, ending he pen ion geome e p oce f om IDS men .
calib a ion o igh Refe o he ele an Technical Se ice B lle in). C lea he
ole ance mode DTC and e fo no mal ope a ion. Onl if he DTC e-occ ,
ho ld he em be calib a ed ing he app o ed diagno ic
em. C lea he DTC and e fo no mal ope a ion.
C 1A0119 LED S i ch pack LED Refe o he g ided diagno ic o ine fo hi code on he
ci c i , ho ci c i app o ed diagno ic em.
o po e
One o mo e LED
ho ci c i o each
o he

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C 1A031C Lef F Lef -ha d f Vi a i ec he i i g ha e a d c ec f ae
Heigh Se heigh e ig a i g e . F heigh e i age, i g a d ci c i e
age f a ge efe he g ided diag ic i e he a ed
Wa e i g e diag ic e . C hec he heigh e b ac e c di i
i i g ha e a d ec i . C hec he heigh e f c ec i a ai
c ec a d e f fi i g . If a heigh e fi i g a e
Heigh e ac e ed f d be e, a heigh e ha bee
i age di c ec ed cha ged, he ehic e ide heigh be e-ca ib a ed.
Heigh e C a ib a e he e i g he a ed diag ic e .
i age Refe he a a ic a d ced e a a if a
da aged/be d e i ec .
Heigh e
di c ec ed
Heigh e
i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
i a ed g
ide f ehic e
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i
Ai e i
c d e
fai e
C 1A0326 Lef F Lef -ha d f Vi a i ec he i i g ha e a d c ec f ae
Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
age c hi he a ed diag ic e . Refe he a a ic
ehic e i d i e a d ced e a a if a d e i ec .
Wa e i g e
i i g ha e
c ec
Heigh e
i age di c ec ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A0329 Lef F Lef -ha d f Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
i a id he a ed diag ic e . C hec he heigh e
Wa e i g e b ac e c di i a d ec i . C hec he heigh e f
i i g ha e c ec i a ai a d e f fi i g . If a heigh e
c ec fi i g a e ac e ed f d be e, a heigh e
Heigh e ha bee cha ged, he ehic e ide heigh be e-
i age ca ib a ed. C a ib a e he e i g he a ed diag ic
da aged/be e .
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e

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ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i ce
C 1A0392 Lef F Lef -ha d f C hec ha he ehic e i f ee f b ci . C hec he heigh
Heigh Se heigh e heigh e f c ec i a ai a d e f fi i g . If a
cha gi g e ha heigh e fi i g a e ac e ed f d be e, a
e ec ed heigh e ha bee cha ged, he ehic e ide heigh
S e i be e-ca ib a ed. C a ib a e he e i g he a ed
e e ed f diag ic e . Refe he g ided diag ic i e f
i g hi c de he a ed diag ic e . C hec f a ai
Heigh e i g ea . C hec he ai ha e f e ide ce f e i g,
i c ec i a ed c hi g, i i g c a i g. C hec he f a d ea a e
Ai i g ea b c i e f c ec i ga di a a i . C hec he
Ai ha e ea e e i a e b c i e f c ec i ga di a ai .
B c ed/da aged Refe he a ed diag ic e f c e , e e i
ai ha e a d e ha a e chec . C hec he c e a e f ea .
B c ed/da aged
ga e i e
C e a e c
c ed
F ea a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
c e
E ha a e c
c ed
C e a e ai
ea
P e e e fa
Heigh e fai e

C 1A041C Righ F Righ -ha d f Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
age f a ge he a ed diag ic e . C hec he heigh e
Wa e i g e b ac e c di i a d ec i . C hec he heigh e f
i i g ha e c ec i a ai a d e f fi i g . If a heigh e
c ec fi i g a e ac e ed f d be e, a heigh e
Heigh e ha bee cha ged, he ehic e ide heigh be e-
i age di c ec ed ca ib a ed. C a ib a e he e i g he a ed diag ic
Heigh e e . Refe he a a ic a d ced e a a if
i age a d e i ec .
da aged/be
Heigh e
di c ec ed
Heigh e
i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
i a ed g
ide f ehic e
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
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high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i
Ai e i
c d e
fai e

C 1A0426 Righ F Righ -ha d f Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
age c hi he a ed diag ic e . Refe he a a ic
ehic e i d i e a d ced e a a if a d e i ec .
Wa e i g e
i i g ha e
c ec
Heigh e
i age di c ec ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A0429 Righ F Righ -ha d f Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
i a id: he a ed diag ic e . C hec he heigh e
Wa e i g e b ac e c di i a d ec i . C hec he heigh e f
i i g ha e c ec i a ai a d e f fi i g . If a heigh e
c ec fi i g a e ac e ed f d be e, a heigh e
Heigh e ha bee cha ged, he ehic e ide heigh be e-
i age ca ib a ed. C a ib a e he e i g he a ed diag ic
da aged/be e .
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i ce

C 1A0492 Righ F Righ -ha d f C hec ha he ehic e i f ee f b ci . C hec he heigh

Heigh Se heigh e heigh e f c ec i a ai a d e f fi i g . If a
cha gi g e ha heigh e fi i g a e ac e ed f d be e, a
e ec ed heigh e ha bee cha ged, he ehic e ide heigh
S e i be e-ca ib a ed. C a ib a e he e i g he a ed
e e ed f diag ic e . Refe he g ided diag ic i e f
i g hi c de he a ed diag ic e . C hec f a ai
Heigh e i g ea . C hec he ai ha e f e ide ce f e i g,
i c ec i a ed c hi g, i i g c a i g. C hec he f a d ea a e
Ai i g ea b c i e f c ec i ga di a a i . C hec he
Ai ha e ea e e i a e b c i e f c ec i ga di a ai .
B c ed/da aged Refe he a ed diag ic e f c e , e e i
ai ha e a d e ha a e chec . C hec he c e a e f ea .
B c ed/da aged
ga e i e
C e a e c
c ed
F ea a e
b c i e
i c ec i a ed
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( i e e ed)
Re e i a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
c e
E ha a e c
c ed
C e a e ai
ea
P e e e fa
Heigh e fai e

C 1A051C Lef Rea Lef -ha d ea heigh Vi a i ec he i i g ha e a d c ec f ae

Heigh Se e ig a age i g e . Refe he g ided diag ic i e f hi c de
f a ge he a ed diag ic e . C hec he heigh e
Wa e i g e b ac e c di i a d ec i . C hec he heigh e f
i i g ha e c ec i a ai a d e f fi i g . If a heigh e
c ec fi i g a e ac e ed f d be e, a heigh e
Heigh e ha bee cha ged, he ehic e ide heigh be e-
i age di c ec ed ca ib a ed. C a ib a e he e i g he a ed diag ic
Heigh e e . Refe he a a ic a d ced e a a if
i age a d e i ec .
da aged/be
Heigh e
di c ec ed
Heigh e
i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
i a ed g
ide f ehic e
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i
Ai e i
c d e
fai e

C 1A0526 Lef Rea Lef -ha d ea heigh Vi a i ec he i i g ha e a d c ec f ae

Heigh Se e ig a age i g e . Refe he g ided diag ic i e f hi c de
c hi ehic e he a ed diag ic e . Refe he a a ic
i d i e a d ced e a a if a d e i ec .
Wa e i g e
i i g ha e
c ec
Heigh e
i age di c ec ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

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C 1A0529 Lef Rea Lef -ha d ea heigh Vi a i ec he i i g ha e a d c ec f ae
Heigh Se e ig a i a id i g e . Refe he g ided diag ic i e f hi c de
Wa e i g e he a ed diag ic e . C hec he heigh e
i i g ha e b ac e c di i a d ec i . C hec he heigh e f
c ec c ec i a ai a d e f fi i g . If a heigh e
Heigh e fi i g a e ac e ed f d be e, a heigh e
i age ha bee cha ged, he ehic e ide heigh be e-
da aged/be ca ib a ed. C a ib a e he e i g he a ed diag ic
Heigh e e .
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i ce

C 1A0592 Lef Rea Lef -ha d ea heigh C hec ha he ehic e i f ee f b ci . C hec he heigh
Heigh Se e heigh e f c ec i a ai a d e f fi i g . If a
cha gi g e ha heigh e fi i g a e ac e ed f d be e, a
e ec ed heigh e ha bee cha ged, he ehic e ide heigh
S e i be e-ca ib a ed. C a ib a e he e i g he a ed
e e ed f diag ic e . Refe he g ided diag ic i e f
i g hi c de he a ed diag ic e . C hec f a ai
Heigh e i g ea . C hec he ai ha e f e ide ce f e i g,
i c ec i a ed c hi g, i i g c a i g. C hec he f a d ea a e
Ai i g ea b c i e f c ec i ga di a a i . C hec he
Ai ha e ea e e i a e b c i e f c ec i ga di a ai .
B c ed/da aged Refe he a ed diag ic e f c e , e e i
ai ha e a d e ha a e chec . C hec he c e a e f ea .
B c ed/da aged
ga e i e
C e a e c
c ed
F ea a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
c e
E ha a e c
c ed
C e a e ai
ea
P e e e fa
Heigh e fai e

C 1A061C Righ Rea Righ -ha d ea Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
age f a ge he a ed diag ic e . C hec he heigh e
Wa e i g e b ac e c di i a d ec i . C hec he heigh e f
i i g ha e c ec i a ai a d e f fi i g . If a heigh e
c ec fi i g a e ac e ed f d be e, a heigh e
Heigh e ha bee cha ged, he ehic e ide heigh be e-
i age di c ec ed ca ib a ed. C a ib a e he e i g he a ed diag ic
Heigh e e . Refe he a a ic a d ced e a a if
i age a d e i ec .
da aged/be
Heigh e
di c ec ed
Heigh e

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i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
i a ed g
ide f ehic e
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i
Ai e i
c d e
fai e
C 1A0626 Righ Rea Righ -ha d ea Vi a i ec he i i g ha e a d c ec f ae
Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
age c hi he a ed diag ic e . Refe he a a ic
ehic e i d i e a d ced e a a if a d e i ec .
Wa e i g e
i i g ha e
c ec
Heigh e
i age di c ec ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A0629 Righ Rea Righ -ha d ea Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
i a id he a ed diag ic e . C hec he heigh e
Wa e i g e b ac e c di i a d ec i . C hec he heigh e f
i i g ha e c ec i a ai a d e f fi i g . If a heigh e
c ec fi i g a e ac e ed f d be e, a heigh e
Heigh e ha bee cha ged, he ehic e ide heigh be e-
i age ca ib a ed. C a ib a e he e i g he a ed diag ic
da aged/be e .
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
I c ec heigh
ca ib a i ce

C 1A0692 Righ Rea Righ -ha d ea C hec ha he ehic e i f ee f b ci . C hec he heigh

Heigh Se heigh e heigh e f c ec i a ai a d e f fi i g . If a
cha gi g e ha heigh e fi i g a e ac e ed f d be e, a
e ec ed heigh e ha bee cha ged, he ehic e ide heigh
S e i be e-ca ib a ed. C a ib a e he e i g he a ed
e e ed f diag ic e . Refe he g ided diag ic i e f
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i g hi c de he a ed diag ic e . C hec f a ai
Heigh e i g ea . C hec he ai ha e f e ide ce f e i g,
i c ec i a ed c hi g, i i g c a i g. C hec he f a d ea a e
Ai i g ea b c i e f c ec i ga di a ai . C hec he
Ai ha e ea e e i a e b c i e f c ec i ga di a ai .
B c ed/da aged Refe he a ed diag ic e f c e , e e i
ai ha e a d e ha a e chec . C hec he c e a e f ea .
B c ed/da aged
ga e i e
C e a e c
c ed
F ea a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
b c i e
i c ec i a ed
( i e e ed)
Re e i a e
c e
E ha a e c
c ed
C e a e ai
ea
P e e e fa
Heigh e fai e

C 1A0762 C C a ic a i F he ce de ai ed i he e e a ecia e ice

A ic a i a ge hi e age (SSM). C hec he c di i a d ec i f he heigh
ehic e i d i e e b ac e ( ). C hec he heigh e f c ec fi e
Wa e i g e a d fi i g e. If a heigh e fi i g a e ac e ed
i i g ha e f d be e, a heigh e ha bee cha ged, he
c ec ehic e ide heigh be e-ca ib a ed. C a ib a e he e
Heigh e i g he a ed diag ic e .
i age
da aged/be
Heigh e
i age
e/di c ec ed
Heigh e
b ac e
da aged/be
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e
e ed a d
ei a ed i h
bei g eca ib a ed
Ne heigh e
i a ed i h
ca ib a i
I c ec heigh
ca ib a i
Heigh e fai e

C 1A081C P e e P e e e Refe he g ided diag ic i e f hi c de he

Se S age fa ed diag ic e . Refe he a a ic a d
a ge ced e a a if a d e i ec .
P e e e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
P e e e
fai e
Ai e i
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con ol mod le
fail e

C 1A091C P e e P e e en o Refe o he g ided diagno ic o ine fo hi code on he

Sen o Signal ignal ol age o of app o ed diagno ic em. Refe o he a an polic and
ange p oced e man al if a mod le i pec .
P e e en o
di connec ed
P e e en o
ha ne i ing ho
ci c i o g o nd,
ho ci c i o po e
o high e i ance
P e e en o
fail e
Ai pen ion
con ol mod le
fail e

C 1A1064 P e e Re e oi and ai C heck he e e oi and ai p ing pipe fo co ec o ing

Fl c a e p ing pipe and in alla ion. Refe o he g ided diagno ic o ine fo hi
When S em inco ec l in alled code on he app o ed diagno ic em. Refe o he a an
Inac i e o f on o ea al e polic and p oced e man al if a mod le i pec .
block ( nion
e e ed)
C o ne al e ck
open
P e e en o
ha ne i ing ho
ci c i o g o nd,
ho ci c i o po e
o high e i ance
P e e en o
fail e
Ai pen ion
con ol mod le
fail e

C 1A1164 P e e Re e oi and ai C heck he e e oi and ai p ing pipe fo co ec o ing

Fl c a e p ing pipe and in alla ion. Fo co ne al e, e e oi al e, p e e
When S em inco ec l in alled en o and ci c i e efe o he g ided diagno ic o ine
Inac i e o f on o ea al e fo hi code on he app o ed diagno ic em.
block ( nion
e e ed)
C o ne al e
in e nal leak
Re e oi al e
in e nal leak
P e e en o
ha ne i ing ho
ci c i o g o nd,
ho ci c i o po e
o high e i ance
P e e en o
fail e

C 1A1364 P e e Doe E ha al e ck Refe o he g ided diagno ic o ine fo hi code on he

No Dec ea e clo ed app o ed diagno ic em. C heck he Ai pen ion e ha
When Ven ing E ha al e doe pipe and ilence fo blockage/ e ic ion. C heck he e e oi
Galle no hold minim m al e block pipe fo co ec o ing and in alla ion.
e en ion p e e
Galle pipe
blocked/damaged
P e e en o fa l
Ai pen ion
e ha ilence
blocked/ e ic ed
Ai pen ion
e ha pipe
blocked/damaged
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Reservoir valve
block pipes
incorrectl installed
(unions reversed)

C 1A1864 Pressure Reservoir valve Refer to the guided diagnostic routine for this code on the
Increase Too stuck closed approved diagnostic s stem.
Rapid When Reservoir pipe
Filling blocked/damaged
Reservoir Reservoir port
blocked/restricted
Pressure sensor fault

C 1A2064 Pressure C ompressor fault Refer to the guided diagnostic routine for this code on the
Increase Too Reservoir pipe air approved diagnostic s stem. C heck the Air suspension intake
Slow When leak pipe and silencer for blockage/restriction.
Filling Reservoir air leak
Reservoir Galler pipe air leak
Intake filter
blocked/restricted
Intake pipe
blocked/restricted
Air suspension
intake silencer
blocked/restricted
C orner valve stuck
open
Pressure sensor fault

C 1A2464 No Air compressor C heck the securit of the compressor c linder head
Temperature c linder head temperature sensor and electrical connection. Refer to the
Increase When temperature sensor guided diagnostic routine for this code on the approved
C ompressor disconnected diagnostic s stem.
Requested Air compressor
c linder head
temperature sensor
detached from
c linder head
Air compressor
c linder head
temperature sensor
fault
Air compressor fault

C 1A2467 No Temperature takes C heck the securit of the compressor c linder head
Temperature too long to read temperature sensor and electrical connection. Refer to the
Increase When after suitable guided diagnostic routine for this code on the approved
C ompressor compressor runtime diagnostic s stem.
Requested Air compressor
c linder head
temperature sensor
disconnected
Air compressor
c linder head
temperature sensor
fault
Air compressor
disconnected
Air compressor
ground circuit high
resistance
Air compressor fault

C 1A2616 Temperature Temperature sensor Refer to the guided diagnostic routine for this code on the
Sensor C ircuit voltage out of range approved diagnostic s stem. Refer to the warrant polic and
Air compressor procedures manual if a module is suspect.
c linder head
temperature sensor
harness wiring short
circuit to ground,

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C 1A2712 C C R
C .R
.

C 1A2714 C C C / .R
C .R
.R
.
A

(C OMP_V)

(BJB)

A /

BJB
/
A

C 1A2729 C C DTC C 1A2712 .R

C .R

A .

C 1A2864 W N W C / .R .
LED LED R
I LED .R / .R
A .

(BATTERY)

(BJB)

LED

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One o mo e LED
ho ci c i o each
o he
S i ch pack fail e
Ai pen ion
con ol mod le
fail e
C 1A2992 S i ch Ride heigh change Refe o he g ided diagno ic o ine fo hi code on he
Ac i a ion Too i ch ac i a ion oo app o ed diagno ic em. Refe o he a an polic and
Long long p oced e man al if a mod le i pec .
S i ch p e ed fo
mo e han 255
econd
S i ch pack ha ne
i ing ho ci c i o
g o nd, ho ci c i
o po e o high
e i ance
S i ch pack fail e
Ai pen ion
con ol mod le
fail e

C 1A3064 Bo h S i che C heck/ ene f e a nece a . Refe o he elec i cal g ide .

P e ed A Rai e and lo e Refe o he g ided diagno ic o ine fo hi code on he
Same Time i che ac i a ed a app o ed diagno ic em. Refe o he a an polic and
ame ime p oced e man al if a mod le i pec .
Ai pen ion
con ol mod le
ppl (BATTERY)
f e in ba e
j nc ion bo (BJB)
failed
S i ch pack ha ne
i ing ho ci c i o
g o nd, ho ci c i
o po e o high
e i ance
S i ch pack fail e
Ai pen ion
con ol mod le
fail e

C 1A3101 Lef F on Lef -hand f on Refe o he g ided diagno ic o ine fo hi code on he

C o ne Val e co ne al e, app o ed diagno ic em. Refe o he a an polic and
gene al elec ical p oced e man al if a mod le i pec .
fail e
F on al e block
di connec ed
F on al e block
ha ne i ing ho
ci c i o g o nd o
high e i ance
Lef -hand f on
co ne al e fail e
Ai pen ion
con ol mod le
fail e

C 1A3201 Righ F on Righ -hand f on Refe o he g ided diagno ic o ine fo hi code on he

C o ne Val e co ne al e, app o ed diagno ic em. Refe o he a an polic and
gene al elec ical p oced e man al if a mod le i pec .
fail e
F on al e block
di connec ed
F on al e block
ha ne i ing ho
ci c i o g o nd o
high e i ance
Righ -hand f on
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co ne al e fail e
Ai pen ion
con ol mod le
fail e

C 1A3301 Lef Rea Lef -hand ea Refe o he g ided diagno ic o ine fo hi code on he
C o ne Val e co ne al e, app o ed diagno ic em. Refe o he a an polic and
gene al elec ical p oced e man al if a mod le i pec .
fail e
Rea al e block
di connec ed
Rea al e block
ha ne i ing ho
ci c i o g o nd o
high e i ance
Lef -hand ea
co ne al e fail e
Ai pen ion
con ol mod le
fail e

C 1A3401 Righ Rea Righ -hand ea Refe o he g ided diagno ic o ine fo hi code on he
C o ne Val e co ne al e, app o ed diagno ic em. Refe o he a an polic and
gene al elec ical p oced e man al if a mod le i pec .
fail e
Rea al e block
di connec ed
Rea al e block
ha ne i ing ho
ci c i o g o nd o
high e i ance
Righ -hand ea
co ne al e fail e
Ai pen ion
con ol mod le
fail e

C 1A3501 Re e oi Re e oi al e Refe o he g ided diagno ic o ine fo hi code on he

Val e gene al elec ical app o ed diagno ic em. Refe o he a an polic and
fail e p oced e man al if a mod le i pec .
Re e oi al e
block di connec ed
Re e oi al e
block ha ne i ing
ho ci c i o
g o nd o high
e i ance
Re e oi al e
block fail e
Ai pen ion
con ol mod le
fail e

C 1A3601 E ha Val e E ha al e, Refe o he g ided diagno ic o ine fo hi code on he

gene al elec ical app o ed diagno ic em. Refe o he a an polic and
fail e p oced e man al if a mod le i pec .
E ha al e
di connec ed
E ha al e
ha ne i ing ho
ci c i o g o nd o
high e i ance
E ha al e fail e
Ai pen ion
con ol mod le
fail e

C 1A3701 F on C o - F on c o -link Refe o he g ided diagno ic o ine fo hi code on he

Link Val e al e gene al app o ed diagno ic em. Refe o he a an polic and
elec ical fail e p oced e man al if a mod le i pec .
F on al e block
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disconnected
Front valve block
harness wiring short
circuit to ground or
high resistance
Front cross-link
valve failure
Air suspension
control module
failure

C 1A3801 Rear C ross- Rear cross-link valve Refer to the guided diagnostic routine for this code on the
Link Valve general electrical approved diagnostic s stem. Refer to the warrant polic and
failure procedures manual if a module is suspect.
Rear valve block
disconnected
Rear valve block
harness wiring short
circuit to ground or
high resistance
Rear cross-link valve
failure
Air suspension
control module
failure

C 1A5501 Ignition Switch Ignition switch input Refer to the guided diagnostic routine for this code on the
Input C ircuit circuit; ignition on approved diagnostic s stem.
while wake-up off or
ignition off while
engine running
Ignition switch input
circuit short circuit to
ground, short circuit
to power or high
resistance

C 1A681C Left Front Left-hand front Refer to the guided diagnostic routine for this code on the
Height Sensor height sensor suppl approved diagnostic s stem. Refer to the warrant polic and
Suppl circuit voltage out of procedures manual if a module is suspect.
range
Height sensor
harness wiring short
circuit to ground,
short circuit to power
or high resistance
Height sensor failure
Air suspension
control module
failure

C 1A691C Right Front Right-hand front Refer to the guided diagnostic routine for this code on the
Height Sensor height sensor suppl approved diagnostic s stem. Refer to the warrant polic and
Suppl circuit voltage out of procedures manual if a module is suspect.
range
Height sensor
harness wiring short
circuit to ground,
short circuit to power
or high resistance
Height sensor failure
Air suspension
control module
failure

C 1A701C Left Rear Left-hand rear height Refer to the guided diagnostic routine for this code on the
Height Sensor sensor suppl circuit approved diagnostic s stem. Refer to the warrant polic and
Suppl voltage out of range procedures manual if a module is suspect.
Height sensor
harness wiring short

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ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e
C 1A711C Righ Rea Righ -ha d ea Refe he g ided diag ic i e f hi c de he
Heigh Se heigh e a ed diag ic e . Refe he a a ic a d
S ci c i age f ced e a a if a d e i ec .
a ge
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A721C Lef F Lef -ha d f Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
Mecha i age f a ge he a ed diag ic e . C hec he heigh e
( echa ica ) b ac e c di i a d ec i . C hec he heigh e f
Wa e i g e c ec i a ai a d e f fi i g . If a heigh e
i i g ha e fi i g a e ac e ed f d be e, a heigh e
c ec ha bee cha ged, he ehic e ide heigh be e-
Heigh e ca ib a ed. C a ib a e he e i g he a ed diag ic
i age di c ec ed e . Refe he a a ic a d ced e a a if
Heigh e a d e i ec .
i age
da aged/be
Heigh e
di c ec ed
Heigh e
i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
I c ec heigh
ca ib a i
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A731C Lef F Righ -ha d f Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e i g e . Refe he g ided diag ic i e f hi c de
Mecha i age f a ge he a ed diag ic e . C hec he heigh e
( echa ica ) b ac e c di i a d ec i . C hec he heigh e f
Wa e i g e c ec i a ai a d e f fi i g . If a heigh e
i i g ha e fi i g a e ac e ed f d be e, a heigh e
c ec ha bee cha ged, he ehic e ide heigh be e-
Heigh e ca ib a ed. C a ib a e he e i g he a ed diag ic
i age di c ec ed e . Refe he a a ic a d ced e a a if
Heigh e a d e i ec .
i age
da aged/be
Heigh e
di c ec ed

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Heigh e
i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
I c ec heigh
ca ib a i
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A741C Lef Rea Lef -ha d ea heigh Vi a i ec he i i g ha e a d c ec f ae

Heigh Se e ig a age i g e . Refe he g ided diag ic i e f hi c de
Mecha i f a ge he a ed diag ic e . C hec he heigh e
( echa ica ) b ac e c di i a d ec i . C hec he heigh e f
Wa e i g e c ec i a ai a d e f fi i g . If a heigh e
i i g ha e fi i g a e ac e ed f d be e, a heigh e
c ec ha bee cha ged, he ehic e ide heigh be e-
Heigh e ca ib a ed. C a ib a e he e i g he a ed diag ic
i age di c ec ed e . Refe he a a ic a d ced e a a if
Heigh e a d e i ec .
i age
da aged/be
Heigh e
di c ec ed
Heigh e
i age gg ed (
e ai gi e e e
di ec i )
Heigh e
b ac e
da aged/be
Heigh e
i c ec i a ed
I c ec heigh
ca ib a i
Heigh e
ha e i i g h
ci c i g d,
h ci c i e
high e i a ce
Heigh e fai e
Ai e i
c d e
fai e

C 1A751C Righ Rea Righ -ha d ea Vi a i ec he i i g ha e a d c ec f ae

Heigh Se heigh e ig a i g e . Refe he g ided diag ic i e f hi c de
Mecha i age f a ge he a ed diag ic e . C hec he heigh e
( echa ica ) b ac e c di i a d ec i . C hec he heigh e f
Wa e i g e c ec i a ai a d e f fi i g . If a heigh e
i i g ha e fi i g a e ac e ed f d be e, a heigh e
c ec ha bee cha ged, he ehic e ide heigh be e-
Heigh e ca ib a ed. C a ib a e he e i g he a ed diag ic
i age di c ec ed e . Refe he a a ic a d ced e a a if
Heigh e a d e i ec .
i age
da aged/be
Heigh e
di c ec ed
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Heigh en o
linkage oggled (no
ope a ing in e e e
di ec ion)
Heigh en o
b acke
damaged/ben
Heigh en o
inco ec l in alled
Inco ec heigh
calib a ion
Heigh en o
ha ne i ing ho
ci c i o g o nd,
ho ci c i o po e
o high e i ance
Heigh en o fail e
Ai pen ion
con ol mod le
fail e

C 1B1862 S ppl Vol age Incon i en ba e Refe o he g ided diagno ic o ine fo hi code on he
X-Ref C heck ol age ecei ed b app o ed diagno ic em.
Ai pen ion
con ol mod le
Ai pen ion
con ol mod le
ppl ci c i ( )
ho ci c i o
g o nd
Ai pen ion
con ol mod le
ppl ci c i ( ) high
e i ance
Ai pen ion
con ol mod le
fail e

C 1B1903 Doo S a Doo a ignal, Refe o he g ided diagno ic o ine fo hi code on he

Signal p l e id h app o ed diagno ic em.
mod la ed fail e
Inco ec of a e
loaded o Ai
pen ion con ol
mod le
C en al j nc ion bo
o Ai pen ion
mod le ha ne
i ing ho ci c i o
g o nd, ho ci c i
o po e o high
e i ance
C en al j nc ion bo
fa l

C 1B211C C omp e o C omp e o b h Refe o he g ided diagno ic o ine fo hi code on he

B h Ca d ca d empe a e app o ed diagno ic em. Refe o he a an polic and
Tempe a e en o ci c i , p oced e man al if a mod le i pec .
Sen o C i c i ol age o of ange
C omp e o b h
ca d empe a e
en o ha ne
i ing ho ci c i o
g o nd, ho ci c i
o po e o high
e i ance
C omp e o b h
ca d empe a e
en o fail e
Ai pen ion

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con ol mod le
fail e
U007388 C on ol Mod le C AN b connec ion Refe o he Ne o k C omm nica ion ec ion of he o k hop
C omm nica ion ho ci c i o each man al.
B 'A' Off o he

U010087 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion EC M di connec ed man al.
Wi h EC M/PC M EC M no config ed
"A" EC M fail e

U010187 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion T an mi ion con ol man al.
Wi h mod le (TC M)
T an mi ion di connec ed
C on ol Mod le TC M no config ed
TC M fail e

U010287 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion T an fe bo con ol man al.
Wi h T an fe mod le di connec ed
Bo C on ol T an fe bo con ol
Mod le mod le no
config ed
T an fe bo con ol
mod le fail e

U012287 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion ABS mod le man al.
Wi h Vehicle di connec ed
D namic ABS mod le no
C on ol Mod le config ed
ABS mod le fail e

U012687 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion SASM di connec ed man al.
Wi h S ee ing SASM no
Angle Sen o config ed/calib a ed
Mod le SASM fail e

U012887 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion Pa k b ake mod le man al.
Wi h Pa k di connec ed
B ake C on ol Pa k b ake mod le
Mod le no config ed
Pa k b ake mod le
fail e

U013387 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion Vehicle d namic man al.
Wi h Ac i e Roll pen ion em
C on ol Mod le mod le di connec ed
Vehicle d namic
pen ion em
mod le no
config ed
ABS mod le fail e

U013687 Lo C AN b fa l Refe o he Ne o k C omm nica ion ec ion of he o k hop

C omm nica ion Elec onic ea man al.
Wi h diffe en ial con ol
Diffe en ial mod le di connec ed
C on ol Mod le Elec onic ea
- Rea diffe en ial con ol
mod le no
config ed
Elec onic ea
diffe en ial con ol
mod le fail e

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U015587 Lost C AN bus fault Refer to the Network C ommunications section of the workshop
C ommunication Instrument cluster manual.
With disconnected
Instrument Instrument cluster
Panel C luster not configured
(IPC ) C ontrol Instrument cluster
Module failure

U030055 Internal Incorrect software C onfigure the Air suspension control module and instrument
C ontrol Module loaded cluster as necessar using the approved diagnostic s stem.
Software C AN wiring to
Incompatibilit instrument cluster
high resistance
Incorrect instrument
cluster C AN
configuration

U040186 Invalid Data Engine management Refer to the Network C ommunications section of the workshop
Received From s stem fault manual.
EC M/PC M A
U041686 Invalid Data Warnings and Refer to the Network C ommunications section of the workshop
Received From Messages: manual. C heck for ABS s stem DTC s and repair as necessar .
Vehicle - Warning - Two
D namics C himes
C ontrol Module - Displa ed
message - SLOW
DOWN OR
VEHIC LE WILL
LOWER
Subsequent Warning
& Message
- Warning - One
C hime.
- Message -
SUSPENSION
LOWERED
- Meaning -
Vehicle has
lowered to Access
height because of
failure of another
vehicle s stem
ABS fault

U041786 Invalid Data Park brake fault Refer to the Network C ommunications section of the workshop
Received From manual.
Park Brake
C ontrol Module
U042886 Invalid Data SASM not C heck the securit of the electrical connection.
Received From configured/calibrated C onfigure/calibrate the SAS using the approved diagnostic
Steering Angle SAS fault s stem. Refer to the Network C ommunications section of the
Sensor Module workshop manual.
(SASM)
U043486 Invalid Data Vehicle d namic Refer to the Network C ommunications section of the workshop
Received From suspension s stem manual.
Active Roll fault
C ontrol Module
U1A1387 Lost Lost communication Refer to the Network C ommunications section of the workshop
C ommunication with all terrain manual.
With All Terrain optimi ation switch
C ontrol Module C AN bus fault
Terrain optimi ation
switch disconnected
Terrain response
module not
configured
Terrain response
module failure

U1A1449 C AN Internal electronic Refer to the Network C ommunications section of the workshop
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Initiali ation failure manual.
Failure
U1A3562 VIN Data VIN from instrument C onfigure the instrument cluster using the approved diagnostic
cluster does not s stem.
match VIN at time of
calibration
Air suspension
control module has
been swapped with
another vehicle
Instrument cluster
not configured

U200067 Motor Temperature sensor Refer to the guided diagnostic routine for this code on the
Temperature voltage takes too approved diagnostic s stem.
long to read after
suitable compressor
runtime
C ompressor brush
card temperature
sensor harness
wiring short circuit to
ground, short circuit
to power or high
resistance
C ompressor brush
card temperature
sensor failure
C ompressor fault

U200701 Valve(s) Valve circuit short DTC C 1A001D will be set first. Visuall inspect the wiring
circuit to ground harness and connectors between the Air suspension control
Water ingress to module and the control valves for water ingress. Refer to the
wiring harness or guided diagnostic routine for this code on the approved
connectors diagnostic s stem.
Valve harness wiring
short circuit to
ground or high
resistance
Air suspension
control module
failure

U200711 Valve(s) Valve circuit short Visuall inspect the wiring harness and connectors between the
circuit to ground Air suspension control module and the control valves for water
when s stem is ingress. Refer to the guided diagnostic routine for this code on
inactive the approved diagnostic s stem.
Water ingress to
wiring harness or
connectors
Valve harness wiring
short circuit to
ground or high
resistance
Air suspension
control module
failure

U200719 Valve(s) Valve circuit current Refer to the guided diagnostic routine for this code on the
above threshold approved diagnostic s stem.
Valve suppl
circuit(s) intermittent
short circuit to
ground or high
resistance
Valve failure
Air suspension
control module
failure

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U200767 Valve(s) Valve signal Visuall inspect the wiring harness and connectors between the
incorrect after event Air suspension control module and the control valves for water
Water ingress to ingress. Refer to the guided diagnostic routine for this code on
wiring harness or the approved diagnostic s stem. Refer to the warrant polic
connectors and procedures manual if a module is suspect.
Valve suppl
circuit(s) short circuit
to ground, short
circuit to power or
high resistance
Air suspension
control module
failure

Air suspension deflation e it routine

1. 1. Ke on, engine off.

2. 2. Ke off.

3. 3. Press and release raise switch.

4. 4. Press and release lower switch.

5. 5. Ke on, engine off.

6. 6. Ke on, engine running.

7. 7. Press and release raise switch twice.

8. 8. Press and release lower switch twice.

9. 9. Press and release raise switch.

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Vehicle D namic Suspension - Air Suspension S stem Depressuri e and
Pressuri e
General Procedures

• WARNINGS:

A small amount of air pressure will be left in the air suspension system.

Eye protection must be worn.

Wear protective gloves.

• C AUTIONS:

Make sure tailgate, hood and all doors are closed.

Make sure the vehicle is in a clear working area.

1. WARNING: The air suspension system is pressurised

up to 16.8 bar (244 lbf/in ). Make sure no dirt or grease
enters the system. Always wear hand, eye and ear safety
standard protection when working on the system.

Using T4, depressurize the air suspension.

2. Using T4, pressurize the air suspension.

Start and run the engine.

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Vehicle D namic Suspension - Ride Height Adjustments
General Procedures

Special Tool(s)
Gauge, Ride height

204-557B

C AUTIONS:

Make sure the wheels and tires, tie rod ends, suspension joints and wheel bearings are free from damage, wear
and free play.

Make sure there are no heavy objects in the vehicle.

The ride height must be measured with the vehicle weight supported by the suspension.

With the engine running and all vehicle doors closed, make sure the air suspension is functioning and the
vehicle height can be raised and lowered using the air suspension switch.

Drive the vehicle on to a flat, level surface.

Make sure the steering is in the straight ahead position.

NOTE: This procedure must be carried out after replacement of the air suspension control module or height sensor
link arm, removal or replacement of the front or rear upper arms or the height sensor. The ride height does not need
calibration after removal or replacement of the front or rear air springs or shock absorbers.

1. Using the Land Rover approved diagnostic system, carry

out the ride height adjustments.

2. C AUTION: Make sure the vehicle is not moved once it

has been positioned to take measurements.

Position the vehicle on a flat level surface.

3. C onnect IDS to the vehicle data link connector.

C onnect the vehicle data link cable into the vehicle

communications module.

C onnect the IDS USB Lead into the vehicle

communications module.

C onnect the data link cable to the data link connector.

C onnect the IDS USB lead to the IDS USB port.

4. C AUTION: Make sure the ignition switch is turned off,

the park brake is on and the selector lever is in park.

NOTE: IDS already loaded with the latest issue of software.

Switch IDS on and navigate to the vehicle identification

number (VIN) input screen.
5. Enter the VIN and navigate to the vehicle configuration
menu.
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Select setup and configuration.

Select air suspension height calibration and read all

warnings and cautions.

. NOTE: Do not install the special tool over a locking wheel

nut.

NOTE: Make sure the special tool is square to the wheel

face with the measuring rod in a vertical position.

NOTE: Take the measurement from the top edge of the

slider on the special tool.

Once in the suspension height measurement screen, use

the special tool to measure and record the height setting
from each wheel center to the wheel arch.

. C AUTION: IDS will now cause the vehicle height to

change.

Input the ride height measurements taken from the vehicle

into IDS.
. Using the special tool, repeat the vehicle ride height
measurements.
. After successful calibration of the air suspension switch off
IDS and return to its original position.

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Vehicle D namic Suspension - Air Leaks
General Procedures

Special Tool(s)
Hose C utter

204-494 (LRT 60-002)

1. C AUTION: Any leak detection spray used must have a

corrosion inhibitor, and must not cause damage to paintwork,
plastics, metals or plastic lines.

NOTE: The recommended leak detection spray is GOTEC

LDS, Landrover part number STC 1090.

The recommended leak detection spray should be used to

identify any suspected leaks. This procedure should also be
used where any of the air suspension components have
been disturbed.
2. C lean around the area of the suspected air leak.
3. Using the recommended leak detection spray, spray around
all of the air suspension components, working systematically
until the source of the air leak has been found.
4. If any of the air suspension components are found to be
leaking e.g. air spring, compressor, reservoir or a solenoid
valve block, repair is effected by replacement only.
5. Using T4, depressurize the air suspension system.
For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
6. C AUTIONS:

Different air lines in the air suspension system have

different material properties and wall thicknesses. It is
important, in order to prevent subsequent air line failure,
that the new air line material and wall thicknesses are
identical to those of the air line being removed.

Replacement air line must be cut from a new air line

with the equivalent Land Rover part number as the one
being replaced. Do not use air line cut from a roll or coil.

Any existing heatsleeves and abrasion sleeves must

be replaced as part of the repair.

Air line connectors should be positioned in areas away

from heat sources such as the exhaust system, and away
from any section of air line with a heat shield installed.

Do not trim air line ends. If the end of the air line is
damaged, the air line must be cut and a new section added
using a Land Rover approved air line connector, or the air
line must be renewed completely.

NOTE: Air lines must only be cut using either Hose cutter
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204-494 (LRT 60-002), available from SPX LTD or Hose
cutter YA1000A, available from Snap-On Tools. Make sure
the cut air line end is free from damage or burrs.

NOTE: Only Land Rover approved air lines have been

tested to the correct pressure and temperature
specifications.

NOTE: Only the Land Rover approved air line connector,

RYC 500210, has been tested to the correct pressure and
temperature specifications.

NOTE: If the markings or tape adjacent to the air line

connections are removed when cutting air lines, the cut end
of the air line must be clearly marked with a suitable
colored tape or paint mark.

If the source of the air leak is found to be an air line

connection, renew the Voss connector and, if required,
the end of the air line. Using the special tool, cut off the
damaged end of the air line and replace with new Land
Rover approved air line and air line connectors as
required.
. If the source of the air leak is found to be in a section of air
line, either; renew the air line, or, using the special tool, cut
out the damaged section of air line and replace with new
Land Rover approved air line, and air line connectors, as
required.
. NOTE: If the repair has been unsuccessful repeat the above
steps until the air leak is rectified.

Using T4, pressurize the air suspension system.

For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).

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Vehicle D namic Suspension - Suspension Height Sensor
Removal and Installation

Removal
NOTE: This procedure covers removal and installation of both the front and rear suspension height sensors.

NOTE: The right hand sensor has a black colored lever and the left hand sensor has a white colored lever.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. C AUTION: Do not use excessive force to disconnect

the height sensor link.

Remove the suspension height sensor.

Disconnect the height sensor link.

Disconnect the electrical connector.

Remove the 2 Torx screws.

Installation

1. C AUTION: Make sure the Torx screw is not over

tightened. Failure to follow this instruction will result in damage
to the vehicle.

To install, reverse the removal procedure.

Tighten the screws to 3 Nm (2 lb.ft).

2. Using Land Rover approved diagnostic equipment, calibrate

the ride hight.

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Vehicle D namic Suspension - Air Suspension Reservoir
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Using T4, depressuri e the air suspension.
For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).
3. C AUTIONS:

Before the disconnection or removal of an

components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

The air line must onl be disconnected b removal of

the voss connector. Do not remove the air line retaining
boss from the air suspension reservoir. Failure to follow this
instruction ma result in damage to the vehicle.

Visuall inspect the air line ends for damage or wear.

Repair or replace the air line as necessar .

Disconnect the air line from the air suspension reservoir.

4. Remove the air suspension reservoir.

Remove the 4 bolts.

5. Remove the Voss connector from the air line.

Remove and discard the collet and the union.

Installation

1. C AUTION: Make sure the new Voss connector is

installed and full tightened with the alignment plug installed.

Install a new Voss connector to the air reservoir.

Tighten the new Voss connector to 5 Nm (4 lb.ft).

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. Install the air suspension reservoir.

Locate the air reservoir to the chassis brackets, fit the

bolts and tighten to 23 Nm (17 lb.ft).

Full seat the air line into the Voss connector.

Pull on the air line to make sure it is full installed into

the Voss connecter.

. Using T4, pressuri e the air suspension.

For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).

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Vehicle D namic Suspension - Air Suspension Control Module
Removal and Installation

Removal
1. Driver side: Remove the cowl side trim panel.
For additional information, refer to: C owl Side Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. Remove the closing trim panel.

Release the clip.

Remove the 2 screws.

Disconnect the electrical connector.

3. Remove the air suspension control module.

Disconnect the 4 electrical connectors.

Remove the bolt.

Release from the 2 clips.

Installation
1. Install the air suspension control module.

Secure with the clips.

C onnect the electrical connectors.

Tighten the bolt to 9 Nm (7 lb.ft).

2. Install the closing trim panel.

C onnect the electrical connector.

Secure the clip.

Tighten the screws.

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. In all he co l ide im panel.

Fo addi ional info ma ion, efe o: C o l Side T im Panel
(501-05 In e io T im and O namen a ion, Remo al and
In alla ion).
. Ini ia e a ne con ol mod le ing T4.

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Vehicle D namic Suspension - Air Suspension Reservoir Solenoid Valve Block
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Using T4, depressurize the air suspension.
For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
3. Remove the air suspension compressor lower cover.

Remove the 3 bolts.

Release the 5 clips.

4. Move the air compressor electrical connector aside.

Release the 2 clips.

5. C AUTIONS:

Before the disconnection or removal of any

components, ensure the area around joint faces and
connections are clean. Plug any open connections to
prevent contamination.

Visually inspect the air line ends for damage or wear.

Repair or replace the air line as necessary.

NOTE: Note the air line fitted positions.

Remove the air suspension reservoir solenoid valve

block.

Disconnect the 4 air lines.

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Disconnect the 2 electrical connectors.

Release the valve block 3 rubber insulators.

6. Remove the Voss connectors.

Remove and discard the collets and the unions.

In alla ion

1. C AUTION: Make sure the new Voss connector is

installed and fully tightened with the alignment plug installed.

NOTE: New air suspension components are supplied with

new Voss connectors tightened to the correct torque. Do not
install new voss connectors if a new component is being
installed.

Install new Voss connectors to the air suspension reservoir

solenoid valve block.

Tighten to 2.5 Nm (1.7 lb.ft).

2. NOTE: Make sure the valve block does not become

detached during connection of the air lines.

Install the air suspension reservoir solenoid valve block.

Secure the 3 valve block rubber insulators.

C onnect the electrical connectors.

C onnect the air lines into the Voss connector.

Pull on each air line to make sure it is fully installed into

the Voss connecter.

3. Secure the air compressor electrical connector.

4. Install the air suspension compressor lower cover.

Install the bolts and tighten to 10 Nm (7 lb.ft).

5. Using T4, pressurize the air suspension.

For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).

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Vehicle D namic Suspension - Air Suspension Compressor Drier
Removal and Installation

Removal

C AUTION: If a new air suspension compressor, air compressor drier or air compressor deliver valve kit is
installed due to failure, an air compressor rela must be installed. Failure to follow this instruction ma result in
damage to the air suspension s stem components.

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the air suspension compressor.
For additional information, refer to: Air Suspension
C ompressor (204-05 Vehicle D namic Suspension, Removal
and Installation).

3. C AUTION: Before disconnecting or removing the

components, ensure the area around the joint faces and
connections are clean and dr . Plug open connections to
prevent contamination.

Disconnect the air line from the air suspension compressor

drier.

Release the air line from the retaining clip.

4. NOTE: If equipped, note the position of the air

suspension compressor retaining cable.

Remove the air suspension compressor drier.

Remove the retaining screw.

Remove and discard the O-ring seal.

Installation
1. Install a new O-ring seal.

Lubricate the O-ring with a lithium based grease.

2. NOTE: If equipped, make sure the air suspension

compressor retaining cable is correctl routed around the
compressor c linder head.

Install the air suspension compressor drier.

Install the retaining screw and tighten to 3 Nm (2.2

lb.ft).

3. C AUTIONS:

Visuall inspect the air line ends for damage or wear.

Replace the air line as necessar .
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Pull on the air line to make sure it is securel intalled in

the connector.

C onnect the air line to the air suspension compressor drier.

Attach the air line to the retaining clip.

. Install the air suspension compressor.

For additional information, refer to: Air Suspension
C ompressor (204-05 Vehicle D namic Suspension, Removal
and Installation).

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Vehicle D namic Suspension - Air Suspension Compressor
Removal and Installation

Removal

WARNING: Steps 1 and 2 must be carried out within 10 minutes of each other, failure to follow this instruction
may result in personnel injury.

C AUTION: If a new air suspension compressor, air compressor drier or air compressor delivery valve kit is
installed due to failure, an air compressor relay must be installed. Failure to follow this instruction may result in
damage to the air suspension system components.

1. C AUTION: Make sure the ignition switch is turned off,

the park brake is on and the selector lever is in park position.

Open the front door.

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle, make sure at least one of the
wheels is off the ground.
3. Remove the air suspension compressor lower cover.

Remove the bolt.

Release the 5 clips.

4. C AUTION: Always plug any open connections to

prevent contamination.

NOTE: Access to the top compressor fixing bolt is very

restricted. It is advisable to use a 3/8 inch drive socket with
a flexible coupling.

Remove the air suspension compressor.

Disconnect the 3 air lines.

Disconnect the 2 electrical connectors.

Remove the 3 bolts.

Installation
1. C AUTIONS:

Make sure that the wiring harness and the air

suspension pipes are not trapped behind the air suspension

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compressor bracket.

Make sure the air suspension compressor upper cover is

correctly positioned.

NOTE: Install the upper retaining bolt, but do not fully

tighten, before installing the 2 lower retaining bolts.

Install the air suspension compressor.

Tighten the bolts to 23 Nm (17 lb.ft).

C onnect the air lines.

C onnect the electrical connectors.

. C AUTIONS:

Make sure the air suspension exhaust pipe is correctly

located in to the air suspension upper cover.

Make sure the air suspension compressor upper cover is

correctly positioned.

Install the air suspension compressor lower cover.

Install the bolt and tighten to 9 Nm (7 lb.ft).

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Vehicle D namic Suspension - Air Suspension Front Solenoid Valve Block
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the RH fender splash shield.
For additional information, refer to: Fender Splash Shield
(501-02 Front End Body Panels, Removal and Installation).
3. Using T4, depressurize the air suspension.
For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
4. C AUTIONS:

Before the disconnection or removal of any components,

ensure the area around joint faces and connections are clean.
Plug any open connections to prevent contamination.

Visually inspect the air line ends for damage or wear.

Repair or replace the air line as necessary.

NOTE: Note the air line fitted positions.

Disconnect the 3 air lines from the air suspension front

solenoid valve block.
5. Remove the air suspension front solenoid valve block.

Disconnect the electrical connector.

Release the valve block 3 rubber insulators.

6. Remove the Voss connectors from the air lines.

Remove and discard the collet and the union.

Installation

1. C AUTION: Make sure the new Voss connector is

installed and fully tightened with the alignment plug installed.

NOTE: New air suspension components are supplied with

new Voss connectors tightened to the correct torque. Do not
install new voss connectors if a new component is being
installed.

Install new Voss connectors to the air suspension front

solenoid valve block.

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Tighten to 2.5 Nm (1.7 lb.ft).

. NOTE: Make sure the valve block does not become

detached during connection of the air lines.

Install the air suspension front solenoid valve block.

Secure the 3 valve block rubber insulators.

C onnect the air lines into the Voss connector.

Pull on each air line to make sure it is full installed into

the Voss connecter.

C onnect the electrical connector.

. Using T4, pressuri e the air suspension.

For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).
. Install the RH fender splash shield.
For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).

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P bli hed: 11-Ma -2011

Vehicle D namic Suspension - Air Suspension Muffler
Remo al and In alla ion

Removal

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he m ffle a embl .
Fo addi ional info ma ion, efe o: M ffle (309-00B
E ha S em - V8 4.4L Pe ol, Remo al and In alla ion).
3. Remo e he e apo a i e emi ion cani e .
Fo addi ional info ma ion, efe o: E apo a i e Emi ion
C ani e (303-13A E apo a i e Emi ion - V6 4.0L Pe ol,
Remo al and In alla ion).
4. Remo e he ai pen ion comp e o .
Fo addi ional info ma ion, efe o: Ai S pen ion
C omp e o (204-05 Vehicle D namic S pen ion, Remo al
and In alla ion).
5. Remo e he ai pen ion comp e o ppe co e .

6. Di connec he ai pen ion in ake fil e pipe.

7. Remo e he ai pen ion m ffle .

Relea e clip f om he ai pen ion m ffle pipe.

Relea e he ai pen ion comp e o o ai

pen ion ilence pipe .

Installation
1. In all he ai pen ion m ffle .

Loca e he ai pen ion m ffle pipe .

Sec e he clip.

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. C onnect the air suspension intake filter.

. C AUTION: Make sure the air suspension compressor

upper cover is correctl positioned.

Install the air suspension compressor upper cover.

. Install the air suspension compressor.
For additional information, refer to: Air Suspension
C ompressor (204-05 Vehicle D namic Suspension, Removal
and Installation).
. Install the evaporative emissions canister.
For additional information, refer to: Evaporative Emission
C anister (303-13A Evaporative Emissions - V6 4.0L Petrol,
Removal and Installation).
. Install the muffler assembl .
For additional information, refer to: Muffler (309-00B
E haust S stem - V8 4.4L Petrol, Removal and Installation).

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Vehicle D namic Suspension - Air Suspension Rear Solenoid Valve Block
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the LH rear wheel and tire.
3. Using T4, depressurize the air suspension.
For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
4. C AUTIONS:

Before the disconnection or removal of any components,

ensure the area around joint faces and connections are clean.
Plug any open connections to prevent contamination.

Visually inspect the air line ends for damage or wear.

Repair or replace the air line as necessary.

NOTE: Note the air line fitted positions.

Disconnect 3 air lines from the rear valve block.

5. Disconnect the electrical connector.
6. Remove the rear valve block.

Release the valve block 3 rubber insulators.

7. Remove the Voss connectors from the air lines.

Remove and discard the collets and the unions.

Installation
1. NOTE: New air suspension components are supplied with
new Voss connectors tightened to the correct torque. Do not
install new voss connectors if a new component is being
installed.

Install new Voss connectors to the rear valve block.

Tighten to 2.5 Nm (1.7 lb.ft).

2. Install the rear valve block.

Secure the 3 valve block rubber insulators.

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C onnect the electrical connector.

C onnect the air lines into the Voss connector.

Pull on each air line to make sure it is full installed into

the Voss connecter.

. Using T4, pressuri e the air suspension.

For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).
. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Vehicle D namic Suspension - Air Suspension Air Filter
Removal and Installation

Removal
1. Open the liftgate and tailgate.
2. Remove the spare wheel and tire.
3. Remove the 4 nuts securing the LH rear tail pipe heat
shield.

4. Reposition the LH rear tail pipe heat shield.

5. Disconnect the air suspension intake filter pipe.
6. Detach the air suspension intake filter.

Release the grommet.

Release from the clip.

7. Remove the LH lower rear quarter trim access panel.

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. Remo e he ai pen ion in ake fil e .

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In alla ion
1. Install the air suspension intake filter.

Install the grommet.

2. Install the LH lo er rear quarter trim access panel.

3. Attach the air suspension intake filter.
4. C onnect the air suspension intake filter.
5. Reposition the LH rear tail pipe heat shield.

Install the nuts.

6. Install the spare heel and tire.

7. C lose the liftgate and tailgate.

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Vehicle D namic Suspension - Front Air Shock Absorber
Removal and Installation

Special Tool(s)
Air spring tester

204-538

Remover front air shocker

absorber spindle nut

204-700

Removal
NOTE: This procedure should also be used to remove the front air spring.

1. Remove the front shock absorber and air spring assembly.

For additional information, refer to: Front Shock Absorber
and Air Spring Assembly (204-05 Vehicle Dynamic
Suspension, Removal and Installation).
2. NOTE: If no leak is detected, investigate other areas of the
air suspension for faults.

C heck the assembly for leaks.

Inflate the module to 4 bar and check for pressure loss

using leak detector spray.

If a leak is suspected, immerse the shock absorber and

air spring assembly in a tank of water to locate the
source of the leak and mark the area.

3. Remove the nylon retaining pin.

4. Using the special tool, remove the nut.

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. Remove the rebound washer.

. C AUTIONS:

Make sure protective jaws are installed to the vice.

Failure to follow this instruction ma result in damage to the
component.

Do not clamp the shock absorber tube. Failure to

follow this instruction ma result in damage to the
component.

Position the front shock absorber and air spring assembl

in a vice.

. Remove and discard the 3 spacers and 2 O-ring seals.

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. Remove the air spring.

Using a soft faced mallet, gentl tap the sleeve

support upwards to release it from the O-ring seals.

. NOTE: Note the fitted position.

Remove the bump plate and spring aid.

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10. Remove and discard the 2 large black O-ring seals from
the lower seal carrier.

11. Remove the front shock absorber and air spring assembl
from the vice.

In alla ion
1. C AUTIONS:

Make sure protective jaws are installed to the vice.

Failure to follow this instruction ma result in damage to the
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componen .

Do no clamp he hock ab o be be. Fail e o

follo hi in c ion ma e l in damage o he
componen .

Po i ion he f on hock ab o be and ai p ing a embl

in a ice.

. C AUTION: U e comp e ed ai and lin f ee non-

flocking ma e ial.

C lean he componen .
. Lif he eal ca ie o e po e he O- ing eal ack.

Make e ha he dampe bod O- ing eal and

pace a e f ll ea ed o he p ing ea .

. C AUTION: Take ca e no o damage he O- ing

eal d ing in alla ion.

In all ne O- ing eal o he eal ca ie .

Appl loc i e 8021 ( ilicon-ba ed oil) o he O- ing

eal .

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. NOTE: Make sure that these components are installed to

the noted removal position.

Install the bump plate and spring aid.

. Install the air spring.

Align the sleeve support with the first O-ring seal

making sure that the location tag is correctl aligned
with the spring seat cut-out.

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. C AUTIONS:

Make sure that the threads of the front air shock

absorber are covered with protective tape.

Take care not to damage the O-ring seals during

installation.

Install the components in the following order:

1. O-ring seal

2. Spacer

3. O-ring seal

4. Spacer

5. Spacer

. NOTE: The "T5" stamp on the upper face of the rebound

washer must be visable after assembl .

Install the rebound washer.

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. Install a new nut and using the special tool, and tighten
to 98 Nm (72 lb.ft).

10. C AUTIONS:

The air supply must be free of any moisture.

If during disassembly the air sleeve is unrolled, the

air sleeve may inflate incorrectly (to one side). If this
occurs, release the air pressure, and insert a suitable tool
that will not damage the air sleeve or piston (a screw driver
handle), into the side opposite the bulge. Inflate and deflate
until the air sleeve inflates correctly (the air sleeve will be
uniform inside the shroud).

NOTE: To prevent damage when seating the sleeve

support over the large black O-rings, compressed air should
be used to inflate the air spring.

Using the special tool coupled to a tire inflator with a

gauge, apply approximately 2 bar of air pressure to the
air spring to fully seat the sleeve support over the O-ring
seals.
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. C heck the assembl for leaks.

Inflate the module to 4 bar and check for pressure loss

using leak detector spra .

If a leak is suspected, immerse the shock absorber and

air spring assembl in a tank of water to locate the
source of the leak.

. Depressuri e and remove the special tool from the shock

absorber and air spring assembl .
. Install the n lon retaining pin.

. NOTE: Install a new air spring pipe connector.

Install the front shock absorber and air spring assembl .

For additional information, refer to: Front Shock Absorber
and Air Spring Assembl (204-05 Vehicle D namic
Suspension, Removal and Installation).

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Vehicle D namic Suspension - Rear Air Shock Absorber
Removal and Installation

Special Tool(s)
Air spring tester

204-538

Band-it Thrift tool

100-050 (LRT-99-019)

Removal
NOTE: This procedure should also be used to remove the rear air spring.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the shock absorber and spring assembly.
For additional information, refer to: Rear Shock Absorber
and Air Spring Assembly (204-05 Vehicle Dynamic
Suspension, Removal and Installation).
4. Remove the gaiter.

Remove and discard the 2 straps.

5. Remove the nut, rebound washer and rubber bushing.

Discard the nut.

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. Remove and discard the O-ring seals and spacer.

. Remove the n lon retaining pin.

. Remove the rebound plate and spring aid.

. Remove the air spring.

Using a soft faced mallet, gentl tap the sleeve

support upwards to release it from the O-ring seals.

Remove and discard the 2 O-ring seals.

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10. Remove the shock absorber from the vise.

In alla ion
1. Install the shock absorber in the vise.
2. C lean the components.
3. Lubricate and install new O-rings to the seal carrier.
4. Install the spring aid and rebound plate.
5. Install the air spring.

Align the piston with the first O-ring seal, making

sure the location tag is correctl aligned.

6. Install the new O-ring seals and spacer, taking care not to
damage the seals.
7. Install the rubber bushing and rebound washer.

Make sure the formed insert on the bushing is

located against the O-ring seal.

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. In all and ligh l igh en he n .

. C AUTIONS:

The ai ppl m be f ee of an moi e.

If d ing di a embl he ai lee e i n olled, he ai

lee e ma infla e inco ec l ( o one ide). If hi occ ,
elea e he ai p e e, and in e a i able ool ha ill no
damage he ai lee e o pi on (a c e d i e handle), in o
he ide oppo i e he b lge. Infla e and defla e n il he ai
lee e infla e co ec l ( he ai lee e ill be nifo m in ide
he h o d).

In all he ai p ing pi on o e he O- ing eal .

U ing he pecial ool co pled o a i e infla o iha

ga ge, appl app o ima el 2 ba of ai p e e o he
ai p ing o f ll ea he pi on o e he O- ing eal .

10. Tigh en he op n o 98 Nm (72 lb.f ).

11. C heck he a embl fo leak .

Infla e he mod le o 4 ba and check fo p e e lo .

If a leak i pec ed, imme e he p ing and hock

ab o be a embl in a ank of a e o loca e he
o ce of he leak.

12. In all he gai e .

U ing he pecial ool, in all ne ap .

13. In all he hock ab o be and p ing a embl .

Fo addi ional info ma ion, efe o: Rea Shock Ab o be
and Ai Sp ing A embl (204-05 Vehicle D namic
S pen ion, Remo al and In alla ion).

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Vehicle D namic Suspension - Front Shock Absorber and Air Spring Assembl
Removal and Installation

Removal
NOTE: Only the air spring being removed needs to be depressurized.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Using the Land Rover approved diagnostic system,
depressurize the air suspension.
For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
4. Disconnect the shock absorber and air spring assembly
from the lower arm.

Remove the nut and bolt.

5. Release the shock absorber and air spring assembly.

Remove the 3 nuts.

6. C AUTION: Always plug any open connections to

prevent contamination.

Reposition the shock absorber and air spring assembly.

Disconnect the air line.

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7. Remove the shock absorber and air spring assembly.

8. Remove the Voss connector from the air line.

Remove and discard the collet and the union.

In alla ion

1. C AUTION: Make sure the new Voss connector is

installed and fully tightened with the alignment plug installed.

Install a new Voss connector to the air spring.

Tighten to 3.5 Nm (2.6 lb.ft)

2. NOTE: Remove and discard the blanking caps.

NOTE: C lean the component mating faces.

Install the shock absorber and air spring assembly.

C onnect the air line into the Voss connector.

Pull on the air line to make sure it is fully installed into

the Voss connector.

Install the nuts and tighten to 63 Nm (46 lb.ft).

3. C onnect the shock absorber and air spring assembly to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

4. Using the Land Rover approved diagnostic system,

pressurize the air suspension.
For additional information, refer to: Air Suspension System
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Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).
. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Published: 01-Dec-2011
Vehicle D namic Suspension - Rear Shock Absorber and Air Spring Assembl
Removal and Installation

Removal
NOTE: Only the air spring being removed needs to be depressurised.

NOTE: RH illustration shown, LH is similar.

1. Using the Land Rover approved diagnostic system,

depressurize the air suspension.
For additional information, refer to: Air Suspension System
Depressurize and Pressurize (204-05 Vehicle Dynamic
Suspension, General Procedures).
2. Remove the loadspace floor panel.

3. Remove the jack and wheel brace.

4. Remove the spare wheel/tool compartment cover.

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. Lo er the spare heel and tire.

. Remo e the spare heel.

Disconnect the spare heel release strap and

position aside.

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. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. C AUTION: Make sure that all openings are sealed. Use

new blanking caps.

Remove the Voss connector from the air line.

Remove and discard the collet and the union.

Disconnect the active damping wiring.

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. Remove the wheel and tire.

10. Disconnect the shock absorber and air spring assembl
from the lower arm.

Remove the nut and bolt.

11. Remove the three shock absorber and air spring

retaining nuts.

Remove the shock absorber and air spring

assembl .

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In alla ion
1. Install the shock absorber and air spring assembl .

Make sure the shock absorber and air spring assembl

top mounting to bod mating faces are clean.

Fit the nuts and tighten to 63 Nm (46 lb.ft).

C onnect the air line into the Voss connector.

Tug on the air line to make sure it is full installed into

the Voss connecter.

2. C onnect the shock absorber and air spring assembl to the

lower arm.

Tighten the nut and bolt to 300 Nm (221 lb.ft).

3. C AUTION: Make sure the new Voss connector is

installed and full tightened with the alignment plug installed.

Install a new Voss connector to the air spring.

Tighten to 3.5 Nm (2.6 lb.ft)

Attach the active damping wiring.

4. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

5. Lower the vehicle on the lift.

6. C onnect the spare wheel release strap to the spare wheel
and tire.
7. Install the spare wheel and tire.

Raise the spare wheel and tire.

8. Install the spare wheel/tool compartment cover.

9. Install the jack and wheel brace.
10. Install the loadspace floor panel.
11. Using the Land Rover approved diagnostic s stem,
pressuri e the air suspension.
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For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).

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Published: 11-Ma -2011

Vehicle D namic Suspension - Air Suspension Pressure Sensor
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the air compressor housing cover.

Remove the 3 bolts.

Release the 5 clips.

3. Using T4, depressuri e the air suspension.

For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).
4. NOTE: Make sure the valve block does not become
detached during removal of the air pressure sensor.

Disconnect the electrical connector.

5. C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

Remove the air pressure sensor.

Remove and discard the O-ring seal.

Installation
1. NOTE: Make sure the valve block does not become
detached during installation of the air pressure sensor.

Install the air pressure sensor.

Install a new O-ring seal.

Tighten to 5 Nm (4 lb.ft).

2. C onnect the electrical connector.

3. Using T4, pressuri e the air suspension.

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For additional information, refer to: Air Suspension S stem
Depressuri e and Pressuri e (204-05 Vehicle D namic
Suspension, General Procedures).
. C AUTIONS:

Make sure the air suspension compressor upper cover is

correctl positioned.

Make sure the air suspension e haust pipe is correctl

located in to the air suspension upper cover.

Install the air compressor housing cover.

Install the bolts and tighten to 9 Nm (7 lb.ft).

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Published: 11-Ma -2011

Ride and Handling Optimi ation - Ride and Handling Optimi ation
Description and Operation

Terrain Response - C omponent Location

I em Pa N mbe
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
De c ip ion
Air suspension control module
Instrument cluster
Terrain Response rotar control and control module
Rear differential control module (if fitted)
Rear differential
Transfer bo (center differential and high/lo range)
Engine control module
Transfer bo control module

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9 - Transmission control module (automatic transmission only)
10 - ABS module

GENERAL

The Terrain Response system allows the driver to select a program which aims to provide the optimum settings for
traction and performance for the prevailing terrain conditions. The system cannot be switched off. The 'special
programs off' is the default program and covers all general driving conditions. Four specific terrain programs are
selectable to cover all terrain surfaces.

The system is controlled by a rotary control located on the center console, rearward of the selector lever (automatic
transmission) or gearshift lever (manual transmission). The rotary control allows the selection of one of the following
five programs:

Special programs off

Grass/Gravel/Snow
Mud/Ruts
Sand
Rock crawl.

The rotary control can be rotated through 360 degrees or more in either direction and selects each program in turn.
When Terrain Response is fitted to a vehicle, a hi-line instrument cluster will also be fitted which will display the
selected program in the message center.

The Terrain Response system uses a combination of a number of vehicle subsystems to achieve the required vehicle
characteristics for the terrain selected. The following subsystems make up the Terrain Response system:

Engine management system

Automatic transmission (if fitted)
Transfer box (center differential)
Rear differential (electronically controlled)
Brake system (ABS/DSC /ETC /HDC functions)
Air suspension.

A Terrain Response control module is located below the rotary control. The control module detects the selection made
on the rotary control and transmits a signal on the high speed C AN which is received by each of the subsystem
control modules. Each of the affected control modules contain software which applies the correct operating
parameters to their controlled system for the Terrain Response program selection made. Each control module also
provides a feedback for the selected program so that the Terrain Response control module can check that all systems
have changed to the correct operating parameters.

Information is displayed in the instrument cluster message center which informs the driver of improvements which
can be made to the vehicle operating parameters to optimise the vehicle for the prevailing conditions. Inexperienced
off-road drivers may benefit from the automatic assistance of the Terrain Response system and the driver
information. Experienced off-road drivers can select the specific programs for extreme conditions to access control
over the vehicle systems (e.g., throttle shift maps or traction settings) which are not accessible on vehicles without
Terrain Response.

TERRAIN RESPONSE ROTAR CONTROL AND MODULE

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I em Pa N mbe De c ip ion
1 - Te ai Re e a c
2 - T a fe b high/ a ge i ch
3 - Ai e i i ch
4 - Te ai Re e c d e
5 - S ecia g a ff
6 - G a /g a e / g a
7 - M d/ g a
8 - Sa d g a
9 - R c /c a g a
10 - HDC i ch
The Te ai Re e a c i ca ed i he ce e c e a da he e ec i f fi e e ai g
g a . Each g a i de ed b a b hich e e e he e ai e c e ed. The a c ca be
a ed e ec he e i ed g a . The c i e ec he a g a i i di ec i f a i . F he
ai f he c ce he a g a i ei he di ec i ha bee e ec ed, i ha e effec , e.g. ce c
c a ha bee e ec ed, f he ai i a c c i e di ec i i ha e effec .
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The Terrain Response control module is located below the rotary control. The module is connected via a harness
connector which also contains the wiring for the HDC switch, the transfer box high/low range switch, the air
suspension switch and the switch illumination circuits. The control module and switch uses four of these wires for a
12V battery supply when the ignition switch is in ignition position II, a ground and high speed C AN positive and
negative.

TERRAIN RESPONSE OPERATION

The following vehicle subsystem control modules are used for the Terrain Response system:

Engine management (engine control module)

Transmission control (transmission control module - automatic transmission only)
Transfer box control (transfer box control module)
Rear differential control (rear differential control module - if fitted)
Air suspension control (air suspension control module)
Brake system (ABS/DSC /ETC /HDC functions) (ABS module)

Each subsystem operates in different ways in relation to the selected Terrain Response program to achieve the
optimum traction, stability and ease of control for the terrain encountered. The system has a safety factor built in
which ensures that any program can be safely used on any surface, even when an inappropriate program selection
has been made.

Engine Management S stem (EMS)

The EMS varies the throttle pedal response to control the engine torque output. The EMS can change the throttle maps
to change the amount of torque per percentage of pedal travel. The EMS can also change the throttle response to
control the allowed torque change relative to the percentage pedal travel.

Each terrain program uses a combination of operating parameters for each subsystem. C hanging between terrain
programs initiates a different set of operating characteristics which will be noticeable to the driver. The driver will
notice differences in engine and throttle response when, for example, the throttle pedal is held in a constant position
and the terrain program is changed from grass/gravel/snow to sand, the driver will notice the torque and engine
speed increase. If the terrain program is changed from sand to grass/gravel/snow the driver will notice a reduction in
torque and engine speed.

• NOTE: The change in torque and engine speed can take approximately 30 seconds and care must be taken not to
confuse the Terrain Response system operation with an EMS fault.

Transmission Control

The transmission control module changes the shift maps for the Terrain Response program selected. This changes the
shift points providing early or late upshifts and downshifts.

On slippery surfaces the transmission will select 2nd gear in high range or 3rd gear in low range for starting from a
standstill to minimise wheel slip. In muddy conditions the transmission will provide maximum torque output from the
transmission. In sand the transmission will provide an output which passes maximum engine power from the
transmission.

In rock crawl special program (low range) the transmission will select 1st gear for driving off.

Sport mode is only available when the general program is selected and the transfer box is in high range. Sport mode
is disabled in low range and all Terrain Response special programs. C ommandShift is available in any program and
also in high or low range.

If the transmission is in 'Sport' mode and a special program is subsequently selected, the transmission will
automatically change to manual 'C ommandShift ' mode. If a special program is already selected and the
transmission selector lever is moved from drive 'D' to the 'Sport' mode position, the transmission will automatically
change to 'C ommandShift ' mode.

Transfer Bo and Rear Differential Control

The transfer box electronically controlled differential and the rear electronically controlled differential (if fitted) are
treated as one system. The electronic rear differential is an optional fitment on vehicles fitted with the Terrain
Response system. The differential control has two operating strategies; pre-emptive and reactive.

The pre-emptive strategy anticipates and predicts the locking torque value required for each differential to minimise
slip and maximise stability. Each Terrain Response program has a different threshold and input criteria for the pre-
emptive strategy. The pre-emptive strategy improves vehicle traction and composure by avoiding wheel spin. This is
achieved by anticipating the amount of differential lock required for the program selected. For example, a high
locking torque would be applied for rock crawl or slippery surfaces.

The reactive strategy varies the amount of locking torque in response to the actual slip level and the dynamic
behaviour of the vehicle. Each Terrain Response program has a different threshold and input for the reactive

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strategy. The reactive strategy improves vehicle traction and composure by eliminating any wheel spin which has
occurred after the pre-emptive strategy was applied. The locking response applied is applicable to the terrain
program selected, for example, very sensitive on slippery surfaces to provide maximum traction and minimise
surface damage.

The locking torque calculations use various signals from other subsystems, for example, engine torque, throttle
position, selected gear, steering angle, vehicle speed, lateral acceleration, yaw behaviour.

The Dynamic Stability C ontrol function of the ABS system can override the Terrain Response differential control and
reduce any applied locking torque during DSC action.
For additional information, refer to: Anti-Lock C ontrol - Traction C ontrol (206-09A Anti-Lock C ontrol - Traction
C ontrol, Description and Operation).

Ai S pen ion Con ol

The air suspension control module contains a strategy which provides automatic switching between normal and off-
road heights. C hanges in vehicle height settings will be relayed to the driver via the instrument cluster message
center and LED illuminated icons on the switch. The automatic selection and deselection of the vehicle height provides
automatic increase and decrease in ground clearance and aims to provide maximum benefit to the selected terrain
program.

On a vehicle fitted with a correctly installed, Land Rover approved trailer socket, if an electrical load is sensed on the
trailer socket, height changes are prohibited and the message center displays a message advising that a trailer is
connected and off-road height is not automatically selected. The driver can raise the suspension manually using the
air suspension switch.

NOTE: The prohibiting of the automatic ride height selection is only operational if a Land Rover approved trailer
socket is fitted and an electrical load is sensed on the socket.

ABS Con ol

The ABS module controls several vehicle functions and adjusts the operating parameters of these functions to
optimise the selected Terrain Response program.

Traction control uses different slip/acceleration thresholds to improve traction and vehicle composure. For example,
the system sensitivity is increased on slippery surfaces to reduce wheel spin.

If DSC is switched off (with the DSC switch on the instrument panel) when using a Terrain Response special program,
if the special program is subsequently changed for a different program DSC is automatically switched back on.

The stability control uses different threshold values for the selected program to automatically reduce DSC
intervention, removing the requirement for the driver to disable the DSC system in order to reduce engine
intervention which is sometimes induced in extreme off-road conditions. In extreme sand conditions, there may be an
additional benefit of disabling the DSC function using the DSC switch on the instrument panel in addition to selecting
the sand program.

HDC is automatically switched on or off and target speeds are adjusted in response to the Terrain Response program
selected. The responsiveness of the HDC function is also increased where required.

Automatic operation of HDC aims to assist the driver by switching the system on or off when it is of most benefit.
Target speeds for HDC operation are also adjusted according the vehicle operating conditions.

Inco ec P og am U age

Selection of an inappropriate program is discouraged in the following ways:

The active program icon is continually displayed in the instrument cluster message center
The Terrain Response control module 'locks' out certain functions in some programs, e.g. ,
- cruise control is only available with the special programs off or grass/gravel/snow program
- transmission 'Sport' mode is deactivated in all special programs.
In any special program, except the grass/gravel/snow program, when the ignition has been in the off position
continually for more than 6 hours, the Terrain Response system defaults to the Special Programs Off
When in the grass/gravel/snow program, the Terrain Response system will never default to the Special
Programs Off. This is to allow for drivers in cold climates where continuous use of the grass/gravel/snow
program would be beneficial
The rock crawl program is only available with the transfer box in low range.

Selection of an inappropriate program for the terrain conditions will not endanger the driver or cause damage to the
vehicle. C ontinued use of an inappropriate program may reduce the life of some components. The driver may notice
reduced vehicle response, with the engine and transmission being less responsive than in the special programs off.
Also, in some programs, HDC will remain on, signified by illumination of the HDC indicator in the instrument cluster.
The driver may also notice torque 'wind-up' in the center and rear differentials causing a 'braking' effect when the
vehicle is manoeuvred in some special programs.

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The use of the special programs in the Terrain Response system is monitored by the Terrain Response control module
which records the mileage and time the vehicle has operated in a specific program in high and low range. This
information can be retrieved using T4 and used by the dealer technician to check customer concerns, e.g. high fuel
consumption which may be due to continued use of a certain program.

Driver Information

The high specification instrument cluster fitted to all vehicles with Terrain Response, contains a message center which
displays vehicle information to the driver. The message center contains the Terrain Response program icons which
display the currently selected program. If no symbol is displayed, no special program is selected and the system is in
special programs off.

Any required changes to the subsystems are also passed to the driver in the form of indicator illumination in the
instrument cluster or appropriate messages in the message center, HDC off or air suspension height change for
example.

In certain operating conditions, the Terrain Response system also displays advice or warning messages to ensure the
driver is using the vehicle to its full potential, e.g.,

Steering angle is displayed in the message center to avoid driving in deep ruts with steering lock applied
gear information is displayed to recommend a gear for slippery conditions
if the system automatically provided off road ride height, but the driver subsequently lowers the vehicle to
normal height, then the system may advise that this will cause a risk of grounding.

The messages which can be displayed in the instrument cluster message center are detailed in the Information and
Message C enter section.
For additional information, refer to: Information and Message C enter (413-08, Description and Operation).

DIAGNOSTICS

The Terrain Response control module stores information on detected Terrain Response faults and C AN errors which
can be interrogated using T4. The Terrain Response sub-systems and the instrument cluster also store fault
information relating to C AN errors from the Terrain Response control module.

The control module also stores the miles travelled and time elapsed in high range for the individual programs and in
low range for use of all programs which can also be retrieved using T4. This information aids diagnosis of the Terrain
Response system and also provides an indication of Terrain Response system abuse by the driver which can lead to
premature component failure.

Terrain Response S stem Fault Diagnosis

Terrain Response relies on the correct functionality of the five sub-systems. If one of the sub-systems develops a
fault, the Terrain Response system will not function, even though the fault is not in the Terrain Response system. The
Terrain Response control module and rotary control should only be investigated if there are no apparent faults in any
of the sub-systems. If a fault in a sub-system is subsequently corrected, the Terrain Response system will function
normally after an ignition on and off cycle.

Terrain Response Sub-S stem Faults

If a fault occurs in a sub-system, the driver is alerted by the illumination of a warning indicator and/or an appropriate
message for that sub-system in the instrument cluster message center. There will be no warning of a Terrain
Response system fault.

When a sub-system fault is present and the driver attempts to select a different Terrain Response program using the
rotary control or at the next ignition on cycle, a message 'SYSTEM FAULT SPEC IAL PROGRAMS NOT AVAILABLE' will
appear in the message center. This implies that the Terrain Response system has a fault, but only because a sub-
system fault is preventing its operation. This message will be displayed for 5 seconds per ignition cycle, but is
repeated if a further selection is made by the driver using the Terrain Response rotary control or at the next ignition
on cycle.

NOTE: The message 'SYSTEM FAULT SPEC IAL PROGRAMS NOT AVAILABLE' can also be generated by a fault in the
Terrain Response rotary control or control module. See following section for details of rotary control or control
module faults.

It is not possible for the Terrain Response control module to cause any fault behaviour (warning indicator illumination
or message generation) in any of the five sub-systems. Illumination of a sub-system warning indicator and/or a sub-
system related message will never be associated with a Terrain Response control module or Terrain Response system
fault.

The sub-system control modules can detect a fault with the C AN signal from the Terrain Response control module. If
a fault in the Terrain Response system is detected, the sub-system control modules will operate in the 'special
programs off' setting. The sub-system control modules will record a fault code for a failure of the Terrain Response
C AN signal. These faults can be retrieved using T4 and will provide useful information to indicate investigation of the

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Te ai Re e c d e he C AN e .

Terrain Response Rotar Control or Control Module Fault

If a fa cc i he Te ai Re e a c ,a a c ic a be LED i be ed ff
(bac g di i ai i e ai )a d ai f he a c i ig ed. The i e c e e age
ce e i di a a e age 'SYSTEM FAULT SPEC IAL PROGRAMS NOT AVAILABLE' he he fa cc , if he fa
i e e a d he d i e a e e ec a ecia g a (if he c d e i ab e d hi ) a he e
ig i i c c e.

If a fai e f a a c ic a be LED cc , he Te ai Re e e i i f ci .A e ec ed
ecia g a i defa ' ecia g a ff' a e e ig i i c c e, i h he e ce i f he
g a /g a e / g a .

The Te ai Re e a c a d he c d e a e a i eg a i . If a fa cc i ei he c e ,
he h e i i e i e e ace e .

CAN Faults

If a C AN fa e i a d e e Te ai Re e e e ai ,a f he Te ai Re e a c ic
LED i be i i a ed a d ai f he a c i ig ed.

If he i e c e d e ecei e a Te ai Re e e C AN e age f he Te ai Re e
C d e, he e age 'SYSTEM FAULT SPEC IAL PROGRAMS NOT AVAILABLE' i be di a ed he he fa
cc a d i be e ea ed a e e ig i i c c e.

User Error

The f i gi c ec age f he e a be i i e e ed a a e fa :

E gi e i g - P g a cha ge a d d i e ad i e age a e a ai ab e i h he e gi e
i g
R c c a g a e ec ed b a fe b i high a ge
S ecia g a cha ge a e ed i h DSC ABS ac i e ( hi i c de ABS c c i g hich i e ai a
he HDC i bei g ed i e e face ).
S ecia g a cha ge a e ed i h e hea c di i e e ce e ea diffe e ia .

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P bli hed: 11-Ma -2011

Ride and Handling Optimi ation - Ride and Handling Optimi ation
Diagno i and Te ing

Overview

Ride and handling op imi a ion inco po a e he e ain e pon e em hich link a n mbe of mod le a o nd he
ehicle o gi e he be combina ion of e ing in he diffe en em .

Fo info ma ion on he de c ip ion and ope a ion of he em, efe o ec ion 204-06 - Ride and Handling
Op imi a ion of he o k hop man al.

Inspection and Verification

C AUTION: Diagno i b b i ion f om a dono ehicle i NOT accep able. S b i ion of con ol mod le
doe no g a an ee confi ma ion of a fa l , and ma al o ca e addi ional fa l in he ehicle being e ed and/o he
dono ehicle.

1. 1. Ve if he c ome conce n.

2. 2. Vi all in pec fo ob io mechanical o elec ical fa l .

Mechanical Electrical
Ti e condi ion, p e e ,e c F e
D i eline componen (co ec in alla ion, damage, e c) Ha ne e /C onnec o
Engine componen (co ec in alla ion, damage, e c) Te ain e pon e mod le
T an mi ion componen (co ec in alla ion, damage, e c) Engine con ol mod le (EC M)
S pen ion componen (co ec in alla ion, damage, e c) T an mi ion con ol mod le (TC M)
T an fe ca e con ol mod le
ABS con ol mod le
Rea diffe en ial con ol mod le
D namic pen ion con ol mod le
C on olle a ea ne o k (C AN) ci c i

3. 3. If an ob io ca e fo an ob e ed o epo ed conce n i fo nd, co ec he ca e (if po ible) befo e

p oceeding o he ne ep.

4. 4. U e he app o ed diagno ic em o a can ool o e ie e an diagno ic o ble code (DTC ) befo e

mo ing on o he mp om cha o DTC inde . Refe o he ele an ec ion of he o k hop man al.

Make e ha all DTC a e clea ed follo ing ec ifica ion.

S mptom chart

Beca e he o e all f nc ion of he em i dependen on b- em , i i po ible o mi in e p e di pla in he

me age cen e a being e ain e pon e fa l hen he a e ac all a e l of a fa l in one of he b- em .

Refe o he able belo fo help in deciding hen o in e iga e e ain e pon e fa l and hen he fa l i likel o
be in a b- em.

S mptom Description Possible causes Action

Me age cen e di pla The me age cen e indica e o he An b- Fo de ail of he a ailable
indica ing a b- em d i e ha a fa l ha occ ed and em fa l me age , efe o he ele an
fa l in hich b- em ppo ed b ec ion of he o k hop man al.
he me age Ca o a comple e ehicle DTC
cen e ead and follo he diagno ic
o ine( ) indica ed.
Me age cen e Thi me age ill di pla hen a An b- Fo de ail of he a ailable
di pla : S stem fault b- em fa l ha occ ed if he em fa l me age , efe o he ele an
special programs d i e a emp o change he ppo ed b ec ion of he o k hop man al.
not available, e ain pecial p og am, and a each he me age C a o a comple e ehicle DTC
e pon e i ch igni ion on c cle fo 5 econd n il cen e ead and follo he diagno ic
ope a ion no mal he fa l i ec ified o ine( ) indica ed.
Me age cen e C AN ci c i e o C AN ci c i : C a o a comple e ehicle DTC
di pla : S stem fault ho ci c i o ead and follo he diagno ic
special programs g o nd o ine( ) indica ed.
not available, ALL C AN ci c i :
e ain e pon e i ch ho ci c i o

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LEDs illuminated power
C AN circuit:
high
resistance

Special program User error Engine not Refer to the relevant section of the
changes not available running workshop manual. Make sure that
Rock crawl the driver is familiar with the
selected with correct operation of the system.
transfer box
in high range
Special
program
change
attempted
with ABS or
DSC active
- This
includes
ABS
cycling as
part of
HDC
Special
program
change
attempted
with an
overheat
condition
present in the
center or rear
differential

DTC inde

NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer
to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in
operation, prior to the installation of a new module/component.

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three
decimal places and with a current calibration certificate. When testing resistance, always take the resistance of the
DMM leads into account.

DTC Description Possible causes Action

C 1A00- C ontrol The terrain Rectify this DTC before attempting to rectify others. Record all
46 module - response control DTC s logged and clear them. With ignition on select a terrain
calibration / module has response special program, turn off the ignition, then turn back on
parameter indicated a the ignition and verify the selected special program is still active. If
memory calibration / the selected terrain response special program is not still active and
failure parameter has returned to the general program, confirm if DTC has returned.
memory failure for Repeat procedure again once more. If DTC is still present install a
embedded new terrain response rotary control and control module.
systems using
FLASH memory.
This is equivalent
to EEPROM in
RAM/ROM/EEPROM
embedded
systems
C orruption in the
non-volatile
memory storage
system (EEPROM)
in the terrain
response control
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module

C 1A01- LED – Terrain response • NOTE: If the system is in 'failsafe default mode due to another
96 component rotary control and issue no LEDs will illuminate. This fault does not cause the system
internal failure control module - to go to 'failsafe default'.
LED short circuit to
ground Refer to the Description and Operation section of workshop manual.
Terrain response C heck terrain response system, special program LEDs. One or
rotary control and more of the LEDs is suspected of not illuminating as appropriate.
control module - With the engine running move the terrain response rotary control
LED open circuit through all five programs and confirm the appropriate special
program LED does not illuminate when the terrain response rotary
control is in that position. Suspect the terrain response rotary
control and control module, check and install a new terrain
response rotary control and control module as required, refer to the
new module/component installation note at the top of the DTC
Index.
C 1A02- Rotary The terrain C heck that the terrain response control is correctly located into a
94 encoder stuck response rotary detent. Using the manufacturer approved diagnostic system, clear
in intermediate control is held in the DTC . With the engine running check the system responds to
position – an intermediate switch rotation and the DTC does not return. C heck for foreign
unexpected position (between object preventing correct operation of terrain response rotary
operation the special control. C heck for mechanical damage to the terrain response
programs) for rotary control. Rectify as required.
more than 60
seconds
Foreign object
preventing correct
operation of
terrain response
rotary control
Mechanical
damage to the
terrain response
rotary control

U0073- C ontrol Bus off. The Refer to electrical circuit diagrams, check C AN circuit for open
88 module terrain response circuit, short to ground, short to power, repair/renew as necessary.
communication control module Using the manufacturer approved diagnostic system, carry out
bus A off – has detected the network integrity test. C heck the system is operating correctly and
bus off data bus is not the DTC does not return.
available
C AN bus open
circuit
C AN bus short
circuit to ground
C AN bus short
circuit to power
Failure of another
control module on
the C AN bus

U0100- Lost The terrain Using the manufacturer approved diagnostic system, check the
87 communication response control engine control module for DTC s and refer to the relevant DTC
with EC M/PC M module has not index. Using the manufacturer approved diagnostic system, carry
A – missing received one or out network integrity test. Using the manufacturer approved
message more expected diagnostic system, re-configure the engine control module. Refer to
messages from electrical circuit diagrams, check power feed and ground supplies,
the engine control to engine control module for open circuit. C heck for open circuit
module engine control module high speed C AN low circuit. C heck for open
High speed C AN circuit engine control module high speed C AN high circuit, repair as
circuit necessary. Suspect the engine control module, check and install a
communications new engine control module as required, refer to the new
failure module/component installation note at the top of the DTC Index.
Open circuit C heck the system is operating correctly and the DTC does not
engine control return.
module, power
feed
Open circuit
engine control

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module, ground
supply
Engine control
module
disconnected from
the high speed
C AN
communication
bus
Open circuit
engine control
module high speed
C AN low circuit
Open circuit
engine control
module high speed
C AN high circuit
Engine control
module not
configured
Engine control
module failure

U0101- Lost The terrain Using the manufacturer approved diagnostic system, check the
87 communication response control transmission control module for DTC s and refer to the relevant DTC
with module has not index. Using the manufacturer approved diagnostic system, carry
transmission received one or out network integrity test. Using the manufacturer approved
control module more expected diagnostic system, re-configure the transmission control module.
missing messages from Refer to electrical circuit diagrams, check power feed and ground
message the transmission supplies, to transmission control module for open circuit. C heck for
control module open circuit transmission control module high speed C AN low
High speed C AN circuit. C heck for open circuit transmission control module high
circuit speed C AN high circuit, repair as necessary. Suspect the
communications transmission control module, check and install a new transmission
failure control module as required, refer to the new module/component
Open circuit installation note at the top of the DTC Index. C heck the system is
transmission operating correctly and the DTC does not return.
control module,
power feed
Open circuit
transmission
control module,
ground supply
Transmission
control module
disconnected from
the high speed
C AN
communication
bus
Open circuit
transmission
control module
high speed C AN
low circuit
Open circuit
transmission
control module
high speed C AN
high circuit
Transmission
control module not
configured
Transmission
control module
failure

U0102- Lost The terrain Using the manufacturer approved diagnostic system, check the
87 communication response control transfer box control module for DTC s and refer to the relevant DTC
with transfer module has not index. Using the manufacturer approved diagnostic system, carry

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ca e c ecei ed e e i eg i e . U i g he a fac e a ed
d e - e e ec ed diag ic e , e-c fig e he a fe b c d e.
i i g e age f Refe e ec ica ci c i diag a , chec e feed a d g d
e age he a fe b ie , a fe b c d e f e ci c i . C hec f
c d e e ci c i a fe b c d e high eed C AN ci c i .
High eed C AN C hec f e ci c i a fe b c d e high eed C AN
ci c i high ci c i , e ai a ece a . S ec he a fe b c
c ica i d e, chec a d i a a e a fe b c d e a
fai e e i ed, efe he e d e/c e i a ai e a
O e ci c i he f he DTC I de . C hec he e i e ai gc ec
a fe b a d he DTC d e e .
c d e,
e feed
O e ci c i
a fe b
c d e,
g d
T a fe b
c d e
di c ec ed f
he high eed
C AN
c ica i
b
O e ci c i
a fe b
c d e
high eed C AN
ci c i
O e ci c i
a fe b
c d e
high eed C AN
high ci c i
T a fe b
c d e
c fig ed
T a fe b
c d e
fai e

U0122- L The e ai U i g he a fac e a ed diag ic e , chec he

87 c ica i e e c d a ic e e c d e f DTC a d efe he
i h ehic e d e ha e e a DTC i de . U i g he a fac e a ed diag ic
d a ic ecei ed e e , ca e i eg i e . U i g he a fac e
c d e e e ec ed a ed diag ic e , e-c fig e he d a ic e e
- i i g e age f c d e. Refe e ec ica ci c i diag a , chec e
e age he d a ic feed a d g d ie , d a ic e e c d e f
e e c e ci c i . C hec f e ci c i d a ic e e c
d e d e high eed C AN ci c i . C hec f e ci c i d a ic
High eed C AN e e c d e high eed C AN high ci c i , e ai a
ci c i ece a . S ec he d a ic e e c d e, chec
c ica i a di a a e d a ic e e c d e a e i ed,
fai e efe he e d e/c e i a ai e a he f
O e ci c i he DTC I de . C hec he e i e ai gc ec a d he
d a ic e e DTC d e e .
c d e,
e feed
O e ci c i
d a ic e e
c d e,
g d
D a ic e e
c d e
di c ec ed f
he high eed
C AN
c ica i
b
O e ci c i

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dynamic response
control module
high speed C AN
low circuit
Open circuit
dynamic response
control module
high speed C AN
high circuit
Dynamic response
control module not
configured
Dynamic response
control module
failure
U0132- Lost The terrain Using the manufacturer approved diagnostic system, check the air
87 communication response control suspension control module for DTC s and refer to the relevant DTC
with module has not index. Using the manufacturer approved diagnostic system, carry
suspension received one or out network integrity test. Using the manufacturer approved
control module more expected diagnostic system, re-configure the air suspension control module.
A - missing messages from Refer to electrical circuit diagrams, check power feed and ground
message the air suspension supplies, to air suspension control module for open circuit. C heck
control module for open circuit air suspension control module high speed C AN low
High speed C AN circuit. C heck for open circuit air suspension control module high
circuit speed C AN high circuit, repair as necessary. Suspect the air
communications suspension control module, check and install a new air suspension
failure control module as required, refer to the new module/component
Open circuit air installation note at the top of the DTC Index. C heck the system is
suspension control operating correctly and the DTC does not return.
module, power
feed
Open circuit air
suspension control
module, ground
supply
Air suspension
control module
disconnected from
the high speed
C AN
communication
bus
Open circuit air
suspension control
module high speed
C AN low circuit
Open circuit air
suspension control
module high speed
C AN high circuit
Air suspension
control module not
configured
Air suspension
control module
failure

U0155- Lost The terrain Using the manufacturer approved diagnostic system, check the
87 communication response control instrument cluster for DTC s and refer to the relevant DTC index.
with module has not Using the manufacturer approved diagnostic system, carry out
instrument received one or network integrity test. Using the manufacturer approved diagnostic
panel cluster more expected system, re-configure the instrument cluster. Refer to electrical
(IPC ) control messages from circuit diagrams, check power feed and ground supplies, to
module - the instrument instrument cluster for open circuit. C heck for open circuit
missing cluster instrument cluster high speed C AN low circuit. C heck for open
message High speed C AN circuit instrument cluster high speed C AN high circuit, repair as
circuit necessary. Suspect the instrument cluster, check and install a new
communications instrument cluster as required, refer to the new module/component
failure installation note at the top of the DTC Index. C heck the system is
Open circuit operating correctly and the DTC does not return.
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i e c e ,
e feed
O e ci c i
i e c e ,
g d
I e c e
di c ec ed f
he high eed
C AN
c ica i
b
O e ci c i
i e c e
high eed C AN
ci c i
O e ci c i
i e c e
high eed C AN
high ci c i
I e c e
c fig ed
I e c e
fai e

U0300- I e a The e ai U i g he a fac e a ed diag ic e , chec he

55 c d e e e c ehic e c fig a i fi e, ec if a ece a . C hec c ec
f a e d e ha fai ed f a e e i i i a ed b h e ai e e c d e
i c a ibi i ec g i e he a di e c e , da e a ece a . C hec he e i
- c ec a e e ai gc ec a d he DTC d e e .
c fig ed c fig a i ID
f he C AN da a
b a e , he
i e c e
Te ai e e
c d e
c ec
c fig ed
I e c e
c ec
c fig ed

U0401- I a id da a The e ai U i g he a fac e a ed diag ic e , chec he

94 ecei ed f e e c e gi e c d e f DTC a d efe he e e a DTC
EC M/PC M A - d e ha i de , ec if a e i ed. C hec he e i e ai gc ec
e ec ed de ec ed ha he a d he DTC d e e .S ec he e gi e c d e,
e ai e gi e c chec a d i a a e e gi e c d e a e i ed, efe
d e he e d e/c e i a ai e a he f he DTC
c e had I de .
e a ed i a a
a a i e ha i
had bee
c a ded
e ae
The e gi e
a age e
e , e gi e
c d e i
ab e
a e ai
e e
f c i a i , he
e ai e e
e i g i
defa c di i
E gi e
a age e
e fa
E gi e c
d e fai e

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U0402- I a id da a The e ai U i g he a fac e a ed diag ic e , chec he
94 ecei ed f e e c a i i c d e f DTC a d efe he e e a DTC
a i i d e ha i de , ec if a e i ed. C hec he e i e ai gc ec
c d e de ec ed ha he a d he DTC d e e .S ec he a i i c
- e ec ed a i i d e, chec a d i a a e a i i c d e a
e ai c d e e i ed, efe he e d e/c e i a ai e a
c e had he f he DTC I de .
e a ed i a a
a a i e ha i
had bee
c a ded
e ae
The a i i
e ,
a i i
c d e i
ab e
a e ai
e e
f c i a i , he
e ai e e
e i g i
defa c di i
T a i i
e fa
T a i i
c d e
fai e

U0403- I a id da a The e ai U i g he a fac e a ed diag ic e , chec he

94 ecei ed f e e c a fe b c d e f DTC a d efe he e e a DTC
a fe ca e d e ha i de , ec if a e i ed. C hec he e i e ai gc ec
c d e de ec ed ha he a d he DTC d e e .S ec he a fe b c
- e ec ed a fe b d e, chec a d i a a e a fe b c d e a
e ai c d e e i ed, efe he e d e/c e i a ai e a
c e had he f he DTC I de .
e a ed i a a
a a i e ha i
had bee
c a ded
e ae
The a fe b
e , a fe
b c
d e i ab e
a
e ai e e
f c i a i , he
e ai e e
e i g i
defa c di i
T a fe b
e fa
T a fe b
c d e
fai e

U0416- I a id da a The e ai U i g he a fac e a ed diag ic e , chec he

94 ecei ed f e e c d a ic e e c d e f DTC a d efe he
ehic e d e ha e e a DTC i de , ec if a e i ed. C hec he e i
d a ic de ec ed ha he e ai gc ec a d he DTC d e e .S ec he
c d e d a ic e e d a ic e e c d e, chec a d i a a e d a ic
- e ec ed c d e e e c d e a e i ed, efe he e
e ai c e had d e/c e i a ai e a he f he DTC I de .
e a ed i a a
a a i e ha i
had bee
c a ded
e ae

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The d a ic
e e e ,
d a ic e e
c d e i
ab e
a e ai
e e
f c i a i , he
e ai e e
e i g i
defa c di i
D a ic e e
e fa
D a ic e e
c d e
fai e
U0421- I a id da a The e ai U i g he a fac e a ed diag ic e , chec he ai
94 ecei ed f e e c e i c d e f DTC a d efe he e e a DTC
e i d e ha i de , ec if a e i ed. C hec he e i e ai gc ec
c d e de ec ed ha he a d he DTC d e e .S ec he ai e i c
A - ai e i d e, chec a d i a a e ai e i c d e a
e ec ed c d e e i ed, efe he e d e/c e i a ai e a
e ai c e had he f he DTC I de .
e a ed i a a
a a i e ha i
had bee
c a ded
e ae
The ai e i
e , ai
e i c
d e i ab e
a
e ai e e
f c i a i , he
e ai e e
e i g i
defa c di i
Ai e i
e fa
Ai e i
c d e
fai e

U1A03- Vehic e The e ai U i g he a fac e a ed diag ic e , chec he

4A c fig a i e e c ehic e c fig a i fi e, ec if a ece a . C hec c ec
a a e e - d e ha c e f ehic e c fig a i a e i a ed, ec if a
i c ec de ec ed a ece a . C hec he e i e ai gc ec a d he DTC
c e i a ch be ee d e e .
i a ed he ha d a e
c ec ed a d he
ha d a e
e ec ed
Vehic e
c ec
c fig ed
I c ec
c e
i a ed f
ehic e
c fig a i

U1A14- C AN The e ai U i g he a fac e a ed diag ic e , chec c ec

49 i i ia i a i e e c f a e e i i i a ed e ai e e c d e.
fai e - d e ha S ec he e ai e e c d e, chec a d i a a
i e a i dica ed he e e ai e e c d e a e i ed, efe he e
e ec ic de ec i fa d e/c e i a ai e a he f he DTC I de .
fai e i e a ci c i
fai e
The C AN c e
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ini iali a ion ha
failed
Te ain e pon e
con ol mod le
in e nal fail e

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Published: 11-May-2011
Ride and Handling Optimi ation - Ride and Handling Optimi ation Switch
Removal and Installation

Removal
NOTE: Automatic transmission shown. Manual transmission is similar.

1. WARNING: The gear lever knob will be released

suddenly, keep face clear during removal.

Remove the selector lever knob.

Pull the knob upwards.

2. Release the ride and handling optimization switch

assembly.

Release the 4 clips.

3. Release the selector lever panel.

Release the 4 clips.

4. Remove the ride and handling optimization switch

assembly.

Disconnect the 2 electrical connectors.

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5. Remove the selector lever panel.

In alla ion
1. Install the selector lever panel.
2. Install the ride and handling optimi ation switch assembl .

C onnect the electrical connectors.

Secure the selector lever trim panel.

3. C AUTION: Onl fit the selector knob when the selector

lever is in the 'P' position.

Install the selector lever knob.

Engage the locating tang of the knob with the slot in the
selector lever.

Push the knob full onto the selector lever.

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Published: 11-May-2011
D i e haf -
F D i e (P e e ) Shaf
I e S ecifica i
Type One piece, variable length steel tube.
C onstant velocity joints Plunging type, fitted at front and rear.
Rea D i e (P e e ) Shaf
I e S ecifica i
Type Two piece, variable length steel tube with isolated centre bearing and swaged front section to provide
controlled collapse of the shaft during a crash.
C onstant Plunging constant velocity joints are positioned at the front and centre of the shaft with a fixed,
velocity joints Hookes type universal joint at the rear.
T e S ecif ica i
De c i i N b-f
*F d i e haf f a e d i e f a ge T b :
Stage 1 45 33
Stage 2 Further 90 Further 90
*F d i e haf a fe ca e d i e f a ge T b :
Stage 1 45 33
Stage 2 Further 90 Further 90
* Rear driveshaft to rear axle drive flange Torx bolts 150 110
Rear driveshaft to transfer case drive flange Torx bolts 73 54
Rear driveshaft center bearing bolts 30 22
Fuel tank heat shield bolts 5 4
Fuel tank heat shield nuts 3 2
* Ne 'Pa ched' T b be i a ed

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Published: 11-Ma -2011

Dri eshaft - Dri eshaft
Description and Operation

Drive shaft C omponent Location

I em Pa N mbe De c ip ion
1 - Front drive shaft
2 - Rear drive shaft

GENERAL

Drive shafts are used to transmit drive from the transfer bo to the front and rear differentials.

The front drive shaft is a one-piece unit, connected to the transfer bo and front differential unit via C onstant Velocit
(C V) joints.

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T - , .T
CV .T
.

T
.

FRONT DRIVE SHAFT

I em Pa N mbe De c ip ion
1 - CV
2 - F
T 1.7 . A CV
( 'H J ' CV ). T 713
.

E CV ,
.T CV T
.

T .T
CV .

A CV .T
.T .
T CV
.

REAR DRIVE SHAFT ASSEMBL

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I em Pa N mbe De c ip ion
1 - C V join
2 - C ollap ible c a h ec ion
3 - F on haf a embl
4 - S ppo bea ing
5 - Rea haf a embl
6 - Uni e al join
The ea d i e haf a embl comp i e f on and ea haf a emblie and a cen all mo n ed haf bea ing. The
ea d i e haf a embl ha an o e all nominal leng h of 1309 mm.

Front Shaft Assembl

The f on haf a embl inco po a e a c a h fea e i hin he be, hich con ol he collap e of he d i e haf
d ing a c a h.

The f on haf a embl comp i e a C V join a each end ( ee 'Half haf Join ' ec ion fo mo e info ma ion on C V
join ).

The f on C V join ( an fe bo end) ha i adial hole , hich p o ide fo he a achmen o he an fe bo ea

o p flange. The join i ec ed o he o p flange i h i o bol , hich c e in o h eaded hole in he
flange. Th ee comp e ion link a he a e fi ed nde each pai of bol . The ea plined haf ma e i h pline
in he ea haf C V join h b and i p e ed in and fi ed i h Lock i e. A machined face on he haf accep he
haf bea ing, hich i a p e fi .

Rear Shaft Assembl

The ea haf a embl comp i e a Hooke pe ni e al join a he ea ( ea diffe en ial end).

The ni e al join i elded o he ea haf be and i ec ed o he inp haf of he ea diffe en ial i h fo

flanged n . The oppo i e end of he ea haf be i elded di ec l o he C V join bod .

Shaft Bearing Assembl

The haf bea ing a embl comp i e a p e ed eel ho ing, a bbe diaph agm and a ball bea ing. The
diaph agm i bonded in o he ho ing. An in e nal me al ing, bonded o he b h, allo fo he bea ing o be p e
fi ed in o i . The bbe b h allo fo mall de ia ion in alignmen and al o ab o b ib a ional fo ce . The haf
bea ing a embl i loca ed b c e , hich pa h o gh plain hole in he bea ing a embl and loca e in o n
elded on he in ide face of he cha i c o -membe .

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Dri eshaft - Uni ersal Joints
Description and Operation

A Hookes t pe universal joint is used to connect the rear drive shaft assembl to the rear differential, allowing for
angular deviations of the drive shafts due to acceleration and braking.

The joint is bolted to the input shaft of the rear differential with four flanged adhesive screws and is lubricated during
manufacture and sealed for life.

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Published: 11-May-2011
Dri eshaft - Front Dri eshaftV8 4.4L Petrol
Removal and Installation

Remo al

C AUTION: It is possible to fit the driveshaft incorrectly. Note the orientation before removal.

NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect
the operation or durability of the joint.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the transmission crossmember.
For additional information, refer to: Transmission Support
C rossmember (502-02 Full Frame and Body Mounting,
Removal and Installation).
3. Remove the transmission heat shield.

Remove the 4 bolts.

4. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the transfer case drive

flange.

Remove the 6 bolts and washers, discard the bolts.

5. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the front axle drive flange.

Remove the 6 bolts and washers, discard the bolts.

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6. Remo e he f on d i e haf .

C omp e he join o di engage he d i e flange .

In alla ion
1. NOTE: A mall amo n of oil ma eep f om he d i e haf
join d ing o age. The lo of hi oil ill no affec he
ope a ion o d abili of he join .

In all he d i e haf .

C lean he componen .

C omp e he join o engage he d i e flange .

2. Sec e he d i e haf o he f on a le d i e flange.

S age 1: Tigh en he bol o 45 Nm (33 lb.f ).

S age 2: Tigh en he bol af he 90 deg ee .

3. Sec e he d i e haf o he an fe ca e d i e flange.

S age 1: Tigh en he bol o 45 Nm (33 lb.f ).

S age 2: Tigh en he bol af he 90 deg ee .

4. In all he an mi ion hea hield.

Tigh en he bol o 10 Nm (7 lb.f ).

5. In all he an mi ion c o membe .

Fo addi ional info ma ion, efe o: T an mi ion S ppo
C o membe (502-02 F ll F ame and Bod Mo n ing,
Remo al and In alla ion).

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Published: 11-May-2011
Dri eshaft - Front Dri eshaftV6 4.0L Petrol
Removal and Installation

Remo al

C AUTION: It is possible to fit the driveshaft incorrectly. Note the orientation before removal.

NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect
the operation or durabilty of the joint.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

3. Remove the exhaust system.
For additional information, refer to: Exhaust System (309-
00A Exhaust System - V6 4.0L Petrol, Removal and
Installation).
4. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the transfer case drive

flange.

Remove the 6 Torx bolts and washers, discard the

bolts.

5. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the front axle drive flange.

Remove the 6 Torx bolts and washers, discard the

bolts.

6. Remove the front driveshaft.

C ompress the joints to disengage the drive flanges.

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In alla ion
1. NOTE: A mall amo n of oil ma eep f om he d i e haf
join d ing o age. The lo of hi oil ill no affec he
ope a ion o d abil of he join .

In all he d i e haf .

C lean he componen .

C omp e he join o engage he d i e flange .

2. A ach he d i e haf o he f on a le d i e flange.

Tigh en he ne To bol o 45 Nm (33 lb.f ), hen a

f he 90 deg ee .

3. A ach he d i e haf o he an fe ca e d i e flange.

Tigh en he ne To bol o 45 Nm (33 lb.f ), hen a

f he 90 deg ee .

4. In all he e ha em.
Fo addi ional info ma ion, efe o: E ha S em (309-
00A E ha S em - V6 4.0L Pe ol, Remo al and
In alla ion).
5. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Published: 11-May-2011
Dri eshaft - Front Dri eshaftTDV6 2.7L Diesel
Removal and Installation

Remo al

C AUTION: It is possible to fit the driveshaft incorrectly. Note the orientation before removal.

NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect
the operation or durabilty of the joint.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

3. Remove the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Body Panels, Removal and Installation).
4. Remove the crossmember.
For additional information, refer to: Transmission Support
C rossmember (502-02 Full Frame and Body Mounting,
Removal and Installation).
5. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the transfer case drive

flange.

Remove the 6 Torx bolts and washers, discard the

bolts.

6. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the front axle drive flange.

Remove the 6 Torx bolts and washers, discard the

bolts.

7. Remove the front driveshaft.

C ompress the joints to disengage the drive flanges.

Remove the washer from the transfer case drive

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flange.

In alla ion
1. NOTE: A mall amo n of oil ma eep f om he d i e haf
join d ing o age. The lo of hi oil ill no affec he
ope a ion o d abil of he join .

In all he d i e haf .

C lean he componen .

In all he a he .

C omp e he join o engage he d i e flange .

2. A ach he d i e haf o he f on a le d i e flange.

Tigh en he ne To bol o 45 Nm (33 lb.f ), hen a

f he 90 deg ee .

3. A ach he d i e haf o he an fe ca e d i e flange.

Tigh en he ne To bol o 45 Nm (33 lb.f ), hen a

f he 90 deg ee .

4. In all he an mi ion c o membe .

Fo addi ional info ma ion, efe o: T an mi ion S ppo
C o membe (502-02 F ll F ame and Bod Mo n ing,
Remo al and In alla ion).
5. In all he engine nde hield.
Fo addi ional info ma ion, efe o: Engine Unde hield
(501-02 F on End Bod Panel , Remo al and In alla ion).
6. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Published: 11-May-2011
Dri eshaft - Rear Dri eshaft
Removal and Installation

Remo al
NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect
the operation or durability of the joint.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the fuel tank heat shield.

Remove the 3 bolts and 2 nuts.

3. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the transfer case drive

flange.

Remove the 6 Torx bolts and washers.

4. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

the driveshaft to hang.

Release the driveshaft from the rear axle drive flange.

Remove and discard the 4 Torx bolts.

5. With assistance, remove the driveshaft.

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Remo e he 2 d i e haf cen e bea ing mo n bol .

In alla ion
1. NOTE: A mall amo n of oil ma eep f om he d i e haf
join d ing o age. The lo of hi oil ill no affec he
ope a ion o d abili of he join .

A ach he d i e haf o he ea a le d i e flange.

C lean he componen ma ing face .

A ach he d i e haf o he ea a le d i e flange.

Tigh en he ne To bol o 150 Nm (110 lb.f ).

2. NOTE: A mall amo n of oil ma eep f om he d i e haf

join d ing o age. The lo of hi oil ill no affec he
ope a ion o d abili of he join .

A ach he d i e haf o he an fe ca e d i e flange.

C lean he componen ma ing face .

Tigh en he To bol o 73 Nm (54 lb.f ).

3. C AUTIONS:

Align he d i e haf cen e bea ing mo n b mo ing he

floa ing f on ec ion of he haf back a d o fo a d n il
he bol hole in he mo n align i h he hole in he cha i .

Make e he cen e bea ing mo n i no nde

en ion.

In all he d i e haf cen e bea ing mo n bol .

Align he cen e bea ing mo n .

Tigh en he d i e haf cen e bea ing e aining bol o

30 Nm (22 lb.f ).

4. In all he f el ank hea hield.

Tigh en he bol o 6 Nm (4 lb.f ).

Tigh en he n o 3 Nm (2 lb.f ).

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P b i hed: 11-Ma -2011

Rea D i e A e/Diffe e ia -
Sea e
I e La d R e Pa N .
I haf f a ge STC 50553
I haf i e STC 50554
Diffe e ia (ETM) i c i g STC 50550
L b ica
I e S ecifica i
* Rec e ded b ica :
'O e ' i Ca SAF-XO - 75W/90
E ec ic e a aged (ETM) i Ca SAF C a b M dP
*D e a b ica he ha ha ecified
Ca aci ie
U i Ca aci
'O e ' diffe e ia 1.1 i e (2.3 US i ) (1.16 US a )
E ec ic e a aged (ETM) diffe e ia 1.5 i e (3.17 US i ) (1.6 US a )
Rea 'O e ' Dif f e e ia
I e S ecifica i
Red c i a i :
V6 Die e e gi e - Ma a a i i 3.07:1
V6 Die e e gi e - A a ic a i i 3.54:1
V6 Pe e gi e - A a ic a i i 3.73:1
V8 Pe e gi e - A a ic a i i 3.54:1
Rea E ec ic T e Ma aged (ETM) Dif f e e ia
I e S ecifica i
E ec ic ea aged U 2500 N (98.5 bf/f )
(ETM) a ge
E ec ic e a aged O e a e he ba / a echa i a d e c ch. M i c ae a e e a e
(ETM) e a di c ed b a EC U
Diffe e ia e 4 i
Red c i a i :
V6 Die e e gi e - Ma a 3.07:1
a i i
V6 Die e e gi e - A a ic 3.54:1
a i i
V6 Pe e gi e - A a ic 3.73:1
a i i
V8 Pe e gi e - A a ic 3.54:1
a i i
T e S ecif ica i
De c i i N b-f
Oi d ai g, i h He ag a d i e g 54 40
Oi d ai g, i h 3/8'' a e d i e g 28 21
Oi fi e g 34 25
Oi e e a e e 22 16
++ Diffe e ia c i g 10 7
Diffe e ia f i gb 275 203
Diffe e ia ea i gb 175 129
* D i e haf ea a e d i e f a ge T b 150 110
L e a hee c e 275 203
T e i b 175 129
S abi i e ba i 115 85
**+ Ha f haf e ai i g 350 258
F e a hea hie d a db 10 7
R ad hee 140 103
* Ne ''Pa ch 'T b be i a ed

** Ne be i a ed
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+ Stake nut on completion of tightening operation

++ Appl sealant, Part No. STC 50550 to flange of locking motor

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Published: 01-Nov-2011
Rear Drive A le/Differential - Rear Drive A le and Differential
Description and Operation

GENERAL

I em Pa N mbe De c ip ion
A - Electronic rear differential
B - Open rear differential
1 - Rear driveshaft
2 - Electronic rear differential
3 - RH rear drive halfshaft
4 - Actuator (locking) motor assembl
5 - LH rear drive halfshaft
6 - Rear differential
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The open rear differential converts the 'angle of drive' through 90 and distributes drive, via the rear drive halfshafts,
to the rear wheels.

The open rear differential for the V6 and V8 petrol variants has the same output ratio, but the output ratios for the
TdV6 diesel are different, depending on whether automatic or manual transmission is fitted.

The open rear differential is located centrally in the rear of the chassis.

The units are mounted to the chassis via rubber bushes and bolts; two mounting points at the rear of the unit and one
at the front.

OPEN REAR DIFFERENTIAL ASSEMBL

Open Rear Differential - Exploded View

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I em Pa N mbe De c ip ion
1 - Ca
2 - Seal

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3 - Bea i g a e b , i h ace
4 - Bea i g e- ad ace
5 - Bea i g
6 - R e bea i g c
7 - C e
8 - Sea
9 - Diffe e ia ca ie
10 - Gea a d i i a e b
11 - Bea i g
12 - R e bea i g c
13 - Shi
14 - C a ib e ace
15 - Pi i
16 - Re ai e
17 - F a ge
18 - O e def ec
19 - I e def ec
20 - Oi ea
21 - Bea i g
22 - R e bea i g c
23 - R i
24 - B ea he ca
25 - B ea he
26 - Ca e
27 - Da a ca i
28 - M i gb h
29 - Bea i g
30 - Bea i g e- ad ace
31 - R e bea i g c
32 - P g
33 - D ai g
34 - Th a he
35 - P a e gea
36 - C i haf
37 - S hee
38 - Th a he
39 - B , 10 f
40 - B , 12 f
The ca i ca i g c i e a ; a c e a d a ca ie . The ca ie ide ca i f a he i e a
c e . The ca ie i ea ed he c e ia a O- i g ea a d ec ed i h e e b . The c e a d
ca ie ha e ca fi , hich a i bi i . A b ea he be i fi ed he f he ca ie . Thi a a a ic
be be fi ed a d ed a high i de he ehic e b d , e e i g he i g e f ae he he ehic e
i adi g.

The ca ie c ai a i d ai g. The diffe e ia i c ai a i a e 1.16 i e f i f ad fi . If i

i bei g e aced, a a e a i f i i be e i ed d e e id a i e ai ed i he i i h i g.

The diffe e ia i a c e i a de ig i gah id gea a , i ia he f diffe e ia . The e ea

diffe e ia i a ai ab e i h ee a i . V8 e e gi e ehic e e a diffe e ia i h a fi a d i e a i f 3.73:1, V6
e e gi e ehic e e a diffe e ia i h a fi a d i e a i f 3.73:1 a d TdV6 e gi e ehic e e a fi a d i e
ai f 3.54, f ehic e iha a ic a i i a d 3.07 f ehic e ih a a a i i . C ha gi g he
be f ee h be ee he c hee d i e gea a d i i gea cha ge he a i .

The diffe e ia c i e a i i haf a d h id i i gea a d a c hee d i e gea i h a i eg a cage,

hich h e a e gea . T hee a e a ca ed i he cage a d a he ai a d i e he d i e
haf .

The i i haf i ed ed a e e bea i g , i h a c a ab e ace ca ed be ee he .

The ace i ed h d he bea i g i a ig e a da c a e de he e e a ied he i i
f a ged . Thi a he f a ged be igh e ed a ede e i ed e, hich c a e he ace , e i g
he c ec bea i g e ad.

The i i haf ha a e e a i ed e e d, hich acce a d ca e he i f a ge, hich i e ai ed b

he i i a d e ai e . The i f a ge ha f h eaded h e a d a e i h he ea d i e haf . F b
ec e he ea d i e haf he i f a ge. A i ea i e ed i he i i h i g a d ea he i f a ge

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to the pinion housing. The pinion shaft has a hypoid gear at its inner end, which mates with the crown wheel drive
gear.

The crown wheel drive gear is located on the differential case and secured with ten screws. The differential case is
mounted on taper roller bearings located in machined bores on each side of the pinion housing. Shims are retained in
the casing behind the bearing cups, the shim thickness is selected to apply the correct bearing preload and hypoid
backlash.

The differential carrier has a through hole, which provides location for the shaft. The shaft is supported by a sun gear
and a needle roller bearing. The shaft is fitted with a snap ring at one end, which locates in a machined groove in the
sun gear, locking the shaft in position.

The sun gears are located in pockets in the carrier cage and mesh with the planet gears. Spacers are fitted between
the sun wheels and the carrier and set the correct mesh contact between the planet gears and the sun wheels. Each
sun wheel has a machined bore with internal splines and machined groove near the splined end. The groove provides
positive location for a snap ring fitted to the end of each output flange.

Each output shaft has a spline, which locates in each sun wheel. A snap ring fitted to the splined shaft locates in the
groove the sun wheel bore and positively located the output shaft. Oil seals are pressed into each side of the pinion
housing and seal the seal the output shaft.

Differential Operation

The operating principles of the front and rear differentials are the same. Rotational input from the drive shaft is
passed via the input flange to the pinion shaft and pinion gear. The angles of the pinion gear to the crown wheel drive
gear moves the rotational direction through 90 .

The transferred rotational motion is now passed to the crown wheel drive gear, which in turn rotates the differential
casing. The shaft, which is secured to the casing, also rotates at the same speed as the casing. The planet gears,
which are mounted on the shaft, also rotate with the casing. In turn, the planet gears transfer their rotational motion
to the left and right hand sun wheels, rotating the drive halfshafts.

When the vehicle is moving in a forward direction, the torque applied through the differential to each sun wheel is
equal. In this condition both drive halfshafts rotate at the same speed. The planet gears do not rotate and effectively
lock the sun wheels to the differential casing.

If the vehicle is turning, the outer wheel will be forced to rotate faster than the inner wheel by having a greater
distance to travel. The differential senses the torque difference between the sun wheels. The planet gears rotate on
their axes to allow the outer wheel to rotate faster than the inner one.

SERVICE

The oil used in the open rear differential is C astrol SAF-XO. The oil contains unique additives, which enhance the
differentials operation. No other oil must be used in the open rear differential.

Open Rear Differential Ser iceable Components

Needle roller bearing assemblies

Halfshaft seals
C hassis bush/fixings
Lubricant.

ELECTRONIC REAR DIFFERENTIAL ASSEMBLY

Electronic Rear Differential - Exploded View

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I em Pa N mbe De c ip ion
1 - C ap
2 - O ing

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3 - Bea i g e- ad ace
4 - Bea i g
5 - Bea i g c
6 - B ,4 f
7 - H i ga d a e b
8 - Da e
9 - Gea a d i i a e b
10 - Bea i g
11 - Bea i g c
12 - Shi
13 - C a ib e ace
14 - Pi i
15 - Re ai e
16 - F a ge
17 - Def ec , e
18 - Def ec , i e
19 - Sea
20 - Bea i g
21 - Bea i g c
22 - B ea he ca
23 - B ea he
24 - Ca e
25 - Da a ca i
26 - M i gb h
27 - Bea i g
28 - Bea i g a e b ih ace
29 - Bea i g c
30 - Fi e g
31 - D ai g
32 - E ec ic diffe e ia a e b
33 - B , 10 f
34 - O i g
35 - C e
36 - B , 12 f
37 - Te e a e e
The e ec ic ea diffe e ia ha he a e f c i a i a he e ea diffe e ia b i c ae a c i g
fea e.

A e ec ica c ed i- a e c ch ide a ea diffe e ia c a d e bia i g f ci gi e

i ed ac i e f a ce a d ehic e d a ic abi i .

A a eg , e ec ica c he ea diffe e ia i- a e c ch a e b , ha bee de e ed ide:

a e- adi g f c i , i c ea i g c i g e i h i c ea ed d i i g e
a i c e i c ea e c i g e de ff- ad c di i a d dec ea e c i g e f i
c f , e.g. a i g.

The i ecei e a e i f he a fe b haf , hich i a ed h gh he i

f he ea d i e ha f haf .

The i de ec hee i ia a i ehic e e i he e ec ic ea diffe e ia c d e a d

c he diffe e ia acc di g .

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I em Pa N mbe De c ip ion
1 - Actuator
2 - C lutch pack
3 - Differential
The electronic rear differential locking and biasing feature is actuated via a DC motor, which is controlled b the
electronic rear differential control module, via a Pulse Width Modulation (PWM) signal.

Multi-plate Clutch Assembl

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I em Pa N mbe De c ip ion
1 - P e e di c
2 - C ch a e a e b
3 - P e e di c
4 - Th ace
5 - O ac a
6 - Ac a ba
7 - I ac a
8 - Bea i g e- ad ace
9 - Red c i gea e
10 - Ac a
The i- a e c ch a e b f b h ce e ( a fe b ) a d e ec ic ea diffe e ia ac i a i i a a .
The ai f he i- a e c ch a e b i e e e ce i e diffe e ia i a d he ef e a i i e he ac i
e f a ce f he ehic e. Thi i f da e a diffe e f he 'b a ed' ac i c , hich ca c e
ac diffe e ia i he i cc .

A ce ai a f diffe e ia i i e i ed a he ehic e c e a d e ai ab e de c
f he A i- c B a i g S e (ABS). The a fe b c d e i he d i e ' de a d h gh
i a ehic e c a da a ica e he i e a he ea diffe e ia ia he e ec ic ea
diffe e ia c d e. The e i c e e a a ic a d d e e i e a ecia d i e i .

The i- a e c ch a e b ac i e c he e f h gh he ea diffe e ia a d i i e he e
di ib i i he d i e i e. The c ch a e b bia e he e f he diffe e ia he hee i h he highe
g i a d e e he hee i h he e g i f i i g.

B i g he i ac a di c, ia he haf , he ac a i a ed. Thi e e ac 5 ba

i a a echa i be ee he i a d ac a a d gi e a defi ed a ia e e . The e e
f ce he e e di c i d ce f ic i be ee he gea a d diffe e ia ca e ia he c ch a e ed
b he gea a d he a e ed b he c ch ba e he diffe e ia ca e. Thi f ic i a f ce i hibi he
diffe e ia ai ; he diffe e ia ca e a d ef ha d diffe e ia ide gea a e c ed ge he .

Elec ronic Rear Differen ial Con rol Mod le

The e ec ic ea diffe e ia c d e c he i- a e c ch ac ai . The c d e i ed

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a b ac e ca ed he LH C - i a , behi d he i .

I em PaN mbe De c ip ion

1 - E ec ic ea diffe e ia c d e
The c d e i c ec ed he C e A ea Ne (C AN) b a dc he diffe e ia e ai
i g C AN e age f he c d e he e .

The c d e e h ee c ec f a i a d .I ecei e a e a e e ia a 40A

f ib e i ca ed i he Ba e J c i B (BJB), a d a ig i i ia f e 24 ca ed i he C e a J ci
B (C JB).

The c d e e i e he ii f he e ec ic ea diffe e ia he he ig i i i i ched ff.

The c d e c he c ed ii e i g e i hi he a d eg a e he e
he .

If he c d e i e aced, T4 be c ec ed he ehic e a d he e ec ic ea diffe e ia c

d e e f-ca ib a i ced e be e f ed. Thi ced e a be e f ed if he
diffe e ia a e b i e aced.

If a fa cc i h he e ec ic ea diffe e ia , he c d e e f he e i ed i ig a , i.e. ad
eed ig a , he c d e ec d a e c de a d a a i g a ,i he i e c e ,i i ae
e a e .

Elec onic Rea Diffe en ial Con ol Mod le Pin O De ail

Connec o C2162
Pin No. De c ip ion Inp /o p
1 N ed -
2 C AN b I /
3 C AN b high I /
4 N ed -
5 C AN b high I /
6 C AN b I /
Connec o C2163

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Pin No. De c ip ion Inp /o p
1 N ed -
2 N ed -
3 G d -
4 Ig i i feed I
5 N ed -
6 G d -
7 Ba e feed I
8 Ba e feed I
Connector C2164
Pin No. De c ip ion Inp /o p
1 + e f ac a Ha e I
2 N ed -
3 Ac a O
4 Ha e - Sig a A I
5 N ed -
6 N ed -
7 Ha e - Sig a B I
8 Diffe e ia i e e a e e I
9 N ed -
10 G d - Ha e -
11 Diffe e ia i e e a e e O
12 Ac a I
13 M e e a e e O
14 N ed -
15 N ed -
16 M e e a e e I
17 M b a e e id O
18 M b a e e id I
CAN Bus Messages

The C AN b i a high eed b adca e c ec ed be ee a i ehic e c d e .I a he fa

e cha ge f da a be ee c d e e e fe ic ec d . The b c i e i e , hich a e i ed
ge he i i i e e ec ag e ic i e fe e ce ( i e) d ced b he C AN e age .
F addi i a i f a i , efe :C ica i Ne (418-00 M d e C ica i Ne , De c i i
a d O e a i ).

The e ec ic ea diffe e ia c d e i c ec ed he C AN b , ia he a fe b c d e, a d
c diffe e ia e ai i g C AN e age f he c i he e . Whee eed, ee i g
a g e, a a ic a i i eed, e e a e i f a i , ca c fig a i , a e a i a d de i ,a e
e f he ai ig a ecei ed b he c d e.

The c d e a e d e age ia he C AN b e he c d e he e , he a f
he e ec ic ea diffe e ia . The c ch e a d defa de a a e e f he ai ig a e b
he c d e.

The f i g ab e h he e age ha ca be di a ed i he e age ce e f a high- i e i e c e

eai g he e ec ic ea diffe e ia :

Me age De c ip ion Chime

'TRANSMISSION Rea diffe e ia e e a e ha eached i a achi g he e hea h e h d. N e
OVERHEAT'
'SLOW DOWN'
'TRANSMISSION T a fe b c d e ha ed a i i g C AN b e age . Defa N e
FAULT' e ce e diffe e ia .
'TRAC TION REDUC ED' Me age a di a ed he fa cc i h e ec ic ea diffe e ia .
'TRANSMISSION Fa ha cc ed i h e ec ic ea diffe e ia . S ehic e a ea ie i . Si g e
FAULT'
'STOP SAFELY'
O ehic e fi ed i h he i e i e c e ,i ace f he e age ce e he e i be a a a ,
hich ha he f i g gic:

A be - O e e e a e
Red - Fai e, ehic e

TERRAIN RESPONSE
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The Terrain Response system allows the driver to select a program, which will provide the optimum settings for
traction and performance for the prevailing terrain conditions.

The system is controlled by a rotary control located on the centre console.

The system uses a combination of vehicle subsystems to achieve the required vehicle characteristics for the terrain
selected. The following subsystems form the Terrain Response system:

Engine management system

Automatic transmission (if fitted)
Transfer box
Brake system
Air suspension.

Each subsystem control module provides a feedback for the selected program so that the Terrain Response control
module can check that all systems are controlling the system correctly. The exception to this is the electronic rear
differential control module which does not provide feedback to the Terrain Response system as it is a slave to the
transfer box control module.
For additional information, refer to: Ride and Handling Optimization (204-06 Ride and Handling Optimization,
Description and Operation).

SERVICE

The oil used in the electronic rear differential is C astrol SAF-C arbon Mod Plus. The oil contains unique additives and
friction modifiers, which enhance the differentials operation. No other oil must be used in the electronic rear
differential.

Electronic Rear Differential Ser iceable Components

Halfshaft seals
Needle roller bearing assembly
C hassis bush/fixings
Actuator motor
Temperature sensor
C ontrol module and bracket
Lubricant.

DIAGNOSTICS

The electronic rear differential control module can store fault codes, which can be retrieved using T4 or a diagnostic
tool using ISO-14229 protocol.

The information is communicated via a diagnostic socket.

The diagnostic socket allows the exchange of information between the various control modules on the bus systems
and T4 or another suitable diagnostic tool. The information is communicated to the socket via the C AN bus. This
allows the retrieval of diagnostic information and programming of certain functions using T4 or another suitable
diagnostic tool.

The electronic rear differential control module uses Diagnostic Trouble C odes (DTC ), which relate to electronic rear
differential electrical faults.

ELECTRONIC REAR DIFFERENTIAL CONTROL DIAGRAM

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NOTE: A = Hardwired

I em Pa N mbe De c ip ion
1 - Ignition switch
2 - Fusible link (battery)
3 - Actuator motor
4 - Oil temperature sensor
5 - Electronic rear differential control module
6 - Fuse (ignition)

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P b i hed: 11-Ma -2011

Rea D i e A le/Diffe en ial - Rea D i e A le and Diffe en ial
Diag i a d Te i g

P inciple of Ope a ion

F addi i a i f ai , efe ec i 205-02 - Rea D i e A e/Diffe e ia f he h a a.

In pec ion and Ve ifica ion

1. 1. Ve if he c e c ce .

2. 2. C fi hich, if a , a i g igh a d/ e age e e di a ed he i e c e .F a i f

e age , efe he e e a ec i f he h a a.

3. 3. Vi a i ec f b i echa ica e ec ica fa .

Vi al in pec ion
Mechanical Elec ical
Diffe e ia i ea age e
Se i a ai F e( )
Wi i g ha e h ica da age ae i g e
L e c ded e ec ica c ec
C e a ea e (C AN) ci c i
Se
Rea diffe e ia c d e

4. 4. If a b i ca e f a b e ed e ed c ce i f d, c ec he ca e (if ib e) bef e
ceedi g he e e .

5. 5. U e he a ed diag ic e a ca e ie e a diag ic b e c de (DTC ) bef e

i g he cha DTC i de .

Ma e e ha a DTC a e c ea ed f i g ec ifica i .

S mp om Cha

Po ible Po ible o he
S mp om me age a ning Po ible ca e Ac ion
R i ga Rea D i ei e e hea Wa e Vi a i ec he i i g ha e
ed ced diffe e ia a i g a i g e a dc ec f ae i g e .
ca abi i ih fa i i a ed i i g Refe he a a ic a d
fa e e Rea ha e ced e a a if a d e i
diffe e ia /d i e i e c ec ec .
fa a i g a Red ced
i i a ed diffe e ia
ca abi i
Diffe e ia
i c ea ed
e a ce
I e a
fa
Rea
diffe e ia
c
d e fa
(Rea
diffe e ia
c
d e)

Rea Rea D i ei e e hea Oi e e C hec f c ec i a i a d

diffe e ia diffe e ia a i g a i c ec ecifica i . Refe he e e a
e hea O e hea i i a ed Oi e e ec i f he h a a.
S i c ec
D ecifica i
Se fa
I e a
fa
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DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: Intermittent faults may cause DTC s to be logged, however some DTC s may be cleared during an ignition off,
ignition on cycle. C arry out a road test (if safe to do so), check the functionality of the system and retrieve any DTC s
before turning the ignition off.

DTC Description Possible causes Action

P0562- System Voltage Rear differential C heck the power charge condition, refer to the electrical
00 Low - no sub type control module guides and check the differential actuator sensor circuit,
information voltage supply repair as necessary
below 9V

P0563- System Voltage Rear differential C heck the charging circuit and power condition
00 High - no sub type control module
information voltage supply
below 16V

P0604- Internal C ontrol Rear differential C lear the DTC and retest. If the problem persists, renew the
00 Module Random control module control module. Refer to the warranty policy and procedures
Access Memory internal error manual if a module is suspect
(RAM) Error - no
sub type
information
P0605- Internal C ontrol Rear differential C lear the DTC and retest. If the problem persists, renew the
00 Module Read Only control module control module. Refer to the warranty policy and procedures
Memory (ROM) internal error manual if a module is suspect
Error - no sub type
information
P0606- C ontrol Module Watchdog reset This is a control module internal check DTC and is not
00 Processor - no sub necessarily a fault. If no other DTC s are logged and no
type information customer complaint exists, clear/ignore this DTC
P0607- C ontrol Module Rear differential C lear the DTC and retest. If the problem persists, renew the
00 Performance - no control module control module. Refer to the warranty policy and procedures
sub type internal error manual if a module is suspect
information
P0652- Sensor Reference Actuator internal Refer to the electrical guides and check the differential
00 Voltage 'B' C ircuit position sensor actuator sensor position circuit, repair as necessary. If no
Low - no sub type supply voltage circuit problems exist, renew the differential actuator
information below 57V

P0653- Sensor Reference Actuator internal Refer to the electrical guides and check the differential
00 Voltage 'B' C ircuit position sensor actuator sensor position circuit, repair as necessary. If no
High - no sub type supply voltage circuit problems exist, renew the differential actuator
information below 83V

P0666- PC M/EC M/TC M Rear differential This is a control module internal check DTC and is not
00 Internal control module necessarily a fault. If no other DTC s are logged and no
Temperature internal customer complaint exists, clear this DTC and retest. If the
Sensor 'A' C ircuit - temperature sensor problem persists, renew the control module. Refer to the
no sub type value above 105°C warranty policy and procedures manual if a module is suspect
information
P0712- Transmission Fluid Differential actuator Refer to the electrical guides and check the differential
00 Temperature internal actuator sensor circuit, repair as necessary. If no circuit
Sensor 'A' C ircuit temperature sensor problems exist, renew the differential actuator
Low - no sub type open circuit or
information short circuit to
ground

P0713- Transmission Fluid Differential actuator Refer to the electrical guides and check the differential
00 Temperature internal actuator sensor circuit, repair as necessary. If no circuit
Sensor 'A' C ircuit temperature sensor problems exist, renew the differential actuator
High - no sub type open circuit or
information short circuit to
power

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P0806- C lutch Position Mismatch of actual C alibrate the clutch and range change mechanism using the
00 Sensor C ircuit and approved diagnostic system or by the procedure listed in the
Range/Performance expected/calculated description and operation. Refer to the relevant section of the
- no sub type actuator position workshop manual. C lear the DTC and retest. If the problem
information - Internal persists, renew the differential actuator
differential
actuator error

P0807- C lutch Position Differential actuator Refer to the electrical guides and check the differential
00 Sensor C ircuit Low internal position actuator circuit, repair as necessary. If no circuit problems
- no sub type sensor supply, exist, renew the differential actuator
information ground, signal 1 or
2 open circuit or
sensor supply,
signal 1 or 2 short
circuit to ground

P0808- C lutch Position Differential actuator Refer to the electrical guides and check the differential
00 Sensor C ircuit High internal position actuator circuit, repair as necessary. If no circuit problems
- no sub type sensor signal 1 or 2 exist, renew the differential actuator
information short circuit to
power

P080A- C lutch Position Not Rear differential Using the approved diagnostic equipment, calibrate the rear
00 Learned - no sub control module differential control module. C lear the DTC and retest. If the
type information (RDC M) not problem persists, renew the rear differential assembly. Refer
calibrated to the warranty policy and procedures manual if a differential
Differential clutch is suspect
stuck or out of
tolerance

P0810- C lutch Position This DTC is for If DTC P186D-00 is also logged in the rear differential control
92 C ontrol Error - information only module, refer to repair actions as necessary. If DTC P186D-
performance or 00 is not logged no repair action is necessar .
incorrect operation
P0894- Transmission Differential actuator Renew the differential actuator
00 C omponent internal magnetic
Slipping - no sub brake is slipping
type information
P0900- C lutch Actuator Differential actuator Refer to the electrical guides and check the differential
00 C ircuit/Open - no supply open circuit actuator circuit, repair as necessary
sub type
information
P0901- C lutch Actuator Differential actuator Refer to the electrical guides and check the differential
00 C ircuit supply short circuit actuator circuit, repair as necessary
Range/Performance
- no sub type
information
P0902- C lutch Actuator Differential actuator Refer to the electrical guides and check the differential
00 C ircuit Low - no sub supply circuit short actuator circuit, repair as necessary
type information to ground.

P0903- C lutch Actuator Differential actuator Refer to the electrical guides and check the differential
00 C ircuit High - no supply circuit short actuator circuit, repair as necessary
sub type to power
information
P1603- EEPROM Rear differential C lear the DTC and retest. If the problem persists, renew the
00 Malfunction - no control module control module. Refer to the warranty policy and procedures
sub type internal error manual if a module is suspect
information
P1783- Transmission Over- Rear Differential oil C onfirm the customer complaint and vehicle usage at the time
00 Temperature sump temperature of DTC event. C heck the operation of the rear differential.
C ondition - no sub sensor value above C heck the rear differential oil quantity and specification. Refer
type information 150 C to the relevant section of the workshop manual. C lear the
DTC and retest. If the problem persists, renew the rear
differential assembly. Refer to the warranty policy and
procedures manual if a differential is suspect
P186A- Differential Lock-Up Open circuit of Refer to the electrical guides and check the differential
00 Actuator Brake actuator internal actuator circuit, repair as necessary. If no circuit problems

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C ontrol magnetic brake exist, renew the differential actuator
C ircuit/Open - no supply leads
sub type
information
P186B- Differential Lock-Up Short circuit to Refer to the electrical guides and check the differential
00 Actuator Brake ground of both actuator circuit, repair as necessary. If no circuit problems
C ontrol C ircuit Low differential actuator exist, renew the differential actuator
- no sub type internal magnetic
information brake pins

P186C - Differential Lock-Up Short circuit to Refer to the electrical guides and check the differential
00 Actuator Brake power of both actuator circuit, repair as necessary. If no circuit problems
C ontrol C ircuit High differential actuator exist, renew the differential actuator
- no sub type internal magnetic
information brake pins

P186D- C lutch Actuator Actuator fault Using the approved diagnostic equipment, calibrate the rear
00 Stuck - no sub type differential control module/clutch actuator. C lear the DTC and
information retest. If the problem persists, renew the actuator
P2742- Transmission Fluid Rear differential oil Refer to the electrical guides and check the differential oil
00 Temperature sump temperature temperature sensor circuit, repair as necessary
Sensor 'B' C ircuit sensor short circuit
Low - no sub type to ground
information
P2743- Transmission Fluid Rear differential oil Refer to the electrical guides and check the differential oil
00 Temperature sump temperature temperature sensor circuit, repair as necessary
Sensor 'B' C ircuit sensor open circuit
High - no sub type or short circuit to
information power

P2785- C lutch Actuator Actuator internal C onfirm the customer complaint and vehicle usage at the time
00 Temperature Too temperature sensor of DTC event. C heck the operation of the rear differential.
High - no sub type value above 150 C C heck the rear differential oil quantity and specification. Refer
information - Extensive to the relevant section of the workshop manual. C lear the
prolonged off- DTC and retest. If the problem persists, renew the rear
road use differential assembly. Refer to the warranty policy and
- Insufficient oil procedures manual if a differential is suspect
quantity
- Incorrect oil
specification
- Internal
differential
problem

P2787- C lutch Temperature Rear differential C onfirm the customer complaint and vehicle usage at the time
00 Too High - no sub clutch pack of DTC event. C heck the operation of the rear differential.
type information temperature C heck the rear differential oil quantity and specification. Refer
(calculated) aboveto the relevant section of the workshop manual. C lear the
200 C DTC and retest. If the problem persists, renew the rear
differential assembly. Refer to the warranty policy and
procedures manual if a differential is suspect
U0001- High Speed C AN High speed C AN Refer to the Network C ommunications section of the
88 C ommunication Bus communication Bus workshop manual
- bus off (C AN Bus Off)

U0102- Lost Lost communication Refer to the bus off statement within workshop manual
87 C ommunication with TC C M section 418-00. Refer to the Network C ommunications section
With Transfer C ase of the workshop manual
C ontrol Module -
missing message
U0122- Lost Lost communication Refer to the bus off statement within workshop manual
87 C ommunication with VDM section 418-00. Refer to the Network C ommunications section
With Vehicle of the workshop manual
Dynamics C ontrol
Module - missing
message
U0300- Internal C ontrol Rear differential C onfigure the module using the approved diagnostic system
55 Module Software control module not
Incompatibility - configured
not configured
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U1A14- C AN Initiali ation Rear differential C onfigure the module using the approved diagnostic s stem.
49 Failure - internal control module C lear the DTC and retest. If the problem persists, renew the
electronic failure supervision control module. Refer to the warrant polic and procedures
software failure manual if a module is suspect
Internal control
module failure

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Published: 11-May-2011
Rear Drive A le/Differential - Differential Draining and Filling
General Procedures

C AUTION: Do not fill the differential with lubricant up to the filler plug. The filler plug is only used to fill the
differential with lubricant, and not to act as a level indicator.

NOTE: The only way to check the fluid level in the differential is to drain all the fluid out and refill with the correct
quantity, shown in the specification section.
For additional information, refer to: Specifications (205-02 Rear Drive Axle/Differential, Specifications).

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. C AUTION: Do not undo or remove the large

protruding hexagon on the differential casing.

Remove the differential case lubricant filler plug.

C lean the area around the lubricant filler plug.

Position container to collect fluid loss.

3. Drain the differential lubricant.

C lean the area around the drain plug.

Remove the fluid drain plug.

4. C AUTION: There has been 2 different types of fixings

used for the drain plug. Note the type and make sure the
correct torque is applied, see below.

Install the lubricant drain plug.

C lean the drain plug.

Up to differential serial number 254325: Tighten the

hexagonal drive drain plug to 54 Nm (40 lb.ft).

From differential serial number 254326: Tighten the

3/8'' square drive drain plug to 28 Nm (21 lb.ft).

5. C AUTIONS:

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The e ha e bee 2 diffe e e f fi i g ed f he

d ai g. N e he e a d diffe e ia e ia be , a d
a e e he c ec e i a ied, ee be .

Ma e e he c ec ecifica i a d a i f i i
ed.

Fi he diffe e ia i h he c ec a f b ica .
F addi i a i f a i , efe : S ecifica i (205-02
Rea D i e A e/Diffe e ia , S ecifica i ).
.I a he diffe e ia fi e g.

C ea he fi e g.

Tigh e he fi e g 34 N (25 b.f ).

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Rear Drive A le/Differential - Differential Locking Motor
In-vehicle Repair

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the differential locking motor.

Disconnect the electrical connector.

Remove the 4 bolts.

Installation
1. C lean the component mating faces.
2. Appl continuous bead of sealant to the motor mating
face on the differential.

3. Install the differential locking motor.

Tighten the bolts to 10 Nm (7 lb.ft).

C onnect the electrical connector.

4. Lower the vehicle.

5. C alibrate the differential locking motor using the diagnostic
tool.

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P bli hed: 11-Ma -2011

Rear Drive A le/Differential - Rear A le Oil Temperature Sensor
In- ehicle Repai

Removal

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. D ain he diffe en ial l b ican .
Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-02 Rea D i e A le/Diffe en ial, Gene al
P oced e ).
3. Di connec he elec ical connec o .

Relea e he i ing ha ne e aining clip.

4. Remo e he oil empe a e en o .

Remo e and di ca d he O- ing eal.

Installation
1. C lean he componen ma ing face .
2. In all he oil empe a e en o .

Tigh en o 22 Nm (16 lb.f ).

3. C onnec he elec ical connec o .

Sec e he i ing ha ne clip.

4. Fill he diffe en ial i h he co ec amo n of l b ican .

Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-02 Rea D i e A le/Diffe en ial, Gene al
P oced e ).

