RANGE ROVER SPORT L320 2005-2012 MANUAL SERVICE & REPAIR

Description

WORKSHOP MANUAL SERVICE & REPAIR GUIDE for RANGE ROVER SPORT L320 2005-2012 

RANGE ROVER SPORT L320 OFFICIAL FACTORY WORKSHOP
SERVICE & REPAIR MANUAL

The same is used by the car manufacturer to build your car!
Exactly the same as used by Official and Authorised Car manufacturers’ Services to fix your car!
100% Complete and 100% Approved

RANGE ROVER SPORT L320 2005-2012 MANUAL SERVICE REPAIR

Technical Information
Applies to
RANGE ROVER SPORT L320
2005-2012

MODELS
SPORT L320
ENGINE
V8 5.0L Petrol/V8 S/C 5.0L Petrol, TDV6 3.0L Diesel
MODEL YEARS
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
GEARBOXES
Automatic, Manual
LANGUAGE
ENGLISH
WIRING
NO

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CONTENT
In the Workshop Manual you will find:
All Official Factory Car Manufacturers’ specifications like parts and tools numbers, tightening torques specifications, lubricants specifications, and guides.
Diagrams, illustrations, tables with technical information,
Detailed documentation and repair instruction step by step with diagnostic procedures
Maintenance guide
Wiring diagrams
Engine Supplements
Everything you need to make professional repairs and maintenance of your car! Exactly the same Workshop Manual as official and authorized services use.
Everyone will find useful information, doesn’t matter if you are a garage, mechanic, or just a car user. Offer professional technical procedures and managing of your job to your customer! Perform the repair in a professional way. It contains all the official RANGE ROVER manufacturer specifications, and repair instructions step by step with illustrations and wiring diagrams.

TABLE OF CONTENTS

1: General Information
100: Service Information
100-00: General Information
Description and Operation
About This Manual
About This Manual
Important Safety Instructions
How To Use This Manual
General Service Information
Standard Workshop Practices
Health and Safety Precautions
Solvents, Sealants, and Adhesives
Road/Roller Testing
Special Tool Glossary
Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
DTC: Adaptive Damping Control Module (ADCM)
DTC: Adaptive Speed Control Module (ASCM)
DTC: Air Suspension Control Module
DTC: Anti-Lock Braking System Control Module (ABS)
DTC: Audio Amplifier Control Module (AAM)
DTC: Auto High Beam Control Module (AHBCM)
DTC: Automatic Temperature Control Module (ATC)
DTC: Central Junction Box (CJB)
DTC: Digital Radio Control Module (DRCM)
DTC: Driver/Passenger Door Module (DDM/PDM)
DTC: Driver/Passenger Seat Module (DSM/PSM)
DTC: Dynamic Response Control Module (DRM)
DTC: Electric Park Brake Control Module (EPBCM)
DTC: Electric Steering Column Lock Control Module (ESCL)
DTC: Fuel Fired Booster Heater Control Module (FFBH)
DTC: Headlamp Leveling Control Module (HCM)
DTC: Instrument Cluster (IC)
DTC: Integrated Audio Module (IAM) – High Line
DTC: Integrated Control Panel (ICP)
DTC: Integrated Control Panel B (ICPB)
DTC: Keyless Vehicle Module (KVM)
DTC: Occupant Classification Sensor Control Module (OCSCM)
DTC: Parking Aid Control Module (PACM)
DTC: Rear Differential Control Module (RDCM)
DTC: Rear Seat Entertainment Control Module (RSECM)
DTC: Rear View Camera (RVC)
DTC: Restraints Control Module (RCM)
DTC: Satellite Radio Control Module (SRCM)
DTC: Steering Angle Sensor Module (SASM)
DTC: Tailgate Control Module (TGCM)
DTC: Terrain Response Switch Pack (TR)
DTC: (TS)
DTC: Module Name: Transfer Case Control Module
DTC: Transmission Control Switch (TCS)
DTC: Transmission Control Module (TCM)
DTC: TV Control Module (TVCM)
TDV6 3.0L Diesel, DTC: Engine Control Module (ECM)
V8 5.0L Petrol/V8 S/C 5.0L Petrol, DTC: Engine Control Module (ECM)
100-01: Identification Codes
Description and Operation
Identification Codes
100-02: Jacking and Lifting
Description and Operation
Jacking
Lifting
Vehicle Recovery
100-03: Maintenance Schedules
Description and Operation
Maintenance Schedules – Gasoline Engines
Maintenance Schedules – Diesel Engines
100-11: Vehicle Transportation Aids and Vehicle Storage
Description and Operation
GETtheMANUALS.org
New Vehicle Storage
New Vehicle Storage Form
101: Pre-Delivery Information
101-01: Pre-Delivery Inspection Manual
Description and Operation
Preliminary
Vehicle Interior
Vehicle Exterior
Road Test
Quality Assurance Checks
101-02: Showroom Preparation
Description and Operation
Showroom Preparation
2: Chassis
204: Suspension
204-00: Suspension System – General Information
Specification
Diagnosis and Testing
Suspension System
General Procedures
Four-Wheel Alignment (57.65.04)
Front Wheel Bearing and Wheel Hub Runout Check
204-01: Front Suspension
Specification
Description and Operation
Front Suspension
Diagnosis and Testing
Front Suspension
Removal and Installation
Front Stabilizer Bar (60.10.01)
Front Stabilizer Bar Link (60.10.02/60.10.04)
Upper Arm Ball Joint (60.15.02)
Lower Arm Ball Joint (60.15.03)
Wheel Knuckle (60.25.01)
Front Wheel Bearing and Wheel Hub (60.25.14)
Upper Arm (60.35.01)
Lower Arm (60.35.02)
Upper Arm Bushing (60.35.32)
Lower Arm Bushing (60.35.33)
Lower Arm Rear Bushing (60.35.25) (60.35.36) (60.35.36.47)
204-02: Rear Suspension
Specification
Description and Operation
Rear Suspension
Diagnosis and Testing
Rear Suspension
Removal and Installation
Wheel Bearing and Wheel Hub (64.15.14)
Upper Arm (64.35.60)
Lower Arm (64.35.54)
Upper Arm Ball Joint (64.15.07)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Lower Arm Bushing (64.35.15)
Upper Arm Bushing (64.35.22)
Lower Arm Ball Joint (64.15.08)
Toe Link (64.35.70)
Wheel Knuckle (64.35.10)
204-04: Wheels and Tires
Specification
Description and Operation
Wheels and Tires
Diagnosis and Testing
Wheels and Tires
Removal and Installation
Tire Low-Pressure Sensor (74.10.05)
Tire Pressure Monitoring System (TPMS) Front Antenna (86.53.16)
Tire Pressure Monitoring System (TPMS) Rear Antenna (86.53.17)
Tire Pressure Monitoring System (TPMS) Module (86.54.05)
204-05: Vehicle Dynamic Suspension
Specification
Description and Operation
Vehicle Dynamic Suspension
Diagnosis and Testing
Vehicle Dynamic Suspension
General Procedures
Ride Height Adjustments (60.90.03)
Air Suspension System Depressurize and Pressurize (60.50.38)
Air Leaks
Removal and Installation
GETtheMANUALS.org
Front Shock Absorber and Air Spring Assembly (60.21.01.99)
Front Air Shock Absorber (60.30.02.45)
Suspension Height Sensor (60.36.01)
Air Suspension Reservoir (60.50.03)
Air Suspension Control Module (60.50.04)
Air Suspension Reservoir Solenoid Valve Block (60.50.05)
Air Suspension Compressor Drier (60.50.09)
