land rover warranty codes manual

Warranty Codes Manual Garantiecodeshandboek Manuel des codes de garantie Reklamationscodes Manuale codici di garanzia Manual de códigos de garantía Manual dos códigos da garantia

LAND ROVER WARRANTY CODES MANUAL

WARRANTY CODES MANUAL CONTENTS

Introduction ................................................................................................................. 1 Complaint Code Index ................................................................................................ 2 Section 1 - Engine....................................................................................................... 4 Section 2 - Engine, Auxiliaries .................................................................................... 6 Section 3 - Power Train, Clutch, Manual Gearbox ...................................................... 8 Section 4 - Automatic Gearbox, Final Drive ................................................................ 10 Section 5 - Chassis, Steering & Suspension .............................................................. 12 Section 6 - Brakes....................................................................................................... 14 Section 7 - Electrical & Instruments ............................................................................ 16 Section 8 - Body Interior & Locks ................................................................................ 18 Section 9 - Body Exterior ............................................................................................ 20 Paint Refinishing Codes - Introduction ....................................................................... 22 Paint Refinishing Codes - Complaint Codes ............................................................... 23

Publication Part No. LRL 0096ENG (c) 1997 Rover Group Limited

INTRODUCTION USING THESE CODES These codes are used to analyse warranty claims and consist of four digits in the sequence, number - letter - number. SELECTING THE CORRECT CODE To establish a code, select the appropriate section from the index e.g: Section 1 Engine, or Section 6 Brakes, or Section 9 Body Exterior The section 'number' becomes the first digit of the complaint code Turn to section page and select the complaint area e.g: 1E Piston and Connecting Rod, or 6H ServoSystem The component area reference 'letter' becomes the second digit of the complaint code Then identify the individual part or assembly e.g: 1E3 Gudgeon pin, or 6H4 Non-Return Valves The part or assembly reference 'number' becomes the third digit of the complaint code To complete the complaint code with the fourth digit, select from the bottom of the section page that description which accurately fits the cause of the component or assembly failure e.g: 1E3F Gudgeon Pin Seized, or 6H4D Non-return Valve broken The fault description reference 'letter' completes the complaint code. It is essential that your interpretation of the cause of the failure is accurate and that you avoid coding the result eg. clutch slipping - oil on drive plate; select a complaint code which describes what has caused the oil leak, not a code which describes the clutch drive plate contaminated with oil. PAINT CODES Whilst the layout of the page is different the procedure for selecting a code remains broadly the same. An example is given on the title page of the paint code section. IF YOU HAVE DIFFICULTY Contact the Warranty Department at Service Division, P.O. Box 58, Cowley, Oxford, OX4 2HU, England.

1

COMPLAINT CODE INDEX SECTION 1 - ENGINE

SECTION 4 - AUTOMATIC GEARBOX AND FINAL DRIVE

1A 1B 1C 1E 1F 1G 1H 1J 1K 1M 1N 1Q 1R 1S 1T 1U

4A 4B 4C 4D 4E 4F 4G 4H 4J 4K 4L 4M 4N 4P 4Q 4R 4S

BLOCK SPECIAL CONDITIONS CRANKSHAFT PISTON AND CON' ROD CYLINDER HEAD VALVE GEAR VALVE GEAR VALVE GEAR CAMSHAFT DRIVE CAMSHAFT DRIVE COVERS AND PLATES SEALS AND RINGS CRANKCASE BREATHING JOINTS AND GASKETS CRANKCASE BREATHING EXHAUST GAS RECIRCULATION

FINAL DRIVE AUTOMATIC GEARBOX EXTERNAL AUTOMATIC GEARBOX INTERNAL AUTOMATIC GEARBOX INTERNAL AUTOMATIC GEARBOX INTERNAL AUTOMATIC GEARBOX CONTROLS AUTO BOX SPECIAL CONDITIONS SEAL JOINTS AUTO BOX SEALS/JOINTS P'SHAFT G'BOX TO AXLE DRIVE SHAFT TO WHEEL AUTO BOX REPLACEMENT FINAL DRIVE/AXLE CASE FRONT AXLE GEARS AND PINIONS AXLE GEARS AND PINIONS REAR AXLE GEARS AND PINIONS DIFFERENTIAL SEALS AND JOINTS

SECTION 2 - ENGINE AUXILIARIES SECTION 5 - CHASSIS STEERING AND SUSPENSION 2A 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P 2Q 2R 2S 2T 2U 2V 2W 2X 2Y 2Z

LUBRICATION COOLING COOLING WATER HOSES AIR CLEANER INTAKE BELT DRIVES AND PULLEYS BELT DRIVERS AND PULLEYS CARBURETTOR/MANIFOLD CARBURETTOR CARBURETTOR DIESEL - ELECTRONIC FUEL INJECTION FUEL SYSTEM DIESEL INJECTION FUEL SYSTEM FUEL SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM SEALS AND JOINTS SEALS AND JOINTS CRUISE SPEED CONTROL CRUISE SPEED CONTROL TURBOCHARGER AND AUXILIARIES EXHAUST SYSTEM

5A 5B 5C 5D 5E 5F 5G 5H 5J 5L 5M 5N 5P 5R 5T 5V 5W 5X 5Y 5Z

CHASSIS AND FITTINGS CHASSIS AND FITTINGS RUBBER MOUNTINGS STEERING COLUMN STEERING LINKAGE STEERING BOX POWER STEERING PUMP/HOSES FRONT SUSPENSION FRONT SUSPENSION REAR SUSPENSION REAR SUSPENSION FRONT SPRINGS REAR SPRINGS SHOCK ABSORBERS LEVELLING UNIT FRONT HUBS REAR HUBS WHEELS AND TYRES AIR SUSPENSION AIR SUSPENSION

SECTION 6 - BRAKES SECTION 3 - PT, CLUTCH, MANUAL GEARBOX ANDOVERDRIVE 3A 3B 3C 3D 3E 3F 3G 3H 3J 3K 3L 3M 3N 3P 3Q 3R 3S 3T 3U 3V 3W 3X 3Y 3Z

2

CLUTCH AND RELEASE MECHANISM CLUTCH AND RELEASE MECHANISM GEARS GEARBOX CASE/COVERS GEARS GEARBOX EXTERNAL SYNCHROMESH AND HUBS SHAFTS AND BEARINGS GEARCHANGE EXTERNAL SPECIAL CONDITIONS TRANSFER CASING/GEARS GEARCHANGE INTERNAL TRANSFER SHAFTS/BEARINGS SYNCROMESH HUBS SHAFT AND GEARS SEALS AND JOINTS SEALS AND JOINTS MISCELLANEOUS COMPONENTS POWER TAKE OFF POWER TAKE OFF UNITS TRANSFER GEARBOX (VISCOUS) TRANSFER GEARBOX (SPECIAL CONDITIONS) GEAR CHANGE AND INTERNAL SEALS AND JOINTS

6A 6B 6C 6D 6F 6G 6H 6J 6K 6L 6M

TRANSMISSION BRAKE TRANSMISSION BRAKE DISC BRAKE FRONT DISC BRAKE REAR DRUM BRAKES REAR MASTER CYLINDER/PIPES SERVO SYSTEM BRAKE PEDAL ASSEMBLY BRAKES ANTI LOCK BRAKES ANTI LOCK TRACTION CONTROL

SECTION 6 - 6N ONWARDS - ELECTRICAL AND INSTRUMENTS

SECTION 9 - BODY EXTERIOR

6N 6P 6Q 6R 6S 6T 6U 6V 6W 6X 6Y 6Z

9A 9B 9C 9D 9E 9F 9G 9H 9J 9K 9L 9M 9N 9P 9Q 9R 9S 9T 9U 9V 9W 9Y 9Z

LIGHTS SWITCHES WASHERS AIR SUSPENSION ALARM SYSTEM AIR BAG CONTROL UNITS ELECTRIC WINDOWS AND SUNROOF AIR SUSPENSION RADIO/TAPE SYSTEM HEATER AND AIR CONDITIONING RADIO/TAPE SYSTEM AND MISCELLANEOUS

SECTION 7 - ELECTRICAL AND INSTRUMENTS 7A 7B 7C 7D 7E 7F 7G 7H 7J 7K 7L 7M 7N 7P 7Q 7R 7S 7T 7U 7V 7W 7X 7Y 7Z

IGNITION SYSTEM IGNITION SYSTEM STARTING SYSTEM CHARGING AND ENGINE MISC CHARGING SYSTEM AND ENGINE MISC ENGINE MISCELLANEOUS ELECTRONIC FUEL INJECTION TRANSMISSION LIGHTS LIGHTS LIGHT SWITCHES SWITCHES, RELAYS ETC BRAKES SEAT BELT WARNING WASHERS AND HORNS WIPERS HEATING AND AIR CONDITIONING INSTRUMENTS INSTRUMENTS INSTRUMENTS ELEC INJECTION AND EMISSION ELECTRIC WINDOW WIRING HARNESS MISCELLANEOUS

SHELL AND FIXED PANELS SHELL AND FIXED PANELS MOVING HINGED PANELS FRONT SUNROOF SOFT/HARD TOP HINGES AND SUPPORTS HINGES AND SUPPORTS SEALS SEALS BODY AND FIXED PANEL WELDS BODY SEAMS EXTERIOR FITTINGS EXTERIOR FITTINGS EXTERIOR COVERINGS EXTERIOR COVERINGS EXTERIOR FITTINGS REAR SUNROOF COACH LINE/TAPE BODY SEAM FILLER EXTERNAL BODY SEAM FILLER EXTERNAL TACHOGRAPH SEALS BODY MISCELLANEOUS

SECTION 8 - BODY AND INTERIOR AND LOCKS 8A 8B 8C 8D 8E 8F 8G 8H 8J 8K 8L 8M 8N 8P 8Q 8R 8S 8T 8U 8V 8W 8X 8Y 8Z

SEATS SEATS TRIM AND INSULATION TRIM AND INSULATION TRIM AND INSULATION WINDOW CATCHES/MECHANISM WINDOW GLASS SEATS HEATED SEATS ELECTRIC DOOR LOCK TRIM AND INSULATION HEATING HEATING/AIR-CONDITIONING SEAT BELTS AIR CONDITIONING AIR CONDITIONING (ELECTRIC) INTERIOR FITTINGS TOOLS/INTERIOR FITTINGS SIDE DOOR LOCKS, ETC TAIL DOOR LOCKS, ETC MISCELLANEOUS LOCKS AIR BAG SEAT BELTS MISCELLANEOUS

3

SECTION 1 - ENGINE 1A 1 2 3 4 5 6 7 8 9 0

BLOCK BLOCK BORES OILWAYS/DRILLINGS LINERS CORE PLUGS DIPSTICK AND TUBE CROSS BOLTS TAPPINGS STUDS AND SCREWS MAIN BEARING CAPS AND BOLTS

1B 1 2 3 4 5 6 7 8 9 0

SPECIAL CONDITIONS EXCESSIVE OIL CONSUMPTION ENGINE OVERHEATING ENGINE RUNNING ON EXCESSIVE SMOKE ENGINE VIBRATION PINKING SHUNTING/SURGING

1E 1 2 3 4 5 6 7 8 9 0

PISTON AND CONNECTING ROD PISTON PISTON RINGS GUDGEON PIN LITTLE END BEARING CONECTING ROD AND CAP CONNECTING ROD CAP BOLTS/NUTS GUDGEON PIN CIRCLIP

MOUNTINGS SEE 5C

ENGINE OIL LEVEL LOW ENGINE OIL LEVEL HIGH USE ONLY FOURTH DIGIT 'X'

1C 1 2 3 4 5 6 7 8 9 0

CRANKSHAFT CRANKSHAFT SPIGOT BUSH/BEARING MAIN BEARING BIG END BEARING THRUST WASHERS/BEARINGS FLYWHEEL STARTER RING GEAR OIL WAYS/DRILLINGS VIBRATION DAMPER CRANKSHAFT GEAR/PULLEY BOLT CONVERTER DRIVE PLATE 4A5

1F 1 2 3 4 5 6 7 8 9 0 *

CYLINDER HEAD CYLINDER HEAD VALVE SEATS VALVE GUIDES CYLINDER HEAD CORE PLUGS CAMSHAFT CARRIER/BRG. CAPS INJECTOR SLEEVE COMBUSTION CHAMBER HOT PLUG TAPPINGS/STUDS/SCREWS/BOLTS