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Rear Drive A le/Differential - Drive Pinion Seal
In-vehicle Repair

Special Tool(s)
Flange holding tool

205-053

Adapter for

205-053

Impulse e tractor

100-012(LRT-99-004)

Installer drive pinion oil seal

205-821

Remover drive flange

205-824

Remover drive pinion seal

205-823

Seal installer, adaptor

205-821-01

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Remo al
C AUTIONS:

The input flange must not be change for one from another unit.

The drive pinion seal must only be renewed for 1 repair.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Drain the differential lubricant.
For additional information, refer to: Differential Draining and
Filling (205-02 Rear Drive Axle/Differential, General
Procedures).
3. Remove the fuel tank heat shield.

Remove the 3 bolts and 2 nuts.

4. C AUTION: Mark the position of the driveshaft flange

in relation to the drive pinion flange.

Release the driveshaft from the rear axle drive pinion

flange.

Remove and discard the 4 Torx bolts.

5. Measure the depth of the pinion nut on the pinion shaft.

Note measurement for installation.

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. C AUTION: This step must be carried out to make

sure that the drive pinion nut is correctl tightend on
assembl .

Accuratel scribe a line to mark the drive pinion shaft to

the drive pinion nut and pinion flange.

. Remove the drive pinion flange retaining nut.

Using the special tool, counter hold the drive pinion

flange.

Note number of turns for installation.

. Using the special tool, remove the drive pinion flange.

C heck flange seal journal for an damage.

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9. Using the special tool, remo e the dri e pinion seal.

In alla ion
1. C lean the dri e pinion flange.
2. C lean the dri e pinion seal mating faces.
3. Using the special tool, install the ne dri e pinion seal.

4. Remo e the special tool.

Install special tool 205-821-01 to the seal face.

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. C AUTION: Make e adap o i emo ed o

damage o he ehicle ma occ .

U ing he pecial ool, in all he ne d i e pinion eal.

Remo e he pecial ool .

. C AUTION: Make e he d i e pinion flange c ibed

ma k a e aligned.

In all he d i e pinion flange.

. C AUTIONS:

Make e he ma k on he d i e pinion n i ne e
igh ened ho of he c ibed ma k on he d i e pinion
haf .

Make e he d i e pinion flange ha no end floa

and i f ee o o a e.

Make e he c ibed ma k on he d i e pinion n i

no mo e han a ma im m of 5 deg ee pa he c ibed
ma k on he d i e pinion haf .

In all he d i e pinion flange e aining n .

U ing he pecial ool, co n e hold he d i e pinion

flange.

In all n o p e io l no ed n mbe of n .

Mea e he dep h of he pinion n on he pinion

haf .

. A ach he d i e haf o he ea a le d i e flange.

C lean he componen ma ing face .

A ach he d i e haf o he ea a le d i e flange.

Tigh en he ne To bol o 150 Nm (110 lb.f ).

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.I a he f e a hea hie d.

Tigh e he b a d 10 N (7 b.f ).

10. C AUTION: Ma e e he c ec ecifica i a d

a i f i i ed.

Fi he diffe e ia i h he c ec a f b ica .
F addi i a i f a i , efe : Diffe e ia D ai i g a d
Fi i g (205-02 Rea D i e A e/Diffe e ia , Ge e a
P ced e ).

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Rear Drive A le/Differential - Differential Locking Module
In-vehicle Repair

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the rear quarter trim panel.
For additional information, refer to: Rear Quarter Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
3. Release the parking aid module.

Remove the 2 nuts.

4. Remove the differential locking module.

Disconnect the 3 electrical connectors.

Remove the 3 bolts.

Installation
1. Install the differential locking module.

Install the bolts and tighten to 10 Nm (7 lb.ft).

C onnect and secure the electrical connectors.

2. Install the parking aid module.

Tighten the nuts to 10 Nm (7 lb.ft).

3. Install the rear quarter trim panel.

For additional information, refer to: Rear Quarter Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
4. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,

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Specifications).
. Use T4 to calibrate a ne differential locking module.

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P bli hed: 11-Ma -2011

Rear Drive A le/Differential - A le Assembl
Remo al and In alla ion

Removal

C AUTION: Do no loo en o emo e he la ge p o ding he agon on he diffe en ial ca ing.

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he ea heel and i e .
3. Remo e he m ffle a embl .
Fo addi ional info ma ion, efe o: M ffle (309-00A
E ha S em - V6 4.0L Pe ol, Remo al and In alla ion)
/
M ffle (309-00B E ha S em - V8 4.4L Pe ol, Remo al
and In alla ion) /
M ffle - Vehicle Wi ho : Die el Pa ic la e Fil e (DPF)
(309-00C E ha S em - TDV6 2.7L Die el, Remo al and
In alla ion).
4. D ain he diffe en ial fl id.
Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-02 Rea D i e A le/Diffe en ial, Gene al
P oced e ).
5. Remo e he RH ea half haf .
Fo addi ional info ma ion, efe o: Rea Half haf (205-05
Rea D i e Half haf , Remo al and In alla ion).

6. C AUTION: U e a ench on he he agon p o ided

o p e en he ball join o a ing.

Remo e he LH ea abili e ba link.

Remo e and di ca d he 2 n .

7. Relea e he pa king b ake cable f om he LH lo e a m.

8. Relea e he LH ea oe link.
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Remo e he bol .

. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

Relea e he LH ea heel kn ckle f om he lo e a m.

Remo e he bol .

U ing a i able and, ppo he LH ea heel

kn ckle.

10. NOTE: RH ill a ion ho n, LH i imila

Relea e he LH ea half haf f om he a le a embl .

Remo e and di ca d he nap ing.

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. C AUTION: Ma k he po i ion of he d i e haf

flange in ela ion o he d i e pinion flange.

Relea e he d i e haf f om he ea a le d i e flange.

Remo e and di ca d he 4 bol .

S ppo he d i e haf ing a i able ie ap.

. Vehicle i h diffe en ial locking mo o : Di connec he

2 elec ical connec o .

Relea e he 2 i ing ha ne clip .

. U ing a an mi ion jack, ppo he ea a le

a embl .

. C AUTION: Befo e di connec ing o emo ing he

componen , make e he a ea a o nd he join face and
connec ion a e clean. Pl g open connec ion o p e en
con amina ion.

Wi h a i ance, emo e he ea a le a embl .

Remo e he 3 bol .

Di connec he b ea he line.

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In alla ion
1. Wi h a i ance, in all he ea a le a embl .

Tigh en he f on mo n ing bol o 275 Nm (203 lb.f ).

Tigh en he ea mo n ing bol o 175 Nm (129 lb.f ).

C onnec he b ea he line.

2. Vehicle i h diffe en ial locking mo o : C onnec he

elec ical connec o .

Sec e he i ing ha ne clip .

3. NOTE: In all ne bol .

Sec e he d i e haf o he ea a le d i e flange.

C lean he componen ma ing face .

Tigh en he bol o 150 Nm (110 lb.f ).

4. In all a ne nap ing o he LH half haf .

5. NOTE: Do no f ll engage he half haf n il he oil eal
p o ec o ha been emo ed.

Sec e he LH half haf in he a le a embl .

1. Open he half haf eal p o ec o and in all he

half haf .

2. Relea e he half haf eal p o ec o f om he

half haf eal.

3. Remo e he half haf eal p o ec o .

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4. F ll in all he half haf .

5. Make e he nap ing i f ll engaged and

e ain he half haf .

. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e of
he join .

Sec e he LH ea heel kn ckle o he lo e a m.

Tigh en he n and bol o 275 Nm (203 lb.f ).

. Sec e he LH ea oe link.

Tigh en he bol o 175 Nm (129 lb.f ).

. Sec e he pa king b ake cable o he LH lo e a m.

. NOTE: In all ne n .

In all he LH ea abili e ba link.

Tigh en he n o 115 Nm (85 lb.f ).

10. In all he RH ea half haf .

Fo addi ional info ma ion, efe o: Rea Half haf (205-05
Rea D i e Half haf , Remo al and In alla ion).
11. Fill he diffe en ial i h fl id.
Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-02 Rea D i e A le/Diffe en ial, Gene al
P oced e ).
12. In all he m ffle a embl .
Fo addi ional info ma ion, efe o: M ffle (309-00A
E ha S em - V6 4.0L Pe ol, Remo al and In alla ion)
/
M ffle (309-00B E ha S em - V8 4.4L Pe ol, Remo al
and In alla ion) /
M ffle - Vehicle Wi ho : Die el Pa ic la e Fil e (DPF)
(309-00C E ha S em - TDV6 2.7L Die el, Remo al and
In alla ion).
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1 . Install the heels and tires.

Tighten the heel nuts to 140 Nm (103 lb.ft).

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Rear Drive A le/Differential - A le Housing Bushing
Removal and Installation

Special Tool(s)
Remover rear differential rear
bush

502-009/2

H draulic two legged puller

211-294

Adaptor/button

205-825/4

Installer rear differential front bush

205-825/3

Receiver cup rear differential front

bush

205-825/5

Bearing Housing

205-825/6

Bearing Set for 16mm Bolt 51203

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Remover/Installer long 16mm bolt

205-825/7

Nut for long 16mm bolt

205-825/8

Remo al
NOTE: Take note of the fitted position of the bush.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the muffler assembly.
For additional information, refer to: Muffler (309-00B
Exhaust System - V8 4.4L Petrol, Removal and Installation).
3. Remove the fuel tank heat shield.

Remove the 3 bolts and 2 nuts.

4. C AUTIONS:

Mark the position of the driveshaft flange in relation to

the drive pinion flange.

To avoid damage to the joint or gaiter, do not allow

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he d i e haf o hang.

Relea e he d i e haf f om he ea a le d i e flange.

Remo e and di ca d he 4 To bol .

5. C AUTION: Make e he eigh of he a le i

al a ppo ed.

U ing a i able jack, lo e he f on of he a le.

Remo e he a le f on e aining bol .

6. U ing he pecial ool , emo e he a le ho ing b hing.

In alla ion
1. U ing he pecial ool , in all he a le ho ing b hing.

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. C AUTION: Make e he eigh of he a le i al a

ppo ed.

U ing a i able jack, ai e he f on of he diffe en ial.

In all he a le f on e aining bol .

Tigh en o 275 Nm (203 lb.f ).

. A ach he d i e haf o he ea a le d i e flange.

C lean he componen ma ing face .

A ach he d i e haf o he ea a le d i e flange.

Tigh en he ne To bol o 150 Nm (110 lb.f ).

. In all he f el ank hea hield.

Tigh en he bol and n o 10 Nm (7 lb.f ).

. In all he m ffle a embl .

Fo addi ional info ma ion, efe o: M ffle (309-00B
E ha S em - V8 4.4L Pe ol, Remo al and In alla ion).

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Rear Drive A le/Differential - Rear A le Housing Support Insulator
Removal and Installation

Special Tool(s)
Remover/Installer long 14mm bolt

502-009/5

Bearing set for 14mm and 16mm

bolt, 51203

Receiver cup rear differential rear

bush

502-009/1

Remover rear differential rear

bush

502-009/2

Installer rear differential rear bush

502-009/3

Removal
NOTE: Take note of the fitted position of the bush.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the wheels and tires.
3. Remove the rear differential.
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Fo addi ional info ma ion, efe o: A le A embl (205-02
Rea D i e A le/Diffe en ial, Remo al and In alla ion).
4. NOTE: Take no e of he fi ed po i ion of he b h.

U ing he pecial ool , emo e he ea a le ho ing

ppo in la o .

In alla ion
1. U ing he pecial ool , in all he ea a le ho ing
ppo in la o .

2. In all he ea diffe en ial.

Fo addi ional info ma ion, efe o: A le A embl (205-02
Rea D i e A le/Diffe en ial, Remo al and In alla ion).
3. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

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F D i e A e/Diffe e ia -
Sea e
I e La d R e Pa N .
Input shaft flange nut STC 50553
Input shaft splines STC 50554
L b ica
I e S ecifica i
* Recommended lubricant C astrol SAF-XO - 75W/90
*D e a b ica he ha ha ecified
Ca aci ie
I e Ca aci
Front differential 0.61 litres (1.07 pints) (0.64 US quarts)
A e T be
I e S ecifica i
Axle tube seal (Used on later models. Earlier models used an o-ring) Land Rover Part No: STC 50550
F Dif f e e ia
I e S ecifica i
Red c i a i :
V6 Diesel engine - Manual transmission 3.07:1
V6 Diesel engine - Automatic transmission 3.54:1
V6 Petrol engine - Automatic transmission 3.73:1
V8 Petrol engine - Automatic transmission 3.54:1
T e S ecif ica i
De c i i N b-f
Oil drain plug 54 40
Oil filler plug 34 25
Differential locking module bolts 10 7
Parking aid module nuts 10 7
Diffe e ia ca e b :
M14 Front bolt 105 77
*Axle carrier to differential bolts - Stage 1 80 59
*Axle carrier to differential bolts - Stage 2 Further 60 Further 60
Front axle crossmember bolts 115 85
** D i e haf f a e d i e f a ge T b
Stage 1 45 33
Stage 2 Further 90 Further 90
Road wheel nuts 140 103
* Ne b be fi ed

** Ne 'Pa ch 'T b be fi ed

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Front Drive A le/Differential - Front Drive A le and Differential
Description and Operation

GENERAL

I em Pa N mbe De c ip ion
1 - RH front drive halfshaft
2 - Front differential assembly
3 - Front driveshaft
4 - LH front drive halfshaft
The front differential converts the 'angle of drive' through 90 and distributes drive, via the front drive halfshafts, to
the front wheels.

The front differential for the V6 and V8 petrol variants have the same output ratio, but the output ratios for the TdV6
are different, depending on whether automatic or manual transmission is fitted.

The front differential is mounted on the LH side of the chassis.

FRONT DIFFERENTIAL ASSEMBLY

Front Differential - Exploded View

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I em Pa N mbe De c ip ion
1 - Protection cap
2 - Mounting bush assembl

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3 - Seal
4 - Bea ing a embl
5 - F on be
6 - Bol , 4 of
7 - O- ing
8 - D ain pl g
9 - Bol , 14 of
10 - C o e a embl
11 - C o e eal
12 - Rolle bea ing c p
13 - Bea ing p eload pace
14 - Tape olle bea ing
15 - Bol , 10 of
16 - Diffe en ial ca e
17 - Roll pin
18 - Gea and pinion a embl
19 - Tape olle bea ing
20 - Rolle bea ing c p
21 - Shim
22 - C ollap ible pace
23 - Rolle bea ing c p
24 - Tape olle bea ing
25 - Oil eal
26 - Inne deflec o
27 - O e deflec o
28 - Flange
29 - Pinion n e aine
30 - Pinion n
31 - Mo n ing b h a embl
32 - A le mo n ing b acke
33 - Da a label
34 - B ea he be
35 - C ap
36 - Fill pl g
37 - Bol , 3 of
38 - Tape olle bea ing
39 - Bea ing p eload pace
40 - Rolle bea ing c p
41 - Th a he
42 - Plane gea
43 - Shaf
44 - S n heel
45 - Th a he
46 - Mo n ing b h a embl
The ca ing comp i e o hal e i h machined ma ing face . When a embled, he ca i on ca ing hal e a e
ealed i h a hin film of Loc i e 5999 ealan and ec ed oge he i h fo een bol . A b ea he be i fi ed o he
ca ing . Thi allo a pla ic be o be fi ed and o ed o a high poin in he engine compa men , p e en ing he
ing e of a e hen he ehicle i ading.

The RH ca ing i fi ed i h a d ain pl g. The f on diffe en ial ni con ain app o ima el 0.7 li e of oil fo a d fill.

The diffe en ial i a con en ional de ign ing a h poid gea la o . Thi emplo a h poid be el pinion gea and
c o n heel, i h he pinion off e abo e he cen e line of he c o n heel. Thi de ign allo fo a la ge pinion
gea o be ed, hich ha he ad an age of inc ea ed gea eng h and ed ced ope a ing noi e.

The f on diffe en ial i a ailable in h ee a io . V8 and V6 pe ol engine ehicle e a f on diffe en ial i h a final
d i e a io of 3.73:1 and TdV6 die el engine ehicle e a final d i e a io of 3.07:1, fo ehicle i h man al
an mi ion, and 3.54:1 fo ehicle i h a oma ic an mi ion. C hanging he n mbe of ee h be een he c o n-
heel d i e gea and pinion gea change he a io.

The diffe en ial comp i e a pinion haf and h poid be el gea , a c o n heel d i e gea i h an in eg al cage, hich
ho e o plane gea . T o n heel a e al o loca ed in he cage and pa he o a ional d i e o he d i e haf
haf .

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The pinion shaft is mounted on two opposed taper roller bearings with a collapsable spacer located between them.
The spacer is used to hold the bearings in alignment and also collapses under the pressure applied to the pinion nut.
This allows the nut to be tightened to a predetermined torque, which collapses the spacer, setting the correct bearing
preload.

The pinion shaft has an externally splined outer end which accepts and locates the input flange, which is retained by
the pinion nut. The opposite end of the output flange has an internal spline which provides positive location for the
front propeller shaft. The flange has an external O-ring seal which seals against the front propeller shaft shroud
preventing the ingress of dirt and moisture into the splines. An oil seal is pressed into the LH casing and seals the
input flange to the differential unit. The pinion shaft has a hypoid bevel gear at its inner end which mates with the
crown wheel drive gear.

The crown wheel drive gear is located on the carrier and secured with ten screws. The carrier is mounted on taper
roller bearings located in each casing half. The bearings are press fitted into the casing and a spacer is located on the
outside face to set backlash and apply preload to the bearing.

The carrier is fitted with a shaft onto which the two planet gears are mounted. The shaft is secured in the carrier with
a roll pin. The sun wheels are located in pockets within the carrier and mesh with the planet gears. Thrust washers
are located between the carrier and the sun wheels and hold the sun wheels in mesh with the planet gears. Each sun
wheel has a machined, splined, bore to accept the drive shaft. A groove is machined in the bore to locate the snap
ring fitted to the drive shaft, providing positive drive shaft location.

Differential Operation

The operating principles of the front and rear differentials are the same. Rotational input from the propeller shaft is
passed via the input flange to the pinion shaft and pinion gear. The angles of the pinion gear to the crown wheel drive
gear moves the rotational direction through 90 .

The transferred rotational motion is now passed to the crown wheel drive gear, which in turn rotates the carrier. The
shaft, which is secured to the carrier, also rotates at the same speed as the carrier. The planet gears, which are
mounted on the shaft, also rotate with the carrier. In turn, the planet gears transfer their rotational motion to the left
and right hand sun wheels, rotating the drive shafts.

When the vehicle is moving in a forward direction, the torque applied through the differential to each sun wheel is
equal. In this condition both drive shafts rotate at the same speed. The planet gears do not rotate and effectively lock
the sun wheels to the carrier.

If the vehicle is turning, the outer wheel will be forced to rotate faster than the inner wheel by having a greater
distance to travel. The differential senses the torque difference between the sun wheels. The planet gears rotate on
their axes to allow the outer wheel to rotate faster than the inner one.

SERVICE

The oil used in the front differential is C astrol SAF-XO. The oil contains unique additives, which enhance the
differentials operation. No other oil must be used in the front differential.

Front Differential Ser iceable Components

Halfshaft seals
Needle roller bearing assemblies
C hassis bush/fixings
Lubricant.

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Front Drive A le/Differential - Differential Draining and Filling
General Procedures

C AUTION: Do not fill the differential with lubricant up to the filler plug. The filler plug is only used to fill the
differential with lubricant, not to act as a level indicator.

NOTE: The only way to check the fluid level in the differential is to drain all the fluid out and refill with the correct
quantity, shown in the specification section.
For additional information, refer to: Specifications (205-03 Front Drive Axle/Differential, Specifications).

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Body Panels, Removal and Installation).
3. Remove the differential case lubricant filler plug.

C lean the area around the lubricant filler plug.

Position container to collect fluid loss.

4. Drain the differential lubricant.

C lean the area around the drain plug.

Remove the fluid drain plug.

5. C AUTION: There have been 2 different types of fixings

used for the drain plug. Note the type and differential serial
number, and make sure the correct torque is applied, see
below.

Install the lubricant drain plug.

C lean the drain plug.

Up to differential serial number 254845: Tighten the

hexagonal drive drain plug to 54 Nm (40 lb.ft).

From differential serial number 254846: Tighten the

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3/8'' a e d i e d ai g 28 N (21 b.f ).

. C AUTION: D fi he diffe e ia i h b ica

he fi e g. The fi e gi ed fi he
diffe e ia i h b ica , ac a a e e i dica .

Fi he diffe e ia i h he c ec a f b ica .
F addi i a i f a i , efe : S ecifica i (205-03
F D i e A e/Diffe e ia , S ecifica i ).
.I a he diffe e ia fi e g.

Tigh e he fi e g 34 N (25 b.f ).

.I a he e gi e de hie d.
F addi i a i f a i , efe : E gi e U de hie d
(501-02 F E d B d Pa e , Re a a dI a ai ).

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Front Drive A le/Differential - Drive Pinion Seal
In- ehicle Repai

Special Tool(s)
Flange holding ool

205-053

Remo e d i e flange

205-824

In alle - d i e pinion oil eal

205-820

Imp l e e ac o

100-012(LRT-99-004)

Removal

C AUTION: The d i e pinion eal m onl be ene ed once.

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. D ain he diffe en ial l b ican .
Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-03 F on D i e A le/Diffe en ial, Gene al
P oced e ).
3. Remo e he f on d i e haf . Fo addi ional info ma ion,
efe o: (205-01 D i e haf )

F on D i e haf - V8 4.4L Pe ol (Remo al and

In alla ion),
F on D i e haf - V6 4.0L Pe ol (Remo al and
In alla ion),

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Front Driveshaft - TDV6 2.7L Diesel (Removal and
Installation).
. Measure the depth of the pinion nut on the pinion shaft.

Note measurement for installation.

. C AUTION: This step must be carried out to make

sure that the drive pinion nut is correctl tightend on
assembl .

Accuratel scribe a line to mark the drive pinion shaft to

the drive pinion nut and pinion flange.

. Remove the drive pinion flange retaining nut.

Using the special tool, counter hold the drive pinion

flange.

Note number of turns for installation.

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7. C AUTION: Make sure onl a bolt is used with the

special tool, to draw the drive pinion flange off the drive
pinion shaft.

Using the special tool, remove the drive pinion flange.

8. Using the special tool, remove the drive pinion seal.

In alla ion
1. C lean the drive pinion flange.
2. C lean the drive pinion seal mating faces.
3. Using the special tool, install the new drive pinion seal.

4. C AUTION: Make sure the drive pinion flange scribed

marks are aligned.

Install the drive pinion flange.

5. C AUTIONS:

Make sure the mark on the drive pinion nut is never

tightened short of the scribed mark on the drive pinion
shaft.

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Ma e e he d i e i i f a ge ha e df a
a d i f ee a e.

Ma e e he c ibed a he d i e i i i
e ha a a i f 5 deg ee a he c ibed
a he d i e i i haf .

I a he d i e i i f a ge e ai i g .

U i g he ecia ,c e h d he d i e i i
f a ge.

I a e i ed be f .

Mea e he de h f he i i he i i
haf .

.I a he f d i e haf . F addi i a i f ai , efe

: (205-01 D i e haf )

F D i e haf - V8 4.4L Pe (Re a a d

I a a i ),
F D i e haf - V6 4.0L Pe (Re a a d
I a a i ),
F D i e haf - TDV6 2.7L Die e (Re a a d
I a a i ).

. C AUTION: Ma e e he c ec ecifica i a d
a i f i i ed.

Fi he diffe e ia i h he c ec a f b ica .
F addi i a i f a i , efe : Diffe e ia D ai i g a d
Fi i g (205-03 F D i e A e/Diffe e ia , Ge e a
P ced e ).

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Front Drive A le/Differential - Front A le Housing Support Insulator
In-vehicle Repair

Special Tool(s)
Bearing Housing

502-009/6

Bearing set for 14mm bolt 51204

Installer rear a le front bush

205-825/3

Remover rear differential rear

bush

502-009/2

Remover/Installer long 14mm bolt

502-009/5

Nut for long 14mm bolt

502-009/4

Receiver cup front a le front bush

205-825/1

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Remo al

C AUTION: Make sure the bush is correctly aligned.

NOTE: Take note of the fitted position of the bush.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the front wheels and tires.
3. Remove the front differential.
For additional information, refer to: Axle Assembly (205-03
Front Drive Axle/Differential, Removal and Installation).
4. NOTE: Take note of the fitted position of the bush.

Using the special tools, remove the front axle housing

support insulator.

Installation

1. C AUTION: Make sure the bush is correctly aligned.

Using the special tools, install the front axle housing

support insulator.

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. In all he f on diffe en ial.

Fo addi ional info ma ion, efe o: A le A embl (205-03
F on D i e A le/Diffe en ial, Remo al and In alla ion).
. In all he f on heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

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Front Drive A le/Differential - A le Tube
In- ehicle Repai

Removal
1. Remo e he RH half haf .
Fo addi ional info ma ion, efe o: F on Half haf RH (205-
04 F on D i e Half haf , Remo al and In alla ion).
2. Remo e he a le be.

Remo e he bol f om he b hing.

Remo e he 4 bol .

Ro a e and emo e he a le be.

Ea l model : Remo e and di ca d he O- ing eal.

La e model : Remo e he ealan .

Installation
1. In all he a le be.

C lean he componen ma ing face .

Ea l model : In all a ne O- ing eal.

La e model : Appl ealan o he ma ing face.

Fo addi ional info ma ion, efe o: Specifica ion (205-
03 F on D i e A le/Diffe en ial, Specifica ion ).

Tigh en he 4 a le be bol o 50 Nm (37 lb.f ).

Tigh en he a le be b hing bol o 63 Nm (46 lb.f ).

2. In all he RH half haf .

Fo addi ional info ma ion, efe o: F on Half haf RH (205-
04 F on D i e Half haf , Remo al and In alla ion).

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Front Drive A le/Differential - A le Assembl
Remo al and In alla ion

Special Tool(s)
Ball join epa a o

205-754

Removal
All ehicle

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
3. Remo e he f on heel and i e .
4. Remo e he a le be.
Fo addi ional info ma ion, efe o: A le T be (205-03 F on
D i e A le/Diffe en ial, In- ehicle Repai ).
5. Remo e he f on a le c o membe .

Remo e he 4 bol .

6. Relea e he LH b ake ho e b acke f om he heel

kn ckle.

Remo e he bol .

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. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he LH ie- od end ball join

f om he heel kn ckle.

Remo e and di ca d he n .

. C AUTIONS:

Make e he ball join eal i no damaged. A

damaged eal ill lead o he p ema e fail e of he join .

The lo e a m ball join can be damaged b

e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o
hang on he lo e a m. Fail e o follo hi in c ion ill
e l in damage o ehicle.

U ing he pecial ool, elea e he LH ppe a m ball join .

Remo e and di ca d he n .

. Relea e he LH half haf f om he a le a embl .

Remo e and di ca d he nap ing.

U ing a i able ie ap, ppo he LH half haf .

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. C AUTION: Ma k he po i ion of he d i e haf

flange in ela ion o he d i e pinion flange.

Relea e he d i e haf f om he f on a le d i e flange.

Remo e he 6 bol and a he , di ca d he bol .

U ing a i able ie ap, ec e he d i e haf end

pla e.

. C AUTION: Befo e he di connec ion o emo al of

an componen , make e he a ea a o nd join face
and connec ion a e clean. Pl g an open connec ion o
p e en con amina ion.

Di connec he b ea he line.

Relea e he clip.

Vehicle b il p o 02/2007
. NOTE: If a ne a le i being in alled, a ne b ea he line
m al o be in alled.

Remo e and di ca d he f on a le b ea he line.

Relea e f om he 3 clip .

All ehicle
. U ing a an mi ion jack, ppo he f on a le
a embl .
. Wi h a i ance, emo e he f on a le a embl .

Remo e and di ca d he 3 a le a embl ea

mo n ing bol .

Remo e he f on a le a embl f on mo n ing bol .

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In alla ion
All ehicle
1. Wi h a i ance, in all he f on a le a embl .
2. Wi h a i ance, align and ec e he f on a le a embl .

Tigh en he M14 bol o 105 Nm (77 lb.f ).

Tigh en he 3 ne bol in he f on a le a embl o 80

Nm (59 lb.f ), hen a f he 60 deg ee .

Vehicle b il p o 02/2007
3. NOTE: If a ne a le i being in alled, a ne b ea he line
m al o be in alled.

In all he ne f on a le b ea he line.

Sec e in he clip .

All ehicle
4. C onnec he b ea he line.
5. NOTE: Ne bol m be in alled.

Sec e he d i e haf o he f on a le d i e flange.

Remo e and di ca d he ie ap.

S age 1: Tigh en he bol o 45 Nm (33 lb.f ).

S age 2: Tigh en he bol af he 90 deg ee .

6. In all a ne nap ing o he LH half haf .

Remo e and di ca d he ie ap.

7. NOTE: Do no f ll engage he half haf n il he oil eal

p o ec o ha been emo ed.

Sec e he LH half haf in he a le a embl .

1. Open he half haf eal p o ec o and in all he

half haf .

2. Relea e he half haf eal p o ec o f om he

half haf eal.

3. Remo e he half haf eal p o ec o .

4. F ll in all he half haf .

5. Make e he nap ing i f ll engaged and

e ain he half haf .
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. NOTE: In all a ne n .

Sec e he LH ppe a m o he heel kn ckle.

Tigh en he n o 70 Nm (52 lb.f ).

. NOTE: In all a ne n .

Sec e he LH ie- od end ball join o he heel kn ckle.

In all a ne n and igh en o 76 Nm (56 lb.f ).

10. Sec e he LH b ake ho e b acke o he heel kn ckle.

Tigh en he bol o 22 Nm (16 lb.f ).

11. In all he f on a le c o membe .

Tigh en he 4 bol o 115 Nm (85 lb.f ).

12. In all he a le be.

Fo addi ional info ma ion, efe o: A le T be (205-03 F on
D i e A le/Diffe en ial, In- ehicle Repai ).
13. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

14. C onnec he ba e g o nd cable.

Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Front Drive A le/Differential - A le Carrier Bushing
Removal and Installation

Special Tool(s)
Installer rear axle front bush

205-825/3

Receiver cup rear differential front

bush

205-825/5

Remover rear differential rear

bush

502-009/2

Removal

C AUTION: Make sure the bush is correctly aligned.

NOTE: Take note of the fitted position of the bush.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the exhaust system.
For additional information, refer to: Exhaust System (309-
00A Exhaust System - V6 4.0L Petrol, Removal and
Installation).
3. Using a suitable jack, support the axle assembly.
4. Remove the axle carrier bushing heat shield.

Remove the two retaining bolts.

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5. C AUTION: The bolts must onl be used once.

Remove the a le carrier.

Remove and discard the three bolts retaining the

a le carrier to the a le.

Remove the a le carrier bushing bolt.

6. NOTE: Take note of the fitted position of the bush.

Using the special tools, remove the a le carrier bushing.

In alla ion

1. C AUTION: Make sure the bush is correctl aligned.

Using the special tools, install the a le carrier bushing.

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. In all he a le ca ie .

Tigh en he M14 bol o 105 Nm (77 lb.f ).

Tigh en he ne a le ca ie b acke bol o 80 Nm (59

lb.f ), hen a f he 60 deg ee .

. In all he a le ca ie b hing hea hield.

. Remo e he a le ppo .
. In all he e ha em.
Fo addi ional info ma ion, efe o: E ha S em (309-
00A E ha S em - V6 4.0L Pe ol, Remo al and
In alla ion).

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Front Drive A le/Differential - A le Tube Bushing
Removal and Installation

Special Tool(s)
Remover/installer - Front a le
e tension support bush

308-625/1

Remover/installer - Front a le
e tension support bush

308-625/2

Remover/installer - Front a le
e tension support bush

308-625/3

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Raise and support the vehicle.
3. Remove the a le tube.
For additional information, refer to: A le Tube (205-03 Front
Drive A le/Differential, In-vehicle Repair).
4. NOTE: Note the fitted position.

Using the special tools, remove the bushing.

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In alla ion
1. NOTE: No e he fi ed po i ion.

U ing he pecial ool , in all he b hing.

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. Install the a le tube.

For additional information, refer to: A le Tube (205-03 Front
Drive A le/Differential, In-vehicle Repair).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Front Drive A le/Differential - A le Cover Bushing
Removal and Installation

Special Tool(s)
Bearing Housing

502-009/6

Bearing set for 14mm bolt 51204

Installer rear a le front bush

205-825/3

Remover rear differential rear

bush

502-009/2

Remover/Installer long 14mm bolt

502-009/5

Nut for long 14mm bolt

502-009/4

Receiver cup front a le front bush

205-825/1

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Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he f on heel and i e .
3. Remo e he f on diffe en ial.
Fo addi ional info ma ion, efe o: A le A embl - 4.2L
(205-03, Remo al and In alla ion).
4. NOTE: Take no e of he fi ed po i ion of he b h.

U ing he pecial ool , emo e he f on a le ho ing

ppo in la o .

Installation

1. C AUTION: Make e he b h i co ec l aligned.

U ing he pecial ool , in all he f on a le ho ing

ppo in la o .

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. In all he f on diffe en ial.

Fo addi ional info ma ion, efe o: A le A embl - 4.2L
(205-03, Remo al and In alla ion).
. In all he f on heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

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P bli hed: 11-Ma -2011

F D i e Ha f haf -
Ge e a S ecif ica i
I e S ecifica i
T pe F ll floa ing, fi ed leng h, olid haf inco po a ing con an eloci join a each end of haf
L b ica
I e S ecifica i
O boa d join U e g ea e pplied i h eplacemen boo ki (Op imol MS139G)
Inboa d join U e g ea e pplied i h eplacemen boo ki (1 L be C MS132G)
Ge e a S ecif ica i
I e S ecifica i
T pe F ll floa ing, olid haf inco po a ing 'pl g-in' con an eloci join a inboa d end and fi ed con an
eloci join a o boa d end of haf
T e S ecif ica i
De c i i N b-f
* S abili e ba link n 115 85
* S abili e link n 115 85
* Tie od end ball join n 76 56
B ake ho e e aining b acke o heel kn ckle bol 25 18
*+ Half haf e aining n 230 169
Road heel n 140 103
* Ne be fi ed

+S a e c e i

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Front Dri e Halfshafts - Front Dri e Halfshafts
Description and Operation

Front Drive Halfshaft C omponent Location

I em Pa N mbe De c ip ion
1 - RH front drive halfshaft
2 - LH front drive halfshaft

GENERAL

The front drive shafts are handed components with the RH drive shaft being longer than the LH drive shaft. Both
shafts are of similar construction with C onstant Velocit (C V) joints at each end to allow for steering and suspension
movement.

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FRONT DRIVE HALFSHAFT ASSEMBL

I em Pa N mbe De c ip ion
1 - RH o e C V join
2 - RH f on d i e half haf
3 - RH inne C V join
4 - LH inne C V join
5 - LH f on d i e half haf
6 - LH o e C V join
The f on d i e haf a e imila in hei con c ion. The onl diffe ence i he leng h of each haf , he LH d i e
haf i a longe haf i h an e ended em.

The o e C V join ha e a a ge heel on he o e diame e . Thi i ed b he ABS heel peed en o fo

ehicle and heel peed calc la ion .

Each d i e haf comp i e o C V join (inne and o e ), boo , an o e be and a olid ba haf , hich i
e ained in he f on diffe en ial b a ci clip ( ee 'Half haf Join ' ec ion fo mo e info ma ion on C V join ).

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Published: 11-May-2011
Front Dri e Halfshafts - Halfshaft Joint
Description and Operation

Front Drive HalfShaft Sectional Views

I em Pa N mbe De c ip ion
A - Front outboard halfshaft joint
B - Rear outboard halfshaft joint
C - Rear inboard halfshaft joint
D - Front inboard halfshaft joint
The outboard and rear inboard C V joints are of the Birfield design. This design uses longitudinal, elliptical grooves,
which retain six steel balls. The balls are further retained by a cage. The constant velocity is achieved by the position
of the steel balls. If a centre line is drawn through the balls and the driven hub or differential shaft, the two centre
lines always bisect each other at the angle of drive. This condition allows the rotational speed of the driven shaft to be
passed to the driven hub or differential shaft with no loss of rotational speed regardless of the shaft angle. The C V
joints are packed with grease, which is retained in the joint by a synthetic rubber gaiter. The gaiter is retained at each
end by a metal clamp, which provides a water tight seal to prevent the ingress of dirt and moisture. The C V joints are
retained on their respective shaft or tube by an internal snap ring. The snap rings are located in a groove on each
shaft or tube end and locate in a mating groove in the C V joint.

C AUTION: The inner hub is not retained in the joint body on this type of joint. The joint is held together in it's
unfitted state only by the boot. Pulling on the barshaft can therefore pull the hub out of the joint body. For this reason
care must be taken when handling and fitting the front driveshafts.

The shaft is a sliding fit inside the outer tube, which allows for the small length changes, which occur with articulation
of the suspension. The shaft is located in a ball cage, which is retained inside the outer tube. The ball cage ensures
that the shaft is held rigidly in the outer tube whilst allowing it to freely move in and out of the tube as necessary. A
sealing plug is pressed into the outer tube and retains grease around the balls in the cage.

The inner C V joints are similar in design and operation to the outer joints except that the inner joints use rollers
rather than balls to transmit the drive.

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I em Pa N mbe De c ip ion
A - I CV
B - O CV
1 - T
2 - T (3 )
3 - S
4 - R (3 )
5 - O
6 - S (6 )
7 - C
8 - I
T ' ', ' ' ' '. T
.T
.

T CV .T
CV .

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Published: 29-Sep-2011
Front Dri e Halfshafts - Front Halfshaft LH
Removal and Installation

Special Tool(s)
Ball joint separator

205-754(LRT-54-027)

Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Halfshaft installer adapter

204-506-01(LRT-60-030/4)

Retainers - halfshaft
remover/replacer

204-506/5(LRT-60-030/5)

A le oil seal remover

308-005(LRT-37-004/2)

Impulse e tractor

100-012(LRT-99-004)

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Installer/Guide halfshaft oil seal

308-626/2

Installer halfshaft oil seal

308-626/1

Remo al
C AUTIONS:

Do not store or install halfshafts with joints at maximum articulation or damage may occur to the joint.

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining
mechanism and can separate.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Drain the differential lubricant.
For additional information, refer to: Differential Draining and
Filling (205-03 Front Drive Axle/Differential, General
Procedures).
3. Remove the wheel and tire.
4. Remove the halfshaft retaining nut.

Discard the nut.

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. C AUTION: Use a wrench on the hexagon provided

to prevent the ball joint rotating.

Disconnect the RH stabili er bar link.

Remove and discard the nut.

. C AUTION: Use a wrench on the hexagon provided

to prevent the ball joint rotating.

Remove the stabili er bar link nut.

Remove and discard the nut.

. Release the brake hose bracket from the wheel knuckle.

Remove the bolt.

. Loosen the tie-rod end ball joint retaining nut.

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. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he ie- od end ball join

f om he heel kn ckle.

Di ca d he n .

10. C AUTION: To p e en he heel kn ckle falling

o a d and di connec ion of he half haf inne join ,
ppo he heel kn ckle.

Loo en he ppe a m e aining n .

11. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he ppe a m ball join .

Remo e and di ca d he e aining n .

12. C AUTIONS:

The lo e a m ball join can be damaged b

e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o
hang on he lo e a m. Fail e o follo hi in c ion ill
e l in damage o ehicle.

Do no e a hamme o de ach he half haf f om he

h b a embl , fail e o follo hi in c ion ma e l in
damage o he half haf .

Do no e a hamme o de ach he half haf f om he

h b a embl , fail e o follo hi in c ion ma e l in
damage o he half haf .

U ing he pecial ool , elea e he half haf f om he

heel h b.
13. Relea e he half haf f om he heel kn ckle.
14. Relea e he half haf f om he diffe en ial ho ing.

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1 . Remove the halfshaft.

Raise the stabili er bar to allow removal of the

halfshaft.

Remove and discard the snap ring.

1 . Using the special tools, remove and discard the

halfshaft oil seal.

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In alla ion
1. C lean he componen .
2. U ing he pecial ool , in all a ne half haf oil eal.

The half haf oil eal p o ec o m be lef in place,

n il he half haf i f ll in alled.

3. NOTE: Do no f ll engage he half haf n il he oil eal

p o ec o ha been emo ed.

In all he half haf .

In all he nap ing.

L b ica e he eal and he bea ing nning face

i h clean a le oil.

Make e he nap ing i f ll engaged and e ain

he half haf .

Open he half haf oil eal p o ec o .

4. NOTE: The oil eal p o ec o i de igned o b eak in o

o piece .

Remo e and di ca d he half haf oil eal p o ec o .

5. C AUTION: The lo e a m ball join can be damaged

b e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o
hang on he lo e a m. Fail e o follo hi in c ion ill
e l in damage o ehicle.

U ing he pecial ool , in all he half haf in he heel

h b.

6. C onnec he ppe a m and heel kn ckle.

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In all a ne n and igh en o 70 Nm (52 lb.f ).

. Sec e he abili e ba link.

In all a ne n and igh en o 115 Nm (85 lb.f ).

. C onnec he ie- od end ball join .

In all a ne n and igh en o 76 Nm (56 lb.f ).

. C AUTION: In all he half haf n finge igh .

In all a ne half haf e aining n and ligh l igh en.

10. Sec e he b ake ho e e aining b acke o he heel
kn ckle.

Tigh en he bol o 22 Nm (16 lb.f ).

11. Sec e he RH abili e link.

In all a ne n and igh en o 115 Nm (85 lb.f ).

12. C AUTION: Do no e ai ool o in all he n .

Fail e o follo hi in c ion ma e l in damage o he
componen .

Tigh en he ne half haf e aining n o 230 Nm (170 lb.f ).

S ake he n o he half haf .

13. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

14. C AUTION: Do no fill he diffe en ial i h l b ican p

o he fille pl g. The fille pl g i onl ed o fill he
diffe en ial i h l b ican , and no o ac a a le el indica o .

Fill he diffe en ial i h he co ec amo n of l b ican .

Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-03 F on D i e A le/Diffe en ial, Gene al
P oced e ).

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Front Dri e Halfshafts - Front Halfshaft RH
Removal and Installation

Special Tool(s)
Ball joint separator

205-754(LRT-54-027)

Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Halfshaft installer adapter

204-506-01(LRT-60-030/4)

Retainers - halfshaft
remover/replacer

204-506/5(LRT-60-030/5)

A le oil seal remover

308-005(LRT-37-004/2)

Impulse e tractor

100-012(LRT-99-004)

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Installer/Guide halfshaft oil seal

308-626/2

Installer halfshaft oil seal

308-626/1

Halfshaft bearing installer

205-819

Remo al
C AUTIONS:

Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining
mechanism and can separate.

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Do not store or install halfshafts with joints at maximum articulation or damage may occur to the joint.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Drain the differential lubricant.
For additional information, refer to: Differential Draining and
Filling (205-03 Front Drive Axle/Differential, General
Procedures).
3. Remove the wheels and tires.
4. Remove the halfshaft retaining nut.

Discard the nut.

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. C AUTION: Use a wrench on the hexagon provided

to prevent the ball joint rotating.

Disconnect the LH stabili er bar link.

Remove and discard the nut.

. C AUTION: Use a wrench on the hexagon provided

to prevent the ball joint rotating.

Remove the stabili er bar link nut.

. Release the brake hose bracket from the wheel knuckle.

Remove the bolt.

. Loosen the tie-rod end ball joint retaining nut.

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. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he ie- od end ball join

f om he heel kn ckle.

Di ca d he n .

10. C AUTION: To p e en he heel kn ckle falling

o a d and di connec ion of he half haf inne join ,
ppo he heel kn ckle.

Loo en he ppe a m e aining n .

11. C AUTION: Make e he ball join eal i no

damaged. A damaged eal ill lead o he p ema e fail e
of he join .

U ing he pecial ool, elea e he ppe a m ball join .

Remo e and di ca d he e aining n .

12. C AUTIONS:

The lo e a m ball join can be damaged b

e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o
hang on he lo e a m. Fail e o follo hi in c ion ill
e l in damage o ehicle.

Do no e a hamme o de ach he half haf f om he

h b a embl , fail e o follo hi in c ion ma e l in
damage o he half haf .

U ing he pecial ool , elea e he half haf f om he

heel h b.

13. Relea e he half haf f om he heel kn ckle.

14. Po i ion a con aine o collec he oil pillage.
15. Relea e he half haf f om he diffe en ial ho ing.

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1 . C AUTION: Keep the halfshaft hori ontal to avoid

damaging the oil seal.

Remove the halfshaft.

Raise the stabili er bar to allow removal of the

halfshaft.

Remove and discard the snap ring.

1 . Using the special tools, remove and discard the

halfshaft oil seal.

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In alla ion
1. C lean he componen .
2. U ing he pecial ool , in all a ne half haf oil eal.

The half haf oil eal p o ec o m be lef in place,

n il he half haf i f ll in alled.

3. NOTE: Do no f ll engage he half haf n il he oil eal

p o ec o ha been emo ed.

In all he half haf .

In all he nap ing.

L b ica e he eal and he bea ing nning face

i h clean a le oil.

Make e he nap ing i f ll engaged and e ain

he half haf .

Open he half haf oil eal p o ec o .

4. NOTE: The oil eal p o ec o i de igned o b eak in o

o piece .

Remo e and di ca d he half haf oil eal p o ec o .

5. C AUTION: The lo e a m ball join can be damaged

b e ce i e a ic la ion. The heel kn ckle m be f ll
ppo ed a all ime . Do no allo he heel kn ckle o
hang on he lo e a m. Fail e o follo hi in c ion ill
e l in damage o ehicle.

U ing he pecial ool , in all he half haf in he heel

h b.

6. C onnec he ppe a m and heel kn ckle.

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In all a ne n and igh en o 70 Nm (52 lb.f ).

. Sec e he abili e ba link.

In all a ne n and igh en o 115 Nm (85 lb.f ).

. C onnec he ie- od end ball join .

In all a ne n and igh en o 76 Nm (56 lb.f ).

. C AUTION: In all he half haf n finge igh .

In all a ne half haf e aining n and ligh l igh en.

10. Sec e he b ake ho e e aining b acke o he heel
kn ckle.

Tigh en he bol o 22 Nm (16 lb.f ).

11. Sec e he LH abili e link.

In all a ne n and igh en o 115 Nm (85 lb.f ).

12. C AUTION: Do no e ai ool o in all he n .

Fail e o follo hi in c ion ma e l in damage o he
componen .

Tigh en he ne half haf e aining n o 230 Nm (170 lb.f ).

S ake he n o he half haf .

13. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

14. C AUTION: Do no fill he diffe en ial i h l b ican p

o he fille pl g. The fille pl g i onl ed o fill he
diffe en ial i h l b ican , and no o ac a a le el indica o .

Fill he diffe en ial i h he co ec amo n of l b ican .

Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-03 F on D i e A le/Diffe en ial, Gene al
P oced e ).

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Published: 14-Jun-2011
Front Drive Halfshafts - Outer Constant Velocit (CV) Joint Boot
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the halfshaft.
For additional information, refer to: Front Halfshaft LH (205-
04 Front Drive Halfshafts, Removal and Installation).
4. C lamp the halfshaft in a vise.
5. Remove and discard the C V joint boot retaining clamps.

6. Slide the C V joint boot along the halfshaft to gain access to

the joint.
7. Using a drift against the inner part of the C V joint,
remove the C V joint from the halfshaft.

Remove and discard the snap ring.

8. Remove the outer C V joint boot.

Installation
1. C lean the components.
2. Install the C V joint boot.
3. Install the outer C V joint.

Install the snap ring.

Position the C V joint on the halfshaft, press the snap

ring into it's groove and push the C V joint full on to
the halfshaft.

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P ll on he C V join o en e he nap ing ha f ll
engaged.

. Pack he C V join i h he g ea e pplied.

. C AUTIONS:

Make e he C V boo i no p hed oo fa on o he

d i e haf and he ece i e po ed, fail e o follo hi
in c ion ma e l in damage o he componen .

Af e he clamp ha e been ec ed do no adj

hem, fail e o follo hi in c ion ma e l in damage
o he componen .

In all he C V join boo o he C V join .

U ing a i able ool, ec e he C V join boo ih

he ne clamp .

. In all he half haf .

Fo addi ional info ma ion, efe o: F on Half haf LH (205-
04 F on D i e Half haf , Remo al and In alla ion).
. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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Published: 14-Jun-2011
Front Drive Halfshafts - Outer Constant Velocit (CV) Joint
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the halfshaft.
For additional information, refer to: Front Halfshaft LH (205-
04 Front Drive Halfshafts, Removal and Installation).
4. C lamp the halfshaft in a vise.
5. Remove and discard the C V joint boot retaining clamps.

6. Slide the C V joint boot along the halfshaft to gain access to

the joint.
7. Using a drift against the inner part of the C V joint,
remove the C V joint from the halfshaft.

Remove and discard the snap ring.

8. Remove the outer C V joint boot.

Installation
1. C lean the components.
2. Install the C V joint boot.
3. Install the outer C V joint.

Install the snap ring.

Position the C V joint on the halfshaft, press the snap

ring into it's groove and push the C V joint full on to
the halfshaft.

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P ll on he C V join o en e he nap ing ha f ll
engaged.

. Pack he C V join i h he g ea e pplied.

. C AUTIONS:

Make e he C V boo i no p hed oo fa on o he

d i e haf and he ece i e po ed, fail e o follo hi
in c ion ma e l in damage o he componen .

Af e he clamp ha e been ec ed do no adj

hem, fail e o follo hi in c ion ma e l in damage
o he componen .

In all he C V join boo o he C V join .

U ing a i able ool, ec e he C V join boo ih

he ne clamp .

. In all he half haf .

Fo addi ional info ma ion, efe o: F on Half haf LH (205-
04 F on D i e Half haf , Remo al and In alla ion).
. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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Front Drive Halfshafts - Inner Constant Velocit (CV) Joint Boot
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the halfshaft.
For additional information, refer to: Front Halfshaft LH (205-
04 Front Drive Halfshafts, Removal and Installation).
4. C lamp the halfshaft in a vise.
5. Remove and discard the C V joint boot retaining clamps.

6. Slide the C V joint boot along the halfshaft to gain access

to the joint.

7. Using a drift against the inner part of the C V joint,

remove the C V joint from the halfshaft.

Remove and discard the snap ring.

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8. Remove the inner joint boot.

In alla ion
1. C lean the components.
2. Install the inner joint boot.
3. Install the inner joint.

Install a new snap ring.

Position the C V joint on the halfshaft, press the snap

ring into it's groove and push the C V joint full on to
the halfshaft.

Pull on the C V joint to ensure the snap ring has full

engaged.

4. Pack the joint with the grease supplied.

5. Install the C V joint boot to the C V joint.

Secure with the new clamps.

6. Install the halfshaft.

For additional information, refer to: Front Halfshaft LH (205-
04 Front Drive Halfshafts, Removal and Installation).
7. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Front Dri e Halfshafts - Halfshaft Seal LH
Removal and Installation

Special Tool(s)
Ball joint separator (LRT-54-027)

205-754

Halfshaft remover/replacer (LRT-

60-030/1)

204-506/1

Halfshaft remover/replacer (LRT-

60-030/3)

204-506/3

Halfshaft installer adapter

204-506-01

Retainers - halfshaft
remover/replacer (LRT-60-030/5)

204-506/5

A le oil seal remover (LRT-37-

004/2)

308-005

Impulse e tractor (LRT-99-004)

100-012

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Installer/Guide halfshaft oil seal

308-626/2

Installer halfshaft oil seal

308-626/1

Remo al
C AUTIONS:

Do not store or install halfshafts with joints at maximum articulation or damage may occur to the joint

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining
mechanism and can separate.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the LH halfshaft.
For additional information, refer to: Front Halfshaft LH (205-
04 Front Drive Halfshafts, Removal and Installation).
3. Using the special tools, remove and discard the halfshaft
oil seal.

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In alla ion
1. Using the special tools, install a new halfshaft oil seal.

The halfshaft oil seal protector must be left in place,

until the halfshaft is full installed.

2. Install the LH halfshaft.

For additional information, refer to: Front Halfshaft LH (205-
04 Front Drive Halfshafts, Removal and Installation).

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Front Dri e Halfshafts - Halfshaft Seal RH
Removal and Installation

Special Tool(s)
Ball joint separator (LRT-54-027)

205-754

Halfshaft remover/replacer (LRT-

60-030/1)

204-506/1

Halfshaft remover/replacer (LRT-

60-030/3)

204-506/3

Halfshaft installer adapter

204-506-01

Retainers - halfshaft
remover/replacer (LRT-60-030/5)

204-506/5

A le oil seal remover (LRT-37-

004/2)

308-005

Impulse e tractor (LRT-99-004)

100-012

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Installer/Guide halfshaft oil seal

308-626/2

Installer halfshaft oil seal

308-626/1

Remo al
C AUTIONS:

Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining
mechanism and can separate.

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the RH halfshaft.
For additional information, refer to: Front Halfshaft RH (205-
04 Front Drive Halfshafts, Removal and Installation).
3. Using the special tools, remove and discard the halfshaft
oil seal.

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In alla ion
1. Using the special tools, install a ne halfshaft oil seal.

2. Install the RH halfshaft.

For additional information, refer to: Front Halfshaft RH (205-
04 Front Dri e Halfshafts, Remo al and Installation).

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P bli hed: 11-Ma -2011

Rea D i e Ha f haf -
Rec e ded L b ica
I e S ecifica i
O boa d join U e g ea e pplied i h eplacemen boo ki (Op imol MS139G)
Inboa d join U e g ea e pplied i h eplacemen boo ki (The ma MS141G )
Ge e a S ecif ica i
I e S ecifica i
T pe F ll floa ing, olid haf inco po a ing pl nging con an eloci join a inboa d end and fi ed con an
eloci join a o boa d end of haf
T e S ecif ica i
De c i i N b-f
* Lo e a m o heel kn ckle n 275 203
Toe link bol 175 129
*+ Half haf n 350 258
Road heel n 140 103
* Ne be fi ed

+S a e c e i

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Rear Dri e Halfshafts - Rear Dri e Halfshafts
Description and Operation

Rear Drive Halfshaft C omponent Locations

I em Pa N mbe De c ip ion
1 - RH rear drive halfshaft
2 - LH rear drive halfshaft

GENERAL

The rear drive halfshafts are identical in their construction with a C onstant Velocit (C V) joint at each end to allow for
suspension movement.

REAR DRIVE SHAFT ASSEMBLY

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I em Pa N mbe De c ip ion
1 - RH outer C V joint
2 - RH rear drive halfshaft
3 - RH inner C V joint
4 - LH inner C V joint
5 - LH rear drive halfshaft
6 - LH outer C V joint
Each outer C V joint has a target wheel on the outer diameter. This target is used b the ABS wheel speed sensor for
vehicle and wheel speed calculations.

Each rear drive halfshaft comprises two C V joints (inner and outer), boots and a solid barshaft, which is retained in
the rear differential b a circlip.

The C V joints used on the rear drive halfshafts share the same design and operating principles as the front drive
halfshafts C V joints (see 'Halfshaft Joint' section for more information on C V joints). The rear drive halfshaft inner
joint hubs are retained b peening over the lip of the joint bod .

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Published: 18-Ma -2011

Rear Dri e Halfshafts - Rear Halfshaft
Removal and Installation

Special Tool(s)
Halfshaft remover/replacer

204-506/1(LRT-60-030/1)

Retainers - halfshaft
remover/replacer

204-506/5(LRT-60-030/5)

Halfshaft remover/replacer

204-506/3(LRT-60-030/3)

Halfshaft installer adapter

204-506-01(LRT-60-030/4)

A le oil seal remover

308-005(LRT-37-004/2)

Impulse e tractor

100-012(LRT-99-004)

Installer halfshaft oil seal

308-626/1

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Installer/Guide halfshaft oil seal

308-626/2

Remo al
C AUTIONS:

Do not allow halfshafts to hang unsupported at one end or joint damage will occur.

Do not store or install halfshafts with joints at maximum articulation or damage may occur to the joint.

Angularly Adjusted Roller (AAR) joints, used at the inboard end of some halfshafts have no internal retaining
mechanism and can separate.

Do not undo or remove the large protruding hexagon on the differential casing.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Drain the differential lubricant.
For additional information, refer to: Differential Draining and
Filling (205-02 Rear Drive Axle/Differential, General
Procedures).
3. Remove the wheel and tire.
4. Loosen the halfshaft retaining nut.

Discard the nut.

5. Remove the stabilizer bar link.

For additional information, refer to: Rear Stabilizer Bar Link
(204-02 Rear Suspension, Removal and Installation).

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. Release the parking brake cable from the lower arm.

. Disconnect the toe link.

Remove the bolt.

. Remove and discard the halfshaft retaining nut.

. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure
of the joint.

Release the knuckle from the lower arm.

Remove the bolt.

10. C AUTION: Do not use a hammer to detach the

halfshaft from the hub assembl , failure to follow this
instruction ma result in damage to the halfshaft.

Using the special tools, release the halfshaft from the

wheel hub.

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11. Position a container to collect the oil spillage.
12. Release the halfshaft from the differential housing.
13. With assistance, remove the halfshaft.

Remove and discard the snap ring.

14. Using the special tools, remove and discard the

halfshaft oil seal.

In alla ion
1. C lean the components.
2. Using the special tools, install a new halfshaft oil seal.

The halfshaft oil seal protector must be left in place,

until the halfshaft is full installed.

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. With assistance, install the halfshaft.

Install the snap ring.

Open the halfshaft oil seal protector.

Make sure the snap ring is full engaged and retains

the halfshaft.

. NOTE: The oil seal protector is designed to break into

two pieces.

Remove and discard the halfshaft oil seal protector.

. Using the special tools, install the halfshaft in the wheel

hub.

. C AUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure of
the joint.

C onnect the lower arm to the wheel knuckle.

Tighten to 275 Nm (203 lb.ft).

Tighten the new nut to 275 Nm (203 lb.ft).

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. C AUTION: In all he half haf n finge igh .

In all a ne half haf e aining n and ligh l igh en.

. C onnec he oe link.

Tigh en he bol o 175 Nm (129 lb.f ).

. Sec e he pa king b ake cable o he lo e a m.

10. In all he abili e ba link.
Fo addi ional info ma ion, efe o: Rea S abili e Ba Link
(204-02 Rea S pen ion, Remo al and In alla ion).

11. C AUTION: Do no e ai ool o in all he n .

Fail e o follo hi in c ion ma e l in damage o he
componen .

Tigh en he ne half haf e aining n o 350 Nm (258 lb.f ).

S ake he n o he half haf .

12. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

13. C AUTION: Do no fill he diffe en ial i h l b ican p

o he fille pl g. The fille pl g i onl ed o fill he
diffe en ial i h l b ican , and no o ac a a le el indica o .

Fill he diffe en ial i h he co ec amo n of l b ican .

Fo addi ional info ma ion, efe o: Diffe en ial D aining and
Filling (205-02 Rea D i e A le/Diffe en ial, Gene al
P oced e ).

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Rear Drive Halfshafts - Outer Constant Velocit (CV) Joint Boot
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the halfshaft.
For additional information, refer to: Rear Halfshaft (205-05
Rear Drive Halfshafts, Removal and Installation).
4. C lamp the halfshaft in a vise.
5. Remove and discard the C V joint boot retaining clamps.

6. Slide the C V joint boot along the halfshaft to gain access to

the joint.
7. Using a drift against the inner part of the C V joint,
remove the C V joint from the halfshaft.

Remove and discard the snap ring.

8. Remove the outer C V joint boot.

Installation
1. C lean the components.
2. Install the C V joint boot.
3. Install the outer C V joint.

Install the snap ring.

Position the C V joint on the halfshaft, press the snap

ring into it's groove and push the C V joint full on to
the halfshaft.

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Pull on the C V joint to ensure the snap ring has full
engaged.

. Pack the C V joint with the grease supplied.

. Install the C V joint boot to the C V joint.

Secure with the new clamps.

. Install the halfshaft.

For additional information, refer to: Rear Halfshaft (205-05
Rear Drive Halfshafts, Removal and Installation).
. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Rear Drive Halfshafts - Inner Constant Velocit (CV) Joint Boot
Removal and Installation

Removal

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Remove the halfshaft.
For additional information, refer to: Rear Halfshaft (205-05
Rear Drive Halfshafts, Removal and Installation).
4. C lamp the halfshaft in a vise.
5. Remove and discard the C V joint boot retaining clamps.

6. Slide the C V joint boot along the halfshaft to gain access to

the joint.
7. Using a drift against the inner part of the C V joint,
remove the C V joint from the halfshaft.

Remove and discard the snap ring.

8. Remove the inner C V joint boot.

Installation
1. C lean the components.
2. Install the inner C V joint boot.
3. Install the inner joint.

Install a new snap ring.

Position the C V joint on the halfshaft, press the snap

ring into it's groove and push the C V joint full on to
the halfshaft.

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Pull on the C V joint to ensure the snap ring has full
engaged.

. Pack the joint with the grease supplied.

. Install the boot to the joint.

Secure with the new clamps.

. Install the halfshaft.

For additional information, refer to: Rear Halfshaft (205-05
Rear Drive Halfshafts, Removal and Installation).
. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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P bli hed: 11-Ma -2011

Rear Dri e Halfshafts - Halfshaft Bearing
Remo al and In alla ion

Special Tool(s)
A le oil eal emo e

308-005 (LRT-37-004/2)

Imp l e e ac o

100-012 (LRT-99-004)

Half haf bea ing in alle

205-819

Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.
3. Remo e and di ca d he half haf oil eal.
Fo addi ional info ma ion, efe o: Rea Half haf (205-05
Rea D i e Half haf , Remo al and In alla ion).
4. U ing he pecial ool, emo e and di ca d he half haf
bea ing.

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In alla ion
1. U ing he pecial ool , in all a ne half haf bea ing.

2. In all a ne half haf oil eal.

Fo addi ional info ma ion, efe o: Rea Half haf (205-05
Rea D i e Half haf , Remo al and In alla ion).
3. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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Published: 11-Ma -2011

Brake S stem - General Information -
Brake H draulic Fluid
Item Specification
* Recommended h draulic fluid SHELL DONAX YB DOT4 ESL FLUID

C AUTION: * If the above fluid is not available, use a low viscosit DOT 4 brake fluid meeting ISO 4925 C lass 6
and Land Rover LRES22BF03 requirements.
General Specif ication
Item Specification
Footbrake t pe H draulic, servo assisted, self-adjusting with front/rear split h draulic s stem and pin sliding calipers
Parking brake Twin shoe (leading/trailing) operating on rear wheels and controlled from electric park brake
t pe actuator via twin cables

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P b i hed: 11-Ma -2011

Brake S stem - General Information - Brake S stem
Diag i a d Te i g

Principle of Operation

The b a e e i a fai aigh f a d de ig e i i g ecia i ed ech i e f diag i .

F i f ai he de c i i a d e ai f he e , efe he e e a ec i f he h a a.

Inspection and Verification

1. 1. Ve if he c e c ce .

If a ad e i ece a a e e he ehic e i afe d .

2. 2. Vi a i ec f b i echa ica fa .

Visual inspection
Mechanical
B a e ad( ) c di i a di a ai
B a e ca i e ( ) c di i a di a ai
B a e di c( ) c di i a di a ai
Pa i g b a e di c( )/ a i g b a e d ( )c di i a di a ai
Pa i g b a e h e c di i a di a ai
Pa i g b a e cab e( ) c di i a di a ai
B a e b e c di i a di a ai
B a e b e ac h e c di i a di a ai
B a e a e c i de c di i a di a ai
H d a ic c i (HC U)
B a e f id ea
B a e a i g i dica

3. 3. If a b i ca e f a b e ed e ed c ce i f d, c ec he ca e (if ib e) bef e
ceedi g he e e .

4. 4. U e he a ed diag ic e a ca e ie e a diag ic b e c de (DTC ) bef e

i g he cha .

F a i f diag ic b e c de (DTC ) efe i g he a i- c b a e e , efe ec i

206-09 - T ac i C i he h a a.
Ma e e ha a DTC a e c ea ed f i g ec ifica i
S mptom Chart
S mptom Possible causes Action
B a e i e Deb i Refe he e e a ec i f he h a a.
B a e ad
B a e di c( )

B a e ib a i S e i Refe he e e a ec i f he h a a.
c e
B a e di c( )

E ce i e b a e eda B a e ad W ad a a e he eda a e e ce i e, e ad a a e
a e /b a e eda Ai i he he eda g . C hec af e beddi g i he ad . C hec he eda
g b a e e a e . If he eda " - ", ec ai i he e . C hec f a
B a e a e ca e f ai i g e , ec if a ece a . If he eda i he
c i de f he he d de e e he he e a e e e a ea ,
B a e f id ec a a e c i de fa . Refe he ee a ec i f he
ea ( ee h a a.
i a
i ec i )

E ce i e b a e eda B a e i e( ) C hec f da aged b a e i e . C hec he b a e ca i e . C hec he

eff /b a e eda B a e ca i e b a e ac i e f ai ea , ec if a ece a . C hec he b a e
ha d ide( ) ac e a i . Refe he e e a ec i f he h
B a e ca i e a a . C hec he b a e b e .
i ( )
B a e ac
i e
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B

L B ( ) C .I .
/ P C .C .R
/ / B .
( )
B
( )
B ( )

P P C ( ) / .C
( )
L P ( ). I .C
/ .C
/ P ( )/ ( ). C
/ .R
R .
( )/
( )
P

B B C , .I .
C .R .
C .R
B .
B

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Brake S stem - General Information - Brake S stem Bleeding
General Procedures

WARNING: If any components upstream of the Hydraulic C ontrol Unit (HC U), including the HC U itself are
replaced, the brake system MUST be bled using the procedure on T4, to ensure that all the air is expelled from the
new component(s).

NOTE: Bleeding of the brake system can be carried out using the procedures given on T4, or by using the procedure
below. The following procedure covers bleeding the brake system if components downstream of the HC U have been
replaced.

NOTE: Where only the primary or secondary brake circuits have been disturbed in isolation, it should only be
necessary to bleed that circuit. Partial bleeding of the hydraulic system is only permissible if a brake tube or hose has
been disconnected with only minimal loss of fluid.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. C heck that all the brake line connections are tight and that
there are no signs of leaks. If any leak of brake fluid is
observed, investigate and rectify the cause of the leak
before bleeding the brakes.
For additional information, refer to: Specifications (206-00
Brake System - General Information, Specifications).
3. Pump the brake pedal until the brake vacuum assistance is
exhausted.
4. Remove the plenum chamber panel.

Release the 2 clips.

5. WARNING: Do not allow dirt or foreign liquids to enter

the reservoir. Use only new brake fluid of the correct
specification from airtight containers. Do not mix brands of
brake fluid as they may not be compatible.

C AUTION: Brake fluid will damage paint finished

surfaces. If spilled, immediately remove the fluid and clean
the area with water.

Remove the brake fluid reservoir cap.

Disconnect the brake fluid reservoir electrical

connector.

6. Fill the brake fluid reservoir to the MAX mark.

7. Install the bleed tube to the brake caliper bleed screw and
immerse the free end of the bleed tube in a bleed jar
containing a small quantity of approved brake fluid.
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. Starting at the brake caliper furthest awa from the
brake master c linder, loosen the bleed screw b one-
half to three-quarters of a turn.

. C AUTION: The brake fluid reservoir must remain full

with new, clean brake fluid at all times during bleeding.

With the aid of an assistant, depress the brake pedal

steadil through its full stroke and allow to return to the rest
position. Repeat the procedure until a flow of clean, air-free
fluid is being pumped into the bleed jar.
. When a flow of clean, air-free fluid is being pumped into
the bleed jar, depress and hold the brake pedal.

. C AUTION: Make sure the bleed screw cap is installed

after bleeding. This will prevent corrosion to the bleed screw.

With the brake pedal full depressed, tighten the bleed

screw to 10 Nm (7 lb.ft).
. Fill the brake fluid reservoir to the MAX mark.

. WARNING: Braking efficienc ma be seriousl

impaired if an incorrect bleed sequence is used.

Repeat the brake bleeding procedure for each brake caliper,

following the above sequence.
. Fill the brake fluid reservoir to the MAX mark.
. Appl the brakes and check for leaks.
. Install the brake fluid reservoir cap.

C onnect the brake fluid reservoir electrical connector.

. Install the plenum chamber panel.

Secure the clips.

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Published: 11-May-2011
Brake S stem - General Information - Brake S stem Pressure Bleeding
General Procedures

WARNING: If any components upstream of the Hydraulic C ontrol Unit (HC U), including the HC U itself are
replaced, the brake system must be bled using the procedure on T4, to ensure that all the air is expelled from the
new component(s).

NOTE: The following procedure covers bleeding the complete system. Where only the primary or secondary brake
circuits have been disturbed in isolation, it should only be necessary to bleed that circuit. Partial bleeding of the
hydraulic system is only permissible if a brake tube or hose has been disconnected with only minimal loss of fluid.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. C heck that all the brake line connections are tight and that
there are no signs of leaks.
For additional information, refer to: Specifications (206-00,
Specifications).
3. Release the 3 clips and remove the cover.

4. WARNING: Do not allow dirt or foreign liquids to enter

the reservoir. Use only new brake fluid of the correct
specification from airtight containers. Do not mix brands of
brake fluid as they may not be compatible.

C AUTION: Brake fluid will damage paint finished

surfaces. If spilled, immediately remove the fluid and clean
the area with water.

Fill the brake fluid reservoir to the MAX mark.

5. Install the bleed tube to the brake caliper bleed screw and
immerse the free end of the bleed tube in a bleed jar
containing a small quantity of approved brake fluid.
6. Starting at the brake caliper furthest away from the brake
master cylinder, loosen the bleed screw by one-half turn.

7. C AUTION: The brake fluid reservoir must remain full

with new, clean brake fluid at all times during bleeding.

Depress the brake pedal steadily through its full stroke and
allow to return to the rest position. Repeat the procedure
until a flow of clean, air-free fluid is being pumped into the
bleed jar.

8. C AUTION: Make sure the bleed screw cap is installed

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after bleeding. This will prevent corrosion to the bleed screw.

With the brake pedal full depressed, tighten the bleed

screw to 10 Nm (7 lb.ft).
. Fill the brake fluid reservoir to the MAX mark.

10. WARNING: Braking efficienc ma be seriousl

impaired if an incorrect bleed sequence is used.

Repeat the brake bleeding procedure for each brake caliper.

11. Using T4, bleed the braking s stem.
12. Appl the brakes and check for leaks.
13. Install the cover.

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Brake S stem - General Information - Front Brake Disc Runout Check
Ge e a P ced e

Special Tool(s)
Dia i dica ga ge h di g fi e

100-053 (LRT-99-503)

C AUTION: B a e di c be e e ed i ai , e e di c e i e cha gi g bef e 1000 i e (1500

i e e )f e .

1. Re ea e he b a e h e b ac e f he hee c e.

Re e he b .

2. C AUTION: The b a e ad ea i dica e i

ea i da aged. D e a e e e e he e .U e
fi ge .

LH ide : Di c ec he b a e ad ea i dica
e .
3. Re e he b a e ca i e e b .

4. Re e he b a e ca i e e b .

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. Tie he b ake calipe ho ing a ide.

. Remo e he b ake calipe ancho pla e.

Remo e he 2 bol .

. Mea e he b ake di c hickne a fo poin a o nd

he b ake di c.

Rene he b ake di c if he hickne i le han he

e ice limi , o if he ma im m hickne a ia ion
i e ceeded. B ake di c hickne , NEW = 30 mm,
Se ice limi = 27 mm.

. U ing he pecial ool, in all a dial indica o ga ge o he

b ake calipe lo e mo n ing.

Po i ion he dial indica o ga ge pl nge 5 mm in

f om he o e edge of he b ake di c.

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. In all he heel n .

In all pace a he nde he heel n .

Tigh en he heel n o 140 Nm (103 lb.f ).

. Ro a e he b ake di c one e ol ion o mea e he b ake

di c n-o .

B ake di c n-o m no e ceed 0.05 mm.

. If he b ake di c n-o i o ide he limi . Remo e he

b ake di c.
. Make e he b ake di c and h b ma ing face a e
clean.
. In all he b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

. In all he heel n .

In all pace a he nde he heel n .

Tigh en he heel n o 140 Nm (103 lb.f ).

. Ro a e he b ake di c one e ol ion o mea e he b ake

di c n-o .

B ake di c n-o m no e ceed 0.05 mm.

. If he b ake di c n-o i ill o ide he limi , in all a

ne b ake di c and/o h b.
. Remo e he dial indica o ga ge and he pecial ool.

. WARNING: Do no e comp e ed ai o clean b ake

componen . D f om f ic ion ma e ial can be ha mf l if
inhaled.

C lean he calipe ho ing and ancho pla e ing b ake

cleaning fl id.
. In all he ancho pla e.

Tigh en he bol o 275 Nm (203 lb.f ).

. In all he b ake calipe ho ing and fi he op bol .

Tigh en he bol o 32 Nm (24 lb.f ).

. In all he b ake pad .

In all he o clip .

. Ro a e he b ake calipe do n a d .

Tigh en he bol o 32 Nm (24 lb.f ).

. C onnec he b ake pad ea indica o en o .

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2 . Secure the brake hose retaining bracket to the wheel
knuckle.

Tighten the bolt to 22 Nm (16 lb.ft).

2 . Depress the brake pedal several times, check the fluid

level in the brake fluid reservoir and top-up with brake fluid
if necessar .

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Brake S stem - General Information - Rear Brake Disc Runout Check
General Procedures

Special Tool(s)
Dial indicator gauge holding fixture

100-053 (LRT-99-503)

NOTE: If the parking brake shoes or the brake discs have been removed for access to other components then DO
NOT carry out the bedding in procedure.

1. C AUTION: Do not turn the ignition on when the

parking brake service mode has been set, this will result in the
parking brake being released from the service mode.

Enter the parking brake into the service mode.

Turn the ignition key to position II.

Apply, and hold, the footbrake.

Apply, and hold, the parking brake switch to the

RELEASE position.

Turn the ignition key to position '0' and remove the

key.

Release the footbrake.

Release the parking brake switch.

2. C AUTION: The brake pad wear indicator sensor is

easily damaged. Do not use a lever to remove the sensor.
Use fingers only.

RH side only: Disconnect the brake pad wear indicator

sensor.

3. Remove the brake caliper lower bolt.

4. Remove the brake pads.

Rotate the brake caliper upwards.

Remove the two clips.

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. Remo e he b ake calipe ppe bol .

. C AUTION: Do no allo he b ake calipe o hang on

he b ake ho e.

Tie he b ake calipe ho ing a ide.

. Remo e he b ake calipe ancho pla e.

. Mea e he b ake di c hickne a fo poin a o nd

he b ake di c.

Rene he b ake di c if he hickne i le han he

e ice limi , o if he ma im m hickne a ia ion
i e ceeded. B ake di c hickne , NEW = 20 mm,
Se ice limi = 17 mm.

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. U ing he pecial ool, in all a dial indica o ga ge o he

b ake calipe lo e mo n ing.

Po i ion he dial indica o ga ge pl nge 5 mm in

f om he o e edge of he b ake di c.

10. In all he heel n .

In all pace a he nde he heel n .

Tigh en he heel n o 140 Nm (103 lb.f ).

11. Ro a e he b ake di c one e ol ion o mea e he b ake

di c n-o .

B ake di c n-o m no e ceed 0.09 mm.

12. If he b ake di c n-o i o ide he limi . Remo e he

b ake di c.
13. Make e he b ake di c and h b ma ing face a e
clean.
14. In all he b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

15. In all he heel n .

In all pace a he nde he heel n .

Tigh en he heel n o 140 Nm (103 lb.f ).

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1 . Ro a e he b ake di c one e ol ion o mea e he b ake

di c n-o .

B ake di c n-o m no e ceed 0.09 mm.

1 . If he b ake di c n-o i ill o ide he limi , in all a

ne b ake di c and/o h b.
1 . Remo e he dial indica o ga ge and he pecial ool.
1 . In all he ancho pla e.

Tigh en he bol o 115 Nm (85 lb.f ).

20. In all he b ake calipe ho ing and fi he op bol .

Tigh en he bol o 32 Nm (24 lb.f ).

21. In all he b ake pad .

In all he 2 clip .

In all he o clip .

22. Ro a e he b ake calipe do n a d .

Tigh en he bol o 32 Nm (24 lb.f ).

23. C onnec he b ake pad ea indica o en o .

24. Dep e he b ake pedal e e al ime , check he fl id
le el in he b ake fl id e e oi and op- p i h b ake fl id
if nece a .

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Front Disc Brake -
Item Specification
Di c pe Ven ila ed
Disc diameter:
V6 Pe ol and V6 Die el engine 320 mm (12.6 in)
V8 Pe ol engine 344 mm (13.5 in)
Disc thickness:
Ne 30.0 mm (1.18 in)
Se ice limi 27.0 mm (1.063 in)
Ma im m di c n-o - di c in alled 0.05 mm (0.002 in)
C alipe pe Sliding pin, in pi on
Pi on diame e 48.0 mm (1.8 in)
Pad minim m hickne 3.0 mm (0.12 in)
Brake pad ear arning lead:
Loca ion F on lef hand b ake pad
Ac i a e a 75% of pad life ili ed
Torque Specif ications
Description Nm lb-ft
B ake calipe bleed c e 14 10
B ake di c To c e 35 26
B ake calipe ancho pla e bol 275 202
B ake calipe ho ing bol 35 26
B ake ho e nion 32 24
B ake ho e e aining b acke o heel kn ckle bol 22 16
Road heel n 140 103

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F on Di c B ake - F on Di c B ake
De c ip ion and Ope a ion

C OMPONENT LOC ATIONS

I em Pa N mbe De c ip ion
1 - H b bea ing a embl bol ( 4)
2 - C alipe bol ( 2)
3 - Wheel peed en o
4 - B ake pad ea en o lead
5 - Wheel peed en o bol
6 - G ide pin ( 2)
7 - G ide pin d co e ( 2)
8 - G ide pin bol ( 2)

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9 - C alipe bod
10 - Bleed c e d cap
11 - Bleed c e
12 - Pi on eal ( 2)
13 - Pi on ( 2)
14 - Pi on d co e ( 2)
15 - B ake pad
16 - B ake pad e aine
17 - C alipe ca ie
18 - B ake di c e aining bol
19 - B ake di c
20 - H b bea ing a embl
21 - D hield c e ( 5)
22 - D hield
23 - F on kn ckle

GENE AL

The f on b ake each con i of a in pi on b ake calipe , a en ila ed b ake di c and a d hield. 4.4L model
fea e a diffe en calipe and a la ge diame e b ake di c han he 4.0L and 2.7L Die el model . The d hield i
common on all de i a i e .

The b ake calipe i a ached o he ea of he f on kn ckle. The b ake pad a e made f om an a be o f ee

ma e ial. The inboa d b ake pad of he lef f on b ake inco po a e a ea en o .

When h d a lic p e e i pplied o he calipe , he pi on e end and fo ce he inne pad again he di c. The
calipe bod eac and lide on he g ide pin o b ing he o e pad in o con ac i h he di c.

The f on b ake pad ea en o i connec ed in e ie i h he ea b ake pad ea en o , be een he in men

cl e and g o nd. When a b ake pad inco po a ing a b ake pad ea en o i app o ima el 75% o n, he b ake
pad ea en o goe open ci c i . When he in men cl e de ec he open ci c i , i ill mina e he ambe Ligh
Emi ing Diode (LED) in he b ake a ning indica o . Vehicle i h he high line in men cl e al o di pla an
app op ia e a ning in he me age cen e and o nd a a ning chime.
Fo addi ional info ma ion, efe o: In men C l e (413-01 In men C l e , De c ip ion and Ope a ion).

A he beginning of each igni ion c cle, he in men cl e pe fo m a b lb check on he b ake a ning indica o :
he indica o i ill mina ed ambe fo 1.5 econd , ed fo 1.5 econd , hen goe off.

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Front Disc Brake - Brake Disc
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Release the brake hose bracket from the wheel knuckle.

Remove the bolt.

4. C AUTION: The brake pad wear indicator sensor is

easil damaged. Do not use a lever to remove the sensor. Use
fingers onl .

LH side onl : Disconnect the brake pad wear indicator

sensor.
5. Remove the brake caliper lower bolt.

6. Remove the brake pads.

Rotate the brake caliper upwards.

Remove the two clips.

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. Remo e he b ake calipe ppe bol .

. C AUTION: Do no allo he b ake calipe o hang on

he b ake ho e.

Tie he b ake calipe ho ing a ide.

. Remo e he b ake calipe ancho pla e.

Remo e he 2 bol .

10. Remo e he b ake di c.

Remo e he To c e .

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In alla ion
1. Make e he b ake di c and h b ma ing face a e
clean.
2. In all he b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

3. WARNING: Do no e comp e ed ai o clean b ake

componen . D f om f ic ion ma e ial can be ha mf l if
inhaled.

C lean he calipe ho ing and ancho pla e ing b ake

cleaning fl id.
4. In all he ancho pla e.

Tigh en he bol o 275 Nm (203 lb.f ).

5. In all he b ake calipe ho ing and fi he op bol .

Tigh en he bol o 35 Nm (26 lb.f ).

6. In all he b ake pad .

In all he o clip .

7. Ro a e he b ake calipe do n a d .

Tigh en he bol o 35 Nm (26 lb.f ).

8. C onnec he b ake pad ea indica o en o .

9. Sec e he b ake ho e e aining b acke o he heel
kn ckle.

Tigh en he bol o 22 Nm (16 lb.f ).

10. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

11. Dep e he b ake pedal e e al ime , check he fl id

le el in he b ake fl id e e oi and op- p i h b ake fl id
if nece a .

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Published: 09-Jun-2011
Front Disc Brake - Brake Pads
Removal and Installation

Remo al
WARNINGS:

Brake pads must be renewed in axle sets only, otherwise braking efficiency may be impaired.

If the brake pad wear warning light has been activated, the pad wear sensor must be replaced.

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the wheel and tires.

3. C AUTION: The brake pad wear indicator sensor is

easily damaged. Do not use a lever to remove the sensor. Use
fingers only.

LH side only: Disconnect the brake pad wear indicator

sensor.
4. Remove the brake caliper lower bolt.

5. Remove the brake pads.

Rotate the brake caliper upwards.

Remove the 2 clips.

6. Repeat the above 2 steps for the other side.

Installation

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. WARNING: Do not use compressed air to clean brake

components. Dust from friction materials can be harmful if
inhaled.

C lean the caliper housing and anchor plate using brake

cleaning fluid.
. Inspect the caliper piston and slide pin seals for damage.

. C AUTIONS:

The brake caliper should move freely on both slide pins.

If necessary, renew the components.

C heck the slide pins for correct operation.

. C AUTION: C heck the brake fluid reservoir level before

pushing the piston back, failure to follow this instruction may
result in damage to the vehicle.

NOTE: As the piston is pushed back into the caliper housing,

the brake fluid level in the reservoir will rise. Do not allow the
reservoir to overflow.

Press the pistons into the caliper housing.

. NOTE: Make sure the brake pads are installed in the correct
orientation.

Install the brake pads.

Install the 2 clips.

Apply a suitable amount of the supplied grease to the

mating faces of the brake pads and brake calipers.

. Rotate the brake caliper downwards.

Tighten the bolt to 35 Nm (26 lb.ft).

. Repeat the above procedure for the other side.

. LH side front: C onnect the brake pad wear indicator wiring
harness electrical connection.
. Install the wheel and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

. Depress the brake pedal several times, check the fluid

level in the brake fluid reservoir and top up with brake fluid
if necessary.

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Front Disc Brake - Brake Caliper
Remo al and In alla ion

Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.
3. Remo e he b ake calipe lo e bol .

4. LH ide onl : Di connec he b ake pad ea indica o

en o .
5. Di connec he b ake ho e f om he b ake calipe .

Remo e he nion.

Remo e and di ca d he o ealing a he .

In all blanking cap o he e po ed po .

6. Remo e he b ake pad .

Ro a e he b ake calipe p a d .

Remo e he o clip .

7. Remo e he b ake calipe ppe bol .

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8. Remove the brake caliper housing.

In alla ion

1. WARNING: Do not use compressed air to clean brake

components. Dust from friction materials can be harmful if
inhaled.

C lean the caliper housing and anchor plate using brake

cleaning fluid.
2. Install the brake caliper.
3. Install the brake caliper upper bolt.

Tighten the bolt to 35 Nm (26 lb.ft).

4. Install the brake pads.

Install the two clips.

5. Rotate the brake caliper downwards.

Tighten the bolt to 35 Nm (26 lb.ft).

6. C onnect the brake hose to the brake caliper.

Remove the blanking caps from the ports.

Install new sealing washers.

Tighten the brake hose union to 32 Nm (24 lb.ft).

7. C onnect the brake pad wear indicator sensor.

8. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

9. Bleed the brake s stem.

For additional information, refer to: Brake S stem Bleeding
(206-00 Brake S stem - General Information, General
Procedures).

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Rear Disc Brake -
Item Specification
Di c pe Ven ila ed
Disc diameter:
V6 Pe ol and V6 Die el engine 325 mm (12.7 in)
V8 Pe ol engine 344 mm (13.5 in)
Disc thickness - All engines:
Ne 20.0 mm (0.78 in)
Se ice limi 17.0 mm (0.67 in)
Ma im m di c n-o - di c in alled 0.09 mm (0.003 in)
C alipe pe Sliding pin, ingle pi on
Pi on diame e 45.0 mm (1.7 in)
Pad minim m hickne 3.0 mm (0.12 in)
Brake pad ear arning lead:
Loca ion Rea igh hand b ake pad
Ac i a e a 75% of pad life ili ed
Torque Specif ications
Description Nm lb-ft
B ake calipe bleed c e 14 10
B ake calipe bol 32 24
B ake ho e nion 28 21
B ake di c To c e 35 26
B ake calipe ancho pla e bol 115 85
C alipe ho ing bol 32 24
Road heel n 140 103

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Rea Di c B ake - Rea Di c B ake
De c ip ion and Ope a ion

C OMPONENT LOC ATIONS

I em Pa N mbe De c ip ion
1 - B ake pad ea en o lead
2 - Wheel peed en o
3 - Wheel peed en o bol
4 - C alipe bol ( 2)
5 - Rea kn ckle
6 - Backpla e a embl and d hield
7 - D hield c e ( 3)
8 - D i e flange a embl

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9 - B ake di c
10 - B ake di c e aining bol
11 - B ake pad e aine
12 - C alipe ca ie
13 - G ide pin d co e ( 2)
14 - G ide pin ( 2)
15 - B ake pad
16 - Pi on eal
17 - Pi on
18 - Pi on d co e
19 - Bleed c e
20 - Bleed c e d cap
21 - G ide pin bol ( 2)
22 - C alipe bod

GENE AL

The ea b ake each con i of a ingle pi on b ake calipe , a en ila ed b ake di c and a d hield (in eg a ed a
pa of he pa king b ake). 4.4L model fea e a diffe en calipe and a la ge diame e b ake di c han he 4.0L and
2.7L Die el model . The d hield and pa king b ake a e common on all de i a i e .

The b ake calipe i a ached o he ea of he ea kn ckle. The b ake pad a e made f om an a be o f ee

ma e ial. The inboa d b ake pad of he igh ea b ake inco po a e a ea en o .

When h d a lic p e e i pplied o he calipe , he pi on e end and fo ce he inne pad again he di c. The
calipe bod eac and lide on he g ide pin o b ing he o e pad in o con ac i h he di c.

The ea b ake pad ea en o i connec ed in e ie i h he f on b ake pad ea en o , be een he in men

cl e and g o nd. When a b ake pad inco po a ing a b ake pad ea en o i app o ima el 75% o n, he b ake
pad ea en o goe open ci c i . When he in men cl e de ec he open ci c i , i ill mina e he ambe Ligh
Emi ing Diode (LED) in he b ake a ning indica o . Vehicle i h he high line in men cl e al o di pla an
app op ia e a ning in he me age cen e and o nd a a ning chime.
Fo addi ional info ma ion, efe o: In men C l e (413-01 In men C l e , De c ip ion and Ope a ion).

A he beginning of each igni ion c cle, he in men cl e pe fo m a b lb check on he b ake a ning indica o :
he indica o i ill mina ed ambe fo 1.5 econd , hen ed fo 1.5 econd .

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Rear Disc Brake - Brake Disc
Removal and Installation

Remo al
NOTE: If the parking brake shoes or the brake discs have been removed for access to other components then DO
NOT carry out the bedding in procedure.

1. C AUTION: Do not turn the ignition on when the

parking brake service mode has been set, this will result in the
parking brake being released from the service mode.

Enter the parking brake into the service mode.

Turn the ignition key to position II.

Apply, and hold, the footbrake.

Apply, and hold, the parking brake switch to the

RELEASE position.

Turn the ignition key to position '0' and remove the

key.

Release the footbrake.

Release the parking brake switch.

2. Isolate the parking brake electrical circuit.

Remove fuse number 8 from the BJB.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the wheel and tire.
5. Remove the brake caliper anchor plate.
For additional information, refer to: Brake C aliper Anchor
Plate (206-04 Rear Disc Brake, Removal and Installation).
6. Release the parking brake shoe adjustment.

Remove the plug from the access hole in the brake

disc.

Using a suitable tool, rotate the brake shoe adjuster

to release the adjustment.

Install the access plug.

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7. Remo e he b ake di c.

Remo e he To c e .

In alla ion
1. Make e he b ake di c and h b ma ing face a e
clean.
2. In all he b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

3. In all he b ake calipe ancho pla e.

Fo addi ional info ma ion, efe o: B ake C alipe Ancho
Pla e (206-04 Rea Di c B ake, Remo al and In alla ion).
4. Adj he pa king b ake.
Fo addi ional info ma ion, efe o: Pa king B ake Shoe and
Lining Adj men (206-05 Pa king B ake and Ac a ion,
Gene al P oced e ).
5. In all f e n mbe 8 in o he BJB.

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. Install the heel and tire.

Tighten the heel nuts to 140 Nm (103 lb.ft).

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Rear Disc Brake - Brake Pads
Removal and Installation

Remo al
WARNINGS:

Brake pads must be renewed in axle sets only, otherwise braking efficiency may be impaired.

If the brake pad wear warning light has been activated, the pad wear sensor must be replaced.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.

3. C AUTION: The brake pad wear indicator sensor is

easily damaged. Do not use a lever to remove the sensor. Use
fingers only.

RH side only: Disconnect the brake pad wear indicator

sensor.
4. Remove the brake caliper lower bolt.

5. Remove the brake pads.

Rotate the brake caliper upwards.

Remove the 2 clips.

Installation

1. WARNING: Do not use compressed air to clean brake

components. Dust from friction materials can be harmful if
inhaled.

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C lean the brake caliper housing and anchor plate using
brake cleaning fluid.
. Inspect the caliper piston and slide pin seals for damage.
. Position a bleed jar containing a small quantit of approved
brake fluid. C onnect the bleed tube to the bleed screw and
loosen the screw.
. Press the piston into the caliper housing.

Tighten the bleed screw to 14 Nm (10 lb.ft).

. Disconnect the bleed tube and remove the jar.

. C AUTION: If equipped, the adhesive strips covering

the outer brake pads must be removed before installation.
Failure to follow this instruction ma result in damage to the
vehicle.

If equipped, remove the adhesive strips from the 2 outer

brake pads.

. Install the brake pads.

Install the 2 clips.

. Rotate the brake caliper downwards.

Tighten the bolt to 32 Nm (24 lb.ft).

. C onnect the brake pad wear indicator sensor.

. Repeat the above procedure for the other side.
. Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

. Depress the brake pedal several times, check the fluid

level in the brake fluid reservoir and top-up with brake fluid
if necessar .

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P bli hed: 11-Ma -2011

Rear Disc Brake - Brake Caliper
Remo al and In alla ion

Remo al

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Remo e he heel and i e.

3. C AUTION: The b ake pad ea indica o en o i

ea il damaged. Do no e a le e o emo e he en o . U e
finge onl .

RH ide onl : Di connec he b ake pad ea indica o

en o .
4. Remo e he b ake calipe lo e bol .

5. Remo e he b ake pad .

Ro a e he b ake calipe p a d .

Remo e he 2 clip .

6. Di connec he b ake ho e f om he b ake calipe .

Remo e he nion.

Remo e and di ca d he o ealing a he .

In all blanking cap o he e po ed po .

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7. Remo e he b ake calipe ppe bol .

8. Remo e he b ake calipe ho ing.

In alla ion

1. WARNING: Do no e comp e ed ai o clean b ake

componen . D f om f ic ion ma e ial can be ha mf l if
inhaled.

C lean he calipe ho ing and ancho pla e ing b ake

cleaning fl id.
2. In all he b ake calipe .
3. In all he b ake calipe ppe bol .

Tigh en he bol o 35 Nm (26 lb.f ).

4. C onnec he b ake ho e o he b ake calipe .

Remo e he blanking cap f om he po .

In all ne ealing a he .

Tigh en he b ake ho e nion o 28 Nm (21 lb.f ).

5. In all he b ake pad .

In all he o clip .

6. Ro a e he b ake calipe do n a d .

Tigh en he bol o 35 Nm (26 lb.f ).

7. C onnec he b ake pad ea indica o en o .

8. In all he heel and i e.

Tigh en he heel n o 140 Nm (103 lb.f ).

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. Bleed the brake s stem.

For additional information, refer to: Brake S stem Bleeding
(206-00 Brake S stem - General Information, General
Procedures).

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Rear Disc Brake - Brake Caliper Anchor Plate
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.

3. C AUTION: The brake pad wear indicator sensor is

easil damaged. Do not use a lever to remove the sensor. Use
fingers onl .

RH side onl : Disconnect the brake pad wear indicator

sensor.
4. Remove the brake caliper lower bolt.

5. Remove the brake pads.

Rotate the brake caliper upwards.

Remove the two clips.

6. Remove the brake caliper upper bolt.

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7. C AUTION: Do no allo he b ake calipe o hang on

he b ake ho e.

Tie he b ake calipe ho ing a ide.

8. Remo e he b ake calipe ancho pla e.

9. Remo e he g ide pin and eal .

In alla ion

1. WARNING: Do no e comp e ed ai o clean b ake

componen . D f om f ic ion ma e ial can be ha mf l if
inhaled.

C lean he calipe ho ing and ancho pla e ing b ake

cleaning fl id.
2. C lean and l b ica e he g ide pin .
3. In all he g ide pin .
4. In all he ancho pla e.
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Tighten the bolts to 115 Nm (85 lb.ft).

. Install the brake caliper housing and fit the top bolt.

Tighten the bolt to 35 Nm (26 lb.ft).

. Install the brake pads.

Install the 2 clips.

. Rotate the brake caliper do n ards.

Tighten the bolt to 35 Nm (26 lb.ft).

. C onnect the brake pad ear indicator sensor.

. Install the heel and tire.

Tighten the heel nuts to 140 Nm (103 lb.ft).

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P bli hed: 11-Ma -2011

Parking Brake and Actuation -
General Specif ication
Item Specification
Make C on inen al Te e
Model/ pe N5528001
Ope a ion T in cable ope a ion o pa k b ake i h eme genc cable elea e loca ed in
pa enge compa men
Minim m b ake lining ma e ial 2.0 mm (0.078 in)
hickne
Torque Specif ications
Description Nm lb-ft
Wedge adj e Allen c e 7 5
Rea b ake di c To c e 35 26
B ake calipe ancho pla e o heel kn ckle bol 115 85
B ake calipe o ancho pla e bol 35 26
Pa king b ake ac a o and cable a embl n 5 4
Pa king b ake ac a o mo n ing b acke bol 22 16
F el ank hea hield n 3 2
F el ank hea hield bol 6 4
* LH/RH pa king b ake cable bol 22 16
Pa king b ake cable co pling 8 6
Road heel n 140 103
* Ne nuts/bolts must be installed

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Parking Brake and Ac a ion - Parking Brake
Description and Operation

C OMPONENT LOC ATIONS

I em Pa N mbe
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
De c ip ion
C lutch pedal position sensor (manual transmission models onl )
Parking brake indicators (all e cept NAS (north American specification))
Parking brake indicators (NAS onl )
Drum brake
Parking brake module
Parking brake cable
Emergenc release cable
Parking brake s itch

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GENERAL

The parking brake is an electrically actuated system that operates drum brakes integrated into the rear brake discs.
The parking brake system consists of:

A parking brake switch.

Left and right drum brakes.
Left and right brake cables.
An emergency release cable.
A clutch pedal position sensor (manual transmission models only).
Two parking brake indicators.
A parking brake module.

The parking brake is operated by the parking brake module, which adjusts the tension of the brake cables to apply
and release the drum brakes. Operation of the parking brake module is initiated by the parking brake switch.

PARKING BRAKE S ITCH

I em Pa N mbe De c ip ion
1 - C over
2 - Parking brake switch
3 - Securing screw
4 - Electrical connector
The parking brake switch is used by the driver to apply and release the parking brake, and is installed in the center
console adjacent to the gear lever.

Slots on the sides of the parking brake switch engage with the top panel of the center console, and a screw secures
the parking brake switch in position. An electrical connector on the back of the switch provides the interface with the
vehicle wiring. A brake symbol on the switch illuminates when the exterior lamps are selected on.

There are three states for the parking brake switch:

Apply request, when the handle of the parking brake switch is pulled up.
Release request, when the handle of the parking brake switch is pushed down.
Idle, when the handle of the parking brake switch is in the central or rest position.

Microswitches, incorporated into the parking brake switch, are activated by the handle of the parking brake switch. To
determine the operating state of the parking brake switch, the parking brake module scans the circuits containing the
microswitches.

DRUM BRAKES

NOTE: RH brake shown, LH brake similar

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I em Pa N mbe De c ip ion
1 - Brake shoe
2 - Shoe locating pin and clip
3 - Adjuster spring
4 - Toothed wheel adjuster
5 - Backplate
6 - Return spring
7 - C ross strut
8 - Wedge adjuster screw
9 - Dust shield
10 - Rear brake disc
11 - Adjuster access plug
Each drum brake consists of a pair of brake shoes installed on a backplate attached to the rear hub carrier. The
brake shoes operate on the drum integrated into the rear brake disc. The orientation of the brake shoes differ by
180 between the left-hand (LH) and right-hand (RH) brakes.

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When the parking brake module tensions the brake cables, the movement is transmitted to an operating lever on one
of the brake shoes. The operating lever pivots against a cross strut, which forces the brake shoes apart and into
contact with the drum in the rear brake disc. Brake shoe to drum clearance is set with two manual adjusters, which
are accessed through a hole in the brake disc. One of the adjusters is a conventional toothed wheel adjuster. The
second adjuster is a wedge adjuster operated b an Allen screw.

After replacement of the brake shoes or brake discs, a bedding in procedure must be performed to ensure the drum
brakes operate satisfactoril .
For additional information, refer to: Parking Brake Shoe and Lining Adjustment (206-05 Parking Brake and Actuation,
General Procedures).

Prior to removing a brake disc from a vehicle, power should be disconnected from the parking brake module.
Operation of the parking brake switch while a brake disc is removed can cause the actuating mechanism in the
parking brake module to sei e.

B AKE CABLE

I em Pa N mbe De c ip ion
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1 - G
2 - P
3 - C
4 - S
5 - T
6 - S
7 - F
8 - S
9 - L
10 - S
11 - C
T B .N ,
,
.I ,
.I ,
.

T RH ' ' ;
.

T LH (LH );
,
.

W , LH ,
.T
.

P , .O

.I , 20 - .A -
.

EMERGENC RELEASE CABLE

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I em Pa N mbe De c ip ion
1 - Pull ring
2 - Quick release fitting
3 - Parking brake module
4 - Sealing collar
5 - Spring
6 - Inner cable
7 - Nipple
8 - Pulle wheel
The emergenc release cable allows the parking brake to be mechanicall released if:

The parking brake cannot be electricall released because of a s stem fault.

The batter is disconnected or batter voltage decreases below 7.5 volts while the parking brake is applied, so
that the parking brake cannot be electricall released.

The parking brake is mechanicall released b disconnecting the force sensor from the spline shaft in the parking

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.D ,
, .

T B .
T
.A
.A ,
.

I , .T
, , .

T 200 N (45 ). W
,
.

A ,
,
.T
.T - .A
.

CLUTCH PEDAL POSITION SENSOR (MANUAL TRANSMISSION MODELS ONL )

I em Pa N mbe De c ip ion
1 - C
2 - E
3 - C
T .

T H .T
,
.T
.

PARKING BRAKE INDICATORS

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I em Pa N mbe De c ip ion
1 - R ( NAS)
2 - A ( NAS)
3 - R (NAS )
4 - A (NAS )
T , ,
.

Amber Parking Brake Warning Indicator

T .
O (C AN)
.

Red Parking Brake Warning Indicator

W ,
3 .I
, , .

W , C AN .W
,
.

Te t Messages

O , ,
.
F , :I M C (413-08 I M C ,
D O ).

PARKING BRAKE MODULE

T
.

T .T
, , .
T
.

T :

A PC B ( ) ASIC ( )
.
A .
A .
A .
A .

T .T
.T
.

T , , .
T .T
.

I P B M

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I em Pa N mbe De c ip ion
1 - Elec ical connec o
2 - Ho ing
3 - Elec ic mo o
4 - PC B
5 - Spline haf
6 - Gea bo
7 - Fo ce en o
Inp and O p

A 32 pin elec ical connec o on he RH ide of he pa king b ake mod le p o ide he in e face be een he PC B and
he ehicle i ing.

The pa king b ake mod le i po e ed b o pe manen ba e po e feed f om he ba e j nc ion bo (BJB).

T o connec ion i h he cen al j nc ion bo (C JB) p o ide ba e ol age ignal hen he ke i in he igni ion
i ch (ke in) and hen he igni ion i ch i in po i ion II (igni ion). O he ha d i ed inp con i of ho e f om
he pa king b ake i ch and, on man al an mi ion model , he cl ch pedal po i ion en o .

In addi ion o he ha d i ed connec ion , he pa king b ake mod le i connec ed o he high peed C AN b o enable
comm nica ion i h o he ehicle em .

Pa king B ake Mod le Ha ne C onnec o C 2178

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Pa king B ake Mod le Ha ne Connec o C2178 Pin De ail

Pin No. De c ip ion Inp /O p
A1 Not used -
A2 High speed C AN bus low out Input/Output
A3 High speed C AN bus high in Input/Output
A4 High speed C AN bus low in Input/Output
B1 Not used -
B2 High speed C AN bus high out Input/Output
B3 Parking brake switch SW1 Input
B4 Parking brake switch SW4 Input
C 1 and C 2 Not used -
C3 Parking brake switch SW2 Input
C4 Parking brake switch SW5 Output
D1 to E1 Not used -
E2 C lutch pedal position sensor ground Input
E3 C lutch pedal position sensor signal Input
E4 C lutch pedal position sensor power suppl Output
F1 Not used -
F2 Ke in ignition switch Input
F3 Ignition power suppl Input
F4 Red parking brake indicator Output
G1 Not used -
G2 Ground Output
G3 Not used -
G4 Batter power suppl Input
H1 Not used -
H2 Ground Output
H3 Not used -
H4 Batter power suppl Input

PARKING BRAKE OPERATION

The parking brake can be applied at an time provided sufficient batter power is available. For the parking brake to
be released, various pre-conditions are required. The parking brake has manual and automatic operating modes, to
cater for different operating circumstances, as detailed in the following table:

Ope a ing Mode

Mode P e-Condi ion D i e Ac ion
Static appl Vehicle speed less than 2.5 km/h (1.6 mph). Pull up parking brake switch.
Static release 1. Vehicle speed less than 2.5 km/h (1.6 mph). Press down parking brake switch.
2. Engine running.
OR
Ignition switch in position II and brake pedal or
clutch pedal pressed (manual transmission).
OR
Ignition switch in position II and brake pedal or
accelerator pedal pressed (automatic
transmission).
Ke out appl 1. Vehicle speed less than 10 km/h (6.25 mph). Remove ke from ignition switch.
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(manual transmission only) 2. Ignition switch in position 0.
3. Key in ignition switch.
Key out apply inhibit 1. Vehicle speed less than 2.5 km/h (1.6 mph). Remove key from ignition switch
2. Ignition switch in position 0. while pressing down parking brake
3. Key in ignition switch. switch.
Dynamic apply Vehicle speed more than 2.5 km/h (1.6 mph). Pull up parking brake switch as
required.
Dynamic release Vehicle speed more than 2.5 km/h (1.6 mph). Release (to neutral position) or press
down parking brake switch.
DAR (drive away release) 1. Ignition switch in position II. None. Parking brake released
(automatic transmission 2. Transmission in gear 1, 2 or R (with high range automatically on drive away.
only) selected) or 1, 2, 3 or R (with low range selected).
3. Accelerator pedal pressed more than 5%.
Ope a ing Vol age

Actuation of the parking brake (apply or release) is only started if the power supply to the parking brake module is
within 9 to 18 volts. At any voltage in this range, the parking brake module is able to tighten the brake cables to the
maximum, to fully apply the parking brake, although at voltages between 9 and 10.5 volts the actuation time may
exceed 1.0 second.

During a parking brake actuation:

If the power supply to the parking brake module decreases to less than 8.3 volts, the parking brake module
continues the actuation, but stores a related fault code. If the ignition is on, the parking brake module also
signals the instrument cluster to illuminate the amber parking brake warning indicator and flash the red
parking brake warning indicator. On vehicles with the high line instrument cluster, a message advising there is
a parking brake fault is shown in the message center. The warning indications are discontinued if the power
supply voltage increases to 8.3 volts or more.
If the power supply voltage decreases to less than 7.5 volts, the parking brake module discontinues the
actuation. Actuation is automatically resumed if the power supply voltage subsequently increases to 7.5 volts
or more and the parking brake switch request is still valid.
If the power supply voltage decreases below 6.5 volts, the parking brake function is disabled for the remainder
of the ignition cycle.
If the power supply voltage increases to more than 18.0 volts, the parking brake module immediately disables
the parking brake function and stores a related fault code. If the ignition is on, the parking brake module also
signals the instrument cluster to illuminate the amber parking brake warning indicator and flash the red
parking brake warning indicator. On vehicles with the high line instrument cluster, a message advising that the
parking brake has a fault and is not functioning is shown in the message center. The parking brake function
remains disabled until the power supply voltage is within 9 to 18 volts again. When the power supply voltage is
within 9 to 18 volts again, the warning indications are cancelled and actuation is automatically resumed if the
parking brake module is in a dynamic mode of operation with a valid parking brake switch request.

NOTE: The instrument cluster shuts down below 8 volts, so warning indications and messages are not displayed
below 8 volts. C AN transmission stops if battery voltage drops below 7.0 volts and re-starts when voltage goes above
7.5 volts.

Sleep Mode

To reduce quiescent drain on the vehicle battery, the parking brake module incorporates a sleep mode. The parking
brake module enters the sleep mode, provided the ignition is off and there are no signals from the wheel speed
sensors, when one of the following occurs:

20 minutes elapse after the last actuation of the parking brake.

If no actuation occurred, 20 minutes elapse after the ignition is switched off.

The parking brake module wakes up from the sleep mode when on of the following occurs:

An apply or release request is made with the parking brake switch.

The ignition is turned on.
A key out apply is activated.

The parking brake module wakes up within 500 ms. The high speed C AN bus is activated within 200 ms maximum.

When the parking brake module is woken with a release request from the parking brake switch, the parking brake
module ignores the request but illuminates the red brake warning indicator. The parking brake module extinguishes
the red brake warning indicator and goes back to sleep immediately the switch is released to the neutral position.

When the parking brake module is woken with an apply request from the parking brake switch, if the parking brake is
already applied the parking brake module ignores the request but illuminates the red brake warning indicator. The
parking brake module extinguishes the red brake warning indicator and goes back to sleep immediately the switch is
released to the neutral position. If the parking brake is in the released condition when the apply request is made, the
parking brake module illuminates the red brake warning indicator and applies the parking brake. The parking brake
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3 ,
, .

D namic Appl

I , 10 / (6.25 )
, ABS .
W , .O
, .I ,
, , .

T - (ABS) ,
.A - -
.

T .

F 1 2.5 / (1.25 ) V
ABS .W 1
, , .T
ABS ,
.D
ABS - .
W 2.5 / (1.25 )
.
F 2 ABS
C AN .W 2 ,
.T
, - .

W , 1 2,
C AN :

T ABS , .
T , , 0.5 , 1.0 .
T , .T
2, .

DAR Pre-arming

T DAR -
DAR - . DAR - :

T II.
T 1, 2 R.
T .
N .

Automatic Load Adjustment

W , .I
,
.

Failsafe Tighten. I , - , ,
.

Automatic Appl . W ,
, .

Automatic Release. W ,
, .

Parking Brake Switch Monitoring

T .I
, :

S - .
B .
P .

T - .I

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brake module can still determine the operating state of the parking brake switch. Short circuits or multiple failures
cause the parking brake module to disable the parking brake switch for the remainder of the ignition cycle. The
parking brake module also disables the parking brake switch if a plausibility fault occurs. However, since plausibility
faults are usually caused by incomplete operation of the parking brake switch, the parking brake switch is re-enabled
if the parking brake module subsequently establishes a plausible operating state.

If a single microswitch fault is detected, the parking brake module signals the instrument cluster to illuminate the
amber parking brake warning indicator. On vehicles with the high line instrument cluster, the parking brake module
also signals the instrument cluster to display a message advising there is a parking brake fault. During an apply
actuation, the parking brake module also signals the instrument cluster to flash the red parking brake warning
indicator.

For all other fault types, the parking brake module signals the instrument cluster to illuminate the amber parking
brake warning indicator, and, on vehicles with the high line instrument cluster, to display a message advising the
parking brake has a fault and is not functioning. If it makes an apply actuation, the parking brake module signals the
instrument cluster to flash the red parking brake warning indicator for the remainder of the ignition cycle.

On the next ignition cycle, the warning indicators and the messages are only activated if the fault is still present,
although the fault code is retained by the parking brake module until cleared by T4.

CON ROL DIAGRAM

NOTE: A = Hardwired connection; D = High speed C AN bus; N = Medium speed C AN bus

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I em Pa N mbe De c ip ion
1 - Batter
2 - Fusible link 11E, BJB

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3 - Fusible link 8E, BJB
4 - Air suspension control module
5 - Diagnostic socket
6 - Instrument cluster
7 - Integrated head unit
8 - Parking brake module
9 - automatic temperature control (ATC ) module
10 - Tire Pressure Monitoring Module (TPMM)
11 - Parking Aid module
12 - C JB
13 - Transfer bo control module
14 - engine control module (EC M)
15 - Rear differential control module
16 - ABS module
17 - transmission control module (TC M)
18 - C lutch pedal position sensor
19 - restraints control module (RC M)
20 - Parking brake s itch
21 - Fuse 41P, C JB (ignition)
22 - Ignition s itch
23 - Fuse 40P, C JB (ke -in)

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P bli hed: 11-Ma -2011

Pa king B ake and Ac a ion - Pa king B ake
Diagno i and Te ing

O e ie

Plea e no e hi i a ealed ni and no a emp m be made o open he ac a o a i ill in alida e

he a an claim.

Fo info ma ion on he ope a ion of he em.

REFER o: Pa king B ake (206-05 Pa king B ake and Ac a ion, De c ip ion and Ope a ion).

In pec ion and Ve ifica ion

1. 1. Ve if he c ome conce n.

2. 2. Vi all in pec fo ob io mechanical o elec ical fa l .

Vi al In pec ion
Mechanical Elec ical
Pa king b ake cable( ) condi ion and fi men Pa king b ake indica o
Pa king b ake hoe condi ion and fi men F e
Pa king b ake d m (in eg a ed in o ea b ake - F e bo - engine compa men - f e 11E
di c ) - F e bo - engine compa men - f e 8E
Pa king b ake ac a o mod le condi ion and fi men - F e bo - pa enge compa men - f e
40P
- F e bo - pa enge compa men - f e
41P
Wi ing ha ne /elec ical connec o
- C heck fo ben /co oded pin
C on olle a ea ne o k (C AN) ci c i
Pa king b ake i ch
Pa king b ake ac a o mod le

3. 3. If an ob io ca e fo an ob e ed o epo ed conce n i fo nd, co ec he ca e (if po ible) befo e

p oceeding o he ne ep.

4. 4. U e he app o ed diagno ic em o a can ool o e ie e an DTC befo e mo ing on o he mp om

cha o DTC inde .

Make e ha all DTC a e clea ed follo ing ec ifica ion.

S mp om Cha

S mp om Po ible ca e Ac ion
Pa king b ake ill Pa king b ake C heck he pa king b ake cable fo fo ling, apping o damage. C heck
no engage o cable fo led, he cable fo co ec o ing. C heck ha he cable end fi ing
elea e apped o connec o ( ) a e co ec l fi ed o he ope a ing le e ( ). In pec he
Lo pa king damaged pa king b ake hoe and d m fo condi ion/ ea /con amina ion,
b ake Pa king b ake REFER o: B ake Di c (206-04 Rea Di c B ake, Remo al and
efficienc /pa king cable inco ec l In alla ion) /
b ake o ed o fi ed Pa king B ake Shoe (206-05 Pa king B ake and Ac a ion, Remo al
icking/binding Pa king b ake and In alla ion).
hoe , lining C heck he pa king b ake hoe fo co ec adj men .
o n/con amina ed REFER o: Pa king B ake Shoe and Lining Adj men (206-05 Pa king
Pa king b ake B ake and Ac a ion, Gene al P oced e ).
d m (in eg a ed C heck he ope a ion of he pa king b ake ac a o mod le, check fo
in o ea b ake damage and/o e ce i e noi e d ing ope a ion. C heck fo pa king
di c ) b ake ac a o mod le DTC .
Pa king b ake
hoe inco ec l
adj ed follo ing
eplacemen
Pa king b ake
ac a o mod le
malf nc ion

DTC inde
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NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

DTC De c ip ion Po ible ca e Ac ion

C 110468 Brake Event information This is not a fault. This is where the parking brake bedding-in
bedding-in mode has been activated. For information on how the
mode bedding-in mode is activated and deactivated,
REFER to: Parking Brake Shoes Bedding-In (206-05 Parking
Brake and Actuation, General Procedures).
C 1A0000 C ontrol Parking brake actuator C lear DTC s, complete drive cycle 1 to test for normal
module failure module fault operation, refer to the relevant drive cycle shown below this
table. Refer to the warranty policy and procedures manual if
a module is suspect.
C 1A0016 Parking brake Battery voltage below C heck the charging system, charging voltage and battery
actuator 8.3V at parking brake condition. C heck the parking brake actuator power and
module, actuator module ground circuits. Refer to the electrical guides. C lear DTC s,
voltage low C harging system complete drive cycle 3 to test for normal operation, refer to
under charging the relevant drive cycle shown below this table.
Parking brake actuator
module supply circuit:
short circuit to ground
Parking brake actuator
module supply circuit:
open circuit
Parking brake actuator
module ground circuit:
short circuit to power
Parking brake actuator
module ground circuit:
open circuit

C 1A0017 Parking brake Vehicle started using a C heck the charging system and charging voltage. C heck the
actuator booster pack parking brake actuator power circuits. Refer to the electrical
module, Battery voltage at guides. C lear DTC s, complete drive cycle 3 to test for normal
voltage high parking brake actuator operation, refer to the relevant drive cycle shown below this
module has been table.
greater than 17V
C harging system over
charging
Parking brake actuator
module supply circuit:
short circuit to power

C 1A004B C ontrol NOTE: This is not a fault. If the red parking brake warning indicator flashes the fault is
module the result of short term protection (message displayed). Allow
Parking brake actuator the parking brake to cool for 60 seconds and retest for
module temperature functionality. If the parking brake does not apply, check for
protection invoked, other DTC s. Rectify as necessary. C lear DTC s, complete
typically due to drive cycle 3 to test for normal operation, refer to the
overuse where there relevant drive cycle shown below this table.
have been more than
15 apply and release
cycles continuously

C 1A4001 Longitudinal NOTE: The longitudinal C lear DTC s and check if the fault reoccurs when the vehicle
acceleration acceleration sensor is part of is stationary. Refer to the warranty policy and procedures
sensor - the parking brake actuator manual if a module is suspect. C lear DTC s, complete drive
general module cycle 1 to test for normal operation, refer to the relevant
electrical drive cycle shown below this table.
failure Longitudinal
acceleration sensor
fault

C 1A4002 Longitudinal NOTE: The longitudinal C lear DTC s and check if the fault reoccurs when the vehicle
acceleration acceleration sensor is part of is stationary. C alibrate the longitudinal acceleration sensor.
sensor - the parking brake actuator To calibrate the sensor make sure the vehicle is on a level
general signal module surface and run the calibration routine from the configuration
failure menu of the approved diagnostic system. If calibration was
Longitudinal not successful check that the parking brake actuator module
acceleration sensor
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plausibility failure is correctly installed. Refer to the warranty policy and
procedures manual if a module is suspect. C lear DTC s,
complete drive cycle 2 to test for normal operation, refer to
the relevant drive cycle shown below this table.
C 1A4054 Longitudinal NOTE: The longitudinal C lear DTC s and calibrate the longitudinal acceleration sensor.
acceleration acceleration sensor is part of To calibrate the sensor make sure the vehicle is on a level
sensor - the parking brake actuator surface and run the calibration routine from the configuration
missing module menu of the approved diagnostic system. Retest for
calibration functionality. C lear DTC s, complete drive cycle 1 to test for
Longitudinal normal operation, refer to the relevant drive cycle shown
acceleration sensor not below this table.
calibrated

C 1A4101 C lutch pedal C lutch pedal sensor C heck the clutch pedal sensor and circuits. Refer to the
sensor circuit - circuit : open circuit electrical guides. Install a new clutch pedal sensor as
general C lutch pedal sensor necessary. C lear DTC s, complete drive cycle 1 to test for
electrical circuit: short circuit to normal operation, refer to the relevant drive cycle shown
failure ground below this table.
C lutch pedal sensor
circuit: short circuit to
power
C lutch pedal sensor
fault

C 1A4102 C lutch pedal
sensor circuit -
general signal
failure
C lutch pedal sensor C heck the clutch pedal sensor and circuits. Refer to the
circuit : open circuit electrical guides. Install a new clutch pedal sensor as
C lutch pedal sensor necessary. C lear DTC s, complete drive cycle 2 to test for
circuit: short circuit to normal operation, refer to the relevant drive cycle shown
ground below this table.
C lutch pedal sensor
circuit: short circuit to
power
C lutch pedal sensor
fault

C 1A4300 Motor supply NOTE: The electric motor is C heck that the brake cables are connected correctly and are
circuit part of the parking brake not loose/damaged. If the cables need to be re-connected
actuator module use the approved diagnostic system to drive the cables to the
"mount" position so that maximum cable length is available.
Brake cables C heck the parking brake shoes adjustment and condition,
loose/broken/damaged REFER to: Parking Brake Shoe and Lining Adjustment (206-05
Brake shoes Parking Brake and Actuation, General Procedures) /
worn/damaged Brake Disc (206-04 Rear Disc Brake, Removal and
Electric motor jammed Installation) /
Parking Brake Shoes (206-05 Parking Brake and Actuation,
Removal and Installation).
If the parking brake actuator module is stuck, re-cycle the
ignition. If the parking brake actuator module cannot be
operated from the switch then use the approved diagnostic
system to drive the parking brake actuator module using the
"unjam" application in the set-up and configuration menu.
Retest for functionality. Refer to the warranty policy and
procedures manual if a module is suspect. C lear DTC s,
complete drive cycle 1 to test for normal operation, refer to
the relevant drive cycle shown below this table.
C 1A4301 Motor supply NOTE: The electric motor is C lear DTC s, complete drive cycle 3 to test for normal
circuit part of the parking brake operation, refer to the relevant drive cycle shown below this
actuator module table. Refer to the warranty policy and procedures manual if
a module is suspect.
Internal motor circuit
fault

C 1A4662 Parking brake Parking brake cables
actuator fouled, trapped or
module damaged
plausibility Parking brake shoes,
check linings worn
Parking brake shoes
incorrectly adjusted
following replacement
Parking brake actuator
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C heck the parking brake cables for fouling, trapping or
damage. C heck the parking brake shoes for correct
adjustment,
REFER to: Parking Brake Shoe and Lining Adjustment (206-05
Parking Brake and Actuation, General Procedures).
Inspect the parking brake shoes for excessive wear.
REFER to: Brake Disc (206-04 Rear Disc Brake, Removal and
Installation) /
Parking Brake Shoes (206-05 Parking Brake and Actuation,
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module circuit(s): Removal and Installation).
short circuit to ground, C heck the parking brake actuator module circuits. Refer to
short circuit to power, the electrical guides. Refer to the warranty policy and
high resistance procedures manual if a module is suspect.
Parking brake actuator
module fault

C 1A4701 Force sensor - NOTE: The force sensor is C lear DTC s, complete drive cycle 1 to test for normal
general part of the parking brake operation, refer to the relevant drive cycle shown below this
electrical actuator module table. Refer to the warranty policy and procedures manual if
failure a module is suspect.
Internal force sensor
electrical fault

C 1A4702 Force sensor - NOTE: The force sensor is C lear DTC s, complete drive cycle 3 to test for normal
general signal part of the parking brake operation, refer to the relevant drive cycle shown below this
failure actuator module table. Refer to the warranty policy and procedures manual if
a module is suspect.
Internal force sensor
plausibility failure

C 1A4754 Force sensor - NOTE: The force sensor is C lear DTC s, complete drive cycle 1 to test for normal
missing part of the parking brake operation, refer to the relevant drive cycle shown below this
calibration actuator module table. Refer to the warranty policy and procedures manual if
a module is suspect.
Internal force sensor
not calibrated

C 1A4801 Warning lamp Parking brake actuator C heck the parking brake actuator module to instrument
circuit - module to instrument cluster warning lamp circuit. Refer to the electrical guides.
general cluster warning lamp Rectify as necessary. Refer to the warranty policy and
electrical circuit: open circuit procedures manual if a module is suspect. C lear DTC s,
failure Parking brake actuator complete drive cycle 1 to test for normal operation, refer to
module to instrument the relevant drive cycle shown below this table.
cluster warning lamp
circuit: short circuit to
ground
Parking brake actuator
module to instrument
cluster warning lamp
circuit: short circuit to
power
Parking brake actuator
module fault
Instrument cluster
fault

C 1A5368 Manual Emergency release C heck that the emergency release cable is not permanently
emergency cable activated and pulled (or stuck). C heck the parking brake cables for broken
release stuck/damaged or loose connections. Attempt to re-engage the parking brake
activated - Parking brake cables by pulling the apply switch TWIC E. C lear DTC s, complete the
automatic seized/damaged following drive cycle. Pull the parking brake emergency
parking brake Actuator jammed release cable. Pull the parking brake switch to the apply
actuator position, hold until the parking brake motor has stopped (this
module cable may take up to 20 seconds). Release the switch to idle
re- position. For parking brake actuator module manual
engagement emergency release
(latching) REFER to: Parking Brake (206-05 Parking Brake and
failed, Actuation, Description and Operation).
C 1A5564 Ignition switch Parking brake actuator C heck the parking brake actuator module ignition and key in
input circuit - module ignition supply circuits. Refer to the electrical guides. Rectify as necessary.
signal circuits: short circuit to C lear DTC s, complete drive cycle 1 to test for normal
plausibility ground, short circuit to operation, refer to the relevant drive cycle shown below this
failure power, high resistance table.
Parking brake actuator
module key in supply
circuit: short circuit to
ground, short circuit to
power, high resistance
Ignition switch fault

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U007388 Pa king b ake C on olle a ea Ca o a comple e ehicle ead fo DTC indica ing a C AN
ac a o ne o k (C AN) ci c i : o mod le fa l . C heck he C AN ci c i . Rec if a
mod le open ci c i nece a . Refe o he a an polic and p oced e
comm nica ion C AN ci c i : ho man al if a mod le i pec . C lea DTC , comple e d i e
b off ci c i o each o he c cle 1 o e fo no mal ope a ion, efe o he ele an
C AN ci c i : ho d i e c cle ho n belo hi able.
ci c i o po e
C AN ci c i : ho
ci c i o ea h
Pa king b ake ac a o
mod le fa l

U010087 Lo In alid da a Ca o a comple e ehicle ead fo DTC indica ing a C AN

comm nica ion an mi ed b EC M o mod le fa l . Lo comm nica ion code indica e ha a
i h engine C on olle a ea mod le i no ecei ing C AN info ma ion f om ano he
con ol mod le ne o k (C AN) ci c i : mod le, b ha i o n an mi ion a e OK. C heck fo
(EC M) - open ci c i ela ed "in alid da a" DTC in o he mod le and o he EC M
mi ing C AN ci c i : ho DTC . Rec if a nece a . C lea DTC , comple e d i e
me age ci c i o each o he c cle 1 o e fo no mal ope a ion, efe o he ele an
C AN ci c i : ho d i e c cle ho n belo hi able. If DTC e e ca o a
ci c i o po e ne o k in eg i e . Re ie he DTC o iden if an end
C AN ci c i : ho ch a a n mbe of mod le epo ing ha ing lo
ci c i o ea h comm nica ion i h a pa ic la mod le. Rec if a
EC M fa l nece a . Thi DTC ma occ af e /d ing c anking if
C AN con ol mod le ba e capaci i lo . Refe o he a an polic and
fa l p oced e man al if a mod le i pec . C lea DTC ,
comple e d i e c cle 1 o e fo no mal ope a ion, efe o
he ele an d i e c cle ho n belo hi able.
U010187 Lo In alid da a Ca o a comple e ehicle ead fo DTC indica ing a C AN
comm nica ion an mi ed b TC M o mod le fa l . Lo comm nica ion code indica e ha a
ih In alid da a mod le i no ecei ing C AN info ma ion f om ano he
an mi ion an mi ed b an fe mod le, b ha i o n an mi ion a e OK. C heck fo
con ol mod le bo con ol mod le ela ed "in alid da a" DTC in o he mod le and o he EC M
(TC M) o C on olle a ea DTC . Rec if a nece a . C lea DTC , comple e d i e
an fe bo ne o k (C AN) ci c i : c cle 1 o e fo no mal ope a ion, efe o he ele an
con ol mod le open ci c i d i e c cle ho n belo hi able. If DTC i ill p e en af e
- mi ing C AN ci c i : ho clea do n ca o a ne o k in eg i e . Re ie he
me age ci c i o each o he DTC o iden if an end ch a a n mbe of mod le
C AN ci c i : ho epo ing ha ing lo comm nica ion i h a pa ic la mod le.
ci c i o po e Rec if a nece a . Thi DTC ma occ af e /d ing
C AN ci c i : ho c anking if ba e capaci i lo . Refe o he a an
ci c i o ea h polic and p oced e man al if a mod le i pec . C lea
TC M fa l DTC , comple e d i e c cle 1 o e fo no mal ope a ion,
T an fe bo con ol efe o he ele an d i e c cle ho n belo hi able.
mod le fa l
C AN con ol mod le
fa l

U012287 Lo In alid da a Ca o a comple e ehicle ead fo DTC indica ing a C AN

comm nica ion an mi ed b ehicle o mod le fa l . Lo comm nica ion code indica e ha a
i h ehicle d namic con ol mod le i no ecei ing C AN info ma ion f om ano he
d namic mod le mod le, b ha i o n an mi ion a e OK. C heck fo
con ol mod le C on olle a ea ela ed "in alid da a" DTC in o he mod le and o he
- mi ing ne o k (C AN) ci c i : d namic con ol mod le DTC . Rec if a nece a . C lea
me age open ci c i DTC , comple e d i e c cle 1 o e fo no mal ope a ion,
C AN ci c i : ho efe o he ele an d i e c cle ho n belo hi able. If
ci c i o each o he DTC e e ca o a ne o k in eg i e . Re ie he
C AN ci c i : ho DTC o iden if an end ch a a n mbe of mod le
ci c i o po e epo ing ha ing lo comm nica ion i h a pa ic la mod le.
C AN ci c i : ho Rec if a nece a . Thi DTC ma occ af e /d ing
ci c i o ea h c anking if ba e capaci i lo . Refe o he a an
Vehicle d namic polic and p oced e man al if a mod le i pec . C lea
con ol mod le fa l DTC , comple e d i e c cle 1 o e fo no mal ope a ion,
C AN con ol mod le efe o he ele an d i e c cle ho n belo hi able.
fa l

U015587 Lo In alid da a Ca o a comple e ehicle ead fo DTC indica ing a C AN

comm nica ion an mi ed b o mod le fa l . Lo comm nica ion code indica e ha a
ih in men cl e mod le i no ecei ing C AN info ma ion f om ano he

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instrument C ontroller area module, but that its own transmissions are OK. C heck for
cluster - network (C AN) circuit:related "invalid data" DTC s in other modules and other
missing open circuit instrument cluster DTC s. Rectif as necessar . C lear DTC s,
message C AN circuit: short complete drive c cle 1 to test for normal operation, refer to
circuit to each other the relevant drive c cle shown below this table. If DTC resets
C AN circuit: short carr out a network integrit test. Review the DTC s to
circuit to power identif an trends such as a number of modules reporting
Instrument cluster having lost communication with a particular module. Rectif
fault as necessar . This DTC ma occur after/during cranking if
C AN control module batter capacit is low. Refer to the warrant polic and
fault procedures manual if a module is suspect. C lear DTC s,
complete drive c cle 1 to test for normal operation, refer to
the relevant drive c cle shown below this table.
U030055 Internal Parking brake module C heck that the correct module is fitted to the vehicle. C heck
control module configuration does not that the car configuration file (C C F) is being used.
software match vehicle Reprogramme (C C F) as necessar .
incompatibilit configuration
Parking brake actuator
module fault

U1A0300 Vehicle Parking brake module C heck for other communication/invalid data DTC 's. Rectif as
configuration configuration does not necessar . C heck that the correct module is fitted to the
parameter match vehicle vehicle. C heck if the correct car configuration file (C C F) is
configuration being used. Reprogramme (C C F) as necessar . C lear DTC s,
Wrong vehicle car complete drive c cle 1 to test for normal operation, refer to
configuration file (C C F) the relevant drive c cle shown below this table.

U1A1449 C ontroller Parking brake actuator C lear DTC s, complete drive c cle 1 to test for normal
area network module fault operation, refer to the relevant drive c cle shown below this
(C AN) table. Refer to the warrant polic and procedures manual if
initiali ation a module is suspect.
failure
U200201 Parking brake Parking brake switch Note that this DTC can be set b ver slow operation of the
switch circuit(s): open circuit parking brake switch. C heck the parking brake switch and
Parking brake switch circuits. With the parking brake switch connected the
circuit(s): short circuit following resistance should be measured at the parking brake
to ground actuator module end: (between 2584 ohms and 2636 ohms)
Parking brake switch between C 2178-B3 & C 2178-C 4 and (between 2584 ohms
circuit(s): short circuit and 2636 ohms) between C 2178-B4 & C 2178-C 3. Refer to
to power the electrical guides. Install a new parking brake switch as
Parking brake switch necessar . C lear DTC s, complete drive c cle 1 to test for
circuit(s): short circuit normal operation, refer to the relevant drive c cle shown
to each other below this table.
Parking brake switch
fault

Drive C cle 1 Description

Ignition On
Make sure that no parking brake activation (diagnostic command or switch input) is attempted for a minimum
of 3 seconds
Retest for functionalit

Drive C cle 2 Description

Ignition On
Drive vehicle at a constant speed of 20kph (13mph) or slightl above in 2nd gear
At a constant speed of 20kph (13mph) or slightl above appl the parking brake via the parking brake switch
Press the brake pedal

Drive C cle 3 Description

Ignition On
Make sure that the vehicle is stationar and that the parking brake is released
Pull the parking brake switch to the appl position and hold in this position until the parking brake motor has
stopped (this ma take up to 5 seconds)
Release the parking brake switch to the idle position, leave in the idle position for 2 seconds
Push the parking brake switch to the release position (with foot on the brake pedal) and keep in this position
until the parking brake motor has stopped (this ma take up to 5 seconds)
Release the parking brake switch to the idle position

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Pa king B ake and Ac a ion - Pa king B ake Shoe and Lining Adj men
General Procedures

NOTE: This procedure must be carried out if, new parking brake shoes are fitted, new rear brake discs are fitted or
if the vehicle has been mud wading (not water) for more than 50 miles.

1. C heck the parking brake for correct operation.

2. C AUTIONS:

When the vehicle is in the mounting position a red

flashing light may appear on the instrument cluster. This
indicates that the parking brake actuator is in the mounting
position. It does not indicate a vehicle fault.

The warning lamp on the instrument cluster will flash

whilst the parking brake is being driven into the mounting
position.

Using the Land Rover approved diagnostic system, drive the

parking brake to the mounting position.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the wheels and tires.
5. NOTE: Align the access hole with the indicators located
on the back plate.

Locate the parking brake shoe adjuster.

Remove the access plug.

Rotate the brake disc.

6. C AUTION: Failure to follow this step may cause

damage to the parking brake system. Failure to displace the
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parking brake shoes, as shown, will result in incorrect
clearance when carrying out the adjustment step.

NOTE: The movement of the parking brake shoe will be

small and may not be felt when levering.

NOTE: LH shown.

Using a flat blade screwdriver, lever the brake shoes as

indicated.

. C AUTION: Failure to follow this step may cause

damage to the parking brake system. Failure to displace the
parking brake shoes, as shown, will result in incorrect
clearance when carrying out the adjustment step.

NOTE: The movement of the parking brake shoe will be

small and may not be felt when levering.

NOTE: RH Shown.

Using a flat blade screwdriver, lever the brake shoes as

indicated.

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. C AUTION: Do do appl e ce i e fo ce on he
b ake hoe adj e . Fail e o follo hi in c ion ma
e l in damage o he pa king b ake em

U ing a fla bladed c e d i e o a e he b ake hoe

adj e o e end i n il he b ake di c i locked hand
igh .

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. C AUTION: The following steps sets the running

clearance for the parking brake shoes, failure to adhere to
the paint marking process ma cause damage to the park
brake s stem when the adjustment steps are carried out.

Using suitable marker, mark the position of the brake

shoe adjuster.

10. C AUTION: The parking brake adjuster must be

rotated back EXAC TLY one full revolution. Failure to follow this
instruction ma result in damage to the parking brake s stem.

Rotate the adjuster back one revolution until paint mark is

visible.

11. C AUTION: The wedge adjuster must be correctl

seated to make sure the parking brake cable is correctl
adjusted. Failure to follow this instruction ma result in
damage to the parking brake s stem.

Loosen the wedge adjuster Allen screw half a turn.

Tap the brake disc lightl with a soft faced mallet,

around the parking brake shoe location within the
brake disc.

Tighten the wedge adjuster Allen screw to 6 Nm (5

lb.ft).

Install the access plug.

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. Repeat the above procedure for the other side.

. Take the vehicle out of the mounting position b operating
the parking brake twice.

. C AUTION: If the parking brake shoes or the brake

discs have been removed for access to other components then
DO NOT carr out this procedure.

C arr out the parking brake shoe bedding-in procedure.

For additional information, refer to: Parking Brake Shoes
Bedding-In (206-05 Parking Brake and Actuation, General
Procedures).

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Pa king B ake and Ac a ion - Pa king B ake Shoe Bedding-In
General Procedures

NOTE: This procedure must be carried out if, new parking brake shoes are fitted, new rear brake discs are fitted or
if the vehicle has been mud wading (not water) for more than 50 miles.

1. C arry out the parking brake shoe bedding-in procedure.

2. NOTE: The electronic parking brake 'Service Bedding-in
Procedure mode' will be active for the remainder of the igntion
cycle, or until the vehicle speed exceeds 31 mph (50 kph). If
the procedure needs to be re-entered, the entry actions must
be repeated.

To enter 'Service Bedding-in Procedure' mode.

Start and run the engine.

Apply the footbrake 3 times within 10 seconds and hold

applied after the 3rd application.

Apply the electronic parking brake switch 4 times,

followed by 3 release applications within 10 seconds.

3. Once the Service Bedding-in procedure mode has been

entered, the electronic parking brake linings can be bedded-
in by conducting 10 repeated stops from 30 - 35 kph (19 -
22 mph), followed by a 500 metre (547 yard) interval
between each stop to allow the brakes to cool, using the
electronic parking brake control switch.

The electronic parking brake brake force will be

increased up to the dynamic maximum so long as the
switch is held in the applied position.

If the switch is released to either the NEUTRAL or OFF

positions, the electronic parking brake will be released.

The electronic parking brake MUST be allowed to cool

between applications, either by driving at 19 mph (30
kph) for 500 metres (547 yards) or remaining
stationary for 1 minute between each application.

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Parking Brake and Ac a ion - Parking Brake Cable LH
Removal and Installation

Remo al

C AUTION: To avoid accidental operation of the parking brake, and possible damage to the parking brake
actuator, remove Fusible link 8, located in the engine compartment fuse box before commencing work.

NOTE: If the parking brake system has completed less than 50,000 cycles it is permissible to replace the parking
brake cables. If over 50,000 cycles have been completed, then the cables can only replaced as part of the parking
brake actuator and cable assembly. The parking brake cycle count can be checked using T4, (ON/OFF = 1 cycle). If a
cable breaks or becomes detached whilst the vehicle is being driven, a 'parking brake actuator unblocking procedure'
may be required via T4.

1. Using the Land Rover approved diagnostic system, drive

the parking brake to the 'mounting position'.
2. Isolate the parking brake electrical circuit.

Remove fuse number 8 from the BJB.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove both rear wheels and tires.
5. Release the parking brake shoe adjustment.

Loosen the screw.

6. C AUTION: Do not allow the brake caliper to hang

on the brake hose.

Reposition the LH rear brake caliper.

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Remove the 2 bolts.

Using a suitable tie strap, support the brake caliper.

. Remove the LH rear brake disc.

Remove the screw.

. Disconnect parking brake cable from the wheel hub.

Full loosen the nut.

Release the cable from the lower arm.

Disconnect the inner cable from the brake shoe.

. Release the LH parking brake cable.

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Remove the 2 bolts.

Release the 3 wiring harness clips.

Release the cable from the clip on the chassis.

10. Release the LH parking brake cable.

11. Remove the LH parking brake cable.

Release the retaining nut.

Release and remove the cable.

In alla ion
1. Install the LH parking brake cable.

LH cable: Screw the cable in 5 complete turns.

Tighten the retaining nut.

2. Locate and secure the LH parking brake cable.

Tighten the bolts to 22 Nm (16 lb.ft).

Secure the wiring harness.

Secure the cable grommet to the integrated bod

frame bracket.

3. NOTE: Make sure that the brake cable circlip is

positioned as shown.

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C onnec he pa king b ake cable o he heel h b.

C onnec he cable o he b ake hoe le e .

Loca e he cable o he backpla e.

Tigh en he n o 8 Nm (6 lb.f ).

. C AUTION: Make e ha he componen i clean,

f ee of fo eign ma e ial and l b ican .

In all he LH ea b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

. Sec e he LH ea b ake calipe .

Remo e and di ca d he ie ap.

Tigh en he bol o 115 Nm (85 lb.f ).

. NOTE: The adj men p oced e m be ca ied o in

f ll.

Adj he pa king b ake hoe .

Fo addi ional info ma ion, efe o: Pa king B ake Shoe and
Lining Adj men (206-05, Gene al P oced e ).
. In all he ea heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

. In all f e n mbe 8 in o he BJB.

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Parking Brake and Ac a ion - Parking Brake Cable RH
Removal and Installation

Remo al

C AUTION: To avoid accidental operation of the parking brake, and possible damage to the parking brake
actuator, remove Fusible link 8, located in the engine compartment fuse box before commencing work.

NOTE: If the parking brake system has completed less than 50,000 cycles it is permissible to replace the parking
brake cables. If over 50,000 cycles have been completed, then the cables can only replaced as part of the parking
brake actuator and cable assembly. The parking brake cycle count can be checked using T4, (ON/OFF = 1 cycle). If a
cable breaks or becomes detached whilst the vehicle is being driven, a 'parking brake actuator unblocking procedure'
may be required via T4.

1. Using the Land Rover approved diagnostic system, drive

the parking brake to the 'mounting position'.
2. Isolate the parking brake electrical circuit.

Remove fuse number 8 from the BJB.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the wheels and tires.
5. Release the parking brake shoe adjustment.

Loosen the screw.

6. C AUTION: Do not allow the brake caliper to hang

on the brake hose.

Reposition the RH rear brake caliper.

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Remove the 2 bolts.

Using a suitable tie strap, support the brake caliper.

. Remove the RH rear brake disc.

Remove the screw.

. Disconnect parking brake cable from the wheel hub.

Full loosen the nut.

Release the cable from the lower arm.

Disconnect the inner cable from the brake shoe.

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. C AUTION: The fuel tank breather line bracket can

be easil damaged when releasing it from the chassis.

Release the fuel tank breather line bracket.

Remove the plastic insert.

10. Release the RH parking brake cable.

Remove the 2 bolts.

Release the parking brake cable from the 2 pipe

clips.

Release the cable from the clip on the chassis.

11. Release the RH parking brake cable.

12. C AUTION: Make sure that no dirt or moisture

enters the actuator during cable replacement.

Remove the RH parking brake cable.

Release the retaining nut.

Release the cable retaining clip.

Release and remove the cable.

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In alla ion
1. In all he RH pa king b ake cable.

In all he cable.

In all he cable e aining clip.

Tigh en he e aining n .

2. Sec e he f el ank b ea he line b acke .

In all he pla ic in e .

3. Loca e and ec e he RH pa king b ake cable.

Tigh en he bol o 22 Nm (16 lb.f ).

Sec e he pa king b ake cable o he 2 pipe clip .

Sec e he cable g omme o he in eg a ed bod

f ame b acke .

4. NOTE: Make e ha he b ake cable ci clip i

po i ioned a ho n.

C onnec he pa king b ake cable o he heel h b.

C onnec he cable o he b ake hoe le e .

Loca e he cable o he backpla e.

Tigh en he n o 8 Nm (6 lb.f ).

5. C AUTION: Make e ha he componen i clean,

f ee of fo eign ma e ial and l b ican .

In all he RH ea b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

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. Sec e he RH ea b ake calipe .

Remo e and di ca d he ie ap.

Tigh en he bol o 115 Nm (85 lb.f ).

. NOTE: The adj men p oced e m be ca ied o in

f ll.

Adj he pa king b ake hoe .

Fo addi ional info ma ion, efe o: Pa king B ake Shoe and
Lining Adj men (206-05 Pa king B ake and Ac a ion,
Gene al P oced e ).
. In all he ea heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

. In all f e n mbe 8 in o he BJB.

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Pa king B ake and Ac a ion - Pa king B ake S i ch
Removal and Installation

Remo al
1. Remove the parking brake switch.

Remove the cover.

Remove the retaining screw.

Disconnect the electrical connector.

In alla ion
1. To install, reverse the removal procedure.

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Parking Brake and Ac a ion - Parking Brake Ac a orV6 4.0L Pe rol/V8 4.4L
Pe rol
Removal and Installation

Remo al
1. Using the Land Rover approved diagnostic s stem, drive
the parking brake to the 'mounting position'.
2. Isolate the parking brake electrical circuit.

Remove fuse number 8 from the BJB.

3. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

4. Remove the rear wheels and tires.
5. Release the parking brake shoe adjustment.

Remove the plug from the access hole in the brake

disc.

Using a suitable tool, rotate the brake shoe adjuster

to release the adjustment.

6. C AUTION: Do not allow the brake caliper to hang

on the brake hose.

Reposition the RH rear brake caliper.

Remove the 2 bolts.

Using a suitable tie strap, support the brake caliper.

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. Remo e he RH ea b ake di c.

Remo e he c e .

. C AUTION: Do no allo he b ake calipe o hang

on he b ake ho e.

Repo i ion he LH ea b ake calipe .

Remo e he 2 bol .

U ing a i able ie ap, ppo he b ake calipe .

. Remo e he LH ea b ake di c.

Remo e he c e .

10. Di connec bo h pa king b ake cable f om he heel

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hubs.

Full loosen the nut.

Release the cable from the lower arm.

Disconnect the inner cable from the brake shoe.

. Release the LH parking brake cable.

Remove the 2 bolts.

Release the 3 wiring harness clips.

Release the cable from the clip on the chassis.

. Release the LH parking brake cable.

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1 . C AUTION: The fuel tank breather line bracket can

be easil damaged when releasing it from the chassis.

Release the fuel tank breather line bracket.

Remove the plastic insert.

1 . Raise the RH side of the rear stabili er bar.

Loosen the 2 bolts.

1 . Release the RH parking brake cable.

Remove the 2 bolts.

Release the parking brake cable from the 2 pipe

clips.

Release the cable from the clip on the chassis.

1 . Release the RH parking brake cable.

1 . Remove the fuel tank heat shield.

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Remove the 3 bolts and 2 nuts.

1 . C AUTION: Inspect the parking brake emergency

release cable to body seal and replace if damaged.

NOTE: Note the fitted position of the parking brake

emergency release cable to body seal.

Release the parking brake emergency release cable.

