Land Rover Discovery Series I - Manual de Taller - Service Manual

LAND ROVER DISCOVERY (1995) - MANUAL DE TALLER - WORKSHOP MANUAL


- English and Spanish Service Manual, in PDF format, to vehicles Land Rover Discovery.

- Manual en español e inglés, en formato PDF, para la reparación de los vehículos Land Rover Discovery.


INDEX:


WORKSHOP MANUAL

01 - INTRODUCTION
INFORMATION
- Introduction
- Dimensions
- References
- Repairs and replacements
- Poisonous substances
- Fuel handling precautions
- Synthetic rubber
- Recommended sealants
- Used engine oil
- Accessories and conversions
- Wheels and tyres
- Steam cleaning
- Specification
- Special service tools
- Copyright
- Jacking
- Hydraulic vehicle ramp (four post)
- Two post vehicle ramps
- Dynamometer testing - non anti-lock brake vehicles
- Dynamometer testing - vehicles with anti-lock brakes (abs)
- Towing
- Transporting the vehicle by trailer
- Jump starting
- Abbreviations and symbols used in this manual
- Cross reference of emission system terminology
- Vehicle identification number (vin)
- Location of identification numbers
- Fault diagnostic equipment
- Reading this manual
04 - GENERAL SPECIFICATION DATA
INFORMATION
- Engine 3.9 v8i
- Engine 4.0 v8
- Fuel system 3.9 v8i
- Fuel system (gems) 4.0 v8 engine
- Shift speed automatic zf on 3.9 v8i
- Shift speed automatic zf on tdi engine
- Transmission 3.9 v8i
- Cooling system 3.9 v8i
- Steering
- Suspension
- Road spring data
- Shock absorbers
- Brakes
- Air conditioning
- Wiper motors
- Electrical
- Bulbs
- Vehicle weights and payload
- Tyre pressures
- Wheels and tyres
- 300 tdi engine
- Fuel system - 300 tdi
- Cooling system - 300 tdi
- Clutch - 300 tdi
- Transmission - 300 tdi
- Engine - mpi - 2.0 litre
- Fuel system - mpi
- Cooling system - mpi
- Clutch - mpi
- Transmission - mpi
- Vehicle dimensions
05 - ENGINE TUNING DATA
INFORMATION
- Engine 3.9 v8i
- Engine - 4.0 v8
- 300 tdi engine
Injection Pump
Glow Plugs
Injectors
Turbocharger
- Engine - mpi - 2.0 litre
07 - GENERAL FITTING REMINDERS
INFORMATION
- General fitting reminders
- Precautions against damage
- Safety precautions
- Preparation
- Dismantling
- Inspection-general
- Ball and roller bearings
- Oil seals
- Joints and joint faces
- Flexible hydraulic pipes, hoses
- Fuel system hoses
- Metric bolt identification
- Metric nut identification
- Keys and keyways
- Tab washers
- Cotter pins
- Nuts
- Locking wire
- Screw threads
- Unified thread identification
09 - LUBRICANTS, FLUIDS AND CAPACITIES
INFORMATION
- Recommended lubricants and fluids - usa vehicles
- Recommended lubricants and fluids
- Lubrication practice
- Capacities
- Anti-freeze
- Fuel requirements
- Recommended fuel
10 - MAINTENANCE
MAINTENANCE
- Service schedule
- Vehicle interior
- Vehicle exterior
- Under bonnet [hood] maintenance
- Under vehicle maintenance
- Recommended service items
12 - ENGINE - Tdi
REPAIR
- Drive belt information
- Drive belt renew
- Compressor drive belt
- Engine
- Crankshaft pulley
- Front cover plate
- Camshaft drive belt and gears
- Front cover/timing gear housing gasket
- Oil sump
- Oil pick-up strainer
- Flywheel
- Crankshaft rear oil seal
- Crankshaft bearing bush
- Flywheel housing
- Oil filter
- Oil temperature control valve
- Oil filter head gasket
- Cylinder head gasket
- Vacuum pump
- Generator
SPECIFICATIONS, TORQUE
- Torque values
12 - ENGINE - V8i
DESCRIPTION AND OPERATION