1D 1 2 3 4 5 6 7 8 9 0

BEARING LADDER LADDER FRAME OIL FEED RAIL INTERNAL OIL GALLERIES

1G 1 2 3 4 5 6 7 8 9 0

VALVE GEAR INLET VALVE INLET VALVE SPRING INLET VALVE SPLIT COTTERS EXHAUST VALVE EXHAUST VALVE SPRING EXHAUST VALVE SPLIT COTTERS CAP-SPRING CAP-VALVE STEM VALVE STEM SEAL-INLET VALVE STEM SEAL-EXHAUST

1H 1 2 3 4 5 6 7 8 9 0

VALVE GEAR CAMSHAFT ROLLER HYDRAULIC TAPPET ROCKER SHAFT PEDESTALS PUSH ROD ROCKER AND SCREW/LOCKNUT ROCKER SHAFT SHIMS CAMSHAFT CAMSHAFT BEARINGS CAMSHAFT RETAINER PLATE

1J 1 2 3 4 5 6 7 8 9 0

VALVE GEAR BRASS TAPPET SLIDE TAPPET GUIDE TAPPET GUIDE-BOLT

1K 1 2 3

CAMSHAFT/DRIVE CRANKSHAFT SPROCKET/GEAR INTERMEDIATE/IDLER SPROCKET CAMSHAFT SPROCKET/GEAR/DAMPER WOODRUFF KEY-CAMSHAFT DRIVE CHAIN VACUUM PUMP-INTERNAL

1L 1 2 3

TWIN CAMSHAFTS EXHAUST CAMSHAFT INLET CAMSHAFT

1M 1 2 3

CAMSHAFT/DRIVE GEAR

4 5 6 7 8 9 0

FUEL PUMP D GEAR/PLUNGER IDLER/IDLER GEAR

J K L M

WORN/STRETCHED NOISY/CHAFED

4 5 6 7 8 9 0

TAPPINGS, STUDS & SCREWS

CHAIN GUIDES TENSIONER

4 5 6 7 8 9 0

CYLINDER HEAD BOLTS HEAD GASKET 1S6

OIL PUMP DRIVE GEAR VERTICAL DRIVE GEAR

FUEL INJECTION PUMP GEAR V8 DISTRIBUTOR DRIVE GEAR

(CAMSHAFT DRIVE BELT SEE 2G8 VACUUM PUMP-EXTERNAL SEE 6H2)

A B C D

4

WRONGLY ADJUSTED POROUS/ADRIFT BAD FIT BROKEN

E F G H

CRACKED/SPLIT/CUT SEIZED/STIFF LOOSE CORRODED/PLATING FAILURE

COOLANT LEAKS

SECTION 1 - ENGINE 1N 1 2 3 4 5 6 7 8 9 0

COVERS AND PLATES SUMP OIL FILLER CAP

1R 1 2 3 4 5 6 7 8 9 0

CRANKCASE BREATHING PCV FILTER ELEMENT PCV VENT CRANKCASE PCV RESTRICTOR "T" PIECE

1U 1 2 3 4 5 6 7 8 9 0

EXHAUST GAS RECIRCULATION E G R VALVE E G R GAS PIPES E G R VACUUM CONTROL PIPES E G R CUT OFF VALVE E G R FUEL TRAP E G R COOLER

ROCKER COVER/CAMSHAFT COVER SIDE COVER FRONT/TIMING COVER REAR COVER/BACKPLATE SUMP PLUG WADING PLUG JOINTS/GASKETS SEE 1S

1X 1 2 3 4 5 6 7 8 9 0

N P Q R

LEAKS NOT COOLANT LOSS

FACTORY DAMAGE

1P 1 2 3 4 5 6 7 8 9 0

1S 1 2 3 4 5 6 7 8 9 0

JOINTS/GASKETS TOP ROCKER CAMSHAFT COVER FRONT TIMING COVER SIDE COVER REAR COVER/BACKPLATE SUMP/TRANSMISSION CASE HEAD GASKET CAMSHAFT END COVER INJECTOR HEAT SHIELD WASHERS CAM CARRIER TO CYLINDER HEAD BRG. LADDER TO CYLINDER HEAD * MAIN BEARING CAP SEAL 1Q4 MANIFOLD JOINTS SEE 2U

1Q 1 2 3 4 5 6 7 8 9 0

SEALS AND RINGS FRONT CRANK/TIMING COVER SEAL CRANKSHAFT REAR SEAL VALVE STEM SEAL MAIN BEARING CAP SEAL FLYWHEEL HOUSING SEAL CAMSHAFT OIL SEAL

1T 1 2 3 4 5 6 7 8 9 0

CRANKCASE BREATHING OIL SEPARATOR TOP BREATHER HOSE

1V 1 2 3 4 5 6 7 8 9 0

1W 1 2 3 4 5 6 7 8 9 0

1Y 1 2 3 4 5 6 7 8 9 0

1Z 1 2 3 4 5 6 7 8 9 0

S T U V

OPEN CIRCUIT/BLOCKED THREAD DAMAGE INACCURATE/SLIPPING

W X Y Z

DISTRIBUTOR OIL SEAL LINER SEALS

BOTTOM BREATHER HOSE TOP BREATHER VALVE BOTTOM BREATHER VALVE HOSES/CLIPS CRANK/CLUTCH BREATHER REGULATOR VALVE ONE WAY VALVE

VIBRATION/OUT OF BALANCE SPECIAL CODES ONLY INOPERATIVE

5

SECTION 2 - ENGINE AUXILARIES 2A 1 2 3 4 5 6 7 8 9 0

LUBRICATION OIL PUMP SUMP PICKUP/STRAINER RELIEF VALVE/SEAT SQUIRT JET EXTERNAL/TURBO OIL PIPES OIL FILTER/ADAPTOR OIL COOLER ENGINE OIL PUMP DRIVE SHAFT OIL COOLER PIPES ENGINE OIL FILTER HEAD/BOWL SUMP 1N1 DIPSTICK 1A6 SWITCHES ETC SEE 7U 7V

2B 1 2 3 4 5 6 7 8 9 0

LUBRICATION

2C 1 2 3 4 5 6 7 8 9 0

COOLING FAN VISCOUS DRIVE WATER PUMP THERMOSTAT RADIATOR HEADER TANK EXPANSION/OVERFLOW TANK DRAIN TAPS EXPANSION TANK CAP RADIATOR BLEED PLUG ELECTRICAL FAN SEE 7F BELTS & PULLEYS SEE 2G 2H SWITCHES ETC SEE 7U

2D 1 2 3 4 5 6 7 8 9 0

COOLING RADIATOR FILLER CAP COWLING SURROUND COWLING/BRACKETS RADIATOR MOUNTINGS THERMOSTAT HOUSING CYL HD BRIDGE RAIL VM DIESEL "Y" PIECE/EJECTOR PUMP COOLANT LEVEL SENSOR ANTI-FREEZE MIX

2E 1 2 3 4 5 6 7 8 9 0

WATER HOSES TOP HOSE BOTTOM HOSE BY PASS HOSE HEATER SUPPLY HOSES HEATER RETURN HOSES EXPANSION TANK HOSE HEADER TANK TO RAD HOSE WATER HOSE CLIPS "Y" PIECE HOSES IRD THERMOSTAT/HSG

2F 1 2 3 4 5 6 7 8 9 0

AIR CLEANER INTAKE AIR CLEANER CASE INTAKE HOSE/INTAKE GRILL BRACKETS AND CLIPS AIR CLEANER ELEMENT AIR CLEANER DUMP VALVE AIR INTAKE SENSOR AIR INTAKE RESONATOR CROSSOVER DUCT DIESEL AIR CLEANER INDICATOR TEMPERATURE CONTROL SENSOR ALSO SEE 2Z

2G

BELT DRIVES AND PULLEYS

2H

BELT DRIVES AND PULLEYS

2J

1 2 3 4 5 6 7 8 9 0

CRANKSHAFT PULLEY/DAMPER ALTERNATOR PULLEY ALTERNATOR DRIVE BELT SERPENTINE DRIVE BELT WATER PUMP DRIVE BELT AIR CONDITIONING PUMP PULLEY AIR CONDITIONING PUMP BELT CAMSHAFT DRIVE BELT CAMSHAFT DRIVE BELT TENSIONER AIR CONDITIONING JOCKEY PULLEY

1 2 3 4 5 6 7 8 9 0

VACUUM PUMP DRIVE PULLEY VACUUM PUMP DRIVE BELT POWER STEERING JOCKEY PULLEY POWER STEERING PUMP PULLEY POWER STEERING DRIVE BELT

1 2 3 4 5 6 7 8 9 0

CARBURETTER/INJECTION /MANIFOLD INLET MANIFOLD INLET MANIFOLD FIXINGS DIAPHRAGM CARBURETTER BODY FLOAT CHAMBER AND PIPE FLOAT NEEDLE SEAT AND LEVER FLOAT BUTTERFLY AND SPINDLE DASHPOT, PISTON AND DAMPER ACCELERATOR PUMP

2K

CARBURETTER/INJECTION

2L

CARBURETTER

2M

1 2

JET ASSEMBLY CHOKE

1 2

TEMP COMPANSATING DEVICE

1 2

3 4 5 6 7 8 9 0

CHOKE CONTROL THROTTLE BODY ACCELERATOR LINKAGE ACCELERATOR RETURN SPRING ACCELERATOR PEDAL

3 4 5 6 7 8 9 0

TAPPINGS

CARB VENT SOLENOID FUEL STOP VALVE & SOLENOID

3 4 5 6 7 8 9 0

A B C D


E F G H


J K L M

6

CARBURETTER NEEDLE HAND THROTTLE CONTROL AIR CLEANER SEE 2F

IDLER PULLEY WATER PUMP PULLEY AUTO TENSIONER

DIESEL - ELECTRONIC FUEL INJECTION ELECTRONIC DIESEL CONTROL ELECTRONIC EXHAUST GAS RECIRCULATION BOOST PRESSURE SENSOR GLOW PLUG RELAY NEEDLE SENSOR INJECTOR

WORN/STRETCHED NOISY/CHAFED JUDDER/POOR CONNECTION

SECTION 2 - ENGINE AUXILARIES 2N 1 2 3 4 5 6 7 8 9

FUEL SYSTEM ANTI SURGE VALVE FLOAT/ROLLOVER VALVE PRESSURE RELIEF VALVE PURGE CONTROL VALVE FUEL RAIL FUEL TANK PRESSURE SENSOR FUEL TANK CRADLE FUEL TANK HEATSHIELD CANNISTOR VENT SOLENOID

2P 1 2 3 4 5 6 7 8 9

DIESEL INJECTION INJECTION PUMP INJECTORS INJECTOR PIPES FUEL RETURN SYSTEM STOP CONT/SHUT OFF VALVE ACCELERATOR LINKAGE CABLE ACCELERATOR RETURN SPRING VACUUM GOVERNOR/CONTROL UNIT STOP CONTROL CABLE/FUEL CUT OFF SOLENOID FAST IDLE UNIT ACCEL MECH SEE 2K

2Q 1 2 3 4 5 6 7 8 9

FUEL SYSTEM FUEL DELIVERY PUMP (MECHANICAL) FILTER (FUEL PUMP) AGGLOMERATOR/WATER TRAP RIGID PIPES AND UNIONS FLEXIBLE PIPES AND UNIONS CHANGE OVER TAP NON RETURN VALVE FUEL TANK (MAIN) FUEL TANK (AUXILLARY)

0

FUEL COOLER

0

0

FUEL FILLER NECK * ELECTRIC PUMP 7F9 FUEL CAP 9M3, FUEL CAP LOCK 8W6 FUEL FILLER COVER 9P9

2R 1

FUEL SYSTEM CHARCOAL CANISTERS

2S 1

EXHAUST SYSTEM MANIFOLD

2T 1

BREATHER TUBES FUEL LINE FILTER ANTI RUN ON VALVE PLENUM CHAMBER PRESSURE REGULATOR VALVE

2 3 4 5 6

DOWN PIPE (RH CATALYST) DOWN PIPE DOWN PIPE (LH CATALYST) INTERMEDIATE PIPE MANIFOLD HEATSHIELDS

2 3 4 5 6

VAPOUR SEPERATOR/BREATHER EXPANSION TANK FUEL TANK LOCKING RING(PUMP UNIT) FUEL TANK FILLER NECK LOCKING RING SOLENOID 7WO