1 . C AUTION: Before disconnecting or removing the

components, make sure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

RH side rear: Disconnect the brake line.

Position an absorbent cloth to collect fluid spillage.

Disconnect the line union.

Remove the clip.

20. NOTE: Note the routing of the parking brake emergency

release cable.

Displace the parking brake actuator and cable assembly.

Disconnect the electrical connector.

Remove the 2 nuts.

21. NOTE: Brake cable shown removed for clarity.

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Remove the parking brake actuator and cable assembl .

Withdraw from the RH rear wheel arch aperture.

In alla ion
1. NOTE: Note the routing of the parking brake emergenc
release cable.

Install the parking brake actuator and cable assembl .

Install the 2 nuts.

C onnect the electrical connector.

2. NOTE: Remove and discard the blanking caps.

RH side rear: C onnect the brake line.

C lean the component mating faces.

Secure the clip.

Tighten the brake line union to 16 Nm (12 lb.ft).

3. C AUTION: Make sure the parking brake emergenc

release cable to bod seal is installed correctl .

Locate and secure the parking brake emergenc release

cable.
4. Install the fuel tank heat shield.

Tighten the bolts to 6 Nm (4 lb.ft).

Tighten the nuts to 3 Nm (2 lb.ft).

5. Secure the fuel tank breather line bracket.

Install the plastic insert.

6. Locate and secure the RH parking brake cable.

Tighten the bolts to 22 Nm (16 lb.ft).

Secure the parking brake cable to the 2 pipe clips.

Secure the cable grommet to the integrated bod

frame bracket.

7. Locate and secure the LH parking brake cable.

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Tigh en he bol o 22 Nm (16 lb.f ).

Sec e he i ing ha ne .

Sec e he cable g omme o he in eg a ed bod

f ame b acke .

. NOTE: Make e ha he b ake cable ci clip i

po i ioned a ho n.

C onnec he pa king b ake cable o he heel h b .

C onnec he cable o he b ake hoe le e .

Loca e he cable o he backpla e.

Tigh en he n o 8 Nm (6 lb.f ).

. C AUTION: Make e ha he componen i clean,

f ee of fo eign ma e ial and l b ican .

In all he LH ea b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

. Sec e he LH ea b ake calipe .

Remo e and di ca d he ie ap.

Tigh en he bol o 115 Nm (85 lb.f ).

. C AUTION: Make e ha he componen i clean,

f ee of fo eign ma e ial and l b ican .

In all he RH ea b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

. Sec e he RH ea b ake calipe .

Remo e and di ca d he ie ap.

Tigh en he bol o 115 Nm (85 lb.f ).

. Adj he pa king b ake hoe .

Fo addi ional info ma ion, efe o: Pa king B ake Shoe and
Lining Adj men (206-05 Pa king B ake and Ac a ion,
Gene al P oced e ).
. Bleed he b ake em.
Fo addi ional info ma ion, efe o: B ake S em Bleeding
(206-00 B ake S em - Gene al Info ma ion, Gene al
P oced e ).
. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

. In all f e n mbe 8 in o he BJB.

. U ing he Land Ro e app o ed diagno ic em,
calib a e he pa king b ake ac a o on an e en face.
. Appl and elea e hand b ake o confi m ope a ion.

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Pa king B ake and Ac a ion - Pa king B ake Shoe
Removal and Installation

Remo al
NOTE: If the parking brake shoes or the brake discs have been removed for access to other components then DO
NOT carry out the bedding in procedure.

1. Using the Land Rover approved diagnostic system, drive

the parking brake to the mounting position.
2. Isolate the parking brake electrical circuit.

Remove fuse number 8 from the BJB.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the wheels and tires.
5. Release the brake caliper.

Remove the brake caliper anchor bolts.

6. C AUTION: Do not allow the brake caliper to hang on

the brake hose.

Tie the brake caliper aside.

7. Release the park brake shoe adjustment.

Remove the plug from the access hole in the brake

disc.

Using a suitable tool, rotate the brake shoe adjuster

to release the adjustment.

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. Remo e he b ake di c.

Remo e he To c e .

. Remo e he adj e and e n p ing.

Relea e he he pa king b ake hoe adj e o he

minim m adj men .

10. Remo e he p ima b ake hoe.

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Remove the hold-down spring and retaining pin.

Pivot the shoe to release it from the spreader plate

and return spring.

. Remove the spreader plate and spring.

. Remove the return spring.

. Remove the secondar brake shoe.

Remove the hold-down spring and retaining pin.

Disconnect the parking brake cable retaining spring

from the brake shoe lever.

Release the parking brake cable.

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14. Repeat the above procedure for the other side.

In alla ion

1. WARNING: Do not use compressed air to clean brake

components. Dust from friction materials can be harmful if
inhaled.

C lean the backing plate and apply grease to the brake shoe
contacts.
2. C lean the adjuster and set it to its minimum extension.
3. C AUTIONS:

Make sure the brake shoe spring is not over

stretched.

Make sure the closed end of the retaining clip is

installed facing the brake shoe adjuster. Failure to follow
this instruction may result in damage to the vehicle.

Illustration 'A' is the LH side and 'B' is the RH side.

Install the secondary brake shoe.

C onnect the parking brake cable.

C onnect the parking brake cable retaining spring to

the brake shoe lever, making sure the spring is not
twisted.

Install the hold-down spring and retaining pin.

4. Install the spreader plate and the spring.

Using a tie strap, tie back the spreader plate spring.

5. WARNING: Make sure the return spring and the

adjuster spring are correctly installed to the primary shoe.

C AUTIONS:

Make sure the brake shoe spring is not over

stretched.

Make sure the closed end of the retaining clip is

installed facing the brake shoe adjuster. Failure to follow
this instruction may result in damage to the vehicle.

Illustration 'A' is the LH side and 'B' is the RH side.

Install the primary brake shoe.

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In all he e n p ing.

C onnec he p ima b ake hoe o he e n p ing.

Loca e he p ima b ake hoe o he p eade pla e.

In all he hold-do n p ing and e aining pin.

. C AUTION: Make e he b ake hoe p ing i no

o e e ched.

In all he b ake hoe adj e and he e aining p ing.

. Remo e and di ca d he p eade pla e p ing ie ap.
. Make e he b ake di c and h b ma ing face a e
clean.
. In all he b ake di c.

Tigh en he To c e o 35 Nm (26 lb.f ).

10. In all he b ake calipe .

Tigh en he bol o 115 Nm (85 lb.f ).

11. Repea he abo e p oced e fo he o he ide.

12. Adj he pa king b ake.
Fo addi ional info ma ion, efe o: Pa king B ake Shoe and
Lining Adj men (206-05 Pa king B ake and Ac a ion,
Gene al P oced e ).
13. In all he heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

14. In all f e n mbe 8 in o he BJB.

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H draulic Brake Actuation -
General Specif ications
Item Specification
Master c linder bore diameter:
Primar 27 mm (1.1 in)
Secondar 20.6 mm (0.8 in)
Stroke 36 mm (1.4 in)
Torque Specif ications
Description Nm lb-ft
Brake pedal nut and bolt - Automatic gearbo 45 33
Brake pedal bracket Tor bolts - Automatic gearbo 10 7
Brake booster to brake pedal bracket nuts - Automatic gearbo 25 18
Brake master c linder nuts 26 19
Brake pipe unions 18 13

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H draulic Brake Actuation - H draulic Brake Actuation
Description and Operation

C OMPONENT LOC ATIONS

NOTE: RHD shown, LHD similar

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I em Pa N mbe De c ip ion
1 - Brake pedal (automatic sho n)
2 - Brake arning indicator (NAS)

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3 - Brake warning indicator (all except NAS)
4 - Brake pipes and hoses
5 - Brake master cylinder and reservoir

GENERAL

Hydraulic brake actuation consists of the brake pedal, the brake master cylinder and the hydraulic pipes and hoses.

BRAKE PEDAL

NOTE: Automatic gearbox model shown, manual gearbox model similar

I em Pa N mbe De c ip ion
1 - In-vehicle cross beam
2 - Brake pedal buffer
3 - Stoplamp switch
4 - Brake pedal
5 - C levis pin and clip
6 - Brake pedal bracket
The brake pedal is mounted in a bracket attached to the rear side of the engine bulkhead. On Left Hand Drive (LHD)
manual gearbox models, the brake pedal shares a bracket and pivot bolt with the clutch pedal. On Right Hand Drive
(RHD) manual gearbox models, the brake pedal has a separate bracket. A clevis pin and clip connect the brake pedal
to the push rod of the brake booster. A brake pedal buffer is installed on the in-vehicle cross beam to restrain
rearward movement of the brake pedal in an accident.

The stoplamp switch is mounted in the brake pedal bracket and operated by the brake pedal.
For additional information, refer to: Anti-Lock C ontrol - Traction C ontrol (206-09A Anti-Lock C ontrol - Traction
C ontrol, Description and Operation).

BRAKE MASTER C LINDER AND RESERVOIR

NOTE: RHD version shown, LHD version similar

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I em Pa N mbe De c ip ion
1 - Reservoir
2 - C lutch outlet spigot and sealing cap
3 - Primar outlet spigot
4 - Reservoir to master c linder seal, primar inlet
5 - Primar outlet port
6 - Reservoir securing lug
7 - Secondar outlet port
8 - C linder housing
9 - Reservoir to master c linder seal, secondar inlet
10 - Reservoir securing straps
11 - Secondar outlet spigot
12 - Filter
13 - Float
14 - Magnet

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15 - Reservoir cap and level switch
The brake master cylinder and reservoir is attached to the front of the brake booster, on the driver side of the engine
compartment.

Master C linder

The brake master cylinder consists of a cylinder housing containing two pistons in tandem. The rear piston produces
pressure for the primary circuit and the front piston produces pressure for the secondary circuit. The pistons
incorporate center valves with a high flow rate to ensure there is always sufficient fluid available at the hydraulic
control unit for stability control operations.

When the brake pedal is pressed, the front push rod in the brake booster pushes the primary piston along the bore of
the cylinder housing. This produces pressure in the primary pressure chamber which, in conjunction with the primary
spring, overcomes the secondary spring and simultaneously moves the secondary piston along the bore. The initial
movement of the pistons, away from the piston stops, closes the primary and secondary center valves. Further
movement of the pistons then pressurizes the fluid in the primary and secondary pressure chambers, and thus the
brake circuits. The fluid in the chambers behind the pistons is unaffected by the movement of the pistons and can flow
unrestricted through the feed holes between the chambers and the reservoir.

When the brake pedal is released, the primary and secondary springs push the pistons back down the bore of the
cylinder housing. As the pistons contact the piston stops, the primary and secondary center valves open, which allows
fluid to circulate unrestricted between the two hydraulic circuits and the reservoir, through the center valves, the
chambers behind the pistons and the cylinder housing inlets.

Should a failure occur in one of the brake circuits, the remaining brake circuit will still operate effectively, although
brake pedal travel and vehicle braking distances will increase.

Reservoir

The reservoir is installed on top of the master cylinder to provide a supply of brake fluid for the primary and
secondary circuits of the brake system. On manual gearbox models, the reservoir also provides a supply of brake
fluid for the clutch.
For additional information, refer to: C lutch C ontrols (308-02 C lutch C ontrols - TDV6 2.7L Diesel, Description and
Operation).

Two straps, integrated onto the sides of the reservoir, engage with lugs on the master cylinder to secure the reservoir
in position. Two outlet spigots on the underside of the reservoir locate in seals installed in the inlet ports of the master
cylinder. An outlet spigot is installed on the left side of the reservoir for the clutch hydraulic circuit, if required. On
automatic gearbox models, the clutch outlet spigot is sealed with a cap, formed during manufacture of the reservoir,
which is only removed if the reservoir is installed on a manual gearbox model.

The reservoir is internally divided to isolate the circuits from each other at low fluid levels, and so prevent a leak in
one circuit from disabling the other circuit(s). The dividing walls support a central well and divide the area around the
well into a further eight separate compartments. The well forms an extension of the filler neck and contains the filter
and the fluid level switch.

The well and the surrounding compartments are interconnected by slots in the dividing walls. The slots are positioned
such that when the reservoir is full, fluid can move between the well and all of the surrounding compartments, but at
low fluid levels the interior forms separate reservoirs for each circuit. The following figure shows the separate
reservoirs for each circuit and the amount retained in each reservoir if there is a leak from one of the other circuits.

Reservoir Interior

NOTE: A = C lutch reservoir; B = Primary circuit reservoir; C = Secondary circuit reservoir

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I em Pa N mbe De c ip ion
1 - P ima o le
2 - C l ch o le
3 - Seconda o le
The fille neck of he e e oi i ealed i h a cap inco po a ing he le el i ch. The le el i ch i ope a ed b a
magne , hich i in alled in he floa on he bo om of he i ch. The i ch eac o he infl ence of he magne ic
field o nding he magne .

When he e e oi i f ll, he floa e again he bo om of he i ch and hold he le el i ch open. When he

fl id le el dec ea e , he floa mo e do n and he i ch clo e o connec a g o nd o he in men cl e . When
he g o nd i made, he in men cl e ill mina e he ed Ligh Emi ing Diode (LED) in he b ake a ning
indica o . Vehicle i h he high line in men cl e al o di pla an app op ia e a ning in he me age cen e .
Fo addi ional info ma ion, efe o: In men C l e (413-01 In men C l e , De c ip ion and Ope a ion).

A he beginning of each igni ion c cle, he in men cl e pe fo m a b lb check on he b ake a ning indica o ;
he indica o i ill mina ed ambe fo 1.5 econd , hen ed fo 1.5 econd .

The in men cl e b oadca he a of he b ake fl id le el, on he high peed C on olle A ea Ne o k

(C AN) b , o he An i-lock B ake S em (ABS) mod le.
Fo addi ional info ma ion, efe o: An i-Lock C on ol - T ac ion C on ol (206-09A An i-Lock C on ol - T ac ion
C on ol, De c ip ion and Ope a ion).

B AKE PIPE AND HO E

The b ake pipe and ho e connec he ma e c linde o he heel b ake ia he h d a lic con ol ni . The pipe
a e a anged o p o ide a f on and ea pli b aking em. The b ake on he f on a le a e ope a ed b he
p ima em; he b ake on he ea a le a e ope a ed b he econda em.

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H draulic Brake Actuation - Brake Fluid Reservoir
Removal and Installation

Removal

C AUTION: Brake fluid will damage paint finished surfaces. If spilled, immediatel remove the fluid and clean the
area with water.

All vehicles
1. Remove the cover.

2. Position an absorbent cloth to collect fluid spillage.

3. Disconnect the low brake fluid warning indicator switch
electrical connector.

Vehicles with manual transmission

4. C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the clutch master c linder suppl line.

All vehicles

5. C AUTION: Alwa s plug an open connections to

prevent contamination.

Remove the brake fluid reservoir.

Release the 2 clips.

Remove and discard 2 brake fluid reservoir seals.

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In alla ion
All vehicles
1. C lean the components.
2. Install the brake fluid reservoir.

Install new brake fluid reservoir seals.

Vehicles with manual transmission

3. C onnect the clutch master c linder suppl line.

All vehicles
4. C onnect the low brake fluid warning indicator switch
electrical connector.
5. Bleed the brake s stem using T4.
For additional information, refer to: Brake S stem Bleeding
(206-00, General Procedures).

Vehicles with manual transmission

6. Bleed the clutch s stem.
For additional information, refer to: C lutch S stem Bleeding
(308-00, General Procedures).

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H draulic Brake Actuation - Brake Master C linder
Removal and Installation

Removal
1. Remove the brake fluid reservoir.
For additional information, refer to: Brake Fluid Reservoir
(206-06 H draulic Brake Actuation, Removal and
Installation).

2. C AUTION: Before the disconnection or removal of an

components, ensure the area around joint faces and
connections are clean. Plug an open connections to prevent
contamination.

Disconnect the brake master c linder brake tubes.

3. Remove the brake master c linder.

Remove the 2 nuts.

Remove and discard the O-ring seal.

Installation
1. Install the brake master c linder.

Install a new O-ring seal.

Tighten the nuts to 26 Nm (19 lb.ft).

2. C onnect the brake tubes.

Tighten the brake tube unions to 18 Nm (13 lb.ft).

3. Install the brake fluid reservoir.

For additional information, refer to: Brake Fluid Reservoir
(206-06 H draulic Brake Actuation, Removal and
Installation).

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P bli hed: 11-Ma -2011

H draulic Brake Actuation - Brake PedalVehicles With: 6HP26 6-Speed
Automatic Transmission
Remo al and In alla ion

Removal
1. Remo e he headlamp i ch.
Fo addi ional info ma ion, efe o: Headlamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).
2. Remo e he oplamp i ch.
Fo addi ional info ma ion, efe o: S oplamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).
3. Remo e he in men panel acce panel.

Relea e he 2 clip .

4. Remo e he b ake pedal b acke .

Relea e he i ing ha ne clip.

Remo e he 4 To bol .

5. Remo e he b ake pedal cle i pin.

Remo e he clip.

6. Remo e he b ake pedal.

Remo e he n and bol .

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7. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he b ake pedal pad.

In alla ion
1. In all he b ake pedal pad.
2. In all he b ake pedal.

C lean he componen ma ing face .

Tigh en he n and bol o 45 Nm (33 lb.f ).

3. In all he b ake pedal cle i pin.

In all he clip.

4. In all he b ake pedal b acke .

Tigh en he To bol o 10 Nm (7 lb.f ).

Sec e he i ing ha ne .

5. In all he in men panel acce panel.

Sec e i h he clip .

6. In all he oplamp i ch.

Fo addi ional info ma ion, efe o: S oplamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).
7. In all he headlamp i ch.
Fo addi ional info ma ion, efe o: Headlamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).

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P bli hed: 11-Ma -2011

H draulic Brake Actuation - Brake Pedal and BracketVehicles With: 6HP26 6-
Speed Automatic Transmission
Remo al and In alla ion

Removal
1. Remo e he headlamp i ch.
Fo addi ional info ma ion, efe o: Headlamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).
2. Remo e he oplamp i ch.
Fo addi ional info ma ion, efe o: S oplamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).
3. Remo e he in men panel acce panel.

Relea e he 2 clip .

4. Remo e he b ake pedal b acke .

Relea e he i ing ha ne clip.

Remo e he 4 To bol .

5. Remo e he b ake pedal cle i pin.

Remo e he clip.

6. Relea e he oplamp i ing ha ne .

Relea e he 2 clip .

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7. Remo e he b ake pedal a embl .

Remo e he 6 n .

Po i ion he b ake boo e fo a d o aid he

emo al of he b ake pedal a embl .

In alla ion
1. In all he b ake pedal a embl .

Po i ion he b ake boo e o he b ake pedal b acke .

Tigh en he n o 25 Nm (18 lb.f ).

2. Sec e he i ing ha ne .

Sec e he clip .

3. In all he b ake pedal cle i pin.

In all he clip.

4. In all he b ake pedal b acke .

Tigh en he To bol o 10 Nm (7 lb.f ).

Sec e he i ing ha ne .

5. In all he in men panel acce panel.

Sec e i h he clip .

6. In all he oplamp i ch.

Fo addi ional info ma ion, efe o: S oplamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).
7. In all he headlamp i ch.
Fo addi ional info ma ion, efe o: Headlamp S i ch (417-
01 E e io Ligh ing, Remo al and In alla ion).

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P bli hed: 11-Ma -2011

Power Brake Actuation -
Sealant
Application Land Rover Part No.
B ake ac m p mp - 2.7 Li e engine 8510302
General Specif ications
Item Specification
B ake boo e pe T in chambe 228 and 254 mm (9.0 and 10.0 in)
Boo a io 7:1
Brake vacuum pump make and t pe:
V6 - 2.7 li e die el engine Bo ch 240cc SWP
V6 - 4.0 li e and V8 - 4.4 li e pe ol engine Hella UP28
Torque Specif ications
Description Nm lb-ft
B ake boo e n 23 17
B ake ma e c linde n 26 19
M12 b ake pipe nion 16 12
M14 b ake pipe nion 18 13
B ake pedal b ffe bol 10 7
B ake ac m p mp n - 4.0 and 4.4 li e engine 5 4
B ake ac m p mp bol - 2.7 li e engine 23 17
B ake ac m p mp e aining d - 2.7 li e engine 13 10
B ake ac m p mp e aining n - 2.7 li e engine 13 10
High p e e f el ppl line e aining bol - 2.7 li e engine 10 7
* E ha c o -o e pipe n 2.7 li e engine 22 16
E ha c o -o e pipe ppo b acke bol - 2.7 li e 25 18
E ha manifold hea hield bol - 2.7 li e 10 7
* New nuts must be fitted

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Published: 02-Sep-2011
Po er Brake Actuation - Brake Booster
Description and Operation

C OMPONENT LOC ATIONS - 4.0L

NOTE: RHD shown, LHD similar

I em Pa N mbe De c ip ion
1 - Brake booster
2 - Vacuum pump relay
3 - Vacuum pump
4 - Vacuum pipe connections to vacuum pump and inlet manifold
5 - C heck valve
6 - Vacuum pipe connection to brake booster
7 - Vacuum pipes
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C OMPONENT LOC ATIONS - 4.4L

NOTE: LHD shown, RHD similar

I em Pa N mbe De c ip ion
1 - Vacuum pump relay
2 - Brake booster
3 - Vacuum pump
4 - Vacuum pipe connection to brake booster
5 - C heck valve
6 - Vacuum pipe connection to vacuum pump
7 - Vacuum pipes
8 - Vacuum pipe connection to inlet manifold
C OMPONENT LOC ATIONS - 2.7L DIESEL

NOTE: LHD shown

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I em Pa N mbe De c ip ion
1 - Vacuum pump
2 - Brake booster
3 - Vacuum pipe connection to brake booster (includes check valve)
4 - Vacuum pipe connection to vacuum pump
5 - Vacuum pipes

GENERAL

Power assistance for the brakes is provided b a vacuum operated brake booster. On petrol models, the vacuum is
produced b the intake manifold and an electric vacuum pump. On diesel models, the vacuum is produced b an
engine driven vacuum pump.

AC M PIPES

Plastic vacuum pipes connect the brake booster to the vacuum source. C heck valves are incorporated into the
vacuum pipes. On petrol models there are two in-line check valves, to maintain the vacuum in the brake booster
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hen he h o le i open and he ac m p mp i no nning, and p e en f el apo en e ing he b ake boo e . On
die el model he e i a ingle check al e in eg a ed in o he ac m pipe connec ion i h he b ake boo e , o
main ain he ac m in he b ake boo e hen he ac m p mp i ope a ing a le han he op im m.

B AKE BOO E

The b ake boo e i in alled in he d i e ide of he engine compa men , on he engine b lkhead.

The b ake boo e i a d al diaph agm ni i h a boo a io of 8.0 : 1 and 28 ba loop-in in all engine a ian . The
inp p h od i connec ed o he b ake pedal. The o p p h od loca e in he p ima pi on of he b ake ma e
c linde . A ac m pipe, in alled in a g omme in he f on face of he ho ing, connec he b ake boo e o he
in ake manifold and elec ic ac m p mp (pe ol model ) o he engine d i en ac m p mp (die el model ).

AC M P MP (4.0L AND 4.4L)

I em Pa N mbe De c ip ion
1 - An i- ib a ion mo n
2 - P mp co e
3 - Vac m p mp inle
4 - R bbe h o d fo e ha po
5 - Mo o co e
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6 - Electrical connector
On petrol models the electric vacuum pump supplements the main vacuum supply from the engine manifold.

The vacuum pump is installed on a mounting bracket in the front left corner of the engine compartment. Two anti-
vibration mounts on the vacuum pump are located on studs on the mounting bracket and secured with nuts.

The vacuum pump consists of a radial vane pump driven by an electric motor. The rotor and vanes of the pump are
made from a self-lubricating carbon based material. A stub pipe is installed in the inlet of the pump to provide a
connection point for the vacuum pipe from the brake booster. A second stub pipe, which is covered by a rubber
shroud, is installed in the outlet from the pump.

Operation of the vacuum pump is controlled by the Engine C ontrol Module (EC M), which uses the brake vacuum pump
relay in the Battery Junction Box (BJB) to switch power to the vacuum pump. The EC M controls the time for which the
vacuum pump is switched on and has in-built safeguards to protect the pump from overuse, e.g. continuous running is
not allowed so a minimum delay time is specified between applications.

AC M P MP (2.7L DIE EL)

I em Pa N mbe De c ip ion
1 - Vacuum connection (not used)
2 - Vacuum connection for brake booster
3 - Drive dog
4 - Seal
5 - Oil inlet port
6 - Oil return/air vent
A vacuum pump is installed on diesel models as the air inlet system does not produce sufficient vacuum for
satisfactory operation of the brake booster.

The vacuum pump is a radial vane pump which is attached to the rear of the RH cylinder head and driven at half
engine speed by the exhaust camshaft. The vacuum pipe from the brake booster connects to an elbow on the rim of
the vacuum pump.

The vacuum pump is lubricated and cooled by engine oil supplied to a port in the front face of the vacuum pump from
a gallery in the cylinder head. The oil return is through a vent in the front face of the pump into a drain cavity in the
cylinder head. Air extracted from the brake booster is vented into the drain cavity with the returning engine oil.

AC M P MP CON OL DIAG AM (4.0L AND 4.4L)

NOTE: A = Hardwired connection

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I em Pa N mbe De c ip ion
1 - Batter
2 - Fuse 24E, batter junction bo
3 - Vacuum pump rela
4 - Vacuum pump
5 - Engine control module

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P bli hed: 11-Ma -2011

Po e B ake Ac a ion - B ake Boo e
Remo al and In alla ion

Remo al

All ehicle
1. P mp he b ake pedal n il he b ake ac ma i ance i
e ha ed.
2. Remo e he a ilia ba e co e .

Relea e he 2 clip .

3. If in alled, emo e he a ilia ba e .

4. Remo e he a ilia ba e compa men ide all.

Relea e he fo clip .

5. Relea e he Ai C ondi ioning (A/C ) pipe .

Remo e he e aining c e .

6. Remo e he a ilia ba e a .

Remo e he 3 bol .

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. Release the Anti-lock Brake S stem (ABS) module.

Remove the 3 nuts.

Release the brake tubes from the clip.

. Disconnect the low brake fluid warning indicator switch

electrical connector.

. C AUTION: Brake fluid will damage paint finished

surfaces. If spilled, immediatel remove the fluid and clean
the area with water.

Position an absorbent cloth to collect fluid spillage.

Vehicles with manual transmission

10. Disconnect the clutch master c linder suppl line.

All vehicles
11. Disconnect the brake booster vacuum hose from the
brake booster.

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. C AUTIONS:

Make e ha e ce i e fo ce i no ed. Fail e o

follo hi in c ion ma e l in damage o he ehicle.

Make e he ing and im panel a e co e ed and

p o ec ed, fail e o follo hi in c ion ma e l in
damage o he ehicle.

Di place he ma e c linde .

Remo e he 2 n .

. Remo e he o e plen m ba e.

Remo e he 3 n .

. Remo e he d i e ide clo ing im panel.

Relea e he clip.

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Remove the 2 screws.

Disconnect the electrical connector.

15. NOTE: The cover is shown removed for clarit .

Remove the brake booster push rod clevis pin.

Remove the retaining clip.

16. Remove the brake booster.

Remove the 4 nuts.

In alla ion
All vehicles
1. Install the brake booster.

Tighten the nuts to 23 Nm (17 lb.ft).

2. Install the brake booster push rod clevis pin.

Install the retaining clip.

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. In all he clo ing im panel.

C onnec he elec ical connec o .

Sec e he clip.

Tigh en he c e .

. C onnec he b ake boo e ac m ho e.

. In all he o e plen m ba e.

C a ef ll lif he an i-lock b ake em mod la o fo

acce .

In all he 3 n .

. C AUTION: Make e he ma e c linde i co ec l

aligned. Fail e o make e he ma e c linde i co ec l
aligned o he b ake boo e ac a ion od ma ca e
componen damage o poo b ake pe fo mance.

In all he b ake ma e c linde .

Tigh en he n o 26 Nm (19 lb.f ).

. Sec e he an i-lock b ake em mod la o .

In all he 3 n .

Sec e he b ake be o he clip.

Vehicle i h man al an mi ion

. C onnec he cl ch ma e c linde ppl line.

All ehicle
. C onnec he lo b ake fl id a ning indica o i ch
elec ical connec o .
. In all he a ilia ba e a .

In all he 3 bol .

. In all he a ilia ba e compa men ide all.

Sec e i h he fo e aining clip .

. Sec e he A/C pipe .

In all he e aining c e .

. If in alled, in all he a ilia ba e .

Vehicle i h man al an mi ion

. Bleed he cl ch em.
Fo addi ional info ma ion, efe o: C l ch S em Bleeding
(308-00 Man al T an mi ion/T an a le and C l ch -
Gene al Info ma ion, Gene al P oced e ).

All ehicle
.S a engine and check he b ake boo e ope a ion.

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Published: 11-Ma -2011

Po e B ake Ac a ion - B ake Vac m P mpV6 4.0L Pe ol/V8 4.4L Pe ol
Removal and Installation

Remo al

1. C AUTION: Alwa s plug an open connections to

prevent contamination.

Remove the brake vacuum pump.

Release and disconnect the electrical connector.

Disconnect the vacuum line.

Remove the 2 nuts.

2. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the 2 rubber insulators.

In alla ion
1. To install, reverse the removal procedure.

Tighten the nuts to 5 Nm (4 lb.ft).

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Published: 11-Ma -2011

A i-L c C - T ac i C -
Ge e a S ecif ica i
I e S ecifica i
S stem Bosch 8.0 Anti-lock braking s stem with Electronic Brake Distribution (EBD), C orner Brake C ontrol (C BC ),
make/t pe Electronic Traction C ontrol (ETC ), Hill Descent C ontrol (HDC ), Anti-roll Mitigation (ARM), Emergenc Brake
Assist (EBA), and D namic Stabilit C ontrol (DSC )
Whee
eed
e :
Make/t pe Bosch DF11i
Location Front and rear knuckles with the active directional sensor acting on the driveshaft pole wheel
Yaw rate Bosch DRS MM1.OR
sensor
make/t pe
T e S ecif ica i
De c i i N b-f
Front road wheel speed sensor bolt 9 7
Front brake caliper anchor plate bolts 275 203
Front brake caliper housing bolts 32 24
Front brake hose retaining bracket to wheel knuckle bolt 25 18
Rear road wheel speed sensor to wheel knuckle bolt 9 7
ABS module mounting bracket nuts 8 6
ABS module to mounting bracket nuts 23 17
M10 Brake tube union nuts 15 11
M12 Brake tube union nuts 15 11
M14 Brake tube union nut 17 13
Yaw rate sensor bolts 7 5
Road wheel nuts 140 103

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Published: 11-Ma -2011

An i-Lock Con rol - Trac ion Con rol - An i-Lock Con rol - Trac ion Con rol
Description and Operation

C OMPONENT LOC ATIONS - SHEET 1 OF 2

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I em Pa N mbe De c ip ion
1 - H draulic control unit with attached anti-lock brake s stem (ABS) module
2 - Stoplamp switch

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3 - Righ ea heel peed en o
4 - Lef ea heel peed en o
5 - Ya a e and la e al accele a ion en o
6 - HDC (hill de cen con ol) ela (non- e iceable, in eg a ed in o cen al j nc ion bo (C JB))
7 - S ee ing angle en o
8 - Lef f on heel peed en o
9 - Righ f on heel peed en o
C OMPONENT LOC ATIONS - SHEET 2 OF 2

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I em Pa N mbe De c ip ion
1 - Brake warning indicator (NAS (north American specification) onl )
2 - ABS warning indicator

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3 - B a e a i g i dica (a e ce NAS)
4 - DSC (d a ic abi i c ) i ch
5 - HDC (hi de ce c ) i ch
6 - HDC a i g i dica ( i e i e c e )
7 - HDC i f ai i dica
8 - DSC a i g i dica

GENERAL

The a i- c c - ac i c e i ba ed he 4 cha e B ch 8.0 e a d ide he f i g

b a e f ci :

ABS.
ARM (ac i e i iga i ).
C BC (c e b a e c ).
DSC .
e ec ic b a e f ce di ib i (EBD).
ETC (e ec ic ac i c ).
e e ge c b a e a i (EBA).
EDC (e gi e d ag- e c ).
HDC .

The e c i f he f i gc e :

A DSC i ch.
A HDC i ch.
A HDC e a .
A a i ch.
F hee eed e .
A a a e a d a e a acce e a i e .
A ee i g a g e e .
Wa i g i dica ;f ehic e i h a high i e i e c e a d fi e ehic e iha i e
i e c e .
A h d a ic c i (HC U) i h a ached ABS d e.

DSC S ITCH

The DSC i ch a he DSC f c i be e ec ed ff. A h gh La d R e ec e d ha DSC i e ec ed

f a a d i i g c di i ,i a be be eficia de- e ec DSC , a i i e ac i , de he f i g
c di i :

If he ehic e eed be c ed fah a f face.

D i i g e face ih chai .
D i i g i dee a d, d.
O ac i h dee gi di a .

The DSC i ch i a - a chi g i ch i a ed i he ce e i ch ac he i e a e . P e i g he DSC

i ch c ec a ig i i e feed he ABS d e. Wi h he fi e f he DSC i ch, he ABS d e
di ab e he DSC f c i . Whe he DSC i ch i e ed agai , he ABS d e e-e ab e he DSC f c i .
The DSC i ch be e ed f a i i f 0.3 f he ABS d e eac . The DSC f c i i e-e ab ed
a he begi i g f each ig i i c c e.

The a f he DSC i ch e ec i i h b he DSC a i g i dica . The DSC a i g i dica i ff hi e

DSC i e ec ed ,a dc i i i a ed hi e DSC i e ec ed ff.

A DSC i ch e e di ab e DSC i ig ed if he ai e i e ha fai ed, i i ff- ad heigh a

eed ab e 60 /h (37.5 h).

T g a d agai i c ec e ai ab e i ch, if he i f he DSC i ch i he d high f e ha

e i e, a fai e i ed i he ABS d e.

E e if DSC i de e ec ed, d i i g a e e ihe e e a a e a acce e a i a igge DSC ac i i

a i ehic e abi i .

HDC S ITCH

The HDC i ch c he e ec i f he HDC f ci .

The HDC i ch i a - a chi g i ch i a ed he ce e c e, he ea f he gea hif e e . P e i g

a d e ea i g he HDC i ch e a i c ec a ig i i e feed he ABS d e. Wi h he fi e
a d e ea e f he HDC i ch, he ABS d e e ab e e ai f he HDC f c i . Whe he HDC i ch i
e ed a d e ea ed agai , he ABS d e di ab e e ai f he HDC f ci .
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To guard against incorrect operation or a broken switch, if the switch is pressed for more than 10 seconds no change
of state occurs. If the input from the HDC switch is held high for more than one minute, a failure is stored in the ABS
module.

HDC RELA

The HDC rela is used to illuminate the stoplamps when the brakes are activated during HDC operation and during
d namic application of the parking brake.

The HDC rela is a non-serviceable, solid state rela on the circuit board of the C JB. Operation of the HDC rela is
controlled b the ABS module switching the coil to ground. The ABS module monitors brake s stem h draulic
pressure and energi es the HDC rela during active braking. A pressure threshold and time filter prevent the
stoplamps from flickering when HDC is braking.

STOPLAMP SWITCH

The stoplamp switch is mounted in the brake pedal bracket and operated b the brake pedal. The stoplamp switch is
a two pole switch: The Brake Switch (BS) pole supplies a brake pedal status signal to the ABS module; the Brake
Lamp Switch (BLS) pole operates the stoplamps and also supplies a brake pedal status signal to the ABS module and
to the engine control module (EC M).

While the brake pedal is released:

The BS contacts are closed, and connect an ignition power feed from the C JB to the ABS module.
The BLS contacts are open.

When the brake pedal is pressed:

The BS contacts open.

The BLS contacts close, and connect an ignition power feed from the C JB to the three stoplamps, the ABS
module and the EC M.

The ABS module monitors the status inputs from the stoplamp switch and broadcasts the brake pedal status and an
associated qualit factor on the high speed controller area network (C AN) bus.

WHEEL SPEED SENSORS

I em Pa N mbe De c ip ion
1 - Knuckle assembl
2 - Sensor ring
3 - Halfshaft
4 - Wheel speed sensor
5 - Screw
An active wheel speed sensor is installed in each wheel hub to provide the ABS module with a rotational speed signal
from each road wheel. The head of each wheel speed sensor is positioned close to a 48 tooth sensor ring on the outer
diameter of the constant velocit joint of the halfshaft. A fl ing lead connects each sensor to the vehicle wiring.

The wheel speed sensors each have a power suppl connection and a signal connection with the ABS module. When
the ignition switch is in position II, the ABS module supplies power to the wheel speed sensors and monitors the
return signals. An rotation of the halfshafts induces current fluctuations in the return signals which are converted into
individual wheel speeds and the overall vehicle speed b the ABS module.

The ABS module outputs the individual wheel speeds and the vehicle speed on the high speed C AN bus for use b
other s stems. The qualit of the vehicle speed signal is also broadcast on the high speed C AN bus. If all wheel speed
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ig a a e a ai ab e ca c a e ehic e eed f , he ai f he ehic e eed ig a i e 'da a ca c a ed
i hi ecified acc ac '. If e e hee eed e i fa , he ai f he ehic e eed ig a i e
'acc ac ide ecifica i '.

The ABS d e i he hee eed e ci c i f fa . If a fa i de ec ed he ABS d e e a

e a ed fa c de a d i i a e he a ia e a i g i dica , de e di g he e f ci affec ed
(DSC /ETC , ABS, EBA/EBD, HDC ). A a i g chi e d a d, ehic e i h he high i e i e c e ,a
e a ed e age i h i he e age ce e .
F addi i a i f a i , efe :I f ai a d Me age C e e (413-08 I f ai a d Me age C e e ,
De c i i a d O e a i ).

Si ce he hee eed e a e ac i e de ice , a e ig a i a ai ab e he he ad hee a e i g,

hich e ab e he ABS d e chec he e hi e he ehic e i a i a . I addi i , he di ec i f a e
f each hee ca be e ed. Thi i f ai i b adca he high ed C AN b f e b he e .

AW RATE AND LATERAL ACCELERATION SENSOR

The a a e a d a e a acce e a i e ide he ABS d e ihi f a ae a d ae a

acce e a i .

The a a e a d a e a acce e a i e i i a ed de he ce e c e a d ec ed he a i i
e ih b .

Whe he ig i i i ch i i ii II, he a a e a d a e a acce e a i e ecei e a ig i i e feed

f he C JB. The e i e f diag ed b he ABS d e a d ca be i e ga ed i g T4. The ABS d e
b adca he a a e a d a e a acce e a i a e , he high eed C AN b , f e b he e .

The ABS d e i he a ae a d ae a acce e a i e f fa . If a fa i de ec ed he ABS

d e e a e a ed fa c de a d i i ae he DSC a i g i dica a d, ehic e i h he i e
i e c e , he HDC a i g i dica . A a i g chi e d a d, ehic e i h he high i e i e
c e ,a e age ad i i g f a HDC fa i h i he e age ce e .
F addi i a i f a i , efe :I f ai a d Me age C e e (413-08 I f ai a d Me age C e e ,
De c i i a d O e a i ).

STEERING ANGLE SENSOR

I em Pa N mbe De c ip ion
1 - Gea hee
2 - E ec ica c ec
The ee i g a g e e ea e he ee i g hee a g e a d he a e f cha ge f he ee i g hee a g e
( a he ee i g hee a g e eed). The e ea e e a e he high eed C AN b , ge he
iha a i fac ig a , a d ed b he ABS d e f C BC a d DSC e ai .

The ee i g a g e e i fi ed he i b ac e f he ee i g c b h ee c e . A gea hee i he

ee i g a g e e e gage i h a a ic d i e c a fi ed he e haf f he c . I ide he ee i g
a ge e , he gea hee e he i h a gea ai c ai i g ag e . A eigh i e ec ica c ec ide
he i e face be ee he ehic e i i g a d i eg a ed ci c i i he ee i g a g e e .

The ee i g a g e e e he MR ( ag e e i i e) effec , hich e a a e he di ec i f ag e ic fie d ,

ea e he a g a ii f he e haf , a d h he ee i g hee a g e. Whe he ee i g hee ,
he ee i g c e haf a e he gea hee i he ee i g a g e e , hich d i e he gea ai a d
a e he ag e he gea . The di ec i f he ag e ic fie d i c a i ed b he ee i g a g e
e a dc e ed i a ee i g hee a g e a d ee i g hee a g e eed.

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The steering angle sensor performs a plausibility check of the steering wheel angle each time the following conditions
co-exist:

The vehicle is traveling in a straight line.

The vehicle speed is between 20 and 25 km/h (12.5 and 15.6 mph).
The transfer box is in high range.
The brake pedal is not pressed.
There is no ABS, DSC or ETC activity.

The steering angle sensor uses inputs of wheel speed, yaw rate and lateral acceleration to determine when the
vehicle is traveling in a straight line. When all of the conditions co-exist, the steering angle sensor checks the steering
angle, which should be 0 15°. If the steering angle is outside the limits on two successive checks, the steering angle
sensor changes the quality factor signal to 'outside specification' for the remainder of the ignition cycle and stores a
fault code. At the beginning of each ignition cycle the quality factor signal is reset to 'within specified accuracy'.

The status of the steering angle sensor can be determined using T4.

If the steering angle sensor is replaced, the new sensor must be calibrated using T4. The steering angle sensor must
also be re-calibrated any time it is disturbed from the steering column, or if the upper and lower steering columns are
separated.

Steering Angle Sensor Harness C onnector C 0862

S ee ing A ngle Sen o Ha ne Connec o C0862 Pin De ail

Pin No. De c ip ion Inp /O p
1 to 4 Not used -
5 Ignition power supply Input
6 High speed C AN bus high Input/Output
7 High speed C AN bus low Input/Output
8 Ground -

WARNING INDICATORS

The following anti-lock control - traction control indicators are installed in the instrument cluster:

ABS Wa ning Indica o

The ABS warning indicator is an amber colored indicator located between the coolant temperature gage and the fuel
level gage.

The ABS warning indicator is continuously illuminated if there is a fault that affects ABS performance or causes the
ABS function to be disabled.

Operation of the ABS warning indicator is controlled by a high speed C AN bus message from the ABS module to the
instrument cluster.

When the ignition switch is first turned to position II, the ABS warning indicator illuminates for approximately 3
seconds as a bulb check. During the bulb check, if a fault is stored in the memory of the ABS module, the ABS
warning indicator goes off for 0.5 second, 0.5 second after the start of the bulb check. If a fault during the previous
ignition cycle caused the ABS warning indicator to be illuminated, the ABS warning indicator may remain illuminated
after the next bulb check, even if the fault has been rectified and cleared from the ABS module; the ABS warning
indicator remains illuminated until vehicle speed reaches 15-20 km/h (9.5-12.5 mph) while additional checks of the
related inputs are performed.

B ake Wa ning Indica o

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The b ake a ning indica o i a d al colo ed indica o , loca ed in he coolan empe a e gage, ha ill mina e
ambe fo EBA fa l and ed fo EBD fa l . The b ake a ning indica o i al o ed o gi e a ning of:

Lo b ake fl id le el (ill mina e ed).

Fo addi ional info ma ion, efe o: H d a lic B ake Ac a ion (206-06 H d a lic B ake Ac a ion, De c ip ion
and Ope a ion).
B ake pad ea (ill mina e ambe ).
Fo addi ional info ma ion, efe o: Rea Di c B ake (206-04 Rea Di c B ake, De c ip ion and Ope a ion).

Ope a ion of he b ake a ning indica o i con olled b a high peed C AN b me age f om he ABS mod le o he
in men cl e .

When he igni ion i ch i fi ned o po i ion II, he b ake a ning indica o ill mina e ambe fo app o ima el
1.5 econd hen ed fo app o ima el 1.5 econd , a a b lb check.

DSC Warning Indica or

The DSC a ning indica o i an ambe colo ed a ning indica o loca ed in he achome e .

Each ime he DSC o he ETC f nc ion i ac i e, he DSC a ning indica o fla he a 2 H . If DSC ha been elec ed
off, o he e i a fa l ha di able he DSC o he ETC f nc ion, he DSC a ning indica o i con in o l
ill mina ed. If DSC ha been elec ed off, ehicle i h he high line in men cl e al o di pla a me age,
ad i ing ha DSC i i ched off.
Fo addi ional info ma ion, efe o: Info ma ion and Me age C en e (413-08 Info ma ion and Me age C en e ,
De c ip ion and Ope a ion).

Ope a ion of he DSC a ning indica o i con olled b a high peed C AN b me age f om he ABS mod le o he
in men cl e .

When he igni ion i ch i fi ned o po i ion II, he DSC a ning indica o ill mina e fo app o ima el 3
econd a a b lb check. If a fa l d ing he p e io igni ion c cle ca ed he DSC a ning indica o o be
ill mina ed, he DSC a ning indica o ma emain ill mina ed af e he ne b lb check, e en if he fa l ha been
ec ified and clea ed f om he ABS mod le; he DSC a ning indica o ma emain ill mina ed d ing ehicle
ope a ion hile addi ional check of he ela ed inp a e pe fo med.

HDC Informa ion Indica or

The HDC info ma ion indica o i a g een colo ed indica o loca ed in he achome e .

The HDC info ma ion indica o i con in o l ill mina ed hile he HDC f nc ion i elec ed on and he ehicle i
i hin he pa ame e fo HDC ope a ion; hen he ehicle i o ide he pa ame e fo HDC ope a ion, he HDC
info ma ion indica o i fla hed a 2 H .

Ope a ion of he HDC info ma ion indica o i con olled b a high peed C AN b me age f om he ABS mod le o
he in men cl e .

HDC Warning Indica or

On he lo line in men cl e , he HDC a ning indica o i an ambe colo ed indica o loca ed be een he
achome e and he peedome e . On ehicle i h he high line in men cl e , he HDC a ning indica o
con i of a me age in he me age cen e .

On he lo line in men cl e he HDC a ning indica o i con in o l ill mina ed if he e i a fa l ha affec

he HDC f nc ion, and fla hed a 2 H if he HDC f nc ion i empo a il na ailable beca e of b ake o e hea .

On he high line in men cl e , app op ia e me age a e di pla ed in he me age cen e if he e i a fa l ha

affec he HDC f nc ion, o if he HDC f nc ion i empo a il na ailable beca e of b ake o e hea .
Fo addi ional info ma ion, efe o: Info ma ion and Me age C en e (413-08 Info ma ion and Me age C en e ,
De c ip ion and Ope a ion).

Ope a ion of he HDC a ning indica o i con olled b a high peed C AN b me age f om he ABS mod le o he
in men cl e .

On he lo line in men cl e , hen he igni ion i ch i fi ned o po i ion II, he HDC a ning indica o
ill mina e fo app o ima el 3 econd a a b lb check.

HCU

The HC U i a 4 channel ni ha mod la e he ppl of h d a lic p e e o he b ake nde he con ol of he

ABS mod le.

The HC U i a ached b h ee mo n ing b he o a b acke in he plen m bo on he d i e ide of he engine

compa men . H d a lic pipe connec he HC U o he ma e c linde and he b ake .
Fo addi ional info ma ion, efe o: H d a lic B ake Ac a ion (206-06 H d a lic B ake Ac a ion, De c ip ion and
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Operation).

The primar and secondar outlets of the master c linder are connected to primar and secondar circuits within the
HC U. The primar circuit in the HC U has separate outlet ports to the front brakes. The secondar circuit in the HC U
has separate outlet ports to the rear brakes. Each of the circuits in the HC U contain the following components to
control the suppl of h draulic pressure to the brakes:

A normall open, solenoid operated, pilot valve, to enable active braking.

A normall closed, solenoid operated, priming valve, to connect the brake fluid reservoir to the return pump
during active braking.
A return pump, to generate h draulic pressure for active braking and return brake fluid to the reservoir.
Normall open, solenoid operated, inlet valves and normall closed, solenoid operated, outlet valves, to
modulate the h draulic pressure in the individual brakes.
An accumulator and a relief valve, to allow the fast release of pressure from the brakes.
Filters, to protect the components from contamination.

The primar circuit also incorporates a pressure sensor to provide the ABS module with a h draulic pressure signal.

C ontact pins on the HC U mate with contacts on the ABS module to provide the electrical connections from the ABS
module to the return pump motor and the pressure sensor. The solenoids that operate the valves are installed in the
ABS module.

Replacement HC U are supplied pre-filled. After installation on the vehicle, T4 must be used to operate the solenoid
valves and the return pump to ensure correct bleeding of the HC U and brake circuits.

Schematic of HC U

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I em Pa N mbe De c ip ion
1 - Master c linder
2 - Reservoir
3 - Brake booster
4 - Brake pedal
5 - HC U
6 - Pressure sensor
7 - Priming valve
8 - Pilot valve
9 - Return pump motor
10 - Return pump
11 - Inlet valve
12 - Relief valve
13 - Accumulator
14 - Outlet valve

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15 - Lef f b a e
16 - Righ f b a e
17 - Righ ea b a e
18 - Lef ea b a e
The HC U ha h ee e ai g de : N a b a i g/EBD, ABS b a i g a d ac i e b a i g.

No mal B aking/EBD Mode

I i ia , a f he e id e a ed a e a e de-e e gi ed. O e a i g he b a e eda d ce a c e di g

i c ea e dec ea e f e e i he b a e , h gh he e i a e a d i e a e . If he ABS d e
de e i e ha EBD i ece a , i e e gi e he i e a e f he b a e f he ai i g a e, i a e he b a e
f a f he i c ea e i h d a ic e e.

ABS B aking Mode

If he ABS d e de e i e ha ABS b a i g i ece a , i e e gi e he i e a d e a e f he e a ed

b a e a d a he e . The i e a e c e i a e he b a e f e i ed f id; he e a e
e e ea e e e f he b a e i he acc a a d he e ci c i ; he ed ced e e
a he hee acce e a e. The ABS d e he e a e he i e a d e a e d a e he e e i
he b a e a he a i b a i g eff ih c i g he hee . C f he a e f each hee a e
ace i di id a .

Ac i e B aking Mode

The ac i e b a i g de i ed ge e a e a d c h d a ic e e he b a e f f ci he ha
ABS b a i g, e.g. DSC , EBA, ETC , HDC a d d a ic a ica i f he a i g b a e.

F ac i e b a i g, he ABS d e e e gi e he i a e a d i i g a e , a he e a d
e e gi e a f he i e a e . B a e f id, d a f he e e i h gh he a e c i de a d i i g a e,
i e i ed b he e a d ied he i e a e . The ABS d e he e a e he i e a e
a d e a e , a e i ed, d a e he e e i he i di id a b a e . S e i e a be ge e a ed
d i g ac i e b a i g.

ABS MODULE

The ABS d e c he b a e f ci i g he HC U d a e h d a ic e e he i di id a hee

b a e .

The ABS d e i a ached he HC U, i he e b he d i e ide f he e gi e c a e . A 46 i

c ec ide he e ec ica i e face be ee he ABS d e a d he ehic e i i g.

ABS M d e Ha e C ec C 0506

A BS Mod le Ha ne Connec o C0506 Pin De ail

Pin No. De c ip ion Inp /O p
1 G d O
2 Ba e e I
3 Ba e e I
4 G d O
5 F ef hee eed e ig a I
6 Rea ef hee eed e e O
7 Rea igh hee eed e e O
8 Rea igh hee eed e ig a I
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9 F O
10 F I
11 13 N -
14 H C AN I /O
15 Y I
16 Y I
17 N -
18 Y I
19 N -
20 L I
21 N -
22 HDC O
23 25 N -
26 F O
27 R I
28 I I
29 N -
30 S BLS I
31 DSC I
32 N -
33 R O
34 N -
35 H C AN I /O
36 HDC I
37 Y O
38 40 N -
41 S BS I
42 46 N -

S STEM OPERATION

ABS

ABS .T
, .

O , .O ,
.S ,
.T .

ARM

T ARM
.

T ABS
, .T
, , ABS
, ,
.

W , ARM , DSC .

CBC

C BC , DSC ABS ,
. C BC .

DSC

DSC .W
DSC DSC .E DSC
, DSC
.

DSC
.T ABS , ,
.
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In general: in an understeering situation, the inner wheels are braked to counteract the yaw movement towards the
outer edge of the bend; in an oversteering situation, the outer wheels are braked to prevent the rear end of the
vehicle from pushing towards the outer edge of the bend.

The ABS module monitors the tracking stability of the vehicle using inputs from the wheel speed sensors, the steering
angle sensor and the yaw rate and lateral acceleration sensor. The tracking stability is compared with stored target
data and, whenever the tracking stability deviates from the target data, the ABS module intervenes by applying the
appropriate brakes. On vehicles with an automatic transmission, when the DSC function is active, the ABS module
also signals the transmission control module (TC M) to prevent gear shifts. If necessary, the ABS module also signals:

The EC M, to reduce engine torque.

The transfer box control module, to adjust the locking torque of the center differential.
The rear differential control module, to adjust the locking torque of the rear differential.

The DSC function overrides the differential locking torque requests from the terrain response system.

EBD

EBD limits the brake pressure applied to the rear wheels. When the brakes are applied, the weight of the vehicle
transfers forwards, which reduces the ability of the rear wheels to transfer braking effort to the road surface. This can
cause the rear wheels to slip and make the vehicle unstable.

EBD uses the anti-lock braking hardware to automatically optimize the pressure of the rear brakes, below the point
where anti-lock braking would be invoked. Only the rear axle is under EBD control.

E C

ETC attempts to optimize forward traction by reducing engine torque or braking a spinning wheel until it regains grip.

ETC is activated if an individual wheel speed is above that of the vehicle reference speed (positive slip) and the brake
pedal is not pressed. The spinning wheel is braked, allowing the excess torque to be transmitted to the non spinning
wheels through the drive line. If necessary, the ABS module also sends a high speed C AN bus message to the EC M to
request a reduction in engine torque. Torque reduction requests are for either a slow or fast response: a slow
response requests a reduction of throttle angle (4.0L and 4.4L only); a fast response requests an ignition cut-off (4.0L
and 4.4L) or a fuel cut-off (2.7L Diesel).

When the DSC function is selected off with the DSC switch, the engine torque reduction feature is disabled.

On vehicles with an automatic transmission, when the ETC function is active the ABS module also signals the TC M to
prevent gear shifts.

EBA

EBA assists the driver, in emergency braking situations, by automatically maximizing the braking effort. There are
two situations when the ABS module will invoke EBA: when the brake pedal is pressed very suddenly and when the
brake pedal is pressed hard enough to bring the front brakes into ABS operation.

When the brake pedal is pressed very suddenly, the ABS module increases the hydraulic pressure to all of the brakes
until they reach the threshold for ABS operation, thus applying the maximum braking effort for the available traction.
The ABS module monitors for the sudden application of the brakes using the inputs from the stoplamp switch and
from the pressure sensor in the HC U. With the brake pedal pressed, if the rate of increase of hydraulic pressure
exceeds the predetermined limit, the ABS module invokes emergency braking.

When the brake pedal is pressed hard enough to bring the front brakes into ABS operation, the ABS module increases
the hydraulic pressure to the rear brakes up to the ABS threshold.

EBA operation continues until the driver releases the brake pedal enough for the hydraulic pressure in the HC U to
drop below a threshold value stored in the ABS module.

EDC

EDC prevents wheel slip caused by any of the following:

A sudden decrease in engine torque when the accelerator is suddenly released.

The sudden engagement of the clutch after a downshift on manual transmission vehicles.
A downshift using the C ommandShift on automatic transmission vehicles.

When the ABS module detects the onset of wheel slip without the brakes being applied it signals the EC M, on the high
speed C AN bus, to request a momentary increase in engine torque.

HDC

HDC uses brake intervention to control vehicle speed and acceleration during low speed descents in off-road and low
grip on-road conditions. Generally, equal pressure is applied to all four brakes, but pressure to individual brakes can
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be dified b he ABS a d DSC f ci e ai abi i . Se ec i f he HDC f ci i c ed b he HDC
i ch he ce e c e. HDC e a e i b h high a d a ge , a ehic e eed 50 /h (31.3 h).

O a a a i i ehic e , HDC a be ed i fi a d e e e gea i high a ge a d a gea i

a ge. O ce he ehic e i i g, he c ch eda h d be f e ea ed. The ehic e h d be d i e ih
HDC ac i e a d he a i i i e a.

O a a ic a i i ehic e , HDC a be ed i D, R a d C a dShif 1 i high a ge, a d i D, R a d a

C a dShif gea i a ge. Whe i D, he a i i c d e i a a ica e ec he
a ia e gea . The ehic e h d be d i e i h HDC ac i e a d he a i i i N.

HDC ca be e ec ed a eed 80 /h (50 h), b i be e ab ed a eed be 50 /h (31.3

h). Whe HDC i e ec ed:

A eed 50 /h (31.3 h), he HDC i f ai i dica i e a e i i a ed if a a id gea

i e ec ed a d, a a a i i ehic e , he c ch eda i de e ed.
A eed f >50 80 /h (>31.3 50 h) he HDC i f ai i dica f a he a d, ehic e ih
he high i e i e c e , a e age ad i i g ha he eed i high i di a ed i he e age
ce e .
F addi i a i f a i , efe :I f ai a d Me age C e e (413-08 I f ai a d Me age
C e e , De c i i a d O e a i ).
If he HDC i ch i e ed hi e ehic e eed i e ha 80 /h (50 h), he HDC i f ai
i dica i i i a e a d HDC i be e ec ed.
If he eed eache 80 /h (50 h) e, a a i g chi e d , he HDC f c i i i ched ff,
he i f ai i dica g e ff a d, ehic e i h he high i e i e c e , a e age ad i i g
ha HDC ha bee i ched ff i di a ed i he e age ce e .

Whe HDC i e ab ed, he ABS d e ca c a e a a ge eed a d c a e hi i h he ac a ehic e eed.

The ABS d e he e a e he HC U, i he ac i e b a i g de, a e i ed achie e a d ai ai he a ge
eed. D i g ac i e b a i g f HDC , he ABS d e a e e gi e he HDC e a e a e he a .
A i g he f b a e d i g ac i e b a i g a e i a e h gh he b a e eda , hich i a.

The a ge eed a ie , be ee i i a d a i a e f each gea a d a i i a ge, de e di g

d i e i h gh he f eda . If he f eda a e e a ed, he ABS d e ad a defa a ge
eed.

Lo Range Target Speeds

Limit Speed, km/h (mph)
Gear
Automatic Transmission Manual Transmission
1, R D, 2 to 6 1, R 2 to 6
Defa 3.5 (2.19) 6 (3.75) 3.5 (2.19) 6 (3.75)
Mi i 3.5 (2.19) 3.5 (2.19) 3.5 (2.19) 3.5 (2.19)
Ma i 20 (12.5) 20 (12.5) 20 (12.5) 20 (12.5)
High Range Target Speeds
Limit Speed, km/h (mph)
Gear
Automatic Transmission Manual Transmission
1, R D 1, R
Defa 6 (3.75) 10 (6.25) 6 (3.75)
Mi i 6 (3.75) 6 (3.75) 6 (3.75)
Ma i 20 (12.5) 20 (12.5) 20 (12.5)
The a ge eed i a ied be ee he i i a d a i a e i g he acce e a eda .

The a ge eed ca a be a ied b e i g he eed c '+' a d '-' b ( he e fi ed). F addi i a

i f a i , efe :

S eed C (310-03A S eed C - V6 4.0L Pe /V8 4.4L Pe , De c i i a dO e ai ),

S eed C (310-03B S eed C - TDV6 2.7L Die e , De c i i a d O e a i ).

D i g cha ge f a ge eed, he ABS d e i i dece e a i a d acce e a i -0.5 / 2 (-1.65 f / 2 ) a d

+0.5 / 2 (+1.65 f / 2 ) e ec i e .

O a a a i i de a ge eed cha ge a e e ded d i g gea cha ge , e e a ed

b a i g he he acce e a eda i e ea ed cha ge gea . The ABS d e de e i e a gea cha ge i
cc i gf :

Gea ii i f ai he high eed C AN b .

The a e f e ea e f he acce e a eda .
The a f he c ch eda .
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To provide a safe transition from active braking to brakes off, the ABS module invokes a fade out strategy, which
gradually discontinues the braking effort, if it detects any of the following during active braking:

HDC selected off with the HDC switch.

Failure of a component used by HDC , but not critical to fade out function.
Accelerator pedal pressed when transmission is in neutral.
Brake overheat.

If fade out is invoked because of deselection or component failure, the HDC function is cancelled by the ABS module.
If fade out is invoked because the accelerator pedal is pressed with the transmission in neutral, or because of brake
overheat, the HDC function remains in standby and resumes operation when the accelerator pedal is released or the
brakes have cooled.

The fade out strategy increases the target speed, at a constant acceleration rate of 0.5 m/s2 (1.65 ft/s2 ), until the
maximum target speed is reached or until no active braking is required for 0.5 s. If the accelerator pedal is positioned
within the range that influences target speed, the acceleration rate is increased to 1.0 m/s2 (3.3 ft/s2 ).

When fade out is invoked because of component failure, a warning chime sounds and the HDC information indicator is
extinguished. The HDC warning indicator is illuminated (low line instrument cluster) or a message advising there is a
fault is displayed in the message center (high line instrument cluster).

When fade out is invoked because of brake overheat on vehicles with the high line instrument cluster, a message
advising that HDC is temporarily unavailable is displayed. On vehicles with the low line instrument cluster, the HDC
warning indicator flashes. At the end of fade out, the HDC information indicator flashes. The flashing indicators and/or
message continue while HDC remains selected until the brakes have cooled.

To monitor for brake overheat, the ABS module monitors the amount of braking activity and, from this, estimates the
temperature of each brake. If the estimated temperature of any brake exceeds a preset limit, the ABS module
invokes the fade out strategy. After the fade out cycle, the HDC function is re-enabled when the ABS module
estimates that all of the brake temperatures are at less than 64% of the temperature limit.

AN I-LOCK CON ROL DIAGRAM

NOTE: A = Hardwired connections; D = High speed C AN bus

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I em Pa N mbe De c ip ion
1 - Fusible link 11E, batter junction bo (BJB)
2 - Ignition s itch

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3 - F e 37P, C JB
4 - Ya a e and la e al accele a ion en o
5 - F ible link 9E, BJB
6 - F ible link 23E, BJB
7 - F on heel peed en o
8 - F on heel peed en o
9 - Rea heel peed en o
10 - Rea heel peed en o
11 - Na iga ion comp e
12 - ABS mod le
13 - T an mi ion con ol mod le
14 - Diagno ic ocke
15 - In men cl e
16 - Ai pen ion con ol mod le
17 - Pa king b ake mod le
18 - S ee ing angle en o
19 - Rea diffe en ial con ol mod le
20 - Re ain con ol mod le
21 - Lef oplamp
22 - C en e oplamp
23 - Righ oplamp
24 - EC M
25 - T an fe bo con ol mod le
26 - HDC ela (non- e iceable, in eg a ed in o C JB)
27 - F e 15P, C JB
28 - S oplamp i ch
29 - HDC i ch
30 - DSC i ch
31 - F e 66P, C JB

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Published: 11-May-2011
Anti-Lock Control - Traction Control - Anti-Lock Control - Traction ControlVIN
Range: 000303->413981
Diagnosis and Testing

Principle of Operation

For information on the description and operation of the system, refer to section 206-09A - Anti-Lock C ontrol - Traction
C ontrol in the workshop manual.

Many of the functions forming part of the anti-lock braking system (ABS) will communicate with the message center
giving information to the driver about the operation of the system overall, which means that there are no real
symptoms as such which are not covered by either a message or a diagnostic trouble code (DTC ).

For information on the message center, refer to the relevant section in the workshop manual.

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual Inspection
Mechanical Electrical
Stoplamp Switch Fuses
Tire size, condition and installation Harnesses and connectors
Wheel speed sensor condition and installation Warning lamp operation
Steering Angle Sensor (SAS) condition and installation Wheel speed sensors
Yaw rate sensor and accelerometer condition and installation C entral junction box
Hydraulic control unit (with attached ABS module) condition and HDC switch
installation DSC switch
Stoplamp Switch
Yaw rate sensor and
accelerometer
Steering Angle Sensor (SAS)
ABS module
C ontroller area network (C AN)
circuits

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step

4. 4. Use the approved diagnostic system or a scan tool to retrieve any DTC s before moving onto the DTC index.

Make sure that all DTC s are cleared following rectification.

DTC Inde

C AUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the
donor vehicle.

NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer
to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in
operation, prior to the installation of a new module/component.

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: C heck and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

NOTE: Inspect connectors for signs of water ingress, and terminals for damage and/or corrosion.

NOTE: If DTC s are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern
may be the cause. Always check for loose connections and corroded terminals.

DTC Description Possible causes Action

C 1105- Brake Lamp General electrical failure Refer to the electrical guides and check harness
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01 C ontrol - Stoplamp actuation (BLA) short connection to BLA. Ensure that harness is not shorted
General to Power or ground to either ground or suppl .
electrical - Harness/connector
failure damaged

C 1105- Brake Lamp Signal incorrect after event C heck operation of the Stoplamp rela (also known as
67 C ontrol - HDC rela ) and correct illumination of the Stoplamps.
Signal incorrect Harness fault Refer to the electrical guides and check the Stoplamp
after event Stoplamp/hill decent control Switch and circuits.
rela fault

C 1109- Vehicle Signal stuck high - DSC Switch Refer to the electrical guides and check the DSC
24 D namics operation fault switch and circuits.
C ontrol Switch - (If the DSC switch is
- Signal stuck pressed for longer than 1
high minute, the switch is
deemed to be
malfunctioning)

C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
04 - S stem module internal failure a module is suspect.
internal failures
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
05 - S stem module programming failure a module is suspect.
programming
failures
C 1A00- C ontrol Module Vehicle d namics control C heck vehicle batter and charging s stem. Refer to
16 - C ircuit module power suppl circuit the relevant section in the workshop manual. Refer to
voltage below voltage below threshold the electrical guides and check the power suppl
threshold Harness/connector damaged circuits to the module.
C harging circuit fault
Defective or flat batter

C 1A00- C ontrol Module Vehicle d namics control C heck the batter voltage and charging s stem. Refer
17 - C ircuit module power suppl circuit to the relevant section in the workshop manual. Refer
voltage above voltage above threshold to the electrical guides and check the power suppl
threshold C harging circuit fault circuits to the module.
Defective or flat batter

C 1A00- C ontrol Module Vehicle d namics control A momentar low voltage occurred, check vehicle
1C - C ircuit module power suppl circuit batter and charging circuit. Refer to the relevant
voltage out of voltage out of range section in the workshop manual. Refer to the electrical
range guides and check the power suppl circuits to the
module.
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
41 - General module general checksum a module is suspect.
checksum failure
failure
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
42 - General module general memor a module is suspect.
memor failure failure

C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
43 - Special module special memor failure a module is suspect.
memor failure
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
44 - Data memor module data memor failure a module is suspect.
failure
C 1A00- C ontrol Module Vehicle d namics control C lear the DTC and retest. If the problem reset after
45 - Program module program memor several attempts, renew the modulator. Refer to the
memor failure failure warrant polic and procedures manual if a module is
suspect.
C 1A00- C ontrol Module Incorrect car configuration file C onfigure the module using the approved diagnostic
46 - C alibration / (C C F) data received from s stem. C lear the DTC and check if the DTC resets
parameter instrument pack cluster (IPC ) after ignition reset following >10 seconds ignition on.
memor failure or C C F incorrectl configured. If the above is correct and the DTC persists, renew
Modulator installed to the modulator. Refer to the warrant polic and
unrecogni ed vehicle procedures manual if a module is suspect.
configuration
Vehicle d namics control
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module calibration/parameter
memor failure (internal error)

C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
47 - Watchdog / module watchdog/safet a module is suspect.
safet microprocessor failure
microprocessor
failure
C 1A00- C ontrol Module Vehicle d namics control C onfigure the module using the approved diagnostic
48 - Supervision module supervision software s stem.
software failure failure

C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
49 - Internal module internal electronic a module is suspect.
electronic failure
failure
C 1A00- C ontrol Module Vehicle d namics control C onfigure the module using the approved diagnostic
4A - Incorrect module incorrect component s stem.
component installed
installed New modulator installed/not
et configured

C 1A00- C ontrol Module Vehicle d namics control Allow the unit to cool, clear the DTC and retest. Do not
4B - Over module over temperature renew the modulator as this is a protection function to
temperature ensure no valve damage occurs. The DTC ma be set
if the service tool diagnostic tester requests long
periods of valve control.
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
62 - Signal module signal compare failure a module is suspect.
compare
failure
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
63 - C ircuit / module component protection a module is suspect.
component time-out
protection
time-out
C 1A00- C ontrol Module Vehicle d namics control Refer to the warrant polic and procedures manual if
64 - Signal module signal plausibilit a module is suspect.
plausibilit failure
failure
C 1A00- C ontrol Module Vehicle d namics control C heck for an un-calibrated Steering Angle Sensor,
68 - Event module event information defective Steering Angle Sensor, defective wheel
information speed sensor, defective aw rate/lateral acceleration
sensor. Rectif as necessar . C lear the DTC and
retest.
C 1A00- C ontrol Module C AN bus off Refer to the Network C ommunications section in the
88 - Bus off C AN bus harness /wiring workshop manual.
damaged
Incorrect C AN Master C onfig
ID information from instrument
pack

C 1A76- Valve Rela - Modulator internal fault Refer to the warrant polic and procedures manual if
01 General a module is suspect.
electrical
failure
C 1A76- Valve Rela - Modulator valve rela circuit Refer to the warrant polic and procedures manual if
04 S stem internal failures a module is suspect.
internal failures
C 1A77- Valve Rela C ircuit voltage below threshold Refer to the electrical guides and check the harness
16 Suppl C ircuit - connection to the valve rela circuits.
C ircuit voltage Fuse
below Harness/connector damaged
threshold
C 1A78- Left Front Inlet Modulator internal fault Refer to the warrant polic and procedures manual if
04 Valve - S stem a module is suspect.
internal failures

C 1A78- Left Front Inlet Modulator internal fault Refer to the warrant polic and procedures manual if
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09 Valve - a module is suspect.
C omponent
failures
C 1A79- Left Front Modulator internal fault Refer to the warrant polic and procedures manual if
04 Outlet Valve - a module is suspect.
S stem
internal failures
C 1A80- Right Front Modulator internal fault Refer to the warrant polic and procedures manual if
04 Inlet Valve - a module is suspect.
S stem
internal failures
C 1A81- Right Front Modulator internal fault Refer to the warrant polic and procedures manual if
04 Outlet Valve - a module is suspect.
S stem
internal failures
C 1A82- Left Rear Inlet Modulator internal fault Refer to the warrant polic and procedures manual if
04 Valve - S stem a module is suspect.
internal failures
C 1A82- Left Rear Inlet Modulator internal fault Refer to the warrant polic and procedures manual if
09 Valve - a module is suspect.
C omponent
failures
C 1A83- Left Rear Modulator internal fault Refer to the warrant polic and procedures manual if
04 Outlet Valve - a module is suspect.
S stem
internal failures
C 1A84- Right Rear Modulator internal fault Refer to the warrant polic and procedures manual if
04 Inlet Valve - a module is suspect.
S stem
internal failures
C 1A85- Right Rear Modulator internal fault Refer to the warrant polic and procedures manual if
04 Outlet Valve - a module is suspect.
S stem
internal failures
C 1A86- C ommutation Modulator internal fault Refer to the warrant polic and procedures manual if
04 Valve # 1 - a module is suspect.
S stem
internal failures
C 1A86- C ommutation Modulator internal fault Refer to the warrant polic and procedures manual if
09 Valve # 1 - a module is suspect.
C omponent
failures
C 1A87- C ommutation Modulator internal fault Refer to the warrant polic and procedures manual if
04 Valve # 2 - a module is suspect.
S stem
internal failures
C 1A88- High Pressure Modulator internal fault Refer to the warrant polic and procedures manual if
04 Switching a module is suspect.
Valve #1 -
S stem
internal failures
C 1A89- High Pressure Modulator internal fault Refer to the warrant polic and procedures manual if
04 Switching a module is suspect.
Valve #2 -
S stem
internal failures
C 1A90- Wheel Speed Wheel speed sensor suppl Refer to the guided diagnostic routine for this code on
12 Sensor Suppl circuit short circuit to power the approved diagnostic s stem.
- C ircuit short - Harness/connector fault
to batter - Sensor failure

C 1A91- Left Front Wheel speed sensor circuit C heck the wheel speed sensor and refer to the
13 Wheel Speed high resistance electrical guides to check the circuit. Refer to the
Sensor - - Harness/connector fault guided diagnostic routine for this code on the
C ircuit open - Sensor failure approved diagnostic s stem.

C 1A91- Left Front Signal shape/waveform failure C heck the wheel speed sensor and refer to the
25 Wheel Speed - Harness/connector fault electrical guides to check the circuit. Test the vehicle

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Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
shape / the success of an repair. Refer to the guided
waveform diagnostic routine for this code on the approved
failure diagnostic s stem.
C 1A91- Left Front Signal erratic C heck the wheel speed sensor and refer to the
2F Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
erratic the success of an repair. Refer to the guided
diagnostic routine for this code on the approved
diagnostic s stem.
C 1A91- Left Front Signal frequenc too low C heck the wheel speed sensor and refer to the
36 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Refer to the
Sensor - Signal - Incorrect mounting of guided diagnostic routine for this code on the
frequenc too sensor approved diagnostic s stem.
low - Sensor failure

C 1A91- Left Front Signal frequenc incorrect Remove the sensor and visuall inspect the sensor
38 Wheel Speed - Tone ring tooth missing or ring on the constant velocit joint (C VJ) for missing or
Sensor - Signal damaged damaged teeth. If the sensor ring is damaged, renew
frequenc the C VJ. Refer to the guided diagnostic routine for this
incorrect code on the approved diagnostic s stem. Test the
vehicle to a speed greater than 20km/h (12.5mph) to
confirm the success of an repair.
C 1A91- Left Front Signal compare failure C heck the wheel speed sensor and refer to the
62 Wheel Speed - Incorrect wheel or tire electrical guides to check the circuit. Test the vehicle
Sensor - Signal si e installed to a speed greater than 20km/h (12.5mph) to confirm
compare - Harness/connector issue the success of an repair. Refer to the guided
failure - Sensor failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A91- Left Front Signal plausibilit failure C heck the wheel speed sensor and refer to the
64 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
plausibilit the success of an repair. Refer to the guided
failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A91- Left Front Signal has too few C heck the wheel speed sensor and refer to the
65 Wheel Speed transitions/events electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
has too few approved diagnostic s stem.
transitions /
events
C 1A91- Left Front Sensor alignment incorrect C heck the wheel speed sensor installation. Refer to
78 Wheel Speed Sensor air gap incorrect the relevant section in the workshop manual. Refer to
Sensor - the guided diagnostic routine for this code on the
Alignment or approved diagnostic s stem.
adjustment
incorrect
C 1A92- Left Rear Wheel speed sensor circuit C heck the wheel speed sensor and refer to the
13 Wheel Speed high resistance electrical guides to check the circuit. Refer to the
Sensor - - Harness/connector issue guided diagnostic routine for this code on the
C ircuit open - Sensor failure approved diagnostic s stem.

C 1A92- Left Rear Signal shape/waveform failure C heck the wheel speed sensor and refer to the
25 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
shape / the success of an repair. Refer to the guided
waveform diagnostic routine for this code on the approved
failure diagnostic s stem.
C 1A92- Left Rear Signal erratic C heck the wheel speed sensor and refer to the
2F Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
erratic the success of an repair. Refer to the guided
diagnostic routine for this code on the approved
diagnostic s stem.
C 1A92- Left Rear Signal frequenc too low C heck the wheel speed sensor and refer to the
36 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
frequenc too approved diagnostic s stem.
low

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C 1A92- Left Rear Signal frequenc incorrect Remove the sensor and visuall inspect the sensor
38 Wheel Speed - Tone ring tooth missing or ring on the constant velocit joint (C VJ) for missing or
Sensor - Signal damaged damaged teeth. If the sensor ring is damaged, renew
frequenc the C VJ. Refer to the guided diagnostic routine for this
incorrect code on the approved diagnostic s stem. Test the
vehicle to a speed greater than 20km/h (12.5mph) to
confirm the success of an repair.
C 1A92- Left Rear Signal compare failure C heck the wheel speed sensor and refer to the
62 Wheel Speed - Incorrect wheel or tire electrical guides to check the circuit. Test the vehicle
Sensor - Signal si e installed to a speed greater than 20km/h (12.5mph) to confirm
compare - Harness/connector issue the success of an repair. Refer to the guided
failure - Sensor failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A92- Left Rear Signal plausibilit failure C heck the wheel speed sensor and refer to the
64 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
plausibilit the success of an repair. Refer to the guided
failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A92- Left Rear Signal has too few C heck the wheel speed sensor and refer to the
65 Wheel Speed transitions/events electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
has too few approved diagnostic s stem.
transitions /
events
C 1A92- Left Rear Sensor alignment incorrect C heck the wheel speed sensor installation. Refer to
78 Wheel Speed Sensor air gap incorrect the relevant section in the workshop manual. Refer to
Sensor - the guided diagnostic routine for this code on the
Alignment or approved diagnostic s stem
adjustment
incorrect
C 1A93- Right Rear Wheel speed sensor circuit C heck the wheel speed sensor and refer to the
13 Wheel Speed high resistance electrical guides to check the circuit. Refer to the
Sensor - - Harness/connector issue guided diagnostic routine for this code on the
Alignment or - Sensor failure approved diagnostic s stem.
adjustment
incorrect
C 1A93- Right Rear Signal shape/waveform failure C heck the wheel speed sensor and refer to the
25 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
shape / the success of an repair. Refer to the guided
waveform diagnostic routine for this code on the approved
failure diagnostic s stem.
C 1A93- Right Rear Signal erratic C heck the wheel speed sensor and refer to the
2F Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
erratic the success of an repair. Refer to the guided
diagnostic routine for this code on the approved
diagnostic s stem.
C 1A93- Right Rear Signal frequenc too low C heck the wheel speed sensor and refer to the
36 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
frequenc too approved diagnostic s stem.
low
C 1A93- Right Rear Signal frequenc incorrect Remove the sensor and visuall inspect the sensor
38 Wheel Speed - Tone ring tooth missing or ring on the constant velocit joint (C VJ) for missing or
Sensor - Signal damaged damaged teeth. If the sensor ring is damaged, renew
frequenc the C VJ. Refer to the guided diagnostic routine for this
incorrect code on the approved diagnostic s stem. Test the
vehicle to a speed greater than 20km/h (12.5mph) to
confirm the success of an repair.
C 1A93- Right Rear Signal compare failure C heck the wheel speed sensor and refer to the
62 Wheel Speed - Incorrect wheel or tire electrical guides to check the circuit. Test the vehicle
Sensor - Signal si e installed to a speed greater than 20km/h (12.5mph) to confirm
compare - Harness/connector issue the success of an repair. Refer to the guided
failure - Sensor failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A93- Right Rear Signal plausibilit failure C heck the wheel speed sensor and refer to the
64 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
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Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
plausibilit the success of an repair. Refer to the guided
failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A93- Right Rear Signal has too few C heck the wheel speed sensor and refer to the
65 Wheel Speed transitions/events electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
has too few approved diagnostic s stem.
transitions /
events
C 1A93- Right Rear Sensor alignment incorrect C heck the wheel speed sensor installation. Refer to
78 Wheel Speed Sensor air gap incorrect the relevant section in the workshop manual. Refer to
Sensor - the guided diagnostic routine for this code on the
Alignment or approved diagnostic s stem
adjustment
incorrect
C 1A94- Right Front Wheel speed sensor circuit C heck the wheel speed sensor and refer to the
13 Wheel Speed high resistance electrical guides to check the circuit. Refer to the
Sensor - - Harness/connector issue guided diagnostic routine for this code on the
C ircuit open - Sensor failure approved diagnostic s stem.

C 1A94- Right Front Signal shape/waveform failure C heck the wheel speed sensor and refer to the
25 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
shape / the success of an repair. Refer to the guided
waveform diagnostic routine for this code on the approved
failure diagnostic s stem.
C 1A94- Right Front Signal erratic C heck the wheel speed sensor and refer to the
2F Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
erratic the success of an repair. Refer to the guided
diagnostic routine for this code on the approved
diagnostic s stem.
C 1A94- Right Front Signal frequenc too low C heck the wheel speed sensor and refer to the
36 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
frequenc too approved diagnostic s stem.
low
C 1A94- Right Front Signal frequenc incorrect Remove the sensor and visuall inspect the sensor
38 Wheel Speed - Tone ring tooth missing or ring on the constant velocit joint (C VJ) for missing or
Sensor - Signal damaged damaged teeth. If the sensor ring is damaged, renew
frequenc the C VJ. Refer to the guided diagnostic routine for this
incorrect code on the approved diagnostic s stem. Test the
vehicle to a speed greater than 20km/h (12.5mph) to
confirm the success of an repair.
C 1A94- Right Front Signal compare failure C heck the wheel speed sensor and refer to the
62 Wheel Speed - Incorrect wheel or tire electrical guides to check the circuit. Test the vehicle
Sensor - Signal si e installed to a speed greater than 20km/h (12.5mph) to confirm
compare - Harness/connector issue the success of an repair. Refer to the guided
failure - Sensor failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A94- Right Front Signal plausibilit failure C heck the wheel speed sensor and refer to the
64 Wheel Speed - Harness/connector issue electrical guides to check the circuit. Test the vehicle
Sensor - Signal - Sensor failure to a speed greater than 20km/h (12.5mph) to confirm
plausibilit the success of an repair. Refer to the guided
failure diagnostic routine for this code on the approved
diagnostic s stem.
C 1A94- Right Front Signal has too few C heck the wheel speed sensor and refer to the
65 Wheel Speed transitions/events electrical guides to check the circuit. Refer to the
Sensor - Signal - Sensor failure guided diagnostic routine for this code on the
has too few approved diagnostic s stem.
transitions /
events
C 1A94- Right Front Sensor alignment incorrect C heck the wheel speed sensor installation. Refer to
78 Wheel Speed Sensor air gap incorrect the relevant section in the workshop manual. Refer to
Sensor - the guided diagnostic routine for this code on the
Alignment or approved diagnostic s stem
adjustment
incorrect
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C 1A95- Wheel Speed The incorrect wheel speed C heck the wheel speed sensors. C lear the DTC and
4A Sensor - sensor has been installed retest.
Incorrect
component
installed
C 1A95- Wheel Speed Signal compare failure A wheel speed sensor is installed in the reverse
62 Sensor - Signal - Wheel speed sensor direction. C heck the wheel speed sensors for correct
compare rotation plausibility installation.
failure
C 1A95- Wheel Speed Signal plausibility failure C heck for correct wheel/tire sizes. C heck the wheel
64 Sensor - Signal - Wheel speed sensor fault speed sensors and circuits. Remove the sensor and
plausibility (any) visually inspect the sensor ring on the constant
failure - Sensor ring damaged, velocity joint (C VJ) for missing or damaged teeth. If
incorrect or defective the sensor ring is damaged, renew the C VJ. Renew
- Harness fault sensors as necessary. Refer to the relevant section in
Incorrect wheel/tire assembly the workshop manual.
size

C 1A96- Brake Light Stoplamp C ircuit fault Refer to Workshop Manual Section 206-09 Diagnosis
13 Switch - C ircuit and Testing GO to Pinpoint Test A.
Open
C 1A96- Brake Light Stoplamp Switch (BLS) signal Refer to Workshop Manual Section 206-09 Diagnosis
24 Switch - Signal is Active (1)(Footbrake pedal and Testing GO to Pinpoint Test B.
Stuck High pressed condition) for more
than 60 seconds while the
vehicle is not braking
Stoplamp Switch C ircuit fault
Stoplamp Switch internal fault
Stoplamp Switch incorrect
installation
Stoplamp Switch incorrectly
adjusted

C 1A96- Brake Light Signal C ompare Failure the Refer to Workshop Manual Section 206-09 Diagnosis
62 Switch - Signal Stoplamp Switch (BLS) and the and Testing GO to Pinpoint Test C .
C ompare Brake Switch (BS) have shared
Failure the same output state at the
same time
Stoplamp Switch C ircuit fault
Stoplamp Switch internal fault

C 1A96- Brake Light Signal Plausibility Failure the NOTE: C heck for Pressure Sensor DTC s C 1A99-01,
64 Switch - Signal Brake Fluid Hydraulic Pressure C 1A99-29, C 1A99-49 or C 1A99-64. If any of these
Plausibility (PS) has exceeded 10bar and DTC s has been stored carry out the specified action
Failure the Stoplamp Switch output prior to investigating DTC C 1A96-64
state has not switched from
Inacti e (0) to Acti e Refer to Workshop Manual Section 206-09 Diagnosis
(1)(Footbrake pedal pressed and Testing GO to Pinpoint Test D.
condition)
Stoplamp Switch C ircuit fault
Stoplamp Switch internal fault
Stoplamp Switch incorrect
installation
Stoplamp Switch incorrectly
adjusted

C 1A97- Lateral Signal stuck high C heck the combined lateral acceleration/yaw rate
24 Accelerometer - Yaw rate/lateral sensor installation. Refer to the electrical guides and
- Signal stuck acceleration sensor internal check the yaw rate sensor circuit. Repair/renew as
high error necessary. Refer to the relevant section of the
workshop manual. Refer to the guided diagnostic
routine for this code on the approved diagnostic
system.
C 1A97- Lateral Signal rate of change above C heck the combined lateral acceleration/yaw rate
27 Accelerometer threshold sensor installation. Refer to the electrical guides and
- Signal rate of - Harness/connector issue check the yaw rate sensor circuit. Repair/renew as
change above - Yaw rate/lateral necessary. Refer to the relevant section of the
threshold acceleration sensor internal workshop manual. Refer to the guided diagnostic
error routine for this code on the approved diagnostic

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em.
C 1A97- La e al Signal bia le el o of C heck he combined la e al accele a ion/ a ae
28 Accele ome e ange/in e nal e o adj men en o in alla ion. Refe o he elec ical g ide and
- Signal bia fail e check he a a e en o ci c i . Repai / ene a
le el o of - Ya a e/la e al nece a . Refe o he ele an ec ion of he
ange / e o accele a ion en o in e nal o k hop man al. Refe o he g ided diagno ic
adj men e o o ine fo hi code on he app o ed diagno ic
fail e em.
C 1A97- La e al Signal in alid C heck he combined la e al accele a ion/ a ae
29 Accele ome e - Ya a e/la e al en o in alla ion. Refe o he elec ical g ide and
- Signal in alid accele a ion en o in e nal check he a a e en o ci c i . Repai / ene a
e o nece a . Refe o he ele an ec ion of he
o k hop man al. Refe o he g ided diagno ic
o ine fo hi code on he app o ed diagno ic
em.
C 1A97- La e al In e nal elec onic fail e C heck he combined la e al accele a ion/ a ae
49 Accele ome e - Po ible open ci c i on en o in alla ion. Refe o he elec ical g ide and
- In e nal en o ha ne connec o , check he a a e en o ci c i . Repai / ene a
elec onic AY pin nece a . Refe o he ele an ec ion of he
fail e - Ya a e/la e al o k hop man al. Refe o he g ided diagno ic
accele a ion en o in e nal o ine fo hi code on he app o ed diagno ic
e o em.

C 1A97- La e al Signal pla ibili fail e C heck he combined la e al accele a ion/ a ae

64 Accele ome e - Ya a e/la e al en o in alla ion. Refe o he elec ical g ide and
- Signal accele a ion en o in e nal check he a a e en o ci c i . Repai / ene a
pla ibili e o nece a . Refe o he ele an ec ion of he
fail e o k hop man al. Refe o he g ided diagno ic
o ine fo hi code on he app o ed diagno ic
em.
C 1A97- La e al Signal in alid C heck he combined la e al accele a ion/ a ae
86 Accele ome e - Signal ci c i high en o in alla ion. Refe o he elec ical g ide and
- Signal in alid e i ance check he a a e en o ci c i . Repai / ene a
- Signal ci c i ho ci c i nece a . Refe o he ele an ec ion of he
o g o nd o k hop man al. Refe o he g ided diagno ic
- Signal ci c i ho ci c i o ine fo hi code on he app o ed diagno ic
o po e em.
- Ya a e/la e al
accele a ion en o in e nal
e o

C 1A97- La e al C omponen in e nal fail e C heck he combined la e al accele a ion/ a ae

96 Accele ome e - Ya a e/la e al en o in alla ion. Refe o he elec ical g ide and
- C omponen accele a ion en o in e nal check he a a e en o ci c i . Repai / ene a
in e nal fail e e o nece a . Refe o he ele an ec ion of he
o k hop man al. Refe o he g ided diagno ic
o ine fo hi code on he app o ed diagno ic
em.
C 1A98- Ya Ra e Gene al elec ical fail e C heck he combined la e al accele a ion/ a ae
01 Sen o - - Refe ence ci c i high en o in alla ion. Refe o he elec ical g ide and
Gene al e i ance (DRSR pin) check he a a e en o ci c i . Repai / ene a
elec ical - Refe ence ci c i ho nece a . Refe o he ele an ec ion of he
fail e ci c i o g o nd (DRSR pin) o k hop man al. Refe o he g ided diagno ic
- Refe ence ci c i ho o ine fo hi code on he app o ed diagno ic
ci c i o po e (DRSR pin) em.
- Ya a e/la e al
accele a ion en o in e nal
e o

C 1A98- Ya Ra e Signal ampli de g ea e han C heck he combined la e al accele a ion/ a ae

22 Sen o - Signal pecified ma im m en o in alla ion. Refe o he elec ical g ide and
ampli de > - Ya a e/la e al check he a a e en o ci c i . Repai / ene a
ma im m accele a ion en o in e nal nece a . Refe o he ele an ec ion of he
e o o k hop man al. Refe o he g ided diagno ic
- Un-calib a ed S ee ing o ine fo hi code on he app o ed diagno ic
Angle Sen o em.
- Defec i e S ee ing Angle
Sen o

C 1A98- Ya Ra e Signal a e of change abo e C heck he combined la e al accele a ion/ a ae

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27 Sensor - Signal threshold sensor installation. Refer to the electrical guides and
rate of change - Yaw rate/lateral check the aw rate sensor circuit. Repair/renew as
above acceleration sensor internal necessar . Refer to the relevant section of the
threshold error workshop manual. Refer to the guided diagnostic
routine for this code on the approved diagnostic
s stem.
C 1A98- Yaw Rate Signal bias level out of C heck the combined lateral acceleration/ aw rate
28 Sensor - Signal range/internal ero adjustment sensor installation. Refer to the electrical guides and
bias level out failure check the aw rate sensor circuit. Repair/renew as
of range / ero - Yaw rate/lateral necessar . Refer to the relevant section of the
adjustment acceleration sensor internal workshop manual. Refer to the guided diagnostic
failure error routine for this code on the approved diagnostic
s stem.
C 1A98- Yaw Rate Signal invalid C heck the combined lateral acceleration/ aw rate
29 Sensor - Signal - Yaw rate/lateral sensor installation. Refer to the electrical guides and
invalid acceleration sensor internal check the aw rate sensor circuit. Repair/renew as
error necessar . Refer to the relevant section of the
workshop manual. Refer to the guided diagnostic
routine for this code on the approved diagnostic
s stem.
C 1A98- Yaw Rate Signal calculation failure C heck the combined lateral acceleration/ aw rate
61 Sensor - Signal - Yaw rate/lateral sensor installation. Refer to the electrical guides and
calculation acceleration sensor internal check the aw rate sensor circuit. Repair/renew as
failure error necessar . Refer to the relevant section of the
- Un-calibrated Steering workshop manual. Refer to the guided diagnostic
Angle Sensor routine for this code on the approved diagnostic
- Defective Steering Angle s stem.
Sensor

C 1A98- Yaw Rate Signal compare failure C heck the combined lateral acceleration/ aw rate
62 Sensor - Signal - Yaw rate/lateral sensor installation. Refer to the electrical guides and
compare acceleration sensor internal check the aw rate sensor circuit. Repair/renew as
failure error necessar . Refer to the relevant section of the
- Un-calibrated Steering workshop manual. Refer to the guided diagnostic
Angle Sensor routine for this code on the approved diagnostic
- Defective Steering Angle s stem.
Sensor

C 1A98- Yaw Rate Signal plausibilit failure C heck the combined lateral acceleration/ aw rate
64 Sensor - Signal - Yaw rate/lateral sensor installation. Refer to the electrical guides and
plausibilit acceleration sensor internal check the aw rate sensor circuit. Repair/renew as
failure error necessar . Refer to the relevant section of the
- Un-calibrated Steering workshop manual. Refer to the guided diagnostic
Angle Sensor routine for this code on the approved diagnostic
- Defective Steering Angle s stem.
Sensor

C 1A98- Yaw Rate Signal invalid
86 Sensor - Signal - Signal circuit high
invalid resistance (DRSS pin)
- Signal circuit short circuit
to ground (DRSS pin)
- Signal circuit short circuit
to power (DRSS pin)
- Yaw rate/lateral
acceleration sensor internal
error
C heck the combined lateral acceleration/ aw rate
sensor installation. Refer to the electrical guides and
check the aw rate sensor circuit. Repair/renew as
necessar . Refer to the relevant section of the
workshop manual. Refer to the guided diagnostic
routine for this code on the approved diagnostic
s stem.

C 1A98- Yaw Rate Performance or incorrect C heck the combined lateral acceleration/ aw rate
92 Sensor - operation sensor installation. Refer to the electrical guides and
Performance or - C heck that the sensor is check the aw rate sensor circuit. Repair/renew as
incorrect correctl oriented necessar . Refer to the relevant section of the
operation - Yaw rate/lateral workshop manual. Refer to the guided diagnostic
acceleration sensor internal routine for this code on the approved diagnostic
error s stem. A drive test is required before the Instrument
pack lamps will be cleared.
C 1A99- Pressure General electrical failure Renew ABS modulator. Refer to the warrant polic
01 Sensor - - Internal modulator error and procedures manual if a module is suspect.
General
electrical
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failure
C 1A99- Pressure Signal invalid Renew ABS modulator. Refer to the warrant polic
29 Sensor - Signal - Internal modulator error and procedures manual if a module is suspect.
invalid
C 1A99- Pressure Internal electronic failure Renew ABS modulator. Refer to the warrant polic
49 Sensor - - Internal modulator error and procedures manual if a module is suspect.
Internal
electronic
failure
C 1A99- Pressure Signal plausibilit failure Renew ABS modulator. Refer to the warrant polic
64 Sensor - Signal - Internal modulator error and procedures manual if a module is suspect.
plausibilit
failure
C 1B00- Steering Angle Signal rate of change above C heck for Steering Angle Sensor DTC s. Refer to the
27 Sensor - Signal threshold guided diagnostic routine for this code on the
rate of change - Un-calibrated Steering approved diagnostic s stem.
above Angle Sensor
threshold - Steering Angle Sensor
issue

C 1B00- Steering Angle Signal invalid C heck for Steering Angle Sensor DTC s. Refer to the
29 Sensor - Signal - Un-calibrated Steering guided diagnostic routine for this code on the
invalid Angle Sensor approved diagnostic s stem.
- Steering Angle Sensor
issue

C 1B00- Steering Angle Signal calculation failure C heck for Steering Angle Sensor DTC s. Refer to the
61 Sensor - Signal - Un-calibrated Steering guided diagnostic routine for this code on the
calculation Angle Sensor approved diagnostic s stem.
failure - Steering Angle Sensor
issue

C 1B00- Steering Angle Signal plausibilit failure C heck for Steering Angle Sensor DTC s. Refer to the
64 Sensor - Signal - Un-calibrated Steering guided diagnostic routine for this code on the
plausibilit Angle Sensor approved diagnostic s stem.
failure - Steering Angle Sensor
issue

C 1B00- Steering Angle Performance or incorrect C heck for Steering Angle Sensor DTC s. Refer to the
92 Sensor - operation guided diagnostic routine for this code on the
Performance or - Un-calibrated Steering approved diagnostic s stem.
incorrect Angle Sensor
operation - Steering Angle Sensor
issue

C 1B02- Return Pump - Return pump circuit general Renew ABS modulator. Refer to the warrant polic
01 General electrical failure and procedures manual if a module is suspect.
electrical - Internal modulator error
failure
C 1B02- Return Pump - Return pump circuit voltage Refer to the electrical guides and check the harness
16 C ircuit voltage below threshold and fuses to the module and rectif as necessar .
below - Harness / wiring damaged
threshold - Defective fuse

C 1B02- Return Pump - Internal electronic failure Renew ABS modulator. Refer to the warrant polic
49 Internal - Internal modulator error and procedures manual if a module is suspect.
electronic
failure
C 1B22- Hill Descent Signal stuck high Refer to the electrical guides and check the switch and
24 Switch - Signal - If the HDC switch is circuit for short to power. C heck the operation of the
stuck high pressed for longer than 1 HDC switch and rectif /renew as necessar .
minute, this DTC ma be
stored.
- Harness/connector issue

U0100- Lost C AN bus fault C heck the EC M installation/configuration. Refer to the

87 C ommunication EC M disconnected Network C ommunications section in the workshop
With EC M/PC M EC M not configured manual.
"A" - Missing EC M failure

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me age Ha ne /connec o i e

U0101- Lo C AN b fa l C heck he TC M in alla ion/config a ion. Refe o he

87 C omm nica ion TC M di connec ed Ne o k C omm nica ion ec ion in he o k hop
i h TC M - TC M no config ed man al.
Mi ing TC M fail e
me age Ha ne /connec o i e

U0102- Lo C AN b fa l C heck he TC C M in alla ion/config a ion. Refe o

87 C omm nica ion TC C M di connec ed he Ne o k C omm nica ion ec ion in he o k hop
i h T an fe TC C M no config ed man al.
C a e C on ol TC C M fail e
Mod le - Ha ne /connec o i e
Mi ing
me age
U0104- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.
87 C omm nica ion C i e con ol mod le Refe o he Ne o k C omm nica ion ec ion in he
Wi h C i e di connec ed o k hop man al.
C on ol Mod le C i e con ol mod le no
- Mi ing config ed
me age C i e con ol mod le fail e
Ha ne /connec o i e

U0126- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.

87 C omm nica ion S ee ing Angle Sen o mod le Refe o he Ne o k C omm nica ion ec ion in he
Wi h S ee ing di connec ed o k hop man al.
Angle Sen o S ee ing Angle Sen o mod le
Mod le - no config ed
Mi ing S ee ing Angle Sen o mod le
me age fail e
Ha ne /connec o i e

U0128- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.

87 C omm nica ion PBM di connec ed Refe o he Ne o k C omm nica ion ec ion in he
Wi h Pa k PBM no config ed o k hop man al.
B ake C on ol PBM fail e
Mod le - Ha ne /connec o i e
Mi ing
me age
U0132- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.
87 C omm nica ion RLM di connec ed Refe o he Ne o k C omm nica ion ec ion in he
Wi h RLM no config ed o k hop man al.
S pen ion RLM fail e
C on ol Mod le Ha ne /connec o i e
"A" - Mi ing
me age
U0133- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.
87 C omm nica ion ARC di connec ed Refe o he Ne o k C omm nica ion ec ion in he
Wi h Ac i e Roll ARC no config ed o k hop man al.
C on ol Mod le ARC fail e
- Mi ing Ha ne /connec o i e
me age
U0136- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.
87 C omm nica ion RDC M di connec ed Refe o he Ne o k C omm nica ion ec ion in he
Wi h RDC M no config ed o k hop man al.
Diffe en ial RDC M fail e
C on ol Mod le Ha ne /connec o i e
- Rea -
Mi ing
me age
U0138- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.
87 C omm nica ion ATC M di connec ed Refe o he Ne o k C omm nica ion ec ion in he
i h All Te ain ATC M no config ed o k hop man al.
C on ol Mod le ATC M fail e
- Mi ing Ha ne /connec o i e
me age
U0155- Lo C AN b fa l C heck he con ol mod le in alla ion/config a ion.
87 C omm nica ion IPC di connec ed Refe o he Ne o k C omm nica ion ec ion in he
Wi h IPC no config ed o k hop man al.

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Instrument IPC failure
Panel C luster Harness/connector issue
(IPC ) C ontrol
Module -
Missing
message
U0401- Invalid Data Event information C heck for engine management DTC s. Refer to the
68 Received from relevant section in the workshop manual.
EC M/PC M A -
Event
information
U0402- Invalid Data Event information C heck for transmission DTC s. Refer to the relevant
68 Received from section in the workshop manual.
TC M - Event
information
U0403- Invalid Data Event information C heck for transfer case DTC s. Refer to the relevant
68 Received From section in the workshop manual.
Transfer C ase
C ontrol Module
- Event
information
U0405- Invalid Data Event information C heck for cruise control DTC s. Refer to the relevant
68 Received From section in the workshop manual.
C ruise C ontrol
Module - Event
information
U0417- Invalid Data Event information C heck for parking brake DTC s. Refer to the relevant
68 Received From section in the workshop manual.
Park Brake
C ontrol Module
- Event
information
U0421- Invalid Data Event information C heck for d namic suspension DTC s. Refer to the
68 Received from relevant section in the workshop manual.
Suspension
C ontrol Module
A - Event
information
U0424- Invalid Data Event information Ignore this DTC .
68 Received From
HVAC C ontrol
Module - Event
information
U0428- Invalid Data Event information C heck the Steering Angle Sensor and circuits. Refer to
68 Received From the electrical guides. Test the vehicle on roads
Steering Angle requiring var ing steering input to confirm the success
Sensor Module of an repair.
- Event
information
U1A49- Invalid Data Event information C heck for all-terrain DTC s. Refer to the relevant
68 Received From section in the workshop manual.
All Terrain
C ontrol Module
- Event
information
U1A4A- Invalid Data Event information C heck for RDC M DTC s. Refer to the relevant section in
68 Received From the workshop manual.
Differential
C ontrol Module
/ Rear - Event
information
U2001- Reduced Event information This Event is triggered if the EC U reduces the level of
68 S stem - Not a fault condition. functionalit , to prevent over heating of the foundation
Function - S stem operation brakes. It is a normal function of the EC U and is not a
Event suspended while s stem fault. C lear/ignore this DTC .
information cools. C ustomer ma have
seen the warning lamp
illuminated during a period

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of reduced functionality or
may have noticed the
vehicle behaving differently
in relation to a traction
control event.

Pinpoin Te

PINPOINT TEST A : STOPLAMP SWITCH CIRCUIT FAULT (DTC C1A96-13)

E DE AIL / E L /AC ION
CONDI ION
A1: FUSE CHECK
• NOTE: These tests are to be carried out if DTC C 1A96-13 has been stored. This DTC indicates a fault in the
Stoplamp Switch circuit between the Anti-lock Brake System Module (Pin C 0506R-30) and the Stoplamp ground
connection.
• NOTE: The Stoplamp Switch C ircuit is monitored by the Anti-lock Brake System Module on (C 0506R-30) for open
circuit. A small voltage is applied to the Stoplamp Switch circuit by the Anti-lock Brake System Module, this voltage
grounds through the Stoplamps, the Anti-lock Brake System Module monitors this voltage for open circuit.
• NOTE: The Stoplamp Switch and Brake Switch are fused separately.
1 Set the Ignition State to the on position and operate the Footbrake.
Do all the Stoplamps illuminate correctly when the Footbrake is pressed?
Ye
Refer to electrical circuit diagrams and check for an open circuit fault in the Stoplamp circuit
connectors, splices and wiring between the Anti-lock Brake System Module (C 0506R-30) and
splice joint (SJ1814). Repair the circuit as required using the approved process. C lear the stored
DTC , operate the Footbrake and check for correct Stoplamp operation.
No
Refer to electrical circuit diagrams and check for an open circuit fault in the Stoplamp circuit
connectors, splices and wiring between the Anti-lock Brake System Module (C 0506R-30) and the
Stoplamp Ground C ircuit Eyelets (C 2922-1 and C 1355-1). Repair the circuit as required using the
approved process. C lear the stored DTC , operate the Footbrake and check for correct Stoplamp
operation.

Pinpoin Te

PINPOINT TEST B : STOPLAMP SWITCH PLAUSIBILITY FAULT (DTC C1A96-24)

E DE AIL / E L /AC ION
CONDI ION
B1: CUSTOMER INDUCED DTC
• NOTE: These tests are to be carried out if DTC C 1A96-24 has been stored. This DTC indicates plausibility The
Stoplamp Switch signal is high (Footbrake pedal pressed condition) while the vehicle is not braking.
• NOTE: Plausibility detail A DTC will be stored if the Stoplamp Switch signal is high for more than 60 seconds while
the accelerator pedal is pressed and the vehicle speed is greater than 7 mph/10.8 km/h and the Anti-lock Brake
System Module is not actively controlling pressure.
1 C onfirm that the fault is not being provoked by a customer driving habit (Resting a foot on the
brake pedal while accelerating / cruising).
Is the fault being provoked by a customer driving habit?
Ye
Advise the customer that the cause of the DTC being stored maybe due to His/Her foot resting on
the Brake Pedal whilst the vehicle is in motion. C lear the stored DTC , operate the Footbrake and
check for correct Stoplamp operation.
No
GO to B2.
B2: STOPLAMP SWITCH ADJUSTMENT CHECK
• NOTE: Removal and correct installation of the Stoplamp Switch will reset the adjustment. Ensure the Footbrake
Pedal is fully raised against its Upstop, (pedal rest position) when installing the Stoplamp Switch.
1 C heck that the Stoplamp Switch is securely installed and correctly adjusted.
REFER to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
Is the Stoplamp Switch securely installed and correctly adjusted?
Ye
GO to B3.
No
Adjust the Stoplamp Switch using the approved process. C lear the stored DTC , operate the
Footbrake and check for correct Stoplamp operation.
B3: STOPLAMP CIRCUIT SHORT TO POWER
• NOTE: If a circuit short to power is present the Stoplamps may be illuminated (Footbrake Pedal released).

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1
Using the manufacturer approved diagnostic system, monitor the Data Logger Signal, PID-2B00
Brake Input Switch Status - Brake Pedal Switch (brake lamp switch), set the Ignition State to the
on position and with the Footbrake released PID-2B00 Brake Input Switch Status should show
Inacti e (BLS = 0).
Does PID-2B00 Brake Input Switch Status show Inactive (BLS =0)?
Yes
GO to B4.
No
Refer to electrical circuit diagrams to locate the fault. Repair the circuit as required using the
approved process. C lear the stored DTC , operate the Footbrake and check for correct Stoplamp
operation.
B4: SHORT CIRCUIT TO ANOTHER POWER CIRCUIT
NOTE: A short circuit to another circuit will cause the DTC to log in the Anti-lock Brake System Module.
1 Using the manufacturer approved diagnostic system, monitor the Data Logger Signal, PID-2B00
Brake Input Switch Status - Brake Pedal Switch (brake lamp switch), set the Ignition State to the
on position and with the Footbrake released PID-2B00 Brake Input Switch Status should show
Inacti e (BLS = 0).
2 Operate any electrical circuits that could supply a voltage to the Stoplamp Switch circuit.
Does PID-2B00 Brake Input Switch Status show Inactive (BLS =0)?
Yes
Suspect an intermittent fault. C arry out visual and mechanical check of splice joints, all connectors
and cables, check for corrosion, bent or damaged contact faces of pins, terminals and for security
of connectors. Where possible flex cables while using the manufacturer approved diagnostic
system to monitor the Data Logger Signal, PID-2B00 Brake Input Switch Status - Brake Pedal
Switch (brake lamp switch). This test should be carried out with the ignition on and the Footbrake
Pedal in the released position. BLS should remain Inacti e (BLS=0).
No
Refer to electrical circuit diagrams to locate the fault. Repair the circuit as required using the
approved process. C lear the stored DTC , operate the Footbrake and check for correct Stoplamp
operation.

Pinpoint Tests

PINPOINT TEST C : SIGNAL COMPARE PLAUSIBILITY (DTC C1A96-62)

E DE AIL / E L /AC ION
CONDI ION
C1: STOPLAMP SWITCH CIRCUIT
NOTE: These tests are to be carried out if DTC C 1A96-62 Signal C ompare - Plausibility, has been stored. This DTC
indicates that the Brake Lamp Switch and Brake Switch have shared the same state (both switches in the open circuit
condition at the same time).
NOTE: The Stoplamp Switch contains the Brake Lamp Switch (BLS) and the Brake Switch (BS) these are located
within the same housing.
NOTE: Signal C ompare - Plausibility: Brake Lamp Switch and Brake Switch must not be open circuit at the same
time.
NOTE: The Datalogger Signals represent the position of the Stoplamp Switch. Both Brake Lamp Switch (BLS) and
the Brake Switch (BS) are shown as Acti e with the Footbrake pressed and Inacti e with the Footbrake
released. This does not directly reflect the state of the Stoplamp Switch internal switch contacts as shown in the
circuit diagrams.
1 Using the manufacturer approved diagnostic system, monitor the Data Logger Signal, PID-2B00
Brake Input Switch Status - Brake Pedal Switch (brake lamp switch) and PID-2B00 Brake Input
Switch Status - Brake Pedal Switch (brake switch) inputs while the Footbrake pedal is slowly
pressed & released.
2 BLS = Brake Pedal Switch (brake lamp switch), BS = Brake Pedal Switch (brake switch). The
correct inputs should be, Pedal Released BLS = Inacti e (BLS = 0), BS = Inacti e (BS = 0).
Brief Transition (as the pedal is pressed BLS = Acti e (BLS = 1), BS = Inacti e (BS = 0).
Pedal Pressed BLS = Acti e (BLS = 1), BS = Acti e (BS = 1). If either input remains inactive
during the test procedure a fault is evident.
Did the inputs show correctly?
Yes
Suspect an intermittent fault. C arry out visual and mechanical check of splice joints, all connectors
and cables, check for corrosion, bent or damaged contact faces of pins, terminals and for security
of connectors. Where possible flex cables while using the manufacturer approved diagnostic
system, monitor the Data Logger Signal, PID-2B00 Brake Input Switch Status - Brake Pedal
Switch (brake lamp switch) and PID-2B00 Brake Input Switch Status - Brake Pedal Switch (brake
switch). This test should be carried out with the Stoplamp Switch in both the pressed and released
position independently. Refer to electrical circuit diagrams to locate the intermittent open circuit.
Repair the circuit as required using the approved process. C lear the stored DTC , operate the
Footbrake and check for correct Stoplamp operation.
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No
GO to C 2.
C2: STOPLAMP SWITCH CIRCUIT 2
1 If BLS = Inactive (0) BS = Active (1) occurred with the Footbrake Released the fault is with
the (BS) = Brake Pedal Switch (brake switch) circuit. If BLS = Inactive (0) BS = Active
(1) occurred with the Footbrake Pressed the fault is with the (BLS) = Brake Pedal Switch
(brake lamp switch) circuit.
Did BLS (brake lamp switch) = Inactive (0) BS (brake switch) = Active (1) occur with the Footbrake
Released?
Yes
Suspect a Stoplamp Switch (brake switch) circuit fault. Refer to electrical circuit diagrams and
replace blown fuse or locate the open circuit. Repair the circuit as required using the approved
process. C lear the stored DTC , operate the Footbrake and check for correct Stoplamp operation.
No
Suspect a Stoplamp Switch (brake lamp switch) circuit fault. Refer to electrical circuit diagrams
and replace blown fuse or locate the open circuit. Repair the circuit as required using the
approved process. C lear the stored DTC , operate the Footbrake and check for correct Stoplamp
operation.

PINPOINT TEST D : PLAUSIBILITY STOPLAMP SWITCH (BLS) VERSES BRAKE PRESSURE (PS)
(DTC C1A96-64)
E DE AIL / E L /AC ION
CONDI ION
D1: IDS MONITOR
• NOTE: These tests are to be carried out if DTC C 1A96-64 Plausibility Stoplamp Switch (BLS) verses Brake Fluid
Hydraulic Pressure (PS) has been stored.
• NOTE: This DTC indicates Plausibility The Stoplamp Switch must be seen to operate before Brake Fluid Hydraulic
Pressure (PS) exceeds a pressure threshold of 10 Bar.
• NOTE: The Stoplamp Switch status is monitored by the Anti-lock Brake System Module (C 0506R terminal 30).
• NOTE: The Anti-lock Brake System Module contains an Internal Pressure Sensor and monitors the Brake Fluid
Hydraulic Pressure (PS).
1 Using the manufacturer approved diagnostic system, check for Anti-lock Brake System Module
Pressure Sensor DTC s C 1A99-01, C 1A99-29, C 1A99-49 or C 1A99-64. If any of these DTC s has
been stored carry out the specified action prior to investigating DTC C 1A96-64.
2 Using the manufacturer approved diagnostic system, monitor the Data Logger Signal PID-2B00
Brake Input Switch Status - Brake Pedal Switch (brake lamp switch) and PID-2B0D Brake Fluid
Hydraulic Pressure (PS). When the brake pedal is pressed, the Brake Pedal Switch (brake lamp
switch) status should change from Inactive (BLS = 0) to Active (BLS = 1) before the Brake Fluid
Hydraulic Pressure reaches 1000KPa (10 Bar).
Does the Brake Pedal Switch (brake lamp switch) change from Inactive (BLS = 0) to Active (BLS =
1) before the Brake Fluid Hydraulic Pressure reaches 1000KPa (10 Bar)?
Yes
Suspect an intermittent Brake Lamp Switch circuit fault. Refer to electrical circuit diagrams, carry
out visual and mechanical check of the of splice joints, connectors and cables of the Stoplamp
Switch circuit, check for corrosion, bent or damaged contact faces of pins, terminals and for
security of connectors. Where possible flex cables to attempt to induce the intermittent open
circuit. Repair the circuit as required using the approved process. C lear the stored DTC , operate
the Footbrake and check for correct Stoplamp operation.
No
GO to D2.
D2: STOPLAMP SWITCH ADJUSTMENT CHECK
• NOTE: Removal and correct installation of the Stoplamp Switch will reset the adjustment. Ensure the Footbrake
Pedal is fully raised against its Upstop, (pedal rest position) when installing the Stoplamp Switch.
1 C heck that the Stoplamp Switch is securely installed and correctly adjusted.
REFER to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
Is the fault still present with the Stoplamp Switch securely installed and correctly adjusted?
Yes
Suspect a Brake Lamp Switch circuit fault. Refer to electrical circuit diagrams, carry out visual and
mechanical check of the splice joints, connectors and cables of the Stoplamp Switch circuit, check
for corrosion, bent or damaged contact faces of pins, terminals and for security of connectors.
Repair the circuit as required using the approved process. C lear the stored DTC , operate the
Footbrake and check for correct Stoplamp operation.
No
Adjust the Stoplamp Switch using the approved process. C lear the stored DTC , operate the
Footbrake and check for correct Stoplamp operation.

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Published: 11-May-2011
Anti-Lock Control - Traction Control - Anti-Lock Control - Traction ControlVIN
Range: 413982->513325
Diagnosis and Testing

Inspection and Verification

C AUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or
the donor vehicle.

NOTE: If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer
to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in
operation, prior to the installation of a new module/component.

NOTE: C heck and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection
Mechanical Electrical
Tire size, condition and installation Fuses
Wheel speed sensor condition and installation Harnesses and connectors
Steering Angle Sensor (SAS) condition and installation Warning lamp operation
Yaw rate sensor and accelerometer condition and installation Wheel speed sensors
Hydraulic control unit (with attached ABS module) condition and C entral junction box
installation HDC switch
DSC switch
C ombined stop lamp switch / brake
switch
Yaw rate sensor and accelerometer
Steering Angle Sensor (SAS)
Anti-lock Braking (ABS) module
C ontroller Area Network (C AN)
circuits

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. 4. If the cause is not visually evident, check for Diagnostic Trouble C odes (DTC s) and refer to the DTC Index.

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

DTC Description Possible Causes Action

C 1105- Brake lamp NOTE: The stoplamp-switch contains NOTE: C heck for correct operation of the stop-lamps
67 control signal the brake-lamp -switch (BLS) and the
incorrect after brake-switch (BS) these are located Refer to the electrical circuit diagrams and check
event - signal within the same housing the ABS module circuit to the hill decent relay
incorrect after for fault
event The BLS circuit and the BS
circuit have failed the
plausibility test
Switch internal fault
C ircuit fault

C 1109- Vehicle Switch internal fault NOTE: This DTC may be logged if the switch state is
24 dynamics C ircuit short to power active for over 1 minute
control switch
- signal stuck C heck for correct switch operation. Refer to the
high electrical circuit diagrams and check the ABS
module circuit to the centre facia switch pack /
DSC switch for circuit short to power

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C 1A00- C ontrol Low voltage detected NOTE: DTC may be stored due to a vehicle charging
16 module - C ircuit short to ground, open or starting fault
circuit voltage circuit or high resistance
below Using the manufacturer approved diagnostic
threshold system check other modules for related DTC s.
C heck for correct vehicle battery / charging
system operation. Refer to the electrical circuit
diagrams and check the ABS module power
(U ) and ground circuit for fault

C 1A00- C ontrol Voltage detected above preset NOTE: DTC may be stored due to battery charger use
17 module - maximum or vehicle charging fault
circuit voltage
above Using the manufacturer approved diagnostic
threshold system check other modules for related DTC s.
C heck for correct vehicle battery and charging
system operation

C 1A00- C ontrol Momentary low voltage NOTE: DTC may be stored due to a vehicle charging
1C module - detected or starting fault
circuit voltage
out of range Using the manufacturer approved diagnostic
system check other modules for related DTC s.
C heck for correct vehicle charging system
operation. Refer to the electrical circuit diagrams
and check the ABS module power (U ) and
ground circuit for fault

C 1A00- C ontrol Module internal fault Using the manufacturer approved diagnostic
45 module - system. C lear the DTC and retest if the DTC
program returns suspect the ABS module. Replace as
memory required. Refer to the new module / component
failure installation note at the top of the DTC index

C 1A00- C ontrol Incorrect car configuration file C onfigure the module using the approved diagnostic
46 module - (C C F) data received from IPC system. C lear the DTC and check if the DTC resets
calibration / or C C F incorrectly configured after ignition reset following >10 seconds ignition on. If
parameter Module installed to the possible causes listed have been checked and the
memory unrecognized vehicle DTC persists, suspect the ABS module. Replace as
failure configuration required. Refer to the new module / component
Module calibration/parameter installation note at the top of the DTC index
memory failure (internal error)

C 1A00- C ontrol Module internal fault Using the manufacturer approved diagnostic
49 module - system, clear the DTC and retest. If the DTC
internal returns, suspect the ABS module. Replace as
electronic required. Refer to the new module / component
failure installation note at the top of the DTC index

C 1A00- C ontrol The stored vehicle variant Using the manufacturer approved diagnostic
4A module - code in the control module system, confirm that the stored vehicle variant
incorrect (EEPROM) does not match the code and the transmitted variant code match.
component variant code received via the C onfigure as required
installed C AN bus

C 1A00- C ontrol The control module has NOTE: Investigate the cause of the control module
4B module - over excided a preset maximum temperature event
temperature temperature
Module internal fault Using the manufacturer approved diagnostic
system, clear the DTC and retest. If DTC
returns suspect an internal fault with the ABS
module. Replace as required. Refer to the new
module / component installation note at the top
of the DTC index

C 1A00- C ontrol C ontrol module event Using the manufacturer approved diagnostic system,
68 module - information check for DTC s relating to a defective steering angle
event sensor, wheel speed sensor or yaw rate sensor.
information Replace as required. Refer to the new module /
component installation note at the top of the DTC index
C 1A00- C ontrol C AN bus circuit fault Using the manufacturer approved diagnostic
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88 module - bus system, carry out the C AN network integrity
off test. Refer to the electrical circuit diagrams and
check the C AN bus circuit to the ABS module for
circuit short to power, short to ground, open
circuit or high resistance

C 1A76- Valve relay Module internal fault Using the manufacturer approved diagnostic
01 circuit - system, clear the DTC and retest. If DTC
general returns suspect an internal fault with the ABS
electrical module. Replace as required. Refer to the new
failure module / component installation note at the top
of the DTC index

C 1A76- Valve relay Module internal fault Using the manufacturer approved diagnostic
04 circuit - system, clear the DTC and retest. If DTC
system returns suspect an internal fault with the ABS
internal module. Replace as required. Refer to the new
failures module / component installation note at the top
of the DTC index

C 1A77- Valve relay Low voltage detected NOTE: DTC may be stored due to a vehicle charging
16 circuit - circuit C ircuit fault or starting fault
voltage below
threshold Using the manufacturer approved diagnostic
system, check other modules for related DTC s.
C heck for correct vehicle charging system
operation. Refer to the electrical circuit diagrams
and check the ABS module ( B R) power and
ground circuits for fault

C 1A78- Front left inlet Module internal fault Using the manufacturer approved diagnostic
04 valve - system system, clear the DTC and retest. If the DTC
internal returns suspect the ABS module. Replace as
failures required. Refer to the new module / component
installation note at the top of the DTC index

C 1A79- Front left Module internal fault Using the manufacturer approved diagnostic
04 outlet valve - system, clear the DTC and retest. If the DTC
system returns suspect the ABS module. Replace as
internal required. Refer to the new module / component
failures installation note at the top of the DTC index

C 1A80- Front right Module internal fault Using the manufacturer approved diagnostic
04 inlet valve - system, clear the DTC and retest. If the DTC
system returns suspect the ABS module. Replace as
internal required. Refer to the new module / component
failures installation note at the top of the DTC index

C 1A81- Front right Module internal fault Using the manufacturer approved diagnostic
04 outlet valve - system, clear the DTC and retest. If the DTC
system returns suspect the ABS module. Replace as
internal required. Refer to the new module / component
failures installation note at the top of the DTC index

C 1A82- Rear left inlet Module internal fault Using the manufacturer approved diagnostic
04 valve - system system, clear the DTC and retest. If the DTC
internal returns suspect the ABS module. Replace as
failures required. Refer to the new module / component
installation note at the top of the DTC index

C 1A83- Rear left outlet Module internal fault Using the manufacturer approved diagnostic
04 valve - system system, clear the DTC and retest. If the DTC
internal returns suspect the ABS module. Replace as
failures required. Refer to the new module / component
installation note at the top of the DTC index

C 1A84- Rear right inlet Module internal fault Using the manufacturer approved diagnostic
04 valve - system system, clear the DTC and retest. If the DTC
internal returns suspect the ABS module. Replace as
failures required. Refer to the new module / component
installation note at the top of the DTC index

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C 1A85- Rea igh M d e i e a fa U i g he a fac e a ed diag ic

04 e a e - e , c ea he DTC a d e e . If he DTC
e e ec he ABS d e. Re ace a
i e a e i ed. Refe he e d e /c e
fai e i a ai e a he f he DTC i de

C 1A86- C ai M d e i e a fa U i g he a fac e a ed diag ic

04 a e #1 - e , c ea he DTC a d e e . If he DTC
e e ec he ABS d e. Re ace a
i e a e i ed. Refe he e d e /c e
fai e i a ai e a he f he DTC i de

C 1A87- C ai M d e i e a fa U i g he a fac e a ed diag ic

04 a e #2 - e , c ea he DTC a d e e . If he DTC
e e ec he ABS d e. Re ace a
i e a e i ed. Refe he e d e /c e
fai e i a ai e a he f he DTC i de

C 1A88- High e e M d e i e a fa U i g he a fac e a ed diag ic

04 i chi g e , c ea he DTC a d e e . If he DTC
a e #1 - e ec he ABS d e. Re ace a
e e i ed. Refe he e d e /c e
i e a i a ai e a he f he DTC i de
fai e
C 1A89- High e e M d e i e a fa U i g he a fac e a ed diag ic
04 i chi g e , c ea he DTC a d e e . If he DTC
a e #2 - e ec he ABS d e. Re ace a
e e i ed. Refe he e d e /c e
i e a i a ai e a he f he DTC i de
fai e
C 1A90- Whee eed Whee eed e Refe he e ec ica ci c i diag a a d chec
12 e ci c i h e he hee eed e (D ) ci c i f
ci c i - ci c i he ABS d e f h e
h
ba e
C 1A91- F ef O e ci c i fa Refe he e ec ica ci c i diag a a d chec
13 hee eed Se i e a fai e he ci c i be ee he ABS d e a d he
e ci c i - M d e i e a fa f ef hee eed e f e ci c i
ci c i e
C 1A91- F ef C i c i fa Refe he e ec ica ci c i diag a a d chec
25 hee eed Se i e a fai e he ci c i be ee he ABS d e a d he
e ci c i - M d e i e a fa f ef hee eed e f fa
ig a ha e /
a ef
fai e
C 1A91- F ef C i c i fa Refe he e ec ica ci c i diag a a d chec
2F hee eed Se i e a fai e he ci c i be ee he ABS d e a d he
e ci c i - M d e i e a fa f ef hee eed e f fa
ig a e a ic
C 1A91- F ef C i c i fa Refe he e ec ica ci c i diag a a d chec
36 hee eed Se i e a fai e he ci c i be ee he ABS d e a d he
e ci c i - M d e i e a fa f ef hee eed e f fa
ig a
f e e c

C 1A91- F ef F ef hee eed e Vi a i ec he f ef hee eed e

38 hee eed e c i g da aged e c i g f da age. Re ace a e i ed.
e ci c i - Refe he e d e /c e
ig a i a ai e a he f he DTC i de
f e e c
i c ec
C 1A91- F ef C i c i fa Refe he e ec ica ci c i diag a a d chec
62 hee eed Se i e a fai e he ci c i be ee he ABS d e a d he
e ci c i - M d e i e a fa f ef hee eed e f fa
ig a
c a e
fai e
C 1A91- F ef C i c i fa Refe he e ec ica ci c i diag a a d chec
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64 S ABS
- M

C 1A91- F C R
65 S ABS
- M

/
C 1A91- F F C
78
-

C 1A92- R O R
13 S ABS
- M

C 1A92- R C R
25 S ABS
- M
/

C 1A92- R C R
2F S ABS
- M

C 1A92- R C R
36 S ABS
- M

C 1A92- R R V
38 .R .
- R /
DTC

C 1A92- R C R
62 S ABS
- M

C 1A92- R C R
64 S ABS
- M

C 1A92- R C R
65 S ABS
- M

C 1A92- R R C
78
-

C 1A93- R O R
13 S ABS
- M

C 1A93- R C R

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25 S ABS
- M
/

C 1A93- R C R
2F S ABS
- M

C 1A93- R C R
36 S ABS
- M

C 1A93- R R V
38 .R
- .R /
DTC

C 1A93- R C R
62 S ABS
- M

C 1A93- R C R
64 S ABS
- M

C 1A93- R C R
65 S ABS
- M

/
C 1A93- R R C
78
-

C 1A94- F O R
13 S ABS
- M

C 1A94- F C R
25 S ABS
- M
/

C 1A94- F C R
2F S ABS
- M

C 1A94- F C R
36 S ABS
- M

C 1A94- F F V
38 .R
- .R /
DTC

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frequency
incorrect
C 1A94- Front right C ircuit fault Refer to the electrical circuit diagrams and check
62 wheel speed Sensor internal failure the circuit between the ABS module and the
sensor circuit - Module internal fault front right wheel speed sensor for fault
signal
compare
failure
C 1A94- Front right C ircuit fault Refer to the electrical circuit diagrams and check
64 wheel speed Sensor internal failure the circuit between the ABS module and the
sensor circuit - Module internal fault front right wheel speed sensor for fault
signal
plausibility
failure
C 1A94- Front right C ircuit fault Refer to the electrical circuit diagrams and check
65 wheel speed Sensor internal failure the circuit between the ABS module and the
sensor circuit - Module internal fault front right wheel speed sensor for fault
signal has too
few transitions
/ events
C 1A94- Front right Front right wheel speed sensor C heck and correct the front right wheel speed
78 wheel speed to reluctor ring air gap sensor reluctor ring air gap
sensor circuit - incorrect
alignment or
adjustment
incorrect
C 1A95- Wheel speed Incorrect wheel speed sensor C heck the correct wheel speed sensor is
4A sensor circuit - installed installed to vehicle specification
incorrect
component
installed
C 1A95- Wheel speed Incorrectly oriented wheel Locate for the incorrectly orientated wheel speed
62 sensor circuit - speed sensor sensor. Remove and relocate correctly
signal
compare
failure
C 1A95- Wheel speed Multiple circuit faults Refer to the electrical circuit diagrams and check
64 sensor circuit - Multiple sensor internal failures the ABS module circuit to the wheel speed
signal Multiple module internal sensors for multiple circuit or sensor internal
plausibility failures failures. If no individual sensor or circuit faults
failure are evident replace the 4 wheel speed sensors.
Refer to the warranty policy and procedures
manual if a module / component is suspect

C 1A96- Brake light Stoplamp-switch (BLS) signal Refer to Workshop Manual Section 206-09
24 switch circuit - is Acti e (1)(Footbrake pedal Diagnosis and Testing GO to Pinpoint Test A.
signal stuck pressed condition) for more Refer to the electrical circuit diagrams and check
high than 60 seconds while the the ABS module circuit to the stoplamp switch
vehicle is not braking for circuit short to power
Stoplamp-switch circuit fault
Stoplamp-switch internal fault
Stoplamp-switch incorrect
installation
Stoplamp-switch incorrectly
adjusted

C 1A96- Brake light Signal compare failure the Refer to Workshop Manual Section 206-09
62 switch circuit - stoplamp-switch (BLS) and the Diagnosis and Testing GO to Pinpoint Test B.
signal brake-switch (BS) have Refer to the electrical circuit diagrams and check
compare shared the same output state the ABS module circuit to the stoplamp switch
failure at the same time for circuit for fault
Stoplamp-switch circuit fault
Stoplamp-switch internal fault

C 1A96- Brake light Signal plausibility failure the NOTE: C heck for pressure sensor DTC s C 1A99-01 or
64 switch circuit - brake fluid hydraulic pressure C 1A99-49. If either of these DTC s has been stored
signal (PS) has exceeded 10bar and carry out the specified action prior to investigating DTC
plausibility the stoplamp-switch output C 1A96-64
failure state has not switched from
Inacti e (0) to Acti e Refer to Workshop Manual Section 206-09

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( )(Footbrake pedal pressed Diagnosis and Testing GO to Pinpoint Test C .
condition) Refer to the electrical circuit diagrams and check
Stoplamp-switch C ircuit fault the ABS module circuit to the stoplamp switch
Stoplamp-switch internal fault for circuit for fault
Stoplamp-switch incorrect
installation
Stoplamp-switch incorrectly
adjusted

C 1A97- Lateral The signal from the yaw rate Refer to the electrical circuit diagrams and check
24 accelerometer sensor is greater than the anti-lock (ABS) control module C AN bus
circuit - signal expected when the vehicle is circuit to the yaw rate sensor. C heck the power
stuck high stationary and ground supply circuits to the yaw rate
C ircuit short to power sensor also check the installation and location
for security

C 1A97- Lateral The signal from the yaw rate Refer to the electrical circuit diagrams and check
27 accelerometer sensor is above the preset the anti-lock (ABS) control module C AN bus
circuit - signal maximum circuit to the yaw rate sensor. C heck the power
rate of change and ground supply circuits to the yaw rate
above sensor also check the installation and location
threshold for security

C 1A97- Lateral Yaw rate sensor signal bias Refer to the electrical circuit diagrams and check
28 accelerometer level out of range / zero the anti-lock (ABS) control module C AN bus
circuit - signal adjustment failure circuit to the yaw rate sensor. C heck the power
bias level out and ground supply circuits to the yaw rate
of range / zero sensor also check the installation and location
adjustment for security
failure
C 1A97- Lateral The value from the yaw rate NOTE: Driving conditions such as driving in circles or
29 accelerometer sensor is invalid a banked track may cause the DTC to log
circuit - signal
invalid C onfirm that driving style has not caused the
DTC to log. Using the manufacturer approved
diagnostic system. C lear the DTC and retest.
Refer to the electrical circuit diagrams and check
the anti-lock (ABS) control module C AN bus
circuit to the yaw rate sensor. C heck the power
and ground supply circuits to the yaw rate
sensor also check the installation and location
for security

C 1A97- Lateral C ircuit fault Refer to the electrical circuit diagrams and check
49 accelerometer Sensor internal failure the anti-lock (ABS) control module C AN bus
circuit - circuit to the yaw rate sensor. C heck the power
internal and ground supply circuits to the yaw rate
electronic sensor also check the installation and location
failure for security

C 1A97- Lateral C ircuit fault Refer to the electrical circuit diagrams and check
64 accelerometer Sensor internal failure the ABS module C AN bus circuit to the yaw rate
circuit - signal sensor. C heck the power and ground supply
plausibility circuits to the yaw rate sensor also check the
failure installation and location for security

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
08 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the yaw rate
bus signal / sensor. C heck the power and ground supply
message circuits to the yaw rate sensor also check the
failures installation and location for security

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
22 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the yaw rate
signal sensor. C heck the power and ground supply
amplitude > circuits to the yaw rate sensor also check the
maximum installation and location for security

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
28 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the yaw rate
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signal bias sensor. C heck the power and ground suppl
level out of circuits to the aw rate sensor also check the
range / ero installation and location for securit
adjustment
failure
C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
29 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
signal invalid sensor. C heck the power and ground suppl
circuits to the aw rate sensor also check the
installation and location for securit

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
61 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
signal sensor. C heck the power and ground suppl
calculation circuits to the aw rate sensor also check the
failure installation and location for securit

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
62 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
signal sensor. C heck the power and ground suppl
compare circuits to the aw rate sensor also check the
failure installation and location for securit

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
64 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
signal sensor. C heck the power and ground suppl
plausibilit circuits to the aw rate sensor also check the
failure installation and location for securit

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
86 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
signal invalid sensor. C heck the power and ground suppl
circuits to the aw rate sensor also check the
installation and location for securit

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
87 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
missing sensor. C heck the power and ground suppl
message circuits to the aw rate sensor also check the
installation and location for securit

C 1A98- Yaw rate C ircuit fault Refer to the electrical circuit diagrams and check
92 sensor circuit - Sensor internal failure the ABS module C AN bus circuit to the aw rate
performance sensor. C heck the power and ground suppl
or incorrect circuits to the aw rate sensor also check the
operation installation and location for securit

C 1A98- Yaw rate Incorrect component installed C onfirm the correct aw rate sensor. is installed
95 sensor circuit - to vehicle specification
incorrect
assembl
C 1A98- Yaw rate Sensor internal failure Refer to the electrical circuit diagrams and check
96 sensor circuit - the ABS module C AN bus circuit to the aw rate
component sensor. C heck the power and ground suppl
internal failure circuits to the aw rate sensor also check the
installation and location for securit

C 1A99- Pressure ABS module internal failure Using the manufacturer approved diagnostic
01 sensor circuit - s stem clear the DTC and retest. If the DTC
general returns suspect the ABS module. Replace as
electrical required. Refer to the warrant polic and
failure procedures manual if a module / component is
suspect

C 1A99- C ontrol ABS module internal failure Using the manufacturer approved diagnostic
49 module - s stem clear the DTC and retest. If the DTC
internal returns suspect the ABS module. Replace as
electronic required. Refer to the warrant polic and
failure procedures manual if a module / component is
suspect

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C 1B00- Steering angle Steering angle sensor internal Using the manufacturer approved diagnostic
27 sensor -signal failure system, check the steering angle sensor module
rate of change for related stored DTC s
above
threshold
C 1B00- Steering angle Steering angle sensor internal Using the manufacturer approved diagnostic
29 sensor - signal failure system, check the steering angle sensor module
invalid for related stored DTC s

C 1B00- Steering angle Steering angle sensor internal Using the manufacturer approved diagnostic
61 sensor - signal failure system, check the steering angle sensor module
calculation for related stored DTC s
failure
C 1B00- Steering angle Steering angle sensor internal Using the manufacturer approved diagnostic
64 sensor - signal failure system, check the steering angle sensor module
plausibility for related stored DTC s
failure
C 1B00- Steering angle Steering angle sensor internal Using the manufacturer approved diagnostic
92 sensor - failure system, check the steering angle sensor module
performance for related stored DTC s
or incorrect
operation
C 1B02- Return pump ABS module internal failure Suspect the ABS module. Replace as required.
01 circuit - Refer to the warranty policy and procedures
general manual if a module / component is suspect
electrical
failure
C 1B02- Return pump Return pump circuit voltage Refer to the electrical circuit diagrams and check
16 circuit - circuit below threshold the ABS module for battery voltage at the fused
voltage below supply ( BMR) circuit
threshold
C 1B02- Return pump ABS module internal failure Using the manufacturer approved diagnostic
49 circuit - system clear the DTC and retest. If the DTC
internal returns suspect the ABS module. Replace as
electronic required. Refer to the warranty policy and
failure procedures manual if a module / component is
suspect

C 1B22- Hill descent C ircuit short to power • NOTE: This DTC may be logged if the switch is
24 switch - signal pressed for over 1 minute
stuck high
C heck for correct hill decent switch operation.
Refer to the electrical circuit diagrams and check
the C entre-console switch-pack / Hill-decent
Switch circuit for short to power

C 2009- Front axle Incorrect component installed C orrectly relocate the front wheel speed sensors
95 wheel speed
sensors
swapped -
incorrect
assembly
C 200A- Rear axle Incorrect component installed C orrectly relocate the rear wheel speed sensors
95 wheel speed
sensors
swapped -
incorrect
assembly
U0100- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication engine control module the power, ground and C AN bus connections to
with EC M/PC M the module. Using the manufacturer approved
A - missing diagnostic system, complete a C AN network
message integrity test. C heck the engine control module
for related stored DTC s

U0101- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication transmission control module the power, ground and C AN bus connections to
with TC M - the module. Using the manufacturer approved
missing diagnostic system, complete a C AN network
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message integrit test. C heck the transmission control
module for related stored DTC s

U0102- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication transfer case control module the power, ground and C AN bus connections to
with transfer the module. Using the manufacturer approved
case control diagnostic s stem, complete a C AN network
module - integrit test. C heck the transfer case control
missing module for related stored DTC s
message
U0104- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication adaptive cruise control module the power, ground and C AN bus connections to
with cruise the module. Using the manufacturer approved
control module diagnostic s stem, complete a C AN network
- missing integrit test. C heck the adaptive cruise control
message module for related stored DTC s

U0126- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication steering angle sensor module the power, ground and C AN bus connections to
with steering the module. Using the manufacturer approved
angle sensor diagnostic s stem, complete a C AN network
module - integrit test. C heck the steering angle sensor
missing module for related stored DTC s
message
U0128- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication park brake control module the power, ground and C AN bus connections to
with park the module. Using the manufacturer approved
brake control diagnostic s stem, complete a C AN network
module - integrit test. C heck the park brake control
missing module for related stored DTC s
message
U0132- Lost Missing message from the air Refer to the electrical circuit diagrams and check
87 communication suspension control module the power, ground and C AN bus connections to
with ride level the module. Using the manufacturer approved
control module diagnostic s stem, complete a C AN network
- missing integrit test. C heck the air suspension control
message module for related stored DTC s

U0133- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication d namic response module the power, ground and C AN bus connections to
with active roll the module. Using the manufacturer approved
control module diagnostic s stem, complete a C AN network
- missing integrit test. C heck the d namic response
message module for related stored DTC s

U0136- Lost Missing message from the rear Refer to the electrical circuit diagrams and check
87 communication differential control module the power, ground and C AN bus connections to
with the module. Using the manufacturer approved
differential diagnostic s stem, complete a C AN network
control module integrit test. C heck the rear differential control
- rear - module for related stored DTC s
missing
message
U0138- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication terrain response control the power, ground and C AN bus connections to
with all terrain module the module. Using the manufacturer approved
control module diagnostic s stem, complete a C AN network
- missing integrit test. C heck the terrain response control
message module for related stored DTC s

U0155- Lost Missing message from the Refer to the electrical circuit diagrams and check
87 communication instrument panel cluster the power, ground and C AN bus connections to
with control module the module. Using the manufacturer approved
instrument diagnostic s stem, complete a C AN network
panel cluster integrit test. C heck the instrument panel cluster
(IPC ) control control module for related stored DTC s
module -
missing
message
U0401- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
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68 received from engine control module system check the engine control module for
EC M/PC M - related stored DTC s
event
information
U0402- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from transmission control module system check the transmission control module
transmission for related stored DTC s
control module
- event
information
U0403- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from transfer case control module system check the transfer case control module
transfer case for related stored DTC s
control module
- event
information
U0405- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from adaptive cruise control module system check the adaptive cruise control module
cruise control for related stored DTC s
module -
event
information
U0417- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from park brake control module system check the park brake control module for
park brake related stored DTC s
control module
- event
information
U0421- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from air suspension control module system check the air suspension control module
ride level for related stored DTC s
control module
- event
information
U0428- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from steering angle sensor module system check the steering angle sensor module
steering angle for related stored DTC s
sensor module
- event
information
U1A49- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from terrain response control system check the terrain response control
all terrain module module for related stored DTC s
control module
- event
information
U1A4A- Invalid data Invalid data received from the Using the manufacturer approved diagnostic
68 received from rear differential control module system check the rear differential control
differential module for related stored DTC s
control module
- rear - event
information
U2001- Reduced NOTE: Not a fault condition. System NOTE: This DTC is stored if the control module
68 system operation suspended while system reduces the level of functionality, to prevent over-
function - cools. C ustomer may have seen the heating of the foundation brakes. This is a normal
event warning lamp illuminated during a function of the EC U and is not a fault
information period of reduced functionality or
may have noticed the vehicle C lear / ignore this DTC
behaving differently in relation to a
traction control event

Event information

U3000- C ontrol Mismatch with master C heck the correct ABS module is installed to
55 module - not configure ID vehicle specification. C heck that the C entral
configured Broadcast VIN matches the vehicle VIN. Refit
the original module or replace as required

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Pinpoint Tests

PINPOINT TEST A : STOPLAMP-SWITCH PLAUSIBILITY FAULT (DTC C1A96-24)

E DE AIL / E L /AC ION
CONDI ION
A1: CUSTOMER INDUCED DTC
• NOTE: These tests are to be carried out if DTC C 1A96-24 has been stored. This DTC indicates plausibility The
stoplamp-switch signal is high (Footbrake pedal pressed condition) while the vehicle is not braking.
• NOTE: Plausibility detail A DTC will be stored if the stoplamp-switch signal is high for more than 60 seconds while
the accelerator pedal is pressed and the vehicle speed is greater than 7 mph/10.8 km/h and the ABS Module is not
actively controlling pressure.
1 C onfirm that the fault is not being provoked by a customer driving habit (Resting a foot on the
brake pedal while accelerating / cruising).
Is the fault being provoked by a customer driving habit?
Yes
Advise the customer that the cause of the DTC being stored maybe due to his/her foot resting on
the brake pedal whilst the vehicle is in motion. C lear the stored DTC , operate the footbrake and
check for correct stoplamp operation.
No
GO to A2.
A2: STOPLAMP-SWITCH ADJUSTMENT CHECK
• NOTE: Removal and correct installation of the stoplamp-switch will reset the adjustment. Ensure the footbrake
pedal is fully raised against its upstop, (pedal rest position) when installing the stoplamp-switch.
1 C heck that the stoplamp-switch is securely installed and correctly adjusted.
REFER to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
Is the stoplamp-switch securely installed and correctly adjusted?
Yes
GO to A3.
No
Adjust the stoplamp-switch using the approved process. C lear the stored DTC , operate the
Footbrake and check for correct stoplamp operation.
A3: STOPLAMP CIRCUIT SHORT TO POWER
• NOTE: If a circuit short to power is present the stoplamps may be illuminated (Footbrake Pedal released).
1 Using the manufacturer approved diagnostic system, monitor the Data Logger Signal, PID-2B00
(brake input switch status - brake pedal switch / brake lamp switch), set the Ignition-state to the
on position and with the footbrake released PID-2B00 (brake input switch status) should show
Inacti e (BLS = 0).
Does PID-2B00 (brake input switch status) show Inactive (BLS =0)?
Yes
GO to A4.
No
Refer to electrical circuit diagrams to locate the fault. Repair the circuit as required using the
approved process. C lear the stored DTC , operate the Footbrake and check for correct stoplamp
operation.
A4: SHORT CIRCUIT TO ANOTHER POWER CIRCUIT
• NOTE: A short circuit to another circuit will cause the DTC to log in the ABS Module.
1 Using the manufacturer approved diagnostic system, monitor the Data-logger signal, PID-2B00
(brake input switch status - brake pedal switch / brake lamp switch), set the Ignition-state to the
on position and with the footbrake released PID-2B00 (brake input switch status) should show
Inacti e (BLS = 0).
2 Operate any electrical circuits that could supply a voltage to the stoplamp-switch circuit.
Does PID-2B00 (brake input switch status) show Inacti e (BLS =0)?
Yes
Suspect an intermittent fault. C arry out visual and mechanical check of splice joints, all connectors
and cables, check for corrosion, bent or damaged contact faces of pins, terminals and for security
of connectors. Where possible flex cables while using the manufacturer approved diagnostic
system to monitor the Data-logger signal, PID-2B00 (brake input switch status - brake pedal
switch / brake lamp switch). This test should be carried out with the ignition on and the footbrake
pedal in the released position. BLS should remain Inacti e (BLS=0).
No
Refer to electrical circuit diagrams to locate the fault. Repair the circuit as required using the
approved process. C lear the stored DTC , operate the footbrake and check for correct stoplamp
operation.

