2002-2006 Land Rover Range Rover L322 Service & Repair Manual
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CONTENTS
1: General Information
100: Service Information
100-00: General Information
Description and Operation
About This Manual
How To Use This Manual
Important Safety Instructions
Standard Workshop Practices
General Service Information
Health and Safety Precautions
Solvents, Sealants and Adhesives
Special Tool Glossary
Road/Roller Testing
DTC: Module Name: Bluetooth Module
100-01: Identification Codes
Description and Operation
Identification Codes
100-02: Jacking and Lifting
Description and Operation
Jacking
Lifting
Vehicle Recovery
100-03: Maintenance Schedules
Description and Operation
Maintenance Schedules - Gasoline Engines
Maintenance Schedules - Diesel Engines
2: Chassis
204: Suspension
204-00: Suspension System - General Information
Specification
General Procedures
Front Camber, Caster and Toe Adjustment
Four-Wheel Alignment (57.65.04)
204-01: Front Suspension
Specification
Description and Operation
Front Suspension
Removal and Installation
Front Lower Arm (60.35.02) (60.35.03)
Front Lower Arm Bushing (60.35.26)
Front Shock Absorber (60.30.02)
Front Stabilizer Bar (60.10.01)
Front Stabilizer Bar Link (60.10.02/60.10.04)
Rear Lower Arm (60.40.09)
Rear Lower Arm Ball Joint (60.15.04)
Rear Lower Arm Bushing (60.35.26)
Shock Absorber and Spring Assembly (60.30.25/99)
Front Wheel Bearing and Wheel Hub (60.25.14)
Wheel Knuckle (60.25.01)
Disassembly and Assembly
Shock Absorber and Spring Assembly
204-02: Rear Suspension
Specification
Description and Operation
Rear Suspension
Removal and Installation
Lower Arm (64.35.54)
Lower Arm Ball Joint (64.15.08)
Lower Arm Bushing (64.35.15)
Lower Arm Rear Bushing (64.35.15)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Toe Link (64.35.70)
Upper Arm (64.35.60) - TDV8 3.6L Diesel
Upper Arm (64.35.60) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Upper Arm Ball Joint (64.15.07)
Upper Arm Bushing (64.35.22) - TDV8 3.6L Diesel
Upper Arm Bushing (64.35.22) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Upper Arm Front Bushing (64.35.20)
Upper Arm Rear Bushing (64.35.21)
Wheel Bearing and Wheel Hub (64.15.14)
Wheel Knuckle (64.35.10)
204-04: Wheels and Tires
Description and Operation
Wheels and Tires
Diagnosis and Testing
Wheels and Tires
Tire Pressure Monitoring System (TPMS)
Removal and Installation
Tire Low Pressure Sensor (74.10.05)
Tire Pressure Monitoring System (TPMS) Front Antenna (86.53.16)
Tire Pressure Monitoring System (TPMS) Module (86.54.05)
Tire Pressure Monitoring System (TPMS) Rear Antenna (86.53.17)
Wheel and Tire (60.25.06)
204-05: Vehicle Dynamic Suspension
Specification
Description and Operation
Vehicle Dynamic Suspension
General Procedures
Air Suspension System Depressurize and Pressurize (60.50.38)
Ride Height Adjustments (60.90.03)
Removal and Installation
Air Spring Solenoid Valve
Air Suspension Air Filter (64.50.12)
Air Suspension Compressor (60.50.10)
Air Suspension Compressor Drier (60.50.09)
Air Suspension Control Module (60.50.04)
Air Suspension Front Solenoid Valve Block (60.50.11)
Air Suspension Muffler (64.50.01)
Air Suspension Rear Solenoid Valve Block (64.50.11)
Air Suspension Reservoir (60.50.03)
Air Suspension Reservoir Solenoid Valve Block (60.50.05)
Air Suspension Solenoid Valve Block (60.50.11)
Air Suspension Switch
Fill Solenoid Valve
Front Air Shock Absorber (60.30.02.45)
Front Air Spring (60.21.01)
Front Vertical Accelerometer
Rear Air Shock Absorber (64.30.02.45)
Rear Air Spring (64.21.01)
Suspension Height Sensor (60.36.01)
204-06: Ride and Handling Optimization
Specification
Description and Operation
Ride and Handling Optimization
Diagnosis and Testing
Ride and Handling Optimization
Removal and Installation