7 8 9

FRONT SILENCER INTERMEDIATE/MAIN SILENCER REAR SILENCER

7 8 9

EXHAUST SYSTEM RUBBER MOUNTINGS CENTRE/FRONT HEAT SHIELDS STRAPS AND BRACKETS CLAMPS OXYGEN SENSOR (RH) OXYGEN SENSOR (LH)/SINGLE SENSOR RUBBER MOUNTING REAR MANIFOLD FIXINGS MANIFOLD HEATSHIELD FIXINGS

2 3 4 5 6 7 8 9

0

EXHAUST CATALST/CONTAINER ONE SILENCER ONLY FITTED 2S8

0

MANIFOLD HEAT SHEILD FURTHER HEAT SHIELDS SEE 7C4, 7D4, 2Z

2U 1 2 3 4 5 6 7 8 9 0

SEALS AND JOINTS INLET MANIFOLD INJECTION PUMP JOINT WASHER EXHAUST MANIFOLD EXHAUST FLANGE EXHAUST PIPE CARBURETTER FLANGE CARBURETTER MISCELLANEOUS THERMOSTAT HOUSING OIL PUMP HOUSING INJECTOR SEALING WASHERS COMBINED INLET EXHAUST MANIFOLD GASKET 2U1

2V 1 2 3 4 5 6 7 8 9 0

SEALS AND JOINTS OIL FILTER SEAT HOUSING

2W 1 2 3 4 5 6 7 8 9 0

CRUISE SPEED CONTROL SPIRAL CASSETTE ECU ACTUATOR THROTTLE LEVER AND CABLE PUMP RESET BUTTON BRAKE PEDAL SWITCH CLUTCH PEDAL SWITCH WIRING HARNESS ENGINE SPEED TRIP MODULE ROAD SPEED TRANSDUCER SEE 7T2

2X 1 2 3 4 5 6 7 8 9 0

CRUISE SPEED CONTROL ROTARY COUPLER CONVERTER MODULE

2Y 1 2 3 4 5 6 7 8 9 0

TURBOCHARGER AND AUXILIARIES TURBOCHARGER ASSEMBLY INTERCOOLER INTERCOOLER HOSE DUMP VALVE INTERCOOLER WASTE GATE VALVE OIL PIPE HEAT SHIELD BOOST CONTROL PIPE

2Z 1 2 3 4 5 6 7 8 9 0

AIR CLEANER INTAKE AIR INTAKE SENSOR AIR INTAKE RESONATOR CROSS OVER DUCT DIESEL

0

OIL PIPES 'O' RINGS TANK UNIT JET SEALS AND 'O' RINGS WATER PUMP FUEL PIPE WASHERS AND SEALS OIL PIPE BANJO WASHERS FUEL FILTER SEAL AND HOUSING

ALSO SEE 2F

N P Q R

LEAKS

FACTORY DAMAGE

S T U V

BLOCKED THREAD DAMAGE INACCURATE/SLIPPING

W X Y Z

VIBRATION/OUT OF BALANCE SURFACE DAMAGE INTERMITTENT OPERATION INOPERATIVE

7

SECTION 3 - POWER TRAIN CLUTCH, MANUAL GEARBOX 3A 1 2 3 4 5 6 7 8 9 0

CLUTCH AND RELEASE MECHANISM COVER ASSEMBLY DRIVE PLATE ASSEMBLY RELEASE BEARING RELEASE BEARING SLEEVE RELEASE PUSH ROD AND BUSH RELEASE LEVER RELEASE LEVER PIVOT PIN RELEASE FORK AND PINS RELEASE BRG AND GUIDE CROSS SHAFT AND BUSH

3B 1 2 3 4 5 6 7 8 9 0

CLUTCH AND RELEASE MECHANISM RELAESE FORK AND PINS RETURN SPRING RELEASE BEARING LINKAGE MASTER CYLINDER SLAVE CYLINDER PEDAL ASSEMBLY PEDAL BUSHES HYDRAULIC PIPES HYDRAULIC DAMPER RELEASE BEARING AND GUIDE

3C 1 2 3 4 5 6 7 8 9 0

GEARS/SYNCHROMESH HUBS REVERSE IDLER GEAR/BRG/SPACER CONSTANT PINION REVERSE LAYSHAFT GEAR REVERSE BUSH SHIM REVERSE SYNCROMESH UNIT REVERSE BULK RING REVERSE BRAKE

ALSO SEE 3E

3D 1 2 3 4 5 6 7 8 9 0

GEARBOX CASE/COVERS GEARBOX/TRANSMISSION CASE FLYWHEEL HOUSING CLUTCH HOUSING END COVER GEARBOX BREATHER PIPE GEARBOX BREATHER CORE PLUGS DIFFERENTIAL SIDE COVER REAR EXTENSION HOUSING REMOTE CONTROL HOUSING

3E 1 2 3 4 5 6 7 8 9 0

GEARS

SEALS & JOINTS SEE 3R 3S MOUNTINGS 5C2

1ST WITH BUSHES/BEARINGS 2ND WITH BUSHES/BEARINGS 3RD WITH BUSHES/BEARINGS 4TH WITH BUSHES/BEARINGS 5TH WITH BUSHES/BEARINGS REVERSE WITH BUSHES/BEARINGS LAYGEAR SPEEDO DRIVE GEAR AND BUSHES OIL PUMP SEE ALSO 3C

3F 1 2 3 4 5 6 7 8 9 0

GEARBOX EXTERNAL OIL COOLER OIL COOLER PIPES HILL DESCENT COLLAR SWITCH

GEARCHANGE EXTERNAL GEAR LEVER AND KNOB SPHERICAL SEAT AND RETAINER REMOTE CONTROL LINKAGE REVERSE CATCH/PLUNGER HIGH/LOW CONTROL LEVER AND KNOB 4 W D CONTROL LEVER AND KNOB LOWER PIN SELECTOR ROD YOKE/BUSH BIAS SPRING GEAR LEVER ANTI RATTLE DEVICE SELECTOR SHAFT SEAL 3R9

3G 1 2 3 4 5

SYNCHROMESH HUBS 1ST SPEED SYNCHROMESH UNIT 2ND SPEED SYNCHROMESH UNIT 3RD SPEED SYNCHROMESH UNIT 4TH SPEED SYNCHROMESH UNIT 5TH SPEED SYNCHROMESH UNIT

3H 1 2 3 4 5

SHAFTS AND BEARINGS INPUT SHAFT MAIN SHAFT LAYSHAFT REVERSE SHAFT INPUT SHAFT BEARINGS

3J 1 2 3 4 5

6 7 8 9 0

1ST SPEED BAULK RING 2ND SPEED BAULK RING 3RD SPEED BAULK RING 4TH SPEED BAULK RING 5TH SPEED BAULK RING

6 7 8 9 0

MAIN SHAFT BEARINGS LAYSHAFT BEARINGS MAIN SHAFT SPIGOT BEARING OUTPUT FLANGE AND SPLINES OIL PUMP THRUST WASHERS CIRCLIPS AND RETAINING SEE 3T SEE ALSO 3Y

6 7 8 9 0

3L 1 2 3 4 5 6 7 8 9 0

TRANSFER/IRD CASING/GEARS TRANSFER/IRD CASING/COVERS 4 W D FORK SHAFT AND LINKAGE HIGH/LOW SELECTOR MECHANISM SPRINGS, BALLS AND PLUNGERS TRANSFER GEARS/IRD GEARS LOW GEARS AND DOGS HIGH GEARS AND DOGS 4 W D DOGS/DIFF LOCK DOGS TRANSFER BOX DIFFERENTIAL

3M 1 2 3 4 5 6 7 8 9 0

GEARCHANGE INTERNAL 1ST/2ND SELECTOR FORK 3RD/4TH SELECTOR FORK 5TH SELECTOR FORK REVERSE SELECTOR FORK SELECTOR SHAFTS/RAILS DETENT SPRINGS/BALLS/PLUNGERS REVERSE LEVER/PIVOT INTERLOCK DEVICE 5th/REV SELECTOR FORK HIGH/LOW SELECTOR FORKS ALSO SEE 3Y

J K L M

WORN/STRETCHED NOISY/CHAFED JUDDER

SEE ALSO 3C

3K 1 2 3 4 5 6 7 8 9 0

SPECIAL CONDITIONS 1ST GEAR AUTO DISENGAGEMENT 2ND GEAR AUTO DISENGAGEMENT 3RD GEAR AUTO DISENGAGEMENT 4TH GEAR AUTO DISENGAGEMENT 5TH GEAR AUTO DISENGAGEMENT REVERSE AUTO DISENGAGEMENT HIGH RANGE AUTO DISENGAGEMENT LOW RANGE AUTO DISENGAGEMENT GEARBOX OIL LEVEL LOW USE WITH 4TH DIGIT 'X' ONLY

A B C D

8


(CONTINUED AT 3W)

E F G H

CRACKED/SPLIT/CUT SEIZED/STIFF LOOSE/WEAK SYNCHROMESH CORRODED/PLATING FAILURE

SECTIO N 3 - POWER TRAIN CLUTCH, MANUAL GEARBOX 3N 1 2 3 4 5 6 7 8 9 0

TRANSFER/IRD SHAFTS/BEARINGS INTERMEDIATE SHAFT OUTPUT REAR OUTPUT FRONT THRUST WASHERS/BEARINGS OUTPUT FLANGES AND SPLINES IRD INPUT SHAFT IRD ADAPTOR PLATE

3P 1 2 3 4 5 6 7 8 9 0

SYNCHROMESH HUBS REVERSE SYNCHRO UNIT

3R 1 2 3 4 5 6 7 8 9 0

SEALS AND JOINTS VISCOUS HOUSING GASKET SPEED SENSOR GASKET FRONT/FLYWHEEL HOUSING GASKET REAR EXTENSION HOUSING GASKET TOP COVER GASKET INPUT/1ST MOTION SHAFT SEAL OUTPUT SHAFT SEAL DIFFERENTIAL SIDE COVER SEAL SELECTOR SHAFT SEAL FRONT COVER FIXINGS SEE ALSO 3Z

3S 1 2 3 4 5 6 7 8 9 0

3U 1 2 3 4 5 6 7 8 9 0

POWER TAKE OFF PRIMARY SHAFT AND BEARINGS OUTPUT SHAFT AND BEARINGS LINKAGE COVER DRIVING TUBE AND GEAR

3X 1 2 3 4 5 6 7 8 9 0

N P Q

3Q 1 2 3 4 5 6 7 8 9 0

SHAFTS AND BEARINGS ROLL PIN

SEALS AND JOINTS TRANSFER HOUSING GASKETS INTER BOX SEAL MAIN CASE/CENTRE PLATE CENTRE PLATE/EXT CASE DIFFERENTIAL SIDE COVER GASKET DIFFERENTIAL HOUSING GASKET SPEEDO HOUSING GASKET/'O' RING GEAR CHANGE/EXT CASE THERMOSTAT HSG SPEEDO SENSOR GASKET SEE ALSO 3Z

3T 1 2 3 4 5 6 7 8 9 0

MISCELLANEOUS COMPONENTS MAIN SHAFT THRUST WASHER MAIN SHAFT CIRCLIP MAIN SHAFT RETAINING NUT LAYSHAFT THRUST WASHER LAYSHAFT CIRCLIP LAYSHAFT RETAINING NUT INPUT SHAFT THRUST WASHER INPUT SHAFT CIRCLIP SOLENOID HIGH/LOW GEARSHIFT SWITCH AUDIBLE ALARM GEARSHIFT NEUTRAL

3V 1 2 3 4 5 6 7 8 9 0

POWER TAKE OFF/UNITS BOTTOM P T O (HYDRAULIC) BOTTOM P T O (MECHANICAL) CENTRE P T O UNIT REAR P T O UNIT REAR P T O PULLEY CAPSTAN WINCH (MECHANICAL) CAPSTAN WINCH (ELECTRICAL) DRUM WINCH (ELECTRICAL) DRUM WINCH (HYDRAULIC)

3W 1 2 3 4 5 6 7 8 9 0

TRANSFER GEARBOX (VISCOUS) VISCOUS COUPLING HIGH/LOW DRIVE GEAR DRIVEN GEAR CHAIN OIL PUMP OIL PUMP FILTER/PICK-UP LOW RANGE PLANETARY SET HIGH/LOW SELECTOR MECHANISM