- Description
FAULT DIAGNOSIS
- Engine oil pressure test
- Cylinder compression - test
- Engine noises
- Engine starting problems
- Engine running problems
REPAIR
- Drive belt
- Drive belt renew
- Drive belt - check tension
- Drive belt tensioner
- Cylinder head gaskets - renew
- Cylinder heads - renew
- Rocker cover - right hand - renew
- Rocker cover - left hand - renew
- Rocker shaft renew
- Hydraulic tappets renew
- Crankshaft pulley assembly
- Front cover oil seal - renew
- Front cover gasket
- Timing chain and chainwheels
- Flywheel
- Flexible drive plate and ring gear
- Crankshaft rear oil seal
- Engine
- Oil sump
SPECIFICATIONS, TORQUE
- Torque values
SERVICE TOOLS
- Engine
12 - ENGINE - 4.0 V8
DESCRIPTION AND OPERATION
- Description
- Content of this section
REPAIR
- Crankshaft pulley
- Crankshaft front oil seal
- Engine assembly
- Front cover gasket
- Rocker cover gasket - left hand
- Rocker cover gasket - right hand
- Crankshaft rear oil seal
- Drive plate - automatic
- Rocker shaft - overhaul
- Tappets - engine set
12 - ENGINE - Mpi
DESCRIPTION AND OPERATION
- Description
- Cylinder block components
- Cylinder head components
- Timing belt components
REPAIR
- Camshaft front oil seal
- Inlet - exhaust camshaft rear oil plug
- Crankshaft front oil seal
- Crankshaft rear oil seal

- Engine
- Engine sump gasket
- Cylinder head gasket
- Camshaft cover gasket
- Camshaft drive belt
- Check camshaft drive belt
SPECIFICATIONS, TORQUE
- Torque values
SERVICE TOOLS
- Engine
17 - EMISSION CONTROL
DESCRIPTION AND OPERATION
- Emission control
- Exhaust system
- Evaporative control system - pre advanced evaps
- Evaporative emission control system - advanced evaps
FAULT DIAGNOSIS
- Testing evaporative emission control - pre advanced evaps
- Leak detection procedure - advanced evaps
- Drive cycle - advanced evaps
REPAIR
- Positive crankcase ventilation air intake filter
- Positive crankcase ventilation breather filter
- Heated oxygen sensor (ho2s)
- Purge control valve
- Charcoal canister
- Heated oxygen sensor (ho2s) - 4.0 v8
- Catalytic converter/front pipe - 4.0 v8
- Evap canister and purge valve - 4.0 v8
- Evap canister - advanced evaps
- Evap canister purge valve - advanced evaps
- Evap canister vent solenoid - advanced evaps
19 - FUEL SYSTEM - Tdi
DESCRIPTION AND OPERATION
- Description
- Fuel system layout
- Fuel system component location
- Operation
- Description electronic diesel control
- Fuel system component location edc
- Fuel system layout edc
- Operation edc
ADJUSTMENT
- Throttle cable
- Egr throttle position sensor
- Low and high idle speed
- Check turbocharger boost pressure
REPAIR
- Tank sender unit
- Throttle cable
- Intake hose turbocharger
- Turbocharger oil feed pipe
- Turbocharger oil drain pipe
- Turbocharger actuator
- Turbocharger and gasket
- Fuel lift pump
- Fuel filter element
- Intercooler
- Glow plugs
- Egr valve
- Glow plug control unit
- Egr control unit
- Egr throttle position sensor
- Injectors
- Fuel injection pump and timing
- Engine control module (ecm)
- Airflow meter
- Boost pressure sensor
- Injection timing sensor
- Engine speed sensor
- Vehicle speed sensor
- Clutch pedal switch
- Brake pedal switch
- Coolant temperature sensor
- Throttle position sensor
- Electro-pneumatic modulator
19 - FUEL SYSTEM - MFI
DESCRIPTION AND OPERATION
- Description
- Engine mounted components
- Chassis mounted components