Ride and Handling Optimization Switch (86.65.11)
205: Driveline
205-00: Driveline System - General Information
Specification
205-01: Driveshaft
Specification
Description and Operation
Driveshaft
Universal Joints
Removal and Installation
Front Driveshaft (47.15.02) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Front Driveshaft (47.15.02) - TDV8 3.6L Diesel
Rear Driveshaft (47.15.03) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
Rear Driveshaft (47.15.03) - TDV8 3.6L Diesel
Disassembly and Assembly
Driveshaft Universal Joint (47.15.06)
Driveshaft Center Bearing
Driveshaft Slip Yoke
Driveshaft Alignment Bushing
205-02: Rear Drive Axle/Differential
Specification
Description and Operation
Rear Drive Axle and Differential
General Procedures
Differential Draining and Filling (51.25.02)
In-Vehicle Repair
Axle Housing Bushing (51.15.43) - 4.4L NA V8 - AJ41/4.2L SC V8 -
AJV8
Axle Housing Bushing (51.15.43) - TDV8 3.6L Diesel
Axle Shaft Seal
Differential Locking Module (51.30.01)
Differential Locking Motor (51.15.03)
Drive Pinion Seal (51.20.01)
Rear Axle Oil Temperature Sensor (51.15.06)
Removal and Installation
Axle Assembly (51.15.01)
Differential Support Insulator - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
205-03: Front Drive Axle/Differential
Specification
Description and Operation
Front Drive Axle and Differential
General Procedures
Differential Draining and Filling (54.15.02)
In-Vehicle Repair
Drive Pinion Seal (54.10.20)
Removal and Installation
Differential Breather Tube
205-04: Front Drive Halfshafts
Specification
Description and Operation
Front Drive Halfshafts
Halfshaft Joint
Removal and Installation
Front Halfshaft LH (47.10.01)
Front Halfshaft RH (47.10.02)
Halfshaft Bearing (47.10.41)
Halfshaft Seal LH (54.10.18)
Halfshaft Seal RH (54.10.21)
205-05: Rear Drive Halfshafts
Specification
Description and Operation
Rear Drive Halfshafts
Removal and Installation
Rear Halfshaft (47.11.01)
Outer Constant Velocity (CV) Joint Boot (47.11.03)
Inner Constant Velocity (CV) Joint Boot (47.11.16)
Halfshaft Bearing (51.10.29)
206: Brake System
206-00: Brake System - General Information
Specification
General Procedures
Front Brake Disc Runout Check (70.12.15.01)
Rear Brake Disc Runout Check (70.12.36.01)
Brake System Bleeding (70.25.02) - Vehicles With: High Performance
Brakes
Brake System Bleeding (70.25.02) - Vehicles With: Standard Brakes
Brake System Pressure Bleeding (70.25.02)
Component Bleeding - Vehicles With: High Performance Brakes
Component Bleeding - Vehicles With: Standard Brakes
206-03: Front Disc Brake
Specification
Description and Operation
Front Disc Brake
Removal and Installation
Brake Disc (70.12.10) - Vehicles With: Standard Brakes
Brake Disc (70.12.10) - Vehicles With: High Performance Brakes
Brake Pads (70.40.02) - Vehicles With: Standard Brakes
Brake Pads (70.40.02) - Vehicles With: High Performance Brakes
Brake Caliper (70.55.24) - Vehicles With: Standard Brakes
Brake Caliper (70.55.24) - Vehicles With: High Performance Brakes
206-04: Rear Disc Brake
Specification
Description and Operation
Rear Disc Brake
Removal and Installation
Brake Disc (70.12.33)
Brake Pads (70.40.03)
Brake Caliper (70.55.25)
Disassembly and Assembly
Brake Caliper
206-05: Parking Brake and Actuation
Specification
Description and Operation
Parking Brake
General Procedures
Parking Brake Shoe and Lining Adjustment (70.40.11)
Parking Brake Shoes Bedding-In (70.40.12)
Removal and Installation
Parking Brake Actuator (70.35.48)
Parking Brake Cable LH
Parking Brake Cable RH
Parking Brake Shoes (70.40.09)
Parking Brake Switch (70.35.46)
206-06: Hydraulic Brake Actuation
Description and Operation
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.25.31) - Vehicles With: Standard Brakes