TRANSFER BOX SPECIAL CONDITIONS NO HIGH/LOW SHIFT NO LOW/HIGH SHIFT JAMMED IN NEUTRAL

3Y

GEAR CHANGE INTERNAL

3Z

SEALS AND JOINTS

1 2 3 4 5 6 7 8 9 0

YOKE ASSY QUADRANT REVERSE INHIBIT CAM. REVERSE INHIBIT SPRING/SHAFT 5th/REVERSE SELECTOR FORKS ROLL PIN

1 2 3 4 5 6 7 8 9 0

FILLER PLUG DRAIN PLUG OIL PUMP MAIN CASE/CENTRE PLATE CENTRE PLATE/EXTERNAL CASE GEAR CHANGE/EXTERNAL CASE THERMOSTAT HOUSING IRD(FRONT)OUTPUT SEAL IRD(REAR)OUTPUT SEAL IRD INPUT O’ ‘ RING

LEAKS DIFFICULT ENGAGEMENT DISCOLOURED

S T U


W X Y

VIBRATION/OUT OF BALANCE SURFACE DAMAGE INTERMITTENT OPERATION

REVERSE BAULK PIN

9

SECTION 4 - AUTOMATIC GEARBOX & FINAL DRIVE 4A 1 2 3 4 5 6 7 8 9 0

4D 1 2 3 4 5 6 7 8 9 0

AUTO BOX EXTERNAL TRANSMISSION CASING CONVERTER HOUSING CONVERTER HOUSING BUSH/BEARING TORQUE CONVERTER TORQUE CONVERTER DRIVE PLATE FRONT/MAIN OIL PUMP OIL PUMP DRIVE FRONT PUMP BUSH SUMP PAN ELECTRICAL ITEMS SEE 7H SEALS AND JOINTS SEE 4H 4J

AUTOMATIC GEARBOX INTERNAL INPUT SHAFT GEAR TRAIN OUTPUT SHAFT UNI DIRECTIONAL CLUTCHES BEARINGS/WASHERS/BUSHES PARK LOCK MECHANISM SPEEDO DRIVE GEARS STATOR SUPPORT

4B 1 2 3

AUTOMATIC GEARBOX EXTERNAL END FRONT COVER EXTENSION HOUSING AND BUSH RELAY AUTO GEARSHIFT INTERLOCK

4C 1 2 3

4 5 6 7 8 9 0

RELAY GEARSHIFT NEUTRAL

4 5 6 7 8 9 0

4E 1 2 3 4 5 6 7 8 9 0

AUTOMATIC GEARBOX INTERNAL GOVERNOR/GOVERNOR VALVE

DIPSTICK FILLER TUBES OIL COOLER OIL COOLER HOSES/PIPES

ACCUMLATOR

4F 1 2 3 4 5 6 7 8 9 0

*ANGLE DRIVES 7T4

4G 1 2 3 4 5 6 7 8 9

AUTO BOX SPECIAL CONDITIONS NO DRIVE IN 1 NO DRIVE IN 2 NO DRIVE IN 3 NO DRIVE IN D NO DRIVE IN REVERSE

OIL LEVEL LOW AUTO BOX*

0

AUTOMATIC GEARBOX INTERNAL FRONT/FORWARD CLUTCH CLUTCH REAR/TOP/REVERSE ND FRONT/2 GEAR BAND

REAR/REVERSE BAND ND

FRONT 2 GEAR SERVO REAR/REVERSE GEAR SERVO VALVE BLOCK ASSEMBLY DIRECT DRIVE/CONVERTER CLUTCH

AUTOMATIC GEARBOX CONTROLS SELECTOR LEVER SELECTOR LINKAGE/BELL CRANK SELECTOR CABLE PARK CABLE KICKDOWN CABLE AND LINKAGE VACUUM CAPSULE HOSE GEAR SELECTOR INDICATOR PLATE GEAR SELECTOR PLASTIC SLIDE ELECTRICAL ITEMS SEE 7H

4H 1 2 3 4 5 6 7 8 9

SEAL JOINTS CONVERTOR/FRONT PUMP SEAL MAIN OIL PUMP JOINT 'O' RING STATOR SUPPORT SEAL

FRONT COVER GASKET SUMP/VALVE BLOCK COVER GASKET SELECTOR CABLE/SHAFT SEAL KICKDOWN CABLE/LEVER GASKT/SEAL

0

4J 1 2 3 4 5 6 7 8 9

AUTO BOX SEALS/JOINTS

END/FRONT COVER EXTENSION/GOVERNOR SEAL

EXTENSION GOVERNOR GASKET

0

*4TH DIGIT X ONLY

4K 1 2 3 4 5 6 7 8 9 0

P'SHAFT G'BOX TO AXLE PROPELLER SHAFT/S SUPPORT BEARINGS UNIVERSAL JOINTS FIXINGS BOLTS SLIDING SPLINE G.I. JOINT VISCOUS COUPLING TORSINAL DAMPER FLEXIBLE COUPLING

4L 1 2 3 4 5 6 7 8 9 0

DRIVE SHAFT TO WHEEL DRIVE SHAFT/AXLE SHAFT FRONT CONSTANT VELOCITY JOINT CONSTANT VELOCITY JOINT BOOT CONSTANT VELOCITY SHAFT SEAL DRIVE SHAFT/AXLE SHAFT REAR DRIVE SHAFT CIRCLIP

A B C D


E F G H


10

FIXING BOLTS

4M 1 2 3 4 5 6 7 8 9 0

AUTO BOX REPLACEMENT SLIP/LOSS OF FORWARD DRIVE SLIP/LOSS OF REVERSE DRIVE SLIP/LOSS OF ALL GEARS NO UPSHIFT/DOWNSHIFT INCORRECT SHIFT SPEEDS ERRATIC GEAR CHANGE

J K L M


SECTION 4 - AUTOMATIC GEARBOX & FINAL DRIVE 4N 1 2 3 4 5 6 7 8 9 0

FINAL DRIVE/AXLE CASE AXLE CASE/FINAL DRIVE HOUSING BREATHER PINION HOUSING EXTENSION HOUSING MOUNTING BRACKETS RIGID AXLE TUBE FILLER/DRAIN PLUG BREATHER PIPES HARMONIC DAMPER AXLE YOKE & COLLETS

4P 1 2 3 4 5 6 7 8 9 0

FRONT AXLE GEARS AND PINIONS CROWN WHEEL AND PINION CROWN WHEEL BOLTS PINION BEARINGS DIFF GEARS AND SPINDLES DIFF CASING AND THRST WSRS HEAD HEIGHT SPACER PRE - LOAD SPACER INPUT FLANGE AND SPLINE MUD SHIELD INPUT FLANGE

4Q 1 2 3 4 5 6 7 8 9 0

4R 1

REAR AXLE GEARS AND PINIONS CROWN WHEEL AND PINION

4S 1

4T 1

2 3 4 5

CROWN WHEEL BOLTS PINION BEARINGS DIFF GEARS AND SPLINDLES DIFF CASING AND THRST WSRS

2 3 4 5

6 7 8 9 0

PINION SHAFT AND FLANGE PRE - LOAD SPACER INPUT FLANGE AND SPLINE MUD SHIELD INPUT FLANGE DRIVESHAFT RETAINING CIRCLIP N.B. FOR HEAD HEIGHT SPACER SEE 4Q6

6 7 8 9 0

DIFFERENTIAL SEALS AND JOINTS INPUT SHAFT/PINION OIL SEAL REAR AXLE OUTPUT SHAFT SEAL OUTPUT SHAFT GASKET AXLE CASE COVER GASKET INPUT SHAFT/PINION OIL SEAL FRONT AXLE AXLE CASE OUTER OIL SEAL

6 7 8 9 0

*RIGID AXLE HUB SEALS 5V3 5W3

4V 1 2 3 4 5 6 7 8 9 0

4W 1 2 3 4 5 6 7 8 9 0

4X 1 2 3 4 5 6 7 8 9 00

4Y 1 2 3 4 5 6 7 8 9

4Z 1 2 3 4 5 6 7 8 9 0

LEAKS DIFFICULT ENGAGEMENT DISCOLOURED FACTORY DAMAGE

HEAD HEIGHT SPACER

2 3 4 5

4U 1 2 3 4 5 6 7 8 9 0

N P Q R

AXLE GEARS AND PINIONS DIFF GEAR CARRIER BEARINGS DIFF CLUTCH PLATES INPUT FLANGE TO PINION, BOLT/NUT PINION SPLINES

S T U V

BLOCKED SHORT CIRCUIT/THREAD DAMAGE INACCURATE/SLIPPING

W X Y Z


11

SECTION 5 - CHASSIS, STEERING & SUSPENSION 5A 1 2 3 4 5 6 7 8 9 0

CHASSIS AND FITTINGS FRAME SUMP GUARD DETACHABLE CROSS MEMBER LONGTITUDINAL MEMBERS CROSS MEMBERS OUTRIGGERS WELDS/RIVETS/BOLTS ENGINE BRACKETS AND BOLTS FRONT SUB FRAME REAR SUB FRAME

5B 1 2 3 4 5 6 7 8 9 0

CHASSIS AND FITTINGS NATO TOWING HOOK TOWING BALL DRAW BAR/TOWING HOOK TOWING PLATE/MTGS BODY MTG BRACKETS NUDGE BAR UNDER RIDE PROTECTION BAR DETACHABLE TOWING X MEMBER FRONT RECOVERY LOOP REAR RECOVERY LOOP TRAILER SOCKET 7Z6

5C 1 2 3 4 5 6 7 8 9 0

RUBBER MOUNTINGS ENGINE/POWER UNIT GEARBOX ENGINE UPPER TIE BAR BODY ENGINE LOWER TIE BAR DIFFERENTIAL BUSH-FRONT DIFFERENTIAL BUSH-REAR

5D 1 2 3 4 5 6 7 8 9 0

STEERING COLUMN STEERING WHEEL COLUMN BEARINGS/BUSHES MOUNTING BRACKETS STEERING COLUMN STEERING COLUMN LOCK UPPER UJ/FLEXIBLE COUPLING ADJUSTMENT LEVER

5E 1 2 3 4 5 6 7 8 9 0

STEERING LINKAGE DAMPER TELESCOPIC STEERING LOCK STOP SIDE/TRACK RODS AND JOINTS CENTRE TIE RODS AND JOINTS DRAG LINK AND JOINTS FRONT WHEEL ALIGNMENT DROP ARM STEERING ARM

5F 1 2 3 4 5 6 7 8 9 0

STEERING BOX/RACK & PINION ASSY BOX ASSEMBLY MANUAL SEALS/GASKETS MANUAL BEARINGS/BUSHES MANUAL BOX/RACK/POWER SEALS/GASKETS POWER BEARINGS/BUSHES POWER

FRONT SUSPENSION LOWER ARM LOWER ARM BUSHES PANHARD ROD PANHARD ROD BUSHES ANTI ROLL BAR/CLAMPS ANTI ROLL BAR BUSHES ANTI ROLL BAR BALL JOINTS ANTI ROLL BAR LINK LOWER ARM REAR BUSH HSG. ASSY

STEERING COUPLING COVER/GAITER LOWER UJ/FLEXIBLE COUPLING

BOX MOUNTINGS

TRACK ADJUSTMENT 5E6

5G 1 2 3 4 5 6 7 8 9 0

POWER STEERING PUMP/HOSES STEERING PUMP STEERING PUMP SEALS/GASKETS STEERING PUMP BEARINGS/BUSHES PIPES AND HOSES RESERVOIR RESERVOIR CAP/SEAL STEERING PUMP RELIEF VALVE OIL COOLER (PAS)

5H 1 2 3 4 5 6 7 8 9 0

FRONT SUSPENSION RADIUS ARM/BUSHES

TIE BAR AND BUSHES SWIVEL PIN/KING PIN AND BUSHES SWIVEL HUB/STUB AXLE TOP SWIVEL BRG/BALL JOINT BOTTOM SWIVEL BRG/BALL JOINT FRONT SWIVEL HUB OIL SEAL

5J 1 2 3 4 5 6 7 8 9 0

5L 1 2 3 4 5 6 7 8 9 0

REAR SUSPENSION LOWER LINK/BUSHES UPPER LINK/BUSHES UPPER LINK BALL JOINT COMPOSITE LINK ASSY COMPOSITE LINK BUSH 'A' FRAME BUSH 'A' FRAME BALL JOINT COMPOSITE LINK HT SENSOR MNT. PANHARD ROD PANHARD ROD BUSHES

