NRRWM 21/11/01 11:21 am Page 1

Workshop Manual (2006MY)

Service Procedures: SECTION 1 - General Information
PART 100: SERVICE INFORMATION
WSM-6107 Range Rover L322 2006MY
Table of Contents
SECTION 1: General Information
100: Service Information
100-00: General Information
100-00-01: About This Manual
100-00-02: How To Use This Manual
100-00-03: Important Safety Instructions
100-00-04: General Service Information
100-00-05: Standard Workshop Practices
100-00-06: Health and Safety Precautions
100-00-07: Solvents, Sealants and Adhesives
100-00-08: Special Tool Glossary
100-00-09: Road/Roller Testing
100-01: Identification Codes
100-01-01: Identification Codes
100-02: Jacking and Lifting
100-02-01: Jacking
100-02-02: Lifting
100-02-03: Vehicle Recovery
100-03: Maintenance Schedules
100-03-01: Maintenance Schedules - Gasoline Engines
100-03-02: Maintenance Schedules - Diesel Engines
Published: 03-Mar-2015
General Information - About This Manual
Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective is to use
common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with tested and
effective techniques. Following them will help to ensure reliability.

Important Safety Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles
as well as the personal safety of the individual carrying out the work.

Anyone who departs from the instructions provided in this manual must first establish that personal safety or vehicle integrity
is not compromised by the choice of method, tools or components.

Warnings, Cautions and Notes in This Manual

WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury.

CAUTION: Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle
or equipment being used.

NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory
repair.

Generic warnings or cautions are in their relevant description and operation procedure within section 100-00. If the generic
warnings or cautions are required for a procedure, there will be a referral to the appropriate description and operation
procedure.

If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.

Trustmark Authoring Standards (TAS) Removal and Installation Procedures

NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of
the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when
removing/disassembling or installing/assembling a component.

Many of the TAS procedures will have the installation information within the removal steps. These procedures will have the
following note at the beginning of the procedure:

NOTE: Removal steps in this procedure may contain installation details.

Items such as O-ring seals, gaskets, seals, self-locking nuts and bolts are to be discarded and new components installed
unless otherwise stated within the procedure. Coated nuts or bolts are to be reused, unless damaged or otherwise stated
within the procedure.

Specification procedures will contain all technical data that are not part of a repair procedure.

TAS Graphics

Colors used in the graphic are as follows:

Blue - Indicates the target item, item to be removed/installed or disassembled/assembled

Green and Brown - Indicates a secondary item that needs to be detached, removed/installed or
disassembled/assembled prior to the target item
Yellow - Component that is touched or affected in a way but remains in the vehicle. It may be detached, attached,
moved, modified, checked, adjusted etc.
Magenta - Indicates electrical connectors and fasteners such as nuts, bolts, clamps or clips
Pale Blue - is for the special tool(s) and general equipment.

There may be multiple steps assigned to one illustration.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps or clips.
Items in the illustration can be transparent or use cutouts to show hidden detail(s).
TAS Symbols

Symbols are used inside the graphics and in the text area to enhance the information display. The following paragraphs
describe the various types and categories of symbols.

Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks.

Health and Safety symbols recommend the use of particular protection equipment to avoid or at least reduce the risk or
severity of possible injuries.

Warning symbols are used to indicate potential risks resulting from a certain component or area.
Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a component.

Location symbols are used to show the location of a component or system within the vehicle.
Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector lever position is to be set.

Pointer symbols are used to draw the attention to components and give special instructions such as a required sequence or
number of components. The number of components is reflected by the value inside the luty arrow. A sequence number is
located inside the circle. Numbers inside circles are also used to allocate special information such as tightening torques or
chemicals to a particular component.
Movement arrows are used to show three dimensional or rotational movements. These movements can include specific values
inside the symbol if required.

Standard tool symbols recommend the use of certain standard tools. These tools can include dimension values if required.
The following graphic illustrates a set of symbols that are used to provide detailed information on where to apply a material.

Measurement symbols provide detailed information on where to carry out a specific measurement. These symbols can include
specific values if required.
Special Tools and Torque Figure(s)

Special tools will be shown with the tool number in the illustration. The special tool number(s), general equipment, material(s)
and torque figure(s) used for the procedure step will be shown in the text column.
Published: 11-May-2011
General Information - How To Use This Manual
Description and Operation

Copyright Statement

Copyright.© Land Rover Ltd., 2005

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form,
electronic, mechanical, photocopying, recording or other means, without prior written permission of Land Rover Ltd., Banbury
Road, Lighthorne, Warwick, CV35 0RG

How to use This Manual

This manual covers all aspects of 2006 model year updates in order to service the vehicle effectively, and is to be used in
conjunction with the existing workshop manual Part number: LRL0477.

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.

NOTE: Dimensions quoted are to design engineering specifications with service limits quoted, where applicable.

Workshop Manual Organization

The five main sections, together with the areas which they cover are given below:

Section 1 - General Information.

Section 2 - Chassis.
Section 3 - Powertrain.
Section 4 - Electrical.
Section 5 - Body and Paint.

Sub-section numbers appear after the initial section number, for example, Section 412-03 covers air conditioning, which is
part of the electrical section.

In the number given above, the first digit of the number '4' indicates the section i.e. Electrical .

The second and third digits '12' of the number indicate the vehicle system i.e. Air Conditioning .

The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e. Air Conditioning
Compressor .
Published: 11-May-2011
General Information - Important Safety Instructions
Description and Operation

Safety Notice

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles,
as well as the safety of the person doing the work. This manual provides general directions for accomplishing service and
repair work with tested effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the
person doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from the instructions provided in the manual must first establish that neither personal safety
or vehicle integrity is compromised from choices of methods, tools or parts.
Published: 11-May-2011
General Information - General Service Information
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.

Special Tools

The Special Tool(s) Table provided at the beginning of each procedure lists the special tool(s) required to carry out repair
operations within that specific procedure. Wherever possible, illustrations are provided which will assist technicians in
identifying the special tool(s) required and also showing such tool(s) in use.

Special tools may be obtained from the manufacturer, SPX Tools, the addresses of their branches will be found in the Special
Tools Glossary contained within this Section.

Important Safety Instructions

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.