Air Suspension Compressor (60.50.10)
Air Suspension Front Solenoid Valve Block (60.50.11)
Rear Shock Absorber and Air Spring Assembly (64.21.01.99)
Rear Air Shock Absorber (64.30.02.45)
Air Suspension Rear Solenoid Valve Block (64.50.11)
Air Suspension Air Filter (64.50.12)
Air Suspension Muffler (64.50.01)
Air Suspension Pressure Sensor
204-06: Ride and Handling Optimization
Specification
Description and Operation
Ride and Handling Optimization
Active Stabilization System
Diagnosis and Testing
Ride and Handling Optimization
Active Stabilization System
General Procedures
Active Stabilization System Bleeding (60.60.13)
Removal and Installation
Upper Accelerometer (60.60.02)
Lower Accelerometer (60.60.03)
Fluid Pump – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Fluid Pump (60.60.10) – TDV6 3.0L Diesel
Dynamic Response Module (60.60.01)
Valve Block (60.60.20)
Valve Block Filter (60.60.21)
Valve Block to Front Stabilizer Bar Actuator Pipe Assembly
Valve Block to Rear Stabilizer Bar Actuator Pipe Assembly
Valve Block Transducer (60.60.22)
Front Stabilizer Bar Bushing (60.60.47) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Front Stabilizer Bar Bushing (60.60.47) – TDV6 3.0L Diesel
Front Stabilizer Bar (60.60.50) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Front Stabilizer Bar (60.60.50) – TDV6 3.0L Diesel
Rear Stabilizer Bar Bushing (64.60.47)
Rear Stabilizer Bar (64.60.50)
Pressure Control Valve
Ride and Handling Optimization Switch (86.65.11)
Direction Control Valve Solenoid
205: Driveline
205-00: Driveline System – General Information
Diagnosis and Testing
Driveline System
205-01: Driveshaft
Specification
Description and Operation
Driveshaft
Universal Joints
Diagnosis and Testing
Driveshaft
Removal and Installation
Front Driveshaft (47.15.02) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Front Driveshaft (47.15.02) – TDV6 3.0L Diesel
Rear Driveshaft (47.15.03)
205-02: Rear Drive Axle/Differential
Specification
Description and Operation
Rear Drive Axle and Differential
Diagnosis and Testing
Rear Drive Axle and Differential
General Procedures
Differential Draining and Filling (51.25.02)
In-Vehicle Repair
GETtheMANUALS.org
Differential Locking Motor (51.15.03)
Rear Axle Oil Temperature Sensor (51.15.06)
Drive Pinion Seal (51.20.01)
Differential Locking Module (51.30.01)
Removal and Installation
Axle Assembly (51.15.01)
Axle Housing Bushing (51.15.41)
Rear Axle Housing Support Insulator (51.15.44)
205-03: Front Drive Axle/Differential
Specification
Description and Operation
Front Drive Axle and Differential
Diagnosis and Testing
Front Drive Axle
General Procedures
Differential Draining and Filling (54.15.02)
In-Vehicle Repair
Drive Pinion Seal (54.10.20)
Front Axle Housing Support Insulator (54.10.24)
Axle Tube (47.10.42)
Removal and Installation
Axle Assembly (54.10.01)
Axle Carrier Bushing (54.10.26)
Axle Tube Bushing
Axle Cover Bushing
205-04: Front Drive Halfshafts
Specification
Description and Operation
Front Drive Halfshafts
Halfshaft Joint
Diagnosis and Testing
Front Drive Halfshafts
Removal and Installation
Front Halfshaft LH (47.10.01)
Front Halfshaft RH (47.10.02)
Outer Constant Velocity (CV) Joint Boot (47.10.03)
Outer Constant Velocity (CV) Joint (47.10.04)
Inner Constant Velocity (CV) Joint Boot (47.10.16)
Halfshaft Seal LH (54.10.18)
Halfshaft Seal RH (54.10.21)
205-05: Rear Drive Halfshafts
Specification
Description and Operation
Rear Drive Halfshafts
Diagnosis and Testing
Rear Drive Halfshafts
Removal and Installation
Outer Constant Velocity (CV) Joint Boot (47.11.03)
Inner Constant Velocity (CV) Joint Boot (47.11.16)
Rear Halfshaft (47.11.01)
206: Brake System
206-00: Brake System – General Information
Specification
Diagnosis and Testing
Brake System
General Procedures
Front Brake Disc Runout Check (70.12.15.01) – Vehicles Without: High
Performance Brakes
Front Brake Disc Runout Check (70.12.15.01) – Vehicles With High
Performance Brakes
Rear Brake Disc Runout Check (70.12.36.01)
Brake System Bleeding (70.25.02) – Vehicles With High Performance
Brakes
Brake System Bleeding (70.25.02) – Vehicles With Standard Brakes
Brake System Pressure Bleeding (70.25.02)
Component Bleeding – Vehicles With High-Performance Brakes
Component Bleeding – Vehicles With Standard Brakes
Front Brake Disc Runout Check-With Wheel On – Vehicles With Standard
Brakes
GETtheMANUALS.org
Front Brake Disc Runout Check-With Wheel On – Vehicles With High
Performance Brakes
Brake Pad Bedding-In
206-03: Front Disc Brake
Specification
Description and Operation
Front Disc Brake
Diagnosis and Testing
Front Disc Brake
Removal and Installation
Brake Disc (70.12.10) – Vehicles With Standard Brakes
Brake Disc (70.12.10) – Vehicles With High-Performance Brakes
Brake Pads (70.40.02) – Vehicles With Standard Brakes
Brake Pads (70.40.02) – Vehicles With High-Performance Brakes
Brake Caliper (70.55.24) – Vehicles With Standard Brakes
Brake Caliper (70.55.24) – Vehicles With High-Performance Brakes
206-04: Rear Disc Brake
Specification
Description and Operation
Rear Disc Brake
Diagnosis and Testing
Rear Disc Brake
Removal and Installation
Brake Disc (70.12.33)
Brake Pads (70.40.03)
Brake Caliper (70.55.25)
Brake Caliper Anchor Plate (70.55.29)
206-05: Parking Brake and Actuation
Specification
Description and Operation
Parking Brake
Diagnosis and Testing
Parking Brake
General Procedures
Parking Brake Shoe and Lining Adjustment (70.40.11)
Parking Brake Shoes Bedding-In (70.40.12)
Removal and Installation
Parking Brake Cable LH
Parking Brake Cable RH
Parking Brake Switch
Parking Brake Actuator (70.35.48) – Vehicles With Standard Brakes
Parking Brake Actuator (70.35.48) – Vehicles With High Performance
Brakes
Parking Brake Shoes (70.40.09)
206-06: Hydraulic Brake Actuation
Specification
Description and Operation
Hydraulic Brake Actuation
Diagnosis and Testing
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.25.31)
Brake Master Cylinder (70.30.08)
Brake Pedal (70.35.01)
Brake Pedal and Bracket (70.35.03)
206-07: Power Brake Actuation
Specification
Description and Operation
Brake Booster
Diagnosis and Testing
Power Brake System
Removal and Installation
Brake Booster (70.50.01)
Brake Vacuum Pump – TDV6 3.0L Diesel
Brake Vacuum Pump – V8 5.0L Petrol/V8 S/C 5.0L Petrol
206-09A: Anti-Lock Control – Traction Control
Specification
Description and Operation
Anti-Lock Control – Traction Control
GETtheMANUALS.org
Diagnosis and Testing
Anti-Lock Control – Traction Control
Removal and Installation
Anti-Lock Brake System (ABS) Module (70.25.12)
Front Wheel Speed Sensor (70.65.30)
