''''Orlrnlol']ol']TC''l'1ol']nnnt'\ok~ ~ ~ 3 3.37H'2I-.g.12630010405070910,r ~This manual covers vehicles fromintroduction 1995Workshop manualRANGE ROVERVOLUME 101 INTRODUCTION04 GENERAL SPECIFICATION DATA05 ENGINE TUNING DATA06 TORQUE VALUES07 GENERAL FITTING REMINDERS09 LUBRICANTS, FLUIDS AND CAPACITIES10 MAINTENANCE12 ENGINE BMW DIESEL12 ENGINE LANDROVERV817 EMISSION CONTROL19 FUEL SYSTEM BMW DIESEL19 FUEL SYSTEM LANDROVERV819 CRUISE CONTROL26 COOLING SYSTEM BMW DIESEL26 COOLING SYSTEM LANDROVER V830 MANIFOLD AND EXHAUST SYSTEM33 CLUTCH37 MANUAL GEARBOXThis manual supersedes:Workshop manual VDR100370Body Repair Manual LRL0085Published by Rover Technical Communication 1999 Rover Group LimitedPublication part no. LRL0326ENG..01 - INTRODUCTIONCONTENTSPageINFORMATIONINTRODUCTION 1DIMENSIONS 1REFERENCES 1REPAIRS AND REPLACEMENTS 1POISONOUS SUBSTANCES 1FUEL HANDLING PRECAUTIONS 2SYNTHETIC RUBBER 3RECOMMENDED SEALANTS 3USED ENGINE OIL 3ACCESSORIES AND CONVERSIONS 4WHEELS AND TYRES 4STEAM CLEANING 4SPECIFICATION 4SPECIAL SERVICE TOOLS 5COPYRIGHT 5JACKING 6HYDRAULIC VEHICLE RAMP (FOUR POST) 7TWO POST VEHICLE RAMPS 7DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES(ABS) 7JUMP STARTING 8ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL 9VEHICLE IDENTIFICATION NUMBER (VIN) 12LOCATION OF IDENTIFICATION NUMBERS 13EMERGENCY TOWING 15TRANSPORTING THE VEHICLE BY TRAILER 16INTRODUCTION_______nINTRODUCTION REFERENCESThis workshop manual covers the New RangeRover vehicle from introduction in 1995, and isdesigned to be used in conjunction with ElectricalTroubleshooting Manual LRL0329 and ElectricalCircuit Diagrams YVB101590 (2nd Edition).Amendments and additional pages will be issuedto ensure that the manual covers latest models.Amendments and additions will be identified bythe addition of a dated footer at the bottom of thepage.This Workshop Manual is designed to assist skilledtechnicians in the efficient repair and maintenance ofRange Rover vehicles.References to the left or right hand side in the manualare made when viewing the vehicle from the rear.With the engine and gearbox assembly removed, thewater pump end of the engine is referred to as thefront.To reduce repetition, some operations covered in thisManual do not include reference to testing the vehicleafter repair.It is essential that work is inspected and tested aftercompletion and if necessary a road test of the vehicleis carried out particularly where safety related itemsare concerned.WARNINGS, CAUTIONS and NOTES are giventhroughout this Manual in the following form:Individuals who undertake their own repairsshould have some skill and training, and limitrepairs to components which could not affect thesafety of the vehicle or its passengers. Anyrepairs required to safety critical items such assteering, brakes, suspension or supplementaryrestraint system should be carried out by a RangeRover Dealer. Repairs to such items shouldNEVER be attempted by untrained individuals.A WARNING: Procedures which must befollowed precisely to avoid the possibilityof personal injury.CAUTION: This calls attention toprocedures which must be followed toavoid damage to components.REPAIRS AND REPLACEMENTSWhen replacement parts are required it is essentialthat Range Rover parts are used.Attention is particularly drawn to the following pointsconcerning repairs and the fitting of replacement partsand accessories: Safety features embodied in thevehicle may be impaired if other than Range Roverparts are fitted. In certain territories, legislationprohibits the fitting of parts not to the vehiclemanufacturer's specification. Torque spanner valuesgiven in the Workshop Manual must be strictlyadhered to. Locking devices, where specified, must befitted. If the efficiency of a locking device is impairedduring removal it must be replaced with a new one.Certain fasteners must not be re-used. Thesefasteners are specified in the Workshop Manual.NOTE: This calls attention to methodswhich make a job easier or gives helpfulinformation. POISONOUS SUBSTANCESDIMENSIONSThe dimensions quoted are to design engineeringspecification. Alternative unit equivalents, shown inbrackets following the dimensions, have beenconverted from the original specification.Many liquids and other substances used are toxic andshould not be consumed under any circumstances,and should be kept away from open wounds. Thesesubstances amongst others include anti-freeze, brakefluid, fuel, oil, windscreen washer additives, airconditioning refrigerant, lubricants and variousadhesives.INFORMATION I 1INTRODUCTION NEW RANGE ROVERFUEL HANDLING PRECAUTIONSThe following information provides basic precautionswhich must be observed if fuel is to be handled safely.It also outlines other potential risks which must not beignored.This information is issued for basic guidance only; inany case of doubt, seek advice from your local FireOfficer or Fire Department.Fuel vapour is highly flammable and in confinedspaces is also very explosive and toxic.When fuel evaporates it produces 150 times its ownvolume in vapour, which when diluted with airbecomes a readily ignitable mixture. The vapour isheavier than air and will always fall to the lowest level.It can readily be distributed throughout a workshop byair currents, consequently, even a small spillage offuel is very dangerous.Always have a fire extinguisher containing FOAM CO2GAS, or POWDER close at hand when handling fuel,or when dismantling fuel systems and in areas wherefuel containers are stored.A WARNING: It is imperative that the batteryis not disconnected during fuel systemrepairs as arcing at the battery terminalcould ignite fuel vapour in the atmosphere.Always disconnect the vehicle battery BEFOREcarrying out work on the fuel system.Whenever fuel is being handled, transferred orstored, or when fuel systems are beingdismantled, all forms of ignition must beextinguished or removed, any leadlamps usedmust be flame proof and kept clear of spillage.No one should be permitted to repair componentsassociated with fuel without first having had fuelsystem training.2 I INFORMATIONHot fuel handling precautionsA WARNING: Before commencing anyoperation requiring fuel to be drained fromthe fuel tank, the following procedure mustbe adhered to:1. Allow sufficient time for the fuel to cool, thusavoiding contact with hot fuels.2. Vent the system by removing the fuel filler cap ina well ventilated area. Refit the filler cap until thecommencement of fuel drainage.Fuel transferA WARNING: Fuel must not be extracted ordrained from any vehicle while it isstanding over a pit.The transfer of fuel from the vehicle fuel tank must becarried out in a well ventilated area. An approvedtransfer tank must be used according to the transfertank manufacturer's instructions and local regulations,including attention to grounding of tanks.Fuel tank removalA FUEL VAPOUR warning label must be attached tothe fuel tank upon removal from the vehicle.Fuel tank repairUnder no circumstances should a repair to any tankbe attempted.INTRODUCTION_______nSYNTHETIC RUBBER USED ENGINE OILMany '0' ring seals, flexible pipes and other similaritems which appear to be natural rubber are made ofsynthetic materials called Fluoroelastomers. Undernormal operating conditions this material is safe, anddoes not present a health hazard. However, if thematerial is damaged by fire or excessive heat, it canbreak down and produce highly corrosive Hydrofluoricacid which can cause serious burns on contact withskin. Should the material be in a burnt or overheatedcondition, handle only with seamless industrial gloves.Decontaminate and dispose of the gloves immediatelyafter use.A WARNING: Prolonged and repeatedcontact with engine or motor oil will resultin the removal of natural fats from theskin, leading to dryness, irritation and dermatitis.Used engine oil contains potentially harmfulcontaminants which may cause skin cancer.Adequate means of skin protection and washingfacilities should be provided.Handling precautionsIf skin contact does occur, remove any contaminatedclothing immediately and obtain medical assistancewithout delay. In the meantime, wash the affectedarea with copious amounts of cold water or limewaterfor fifteen to sixty minutes.RECOMMENDED SEALANTSA number of branded products are recommended inthis manual for use during maintenance and repairwork.These items include:HYLOMAR GASKET AND JOINTING COMPOUNDandHYLOSIL RTV SILICON COMPOUND.They should be available locally from garageequipment suppliers. If there is any problem obtainingsupplies, contact the following company for adviceand the address of the nearest supplier.MacDERMID LUBRICANTS LTD.Hylo House,Cale lane,New Springs,WiganWN21JRUnited Kingdom1. Avoid prolonged and repeated contact with oils,particularly used engine oils.2. Wear protective clothing, including imperviousgloves where applicable.3. Do not put oily rags in pockets.4. Avoid contaminating clothes, particularlyunderwear, with oil.5. Overalls must be cleaned regularly. Discardunwashable clothing and oil impregnatedfootwear.6. First aid treatment must be obtained immediatelyfor open cuts and wounds.7. Use barrier creams, before each work period, tohelp the removal of oil from the skin.8. Wash with soap and water to ensure all oil isremoved (skin cleansers and nail brushes willhelp). Preparations containing lanolin replace thenatural 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 priorto handling.12. Where there is a risk of eye contact, eyeprotection should be worn, for example, gogglesor face shields; in addition an eye wash facilityshould be provided.Disposing of used oilsEnvironmental protection precautionTel: 01942 824242Fax: 01942 501110It is illegal to pour used oil onto the ground, downsewers or drains, or into waterways.Dispose of used oil through authorised waste disposalcontractors. If in doubt, contact your Local Authorityfor advice on disposal facilities.INFORMATION I 3INTRODUCTION NEW RANGE ROVERACCESSORIES AND CONVERSIONSDO NOT FIT unapproved accessories or conversions,as they could affect the safety of the vehicle.Land Rover will not accept liability for death, personalinjury, or damage to property which may occur as adirect result of the fitment of non-approvedconversions to the Range Rover.WHEELS AND