Pinpoint Tests

PINPOINT TEST B : SIGNAL COMPARE PLAUSIBILITY (DTC C1A96-62)

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E DE AIL / E L /AC ION

CONDI ION
B1: STOPLAMP-SWITCH CIRCUIT
• NOTE: These tests are to be carried out if DTC C 1A96-62 signal compare - plausibility, has been stored. This DTC
indicates that the brake lamp switch and brake switch have shared the same state (both switches in the open circuit
condition at the same time).
• NOTE: The stoplamp switch contains the brake-lamp switch (BLS) and the brake-switch (BS) these are located
within the same housing.
• NOTE: Signal compare - plausibility: Brake lamp switch and brake switch must not be open circuit at the same
time.
• NOTE: The datalogger-signals represent the position of the stoplamp switch. Both the brake lamp switch (BLS) and
the brake switch (BS) are shown as active with the footbrake pressed and inactive with the footbrake
released. This does not directly reflect the state of the stoplamp switch internal switch contacts as shown in the
circuit diagrams.
1 Using the manufacturer approved diagnostic system, monitor the data-logger signal, PID-2B00
(brake input switch status - brake pedal switch / brake lamp switch) and PID-2B00 (brake input
switch status - brake pedal switch /brake switch) inputs while the footbrake pedal is slowly
pressed & released.
2 BLS = Brake Pedal Switch (brake lamp switch), BS = Brake Pedal Switch (brake switch). The
correct inputs should be, pedal released BLS = Inactive (BLS = 0), BS = Inactive (BS = 0).
Brief transition (as the pedal is pressed BLS = Active (BLS = 1), BS = Inactive (BS = 0). Pedal
pressed BLS = Active (BLS = 1), BS = Active (BS = 1). If either input remains inactive during
the test procedure a fault is evident.
Did the inputs show correctly?
Yes
Suspect an intermittent fault. C arry out visual and mechanical check of splice joints, all connectors
and cables, check for corrosion, bent or damaged contact faces of pins, terminals and for security
of connectors. Where possible flex cables while using the manufacturer approved diagnostic
system, monitor the data-logger signal, PID-2B00 (brake input switch status - brake pedal switch /
brake lamp switch) and PID-2B00 (brake input switch status - brake pedal switch /brake switch).
This test should be carried out with the stoplamp-switch in both the pressed and released position
independently. Refer to electrical circuit diagrams to locate the intermittent open circuit. Repair
the circuit as required using the approved process. C lear the stored DTC , operate the footbrake
and check for correct stoplamp operation.
No
GO to B2.
B2: STOPLAMP-SWITCH CIRCUIT 2
1 If BLS = Inactive (0) BS = Active (1) occurred with the footbrake released the fault is with the
(BS) = Brake Pedal Switch (brake switch) circuit. If BLS = Inactive (0) BS = Active (1)
occurred with the footbrake pressed the fault is with the (BLS) = Brake-pedal switch (brake
lamp switch) circuit.
Did BLS (brake lamp switch) = Inactive (0) BS (brake switch) = Active (1) occur with the footbrake
released?
Yes
Suspect a stoplamp-switch (brake switch) circuit fault. Refer to electrical circuit diagrams and
replace blown fuse or locate the open circuit. Repair the circuit as required using the approved
process. C lear the stored DTC , operate the footbrake and check for correct stoplamp operation.
No
Suspect a stoplamp-switch (brake lamp switch) circuit fault. Refer to electrical circuit diagrams
and replace blown fuse or locate the open circuit. Repair the circuit as required using the
approved process. C lear the stored DTC , operate the footbrake and check for correct stoplamp
operation.

PINPOINT TEST C : PLAUSIBILITY STOPLAMP-SWITCH (BLS) VERSES BRAKE PRESSURE (PS)

(DTC C1A96-64)
E DE AIL / E L /AC ION
CONDI ION
C1: IDS MONITOR
• NOTE: These tests are to be carried out if DTC C 1A96-64 plausibility Stoplamp-switch (BLS) verses brake fluid
hydraulic pressure (PS) has been stored.
• NOTE: This DTC indicates plausibility the stoplamp-switch must be seen to operate before brake fluid hydraulic
pressure (PS) exceeds a pressure threshold of 10 Bar.
• NOTE: The stoplamp-switch status is monitored by the ABS module (BLS terminal 30).
• NOTE: The ABS module contains an internal pressure sensor and monitors the brake fluid hydraulic pressure (PS).
1 Using the manufacturer approved diagnostic system, check for ABS module pressure sensor DTC s
C 1A99-01 or C 1A99-49. If either of these DTC s has been stored carry out the specified action
prior to investigating DTC C 1A96-64.
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2 Using the manufacturer approved diagnostic system, monitor the data-logger signal PID-2B00
(brake input switch status - brake pedal switch / brake lamp switch) and PID-2B0D (brake fluid
hydraulic pressure) . When the brake pedal is pressed, the (brake-pedal switch / brake lamp
switch) status should change from Inacti e (BLS = 0) to Acti e (BLS = 1) before the brake
fluid hydraulic pressure reaches 1000KPa (10 Bar).
Does the (brake pedal switch / brake lamp switch) change from Inacti e (BLS = 0) to Acti e (BLS
= 1) before the brake fluid hydraulic pressure reaches 1000KPa (10 Bar)?
Yes
Suspect an intermittent brake-lamp switch circuit fault. Refer to electrical circuit diagrams, carry
out visual and mechanical check of the of splice joints, connectors and cables of the stoplamp-
switch circuit, check for corrosion, bent or damaged contact faces of pins, terminals and for
security of connectors. Where possible flex cables to attempt to induce the intermittent open
circuit. Repair the circuit as required using the approved process. C lear the stored DTC , operate
the Footbrake and check for correct stoplamp operation.
No
GO to C 2.
C2: STOPLAMP-SWITCH ADJUSTMENT CHECK
NOTE: Removal and correct installation of the stoplamp-switch will reset the adjustment. Ensure the footbrake
pedal is fully raised against its upstop, (pedal rest position) when installing the stoplamp switch.
1 C heck that the stoplamp-switch is securely installed and correctly adjusted.
REFER to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
Is the fault still present with the stoplamp-switch securely installed and correctly adjusted?
Yes
Suspect a brake-lamp switch circuit fault. Refer to electrical circuit diagrams, carry out visual and
mechanical check of the splice joints, connectors and cables of the stoplamp-switch circuit, check
for corrosion, bent or damaged contact faces of pins, terminals and for security of connectors.
Repair the circuit as required using the approved process. C lear the stored DTC , operate the
Footbrake and check for correct stoplamp operation.
No
Adjust the stoplamp-switch using the approved process. C lear the stored DTC , operate the
footbrake and check for correct stoplamp operation.

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Anti-Lock Control - Traction Control - Anti-Lock Brake S stem (ABS) Module
Removal and Installation

Removal

C AUTION: Make sure the ignition switch is in position 0.

1. Remove the cover.

2. Disconnect the electrical connector.

3. C AUTIONS:

Brake fluid will damage paint finished surfaces. If

spilled, immediately remove the fluid and clean the area with
water.

Before the disconnection or removal of any components,

ensure the area around joint faces and connections are clean.
Plug any open connections to prevent contamination.

Disconnect the 6 brake tubes.

Position an absorbent cloth to collect fluid spillage.

4. Remove the ABS module from the mounting bracket.

Loosen, but do not remove, the 2 nuts securing the

ABS module to the bracket.

Installation
1. NOTE: Make sure the ABS module locating grommet is
correctly seated in the bracket before installing the ABS
module.

NOTE: Make sure the ABS module locating pin is correcly

located in the grommet, and the 2 front isolators are fully
seated in the bracket slots.
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Install the ABS module.

Tighten the 2 ABS module retaining nuts to 8 Nm (6

lb.ft).

Remove the blanking caps from the ports.

Tighten the two M10 and three M12 brake tube unions
to 15 Nm (11 lb.ft).

Tighten the M14 brake tube union to 17 Nm (13 lb.ft).

C onnect the electrical connector.

Remove the ABS module from the mounting bracket.

. Using T4, bleed the braking s stem.

For additional information, refer to: Brake S stem Pressure
Bleeding (206-00 Brake S stem - General Information,
General Procedures).
. Install the cover.
. If a new ABS module has been installed, interrogate the
ABS s stem using T4.

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Anti-Lock Control - Traction Control - Front Wheel Speed Sensor
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the fender splash shield.
For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
3. Release the brake hose bracket from the wheel knuckle.

Remove the retaining bolt.

4. C AUTION: Do not allow the brake caliper to hang on

the brake hose.

Release the brake caliper anchor plate from the wheel

knuckle and tie the caliper aside.

Remove the two retaining bolts.

5. Release the wheel speed sensor from the wheel knuckle.

Remove the bolt.

6. Remove the wheel speed sensor.

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Disconnect the electrical connector.

Release the wiring harness from the 5 clips.

In alla ion
1. Make sure the wheel speed sensor location in the wheel
knuckle is free of dirt.
2. NOTE: Make sure the electrical connector retaining clip is
attached to the bod wiring harness.

Install the wheel speed sensor.

C onnect the electrical connector.

Attach the wiring harness to the 5 clips.

Tighten the bolt to 9 Nm (7 lb.ft).

3. Secure the brake caliper and anchor plate to the wheel

knuckle.

Tighten the bolts to 275 Nm (203 lb.ft).

4. Secure the brake hose retaining bracket to the wheel

knuckle.

Tighten the bolt to 25 Nm (18 lb.ft).

5. Install the fender splash shield.

For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
6. Install the wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

7. Depress the brake pedal several times, check the fluid level
in the brake fluid reservoir and top-up with brake fluid if
necessar .
8. If a new wheel speed sensor has been installed, interrogate
the ABS s stem using T4.

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Anti-Lock Control - Traction Control - Rear Wheel Speed Sensor
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the wheel and tire.
3. Disconnect the anti-lock brake s stem (ABS) sensor
electrical connector.

Release the wiring harness retaining clip.

4. Release the wheel speed sensor from the wheel knuckle.

Release the wiring harness.

Remove the retaining bolt.

5. Remove the wheel speed sensor.

Release the wiring harness from the 4 clips.

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In alla ion
1. Make sure the wheel speed sensor location in the wheel
knuckle is free of dirt.
2. Install the wheel speed sensor.

Attach the wiring harness to the 4 clips.

3. Secure the wheel speed sensor to the wheel knuckle.

Tighten the bolt to 9 Nm (7 lb.ft).

Attach the wiring harness to the clip.

4. NOTE: Make sure the electrical connector retaining clip is

attached to the bod wiring harness.

C onnect the ABS sensor electrical connector.

Attach the wiring harness.

5. If a new wheel speed sensor has been installed, interrogate

the ABS s stem using T4.

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Anti-Lock Control - Stabilit Assist - Yaw Rate Sensor
Removal and Installation

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the floor console.
For additional information, refer to: Floor C onsole (501-12
Instrument Panel and C onsole, Removal and Installation).

3. C AUTION: Make sure the wiring harness is

protected when cutting the carpet.

Remove the aw rate sensor.

C ut the carpet for access.

Position the wiring harness aside.

Disconnect the electrical connector.

Remove the two retaining bolts.

Installation
1. Install the aw rate sensor.

Tighten the bolts to 7 Nm (5 lb.ft).

C onnect the electrical connector.

Attach the wiring harness.

Attach the carpet.

2. Install the floor console.

For additional information, refer to: Floor C onsole (501-12
Instrument Panel and C onsole, Removal and Installation).
3. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
4. If a new aw rate sensor has been installed, interrogate the
ABS s stem using T4.

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Steering S stem - General Information - Steering S stem
Description and Operation

Steering System C omponent Layout

NOTE: 4.0L V6 Right Hand Drive shown

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I em Pa N mbe De c ip ion
1 - Steering gear
2 - Lo er collapsable shaft

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3 - In e media e haf
4 - S ee ing angle en o
5 - Uppe ee ing col mn a embl
6 - S ee ing col mn m l if nc ion i che
7 - S ee ing heel
8 - Po e ee ing p mp
9 - Po e ee ing e e oi

GENE AL

The ee ing em on all model comp i e he follo ing componen :

ee ing gea
po e ee ing p mp
e e oi
lo e collap able haf
in e media e haf
ppe col mn a embl
ee ing col mn m l if nc ion i che
ee ing heel.

The ee ing em e a ack and pinion ee ing gea i h a con en ional end ake-off and a pinion po e
a i ed ni . The ack i handed depending on ehicle d i e hand b i common o all h ee engine a ian .

Each em e an engine mo n ed po e ee ing p mp hich i d i en b an a ilia bel . The loca ion and
a achmen of he p mp diffe be een engine a ian . A po e ee ing fl id e e oi i mo n ed nea o each
p mp and p o ide fl id ppl o he p mp ia a c ion ho e.

Each ee ing em inco po a e a fl id coole in he h d a lic pipe la o . The coole i o ed nea o he f on of

he ehicle o benefi f om he inc ea ed ai flo hen he ehicle i mo ing. The po e ee ing fl id i cooled a i
e n f om he gea o he e e oi ia he coole b ai flo ing o e he coole .

The ppe col mn componen a e common o all model and d i e hand . A collap able lo e haf i loca ed on he
gea pinion haf b o fla . An in e media e haf i loca ed be een he lo e collap able haf and he ppe
col mn a embl .

The col mn a embl , hich i a ached o he ehicle c o -ca beam, p o ide he loca ion fo he ee ing col mn
each and ake adj men le e , he ee ing col mn m l if nc ion i che , he ee ing heel, he ee ing col mn
lock and he igni ion i ch. The col mn a embl comp i e a n mbe of componen hich a e de igned o allo
he col mn o collap e in a con olled manne in he e en of a f on al impac ( ed cing occ pan load ). The lo e
collap ible haf i de igned o ele cope, and he in e media e haf o de-co ple, o p e en e ce i e f on al impac
load /di placemen being an mi ed o he ee ing col mn.

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Steering S stem - General Information - Steering S stem
Diagnosis and Testing

Overview

The steering is a variable power assist system, the degree of assistance being controlled by the dynamic suspension
control module.

For information on the description and operation of the system, refer to section 211-00 - Steering System of the
workshop manual.

Inspection and Verification

1. 1. Verify the customer concern.

If a road test is necessary make sure the vehicle is safe to do so.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection
Mechanical Electrical
C heck the tires for correct pressure, size and tread pattern Steering angle sensor (SAS) and
C heck for wheel rim and tire damage circuits
C heck road wheel security C ontroller area networks (C AN)
C heck the power steering fluid level and the hydraulic circuit for oil circuits
leaks
C heck the power steering pump drive belt condition and tension
C heck the power steering pump for security, wear, damage and
excessive noise
C heck the steering gear assembly for damage, wear and security
C heck the hydraulic pipes and cooler lines for damage and correct
routing
C heck the steering joints for damage, excessive play, wear and
security
C heck the steering column and joints for damage, excessive play,
wear and security

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits
from the scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra
information read by the manufacturer-approved diagnostic system).

4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTC s) before
moving onto the symptom chart or DTC index.

Because the DTC s are stored in more than one module, a complete vehicle read is recommended
Make sure that all DTC s are cleared following rectification

S mptom Chart

S mptom Possible Causes Action

Steering Excessive C heck for excessive movement or play in the steering system with the engine
wanders free play in running. C heck for play at several different steering positions. C arry out steering
the steering geometry and alignment checks. Refer to the relevant section of the workshop
system manual
Steering
geometry
incorrectly
aligned

Steering Steering C arry out steering geometry and alignment checks using a four wheel alignment
pulls to the geometry system. Refer to section 204-00 - Suspension System - General Information of the
left or right incorrectly workshop manual. Ensure that the tire direction of rotation is correct for the
aligned position on the vehicle (where directional tires are installed)

Steering Steering or Disconnect the steering gear from the suspension. C heck for freedom of

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.D
.C .
C .R
S
S

P P C - ,
.R 204-00 - S S -G
I .C .D
/ .
I R / .C .C
.R

P P C - .R 204-00
-S S -G I .C
.D
/ .R / .C
F .R

P P C - .R
.C .C
.R

S S C .R

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joints dry
Power Lack of C heck the power steering pump pressure. C heck the steering column has no
steering power damage and rotates freely
feels heavier assistance
than normal
through its
operating
range
Power
steering
feels too
light at
speed
Power
steering
feels too
heavy at
standstill and
low speed

DTC Inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: Intermittent faults may cause DTC s to be logged, however some DTC s may be cleared during an ignition off,
ignition on cycle. C arry out a road test (if safe to do so), check the functionality of the system and retrieve any DTC s
before turning the ignition off.

DTC Description Possible Causes Action

B1C 3173 Steering Software error Where an electric column adjustment is not installed, no action
C olumn Motor (electric column necessary, clear/ignore DTC . Where an electric column
Relay not installed) adjustment is installed, refer to the electrical guides and check
Steering column the column motor circuit for short or open circuit and
motor relay fault check/renew the memory control module as necessary
(stuck on)

B1C 3193 Steering Software error Where an electric column adjustment is not installed, no action
C olumn Motor (electric column necessary, clear/ignore DTC . Where an electric column
Relay not installed) adjustment is installed, check/renew the control module as
Memory control necessary
module internal
relay fault
(inoperative)

B1C 3213 Steering Software error Where an electric column adjustment is not installed, no action
C olumn Tilt (electric column necessary, clear/ignore DTC . Where an electric column
Solenoid not installed) adjustment is installed, refer to the electrical guides and check
Steering column the column tilt solenoid circuit for short or open circuit and
motor tilt solenoid check/renew the tilt solenoid as necessary
open load

B1C 3296 Steering Software error Where an electric column adjustment is not installed, no action
C olumn Tilt (electric column necessary, clear/ignore DTC . Where an electric column
Solenoid not installed) adjustment is installed, refer to the electrical guides and check
Steering column the column tilt solenoid circuit for short or open circuit. C heck for
motor tilt solenoid other relevant DTC s and repair as necessary. Allow the solenoid
thermal overload to cool, clear the DTC and check the solenoid/tilt function
operation. If the DTC persists renew the tilt solenoid as
necessary
B1C 333A Steering Software error Where an electric column adjustment is not installed, no action
C olumn Tilt (electric column necessary, clear/ignore DTC . Where an electric column
Feedback not installed) adjustment is installed, refer to the electrical guides and check
Signal Steering column the column tilt solenoid feedback circuit for short or open circuit.
tilt motor moved C heck the solenoid/tilt function operation and range of
beyond expected movement. Renew the tilt solenoid as necessary
range
- Sensor circuit
open or short
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ci c i
- Mo o po i ion
en o fa l

B1C 3413 S ee ing Sof a e e o Whe e an elec ic col mn adj men i no in alled, no ac ion
C ol mn (elec ic col mn nece a , clea /igno e DTC . Whe e an elec ic col mn
Tele copic no in alled) adj men i in alled, efe o he elec ical g ide and check
Solenoid S ee ing col mn he col mn ele copic olenoid ci c i fo ho o open ci c i and
mo o ele copic check/ ene he il olenoid a nece a
olenoid open load

B1C 3496 S ee ing Sof a e e o Whe e an elec ic col mn adj men i no in alled, no ac ion
C ol mn (elec ic col mn nece a , clea /igno e DTC . Whe e an elec ic col mn
Tele copic no in alled) adj men i in alled, efe o he elec ical g ide and check
Solenoid S ee ing col mn he col mn ele copic olenoid ci c i fo ho o open ci c i .
mo o ele copic C heck fo o he ele an DTC and epai a nece a . Allo he
olenoid he mal olenoid o cool, clea he DTC and check he olenoid/ ele copic
o e load f nc ion ope a ion. If he DTC pe i ene he ele copic
olenoid a nece a
B1C 353A S ee ing Sof a e e o Whe e an elec ic col mn adj men i no in alled, no ac ion
C ol mn (elec ic col mn nece a , clea /igno e DTC . Whe e an elec ic col mn
Tele copic no in alled) adj men i in alled, efe o he elec ical g ide and check
Feedback S ee ing col mn he col mn ele copic olenoid feedback ci c i fo ho o open
Signal ele copic mo o ci c i . C heck he olenoid/ ele copic f nc ion ope a ion and
mo ed be ond ange of mo emen . Rene he ele copic olenoid a nece a
e pec ed ange
- Sen o ci c i
open o ho
ci c i
- Mo o po i ion
en o fa l

B1C 363A S ee ing Sof a e e o Whe e an elec ic col mn adj men i no in alled, no ac ion
C ol mn (elec ic col mn nece a , clea /igno e DTC . Whe e an elec ic col mn
Til /Tele cope no in alled) adj men i in alled, efe o he elec ical g ide and check
S i ch S ee ing col mn he col mn il / ele copic i ch ci c i fo ho o open ci c i .
il / ele copic C heck he il / ele copic i ch ope a ion and ene he i ch a
i ch ol age nece a
be ond e pec ed
ange
- Sen o ci c i
open o ho
ci c i
- S i ch fa l

C 005104 S ee ing Wheel S em in e nal C heck he ee ing angle en o , connec o and ci c i . Refe o
Po i ion Sen o fail e he elec ical g ide
Ha ne /connec o
i e

C 005162 S ee ing Wheel Signal compa e C heck he ee ing angle en o , connec o and ci c i . Refe o
Po i ion Sen o fail e he elec ical g ide
Ha ne /connec o
i e

C 005164 S ee ing Wheel Signal pla ibili C heck he ee ing angle en o , connec o and ci c i . Refe o
Po i ion Sen o fail e he elec ical g ide
Ha ne /connec o
i e

C 1B1862 S ppl Vol age Incon i en Refe o he g ided diagno ic o ine fo hi code on he
X-Ref C heck ba e ol age app o ed diagno ic em. Refe o he a an polic and
ecei ed b ai p oced e man al if a mod le i pec
pen ion con ol
mod le
Ai pen ion
con ol mod le
ppl ci c i
ho ci c i o
g o nd

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Air suspension
control module
suppl circuit high
resistance
Air suspension
control module
failure
U007388 C ontrol Module C AN bus off Refer to the Network C ommunications section of the workshop
C ommunication manual
Bus 'A' Off
U012287 Lost C AN module C heck for ABS DTC s. Refer to the Network C ommunications
C ommunication status signals not section of the workshop manual
With Vehicle received from the
D namics VDM in the
C ontrol Module specified time

U012687 Lost C AN bus fault C heck the control module installation/configuration. Refer to the
C ommunication Steering angle Network C ommunications section in the workshop manual
With Steering sensor module
Angle Sensor disconnected
Module Steering angle
sensor module not
configured
Steering angle
sensor module
failure
Harness/connector
issue

U030055 Internal Software C onfigure the modules using the approved diagnostic s stem.
C ontrol Module incompatibilit Refer to the Network C ommunications section of the workshop
Software with ATC M manual
Incompatibilit Not configured

U041686 Invalid Data ABS fault C heck for d namic suspension/ABS DTC s. Refer to the relevant
Received From section of the workshop manual
Vehicle
D namics
C ontrol Module
U1A1449 C AN Internal electronic C onfigure the steering angle sensor module using the approved
Initiali ation fault diagnostic s stem. Refer to the Network C ommunications section
Failure of the workshop manual
U300262 Vehicle Signal compare Program the module using the approved diagnostic s stem
Identification failure
Number

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Published: 11-Ma -2011

Steering S stem - General Information - Power Steering S stem Filling and
Bleeding
General Procedures

1. C heck the power steering fluid level.

2. C AUTION: Fluid must alwa s be present in the

reservoir during bleeding.

Remove the filler cap and fill to the MAX level mark.

Install the reservoir filler cap.

3. Start the engine and allow to run for 10 seconds, stop the
engine.

C heck the power steering fluid, if aerated, wait until

fluid is free from bubbles then top-up reservoir to
UPPER level mark with recommended fluid.

4. C AUTION: Do not hold steering on full lock for longer

than 10 seconds.

Start the engine and turn steering full lock to lock, stop the
engine.

C heck and top-up power steering fluid level.

5. Start and run the engine for 2 minutes, turn the steering
full lock to lock.

C heck and top-up power steering fluid level.

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Steering S stem - General Information - Power Steering S stem Flushing
General Procedures

NOTE: If heavy steering or contamination within the power steering system is found, it is necessary to carry out the
system flush procedure as detailed below. If any components have been replaced in the power steering system the
procedure below must be carried out in full.

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

1. Remove the power steering fluid reservoir cap.

2. Using a suitable syringe, remove the power steering fluid
from the power steering fluid reservoir.

3. C AUTION: Be prepared to collect escaping fluids.

NOTE: Note the orientation of the clip.

Detach the power steering fluid reservoir.

Detach but do not remove the power steering fluid

reservoir.

Release the power steering fluid return hose from

the power steering fluid reservoir.

If a quick release coupling is fitted to the power

steering return hose, release the power steering fluid
return hose from the coupling by removing the clip.

4. C AUTION: Be prepared to collect escaping fluids.

NOTE: Make sure that all openings are sealed. Use new
blanking caps.

Using a suitable blanking cap, cap the power steering

reservoir return pipe.

5. C AUTION: Be prepared to collect escaping fluids.

NOTE: Make sure the extended pipe is not kinked or

twisted and is correctly secured with hose clips.

Attach a suitable pipe to the power steering return hose to

allow the fluid to drain.

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. NOTE: The suitable funnel should have the a capacity of

4 litres and O-ring seal

NOTE: The suitable funnel must be tightly sealed to the

power steering fluid reservoir to avoid fluid leakage.

Install a suitable funnel onto the power steering fluid

reservoir.

. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle with the wheels just clear of
the ground.

. C AUTIONS:

Steps 8 and 9 must be carried out within 2 - 3 seconds

of each other. Failure to follow this instruction may result in
damage to the power steering system.

Be prepared to collect escaping fluids.

Using the suitable funnel, top up the power steering system

with the specified fluid. Make sure the fluid level is
maintained at two thirds full in the funnel.
. C AUTIONS:
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Be p epa ed o collec e caping fl id .

Do no allo he po e ee ing fl id le el in he
po e ee ing fl id e e oi o fall belo he minim m
po e ee ing fl id le el. Fail e o follo hi in c ion
ma e l in damage o he po e ee ing em.

Make e he engine i i ched off a oon a he

f ll 4 li e of po e ee ing fl id ha en e ed he po e
ee ing fl id e e oi .

Fl h he po e ee ing em.

S a he engine

Wi h a i ance n he ee ing lo l lock o lock

3 ime a app o ima el 1 e ol ion e e 5
econd .

C on in e o fl h he po e ee ing em n il 4
li e of po e ee ing fl id ha been added o he
po e ee ing e e oi . Thi ho ld ake
app o ima el 30 econd .

. C AUTION: Be p epa ed o collec e caping fl id .

Remo e he i able f nnel.

. C AUTION: Be p epa ed o collec e caping fl id .

Remo e he i able pipe o he po e ee ing e n

ho e.

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. C AUTION: Be prepared to collect escaping fluids.

NOTE: Note the orientation of the clip.

If a quick release coupling is fitted to the power steering

return hose, connect the power steering fluid return hose to
the coupling by installing the clip.
. Install a new power steering fluid reservoir.
For additional information, refer to: Power Steering Fluid
Reservoir (211-02, Removal and Installation).

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Power Steering -
Power Steering Fluid
Item Specification
Recommended power steering fluid Texaco C old C limate Fluid 14315
Capacit
Item Capacit
System capacity - Maximum - Fill to mark on reservoir 0.89 litre (1.5 pints) (0.9 US quarts)
General Specif ication
I em Specifica ion
Type Power assisted rack and pinion, speed proportional with belt driven pump, remote
hydraulic fluid reservoir and fluid cooler
Steering wheel diameter 395 mm (15.5 in)
Number of turns - lock to 3.32
lock
Turning circle 11.45 m (37.5 ft)
System ratio 17.8:1
System operating pressure 110 bars (11000 kPa)(1595 lbf/in )
Pump relief valve operating 114 ± 4 bar (11400 ± 400 kPa) (1653 ± 58 lbf/in )
pressure
Fluid flow rate - constant 8.8 ± 0.5 litre/min (15.4 ± 0.8 pints/min) (9.2 ± 0.5 US quarts/min)
Steering rack travel 166 mm (6.22 in)
Piston diameter 52 mm (1.9 in)
Rack bar diameter 30 mm (1.12 in)
Steering angle sensor Panasonic EC S64SUKX
make/part number
Torque Specif ications
Description Nm lb-ft
Power steering pump bolts - All engines 25 18
High pressure line to power steering pump - All engines 25 18
Power steering pump bolts - All engines 25 18
High pressure line to power steering pump - All engines 25 18
Low pressure line to power steering pump - All engines 25 18
Steering angle sensor Torx screws 3 2
* Steering column intermediate shaft nut 22 16
++ Steering column intermediate shaft to the lower shaft bolt 25 18
Horn nut 10 7
C oolant expansion tank bolts 10 7
A/C condenser refrigerant line bolts 25 18
++ Power steering fluid lines bolt - 2.7 litre 25 18
+ Power steering gear to cross member bolts 175 129
High pressure line to steering gear bolt 25 18
Power steering line suppport bracket bolt 10 7
High pressure line union nut 30 22
* Tie rod end ball joint nuts 76 56
** Universal joint to steering gear bolt 25 18
Radiator access panel bolts 10 7
Oil filter 18 13
* New nut(s) must be fitted

+ New cage nuts must be fitted

** New 'Patchlok' bolt must be fitted

++ New bolt must be fitted

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Po er Steering - Po er Steering
Description and Operation

C OMPONENT LOC ATION

NOTE: 5.0L RHD shown.

I em Pa N mbe De c ip ion
1 - Power steering pump
2 - Banjo bolt
3 - Spring clip
4 - Suction hose - reservoir to pump
5 - Spring clip
6 - Reservoir
7 - Spring clip
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8 - Fluid cooler and hose assembl - fluid return
9 - Hose assembl - Steering gear to cooler - return
10 - Screw
11 - Steering gear
12 - C aged nut (2 off)
13 - Self-locking nut (2 off)
14 - Bolt (2 off)
15 - Hose - pump to steering gear - pressure
16 - Pipe clip
17 - Screw
18 - C ooler

GENE AL

The steering s stem comprises a TRW manufactured rack and pinion steering gear, a power steering pump, a
reservoir, a fluid cooler and fluid hoses. The steering gear is a conventional end take-off rack and pinion power
assisted unit.

The steering gear rack has a travel of 166 mm (6.53 in). Lock to lock requires 3.33 revolutions of the steering wheel,
which gives a ratio of 45 mm (1.77 in)/revolution at the center position and 52.6 mm (2.07 in)/revolution at end of
lock.

EE ING GEA

I em Pa N mbe De c ip ion
1 - Tie-rod end
2 - Locknut
3 - Tie-rod
4 - Gaitor
5 - Pressure/return connection from/to pump
6 - Valve unit housing
7 - Input shaft
8 - Pressure/return pipes
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9 - S ee ing gea ca ing a achmen l g
10 - Pinion ho ing
The ee ing gea i loca ed a he f on of he engine, belo he acce o bel d i e. The gea i a ached o o
b acke on he cha i and i ec ed o he b acke i h flanged bol and caged n . The cage p e en he n
f om ning hen he bol a e loo ened o igh ened. The cage n can onl be ed once and m be eplaced
hen he gea i emo ed. Fo e ice, M12 N lock n a e a ailable a a eplacemen fo he cage n .

The ee ing gea comp i e an al mini m, ca , one piece ho ing hich con ain a mechanical ee ing ack, a
al e ni and an in eg a ed h d a lic po e ni .

The ee ing gea e a ack i h an in eg a ed pi on hich i g ided on plain bea ing i hin he ack ho ing. The
pinion, hich i a ached o he al e ni , n in bea ing and me he i h he ack ee h. The ack i p e ed
again he pinion b a p ing loaded oke hich en e ha he ee h me h i h he minim m of pla . The pinion i
connec ed o he al e ni ia a o ion ba . The o a mo ion of he ee ing heel i con e ed in o linea
mo emen of he ack b he pinion and i ini ia ed b he al e ni . Thi mo emen i an fe ed in o mo emen of
he oad heel b adj able ie- od .

The 49 mm (1.92 in) diame e pi on of he h d a lic po e ni i loca ed a one end of he gea ho ing. Each ide
of he pi on i connec ed o fl id p e e o fl id e n ia e e nal me al pipe hich a e connec ed o he al e
ni .

Each end of he gea ha a h eaded hole hich p o ide fo he fi men of he ie- od. The e e nal end of he gea
a e ealed i h gai o hich p e en he ing e of di and moi e. The ie- od ha a long h eaded a ea hich
allo fo he fi men of he ie- od end. The h ead allo fo he adj men of he ee ing oe. When he co ec
oe i achie ed, a lockn i igh ened again he ie- od end p e en ing inad e en mo emen .

The gea ha a cen al hole machined along i leng h. The hole allo he ai in he gai o o be balanced hen he
ee ing i ned. The gai o a e e iceable i em and a e e ained on he gea ho ing and he ie- od i h ip
ie .

Val e Unit

I em Pa N mbe De c ip ion
1 - Rack
2 - Pinion haf

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3 - O e ee e
4 - Oi ee e
5 - Di ea
6 - I haf
7 - T i ba
8 - Ci c i
9 - Oi ea
10 - PTFE i g
11 - S ee i g gea ca i g
12 - S
13 - Pi - Pi i haf e ee e
14 - Oi ea
15 - Pi i haf
16 - Bea i g
17 - Pi i haf
The a e i i a i eg a a f he ee i g gea . The i ci e f c i f he a e i i ide a i
e a i a ce (i.e. he a i g) i h i i eff e i ed he ee i g hee .

The i i h i g f he a e i a i eg a a f he ai ee i g gea ca i g. The i i h i g ha f

achi ed hich ide c ec i f e e feed f he e ee i g , e f id he
e e i a d e e feed each ide f he c i de i .

The a e i c i e a e ee e, a i haf , a i ba a d a i i haf . The a e i i c -a ia

i h he i i haf hich i c ec ed he ee i g c ia he i haf . The a e i c e a e
ca ed i he ee i g gea i i h i g hich i ea ed i h a ca .

The e ee e i ca ed i he ai b e f he i i h i g. Th ee a a g e a e achi ed i e
dia e e . PTFE i g a e ca ed be ee he g e a d ea agai he b e f he i i h i g. H e a e
d i ed adia i each a a g e h gh he a f he ee e. The b e f he e ee e i achi ed
acce he i haf . Si e a aced a e achi ed i he b e f he ee e. The e d f he a e
c ed a d d c i e he e d f he e ee e. The adia h e i he e ee e a e d i ed i each
.

The i haf ha achi ed f a a i e e d hich a f he a ach e f he ee i g c

i e edia e haf e. The f a e e ha he i e edia e haf i fi ed i he c ec ii ai ai he
i ha e a g e. The i e e d f he i haf f a d g- h hich a e iha i he i i haf .
The fi f he d g- h i he a a a a f eai e ai be ee he i haf a d he i i
haf bef e he d g- hc ac he a f he . Thi e e ha , if he e a i a ce fai , he ee i g
ca be e a ed a a ih e e i g he i ba . The ce a i f he i haf ha e a
aced gi di a achi ed i i ci c fe e ce. The a e a a ged a e a e a d he i haf .

The i ba i fi ed i ide he i haf a d i a i e fe e ce fi i he i i haf . The i ba i c ec ed

he i haf b a d i e i . The ce a dia e e f he i ba i achi ed a a e dia e e i i
ce a ec i . The a e dia e e a he i ba i i e e e a ied f he ee i g
hee i e a i he g i f he e he ad face.

The i i haf ha achi ed e ee h i ce a dia e e hich ae i h ee h he ee i g gea ac . A

, achi ed i he e e d f he i i haf ae i h he d g- h he i haf . The i i haf
ca e i he i i h i ga d ae ba a d e bea i g .

Power Steering H draulic Operation

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I em Pa N mbe De c ip ion
1 - Reservoir
2 - C ooler
3 - Valve unit
4 - Steering rack and pinion
5 - Flow control/pressure relief return
6 - Flow control/Pressure relief valve
7 - Output port
8 - Power steering pump
9 - Low pressure suction line
When the engine is started the power steering pump draws fluid from the reservoir into the low pressure suction line.
The fluid passes through the pump and emerges as pressurised fluid at the outlet port. The attenuated high pressure
hose passes the pressurised fluid to the steering gear valve unit.

If no steering effort is applied, there is minimal restriction within the s stem and the suppl pressure from the pump
is low. Minimal pressure is applied, via the valve unit, to each side of the piston in the h draulic c linder and the full
flow from the power steering pump returns to the reservoir via the fluid cooler.

When steering effort is applied in either direction, the return flow of fluid to the reservoir is restricted, causing the
suppl pressure from the pump to increase. The pressurised fluid is directed to the applicable side of the piston in the
h draulic c linder, via the valve unit, providing the power assistance required to reduce the steering effort. Fluid
displaced from the low pressure side of the c linder is returned via the valve unit and fluid cooler to the reservoir.
The fluid cooler reduces the fluid temperature which prolongs the life of hoses and seals in the s stem.

PO ER STEERING PUMP

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I em Pa N mbe De c ip ion
1 - 4.0L V6
2 - 5.0L V8
3 - 2.7L, 3.0L TdV6
The power steering pumps used on the four engine variants are basically the same pump with different connection
fittings. The pump is a positive displacement, vane type pump which supplies hydraulic pressure to the steering gear
valve unit. The pump is driven by a Poly Vee belt from the crankshaft pulley and output from the pump increases
proportionally with engine speed. A self-adjusting tensioner is fitted to maintain the correct tension on the belt.

The pump has an internal flow control valve which also incorporates a pressure relief valve. The pressure relief valve
limits the maximum pressure supplied to the steering gear to 114 bar (1653 lbf in2 ) 4 bar (58 lbf in2 ) on V6 petrol
2 2
engines, and 115 bar (1667 lbf in ) 4 bar (58 lbf in ) for V8 petrol, and V6 diesel models. The flow control valve
regulates the flow to a constant value of 8.8 l/min (1.93 gal/min) 0.5 l/min (0.1 gal/min) regardless of engine
speed. The pump has a displacement of 9.6 cc/rev (0.58 in3 /rev) on V6 petrol, and V6 diesel, but 11 cc/rev (0.67
in3 /rev) for V8 petrol.

A shaft runs longitudinally through the pump. One end of the shaft is fitted with a pressed-on drive pulley, the
opposite end of the shaft is closed by a cover. The shaft runs in bearings located in the body and oil seals at each end
of the shaft prevent leakage of hydraulic fluid.

The pump contains ten vanes on petrol models, and eleven vanes on diesel models which rotate within a cam ring
and are driven by the shaft. As the vanes rotate, the cam ring causes the space between the vanes to increase. This
causes a depression between the vanes and fluid is drawn from the reservoir via the suction hose into the space
between the vanes.

As the shaft rotates, the inlet port is closed to the vanes which have drawn in fluid, trapping the fluid between the
vanes. The cam ring causes the space between the vanes to reduce and consequentially compresses and pressurises
the hydraulic fluid trapped between them.

Further rotation of the shaft moves the vanes to the outlet port. As the vanes pass the port plate the pressurised fluid
passes from the pump outlet port into the pressure hose to the steering gear.

The pressurised fluid is subject to control by the flow control and pressure relief valve. The flow control valve
maintains a constant flow of fluid supplied to the steering gear irrespective of engine speed variations. The pressure
relief valve limits the pressure on the output side of the pump. A metering orifice is included in the discharge port of
the pump. If the pressure in the orifice reaches a predetermined level, a spring loaded ball in the center of the flow
control valve is lifted from its seat and allows pressurised fluid to recirculate within the pump.

The pressure relief valve will operate if the discharge from the pump is restricted, i.e.; steering held on full lock. If
the output from the pump is blocked, all output is recirculated through the pump. In this condition, as no fresh fluid is
drawn into the pump from the reservoir, the fluid temperature inside the pump will increase rapidly. C onsequentially,
periods of operation of the steering gear on full lock should be kept to a minimum to prevent overheating of the pump
and the fluid within it.

RESER OIR

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The fluid reservoir is located on a bracket in the left hand side of the engine compartment, behind the radiator. The
reservoir comprises a body, cap and filter. The purpose of the reservoir is to contain a surplus of the hydraulic fluid in
the system to allow for expansion and contraction of the fluid due to temperature variations. The fluid level ensures
that the supply connection on the bottom of the reservoir is covered with fluid at all operating vehicle attitudes. Any
air which is present in the system is exhausted from the system in the reservoir.

The body is a plastic moulding with two ports at the bottom which provide for the connection of the suction supply and
return hoses. Moulded markings on the side of the reservoir denote the upper and lower fluid levels. A non-
serviceable, 100 micron nylon mesh filter is fitted in the body. The filter removes particulate matter from the fluid
before it is drawn into the pump supply connection.

The cap is rotated counterclockwise for one quarter turn to release from the body. The cap is fitted with an O-ring to
prevent fluid leakage. The cap incorporates a breather hole to allow for changes in fluid level during operation and
prevent vacuum or pressurisation of the reservoir.

HIGH PRESS RE HOSE

The high pressure hose connecting the pump to the steering gear valve unit contains two attenuators. Each attenuator
comprises a bullet shaped restrictor which is secured inside the hose. The restrictors damp pressure pulses from the
pump, consequently reducing noise and strain on downstream components. The attenuators are an integral part of
the hose and cannot be serviced separately.

FL ID COOLER

NOTE: Diesel engine vehicles are not fitted with a fluid cooler.

The fluid cooler is located in the return line from the steering gear to the reservoir. The cooler comprises a flexible
hose and a solid pipe which connect between the reservoir and the return pipe from the steering gear. The cooler is
an integral part of the pipe and cannot be replaced as a separate component.

The cooler is a fabricated aluminium tube, through which the power steering fluid passes. The outer diameter of the
cooler tube has aluminium loops attached to it which dissipate heat. C ool air entering the front of the vehicle passes
over the cooler and flows through the loops. The loops act as heat exchangers, conducting heat from the fluid as it
passes through the tube.

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Published: 11-Ma -2011

Po er Steering - Po er Steering Pressure TestV8 4.4L Petrol
General Procedures

Special Tool(s)
Adapter, power steering pressure
test

211-313 (LRT-57-035A)

Hose, power steering pressure test

211-011-02 (LRT-57-002)

Hose, power steering pressure test

211-011-11

Valve block, power steering

pressure test

211-011-01 (LRT-57-001)

Hose and gauge, power steering

pressure test

211-287 (LRT-57-005)

Adapter, power steering pressure

test

211-325 (LRT-57-042)

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
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stands.

Raise and support the vehicle.

. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
. Remove the radiator access panel.

Remove the 4 bolts.

. Remove the front LH splash shield.

Remove the 4 clips.

. Siphon the fluid from the power steering reservoir.

Remove the filler cap.

Install the filler cap.

. Position an absorbent cloth to collect fluid spillage.

. C AUTION: Before disconnecting or removing the

components, ensure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

NOTE: Some fluid spillage is inevitable during this operation.

NOTE: C are must be taken to avoid contamination of the

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drive belt.

Disconnect the power steering high-pressure pipe union.

Remove the bolt.

Remove and discard the 2 sealing washers.

Position a container to collect the fluid.

. Install the special tools to the power steering high-pressure

port.

Install the O-ring seal.

Tie the pressure gauge aside under the hood.

. Install the special tool to the high-pressure union.

Install the O-ring seals.

C onnect the special tool line, to the special tool valve

block assembly.

10. Refill the power steering reservoir.

Remove the filler cap.

11. C onnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
12. NOTE: Ensure the steering components and test
equipment are free from leaks.

NOTE: Maintain the maximum fluid level during the test.

NOTE: Make sure the steering is in the straight ahead

position.

NOTE: Under no circumstances must the low pressure spigot

be removed from the steering pump.

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Wi h he e a e e a he e gi e.

S a he e gi e a d ee i g f c c ,
he e gi e.

T - he e ee i g f id e e i .

I a he e e i fi e ca .

.F c ec e ee i g e e , efe he ee i g
ecifica i ec i .
F addi i a i f a i , efe : S ecifica i (211-02
P e S ee i g, S ecifica i ).
. Wi h he e gi e a id e, he ee i g hee a d
h d f c .

Rec d he e e eadi g.

. Re ea he ab e ced e f he he ide.

Rec d he e e eadi g.

. Wi h he e gi e a id e, e ea e he ee i g hee . The
e e h d be, a be , he e e ecified.

1. P e e ide hi e a ce, i dica e a fa .

. T de e i e if he fa i i he ee i g he
ee i g ac , c e he e a e f a a i f5
ec d .
. If he e e ec ded fa ide he gi e a e ,
e ace he e ee i g .
. If he a i e e i c ec , he ec
he e ee i g ac .
.O c e i f he e he e gi e, di c ec he
ba e g d cab e a d i h he ee i g f id f he
e e i .

Re e he fi e ca .

I a he fi e ca .

. Di a e b e he e e i e .
.C ec he high- e e i e he e ee i g
.

C ea he c e a i g face .

I a he e O- i g ea .

Tigh e he b 25 N (18 b.f ).

.I a he f LH a h hie d.

Sec e i h he c i .

.I a he adia acce a e.

Tigh e he M6 b 10 N (7 b.f ).

Tigh e he M10 b 45 N (33 b.f ).

.C ec he ba e g d cab e.
. Refi a d b eed he e ee i g.
F addi i a i f a i , efe : P e S ee i g S e
Fi i g a d B eedi g (211-00 S ee i g S e - Ge e a
I f a i , Ge e a P ced e ).

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Po er Steering - Steering GearV8 4.4L Petrol
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the radiator access panel.

Remove the 4 bolts.

3. Remove the front RH splash shield.

Remove the 4 clips.

4. Remove the front LH splash shield.

Remove the 4 clips.

5. NOTE: Make sure the steering is in the straight ahead

position.

Release the universal joint from the steering gear.

Remove and discard the bolt.

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. NOTE: LH illustration shown, RH is similar.

Release both tie-rod end ball joints.

Loosen the locknut.

Release both track rods from tie rod ends, note the
number of turns for installation.

. C AUTION: Always plug any open connections to

prevent contamination.

Disconnect the high pressure line from the power steering

pump.

Disconnect the banjo bolt.

Allow the fluid to drain into a container.

Remove and discard the seals.

. C AUTION: Always plug any open connections to

prevent contamination.

NOTE: Under no circumstances must the low pressure

spigot be removed from the steering pump.

Disconnect the low pressure line from the power steering

pump.

Release the clip.

Loosen and release the power steering pump line.

. Disconnect the pressure lines from the power steering

gear.

Remove the bolt.

Position an absorbent cloth to collect fluid spillage.

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Remove and discard the O-ring seals.

10. Remove the steering gear high-pressure line.

Remove the bolt.

11. Remove the steering gear.

Remove the 2 bolts and discard the cage nuts.

With assistance, carefull rotate and release the

steering gear.

In alla ion
1. With assistance, install the steering gear.

C lean the component mating faces.

Tighten the bolts to 175 Nm (129 lb.ft).

2. NOTE: Do not install the support bracket bolt until the

steering gear connections are tightened.

Install the steering gear high pressure line.

3. NOTE: Lubricate the seals with clean power steering fluid.

C onnect the steering gear pressure lines.

C lean the component mating faces.

Install new O-ring seals.

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. C onnect the low pressure line to the power steering pump.

C lean the component mating faces.

Secure with the clip.

. C onnect the high-pressure line to the power steering pump.

C lean the component mating faces.

Install new seals.

C onnect the banjo and tighten to 22 Nm (16 lb.ft).

. Install the power steering line support bracket.

Tighten the bolt to 10 Nm (7 lb.ft).

. C onnect the tie-rod end ball joints.

Attach both tie rods to previousl noted positions.

Tighten the tie-rod locking nut.

. C onnect the universal joint to the steering gear.

Install a new patchlock bolt and tighten to 25 Nm (18

lb.ft).

. Install the radiator access panel.

Install the 4 bolts and tighten to 10 Nm (7 lb.ft).

. Install the front LH splash shield.

. Install the front RH splash shield.
. Fill and bleed the power steering s stem.
For additional information, refer to: Power Steering S stem
Filling and Bleeding (211-00 Steering S stem - General
Information, General Procedures).
. Adjust the front wheel alignment.

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Po e S ee ing - Po e S ee ing Fl id Re e oi V6 4.0L Pe ol/V8 4.4L
Pe ol
Removal and Installation

Remo al
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Siphon the fluid from the power steering reservoir.
3. Release the power steering fluid reservoir from the
bracket.

4. C AUTION: Before disconnecting or removing the

components, make sure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

NOTE: Some fluid spillage is inevitable during this

operation.

Remove the power steering fluid reservoir.

Position an absorbent cloth to collect fluid spillage.

Release the hose clips and disconnect the hoses.

In alla ion
1. To install, reverse the removal procedure.
2. Fill and bleed the power steering system.
For additional information, refer to: Power Steering System
Filling and Bleeding (211-00 Steering System - General
Information, General Procedures).

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Published: 11-May-2011
Po e S ee ing - Po e S ee ing Fl id Coole V6 4.0L Pe ol/V8 4.4L Pe ol
Removal and Installation

Special Tool( )
Spring lock decoupler

310-044

Remo al
1. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the front radiator grille.
For additional information, refer to: Radiator Grille (501-08
Exterior Trim and Ornamentation, Removal and
Installation).
3. Remove the coolant expansion tank.
4. Siphon the fluid from the power steering reservoir.

5. C AUTION: Before disconnecting or removing the

components, ensure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

NOTE: Some fluid spillage is inevitable during this

operation.

Using the special tool, disconnect the cooler line.

Position an absorbent cloth to collect fluid spillage.

6. Disconnect the steering reservoir return hose.

Position an absorbent cloth to collect fluid spillage.

Release the clip.

7. Release the LH radiator air deflector lower clip, position

the deflector aside.

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. Po i ion he LH ho n a ide fo acce .

Remo e he n .

. Remo e he coole line epe a ing clip.

10. NOTE: C a e m be aken o p e en damage o he
coole elemen d ing emo al and in alla ion.

Remo e he po e ee ing fl id coole .

Relea e he 3 clip .

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In alla ion
1. In all he po e ee ing fl id coole .

Po i ion and ec e in he clip .

2. In all he coole line epe a ing clip.

3. In all he ho n a embl .

Tigh en he n o 10 Nm (7 lb.f ).

4. In all he adia o deflec o .

Sec e i h he clip.

5. In all he po e ee ing fl id line and ho e.

C lean he componen ma ing face .

Sec e he ho e i h he clip.

6. In all he coolan e pan ion ank.

7. In all he adia o g ille.
Fo addi ional info ma ion, efe o: Radia o G ille (501-08
E e io T im and O namen a ion, Remo al and
In alla ion).
8. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
9. Fill and bleed he po e ee ing em.
Fo addi ional info ma ion, efe o: Po e S ee ing S em
Filling and Bleeding (211-00 S ee ing S em - Gene al
Info ma ion, Gene al P oced e ).

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Po er S eering - Po er S eering P mpV8 4.4L Pe rol
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05B Accessor Drive - V8 4.4L Petrol, Removal and
Installation).
3. Remove the splash shield.

Remove the 4 clips.

4. C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the low pressure line.

Remove the power steering line bolt.

Allow the fluid to drain into a container.

Remove and discard the O-ring seal.

5. Disconnect the high pressure line at the steering pump

union.

Remove and discard the O-ring seal.

6. Release the power steering line support bracket.

Remove the bolt.

7. Remove the power steering pump front retaining bolts.

Remove the 2 bolts.

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8. Remove the power steering pump rear retaining bolts.

Remove the 2 bolts.

9. Remove the power steering pump.

In alla ion
1. Position the power steering pump and install the front
retaining bolts.

Tighten the bolts to 25 Nm (18 lb.ft).

2. Install the power steering pump rear retaining bolts.

Tighten the bolts to 25 Nm (18 lb.ft).

3. C onnect the high pressure power steering line to the power

steering pump.

Install a new O-ring seal.

Tighten the union to 25 Nm (18 lb.ft).

4. C onnect the low pressure line to the power steering pump.

C lean the component mating faces.

Install a new O-ring seal.

Tighten the bolt to 25 Nm (18 lb.ft).

5. Install the power steering line support bracket.

6. Install the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05B Accessor Drive - V8 4.4L Petrol, Removal and
Installation).
7. Install the splash shield.
8. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
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Batter and C harging S stem - General Information,
Specifications).
. Fill and bleed the power steering s stem.
For additional information, refer to: Power Steering S stem
Filling and Bleeding (211-00 Steering S stem - General
Information, General Procedures).

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P bli hed: 11-Ma -2011

Po e S ee ing - Po e S ee ing P mpTDV6 2.7L Die el, VIN Range:
SALLA000304->END OF 06MY
Remo al and In alla ion

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - 2.7L V6
- TdV6 (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
3. Remo e he cooling fan h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
4. Remo e he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
5. Remo e he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05C Acce o D i e - TDV6 2.7L Die el, Remo al and
In alla ion).

6. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

7. Remo e he LH f on heel and i e.
8. Remo e he fende pla h hield lo e im panel.

Remo e he 4 clip .

9. Remo e he f on LH fende pla h hield.

Fo addi ional info ma ion, efe o: Fende Spla h Shield
(501-02 F on End Bod Panel , Remo al and In alla ion).
10. Remo e he ppe a m and b ake line hea hield fo
acce .

Remo e he 3 n .

Remo e he 3 bol .

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. Re ea e he cha ge ai c e i e i e.

Re e he e ai i g b .

Re e he e ai i g .

. Di c ec he cha ge ai c e i e h e.

L e he c i .

. Di c ec he cha ge ai c e i e h e.

L e he c i .

. NOTE: U e S a - 10 T e Ada (T .

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FRDHM10) and Snap-on 4 inch e en ion (Tool no. FXK4) o
emo e he po e ee ing p mp ea e aining bol .

Remo e he po e ee ing p mp ea e aining bol .

Repo i ion he cha ge ai coole inle pipe o gain

acce o he po e ee ing p mp e aining bol .

1 . WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Lo e he ehicle.
1 . C AUTIONS:

If po e ee ing fl id come in o con ac i h he

pain o k, he affec ed a ea m be immedia el a hed
do n i h cold a e .

Make e he iming blade on he high-p e e pipe

nion i no damaged.

Di connec he po e ee ing high-p e e pipe nion.

Remo e and di ca d he o ealing a he .

In all blanking cap o he e po ed po .

Allo he fl id o d ain in o a con aine .

1 . C AUTION: If po e ee ing fl id come in o

con ac i h he pain o k, he affec ed a ea m be
immedia el a hed do n i h cold a e .

Di connec he po e ee ing p mp ppl ho e.

C lamp he po e ee ing p mp ppl ho e o

minimi e fl id lo .

In all blanking cap o he e po ed po .

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18. R .

R 3
.

In alla ion
1. I .

I 3
, 1/4 .

2. WARNING: D
.A
.

R .
3. NOTE: U S - 10 T A (T .
FRDHM10) S - 4 (T . FXK4)
.

T 22
N (16 . ).

R
.

T
.U
S - 10 , S - 4

S 1. M 22 N (16 . .)
(1).

S 2. A S -
(2) (1).

S 3. D 1 2.

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Step 4. Set the torque wrench to the figure arrived at in
step 3.

Tighten the power steering pump rear retaining bolt to

the torque given b the calculation.

. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Lower the vehicle.

. Tighten the power steering pump front bolts to 22 Nm (16
lb.ft).
. C onnect the power steering suppl hose.

Remove the blanking caps from the ports.

Remove the hose clamp.

. C AUTION: Make sure the timing blade on the high-

pressure pipe union is correctl seated.

C onnect the power steering high-pressure pipe union.

Remove the blanking caps from the ports.

Install new sealing washers.

Tighten the union to 25 Nm (18 lb.ft).

Remove the container.

. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise the vehicle.

. C onnect the charge air cooler inlet hose.

Tighten the clips.

. Secure the charge air cooler inlet pipe.

Install the two retaining bolts.

Install the retaining nut.

Tighten to 10 Nm (7 lb.ft).

. Install the upper arm and brake line heat shields.

Install the 3 bolts.

Install the 3 nuts.

. Install the fender splash shield lower trim panel.

Install the 4 clips.

. Install the front LH fender splash shield.

For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
. Install the wheel and tire.

. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

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Lo e he ehicle.
1 . In all he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05C Acce o D i e - TDV6 2.7L Die el, Remo al and
In alla ion).
1 . In all he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
1 . In all he cooling fan h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
1 . C heck and op- p po e ee ing fl id le el.
Fo addi ional info ma ion, efe o: Po e S ee ing S em
Filling and Bleeding (211-00 S ee ing S em - Gene al
Info ma ion, Gene al P oced e ).
20. In all he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - 2.7L V6
- TdV6 (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
21. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Po er S eering - Po er S eering P mpVIN Range: 07 MODEL YEAR-
>CURRENT
Remo al and In alla ion

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - 2.7L V6
- TdV6 (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
3. Remo e he cooling fan h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
4. Reco e he ai condi ioning (A/C ) ef ige an .
Fo addi ional info ma ion, efe o: Ai C ondi ioning (A/C )
S em Reco e , E ac a ion and C ha ging (412-00
C lima e C on ol S em - Gene al Info ma ion, Gene al
P oced e ).
5. Remo e he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
6. Remo e he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05C Acce o D i e - TDV6 2.7L Die el, Remo al and
In alla ion).

7. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

8. Remo e he LH f on heel and i e.
9. Remo e he fende pla h hield lo e im panel.

Remo e he 4 clip .

10. Remo e he f on LH fende pla h hield.

Fo addi ional info ma ion, efe o: Fende Spla h Shield
(501-02 F on End Bod Panel , Remo al and In alla ion).
11. Remo e he ppe a m and b ake line hea hield fo
acce .

Remo e he 3 n .

Remo e he 3 bol .

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. Relea e he cha ge ai coole inle pipe.

Remo e he o e aining bol .

Remo e he e aining n .

. Di connec he cha ge ai coole inle ho e.

Loo en he clip.

. Di connec he cha ge ai coole inle ho e.

Loo en he clip.

. C AUTIONS:

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Immedia el cap all ef ige an line o p e en

ing e of di and moi e.

Ca e m be aken o a oid damage o he ma ing

face .

Relea e he A/C lo p e e pipe f om he comp e o .

Remo e and di ca d he O- ing eal.

U ing a i able ie ap, ec e he A/C lo -

p e e pipe a ide.

1 . Remo e he po e ee ing p mp ea fi ing b acke

e aining bol .

Repo i ion he cha ge ai coole inle pipe o gain

acce o he po e ee ing p mp e aining bol .

1 . WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Lo e he ehicle.

1 . C AUTION: If po e ee ing fl id come in o

con ac i h he pain o k, he affec ed a ea m be
immedia el a hed do n i h cold a e .

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Di connec he high p e e line f om he po e ee ing
gea .

Remo e and di ca d he O- ing eal.

In all blanking cap o he e po ed po .

Allo he fl id o d ain in o a con aine .

1 . C AUTION: If po e ee ing fl id come in o

con ac i h he pain o k, he affec ed a ea m be
immedia el a hed do n i h cold a e .

Di connec he po e ee ing p mp ppl ho e.

C lamp he po e ee ing p mp ppl ho e o

minimi e fl id lo .

In all blanking cap o he e po ed po .

20. Remo e he po e ee ing p mp.

Remo e he 3 po e ee ing p mp f on e aining

bol .

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In alla ion
1. In all he po e ee ing p mp and b acke .

In all he 3 po e ee ing p mp f on bol and ligh l

igh en, hen back off each bol a 1/4 n.

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e he ehicle.
3. In all he po e ee ing p mp ea fi ing b acke
e aining bol .

Repo i ion he cha ge ai coole inle pipe o gain

acce o he po e ee ing p mp e aining bol .

Tigh en he bol o 25 Nm (18 lb.f ).

4. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Lo e he ehicle.
5. Tigh en po e ee ing p mp f on e aining bol o 24 Nm
(18 lb.f ).
6. C onnec he po e ee ing ppl ho e.

Remo e he blanking cap f om he po .

Remo e he ho e clamp.

7. NOTE: L b ica e he eal i h clean po e ee ing fl id.

C onnec he po e ee ing high-p e e pipe nion.

Remo e he blanking cap f om he po .

In all a ne O- ing eal.

Tigh en he To bol o 25 Nm (18 lb.f ).

Remo e he con aine .

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. C AUTION: L b ica e he ne eal i h clean

ef ige an oil.

In all he A/C lo p e e pipe o he comp e o .

Remo e he blanking cap f om he po .

In all a ne O- ing eal.

Tigh en he bol o 9 Nm (7 lb.f ).

. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e he ehicle.
. C onnec he cha ge ai coole inle ho e.

Tigh en he clip .

. Sec e he cha ge ai coole inle pipe.

In all he o e aining bol .

In all he e aining n .

Tigh en o 10 Nm (7 lb.f ).

. In all he ppe a m and b ake line hea hield .

In all he 3 bol .

In all he 3 n .

. In all he fende pla h hield lo e im panel.

In all he 4 clip .

. In all he f on LH fende pla h hield.

Fo addi ional info ma ion, efe o: Fende Spla h Shield
(501-02 F on End Bod Panel , Remo al and In alla ion).
. In all he heel and i e.

. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Lo e he ehicle.
. In all he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05C Acce o D i e - TDV6 2.7L Die el, Remo al and
In alla ion).
. In all he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
. Recha ge he A/C em
Fo addi ional info ma ion, efe o: Ai C ondi ioning (A/C )
S em Reco e , E ac a ion and C ha ging (412-00
C lima e C on ol S em - Gene al Info ma ion, Gene al
P oced e ).
. In all he cooling fan h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
. C heck and op- p po e ee ing fl id le el.
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For additional information, refer to: Power Steering S stem
Filling and Bleeding (211-00 Steering S stem - General
Information, General Procedures).
. Install the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Po er Steering - Steering Angle Sensor
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the driver side closing trim panel.

Release the clip.

Remove the 2 screws.

Disconnect the electrical connector.

3. Disconnect the steering angle sensor electrical

connector.

4. Disconnect the steering column intermediate shaft from

the steering column.

Note the fitted position.

Remove the special bolt and discard the nut.

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5. Remo e he ee ing angle en o .

Remo e he 3 To c e .

In alla ion
1. In all he ee ing angle en o .

Tigh en he To c e o 3 Nm (2 lb.f ).

2. C onnec he ee ing col mn in e media e haf .

In all he pecial bol and igh en he ne n o 22 Nm

(16 lb.f ).

3. C onnec he ee ing angle en o elec ical connec o .

4. In all he clo ing im panel.

C onnec he elec ical connec o .

Sec e he clip.

Tigh en he c e .

5. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
6. Ini ia e a ne ee ing angle en o ing T4.

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Po e S ee ing - Po e S ee ing P mp o S ee ing Gea P e e Line
Removal and Installation

Remo al
1. Raise and support the vehicle.
2. Remove the front RH splash shield.

Remove the 4 clips.

3. Remove the front LH fender splash shield.

For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
4. Remove the radiator access panel.

Remove the 4 bolts.

5. C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the high pressure line from the power steering

pump.

Loosen and release the power steering pump line.

Allow the fluid to drain into a container.

Remove and discard the 2 sealing washers.

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. Relea e he po e ee ing line ppo b acke .

Remo e he n .

Relea e he ho e.

. Di connec he high p e e line f om he po e

ee ing gea .

Remo e he bol .

Relea e he po e ee ing gea line.

Remo e and di ca d he O- ing eal.

. Remo e he ee ing gea high-p e e line.

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In alla ion
1. Install the steering gear high-pressure line.
2. C onnect the high-pressure line to the power steering gear.

Install the O-ring seal.

Attach the power steering gear high-pressure line.

Tighten the bolt to 25 Nm (18 lb.ft).

3. Install the power steering line support bracket.

Tighten the nut to 10 Nm (7 lb.ft).

Secure the hose with the clip.

4. C AUTION: Alwa s plug an open connections to

prevent contamination.

C onnect the high-pressure line to the power steering pump.

Install new sealing washers.

C onnect the power steering pump high-pressure line.

5. Install the radiator access panel.

Tighten the bolts to 10 Nm (7 lb.ft).

6. Install the front LH fender splash shield.

For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
7. Install the front RH splash shield.

Secure with the clips.

8. Fill and bleed the power steering s stem.

For additional information, refer to: Power Steering S stem
Filling and Bleeding (211-00 Steering S stem - General
Information, General Procedures).

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Steering Linkage -
Torque Specif ications
Description Nm lb-ft
* Tie-rod end nut - Vehicles fitted with an M12 nut 76 56
* Tie-rod end nut - Vehicles fitted with an M14 nut 150 111
Tie-rod locking nut 55 40
Road wheel nuts 140 103
* Ne nut must be installed

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S eering Linkage - S eering Linkage
De c ip ion and Ope a ion

S ee ing Linkage C omponen Loca ion

I em Pa N mbe De c ip ion
1 - S ee ing gea
2 - S ee ing gea boo
3 - Tie od
4 - Lockn
5 - Tie od end
6 - Ball join
7 - Self-locking n

GENERAL

The ee ing linkage comp i e he ie od hich p o ide he connec ion be een he ee ing gea and he f on
heel kn ckle.

Each end of he ee ing gea ha a h eaded hole hich p o ide fo he fi men of he ie od . The e e nal end of
he ie od a e ealed i h ee ing gea boo o p e en he ing e of di and moi e in o he ee ing gea .

The o e end of he ie od a e h eaded o allo he fi men of he ie od end . The ie od end a e c e ed on o

he ie od and locked i h lockn o p e en inad e en mo emen . The h ead on he ie od allo he po i ion
of he ie od end o be adj ed in o de o e he co ec oe angle fo each f on heel.

The ie od end comp i e a fo ged ho ing i h a h eaded bo e fo a achmen o he ie od. The ie od end
inco po a e a non- e iceable ape ed ball join hich loca e in a ape ed hole in he f on heel kn ckle and i
ec ed i h a elf-locking n . The ball join ha an in e nal he agonal d i e hich enable he join o be held
a iona hen he elf-locking n i igh ened.

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Steering Linkage - Tie Rod End
Removal and Installation

Special Tool(s)
Ball joint separator

205-754 (LRT-54-027)

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the front wheel.
3. Loosen the tie rod end ball joint retaining nut.
4. Loosen the tie rod end lock nut.
5. Using the special tool, release the tie-rod end ball joint
from the wheel knuckle.

Remove and discard the tie rod end retaining nut.

6. Remove the tie-rod end, note the number of turns for

installation.

Installation
1. Install the tie rod end, note the number of turns until
adjacent to the locknut.

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. C AUTION: To prevent damage to the tie rods, use an

additional wrench when loosening or tightening the
components.

C onnect the tie rod end ball joint.

C lean the component mating faces.

For vehicles fitted with an M12 nut, install a new nut

and tighten to 76 Nm (56 lb.ft).

For vehicles fitted with an M14 nut, install a new nut

and tighten to 150 Nm (111 lb.ft).

. Tighten the tie rod locking nut.

C lean the component mating faces.

Tighten the nut to 55 Nm (40 lb.ft).

. Install the front wheel.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

. Lower the vehicle.

. Using onl four wheel alignment equipment approved b
Land Rover, check and adjust the wheel alignment.

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Steering Linkage - Steering Gear Boot
Removal and Installation

Remo al
1. Remove the tie-rod end.
For additional information, refer to: Tie Rod End (211-03
Steering Linkage, Removal and Installation).
2. NOTE: Note the fitted position.

Remove the locknut.

3. Remove the steering gear boot.

Release the 2 clips.

Installation
1. Install the steering gear boot.

C lean the component mating faces.

Secure with the clips.

2. Install the locknut.

3. Install the tie-rod end.
For additional information, refer to: Tie Rod End (211-03
Steering Linkage, Removal and Installation).

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Steering Linkage - Tie Rod
Removal and Installation

Special Tool(s)
Ball joint separator

205-754(LRT-54-027)

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the front wheel.
3. Loosen the outer tie-rod end ball joint retaining nut.
4. Loosen the outer tie-rod end lock nut.
5. Using the special tool, release the tie-rod end ball joint
from the wheel knuckle.

Remove and discard the tie rod end retaining nut.

6. Remove the outer tie-rod end, note the number of turns

for installation.

7. Remove the outer tie-rod end lock nut.

8. Remove the steering gear boot.

Release the 2 clips.

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9. Remo e he inne ie- od end.

Loo en he n .

In alla ion
1. In all he inne ie- od end.

Tigh en he n o 100 Nm (74 lb.f ).

2. In all he ee ing gea boo .

Sec e i h he clip .

3. In all he o e ie- od end lock n .

4. In all he ie od end, no e he n mbe of n n il
adjacen o he lockn .

5. C AUTION: To p e en damage o he ie od , e an
addi ional ench hen loo ening o igh ening he
componen .

C onnec he ie- od end ball join .

C lean he componen ma ing face .

Fo ehicle fi ed i h an M12 n , in all a ne n

and igh en o 76 Nm (56 lb.f ).

Fo ehicle fi ed i h an M14 n , in all a ne n

and igh en o 150 Nm (111 lb.f ).

6. Tigh en he ie- od locking n .

C lean he componen ma ing face .

Tigh en he n o 55 Nm (40 lb.f ).

7. In all he f on heel.

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Tighten the wheel nuts to 140 Nm (103 lb.ft).

. Lower the vehicle.

. Using onl four wheel alignment equipment approved b
Land Rover, check and adjust the wheel alignment.

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Steering Column -
General Specif ication
Item Specification
Type Two piece, articulated with flexible coupling to steering rack; fitted with energy absorption system and
having a 120 mm (4.7 in) ride down capability with a 4.5 kN (0.45 ton force) maximum decoupling load
on the intermediate shaft and a 77 mm (3.0 in) collapse stroke on the lower shaft.
Upper
column
adjustment:
Reach 40 mm (1.57 in)
Rake 6
Torque Specif ications
Description Nm lb-ft
Steering angle sensor Torx screws 3 2
* Steering column intermediate shaft to lower shaft bolts 30 22
* Steering column intermediate shaft to steering column nut 22 16
Steering column switch assembly Torx bolts 3 2
Steering wheel bolt 63 46
* Ne bolts/nut must be installed

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S eering Col mn - S eering Col mn
Description and Operation

STEERING COLUMN COMPONENT LOCATION

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I em Pa N mbe De c ip ion
1 - Sc e (3 off)
2 - S ee ing angle en o
3 - Uppe ee ing col mn a embl - Man al
4 - Uppe ee ing col mn a embl - Elec ic
5 - C o l in e
6 - Uppe co l
7 - C ol mn lock a embl
8 - M l if nc ion col mn i ch
9 - S ee ing heel
10 - Bol
11 - D i e ai bag
12 - Lo e co l
13 - C ol mn adj men i ch (Elec ic col mn onl )
14 - Sc e , elf- apping (3 off)
15 - C ol mn lock hea bol (2 off)
16 - Bol , h ead fo ming (2 off)
17 - Bol , h ead fo ming (2 off)
18 - C am bol
19 - Self-locking n
20 - In e media e haf
21 - C ol mn eal - b lkhead
22 - C o e eal - econda b lkhead
23 - Sc e
24 - Lo e collap ible haf
25 - Bol - To - Lo e collap ible haf oke

OVERVIEW

The ee ing col mn comp i e he ppe col mn a embl , he in e media e haf and he lo e collap ible haf . The h ee
componen a e po i i el connec ed oge he o pa d i e o a inp f om he ee ing heel o a linea o p of he
ee ing ack.

The ppe ee ing col mn a embl i adj able fo ee ing heel each and ake and p o ide he loca ion fo he
igni ion i ch, he igni ion lock ba el, he ee ing lock mechani m and he ee ing angle en o . C ol mn adj men i
ob ained ei he man all o elec icall , dependan on col mn a ian fi ed.

MANUAL UPPER COLUMN ASSEMBL

Man al S ee ing C ol mn C omponen La o

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I em Pa N mbe De c ip ion
A - C a h S oke 120.00 mm (4.72 in)
1 - A achmen hole
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2 - Roof b acke
3 - Sc e
4 - Loca ing hook
5 - 'U' b acke
6 - S ee ing heel pline
7 - Lock a embl
8 - C am pla e
9 - C lamp pla e a embl
10 - Adj men le e
11 - B ake pad
12 - Le e n
13 - Le e bol
14 - Shea ing cap le (2 off)
15 - C lamp pla e a embl
16 - Adj men balance p ing (2 off)
17 - Main bod
18 - S ap (2 off)
19 - S ee ing angle en o
20 - Pi o pin
21 - Pi o ho ing
22 - Spide
23 - B h
24 - P e e a he (2 off)
25 - Uppe haf
26 - Uppe bea ing
27 - Tole ance ing
28 - Lock colla
29 - Middle bea ing
30 - Sp ing
31 - Sp ing a he
32 - Lo e haf
33 - Re aining ing
34 - Uni e al join eal
35 - S ing oke
36 - D i ing colla
The ee ing col mn i a ached o he in- ehicle c o beam and ec ed i h fo , 8 mm h ead fo ming, pan head To
d i e c e . The o fo a d a achmen c e a e fi ed h o gh he col mn mo n ing b acke , he o ea a d
mo n ing c e al o pa h o gh he hea ing cap le . In he e en of a high ene g f on al impac , he hea ing
cap le emain fi ed o he c o beam, b he 'U' b acke ( i h he main bod ) di engage f om he cap le , allo ing he
col mn o ho en a iall (collap e), i h he coiled ap ab o bing ene g o ed ce occ pan loading.

WARNING: Take ca e hen handling he col mn no o ap finge if elea ing he adj men le e a an poin d ing
he emo al p oced e hen he col mn i no in he ehicle. The balance p ing ill ca e he col mn o apidl mo e o
i pmo po i ion.

The col mn comp i e a ca magne i m oof b acke hich i a ached o he in- ehicle c o beam. A ached o he oof
b acke a e a pi o ho ing, a 'U' b acke , ppe and lo e haf and a main bod . The oof b acke ha o hook hich
loca e in lo in he in- ehicle c o beam. The hook a i in ppo ing he eigh of he col mn d ing emo al o
in alla ion.

The pi o ho ing i a ached o he fo a d end of he oof b acke ih o pi o pin . The pi o ho ing allo fo
adj men of he col mn ake and con ain a bea ing hich ppo he col mn lo e haf .

The 'U' b acke i a ached o he oof b acke b a c e , b h and pla ic a he a embl ( hi d fi ing) loca ed in a lo in
he op of he oof b acke . When he col mn i a embled in o he ehicle, he hea ing cap le , hich a e a ached o he
'U' b acke , a e clamped p again he oof b acke b he fi ing c e , p e en ing mo emen of he 'U' b acke . The bol
al o pa h o gh ec ang la ec ion eel ap , hich a one end, ha e coil ha loca e a o nd a pla ic b h (po i ioned
on he hea ing cap le). The ap a e ed o con ol he a e of col mn collap e, in he e en of a high ene g f on al
impac .

The main bod i po i ioned in he 'U' b acke ia he le e bol . The bol i cap i e i hin he e ical lo in he 'U' b acke
and he ho i on al lo in he main bod . The bol al o pa e h o gh he clamp pla e a emblie (one on ei he ide of he
'U' b acke ). The bod ho e he middle and ppe bea ing h o gh hich he ppe haf i loca ed. T o off e hole in
he main bod p o ide fo he a achmen of he col mn lock a embl .

The ppe and lo e haf a e loca ed h o gh he leng h of he col mn a embl . The ppe haf i ppo ed in o
bea ing in he main bod and he lo e haf i loca ed in he ppe haf and ppo ed in a bea ing in he pi o ho ing.
The lo e haf ha a b la ec ion i h e e nal pline . The e ma e i h he in e nal pline in he ppe haf . The
p po e of he pline i o an mi o a ional mo emen of he ppe haf o he lo e haf , b allo ing he o
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components to telescope into each other in the event of a collision. The length of the splined sections allow for 120 mm
(4.72 in) of linear movement. The lower shaft is fitted with a universal joint spider to which a swivel yoke is attached. The
swivel yoke attaches to the intermediate shaft of the steering column on the interior side of the bulkhead using a special
cam bolt and self-locking nut.

A steering angle sensor is attached to the pivot housing of the column and its centre gear is rotated by a drive collar which
is attached to the lower shaft and rotates with movement of the steering wheel. The sensor transmits steering angle data on
the high speed C AN bus which is used by various systems on the vehicle. The steering angle sensor is designed to become
detached from the column in the event of a frontal impact. C are must be taken when handling the column assembly to
prevent accidental damage to the sensor.
For additional information, refer to: Anti-Lock C ontrol - Traction C ontrol (206-09A, Description and Operation).

The upper shaft is fitted with a locking collar which engages with the lock bolt of the column lock assembly. The locking
collar is retained by a tolerance ring on the shaft. The tolerance ring allows a specified amount of force to be applied to the
shaft before it slips, preventing damage to the column lock if excessive torque is applied to the steering wheel. The
tolerance ring is designed to slip on the upper shaft when an applied torque exceeds its fitted slip load of 200Nm minimum.
Following rotation, the torque to rotate the lock collar should exceed 100Nm.

The steering column is adjustable for reach and rake. The column can be adjusted for 40 mm (1.57 in) of reach adjustment
and 6 of rake adjustment. The adjustment mechanism comprises an adjustment lever, a cam plate, a lever bolt and nut,
two brake pads and two clamp plate assemblies.

A plastic adjustment lever is located on the underside of the column assembly and is attached to a cam plate. When the
lever is pulled downwards, the cam plate rotates and releases tension in the lever bolt. The lever bolt also passes through
two sets of clamp plate assemblies. When the lever is moved upwards, the cam plate rotates applying tension to the lever
bolt, which applies pressure to the brake pads which in turn apply pressure to the clamp plate assemblies (which lock the
column in the desired position). The lever bolt is retained by a self-locking lever nut, which abuts a thrust bearing.

WARNING: Under no circumstances should the lever nut torque be reduced, as this will reduce the clamping efficiency
of the adjustment mechanism possibly affecting the stability of the column during a frontal impact.

The pivot housing is attached to the roof bracket with two pivot pins. When the rake adjustment is operated, the pivot
housing rotates around the pivot pins to allow for the up and down adjustment, but maintains a positive location to the roof
bracket. An adjustment spring is fitted between the 'U' bracket and the main body, to counteract the weight of the main
body, upper shaft, steering wheel and airbag, preventing the steering wheel from dropping rapidly when the adjustment
lever is released.

In the event of a high energy frontal impact, the upper column assembly is designed to axially collapse reducing impact
injury to the driver. A number of components interact together to ensure that the collapse of the column is in a controlled
manner. The following components control the column collapse:

Pressure washer and bush (third fixing)

Shearing capsules
Straps
Upper and lower shaft (splined) connection.

The shearing capsules have a central hole through which the rearward attachment bolts pass through into the roof bracket.
The capsules are located in the 'U' bracket by tapered slots, which have small cut-outs in the inside faces. The shearing
capsules have a number of small holes which align with the cut-outs in the 'U' bracket. When the capsules are installed,
plastic is injected into the holes and cut-outs. This plastic retention of the capsules provides the initial controlled break-out
force for the column in the event of a collision. After 10 mm of displacement, the 'U' bracket is no longer located by the
shearing capsules. When handling the column, care should be taken that the shearing capsules are not impacted or
dislodged.

The tension in the 'Third Fixing' screw, applies a clamp load to the roof bracket (via the bush and compression washers). In
the event of a collision, this clamp load (supplementary to the shearing capsules) must be overcome before the column can
collapse. When this load has been exceeded (and the fixing has been displaced 20 mm (0.79 in)) it slides easily within the
roof bracket slot, providing directional control to the column, as it collapses. Under no circumstances should the screw
torque be adjusted.

The straps are rectangular section steel, which at one end, have coils that locate around a plastic bush (positioned on the
shearing capsule). The other end is formed into a hook which locates within a slot in the 'U' bracket. When a collision has
occurred, and the 'U' bracket has been displaced from the shearing capsules by 8 mm (0.3 in), the straps begin to un-roll
due to the displacement of the 'U' bracket. The straps provide the main element for energy absorption as the column
collapses. The cross section of the straps change after approximately 40 mm (1.6 in) of extension, changing the amount of
energy that they absorb.

ELECTRIC UPPER COLUMN ASSEMBL

Electric Steering C olumn C omponent Layout

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I em Pa N mbe De c ip ion
A - C rash Stroke 90.00 mm (3.54 in)
1 - Attachment hole
2 - Roof bracket
3 - Locating hook
4 - Steering heel splines
5 - Outer profile
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6 - L
7 - R
8 - R
9 - R
10 - R
11 - P
12 - E
13 - P
14 - P
15 - S
16 - N
17 - D
18 - I
19 - C
20 - R
21 - E
22 - U
23 - U
24 - L
25 - T
26 - C -
27 - F
28 -
29 - L
30 - L
31 - W
32 - R
33 - Y
34 - U
35 - S
36 - S
T .

T - ,8 , , T
.I ,
, ( ),
.

T - .A
, .T
- .T .

T , ( ).
T , 2 ,
.

T
.B .T ( ),
.T
, .T
.T
- .

A
.T
C AN .T
.C
.
F , :A -L C -T C (206-09A, D O ).

T .T
.T
,
.T
200N .F , 100N .

T .T 40.00 (1.57 )
6 .T ,
, , , .

T
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.T
.T .T ,
.

W A ,
, - ,
- .

F , .F ,
.

T .W ,
,
.

T .T
.
F , :S (501-10 S ,D O ).
T
.

I ,
.A .
T :

S
S
U ( ) .

T , A
.T .T
, , ,
.O , ,
, ,
.

WARNING: D .T .

IN E MEDIA E HAF

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I em Pa N mbe De c ip ion
1 - Alignment slot
2 - Attachment hole
3 - Seal sleeve
4 - Load limiter pins
5 - C am bolt
6 - Self-locking nut
7 - Retention spring

C AUTION: C are should be taken when handling the intermediate shaft, to ensure that it is not subject to impacts or
that the retention spring is not displaced.

The non-handed, intermediate shaft is attached at its upper end to the swivel yoke on the lower shaft of the steering column
assembly. The intermediate shaft comprises two main parts; the upper and lower axis which are joined together with a
shear joint.

The upper axis has a cut-out in the shaft which allows for the fitment of the cam bolt. Only when the shaft is located
correctly in the swivel yoke, can the cam bolt be inserted. A self-locking nut is fitted to the cam bolt. The torque applied as
the nut is tightened, rotates the bolt, forcing the cam against the shaft, positioning it correctly in the swivel yoke prior to the
joint being clamped.

NOTE: If the self-locking nut is removed for any reason, it is recommended that a new, correct nut is fitted to maintain the
optimum torque on the cam bolt.

The lower axis is fitted with a plastic molded seal sleeve which provides a suitable surface for the location of the plastic
bearings within the two bulkhead seals. The bottom of the lower axis is machined to a double 'D' shape which tapers at the
end. One side of the taper has a slot which is used to align the intermediate shaft and the lower collapsible shaft to ensure
that the correct orientation of the steering wheel to steering gear is maintained. A hole is drilled through the double 'D'
shape and provides for attachment of the intermediate shaft to the lower collapsible shaft.

The upper and lower axis, are joined together via a load limiter. The load limiter is designed to disconnect the upper and
lower axis in the event of a high energy frontal impact preventing an excessive load being applied to the steering column
(causing intrusion into the passenger compartment or an unstable airbag deployment).

The load limiter comprises two plates which are part of the upper and lower axis. The plates have a central 'guide' pin, and
two retention pins, which pass through bushes in the plates, onto which a rubber and steel washer are staked in position.
The size of the staking controls the load at which the lower axis separates from the upper axis. A wire 'retention' spring is
also fitted to the load limiter.

LO ER COLLAPSABLE SHAFT

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I em Pa N mbe De c ip ion
1 - T
2 - 'U'
3 - U
4 - F
5 - M
6 - F
7 - H
8 - B
9 - P
T
.T
.T
.T
.T 77 (3.03 ) ,
.T
- .A
.

T 'D'
.A
.A , 'D' ,
.C
,
.

T .A ' '
, .A ,
.T '
', .A ' '
( ), .T
.T
( ), 'U' ,
.

EE ING COL MN LOCK

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I em Pa N mbe De c ip ion
1 - Ignition barrel
2 - C olumn lock assembl
3 - Lock bolt
4 - Ignition switch
5 - Attachment hole
6 - Alignment mark
7 - Switch drive
8 - Barrel release hole
9 - Barrel drive
The column lock comprises a cast housing which contains the locking components. The unit is assembled and sealed with a
cover which is secured with roll pins into blind holes. The column lock is not a serviceable part and must be replaced as a
complete component. The lock has a locking bolt which moves up and down on a cam. The cam is part of a shaft which runs
through the lock and is operated b rotation of the ignition ke in the ignition barrel.

The column lock is attached to the column with two shear bolts. When the column lock is fitted to the column, the bolts are
tightened to a specified torque which shears off the heads of the bolts, preventing eas removal of the column lock.

C AUTION: Before removing the ignition switch and/or ke barrel, ensure the lock is in ke position I. Ensure that the
shaft is not rotated from this position when the ignition switch has been removed from the column lock. If the shaft is
rotated be ond ke position 0, a plunger and spring can become unseated from the lock bolt, causing incorrect operation of
the column lock. . If the plunger is not correctl located in the lock bolt, the lock is not serviceable and must be discarded.

The ignition barrel is fitted to the right hand end of the column lock. The lock is pushed into the bore and locks in position.
Removal and fitment of the barrel is achieved b inserting the ignition ke into the ke barrel and turning to position I. To
remove from the column lock, a suitable probe must be inserted through the release hole to depress the locking plunger on
the ke barrel. The ke barrel can then be pulled from the lock using the ke .

The ignition switch is fitted to the left hand end of the column lock. The ignition switch is pushed into the bore and two plastic
clips locate in slots in the lock to retain the switch. Removal of the ignition switch is achieved b ensuring that the ke is in
the ignition barrel and turned to position I, depressing the two plastic clips and pulling the switch from the lock. Before
replacing the ignition barrel, ensure that the switch is in position I (a new switch is supplied in position 0), and ensure that
the drive tangs on the lock shaft are aligned with the alignment mark on the lock casting. Push the switch into the lock and
ensure that it is full engaged on the drive tangs and the plastic clips are full located in the slots.

S eering Wheel Hea ing

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Overview

The heated steering wheel is controlled by the driver using the switch on the steering wheel. The switch is either a dual
function switch, or a separate switch depending on the feature level fitted.

Heated steering wheel switches

The heated steering wheel icon, in the switch, will illuminate as follows:

If the steering wheel heating is on, the icon will show amber,
If the steering wheel heating and headlamps are off, the icon will not illuminate,
If the steering wheel heating is off and headlamps are on, the icon will show green.

S stem Operation

Heated steering wheel, control diagram

NOTE: A = hardwired

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I em Pa N mbe De c ip ion
1 - Battery
2 - Battery junction box (fuse)
3 - Ignition switch
4 - C entral junction box (fuse)
5 - C lockspring
6 - Steering wheel heater module
7 - Steering wheel heater element
8 - Steering wheel heat sensor
9 - Steering wheel heater switches
A non-serviceable heater element is incorporated in the steering wheel which provides a uniform distribution of heat
throughout the rim of the steering wheel. A heat sensor also located in the rim of the steering wheel is monitored by the
steering wheel heater module located under the steering wheel s right-hand switch pack.

The heater element is activated when the driver operates the switch on the steering wheel. The switch provides an input to
the steering wheel heater module, which responds by supplying an output signal to the heater element. The heater module,
via signals from the heat sensor, controls the operation of the heater element to maintain a steering wheel surface
temperature of approximately 30°C (86°F).

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P bli hed: 11-Ma -2011

S eering Col mn - S eering Col mn
Remo al and In alla ion

Remo al

WARNING: Take ca e if elea ing he adj men le e hen he col mn ha been emo ed f om he ehicle.
The p ing i nde a high en ion, and if elea ed, co ld ca e pe onal inj . Make e finge a e clea f om an
a ea , likel o be apped.

C AUTION: Ai ool MUST NOT be ed on ee ing col mn bol .

All ehicle
1. F ll e end he ee ing col mn fo acce .
2. Remo e he ee ing heel.
Fo addi ional info ma ion, efe o: S ee ing Wheel (211-04
S ee ing C ol mn, Remo al and In alla ion).
3. Remo e he d i e ide egi e im panel.
Fo addi ional info ma ion, efe o: D i e Side Regi e
T im Panel (412-01 Ai Di ib ion and Fil e ing, Remo al
and In alla ion).
4. Remo e he d i e ide clo ing im panel.

Relea e he clip.

Remo e he 2 c e .

Di connec he elec ical connec o .

5. Remo e he in men panel acce panel.

Relea e he 2 clip .

6. Remo e he ee ing col mn ppe h o d.

Relea e he 6 clip .

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. Remo e he ee ing col mn lo e h o d.

Remo e he 3 To c e .

Relea e he ee ing col mn adj men le e .

. Remo e he ee ing col mn ide im panel.

Relea e he clip .

Repea he abo e p oced e fo he o he ide.

. Di connec he 2 elec ical connec o f om he ee ing

col mn m l if nc ion i che .

10. Di connec he 2 elec ical connec o f om he

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clock p ing.

. Remo e he ee ing col mn i ch a embl .

Remo e he 4 To bol .

. Remo e he ee ing col mn gai e panel.

Remo e he 2 To c e .

Relea e he 2 clip .

. Di connec he igni ion i ch elec ical connec o .

. Di connec he pa i e coil elec ical connec o .

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1 . Di connec he ee ing angle en o elec ical

connec o .

Vehicle i h elec ic ee ing col mn

1 . Di connec he ee ing col mn adj men mo o
elec ical connec o .

All ehicle
1 . Po i ion he ee ing col mn i ing ha ne a ide.

Relea e he clip.

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1 . Di connec he ee ing col mn in e media e haf f om

he ee ing col mn.

No e he fi ed po i ion.

Remo e he pecial bol and di ca d he n .

1 . WARNING: Take ca e if elea ing he adj men

le e hen he col mn ha been emo ed f om he ehicle.
The p ing i nde a high en ion, and if elea ed, co ld
ca e pe onal inj . Make e finge a e clea f om an
a ea , likel o be apped.

C AUTION: If he ee ing angle en o i damaged

pon emo al of he ee ing col mn, he en o MUST be
eplaced.

Wi h a i ance, emo e he ee ing col mn.

Remo e he 4 To bol .

20. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he igni ion i ch a embl .

Remo e and di ca d he 2 hea bol .

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21. Re e he ee i g a g e e .

Re e he 3 T c e .

In alla ion
Vehic e i h e ec ic ee i g c

1. C AUTION: The e i e e adj e a e

a e i e f each ee i g c . Fai e e e he
c ec c de d i g ca ib a i a e i da age he
ehic e.

N e he e i e e he adeci a c de he e
ee i g c abe f f e efe e ce.

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A
.I .

T T 3N (2.2 . ).

.I .

T .

. C AUTIONS:

M .

T
3 .

A MUST NOT .

W , .

T 25 N (18 . ).

.C .

I 22 N
(16 . ).

.S .

V
.C
.

A
.C .
.C .
.C .
.I .

S .

T T .

.I .

T T 3N (2 . ).
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. C onnect the clockspring and multifunction switch electrical

connectors.
. Install the steering column side trim panels.

Secure with the clips.

. Install the steering column shrouds.

. Install the instrument panel access panel.

Secure with the clips.

. Install the closing trim panel.

C onnect the electrical connector.

Secure the clip.

Tighten the screws.

. Install the steering wheel.

For additional information, refer to: Steering Wheel (211-04
Steering C olumn, Removal and Installation).
. Install the driver side register trim panel.
For additional information, refer to: Driver Side Register
Trim Panel (412-01 Air Distribution and Filtering, Removal
and Installation).
. C alibrate the steering angle sensor using the Land Rover
approved diagnostic tool.

Vehicles with electric steering column

. If a new electric steering column is fitted re-calibrate the
steering column potentiometer using the Land Rover
approved diagnostic s stem.

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Published: 11-Ma -2011

S eering Col mn - S eering Col mn Shaf
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the driver side closing trim panel.

Release the clip.

Remove the 2 screws.

Disconnect the electrical connector.

3. Disconnect the steering column intermediate shaft from

the steering column.

Note the fitted position.

Remove the special bolt and discard the nut.

4. Disconnect the steering column intermediate shaft from

the lower shaft.

Note the fitted position.

Remove and discard the bolt.

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5. Remove the steering column intermediate shaft.

Release the 2 grommets.

6. NOTE: Do not disassemble further if the component is

removed for access only.

NOTE: Note the fitted position.

Remove the 2 intermediate shaft grommets.

In alla ion
1. Install the steering column intermediate shaft.

Install the grommets.

2. C onnect the steering column intermediate shaft to the lower

shaft.

Tighten the new bolt to 25 Nm (18 lb.ft).

3. C onnect the steering column intermediate shaft to the

steering column.

Install the special bolt and tighten the new nut to 22 Nm

(16 lb.ft).

4. Install the driver side closing trim panel.

C onnect the electrical connector.

Secure the clip.

Tighten the screws.

5. C onnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

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S eering Col mn - S eering Col mn Lo er Shaf
Removal and Installation

Remo al

C AUTION: Do not turn the steering wheel with the steering column lower shaft disconnected as damage to the
clockspring and steering wheel switches may occur.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Turn the steering wheel to the straight ahead position.
3. C AUTIONS:

Make sure the steering wheel is in the straight ahead

position.

Do not turn the steering wheel with the steering

column lower shaft disconnected as damage to the
clockspring and steering wheel switches may occur.

NOTE: Note the fitted position.

Remove and discard the steering column lower shaft

upper bolt.

4. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

5. C AUTION: Make sure that the brake hose and the

wiring harnesses are not damaged during the removal and
installation of the heat shields.

Remove the upper suspension arm heat shield for access.

Remove the 3 nuts.

6. C AUTION: Do not turn the steering wheel with the

steering column lower shaft disconnected as damage to the
clockspring and steering wheel switches may occur.

Disconnect the steering column lower shaft from the

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intermediate shaft.
7. Remove the fender splash shield lower trim.

Remove the 4 clips.

8. C AUTION: Make sure that the steering is correctl

positioned using the road wheels. Do not turn the steering
wheel. Failure to follow this instruction m result in damage to
the vehicle.

Turn the steering until access can be gained to the steering

column lower shaft bolt.

9. C AUTION: Do not turn the steering wheel with the

steering column lower shaft disconnected as damage to the
clockspring and steering wheel switches ma occur.

Remove and discard the steering column lower shaft bolt.

10. Remove the steering column lower shaft.

Disconnect the steering column lower shaft from the

steering gear.

In alla ion
1. C lean the component mating faces.

2. C AUTION: Make sure that the road wheels are in the

straight ahead position.

Install the steering column lower shaft.

C onnect the steering column lower shaft to the steering

gear.

C onnect the steering column intermediate shaft to the

lower shaft.

3. Lower the vehicle on the lift.

4. C AUTION: Make sure that a new bolt is installed.

Install the steering column lower shaft upper bolt.

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Install a new bolt and tighten to 30 Nm (22 lb.ft).

. Raise the vehicle on the lift.

. C AUTIONS:

Do not turn the steering wheel with the steering column

lower shaft disconnected as damage to the clockspring and
steering wheel switches ma occur.

Make sure that the steering is correctl positioned using

the road wheels. Do not turn the steering wheel. Failure to
follow this instruction m result in damage to the vehicle.

Turn the steering until access can be gained to the steering

column lower shaft bolt.
. Install the steering column lower shaft to steering gear bolt.

Install a new bolt and tighten to 30 Nm (22 lb.ft).

. Install the fender splash shield lower trim.

Install the 4 clips.

. Install the upper suspension arm heat shield.

Install the 3 nuts.

10. Lower the vehicle on the lift.

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S eering Col mn - S eering Wheel
Removal and Installation

Remo al
1. Remove the driver air bag module.
For additional information, refer to: Driver Air Bag Module
(501-20B Supplemental Restraint System, Removal and
Installation).

2. C AUTION: If the steering wheel timing marks were

not aligned prior to the steering wheel being removed, they
must be aligned on assembly and the steering angle sensor
must be calibrated using the approved Land Rover
diagnostic equipment and a four wheel alignment check
must also be carried out. Failure to follow this instruction
may result in damage to the vehicle.

C heck that the steering wheel is correctly aligned prior to

the steering wheel being removed.

3. C AUTION: Make sure the wheels are in the straight-

ahead position. Failure to follow this instruction may result
in damage to the components.

NOTE: Note the steering wheel to column alignment

marks.

Remove the steering wheel.

Restrain the steering wheel and remove the bolt.

Disconnect the steering wheel switch electrical

connector.

4. NOTE: Do not disassemble further if the component is

removed for access only.

Remove the steering wheel switch.

Remove the 2 Torx screws.

Disconnect the electrical connector.

Repeat the above procedure for the other side.

5. Remove the steering wheel cover.

Release the 4 clips.

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6. Re e he i i g ha e .

In alla ion
1. A ach he i i g ha e .
2. I a he ee i g hee c e .

Sec e i h he c i .

3. I a he ee i g hee i ch.

C ec he e ec ica c ec .

Tigh e he T c e .

Re ea he ab e ced e f he he ide.

4. C AUTION: If he ee i g hee i i g a e e
a ig ed i he ee i g hee bei g e ed, he
be a ig ed a e b a d he ee i g a g e e
be ca ib a ed i g he a ed La d R e
diag ic e i e a daf hee a ig e chec
a be ca ied . Fai e f hi i ci
a e i da age he ehic e.

C ec a ig he ee i g hee he ee i g c .

5. C AUTION: C ec c c i g a ig e ca be f d
b ie i g a e a e h gh he i d i a ed
he c c i g face. If he a e i i ib e, ca ef
he c c i g. If he i gf ce i c ea e bef e he
a e i i ib e, e e e he di ec i a id c e
da age.

C a ef i a he ee i g hee , e gage he c c i g
a d a ig he c .

Tigh e he b 63 N (46 b.f ).

6. I a he d i e ai bag d e.
F addi i a i f a i , efe : D i e Ai Bag M d e
(501-20B S e e a Re ai S e , Re a a d
I a a i ).

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Steering Column S itches -
Torque Specif ications
Description Nm lb-ft
Steering column s itch Tor scre s 3 2

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Steering Column Switches - Steering Column Switches
Description and Operation

The steering column switches comprise the steering column multifunction switch and the ignition switch. Both switches
are located on the steering column assembl .

STEERING COLUMN MULTIFUNCTION SWITCH

I em Pa N mbe De c ip ion
1 - Turn signal indicator switch assembl
2 - Screw (2 off)
3 - C ase
4 - Screw (2 off)
5 - Windshield wiper switch assembl
6 - C lockspring
7 - Screw (4 off)
The steering column multifunction switch comprises a case which houses a turn signal indicator switch assembl , a
windshield wiper switch assembl and a clockspring. The multifunction switch is located behind the steering wheel and
is secured with two screws at the top to the steering column assembl and two screws at the bottom to the column
lock housing.

The clockspring is located in the front of the case and retained with four screws. The clockspring engages in slots in
the steering wheel boss and turns with the rotation of the steering wheel. The clockspring incorporates a tang which
cancels the turn signal indicators when the steering wheel is rotated.
For additional information, refer to: Air Bag and Safet Belt Pretensioner Supplemental Restraint S stem (SRS) (501-
20B Supplemental Restraint S stem, Description and Operation).

Turn Signal Indicator Switch Assembl

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I em Pa
N mbe De c ip ion
1 - High bea
2 - Righ ha d i dica
3 - Head a fa h
4 - Lef ha d i dica
5 - C e f ci b
The ig a i dica i ch a e b i ca ed i he ef ha d ide f he ca e a d i e ai ed i he ca e ih
c e . The i ch i c ec ed he ai ha e ia a c ec he bac f he i ch. The i ch
c he f i gf ci :

Lef / igh ig a e ai
High / bea e ai
Head a fa h
C e f ci e ec i (if fi ed).

Turn Signal Indicators

The ig a i dica a e e a ed b hi g he i ch f igh ha d i dica a dd f ef ha d

i dica . The i ch ha a de e ii hich c he i ch i he e ec ed ii i i i ed he
ce a ff i i . The i ch a ha a ' a e cha ge' f c i hich a he i ch be e a ed i h
i g h gh he de e f e he cha gi g a e a he e a i g. Whe e ea ed f he
' a e cha ge' i i , he i ch i a a ica e ed he ce a ff i i . The ef a d igh ha d
ig a i dica i ch ii a e c ec ed e a ae i e he C e a J c i B (C JB) a d he i ch.
Whe a i ch ii e ec i i ade, a ci c i i c e ed f he C JB g d, ia he e ec ed i ch
i i . The C JB de ec he c e ed ci c i a d e a e he e ec ed ig a i dica i he i ch i
ed he ce a ff i i . The ig a i dica ca be ca ce ed ei he a a b he d i e
a a ica he he ee i g hee i a ed he aigh ahead ii .

High/Lo Beam and Headlamp Flash

High bea i e a ed b hi g he i ch f a d . The i ch i a ched i hi ii a d he high bea i

ac i e i he i ch i a a ed ea a d . The head a fa hf c i i e a ed b i g he i ch
ea a d . The i ch c ac c e e a ci c i a d he head a a e ac i a ed f a g a he i ch i
e a ed. The i ch i - a chi g i hi ii a d he head a fa hi i ched ff he he i ch i e ea ed
a di e i ff i i . The high bea a d head a fa h ii a e c ec ed e a ae i e he
C JB a d g d. Whe a i ch e ec i i ade, a ci c i i c e ed f he C JB g d ia he i ch
c ac .

Computer Function Button (if fitted)

Thi b i fi ed ehic e i h a high ecifica i i e c e . The c e f ci b i

ca ed he e d f he i ch a . The b i a e a i ch a d a he d i e e ec he f i g
i f ai i he i e c e e age ce e :

T i di a ce
Di a ce f e e ai i g i he f e a
F e a e ai i g a i
A e age f e c i
Vehic e ife f e c i
A e age eed
I a a e f e c i .

The b i c ec ed he i e c e a dg d. Whe he b i e ed he ci c i i c e ed a d
he i e c e di a he e i c e i f a i . Re ea ed e e f he b e ec each

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di pla in he me age cen e in n.
Fo addi ional info ma ion, efe o: Info ma ion and Me age C en e (413-08 Info ma ion and Me age C en e ,
De c ip ion and Ope a ion).

Windshield Wiper Switch Assembl

I em Pa N mbe De c ip ion
1 - In e mi en po i ion
2 - Slo peed
3 - Fa peed
A - Flick ipe
B - Rea a h/ ipe
C - Wa h ipe
D - In e mi en dela (6 po i ion )
The ind hield ipe i ch a embl i loca ed on he igh hand ide of he ca e and i e ained in he ca e i h o
c e . The i ch i connec ed o he main ha ne ia a connec o a he back of he i ch. The i ch con ol he
follo ing f nc ion :

Wind hield ipe in e mi en , lo and fa peed

Wind hield ipe flick ipe
Wind hield a h/ ipe
Rea a h/ ipe
In e mi en dela elec ion.

Fo addi ional info ma ion, efe o: Wipe and Wa he (501-16 Wipe and Wa he , De c ip ion and Ope a ion).

Windshield Wiper Switch Operation

The ind hield ipe f nc ion a e ope a ed b mo ing he i ch p o do n. Flick ipe i elec ed b p hing he
i ch do n. The i ch i non-la ching in hi po i ion and ipe ope a ion i opped hen he i ch i elea ed and
i e n o he off po i ion. The flick ipe i ch con ac i connec ed on a ingle i e o he C JB and g o nd. Thi i
he ame connec ion o he C JB a he fa peed ipe. When he i ch i ope a ed he ci c i i comple ed be een
he C JB and g o nd. The C JB de ec he comple ed ci c i and ope a e he ipe fo a long a he i ch con ac
i made.

In e mi en i elec ed b p hing he ipe i ch p, o he de en po i ion, he ipe ope a e a he dela pe iod

elec ed on he o a i ch on he ipe alk. The ipe emain in he in e mi en mode n il he ipe i ch i
mo ed o he off o lo /fa peed po i ion . The in e mi en i ch con ac i connec ed be een he C JB and
g o nd. When he i ch i mo ed o he in e mi en po i ion he ci c i i comple ed. The C JB de ec he comple ed
ci c i and ope a e he ipe in he in e mi en dela elec ed fo a long a he i ch con ac i made.

The in e mi en dela pe iod i elec ed ing a o a con ol on he ipe i ch alk. The o a con ol allo he
d i e o elec i dela pe iod o i he p e ailing ea he condi ion . The o a con ol i connec ed on h ee
i e o he C JB and a ingle i e o g o nd. The i po i ion each e a diffe en combina ion of he h ee i e .
The C JB de ec , ia he h ee i e , hich elec ion ha been made and ope a e he ipe i h he app op ia e
dela .

Slo peed ope a ion i elec ed b p hing he ipe i ch p, o he econd de en po i ion. The ipe ope a e a
lo peed n il he ipe i ch i mo ed o he off, in e mi en o fa peed po i ion . The lo peed i ch
con ac i connec ed be een he C JB and g o nd. When he i ch i mo ed o he lo peed po i ion he ci c i i
comple ed. The C JB de ec he comple ed ci c i and ope a e he ipe a lo peed fo a long a he i ch
con ac i made.

Fa peed ope a ion i elec ed b p hing he ipe i ch p, o he hi d de en po i ion. The ipe ope a e a
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fa eed i he i e i ch i ed he ff, i e i e eed ii . The fa eed i ch
c ac i c ec ed be ee he C JB a d g d. Whe he i ch i ed he fa eed ii he ci c i i
c e ed. The C JB de ec he c e ed ci c i a d e a e he i e a fa eed f a g a he i ch
c ac i ade.

Rear Wash/Wipe S itch Operation

The ea a h/ i e f c i a e e a ed b i g he i ch ea a d . Rea i e i e ec ed b i g he
i e i ch ea a d he fi de e i i . The ea i e i ch i c ec ed be ee he C JB a d g d.
Whe he i ch i ed he ea i e ii he ci c i i c e ed. The C JB de ec he c e ed ci c i
a d e a e he ea i e f a g a he i ch c ac i ade.

The ea a he i e ec ed b i g he i e i ch ea a d he ec d, - a chi g i i . Whe he

i ch i ed hi ii a ci c i i c e ed be ee he C JB a d g d. The C JB de ec he c e ed
ci c i a d e a e he ea a he f a g a he i ch c ac i ade.

IGNITION SWITCH

I em PaN mbe De c ip ion

1 - Ke ba e
2 - C c
3 - L c i g ab
4 - Ig i i i ch
5 - Ha e c ec
6 - D i e haf ca i
7 - Ke i e c e id
The ig i i i ch i ca ed i he ef ha d e d f he ee i g c c a e b . The i ch i he d i he
c c ca i g ih c i g ab hich e gage i i he c c ca i g.

The i ch ha a hich ide f he ca i f he d i e haf hich a e h gh he c c . Thi

haf i a ed b he d i e he he ig i i e i ed i he e ba e . Thi ai ad i ide he
ig i i i ch hich e e ec ica c ac e ec he e i ed ig i i ii .A i g aded ba ca e
i a ea f each f he h ee ig i i i ch ii ,a i g he d i e fee he he e i ed ii i
eached.

O ehic e iha a ic a i i .a e id i ca ed he ide f he ig i i i ch. The e id, hich i

c ed a i ge i e f he a fe b c d e, e e he e f bei g e ed f he e
ba e if he a i i e ec e e i i he PARK (P) i i . The a fe b ecei e he a i i
ii a ia a e age a i ed f he a i i c d e he C AN b .

The e id, he e e gi ed, e a i hich e e he ig i i i ch e i gf he '0' ff ii .

Thi e e he e bei g e ed i he a i i i i he PARK ii .

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S ee ing Col mn S i che - S ee ing Col mn Lock and Igni ion S i ch
Ho ing
Remo al and In alla ion

Remo al

C AUTION: If he igni ion lock c linde and i ch a e bo h emo ed f om he igni ion i ch a embl , he
a embl haf MUST NOT be o a ed. Fail e o compl ill ca e he inco ec ope a ion of he lock, and he
a embl m be eplaced.

1. F ll e end he ee ing col mn fo acce .

2. Remo e he ee ing heel.
Fo addi ional info ma ion, efe o: S ee ing Wheel (211-04
S ee ing C ol mn, Remo al and In alla ion).
3. Remo e he ee ing col mn ppe h o d.

Relea e he 6 clip .

4. Remo e he ee ing col mn lo e h o d.

Remo e he 3 To c e .

Relea e he ee ing col mn adj men le e .

5. Di connec he 2 elec ical connec o f om he ee ing

col mn m l if nc ion i che .

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. Di connec he 2 elec ical connec o f om he
clock p ing.

. Remo e he ee ing col mn i ch a embl .

Remo e he 4 To bol .

. Remo e he pa i e coil.

Di connec he elec ical connec o .

Relea e he 2 clip .

. Remo e he igni ion i ch a embl .

Remo e and di ca d he 2 hea bol .

Di connec he elec ical connec o .

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. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he igni ion lock c linde .

T n he igni ion ke o po i ion 1.

In e a pin, no e ceeding 2 mm diame e , h o gh

he acce hole in he igni ion lock c linde ho ing
o dep e he pl nge , and elea e he igni ion lock
c linde .

. Remo e he igni ion i ch.

Dep e he 2 clip .

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In alla ion
1. In all he igni ion i ch.

Sec e i h he clip .

2. In all he igni ion lock c linde .

T n he igni ion ke o po i ion 1.

Loca e in o g ide and dep e he pl nge .

3. In all he pa i e coil.

Sec e he clip .

C onnec he elec ical connec o .

4. In all he igni ion i ch a embl .

Tigh en he hea bol n il he head hea off.

C onnec he elec ical connec o .

5. In all he ee ing col mn i ch a embl .

Tigh en he To bol o 3 Nm (2 lb.f ).

6. C onnec he clock p ing and m l if nc ion i ch elec ical

connec o .
7. In all he ee ing col mn h o d .
8. In all he ee ing heel.
Fo addi ional info ma ion, efe o: S ee ing Wheel (211-04
S ee ing C ol mn, Remo al and In alla ion).

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S ee ing Col mn S i che - Igni ion S i ch
Remo al and In alla ion

Remo al
1. F ll e end he ee ing col mn fo acce .
2. Remo e he ee ing col mn ppe h o d.

Relea e he 4 clip .

3. Remo e he ee ing col mn lo e h o d.

Remo e he 3 To c e .

Relea e he ee ing col mn adj men le e .

4. C AUTION: The igni ion ke m be emo ed p io

o he emo al of he igni ion i ch.

Remo e he igni ion i ch.

Di connec he elec ical connec o .

Dep e he 2 clip .

In alla ion
1. In all he igni ion i ch.

Sec e i h he clip .

C onnec he elec ical connec o .

2. In all he ee ing col mn h o d .

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Tigh en he To c e .

Sec e he clip .

Sec e he adj men le e .

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S ee ing Col mn S i che - S ee ing Col mn M l if nc ion S i ch RH
Remo al and In alla ion

Remo al
1. F ll e end he ee ing col mn fo acce .
2. Remo e he ee ing col mn ppe h o d.

Relea e he 6 clip .

3. Remo e he ee ing col mn lo e h o d.

Remo e he 3 To c e .

Relea e he ee ing col mn adj men le e .

4. Remo e he ee ing col mn m l if nc ion i ch.

Di connec he elec ical connec o .

Remo e he 2 c e .

In alla ion
1. To in all, e e e he emo al p oced e.

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S ee ing Col mn S i che - S ee ing Col mn M l if nc ion S i ch LH
Remo al and In alla ion

Remo al
1. F ll e end he ee ing col mn fo acce .
2. Remo e he ee ing col mn ppe h o d.

Relea e he 6 clip .

3. Remo e he ee ing col mn lo e h o d.

Remo e he 3 To c e .

Relea e he ee ing col mn adj men le e .

4. Remo e he ee ing col mn m l if nc ion i ch.

Di connec he elec ical connec o .

Remo e he 2 c e .

In alla ion
1. To in all, e e e he emo al p oced e.

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Engine System - General Information - EngineV6 4.0L Petrol
Diagnosis and Testing

Special Tool(s)
Oil pressure testing adaptor, 303-1166

Oil pressure testing gauge, 303-871

Principles of Operation

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step

Engine oil pressure check - 4.0l

• NOTE: Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometres), must be carried out. Do not attempt to
attain engine normal operating temperature by allowing the engine to idle.

1. 1. Disconnect the battery ground cable.

REFER to: Specifications (414-00 Battery and Charging System - General Information, Specifications).

2. • WARNINGS:

The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.

Wear protective gloves.

2. Remove the engine oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14A Electronic Engine Controls - V6 4.0L Petrol, Removal and
Installation).

3. 3. Install the special tool.

4. 4. Install the special tool gauge and tighten the union.

 5. 5. Check and top-up the engine oil if required.

6. 6. Connect the battery ground cable.

REFER to: Specifications (414-00 Battery and Charging System - General Information, Specifications).

7. 7. Start and run the engine.

8. 8. Note the oil pressure readings with the engine running at idle and 3500 RPM.
REFER to: Specifications (303-01A Engine - V6 4.0L Petrol, Specifications).

9. 9. Turn off the engine.

10. 10. Disconnect the battery ground cable.

11. 11. Remove the special tools.

1. Clean the components.

12. 12. Install the oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14A Electronic Engine Controls - V6 4.0L Petrol, Removal and
Installation).

13. 13. Check and top-up the engine oil if required.

14. 14. Connect the battery ground cable.

 Published: 11-May-2011
Engine System - General Information - EngineV8 4.4L Petrol
Diagnosis and Testing

Overview

As diagnosis of the different areas of the engine is covered in other sections and by general procedures, this section is limited to a
compression and an oil pressure test.

For specific areas of the engine, refer to the general procedures in this section and the relevant section of the manual.

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical faults.

Symptom chart
Mechanical
Engine oil level
Coolant level
Transmission fluid level
Fuel level
Coolant leaks
Oil leaks
Fuel leaks
Visibly damaged or worn parts
Loose or missing nuts or bolts
Fuel contamination/grade/quality
Sensor fitment/condition
Viscous fan and solenoid

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before carrying out
the following procedures.

Make sure that all DTCs are cleared following rectification.

Compression test

WARNING: Make sure the parking brake is applied and the gear selector is in neutral (or park for vehicles with automatic
transmission) before beginning this procedure. Failure to follow this instruction may result in personal injury.

1. 1. Remove the fuel pump relay.

2. 2. Start the engine and allow to idle.

The engine will run for a few seconds then stall

3. 3. Remove the spark plugs.

REFER to: Spark Plugs (303-07B Engine Ignition - V8 4.4L Petrol, Removal and Installation).

4. 4. Install a compression tester.

5. 5. Hold the accelerator pedal to the floor and crank the engine a minimum of five and a maximum of ten engine
revolutions and record the reading.

6. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes.

A reliable indicator of a problem is one cylinder reading lower than the others, rather than a minimum figure for all
cylinders

7. 7. Install the components in reverse order, observing the specified tightening torques.

8. 8. Check and clear any DTCs.

Oil Pressure check

 WARNING: The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.
Failure to follow this instruction may result in personal injury.

• NOTE: Before checking the oil pressure, carry out a 6 mile (10 kilometer) road test. Do not attempt to achieve normal operating
temperature by allowing the engine to idle.

1. 1. Remove the engine oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14B Electronic Engine Controls - V8 4.4L Petrol, Removal and
Installation).

2. 2. Install the special tool to the oil filter housing.

3. 3. Install the special tool gauge and tighten the union.

4. 4. Check and top-up the engine oil, if required.

5. 5. Start and run the engine.

6. 6. Note the oil pressure readings with the engine at idle and at 3,500 rpm.
REFER to: Specifications (303-01B Engine - V8 4.4L Petrol, Specifications).

7. 7. Turn off the engine.

8. 8. Remove the special tools.

9. 9. Install the oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14B Electronic Engine Controls - V8 4.4L Petrol, Removal and
Installation).

10. 10. Check and top-up the engine oil, if required.

 Published: 11-May-2011
Engine System - General Information - Engine2.7L V6 - TdV6
Diagnosis and Testing

Overview

As diagnosis of the different areas of the engine is covered in other sections and by general procedures, this section is limited to
an oil pressure test.

For specific areas of the engine, refer to the general procedures in this section and the relevant section of the manual.

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical faults.

Symptom chart
Mechanical
Engine oil level
Coolant level
Transmission fluid level
Fuel level
Coolant leaks
Oil leaks
Fuel leaks
Visibly damaged or worn parts
Loose or missing nuts or bolts
Fuel contamination/grade/quality
Sensor fitment/condition
Viscous fan and solenoid

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step.

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before carrying out
the following procedure.

Make sure that all DTCs are cleared following rectification.

Oil Pressure check

• NOTE: Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometers), must be carried out. Do not attempt to
attain engine normal operating temperature by allowing the engine to idle.

1. • WARNINGS:

The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.

Wear protective gloves.

1. Remove the oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14C Electronic Engine Controls - TDV6 2.7L Diesel, Removal and
Installation).

2. 2. Install the special tool to the oil filter housing.

3. 3. Install the special tool gauge and tighten the union.

 4. 4. Check and top-up the engine oil, if required.

5. 5. Start and run the engine.

6. 6. Note the oil pressure readings with the engine running at idle and 3500 RPM.
REFER to: Specifications (303-01C Engine - TDV6 2.7L Diesel, Specifications).

7. 7. Turn off the engine.

8. 8. Remove the special tools.

9. 9. Install the oil pressure sensor.

REFER to: Engine Oil Pressure (EOP) Sensor (303-14C Electronic Engine Controls - TDV6 2.7L Diesel, Removal and
Installation).

10. 10. Check and top-up the engine oil, if required.

 Published: 11-May-2011
Engine System - General Information - Bearing Inspection
General Procedures

1. Inspect bearings for the following defects.

1. Cratering - fatigue failure

2. Spot polishing - incorrect seating.

3. Imbedded dirt engine oil.

4. Scratching - dirty engine oil.

5. Base exposed - poor lubrication.

6. Both edges worn - journal damaged.

7. One edge worn - journal tapered or bearing not seated.

 Published: 11-May-2011
Engine System - General Information - Camshaft Bearing Journal Clearance
General Procedures

1. NOTE: Make sure that the following stages are followed exactly.
The tappets or followers must be removed to carry out this
measurement.

• NOTE: Make sure that the camshaft is to specification.

• NOTE: The bearing caps and journals should be free from engine oil
and dirt.

Position on a length of plastigage on the bearing cap.

Insert the camshaft, without lubrication, into the cylinder

head.

Position a plastigage strip, which should be equal to the width

of the bearing cap, on the bearing journal.

2. Install the camshaft bearing caps.

Follow the relevant tightening sequence.

3. NOTE: Do not strike the bearing caps.

Remove the camshaft bearing caps.

Follow the relevant loosening sequence.

4. Using the special tool, read off the measurement.

Compare the width of plastigage with the plastigage scale.

The value that is read off is the bearing clearance.

If the values are not to specification install a new camshaft.

 Published: 11-May-2011
Engine System - General Information - Camshaft Bearing Journal Diameter
General Procedures

1. Determine the diameter of the camshaft journals.

Using a micrometer measure the diameter at 90 degrees

intervals to determine if the journals are out-of-round.

Measure at two different points on the journal to determine if

there is any tapering.

If the measurements are out of the specified range, install a

new camshaft.
 Published: 11-May-2011
Engine System - General Information - Camshaft End Play
General Procedures

1. NOTE: Make sure that the camshaft is to specification.

Using the special tool, measure the end play.

Slide the camshaft in both directions. Read and note the

maximum and minimum values on the dial indicator gauge.
1. End play = maximum value minus minimum value.

If the measurement is out of specification, install new

components.
 Published: 11-May-2011
Engine System - General Information - Camshaft Lobe Lift
General Procedures

1. Measure the diameter (1) and diameter (2) with a vernier caliper.
The difference in measurements is the lobe lift.
 Published: 11-May-2011
Engine System - General Information - Camshaft Surface Inspection
General Procedures

1. Inspect camshaft lobes for pitting or damage in the active area.

Minor pitting is acceptable outside the active area.
 Published: 11-May-2011
Engine System - General Information - Connecting Rod Cleaning
General Procedures

1. CAUTION: Do not use a caustic cleaning solution or damage

to connecting rods may occur.

Mark and separate the parts and clean with solvent. Clean the oil
passages.
 Published: 11-May-2011
Engine System - General Information - Connecting Rod Large End Bore
General Procedures

1. Measure the bearing bore in two directions. The difference is the

connecting rod bore out-of-round. Verify the out-of-round is within
specification.

2. Measure the bearing bore diameter in two directions. Verify the

bearing bore is within specification.
 Published: 11-May-2011
Engine System - General Information - Crankshaft End Play
General Procedures

1. Using the Dial Indicator Gauge with Brackets, measure the end
play.

Measure the end play by lifting the crankshaft using a lever.

If the value is out of the specification, install new thrust half

rings to take up the end float and repeat the measurement.
 Published: 11-May-2011
Engine System - General Information - Crankshaft Main Bearing Journal
Clearance
General Procedures

CAUTION: THESES PROCEDURES SHOULD NOT BE CARRIED OUT DURING THE MANUFACTURERS WARRANTY
PERIOD.

1. NOTE: Example - *PJEAL* - Crankshaft Main Journal

Diameter.

Read the grade letters from LEFT to RIGHT = FRONT to REAR of

engine eg. for this example engine, the crank journal at the front
of the engine is grade P, and at the rear is grade L.

The selection of main bearing shells is described in the

following chart.

2. NOTE: Example - *ABAA* - Crankshaft (Big End Bearing)

Crankpin Diameter

• NOTE: For vehicles built up to 2002 MY.

• NOTE: If the crankshaft main bearing carrier retaining bolts

have been marked with a center punch dot, they must be
discarded and new bolts installed.

Read the grade letters from LEFT to RIGHT = FRONT to REAR of

engine eg. for this example engine, the crankpin at the front of the
engine is grade A and at the rear is also grade A.

Grade A = 56,000 to 55,994 mm (Bearing Shell Color Code -

Blue).

Grade B = 55,994 to 55,988 mm (Bearing Shell Color Code -

Green).
 Grade C = 55,988 to 55,982 mm (Bearing Shell Color Code -
Yellow).

3. NOTE: Example - *ABAA* - Crankshaft (Big End Bearing)

Crankpin Diameter

• NOTE: For vehicles built from 2002 MY.

• NOTE: If the crankshaft main bearing carrier retaining bolts

have been marked with a center punch dot, they must be
discarded and new bolts installed.

Read the grade letters from LEFT to RIGHT = FRONT to REAR of

engine eg. for this example engine, the crankpin at the front of the
engine is grade A and at the rear is also grade A.

Grade A = 53,000 to 52,994 mm (Bearing Shell Color Code -

Blue).

Grade B = 52,994 to 52,988 mm (Bearing Shell Color Code -

Green).

Grade C = 52,988 to 52,982 mm (Bearing Shell Color Code -

Yellow).

4. NOTE: Example - *21222122* - Cylinder Bore and Piston

The cylinder bore grades read from LEFT to RIGHT as follows:

Bank 2 - Cylinder 1, Bank 2 - Cylinder 2, Bank 2 - Cylinder 3,

Bank 2 - Cylinder 4, Bank 1 - Cylinder 4,

Bank 1 - Cylinder 3, Bank 1 - Cylinder 2, Bank 1 - Cylinder 1.

(Note, in earlier publications Bank 1 was described as

A-Bank and Bank 2 as B-Bank)

Grade 1 Bore = 85,990 to 86,000 mm.

Grade 2 Bore = 86,000 to 86,010 mm.

Grade 3 Bore = 86,010 to 86,020 mm.

5. NOTE: Example - *WPPNN* - Crankshaft Main Bearing Bore

in Cylinder Block

Read the grade letters from LEFT to RIGHT = FRONT to REAR of

engine eg. for this example engine, the crank journal bore at the
front of the engine is grade W, and at the rear is grade N.

The selection of main bearing shells is described in the

following JOURNAL DIAMETER AND MAIN BEARING
BORE CHART.

6. JOURNAL DIAMETER AND MAIN BEARING BORE CHART

7. NOTE: THIS PROCEDURE SHOULD ONLY BE CARRIED OUT
WHEN REPLACIING MAIN BEARING SHELLS.

• NOTE: Refer to the JOURNAL DIAMETER AND MAIN BEARING

BORE CHART in step 6 for tolerance and bearing information.

The number in each diagonal band represents a PAIR of color

coded main bearing shells which must be used with a specific
journal, depending on the combination of journal diameter and
crankshaft bore diameter. The color codes for each band are as
follows:

1. Blue / Green and Blue / Green

2. Blue / Green and Blue

3. Blue and Blue

4. Blue and Green

5. Green and Green

 6. Green and Yellow

7. Yellow and Yellow

Consider crankshaft journal 5 (from the example grade

markings on the cylinder block) - the cylinder block bore is
Grade N and the crankshaft journal diameter is Grade L. From
the chart, it will be seen that the point of intersection is in
Band 4 which equates to one Blue shell and one Green shell.

When the appropriate pair of color codes have been selected

for a journal, either color may be installed to the cylinder
block or to the bedplate, but, the shell which is to be installed
to the cylinder block must have an oil groove and the shell
which is to be installed to the bedplate must be plain.

8. NOTE: THIS PROCEDURE SHOULD ONLY BE CARRIED OUT

WHEN A REPLACMENT CRANKSHAFT OR CYLINDER BLOCK
HAS BEEN FITTED.

• NOTE: Refer to the JOURNAL DIAMETER AND MAIN BEARING

BORE CHART in step 6 for tolerance and bearing information.

The thickness grade of all main bearing shells are to be selected to

give a total running clearance of not less than 0.022 mm or
greater than 0.040 mm.

Each bearing bore in the block/bedplate assembly should be

measured at two mutually perpendicular diameters 45° to the
vertical in the middle of the bearing.

The minimum diameter of the two is to be used.

Each crankshaft main bearing journal should be measured

dynamically at a point in line with the middle of each bearing.

When the appropriate pair of color codes have been selected

for a journal, either color may be installed to the cylinder
block or to the bedplate, but, the shell which is to be installed
to the cylinder block must have an oil groove and the shell
which is to be installed to the bedplate must be plain.
 Published: 11-May-2011
Engine System - General Information - Cylinder Bore Out-of-Round
General Procedures

1. NOTE: The main bearing caps or lower crankcase must be in place

and tightened to the specified torque; however, the bearing shells
should not be installed.

Measure the cylinder bore with an internal micrometer.

Carry out the measurements in different directions and at

different heights to determine if there is any out-of-
roundness or tapering.

If the measurement is out of the specified range, hone out

the cylinder block or install a new block.
 Published: 11-May-2011
Engine System - General Information - Cylinder Head Distortion
General Procedures

1. Measure the cylinder block/cylinder head distortion.

Using the special tool, measure the mating face distortion.

If the value is not to specification rework the mating face.

 Published: 11-May-2011
Engine System - General Information - Exhaust Manifold Cleaning and
Inspection
General Procedures

1. Inspect the cylinder head joining flanges of the exhaust manifold

for evidence of exhaust gas leaks.
2. Inspect the exhaust manifold for cracks, damaged gasket
surfaces, or other damage that would make it unfit for further use.
 Published: 11-May-2011
Engine System - General Information - Piston Inspection
General Procedures

1. CAUTION: Do not use any aggressive cleaning fluid or a wire

brush to clean the piston.

Carry out a visual inspection.

Clean the piston skirt, pin bush, ring grooves and crown and
check for wear or cracks.

If there are signs of wear on the piston skirt, check whether

the connecting rod is twisted or bent.
 Published: 11-May-2011
Engine System - General Information - Piston Pin Diameter
General Procedures

1. NOTE: The piston and piston pin are a matched pair. Do not mix
up the components.

Measure the piston pin diameter.

Measure the diameter in two directions.

If the values are not to specification, install a new piston and

a new piston pin.
 Published: 11-May-2011
Engine System - General Information - Piston Pin to Bore Diameter
General Procedures

1. NOTE: The piston and piston pin form a matched pair. Do not mix
up the components.

Measure the diameter of the piston pin bore.

Measure the diameter in two directions.

If the values are not to specification, install both a new piston

and a new piston pin.
 Published: 11-May-2011
Engine System - General Information - Piston Ring End Gap
General Procedures

1. CAUTION: Do not mix up the piston rings. Install the piston

rings in the same position and location.

Using the Feeler Gauge, measure the piston ring gap.

The values given in the specification refer to a gauge ring

used during production.
 Published: 11-May-2011
Engine System - General Information - Piston Ring-to-Groove Clearance
General Procedures

1. NOTE: The piston ring must protrude from the piston groove. To
determine the piston ring clearance, insert the Feeler Gauge right to
the back of the groove, behind the wear ridge.

Using the Feeler Gauge, measure the piston ring clearance.

 Published: 11-May-2011
Engine System - General Information - Valve Spring Free Length
General Procedures

1. Using a vernier gauge, measure the free length of each valve

spring. Verify the length is within specification.
 Published: 11-May-2011
Engine System - General Information - Valve Stem Diameter
General Procedures

1. Using a micrometer measure the diameter of the valve stems.

If the measurements are not to specification, install a new

valve.
 Published: 02-Jun-2011
Engine System - General Information - Leakage Test Using Smoke Test
Equipment
General Procedures

CAUTION: The compressed air line supply pressure must be between 3.5 and 12 bar (50 and 175 psi) for the smoke test
equipment to function correctly. Do not exceed this pressure. Failure to follow this instruction may result in damage to the smoke
test equipment.

• NOTE: The vehicle battery must be in good condition and fully charged before carrying out this procedure.

• NOTE: On vehicles with 3.0L TDV6, it will be necessary to insert smoke at both air cleaner outlet pipes independently if the right
hand turbocharger and associated hoses are to be tested.

• NOTE: In some cases it may be necessary to remove undertrays, trim or engine covers to obtain access to all potential leak
locations.

• NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

• NOTE: For further information regarding operation of the test equipment refer to the manufacturers operators manual supplied
with the kit.

1. WARNING: Use an additional support to prevent the hood

from falling if the smoke test equipment is secured to the hood.
Failure to follow this instruction may result in personal injury.

Install the smoke test equipment to a suitable location under the

hood.

2. Connect a suitable compressed air line to the smoke test

equipment.
3. Connect the smoke test equipment positive power cable to the
battery positive terminal.

4. WARNING: Do not connect the smoke test equipment

negative cable to the battery negative terminal.

Connect the smoke test equipment negative cable to a suitable

body ground point.
5. NOTE: A flashing green light indicates low battery voltage. In this
case, place the battery on charge and make sure that the battery is
fully charged before using the smoke test equipment.

Observe the power indicator lamp on the smoke test equipment.

Make sure that a continuous green light is displayed.

6. NOTE: In some cases it may be necessary to remove the air

cleaner(s) to allow access to the air cleaner outlet pipes.

• NOTE: In some cases it will be necessary to cap one of the air

cleaner outlet pipes. Use the blanking caps supplied in the kit to cap
the open orifice.

Disconnect the air cleaner outlet pipe(s).

7. NOTE: Make sure the smoke test equipment adapter is a good fit
to the air cleaner outlet pipe. This must be an air tight seal.

Connect the smoke test equipment supply hose to the air cleaner
outlet pipe.

1. Install the appropriate adapter to the air cleaner outlet

pipe.

2. Connect the smoke test equipment supply hose to the

adapter link hose.

8. NOTE: The flow control valve must be in the fully open position.

• NOTE: Smoke is produced for 5 minutes. The smoke test

equipment will automatically switch off after this period of time.

Switch the smoke test equipment on.

9. Remove the oil filler cap, and observe until a constant flow of
smoke is visible leaving the oil filler orifice. Install the oil filler cap.
10. NOTE: The longer smoke is allowed to exit from a leak, the more
fluorescent dye will be deposited at a leak location.

Using the torch supplied in the kit set to white light, look for
escaping smoke. Alternatively, use the ultraviolet light to look for
fluorescent dye deposits at the source of a leak.
15.12.2011 TOPIx - WSM-4479 - Workshop Manual - Discovery 3 (L319) 2005-2009MY

Published: 11-May-2011
Engine - V6 4.0L Petrol -
Sealers
Item Land Rover Part No.
Engine timing cover to cylinder block STC 50550
Rear main bearing cap to cylinder block 8510302
Lubricant - UK, Europe and ROW - Not NA S/Japan
Item Specification
* The use of 5W/30 oil to Specification WSS - M2C 929-A is preferred. Where oil to this specification is
Recommended not available, then 5W/30 oil meeting specifications AC EA A1/A3 or API SJ or SL may be used.
lubricant
* WSS is a Ford prefi to the oil specification
Lubricant - NA S/Japan
Item Specification
* Recommended Use 5W/30 oil meeting Specification WSS-M2C 929-A (GF4) and 'C ertified for Gasoline Engines' by
lubricant the American Petroleum Institute (API).
* WSS is a Ford prefi to the oil specification

Capacit
Item Capacit
Dry fill including filter 6.4 litres (11.2 pints) (6.7 US
quarts)
Oil and filter change - Maximum 5.7 litres (10.0 pints) (6.0 US
quarts)
Amount of oil required to bring the level from the lower to the upper holes on the 1.4 litres (2.4 pints) (1.5 US
dipstick quarts)
General Specif ication
I em Specifica ion
Type 4.0 litre, 60 degree 'V', petrol engine, single overhead camshaft per cylinder head,
2 valves per cylinder
C ylinder arrangement V6, when looking towards the rear of the engine, cylinders 5 and 6 are at the rear.
C ylinder numbering Number 1, 3, 5 cylinder - right hand bank; Number 2, 4, 6 cylinder - left hand bank
Bore - nominal 100.4 mm (3.952 in)
Stroke 84.4 mm (3.322 in)
C apacity 4009 cm (244.5 in )
Firing order 1-2-3-4-5-6
C ompression ratio 9.75:1
Direction of rotation Anti-clockwise viewed from rear of engine
Maximum power 156 Kw (209 bhp) @ 4750 rev/min
Maximum torque 346 Nm (255 lb-ft) @ 3500 rev/min
Dimensions:
Length 669 mm (26.3 in)
Width 712 mm (28.0 in)
Height 747 mm (29.4 in)
Maximum permissable cylinder 0.08 mm (0.003 in)
head warp
Engine oil pressure:
At Idle 1.8 - 2.0 bars (180 - 200 kPa) (26.0 - 29.0 lb/in )
At 3500 rev/min 3.3 to 3.6 bars (330 - 360 kPa) (48.0 - 52.0 lb/in )
Torque Specif ications
Description Nm lb-ft
Engine RH mounting bracket bolts 80 59
Engine RH mounting bracket nut 90 66
* Engine RH mounting to bracket bolts:
Stage 1 45 33
Stage 2 Further 60° Further 60°
+ LH and RH Exhaust manifold nuts 25 18
Dipstick tube bolt 10 7
* Exhaust system to exhaust manifold bolts 40 30

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15.12.2011 TOPIx - WSM-4479 - Workshop Manual - Discovery 3 (L319) 2005-2009MY
+ RH valve cover bolts/studs 10 7
+ LH valve cover bolts/studs 10 7
C MP sensor bolt 6 4
++ LH/RH camshaft cap bolts:
Stage 1 6 4
Stage 2 16 12
*+ # C linder head bolts:
Stage 1 - M12 bolts 30 22
Stage 2 - M12 Bolts Further 80° Further 80°
Stage 3 - M12 bolts Further 80° Further 80°
M8 bolts 35 26
C ylinder head coolant flange bolts 10 7
RH C ylinder head ground connector bolt 10 7
Generator mounting bracket bolts 45 33
+ Generator bolts 45 33
Generator electrical connector nut 10 7
A/C compressor mounting bracket bolts 45 33
Knock sensor bracket bolt 10 7
Knock sensor retaining clip bolt 10 7
Electrical harness bridge bolt 45 33
EGR pipe nuts:
Stage 1 Lightly tighten Lightly tighten
Stage 2 40 30
Battery terminal clamp nut(s) 5 3.5
Wiring harness clamp bolt - RHD only 10 7
Oil pick-up pipe Torx screws 10 7
Oil strainer bolt 10 7
Oil pump Torx screws 20 15
Oil cooler lines nut and bolt 25 18
Oil cooler adapter 60 44
Transmission fluid lines bolt 10 7
Transmission fluid lines nut 10 7
Transmission support bracket nut 20 15
Transmission bolts 45 33
Engine front cover:
M6 bolts 10 7
M8 bolts and studs 20 15
C oolant pump bolts 10 7
Ground cable nut 20 15
+ C linder block cradle:
Stage 1 Lightly tighten 2 rear bolts Lightly tighten 2 rear bolts
Stage 2 Loosen 2 rear bolts Loosen 2 rear bolts
Stage 3 Lightly tighten 2 rear bolts Lightly tighten 2 rear bolts
Stage 4 - Outer bolts, nuts and Torx screws 10 7
Stage 5 - 2 rear bolts 43 32
Stage 6 - C ylinder block cradle set screws 7 5
Stage 7 - C ylinder block cradle bolts 15 11
Stage 8 - C ylinder block cradle bolts 34 25
* Crankshaft pulle bolt:
Stage 1 55 40
Stage 2 Further 85° Further 85°
LH and RH camshaft sprocket bolts:
Stage 1 20 15
Stage 2 Further 100 Further 100
Oil temperature sensor 20 15
Radiator access panel bolts 10 7
Oil pan bolts 10 7
Wiring harness to oil pan nuts 6 4
** Balance shaft Torx bolts 29 21
LH camshaft drive cassette chain guide bolt 25 18
RH camshaft drive cassette bolt 12 9
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15.12.2011 TOPIx - WSM-4479 - Workshop Manual - Discovery 3 (L319) 2005-2009MY
* RH (R ):

Stage 1 40 35
Stage 2 Further 45 Further 45
*J T (F ):
Stage 1 45 33
Stage 2 Further 70 Further 70
C rankshaft position sensor (C KP) bolt 8 6
* Steering column lower universal joint 'Patchlok' bolts 25 18
Jackshaft thrust plate Torx bolts 10 7
Oil pump drive gear bolt 20 15
LH and RH hydraulic timing chain tensioner 45 33
Primary timing chain tensioner bolt 10 7
Oil filter 18 13
Oil drain plug 37 27
+* Starter motor cable nut 10 7
Starter motor bolts 45 33
Fuel rail bolts 25 18
Valve cover fuel line clip bolt 10 7
+ Intake manifold bolts 10 7
* RH catalytic converter to the exhaust manifold bolts 22 16
* LH catalytic converter to the exhaust manifold bolts 22 16
Flexplate to torque converter Torx bolts 45 33
Road wheel nuts 140 103
*N / ( )

** N T

+B /T /

++ B 2

#L

+* D

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Published: 11-May-2011
Engine - V6 4.0L Pe ol - Engine
Description and Operation

External View

NOTE: Variant without oil cooler shown.

GENERAL

The V6 petrol engine is a 4.0 litre, 6 cylinder, 60 degrees 'V' unit, with 2 valves per cylinder, operated by a single overhead camshaft. The engine
emissions comply with EC D4 (European C ommission Directive) and USA Tier 2 Bin 8 legislative requirements and employs catalytic converters,
electronic engine management control, positive crankcase ventilation and exhaust gas recirculation to limit the emission of pollutants. The cooling
system is a low volume, high velocity system. The fuel injection system is controlled by the Engine C ontrol Module (EC M).

The cylinder block is of cast iron construction with a cast aluminum ladder frame and balance shaft assembly bolted to the bottom of the block. The
cylinder heads are cast aluminum with vinyl ester composite camshaft covers. The single-piece oil sump is formed from pressed steel. The intake
manifold is manufactured from cast aluminum and incorporates a central chamber with six inlet port tracts
For additional information, refer to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - V6 4.0L Petrol, Description and
Operation).
The dual wall stainless steel exhaust manifolds are unique for each cylinder bank and a moulded plastic acoustic cover is fitted over the upper engine to
reduce engine-generated noise.

Technical Fea e

The technical features include:

A six cylinder, 60 degree 'V' configuration liquid cooled cast iron cylinder block
Pistons comprise two compression rings and a three piece oil control ring
Two aluminum cylinder heads, each incorporating a single hollow camshaft
Rocker valve arms with hydraulic lash adjusters
Engine front cover manufactured from aluminum which accommodates the coolant pump assembly
Each camshaft is driven by a separate single row chain
Electronically controlled vacuum operated Exhaust Gas Recirculation (EGR) valve
Exhaust re-treatment by means of catalytic converters
C ast aluminum engine ladder frame assembly
A fully counter balanced cast iron crankshaft

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An advanced engine management system incorporating electronic throttle control
Electronic Intake Manifold Tuning Valve (IMTV) with EC M control
Emissions comply with EC D4 (European C ommission Directive) and USA Tier 2 Bin 8 legislative requirements.

Engine Data

The technical data is detailed below.

DESCRIPTION TYPE
Configuration 60 degree V6
Ma imum po er 156 kW at 4750 rpm
Ma imum torque 346 Nm at 3000 rpm
Displacement 4009cc
Stroke/bore 84.4mm/100.4mm
Compression ratio 9.7:1
Firing order 123456
Oil capacit 6.4 litres

CYLINDER NUMBERING

The cylinders are numbered as shown below, with cylinders 1 and 2 at the front of the engine.

CYLINDER BLOCK COMPONENTS

NOTE: Variant with oil cooler shown.

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I em Pa N mbe De c ip ion
1 - Piston Rings
2 - Piston
3 - Piston pin
4 - C onnecting rod
5 - C onnecting rod bearing - upper
6 - C onnecting rod bearing - lower
7 - C onnecting rod cap
8 - Oil filter
9 - Oil cooler (if fitted)
10 - Oil filter adapter mounting bolt
11 - O ring
12 - O ring
13 - Oil filter adapter
14 - O ring
15 - Knock sensor
16 - C linder block
17 - Locating dowel
18 - Knock sensor
19 - Oil pressure switch
20 - Starter motor
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21 - Gasket
22 - Front cover
23 - Seal
24 - Gasket
25 - Water pump
26 - C rankshaft pulle
27 - Jackshaft shaft chain
28 - Jackshaft shaft sprocket
29 - C hain tensioner
30 - Jackshaft shaft
31 - Jackshaft thrust plate
32 - C hain guide
33 - C hain guide
34 - Oil galler plug
35 - Plug
36 - Spacer
37 - Oil galler plug
C linder Block

The c linder block is a 'V' design, which provides an inherentl rigid structure with good vibration levels. A low volume coolant jacket improves warm-
up times and piston noise levels; the longitudinal flow design of the jacket, with a single c linder head coolant transfer port in each bank, improves
rigidit and head gasket sealing.

Engine Data Locations

I em Pa N mbe De c ip ion
1 - Engine data
2 - Engine data
3 - Vehicle Identification Number (primar location)
4 - Vehicle Identification Number(secondar location)
Engine data is marked at three locations.

Pistons and Connecting Rod Assembl

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I em Pa N mbe De c ip ion
1 - P ,
2 - P ,
3 - P ,
4 - P
5 - P
6 - C
7 - O
8 - C ,
9 - C ,
10 - C
11 - N
12 - B
T , , , - ,
.P , 1, 2, 3 4. T ;
' ' .

T V6 H- ,
.T .

S ; 0.25 , .T -
.

E .T ,
.T .T 2
- .T .

Jackshaft Assembl

I em Pa N mbe De c ip ion
1 - J
2 - T
T .T , .
T LH RH .T J , ,
.T .

Front Cover and Water Pump Assembl

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I em Pa N mbe De c ip ion
1 - Water pump assembly
2 - Engine front cover
3 - Gasket
The aluminum front cover assembly is secured to the engine block by five bolts and five studs and is sealed via a gasket. The front cover also houses
the crankshaft front seal.

The water pump is attached to the engine front cover assembly and is secured and sealed, to the front cover, by twelve bolts and a gasket. A poly-vee
belt drives the water pump via the crankshaft.

Oil Cooler (If Fitted) and Filter Assembl

NOTE: Variant with oil cooler shown.

I em Pa N mbe De c ip ion
1 - O ring
2 - Adapter
3 - O ring
4 - O ring
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5 - Adap e mo n ing bol
6 - C oole a embl (if fi ed)
7 - Oil fil e
A f ll-flo , di po able cani e - pe oil fil e i a ached o he oil coole a embl (if fi ed).

The oil fil e and coole a embl (if fi ed) i a ached he ea RH ide of he c linde block and con i a f ll-flo , di po able cani e - pe fil e ,
coole (if fi ed) and an adap e .

The fil e adap e -mo n ing bol loca e in he c linde block oil galle and i ealed b an 'O' ing. The fil e adap e ho e he adap e bol and i
al o ealed o he c linde block b an 'O' ing.

The oil coole (if fi ed) keep he engine l b ica ion oil cool, nde hea load and high ambien empe a e and i cooled b he engine cooling
em.