Rear Wheel Speed Sensor (70.65.31)
206-09B: Anti-Lock Control – Stability Assist
Specification
Diagnosis and Testing
Anti-Lock Control – Stability Assist
Removal and Installation
Yaw Rate Sensor (70.70.35)
211: Steering System
211-00: Steering System – General Information
Diagnosis and Testing
Steering System
General Procedures
Power Steering System Filling and Bleeding
Power Steering System Flushing
211-02: Power Steering
Specification
Description and Operation
Power Steering
Diagnosis and Testing
Power Steering
General Procedures
Power Steering Pressure Test – TDV6 3.0L Diesel /TDV8 3.6L Diesel
Power Steering Pressure Test – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Removal and Installation
Power Steering Control Valve Actuator (57.10.05)
Power Steering Fluid Reservoir (57.15.08)
Power Steering Fluid Cooler (57.15.11) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Power Steering Pump (57.20.14) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Power Steering Pump (57.20.14) – TDV6 3.0L Diesel
Power Steering Pump to Steering Gear Pressure Line – TDV6 3.0L Diesel
/V8 5.0L Petrol/V8 S/C 5.0L Petrol
Steering Angle Sensor (57.40.02)
Steering Gear (57.10.01) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Steering Gear (57.10.01) – TDV6 3.0L Diesel
211-03: Steering Linkage
Specification
Description and Operation
Steering Linkage
Diagnosis and Testing
Steering Linkage
Removal and Installation
Steering Gear Boot (57.10.29)
Tie Rod (57.55.09)
Tie Rod End (57.55.07)
211-04: Steering Column
Specification
Description and Operation
Steering Column
Diagnosis and Testing
Steering Column
Removal and Installation
Steering Column (57.40.01) (57.40.06)
Steering Column Shaft (57.40.22)
Steering Column Lower Shaft (57.40.16 / 57.40.27)
Steering Wheel (57.61.01)
211-05: Steering Column Switches
Specification
Diagnosis and Testing
Steering Column Switches
Removal and Installation
Steering Column Lock and Ignition Switch Housing (57.40.31)
Ignition Switch (86.65.02)
Steering Column Multifunction Switch RH (86.65.41)
Steering Column Multifunction Switch LH (86.65.55)
3: Powertrain
303: Engine
303-00: Engine System – General Information
Diagnosis and Testing
Engine (12.90.09.01) – TDV6 3.0L Diesel
Engine (12.90.09.01) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
General Procedures
Bearing Inspection
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Cylinder Bore Out-of-Round
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter
Leakage Test Using Smoke Test Equipment
Cylinder Head Gasket Selection – TDV6 3.0L Diesel
Cylinder Head Distortion
Cylinder Compression Test – TDV6 3.0L Diesel
303-01A: Engine – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Engine
General Procedures
Engine Oil Draining and Filling (12.60.05)
Engine Oil Vacuum Draining and Filling
Removal and Installation
Camshaft LH
Camshaft RH
Camshaft Front Seal
Camshaft Rear Seal
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.01)
Crankshaft Rear Seal (12.21.20)
Cylinder Head (12.29.04)
Engine Mount LH (12.45.11)
Engine Mount RH (12.45.12)
Exhaust Manifold (30.15.10)
Exhaust Manifold Crossover Pipe
Flexplate (12.53.13)
Oil Cooler (12.60.68)
Oil Filter Element (12.60.02)
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Timing Belt (12.65.18)
Timing Cover (12.65.01 or 12.65.43)
Valve Cover LH
Valve Cover RH
Removal
Engine
Installation
Engine
303-01B: Engine – V8 5.0L Petrol
Specification
GETtheMANUALS.org
Description and Operation
Engine
Diagnosis and Testing
Engine
General Procedures
Engine Oil Draining and Filling (12.60.05)
Engine Oil Vacuum Draining and Filling
Fuel Pump Camshaft Timing Check
Fuel Pump Camshaft Timing Adjustment
Removal and Installation
Camshaft LH
Camshaft RH
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.01)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH
Cylinder Head RH
Engine Mount LH (12.45.11)
Engine Mount RH (12.45.12)
Exhaust Manifold LH
Exhaust Manifold RH
Flexplate (12.53.13)
Intake Manifold (30.15.02)
Oil Cooler (12.60.68)
Oil Filter Element (12.60.02)
Oil Pan Extension (12.60.41)
Oil Pump (12.60.26)
Oil Restrictor
Timing Cover (12.65.01 or 12.65.43)
Timing Drive Components – Assembly Part Number: INA Timing Drive
Timing Drive Components – Assembly Part Number: Tsubaki Timing Drive
Valve Cover LH
Valve Cover RH
Cylinder Block Oil Gallery Plug
Fuel Pump Camshaft – Assembly Part Number: INA Timing Drive
Fuel Pump Camshaft – Assembly Part Number: Tsubaki Timing Drive
Lower Timing Cover
Timing Chain Tensioner Right
Removal
Engine
Installation
Engine
303-01C: Engine – V8 S/C 5.0L Petrol
Specification
Description and Operation
Engine
Diagnosis and Testing
Engine
General Procedures
Engine Oil Draining and Filling (12.60.05)
Engine Oil Vacuum Draining and Filling
Fuel Pump Camshaft Timing Check
Fuel Pump Camshaft Timing Adjustment
Removal and Installation
Camshaft LH
Camshaft RH
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.01)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH
Cylinder Head RH
Engine Mount LH (12.45.11)
Engine Mount RH (12.45.12)
Exhaust Manifold LH
Exhaust Manifold RH
Flexplate (12.53.13)
Oil Cooler (12.60.68)
Oil Filter Element (12.60.02)
Oil Pan Extension (12.60.41)
GETtheMANUALS.org
Oil Pump (12.60.26)
Timing Cover (12.65.01 or 12.65.43)
Timing Drive Components – Assembly Part Number: INA Timing Drive
Timing Drive Components – Assembly Part Number: Tsubaki Timing Drive
Valve Cover LH
Valve Cover RH
Cylinder Block Oil Gallery Plug
Fuel Pump Camshaft – Assembly Part Number: INA Timing Drive
Fuel Pump Camshaft – Assembly Part Number: Tsubaki Timing Drive
Lower Timing Cover
Timing Chain Tensioner Right
Removal
Engine
Installation
Engine
303-03A: Engine Cooling – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Engine Cooling
General Procedures
Cooling System Draining, Filling, and Bleeding
Removal and Installation
Coolant Expansion Tank
Coolant Pump
Cooling Fan
Cooling Fan Shroud
Radiator
Thermostat
303-03B: Engine Cooling – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
General Procedures
Cooling System Draining and Vacuum Filling
Cooling System Draining, Filling, and Bleeding – V8 S/C 5.0L Petrol
Cooling System Draining, Filling, and Bleeding – V8 5.0L Petrol
Cooling System Partial Draining, Filling, and Bleeding – V8 5.0L Petrol
Cooling System Partial Draining, Filling, and Bleeding – V8 S/C 5.0L Petrol
Removal and Installation
Coolant Expansion Tank – V8 S/C 5.0L Petrol, 5.0L
Coolant Expansion Tank – V8 5.0L Petrol, 5.0L
Cooling Fan – V8 S/C 5.0L Petrol
Cooling Fan – V8 5.0L Petrol
Coolant Pump – V8 S/C 5.0L Petrol
Coolant Pump – V8 5.0L Petrol