Warnings, Cautions and Notes which appear in this manual

As you read through this manual, you will come across Warnings, Cautions and Notes. A Warning, Caution or Note is placed at
the beginning of a series of steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the
specific step after the step number.

Warnings, Cautions and Notes have the following meanings:

Warning: Procedures which must be followed to avoid the possibility of personal injury.

Caution: Calls attention to procedures which must be followed to avoid damage to components.

Note: Gives helpful information.

References

References to the Left Hand (LH) or Right Hand (RH) side given in this manual are made when viewing the vehicle or unit
from the rear.

Fault Diagnostic Equipment

The vehicle is equipped with a number of electronic control systems to provide optimum performance of the vehicle's systems.

Diagnostic Equipment (T4) is available and must be used where specified. The use of this equipment will assist with the fault
diagnostic abilities of the Dealer workshop. In particular, the equipment can be used to interrogate the electronic systems for
diagnosis of faults which may become evident during the life of the vehicle.

This manual is produced as a reference source to supplement T4.

Features of the equipment include:

a. Fully upgradeable support for the technician

b. Structured diagnostics to accommodate all skill levels

c. Direct print-out of screen information and test results

Testing the vehicle

Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work is
inspected and tested after completion and if necessary, a road test of the vehicle is carried out, particularly where safety
related items are concerned.

Repairs and Replacement Parts

Land Rover parts are manufactured to the same exacting standards as the original factory fitted components. For this reason,
it is essential that only genuine Land Rover parts are used during maintenance or repair.

Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories.

Safety features and corrosion prevention treatments embodied in the vehicle may be impaired if other than Land Rover
recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to manufacturer's
specification. Torque wrench setting figures, where given, must be adhered to and locking devices, where specified must be
used. If the efficiency of a locking device is impaired during removal it must be replaced.

Owners purchasing accessories whilst travelling abroad must ensure that the accessory and its fitted location on the vehicle
conform to legal requirements.

The terms of the vehicle warranty may be invalidated by the fitting of parts other than those recommended by Land Rover.

NOTE: The fitting of non-approved Land Rover parts and accessories or the carrying out of non-approved alterations or
conversions may be dangerous. Any of the foregoing could affect the safety of the vehicle and occupants; also, the terms and
conditions of the vehicle warranty may also be invalidated .

All Land Rover recommended parts have the full backing of the vehicle warranty.

Land Rover Dealers are obliged to supply only Land Rover recommended parts.

Specifications

Land Rover are constantly seeking to improve the specification, design and production of their vehicles and alterations take
place accordingly. Whilst every effort is made to ensure the accuracy of this Manual, it should not be regarded as an infallible
guide to current specifications of any particular vehicle.

This Manual does not constitute an offer for sale of any particular vehicle. Land Rover dealers are not agents of Land Rover
and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
Published: 11-May-2011
General Information - Standard Workshop Practices
Description and Operation

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

- Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle moving
forwards or backwards.
- Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
- If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust fumes.
- There is adequate room to raise the vehicle and remove the wheels, if necessary.
- Fender covers are always installed if any work is to be carried out in the engine compartment.
- Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is
raised.

CAUTIONS:

Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery disconnection/connection and
the following paragraphs.
For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information,
Specifications).

When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a surge of
current causing damage to the internal components of the generator.

- If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Battery - General

WARNING: It is essential that a period of 10 minutes elapses after the battery is disconnected before any work is
undertaken on any part of the SRS.

CAUTIONS:

After re-connecting the battery, the steering wheel must be turned to full left-hand and right-hand lock (with engine
running). This allows the DSC system to relearn the steering wheel position. Failure to do so will result in a variety of
instrument warning lights being illuminated.

Prior to carrying out any procedures which involve disconnecting/connecting the battery, refer to the Electrical Section
of this manual - Battery disconnection/connection.
For additional information, refer to: Specifications (414-01, Specifications).

A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be
an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper
cables are connected.

Jump Starting a Vehicle

CAUTIONS:

While it is not recommended that a vehicle is jump started, it is recognized that this may occasionally be the only
practical way to mobilize a vehicle. Reference should be made to the following and also to the Electrical Section of this manual
- Jump Starting.

It is advisable not to use starter/charger sets for jump starting but if this is unavoidable, ensure that the sets are not
used in the 'START' mode.

- Always make sure that the jumper cables are adequate for the task.
- Always make sure that the slave battery is of the same voltage (12 volts) as the vehicle battery. The batteries must be
connected in parallel.
- Ensure that the battery terminals of both batteries are fully tightened.
- Where another vehicle is used to jump start a disabled vehicle, ensure that the two vehicles are not touching.
- It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to ensure that the
battery of the donor vehicle does not also become discharged.
 - Always make sure that switchable electric circuits are OFF before connecting jump cables. This reduces the risk of
arcing occurring when the final connection is made.

Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged as soon
as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of
eight hours continuous driving with no additional loads placed on the battery.

Trickle charging (defined as voltages <16 volts) may be carried out with the battery connected. Ensure that the battery
terminals are fully tightened prior to trickle charging.

CAUTION: Boost charging may only be carried out with the battery disconnected from the vehicle.

Towing the Vehicle

WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section of this
Manual.

When the vehicle is being towed the ignition switch must be in position II (steering lock released and warning lights
illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure to follow these
instructions may result in personal injury. It must be noted that with the engine not running, the power steering and brake
booster will be inoperative therefore, greater effort will be needed to steer the vehicle and apply the brakes.

General Installation Instructions

Component removal

Whenever possible, clean components and the surrounding area before removal.

Blank off openings exposed by component removal.

Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
Seal open ends of exposed oil ways using suitable tapered hardwood plugs or conspicuous plastic plugs.
Immediately a component is removed, place it in a suitable container; use a separate container for each component
and its associated parts.
Clean bench and provide marking materials, labels and containers before disassembling components.

Disassembling

Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or hydraulic
system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if trapped in these
systems.

Blow out all tapped holes, crevices, oil ways and fluid passages with dry, compressed air.

WARNING: Suitable eye protection must be worn.

