Haynes Land Rover Freelander 97-06 Owners Workshop Manual 0857338749, 9780857338747

Citation preview

FREELANDER Ee ae

1997 to Oct 2006 (R to 56 reg) Petrol & Diesel step-by-step maintenance and repair

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

|

https://archive.org/details/landroverfreelanO000unse

Land Rover Freelander Owners Workshop Manual Martynn Randall Models covered

(3929-12AN2/4623-7AP1/5571-416)

Freelander Hardback, Softback & Station Wagon Petrol: 1.8 litre (1796cc) 4-cylinder Turbo-diesel: 2.0 litre (1951cc TD4 & 1994cc L-Series) Does NOT cover models with 2.5 litre V6 petrol engine Does NOT cover new ‘Freelander 2’ range introduced November 2006

© Haynes Publishing 2013 A book in the Haynes Owners Workshop Manual Series

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright

Printed in the USA

Haynes Publishing Sparkford, Yeovil, Somerset BA22 7JJ, England

holder. Haynes North America, Inc

ISBN 978 0 85733 874 7

861 Lawrence Drive, Newbury Park, California 91326, USA

British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.

Haynes Publishing Nordiska AB Box 1504, 751 45 UPPSALA, Sverige

Printed using 33-lb Resolute Book 65 4.0 from Resolute Forest Products Calhoun, TN mill. Resolute is a member of World Wildlife Fund’s Climate Savers programme committed to significantly reducing GHG emissions. This paper uses 50% less wood fibre than traditional offset. The Calhoun Mill is certified to the following sustainable forest management and chain of custody standards: SFI, PEFC and FSC Controlled Wood.

Contents LIVING WITH YOUR

LAND

ROVER

FREELANDER

Introduction

Page

094

Safety first!

Page

0O*5

Roadside repairs Introduction

Page

0°6

If your car won’t start

Page

0°6

Jump starting

Page

0°7

Wheel changing

Page

0e8

Identifying leaks

Page

O99

Towing

Page

0Oe9

Introduction

Page

0°10

Underbonnet check points

Page

0°10

Engine oil level

Page

Oe11

Coolant level

Page

0912

Weekly checks

Brake fluid level

Page

0912

Tyre condition and pressure

Page

0e13

Screen washer fluid level

Page

0°14

Battery

Page

0014.

Electrical systems

Page

0°15

Wiper blades

Page

0¢15

Lubricants and fluids

|

Tyre pressures

Page 0°16 Page 0°16

MAINTENANCE Routine Maintenance and Servicing Land Rover Freelander petrol models

Page

1Ae1

Servicing specifications

Page

1Ae°2

Maintenance schedule

Page

1Ae2

Maintenance procedures

Page

1A°6

Page

1Be1

Servicing specifications

Page

1Be2

Maintenance schedule

Page 1Be2

Maintenance procedures

Page

Land Rover Freelander diesel models

1Be6

Illegal Copying It is the policy of Haynes Publishing to actively protect its Copyrights and Trade Marks. Legal action will be taken against anyone who unlawfully copies the cover or contents of this Manual. This includes all forms of unauthorised copying including digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to the appropriate statutory authorities.

Contents REPAIRS & OVERHAUL Engine and Associated Systems 1.8 litre petrol engine in-car procedures

Page

2.0 litre L-Series diesel engine in-car repair procedures

Page

2Be1

2.0 litre TD4 diesel engine in-car repair procedures

Page

2Ce1

Page

2De1

Engine removal and overhaul procedures

.

2Ae1

Cooling, heating and ventilation systems

Page

3e1

Fuel and exhaust systems — petrol engines

Page

4Ae1

Fuel and exhaust systems — diesel engines

Page

4Be1

Emission control systems

Page

4Ce1

Starting and charging systems

Page

5Ae1

Ignition system — petrol engine models

Page

5Be1

Pre-heating system — diesel engine models

Page

5Ce1

Transmission Clutch

Page

66¢1

Manual transmission

Page

7Ae1

Automatic transmission

Page

7Be1

Intermediate Reduction Drive unit

Page

7Ce1

Driveshafts, Propeller shafts and final drive

Page

861

Brakes and Suspension Braking system

Page

91

Suspension and steering

Page

10¢1

Bodywork and fittings

Page

11¢1

Body electrical systems

Page

12¢1

Body Equipment

Wiring Diagrams 1997 to 2001

Page 12°28

2001 to 2003

Page 12°45

2003-on

Page 12°61

REFERENCE Dimensions and weights

Page

REFe1

Conversion factors

Page

REFe2

Buying spare parts

Page

REFe3

Vehicle identification

Page

REFe3

General repair procedures

Page

REFe4

_ Jacking and vehicle support

Page Page

REFe5 REFe5

Page

REF*6

Page

REFe8

Radio/cassette/CD unit anti-theft system Tools and working facilities

MOT test checks

.

Fault finding

Index.

Page REFe12

|

Page REF*20

oo4 INtroduction levels are further enhanced by features such as Hill Descent Control (HDC), Traction control, ABS, integral rollover cage (3-door), dual front airbags, and seatbelt pretensioners.

In June 2000 and July 2003, the Freelander underwent ‘facelifts’ which involved changes to the external and internal appearance of the vehicle. To coincide with the redesign,

the existing L-Series diesel engine was replaced by the TD4 2.0 litre diesel engine of BMW origin, and an automatic transmission option (5-speed with Steptronic control) was available for the first time. ABS became standard fitment. All models are available with an immobiliser, alarm, remote central locking and air conditioning. For the home mechanic, the Land Rover Freelander is a straightforward vehicle to maintain and most of the items requiring frequent attention are easily accessible.

Your Land Rover Freelander manual

ah

Land Rover Freelander 1.8 litre 3-door Softback

The Land Rover Freelander was launched in the UK in October 1997. Available as a 3- or

5-door Softback or Hardback, as well as a 5-door Station Wagon, with a choice of 1.8 litre petrol or 2.0 litre direct injection diesel engines. Although fashionably styled, the Freelander

has high ground clearance, permanent fourwheel-drive, power assisted steering, and fully independent suspension front and rear, making it a capable off-road performer, as well as exceeding current standards of on-road performance for this type of vehicle. Safety

The aim of this Manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage). It will also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence. The illustrations are numbered by the Section number and paragraph number to which they relate — if there is more than one illustration per paragraph, the sequence is denoted alphabetically. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver’s seat, facing forwards.

Acknowledgements Thanks are due to Draper Tools, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual.

eee

ae,

alan Si gee

Land Rover Freelander 2.0 litre 5-door Station Wagon

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Safety First! o-s Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.

General hazards Scalding e Don’t remove the radiator or expansion tank

cap while the engine is hot. e Engine oil, transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.

Burning e Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.

Crushing

e Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.

Fume or gas intoxication e Exhaust fumes are poisonous; they. . can contain carbon -. Ree eel oe ec eee :S)(20 (RE Ae heii ee es nan Ao Reet APALY Silo ghoe aya Dip SEAGS Bia ao Sietess cesccye Eo a ore.sosra ean UST nia one eC eT eteeel eee ae SAGE's, Sater skese Sc ea ene ENROE SP Re ct i cad ths hee atc EGR recirculation: pipe.boltsy Siccryetschcteio ce: aecteuel cree eeeey terete eet Engine COVEN SCKOW iccis cetadarc\s thee spent e Miercheronse lence SINUSES tac ieraiee onteirane Engine/transmission mountings: Left-hand mounting: Molmnting-to-body: bolts) ss petaran)cestetcrs ners oicement eters areieeen Mountingibracket. throuigh-boltim acim crete eit ieee ones

Bracket-t0-transmiSsiomsbolts)iav)

sistent rere tener erro nceia . 2 secretes wie = = «el

Strut-to-engine mounting bolts «= 25). Right-hand mounting:

Engine mounting plate-to-engine nuts and bolts: SLAGE To. Eacehare shteacsl Mee nw)a Oscars eave RoUT ete Renee Stage 2 FF Pickle cote ale ere ¢ llensis yerapee epee kate ararets eT Mounting bracket-to-engine bolts .............:.....3..... Mounting bracketito upperitic rocie ace iret eeiees ies ne neice

Mounting-to-body'boltsit.s -iim.ctan sete tereericr at eset eae Lower tie:rod bolts sr. S.ene ew. cuciere cen ceraima eee ae tans, oereioan ene aaa Lower tie rod bracket-to-sump bolts ................0eeeeaeee Wppenritieirod-to-body bolts. trac sarciete mettetenemern yer) oo UP nane ene Upper tie rod bracket-to-body bolts ...............00cseveees 7 Upper tie rod to engine mounting bracket .................... Strut-to-starter MOtomboltmr risus. merits eersecs ee eae

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20 Angle-tighten a further 85°

15

63 Angle-tighten a further 90° 10

46

30 65 Angle-tighten a further 90° Angle-tighten a further 90° 10 4

22 48

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7 3

45 80

fuss 59

65 80

48 59

30 Angle-tighten a further 120° 120 80 45 80 45 80 tS0 80 80

22 89 59 33 59 33 59 59 59 59

Flywheel bolts*:

Stage nls Sashn Fee pareve ara oharebree eye tepen she teres 4)sd setateleRee ae STAGES 21 ais onctin Melte as Sy sey hae a Le aneWegcicca no Aer area Fuel injection pump belt cover bolts ...............00ee cues cee

15 : Angle-tighten a further 90° 8

Fuel injection pump belt tensioner bolt ................000eeeees

45

Main bearing cap bolts ss tc13.5% Auenithbseaie iaders Gheeseeee PSE Cheetal ee Maincoiligallery plugins ie vemtoraomanotteres deemeie Se ae usrck ts sera takee Oil cooler mounting bolts: MSiDOltS:. See Nie ais iste nate aa eee nana Aheret asa vee RARE, coleman MLO Dolio ays: «5 chiiedela outitel cielo (ane ReneRL ee. 0)a eine beeen Oil’Coolonipipe UNION MUTSE ase 5 sine e uct le forsee tenes aerate ey ener ae Oil filter:

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11 Slacken the clamp bolt and separate the tail pipe from the intermediate pipe. 12 Free the intermediate pipe from its mounting rubbers then detach the pipe from the flange joints and remove it from underneath the vehicle. Recover the gasket from each joint and discard them.

Tailpipe 13 Slacken joint to the tailpipe from 14 Free the and remove

clamp bolt securing the tailpipe intermediate pipe. Separate the the intermediate pipe. tailpipe from its mounting rubbers it along with its gasket.

Complete system 15 Slacken and remove the retaining screws, and remove the engine undertray. 16 Undo the nuts securing the front pipe flange joint to the turbocharger flange.

17 Working with the aid of an assistant, free the system from all its mounting rubbers and lower it from under the vehicle. Recover the gasket from the front pipe joint.

Heat shields 18 Heat shield(s) are fitted to the underside of the vehicle body. Each shield can be removed once its retaining bolts have been undone.

Refitting 19 Each section is refitted by reversing the removal sequence, noting the following points: : a) Ensure that all traces of corrosion have been removed from the flanges and renew all gaskets. b) Inspect the rubber mountings for signs of damage or deterioration, and renew as

necessary. c) Prior to tightening the exhaust system fasteners to the specified torque, ensure that all rubber mountings are correctly located, and that there is adequate clearance between the exhaust system and vehicle underbody.

