Land Rover L316 12-17 DEFENDER Service Manual – PDF DOWNLOAD
$36.95
Land Rover L316 12-17 DEFENDER Service Manual – PDF DOWNLOAD
Description
Land Rover L316 12-17 DEFENDER Service Manual – PDF DOWNLOAD
FILE DETAILS:
Land Rover L316 12-17 DEFENDER Service Manual – PDF DOWNLOAD
Language : English
Pages :1479
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Land Rover L316 12-17 DEFENDER Service Manual – PDF DOWNLOAD
Description and Operation
electronic, mechanical, photocopying, recording or other means, without prior written permission of Land Rover Ltd.,
Banbury Road, Lighthorne, Warwick, CV35 0RG
This manual covers all aspects necessary in order to service the vehicle effectively.
The manual is structured into five main sections, General Information, Chassis, Powertrain, Electrical and Body and Paint
with each section dealing with a specific part of a vehicle system.
Each of the five main sections contain sub-sections dealing with items which form a part of that specific system.
Pages at the start of the manual list all sections available. Each section has a contents list detailing, where applicable,
Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair Procedures.
Where components need to be removed or disassembled in sequence, each operation in the sequence will be identified
numerically and also graphically in an accompanying illustration
Description and Operation
Introduction
This manual has been written in a format that is designed to meet the needs of Land Rover technicians worldwide and to
assist them in the efficient repair and maintenance of Land Rover vehicles.
This manual provides descriptions and methods for accomplishing adjustment, service and repair work using tested and
effective procedures. Following these procedures will help ensure product reliability.
Appropriate service methods and correct repair procedures are essential for the safe and reliable operation of all motor
vehicles as well as ensuring the personal safety of the individual carrying out the work.
This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Any person who
departs from the instructions provided in this manual must first establish that they compromise neither their personal
safety nor the vehicle integrity by their choice of methods, tools or parts.
Individuals who undertake their own repairs should have some skill or training and limit repairs to components which
could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such as steering,
brakes, suspension or supplemental restraint system should be carried out by a Land Rover Dealer. Repairs to such items
should NEVER be attempted by untrained individuals.
IMAGES PREVIEW OF THE MANUAL:
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TABLE OF CONTENT
Land Rover L316 12-17 DEFENDER Service Manual – PDF DOWNLOAD
100-00: General Information
▪ Description and Operation
▪ How To Use This Manual
▪ Important Safety Instructions
▪ General Service Information
▪ Standard Workshop Practices
▪ Health and Safety Precautions
▪ Special Tool Glossary
▪ About This Manual
▪ DTC: Engine Control Module (PCM)
▪ DTC: Instrument Cluster (IPC)
▪ Diagnostic Trouble Code Index: ABS Control