Brake Fluid Reservoir (70.25.31) - Vehicles With: High Performance
Brakes
Brake Master Cylinder (70.30.08) - Vehicles With: Standard Brakes
Brake Master Cylinder (70.30.08) - Vehicles With: High Performance
Brakes
Brake Pedal (70.35.01) - Vehicles With: 6-Speed Automatic
Transmission - 6HP26
Brake Pedal and Bracket (70.35.03) - Vehicles With: 6-Speed Automatic
Transmission - 6HP26
Brake Pedal Motor
206-07: Power Brake Actuation
Specification
Description and Operation
Brake Booster
Removal and Installation
Brake Booster (70.50.01) - Vehicles With: Standard Brakes
Brake Booster (70.50.01) - Vehicles With: High Performance Brakes
Brake Vacuum Pump (70.50.19) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
206-09A: Anti-Lock Control - Traction Control
Specification
Description and Operation
Anti-Lock Control - Traction Control
Diagnosis and Testing
Anti-Lock Control - Traction Control - VIN Range: 263535->ONWARDS
Removal and Installation
Anti-Lock Brake System (ABS) Module (70.25.12) - Vehicles With:
Standard Brakes
Anti-Lock Brake System (ABS) Module (70.25.12) - Vehicles With: High
Performance Brakes
Front Wheel Speed Sensor (70.65.30)
Rear Wheel Speed Sensor (70.65.31)
206-09B: Anti-Lock Control - Stability Assist
Specification
Removal and Installation
Yaw Rate Sensor (70.70.35)
211: Steering System
211-00: Steering System - General Information
Specification
General Procedures
Power Steering System Filling and Bleeding
Power Steering System Flushing
211-02: Power Steering
Specification
Description and Operation
Power Steering
General Procedures
Removal and Installation
Power Steering Control Valve Actuator (57.10.05)
Power Steering Fluid Cooler (57.15.11) - 4.2L SC V8 - AJV8
Power Steering Pump (57.20.14) - 4.2L SC V8 - AJV8
Steering Angle Sensor (57.40.02)
211-03: Steering Linkage
Specification
Removal and Installation
Steering Gear Boot (57.10.29)
Tie Rod End (57.55.07) - 3-Door
Tie Rod End (57.55.07)
211-04: Steering Column
Specification
Description and Operation
Steering Column
Removal and Installation
Ignition Switch Lock Cylinder
Steering Column (57.40.01) (57.40.06)
Steering Column Shaft (57.40.22)
Steering Column Tilt Motor
Steering Column Telescopic Motor
Steering Wheel (57.61.01)
Tilt/Telescopic Motors
211-05: Steering Column Switches
Specification
Removal and Installation
Hazard Flasher Switch (86.65.50)
Ignition Switch (86.65.02)
Steering Column Control Switch
Steering Column Multifunction Switch LH (86.65.55)
3: Powertrain
303: Engine
303-00: Engine System - General Information
Specification
Diagnosis and Testing
Engine (12.90.09.01) - 4.4L NA V8 - AJ41/4.2L SC V8 - AJV8
General Procedures
Bearing Inspection
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Crankshaft Main Bearing Journal Clearance
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter
303-01A: Engine - 4.2L SC V8 - AJV8
Specification
Description and Operation
Engine
General Procedures
Valve Clearance Check (12.29.73)
Valve Clearance Adjustment (12.29.76)
Engine Oil Draining and Filling (12.60.05)
In-Vehicle Repair
Camshafts RH (12.13.20)
Camshafts LH (12.13.21)
Crankshaft Pulley (12.21.01)
Crankshaft Front Seal (12.21.14)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH (12.29.04)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
Engine Mount LH (12.45.11)
Engine Mount RH (12.45.12)
Flexplate (12.53.13)
Oil Level Indicator and Tube (12.60.09)
Auxiliary Oil Cooler Thermostat (12.60.17)
Oil Pump (12.60.26)
Oil Filter Housing (12.60.27)
Oil Pan (12.60.44)
Oil Cooler (12.60.68)
Engine Front Cover (12.65.01)
Exhaust Manifold LH (30.15.10)
Exhaust Manifold RH (30.15.11)
Auxiliary Oil Cooler
Removal and Installation
Crankshaft Main Bearing Carrier (12.21.42)
Removal
Engine (12.41.01.99)
Disassembly
Engine
Assembly
Engine
Installation