Discard all seals and 'O' rings and replace with new when reassembling.
Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate cracks or
distortion.
Wire or tape mating parts together where necessary to prevent accidental interchange.
Suitably identify parts which are to be renewed and parts requiring further inspection. Keep these parts separate.
To ensure that the correct replacement part has been obtained, do not discard a part due for renewal until after
comparing it with the new part.

Cleaning components

Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned. NEVER use
gasoline (petrol) as a cleaning agent (degreaser). Always ensure that the component being cleaned is compatible with the
cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and ensure that the environment in which
the work is being undertaken is suitable. See Health and Safety Precautions for further information regarding cleaning.

General inspection of components

All components should be inspected for wear or damage before reassembling.

Always ensure that component to be inspected is clean and free from oil or grease.
When a component is to be checked dimensionally against design specified values, use the appropriate measuring
equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
Always ensure that all measuring equipment is correctly calibrated before use.
Reject a component which is not within specified values/limits or if it appears to be damaged.
 A component may be reinstalled if dimensions obtained during checking are at the maximum tolerance limit and it is in
an undamaged condition.
Bearing journal clearances should be checked where necessary using Plastigage.

Joints and Joint Faces

All gaskets should be installed dry unless stated otherwise. Always install new 'O' rings when reassembling components,
always apply the specified lubricant to 'O' rings and install 'O' rings using the fingers only.

Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.

CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.

Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together with its part
number will be found listed in the relevant repair operation and also in the sealants table.

CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified solvents
where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.
Ensure that sealing surfaces are free from oil or grease as sealants will not adhere properly to contaminated surfaces.

Do not allow sealant to enter tapped holes or oil ways.

Locking Devices

Always replace locking devices with one of the same design and of the correct size.

Tab washers

Always release locking tabs before loosening fixings, do not re-use tab washers.

Locknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always install new roll pins of the correct size.

Circlips

Always install new circlips ensuring that they are of the correct size for the groove.

Woodruff keys

Woodruff keys may be re-used provided there is no indication of wear or distortion.

Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and re-use a split pin, always ensure that replacement pins are of the correct size for the hole in
which they are to be installed.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap
or die impairs the strength and fit of the threads and is not recommended.

NOTE: During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap.
Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the
correct size and thread is used.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be re-used. New bolts
having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the
repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread
locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
Always ensure that replacement nuts and bolts are at least equal in strength to those that they are replacing.
Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split
the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque
reading.
 Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or
faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages,
these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve
tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified
torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installation.

Where it is stated that bolts and screws may be re-used, the following procedures must be carried out:

Check that threads are undamaged.

Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.

Ensure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

Bolt and Nut Identification

An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M
or M embossed or indented on top of the bolt head.

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating the strength
grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade symbol stamped on the
flats of the hexagon.

Encapsulated ('Patched') bolts and screws

Encapsulated ('patched') bolts and screws have a thread locking agent applied to the threads during manufacture. Most thread
locking agents are colored, the band of color extending for 360° around the thread. Some locking agents however, are neutral
in color and may not be so easily identified apart from a slightly darker area of thread where the locking agent has been
applied. The locking agent is released and activated by the tightening process and is then chemically cured to provide the
locking action.

Self-locking bolts and screws

Unless stated in a specific repair procedure, self-locking bolts and screws i.e. nylon patched or trilobular thread can be re-used
provided that resistance is felt when the locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent either applied to, or inserted in the threaded portion. They are identified
by the presence of a colored section of thread extending approximately 180° around the thread or by a colored plug inserted
into the bolt.

Trilobular bolts have a special thread form which creates a slight interference with the thread of the hole or nut into which it is
screwed.

CAUTION: Do Not re-use self-locking fasteners in critical locations e.g. drive plates/flywheel or engine bearings. Do not
install non self-locking fasteners where a self-locking fastener is specified.

Trilobular bolts should not be used as a substitute for patched bolts.

Nut identification

A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol 8, 12,
14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the hexagonal flat
opposite the strength grade marking.

A clock face system is sometimes used as an alternative method of indicating the strength grade. The external chamfers or a
face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two dots
identify the 12 o'clock position.

When tightening a slotted or castellated nut, never loosen it to insert a split pin except where specified as part of an
adjustment procedure. If difficulty is experienced in correctly positioning the slot, alternative washers or nuts should be
selected.

Where a nut is tightened to adjust or maintain bearing pre-load, the tightening procedure must be adhered to.

Self-locking nuts

Unless stated in a specific repair procedure, self-locking nuts i.e. those with a nylon insert or deformed thread nuts can be
re-used provided that resistance can be felt when the locking portion of the nut passes over the thread of the bolt or stud.

Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same type and strength grade
installed.

Air Suspension
Always ensure that suitable eye protection is worn when working on the air suspension system.

Ball and Roller Bearings

When removing and installing bearings, ensure that the following practices are observed to ensure component serviceability:

CAUTION: Service tools have been developed for removing the majority of bearings; these must always be used where
specified.

Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain absolute cleanliness
throughout operations.
Conduct a visual inspection for markings on rolling elements, raceways, outer surfaces of outer or inner surfaces of
inner rings. Reject any bearings found to be marked since marking in these areas indicates onset of wear.
Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that it revolves
absolutely smoothly. Repeat holding outer race and rotating inner race. DO NOT spin the bearing.
Rotate outer ring gently using a reciprocating movement whilst holding inner ring; feel for any check or obstruction to
rotation. Reject bearing if movement is not absolutely smooth.
Check bearing for blueing or signs of overheating.
Lubricate bearing with the specified lubricant.
Inspect bearing surface of shaft and bearing housing for discoloration or other markings which indicate overheating of
bearing or movement between bearing and seating.
Before installing bearing, ensure that shaft and bearing housing are clean and free from burrs.
If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a pair unless it is
suspected that one bearing may have been faulty when installed, was installed incorrectly or the fault arose due to oil
seal failure.
Never reinstall a bearing unless it is in a fully serviceable condition.

When installing a bearing to a shaft, only apply force to the inner ring of the bearing. When installing a bearing into a
housing, only apply force to the outer ring of the bearing.

CAUTION: Service tools have been developed for installing the majority of bearings; these must always be used where
specified.

In the case of grease lubricated bearings, fill the space between the bearing and outer seal with the recommended
grade of grease before installing the seal.