TYRESA WARNING: DO NOT replace the roadwheels with any type other than genuineRange Rover wheels which are designedfor multi-purpose on and off road use and havevery important relationships with the properoperation of the suspension system and vehiclehandling. Replacement tyres must be of the makeand sizes recommended for the vehicle, and alltyres must be the same make, ply rating and treadpattern.CAUTION: When refitting a road wheel,& apply a suitable anti-seize compound suchas Raworth 33/04, to the spigot bore of thewheel. This will prevent possible seizure of thewheel to the hub spigot. Ensure that nocompound comes into contact with the brakingcomponents.STEAM CLEANINGTo prevent consequential rusting, any steam cleaningwithin the engine bay MUST be followed by carefulre-waxing of the metallic components affected.Particular attention must be given to the steeringcolumn, engine water pipes, hose clips and ignitioncoil clamp.4 I INFORMATIONSPECIFICATIONThe specification details and instructions set out inthis Manual apply only to a range of vehicles and notto any particular one. For the specification of aparticular vehicle, purchasers should consult theirDealer.The Manufacturers reserve the right to vary theirspecifications with or without notice, and at such timesand in such manner as they think fit. Major as well asminor changes may be involved in accordance withthe Manufacturer's policy of constant productimprovement.While every effort is made to ensure the accuracy ofthe particulars contained in this Manual, neither theManufacturer nor Dealer, by whom this Manual issupplied, shall in any circumstances be held liable forany inaccuracy or the consequences thereof.INTRODUCTION_______nSPECIAL SERVICE TOOLS COPYRIGHTThe use of approved special service tools isimportant. They are essential if service operations areto be carried out efficiently, and safely. Where specialtools are specified, only these tools should be usedto avoid the possibility of personal injury ordamage to the components. Also the amount of timewhich they save can be considerable. Land Rover 1995All rights reserved. No part of this publication may beproduced, stored in a retrieval system or transmittedin any form, electronic, mechanical, recording or othermeans without prior written permission of Land Rover.Every special tool is designed with the closeco-operation of Land Rover, and no tool is put intoproduction which has not been tested and approvedby us. New tools are only introduced where anoperation cannot be satisfactorily carried out usingexisting tools or standard equipment. The user istherefore assured that the tool is necessary and that itwill perform accurately, efficiently and safely.Special tools bulletins will be issued periodically givingdetails of new tools as they are introduced.All orders and enquiries from the United Kingdomshould be sent direct to V. L. Churchill. Overseasorders should be placed with the local V. L. Churchilldistributor, where one exists. Countries where there isno distributor may order direct from:V. L. Churchill Limited,PO Box 3,Daventry, Northants,England, NN11 4NF.The tools recommended in this Workshop Manual arelisted in a multi-language illustrated catalogue,publication number LPA ST ML 95, which isobtainable from V. L. Churchill Limited at the aboveaddress.INFORMATION I 5INTRODUCTION NEW RANGE ROVERJACKINGThe following instructions must be carried out beforeraising the vehicle off the ground.1. Use a solid level ground surface.2. Apply parking brake.3. Select 'P' or 1st gear in main gearbox.4. Select Low range in transfer gearbox.CAUTION: To avoid damage occurring to& the under body components of the vehiclethe following jacking procedures must beadhered to.DO NOT POSITION JACKS OR AXLE STANDSUNDER THE FOLLOWING COMPONENTS.Vehicle jackThe jack provided with the vehicle is only intended tobe used in an emergency, for changing a wheel. DoNOT use the jack for any other purpose. Refer toOwner's Manual for vehicle jack location points andprocedure. Never work under a vehicle supported bythe vehicle jack.Hydraulic jackA hydraulic jack with a minimum 1500 kg, 3,300 Ibsload capacity must be used.CAUTION: Do not commence work on theunderside of the vehicle until suitable axlestands have been positioned under theaxle.CAUTION: If supporting vehicle by the& front crossmember, the safety standsmust be positioned carefully to avoiddamage to air suspension pipes.Body structureBumpersBrake linesPanhard rodRear Trailing linksEngine sumpAir suspension pipesFuel linesFront radius armsSteering linkageFuel tankGearbox bell housingRaise the front of the vehicle1. Position cup of hydraulic arm under differentialcasing.1\ NOTE: The differential casing is notL..J central to the axle. Care should be takenwhen raising the front road wheels off theground as the rear axle has less sway stiffness.6 I INFORMATIONINTRODUCTION_______n2. Raise front road wheels to enable an axle standto be installed under left hand axle tube.3. Position an axle stand under right hand axletube, carefully lower jack until axle sits securelyon both axle stands, remove trolley jack.4. Before commencing work on underside ofvehicle re-check security of vehicle on stands.5. Reverse procedure when removing vehicle fromstands.Raise rear of vehicle1. Position cup of hydraulic arm under differentialcasing.2. Raise vehicle to enable axle stands to beinstalled under left and right hand axle tubes.3. Lower jack until axle sits securely on axlestands, remove trolley jack.4. Before commencing work on underside ofvehicle re-check security of vehicle on stands.5. Reverse procedure when removing vehicle fromstands.DYNAMOMETER TESTING - VEHICLES WITHANTI-LOCK BRAKES (ABS)A WARNING: Do not attempt to test ABSfunction on a dynamometerFour wheel dynamometers1\ NOTE: Before testing a vehicle on a fourL.....J wheel dynamometer disconnect the valverelay. See Electrical Trouble ShootingManual.The ABS function will not work, the ABS warninglight will illuminate. Normal braking will beavailable.Provided that front and rear rollers are rotating atidentical speeds and that normal workshop safetystandards are applied, there is no speed restrictionduring testing except any that may apply to the tyres.Two wheel dynamometersIMPORTANT: Use a four wheel dynamometer forbrake testing if possible.HYDRAULIC VEHICLE RAMP (FOUR POST)Use only a 'drive on' type ramp which supports vehicleby its own road wheels. If a 'wheel-free' condition isrequired, use a 'drive on' ramp incorporating a'wheel-free' system that supports under axle casings.Alternatively, place vehicle on a firm, flat floor andsupport on axle stands.NOTE: ABS will not function on a two6 wheel dynamometer. The ABS light willilluminate during testing. Normal brakingwill be available.If brake testing on a single rig is necessary it must becarried out with propeller shaft to the rear axleremoved, AND neutral selected in BOTH main andtransfer boxes.TWO POST VEHICLE RAMPSIf checking engine performance, the transfer box mustbe in high range and drive shaft to stationary axleremoved.The manufacturer of RANGE ROVER VEHICLESDOES NOT recommend using 'Two Post' rampsthat employ four adjustable support arms. Theseare NOT considered safe for Range Rovervehicles.If a vehicle is installed on a Two Post ramp,responsibility for safety of the vehicle andpersonnel performing service operations isattributable to the Service Provider.A WARNING: Vehicles from 99 MY are fittedwith 4 wheel traction control, which mustbe disabled prior to testing on a singleaxle dynamometer.INFORMATION I 7INTRODUCTION NEW RANGE ROVERJUMP STARTINGA WARNING: Hydrogen and oxygen gasesare produced during normal batteryoperation. This gas mixture can explode ifflames, sparks or lighted tobacco are broughtnear battery. When charging or using a battery inan enclosed space, always provide ventilation andshield your eyes.Keep out of reach of children. Batteries containsulphuric acid. Avoid contact with skin, eyes, orclothing. Also, shield eyes when working nearbattery to protect against possible splashing ofacid solution. In case of acid contact with skin,eyes, or clothing, flush immediately with water fora minimum of fifteen minutes. If acid is swallowed,drink large quantities of milk or water, followed bymilk of magnesia, a beaten egg, or vegetable oil.SEEK MEDICAL AID IMMEDIATELY.To Jump Start - Negative Ground BatteryA WARNING: To avoid any possibility ofinjury use particular care when connectinga booster battery to a discharged battery.1. Position vehicles so that jump leads will reach,ensuring that vehicles DO NOT TOUCH,alternatively a fully charged slave battery may bepositioned on floor adjacent to vehicle.2. Ensure that ignition and all electrical accessoriesare switched off; the parking brake must beapplied and neutral selected on a manualgearbox; for an automatic gearbox select neutral(N) or park (P). Connect the jump leads asfollows;A. Connect one end of first jumper cable to positive(+) terminal of booster battery.B. Connect other end of first jumper cable topositive (+) terminal of discharged battery.C. Connect one end of second jumper cable tonegative terminal of booster battery.D. Connect other end of second jumper cable to agood earth point on the engine, NOT TONEGATIVE TERMINAL OF DISCHARGEDBATTERY. Keep jumper lead away from movingparts, pulleys, drive belts and fan bladeassembly.A WARNING: Making final cable connectioncould cause an electrical arc which ifmade near battery could cause anexplosion.8 I INFORMATION3. If booster battery is installed in another vehicle,start engine and allow to idle.4. Start engine of vehicle with discharged battery,following starting procedure in Owners' Manual.CAUTION: If vehicle fails to start within a& maximum time of 12 seconds, switchignition off and investigate cause. Failingto follow this instruction could result inirrepairable damage to catalysts.5. Remove negative (-) jumper cable from theengine and then terminal of booster battery.6. Remove positive (+) jumper cable from positiveterminals of booster battery and dischargedbattery.INTRODUCTION_______nABBREVIATIONS AND SYMBOLS USED IN THISMANUALAcross flats (bolt size) AFAfter bottom dead centre ABDCAir Conditioning AlCAir Fuel Ratio AFRAfter top dead centre ATDCAir Temperature Control ATCAlternating current acAmbient Air Pressure AAPAmbient Air Temperature AATAmbient Pressure APAmpere amp or AAmpere hour amp hrAnti-lock Braking System ABSAnti-shunt Control ASCAutomatic............................................................ AutoAutomatic Volume Control AVCAuxiliary AUXBattery Backed-Up Sounder BBUSBefore bottom dead centre BBDCBefore top dead centre BTDCBody Electrical Control Module BeCMBoost Pressure BPBottom dead centre............................................. BDCBrake horse power bhpBrake Pedal Positions BPPBritish Standards.................................................... BSCamshaft Position CMPCalculated Load Value CLVCanister Vent Solenoid CVSCarbon Dioxide.................................................... CO2Carbon monoxide.................................................. COCelsius CCentimetre cmCentral Door Locking COLCentre Differential Control CDCCentre High Mounted Stop Lamp CHMSLChlorofluorocarbon CFCClutch Pedal Position CPPCompact Disc CDCompact Disc - Read Only Memory CD-ROMController Area Network CANCrankshaft Position CKPCubic centimetre ern"Cubic feet per minute ft3/minCubic inch in3dB D e d b e ~Degree (angle) deg or 0Degree (temperature) deg or 0Diagnostic Control Unit DCUDial Test Indicator DTIDiameter dia.Digital Diesel Electronics DOEDigital Signal Processing DSPDigital Versatile Disc DVDDirect current dcDirect Ignition System DISDirect Injection 01Directional Control Valve..................................... DCVDouble Overhead Camshaft DOHCDual Mass Flywheel DMFElectronic Air Control Valve EACVElectronic Air Suspension EASElectronic Automatic Transmission EATElectronic Brake pressure Distribution EBDElectronic Control Unit ECUElectronic Diesel Control EDCElectronic Erasable Programmable Read OnlyMemory EEPROMElectronic Fuel Injection EFIElectronic Traction Control ETCElectronic Unit Injector EUIElectronic Vacuum Regulator EVRElectrical Reference Library ERLEmergency Key Access EKAEmergency Locking Retractor ELREngine Control Module ECMEngine Coolant Temperature ECTEngine Fuel Temperature EFTEngine Management System EMSEnhanced Other Network EONEuropean Community Directive ECDEuropean Norm ENEuropean Economic Community EECEuropean On Board Diagnostics EOBDEvaporative Emission EVAPExhaust Gas Recirculation EGRFahrenheit FFast Throttle Control FTCFeet ftFeet per minute ft/minField Effect Transistor FETFmh ~ hFirst 1stFluid ounce fl ozFoot pounds (torque) lbf.ftFourth 4thFuel Burning Heater FBHFuel Injection Pump FIPGallons galGallons (US) US galGramme (force) gfGramme (mass) gGreenwich Mean Time GMTGlobal Positioning System GPSGravity gINFORMATION I 9INTRODUCTION NEW RANGE ROVERHeated Front Screen HFSHeated oxygen sensor H02SHeated Rear Window HRWHeight Dilation Of Precision HOOPHigh HIHigh compression hcHigh Density Polyethylene HOPEHigh Molecular Weight HMWHigh Strength Low Alloy.................................... HSLAHigh tension (electrical) HT or htHill Descent Control HOCHour hHydrocarbons HCHydrofluorocarbon HFCIdle Air Control Valve IACVIn Car Entertainment ICEInches of mercury in. HgInches inInertia-fuel Shut Off IFSInjector Pulse Width IPWInlet Throttle ILTIntake Air Temperature IATIntermediate Frequency IFInternal diameter 1.0. or i.dia.International Organisation for Standardisation ISOKilogramme (force) kgfKilogramme (mass.) kgKilogramme centimetre (torque) kgf.cmKilogrammes per hour kg/hKilogramme per square millimetre kgf/mm2Kilogramme per square centimetre kgf/cm2Kilogramme metres (torque) kgf.mKilometres kmKilometres per hour km/hKiloPascal kPaKilowatts kWKilovolts kVKnock Sensor......................................................... KSLeft-hand................................................................ LHLeft-hand Drive LH0Left-hand thread LHThdLight Emitting Diode LEDLitres ILiquid Crystal Display LCDLiquid Vapour Separator LVSLow LOLow compression IcLow Emission Vehicle LEVLow tension 1.1.Malfunction Indicator Light MILManifold Absolute Pressure MAPMass Air Flow...................................................... MAFMaximum max.MegaPascal MPaMetal Oxide Semiconductor Field EffectTransistor MOSFET10 I INFORMATIONMetre mMillilitre mlMillimetre mmMiles per gallon mpgMiles per hour mphMinus (of tolerance) -Minimum min.Minute (angle) 'Model Year MYModular Engine Management System MEMSMotorised Valve MVMulti-Function Logic MFLMulti-Function Unit MFUMulti-Point injection MPiMultiport Fuel Injection MFINegative (electrical) -veNegative Temperature Coefficient NTCNewton metres (torque) NmNitrogen Dioxide N02Non-Return Valve NRVNorth American Specification.............................. NASNumber No.Off-road Mode.................................................... ORMOhms ohmOn Board Diagnostics OBDOn Board Monitoring OBMOrganic Acid Technology OATOunces (force) ozfOunces (mass) ozOunce inch (torque) ozf.in.Outside diameter 0.0. or o.dia.Overhead Cam OHCOxides of Nitrogen NOxPart number Part No.Percentage %Pints ptPints (US) US ptPlus or Minus Plus (tolerance) +Polytetrafluorethylene PTFEPosition Dilation Of Position POOPPositive (electrical) +vePositive Crankcase Ventilation PCVPositive Temperature Coefficient PTCPound (force) IbfPounds force feet lbf.ftPounds inch (torque) Ibf.inPound (mass) Ib(s)Pounds per square inch psiPounds per square inch Ibf/in2Power Assisted Steering PASPressure Conscious Reducing Valve PCRVPrinted Circuit Board PCBProgramme Information PIPulses Per Second PPSPulse Width Modulation PWMINTRODUCTION_______nRadio Data Service RDSRadio Frequency RFRadius rRatio :Read Only Memory ROMRed/Green/Blue RGBReference ref.Regionalisation REGResearch Octane Number RONRest Of World ROWRevolution per minute rev/minRight-hand RHRight-hand Drive RHORoll Over Valve................................................... ROVRover Engineering Standards RESSCREW THREADSAmerican Standard Taper Pipe NPTFBritish Standard Pipe BSPUnified Coarse UNCUnified Fine UNFSecond (angle) "Second (numerical order) 2ndSecondary Air Injection SAlSelf Levelling and Anti-Lock Brake System SLABSSelf Levelling Suspension SLSSingle Overhead Camshaft SOHCSingle Point Entry SPESociety of Automotive Engineers SAESpecific gravity sp.gr.Square centimetres ern"Square inches in2Standard std.Standard wire gauge s.w.g.Supplementary Restraint System SRSSynchroniser/Synchromesh synchro.Temperature, Manifold Absolute Pressure TMAPThird 3rdThermostsatic Expansion Valve TXVThree Way Catalyst... TWCThrottle Position..................................................... TPTop Dead Centre TDCTorsional Vibration TVTraffic Announcement TATraffic Management Control TMCUnited Kingdom UKUnited States USUS gallons per hour US galls/hVariable Var.Variable Intake System VISVariable Reluctance Sensor VRSVehicle Identification Number VINVehicle Information Communications System VICSVehicle Speed Sensor VSSVelocity Dilation Of Precision VDOPVolts VWatts WWide Open Throttle............................................ WOTINFORMATION 1 11INTRODUCTION NEW RANGE ROVERVEHICLE IDENTIFICATION NUMBER (VIN)An adhesive label containing the Vehicle IdentificationNumber and the recommended maximum vehicleweights is located on the left hand side of the bonnetlocking platform.The number is also stamped on the outside of thechassis in the front RH wheel arch to the rear of theanti-roll bar link.NOTE: It may be necessary to remove6 underseal in order to locate the number;ensure underseal is restored oncompletion.Federal (USA) vehicle identification numberAn adhesive label containing the Vehicle IdentificationNumber, date of manufacture and gross axle weightratings is fixed to the lock face of the front left handdoor. The information includes wheel and tyre sizesand tyre pressures at gross axle weight ratings.ABCDEII ROVER GROUP LTDIJI* *2780 Kg6280 Kg.. 1320 Kg PVG IPVA.,1840 KgLAND?;)IPAINT II TRIM1c::::J ~ R O V E ~1M7003Key to Vehicle Identification Number PlateA. VIN (17 digits)B. Maximum permitted laden weight for vehicleC. Maximum vehicle and trailer weightD. Maximum road weight-front axleE. Maximum road weight-rear axleIn addition, the VIN is stamped on a plate which isvisible through the left side of the windscreen.12 I INFORMATIONLOCATION OF IDENTIFICATION NUMBERSEngine serial number - V8 engineStamped on a cast pad on the cylinder block, betweennumbers 3 and 5 cylinders.NOTE: The engine compression ratio isstamped above the serial number.1M7006Engine serial number - BMW Diesel engineStamped on the LH side of the cylinder block abovethe sump.INTRODUCTION nMain gearbox R380 - 5 speedStamped on a cast pad on the bottom right hand sideof the gearbox.Automatic gearbox ZF4HP22/ZF4HP24Stamped on a plate riveted to the bottom left handside of the gearbox casing.INFORMATION 1 13INTRODUCTION NEW RANGE ROVERTransfer gearbox-Borg WarnerStamped on a plate attached to the gearbox casing,between filler/level and drain plug.Front and rear axleStamped on the left hand axle tubes.14 I INFORMATIONVehicle identification number (VIN)Made up of 17 digits, these numbers are used toidentify manufacturer, model range, specification,body type, engine, transmission/steering, model year,plant and build sequence number and serve to identifythe vehicle.This example shows the sequence:European codeS AL LP A M J 7 M AS EuropeAL UKLP Range RoverA European Spec.M 4 Door Station WagonJ 4.6 Litre Fuel Injection7 Manual right steeringM 1995 Model YearA SolihullFederal (USA) codeS AL P V 1 2 4 2 S AS EuropeAL UKP Range RoverV North America Spec.1 4 Door Station Wagon2 4.0 Litre fuel injection4 Automatic, Left Hand Steering2 Check DigitS 1995 Model YearA SolihullINTRODUCTION_______nEMERGENCY TOWINGCAUTION: The New Range Rover has& permanent four-wheel drive. The followinginstructions must be adhered to whentowing:-Towing the vehicle on four wheelsCAUTION: Power assistance for braking& and steering systems will not be providedwithout the engine running. Greater pedalpressure will be required to apply the brakes, thesteering wheel will require greater effort to turnthe front wheels.The vehicle tow connection should be used onlyin normal road conditions.If it is necessary to recover the vehicle by towing onall four wheels, 'Transfer neutral' MUST be selected.CAUTION: DO NOT remove the starter