5M 1 2 3 4 5 6 7 8 9 0

REAR SUSPENSION RADIUS/TRAILING ARM FRONT BUSH REAR BUSH

E F G H


J K L M


BELT DRIVES SEE 2H

5K 1 2 3 4 5 6 7 8 9 0

A B C D

12


ANTI ROLL BAR/CLAMPS ANTI ROLL BAR BUSHES ANTI ROLL BAR BALL JOINTS

SECTION 5 - CHASSIS, STEERING & SUSPENSION 5N 1 2 3 4 5 6 7 8 9 0

5R 1 2 3 4 5 6 7 8 9 0

FRONT SPRINGS SPRING SPRING CUP/PLATE/STRUT ASSY

SHACKLE PINS/PLATES/BUSHES

BUMP RUBBERS SPRING PACKING/INSULATING RING

SHOCK ABSORBERS FRONT FRONT TOP BUSH FRONT BOTTOM BUSH CLAMP FRONT MOUNTING BRACKETS/BOLTS REAR REAR TOP BUSH REAR BOTTOM BUSH REAR MOUNTING BRACKETS/BOLTS

5U 1 2 3 4 5 6 7 8 9 0

5P 1 2 3 4 5 6 7 8 9 0

REAR SPRINGS SPRING SPRING CUP/PLATE/SEAT/STRUT ASSY SHACKLE PINS/PLATES AND BUSHES

BUMP RUBBERS AND STRAPS SPRING ISOLATORS

5S 1 2 3 4 5 6 7 8 9 0

5V 1 2 3 4 5 6 7 8 9 0

FRONT HUBS HUBS BOLT ON WHEEL/FLANGE HUB SEALS HUB BEARINGS HUB NUT AND WASHER WHEEL STUDS WHEEL NUTS LOCKING WHEEL NUTS

5Q 1 2 3 4 5 6 7 8 9 0

5T 1 2 3 4 5 6 7 8 9 0

LEVELLING UNIT LEVELLING UNIT TOP MOUNTING BUSH BOTTOM MOUNTING BUSH BALL JOINTS

5W 1 2 3 4 5 6 7 8 9 0

REAR HUBS DRIVE FLANGE HUB CARRIER HUB SEALS HUB BEARINGS HUB NUTS AND WASHERS WHEEL STUDS WHEEL NUTS BOLT ON WHEEL

5X 1 2 3 4 5 6 7 8 9 0

WHEELS AND TYRES WHEEL STEEL WHEEL ALLOY SPARE WHEEL ATTACHMENT BRKT TYRE HUB COVER WHEEL CENTRE TRIM SPARE WHEEL COVER WHEEL BALANCE INNER TUBE TYRE VALVE ASSEMBLY

5Y 1 2 3 4 5 6 7 8 9 0

AIR SUSPENSION COMPRESSOR INLET FILTER COMPRESSOR BOBBINS VALVE BLOCK AIR DRYER AIR SPRINGS FRONT AIR SPRINGS REAR COLLETS O RINGS AIR DRYER PIPES

5Z 1 2 3 4 5 6 7 8 9 0

AIR SUSPENSION HEIGHT SENSOR LINK FRONT HEIGHT SENSOR LINK REAR UNDER FLOOR BOX LID/INSPECTION HATCH AIR HARNESS (PIPES) AIR INLET PIPE AIR EXHAUST PIPE AIR RESERVOIR AND PLUG HEIGHT SENSOR HEATSHIELD FRONT

N P Q R

LEAKS

S T U V


W X Y Z


FADED/STAINED/DISCOLOURED FACTORY DAMAGE

13

SECTION 6 - BRAKES 6A 1 2 3 4 5

HAND/TRANSMISSION BRAKE LEVER ASSEMBLY LEVER MOUNTING BRACKET CABLES RODS COMPENSATOR

6B 1 2 3 4 5

TRANSMISSION BRAKE DRUM SHOES AND LININGS BACK PLATE EXPANDER ADJUSTER

6C 1 2 3 4 5

6 7

GAITER

6 7

PULL OFF SPRINGS TRANSMISSION BRAKE SHOE HOLD DOWN SPRINGS

6 7

8 9 0

6D 1 2 3 4 5 6 7 8 9 0

6G 1 2 3 4 5 6 7 8 9 0

DISC BRAKE FRONT DISCS PADS CALIPER PISTON AND SEALS FRONT CALIPER BRAKE PAD RETAINING CLIPS AND SPRINGS - FRONT SLIDE PIN, BOOTS AND PROTECTOR DISC SHIELD

8 9 0

8 9 *0

DISC BRAKE REAR DISCS PADS CALIPER PISTON AND SEALS REAR CALIPER BRAKE PAD RETAINING CLIPS AND SPRINGS - REAR SLIDE PIN, BOOTS AND PROTECTOR DISC SHIELD

6E 1 2 3 4 5

6F 1 2 3 4 5

DRUM BRAKES REAR DRUM SHOES AND LININGS BACKPLATE WHEEL CYLINDER

6 7 8 9 0

6 7 8 9 0

ADJUSTER PULL OFF SPRINGS

MASTER CYLINDER/PIPES MASTER CYLINDER ASSEMBLY SUPPLY TANK/RESERVOIR RIGID PIPES FLEXIBLE PIPES PIPE CONNECTIONS PRESSURE REGULATING VALVES

6H 1 2 3 4 5 6 7 8 9 0

6J 1 2 3 4 5 6 7 8 9 0

BRAKE PEDAL ASSEMBLY BRAKE PEDAL BRAKE PEDAL BUSHES BRAKE PEDAL SPRING PEDAL MOUNTING BRACKET BRAKE PEDAL PAD CLUTCH PEDAL PAD

6M 1 2 3

TRACTION CONTROL/HDC VALVE BLOCK SHUTTLE VALVE SWITCH

WARNING LIGHT ACTUATOR LOAD SENSING VALVE FLUID LEVEL LOW

SERVO SYSTEM SERVO ASSEMBLY VACUUM PUMP-EXTERNAL VACUUM PIPE NON RETURN VALVES MOUNTING BRACKET AIR FILTER BRAKE VACUUM RESERVOIR

BLEED BRAKES AT P D I *USE 4 DIGIT "X" ONLY

VACUUM PUMP-INTERNAL SEE 1K6

6K 1 2 3

BRAKES ANTI-LOCK MASTER CYLINDER FLUID RESERVOIR BOOSTER/MODULATOR UNIT

6L 1 2 3

4 5 6 7 8 9 0

POWER VALVE ISOLATING VALVE SOLENOID CONTROL VALVES SERVO CYLINDERS PUMP UNIT ACCUMULATOR PRESSURE CONCIOUS REDUCING VALVE (PCRV)

4 5 6 7 8 9 0


E F G H

A B C D

14

BRAKES ANTI-LOCK FRONT EXCITER RING REAR EXCITER RING MODULATOR BRACKET/MOUNTING BUSHES

4 5 6 7 8 9 0

TRACTION CONTROL/HDC

J K L M

WORN/STRETCHED NOISY/CHAFED JUDDER/POOR CONNECTION BATTERY DISCHARGE

ELECTRICAL ITEMS SEE 7N


SECTION 6N ONWARDS - ELECTRICAL & INSTRUMENTS 6N 1 2 3 4 5 6 7 8 9 0

LIGHTS HEADLAMP LEVELLING SWITCH HEADLAMP LEVELLING MOTOR WARNING LIGHT CHECK UNIT 'H' GATE ILLUMINATION

WIRING/CONNECTIONS

6P 1 2 3 4 5 6 7 8 9 0

SWITCHES FUEL FILLER FLAP SWITCH INERTIA SWITCH STEERING WHEEL SWITCH (CRUISE) STEERING WHEEL SWITCH (ICE) DOOR OUT STATION HIGH/LOW MICRO SWITCH HIGH/LOW SELECTOR SHAFT SWITCH 1ST GEAR SELECTION SWITCH HDC SELECTION SWITCH WIRING/CONNECTIONS

6Q 1 2 3 4 5 6 7

WASHERS JET 'T' PIECE BOTTLE BOTTLE LEVEL SENSOR AMBIENT SENSOR ONE WAY VALVE WASHER JETS (UNHEATED)

8 9 0

HEADLAMP BLADE/WIPER

FURTHER WASHERS SEE 7Q

6R 1

AIR SUSPENSION ECU (ELECTRONIC CONTROL UNIT)

6S 1

ALARM SYSTEM ECU (ELECTRONIC CONTROL UNIT)

6T 1

2 3 4 5 6 7 8 9 0

PRESSURE SWITCH HEIGHT SENSOR FRONT HEIGHT SENSOR REAR CHASSIS HARNESS CONTROL SWITCH HARNESS CONTROL SWITCHES DISABLE SWITCH DELAY RELAY CALIBRATION

2 3 4 5 6 7 8 9 0

ULTRA SONIC/MICROWAVE SENSOR REMOTE CONTROL ALARM RELAY BONNET SWITCH SOUNDER LED ANTI THEFT IGNITION INTERLOCK TRANSFER GEARBOX SOLENOID WIRING AND CONNECTIONS

2 3 4 5 6 7 8 9 0

6U 1 2 3 4

CONTROL UNITS CONTROL UNIT - MULTI-FUNCTION CONTROL UNIT - WINDOW LIFT CONTROL UNIT - SUNROOF BODY ELECTRICAL CONTROL/MODULE CONTROL UNIT - AUTO BOX CONTROL UNIT - TRANSFER BOX

6V 1 2 3 4

ELECTRIC WINDOWS AND SUNROOF ONE SHOT OPERATION ANTI-TRAP TAIL DOOR WINDOW LIFT SWITCH

6W 1 2 3 4

6X 1 2

RADIO/TAPE SYSTEM SUB WOOFER SPEAKER SIDE WINDOW AERIAL

6Y 1 2

HEATER AND AIRCONDITIONING SOLAR SENSOR EXTERIOR AMBIENT SENSOR

6Z 1 2

3 4 5 6 7

CD CHANGER SLAB AMPLIFIER DATABUS CABLE 'A' POST TWEETER (SPEAKER) SPEAKER BRACKET REAR AIRCONDITIONING

3 4 5 6 7

WATER TEMPERATURE SENSORS EVAPORATOR SENSOR REAR FRESH AIR SERVO AIR DISTRIBUTION SERVO REFRIDGERANT PRESSURE SWITCH

3 4 5 6 7

5 6 7 8 9 0

8 9 0

N P Q R

5 6 7 8 9 0

S T U V

RELAY - HEADLAMP WASHERS REAR FACING INFRARED SENSOR ELECTRICAL HARNESS

AIR SUSPENSION COMPRESSOR RELAY WARNING LAMP RELAY

5 6 7 8 9 0

8 9 0

LEAKS DUST ENTRY FADED/STAINED/DISCOLOURED FACTORY DAMAGE

AIRBAG ELECTRICAL CONTROL UNIT MOUNTING BRACKET ROTARY COUPLER ELECTRICAL CONTROL UNIT CRASH SENSOR FRONT/REAR

RADIO/TAPE SYSTEM BINNACLE RADIO VOLUME SWITCH BINNACLE RADIO WAVE BAND SWITCH BINNACLE RADIO STATION SWITCH TRIP COMPUTER

8 9 0

OPEN CIRCUIT/BLOCKED SHORT CIRCUIT/THREAD DAMAGE INACCURATE/SLIPPING BULB/LIGHT UNIT FAILURE

W X Y Z

VIBRATION/OUT OF BALANCE BRAKE PULL/SURFACE DAMAGE INTERMITTENT OPERATION INOPERATIVE

15

SECTION 7 - ELECTRICAL & INSTRUMENTS 7A 1 2

IGNITION SYSTEM DISTRIBUTOR ASSEMBLY VACUUM ADVANCE/RETARD CAPSULE DISTRIBUTOR CAP POINTS/CONDENSER CRANK SENSOR ROTOR COIL (HT) LEAD COIL SPARKING PLUGS KNOCK SENSOR AUDIBLE IGNITION WARNING 7P6

7B 1 2

IGNITION SYSTEM H T LEADS/TERMINALS IGNITION COVER SHIELD/CLIPS

7C 1 2

STARTING SYSTEM STARTER MOTOR PINION/BENDIX

3 4 5 6 7 8 9 0

BALLAST RESISTOR/LEAD IGNITION/STARTER SWITCH CONSTANT ENERGY IGNITION UNIT TIMING ROTOR/RELUCTOR PICK UP MODULE/STATOR AMPLIFIER UNIT/IGNITER IGNITION RELAY WIRING/CONNECTIONS (NOT H T) AUDIBLE IGNITION WARNING 7P6

3 4 5 6 7 8 9 0

PINION SUPPORT BUSH STARTER MOTOR HEAT SHIELD SOLENOID

7D 1 2 3 4 5 6 7 8 9 0

CHARGING AND ENGINE MISC MANIFOLD HEATER SENSOR MANIFOLD HEATER RELAY ALTERNATOR (24 VOLT) ALTERNATOR HEAT SHIELD/GUARD ALTERNATOR GENERATOR PANEL (LR 24V) ALTERNATOR BRACKETS ALTERNATOR CONTROL UNIT ALTERNATOR FIELD RELAY WIRING CONNECTIONS BELT DRIVES SEE 2G

7E 1 2 3 4 5 6 7 8 9 0

CHARGING/IGNITION/ENGINE MISC.