- Body mounted components
- Micro processor power check
- Fuel injection system
- Engine setting procedure
FAULT DIAGNOSIS
- Engine tuning
- Injector tests
- Base idle speed setting
- Fuel pressure check
REPAIR
- Air cleaner assembly
- Air cleaner element
- Air flow sensor
- Throttle position sensor
- Idle air control valve
- Vehicle speed sensor
- Multiport fuel injection relays
- Engine control module (ecm)-14 cux
- Inertia fuel shutoff switch
- Engine fuel temperature sensor
- Engine coolant temperature sensor
- Depressurising fuel system
- Fuel pressure regulator
- Fuel rail-injectors r/h and l/h
- Plenum chamber
- Ram housing
- Intake manifold
- Fuel filter
- Fuel pipes
- Throttle cable
- Accelerator pedal
- Fuel pump and sender unit
- Fuel tank
SPECIFICATIONS, TORQUE
- Torque values
SERVICE TOOLS
- Fuel system
19 - FUEL SYSTEM - SFI
DESCRIPTION AND OPERATION
- Engine management system
- Engine management system component location - pre advanced evaps
- Engine management system component location - advanced evaps
- Description and operation - advanced evaps
ADJUSTMENT
- Engine tuning
REPAIR
- Camshaft position sensor (cmp sensor)
- Engine coolant temperature sensor (ect sensor)
- Crankshaft position sensor (ckp sensor)
- Fuel system - depressurise
- Engine control module (ecm)
- Mass air flow sensor (maf sensor)
- Fuel rail and injectors
- Fuel temperature sensor
- Ignition coils
- Intake air temperature sensor (iat sensor)
- Throttle position sensor (tp sensor)
- Knock sensor
- Fuel pressure regulator
- Idle air control (iac)
- Plenum chamber
- Relay module - pre advanced evaps
- Relay module - advanced evaps
- Fuel filter - advanced evaps
- Fuel pump and gauge sender unit - advanced evaps
- Fuel system - depressurise - advanced evaps
- Fuel tank - advanced evaps
- Fuel tank - draining - advanced evaps
- Fuel filler neck - advanced evaps
- Fuel tank filler cap - advanced evaps
- Anti-trickle fill valve - advanced evaps
19 - FUEL SYSTEM - Mpi
DESCRIPTION AND OPERATION
- Description
- Mems components & location on vehicle
- Mems components & location on engine
- System operation
ADJUSTMENT
- Throttle cable
REPAIR
- Knock sensor
- Ignition coils
- Coolant temperature sensor
- Crankshaft sensor
- Fuel temperature sensor
- Mems engine control module (ecm)
- Charcoal canister
- Throttle cable
- Throttle potentiometer
- Intake air temperature sensor
- Purge control valve
- Fuel rail and injectors
- Throttle housing
- Fuel pressure regulator
- Oxygen sensor
- Air cleaner
19 - FUEL SYSTEM - Cruise Control
DESCRIPTION AND OPERATION
- Cruise control component locations - tdi auto edc

- Cruise control system - v8i/tdi auto edc
FAULT DIAGNOSIS
- Road test
- Electrical tests
- Cable setting - tdi automatic models
REPAIR
- Brake and clutch pedal switches/vent valves
- Engagement (on/off) switch
- Cruise control switch

- Rotary coupler
- Actuator - v8i
- Actuator link-setting - v8i
- Vacuum pump - tdi
- Cruise control ecu - v8i
- Speed trip ecu - manual v8i
- Vehicle speed sensor
- Neutral lock out relay
- Actuator - tdi
- Cruise control ecu - tdi

26 - COOLING SYSTEM - Tdi
DESCRIPTION AND OPERATION
- Engine cooling
- Coolant circulation
- Viscous fan
FAULT DIAGNOSIS
- Engine overheating
- Engine runs cold
ADJUSTMENT
- Coolant
REPAIR
- Viscous coupling, fan blades, pulley and fan cowl
- Thermostat
- Water pump
- Radiator
26 - COOLING SYSTEM - V8i
DESCRIPTION AND OPERATION