Module
▪ 100-01: Identification Codes
▪ Description and Operation
▪ Identification Codes
▪ 100-02: Jacking and Lifting
▪ Description and Operation
▪ Vehicle Recovery
▪ Jacking
▪ Lifting
▪ 100-03: Maintenance Schedules
▪ Description and Operation
▪ Maintenance Schedules – Diesel Engines
• 2: Chassis
◦ 204: Suspension
▪ 204-00: Suspension System – General Information
▪ Specification
▪ General Procedures
▪ Front Toe Adjustment (57.65.01 or 57.65.14)
▪ 204-01: Front Suspension
▪ Description and Operation
▪ Front Suspension
▪ Removal and Installation
▪ Front Stabilizer Bar (60.10.01)
▪ Front Stabilizer Bar Link (60.10.02/60.10.04)
▪ Panhard Rod (60.10.10)
▪ Spring (60.20.11)
▪ Front Wheel Bearing and Wheel Hub (60.25.14)
▪ Wheel Studs (60.25.22)
▪ Front Shock Absorber (60.30.02)
▪ Bump Stop
▪ Radius Arm (60.35.15)
▪ 204-02: Rear Suspension
▪ Description and Operation
▪ Rear Suspension
▪ Removal and Installation
▪ Wheel Bearing and Wheel Hub (64.15.14)
▪ Spring (64.20.04)
▪ Wheel Studs
▪ Rear Stabilizer Bar (64.35.08)
▪ Rear Shock Absorber (64.30.02)
▪ Rear Stabilizer Bar Link (64.35.24)
▪ Upper Arm (64.35.60)
▪ Lower Arm (64.35.54)
▪ Axle Bump Stop
▪ 204-04: Wheels and Tires
▪ Specification
▪ Description and Operation
▪ Wheels and Tires
▪ Removal and Installation
▪ Wheel and Tire (60.25.06)
◦ 205: Driveline
▪ 205-01: Driveshaft
▪ Description and Operation
▪ Driveshaft
▪ Removal and Installation
▪ Front Driveshaft (47.15.02)
▪ Rear Driveshaft (47.15.03)
▪ Disassembly and Assembly
▪ Driveshaft Universal Joint (47.15.06)
▪ 205-02: Rear Drive Axle/Differential
▪ Specification
▪ Description and Operation
▪ Rear Drive Axle and Differential
▪ Diagnosis and Testing
▪ Rear Drive Axle and Differential
▪ In-Vehicle Repair
▪ Differential Case – 90
▪ Drive Pinion Seal (51.20.01) – 110/130
▪ Drive Pinion Seal (51.20.01) – 90
▪ Stub Shaft Pilot Bearing and Seal – 90
▪ Stub Shaft Pilot Bearing and Seal – 110/130
▪ Removal and Installation
▪ Axle Assembly (51.15.01)
▪ Disassembly and Assembly
▪ Axle – 90/110
▪ Axle – 110/130
▪ 205-03: Front Drive Axle/Differential
▪ Specification
▪ Description and Operation
▪ Front Drive Axle and Differential
▪ Diagnosis and Testing
▪ Front Drive Axle
▪ In-Vehicle Repair
▪ Drive Pinion Seal (54.10.20) – 90
▪ Removal and Installation
▪ Axle Assembly (54.10.01)
▪ Differential Carrier
▪ Disassembly and Assembly
▪ Front Stub Axle, Constant Velocity (CV) Joint and
Swivel Pin Housing
◦ 206: Brake System
▪ 206-00: Brake System – General Information
▪ Specification
▪ Description and Operation
▪ Brake System
▪ General Procedures
▪ Brake System Bleeding (70.25.02)
▪ 206-03: Front Disc Brake
▪ Removal and Installation
▪ Brake Disc (70.12.10)
▪ Brake Pads (70.40.02)
▪ Brake Caliper (70.55.24)
▪ 206-04: Rear Disc Brake
▪ Removal and Installation
▪ Brake Disc (70.12.33)
▪ Brake Pads (70.40.03) – 90
▪ Brake Caliper (70.55.25) – 90
▪ Brake Caliper (70.55.25) – 110/130
▪ Brake Pads (70.40.03) – 110/130
▪ 206-05: Parking Brake and Actuation
▪ General Procedures
▪ Parking Brake Shoe and Lining Adjustment
(70.40.11)
▪ Removal and Installation
▪ Parking Brake Cable (70.35.25)
▪ Shoes
▪ Parking Brake Switch (70.35.46)