keyor turn the switch to position '0' when thevehicle is in motion.1. With the starter key removed, insert a fuse of 5amps or more in fuse position '11' in the RH seatfuse box.2. Turn the starter switch to position '2'; the transferbox will now automatically select neutral.3. Wait until the message centre displays'TRANSFER NEUTRAL' and then turn thestarter switch off, position '0'.4. Turn the starter switch to position '1' to unlockthe steering and leave in this position while thevehicle is being towed.7. To reactivate the transfer box after towing, turnthe starter switch off to position '0' and removethe fuse from position' 11'. On automaticvehicles the transfer box will automaticallyengage the Low or High gear range.8. On manual vehicles, first press the rangechange switch. The transfer box will then engagethe Low or High gear range.Suspended tow by breakdown vehicle1M7000CAUTION: To prevent vehicle damage,& front or rear propeller shaft MUST beremoved, dependant upon which axle isbeing trailed.9. To facilitate reassembly, first mark the propellershaft drive flanges at transfer box and axle.10. Remove propeller shaft fixings and lift shaft fromvehicle.11. If the front axle is to be trailed, turn ignition keyto position' l' to release the steering lock.CAUTION: If the rear axle is to be raised,& the steering wheel and/or linkage MUST besecured in a straight ahead position. DONOT use the steering lock for this purpose.5. Secure tow rope to the front towing eye.6. Release the parking brake.INFORMATION 115INTRODUCTION NEW RANGE ROVERTRANSPORTING THE VEHICLE BY TRAILERIf the vehicle should require transporting on a trailer orthe back of a lorry, the air suspension must be set to'ACCESS' before being lashed. See FRONTSUSPENSION, Description and operation.Lashing eyes are provided on the front and rearchassis cross members to facilitate the securing of thevehicle, as shown.CAUTION: DO NOT secure lashing hooksor trailer fixings to any other part of thevehicle.CAUTION: If the air suspension cannot be& set to the 'ACCESS' position, then thevehicle must be lashed by its wheels andnot the lashing eyes.Install vehicle on the trailer and apply park brake.Select neutral in main gearbox; this will preventdamage to the parking pawl of the automatic gearbox.16 I INFORMATION04 - GENERAL SPECIFICATION DATACONTENTSPageINFORMATIONENGINE - 4.0 V8 1ENGINE - 4.6 V8 4ENGINE - BMW DIESEL 7ENGINE MANAGEMENT SYSTEM (EMS) V8 ENGINE 10FUEL SYSTEM - BMW DIESEL ENGINE 12COOLING SYSTEM - V8 ENGINE 12COOLING SYSTEM - BMW DIESEL ENGINE 12MANUAL TRANSMISSION 13AUTOMATIC TRANSMISSION 14STEERING 15SUSPENSION 15SHOCK ABSORBERS 15AIR CONDITIONING 15BRAKES 16ELECTRICAL 17REPLACEMENT BULBS 18VEHICLE WEIGHTS AND PAYLOAD 19VEHICLE DIMENSIONS 20TYRE PRESSURES 20WHEELS AND TYRES 20GENERAL SPECIFICATION DATA nENGINE - 4.0 V8Type 4.0 litre V8Number of cylinders Eight, two banks of fourBore 94.00 - 94.04 mmStroke 71.04 - 71.20 mmCapacity........................................................................... 3950 ern"Valve operation................................................................ Overhead by push-rodCompression ratio High CompressionUp to 99MY 9.35:1From 99MY 9.38:1Maximum power (at 4750 rev/min)Up to 99MY 140 kWFrom 99MYAll except NAS 136 kWNAS only 140 kW3.7008 - 3.7024 in2.7966 - 2.8031 in241 in3Low Compression8.2:18.23:1132 kW132 kWCrankshaftMain journal diameter 63.500 - 63.487 mm 2.50 - 2.4995 inCrankpin journal diameter 55.513 - 55.500 mm 2.1856 - 2.1850 inCrankshaft end thrust/end float Taken on thrust washers of centre main bearing0.10- 0.20 mm 0.004 - 0.008 inMain bearingsNumber and typeUp to 99MY 5, Vandervell shellsFrom 99MY 5, GlacierVandervell / AS15Material Lead bronze with lead-indium overlayDiametrical clearance 0.010- 0.048 mm 0.0004 - 0.002 inConnecting rodsType Horizontally split big-end, plain small-endLength between centres 155.12 - 155.22 mm 6.1071 - 6.1110 inBig-end bearingsType and materialUp to 99MY Vandervell VP Lead bronze with lead-indium overlayFrom 99MY Glacier Vandervell GPL2120 / AS124ADiametrical clearance 0.015 - 0.055 mm 0.0006 - 0.002 inINFORMATION I 104 GENERAL SPECIFICATION DATA NEW RANGE ROVERPiston pinsLength 60.00 - 60.50 mmDiameter 23.995 - 24.000 mmFit-in connecting rod Press fitClearance in piston 0.015 - 0.006 mmPistonsClearance in bore, measured 10 mm frombase of skirt at right angles to piston pinUp to 99MY 0.020 - 0.050 mmFrom 99MY 0.022 - 0.067 mm2.3622 - 2.3819 in0.9447 - 0.9449 in0.00059 - 0.00024 in0.0008 - 0.0020 in0.0009 - 0.0026 in21Nitrided steel barrel facedTapered spherical barrel marked 'TOP'Up to 99MY 1.21 -1.23 mmFrom 99MY 1.17-1.19mmCompression ring gapBottom 0.40 - 0.65 mmTop 0.3 - 0.5 mmOil control ring typeUp to 99MY AclonoformFrom 99MY 3 Piece AeconoformOil control ring width 3.0 mmOil control ring rail gap 0.38-1.40 mmPiston ringsNumber of compression rings .Number of oil control rings .No 1 compression ring .No 2 compression ring .Width of compression ringsBottom .Top1.478 -1.49 mm 0.0582 - 0.0587 in0.0476 - 0.0484 in0.0461 - 0.0479 in0.0157 - 0.0256 in0.0118 - 0.0197 in0.1181 in0.0150 - 0.0551 inCamshaftLocation CentralBearings Non serviceableNumber of bearings 5Drive Chain 9.52 mm pitch x 54 pitches.Camshaft end floatUp to 99MY 0.076 - 0.355 mm 0.003 - 0.014 inFrom 99MY 0.075 - 0.350 mm 0.002 - 0.013 inTappets Hydraulic self-adjusting2 I INFORMATIONGENERAL SPECIFICATION DATA n0.3411 - 0.3417 in0.3406 - 0.3412 in1.565 - 1.575 in1.3475 -1.3575 in4.590 - 4.620 in4.590 - 4.620 inFrom 99MY45- 4530'45- 4530'0.0010- 0.0026 in0.0015 - 0.0031 in0.3913 in0.025 - 0.066 mm0.038 - 0.078 mm9.94 mmValvesLengthInlet 116.59-117.35mmExhaust 116.59 - 117.35 mmSeat angle Up to 99MYInlet 46- 4625'Exhaust 46- 4625'Head diameterInlet 39.75 - 40.00 mmExhaust 34.227 - 34.48 mmStem diameterInlet 8.664 - 8.679 mmExhaust 8.651 - 8.666 mmStem to guide clearanceInlet .E x h a u ~ .Valve lift (inlet and exhaust) .Valve spring length fittedUp to 99MY 40.40 mm (1.59 in) at pressure of 29.5 kg (65 Ib)From 99MY 40.93 mm (1.61 in) at pressure of 29.5 kg (65 Ib)LubricationSystem type Wet sump, pressure fedOil pump type Crank driven rotorOil pressureUp to 99MY 2.06 to 2.7 bar (30 to 40 lbf/irr') at 2400 rev/min withengine warmFrom 99MY 3.45 bar (50 lbf/in") at 2000 rev/min with engine warmOil filter-internal Wire screen, pump intake filter in sumpOil filter-external Full flow, self-contained cartridgeINFORMATION I 304 GENERAL SPECIFICATION DATA NEW RANGE ROVERENGINE - 4.6 V8Type 4.6 litre V8Number of cylinders Eight, two banks of fourBore 94.00 - 94.04 mmStroke 81.92 - 82.08 mmCapacity........................................................................... 4554 ern"Valve operation................................................................ Overhead by push-rodCompression ratio High CompressionUp to 99MY 9.35:1From 99MY 9.37:1Maximum power (at 4750 rev/min)Up to 99MY 165.5 kWFrom 99MYAll except NAS 160 kWNAS only 165.5 kW3.7008 - 3.7024 in3.2252 - 3.2315 in278 in3Low Compression8.36:18.37:1157 kW150 kWCrankshaftMain journal diameter 63.500 - 63.487 mm 2.50 - 2.4995 inCrankpin journal diameter 55.513 - 55.500 mm 2.21 - 2.20 inCrankshaft end thrust/end float Taken on thrust washers of centre main bearing0.10- 0.20 mm 0.004 - 0.008 inMain bearingsNumber and typeUp to 99MY 5, Vandervell shellsFrom 99MY 5, GlacierVandervell / AS15Material Lead bronze with lead-indium overlayDiametrical clearance 0.010- 0.048 mm 0.0004 - 0.002 inConnecting rodsType Horizontally split big-end, plain small-endLength between centres 149.68 - 149.78 mm 5.893 - 5.897 inBig-end bearingsType and materialUp to 99MY Vandervell VP Lead bronze with lead-indium overlayFrom 99MY Glacier Vandervell GPL2120/AS124ADiametrical clearance 0.015 - 0.055 mm 0.0006 - 0.002 inPiston pinsLength 60.00 - 60.50 mmDiameter 23.995 - 24.000 mmFit-in connecting rod Press fitClearance in piston 0.015 - 0.006 mmPistonsClearance in bore, measured at bottomof skirt at right angles to piston pinUp to 99MY 0.020 - 0.050 mmFrom 99MY 0.022 - 0.067 mm4 I INFORMATION2.3622 - 2.3819 in0.9447 - 0.9449 in0.0006 - 0.0002 in0.0008 - 0.0020 in0.0009 - 0.0026 inGENERAL SPECIFICATION DATA n21Nitrided steel barrel facedTapered spherical barrel marked 'TOP'Up to 99MY 1.21 -1.23 mmFrom 99MY 1.17-1.19mmCompression ring gapBottom 0.40 - 0.65 mmTop 0.3 - 0.5 mmOil control ring typeUp to 99MY AclonoformFrom 99MY 3 Piece AeconoformOil control ring width 3.0 mmOil control ring rail gap 0.38-1.40 mmPiston ringsNumber of compression rings .Number of oil control rings .No 1 compression ring .No 2 compression ring .Width of compression ringsBottom .Top1.478 -1.49 mm 0.0582 - 0.0587 in0.0476 - 0.0484 in0.0461 - 0.0479 in0.0157 - 0.0256 in0.0118 - 0.0197 in0.1181 in0.0150 - 0.0551 inCamshaftLocation CentralBearings Non serviceableNumber of bearings 5Drive Chain 9.52 mm pitch x 54 pitches.Camshaft end floatUp to 99MY 0.076 - 0.355 mm 0.003 - 0.014 inFrom 99MY 0.075 - 0.350 mm 0.002 - 0.013 inTappets Hydraulic self-adjusting0.3411 - 0.3417 in0.3406 - 0.3412 in1.565 - 1.575 in1.3475 -1.3575 in4.590 - 4.620 in4.590 - 4.620 inFrom 99MY45- 4530'45- 4530'0.0010- 0.0026 in0.0015 - 0.0031 in0.3913 in0.025 - 0.066 mm0.038 - 0.078 mm9.94 mmValvesLengthInlet 116.59-117.35mmExhaust 116.59 - 117.35 mmSeat angle Up to 99MYInlet 46- 4625'Exhaust 46- 4625'Head diameterInlet 39.75 - 40.00 mmExhaust 34.227 - 34.48 mmStem diameterInlet 8.664 - 8.679 mmExhaust 8.651 - 8.666 mmStem to guide clearanceInlet .E x h a u ~ .Valve lift (inlet and exhaust) .Valve spring length fittedUp to 99MY 40.40 mm (1.59 in) at pressure of 29.5 kg (65 Ib)From 99MY 40.93 mm (1.61 in) at pressure of 29.5 kg (65 Ib)INFORMATION I 504 GENERAL SPECIFICATION DATA NEW RANGE ROVERLubricationSystem type Wet sump, pressure fedOil pump type Crank driven rotorOil pressureUp to 99MY 2.06 to 2.7 bar (30 to 40 lbf/irr') at 2400 rev/min withengine warmFrom 99MY 3.45 bar (50 lbf/in") at 2000 rev/min with engine warmOil filter-internal Wire screen, pump intake filter in sumpOil filter-external Full flow, self-contained cartridge6 I INFORMATIONGENERAL SPECIFICATION DATA nENGINE - BMW DIESEL3.15 in3.26 in152 in3~ ~ .Number of cylinders .