- Engine cooling
- Coolant circulation
- Viscous fan
FAULT DIAGNOSIS
- Engine overheating
- Engine runs cold
ADJUSTMENT
- Coolant requirements
- Coolant
REPAIR
- Expansion tank
- Viscous coupling, fan blades, pulley and cowl
- Thermostat
- Radiator
- Water pump
SPECIFICATIONS, TORQUE
- Torque values
26 - COOLING SYSTEM - Mpi
REPAIR
- Coolant pump
- Radiator
- Thermostatic sensor
- Thermostat
30 - MANIFOLD AND EXHAUST SYSTEM
DESCRIPTION AND OPERATION
- Catalytic converters - v8i
REPAIR
- Exhaust system complete
- Exhaust manifold - v8i
- Manifold and exhaust system - tdi
- Exhaust manifold - tdi
- Inlet manifold gasket - mpi
- Exhaust manifold gasket - mpi
- Manifold chamber gasket - mpi
SPECIFICATIONS, TORQUE
- Torque values
33 - CLUTCH
DESCRIPTION AND OPERATION
- Description
- Operation
FAULT DIAGNOSIS
- Clutch assembly conditions
- Clutch spin - drag
- Clutch slip
- Clutch judder - fierce
- Fault/symptom chart
- Clutch noise - mechanical faults
- Hydraulic faults
REPAIR
- Clutch assembly
- Bleed hydraulic system
- Master cylinder
- Release bearing assembly
- Slave cylinder
- Renewing hydraulic damper - tdi
OVERHAUL
- Master cylinder
- Slave cylinder
SPECIFICATIONS, TORQUE
- Torque values
37 - MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION
- Manual transmission
FAULT DIAGNOSIS
- Manual gearbox
REPAIR
- R380 manual gearbox
SPECIFICATIONS, TORQUE
- Torque values
SERVICE TOOLS
- Adapter plate gearbox
41 - TRANSFER GEARBOX
DESCRIPTION AND OPERATION
- Lt230t transfer box
- Rear output drive assembly
- Differential and output drive assembly
- Intermediate gear and power take off assembly
- Transfer gear selector components
FAULT DIAGNOSIS
- Lt230t transfer box - oil leaks
REPAIR
- Lt230t transfer gearbox
- Shiftlock solenoid/neutral switch
SPECIFICATIONS, TORQUE
- Torque values
- Lt230t transfer gearbox data
- Joint sealant
SERVICE TOOLS
- Lt230t transfer gearbox
44 - AUTOMATIC GEARBOX - ZF
DESCRIPTION AND OPERATION
- Description
FAULT DIAGNOSIS
- Zf automatic gearbox
- Road test procedure
- Automatic gearbox assembly illustrated
- Fault symptoms
ADJUSTMENT
- Kickdown cable adjustment
REPAIR
- Lt230t transfer gearbox with automatic gearbox assembly - v8
- Lt230t transfer gearbox with automatic gearbox assembly - tdi
- Inhibitor switch
- Selector shaft oil seal
- Oil sump
- Oil screen
- Control unit
- Kickdown cable
- Extension housing
- Governor assembly
- Governor hub
- Parking pawl mechanism
- Replacing torque converter
- Eliminating leaks on pump housing
- Eliminating leaks between gearbox housing and intermediate plate
- Replacing pump
- Gear selector-interlock
SPECIFICATIONS, TORQUE
- Torque values
- Zf gearbox data
SERVICE TOOLS
- Automatic gearbox holding fixture
- Automatic gearbox
47 - PROPELLER SHAFTS
DESCRIPTION AND OPERATION
- Propeller shaft alignment
FAULT DIAGNOSIS
- Vibration harshness
REPAIR
- Front propeller shaft
- Spider assembly components
- Rear propeller shaft
- Flexible coupling
51 - REAR AXLE AND FINAL DRIVE
DESCRIPTION AND OPERATION
- Description
FAULT DIAGNOSIS
- Fault diagnosis
REPAIR
- Rear axle
- Rear brake disc non abs
- Rear brake discs abs
- Rear hub assembly
OVERHAUL
- Axle differential assembly
- Crown wheel/pinion backlash adjustment
- Rear hub assembly
- Rear stub axle
SPECIFICATIONS, TORQUE
- Axle differential data
- Rear hub
- Torque values
SERVICE TOOLS
- Axle differential
- Rear hub