▪ 206-06: Hydraulic Brake Actuation
▪ Removal and Installation
▪ Brake Master Cylinder (70.30.08)
▪ Brake Pedal and Bracket (70.35.03)
▪ Brake Pressure Control Valve
▪ Disassembly and Assembly
▪ Brake Master Cylinder
▪ 206-07: Power Brake Actuation
▪ Specification
▪ Removal and Installation
▪ Brake Booster (70.50.01)
▪ Brake Booster Non-Return Valve
▪ Brake Vacuum Pump (70.50.19)
▪ 206-09A: Anti-Lock Control – Traction Control
▪ Description and Operation
▪ Anti-Lock Control – Traction Control
▪ Diagnosis and Testing
▪ Anti-Lock Control – Traction Control
▪ Removal and Installation
▪ Anti-Lock Brake System (ABS) Module (70.25.12)
▪ Hydraulic Control Unit (HCU) – LHD
▪ Front Wheel Speed Sensor
▪ Rear Wheel Speed Sensor LH
▪ Rear Wheel Speed Sensor RH
▪ Hydraulic Control Unit (HCU) – RHD
▪ 206-09B: Anti-Lock Control – Stability Assist
▪ Removal and Installation
▪ Yaw Rate Sensor
◦ 211: Steering System
▪ 211-00: Steering System – General Information
▪ Specification
▪ Description and Operation
▪ Steering System
▪ Diagnosis and Testing
▪ Steering System
▪ General Procedures
▪ Power Steering System Filling and Bleeding
▪ Power Steering System Flushing
▪ Steering Gear Adjustment
▪ Steering Gear Centralization
▪ Steering Lock Stop Adjustment
▪ 211-02: Power Steering
▪ Specification
▪ Description and Operation
▪ Power Steering
▪ Removal and Installation
▪ Steering Gear (57.10.01)
▪ Power Steering Fluid Reservoir (57.15.08)
▪ Power Steering Pump (57.20.14)
▪ Disassembly and Assembly
▪ Steering Gear
▪ 211-03: Steering Linkage
▪ Removal and Installation
▪ Tie Rod End (57.55.07)
▪ Steering Linkage Damper
▪ Sector Shaft Arm Drag Link
▪ Steering Gear Drop Arm
▪ 211-04: Steering Column
▪ Removal and Installation
▪ Steering Column (57.40.01) (57.40.06)
▪ Steering Column Lower Shaft (57.40.16 /
57.40.27)
▪ Steering Wheel (57.61.01)
▪ 211-05: Steering Column Switches
▪ Description and Operation
▪ Steering Column Switches
▪ Removal and Installation
▪ Steering Column Lock and Ignition Switch
Housing (57.40.31)
▪ Steering Column Multifunction Switch RH
(86.65.41)
▪ Steering Column Multifunction Switch LH
(86.65.55)
▪ Ignition Switch (86.65.02)
• 3: Powertrain
◦ 303: Engine
▪ 303-00: Engine System – General Information – ID4 2.2L Diesel
▪ General Procedures
▪ Bearing Inspection
▪ Camshaft Bearing Journal Clearance
▪ Camshaft Bearing Journal Diameter
▪ Camshaft End Play
▪ Camshaft Lobe Lift
▪ Camshaft Surface Inspection
▪ Connecting Rod Cleaning
▪ Connecting Rod Large End Bore
▪ Crankshaft End Play
▪ Cylinder Bore Out-of-Round
▪ Cylinder Head Distortion
▪ Cylinder Block Distortion
▪ Exhaust Manifold Cleaning and Inspection
▪ Piston Inspection
▪ Piston Pin Diameter
▪ Piston Pin to Bore Diameter
▪ Piston Ring End Gap
▪ Piston Ring-to-Groove Clearance
▪ Valve Spring Free Length
▪ Valve Stem Diameter
▪ Leakage Test Using Smoke Test Equipment
▪ 303-01: Engine – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Engine
▪ Diagnosis and Testing
▪ Engine
▪ General Procedures
▪ Engine Oil Draining and Filling (12.60.05)
▪ Removal and Installation
▪ Camshafts
▪ Crankshaft Pulley (12.21.01)
▪ Crankshaft Front Seal (12.21.14)
▪ Crankshaft Rear Seal (12.21.20)