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Chapter 4 Part C:

Emission control systems Contents

Section number

yatalytic converter — general information and precautions........ jiesel engine emission control systems — testing and component —OSVLMIMEN .. 0uul6 ioGhee RNARCRCRORS bole Nene RS en ee

Section number

4

General information

3

Petrol engine emission control systems — testing and component SEMEN MEthlose nis deuct RRO IO ae CLERC Corl, Gee crook Sea eeane

2

Degrees of difficulty Easy, suitable for

EN Fairly easy, suitable SS Fairly difficult,

novice with little experience

SS |

for beginner with some experience

a |

EN Difficult, suitable

N

suitable for competent% | for experienced DIY &| DIY mechanic eN mechanic ~

Very difficult,

SN

suitable for expert DIY or professional

W NY

specifications

=

os

=

=

‘orque wrench settings

Nm

bf ft

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8 25

6 18

10 25 55

7 18 41

1 General information

All petrol engine models use unleaded etrol and also have various other features

uilt into the fuel system to help minimise

armful emissions. All models are equipped jith a crankcase emission control system, catalytic converter and an evaporative mission control system to keep fuel vapour/ xhaust gas emissions down to a minimum. All diesel engine models are also designed > meet strict emission requirements. All 1odels are fitted with a crankcase emission ontrol system, a catalytic converter and an

xhaust gas recirculation (EGR) system to eep exhaust emissions down to a minimum. The emission control systems function as sllows.

2etrol models

yrankcase emission control

To reduce the emission of unburned ydrocarbons from the crankcase into the tmosphere, the engine is sealed and the low-by gases and oil vapour are drawn from iside the crankcase, through a wire mesh oil

vanes

the engine during normal combustion. Under conditions of high manifold depression (idling, deceleration) the gases will be sucked positively out of the crankcase through a small diameter pipe and into the intake tract ‘downstream’ of the throttle valve. A larger diameter pipe, ‘upstream’ of

oxygen sensor fitted to the exhaust manifold, whilst models equipped with the MEMS 83 engine management system are fitted with two oxygen sensors; one fitted to the exhaust manifold (pre-catalyst sensor), and one ‘downstream’ of the catalytic converter (postcatalyst sensor). The oxygen sensor(s) has a built-in heating element which is controlled by

the throttle valve, allows fresh air to be drawn

the ECM; the heating element is used to warm

back into the crankcase, and mix with the crankcase gases. Under conditions of low manifold depression (acceleration, full-throttle running) the gases are forced out of the crankcase by the (relatively) higher crankcase pressure; and drawn through both pipes upstream and downstream of the throttle valve.

the sensor when the engine is cold to bring it quickly to an efficient operating temperature.

separator, into the intake tract to be burned by

Exhaust emission control To minimise the amount of pollutants which escape into the atmosphere, all models are fitted with a catalytic converter in the exhaust system. The system is of the closed-loop type, in which an oxygen sensor(s) in the exhaust system supplies a voitage signal to the engine management system ECM, enabling the ECM to adjust the mixture to provide the best possible conditions for the converter to operate. Models with MEMS 1.8 engine management systems have one

The oxygen

sensor’s tip is sensitive to

oxygen and sends the ECM a varying voltage depending on the amount of oxygen in the exhaust gases; the leaner the air/fuel mixture, the higher the oxygen content, and the lower the voltage from the sensor(s). If the intake air/ fuel mixture is too rich, the exhaust gases are low in oxygen so the sensor sends a highervoltage signal. Peak conversion efficiency of all major pollutants occurs if the intake air/fuel mixture is maintained at the chemically-correct ratio for the complete combustion of petrol of 14.7 parts (by weight) of air to 1 part of fuel (the ‘stoichiometric’ ratio). The sensor output voltage alters in a large step at this point, the ECM using the signal change as a reference point and correcting the intake air/fuel mixture accordingly by altering the fuel injector pulse width.

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Emission control systems

wc

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2.4 Disconnect the canister hose from the throttle body (arrowed)

2.7 Disconnect the wiring connector from the top of the canister

Evaporative emission control

Exhaust emission control

To minimise the escape into the atmosphere of unburned hydrocarbons, an evaporative emissions control system is also fitted to all models. The fuel tank filler cap is sealed and a charcoal canister is mounted in the engine compartment. The canister collects the petrol vapours generated in the tank when the vehicle ic parked and stores them until they can be cleared from the canister (under the control of the engine management system ECM) via the purge valve into the intake tract to be burned by the engine during normal combustion. To ensure that the engine runs correctly when it is cold and/or idling, and to protect the catalytic converter from the effects of an

To minimise the level of exhaust pollutants released into the atmosphere, a catalytic converter is fitted in the exhaust system of some models. The catalytic converter consists of a canister containing a fine mesh impregnated with a catalyst material, over which the hot exhaust gases pass. The catalyst speeds up

over-rich

mixture, the purge control valve is

not opened by the ECM until the engine has warmed-up, and the engine is under load; the valve solenoid is then modulated on and off to allow the stored vapour to pass into the intake tract.

Diesel models Crankcase emission control To reduce the emission of unburned hydrocarbons from the crankcase into the atmosphere, the engine is sealed and the blow-by gases and oil vapour are drawn from

inside the crankcase, through a wire mesh oil separator, into the intake tract to be burned by the engine during normal combustion. Crankcase gases are drawn via a depression

limiting valve. The valve closes progressively as the engine speed increases, so limiting the maximum depression in the crankcase.

the oxidation

of harmful

carbon

monoxide,

unburned hydrocarbons and soot, effectively reducing the quantity of harmful products released into the atmosphere via the exhaust gases.

Exhaust gas recirculation system This system is designed to recirculate small quantities of exhaust gas into the intake tract, and therefore into the combustion process. This process reduces the level of unburnt hydrocarbons present in the exhaust gas before it reaches the catalytic converter. The system is controlled by the engine management system ECM, using the information from its various sensors, via the EGR valve which is fitted to the metal pipe connecting the inlet and exhaust manifolds. The exhaust gasss are cooled prior to entering the inlet manifold by passing through a cooler mounted on the side of the EGR valve. Engine coolant circulates through the cooler. The EGR valve is vacuum operated and is switched on. and off by an electrical solenoid valve.

2

Petrol engine emission control systems - testing and component renewal

1 The components of this system require no attention other than to check that the hose(s) are clear and undamaged at regular intervals.

Evaporative emission control Testing

Charcoal canister renewal

Models with MEMS 1.8

3 The charcoal canister is located on the hand side of the engine compartment. 4 Trace the outlet hose back from the cani to the throttle body. Release the retaining and disconnect the hose from the thre body (see illustration). 5 Trace the intake hose back from the cani then release the retaining clip and disconr it from the fuel vapour pipe. 6 Release the breather hose from its retair clips so that it is free to be removed with canister. 7 Disconnect the wiring connector from canister purge valve (see illustration). 8 Unclip the canister mounting bracket fi the body and remove the assembly from engine compartment. If necessary, slac'

the clamp bolt and separate the canister :

bracket.

5

9 Refitting is a reverse of the reme procedure ensuring the hoses are corre and securely reconnected. ;

Models with MEMS 3

10 The canister is located under | vehicle, just ahead of the right-hand s rear roadwheel (see illustration). Work underneath the vehicle, unscrew the retain nut (at the front of the canister) and rem« the canister from the bracket. 11 Note the fitted locations of the pip Squeeze together the union lugs < disconnect the tank, air and purge pipes fr

the canister (see illustration). — 12 Refitting is a reverse of the remo procedure, ensuring the hoses are correc and securely reconnected.

Purge valve renewal

2 If the system 2.11 Squeeze together the union lugs and disconnect the tank, air and purge pipes

using specialist electronic equipment whic connected to the engine management sys diagnostic wiring connector (see Chapter 4, the purge control valve or charcoal canister thought to be faulty, they must be renewed

HEE

Crankcase emission control

disconnect

2.10 The canister is located under th vehicle, just ahead of the right-hand si rear roadwheel

is thought

to be faulty,

the hoses from the charcoal

canister and purge control valve and check that they are clear by blowing through them. Full testing of the system can only be carried out

Models with MEMS 1.8

13 The purge valve is mounted onto the1 of the charcoal canister, which is located the left-hand side of the engine compartme

ax) eh Mies

Emission control systems

4Ce3

14 To renew the valve, ensure the ignition is switched off then disconnect the wiring connector from the valve.

15 Release the retaining clip and disconnect the hose from the valve. 16 Release the retaining clips and remove the purge valve from the top of the canister. recover the sealing ring from the valve union

discard it; a new one must be used on fitting. 17 Refitting is the reverse of removal, using a new sealing ring. Ensure the valve and the

jose are securely held by the retaining clips. Models with MEMS 3 18 The valve is located on the left-hand side nner wing in the engine compartment, below he electrical box (see illustration). 19 Ensure the ignition is switched off, and

disconnect the wiring plug from the valve. 20 Disconnect the quick release connector tom the valve, and release the hose. 21 Release the clip and slide the valve from

he bracket. 22 Refitting is a reversal of removal. Ensure he valve and hose are securely held by the etaining clips.

2-way valve renewal 23. The 2-way valve is mounted onto the top of the fuel tank. To gain access, remove the uel tank as described in Chapter 4A. 24 Release the retaining clips then disconnect he hoses from the valve, noting each hose’s sorrect fitted position. 25 Unscrew the retaining nut and remove the

jalve from the tank. 26 Refitting is the reverse of removal snsuring the hoses are correctly and securely

econnected.

Exhaust emission control Testing 27 The performance of the catalytic converter san be checked only by measuring the sxhaust gases using a good-quality, carefullysalibrated exhaust gas analyser. 28 If the CO level at the tailpipe is too high, he vehicle should be taken to a Land Rover

Jealer or specialist so that the complete fuel njection and ignition systems, including the xygen sensor, can be thoroughly checked Ising the special diagnostic equipment. Once

hese have been checked and are known to 9e free from faults, the fault must be in the penne converter, which must be renewed.

zatalytic converter renewal 29 Refer to Chapter 4A.

;. gen sensor(s) renewal : The oxygen sensor is delicate and will 10t work if it is dropped or knocked, if its Jower supply is disrupted, or if any cleaning aterials are used on it.

aust manifold sensor ere the peor is switched off then

2.18 The |purge valve isdated on the

left-hand side inner wing in the engine

2.31

Unscrew the sensorane remove it from the manifold

compartment

Free the connector from its retaining clip and disconnect the two halves of the connector. 31 Unscrew the sensor and remove it from the manifold. Note that the use of a special deep, split socket is recommended (see illustration). Recover the sensor sealing washer and discard it; a new one must be used on refitting. 32 Refitting is a reverse of the removal procedure, using a new sealing washer. Tighten the sensor to the specified torque and ensure that the wiring is correctly routed and in no danger of contacting either the exhaust manifold or the engine.

Post-catalyst sensor (MEMS 3)

ensure the wiring is correctly routed and in no danger of contacting the exhaust system.

Diesel engine emission control systems - testing © and component renewal _

3 Refitting is the reverse of removal ensuring that the valve is positioned the correct way around with the outlet marked F fitted to the intake duct.