54 - FRONT AXLE AND FINAL DRIVE
DESCRIPTION AND OPERATION
- Description
FAULT DIAGNOSIS
- Fault diagnosis
REPAIR
- Front axle assembly
- Front brake discs
- Front hub assembly
OVERHAUL
- Front differential
- Front hub
- Front stub axle, constant velocity joint and swivel pin housing non abs
- Front stub axle, constant velocity joint and swivel pin housing abs
SPECIFICATIONS, TORQUE
- Torque values
- Front hub and swivel data
SERVICE TOOLS
- Front hub
57 - STEERING
DESCRIPTION AND OPERATION
- Description
FAULT DIAGNOSIS
- Insufficient power assistance
- Power steering system - test
- Steering damper
- Steering faults
- Steering stability and veer under braking
GENERAL STEERING
- 2. Steering veer
- 3. Veer under braking
- 4. Directional stability
- Power steering fluid leaks
- Power steering system - excessive noise
- Power steering system - grunt
- Visual and safety checks
- Road test procedure
- Stiff steering checklist
- Visual check and basic adjustments
- Steering linkage inspect
ADJUSTMENT
- Power steering box
- Centralise steering box
- Steering lock stops
- Front wheel alignment
- Power steering pump drive belt
REPAIR
- Power steering fluid pipes
- Power steering box
- Power steering system - bleed
- Power steering fluid reservoir
- Power steering pump drive belt
- Power steering pump - v8i
- Power steering pump - tdi
- Lower steering shaft and universal joints
- Steering column shroud
- Steering wheel
- Upper steering column
- Steering column lock assembly
- Drop arm
- Steering damper
- Track rod and linkage
- Drag link and drag link ends
OVERHAUL
- Power steering box
SPECIFICATIONS, TORQUE
- Steering pump
- Torque values
SERVICE TOOLS
- Power steering box
60 - FRONT SUSPENSION
DESCRIPTION AND OPERATION
- Introduction
- Axle location
REPAIR
- Self locking nuts
- Panhard rod
- Radius arm
- Front shock absorber
- Front road spring
- Bump stop
- Anti-roll[sway] bar assembly front
- Anti-roll[sway] bar ball joint links
SPECIFICATIONS, TORQUE
- Torque values
64 - REAR SUSPENSION
DESCRIPTION AND OPERATION
- Axle location
REPAIR
- Rear road spring
- Rear shock absorber
- Bump stop
- Suspension link upper
- Suspension link lower
- Anti-roll[sway] bar assembly rear
- Anti-roll[sway] bar ball joint links
SPECIFICATIONS, TORQUE
- Torque values
70 - BRAKES
DESCRIPTION AND OPERATION
- Brakes
- Brake system non abs

- Abs components
- Anti-lock brake system - abs
- Brake pipe layout abs
- Brake pipe layout non abs
- Brake servo unit
FAULT DIAGNOSIS
- Abs fault diagnosis
- Fault diagnosis procedure
- Relays and fuses abs
- Abs fault and remedy chart
REPAIR
- General brake service practice
- Fluid level check / top up
- Brake system bleed
- Master cylinder abs
- Master cylinder non abs
- Master cylinder assembly non abs
- Servo assembly
- Front brake pads
- Rear brake pads
- Front brake caliper assembly
- Front brake calipers
- Rear brake calipers
- Parking brake adjust
- Rear brake caliper assembly
- Sensors - front
- Sensor rings
- Sensors - rear
- Stop light switch abs
- Stop light switch - non abs
- Brake components abs
- Modulator unit
- Electronic control unit abs
SPECIFICATIONS, TORQUE
- Torque values
SERVICE TOOLS
- Brake service tools
74 - WHEELS AND TYRES
DESCRIPTION AND OPERATION
- Types of wheel rims and tyres
FAULT DIAGNOSIS
- Tyre wear chart
- Fault - symptoms
REPAIR
- General information
- Tyre inspection
- Wheels inspection
- Valves inspection
