Land Rover Freelander 2001MY Service Procedures Workshop Manual LRL0490 – PDF DOWNLOAD
DESCRIPTION:
Land Rover Freelander 2001MY Service Procedures Workshop Manual LRL0490 – PDF DOWNLOAD
How To Use This Manual:
General:
To assist in the use of this Manual, it is divided into sections and sub-sections. The section title is given at the top of each page and the relevant sub-section is given at the bottom. There is a single contents section at the front of the Manual, which is divided by section and sub-section.
- Each section is numbered from page 1. The individual items comprising repair operations are to be followed in the sequence in which they appear. Item numbers shown in illustrations are referred to in the associated text.
- Adjustment, Repair and Overhaul operations include reference to Service tool numbers and the associated illustration depicts the tool in use.
- Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details. Each adjustment or repair operation is given a Service Repair Operation (SRO) number.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Land Rover Freelander 2001MY Service Procedures Workshop Manual LRL0490 – PDF DOWNLOAD
INTRODUCTION 01-1
How To Use This Manual 01-1
Repairs and Replacements 01-2
Specifications 01-2
Abbreviations and Symbols 01-3
GENERAL INFORMATION 03-1
General precautions 03-1
Safety instructions 03-2
Environmental Precautions 03-3
General fitting instructions 03-7
Ball and roller bearings 03-8
Oil seals 03-9
Joints and joint faces 03-10
Locking devices 03-10
Screw threads 03-11
Bolt identification 03-12
Nut identification 03-13
Flexible pipes and hoses 03-14
Service tools 03-16
Rolling road testing 03-17
Fuel handling precautions 03-18
Electrical precautions 03-19
Supplementary restraint system precautions 03-20
SRS component manual deployment 03-27
SRS component replacement policy 03-28
Air conditioning system precautions 03-29
Remedial actions 03-30
Service precautions 03-30
Air conditioning compressor replacement 03-31
CONTENTS
2 CONTENTS
GENERAL DATA 04-1
Engine – Td4 Diesel 04-1
Engine – K1 8 Petrol 04-6
Engine – KV6 Petrol 04-11
Fuel system – Td4 Diesel 04-16
Fuel system – K1 8 Petrol 04-18
Fuel system – KV6 Petrol 04-18
Cooling system – Td4 Diesel 04-19
Cooling system – K1 8 Petrol 04-19
Cooling system – KV6 Petrol 04-19
Clutch 04-20
Manual Gearbox – Getrag 04-21
Manual Gearbox – PG1 04-22
Intermediate Reduction Drive (IRD) 04-24
Automatic Gearbox – Jatco 04-25
Rear Axle and Final Drive 04-26
Steering 04-27
Front Suspension 04-28
Rear Suspension 04-30
Brakes 04-31
Wheels and tyres 04-32
Tyre pressures 04-32
Heating and Ventilation 04-33
Air Conditioning 04-33
Electrical – Td4 engine 04-34
Electrical – K1 8 engine 04-34
Electrical – KV6 engine 04-34
Dimensions 04-35
Weights 04-36
IDENTIFICATION NUMBERS 05-1
Vehicle Identification Number 05-1
Identification Number Locations 05-2
CONTENTS
CONTENTS 3
TORQUE WRENCH SETTINGS 06-1
Maintenance 06-1
Engine – Td4 06-2
Engine – K1 8 06-4
Engine – KV6 06-6
Emission Control 06-8
Engine Management System – EDC 06-9
Engine Management System – MEMS 06-10
Engine Management System – Siemens 06-11
Fuel Delivery System – Diesel 06-12
Fuel delivery system – Petrol 06-13
Cooling System – Td4 06-14
Cooling System – K1 8 06-14
Cooling System – KV6 06-14
Manifolds and Exhaust System – Td4 06-15
Manifolds and Exhaust Systems – K1 8 06-16
Manifolds and Exhaust Systems – KV6 06-17
Clutch 06-18
Manual Gearbox – PG1 06-19
Manual Gearbox – Getrag 06-20
Intermediate Reduction Drive 06-21
Automatic Gearbox – Jatco 06-22
Driveshafts 06-23
Rear Axles and Final Drive 06-24
Steering 06-25
Front Suspension and Subframe 06-26
Rear Suspension and Subframe 06-27
Brakes 06-28
Supplementary Restraint Systems 06-29
Body 06-30
Heating and Ventilation 06-32
Air Conditioning 06-33
Wipers and Washers 06-34
Electrical 06-35