Radiator – V8 S/C 5.0L Petrol
Radiator – V8 5.0L Petrol
Thermostat Housing – V8 S/C 5.0L Petrol
Thermostat Housing – V8 5.0L Petrol
303-03C: Supercharger Cooling – V8 S/C 5.0L Petrol
Specification
Description and Operation
Supercharger Cooling
Diagnosis and Testing
Supercharger Cooling
Removal and Installation
Coolant Pump
Radiator
303-04A: Fuel Charging and Controls – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
GETtheMANUALS.org
System Operation and Component Description
Diagnosis and Testing
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
Removal and Installation
Fuel Injection Pump
Fuel Injectors LH
Fuel Injectors RH
Fuel Rail LH
Fuel Rail RH
Intake Air Shutoff Throttle
303-04B: Fuel Charging and Controls – Turbocharger – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Turbocharger
Removal and Installation
Turbocharger LH
Turbocharger RH
Turbocharger Bypass Valve
Fixed Vane Turbocharger Actuator
Turbocharger Oil Supply Tube
303-04C: Fuel Charging and Controls – V8 5.0L Petrol
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
Fuel Injection Component Cleaning Using Pressure Cleaner
Removal and Installation
Fuel Injectors
Fuel Rail LH
Fuel Rail RH
High-Pressure Fuel Pump 1
High-Pressure Fuel Pump 2
Throttle Body
303-04D: Fuel Charging and Controls – V8 S/C 5.0L Petrol
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
Fuel Injection Component Cleaning Using Pressure Cleaner
Removal and Installation
Fuel Injectors
Fuel Rail LH
Fuel Rail RH
High-Pressure Fuel Pump 1
High-Pressure Fuel Pump 2
Throttle Body
303-05A: Accessory Drive – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Accessory Drive
Removal and Installation
Accessory Drive Belt
Accessory Drive Belt Idler Pulley
GETtheMANUALS.org
Accessory Drive Belt Tensioner
Fuel Injection Pump Pulley
Rear End Accessory Drive (READ)
303-05B: Accessory Drive – V8 5.0L Petrol
Specification
Description and Operation
Accessory Drive
Diagnosis and Testing
Accessory Drive
Removal and Installation
Accessory Drive Belt
Accessory Drive Belt Idler Pulley
Accessory Drive Belt Tensioner
Cooling Fan Belt
303-05C: Accessory Drive – V8 S/C 5.0L Petrol
Specification
Description and Operation
Accessory Drive
Diagnosis and Testing
Accessory Drive
Removal and Installation
Accessory Drive Belt
Accessory Drive Belt Tensioner
Supercharger Belt
Supercharger Belt Idler Pulley
Supercharger Belt Tensioner
303-06A: Starting System – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Starting System
Removal and Installation
Starter Motor
303-06B: Starting System – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Starting System
Diagnosis and Testing
Starting System
Removal and Installation
Starter Motor
303-07A: Glow Plug System – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Glow Plug System
Removal and Installation
Glow Plugs
303-07B: Engine Ignition – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Engine Ignition
Diagnosis and Testing
Engine Ignition
Removal and Installation
Ignition Coil-On-Plug
Spark Plugs – V8 5.0L Petrol
Spark Plugs – V8 S/C 5.0L Petrol
303-08A: Engine Emission Control – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
GETtheMANUALS.org
System Operation and Component Description
Diagnosis and Testing
Engine Emission Control
Removal and Installation
Crankcase Vent Oil Separator
Exhaust Gas Recirculation (EGR) Valve LH
Exhaust Gas Recirculation (EGR) Valve RH
Exhaust Gas Recirculation (EGR) Valve Outlet Tube LH
Exhaust Gas Recirculation (EGR) Valve Outlet Tube RH
303-08B: Engine Emission Control – V8 5.0L Petrol
Description and Operation
Engine Emission Control
Diagnosis and Testing
Engine Emission Control
303-08C: Engine Emission Control – V8 S/C 5.0L Petrol
Description and Operation
Engine Emission Control
Diagnosis and Testing
Engine Emission Control
303-12A: Intake Air Distribution and Filtering – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner
Air Cleaner Element (19.10.10)
Charge Air Cooler
303-12B: Intake Air Distribution and Filtering – V8 5.0L Petrol
Specification
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner Element
Air Cleaner LH
Air Cleaner RH
Air Cleaner Outlet Pipe LH
Air Cleaner Outlet Pipe RH
Air Cleaner Outlet Pipe T-Connector
303-12C: Intake Air Distribution and Filtering – V8 S/C 5.0L Petrol
Specification
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner Outlet Pipe T-Connector
Charge Air Cooler
Supercharger
Air Cleaner Element
Air Cleaner LH
Air Cleaner RH
Air Cleaner Outlet Pipe LH
Air Cleaner Outlet Pipe RH
Supercharger Spring Isolator
303-13: Evaporative Emissions – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Evaporative Emissions
Diagnosis and Testing
Evaporative Emissions
Removal and Installation
Evaporative Emission Canister Purge Valve – V8 5.0L Petrol
Evaporative Emission Canister Purge Valve – V8 S/C 5.0L Petrol
GETtheMANUALS.org
303-14A: Electronic Engine Controls – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Electronic Engine Controls
Removal and Installation
Camshaft Position (CMP) Sensor (18.30.24)
Crankshaft Position (CKP) Sensor (18.30.12)
Crankshaft Position (CKP) Sensor Ring (18.30.14)
Diesel Particulate Filter (DPF) Differential Pressure Sensor
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Engine Control Module (ECM) (18.30.03)
Engine Oil Level Sensor (12.60.51)
Engine Oil Pressure (EOP) Sensor
Exhaust Gas Temperature Sensor RH
Heated Oxygen Sensor (HO2S) (19.22.16)
Intake Air Temperature (IAT) Sensor (18.30.09)
Manifold Absolute Pressure (MAP) Sensor (18.30.56)
Mass Air Flow (MAF) Sensor (19.22.25)
Oil Temperature Sensor (18.30.41)
Post Catalytic Converter Temperature Sensor
Post DPF Exhaust Gas Temperature Sensor
Pre-Catalytic Converter Temperature Sensor
Pre-DPF Exhaust Gas Temperature Sensor
303-14B: Electronic Engine Controls – V8 5.0L Petrol
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Removal and Installation
Camshaft Position (CMP) Sensor LH
Camshaft Position (CMP) Sensor RH
Catalyst Monitor Sensor LH
Catalyst Monitor Sensor RH
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.03)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Engine Oil Level Sensor (12.60.51)
Front Knock Sensor (KS) LH
Front Knock Sensor (KS) RH
Fuel Rail Pressure (FRP) Sensor
Heated Oxygen Sensor (HO2S) LH
Heated Oxygen Sensor (HO2S) RH
Manifold Absolute Pressure (MAP) Sensor (18.30.56)
Mass Air Flow (MAF) Sensor (19.22.25)
Rear Knock Sensor (KS) LH
Rear Knock Sensor (KS) RH
Variable Valve Timing (VVT) Oil Control Solenoid LH
Variable Valve Timing (VVT) Oil Control Solenoid RH
303-14C: Electronic Engine Controls – V8 S/C 5.0L Petrol