7F 1 2 3 4 5 6 7 8 9 0

ENGINE MISCELLANEOUS HEATER PLUG ELECTRIC FANS (COOLING) HEATER - FUEL FILTER COOLING FAN RELAY FUEL PUMP RELAY COOLING FAN THERMAL SWITCH COOLING FAN AND MOTOR DIAGNOSIS SOCKET/TRANSDUCER FUEL DELIVERY PUMP WIRING/CONNECTIONS CARBURETER HEATING DEVICES SEE 2L

7G 1 2 3 4

ELECTRONIC FUEL INJECTION CONTROL UNIT (ECU) OVERRUN/FUEL CUT OFF SWITCH WATER TEMPERATURE SENSOR AIR TEMPERATURE SENSOR

7H 1 2 3 4

7J 1 2 3 4

LIGHTS HEAD SIDE/FRONT FLASHER STOP/TAIL/REAR FLASHER SIDE MARKER/REPEATER FLASHER

5 6 7 8 9 0

THROTTLE SWITCH/POTENTIOMETER COLD START INJECTOR COLD START RELAY INJECTOR FUEL TEMPERATURE SENSOR WIRING AND CONNECTIONS (CONTINUED AT 7W)

5 6 7 8 9 0

TRANSMISSION REVERSE LIGHT SWITCH AUTOMATIC INHIBITOR SWITCH TRANSFER BOX NEUTRAL SWITCH OIL TEMPERATURE SENSOR GEARBOX THROTTLE SWITCH OIL TEMP SENSOR TRANSFER BOX TRANSFER BOX SPEED SENSOR TRANSFER BOX SHIFT MOTOR DIFFERENTIAL LOCK SWITCH WIRING/CONNECTIONS N.B. SEE 6P8 FOR OTHER SWITCHES

5 6 7 8 9 0

NUMBER PLATE REVERSE LAMP AUXILIARY DRIVING LAMPS REAR FOG GUARD LAMP INTERIOR HIGH MOUNTED STOP LAMP

7K 1 2 3 4 5 6 7 8 9 0 * **

LIGHTS INSTRUMENT ILLUMINATION GEAR QUADRANT BOOT/BONNET CONVOY LAMP RELECTORS FRONT FOG LIGHTS DOOR SAFETY LIGHT WARNING LIGHTS/CONTROL UNIT EMISSION WARNING LIGHT LIGHTING WIRING/CONNECTIONS SEAT BELT WARNING 7P6 ELECTRIC SEATS AND DOOR LOCKS SEE SECTION 8, ELECTRIC SUNROOF AND MIRROR SEE SECTION 9 FURTHER LIGHTS SEE 6N

7L 1 2 3 4 5 6 7 8 9 0

LIGHT SWITCHES MASTER SIDE/HEAD/FOG DIRECTION INDICATOR TRIP DIRECTION INDICATOR HAZARD WARNING INTERIOR HAND OPERATED INTERIOR DOOR OPERATED REAR FOG LIGHT HEADLAMP FLASHER/DIP AUXILIARY LIGHT SWITCHES WIRING/CONNECTIONS HEADLAMP LEVELLING SWITCH SEE 6N1

7M 1 2 3 4 5 6 7 8 9 0

SWITCHES, RELAYS, ETC PANEL LIGHT SWITCH/RHEOSTAT BOOT/BONNET LIGHT SWITCH HEADLAMP RELAY INDICATOR FLASHER UNIT HAZARD WARNING FLASHER UNIT DIM/DIP RELAY/RESISTOR INTERIOR LIGHT DELAY UNIT SUNROOF SWITCH FUEL TANK CHANGE OVER SOLENOID WIRING/CONNECTIONS FURTHER SWITCHES SEE 6P

A B C D

WRONGLY ADJUSTED ADRIFT BAD FIT BROKEN

E F G H


J K L M


3 4 5 6 7 8 9 0

16

BATTERY BATTERY TERMINALS/LEADS BATTERY MOUNTING/CARRIER

CRANK SENSOR CAM SENSOR SPLIT CHARGE BLOCKING DIODE BATTERY CHECK/CHARGE PROCEDURE SEE ALSO 7A

STARTER MOTOR RELAY HEATER PLUG TIMER/CUT OUT WIRING/CONNECTIONS STARTER RING GEAR 1C7

SECTION 7 - ELECTRICAL & INSTRUMENTS 7N 1

BRAKES STOP LAMP SWITCH

7P 1

SEAT BELT WARNING SEAT BELT CONTROL UNIT

7Q 1

2 3 4 5 6 7 8 9 0

FLUID LEVEL SWITCH HYDRAULIC FAILURE SWITCH PAD WEAR WARNING DEVICE FAILURE/TEST CIRCUIT SWITCH HANDBRAKE SWITCH ANTI LOCK SENSOR ANTI LOCK ECU ANTI LOCK RELAYS WIRING/CONNECTIONS

2 3 4 5 6 7 8 9 0

SEAT SWITCH PASSENGERS BELT BUCKLE SWITCH DRIVERS BELT BUCKLE SWITCH

2 3 4 5 6 7 8 9 0

7R 1 2 3

WIPERS WINDSCREEN WIPER MOTOR WINDSCREEN WIPER SWITCH REAR SCREEN WIPER MOTOR

7S 1 2 3

HEATING AND AIR CONDITIONING MOTOR HEATER SWITCH HEATER RELAY - BLOWER MOTOR

7T 1 2 3

4 5 6

LINKAGE REAR SCREEN WIPER SWITCH BLADES/ARMS

4 5 6

MOTOR AIR CONDITIONING SWITCH AIR CONDITIONING AIR CONDITIONING FAN RELAY

4 5 6

7 8 9 0

DELAY UNIT WIPER MOTOR RELAY HEADLAMP WIPER MOTOR HEADLAMP WIPER/WASHER SWITCH WIPER WIRING/CONNECTIONS 7Y9 CONTROL UNIT SEE 6U1

7 8 9 0

COMPRESSOR CLUTCH COMPRESSOR CLUTCH RELAY TEMPERATURE CONTROL SWITCH WIRING/CONNECTIONS

7 8 9 0

7V 1 2 3

INSTRUMENTS FUEL TANK SWITCH OIL PRESSURE GAUGE OIL PRESSURE TRANSMITTER

7W 1 2 3

ELEC INJECTION AND EMISSION STEPPER MOTOR AIR VALVE AIR FLOW METER THERMO TIME SWITCH

4 5 6 7

INSTRUMENTS WATER TEMPERATURE GAUGE LOW OIL LEVEL INDICATOR WATER TEMPERATURE TRANSMITTER WATER LEVEL SWITCH VOLTAGE STABILIZER/M F E S CHOKE LIGHT SWITCH FUEL GAUGE

4 5 6 7

OIL PRESSURE SWITCH LOW COOLANT PROBE LOW COOLANT CONTROL UNIT CLOCK/REMOTE DISPLAY

4 5 6 7

8

FUEL TANK UNIT

8

8

9 0

FUEL LEVEL LIGHT SWITCH ENGINE HOUR METER

9 0

BATTERY INDICATOR/FUEL TEMP SENSOR PRINTED CIRCUITS/MOTHERBOARD INSTRUMENT WIRING/CONNECTIONS

MAIN RELAY (CONTROL CIRCUIT) EXTRA AIR VALVE POWER RESISTOR PACK EMISSION MAINTENANCE CONTROL UNIT EMISSION MAINTENANCE LIGHT

9 0

FUEL CUT OFF RELAY ANTI RUN ON VALVE SOLENOID WIRING/CONNECTIONS 7GO

7X 1

ELECTRIC WINDOW SWITCH/TIMER

7Y 1

WIRING HARNESS MAIN HARNESS

7Z 1

2 3 4 5 6 7 8 9 0 *

MOTOR AND RELAY MECHANISM/LINKAGE HEATED SCREEN CONTROL UNIT THERM CUT OFF WIRING/CONNECTIONS HEATED SCREEN FRONT HEATED SCREEN REAR HEATED SCREEN SWITCH/RELAY SCREEN WIRING/CONNECTIONS CONTROL UNIT SEE 6U1

2 3 4 5 6 7 8 9 0

WASHER WIRING/CONNECTIONS FACIA HARNESS FRONT WIPER PROGRAMMER REAR WIPER PROGRAMMER WIRING FUEL PUMP HORN WIRING/CONNECTIONS ECU WIRING/CONNECTIONS WIPER WIRING/CONNECTIONS ELECTRIC MIRROR HARNESS

2 3 4 5 6 7 8 9 0 *

MISCELLANEOUS CIGAR LIGHTER/ACCESSORY SOCKET FUSE BOX RADIO/TAPE AERIAL SPEAKER TRAILER SOCKET SPEAKER BALANCE CONTROL AERIAL AMPLIFIER LRP ACCESSORIES 100 KPH SPEED WARNING UNIT FURTHER RADIO/TAPE ITEMS CONTINUED AT 6Z

N P Q R


S T U V

OPEN CIRCUIT/BLOCKED SHORT CIRCUIT/THREAD DAMAGE INACCURATE/SLIPPING BULB/LIGHT UNIT FAILURE

W X Y Z

*

7U 1 2 3

AUDIBLE/VISUAL WARNING DEVICE WIRING/HARNESS PLUG AUDIBLE WARNING DOOR SWITCH

WASHERS AND HORNS WINDSCREEN WASHER MOTOR/PUMP WINDSCREEN WASHER SWITCH REAR SCREEN WASH MOTOR/PUMP REAR SCREEN WASHER SWITCH TUBES HORN HORN PUSH/SWITCH HORN RELAY HEATED WASHER JETS HEADLIGHT WASHER MOTOR WASHER WIRING/CONNECTIONS 7Y2 HORN WIRING/CONNECTIONS 7Y7 FURTHER WASHERS SEE 6Q

INSTRUMENTS SPEEDOMETER ASSEMBLY ROAD SPEED TRANSDUCER SPEEDO CABLE(S)/ODOMETER MOTOR SPEEDO ANGLE DRIVE-MECHANICAL TACHOMETER ROAD SPEED TRANSDUCER (EMISSIONS) SPEEDO ANGLE DRIVE-ELECTRICAL OIL TEMPERATURE TRANSMITTER OIL TEMPERATURE GAUGE MESSAGE CENTRE TACHOGRAPH SEE 9W CRUISE CONTROL SEE 2W

VIBRATION/OUT OF BALANCE INTERMITTENT OPERATION INOPERATIVE

17

SECTION 8 - BODY INTERIOR & LOCKS 8A 1 2 3 4 5

SEATS FRONT SLIDE AND ADJUSTER SEAT/FLOOR BOLTS AND BRACKETS FRONT SEAT SQUAB FRONT RAKE ADJUSTER FRONT FRAME AND ARM REST

8B 1 2 3 4 5

SEATS FRONT COVER MATERIAL/FINISHERS HEAD RESTRAINT TIPPING MECHANISM MECHANISM (OCCASIONAL SEAT) RETAINING STRAP

8C 1 2 3 4 5

6 7

REAR FRAME AND ARM REST REAR FOLDING SEAT FRAME AND HINGE(INCLUDING FOLD RELEASE) SEAT PADDING AND SPRINGS FRONT COVER STICHING/WELD REAR COVER STITCHING/WELD

6 7

POWER SEAT FRAME POWER SEAT MOTOR

6 7

TRIM AND INSULATION FLOOR COVERINGS (NOT BOOT) FLOOR COVER FIXINGS (NOT BOOT) FASCIA PANEL GLOVEBOX, HINGES, STRAPS HEADLINING/CONVERTIBLE ROOF INTERIOR TRIM DOOR LINER/CASING DOOR ARM REST TRIM

8 9 0

POWER SEAT SWITCH POWER SEAT HARNESS LUMBAR SUPPORT MECHANISM CONTINUED AT 8H

8 9 0

BONNET INSULATION FLOOR COVER AND LINER (BOOT) BOOT FLOOR COVER FIXINGS

TRIM AND INSULATION SILL PROTECTION/KICK PLATE REAR LOAD COVER/SECURITY BLIND “A”POST TRIM DOOR CAPPING BULKHEAD INSULATION SPARE WHEEL COVER/STRAP TUNNEL B/C POST TRIM D’ ‘ POST TRIM(INCLUDING ROLL BAR TRIM) TOOL COVER *ONE PIECE DOOR LINER 8C6