TD4 engine 4 With reference to Chapter 4B, remove the air cleaner cover. 5 Disconnect the injector wiring plugs, unscrew the three retaining screws, and move the injector harness to one side. 6 Unscrew the four Allen screws, and remove

33 Ensure the ignition is switched off, then working in the passenger compartment, release the clips and free the gear lever gaiter from the centre console. 34 At the rear of the gaiter aperture, disconnect the oxygen sensor wiring plug (see illustration 16.8 in Chapter 4A). 35 Working underneath the vehicle, prise out the grommet and withdraw the oxygen sensor harness through the hole. 36 Unscrew the sensor from the rear of the catalytic converter. Note that the use of a special deep, split socket is recommended. 37: Refitting is a reverse of the removal procedure, using a new sealing washer. Tighten the sensor to the specified torque, and

3

the breather hose then ease the valve out from the intake duct and remove it from the engine compartment.

the depression limiting valve complete with filter (see illustration). 7 Ensure the mating surfaces are clean and dry, refit the valve housing. Tighten the Allen screws to the specified torque. 8 The remainder of refitting is a reversal of removal.

Exhaust emission control Testing 9 The performance of the catalytic converter can be checked only by measuring the exhaust gases using a good-quality, carefullycalibrated exhaust gas analyser. 10 Before assuming that the catalytic converter is faulty, it is worth checking whether the problem is not due to a faulty injector(s). Refer to your Land Rover dealer for further information.

WEE

Crankcase emission control Testing 1 The components of this system require no attention other than to check that the hose(s) are clear and undamaged at regular intervals. If the system is thought to be faulty, renew the crankcase pressure limiting valve as follows.

Pressure limiting valve renewal L-Series engine 2 Slacken the retaining clip and disconnect

3.6 Remove the depression limiting valve complete with filter

4Ce4

3.14

Emission control systems

Disconnect the vacuum

hose from

the EGR valve - L-Series engine

4B for removal

Disconnect the vacuum hose from

the EGR valve - TD4 engine

Catalytic converter renewal 11 Refer to Chapter refitting details.

3.19

TD4 engine and

Exhaust gas recirculation (EGR) Testing 12 Comprehensive testing of the system can only be carried out using specialist electronic equipment which is connected to the injection system diagnostic wiring connector (see Chapter 4B). If the EGR valve or solenoid

valve are thought to be faulty, they must be renewed as follows.

EGR valve renewal L-Series engine 13 Unscrew the retaining bolts and remove the plastic cover from the top of the engine unit, taking care not to lose the spacers from the engine cover mounting rubbers. The EGR valve is fitted to the metal pipe linking the inlet and exhaust manifolds. 14 Disconnect the vacuum hose from the EGR valve (see illustration). 15 Slacken and remove the Allen screws securing the valve to the manifold and connecting pipe and remove it from the engine. Recover the gaskets and discard them; new ones must be used on refitting. If necessary, the connecting pipe can then be unbolted and removed from the other manifold. 16 Refitting is the reverse of the removal, using new gaskets and tightening the valve retaining bolts to the specified torque.

17 Unscrew the retaining screws, and remove the plastic cover from the top of the engine (where fitted). 18 Slacken the retaining clips and disconnect the air intake ducting assembly. Unclip the injector wiring harness, unscrew the two retaining bolts, and remove the ducting assembly. 19 Disconnect the vacuum hose from the EGR valve (see illustration). 20 Completely slacken the clamp screw and disconnect the EGR pipe from the valve (see illustration). 21 Unscrew the four retaining bolts, and remove the EGR valve. 22 Refitting is a reversal of removal, using a new seal and tightening the valve retaining bolts to the specified torque.

EGR solenoid valve renewal L-Series engine 23 The EGR solenoid valve is located on the left-hand side of the engine siete WA, bulkhead. 24 Disconnect the wiring connector and vacuum hoses from the valve then undo the retaining screws and remove the valve from its mounting (see illustration). Note the fitted locations of the vacuum pipes. 25 Refitting is the reverse of removal.

TD4 engine 26 With reference to Chapter 4B, remove the inlet manifold.

3. 20 Completely slacken the clamp scre and disconnect the EGR pipe from the valve

27 Disconnect the wiring plug from 1 solenoid (see illustration). 28 Unscrew the two bolts securing 1 solenoid bracket to the cylinder block. N their fitted locations then disconnect 1 vacuum hoses. If necessary, the solenoid c be separated from the mounting bracket unscrewing the two retaining nuts. 29 Refitting is a reversal of removal.

EGR cooler renewal

30 With reference to Chapter 2C, remove 1 camshaft cover. 31 Completely slacken and remove t clamps securing the EGR pipes to the cool 32 Remove the bolt securing the fuel rails the support bracket. 33 Undo the bolt securing the turbo out pipe to the support bracket at the front le hand side of the engine. 34 Apply the handbrake, then jack up 1 front of the vehicle and support it securely axle stands (see Jacking and vehicle suppo Remove the retaining screws and fastene and remove the undercover from beneath 1 engine and transmission. 35 Working underneath the vehicle, remo the bolt securing the turbo outlet pipe to t upper coolant rail. 36 Remove the two bolts securing the tur outlet pipe support bracket to the. left-ha end of the cylinder head. 37 Release the retaining clip and disconne

-the hose from the vacuum pump. 38 Undo the three bolts securing the EC cooler to the left-hand end of the Syl head. 39 Be prepared for coolant spillage, a disconnect the coolant hoses from the cool 40 Refitting is a reversal of removal. Topthe coolant level as described in Chapter 1£

r4 Catalytic converte general information

TED =

oana

~

Ste

1 The aeawale converter is a reliable al simple device which needs no maintenan 3.24 EGR solenoid valve L-Series engine

3.27 EGR solenoid valve — TD4 engine

in itself, but there are some facts of which. owner should be aware if the converter is function properly for its full service life.

Emission control systems Petrol engine a) DO NOT use leaded petrol or LRP in a vehicle equipped with a catalytic converter — the lead will coat the precious metals, reducing their converting efficiency and will eventually destroy the converter.

b) Always keep the ignition and fuel systems well-maintained in accordance with the manufacturer's schedule. c) If the engine develops a misfire, do not drive the vehicle at all (or at least as little as possible) until the fault is cured. d) DO NOT push- or tow-start the vehicle — this will soak the catalytic converter in unburned fuel, causing it to overheat when the engine does start.

e) DO NOT switch off the ignition at high engine speeds. f) DO NOT use fuel or engine oil additives — these may contain substances harmful to the catalytic converter. g) DO NOT continue to use the vehicle if the engine burns oil to the extent of leaving a visible trail of blue smoke. h) Remember that the catalytic converter operates at very high temperatures. DO NOT, therefore, park the vehicle in dry undergrowth, over long grass or piles of dead leaves after a long run. i) Remember that the catalytic converter is FRAGILE - do not strike it with tools during servicing work. j) In some cases a sulphurous smell (like

4Ce5

that of rotten eggs) may be noticed from the exhaust. This is common to many catalytic converter-equipped vehicles and once the vehicle has covered a few thousand miles the problem should disappear. Sometimes the smell is a result of the fuel used. k,~n The catalytic converter, used on a wellmaintained and well-driven vehicle,

should last for between 50 000 and 100 000 miles — if the converter is no

longer effective it must be renewed.

Diesel engine 2 Refer to the information given in parts f, g, h and i of the petrol engine information given above.

4C°6

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At the time of writing, only new or exchange IRD units are available. Consequently, although the unit can be dismantled with common hand tools, no overhaul parts are available.

If a fault develops, consult a Land Rover dealer or specialist on the best course of action.

7C*6

Bet

Chapter 8 Driveshafts, propeller shafts & final drive Contents

Section number

SeRSCHEtEGAOlS —TONCWAl

cic

cee

cael

cbs cee

Driveshaft overhaul — general... 1.1.0... cece eee ees “inal drive — removal and refitting ......,.... 0. cece eee ee ees

4 5 8

Beancrive oll seals renewal. cn. dies ca eee cob eee e eves 9 -inal drive overhaul — general information ........ 0.0.0.0 0 ee eee 10

Section number Front driveshafts — removal and refitting ................200005 GOnenaunfOnmearlOmmemertae achat) sh crac, Byetertema eietacs ins ola secs Propeller shaft — inspection and overhaul ..................08. Propeller shaft — removal and refitting..............0ceeeeeeee Rear driveshafts — removal and refitting...............0ce0e ees

2 1 7 6 3

Degrees of difficulty Easy, suitable for

SS Fairly easy, suitable SS Fairly difficult,

novice with little

SS for beginner with

NS suitable for BEEN

for experienced DIY “|

suitable forexpert

W

experience

W}

|

mechanic

DIY or professional

EN

some experience

SS Difficult, suitable

DIY mechanic

|

N >

Very difficult,

NN

Specifications

General

"ESEFULLMOT),

2s GS iebo CREO ORCL RIE ONONS |RSS

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Brees ec aN CARY PICMENE

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Howlit.iele:aia salad w diva wlwcabacaie

Solid shaft, with constant velocity (CV) joints. Tripod inner joints, balland-cage outer joints. Early front shafts have dynamic dampers Front and rear tubular sections, with centre viscous coupling unit (VCU). Front tripod-type CV joint, three universal joints with renewable sealed needle-roller bearings Hypoid gears, drive pinion centre-line below centre of ring gear. Aluminium alloy housing

Final drive pinion preload.......................0.000-

1.7 to 2.8 Nm (1.3 to 2.1 Ibf ft)

Torque wrench settings

Nm 400 45 120 on

Ibf ft 295 33 89 20

190 373 25 65 40 205 65 65 115 120 120 28

140 275 18 48 30 151 48 48 85 89 89 21

ERM eRRIIEIER GINO) saycvla/ni cirsahieys) Sinscars xdsis = ( 10¢-S8z_

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Wiring diagrams — 1997 to 2001 models

Wire colours Br BI Ro

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81

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9

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73

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84 85 86

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82

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Fog light switch

89

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83

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RH pretensioner

74

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91 92 93

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87

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12°35

Diagram8

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95

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102 Roof on switch

109 Hill decent switch

Electric window relay RH electric window switch LH electric window switch RH window motor

103 104 105 106

110 111 112 178

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9

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100 LH window motor

107 ABS return pump relay

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108 ABS return pump

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Wiring diagrams — 1997 to 2001 models

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Br BI Ro Ge Gn_

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113 114 115 116 117

106 ABS control module

119 Heated rear window switch

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9

;

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118 Oil pressure switch

120 121 122 123 124

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125 RH front tweeter

132 Engine control module —

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yrs 2481

Wiring diagrams — 1997 to 2001 models

Key to items

12°37

Diagram 10

1

Battery

132 Engine control module

137 Resistor pack

143 Blower motor switch

2 3

Engine fuse box Interior fuse box

133 Engine coolant temperature sensor

138 Blower motor switches 139 A/C clutch

144 Relay module 145 Trinary switch

4 — Ignition switch

134 Condenser fan

140 Recirculating air motor

130 Cooling fan 131 Engine management relay

135 Main relay 136 Heater blower motor

141 Recirculating air switch 142 A/C switch

.

