1994-2002 Land Rover Range Rover P38 Service & Repair Manual

Workshop Manual Werkplaatshandboek Manual d'Atelier Werkstatthandbuch Manuale d'Officina Manual de Taller Manual de Oficina

01 04 05 07 09 10 12 17 19 26 30 33 37 Workshop manual RANGE ROVER VOLUME 1 This manual covers vehicles from introduction 1995 01 INTRODUCTION 04 GENERAL SPECIFICATION DATA 05 ENGINE TUNING DATA 06 TORQUE VALUES 07 GENERAL FITTING REMINDERS 09 LUBRICANTS, FLUIDS AND CAPACITIES 10 MAINTENANCE 12 ENGINE BMW DIESEL 12 ENGINE LANDROVER V8 17 EMISSION CONTROL 19 FUEL SYSTEM BMW DIESEL 19 FUEL SYSTEM LANDROVER V8 19 CRUISE CONTROL 26 COOLING SYSTEM BMW DIESEL 26 COOLING SYSTEM LANDROVER V8 30 MANIFOLD AND EXHAUST SYSTEM 33 CLUTCH 37 MANUAL GEARBOX This manual supersedes: Workshop manual VDR100370 Body Repair Manual LRL0085 Published by Rover Technical Communication  1999 Rover Group Limited Publication part no. LRL0326ENG

01 - INTRODUCTION CONTENTS Page INFORMATION INTRODUCTION 1 .................................................................................................. DIMENSIONS 1 ....................................................................................................... REFERENCES 1 ..................................................................................................... REPAIRS AND REPLACEMENTS 1 ....................................................................... POISONOUS SUBSTANCES 1 .............................................................................. FUEL HANDLING PRECAUTIONS 2 ...................................................................... SYNTHETIC RUBBER 3 ......................................................................................... RECOMMENDED SEALANTS 3 ............................................................................. USED ENGINE OIL 3 .............................................................................................. ACCESSORIES AND CONVERSIONS 4 ............................................................... WHEELS AND TYRES 4 ......................................................................................... STEAM CLEANING 4 .............................................................................................. SPECIFICATION 4 .................................................................................................. SPECIAL SERVICE TOOLS 5 ................................................................................ COPYRIGHT 5 ........................................................................................................ JACKING 6 .............................................................................................................. HYDRAULIC VEHICLE RAMP (FOUR POST) 7 ..................................................... TWO POST VEHICLE RAMPS 7 ............................................................................ DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) 7 .................................................................................................................... JUMP STARTING 8 ................................................................................................ ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL 9 ............................. VEHICLE IDENTIFICATION NUMBER (VIN) 12 ..................................................... LOCATION OF IDENTIFICATION NUMBERS 13 ................................................... EMERGENCY TOWING 15 .................................................................................... TRANSPORTING THE VEHICLE BY TRAILER 16 ................................................

INTRODUCTION 1 INFORMATION INTRODUCTION This workshop manual covers the New Range Rover vehicle from introduction in 1995, and is designed to be used in conjunction with Electrical Troubleshooting Manual LRL0329 and Electrical Circuit Diagrams YVB101590 (2nd Edition). Amendments and additional pages will be issued to ensure that the manual covers latest models. Amendments and additions will be identified by the addition of a dated footer at the bottom of the page. This Workshop Manual is designed to assist skilled technicians in the efficient repair and maintenance of Range Rover vehicles. Individuals who undertake their own repairs should have some skill and training, and limit repairs to components which could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as steering, brakes, suspension or supplementary restraint system should be carried out by a Range Rover Dealer. Repairs to such items should NEVER be attempted by untrained individuals. WARNINGS, CAUTIONS and NOTES are given throughout this Manual in the following form: WARNING: Procedures which must be followed precisely to avoid the possibility of personal injury. CAUTION: This calls attention to procedures which must be followed to avoid damage to components. NOTE: This calls attention to methods which make a job easier or gives helpful information. DIMENSIONS The dimensions quoted are to design engineering specification. Alternative unit equivalents, shown in brackets following the dimensions, have been converted from the original specification. REFERENCES References to the left or right hand side in the manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the water pump end of the engine is referred to as the front. To reduce repetition, some operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned. REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that Range Rover parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories: Safety features embodied in the vehicle may be impaired if other than Range Rover parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the vehicle manufacturer’s specification. Torque spanner values given in the Workshop Manual must be strictly adhered to. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be replaced with a new one. Certain fasteners must not be re-used. These fasteners are specified in the Workshop Manual. POISONOUS SUBSTANCES Many liquids and other substances used are toxic and should not be consumed under any circumstances, and should be kept away from open wounds. These substances amongst others include anti-freeze, brake fluid, fuel, oil, windscreen washer additives, air conditioning refrigerant, lubricants and various adhesives.

