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Workshop Manual System Description & Operation
2002MY ON WORKSHOP MANUAL - SYSTEM DESCRIPTION AND OPERATION
LRL0424NAS (6th Edition) Published by Land Rover – Technical Service © 2003 Land Rover All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without written prior permission from Land Rover.
CONTENTS ENGINE - V8 ............................................................................................. 12-2-1 V8 – External View.......................................................................................................................... 12-2-1 Description ...................................................................................................................................... 12-2-2
ENGINE MANAGEMENT SYSTEM – V8 ................................................. 18-2-1 Engine Management Component Location – Sheet 1 of 2 ............................................................. Engine Management Component Location – Sheet 2 of 2 ............................................................. Engine Management Control Diagram – Sheet 1 of 2 .................................................................... Engine Management Control Diagram – Sheet 2 of 2 .................................................................... Bosch ME 7.2 Engine Management System .................................................................................. Variable Camshaft Control Components ........................................................................................ VCC System ................................................................................................................................... Cruise Control Component Location ............................................................................................... Cruise Control System Control Diagram ......................................................................................... Cruise Control ................................................................................................................................. EVAP System ................................................................................................................................. Emissions........................................................................................................................................
18-2-2 18-2-4 18-2-6 18-2-8 18-2-10 18-2-40 18-2-41 18-2-49 18-2-50 18-2-52 18-2-54 18-2-55
FUEL DELIVERY SYSTEM – V8 .............................................................. 19-2-1 Fuel Delivery System Component Location (All Except NAS) ........................................................ 19-2-2 Fuel Delivery System Component Location (NAS) ......................................................................... 19-2-4 V8 Fuel Delivery System................................................................................................................. 19-2-6
COOLING SYSTEM – V8.......................................................................... 26-2-1 V8 Cooling System – Sheet 1 of 2 .................................................................................................. V8 Cooling System – Sheet 2 of 2 .................................................................................................. V8 Coolant Flow – Models With FBH.............................................................................................. Description .....................................................................................................................................
26-2-2 26-2-4 26-2-6 26-2-8
MANIFOLDS AND EXHAUST SYSTEM – V8 .......................................... 30-2-1 Exhaust Manifold Component Layout ............................................................................................. Inlet Manifold Component Layout ................................................................................................... Exhaust System Component Layout............................................................................................... Description ......................................................................................................................................
30-2-1 30-2-2 30-2-4 30-2-6
TRANSFER BOX ...................................................................................... 41-1 Transfer Box Component Location ................................................................................................. Transfer Box Exploded View........................................................................................................... Transfer Box Control Diagram ........................................................................................................ Description ...................................................................................................................................... Operation ........................................................................................................................................
41-1 41-2 41-4 41-6 41-20
CONTENTS
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CONTENTS AUTOMATIC TRANSMISSION – ZF 5HP24 ............................................ 44-2-1 ZF 5HP24 Automatic Transmission Component Location.............................................................. ZF 5HP24 Automatic Transmission – Exploded View .................................................................... ZF 5HP24 Automatic Transmission – Sectional View .................................................................... ZF 5HP24 Automatic Transmission – Valve Block and Solenoid Valves ....................................... ZF 5HP24 Automatic Transmission Control Diagram..................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................
44-2-1 44-2-2 44-2-4 44-2-6 44-2-8 44-2-10 44-2-49
DRIVE AND PROPELLER SHAFTS......................................................... 47-1 Drive and Propeller Shafts – Component Location......................................................................... 47-1 Description...................................................................................................................................... 47-2
FINAL DRIVE ............................................................................................ 51-1 Differentials – Component Location................................................................................................ 51-1 Description...................................................................................................................................... 51-2 Operation ........................................................................................................................................ 51-10
STEERING ................................................................................................ 57-1 Steering Component Location – Td6 .............................................................................................. Steering Component Location – V8................................................................................................ Steering Control Diagram – Servotronic ......................................................................................... Steering Control Diagram – Column Adjustment – Without Memory.............................................. Steering Control Diagram – Column Adjustment – With Memory................................................... Steering Control Diagram – Column Lock ...................................................................................... Steering Control Diagram – Steering Wheel Heating ..................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................
57-1 57-2 57-3 57-4 57-5 57-6 57-8 57-9 57-22
SUSPENSION ........................................................................................... 60-1 Suspension Component Location................................................................................................... Suspension Control Diagram.......................................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................
60-1 60-2 60-3 60-26
BRAKES.................................................................................................... 70-1 Braking System Component Location ............................................................................................ Front Brake Components................................................................................................................ Rear Brake Components ................................................................................................................ Foundation Brakes.......................................................................................................................... Dynamic Stability Control System Control Diagram ....................................................................... Dynamic Stability Control................................................................................................................ Operation ........................................................................................................................................ Hand Brake Component Location................................................................................................... Hand Brake.....................................................................................................................................