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12°38

Wiring diagrams — 1997 to 2001 models

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Gn Green

Gr Or Pk Pu

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Sw Black LGn Light Green Ws White

1 2_ 3 4

5 9

Battery Engine fuse box Interior fuse box Ignition switch

Central control unit

Header joint K109

1380 Cooling fan

. 132 134 135 139

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143 144 145 146

Blower motor switch Relay module Trinary switch Inertia switch

140 Recirculating air motor 141 Recirculating air switch

147 Starter motor 148 Alternator

142 A/C switch

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12°40

Wiring diagrams — 1997 to 2001 models

Wire colours Br BI Ro Ge Gn

Brown Blue Red Yellow Green

Gr Or Pk Pu Sw

Key to items’ Gray Orange Pink Purple Black

LGn Light Green Ws White

De

1 Battery 2 _ Engine fuse box 3 Interior fuse box 4 Ignition switch 5 Central control unit

69 Brake pedal switch 132 Engine contro! module 133 Engine coolant temperature sensor 135 Main relay

147 148 149 157

9

146 Inertia switch

162 Starter relay

Header joint K109

Starter motor Alternator Fuel pump Air inlet temperature sensor

163 164 165 166 167

‘

Speed sensor EGR valve Mass air flow sensor Glow plug relay Glow plugs

168 Line fuse

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Wiring diagrams — 1997 to 2001 models

_ Wire colours | Brown Blue

Ro Red Ge Yellow

b _

Key to items

Gr Gray Or

1

Orange

Diagram 14

Battery

144 149 158 161 169 170 171

2 _ Engine fuse box

Pk Pink Pu Purple

3 Interior fuse box 4 __ Ignition switch

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.

12°41

elo ae unit leader joint K109

95 Diagnostic socket 132 Engine control module

Relay module 172 173 Fuel pump Throttle position sensor Crankshaft position sensor Needle lift sensor Boost pressure sensor Coolant temperature

Fuel gauge sender Instrument module a) LH direction indicator tell-tail b) RH direction indicator tell-tail c) trailer tell-tail

gauge sensor

f) hazard warning light tell-tail

d) fog light tell-tail

g) speedometer

h) coolant temperature gauge i) fuel level gauge j) tachometer k) dimmer illumination 174

Illumination dimmer switch

e) main beam tell-tail

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Wiring diagrams — 1997 to 2001 models

Wire colours

Key to items

Se

Br

Brown

Gr

Gray

1.

Battery

BI Ro

Blue Red

Or Pk

Orange Pink

2 3

Engine fuse box Interior fuse box

Ge Gn

Yellow Green

Pu Purple Sw Black

5 9

LGn Light Green Ws White

Ra

_ 148 Alternator

n) low brake fluid

149 Fuel pump 162 Starter relay

Central control unit Header joint K109

167 Glow plugs 173 Instrument module

135 Main relay

p) charge warning light = q) engine warning light©

!)_ Seat belt warning light

146 Inertia switch

r) glow plug tell-tail

m) door open warning light

147 Starter motor

Ba

tony

;

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175 Handbrake swit 176 Brake level switety .

_ 177 Oil pressure

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ies owen eels art 8 (285-3 285-1 Ley7

}

Ro/P.

ed ret ped

roentgen

hie ogee {

ct

Ws/Ro + A

a

oe

Wg Gir @

See diagram 15

:

Instrument module

9 "=" Br/Ge

Br/Pu Ws/Pk

Ro/Ws

Ayro S ( Pe

) C= sw

wis+)

|~~

|

>See

———

|

jee

179 Fuel pump relay ape.

Instrument module continued ‘aelicihaieaimeiaas

switch

178 Fuel tank ime

t) ABS warning light —

ee

ee se W/PK Br/Ro

Wiring diagrams — 1997 to 2001 models

Key to items 1 2 3 4 5 9 95 182

.

Battery Engine fuse box Interior fuse box Ignition switch Central contro! unit Header joint K109 Diagnostic socket Engine control module

185 150 151. 152 153 158 161 164

Diagram 16

Main relay Injector cylinder 1 Injector cylinder 2 Injector cylinder3 Injector cylinder 4 Throttle position sensor Crankshaft position sensor EGR valve SEs

J ‘a

S

—— a

1243

168 180 181 182 183 184

Mass air flow sensor Camshaft pressure sensor Fuel pressure regulator Fuel tank pressure sensor Engine speed sensor Turbo boost control pressure sensor

nadada

See diagram 15

Instrument module

ee

~~

ioe : =—

om

-

tor

_—

-_—

=

=

(991+ 1)}

Wa/Br

7

f

:

eet

!

|

164

|

eee

bs] |) v

|

Dy cnieeeciennteniensieentnentienetemetott Br/Gr cu?

7

i old

pms

RO/Ws

eee

()

gecesi

: |

e-1 OO

| {

san

7 RO/Ws

we

Da

err

enem | HY at

180 [RE

ene:neeen's RO/Ws

1806-17 |

Ge _—

|

.

|

184

YY

a

a

i

1606-28 |

eT,

{

181 ae

eatamcemns Roa Cc

A

“0 2) aE

=

a

A

TY =

‘606-38|

Br/81 Cm

A

A

So

ce eee se seme ome wee (4) /] | 1

=

2

=

=

e

=

=

=

x

:

3

=

:

x

=

=

4

Wa/PK

Sw

(E13)

(G08-8

PI *

{fo

or

= E14

Ro/Bl ft

eh

=

ond

603-5 Sc

o/s «Cia eae

er sina ; er

C Yow RO/BI

ee

rm om

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992-8

— Se et me oe (31/8

ee

tt

amen wn) [h/V\/

fellas Ro/BI

#€

MM

—

|

ce D) et ee

oe

Ro/BI A

Ro/BI

A TM

eh mio ae nme F2)/(6)

_.

e Se

\

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oh

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)

9 q

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peers: Bis .)

Ge rate ome

)

‘606.10:

WU

165

‘.

oe

i

RO/We &

f

Wa

A

LA

Ro/Br

FOB

GeaZRo

Br/Ro BI/Ro

ce

ib I

12°44

Wiring diagrams -— 1997 to 2001 models

Wire colours

Key to items

Br

Brown

Gr

Gray

5

Central contro! unit

133 Engine coolant temperature sensor

BI Ro

Blue Red

Or Pk

Orange Pink

9 69

Header joint K109 Brake pedal switch

158 Throttle position sensor 170 Boost pressure sensor

Ge

Yellow

Pu

Purple

95

Diagnostic socket’

177 Oil pressure switch

Gn Green Sw Black LGin Light Green Ws White

132 Engine contro! module

Engine management continued (Td4 engine)

dis

See diagram 15

Cooling fan

S

SLr rc

instore! module ABS

132 ce

:

S =e a

;

Br/Ge

:

OES

el aC

rrr

=

a

Clutch pedal switch S 69

—

652 ~4h

mklB pacar

ABS Cruise control

Gn/Ro

S= S«

ee

} ee

cers

|

4a

Sw/Gr om 26 |

== Wels

189

=

15. i

Ge/Pu a

IT.

rr

!

iey

=i

Sw/e| =m

Br/BI

|

ee

eee

Ge/Br =

Br/Pk

Pk

Or/Gn

Or/Gr Or/Bl

=a a

Wiring diagrams — 2001 to 2003 models

Key to items Gray Orange Pink Purple Black

1 Battery 2 _ Engine fuse box 3 Interior fuse box 4 Ignition switch 5 . Central control unit

White

9 25

Header jointK109 Inertia switch

12¢57

Diagram 13 113 166 167 176 177

Auxiliary relay Starter relay Main relay Engine control module Starter motor

178 Alternator 179 Fuel pump

180 200 201 202 203

Fuel pump relay Fuel tank pump unit Glow plug relay Glow plugs RH seat heater switch

206 207 208 209 210

RH RH LH LH LH

seat seat seat seat seat

204 LH seat heater switch 205 RH seat heater relay

cushion heater back heater heater relay cushion heater back heater

MIS 2

Starting and charging (Td4 engine) a) tee

>

See diagram 15 Instrument module

||167 - ™

ge

eS WD iad

eae

A\40a

on

86

428-16 |

Gn/B!| =m

Heated seats

cod

1331-1 S acemu Br/Ge (Cama

1603-7

12°58

Wiring diagrams — 2001 to 2003 models

Wire colours Br BI Ro

Brown Blue Red

Ge

Gn

Key to items

Gr Or Pk

Gray Orange Pink

Yellow

Pu

Purple

Green

Sw

Black

LGn Light Green Ws White

1 Battery 2 Engine 3. Interior 4 Ignition 5 — Central

9

167 176 210 211 212

fuse box. fuse box switch control unit

Header joint K109

24 Diagnostic socket 161 Crankshaft position sensor

Main relay Engine control module Mass air flow sensor

216 217 218 219 220

*

EGR valve

Camshaft pressure sensor

213 Fuel pressure regulator

Injector cylinder2 Injector cylinder3 Injector cylinder4

r. hina es

Throttle position sensor

Fuel tank pressure sensor

221 Engine speed sensor

214 Turbo boost control pressure sensor 215 Injector cylinder 1

Engine management (Td4 engine) S

See diagram 15 Instrument module

—————————

a

rs

sped arse

eee ome ces RRO/Ws

et ae

VWs /Br

en et ee eee a

ee

me

BE/Gr

ee 63)/\\/5

Sw

* geet ome RRO/W's, A

A

i= =

a

Re a

oe

RO /GE

Br/Pk

re

— eee a

ns

8 /Pk

nn

Sw Sw Sw =

Ro/BI

E12

216 | > O50

6

Fla 80A

oft4/2 |

OO

es

ee

eee

iasay/t RIO ROA

See diagram 7

Interior lighting

v0

'

\

awiteh illumination 8

|a0

|

—

ay

Ya

o74/

RO

caore

P/R

Am

089/

B

23 | SRS system

ne

ob ae/"

—

FO TSA

.

|

any

|oA7/2

Central control unit (not shown)

AUX

ss th NVA) os

|

(not shown)

Ct

mi

N a)

pearson mnnsiie wun cvernss so n [2/8]

Engine management

nT

i

“obB4/A

ma

a cae

ee

P/N

.

8

mene amen ae,

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2

es 4

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lols

y ad

Hee diagram4 Instrurent olustar

-

(BH8 warning light)

a.