01 INTRODUCTION NEW RANGE ROVER 2 INFORMATION FUEL HANDLING PRECAUTIONS The following information provides basic precautions which must be observed if fuel is to be handled safely. It also outlines other potential risks which must not be ignored. This information is issued for basic guidance only; in any case of doubt, seek advice from your local Fire Officer or Fire Department. Fuel vapour is highly flammable and in confined spaces is also very explosive and toxic. When fuel evaporates it produces 150 times its own volume in vapour, which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout a workshop by air currents, consequently, even a small spillage of fuel is very dangerous. Always have a fire extinguisher containing FOAM CO 2 GAS, or POWDER close at hand when handling fuel, or when dismantling fuel systems and in areas where fuel containers are stored. WARNING: lt is imperative that the battery is not disconnected during fuel system repairs as arcing at the battery terminal could ignite fuel vapour in the atmosphere. Always disconnect the vehicle battery BEFORE carrying out work on the fuel system. Whenever fuel is being handled, transferred or stored, or when fuel systems are being dismantled, all forms of ignition must be extinguished or removed, any leadlamps used must be flame proof and kept clear of spillage. No one should be permitted to repair components associated with fuel without first having had fuel system training. Hot fuel handling precautions WARNING: Before commencing any operation requiring fuel to be drained from the fuel tank, the following procedure must be adhered to: 1. Allow sufficient time for the fuel to cool, thus avoiding contact with hot fuels. 2. Vent the system by removing the fuel filler cap in a well ventilated area. Refit the filler cap until the commencement of fuel drainage. Fuel transfer WARNING: Fuel must not be extracted or drained from any vehicle while it is standing over a pit. The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved transfer tank must be used according to the transfer tank manufacturer’s instructions and local regulations, including attention to grounding of tanks. Fuel tank removal A FUEL VAPOUR warning label must be attached to the fuel tank upon removal from the vehicle. Fuel tank repair Under no circumstances should a repair to any tank be attempted.