LIFTING AND TOWING 08-1
Jacking 08-1
Towing 08-2
Emergency starting 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS 09-1
Capacities 09-1
Fluids 09-2
Lubrication 09-3
Sealants 09-4
CONTENTS
4 CONTENTS
MAINTENANCE 10-1
MAINTENANCE
Td4 – Diesel Engine – Under Bonnet View 10-1
K1 8 – Petrol Engine – Under Bonnet View 10-2
KV6 – Petrol Engine – Under Bonnet View 10-3
Seats and Seat Belts 10-4
Lamps, Horns and Warning Indicators 10-4
Wipers and Washers 10-5
Handbrake 10-5
Alarm Handset Battery 10-6
Road Wheels 10-6
Tyres 10-7
Brake Pads and Calipers 10-7
Brake Fluid 10-9
Road Wheel Speed Sensors 10-9
Fuel Filter – Petrol 10-10
Fuel Filter – Diesel 10-10
Fuel Pump and Filter assembly – Diesel – 03 Model Year onwards 10-10
Fuel Sedimenter – Diesel – 03 Model Year onwards 10-10
Door Locks, Hinges, Check Straps and Bonnet Catch 10-11
Anti-freeze 10-12
Cooling System and Intercooler 10-12
Vent filter – turbocharger boost control solenoid valve – Td4 10-13
Spark Plugs – K1 8 10-13
Spark Plugs – KV6 10-13
Air Cleaner – Petrol Models 10-13
Ancillary Drive Belt – Td4 10-14
Ancillary Drive Belt – K1 8 10-14
Ancillary Drive Belt – KV6 10-15
Camshaft Timing Belt – K1 8 10-15
Camshaft Timing Belt – KV6 10-16
Brake/Clutch Reservoir 10-16
PAS Fluid Level 10-17
Intermediate Reduction Drive – Non NAS models 10-17
Intermediate Reduction Drive – NAS models 10-18
Manual Gearbox – PG1 10-18
Manual Gearbox – GETRAG 10-19
Automatic Gearbox – JATCO 10-19
Rear Axle 10-20
Clutch Pipes and Unions 10-21
Windscreen and Rear Washer Reservoir 10-21
Battery 10-21
Engine Oil and Filter – Td4 10-22
Engine Oil and Filter – K1 8 10-23
Engine Oil and Filter – KV6 10-24
Fuel Hoses and Pipes 10-25
Brake Hoses and Pipes 10-26
Check Exhaust System 10-26
Suspension 10-27
Steering 10-28
Road Test 10-28
Endorse Service Record 10-30
Report any Unusual Features 10-30
CONTENTS
CONTENTS 5
ENGINE – K SERIES KV6 12-3-1
ADJUSTMENTS
Engine oil pressure check 12-3-1
REPAIRS
Camshafts – LH cylinder head 12-3-3
Camshafts – RH cylinder head 12-3-5
Inlet camshaft front oil seal 12-3-8
Camshaft rear oil seal 12-3-9
Pulley – crankshaft 12-3-10
Crankshaft front oil seal 12-3-11
Crankshaft rear oil seal 12-3-12
Cylinder head gasket – LH 12-3-13
Cylinder head gasket – RH 12-3-16
Camshaft cover gasket – LH – Up to 03MY 12-3-20
Camshaft cover gasket – LH – from 03MY 12-3-21
Camshaft cover gasket – RH 12-3-23
Cover – engine acoustic 12-3-25
Engine and automatic gearbox – up to 03MY 12-3-25
Engine and automatic gearbox – from 03MY 12-3-35
Arm assembly – engine mounting RH 12-3-45
Engine mounting – LH 12-3-46
Hydramount – engine – RH 12-3-47
Engine steady – upper RH 12-3-47
Engine steady – lower 12-3-48
Torque converter drive plate 12-3-49
Filter – engine oil 12-3-50
Oil pick-up strainer 12-3-50
Gasket – oil pump 12-3-51
Sump – reseal 12-3-53
Switch – oil pressure 12-3-54
Oil pressure relief valve 12-3-55
Oil cooler – engine 12-3-57
Camshaft timing belt 12-3-58
Camshaft timing belt cover – RH front 12-3-66
Camshaft timing belt cover – LH front 12-3-67
Camshaft timing belt cover – LH rear 12-3-68
Camshaft timing belt cover – RH rear 12-3-68
Camshaft rear timing belt – LH cylinder head 12-3-69
Camshaft rear timing belt – RH cylinder head 12-3-73
OVERHAUL
Piston assemblies – engine set 12-3-77
Crankshaft front oil seal 12-3-80
Crankshaft rear oil seal 12-3-81
Crankshaft 12-3-82
Cylinder head gasket – LH 12-3-87
Cylinder head gasket – RH 12-3-91
Cylinder head – decarbonise 12-3-94
Oil pump – Overhaul 12-3-104
Sump – engine oil 12-3-106
Camshaft timing belt 12-3-107
CONTENTS
6 CONTENTS
EMISSION CONTROL 17-1-1
ADJUSTMENTS
Evaporative loss control system (EVAPS) – leak test – NAS 17-1-1
REPAIRS
Valve – depression limiter – Td4 17-1-3
Solenoid – canister purge – KV6 17-1-4
Charcoal canister – petrol – Non NAS 17-1-4
Charcoal canister – NAS 17-1-5