CAUTION: When a waxed oil seal (installed dry) type of oil seal is to be installed, take great care that grease does not
contaminate the running surface of the seal.

Always make suitable reference marks between the components of separable bearings e.g. taper roller bearings when
disassembling to ensure correct location of components when assembling. Never install new rollers in an outer ring,
always install a new bearing assembly.

Brake Pads and Linings

Always install the correct grade and specification of brake pads and linings. When replacing these items, always replace as
complete axle sets.

Brake Hydraulics

Always observe the following recommendations when working on the braking system:

WARNING: Do not mix brake fluid of different specifications.

Always use two spanners when loosening or tightening brake pipes or hose connections.
Ensure that hoses run in a natural curve and are not kinked or twisted.
 Install brake pipes and hoses securely in their retaining clips and ensure that they cannot contact a potential chafing
point.
Containers used for brake fluid must be kept absolutely clean.
Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling point of the
fluid.
Do not allow brake fluid to be contaminated with other fluids such as mineral oil and do not put brake fluid in a
container which has previously been used for storing other fluids.
Do not re-use brake fluid which has been bled from the system.
Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
Always install blanking plugs to hoses, pipes or components immediately after disconnection.
Check thread compatibility of original equipment with replacement components.
Observe absolute cleanliness when working with hydraulic components.

Pipes and Hoses

When removing or installing flexible hydraulic pipes and hoses, ensure that the following procedures are observed to ensure
component serviceability:

Prior to removal, clean area around hose or pipe end which is to be disconnected.
Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that connections can
be plugged immediately following disconnection.
Always install blanking plugs or caps to pipes and unions immediately following disconnection.
Clean hose or pipe and blow through with an air line.

WARNING: Suitable eye protection must be worn.

Check hoses externally for cracks, separation of plies, security of end fittings and external damage; replace faulty
hoses.
Check pipes for signs of corrosion and chafing, replace as necessary.

CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further problems in service.

When installing hoses, ensure that no unnecessary bends are introduced and that hoses are not kinked, twisted or
positioned close to potential chafing points.
When installing pipes, ensure that pipes are positioned and clipped clear of potential chafing points.
Always replace sealing washers installed to banjo bolts, sealing plugs etc.
Always use a backing spanner when tightening unions and do not over tighten union nuts or banjo bolts.
After engagement of 'quick-fit' connection hoses, perform a 'tug' test to make sure connection is secure.
After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies working pressure to
the brake pedal or operates the system that has been worked on.

Fuel system hoses

Some fuel hoses are made up of two laminations, an armoured rubber outer sleeve and an inner viton core. Whenever a hose
is removed, ensure that the inner bore is inspected to check that the viton lining has not become separated from the outer
sleeve.

WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors. The fuel hose and connectors
must be replaced as an assembly.

Fuel system hose clips

Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the clip is
tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with new clips on
reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips by any other
method, do not install any other type of clip.
'Quick-fit' connections are also installed to certain fuel hoses. After engagement of 'quick-fit' connections, perform a 'tug' test
to make sure connection is secure.

Other fuel system hose clips are of the 'Jubilee' type and there may be a tamper proof cover installed over the screw head.
This cover must be carefully removed before slackening the clip and should be replaced after final tightening, ensuring that
the internal hexagon on the cover is correctly located on the clip screw.

Cooling system hoses

CAUTION: The following precautions must be observed to ensure that the integrity of the cooling system hoses and
their connection to the system is maintained.

Hose orientation and connection

Correct orientation of cooling system hoses is important to ensure that hoses do not become fatigued or damaged through
contact with adjacent components.

Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when the hose
is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe provides a positive
indicator.

Hose clips

Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided, position the clip
directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be orientated with the crimped side of the
drive housing facing towards the end of the hose or the hose may become pinched between the clip and the stub pipe
retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lb-ft). Ensure that hose clips do not
foul adjacent components.
Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be re-used.
When installing new clips, ensure clip is positioned on hose before tightening and ensure that when clip is tightened, the tag is
located in the longitudinal slot in the free end of the clip (arrowed in illustration).

'Quick-fit' connections are also installed to certain hoses/pipes. Inspect 'quick-fit' connections for damage, prior to connection.
Replace if damaged. After engagement of 'quick-fit' connections, perform a 'tug' test to make sure connection is secure.

Heat protection

Always ensure that heat shields and protective sheathing are in good condition; replace if damage is evident. Particular care
must be taken when routing hoses close to hot engine components such as the exhaust manifolds and exhaust gas
recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, ensure this movement is taken into account when
routing and securing hoses.

Electrical Precautions

General

The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and
electronic components of this vehicle.

Equipment

Prior to commencing any test procedure on the vehicle, ensure that the relevant test equipment is working correctly and that
any harness or connectors are in good condition. It is particularly important to check the condition of all plugs and leads of
mains operated equipment.

Polarity

Never reverse connect the vehicle battery and always ensure the correct polarity when connecting test equipment.

High voltage circuits

Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to contact
other components, particularly ECU's.

Vehicles installed with Navigation

CAUTION: The following precaution must be observed as failure to comply may result in damage to the navigation
system computer hardware.

A minimum period of two minutes must have elapsed from the ignition being switched to the 'OFF' position prior to
disconnection of the battery.

Vehicles with Bi-Xenon headlamp bulbs installed

WARNING: The following precautions must be observed as failure to comply may result in exposure to ultra-violet rays,
severe electric shock, burns or risk of an explosion.

Safety goggles and gloves must be worn.

Ensure that headlamps are switched off before removing bulbs.
Do not touch the glass portion of the bulb.
On no account should headlamps be switched on with the bulb removed from the headlamp.
Bulb testing may only be carried out with the bulb installed in the headlamp.
Bulbs must be disposed of in accordance with the local authority bye-laws.

Connectors and harnesses

The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors. Always
observe the following:

Ensure electrically related items are dry and oil free before disconnecting/connecting test equipment.
Ensure that disconnected electrical connectors and sensors are protected from any possible oil, coolant or other liquid
contamination. Any such contamination could impair performance or lead to component failure.
Never force connectors apart or pull on the wiring harness.
Always ensure locking tabs are disengaged before disconnecting electrical connectors etc. and ensure that correct
orientation is achieved before connection.
Ensure that any protection covers, insulation etc. are replaced if disturbed.