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Removal and Installation
Camshaft Position (CMP) Sensor LH
Camshaft Position (CMP) Sensor RH
Catalyst Monitor Sensor LH
GETtheMANUALS.org
Catalyst Monitor Sensor RH
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.03)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Engine Oil Level Sensor (12.60.51)
Front Knock Sensor (KS) LH
Front Knock Sensor (KS) RH
Fuel Rail Pressure (FRP) Sensor
Heated Oxygen Sensor (HO2S) LH
Heated Oxygen Sensor (HO2S) RH
Manifold Absolute Pressure (MAP) Sensor (18.30.56)
Mass Air Flow (MAF) Sensor (19.22.25)
Rear Knock Sensor (KS) LH
Rear Knock Sensor (KS) RH
Variable Valve Timing (VVT) Oil Control Solenoid LH
Variable Valve Timing (VVT) Oil Control Solenoid RH
307: Automatic Transmission/Transaxle
307-01A: Automatic Transmission/Transaxle – TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C
5.0L Petrol, Vehicles With 6HP28 6-Speed Automatic Transmission
Specification
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostics
General Procedures
Transmission Fluid Level Check
Transmission Fluid Drain and Refill
Removal and Installation
Input Shaft Seal
Extension Housing Seal
Transmission Control Module (TCM) and Main Control Valve Body
Transmission Fluid Pan, Gasket, and Filter
Transmission Support Insulator
Removal
Transmission – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transmission – TDV6 3.0L Diesel
Installation
Transmission – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transmission – TDV6 3.0L Diesel
307-01B: Automatic Transmission/Transaxle – TDV6 3.0L Diesel, Vehicles With 8HP70
8-Speed Automatic Transmission AWD
Specification
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostics – TDV6 3.0L Diesel , Vehicles With: 8HP70 8-Speed Automatic
Transmission AWD
General Procedures
Transmission Fluid Level Check
Transmission Fluid Drain and Refill
Removal and Installation
Input Shaft Seal
Extension Housing Seal
Transmission Control Module (TCM) and Main Control Valve Body
Transmission Fluid Pan, Gasket, and Filter
Transmission Support Insulator
Removal
Transmission
Installation
Transmission
307-02A: Transmission/Transaxle Cooling – TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C
5.0L Petrol, Vehicles With 6HP28 6-Speed Automatic Transmission
Specification
Description and Operation
Transmission Cooling
Diagnosis and Testing
Transmission Cooling
Removal and Installation
Transmission Fluid Cooler – V8 5.0L Petrol/V8 S/C 5.0L Petrol
GETtheMANUALS.org
Transmission Fluid Cooler – TDV6 3.0L Diesel
Transmission Fluid Cooler Tubes – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transmission Fluid Cooler Tubes – TDV6 3.0L Diesel
307-02B: Transmission/Transaxle Cooling – TDV6 3.0L Diesel, Vehicles With 8HP70 8-
Speed Automatic Transmission AWD
Specification
Description and Operation
Transmission Cooling
Diagnosis and Testing
Transmission Cooling
Removal and Installation
Transmission Fluid Cooler – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transmission Fluid Cooler – TDV6 3.0L Diesel
Transmission Fluid Cooler Tubes – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transmission Fluid Cooler Tubes – TDV6 3.0L Diesel
307-05A: Automatic Transmission/Transaxle External Controls – TDV6 3.0L Diesel /V8
5.0L Petrol/V8 S/C 5.0L Petrol, Vehicles With: 6HP28 6-Speed Automatic Transmission
Specification
Description and Operation
External Controls
Diagnosis and Testing
External Controls
Removal and Installation
Selector Lever Assembly
307-05B: Automatic Transmission/Transaxle External Controls – TDV6 3.0L Diesel,
Vehicles With: 8HP70 8-Speed Automatic Transmission AWD
Specification
Description and Operation
External Controls
Removal and Installation
Transmission Control Switch (TCS)
Transmission Control Switch (TCS) Knob
Emergency Park Position Release Lever
308: Manual Transmission/Transaxle, Clutch and Transfer Case
308-07A: Four-Wheel Drive Systems
Specification
Description and Operation
Four-Wheel Drive Systems
Removal and Installation
Four-Wheel Drive (4WD) Control Module (41.30.01)
Transfer Case Shift Motor (41.30.03)
Transfer Case Clutch Solenoid
High/Low Range Sensor (41.30.07)
308-07B: Transfer Case
Specification
Description and Operation
Transfer Case
Diagnosis and Testing
Transfer Case
General Procedures
Transfer Case Draining and Filling (41.20.04)
In-Vehicle Repair
Transfer Case Input Shaft Seal (41.20.50) – V8 5.0L Petrol/V8 S/C 5.0L
Petrol
Transfer Case Input Shaft Seal (41.20.50) – TDV6 3.0L Diesel
Transfer Case Input Shaft Seal (41.20.50) – TDV8 3.6L Diesel
Removal and Installation
Transfer Case Chain
Transfer Case Front Output Seal
Transfer Case Front Output Shaft Bearing
Transfer Case Rear Output Seal
Transfer Case Rear Output Shaft Bearing
Removal
Transfer Case (41.20.25.99) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transfer Case (41.20.25.99) – TDV6 3.0L Diesel
Transfer Case (41.20.25.99) – TDV8 3.6L Diesel
Installation
Transfer Case (41.20.25) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Transfer Case (41.20.25) – TDV6 3.0L Diesel
GETtheMANUALS.org
Transfer Case (41.20.25) – TDV8 3.6L Diesel
309: Exhaust System
309-00A: Exhaust System – TDV6 3.0L Diesel
Specification
Description and Operation
Exhaust System
Component Location
System Operation and Component Description
Diagnosis and Testing
Exhaust System
Diesel Particulate Filter
General Procedures
Exhaust System Repair
Removal and Installation
Catalytic Converter (17.50.01)
Diesel Particulate Filter (DPF)
Exhaust System (30.10.01)
Front Muffler (30.10.11)
Rear Muffler (30.10.22)
309-00B: Exhaust System – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Exhaust System
Diagnosis and Testing
Exhaust System
General Procedures
Exhaust System Repair
Removal and Installation
Catalytic Converter LH
Catalytic Converter RH
Exhaust System (30.10.01)
Front Muffler (30.10.11)
Rear Muffler (30.10.22)
310: Fuel System
310-00: Fuel System – General Information
Diagnosis and Testing
Fuel System
General Procedures
Diesel Filter Water Drain-Off
Fuel System Pressure Release (19.50.02) – V8 5.0L Petrol/V8 S/C 5.0L
Petrol
Fuel System Pressure Check (19.50.13)
Fuel Tank Draining (19.55.02)
Low-Pressure Fuel System Bleeding (19.50.07) – TDV6 3.0L Diesel
310-01A: Fuel Tank and Lines – TDV6 3.0L Diesel
Specification
Description and Operation
Fuel Tank and Lines
Diagnosis and Testing
Fuel Tank and Lines
Removal and Installation
Fuel Cooler
Fuel Pump and Sender Unit
Fuel Tank (19.55.01)
Fuel Tank Filler Pipe (19.55.07)
Fuel Filter Element (192502)