Valve – canister purge – K1 8 17-1-6
Valve – EGR – Td4 17-1-7
Solenoid/modulator valve – EGR – Td4 17-1-8
Thermal valve – exhaust gas recirculation (EGR) –
Td4 Automatic transmission (hot climates) – from 03 MY 17-1-9
Cooler – EGR – Td4 17-1-9
Module – tank leakage diagnostic (DMTL) 17-1-11
Filter – fuel leak detection pump – KV6 – NAS 17-1-12
Catalytic converter – RH – KV6 – NAS 17-1-12
ENGINE MANAGEMENT SYSTEM – SIEMENS 18-3-1
REPAIRS
Spark plugs – up to 03MY 18-3-1
Spark plugs – from 03MY 18-3-2
Coil – each – LH bank – up to 03MY 18-3-3
Coil – each – LH bank – from 03MY 18-3-3
Coil – each – RH bank – up to 03MY 18-3-4
Coil – each – RH bank – from 03MY 18-3-4
Engine control module (ECM) – Non NAS 18-3-5
Engine control module (ECM) – fuel – NAS 18-3-6
Idle Air Control Valve (IACV) 18-3-7
Sensor – intake air temperature (IAT) – NAS 18-3-8
Sensor – engine coolant temperature (ECT) 18-3-8
Sensor – crankshaft position (CKP) 18-3-9
Sensor – throttle position (TP) 18-3-10
Sensor – thermostat monitoring (TM) – KV6 – NAS 18-3-11
Sensor – camshaft position (CMP) 18-3-12
Sensor – knock (KS) 18-3-13
Switch – throttle pedal – Non NAS 18-3-13
Sensor – combined – manifold absolute pressure/Intake air temperature (MAP/IAT) 18-3-14
Sensor – throttle position (TP) – NAS – up to 03MY 18-3-15
Sensor – throttle position (TP) – NAS – from 03MY 18-3-16
CONTENTS
CONTENTS 7
FUEL DELIVERY SYSTEM – PETROL 19-2-1
ADJUSTMENTS
Throttle cable – check and adjust – KV6 19-2-1
Throttle cable – check and adjust – K1 8 19-2-2
Fuel system – depressurise – KV6 – Non NAS 19-2-2
Fuel system – depressurise – KV6 – NAS 19-2-3
Fuel system – depressurise – K1 8 19-2-4
Fuel system – pressure test – KV6 – Non NAS 19-2-4
Fuel system – pressure test – KV6 – NAS 19-2-5
Fuel system – pressure test – K1 8 19-2-5
Fuel tank – drain 19-2-6
REPAIRS
Air cleaner – K1 8 19-2-7
Element – air cleaner – K1 8 19-2-8
Element – air cleaner – KV6 19-2-8
Element – air cleaner – KV6 – NAS 19-2-9
Cable – throttle – KV6 19-2-10
Switch – inertia 19-2-11
Sensor – heated oxygen (H02S) – pre-catalyst – LH – KV6 – Non NAS 19-2-12
Sensor – heated oxygen (H02S) – pre-catalyst – LH – KV6 – NAS 19-2-13
Sensor – heated oxygen (H02S) – front – K1 8 19-2-14
Sensor – heated oxygen (H02S) – pre-catalyst – RH – KV6 – Non NAS 19-2-15
Sensor – heated oxygen (H02S) pre-catalyst – RH – KV6 – NAS 19-2-16
Sensor – mass air flow (MAF) – NAS 19-2-16
Relay – fuel pump 19-2-17
Throttle housing – K1 8 19-2-17
Throttle housing – KV6 – Non NAS 19-2-19
Throttle housing – KV6 – NAS 19-2-22
Variable induction system (VIS) balance motor – KV6 19-2-23
Sensor – heated oxygen (H02S) – post catalyst – LH – KV6 – Non NAS 19-2-24
Sensor – heated oxygen (H02S) – post catalyst – LH – KV6 – NAS 19-2-25
Sensor – heated oxygen (H02S) – post cat – K1 8 19-2-26
Sensor – heated oxygen (H02S) – post catalyst – RH – KV6 – NAS 19-2-27
Filter – main 19-2-28
Pump – fuel 19-2-29
Tank – Non NAS 19-2-30
Tank – NAS 19-2-32
Filler neck 19-2-34
Fuel rail – KV6 – Non NAS 19-2-35
Fuel rail – KV6 – NAS 19-2-36
Injector – KV6 19-2-38
Injectors – set – K1 8 19-2-39
Actuator unit – cruise control – KV6 – non NAS 19-2-40
Vacuum pump – cruise control – KV6 – non NAS 19-2-41
Switch – cruise control – KV6 – up to 04MY 19-2-41
Switch – engagement (on/off) – from 04MY 19-2-42
Switch – multi-purpose 19-2-42
ECU – cruise control – KV6 19-2-43
Interface ECU – cruise control – KV6 19-2-43
CONTENTS
8 CONTENTS
COOLING SYSTEM – K SERIES KV6 26-3-1
ADJUSTMENTS
Coolant – drain and refill 26-3-1
REPAIRS
Cooling fan and motor 26-3-3
Control unit – radiator cooling fan – 2002 MY On 26-3-3
Radiator assembly 26-3-4
Thermostat 26-3-6
Coolant pump 26-3-7
MANIFOLDS & EXHAUST SYSTEMS – K SERIES KV6 30-3-1
REPAIRS
Front pipe – Non NAS 30-3-1
Front pipe – NAS 30-3-3
Intermediate pipe – Non NAS 30-3-4
Intermediate pipe – NAS 30-3-5