~ f f i .Stroke .Capacity .Compression ratio .Valve operation .Turbo charger .Indirect injection, turbocharged, intercooled680.00 mm82.80 mm2497 ern"22.5:1 1:1OHC chain drivenMitsubishi TD04 - 11G4CamshaftDrive................................................................................. ChainNumber of bearings 7Cylinder headLongitudinal warp 0.1 mmLateral warp 0.05 mm0.004 in0.002 inValve seat widthValve head stand-down:Stem diameter - Standard:Valves and guidesValve head diameter: 1.42 in1.22 in0.274 in0.273 in0.273 in0.272 in0.28 in0.277 in0.278 in0.27 in0.282 in0.28 in0.281 in0.279 in0.02 to 0.03 in0.03 to 0.04 in0.01 and 0.02 in0.02 in1.4 in1.2 in0.007 to 0.09 in0.10 to 0.11 inInlet 36.0 mmExhaust 31.0 mmInlet 6.97 mmService limit 6.95 mmExhaust 6.95 mmService limit 6.93 mmStem diameter - 1st oversize: Inlet 7.07 mmService limit 7.05 mmExhaust 7.06 mmService limit 7.04 mmStem diameter - 2nd oversize: Inlet 7.17 mmService limit 7.15 mmExhaust 7.16 mmService limit 7.14 mmInlet 0.65 to 0.85 mmExhaust 0.85 to 1.05 mmValve head oversizes - increased thickness 0.25 and 0.50 mmValve tilt - inlet and exhaust 0.5 mmValve seats:Valve seat angle 45 10'Correction angle - outside 15Correction angle - inside 60Seat face outside diameter Inlet 35.5 mmExhaust 30.6 mmlnlet. 1.75 to 2.25 mmExhaust 2.60 to 2.90 mmValve guides:Inner diameter for reaming - inlet and exhaustStandard 7.0 mm1st oversize valve stem 7.1 mm2nd oversize valve stem 7.2 mm0.275 in0.28 in0.283 inINFORMATION I 704 GENERAL SPECIFICATION DATA NEW RANGE ROVERCrankshaftMain bearing bearing journal diameterYellow 59.984 to 59.990 mmGreen 59.977 to 59.983 mmWhite 59.971 to 59.976 mmOversize bearings 0.25 and 0.50 mmBig-end journal diameter:Standard 44.975 to 45.00 mm1st undersize - Size 1 - 0.25 mm (0.01 in) 44.725 to 44.75 mm2nd undersize - Size 2 - 0.50 mm (0.02 in) 44.475 to 44.50 mmOversize bearings 0.25 and 0.50 mmCrankshaft end float 0.080 to 0.163 mm2.3616 to 2.3618 in2.3612 to 2.3615 in2.3610 to 2.3611 in0.01 and 0.02 in1.770 to 1.771 in1.761 to 1.762 in1.751 to 1.752 in0.01 and 0.02 in0.003 to 0.006 inMain bearingsNumber and type 7 halved shells with oil groovesDiametrical clearance 0.020 to 0.058 mm 0.001 to 0.002 inConnecting rodsDiametrical clearance (big-end bearings) 0.010 to 0.055 mmGudgeon pin bush bore 28.995 to 29.021 mmMaximum deviation of connecting rod parallelism 0.05 mmMaximum distortion 0.5 mm0.0004 to 0.002 in1.142 to 1.143 in0.002 in0.02 in3.14 0.004 in3.15 0.004 in3.16 0.004 in0.0012 to 0.002 in79.96 0.009 mm80.04 0.009 mm80.21 0.009 mm0.031 to 0.63 mmPistonsType Aluminium alloy, combustion chamber in crownPiston diameter measured 7 mm (0.27 in) from loweredge and at right angles to gudgeon pin .Intermediate size .Oversize 1 .Piston running clearance .Piston ringsType:Top Double keystoneSecond Taper facedOil control Bevelled ring with springGap in bore:All 0.2 to 0.4 mm 0.008 to 0.020 inClearance in piston grooves:Top Not measuredSecond 0.040 to 0.072 mm 0.002 to 0.004 inOil control 0.030 to 0.065 mm 0.001 to 0.003 inCylinder boresStandard 80.00 to 80.04 mmIntermediate 80.08 to 80.12 mm1st oversize 80.25 to 80.29 mmMaximum ovality 0.04 mmMaximum taper 0.04 mm3.150 to 3.151 in3.153 to 3.154 in3.20 to 3.21 in0.002 in0.002 in8 I INFORMATIONGENERAL SPECIFICATION DATA nInternal gear type pump, mounted on front of engineDirect from crankshaft84.10mm 3.3inDisposable cartridgeMounted on front of coolant radiator0.065 mm 0.003 in0.070 mm 0.004 inpiston operated, non-adjustableLubricationSystem .Oil pressure, at idle .Regulated pressure .Oil pump:~ ~ .Drive .Radial clearance:Inner rotor/bearing sleeve (max.) .Outer rotor/pump body (max.) .Axial clearance:Inner rotor/pump body .Outer rotor/pump body .Oil pressure relief valve .Relief valve spring:Length relaxed .Oil filter .Engine oil cooler .Wet sump, pressure fed2.0 bar3.8 bar0.065 mm0.4 mm29.0 Ibf/in255.0 Ibf/in20.003 in0.02 inINFORMATION I 904 GENERAL SPECIFICATION DATA NEW RANGE ROVERENGINE MANAGEMENT SYSTEM (EMS) V8ENGINETypeUp to 99MY Sagem - Lucas Gems 8 hot wire system, electronicallycontrolledFrom 99MY Bosch Motronic M5.2.1, electronically controlledFuel pump High pressure electrical, immersed in the fuel tankFuel pump delivery pressureUp to 99MY 2.4-2.6 bar 34-37 Ibf/in2From 99MY 3.5 bar 50.75Ibf/in2Fuel filter Bosch in-line filter 'canister' typeMass airflow sensorMake and typeUp to 99MY Lucas 'Hot Wire' 20AMFrom 99MY Bosch EH1174 (includes air intake temperaturesensor)InjectorsMake and typeUp to 99MY Lucas 01000From 99MY Bosch EV6CElectronic Control ModuleMake and typeUp to 99MY Lucas GEMS 8.2From 99MY Bosch M5.2.1Fuel pressure regulatorMake and typeUp to 99MY Lucas 8RVFrom 99MY Rochester (part of fuel pump)Coolant temperature sensorMake and type Lucas 8TTBypass air valve (Stepper motor)Make and typeUp to 99MY Lucas 3ACMFrom 99MY BoschThrottle position sensorMake and typeUp to 99MY Lucas 3TPFrom 99MY Bosch OKG110 I INFORMATIONGENERAL SPECIFICATION DATA nHeated oxygen sensor - catalyst vehiclesMake and typeUp to 99MY Lucas 4LSFrom 99MY Bosch LSHCamshaft position sensorMake and Land Rover part no.Up to 99MY Honeywell ERR2261From 99MY Lucas ERR6170Crankshaft position sensorMake and typeUp to 99MY Lucas 4CSFrom 99MY Bosch OG6Knock sensorMake and typeUp to 99MY Lucas 2KSFrom 99MY Bosch KS1SIntake air temperature sensorMake and typeUp to 99MY Lucas 1OTTFrom 99MY Not applicable (combined with MAF sensor)Ignition coilsMake and typeUp to 99MY Lucas 20lS2From 99MY Bosch 0 221 503 407Fuel temperature sensorMake and typeUp to 99MY Lucas 6TTFrom 99MY Not applicableINFORMATION 1 1104 GENERAL SPECIFICATION DATA NEW RANGE ROVER190 of185 9 of15lbf/in2FUEL SYSTEM - BMW DIESEL ENGINEInjection pump type Bosch rotary R515Injection pump timing 0.95 0.02 mm lift at TOCInjectors See ENGINE TUNING DATA, Information.Heater plugs See ENGINE TUNING DATA, Information.Fuel lift pump type Electric in tank fuel pumpFuel filter Paper element typeAir cleaner........................................................................ Paper element typeTurbocharger Mitsubishi T004 11G4COOLING SYSTEM - V8 ENGINESystem type Pressurized, spill return, thermostatically controlledwater and anti freeze mixture. Vertical flow radiatorwith remote header tank and pump assisted.Cooling fan 9 blade axial flow. Viscous coupling.Pump type Centrifugal, impeller, belt driven.Thermostat openingUp to 99MY 88CFrom 99MY 85 5 CExpansion tank cap pressure (system pressure) 1.0 barCOOLING SYSTEM - BMW DIESEL ENGINESystem type Pressurized, spill return, thermostatically controlledwater and anti freeze mixture. Pump assisted thermosyphon. Coolant radiator combined with oil cooler andturbo intercooler.Cooling fan 11 blade axial flow 433 mm diameter. 1.44: 1 driveratio. Viscous coupling.Pump type Centrifugal, impeller, belt driven.Thermostat opening 80C 176 ofExpansion tank cap pressure (system pressure) 1.0 bar 15 Ibf/in212 I INFORMATIONGENERAL SPECIFICATION DATA nMANUAL TRANSMISSIONClutchMake and type - V8 engine AP Borg and Beck, diaphragm springClutch plate diameter 265 mm (10,43 in.)Make and type - Diesel engine Valeo, diaphragm springClutch plate diameter 242 mm (9.53 in.)Transfer gearboxBorg Warner Two speed reduction on main gearbox output, frontand rear drive permanently engaged via a centredifferential controlled by a Viscous unit giving a 50/50nominal front and rear torque split.Transfer gearbox ratiosHigh 1.216:1Low 3.271:1Manual gearboxType R380 5 speed, single helical constant mesh withsynchromesh on all gearsManual gearbox ratios:5th 0.731:14th 1.000: 13rd 1.397:12nd 2.132:11st 3.321:1Reverse 3.429:1Diesel models low first gear 3.692:1Overall ratio (final drive): High transfer5th 3.15:14th 4.30:13rd 6.01:12nd 9.18:11st 14.29:1Reverse 14.76:1Diesel models low 1st gear 15.89: 1Propeller shaftsType:Front Tubular 51mm diameterRear Tubular 51mm diameterUniversal joints Open type Hooks 03EHDRear axleType Spiral bevelRatio 3.54:1Front axleType Spiral bevelRatio 3.54:1Low transfer8.46:111.58:116.18:124.69:138.45:139.70:142.75:1INFORMATION 11304 GENERAL SPECIFICATION DATA NEW RANGE ROVERAUTOMATIC TRANSMISSIONAutomatic gearboxModel2.5 litre Diesel & 4.0 litre Petrol ZF4HP224.6 litre Petrol ZF4HP24Type Four speed and reverse epicyclic gears with fluidtorque converter and lock up.Transfer gearboxBorg Warner Two speed reduction on main gearbox output, frontand rear drive permanently engaged via a centredifferential controlled by a Viscous unit giving a 50/50nominal front and rear torque split.Transfer gearbox ratiosHigh 1.216:1Low 3.271:1Automatic gearbox ratios4th 0.728:13rd 1.000: 12nd 1.480: 11st 2.480:1Reverse 2.086:1Overall ratio (final drive): High transfer4th 3.13:13rd 4.30:12nd 6.37:11st 10.67:1Reverse 8.98:1Propeller shaftsType:Front Tubular 51mm diameterRear Tubular 51mm diameterUniversal joints Open type Hooks 03EHDRear axleType Spiral bevelRatio 3.54:1Front axleType Spiral bevelRatio 3.54:114 I INFORMATIONLow transfer8.43:111.58:117.14:128.72:124.15:1GENERAL SPECIFICATION DATA nSTEERINGPower steering boxMake/type ZF type 8055, recirculating ball steering gearSteering wheel turns, lock-to-Iock 3.2Steering pumpMake/type:V8 engine ZF type 7691, vane typeDiesel engine ZF type7681, vane typeNOTE:Check atkerbweightSteering geometrySteering wheel diameter .Toe-out measurement .Toe-out included angle .Camber angle .Castor angle .Swivel pin inclination static .SUSPENSION406.4mm (16 in.)0.6 to 1.80mm (0.02 - 0.07 in.)05' to 015'048Type:Air suspension Variable rate air springs controlled by an ECU giving 5height profiles. Automatic self levelling. Automaticstandard and low profiles. Driver selected access, lowand high profiles.Lateral location of axle by Panhard rod.Front Fore and aft location by two radius arms.Lateral location of axle by a Panhard rod.Rear Fore and aft movement controlled by two trailingarms.Lateral location of axle by a Panhard rod.SHOCK ABSORBERSType Telescopic, double-acting non-adjustableAIR CONDITIONINGSystem............................................................................. CFC free expansion valve systemCompressorV8 up to 99MY Sanden TRS105NV8 from 99MY and diesel Nippon Denso 10PA17INFORMATION 1 1504BRAKESGENERAL SPECIFICATION DATA NEW RANGE ROVERFront service brakeCaliper Lucas Colette, single sided, two pistonOperation Power hydraulic, self-adjustingDisc Reverse ventilated, outboardDisc