Having confirmed that a component is faulty, carry out the following:

Switch off the ignition and disconnect the battery.

Remove the component and support the disconnected harness.
When replacing electrical components, keep oily hands away from electrical connections and ensure that locking tabs
on connectors are fully engaged.

Battery Disconnection/Connection

Always refer to the Electrical Section of this manual - Battery Disconnect/Connect prior to attempting to connect or disconnect
the battery.
For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information,
Specifications).

Fuel Handling Precautions

The following information lists basic precautions which must be observed if fuel is to be handled safely. It also outlines other
areas of risk which must not be ignored. As this information is issued for basic guidance only, consult your local Fire
Department where any doubt as to personal and environmental safety exists - See also Health and Safety Precautions.

General precautions

Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or draining
fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.

Ensure that suitable warning signs are exhibited.

Keep all sources of ignition well away from areas where fuel is being handled.

Ensure that any lead lamps are flameproof and kept clear of spillage.

WARNINGS:

Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.

No one should be permitted to repair components associated with fuel without first having specialist training.

Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel system.

Fuel tank and system draining

Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this manual.

WARNINGS:

Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel must be carried
out in a well ventilated area.

Never switch on or operate mobile (cellular) phones in the vicinity of vehicles when operations are being carried out on
the fuel system.

Always attach fuel vapor warning labels to fuel tanks immediately after draining.

Containers used for storing fuel must be clearly marked with the contents and placed in a safe storage area which
meets the requirements of the local authority.

CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged, no attempt
must be made to repair the connector, a new fuel line and connector(s) assembly must be installed.

Always release pipe clips fully before attempting to disconnect fuel pipes.
Fuel tank repairs

CAUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a new tank
must be installed.

Oil seals

Always renew oil seals which have been removed either as an individual component or as part of an assembly. Never use a
seal which has been improperly stored or handled.

Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
Carefully examine seal before installation to ensure that it is clean and undamaged.
Ensure that the surface on which the seal is to run and also the seal housing is clean and free from burrs or scratches.
Renew the component if the sealing surface cannot be restored.
Special tools and protection sleeves are provided for installing the majority of seals and must be used when specified.
Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installation. Always check
the relevant repair procedure which will state if a seal must be installed dry. Never touch these seals with oily hands
as the oil will contaminate the protective coating and affect the sealing properties of the seal; also, ensure that
installation tools and protection sleeves are free from oil and grease. Seals which must be lubricated prior to
installation should have the recommended lubricant applied to the areas specified in the repair procedure.
Ensure that a seal is installed the correct way round. For example, the lip of the seal must face towards the lubricant
which it is sealing.
When installing an oil seal, ensure that it is positioned square to shaft and housing. Where the seal is to be installed to
a housing prior to installing over a shaft, take care not to allow the weight of an unsupported shaft to rest on the seal.

Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified, use a
suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use adhesive tape on
the shaft to protect the sealing lip of the seal.

Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the housing
where no shoulder is provided. Ensure that the seal is not tilted in the housing when it is installed.

Supplemental Restraint System (SRS) Precautions

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The following
guidelines and precautions are intended to alert personnel to potential sources of danger and emphasise the importance of
ensuring the integrity of the SRS components installed to the vehicle.
 WARNING: The following precautions MUST be adhered to when working on the SRS:

The correct procedures must always be used when working on SRS components.
Persons working on the SRS must be fully trained and have been issued with the safety guidelines.
The air bag modules contain extremely flammable and hazardous compounds. Contact with water, acids or heavy
metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contact with electricity
before the unit has been deployed.
Always replace a safety belt assembly that has withstood the strain of a severe vehicle impact or if the webbing shows
signs of fraying.
Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work on the SRS.
Always disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with SRS.

CAUTION: Do not expose air bag modules or safety belt pre-tensioners to temperatures exceeding 85° C (185° F).

It should be noted that these precautions are not restricted to operations performed when servicing the SRS. The same care
should be exercised when working on ancillary systems and components located in the vicinity of SRS components; these
include but are not limited to:

Driver air bag, clockspring.

Passenger air bag.
Side Air Curtains - front and rear.
Safety belt pre-tensioners.
SRS harnesses, link leads and connectors.

Making the system safe

Before working on or in the vicinity of SRS components, ensure the system is rendered safe by performing the following
operations:

Remove the ignition key.

Disconnect the battery, earth lead first.
Wait 10 minutes for the SRS power circuit to discharge before commencing work.

NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure under
crash conditions. It is necessary to allow the capacitors sufficient time to discharge (10 minutes) in order to avoid the risk of
accidental deployment.

Installation

In order to ensure system integrity, it is essential that the SRS system is regularly checked and maintained so that it is ready
for effective operation in the event of a collision. Carefully inspect SRS components before installation. Do not install a part
that shows signs of being dropped or improperly handled, such as dents, cracks or deformation.

WARNING: The integrity of the SRS is critical for safety reasons. Ensure the following precautions are always adhered
to:

Do not install accessories or other objects to trim panels which cover air bags.
Never install used SRS components from another vehicle or attempt to repair an SRS component.
When repairing an SRS system, only use genuine new parts.
Never apply electrical power to an SRS component unless instructed to do so as part of an approved test procedure.
Special fixings are necessary for installing an air bag module – do not use other fixings and ensure that all fixings are
tightened to the correct torque.
Always use new fixings when replacing an SRS component.

CAUTIONS:

Take care not to trap air bag modules when installing interior trim components.

Ensure SRS components are not contaminated by oil or grease.

NOTES:

Following safety belt pre-tensioner deployment, the safety belts can still be used as conventional safety belts but will
need to be replaced as soon as possible to ensure full SRS protection.

If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following:
 WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only T4 to diagnose
system faults.

WARNING: Do not use electrical test equipment on the SRS harness while it is connected to any of the SRS
components, it may cause accidental deployment and injury.

