Discovery Workshop Manual - 2nd Edition - Eng

Discovery Workshop Manual - 2nd Edition - Eng

Discovery Workshop Manual - 2nd Edition
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
  - INFORMATION|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)
  - INFORMATION|TOWING
  - TRANSPORTING THE VEHICLE BY TRAILER
  - JUMP STARTING
  - JUMP STARTING|Page 28
  - ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL
  - CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY
  - VEHICLE IDENTIFICATION NUMBER (VIN)
  - VEHICLE IDENTIFICATION NUMBER (VIN)|Page 32
  - LOCATION OF IDENTIFICATION NUMBERS
  - LOCATION OF IDENTIFICATION NUMBERS|Page 34
  - FAULT DIAGNOSTIC EQUIPMENT
  - READING THIS MANUAL
04 - GENERAL SPECIFICATION DATA
- INFORMATION
  - ENGINE 3.9 V8i
  - ENGINE 3.9 V8i|Page 40
  - ENGINE 4.0 V8
  - ENGINE 4.0 V8|Page 42
  - 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
  - INFORMATION|BRAKES
  - AIR CONDITIONING
  - WIPER MOTORS
  - ELECTRICAL
  - ELECTRICAL|Page 57
  - INFORMATION|BULBS
  - VEHICLE WEIGHTS AND PAYLOAD
  - TYRE PRESSURES
  - WHEELS AND TYRES
  - 300 Tdi ENGINE
  - 300 Tdi ENGINE|Page 63
  - FUEL SYSTEM - 300 Tdi
  - COOLING SYSTEM - 300 Tdi
  - CLUTCH - 300 Tdi
  - TRANSMISSION - 300 Tdi
  - ENGINE - Mpi - 2.0 LITRE
  - ENGINE - Mpi - 2.0 LITRE|Page 69
  - FUEL SYSTEM - Mpi
  - COOLING SYSTEM - Mpi
  - CLUTCH - Mpi
  - TRANSMISSION - Mpi
  - VEHICLE DIMENSIONS
05 - ENGINE TUNING DATA
- INFORMATION
  - ENGINE 3.9 V8i
  - ENGINE 3.9 V8i|Page 78
  - 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
10 - MAINTENANCE
- MAINTENANCE
12 - ENGINE - Tdi
- REPAIR
- SPECIFICATIONS, TORQUE
12 - ENGINE - V8i
- DESCRIPTION AND OPERATION
- FAULT DIAGNOSIS
  - ENGINE OIL PRESSURE TEST
  - CYLINDER COMPRESSION - TEST
  - ENGINE NOISES
  - ENGINE STARTING PROBLEMS
  - ENGINE RUNNING PROBLEMS
  - ENGINE RUNNING PROBLEMS|Page 186
  - ENGINE RUNNING PROBLEMS|Page 187
- 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
  - 12 - ENGINE - V8i|ENGINE
  - 12 - ENGINE - V8i|ENGINE|Page 207
  - 12 - ENGINE - V8i|ENGINE|Page 208
  - OIL SUMP
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
- SERVICE TOOLS
  - SERVICE TOOLS|ENGINE
12 - ENGINE - 4.0 V8
- DESCRIPTION AND OPERATION
  - DESCRIPTION
  - CONTENT OF THIS SECTION
- REPAIR
12 - ENGINE - Mpi
- DESCRIPTION AND OPERATION
- REPAIR
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
- SERVICE TOOLS
17 - EMISSION CONTROL
- DESCRIPTION AND OPERATION
- 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
  - HEATED OXYGEN SENSOR (HO2S) - 4.0 V8|Page 297
  - 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
  - FUEL SYSTEM COMPONENT LOCATION|Page 308
  - OPERATION
  - OPERATION|Page 310
  - DESCRIPTION ELECTRONIC DIESEL CONTROL
  - FUEL SYSTEM COMPONENT LOCATION EDC
  - FUEL SYSTEM COMPONENT LOCATION EDC|Page 313
  - FUEL SYSTEM LAYOUT EDC
  - OPERATION EDC
  - OPERATION EDC|Page 316
- 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
  - FUEL INJECTION PUMP AND TIMING|Page 340