310-01B: Fuel Tank and Lines – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Fuel Tank and Lines
Diagnosis and Testing
Fuel Tank and Lines
Removal and Installation
Fuel Filter (19.25.03)
Fuel Tank (19.55.01)
Fuel Tank Filler Pipe (19.55.07)
Fuel Pump and Sender Unit
310-03A: Speed Control – TDV6 3.0L Diesel
Specification
GETtheMANUALS.org
Description and Operation
Speed Control
Diagnosis and Testing
Speed Control
General Procedures
Speed Control Sensor Adjustment
Removal and Installation
Speed Control Deactivator Switch
Speed Control Module
Speed Control Sensor
Speed Control Switch
310-03B: Speed Control – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Speed Control
Diagnosis and Testing
Speed Control
General Procedures
Speed Control Sensor Adjustment
Removal and Installation
Speed Control Deactivator Switch
Speed Control Module
Speed Control Sensor
Speed Control Switch
4: Electrical
412: Climate Control System
412-00: Climate Control System – General Information
Specification
Diagnosis and Testing
Climate Control System
General Procedures
Air Conditioning (A/C) System Recovery, Evacuation, and Charging
(82.30.02)
Air Conditioning (A/C) Compressor Commissioning
412-01: Air Distribution and Filtering
Description and Operation
Air Distribution and Filtering
Diagnosis and Testing
Air Distribution and Filtering
Removal and Installation
Driver Side Register Trim Panel
Passenger Side Register Trim Panel
Pollen Filter (80.15.42)
Plenum Chamber (80.15.62)
412-02A: Heating and Ventilation
Description and Operation
Heating and Ventilation
Diagnosis and Testing
Heating and Ventilation
Removal and Installation
Blower Motor (80.20.15)
Heater Core (80.20.29) – LHD AWD
Heater Core (80.20.29) – RHD AWD
412-02B: Auxiliary Heating
Specification
Description and Operation
Auxiliary Heater
Diagnosis and Testing
Fuel Fired Booster Heater
Removal and Installation
Fuel-Fired Booster Heater – TDV6 3.0L Diesel
Fuel Fired Booster Heater Glow Plug And Burner Assembly – TDV6 3.0L
Diesel
Fuel Fired Booster Heater Receiver Unit
412-03A: Air Conditioning – TDV6 3.0L Diesel
Specification
Description and Operation
Air Conditioning
Diagnosis and Testing
Air Conditioning
Removal and Installation
Air Conditioning (A/C) Compressor
Air Conditioning (A/C) Pressure Transducer (82.20.38)
Condenser Core (82.15.07)
Evaporator Core (82.25.20) (82.25.22)
Thermostatic Expansion Valve (82.25.01)
412-03B: Air Conditioning – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Air Conditioning
Diagnosis and Testing
Air Conditioning
Removal and Installation
Air Conditioning (A/C) Compressor
Condenser Core – V8 S/C 5.0L Petrol
Condenser Core – V8 5.0L Petrol
Evaporator Core (82.25.20) (82.25.22) – V8 S/C 5.0L Petrol
Evaporator Core (82.25.20) (82.25.22) – V8 5.0L Petrol
Thermostatic Expansion Valve (82.25.01)
Air Conditioning (A/C) Pressure Transducer (82.20.38)
412-04: Control Components
GETtheMANUALS.org
Description and Operation
Control Components
Diagnosis and Testing
Control Components
Removal and Installation
Ambient Air Temperature Sensor (80.40.31)
Climate Control Assembly (80.10.02)
Defrost Vent/Register Blend Door Actuator (80.10.36) – LHD AWD
Defrost Vent/Register Blend Door Actuator (80.10.36) – RHD AWD
Driver Side Temperature Blend Door Actuator (80.10.37) – LHD AWD
Driver Side Temperature Blend Door Actuator (80.10.37) – RHD AWD
Instrument Panel Blend Door Actuator (80.20.09) – LHD AWD
Instrument Panel Blend Door Actuator (80.20.09) – RHD AWD
In-Vehicle Temperature Sensor (82.20.93)
Passenger Side Temperature Blend Door Actuator (80.10.38) – LHD AWD
Passenger Side Temperature Blend Door Actuator (80.10.38) – RHD AWD
Recirculation Blend Door Actuator – LHD AWD
Recirculation Blend Door Actuator – RHD AWD
Sun load Sensor (82.20.92)
413: Instrumentation and Warning Systems
413-01: Instrument Cluster
Specification
Description and Operation
Instrument Cluster
Diagnosis and Testing
Instrument Cluster
Removal and Installation
Instrument Cluster (80.20.01.99) (88.20.01)
Instrument Cluster Lens
413-06: Horn
Description and Operation
Horn
Diagnosis and Testing
Horn
413-08: Information and Message Center
Description and Operation
Information and Message Center
Diagnosis and Testing
Information and Message Center
413-09A: Warning Devices
Specification
Removal and Installation
Low Tire Pressure Module (86.54.05)
413-09B: Engine Protection System
Specification
413-13: Parking Aid
Description and Operation
Parking Aid
Diagnosis and Testing
Parking Aid
Removal and Installation
Parking Aid Camera Module
Parking Aid Speaker (86.54.19)
Parking Aid Module (86.54.10)
Front Inner Parking Aid Sensor
Front Outer Parking Aid Sensor
Front Parking Aid Camera
Rear Inner Parking Aid Sensor
Rear Outer Parking Aid Sensor
Side Parking Aid Camera
Parking Aid Camera
414: Battery and Charging System
414-00: Battery and Charging System – General Information
Specification
Description and Operation
Battery Care Requirements
Quiescent Drain
Battery Report Form – In-Service Batteries Only
Diagnosis and Testing
GETtheMANUALS.org
Charging System
414-01: Battery, Mounting, and Cables
Specification
Description and Operation
Battery and Cables
Diagnosis and Testing
Battery
Removal and Installation
Battery (86.15.01)
Battery Tray (76.10.30)
Auxiliary Battery Tray (76.10.31)
414-02A: Generator and Regulator – TDV6 3.0L Diesel
Specification
Description and Operation
Component Location
Overview
System Operation and Component Description
Diagnosis and Testing
Generator
Removal and Installation
Generator
414-02B: Generator and Regulator – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Specification
Description and Operation
Generator
Diagnosis and Testing
Generator
Removal and Installation
Generator
415: Information and Entertainment Systems
415-00: Information and Entertainment System – General Information
Description and Operation
Navigation System Map Updates
Diagnosis and Testing
Information and Entertainment System
Cellular Phone
Navigation System
415-01A: Audio Unit
Specification
Diagnosis and Testing
Audio System
Removal and Installation
Audio Unit
Audio Amplifier
415-01B: Information and Entertainment System
Description and Operation
Speakers
Component Location
Overview
System Operation and Component Description
Removal and Installation
Digital Audio Module
415-02: Antenna
Diagnosis and Testing
Antenna
415-03: Speakers
Specification
Diagnosis and Testing
Speakers
Removal and Installation
Subwoofer Speaker
Front Door Speaker (86.50.10)
Instrument Panel Speaker (86.50.11)
Rear Door Speaker (86.50.12)
415-07: Video System
Description and Operation
Video System
Diagnosis and Testing