Handling and storage

Always observe the following precautions when handling SRS components:

Never drop an SRS component. The air bag diagnostic control unit is a particularly shock sensitive device and must be
handled with extreme care. Air bag modules and safety belt pre-tensioners could deploy if subjected to a strong shock.
Never wrap your arms around an air bag module. If a module has to be carried, hold it by the cover with the cover
uppermost and the base away from your body.
Never transport air bag modules or safety belt pre-tensioners in the passenger compartment of a vehicle. Always use
the luggage compartment of the vehicle for carrying air bag modules and safety belt pre-tensioner units.
Never attach anything to an air bag cover or any trim component covering an air bag module. Do not allow anything to
rest on top of an air bag module.
Always keep components cool, dry and free from contamination.
Never apply grease or cleaning solvents to safety belt pre-tensioner units, component failure could result.
Always store an air bag module with the deployment side uppermost. If it is stored deployment side down, accidental
deployment will propel the air bag module with sufficient force to cause serious injury.
Keep new air bag modules in their original packaging until just prior to installation. Place the old module in the empty
packaging for carriage.
WARNINGS:

When handling any SRS component, hold by the gas generator housing, DO NOT hold by the air bag. Do not wrap the
thumb around the gas generator while holding. Do not drape air bag over shoulder or around neck. For safety belt buckle type
pre-tensioners, hold by the piston tube, with the open end of the piston tube pointing towards the ground and the buckle
facing away from your body. Do not cover the end of the piston tube. DO NOT hold buckle type pre-tensioners by the bracket
assembly or cable. Never point the piston tube towards your body or other people.

Air bag modules and safety belt pre-tensioners are classed as explosive devices. For overnight and longer term storage,
they must be stored in a secure steel cabinet which has been approved as suitable for the purpose and has been registered
with the local authority.

Store air bag modules or safety belt pre-tensioners in a designated storage area. If there is no designated storage area
available, store in the locked luggage compartment of the vehicle and inform the workshop supervisor.

CAUTION: Improper handling or storage can internally damage the air bag module making it inoperative. If you suspect
the air bag module has been damaged, install a new module and refer to the deployment/disposal procedures for disposal of
the damaged module.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:

Never attempt to modify, splice or repair SRS wiring.

Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system in such a
way that it could generate electrical interference in the air bag harness. Seek specialist advice when installing such
equipment.

NOTE: SRS wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe
protective coverings are sometimes used).

WARNING: Always ensure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS wiring.
 WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses. Look for
possible chafing points.

Impact sensors - inspection

After any degree of side or frontal body damage, inspect the impact sensors. Replace a sensor if there is any sign of damage.

CAUTION: Take extra care when painting or carrying out bodywork repairs in the vicinity of the impact sensors. Avoid
direct exposure of the impact sensors or link harnesses to heat guns, welding or spraying equipment. Take care not to
damage sensor or harness when reinstalling components.

Clockspring

CAUTION: Always follow the procedure for installing and checking the clockspring as instructed in the SRS repairs
section. Comply with all safety and installation procedures to ensure the system functions correctly. Observe the following
precautions:

Do not unlock and rotate the clockspring when it is removed from the vehicle.
Do not turn the road wheels when the clockspring is removed from the vehicle.
Always ensure the clockspring is removed and installed in its central position and with the front road wheels in the
straight ahead position - refer to SRS repair section for the correct removal and installation procedure.
If a new clockspring is being installed, ensure the locking tab holding the spring's rotational position is not broken;
units with a broken locking tab must not be used.

Air bag and pre-tensioner deployment

WARNING: During deployment parts of the air bag module become hot enough to burn you. Wait 30 minutes after
deployment before touching the air bag module.

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who have
undergone the appropriate training should undertake deployment of air bag and pre-tensioner modules. The following
precautions must be complied with:

Only use deployment equipment approved for the intended purpose.

Deployment of air bag/pre-tensioner modules must be performed in a well ventilated area which has been designated
for the purpose.
Ensure air bag/pre-tensioner modules are not damaged or ruptured before attempting to deploy.
Where local legislation exists, notify the relevant authorities of intention to deploy air bag and pretensioner units.
When deploying air bag pre-tensioner units, ensure that all personnel are at least 15 metres (45 feet) away from the
deployment zone.
Ensure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of this
manual. In particular, ensure deployment tool is NOT connected to battery supply before connecting to air bag module
connector.
When deploying safety belt pre-tensioners, ensure pre-tensioner unit is secured correctly to the seat.
When removing deployed air bag modules and pre-tensioner units, wear protective clothing. Use gloves and seal
deployed units in a plastic bag.
Following deployment of any component of the SRS system within the vehicle, all SRS components must be replaced.
DO NOT re-use or salvage any parts of the SRS system.
Do not lean over an air bag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed air bag modules and pre-tensioner units must be manually deployed. In this case
air bags can be deployed in the vehicle. Before deployment, ensure the air bag module is secure within its correct mounting
position. Deployment of the driver air bag in the vehicle may damage the steering wheel; if the vehicle is not being scrapped,
deploy the module outside of the vehicle.

SRS Component Replacement Policy

CAUTIONS:

The Restraints Control Module (RCM) will log a crash fault after every impact which is severe enough to cause air bag
deployment. It is possible to have three crashes/impacts logged after one event where, for example, a front, side and rollover
has occurred. After the third fault is logged, the SRS warning lamp will be illuminated and the restraints control module (RCM)
must be replaced.

The SRS side/front impact sensor(s) must be replaced if there are any signs of physical damage or if the restraints
control module (RCM) is registering a fault.

The following information details the policy for replacement of SRS components as a result of a vehicle accident.

Impacts which do not deploy the air bags or pre-tensioners

Check for structural damage in the area of the impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Impacts which deploy the air bags or pre-tensioners

The replacement and inspection policy is dependent on the type and severity of the crash condition. The following guidelines
are the minimum that should be exercised as a result of the deployment of specific SRS components.

Check for structural damage in the area of impact paying particular attention to bumper armatures, longitudinals and
bracketry.