  - FUEL INJECTION PUMP AND TIMING|Page 341
  - 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
  - DESCRIPTION|Page 356
  - DESCRIPTION|Page 357
  - 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
  - PLENUM CHAMBER|Page 385
  - PLENUM CHAMBER|Page 386
  - PLENUM CHAMBER|Page 387
  - PLENUM CHAMBER|Page 388
  - PLENUM CHAMBER|Page 389
  - RAM HOUSING
  - INTAKE MANIFOLD
  - INTAKE MANIFOLD|Page 392
  - INTAKE MANIFOLD|Page 393
  - FUEL FILTER
  - FUEL PIPES
  - THROTTLE CABLE
  - ACCELERATOR PEDAL
  - FUEL PUMP AND SENDER UNIT
  - FUEL PUMP AND SENDER UNIT|Page 399
  - FUEL TANK
  - FUEL TANK|Page 401
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
- SERVICE TOOLS
  - FUEL SYSTEM
19 - FUEL SYSTEM - SFI
- DESCRIPTION AND OPERATION
- 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 RAIL AND INJECTORS|Page 429
  - 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
  - PLENUM CHAMBER|Page 438
  - RELAY MODULE - PRE ADVANCED EVAPS
  - RELAY MODULE - ADVANCED EVAPS
  - FUEL FILTER - ADVANCED EVAPS
  - FUEL PUMP AND GAUGE SENDER UNIT - ADVANCED EVAPS
  - FUEL PUMP AND GAUGE SENDER UNIT - ADVANCED EVAPS|Page 443
  - FUEL PUMP AND GAUGE SENDER UNIT - ADVANCED EVAPS|Page 444
  - FUEL SYSTEM - DEPRESSURISE - ADVANCED EVAPS
  - FUEL TANK - ADVANCED EVAPS
  - FUEL TANK - ADVANCED EVAPS|Page 447
  - FUEL TANK - ADVANCED EVAPS|Page 448
  - FUEL TANK - ADVANCED EVAPS|Page 449
  - FUEL TANK - DRAINING - ADVANCED EVAPS
  - FUEL TANK - DRAINING - ADVANCED EVAPS|Page 451
  - FUEL FILLER NECK - ADVANCED EVAPS
  - FUEL FILLER NECK - ADVANCED EVAPS|Page 453
  - FUEL TANK FILLER CAP - ADVANCED EVAPS
  - ANTI-TRICKLE FILL VALVE - ADVANCED EVAPS
19 - FUEL SYSTEM - Mpi
- DESCRIPTION AND 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
  - VISCOUS FAN|Page 514
- FAULT DIAGNOSIS
  - ENGINE OVERHEATING
  - ENGINE RUNS COLD
- ADJUSTMENT
  - ADJUSTMENT|COOLANT
- REPAIR
  - VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL
  - THERMOSTAT
  - WATER PUMP
  - RADIATOR
26 - COOLING SYSTEM - V8i
- DESCRIPTION AND OPERATION
- FAULT DIAGNOSIS
  - ENGINE OVERHEATING
  - ENGINE RUNS COLD
- ADJUSTMENT
  - COOLANT REQUIREMENTS
  - ADJUSTMENT|COOLANT
  - ADJUSTMENT|COOLANT|Page 538
- REPAIR
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
26 - COOLING SYSTEM - Mpi
- REPAIR
  - COOLANT PUMP
  - RADIATOR
  - RADIATOR|Page 553
  - THERMOSTATIC SENSOR
  - THERMOSTAT
  - THERMOSTAT|Page 556
30 - MANIFOLD AND EXHAUST SYSTEM
- DESCRIPTION AND OPERATION
  - CATALYTIC CONVERTERS - V8i
- REPAIR
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
33 - CLUTCH
- DESCRIPTION AND OPERATION
  - DESCRIPTION
  - OPERATION
  - OPERATION|Page 577
- 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
  - MANUAL GEARBOX|Page 603
- REPAIR
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
- SERVICE TOOLS
  - ADAPTER PLATE GEARBOX
41 - TRANSFER GEARBOX
- DESCRIPTION AND OPERATION
- FAULT DIAGNOSIS
  - LT230T TRANSFER BOX - OIL LEAKS
  - LT230T TRANSFER BOX - OIL LEAKS|Page 621
- REPAIR