diameter 297.2 mm (11.7 in.)Disc thickness 25 mm (1 in.)Wear limit 22.0 mm (0.87 in.)Disc run out maximum 0.15 mm (0.006 in)Pad area 64.9 ern" (10 irr') per padTotal swept area 844 ern" (130.8 irr') per discPad minimum thickness 2 mm (0.08 in.)Rear service brakeCaliper Lucas Colette,single sided, single pistonOperation Power hydraulic, self-adjustingDisc Solid, outboardDisc diameter 304.0 mm (12 in.)Disc thickness 12.6 mm (0.5 in.)Wear limit 11.7 mm (0.46 in.)Disc run out maximum 0.15 mm (0.006 in)Pad area 34.4 ern" (5.33 in2) per padTotal swept area 798 ern" (123.7 irr') per discPad minimum thickness 2 mm (0.08 in.)Parking brakeType Mechanical-cable operated drum brake on the rearof the transfer gearbox output shaftDrum internal diameter 254 mm (10 in.)Width 70 mm (2.75 in)Anti-lock brake systemManufacturer/type Wabco/power hydraulic - 4 channel, 4 wheel sensedintegrated anti-lock brake system.ABS control...................................................................... Microprocessor based ECUSystem split Front/rearPower source Electrically driven pumpPower storage Hydraulic accumulatorMaximum boost pressure 180 barReservoir Built in low fluid warning. Supplies clutch hydraulicsystemElectronic traction controlType Integrated with ABS systemETC control Integrated with ABS ECU16 I INFORMATIONGENERAL SPECIFICATION DATA nELECTRICALSystem 12 volt, negative groundBatteryMake: Land Rover Parts and Equipment maintenance freeType:V8 072, 72 amp/hrDiesel 664, 107 amp/hrAlternatorMake and typeV8 up to 99MY and diesel Magnetti Marelli A133, 100A, 105A or 120AV8 from 99MY Bosch NC90/150, 150AFusesType Autofuse (blade type) blow ratingsto suit individual circuitsHornsMake/type Klamix (Mixo) TR99Starter motorMake and type:V8 Engine Bosch 331.303.006.808 pre-engagedDiesel Engine Bosch 0.001.362.092 pre-engagedINFORMATION 1 1704 GENERAL SPECIFICATION DATA NEW RANGE ROVERREPLACEMENT BULBSBULB LOCATION TYPEExterior:Dip/main headlamps 12V - GO/55W (Halogen)Inboard main beam headlamps 12V - 55W (Halogen)Front fog lamps 12V - 55W H3 (Halogen)Sidelamps 12V - 5W caplessTail lamps 12V - 5W caplessRear fog lamps 12V - 21W bayonetReverse lamps 12V - 21W bayonetStop lamps.............................................................. 12V - 21W bayonetDirection indicator lamps 12V - 21W bayonetSide repeater lamps 12V - 5W caplessNumber plate lamps 12V - 5W caplessInterior:Front interior roof lamps 12V - 10W 'Festoon'Map reading lamp 12V - 5W caplessRear interior roof lamps 12V - 5W 'Festoon'Map reading lamp 12V - 5W caplessPuddle lamps 12V - 3W caplessGlovebox lamp 12V - 5W 'Festoon'Vanity mirror lamp 12V - 1.2W 'Festoon'Rear footweillamp 12V - 5W 'Festoon'Load space lamp 12V - 10W 'Festoon'Clock illumination 12V - 2W bayonetCigar lighter illumination 12V - 1.2W caplessAuxiliary switch illumination 12V - O.2WcaplessAuxiliary switch warning lamp 12V - O.2WcaplessHeater/air conditioning graphics illumination 12V - 1.2W caplessInstrument panel:Instrument panel illumination 14V - 3.4W T10 bulb/holder unitWarning lamps 14V - 1.4W T5 bulb/holder unitLCD background 14V - 1.4W T5 bulb/holder unitNOTE: The correct specification Toshiba bulbs must be used in the instrument panel to ensure thecorrect level of illumination.CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damageto vehicle wiring and switches.18 I INFORMATIONGENERAL SPECIFICATION DATA nVEHICLE WEIGHTS AND PAYLOADWhen loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the vehicle kerbweight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximumvalues. It is the customer's responsibility to limit the vehicle's payload in an appropriate manner such that neithermaximum axle loads nor Gross Vehicle Weight are exceeded.GROSS VEHICLE WEIGHTPetrol Models Diesel ModelsFrontAxle 1320 kg (2910 Ib) 1320 kg (2910 Ib)Rear Axle 1840 kg (4056 Ib) 1840 kg (4056 Ib)Total 2780 kg (6129Ib) 2780 kg (6129Ib)Maximum Payload 603 kg (1329Ib) 596 kg (1314Ib)EEC KERB WEIGHT AND DISTRIBUTION4.0 Litre Manual 4.0 Litre Automatic 4.6 Litre AutomaticEEC Kerb Weight 2090 kg (4607 Ib) 2100 kg (4629 Ib) 2220 kg (4894 Ib)FrontAxle 1095 kg (2414Ib) 1100 kg (2425Ib) 1165 kg (2568Ib)Rear Axle 995 kg (2193 Ib) 1000 kg (2204 Ib) 1055 kg (2325 Ib)2.5 Diesel Manual 2.5 Diesel AutomaticEEC Kerb Weight 2115 kg (4662Ib) 2130 kg (4695Ib)FrontAxle 1110 kg (2447Ib) 1120 kg (2469Ib)Rear Axle 1005 kg (2215Ib) 1010 kg (2226Ib)NOTE: EEC KERB WEIGHT is the minimum vehicle specification plus full fuel tank and 75 kg (165Ib) driver.NOTE: GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver,passengers, and equipment. This figure is liable to vary according to legal requirements in certaincountries.NOTE: MAXIMUM ROOF RACK LOAD (including weight of rack) 75 kg (165Ib) must be included intotal vehicle weight.INFORMATION 1 1904 GENERAL SPECIFICATION DATA NEW RANGE ROVERVEHICLE DIMENSIONSmmOverall length 4713Width excluding door mirrors 1853Width including door mirrors 2228Overall height at standard profile 1817.5Wheelbase 2745Track:Front 1540Rear 1530Turning circle between kerbs 11.9 m (39 ft)TYRE PRESSURESNormal on and off-road use. All speeds and loadsFrontbar 1.9Ibf/in228kgf/cm22.0inches185.673.087.771.6108.160.660.2Rear2.6382.76ANOTE: Check pressures with tyres coldWARNING: After any off-road driving, tyres and wheels should be inspected for damage,particularly if high cruising speeds are subsequently to be used.WHEELS AND TYRESWheel type and size Alloy 7.00J X 16 (use with 235/70 tyres)Alloy 8.00J X 16 (use with 255/65 tyres)Alloy 8.00J X 18 (use with 255/55 tyres)A WARNING: All vehicles are fitted with tubeless alloy road wheels as original equipment. Note thatthese wheels DO NOT accept inner tubes and tubed tyres MUST NOT be fitted.20 I INFORMATION05 - ENGINE TUNING DATACONTENTSPageINFORMATIONENGINE - 4.0 V8 1ENGINE - 4.6 V8 2ENGINE - BMW DIESEL 3ENGINE TUNING DATA nENGINE - 4.0 V8Type 4.0 Litre V8Firing order 1-8-4-3-6-5-7-2Cylinder NumbersLeft bank 1-3-5-7Right bank 2-4-6-8No 1 Cylinder location Pulley end of left bankSpark plugsMake and typeUp to 99MY Champion RN11YCCFrom 99MY Champion RC11PYB4GapUp to 99MY 0.90 - 1.00 mmFrom 99MY 1.00 0.05 mmNOTE: Do not attempt to adjust the gaps of RC11PYB4 spark plugs.Valve timing InletOpens 28BTDCCloses 77ABDCIdle speed - controlled by Engine Management SystemUp to 99MY 700 20 rev/minFrom 99MY 660 rev/min0.035 - 0.040 in0.040 0.002 inExhaust66BBDC39ATDCBase idle setting Not adjustable (idle air control valve position checkedvia TestBook)CO at idle (vehicles without heated oxygen sensors)Up to 99MY 1.0 - 2.0 %From 99MY 0.5 - 1.0 %Calculated Load Value (CLV) - Engine fully warm, in neutral gear, with all loads offAt Idle 2.8 to 3.8%At 2500 rev/min 10% 1%Air mass flow at sea level - Engine fully warm, in neutral gear, with all loads offAt Idle 20 3 kg/hrAt 2500 rev/min 60 3 kg/hrINFORMATION I 1105 ENGINE TUNING DATA NEW RANGE ROVERENGINE - 4.6 V8Type 4.6 Litre V8Firing order 1-8-4-3-6-5-7-2Cylinder NumbersLeft bank 1-3-5-7Right bank 2-4-6-8No 1 Cylinder location Pulley end of left bankSpark plugsMake and typeUp to 99MY Champion RN11YCCFrom 99MY Champion RC11PYB4GapUp to 99MY 0.90 - 1.00 mmFrom 99MY 1.00 0.05 mmNOTE: Do not attempt to adjust the gaps of RC11PYB4 spark plugs.Valve Timing InletUp to 99MYOpens 14BTDCCloses 700ABDCFrom 99MYOpens 28BTDCCloses 64ABDCIdle speed - controlled by Engine Management SystemUp to 99MY 700 20 rev/minFrom 99MY 660 rev/min0.035 - 0.040 in0.040 0.002 inExhaust72BBDC200ATDCBase idle setting Not adjustable (idle air control valve position checkedvia TestBook)CO at idle (vehicles without heated oxygen sensors)Up to 99MY 1.0 - 2.0 %From 99MY 0.5 - 1.0 %Calculated Load Value (CLV) - Engine fully warm, in neutral gear, with all loads offAt Idle 2.8 to 3.8%At 2500 rev/min 10% 1%Air mass flow at sea level - Engine fully warm, in neutral gear, with all loads offAt Idle............................................................................... 20 kg/hr 3 kg\hrAt 2500 rev/min 61 kg\hr 3 kg\hr2 I INFORMATIONENGINE TUNING DATA nENGINE - BMW DIESELENGINEType 2.5 Litre turbocharged diesel, indirect injection enginewith intercoolerFiring order 1-5-3-6-2-4Injection timing at TDC, No.1 cylinder 0.95 0.02 mm lift 0.04 0.0008 in liftTiming marks:Valve timing Slot for pin in flywheelInjection timing Dial gauge inserted into pumpMaximum governed speeds:Full load (speed cut-off starts) 4400 rev/minNo load (flight speed) 4950 150 rev/minIdle speed 750 50 rev/minINJECTION PUMPMake/type:Digital Diesel Electronic Control - DOE Bosch rotary R515 type with electronic control of fueland timing. Constant pressure delivery valves.Direction of rotation Clockwise, viewed from drive endINJECTORSMake/typeStandard Bosch KCA 21 S 71Nozzle type...................................................................... ON 0 SO 300Opening (injection) pressureMinimum pressure 140 barMaximum pressure 160 barMaximum pressure deviation 10 barNeedle lift sensor in no.4 injector Bosch KCA 21 S 76HEATER PLUGSMake/type Beru, probe type, 12 voltsTemperature after 5 seconds of operation 800CResistance at 20 c 0.4 - 0.6 OhmsTURBOCHARGERMake/type MitsubishiITD04 - 11G42030 Ibf/in22320 Ibf/in2145 Ibf/in2INFORMATION I 306 - TORQUE VALUESCONTENTSPageINFORMATIONMAINTENANCE 1ENGINE - BMW DIESEL 1ENGINE - V8 PETROL 3EMISSION CONTROL 4FUEL SYSTEM - BMW DIESEL 4FUELSYSTEM-V8PETROL 5COOLING SYSTEM - BMW DIESEL 5COOLING SYSTEM - V8 PETROL 5MANIFOLD AND EXHAUST SYSTEM - BMW DIESEL 6MANIFOLD AND EXHAUST SYSTEM - V8 PETROL 6CLUTCH - BMW DIESEL 7CLUTCH-V8PETROL 7MANUAL GEARBOX - R380 7TRANSFER GEARBOX 7AUTOMATIC GEARBOX - ZF 8PROPELLER SHAFTS 8REAR AXLE AND FINAL DRIVE 8FRONT AXLE AND FINAL DRIVE 9STEERING 9FRONT SUSPENSION 10REAR SUSPENSION 11BRAKES 11SUPPLEMENTARY RESTRAINT SYSTEM 12CHASSIS AND BODY 12SEATS 13AIR CONDITIONING 13WIPERS AND WASHERS 13ELECTRICAL 13INSTRUMENTS 13Description NmTORQUE VALUES ~IbUt10- MAINTENANCERoad wheels.................................................................... 