Oil i deli e ed o and f om he oil coole (if fi ed) h o gh galle ie in he c linde block. Ho e f om he engine cooling em a e connec ed o o
pipe on he oil coole fo he ppl and e n of coolan .

Knock Sensors

I em Pa N mbe De c ip ion
1 - RH knock en o
2 - LH knock en o
The knock en o a e in alled in he c linde block in o diffe en loca ion . One i loca ed on he inboa d of he RH c linde bank and one i loca ed
a he f on of he LH ide of he c linde block, ne o he oil p e e i ch. The a e pie o-elec ic en o ha p o ide inp o de ec and loca e
de ona ion d ing comb ion.
Fo addi ional info ma ion, efe o: Elec onic Engine C on ol (303-14A Elec onic Engine C on ol - V6 4.0L Pe ol, De c ip ion and Ope a ion).

Oil Pressure S itch

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I em Pa N mbe De c ip ion
1 - Oil Pressure Switch
The oil pressure switch is located in a port at the front LH side of the c linder block. It detects when a safe operating pressure has been reached during
engine starting and initiates the illumination of a warning light in the instrument cluster if the oil pressure drops below a given value. The switch
operates at a pressure of 0.15 to 0.41 bar (2.2 to 5.9 psi).

Engine Block Hea er

For cold climate markets an engine block heater is fitted, which is located at the front of the LH side of the c linder block.

CRANKSHAFT, SUMP AND OIL PUMP COMPONENTS

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I em Pa N mbe De c ip ion
1 - Tensioner
2 - C hain
3 - Balance shaft assembl
4 - Main bearing, upper
5 - Main thrust bearing, upper
6 - C rankshaft
7 - C rankshaft oil seal, rear
8 - Main thrust bearing, lower
9 - Main bearing, lower
10 - Main bearing cap, rear
11 - Intermediate shaft
12 - Oil pump
13 - Pick-up pipe adapter
14 - Ladder frame
15 - Oil pick-up pipe
16 - Sump
17 - C rankshaft oil seal, front
18 - Ke
C ank haf and Main Bea ing

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I em Pa N mbe De c ip ion
1 - M
2 - M ,
3 - K
4 - C
5 - M ,
6 - M ,
T , 30 .C
S G (SG) , , , .T
.T
- .

O , ,
- .

Balance Shaft Assembl

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I em Pa N mbe De c ip ion
1 - Drive chain
2 - Tensioner assembl
3 - Balance assembl
4 - C hain guide
A 60 degree V6 is often thought of inherentl balanced, because its first-order forces can be compensated b crankshaft counter-weighting. However,
the V6 4.0L engine generates a second-order unbalanced at twice the crank speed.

To achieve the desired smoothness, the V6 4.0L engine includes a unique counter-rotating balance shaft, which is chain driven b the crankshaft and
runs at twice engine speed. The shaft produces an opposite second-order force, which cancels the inherent unbalance.

Since the balance shaft is positioned on the bottom the c linder block, on the RH side and is secured b 4 bolts. Because the unit is near the engine oil
level, it is encased in a steel tube to avoid aerating the oil. The balance shaft attaches to the engine as an assembled unit, including an integrated gear
and lubrication s stem. The gear is needed to rotate the shaft in the same direction as the unbalanced force.

C ank haf Oil Seal

I em Pa N mbe De c ip ion
A - Rear
B - Front
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1 - Rear seal
2 - Front cover
3 - Front seal
The rear crankshaft oil seal is a press fit in the rear of the c linder block. The front crankshaft oil seal is located in the engine front cover assembl ,
just below the water pump.

Oil Pump

I em Pa N mbe De c ip ion
1 - Oil pump
2 - Pick-up pipe adapter assembl
3 - Intermediate shaft
4 - C lamp
5 - Drive assembl
The oil pump is located on the RH rear underside of the c linder block, contained within the ladder frame assembl , and is secured b two bolts. The
unit is driven b the jackshaft, via an intermediate shaft, and receives its oil feed from the main galler via drillings in the c linder block. The
intermediate shaft locates through the c linder block and is connected to the drive assembl , which is situated in the 'V' at the rear of the engine and
held in place via a clamp. The oil pump housing includes the oil pressure relief valve.

Engine Ladder Frame Assembl

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I em Pa N mbe De c ip ion
A - 69.8 mm minimum
1 - Engine bulkhead housing
2 - C rankshaft main bearing cap adjustment screw
The ladder frame is fitted to the lower c linder block, via 20 bolts and 2 studs and nuts, to stiffen the base structure thus helping to reduce Noise,
Vibration and Harshness (NVH). The frame is made of high-pressure die cast aluminum.

Located in the bulkhead housing are eight crankshaft main bearing cap adjustment screws.

A gasket seals the joint between the bulkhead housing and the c linder block.

A port for the oil level gauge tube is included in the casting on the LH side of the c linder block.

S mp

I em Pa N mbe De c ip ion
1 - Sump
The pressed steel sump is a wet-t pe, sealed to the ladder frame using a gasket and 10 bolts.

Oil Pick- p

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I em Pa N mbe De c ip ion
1 - Oil pick-up
The oil pick-up is a two-piece unit with strainer located in the center of the sump oil well, as a source for the suppl of engine lubrication oil to the oil
pump. Oil is drawn though the end of the pick-up and strained to prevent solid matter from entering the oil pump.

CAM HAF IMING COMPONEN

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I em Pa N mbe De c ip ion
A - Front of engine
1 - LH camshaft drive assembl
2 - RH camshaft drive assembl
3 - Spacer
4 - Jackshaft sprocket
5 - C hain guide
6 - Jackshaft chain tensioner
7 - Tensioner pin
8 - Jackshaft chain
Camshaft Drive Assembl

Each camshaft drive assembl comprises:

A jackshaft gear
A camshaft gear
A drive chain
A chain guide

The LH drive assembl is driven from the front of the jackshaft and the RH assembl from the rear.

CYLINDER HEAD COMPONENTS

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I em Pa N mbe De c ip ion
1 - Hose, crankcase emissions, RH camshaft cover to intake manifold
2 - End cover
3 - RH Fuel rail
4 - LH injectors (3 of)
5 - Fuel suppl line
6 - Schrader valve
7 - RH injectors (3 of)
8 - Hose, crankcase emissions, LH camshaft cover to intake manifold
9 - Electricall heated positive crankcase ventilation valve
10 - C amshaft position (C MP) sensor
11 - Oil filler cap
12 - LH camshaft cover
13 - LH valve rocker arm oil suppl tube
14 - LH camshaft bearing caps
15 - LH camshaft
16 - Valve rocker arm
17 - C ollet
18 - Valve spring retainer seat
19 - H draulic lash adjuster
20 - Valve spring
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21 - Val e em eal
22 - LH c linde head
23 - LH e ha manifold ga ke
24 - Val e
25 - C linde head ga ke
26 - Vol me ed c ion pl g/ al e
27 - Timing chain en ione
28 - RH e ha manifold ga ke
29 - Timing chain en ione
30 - RH c linde head
31 - RH cam haf
32 - RH cam haf bea ing cap
33 - RH al e ocke a m oil ppl be
34 - RH cam haf co e
35 - C ankca e en ila ion al e
C linder Heads

I em Pa N mbe De c ip ion
1 - RH c linde head
2 - LH c linde head
The c o -flo c linde head a e ba ed on a in al e, cen al pa k pl g comb ion chambe , i h he inle po de igned o ind ce i l and
con ol he peed of he ind c ion cha ge. Thi e e o imp o e comb ion and hence f el econom , pe fo mance and e ha emi ion .

LH and RH c linde head a e iden ical ca ing .

Camshafts

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I em Pa N mbe De c ip ion
1 - Bearing cap
2 - C amshaft
A single camshaft on each c linder bank is retained b a camshaft carrier, line bored with the c linder head. The camshafts are located b a flange,
which also controls end-float.

The LH camshaft incorporates a reluctor, which is used in conjunction with the C amshaft Position (C MP) sensor to measure engine position.

Valves and H draulic Lash Adjusters

I em Pa N mbe De c ip ion
1 - Valve stem seal
2 - Valve spring
3 - Valve spring retainer seat
4 - Valve spring retainer ke
5 - Rocker arm
6 - H draulic lash adjuster
7 - Valve
The valve springs are made from spring steel and are of the parallel single-coil t pe. The bottom end of each spring rests on the flange of a spring
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e aine , hich ha an in eg al al e em eal. The op end of he p ing i held in place b a p ing e aine , hich i held in po i ion a he op end of
he al e em b pli ape colle . The ape colle ha e g oo e on he in e nal bo e ha loca e o g oo e g o nd in o he ppe em of he
al e .

Val e ea and al e g ide a e an in e fe ence fi in he c linde head.

The al e a e ope a ed h o gh olle - pe finge ocke and h d a lic la h adj e , ac a ed b he cam haf lobe . When he cam haf lobe
p e e do n on he op of a finge ocke , olle mechani m, he e pec i e al e i fo ced do n, opening he affec ed inle o e ha al e. The e
of hi pe of ac a ion me hod help ed ce f ic ion in he al e iming mechani m.

The bod of he h d a lic la h adj e con ain a pl nge and o chambe fo oil feed and p e i ed oil. The p e i ed oil i pplied o he la h
adj e ia he main oil galle ie in he c linde head and h o gh a hole in he ide of he la h adj e bod . The oil pa e in o a feed chambe in
he la h adj e and hen h o gh o a epa a e p e e chambe ia a one a ball al e.

Oil flo f om he p e e chambe i de e mined b he amo n of clea ance be een he la h adj e o e bod and he cen e pl nge . Oil e cape
p he ide of he pl nge e e ime he la h adj e i ope a ed, he do n a d p e e on he pl nge fo cing a co e ponding amo n of oil in he
la h adj e bod o be di placed. When he do n a d p e e f om he cam haf and finge ocke i emo ed (i.e. af e he ailing flank of he
cam haf lobe ha pa ed), oil p e e fo ce he la h adj e ' pl nge p again. Thi p e e i no fficien o effec he al e ope a ion, b
elimina e he clea ance be een he finge ocke and op of he al e em.

Valve Rocker Arm Oil Suppl Tube

I em Pa N mbe De c ip ion
1 - Val e ocke a m oil ppl be
The al e ocke a m oil ppl be loca e on op of each cam haf and i ec ed b o bol o he f on and ea cam haf bea ing cap . Oil i
pplied o he be ia a galle in he c linde head and i di ib ed o each ocke a m h o gh adjacen p a hole in he be.

C linder Head Gasket

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I em Pa N mbe De c ip ion
1 - LH c linder head gasket
2 - RH c linder head gasket
The multi-la ered steel c linder head gasket has c linder specific water flow cross-sections for uniform coolant flow.

F el Injec o

I em Pa N mbe De c ip ion
1 - Fuel rail
2 - Injector
3 - Adapter
The fuel injectors are installed in each of the two fuel rails, one per c linder head. The injectors are electromagnetic solenoid valves controlled b the
EC M. Each injector no le locates in the c linder head via an injector insert adapter. An 'O' ring seals each injector to the fuel rail. The fuel jets from
the injectors are directed onto the back of the intake valves.
For additional information, refer to: Electronic Engine C ontrols (303-14A Electronic Engine C ontrols - V6 4.0L Petrol, Description and Operation).

Cam haf Co e

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I em Pa N mbe De c ip ion
1 - C rankcase ventilation valve
2 - RH camshaft cover
3 - LH camshaft cover
4 - Oil filler cap and e tension
5 - C amshaft Position (C MP) sensor
6 - Electricall heated positive crankcase ventilation valve
The camshaft covers are manufactured from thermo-plastic. The LH cover incorporates a hole, located directl above the camshaft reluctor, for the
camshaft position sensor. The LH cover also incorporates the engine oil filler aperture.

Cam haf Po i ion (CMP) Sen o

I em Pa N mbe De c ip ion
1 - C MP sensor
The C MP sensor is installed at the front of the LH camshaft cover. It is a variable reluctance sensor that provides an input to the EC M regarding the
position of the camshaft.
For additional information, refer to: Electronic Engine C ontrols (303-14A Electronic Engine C ontrols - V6 4.0L Petrol, Description and Operation).

The reluctor for the camshaft position sensor is located at the front of the LH camshaft. A flat, machined surface near the front of each camshaft,

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enables the camshafts to be locked during the valve timing procedure.

LUBRICATION SYSTEM

NOTE: Variant with oil cooler shown.

The lubrication system is of the full-flow filtration, force-fed type.

Oil is drawn, via a strainer and pick-up pipe in the sump into the jackshaft driven oil pump which has an integral pressure relief valve. The strainer in
the pick-up pipe prevents any ingress of foreign particles from passing through to the inlet side of the oil pump and damaging the oil pump and
restricting oil drillings. The oil pressure relief valve in the oil pump opens if the oil pressure becomes excessive and diverts oil back around the pump.

Pressurized oil is pumped through the oil filter, mounted on the oil pump housing. The lubrication system is designed so that a higher proportion of oil
flow is directed to the cylinder block main oil gallery while a lower proportion of oil flow, (controlled by a restrictor in the oil filter housing), is directed to
the engine oil cooler (if fitted). The remainder of the oil flow from the outlet side of the oil filter is combined with the return flow from the oil cooler (if
fitted) before being passed into the cylinder block main oil gallery.

The main oil gallery has drillings that direct the oil to each cylinder head and the main bearings. C ross drillings in the crankshaft main bearings carry
the oil to the connecting rod big-end bearings. Oil galleries in the cylinder head carry the oil to the camshafts and the hydraulic lash adjusters.

The oil pressure switch is located in the cylinder block to sense the oil pressure level before the oil flow enters the main gallery in the cylinder block. A
warning lamp in the instrument cluster is illuminated if low oil pressure is detected.

Oil at reduced pressure is directed to each cylinder bank via two restrictors in the cylinder block/cylinder head locating dowels, one at the front on the
LH bank and the other at the rear on the RH bank. Oil then passes through a drilling in the cylinder head to the camshaft carrier, where it is directed via
separate galleries to the camshaft bearings and hydraulic tappet housings. Return oil from the cylinder head drains into the sump via the cylinder head
bolt passages.

Oil Le el Ga ge

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I em Pa N mbe De c ip ion
1 - Oi e e ga ge
2 - Oi e e ga ge be
The i e e ga ge ca e a g he LH ide f he c i de b c , ed i a be i a ed i he .T h e i he e d f he ga ge i dica e
he i i a d a i i e e . The e i a diffe e ce f a i a e 1.5 i e (1.58 US a ) be ee he e e .

E HAUST MANIFOLD

The d a a ai e ee e ha a if d a e i e f each c i de ba .

The e ha a if d a e ea ed he c i de head ia e a ga e .

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Published: 11-Ma -2011

Engine - V6 4.0L Pe rol - Engine Oil Draining and Filling
General Procedures

1. Disconnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
4. Remove the oil pan drain plug.

Position a container to collect the fluid.

Discard the oil drain plug seal.

5. Remove the oil filter.

Position a container to collect the fluid.

Discard the oil filter.

6. To install, reverse the removal procedure.

Lubricate the oil filter seal with clean engine oil and
tighten to 18 Nm.

Install a new seal.

Tighten the drain plug to 37 Nm.

7. Fill the engine with oil.

8. C heck and top-up the engine oil.

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Engine - V6 4.0L Pe ol - Cam haf Timing
General Procedures

Special Tool( )
C amshaft timing checking tool

303-1146

C rankshaft TDC timing/locking tool

303-573

C amshaft Bolt Tool

303-575

C amshaft Bolt Socket

303-565

C amshaft locking tool adaptor

303-576

C amshaft sprocket
adjusting/locking tool

303-597-01

C amshaft timing chain tensioning

tool

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303-571

. C heck the camshaft timing.

. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. Remove both valve covers.
. Rotate the crankshaft clockwise, until number one c linder
is on TDC . C heck the camshaft lobes are on the back of the
cam.
. Lock the crankshaft.

Install the special tool.

Tighten the screw.

. Install the special tool to the slot in the camshaft, the

base of the special tool must remain in contact with the
c linder head. If the special tool can be passed from one
side of the c linder head to the other without resistance
then the camshaft is correctl timed. Repeat the
procedure on the other camshaft. If both camshafts are
found to be correct, then no further action is required.

. If the camshaft timing is found to be incorrect, proceed with

the adjustment. Note both camshafts must be re-timed with
the camshaft roller followers removed.
. Remove the camshaft roller followers.
For additional information, refer to: C amshaft Roller
Follower (303-01A Engine - V6 4.0L Petrol, In-vehicle
Repair).
. Position the generator aside for access.

Remove the 3 bolts.

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. Remove the RH cylinder head harness carrier bolt.

Position the harness carrier aside for access.

. C AUTION: Damage to the camshaft will occur if

the alignment tool is used to release the camshaft sprocket
bolt.

NOTE: The camshaft timing slot is off center. C orrectly

timed the slot will be horizontal and below the center line.

Install the camshaft alignment special tool.

C lean the component mating faces.

Tighten the bolts to 10 Nm (7 lb.ft).

Lock the camshaft, tighten the special tool bolt to 45

Nm (33 lb.ft).

. Install the special tool to the RH cylinder head.

C lean the component mating faces.

Tighten the bolts to 10 Nm (7 lb.ft).

Tighten the saddle clamp bolts to 10 Nm (7 lb.ft).

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1 . C AUTION: The RH camshaft sprocket bolt has a

left hand thread.

Using the special tool, loosen the RH camshaft sprocket

bolt.

Remove and discard the bolt.

1 . Loosen the special tool saddle clamp bolts.

1 . C AUTION: Before disconnecting or removing the

components, ensure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

Remove the RH h draulic timing chain tensioner.

1 . Install the special tool.

C lean the component mating faces.

1 . Tighten the saddle clamp bolts to 10 Nm (7 lb.ft).

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1 . Using the special tool, tighten the camshaft sprocket

bolt to 20 Nm (15 lb.ft), then a further 100 degrees.

1 . Remove the special tools.

20. Install the RH hydraulic timing chain tensioner.

Install a new seal.

C lean the component mating faces.

Tighten the tensioner to 44 Nm (32 lb.ft).

21. NOTE: If either camshaft is disturbed, both camshafts

MUST be retimed.

NOTE: The LH camshaft sprocket bolt has a right hand

thread.

Repeat the above procedure to adjust the LH camshaft

timing.
22. Install the camshaft roller followers.
For additional information, refer to: C amshaft Roller
Follower (303-01A Engine - V6 4.0L Petrol, In-vehicle
Repair).

23. C AUTION: Tighten the bolts in the sequence

shown.

Install the generator.

C lean the component mating faces.

Tighten the bolts to 45 Nm (33 lb.ft).

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2 . C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Camshaft RH
In-vehicle Repair

Remo al
NOTE: Removal of the LH camshaft is similar to this procedure.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Refer to valve timing check and adjust.
For additional information, refer to: C amshaft Timing (303-
01, In-vehicle Repair).
3. Remove the camshaft sprocket bolt.

Position the sprocket and chain aside.

4. NOTE: Remove the camshaft bearing caps evenly and in

stages.

NOTE: Note the fitted position.

Remove the camshaft bearing caps.

Remove the 8 bolts.

C ollect the camshaft oil supply line.

5. Remove the camshaft.

Installation
1. Install the camshaft.

C lean the component mating faces.

Lubricate the components with clean engine oil.

2. NOTE: Note the fitted position.

Install the camshaft bearing caps.

C lean the component mating faces.

Lubricate the components with clean engine oil.

3. NOTE: After installing the bolts check the camshaft is free

to rotate.

Install the camshaft oil supply line.

Thoroughly clean and inspect the oil supply line.

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Prime the oil suppl line with clean engine oil.

Working in a diagonal sequence, evenl and

progressivel tighten the bolts in 2 stages.

Tighten the bolts to 6 Nm (4 lb.ft).

Tighten the bolts to 16 Nm (12 lb.ft).

. Install the camshaft sprocket bolt.

Install the bolt, but do not tighten full at this stage.

. Adjust the valve timing.

For additional information, refer to: C amshaft Timing (303-
01, In-vehicle Repair).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Crankshaft Pulle
In-vehicle Repair

Special Tool(s)
C rankshaft TDC timing/locking tool

303-573

Remover crankshaft damper pulle

303-1049

Remover oil seal front cover

303-107

Installer oil seal front cover

303-1148

Installer - crankshaft damper

pulle

303-102

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
3. Using the special tool, retain the crankshaft front pulle .

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4. NOTE: The crankshaft pulle retaining bolt will be ver
tight.

Remove the crankshaft pulle retaining bolt.

Discard the bolt.

5. Using the special tools, remove the crankshaft pulle .

C ollect the washer.

Remove the special tools.

6. Using the special tool, remove the crankshaft front seal.

7. C heck the crankshaft damper pulle and the washer for

damage.

In alla ion
1. C lean all the crankshaft pulle mating faces.
2. Using the special tool, install the crankshaft front seal.

Lubricate the seal with clean engine oil.

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. Using the special tool, install the crankshaft pulle .

Lubricate the seal with clean engine oil.

Remove the special tool.

. C AUTION: The screw thread in the crankshaft pulle

must be cleaned out before installing a new crankshaft pulle
bolt.

Install, but do not tighten, the new crankshaft pulle bolt.

. Tighten the crankshaft pulle bolt.

Install the special tool.

Tighten the bolt to 55 Nm (40 lb.ft).

Tighten the bolt a further 85 degrees.

Remove the special tool.

. Install the accessor drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Crankshaft Front Seal
In-vehicle Repair

Special Tool(s)
C rankshaft TDC timing/locking tool

303-573

Remover crankshaft damper pulle

303-773

Remover oil seal front cover

303-107

Installer oil seal front cover

303-1148

Installer crankshaft damper pulle

303-102

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
3. Using the special tool, retain the crankshaft front pulle .

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4. NOTE: The crankshaft pulle retaining bolt will be ver
tight.

Remove the crankshaft pulle retaining bolt.

Discard the bolt.

5. Using the special tools, remove the crankshaft pulle .

C ollect the washer.

6. Remove the special tools from the crankshaft pulle .

7. Using the special tool, remove the crankshaft front seal.

8. C heck the crankshaft damper pulle and the washer for

damage.

In alla ion
1. C lean all the crankshaft pulle mating faces.
2. Using the special tool, install the crankshaft front seal.

Lubricate the seal with clean engine oil.

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. Using the special tool, install the crankshaft pulle .

Lubricate the seal with clean engine oil.

Remove the special tool.

. C AUTION: The screw thread in the crankshaft pulle

must be cleaned out before installing a new crankshaft pulle
bolt.

Install, but do not tighten, a new crankshaft pulle bolt.

. Tighten the crankshaft pulle bolt.

Install the special tool.

Tighten the bolt to 45 Nm (33 lb.ft).

Tighten the bolt a further 85 degrees.

Remove the special tool.

. Install the accessor drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Crankshaft Rear Seal
In-vehicle Repair

Special Tool(s)
Oil seal remover

303-903 (LRT-12-092)

C rankshaft rear oil seal installer

303-527

C rankshaft rear ol seal installer

303-525

C rankshaft rear oil seal installer

303-579

Remo al
NOTE: The seal installation tools are available individually or as a set 303-S524

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

3. Remove the torque converter flexplate.
For additional information, refer to: Flexplate (303-01A
Engine - V6 4.0L Petrol, In-vehicle Repair).
4. Remove the closing plate.

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5. C AUTION: C a e be a e a id da age
he ea egi e a d i g face.

U i g he ecia , e e a d di ca d he
c a haf ea i ea .

In alla ion
1. I a he ecia , 303-527.

Ma e e he c e a e c ea a dd .

Tigh e he 2 A e c e .

2. C AUTION: Ma e e he ea i i a ed a a e

U i g he ecia ,i a he c a haf ea i ea .

L b ica e he ea i h c ea e gi e i.

Pa ia i a he c a haf ea i ea .

Tigh e he b f i a he ea .

3. I a he c i g a e.

C ea he c e .

4. I a he e c e e fe a e.
F addi i a i f a i , efe : Fe a e (303-01A
E gi e - V6 4.0L Pe , I - ehic e Re ai ).
5. C ec he ba e g d cab e.
F addi i a i f ai , efe : S ecifica i (414-00
Ba e a d C ha gi g S e - Ge e a I f ai ,

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Specifica ion ).
. C heck and op- p he engine oil.

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Petrol - C linder Block Cradle
In- ehicle Repai

Special Tool(s)
C linde block c adle in e
adj men ool

303-596

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. Remo e he RH f on heel and i e.
4. Po i ion he a e mo o o one ide.

Remo e he 2 bol .

Remo e he e minal ppe co e .

Remo e he e minal lo e co e .

Remo e he n .

Di connec he 2 elec ical connec o .

5. Remo e he f on a le be.
Fo addi ional info ma ion, efe o: A le T be (205-03 F on
D i e A le/Diffe en ial, In- ehicle Repai ).
6. Remo e he oil pan.
Fo addi ional info ma ion, efe o: Oil Pan (303-01A Engine
- V6 4.0L Pe ol, In- ehicle Repai ).
7. Remo e he f on abili e ba .
8. Remo e he adia o acce panel.

Remo e he 4 bol .

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. Release the engine oil cooler lines.

Remove the bolt.

Remove the nut.

Tie the lines aside.

10. C AUTION: Before disconnecting or removing the

components, make sure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

Remove the oil temperature sensor.

Disconnect the electrical connector.

Remove and discard the O-ring seal.

11. Remove the oil strainer pick-up assembl .

Remove the bolt.

12. Remove the dipstick.

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1 . U ing i able ie , ec e he an mi ion fl id line and
he i ing ha ne clea of he c linde block c adle flange.
1 . NOTE: No e he fi ed po i ion of he 2 ealing a he .

Remo e he 8 c linde block c adle bol .

Remo e and di ca d he 2 ealing a he .

1 . C AUTION: Fail e o loo en he e c e ma

e l in damage o he c linde block c adle.

U ing he pecial ool, loo en he 8 c linde block c adle

e c e .

1 . Remo e he c linde block c adle.

Remo e he 2 ea bol .

Remo e he 2 To c e .

Remo e he 2 n .

Remo e he 20 bol .

Remo e and di ca d he ga ke .

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In alla ion
1. C lean the c linder block cradle.

C lean the component mating faces.

Remove the sealant from the main bearing cap

cavities.

2. C AUTION: Failure to loosen the set screws ma

result in damage to the c linder block cradle.

Position the c linder block cradle set screws.

Using the special tool, adjust the set screws until

the are below the c linder block cradle boss face.

3. NOTE: The cradle must be installed within 20 minutes of

the sealant application.
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A ea a he c i de b c c ad e.

A ea a he 6 ace h .

. C AUTION: Ma e e he ga e i i a ed c ec .

I a he c i de b c c ad e.

I a a e ga e .

I a , he e e a d g e i e igh igh e he
e b , a dT c e .

. A ig he c i de b c c ad e he c i de b c ea
face.

I a a d igh e he 2 ea b .

L e he 2 ea b .

Ligh igh e he 2 ea b .

.E e a d g e i e , igh e he e b , a d
T c e 10 N (7 b.f ).
. Tigh e he 2 ea b 43 N (32 b.f ).
. U i g he ecia , igh e he 8 c i de b c c ad e
e c e .

Tigh e he e c e i he e e ce h 7
N (5 b.f ).

. NOTE: The ea i g a he a e fi ed he i e
c ed b . The i e c ed b a e fi ed i he 2
f a dh e .

I a he 8 c i de b c c ad e b a d igh e i 2
age .

I a 2 e ea i g a he .

Tigh e he b i e e ce 15 N (11 b.f ).

Tigh e he b i e e ce 34 N (25 b.f ).

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. NOTE: L b ica e ne eal i h clean engine oil.

In all he oil aine pick- p a embl .

C lean he componen .

Tigh en he bol o 10 Nm (7 lb.f ).

. In all he oil pan.

Fo addi ional info ma ion, efe o: Oil Pan (303-01A Engine
- V6 4.0L Pe ol, In- ehicle Repai ).
. In all he dip ick.

C lean he componen .

. NOTE: L b ica e ne eal i h clean engine oil.

In all he oil empe a e en o .

C lean he componen ma ing face .

In all a ne O- ing eal.

Tigh en he oil empe a e en o o 20 Nm (15 lb.f ).

C onnec he elec ical connec o .

. Po i ion he engine oil coole line .

Tigh en he bol and he n o 25 Nm (18 lb.f ).

. In all he adia o acce panel.

Tigh en he 4 bol o 10 Nm (7 lb.f ).

. In all he f on abili e ba .
. In all he f on a le be.
Fo addi ional info ma ion, efe o: A le T be (205-03 F on
D i e A le/Diffe en ial, In- ehicle Repai ).
. In all he a e mo o .

C lean he componen ma ing face .

C onnec he elec ical connec o .

Tigh en he n o 10 Nm (7 lb.f ).

In all he e minal lo e co e .

In all he e minal ppe co e .

Tigh en he bol o 45 Nm (33 lb.f ).

. In all he RH f on heel and i e.

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0. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - C linder Head LH
In-vehicle Repair

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Drain the coolant.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
3. Refer to camshaft timing. For additional information, refer
to: C amshaft Timing (303-01A Engine - V6 4.0L Petrol,
General Procedures).
4. Remove the e haust manifold.
For additional information, refer to: E haust Manifold LH
(303-01A Engine - V6 4.0L Petrol, In-vehicle Repair).
5. Release the harness bridge for access.

Remove the bolt.

6. Position the A/C compressor mounting bracket assembl

aside.

Remove the 4 bolts.

Release the knock sensor electrical connector

retaining clips.

Tie the bracket aside.

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. Re e he LH h d a ic i i g chai e i e .

C ea he c e a i g face .

. Re e he T b e ai i g he chai g ide.

Re e a d di ca d he O- i g ea .

. Re e he ca haf c e b .

Re e he ca haf c e .

Sec e he chai he g ide i h a cab e ie.

10. C AUTION: W i g i a diag a e e ce,

g e i e e he b .

Re e he 10 c i de head b .

Di ca d he b .

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. Remove the cylinder head LH assembly.

Release the KS electrical harness clip.

Remove the bolt.

. Remove and discard the cylinder head gasket.

C lean the cylinder head locating dowels.

C lean and inspect the cylinder head and cylinder

block.

. NOTE: Remove the camshaft bearing caps evenly and in

stages.

NOTE: Note the fitted position.

NOTE: Do not disassemble further if the component is

removed for access only.

Remove the camshaft bearing caps.

Remove the 8 bolts.

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C ollect the camshaft oil suppl line.

14. Remove the camshaft.

In alla ion
1. Install the camshaft.

C lean the component mating faces.

Lubricate the components with clean engine oil.

2. NOTE: Note the fitted position.

Install the camshaft bearing caps.

C lean the component mating faces.

Lubricate the components with clean engine oil.

3. NOTE: After installing the bolts check the camshaft is free

to rotate.

Install the camshaft oil suppl line.

Thoroughl clean and inspect the oil suppl line.

Prime the oil suppl line with clean engine oil.

Tighten the bolts evenl in 2 stages to the sequence

shown.

Tighten the bolts to 6 Nm (4 lb.ft).

Tighten the bolts to 16 Nm (12 lb.ft).

4. C lean the component mating faces.

5. C heck c linder head face for distortion, across the center
and from corner to corner.
For additional information, refer to: Specifications (303-
01A Engine - V6 4.0L Petrol, Specifications).

6. C AUTION: The head gasket must be installed over the

c linder block dowels.

Install a new c linder head gasket.

7. Install the c linder head LH assembl .

Install the knock sensor bracket.

Tighten the bolt to 10 Nm (7 lb.ft).

8. NOTE: Tighten the bolts 1 to 8 in the sequence shown.

The M12 bolts are tightened in 3 stages.

Install the c linder head bolts.

Lubricate the new c linder head bolt threads with

clean engine oil.
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Tigh en he M12 bol o 30 Nm (22 lb.f ), hen a

f he 80 deg ee .

Tigh en he M12 bol af he 80 deg ee .

Tigh en he M8 bol o 35 Nm (26 lb.f ).

. In all he e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold LH
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
10. In all he To bol e aining he chain g ide.

In all a ne O- ing eal.

Tigh en he bol o 10 Nm (7 lb.f ).

C lean he componen ma ing face .

11. In all he A/C comp e o mo n ing b acke a embl .

C lean he componen ma ing face .

Tigh en he bol o 45 Nm (33 lb.f ).

Sec e he i ing ha ne .

Tigh en he KS clip e aining bol o 10 Nm (7 lb.f ).

12. In all he LH h d a lic iming chain en ione .

13. Adj he al e iming. Fo addi ional info ma ion, efe
o: C am haf Timing (303-01A Engine - V6 4.0L Pe ol,
Gene al P oced e ).
14. In all he elec ical ha ne b idge.

Tigh en he bol o 45 Nm (33 lb.f ).

15. C onnec he ba e g o nd cable.

Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
16. Refill and bleed he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Pe ol, Gene al P oced e ).

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Petrol - C linder Head RH
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. D ain he coolan .
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Pe ol, Gene al P oced e ).
3. Refe o cam haf iming. Fo addi ional info ma ion, efe
o: C am haf Timing (303-01A Engine - V6 4.0L Pe ol,
Gene al P oced e ).
4. Remo e he e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold RH
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
5. Po i ion he gene a o mo n ing b acke a ide.

Remo e he 3 bol .

Relea e he i ing ha ne clip.

Di connec he engine coolan empe a e (EC T)

en o elec ical connec o .

6. Remo e he c linde block coolan o le elbo .

Di connec he engine coolan empe a e (EC T)

en o elec ical connec o .

Relea e he clip ec ing he coolan p mp ho e.

Remo e he 3 bol .

7. Remo e he RH h d a lic iming chain en ione .

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. Remove the camshaft sprocket bolt.

Remove the camshaft sprocket.

Secure the chain to the guide with a cable tie.

. C AUTION: Working in a diagonal sequence,

progressivel loosen the bolts.

Remove the 10 c linder head bolts.

Discard the bolts.

10. Remove the RH c linder head assembl .

Disconnect the c linder head earth connector.

Remove the bolt.

11. Remove and discard the c linder head gasket.

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C lean the cylinder head locating dowels.

C lean and inspect the cylinder head and cylinder

block.

12. NOTE: Remove the camshaft bearing caps evenly and in

stages.

NOTE: Note the fitted position.

NOTE: Do not disassemble further if the component is

removed for access only.

Remove the camshaft bearing caps.

Remove the 8 bolts.

C ollect the camshaft oil supply line.

13. Remove the camshaft.

In alla ion
1. Install the camshaft.

C lean the component mating faces.

Lubricate the components with clean engine oil.

2. NOTE: Note the fitted position.

Install the camshaft bearing caps.

C lean the component mating faces.

Lubricate the components with clean engine oil.

3. NOTE: After installing the bolts check the camshaft is free

to rotate.

Install the camshaft oil supply line.

Thoroughly clean and inspect the oil supply line.

Prime the oil supply line with clean engine oil.

Tighten the bolts evenly in 2 stages to the sequence

shown.

Tighten the bolts to 6 Nm (4 lb.ft).

Tighten the bolts to 16 Nm (12 lb.ft).

4. C lean the component mating faces.

5. C heck cylinder head face for distortion, across the center
and from corner to corner.
For additional information, refer to: Specifications (303-
01A Engine - V6 4.0L Petrol, Specifications).

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. C AUTION: The head ga e be i a ed e he

c i de b c d e .

I a a e c i de head ga e .
. NOTE: C a e be a e he i a i g he g d
c ec i . The e gi e i fai a ei he b h
ba if he g di .

I a he c i de head RH a e b .

C ec he c i de head ea h g dc ec .

Tigh e he b 10 N (7 b.f ).

. NOTE: Tigh e he b 1 8 i he e e ce h .
The M12 b a e igh e ed i 3 age .

I a he c i de head b .

L b ica e he e c i de head b h ead ih

c ea e gi e i .

Tigh e he M12 b 30 N (22 b.f ), he a

f he 80 deg ee .

Tigh e he M12 b af he 80 deg ee .

Tigh e he M8 b 35 N (26 b.f ).

.I a he e ha a if d.
F addi i a i f a i , efe : E ha Ma if d RH
(303-01A E gi e - V6 4.0L Pe , I - ehic e Re ai ).
10. NOTE: The h ead i ef ha ded.

I a he ca haf c e b .

Re e a d di ca d he cab e ie.

C ea he c e a i g face .

I a a d igh igh e he ca haf c e b .

11. I a he RH h d a ic i i g chai e i e .

Tigh e he e i e 45 N (33 b.f ).

12. I a he c i de head c a f a ge.

C ea he c e a i g face .

Tigh e he b 10 N (7 b.f ).
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Secure the hose with the clip.

C onnect the EC T sensor electrical connector.

1 . Install the generator mounting bracket.

C lean the component mating faces.

Tighten the bolts to 45 Nm (33 lb.ft).

Secure the wiring harness.

C onnect the EC T sensor electrical connector.

1 . Adjust the valve timing. For additional information, refer

to: C amshaft Timing (303-01A Engine - V6 4.0L Petrol,
General Procedures).
1 . C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
1 . Refill and bleed the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).

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Engine - V6 4.0L Petrol - Val e Co er LH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the fuel rail.
For additional information, refer to: Fuel Rail (303-04A Fuel
C harging and C ontrols - V6 4.0L Petrol, Removal and
Installation).
3. Position the injector harness aside.

Release the 2 clips.

Disconnect the 3 fuel injector electrical connectors.

4. Disconnect the 3 electrical connectors.

Release the harness clip from the filler neck.

Noting the installed position of the Knock sensor

electrical harness in relation to the oil filler tube,
remove and discard the cable tie.

5. C AUTION: Before disconnecting or removing the

components, ensure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

Remove the valve cover.

Remove the 3 bolts.

Remove the 3 studs.

6. NOTE: Do not disassemble further if the component is

removed for access onl .

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Remo e and di ca d he ga ke .
. NOTE: No e he fi ed po i ion.

Remo e he bol and d . Remo e and di ca d he

eal .

. Remo e he cam haf po i ion (C MP) en o .

Remo e he bol .

Remo e and di ca d he O- ing eal.

. Remo e he engine b ea he al e.

Remo e and di ca d he O- ing eal.

10. Remo e he oil fille cap.

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In alla ion
1. Install the oil filler cap.
2. Install the engine breather valve.

Install a new O-ring seal.

3. Install the C MP sensor.

Install a new O-ring seal.

Tighten the bolt to 6 Nm (4 lb.ft).

4. Install the bolts and studs.

Install the new O-ring seals.

Install the new gasket.

5. Install the valve cover.

C lean the component mating faces.

Evenl and progressivel tighten the bolts and studs, in

the sequence shown, to 10 Nm (7 lb.ft).

Secure the electrical harness with the clip.

6. C AUTION: Make sure the knock sensor electrical

harness is returned to the original fitted position.

Install the injector harness.

Secure with the clips.

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C onnect the fuel injector electrical connectors.

C onnect the 3 electrical connectors.

Install a new cable tie.

. Install the fuel rail.

For additional information, refer to: Fuel Rail (303-04A Fuel
C harging and C ontrols - V6 4.0L Petrol, Removal and
Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

Engine - V6 4.0L Petrol - Val e Co er RH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the fuel rail.
For additional information, refer to: Fuel Rail (303-04A Fuel
C harging and C ontrols - V6 4.0L Petrol, Removal and
Installation).
3. Position the injector harness aside.

Release the 2 clips.

Disconnect the 3 fuel injector electrical connectors.

4. C AUTION: Before disconnecting or removing the

components, ensure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.

Remove the valve cover.

Release the wiring harness retaining clip.

Remove the 2 bolts.

Remove the 4 studs.

5. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove and discard the gasket.

6. NOTE: Note the fitted position.

Remove the bolts and studs. Remove and discard the

seals.

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In alla ion
1. Install the bolts and studs.

Install the new O-ring seals.

Install the new gasket.

2. Install the valve cover.

C lean the component mating faces.

Evenl and progressivel tighten the bolts and studs, in

the sequence shown, to 10 Nm (7 lb.ft).

Secure the electrical harness with the clip.

3. Install the injector harness.

Secure with the clips.

C onnect the fuel injector electrical connectors.

4. Install the fuel rail.

For additional information, refer to: Fuel Rail (303-04A Fuel
C harging and C ontrols - V6 4.0L Petrol, Removal and
Installation).
5. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-May-2011
Engine - V6 4.0L Petrol - Camshaft Roller Follo er
In-vehicle Repair

Special Tool(s)
C amshaft roller follower
remover/replacer

303-581

Remo al
1. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the LH valve cover.
For additional information, refer to: Valve C over LH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Remove the RH valve cover.
For additional information, refer to: Valve C over RH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
4. Remove the viscous fan assembly.
For additional information, refer to: C ooling Fan (303-03A
Engine C ooling - V6 4.0L Petrol, Removal and Installation).
5. NOTE: Make sure the camshaft lobe is opposite the
camshaft roller follower, prior to removal.

NOTE: Mark each camshaft roller follower and lash

adjuster. Make sure each component is returned to its
original fitted position.

Using the special tool, remove the camshaft roller

followers.

Depress the valve spring.

6. Rotate the engine as required to access the remaining

camshaft roller followers.

7. Remove the hydraulic lash adjusters.

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In alla ion
1. NOTE: Install the components to their original fitted
positions.

Install the h draulic lash adjusters.

C lean the component mating faces.

Lubricate the components with clean engine oil.

2. NOTE: Install the components to their original fitted

positions.

Using the special tool, install the camshaft roller followers.

C lean the component mating faces.

Lubricate the components with clean engine oil.

To install, reverse the removal procedure.

3. Rotate the engine as required to access the remaining

camshaft roller followers.
4. Install the viscous fan assembl .
For additional information, refer to: C ooling Fan (303-03A
Engine C ooling - V6 4.0L Petrol, Removal and Installation).
5. Install the RH valve cover.
For additional information, refer to: Valve C over RH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
6. Install the LH valve cover.
For additional information, refer to: Valve C over LH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
7. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Pe rol - Engine Mo n LH
In- ehicle Repai

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. Remo e he LH e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold LH
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
4. Relea e he a e mo o cable.

Relea e he e minal co e .

Remo e he e minal n in la o .

Remo e he n .

5. C AUTION: P o ec he engine d ing hi ope a ion.

Remo e he engine mo n b acke .

S ppo he engine.

Remo e he 4 bol .

6. Remo e he engine mo n .

Remo e and di ca d he 2 bol .

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In alla ion
1. In all he engine mo n .

C lean he componen ma ing face .

Tigh en he ne bol o 45 Nm (33 lb.f ), hen a f he

60 deg ee .

2. In all he engine mo n b acke .

C lean he componen ma ing face .

Tigh en he bol o 80 Nm (59 lb.f ).

Remo e he engine ppo .

3. C onnec he a e mo o cable.

Tigh en he n o 10 Nm (7 lb.f ).

In all he e minal n in la o .

In all he co e .

4. In all he e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold LH
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
5. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Pe ol - Engine Mo n RH
In- ehicle Repai

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. Remo e he RH e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold RH
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).

4. C AUTION: P o ec he engine d ing hi ope a ion.

Remo e he engine mo n b acke .

S ppo he engine.

Remo e he n .

Remo e he 4 bol .

5. Remo e he engine mo n .

Remo e and di ca d he 2 bol .

In alla ion
1. In all he engine mo n .

C lean he componen ma ing face .

Tigh en he ne bol o 45 Nm (33lb.f ), hen a f he

60 deg ee .

2. In all he engine mo n b acke .

C lean he componen ma ing face .

Tigh en he bol o 80 Nm (59 lb.f ).

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Remove the engine support.

Tighten the nut to 90 Nm (66 lb.ft).

. Install the e haust manifold.

For additional information, refer to: E haust Manifold RH
(303-01A Engine - V6 4.0L Petrol, In-vehicle Repair).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P : 11-M -2011
Engine - V6 4.0L Petrol - Fle plate
I - R

Special Tool(s)
F

303-947 (LRT-12-145)

Removal
1. D .
F , :S (414-00
B C S -G I ,
S ).

2. WARNING: D
.A
.

R .
3. R .
F , :T (307-01A
A T /T - V6 4.0L P ,
R I ).
4. F .

R 1
TDC . T
.

U , .

R T
.

M
.

5. R .
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Re e he 7 e ai i g T b .

Re e he ace .

In alla ion
1. I a he e c e e fe a e.

C ea he c e a i g face .

I a he ace .

A ig he b h e i h he a ig e ch, he
a e i ade he c a haf .

U i g he ecia , c he f e a e.

Tigh e he T b e e i 2 age , i he
e e ce h .

Tigh e he T b 15 N (11 b.f ).

Tigh e he T b 72 N (53 b.f )

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. Install the transmission.

For additional information, refer to: Transmission (307-01A
Automatic Transmission/Transa le - V6 4.0L Petrol,
Removal and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Pe rol - Oil P mp
In- ehicle Repai

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. Remo e he f on heel and i e .
4. Remo e he c linde block c adle.
Fo addi ional info ma ion, efe o: C linde Block C adle
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
5. Remo e he oil p mp a embl .

Remo e he 2 To c e .

Remo e he d i e haf .

6. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he oil pick p pipe.

Remo e he 3 To c e .

Remo e and di ca d he eal.

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In alla ion
1. In all he oil pick p pipe.

C lean he componen ma ing face .

In all a ne eal.

Tigh en he To c e o 10 Nm (7 lb.f ).

2. C AUTION: The oil p mp d i e haf i no

mme ical. The longe end ho n, i fi ed in o he oil
p mp.

In all he oil p mp a embl .

C lean he componen ma ing face .

P ime he oil p mp.

In all he d i e haf .

Tigh en To c e o 20 Nm (15 lb.f ).

3. In all he c linde block c adle.

Fo addi ional info ma ion, efe o: C linde Block C adle
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
4. In all he f on heel and i e .
5. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Engine - V6 4.0L Petrol - Oil Pan
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Drain the engine oil.
For additional information, refer to: Engine Oil Draining and
Filling (303-01A Engine - V6 4.0L Petrol, General
Procedures).
4. Release the harness bracket.

Remove the 2 nuts.

5. Remove the oil pan.

Remove the 10 bolts.

Remove and discard the gasket.

Installation
1. Install the oil pan.

C lean the component mating faces.

Install a new gasket.

Evenl and progressivel tighten the bolts to 10 Nm (7

lb.ft).

2. Install the harness bracket.

Tighten the nuts to 6 Nm (4 lb.ft).

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. Fill the engine with oil.

For additional information, refer to: Engine Oil Draining and
Filling (303-01A Engine - V6 4.0L Petrol, General
Procedures).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Oil Cooler
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the oil filter.

Position a container to collect the fluid.

4. NOTE: Note the fitted position of the oil cooler assembl .

Remove the oil filter adapter.

Release the cooler from the oil filter head.

5. C lamp, then disconnect the coolant hoses from the oil

cooler.

6. Remove the oil cooler.

Installation
1. NOTE: Fill the oil cooler with coolant to eliminate the air,
prior to connecting the coolant hoses.

To install, reverse the removal procedure.

Tighten the adapter to 60 Nm (44 lb.ft)

Lubricate the oil filter seal with clean engine oil and
tighten to 18 Nm (13 lb.ft).

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. C heck and op- p he engine oil.

. Top- p and bleed he coolan .

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Engine - V6 4.0L Petrol - Engine Front Co er
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Drain the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
3. Remove the intake manifold.
For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
4. Remove the crankshaft pulle .
For additional information, refer to: C rankshaft Pulle (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
5. Remove the cooling fan lower shroud.

Release 2 clips from the cooling fan lower shroud.

Release and remove the cooling fan lower shroud

from the cooling pack.

6. Position the A/C compressor mounting bracket assembl

aside.

Remove the 4 bolts.

Tie aside.

7. Disconnect the 2 hoses from the coolant pump.

Release the c linder head coolant flange, to aid

coolant hose removal.

Remove the 3 bolts.

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Po i ion he coolan ho e a ide fo acce .

. Di connec he engine g o nd cable.

Remo e he n .

. Relea e he an mi ion line ppo b acke .

Remo e he n .

Po i ion a ide.

10. Remo e he engine f on co e .

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Remove the 5 studs.

Remove the 4 bolts.

Remove the 5 cylinder cradle bolts.

Remove and discard the gasket.

11. NOTE: Do not disassemble further if the component is

removed for access only.

Remove the coolant pump.

Remove the 12 bolts.

Remove and discard the gasket.

In alla ion
1. Install the coolant pump.

C lean the component mating faces.

Install the new gasket.

Tighten the bolts to 10 Nm (7 lb.ft).

2. C AUTION: C are must be taken when removing sealant

from gasket faces, prevent damage to the mating faces.

NOTE: The component must be installed within 20 minutes of

the sealant application.

NOTE: Make sure the cylinder block cradle gasket is located

correctly around the front oil seal.

Install the engine front cover.

C lean the component mating faces.

Spirit wipe the gasket mating faces.

Install a new gasket.

Apply sealant to the 4 places shown.

3. NOTE: Tighten the bolts in two stages.

Install the engine front cover bolts.

Evenly and progressively tighten the bolts and studs to

8 Nm (6 lb.ft).

Tighten the M6 bolts to 10 Nm (7 lb.ft).

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Tighten the M8 bolts and studs to 20 Nm (15 lb.ft).

. Install the transmission support bracket.

Tighten the nut to 20 Nm (15 lb.ft).

. NOTE: C are must be taken when installing the ground

connections. The engine will fail to start on either or both
banks if the ground is poor.

C onnect the engine ground cable, make sure the mating

faces are clean.

Tighten the nut to 20 Nm (15 lb.ft).

. Install the A/C compressor mounting bracket assembl .

Release the cable tie.

Tighten the bolts to 45 Nm (33 lb.ft).

. Install the crankshaft pulle .

For additional information, refer to: C rankshaft Pulle (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
. Install the cooling fan shroud.
. Install the intake manifold.
For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
10. Refill and bleed the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
11. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Timing Dri e Components
In-vehicle Repair

Special Tool(s)
C rankshaft rotating tool

303-674

Remo al
NOTE: This procedure covers the removal and installation of the following components: Primary timing chain
tensioner, timing chain guide, jackshaft sprocket, crankshaft sprocket and timing chain.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the engine front cover.
For additional information, refer to: Engine Front C over
(303-01A Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Remove the primary timing chain tensioner.

Remove the 2 bolts.

4. Remove the primary timing chain tensioner guide.

Remove the 2 bolts.

5. Install the special tool to the crankshaft.

6. Remove the jackshaft sprocket.

Using an additional wrench and the special tool,

restrain the jackshaft sprocket.

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Remo e and di ca d he To bol .

7. NOTE: No e he fi ed po i ion.

Remo e he c ank haf p ocke .

Remo e he p ima iming chain.

In alla ion
1. In all he p ima iming chain.

C lean he componen ma ing face .

In all he c ank haf p ocke , he ece ed face

loca e o he c ank haf ide.

In all he pecial ool o he c ank haf .

2. In all he jack haf p ocke .

C lean he componen ma ing face .

Loca e he p ima iming chain o he p ocke .

In all a ne To bol , ligh l igh en a hi age.

3. In all he iming chain g ide.

C lean he componen ma ing face .

Tigh en he bol o 20 Nm (15 lb.f ).

4. In all he iming chain en ione .

C lean he componen ma ing face .

Tigh en he bol o 10 Nm (7 lb.f ).

5. Tigh en he ne To bol o 45 Nm (33 lb.f ), hen a f he

70 deg ee .
6. In all he engine f on co e .
Fo addi ional info ma ion, efe o: Engine F on C o e
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).

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. Adjust the valve timing.
For additional information, refer to: C amshaft Timing (303-
01A Engine - V6 4.0L Petrol, General Procedures).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Camshaft Dri e Cassette LH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the c linder head LH assembl .
For additional information, refer to: C linder Head LH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Remove the timing drive components.
For additional information, refer to: Timing Drive
C omponents (303-01A Engine - V6 4.0L Petrol, In-vehicle
Repair).
4. Remove the camshaft drive cassette assembl .

Remove the bolt retaining the chain guide.

5. NOTE: Do not disassemble further if the component is

removed for access onl .

Disassemble the cassette assembl .

Release the cable tie.

Remove the sprockets and the chain.

C lean and inspect the components for deterioration.

Installation
1. Assemble the cassette assembl .

Install the chain and the sprockets.

Secure with a cable tie.

2. Install the camshaft drive cassette assembl .

Tighten the bolt to 25 Nm (18 lb.ft).

3. Install the timing drive components.

For additional information, refer to: Timing Drive
C omponents (303-01A Engine - V6 4.0L Petrol, In-vehicle
Repair).

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. Install the c linder head LH assembl .
For additional information, refer to: C linder Head LH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Camshaft Dri e Cassette RH
In-vehicle Repair

Special Tool(s)
Sprocket holding tool RH rear
cassette

303-643

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the RH c linder head assembl .
For additional information, refer to: C linder Head RH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Remove the torque converter fle plate.
For additional information, refer to: Fle plate (303-01A
Engine - V6 4.0L Petrol, In-vehicle Repair).
4. Remove the c linder block jackshaft plug.

Drift to release.

5. Using the special tool, remove the RH cassette jackshaft

drive, sprocket bolt.

Remove and discard the Tor bolt.

6. Remove the camshaft drive cassette assembl .

Remove the bolt retaining the chain guide.

Remove and discard the O-ring seal.

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7. NOTE: D
.

D .

R .

R .

C .

In alla ion
1. A .

I .

S .

2. I .

I O- .

T 12 N (9 . ).

3. U ,
40 N (30 . ), 45 .

4. I .

C .

5. I .
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For additional information, refer to: Fle plate (303-01A
Engine - V6 4.0L Petrol, In-vehicle Repair).
. Install the c linder head RH assembl .
For additional information, refer to: C linder Head RH (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Petrol - Engine D namic Balance Shaft
In- ehicle Repai

Special Tool(s)
C ank haf TDC iming/locking ool

303-573

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. Remo e he f on heel and i e .
4. Remo e he c linde block c adle.
Fo addi ional info ma ion, efe o: C linde Block C adle
(303-01A Engine - V6 4.0L Pe ol, In- ehicle Repai ).
5. Remo e he balance haf .

Remo e he 4 To bol .

Remo e he d i e chain en ione .

Remo e he en ione blade.

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In alla ion
1. NOTE: Vehicles fitted with early type balance shaft.

NOTE: Due to the gear ratio, it may be necessary to

rotate the balance shaft up to 7 complete turns to find the
correct position.

Align the balance shaft.

C lean the components.

Lubricate the components.

Install a 4 mm (0.16 in) pin to lock the shaft as

shown.

2. NOTE: Vehicles fitted with later type balance shaft.

NOTE: If a new balance shaft is being fitted make sure the

timing pin is not removed prior to fitting.

NOTE: Due to the gear ratio, it may be necessary to

rotate the balance shaft up to 7 complete turns to find the
correct position.

Align the balance shaft.

C lean the components.

Lubricate the components.

Install a 4 mm (0.16 in) pin to lock the shaft as

shown and that the shaft can not rotate.

Make sure the drive gear timing marks are aligned

as shown.

3. Rotate crankshaft clockwise until number one cylinder is

at TDC and install the special tool.

4. Install the balance shaft.

C lean the component mating faces.

Engage the drive chain.

Install the drive chain tensioner.

Tighten the Torx bolts to 15 Nm (11 lb.ft).

Tighten a further 90 degrees.

Remove the locking pin.

Remove the special tool.

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. Install the c linder block cradle.

For additional information, refer to: C linder Block C radle
(303-01A Engine - V6 4.0L Petrol, In-vehicle Repair).
. Install the front wheels and tires.
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - Jackshaft
In-vehicle Repair

Special Tool(s)
Sprocket holding tool RH rear
cassette

303-643

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the torque converter fle plate.
For additional information, refer to: Fle plate (303-01A
Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Remove the c linder block jackshaft plug.

Drift to release.

4. Using the special tool, remove the RH cassette jackshaft

drive, sprocket bolt.

Remove and discard the Tor bolt.

5. Remove the camshaft drive cassette LH assembl .

For additional information, refer to: C amshaft Drive
C assette LH (303-01A Engine - V6 4.0L Petrol, In-vehicle
Repair).
6. Remove the oil pump drive gear.

Remove the bolt.

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Remo e he clamp.

Remo e and di ca d he O- ing eal.

7. Remo e he jack haf h pla e.

Remo e he 2 To bol .

8. Remo e he jack haf .

C ollec he pace .

In alla ion
1. In all he jack haf .

C lean he componen ma ing face .

In all he jack haf pace .

L b ica e he componen i h clean engine oil.

2. NOTE: The g oo e in he h pla e m face he

c linde block.

In all he jack haf h pla e.

C lean he componen ma ing face .

L b ica e he componen i h clean engine oil.

Tigh en he To bol o 10 Nm (7 lb.f ).

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.I .

C .

L .

I O- .

I .

T 20 N (15 . ).

.I LH .
F , :C D
C LH (303-01A E - V6 4.0L P ,I -
R ).
.U , RH
, .

C .

U ,
40 N (30 . ), 45
.

.I .

C .

.I .
F , :F (303-01A
E - V6 4.0L P ,I - R ).
.C .
F , :S (414-00
B C S -G I ,
S ).

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Engine - V6 4.0L Petrol - Jackshaft
In-vehicle Repair

Special Tool(s)
Sprocket holding tool RH rear
cassette

303-643

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the torque converter fle plate.
For additional information, refer to: Fle plate (303-01A
Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Remove the c linder block jackshaft plug.

Drift to release.

4. Using the special tool, remove the RH cassette jackshaft

drive, sprocket bolt.

Remove and discard the Tor bolt.

5. Remove the camshaft drive cassette LH assembl .

For additional information, refer to: C amshaft Drive
C assette LH (303-01A Engine - V6 4.0L Petrol, In-vehicle
Repair).
6. Remove the oil pump drive gear.

Remove the bolt.

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Remo e he clamp.

Remo e and di ca d he O- ing eal.

7. Remo e he jack haf h pla e.

Remo e he 2 To bol .

8. Remo e he jack haf .

C ollec he pace .

In alla ion
1. In all he jack haf .

C lean he componen ma ing face .

In all he jack haf pace .

L b ica e he componen i h clean engine oil.

2. NOTE: The g oo e in he h pla e m face he

c linde block.

In all he jack haf h pla e.

C lean he componen ma ing face .

L b ica e he componen i h clean engine oil.

Tigh en he To bol o 10 Nm (7 lb.f ).

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.I .

C .

L .

I O- .

I .

T 20 N (15 . ).

.I LH .
F , :C D
C LH (303-01A E - V6 4.0L P ,I -
R ).
.U , RH
, .

C .

U ,
40 N (30 . ), 45
.

.I .

C .

.I .
F , :F (303-01A
E - V6 4.0L P ,I - R ).
.C .
F , :S (414-00
B C S -G I ,
S ).

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Engine - V6 4.0L Petrol - H draulic Timing Chain Tensioner LH
In-vehicle Repair

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the intake manifold.
For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).

3. C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

Remove the LH h draulic timing chain tensioner.

Installation
1. Install the LH h draulic timing chain tensioner.

C lean the component mating faces.

Tighten the tensioner to 45 Nm (33 lb.ft).

2. Install the intake manifold.

For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
3. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V6 4.0L Petrol - H draulic Timing Chain Tensioner RH
In-vehicle Repair

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - V6 4.0L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).

3. C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

Remove the RH h draulic timing chain tensioner.

Installation
1. Install the RH h draulic timing chain tensioner.

C lean the component mating faces.

Tighten the tensioner to 45 Nm (33 lb.ft).

2. Install the engine cover.

For additional information, refer to: Engine C over - V6 4.0L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-May-2011
Engine - V6 4.0L Petrol - Intake Manifold
In-vehicle Repair

Special Tool(s)
Fuel spring lock decoupling tool

310-044

Remo al
NOTE: Removal of the intake manifold on early vehicles will involve the partial dismantling of the fuel rail and the
removal of the purge valve and mounting bracket. Once removed, it will also be necessary to remove some excess
material from the intake manifold, see 'installation' steps 1 and 2.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Secure the hood in the service position.

Release the support struts.

3. Remove the engine cover.

For additional information, refer to: Engine C over - V6 4.0L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
4. Remove the air intake resonator.
For additional information, refer to: Intake Air Resonator
(303-12A Intake Air Distribution and Filtering - V6 4.0L
Petrol, Removal and Installation).
5. Disconnect the throttle body electrical connector.

6. Disconnect the intake manifold coolant hose.

C lamp the relevant hose, to minimise coolant loss.

Release the clip.

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. Disconnect the throttle bod coolant hose.

C lamp the hose to minimise coolant loss.

Release the clip.

. C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

Disconnect the crankcase vent hose.

. Remove the RH crankcase vent hose.

10. Disconnect the EGR valve electrical connector.

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. Disconnect the EGR valve feed pipe.

Loosen the EGR valve feed pipe union nut, at the

e haust manifold.

Disconnect the union nut, securing the EGR pipe to

the valve.

. Disconnect the intake manifold vacuum pipe assembl .

. Disconnect the intake manifold tuning valve electrical

connector.

. Release the purge line from the intake manifold.

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Remo e he clip e aining bol .

C ollec he pace .

1 . Relea e he coil i ing ha ne .

Relea e he 6 clip .

Remo e he 2 coil ha ne g o nd n .

1 . Di connec he 6 coil elec ical connec o .

1 . NOTE: No e he fi ed po i ion of he fa ene .

Remo e he 2 ea igni ion coil .

Di connec he pa king pl g lead elbo a he

coil .

Remo e he 2 bol and 2 d .

Di ca d he fa ene O- ing o aid in alla ion.

1 . Di connec he HT lead a he pa king pl g .

Po i ion he lead a ide.

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1 .P .

20. R 8 .

21. NOTE: T
.

R .

22. WARNINGS:

P ,
'N S /P F '
.

T
.E
.

W 30
-
.F
.

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If fuel contacts the eyes, flush the eyes with cold

water or eyewash solution and seek immediate medical
attention.

Using the special tool, disconnect the fuel line.

Remove the security clip.

Early vehicles only: Remove 4 bolts and release the

fuel rail and injectors.

Early vehicles only: Disconnect the LH and RH

cylinder head, rear fuel injector electrical
connectors.

Early vehicles only: Remove the bolt and release the

valve cover fuel line clip.

Early vehicles only: C able tie the purge valve to the

wiring harness.

. C AUTIONS:

Early vehicles only: The purge valve and mounting

bracket are bolted to the rear of the intake manifold and
foul the fuel rail crossover link. Damage will occur if force is
used when attempting to remove the intake manifold. If this
occurs, remove the LH side, battery tray inner wall and
base, for access to the purge valve bolt.

C are must be taken to avoid damaging the purge vale

assembly during removal of the intake manifold.

NOTE: Due to the lack of access it may be necessary to

break the engine and transmission wiring harness clips,
care must be taken not to damage the wiring harnesses.

Release and then remove the intake manifold.

Discard the gaskets.

Install blanking caps to the exposed ports.

. NOTE: Do not disassemble further if the component is

removed for access only.

Remove the throttle body.

Remove the 4 bolts.

Remove and discard the throttle body gasket.

Disconnect the coolant hose.

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2 . Di connec he EGR al e ac m ho e.

Di connec and emo e he ac m ho e a he

in ake manifold.

2 . Remo e he EGR al e.

Remo e he 2 bol .

C ollec and di ca d he ga ke .

2 . Remo e he emaining igni ion coil .

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Di connec he pa king pl g lead elbo a he coil .

Remo e he bol and d . Remo e and di ca d he

eal .

28. Remo e he HT lead .

Relea e he 6 pl g lead clip .

29. Remo e he in ake manifold ning al e.

Remo e he 2 bol .

Di ca d he O- ing eal.

In alla ion

1. WARNING: Make e he e a e no ha p edge

af e emo ing ma e ial.

Ea l ehicle onl : Remo e he cen e ca ing l g.

2. Ea l ehicle onl : Remo e e ce ma e ial f om he

o ide edge of he 6 in ake manifold flange face ; file
o i hin 2 mm of he ga ke edge.

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. Earl vehicles onl : Install the fuel rail and injectors.

C lean the component mating faces.

Tighten the bolts to 25 Nm (18 lb.ft).

C onnect the fuel injector electrical connectors.

Tighten the M6 bolt to 10 Nm (7 lb.ft).

. Install the intake manifold tuning valve.

C lean the component mating faces.

Install a new O-ring seal.

Tighten the bolts to 10 Nm (7 lb.ft).

. Secure the HT leads to the intake manifold with clips.

. NOTE: Note the fitted position of the fasteners.

Install the 4 ignition coils.

Tighten the bolts to 6 Nm (4 lb.ft).

Tighten the studs to 6 Nm (4 lb.ft).

C onnect the HT electrical connections.

. Install the EGR valve.

C lean the component mating faces.

Install a new gasket.

Tighten the bolts to 25 Nm (18 lb.ft).

. C onnect the vacuum hose to the EGR valve.

. C onnect the EGR vacuum hose to the intake manifold.

C lean the component mating faces.

C onnect the vacuum hose to the EGR valve.

10. Install the throttle bod .

C lean the component mating faces.

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Install a new gasket.

Tighten the 4 bolts to 10 Nm (7 lb.ft).

. Install the throttle body coolant hose.

Secure the clip.

Remove the hose clamp.

. Secure the wiring harness to the intake manifold.

Secure the wiring harness clip.

. C AUTION: C are must be taken prior to tightening

the intake manifold bolts. Make sure the electrical harness,
vacuum and purge valve lines are not trapped.

NOTE: To aid installation: Position a Torx drive and

extension, to the rear LH bank intake manifold Torx bolt,
prior to installing the intake manifold. Retain with tape.

NOTE: The ignition coils are removed from the illustration

for clarity.

Install the intake manifold.

C lean the component mating faces.

Install the gaskets.

Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm (7 lb.ft).

. Install the remaining ignition coils.

Tighten the bolts to 6 Nm (4 lb.ft).

Tighten the studs to 6 Nm (4 lb.ft).

C onnect the HT electrical connections.

. C onnect the ignition coil electrical connectors.

. C onnect the fuel line to the fuel rail.

C lean the component mating faces.

Install the clip.

. Secure the coil wiring harness.

C onnect the coil harness ground cables.

Tighten the nuts to 6 Nm (4 lb.ft).

Position and secure the clips.

. C onnect the intake manifold tuning valve electrical

connector.
. C onnect the vacuum pipe to the inlet manifold.
. Secure the purge line to the intake manifold.

Install the spacer.

Install the bolt.

Tighten the bolt to 6 Nm (4 lb.ft).

. C onnect the crankcase vent hose.

C lean the component mating faces.

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. C onnect the intake manifold coolant hose.

Secure the clip.

Remove the hose clamp.

. Install the air intake resonator.

For additional information, refer to: Intake Air Resonator
(303-12A Intake Air Distribution and Filtering - V6 4.0L
Petrol, Removal and Installation).
. Install the engine cover.
For additional information, refer to: Engine C over - V6 4.0L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
. C onnect the hood support struts.
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. C heck and top-up the coolant.

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Petrol - E haust Manifold LH
In- ehicle Repai

Removal

All ehicle
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V6 4.0L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).

Righ -hand d i e ehicle

3. Relea e he ba e po i i e cable.

Loo en he clamp.

Relea e he g omme .

Righ -hand d i e ehicle

4. Relea e he i ing ha ne clip.

Remo e he bol .

All ehicle

5. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

6. Remo e he engine nde hield.
Fo addi ional info ma ion, efe o: Engine Unde hield
(501-02 F on End Bod Panel , Remo al and In alla ion).
7. Relea e he e ha em f om he e ha manifold.

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Remo e and di ca d he 2 bol .

. Lo e he ehicle.

. C AUTION: P o ec he engine d ing hi ope a ion.

Rai e he engine clea of i LH mo n .

Remo e he n .

10. C AUTION: Befo e di connec ing o emo ing he

componen , en e he a ea a o nd he join face and
connec ion a e clean. Pl g open connec ion o p e en
con amina ion.

Remo e he EGR pipe.

Relea e he 2 nion n .

11. Di connec he high en ion (HT) elec ical connec o .

Mo e he lead a ide fo acce .

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12. C AUTION: B
,
.P
.

R .

R .

R .

D O- .

13. R .

R 6 .

R .

In alla ion
A
1. NOTE: T
.

I .

I .

C .

T 25
N (18 . ).

2. I .

C .

I O- .

L .

T 10 N (7 . ).

I .

3. C HT .
4. I EGR .

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C lean he componen ma ing face .

Ini iall , finge igh en he n .

Finall , igh en he n o 40 Nm (30 lb.f ).

. Lo e he engine on o i mo n .

Tigh en he n o 90 Nm (66 lb.f ).

. Rai e he ehicle.
. In all he e ha em.

C lean he componen ma ing face .

In all ne bol and igh en o 40 Nm (30 lb.f ).

. In all he engine nde hield.

Fo addi ional info ma ion, efe o: Engine Unde hield
(501-02 F on End Bod Panel , Remo al and In alla ion).
. Lo e he ehicle.

Righ -hand d i e ehicle

10. NOTE: Appl pe ole m jell o he ba e e minal .

C onnec he ba e po i i e cable.

C lean he componen ma ing face .

In all he g omme .

Tigh en he clamp n o 10 Nm (7 lb.f ).

Righ -hand d i e ehicle

11. Sec e he i ing ha ne clip.

Tigh en he bol o 10 Nm (7 lb.f ).

All ehicle
12. In all he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V6 4.0L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
13. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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P bli hed: 11-Ma -2011

Engine - V6 4.0L Petrol - E haust Manifold RH
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V6 4.0L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).

3. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

4. Relea e he e ha em f om he e ha manifold.

Remo e and di ca d he 2 bol .

5. Lo e he ehicle.
6. Di connec he high en ion (HT) elec ical connec o .

Mo e he lead a ide fo acce .

7. Remo e he e ha manifold.

Remo e he 6 n .

Remo e and di ca d he ga ke .

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In alla ion
1. In all he e ha manifold.

C lean he componen ma ing face .

In all a ne ga ke .

E enl and p og e i el , igh en he n o 25 Nm

(18 lb.f ).

2. C onnec he HT elec ical connec o .

3. Rai e he ehicle.
4. In all he e ha em.

C lean he componen ma ing face .

In all ne bol and igh en o 40 Nm (30 lb.f ).

5. Lo e he ehicle.
6. In all he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V6 4.0L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
7. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Engine - V6 4.0L Petrol - Engine
Removal

Special Tool(s)
Engine lifting cradle - 4.0L

303-1147

Engine lifting bracket

303-940 (LRT-12-138)

Lifting chains

303-940/1

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Secure the hood in the service position.
3. Raise and support the vehicle.
4. Drain the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
5. Drain the engine oil.
For additional information, refer to: Engine Oil Draining and
Filling (303-01A Engine - V6 4.0L Petrol, General
Procedures).
6. NOTE: Earl vehicles will require the partial release of the
fuel rail, to allow the intake manifold to be removed.

Remove the intake manifold.

For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
7. Remove the batter tra .
For additional information, refer to: Batter Tra (414-01
Batter , Mounting and C ables, Removal and Installation).
8. Disconnect the 2 EC M electrical connectors.

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. Release the wiring harness from the plenum.

Release the 2 clips.

Position the wiring harness aside.

10. Remove the accessor drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
11. Remove the lower fan shroud.

Release 2 clips from the cooling fan lower shroud.

12. Install a shield to protect the radiator core from damage.

13. Disconnect the generator electrical connectors.

Disconnect the electrical connector.

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1 . Position the generator mounting bracket aside.

Remove the 3 bolts.

Release the wiring harness clip.

Remove and discard the cable tie.

1 . C AUTION: The A/C s stem will remain full

charged during this procedure, care must be taken when
positioning the assembl aside.

Position the A/C compressor mounting bracket assembl

aside.

Disconnect the A/C compressor electrical connector.

Release the LH KS electrical connector retaining clip.

Remove the 4 bolts.

1 . Disconnect the engine oil pressure (EOP) sensor

electrical connector.

1 . Disconnect the engine ground cable.

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Remove the nut.

1 . Release the transmission cooler pipes.

Remove the nut.

Position aside.

1 . Remove the EGR pipe.

Loosen the EGR union nut and release the pipe.

20. C heck the road wheels are in the straight ahead position,
then remove the upper clamp bolt.

Discard the retaining bolt.

21. Remove the steering gear universal joint clamp bolt.

Discard the retaining bolt.

22. Release the upper steering column shaft.

23. Release and remove the shaft and joint assembl .

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2 . Relea e he coolan p mp ho e.

Po i ion a ide.

Relea e f om he clip.

2 . Di connec he 2 engine oil coole , coolan ho e .

Relea e he 2 clip .

2 . Remo e he an mi ion hea hield.

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Remove the 4 bolts.

2 . Disconnect the LH catal st monitor sensor electrical

connector.

Release HO2S harness from bracket.

2 . Disconnect the LH catal tic converter from the e haust

manifold.

Remove the 2 bolts.

2 . Disconnect the RH catal st monitor sensor electrical

connector.

Release HO2S harness from bracket.

30. Disconnect the RH catal tic converter from the e haust

manifold.

Remove the 2 bolts.

31. Disconnect the engine oil temperature sensor electrical

connector.

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. Relea e he a e mo o .

Remo e he 2 bol .

. Relea e he ha ne b acke .

Remo e he 2 n .

. Di connec he c ank haf po i ion (C KP) en o

elec ical connec o .

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3 . Install the engine lifting bracket.

Tighten the bolts to 45 Nm (33 lb.ft).

Evenl and progressivel , tighten the nuts to 25 Nm

(18 lb.ft).

3 . Release the fle plate.

Rotate the crankshaft to access the retaining bolts.

Remove the 4 bolts.

3 . Release the fuel pipe and purge line heat shield.

Remove the 2 bolts.

Position the fuel line shield aside for access.

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3 . WARNING: Support the engine. The engine will fall

forward when the transmission is removed.

Remove the transmission bolts.

C onnect the lifting chains.

Support the transmission.

Remove the 8 bolts.

3 . WARNING: Make sure the torque converter

remains with the transmission.

Remove the engine.

Remove the 2 engine mount nuts.

Remove the engine RH mount.

Raise the engine.

With assistance, carefull remove the engine.

40. Install the torque converter retainer.

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P b i hed: 11-Ma -2011

Engine - V6 4.0L Pe ol - Engine
I a ai

In alla ion
1. Re e he e c e e e ai e .
2. I a he e gi e.

C ec he if i g chai .

C a ef e he e gi e i a i ae 35
ab e e gi e .

Wi h a i a ce a ig he e gi e he a i i
a d e gi e .

3. I a he RH e gi e .
4. I a he a i i e ai i g b .

C ea he c e a i g face .

Re e he g ide i .

Tigh e he b 45 N (33 b.f ).

5. Tigh e he e gi e 90 N (66 b.f ).

6. Re e he e gi e if i g b ac e .

Di c ec he if i g chai .

Re e he 7 b .

Re e he 12 .

7. A ach he f e ae he e c e e .

R a e he c a haf acce he e ai i g b .

Tigh e he b 45 N (33 b.f ).

I a he g e .

8. C ec he C KP e e ec ica c ec .

C ea he c e a i g face .

9. C ec he HO2S e ec ica c ec .
10. I a he e gi e i i g ha e b ac e .
11. C ec he e gi e i e e a e e e ec ica
c ec .
12. I a he a e .

C ea he c e a i g face .

Tigh e he b 45 N (33 b.f ).

13. P ii he f e i e a d ge i e hea hie d a d

ec e ihb .
14. P i i he RH ca a ic c e e he e ha
a if d.

C ea he c e .

Tigh e he e b 22 N (16 b.f ).

15. C AUTION: Ma e e he e i a c ea a ce (A) f

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25 mm o 30 mm be een he clo e poin of he LH
ca al ic con e e and he f on d i e haf .

Po i ion he LH ca al ic con e e o he e ha
manifold.

C lean he componen .

Tigh en he ne bol o 22 Nm (16 lb.f ).

. In all he an mi ion hea hield.

. C onnec he engine oil coole ho e .

Sec e i h he clip .

. C onnec he coolan p mp ho e.

Sec e i h he clip.

. In all he ee ing col mn lo e ni e al join a embl .

In all ne pa chlock bol and igh en o 25 Nm (18

lb.f ).

. C onnec he EC T en o elec ical connec o .

. In all he EGR pipe.

C lean he componen ma ing face .

In all o he e ha manifold, b do no f ll igh en

he nion n a hi age.

. In all he an mi ion coole pipe .

In all he ppo b acke .

Tigh en he n o 10 Nm (7 lb.f ).

. C onnec he engine g o nd cable, make e he ma ing

face a e clean.

Tigh en he n o 25 Nm (18 lb.f ).

In all he co e .

. In all he A/C comp e o mo n ing b acke a embl .

C lean he componen ma ing face .

Tigh en he bol o 45 Nm (33 lb.f ).

In all he KS elec ical connec o clip.

C onnec he A/C comp e o elec ical connec ion.

. In all he gene a o mo n ing b acke .

C lean he componen ma ing face .

Tigh en he bol o 45 Nm (33 lb.f ).

Sec e he clip.

In all a ne cable ie.

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.C ec he EOP e e ec ica c ec .
.C ec he ge e a e ec ica c ec .
.I a he acce d i e be .
F addi i a i f a i , efe : Acce D i e Be
(303-05A Acce D i e - V6 4.0L Pe , Re a a d
I a a i ).
.I a he c i g fa e h d.

Re e he adia ec i .

P ii a d ec e i he c i .

.I a he i i g ha e he e .

Sec e i h he c i .

.C ec he EC M e ec ica c ec .
.I a he ba e a .
F addi i a i f a i , efe : Ba e T a (414-01
Ba e , M i g a d C ab e , Re a a dI a a i ).
.I a he i a e a if d.
F addi i a i f a i , efe : I a e Ma if d (303-
01A E gi e - V6 4.0L Pe , I - ehic e Re ai ).
. Tigh e he ec i g he EGR i e he e ha
a if d a d EGR a e 25 N (18 b.f ).
. Fi he e gi e i h i .
F addi i a i f a i , efe : E gi e Oi D ai i g a d
Fi i g (303-01A E gi e - V6 4.0L Pe , Ge e a
P ced e ).
. Refi a d b eed he c i g e .
F addi i a i f a i , efe :C i gS e
D ai i g, Fi i g a d B eedi g (303-03A E gi e C i g - V6
4.0L Pe , Ge e a P ced e ).
. Re he h df he e ice ii .

Re ea e he 2 c i .

C ec he a d ec e i h he c i .

.C ec he ba e g d cab e.
F addi i a i f a i , efe : S ecifica i (414-00
Ba e a d C ha gi g S e - Ge e a I f ai ,
S ecifica i ).
. U i g he a ed diag ic e i e , c ea he
e ai c d e (PC M) ada i .

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Published: 13-Sep-2011
E gi e - V8 4.4L Pe -
Sea e
I e La d R e Pa N .
Valve cover gasket 8510303
Sump pan 8510303
Oil strainer pick-up pipe bolts STC 50553
C ylinder block core plugs STC 50554
Timing cover seal apertures 8510303
C ylinder block coolant outlet elbow stub pipe STC 50554
Bedplate to cylinder block 8510303
L b ica - UK, E e a d ROW - N NA S/Ja a
I e S ecifica i
* Recommended Lubricant 5W/30 Preferred: WSS–M2C 913–B Alternative: AC EA A3/B3
* WSS i a F d efi he i ecifica i
L b ica NA S/Ja a
I e S ecifica i
* Recommended Lubricant 5W/30 – ILSAC GF4 and API SM
* WSS i a F d efi he i ecifica i
Ca aci
I e Ca aci
Dry fill including filter 8 litres (14 pints) (8.5 US quarts)
Oil and filter change 7.7 litres (13.6 pints) (8.1 US
quarts)
Amount of oil required to bring the level from the lower to the upper holes on the 1.5 litres (2.6 pints) (1.5 US
dipstick quarts)
Ge e a S ecif ica i
I em Specifica ion
Type 4.4 litre 90° 'V', petrol engine, twin overhead camshafts per cylinder head, 4 valves
per cylinder
Bore - nominal 88.0 mm (3.465 in)
Stroke 90.3 mm (3.55 in)
C apacity 4396 cm (268.3 in )
Firing order Refer to Description and Operation section
C ompression ratio 10.5:1
Direction of rotation Anti-clockwise - viewed from rear of engine
Ma i e :
UK/Europe and ROW - Not 220 kW (295 bhp) @ 5500 rev/min
NAS/Japan
NAS/Japan 300 bhp (224 kW) @ 5500 rev/min
Ma i e:
UK/Europe and ROW - Not 425 Nm (313 lb-ft) @ 4000 rev/min
NAS/Japan
NAS/Japan 315 lb-ft (427 Nm) @ 4000 rev/min
Di e i :
Length 720 mm (28.3 in)
Width 720 mm (28.3 in)
Height 785 mm (30.9 in)
* E gi e i e e:
At idle 1.0 bars (100 kPa) (15.0 lb/in )
At 3500 rev/min 3.0 bars (300 kPa) (44.0 lb/in )
** Va e c ea a ce :
Inlet 0.18 to 0.22 mm (0.007 to 0.008 in)
Exhaust 0.23 to 0.27 mm (0.009 to 0.010 in)
C i de Head
Maximum permitted warp 0.125 mm (0.005 in)
* N e: i chec i g he e gi e i e e, a ad e f 6 i e (10 i e e ) be ca ied
.D a e a ai e gi e a e a i g e e a e b a i g he e gi e id e

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** Note: that there are 50 different thicknesses of graded tappet available ranging from 2.950 to 3.685
mm (0.116 to 0.145 in) rising in increments of 0.015 mm (0.0005 in)
Torque Specif ications
Description Nm lb-ft
Exhaust manifold heat shield bolt 25 18
* Exhaust manifold to cylinder head bolts 20 15
Battery clamp nut 10 7
*+ C linder head bolts:
Stage 1 - Tighten bolts 1 to 10 20 15
Stage 2 - Tighten bolts 1 to 10 35 26
Stage 3 - Tighten bolts 1 to 10 Further 90 Further 90
Stage 4 - Tighten bolts 1 to 10 Further 90 Further 90
Stage 5 - Tighten the M8 bolts 11 and 12 25 18
EGR pipe to exhaust manifold flange nuts 25 18
C MP sensor Torx screw 7 5
Oil filter adapter 60 44
++ Oil filter 18 13
Oil drain plug 25 18
Oil cooler bolts 10 7
Oil cooler Allen bolt 60 44
Primary timing chain tensioner guide bolts 12 9
Primary timing chain tensioner bolts 12 9
Secondary timing chain tensioner bolts 12 9
Primary timing chain tensioner guide stud 12 9
** VC T oil control unit bolts 22 16
LH VC T oil control unit nut 10 7
* C amshaft bearing cap bolts 10 7
** Intake camshaft sprocket retaining bolt
Stage 1 20 15
Stage 2 Further 90 Further 90
** E haust camshaft sprocket retaining bolt
Stage 1 20 15
Stage 2 Further 90 Further 90
Engine front mount bolts:
Stage 1 45 33
Stage 2 Further 60 Further 60
Engine to front mount nut 90 66
Engine ground cable bolt 25 18
Starter motor bolts 45 33
+++ Starter motor cable nut 10 7
*+ Steering column lower universal joint bolts 25 18
Brake hose to upper arm bolt 23 17
** Upper arm/wheel knuckle nut 70 52
Stabilizer bar link nuts 175 129
*+ C rankshaft pulley bolt 380 280
PC V valve bolts 6 4
* RH valve cover bolts 12 9
* LH valve cover bolts 12 9
Oil level indicator tube nut 6 4
* Sump pan bolts 20 15
Transmission retaining bolts 45 33
Transmission cooler pipes clamp bolt 25 18
A/C compressor bolts 25 18
Power steering pump bolts 25 18
Differential extension bolts 45 33
HO2S mounting bracket bolts 10 7
Oil pump to cylinder block bolts 10 7
**+ Oil strainer pick-up pipe bolts - M5 6 4
Oil strainer pick-up pipe bolt - M6 10 7
C oolant pump pulley bolts 10 7

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C oolan c o o e be bol 6 4
Acce o d i e bel idle p lle bol 25 18
Acce o d i e bel en ione bol 40 30
Vi co fan d i e bel en ione p lle bol 25 18
Vi co fan d i e bel en ione bol 40 30
Radia o acce panel bol 10 7
Engine oil p e e en o 12 9
E ha manifold EGR pipe o flange n and bol 25 18
EGR al e o EGR pipe bol 25 18
Uppe pen ion a m and b ake line hea hield n and bol 10 7
Ba e po i i e cable o ba e j nc ion bo (BJB) bol 10 7
F e a e e c e e b :
S age 1 15 11
S age 2 110 81
Hood bol 25 18
Road heel n 140 103
Engine oil empe a e en o 20 15
Engine f on co e bol 12 9
Gene a o mo n ing b acke bol 45 33
Gene a o mo n ing bol 48 35
*B be igh e ed i e e ce

** Ne /b be i a ed

**+ A ea a h ead

*+ Ne Pa ch b ( ) be i a ed

+ Ligh i b h ead

++ A e gi e i ea

+++ Da age i e a c ec i i e if hi e i e ceeded

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P : 11-M -2011
Engine - V8 4.4L Pe rol - Engine
D O

E V

GENERAL

T V8 4.4 ,8 , 90 'E 'V , 4 ,

.T EC D3 (E C D ) US F
T 2B 8 , ,
- .T
, .T E C M (EC M) .

T
.T -
.T - .T
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- .

E S

I em Pa N mbe De c ip ion
1 - C
2 - C
3 - B
4 - S

ECHNICAL FEA E

T :

A 90 'E V'

P - ,
T ,
F
A ( )
V V T (VVT) ( )
T , 12-
E
P
A
A
F - -
A - ,
F
E E G R (EGR)
A
M , E O -B D (EOBD) III, US
F OBD C OBDII .

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ENGINE DATA

DESCRIPTION TYPE
C fig a i 90 degree V8
Ma i e 220 kW at 6000 rpm
Ma i e 425 Nm at 4000 rpm
Di ace e 4.396 litres
S e/b e 90.3/88.0 mm
C e i a i 10.50 : 1
Fi i g de ( e 2005) 15426378
Fi i g de (2005 a d ) 12734568
E gi e eigh 208 kg (appro .)
Oi e 7.5 litres ( et)

CYLINDER BLOCK COMPONENTS

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I em Pa N mbe De c ip ion
1 - Pi on ing
2 - Pi on

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3 - C irclip
4 - C onnecting rod
5 - Bolts
6 - C onnecting rod bearing shells
7 - Bearing
8 - Gudgeon pin
9 - C irclip
10 - C linder block
11 - Pistons
12 - Bolts
13 - Fl wheel
14 - Seal
15 - Dowel
16 - C rankshaft
17 - Thrust washer
18 - Thrust washer
19 - Bearing shells - upper
20 - Bearing shells - lower
21 - Oil level gauge tube
22 - Oil level gauge
23 - Bedplate
24 - Bolts
25 - Bolts
26 - Windage tra
27 - Bolts
28 - Bolts
29 - Bolts
30 - Bolt
31 - Bolt
32 - Oil pick-up pipe
33 - Bolts
34 - Sump
35 - Bolts
36 - Bolts
37 - Bolts
38 - Oil filter
39 - Oil cooler assembl
40 - Bolts
41 - Oil filter head assembl
42 - Seals
43 - Bolts
44 - Oil pump
45 - C rankshaft bolt
46 - Taper collet
47 - C rankshaft pulle
48 - C rankshaft sprocket
C linder Block

The c linder block is an 'Enclosed V' design, which provides an inherentl rigid structure with good vibration levels. A
low volume coolant jacket improves warm-up times and piston noise levels; the longitudinal flow design of the jacket,
with a single c linder head coolant transfer port in each bank, improves rigidit and head gasket sealing.

C linder Numbering Convention

Pre 2005

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2005 on ards

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Engine Da a Loca ion

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I em Pa De c ip ion
N mbe
1 - Engine part number
2 - Engine data (main bearing diameters, c linder bore diameters, etc), emissions code and engine
number
Engine data is marked at three locations, two on the c linder block (shown) and one on the engine front cover, which
consists a label displa ing the engine number. C omponent diameters are represented b alphabetical and numerical
codes; ke s to the codes are in the Service Repair Procedures (SRP) Manual.

Connec ing Rod and Pi on

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The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing
caps are produced b fracturing the opposing sides of the connecting rod at the bearing hori ontal centre line. As well
as being easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint.
The c linder position is marked on adjoining sides of the joint to identif matching connecting rods and bearing caps.
The connecting rod bearings are aluminium/tin split plain bearings.

The pistons are of the open-ended skirt design. Three piston rings, two compression and one oil control, are installed
on each piston. Each piston is installed on a gudgeon pin located in a aluminium/tin bushing in the connecting rod.

C onnecting Rod and Piston Installation

I em Pa N mbe De c ip ion
1 - Bank A (RHS)
2 - Bank B (LHS)
3 - Piston
The piston grade number is stamped on the crown of the piston and must coincide with that for each c linder bore.
The piston must be assembled in the correct orientation for the designated c linder bore:

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Bank 'A' - pi on g ade n mbe and he hick flange of he connec ing od m face he f on of he engine
Bank 'B' - pi on g ade n mbe and he hin flange of he connec ing od m face he f on of he engine

C ank haf Po i ion Sen o

I em Pa N mbe De c ip ion
1 - C ank haf po i ion en o (C KP)
The C KP en o i in alled a he ea of he mp. I i a a iable el c ance en o ha p o ide an inp of engine
c ank haf peed and po i ion.
Fo addi ional info ma ion, efe o: Elec onic Engine C on ol (303-14B Elec onic Engine C on ol - V8 4.4L Pe ol,
De c ip ion and Ope a ion).

Knock Sen o

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I em Pa N mbe De c ip ion
1 - Bolt
2 - Knock sensor
The knock sensors are installed in the c linder block on the inboard side of each c linder bank. The are pie o-
electric sensors that provide inputs to detect and locate detonation during combustion.
For additional information, refer to: Electronic Engine C ontrols (303-14B Electronic Engine C ontrols - V8 4.4L Petrol,
Description and Operation).

S ar er

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I em Pa N mbe De c ip ion
1 - Bolt
2 - Starter motor
3 - Bolt
The engine starter motor is installed at the rear right side of the engine, at the c linder block to bedplate split line.
For additional information, refer to: Starting S stem (303-06B Starting S stem - V8 4.4L Petrol, Description and
Operation).

Coolan Drain Pl g/Hea er

A coolant drain plug is installed on the rear left side of the c linder block. On vehicles with the cold climate package,
the c linder block heater replaces the drain plug.

On vehicles destined for C anada, the coolant heater is installed during engine manufacture, but for Scandinavian
vehicles the heater is supplied in kit form to be installed at the dealership.

Coolan P mp

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I em Pa N mbe De c ip ion
1 - C oolant pump
2 - Bolt
3 - Pulle
4 - Bolt
The coolant pump is installed between the two c linder banks, on the front face of the c linder block.

The mo a Ho ing

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I em Pa N mbe De c ip ion
1 - C oolant outlet elbow
2 - Bolt
3 - Thermostat housing
4 - Bolt
The composite thermostat housing is installed between the two c linder banks, immediatel above the coolant pump.
The thermostat controls the flow of coolant through the radiator.

C ANK HAF AND MP COMPONEN

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I em Pa N mbe De c ip ion
1 - Bedplate
2 - Main bearings - lo er
C ank haf and Main Bea ing

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I em Pa N mbe De c ip ion
1 - C ank haf
2 - Th a he
3 - Th a he
4 - Main bea ing - ppe
Si co n e -balance eigh en e good ib a ion le el f om he fo h o , fi e bea ing c ank haf . Man fac ed
in ca i on, he c ank haf al o ha nde c and olled fille fo imp o ed eng h.

The c ank haf ea oil eal i a p e fi in he bedpla e o c linde block in e face.

The main bea ing a e al mini m/ in pli plain bea ing . An oil g oo e in he ppe half of each bea ing an fe he
oil in o he c ank haf fo l b ica ion of he connec ing od bea ing . A al mini m/ in h a he i in alled each
ide of he op half of he cen e main bea ing.

Bedpla e

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T .T
.I , ,
.

T .

B .

S mp

T .A
,
.A
.T .

A .

Oil P mp

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The oil p mp i in alled on he c ank haf a he f on of he engine. The p mp inle and o le po align i h oil
pa age in he bedpla e.

Starter Dri e Plate

I em Pa N mbe De c ip ion
1 - S a e d i e pla e
2 - Bol
The a e d i e pla e i a ached o he ea of he c ank haf . A iming di c, fo he engine peed en o , i po
elded o he f on face of he d i e pla e.

Timing Di c

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CAM HAF IMING COMPONEN

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I em Pa N mbe De c ip ion
1 - Secondar chain tensioner
2 - Secondar chain

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3 - V
4 - P
5 - P
Timing Gear

M .T
.T
- .

A .T '
.T - , -
;
/ .

E .T
, .A
.T
.T .G
.

Timing Co er

T ( PTFE ). S -
.

CYLINDER HEAD COMPONENTS

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I em Pa N mbe De c ip ion
1 - C am haf bea ing cap
2 - Tappe ( himle )

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3 - C
4 - V
5 - V
6 - V
7 - V
8 - I
9 - E
C linder Heads

T .D - , ,
.T .

T 14 , , .

T - ; ( ) .

Camshaft Covers

T - .T A
.T B
.I .
F , :E E C (303-14B E E C - V8 4.4L P ,
D O ).

S - .T
,
, .

C linder Head Gasket

T - - .

Camshafts

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The camshafts are manufactured in chilled cast iron. Five aluminium allo caps retain each camshaft. Location
numbers, 0 to 4 for the intake camshaft and 5 to 9 for the e haust camshaft, are marked on the outer faces of the
caps.

Sensor Ring

I em Pa N mbe De c ip ion
1 - Inlet camshaft
2 - Sensor ring
Timing rings for each camshaft position sensor are located at the rear of both intake camshafts. A flat, machined near
the front of each camshaft, enables the camshafts to be locked during the valve timing procedure.

Cam haf Po i ion Sen o

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The ca haf ii e a e i a ed i each c i de head a he ea f he i a e ca haf . I i a a iab e

e c a ce e ha ide a i he EC M ega di g he ii f he ca haf .
F addi i a i f a i , efe : E ec ic E gi e C (303-14B E ec ic E gi e C - V8 4.4L Pe ,
De c i i a d O e a i ).

Inlet and E haust Valves

Each c i de head i c ae d a e head ca haf e ai gf a e e c i de ia id hi e

a i i a a e if e .

The igh eigh a e gea ide g d ec a d i e e e . Va e head dia e e a e 31 (1.220 i ) f

he e ha a d 35 (1.378 i ) f he i a e. A a e ha e 5 (0.197 i ) dia e e e ed i
i e ed e a ea a d g ide i e . C e , a e c a a d i g ea ca e i g e a e i g b h
i a e a d e ha a e . Va e e ea a e i eg a ed i he i g ea .

C AUTION: D e igh a ia i i e g h, he a e a e not i e cha geab e be ee a e (La d R e ,

Jag a a d A Ma i ).

Fuel Injectors

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Eight, top fed, 12-jet, fuel injectors are installed in the fuel rails. The injectors are electromagnetic solenoid valves
controlled by the EC M. Two O-rings seal each injector to manifold interface. The fuel jets from the injectors are
directed onto the back of the intake valves.
For additional information, refer to: Electronic Engine C ontrols (303-14B Electronic Engine C ontrols - V8 4.4L Petrol,
Description and Operation).

VARIABLE VALVE TIMING (VVT)

The continuously VVT unit turns the intake camshaft in relation to the primary chain to advance and retard the timing.

The system improves low and high-speed engine performance, engine idle quality and exhaust emission.

The VVT system changes the phasing of the intake valves, relative to the fixed timing of the exhaust valves, to alter:

the mass of air flow into the engine's cylinders,

and the engine's torque response and emissions.

The VVT unit uses a vane device to control the camshaft angle (refer to VVT operation). The system operates over a
range of 48 and is advanced or retarded to the optimum angle within this range.

The EC M controls the VVT, using engine speed and load, and engine oil temperature signals to calculate the
appropriate camshaft position.
For additional information, refer to: Electronic Engine C ontrols (303-14B Electronic Engine C ontrols - V8 4.4L Petrol,
Description and Operation).

The continuous VVT system provides the following advantages:

Reduces engine emissions and fuel consumption by further optimising the camshaft timing, this improves the
engine's internal exhaust gas re-circulation (EGR) effect over a wider operating range
Improves full-load torque characteristics as the camshaft timing is optimised at all engine speeds for superior
volumetric efficiency
Improves fuel economy by optimising torque over the engine's speed range.

This system also has the added benefits of operating at a lower oil-pressure and faster response time when compared
to a non-VVT system.

Variable Val e Timing Operation

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I em Pa N mbe De c ip ion
A - Retarded
B - Advanced
1 - Engine oil pressure
The VVT unit is a hydraulic actuator mounted on the end of the intake camshaft, which advances or retards the intake
camshaft timing and thereby alters the camshaft to crankshaft phasing. The oil control solenoid, controlled by the
EC M, routes oil pressure to either the advance or retard chambers located either side of the three vanes interspersed
within the machined housing of the unit.

The VVT unit is driven by the primary chain and rotates relative to the exhaust camshaft sprocket. When the EC M
requests the camshaft timing to advance, the oil control solenoid is energized moving the shuttle valve to the relevant
position to allow engine oil pressure, via a filter, into the VVT unit's advance chambers. When the camshaft timing is
requested to retard, the shuttle valve moves position to allow oil pressure to exit the advance chambers, while
simultaneously routing the oil pressure into the retard chambers.

When directed by the EC M, the VVT unit will be set to the optimum position between full advance and retard for a
particular engine speed and load. This is achieved when the EC M sends the energising signal to the oil control
solenoid until the target position is met. At this point, the energizing signal is reduced to hold the solenoid position,
and as a result the position of the shuttle valve. This function is under closed-loop control, where the EC M will assess
any decrease in shuttle-valve oil-pressure, via signals from the camshaft position sensor. The EC M will increase the
energizing signal, when required, to maintain the shuttle-valve hold position.

Engine oil properties and temperature can affect the ability of the VVT mechanism to follow demand changes to the
cam phase angle. At very low oil-temperatures, movement of the VVT mechanism is sluggish due to increased
viscosity, and at high oil-temperatures the reduced viscosity may impair operation if the oil pressure is too low. To
maintain satisfactory VVT performance, an increased capacity oil pump is installed, plus an engine oil temperature
sensor to enable monitoring by the EC M. The VVT system is normally under closed-loop control except in extreme
temperature conditions, such as cold starts below 0 C . At extremely high oil-temperatures, the EC M may limit the
amount of VVT advance to prevent the engine from stalling when returning to idle speed.

The VVT does not operate when engine oil-pressure is below 1.25 bar, as there is insufficient pressure to release the
VVT unit's internal stopper pin. This usually occurs when the engine is shutting-down and the VVT has returned to the
retarded position. The stopper pin locks the camshaft to the VVT unit to ensure camshaft stability during the next
engine start-up.

LUBRICATION S STEM

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General

Oi i d a f he e e i i he i a a d e i ed b he i . The f he i i he
fi e ed, c ed a d di ib ed h gh i e a i a age .

A i g a a e b ica ed b e e a h i. P e i ed i i a ided f e ai f he a iab e

a e i i g i a d he i i g gea chai e i e .

The i e he i a de g a i . La ge d ai h e h gh he c i de head a d c i de b c e e
he ic e f he i , ed ci g he e f i e i ed a d e ab i g a acc a e chec f he c e
af e he e gi e .

S e e e i h e i h gh he i fi e ca he ba 'B' ca haf c e .

Wi h he e ce i f he ,a i e c e a e i a ed he c a .

Oil Pick- p

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The fabricated steel oil pick-up is immersed in the oil reservoir to provide a suppl to the oil pump during all normal
vehicle attitudes. A mesh screen in the inlet prevents debris from entering the oil s stem.

Oil Pump

The oil pump is installed on the crankshaft at the front of the engine. The pump inlet and outlet ports align with oil
passages in the bedplate.

The pumping element is an eccentric rotor, which is directl driven b flats on the crankshaft. An integral pressure
relief valve regulates pump outlet pressure at 4.5 bar (65.25 psi).

Oil Filter and Oil Pressure S itch

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The oil filter is a replaceable cartridge installed on an adapter. An internal b pass facilit permits full flow b pass if
the filter is blocked.

The oil pressure switch connects a ground input to the instrument cluster when oil pressure is present. The switch
operates at a pressure of 0.15 to 0.41 bar (2.2 to 5.9 psi).

Oil Le el Ga ge

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The i e e ga ge ca e a g he ef ide f he i a , ed i a be i a ed i he .T h e i
he e d f he ga ge i dica e he i i a d a i i e e . The e i a diffe e ce f a i a e 1.5 i e
(1.58 US a ) be ee he e e .

E HAUST MANIFOLD

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The fabricated stainless steel t in skin e haust manifolds are unique for each c linder bank. The bank B manifold has
a connection for the EGR transfer pipe.

Spacers on the securing bolts allo the manifolds to e pand and retract ith changes of temperature hile
maintaining the clamping loads.

Heat shields are integrated into the e haust manifold gaskets.

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Published: 11-Ma -2011

Engine - V8 4.4L Petrol - Val e Clearance Check
General Procedures

1. Disconnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the cooling fan.
For additional information, refer to: C ooling Fan (303-03B
Engine C ooling - V8 4.4L Petrol, Removal and Installation).
3. Remove the LH valve cover.
For additional information, refer to: Valve C over LH (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).
4. Remove the RH valve cover.
For additional information, refer to: Valve C over RH (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).

5. C AUTION: C amshaft lobes must be 180 degrees awa

from each valve tappet or valve clearance will be incorrect.

Rotate the engine clockwise to position the camshaft lobe

awa from the valve tappet
6. Using the feeler gauge set, measure the clearance
between the camshaft and the valve tappet.

7. Repeat the above procedure for the remaining 31 tappets.

8. Adjust the clearance as necessar .
9. For c linder head data, refer to specifications.
For additional information, refer to: Specifications (303-01B
Engine - V8 4.4L Petrol, Specifications).
10. Install the RH valve cover.
For additional information, refer to: Valve C over RH (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).
11. Install the LH valve cover.
For additional information, refer to: Valve C over LH (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).
12. Install the cooling fan.
For additional information, refer to: C ooling Fan (303-03B
Engine C ooling - V8 4.4L Petrol, Removal and Installation).
13. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-May-2011
Engine - V8 4.4L Pe ol - Val e Clea ance Adj men
General Procedures

NOTE: The valve clearances adjustment procedure is part of the the camshafts removal and installation procedure.

1. Remove the camshafts.

For additional information, refer to: C amshafts RH (303-01B
Engine - V8 4.4L Petrol, In-vehicle Repair).
2. Install the camshafts.
For additional information, refer to: C amshafts RH (303-01B
Engine - V8 4.4L Petrol, In-vehicle Repair).

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Published: 11-Ma -2011

Engine - V8 4.4L Pe rol - Engine Oil Draining and Filling
General Procedures

1. Disconnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
4. Remove the oil pan drain plug.

Position a container to collect the fluid.

Discard the oil drain plug seal.

5. Remove the radiator access panel.

Remove the 4 bolts.

6. Remove the oil filter.

Position a container to collect the fluid.

Discard the oil filter.

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. Install the engine oil filter.

Lubricate the oil filter seal with clean engine oil and
tighten to 18 Nm (13 lb.ft).

Install a new seal.

Tighten the drain plug to 25 Nm (18 lb.ft).

. Tighten the drain plug to 25 Nm (18 lb.ft).

Install a new seal.

. Install the engine undershield.

For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
10. Fill the engine with oil.
11. C heck and top-up the engine oil.
12. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

Engine - V8 4.4L Petrol - Camshafts RH
In-vehicle Repair

Special Tool(s)
Timing Setting tool

303-645

C amshaft setting/locking tool

303-530

Timing chain tensioning tool

303-532

Timing shim tool

303-530/04

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the batter tra .
For additional information, refer to: Batter Tra (414-01
Batter , Mounting and C ables, Removal and Installation).

3. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

4. Remove the engine front cover.
For additional information, refer to: Engine Front C over
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
5. Remove the crankshaft position (C KP) sensor.
For additional information, refer to: C rankshaft Position
(C KP) Sensor (303-14B Electronic Engine C ontrols - V8 4.4L
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Petrol, Removal and Installation).
. Rotate the crankshaft until the flats on the camshafts are
parallel with the c linder head joint faces.
. NOTE: The engine is now in the SAFE position.

Lock the crankshaft.

Install the special tool.

Install the screw.

. Remove the RH variable camshaft timing (VC T) control

unit.

Remove the 3 bolts.

Remove and discard the O-ring seals.

. Install the special tools to the RH c linder head.

Install the 3 bolts.

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. Remove the primar timing chain tensioner.

Remove the 2 bolts.

. Remove the primar timing chain tensioner guide.

Remove the bolt.

. Remove the primar timing chain.

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1 . Remove the secondary timing chain tensioner and the

secondary timing chain.

Remove the 2 retaining bolts.

1 . C AUTION: Discard the bolts.

Remove the camshaft sprockets.

Remove the 2 bolts.

1 . Remove the special tools from the RH cylinder head.

Remove the 3 bolts.

1 . C AUTION: Evenly and progressively, release the

camshaft bearing caps.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

Remove the camshaft bearing caps.

Remove the 20 bolts.

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17. R .

In alla ion
1. C .
2. R , .

A
.

3. I .

C .

L .

4. I .

E
10 N .

5. C AUTION: M .

I T .

6. C AUTION: C 180

M .

R T .

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. C AUTION: Evenly and progressively, release the

camshaft bearing caps.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

Remove the camshaft bearing caps.

Remove the 20 bolts.

. Remove the camshafts.

. Remove the valve tappets, replace with selected tappets.
10. Install the camshafts.

Lubricate the journals and camshaft lobes.

C lean the component mating faces.

11. Install the camshaft bearing caps.

Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm.

12. C AUTION: C amshaft lobes must be 180 degrees

away from each valve tappet or valve clearance will be
incorrect.

C heck valve tappet clearances are correct.

Rotate the camshafts using the Torx bolts.

Remove the camshaft Torx bolts after the check is

complete.

13. Install the special tools to the RH cylinder head.

Install the 3 bolts.

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1 . Retain the RH secondar timing chain tensioner piston.

Using 1 mm diameter metal rod, retain the chain

tensioner piston.

1 . Install the secondar timing chain tensioner and chain to

the camshaft sprockets.
1 . NOTE: Lightl tighten the camshaft sprocket Tor bolts,
the sprockets MUST be free to move.

Install the secondar timing chain and sprockets to the

camshafts.

Install the sprocket retaining Tor bolts to the

camshafts.

1 . Install the secondar timing chain tensioner retaining

bolts.

Tighten the bolts to 12 Nm.

1 . Tension the secondar timing chain.

Remove the retaining rod.

1 . Install the primar timing chain.

Make sure the timing chain slack is on the tensioner

side of the timing chain.

20. Install the primar tensioner guide.

Tighten the bolts to 12 Nm.

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. C AUTION: D ing iming chain en ione

comp e ion, do no elea e he a che em n il he
iming chain en ione pi on i f ll bo omed in i bo e o
damage o he a che em ill e l .

In all he p ima chain en ione .

U ing 3 mm diame e me al od, e ain he chain

en ione pi on.

Tigh en he bol o 12 Nm.

Remo e he e aining od.

. C AUTIONS:

The in ake cam haf p ocke e aining bol MUST be

igh ened befo e he e ha cam haf p ocke e aining
bol . Engine damage ill occ if hi p oced e i no
follo ed.

U ing he pecial ool, appl fo ce o he ool in a

co n e -clock i e di ec ion, o en ion he p ima iming
chain on i d i e ide.

In all he pecial ool o he e ha cam haf p ocke .

Tigh en he in ake cam haf p ocke e aining bol

o 20 Nm + 90 deg.

Tigh en he e ha cam haf p ocke e aining bol

o 20 Nm + 90 deg.

. Remo e he pecial ool f om he RH c linde head.

. In all he RH VC T oil con ol ni .

In all he ne O- ing eal .

Tigh en he ne bol o 22 Nm.

. Remo e he c ank haf locking ool.

Remo e he c e .

. In all he C KP en o .
Fo addi ional info ma ion, efe o: C ank haf Po i ion
(C KP) Sen o (303-14B Elec onic Engine C on ol - V8 4.4L
Pe ol, Remo al and In alla ion).
. NOTE: Befo e in alling he al e co e , check he al e
clea ance .

In all he engine f on co e .
Fo addi ional info ma ion, efe o: Engine F on C o e
(303-01B Engine - V8 4.4L Pe ol, In- ehicle Repai ).
. In all he ba e a .
Fo addi ional info ma ion, efe o: Ba e T a (414-01
Ba e , Mo n ing and C able , Remo al and In alla ion).

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Engine - V8 4.4L Petrol - Camshafts LH
In-vehicle Repair

Special Tool(s)
Timing Setting tool

303-645

C amshaft setting/locking tool

303-530

Timing chain tensioning tool

303-532

Timing shim tool

303-530/04

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the batter tra .
For additional information, refer to: Batter Tra (414-01
Batter , Mounting and C ables, Removal and Installation).

3. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

4. Remove the engine front cover.
For additional information, refer to: Engine Front C over
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
5. Remove the crankshaft position (C KP) sensor.
For additional information, refer to: C rankshaft Position
(C KP) Sensor (303-14B Electronic Engine C ontrols - V8 4.4L
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Petrol, Removal and Installation).
. Rotate the crankshaft until the flats on the camshafts are
parallel with the c linder head joint faces.
. NOTE: The engine is now in the SAFE position.

Lock the crankshaft.

Install the special tool.

Install the screw.

. Remove the RH variable camshaft timing (VC T) control

unit.

Remove the 3 bolts.

Remove and discard the O-ring seals.

. Install the special tools to the RH c linder head.

Install the 3 bolts.

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. Remove the RH primar timing chain tensioner

assembl .

Remove the 2 bolts.

. Remove the RH primar timing chain tensioner guide.

Remove the bolt.

. Remove the RH primar timing chain.

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1 . Remove the special tools from the RH c linder head.

Remove the 3 bolts.

1 . Remove the LH variable camshaft timing (VC T) control

unit.

Remove the 2 bolts.

Remove the nut.

Remove and discard the O-ring seals.

1 . Install the special tools to the LH c linder head.

Install the 3 bolts.

1 . Remove the LH primar timing chain tensioner.

Remove the 2 bolts.

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1 . Remove the LH upper and lower primar timing chain

tensioner guides.

Remove the stud.

Remove the bolt.

1 . Remove the LH primar timing chain.

1 . C AUTION: Discard the bolts.

Remove the camshaft sprockets.

Remove the 2 bolts.

20. Remove the secondar timing chain tensioner and the

secondar timing chain.

Remove the 2 bolts.

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21. Remove the special tools from the LH cylinder head.

Remove the 3 bolts.

22. C AUTION: Evenly and progressively, release the

camshaft bearing caps.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

Remove the camshaft bearing caps.

Remove the 20 bolts.

23. Remove the camshafts.

In alla ion
1. C heck and adjust the valve tappet clearances.
2. Replace the valve shims, with the smallest shim available.

Apply a light coat of clean engine oil to the replacement

valve shims.

3. Install the camshafts.

C lean the component mating faces.

Lubricate the journals and camshaft lobes.

4. Install the camshaft bearing caps.

Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm.

5. C AUTION: Make sure that new bolts are installed.

Install the sprocket retaining Torx bolts to the camshafts.

6. C AUTION: C amshaft lobes must be 180 degrees

away from each valve tappet or valve clearance will be
incorrect.

Measure and record the tappet clearances.

Rotate the camshafts using the Torx bolts.

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. NOTE: Remove the camshaft bearing caps evenly and in

stages.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

Remove the camshafts.

Remove the 20 bolts.

. Remove the valve tappets, replace with selected tappets.

. Install the camshafts.

Lubricate the journals and camshaft lobes.

C lean the component mating faces.

10. Install the camshaft bearing caps.

Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm.

11. C AUTION: C amshaft lobes must be 180 degrees

away from each valve tappet or valve clearance will be
incorrect.

C heck valve tappet clearances are correct.

Rotate the camshafts using the Torx bolts.

Remove the camshaft Torx bolts after the check is

complete.

12. Install the special tools to the LH cylinder head.

Install the 3 bolts.

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1 . NOTE: RH ill a ion ho n, LH i imila .

Dep e he LH econda iming chain en ione pi on.

U ing 1 mm diame e me al od, e ain he chain

en ione pi on.

1 . In all he LH econda iming chain en ione and chain

o he cam haf p ocke .
1 . In all he LH econda iming chain en ione e aining
bol .

Tigh en he bol o 12 Nm.

1 . NOTE: Ligh l igh en he cam haf p ocke To bol ,

he p ocke MUST be f ee o mo e.

In all he LH econda iming chain and p ocke o he

cam haf .

In all he p ocke e aining To bol o he

cam haf .

1 . Ten ion he econda iming chain.

Remo e he e aining od.

1 . In all he LH p ima iming chain.

Make e he iming chain lack i on he en ione

ide of he iming chain.

1 . In all he LH p ima chain en ione g ide.

Tigh en he d o 12 Nm.

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. C AUTION: D ing iming chain en ione

comp e ion, do no elea e he a che em n il he
iming chain en ione pi on i f ll bo omed in i bo e o
damage o he a che em ill e l .

In all he LH p ima iming chain en ione .

U ing 3 mm diame e me al od, e ain he chain

en ione pi on.

Tigh en he bol o 12 Nm.

Remo e he e aining od.

. C AUTIONS:

U ing he pecial ool, appl fo ce o he ool in a

co n e -clock i e di ec ion, o en ion he p ima iming
chain on i d i e ide.

The in ake cam haf p ocke e aining bol MUST be

igh ened befo e he e ha cam haf p ocke e aining
bol . Engine damage ill occ if hi p oced e i no
follo ed.

Make e ha ne bol a e in alled.

In all he pecial ool o he e ha cam haf p ocke .

Tigh en he in ake cam haf p ocke e aining bol

o 20 Nm + 90 deg.

Tigh en he e ha cam haf p ocke e aining bol

o 20 Nm + 90 deg.

. In all he LH VC T oil con ol ni .

In all he ne O- ing eal .

Tigh en he ne bol o 22 Nm.

Tigh en he n o 10 Nm.

. Remo e he pecial ool f om he LH c linde head.

Remo e he 3 bol .

. In all he pecial ool o he RH c linde head.

In all he 3 bol .

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2 . In all he RH p ima iming chain.

Make e he iming chain lack i on he en ione

ide of he iming chain.

2 . In all he RH p ima iming chain en ione g ide.

Tigh en he bol o 12 Nm.

2 . C AUTION: D ing iming chain en ione

comp e ion, do no elea e he a che em n il he
iming chain en ione pi on i f ll bo omed in i bo e o
damage o he a che em ill e l .

In all he RH p ima iming chain en ione .

U ing 3 mm diame e me al od, e ain he chain

en ione pi on.

Tigh en he bol o 12 Nm.

Remo e he e aining od.

2 . C AUTIONS:

U ing he pecial ool, appl fo ce o he ool in a

co n e -clock i e di ec ion, o en ion he p ima iming
chain on i d i e ide.

The in ake cam haf p ocke e aining bol MUST be

igh ened befo e he e ha cam haf p ocke e aining bol .
Engine damage ill occ if hi p oced e i no follo ed.

Make e ha ne bol a e in alled.

In all he pecial ool o he e ha cam haf p ocke .

Tigh en he in ake cam haf p ocke e aining bol o

20 Nm + 90 deg.

Tigh en he e ha cam haf p ocke e aining bol o

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20 Nm + 90 deg.

2 . Install the RH VC T oil control unit.

Install the new O-ring seals.

Tighten the new bolts to 22 Nm.

30. Remove the special tools from the RH c linder head.

Remove the 3 bolts.

31. Remove the crankshaft locking tool.

Remove the screw.

32. Install the C KP sensor.

For additional information, refer to: C rankshaft Position
(C KP) Sensor (303-14B Electronic Engine C ontrols - V8 4.4L
Petrol, Removal and Installation).
33. NOTE: Before installing the valve covers, check the valve
clearances.

Install the engine front cover.

For additional information, refer to: Engine Front C over
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
34. Install the batter tra .
For additional information, refer to: Batter Tra (414-01
Batter , Mounting and C ables, Removal and Installation).

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Engine - V8 4.4L Petrol - Crankshaft Pulle
In-vehicle Repair

Special Tool(s)
Holding Tool C rankshaft Pulle

303-893(LRT-12-080)

Adapter

303-191-03

Bolts and spacers

303-191-04

Remover, crankshaft pulle

303-588

Remover, crankshaft seal

303-D121

Installer, crankshaft seal

303-1100

Adapter - C rankshaft seal installer

303-1100-01

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Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05B Accessor Drive - V8 4.4L Petrol, Removal and
Installation).
4. Remove the cooling fan shroud.

Release 2 clips from the cooling fan lower shroud.

Release and remove the cooling fan lower shroud

from the cooling pack.

5. Using the special tools, retain the crankshaft pulle .

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. C AUTION: Under no circumstances should the

crankshaft setting peg, 303-645, be used in the following
operations, to restrain the crankshaft.

NOTE: The crankshaft pulley retaining bolt will be very tight.

Remove the crankshaft pulley retaining bolt.

Discard the bolt.

. Remove the special tools.

. Using the special tools, remove the crankshaft pulley.

C ollect the locking ring.

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9. Remove the special tools from the crankshaft pulle .

10. Using the special tool, remove the crankshaft front seal.

Remove the outer section of the seal.

Repeat the process to remove the inner section of

seal.

11. C heck the crankshaft damper pulle and locking ring for
damage.

In alla ion
1. C lean all the crankshaft pulle mating faces.
2. Using the special tools, install the crankshaft front seal.

Lubricate the seal with clean engine oil.

Use the discarded crankshaft bolt with the service

tool.

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. Install the crankshaft pulle .

Lubricate the seal with clean engine oil.

. Install the crankshaft pulle locking ring.

. C AUTION: The screw thread in the crankshaft pulle

must be cleaned out before installing a new crankshaft pulle
bolt.

Install, but do not tighten, the new crankshaft pulle bolt.

. C AUTION: Under no circumstances should the

crankshaft setting peg, 303-645, be used in the following
operations, to restrain the crankshaft.

Using the special tools, retain the crankshaft pulle .

Tighten the crankshaft pulle bolt to 380 Nm (280

lb.ft).

. Remove the special tools.

. Install the cooling fan lower shroud.
. Install the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05B Accessor Drive - V8 4.4L Petrol, Removal and
Installation).
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. C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - V8 4.4L Petrol - Crankshaft Front Seal
In-vehicle Repair

Special Tool(s)
Remover, crankshaft seal

303-D121

Installer, crankshaft seal

303-1100

Adapter - C rankshaft seal installer

303-1100-01

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the crankshaft pulle .
For additional information, refer to: C rankshaft Pulle (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).

3. C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

Using the special tool, remove the crankshaft front seal.

Installation
1. Using the special tools, install the crankshaft front seal.

C lean the component mating faces.

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. Install the crankshaft pulle .

For additional information, refer to: C rankshaft Pulle (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).

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P : 11-M -2011
Engine - V8 4.4L Petrol - Crankshaft Rear Seal
I - R

Special Tool(s)
C
/

303-538

Remo al
1. D .
F , :S (414-00
B C S -G I ,
S ).

2. WARNING: D
.A
.

R .
3. R .
F , :F (303-01B
E - V8 4.4L P ,I - R ).
4. I .

I 2 .

T 2 .

5. U ,
6 - .

6. U ,
.

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I 6 - .

A 2 .

T .

In alla ion

1. C AUTION: D .

P .

M .

C ,
.

2. C AUTION: M

U , .

T
.

3. I .
F , :F (303-01B
E - V8 4.4L P ,I - R ).

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Published: 15-Jul-2011
Engine - V8 4.4L Petrol - C linder Head LH
In-vehicle Repair

Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00 Battery and
C harging System - General Information, Specifications).
2. Remove the intake manifold.
For additional information, refer to: Intake Manifold Assembly (303-04B
Fuel C harging and C ontrols - V8 4.4L Petrol, Removal and Installation).
3. Remove the LH bank camshafts.
For additional information, refer to: C amshafts LH (303-01B Engine -
V8 4.4L Petrol, In-vehicle Repair).
4. Remove the camshaft position (C MP) sensor.

Remove the Torx screw.

Disconnect the electrical connector.

5. Disconnect the exhaust manifold EGR pipe flange.

Remove the 2 nuts.

6. C AUTIONS:

The bolts can only be used twice, mark the bolts with a center
punch. If two punch marks are visible, discard the bolts.

Vehicles fitted with Polydrive cylinder head bolts, the cylinder head
bolts must be removed using a 10 mm Polydrive socket or a 10 mm Allen
key. Failure to follow this instruction may result in damage to the
component.

NOTE: Remove the bolts in the indicated sequence.

Remove the 12 cylinder head bolts.

7. Remove the LH cylinder head assembly.

With assistance remove the cylinder head.

8. Remove and discard the cylinder head gasket.

C lean the cylinder head locating dowels.

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9. NOTE: Do not disassemble further if the component is removed for

access only.

Remove the exhaust manifold.

Remove the 8 bolts.

Discard the gasket and the bolts.

In alla ion
1. C AUTIONS:

If a new cylinder head is to be installed to a vehicle with variable

valve timing (VVT), the cylinder head must have the oil gallery blind rivet
removed before installation.

Make sure that all debris and foreign material is removed from the
cylinder head and cylinder head oil gallery.

NOTE: The centre bore of the blind rivet is 6 mm (0.24 inch) diameter.

Vehicles fitted with VVT: remove the blind rivet from the VVT oil
gallery.

Identify the VVT oil supply gallery and the 8 mm (0.31 inch) blind
rivet.

Using a suitable 3 mm (0.12 inch) punch release the centre of the

blind rivet until it is released from the outer part of the blind rivet.

Using a suitable extraction tool, remove the remaining part of the

blind rivet.

2. C lean the component mating faces.

3. C heck cylinder head face for distortion, across the center and from
corner to corner.

4. For cylinder head face distortion data, refer to specifications.

For additional information, refer to: Specifications (303-01B Engine - V8

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4.4L Pe , S ecifica i ).
. NOTE: F
c i de head i h
di i ab e he
a i
a a ce, he
c i de head
a e ia be
ea ed.

Mea e he
c i de head
a e ia .

C hec
ea e e
f he
ce e f he
e ha
d e he
c i de head
face a
h .

If he
ea e e
i e ha
51.88
he c i de
head e i e
e ace e .

.I a he e ha a if d.

C ea he c e a i g face .

I a he ga e /hea hie d.

Tigh e he hea hie d b 25 N (18 b.f ).

E e a d g e i e , igh e he b i he e e ce h
20 N (15 b.f ).

. C AUTION: The head ga e be i a ed e he c i de

b c d e .

I a a e c i de head ga e .
. Wi h a i a ce i a he c i de head.
. NOTE: Tigh e he b 1 10 i he e e ce h .

I a he c i de head b .

L b ica e he e c i de head b h ead i h c ea e gi e i.

Tigh e he b 20 N (15 b.f ).

Tigh e he b 35 N (26 b.f ).

Tigh e he b 1 10, a f he 90 deg ee .

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Tigh en he bol 1 o 10, a f he 90 deg ee .

Tigh en he M8 bol 11 and 12, o 25 Nm (18 lb.f ).

. C onnec he EGR pipe and e ha manifold flange .

Tigh en he n o 25 Nm (18 lb.f ).

. In all he C MP en o .

Tigh en he To c e o 7 Nm (5 lb.f ).

C onnec he elec ical connec o .

. In all he LH bank cam haf .

Fo addi ional info ma ion, efe o: C am haf LH (303-01B Engine -
V8 4.4L Pe ol, In- ehicle Repai ).
. In all he in ake manifold.
Fo addi ional info ma ion, efe o: In ake Manifold A embl (303-04B
F el C ha ging and C on ol - V8 4.4L Pe ol, Remo al and In alla ion).
. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00 Ba e and
C ha ging S em - Gene al Info ma ion, Specifica ion ).

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Engine - V8 4.4L Petrol - Val e Co er LH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the ignition coil-on-plug.
For additional information, refer to: Ignition C oil-On-Plug
(303-07B Engine Ignition - V8 4.4L Petrol, Removal and
Installation).
3. Remove the remaining ignition coil-on-plugs.
4. Remove the oil level indicator and tube.

Remove the dipstick.

Remove the nut.

Discard the O-ring seal.

5. Release the engine wiring harness from the retaining

bracket.

6. Disconnect the variable camshaft timing ( VC T) oil solenoid

electrical connector.
7. Disconnect the valve cover breather hose.

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. NOTE: Note the fitted position of the retaining bolts prior

to removal.

Remove the valve cover assembl .

Remove the 14 valve cover retaining bolts.

. Remove and discard the valve cover gaskets.

10. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the oil filler tube.

Remove and discard the O-ring seal.

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In alla ion
1. Install the oil filler tube.

Install a new O-ring seal.

2. Install new valve cover plug aperture seals

3. Install a new valve cover gasket.
4. NOTE: Appl two beads of silcone gasket sealant as
shown on the illustration. The application of the sealant
must be 3mm diameter 12mm long. Install the valve cover
immediatel after appl ing the sealant. The cover should be
fitted directl to the head without smearing the sealant or
the seals.

Install the valve cover.

C lean the component mating faces.

5. Install the valve cover retaining bolts.

Install valve cover retaining bolts to their position

previousl noted.

C omplete the tightening sequence as illustrated.

Tighten the bolts to 12 Nm (9 lb.ft).

6. C onnect the VC T oil solenoid electrical connector.

7. Attach the engine wiring harness to the retaining bracket.
8. With assistance, install the oil level indicator and tube.

C lean the component mating faces.

Install a new O-ring seal.

Lubricate the seal with clean engine oil.

Tighten the nut to 6 Nm (4 lb.ft).

9. Install the ignition coil-on-plug.

For additional information, refer to: Ignition C oil-On-Plug
(303-07B Engine Ignition - V8 4.4L Petrol, Removal and
Installation).
10. Install the remaining ignition coil-on-plugs.

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Engine - V8 4.4L Petrol - Val e Co er RH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the air intake resonator.
For additional information, refer to: Resonator (303-12,
Removal and Installation).
3. Remove the air cleaner assembl .
For additional information, refer to: Air C leaner (303-12B
Intake Air Distribution and Filtering - V8 4.4L Petrol,
Removal and Installation).
4. Remove the ignition coil-on-plug.
For additional information, refer to: Ignition C oil-On-Plug
(303-07B Engine Ignition - V8 4.4L Petrol, Removal and
Installation).
5. Remove the remaining ignition coil-on-plugs.
6. Disconnect the positive crankcase ventilation (PC V) line.

7. Release the engine wiring harness from the retaining

bracket.

8. Disconnect the variable camshaft timing ( VC T) oil

solenoid electrical connector.

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. NOTE: Note the fitted position of the retaining bolts prior

to removal.

Remove the valve cover assembl .

Remove the 14 valve cover retaining bolts.

Remove the engine cover bracket.

10. Remove and discard the valve cover gasket.

11. Remove the valve cover plug aperture seals.

12. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the PC V valve.

Remove the 2 bolts.

Remove and discard the O-ring seal.

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In alla ion
1. Install the PC V valve.

C lean the component mating faces.

Install a new O-ring seal.

Tighten the bolts to 6 Nm (4 lb.ft).

2. Install new valve cover plug aperture seals

3. Install a new valve cover gasket.
4. NOTE: Appl two beads of silcone gasket sealant as
shown on the illustration. The application of the sealant
must be 3mm diameter 12mm long. Install the valve cover
immediatel after appl ing the sealant. The cover should be
fitted directl to the head without smearing the sealant or
the seals.

Install the valve cover.

C lean the component mating faces.

5. Install the valve cover retaining bolts.

Install valve cover retaining bolts to their position

previousl noted.

Tighten the bolts to 12 Nm (9 lb.ft).

C omplete the tightening sequence as illustrated.

6. C onnect the VC T oil solenoid electrical connector.

7. Install the ignition coil-on-plugs.
For additional information, refer to: Ignition C oil-On-Plug
(303-07B Engine Ignition - V8 4.4L Petrol, Removal and
Installation).
8. Install the remaining ignition coil-on-plugs.
9. Attach the engine wiring harness to the retaining bracket.
10. C onnect the PC V line.
11. Install the air cleaner assembl .
For additional information, refer to: Air C leaner (303-12B
Intake Air Distribution and Filtering - V8 4.4L Petrol,
Removal and Installation).
12. Install the air intake resonator.
For additional information, refer to: Resonator (303-12,
Removal and Installation).

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Engine - V8 4.4L Pe ol - Engine Mo n LH
In-vehicle Repair

Special Tool( )
Ball joint separator

205-754 (LRT-54-027)

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the LH front wheel.
4. Remove the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
5. Remove the engine compartment LH upper heat shield.

Remove the screw.

6. NOTE: The heatshield consists of 3 parts.

Remove the upper suspension arm and brake line heat

shields for access.

Remove the 3 nuts.

Remove the 3 bolts.

7. Disconnect the height sensor link arm.

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. C AUTION: U e a ench on he he agon p o ided o

p e en he ball join o a ing.

Remo e he abili e ba link n .

. C AUTION: To p e en he heel kn ckle falling

o a d and di connec ion of he half haf inne join ,
ppo he heel kn ckle.

Loo en he ppe a m e aining n .

10. U ing he pecial ool, elea e he ppe a m ball join .

Remo e and di ca d he e aining n .

11. Relea e he b ake ho e f om he ppe a m.

12. Tie he ppe pen ion a m a ide fo acce .

13. Remo e he ee ing col mn lo e ni e al join
a embl fo acce .

Remo e and di ca d he bol .

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14. Support the engine.

15. Raise the engine.

Remove the nut.

16. Remove the engine front mount.

Remove and discard the 2 bolts.

In alla ion
1. C lean the component mating faces.
2. Install the engine front mount.

Tighten the bolts to 45 Nm (33 lb.ft), then a further 60

degrees.

3. Lower the engine onto the mount.

Tighten the nut to 90 Nm (66 lb.ft).

4. Remove the engine support.

5. Install the steering column lower universal joint assembl .

Install new patchlock bolts and tighten to 25 Nm (18

lb.ft).

6. Secure the brake hose to the upper arm.

Tighten the bolt to 23 Nm (17 lb.ft).

7. C onnect the upper arm and wheel knuckle.

Remove the cable tie securing the upper arm.

Install a new nut and tighten to 70 Nm (52 lb.ft).

8. Secure the stabili er bar link.

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Tighten the nut to 115 Nm (85 lb.ft).

. C onnect the height sensor link arm.

10. Install the upper suspension arm and brake line heat
shields.

Install the bolts.

Install the nuts.

11. Install the engine compartment upper LH heat shield.

Install the screw.

12. Install the engine undershield.

For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
13. Install the front wheel.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Engine - V8 4.4L Pe ol - Engine Mo n RH
In-vehicle Repair

Special Tool( )
Ball joint separator

205-754 (LRT-54-027)

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the RH front wheel.
4. Remove the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
5. Remove the engine compartment upper RH heat shield.

Remove the screw.

6. NOTE: The heatshield consists of 3 parts.

Remove the upper suspension arm and brake line heat

shields for access.

Remove the 3 nuts.

Remove the 3 bolts.

7. Disconnect the height sensor link arm.

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. C AUTION: Use a wrench on the hexagon provided to

prevent the ball joint rotating.

Remove the stabili er bar link nut.

. C AUTION: To prevent the wheel knuckle falling

outwards and disconnection of the halfshaft inner joint,
support the wheel knuckle.

Loosen the upper arm retaining nut.

10. Using the special tool, release the upper arm ball joint.

Remove and discard the retaining nut.

11. Release the brake hose from the upper arm.

12. Tie the upper suspension arm aside for access.

13. Support the engine.
14. Raise the engine.

Remove the nut.

15. Remove the engine front mount.

Remove and discard the 2 bolts.

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In alla ion
1. C lean the component mating faces.
2. Install the engine front mount.

Tighten the bolts to 45 Nm (33 lb.ft), then a further 60

degrees.

3. Lower the engine onto the mount.

Tighten the nut to 90 Nm (66 lb.ft).

4. Remove the engine support.

5. Secure the brake hose to the upper arm.

Tighten the bolt to 23 Nm (17 lb.ft).

6. C onnect the upper arm and wheel knuckle.

Remove the cable tie securing the upper arm.

Install a new nut and tighten to 70 Nm (52 lb.ft).

7. Secure the stabili er bar link.

Tighten the nut to 115 Nm (85 lb.ft).

8. C onnect the height sensor link arm.

9. NOTE: The heatshield consists of 3 parts.

Install the upper suspension arm and brake line heat

shields.

Install the bolts.

Install the nuts.

10. Install the engine compartment upper RH heat shield.

Install the screw.

11. Install the engine undershield.

For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
12. Install the front wheel.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

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Engine - V8 4.4L Petrol - Fle plate
In-vehicle Repair

Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

3. Remove the transmission.
For additional information, refer to: Transmission (307-01B
Automatic Transmission/Transaxle - V8 4.4L Petrol,
Removal and Installation).

4. C AUTION: The bolts can only be used 3 times,

mark the bolts with a center punch. If 2 punch marks are
visible, discard the bolts.

NOTE: Prevent the flexplate from rotating.

Remove the torque converter flexplate.

Remove the 8 bolts.

Installation
1. NOTE: Prevent the flexplate from rotating.

Install the torque converter flexplate.

C lean the component mating faces.

Tighten the bolts evenly and progressively in 2 stages.

Tighten the bolts to 15 Nm (11 lb ft).

Tighten the bolts to 110 Nm (81 lb.ft).

2. Install the transmission.

For additional information, refer to: Transmission (307-01B
Automatic Transmission/Transaxle - V8 4.4L Petrol,
Removal and Installation).
3. C onnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

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Engine - V8 4.4L Pe ol - Oil P mp
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the timing drive components.
For additional information, refer to: Timing Drive
C omponents (303-01B Engine - V8 4.4L Petrol, In-vehicle
Repair).
3. Remove the sump pan.
For additional information, refer to: Oil Pan (303-01B Engine
- V8 4.4L Petrol, In-vehicle Repair).
4. Remove the oil strainer pick up assembl .

Remove the 3 bolts.

Remove and discard the O-ring seal.

5. Remove the oil pump assembl .

Remove the 4 bolts.

Remove and discard the gasket.

C lean the component mating faces.

In alla ion
1. Install the oil pump assembl .

Install the new gasket.

Tighten the bolts to 10 Nm (7 lb.ft).

2. Install the oil strainer pick up assembl .

Install the O-ring seal.

Tighten the bolt to 6 Nm (4.4 lb.ft).

Tighten the bolts to 10 Nm (7 lb.ft).

3. Install the sump pan.

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For additional information, refer to: Oil Pan (303-01B Engine
- V8 4.4L Petrol, In- ehicle Repair).
. Install the timing dri e components.
For additional information, refer to: Engine Front C o er
(303-01B Engine - V8 4.4L Petrol, In- ehicle Repair).

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P bli hed: 11-Ma -2011

Engine - V8 4.4L Petrol - Oil Pan
In- ehicle Repai

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. D ain he engine oil.
4. Remo e he oil coole a embl .
Fo addi ional info ma ion, efe o: Oil C oole (303-01B
Engine - V8 4.4L Pe ol, In- ehicle Repai ).
5. Remo e he engine f on co e .
Fo addi ional info ma ion, efe o: Engine F on C o e
(303-01B Engine - V8 4.4L Pe ol, In- ehicle Repai ).
6. Remo e he f on diffe en ial.
Fo addi ional info ma ion, efe o: A le A embl (205-03
F on D i e A le/Diffe en ial, Remo al and In alla ion).
7. Remo e he ee ing gea .
Fo addi ional info ma ion, efe o: S ee ing Gea - V8 4.4L
Pe ol (211-02 Po e S ee ing, Remo al and In alla ion).
8. Remo e he gene a o .
Fo addi ional info ma ion, efe o: Gene a o (414-02B
Gene a o and Reg la o - V8 4.4L Pe ol, Remo al and
In alla ion).
9. Remo e he gene a o mo n ing b acke .

Remo e he 4 bol .

10. Di connec he hea ed o gen en o (HO2S) elec ical

connec o .

Relea e he 8 i ing ha ne ec ing clip .

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11. Release the HO2S mounting bracket.

Remove the 2 bolts.

12. Release the HO2S wiring harness from the oil pan.

Release the 3 clips.

13. Remove the transmission retaining bolts.

Remove the 3 bolts.

14. Remove the sump pan.

Remove the 16 bolts.

In alla ion
1. Install the sump pan.

C lean the component mating faces.

Appl a bead of sealant, 3 mm diameter b 130 cm

long, to the areas indicated.

Tighten the bolts to 20 Nm (15 lb.ft).

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. In all he an mi ion e aining bol .

Tigh en he bol o 45 Nm (33 lb.f ).

. In all he HO2S mo n ing b acke .

Tigh en he 2 bol o 10 Nm (7 lb.f ).

. C onnec he HO2S elec ical connec o .

In all he i ing ha ne clip .

. In all he HO2S ing ha ne .

Sec e he clip .

. In all he gene a o mo n ing b acke .

C lean he componen ma ing face .

. In all he gene a o .
Fo addi ional info ma ion, efe o: Gene a o (414-02B
Gene a o and Reg la o - V8 4.4L Pe ol, Remo al and
In alla ion).
. In all he ee ing gea .
Fo addi ional info ma ion, efe o: S ee ing Gea - V8 4.4L
Pe ol (211-02 Po e S ee ing, Remo al and In alla ion).
. In all he f on diffe en ial.
Fo addi ional info ma ion, efe o: A le A embl (205-03
F on D i e A le/Diffe en ial, Remo al and In alla ion).
. In all he oil coole a embl .
Fo addi ional info ma ion, efe o: Oil C oole (303-01B
Engine - V8 4.4L Pe ol, In- ehicle Repai ).
. In all he engine f on co e .
Fo addi ional info ma ion, efe o: Engine F on C o e
(303-01B Engine - V8 4.4L Pe ol, In- ehicle Repai ).
. Fill he engine i h oil.
. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Engine - V8 4.4L Petrol - Oil Cooler
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the radiator access panel.

Remove the 4 bolts.

4. Remove the oil filter.

Position a container to collect the fluid.

5. NOTE: Note the fitted position of the oil cooler assembl .

Remove the oil filter adapter.

Release the cooler from the oil filter head.

6. C lamp, then disconnect the coolant hoses from the oil

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coole .

7. Remo e he oil coole .

In alla ion
1. NOTE: Fill he coole i h coolan o elimina e he ai , p io
o connec ing he coolan ho e .

To in all, e e e he emo al p oced e.

Tigh en he adap e o 60 Nm (44 lb.f )

L b ica e he oil fil e eal i h clean engine oil and

igh en o 18 Nm (13 lb.f ).

Tigh en he bol o 10 Nm (7 lb.f ).

2. C heck and op p he engine oil.

3. Top p and bleed he coolan .

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Engine - V8 4.4L Petrol - Engine Front Co er
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Drain the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Petrol, General Procedures).
4. Remove the throttle bod gasket.
For additional information, refer to: Throttle Bod Gasket
(303-04B Fuel C harging and C ontrols - V8 4.4L Petrol,
Removal and Installation).
5. Remove the crankshaft front oil seal.
For additional information, refer to: C rankshaft Front Seal
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
6. Remove the cooling fan lower shroud.

Release 2 clips from the cooling fan lower shroud.

Release and remove the cooling fan lower shroud

from the cooling pack.

7. Remove the air conditioning (A/C ) compressor.

For additional information, refer to: Air C onditioning (A/C )
C ompressor (412-03B Air C onditioning - V8 4.4L Petrol,
Removal and Installation).
8. Remove the A/C compressor mounting bracket.

Remove the 2 bolts.

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. Remo e the cooling fan dri e belt tensioner.

Remo e the bolt.

10. Disconnect the coolant e pansion tank hose.

Release the clip.

11. Remo e the coolant manifold.

Release the clips and disconnect the 4 coolant hoses.

Remo e the 4 bolts.

Disconnect the electrical connector.

Position the coolant hoses aside for access.

12. Release the engine iring harness clips.

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1 . Remo e he acce o d i e bel idle p lle .

Remo e he bol .

1 . Remo e he coolan p mp p lle .

Remo e he 3 bol .

1 . Remo e he RH e ha manifold hea hield.

Remo e he 2 c e .

1 . Di connec he ba e po i i e cable.

Relea e he co e .

Remo e he n .

Di connec he elec ical connec o .

1 . Remo e he gene a o .

Remo e he 3 bol .

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1 . Remo e he gene a o mo n ing b acke .

Remo e he 4 bol .

1 . Remo e he RH al e co e .
Fo addi ional info ma ion, efe o: Val e C o e RH (303-
01B Engine - V8 4.4L Pe ol, In- ehicle Repai ).
20. Remo e he LH al e co e .
Fo addi ional info ma ion, efe o: Val e C o e LH (303-
01B Engine - V8 4.4L Pe ol, In- ehicle Repai ).
21. Remo e he engine f on co e .

Relea e he engine i ing ha ne clip .

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Remove the 24 bolts.

Remove and discard the gasket.

In alla ion
1. Install the engine front cover.

C lean the component mating faces.

Appl a bead of sealant 3 mm diameter, b 12 mm

long, to the 8 places indicated.

2. Evenl and progressivel tighten the bolts in the

sequence shown to 12 Nm (9 lb.ft).

3. Install the crankshaft front oil seal.

For additional information, refer to: C rankshaft Front Seal
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
4. Install the LH valve cover.
For additional information, refer to: Valve C over LH (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).
5. Install the RH valve cover.
For additional information, refer to: Valve C over RH (303-
01B Engine - V8 4.4L Petrol, In-vehicle Repair).
6. Install the generator mounting bracket.

C lean the locating dowels.

C lean the component mating faces.

Tighten the bolts to 45 Nm (33 lb.ft).

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. In all he gene a o .

C lean he componen ma ing face .

Tigh en he bol o 48 Nm (35 lb.f ).

. C onnec he ba e po i i e cable.

Tigh en he n o 10 Nm (7 lb.f ).

Sec e he co e .

. In all he RH e ha manifold hea hield.

Tigh en he c e .

. In all he coolan manifold.

Tigh en he bol o 6 Nm (4 lb.f ).

In all he coolan ho e .

Sec e i h he clip .

. In all he coolan e pan ion ank ho e.

C onnec he clip.

. In all he coolan p mp p lle .

Tigh en he bol o 10 Nm (7 lb.f ).

. In all he acce o d i e bel idle p lle .

Tigh en he bol o 25 Nm (18 lb.f ).

. NOTE: C a e m be aken hen in alling he pl g op

coil g o nd connec ion . The engine ill fail o a on ei he
o bo h bank if he g o nd i poo .

Sec e he engine i ing ha ne clip .

. In all he cooling fan d i e bel en ione .

Tigh en he p lle bol o 25 Nm (18 lb.f ).

Tigh en he en ione bol o 40 Nm (30 Ib.f ).

. In all he A/C mo n ing b acke .

. In all he A/C comp e o .
Fo addi ional info ma ion, efe o: Ai C ondi ioning (A/C )
C omp e o (412-03B Ai C ondi ioning - V8 4.4L Pe ol,
Remo al and In alla ion).
. In all he cooling fan h o d.
. In all he h o le bod ga ke .
Fo addi ional info ma ion, efe o: Th o le Bod Ga ke
(303-04B F el C ha ging and C on ol - V8 4.4L Pe ol,
Remo al and In alla ion).
. Refill and bleed he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Pe ol, Gene al P oced e ).

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Engine - V8 4.4L Petrol - Timing Dri e Components
In-vehicle Repair

Special Tool(s)
C amshaft setting/locking tool

303-530

Timing Setting tool

303-645

Timing chain tensioning tool

303-532

Timing shim tool

303-530/04

Remo al
NOTE: This procedure covers the removal and installation of the following components: timing chains, chain guides,
tensioners and sprockets.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

3. Remove the engine front cover.
For additional information, refer to: Engine Front C over
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
4. Remove the crankshaft position (C KP) sensor.
For additional information, refer to: C rankshaft Position
(C KP) Sensor (303-14B Electronic Engine C ontrols - V8 4.4L
Petrol, Removal and Installation).
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. Lock the crankshaft.

Install the special tool.

Install the screw.

. Remove the RH variable camshaft timing (VC T) control

solenoid housing.

Remove the 3 bolts.

Remove and discard the O-ring seals.

. Install the special tools to the RH c linder head.

Install the 3 bolts.

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. Remove the RH primar timing chain tensioner

assembl .

Remove the 2 bolts.

. Remove the RH primar timing chain tensioner guide.

Remove the bolt.

10. Remove the RH primar timing chain.

Remove the bolt retaining the chain guide.

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. Remove the special tools from the RH c linder head.

Remove the 3 bolts.