Video System
GETtheMANUALS.org
Removal and Installation
Digital Versatile Disc (DVD) Player
Video Display
417: Lighting
417-01: Exterior Lighting
Specification
Description and Operation
Exterior Lighting
Diagnosis and Testing
Headlamps
Autolamps
Stop lamps
Turn Signal, Cornering, and Hazard Lamps
Parking, Rear, and License Plate Lamps
Front Fog Lamps
Rear Fog Lamps
Reversing Lamps
Trailer Lamps
Headlamp Leveling
General Procedures
Front Fog Lamp Adjustment
Headlamp Adjustment (86.40.17)
Brake Pedal Position (BPP) Switch Adjustment
Removal and Installation
Stoplamp Switch (70.35.42)
Headlamp Assembly
Side Turn Signal Lamp (86.40.53)
Rear Lamp Assembly (86.40.70)
Front Fog Lamp
High Mounted Stoplamp
Approach Lamp – Vehicles With Parking Aid Camera
Approach Lamp – Vehicles Without Parking Aid Camera
Adaptive Front Lighting Module (86.54.06)
Headlamp Switch
417-02: Interior Lighting
Description and Operation
Interior Lighting
Diagnosis and Testing
Interior Lighting
417-04: Daytime Running Lamps (DRL)
Description and Operation
Daytime Running Lamps (DRL)
Diagnosis and Testing
Daytime Running Lamps (DRL)
418: Electrical Distribution
418-00: Module Communications Network
Specification
Diagnosis and Testing
Communications Network
Removal and Installation
Battery Junction Box (BJB) (86.70.55) – 5.0L
Battery Junction Box (BJB) (86.70.55) – 3.0L Diesel
Central Junction Box (CJB) (86.70.56)
418-02: Wiring Harnesses
Description and Operation
Wiring Harness
General Procedures
Wiring Harness Repair
Removal and Installation
Engine Wiring Harness (86.70.17) – TDV6 3.0L Diesel
Engine Wiring Harness (86.70.17) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Front Parking Aid Camera Wiring Harness – Front Section
Right-Hand Parking Aid Camera Wiring Harness
Rear Parking Aid Camera Wiring Harness
Left Hand Parking Aid Camera Wiring Harness
Front Parking Aid Camera Wiring Harness – Main Body Section
Suspension Air Supply Unit Wiring Harness
419: Electronic Feature Group
419-01A: Anti-Theft – Active
GETtheMANUALS.org
Specification
Description and Operation
Anti-Theft – Active
Removal and Installation
Antenna (86.77.31)
Hood Switch (86.77.20)
419-01B: Anti-Theft – Passive
Description and Operation
Anti-Theft – Passive
419-02: Remote Convenience
Description and Operation
Universal Transmitter
419-07: Navigation System
Description and Operation
Navigation System
Diagnosis and Testing
Navigation System
Removal and Installation
Navigation System Antenna (86.53.61)
Navigation System Compact Disc (CD) Unit (86.53.01)
Navigation System Display Module
419-08: Cellular Phone
Specification
Description and Operation
Cellular Phone
Removal and Installation
Transceiver Module
419-10: Multifunction Electronic Modules
Diagnosis and Testing
Driver Door Module (DDM)
Driver Seat Module (DSM)
Removal and Installation
Rear Entertainment Control Module
5: Body and Paint
501: Body and Paint
501-02: Front-End Body Panels
Specification
Removal and Installation
Fender Splash Shield (76.10.48)
Fender (76.10.24)
Engine Undershield (76.10.50)
501-03: Body Closures
Description and Operation
Component Location
Overview
System Operation and Component Description
Removal and Installation
Fuel Filler Interlock Catch (19.55.17)
Fuel Filler Door Assembly (19.55.04)
Liftgate (76.28.29/99)
Power Liftgate Module
Power Liftgate Switch (86.65.04)
Front Door (76.28.01/99)
Rear Door (76.28.02/99)
501-05: Interior Trim and Ornamentation
Specification
Removal and Installation
A-Pillar Trim Panel (76.13.26)
B-Pillar Upper Trim Panel (76.13.28)
B-Pillar Lower Trim Panel (76.13.29)
C-Pillar Upper Trim Panel (76.13.35)
D-Pillar Trim Panel (76.13.30)
Front Door Trim Panel (76.34.01)
Rear Door Trim Panel (76.34.04)
Scuff Plate Trim Panel (76.49.54)
Rear Quarter Trim Panel (76.13.12)
Headliner (76.64.15)
Engine Cover (12.30.50) – V8 5.0L Petrol/V8 S/C 5.0L Petrol
Engine Cover (12.30.50) – TDV6 3.0L Diesel
Cowl Side Trim Panel (76.13.27)
Loadspace Scuff Plate Trim Panel (76.76.03)
Loadspace Trim Panel LH (76.19.21)
Loadspace Trim Panel RH (76.19.22)
Liftgate Trim Panel (76.34.11)
Front Door Trim Veneer
Rear Door Trim Veneer
501-08: Exterior Trim and Ornamentation
Specification
Removal and Installation
Radiator Grille (76.55.03)
A-Pillar Moulding LH
Rear Quarter Window Moulding
Liftgate Moulding
Rear Spoiler
Liftgate Window Glass Trim Panel
501-09: Rear View Mirrors
Specification
Description and Operation
Rear View Mirrors
Diagnosis and Testing
Rear View Mirrors
Removal and Installation
Exterior Mirror (76.11.10)
Interior Mirror (76.10.51)
Exterior Mirror (76.11.10) – Vehicles Without Parking Aid Camera
Exterior Mirror (76.11.10) – Vehicles With Parking Aid Camera
Exterior Mirror Cover
Exterior Mirror Glass (76.11.08)
Exterior Mirror Motor (76.11.09)
501-10: Seating
GETtheMANUALS.org
Specification
Description and Operation
Seats
Diagnosis and Testing
Seats
Removal and Installation
Rear Seat (78.10.70/78.10.71)
Front Seat (78.10.44/99)
Front Seat Track Motor (78.70.25)
Front Seat Recliner Motor (78.70.34)
Front Seat Cushion Cover (78.30.01)
Front Seat Cushion Heater Mat (78.30.23)
Rear Seat Cushion Cover (78.40.70)
Front Seat Height Adjustment Motor (78.70.27)
Front Seat Backrest Cover (78.90.08)
Rear Seat Backrest Cover (78.90.72)
Front Seat Cushion (78.10.12/99)
Seat Track – Vehicles With Power Seats
Front Seat Manual Height Adjustment Lever
Front Seat Armrest
501-11: Glass, Frames, and Mechanisms
Specification
Description and Operation
Glass, Frames, and Mechanisms
Diagnosis and Testing
Glass, Frames, and Mechanisms
Fixed Window Glass
General Procedures
Door Window Motor Initialization
Removal and Installation
Rear Door Window Glass (76.31.02)
Rear Door Fixed Window Glass (76.31.31)
Rear Quarter Window Glass (76.81.20)
Front Door Window Regulator and Motor
Rear Door Window Regulator and Motor (86.25.05)
Front Door Window Control Switch
Rear Door Window Control Switch
Liftgate Window Glass
Windshield Glass (76.81.01)
Front Door Window Glass
501-12: Instrument Panel and Console
Specification
Description and Operation
Instrument Panel
Floor Console
Overhead Console
Removal and Installation
Cool Box
Floor Console (76.25.01)
Floor Console Upper Section
Glove Compartment (76.52.03)
Instrument Panel (76.46.23/99)
Instrument Panel Upper Section (76.46.04)
Instrument Panel Driver Side Reinforcement
Instrument Panel Passenger Side Reinforcement (76.46.32)
Instrument Panel Center Reinforcement
Instrument Panel Console Switch Assembly
501-14: Handles, Locks, Latches and Entry Systems
Specification
Description and Operation
Handles, Locks, Latches, and Entry Systems