▪ Cylinder Head
▪ Engine Mount LH
▪ Engine Mount RH
▪ Exhaust Manifold (30.15.10)
▪ Intake Manifold (30.15.02)
▪ Oil Cooler
▪ Oil Pan
▪ Oil Pump
▪ Timing Cover
▪ Timing Chain
▪ Valve Cover
▪ Flywheel
▪ Oil Filter Housing
▪ Removal
▪ Engine (12.41.01.99)
▪ Disassembly
▪ Engine
▪ Assembly
▪ Engine
▪ Installation
▪ Engine (12.41.01.99)
▪ 303-03: Engine Cooling – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Engine Cooling
▪ Diagnosis and Testing
▪ Engine Cooling
▪ General Procedures
▪ Cooling System Draining, Filling and Bleeding
(26.10.01)
▪ Cooling System Draining and Vacuum Filling
▪ Removal and Installation
▪ Coolant Expansion Tank (26.15.01)
▪ Cooling Fan (26.25.19)
▪ Cooling Fan Shroud (26.25.11)
▪ Coolant Pump (26.50.01)
▪ Radiator (26.40.01)
▪ Thermostat (26.45.01)
▪ 303-04A: Fuel Charging and Controls – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Fuel Charging and Controls
▪ Diagnosis and Testing
▪ Fuel Charging and Controls
▪ General Procedures
▪ Fuel Injection Component Cleaning
▪ Removal and Installation
▪ Fuel Injector (19.60.10)
▪ Fuel Injection Pump
▪ Fuel Metering Valve
▪ Fuel Rail (19.60.04)
▪ Throttle Body (19.22.44)
▪ 303-04B: Fuel Charging and Controls – Turbocharger – ID4
2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Turbocharger
▪ Diagnosis and Testing
▪ Turbocharger
▪ Removal and Installation
▪ Turbocharger Actuator Rod
▪ Turbocharger (19.42.01)
▪ 303-05: Accessory Drive – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Accessory Drive
▪ Diagnosis and Testing
▪ Accessory Drive
▪ Removal and Installation
▪ Accessory Drive Belt (86.10.03)
▪ Accessory Drive Belt Idler Pulley (86.10.23)
▪ Accessory Drive Belt Tensioner (86.10.06)
▪ Accessory Drive Component Bracket
▪ 303-06: Starting System – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Starting System
▪ Diagnosis and Testing
▪ Starting System
▪ Removal and Installation
▪ Starter Motor (86.60.01)
▪ 303-07: Glow Plug System – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Glow Plug System
▪ Diagnosis and Testing
▪ Glow Plug System
▪ Removal and Installation
▪ Glow Plug (19.60.41)
▪ 303-08: Engine Emission Control – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Engine Emission Control
▪ Diagnosis and Testing
▪ Engine Emission Control
▪ Removal and Installation
▪ Exhaust Gas Recirculation (EGR) Cooler
(17.45.38)
▪ Exhaust Gas Recirculation (EGR) Valve
(17.45.01)
▪ 303-12: Intake Air Distribution and Filtering – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Intake Air Distribution and Filtering
▪ Diagnosis and Testing
▪ Intake Air Distribution and Filtering
▪ Removal and Installation
▪ Air Cleaner (19.10.01)
▪ Air Cleaner Element (19.10.10)
▪ Air Cleaner Outlet Pipe
▪ Charge Air Cooler (19.46.19)
▪ 303-14: Electronic Engine Controls – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Electronic Engine Controls
▪ Diagnosis and Testing
▪ Electronic Engine Controls
▪ Removal and Installation
▪ Accelerator Pedal Position (APP) Sensor
(19.22.49)
▪ Camshaft Position (CMP) Sensor (18.30.24)
▪ Crankshaft Position (CKP) Sensor (18.30.12)
▪ Cylinder Head Temperature (CHT) Sensor
▪ Engine Control Module (ECM) (18.30.03)