- Tyre pressures
- Wheel balancing
- Tyre fitting
- Wheels
- Wheel stud
75 - SUPPLEMENTARY RESTRAINT SYSTEM
DESCRIPTION AND OPERATION
- System components
- Operation
- General precautions
- Vehicle recovery
- Airbag storage
FAULT DIAGNOSIS
- Crash sensor inspection - distributed srs
- Airbag harness
- Warning labels
REPAIR
- System precautions
- Driver’s airbag module
- Steering wheel
- Rotary coupler
- Rotary coupler centralise
- Column switch assembly
- Passenger’s airbag module
- Crash sensor - distributed srs
- Airbag diagnostic control unit - distributed srs
- Srs warning light bulbs
- Airbag harness
- Airbag manual deployment
- Airbag diagnostic control unit - sps srs
DATA, TORQUE & TOOLS
- Torque values
76 - CHASSIS AND BODY
REPAIR
- Front door
- Front door trim panel
- Front door glass and regulator
- Front door lock, outside and inside door release handles
- Adjustment-front door lock and handle assembly
- Rear side doors
- Rear side door - trim panel
- Rear side door lock, inside and outside release handles
- Adjustment-rear side door lock and handle
- Rear side door glass and regulator
- Rear door
- Rear door trim panel
- Rear door lock and inner and outer release handles
- Rear door check stay
- Rear compartment lower trim panels
- Alpine light trim casing
- Front bodyside trim casing
- Headlining
- ’D’ post trim casing
- Body side opening windows
- Body side window hinges
- Rear side fixed windows
- Rear door glass
- Front folding seats 3 door vehicles
- Seat base
- Seat base torsion bars
- Front seats 5 door vehicles
- Front seat covers
- Rear passenger seat
- Rear seat squab
- Rear seat squab cover
- Rear seat cushion cover
- Split rear seat locking mechanism
- Rear fold down seats
- Front seat belts
- Rear outer seats belt
- Rear centre seat belt
- Rear fold down seat belts
- Rear grab handle
- Wings [fenders]
- Sill finisher
- Bonnet [hood]
- Air intake plenum cowl
- Sunroof electric/manual
- Sunroof glass front and rear
- Sunroof assembly - electrical, front and rear
- Sunroof electric motors
- Sunroof electric control unit
- Sunroof assembly - manual, front and rear
- Sunroof regulator manual
- Sun blind assembly
- Centre console
- Drinks tray
- Dash panel central louvre panel
- Dash panel assembly
- Windscreen glass
- Front seat - electric
- Front seat - manual - 5 door (96 models)
- Interior mirror (96 models)
- Sun visor
- Wheel arch liner - front
- Mud flap - rear - lh
- Rear compartment lower trim panel - lh - with rear air conditioning fitted
- ’E’ post trim casing - rh
- ’E’ post trim casing - lh - with rear air conditioning fitted
- Alpine light trim casing - lh - with rear air conditioning fitted
- Rear door upper trim panel - with rear air conditioning fitted
- ’D’ post trim casing - lh - with rear air conditioning fitted - 5 door
- Switch pack - dash panel central louvre panel
- Grab handle
- Grab handle - tail door - with rear air conditioning fitted
- Headlining - with sun roof and rear air conditioning fitted - 5 door
- Ash tray - dash panel central louvre panel
- Headlining stowage panel - front - with sun roof fitted
- Rear fold down seat belts - lh with rear air conditioning fitted
- Front seat belts - 5 door (96 models)
80 - HEATING AND VENTILATION
DESCRIPTION AND OPERATION
- Heating and ventilation unit
FAULT DIAGNOSIS
- Heater output
REPAIR
- Heater blower switch and illumination bulb
- Heater control unit