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
  - LT230T TRANSFER GEARBOX DATA
  - JOINT SEALANT
- SERVICE TOOLS
  - LT230T TRANSFER GEARBOX
44 - AUTOMATIC GEARBOX - ZF
- DESCRIPTION AND OPERATION
- FAULT DIAGNOSIS
- ADJUSTMENT
  - KICKDOWN CABLE ADJUSTMENT
- REPAIR
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
  - ZF GEARBOX DATA
- SERVICE TOOLS
47 - PROPELLER SHAFTS
- DESCRIPTION AND OPERATION
  - PROPELLER SHAFT ALIGNMENT
- FAULT DIAGNOSIS
  - VIBRATION HARSHNESS
- REPAIR
  - FRONT PROPELLER SHAFT
  - FRONT PROPELLER SHAFT|Page 694
  - 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
  - REAR HUB ASSEMBLY|Page 708
- OVERHAUL
- SPECIFICATIONS, TORQUE
  - AXLE DIFFERENTIAL DATA
  - REAR HUB
  - TORQUE VALUES
  - TORQUE VALUES|Page 725
- SERVICE TOOLS
54 - FRONT AXLE AND FINAL DRIVE
- DESCRIPTION AND OPERATION
  - DESCRIPTION
  - DESCRIPTION|Page 734
- FAULT DIAGNOSIS
  - FAULT DIAGNOSIS
- REPAIR
- OVERHAUL
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES
  - FRONT HUB AND SWIVEL DATA
- SERVICE TOOLS
57 - STEERING
- DESCRIPTION AND OPERATION
- FAULT DIAGNOSIS
  - INSUFFICIENT POWER ASSISTANCE
  - POWER STEERING SYSTEM - TEST
  - STEERING DAMPER
  - STEERING FAULTS
  - STEERING FAULTS|Page 777
  - STEERING FAULTS|Page 778
  - STEERING STABILITY AND VEER UNDER BRAKING
  - 1. 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 BOX|Page 801
  - POWER STEERING BOX|Page 802
  - POWER STEERING SYSTEM - BLEED
  - POWER STEERING FLUID RESERVOIR
  - POWER STEERING PUMP DRIVE BELT
  - POWER STEERING PUMP - V8i
  - POWER STEERING PUMP - Tdi
  - POWER STEERING PUMP - Tdi|Page 808
  - LOWER STEERING SHAFT AND UNIVERSAL JOINTS
  - STEERING COLUMN SHROUD
  - STEERING WHEEL
  - STEERING WHEEL|Page 812
  - UPPER STEERING COLUMN
  - UPPER STEERING COLUMN|Page 814
  - UPPER STEERING COLUMN|Page 815
  - STEERING COLUMN LOCK ASSEMBLY
  - DROP ARM
  - STEERING DAMPER
  - TRACK ROD AND LINKAGE
  - DRAG LINK AND DRAG LINK ENDS
- OVERHAUL
- SPECIFICATIONS, TORQUE
  - STEERING PUMP
  - TORQUE VALUES
- SERVICE TOOLS
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
- 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 NON ABS|Page 889
  - MASTER CYLINDER NON ABS|Page 890
  - MASTER CYLINDER NON ABS|Page 891
  - MASTER CYLINDER ASSEMBLY NON ABS
  - SERVO ASSEMBLY
  - FRONT BRAKE PADS
  - REAR BRAKE PADS
  - FRONT BRAKE CALIPER ASSEMBLY
  - FRONT BRAKE CALIPERS
  - FRONT BRAKE CALIPERS|Page 898
  - 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
  - WHEEL BALANCING|Page 927
  - TYRE FITTING
  - 74 - WHEELS AND TYRES|WHEELS
  - WHEEL STUD
75 - SUPPLEMENTARY RESTRAINT SYSTEM
- DESCRIPTION AND OPERATION
- FAULT DIAGNOSIS
  - CRASH SENSOR INSPECTION - DISTRIBUTED SRS
  - AIRBAG HARNESS
  - WARNING LABELS
  - WARNING LABELS|Page 943
- REPAIR
- DATA, TORQUE & TOOLS
  - TORQUE VALUES
76 - CHASSIS AND BODY
- REPAIR
  - FRONT DOOR
  - FRONT DOOR TRIM PANEL
  - FRONT DOOR GLASS AND REGULATOR
  - FRONT DOOR GLASS AND REGULATOR|Page 975