Tail pipe & silencer 30-3-6
Heat shield – A/C compressor – KV6 – NAS 30-3-7
Gasket – inlet manifold – LH 30-3-8
Gasket – exhaust manifold – RH – Non NAS 30-3-9
Gasket(s) – exhaust manifold – RH – KV6 – NAS 30-3-10
Gasket – exhaust manifold – LH – Non NAS 30-3-11
Gasket(s) – exhaust manifold – LH – NAS 30-3-12
Seals – inlet manifold chamber – up to 03MY 30-3-13
Seals – inlet manifold chamber – from 03MY 30-3-18
Gasket – inlet manifold – RH 30-3-23
OVERHAUL
Seals – manifold chamber – up to 03MY 30-3-25
Seals – manifold chamber – from 03MY 30-3-27
INTERMEDIATE REDUCTION DRIVE 41-1
ADJUSTMENTS
Intermediate reduction drive (IRD) fluid – drain & refill – Non NAS 41-1
Intermediate reduction drive (IRD) lubrication system – drain & refill – NAS 41-2
REPAIRS
Intermediate reduction drive (IRD) unit – Td4 41-3
Intermediate reduction drive (IRD) unit – K1 8 41-7
Intermediate reduction drive (IRD) unit – KV6 41-10
Gasket – end cover – IRD housing – Td4 41-14
Gasket – end cover – IRD housing – KV6 41-15
Gasket – end cover – IRD housing – K1 8 41-18
Seals – primary gear shaft 41-19
Seal – pinion gear 41-21
Seal – driveshaft – LH – Td4 & KV6 models 41-23
Seal – drive shaft – LH – K1 8 41-24
Seal – driveshaft – RH 41-25
Seal – pinion gear housing – Td4 41-25
Seal – pinion gear housing – K1 8 41-27
Seal – pinion gear housing – KV6 – Non NAS 41-28
Seal – pinion gear housing – KV6 – NAS 41-30
CONTENTS
CONTENTS 9
AUTOMATIC GEARBOX – JATCO 44-1
ADJUSTMENTS
Inhibitor switch – adjust 44-1
Gearbox fluid – drain & refill 44-2
Selector cable – adjust 44-3
REPAIRS
Selector housing 44-5
Gear knob 44-6
Selector cable 44-7
Selector indicator – up to 03 MY 44-8
Selector indicator – from 04MY 44-9
Inhibitor switch 44-10
ECU 44-10
Oil seal – torque converter 44-11
Gearbox – KV6 – with engine and gearbox removed 44-12
Gearbox – KV6 44-17
Gearbox – Td4 44-23
Fluid pan – reseal 44-27
Fluid cooler – air blast – Td4 (hot climates) 44-28
Fluid cooler – Td4 44-30
Fluid cooler – KV6 44-31
Hose – fluid cooler 44-32
DRIVESHAFTS 47-1
REPAIRS
Shaft with both joints – LH 47-1
Shaft with both joints – RH 47-3
Gaiter – bell & joint – outer – front 47-5
Bell & joint – outer – LH – front 47-5
Gaiter – inner joint 47-6
Shaft with both joints – rear 47-6
Gaiter – outer – rear 47-8
Bell & joint – outer – rear 47-8
Gaiter – inner joint – rear 47-9
Propeller shaft assembly 47-9
Propeller shaft – front 47-11
Propeller shaft – rear 47-12
Propeller shaft – front /rear – overhaul 47-13
Gaiter – sliding joint – front propeller shaft 47-14
Viscous coupling assembly 47-15
Support bearing – front 47-16
CONTENTS
10 CONTENTS
REAR AXLE & FINAL DRIVE 51-1
REPAIRS
Differential assembly 51-1
Cover – rear – differential 51-2
Bush – differential mounting – front 51-3
Bush – differential mounting – rear 51-4
Oil seal – pinion 51-5
Oil seal – differential housing 51-6
STEERING 57-1
ADJUSTMENTS
Power assisted steering (PAS) system – bleed 57-1
Cable – key interlock – adjust 57-1
Front wheel alignment – check & adjust 57-2
Alignment – rear wheel – check & adjust 57-3
Power steering – pressure test 57-4
REPAIRS
Power steering rack 57-5
Gaiter – PAS rack 57-8
Oil cooler – Td4 & K1 8 models 57-9
Oil cooler – KV6 models 57-10
Drive belt – K1 8 57-11
Pump – steering – KV6 57-12
Pump – steering – K1 8 57-14
Pump – steering – Td4 57-15
Nacelle – column 57-16
Column lock & ignition/starter switch assembly 57-17
Cable – key interlock 57-18
Column assembly – inner & outer 57-19
Ball joint – track rod 57-23
Track rod 57-24
Steering wheel 57-25
FRONT SUSPENSION 60-1
REPAIRS
Anti roll bar 60-1
Ball joint link – anti roll bar 60-2
Mounting rubbers – anti roll bar – set 60-2
Bearing – hub 60-3
Damper 60-7
Lower arm assembly 60-10
Rear beam 60-13
Bush – lower arm – front 60-15
Bush – lower arm – rear 60-16
CONTENTS
CONTENTS 11
REAR SUSPENSION 64-1
REPAIRS