- Control cables
- Resistor unit
- Water valve
- Vacuum switch - water valve
- Recirculation switch
- Recirculation flap solenoid
- Blower motor unit - heater and air conditioning
- Blower motor
- Heater matrix
SPECIFICATIONS, TORQUE
- Torque values
82 - AIR CONDITIONING
DESCRIPTION AND OPERATION
- Air conditioning system components
- Schematic layout of the air conditioning system
- Air conditioning system operation
- Air conditioning control system
FAULT DIAGNOSIS
- Air conditioning faults
- Refrigeration system faults
- Heater and air conditioning - circuit diagrams
ADJUSTMENT
- General precautions
- Remedial actions
- Servicing precautions
- Refrigerant recovery recycling recharging
- Leak test system
- Air conditioning system - performance test
- System test
- Compressor drive belt
REPAIR
- Precautions in handling refrigerant lines
- Periodic maintenance
- Receiver drier
- Air conditioning switch
- Dual pressure switch
- Compressor
- Condenser
- Condenser fans and motors
- Heater and cooler unit
- Evaporator and expansion valve
- Thermostat
- Evaporator/blower motor assembly - rear
- Blower motor - rear
- Electronic control unit - rear air conditioning
- Solenoid - high pressure pipe control valve - rear
- Control valve - high pressure pipe - rear
- Expansion valve - rear
- Evaporator - rear
- Thermostat - rear
- Harness - evaporator/blower motor assembly - rear
- Rear air conditioning switch
- Rear blower motor switch
- Bulb - rear air conditioning switch
- Bulb - rear air conditioning switch pack
- Air duct - centre - with rear air conditioning fitted - 5 door
- Upper tail door air duct
- Alpine light duct
- Evaporator to alpine light duct
- Blower motor resistor - rear
SPECIFICATIONS, TORQUE
- Torque values
- Air conditioning charge data
84 - WIPERS AND WASHERS
DESCRIPTION AND OPERATION
- Windscreen wiper and washer operation
- Rear window wiper and washer operation
FAULT DIAGNOSIS
- Wiper motor checking
REPAIR
- Washer reservoir
- Washer pump - windscreen, rear window or power wash
- Windscreen washer jets
- Windscreen washer tubes
- Wiper arms - windscreen
- Wiper arm - rear window
- Wiper blades
- Rear window washer jet
- Windscreen wiper motor and linkage
- Rear door wiper motor
- Headlamp power wash jet
- Power wash hose
86 - ELECTRICAL
DESCRIPTION AND OPERATION
- Electrical equipment
- Generator
- Anti-theft system function
- Built in test procedure
- Anti theft alarm system
- Alarm components
- Alarm component locations (96 models)
- Anti-theft alarm description (96 models)
- Anti-theft alarm operation (96 models)
- Anti-theft alarm built-in test (96 models)
FAULT DIAGNOSIS
- General information
- Generator testing
- Lucas constant energy ignition system - v8i
ADJUSTMENT
- Ignition timing
REPAIR
- Fuse box - interior
- Fuse box - engine compartment
- Battery
- Distributor-lucas 35 dlm8 - v8i
- Electronic ignition - v8i
- Ignition coil
- Distributor - v8i
- Automatic gear selector-panel bulb
- Start inhibit / reverse light switch
- Park brake warning switch
- Gear selector-interlock
- Handset initialisation
- Central door locking
- Front door actuator unit
- Exterior driving mirrors
- Rear door actuator
- Rear side door actuator units
- Bulb replacement
- Headlight
- Sidelight bulb
- Front direction indicators
- Rear light unit
- Stop, reversing, fog guard bulbs
- Rear lights, bumper mounted
- Direction indicator, tail light bulbs.