PASE

K meee

:

areoremadt o

Kee

eo

Engine management

70(not or

K earcsreren

ees

A

See diagram SRS svoter3

Central control unit (not shown) See

diagram4 —

cluster transmission —

SO

|

See dlagran 4

Diagnostic socket

o

12°64

Wiring diagrams — 2003-o0n models

Wire colours B Black G Green K_ Pink

Key to items P R_ S

Purple Red Slate

1 4 5

Battery Ignition switch Engine fusebox

c = d = e@ =

fuel gauge tachometer speedometer

q = _ low fuel warning light r = alarm warning light s = main beam warning light—

Lg Light green

U

Blue

6

Passenger fusebox

f =

overspeed warning light

t =

LH indicator waring light

N O

W Y

White Yellow

10 Fuel tank unit b = fuel gauge sender

g = h =

low oil warning light cruise control warning light

u = Vv =

RH indicator warning light trailer warning light

33 Central control unit 34 Engine management control unit 35 Oil pressure switch 36 Handbrake switch 37 Instrument cluster a = control unit b = coolant temp gauge

i = engine management warning light j = glow plug warning light k = TCS warning light | = ABS warning light m= hill descent fault warning light = n = _ handbrake/brake fluid warning light o = hill descent warning light

w = x = y = z = alt= b1= c1=

alternator warning light door ajar warning light oil pressure warning light SRS system warning light seatbelt warning light LCD illumination instrument cluster illumination

Brown Orange ;

Instrument cluster

p =

engine warning light

NS oe

9

6

a0

"¢632/1 FL360A 6571/3) 6574/2:

FL480A

ai

om. P/B Coe «

Air conditioning

(not shown)

ant o

33 prec

N/V sence

me

A a0/7

6230/22

J

0575/7: “rials api

e230/10

Immobiliser control unit

eenneny

=

=

(not shown)

©230/4 6233/4 6230/21

=i

i

2) ,

ihe AE

Lp/9092 ==—=—(1 (j0.Q¢d) N/M (je¢81q) S/N

g

N/M (jee01q) == — (joned) N/M =

=a ‘{ Central control unit (not shown)

See diagram 5

Main beam Engine management control unit (not shown)

G/R See diagram 7 Direction indicators & hazard warning

L N/Y (Diesel) =m: See diagram 2 Alternator

headlights ==—"""“"""="_ U/G

N/Y (petrol)

ss

G/P

ee

i}

ne

Na

P/B a

See diagram 3 SRS control unit

oo

ae

sa —— = = =

,

nT

YR

Sammy

a

Y/N

i a

Y/R

ace

R/P G

ABS control unit

Immobiliser control unit

See diagram 5

(not shown)

(not shown)

Reversing lights

Hill descent switch

(not shown)

Nn

ee

a

:

RW ‘ooo rs

css WR mC

Cruise contro! control unit, (not shown)

See diagram 3 Diagnostic socket a

a

nO

K

a

a

he

i

ce cen

cn eae

W/U Paro,

:

Ke

See diagram 7 Interior | hting

switch illumination A

Wa em cme cancer cet cocam comers seam R/C)

©

ee AER A

AE

EN

SET

SY PO

SO

A

SN A

ON NE

I Se

R/O

Wiring diagrams — 2008-0n models

col

Key to items

ack

P

Purple

1k

S

Slate

en

R

t green U W : Y

ps

OE ol ee

Diagram 5

1

Battery

42 Starter inhibitor/reversing light switeh

48 High level stop light

5

Engine fusebox

43 Reversing light switch (manual trans)

50 Light switeh

Red

4

Ignition switch

(automatic trans.)

Blue White Yellow

6

44 LH reversing light 45 RH reversing light 46 LH rear light unit a = stop light b = tall light

40 Stop light switch 41 Automatic transmission control unit

47 RH rear light unit (as above

Passenger fusebox a =reversing light relay (automatic trans.) R2 = main beam relay - 33 Central control unit

49 Number plate light

a = alce/headlight 51 LH headlight unit a = side light b= dip beam © = main beam 62 RH heaellight unit (as abave)

;

‘

(_ Stop & reversing lights ) ie,

i

passage

|Side, tail &number plate lights | free,

bag

N (int INQ

| gg

oes NW meen GNA

in

WRRRNECe Ngicre ccc ecte ice

teen

ii

ee

A

0692/1 FLA2 404 o575/12)

:

ad cdeee

_ ob ar/a acct:

‘

ch0e/2

FVB

i

a

control uni

i)

iti

_ }eHRO/E

P/O

i

C0

1587/2 4 89 | 2624/5 / ' .STSTTT!

al (mai 46 Laz | | Ve el | | pe iste » MM base 8 forts |apaany a ar v meee ee ite) «|OO |

(not shown)

B

=

fealty ‘ehai/a|

P/E weal acme sit iat

Y ee

} 80 ~

Fy nee

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| 0632/1 FL360A 6571/3:

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|

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be VY

wo

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ow

|

we

aa

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22 \! lrallar

Y

FRAOA

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socket

(nat ahowr

N/G mC 0992/28 woo G/W

| rama

Thorsten

ca

=

BS il :

3

(tl 0932/50

|

| Headlights |

Oe G/WV Galo

|

42

(

See diagram 4 Instrument cluster

3

a

dns

See diagram 4

Osntral cantral unit

Instrument cluster

(nat shown)

(main beam warning light)

a yer |

o ®

1206

Wiring diagrams = 200G-o0n models >

.

4

ran Phe othaanyy & Vihar Wing Sibt) EAT A

.

RA) J

an

;n

w

ow

w Ke

ay

oe \ » e \hahat ] antonWRWRATRAA

mete OBS 5c's Dimrytrt Gara) (Ht ay

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mr " ; oneny

Wiring diagrams — 2003-on models

Key to items 1 4

Battery Ignition switch

Blue

6

Passenger fusebox

White Yellow

c = hazard warning relay R15 = indicator relay 33 Central control unit 46 LH rear light unit c = direction indicator 47 RH rear light unit (as above)

5

50 Light switch a = side/headlight

Engine fusebox

Direction indicators &

7

51 LH headlight e =

}

~

73 Interior light (8 door)

74 Front interior light (5 door) 75 Rear interior light (6 door)

Haa5e4

switch illumination

+7

a

| ~

“ahs

'

;

72 Glove box light switch

direction indicator

Interior lighting &

Ferd bicghrgrly ab

0

ee

70 Luggage compartment light 71 Glove box light

52 RH headlight (as above) 65 LH indicator side repeater 66 RH indicator side repeater 67 Hazard warning switch 68 Direction indicator switch 69 Immobiliser coil transponder

See diagram 7

hazard warning lights

nT

Diagram 7

Purple Red

Slate

12°67

a

1) ino

Rca

Y

F18 154

B/O mCumm 6428/23 0593/H Com P/S wmCummt 6288/24 c593/A Com

_@

{

on P/W so Cumin 428/21

(Bai: | 33 P|

| | See diagram 11 Central locking (earthed via door lock assemblies)

some seman P/\\/ ~e

{

: €589/14

' 0589/17

; iw)

HR och

3mm)

F1710A

en tk hee

:{ 6a;

i

2

d

3

Y=} |T=

| T=

Ne

fI

\\/d me =a

of.

See diagrams 3,8,10 & 11 Switch illumination feed B

See diagrams 4,6 & 9 Switch illumination feed A

See diagram 4

== G/P

Instrument cluster === G/R

poe Sc ee /\)\/C) ee ee NYS ee

©

Trailer socket (not shown)

ot ————

12°68

Wiring diagrams — 2003-on models

Wire colours

Key to items

B Q

Black Green

P R

Purple Rect

N ©

Brown Orer

W Y

White Yell

1 4

K Pink § Slate Lg Light green U Blue

ais

LOE

Battery Ignition awiteh

82 Heater blower motor 83 Heater blower relay

5 Engine fusebox 6 Passenger fusebox

84 Heated rear window switch 85 Heated rear window

OW

83. Central control unit

88 Heated front screen relay

85 Oil pressure awiteh

89 Heated front screen switch

SI

a is

Tn

Ramer yy Ee a

Matte’,

90 Fuseholder 91 LH heated front screen element

ae

iyi

HC

MR

ata:

ie

esask

|Heated front screen

| Heater blower )

0692/1 FLIIS0A FLRGOA 0871/2) FB GOA Ss

94 Sunroofmotor

© » heated rear window relay 86 Hardtop switch d= auxiliary relay 87 Tailgate window switch

80 Heater blower switch 81 Heater blower resistors

|

ASOT

92 RH heated front screen element — 93 Sunroof switch Mae tise

wey D nO

.

ob70/3: cena


] Front roadwheels out of balance (vibration felt mainly through the

== wiei“thoes lonaases 0) eekly checks).

|

|] Defective shock absorbers (Chapters 1 and 10),

Rear roadwheels out of balance (vibration felt throughout the

vehicle) (Chapter 10).

.

=

steering wheel) (Chapter 10).

:

Excessively-stiff steering

Yi

Roadwheels damaged or distorted (Chapter Ity or damaged tyre (see Weekly checks).

10),

[| Seized track rod end balljoint or =

4 and 10).

‘and 10).

suspension balljoint (Chapters 1

ted

iz

Steering gear damaged (Chapter 10).

~

Z

poe

arias

|_| Broken or incorrectly adjusted auxiliary drivebelt (Chapter 1). Incorrect front wheel alignment (Chapter 10).

bs 1 steering a suspension joints, Giishes cr pomporiertia

a

a Se)

reFeis Fault finding Steering and suspension (continued) Excessive play in steering | Worn steering column universal joint(s) (Chapter 10). |_| Worn steering track rod end balljoints (Chapters 1 and 10).

|_| Worn steering gear (Chapter 10).

y |_| Worn steering or suspension joints, bushes or components (Chapters 1 and 10).

Lack of power assistance |_| |_| |_| |_|

Broken or incorrectly-adjusted auxiliary drivebelt (Chapter ye Incorrect power steering fluid level (see Weekly checks). Restriction in power steering fluid hoses (Chapter 10). Faulty power steering pump (Chapter 10).

|_| Faulty steering gear (Chapter 10).

Tyre wear excessive Tyres worn on inside or outside edges |_| Tyres under-inflated (wear on both edges) (see Weekly checks). |_| Incorrect camber or castor angles (wear on one edge only) (Chapter 10).

Worn steering or suspension joints, bushes or components (Chapters 1 and 10). Excessively-hard cornering. Accident damage.

Tyre treads exhibit feathered edges _| Incorrect toe setting (Chapter 10). Tyres worn in centre of tread Tyres over-inflated (see Weekly checks).

Tyres worn on inside and outside edges Tyres under-inflated (see Weekly checks). Worn shock absorbers (Chapter 10).

Tyres worn unevenly Tyres/wheels out of balance (see Weekly checks). Excessive wheel or tyre run-out (Chapter 10). Worn shock absorbers (Chapters 1 and 10). | Faulty tyre (see Weekly checks).

Electrical system Note: For problems associated with the starting system, refer to the faults listed under ‘Engine’ earlier in this Section.

Instrument readings inaccurate or erratic

Battery will not hold a charge for more than a few days .

|_| Faulty voltage regulator (Chapter 12).

Battery defective internally (Chapter 5A). Battery electrolyte level low = where applicable (Chapter 5A). Battery terminal connections loose or corroded (see Weekly

|_|

checks), Auxiliary drivebelt worn — or incorrectly adjusted, where applicable (Chapter 1). Alternator not charging at correct output (Chapter 5A), Alternator or voltage regulator faulty (Chapter 5A).

Short-circuit causing continual battery drain (Chapters 5 and 12).

Ignition/no-charge warning light remains illuminated with engine running |_| Auxiliary drivebelt broken, worn, or incorrectly adjusted (Chapter 1).

|_| Internal fault in alternator or voltage regulator (Chapter 5A). |_| Broken, disconnected, or loose wiring in charging circuit (Chapter 5A).

Ignition/no-charge warning light fails to come on |_| Warning light bulb blown (Chapter 12). |_| Broken, disconnected, or loose wiring in warning light circuit (Chapter 12). |_| Alternator faulty (Chapter 5A).

Lights inoperative

Instrument readings increase with engine speed

Fuel or temperature gauges give no reading |_| Faulty gauge sender unit (Chapters 3 and 4). |_| Wiring open-circuit (Chapter 12). (_] Faulty gauge (Chapter 12).