Bush – trailing link 64-1
Bearing – hub 64-2
Damper 64-5
Trailing arm 64-8
Bush – trailing arm 64-9
Link – adjustable – transverse 64-10
Link – transverse fixed 64-11
Bush – link – transverse 64-12
Sub frame 64-13
BRAKES 70-1
ADJUSTMENTS
Brake bleed 70-1
Cable – handbrake – check and adjust 70-2
REPAIRS
Drum – rear 70-3
Disc – front 70-5
Hose – front – primary – LH 70-6
Hose – rear 70-7
Cylinder – master – tandem – LHD 70-8
Cylinder – master – tandem – RHD 70-9
Lever assembly – handbrake 70-10
Cable – handbrake 70-11
Switch – handbrake warning 70-12
Switch – stop light 70-13
Sensor – brake pedal position 70-13
Shoes/pads – front – set 70-14
Brake Shoes – rear set 70-15
Servo assembly – LHD 70-17
Servo assembly – RHD 70-19
Vacuum pump – Td4 – manual 70-20
Vacuum pump – Td4 – automatic 70-21
Vacuum – enhancer – KV6 70-22
Carrier assembly – calliper – front 70-23
Wheel cylinder – rear 70-24
Switch – low fluid level 70-25
Sensor & harness – front wheel – RH 70-25
Sensor & harness – front wheel – LH 70-27
Sensor & harness – rear wheel 70-29
Modulator unit 70-30
Switch – hill descent – from 04MY 70-31
Switch – hill descent – up to 03MY 70-32
CONTENTS
12 CONTENTS
RESTRAINT SYSTEMS 75-1
REPAIRS
Automatic belt assembly – front – 3 door 75-1
Automatic belt assembly – front – 5 door 75-2
Seat belt – centre – rear 75-3
Seat belt – rear – LH 75-4
Adjustable mounting – seat belt – ‘B’ pillar 75-5
Stalk – rear seat belt – LH – 3 door 75-6
Stalk – rear seat belt – LH – 5 door 75-7
Pre-tensioner – seat belt – front 75-8
Pre-tensioner – seat belt – front – deployment – off vehicle 75-9
Stalk – rear seat belt – centre 75-11
Air bag – steering wheel 75-13
Air bag – fascia – passenger – up to 04MY 75-14
Air bag – fascia – passenger – from 04MY 75-15
Diagnostic control unit (DCU) 75-16
Airbag – passenger – deployment – off vehicle 75-17
Rotary coupler – (SRS) air bag system 75-19
Airbag module – steering wheel – deployment – off vehicle 75-20
Airbag module – steering wheel – deployment – in-vehicle 75-21
Pre-tensioner – front seatbelt – deployment – in-vehicle 75-23
DOORS 76-1-1
ADJUSTMENTS
Door – front or rear – adjust on striker 76-1-1
Door – front – align on hinges 76-1-2
REPAIRS
Door assembly – front – remove for access & refit 76-1-3
Door assembly – rear – remove for access & refit 76-1-4
Door – tail assembly – remove for access & refit 76-1-5
Glass – front door 76-1-6
Glass – rear door 76-1-7
Rubber/felt – glass channel – front door 76-1-8
Rubber/felt – glass channel – rear door 76-1-9
Glass – tail door 76-1-10
Quarter light – rear door 76-1-11
Glass regulator – tail door 76-1-12
Seal – waist inner – tail door 76-1-13
Trim casing – front door – 3 door 76-1-14
Trim casing – front door – 5 door – up to 04MY 76-1-15
Trim casing – front door – 5 door – from 04MY 76-1-16
Trim casing – rear door – up to 04MY 76-1-18
Trim casing – rear door – from 04MY 76-1-20
Trim casing – tail door 76-1-22
Plastic sheet – front door – lower – 3 door 76-1-23
Pocket – front door – 3 door 76-1-23
Plastic sheet – front door – upper – 3 door 76-1-24
Plastic sheet – tail door 76-1-24
Plastic sheet – front door – 5 door 76-1-25
Plastic sheet – rear door 76-1-25
Latch – front door – 3 door 76-1-26
Latch – front door – 5 door 76-1-27
Latch – rear door 76-1-28
Latch – tail door 76-1-29
CONTENTS
CONTENTS 13
Remote control – front door 76-1-30
Remote control – rear door 76-1-30
Operating cable – lock remote control – 5 door 76-1-31
Finisher – rear screen – side – 5 door 76-1-31
Handle – exterior – rear door 76-1-32
Handle – exterior – tail door 76-1-33
Handle – exterior – front door 76-1-34
Door pull – 5 door – up to 04MY 76-1-35
EXTERIOR FITTINGS 76-2-1
REPAIRS
Wing – front 76-2-1
Liner – front wheel arch 76-2-2
Liner – rear wheel arch 76-2-3
Panel – underbelly 76-2-4
Mirror – exterior – electric 76-2-4
Mud flap – front 76-2-5