▪ Engine Coolant Temperature (ECT) Sensor
(18.30.10)
▪ Engine Oil Pressure (EOP) Sensor (12.60.50)
▪ Engine Oil Level Sensor
▪ Fuel Rail Pressure (FRP) Sensor (19.22.29)
▪ Heated Oxygen Sensor (HO2S) (19.22.16)
▪ Manifold Absolute Pressure and Temperature
(MAPT) Sensor
▪ Mass Air Flow (MAF) Sensor (19.22.25)
▪ Post Catalytic Converter Temperature Sensor
▪ Pre Catalytic Converter Temperature Sensor
▪ Post DPF Exhaust Gas Temperature Sensor
◦ 308: Manual Transmission/Transaxle, Clutch and Transfer Case
▪ 308-00: Manual Transmission/Transaxle and Clutch – General
Information – Vehicles With: MT82 6-Speed Manual
Transmission
▪ General Procedures
▪ Clutch Pedal Freeplay Adjustment
▪ 308-01: Clutch – Vehicles With: MT82 6-Speed Manual
Transmission
▪ Specification
▪ Description and Operation
▪ Clutch
▪ Removal and Installation
▪ Clutch Disc and Pressure Plate (33.10.01)
▪ Pilot Bearing (12.21.45)
▪ 308-02: Clutch Controls – Vehicles With: MT82 6-Speed
Manual Transmission
▪ Specification
▪ Description and Operation
▪ Clutch Controls
▪ Removal and Installation
▪ Clutch Master Cylinder (33.20.01) – LHD
▪ Clutch Master Cylinder (33.20.01) – RHD
▪ Clutch Slave Cylinder (33.35.01)
▪ 308-03: Manual Transmission/Transaxle – Vehicles With: MT82
6-Speed Manual Transmission
▪ Specification
▪ Description and Operation
▪ Manual Transmission
▪ General Procedures
▪ Transmission Draining and Filling (37.24.01)
▪ In-Vehicle Repair
▪ Gearshift Control Shaft Seal (37.23.10)
▪ Input Shaft Seal (37.23.06)
▪ Output Shaft Seal (37.23.01)
▪ Removal and Installation
▪ Selector Shaft Detents
▪ 1st-2nd and Reverse Gear Selector Shaft Detents
▪ Removal
▪ Transmission (37.20.02.99)
▪ Disassembly
▪ Transmission
▪ Disassembly and Assembly of Subassemblies
▪ Synchronizers
▪ Assembly
▪ Transmission
▪ Installation
▪ Transmission (37.20.02.99)
▪ 308-06: Manual Transmission/Transaxle External Controls –
Vehicles With: MT82 6-Speed Manual Transmission
▪ Specification
▪ Description and Operation
▪ External Controls
▪ Removal and Installation
▪ Gearshift Lever (37.16.04)
▪ 308-07A: Transfer Case – Vehicles With: MT82 6-Speed
Manual Transmission
▪ Specification
▪ Description and Operation
▪ Transfer Case
▪ General Procedures
▪ Transfer Case Draining and Filling (41.20.04)
▪ Transfer Case High/Low Range Selector Rod
Adjustment
▪ In-Vehicle Repair
▪ Transfer Case Extension Housing
▪ Transfer Case Front Output Shaft Seal (41.20.51)
▪ Transfer Case High/Low Range Linkage
▪ Transfer Case Input Shaft Seal (41.20.50)
▪ Transfer Case Lower Cover
▪ Transfer Case Rear Cover
▪ Transfer Case Rear Output Shaft Seal (41.20.54)
▪ Removal
▪ Transfer Case (41.20.25.99)
▪ Installation
▪ Transfer Case (41.20.25)
▪ 308-07B: Four-Wheel Drive Systems – Vehicles With: MT82 6-
Speed Manual Transmission
▪ General Procedures
▪ Differential Lock Indicator Switch Adjustment
▪ Removal and Installation
▪ Transfer Case Low Range Indicator Switch
▪ Differential Lock Indicator Switch
◦ 309: Exhaust System
▪ 309-00: Exhaust System – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Exhaust System – ID4 2.2L Diesel
▪ Component Location
▪ System Operation and Component Description
▪ Diagnosis and Testing