. Remove the LH variable camshaft timing (VC T) control

solenoid housing.

Remove the 2 bolts.

Remove the nut.

Remove and discard the O-ring seals.

. Install the special tools to the LH c linder head.

Install the 3 bolts.

. Remove the LH primar timing chain tensioner.

Remove the 2 bolts.

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1 . Remo e he LH ppe and lo e p ima iming chain

en ione g ide .

Remo e he 2 bol .

1 . Remo e he LH p ima iming chain.

1 . Remo e he LH cam haf p ocke a embl .

Remo e he 2 To bol .

1 . Remo e he LH econda iming chain en ione and

he econda iming chain.

Remo e he 2 bol .

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1 . Remove the RH camshaft sprocket assembl .

Remove the 2 Tor bolts.

20. Remove the RH secondar timing chain tensioner and

the secondar timing chain.

Remove the 2 retaining bolts.

21. NOTE: Note the orientation of the crankshaft sprocket.

Remove the crankshaft sprocket.

Remove the crankshaft sprocket ke .

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In alla ion
1. Install the crankshaft sprocket ke .

C lean the component mating faces.

2. Install the crankshaft sprocket.

3. Depress the LH secondar timing chain tensioner piston.

Using 1 mm diameter metal rod, retain the chain

tensioner piston.

4. NOTE: RH illustration shown, LH is similar.

Install the LH secondar timing chain tensioner and chain

to the camshaft sprockets.

5. Install the LH secondar timing chain tensioner retaining

bolts.

Tighten the bolts to 12 Nm.

6. Install the LH primar timing chain.

Make sure the timing chain slack is on the tensioner

side of the timing chain.

7. Install the LH primar timing chain tensioner guides.

Tighten the bolts to 12 Nm.

8. C AUTION: During timing chain tensioner

compression, do not release the ratchet stem until the
timing chain tensioner piston is full bottomed in its bore or
damage to the ratchet stem will result.

Install the LH primar timing chain tensioner.

Using 3 mm diameter metal rod, retain the chain

tensioner piston.

Tighten the bolts to 12 Nm.

Remove the retaining rod.

9. C AUTIONS:

Using the special tool, appl force to the tool in a

counter-clockwise direction, to tension the primar timing
chain on its drive side.

The intake camshaft sprocket retaining bolt MUST be

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igh ened befo e he e ha cam haf p ocke e aining
bol . Engine damage ill occ if hi p oced e i no
follo ed.

Make e ha ne bol a e in alled.

In all he pecial ool o he LH e ha cam haf

p ocke .

Tigh en he in ake cam haf p ocke e aining bol

o 20 Nm + 90 deg.

Tigh en he e ha cam haf p ocke e aining bol

o 20 Nm + 90 deg.

. In all he LH VC T con ol olenoid ho ing.

In all he ne O- ing eal .

Tigh en he ne bol o 22 Nm.

Tigh en he n o 10 Nm.

. Remo e he pecial ool f om he LH c linde head.

Remo e he 3 bol .

. In all he pecial ool o he RH c linde head.

In all he 3 bol .

. Re ain he RH econda iming chain en ione pi on.

U ing 1 mm diame e me al od, e ain he chain

en ione pi on.

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1 . In all he RH econda iming chain en ione and he
econda iming chain o he cam haf p ocke .
1 . NOTE: Ligh l igh en he cam haf p ocke To bol ,
he p ocke MUST be f ee o mo e.

In all he RH econda iming chain and p ocke o he

cam haf .

In all he p ocke e aining To bol o he

cam haf .

1 . In all he RH econda iming chain en ione e aining

bol .

Tigh en he bol o 12 Nm.

1 . Ten ion he econda iming chain.

Remo e he e aining od.

1 . In all he RH p ima iming chain.

Make e he iming chain lack i on he en ione

ide of he iming chain.

1 . In all he RH p ima iming chain en ione g ide.

Tigh en he bol o 12 Nm.

20. C AUTION: D ing iming chain en ione

comp e ion, do no elea e he a che em n il he iming
chain en ione pi on i f ll bo omed in i bo e o damage
o he a che em ill e l .

In all he RH p ima iming chain en ione .

U ing 3 mm diame e me al od, e ain he chain

en ione pi on.

Tigh en he bol o 12 Nm.

Remo e he e aining od.

21. C AUTIONS:

The in ake cam haf p ocke e aining bol MUST be

igh ened befo e he e ha cam haf p ocke e aining
bol . Engine damage ill occ if hi p oced e i no
follo ed.

U ing he pecial ool, appl fo ce o he ool in a

co n e -clock i e di ec ion, o en ion he p ima iming
chain on i d i e ide.

Make e ha ne bol a e in alled.

In all he pecial ool o he RH e ha cam haf

p ocke .

Tigh en he in ake cam haf p ocke e aining bol

o 20 Nm + 90 deg.

Tigh en he e ha cam haf p ocke e aining bol

o 20 Nm + 90 deg.

22. In all he RH VC T con ol olenoid ho ing.

In all he ne O- ing eal .

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Tighten the new bolts to 22 Nm.

. Remove the special tool from the RH c linder head.

. Install the engine front cover.
For additional information, refer to: Engine Front C over
(303-01B Engine - V8 4.4L Petrol, In-vehicle Repair).
. Remove the crankshaft locking tool.

Remove the screw.

. Install the C KP sensor.

For additional information, refer to: C rankshaft Position
(C KP) Sensor (303-14B Electronic Engine C ontrols - V8 4.4L
Petrol, Removal and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - V8 4.4L Petrol - E haust Manifold LH
In- ehicle Repai

Removal

All ehicle
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he e ha em.
Fo addi ional info ma ion, efe o: E ha S em (309-
00B E ha S em - V8 4.4L Pe ol, Remo al and
In alla ion).
3. Remo e he fende pla h hield.
Fo addi ional info ma ion, efe o: Fende Spla h Shield
(501-02 F on End Bod Panel , Remo al and In alla ion).
4. NOTE: The hea hield con i of 3 pa .

Remo e he ppe pen ion a m and b ake line hea

hield fo acce .

Remo e he 3 n .

Remo e he 3 bol .

Lef -hand d i e ehicle

5. C heck he oad heel a e in he aigh ahead po i ion,
hen emo e he ee ing col mn ni e al join ppe
clamp bol .

Di ca d he e aining bol .

6. Relea e he ppe ee ing col mn haf .

7. Remo e he ee ing ack ni e al join clamp bol .

Di ca d he e aining bol .

8. Relea e and emo e he haf and join a embl .

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All ehicle

. C AUTION: Fail e o follo hi p oced e can lead

o he EGR pipe e c acking.

Di connec he e ha manifold EGR pipe flange.

Remo e he 2 n .

Di ca d he ga ke .

Loo en, b do no emo e 2 bol , ec ing he EGR

pipe o he EGR al e.

10. Remo e he e ha manifold.

Remo e he 8 bol .

C ollec he pace and di ca d he bol .

Remo e he ga ke /hea hield e aining bol .

Di ca d he ga ke /hea hield.

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In alla ion
A
1. C .
2. I .

I / .

T 25 N (18 . ).

I , .

E ,
20 N (15 . ).

3. C EGR .

I .

T 25 N (18 . ).

T 25 N (18 . ).

L -
4. I .

C .

I 25 N (18
. ).

A
5. NOTE: T 3 .

I
.

I .

I .

6. I .
F , :F S S
(501-02 F E B P ,R I ).

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. Install the e haust s stem.
For additional information, refer to: E haust S stem (309-
00B E haust S stem - V8 4.4L Petrol, Removal and
Installation).
. C onnect the batter ground cable.

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Published: 11-Ma -2011

Engine - V8 4.4L Petrol - E haust Manifold RH
In-vehicle Repair

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the e haust s stem.
For additional information, refer to: E haust S stem (309-
00B E haust S stem - V8 4.4L Petrol, Removal and
Installation).
3. Remove the fender splash shield.
For additional information, refer to: Fender Splash Shield
(501-02 Front End Bod Panels, Removal and Installation).
4. NOTE: The heatshield consists of 3 parts.

Remove the upper suspension arm and brake line heat

shields for access.

Remove the 3 nuts.

Remove the 3 bolts.

5. Remove the e haust manifold.

Remove the 8 bolts.

C ollect the spacers and discard the bolts.

Remove the gasket/heat shield retaining bolt.

Discard the gasket/heat shield.

Installation
1. C lean the component mating faces.
2. Install the e haust manifold.

Install the gasket/heat shield.

Tighten the heat shield bolt to 25 Nm (18 lb.ft).

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E e a d g e i e , igh e he b i he
e e ce h 20 N (15 b.f ).

. NOTE: The hea hie d c i f3 a .

I a he e e i a a d b a e i e hea
hie d .

I a he b .

I a he .

.I a he fe de a h hie d.
F addi i a i f a i , efe : Fe de S a h Shie d
(501-02 F E d B d Pa e , Re a a dI a a i ).
.I a he e ha e .
F addi i a i f a i , efe : E ha S e (309-
00B E ha S e - V8 4.4L Pe , Re a a d
I a a i ).
.C ec he ba e g d cab e.
F addi i a i f ai , efe : S ecifica i (414-00
Ba e a d C ha gi g S e - Ge e a I f ai ,
S ecifica i ).

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Published: 11-May-2011
Engine - V8 4.4L Petrol - Variable Camshaft Timing (VCT) Unit
In-vehicle Repair

Remo al
NOTE: The removal and installation of the RH VC T unit is similar to the LH and is covered within the timing drive
component procedure.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the timing drive components.
For additional information, refer to: Timing Drive
C omponents (303-01B Engine - V8 4.4L Petrol, In-vehicle
Repair).

Installation
1. Install the timing drive components.
For additional information, refer to: Timing Drive
C omponents (303-01B Engine - V8 4.4L Petrol, In-vehicle
Repair).
2. C onnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

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Published: 11-Ma -2011

Engine - V8 4.4L Pe ol - C ank haf Main Bea ing Ca ie
Removal and Installation

Special Tool( )
Adapter

303-191-03

Bolts and spacers

303-191-04

Holding Tool C rankshaft Pulle

303-893(LRT-12-080)

Remover, crankshaft pulle

303-588

Remover, crankshaft seal

303-D121

Timing Setting tool

303-645

C amshaft setting/locking tool

303-530

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C rankshaft rear oil seal

remover/installer

303-538

Installer, crankshaft seal

303-1100

Adapter - C rankshaft seal installer

303-1100-01

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the engine.
For additional information, refer to: Engine (303-01B Engine
- V8 4.4L Petrol, Removal).
4. Mount the engine to an engine stand.
5. Remove the air conditioning compressor (A/C ) support
bracket.

Remove the 2 bolts.

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. Remove the cooling fan drive belt tensioner.

Remove the bolt.

. Remove the coolant manifold.

Release the clips and disconnect the 4 coolant hoses.

Remove the 4 bolts.

Disconnect the engine coolant temperature (EC T)

sensor electrical connector.

. Remove the coolant pump and accessor drive belt idler

pulle s.

Remove the bolts.

. Remove the e haust manifold heat shield.

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Remove the 2 bolts.

. Disconnect the batter positive cable.

Remove the batter positive cable cover.

Remove the nut.

. Remove the generator.

Disconnect the electrical connector.

Remove the 3 bolts.

. Remove the generator mounting bracket.

Remove the 4 bolts.

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1 . Disconnect the engine oil temperature sensor electrical

connector.

1 . Disconnect the engine oil pressure (EOP) sensor electrical

connector.
1 . NOTE: Some oil spillage is inevitable during this operation.

NOTE: C lean the components general area prior to

dismantling.

Remove the oil filter.

1 . Remove the oil filter housing.

Remove the 3 bolts.

Remove and discard the O-ring seal.

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1 . C AUTION: Under no circumstances should the

crankshaft setting peg, 303-645, be used in the following
operations, to restrain the crankshaft.

Using the special tools, retain the crankshaft pulle .

1 . NOTE: The crankshaft pulle retaining bolt will be ver

tight.

Using the special tools, remove the crankshaft pulle bolt.

Discard the bolt.

Remove the special tools.

1 . NOTE: The crankshaft pulle will be ver tight.

Using the special tools, remove the crankshaft pulle .

C ollect the locking ring.

Remove the special tools.

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. U ing he pecial ool, emo e and di ca d he

c ank haf f on eal.

. Remo e he RH igni ion coil-on-pl g co e .

Relea e f om he 2 clip .

. Di connec he RH igni ion coil-on-pl g elec ical

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connec o .

. Remo e he RH igni ion coil-on-pl g.

Remo e he bol .

Remo e and di ca d he eal.

. Remo e he emaining igni ion coil-on-pl g .

. Di connec he po i i e c ankca e en ila ion (PC V)
line.

. Di connec he LH a iable cam haf iming ( VC T) oil

olenoid elec ical connec o .
. Di connec he al e co e b ea he ho e.

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2 . Release the engine iring harness from the retaining

bracket.

2 . Disconnect the RH ariable camshaft timing (VC T) oil

solenoid electrical connector.

30. NOTE: Note the fitted position of the retaining bolts prior
to remo al.

Remo e the RH al e co er.

Remo e the 14 al e co er retaining bolts.

Remo e the engine co er bracket.

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. Remo e and di ca d he RH al e co e ga ke .

Remo e and di ca d he eal .

. Remo e he LH igni ion coil-on-pl g co e .

Relea e f om he 2 clip .

. Di connec he LH igni ion coil-on-pl g elec ical

connec o .

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. Remo e he LH igni ion coil-on-pl g.

Remo e he bol .

Remo e and di ca d he eal.

. Remo e he emaining LH igni ion coil-on-pl g .

. Remo e he oil le el indica o and be.

Remo e he oil le el indica o .

Remo e he n .

Remo e he be.

Remo e and di ca d he O- ing eal.

. Relea e he engine i ing ha ne f om he e aining

b acke .

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3 . NOTE: No e he fi ed po i ion of he e aining bol p io
o emo al.

Remo e he LH al e co e .

Remo e he 14 al e co e e aining bol .

3 . Remo e and di ca d he LH al e co e ga ke .

Remo e and di ca d he eal .

40. Relea e he engine i ing ha ne .

Relea e he 2 clip .

Remo e he bol .

41. Remo e he po e ee ing p mp mo n ing b acke .

Remo e he 5 bol .

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. Relea e he i ing ha ne f om he LH ide of he

engine.

Relea e he 3 clip .

. Relea e he i ing ha ne f om he RH ide of he

engine.

Relea e he 3 clip .

. Remo e he half haf ppo bea ing ho ing.

Remo e he 4 bol .

Remo e and di ca d he O- ing eal.

. Di connec he c ank haf po i ion (C KP) en o elec ical

connec o .
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4 . Remo e he C KP en o .

Remo e he bol .

4 . NOTE: In all he pecial ool o he c ank haf en o

ape e.

Lock he c ank haf .

In all he pecial ool.

In all he c e .

4 . Remo e he engine f on co e .

Remo e he 24 bol .

Remo e and di ca d he ga ke .

Remo e and di ca d he 3 O- ing eal .

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4 . Remove the RH VC T housing.

Remove the 3 bolts.

Remove and discard the O-ring seals.

50. Install the special tool to the RH c linder head.

Install the 3 bolts.

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. Remove the RH primar timing chain tensioner

assembl .

Remove the 2 bolts.

. Remove the RH primar timing chain tensioner guide.

Remove the bolt.

. Remove the RH primar timing chain.

. Remove the LH VC T housing.

Remove the 3 bolts.

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Remove and discard the O-ring seals.

. Install the special tool to the LH c linder head.

Install the 3 bolts.

. Remove the LH primar timing chain tensioner.

Remove the 2 bolts.

. Remove the LH upper and lower primar timing chain

tensioner guides.

Remove the 2 bolts.

. Remove the LH primar timing chain.

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5 . NOTE: N e he ie ai f he c a haf c e .

Re e he c a haf c e .

Re e he c a haf c e e .

60. Re e he ecia .

61. C AUTION: The b ca be ed 3 i e ,

a he b i h a ce e ch. If 2 ch a a e
i ib e, di ca d he b .

Re e he e c e e fe a e.

Re e he 8 b .

62. C AUTION: N e he ii f he b , i

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removal.

Remove the oil pan.

Remove the 17 bolts.

Remove and discard the gasket.

3. Remove the oil strainer pick-up assembl .

Remove the 2 bolts.

Remove and discard the O-ring seal.

4. Remove the oil pan e tension.

Remove the 18 bolts.

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. Remove the oil pump assembly.

Remove the 4 bolts.

Remove and discard the gasket.

C lean the component mating faces.

. Remove the baffle plate.

Remove the 6 bolts.

. C AUTION: To make sure damage does not occur to

the crankshaft and piston components, the engine must be
inverted on the engine stand. Failure to follow this instruction
may result in damage to the engine.

NOTE: If the crankshaft main bearing carrier retaining bolts

have been marked with a center punch dot, they must be
discarded and new bolts installed.

Remove the crankshaft main bearing carrier.

Remove the crankshaft main bearing carrier retaining

bolts in the indicated sequence.

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68. Remo e and discard the rear crankshaft oil seal.

In alla ion

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. C AUTIONS:

Use only a plastic scraper when removing the sealing

material.

If any new bolts are to be installed to retain the

crankshaft main bearing carrier, pre-stress the retaining bolts
by installing the crankshaft main bearing carrier without any
sealant and tightening the new retaining bolts to the specified
torque. Remove the crankshaft main bearing carrier once the
bolts have been pre-stressed. Failure to follow this instruction
may result in damage to the vehicle.

C lean all the mating faces and reusable parts thoroughly

and check for damage.
. NOTE: Install the crankshaft main bearing carrier and
tighten bolts to specification within twenty minutes of applying
the sealant.

Apply a 2 mm (0.08in) bead of sealant to the cylinder block

in the area shown.

Use WSS-M4G323-A4-RTV sealant.

. NOTE: Install the crankshaft main bearing carrier and

tighten bolts to specification within twenty minutes of
applying the sealant.

Apply a 1 mm (0.039in) bead of sealant to the cylinder

block in the area shown.

Use WSS-M4G323-A4-RTV sealant.

. C AUTION: Make sure all dowels are fully seated into

the crankshaft main bearing carrier prior to tightening the
bolts.

NOTE: Do not lubricate the crankshaft main bearing carrier

retaining bolts.

NOTE: Do not rotate the crankshaft until all the retaining

bolts are tightened to specification.

NOTE: The retaining bolts must be tightened within twenty

minutes of applying the sealant.

NOTE: Tighten the retaining bolts in the sequence shown.

Install the crankshaft main bearing carrier to the cylinder

block.

1. Stage 1: Bolts 21 to 32, tighten to 15 Nm (11 lb.ft).

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2. S age 2: Bol 33 o 34, igh en o 15 Nm (11 lb.f ).

3. S age 3: Bol 1 o 10, igh en o 25 Nm (18 lb.f ).

4. S age 4: Bol 11 o 20, igh en o 15 Nm (11 lb.f ).

5. S age 5: Bol 1 o 10, igh en o 35 Nm (26 lb.f ),

hen a f he 135 deg ee .

6. S age 6: Bol 11 o 20, igh en o 20 Nm (15 lb.f ),

hen a f he 150 deg ee .

7. S age 7: Bol 21 o 32, igh en o 20 Nm (15 lb.f ),

hen a f he 90 deg ee .

8. S age 8: Bol 33 o 34, igh en o 20 Nm (15 lb.f ),

hen a f he 150 deg ee .

9. S age 9: C en e p nch each of he bol head o

indica e i ha been e ed.

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. Remove the special tool.

. Remove the special tool from the left-hand c linder head.

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. Remove the special tool from the right-hand c linder head.

. C AUTION: Make sure that number 1 c linder intake

camshaft lobes are vertical to the c linder head face.

Position the right-hand camshafts to the neutral position.

. C AUTION: Make sure that number 2 c linder

e haust camshaft lobes are vertical to the c linder head
face.

Position the left-hand camshafts to the neutral position.

10. C AUTIONS:

Make sure no binding of the crankshaft occurs.

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Make sure the spark plugs are removed to enable the

engine to rotate freely.

C arefully rotate the crankshaft two complete turns to check

for correct operation.
. Install the baffle plate.

Tighten the 6 bolts to 6 Nm ( 4 lb.ft).

. NOTE: C arefully remove the transit sleeve, leaving the

seal in place.

NOTE: Make sure that the transit sleeve is correctly

positioned and install the new seal over the crankshaft. Do not
use any lubricant on the seal, the transit sleeve or the
crankshaft.

Using the special tool, position the crankshaft rear oil seal.

Install the special tool to the crankshaft.

. C AUTION: Alternate the nut tightening to correctly

seat the crankshaft rear oil seal.

Using the special tool, install the rear crankshaft oil seal.

. C AUTION: Make sure that the crankshaft rear oil seal

is correctly located.

Remove the special tool.

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1 . NOTE: P e e he f e ae f a i g.

I a he e c e e fe a e.

C ea he c e a i g face .

Tigh e he b e e i 2 age he e e ce
h .

Tigh e he b 15 N (11 b f ).

Tigh e he b 110 N (81 b.f ).

1 . C AUTIONS:

Ma e e he a g a e e ed e ab e he
e gi e a e f ee .

D a e he c a haf c e c c i e.

R a e he c a haf c c i e ii he e gi e
dead ce e (TDC ) N . 1 c i de

I a he ecia .

1 .I a he ecia he ef -ha d c i de head.

1 .I a he ecia he igh -ha d c i de head.

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1 . NOTE: Install a new gasket.

Install the oil pump assembl .

C lean the component mating faces.

Install the gasket.

Tighten the bolts to 10 Nm (7 lb.ft).

20. NOTE: Install a new O-ring seal.

Install the oil strainer pick-up assembl .

Install the O-ring seal.

Tighten the M6 bolt to 10 Nm (7 lb.ft).

Appl sealant to the M5 bolts.

Tighten the M5 bolts to 6 Nm (4 lb.ft).

21. Install the crankshaft sprocket.

C lean the component mating faces.

Install the crankshaft sprocket ke .

22. Install the LH primar timing chain.

Make sure the timing chain slack is on the tensioner

side of the timing chain.

23. Install the LH primar timing chain tensioner guides.

Tighten the bolts to 12 Nm (9 lb.ft).

24. C AUTION: During timing chain tensioner

compression, do not release the ratchet stem until the
timing chain tensioner piston is full bottomed in its bore or
damage to the ratchet stem will result.

Install the LH primar timing chain tensioner.

Using a 3 mm (0.118 in) diameter rod, retain the

chain tensioner piston.

Tighten the bolts to 12 Nm (9 lb.ft).

Remove the retaining rod.

25. C AUTION: Make sure that new bolts are installed.

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NOTE: Install new O-ring seals.

Install the LH VC T control solenoid housing.

Install the O-ring seals.

Tighten the bolts to 22 Nm (16 lb.ft).

Tighten the nut to 10 Nm (7 lb.ft).

2 . Install the RH primary timing chain.

Make sure the timing chain slack is on the tensioner

side of the timing chain.

2 . Install the RH primary timing chain tensioner guide.

Tighten the bolts to 12 Nm (9 lb.ft).

2 . C AUTION: During timing chain tensioner

compression, do not release the ratchet stem until the
timing chain tensioner piston is fully bottomed in its bore or
damage to the ratchet stem will result.

Install the RH primary timing chain tensioner.

Using a 3 mm (0.118 in) diameter rod, retain the

chain tensioner piston.

Tighten the bolts to 12 Nm (9 lb.ft).

Remove the retaining rod.

2 . C AUTION: Make sure that new bolts are installed.

NOTE: Install new O-ring seals.

Install the RH VC T control solenoid housing.

Install the O-ring seals.

Tighten the bolts to 22 Nm (16 lb.ft).

Tighten the nut to 10 Nm (7 lb.ft).

30. Remove the special tool from the RH cylinder head.

31. Remove the special tool from the LH cylinder head.

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. Install the oil pan e tension.

C lean the component mating faces.

Appl a 3 mm (0.118 in) diameter bead of sealant,

to the area indicated.

Install the bolts, but do not tighten full at this stage.

. Tighten the oil pan bolts in the sequence sho n to 20 Nm

(15 lb.ft).

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. Remo e he pecial ool.

Remo e he bol .

. In all he C KP en o .

Tigh en he bol o 8 Nm (6 lb.f )

. A ach he i ing ha ne o he LH ide of he engine

Sec e he clip .

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3 . Attach the wiring harness to the RH side of the engine.

Secure the clips.

3 . Install the power steering pump mounting bracket.

Tighten the bolts to 25 Nm (18 lb.ft).

3 . NOTE: Install a new gasket.

NOTE: Install a new O-ring seal.

Install the engine front cover.

C lean the component mating faces.

Apply a 3 mm (0.118 in) diameter bead of sealant

12mm (0.47 in) long, to the 8 places indicated.

Install the gasket.

Install the O-ring seal.

40. Evenly and progressively tighten the bolts in the

sequence shown to 12 Nm (9 lb.ft).

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. Attach the engine wiring harness.

Secure the clips.

Tighten the bolt to 10 Nm (7 lb.ft).

. NOTE: Install new seals.

Install the LH valve cover plug aperture seals.

. NOTE: Install a new gasket.

NOTE: Apply two beads of silicone gasket sealant as

shown on the illustration. The application of the sealant
must be 3 mm (0.118 in) diameter 12 mm (0.47 in) long.
Install the valve cover immediately after applying the
sealant. The cover should be fitted directly to the head
without smearing the sealant or the seals.

Install the LH valve cover.

C lean the component mating faces.

Install the valve cover gasket.

. Install the LH valve cover bolts.

Install the LH valve cover bolts to the positions

previously noted.

Tighten the bolts in the sequence shown to 12 Nm (9

lb.ft).

. C onnect the LH VC T oil solenoid electrical connector.

. Attach the engine wiring harness to the retaining bracket.
. NOTE: Install a new O-ring seal.

With assistance, install the oil level indicator and tube.

C lean the component mating faces.

Install the O-ring seal.

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Lubricate the O-ring seal with clean engine oil.

Tighten the nut to 6 Nm (4 lb.ft).

4 . NOTE: Install new O-ring seals.

Install the 4 LH ignition coil-on-plugs.

Install the O-ring seals.

Install the 4 ignition coil-on-plugs.

Tighten the bolts to 6 Nm (4 lb.ft).

4 . C onnect the 4 electrical connectors.

50. Install the LH ignition coil-on-plug cover.

51. NOTE: Install new seals.

Install new RH valve cover plug aperture seals.

52. NOTE: Install a new gasket.

NOTE: Apply two beads of silicone gasket sealant as

shown on the illustration. The application of the sealant
must be 3 mm (0.118 in) diameter 12 mm (0.47 in) long.
Install the valve cover immediately after applying the
sealant. The cover should be fitted directly to the head
without smearing the sealant or the seals.

Install the RH valve cover.

C lean the component mating faces.

Install the gasket.

53. Install the RH valve cover bolts.

Install the RH valve cover bolts to the positions

previously noted.

Tighten the bolts in the sequence shown to 12 Nm (9

lb.ft).

54. NOTE: Install new O-ring seals.

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Install the 4 RH ignition coil-on-plugs.

Install the O-ring seals.

Install the 4 ignition coil-on-plugs.

Tighten the bolts to 6 Nm (4 lb.ft).

. C onnect the 4 electrical connectors.

. C onnect the RH VC T oil solenoid electrical connector.

. Attach the engine wiring harness to the retaining bracket.
. C onnect the PC V line to the RH valve cover.
. C lean the crankshaft pulle mating faces.
. Using the special tool, install the crankshaft front seal.

Lubricate the seal with clean engine oil.

Use the discarded crankshaft bolt with the special

tool.

Remove the special tools.

. Install the crankshaft pulle .

Lubricate the seal with clean engine oil.

. Install the crankshaft pulle locking ring.

. C AUTION: The screw thread in the crankshaft pulle

must be cleaned out before installing a new crankshaft pulle
bolt.

Install, but do not tighten, the new crankshaft pulle bolt.

. C AUTION: Under no circumstances should the

crankshaft setting peg, 303-645, be used in the following
operations, to restrain the crankshaft.

Using the special tools, tighten the crankshaft pulle bolt.

Tighten the crankshaft pulle bolt to 380 Nm (280

lb.ft).

Remove the special tools.

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. In all he oil fil e ho ing.

C lean he componen ma ing face .

In all a ne O- ing eal.

Tigh en he bol o 20 Nm (15 lb.f ).

. In all he engine oil fil e .

L b ica e he oil fil e eal i h clean engine oil and

igh en o 18 Nm (13 lb.f ).

. C onnec he EOP en o elec ical connec o .

. C onnec he engine oil empe a e en o elec ical
connec o .
. In all he gene a o mo n ing b acke .

Tigh en he 4 bol o 45 Nm (33 lb.f ).

0. In all he gene a o .

Tigh en he 3 bol o 48 Nm (35 lb.f ).

C onnec he elec ical connec o .

1. C onnec he ba e po i i e cable.

Tigh en he n o 10 Nm (7 lb.f ).

In all he ba e po i i e cable co e .

2. In all he e ha manifold hea hield.

Tigh en he 2 bol .

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. In all he acce o d i e bel idle p lle .

Tigh en he bol o 25 Nm (18 lb.f ).

. In all he coolan p mp p lle .

Tigh en he bol o 10 Nm (7 lb.f ).

. NOTE: In all ne O- ing eal .

In all he coolan manifold.

C lean he componen .

In all he O- ing eal .

C onnec he 4 coolan ho e and in all he clip .

A ach he i ing ha ne b acke .

Tigh en he To c e o 10 Nm (7 lb.f ).

. C onnec he EC T en o elec ical connec o .

. In all he cooling fan d i e bel en ione .

Tigh en he bol o 40 Nm (30 lb.f ).

. In all he A/C comp e o mo n ing b acke .

Tigh en he bol o 25 Nm (18 lb.f ).

. Remo e he engine f om he engine and.

0. In all he engine.
Fo addi ional info ma ion, efe o: Engine (303-01B Engine
- V8 4.4L Pe ol, Remo al).
1. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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P bli hed: 11-Ma -2011

Engine - V8 4.4L Petrol - Engine
Remo al

Special Tool(s)
Engine lif ing c adle

303-1144

F el p ing lock deco pling ool

310-D005

Ball join epa a o

205-754(LRT-54-027)

Remo al
1. Po i ion he ehicle on a lif .
2. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
3. Sec e he hood in he e ice po i ion.
4. Remo e he ba e a .
Fo addi ional info ma ion, efe o: Ba e T a (414-01
Ba e , Mo n ing and C able , Remo al and In alla ion).
5. Remo e he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
6. Remo e he ai cleane a embl .
Fo addi ional info ma ion, efe o: Ai C leane (303-12B
In ake Ai Di ib ion and Fil e ing - V8 4.4L Pe ol,
Remo al and In alla ion).
7. Remo e he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05B Acce o D i e - V8 4.4L Pe ol, Remo al and
In alla ion).
8. D ain he coolan .
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Pe ol, Gene al P oced e ).
9. Di connec he coolan e pan ion ank lo e ho e.

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Release the clip.

. Disconnect the thermostat housing coolant hoses.

Release the 2 clips.

. Disconnect the upper coolant hose assembl .

Release the 2 clips.

. Disconnect the engine oil cooler coolant hoses.

Release the 2 clips.

Remove the hose assembl .

. Tie the hose assembl aside for access.

Remove the bolt.

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1 . Remo e he acce o d i e bel en ione .

Remo e he bol .

1 . Remo e he fende pla h hield .

Fo addi ional info ma ion, efe o: Fende Spla h Shield
(501-02 F on End Bod Panel , Remo al and In alla ion).
1 . Remo e he e ha em.
Fo addi ional info ma ion, efe o: E ha S em (309-
00B E ha S em - V8 4.4L Pe ol, Remo al and
In alla ion).
1 . D ain he engine oil.
Fo addi ional info ma ion, efe o: Engine Oil D aining and
Filling (303-01B Engine - V8 4.4L Pe ol, Gene al
P oced e ).
1 . Relea e he po e ee ing p mp and ie a ide

Remo e he 3 bol .

1 . Relea e he A/C comp e o and ie a ide.

Remo e he 3 bol .

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. Release the transmission cooler pipes.

Position a container to collect the fluid.

Remove the bolt.

Release the 2 clips.

Move the transmission pipes aside.

. Release the fle plate.

Remove the grommet.

Rotate the crankshaft to access the retaining bolts.

Remove the 3 bolts.

. Disconnect the batter positive cable from the BJB.

Remove the bolt.

Position the positive cable aside.

. Disconnect the evaporative emission hose from the

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intake manifold assembl .

Position the hose aside for access.

2 . C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to
prevent contamination.

Position the EGR valve aside.

Remove the 4 bolts.

Remove and discard the gasket.

2 . Install the special tool.

2 . Disconnect the engine wiring harness.

Release the cassette.

Release and disconnect the 2 electrical connectors.

Remove the ground cable bolt.

2 . Disconnect the brake booster vacuum hose from the

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intake manifold.

2 . Depressuri e the fuel rail.

Position an absorbent cloth to collect fluid spillage.

2 . Using the special tool, disconnect the fuel line.

Position the suppl line aside.

30. Release the heat shield for access to the transmission

bolts.

Remove the 2 bolts.

Move the shield aside.

31. Remove the transmission bolts.

Support the transmission.

Remove the 16 bolts.

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. Remo e he ppe pen ion a m and b ake line hea

hield fo acce .

Remo e he 3 bol .

Remo e he 3 n .

. Loo en he Allen bol and o a e he engine oil coole

a ide fo acce .

. Remo e he 2 engine mo n n .

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3 . Release the engine from mounts and the transmission.

Install the lifting chains.

Raise the RH side of the engine b appro imatel 35

mm.

3 . Remove the engine RH mount bracket.

Remove 4 bolts securing the engine mount bracket

to the c linder block.

Disconnect the engine ground cable from the RH

mounting bracket.

3 . C AUTIONS:

Make sure the torque converter remains connected to

the transmission.

C are must be taken to avoid damaging the steering rack

and differential.

C arefull and progressivel raise and remove the engine.

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3 . Di connec he lif ing chain .

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Published: 11-Ma -2011

Engine - V8 4.4L Pe ol - Engine
Disassembl

Special Tool( )
Timing Setting tool

303-645

C amshaft setting/locking tool

303-530

Adapter - C rankshaft seal installer

303-1100-01

Adapter

303-191-03

Holding Tool C rankshaft Pulle

303-893(LRT-12-080)

Bolts and spacers

303-191-04

Timing chain tensioning tool

303-532

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Disassembl
1. Remove the engine assembl .
For additional information, refer to: Engine (303-01B Engine -
V8 4.4L Petrol, Installation).
2. Secure the engine to the engine stand.

Align the engine to the engine stand.

Adjust the engine stand legs into position.

Mount the engine to an engine stand.

Full tighten the engine stand leg nuts.

3. Release the camshaft position (C MP) sensor connector

block from the intake manifold assembl .

4. Remove the coolant manifold.

Remove the 4 bolts.

Disconnect the electrical connector.

5. Position the wiring harness support bracket aside for

access.

Remove the 2 bolts.

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. NOTE: RH ill a ion ho n, LH i imila .

Remo e bo h he igni ion coil-on-pl g co e .

Relea e f om he 2 clip .

. NOTE: RH ill a ion ho n, LH i imila .

Di connec he 8 igni ion coil-on-pl g elec ical connec o .

. Remo e he 8 igni ion coil-on-pl g .

Remo e he 8 bol .

. Di connec he al e co e b ea he ho e.

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Disconnect the variable camshaft timing (VC T) oil
control solenoid electrical connector.

Repeat the operation for the other side.

. Disconnect the engine coolant temperature (EC T) sensor

electrical connector.

. Disconnect the C MP sensor electrical connector.

Repeat the above procedure for the RH side.

. Disconnect the c linder head earth connector.

Remove the bolt.

Release the 3 clips.

. Disconnect the knock sensors (KS) electrical connector.

. Release the purge valve from the mounting bracket.
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Di c ec he ic e ea e c ec .

Di c ec he e ec ica c ec .

Re e he b .

1 . Re ea e he 5 ai c di i i g (A/C ) ha e e ai i g
ci .

1 . Re e he c a haf ii (C KP) e .

Di c ec he e ec ica c ec .

Re e he T c e .

1 . Re e he e ee i g i g b ac e .

Re e he 3 b .

Re ea e he a i i c e i e ci .

1 . Re e he A/C c e i g b ac e .

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Remo e he 2 bol .

1 . Di connec he a e mo o connec o .

20. Di connec he oil empe a e and oil p e e en o .

21. Di connec he gene a o connec o .

22. Relea e he 4 clip ec ing he gene a o ha ne .

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. Remove the 10 intake manifold bolts.

. C AUTION: Before the disconnection or removal of

an components, ensure the area around joint faces and
connections are clean. Plug an open connections to prevent
contamination.

Remove the intake manifold.

Disconnect the brake booster vacuum hose from the

intake manifold.

Discard the gaskets.

Disconnect the manifold absolute pressure (MAP)

sensor electrical connector.

. Remove the accessor drive belt idler pulle .

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Remove the bolt.

2 . Remove the coolant pump pulle .

Remove the 3 bolts.

2 . Remove the coolant pump.

2 . Remove the generator.

Disconnect the electrical connector.

Remove the 3 bolts.

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2 . Remo e he gene a o mo n ing b acke .

Remo e he 4 bol .

30. Remo e he oil le el indica o and be.

Remo e he n .

Di ca d he O- ing eal.

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. Remove the RH valve cover.

Remove the 14 valve cover retaining bolts.

Remove and discard the valve cover gasket.

Remove and discard the valve cover plug aperture

seals.

Repeat the operation for the LH side.

. Remove the engine front cover.

Release the engine wiring harness clips.

Remove the 24 bolts.

Remove and discard the gasket.

. Rotate the crankshaft until the flats on the camshafts are

parallel with the c linder head joint faces.
. NOTE: The engine is now in the SAFE position.

Lock the crankshaft.

Install the special tool.

Install the screw.

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3 . Remove the RH VC T control unit.

Remove the 3 bolts.

Remove and discard the O-ring seals.

3 . Install the special tool to the RH c linder head.

Install the 3 bolts.

3 . Remove the RH primar timing chain tensioner assembl .

Remove the 2 bolts.

3 . Remove the RH primar timing chain tensioner guide.

Remove the bolt.

3 . Remove the RH primar timing chain.

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. Remove the LH VC T control unit.

Remove the 2 bolts.

Remove the nut.

Remove and discard the O-ring seals.

. Install the special tool to the LH c linder head.

Install the 3 bolts.

. Remove the LH primar timing chain tensioner.

Remove the 2 bolts.

. Remove the LH upper and lower primar timing chain

tensioner guides.

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Remove the stud.

Remove the bolt.

. Remove the LH primar timing chain.

. C AUTION: Discard the bolts.

Remove the camshaft sprockets.

Remove the 2 bolts.

. Remove the secondar timing chain tensioner and the

secondar timing chain.

Remove the 2 bolts.

. Remove the special tool from the LH c linder head.

Remove the 3 bolts.

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4 . C AUTION: Evenly and progressively, release the

camshaft bearing caps.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

Remove the camshaft bearing caps.

Remove the 20 bolts.

4 . Remove the camshafts.

50. Install the special tool to the RH cylinder head.

Install the 3 bolts.

51. C AUTION: Discard the bolts.

NOTE: LH illustration shown, RH is similar.

Remove the camshaft sprockets.

Remove the 2 bolts.

52. NOTE: LH illustration shown, RH is similar.

Remove the secondary timing chain tensioner and the

secondary timing chain.

Remove the 2 bolts.

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. C AUTION: Evenly and progressively, release the

camshaft bearing caps.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

NOTE: LH illustration shown, RH is similar.

Remove the camshaft bearing caps.

Remove the 20 bolts.

. C AUTIONS:

The bolts can only be used twice, mark the bolts with a
center punch. If two punch marks are visible, discard the
bolts.

Vehicles fitted with Polydrive cylinder head bolts, the

cylinder head bolts must be removed using a 10 mm
Polydrive socket or a 10 mm Allen key. Failure to follow this
instruction may result in damage to the component.

Remove the LH cylinder head assembly.

Remove the 12 cylinder head bolts.

With assistance remove the cylinder head.

Remove and discard the cylinder head gasket.

C lean the cylinder head locating dowels.

C lean the component mating faces.

Repeat the operation for the RH side.

. Remove 4 bolts securing the engine mount bracket to the

cylinder block.

. C AUTION: Note the position of the bolt.

Remove the starter motor.

Remove the remaining starter motor bolt.

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5 . Remo e he KS.

5 . Remo e he fle pla e.

Remo e and di ca d he 8 bol .

5 . NOTE: Some
a ia ion in he
ill a ion ma
occ , b he
e en ial
info ma ion i
al a co ec .

Remo e he oil
pan.

Remo e
he 18
bol .

C lean all
he ma ing
face and
e able
pa

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thoroughl
and check
for
damage.

0. Remove the oil strainer pick-up assembl .

Remove the 2 bolts.

Remove and discard the O-ring seal.

1. Remove the baffle plate.

Remove the 6 bolts.

2. Remove the oil pump assembl .

Remove the 4 bolts.

Remove and discard the gasket.

C lean the component mating faces.

3. Remove the engine from the engine stand.

With assistance, remove the engine block from the

stand.

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Published: 11-Ma -2011

Engine - V8 4.4L Pe ol - Engine
Assembl

Special Tool( )
Timing Setting tool

303-645

C amshaft setting/locking tool

303-530

Adapter - C rankshaft seal installer

303-1100-01

Adapter

303-191-03

Holding Tool C rankshaft Pulle

303-893(LRT-12-080)

Bolts and spacers

303-191-04

Timing chain tensioning tool

303-532

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Assembl
1. Secure the engine to the engine stand.

Align the engine to the engine stand.

Adjust the engine stand legs into position.

Mount the engine to an engine stand.

Full tighten the engine stand leg nuts.

2. NOTE: Install a new gasket.

Install the oil pump assembl .

C lean the component mating faces.

Install the gasket.

Tighten the bolts to 10 Nm.

3. Install the baffle plate.

Tighten the 6 bolts to 6 Nm.

4. NOTE: Install a new O-ring seal.

Install the oil strainer pick-up assembl .

Install the O-ring seal.

Tighten the M6 bolt to 10 Nm.

Appl sealant to the M5 bolts.

Tighten the M5 bolts to 6 Nm.

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.I a he i a .

C ea he c e a i g face .

A a3 dia e e bead f ea a , he a ea
i dica ed.

I a he b ,b d igh e f a hi age.

. Tigh e he i a b i he e e ce h 20
N .

. NOTE: P e e he f e ae f a i g.

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I a he f e a e.

C ea he c e a i g face .

Tigh e he b e e i 2 age he e e ce
h .

Tigh e he b 15 N .

Tigh e he b 110 N .

.I a he c a .

Tigh e he 5 b 10 N .

. NOTE: S e a ia i i he i ai a cc ,b
he e e ia i f ai i a a c ec .

I a he c e (KS).

Tigh e he b 20 N .

10. I a he a e .

Tigh e he b 45 N

11. A ach he e gi e i g b ac e .

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. NOTE: The cylinder head gaskets must be installed over

the cylinder head to block dowels.

Install the RH cylinder head.

C lean the component mating faces.

C lean the cylinder head locating dowels.

Install a new cylinder head gasket.

With assistance install the cylinder head.

Repeat the operation for the LH side.

. C AUTION: Vehicles fitted with Polydrive cylinder

head bolts, the cylinder head bolts must be installed using a
10 mm Polydrive socket or a 10 mm Allen key. Failure to
follow this instruction may result in damage to the
component.

NOTE: Tighten the bolts 1 to 10 in the sequence shown.

NOTE: LH illustration shown, RH is similar.

Install the cylinder head bolts.

Tighten the bolts to 20 Nm.

Tighten the bolts to 35 Nm.

Tighten the bolts 1 to 10, a further 90 degrees.

Tighten the bolts 1 to 10, a further 90 degrees.

Tighten the M8 bolts 11 and 12, to 25 Nm.

Repeat the operation for the LH side.

. Install the LH camshafts.

C lean the component mating faces.

Lubricate the journals and camshaft lobes.

. Install the camshaft bearing caps.

Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm (7 lb.ft).

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1 . Install the sprocket retaining Torx bolts to the camshafts.

1 . C AUTION: C amshaft lobes must be 180 degrees

away from each valve tappet or valve clearance will be
incorrect.

Measure and record the tappet clearances.

Rotate the camshafts using the Torx bolts.

1 . NOTE: Remove the camshaft bearing caps evenly and

in stages.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).

Remove the camshafts.

Remove the 20 bolts.

1 . Remove the valve tappets, replace with selected tappets.

20. Install the camshafts.

Lubricate the journals and camshaft lobes.

C lean the component mating faces.

21. Install the camshaft bearing caps.

Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm (7 lb.ft).

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. C AUTION: C am haf lobe m be 180 deg ee

a a f om each al e appe o al e clea ance ill be
inco ec .

C heck al e appe clea ance a e co ec .

Ro a e he cam haf ing he To bol .

Remo e he cam haf To bol af e he check i

comple e.

. Repea he ope a ion fo he RH cam haf .

. In all he pecial ool o he LH c linde head.

. NOTE: RH ill a ion ho n, LH i imila .

Dep e he LH econda iming chain en ione pi on.

U ing 1 mm diame e me al od, e ain he chain

en ione pi on.

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2 . In all he LH econda iming chain en ione
e aining bol .

Tigh en he bol o 12 Nm.

2 . NOTE: Ligh l igh en he cam haf p ocke To bol ,

he p ocke MUST be f ee o mo e.

In all he LH econda iming chain and p ocke o he

cam haf .

In all he p ocke e aining To bol o he

cam haf .

2 . Ten ion he econda iming chain.

Remo e he e aining od.

2 . Repea he ope a ion fo he RH cam haf .

30. NOTE: RH ill a ion ho n, LH i imila .

In all he LH p ima iming chain.

Make e he iming chain lack i on he en ione

ide of he iming chain.

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. In all he LH p ima chain en ione g ide.

Tigh en he d o 12 Nm.

. C AUTION: D ing iming chain en ione

comp e ion, do no elea e he a che em n il he
iming chain en ione pi on i f ll bo omed in i bo e o
damage o he a che em ill e l .

In all he LH p ima iming chain en ione .

U ing 3 mm diame e me al od, e ain he chain

en ione pi on.

Tigh en he bol o 12 Nm.

Remo e he e aining od.

. C AUTIONS:

U ing he pecial ool, appl fo ce o he ool in a

co n e -clock i e di ec ion, o en ion he p ima iming
chain on i d i e ide.

The in ake cam haf p ocke e aining bol MUST be

igh ened befo e he e ha cam haf p ocke e aining
bol . Engine damage ill occ if hi p oced e i no
follo ed.

Make e ha ne bol a e in alled.

In all he pecial ool o he e ha cam haf p ocke .

Tigh en he in ake cam haf p ocke bol o 20 Nm

hen a f he 90 deg ee .

Tigh en he e ha cam haf p ocke bol o 20 Nm

hen a f he 90 deg ee .

. In all he LH a iable cam haf iming (VC T) oil con ol

ni .

In all he ne O- ing eal .

Tigh en he ne bol o 22 Nm.

Tigh en he n o 10 Nm.

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3 . Install the RH primar timing chain.

Make sure the timing chain slack is on the tensioner

side of the timing chain.

3 . Install the RH primar timing chain tensioner guide.

Tighten the bolts to 12 Nm.

3 . C AUTION: During timing chain tensioner

compression, do not release the ratchet stem until the
timing chain tensioner piston is full bottomed in its bore or
damage to the ratchet stem will result.

Install the RH primar timing chain tensioner.

Using 3 mm diameter metal rod, retain the chain

tensioner piston.

Tighten the bolts to 12 Nm.

Remove the retaining rod.

3 . C AUTIONS:

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U ing he pecial ool, appl fo ce o he ool in a

co n e -clock i e di ec ion, o en ion he p ima iming
chain on i d i e ide.

The in ake cam haf p ocke e aining bol MUST be

igh ened befo e he e ha cam haf p ocke e aining
bol . Engine damage ill occ if hi p oced e i no
follo ed.

Make e ha ne bol a e in alled.

In all he pecial ool o he e ha cam haf p ocke .

Tigh en he in ake cam haf p ocke bol o 20 Nm

hen a f he 90 deg ee .

Tigh en he e ha cam haf p ocke bol o 20 Nm

hen a f he 90 deg ee .

3 . In all he RH VC T oil con ol ni .

In all he ne O- ing eal .

Tigh en he ne bol o 22 Nm.

40. Remo e he pecial ool f om he LH c linde head.

41. Remo e he pecial ool f om he RH c linde head.

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. Remove the crankshaft locking tool.

Remove the screw.

. Install the engine front cover.

C lean the component mating faces.

Appl a bead of sealant 3 mm diameter, b 12 mm

long, to the 8 places indicated.

. Evenl and progressivel tighten the bolts in the

sequence shown to 12 Nm.

. Using the special tools, install the crankshaft front seal.

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C lean the component mating faces.

Lubricate the seal with clean engine oil.

Use the discarded crankshaft bolt with the service

tool.

. Using the special tools, install the crankshaft front seal.

C lean the component mating faces.

. Install the crankshaft pulle .

Lubricate the seal with clean engine oil.

. Install the crankshaft pulle locking ring.

. C AUTION: The screw thread in the crankshaft pulle

must be cleaned out before installing a new crankshaft pulle
bolt.

Install, but do not tighten, the new crankshaft pulle bolt.

0. C AUTION: Under no circumstances should the

crankshaft setting peg, 303-645, be used in the following
operations, to restrain the crankshaft.

Using the special tools, retain the crankshaft pulle .

Tighten the crankshaft pulle bolt to 380 Nm.

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1. Remove the special tools.

2. Install new valve cover plug aperture gaskets.

Install a new valve cover gasket.

3. NOTE: Appl two beads of silcone gasket sealant as

shown on the illustration. The application of the sealant
must be 3mm diameter 12mm long. Install the valve cover
immediatel after appl ing the sealant. The cover should be
fitted directl to the head without smearing the sealant or
the seals.

Install the valve cover.

C lean the component mating faces.

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. Install the valve cover retaining bolts.

Install valve cover retaining bolts to their position

previousl noted.

C omplete the tightening sequence as illustrated.

Tighten the bolts to 12 Nm.

. Install new valve cover plug aperture gaskets.

Install a new valve cover gasket.

. NOTE: Appl two beads of silcone gasket sealant as

shown on the illustration. The application of the sealant
must be 3mm diameter 12mm long. Install the valve cover
immediatel after appl ing the sealant. The cover should be
fitted directl to the head without smearing the sealant or
the seals.

Install the valve cover.

C lean the component mating faces.

. Install the valve cover retaining bolts.

Install valve cover retaining bolts to their position

previousl noted.

Tighten the bolts to 12 Nm.

C omplete the tightening sequence as illustrated.

. Install the 8 ignition coil-on-plugs.

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Install the 8 bolts.

Tighten the bolts to 6 Nm.

5 . Install the generator mounting bracket.

C lean the locating do els.

C lean the component mating faces.

Tighten the bolts to 45 Nm.

60. Install the A/C mounting bracket.

61. Install the coolant manifold.

Tighten the bolts to 6 Nm.

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. Install the coolant pump pulle .

Tighten the bolts to 10 Nm.

. Install the accessor drive belt idler pulle .

Tighten the bolt to 25 Nm.

. With assistance, install the intake manifold.

Install the gaskets.

Evenl and progressivel tighten the bolts to 20 Nm.

. Install the purge valve.

Secure the electrical harness with the clip.

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Tigh en he bol o 6 Nm.

C onnec and ec e he elec ical connec o .

. C onnec he a e mo o po i i e cable.

Sec e he co e .

. C onnec he oil empe a e and oil p e e en o .

. In all he gene a o .

C lean he componen ma ing face .

Tigh en he bol o 48 Nm.

C onnec he gene a o elec ical connec o .

Sec e he clip .

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6 . Install the crankshaft position (C KP) sensor electrical

connector.

C onnect the C KP sensor electrical connector.

70. Install the po er steering pump mounting bracket.

C lean the component mating faces.

Tighten the bolts to 25 Nm.

Secure the transmission cooler pipes into clips.

71. C onnect and secure the C MP sensor electrical

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connectors.

Repeat the operation for the RH side.

2. NOTE: Some variation in the illustrations ma occur,

but the essential information is alwa s correct.

C onnect the KS electrical connector.

3. C onnect the engine coolant temperature (EC T) sensor

electrical connector.

4. C onnect the ignition coil-on-plug electrical connections.

Install the clips.

Repeat the above procedure for the other side.

5. C onnect the VC T oil solenoid electrical connector.

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Repeat the above procedure for the other side.

C onnect the valve cover breather hose.

. C onnect the c linder head earth ground connector.

Install the bolt.

Secure the 3 clips.

. Install the ignition coil-on-plug cover.

Secure the clips.

Repeat the above procedure for the other side.

. Remove the engine from the engine stand.

. Install the engine assembl .

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P bli hed: 11-Ma -2011

Engine - V8 4.4L Pe ol - Engine
In alla ion

Special Tool( )
Engine lif ing c adle

303-1144

F el p ing lock deco pling ool

310-D005

Ball join epa a o

205-754(LRT-54-027)

In alla ion
1. In all he engine.

In all he lif ing chain .

Rai e he engine.

C lean he componen ma ing face .

C lean he loca ing do el .

2. C a ef ll lo e he engine n il app o ima el 35mm abo e

engine mo n .
3. In all he engine f on mo n b acke .

Tigh en he ne bol o 45 Nm (33 lb.f ), hen a

f he 60 deg ee .

C onnec he engine g o nd cable and igh en he bol

o 25 Nm (18 lb.f ).

4. C lean he componen ma ing face .

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. Wi h a i a ce a ig he e gi e he a i i a d
e gi e .

I a he a i i e ai i g b .

Tigh e he b 45 N (33 b.f ).

Tigh e he e gi e 90 N (66 b.f ).

. A ach he f e ae he e c e e .

R a e he c a haf acce he e ai i g b .

Tigh e he b e e a d g e i e i 2
age .

Tigh e he b 15 N (11 b f ).

Tigh e he b 110 N (81 b.f ).

I a he g e .

.I a he a i i hea hie d.

.I a he a i i c e i e .

C ea he c e a i g face .

I a e O- i g ea .

I a he c a .

Tigh e he b 25 N (18 b.f ).

.I a he A/C c e a e b .

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Tigh en he bol o 25 Nm (18 lb.f ).

. In all he po e ee ing p mp.

Tigh en he bol o 25 Nm (18 lb.f ).

. In all he e ha em.
Fo addi ional info ma ion, efe o: E ha S em (309-
00B E ha S em - V8 4.4L Pe ol, Remo al and
In alla ion).
. Align he engine oil coole o he fi ed po i ion.

Tigh en he Allen bol o 60 Nm (44 lb.f ).

. Di connec he lif ing chain .

. Remo e he pecial ool .

Remo e he lif ing b acke .

. Po i ion he EGR al e o he EGR pipe, fi he bol and

igh en o 25 Nm (18 lb.f ).

In all and align ne ga ke .

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1 . In all he ppe pen ion a m and b ake line hea

hield .

In all he bol and igh en o 10 Nm (7 lb.f ).

Tigh en he n o 10 Nm (7 lb.f ).

1 . C onnec he f el line o he f el ail.

C lean he componen ma ing face .

Sec e i h he clip .

1 . C onnec he b ake boo e ac m ho e o he in ake

manifold.

1 . C onnec he engine i ing ha ne .

C onnec he g o nd cable.

C onnec he elec ical connec o .

In all he ca e e.

20. C onnec he e apo a i e emi ion ho e o he in ake

manifold.

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. C onnect the batter positive cable to the BJB.

Tighten the bolt to 10 Nm (7 lb.ft).

. C onnect and secure the coolant hoses.

. Install the accessor drive belt tensioner.

Tighten the bolt to 45 Nm (33 lb.ft).

. Install the accessor drive belt.

For additional information, refer to: Accessor Drive Belt

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(303-05B Acce D i e - V8 4.4L Pe , Re a a d
I a a i ).
2 .I a he RH ai c ea e a e b .
F addi i a i f ai , efe : Ai C ea e (303-12B
I a e Ai Di ib i a d Fi e i g - V8 4.4L Pe ,
Re a a dI a ai ).
2 .I a he a i ia ba e a .
F addi i a i f a i , efe : A i ia Ba e T a
(414-01 Ba e , M i g a d C ab e , Re a a d
I a a i ).
2 .I a he ba e a .
F addi i a i f a i , efe : A i ia Ba e T a
(414-01 Ba e , M i g a d C ab e , Re a a d
I a a i ).
2 . Fi he e gi e i h i .
F addi i a i f a i , efe : E gi e Oi D ai i g a d
Fi i g (303-01B E gi e - V8 4.4L Pe , Ge e a
P ced e ).
2 .C ec he ba e g d cab e.
F addi i a i f a i , efe : S ecifica i (414-00
Ba e a d C ha gi g S e - Ge e a I f ai ,
S ecifica i ).
30. Refi he c i g e .
F addi i a i f a i , efe :C i gS e
D ai i g, Fi i g a d B eedi g (303-03B E gi e C i g - V8
4.4L Pe , Ge e a P ced e ).
31. Re he h df he e ice ii .

Re ea e he 2 c i .

C ec he a d ec e i h he c i .

32. U i g he a ed diag ic e i e , c ea he
e ai c d e (PC M) ada i .

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Published: 11-May-2011
E gi e - TDV6 2.7L Die e -
Sea e
De c i i La d R e Pa N .
C amshaft caps 8510302
‘T’ joints - ladder frame to engine block STC 50550
C oolant plug - threaded STC 50552
Oil pump upper middle retaining bolt STC 50552
L b ica
De c i i S ecifica i
Engine oil, SAE 5W-30 Use 5W/30 oil to specification WSS-M2C -913B meeting AC EA B1/B3
N e: WSS i a F d efi he i ecifica i
Ca aci ie
E gi e Oi Ca aci S ecifica i
Dry fill including filter for factory fitted engine 6.55 litres (11 5 pints) (6.9 US
quarts)
Dry fill including filter for all new engines fitted in service 7.05 litres (12.4 pints) (7.4 US
quarts)
Oil and filter change 5 54 litres (9 6 pints) (5.8 US quarts)
Amount of oil required to bring level from 'MIN' to 'MAX' mark on oil level 1 5 litres (2 6 pints) (1.6 US quarts)
indicator
Di e i
I e S ecifica i
Length 523 mm (20 59 in)
Width 717 mm (28 25 in)
Height 771 mm (30 35 in)
Ge e a S ecif ica i
I e S ecifica i
Type 2.7 litre, 60 degree 'V', common rail direct injection, turbocharged and intercooled diesel,
twin overhead camshafts, 4 valves per cylinder
C ylinder arrangement V6, numbers 1 and 4 cylinders at front of engine when engine is viewed from rear
C ylinder numbering Number 1 cylinder - right hand bank; Number 4 cylinder - left hand bank
Bore - nominal 81 0 mm (3 188 in)
Stroke 88 0 mm (3 464 in)
C apacity 2720 cm³ (165 9 in³)
Firing order 1-4-2-5-3-6
C ompression ratio 17.3:1
Direction of rotation Anti-clockwise viewed from rear of engine
Maximum power 147 kW (200 PS) (197 bhp) @ 4000 rev/min
Maximum torque 440 Nm (324 lb-ft) @ 1900 rev/min
E gi e i e e:
At idle 0.7 bar (70 kPa) (10 lb/in²)
At 3500 rev/min 1.9 bar (190kPa) (27.5 lb/ft²)
Ma i e i ib e c i de head a
Total flame face 0.1 mm
150 mm x 150 mm square 0.05 mm
on flame face
25 mm x 25 mm square 0.025 mm
on flame face
T e S ecif ica i
De c i i N b-f
Accessory drive belt idler retaining bolt 47 35
Accessory drive belt tensioner M8 retaining bolts 47 35
Accessory drive belt tensioner M10 retaining bolts 25 18
Air conditioning (A/C ) compressor retaining bolts 23 17
A/C compressor mounting bracket retaining bolts 23 17
A/C compressor low pressure pipe fixing 9 7
A/C manifold retaining bolt 20 15

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Battery positive cable mounting bolts 10 7
* Camshaft inner bearing cap retaining bolts
Stage 1: tighten bolts 1 to 14 1 1
Stage 2: tighten bolts 1 to 14 5 4
Stage 3: tighten bolts 1 to 14 10 7
* Camshaft outer bearing cap retaining bolts
Stage 1: tighten bolts 1 to 4 1 1
Stage 2: tighten bolts 1 to 4 5 4
Stage 3: tighten bolts 1 to 4 10 7
C amshaft position sensor retaining bolt 10 7
+¹ Camshaft hub retaining bolts
Stage 1 80 59
Stage 2 Further 90 Further 90
C amshaft pulley retaining bolts 23 17
C amshaft timing belt cover securing bolts 10 7
+ Crankshaft pulley retaining bolt
Stage 1 100 74
Stage 2 Further 90 Further 90
C rankshaft damper bolts 14 10
C rankshaft position sensor retaining bolt 5 4
C rankshaft rear seal retainer plate 10 7
C oolant outlet elbow 10 7
*+ Cylinder head retaining bolts
Stage 1 20 15
Stage 2 40 30
Stage 3 80 59
Stage 4 Further 180 Further 180
Differential front mounting bracket heat shield 10 7
EGR valve inlet tube 10 7
EGR valve mounting bolts 10 7
EGR valve support bracket fixing 10 7
Engine breather tube securing bolt 10 7
Engine mount retaining nuts to cross member 62 46
Engine mount bracket to engine mount retaining bolts 62 46
Engine mount bracket to engine block retaining bolts 115 85
Exhaust cross over pipe retaining nuts 24 18
Exhaust manifold heat shield retaining bolts 10 7
Exhaust manifold retaining nuts 23 17
Exhaust manifold retaining studs 13 10
*+ Flexplate retaining bolts
Stage 1 50 37
Stage 2 Further 45 Further 45
Stage 3 Further 45 Further 45
Fuel injection pump 23 17
Fuel injection pump pulley retaining nut 50 37
Fuel injection supply manifold 23 17
Fuel injection supply manifold securing bracket 23 17
Fuel injection supply line unions
Stage 1 - High pressure fuel supply line union at the fuel injection diverter rail 15 11
Stage 2 - High pressure fuel supply line union at the fuel injection supply manifold 15 11
Stage 3 - High pressure fuel supply line union at the fuel injection diverter rail 30 22
Stage 4 - High pressure fuel supply line union at the fuel injection supply manifold 30 22
Fuel injection high pressure supply line mounting bolt 10 7
Fuel injector retaining bolts 10 7
Fuel filter mounting bolts 10 7
Generator retaining bolts 23 17
Generator mount bracket retaining bolts 23 17
Glow plugs 11 8
Intake air shut off throttle elbow support bracket bolts 10 7
Knock sensor retaining bolts 20 15
Oil cooler to cylinder block retaining bolts 10 7
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Oil le el indica o be ppe e aining bol 10 7
Oil pan e aining bol 10 7
Oil p mp c een and pick- p be 10 7
Oil p mp o engine block e aining bol 10 7
Oil pan d ain pl g 23 17
Oil epa a o e aining bol 10 7
Oil empe a e en o 10 7
Oil fil e 25 18
Pi on cooling je e aining bol 10 7
Po e ee ing b acke e aining bol 23 17
Po e ee ing p mp e aining bol 23 17
Po e ee ing high p e e pipe fi ing 25 18
P ima iming chain en ione e aining bol 10 7
Seconda iming chain en ione bol 10 7
S a e mo o e aining bol 45 33
Timing bel en ione e aining bol 24 18
Timing bel idle p lle e aining bol 45 33
T an mi ion fl id coole pipe ec ing b acke 10 7
T an mi ion e aining bol 45 33
T bo hea hield 10 7
T bo ppo b acke 22 16
C oolan p mp e aining bol 10 7
C oolan p mp p lle e aining bol 23 17
C oolan p mp o le pipe e aining bol 10 7
Val e co e e aining bol 10 7
Vac m p mp e aining bol 23 17
Vac m p mp e aining n 13 10
* Bolts must be tightened in sequence

+ New bolts must be installed

¹ Lightly oil bolt threads

Do not apply lubricant to bolt threads

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P : 11-M -2011
Engine - TDV6 2.7L Die el - Engine
D O

E V

GENERAL

T T V6 2.7 , , - ,
60 .T 4 ,
.T EC D3 (E C D )
, ,
.T -
.T .

T C G I (C GI)
, .T
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.T - .T

- .

TECHNICAL FEATURES

T :

60 ' '6 C GI
P
T , ,
4-
S
T
V G T
C
H
G
T E G R (EGR)
T EGR
E -

C - .

ENGINE DATA

T :

DESCRIPTION TYPE
Configuration 60 V6
Ma imum po er 147 W 4000
Ma imum torque 440 N 1900
Displacement 2720
Stroke/bore 81 /88
Compression ratio 17.3:1
Firing order 142536
Oil capacit 6.55 ( )
5.45 ( , )
Engine eight ( ith oil) 235 (A )
260 (M , . )

CYLINDER BLOCK COMPONENTS

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I em Pa N mbe De c ip ion
1 - Oil filter cap
2 - Oil filter element
3 - Scavenge pipe
4 - Diaphragm
5 - Spring
6 - Scavenge pipe
7 - C rankcase ventilation oil separator assembl
8 - Turbocharger feed filter
9 - Bolt
10 - C rankcase ventilation drain reservoir assembl
11 - Bolt
12 - C rankcase ventilation oil return tube
13 - Bracket
14 - Bolt

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15 - C rankcase ventilation oil return assembl
16 - Bolt
17 - Bolt
18 - Oil level gauge
19 - Bolt
20 - C rankcase ventilation return hose
21 - C linder head locating dowels
22 - C ore plug
23 - Seal
24 - Transmission locating dowel
25 - Bolt, 2 of
26 - Water inlet connector assembl
27 - O ring
28 - Bolt
29 - C rankshaft position (C KP) sensor
30 - C linder block aperture cover
31 - Bolt
32 - Blanking plug
33 - O ring
34 - C rankshaft timing plug
35 - Bolt
36 - Bolt, 3 of
37 - Piston cooling jets
38 - O ring
39 - Water pump
40 - Bolt, 3 of
41 - Bolt, 3 of
42 - Water pump pulle
43 - C ore plug
44 - Stud bolts, 3 of
45 - C oolant drain plug
46 - C linder head locating dowels
47 - Lower oil filter and cooler assembl
48 - Seal
49 - Upper oil filter and cooler assembl
50 - Bolt, 8 of
51 - Fuel cooler
C linder Block

The c linders and crankcase are contained in the c linder block, which is of single cast C GI construction with a hollow
beam structure. With this t pe of construction less material is required than for a conventional cast iron block,
therefore, reducing engine weight and length.

Piston C ooling Jets

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I em Pa N mbe De c ip ion
1 - Bolt
2 - Piston cooling jet
Jets located in the c linder block provide piston and gudgeon pin lubrication and cooling. These jets spra oil on to the
inside of the piston, the oil then flows through two internal wave shaped channels to help cool each piston crown.

Lubrication oil is distributed through the c linder block, via the main oil galler and channels bored in the block, to all
critical moving parts. These channels divert oil to the main and big-end bearings via holes machined into the
crankshaft.

A tapping at the rear RH side of the c linder block, below the RH c linder head, connects a pipe to the turbocharger
b means of a banjo connection. Oil is supplied, under pressure, via this tapping, from the oil pump to provide
lubrication for the turbocharger bearings.

C linder cooling is achieved b coolant circulating through chambers in the c linder block casting.

Two hollow metal dowels are used to locate the c linder heads to the c linder block, one on each side at the rear of
the unit.

A port is included at the rear LH side of the ladder frame, below the turbocharger, to connect the turbocharger oil
return pipe to the sump.

A plug sealing the lubrication cross-drilling galler is located at the front RH side of the c linder block. Plugs for the
main lubrication galler are included at the front and rear of the c linder block.

Engine Data Locations

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I em Pa N mbe De c ip ion
1 - Engine data locations
Engine data is marked at two locations at the back of the c linder block. C omponent diameters are represented b
alphabetical and numerical codes; ke s to the codes are in the Service Repair Procedures (SRP) Manual.

Connec ing Rod and Pi on

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The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing
caps are produced by fracturing the opposing sides of the connecting rod at the bearing horizontal centre-line. As well
as being easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint.
The cylinder position is etched on adjoining sides of the joint to identify matching connecting rods and bearing caps.
The selective connecting rod bearings are aluminium/tin split plain bearings. The connecting rod bearing is 'sputter
coated', which is a manufacturing process that layers the bearing material to produce a higher load capacity for
improved durability.

NOTE: The connecting rods are not selective.

C onnecting Rod Installation

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I em Pa N mbe De c ip ion
1 - Piston and connecting rod assembl , c linders 4-6
2 - Piston and connecting rod assembl , c linders 1-3
3 - Bolts
4 - C onnecting rod bearing cap
5 - C onnecting rod lower bearing
When installing a connecting rod, ensure the back of the connecting rod faces the centre of the 'vee'.

The pistons are made from aluminium allo and are fitted with three rings. The piston crown incorporates a
pronounced bowl; this forms the combustion chamber, which promotes swirl and turbulence necessar for good
combustion and improved emissions. In addition, the piston skirt has a mol bdenum-coated surface, which
counteracts scoring of the c linder bore and piston.

The piston also incorporates a double wave galler within the piston crown to enhance piston cooling. The pistons are
supplied oil b means of spra jets located in the c linder block oil galler . These jets ensure optimum piston cooling
to counteract the high temperatures generated b the combustion process.

Each piston is installed on a wrist pin located in a aluminium/tin bushing in the connecting rod.

Piston Installation

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When installing pistons ensure the arrows on the piston crowns all point to the front of the engine and the pistons are
located in the correct cylinder banks, i.e. cylinders 1, 2, 3 or cylinders 4, 5, 6.

NOTE: All pistons are common single grade/single part number for all engines.

The piston top ring is a taper type and is fitted with the taper to the top of the piston. All rings marked 'top' are
assembled with 'top' uppermost. All rings must be spaced evenly around the piston before installing. The
circumference gap of the double bevelled oil control ring must be opposite the spiral control joint.

C ank haf Po i ion Sen o

The C rankshaft Position (C KP) sensor is located at the rear of the crankshaft, behind the flywheel in the LH side of the
rear oil seal retainer. The sensor provides an input of engine crankshaft speed and position. The sensor works on the
principle of the Hall effect and scans a trigger wheel (magnetic disc) on the crankshaft. An air gap of 0.4 to 1.5mm,
between the trigger wheel and the C KP sensor, is achieved by the positional mounting of the sensor.
For additional information, refer to: Electronic Engine C ontrols (303-14C Electronic Engine C ontrols - TDV6 2.7L
Diesel, Description and Operation).

S a e Mo o
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The engine starter motor is installed at the rear RH side of the ladder frame, at the c linder block to ladder frame
split line.
For additional information, refer to: Starting S stem (303-06C Starting S stem - TDV6 2.7L Diesel, Description and
Operation).

Coolant Drain Plug

Two coolant drain plugs are installed in the c linder block, one is fitted in the rear RH side, and the other is fitted in
the middle of the c linder block on the LH side.

C linder Block Heater

On vehicles destined for cold climates, a c linder block heater replaces a core plug in the middle of the c linder block
on the LH side.

Coolant Pump

I em Pa N mbe De c ip ion
1 - Bolts
2 - Water pump
3 - 'O' ring seal
The coolant pump is installed on the LH side of the c linder block front face and is secured and sealed via three bolts
and an 'O' ring. The coolant pump is driven b a pol -vee belt via the crankshaft.

High-Pressure Fuel Pump

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I em Pa N mbe De c ip ion
1 - Fuel pipe
2 - Diverter rail assembl
3 - Rear cover
4 - Belt
5 - Fuel pump pulle
6 - Front cover
7 - Nut
8 - Bolt
9 - Bolt
10 - Tensioner
11 - LH e haust camshaft pulle
12 - High pressure fuel pump
13 - Bolt
14 - Stud bolts

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The high-p e e f el p mp pplie he common ail i h f el and i fi ed o he ea of he c linde block in he
cen e of he ' ee'. The p mp i a 3 adial pi on pe con olled b he EMS and bel d i en f om he e ha
cam haf of he LH c linde head.
Fo addi ional info ma ion, efe o: Elec onic Engine C on ol (303-14C Elec onic Engine C on ol - TDV6 2.7L
Die el, De c ip ion and Ope a ion) /
F el C ha ging and C on ol (303-04C F el C ha ging and C on ol - TDV6 2.7L Die el, De c ip ion and Ope a ion).

C ANK HAF AND MP COMPONEN

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I em Pa N mbe De c ip ion
1 - Bolts, 3 of
2 - Fan dri er bracket

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3 - Oil pump
4 - Seal
5 - C ylinder block
6 - Rear oil seal retainer
7 - Bolts, 10 of
8 - C rankshaft position sensor trigger wheel
9 - Bolts, 8 of
10 - Main thrust bearing, upper
11 - Piston and connecting rod assembly
12 - Flywheel
13 - Lower main thrust bearing
14 - Main bearing caps, 4 of
15 - C ross bolts, 4 of
16 - Main bearing cap bolts, 16 of
17 - Gasket
18 - Seal
19 - Bracket
20 - Bolts, 2 of
21 - Bolts, 6 of
22 - Gasket
23 - Oil pick-up
24 - Bolt
25 - Oil temperature sensor
26 - Seal
27 - Drain plug
28 - Bolts, 14 of
29 - Oil pan assembly
30 - Bolts, 12 of
31 - Ladder frame
32 - Dowel
33 - Bolts, 2 of
34 - C onnecting rod cap
35 - C onnecting rod cap bearing
36 - C onnecting rod bearing
37 - C onnecting rod
38 - Piston
39 - Piston pin retainer
40 - Piston pin
41 - C ross bolts, 4 of
42 - Lower main bearings
43 - Bolts, 5 of
44 - C rankshaft damper pulley
45 - Bolt
46 - C rankshaft drive pulley
47 - C rankshaft front oil seal
48 - Upper main bearings
49 - Bolts, 10 of
50 - Seal
C ank haf

The crankshaft is forged steel and fillet rolled with induction hardened journals, which run in four bearings with
clamped two layer bearing shells.

The main bearing caps are double and cross-bolted, this adds to the strength and rigidity of the engine block.

The crankshaft drive pulley is not keyed onto the crankshaft; it is secured to the crankshaft by a single bolt.

NOTE: Under no circumstances must the crankshaft pulley be tightened or loosened with the timing belt fitted.

NOTE: Do not attempt to remove the crankshaft drive pulley unless you have the correct special crankshaft-locking
tool.

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I em Pa N mbe De c ip ion
1 - Housing
2 - Seal
3 - C rankshaft
4 - Rear oil seal retainer
5 - Bolt
The crankshaft rear oil seal is a press fit in the rear oil seal retainer. The rear oil seal retainer also houses the C KP
sensor.

I em Pa N mbe De c ip ion
1 - C KP sensor trigger wheel
The trigger wheel is located on the rear of the crankshaft. It is pressed onto the crankshaft using a special tool, which
also precisel aligns the trigger wheel for crankshaft position and timing. The trigger wheel consists of 60 magnets,
minus 2 for EC M crankshaft position reference and s nchronisation. The magnets cannot be seen on the trigger-
wheel; therefore, it can onl be positioned using the special tool.

The C KP sensor air gap is 0.4mm to 0.5mm there is no adjustment. The sensor bolts into the rear oil seal retainer

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and the tolerance on the retainer and sensor gives an air gap within the specified range.

NOTE: If the trigger wheel is removed for any reason, a new trigger wheel must be fitted. Do not reuse the old
trigger wheel.

Main Bearings

The main bearings are aluminium/tin split plain selective bearings. An oil groove in the top half of each bearing
transfers oil into the crankshaft for lubrication of the connecting rod bearings. The upper and lower shells of bearing
number four contain integral thrust washers, which limits the end float of the crankshaft.

Ladder Frame

I em Pa N mbe De c ip ion
1 - Ladder frame
The ladder frame is fitted to the lower cylinder block to stiffen the base structure thus helping to reduce Noise,
Vibration and Harshness (NVH). The frame is made of high-pressure die cast aluminium and also incorporates an oil
baffle plate to reduce oil foaming and slosh.

The ladder frame is secured to the cylinder block with 2 dowels, 2 locator pins for the gasket and 18 retaining bolts;
three different lengths of bolts are used:

M6 x 20, 6 of
M8 x 75, 4 of
M6 x 105, 8 of

Iron inserts, cast into the main bearing supports of the ladder frame, minimise main bearing clearance changes due
to heat expansion.

A gasket seals the joint between the ladder frame and the cylinder block.

A port for the oil level gauge tube is included in the casting on the LH side of the ladder frame.

An oil pick-up pipe with integral strainer locates in the front of the ladder frame to provide oil to the crankshaft driven
oil pump.

S mp
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The mp con i of a p e ed eel oil pan bol ed o he al mini m allo ladde f ame i h 14 M6 16 bol . The
engine oil d ain pl g and he oil empe a e en o a e loca ed a he ea lef co ne of he mp.

A e able ga ke eal he join be een he oil pan and he ladde f ame; a bead of ealan eal he join be een
he mp and he ladde f ame.

Oil Temperature Sensor

The engine oil empe a e en o i loca ed a he ea lef co ne of he mp. The en o p o ide he EC M and he
in men pack i h he engine oil empe a e a .

The en o ci c i con i of an in e nal ol age di ide ci c i hich, inco po a e an Nega i e Tempe a e

C oefficien (NTC ) he mi o . A he engine oil empe a e i e he e i ance h o gh he en o dec ea e and
i a e a. The o p f om he en o i he change in ol age, a he he mi o allo mo e c en o pa o
ea h ela i e o he empe a e of he oil.
Fo addi ional info ma ion, efe o: Elec onic Engine C on ol (303-14C Elec onic Engine C on ol - TDV6 2.7L
Die el, De c ip ion and Ope a ion).

Rear Oil Seal Retainer

The c ank haf ea oil eal e aine i a ached o he ea of he c linde block b en bol and i ealed iha
bbe eal. The e aine al o ho e he c ank haf po i ion en o .

Dual Mass Fl wheel

On ehicle i h man al an mi ion, he d al ma fl heel i bol ed on he ea of he c ank haf i h eigh bol .

A do el on he c ank haf flange en e ha he fl heel i co ec l loca ed. A ing gea i fi ed on he o e
diame e of he fl heel. The ing gea i no e iceable.

The d al ma fl heel i ed o in la e he gea bo f om o ional and an ien ib a ion p od ced b he

engine.
Fo addi ional info ma ion, efe o: C l ch (308-01 C l ch - TDV6 2.7L Die el, De c ip ion and Ope a ion).

CAMSHAFT TIMING COMPONENTS

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I em Pa N mbe De c ip ion
1 - Rear Engine Accessor Drive (READ) rear cover
2 - READ tensioner

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3 - Bol
4 - F el p mp p lle
5 - N
6 - READ cam haf p lle
7 - READ bel
8 - Bol
9 - READ f on co e
10 - RH chain en ione
11 - RH iming chain
12 - RH inle cam haf
13 - RH e ha cam haf
14 - LH inle cam haf
15 - LH e ha cam haf
16 - LH chain en ione
17 - LH iming chain
18 - Timing bel
19 - F on co e b idge
20 - P ima d i e co e
21 - Idle
22 - Bol
23 - Bol
24 - Ten ione
25 - Bol
26 - Idle
27 - C am haf h b
28 - LH cam haf iming p lle
29 - Bol , 3 of
30 - Bol , 1 of
31 - Idle
32 - Bol , 1 of
33 - Bol , 3 of
34 - Bol , 1 of
35 - RH cam haf iming p lle
36 - C am haf h b
Primar Drive

P ima d i e i p o ided b a ingle oo hed bel f om he c ank haf o he e ha cam haf gea of each c linde
bank ia o idle p lle and a en ione .

Timing bel adj men i ca ied o b an eccen ic pe en ione mo n ed on he RH f on face of he c linde

block.

Secondar Drive

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I em Pa N mbe De c ip ion
1 - Timing chain
2 - Bol
3 - Inle cam haf
4 - E ha cam haf
5 - Ten ione fi ing pin
Seconda d i e i p o ided b o ho c o o e chain , hich an fe d i e f om he e ha cam haf gea o
he inle cam haf gea . The c o o e d i e a e loca ed a he ea of he RH c linde bank and he f on of he LH
c linde bank. Thi allo fo a m ch ho e and imple n fo he main cam haf d i e bel a he f on of he
engine.

Each c o o e chain i en ioned ia an a oma ic chain en ione , hich ac di ec l on he chain ia a g ide ail.
The en ione a e loca ed be een he e ha and inle cam haf a he f on o ea of he c linde head,
depending on he c linde bank.

Timing Co er

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I em Pa N mbe De c ip ion
A - Bol (M6 32), 13 of
B - Bol (M6 36), 2 of
C - Bol (M6 30), 2 of
The pla ic iming co e i bol ed o he f on of he c linde block and c linde head i h i een bol and ealed
i h a bbe eal.

C LINDER HEAD COMPONENTS

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I em Pa N mbe De c ip ion
1 - H draulic lash adjusters
2 - Valve spring retainers

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3 - Roller rockers
4 - Valve stem seals
5 - Valve guides
6 - E haust valves
7 - Intake valves
8 - E haust valve seats
9 - Intake valve seats
10 - Valve springs
11 - Bolt
12 - Bracket
13 - C over
14 - Lifting e e
15 - Washer
16 - Bolt
17 - Bracket
18 - Bolt
19 - Seal
20 - C ap
21 - Inlet manifold cover assembl
22 - Washer
23 - Bolt
24 - Lifting e e
25 - Seal
26 - C amshaft bearing caps
27 - Bolts
28 - Gasket
29 - C amshaft bearing cap and seal housing
30 - C amshaft bearing cap and seal housing
31 - Inlet camshaft
32 - E haust camshaft
33 - LH c linder head
34 - C linder head bolts
35 - E haust manifold studs
36 - LH c linder head gasket
37 - C ore plug
38 - Plug
39 - Seal
40 - Oil filler tube
41 - Oil filler cap
42 - C over
43 - Injectors
44 - Bolts
45 - Bolt
46 - Vacuum pump
47 - Water outlet assembl
48 - Bolts
C linder Heads

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The aluminium gravity die cast cylinder heads are unique to each cylinder bank. Eight deep-seated bolts, to reduce
distortion, secure each cylinder head to the cylinder block. The cylinder head bolts are located beneath the
camshafts, four under the inlet camshaft and four under the exhaust camshaft. Two hollow dowels align each cylinder
head with the cylinder block.

NOTE: The cylinder head bolts are not accessible with the camshafts fitted.

NOTE: The cylinder head cannot be reworked.

The cylinder head has four ports machined at each cylinder location, two exhaust ports and two inlet ports. One of the
inlet ports is helical and functions as a swirl port, the other is arranged laterally as a tangential port and functions as a
charge port.

The six fuel injection nozzles are centrally mounted; one above each cylinder and each is fixed to the cylinder head
by means of a clamp and two M6 x 35 bolts.
For additional information, refer to: Electronic Engine C ontrols (303-14C Electronic Engine C ontrols - TDV6 2.7L
Diesel, Description and Operation) /

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Fuel C harging and C ontrols (303-04C Fuel C harging and C ontrols - TDV6 2.7L Diesel, Description and Operation).

I em Pa N mbe De c ip ion
1 - Harness connector
2 - Glow plugs
The glow plugs are arranged centrall on the inlet side of the c linder head, between the two inlet ports of each
c linder.
For additional information, refer to: Electronic Engine C ontrols (303-14C Electronic Engine C ontrols - TDV6 2.7L
Diesel, Description and Operation).

I em Pa N mbe De c ip ion
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1 - C am haf Po i ion (C MP) en o
The C MP en o loca e h o gh a hole in a flange on he f on LH ide of he LH c linde head. The e ha cam haf
gea of he LH c linde head inco po a e a igge heel, hich i ed in conj nc ion i h he en o o mea e
engine po i ion.
Fo addi ional info ma ion, efe o: Elec onic Engine C on ol (303-14C Elec onic Engine C on ol - TDV6 2.7L
Die el, De c ip ion and Ope a ion).

The engine lif ing e e a e bol ed o he c linde head, one a he f on and oa he ea , one pe c linde head.

Camshaft Co ers

I em Pa N mbe De c ip ion
1 - S d bol M6 40, 6 of
2 - Bol M6 40, 7 of
3 - Oil fille ape e
4 - RH cam haf co e a embl
The cam haf co e a e man fac ed f om in l e e compo i e. The RH bank cam haf co e inco po a e an
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outlet for the full load engine breather and the engine oil filler cap. The LH bank camshaft cover incorporates an outlet
for the part load engine breather.
For additional information, refer to: Engine Emission C ontrol (303-08C Engine Emission C ontrol - TDV6 2.7L Diesel,
Description and Operation).

Silicon rubber in-groove gaskets seal the joints between the camshaft covers and the cylinder heads. Together with
spacers and seals on the camshaft cover fasteners, they also isolate the covers from direct contact with the cylinder
heads, to reduce noise.

C linder Head Gasket

The cylinder head gasket is a three-layer, laminated steel type and is available in five different thickness. The choice
of gasket thickness is dependent on the maximum piston protrusion. Gasket thickness is identified by serrations cut
into the front end of the gasket.

Gasket Selection Table

Pi on P o ion (mm) Ga ke Thickne (mm) Iden ifica ion
0.541 - 0.590 1.12 1
0.591 - 0.640 1.17 2
0.641 - 0.690 1.22 3
0.691 - 0.740 1.27 4
0.741 - 0.790 1.32 5
To calculate the correct cylinder head gasket thickness, each piston must be measured at two points, with an average
of the two measurements taken to determine the piston protrusion. The highest of the three measurements will
determine the gasket required for that particular cylinder head.

NOTE: The difference between the maximum and minimum protrusion measurement in any one bank should not be
greater than 0.1mm. It is permissible to have a different grade of gaskets between the LH and RH banks.

Camshafts

The camshafts are of a hollow steel tube construction, with pressed on sintered lobes. Each camshaft is retained by
aluminium alloy caps, five for the exhaust camshafts and four for the inlet camshafts. Location letters, A to I for the
intake camshaft and R to Z for the exhaust camshaft, are marked on the outer faces of the caps for each cylinder
head.

The LH cylinder bank exhaust camshaft is machined to accept a rear camshaft gear. The rear camshaft gear provides
drive for High Pressure (HP) fuel pump, located centrally at the rear of the 'vee', via a short-toothed belt and
tensioner pulley.

The RH cylinder head exhaust camshaft is machined at the rear end to provide a drive connection for the vacuum
pump.

NOTE: The camshaft drive sprockets also form the thrust faces for the camshaft endfloat. In production the endfloat
is 0.065mm to 0.185mm. In service, if the endfloat is out of specification, the camshaft(s) or cylinder head(s) may
have to be replaced.

Camshaf t Timing
Valve Position
Inlet valve opens 8.5° BTDC
Inlet valve closes 35.5° ABDC
Exhaust valve opens 64° BBDC
Exhaust valve closes 12° ATDC
Inlet and E haust Valves

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I em Pa N mbe De c ip ion
1 - Val e p ing colle
2 - Val e p ing e aine
3 - Val e p ing
4 - Val e em eal
5 - Inle al e
6 - E ha al e
Each c linde head inco po a e o o e head cam haf ope a ing fo al e pe c linde ia eel olle ocke
i h h d a lic la h adj e .

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I em Pa N mbe De c ip ion
1 - Rolle ocke
2 - H d a lic la h adj e
The ligh eigh al e gea p o ide good econom and noi e le el . Val e head diame e a e 31mm (1.220 in) fo
he e ha and 35mm (1.378 in) fo he in ake. All al e ha e 5mm (0.197 in) diame e em ppo ed in
in e ed me al ea and g ide in e . C olle , al e colla and p ing ea loca e ingle al e p ing on bo h
in ake and e ha al e . Val e em eal a e in eg a ed in o he p ing ea .

Vac m P mp

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I em Pa N mbe De c ip ion
1 - L
2 - B
3 - V
4 - B
5 - B
6 - N
7 - B ( )
8 - S
T RH .

Fuel Injectors

I em Pa N mbe De c ip ion
1 - B ,2
2 - C
3 - I
T
.T -
.

T , , .T
EC M. T O- .
F , :E E C (303-14C E E C - TDV6 2.7L
D ,D O )/
F C C (303-04C F C C - TDV6 2.7L D ,D O ).

Water Outlet Assembl

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I em Pa N mbe De c ip ion
1 - B ,4
2 - W
3 - S
A - W , EGR
B - W ,
C - W ,
T LH
RH EGR .

LUBRICATION SYSTEM

Gene al

O .T
.

A .P
.

T - .T
,
.T .T
.

T , , .I
.

T .L
,
.

S RH .

W , .

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Oil Pick- p

The moulded composite oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all
normal vehicle attitudes. The castellated inlet allows the supply to be maintained even if the sump pan is deformed
(e.g. by 'grounding'). A mesh screen in the inlet prevents debris from entering the oil system.

Oil P mp

I em Pa N mbe De c ip ion
1 - Oil pump
2 - Bolt
The oil pump is a gear type pump and is bolted and dowelled to the front of the engine block. It is sealed by means of
a rubber gasket, which is recessed into the oil pump housing. The pump inlet and outlet ports align with oil passages
in the ladder frame.

The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure
relief valve regulates pump outlet pressure at 4.5 Bar (65.25 Psi).

The front crankshaft oil seal is housed in the oil pump casing and is fitted such that its front face is 1mm underflush
with the machined front face of the oil pump.

NOTE: The seal is not to be pushed all the way into the bore as this will block the seal drains.

Oil Fil er

The oil filter is a replaceable cartridge installed on an adapter in the centre of the 'vee'. An internal bypass facility
permits full flow bypass if the filter is blocked.

NOTE: In service care must be taken when removing the oil filter to minimise oil drips and spillage into the engine
'vee' and cam covers:

Do not use air/power tools

Unscrew oil filter cap 4-5 turns
Leave for a minimum of 1 minute to allow to drain
Remove cap, ensuring minimal oil spillage
Replace oil filter element into the cap (can only be fitted in one direction)

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Re ace ca a d e ecifica i .

Oil P e eS i ch

I em Pa N mbe De c ip ion
1 - Oi e e i ch
The i e e i ch, ca ed i he ' ee' a he f f he LH c i de head, c ec a g di he
i e c e he i e e i e e . The i ch e ae a a e e f 0.15 0.41 Ba (2.2 5.9 P i).

Oil Le el Ga ge

The i e e ga ge ca e id a a g he LH ide f he i a , ed i a be i a ed i he adde f a e.

T h e i he e d f he ga ge i dica e he i i a d a i i e e . The e i a diffe e ce f
a i a e 1 i e (1 US a ) be ee he e e .

EXHAUST MANIFOLD

I em Pa N mbe De c ip ion
1 - LH e ha a if d
2 - RH e ha a if d
The e ha a if d a e ca f ee a a da e i e f each c i de ba . The a e ea ed he
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c linde head b mean of a eel ga ke . Sac ificial pla ic lee e a e ed o align he manifold . The e lee e
m be changed hen efi ing he manifold . Space on he ec ing bol allo he manifold o e pand and
e ac i h change of empe a e hile main aining he clamping load .

Each manifold ha a connec ion fo he EGR an fe pipe.

The engine i fi ed i h a Va iable Geome T bocha ge (VGT), hich i fi ed o he e ha manifold b a h ee

hole flange i h a eel ga ke .

C o o e Pipe

A c o o e pipe ca ie he e ha ga e f om he RH e ha manifold o he bocha ge on he LH e ha

manifold. The c o o e pipe i loca ed a he ea of he engine and i o ed ac o he op of he an mi ion bell
ho ing.

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - Engine Oil D aining and Filling
General Procedures

Special Tool( )
Oil filter element remover

303-1128

1. Disconnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).

4. C AUTION: When removing the oil filter assembl ,

make sure the fuel temperature sensor is not damaged.

Using the special tool, remove the oil filter element.

Loosen the element cover 4 complete turns to allow

engine oil to drain from the filter cover.

Remove element cover.

Remove and discard the O-ring seal.

5. Remove the engine undershield.

For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
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. Remove the lubricant drain plug.

Position a container to collect the fluid.

Discard the oil pan drain plug seal.

. Install the lubricant drain plug.

C lean the component mating faces.

Install a new sealing washer.

Tighten the drain plug to 25 Nm (18 lb.ft).

. Install the oil filter element.

C lean the components.

Make sure the oil filter element spigot aligns with the
hole in the filter housing.

Install a new O-ring seal.

Tighten the element cover to 25 Nm (18 lb.ft).

. Fill the engine with oil.

10. Install the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
11. Install the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
12. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
13. C heck and top-up the engine oil.

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Published: 11-Ma -2011

Engine - TDV6 2.7L Diesel - Camshaft RH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the camshaft front seal.
For additional information, refer to: C amshaft Front Seal
(303-01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
3. Remove the brake vacuum pump.
For additional information, refer to: Brake Vacuum Pump -
TDV6 2.7L Diesel (206-07 Power Brake Actuation, Removal
and Installation).
4. Remove the RH valve cover.
For additional information, refer to: Valve C over RH (303-
01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
5. Retain the secondar timing chain tensioner piston.

Reposition the secondar timing chain tensioner.

Install a 1.5 mm (0.060 in.) diameter pin into the

secondar timing chain tensioner piston.

6. C AUTION: Evenl and progressivel , release the

camshaft bearing caps.

Remove the camshaft bearing caps.

Remove the 18 retaining bolts.

7. Remove the camshafts and secondar timing chain

tensioner assembl .

Remove the two retaining bolts.

Release the RH secondar timing chain tensioner.

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8. Remove the secondar timing chain tensioner.

9. Remove the RH camshafts.

Release the secondar timing chain from the RH

camshafts.

In alla ion
1. Install the secondar timing chain onto the camshafts.

2. C AUTION: Do not release the secondar timing

chain tensioner locking pin until all of the camshaft bearing
caps have been installed.

Install the secondar timing chain tensioner.

Align the marks on the camshafts with the marks on

the secondar timing chain.

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.I a he ca haf a d ec da i i g chai e i e
a e b .

L b ica e he j a a d ca haf be .

. A ach he RH ec da i i g chai e i e .

Tigh e he e ai i g b 10 N (7 b.f ).

.I a he ca haf bea i g ca .

D i a he e ha ca haf e d bea i g
ca a hi age.

Tigh e he b e e i h ee age i he
e e ce h .

S age e: Tigh e 1N (1 b.f ).

S age : Tigh e 5N (4 b.f ).

S age h ee: Tigh e 10 N (7 b.f ).

.A ea a he e ha ca haf e d bea i g
ca a he ii h .
F addi i a i f a i , efe : S ecifica i (303-
01C E gi e - TDV6 2.7L Die e , S ecifica i ).

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. Install the camshaft bearing caps.

Tighten the bolts evenl in three stages in the

sequence shown.

Stage one: Tighten to 1 Nm (1 lb.ft).

Stage two: Tighten to 5 Nm (4 lb.ft).

Stage three: Tighten to 10 Nm (7 lb.ft).

. Release the secondar timing chain tensioner piston.

Remove the locking pin.

. Install the RH valve cover.

For additional information, refer to: Valve C over RH (303-
01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
10. Install the brake vacuum pump.
For additional information, refer to: Brake Vacuum Pump -
TDV6 2.7L Diesel (206-07 Power Brake Actuation, Removal
and Installation).
11. Install the camshaft front seal.
For additional information, refer to: C amshaft Front Seal
(303-01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
12. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
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Specifica ion ).

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Published: 13-Jul-2011
Engine - TDV6 2.7L Diesel - Camshaft Front Seal
In-vehicle Repair

Special Tool(s)
Holder - C amshaft Pulle s Front

303-1124

Installer - C amshaft Oil Seal

303-1119

Remover - C amshaft Oil Seal

303-1118

Timing Pin - C amshaft Pulle s

303-1126

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Raise and support the vehicle.
3. Remove and discard the timing belt.
For additional information, refer to: Timing Belt (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).
4. Remove the special tool.

Stage one: Retain the camshaft pulle .

Stage two: Remove the special tool.

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. Remove the camshaft pulle .

Remove the three retaining bolts.

. Using the special tool, remove the camshaft pulle hub.

Remove and discard the retaining bolt.

. Install the special tool to the camshaft.

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. C AUTION: Make e he pecial ool i co ec l

ea ed behind he cam haf eal. Fail e o follo hi
in c ion ma e l in damage o he pecial ool.

In all he pecial ool in o he cam haf f on eal.

. In all he pecial ool e ac ing bol .

10. In all he pecial ool in o he cam haf f on eal.

11. U ing he pecial ool, emo e he cam haf f on eal.

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In alla ion
1. C AUTIONS:

Make sure the seal is installed correctl .

Do not use an lubricant on the camshaft front seal or

the camshaft. Failure to follow this instruction ma result in
damage to the vehicle.

Using the special tool, install the camshaft front seal.

C lean the component mating faces.

Use the discarded camshaft pulle hub retaining bolt

with the special tool.

2. Using the special tool, install the camshaft pulle hub.

Install a new retaining bolt.

Tighten the retaining bolt in two stages:

Stage one: Tighten to 80 Nm (59 lb.ft).

Stage two: Tighten a further 80 degrees.

3. Install the camshaft pulle .

Install the bolts, but do not tighten full at this stage.

4. Install the special tool.

Stage one: Retain the camshaft pulle .

Stage two: Install the special tool.

5. Install the new timing belt.

For additional information, refer to: Timing Belt (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).
6. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 13-Jul-2011
Engine - TDV6 2.7L Diesel - Camshaft Rear Seal
In-vehicle Repair

Special Tool(s)
C amshaft Seal Remover

303-1118

C amshaft Seal Installer

303-1119

C amshaft pulle holding tool

303-1145/1

C amshaft pulle bolt remover

303-1145/2

C amshaft pulle bolt socket

303-1145/3

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt
- VIN Range: SALLA000304->END OF 06 MY (303-05C
Accessor Drive - TDV6 2.7L Diesel, Removal and
Installation).
3. Install the special tool to the camshaft rear pulle .

Rotate the crankshaft to align the special tool to the

engine lifting bracket.

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Install the special tool retaining bolt.

. Install the special tool to the camshaft rear pulle

retaining bolt.

. Using the special tools, remove and discard the camshaft

rear pulle retaining bolt.

Rotate the crankshaft clockwise to retain the camshaft

rear pulle .

. Remove the special tools.

. Remove the camshaft rear pulle .

. Install the special tool to the camshaft.

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. C AUTION: Make sure the special tool is correctl

seated behind the camshaft seal. Failure to follow this
instruction ma result in damage to the special tool.

Install the special tool into the camshaft rear seal.

10. C AUTION: Make sure the special tool is correctl

seated behind the camshaft seal. Failure to follow this
instruction ma result in damage to the special tool.

Install the special tool into the camshaft rear seal.

11. Using the special tool, remove and discard the camshaft
rear seal.

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In alla ion
1. Using the special tool, install the new camshaft rear seal.

2. Install the camshaft rear pulle .

Install a new camshaft pulle retaining bolt.

3. Install the special tool to the camshaft rear pulle .

Install the special tool retaining bolt.

4. Install the special tool to the camshaft rear pulle

retaining bolt.

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. C AUTION: Make sure the torque wrench setting

procedure is followed correctl . Failure to follow this
instruction ma result in damage to the vehicle.

C alculate the setting for the torque wrench.

Stage 1: Multipl the required torque b the effective

length of the torque wrench (1).

Stage 2: Add the effective length of the special tool (2)

to the effective length of the torque wrench.

Stage 3: Divide the total of stage 1 b the total of stage

2.

Stage 4: Set the torque wrench to the figure arrived at

in stage 3.

. C AUTION: Make sure the torque wrench setting

procedure is followed correctl . Failure to follow this
instruction ma result in damage to the vehicle.

Using the special tools, tighten the camshaft rear pulle

retaining bolt to 40 Nm (30 lb.ft).

. C AUTION: Make sure the torque wrench setting

procedure is followed correctl . Failure to follow this
instruction ma result in damage to the vehicle.

Rotate the crankshaft counter-clockwise to retain the

camshaft rear pulle .

Stage one: Tighten to 80 Nm (59 lb.ft).

Stage two: Tighten a further 80 degrees.

. Remove the special tools.

. C AUTION: Install a new fuel injection pump belt.

Failure to follow this instruction ma result in damage to the
vehicle.

Install the fuel injection pump belt.

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For additional information, refer to: Fuel Injection Pump Belt
- VIN Range: SALLA000304->END OF 06 MY (303-05C
Accessor Drive - TDV6 2.7L Diesel, Removal and
Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

Engine - TDV6 2.7L Diesel - Crankshaft Front Seal
In-vehicle Repair

Special Tool(s)
Locking Tool - Fl wheel

303-1123

Timing Pin - Manual Transmission

303-1116

Timing Pin - Automatic

Transmission

303-1117

C rankshaft Front Seal Remover

303-1120

C rankshaft Front Seal Sleeve

303-1122

C rankshaft Front Seal Installer

303-1121

Remo al

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All vehicles
. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. Remove and discard the timing belt.
For additional information, refer to: Timing Belt (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).

. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

Vehicles with automatic transmission

. Remove the special tool.

Vehicles with manual transmission

. Remove the special tool.

All vehicles
. Install the special tool.

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. Loosen the crankshaft pulle retaining bolt.

. Using a suitable tool, release the crankshaft pulle .
. Remove the crankshaft pulle .

Remove the crankshaft pulle retaining bolt.

Discard the bolt.

10. Install the special tool to the crankshaft.

11. Using the special tool, remove the crankshaft front seal.

Remove the special tool.

Remove and discard the seal from the special tool.

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In alla ion
All vehicles

1. C AUTION: Do not use any lubricant on the

crankshaft front seal, special tools or the crankshaft. Failure
to follow this instruction may result in damage to the
vehicle.

NOTE: Make sure all component mating faces are clean.

Install a new crankshaft front seal to the special tool.

2. Reposition the crankshaft front seal along the special

tool.

Remove the sleeve from the special tool.

3. Install the special tool to the crankshaft.

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. Install the special tool to the crankshaft.

. C AUTION: Make sure the seal is installed correctl .

Using the special tool, install the crankshaft front seal.

Use the discarded crankshaft bolt with the service

tool.

. C AUTION: Make sure the seal is installed correctl .

Remove the special tool.

Remove and discard the crankshaft pulle retaining

bolt.

. Install the crankshaft pulle .

Install a new crankshaft pulle retaining bolt.

Tighten the retaining bolt in two stages:

Stage one: Tighten to 100 Nm (74 lb.ft).

Stage two: Tighten a further 90 degrees.

. Remove the special tool.

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Vehicles with manual transmission
. Install the special tool.

Vehicles with automatic transmission

10. Install the special tool.

All vehicles
11. Install the new timing belt.
For additional information, refer to: Timing Belt (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).
12. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-May-2011
Engine - TDV6 2.7L Diesel - Crankshaft Rear Seal ith Retainer Plate
In-vehicle Repair

Remo al
NOTE: The crankshaft rear seal and retainer plate are supplied as an assembly and cannot be serviced separately.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

3. Remove the C KP sensor ring.
For additional information, refer to: C rankshaft Position
(C KP) Sensor Ring (303-14C Electronic Engine C ontrols -
TDV6 2.7L Diesel, Removal and Installation).
4. Remove the crankshaft retainer plate.

Remove the 14 bolts.

Installation
1. C AUTIONS:

Oil seals must be fitted dry.

Tighten the bolts securing the seal retainer to the

cylinder block first.

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Install the crankshaft retainer plate.

C lean the component mating faces.

Install the seal retainer with its protection sleeve

onto the crankshaft.

Locate the seal retainer onto the sump flange.

Engage the seal retainer dowels with the c linder

block and lightl tighten 2 bolts on opposite sides of
the retainer.

Remove the seal protection sleeve.

Install remaining bolts and tighten all bolts evenl to

10 Nm (7 lb.ft).

. Install the C KP sensor ring to the crankshaft.

For additional information, refer to: C rankshaft Position
(C KP) Sensor Ring (303-14C Electronic Engine C ontrols -
TDV6 2.7L Diesel, Removal and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - C linder Head LH
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he LH bank cam haf .
3. Remo e he LH e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold LH
(303-01C Engine - TDV6 2.7L Die el, In- ehicle Repai ).
4. Di connec he LH glo pl g i ing ha ne elec ical
connec o .

5. Remo e he c linde head coolan o le connec o .

6. Remo e he h d a lic adj e and ocke a emblie .

7. C AUTIONS:

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Only use a plastic scraper to clean off the old gasket.

The cylinder head must not be placed mating face

down. Failure to follow this instruction may result in damage
to the vehicle.

Remove the LH cylinder head assembly.

Remove and discard the eight cylinder head bolts.

Remove and discard the cylinder head gasket.

In alla ion
1. C lean the component mating faces.
2. C heck cylinder head face for distortion, across the center
and from corner to corner.
3. NOTE: The cylinder head gasket must be installed over the
cylinder head to cylinder block dowels.

Install a new cylinder head gasket.

4. C AUTION: Use care when installing the cylinder

head. Damage to the cylinder block, cylinder head or
cylinder head gasket may result.

NOTE: Install a new cylinder head gasket.

NOTE: The cylinder head gasket must be installed over

the cylinder head to cylinder block dowels.

NOTE: Make sure the cylinder head is installed in its

original position.

NOTE: Tighten the retaining bolts in the indicated

sequence in four stages.

Install the LH cylinder head assembly and install new

cylinder head retaining bolts.

Stage one: Tighten to 20 Nm (15 lb.ft).

Stage two: Tighten to 40 Nm (30 lb.ft).

Stage three: Tighten to 80 Nm (59 lb.ft).

Stage four: Tighten a further 180 degrees.

5. Install the hydraulic adjuster and rocker assemblies.

6. C onnect the LH glow plug wiring harness electrical
connector.
7. NOTE: Install new O-ring seals.

Install the cylinder head coolant outlet connector.

Install the four retaining bolts and tighten to 10 Nm (7

lb.ft).

8. Install the LH exhaust manifold.

For additional information, refer to: Exhaust Manifold LH
(303-01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
9. Install the LH bank camshafts.
10. C onnect the battery ground cable.
For additional information, refer to: Specifications (414-00

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Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - C linder Head RH
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he RH e ha manifold.
Fo addi ional info ma ion, efe o: E ha Manifold RH
(303-01C Engine - TDV6 2.7L Die el, In- ehicle Repai ).
3. Remo e he RH cam haf .

4. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

5. Relea e he engine b ea he be.

Remo e he e aining bol .

6. Relea e he coolan bleed ho e.

Relea e he e aining clip.

7. Remo e he c linde head coolan elbo .

Relea e he o e aining clip and di connec he

ho e .

Remo e he fo e aining bol .

Remo e and di ca d he O- ing eal .

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8. Remove the h draulic adjuster and rocker assemblies.

9. C AUTIONS:

The c linder head must not be placed mating face

down. Failure to follow this instruction ma result in damage
to the vehicle.

Onl use a plastic scraper to clean off the old gasket.

Remove the RH c linder head assembl .

Remove and discard the eight c linder head bolts.

Remove and discard the c linder head gasket.

In alla ion
1. C lean the component mating faces.
2. C heck c linder head face for distortion, across the center
and from corner to corner.
For additional information, refer to: Specifications (303-01C
Engine - TDV6 2.7L Diesel, Specifications).

3. C AUTION: The head gasket must be installed over the

c linder block dowels.

Install a new c linder head gasket.

4. NOTE: Tighten the retaining bolts in the indicated
sequence in four stages.

Install the RH c linder head assembl

Install new c linder head retaining bolts.

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T
.

S :T 20 N (15 . ).

S :T 40 N (30 . ).

S :T 80 N (59 . ).

S :T 180 .

.I .
.I .

I O- .

I 10 N (7
. ).

C .

.S .
.S .

T 10 N (7 . ).

.I RH .
10. I RH .
F , :E M RH
(303-01C E - TDV6 2.7L D ,I - R ).
11. C .
F , :S (414-00
B C S -G I ,
S ).

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Published: 11-May-2011
Engine - TDV6 2.7L Diesel - Val e Co er LH
In-vehicle Repair

Remo al
WARNINGS:

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

C AUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the intake air shutoff throttle.
For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).
3. Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt
(303-05C Accessory Drive - TDV6 2.7L Diesel, Removal and
Installation).
4. Remove the accessory drive belt idler pulley.

Remove the retaining bolt.

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. Relea e he knock en o (KS) ha ne f om he al e

co e .
. Di connec he KS elec ical connec o .

. Relea e he glo pl g ha ne f om he al e co e .

. Di connec he engine oil p e e (EOP) en o

elec ical connec o .

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. Di connec he al e co e b ea he ho e.

10. Remo e he f el injec o .

Fo addi ional info ma ion, efe o: F el Injec o (303-04C
F el C ha ging and C on ol - TDV6 2.7L Die el, Remo al
and In alla ion).
11. Remo e he 2 emaining f el injec o .
12. Relea e he high-p e e f el ppl line.

Remo e he e aining bol .

13. C AUTION: Make e ha he high-p e e f el

ppl line emain in con ac i h he f el injec ion ppl
manifold and he f el injec ion di e e ail n il bo h nion
ha e been de ached and cleaned. Fail e o follo hi
in c ion ma e l in fo eign ma e ing e o he f el
injec ion em.

Remo e and di ca d he high-p e e f el ppl line.

In all blanking cap o he e po ed po .

14. Remo e he f el injec ion ppl manifold.

Remo e he o e aining bol .

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1 . Remove the fuel injection suppl manifold securing

bracket.

Release the dipstick tube.

Remove the three retaining bolts.

1 . Remove the engine cover locating studs.

1 . Release the timing belt cover.

Reposition the timing cover to access the two front

valve cover retaining bolts.

Full loosen the seven timing belt cover retaining

bolts shown.

1 . Remove the LH valve cover.

Loosen the 13 valve cover retaining bolts.

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In alla ion
1. Install the LH valve cover.

Tighten the 13 retaining bolts to 10 Nm (7 lb.ft).

2. Attach the timing belt cover.

Tighten the seven retaining bolts to 10 Nm (7 lb.ft).

3. Install the engine cover locating studs.

4. Install the fuel injection suppl manifold securing bracket.

Install the two retaining bolts.

Tighten the bolts to 23 Nm (17 lb.ft).

Secure the dipstick tube.

5. Install the fuel injection suppl manifold.

Install the two bolts, but do not full tighten at this

stage.

6. Install a new high-pressure fuel suppl line.

Remove the blanking caps from the ports.

Install the new high-pressure fuel suppl line, but do

not tighten unions at this stage.

Tighten the fuel injection suppl manifold retaining

bolts to 23 Nm (17 lb.ft).

Tighten the fuel injection suppl line unions in the

sequence shown in four stages:

Stage 1: Tighten the high-pressure fuel suppl line

union at the fuel injection diverter rail to 15 Nm (11
lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line

union at the fuel injection suppl manifold to 15 Nm
(11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line

union at the fuel injection diverter rail to 30 Nm (22
lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line

union at the fuel injection suppl manifold to 30 Nm
(22 lb.ft).

7. Secure the high-pressure fuel suppl line.

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Tighten the retaining bolt to 10 Nm (7 lb.ft).

. Install the fuel injector.

For additional information, refer to: Fuel Injector (303-04C
Fuel C harging and C ontrols - TDV6 2.7L Diesel, Removal
and Installation).
. Install the 2 remaining fuel injectors.
. C onnect the valve cover breather hose.
. C onnect the EOP sensor electrical connector.
. C onnect the KS electrical connector.
. Attach the glow plug harness and KS harness to the valve
cover.
. Install the accessor drive belt idler pulle .

Install the retaining bolt and tighten to 47 Nm (35 lb.ft).

. Install the accessor drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05C Accessor Drive - TDV6 2.7L Diesel, Removal and
Installation).
. Install the intake air shutoff throttle.
For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Diesel - Val e Co er RH
In-vehicle Repair

Remo al
WARNINGS:

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

C AUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the intake air shutoff throttle.
For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).
3. Release the glow plug harness from the valve cover.

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. Relea e he knock en o (KS) ha ne f om he al e

co e .

. Di connec he KS elec ical connec o .

. Di connec he al e co e b ea he ho e.

. Remo e he f el injec o .

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Fo addi ional info ma ion, efe o: F el Injec o (303-04C
F el C ha ging and C on ol - TDV6 2.7L Die el, Remo al
and In alla ion).
. Remo e he emaining f el injec o .
. Relea e he high-p e e f el ppl line.

Remo e he e aining bol .

10. C AUTION: Make e ha he high-p e e f el

ppl line emain in con ac i h he f el injec ion ppl
manifold and he f el injec ion di e e ail n il bo h nion
ha e been de ached and cleaned. Fail e o follo hi
in c ion ma e l in fo eign ma e ing e o he f el
injec ion em.

Remo e and di ca d he high-p e e f el ppl line.

In all blanking cap o he e po ed po .

11. Remo e he f el injec ion ppl manifold.

Remo e he o e aining bol .

12. De ach he f el line .

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1 . Remove the fuel line securing bracket.

Remove the retaining bolt.

1 . Remove the fuel injection suppl manifold securing

bracket.

Remove the two retaining bolts.

1 . Remove the engine cover locating studs.

1 . Remove the RH valve cover.

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Full loosen the 14 valve cover retaining bolts.

In alla ion
1. Install the RH valve cover.

Tighten the 14 retaining bolts to 10 Nm (7 lb.ft).

2. Install the engine cover locating studs.

3. Install the fuel injection suppl manifold securing bracket.

Install the two retaining bolts.

Tighten the bolts to 23 Nm (17 lb.ft).

4. Install the fuel line retaining bracket.

Tighten to 10 Nm (7 lb.ft).

5. Attach the fuel lines to the retaining bracket.

6. Install the fuel injection suppl manifold.

Install the two bolts, but do not full tighten at this

stage.

7. Install a new high-pressure fuel suppl line.

Remove the blanking caps from the ports.

Loosel install the new high-pressure fuel suppl

line.

Tighten the fuel injection suppl manifold retaining

bolts to 23 Nm (17 lb.ft).

Tighten the fuel injection suppl line unions in the

sequence shown in four stages:

Stage 1: Tighten the high-pressure fuel suppl line

union at the fuel injection diverter rail to 15 Nm (11
lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line

union at the fuel injection suppl manifold to 15 Nm
(11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line

union at the fuel injection diverter rail to 30 Nm (22
lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line

union at the fuel injection suppl manifold to 30 Nm
(22 lb.ft).

8. Secure the high-pressure fuel suppl line.

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Tighten the bolt to 10 Nm (7 lb.ft).

. Install the fuel injector.

For additional information, refer to: Fuel Injector (303-04C
Fuel C harging and C ontrols - TDV6 2.7L Diesel, Removal
and Installation).
10. Install the remaining fuel injectors.
11. C onnect the valve cover breather hose.
12. C onnect the KS electrical connector.
13. Attach the glow plug harness and KS harness to the valve
cover.
14. Install the intake air shutoff throttle.
For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).
15. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Die el - Engine Mo n LH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the turbocharger.
For additional information, refer to: Turbocharger (303-04D
Fuel C harging and C ontrols - Turbocharger - TDV6 2.7L
Diesel, Removal and Installation).

3. C AUTION: Protect the engine during this operation.

Support the engine.

Raise the engine clear of its LH mount.

4. Remove the engine mount.

Remove the retaining nut.

Raise the engine clear of its LH mount.

Remove and discard the two retaining bolts.

In alla ion
1. Install the engine mount.

C lean the component mating faces.

Install new retaining bolts.

Tighten the bolts to 45 Nm (33 lb.ft), then a further 60

degrees.

2. C AUTION: Protect the engine during this operation.

Lower the engine onto its mount.

3. Install the engine mount retaining nut.

Tighten the nut to 90 Nm (66 lb.ft).

4. Install the turbocharger.

For additional information, refer to: Turbocharger (303-04D
Fuel C harging and C ontrols - Turbocharger - TDV6 2.7L
Diesel, Removal and Installation).
5. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Diesel - Camshafts LH
In-vehicle Repair

Special Tool(s)
C amshaft pulle holding tool

303-1145/1

C amshaft pulle bolt remover

303-1145/2

C amshaft pulle bolt socket

303-1145/3

Installer - C amshaft Oil Seal

303-1119

Materials
Name Specification
Loctite 242 ESK-M4G247-A1

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00 Batter
and C harging S stem - General Information, Specifications).
2. Remove the camshaft front seal.
For additional information, refer to: C amshaft Front Seal (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).
3. Remove the LH valve cover.
For additional information, refer to: Valve C over LH (303-01C Engine
- TDV6 2.7L Diesel, In-vehicle Repair).
4. Remove the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt - VIN
Range: SALLA000304->END OF 06 MY (303-05C Accessor Drive -
TDV6 2.7L Diesel, Removal and Installation).
5. Install the special tool to the camshaft rear pulle .

Rotate the crankshaft to align the special tool to the engine lifting
bracket.

Install the special tool retaining bolt.

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. Install the special tool to the camshaft rear pulle retaining bolt.

. Using the special tools, remove and discard the camshaft rear pulle
retaining bolt.

Rotate the crankshaft clockwise to retain the camshaft rear

pulle .

. Remove the special tools.

. Remove the camshaft rear pulle .

10. Remove the fuel injection pump belt rear cover.

Remove the fuel injection pump belt rear cover retaining bolt.

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. Retain the secondar timing chain tensioner piston.

Reposition the secondar timing chain tensioner.

Install a 1.5 mm (0.060 in.) diameter pin into the secondar

timing chain tensioner piston.

. C AUTION: Evenl and progressivel , release the camshaft

bearing caps.

Remove the camshaft bearing caps.

Remove the 18 retaining bolts.

. Remove the camshafts and secondar timing chain tensioner

assembl .

Remove the two retaining bolts.

Release the LH secondar timing chain tensioner.

. Remove the secondar timing chain tensioner.

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15. R LH .

R LH .

R LH .

In alla ion
1. I .

2. C AUTION: D
.

I .

A
.

3. I
.

L .

4. A LH .

T 10 N (7 . ).

5. I .

D
.

T .

S :T 1N (1 . ).

S :T 5N (4 . ).

S :T 10 N (7 . ).

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. Appl sealant
to the t o
e haust
camshaft end
bearing caps
at the positions
sho n.
For additional
information,
refer to:
Specifications
(303-01C
Engine - TDV6
2.7L Diesel,
Specifications).

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.I .

T .

S :T 1N (1 . ).

S :T 5N (4 . ).

S :T 10 N (7 . ).

.R .

R .

.I .

I .

10. U , .

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. Install the camshaft rear pulle .

Appl loctite 242 to the new camshaft pulle bolt.

Install a new camshaft pulle retaining bolt.

. Install the special tool to the camshaft rear pulle .

Install the special tool retaining bolt.

. Install the special tool to the camshaft rear pulle retaining bolt.

. C AUTION: Make sure the torque wrench setting procedure is

followed correctl . Failure to follow this instruction ma result in
damage to the vehicle.

C alculate the setting for the torque wrench.

Stage 1: Multipl the required torque b the effective length of

the torque wrench (1).

Stage 2: Add the effective length of the special tool (2) to the
effective length of the torque wrench.

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Stage 3: Divide the total of stage 1 b the total of stage 2.

Stage 4: Set the torque wrench to the figure arrived at in stage

3.

1 . C AUTION: Make sure the torque wrench setting procedure is

followed correctl . Failure to follow this instruction ma result in
damage to the vehicle.

Using the special tools, tighten the camshaft rear pulle retaining bolt
to 40 Nm (30 lb.ft).

1 . C AUTION: Make sure the torque wrench setting procedure is

followed correctl . Failure to follow this instruction ma result in
damage to the vehicle.

Using the special tools, tighten the camshaft rear pulle bolt a further
75 Nm (56 lb.ft).

Rotate the crankshaft counter-clockwise to retain the camshaft

rear pulle .

1 . Remove the special tools.

1 . Install the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt - VIN
Range: SALLA000304->END OF 06 MY (303-05C Accessor Drive -
TDV6 2.7L Diesel, Removal and Installation).
1 . Install the LH valve cover.
For additional information, refer to: Valve C over LH (303-01C Engine
- TDV6 2.7L Diesel, In-vehicle Repair).
20. Install the camshaft front seal.
For additional information, refer to: C amshaft Front Seal (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).
21. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00 Batter
and C harging S stem - General Information, Specifications).

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Engine - TDV6 2.7L Die el - Engine Mo n RH
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the generator.
For additional information, refer to: Generator (414-02C
Generator and Regulator - TDV6 2.7L Diesel, Removal and
Installation).
4. Disconnect the ground cable.

Remove the ground cable retaining bolt.

5. Remove the engine mount bracket.

Remove the nut.

6. C AUTION: Protect the engine during this operation.

Detach the engine mounting bracket.

Support the engine.

Remove the four retaining bolts.

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7. Remove the engine mount.

Remove and discard the two retaining bolts.

In alla ion
1. Install the engine mount.

C lean the component mating faces.

Install new retaining bolts.

Tighten the two new bolts to 45 Nm (33 lb.ft), then a

further 60 degrees.

2. Install the engine mount bracket.

C lean the component mating faces.

Tighten the four retaining bolts to 80 Nm (59 lb.ft).

3. Attach the engine mounting bracket.

Lower the engine onto its mount.

Tighten the nut to 90 Nm (66 lb.ft).

4. C onnect the ground cable.

Install the retaining bolt.

5. Install the generator.

For additional information, refer to: Generator (414-02C
Generator and Regulator - TDV6 2.7L Diesel, Removal and
Installation).
6. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Diesel - Fl wheel
In-vehicle Repair

Removal

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Remove the pressure plate and clutch disc.
For additional information, refer to: C lutch Disc and
Pressure Plate (308-01 C lutch - TDV6 2.7L Diesel, Removal
and Installation).
3. NOTE: Prevent the flywheel from rotating.

Remove the flywheel.

Remove the 8 Torx bolts.

Installation

1. C AUTION: Tighten the bolts in a diagonal sequence.

NOTE: Prevent the flywheel from rotating.

Install the flywheel.

C lean the component mating faces.

Tighten the retaining bolts in three stages.

Tighten the Torx bolts to 45 Nm (33 lb.ft).

Tighten the Torx bolts by 45 degrees.

Tighten the Torx bolts by a further 45 degrees.

2. Install the clutch disc and pressure plate.

For additional information, refer to: C lutch Disc and
Pressure Plate (308-01 C lutch - TDV6 2.7L Diesel, Removal
and Installation).

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P : 11-M -2011
Engine - TDV6 2.7L Diesel - Fle plate
I - R

Special Tool(s)
F (LRT-12-
145)

303-947

Removal
1. D .
F , :S (414-00
B C S -G I ,
S ).

2. WARNING: D
.A
.

R .
3. R .
F , :T (307-01C
A T /T - TDV6 2.7L D ,
R I ).
4. R .

U , .

R 8T .

Installation

1. C AUTION: T .

I .

C .

U , .

T T 3 .

T T 50 N (37 . ).

T T 45 .

T T 45 .

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. Install the transmission.

For additional information, refer to: Transmission (307-01C
Automatic Transmission/Transa le - TDV6 2.7L Diesel,
Removal and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Diesel - Oil P mp
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the generator.
For additional information, refer to: Generator (414-02C
Generator and Regulator - TDV6 2.7L Diesel, Removal and
Installation).
3. Remove the accessor drive belt tensioner.

Remove the LH retaining bolt.

4. Remove the oil pan e tension.

5. Remove the crankshaft front oil seal.
For additional information, refer to: C rankshaft Front Seal
(303-01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).
6. Remove the generator mounting bracket.

Remove the five retaining bolts.

7. Remove the timing belt idler pulle .

Remove the LH retaining bolt.

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. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. Release the batter positive cable.

Remove the two retaining bolts.

10. Remove the oil pump lower retaining bolts.

Remove the four retaining bolts.

11. Remove the oil pump.

Remove the ten retaining bolts.

Remove the timing belt cover sealing strips.

Remove and discard the gasket.

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In alla ion
1. Prime the oil pump.

Fill the orifice shown with 20 ml of engine oil.

Rotate the oil pump drive 2 complete turns.

2. C AUTIONS:

Make sure that the mating faces are clean and free of
foreign material.

Make sure the gasket is installed correctly.

Install the oil pump.

C lean the component mating faces.

Install a new gasket.

Lightly tighten the bolts in the position shown.

3. C AUTION: Make sure the base of the oil pump is

aligned within 0.2 mm of the base of the engine block.
Failure to follow this instruction may result in damage to the
vehicle.

NOTE: Vehicles fitted with oil pumps without dowels.

C heck the oil pump to engine block alignment.

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. Sec e he i .

Tigh e he b i he e e ce h 10 N .

.I a he i e e ai i g b .

Tigh e he 4 b 10 N (7 b.f ).

.I a he ba e i i e cab e.

Tigh e he e ai i g b 10 N (7 b.f ).

.I a he i i g be id e e .

Tigh e he b 45 N (33 b.f ).

.I a he c a haf f i ea .
F addi i a i f a i , efe :C a haf F Sea
(303-01C E gi e - TDV6 2.7L Die e , I - ehic e Re ai ).
.I a he i a e e i .
10. I a he ge e a i g b ac e .

Tigh e he b 22 N (16 b.f ).

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. Install the accessor drive belt tensioner.

Tighten the bolt to 45 Nm (33 lb.ft).

. Install the generator.

For additional information, refer to: Generator (414-02C
Generator and Regulator - TDV6 2.7L Diesel, Removal and
Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Diesel - Oil Pressure S itch
In-vehicle Repair

1. Refer to Engine Oil Pressure (EOP) Sensor.

For additional information, refer to: Engine Oil Pressure
(EOP) Sensor (303-14C Electronic Engine C ontrols - TDV6
2.7L Diesel, Removal and Installation).

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Engine - TDV6 2.7L Diesel - Oil Cooler
In-vehicle Repair

Remo al
WARNINGS:

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

C AUTIONS:

Before disconnecting or removing components, ensure the area around the joint faces and connections are
clean. Plug open connections to prevent contamination.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Drain the cooling system.
For additional information, refer to: C ooling System
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).
3. Remove the crankcase vent oil separator.
For additional information, refer to: C rankcase Vent Oil
Separator (303-08C Engine Emission C ontrol - TDV6 2.7L
Diesel, Removal and Installation).
4. Release the coolant bleed hose from the LH exhaust gas
recirculation (EGR) coolant inlet hose.

Release the retaining clip.

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. Remove the c linder head coolant elbow.

Release the two retaining clips and disconnect the

hoses.

Remove the four retaining bolts.

Remove and discard the O-ring seals.

. Disconnect the knock sensors (KS) electrical connector.

Release the KS harness from the valve cover.

. Remove the LH KS.

Remove the retaining bolt.

. NOTE: Some fluid spillage is inevitable during this

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operation.

Remove the oil cooler.

Remove the eight retaining bolts.

Remove and discard the gasket.

Remove and discard the O-ring seal.

In alla ion

1. C AUTION: Make sure the gasket is installed correctly.

NOTE: Make sure all component mating faces are clean.

Install the oil cooler.

Install a new gasket.

Install a new O-ring seal.

Install the eight retaining bolts and tighten to 10 Nm (7

lb.ft).

2. Install the LH KS.

Install the retaining bolt and tighten to 20 Nm (15 lb.ft).

C onnect the knock sensor electrical connector.

Attach the KS harness to the valve cover.

3. Install the cylinder head coolant outlet elbow.

Install new O-ring seals.

Install the four retaining bolts and tighten to 10 Nm (7

lb.ft).

C onnect the hoses and secure with the clips.

4. Secure the coolant bleed hose to the EGR coolant inlet

hose.
5. Install the crankcase vent oil separator.
For additional information, refer to: C rankcase Vent Oil
Separator (303-08C Engine Emission C ontrol - TDV6 2.7L
Diesel, Removal and Installation).
6. C onnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
7. Refill and bleed the cooling system.
For additional information, refer to: C ooling System
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).
8. C heck and top-up the engine oil.

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Engine - TDV6 2.7L Die el - Oil P mp Sc een and Pick p T be
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the oil pan.
For additional information, refer to: Oil Pan (303-01C Engine
- TDV6 2.7L Diesel, In-vehicle Repair).
4. Remove the oil pump screen and pickup tube.

Remove the bolt.

Remove and discard both O-ring seals.

C lean the seal contact area.

In alla ion
1. NOTE: Lubricate new seals with clean engine oil.

Install the oil pump screen and pickup tube.

C lean the components.

Install new O-ring seals.

Tighten the bolt to 10 Nm (7 lb.ft).

2. Install the oil pan.

For additional information, refer to: Oil Pan (303-01C Engine
- TDV6 2.7L Diesel, In-vehicle Repair).
3. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine - TDV6 2.7L Diesel - Oil Pan
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).

3. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

4. Drain the engine oil.
For additional information, refer to: Engine Oil Draining and
Filling (303-01C Engine - TDV6 2.7L Diesel, General
Procedures).
5. Remove the oil temperature sensor.

Disconnect the engine oil temperature sensor

electrical connector.

Remove and discard the O-ring seal.

6. Disconnect the engine wiring harness.

Release the engine wiring harness from the retaining

bracket.

7. Remove the oil pan.

Remove the 14 oil pan bolts.

Remove and discard the gasket.

Installation
1. Install the oil pan.

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C lean the component mating faces.

Install a new gasket.

Evenl and progressivel tighten the bolts to 10 Nm (7

lb.ft).

. C onnect the engine wiring harness.

Attach the engine wiring harness to the retaining

bracket.

. Install the oil temperature sensor.

Install a new O-ring seal.

Tighten the sensor to 10 Nm (7 lb.ft).

C onnect the electrical connector.

. Fill the engine with oil.

For additional information, refer to: Engine Oil Draining and
Filling (303-01C Engine - TDV6 2.7L Diesel, General
Procedures).
. Install the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - Oil Pan E tension
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he engine compa men ppe hea hield.

Remo e he c e .

3. Repo i ion he injec o o nd p oofing.

4. Relea e he oil le el indica o and be f om he oil pan

e en ion.

Remo e he bol .

Remo e and di ca d he O- ing eal.

5. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

6. Remo e he f on heel and i e .
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. Remo e he f on a le be.
Fo addi ional info ma ion, efe o: A le T be (205-03 F on
D i e A le/Diffe en ial, In- ehicle Repai ).
. Remo e he oil pan.
Fo addi ional info ma ion, efe o: Oil Pan (303-01C Engine
- TDV6 2.7L Die el, In- ehicle Repai ).
. Remo e he a e mo o .
Fo addi ional info ma ion, efe o: S a e Mo o (303-06C
S a ing S em - TDV6 2.7L Die el, Remo al and
In alla ion).
10. Remo e he oil aine pick- p a embl .

Remo e he bol .

Remo e and di ca d he O- ing eal.

11. Remo e he 3 bol f om he ba e o a e mo o

olenoid cable.

12. Remo e he bol f om he acce o d i e bel

en ione b acke .

13. Remo e he lo e bol f om he ai condi ioning (A/C )

comp e o .

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1 . Relea e he bocha ge oil e n be.

Relea e he i ing ha ne clip.

Remo e he bol .

1 . Remo e he bocha ge oil e n be.

Remo e he 2 bol .

Remo e and di ca d he ga ke .

Remo e and di ca d he O- ing eal .

In all blanking cap o he e po ed po .

1 . Remo e he 2 bol f om he bocha ge ppo

b acke .

1 . Remo e he 3 lo e bol f om he an mi ion o he

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engine.

1 . Remo e he f on a le c o membe .

Remo e he 4 bol .

1 . U ing a an mi ion jack, ppo he f on a le

a embl .
20. Remo e he f on a le a embl f on mo n ing bol .

C a ef ll lo e he f on a le a embl .

21. NOTE: No e he fi ed po i ion of he e aining bol p io

o emo al.

Remo e he oil pan e en ion.

Remo e he 18 bol .

Remo e and di ca d he ga ke .

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In alla ion
1. NOTE: Make sure that all the component mating faces
are clean.

NOTE: It is important that the oil pan extension is bolted

to the crankshaft main bearing carrier within twenty
minutes of applying the sealant.

Apply an 8 mm bead of sealant to the cylinder block in

the areas shown.

Use WSS-M4G323-A4-RTV sealant.

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. Install the oil pan e tension.

Install a ne gasket.

Loosel install all oil pan e tension retaining bolts.

. Tighten the retaining bolts in the sequence sho n.

1. Tighten bolts A to 10 Nm (7 lb.ft). Tighten bolts B

to 4 Nm (2 lb.ft).

2. Tighten bolts A to 24 Nm (18 lb.ft). Tighten bolts B

to 10 Nm (7 lb.ft).

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. Align and secure the front axle assembly.

Tighten the M14 bolt to 105 Nm (77 lb.ft).

. Install the front axle crossmember.

Tighten the 4 bolts to 115 Nm (85 lb.ft).

. Install the 3 lower bolts from the transmission to the

engine.

Tighten the bolts to 45 Nm (33 lb.ft).

. Install the 2 bolts to the turbocharger support bracket.

Tighten the 2 bolts to 23 Nm (17 lb.ft).

. NOTE: Make sure that all the component mating faces are
clean.

NOTE: Remove and discard the blanking caps.

Install the turbocharger oil return tube.

Install new O-ring seals.

Install a new gasket.

Tighten the 2 bolts to 10 Nm (7 lb.ft).

. Install the bolt to the turbocharger oil return tube.

Secure the wiring harness to the turbocharger oil return

tube.

10. Install the lower bolt to the A/C compressor.

Tighten the bolt to 24 Nm (18 lb.ft).

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. In all he bol o he acce o d i e bel en ione

b acke .

Tigh en he ne bol o 24 Nm (18 lb.f ).

. Sec e he ba e o a e mo o olenoid cable.

Tigh en he M8 bol o 22 Nm (16 lb.f ).

Tigh en he M6 bol o 10 Nm (7 lb.f ).

. NOTE: Make e ha all he componen ma ing face a e

clean.

In all he oil aine pick- p a embl .

In all a ne O- ing eal.

Tigh en he bol o 10 Nm (7 Ib.f ).

. In all he a e mo o .
Fo addi ional info ma ion, efe o: S a e Mo o (303-06C
S a ing S em - TDV6 2.7L Die el, Remo al and
In alla ion).
. In all he oil pan.
Fo addi ional info ma ion, efe o: Oil Pan (303-01C Engine
- TDV6 2.7L Die el, In- ehicle Repai ).
. In all he f on a le be.
Fo addi ional info ma ion, efe o: A le T be (205-03 F on
D i e A le/Diffe en ial, In- ehicle Repai ).
. In all he f on heel and i e .

Tigh en he heel n o 140 Nm (103 lb.f ).

. NOTE: Make e ha all he componen ma ing face a e

clean.

Sec e he oil le el indica o and be in o he oil pan

e en ion.

In all a ne O- ing eal.

In all he bol .

. Repo i ion he injec o o nd p oofing.

. In all he engine compa men ppe hea hield.

In all he c e .

. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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Engine - TDV6 2.7L Diesel - Timing Belt Co er
In-vehicle Repair

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Release the intake air shutoff throttle elbow.

Remove the retaining bolt.

4. Release the intake air shutoff throttle elbow.

Release the retaining clip.

Disconnect the electrical connector.

5. Remove the intake air shutoff throttle elbow support

bracket.

Remove the three retaining bolts.

6. Remove the fan cowl.

For additional information, refer to: C ooling Fan Shroud

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(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
. Remo e he c ank haf dampe .

Remo e he i e aining bol .

. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

. D ain he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Die el, Gene al P oced e ).
10. Di connec he coolan ho e f om he c linde head
coolan o le elbo .

Relea e he coolan ho e e aining clip.

Repo i ion he coolan op ho e.

11. Remo e he acce o d i e bel idle .

Remo e he e aining bol .

12. NOTE: Righ -hand ho n, lef -hand imila .

Relea e he e ha ga eci c la ion (EGR) al e o le

be clamp f om he iming co e .

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Remo e he e aining bol .

1 . Di connec he igh -hand EGR coolan inle ho e f om

he EGR coole .

Relea e he coolan ho e e aining clip.

1 . Po i ion he EGR coolan ho e a ide fo acce .

1 . Remo e he coolan p mp and acce o d i e bel
idle p lle .

Remo e he i e aining bol .

1 . Remo e he iming bel co e .

F ll loo en he 16 iming bel co e e aining bol .

Relea e he 2 i ing ha ne clip .

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In alla ion
1. In all he iming bel co e .

A ach he 2 i ing ha ne clip .

Tigh en he 16 iming bel co e e aining bol o 10

Nm (7 lb.f ).

2. In all he coolan p mp and acce o d i e bel idle

p lle .

Tigh en he i e aining bol o 23 Nm (17 lb.f ).

3. C onnec he igh -hand EGR coolan inle ho e o he EGR

coole .

In all he coolan ho e e aining clip.

4. Sec e he EGR al e o le be clamp o he iming

co e .

In all he o e aining bol .

5. C onnec he coolan ho e o he c linde head coolan o le

elbo .

In all he e aining clip.

6. In all he acce o d i e bel idle .

In all he e aining bol and igh en o 47 Nm (35 lb.f ).

7. In all he c ank haf dampe .

Tigh en he i e aining bol o 23 Nm (17 lb.f ).

8. In all he fan co l.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
9. In all he in ake ai h off h o le elbo ppo b acke .

In all he h ee e aining bol and igh en o 10 Nm (7

lb.f ).

10. Sec e he in ake ai h off h o le elbo .

In all he e aining clip.

In all he e aining bol .

C onnec he elec ical connec o .

11. In all he engine co e .

Fo addi ional info ma ion, efe o: Engine C o e - 2.7L V6
- TdV6 (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
12. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
13. Refill and bleed he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Die el, Gene al P oced e ).

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Engine - TDV6 2.7L Diesel - Timing Belt
In-vehicle Repair

Special Tool(s)
C heck Pin - C amshaft Pulle s

303-1132

Timing Pin - C amshaft Pulle s

303-1126

Timing Pin - Automatic

Transmission

303-1117

Timing Pin - Manual Transmission

303-1116

Remo al
All vehicles
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the timing belt cover.
For additional information, refer to: Timing Belt C over (303-
01C Engine - TDV6 2.7L Diesel, In-vehicle Repair).

3. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

4. Remove the starter motor.
For additional information, refer to: Starter Motor (303-06C
Starting S stem - TDV6 2.7L Diesel, Removal and
Installation).

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. Remo e he c ank haf iming alignmen g omme f om he
engine block.
. Ro a e he c ank haf clock i e o align he c ank haf
alignmen hole in he fl heel o fle pla e i h he block
ape e.
. C heck he cam haf p lle alignmen hole a e
co ec l aligned. If he alignmen hole a e no
aligned, o a e he c ank haf one f ll n clock i e.

Vehicle iha oma ic an mi ion

. U ing he pecial ool, lock he fle pla e.

In all a a e mo o bol o e ain he pecial ool.

Vehicle i h man al an mi ion

. U ing he pecial ool, lock he fl heel.

In all a a e mo o bol o e ain he pecial ool.

10. In all he pecial ool o he e ha cam haf p lle .

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. C AUTION: Do no e he pecial ool o lock he

cam haf . Fail e o follo hi in c ion ma e l in
damage o he engine o he pecial ool .

Loo en he i e ha cam haf p lle dampe e aining

bol .

U ing a i able ool, co n e hold he cam haf

p lle cen e e aining bol .

. Remo e and di ca d he iming bel en ione .

Remo e and di ca d he bol .

. Remo e and di ca d he iming bel .

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In alla ion
A ehic e
1. R ae b h ca haf e c c i e.

2. I a a e i i g be e i e .

I a a e b ,b d f igh e a hi age.

3. C AUTION: Ma e e he ca haf e e ai
i he c c i e ii .

I a he e i i g be .

S a i ga he c a haf e ,i a he i i g
be i a c e -c c i e di ec i , i he e e ce
h .

S age e: A ach he i i g be he c a haf

e .

S age : A ach he i i g be he id e e .

S age h ee: A ach he i i g be he ef -ha d

ca haf e .

S age f : A ach he i i g be he id e e .

S age fi e: A ach he i i g be he RH ca haf

e .

S age i : A ach he i i g be he i i g be
e i e .

4. C AUTION: Ma e e he i i g be e i e
i d i a ig ed i h he g e.

Te i he i i g be .

R a e he e i e a e b c e c c i e.

Tigh e 24 N (18 b.f ).

5. C AUTION: D e he ecia c he
ca haf . Fai e f hi i ci a e i

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damage o he engine o he pecial ool .

U ing a i able ool, co n e hold he cam haf p lle

cen e e aining bol .

Tigh en he i e ha cam haf p lle dampe

e aining bol .

Tigh en he bol o 23 Nm (17 lb.f ).

. Remo e he pecial ool f om he cam haf p lle .

Vehicle i h man al an mi ion

. Remo e he pecial ool f om he fl heel.

Vehicle iha oma ic an mi ion

. Remo e he pecial ool f om he fle pla e.

All ehicle
. Ro a e he engine o comple e n clock i e.

Vehicle i h man al an mi ion

10. U ing he pecial ool, lock he fl heel.

In all a a e mo o bol o e ain he pecial ool.

Vehicle iha oma ic an mi ion

11. U ing he pecial ool, lock he fle pla e.

In all a a e mo o bol o e ain he pecial ool.

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. In all he pecial ool o he e ha cam haf p lle .

If he pecial ool doe no fi co ec l , epea he

iming bel in alla ion p oced e.

Remo e he pecial ool f om he cam haf p lle .

Vehicle i h man al an mi ion

. Remo e he pecial ool f om he fl heel.

In all he g omme .

Vehicle iha oma ic an mi ion

. Remo e he pecial ool f om he fle pla e.

In all he g omme .

All ehicle
. In all he a e mo o .
Fo addi ional info ma ion, efe o: S a e Mo o (303-06C
S a ing S em - TDV6 2.7L Die el, Remo al and
In alla ion).
. In all he iming bel co e .
Fo addi ional info ma ion, efe o: Timing Bel C o e (303-
01C Engine - TDV6 2.7L Die el, In- ehicle Repai ).
. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - E haust Manifold LH
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he bocha ge .
Fo addi ional info ma ion, efe o: T bocha ge (303-04D
F el C ha ging and C on ol - T bocha ge - TDV6 2.7L
Die el, Remo al and In alla ion).
3. D ain he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Die el, Gene al P oced e ).
4. Remo e he ba e a .
Fo addi ional info ma ion, efe o: Ba e T a (414-01
Ba e , Mo n ing and C able , Remo al and In alla ion).
5. Remo e he LH EGR al e o le be.
Fo addi ional info ma ion, efe o: E ha Ga
Reci c la ion (EGR) Val e O le T be (303-08C Engine
Emi ion C on ol - TDV6 2.7L Die el, Remo al and
In alla ion).
6. Di connec he coolan o le ho e f om he LH EGR
al e.

Relea e he clip.

7. Relea e he LH EGR al e inle be.

Remo e he o ppo b acke e aining bol .

Remo e he ppo b acke .

Remo e and di ca d he e aining clip.

8. Remo e he LH EGR al e inle be.

Remo e he o e aining bol .

Remo e and di ca d he ga ke .

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. Disconnect the LH EGR valve electrical connector.

10. Disconnect the coolant inlet hose from the LH EGR

valve.

Release the clip.

11. Remove the LH EGR valve.

Remove the three retaining bolts.

12. Remove the LH e haust manifold heat shield.

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Remo e he o e aining bol .

1 . Remo e he h ee e ha c o -o e pipe e aining

n .

1 . Remo e he LH e ha manifold.

Remo e he i e aining n .

1 . Remo e and di ca d he LH e ha manifold ga ke .

Remo e and di ca d he d .

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In alla ion
1. Tigh e he LH e ha a if d e ai i g d 13 N
(10 b.f ).

I a a e ga e .

2. NOTE: Tigh e he e ai i g i he e e ce h .

I a he LH e ha a if d.

Tigh e he 24 N (18 b.f ).

3. I a he h ee e ha c - e i e e ai i g .

Tigh e he 24 N (18 b.f ).

4. I a he LH e ha a if d hea hie d.

I a he e ai i g b a d igh e 10 N (7
b.f ).

5. I a he LH EGR a e.

I a he h ee EGR a e e ai i g b ,b d
f igh e a hi age.

6. NOTE: D f c e he e ai i g c i a hi age.

I a he LH EGR a e i e be.

I a a e e ai i g c i .

I a a e ga e .

L e i a he EGR a e i e be e ai i g
b .

7. F c e he e ai i g c i .
8. Tigh e he EGR a e i e be e ai i g b 10
N (7 b.f ).
9. Tigh e he h ee EGR a e e ai i g b 10 N (7
b.f ).
10. I a he b ac e .

Tigh e he e ai i g b 10 N (7 b.f ).