Fuel or temperature gauges give continuous maximum reading |_| Faulty gauge sender unit (Chapters 3 and 4).

|_| Wiring short-circuit (Chapter 12). |_|] Faulty gauge (Chapter 12).

Horn inoperative, or unsatisfactory in operation Horn operates all the time |_| Horn contacts permanently bridged or horn push stuck down (Chapter 12).

Horn fails to operate

|_|] Blown fuse (Chapter 12). (Chapter 12).

(| Faulty horn (Chapter 12).

|_| Bulb blown (Chapter 12).

|_| Corrosion of bulb or bulbholder contacts (Chapter 12). |_| Blown fuse (Chapter 12),

|_| Faulty relay (Chapter 12). (|_|

|_|

Broken, loose, or disconnected wiring (Chapter 12).

Faulty switch (Chapter 12).

;

|_] Cable or cable connections loose, broken or disconnected

Horn emits intermittent or unsatisfactory sound (_| Cable connections loose (Chapter 12).

(|_| Horn mountings loose (Chapter 12). |_| Faulty horn (Chapter 12).

Fault finding rere19 Electrical system (continued)

\

Windscreen/tailgate wipers inoperative, or unsatisfactory in operation

Electric windows inoperative, or unsatisfactory in operation

Wipers fail to operate, or operate very slowly

Window glass will only move in one direction

Wiper blades stuck to screen, or linkage seized or binding (see Weekly checks and Chapter 12). Blown fuse (Chapter 12). Cable or cable connections loose, broken or disconnected (Chapter 12). Faulty relay (Chapter 12). Faulty wiper motor (Chapter 12). Cini SIEM

Wiper blades sweep over too large or too small an area of _ the glass (_] Wiper arms incorrectly positioned on spindles (Chapter 12). [|] Excessive wear of wiper linkage (Chapter 12). {| Wiper motor or linkage mountings loose or insecure (Chapter 12).

Wiper blades fail to clean the glass effectively |] Wiper blade rubbers worn or perished (see Weekly checks). |] Wiper arm tension springs broken, or arm pivots seized (Chapter 12). |] Insufficient windscreen washer additive to adequately remove road film (see Weekly checks).

Windscreen/tailgate washers inoperative, or unsatisfactory in operation One or more washer jets inoperative _] _] |

Blocked washer jet (Chapter 12). Disconnected, kinked or restricted fluid hose (Chapter 12). Insufficient fluid in washer reservoir (see Weekly checks).

Washer pump fails to operate (| Broken or disconnected wiring or connections (Chapter 12). {_] Blown fuse (Chapter 12).

(| Faulty washer switch (Chapter 12). (] Faulty washer pump (Chapter 12). Washer pump runs for some time before fluid is emitted from jets (_] Faulty one-way valve in fluid supply hose (Chapter 12).

Faulty switch (Chapter 12).

Window glass slow to move

[_|

Regulator seized or damaged, or in need of lubrication (Chapter 11). Door internal components or trim fouling regulator (Chapter 11). Faulty motor (Chapter 11).

Window glass fails to move Blown fuse (Chapter 12). Faulty relay (Chapter 12). Broken or disconnected wiring or connections (Chapter 12). Faulty motor (Chapter 12).

Central locking system inoperative, or unsatisfactory in operation Complete system failure Blown fuse (Chapter 12). Faulty relay (Chapter 12). Broken or disconnected wiring or connections (Chapter 12). Faulty motor (Chapter 11).

Latch locks but will not unlock, or unlocks but will not lock Faulty switch (Chapter 12). Broken or disconnected latch operating rods or levers (Chapter 11). Faulty relay (Chapter 12). Faulty motor (Chapter 11).

One solenoid/motor fails to operate Broken or disconnected wiring or connections (Chapter 12).

Faulty motor (Chapter 11). Broken, binding or disconnected lock operating rods or levers (Chapter 11). Fault in door lock (Chapter 11).

REFe20

INdeXx

Note: References throughout this index are in the form “Chapter number” ¢ “Page number”. So, for example, 2Ce15 refers to page 15 of Chapter 2C

A

Braking system - 1A¢13, 1B°14, 91 et seq,

REFe8, REFe9, REFe10 calipers - 1Ae14, 1Be15 discs —- 1A°11, 1Be11 fault finding - REFe17 hoses — 1A¢°11, 1Be11

A-pillar trim panel - 11¢21 Accelerator cable — 4Ae3 Accelerator pedal — 4A*4, 4Be6 Accessory shops - REFe3 Acknowledgements — 0¢4 Aerial -— 12¢22

pads - 1Ae11, 1Be11 pipes - 1Ae11, 1Be11

Air conditioning system — 3¢5, 3°16, 3°17 switch — 125, 12¢7 Air control valve — 4Ae9 Air filter —- 1A°14, 1B°14, 4Ae3, 4Be4 Air recirculation servo motor — 3°14 Air recirculation switch — 12¢5, 12¢7 Air temperature sensor — 4A¢8, 4Be14, 4Be15 Airbags — 0¢5, 1A°12, 1Be12, 1222, 12023 module — 1A9°18, 1B°18

rotary contact unit - 12¢24, 12°26 warning light bulb - 12°25, 12¢26 Airflow meter — 4Be14 Airflow sensor - 4Be15 Alarm system — 12¢27 Alternator — 5Ae¢4, 5Ae5 drivebelt —- 1A°9

Anti-lock braking system (ABS) — 9e15, 9e16 Antifreeze - 0°12, 0°16, 1Ae16, Anti-roll bar — 10°7, 10¢8

1B°16

Anti-theft alarm system — 12¢26, 12¢27, REFe5 Asbestos —- 0¢5 Audio system remote control switches - 12¢5, 12¢7 Automatic transmission — 2De7, 7Be1 et seq, REFe16 Automatic transmission fluid - 0°16, 1Be8, 1Be18 Automatic transmission selector bulb - 12014 Auxiliary drivebelt(s) - 1Ae9, 1Be9

B-pillar trim panels — 11¢21 Badges - 11°18

Battery — 0°5, 0¢14, 5Ae2, 5Ae3 Battery (handset) - 1A¢14, 1Be15 Big-end bearings — 2De26 Bleeding brakes — 9e2 clutch — 6¢3 fuel system - 4Be7 power steering — 10°19 Blower fan switch — 12¢5 Body corrosion - 1Ae7, 1Be7, REFe11 Body electrical systems - 12¢1 et seq Body under-panels — 11°18 Bodywork and fittings - 11°¢1 et seq Bonnet - 11°7, 11¢8 Boost pressure control solenoid valve — 4Be17 Boost pressure sensor — 4Be17

Boot light - 12°13 Brake fluid — 0°12, 0°16, 1A°16, Brake pedal — 9e11 position switch —- 9e14

1B°16

wheel cylinders - 1Ae14, 1Be15

Bulbs — 12¢8, 12°13 Bumpers — 11°4, 11¢5 Burning — 0¢5

Buying spare parts — REFe3

C C-pillar trim panel — 11°22 Cables accelerator — 4Ae3 automatic transmission selector — 7Be2 bonnet release - 11¢7 handbrake — 9e13

ignition switch interlock - 10°13 Calipers — 1A¢°14, 1Be15, 9e¢9 Camshafts — 2A°9, 2Be12, 2Ce6 cover — 2Ae4, 2Be4, 2Ce5 oil seals - 2Ae¢9, 2Be12 position sensor — 4Ae10, 4Be18 sprockets — 2Ae8, 2Be10, 2Be11 Carpets - 11¢2, 11°23 Cassette player - 12¢21

anti-theft system — REFe5 Catalytic converter - 4Ae12, 4Be23, 4Ce4 CD autochanger - 12¢21 anti-theft system — REFe5 Central locking system — 11°15, 1226 switch — 12°6, 12¢8 Centre console - 11°24 Charcoal canister — 4Ce2 Charging — 5Ae2, 5Ae3 Cigarette lighter - 12°18 illumination - 12¢14 Clock — 12°18 illumination — 12°14 Clutch — 6¢1 et seq fault finding - REFe15 master cylinder -— 6¢2 pedal — 62 release mechanism — 6e5 slave cylinder - 6e2 Coil(s) — 5Be2 Compression test — 2Ae¢3, 2Be3, 2Ce4 Compressor — 3°17 drivebelt —- 1Be10 Condenser - 3¢17 Connecting rods — 2De17, 2De23, 2De30 Console - 11¢24 Conversion factors — REFe2 Coolant — 0°12, 0°16, 1Ae15, 1B°16 level sensor — 3012 pump — 3¢8 temperature sensor - 4Ae9, 4Be14 Cooling, heating and ventilation systems 3e1 et seq fault finding - REFe15 sensors — 3e11

Courtesy lamp delay — 12°26 Crankcase emission control — 4Ce1, 4Ce2, 4Ce3 Crankshaft — 2De20, 2De25, 2De27 oil seals - 2Ae15, 2Be19, 2Ce14 pilot bearing - 2C°16 position sensor — 4A¢9 pulley — 2Ae5, 2Be5, 2Ce5 sensor - 4Be13 sprocket — 2Ae8, 2Be10, 2De14 Cruise control switches — 12¢6, 12¢8 Crushing — 0¢5 Cup holder - 11°23 Cut-off inertia switch — 4A°10, 4Be16 Cut-off solenoid — 4Be15 Cylinder block — 2De21 Cylinder head - 2Ae¢11, 2Be13, 2Ce8, 2De14 2De15, 2De16

D

1

Daytime running lamps —- 12°27 Dents — 11¢2 Depressurisation (fuel injection system) — 4Ae5 Diesel engine in-car repair procedures L-Series - 2Be1 et seq TD4 - 2Ce1 et seq Diesel injection equipment — 0°5 Dimensions — REFe1 Direction indicators — 12¢4, 12¢6, 129, 12°10, 12°12, 12¢15 Discs - 1Ae¢11, 1Be11, 9¢8 Distributor - 5Be2 Doors — 11°8, 11°9, 11°11, 11°13, 12¢26, REFe9 f Drivebelt(s) — 1A°9, 1Be9 fuel injection pump — 2Be9, 2Be11 Driveplate — 2Ce15 Driveshafts, propeller shafts & final drive 8e1 et seq Driveshafts - 1A°12, 1B°12, REFe10 fault finding —- REFe16 oil seals - 7Ae4, 7Ce3, 8e9 Drivetrain — 1A¢13, 1Be14 Drums - 9¢8

E Earth fault — 12¢2

Electric cooling fan — 3°10 Electric shock — 0¢5 Electric sunroof switch — 126, 12¢8 Electric windows — 12¢26 switches — 12¢5, 12¢8 Electrical equipment — 0°15, 1A°12, 1A°13, 1Be12, 1B°14, REFe9 fault finding - 12°2, REFe18, REFe19

Electronic Brake Force Distribution - 9°15 Electronic Control Module/Unit ABS - 9°17 airbag — 12°24 automatic transmission — 7Be5 fuel system - 4A®9, 4Be15 mirrors — 11°18

preheating system - 5Ce3

INdex ReEFe21 Note: References throughout this index are in the form “Chapter number” ¢ “Page number”. So, for example, 2C°15 refers to page 15 of Chapter 2C. Electronic Diesel Control (EDC) system — 4Be13 Electronic Traction Control — 9°15 Emission control systems - 1A°12, 1Be12, 4Ce1 et seg, REFe11 . Engine fault finding - REFe13, REFe14