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CONTENTS
70-2 70-4 70-5 70-6 70-12 70-14 70-26 70-32 70-34
CONTENTS RESTRAINT SYSTEMS ............................................................................ 75-1 Front Seat Belts .............................................................................................................................. Rear Seat Belts ............................................................................................................................... SRS Component Layout – Sheet 1 of 2 .......................................................................................... SRS Component Layout – Sheet 2 of 2 .......................................................................................... Description ...................................................................................................................................... SRS Control Diagram ..................................................................................................................... Operation ........................................................................................................................................
75-1 75-2 75-3 75-4 75-5 75-18 75-20
DOORS ..................................................................................................... 76-1-1 Front Door ....................................................................................................................................... 76-1-1 Doors .............................................................................................................................................. 76-1-2 Operation ........................................................................................................................................ 76-1-10
INTERIOR TRIM COMPONENTS ............................................................. 76-3-1 Interior Mirror .................................................................................................................................. 76-3-1 Description ...................................................................................................................................... 76-3-2
SCREENS ................................................................................................. 76-4-1 Front Screen ................................................................................................................................... 76-4-1 Screens ........................................................................................................................................... 76-4-2
SEATS....................................................................................................... 76-5-1 Front Seat ....................................................................................................................................... 76-5-1 Description ...................................................................................................................................... 76-5-2 Seat Heating ................................................................................................................................... 76-5-8
SUNROOF................................................................................................. 76-6-1 Sunroof Layout................................................................................................................................ 76-6-1 Sunroof ........................................................................................................................................... 76-6-2 Operation ........................................................................................................................................ 76-6-3
AIR CONDITIONING ................................................................................. 82-1 Refrigerant System Component Location ....................................................................................... Heater Assembly and Ducting Component Location ...................................................................... Control System Component Location ............................................................................................. FBH System Component Location.................................................................................................. Description ...................................................................................................................................... A/C Control Diagram – Low Line System, Sheet 1 of 2 .................................................................. A/C Control Diagram – Low Line System, Sheet 2 of 2 .................................................................. A/C Control Diagram – High Line System, Sheet 1 of 2 ................................................................. A/C Control Diagram – High Line System, Sheet 2 of 2 ................................................................. Operation ........................................................................................................................................
82-1 82-2 82-4 82-5 82-6 82-32 82-34 82-36 82-38 82-40
CONTENTS
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CONTENTS WIPERS AND WASHERS ........................................................................ 84-1 Wiper and Washer System Component Location........................................................................... Wipers and Washers Control Diagram ........................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................
84-2 84-4 84-6 84-18
CHARGING AND STARTING ................................................................... 86-1-1 Charging and Starting Component Location – Td6 ........................................................................ 86-1-1 Charging and Starting Component Location – V8 .......................................................................... 86-1-2 Description...................................................................................................................................... 86-1-3
LIGHTING.................................................................................................. 86-2-1 Exterior Lighting Component Location............................................................................................ Exterior Lighting Control Diagram – Sheet 1 of 2 ........................................................................... Exterior Lighting Control Diagram – Sheet 2 of 2 ........................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................ Interior Lighting Component Location............................................................................................. Interior Lighting Control Diagram.................................................................................................... Description...................................................................................................................................... Operation ........................................................................................................................................
86-2-2 86-2-4 86-2-6 86-2-8 86-2-27 86-2-32 86-2-34 86-2-36 86-2-38
BODY CONTROL UNIT ........................................................................... 86-3-1 BCU Component Location .............................................................................................................. 86-3-1 Description...................................................................................................................................... 86-3-2
COMMUNICATION DATA BUSES ........................................................... 86-4-1 Communication Data Buses Control Diagram – Sheet 1 of 2......................................................... 86-4-2 Communication Data Buses Control Diagram – Sheet 2 of 2......................................................... 86-4-4 Description...................................................................................................................................... 86-4-6
SECURITY................................................................................................. 86-5-1 Locking and Alarm Component Layout – Sheet 1 of 2 ................................................................... Locking and Alarm Component Layout – Sheet 2 of 2 ................................................................... Immobilisation Component Layout ................................................................................................. Description...................................................................................................................................... Alarm and Locking Control Diagram............................................................................................... Immobilisation Control Diagram – Diesel........................................................................................ Immobilisation Control Diagram – Petrol ........................................................................................ Operation ........................................................................................................................................
86-5-1 86-5-2 86-5-3 86-5-4 86-5-16 86-5-18 86-5-19 86-5-20
WINDOWS................................................................................................. 86-6-1 Windows Component Layout.......................................................................................................... Description...................................................................................................................................... Windows Control Diagram .............................................................................................................. Operation ........................................................................................................................................