8E 1 2 3 4 5 6 7 8 9

TRIM AND INSULATION HIGH/LOW LEVER GAITER FASCIA UPPER CONSOLE TUNNEL FINISHER/CONSOLE MAIN GEAR LEVER GAITER HANDBRAKE LEVER GAITER CONSOLE CAPPING STEERING NACELLE STEERING WHEEL CENTRE FINISHER CUBBY BOX

8F 1 2 3 4 5 6 7 8 9

WINDOW CATCHES/MECHANISM REGULATOR MECHANISM (MANUAL) REGULATOR HANDLE HINGE/CATCH SIDE WINDOW HINGE/CATCH VENT WINDOW

0

FACIA PANEL CAPPING/RUBBER MATS

0

SEATS INNER FACING SEAT FRAME INNER FACING SEAT SQUAB INNER FACING SEAT BACKREST REAR SEAT SQUAB REAR SEAT COVER MATERIAL REAR FOLDING SEAT CATCH REAR FOLDING SEAT RELEASE & LOCK DOWN INDICATOR MEMORY SEAT CONTROL SWITCH MEMORY SEAT ECU RELAY - SEAT ADJUSTMENT

8J 1 2 3 4 5 6 7

TRIM AND INSULATION ALPINE LIGHT TRIM LH ALPINE LIGHT TRIM RH REAR SIDE INTERIOR TRIM LH REAR SIDE INTERIOR TRIM RH REAR HEADER TRIM E’ ‘ POST TRIM/’DE’POST TRIM ONE PIECE CONTROLS - FRONT ACCESS PANEL REAR AIRCONDITIONING VENT ASSEMBLY-HEADLINING REAR AIR-CONDITIONING VENT ASSEMBLY-HEADER REAR AIRCONDITIONING

8M 1 2 3 4 5 6

HEATING HEATER UNIT HEATER UNIT RADIATOR HEATER FAN (NOT MOTOR) HEATER FLAPS AIR INTAKE FILTER

7 8

CONTROLS - FRONT CONTROLS - REAR

9

FACE LEVEL VENTS AND CONTROLS

0

CONTROL CABLES ELECTRICAL ITEMS SEE 7S WATER HOSES 2E4 2E5


J K L M

WORN/STRETCHED NOISY/CHAFED JUDDER/POOR CONNECTION REMOTE OPERATION

8 9 0

8D 1 2 3 4 5 6 7 8 9 0

8G 1 2 3 4 5 6 7 8 9 0

WINDOW GLASS FRONT SCREEN REAR SCREEN SIDE WINDOWS(DOOR GLASS) ALPINE LIGHT SUNROOF GLASS SUNROOF GLASS STOWAGE BAG SCREEN HEADER TRIM

SIXTH LIGHT/QUARTERLIGHT GLASS (OPENING & FIXED) WATER ENTRY SEE 9H 9J SOFT TOP WINDOWS 9E9

8H 1 2 3 4 5 6 7 8 9 0

8K 1 2 3 4 5 6

ELECTRIC DOOR LOCK HEATING ELEMENT SUPER LOCKING DOOR LOCK SOLENOID BRACKET DOOR LOCK SOLENOID/MOTOR DOOR LOCK SWITCH

8L 1 2 3 4 5 6

7 8

DOOR LOCK RELAY/CONTROL BOX UPPER TAILGATE SOLENOID

7 8

9

UPPER TAILGATE SOLENOID COVER

9

0

0

*

WIRING CONNECTIONS MECHANICAL FAULTS SEE 8U CONTROL UNIT SEE 6U1

A B C D


E F G H

18

FRONT CHANNEL WINDOW LIFT REAR CHANNEL WINDOW LIFT DOOR GLASS CHANNEL FRONT DOOR GLASS CHANNEL REAR

ELECTRIC WINDOW SEE 7X

HEATED SEATS HEATER PAD HEATED SEAT CONTROL SWITCH HEATED SEAT RELAY

8 9 0

SECTION 8 - BODY INTERIOR & LOCKS 8N 1 2 3 4 5 6 7 8 9 0

HEATING/AIR-CONDITIONING DUCTS AND AIR HOSES WATER TAP/CENTRE VALVE VACUUM MOTORS VACUUM HOSES VACUUM SWITCH/SOLENOID NON RETURN VALVE REAR AIR-CONDITIONING UNIT REAR MOTOR - AIR-CONDITIONING SWITCH - REAR AIR-CONDITIONING DUCTING - REAR AIR-CONDITIONING

8P 1 2 3 4 5 6 7 8 9 0

SEAT BELTS FRONT BELT REEL FRONT BELT CENTRE BUCKLE/STALK FRONT BELT WEBBING FRONT BELT MOUNTING REAR BELT REEL REAR BELT CENTRE BUCKLE/STALK REAR BELT WEBBING REAR BELT MOUNTING REAR BELT REEL COVER SEAT BELT HEIGHT ADJUSTER ELECTRICAL ITEMS SEE 7P SEAT BELTS CONTINUED AT 8Y

8Q 1 2 3 4 5 6 7 8 9 0

AIR CONDITIONING COMPRESSOR UNIT CONDENSER DRIER BOTTLE PIPES REFRIDGERANT HOSES VACUUM EVAPORATION UNIT OUTLET DUCTS EXPANSION VALVE BRACKETS AND MOUNTINGS BELT DRIVES SEE 2G ELECTRICAL ITEMS SEE 7S 8R

8R 1

AIR CONDITIONING (ELECTRIC) FAN SWITCH

8S 1

INTERIOR FITTINGS MIRROR FIXINGS/BEZEL

8T 1

2 3 4 5 6 7

AMBIENT SENSOR HIGH PRESSURE SWITCH IN CAR SENSOR FAN SPEED RESISTOR MODE SELECTOR VACUUM RESERVOIR

2 3 4 5 6 7

INSTRUMENT BINNACLE MIRROR SUN VISORS ASH TRAY FRONT DOOR BIN CASSETTE STORAGE TRAY

2 3 4 5 6 7

8 9 0

VACUUM SWITCH CONDENSER FAN MOTOR WIRING CONNECTIONS TEMPEERATURE CONTROL SWITCH SEE 7S9

8 9 0

STOWAGE NETS GRAB HANDLES VANITY MIRROR DIPPING MIRROR SEE 8T

8 9 0

TOOLS/INTERIOR FITTINGS SECURITY BAGLOCKABLE STOWAGE BOX LID ASSEMBLY TOOL CONTAINER HAND TOOLS JACK JACK HANDLE DIPPING INTERIOR MIRROR SENSOR DIPPING INTERIOR MIRROR MECHANISM MIRROR - MAP LIGHT “A”POST MAP POCKET SUB WOOFER GRILLE

8U 1 2 3 4 5 6 7 8 9

SIDE DOOR LOCKS, ETC LOCK ASSEMBLY STRIKER CHILD SAFETY DEVICE INTERIOR OPENING DEVICE INTERIOR LOCKING DEVICE EXTERIOR HANDLE/FLAP INTERIOR HANDLE LINKAGE EXTERIOR HANDLE LINKAGE EXTERIOR HANDLE SEATING WASHER DOOR LOCKING BARREL ELECTRICALLY OPERATED DOOR LOCKS SEE 8K

8V 1 2 3 4 5 6 7 8 9

TAIL DOOR LOCKS ETC LOCK ASSEMBLY STRIKER CHILD SAFETY DEVICE LOWER TAILGATE LOCK INTERIOR OPENING DEVICE EXTERIOR HANDLE INTERIOR LINKAGE EXTERIOR HANDLE LINKAGE INTERIOR LOCKING DEVICE

8W 1 2 3 4 5 6 7 8 9

0

LOCKING BARREL

0

8X 1 2 3 4 5 6 7 8 9 0

AIR BAG AIR BAG - DRIVER ASSEMBLY AIR BAG - PASSENGER ASSEMBLY KNEE BOLSTER DRIVER FOAM KNEE BOLSTER FUSE BOX COVER KNEE BOLSTER GEARBOX COVER KNEE BOLSTER PASSENGER FOAM

8Y 1 2 3 4 5 6 7 8 9 0

SEAT BELTS CENTRE SEAT LAP BELT CENTRE LAP BELT BUCKLE/STALK INNER FACING SEAT LAP BELT INNER SEAT LAP BELT BUCKLE/STALK HEIGHT ADJUSTER REAR

8Z 1 2 3 4 5 6 7 8 9 0

MISCELLANEOUS HANDBOOK/LITERATURE PACK FUSE BOX LID FASCIA DRINKS TRAY

N P Q R


S T U V

OPEN CIRCUIT/BLOCKED SHORT CIRCUIT/THREAD DAMAGE INACCURATE/SLIPPING

W X Y Z


0

MISCELLANEOUS LOCKS BONNET CATCH MAIN BONNET CATCH SAFETY LINKAGE/CABLE KEY CUBBY BOX LOCK FUEL TANK CAP/FILLER FLAP LOCK BOOT FLOOR STOWAGE LID LOCK BONNET LOCK

SUNROOF ROLLER BLIND ACOUSTIC PAD (BELL HOUSING) ACOUSTIC PAD (ROCKER COVER) REAR DOOR BIN CUBBY BOX DRINKS TRAY

19

SECTION 9 - BODY EXTERIOR 9A 1 2 3 4 5 6 7 8 9 0

SHELL AND FIXED PANELS SHELL ROOF PANEL FRONT WINGS REAR WINGS AIR INTAKE/VENT/SCUTTLE PANEL SILL PANELS FRONT SIDE PANEL REAR SIDE PANEL CAP REAR PANEL REAR LOWER PANEL WATER/DUST ENTRY SEE 9L

9B 1 2 3 4 5 6 7 8 9 0

SHELL AND FIXED PANELS LOAD FLOOR PASSENGER FLOOR REAR DOOR APERATURE PANEL 'A' POST 'B'/'C' POST 'D' POST HEADLAMP SURROUND PANEL REAR SPOILER FRONT/SPOILER/AIR DAM SIDE SKIRTS WATER/DUST ENTRY SEE 9L

9C 1 2 3 4 5 6 7 8 9 0

MOVING/HINGED PANELS FRONT SIDE DOOR HINGED REAR SIDE DOOR HINGED WINDOW FRAME

9D 1

FRONT SUNROOF SUNROOF PANEL

9E 1

9F 1

HINGES AND SUPPORTS SIDE DOOR HINGES

2 3 4 5 6 7 8

SWITCH WATER CHANNELS AND TUBES SUNROOF SEALS SLIDE MECHANISM/GUIDES/RAILS WIND DEFLECTOR ASSEMBLY MOTOR BRACKET AND GUIDE TUBES MOTOR

2 3 4 5 6 7 8

2 3 4 5 6 7 8

REAR DOOR HINGES TAILGATE HINGES BONNET HINGES WINDSCREEN HINGES BONNET SUPPORT/STRUT CHECK ARM/STRAP LOWER TAILGATE STAYS

9

RELAY

9

9

TAIL GATE SUPPORT/STRUT

0 *

WIRING CONNECTIONS SUNROOF SWITCH SEE 7M8 CONTROL UNIT SEE 6U3 N.B. SEE ALSO 9G

0

SOFT/HARD TOP HOOD COVER & TRANSIT COVER (SOFT TOP) STITCH/WELD SEAMS(SOFT TOP) FRAME ASSEMBLY(SOFT TOP) CLAMPS/STRIKERS SEALING TILT COVER HARD TOP PANEL HOOD REAR/SIDE GLAZING(HARD TOP) HOOD WINDOWS(REAR/SIDE GLAZING(SOFT TOP) ROOF ON/OFF SWITCH(3 DOOR)

0

TAILGATE/REAR END DOOR WEDGE

9G 1 2 3 4 5 6 7 8 9 0

HINGES AND SUPPORTS LOWER TAILGATE TORSION BAR BONNET TORSION BAR SUNROOF TILT MECHANISM SUNROOF HINGE SUNROOF PANEL STOWAGE

9H 1 2 3 4 5 6 7 8 9 0

SEALS DOOR APERTURE SEAL WINDOW FIXED SEAL QUARTER LIGHT SEAL WINGS SEAL HEATER APERTURE SEAL FRONT SCREEN SEAL REAR SCREEN SEAL REAR BUMPER TO BODY SEAL GROMMETS AND BLANKING PLATES BONNET APERTURE SEAL WATER TH TH ENTRY 4 DIGIT N ‘ ’DUST ENTRY 4 DIGIT P ‘’