INTRODUCTION 3 INFORMATION SYNTHETIC RUBBER Many ’O’ ring seals, flexible pipes and other similar items which appear to be natural rubber are made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe, and does not present a health hazard. However, if the material is damaged by fire or excessive heat, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious burns on contact with skin. Should the material be in a burnt or overheated condition, handle only with seamless industrial gloves. Decontaminate and dispose of the gloves immediately after use. If skin contact does occur, remove any contaminated clothing immediately and obtain medical assistance without delay. In the meantime, wash the affected area with copious amounts of cold water or limewater for fifteen to sixty minutes. RECOMMENDED SEALANTS A number of branded products are recommended in this manual for use during maintenance and repair work. These items include: HYLOMAR GASKET AND JOINTING COMPOUND and HYLOSIL RTV SILICON COMPOUND. They should be available locally from garage equipment suppliers. If there is any problem obtaining supplies, contact the following company for advice and the address of the nearest supplier. MacDERMID LUBRICANTS LTD. Hylo House, Cale lane, New Springs, Wigan WN2 1JR United Kingdom Tel: 01942 824242 Fax: 01942 501110 USED ENGINE OIL WARNING: Prolonged and repeated contact with engine or motor oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. Used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities should be provided. Handling precautions 1. Avoid prolonged and repeated contact with oils, particularly used engine oils. 2. Wear protective clothing, including impervious gloves where applicable. 3. Do not put oily rags in pockets. 4. Avoid contaminating clothes, particularly underwear, with oil. 5. Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. 6. First aid treatment must be obtained immediately for open cuts and wounds. 7. Use barrier creams, before each work period, to help the removal of oil from the skin. 8. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. 9. Do not use gasoline, kerosene, diesel fuel, petrol, thinners or solvents for washing the skin. 10. If skin disorders develop, obtain medical advice. 11. Where practicable, degrease components prior to handling. 12. Where there is a risk of eye contact, eye protection should be worn, for example, goggles or face shields; in addition an eye wash facility should be provided. Disposing of used oils Environmental protection precaution It is illegal to pour used oil onto the ground, down sewers or drains, or into waterways. Dispose of used oil through authorised waste disposal contractors. If in doubt, contact your Local Authority for advice on disposal facilities.

01 INTRODUCTION NEW RANGE ROVER 4 INFORMATION ACCESSORIES AND CONVERSIONS DO NOT FIT unapproved accessories or conversions, as they could affect the safety of the vehicle. Land Rover will not accept liability for death, personal injury, or damage to property which may occur as a direct result of the fitment of non-approved conversions to the Range Rover. WHEELS AND TYRES WARNING: DO NOT replace the road wheels with any type other than genuine Range Rover wheels which are designed for multi-purpose on and off road use and have very important relationships with the proper operation of the suspension system and vehicle handling. Replacement tyres must be of the make and sizes recommended for the vehicle, and all tyres must be the same make, ply rating and tread pattern. CAUTION: When refitting a road wheel, apply a suitable anti-seize compound such as Raworth 33/04, to the spigot bore of the wheel. This will prevent possible seizure of the wheel to the hub spigot. Ensure that no compound comes into contact with the braking components. STEAM CLEANING To prevent consequential rusting, any steam cleaning within the engine bay MUST be followed by careful re-waxing of the metallic components affected. Particular attention must be given to the steering column, engine water pipes, hose clips and ignition coil clamp. SPECIFICATION The specification details and instructions set out in this Manual apply only to a range of vehicles and not to any particular one. For the specification of a particular vehicle, purchasers should consult their Dealer. The Manufacturers reserve the right to vary their specifications with or without notice, and at such times and in such manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer’s policy of constant product improvement. While every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the Manufacturer nor Dealer, by whom this Manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof.

INTRODUCTION 5 INFORMATION SPECIAL SERVICE TOOLS The use of approved special service tools is important. They are essential if service operations are to be carried out efficiently, and safely. Where special tools are specified, only these tools should be used to avoid the possibility of personal injury or damage to the components. Also the amount of time which they save can be considerable. Every special tool is designed with the close co-operation of Land Rover, and no tool is put into production which has not been tested and approved by us. New tools are only introduced where an operation cannot be satisfactorily carried out using existing tools or standard equipment. The user is therefore assured that the tool is necessary and that it will perform accurately, efficiently and safely. Special tools bulletins will be issued periodically giving details of new tools as they are introduced. All orders and enquiries from the United Kingdom should be sent direct to V. L. Churchill. Overseas orders should be placed with the local V. L. Churchill distributor, where one exists. Countries where there is no distributor may order direct from: V. L. Churchill Limited, PO Box 3, Daventry, Northants, England, NN11 4NF. The tools recommended in this Workshop Manual are listed in a multi-language illustrated catalogue, publication number LPA ST ML 95, which is obtainable from V. L. Churchill Limited at the above address. COPYRIGHT  Land Rover 1995 All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission of Land Rover.

1994-2002 Land Rover Range Rover P38 Service & Repair Manual

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