▪ Exhaust System
▪ Removal and Installation
▪ Muffler and Tailpipe
▪ Catalytic Converter (17.50.01)
▪ Front Muffler
▪ Diesel Particulate Filter (DPF)
◦ 310: Fuel System
▪ 310-00: Fuel System – General Information
▪ General Procedures
▪ Diesel Filter Water Drain-Off
▪ Fuel Tank Draining (19.55.02)
▪ Low-Pressure Fuel System Bleeding (19.50.07)
▪ Quick Release Coupling
▪ 310-01: Fuel Tank and Lines – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Fuel Tank and Lines – ID4 2.2L Diesel
▪ Removal and Installation
▪ Fuel Cooler
▪ Fuel Filter (19.25.03)
▪ Fuel Level Sender
▪ Fuel Pump
▪ Fuel Tank (19.55.01)
▪ Fuel Tank Filler Pipe (19.55.07)
• 4: Electrical
◦ 412: Climate Control System
▪ 412-00: Climate Control System – General Information
▪ Specification
▪ Description and Operation
▪ Climate Control System
▪ Diagnosis and Testing
▪ Climate Control System
▪ General Procedures
▪ Air Conditioning (A/C) System Recovery,
Evacuation and Charging (82.30.02)
▪ Refrigerant System Tests
▪ Electronic Leak Detection
▪ 412-01: Air Distribution and Filtering
▪ Description and Operation
▪ Air Distribution and Filtering
▪ Removal and Installation
▪ Air Inlet Duct (80.15.31)
▪ 412-02: Heating and Ventilation
▪ Specification
▪ Removal and Installation
▪ Blower
▪ Blower Motor (80.20.15)
▪ Heater Control Valve
▪ Heater Core (80.20.29)
▪ Heater Core and Evaporator Core Housing
▪ Heater Core Housing
▪ 412-03: Air Conditioning – ID4 2.2L Diesel
▪ Specification
▪ Removal and Installation
▪ Air Conditioning (A/C) Compressor (82.10.20)
▪ Air Conditioning (A/C) Switch
▪ Condenser Core (82.15.07)
▪ Condenser Fan
▪ De-Icing Switch
▪ Evaporator Core (82.25.20) (82.25.22)
▪ Thermostatic Expansion Valve (82.25.01)
▪ Receiver Drier (82.17.03)
▪ 412-04: Control Components
▪ Removal and Installation
▪ Climate Control Assembly (80.10.02)
▪ Blower Motor Resistor
◦ 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
▪ Removal and Installation
▪ Horn (86.30.09)
▪ 413-07: Clock
▪ Specification
▪ Removal and Installation
▪ Clock (88.15.07)
◦ 414: Battery and Charging System
▪ 414-00: Battery and Charging System – General Information
▪ Description and Operation
▪ Battery Care
▪ Quiescent Drain
▪ Diagnosis and Testing
▪ Charging System
▪ 414-01: Battery, Mounting and Cables
▪ Specification
▪ General Procedures
▪ Battery Disconnect and Connect
▪ Removal and Installation
▪ Battery
▪ 414-02: Generator and Regulator – ID4 2.2L Diesel
▪ Specification
▪ Description and Operation
▪ Generator – ID4 2.2L Diesel
▪ Removal and Installation
▪ Generator (86.10.02)
◦ 415: Information and Entertainment Systems
▪ 415-01A: Audio Unit
▪ Description and Operation
▪ Audio System
▪ Removal and Installation
▪ Audio Unit (86.50.81)
▪ 415-01B: Information and Entertainment System
▪ Description and Operation
▪ Navigation System
▪ 415-02: Antenna
▪ Removal and Installation
▪ Antenna
▪ 415-03: Speakers
▪ Description and Operation
▪ Speakers
▪ Removal and Installation
▪ Instrument Panel Speaker (86.50.11)
▪ D-Pillar Speaker
▪ Rear Door Speaker (86.50.12)
◦ 417: Lighting
▪ 417-01: Exterior Lighting
▪ Specification
▪ Description and Operation
▪ Exterior Lighting
▪ General Procedures