Mud flap – rear 76-2-5
Bracket – spare wheel mounting 76-2-6
Side rail – integral roof rack – 5 door 76-2-7
Bonnet 76-2-7
Cable/rod – bonnet lock control 76-2-8
Bumper – assembly – front – up to 04MY 76-2-10
Bumper – assembly – front – from 04MY 76-2-11
Bumper valance – rear – up to 04MY 76-2-13
Bumper valance – rear – from 04MY 76-2-13
Finisher – sill – lower 76-2-16
Moulding – roof – 5 door 76-2-17
Wheelarch extension – rear wing part 76-2-18
Body quarter vent assembly – 3 door 76-2-19
CONTENTS
14 CONTENTS
INTERIOR TRIM COMPONENTS 76-3-1
REPAIRS
Sun visor 76-3-1
Trim casing – rear quarter – lower – 3 door 76-3-1
Trim casing – rear quarter – lower – 5 door 76-3-2
Trim casing – rear quarter – upper – 3 door 76-3-3
Trim casing – rear quarter – upper – 5 door 76-3-4
Trim finisher – ‘A’ post – upper – renew 76-3-5
Trim finisher – ‘B/C’ post – upper – renew 76-3-6
Trim finisher – ‘B’ post – lower – 5 door 76-3-7
Trim casing – body side – rear – 3 door 76-3-8
Console – front – up to 04MY 76-3-9
Console assembly – front – from 04MY 76-3-11
Console – rear 76-3-12
Cup holder – fascia – from 04MY 76-3-13
Fascia – up to 04MY 76-3-14
Fascia – from 04MY 76-3-19
Drink tray assembly – fascia – up to 04MY 76-3-23
Stowage box – fascia 76-3-23
Carpet – luggage compartment 76-3-24
Glove box 76-3-25
Headlining – 3 door 76-3-25
Headlining – 5 door 76-3-27
SCREENS 76-4-1
REPAIRS
Windscreen 76-4-1
Glass – body side – rear 76-4-3
SEATS 76-5-1
REPAIRS
Front seat 76-5-1
Rear seat – LH 76-5-1
Rear seat – RH 76-5-2
Cushion & squab – rear seat – bench type – 3 door 76-5-2
Cover – one piece – front seat cushion 76-5-3
Cover – rear seat cushion – RH 76-5-4
Cover – rear seat cushion – LH 76-5-6
Cover – cushion – rear single seat – 3 door 76-5-7
Finisher – seat base – front – each 76-5-8
Finisher – cushion side – front seat 76-5-9
Manual mechanism – lumbar support – front seat 76-5-9
Latch – rear squab – RH 76-5-11
Latch – rear squab – LH 76-5-11
Cover – squab – front seat 76-5-12
Cover – squab – rear seat – side – LH 76-5-13
Cover – squab – rear seat – RH 76-5-14
Cover – squab – rear single seat – 3 door 76-5-16
CONTENTS
CONTENTS 15
SUNROOF 76-6-1
REPAIRS
Sun/sliding roof – complete – front – 3 door 76-6-1
Wind deflector – sun/sliding roof – 3 door 76-6-2
Seal – tray – sun /sliding roof – front 76-6-3
Sun/sliding roof – complete – front – 5 door 76-6-4
Glass panel – sun/sliding roof – front – 5 door 76-6-4
Seal – panel glass – sun roof – 5 door 76-6-5
Motor – sun/sliding roof – front – 5 door 76-6-5
Drive cables & slide assemblies – sun/sliding roof – front – 5 door 76-6-7
Drain tube – sun/sliding roof – front – each – 5 door 76-6-8
Drain tube – sun/sliding roof – rear – each – 5 door 76-6-9
Finisher – flange to headlining – front 76-6-9
Wind deflector – sun/sliding roof – 5 door 76-6-10
Sun blind – front – one – 5 door 76-6-10
Switch – sun/sliding roof – front 76-6-11
Seal – tray – sun /sliding roof – front – 5 door 76-6-11
HOOD 76-7-1
REPAIRS
Hard top – remove for access & refit 76-7-1
Frame & hood cover – assembly – remove for access & refit 76-7-2
Hood outer cover 76-7-4
Glass – body side – hard back 76-7-5
Seal – hard back – primary 76-7-7
Catch and retainer – hard-back – front 76-7-8
Catch and retainer – hard-back – rear 76-7-9
BODY DIMENSIONS 77-1-1
BODY DIMENSIONS
Dimensional Information 77-1-1
Dimensional Illustrations 77-1-3
BODY GAPS AND PROFILES
Gap and Profile Measurements 77-1-17
CONTENTS
16 CONTENTS
PANEL REPAIRS 77-2-1
BODY REPAIRS
General 77-2-1
REPLACEMENT PANELS
Serviceable Panels 77-2-3
Inner front end panels 77-2-4
Outer body side panels – 3 door 77-2-5
Outer body side panels – 5 door 77-2-6
Front inner body side panels – 3 door 77-2-7
Front inner body side panels – 5 door 77-2-8
Rear inner body side panels – 3 door 77-2-9
Rear inner body side panels – 5 door 77-2-10