11. C ec he c a i e h e he LH EGR a e.
12. C ec he LH EGR a e e ec ica c ec .
13. C ec he c a e h e he LH EGR a e.
14. I a he LH EGR a e e be.
F addi i a i f a i , efe : E ha Ga
Reci c a i (EGR) Va e O e T be (303-08C E gi e
E i i C - TDV6 2.7L Die e , Re a a d
I a a i ).
15. I a he ba e a .

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For additional information, refer to: Batter Tra (414-01
Batter , Mounting and C ables, Removal and Installation).
1 . Install the turbocharger.
For additional information, refer to: Turbocharger (303-04D
Fuel C harging and C ontrols - Turbocharger - TDV6 2.7L
Diesel, Removal and Installation).
1 . C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
1 . Refill and bleed the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - E haust Manifold RH
In- ehicle Repai

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. D ain he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Die el, Gene al P oced e ).
4. Remo e he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
5. Remo e he RH e ha ga eci c la ion (EGR) al e
o le be.
Fo addi ional info ma ion, efe o: E ha Ga
Reci c la ion (EGR) Val e O le T be (303-08C Engine
Emi ion C on ol - TDV6 2.7L Die el, Remo al and
In alla ion).
6. Remo e he f el line b acke .

Relea e he f el line .

Remo e he bol .

7. Di connec he EGR al e elec ical connec o .

8. Di connec he coolan inle ho e f om he EGR al e.

Relea e he clip.
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. Di connec he coolan o le ho e f om he EGR al e.

Remo e he bol .

Relea e he clip.

10. Remo e he EGR al e inle be.

Relea e he clip.

Remo e he 2 bol .

Remo e and di ca d he ga ke .

Remo e and di ca d he clip.

11. Remo e he RH f on heel and i e.

12. Remo e he ppe pen ion a m and b ake line hea
hield fo acce .

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1 . Remove the RH EGR valve and cooler assembl .

Remove the 3 bolts.

1 . Remove the RH e haust manifold heat shield.

Remove the 3 bolts.

1 . Remove the 2 e haust cross-over pipe nuts.

1 . Remove the remaining e haust cross-over pipe nut.

1 . Remove the RH e haust manifold.

Remove the 6 nuts.

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Re e a d di ca d he ga e .

Re e a d di ca d he d .

In alla ion
1. Tigh e he e ha a if d d 13 N (10 b.f ).

I a a e ga e .

2. NOTE: Tigh e he e ai i g i he e e ce h .

I a he RH e ha a if d.

Tigh e he 24 N (18 b.f ).

3. Tigh e he e ha c - e i e 24 N (18 b.f ).

4. Tigh e he 2 e ha c - e i e 24 N (18
b.f ).
5. I a he RH e ha a if d hea hie d.

I a he b a d igh e 10 N (7 b.f ).

6. I a he RH EGR a e a dc e a e b .

I a he EGR a e b ,b d f igh e a
hi age.

7. NOTE: D f c e he e ai i g c i a hi age.

I a he EGR a e i e be.

I a a e ga e .

I a a e ci .

L e i a he 2 EGR a e i e be b .

8. F c e he c i .
9. Tigh e he EGR a e i e be b 10 N (7
b.f ).
10. Tigh e he h ee EGR a e b 10 N (7 b.f ).
11. I a he e e i a a d b a e i e hea
hie d .

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. In all he heel and i e.
. Tigh en he EGR al e bol o 10 Nm (7 lb.f ).
. C onnec he coolan o le ho e o he EGR al e.
. C onnec he coolan inle ho e o he EGR al e.
. C onnec he EGR al e elec ical connec o .
. In all he f el line b acke .

In all he f el line e aining b acke bol and igh en o

10 Nm (7 lb.f ).

Sec e he f el line .

. In all he RH EGR al e o le be.

Fo addi ional info ma ion, efe o: E ha Ga
Reci c la ion (EGR) Val e O le T be (303-08C Engine
Emi ion C on ol - TDV6 2.7L Die el, Remo al and
In alla ion).
. In all he a ilia ba e a .
Fo addi ional info ma ion, efe o: A ilia Ba e T a
(414-01 Ba e , Mo n ing and C able , Remo al and
In alla ion).
. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
. Fill and bleed he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Die el, Gene al P oced e ).

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - Oil Fil e Ho ing
In-vehicle Repair

1. Refer to oil cooler.

For additional information, refer to: Oil C ooler (303-01C
Engine - TDV6 2.7L Diesel, In-vehicle Repair).

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - E haust Manifold Crossover Pipe
Remo al and In alla ion

Removal
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. Remo e he an mi ion ppo c o membe .
Fo addi ional info ma ion, efe o: T an mi ion S ppo
C o membe (502-02 F ll F ame and Bod Mo n ing,
Remo al and In alla ion).
4. Remo e he e ha em. Fo addi ional info ma ion,
efe o: (309-00C E ha S em - TDV6 2.7L Die el)

E ha S em - Vehicle Wi ho : Die el Pa ic la e
Fil e (DPF) (Remo al and In alla ion),
E ha S em - Vehicle Wi h: Die el Pa ic la e Fil e
(DPF) (Remo al and In alla ion).
5. Lo e he ea of he an mi ion fo acce .
6. Remo e he e ha manifold c o o e pipe LH ppo
b acke .

Relea e he i ing ha ne .

Remo e he 3 bol .

7. Remo e he e ha manifold c o o e pipe RH ppo

b acke .

Remo e he 3 bol .

8. Remo e he e ha manifold c o o e pipe cen e

ppo b acke .

Remo e he 2 bol .

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. C AUTION: Take ca e hen handling he c o o e

pipe a damage o he in la ing ma e ial ma occ .

Relea e he e ha manifold c o o e pipe f om he

bocha ge .

Remo e he bocha ge hea hield bol .

Remo e and di ca d he 3 n .

10. Remo e he RH e ha manifold hea hield.

11. Remo e he e ha manifold c o o e pipe.

Remo e and di ca d he 3 n .

Remo e and di ca d he 2 ga ke .

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In alla ion
1. I a e e ha a if d d .
2. I a e b cha ge d .

3. C AUTION: Ta e ca e he ha d i g he c e
i e a da age he i a i g a e ia a cc .

I a he e ha a if d c e i e.

C ea he c e a i g face .

I a e ga e .

I a e .

Tigh e he 6 24 N (18 b. f ).

4. I a he e ha a if d c e i e ce e
b ac e .

L e i a he 2 b .

5. I a he e ha a if d c e i e RH
b ac e .

L e i a he 3 b .

6. I a he e ha a if d c e i e LH
b ac e .

L e i a he 3 b .

7. Tigh e he e ha a if d c e i e i g
b ac e b i he f i g e e ce.

Tigh e he 2 b a ed 1 10 N (7 b.f ).

L e he 2 b b 90 deg ee .

Tigh e he 2 b a ed 3 10 N (7 b.f ).

L e he 2 b b 90 deg ee .

Tigh e he 4 b a ed 2 25 N (18 b. f ).

Tigh e he 2 b a ed 1 25 N (18 b. f ).

Tigh e he 2 b a ed 3 25 N (18 b. f ).

A ach he i i g ha e .

8. I a he RH e ha a if d hea hie d.

Tigh e he 3 b 10 N (7 b.f ).

9. I a he b cha ge hea hie d.

Tigh e he b 10 N (7 Ib.f ).

10. I a he e ha e . F addi i a i f ai ,
efe : (309-00C E ha S e - TDV6 2.7L Die e )

E ha S e - Vehic e Wi h : Die e Pa ic a e
Fi e (DPF) (Re a a d I a a i ),
E ha S e - Vehic e Wi h: Die e Pa ic a e Fi e
(DPF) (Re a a dI a a i ).
11. I a he a i i c e be .
F addi i a i f a i , efe :T a i i S
C e be (502-02 F F a e a dB d M i g,
Re a a d I a a i ).

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. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - EngineVehicle Wi h: 6HP26 6-Speed A oma ic
T an mi ion
Removal

Special Tool( )
Engine lifting cradle

303-1141

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the wheels and tires.
4. Remove the bod .
For additional information, refer to: Bod - TDV6 2.7L Diesel
(502-02 Full Frame and Bod Mounting, Removal and
Installation).
5. Remove the cooling fan shroud.
For additional information, refer to: C ooling Fan Shroud
(303-03C Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).
6. Remove the intake air shutoff throttle.
For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).
7. Remove the intake air shutoff throttle elbow support
bracket.

Remove the 3 bolts.

8. Disconnect the upper coolant hose from the coolant

distribution manifold.

Remove the clip.

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. Di connec he RH e ha ga eci c la ion (EGR)

coolan ho e.

Relea e he clip.

10. Remo e he acce o d i e bel .

Ro a e he acce o d i e bel en ione co n e -

clock i e.

11. Remo e he 2 LH ppe pen ion a m and b ake line

hea hield .

Remo e he 2 n .

Remo e he 3 bol .

12. Di connec he b ea he ho e.

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Relea e he clip.

1 . Relea e he cha ge ai coole inle pipe.

Remo e he n .

Remo e he 2 bol .

1 . C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he ai condi ioning (A/C ) comp e o lo -

p e e line.

Remo e he bol .

Remo e and di ca d he O- ing eal.

1 . Di connec he cha ge ai coole inle ho e.

Loo en he clip.

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1 . Di connec he cha ge ai coole inle ho e.

Loo en he clip.

1 . Di connec he coolan lo e ho e.

Relea e he clip.

1 . Remo e he po e ee ing p mp ea bol .

1 . Repo i ion he po e ee ing p mp.

Remo e he 3 bol .

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. Remo e he cha ge ai coole inle pipe.

. C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he A/C comp e o high-p e e pipe.

Remo e he bol .

Remo e and di ca d he O- ing eal.

. Repo i ion he lo e coolan ho e.

. Remo e he bocha ge in ake be.

Loo en he clip.

. Relea e he an mi ion fl id line .

Remo e he n .

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2 . Release the batter positive cable.

Release the clip.

2 . Release the e haust from the turbocharger.

Remove and discard the 3 nuts.

Remove and discard the gasket.

2 . Remove the turbocharger support bracket.

Remove the 2 bolts.

Remove the nut.

2 . Release the e haust cross-over pipe bracket.

Remove the 6 bolts.

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2 . C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he 2 f el line .

30. Relea e he 2 f el line .

Remo e he bol .

Relea e f om he 2 clip .

31. Relea e he an mi ion b ea he line .

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Remo e he bol .

. Relea e and epo i ion he f el coole .

Remo e he bol .

. Relea e he engine g o nd cable.

Remo e he bol .

. Remo e he a e mo o ppo b acke .

Remo e he 4 bol .

. Di connec he 2 a e mo o i ing ha ne

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connectors from the starter motor solenoid.

Remove the rubber insulator.

Remove the 2 nuts.

3 . Remove the starter motor.

Remove the 2 bolts.

3 . Release the fle plate.

Remove the access plug.

Remove and discard the 4 bolts.

3 . Remove the LH engine mount nut.

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3 . Remo e he RH engine mo n n .

40. In all he pecial ool.

In all and igh en he bol .

41. Relea e he an mi ion f om he engine.

Remo e he 14 bol .

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2. NOTE: Note the routing of the battery positive cable.

NOTE: Note the routing of the transmission wiring harness.

With assistance, carefully remove the engine.

Using a suitable hydraulic jack, support the

transmission.

C arefully guide the transmission wiring harness out as

the engine is being removed.

C arefully guide the battery positive cable out as the

engine is being removed.

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - EngineVehicle Wi h: Man al T an mi ion
Removal

Special Tool( )
Engine lifting cradle

303-1141

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

2. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

3. Remove the wheels and tires.
4. Release the rear driveshaft from the transfer case drive
flange.

Remove the 6 bolts.

C ollect the three washers.

5. Release the front driveshaft from the transfer case drive

flange.

Remove and discard the 6 bolts.

C ollect the three washers.

6. Remove the bod .

For additional information, refer to: Bod - TDV6 2.7L Diesel
(502-02 Full Frame and Bod Mounting, Removal and
Installation).

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. Remo e he cooling fan h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
. Remo e he in ake ai h off h o le.
Fo addi ional info ma ion, efe o: In ake Ai Sh off
Th o le (303-04C F el C ha ging and C on ol - TDV6 2.7L
Die el, Remo al and In alla ion).
. Remo e he in ake ai h off h o le elbo ppo
b acke .

Remo e he 3 bol .

10. Di connec he ppe coolan ho e f om he coolan

di ib ion manifold.

Remo e he clip.

11. Di connec he RH e ha ga eci c la ion (EGR)

coolan ho e.

Relea e he clip.

12. Remo e he acce o d i e bel .

Ro a e he acce o d i e bel en ione co n e -

clock i e.

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1 . Remo e he 2 LH ppe pen ion a m and b ake line

hea hield .

Remo e he 2 n .

Remo e he 3 bol .

1 . Di connec he b ea he ho e.

Relea e he clip.

1 . Relea e he cha ge ai coole inle pipe.

Remo e he 2 n .

Remo e he bol .

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1 . C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he ai condi ioning (A/C ) comp e o lo -

p e e line.

Remo e he bol .

Remo e and di ca d he O- ing eal.

1 . Di connec he cha ge ai coole inle ho e.

Loo en he clip.

1 . Di connec he cha ge ai coole inle ho e.

Loo en he clip.

1 . Di connec he coolan lo e ho e.

Relea e he clip.

20. Remo e he po e ee ing p mp ea bol .

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. Repo i ion he po e ee ing p mp.

Remo e he 3 bol .

. Remo e he cha ge ai coole inle pipe.

. C AUTIONS:

Make e ha all opening a e ealed. U e ne

blanking cap .

Ca e m be aken o a oid damage o he ma ing

face .

Di connec he A/C comp e o high-p e e pipe.

Remo e he bol .

Remo e and di ca d he O- ing eal.

. Repo i ion he lo e coolan ho e.

. Remo e he bocha ge in ake be.

Loo en he clip.

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2 . Release the batter positive cable.

Release the clip.

2 . Release the e haust from the turbocharger.

Remove and discard the 3 nuts.

Remove and discard the gasket.

2 . Remove the turbocharger support bracket.

Remove the 2 bolts.

Remove the nut.

2 . Release the e haust cross-over pipe bracket.

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Remo e he 6 bol .

. C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he 2 f el line .

. Relea e he an mi ion b ea he line .

Remo e he bol .

. Relea e he engine g o nd cable.

Remo e he bol .

. Remo e he LH engine mo n n .

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. Remo e he RH engine mo n n .

. Remo e he an mi ion ppo in la o bol .

. In all he pecial ool.

. NOTE: No e he po i ion of he ee ing col mn lo e

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shaft.

Using the special tool, remove the engine and

transmission assembl .

3 . Remove the 2 starter motor bolts.

3 . NOTE: Note the routing of the transmission wiring

harness.

With assistance, carefull remove the engine from the

transmission.

Remove the 14 bolts.

C arefull guide the transmission wiring harness out

as the engine is being removed.

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P bli hed: 11-Ma -2011

Engine - TDV6 2.7L Diesel - Engine
Di a embl

Special Tool(s)
Timing Pin - A oma ic
T an mi ion

303-1117

Timing Pin - Man al T an mi ion

303-1116

C am haf p lle holding ool

303-1145/1

Holde - C am haf P lle F on

303-1124

Fle pla e locking ool

303-947

Locking Tool - Fl heel

303-1123

Disassembl
All ehicle
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. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

. Drain the engine oil.
For additional information, refer to: Engine Oil Draining and
Filling (303-01C Engine - TDV6 2.7L Diesel, General
Procedures).
. Remove the engine.
For additional information, refer to: Engine - Vehicles With:
6HP26 6-Speed Automatic Transmission (303-01C Engine -
TDV6 2.7L Diesel, Removal) /
Engine - Vehicles With: Manual Transmission (303-01C
Engine - TDV6 2.7L Diesel, Removal).
. Install the engine to a suitable engine stand.
. Remove the power steering pump bracket.

Remove the 3 bolts.

. Remove the air conditioning (A/C ) compressor.

Disconnect the electrical connector.

Remove the 3 bolts.

. Remove the A/C compressor bracket.

Remove the 2 bolts.

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. Remo e he LH engine mo n b acke .

Remo e he 4 bol .

10. C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Remo e he oil le el indica o and be.

Relea e he i ing ha ne clip.

Remo e he bol .

Remo e and di ca d he O- ing eal.

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. Remo e he LH e ha ga eci c la ion (EGR) al e
and coole a embl .

Di connec he elec ical connec o .

Remo e and di ca d he clip.

Relea e he clip and di connec he coolan ho e.

Remo e he 5 bol .

C ollec he b acke .

. Remo e he LH e ha manifold hea hield.

Remo e he 2 bol .

. Remo e he bocha ge hea hield.

Remo e he 2 bol .

. C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Remo e he bocha ge oil e n be.

Relea e he i ing ha ne clip.

Remo e he 3 bol .

Remo e and di ca d he ga ke .

Remo e and di ca d he O- ing eal.

. Relea e he bocha ge ppo b acke .

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Remo e he 4 bol .

1 . C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he bocha ge oil ppl be.

Remo e he banjo bol .

Remo e and di ca d he 2 ealing a he .

1 . Relea e he e ha c o -o e pipe f om he LH
e ha manifold.

Remo e and di ca d he 3 n .

Remo e and di ca d he ga ke .

1 . Remo e he LH e ha manifold and bocha ge

a embl .

Remo e and di ca d he 6 n .

Remo e and di ca d he ga ke .

1 . Remo e he c linde block coolan inle pipe.

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Remove the 2 bolts.

Remove and discard the O-ring seal.

. Remove the crankshaft position (C KP) sensor.

Disconnect the electrical connector.

Reposition the access cover.

Remove the bolt.

. Remove the RH EGR valve and cooler assembl .

Disconnect the electrical connector.

Remove and discard the clip.

Release the clip and disconnect the coolant hose.

Remove the 4 bolts.

. Disconnect the generator electrical connectors.

Reposition the rubber insulator.

Remove the nut.

. Remove the generator.

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Remove the 3 bolts.

2 . Remove the RH e haust manifold heat shield.

Remove the 3 bolts.

2 . Remove the RH engine mount bracket.

Remove the 4 bolts.

2 . Remove the generator bracket.

Remove the 5 bolts.

2 . Remove the RH e haust manifold and e haust cross-

over pipe assembl .
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Remove and discard the 6 nuts.

Remove and discard the gasket.

2 . Remove the EGR valve coolant pipe.

Remove the bolt.

Disconnect the electrical connector.

Release from the 2 clips.

Release the clip.

2 . Remove the coolant pump.

Remove the 3 bolts.

Remove and discard the O-ring seal.

30. Remove the accessor drive belt idler pulle .

Remove the bolt.

31. Remove the cooling fan pulle .

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Remove the 3 bolts.

. Remove the crankshaft pulle .

Remove the 6 bolts.

. Remove the timing belt cover.

Full loosen the 16 bolts.

. NOTE: Note the fitted position.

Remove the 2 low pressure fuel pipes.

Disconnect the 2 quick release connectors.

. Disconnect the engine oil pressure (EOP) sensor

electrical connector.
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Release the iring harness clip.

3 . NOTE: LH sho n, RH is similar

Disconnect the 6 fuel injector electrical connectors.

Release the 4 iring harness clips.

3 . Disconnect the camshaft position (C MP) sensor

electrical connector.

Release the iring harness clip.

3 . Disconnect the engine oil temperature sensor electrical

connector.

Release the iring harness clip.

3 . NOTE: LH sho n, RH is similar.

Disconnect the 2 knock sensor (KS) electrical connectors.

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. Di connec he f el empe a e en o elec ical

connec o .

. Remo e he c ankca e en oil epa a o .

Di connec and elea e he 2 b ea he ho e .

. Di connec he f el ail p e e (FRP) en o elec ical

connec o .

. Di connec he 2 f el injec ion p mp elec ical

connec o .

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. Remove the engine wiring harness.

Remove the nut.

Release the 2 clips.

Vehicles built up to 12/2006

. C AUTION: Make sure that all openings are sealed.

Use new blanking caps.

NOTE: RH shown, LH is similar

Remove and discard the 2 high-pressure fuel rail supply

lines.

Release the 2 clips.

. C AUTION: Make sure that all openings are sealed.

Use new blanking caps.

Remove and discard the high-pressure fuel diverter rail

supply line.

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Vehicles built 01/2007 onwards

4 . C AUTION: Make sure that all openings are sealed.

Use new blanking caps.

NOTE: LH shown, RH is similar

Remove and discard the 2 high-pressure fuel rail supply

lines.

Release the clip.

All vehicles
4 . C AUTIONS:

Make sure the high-pressure fuel supply line remains

in contact with both the fuel injector and the fuel injection
supply manifold until both unions have been detached and
cleaned. Failure to follow this instruction may result in
foreign matter ingress to the fuel injection system.

Make sure that the fuel injector adaptor union does

not move when loosening the high-pressure fuel supply
lines. Failure to follow this instruction may result in damage
to the fuel injector or the fuel injector adaptor union.

Make sure that all openings are sealed. Use new

blanking caps.

Remove and discard the 6 high-pressure fuel supply lines.

4 . Disconnect the fuel return line from the fuel injectors.

Remove and discard the 6 clips.

50. Remove the two fuel injector bolts.

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. Install the special tool studs.

. C AUTION: Make sure the fuel injector remover

legs are correctl engaged to the fuel injector. Failure to
follow this instruction ma result in damage to the
component.

Install the special tool remover legs to the studs.

. Remove the fuel injector.

Rotate the special tool bolts evenl , in a clockwise

direction.

Remove the special tool.

Remove and discard the fuel injector clamp.

Remove and discard the sealing washer.

. Remove the remaining fuel injectors.

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. NOTE: LH ho n, RH i imila .

Remo e he 2 f el ail .

Remo e he 4 bol .

. NOTE: RH ho n, LH i imila

Remo e he 2 f el ail b acke .

Remo e he 4 bol .

. Remo e he f el injec ion p mp bel co e .

Relea e he 2 clip .

. Remo e and di ca d he f el injec ion p mp bel

en ione .

Remo e he bol .

. Remo e and di ca d he f el injec ion p mp bel .

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0. Install the special tool to the camshaft rear pulle .

Rotate the crankshaft to align the special tool to the

engine lifting bracket.

Install and tighten the bolt.

1. NOTE: Discard the bolt.

Using the special tool, remove the camshaft rear pulle

bolt.

2. Remove the special tool.

Remove the bolt.

3. Remove the camshaft rear pulle .

4. Remove the fuel injection pump belt rear cover.

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Full loosen the 2 bolts.

. Remove the LH engine cover locating studs.

. Remove the LH valve cover.

Release the KS electrical connector from the valve

cover.

Full loosen the 13 bolts.

Remove the fuel line support bracket.

Remove and discard the gasket.

. Remove the RH engine cover locating studs.

Remove the nut.

Remove the bolt.

Remove the bracket.

. Remove the RH valve cover.

Release the glow plug electrical connector from the

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valve cover.

Release the KS electrical connector from the valve

cover.

Full loosen the 13 bolts.

Remove and discard the gasket.

6 . Remove the brake vacuum pump.

Remove the 3 bolts.

Remove the bracket.

Remove and discard the gasket.

70. Remove the breather line.

Remove the bolt.

Release the clip.

71. Remove the turbocharger oil suppl line.

Remove the bolt.

Remove and discard the 2 O-ring seals.

72. Remove the c linder head coolant outlet assembl .

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Remo e he 4 bol .

Remo e and di ca d he O- ing eal.

. C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Di connec he f el pipe f om he f el coole .

. C AUTION: Make e ha all opening a e ealed.

U e ne blanking cap .

Remo e and di ca d he f el injec o e n line.

. Ro a e he c ank haf clock i e o align he

c ank haf alignmen hole in he fl heel o fle pla e
i h he c linde block ape e.

. C heck he cam haf p lle alignmen hole a e co ec l

aligned. If he alignmen hole a e no aligned, o a e he
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c ank haf one f ll n clock i e.

Vehicle iha oma ic an mi ion

. U ing he pecial ool, lock he fle pla e.

In all a a e mo o bol o e ain he pecial ool.

Vehicle i h man al an mi ion

. U ing he pecial ool, lock he fl heel.

In all a a e mo o bol o e ain he pecial ool.

All ehicle

. C AUTION: Do no e he pecial ool o lock he

cam haf . Fail e o follo hi in c ion ma e l in
damage o he engine o he pecial ool .

Loo en he 6 e ha cam haf p lle bol .

0. Remo e and di ca d he iming bel en ione .

Remo e he bol .

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1. Remove the 2 timing belt idler pulle 's.

Remove the 2 bolts.

C ollect the plastic shield from behind the upper idler

pulle .

2. Remove and discard the timing belt.

3. NOTE: LH shown, RH is similar.

Remove the 2 camshaft pulle s.

Remove the 6 bolts.

4. Using the special tool, remove the 2 camshaft pulle

hubs.

Remove and discard the 2 bolts.

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. Remove the cooling fan drive hub bearing.

Remove the 3 bolts.

. Retain the RH secondar timing chain tensioner piston.

Reposition the secondar timing chain tensioner.

Install a 1.5 mm (0.060 in.) diameter pin into the

secondar timing chain tensioner piston.

. C AUTION: Evenl and progressivel , release the

camshaft bearing caps.

Remove the RH bank camshaft bearing caps.

Remove the 18 bolts.

. Remove the RH bank camshafts and secondar timing

chain tensioner assembl .

Remove the 2 bolts.

Release the RH secondar timing chain tensioner.

. Remove the RH bank secondar timing chain tensioner.

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0. Remove the RH bank camshafts.

Release the secondar timing chain from the RH

camshafts.

Remove and discard the seal.

1. C AUTIONS:

The c linder head must not be placed mating face

down. Failure to follow this instruction ma result in damage
to the vehicle.

Onl use a plastic scraper to clean off the old gasket.

Remove the RH c linder head assembl .

Remove and discard the 8 bolts.

Remove and discard the gasket.

2. Retain the LH secondar timing chain tensioner piston.

Reposition the secondar timing chain tensioner.

Install a 1.5 mm (0.060 in.) diameter pin into the

secondar timing chain tensioner piston.

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3. C AUTION: Evenl and progressivel , release the

camshaft bearing caps.

Remove the LH bank camshaft bearing caps.

Remove the 18 bolts.

4. Remove the LH bank camshafts and secondar timing

chain tensioner assembl .

Release the LH secondar timing chain tensioner.

Remove the 2 bolts.

5. Remove the LH bank secondar timing chain tensioner.

6. Remove the LH bank camshafts.

Release the secondar timing chain from the LH

camshafts.

Remove and discard the 2 seals.

7. C AUTIONS:

The c linder head must not be placed mating face

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do n. Fail e o follo hi in c ion ma e l in damage
o he ehicle.

Onl e a pla ic c ape o clean off he old ga ke .

Remo e he LH c linde head a embl .

Remo e and di ca d he 8 bol .

Remo e and di ca d he ga ke .

Vehicle iha oma ic an mi ion

. Remo e he pecial ool f om he fle pla e.

. Remo e he fle pla e.

U ing he pecial ool, lock he fle pla e.

Remo e he 8 bol .

Vehicle i h man al an mi ion

100. Remo e he pecial ool f om he fle pla e.

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. Install the special tool.

. C AUTION: Working in a diagonal sequence,

progressively loosen the bolts.

NOTE: Restrain the flywheel.

Remove the clutch disc and pressure plate.

Remove the 6 bolts.

. NOTE: Restrain the flywheel.

Remove the flywheel.

Remove the 8 bolts.

. Remove the special tool.

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All vehicles
10 . Remove the oil cooler assembl .

Remove the 8 bolts.

Remove and discard the gasket.

10 . Remove the fuel injection pump.

Remove the 4 bolts.

10 . Remove the oil pan.

Remove the 14 bolts.

Remove and discard the gasket.

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10 . Remove the oil pump screen and pickup tube.

Remove the bolt.

Remove and discard the 2 O-ring seals.

10 . Remove the oil pan e tension.

Remove the 18 bolts.

Remove and discard the gasket.

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - Engine
Assembl

Special Tool( )
Timing Pin - Automatic Transmission

303-1117

Timing Pin - Manual Transmission

303-1116

C amshaft pulle holding tool

303-1145/1

Holder - C amshaft Pulle s Front

303-1124

Fle plate locking tool

303-947

Locking Tool - Fl heel

303-1123

Timing Pin - C amshaft Pulle s

303-1126

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Assembl
All vehicles
1. NOTE: C lean the component mating faces.

NOTE: It is important that the oil pan extension is bolted to the

crankshaft main bearing carrier within twenty minutes of applying
the sealant.

Apply an 8 mm bead of sealant to the cylinder block in the areas

shown.

Use WSS-M4G323-A4-RTV sealant.

2. NOTE: C lean the component mating faces.

Install the oil pan extension.

Install a new gasket.

Loosely install the bolts.

3. C AUTION: Tighten the bolts in the indicated sequence in 2

stages.

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Secure the oil pan extension.

1. Tighten bolts A to 10 Nm (7 lb.ft). Tighten bolts B to 4

Nm (2 lb.ft).

2. Tighten bolts A to 24 Nm (18 lb.ft). Tighten bolts B to 10

Nm (7 lb.ft).

. NOTE: Lubricate the new seals with clean engine oil.

NOTE: C lean the components.

Install the oil pump screen and pickup tube.

C lean the components.

Install new O-ring seals.

Tighten the bolt to 10 Nm (7 lb.ft).

. NOTE: C lean the component mating faces.

Install the oil pan.

Install a new gasket.

Evenly and progressively tighten the bolts to 10 Nm (7 lb.ft).

. Install the fuel injection pump.

Tighten the bolts to 23 Nm (17 lb.ft).

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. C AUTION: Make sure the gasket is installed correctly.

NOTE: C lean the component mating faces.

Install the oil cooler assembly.

Install a new gasket.

Install a new O-ring seal.

Tighten the bolts to 10 Nm (7 lb.ft).

. Install the crankshaft position (C KP) sensor.

Tighten the bolt to 5 Nm (4 lb.ft).

C onnect the electrical connector.

Reposition the access cover.

Vehicles with automatic transmission

. C AUTIONS:

Tighten the bolts in a diagonal sequence.

Tighten the bolts in the stages shown.

NOTE: C lean the component mating faces.

Install the flexplate.

Using the special tool, lock the flexplate.

Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).

Stage 2:Tighten the bolts 45 degrees.

Stage 3:Tighten the bolts a further 45 degrees.

Remove the special tool.

10. Using the special tool, lock the flexplate.

Rotate the crankshaft clockwise to align the crankshaft

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alignment hole in the flywheel or flexplate with the cylinder
block aperture.

Install a starter motor bolt to retain the special tool.

Vehicles with manual transmission

. Install the special tool.

. C AUTIONS:

Tighten the bolts in a diagonal sequence.

Tighten the bolts in the stages shown.

NOTE: C lean the component mating faces.

Install the flywheel.

Stage 1: Tighten the bolts to 50 Nm (37 lb.ft).

Stage 2:Tighten the bolts 45 degrees.

Stage 3:Tighten the bolts a further 45 degrees.

. C AUTIONS:

Install the clutch disc with 'TRANSMISSION SIDE' marking

against the clutch cover.

Use the special tool to align the components.

Working in a diagonal sequence, progressively tighten the

bolts.

NOTE: C lean the component mating faces.

Using the special tool, install the clutch disc and pressure plate.

Tighten the bolts to 25 Nm (18 lb.ft).

. Remove the special tool.

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1 . Using the special tool, lock the flywheel.

Rotate the crankshaft clockwise to align the crankshaft

alignment hole in the flywheel or flexplate with the cylinder
block aperture.

Install a starter motor bolt to retain the special tool.

All vehicles
1 . C heck the LH cylinder head face for distortion, across the center
and from corner to corner.
1 . NOTE: The cylinder head gasket must be installed over the
cylinder head to cylinder block dowels.

NOTE: C lean the component mating faces.

Install a new LH cylinder head gasket.

1 . C AUTIONS:

Use care when installing the cylinder head. Damage to the

cylinder block, cylinder head or cylinder head gasket may result.

Make sure that new bolts are installed.

NOTE: The cylinder head gasket must be installed over the

cylinder head to cylinder block dowels.

NOTE: Make sure the cylinder head is installed in its original

position.

NOTE: Tighten the bolts in the indicated sequence in 4 stages.

NOTE: C lean the component mating face.

Install the LH cylinder head assembly.

Stage 1: Tighten the bolts to 20 Nm (15 lb.ft).

Stage 2: Tighten the bolts to 40 Nm (30 lb.ft).

Stage 3: Tighten the bolts to 80 Nm (59 lb.ft).

Stage 4: Tighten the bolts a further 180 degrees.

1 . C heck the RH cylinder head face for distortion, across the

center and from corner to corner.
20. NOTE: The cylinder head gasket must be installed over the
cylinder head to cylinder block dowels.

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NOTE: C lean the component mating faces.

Install a new RH cylinder head gasket.

. C AUTIONS:

Use care when installing the cylinder head. Damage to the

cylinder block, cylinder head or cylinder head gasket may result.

Make sure that new bolts are installed.

NOTE: The cylinder head gasket must be installed over the

cylinder head to cylinder block dowels.

NOTE: Make sure the cylinder head is installed in its original

position.

NOTE: Tighten the bolts in the indicated sequence in four stages.

Install the RH cylinder head assembly.

Stage 1: Tighten to 20 Nm (15 lb.ft).

Stage 2: Tighten to 40 Nm (30 lb.ft).

Stage 3: Tighten to 80 Nm (59 lb.ft).

Stage 4: Tighten a further 180 degrees.

. Install the secondary timing chain to the RH bank camshafts.

. C AUTION: Do not release the secondary timing chain

tensioner locking pin until all of the camshaft bearing caps have
been installed.

Install the RH bank secondary timing chain tensioner.

Align the marks on the camshafts with the marks on the

secondary timing chain.

. NOTE: C lean the components.

NOTE: Install a new seal.

Install the RH bank camshafts and secondary timing chain

tensioner assembly.

Lubricate the journals and camshaft lobes.

. Secure the RH bank secondary timing chain tensioner.

Tighten the bolts to 10 Nm (7 lb.ft).

. C AUTION: Tighten the bolts evenly in 3 stages in the

sequence shown.

NOTE: Do not install the two exhaust camshaft end bearing caps at
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this stage.

NOTE: C lean the component mating faces.

Install the RH bank camshaft bearing caps.

Stage 1: Tighten to 1 Nm (1 lb.ft).

Stage 2: Tighten to 5 Nm (4 lb.ft).

Stage 3: Tighten to 10 Nm (7 lb.ft).

2 . Apply
sealant
to the
RH
exhaust
camshaft
end
bearing
cap at
the
positions
shown.

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2 . C AUTION: Tighten the bolts in the sequence shown.

NOTE: C lean the component mating faces.

Install the RH bank exhaust camshaft end bearing caps.

Stage 1: Tighten to 1 Nm (1 lb.ft).

Stage 2: Tighten to 5 Nm (4 lb.ft).

Stage 3: Tighten to 10 Nm (7 lb.ft).

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2 . Release the RH bank secondary timing chain tensioner piston.

Remove the locking pin.

30. Install the secondary timing chain to the LH bank camshafts.

31. C AUTION: Do not release the secondary timing chain

tensioner locking pin until all of the camshaft bearing caps have
been installed.

Install the LH bank secondary timing chain tensioner.

Align the marks on the camshafts with the marks on the

secondary timing chain.

32. NOTE: C lean the components.

NOTE: Install new seals.

Install the LH bank camshafts and secondary timing chain

tensioner assembly.

Lubricate the journals and camshaft lobes.

33. Secure the LH bank secondary timing chain tensioner.

Tighten the bolts to 10 Nm (7 lb.ft).

34. C AUTION: Tighten the bolts evenly in 3 stages in the

sequence shown.

NOTE: Do not install the two exhaust camshaft end bearing caps at
this stage.

NOTE: C lean the component mating faces.

Install the LH bank camshaft bearing caps.

Stage 1: Tighten to 1 Nm (1 lb.ft).

Stage 2: Tighten to 5 Nm (4 lb.ft).

Stage 3: Tighten to 10 Nm (7 lb.ft).

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3 . Appl
sealant
to the 2
LH
e haust
camshaft
end
bearing
caps at
the
positions
sho n.

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3 . C AUTION: Tighten the bolts in the sequence shown.

NOTE: C lean the component mating faces.

Install the LH bank exhaust camshaft end bearing caps.

Stage 1: Tighten the bolt to 1 Nm (1 lb.ft).

Stage 2: Tighten the bolt to 5 Nm (4 lb.ft).

Stage 3: Tighten the bolt to 10 Nm (7 lb.ft).

3 . Release the LH bank secondary timing chain tensioner piston.

Remove the locking pin.

3 . Install the fuel injection pump belt rear cover.

Tighten the bolts to 10 Nm (7 lb.ft).

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3 . Install the camshaft rear pulle .

Install a new camshaft pulle bolt.

40. Install the special tool to the camshaft rear pulle .

Install and tighten the bolt.

41. C AUTION: Tighten the bolts in the stages shown.

Secure the camshaft rear pulle .

Stage 1: Tighten the bolt to 40 Nm (30 lb.ft).

Stage 2: Tighten the bolt to 75 Nm (56 lb.ft).

42. Remove the special tools.

Remove the bolt.

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. C AUTION: Do not install the new fuel injection pump belt to

the pulleys with the fuel pump belt tensioner installed. Failure to
follow this instruction may result in damage to the fuel pump belt.

NOTE: The fuel injection pump rotates in a counter-clockwise

direction when viewed from the rear of the engine.

Install the new fuel injection pump belt.

. C AUTIONS:

Make sure that the fuel injection pump belt tensioner locking
pin is not removed until the fuel injection pump belt tensioner is fully
installed.

Make sure that the fuel injection pump belt tensioner tang is
correctly located to the fuel injection pump belt rear cover. Failure
to follow this instruction may result in damage to the engine.

Install a new fuel injection pump belt tensioner.

Locate the tang on the new fuel injection pump belt tensioner
into the fuel injection pump rear cover.

Tighten the bolt to 25 Nm (18 lb.ft).

Remove and discard the fuel injection pump belt tensioner

locking pin.

. Install the fuel injection pump belt cover.

. Install the cooling fan drive hub bearing.

Tighten the bolts to 90 Nm (66 lb.ft).

. C AUTION: Make sure that new bolts are installed.

NOTE: LH is shown, RH is similar.

NOTE: C lean the component mating faces.

Using the special tool, install the 2 camshaft pulley hubs.

Stage 1: Tighten to 80 Nm (59 lb.ft).

Stage 2: Tighten a further 90 degrees.

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4 . Install the 2 e haust camshaft pulle s.

Install the bolts, but do not tighten full at this stage.

4 . Install the special tools.

Rotate the camshafts.

50. Install the 2 timing belt idler pulle s.

Install the plastic shield behind the upper idler pulle .

Tighten the bolts to 45 Nm (33 lb.ft).

51. Rotate both camshaft pulle s clock ise.

52. Install a ne timing belt tensioner.

Install a ne bolt, but do not full tighten at this stage.

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. C AUTION: Make sure the camshaft pulle s remain in the

clockwise position.

Install the new timing belt.

Starting at the crankshaft pulle , install the timing belt in a

counter-clockwise direction, in the sequence shown.

Stage 1: Attach the timing belt to the crankshaft pulle .

Stage 2: Attach the timing belt to the idler pulle .

Stage 3: Attach the timing belt to the left-hand camshaft

pulle .

Stage 4: Attach the timing belt to the idler pulle .

Stage 5: Attach the timing belt to the RH camshaft pulle .

Stage 6: Attach the timing belt to the timing belt tensioner.

. C AUTION: Make sure the timing belt tensioner window is

aligned with the groove.

Tension the timing belt.

Rotate the tensioner assembl counter-clockwise.

Tighten the bolt to 24 Nm (18 lb.ft).

. C AUTION: Do not use the special tools to lock the

camshafts. Failure to follow this instruction ma result in damage to
the engine or the special tools.

Secure the camshaft pulle s.

Using a suitable tool, hold the camshaft pulle center bolts.

Tighten the bolts to 23 Nm (17 lb.ft).

. Remove the special tools.

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Vehicle iha oma ic an mi ion

. Remo e he pecial ool.

Remo e he bol .

Vehicle i h man al an mi ion

. Remo e he pecial ool.

Remo e he bol .

All ehicle
. Ro a e he engine o comple e n clock i e.

Vehicle iha oma ic an mi ion

0. U ing he pecial ool, lock he fle pla e.

In all a a e mo o bol o e ain he pecial ool.

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Vehicle i h man al an mi ion

1. U ing he pecial ool, lock he fl heel.

In all a a e mo o bol o e ain he pecial ool.

All ehicle
2. In all he pecial ool o he e ha cam haf p lle .

If he pecial ool doe no fi co ec l , epea he iming bel

in alla ion p oced e.

Remo e he pecial ool f om he cam haf p lle .

Vehicle iha oma ic an mi ion

3. Remo e he pecial ool.

Remo e he bol .

Vehicle i h man al an mi ion

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. Remove the special tool.

Remove the bolt.

All vehicles
. NOTE: Remove and discard the blanking caps.

Install a new fuel injector return line.

. NOTE: Remove and discard the blanking caps.

C onnect the fuel pipe to the fuel cooler.

. NOTE: Install new O-ring seals.

NOTE: C lean the component mating faces.

Install the cylinder head coolant outlet assembly.

Tighten the bolts to 10 Nm (7 lb.ft).

. NOTE: Install new O-ring seals.

Install the turbocharger oil supply line.

Tighten the bolts to 10 Nm (7 lb.ft).

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6 . Install the breather line.

Secure the clip.

Tighten the bolt to 10 Nm (7 lb.ft).

70. NOTE: C lean the component mating faces.

NOTE: Install a new gasket.

Install the brake vacuum pump.

Install the bracket.

Tighten the bolts to 23 Nm (17 lb.ft).

71. NOTE: C lean the component mating faces.

NOTE: Install a new gasket.

Install the RH valve cover.

Tighten the bolts to 10 Nm (7 lb.ft).

Secure the glow plug electrical connector in the valve cover.

Secure the knock sensor (KS) electrical connector in the

valve cover.

72. Install the RH engine cover locating studs.

Install the bracket.

Tighten the nut to 10 Nm (7 lb.ft).

Tighten the bolt to 10 Nm (7 lb.ft).

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. NOTE: C lean the component mating faces.

NOTE: Install anew gasket.

Install the LH valve cover.

Tighten the bolts to 10 Nm (7 lb.ft).

Secure the KS electrical connector in the valve cover.

. Install the LH engine cover locating studs.

. Install the fuel rail brackets.

Tighten the bolts to 23 Nm (17 lb.ft).

. Install the fuel rails.

Install the bolts, but do not tighten fully at this stage.

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Vehicles built up to 12/2007

. NOTE: Remove and discard the blanking caps.

Install the new RH fuel rail high-pressure suppl line.

Tighten the fuel injection suppl manifold retaining bolts to 23

Nm (17 lb.ft).

Stage 1: Tighten the high-pressure fuel suppl line union at

the fuel injection diverter rail to 15 Nm (11 lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line union at

the fuel rail to 15 Nm (11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line union at

the fuel injection diverter rail to 30 Nm (22 lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line union at

the fuel rail to 30 Nm (22 lb.ft).

Secure the clip.

. NOTE: Remove and discard the blanking caps.

Install the new LH fuel rail high-pressure suppl line.

Tighten the fuel injection suppl manifold retaining bolts to 23

Nm (17 lb.ft).

Stage 1: Tighten the high-pressure fuel suppl line union at

the fuel injection diverter rail to 15 Nm (11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line union at

the fuel injection diverter rail to 30 Nm (22 lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line union at

the fuel rail to 15 Nm (11 lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line union at

the fuel rail to 30 Nm (22 lb.ft).

Secure the clip.

. NOTE: Remove and discard the blanking caps.

Install the new fuel diverter rail high-pressure suppl line.

Stage 1: Tighten the high-pressure fuel suppl line union at

the fuel injection pump to 15 Nm (11 lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line union at

the fuel injection diverter rail to 15 Nm (11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line union at

the fuel injection pump to 30 Nm (22 lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line union at

the fuel injection diverter rail to 30 Nm (22 lb.ft).

Vehicles built 01/2007 onwards

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0. NOTE: Remove and discard the blanking caps.

Install the new RH fuel rail high-pressure suppl line.

Tighten the fuel injection suppl manifold retaining bolts to 23

Nm (17 lb.ft).

Stage 1: Tighten the high-pressure fuel suppl line union at

the fuel injection pump to 15 Nm (11 lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line union at

the fuel rail to 15 Nm (11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line union at

the fuel injection pump to 30 Nm (22 lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line union at

the fuel rail to 30 Nm (22 lb.ft).

Secure the clip.

1. NOTE: Remove and discard the blanking caps.

Install the new LH fuel rail high-pressure suppl line.

Tighten the fuel injection suppl manifold retaining bolts to 23

Nm (17 lb.ft).

Stage 1: Tighten the high-pressure fuel suppl line union at

the fuel injection pump to 15 Nm (11 lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line union at

the fuel rail to 15 Nm (11 lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line union at

the fuel injection pump to 30 Nm (22 lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line union at

the fuel rail to 30 Nm (22 lb.ft).

Secure the clip.

All vehicles
2. C AUTIONS:

Do not disassemble the fuel injectors or clean the no les,

even with an ultrasonic cleaner. Alwa s install new fuel injectors
when required.

Do not use tools to install the new fuel return line retaining
clip. Failure to follow this instruction will result in damage to the
retaining clip.

Install a new fuel injector clamp.

1. Install the fuel injector retaining clamp spacer.

2. Install a new fuel return line retaining clip.

3. Install a new sealing washer.

3. Install the fuel injector.

Tighten the bolts to 10 Nm (7 lb.ft).

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. Install the remaining fuel injectors.

. C AUTIONS:

Do not allow the unions to hit the olive ends of the high-
pressure fuel supply line as this may damage the ends of the line
and allow foreign matter to enter the fuel injection system.

Maintain pressure on the high-pressure fuel supply lines to

keep the olives in contact with the fuel injectors and the fuel rail
cones while installing the unions.

Do not use any aggressive cleaning fluid or a wire brush to

clean the fluid injector nozzle.

NOTE: Remove and discard the blanking caps.

Install new high-pressure fuel supply lines.

1. Install the new high-pressure fuel supply line, tighten the

fuel supply line unions finger tight.

Tighten the high-pressure fuel supply line in the sequence

shown:

Tighten the high-pressure fuel supply line union 1 to fuel

injector to 15 Nm.

Tighten the high-pressure fuel supply line union 2 to fuel rail

to 15 Nm.

Tighten the high-pressure fuel supply line union 1 to fuel

injector to 30 Nm.

Tighten the high-pressure fuel supply line union 2 to fuel rail

to 30 Nm.

. C AUTION: Make sure the fuel return line retaining clip is

correctly installed to the fuel injector before installing the return line.

C onnect the fuel return line to the fuel injectors.

Apply a light coating of petroleum jelly to the fuel return line

O-ring seals.

. Install the engine wiring harness.

Tighten the nut to 10 Nm (7 lb.ft).

Secure the clips.

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. C onnec he f el injec ion p mp elec ical connec o .

. C onnec he f el ail p e e (FRP) en o elec ical connec o .

0. In all he c ankca e en oil epa a o .

C onnec and ec e he 2 b ea he ho e .

1. C onnec he f el empe a e en o elec ical connec o .

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2. NOTE: LH sho n, RH is similar.

C onnect the 2 KS electrical connectors.

3. C onnect the engine oil temperature sensor electrical connector.

Secure the iring harness clip.

4. C onnect the camshaft position (C MP) sensor electrical

connector.

Secure the iring harness clip.

5. NOTE: RH sho n, LH is similar

C onnect the 6 fuel injector electrical connectors.

Secure the 4 iring harness clips.

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. C onnect the engine oil pressure (EOP) sensor electrical

connector.

Secure the wiring harness clip.

. Install the 2 low pressure fuel pipes.

. Install the timing belt cover.

Tighten the bolts to 10 Nm (7 lb.ft).

. Install the crankshaft pulle .

Tighten the bolts to 14 Nm (10 lb.ft).

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. Install the cooling fan pulley.

Tighten the bolts to 23 Nm (17 lb.ft).

. Install the accessory drive belt idler.

Tighten the bolt to 47 Nm (35 lb.ft).

. NOTE: C lean the component mating faces.

NOTE: Install a new O-ring seal.

Install the coolant pump.

Tighten the bolts to 10 Nm (7 lb.ft).

. Install the exhaust gas recirculation (EGR) valve coolant pipe.

Install the bolt.

C onnect the electrical connector.

Secure in the 2 clips.

Secure the clip.

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10 . C AUTION: Make sure that new nuts are installed.

NOTE: Tighten the nuts in the sequence shown.

NOTE: Install a new gasket.

Install the RH exhaust manifold and exhaust cross-over pipe

assembly.

Tighten the nuts to 24 Nm (18 lb.ft).

10 . Install the generator bracket.

Tighten the bolts to 23 Nm (17 lb.ft).

10 . Install the RH engine mount bracket.

Tighten the bolts to 110 Nm (81 lb.ft).

10 . Install the RH exhaust manifold heat shield.

Tighten the bolts to 10 Nm (7 lb.ft).

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10 . C AUTION: Tighten the bolts in the sequence shown.

Install the generator.

Tighten the bolts to 47 Nm (35 lb.ft).

10 . C onnect the generator electrical connectors.

Tighten the nut to 12 Nm (9 lb.ft).

Reposition the rubber insulator.

110. Install the RH EGR valve and cooler assembl .

Tighten the bolts to 10 Nm (7 lb.ft).

C onnect the coolant hose and secure with the clip.

C onnect the electrical connector.

Install and secure the new clip.

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. NOTE: Install a new O-ring seal.

Install the cylinder block coolant inlet pipe.

Tighten the bolts to 10 Nm (7 lb.ft).

. WARNING: Make sure that new nuts are installed.

NOTE: Tighten the nuts in the sequence shown.

NOTE: Install a new gasket.

Install the LH exhaust manifold and turbocharger assembly.

Tighten the nuts to 24 Nm (18 lb.ft).

. C AUTION: Make sure that new nuts are installed.

NOTE: Install a new gasket.

Secure the exhaust cross-over pipe to the LH exhaust manifold.

Tighten the nuts to 24 Nm (18 lb.ft).

. NOTE: Remove and discard the blanking caps.

NOTE: Install new sealing washers.

C onnect the turbocharger oil supply tube.

Tighten the banjo bolt to 30 Nm (22 lb.ft).

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11 . Secure the turbocharger support bracket.

Tighten the bolts to 23 Nm (17 lb.ft).

11 . NOTE: Remove and discard the blanking caps.

NOTE: Install a new O-ring seal.

NOTE: Install a new gasket.

Install the turbocharger oil return tube.

Tighten the bolts to 10 Nm (7 lb.ft).

11 . Install the turbocharger heat shield.

Tighten the bolts to 10 Nm (7 lb.ft).

11 . Install the LH exhaust manifold heat shield.

Tighten the bolts to 10 Nm (7 lb.ft).

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11 . NOTE: Install a new clip.

Install the LH EGR valve and cooler assembly.

Install the support bracket.

Tighten the bolts to 10 Nm (7 lb.ft).

C onnect the coolant hose and secure with the clip.

C onnect the electrical connector.

Install and secure the clip.

120. NOTE: Remove and discard the blanking caps.

NOTE: Install a new O-ring seal.

Install the oil level indicator and tube.

Tighten the bolt to 10 Nm (7 Lb.ft).

Secure the wiring harness clip.

121. Install the LH engine mount bracket.

Tighten the bolts to 110 Nm (81 lb.ft).

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. In all he ai condi ioning (A/C ) comp e o b acke .

Tigh en he bol o 23 Nm (17 lb.f ).

. In all he A/C comp e o .

Tigh en he bol o 23 Nm (17 lb.f ).

C onnec he elec ical connec o .

. In all he po e ee ing p mp b acke .

Tigh en he bol o 23 Nm (17 lb.f ).

. Remo e he engine f om he engine and.

. In all he engine.
Fo addi ional info ma ion, efe o: Engine - Vehicle Wi h: 6HP26
6-Speed A oma ic T an mi ion (303-01C Engine - TDV6 2.7L
Die el, In alla ion) /
Engine - Vehicle Wi h: Man al T an mi ion (303-01C Engine -

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TDV6 2.7L Die el, In alla ion).
12 . Fill he engine i h he ecommended oil o he co ec le el.
Fo addi ional info ma ion, efe o: Engine Oil D aining and Filling
(303-01C Engine - TDV6 2.7L Die el, Gene al P oced e ).

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - EngineVehicle Wi h: 6HP26 6-Speed A oma ic
T an mi ion
Installation

Special Tool( )
Engine lifting C radle

303-1141

In alla ion
1. C AUTIONS:

Appl grease of the correct specification to the torque

converter spigot.

Make sure the torque converter is full located into the

oil pump drive.

With assistance, carefull install the engine.

C lean the component mating faces.

C arefull guide the transmission wiring harness in as

the engine is being installed.

C arefull guide the batter positive cable in as the

engine is being installed.

2. C AUTION: Make sure the torque converter remains

connected to the transmission.

Secure the engine to the transmission.

Tighten the bolts to 45 Nm (33 lb.ft).

Remove the jack supporting the transmission.

3. Secure both the LH and the RH engine mounts.

Lower the engine onto its mounts.

Tighten the nuts to 90 Nm (66 lb.ft).

4. Remove the special tool.

Remove the bolts.

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. NOTE: Ma e e ha e b a e i a ed.

Sec e he f e ae he e c e e .

Tigh e he b 45 N (33 b.f ).

I a he acce g.

.I a he a e .

Tigh e he b 48 N (35 b.f ).

.C ec he 2 a e i i g ha e c ec
he a e e id.

Tigh e he e id e i a i eg a c ec
8 N (6 b.f ).

Tigh e he ba e i i e cab e 11 N (8 b.f ).

I a he bbe i a .

.I a he a e b ac e .

Tigh e he b 10 N (7 b.f ).

. Sec e he e gi e g d cab e.

Tigh e he b 22 N (16 b.f ).

. Sec e he f e c e .

Tigh e he b 10 N (7 b.f ).

. NOTE: Re e a d di ca d he b a i g ca .

C ec he f e i e .
. Sec e he f e i e .

Tigh e he b 22 N (16 b.f ).

Sec e i he c i .

. Sec e he a i i b ea he i e .

Tigh e he b 7N (5 b.f ).

.I a he b cha ge b ac e .

Tigh e he b 48 N (35 b.f ).

Tigh e he 22 N (16 b.f ).

. NOTE: Ma e e ha e a e i a ed.

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NOTE: Make sure that all the component mating faces are
clean.

Secure the exhaust to the turbocharger.

Install a new gasket.

Tighten the nuts to 48 Nm (35 lb.ft).

. Install the exhaust manifold crossover pipe center support

bracket.

Loosely install the 2 bolts.

. Install the exhaust manifold crossover pipe RH support

bracket.

Loosely install the 3 bolts.

. Install the exhaust manifold crossover pipe LH support

bracket.

Loosely install the 3 bolts.

. Tighten the exhaust manifold crossover pipe mounting

bracket bolts in the following sequence.

Tighten the 2 bolts marked 1 to 10 Nm (7 lb.ft).

Loosen the 2 bolts by 90 degrees.

Tighten the 2 bolts marked 3 to 10 Nm (7lb.ft).

Loosen the 2 bolts by 90 degrees.

Tighten the 4 bolts maked 2 to 25 Nm (18 lb. ft).

Tighten the 2 bolts maked 1 to 25 Nm (18 lb. ft).

Tighten the 2 bolts maked 3 to 25 Nm (18 lb. ft).

Attach the wiring harness.

. Secure the battery positive cable.

Secure with the clip.

. Secure the transmission fluid lines.

Tighten the nut to 10 Nm (7 lb.ft).

. Install the turbocharger intake tube.

Tighten the clip.

. Reposition the lower coolant hose.

. NOTE: Remove and discard the blanking caps.

C onnect the A/C compressor high-pressure line.

Install a new O-ring seal.

Tighten the bolt to 9 Nm (7 lb.ft).

. Install the charge air cooler inlet pipe.

. Position the power steering pump to the power steering
pump bracket.

Loosely install the rear bolt.

. Secure the power steering pump.

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Tighten the 3 front bolts to 22 Nm (16 lb.ft).

Loosen the 3 front bolts b a quarter of a turn.

Tighten the rear bolt to 22 Nm (16 lb.ft).

Tighten the 3 front bolts to 22 Nm (16 lb.ft).

. C onnect the coolant lower hose.

Secure with the clip.

. C onnect the charge air cooler inlet hoses.

Tighten the clips.

. NOTE: Remove and discard the blanking caps.

C onnect the A/C compressor low-pressure pipe.

Install a new O-ring seal.

Tighten the bolt to 9 Nm (7 lb.ft).

. Secure the charge air cooler inlet pipe.

Tighten the bolts to 10 Nm (7 Lb.ft).

Tighten the nut to 10 Nm (7 lb.ft).

. C onnect the breather hose.

Secure with the clip.

. Install the LH upper suspension arm and brake line heat

shields.

Tighten the bolts to 10 Nm (7 Lb.ft).

Tighten the nuts to 10 Nm (7 lb.ft).

. Install the accessor drive belt.

Rotate the accessor drive belt tensioner counter-

clockwise.

. C onnect the RH EGR coolant hose.

Secure with the clip.

. C onnect the upper coolant hose to the coolant distribution

manifold.

Install the clip.

. Install the intake air shutoff throttle elbow support

bracket.

Tighten the bolts to 10 Nm (7 Lb.ft).

. Install the intake air shut off valve.

For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).
. Install the cooling fan shroud.
For additional information, refer to: C ooling Fan Shroud
(303-03C Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).
. Install the bod .
For additional information, refer to: Bod - TDV6 2.7L Diesel
(502-02 Full Frame and Bod Mounting, Removal and
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Installation).
1. Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

2. C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

Engine - TDV6 2.7L Die el - EngineVehicle Wi h: Man al T an mi ion
Installation

Special Tool( )
Engine lifting C radle

303-1141

In alla ion
1. With assistance, install the engine to the transmission.

C lean the component mating faces.

C arefull guide the transmission wiring harness in as

the engine is being installed.

2. Secure the engine to the transmission.

Tighten the bolts to 45 Nm (33 lb.ft).

3. Install the starter motor bolts.

Tighten the bolts to 48 Nm (35 lb.ft).

4. NOTE: Note the position of the steering column lower shaft.

Install the engine and transmission assembl .

5. Remove the special tool.

6. Install the transmission support insulator bolt and tighten to

175 Nm (129 lb.ft).
7. Secure both the LH and the RH engine mounts.

Tighten the nuts to 90 Nm (66 lb.ft).

8. Secure the engine ground cable.

Tighten the bolt to 22 Nm (16 lb.ft).

9. NOTE: Remove and discard the blanking caps.

C onnect the fuel lines.

10. Secure the transmission breather lines.

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Tighten the bolt to 7 Nm (5 lb.ft).

. Install the turbocharger support bracket.

Tighten the bolts to 48 Nm (35 lb.ft).

Tighten the nut to 22 Nm (16 lb.ft).

. WARNING: Make sure that new nuts are installed.

NOTE: Make sure that all the component mating faces are
clean.

Secure the exhaust to the turbocharger.

Install a new gasket.

Tighten the nuts to 48 Nm (35 lb.ft).

. Install the exhaust manifold crossover pipe center support

bracket.

Loosely install the 2 bolts.

. Install the exhaust manifold crossover pipe RH support

bracket.

Loosely install the 3 bolts.

. Install the exhaust manifold crossover pipe LH support

bracket.

Loosely install the 3 bolts.

. Tighten the exhaust manifold crossover pipe mounting

bracket bolts in the following sequence.

Tighten the 2 bolts marked 1 to 10 Nm (7 lb.ft).

Loosen the 2 bolts by 90 degrees.

Tighten the 2 bolts marked 3 to 10 Nm (7lb.ft).

Loosen the 2 bolts by 90 degrees.

Tighten the 4 bolts maked 2 to 25 Nm (18 lb. ft).

Tighten the 2 bolts maked 1 to 25 Nm (18 lb. ft).

Tighten the 2 bolts maked 3 to 25 Nm (18 lb. ft).

Attach the wiring harness.

. Secure the battery positive cable.

Secure with the clip.

. Install the turbocharger intake tube.

Tighten the clip.

. Reposition the lower coolant hose.

. NOTE: Remove and discard the blanking caps.

C onnect the A/C compressor high-pressure line.

Install a new O-ring seal.

Tighten the bolt to 9 Nm (7 lb.ft).

. Install the charge air cooler inlet pipe.

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. Position the power steering pump to the power steering
pump bracket.

Loosel install the rear bolt.

. Secure the power steering pump.

Tighten the 3 front bolts to 22 Nm (16 lb.ft).

Loosen the 3 front bolts b a quarter of a turn.

Tighten the rear bolt to 22 Nm (16 lb.ft).

Tighten the 3 front bolts to 22 Nm (16 lb.ft).

. C onnect the coolant lower hose.

Secure with the clip.

. C onnect the charge air cooler inlet hoses.

Tighten the clips.

. NOTE: Remove and discard the blanking caps.

C onnect the A/C compressor low-pressure pipe.

Install a new O-ring seal.

Tighten the bolt to 9 Nm (7 lb.ft).

. Secure the charge air cooler inlet pipe.

Tighten the bolt to 10 Nm (7 lb.ft).

Tighten the nuts to 10 Nm (7 lb.ft).

. C onnect the breather hose.

Secure with the clip.

. Install the LH upper suspension arm and brake line heat

shields.

Tighten the bolts to 10 Nm (7 lb.ft).

Tighten the nuts to 10 Nm (7 lb.ft).

. Install the accessor drive belt.

Rotate the accessor drive belt tensioner counter-

clockwise.

. C onnect the RH EGR coolant hose.

Secure with the clip.

. C onnect the upper coolant hose to the coolant distribution

manifold.

Install the clip.

. Install the intake air shutoff throttle elbow support

bracket.

Tighten the bolts to 10 Nm (7 Lb.ft).

. Install the intake air shut off valve.

For additional information, refer to: Intake Air Shutoff
Throttle (303-04C Fuel C harging and C ontrols - TDV6 2.7L
Diesel, Removal and Installation).

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. Install the cooling fan shroud.
For additional information, refer to: C ooling Fan Shroud
(303-03C Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).
. Install the bod .
For additional information, refer to: Bod - TDV6 2.7L Diesel
(502-02 Full Frame and Bod Mounting, Removal and
Installation).
. NOTE: Install new bolts.

Secure the front driveshaft to the transfer case drive flange.

Install the washers.

Stage 1: Tighten the bolts to 45 Nm (40 lb.ft).

Stage 2: Tighten the bolts a further 90 degrees.

. Secure the rear driveshaft to the transfer case drive

flange.

Install the washers.

Tighten the bolts to 55 Nm (40 lb.ft).

. Install the wheels and tires.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

0. C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 27-Jun-2011
Engine Cooling - V6 4.0L Petrol -
Fluids
Item Specification
* Anti-freeze Havoline Extended Life C oolant (XLC ) or any ethylene glycol based anti-
freeze containing no methanol with only Organic Acid Technology (OAT)
corrosion inhibitors
Anti-freeze concentration - Will provide 50%
frost protection to -40°C (-40°F)
Specific gravity of coolant at 20°C 1.068
(68°F), to protect against frost down to
-40°C (-40°F)
Amount of anti-free e to use for
50% concentration:
Without rear passenger compartment 4.2 litres (6.7 pints) (4.0 US quarts)
heater
With rear passenger compartment 5.6 litres (8.9 pints) (5.35 US quarts)
heater

C AUTION: No other anti-freeze should be used with Havoline Extended Life C oolant.
Capacit
Item Capacit
Without rear passenger compartment heater 8.4 litres (13.4 pints) (8.0 US quarts)
With rear passenger compartment heater 11.1 litres (17.8 pints) (10.7 US quarts)
General Specif ications
Item Specification
C ooling system type Pressurised, thermostatically controlled with remote header tank
Radiator C ross flow with integral transmission oil cooler
Expansion tank Remote - fitted with a bleed screw and low coolant level sensor
Pressure cap rating 110 kPa (1.1 bar) (16 lbf/in )
Thermostat:
Starts to open 88° C (190° F)
Fully open 95° C (203° F)
C ooling fan Engine driven, viscous coupled with electronic control
C ooling fan diameter 470 mm (18.5 in)
Direction of rotation C ounter clockwise
C oolant pump C entrifugal flow impellor, belt driven from crankshaft
Torque Specif ications
Description Nm lb-ft
C oolant pump bolts 10 7
C oolant pump pulley bolts 25 18
Power steering pipe clip bolt 10 7
C oolant expansion tank bolt 10 7
Vacuum pump bolts 10 7
Radiator bolts 25 18
Air C onditioning (A/C ) condenser bolt 6 4
Radiator access panel bolts 10 7
C ooling fan viscous coupling bolts 10 7
C ooling fan assembly 65 48
C oolant bleed screw(s) 3 2

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Published: 11-Ma -2011

Engine Cooling - V6 4.0L Pe rol - Engine Cooling
Description and Operation

C ooling S stem C omponent La out

I em Pa N mbe
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
De c ip ion
Heater hose, inlet and outlet
Heater hose, inlet and outlet for vehicles with rear heater (optional)
Hose, radiator to intake manifold
Radiator top hose
Engine C oolant Temperature (EC T) sensor
Water pump
Throttle bod
Inlet manifold

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9 - Throttle body coolant hose
10 - Hose, engine to expansion tank
11 - Expansion tank
12 - Radiator bottom hose
13 - Engine oil cooler (if fitted)
14 - Hose (for vehicles without engine oil cooler)
15 - Hose, inlet and outlet (for vehicles with engine oil cooler)
16 - C ooling fan
17 - Transmission oil cooler pipes
18 - Radiator cowl, lower
19 - Radiator
20 - Radiator cowl, upper

GENERAL

The cooling system employed is of the pressure relief by-pass type, which allows coolant to circulate around the
engine and the heater circuit while the thermostat main valve is closed. The primary function of the cooling system is
to maintain the engine within an optimum temperature range under changing ambient and engine operating
conditions. Secondary functions are to provide heating for the passenger compartment and cooling for the
transmission fluid and engine oil.

The cooling system comprises:

A radiator
A passenger compartment heater matrix
An Engine Oil C ooler (EOC )
A coolant pump
A Pressure Relief Thermostat (PRT)
An expansion tank
A viscous fan
C onnecting hoses and pipes.

ENGINE COOLING S STEM

The coolant is circulated by a centrifugal pump mounted on the front of the engine and driven by an ancillary drive
'polyvee' belt. The coolant pump circulates coolant through the cylinder block and cylinder heads via a chamber
located in the 'vee' of the engine. Having passed through the engine the coolant returns to the thermostat housing via
the bypass pipe. C oolant also circulates through the top hose to the heater matrix. The coolant returns via the EOC to
the engine side of the PRT.

The PRT housing contains a normal thermostat, which is positioned such that the wax's temperature is controlled by
both the coolant from the radiator and the bypass. This results in the thermostat being able to vary its opening
temperature dependant on ambient conditions. The PRT also contains a sprung loaded valve, which limits the amount
flow using the bypass. This means that the engine can run without coolant flowing through the bypass temporarily, to
improve heater performance.

The radiator is a cross flow type with an aluminium matrix and has a drain tap on the lower right-hand rear face. The
lower radiator mountings are located part way up the end tanks. The mountings are fitted with rubber bushes, which
sit on the upper chassis rails. The radiator upper is mounted by pins, which are pushed through rubber bushes
mounted in the Front End C arrier (FEC ) above the radiator. The radiator also incorporates two connections for the
transmission oil cooler pipes.

The radiator top hose is connected to the PRT by the bypass hose and the bottom hose is directly connected to the
outlet side of the thermostat housing.

The expansion tank is fitted forward of the LH suspension turret in the engine compartment. The expansion tank
allows for the expansion of the coolant as the engine gets hot and also supplies the engine with coolant as the coolant
in the engine contracts. The tank also allows any air trapped in the coolant to be removed.

The liquid cooled transmission fluid cooler is mounted in the cold side radiator end tank. It is positioned in the middle
of the LH end tank.

For additional airflow through the radiator matrix, particularly when the vehicle is stationary, there is an engine driven
Viscous fan unit fitted to the rear of the radiator. The fan is used for engine cooling and for Air C onditioning (A/C )
system cooling. The fan is mounted using a left hand thread.

The viscous fan unit is electronically controlled by the EC M to optimise fan speed for all operating conditions.

NOTE: If the electrical connections to the viscous fan are disconnected the fan will 'idle' and overheating may result.
The EC M stores the appropriate fault codes in this case.

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ENGINE COOLING S STEM OPERATION

C ooling S stem C oolant Flow, Without Engine Oil C ooler

C ooling S stem C oolant Flow, With Engine Oil C ooler

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When the engine is running the coolant pump is driven by the ancillary drive belt. This forces coolant to circulate
around the engine, heater and EOC , while the thermostat and bypass valve are shut. As the temperature and
pressure increases the bypass valve is forced open allowing coolant to circulate through the bypass valve. When the
temperature reaches 82 C (180 F) the main thermostat begins to open, allowing coolant to circulate through the main
radiator. As the thermostat progressively opens (fully open at 95 C (203 F)), the bypass valve progressively closes
forcing any coolant through the heater or radiator. Once coolant is allowed to circulate through the radiator, the
transmission fluid cooler begins to receive coolant flow.

The increased coolant volume, created by heat expansion, is directed to the expansion tank through a bleed hose
from the top of the radiator. The expansion tank has an outlet hose which is connected into the coolant circuit. This
outlet hose returns the coolant to the system when the engine cools.

C oolant flows through the radiator from the top right hand tank to the bottom left hand tank and is cooled by air
passing through the matrix. The temperature of the cooling system is monitored by the Engine C ontrol Module (EC M)
via the Engine C oolant temperature (EC T) sensor located in the cylinder head. The EC M uses signals from this sensor
to adjust fuelling according to engine temperature.
For additional information, refer to: Electronic Engine C ontrols (303-14A Electronic Engine C ontrols - V6 4.0L Petrol,
Description and Operation).
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To control the cooling fan, the EC M sends a Pulse Width Modulated (PWM) signal to the cooling fan module (integral to
the EC M). The frequency of the PWM signal is used by the cooling fan module to determine the output voltage
supplied to the fan motor.

The EC M varies the duty cycle of the PWM signal between 0 and 100% to vary the fan speed. If the PWM signal is
outside the 0 to 100% range, the cooling fan module interprets the signal as an open or short circuit and runs the fans
at maximum speed to ensure the engine and gearbox do not overheat.

The speed of the cooling fan is also influenced by vehicle road speed. The EC M adjusts the speed of the cooling fans,
to compensate for the ram effect of vehicle speed, using the C ontroller Area Network (C AN) road speed signal
received from the Anti-lock Braking System (ABS) module.

P e e Relief The mo a (PRT)

The thermostat is exposed to 85% hot coolant from the engine on one side and 15% cold coolant returning from the
radiator bottom hose on the other side. This allows the thermostat to react to the ambient conditions and provide
coolant control for both winter and summer use. Hot coolant from the engine passes via holes in the by-pass flow
valve into a tube which surrounds 85% of the thermostat sensitive area. C old coolant from the radiator conducts
through the remaining 15% of the sensitive area. In cold ambient conditions, the engine temperature is raised by
approximately 10 C (50 F) to compensate for the heat loss of 15% exposure to the cold coolant returning from the
bottom hose. This improves heater performance and engine warm-up.

The by-pass flow valve is held closed by a light spring and operates to further assists engine and heater warm-up.
When the main valve is closed and the engine speed is at idle, the coolant pump does not produce sufficient flow and
pressure to overcome the spring and open the valve. In this condition the valve prevents coolant circulating through
the by-pass circuit and directs coolant through the heater matrix only. This provides a higher flow of coolant through
the heater matrix improving passenger comfort in cold conditions.

When the engine speed increases above idle, the coolant pump produces a greater flow and pressure than the heater
circuit can accommodate. The build up of pressure acts on the flow valve, overcoming the spring pressure, opening
the valve and relieving the pressure in the heater circuit. The valve then modulates to provide maximum coolant flow
through the heater matrix and allowing excess coolant to flow into the by-pass circuit to provide the engine's cooling
requirements at higher engine speeds. The thermostat then regulates the flow through the radiator to maintain the
engine at the optimum temperature. Maximum opening of the thermostat, and therefore maximum flow through the
radiator, occurs if the coolant temperature reaches 95 C (203 F).

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Published: 11-May-2011
Engine Cooling - V6 4.0L Petrol - Engine Cooling
Diagnosis and Testing

Inspection and verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection
Mechanical Electrical
C oolant leaks Fuses
C oolant Hoses Wiring harness
C oolant expansion tank Loose or corroded connector(s)
Radiator Engine coolant temperature (EC T) sensor
Heater core
Accessory drive belt
Viscous fan

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTC s) before
moving onto the symptom chart or DTC index.

Make sure that all DTC s are cleared following rectification

S mptom chart

S mptom Possible cause Action

C oolant loss Hoses C arry out a visual inspection. If there are no obvious leaks, carry out a
Hose connections pressure test using your workshop tester. Rectify as necessary. Refer ti the
Radiator relevant section of the workshop manual.
Water pump
Heater core
Gaskets
Engine casting
cracks
Engine block core
plugs

Overheating Low/C ontaminated C heck the coolant level and condition. C heck the thermostat and rectify as
coolant necessary. C arry out a cooling system pressure test. C heck the viscous fan
Thermostat operation, make sure the viscous fan rotates freely. C heck for obstructions to
Viscous fan the air flow over the radiator. Rectify as necessary. Refer to the relevant
EC T sensor section of the workshop manual.
Restricted air flow
over the radiator

Engine not Thermostat C heck the thermostat operation. C heck the viscous fan operation, make sure
reaching Viscous fan the viscous fan is not seized.
normal
temperature

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

DTC Description Possible causes Action

P011623 Engine C oolant Low coolant level C heck the coolant level and the thermostat operation
Temperature Engine thermostat (stuck open). Refer to the relevant section of the workshop
Sensor 1 C ircuit failure manual. Refer to the guided diagnostic routine for this code
Range/Performance EC T sensor sensing on the approved diagnostic system.
circuit intermittent
high resistance
EC T sensor failure
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P011624 Engine C oolant Low coolant level C heck the coolant level and the thermostat operation
Temperature Engine coolant (stuck open). Refer to the relevant section of the workshop
Sensor 1 C ircuit thermostat failure manual. Refer to the guided diagnostic routine for this code
Range/Performance EC T sensor sensing on the approved diagnostic s stem.
circuit intermittent
high resistance
EC T sensor failure

P011629 Engine C oolant Low coolant level C heck the coolant level and the thermostat operation
Temperature Engine coolant (stuck open). Refer to the relevant section of the workshop
Sensor 1 C ircuit thermostat failure manual. Refer to the guided diagnostic routine for this code
Range/Performance EC T sensor sensing on the approved diagnostic s stem.
circuit intermittent
high resistance
EC T sensor failure

P011700 Engine C oolant EC T sensor Refer to the guided diagnostic routine for this code on the
Temperature disconnected approved diagnostic s stem.
Sensor 1 C ircuit Engine coolant
Low temperature (EC T)
sensor sensing circuit
high resistance, short
circuit to power
EC T sensor failure

P011800 Engine C oolant Engine overheat C heck the coolant level and the thermostat operation
Temperature condition/cooling fan (stuck closed). C heck for cooling fan DTC s. Refer to the
Sensor 1 C ircuit failure guided diagnostic routine for this code on the approved
High EC T sensor wiring diagnostic s stem.
short circuit to
ground
EC T sensor failure

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P bli hed: 11-Ma -2011

Engine Cooling - V6 4.0L Petrol - Cooling S stem Draining, Filling and Bleeding
Gene al P oced e

WARNING: Since inj ch a calding co ld be ca ed b e caping eam o coolan , do no emo e he fille

cap f om he coolan e pan ion ank hile he em i ho .

All ehicle
1. Po i ion he ehicle on a lif .
2. Se he hea e con ol o ma im m.
3. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
4. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V6 4.0L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).

5. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

Remo e he coolan e pan ion ank cap.

6. Remo e he f on LH pla h hield.

Remo e he 4 clip .

7. Remo e he adia o acce panel.

Remo e he 4 bol .

8. Po i ion a con aine o collec he fl id.

9. C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Relea e he clip and di connec he adia o lo e ho e,

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allo he coolan o d ain.

Vehicle iha ilia clima e con ol

. Remo e he pa e heel and i e.

Remo e he ool ki .

Acce he inch.

. Po i ion a con aine o collec he fl id.

. Di connec he ea hea e coolan ho e .

Relea e he 2 clip .

Allo he coolan o d ain.

Vehicle iha ilia clima e con ol

. C onnec he ea hea e coolan ho e .

Sec e he clip .

. In all he pa e heel and i e.

S o he ool ki .

. C onnec and ec e he adia o lo e ho e.

Sec e i h he clip.

All ehicle
. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
. C onnec e ha e ac ion ho e o he ail pipe .
. Loo en he coolan e pan ion ank bleed c e .

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. Refi he c i g e .
.S a a d he e gi e.

H d he e gi e eed a 2,500 RPM f 30 ec d .

Re he e gi e id e f 30 ec d .

Re ea he ab e ced e af he f i e .

. Fi he c i g e , ee i g c a he e e e
a f he e a i a i a ead ea fc a
i ee e i g he e a i a . Tigh e he
e a i a b eed c e .

H d he e gi e eed a 3,000 RPM f e i e.

. NOTE: Whe he c a b eed i c e e a d i

i a i g he e a i a ca , - he e a i a
30 ab e he a i e e.

I a he c a e a i a ca .
.R he e gi e i he he a e .
. S i ch he e gi e ff a d a c .
.I a he e gi e c e .
F addi i a i f a i , efe : E gi e C e - V6 4.0L
Pe (501-05 I e i T i a d O a e a i , Re a
a dI a a i ).
. C ea a e ai i g c a f he cha i a d
di g a ea.
.I a he adia acce a e.

Tigh e he 4 b 10 N (7 b.f ).

.I a he f LH a h hie d.
. C hec a d - he c a if e i ed.

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Published: 11-May-2011
Engine Cooling - V6 4.0L Petrol - Cooling S stem Draining and Vacuum Filling
General Procedures

WARNING: To avoid having scalding hot coolant or steam blowing out of the cooling system, use extreme care
when removing the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a
thick cloth around the coolant pressure cap and turn it slowly until the pressure begins to release. Step back while the
pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and
remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may result in
personal injury.

C AUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the vehicle.

Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the
area with water.

1. Set the heater controls to maximum HOT.

2. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, do not remove the filler
cap from the coolant expansion tank while the system is hot.

Remove the coolant expansion tank cap.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the front LH splash shield.

Remove the 4 clips.

5. Remove the radiator access panel.

Remove the 4 bolts.

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. Po i ion a con aine o collec he fl id.
. Di connec he coolan ho e f om he he mo a
ho ing.

Relea e he 2 clip .

Allo he coolan o d ain.

. Remo e he pa e heel and i e.

Remo e he ool ki .

Acce he inch.

. Po i ion a con aine o collec he fl id.

. Di connec he ea hea e coolan ho e .

Relea e he 2 clip .

Allo he coolan o d ain.

. C onnec he ea hea e coolan ho e .

Sec e he clip .

. In all he pa e heel and i e.

In all he ool ki .

. C onnec he coolan ho e o he he mo a ho ing.

Sec e i h he clip .

. P epa e a fficien amo n of coolan o he pecified

concen a ion.
. In all he cooling em ac m efill adap o o he
e pan ion ank.

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1 . Install the vacuum filler gauge to the cooling system

vacuum refill adaptor.

1 . Install the venturi tube assembly to the vacuum filler

gauge.

1 . NOTE: Make sure both valves on gauge assembly are in

the closed position.

NOTE: Small diameter or long airlines may restrict airflow

to the coolant vacuum fill tool.

NOTE: The coolant vacuum fill tool needs an air pressure

of 6 to 8 bar (87 to 116 psi) to operate correctly.

C onnect a regulated compressed air supply to the venturi

tube assembly.

1 . NOTE: Make sure air cannot enter the hose.

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Position the coolant pick-up pipe into a container of clean
coolant.
. Position the evacuated air hose into a container.
. Open the air suppl valve.

. Open the coolant suppl valve for 2 seconds to prime

the coolant suppl hose.

. Appl air pressure progressivel until the arrow on the

vacuum filler gauge reaches the green segment.

. C lose the air suppl valve.

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2 . Allo one min e o check he ac m i held.

Di connec he comp e ed ai ppl .

2 . NOTE: C lo e he coolan ppl al e hen he coolan

e pan ion ank MAX ma k i eached o coolan mo emen
ha cea ed.

Open he coolan ppl al e and allo he coolan o be

d a n in o he em.

2 . Remo e he ac m fille ga ge and cooling em

ac m efill adap o a embl .
2 . C onnec e ha e ac ion ho e o he ail pipe .
2 .S a and n he engine.

Hold he engine peed a 2,500 RPM fo 30 econd .

Re n he engine o idle fo 30 econd .

Repea he abo e p oced e af he 4 ime .

30. Keep he coolan le el in he e pan ion ank a he

ma im m le el ma k n il a ead eam of coolan can
be een e ning.
31. NOTE: When he coolan bleed i comple e and p io o
in alling he e pan ion ank cap, op- p he e pan ion ank o
30mm abo e he ma im m le el.

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I .
.R .
.S .
.C .
.I .

1. T 2 10 N (7 . ).

2. T 2 62 N (46 . ).

.I LH .

I 4 .

. WARNING: S
,

C - .

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Published: 11-May-2011
Engine Cooling - V6 4.0L Petrol - Cooling S stem Pressure Test
General Procedures

NOTE: The following procedure will enable the cooling system to be pressure tested for condition and leaks. Stage 1
will check the expansion tank cap register seal and the cap for leaks. Stage 2 will check the entire cooling system.

NOTE: It will be necessary to use the cooling system test kit, Part Number LR-218, which is available under the
equipment programme.

1. Examine the coolant hoses for signs of cracking, distortion

and security of the hose connections.

2. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.

Disconnect the coolant expansion tank bleed hose.

Release the clip.

3. Install the 'T' piece adaptor (part of the cooling system test
kit) between the coolant expansion tank and the coolant
bleed hose.

Secure with the 2 clips.

4. Install the coolant pressure pump assembly.

C onnect to the 'T' piece.

5. Pressurize the cooling system.

Slowly pressurize the cooling system to 1.0 bar (100

kPa) (14.5 psi).

C heck the pressure remains above 0.9 bar (90 kPa)

(13 psi) after waiting for 30 seconds.

During the pressure drop check, listen for a hissing

noise from the expansion tank cap.

6. NOTE: If the coolant expansion tank cap is found to be

leaking, replace the cap.

Depressurize the cooling system.

Disconnect the 'T' piece.

C onnect the coolant expansion tank bleed hose.

Secure the clip.

7. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.
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Remove the coolant expansion tank cap.
. NOTE: This adaptor is part of the cooling system test kit.

Install adaptor K83 to the coolant expansion tank.

C lean the component mating faces.

Lubricate the seal.

. Install the coolant pressure pump assembly.

Slowly pressurize the cooling system to 1.5 bar

(150kPa) (22 psi), check the pressure over a 5
minute period. A small pressure decay of
approximately 0.15 bar (15 kPa) (1 psi) over the
first minute is normal, as the air in the expansion
tank cools.

If the pressure continues to drop after the initial

tolerance, there is a coolant leak.

10. Depressurize and remove the pressure pump and

gauge.

Install the coolant expansion tank cap.

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P bli hed: 11-Ma -2011

Engine Cooling - V6 4.0L Petrol - Coolant E pansion Tank
Remo al and In alla ion

Removal
1. Remo e he LH headlamp a embl .
Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).
2. Relea e he ind hield a he e e oi fille neck.
3. Relea e he coolan e pan ion ank.

Remo e he 2 bol .

4. Relea e he po e ee ing fl id e e oi .

5. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he
fille cap f om he coolan e pan ion ank hile he em
i ho .

C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Di connec he 2 ho e f om he coolan e pan ion ank.

Po i ion an ab o ben clo h o collec fl id pillage.

Po i ion a con aine o collec he fl id.

C lamp he ho e

Relea e he 2 clip .

6. Remo e he coolan e pan ion ank.

Di connec he coolan lo le el en o elec ical

connec o .

7. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he coolan lo le el en o .

Remo e he coolan e pan ion ank ppo b acke .

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In alla ion
1. In all he b acke .
2. In all he coolan lo le el en o .
3. In all he coolan e pan ion ank.

C onnec he coolan lo le el en o elec ical

connec o .

4. C onnec he coolan ho e o he e pan ion ank.

Sec e i h he clip .

5. Top- p he coolan .

Loo en he coolan e pan ion ank bleed c e .

Fill he coolan e pan ion ank n il coolan eme ge

f om he cooling em ai bleed c e .

Remo e he ho e clamp .

Tigh en he bleed c e o 8 Nm (6 lb.f ).

6. Sec e he coolan e pan ion ank.

Tigh en he bol o 10 Nm (7 lb.f ).

7. C heck and op- p he coolan .

In all he coolan e pan ion ank p e e cap.

8. Sec e he po e ee ing fl id e e oi .

A ach o he mo n ing b acke .

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. Sec e he ind hield a he e e oi fille neck.

Loca e in clip.

10. In all he LH headlamp a embl .

Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).

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Engine Cooling - V6 4.0L Petrol - Cooling Fan
Removal and Installation

Special Tool(s)
Viscous coupling spanner

303-1142

Viscous coupling pulle retaining

tool

303-1167

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the cooling fan shroud.
For additional information, refer to: C ooling Fan Shroud
(303-03A Engine C ooling - V6 4.0L Petrol, Removal and
Installation).
3. Disconnect the cooling fan control electrical connector.

4. NOTE: The thread is right handed.

Using the special tools, remove the cooling fan.

Remove the cooling fan assembl .

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5. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the viscous coupling from the cooling fan.

Remove the 4 bolts.

In alla ion
1. To install, reverse the removal procedure.

Install the cooling fan to the viscous coupling, tighten

the bolts to 10 Nm (7 lb.ft).

Tighten the cooling fan assembl to 65 Nm (48 lb.ft).

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Engine Cooling - V6 4.0L Pe ol - Cooling Fan Sh o d
Remo al and In alla ion

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he ai in ake e ona o .
Fo addi ional info ma ion, efe o: In ake Ai Re ona o
(303-12A In ake Ai Di ib ion and Fil e ing - V6 4.0L
Pe ol, Remo al and In alla ion).
3. Remo e he ppe fan h o d.

Relea e he coolan e pan ion ho e.

Relea e he fan i ing ha ne clip.

Relea e he 4 fan h o d clip .

In alla ion
1. To in all, e e e he emo al p oced e.

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P bli hed: 11-Ma -2011

Engine Cooling - V6 4.0L Petrol - Engine Coolant Le el S itch
Remo al and In alla ion

Remo al
1. Relea e he po e ee ing fl id e e oi f om he
b acke .

2. Relea e he ind hield a he e e oi fille neck.

3. Repo i ion he coolan e pan ion ank.

Remo e he 2 bol .

4. Remo e he engine coolan le el i ch.

Di connec he engine coolan le el i ch elec ical

connec o .

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In alla ion
1. NOTE: An a dible click can be hea d hen he engine
coolan le el i ch i co ec l in alled.

In all he engine coolan le el i ch.

C onnec he engine coolan le el i ch elec ical

connec o .

2. C AUTION: Make e ha he componen i co ec l

loca ed on he loca ing peg .

Sec e he coolan e pan ion ank.

Tigh en he bol o 10 Nm (7 lb.f ).

3. Sec e he ind hield a he e e oi fille neck.

4. Sec e he po e ee ing fl id e e oi o he b acke .

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Published: 11-May-2011
Engine Cooling - V6 4.0L Petrol - Radiator
Removal and Installation

Remo al

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler
cap from the coolant expansion tank while the system is hot.

C AUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and
clean the area with water.

NOTE: Always protect the cooling pack elements to prevent accidental damage.

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Disconnect the battery ground cable.
For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
3. Drain the cooling system.
For additional information, refer to: C ooling System
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
4. Remove the viscous fan assembly.
For additional information, refer to: C ooling Fan (303-03A
Engine C ooling - V6 4.0L Petrol, Removal and Installation).
5. Remove the radiator grille.
For additional information, refer to: Radiator Grille (501-08
Exterior Trim and Ornamentation, Removal and
Installation).
6. Remove the lower fan shroud.

Release the 4 clips.

Release the coolant hose.

7. Disconnect the coolant expansion tank hose.

Release the clip.

8. Disconnect the radiator upper hose.

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Release the clip.

. C AUTION: Always plug any open connections to

prevent contamination.

NOTE: Some fluid spillage is inevitable during this

operation.

Disconnect the transmission cooler hoses.

Release the 2 clips.

Position a container to collect the fluid.

10. Remove the radiator securing pegs.

11. Remove the radiator upper deflector.

Release the 2 clips.

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. Release the po er steering fluid cooler.

Release the clips.

Tie the line aside.

. Release the front differential breather line.

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1 . Release the A/C condenser.

Remo e the 2 scre s.

Remo e the bolt.

Release from the 2 clips.

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15. Remo e he adia o .

P o ec he elemen f om damage.

Remo e he 2 adia o e aining bol .

16. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he po e ee ing fl id coole line clip.

In alla ion
1. In all he po e ee ing fl id coole line clip.
2. In all he adia o .

Remo e he elemen p o ec ion.

Tigh en he bol o 25 Nm (18 lb.f ).

3. In all he adia o ppe deflec o .

4. In all he A/C conden e .

Sec e in he clip .

Tigh en he c e .

Tigh en he bol o 6 Nm (4 lb.f ).

5. In all he po e ee ing fl id coole .

Sec e in he 3 clip .

6. In all he adia o ec ing peg .

7. In all he an mi ion coole ho e .

In all he clip .

8. C onnec he adia o ppe ho e.

Sec e i h he clip.

9. C onnec he e pan ion ank ho e.

Sec e i h he clip.

10. In all he lo e fan h o d.

Sec e in he clip .

Sec e he coolan ho e.

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. Install the radiator grille.
For additional information, refer to: Radiator Grille (501-08
E terior Trim and Ornamentation, Removal and
Installation).
. Install the viscous fan assembl .
For additional information, refer to: C ooling Fan (303-03A
Engine C ooling - V6 4.0L Petrol, Removal and Installation).
. Refill the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. C heck automatic transmission fluid level.
For additional information, refer to: Transmission Fluid Level
C heck (307-01B Automatic Transmission/Transa le - V8
4.4L Petrol, General Procedures).

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Published: 11-Ma -2011

Engine Cooling - V6 4.0L Petrol - Thermostat
Removal and Installation

Remo al
1. Drain the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Petrol, General Procedures).
2. Remove the thermostat.

Release the clips and disconnect the 4 remaining

coolant hoses.

Installation
1. To install, reverse the removal procedure.
2. Refill the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Petrol, General Procedures).
3. NOTE: For NAS vehicles onl .

If required, carr out a long drive c cle.

For additional information, refer to: Powertrain C ontrol
Module (PC M) Long Drive C cle Self-Test (303-14A
Electronic Engine C ontrols - V6 4.0L Petrol, General
Procedures).

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P bli hed: 11-Ma -2011

Engine Cooling - V6 4.0L Pe rol - Coolan P mp
Remo al and In alla ion

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

D ain he cooling em.

Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Pe ol, Gene al P oced e ).
4. Remo e he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05A Acce o D i e - V6 4.0L Pe ol, Remo al and
In alla ion).
5. Remo e he bol f om he po e ee ing pipe clip.

Po i ion he pipe a ide hen emo ing he coolan

p mp.

6. Remo e he coolan p mp.

Di connec he coolan ail ho e f om he coolan

p mp.

Remo e he 12 bol .

Di ca d he ga ke .

7. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he coolan p mp d i e p lle .

Remo e and di ca d he 4 bol .

Remo e he coolan p mp capping ho e.

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In alla ion
1. To install, reverse the removal procedure.

Install the coolant pump pulle .

C lean the component mating faces.

Install a new gasket.

2. Tighten the coolant pump retaining bolts.

Tighten to 10 Nm (7 lb.ft).

3. Tighten the coolant pump pulle retaining bolts.

Tighten to 25 Nm (18 lb.ft).

4. Install the power steering pipe.

Tighten the bolt to 10 Nm (7 lb.ft).

5. Install the accessor drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
6. Refill the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03A Engine C ooling - V6
4.0L Petrol, General Procedures).
7. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 27-Jun-2011
Engine Cooling - V8 4.4L Petrol -
Fluids
Item Specification
* Anti-freeze Havoline Extended Life C oolant (XLC ) or any ethylene glycol based anti-
freeze containing no methanol with only Organic Acid Technology (OAT)
corrosion inhibitors
Anti-freeze concentration - Will provide 50%
frost protection to -40°C (-40°F)
Specific gravity of coolant at 20°C 1.068
(68°F), to protect against frost down to
-40°C (-40°F)
Amount of anti-free e to use for
50% concentration:
Without rear passenger compartment 4.6 litres (8.1 pints) (4.9 US quarts)
heater
With rear passenger compartment 6.0 litres (10.6 pints) (5.3 US quarts)
heater

C AUTION: No other anti-freeze should be used with Havoline Extended Life C oolant.
Capacit
Item Capacit
Without rear passenger compartment 9.3 litres (16.3 pints) (9.8 US quarts)
With rear passenger compartment 12.05 litres (21.2 pints) (10.6 US quarts)
General Specif ications
Item Specification
C ooling system type Pressurised, thermostatically controlled with remote header tank
Radiator C ross flow with integral transmission fluid cooler
Expansion tank Remote - fitted with a bleed screw and low coolant level sensor
Pressure cap rating 110 kPa (1.1 bar) (16 lbf/in )
Thermostat:
Starts to open 88° C (190°F)
Fully open 95° C (203° F)
C ooling fan Engine driven, viscous coupled with electronic control
C ooling fan diameter 500 mm (19.6 in)
Direction of rotation C lockwise when viewed from front of engine
C oolant pump C entrifugal flow impellor, belt driven from crankshaft
Torque Specif ications
Description Nm lb-ft
C oolant pump bolts 10 7
C oolant pump pulley retaining bolts 10 7
C ooling fan to viscous coupling bolts 10 7
* C ooling fan assembly 65 48
Thermostat housing bolts 10 7
Radiator bolts 25 18
Air C onditioning (A/C ) condenser clip bolts 6 4
A/C manifold bolt 10 7
Expansion tank bolt 10 7
Vacuum pump bolts 10 7
Radiator access panel bolts 10 7
C oolant bleed screw(s) 3 2
* Note: Left-hand thread

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Published: 11-Ma -2011

Engine Cooling - V8 4.4L Pe rol - Engine Cooling
Description and Operation

C ooling S stem C omponent La out

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I em Pa N mbe De c ip ion
1 - Heater hose, in and out
2 - C onnections for rear heater
3 - Hose, radiator to e pansion tank

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4
5 -- Th
EGR ae be d
6 - B eed c e
7 - H e, a e e c i de b c
8 - Wa e e i e a e b
9 - E a i a
10 - H e, hea e he a
11 - C i de b c
12 - Wa e
13 - H e, adia he a
14 - Oi c e
15 - C i g fa
16 - Sh d, e
17 - T a i i i i e
18 - Radia
19 - Sh d, e
20 - H e, a e e adia

GENERAL

The c i g e e ed i f he e e e ief b - a e, hich a c a ci c a e a d he e gi e

a d he hea e ci c i hi e he he a ai a e i c ed. The i a f c i f he c i g e i
ai ai he e gi e i hi a i e e a e a ge de cha gi g a bie a d e gi e e a i g c di i .
Sec da f c i a e ide hea i gf he a e ge c a e a dc i gf he a i i f id a d
e gi e i .

The c i g e c i e :

A adia
A a e ge c a e hea e a i
A c a
A he a
A e a i a
A e ec - i c fa
C ec i g h e a d i e .

ENGINE COOLING S STEM

The c a i ci c a ed b a ce if ga ed he f f he e gi e a d d i e b a a ci a d i e
' ee' be . The c a ci c a e c a h gh he c i de b c a d c i de head ia a cha be ca ed
i he ' ee' f he e gi e. Ha i g a ed h gh he e gi e he c a e he he a h i g. The c a
he g e e d he ' h e' he hea e i e. The hea e i e ead he b head a d e he e gi e
ide f he he a.

The e gi e c ai a a he a hich i i i ed ch ha he a ' e e a e i c ed b b h he

c a f he adia a d he b a . Thi e i he he a bei g ab e a i e i g e e a e
de e da a bie c di i . The he a h i ga c ai a g aded a e, hich i i he a
f i g he b a . Thi ea ha he e gi e ca ih c a f i g h gh he b a e a i ,
i e hea e e f a ce.

The adia i ac f e iha a i i a i a d ha a d ai a he e igh -ha d ea face. The

e adia i g a e ca ed a a he e d a . The i g a e fi ed i h bbe b he , hich i
he e cha i ai . The adia e i ed b i , hich a e hed h gh bbe b he ed i
he F E d C a ie (FEC ) ab e he adia . The adia a i c ae c ec i f he a i i i
i e .

The a db h e a e ed he i e a d e ide f he he a h i g.

The e a i a i fi ed f a d f he LH e i e i he e gi e c a e . The e a i a a
f he e a i f he c a a he e gi e ge h a d a ie he e gi e i h c a a he c a i he
e gi e c ac . The a a a a ai a ed i he c a be e ed.

The i id c ed a i i f id c e i ed i he c d ide adia e d a .I i ii ed i he idd e f

he LH e d a .

The e gi e i c e (EOC ) i feed c a f he b h e. C a i di e ed f be ee he adia a d

he he a , di ec ed he c e a d he e ed he b h e.

F addi i a ai f h gh he adia a i , a ic a he he ehic e i a i a , he e i a e gi e d i e

e ec - i c i . Thi i f ci a a a i c fa , b i h e ec ic c e he e e e gage e
f he c ch. The E gi e C M d e (EC M), hich de e i e he e i ed fa eed, c he e e f c ch
e gage e . The EC M de e i e e gage e ba ed he c a , a bie a d a i i i e e a e a d
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air conditioning (A/C ) system pressure. The fan is mounted using a left hand thread.

The viscous fan unit is electronically controlled by the EC M to optimise fan speed for all operating conditions.

NOTE: If the electrical connections to the viscous fan are disconnected the fan will 'idle' and overheating may result.
The EC M stores the appropriate fault codes in this case.

ENGINE COOLING S STEM OPERATION

C ooling System C oolant Flow

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When the engine is running the coolant pump is driven by the ancillary drive belt. This forces coolant to circulate around
the engine and heater, while the thermostat and bypass valve are shut. As the temperature and pressure increases the
bypass valve is forced open allowing coolant to circulate through the bypass valve. When the temperature reaches
82 C (180 F) the main thermostat begins to open allowing coolant to circulate through the main radiator. As the
thermostat progressively opens (fully open at 95 C (203 F)), the bypass valve progressively closes forcing any coolant
through the heater or radiator. Once coolant is allowed to circulate through the radiator, the transmission fluid and the
engine oil coolers begin to receive coolant flow.

The increased coolant volume, created by heat expansion, is directed to the expansion tank through a bleed hose from
the top of the radiator. The expansion tank has an outlet hose which is connected into the coolant circuit. This outlet
hose returns the coolant to the system when the engine cools.

C oolant flows through the radiator from the top right hand tank to the bottom left hand tank and is cooled by air
passing through the matrix. The temperature of the cooling system is monitored by the EC M via the Engine C oolant
temperature (EC T) sensor located in the cylinder head. The EC M uses signals from this sensor to control the cooling fan
operation and adjust fuelling according to engine temperature.
For additional information, refer to: Electronic Engine C ontrols (303-14C Electronic Engine C ontrols - TDV6 2.7L Diesel,
Description and Operation).

To control the cooling fan, the EC M sends a Pulse Width Modulated (PWM) signal to the cooling fan module (integral to
the EC M). The frequency of the PWM signal is used by the cooling fan module to determine the output voltage supplied
to the fan motor.

The EC M varies the duty cycle of the PWM signal between 0 and 100% to vary the fan speed. If the PWM signal is
outside the 0 to 100% range, the cooling fan module interprets the signal as an open or short circuit and runs the fans
at maximum speed to ensure the engine and gearbox do not overheat.

The EC M operates the fan in response to inputs from the EC T sensor, the transmission oil temperature sensor, the A/C
switch and the A/C pressure sensor.
For additional information, refer to: Air C onditioning (412-03A Air C onditioning - V6 4.0L Petrol, Description and
Operation).

The speed of the cooling fan is also influenced by vehicle road speed. The EC M adjusts the speed of the cooling fans, to
compensate for the ram effect of vehicle speed, using the C ontroller Area Network (C AN) road speed signal received
from the Anti-lock Braking System (ABS) module.

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Engine Cooling - V8 4.4L Petrol - Engine Cooling
Diagnosis and Testing

Inspection and verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection
Mechanical Electrical
C oolant leaks Fuses
C oolant Hoses Wiring harness
C oolant expansion tank Loose or corroded connector(s)
Radiator Engine coolant temperature (EC T) sensor
Heater core
Accessory drive belt
Viscous fan

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTC s) before
moving onto the symptom chart or DTC index.

Make sure that all DTC s are cleared following rectification

S mptom chart

S mptom Possible cause Action

C oolant loss Hoses C arry out a visual inspection. If there are no obvious leaks, carry out a
Hose connections pressure test using your workshop tester. Rectify as necessary. Refer ti the
Radiator relevant section of the workshop manual.
Water pump
Heater core
Gaskets
Engine casting
cracks
Engine block core
plugs

Overheating Low/C ontaminated C heck the coolant level and condition. C heck the thermostat and rectify as
coolant necessary. C arry out a cooling system pressure test. C heck the viscous fan
Thermostat operation, make sure the viscous fan rotates freely. C heck for obstructions to
Viscous fan the air flow over the radiator. Rectify as necessary. Refer to the relevant
EC T sensor section of the workshop manual.
Restricted air flow
over the radiator

Engine not Thermostat C heck the thermostat operation. C heck the viscous fan operation, make sure
reaching Viscous fan the viscous fan is not seized.
normal
temperature

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

DTC Description Possible causes Action

P011623 Engine C oolant Low coolant level C heck the coolant level and the thermostat operation
Temperature Engine thermostat (stuck open). Refer to the relevant section of the workshop
Sensor 1 C ircuit failure manual. Refer to the guided diagnostic routine for this code
Range/Performance EC T sensor sensing on the approved diagnostic system.
circuit intermittent
high resistance
EC T sensor failure
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P011624 Engine C oolant Low coolant level C heck the coolant level and the thermostat operation
Temperature Engine coolant (stuck open). Refer to the relevant section of the workshop
Sensor 1 C ircuit thermostat failure manual. Refer to the guided diagnostic routine for this code
Range/Performance EC T sensor sensing on the approved diagnostic s stem.
circuit intermittent
high resistance
EC T sensor failure

P011629 Engine C oolant Low coolant level C heck the coolant level and the thermostat operation
Temperature Engine coolant (stuck open). Refer to the relevant section of the workshop
Sensor 1 C ircuit thermostat failure manual. Refer to the guided diagnostic routine for this code
Range/Performance EC T sensor sensing on the approved diagnostic s stem.
circuit intermittent
high resistance
EC T sensor failure

P011700 Engine C oolant EC T sensor Refer to the guided diagnostic routine for this code on the
Temperature disconnected approved diagnostic s stem.
Sensor 1 C ircuit Engine coolant
Low temperature (EC T)
sensor sensing circuit
high resistance, short
circuit to power
EC T sensor failure

P011800 Engine C oolant Engine overheat C heck the coolant level and the thermostat operation
Temperature condition/cooling fan (stuck closed). C heck for cooling fan DTC s. Refer to the
Sensor 1 C ircuit failure guided diagnostic routine for this code on the approved
High EC T sensor wiring diagnostic s stem.
short circuit to
ground
EC T sensor failure

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P bli hed: 11-Ma -2011

Engine Cooling - V8 4.4L Petrol - Cooling S stem Draining, Filling and Bleeding
Gene al P oced e

WARNING: Since inj ch a calding co ld be ca ed b e caping eam o coolan , do no emo e he fille

cap f om he coolan e pan ion ank hile he em i ho .

1. Po i ion he ehicle on a lif .

2. Se he hea e con ol o ma im m.
3. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
4. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V8 4.4L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).

5. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

Remo e he coolan e pan ion ank cap.

6. Remo e he f on LH pla h hield.

Remo e he 4 clip .

7. Remo e he adia o acce panel.

Remo e he 4 bol .

8. Po i ion a con aine o collec he fl id.

9. C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Relea e he clip and di connec he adia o lo e ho e,

allo he coolan o d ain.

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. Remo e he pa e heel and i e.

Remo e he ool ki .

Acce he inch.

. Po i ion a con aine o collec he fl id.

. Di connec he ea hea e coolan ho e .

Relea e he 2 clip .

Allo he coolan o d ain.

. C onnec he ea hea e coolan ho e .

Sec e he clip .

. In all he pa e heel and i e.

S o he ool ki .

. C onnec and ec e he adia o lo e ho e.

Sec e i h he clip.

. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
. C onnec e ha e ac ion ho e o he ail pipe .
. Loo en he coolan ho e bleed c e .

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1 . Loo en he coolan e pan ion ank bleed c e .

20. Fill he cooling em o he ppe le el ma k of he

e pan ion ank.
21. S a and n he engine.

Hold he engine peed a 2,500 RPM fo 30 econd .

Re n he engine o idle fo 30 econd .

Repea he abo e p oced e af he fo ime .

22. When a ead eam of coolan i nning f om he

bleed poin , clo e he coolan ho e bleed c e .
23. Fill he cooling em, keeping coolan o he ppe le el
ma k of he e pan ion ank n il a ead eam of coolan
i een e ning o he e pan ion ank. Tigh en he
e pan ion ank bleed c e .
24. NOTE: When he coolan bleed i comple e and p io o
in alling he e pan ion ank cap, op- p he e pan ion ank
o 30mm abo e he ma im m le el.

In all he coolan e pan ion ank cap.

25. R n he engine n il he he mo a open .

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2 . Switch the engine off and allow to cool.
2 . Install the engine cover.
For additional information, refer to: Engine C over - V8 4.4L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
2 . C lean an spilt coolant from the vehicle.
2 . Install the radiator access panel.

Tighten the 4 bolts to 10 Nm (7 lb.ft).

30. Install the front LH splash shield.

31. C heck and top-up the coolant if required.

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Published: 11-May-2011
Engine Cooling - V8 4.4L Petrol - Cooling S stem Draining and Vacuum Filling
General Procedures

WARNING: To avoid having scalding hot coolant or steam blowing out of the cooling system, use extreme care
when removing the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a
thick cloth around the coolant pressure cap and turn it slowly until the pressure begins to release. Step back while the
pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and
remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may result in
personal injury.

C AUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the vehicle.

Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the
area with water.

1. Set the heater controls to maximum HOT.

2. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, do not remove the filler
cap from the coolant expansion tank while the system is hot.

Remove the coolant expansion tank cap.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the front LH splash shield.

Remove the 4 clips.

5. Remove the radiator access panel.

Remove the 4 bolts.

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. Po i ion a con aine o collec he fl id.

. C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Di connec he adia o lo e ho e.

Relea e he clip.

Allo he coolan o d ain.

. Remo e he pa e heel and i e.

Remo e he ool ki .

Acce he inch.

. Po i ion a con aine o collec he fl id.

. C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Di connec he ea hea e coolan ho e .

Relea e he 2 clip .

Allo he coolan o d ain.

. C onnec he ea hea e coolan ho e .

Sec e he clip .

. In all he pa e heel and i e.

In all he ool ki .

. C onnec and ec e he adia o lo e ho e.

Sec e i h he clip.

. P epa e a fficien amo n of coolan o he pecified

concen a ion.
. In all he cooling em ac m efill adap o o he
e pan ion ank.

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1 . Install the vacuum filler gauge to the cooling system

vacuum refill adaptor.

1 . Install the venturi tube assembly to the vacuum filler

gauge.

1 . NOTE: Make sure both valves on gauge assembly are in

the closed position.

NOTE: Small diameter or long airlines may restrict airflow

to the coolant vacuum fill tool.

NOTE: The coolant vacuum fill tool needs an air pressure

of 6 to 8 bar (87 to 116 psi) to operate correctly.

C onnect a regulated compressed air supply to the venturi

tube assembly.

1 . NOTE: Make sure air cannot enter the hose.

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Position the coolant pick-up pipe into a container of clean
coolant.
. Position the evacuated air hose into a container.
. Open the air suppl valve.

. Open the coolant suppl valve for 2 seconds to prime

the coolant suppl hose.

. Appl air pressure progressivel until the arrow on the

vacuum filler gauge reaches the green segment.

. C lose the air suppl valve.

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2 . Allo one min e o check he ac m i held.

Di connec he comp e ed ai ppl .

2 . NOTE: C lo e he coolan ppl al e hen he coolan

e pan ion ank MAX ma k i eached o coolan mo emen
ha cea ed.

Open he coolan ppl al e and allo he coolan o be

d a n in o he em.

2 . Remo e he ac m fille ga ge and cooling em

ac m efill adap o a embl .
2 . C onnec e ha e ac ion ho e o he ail pipe .
2 .S a and n he engine.

Hold he engine peed a 2,500 RPM fo 30 econd .

Re n he engine o idle fo 30 econd .

Repea he abo e p oced e af he 4 ime .

30. Keep he coolan le el in he e pan ion ank a he

ma im m le el ma k n il a ead eam of coolan can
be een e ning.
31. NOTE: When he coolan bleed i comple e and p io o
in alling he e pan ion ank cap, op- p he e pan ion ank o
30mm abo e he ma im m le el.

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I .
.R .
.S .
.C .
.I .

T 4 10 N (7 . ).

.I LH .

I 4 .

. WARNING: S
,

C - .

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Published: 11-May-2011
Engine Cooling - V8 4.4L Petrol - Cooling S stem Pressure Test
General Procedures

NOTE: The following procedure will enable the cooling system to be pressure tested for condition and leaks. Stage 1
will check the expansion tank cap register seal and the cap for leaks. Stage 2 will check the entire cooling system.

NOTE: It will be necessary to use the cooling system test kit, Part Number LR-218, which is available under the
equipment programme.

1. Examine the coolant hoses for signs of cracking, distortion

and security of the hose connections.

2. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.

Disconnect the coolant expansion tank bleed hose.

Release the clip.

3. Install the 'T' piece adaptor (part of the cooling system test
kit) between the coolant expansion tank and the coolant
bleed hose.

Secure with the 2 clips.

4. Install the coolant pressure pump assembly.

C onnect to the 'T' piece.

5. Pressurize the cooling system.

Slowly pressurize the cooling system to 1.0 bar (100

kPa) (14.5 psi).

C heck the pressure remains above 0.9 bar (90 kPa)

(13 psi) after waiting for 30 seconds.

During the pressure drop check, listen for a hissing

noise from the expansion tank cap.

6. NOTE: If the coolant expansion tank cap is found to be

leaking, replace the cap.

Depressurize the cooling system.

Disconnect the 'T' piece.

C onnect the coolant expansion tank bleed hose.

Secure the clip.

7. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.
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Remove the coolant expansion tank cap.
. NOTE: This adaptor is part of the cooling system test kit.

Install adaptor K83 to the coolant expansion tank.

C lean the component mating faces.

Lubricate the seal.

. Install the coolant pressure pump assembly.

Slowly pressurize the cooling system to 1.5 bar

(150kPa) (22 psi), check the pressure over a 5
minute period. A small pressure decay of
approximately 0.15 bar (15 kPa) (1 psi) over the
first minute is normal, as the air in the expansion
tank cools.

If the pressure continues to drop after the initial

tolerance, there is a coolant leak.

10. Depressurize and remove the pressure pump and

gauge.

Install the coolant expansion tank cap.

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P bli hed: 11-Ma -2011

Engine Cooling - V8 4.4L Petrol - Coolant E pansion Tank
Remo al and In alla ion

Removal
1. Remo e he LH headlamp a embl .
Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).
2. Relea e he ind hield a he e e oi fille neck.
3. Relea e he coolan e pan ion ank.

Remo e he 2 bol .

4. Relea e he po e ee ing fl id e e oi .

5. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he
fille cap f om he coolan e pan ion ank hile he em
i ho .

C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Di connec he 2 ho e f om he coolan e pan ion ank.

Po i ion an ab o ben clo h o collec fl id pillage.

Po i ion a con aine o collec he fl id.

C lamp he ho e

Relea e he 2 clip .

6. Remo e he coolan e pan ion ank.

Di connec he coolan lo le el en o elec ical

connec o .

7. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he coolan lo le el en o .

Remo e he coolan e pan ion ank ppo b acke .

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In alla ion
1. In all he b acke .
2. In all he coolan lo le el en o .
3. In all he coolan e pan ion ank.

C onnec he coolan lo le el en o elec ical

connec o .

4. C onnec he coolan ho e o he e pan ion ank.

Sec e i h he clip .

5. Top- p he coolan .

Loo en he coolan e pan ion ank bleed c e .

Fill he coolan e pan ion ank n il coolan eme ge

f om he cooling em ai bleed c e .

Remo e he ho e clamp .

Tigh en he bleed c e o 8 Nm (6 lb.f ).

6. Sec e he coolan e pan ion ank.

Tigh en he bol o 10 Nm (7 lb.f ).

7. C heck and op- p he coolan .

In all he coolan e pan ion ank p e e cap.

8. Sec e he po e ee ing fl id e e oi .

A ach o he mo n ing b acke .

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. Sec e he ind hield a he e e oi fille neck.

Loca e in clip.

10. In all he LH headlamp a embl .

Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).

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Published: 11-Ma -2011

Engine Cooling - V8 4.4L Petrol - Cooling Fan
Removal and Installation

Special Tool(s)
Viscous coupling spanner

303-1142

Viscous coupling pulle retaining

tool

303-1143

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the cooling fan shroud.
For additional information, refer to: C ooling Fan Shroud
(303-03B Engine C ooling - V8 4.4L Petrol, Removal and
Installation).
3. Disconnect the cooling fan control electrical connector.

4. NOTE: The thread is left handed.

Using the special tools, remove the cooling fan.

Remove the cooling fan assembl .

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5. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the viscous coupling from the cooling fan.

Remove the 4 bolts.

In alla ion
1. To install, reverse the removal procedure.

Install the cooling fan to the viscous coupling, tighten

the bolts to 10 Nm (7 lb.ft).

Tighten the cooling fan assembl to 65 Nm (48 lb.ft).

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Engine Cooling - V8 4.4L Pe ol - Cooling Fan Sh o d
Remo al and In alla ion

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
2. Remo e he ai in ake e ona o .
Fo addi ional info ma ion, efe o: Re ona o (303-12,
Remo al and In alla ion).
3. Remo e he ppe fan h o d.

Relea e he coolan e pan ion ho e f om he clip .

Relea e he fan i ing ha ne clip.

Relea e he 3 fan h o d clip .

In alla ion
1. To in all, e e e he emo al p oced e.

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Engine Cooling - V8 4.4L Petrol - Engine Coolant Le el S itch
Remo al and In alla ion

Remo al
1. Relea e he po e ee ing fl id e e oi f om he
b acke .

2. Relea e he ind hield a he e e oi fille neck.

3. Repo i ion he coolan e pan ion ank.

Remo e he 2 bol .

4. Remo e he engine coolan le el i ch.

Di connec he engine coolan le el i ch elec ical

connec o .

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In alla ion
1. NOTE: An a dible click can be hea d hen he engine
coolan le el i ch i co ec l in alled.

In all he engine coolan le el i ch.

C onnec he engine coolan le el i ch elec ical

connec o .

2. C AUTION: Make e ha he componen i co ec l

loca ed on he loca ing peg .

Sec e he coolan e pan ion ank.

Tigh en he bol o 10 Nm (7 lb.f ).

3. Sec e he ind hield a he e e oi fille neck.

4. Sec e he po e ee ing fl id e e oi o he b acke .

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P bli hed: 11-Ma -2011

Engine Cooling - V8 4.4L Petrol - Radiator
Remo al and In alla ion

Remo al
1. Rai e and ppo he ehicle.
2. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

3. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

D ain he cooling em.

Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Pe ol, Gene al P oced e ).
4. Remo e he i co fan a embl .
Fo addi ional info ma ion, efe o: C ooling Fan (303-03B
Engine C ooling - V8 4.4L Pe ol, Remo al and In alla ion).
5. Remo e he adia o g ille.
Fo addi ional info ma ion, efe o: Radia o G ille (501-08
E e io T im and O namen a ion, Remo al and
In alla ion).
6. Remo e he lo e fan h o d.

Relea e 2 clip f om he cooling fan lo e h o d.

Relea e and emo e he cooling fan lo e h o d

f om he cooling pack.

7. Di connec he coolan e pan ion ank ho e.

Relea e he clip.

8. Di connec he adia o ppe ho e.

Relea e he clip.

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. C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the transmission cooler hoses.

Release the 2 clips.

Position a container to collect the fluid.

10. Remove the radiator securing pegs.

Depress the 2 clips.

11. Remove the radiator upper deflector.

Release the 2 clips.

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. Relea e he po e ee ing fl id coole .

Relea e he clip .

Tie he line a ide.

. Relea e he f on diffe en ial b ea he line.

. Remo e he po e ee ing fl id coole line clip.

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1 . Remo e the A/C manifold bolt.

1 . Release the A/C condenser.

Remo e the 2 bolts.

Release from the 2 clips.

1 . Remo e the radiator.

Protect the elements from damage.

With assistance, remo e the radiator.

Remo e the 2 radiator retaining bolts.

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In alla ion
1. In all he adia o .

Remo e he elemen p o ec ion.

Wi h a i ance in all he adia o .

Align he adia o .

In all he adia o e aining bol .

Tigh en he bol o 25 Nm (18 lb.f ).

2. In all he A/C conden e .

Sec e in he clip .

Tigh en he bol o 6 Nm (4 lb.f ).

3. In all he A/C manifold bol .

Tigh en he bol o 10 Nm (7 lb.f ).

4. In all he po e ee ing fl id coole line clip.

5. In all he adia o ppe deflec o .
6. In all he po e ee ing fl id coole .

Sec e in he 3 clip .

7. In all he adia o ec ing peg .

8. In all he an mi ion coole ho e .

In all he clip .

9. In all he adia o ppe ho e.

In all he clip.

10. In all he adia o lo e ho e.

In all he clip.

11. In all he coolan e pan ion ank ho e o he ppe

adia o ..

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In all he e pan ion ank ho e clip.

. In all he lo e fan h o d.

In all he cooling fan lo e h o d.

In all he 2 clip o he lo e fan h o d.

. In all he adia o g ille.

Fo addi ional info ma ion, efe o: Radia o G ille (501-08
E e io T im and O namen a ion, Remo al and
In alla ion).
. In all he i co fan a embl .
Fo addi ional info ma ion, efe o: C ooling Fan (303-03B
Engine C ooling - V8 4.4L Pe ol, Remo al and In alla ion).
. Refill he cooling em.
Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Pe ol, Gene al P oced e ).
. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
. C heck a oma ic an mi ion fl id le el.

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Published: 11-Ma -2011

Engine Cooling - V8 4.4L Petrol - Thermostat
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the thermostat housing.

Position a container to collect the fluid.

Disconnect the coolant hoses from the thermostat

housing.

Remove the 3 bolts.

Remove and discard the seal.

3. WARNING: E e protection must be worn.

Remove the thermostat.

Position the thermostat housing in a vice.

Release and remove the thermostat.

Installation
1. C lean the thermostat cover and housing mating faces.
2. To install, reverse the removal procedure.

Install a new thermostat seal.

1. Tighten the bolts to 10 Nm (7 lb.ft).

3. Top up and bleed the coolant.

4. NOTE: For NAS vehicles onl .

If required, carr out a long drive c cle.

For additional information, refer to: Powertrain C ontrol
Module (PC M) Long Drive C cle Self-Test (303-14A
Electronic Engine C ontrols - V6 4.0L Petrol, General
Procedures).

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P bli hed: 11-Ma -2011

Engine Cooling - V8 4.4L Pe ol - Coolan P mp
Remo al and In alla ion

Remo al
1. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

2. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

3. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

D ain he cooling em.

Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Pe ol, Gene al P oced e ).
4. Remo e he acce o d i e bel .
Fo addi ional info ma ion, efe o: Acce o D i e Bel
(303-05B Acce o D i e - V8 4.4L Pe ol, Remo al and
In alla ion).
5. Remo e he coolan p mp d i e p lle .

Remo e he 3 bol .

6. Remo e he coolan p mp.

Remo e he 5 bol .

Di ca d he ga ke .

In alla ion
1. To in all, e e e he emo al p oced e.

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C lean the component mating faces.

. Tighten the coolant pump retaining bolts.

Tighten the 5 bolts to 10 Nm (7 lb.ft).

. Tighten the coolant pump pulle retaining bolts.

Tighten the bolts to 10 Nm (7 lb.ft).

. Install the accessor drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05B Accessor Drive - V8 4.4L Petrol, Removal and
Installation).
. Refill the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03B Engine C ooling - V8
4.4L Petrol, General Procedures).

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Published: 27-Jun-2011
Engine Cooling - TDV6 2.7L Diesel -
Fluids and Capacities
Item Specification
* Anti-freeze Havoline Extended Life C oolant (XLC ) or any ethylene glycol based anti-
freeze containing no methanol with only Organic Acid Technology (OAT)
corrosion inhibitors
Anti-freeze concentration - Will provide 50%
frost protection to -40°C (-40°F)
Specific gravity of coolant at 20°C 1.068
(68°F), to protect against frost down to
-40°C (-40°F)
Amount of anti-free e to use for
50% concentration:
Without rear passenger compartment 4.7 litres (8.25 pints) (4.9 US quarts)
heater or fuel burning heater
With rear passenger compartment 6.0 litres (10.6 pints) (6.4 US quarts)
heater but without fuel burning heater
Without rear passenger compartment 5.1 litres (9.1 pints) (5.4 US quarts)
heater but with fuel burning heater
With rear passenger compartment 6.5 litres (11.5 pints) (6.9 US quarts)
heater and fuel burning heater

C AUTION: * No other anti-freeze should be used with Havoline Extended Life C oolant.
Capacit
Item Capacit
Without rear passenger compartment heater or fuel burning heater 9.4 litres (16.5 pints) (9.9 US quarts)
With rear passenger compartment heater but without fuel burning heater 12.15 litres (21.4 pints) (12.8 US quarts)
Without rear passenger compartment heater but with fuel burning heater 10.35 litres (18.2 pints) (10.9 US pints)
With rear passenger compartment heater and fuel burning heater 13.1 litres (23.0 pints) (13.8 US quarts)
General Specif ications
Item Specification
C ooling system type Pressurised, thermostatically controlled with remote header tank
Radiator C ross flow with integral transmission fluid and charge air coolers
Expansion tank Remote - fitted with a bleed screw and low coolant level sensor
Pressure cap rating 110 kPa (1.1 bar) (16 lbf/in )
Thermostat:
Starts to open 88° C (190° F)
Fully open 95° C (203° F)
C ooling fan Engine driven, viscous coupled with electronic control
C ooling fan diameter 500 mm (19.6 in)
Direction of rotation C lockwise when viewed from front of engine
C oolant pump C entrifugal flow impellor, belt driven from crankshaft
Torque Specif ications
Description Nm lb-ft
C oolant expansion tank bolts 10 7
Radiator access panel 10 7
C oolant pump bolts 10 7
C oolant pump pulley bolts 25 18
Radiator securing bolts 25 18
Air C onditioning (A/C ) condenser bolts 6 4
C harge air outlet hose clip 10 7
C harge air inlet hose clip 10 7
C ooling fan to viscous coupling bolts 10 7
* C ooling fan assembly 65 48
C oolant bleed screw(s) 3 2
* Note: Left-hand thread

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Published: 11-May-2011
Engine Cooling - TDV6 2.7L Die el - Engine Cooling
Description and Operation

C ooling System C omponent Layout Manual Gearbox Without Fuel Burning Heater (FBH)

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I em Pa N mbe De c ip ion
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A - 2007 model year onwards
1 - Heater hose, in and out
2 - Heater hose, in and out, for vehicles with rear heater (optional)
3 - EGR valve
4 - Hose, EGR
5 - Water outlet assembly
6 - EGR valve
7 - Hose, EGR inlet
8 - Fuel cooler
9 - Expansion tank
10 - Hose, fuel cooler
11 - C ooling fan
12 - Hose, radiator to expansion tank
13 - Shroud, lower
14 - Radiator
15 - Shroud, upper
16 - Hose and thermostat assembly
17 - Water pump
18 - Water inlet connector
19 - Heater hose, thermostat
20 - EGR thermostat, 2 off (2007 model year onwards)
C ooling System C omponent Layout Manual Gearbox, With FBH

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A - 2007 model year onwards
1 - Heater hose, in and out
2 - C onnections for rear heater (optional)
3 - EGR valve
4 - Water outlet assembly
5 - Hose, EGR
6 - EGR valve
7 - Hose, EGR inlet
8 - FBH
9 - Fuel cooler
10 - Expansion tank
11 - Hose, fuel cooler
12 - C ooling fan
13 - Hose, radiator to expansion tank
14 - Shroud, lower
15 - Radiator
16 - Shroud, upper
17 - Hose and thermostat assembly
18 - Water pump
19 - Water inlet connector
20 - FBH hose, in and out
21 - EGR thermostat, 2 off (2007 model year onwards)
C ooling System C omponent Layout Automatic Gearbox Without FBH

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A - 2007 model year onwards
1 - Heater hose, in and out
2 - C onnections for rear heater (optional)
3 - EGR valve
4 - Water outlet assembly
5 - Hose, EGR
6 - EGR valve
7 - Hose, EGR inlet
8 - Fuel cooler
9 - Expansion tank
10 - Transmission oil cooler pipes
11 - Hose, fuel cooler
12 - C ooling fan
13 - Hose, radiator to expansion tank
14 - Shroud, lower
15 - Radiator
16 - Shroud, upper
17 - Hose and thermostat assembly
18 - Water pump
19 - Water inlet connector
20 - Heater hose, thermostat
21 - EGR thermostat, 2 off (2007 model year onwards)
C ooling System C omponent Layout Automatic Gearbox, With FBH

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A - 2007 model ea on a d
1 - Hea e ho e, in and o
2 - C onnec ion fo ea hea e (op ional)
3 - EGR al e
4 - Wa e o le a embl
5 - Ho e, EGR
6 - EGR al e
7 - FBH
8 - F el coole
9 - E pan ion ank
10 - T an mi ion oil coole pipe
11 - Ho e, f el coole
12 - C ooling fan
13 - Ho e, adia o o e pan ion ank
14 - Sh o d, lo e
15 - Radia o
16 - Sh o d, ppe
17 - Ho e and he mo a a embl
18 - Wa e p mp
19 - Wa e inle connec o
20 - FBH ho e, in and o
21 - EGR he mo a , 2 off (2007 model ea on a d )

GENERAL

The cooling em emplo ed i of he p e e elief b -pa pe, hich allo coolan o ci c la e a o nd he

engine and he hea e ci c i hile he he mo a main al e i clo ed. The p ima f nc ion of he cooling em i
o main ain he engine i hin an op im m empe a e ange nde changing ambien and engine ope a ing
condi ion . Seconda f nc ion a e o p o ide hea ing fo he pa enge compa men and cooling fo he
an mi ion fl id and engine oil.

The cooling em comp i e :

A adia o
An in e coole
A pa enge compa men hea e ma i
T o f el coole
T o E ha Ga Reci c la ion (EGR) coole
A F el B ning Hea e (FBH) (Ma ke dependan )
A coolan p mp
A P e e Relief The mo a (PRT)
An e pan ion ank
An elec o- i co fan
C onnec ing ho e and pipe .

ENGINE COOLING S STEM

The coolan i ci c la ed b a cen if gal pe p mp mo n ed on he f on of he engine and d i en b he ancilla

d i e 'pol ee' bel . The coolan p mp ci c la e coolan a o nd he c linde block and c linde head ia a chambe
loca ed in he ' ee' of he engine. Some of he coolan flo i di e ed h o gh he in eg a ed f el and engine oil
coole . Ha ing pa ed h o gh he engine and oil coole , he coolan e n o he he mo a ho ing ia he b -
pa pipe. C oolan al o ci c la e h o gh he EGR coole o he hea e ma i and e n o he engine ide of he
PRT.

On ehicle fi ed i h FBH, he coolan ci c la e h o gh he EGR coole o he FBH ni ( he he ac i e o no ) and

hen on o he hea e ma i . The coolan hen e n o he engine ide of he PRT

On ehicle f om 2007 model ea , he e i a he mo a loca ed in each EGR coole o le pigo . The e he mo a

con ol coolan flo h o gh he EGR coole benefi ing bo h engine emi ion and engine/hea e a m- p.

The PRT ho ing con ain a no mal he mo a , hich i po i ioned ch ha he a ' empe a e i con olled b
bo h he coolan f om he adia o and he b pa . Thi e l in he he mo a being able o a i opening
empe a e dependan on ambien condi ion . The PRT al o con ain a p ng loaded al e, hich limi he amo n
flo ing he b pa . Thi mean ha he engine can n i ho coolan flo ing h o gh he b pa empo a il , o
imp o e hea e pe fo mance.

The adia o i a c o flo pe i h an al mini m ma i and ha a d ain ap on he lo e RH ea face. The lo e

adia o mo n ing a e loca ed pa a p he end ank . The mo n ing a e fi ed i h bbe b he , hich i on

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the upper chassis rails. The radiator upper is mounted by pins, which are pushed through rubber bushes mounted in
the Front End C arrier (FEC ) above the radiator.

The intercooler is attached to the bottom of the radiator by two pins, which locate into fittings in the radiator end
tanks.

The radiator top hose is connected to the PRT by the bypass hose and the bottom hose is directly connected to the
outlet side of the thermostat housing.

The expansion tank is fitted forward of the LH suspension turret in the engine compartment. The expansion tank
allows for the expansion of the coolant as the engine gets hot and also supplies the engine with coolant as the coolant
in the engine contracts. The tank also allows any air trapped in the coolant to be removed.

The liquid cooled transmission fluid cooler (automatic models only) is mounted in the cold side radiator end tank. It is
positioned in the middle of the LH end tank.

The 2nd fuel cooler is fed from the cold side end tank of the radiator from a sub cooled section and returns into the
PRT housing on the radiator side.

On vehicles fitted with a FBH, the unit is located forward of the LH suspension turret. C oolant flows through the FBH
whether it is active or not. The exhaust from the burner is vented into the front LH wheel arch.
For additional information, refer to: Auxiliary Heater (412-02B Auxiliary Heating, Description and Operation).

For additional airflow through the radiator matrix, particularly when the vehicle is stationary, there is an engine driven
electro-viscous fan unit fitted to the rear of the radiator. The fan is used for engine cooling and for Air C onditioning
(A/C ) system cooling. This unit functions as a normal viscous fan, but with electronic control over the level
engagement of the clutch. The Engine C ontrol Module (EC M), which determines the required fan speed, controls the
level of clutch engagement. The EC M determines engagement based on the coolant, charge air, ambient and
transmission oil temperatures and the A/C pressure. The fan is mounted using a left hand thread.

The viscous fan unit is electronically controlled by the EC M to optimise fan speed for all operating conditions.

• NOTE: If the electrical connections to the viscous fan are disconnected the fan will 'idle' and overheating may result.
The EC M stores the appropriate fault codes in this case.

ENGINE COOLING S STEM OPERATION

C ooling System C oolant Flow Manual Gearbox Without FBH

• NOTE: Pre-2007 model year shown, 2007 model year onwards similar

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C ooling System C oolant Flow Manual Gearbox With FBH

• NOTE: Pre-2007 model year shown, 2007 model year onwards similar

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C ooling System C oolant Flow Automatic Gearbox Without FBH

• NOTE: Pre-2007 model year shown, 2007 model year onwards similar

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C ooling System C oolant Flow Automatic Gearbox With FBH

• NOTE: Pre-2007 model year shown, 2007 model year onwards similar

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When the engine is running the coolant pump is driven by the ancillary drive belt. This forces coolant to circulate
around the engine and heater, while the thermostat and bypass valve are shut. As the temperature and pressure
increases the bypass valve is forced open allowing coolant to circulate through the bypass valve. When the
temperature reaches 82 C (180 F) the main thermostat begins to open, allowing coolant to circulate through the main
radiator. As the thermostat progressively opens (fully open at 95 C (203 F)), the bypass valve progressively closes
forcing any coolant through the heater or radiator. Once coolant is allowed to circulate through the radiator, the
transmission fluid (automatic models only) and fuel coolers begin to receive coolant flow.

The increased coolant volume, created by heat expansion, is directed to the expansion tank through a bleed hose
from the top of the radiator. The expansion tank has an outlet hose which is connected into the coolant circuit. This
outlet hose returns the coolant to the system when the engine cools.

C oolant flows through the radiator from the top right hand tank to the bottom left hand tank and is cooled by air
passing through the matrix. The temperature of the cooling system is monitored by the EC M via the Engine C oolant
temperature (EC T) sensor located in the cylinder head. The EC M uses signals from this sensor to control the cooling
fan operation and adjust fuelling according to engine temperature.
For additional information, refer to: Electronic Engine C ontrols (303-14C Electronic Engine C ontrols - 2.7L Diesel,
Description and Operation).
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To control the cooling fan, the EC M sends a Pulse Width Modulated (PWM) signal to the cooling fan module (integral to
the EC M). The frequency of the PWM signal is used by the cooling fan module to determine the output voltage
supplied to the fan motor.

The EC M varies the duty cycle of the PWM signal between 0 and 100% to vary the fan speed. If the PWM signal is
outside the 0 to 100% range, the cooling fan module interprets the signal as an open or short circuit and runs the fans
at maximum speed to ensure the engine and gearbox do not overheat.

The EC M operates the fan in response to inputs from the EC T sensor, the transmission oil temperature sensor, the
charge air temperature sensor, the A/C switch and the A/C pressure sensor.
For additional information, refer to: Air C onditioning (412-03A Air C onditioning - 4.0L, Description and Operation).

The speed of the cooling fan is also influenced by vehicle road speed. The EC M adjusts the speed of the cooling fans,
to compensate for the ram effect of vehicle speed, using the C ontroller Area Network (C AN) road speed signal
received from the Anti-lock Braking System (ABS) module.

P e e Relief The mo a (PRT)

The thermostat is exposed to 85% hot coolant from the engine on one side and 15% cold coolant returning from the
radiator bottom hose on the other side. This allows the thermostat to react to the ambient conditions and provide
coolant control for both winter and summer use. Hot coolant from the engine passes via holes in the by-pass flow
valve into a tube which surrounds 85% of the thermostat sensitive area. C old coolant from the radiator conducts
through the remaining 15% of the sensitive area. In cold ambient conditions, the engine temperature is raised by
approximately 10 C (50 F) to compensate for the heat loss of 15% exposure to the cold coolant returning from the
bottom hose. This improves heater performance and engine warm-up.

The by-pass flow valve is held closed by a light spring and operates to further assists engine and heater warm-up.
When the main valve is closed and the engine speed is at idle, the coolant pump does not produce sufficient flow and
pressure to overcome the spring and open the valve. In this condition the valve prevents coolant circulating through
the by-pass circuit and directs coolant through the heater matrix only. This provides a higher flow of coolant through
the heater matrix improving passenger comfort in cold conditions.

When the engine speed increases above idle, the coolant pump produces a greater flow and pressure than the heater
circuit can accommodate. The build up of pressure acts on the flow valve, overcoming the spring pressure, opening
the valve and relieving the pressure in the heater circuit. The valve then modulates to provide maximum coolant flow
through the heater matrix and allowing excess coolant to flow into the by-pass circuit to provide the engine's cooling
requirements at higher engine speeds. The thermostat then regulates the flow through the radiator to maintain the
engine at the optimum temperature. Maximum opening of the thermostat, and therefore maximum flow through the
radiator, occurs if the coolant temperature reaches 95 C (203 F).

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Published: 11-May-2011
Engine Cooling - TDV6 2.7L Diesel - Engine Cooling
Diagnosis and Testing

Inspection and verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection
Mechanical Electrical
C oolant leaks Fuses
C oolant Hoses Harnesses
C oolant expansion tank Loose or corroded connector(s)
Radiator Engine coolant temperature (EC T) sensor
Heater core
Accessory drive belt
Viscous fan

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTC s) before
moving onto the symptom chart or DTC index.

Make sure that all DTC s are cleared following rectification

S mptom chart

S mptom Possible cause Action

C oolant loss Hoses C arry out a visual inspection. If there are no obvious leaks, carry out a
Hose connections pressure test using your workshop tester. Rectify as necessary. Refer to the
Radiator relevant section of the workshop manual.
Water pump
Heater core
Gaskets
Engine casting
cracks
Engine block core
plugs

Overheating Low/C ontaminated C heck the coolant level and condition. C heck the thermostat and rectify as
coolant necessary. C arry out a cooling system pressure test. Refer to the relevant
Thermostat section of the workshop manual. C heck the viscous fan operation, make sure
Viscous fan the viscous fan rotates freely. C heck for obstructions to the air flow over the
EC T sensor radiator.
Restricted air flow
over the radiator

Engine not Thermostat C heck the thermostat operation. C heck the viscous fan operation, make sure
reaching Viscous fan the viscous fan is not seized.
normal Thermostat
temperature Electric fan
Fan speed module

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

DTC Description Possible causes Action

P011600 Engine C oolant Engine coolant C heck the EC T sensor and circuits. Refer to the electrical
Temperature temperature guides. With the engine cold, read the coolant temperature
Sensor 1 C ircuit (EC T) sensor sensor using a data logger function and start the engine. Record
Range/Performance circuit high the value and allow the engine to idle for 20 minutes. After 20
resistance minutes, recheck the value. If the value has not increased by
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EC T sensor more than 10 C , install a new sensor. Refer to the relevant
circuit short section of the workshop manual. C lear the DTC s and test for
circuit to ground normal operation.
EC T sensor
circuit short
circuit to power
EC T sensor
failure

P011700 Engine C oolant EC T sensor Refer to the guided diagnostic routine for this code on the
Temperature disconnected approved diagnostic system.
Sensor 1 C ircuit Engine coolant
Low temperature
(EC T) sensor
sensing circuit
high resistance,
short circuit to
power
EC T sensor
failure

P011800 Engine C oolant Engine overheat C heck the coolant level and the thermostat operation (stuck
Temperature condition/cooling closed). C heck for cooling fan DTC s. Refer to the guided
Sensor 1 C ircuit fan failure diagnostic routine for this code on the approved diagnostic
High EC T sensor system.
wiring short
circuit to ground
EC T sensor
failure

P011900 Engine C oolant Engine coolant C heck the EC T sensor and circuits. Refer to the electrical
Temperature temperature guides. With the engine cold, read the coolant temperature
Sensor 1 C ircuit (EC T) sensor sensor using a data logger function and start the engine. Record
Intermittent/Erratic circuit high the value and allow the engine to idle for 20 minutes. After 20
resistance minutes, recheck the value. If the value has not increased by
EC T sensor more than 10 C , install a new sensor. Refer to the relevant
circuit short section of the workshop manual. C lear the DTC s and test for
circuit to ground normal operation.
EC T sensor
circuit short
circuit to power
EC T sensor
failure

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P bli hed: 11-Ma -2011

Engine Cooling - TDV6 2.7L Diesel - Cooling S stem Draining, Filling and
Bleeding
Gene al P oced e

All ehicle
1. Po i ion he ehicle on a lif .
2. Se he hea e con ol o ma im m.
3. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
4. Remo e he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - 2.7L V6
- TdV6 (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).

5. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

Remo e he coolan e pan ion ank cap.

6. Remo e he adia o acce panel.

Remo e he 4 bol .

7. Po i ion a con aine o collec he fl id.

8. C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Relea e he clip and di connec he adia o lo e ho e,

allo he coolan o d ain.

9. Remo e he con aine .

Vehicle iha ilia clima e con ol

10. Remo e he pa e heel and i e.

Remo e he ool ki .

Acce he inch.
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. Po i ion a con aine o collec he fl id.

. Di connec he ea hea e coolan ho e .

Relea e he 2 clip .

Allo he coolan o d ain.

. Remo e he con aine .

. C onnec he ea hea e coolan ho e .

Sec e he o clip .

. In all he pa e heel and i e.

S o he ool ki .

All ehicle
. C onnec and ec e he adia o lo e ho e.

Sec e i h he clip.

. C onnec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).
. C onnec e ha e ac ion ho e o he ail pipe .
. Loo en he coolan e pan ion ank bleed c e .

. Loo en he c linde head bleed ho e bleed c e .

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.R .
.T 14 N (10 . ).
.F ,
,
.
. NOTE: W
,
30 .

I .

. WARNING: R
.
C
.F
.

S .

H 3,000 RPM .

R .

H 3,000 RPM .

R .

R ,
- .I .

.S .
.I .
F , :E C - 2.7L V6
- T V6 (501-05 I T O ,R
I ).
.C
.
.I .

T 4 10 N (7 . ).

.C - .

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Published: 11-May-2011
Engine Cooling - TDV6 2.7L Diesel - Cooling S stem Draining and Vacuum
Filling
General Procedures

WARNING: To avoid having scalding hot coolant or steam blowing out of the cooling system, use extreme care
when removing the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a
thick cloth around the coolant pressure cap and turn it slowly until the pressure begins to release. Step back while the
pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and
remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may result in
personal injury.

C AUTIONS:

The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to
prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.

Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the
area with water.

1. Set the heater controls to maximum HOT.

2. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, do not remove the filler
cap from the coolant expansion tank while the system is hot.

Remove the coolant expansion tank cap.

3. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

4. Remove the front LH splash shield.

Remove the 4 clips.

5. Remove the radiator access panel.

Remove the 4 bolts.

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. Po i ion a con aine o collec he fl id.

. Di connec he coolan ho e f om he he mo a .

Relea e he clip.

Allo he coolan o d ain.

. Di connec he coolan ho e f om he he mo a .

Relea e he clip.

Allo he coolan o d ain.

. Remo e he pa e heel and i e.

Remo e he ool ki .

Acce he inch.

10. Po i ion a con aine o collec he fl id.

11. Di connec he ea hea e coolan ho e .

Relea e he 2 clip .

Allo he coolan o d ain.

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. C onnec he ea hea e coolan ho e .

Sec e he clip .

. In all he pa e heel and i e.

S o he ool ki .

. C onnec he he mo a ho ing coolan ho e .

Sec e i h he clip.

. P epa e a fficien amo n of coolan o he pecified

concen a ion.
. In all he cooling em ac m efill adap o o he
e pan ion ank.

. In all he ac m fille ga ge o he cooling em

ac m efill adap o .

. In all he en i be a embl o he ac m fille

ga ge.

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1 . NOTE: Make sure both valves on gauge assembly are in

the closed position.

NOTE: The coolant vacuum fill tool needs an air pressure of

6 to 8 bar (87 to 116 psi) to operate correctly.

NOTE: Small diameter or long airlines may restrict airflow to

the coolant vacuum fill tool.

C onnect a regulated compressed air supply to the venturi

tube assembly.

20. NOTE: Make sure air cannot enter the hose.

Position the coolant pick-up pipe into a container of clean

coolant.
21. Position the evacuated air hose into a container.
22. Open the air supply valve.

23. Open the coolant supply valve for 2 seconds to prime the
coolant supply hose.

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.A ai e e g e i e i he a he
ac fi e ga ge eache he g ee eg e .

.C e he ai a e.

.A e i e chec he ac i he d.

Di c ec he c e ed ai .

. NOTE: C e he c a a e he he c a
e a i a MAX a i eached c a e e
ha cea ed.

O e he c a a e a da he c a be
d a i he e .

. Re e he ac fi e ga ge a d c i g e
ac efi ada a e b .
.C ec e ha e ac i h e he ai i e .
0. C hec a d - he c a if e i ed.

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.I .
.S .

H 3,000 RPM .

R .

H 3,000 RPM .

R .

.S .
.C .
.I .

T 4 10 N (7 . ).

.I LH .

I .

. WARNING: S
,

C - .

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Published: 11-May-2011
Engine Cooling - TDV6 2.7L Diesel - Cooling S stem Pressure Test
General Procedures

NOTE: The following procedure will enable the cooling system to be pressure tested for condition and leaks. Stage 1
will check the expansion tank cap register seal and the cap for leaks. Stage 2 will check the entire cooling system.

NOTE: It will be necessary to use the cooling system test kit, Part Number LR-218, which is available under the
equipment programme.

1. Examine the coolant hoses for signs of cracking, distortion

and security of the hose connections.

2. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.

Disconnect the coolant expansion tank bleed hose.

Release the clip.

3. Install the 'T' piece adaptor (part of the cooling system test
kit) between the coolant expansion tank and the coolant
bleed hose.

Secure with the 2 clips.

4. Install the coolant pressure pump assembly.

C onnect to the 'T' piece.