▪ Headlamp Adjustment (86.40.17)
▪ Removal and Installation
▪ Headlamp Assembly (86.40.49)
▪ Headlamp Leveling Motor
▪ Headlamp Leveling Switch
▪ Headlamp Switch (86.65.09)
▪ High Mounted Stoplamp (86.41.32)
▪ License Plate Lamp (86.40.86)
▪ License Plate Lamp Bulb
▪ Rear Fog Lamp Bulb
▪ Rear Lamp Assembly (86.40.70)
▪ Reversing Lamp
▪ Reversing Lamp Switch
▪ Side Marker Lamp
▪ Side Turn Signal Lamp (86.40.53)
▪ Stoplamp Switch (70.35.42)
▪ 417-02: Interior Lighting
▪ Description and Operation
▪ Interior Lighting
▪ Removal and Installation
▪ Interior Lamp
▪ Interior Lamp Bulb
◦ 418: Electrical Distribution
▪ 418-00: Module Communications Network
▪ Description and Operation
▪ Communications Network
▪ 418-02: Wiring Harnesses
▪ Description and Operation
▪ Wiring Harness
▪ General Procedures
▪ Wiring Harness Repair
▪ Removal and Installation
▪ Engine Wiring Harness (86.70.17)
◦ 419: Electronic Feature Group
▪ 419-01A: Anti-Theft – Active
▪ Description and Operation
▪ Anti-Theft – Active
▪ 419-01B: Anti-Theft – Passive
▪ Description and Operation
▪ Anti-Theft – Passive
▪ Removal and Installation
▪ Passive Anti-Theft System (PATS) Transceiver
▪ Passive Anti-Theft System (PATS) Module
(86.77.07)
▪ 419-12: Winch
▪ Specification
▪ Description and Operation
▪ Component Location
▪ Overview
▪ System Operation and Component Description
▪ Diagnosis and Testing
▪ Winch
▪ Removal and Installation
▪ Licence Plate Panel
▪ Winch
▪ Winch Cable
▪ Winch Cable Roller Assembly
▪ Winch Control Unit
▪ Winch Gear Assembly
▪ Winch Motor
▪ Winch Solenoid
• 5: Body and Paint
◦ 501: Body and Paint
▪ 501-02: Front End Body Panels
▪ Removal and Installation
▪ Fender (76.10.24)
▪ Fender Splash Shield (76.10.48)
▪ Hood
▪ 501-03: Body Closures
▪ Description and Operation
▪ Body Closures – Vehicles Built From: 07/2001
▪ General Procedures
▪ Taildoor Striker Adjustment
▪ Door Striker Adjustment
▪ Removal and Installation
▪ Door
▪ Front Door Reinforcement Panel
▪ Rear Door Reinforcement Panel
▪ Taildoor
▪ 501-05: Interior Trim and Ornamentation
▪ Description and Operation
▪ Interior Trim
▪ Removal and Installation
▪ Cowl Side Trim Panel (76.13.27)
▪ C-Pillar Upper Trim Panel (76.13.35) – 90/Station
Wagon
▪ C-Pillar Upper Trim Panel (76.13.35) – 110/Station
Wagon
▪ Front Door Trim Panel (76.34.01)
▪ Front Headliner – 90/Station Wagon
▪ Headliner Rear Trim Panel – 90/110/Station
Wagon
▪ Interior Rollover Bar
▪ Rear Door Trim Panel (76.34.04)
▪ Rear Grab Handle – 90/110/Station Wagon
▪ Rear Headliner – 90/Station Wagon
▪ Rear Quarter Trim Panel (76.13.12)
▪ Steering Column Shrouds (57.40.29)
▪ Sun Visor
▪ Taildoor Trim Panel (76.34.09)
▪ Engine Cover (12.30.50)
▪ 501-08: Exterior Trim and Ornamentation
▪ Removal and Installation
▪ Exterior Rollover Bar
▪ Radiator Grille (76.55.03)
▪ Rear Folding Step
▪ Towbar
▪ 501-09: Rear View Mirrors
▪ Removal and Installation
▪ Interior Mirror (76.10.51)
▪ Exterior Mirror (76.11.10)
▪ Exterior Mirror Glass (76.11.08)
▪ 501-10: Seating
▪ Specification
▪ Description and Operation
▪ Seats
▪ Removal and Installation
▪ Front Seat (78.10.44/99)
▪ Front Seat Backrest
▪ Front Seat Backrest Cover (78.90.08)