- Number plate lights
- Door edge light
- High mounted stop light
- Stop light bulb
- Interior light
- Rear loadspace light
- Side repeater light
- Bumper mounted side light
- Radio
- Speakers
- Speakers and amplifier pack, rear door
- Starter motor - mpi
- Trailer socket
- Window lift motor - front
- Window lift motor - rear
- Instrument panel finisher
- Instrument binnacle
- Instrument illumination and warning light bulbs
- Main printed circuit
- Circuit board
- Instrument binnacle components
- Printed circuit and warning lights
- Instrument cowl and illumination board
- Speedometer
- Tachometer
- Coolant temperature and fuel gauges
- Speedometer transducer
- Reverse light switch
- Heater/ventilation and air conditioning control panel bulb
- Cigar lighter and bulb
- Oil pressure warning switch - v8i
- Instrument illumination electronic dimmer/rheostat
- Window lift/heated seat cushion switches and bulbs
- Coolant temperature transmitter - v8i
- Heated front screen
- Fog lamp - front
- Anti-theft alarm ecu (96 models)
- Handset (96 models)
- Passive coil (96 models)
- Bonnet switch
- Ultrasonic sensor
- Anti-theft alarm indicator light (96 models)
- Engine immobilisation warning light (96 models)
- Sounder (96 models)
- Switch - electric seat
- Starter motor - 4.0 v8
- Starter motor heat shield - 4.0 v8
- Bulb - front fog lamp
- Clock
- Rear speaker
- Digital diesel shut-off valve (dds) - 97 my
- Antenna amplifier - 97 my
OVERHAUL
- Distributor-lucas 35dlm8
- Distributor cap
- Rotor arm
- Insulation cover (flash shield)
- Vacuum unit
- Amplifier module

- Pick-up and base plate assembly
SPECIFICATIONS, TORQUE
- Torque values
300 TDI DIESEL ENGINE OVERHAUL MANUAL
300 TDi Diesel Engine Overhaul Manual
INTRODUCTION
- Introduction
- Repairs and replacements
- Specification
DESCRIPTION AND OPERATION
- Cylinder block, pistons and camshaft
- Crankshaft, sump and oil pump
- Rocker shaft and cover
- Cylinder head
- Timing belt rear cover and gears
- Timing belt and front cover
- Operation
OVERHAUL
TIMING BELT, TENSIONER AND GEARS
- Timing belt - remove
- Timing belt tensioner and timing gears - remove
- Timing belt tensioner and gears - refit
- Timing belt - refit and adjust tension
ROCKER SHAFT
- Rocker shaft - dismantling
- Rocker arm bushes - replace
- Rocker shaft - assembling
- Rocker shaft - refit
VALVE CLEARANCES - ADJUST
CYLINDER HEAD
- Valves and springs - remove
- Cylinder head - inspection
- Valve springs - inspection
- Valves and guides - inspection
- Valve guides - renew
- Valve seat inserts - refacing
- Valve seat inserts - renew
- Lapping-in valves
- Valve head stand down - checking
- Valves and springs - refit
- Cylinder head gasket selection
- Cylinder head - refit
TIMING BELT REAR COVER AND OIL PUMP
- Timing belt rear cover - remove
- Oil pump and oil pressure relief valve - remove
- Oil pump and oil pressure relief valve - refit
- Timing belt rear cover - refit
OIL FILTER HEAD
- Thermostatic valve - remove
- Thermostatic valve - refit
- Oil filter head - refit
FUEL INJECTION PUMP
FUEL LIFT PUMP
FUEL INJECTORS
GLOW PLUGS
BRAKE SERVO VACUUM PUMP
SUMP, OIL PICK-UP AND DRAIN PIPES
- Sump - remove
- Oil pick-up and drain pipes - remove
- Oil pick-up and drain pipes - refit

- Sump - refit
FLYWHEEL AND STARTER RING GEAR
- Flywheel - remove
- Starter ring gear - replace
- Flywheel - refit
DRIVE PLATE
- Drive plate - refit
FLYWHEEL/DRIVE PLATE HOUSING
CRANKSHAFT, CAMSHAFT, PISTONS AND CYLINDER BLOCK
- Crankshaft rear oil seal - remove
- Big-end bearings - remove
- Crankshaft and main bearings - remove
- Crankshaft - inspection
- Crankshaft - regrinding
- Main bearing caps and saddles - inspection
- Main bearing clearance - checking
- Crankshaft end-float - checking
- Big-end bearing clearance - checking
- Crankshaft, main and big-end bearings - refit
- Crankshaft rear oil seal - refit
- Pistons and connecting rods - remove
- Pistons and connecting rods - inspection
- Piston rings - checking
- Oil jet tubes - inspection
- Pistons and connecting rods - refit
- Oil jet tubes - refit
- Camshaft - remove
- Camshaft, bearings and cam followers - inspection
- Camshaft - refit and check end-float
- Cylinder block - inspection
DATA, TORQUE & TOOLS
- Engine data
- Torque figures
- Tool numbers