Diagnosis and Testing
Locks, Latches, and Entry Systems
General Procedures
Liftgate Striker Adjustment (76.37.28)
Liftgate Window Latch Adjustment
Removal and Installation
Front Door Latch (76.37.12)
Rear Door Latch (76.37.13)
GETtheMANUALS.org
Liftgate Latch
Exterior Liftgate Release Switch
Interior Liftgate Release Switch
Hood Latch Release Handle (76.16.30)
Exterior Rear Door Handle (76.58.02)
Door Lock Cylinder (76.37.39)
Exterior Front Door Handle (76.58.07)
Ignition Lock Cylinder (57.40.28)
Liftgate Latch Actuator
Remote Keyless Entry (RKE) Module
501-16: Wipers and Washers
Specification
Description and Operation
Wipers and Washers
Diagnosis and Testing
Wipers and Washers
Removal and Installation
Front Wiper Pivot Arm (84.15.02)
Rear Wiper Pivot Arm (84.35.01)
Windshield Wiper Motor (84.15.12)
Rear Window Wiper Motor
Windshield Washer Pump (84.10.21)
Windshield Washer Reservoir (84.10.03)
Rain Sensor (84.12.11)
Headlamp Washer Pump (84.20.21)
Headlamp Washer Jet (84.20.08)
501-17: Roof Opening Panel
Specification
Description and Operation
Roof Opening Panel
Diagnosis and Testing
Roof Opening Panel
General Procedures
Roof Opening Panel Alignment (76.84.82)
Removal and Installation
Air Deflector
Driver Side Roof Opening Panel Front Drain Hose
Passenger Side Roof Opening Panel Front Drain Hose
Roof Opening Panel Glass (76.84.03)
Roof Opening Panel Motor (76.84.07)
Roof Opening Panel Module (76.84.46)
Roof Opening Panel (76.84.01)
Roof Opening Panel Weatherstrip
Roof Opening Panel Rear Drain Hose
501-19: Bumpers
Specification
Removal and Installation
Front Bumper
Front Bumper Cover
Front Bumper Lower Cover
Rear Bumper Cover (76.22.74)
501-20A: Safety Belt System
Specification
Description and Operation
Safety Belt System
Diagnosis and Testing
Safety Belt System
Removal and Installation
Front Safety Belt Retractor (76.73.13)
Second Row Center Safety Belt Retractor (76.73.20)
Second Row Safety Belt Retractor (76.73.23)
Front Safety Belt Buckle (76.73.30)
Rear Safety Belt Buckle LH (76.73.60) – Vehicles With 60/40 Split Seat
Rear Safety Belt Buckle RH (76.73.62) – Vehicles With 60/40 Split Seat
Rear Center Safety Belt Buckle (76.73.64) – Vehicles With 60/40 Split Seat
501-20B: Supplemental Restraint System
Specification
Description and Operation
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
GETtheMANUALS.org
Diagnosis and Testing
Air Bag Supplemental Restraint System (SRS)
Removal and Installation
Front Impact Severity Sensor (76.74.08)
Driver Air Bag Module (76.74.01)
Passenger Air Bag Module (76.74.02)
Side Air Curtain Module (76.74.40)
Side Air Bag Module (76.74.30)
Passenger Air Bag Deactivation (PAD) Switch (76.74.19)
Clockspring (76.74.20)
B-Pillar Side Impact Sensor (76.74.23)
C-Pillar Side Impact Sensor (76.74.24)
Front Door Side Impact Sensor (76.74.25)
Restraints Control Module (RCM) (76.74.68)
Occupant Classification Sensor (76.74.76)
501-25A: Body Repairs – General Information
Description and Operation
Body Repairs
501-25B: Body Repairs – Corrosion Protection
Description and Operation
Corrosion Protection
501-25C: Body Repairs – Water Leaks
Description and Operation
Water Leaks
501-26: Body Repairs – Vehicle Specific Information and Tolerance Checks
Description and Operation
Body and Frame
501-27: Front End Sheet Metal Repairs
Specification
Description and Operation
Front End Sheet Metal
Removal and Installation
Hood Latch Panel (76.16.22)
Front Crossmember (77.20.25)
Front Side Member (77.30.22/23)
Front Side Member Section (77.30.20/21)
Fender Apron Panel Reinforcement
Fender Apron Panel
Fender Apron Panel Section
Front Wheelhouse
Front Wheelhouse Reinforcement
Front Wheelhouse Section
Fender Apron Panel Closing Panel
Fender Apron Panel Reinforcement Front Section
Fender Apron Panel Reinforcement Rear Section
501-28: Roof Sheet Metal Repairs
Description and Operation
Roof
Removal and Installation
Roof Panel
501-29: Side Panel Sheet Metal Repairs
Description and Operation
Side Panel Sheet Metal
Removal and Installation
A-Pillar Outer Panel
B-Pillar Outer Panel
A-Pillar Reinforcement
B-Pillar Reinforcement
Side Panel Front Section
Rocker Panel (77.40.60)
501-30: Rear End Sheet Metal Repairs
Description and Operation
Rear End Sheet Metal
Removal and Installation
Quarter Panel (77.40.09)
Inner Quarter Panel (77.40.37)
Rear Inner Quarter Panel
Water Drain Panel
Rear Wheelhouse Outer (77.40.36)
GETtheMANUALS.org
Rear Lamp Mounting Panel (77.80.25)
Back Panel (77.80.20)
Rear Floor Panel Section (77.70.02)
Rear Side Member Section (77.70.07)
D-Pillar Inner Lower Panel
D-Pillar Closing Panel
D-Pillar Inner Lower Panel Assembly
502: Frame and Mounting
502-02: Full Frame and Body Mounting
Specification
General Procedures
Tow Bar Mounting Check
Removal and Installation
Body – TDV6 3.0L Diesel
Body – V8 5.0L Petrol
Body – V8 S/C 5.0L Petrol
Rear Crossmember
Transmission Support Crossmember (76.10.09 or 76.10.92) – TDV6 3.0L
Diesel
Transmission Support Crossmember (76.10.09 or 76.10.92) – V8 5.0L
Petrol/V8 S/C 5.0L Petro

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FEATURES OF THE WORKSHOP MANUAL
This is the Official Factory Workshop Manual – exactly the same as used by the car manufacturer to build your car and the same as used by the car manufacturers’ services when they are fixing your car! Follow official repair and diagnostic procedures – step by step!
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In the Workshop Manual is a Search option (press ‘Crtl + F’) so you can find any keyword
In the Workshop Manual, there is a Table of Contents!
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ABOUT THE MANUAL & IMPORTANT INFORMATION
The workshop manual is the same as used in official and authorized Dealer services and professional automotive services
You can follow all processes precisely as the car manufacturer recommended – maintain your car in the same way as professional and official services do
The PDF file is compatible with all systems i.e. Android, iOS, Windows, Linux
The PDF file is compatible with all devices like Notebooks, laptops, tablets, smartphones, PC, etc.
You can find any keywords in the Workshop Manual by search option
The Workshop Manual contains a Table of Contents
Any page, chapter, or whole manual can be printed out at every moment

The manual contains the following:
All official manufacturer specifications (for example Tightening torques, parts/ tools numbers, and specifications)
Repair instructions and information step by step
Maintenance guidance
A lot of diagrams
Ilustrations and tables
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