2002-2006 Range Rover L322 Service & Repair Manual

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)

2002-2006 Range Rover L322 Service & Repair Manual

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