5. Pressurize the cooling system.

Slowly pressurize the cooling system to 1.0 bar (100

kPa) (14.5 psi).

C heck the pressure remains above 0.9 bar (90 kPa)

(13 psi) after waiting for 30 seconds.

During the pressure drop check, listen for a hissing

noise from the expansion tank cap.

6. NOTE: If the coolant expansion tank cap is found to be

leaking, replace the cap.

Depressurize the cooling system.

Disconnect the 'T' piece.

C onnect the coolant expansion tank bleed hose.

Secure the clip.

7. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.
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Remove the coolant expansion tank cap.
. NOTE: This adaptor is part of the cooling system test kit.

Install adaptor K83 to the coolant expansion tank.

C lean the component mating faces.

Lubricate the seal.

. Install the coolant pressure pump assembly.

Slowly pressurize the cooling system to 1.5 bar

(150kPa) (22 psi), check the pressure over a 5
minute period. A small pressure decay of
approximately 0.15 bar (15 kPa) (1 psi) over the
first minute is normal, as the air in the expansion
tank cools.

If the pressure continues to drop after the initial

tolerance, there is a coolant leak.

10. Depressurize and remove the pressure pump and

gauge.

Install the coolant expansion tank cap.

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P bli hed: 11-Ma -2011

Engine Cooling - TDV6 2.7L Diesel - Coolant E pansion Tank
Remo al and In alla ion

Removal
1. Remo e he LH headlamp a embl .
Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).
2. Relea e he ind hield a he e e oi fille neck.
3. Relea e he coolan e pan ion ank.

Remo e he 2 bol .

4. Relea e he po e ee ing fl id e e oi .

5. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he
fille cap f om he coolan e pan ion ank hile he em
i ho .

C AUTION: Engine coolan ill damage he pain

fini hed face . If pil , immedia el emo e he coolan
and clean he a ea i h a e .

Di connec he 2 ho e f om he coolan e pan ion ank.

Po i ion an ab o ben clo h o collec fl id pillage.

Po i ion a con aine o collec he fl id.

C lamp he ho e

Relea e he 2 clip .

6. Remo e he coolan e pan ion ank.

Di connec he coolan lo le el en o elec ical

connec o .

7. NOTE: Do no di a emble f he if he componen i

emo ed fo acce onl .

Remo e he coolan lo le el en o .

Remo e he coolan e pan ion ank ppo b acke .

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In alla ion
1. In all he b acke .
2. In all he coolan lo le el en o .
3. In all he coolan e pan ion ank.

C onnec he coolan lo le el en o elec ical

connec o .

4. C onnec he coolan ho e o he e pan ion ank.

Sec e i h he clip .

5. Top- p he coolan .

Loo en he coolan e pan ion ank bleed c e .

Fill he coolan e pan ion ank n il coolan eme ge

f om he cooling em ai bleed c e .

Remo e he ho e clamp .

Tigh en he bleed c e o 8 Nm (6 lb.f ).

6. Sec e he coolan e pan ion ank.

Tigh en he bol o 10 Nm (7 lb.f ).

7. C heck and op- p he coolan .

In all he coolan e pan ion ank p e e cap.

8. Sec e he po e ee ing fl id e e oi .

A ach o he mo n ing b acke .

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. Sec e he ind hield a he e e oi fille neck.

Loca e in clip.

10. In all he LH headlamp a embl .

Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).

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Engine Cooling - TDV6 2.7L Diesel - Cooling Fan
Removal and Installation

Special Tool(s)
Viscous coupling spanner

303-905 (LRT-12-094)

Viscous coupling pulle retaining

tool

303-1143

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the air cleaner assembl .
For additional information, refer to: Air C leaner (303-12C
Intake Air Distribution and Filtering - TDV6 2.7L Diesel,
Removal and Installation).
3. Remove the cooling fan shroud.

Release the coolant hose.

Release the 3 clips.

4. NOTE: The thread is left handed.

Remove the cooling fan assembl .

Disconnect the electrical connector.

Use the special tools.

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5. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the viscous coupling.

Remove the 4 bolts.

In alla ion
1. Install the viscous coupling.

C lean the component mating faces.

Tighten the bolts to 10 Nm (7 lb.ft).

2. Install the cooling fan assembl .

C lean the component mating faces.

Tighten the cooling fan assembl to 65 Nm (48 lb.ft).

C onnect the electrical connector.

3. Install the cooling fan shroud.

4. Install the air cleaner assembl .
For additional information, refer to: Air C leaner (303-12C
Intake Air Distribution and Filtering - TDV6 2.7L Diesel,
Removal and Installation).
5. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Engine Cooling - TDV6 2.7L Diesel - Cooling Fan Shro d
Removal and Installation

Remo al

1. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise and support the vehicle.

2. Remove the cooling fan assembl .
For additional information, refer to: C ooling Fan (303-03C
Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).
3. Remove the radiator access panel.

Remove the 4 bolts.

4. Release the coolant pipes and hoses from the lower

shroud.

5. Remove the cooling fan lower shroud.

Release the 2 clips.

Remove the screw.

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In alla ion
1. Install the cooling fan lower shroud.

Tighten the screw.

Secure with the clips.

2. Install the coolant pipes and hoses to the lower shroud.

3. Install the radiator access panel.

Tighten the bolts to 10 Nm (7 lb.ft).

4. Install the cooling fan assembl .

For additional information, refer to: C ooling Fan (303-03C
Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).

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Engine Cooling - TDV6 2.7L Diesel - Engine Coolant Le el S itch
Remo al and In alla ion

Remo al
1. Relea e he po e ee ing fl id e e oi f om he
b acke .

2. Relea e he ind hield a he e e oi fille neck.

3. Repo i ion he coolan e pan ion ank.

Remo e he 2 bol .

4. Remo e he engine coolan le el i ch.

Di connec he engine coolan le el i ch elec ical

connec o .

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In alla ion
1. NOTE: An a dible click can be hea d hen he engine
coolan le el i ch i co ec l in alled.

In all he engine coolan le el i ch.

C onnec he engine coolan le el i ch elec ical

connec o .

2. C AUTION: Make e ha he componen i co ec l

loca ed on he loca ing peg .

Sec e he coolan e pan ion ank.

Tigh en he bol o 10 Nm (7 lb.f ).

3. Sec e he ind hield a he e e oi fille neck.

4. Sec e he po e ee ing fl id e e oi o he b acke .

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P bli hed: 11-Ma -2011

Engine Cooling - TDV6 2.7L Diesel - Radiator
Remo al and In alla ion

Remo al

All ehicle

1. WARNING: Do no o k on o nde a ehicle

ppo ed onl b a jack. Al a ppo he ehicle on afe
and .

Rai e and ppo he ehicle.

2. Di connec he ba e g o nd cable.
Fo addi ional info ma ion, efe o: Specifica ion (414-00
Ba e and C ha ging S em - Gene al Info ma ion,
Specifica ion ).

3. WARNING: Since inj ch a calding co ld be

ca ed b e caping eam o coolan , do no emo e he fille
cap f om he coolan e pan ion ank hile he em i ho .

D ain he cooling em.

Fo addi ional info ma ion, efe o: C ooling S em
D aining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Die el, Gene al P oced e ).
4. Remo e he cooling fan lo e h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
5. Remo e he adia o g ille.
Fo addi ional info ma ion, efe o: Radia o G ille (501-08
E e io T im and O namen a ion, Remo al and
In alla ion).
6. Remo e he LH headlamp a embl .
Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).
7. Relea e he coolan e pan ion ank.

Remo e he 2 bol .

8. Di connec he adia o bleed ho e.

Relea e he clip.

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. Remove the front RH splash shield.

Remove the 4 retaining clips.

10. C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the charge air cooler inlet hose.

Loosen the clip.

Tie aside.

11. C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the charge air cooler outlet hose.

Loosen the clip.

Tie aside.

12. Disconnect the radiator upper hose.

Release the clip.

Tie aside.

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1 . Disconnect the radiator lower hose.

Release the clip.

Tie aside.

1 . Tie the engine air intake duct towards the engine.

Vehicles with automatic transmission

1 . C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the 2 transmission fluid cooler pipes.

Release the clips.

Position a container to collect the fluid spillage.

Tie aside.

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All ehicle
1 . Di connec he f el coole line.

Relea e he clip.

1 . Remo e he adia o ec ing peg .

Relea e he clip .

1 . Remo e he adia o ppe deflec o .

Relea e he 2 clip .

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1 . Relea e he po e ee ing fl id coole .

Relea e he 2 clip .

Tie he line a ide.

20. Relea e he f on diffe en ial b ea he line.

21. Remo e he po e ee ing fl id coole line e aining

clip.

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. Relea e he A/C conden e .

Remo e he 3 bol .

Relea e he 2 clip .

. Relea e he adia o .

Remo e he 2 bol .

Lif he adia o clea of i mo n ing .

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2 . Tie the A/C condenser forwards, clear of the radiator.

2 . NOTE: Left-hand shown, right-hand similar.

Remove the 2 clips retaining the radiator to the charge air

cooler.

2 . C AUTION: Protect the radiator during this operation.

NOTE: Do not disassemble further if the component is

removed for access only.

C arefully remove the radiator.

2 . NOTE: Note the fitted position.

Remove the fuel cooler hose.

Loosen the clip.

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28. Remove the radiator lower deflector.

29. Remove the radiator rubber insulators.

In alla ion

All vehicles
1. Install the rubber insulators.
2. Install the radiator lower deflector.
3. Install the fuel cooler hose.

Tighten the clip.

4. C AUTION: Protect the radiator during this operation.

C arefull install the radiator.

5. Install the 2 clips, to retain the charge air cooler to the
radiator.
6. Position the radiator.

Lift the radiator onto its mountings.

Tighten the bolts to 25 Nm (18 lb.ft).

7. Attach the A/C condenser.

Remove and discard the 2 cable ties.

Lift it into the clips.

Tighten the bolt to 6 Nm (4 lb.ft).

8. Position the front differential breather line.

9. Attach the power steering fluid cooler.

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Sec e in o he 3 clip .

. In all he adia o ppe deflec o .

. In all he adia o ec ing peg .
. C onnec he f el coole line.

Sec e i h he clip.

Vehicle iha oma ic an mi ion

. C onnec he an mi ion fl id coole coolan ho e .

In all he clip .

All ehicle
. In all he adia o lo e ho e.

Sec e i h he clip.

. Relea e he ai in ake d c .

Remo e and di ca d he cable ie.

. C onnec he adia o ppe ho e.

Remo e and di ca d he cable ie.

Sec e i h he clip.

. C onnec he adia o lo e ho e.

Remo e and di ca d he cable ie.

Sec e i h he clip.

. C onnec he cha ge ai o le ho e.

Tigh en he clip o 10 Nm (7 lb.f ).

. C onnec he cha ge ai inle ho e.

Tigh en he clip o 10 Nm (7 lb.f ).

. In all he f on RH pla h hield.

In all he fo clip .

. Sec e he coolan e pan ion ank.

Tigh en he o e aining bol o 10 Nm (7 lb.f ).

. C onnec he adia o bleed ho e.

Sec e i h he clip.

. In all he LH headlamp a embl .

Fo addi ional info ma ion, efe o: Headlamp A embl
(417-01 E e io Ligh ing, Remo al and In alla ion).
. In all he adia o g ille.
Fo addi ional info ma ion, efe o: Radia o G ille (501-08
E e io T im and O namen a ion, Remo al and
In alla ion).
. In all he cooling fan lo e h o d.
Fo addi ional info ma ion, efe o: C ooling Fan Sh o d
(303-03C Engine C ooling - TDV6 2.7L Die el, Remo al and
In alla ion).
. C onnec he ba e g o nd cable.
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For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2 . Refill the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).

Vehicles with automatic transmission

2 . C heck automatic transmission fluid level.

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Engine Cooling - TDV6 2.7L Diesel - Thermostat
Removal and Installation

Remo al
1. Drain the cooling s stem.
2. Position a container to collect the fluid spillage.
3. Disconnect the radiator upper hose from the thermostat.

Release the clip.

4. Disconnect the heater hose from the thermostat.

Release from the clip.

5. Disconnect the engine inlet hose from the thermostat.

Release the clip.

6. Disconnect the radiator lower hose from the thermostat.

Release the clip.

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7. Di connec he coolan e pan ion ank ho e f om he

he mo a .

Relea e he clip.

8. Remo e he he mo a .

Di connec he coolan ho e f om he he mo a .

9. Remo e he con aine .

In alla ion
1. In all he he mo a .

C onnec he coolan ho e o he he mo a .

Sec e i h he clip.

2. C onnec he coolan e pan ion ank ho e o he he mo a .

Sec e i h he clip.

3. C onnec he adia o lo e ho e o he he mo a .

Sec e i h he clip.

4. C onnec he engine inle ho e o he he mo a .

Sec e i h he clip.

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. C onnect the heater hose to the thermostat.

Secure with the clip.

. C onnect the radiator upper hose to the thermostat.

Secure with the clip.

Position the radiator upper hose to the cooling fan

shroud.

. Refill and bleed the cooling s stem.

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Engine Cooling - TDV6 2.7L Die el - The mo a Ho ing
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Drain the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).
3. Remove the cooling fan shroud.
For additional information, refer to: C ooling Fan Shroud
(303-03C Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).
4. Remove the radiator access panel.

Remove the four retaining bolts.

5. Remove the front LH splash shield.

Remove the four clips.

6. Disconnect the fuel cooler return hose from the

thermostat.

Release the clip.

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. Di connec he hea e e n ho e f om he hea e e n

pipe.

Relea e f om he clip.

. Di connec he he mo a o op ho e 'T' piece ho e.

Relea e f om he clip.

. Di connec he he mo a ho e f om he engine coolan

ail.

Relea e he clip.

10. Di connec he he mo a o f el fi ed hea e ho e

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from the fuel fired heater.

Release the clip.

. Disconnect the radiator lo er hose from the radiator.

Release the clip.

. Release the securing straps.

. Release the coolant hose retaining clip.

. Release the coolant hose retaining clip.

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15. Remove the thermostat and hose assembl .

In alla ion
1. Install the thermostat and hose assembl .
2. Install the coolant hose retaining clip.
3. Install the coolant hose retaining clip.
4. Install the securing straps.
5. C onnect the radiator lower hose to the radiator.
6. C onnect the thermostat to fuel fired heater hose to the fuel
fired heater.
7. C onnect the thermostat hose to the engine coolant rail.
8. C onnect the thermostat to top hose 'T' piece hose.
9. C onnect the heater return hose to the heater return pipe.
10. C onnect the fuel cooler return hose to the thermostat.
11. Install the front LH splash shield.

Install the four clips.

12. Install the radiator access panel.

Install the four retaining bolts.

13. Install the cooling fan shroud.

For additional information, refer to: C ooling Fan Shroud
(303-03C Engine C ooling - TDV6 2.7L Diesel, Removal and
Installation).
14. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
15. Refill and bleed the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).

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Published: 11-Ma -2011

Engine Cooling - TDV6 2.7L Die el - Coolan P mp
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Drain the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).
3. Remove the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05C Accessor Drive - TDV6 2.7L Diesel, Removal and
Installation).
4. NOTE: Loosen the bolts prior to removing the accessor
drive belt.

Remove the coolant pump pulle .

Remove the 3 bolts.

5. Remove the coolant pump.

Remove the 3 bolts.

Discard the O-ring seal.

In alla ion
1. Install the coolant pump.

C lean the component mating faces.

Install a new O-ring seal.

Tighten the bolts to 10 Nm (7 lb.ft).

2. Install the coolant pump pulle .

C lean the components.

Tighten the bolts to 25 Nm (18 lb.ft).

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. Install the accessor drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05C Accessor Drive - TDV6 2.7L Diesel, Removal and
Installation).
. Refill and bleed the cooling s stem.
For additional information, refer to: C ooling S stem
Draining, Filling and Bleeding (303-03C Engine C ooling -
TDV6 2.7L Diesel, General Procedures).

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P bli hed: 11-Ma -2011

F e Cha gi g a d C - V6 4.0L Pe -
Ge e a S ecif ica i
I e S ecifica i
Rec e ded f e :
UK and ROW e cep NAS Unleaded 98 RON o EN 228 Specifica ion
NAS onl P emi m nleaded ga oline i h a C LC o AKI oc ane a ing of 91 o highe .
F e i jec :
Make Bo ch
T pe EV14 19lb
F e P e e
C e ba i
F el p mp 4.5 65
F el ail 4.5 65
T e S ecif ica i
I e N b-f
Th o le bod bol 10 7
Sch aede al e bol 6 4
F el p e e eg la o bol 6 4
F el ail bol 25 18
F el line o f el ail clip bol 6 4
F el p e e eg la o bol 6 4

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P : 11-M -2011
F el Cha ging and Con ol - V6 4.0L Pe ol - F el Cha ging and Con ol
D O

C L

I em Pa N mbe De c ip ion
1 - T
2 - I
3 - F
4 - F
5 - F (6 )

GENERAL

T , ,
.T ,
, .T .

INTAKE MANIFOLD

T .T
.T .
F , :I A D F (303-12A I A D F -
V6 4.0L P ,D O ).

FUEL PUMP

T .A
.

T , , .T
.E .T
;
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.
F , :F T L (310-01A F T L - V6 4.0L P ,D
O ).

T EC M , B J B (BJB).

W II, EC M
95 EC M C 0634. T .W EC M
C P (C KP) ,
EC M .
F , :E E C (303-14A E E C - V6 4.0L P ,
D O ).

THROTTLE BOD

T .T
.A .T
EMS
.S
.
F , :E E C (303-14A E E C - V6 4.0L P ,
D O ).

FUEL RAIL

I em Pa N mbe De c ip ion
1 - E
2 - RH
3 - F
4 - F
5 - LH
6 - I
7 - S
8 - I (6 )

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E 4.5 (65 )
.T . 'O'
.A
.

A LH RH .
T - , .A
.

A S LH
.

INJEC O

S .T
'O' , .A
'O' .N .
E .

E - , - .
T EC M. T EC M
.W ,
.T EC M
.
F , :E E C (303-14A E E C - V6 4.0L P ,
D O ).

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P : 11-M -2011
Fuel Charging and Controls - V6 4.0L Petrol - Fuel Charging and Controls
D T

Overview

F , : 303-04 - F C
C .

Inspection and Verification

1. 1. V .

2. 2. V .
Visual inspection
Mechanical Electrical
F F
D I
D L
F H
F / / S ( )
T E (EC M)
D
D

3. 3. I , ( )
.

4. 4. U (DTC )
DTC .

M DTC .

S mptom Chart

S mptom Possible causes Action

E , L /C C .F ,
I .C
F DTC . F C KP .R
C .R
(C KP) .
H
EC M

E E F ,
, .C DTC . F ,
F .
S
I ( )

D C - F ,
.F C KP ,
B .C DTC . F
C , .
(C KP)
F
E

D I C DTC . F , IAT
F MAF ,
F .F ,
.
I
(IAT)
M (MAF)

E
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D I C DTC . F , IAT
F MAF ,
( F .F ,
.
IAT
MAF
) E

E B C .C EC M .
/ F MAF FRP ,
EC M .F
MAF ,
F .
(FRP)
I
A
A
F

E F F ,
/ F .C DTC . F
I , TP APP ,
F .F
A .F
T (TP) , .
C DTC HO2 , DTC .F
A ,
(APP) .C .
T
I
HO2
T

R
( , )

E F F ,
F .F MAF
A APP ,
MAF .C DTC HO2 , DTC
APP .F ,
HO2 .
I

E F F ,
F .F MAF TP ,
MAF .F
H
TP .F ,
T .
I

E F F ,
/ F .F FRP , MAF
F , .
K C DTC HO2 , DTC .F
(KS)/ , .
R
FRP .
MAF
HO2
A
BARO
(
EC M )

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No throttle APP sensor For APP sensor and TP sensor tests, refer to the relevant section of
response malfunction the workshop manual. For throttle motor tests refer to the guided
TP sensors diagnostic routine on the approved diagnostic system.
Throttle motor

Poor throttle APP sensor For APP sensor, TP sensor, EC T sensor and MAF sensor tests, refer
response malfunction to the relevant section of the workshop manual. For transmission
TP sensors information, refer to the relevant section of the workshop manual.
EC T sensor For intake system checks, refer to the relevant section of the
MAF sensor workshop manual. For breather system checks, refer to the relevant
Transmission section of the workshop manual.
malfunction
Traction control event
Air leakage
Breather system
disconnected/restricted

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: For a full list of EC M DTC s, refer to section 303-14 - Electronic Engine C ontrols in the workshop manual.

DTC Description Possible Causes Action

P017100 System Too Lean Air intake leak C heck the intake air system for leaks, etc. C heck the fuel
(Bank 1) between MAF system for restrictions, DTC s, etc. C heck the exhaust system
sensor and for leaks, etc. C heck for evaporative emission DTC s.
cylinder head
MAF sensor fault
(low intake air
flow)
Fuel filter/system
restriction
Low fuel pressure
Fuel injector
restriction
Exhaust leak
(before catalyst)
Evaporative
emission system
fault

P017200 System Too Rich Restricted air filter C heck the intake air system for restrictions, etc. C heck the
(Bank 1) High fuel pressure fuel system for leaks, DTC s, etc. C heck the oil condition.
Leaking fuel C heck for MAF sensor and evaporative emission DTC s.
injector(s)
Oil contaminated
with fuel (too many
cold starts with
vehicle
subsequently not
getting hot enough
for long enough)
MAF sensor fault
Evaporative
emission system
fault

P017400 System Too Lean Air intake leak C heck the intake air system for leaks, etc. C heck the fuel
(Bank 2) between MAF system for restrictions, DTC s, etc. C heck the exhaust system
sensor and for leaks, etc. C heck for evaporative emission DTC S.
cylinder head
MAF sensor fault
(low intake air
flow)
Fuel filter/system
restriction
Low fuel pressure
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F

E
( )
E

P017500 S R R C , .C
(B 2) H , DTC , .C .
L C MAF DTC .
( )
O
(

)
MAF
E

P020100 C 1I I F ,
C /O .R
I .

P020200 C 2I I F ,
C /O .R
I .

P020300 C 3I I F ,
C /O .R
I .

P020400 C 4I I F ,
C /O .R
I .

P020500 C 5I I F ,
C /O .R
I .

P020600 C 6I I F ,
C /O .R
I .

I
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P210129 Throttle Actuator A Jammed throttle C heck for fuel charging DTC s and a message in the
C ontrol Motor blade, gearing or instrument cluster. Rectif as necessar . If the problem
C ircuit motor persists, renew the throttle bod . Refer to the relevant
Range/Performance workshop manual section.
P210164 Throttle Actuator A Jammed throttle C heck for fuel charging DTC s and a message in the
C ontrol Motor blade, gearing or instrument cluster. Rectif as necessar . If the problem
C ircuit motor persists, renew the throttle bod . Refer to the relevant
Range/Performance workshop manual section.
P210329 Throttle Actuator A Throttle Actuator C heck the electric throttle unit and circuits. Refer to the
C ontrol Motor control circuit short electrical guides. C lear the DTC s and test for normal
C ircuit High circuit to power operation. Refer to the guided diagnostic routine for this code
EC M fault on the approved diagnostic s stem. Refer to the warrant
polic and procedure manual if an EC M is suspect.
P210364 Throttle Actuator A C ontrol circuit C heck the electric throttle unit and circuits. Refer to the
C ontrol Motor short circuit to electrical guides. C lear the DTC s and test for normal
C ircuit High power operation. Refer to the guided diagnostic routine for this code
EC M fault on the approved diagnostic s stem. Refer to the warrant
polic and procedure manual if an EC M is suspect.
P210500 Throttle Actuator Throttle MIL C heck for DTC s indicating the reason for the fuel cut. Follow
C ontrol S stem - request due to fuel the action indicated for those DTC s.
Forced Engine cut
Shutdown
P210629 Throttle Motor Throttle MIL C heck for DTC s indicating the reason for the fuel cut. Follow
C ontrol S stem - request due to fuel the action indicated for those DTC s.
Forced Engine cut
Shutdown
P210664 Throttle Actuator Intended reduced C heck for fuel charging DTC s and a message in the
C ontrol S stem - availabilit fault instrument cluster. Rectif as necessar . If the problem
Forced Limited (limp home) persists, renew the throttle bod . Refer to the relevant
Power workshop manual section.
P211800 Throttle Actuator Throttle motor Refer to the electrical guides and check the wiring between
C ontrol Motor over current the EC M and throttle actuator. Refer to the guided diagnostic
C urrent condition detected routine for this code on the approved diagnostic s stem.
Range/Performance EC M fault Refer to the warrant polic and procedures manual if an
EC M is suspect.
P211900 Throttle Actuator Throttle spring C heck the throttle return spring on the throttle bod .
C ontrol Throttle fault Repair/renew as necessar . C heck for fuel charging DTC s
Bod and a message in the instrument cluster. Rectif as
Range/Performance necessar . If the problem persists, renew the throttle bod .
Refer to the relevant workshop manual section.

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Published: 11-May-2011
F el Cha ging and Con ol - V6 4.0L Pe ol - F el Rail
Removal and Installation

Special Tool( )
Fuel spring lock decoupling tool

310-044

Remo al
WARNINGS:

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the intake manifold.
For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
3. Release the fuel supply line.

Remove the bolt.

4. WARNING: The spilling of fuel is unavoidable during

this operation. Ensure that all necessary precautions are
taken to prevent fire and explosion.

Using the special tool, disconnect the fuel line.

Position an absorbent cloth to collect fluid spillage.

Depress the quick release connector.

5. WARNING: The spilling of fuel is unavoidable during

this operation. Ensure that all necessary precautions are
taken to prevent fire and explosion.

Remove the fuel rail.

Remove the 4 bolts.

Position an absorbent cloth to collect fluid spillage.

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6. Relea e and emo e he f el injec o .

Remo e and di ca d he f el injec o O- ing eal .

7. Remo e he ch aede al e.

Remo e he 2 To bol .

Di ca d he O- ing eal.

In alla ion
1. In all he ch aede al e.

C lean he componen ma ing face .

In all a ne O- ing eal.

Tigh en he bol o 6 Nm (4 lb.f ).

2. C lean he componen .
3. In all he f el ail.

In all f el injec o O- ing eal .

L b ica e he O- ing eal .

Tigh en he bol o 25 Nm (18 lb.f ).

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. C onnect the fuel line to the fuel rail.

C lean the component mating faces.

Install the clip.

Tighten the bolt to 6 Nm (4 lb.ft).

. Install the intake manifold.

For additional information, refer to: Intake Manifold (303-
01A Engine - V6 4.0L Petrol, In-vehicle Repair).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

Fuel Charging and Controls - V6 4.0L Petrol - Throttle Bod Gasket
Removal and Installation

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - V6 4.0L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Remove the air intake resonator.
For additional information, refer to: Intake Air Resonator
(303-12A Intake Air Distribution and Filtering - V6 4.0L
Petrol, Removal and Installation).
4. Remove the throttle bod .

Remove the 4 bolts.

Remove and discard the throttle bod gasket.

Installation
1. Install the throttle bod .

C lean the components.

Install a new gasket.

Tighten the 4 bolts to 10 Nm (7 lb.ft).

2. Install the air intake resonator.

For additional information, refer to: Intake Air Resonator
(303-12A Intake Air Distribution and Filtering - V6 4.0L
Petrol, Removal and Installation).
3. Install the engine cover.
For additional information, refer to: Engine C over - V6 4.0L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
4. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 11-Ma -2011

F el Cha ging and Con ol - V6 4.0L Pe ol - F el Injec o
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. WARNINGS:

Do not smoke or carr lighted tobacco or open flame of

an t pe when working on or near an fuel related
components. Highl flammable vapors are alwa s present and
ma ignite. Failure to follow these instructions ma result in
personal injur .

Do not carr or operate cellular phones when working

on or near an fuel related components. Highl flammable
vapors are alwa s present and ma ignite. Failure to follow
these instructions ma result in personal injur .

C AUTION: Before the disconnection or removal of an

components, ensure the area around joint faces and
connections are clean. Plug an open connections to prevent
contamination.

Remove the fuel rail.

For additional information, refer to: Fuel Rail (303-04A Fuel
C harging and C ontrols - V6 4.0L Petrol, Removal and
Installation).
3. Remove the fuel injector.

Release the injector.

Disconnect the electrical connector.

Remove and discard the O-ring seal.

In alla ion
1. C lean the component mating faces.
2. To install, reverse the removal procedure.

Lubricate the new O-ring seal with clean engine oil.

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P bli hed: 11-Ma -2011

Fuel Charging and Controls - V8 4.4L Petrol -
General Specif ication
Item Specification
Recommended fuel:
UK and ROW e cep NAS Unleaded 95 RON o EN228 Specifica ion
NAS P emi m nleaded ga oline i h a C LC o AKI oc ane a ing of 91 o highe .
Injectors:
Make Den o
T pe - No NAS 2W93-9F593-BA
T pe - NAS 2W93-9F593-AA
Fuel Pressures
Component bar psi
F el p mp 4.5 65
F el Rail 4.5 65
Torque Specif ications
Description Nm lb-ft
Engine co e mo n ing b acke n 6 4
F el ail To bol 10 7
In ake manifold MAP en o ho ing bol 10 7
In ake manifold ca ing bol 10 7
* In ake manifold bol 20 15
E ha ga eci c la ion (EGR) al e bol 10 7
Engine i ing ha ne ppo b acke bol 10 7
Th o le bod e aining bol 10 7
* Tighten bolts progressivel , working from the centre outwards

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F el Cha ging and Con ol - V8 4.4L Pe ol - F el Cha ging and Con ol
Description and Operation

C omponent Location

I em Pa N mbe De c ip ion
1 - Electronic throttle bod
2 - Induction elbow
3 - Fuel suppl cross over pipe
4 - Intake manifold
5 - RH fuel rail
6 - Fuel jump hose
7 - Injector housing
8 - Injectors (8 of)

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9 - LH

GENERAL

T , ,
.T ,
, .T .T
, E C M (EC M),
.A .A S
.

INTAKE MANIFOLD

T
.T
.T 10 .

R , , .
F , :I A D F (303-12B I A D F -
V8 4.4L P ,D O ).

FUEL PUMP

T
.T , ,
.
F , :F T L (310-01B F T L - V8 4.4L P ,D
O ).

THROTTLE BODY

T .I'
, ,A P P (APP) EC M.

T APP .T EMS
.S
.
F , :E E C (303-14B E E C - V8 4.4L P ,
D O ).

Induction Elbo

T .C
' .A
E G R (EGR) .

FUEL RAIL

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I em Pa N mbe De c ip ion
1 - RH fuel rail
2 - Fuel suppl cross over pipe
3 - Fuel temperature sensor
4 - Fuel jump hose
5 - C ooper fitting
6 - Fuel pressure accumulators
7 - LH fuel rail
8 - Injectors (8 of)
Each fuel rail maintains a constant fuel pressure of 4.5bar (65 psi). Four fuel injectors are installed in each injector
housing and are connected to the fuel rail. 'O' ring seals are used to seal the injectors in the fuel rails and inlet
manifold. A 'C ooper' st le fitting is used to connect the fuel jump hose to the LH fuel rail.

A fuel pressure accumulator is attached to each of the fuel rails and a Schraeder valve is installed in the front end of
the LH fuel rail to provide a pressure test connection for maintenance.

F EL P E E ACC M LA O

A fuel pressure accumulator is attached centrall to each of the fuel rails. The accumulators act as a damper to damp
pulses from the pump and ensure that the fuel pressure in the rail and to the injectors is constant.

F EL EMPE A E EN O

The fuel temperature sensor is located in the rear of the RH fuel rail. The sensor is an NTC sensor, which is connected
to the EC M b two wires.
For additional information, refer to: Electronic Engine C ontrols (303-14B Electronic Engine C ontrols - V8 4.4L Petrol,
Description and Operation).

INJEC O

Eight, top fed, 12-jet, fuel injectors are installed in the fuel rails. Two 'O' rings seal each injector to the manifold
interface and should be renewed whenever an injector is refitted to an engine. A small amount of engine oil can be
applied to the 'O' rings to aid installation. No other form of lubrication should be used. The fuel jets from the injectors
are directed onto the back of the intake valves.
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The injectors are electromagnetic solenoid valves controlled b the EC M. Each injector contains a solenoid-operated
needle valve, which is closed while the solenoid winding is de-energised. The solenoid winding is connected to a
power feed from the main rela and to an earth through the EC M. The EC M switches the earth to control the opening
and closing of the needle valve. While the needle valve is open, fuel is spra ed into the c linder intake tract onto the
back of the intake valves. The EC M meters the amount of fuel injected b adjusting the time that the needle valve is
open.
For additional information, refer to: Electronic Engine C ontrols (303-14B Electronic Engine C ontrols - V8 4.4L Petrol,
Description and Operation).

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P : 11-M -2011
Fuel Charging and Controls - V8 4.4L Petrol - Fuel Charging and Controls
D T

Overview

F , 303-04 - F C
C .

Inspection and Verification

1. 1. V .

2. 2. V .
Visual inspection
Mechanical Electrical
F F
D I
D L
F H
F / / S ( )
T E (EC M)
D
D

3. 3. I , ( )
.

4. 4. U (DTC )
DTC .

M DTC .

S mptom Chart

S mptom Possible causes Action

E , L /C C .F ,
I .C
F DTC . F C KP .R
C .R
(C KP) .
H
EC M

E E F ,
, .C DTC . F ,
F .
S
I ( )

D C - F ,
.F C KP ,
B .C DTC . F
C , .
(C KP)
E
(EGR)

F
E

D I C DTC . F , IAT
F MAF ,
F .F ,
.
I
(IAT)
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M (MAF)

D I C DTC . F , IAT
F MAF ,
( F .F ,
.
IAT
MAF
) E

E B C .C EC M .
/ F MAF FRP ,
EC M .F
MAF ,
I .
A
A
F

E F F ,
/ F .C DTC . F
I , TP APP ,
F .F
A .F
T (TP) , .
C DTC HO2 , DTC .F
A ,
(APP) .C .
T
I
EGR
HO2
T

R
( , )

E F F ,
F .F MAF
A APP ,
MAF .C DTC HO2 , DTC
APP .F ,
HO2 .
I

E F F ,
F .F MAF TP ,
MAF .F
H
TP .F ,
T .
I

E F F ,
/ F .F FRP , MAF
F , .
K C DTC HO2 , DTC .F
(KS)/ , .
R
MAF .
HO2
A
BARO
(
EC M )
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No throttle APP sensor For APP sensor and TP sensor tests, refer to the relevant section of
response malfunction the workshop manual. For throttle motor tests refer to the guided
TP sensors diagnostic routine on the approved diagnostic system.
Throttle motor

Poor throttle APP sensor For APP sensor, TP sensor, EC T sensor and MAF sensor tests, refer
response malfunction to the relevant section of the workshop manual. For transmission
TP sensors information, refer to the relevant section of the workshop manual.
EC T sensor For intake system checks, refer to the relevant section of the
MAF sensor workshop manual. For breather system checks, refer to the relevant
Transmission section of the workshop manual.
malfunction
Traction control event
Air leakage
Breather system
disconnected/restricted

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: For a full list of EC M DTC s, refer to workshop manual section 303-14 - Electronic Engine C ontrols.

DTC Description Possible Causes Action

P008700 Fuel rail/system Fuel rail pressure For FRP sensor tests, refer to the relevant workshop manual
pressure too low (FRP) sensor section. C heck the fuel lines, check the fuel pressure and the
disconnected fuel pump module circuits.
FRP sensor to EC M
sensing circuit
short circuit to
ground
FRP sensor supply
circuit high
resistance
FRP sensor failure
Fuel line leak
Restricted fuel line
Fuel pump module
circuit high
resistance
Fuel pump module
circuit short circuit
to ground
Fuel pump module
failure

P008800 Fuel rail/system Fuel rail pressure For FRP sensor tests, refer to the relevant workshop manual
pressure too high (FRP) sensor to section. C heck the fuel lines, check the fuel pressure and the
EC M wiring fuel pump module circuits.
(supply/sense):
short circuit to
each other
FRP sensor to EC M
sense circuit short
circuit to power
FRP sensor failure
Fuel pressure
control valve
(FPC V) fault
Fuel pump module
circuit short circuit
to power
Fuel pump module
failure

P017100 System Too Lean Air intake leak C heck the intake air system for leaks, etc. C heck the fuel
(Bank 1) between MAF system for restrictions, DTC s, etc. C heck the exhaust system
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, .C DTC .

MAF
(
)
F /

L
F

E
( )
E

P017200 S T R R C , .C
(B 1) H , DTC , .C .
L C MAF DTC .
( )
O
(

)
MAF
E

P017400 S T L A C , .C
(B 2) MAF , DTC , .C
, .C DTC S.

MAF
(
)
F /

L
F

E
( )
E

P017500 S R R C , .C
(B 2) H , DTC , .C .
L C MAF DTC .
( )
O
(

)
MAF
E

P020100 C 1I I F ,
C /O .R
I .

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resistance, short
circuit to ground
Injector failure
P020200 C linder 2 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit / Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P020300 C linder 3 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit / Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P020400 C linder 4 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit / Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P020500 C linder 5 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit / Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P020600 C linder 6 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit / Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P020700 C linder 7 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit/Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P020800 C linder 8 Injector Injector For fuel s stem tests, refer to the relevant workshop manual
C ircuit/Open disconnected section. Refer to the guided diagnostic routine for this code
Injector harness on the approved diagnostic s stem.
wiring high
resistance, short
circuit to ground
Injector failure

P210129 Throttle Actuator A Jammed throttle C heck for fuel charging DTC s and a message in the
C ontrol Motor blade, gearing or instrument cluster. Rectif as necessar . If the problem
C ircuit motor persists, renew the throttle bod . Refer to the relevant
Range/Performance workshop manual section.
P210164 Throttle Actuator A Jammed throttle C heck for fuel charging DTC s and a message in the
C ontrol Motor blade, gearing or instrument cluster. Rectif as necessar . If the problem
C ircuit motor persists, renew the throttle bod . Refer to the relevant
Range/Performance workshop manual section.
P210329 Throttle Actuator A Throttle Actuator C heck the electric throttle unit and circuits. Refer to the
C ontrol Motor control circuit short electrical guides. C lear the DTC s and test for normal
C ircuit High circuit to power operation. Refer to the guided diagnostic routine for this code

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EC M fault on the approved diagnostic s stem. Refer to the warrant
polic and procedure manual if an EC M is suspect.
P210364 Throttle Actuator A C ontrol circuit C heck the electric throttle unit and circuits. Refer to the
C ontrol Motor short circuit to electrical guides. C lear the DTC s and test for normal
C ircuit High power operation. Refer to the guided diagnostic routine for this code
EC M fault on the approved diagnostic s stem. Refer to the warrant
polic and procedure manual if an EC M is suspect.
P210500 Throttle Motor Throttle MIL C heck for DTC s indicating the reason for the fuel cut. Follow
C ontrol S stem - request due to fuel the action indicated for those DTC s.
Forced Engine cut
Shutdown
P210629 Throttle Actuator Intended reduced C heck for fuel charging DTC s and a message in the
C ontrol S stem - availabilit fault instrument cluster. Rectif as necessar . If the problem
Forced Limited (limp home) persists, renew the throttle bod . Refer to the relevant
Power workshop manual section.
P210664 Throttle Actuator Intended reduced C heck for fuel charging DTC s and a message in the
C ontrol S stem - availabilit fault instrument cluster. Rectif as necessar . If the problem
Forced Limited (limp home) persists, renew the throttle bod . Refer to the relevant
Power workshop manual section.
P211800 Throttle Actuator Throttle motor Refer to the electrical guides and check the wiring between
C ontrol Motor over current the EC M and throttle actuator. Refer to the guided diagnostic
C urrent condition detected routine for this code on the approved diagnostic s stem.
Range/Performance EC M fault Refer to the warrant polic and procedures manual if an
EC M is suspect.
P211900 Throttle Actuator Throttle spring C heck the throttle return spring on the throttle bod .
C ontrol Throttle fault Repair/renew as necessar . C heck for fuel charging DTC s
Bod and a message in the instrument cluster. Rectif as
Range/Performance necessar . If the problem persists, renew the throttle bod .
Refer to the relevant workshop manual section.

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Published: 11-May-2011
F el Cha ging and Con ol - V8 4.4L Pe ol - F el Rail
Removal and Installation

Special Tool( )
Fuel spring lock decoupling tool
310-D005

Remo al
WARNINGS:

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - V8 4.4L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Remove the engine cover studs.

Release the electrical connectors from the engine

cover brackets.

Remove the 4 nuts.

4. C AUTION: Before the disconnection or removal of any

components, ensure the area around joint faces and
connections are clean. Plug any open connections to prevent
contamination.

Disconnect the crankcase vent hoses.

5. Disconnect the evaporative emission hose from the intake
manifold assembly.
6. Release the evaporative loss control valve from the
intake manifold mounting, move the hose assembly aside
for access.

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. Relea e he f el pipe f om he clip .

. WARNING: The pilling of f el i na oidable d ing

hi ope a ion. En e ha all nece a p eca ion a e
aken o p e en fi e and e plo ion.

U ing he pecial ool, di connec he f el line.

Po i ion an ab o ben clo h o collec fl id pillage.

. Po i ion he i ing ha ne ppo b acke a ide fo

acce .

Remo e he 2 bol .

10. Relea e he engine i ing ha ne clip f om he f el ail.

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. Disconnect the fuel injector electrical connectors.

. Disconnect the engine gas recirculation modulator

electrical connection.
. Disconnect the fuel temperature sensor electrical
connector.

. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the fuel rail.

Remove the 4 Tor bolts.

Remove and discard the fuel injector O-ring seals.

. Remove the fuel temperature sensor.

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16. Remove the fuel injectors.

Remove the retaining clips.

Release the fuel injectors.

Remove and discard the fuel injector O-ring seals.

In alla ion
1. C lean the components.
2. Install the fuel injectors to the fuel rail.

Install fuel injector O-ring seals.

Lubricate the O-ring seals with clean engine oil.

Install the fuel injectors.

Secure the fuel injector retaining clips.

3. C lean the components.

4. Install the fuel temperature sensor.

Appl sealant to the sensor thread.

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. In all he f el ail.

In all f el injec o O- ing eal .

L b ica e he O- ing eal i h clean engine oil.

Tigh en he To bol o 10 Nm (7 lb.f ).

. C onnec he f el empe a e en o elec ical connec o .

. C onnec he f el injec o elec ical connec o .
. C onnec he engine i ing ha ne o he in ake manifold.
. In all he engine i ing ha ne ppo b acke .

Tigh en he bol o 10 Nm (7 lb.f ).

. C onnec he f el line o he f el ail.

C lean he componen ma ing face .

Po i ion he f el pipe in o clip .

. In all he e apo a i e lo al e a embl o he in ake

manifold b acke and connec he ho e.

C lean he componen ma ing face .

. C onnec he c ankca e en ho e .

C lean he componen ma ing face .

. In all he engine co e mo n ing b acke .

Tigh en he n o 6 Nm (4 lb.f ).

A ach he i ing ha ne connec o block o he

b acke .

. In all he engine co e .
Fo addi ional info ma ion, efe o: Engine C o e - V8 4.4L
Pe ol (501-05 In e io T im and O namen a ion, Remo al
and In alla ion).
. C onnec he ba e g o nd cable.

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Published: 11-Ma -2011

F el Cha ging and Con ol - V8 4.4L Pe ol - F el Injec o
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. WARNINGS:

Do not smoke or carr lighted tobacco or open flame of

an t pe when working on or near an fuel related
components. Highl flammable vapors are alwa s present and
ma ignite. Failure to follow these instructions ma result in
personal injur .

Do not carr or operate cellular phones when working

on or near an fuel related components. Highl flammable
vapors are alwa s present and ma ignite. Failure to follow
these instructions ma result in personal injur .

C AUTION: Before the disconnection or removal of an

components, ensure the area around joint faces and
connections are clean. Plug an open connections to prevent
contamination.

Remove the fuel rail.

For additional information, refer to: Intake Manifold
Assembl (303-04B Fuel C harging and C ontrols - V8 4.4L
Petrol, Removal and Installation).
3. Remove the fuel injectors.

Release the 8 clips.

Discard the fuel injector O-ring seals.

In alla ion
1. C lean the component mating faces.
2. To install, reverse the removal procedure.

Install fuel injector O-ring seals.

Lubricate the O-ring seals with clean engine oil.

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Published: 11-Ma -2011

Fuel Charging and Controls - V8 4.4L Petrol - Intake Manifold Assembl
Removal and Installation

Special Tool(s)
Fuel spring lock decoupling tool

310-005

Removal
1. Secure the hood in the service position.

Release the support struts.

2. Disconnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
3. Remove the throttle bod gasket.
For additional information, refer to: Throttle Bod Gasket
(303-04B Fuel C harging and C ontrols - V8 4.4L Petrol,
Removal and Installation).
4. Remove the engine cover brackets.

Release the electrical connectors from the engine

cover brackets.

Remove the 4 nuts.

5. C AUTION: Before the disconnection or removal of an

components, ensure the area around joint faces and
connections are clean. Plug an open connections to prevent
contamination.

Disconnect the crankcase vent hoses.

6. Disconnect the evaporative emission hose from the intake
manifold assembl .
7. Release the evaporative loss control valve from the
intake manifold mounting, move the hose assembl aside
for access.

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. Release the fuel pipe from the clips.

. Using the special tool, disconnect the fuel line.

Position an absorbent cloth to collect fluid spillage.

10. Release the camshaft position (C MP) sensor connector

block from the intake manifold assembl .

11. Position the wiring harness support bracket aside for

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acce .

Remo e he 2 bol .

. Relea e he EGR al e.

Remo e he 2 bol .

Di ca d he ga ke .

. Relea e he engine i ing ha ne clip f om he f el ail.

. Di connec he f el injec o elec ical connec o .

. Di connec he f el empe a e en o elec ical

connec o .

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1 . Remove the 10 intake manifold bolts.

1 . Remove the intake manifold.

Disconnect the mass air flow (MAF) sensor electrical

connector.

Disconnect the brake booster vacuum hose from the

intake manifold.

Discard the gaskets.

1 . NOTE: Do not disassemble further if the component is

removed for access onl .

Remove the NVH pad from the RH side of the intake

manifold.
1 . Remove the intake manifold casting.

Disconnect the vacuum hose from the intake

manifold.

Remove the 4 bolts.

20. Remove the intake manifold MAP sensor housing.

Remove the 7 bolts.

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21. Remo e he f el ail.

Remo e he 4 To bol .

Relea e he f el injec o .

Di ca d he f el injec o O- ing eal .

22. Remo e he f el injec o ho ing .

Remo e he 10 To c e .

Relea e he f el injec o ho ing and di ca d he

ga ke .

In alla ion
1. In all he f el injec o ho ing .

C lean he componen ma ing face .

In all he ga ke .

In all he To c e .

2. In all he f el ail.

C lean he componen ma ing face .

In all f el injec o O- ing eal .

L b ica e he O- ing eal i h clean engine oil.

Tigh en he 4 To bol o 10 Nm (7 lb.f ).

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. Install the intake manifold MAP sensor housing.

C lean the component mating faces.

Tighten the 7 bolts to 10 Nm (7 lb.ft).

. Install the intake manifold casting.

C lean the component mating faces.

Install the 4 bolts and tighten to 10 Nm (7 lb.ft).

. Install the NVH pad to the RH side of the intake manifold.

. C lean the components.
. With assistance, install the intake manifold.

Install the gaskets.

C onnect the mass air flow (MAF) sensor electrical

connector.

C onnect the brake booster vacuum hose to the intake

manifold.

. Install the bolts.

Evenl and progressivel tighten the bolts to 20 Nm (15

lb.ft).

. C onnect the fuel temperature sensor electrical connector.

. C onnect the fuel injector electrical connectors.
. C onnect the engine wiring harness to the intake manifold.
. Install the EGR valve.

Install a new gasket.

Tighten the bolts to 10 Nm (7 lb.ft).

. Install the engine wiring harness support bracket.

Tighten the bolts to 10 Nm (7 lb.ft).

. Position the C MP sensor electrical connector block, to the

intake manifold.
. C onnect the fuel line to the fuel rail.

C lean the component mating faces.

Position the fuel pipe into clips.

. Install the evaporative loss valve assembl to the intake

manifold bracket and connect the hose.

C lean the component mating faces.

. C onnect the crankcase vent hoses.

C lean the component mating faces.

. Install the engine cover mounting brackets.

Tighten the nuts to 6 Nm (4 lb.ft).

Attach the wiring harness connector blocks to the

brackets.

. Install the throttle bod gasket.

For additional information, refer to: Throttle Bod Gasket
(303-04B Fuel C harging and C ontrols - V8 4.4L Petrol,
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Removal and Installation).
. C onnect the batter ground cable.
. C onnect the hood support struts.

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Published: 11-Ma -2011

Fuel Charging and Controls - V8 4.4L Petrol - Throttle Bod Gasket
Removal and Installation

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - V8 4.4L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Remove the air intake resonator. For additional information,
refer to: Intake Air Resonator (303-12B Intake Air
Distribution and Filtering - V8 4.4L Petrol, Removal and
Installation).
4. Release the throttle bod .

Remove the 4 bolts.

Remove and discard the throttle bod gasket.

Installation
1. Install the throttle bod .

C lean the components.

Install a new gasket.

Tighten the 4 bolts to 10 Nm (7 lb.ft).

2. Install the air intake resonator. For additional information,

refer to: Intake Air Resonator (303-12B Intake Air
Distribution and Filtering - V8 4.4L Petrol, Removal and
Installation).
3. Install the engine cover.
For additional information, refer to: Engine C over - V8 4.4L
Petrol (501-05 Interior Trim and Ornamentation, Removal
and Installation).
4. C onnect the batter ground cable.
5. Using the approved diagnostic equipment, clear the
powertrain control module (PC M) adaptions.

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P bli hed: 09-A g-2011

Fuel Charging and Controls - TDV6 2.7L Diesel -
General Specif ication
Item Description
* Recommended f el Die el o A omo i e Ga Oil (AGO) o EN590 Specifica ion
* This engine is NOT compatible with 'Bio-diesel' fuel
Torque Specif ications
Description Nm lb-ft
High pressure fuel suppl lines to injector and suppl manifold unions:
S age 1 - Union o injec o 15 11
S age 2 - Union o ppl manifold 15 11
S age 3 - Union o injec o 30 22
S age 4 - Union o ppl manifold 30 22
High pressure fuel suppl lines to suppl manifold and diverter rail unions:
S age 1 - Union o ppl manifold 15 11
S age 2 - Union o di e e ail 15 11
S age 3 - Union o ppl manifold 35 26
S age 4 - Union o di e e ail 35 26
F el injec ion di e e ail d 23 17
F el ppl line e aining bol 10 7
C ankca e en oil epa a o loca ing d 10 7
EGR coolan c o -o e pipe bol 13 10
In ake ai h -off h o le e aining d 10 7
In ake ai h -off h o le elbo e aining bol 10 7
F el injec ion p mp p lle n 50 37
F el injec ion p mp ec ing bol 23 17
F el injec ion p mp bel ea co e e aining bol 7 5
F el injec ion p mp bel en ione e aining bol 25 18
F el injec o e aining bol 10 7
Fuel Pressures
Component bar psi
F el p mp 0.5 7.25
High p e e f el injec ion p mp 1650 ma im m 23931 ma im m

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P : 11-M -2011
F el Cha ging and Con ol - TDV6 2.7L Die el - F el Cha ging and Con ol
D O

C L

I em Pa N mbe De c ip ion
1 - H - (HP) (2 )
2 - HP -F (6 )
3 - I (6 )
4 - L P (LP) -F
5 - HP -H P P (HPP)
6 - LP -I -
7 - C ( 6)
8 - HPP
9 - HPP
10 - HP
11 - R E A D (READ)
12 - LH

GENERAL

T T V6 H -P (HP) .W ,
H -P P (HPP) ( ),
.P , , 1650 .

T - ( ) , .

F .

T E C M (EC M),
.

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The common rail fuel injection system has the following features:

High fuel injection pressures of up to 1650 bar for greater atomisation of fuel (increasing performance and
lowering emissions)
Variable injection to optimise combustion in all engine operating conditions
Low tolerances and high precision throughout the life of the system

The fuel system is divided into 2 sub systems:

Low-Pressure (LP) system

HP system.

The LP system features the following components:

In-tank fuel pump

Fuel pressure regulator (integral to the fuel delivery module)
Fuel filter
Return pipes and fuel cooler
Injector return pipes
Fuel coolers (engine and vehicle)

The LP system pressure is regulated to 0.5 bar.

The HP system features the following components:

HPP
C ommon rails and diverter rail
HP fuel pipes
Injectors.

LP SYSTEM

In- ank F el P mp

The electric fuel pump is located inside the fuel tank. Fuel is pumped from the tank via the in-tank fuel pump, to the
HPP via the fuel filter.
For additional information, refer to: Fuel Tank and Lines (310-01C Fuel Tank and Lines - TDV6 2.7L Diesel, Description
and Operation).

F el Fil er

The fuel filter is located in the engine compartment on the left hand side, packaged to be protected against damage.
Incorporated in the fuel filter housing is a bimetallic temperature valve, which will start to close at 30 C (86 F) and
will fully close at 50 C (122 F). This allows pre-heated diesel fuel to circulate inside the fuel filter to prevent waxing in
cold operating conditions.

F el Cooler

Two fuel coolers are fitted to the vehicle. One is located in the 'vee' of the engine block, and has a coolant system
connection to aid heat transfer. The second cooler is located in the fuel return line and is a fuel to air cooler.
For additional information, refer to: Fuel Tank and Lines (310-01C Fuel Tank and Lines - TDV6 2.7L Diesel, Description
and Operation).

HP SYSTEM

HPP

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The HPP i a h ee- i (120 deg ee a a ) adia ge i h a HP di ace e f 0.8 cc. A e i ed, i
ha he abi i d ce a a i e e f 1650 ba . The h i g i ca f i , he f a ge i ca f
a i i .

The i d i e f he ca haf ia a hed be . I d e eed be i ed he e gi e d i g be

e ace e i e ice.

The e i ed e e he HPP i -0.3 ba +0.5 ba ga ge. The e e e i -0.3 ba +0.8 ba

ga ge.

The i i ed de i e fficie f e he HP ai f a e gi e- e ai gc di i .

The HPP c i f he f i gc e :

I e a T a fe P (ITP)
V e C Va e (VC V)
HP i gee e (3 f)
P e e C Va e (PC V)

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The ITP is a 5 vane pump. This conve s fuel to the VC V.

The VC V is a variable position solenoid valve electronicall controlled b the EC M. The VC V is located between the
ITP and the HP pumping elements. The VC V determines the amount of fuel that is delivered to the HP pumping
elements. When there is no signal to the VC V the valve is closed, therefore no fuel deliver .

The 3 HP pumping elements are connected together in a fuel ring circuit within the pump. There is a single HP outlet
connection for the HP pipe to the HP diverter rail.

The PC V is a variable position solenoid valve electronicall controlled b the EC M. The PC V is located between the HP
pumping elements and the HP outlet connection. The PC V regulates the amount of fuel pressure in the fuel rails and is
controlled b the EC M. When there is no signal to the PC V the valve is open, therefore no rail pressure can be
generated.

High Pressure Fuel Flo

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I em Pa N mbe De c ip ion
A - LP fuel suppl
B - Fuel suppl to the HP pumping elements

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C - HP outlet connection to the HP diverter rail
D - LP fuel return (spill)
1 - LP side of ITP
2 - ITP pressure relief valve
3 - Screen filter
4 - VC V
5 - ITP
6 - Edge filter (to protect PC V)
7 - PC V
8 - N/A
9 - Eccentric on HPP drive shaft
10 - Pumping element inlet valve
11 - Pumping element outlet valve
12 - HP ring line
13 - HPP elements (3 of)
14 - Lubricating valve
The fuel induced by the ITP (5) is conveyed to the VC V (4) and the lubricating valve (14).

When the VC V is closed, the ITP pressure relief valve (2), lying parallel to the transfer pump, opens and conveys the
fuel back to the LP side (1) of the transfer pump.

The fuel passes through the lubricating valve (14) into the interior of the HPP and from there to the fuel return (D).
The fuel is used to lubricate the pump.

The VC V (4) determines the quantity of fuel (B) that is supplied to the pumping elements (13).

The fuel from the HP outlets (11) of the three pumping elements comes together in a ring line (12) and is conveyed
through the HP outlet of the HPP ) to the rails.

The PC V (7) regulates the fuel pressure in the fuel rails. Reducing rail pressure via the PC V results in fuel from the
rail returning to the LP fuel return (D).

I em Pa N mbe De c ip ion
A - Pump pressure (bar)
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B - P eed ( )
The HPP ca 1600 ba f e e e c i ih h e c i 1650 ba . P eed i 5/6
e gi e eed. H e e i i ca ib a ed de i e f e e e de e da e gi e eed a d ad a d i a a
de f c .

Whe he HPP i a ed, e e i c ea ed he he VC V i e a d he PC V i c ed. The VC V a d PC V a e

a iab e ii a a iab e f e de i e a d e e c .

Whe he EC M ac a e he ie ac a , he ai e e d i ff- e b addi i a f e bei g de i e ed he

HP ai b he PC V.

P e e Red c ion Af e Engine Ha S opped

The f e e e i he e i ed ced i hi a fe ec d af e he e gi e ha ed a he PC V ge
ha he h di g c e i e i e , a d he ef e e . N e id a e e e ai i he e a d he f e i
e ed he f e e i e (D) h gh he e PC V. The e i e ee .

F nc ion of High A P e e Elemen

F e I d ci

D i g he d a d i f he i (3), a ac i he c i de i ge e a ed, hich e he i e

a e (1) agai he f ce e e ed b he a e i g. The f e (A), hich i f i g a he VC V, i c ed i . A
he a e i e he e a e (2) i c ed d e he e e diffe e ce be ee he c i de a d he HP f e
i he i g i e.

F e De i e

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The eccen ic on he HPP d i e haf (5) p e e he pi on (3) p a d . The inle al e (1) i hen clo ed h o gh he
fo ce e e ed b he al e p ing and he p e e being b il p in he p mp c linde . The o le al e (2) open
hen he p e e in he p mp c linde i g ea e han he f el p e e in he ing line (B).

Vol me Con rol Val e (VCV)

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I em Pa N mbe De c ip ion
1 - Piston
2 - Sleeve
3 - C ompression spring
4 - C oil
5 - Armature
6 - VC V
The VC V is fixed directly to the HPP.

The VC V regulates the fuel supply (and hence the quantity of fuel) from the transfer pump to the HPP elements,
depending on the fuel pressure in the rail.

This makes it possible to match the delivery of the HPP to the requirements of the engine from the low-pressure side.
The quantity of fuel flowing back to the main fuel supply line is kept to a minimum.

In addition, this adjustment reduces the power consumption of the HPP, improving the efficiency of the engine.

NOTE: The fuel volume control valve default is closed without electrical supply. An open circuit connector will
prevent the engine from running.

NOTE: The VC V cannot be replaced as a separate component in service.

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I em Pa N mbe De c ip ion
A - VC V not actuated
B - VC V actuated
1 - Fuel suppl from the transfer pump
2 - Piston
3 - Fuel suppl to the HPP
4 - C oil energised
5 - Quantit of fuel
6 - C ontrol current
7 - VC V at constant engine speed
VCV No Ac a ed (A)

When there is no power supplied, the piston (2) closes the opening between the two connections (1) and (3) through
the force of the compression spring. The fuel suppl to the HPP is interrupted.

VCV Ac a ed (B)

The EC M energi es the coil (4) of the valve, according to the engines requirements. The armature force is
proportional to the control current and counteracts the compression spring through the moving piston (2).

As a result, the opening between the two connections (1) and (3) and hence the quantit of fuel (5) supplied through
the connector (3) to the HPP is also proportional to the control current (6). This means that the greater the opening
cross-section, the greater the quantit of fuel supplied.

P e e Con ol Val e (PCV)

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The PC V is located on the HPP. It governs the fuel pressure at the HP outlet of the HPP and thus, the fuel pressure
within the rail. In addition, the PC V dampens the fluctuations in the pressure, which occur during the delivery of fuel
through the HPP and through the injection process.

The PC V ensures that optimum pressure exists in the rail for every operating condition of the engine.

The PC V is an electro-magnetically operated valve with spring support.

The electrical current supplied by the EC M through the solenoid pulls back the control pin. This allows the diesel fuel
to pass the ball valve and thus the fuel flow into the common rails.

The entire armature is coated with fuel for lubrication and cooling.

NOTE: The PC V cannot be replaced as a separate component in service.

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I em Pa N mbe De c ip ion
A - PC V non-con olled
B - PC V con olled
1 - F el f om he HPP
2 - To f el e n
3 - Ball al e
4 - C omp e ion p ing
5 - A ma e
6 - C oil ene gi ed
7 - C on ol pin
8 - High p e e f el
9 - C on ol c en
10 - C ha ac e i ic of he PC V
PCV Non-con olled (A)

The ball al e (3) ill onl be ope a ed h o gh he fo ce e e ed pon i b he p ing (4). The eb , he PC V i
cla ed a open.

PCV Con olled (B)

The c en flo ing h o gh he olenoid (6) d a he pin (7) do n. Thi in n an fe he magne ic fo ce ia he

pin o he ball al e (3). The p ll of he pin, and he p e e on he ball al e, i p opo ional o he al e flo (9).

HP Common F el Rail

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The f el ail a e man fac ed f om fo ged eel. The o e he f el a high p e e and p e en p e e

fl c a ion in he HP em.

All HP pipe ha e an in e nal diame e of 2.5mm e cep he pipe o he injec o , hich a e 3.0mm. To al ail ol me
i 33cc.

F EL INJEC O

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I em Pa N mbe De c ip ion
1 - Harness connection
2 - HP connection
3 - C ontrol piston
4 - Nozzle needle
5 - Nozzle HP chamber
6 - Nozzle spray holes
7 - Valve mushroom
8 - Fuel return
9 - Valve piston
10 - Piezo actuator
The fuel injectors are operated directly by the EC M for fuel metering (start of injection and quantity of fuel injected).

The operating components of the piezo fuel injectors are:

The piezo actuator

The injector body containing the hydraulic servo system
The fuel injector nozzle

NOTE: New injectors can be installed in any cylinder and DO NOT have to be configured.

NOTE: Each Injection event is controlled by a charge and discharge cycle allowing energy to dissipate in, and
recover from, the injector. Never disconnect the wiring connector when the vehicle is running. The injector may
remain open thus causing engine damage.

NOTE: For safety reasons, the engine must be at standstill for 30 seconds before starting work on the HP fuel
systems.

F el Injec or No Ac a ed (No Injec ing F el)

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I em Pa N mbe De c ip ion
1 - Pie o actuator
2 - HP connection
3 - H draulic force applied on control piston
4 - H draulic force acting on tip of no le
5 - C ontrol piston
6 - Fuel return
7 - Fuel return
8 - C ontrol piston
9 - No le needle
10 - High pressure chamber of no le
11 - C ontrol chamber
12 - Valve mushroom
The HP fuel from the fuel-rail passes through the HP connection (2) into the control chamber (11) and into the HP
chamber (10) of the fuel injector no le.

The pie o actuator (1) is currentless and the valve mushroom (12) closes the bore to the fuel return (7) b means of
spring pressure.

There is how ever a continuous fuel return (6) to vent internal leakage within the injector.

The h draulic force (3), which is now applied on the control piston b the fuel under high pressure in the control
chamber (11) through the control piston (8), is greater than the h draulic force (4) acting on the tip of the no le
(since the area of the control piston in the control chamber is greater than the area of the tip of the no le).

F el Injec or Ac a ed (Injec ing F el)

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I em Pa N mbe De c ip ion
1 - High p e e ppl
2 - Val e pi on
3 - H d a lic fo ce applied on con ol pi on
4 - H d a lic fo ce ac ing on ip of no le
5 - C on ol pi on
6 - F el e n
7 - Pie o ac a o
8 - F el e n
9 - Val e pi on
10 - Val e m h oom
11 - C on ol chambe
12 - C on ol pi on
13 - No le needle
The pie o ac a o (7) ene gi ed b he EC M e end (cha ging pha e) and p e e on he al e pi on (9). The al e
m h oom (10) open he bo e, hich connec he con ol chambe (11) o he f el e n (8 hen 6).

A a e l , he p e e in he con ol chambe d op , and he h d a lic fo ce (4) ac ing on he ip of he no le

needle i no g ea e han he fo ce (3) ac ing on he con ol pi on in he con ol chambe .

The no le needle (13) mo e p a d and he f el pa e h o gh he i p a hole in o he comb ion chambe .

Engine S ar ing

D ing a ing, he f el ail p e e m be a lea 150 ba . Sho ld he p e e be belo hi fig e, he injec o

ill no ope a e, e l ing in he ehicle no a ing.

Engine S opped

To op he engine he EC M op ene gi ing he pie o ac ao , he efo e, no f el i injec ed and he engine peed

d op o e o.

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Published: 11-May-2011
F el Cha ging and Con ol - TDV6 2.7L Die el - F el Cha ging and Con ol
Diagnosis and Testing

O e ie

C ommon rail diesel

The 2.7L fuel injection system is a common-rail design, running at the high-pressures of up to 1,600 bar (23,206
lb/in ) typical of such systems.

The fuel volume control valve (FVC V) regulates the amount of fuel supplied to the high-pressure side of the fuel
injection pump, while the fuel pressure control valve (FPC V) regulates the pressure.

The high-pressure fuel is delivered to the fuel rail where it is stored, ready for use by the fuel injectors.

The fuel injectors are Piezo type, and are controlled by the engine control module (EC M) from inputs from the engine
management sensors.

The fuel injectors operate in stages, giving a pilot injection before the main injection to reduce detonation noise and
help improve the efficiency of the engine.

For additional information, refer to the workshop manual section 303-04 - Fuel C harging and C ontrols.

In pec ion and Ve ifica ion

• WARNINGS:

Do NOT carry out any work on the fuel system with the engine running. The fuel pressure within the system can
be as high as 1600 bar (23,206 lb/in ). Failure to follow this instruction may result in personal injury.

Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow
this instruction may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow this instruction may result in personal injury.

After carrying out repairs, the fuel system must be checked visually for leaks. This should be done after the
engine has been run, but with the engine switched OFF. Failure to follow this instruction may result in personal injury.

If taken internally, DO NOT induce vomiting. Seek immediate medical attention. Failure to follow this instruction
may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure
to follow this instruction may result in personal injury.

Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention. Failure to follow this instruction may result in personal injury.

• C AUTIONS:

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 the fuel system. Failure to follow this instruction may
result in damage to the vehicle.

The fuel pipes between the injectors and the rail must be discarded after each use, and new pipes installed.
Failure to follow this instruction may result in damage to the vehicle.

It is essential that absolute cleanliness is observed when working with these components. Always install
blanking plugs to any open orifices or lines. Failure to follow this instruction may result in damage to the vehicle.

Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible.
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Areas in which work on clutches, brakes or where welding or machining are carried out are not suitable in view of the
risk of contamination to the fuel system. Failure to follow this instruction may result in damage to the vehicle.

Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Failure to
follow this instruction may result in damage to the vehicle.

Make sure that any protective gloves worn are new and are of the non-powdered latex type. Failure to follow
this instruction may result in damage to the vehicle.

Make sure that clean, non-plated tools are used. C lean tools using a new brush that will not lose it's bristles and
fresh cleaning fluid prior to starting work on the vehicle. Failure to follow this instruction may result in damage to the
vehicle.

Use a steel-topped work bench and cover it with clean, lint-free, non-flocking material. Failure to follow this
instruction may result in damage to the vehicle.

NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal
places, and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM
leads into account.

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection
Mechanical Electrical
Fuel level Glow plug indicator
C ontaminated fuel Inertia fuel shutoff (IFS) switch
Fuel supply line(s) Fuel pump module
Fuel return line(s) Sensor(s)
High-pressure fuel supply line(s) Engine control module (EC M)
Fuel tank filler pipe Fuel volume control valve (FVC V)
Fuel leak(s) Fuel pressure control valve (FPC V)
Fuel tank Fuel rail pressure (FRP) sensor
Fuel filler cap Fuel temperature sensor
Fuel filter Fuel injector(s)
Push connect fittings EGR system
Fuel rail
Fuel injection pump
Exhaust gas recirculation (EGR) system

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTC s) before
moving onto the symptom chart or DTC index.

Make sure that all DTC s are cleared following rectification.

S mptom Chart

S mptom Possible causes Action

Engine IFS switch C heck that the inertia switch has not tripped. C heck the fuel
cranks, but Low/C ontaminated level/condition. C heck the low pressure fuel system for leaks/damage.
does not fuel C heck the fuel pump module operation. C heck the fuel filter, FVC V and
start Air ingress FPC V for blockages or contamination. C heck the fuel injection pump. For
Low pressure fuel C KP sensor circuit tests, refer to the relevant section of the workshop
system fault manual. Refer to the warranty policy and procedures manual if a module is
Fuel pump module suspect.
fault
Blocked fuel filter
FVC V
blocked/contaminated
FPC V
blocked/contaminated
Fuel injection pump
failure

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C ank haf po i ion
(C KP) en o
EC M fa l

Diffic l o Glo pl g em C heck he glo pl g ci c i . C heck he f el le el/condi ion. C heck he f el

a fa l ( e cold p mp mod le ope a ion, check he lo p e e f el em fo
condi ion ) leak /damage. C heck he f el fil e , FVC V and FPC V fo blockage o
Lo /C on amina ed con amina ion. Fo EGR al e e , efe o he ele an ec ion of he
f el o k hop man al.
F el p mp mod le
fa l
Ai ing e
Lo p e e f el
em fa l
Blocked f el fil e
FVC V
blocked/con amina ed
FPC V
blocked/con amina ed
Lo p e e ci c i
fa l
EGR al e( ) fa l

Ro gh idle Ai ing e C heck he in ake ai em fo leak . C heck he f el le el/condi ion.

Lo /C on amina ed C heck he lo p e e f el em fo leak /damage. C heck he f el
f el fil e , FVC V and FPC V fo blockage o con amina ion. Fo EGR al e e ,
Lo p e e f el efe o he ele an ec ion of he o k hop man al.
em fa l
Blocked f el fil e
FVC V
blocked/con amina ed
FPC V
blocked/con amina ed
EGR al e( ) fa l

Lack of In ake ai em C heck he in ake ai em. C heck fo a blockage/ e ic ion in he

po e hen fa l e ha em, in all ne componen a nece a . C heck he f el
accele a ing Re ic ed e ha p e e. Fo EGR al e e and VGT ac a o e , efe o he ele an
em ec ion of he o k hop man al.
Lo f el p e e
EGR al e( ) fa l
Va iable geome
bocha ge (VGT)
ac a o fa l

Engine Ai ing e C heck he in ake ai em fo leak . C heck he f el le el/condi ion.

op / all Lo /C on amina ed C heck he lo p e e f el em fo leak /damage. C heck he FVC V
f el and FPC V fo blockage o con amina ion. C heck he high p e e f el
Lo p e e f el em fo leak . Fo EGR al e e , efe o he ele an ec ion of he
em fa l o k hop man al.
High p e e f el
leak
FVC V
blocked/con amina ed
FPC V
blocked/con amina ed
EGR al e( ) fa l

Engine Lo /C on amina ed C heck he f el le el/condi ion. C heck he lo p e e f el em fo

j dde f el leak /damage. C heck he FVC V and FPC V fo blockage o con amina ion.
Ai ing e C heck he high p e e f el em fo leak . C heck he f el injec ion
Lo p e e f el p mp. Refe o he ele an ec ion of he o k hop man al.
em fa l
F el me e ing al e
blocked/con amina ed
FVC V
blocked/con amina ed
FPC V
blocked/con amina ed
High p e e f el

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leak
Fuel injection pump
fault
Excessive Low pressure fuel C heck the low pressure fuel system for leaks/damage. C heck the FVC V
fuel system fault and FPC V for blockages or contamination. C heck the fuel temperature
consumption FVC V sensor, fuel injection pump, etc for leaks. C heck for injector DTC s. For
blocked/contaminated EGR valve tests, refer to the relevant section of the workshop manual.
FPC V
blocked/contaminated
Fuel temperature
sensor leak
High pressure fuel
leak
Injector(s) failure
EGR valve(s) fault

DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: For a full list of EC M DTC s, refer to workshop manual section 303-14 - Electronic Engine C ontrols.

Power latch

There are references to "power latch" within the DTC index. This is where the module must be reset by means of a
complete power down and power up.

DTC Condition Possible causes Action

P000100 Fuel Volume Fuel volume NOTE: An open circuit will prevent the engine from running.
Regulator C ontrol control valve
C ircuit / Open (VC V) circuit Refer to the electrical guides and check the fuel volume control
high resistance valve and circuits. C heck the resistance of the valve and install
VC V circuit a new high pressure fuel pump if the resistance is not between
open circuit 1.5 and 15 ohms (the fuel volume control valve cannot be
VC V failure serviced separately). C lear the DTC s and test for normal
operation. Refer to the warranty policy and procedures manual if
a HPP is suspect.
P000200 Fuel Volume Fuel volume NOTE: An open circuit will prevent the engine from running.
Regulator C ontrol control valve
C ircuit (VC V) circuit Refer to the electrical guides and check the fuel volume control
Range/Performance high resistance valve and circuits. C heck the resistance of the valve and install
VC V circuit a new high pressure fuel pump if the resistance is not between
short circuit to 1.5 and 15 ohms (the fuel volume control valve cannot be
ground serviced separately). C lear the DTC s and test for normal
VC V circuit operation. Refer to the warranty policy and procedures manual if
short circuit to a HPP is suspect.
power
VC V failure

P000300 Fuel Volume Fuel volume NOTE: An open circuit will prevent the engine from running.
Regulator C ontrol control valve
Low (VC V) circuit Refer to the electrical guides and check the fuel volume control
high resistance valve and circuits. C heck the resistance of the valve and install
VC V circuit a new high pressure fuel pump if the resistance is not between
short circuit to 1.5 and 15 ohms (the fuel volume control valve cannot be
ground serviced separately). C lear the DTC s and test for normal
VC V failure operation. Refer to the warranty policy and procedures manual if
EC M failure a HPP is suspect.

P000400 Fuel Volume Fuel volume Refer to the electrical guides and check the fuel volume control
Regulator C ontrol control valve valve and circuits. C heck the resistance of the valve and install
C ircuit High (VC V) circuit a new high pressure fuel pump if the resistance is not between
short circuit to 1.5 and 15 ohms (the fuel volume control valve cannot be
power serviced separately). C lear the DTC s and test for normal
VC V failure operation. Refer to the warranty policy and procedures manual if
EC M failure a HPP is suspect.

P008700 Fuel rail/system Fuel rail Refer to the electrical guides and check the FRP sensor circuits.
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pressure too low pressure (FRP) For FRP sensor tests, refer to the relevant workshop manual
sensor section. C heck the low pressure fuel lines for damage or
disconnected restrictions. C heck the fuel pressure. C heck the low pressure
FRP sensor to fuel pump module circuits and operation. C heck for fuel rail and
EC M sensing high pressure fuel line leaks. C heck for VC V and PC V DTC s and
circuit short rectif as necessar .
circuit to
ground
FRP sensor
suppl circuit
high resistance
FRP sensor
failure
Fuel line leak
Restricted fuel
line
Fuel pump
module circuit
high resistance
Fuel pump
module circuit
short circuit to
ground
Fuel pump
module failure
Volume control
valve fault
Pressure
control valve
fault

P008800 Fuel rail/s stem Fuel rail C heck the FRP sensor circuits. Refer to the electrical guides. For
pressure too high pressure (FRP) FRP sensor tests, refer to the relevant workshop manual section.
sensor to EC M C heck the fuel lines, check the fuel pressure and the fuel pump
wiring module circuits.
(suppl /sense):
short circuit to
each other
FRP sensor to
EC M sense
circuit short
circuit to power
FRP sensor
failure
Fuel pressure
control valve
(FPC V) fault
Fuel pump
module circuit
short circuit to
power
Fuel pump
module failure

P009000 Fuel Pressure
Regulator 1 C ontrol
C ircuit/Open
Fuel pressure C heck the fuel pressure control valve and circuits. Refer to the
control valve electrical guides. C heck the resistance of the fuel pressure
(PC V) circuit control valve. If the resistance is not between 0 and 5.4 ohms,
high resistance install a new high pressure fuel pump (the fuel pressure control
FPC V circuit valve cannot be serviced separatel ). Refer to the relevant
short circuit to section of the workshop manual. Refer to the warrant polic
ground and procedures manual if a high pressure fuel pump is suspect.
PC V failure C lear the DTC s and test for normal operation.

P009100 Fuel Pressure
Regulator 1 C ontrol
C ircuit Low
Fuel pressure C heck the fuel pressure control valve and circuits. Refer to the
control valve electrical guides. C heck the resistance of the fuel pressure
(PC V) circuit control valve. If the resistance is not between 0 and 5.4 ohms,
high resistance install a new high pressure fuel pump (the fuel pressure control
PC V circuit valve cannot be serviced separatel ). Refer to the relevant
short circuit to section of the workshop manual. Refer to the warrant polic
ground and procedures manual if a high pressure fuel pump is suspect.

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PC V failure C lear the DTC s and test for normal operation.

P009200 Fuel Pressure Fuel pressure C heck the fuel pressure control valve and circuits. Refer to the
Regulator 1 C ontrol control valve electrical guides. C heck the resistance of the fuel pressure
C ircuit High (PC V) circuit control valve. If the resistance is not between 0 and 5.4 ohms,
short circuit to install a new high pressure fuel pump (the fuel pressure control
power valve cannot be serviced separately). Refer to the relevant
PC V failure section of the workshop manual. Refer to the warranty policy
and procedures manual if a high pressure fuel pump is suspect.
C lear the DTC s and test for normal operation.
P018100 Fuel Temperature Fuel C heck the fuel temperature sensor and circuits. Refer to the
Sensor A C ircuit temperature electrical guides. C heck the fuel temperature using a data logger
Range/Performance sensor circuit function. Make sure the fuel temperature is less than 30°C
high resistance (86°F). Start the engine and allow to warm up for ten minutes.
Fuel Recheck the fuel temperature. If the value has not increased by
temperature more than 8°C in this time, install a new sensor. Refer to the
sensor circuit relevant section of the workshop manual. C lear the DTC s and
short circuit to test for normal operation.
ground
Fuel
temperature
sensor circuit
short circuit to
power
Fuel
temperature
sensor failure

P018200 Fuel Temperature Fuel C heck the fuel temperature sensor and circuits. Refer to the
Sensor A C ircuit temperature electrical guides. C heck the fuel temperature using a data logger
Low sensor circuit function. Make sure the fuel temperature is less than 30°C
high resistance (86°F). Start the engine and allow to warm up for ten minutes.
Fuel Recheck the fuel temperature. If the value has not increased by
temperature more than 8°C in this time, install a new sensor. Refer to the
sensor circuit relevant section of the workshop manual. C lear the DTC s and
short circuit to test for normal operation.
ground
Fuel
temperature
sensor failure

P018300 Fuel Temperature Fuel C heck the fuel temperature sensor and circuits. Refer to the
Sensor A C ircuit temperature electrical guides. C heck the fuel temperature using a data logger
High sensor circuit function. Make sure the fuel temperature is less than 30°C
short circuit to (86°F). Start the engine and allow to warm up for ten minutes.
power Recheck the fuel temperature. If the value has not increased by
Fuel more than 8°C in this time, install a new sensor. Refer to the
temperature relevant section of the workshop manual. C lear the DTC s and
sensor failure test for normal operation.

P018400 Fuel Temperature Fuel C heck the fuel temperature sensor and circuits. Refer to the
Sensor A C ircuit temperature electrical guides. C heck the fuel temperature using a data logger
Intermittent sensor circuit function. Make sure the fuel temperature is less than 30°C
high resistance (86°F). Start the engine and allow to warm up for ten minutes.
Fuel Recheck the fuel temperature. If the value has not increased by
temperature more than 8°C in this time, install a new sensor. Refer to the
sensor circuit relevant section of the workshop manual. C lear the DTC s and
short circuit to test for normal operation.
ground
Fuel
temperature
sensor circuit
short circuit to
power
Fuel
temperature
sensor failure

P019100 Fuel Rail Pressure Air in fuel NOTE: If DTC P229000 is also logged, deal with that code first.
Sensor A C ircuit system, unable
C heck the fuel level and the condition and correct connection of
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Range/Performance to maintain the low-pressure fuel circuit lines (incorrect connection of the
correct fuel lines to and from the fuel filter can cause serious fuel pressure
pressure at fluctuations). C heck fuel system including all lines and
start up. components for leaks/air ingress. Perform fuel system bleed
procedure. C lear the DTC s and test for normal operation.

P019200 Fuel Rail Pressure Fuel rail C heck the FRP sensor and circuits. Refer to the electrical guides.
Sensor A C ircuit pressure (FRP) Start the engine and allow to idle. C heck the fuel pressure value
Low sensor circuit using a data logger function. If the value is 0 MPa (0 lbs/in ),
high resistance install a new sensor. Refer to the relevant section of the
FRP sensor workshop manual. C lear the DTC s and test for normal
circuit short operation.
circuit to
ground
FRP sensor
failure

P019300 Fuel Rail Pressure Fuel rail C heck the FRP sensor and circuits. Refer to the electrical guides.
Sensor A C ircuit pressure (FRP) Start the engine and allow to idle. C heck the fuel pressure value
High sensor circuit using a data logger function. If the value is greater than 180
short circuit to MPa (26,106 lbs/in ), install a new sensor. Refer to the relevant
power section of the workshop manual. C lear the DTC s and test for
FRP sensor normal operation.
failure

P019400 Fuel Rail Pressure Fuel rail C heck the FRP sensor and circuits. Refer to the electrical guides.
Sensor A C ircuit pressure (FRP) Start the engine and allow to idle. C heck the fuel pressure value
Intermittent/Erratic sensor circuit using a data logger function. Increase the engine speed to 2,000
high resistance rpm and recheck the fuel pressure. If the value has changed by
FRP sensor more than 40 MPa (5,801 lbs/in ) per 10 ms, install a new
circuit short sensor. Refer to the relevant section of the workshop manual.
circuit to C lear the DTC s and test for normal operation.
ground
FRP sensor
circuit short
circuit to power
FRP sensor
failure

P020100 C ylinder 1 Injector Fuel injector During the following, clear DTC s and recheck after each step.
C ircuit / Open circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector security. Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
failure ground, short circuit to power and for high resistance. Refer to
the electrical guides. Repair/renew as necessary. C lear the
DTC s and test for normal operation.
P020200 C ylinder 2 Injector Fuel injector During the following, clear DTC s and recheck after each step.
C ircuit / Open circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector security. Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
failure ground, short circuit to power and for high resistance. Refer to
the electrical guides. Repair/renew as necessary. C lear the
DTC s and test for normal operation.
P020300 C ylinder 3 Injector Fuel injector During the following, clear DTC s and recheck after each step.
C ircuit / Open circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector security. Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
failure ground, short circuit to power and for high resistance. Refer to

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the electrical guides. Repair/renew as necessar . C lear the
DTC s and test for normal operation.
P020400 C linder 4 Injector Fuel injector During the following, clear DTC s and recheck after each step.
C ircuit / Open circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector securit . Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
failure ground, short circuit to power and for high resistance. Refer to
the electrical guides. Repair/renew as necessar . C lear the
DTC s and test for normal operation.
P020500 C linder 5 Injector Fuel injector During the following, clear DTC s and recheck after each step.
C ircuit / Open circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector securit . Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
failure ground, short circuit to power and for high resistance. Refer to
the electrical guides. Repair/renew as necessar . C lear the
DTC s and test for normal operation.
P020600 C linder 6 Injector Fuel injector During the following, clear DTC s and recheck after each step.
C ircuit / Open circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector securit . Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
failure ground, short circuit to power and for high resistance. Refer to
the electrical guides. Repair/renew as necessar . C lear the
DTC s and test for normal operation.
P020A00 C linder 1 Injection Fuel injector During the following, clear DTC s and recheck after each step.
Timing circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector securit . Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
circuit short ground, short circuit to power and for high resistance. Refer to
circuit to power the electrical guides. Repair/renew as necessar . C lear the
Fuel injector DTC s and test for normal operation.
failure

P020B00 C linder 2 Injection Fuel injector During the following, clear DTC s and recheck after each step.
Timing circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector securit . Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
circuit short ground, short circuit to power and for high resistance. Refer to
circuit to power the electrical guides. Repair/renew as necessar . C lear the
Fuel injector DTC s and test for normal operation.
failure

P020C 00 C linder 3 Injection Fuel injector During the following, clear DTC s and recheck after each step.
Timing circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector securit . Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
circuit short ground, short circuit to power and for high resistance. Refer to
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circuit to power the electrical guides. Repair/renew as necessary. C lear the
Fuel injector DTC s and test for normal operation.
failure

P020D00 C ylinder 4 Injection Fuel injector During the following, clear DTC s and recheck after each step.
Timing circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector security. Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
circuit short ground, short circuit to power and for high resistance. Refer to
circuit to power the electrical guides. Repair/renew as necessary. C lear the
Fuel injector DTC s and test for normal operation.
failure

P020E00 C ylinder 5 Injection Fuel injector During the following, clear DTC s and recheck after each step.
Timing circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector security. Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
circuit short ground, short circuit to power and for high resistance. Refer to
circuit to power the electrical guides. Repair/renew as necessary. C lear the
Fuel injector DTC s and test for normal operation.
failure

P020F00 C ylinder 6 Injection Fuel injector During the following, clear DTC s and recheck after each step.
Timing circuit high Turn the ignition off and wait 20 seconds before turning the
resistance ignition back on to recheck DTC s. C heck the connections for
Fuel injector security. Disconnect the injector and measure the resistance and
circuit short capacitance of the injector. If the resistance is not between 180
circuit to and 220 Kohms, or the capacitance not greater than 3
ground microfarad, install a new injector. If the injector is within
Fuel injector specification, check the injector circuits for short circuit to
circuit short ground, short circuit to power and for high resistance. Refer to
circuit to power the electrical guides. Repair/renew as necessary. C lear the
Fuel injector DTC s and test for normal operation.
failure

P029A00 C ylinder 1- Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Max Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc

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Injector fault

P029B00 C ylinder 1- Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Min Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P029E00 C ylinder 2- Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Max Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P029F00 C ylinder 2 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Min Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder

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compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault
P02A200 C ylinder 3 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Max Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P02A300 C ylinder 3 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Min Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault
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P02A600 C ylinder 4 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Max Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P02A700 C ylinder 4 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Min Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P02AA00 C ylinder 5 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Max Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression

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low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault
P02AB00 C ylinder 5 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Min Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P02AE00 C ylinder 6 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Max Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

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P02AF00 C ylinder 6 - Fuel Fuel injector Refer to the electrical guides and check the fuel injector circuit.
Trim at Min Limit circuit high C heck the injector and surrounding area for evidence of fuel
resistance leakage. Disconnect the injector and check for evidence of fuel
Fuel injector leakage in the connector. Rectify as necessary. C lear the DTC s.
circuit short Reconnect the injector and start the engine. Allow to warm up to
circuit to above 60 C (140 F) and allow to idle (cylinder balance diagnosis
ground is now active). If the DTC resets, check for C ylinder leakage
Fuel injector and rectify as necessary. C lear the DTC s and recheck. C arry
circuit short out a compression test only if the DTC resets. If the above tests
circuit to power are all within range, install a new injector.
Injector leak
C ylinder
compression
low
- C ylinder
leakage
past the
injector
- C ylinder
leakage
past the
glow plug
- Mechanical
fault, valve,
piston/ring,
etc
Injector fault

P062D00 Fuel Injector Driver Injector(s) Refer to the electrical guides and check the injector circuits.
C ircuit Performance disconnected Rectify as necessary. C lear the DTC s and test for normal
Bank 1 Injector circuit operation. Refer to the relevant workshop manual section. Refer
high resistance, to the warranty policy and procedures manual if a module is
short circuit to suspect.
ground, short
circuit to power
Injector failure
EC M failure

P062D01 Fuel Injector Driver Injector(s) If non start condition check for shorts on injector circuits. If
C ircuit Performance short circuit rough running check for intermitent open circuits or high
Bank 1 Injector circuit resistance on injector circuits. If no wiring faults are found, using
high resistance, approved diagnostic equipment perform injector spill tests.
short circuit to Follow actions recommended based on results from spill tests.
ground, short
circuit to power
Injector failure
EC M failure

P062E00 Fuel Injector Driver Injector(s) Refer to the electrical guides and check the injector circuits.
C ircuit Performance disconnected Rectify as necessary. C lear the DTC s and test for normal
Bank 2 Injector circuit operation. Refer to the relevant workshop manual section. Refer
high resistance, to the warranty policy and procedures manual if a module is
short circuit to suspect.
ground, short
circuit to power
Injector failure
EC M failure

P062E01 Fuel Injector Driver Injector(s) If non start condition check for shorts on injector circuits. If
C ircuit Performance short circuit rough running check for intermitent open circuits or high
Bank 2 Injector circuit resistance on injector circuits. If no wiring faults are found, using
high resistance, approved diagnostic equipment perform injector spill tests.
short circuit to Follow actions recommended based on results from spill tests.
ground, short
circuit to power
Injector failure
EC M failure

P120000 Injector Fuel injector Refer to the electrical guides and check the injector circuits.
Range/Performance circuit high Refer to the relevant workshop manual section. Refer to the
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resistance warrant polic and procedures manual if a module is suspect.
Fuel injector
circuit short
circuit to
ground
Fuel injector
circuit short
circuit to power
Fuel injector
leaking
Fuel injector
failure
EC M failure

P155100 C linder 1 Injector Injector C heck the injector circuits. Refer to the electrical guides. Rectif
C ircuit disconnected as necessar . Refer to the relevant workshop manual section.
Range/Performance Injector circuit
high resistance,
short circuit to
ground, short
circuit to power
Injector failure

P155200 C linder 2 Injector Injector C heck the injector circuits. Refer to the electrical guides. Rectif
C ircuit disconnected as necessar . Refer to the relevant workshop manual section.
Range/Performance Injector circuit
high resistance,
short circuit to
ground, short
circuit to power
Injector failure

P155300 C linder 3 Injector Injector C heck the injector circuits. Refer to the electrical guides. Rectif
C ircuit disconnected as necessar . Refer to the relevant workshop manual section.
Range/Performance Injector circuit
high resistance,
short circuit to
ground, short
circuit to power
Injector failure

P155400 C linder 4 Injector Injector C heck the injector circuits. Refer to the electrical guides. Rectif
C ircuit disconnected as necessar . Refer to the relevant workshop manual section.
Range/Performance Injector circuit
high resistance,
short circuit to
ground, short
circuit to power
Injector failure

P155400 C linder 5 Injector Injector C heck the injector circuits. Refer to the electrical guides. Rectif
C ircuit disconnected as necessar . Refer to the relevant workshop manual section.
Range/Performance Injector circuit
high resistance,
short circuit to
ground, short
circuit to power
Injector failure

P155600 C linder 6 Injector Injector C heck the injector circuits. Refer to the electrical guides. Rectif
C ircuit disconnected as necessar . Refer to the relevant workshop manual section.
Range/Performance Injector circuit
high resistance,
short circuit to
ground, short
circuit to power
Injector failure

P156300 Injection Pump Internal control C lear the DTC . C cle the ignition, allow power latch and retest.
C ontrol Module module If the DTC resets, refer to the warrant polic and procedures

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R E a a a .
S a
P226900 Wa F Wa D a a .C a DTC a .I
C DTC , .R a
Wa .I a , a a .

Wa
a

P228800 I C F C , a
P T H a a a.C a
(FPC V) FPC V .R a .F FPC V a
, a a a .
a
F

FPC V
a
FPC V a
F

F
a
F
a

P229000 I C F C , a
P T L a a a.C a
(FPC V) FPC V .R a .F FPC V a
a , a a a .
a
F

F a
F
/

FPC V
a
FPC V a
F

F
a
F
a

P229200 I C F C , a
P E a a a.C a
FPC V .R a .F FPC V a
a , a a a .
FPC V
a
FPC V a
F

a ,

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circuit to po er
Fuel pump
module failure
Fuel injection
pump failure

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Published: 11-Ma -2011

F el Cha ging and Con ol - TDV6 2.7L Die el - F el Injec o Balance and
Spill Check
General Procedures

Special Tool( )
Fuel Injector Spill Test Kit 310-152

Fuel Return Blanking C aps 310-

152-02

1. Disconnect the batter ground cable.

For additional information, refer to: Specifications (414-00
C harging S stem - General Information, Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L
Diesel (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Remove the injector sound proofing.

4. Release the EGR coolant cross-over pipe.

Remove the 2 bolts.

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. Release the fuel suppl and fuel return clips from the
heater hose.

. Release the engine harness and heater hose from clip.

. Release the coolant pipe on bulkhead and position aside.

Do not disconnect the coolant pipe.

. Disconnect the fuel injector electrical connectors.

. Detach the fuel injection wiring harness.

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. C ut and remove cable ties securing harness to support

tra .

. Release the harness bracket clips and remove the

support tra s.

. Disconnect the fuel return line from the fuel injectors.

. Blank-off each spill return with plugs from kit.

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1 . C onnect the fuel injector electrical connectors.

1 . C onnect spill bottle to each of the injectors.

1 . C onnect the batter ground cable.

1 . C onnect Land Rover approved diagnostic equipment to
vehicle.
1 . Run c linder balance test from 'live data'.

Injector balance limits are between 700 and 1.3 k.

Note an injector that is outside of these figures (a

figure below the limit will usuall mean a reduction in
fuelling, and a figure above will result in an increase to
fuelling).

1 . WARNING: Before starting engine, ensure all

connectors are properl secure.

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C AUTION: Do not reject any of the injectors if the spill

rates are even but outside of the correct rates shown. The spill
rate can be affected by varying fuel rail pressure and fuel
temperature. Only suspect a faulty injector(s) if the amount of
fuel collected is significantly higher than the others. A faulty
injector could fill a bottle within 2 minutes.

NOTE: The figures shown are to be used as a guide only.

Start the engine and immediately check the spill rate into
the bottles. If possible, allow engine to run for 2 minutes. If
any bottle is filling at a very fast rate and is likely to fill
before 2 minutes is reached, stop engine and note which
injector the fuel is coming from.

Time Flo Rate

1 minute idle Min rate 10 ml - Max rate 25 ml
4 minute idle Min rate 15 ml - Max rate 26 ml
20. Disconnect the battery ground cable.
21. Disconnect all spill pipes and bottles. Replace an
injector(s) that has either excessive spill or failed the
balance check.
22. Remove blank-off plugs from spill return pipes.

23. C AUTION: Make sure the fuel return line retaining

clip is correctly installed to the fuel injector before installing
the return line.

C onnect the fuel return line to the fuel injector.

Visually inspect the fuel return line O-ring seals for

damage.

Apply a light coating of petroleum jelly to the fuel

return line O-ring seals.

24. Disconnect the injector electrical connectors and release

the wiring harness.
25. Install the injector harness support trays and secure with
cable ties.
26. C onnect and secure the fuel injector wiring harness
electrical connectors.
27. Secure the engine harness to heater hose clip.
28. Secure the fuel supply and fuel return to heater hose
clips.
29. Refit coolant pipe to mounting at rear of engine.
30. Install the EGR coolant cross-over pipe.

Tighten the bolts to 13 Nm (10 lb.ft).

31. Install the injector sound proofing.

32. Install the engine cover.
For additional information, refer to: Engine C over - 2.7L
Diesel (501-05 Interior Trim and Ornamentation, Removal
and Installation).
33. C onnect the battery ground cable.
For additional information, refer to: Specifications (414-00
C harging System - General Information, Specifications).

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Published: 11-May-2011
F el Cha ging and Con ol - TDV6 2.7L Die el - F el Injec ion Componen
Cleaning
General Procedures

WARNINGS:

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1700 bar (24,656 lb-sq-in). Failure to follow this instruction may result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical
attention.

Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the
vehicle.

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention.

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

C AUTIONS:

Before using the cleaning fluid, protect all electrical components and connectors with lint-free non-flocking
material.

Make sure that all parts removed from the vehicle are placed on the lint-free non-flocking material.

Make sure that any protective clothing worn is clean and made from lint-free non-flocking material.

Make sure that clean non-plated tools are used. C lean tools using a new brush that will not lose its bristles and
fresh cleaning fluid, prior to starting work on the vehicle.

Use a steel topped workbench and cover it with clean, lint-free non-flocking material.

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

NOTE: Pneumatic vacuum gun

1. Using a new brush that will not lose its bristles, brush
cleaning fluid onto the components being removed and onto
the surrounding area.
2. Using a pneumatic vacuum gun, remove all traces of
cleaning fluid and foreign material.
3. Dispose of any used cleaning fluid and the brush after
completing the repair.

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Published: 08-Aug-2011
F el Cha ging and Con ol - TDV6 2.7L Die el - F el P mpVIN Range:
SALLA000304->END OF 06MY
Removal and Installation

Special Tool( )
Holder - Fuel Pump Pulley

310-139

Reaction Arm - Fuel Pump Pulley

310-138

Remo al
WARNINGS:

Do not carry or operate cellular phones when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal
injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

C AUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel
pump when required.

1. Disconnect the battery ground cable.

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For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. Remove the crankcase vent oil separator.
For additional information, refer to: C rankcase Vent Oil
Separator (303-08C Engine Emission C ontrol - TDV6 2.7L
Diesel, Removal and Installation).
. Remove the fuel injection pump belt cover.

Reposition the engine wiring harness to allow access

to the fuel injection pump belt cover.

. NOTE: The fuel injection pump belt is not timed to the

engine.

Remove and discard the fuel injection pump belt

tensioner.

Remove the LH retaining bolt.

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. NOTE: The f el injec ion p mp o a e in a co n e -

clock i e di ec ion hen ie ed f om he ea of he
engine.

Remo e and di ca d he f el injec ion p mp bel .

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. Remove the fuel injection pump belt rear cover retaining
bolts.

. Remove the crankcase vent oil separator locating stud.

. NOTE: Left-hand shown, right-hand similar.

Release the high-pressure fuel supply lines.

Remove the LH retaining bolt.

. C AUTION: Make sure that the high-pressure fuel

supply line remains in contact with the fuel injection supply
manifold and the fuel injection diverter rail until both unions
have been detached and cleaned. Failure to follow this
instruction may result in foreign matter ingress to the fuel
injection system.

NOTE: Left-hand shown, right-hand similar.

Remove and discard the high-pressure fuel supply lines.

Install blanking caps to the exposed ports.

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. Release the fuel charging wiring harness.

Remove the retaining nut.

. Remove the fuel injection diverter rail.

Remove the 2 studs.

. Remove the fuel injection pump.

Remove the four retaining bolts.

. NOTE: Do not disassemble further if the component is

removed for access onl .

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Using the special tool, remove the fuel injection pump
pulle retaining nut.

14. Using the special tool, remove the fuel injection pump
pulle .

In alla ion
1. Using the special tool, install the fuel injection pump
pulle .

Tighten to 50 Nm (37 lb.ft).

2. Install the fuel injection pump.

Tighten the bolts to 23 Nm (17 lb.ft).

3. Install the fuel injection diverter rail.

Install the two retaining studs, but do not full tighten

at this stage.

4. Attach the fuel charging wiring harness.

Install the retaining nut.

5. Install the new high-pressure fuel suppl lines.

Remove the blanking caps from the ports.

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Loosely install the new high-pressure fuel supply lines.

Tighten the fuel injection diverter rail retaining studs to

23 Nm (17 lb.ft).

Stage 1: Tighten the high-pressure fuel supply line

union at the fuel injection supply manifold to 15 Nm (11
lb.ft).

Stage 2: Tighten the high-pressure fuel supply line

union at the fuel injection diverter rail to 15 Nm (11
lb.ft).

Stage 3: Tighten the high-pressure fuel supply line

union at the fuel injection supply manifold to 35 Nm (26
lb.ft).

Stage 4: Tighten the high-pressure fuel supply line

union at the fuel injection pump to 35 Nm (26 lb.ft).

. Attach the high-pressure fuel supply lines.

Install the two retaining bolts.

Tighten to 10 Nm (7 lb.ft).

. Install the crankcase vent oil separator locating stud.

Tighten the stud to 10 Nm (7 lb.ft).

. Install the fuel injection pump belt rear cover retaining

bolts.

Tighten to 7 Nm (5 lb.ft).

. C AUTION: Do not install the new fuel injection pump

belt to the pulleys with the fuel pump belt tensioner installed.
Failure to follow this instruction may result in damage to the
fuel pump belt.

NOTE: The fuel injection pump rotates in a counter-clockwise

direction when viewed from the rear of the engine.

Install the new fuel injection pump belt.

10. C AUTION: Make sure that the fuel injection pump

belt tensioner tang is correctly located to the fuel injection
pump belt rear cover. Failure to follow this instruction may
result in damage to the engine.

Install a new fuel injection pump belt tensioner.

Locate the tang on the new fuel injection pump belt

tensioner into the fuel injection pump rear cover.

Tighten to 25 Nm (18 lb.ft).

Remove and discard the fuel injection pump belt

tensioner locking pin.

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. Install the fuel injection pump belt cover.

Reposition the engine wiring harness to allow access to

the fuel injection pump belt cover.

. Install the crankcase vent oil separator.

For additional information, refer to: C rankcase Vent Oil
Separator (303-08C Engine Emission C ontrol - TDV6 2.7L
Diesel, Removal and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. Bleed the fuel s stem.
For additional information, refer to: Low-Pressure Fuel
S stem Bleeding (310-00 Fuel S stem - General
Information, General Procedures).

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Published: 19-Aug-2011
F el Cha ging and Con ol - TDV6 2.7L Die el - F el Injec o
Removal and Installation

Special Tool( )
Fuel Injector remover

303-1127

Remo al
WARNINGS:

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

C AUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

Do not disconnect the fuel injector electrical connectors with the engine running. Failure to follow this instruction
may result in serious damage to the engine.

Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new
fuel injectors when required.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Disconnect the low-pressure fuel lines.
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I a ba i g ca he e ed .

. Di c ec b h e ha ga eci c a i (EGR) c a
c - e i e h e .

Ca he EGR c a h e i i i e c a
.

. Re e he EGR c a c - e i e.

Re e he e ai i g b .

. Re e he ba e .
F addi i a i f a i , efe : Ba e (414-01 Ba e ,
M i g a d C ab e , Re a a dI a a i ).
. NOTE: Righ ha d d i e h ,f Lef ha d d i e
e e e he e e ce.

Di c ec he h ee e gi e ha e e ec ica c ec
i he de h .

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. Relea e he engine i ing ha ne f om he b lkhead.

. Remo e he injec o o nd p oofing.

10. Di connec he f el injec o elec ical connec o .

11. Relea e he engine i ing ha ne .

Relea e he 4 clip .

12. C AUTIONS:
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Make sure that the high-pressure fuel supply line

remains in contact with the fuel pump and fuel injection
diverter rail until both unions have been detached and
cleaned. Failure to follow this instruction may result in foreign
matter ingress to the fuel injection system.

Do not use any aggressive cleaning fluid or a wire brush

to clean the fuel injector nozzle.

Using the pneumatic vacuum gun, vacuum foreign material

from the high-pressure fuel supply line, the fuel injector and
the fuel injection supply manifold.
For additional information, refer to: Fuel Injection
C omponent C leaning (303-04C Fuel C harging and C ontrols -
TDV6 2.7L Diesel, General Procedures).
1 . C AUTIONS:

Make sure that the high-pressure fuel supply line

remains in contact with the fuel injection supply manifold
and the fuel injection diverter rail until both unions have
been detached and cleaned. Failure to follow this instruction
may result in foreign matter ingress to the fuel injection
system.

Make sure that the fuel injector adaptor union does

not move when loosening the high-pressure fuel supply
lines. Failure to follow this instruction may result in damage
to the fuel injector or the fuel injector adaptor union.

Loosen the high-pressure fuel supply line from the fuel

injector and fuel rail.

1 . C AUTION: Make sure that all openings are sealed.

Use new blanking caps.

NOTE: Right-hand shown, left-hand similar.

Remove and discard the high-pressure fuel supply line.

1 . Disconnect the fuel return line from the fuel injector.

Remove and discard the fuel return line retaining

clip.
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1 . Remove the two fuel injector retaining bolts.

Remove the fuel injector retaining clamp spacer.

1 . Install the special tool studs.

1 . C AUTION: Make sure the fuel injector remover

legs are correctl engaged to the fuel injector. Failure to
follow this instruction ma result in damage to the
component.

Install the special tool remover legs to the studs.

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19. C AUTION: Make sure the fuel injector remover

legs are correctly engaged to the fuel injector. Failure to
follow this instruction may result in damage to the
component.

Remove the fuel injector.

Rotate the special tool bolts evenly, in a clockwise

direction.

Remove the special tool.

Remove and discard the fuel injector retaining

clamp.

Remove and discard the sealing washer.

In alla ion
1. C AUTIONS:

Do not disassemble the fuel injectors or clean the

nozzles, even with an ultrasonic cleaner. Always install new
fuel injectors when required.

Do not use tools to install the new fuel return line clip.
Failure to follow this instruction will result in damage to the
retaining clip.

Install a new fuel injector retaining clamp.

1. Install a new fuel injector retaining clamp.

2. Install the fuel injector retaining clamp spacer.

3. Install a new fuel return line retaining clip.

4. Install a new sealing washer.

2. Install the fuel injector.

Install the two bolts and tighten to 10 Nm (7 lb.ft).

3. C AUTION: Make sure the fuel return line retaining clip

is correctly installed to the fuel injector before installing the
return line.

C onnect the fuel return line to the fuel injector.

Visually inspect the fuel return line O-ring seals for

damage.

Apply a light coating of petroleum jelly to the fuel

return line O-ring seals.

4. C AUTIONS:

Do not allow the unions to hit the olive ends of the

high-pressure fuel supply line as this may damage the ends
of the line and allow foreign matter to enter the fuel
injection system.

Maintain pressure on the high-pressure fuel supply

lines to keep the olives in contact with the fuel rail and the
fuel injector cones while installing unions.

NOTE: Remove and discard the blanking caps.

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Install the new high-pressure fuel suppl lines.

Install the new high-pressure fuel suppl line, tighten

the fuel suppl line unions finger tight.

Tighten the high-pressure fuel suppl line in the

shown sequence.

Tighten the high-pressure fuel suppl line union 1 to

fuel injector to 15 Nm.

Tighten the high-pressure fuel suppl line union 2 to

fuel rail to 15 Nm.

Tighten the high-pressure fuel suppl line union 1 to

fuel injector to 35 Nm.

Tighten the high-pressure fuel suppl line union 2 to

fuel rail to 35 Nm.

. Attach the engine wiring harness.

. C onnect the fuel injector electrical connectors.
. Install the injector sound proofing.
. Attach the engine wiring harness to the bulkhead.
. C onnect the three engine harness electrical connectors.
. Install the batter .
For additional information, refer to: Batter (414-01 Batter ,
Mounting and C ables, Removal and Installation).
. Install the EGR coolant cross-over pipe.

Install the two retaining bolts.

Tighten the bolts to 13 Nm (10 lb.ft).

. C onnect both EGR coolant cross-over pipe hoses.

Remove the EGR coolant hose clamps.

. C onnect the low-pressure fuel lines.

Remove the blanking caps from the ports.

. C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. C heck and top-up the coolant.
. Bleed the fuel s stem.

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Published: 19-Aug-2011
F el Cha ging and Con ol - TDV6 2.7L Die el - F el Injec o
Removal and Installation

Special Tool( )
Fuel Injector remover

303-1127

Remo al
WARNINGS:

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

C AUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

Do not disconnect the fuel injector electrical connectors with the engine running. Failure to follow this instruction
may result in serious damage to the engine.

Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new
fuel injectors when required.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Disconnect the low-pressure fuel lines.
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I a ba i g ca he e ed .

. Di c ec b h e ha ga eci c a i (EGR) c a
c - e i e h e .

Ca he EGR c a h e i i i e c a
.

. Re e he EGR c a c - e i e.

Re e he e ai i g b .

. Re e he ba e .
F addi i a i f a i , efe : Ba e (414-01 Ba e ,
M i g a d C ab e , Re a a dI a a i ).
. NOTE: Righ ha d d i e h ,f Lef ha d d i e
e e e he e e ce.

Di c ec he h ee e gi e ha e e ec ica c ec
i he de h .

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. Release the engine wiring harness from the bulkhead.

. Remove the NVH pads from each c linder bank.

10. Disconnect the fuel injector electrical connectors.

11. Release the engine wiring harness.

Release the 4 clips.

12. C AUTIONS:
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Make sure that the high-pressure fuel supply line

remains in contact with the fuel pump and fuel injection
diverter rail until both unions have been detached and
cleaned. Failure to follow this instruction may result in foreign
matter ingress to the fuel injection system.

Do not use any aggressive cleaning fluid or a wire brush

to clean the fuel injector nozzle.

Using the pneumatic vacuum gun, vacuum foreign material

from the high-pressure fuel supply line, the fuel injector and
the fuel injection supply manifold.
1 . C AUTIONS:

Make sure that the high-pressure fuel supply line

remains in contact with the fuel injection supply manifold
and the fuel injection diverter rail until both unions have
been detached and cleaned. Failure to follow this instruction
may result in foreign matter ingress to the fuel injection
system.

Make sure that the fuel injector adaptor union does

not move when loosening the high-pressure fuel supply
lines. Failure to follow this instruction may result in damage
to the fuel injector or the fuel injector adaptor union.

Loosen the high-pressure fuel supply line from the fuel

injector and fuel rail.

1 . C AUTION: Make sure that all openings are sealed.

Use new blanking caps.

NOTE: Right-hand shown, left-hand similar.

Remove and discard the high-pressure fuel supply line.

1 . Disconnect the fuel return line from the fuel injector.

Remove and discard the fuel return line retaining

clip.

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1 . Remove the two fuel injector retaining bolts.

Remove the fuel injector retaining clamp spacer.

1 . Install the special tool studs.

1 . C AUTION: Make sure the fuel injector remover

legs are correctl engaged to the fuel injector. Failure to
follow this instruction ma result in damage to the
component.

Install the special tool remover legs to the studs.

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19. C AUTION: Make sure the fuel injector remover

legs are correctly engaged to the fuel injector. Failure to
follow this instruction may result in damage to the
component.

Remove the fuel injector.

Rotate the special tool bolts evenly, in a clockwise

direction.

Remove the special tool.

Remove and discard the fuel injector retaining

clamp.

Remove and discard the sealing washer.

In alla ion
1. C AUTIONS:

Do not disassemble the fuel injectors or clean the

nozzles, even with an ultrasonic cleaner. Always install new
fuel injectors when required.

Do not use tools to install the new fuel return line clip.
Failure to follow this instruction will result in damage to the
retaining clip.

Install a new fuel injector retaining clamp.

1. Install a new fuel injector retaining clamp.

2. Install the fuel injector retaining clamp spacer.

3. Install a new fuel return line retaining clip.

4. Install a new sealing washer.

2. Install the fuel injector.

Install the two bolts and tighten to 10 Nm (7 lb.ft).

3. C AUTION: Make sure the fuel return line retaining clip

is correctly installed to the fuel injector before installing the
return line.

C onnect the fuel return line to the fuel injector.

Visually inspect the fuel return line O-ring seals for

damage.

Apply a light coating of petroleum jelly to the fuel

return line O-ring seals.

4. C AUTIONS:

Do not allow the unions to hit the olive ends of the

high-pressure fuel supply line as this may damage the ends
of the line and allow foreign matter to enter the fuel
injection system.

Maintain pressure on the high-pressure fuel supply

lines to keep the olives in contact with the fuel rail and the
fuel injector cones while installing unions.

NOTE: Remove and discard the blanking caps.

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Install the new high-pressure fuel suppl lines.

Install the new high-pressure fuel suppl line, tighten

the fuel suppl line unions finger tight.

Tighten the high-pressure fuel suppl line in the

shown sequence.

Tighten the high-pressure fuel suppl line union 1 to

fuel injector to 15 Nm.

Tighten the high-pressure fuel suppl line union 2 to

fuel rail to 15 Nm.

Tighten the high-pressure fuel suppl line union 1 to

fuel injector to 35 Nm.

Tighten the high-pressure fuel suppl line union 2 to

fuel rail to 35 Nm.

. Attach the engine wiring harness.

. C onnect the fuel injector electrical connectors.
. Install the NVH pads on the c linder banks.
. Attach the engine wiring harness to the bulkhead.
. C onnect the three engine harness electrical connectors.
. Install the batter .
For additional information, refer to: Batter (414-01 Batter ,
Mounting and C ables, Removal and Installation).
. Install the EGR coolant cross-over pipe.

Install the two retaining bolts.

Tighten the bolts to 13 Nm (10 lb.ft).

. C onnect both EGR coolant cross-over pipe hoses.

Remove the EGR coolant hose clamps.

. C onnect the low-pressure fuel lines.

Remove the blanking caps from the ports.

. C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. C heck and top-up the coolant.
. Bleed the fuel s stem.

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Published: 11-Ma -2011

F el Cha ging and Con ol - TDV6 2.7L Die el - In ake Ai Sh off Th o le
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Disconnect the three electrical connectors.

Release the fuel return line valve.

4. Remove the intake air shutoff throttle elbow retaining

bolt.

5. Release the intake air shutoff throttle elbow.

Remove the intake air shutoff throttle retaining stud.

6. Release the LH EGR valve outlet tube retaining clip.

7. Release the RH EGR valve outlet tube retaining clip.
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8. Reposition the intake air shutoff throttle.

9. Remove the intake air shutoff throttle.

10. NOTE: Do not disassemble further if the component is

removed for access onl .

Remove and discard the O-ring seals.

In alla ion

1. C AUTION: The O-ring seals are to be reused unless

damaged.

Install the intake air shutoff throttle.

2. Align the intake air shutoff throttle.
3. Secure the RH EGR valve outlet tube.
4. Secure the LH EGR valve outlet tube.
5. Secure the intake air shutoff throttle elbow.

Tighten the intake air shutoff throttle retaining stud to

10 Nm (7 lb.ft).

6. Tighten the intake air shutoff throttle elbow retaining bolt to

10 Nm (7 lb.ft).
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. C onnect the three electrical connectors.

Secure the fuel line return valve.

. Install the engine cover.

For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Published: 19-Aug-2011
F e Cha gi g a d C - TDV6 2.7L Die e - F e Di e e Rai
Removal and Installation

Ge e a E i e
Pneumatic vacuum gun

Re a
WARNINGS:

Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel
injection system. Failure to follow this instruction may result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may
result in personal injury.

This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.

Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system
can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

C AUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel
system and may result in later malfunction.

Always carry out the cleaning process before carrying out any repairs to the fuel injection system components.
Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore
essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to
any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.

Do not remove the fuel rail pressure sensor from the fuel injection diverter rail.

NOTE: If a new fuel rail pressure sensor is to be installed, a new fuel injection diverter rail and fuel rail pressure
sensor must be installed as an assembly.

1. Disconnect the battery ground cable.

For additional information, refer to: Specifications (414-00
Battery and C harging System - General Information,
Specifications).
2. Remove the engine cover.
For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
3. Disconnect the low-pressure fuel lines.

Install blanking caps to the exposed ports.

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. Di connec bo h e ha ga eci c la ion (EGR) coolan

c o -o e pipe ho e .

C lamp he EGR coolan ho e o minimi e coolan

lo .

. Remo e he EGR coolan c o -o e pipe.

Remo e he o e aining bol .

. C AUTIONS:

Make e ha he high-p e e f el ppl line

emain in con ac i h he f el injec ion ppl manifold
and he f el injec ion di e e ail n il bo h nion ha e
been de ached and cleaned. Fail e o follo hi in c ion
ma e l in fo eign ma e ing e o he f el injec ion
em.

Make e ha he f el injec o adap o nion doe

no mo e hen loo ening he high-p e e f el ppl
line . Fail e o follo hi in c ion ma e l in damage
o he f el injec o o he f el injec o adap o nion.

Loo en he high-p e e f el ppl line f om he f el

injec o and f el ail.

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. C AUTION: Make sure that all openings are sealed.

Use new blanking caps.

NOTE: Right-hand shown, left-hand similar.

Remove and discard the high-pressure fuel supply line.

. C AUTION: Make sure that the high-pressure fuel

supply line remains in contact with the fuel pump and fuel
injection diverter rail until both unions have been detached
and cleaned. Failure to follow this instruction may result in
foreign matter ingress to the fuel injection system.

NOTE: C rankcase vent oil separator shown removed for

clarity.

Remove and discard the high-pressure fuel supply line.

Install blanking caps to the exposed ports.

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. C AUTION: Make e ha he high-p e e f el

ppl line emain in con ac i h he f el injec ion ppl
manifold and he f el injec ion di e e ail n il bo h nion
ha e been de ached and cleaned. Fail e o follo hi
in c ion ma e l in fo eign ma e ing e o he f el
injec ion em.

U ing he pne ma ic ac m g n, ac m fo eign ma e ial

f om he high-p e e f el ppl line, he f el injec o
and he f el ail.
Fo addi ional info ma ion, efe o: F el Injec ion
C omponen C leaning (303-04C F el C ha ging and C on ol -
TDV6 2.7L Die el, Gene al P oced e ).
10. Relea e he lo -p e e f el line.

Di connec he lo -p e e f el line.

In all blanking cap o he e po ed po .

11. Di connec he f el ail p e e (FRP) en o elec ical

connec o .

Relea e he f el cha ging i ing ha ne .

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12. Remove the FRP and fuel injection diverter rail

assembl .

Remove the 2 studs.

In alla ion
1. Install the FRP and fuel injection diverter rail assembl .

Install the two retaining studs, but do not full tighten

at this stage.

2. C onnect the FRP sensor electrical connector.

Attach the fuel charging wiring harness.

3. C AUTIONS:

Do not disassemble the fuel injectors or clean the

no les, even with an ultrasonic cleaner. Alwa s install new
fuel injectors when required.

Do not use an aggressive cleaning fluid or a wire

brush to clean the fuel injector no le.

Install the new high-pressure fuel suppl line.

Install the new high-pressure fuel suppl line, tighten

the fuel suppl line unions finger tight.

Tighten the high-pressure fuel suppl line in the

shown sequence.

Tighten the high-pressure fuel suppl line union 1 to

fuel injector to 15 Nm.

Tighten the high-pressure fuel suppl line union 2 to

fuel rail to 15 Nm.

Tighten the high-pressure fuel suppl line union 1 to

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fuel injector to 35 Nm.

Tighten the high-pressure fuel suppl line union 2 to

fuel rail to 35 Nm.

. Attach the low-pressure fuel line.

Remove the blanking caps from the ports.

C onnect the low-pressure fuel line.

. Install the new high-pressure fuel suppl lines.

Remove the blanking caps from the ports.

Loosel install the new high-pressure fuel suppl lines.

Stage 1: Tighten the high-pressure fuel suppl line

union at the fuel injection suppl manifold to 15 Nm (11
lb.ft).

Stage 2: Tighten the high-pressure fuel suppl line

union at the fuel injection diverter rail to 15 Nm (11
lb.ft).

Stage 3: Tighten the high-pressure fuel suppl line

union at the fuel injection suppl manifold to 35 Nm (26
lb.ft).

Stage 4: Tighten the high-pressure fuel suppl line

union at the fuel injection diverter rail to 35 Nm (26
lb.ft).

. Secure the high-pressure fuel suppl lines.

Tighten the two retaining bolts to 10 Nm (7 lb.ft).

. Install the EGR coolant cross-over pipe.

Install the two EGR coolant cross-over pipe retaining

bolts.

Tighten to 13 Nm (10 lb.ft).

. C onnect both EGR coolant cross-over pipe hoses.

Remove the EGR coolant hose clamps.

. C onnect the low-pressure fuel lines.

Remove the blanking caps from the ports.

. Install the engine cover.

For additional information, refer to: Engine C over - 2.7L V6
- TdV6 (501-05 Interior Trim and Ornamentation, Removal
and Installation).
. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
. Bleed the fuel s stem.
For additional information, refer to: Low-Pressure Fuel
S stem Bleeding (310-00 Fuel S stem - General
Information, General Procedures).
. C heck and top-up the coolant.

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Published: 11-Ma -2011

Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel -
Torque Specif ications
Description Nm lb-ft
Oil suppl tube union to turbocharger retaining bolt 30 22
Oil suppl tube to c linder block retaining bolt 10 7
Oil return tube to turbocharger retaining bolts 10 7
Oil return tube to c linder block retaining bolt 10 7
E haust gas recirculation (EGR) valve to c linder head retaining bolts 10 7
EGR cooler mount bracket retaining bolt 10 7
EGR valve tube to e haust manifold retaining bolts 10 7
* Turbocharger to e haust manifold retaining nuts 24 18
Turbocharger heatshield retaining bolts 10 7
* E haust manifold retaining studs 13 10
*+ E haust manifold retaining nuts 24 18
Differential mounting bracket heat shield bolts 10 7
E haust heat shield bolts 10 7
E haust heat shield nut 10 7
Oil level indicator tube retaining bolt 10 7
Turbocharger securing bracket stud 13 10
Turbocharger securing bracket bolts 32 24
Turbocharger to transmission support bracket nut 25 18
Turbocharger to transmission support bracket bolts 48 35
+ Nuts must be tightened in sequence

* Ne nuts/studs must be installed

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P : 11-M -2011
F el Cha ging and Con ol - T bocha ge - TDV6 2.7L Die el -
T bocha ge
D O

I em Pa N mbe De c ip ion
1 - O
2 - LH
3 - A
4 - A
5 - O
6 - T
T , LH T V6 ,
, .T
, , .T

.V
,
' '.

A :

H
C
N , , -

L
L
O

T F T 4 .H ,
.

T DC .T .
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A .W ,
; .T
E C M (EC M).

T , (
) .T EC M
D T C (DTC ).

I em Pa N mbe De c ip ion
A - C ( )
B - O ( ),
1 - T
2 - V
3 - A
A , ,
.
C , , .

A ,
.

T .I ,
, .C ,
.

T EC M .
F , :E E C (303-14C E E C - TDV6 2.7L
D ,D O ).

T .I ,
.

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Published: 11-May-2011
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel -
Turbocharger
Diagnosis and Testing

Overview

For information on the operation of the system, refer to the relevant section in the workshop manual.

Inspection and verification

WARNINGS:

The following tests may involve working in close proximity to hot components. Make sure adequate protection is
used. Failure to follow this instruction may result in personal injury.

The turbocharger can continue to rotate after the engine has stopped. Do not attempt to check the turbocharger
until one minute has elapsed since the engine was switched off. Failure to follow this instruction may result in personal
injury.

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious mechanical or electrical faults.

Visual inspection chart
Mechanical Electrical
Intake air system C ircuit(s)
Hose(s)/hose connections Turbocharger actuator
Turbocharger Engine control module (EC M)
General engine condition. Electrical connections and harnesses

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step

4. 4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTC s) before
moving onto the symptom chart or DTC index.

Make sure that all DTC s are cleared following rectification

S mptom chart

S mptom Possible source Action

Poor Low/C ontaminated C heck the fuel level and condition. C heck the air intake for restriction.
performance fuel C heck the engine condition, compressions, etc. C heck for DTC s. Refer to
Restricted air the warranty policy and procedures manual if an EC M is suspect.
intake system
General engine
condition
EC M failure

No boost Electrical C heck the electrical connections and harnesses. C heck the air intake for
connections and restriction/leakage (see visual inspection). For air intake checks. C heck
harnesses the turbocharger actuator and circuits. Refer to the electrical guides.
Restricted air C heck the turbocharger mechanical condition. Refer to the warranty policy
intake system and procedures manual if an EC M is suspect.
C harge air cooler
restricted/leaking
Turbocharger
actuator failure
Turbocharger
failure
EC M failure

No Turbocharger Disconnect the turbocharger intake and outlet pipework and turn the
boost/excessive failure turbocharger by hand. Any roughness indicates a fault. C heck any up and
noise down movement in the turbocharger shaft. Excessive movement indicates
a fault. If in doubt, compare the suspect unit with a new turbocharger.
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DTC inde

NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: For a full list of powertrain DTC s, refer to workshop manual section 303-14 - Electronic Engine C ontrols.

DTC Condition Possible causes Action

P004500 Turbocharger/Supercharger Variable Refer to the electrical guides and check the VGT circuit.
Boost C ontrol A C ircuit / geometry Refer to the warranty policy and procedures manual if a
Open turbocharger module is suspect.
(VGT)
actuator
circuit high
resistance
VGT actuator
circuit short
circuit to
ground
VGT actuator
failure
EC M failure

P004600 Turbocharger/Supercharger Variable Refer to the electrical guides and check the VGT circuit.
Boost C ontrol A C ircuit geometry Refer to the warranty policy and procedures manual if a
Range/Performance turbocharger module is suspect.
(VGT)
actuator
circuit high
resistance
VGT actuator
circuit short
circuit to
ground
VGT actuator
circuit short
circuit to
power
VGT actuator
failure
EC M failure

P004700 Turbocharger/Supercharger Variable Refer to the electrical guides and check the VGT circuit.
Boost C ontrol A C ircuit Low geometry Refer to the warranty policy and procedures manual if a
turbocharger module is suspect.
(VGT)
actuator
circuit high
resistance
VGT actuator
circuit short
circuit to
ground
VGT actuator
failure
EC M failure

P004800 Turbocharger/Supercharger Variable Refer to the electrical guides and check the VGT circuit.
Boost C ontrol A C ircuit High geometry Refer to the warranty policy and procedures manual if a
turbocharger module is suspect.
(VGT)
actuator
circuit short
circuit to
power
VGT actuator
failure
EC M failure

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P023400 T bocha ge /S pe cha ge Ai leakage Refe o he ele an o k hop man al ec ion. C heck he
A O e boo C ondi ion Manifold MAP en o and ci c i . Refe o he elec ical g ide . Fo
ab ol e EGR al e e , efe o he ele an o k hop man al
p e e ec ion. C heck fo DTC indica ing EGR o VGT ac a o
(MAP) en o fa l . Refe o he a an polic and p oced e man al
ci c i high if a mod le i pec .
e i ance
MAP en o
ci c i ho
ci c i o
g o nd
MAP en o
ci c i ho
ci c i o
po e
MAP en o
fail e
E ha ga
eci c la ion
(EGR) fa l
VGT ac a o
fa l

P029900 T bocha ge /S pe cha ge Ai leakage Refe o he ele an o k hop man al ec ion. C heck he
A Unde boo C ondi ion po MAP en o and ci c i . Refe o he elec ical g ide . Fo
bocha ge EGR al e e , efe o he ele an o k hop man al
MAP en o ec ion. C heck fo DTC indica ing EGR o VGT ac a o
ci c i high fa l . Refe o he a an polic and p oced e man al
e i ance if a mod le i pec .
MAP en o
ci c i ho
ci c i o
g o nd
MAP en o
ci c i ho
ci c i o
po e
MAP en o
fail e
E ha ga
eci c la ion
(EGR) fa l
VGT fa l
EC M fail e

P226300 T bocha ge /S pe cha ge Ai leakage C heck he bocha ge and linkage mechanical condi ion.
Boo S em Pe fo mance po C heck he in ake ai em condi ion, ec if a
bocha ge nece a . C heck fo en o DTC . C heck he IAT and
In ake ai MAP en o ci c i . Refe o he elec ical g ide and
empe a e ec if a nece a . U ing a da alogge f nc ion, check
(IAT) en o he bocha ge ac a o po i ion. T n he igni ion on,
ci c i high engine off and command he bocha ge ac a o o 95%
e i ance, p l e id h mod la ed (PWM) hen o 5% p l e id h
ho ci c i mod la ed (PWM) and echeck he bocha ge ac a o
o g o nd, po i ion. The al e a 95% p l e id h mod la ed (PWM)
ho ci c i ho ld be 80 - 95%, and a 5% p l e id h mod la ed
o po e (PWM), 0 - 20%. If hi i no he ca e, in all a ne
Manifold bocha ge . C lea he DTC and e fo no mal
ab ol e ope a ion.
p e e
(MAP) en o
ci c i high
e i ance,
ho ci c i
o g o nd,
ho ci c i
o po e
Ma ai flo
(MAF) en o
ci c i high

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e i ance,
ho ci c i
o g o nd,
ho ci c i
o po e
E ha ga
eci c la ion
(EGR) ci c i
high
e i ance,
ho ci c i
o g o nd,
ho ci c i
o po e
VGT ac a o
fail e
T bocha ge
ane
ck/ icking

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Published: 11-May-2011
F el Cha ging and Con ol - T bocha ge - TDV6 2.7L Die el -
T bocha ge
Removal and Installation

Remo al
All vehicles

1. WARNING: Do not work on or under a vehicle

supported only by a jack. Always support the vehicle on safety
stands.

Raise and support the vehicle.

2. Open the hood.

Left-hand drive vehicles

3. C AUTIONS:

Do not turn the steering wheel with the steering

column lower shaft disconnected as damage to the
clockspring and steering wheel switches may occur.

Make sure the steering is in the straight ahead

position.

NOTE: Note the fitted position.

Loosen the steering column lower shaft to steering column

upper shaft bolt.

All vehicles
4. Remove the LH front wheel and tire.
5. Remove the transmission undershield.

Remove the 6 bolts.

6. Remove the engine undershield.

For additional information, refer to: Engine Undershield
(501-02 Front End Body Panels, Removal and Installation).

Left-hand drive vehicles

7. Remove the radiator access panel.

Remove the 2 bolts.

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All vehicles
. Release the downpipe catal tic converter support
insulator.

. Remove the transmission support insulator through-bolt.

Using a transmission jack, support the transmission.

10. With assistance, remove the transmission support

crossmember.

Remove the 4 nuts and bolts.

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. Wi h a i ance, emo e he do npipe ca al ic
con e e .

Loo en he clamp.

Remo e and di ca d he 3 n .

Remo e and di ca d he ga ke .

. Remo e he e ha f on hea hield.

Remo e he 3 n .

Remo e he bol .

. In all he an mi ion ppo c o membe .

In all b do no f ll igh en a hi age he 2

an mi ion ppo c o membe bol .

In all b do no f ll igh en a hi age he

an mi ion ppo in la o h o gh-bol .

Remo e he an mi ion jack.

. Remo e he diffe en ial mo n ing b acke hea hield.

Remo e he 2 bol .

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1 . Remo e he bocha ge ppo b acke .

Remo e he 2 bol .

Remo e he n .

1 . Remo e he 2 bol f om he bocha ge ppo

b acke .

1 . Loo en he bocha ge lo e n .

1 . Remo e he LH ppe a m.
Fo addi ional info ma ion, efe o: Uppe A m (204-01
F on S pen ion, Remo al and In alla ion).
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1 . Turn the ignition ke to position I.

Turn the steering wheel until the head of the steering

column lower shaft bolt can be seen through the LH
wheel arch.

20. C AUTION: Do not turn the steering wheel with the

steering column lower shaft disconnected as damage to the
clockspring and steering wheel switches ma occur.

Remove and discard the steering column lower shaft bolt.

21. Turn the steering wheel to the straight ahead position.

Remove the ignition ke .

22. Remove the steering column lower shaft.

Remove and discard the steering column lower shaft

upper bolt.

All vehicles
23. Remove the fender splash shield lower trim.

Remove the 4 clips.

24. Remove the turbocharger heat shield.

Remove the 2 bolts.

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2 . C AUTION: Alwa s plug an open connections to

prevent contamination.

Disconnect the turbocharger oil suppl tube.

Remove the turbocharger banjo bolt.

Remove and discard the sealing washers.

2 . C AUTION: Alwa s plug an open connections to

prevent contamination.

Remove the turbocharger oil return tube bolt.

Release the wiring harness clip.

2 . Remove the turbocharger oil return tube.

Remove the 2 bolts.

Remove and discard the gasket.

Remove and discard the O-ring seal.

2 . Remove the turbocharger support bracket.

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Remove the 2 bolts.

2 . Loosen the turbocharger intake and outlet pipe clips.

30. Disconnect the turbocharger electrical connector.

31. WARNING: Eye protection must be worn.

C AUTIONS:

Make sure that only the turbocharger studs are drilled.

Make sure that the depth of the drill does not exceed 14
mm (0.6 inch).

C arefully drill the turbocharger 2 upper studs.

C enter punch the turbocharger 2 upper studs.

Drill a pilot hole in the center of the turbocharger studs

progressively drill out the studs until a 8 mm (0.3 inch)
hole is achieved.

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32. With assistance, remove the turbocharger.

Loosen the turbocharger lower nut.

In alla ion
All vehicles
1. WARNINGS:

E e protection must be worn.

Never direct a high-pressure no le at the skin as the

high-pressure air ma penetrate to the underl ing tissue,
and cause serious injur .

C AUTION: Alwa s keep high-pressure equipment in

good condition, and regularl maintained, particularl at
joints and unions.

Drill two 8 mm (0.3 inches) holes in the turbocharger as

shown.

C lean the turbocharger and blow out with an air line.

2. Install a new stud to turbocharger lower hole.

3. With assistance, install the turbocharger.

C lean the turbocharger mating faces.

Align the turbocharger intake and outlet pipes.

4. With assistance, tighten the turbocharger upper nuts and

bolts to 24 Nm (18 lb.ft).
5. Tighten the turbocharger lower nut to 24 Nm (18 lb.ft).
6. C onnect the turbocharger electrical connector.
7. Tighten the turbocharger intake and outlet pipe clips.
8. Install the turbocharger support bracket.

Tighten the bolts to 23 Nm (17 lb.ft).

9. C onnect the turbocharger oil suppl tube.

Install new sealing washers.

Tighten the turbocharger oil suppl tube bolt to 30 Nm

(22 lb.ft).

10. Install the turbocharger heat shield.

Install the 2 bolts.

11. Install the 2 turbocharger oil return tube bolts.

Install a new gasket.

Install a new O-ring seal.

Tighten the 2 bolts to 10 Nm (7 lb.ft).

12. Install the turbocharger oil return tube bolt.

Attach the wiring harness clip.

13. Install the fender splash shield lower trim.

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In all he 4 clip .

Lef -hand d i e ehicle

. In all he ee ing col mn lo e haf .

C onnec he ee ing col mn lo e haf o he ee ing

col mn ppe haf .

C onnec he ni e al join o he ee ing gea .

. In all b do no f ll igh en a hi age a ne ee ing

col mn lo e haf o ee ing col mn ppe haf bol .

. C AUTION: Do no n he ee ing heel i h he

ee ing col mn lo e haf di connec ed a damage o he
clock p ing and ee ing heel i che ma occ .

T n he igni ion ke o po i ion I.

T n he ee ing heel n il he ee ing col mn lo e

haf bol hole can be een h o gh he LH heel a ch.

. In all he ee ing col mn lo e haf o ee ing gea

bol .

In all a ne bol and igh en o 30 Nm (22 lb.f ).

.T n he ee ing heel o he aigh ahead po i ion.

Remo e he igni ion ke .

. Tigh en he ee ing col mn lo e haf o ee ing col mn

ppe haf bol o 30 Nm (22 lb.f ).

All ehicle
. In all he LH ppe a m.
Fo addi ional info ma ion, efe o: Uppe A m (204-01
F on S pen ion, Remo al and In alla ion).
. In all he 2 bocha ge ppo b acke bol .

Tigh en he 2 bol o 23 Nm (17 lb.f ).

. In all he bocha ge ppo b acke .

In all he bocha ge ppo b acke d.

Tigh en he 2 bol o 48 Nm (35 lb.f ).

Tigh en he n o 25 Nm (18 lb.f ).

. In all he diffe en ial mo n ing b acke hea hield.

In all he 2 bol and igh en o 10 Nm (7 lb.f ).

. Remo e he an mi ion ppo c o membe .

U ing a an mi ion jack, ppo he an mi ion.

. In all he e ha f on hea hield.

In all he 3 n .

In all he bol .

. Wi h a i ance, in all he do npipe ca al ic con e e .

In all ne d and n .

In all a ne ga ke .
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Tighten the downpipe catal tic converter nuts and
clamp to 48 Nm (35 lb.ft).

2 . Install the transmission support crossmember.

Tighten the nuts and bolts to 90 Nm (66 lb.ft).

Install the transmission support insulator through-bolt

and tighten to 175 Nm (129 lb.ft).

Remove the transmission jack.

2 . Attach the downpipe catal tic converter hanger.

Left-hand drive vehicles

2 . Install the radiator access panel.

Tighten the 2 bolts to 10 Nm (7 lb.ft).

All vehicles
30. Install the engine undershield.
For additional information, refer to: Engine Undershield
(501-02 Front End Bod Panels, Removal and Installation).
31. Install the transmission undershield.

Tighten the bolts to 10 Nm (7 lb.ft).

32. Install the LH front wheel and tire.

Tighten the wheel nuts to 140 Nm (103 lb.ft).

33. C heck and top-up the engine oil.

34. C lose the hood.

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F el Cha ging and Con ol - T bocha ge - TDV6 2.7L Die el -
T bocha ge In ake T be
Removal and Installation

Remo al
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the power steering pump.
For additional information, refer to: Power Steering Pump -
TDV6 2.7L Diesel, VIN Range: SALLA000304->END OF 06MY
(211-02 Power Steering, Removal and Installation).
3. Remove the support bracket.

Remove the two retaining bolts.

4. WARNING: Do not work on or under a vehicle

supported onl b a jack. Alwa s support the vehicle on safet
stands.

Raise the vehicle.

5. Disconnect the breather hose.

Release the clip.

6. Disconnect the turbocharger intake tube.

Loosen the clip.

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7. Remo e he cha ge ai coole in ake pipe.

Wi h a i ance, epo i ion he bocha ge in ake

be.

8. Wi h a i ance, emo e he bocha ge in ake be.

In alla ion
1. To in all, e e e he emo al p oced e.

Tigh en he o e aining bol o 10 Nm (7 lb.f ).

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F el Cha ging and Con ol - T bocha ge - TDV6 2.7L Die el -
T bocha ge Ac a o Rod
Removal and Installation

Remo al

C AUTION: Always plug any open connections to prevent contamination.

NOTE: Some variation in the illustrations may occur, but the essential information is always correct.

1. Remove the turbocharger.For additional information, refer

to: Turbocharger (303-04D Fuel C harging and C ontrols -
Turbocharger - TDV6 2.7L Diesel, Removal and Installation).

2. C AUTION: Make sure that no parts of the

turbocharger actuator linkage are allowed to move beyond
the normal operating limits. Failure to follow this instruction
may result in damage to the vehicle.

Position the turbocharger actuator connecting rod to the

mid point position.

3. Using a suitable marker, mark the mid point position of

the actuator arm.

4. C AUTION: Make sure that two spanners are used to

remove the bolt. Failure to follow this instruction may result
in damage to the vehicle.

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Remove the bolt.

5. Remove the turbocharger actuator connecting rod.

In alla ion
1. C AUTIONS:

Make sure that no parts of the turbocharger actuator

linkage are allowed to move be ond the normal operating
limits. Failure to follow this instruction ma result in damage to
the vehicle.

Make sure that the marks are aligned. Failure to follow

this instruction ma result in damage to the vehicle.

Make sure that two spanners are used to install the bolt.
Failure to follow this instruction ma result in damage to the
vehicle.

To install, reverse the removal procedure.

2. Tighten the bolt to 5 Nm.

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. In all he bocha ge .Fo addi ional info ma ion, efe o:

T bocha ge (303-04D F el C ha ging and C on ol -
T bocha ge - TDV6 2.7L Die el, Remo al and In alla ion).

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Accessor Drive - V6 4.0L Petrol -
Torque Specif ications
Description Nm lb-ft
Generator drive belt tensioner bolt 45 33
Accessor drive belt idler pulle bolt 45 33

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Accessor Drive - V6 4.0L Petrol - Accessor Drive
Description and Operation

I em Pa N mbe De c ip ion
1 - Generator
2 - Deflection pulle
3 - Power steering pump
4 - A/C compressor
5 - C oolant pump
6 - C rankshaft pulle
7 - Accessor drive belt
8 - Tensioner assembl
The engine crankshaft pulle drives the accessor components, which comprise the torsional vibration damper,
generator, power steering pump, A/C compressor and coolant pump, via the accessor drive belt.
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The belt, which is maintenance free pol -V t pe belts, are automaticall pre-loaded b the tensioning rollers and are
routed over deflection pulle s in order to maintain sufficient adhesion about the drive wheels. This ensures slip-free
drive of the accessor components.

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P bli hed: 11-Ma -2011

Acce o D i e - V6 4.0L Pe ol - Acce o D i e
Diagno i and Te ing

O e ie

The e a e 2 acce o d i e bel on he pe cha ged engine and hi ec ion co e ba ic check fo bo h.

Fo ea e of iden ifica ion, he 2 bel a e efe ed o a p ima and econda d i e bel .

Fo addi ional info ma ion on he de c ip ion and ope a ion of he em, efe o he ele an o k hop man al
ec ion.

In pec ion and Ve ifica ion

1. 1. Ve if he c ome conce n.

2. 2. Vi all in pec fo ob io mechanical fa l .

S mp om cha
Mechanical
P ima d i e bel condi ion (c acking/damage/con amina ion)
Seconda d i e bel condi ion (c acking/damage/con amina ion)
Bel en ion
P lle alignmen
C oolan p mp
P ima en ione a embl
Ai condi ioning comp e o
Po e ee ing p mp
C ank haf p lle
Gene a o
D namic e pon e p mp p lle
Deflec ion p lle
S pe cha ge p lle
Seconda en ione a embl
C ooling fan p lle

3. 3. If an ob io ca e fo an ob e ed o epo ed conce n i fo nd, co ec he ca e (if po ible) befo e

p oceeding o he ne ep.

C AUTION: If he engine i n i ho he acce o d i e bel connec ed o elimina e d i en componen ,

diagno ic o ble code , (DTC ) ma be e hich m be clea ed befo e he ehicle i e ned o he o ne . The
engine ho ld no be n fo mo e han 2-3 min e i h he bel di connec ed. Fail e o follo hi in c ion ma
e l in damage o he ehicle.

4. 4. U e he app o ed diagno ic em o a can ool o e ie e an DTC befo e mo ing on o he mp om

cha o DTC inde .

Make e ha all DTC a e clea ed follo ing ec ifica ion.

S mp om cha

S mp om Po ible ca e Ac ion
Noi e Bel condi ion C heck he bel condi ion ( ee i al in pec ion). C heck he en ione f nc ion.
Bel en ion C heck he p lle alignmen . C heck he d i en componen fo e ce i e
P lle e i ance o o a ion. Rec if a nece a .
mi aligned
D i en
componen
(incl ding
en ione )

D i e bel Bel condi ion C heck he bel condi ion ( ee i al in pec ion). C heck he en ione f nc ion.
doe no Ten ione Rec if a nece a .
hold en ion fa l

DTC inde

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NOTE: Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the
scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read
by the manufacturer-approved diagnostic system).

NOTE: For a full list of EC M DTC s, refer to workshop manual section 303-14 - Electronic Engine C ontrols.

DTC De c ip ion Po ible o ce Ac ion

P050600 Idle Air C ontrol Air intake restriction C heck the air intake system. C heck the accessory drive
System RPM Lower Accessory drive belt and components. Refer to the relevant workshop
Than Expected overload manual section.
(defective/seized
component)

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Accessor Drive - V6 4.0L Petrol - Accessor Drive Belt
Removal and Installation

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the viscous fan assembl .
For additional information, refer to: C ooling Fan (303-03A
Engine C ooling - V6 4.0L Petrol, Removal and Installation).
3. Release the accessor drive belt.

Rotate the accessor drive belt tensioner

counterclockwise.

4. Remove the accessor drive belt.

Installation
1. To install, reverse the removal procedure.

C lean and inspect the drive pulle s for damage.

2. C onnect the batter ground cable.

For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Accessor Drive - V6 4.0L Petrol - Accessor Drive Belt Tensioner
Removal and Installation

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the generator drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
3. Remove the generator drive belt tensioner.

Remove the generator drive belt tensioner bolt.

Installation
1. Install the generator drive belt tensioner.

C lean the component mating faces.

Tighten the bolt to 45 Nm (33 lb.ft).

2. Install the generator drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
3. C onnect the batter ground cable.

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Accessor Drive - V6 4.0L Petrol - Accessor Drive Belt Idler Pulle
Removal and Installation

Removal
1. Disconnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).
2. Remove the generator drive belt.
For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
3. Remove the accessor drive belt idler pulle .

Remove the bolt.

Installation
1. Install the accessor drive belt idler pulle .

Tighten the bolt to 45 Nm (33 lb.ft).

2. Install the generator drive belt.

For additional information, refer to: Accessor Drive Belt
(303-05A Accessor Drive - V6 4.0L Petrol, Removal and
Installation).
3. C onnect the batter ground cable.
For additional information, refer to: Specifications (414-00
Batter and C harging S stem - General Information,
Specifications).

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Accessor Drive - V8 4.4L Petrol -
Torque Specif ications
Description Nm lb-ft
C ooling fan belt tensioner pulle bolt 25 18
C ooling fan belt tensioner bolt 45 33
C ooling fan drive pulle bolts 25 18
Accessor drive belt idler pulle bolt 25 18
Viscous fan drive hub bearing/pulle