Engine (12.41.01.99)
303-03A: Engine Cooling - 4.2L SC V8 - AJV8
Specification
Description and Operation
Engine Cooling
General Procedures
Cooling System Draining, Filling and Bleeding (26.10.01)
Cooling System Pressure Test
Removal and Installation
Coolant Expansion Tank (26.15.01)
Cooling Fan (26.25.19)
Radiator (26.40.01)
Thermostat (26.45.01)
Coolant Pump (26.50.01)
Coolant Manifold (26.30.64)
303-03D: Supercharger Cooling
Specification
Description and Operation
Supercharger Cooling
General Procedures
Supercharger Cooling System Draining, Filling and Bleeding (19.46.01)
Removal and Installation
Coolant Pump (26.50.26)
Radiator (26.40.10)
Intercooler Hose
303-04A: Fuel Charging and Controls - 4.2L SC V8 - AJV8
Specification
Description and Operation
Fuel Charging and Controls
Removal and Installation
Fuel Rail (19.60.04)
Fuel Injector (19.60.10)
Throttle Body Gasket
303-04D: Fuel Charging and Controls - Turbocharger
Description and Operation
Turbocharger
Diagnosis and Testing
Turbocharger
Removal and Installation
Turbocharger LH
Turbocharger RH
Turbocharger Actuator Rod
303-05A: Accessory Drive - 4.2L SC V8 - AJV8
Specification
Description and Operation
Accessory Drive
Removal and Installation
Cooling Fan Belt (26.25.01)
Cooling Fan Belt Tensioner (26.25.02)
Accessory Drive Belt (86.10.03)
Accessory Drive Belt Tensioner (86.10.06)
Accessory Drive Belt Idler Pulley (86.10.23)
303-06A: Starting System - 4.2L SC V8 - AJV8
Specification
Description and Operation
Starting System
Removal and Installation
Starter Motor (86.60.01)
303-07A: Engine Ignition - 4.2L SC V8 - AJV8
Specification
Description and Operation
Engine Ignition
Removal and Installation
Spark Plugs (18.20.02)
Ignition Coil-On-Plug (18.20.44)
303-07C: Glow Plug System
Specification
Description and Operation
Glow Plug System
Diagnosis and Testing
Glow Plug System
Removal and Installation
Glow Plugs (19.60.31)
303-08B: Engine Emission Control - 4.2L SC V8 - AJV8
Description and Operation
Engine Emission Control
303-12A: Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8
Specification
Description and Operation
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner (19.10.01)
Air Cleaner Element (19.10.10)
Supercharger (19.46.15)
Supercharger Outlet Pipe (19.46.16)
Intake Air Resonator (19.70.03)
Charge Air Cooler LH (19.46.19)
Charge Air Cooler RH (19.46.18)
Throttle Body Elbow (19.22.43)
303-13A: Evaporative Emissions - 4.2L SC V8 - AJV8
Specification
Description and Operation
Evaporative Emissions
General Procedures
Evaporative Emission System Leak Test (17.90.02.01)
Removal and Installation
Evaporative Emission Canister Purge Valve (17.15.39)
Evaporative Emission Canister Vent Solenoid
Evaporative Emission Canister (17.15.13)
303-14A: Electronic Engine Controls - 4.2L SC V8 - AJV8
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Removal and Installation
Engine Oil Pressure (EOP) Sensor (12.60.50)
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The Land Rover Range Rover L322 Complete Workshop Service Repair Manual for the years 2002 to 2006 is a comprehensive resource for all your repair and service needs.
Whether you are a professional mechanic or a DIY enthusiast, this manual provides easy-to-follow step-by-step instructions and detailed images for servicing and repairs, allowing you to save on costly repairs.
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All models, engines, trim levels, and transmission types are covered in this high-quality manual, ensuring that every repair and service procedure is included from A to Z.
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Customer satisfaction is guaranteed, making this manual a reliable and convenient solution for your Land Rover Range Rover L322 repair and service needs.