108Spark plugs 20Air suspension air reservoir drain plug 70Sump drain plug - BMW diesel- M12 25- M22 60Sump drain plug - V8 petrol up to 99MY 45Sump drain plug - V8 petrol from 99MY 32Automatic gearbox oil drain plug 15Automatic gearbox oil filler / level plug............................. 30Manual gearbox oil drain plug 30Manual gearbox oil filler/level plug 30Transfer gearbox oil drain plug 30Transfer gearbox oil filler/level plug 3012 - ENGINE - BMW DIESELAdaptor DA 102-85 to No.1 glow plug location 20Glow plug to cylinder head 20Feed wires to glow plugs 4* Camshaft cover bolts..................................................... 15+ Crankshaft pulley hub bolt:- Stage 1 100- Stage 2 - Tighten further 60- Stage 3 - Tighten further 60- Stage 4 - Tighten further 30Damper and pulley to hub bolts 23Pulley to water pump bolts 10Crankshaft rear oil seal to cylinder block:- M6 bolts 10- M8 bolts......................................................................... 22Manual gearbox harness bracket bolt.............................. 6+ Propeller shaft flanges nuts and bolts 48Engine mounting nuts 45Manual gear lever bolts.................................................... 25Pipes to air conditioning compressor bolts 23Pipes to air conditioning condenser 15Feed hose to PAS pump union 30Pipes to gearbox oil cooler 30+ Flywheel to crankshaft bolts - manual gearbox 105+ Drive plate to crankshaft bolts - automatic gearbox 120Front cover to cylinder block bolts 10Steering pump bracket to front cover / cylinderblock bolts........................................................................ 22801552184433241122222222221515311746060301777164353318171122227788716DATA, TORQUE & TOOLS I 1TORQUE VALUES NEW RANGE ROVER+ * Cylinder head bolts:- Stage 1 - Tighten to 80- Stage 2 - Slacken........................................................... 180- Stage 3 - Tighten to 50- Stage 4 - Tighten further 90- Stage 5 - Tighten further 90- Stage 6 - Run engine 25 mins- Stage 7 - Allow to cool................................................... -- Stage 8 - Tighten further 90Cylinder head to timing cover nut and bolts:- M6 10- M7 15-M8 ~Camshaft cover blanking plate bolts 22Drive belt tensioner plug 20+ Camshaft sprocket bolt:- Stage 1 - Tighten to 20- Stage 2 - Tighten further 35Turbocharger to exhaust manifold bolts 45Pipes to engine oil cooler 30Oil filter bolt 33Oil filter head to cylinder block bolts 22Oil pump bolts 22Oil pick-up strainer bolts 10Oil pressure switch 40Oil sump to cylinder block bolts:-M68.8 10-M610.9 12-M8 ~Oil pump cover screws 20Oil sump drain plug:- M12 25- M22 60Fuel injection pump sprocket nut 50Timing chain tensioner access plug 40Camshaft bearing cap nuts:- M6 10- M7 15-M8 ~+*Main bearing cap bolts:- Stage 1 20- Stage 2 - Tighten further 50Oil cooling jets 12+ Reinforcing plate bolts:-M8 ~- M10 432 I DATA, TORQUE & TOOLS5918037909025 mins711151615153533222416167307915151844373071115155091632TORQUE VALUES_______nCylinder block coolant drain plug 25+*Big-end bearing cap bolts:- Stage 1 5- Stage 2 20- Stage 3 - Tighten further 701841570+ New nuts/bolts must be fitted* Tighten in sequence12 - ENGINE - V8 PETROLAlternator mounting bracket to engine bolts 40Camshaft drive gear bolt.................................................. 50Coolant rail to inlet manifold bolt 22Crankshaft pulley bolt... 270Water pump pulley bolts 22Hub aligner to crankshaft Allen screws- automatic gearbox......................................................... 85Drive plate clamp ring bolts - automatic gearbox 45Flywheel to crankshaft bolts - manual gearbox 80Manual gearbox harness bracket bolt.............................. 6+ Propeller shaft flanges nuts and bolts 48Engine mounting nuts 45Manual gear lever bolts.................................................... 25Pipes to air conditioning compressor bolts 23Pipes to air conditioning condenser 15Feed hose to PAS pump union 16Pipes to engine oil cooler 30Gearbox cooler pipes to LH engine mounting bracketb o ~ 18Pipes to gearbox oil cooler 30Fuel pipe to fuel rail union 16Camshaft position sensor to timing cover bolt.. 8Oil pressure switch to timing cover 15Water pump to timing cover bolts 22* Timing cover bolts 22Camshaft position sensor multi plug bracket bolts 22* Cylinder head bolts:- Stage 1 20- Stage 2 - Tighten further 90- Stage 3 - Tighten further 90Oil cooler pipes to front cover.......................................... 15Auxiliary drive belt tensioner bolt - up to 99MY 50Auxiliary drive belt tensioner bolt - from 99MY 45Auxiliary drive belt idler pulley bolt 50Auxiliary drive belt cover bolts 18Oil filter head adaptor 13Oil pick-up strainer bolts 8Oil pick-up strainer to main bearing cap nut 25+ Engine mounting flange nuts 45Engine rear mounting to gearbox bolts 4530371620016633359435331817111222132212611161616159090113733371396183333DATA, TORQUE & TOOLS I 3TORQUE VALUES NEW RANGE ROVERCrossmember to chassis 45+ Gearbox mounting to crossmember nuts/bolts 45Rear engine mounting to gearbox bolts 45Rocker cover to cylinder head bolts - up to 99MY:Stage 1 4Stage 2 8Stage 3 - re-torque to: 8+ Rocker cover to cylinder head bolts - from 99MY:Stage 1 3Stage 2 7* Rocker shaft to cylinder head bolts 38* Oil sump to cylinder block nuts/bolts 23Oil sump to bell housing bolts 45Oil sump drain plug - up to 99MY 45Oil sump drain plug - from 99MY 32+ New nuts/bolts must be fitted* Tighten in sequence17 - EMISSION CONTROLSAl control valve to engine manifold bracket bolts 10Vacuum reservoir to mounting bracket bolt., 10SAl pump rubber mountings 10SAl pump to mounting bracket nuts 10SAl air injection pipe unions 2519 - FUEL SYSTEM - BMW DIESELFuel injection pump flange nuts 22Rear support bolt., 22Fuel injection pump access hole bolt 25High pressure pipes to fuel injection pump unions 20High pressure pipes to injectors unions 20Air suspension drier to air cleaner bolt............................. 8Engine coolant temperature sensor 18Crankshaft position sensor to bracket bolt 8Fuel feed pipe to fuel injection pump and filter union 14Glow plugs to cylinder head 20Feed wires to glow plugs nuts 4+ Sprocket to fuel injection pump nut 50Fuel return pipe to fuel injection pump 25Adaptor to fuel filter.......................................................... 10Fuel filter hollow bolt 14Fuel injectors to cylinder head 65Air intake sensor to inlet manifold 14Throttle position sensor bolts........................................... 5Turbocharger to exhaust manifold bolts 45Oil feed pipe to turbocharger banjo bolt 25Fuel feed and return pipes to tank unit., 16+ New nut must be fitted4 I DATA, TORQUE & TOOLS3333333662.25.228173333247777181616181515613610153371871048104331812TORQUE VALUES_______n19-FUELSYSTEM-V8PETROLIntake air temperature sensor to air cleaner 8Air suspension drier to air cleaner bolts........................... 8Camshaft position sensor to timing cover bolt.. 8Engine coolant temperature sensor to manifold 20Crankshaft position sensor to cylinder blockadaptor plate bolts............................................................ 6Fuel pressure regulator to fuel rail bolts 10Ignition coil bracket to inlet manifold nuts 8Fuel feed pipe to fuel rail union 16Ram housing to inlet manifold bolts 24Fuel temperature sensor to fuel rail 17Heated oxygen sensor..................................................... 20Spark plugs to cylinder head 20Fuel rail/ignition coil bracket to manifold nuts 8Throttle position sensor clamp plate bolts 2RH knock sensor to cylinder block 16Fuel pressure regulator bolts 10Stepper motor bolts 2Idle air control bolts 2.3Water jacket to plenum chamber bolts 13Throttle linkage bracket to plenum chamber bolts 8Plenum chamber to ram pipe housing bolts 24Throttle potentiometer to stepper motor bolts 2Fuel hoses to filter 20Fuel feed and return pipes to tank unit.. 16Fuel spill return pipe to tank 16Fuel feed pipe to filter 2066615476121813151561.51271.52106181.51512121526 - COOLING SYSTEM - BMW DIESELRadiator drain plug 6Oil cooler pipes to radiator - manual gearbox 30Water pump bolts 10Pulley to water pump bolts 10Fan to coupling bolts 10Viscous coupling to water pump 40Thermostat housing to front cover bolts........................... 10Coolant connecting pipe to front cover bolt 10422777307726 - COOLING SYSTEM - V8 PETROLRadiator drain plug 6Fan to coupling bolts 24Fan assembly to water pump 56Water pump bolts 22Pulley to water pump bolts 22418411616DATA, TORQUE & TOOLS I 5TORQUE VALUES NEW RANGE ROVER30 - MANIFOLD AND EXHAUST SYSTEM - BMWDIESEL* Exhaust manifold to cylinder head nuts 22Turbocharger to manifold bolts 45Coolant connecting pipe to front cover bolt 10Front pipe to turbocharger nuts:- Stage 1 14- Stage 2 - Slacken 2.5 turns -* Inlet manifold to cylinder head nuts 22Intermediate exhaust pipe flange nuts 2597MYon:Tail pipe flange to intermediate pipe flange nuts 25* Tighten progressively working from centre outwards30 - MANIFOLD AND EXHAUST SYSTEM - V8PETROL* Exhaust manifold to cylinder head bolts 55Outer heat shield bolts 8RH shock absorber top mounting bolt 85Front exhaust pipe to manifold nuts - up to 99MY 50Front exhaust pipe to manifold nuts - from 99MY 30Front exhaust pipe to intermediate pipe nuts 25+ Gearbox cross member to chassis nuts and bolts 45+ Gearbox mounting to cross member flange nuts 45* Inlet manifold to cylinder head bolts:Ignition coil bracket to inlet manifold nuts 8Fuel feed pipe to fuel rail union 16Inlet manifold to cylinder head bolts:- Stage 1 - Tighten gasket clamp bolts 0.7- Stage 2 - Tighten manifold bolts 10- Stage 3 - Tighten manifold bolts 50- Stage 4 - Tighten gasket clamp bolts 1797 MYon:Heated oxygen sensor to front pipe 20LH to RH tail pipe clamps 65Tail pipe flange to intermediate pipe flange nuts 25RH tail pipe to LH tail pipe nut 65+ New nuts/bolts must be fitted* Tighten in sequence6 I DATA, TORQUE & TOOLS16337101618184066337221833336120.5737121548184833 - CLUTCH - BMW DIESELCover to flywheel bolts:- M8 8.8 24- M8 10.9 34Clutch housing bolts:-M8 V- M10 51- M12 86Slave cylinder to clutch housing bolts 4533-CLUTCH-V8PETROLCover to flywheel bolts..................................................... 40Clutch housing bolts 40Slave cylinder to clutch housing bolts 4537 - MANUAL GEARBOX - R380Bell housing extension to gearbox bolts 45Clutch release bearing spigot bolts 18Transfer gearbox to gearbox bolts 45Gearbox to bell housing bolts 45+ Propeller shafts to transfer box drive flangesnuts 48Gear lever bolts................................................................ 