▪ Front Seat Backrest Heater Mat (78.90.36)
▪ Front Seat Cushion (78.10.12/99)
▪ Front Seat Cushion Cover (78.30.01)
▪ Front Seat Cushion Heater Mat (78.30.23)
▪ Heated Seat Switch
▪ Rear Seat (78.10.70/78.10.71)
▪ Rear Seat Backrest
▪ Rear Seat Backrest Cover (78.90.72)
▪ Rear Seat Cushion
▪ Rear Seat Cushion Cover (78.40.70)
▪ Third Row Seat (78.10.39)
▪ Third Row Seat Backrest
▪ Third Row Seat Backrest Cover (78.90.17)
▪ Third Row Seat Cushion (78.40.52)
▪ Third Row Seat Cushion Cover (78.40.06)
▪ 501-11: Glass, Frames and Mechanisms
▪ Description and Operation
▪ Glass, Frames and Mechanisms
▪ Removal and Installation
▪ Front Door Window Glass (76.31.01)
▪ Front Door Window Regulator and Motor
(86.25.03)
▪ Heated Windshield Relay
▪ Rear Door Window Glass (76.31.02)
▪ Rear Door Window Regulator and Motor
(86.25.05)
▪ Taildoor Window Glass
▪ Window Control Switch (86.25.08)
▪ 501-12: Instrument Panel and Console
▪ Specification
▪ Description and Operation
▪ Instrument Panel
▪ Removal and Installation
▪ Instrument Panel (76.46.23/99)
▪ Instrument Panel Console (76.25.03)
▪ In-Vehicle Crossbeam
▪ Floor Console (76.25.01)
▪ Instrument Panel Switches
▪ 501-14: Handles, Locks, Latches and Entry Systems
▪ Specification
▪ Description and Operation
▪ Handles, Locks, Latches and Entry Systems
▪ General Procedures
▪ Latch Cable Adjustment
▪ Removal and Installation
▪ Front Door Latch (76.37.12)
▪ Rear Door Latch (76.37.13)
▪ Door Lock Cylinder (76.37.39)
▪ Exterior Front Door Handle (76.58.07)
▪ Exterior Rear Door Handle (76.58.02)
▪ Interior Rear Door Handle
▪ Interior Front Door Handle
▪ Hood Latch (76.16.21)
▪ Hood Latch Release Handle (76.16.30)
▪ Front Door Lock Actuator
▪ Front Door Push Button Rod and Linkage
▪ Rear Door Lock Actuator
▪ Rear Door Push Button Rod and Linkage
▪ Taildoor Latch (76.37.16)
▪ Taildoor Lock Cylinder
▪ Taildoor Lock Motor
▪ 501-16: Wipers and Washers
▪ Description and Operation
▪ Wipers and Washers
▪ Removal and Installation
▪ Front Wiper Pivot Arm (84.15.02)
▪ Rear Window Washer Jet
▪ Rear Window Wiper Motor (84.35.12)
▪ Windshield Washer Pump (84.10.21)
▪ Windshield Wiper Motor (84.15.12)
▪ Windshield Wiper/Washer Switch (86.65.41)
▪ Wiper Mounting Arm and Pivot Shaft
▪ 501-17: Roof Opening Panel
▪ Removal and Installation
▪ Roof Opening Panel (76.84.01)
▪ 501-18: Convertible Top
▪ Description and Operation
▪ Convertible Top
▪ 501-19: Bumpers
▪ Removal and Installation
▪ Front Bumper (76.22.49)
▪ 501-20: Safety Belt System
▪ Specification
▪ Description and Operation
▪ Safety Belt System
▪ Diagnosis and Testing
▪ Safety Belt System
▪ Removal and Installation
▪ Front Safety Belt Buckle (76.73.30)
▪ Front Safety Belt Retractor (76.73.13)
▪ Rear Center Safety Belt Buckle (76.73.64)
▪ Rear Center Safety Belt Retractor
▪ Rear Safety Belt Retractor
▪ Rear Safety Belt Buckle LH (76.73.60)
▪ Rear Safety Belt Buckle RH (76.73.62)
▪ Third Row Safety Belt Buckle
▪ Third Row Safety Belt Retractor (76.73.28)
▪ 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
▪ Diagnosis and Testing
▪ Water Leak
▪ 501-26: Body Repairs – Vehicle Specific Information and
Tolerance Checks
▪ Description and Operation
▪ Body and Frame
S.M