  - FRONT DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES
  - FRONT DOOR LOCK, OUTSIDE AND INSIDE DOOR RELEASE HANDLES|Page 977
  - 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 LOCK AND INNER AND OUTER RELEASE HANDLES|Page 987
  - REAR DOOR LOCK AND INNER AND OUTER RELEASE HANDLES|Page 988
  - 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
  - CENTRE CONSOLE|Page 1028
  - DRINKS TRAY
  - DASH PANEL CENTRAL LOUVRE PANEL
  - DASH PANEL ASSEMBLY
  - DASH PANEL ASSEMBLY|Page 1032
  - WINDSCREEN GLASS
  - WINDSCREEN GLASS|Page 1034
  - WINDSCREEN GLASS|Page 1035
  - WINDSCREEN GLASS|Page 1036
  - FRONT SEAT - ELECTRIC
  - FRONT SEAT - MANUAL - 5 DOOR (96 MODELS)
  - INTERIOR MIRROR (96 MODELS)
  - INTERIOR MIRROR (96 MODELS)|Page 1040
  - 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
  - HEADLINING - WITH SUN ROOF AND REAR AIR CONDITIONING FITTED - 5 DOOR|Page 1054
  - HEADLINING - WITH SUN ROOF AND REAR AIR CONDITIONING FITTED - 5 DOOR|Page 1055
  - 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)
  - FRONT SEAT BELTS - 5 DOOR (96 MODELS)|Page 1060
80 - HEATING AND VENTILATION
- DESCRIPTION AND OPERATION
- 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
- FAULT DIAGNOSIS
- 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
  - RECEIVER DRIER|Page 1108
  - AIR CONDITIONING SWITCH
  - DUAL PRESSURE SWITCH
  - COMPRESSOR
  - CONDENSER
  - CONDENSER FANS AND MOTORS
  - HEATER AND COOLER UNIT
  - EVAPORATOR AND EXPANSION VALVE
  - EVAPORATOR AND EXPANSION VALVE|Page 1116
  - THERMOSTAT
  - EVAPORATOR/BLOWER MOTOR ASSEMBLY - REAR
  - EVAPORATOR/BLOWER MOTOR ASSEMBLY - REAR|Page 1119
  - BLOWER MOTOR - REAR
  - ELECTRONIC CONTROL UNIT - REAR AIR CONDITIONING
  - SOLENOID - HIGH PRESSURE PIPE CONTROL VALVE - REAR
  - CONTROL VALVE - HIGH PRESSURE PIPE - REAR
  - CONTROL VALVE - HIGH PRESSURE PIPE - REAR|Page 1124
  - EXPANSION VALVE - REAR
  - EVAPORATOR - REAR
  - EVAPORATOR - REAR|Page 1127
  - 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
  - ANTI-THEFT SYSTEM FUNCTION|Page 1166
  - 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)
  - ANTI-THEFT ALARM BUILT-IN TEST (96 MODELS)|Page 1174
  - ANTI-THEFT ALARM BUILT-IN TEST (96 MODELS)|Page 1175
  - ANTI-THEFT ALARM BUILT-IN TEST (96 MODELS)|Page 1176
- FAULT DIAGNOSIS
- ADJUSTMENT
  - IGNITION TIMING
- REPAIR
  - FUSE BOX - INTERIOR
  - FUSE BOX - ENGINE COMPARTMENT
  - BATTERY
  - DISTRIBUTOR-LUCAS 35 DLM8 - V8i
  - DISTRIBUTOR-LUCAS 35 DLM8 - V8i|Page 1191
  - ELECTRONIC IGNITION - V8i
  - IGNITION COIL
  - DISTRIBUTOR - V8i
  - DISTRIBUTOR - V8i|Page 1195
  - AUTOMATIC GEAR SELECTOR-PANEL BULB
  - START INHIBIT / REVERSE LIGHT SWITCH
  - PARK BRAKE WARNING SWITCH
  - GEAR SELECTOR-INTERLOCK
  - GEAR SELECTOR-INTERLOCK|Page 1200
  - GEAR SELECTOR-INTERLOCK|Page 1201
  - 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 - 4.0 V8|Page 1262
  - 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
  - PICK-UP AND BASE PLATE ASSEMBLY|Page 1277
- SPECIFICATIONS, TORQUE
  - TORQUE VALUES