Roof assemblies – 3 door 77-2-11
Roof assembly – 5 door 77-2-12
Rear end panels 77-2-13
Door assemblies 77-2-14
WELDING PROCEDURES
ECU locations (3 door model shown, 5 door model similar) 77-2-15
General Welding Precautions 77-2-16
PROCEDURES
Panel replacement procedure 77-2-19
REPAIRS
Front bulkhead assembly 77-2-25
Bonnet locking platform 77-2-27
Headlamp mounting panel 77-2-28
Front lower crossmember 77-2-29
Front sidemember (complete) 77-2-30
Front sidemember (front section) 77-2-32
Front valance assembly 77-2-33
Valance upper front 77-2-36
Valance front 77-2-37
Valance outer reinforcement 77-2-39
‘A’ post – 3 door 77-2-40
‘A’ post – 5 door 77-2-41
Sill reinforcement – 3 door 77-2-43
Sill reinforcement – 5 door 77-2-44
‘B/C’ post reinforcement – 3 door 77-2-45
‘B/C’ post reinforcement – 5 door 77-2-46
Complete rear quarter – 3 door 77-2-48
Complete rear quarter – 5 door 77-2-50
Outer rear wheel arch – 3 door 77-2-53
Outer rear wheel arch – 5 door 77-2-54
Inner ‘e’ post – 3 door 77-2-55
Inner ‘e’ post – 5 door 77-2-56
Rear floor crossmember assembly 77-2-58
Rear floor 77-2-59
Floor longitudinal 77-2-60
Front roof assembly – 3 door 77-2-61
Rear roof assembly – 3 door 77-2-61
Roof assembly – 5 door 77-2-62
TIMES
TIME SCHEDULES 77-2-63
CONTENTS
CONTENTS 17
BODY SEALING MATERIALS 77-3-1
MATERIALS AND APPLICATIONS
77-3-1
APPROVED MATERIALS
77-3-3
APPLICATION EQUIPMENT
Application Equipment 77-3-5
CORROSION PREVENTION AND SEALING 77-4-1
CORROSION PREVENTION
Cavity wax treatment areas and injection holes – 3 door 77-4-1
Key to Figure, cavity wax treatment areas and injection holes – 3 door 77-4-2
Sill cavity wax injection holes – 5 door 77-4-3
Door cavity wax treatment areas and injection hole – 5 door 77-4-4
Corrosion Prevention 77-4-5
SEALING
Underbody sealer treatment areas 77-4-7
Underbody sealer 77-4-8
INTERNAL SEALING
Expanding foam acoustic seals 77-4-27
Expanding foam acoustic seals 77-4-28
LEAK DETECTION
Water Leaks 77-4-31
PAINTING 77-5-1
PANEL PROCEDURES
Panel Preparation 77-5-1
PAINT PROCEDURES
Paint preparation 77-5-2
CONTENTS
18 CONTENTS
HEATING AND VENTILATION 80-1
REPAIRS
Controls – heater – up to 04MY 80-1
Controls – heater – from 04MY 80-2
Servo – air recirculation 80-3
Switch – recirculation control 80-3
Switch – fan – front heater 80-4
Ventilator – face level – LH 80-5
Plenum – air intake 80-6
Heater unit 80-7
Element – positive temperature co-efficient (PTC) heater – Td4 models 80-10
Harness – positive temperature co-efficient (PTC) heater – Td4 models 80-11
Microswitch – positive temperature co-efficient (PTC) heater – Td4 models 80-14
Blower assembly 80-14
Resistor unit – fan motor 80-15
Matrix – heater 80-15
Relay – power – positive temperature co-efficient (PTC) – Td4 models 80-16
Relay – control – positive temperature co-efficient (PTC) – Td4 models 80-17
Fuel burning heater (FBH) 80-18
Sensor – outside temperature (OT) 80-19
Fuel pump – fuel burning heater – up to 03MY 80-20
Fuel pump – fuel burning heater – from 03MY 80-21
AIR CONDITIONING 82-1
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery – recycling and recharge 82-1
ADJUSTMENTS
Drive belt – compressor – Td4 82-3
REPAIRS
Drive belt – compressor – Td4 82-5
Compressor – Td4 82-6
Compressor – KV6 82-7
Compressor – K1 8 82-8
Condenser 82-10
Receiver drier 82-12
Switch – control 82-13
Sensor – refrigerant pressure 82-14
Valve – thermostatic expansion (TXV) 82-15
Evaporator 82-16
CONTENTS
CONTENTS 19
WIPERS AND WASHERS 84-1
REPAIRS
Reservoir – washer 84-1
Jet – washer – each 84-2
Pump – washer 84-2
Arm – wiper – each 84-3
Blade – wiper – each 84-3
Motor & linkage – wiper 84-4
Switch – wiper/washer 84-4
Pump – washer 84-5
Arm – wiper 84-5
Blade – wiper 84-6
Motor – wiper 84-7
Switch – combined wiper/washer 84-8
Relay – tailgate wipe – 5 door 84-8
CHARGING AND STARTING 86-1-1
ADJUSTMENTS
Ancillary drive belt – K1 8 86-1-1