9J 1 2 3 4 5 6 7 8 9 0

SEALS REAR DOOR SEALS DOOR GLASS CHANNEL SEAL DOOR GLASS WAIST SEAL ONE PIECE/UPPER TAILGATE SEAL LOWER TAILGATE SEAL WIPER SPINDLE GROMMET DOOR INTERNAL APERTURE SEALING HOOD BOW/HEADER RAIL SEAL DRAUGHT EXCLUDER TH TAIL LAMP SEAL WATER ENTRY 4 TH DIGIT N ‘ ’DUST ENTRY 4 DIGIT P ‘’

9K 1 2 3 4 5 6 7 8 9

BODY AND FIXED PANEL WELDS MONOCOQUE ROOF BULKHEAD

9L 1 2 3 4 5 6 7 8 9

BODY SEAMS FRONT WHEEL ARCH SEAMS REAR WHEEL ARCH SEAMS FLOOR SEAMS ROOF/GUTTER SEAMS BULKHEAD SEAMS FUEL FILLER BOX SEAMS AIR INTAKE/PLENUM SEAMS AIR EXTRACTOR RUBBER ROOF MOULDING RUBBER & ROOF JOINT FINISHER SIDE RUBBING STRIP VISIBLE DEFECTS WITH EXTERIOR SEAM FILLER SEE 9U AND 9V WATER TH TH ‘ ’DUST ENTRY 4 ENTRY 4 DIGIT N DIGIT P ‘’

9M 1 2 3 4 5 6 7 8 9

EXTERIOR FITTINGS FRONT BUMPER REAR EXTRACTOR VENT FUEL CAP HEATER INTAKE & PLENUM FINISHER HEADLAMP SURROUND SIDE AND TAIL LAMP SURROUND GRILLE AND SURROUND LAMP GUARDS BADGES/MOTIFS

0

BUMPER RUBBER/RUBBING STRIP REAR BUMPER 9R8


J K L M


0

A B C D

20

0

WRONGLY ADJUSTED ADRIFT BAD FIT BROKEN

E F G H

TAILGATE ONE PIECE/UPPER TAILGATE LOWER REAR DOOR BONNET ROOF VENTS HINGE ADJUST SEE 9F STRIKER ADJUST SEE 8U2 WATER/DUST ENTRY SEE 9H 9J

SECTION 9 - BODY EXTERIOR 9N 1 2 3 4 5 6 7 8

EXTERIOR FITTINGS FRONT/REAR SCREEN SURROUND ROOF GUTTER/SEAL MOULDING SILL FINISHER DOOR WAIST MOULDING WING MOULDING/STONEGUARD WING AIR INTAKE GRILLES LOWER TAILGATE TOP FINISHER ROOF GUTTER FINISHER

9P 1 2 3 4 5 6 7 8

EXTERIOR FITTINGS DOOR MIRROR DOOR MIRROR MOTOR DOOR MIRROR CONTROLS (MECH) SIDE STEP MUD FLAPS WHEEL ARCH LINER DOOR MIRROR CONTROL SWITCH SPARE WHEEL RETNER/CARRIER/SLING FUEL FILLER FLAP DOOR MIRROR ELEMENT SEE 8F8 FOR DOOR GLASS CHANNEL FURTHER EXTERIOR FITTINGS SEE 9R

9Q 1 2 3 4 5 6 7 8

EXTERIOR COVERINGS 'A' POST FINISHER FRONT SCREEN FINISHER - UPPER "B/C" POST FINISHER 'D' POST/REAR QUARTER COVERING 'E' POST FINISHER FRONT SCREEN FINISHER - LOWER SPARE WHEEL COVER WAX INJECTION MATERIAL

9 0

BODY CAPPINGS-METAL UPPER TAILGATE LOWER FINISHER

9 0

9 0

HEAVY DUTY UNDERBODY WAX UNDER BODY SEAL

9R 1 2 3 4 5 6 7 8 9 0

EXTERIOR FITTINGS NUMBER PLATE MOUNTING BUMPER END CAP BUMPER RUBBER MAT TOWING SOCKET BRACKET DOOR MIRROR - MEMORY DOOR MIRROR MEMORY SWITCH CRASH CAN COVERS REAR BUMPER REAR STEP UPPER TAILGATE UPPER FINISHER

9S 1 2 3 4 5 6 7 8 9 0 *

REAR SUNROOF SUNROOF PANEL TRIM COVER WATER CHANNELS AND TUBES SUNROOF SEALS SLIDE MECHANISM/GUIDES/RAILS WIND DEFLECTOR ASSEMBLY MOTOR BRACKET AND GUIDE TUBES MOTOR RELAY WIRING AND CONNECTIONS CONTROL UNIT SEE 6U3

9T 1 2 3 4 5 6 7 8 9 0

COACH LINE/TAPE FRONT WING REAR WING FRONT DOOR REAR DOOR SIDE PANEL LOWER SILL TAILGATE COMPLETE SET SIGNWRITING/TRANSFERS TH USE 4 DIGIT V FOR REPLACEMENT DUE TO PAINTWORK RECTIFICATION (COACH TAPES FLATTING OPS ONLY)

9U 1 2 3 4 5

BODY SEAM FILLER EXTERNAL FRONT LOWER PANEL SEAMS REAR LOWER PANEL SEAMS BODY SIDE PANEL SEAMS CENTRE BODY SIDE PANEL SEAMS LOWER SIDE DOOR APERTURE SEAMS FRONT SIDE DOOR APERTURE SEAMS REAR BOOT/TAILGATE APERTURE SEAMS BONNET APERTURE SEAMS FUEL FILLER APERTURE SEAMS LOWER SILL SEAMS TO BE USED ONLY WHERE REPAIR IS ADDITIONAL TO THE PAINT SYSTEM REPAIR PROCESS WATER ENTRY AND DUST ENTRY SEE 9L

9V 1 2 3 4 5

BODY SEAM FILLER EXTERNAL REAR ROOF TO WING PANEL SEAMS FRONT WING/GRILLE PANEL SEAMS

9W 1 2 3 4 5

TACHOGRAPH TACHOGRAPH TACHOGRAPH DRIVE CABLES SPLITTER BOX

6 7 8 9 0

AIR EXTRACTOR SEAMS AIR INTAKE/PLENUM SEAMS SIDE DOORS CLINCHED SEAMS BONNET CLINCHED SEAMS BOOT/TAILGATE CLINCHED SEAMS TO BE USED ONLY WHERE REPAIR IS ADDITIONAL TO THE PAINT SYSTEM REPAIR PROCESS WATER ENTRY AND DUST ENTRY SEE 9L

6 7 8 9 0

9X 1 2 3

9Y 1 2 3

SEALS LOWER DOOR SEAL TAILGATE WAIST SEAL TAILGATE/REAR END DOOR WAIST SEAL

9Z 1 2 3

4

4

4

5 6 7 8 9 0

5 6 7 8 9 0

5 6 7 8 9 0

6 7 8 9 0

ROOF VENT SEAMS ROOF GUTTER SEAMS

BODY MISCELLANEOUS BELLY PANEL/COOLING TRAY VIN PLATE BODY CAPPING FOR CONVERTIBLE ROOF EXTERIOR BODY CLADDING (FACTORY FITTED) ROOF RACK (FACTORY FITTED) LONGITUDINAL ROOF RAILS ROOF RACK CROSS RAILS

SIDE JERRY CAN DOORS

__________________________________________________________________________________________________________ N P Q

LEAKS DUST ENTRY FADED/STAINED/DISCOLOURED

S T U

OPEN CIRCUIT/BLOCKED SHORT CIRCUIT/THREAD DAMAGE INACCURATE/SLIPPING

W X Y

VIBRATION SURFACE DAMAGE INTERMITTENT OPERATION

21

PAINT REFINISHING COMPLAINT CODES INTRODUCTION The Paint Defect Complaint Codes have been designed to provide accurate defect reporting. The codes are of an alphabetical four-digitconstruction The first two digits identify defect type, the third digit refers to the panel on which defect occurs, the fourth digit identifies colour non-metallic or metallic. IMPORTANT As many defects can be rectified using the compound and polish process, where practical this should be attempted on a trial area first and, if successful, used as the method of repair. SELECTING THE CORRECT CODE Select from the alphabetical list of defects, the two complaint code digits that identify the complaint, for Glue Marks/Stains this would be, EE. Where are the glue marks or stains? for the 'Panel Definition' list, select the statement that suits the requirement May be the glue marks or stains are on the interior doors, so complaint code S applies. From the COLOUR list select the code that defines the colour. You now have the complete four digit paint complaint code.

22

DEFECT/COMPLAINT

Blistering - Fine contamination Blistering - Course/Regular pattern Brake fluid attack Bleaching/Bloom Corrosion - At clinched panel seams Corrosion - At edges Corrosion - Finishers/Motifs Corrosion - At sealed seams Chipped paint -Factory damage Cissing/Fish eyes/Cratering Craking/Rough seam filler Crazing Dirt inclusions - (Also dirt in clearcoat) Dry spray/Matt finish - (not overspray) Dull finish Dirt on basecoat Dissolution - (aluminium protusion) Flaking - To metal Flaking - To electrocoat Flaking - To sealer coat Flaking -Colour from colour Flatting marks Flaking clearcoat - From basecoat Flaking clearcoat - from clearcoat Flaking from primer - Plastic components Flaking from plastic - Plastic components Glue marks/Strains Inadequate colour coverage Lining up Masking lines Metal finish - Poor/Panel imperfections Offshade factory repairs Overspray Overloading Pin holing Runs - Small Runs - Large sags Rectification - Due to consequential damage Soft finish Shadiness - Metallics only Sinkage Solvent boil Wax retention - (transit wax only)

COMPLAINT

RECOMMENDED REFINISH PROCESS DEPENDANT UPON SEVERITY LOCAL LOCAL GENERAL GENERAL SEVERE SEVERE 3 3 2+8 1 3 3 2+8 1 6 3 5 2+8 6 3 5 2 3 3 2+7 2+8 3 3 2+ 8 3 3 2+8 3 3+ 7 7+6 3 6 3 4 or 2 1 7 3 6 3 4 2 6 3 4 2 6 6 5 5 6 6 5 4 3 3 2 2 3 3 2 2 3 1 3 1 3 2 3 3 2 2 6 6 4 4 3 3 2 2 3 3 2 1 3 3 2 1

1st

2nd

A A A A B B B B B B B B C C C B C D D D D D D D D

B B C D B C D E F G K L C D E N F D E F G H J K L

D

M

3

2

1

1

E F F G G H H H J K K K

E F G G H H J J J K L M

6 3 3 6 6 6 3 6 -

6 3 3 6 3 6 3 3 3 -

3 2 2 4 2 2 4 2 2 3 -

3 2 1 4 2+8 2 4 2 2 2 -

S L L L M

A N P Q A

6 6

3 6

1 2 5 4 5

1 2 2 2 5

23

PANEL DEFINITION ROOFS AND HARDTOPS BONNETS SCUTTLES BOOT LIDS/TAILGATES TAILBOARDS DOORS WINGS BODY SIDE PANELS SURROUND PANELS - GRILLE & BOOT LOWER PANELS WINDOW/SCREEN FRAMES SILLS COMPLETE VEHICLE APERATURE INTERIOR ROOF & SIDE PANELS INTERIOR BONNET PANELS INTERIOR BOLTS LIDS INTERIOR DOORS INTERIOR WINDOWS FRAMES DASH/FASCIA INTERIOR ENGINE COMPARTMENT INTERIOR BOOT COMPARTMENT INTERIOR WHEEL ARCHES INTERIOR FLOOR PANELS INTERIOR STEP COMPLETE

COMPLAINT CODE A B C D E F G H J K L M N P Q R S T U V W X Y Z

COLOUR NON-METALLIC BLACK WHITE GREY BROWN BEIGE RED BLUE YELLOW GREEN

A B C D E F G H J

METALLIC GREY BROWN BEIGE RED BLUE YELLOW GREEN GREY/SILVER

L M N P Q R S T

CLEAR COAT METALLICS BROWN/BEIGE RED BLUE GREEN GOLD

U V W X Y

NON-FACTORY APPLIED COLOUR (OWN LIVERY) INFRA-RED REFLECTIVE COLOUR

24

COMPLAINT CODE

K Z