25Selector remote housing to gearbox bolts........................ 25Pipes to oil cooler unions 22+ New nuts must be fitted41 - TRANSFER GEARBOXRatio motor to transfer gearbox bolts............................... 10+ Front and rear output shaft flanges Nyloc nut 148+ Propeller shaft flanges nuts 48Transfer gearbox to gearbox bolts 45Gear lever bolts................................................................ 25+ New nuts must be fittedTORQUE VALUES ~18252038633330303333133333351818167109353318DATA, TORQUE & TOOLS I 7TORQUE VALUES NEW RANGE ROVER44 - AUTOMATIC GEARBOX - ZFOil drain plug 15Oil filler / level plug 30Extension housing bolts................................................... 25Parking pawl guide Torx screw 10Breather pipes to gearbox bolts 15Intermediate plate Allen plugs (M14) 40Intermediate plate Allen plugs (M20) 50Fluid pump to intermediate plate bolts 10Oil cooler adaptors 42Valve block to gearbox bolts............................................ 8Lock-up solenoid valve, retaining fork Torx screw 8Lock-up solenoid valve assembly to valve body Torx 8screws .Pressure regulator to valve body Torx screws 8Fluid filter to valve block bolts 8Oil pick-up tube bolt 8Fluid pan to gearbox bolts 8Oil filler tube to fluid pan (up to 99MY) 70Snubber bar to crossmember (from 99MY) 45Transfer gearbox to gearbox bolts 45Gearbox to engine bolts 45Fluid cooler pipe unions 22Gearbox mounting assembly bolts 45+ Propeller shafts to transfer box output flanges nuts 48Torque converter to drive plate bolts - from 99MY 50+ New nuts must be fitted47-PROPELLERSHAFTS+ Front propeller shaft nuts 48+ Rear propeller shaft to differential drive flange nuts 48Rear propeller shaft to brake drum nuts 48+ New nuts must be fitted51 - REAR AXLE AND FINAL DRIVEAxle to trailing arms:- M12 nuts and bolts 125- M16 nuts and bolts - 8.8 Grade 160- M16 nuts and bolts - 10.9 Grade 240Trailing arms to chassis bolts 160Shock absorbers to axle nuts 45Panhard rod to axle bolt 200+ Propeller shaft to rear axle nuts 48Differential to axle case nuts 40Differential drive flange:-Nut(t01997.5MY) 135- Bolt (1997.5 MY onwards) 100Mass damper to rear axle bolts 45+ New nuts must be fitted8 I DATA, TORQUE & TOOLS11221871130377306666666523333331633353735353592118177118331483530100743354 - FRONT AXLE AND FINAL DRIVEDifferential to axle case nuts 40+ Propeller shaft to differential nuts 48Radius arms to axle nuts and bolts 125Radius arms to chassis nuts 160Shock absorbers to axle nuts 45Air spring securing pin retaining bolts 20+ Propeller shaft to front axle nuts 48Track rods to steering knuckles nuts 50Panhard rod to axle bolt 200Drag link to steering knuckle nut 50Brake calipers to steering knuckles bolts 220Mass damper to front axle bolts 45+ New nuts must be fitted57 - STEERINGFluid pipes to PAS pump:- M14 30- M16 50Feed hose to PAS pump union:- BMW diesel 30- V8 petrol......................................................................... 16Track rod adjuster clamps nuts and bolts:- 8 mm 22-10mm 47Steering column to bulkhead bolts 25Steering column to pedal box nuts and bolts 25Steering column universal joints bolts 25Drag link clamps nuts and bolts:- 8 mm 22-10mm 47Drag link to drop arm and swivel hubsnuts and bolts 50Damper to drag link nut and bolt:- 95 & 96 MY 125- 97 MY on 50Damper to chassis fixing 125Feed hose to steering box banjo bolt 30Return hose to steering box banjo bolt 50Bleed screw 4Steering box to chassis nuts and bolts 125Drag link to drop arm nut 50PAS pump to bracket bolts 22PAS pulley to pump bolts 22TORQUE VALUES ~3035921183315353714837162332237221216351818181635379237922237392371616DATA, TORQUE & TOOLS I 9TORQUE VALUES NEW RANGE ROVERV8 petrol:- PAS pump and compressor mounting bracket toengine bolts 40- PAS pump to mounting bracket bolts - up to 99MY 18- PAS pump to mounting bracket bolts - from 99MY 22- Pulley to PAS pump bolts 25Steering wheel bolt........................................................... 33Pad to steering wheel bolts 8Track rods to steering knuckles nuts 50Road wheel nuts 108Composite link to axle nuts:-M12 125-M16 160Composite link to chassis nut.. 160PAS reservoir to radiator bracket bolt 10PAS pipes to steering box nut 2560 - FRONT SUSPENSIONAir hose to compressor union 7Compressor to air supply unit nuts 2Air reservoir to air bracket bolts 25Anti-roll bar rubber bush clamp bolts 125Anti-roll bar link nuts 125Compressor air inlet filter 1Air drier to bracket 12Height sensor retaining bolts:- 95 & 96 MY 12- 97 MY on 6Height sensor link to radius arm nut 8Heat shield bracket/height sensor bolts 6Heat shield to bracket bolts 6Hub and drive shaft assembly bolts 135Drive shaft nut.................................................................. 260Panhard rod to chassis nut and bolt 200Panhard rod to axle bolt 200Panhard rod to axle securing bolt lockingplate screw 20Radius arm to chassis 160Radius arm to axle nut and bolt 125Shock absorber upper retaining bolt 125Shock absorber lower retaining bolt 45Road wheel nuts 108Swivel hub upper joint to axle nut 110Swivel hub lower joint to axle nut 160Track and drag links to swivel hub nuts 80Pressure switch to valve block......................................... 23Solenoid coil to valve block screws 1.5Front air spring to axle bolt.. 20Air distribution box to body bolt 6Air drier to air cleaner bolt................................................ 310 I DATA, TORQUE & TOOLS3013161824637809211811871851.51892920.7599464410019214814815118929233808111859171154264 - REAR SUSPENSIONHeight sensor to chassis bolts:- 95 & 96 MY 12- 97 MY on 6Hub to axle case bolts 65Drive shaft nut.................................................................. 260Panhard rod to chassis nut and bolt 200Panhard rod to axle bolt 200Panhard rod to axle locking plate screw 20Shock absorber top mounting bolt 125Shock absorber lower mounting nut 45Road wheel nuts 108Trailing arm to chassis nuts and bolts:-M12 125-M16 16070 - BRAKESParking brake shoe adjusting bolt 25High pressure hose to pump banjo bolt 24Pump/motor to mounting nuts 8High pressure hose to booster unit banjo bolt 24Booster unit to pedal box bolts 45Brake pipes to booster unit unions 14Front caliper to hub bolts 165Flexible hose to front caliper banjo bolt 32Rear caliper to hub bolts 100Flexible hose to rear caliper banjo bolt 32ECU to bracket bolts........................................................ 6Front brake disc shield bolts 8Brake disc screw 25Rear brake disc shield strap bolts 8Rear brake disc shield bolts 8Rear brake disc screw 25Rear caliper bolts 100Front brake pads guide pin bolt 30Road wheel nuts 108Rear brake pads guide pin bolts 30Propeller shaft to parking brake drum bolts 48PCRV valve to valance bolts............................................ 8Pipes to PCRV unions 14Pump motor to valance nuts 8High pressure hose to pump banjo bolt 24Reservoir bracket bolt...................................................... 10TORQUE VALUES ~94481921481481592338092118181861833101222474244618661874228022356106187DATA, TORQUE & TOOLS 1 11TORQUE VALUES NEW RANGE ROVER75 - SUPPLEMENTARY RESTRAINT SYSTEMCrash sensor bolts........................................................... 9DCU bolts 9Driver's air bag module to steering wheel bolts 9Passenger's air bag module to fascia Torx screws 9Side impact airbag nuts 5.576 - CHASSIS AND BODYFront door hinge bolts 30Striker bolts 22Rear door hinge bolts 25Chassis crossmember to chassis nuts and bolts 45Gearbox mounting to crossmember nuts 45Front bumper valance bolts 70Rear bumper and support bracket bolts 29Rear bumper valance mounting bolts 70Road wheel nuts 108Pedal box to fascia bolt.................................................... 25Fascia to base of 'A' post nuts 25Fascia to scuttle panel bolts 25Fascia to tunnel brackets nuts 25Gear lever to gearbox remote bolts.................................. 25Air conditioning pipes to TXV clamp bolt 6Seat belt top mountings - '8' and '0' posts bolts 25Front seat belt stalk bolt 35Front seat belt reel bolts - up to 99MY 35Front seat belt reel bolts - from 99MY 32Front seat belt upper anchorage bolt - up to 99MY 25Front seat belt upper anchorage bolt - from 99MY 22Front seat belt to seat mounting bolt - from 99MY 32Seat belt adjustable mounting to '8' post bolts 25Seat belt adjustable mounting to '0' post bolts 25Rear seat belt to seat pan bolt......................................... 35Rear seat stalk to squab hinge bolt 35Rear seat belt to upper anchorage point nut 25Rear seat belt reel bolt..................................................... 35Rear seat squab to cushion bolts 45Tailgate hinge bolts 25Tailgate support stays to body bolt 22Tailgate striker bolts 8Wind deflector Torx screws 2Sunroof guide assembly screws:Front 3Rear 1.5Sunroof motor screws 2Sunroof cable locator screws 3Sunroof to body bolts 6Sunroof tilt mechanism screws 5Sunroof panel nuts 512 I DATA, TORQUE & TOOLS77774221618333352225280181818181841826262418162418182626182633181661.52.21.11.52.24.544TORQUE VALUES_______n78 - SEATSFront seat fixing bolts 29Front seat slides to cushion frames bolts 30Rear seat squab latch securing screws 14Rear seat front and rear retaining bolts 29Seat outstation - cushion pan to frame bolts 29Rear seat belt stalk to latch bolt 35Rear seat latch to cushion and squab bolt 302122102221262282 - AIR CONDITIONINGCompressor to mounting bracket bolts - V8 from 99MY .. 22Pipes to condenser 15Pipes to compressor bolt.. 2316111784 - WIPERS AND WASHERSHeadlamp wiper arm to spindle nut 9Headlamp wiper motor securing nut 9Screen wiper spindle housing to scuttle nuts 11Screen wiper motor securing bolts 7Rear wiper arm to spindle nut 17Rear wiper motor mounting bolts 7Rear wiper motor spindle seal retaining nut 4Front wiper arm to spindle nut 19778512531486 - ELECTRICALBMW diesel:- Pulley to alternator nut 50- Starter motor securing nuts and bolts 48- Clutch fluid pipe bracket lower bolt 86V8 petrol:- Battery lead to starter solenoid nut - from 99MY 18- Engine harness to alternator nuts - from 99MYB+ terminal 18D+ terminal 5- Engine harness to cylinder head bolt - from 99MY 20- Earth lead to alternator bracket bolt - from 99MY 20- Earth lead to RH front wing valance nut - from 99MY 10- Pulley to alternator nut 40- Alternator to mounting bracket bolts 25- Tensi