Fuel and exhaust systems - diesel engines — 4Be1 et seq Fuel and exhaust systems — petrol engines — 4Ae1 et seg fault finding - REFe15 Fuel cooler matrix — 4B°18

Engine oil - 0°11, 0°16, 1A°6, 1B°6

Fuel cut-off inertia switch — 4A°10, 4Be16 Fuel cut-off solenoid — 4Be15

Engine removal and overhaul procedures —

2De1 et seq Environmental considerations — REFe4 Evaporative emission control - 4Ce2

Evaporator - 3°17 Exhaust emission — 1A¢12, 1B°12, 4Ce1, 4Ce2, 4Ce3 Exhaust gas recirculation system — 4Ce2, 4Ce4 Exhaust manifold - 4A°11, 4Be22 Exhaust specialists — REFe3 Exhaust system - 1A¢10, 1Be1.0, 4Ae12, 4Be22, REFe10, REFe11 Expansion tank — 3°6

F Facia panel — 11°26 Facia stowage box - 11°23 Fan - 3°10 switch — 12¢5 Fault finding — REFe12 et seq

*

automatic gearbox — REFe16 braking system — REFe17 clutch - REFe15 cooling system — REFe15

driveshafts - REFe16

Fuel filter — 1Ae18, 1B°13, 1Be17 sedimenter — 1Be14 Fuel gauge sender unit - 4A¢6, 4Be7 Fuel high-pressure sensor - 4Be17 Fuel injection pump - 4Be9 belt - 2Be9 belt tensioner and sprockets — 2Be11 sprocket — 2Be11, 2De14 Fuel injection system — 4Ae4, 4Ae7, 4Ae8,

4Be6, 4Be9, REFe11 Fuel injector needle lift sensor — 4Be14 Fuel injectors — 4Ae8, 4Be12 Fuel lift pump — 4Be18 Fuel low-pressure sensor — 4Be17 Fuel pressure damper — 4Ae¢8 Fuel pressure regulator — 4Be17 Fuel pump -— 4Ae5, 4Be8 Fuel quantity servo position sensor — 4Be14 Fuel rail —- 4A¢8

Fluids — 0°16 Flywheel — 2A¢15, 2Be20, 2Ce14 _ Foglights - 12°12, 12°26 switch — 1204, 12¢7 Followers — 2A°9, 2Be12, 2C°6

High-level stop-light — 12°10, 12¢12, 12¢15 High-pressure fuel sensor — 4Be17 Hill Descent Control - 9°15 switch — 9°18, 12°5, 12¢8 Hinge lubrication -— 1Ae12, 1B°12 Horn — 12°18 switches — 12¢4, 12¢7 Hoses — 1Ae11, 1B°11, 3¢5, 9e3 leaks — 1Ae8, 1Be8

Fume or gas intoxication — 0¢5 Fusebox — 12¢3 Fuses — 1293

Gaiters

Final drive - 8°9 fault finding - REFe16 oil - 0°16, 1A°8, 1Be9 oil seals — 8¢9 Fire —-0¢5 First gear switch — 7A°6 Fixed windows - 11°17 Fluid cooler - 7Be4 Fluid leaks - 1A*8, 1Be8

Heated rear window —- 12°26 switch -— 12¢5, 12°7 Heated seats - 12°27 switches — 12°6, 12¢8 Heated windscreen — 12¢26 Heater blower motor — 3¢14 switch — 12¢5, 12°7 Heater control panel - 3e14 illumination — 12°14 Heater matrix -— 3e14 Heater unit — 3e12

Hinged rear side windows — 11°16

intermediate reduction drive unit - REFe16

pollen — 1A913 turbocharger boost control solenoid valve vent — 1Be14

beam alignment - 12°16 levelling switch — 12¢5, 12¢7 switch — 12¢4, 12¢6 Headilining — 11°23 Heat shield(s) — 4A¢12, 4Be23

Fuel temperature sensor — 4Be14 Fuel temperature switch — 4Be16 Fuel-burning heater (FBH) - 3e15, 3°16

G

REFe17, REFe18 Filter air -—1A¢14, 1Be14, 4A*e3, 4Be4 fuel —1A°18, 1B°13, 1Be17 fuel sedimenter - 1Be14 oil -— 1A°6, 1Be6

Hard top sensing switch — 12¢6, 12°8 Hazard warning light switch — 12¢5, 12¢7 Headlight -— 12¢9, 12°11, 12015

Fuel tank — 4Ae7, 4Be5

electrical system — 12¢2, REFe18, REFe19 engine — REFe13, REFe14 final drive — REFe16 fuel and exhaust systems — REFe15 manual gearbox — REFe16 propshaft — REFe16 finding steering and suspension —

—_Handles door - 11°11 grab — 11°23 Handset battery — 1A°14, 1Be15

driveshaft — 1Ae¢12,

HT coil(s) — 5Be2 Hydrofluoric acid — 0e5

Identifying leaks — 0°9 1Be12, 8e5

steering rack — 10e15 Gashes - 1193 Gaskets — REFe4 Gauges — 12°18 Gearchange linkage — 7Ae3 Gearchange selector shaft oil seal — 7Ae4 General repair procedures — REFe4 Glass and regulator — 11°13, 11°16 Glossary of technical terms — REFe20 et seq Glovebox — 11°23 illumination light bulb - 12°13 light switch — 12¢5, 12¢7 Glow plugs — 5Ce2, 5Ce3 Grab handles - 11°23 Grille — 11°18

H Handbrake - 1A¢12, 1B°12, 9e12, 9°13, _ REFe8 ‘on’ switch — 12°6, 12¢8 warning — 12°26 warning light switch — 9°14

-Idle air control valve — 4Ae¢9

Idler pulley — 2Be11 Ignition HT coil(s) - 5Be2 Ignition switch -— 10°12 interlock cable - 10e13 Ignition system —- petrol engine models — 1A°¢17, 5Be1 et seq Ignition timing — 5Be2

Indicators — 12¢9, 12°10, 12°12, 12°15 switch - 12¢4, 12¢6 Inertia switch — 4A¢10, 4Be16 Inertia cut-off solenoid — 4Be15 Inhibitor switch - 7Be3 Injection pump — 4Be9

belt — 2Be9 belt tensioner and sprockets — 2Be11 sprocket — 2Be11, 2De14 Injector needle lift sensor — 4Be14 Injectors — 4Ae8, 4Be12 Inlet manifold - 4A°10, 4Be21, 4Be22 Input shaft oil seal — 7Ae4 Instrument panel — 12°16, 12°17 illumination — 12°14 Instruments — 1A¢13, 1B°14 Intake air temperature sensor — 4A°8, 4Be14, 4Be15

REFe22 INdex Note: References throughout this index are in the form “Chapter number” « “Page number’. So, for example, 2C15 refers to page 15 of Chapter 2C. Intake ducts — 4Ae3 Intercooler — 4Be20 Interlock cable - 10°13. Intermediate Reduction Drive unit — 7Ce1

et seq

fault finding - REFe16 oil — 0°16, 1A°8, 1B°9,

7C #2

J Jacking and vehicle support — REFe5 Joint mating faces — REFe4 Jump starting — 0¢7

MOT test checks — REFe8 et seq Motor factors — REFe3 Mountings — 2Ae16, 2Be21, 2Ce15

L Land Rover Freelander manual — 0¢4 Leakdown test - 2Be4, 2C «4 Leaks - 0°9, 1Ae8, 1Be8 Light units — 12¢8, 12°13, 12015 switches — 12°6 Light-on alarm —- 12°26 Links — 10°10 bushes — 10¢11 Locknuts, locktabs and washers — REFe4 Locks bonnet — 11¢8

central locking system — 11°15 door — 11°11 lubrication - 1A°12, 1Be12 steering column — 10°12 tailgate — 11°15, 1226

Lower arm - 10¢5 Low-pressure fuel sensor — 4Be17 L-Series diesel engine in-car repair procedures — 2Be1 et seq Lubricants and fluids — 0°16 Luggage area side trim panel — 11°22 Luggage compartment light — 12°13

M Main bearings — 2De26 Manifold absolute pressure (MAP) sensor —

4Ae9, 4Be14 Manifolds — 4A°10, 4Ae11, 4Be21, 4Be22 Manual gearbox — 2De4, 2De7, 7Ae1 et seq fault finding - REFe16

oil — 0°16, 1A°®7, 1Be8, 7Ae2 Map reading light — 12°13 ' Mass airflow sensor — 4Be15 Master cylinder brake — 9°10 clutch — 6¢2 Matrix fuel cooler - 4Be18 Mirrors — 11°17, REFe8

switch - 12¢5,12¢8 © Modulator assembly (ABS) - 9°16

fault finding - REFe16 pinion oil seal — 8¢9 Puncture repair — 0¢8

N

Purge valve - 4Ce2

Needle lift sensor — 4Be14 Number plate light — 12°10, 12°12, 12°16

Q

O

Quarter-light — 11°13

Oil engine — 0°11, 0°16, 1A*6, 1Be°6 final drive —- 0°16, 1A*8, 1Be9 intermediate reduction drive unit — 0°16,

Key-in alarm - 12°26

Propeller shaft - 8°6, 8¢7

1A°8, 1Be9, 7Ce2 manual gearbox — 0°16, 1Ae7, 1B°8, 7Ae2 Oil cooler — 2Be19, 2C°14

Oil filter — 1A°6, 1Be6 Oil pressure warning light switch — 5Ae6 Oil pump — 2A913, 2A9°14, 2Be17, 2Ce12, 20913 Oil seals — 7Ae4, 7Ce2, 8°9, REFe4 camshaft — 2Ae9, 2Be12 . crankshaft — 2Ae15, 2Be19, 2Ce14 torque converter — 7Be5 Oil temperature sensor — 5Ae7 Open-circuit — 12¢2 Outside temperature sensor — 3°16 Oxygen sensor(s) - 4Ce3

p Pads - 1Ae11, 1B°11, 9e4 Parts - REFe3 ~ Pedals accelerator — 4Ae4, 4Be6 brake — 9e11, 914 clutch - 6e2 position sensor — 4Be14 Petrol engine in-car repair procedures — 2Ae1 et seq Pinion housing O-ring - 7Ce3

Pipes — 1Ae11, 1B°11, 9e3

Piston rings — 2De26 Pistons — 2De17, 2De23, 2De30 Plastic components — 11¢3 Poisonous or irritant substances —- 0¢5 Pollen filter — 1Ae¢13, 1B°13 Positive temperature co-efficient (PTC) heater — 3¢15 Power steering fluid —- 0°16, 1A°7, 1Be7 cooler — 10°18 pump — 10°16 pump drivebelt - 1A°9 Preheating system - diesel engine models — 5Ce1 et seq Pressure limiting valve — 4Ce3 Primary shaft oil seals — 7Ce3 Priming and bleeding fuel system — 4Be7 Printed circuit — 12°18

R Radiator — 1A°15, 1B°16, 3°6 grille - 11°18 Radio - 12¢21 aerial —- 12¢22 anti-theft system — REFe5