Ancillary drive belt – K1 8 with A/C 86-1-2
REPAIRS
Alternator – Td4 86-1-3
Alternator – KV6 86-1-5
Alternator – K1 8 86-1-6
Ancillary drive belt – Td4 86-1-7
Ancillary drive belt – K1 8 without A/C 86-1-8
Ancillary drive belt – K1 8 with A/C 86-1-9
Ancillary drive belt – KV6 86-1-10
Tensioner – ancillary drive belt – Td4 86-1-11
Battery 86-1-12
Carrier – battery 86-1-13
Relay – main 86-1-14
Starter motor – Td4 86-1-15
Starter motor – KV6 86-1-16
Starter motor – K1 8 86-1-17
Relay – starter 86-1-18
CONTENTS
20 CONTENTS
LIGHTING 86-2-1
ADJUSTMENTS
Headlamps – pair – align beam – up to 04MY 86-2-1
Headlamps – pair – align beam – from 04MY 86-2-1
REPAIRS
Headlamp assembly – up to 04MY 86-2-3
Headlamp assembly – from 04MY 86-2-4
Lamp assembly – flasher side repeater – front 86-2-5
Lamp assembly – tail 86-2-5
Lamp assembly – number plate 86-2-6
Lamp assembly – fog/driving – from 04MY 86-2-6
Lamp assembly – rear 86-2-7
Lamp assembly – centre high mounted stop (CHMSL) 86-2-7
Lamp assembly – glove compartment 86-2-8
Lamp assembly – load space 86-2-8
Switch – headlamp levelling 86-2-9
Switch – glove compartment 86-2-9
Switch – hazard warning 86-2-10
Switch – combined direction indicator/headlight/horn 86-2-10
Switch – rear fog lamp 86-2-11
CONTROL UNITS 86-3-1
REPAIRS
Control unit – window lift 86-3-1
Relay – power folding mirrors – from 02MY 86-3-1
Central Control Unit (CCU) 86-3-2
Control Unit – power fold mirrors – up to 02MY 86-3-3
SECURITY 86-4-1
REPAIRS
Solenoid/motor – taildoor 86-4-1
Switch/push – horn 86-4-2
Horn 86-4-2
Immobilisation – electronic control unit (ECU) – 86-4-3
Sensor – volumetric – alarm system – 3 door 86-4-3
Module (ECU) – volumetric – alarm system – 5 door – without sunroof 86-4-5
Module (ECU) – volumetric – alarm system – 5 door – with sunroof 86-4-7
Receiver – alarm system 86-4-10
Coil – passive immobilisation – alarm system 86-4-10
CONTENTS
CONTENTS 21
WINDOWS 86-5-1
REPAIRS
Motor & control unit – front door – 3 door 86-5-1
Motor & control unit – front door – 5 door 86-5-2
Switch – master window – 5 door – from 04MY 86-5-2
Relay – control – tail door glass 86-5-3
Microswitch – hardtop sensing – 3 door 86-5-4
Relay – heated front screen 86-5-5
Switch – backlight heater 86-5-6
IN CAR ENTERTAINMENT 86-6-1
REPAIRS
Radio – up to 04MY 86-6-1
Radio/CD – from 04MY 86-6-2
Speaker – rear – 3 door 86-6-3
Speaker – rear – 5 door 86-6-3
Speaker – front 86-6-4
Aerial – manual – 3 door 86-6-4
Aerial – manual – 5 door 86-6-5
Coaxial lead – front aerial – 3 door 86-6-6
Coaxial lead – front aerial – 5 door 86-6-7
Speaker – tweeter – front 86-6-8
Speaker – tweeter – rear – 3 door 86-6-9
Amplifier – power 86-6-10
Sub-woofer assembly 86-6-11
Coaxial lead – extension 86-6-12
HARNESSES 86-7-1
REPAIRS
Fuse box – passenger compartment 86-7-1
Harness – main 86-7-2
Harness – tailgate 86-7-12
Harness – interior lights – 5 door 86-7-15
Harness – front door – 5 door 86-7-15
Harness – rear door 86-7-16
DRIVER CONTROLS 86-8-1
REPAIRS
Switch – remote control – audio system 86-8-1
Switch – park distance control (PDC) – from 04 MY 86-8-1
Control unit (ECU) – parking aid – from 04MY 86-8-2
Sensor – parking aid – rear – from 04MY 86-8-2
Sounder – parking aid – rear – from 04MY 86-8-3
Switch – handbrake warning 86-8-3
Switch – hazard warning – from 04MY 86-8-4
Cigar lighter – front 86-8-4
Switch – control – exterior mirror 86-8-5
CONTENTS
22 CONTENTS
NAVIGATION SYSTEM 87-1
REPAIRS
Interface unit – remote control 87-1
Display unit – navigation system 87-1
INSTRUMENTS 88-1
REPAIRS
Clock 88-1
Instrument panel – up to 04MY 88-2
Instrument panel – from 04MY 88-3
Cowl – instrument – up to 04MY 88-4
Cowl – instrument – from 04MY 88-5
Sender unit – fuel tank gauge 88-6
Sender unit assembly – fuel tank – Td4 models – from 03MY 88-6
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V