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CONTENTS
86-6-1 86-6-2 86-6-6 86-6-8
CONTENTS ENTERTAINMENT AND INFORMATION SYSTEMS .............................. 86-8-1 MID Audio System Component Location ........................................................................................ MID Audio System Control Diagram ............................................................................................... Multi-Function Display Audio Component Location ........................................................................ Multi-Function Display Audio Control Diagram ............................................................................... Screen Aerial Components ............................................................................................................. Speaker System Component Location ........................................................................................... Base Speaker Control Diagram ...................................................................................................... Power Amplifier Speaker System Control Diagram ........................................................................ DSP Amplifier Speaker System Control Diagram ........................................................................... Logic 7 Speaker Control Diagram ................................................................................................... Audio Systems ................................................................................................................................ Navigation System Component Location (Except Japan)............................................................... Navigation System Control Diagram (Except Japan)...................................................................... Navigation System Component Location (Japan Only) .................................................................. Navigation System Control Diagram (Japan Only) ......................................................................... New Range Rover Navigation System............................................................................................ Telephone System Component Location ........................................................................................ Telephone System Control Diagram ............................................................................................... Telecommunication System ............................................................................................................ Voice Recognition System Control ................................................................................................. Rear Multimedia System Component Location............................................................................... Rear Multimedia System Description .............................................................................................. Rear Multimedia System Operation ................................................................................................
86-8-2 86-8-4 86-8-6 86-8-8 86-8-10 86-8-11 86-8-12 86-8-14 86-8-16 86-8-18 86-8-20 86-8-41 86-8-42 86-8-44 86-8-46 86-8-48 86-8-59 86-8-60 86-8-62 86-8-69 86-8-74 86-8-76 86-8-84
DRIVING AIDS .......................................................................................... 86-10-1 Park Distance Control Component Layout ..................................................................................... PDC Control Diagram ..................................................................................................................... Description ...................................................................................................................................... Operation ........................................................................................................................................ Tyre Pressure Monitoring Component Layout ............................................................................... TPM Control Diagram ..................................................................................................................... Description ...................................................................................................................................... Operation ........................................................................................................................................
86-10-1 86-10-2 86-10-3 86-10-6 86-10-9 86-10-10 86-10-12 86-10-15
INSTRUMENTS......................................................................................... 88-1 Instrument Pack – Front View ......................................................................................................... Instrument Pack – Front View – NAS Only ..................................................................................... Instrument Pack – Control Diagram ................................................................................................ Description ...................................................................................................................................... Operation ........................................................................................................................................
88-1 88-2 88-4 88-6 88-31
CONTENTS
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ENGINE - V8 ENGINE - V8 AND OPERATION DESCRIPTION
V8 – External View
M12 7816
DESCRIPTION AND OPERATION
12-2-1
ENGINE - V8 Description General The V8 petrol engine is a 4.4 litre, eight cylinder water cooled engine having two banks of four cylinders, arranged at 90 degrees to each other, with four valves per cylinder. The engine emissions comply with ECD3 (European Commission Directive) and NAS LEV 2 legislative requirements. The engine comprises five main castings - two cylinder heads, cylinder block, timing cover and the oil sump, all of which are manufactured from aluminium alloy. Plastic rocker covers are fitted to the cylinder heads and, between the cylinder heads, is a plastic manifold intake assembly. A plastic moulded acoustic cover is fitted over the upper engine to reduce engine generated noise. The engine is supported, between cast mounting brackets and the front subframe, on two self-contained hydraulically damped mounts. Technical Features The technical features include: l l l l l l
Four valves per cylinder Single plenum chamber Variable Camshaft Control (VCC) system Double roller timing chain Hydraulic Valve Adjusters (HVA) Water Cooled Oil Cooler.
Engine Data The technical data is detailed below Engine type Cylinders Displacement Stroke/bore Maximum Power
90° V 8 4398 ccm 82.7/92.0 mm 210 kW (285 PS; 282 bhp) @ 5400 rev/min Maximum Torque 440 Nm (324 lbf.ft) @ 3600 rev/min Compression ratio 10: 1 Firing order 1–5–4–8–6–3–7–2
The cylinders are numbered as follows: RH bank (bank 1) LH bank (bank 2)
NOTE: Cylinders 4 and 8 are at the rear of the engine Cylinder Block Components The cylinder block components are described below:
12-2-2
DESCRIPTION AND OPERATION
Cylinders 1 to 4 Cylinders 5 to 8
ENGINE - V8 Crankcase
The crankcase is made from Alusil for markets where the fuel contains a high sulphur content. The cylinder barrels have a nickel dispersion coating (Nikasil), and are finished by polishing only. An adaptor plate for the feed and return flexible pipes to the oil filter assembly is fitted to the left side of the crankcase. A water drain plug is located at the lower LH rear corner to drain coolant from the crankcase.
DESCRIPTION AND OPERATION
12-2-3