Rear light cluster - 12°10, 12e12, 12e15 Rear screen wiper — 12°26 Rear side trim panel — 11°22 Rear window -— 12°26 surround — 1122 switch - 12¢5 Receiver/drier — 3°18 Refrigerant pressure sensor — 3°18

Regulator (window glass) - 11°13, 11°16 Relays -— 123

ABS - 9°18 fuel system — 4Be16 glow plug — 5Ce3 Release mechanism (clutch) — 6¢5 Repair procedures — REFe4 Reversing light switch - 7Ae5

Road test - 1Ae13, 1B°14 Roadside repairs — 0°6 et seq Roadwheel anti-seize check — 1Ae12 — 1Be12 speed sensors — 1A913, 1Be12 Rocker arms — 2Ce6 Roof rails - 11°18 Routine maintenance - bodywork and underframe — 11¢2 Routine maintenance - upholstery and carpets — 11¢2 Routine maintenance and servicing -

diesel Routine petrol Running

models — 1Be1 et seq maintenance and servicing — models - 1Ae1 et seq lamps —- 12¢27

Rust holes or gashes - 11¢3

S Safety first! —- 05, 0°12 Scalding — 0¢5 Scratches - 11¢2

Screen washer fluid — 0°14 Screw threads and fastenings — REFe4

INdexX reFe23 Note: References throughout this index are in the form “Chapter number” « “Page number”. So, for example, 2C®15 refers to page 15 of Chapter 2C. Seat belts - 1Ae12, 1Be12, 11°19 pretensioners — 1A°18, 1B°18 switches — 12¢6 warning — 12¢26 Seats - 11°19, 12°27 Sedimenter — 1Be14 Selector cable — 7Be2 housing - 7Be2 indicator — 7Be2

Selector shaft oil seal — 7Ae4 Servo unit -— 9°11, 9°12 Shock absorbers - 1Ae11,

ignition —

~

Shoes - 9¢5 ’ Short-circuit — 122

Side trim panel -— 11°22 Side windows - 11°16

Sidelight - 12°9, 12°11 Sill finishers — 11°18

inner trim panels — 11¢21 Slave cylinder (clutch) — 6¢2 Soft top - 11°17 sensing switch — 12e6, 12¢8 Spare parts — REFe3 Spare wheel mounting bracket — 11°18

Spark plugs — 1A¢16 Speakers - 12¢21 Speed sensors — 1A¢13, 1B912, 4Ae9, 4Be14 Speedometer drive — 7A°6, 12°18 Springs — REFe10 Starter motor — 5Ae5, 5A*6 Starting and charging systems — 5Ae1 et seq Start-up after overhaul - 2De32 Steering — 1A¢11, 1A°13, 1B°11, 1B°14, REFe9, REFe10 Steering angles — 10¢20 Steering column — 10¢14, REFe8 lock - 10°12 Steering rack - 10°15 Steering wheel — 10°12, REFe8 Stop-light — 12¢10, 12¢12, 12¢15 switch — 4Be15, 9°13 Stowage box -— 11°23 Strut : - suspension — 10¢3, 10°9 tailgate - 11°14 Subframe — 10¢8, 10°11 Sump - 2A¢13, 2Be16, 2Ce11 Sunroof — 11°17 switch — 12°6, 12¢8

washer jet — 12¢21 window — 12°26 wiper motor — 12°20 Tappets — 2Ae9, 2Be12, 2Ce6 TD4 diesel engine in-car repair procedures — 2Ce1 et seq Temperature gauge sender unit — 3°12 Temperature sensor — 3°11, 3°15, 4Ae8,

4Ae9, 4Be14, 4Be15, 5A°7 Temperature switch -— 4Be16 Tensioner — 2Ae8, 2Be10, 2Be11 Thermostat — 3°¢7 Thermostatic expansion valve — 3°18 Throttle housing — 4Ae7 Throttle pedal position sensor - 4Be14 Throttle position sensor — 4A¢8

Underbonnet check points — 0°10, 0°11 Underframe — 11°24 Under-panels — 11°18 Unleaded petrol — 4A¢4

Tie rods — 2Be21

Vacuum pump - 9e14 Vacuum servo unit — 9°11, 9¢12 Valve timing — 2A*4, 2Be4, 2Ce4 Valves - 2De15

Vanity mirror light - 12°13 Vehicle identification — REFe3, REFe9 Vehicle speed sensor — 4Ae9, 4Be14 Vehicle support — REFe5 Ventilation system — 3°12 Viscous coupling unit - 8°8

W Warning lights — 12°14

jets - 12¢21

Timing belt - 2Ae6, 2Be7 covers — 2Ae5, 2Be5 tensioner and sprockets — 2A¢8, 2Be10 Timing chains, tensioner and sprockets —

2De13

pumps — 12¢15 reservoir — 12°20 Water pump - 3¢8 Weekly checks — 0°10 et seq

Weights — REFe1 Wheels — REFe11 alignment — 10e20

chain cover — 2De12 Timing — 5Be2 Timing marks — 2Ae4, 2Be4

Timing settings —- 2C°4 Tools and working facilities

V

Wash/wipe switch — 12¢4, 12¢7 Washer

Tie rod — 2Ae17, 2C*16

— REFe6 et seq,

REFe4 Torque converter oil seal —- 7Be5 Towing — 0°9 Track rod — 10°19, 10¢20

Trailing link - 10°10 Transit mode — 12°26 Transmission mountings — 2Ae¢16, 2Be21,

2Ce15 Transverse links — 10°10

Suspension and steering — 1Ae11, 1A¢13, 1Be11, 1Be14, 10¢1 et seq, REFe9, REFe10 fault finding - REFe17, REFe18 Switches - 12¢4 automatic transmission inhibitor —- 7Be3 brake pedal position — 9¢14

Trim panels — 11°9, 11°18, 11°21

braking system — 9°13

U

Upholstery — 11°2

Tailgate — 11¢14, 11°15, 11¢16 glass switch — 12°6, 12¢8 lock — 12°26

Sunvisors - 11°29

first gear — 7Ae6

Tyres — REFe11 condition and pressure — 0°13 pressures — 0°16 specialists — REFe3

10°12, 10¢13

illumination — 12¢14 inertia fuel cut-off - 4Be16 oil pressure warning light — 5Ae6 reversing light — 7Ae5 stop-light — 4Be15, light —- 9e13

1Be11, REFe9,

REFe10

‘

fuel temperature —- 4Be16 handbrake warning light - 9°14 heater control panel — 3¢14 Hill Descent Control — 9¢18

Trinary pressure switch - 3°18

Turbocharger — 4Be19, 4B°20 boost control solenoid valve vent filter — 1B°14 boost pressure control solenoid valve - 4Be17 boost pressure sensor — 4Be17

bearings — 10e6, 10e11, REFe10 changing — 0°8 Wheel arch liners — 11°18 Wheel cylinders — 1Ae14,

1Be15, 9¢11

Wheel mounting bracket — 11°18

Wheel sensors (ABS) -9°17,9°18

—,

Windows — 11°13, 11°16, 11°17, 12¢26 glass and regulator — 11°13, 11°16 surround — 11°22 switches — 12¢5, 12¢8

Windscreen — 11¢17, 12°26, REFe8 wash/wipe switch — 12¢4, 12¢7

washer jets — 12¢21 Wipers — 12°26 Wiper arm - 12°18 Wiper blades — 0°15 Wiper motor and linkage — 12°19, 12°20 Wiring diagrams — 12°28 et seq Working facilities — REF°7

Preserving Our Motoring Heritage eae

The Model J Duesenberg Derham Tourster. Only eight of these magnificent cars were ever built — this is the only example to be found outside the United States of America

Almost every car you've ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum. Over 300 immaculately presented cars and motorbikes represent every aspect of our motoring heritage, from elegant reminders of bygone days, such as the superb Model JDuesenberg to curiosities like the bug-eyed BMW Isetta. There are also many old friends and flames. Perhaps you remember the 1959 Ford Popular that you did your courting in? The magnificent ‘Red Collection’ is a spectacle of classic sports cars including AC, Alfa Romeo, Austin Healey, Ferrari, Lamborghini, Maserati, MG, Riley, Porsche and Triumph.

A Perfect Day Out Each and every vehicle at the Haynes Motor Museum has played its part in the history and culture of Motoring. Today, they make a wonderful spectacle and a great day out for all the family. Bring the kids, bring Mum and Dad, but above all bring your camera to capture those golden memories for ever. You will also find an impressive array of motoring memorabilia, a comfortable 70 seat video cinema and one of the most extensive transport book shops in Britain. The Pit Stop Cafe serves everything from a cup of tea to wholesome, home-made meals or, if you prefer, you can enjoy the large picnic area nestled in the beautiful rural surroundings of Somerset.

John Haynes O.B.E., Founder and Chairman of the

museum at the wheel of a Haynes Light 12.

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MUSEUM

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< Graham Hill’s Lola | Cosworth Formula 1

car next to a 1934 Riley Sports.

The Museum is situated on the A359 Yeovil to Frome road at Sparkford, just off the A303 in Somerset. It is about 40 miles south of Bristol, and 25 minutes drive from the M5 intersection at Taunton. Open 9.30am - 5.30pm (10.00am - 4.00pm Winter) 7 days a week, except Christmas Day, Boxing Day and New Years Day Special rates available for schools, coach parties and outings Charitable Trust No. 292048 .

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AyVaietslamicevaamar-lalelsmeyal experience fof-lal fo Micolaam tal-merelan) o)(-1- mtg)emele\an lple) _ rebuild of several Freelanders in our Project Workshop, this manual can help you understand, care for and repair your Freelander. We do it ourselves to _ help you do-it-yourself, and whatever your mechanical ability, the practical ee step-by-step explanations, linked to over 900 photos, will help you get the imma (oe (e)at-Mate)aiemn\-vel0)t-\ar\-1avi (eae m-lare Manr-liaitciar- (ale, Me)m\(ol0 mimic-1-\(-lale(-mer-la) ~ help maintain its resale value, save you money, and make it safer to drive. .

HAYNES

MANUALS EXPLAIN BEST - SEE HAYNES, SEE HOW

“The most useful tool... is a Haynes Manual” Land Rover Monthly

“|. It’s the paper equivalent of talking to a mate who’s happy to help... a great way for owners to save cash by tackling jobs themselves...”

Auto Express

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Taksiie(=m dalcs Manual

“,_..knowledge is power, late tarcim carey iuccre(e(-mimip your workshop manual...”

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Practical Classics

.

Maintenance Simple weekly checks to keep you on the road

;

Servicing Complete, fully illustrated step-by-step guide

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Fault finding Pinpoint specific problems easily The MoT Step-by-step test checks

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Fuel saving Expert advice on maximising mpg

« ..Haynes are the

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Electrics Easy-to-read wiring diagrams Haynes tips Valuable short cuts make many tasks easier

2, sal a eoatltae manuals...”

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ISBN 978 0 85733 8747

Classic Car Weekly

Miodels covered by this Manual as

UPC CODE

Freelander Hardback, Softback & Station Wagon Petrol: Turbo-diesel:

1.8 litre (1796cc) 4-cylinder 2.0 litre (1951cc TD4 & 1994cc L-Series)

Does NOT cover models with 2.5 litre V6 petrol engine Does NOT cover new ‘Freelander 2’ range introduced November 2006 Haynes Publishing, Sparkford, Yeovil, Somerset BA22 7JJ England

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