Front Air Bag Deployment - Driver and Passenger

CAUTION: If the front air bags are deployed, the following components must be replaced:

Driver air bag module

Passenger air bag module
Fly leads (where applicable) connecting front air bag modules to SRS harness
Front safety belt buckle pre-tensioner
Rear safety belt pre-tensioners - if installed
Driver safety belt retractor - if installed
Clockspring
Any front impact sensors that have been physically damaged or if a fault is being registered
Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

Front passenger safety belt retractor and webbing, tongue latching function, 'D' loop and body anchorage point
Rear safety belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
Instrument panel moulding adjacent to passenger air bag module
Steering wheel
Front seat frames and head restraints
Steering column - if adjustment is lost or if there are signs of collapse
Safety belt height adjusters
Rear safety belts

Side Air Bags

CAUTION: If the side air curtains are deployed, the following components must be replaced on the side of the vehicle on
which the deployment occurred:

Side air curtains

Any side impact sensors that have been physically damaged or if a fault is being registered
Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear safety belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Front seat frame and head restraints
Door trim casing
Safety belt height adjusters
Rear safety belts

Side Air Curtain modules

CAUTION: If the side air curtain modules are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:
 Side air curtain modules
Link lead between side air curtain gas generator and restraints control module (RCM) harness
Side air curtain module retaining clips
Internal trim finisher
Front safety belt buckle pre-tensioners
Any side impact sensors that have been physically damaged or if a fault is being registered
Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

Headlining
Component mounting brackets
Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear safety belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Adjacent trim components
Safety belt height adjusters

Rear impacts

CAUTION: If the safety belt pre-tensioners are deployed during a rear impact, the following components must be
replaced:

Safety belt pre-tensioners

Front and rear safety belt retractors deployed during the impact
Restraints Control Module (RCM) if the three crashes/impacts have been stored

Additionally, the following items must be inspected for damage and replaced as necessary:

Safety belt height adjusters

Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear safety belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Air Conditioning (A/C) System Precautions

The A/C system contains fluids and components which could be potentially hazardous to the service engineer or the
environment if not serviced and handled correctly. The following guidelines are intended to alert the service engineer to
potential sources of danger and emphasise the importance of ensuring the integrity of the A/C operating conditions and
components installed to the vehicle.

Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the Health and
Safety Section. These precautions must be referred to prior to commencing repair operations.

The refrigerant used in the A/C system is HC-134a (Hydrofluorocarbon) R134a.

WARNINGS:

Servicing must only be carried out by personnel familiar with both the vehicle system and the charging and testing
equipment. All operations must be carried out in a well ventilated area away from open flame and heat sources.

R134a is a hazardous liquid and when handled incorrectly can cause serious injury. Suitable protective clothing,
consisting of face protection, heat proof gloves, rubber boots and rubber apron or waterproof overalls, must be worn when
carrying out operations on the A/C system.

Remedial actions

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed on any part of
the body will cause immediate freezing of that area. Also, refrigerant cylinders and replenishment trolleys when discharging
will freeze skin to them if contact is made.

If an accident involving R134a should occur, conduct the following remedial actions:

If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing, cover the
eye with a clean pad and seek immediate medical attention.
If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the temperature.
Implement the same action if the skin comes in contact with discharging cylinders. Wrap the contaminated body parts
in blankets (or similar materials) and seek immediate medical attention.
If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or oxygen
and seek immediate medical attention.

Service precautions

Observe the following precautions when handling components used in the system:
 A/C units must not be lifted by their hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by kinks or
restrictions. Ensure that hoses are correctly positioned before tightening couplings, and ensure that all clips and
supports are utilised.
Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected by heat
shielding.
Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of components
and panels may transmit noise and so must be eliminated.
The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value. An
additional spanner must be used to hold the union to prevent twisting of the pipe when tightening connections.
Before connecting any hose or pipe, ensure that refrigerant oil is applied to the seat of the new 'O' rings, BUT NOT to
the threads of the connection.
All protective plugs or caps must remain in place in the component until immediately prior to connection.
Ensure components are at room temperature before uncapping/unplugging, to prevent condensation of moisture from
the air that enters it.
When disconnecting, immediately plug or cap all pipes to prevent ingress of dirt and moisture into the system.
Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 24 hours or
longer, a new receiver/drier must be installed.
The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A receiver/drier
that has been left uncapped for longer than 24 hours must not be used; fit a new unit.
The receiver/drier should be the last component connected to the system to ensure optimum dehydration and
maximum moisture protection of the system.
Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new receiver/drier
unit.
Use alcohol and a clean lint-free cloth to clean dirty connections.
Ensure that all new parts installed are marked for use with R134a.
When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this manual
for the correct procedure.

Refrigerant oil

CAUTION: Refrigerant oil (ND-8 PAG) easily absorbs water and must not be stored for long periods. Do not pour unused
refrigerant oil back into the container. Always use an approved refrigerant oil.

When replacing components in the system, drain the refrigerant oil from the component being replaced into a graduated
container. On assembly, add the quantity of refrigerant oil drained to the new component - See Compressor Replacement in
this Section.

A/C Compressor

A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release the sealing
cap; gas pressure should be heard to vent as the seal is broken.

CAUTION: A new compressor should always be sealed and should be pressurised with nitrogen gas. To avoid possible oil
loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to connecting the pipes to the
compressor.

Rapid refrigerant discharge

If the A/C system is damaged as a result of an accident and the system is punctured, the refrigerant will discharge rapidly.
The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The compressor must be
removed and all the remaining oil in the compressor drained and refilled as instructed in the air conditioning section of this
manual.

Precautions for refrigerant recovery, recycling and recharging

When the A/C system is recharged, any existing refrigerant is first recovered from the system and recycled. The system is
then charged with the required weight of refrigerant and volume of refrigerant oil.

WARNING: Refrigerant must always be recycled before re-use to ensure that the purity of the refrigerant is high enough
for safe use in the system. Recycling should always be carried out with equipment which is design certified by Underwriter
Laboratory Inc. for compliance with SAE J1991. Other equipment may not recycle refrigerant to the required level of purity.

CAUTIONS:

A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of refrigerant.
Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle systems.

The system must be evacuated immediately before recharging commences. Delay between evacuation and recharging is
not permitted.

A/C Compressor Replacement

A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.

A calculated quantity of oil must be drained from the new compressor before installation. To calculate the quantity of oil to be
drained:

Remove the drain plug from the old compressor.

Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor clutch to
ensure the compressor is completely drained.
Note the quantity of oil drained (Y cm³).
Calculate the quantity of oil to be drained from the new compressor using the following formula: X cm³ — (Y cm³ + 20
cm³) = Q cm³
Remove the drain plug from the new compressor and drain Q cm³ of oil. Install and tighten the compressor drain plug.

Vehicle Weights
Item kg lb
* Maximum Gross Vehicle Weight (GVW) 3200 7055
Maximum front axle load 1530 3373
Maximum rear axle load 1850 4078
Approximate EEC kerb weights (full fuel tank):
Petrol engine vehicles 2440-2570 5379-5666
Diesel engine vehicles 2435-2570 5368-5666
Maximum weight of unbraked trailer:
On-road 750 1650
Off-road 750 1650
Maximum weight of trailer with overrun brakes:
On-road 3500 7700
Off-road 1000 2205
Maximum roof rack load (Including the mass of the roof rack):
On-road 100 220
Off-road 30 66
* Weight quoted is the maximum weight possible for vehicles in this model range; weights may be less for certain variants
depending upon trim level, territorial requirements etc.

Vehicle Dimensions
Item mm in
Length - including number plate plinth - All models 4950 194.8
Width - All models:
Mirrors extended 2191 86.3
Mirrors folded 2009 79.1
Overall height - All models:
Access height 1820 74.4
Motorway height 1840 72.4
Standard height 1863 73.3
Off-road height 1913 75.3
Wheelbase - All models 2880 113.4
Front overhang - All models 875 34.5
Rear overhang - Vehicles without towbar 1195 47
Rear overhang - Vehicles with towbar 1260 49.6
Front track 1629 64.0
Rear track 1626 64.0
Wading depth 500 19.7
Minimum ground clearance (off-road height) 281 11.06
Approach angle (at EEC kerb weight) 35° 35°
Breakover angle (at EEC kerb weight) 30° 30°
Departure angle - Towbar NOT installed (at EEC kerb weight) 29° 29°
Departure angle - Towbar installed (at EEC kerb weight) - Vehicle at Standard ride height 15.1° 15.1°
Departure angle - Towbar installed (at EEC kerb weight) - Vehicle at Off-road ride height 17.4° 17.4°
Published: 11-May-2011
General Information - Health and Safety Precautions
Description and Operation

Introduction

Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal health
and the environment. Also, many of the procedures associated with vehicle maintenance and repair involve physical hazards
or other risks to health.

This subsection lists some of these hazardous operations and the materials and equipment associated with them. Precautions
necessary to avoid these hazards are identified.

The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with health
and safety in mind.

Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be consulted.

WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances
be consumed and should, as far as possible, be kept from contact with the skin. These liquids and substances include acid,
anti-freeze, brake fluid, fuel, windscreen washer additives, lubricants, refrigerants and various adhesives.

Acids and Alkalis

For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in batteries.

Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can destroy ordinary
protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath
mists.

Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.

Display Eye Hazard sign.

Air Bags

Highly flammable, explosive – observe No Smoking policy.

Used within the vehicle as safety restraints.

The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C).

The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air bag module and
is completely consumed during deployment. No attempt should be made to open an air bag inflator as this will lead to the risk
of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be worn when dealing with the
spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste
site.

Following any direct contact with Sodium Azide:

- Wash affected areas thoroughly with water.

- SEEK IMMEDIATE MEDICAL ASSISTANCE.

Air Bags - Do's

- Do store modules in an upright position.

- Do keep modules dry.
- Do carry modules with the cover side pointing away from the body.
- Do place modules with their cover side upwards.
- Do carefully inspect modules for damage.
- Do stand to one side when connecting modules.
- Do make sure all test equipment is properly calibrated and maintained.
- Do wash hands after handling deployed air bags.

Air Bags - Do Not

- Do Not store highly flammable material together with modules or gas generators.
- Do Not store gas generators at temperatures exceeding 80°C.
- Do Not store modules upside down.
- Do Not attempt to open a gas generator housing.
 - Do Not expose gas generators to open flame or sources of heat.
- Do Not place anything on top of a module cover.
- Do Not use damaged modules.
- Do Not touch a fired module or gas generator for at least 10 minutes after firing.
- Do Not use any electrical probes on the wiring circuit.

Air Suspension

Whenever work is being undertaken on the air suspension system, suitable eye protection must be worn.

Air Conditioning Refrigerant

Highly flammable, combustible – observe No Smoking policy.

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles.

If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should also be
rinsed with an appropriate irrigation solution such as a solution of 9% Sodium Chloride and Purified Water. DO NOT RUB THE
EYES AND SEEK IMMEDIATE MEDICAL ATTENTION.

Air Conditioning Refrigerant

Do Not

- Do Not expose refrigerant bottles to sunlight or heat.

- Do Not expose refrigerant bottles to frost.
- Do Not drop refrigerant bottles.
- Do Not vent refrigerant to atmosphere under any circumstance.
- Do Not mix refrigerants.

Adhesives and Sealants

Many adhesives and sealants are highly flammable – OBSERVE NO SMOKING POLICY. These items, should be stored in
flameproof cabinets in No Smoking areas. Cleanliness and tidiness in use should be observed, for example disposable paper
covering benches. All adhesives and sealants should be dispensed from applicators where possible; containers, including
secondary containers, should be labelled appropriately.

Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives

Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturer's instructions followed.

Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean
moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull skin tissue apart. Use in well ventilated areas
as vapors can cause irritation to the nose and eyes.

For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Solvent-based Adhesives/Sealers - See Solvents

Follow manufacturers instructions.

Water-based Adhesives/Sealers

Those based on polymer emulsions and rubber/latex may contain small amounts of volatile, toxic and harmful chemicals. Skin
and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives

In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation
of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate extraction.

Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based

Mixing should be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful
chemicals through the skin. Splashes can damage the eyes.

Provide adequate ventilation and avoid skin and eye contact.

Isocyanate (Polyurethane) Adhesives/Sealers

See also Resin-based Adhesives

Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions
can occur.

Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous
system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapour
concentrations may result in adverse health effects.

Prolonged contact with the skin may lead to skin irritation and in some cases, dermatitis.

Splashes entering the eye will cause discomfort and possible damage.

Any spraying should preferably be carried out in ventilated booths which incorporate facilities for removing vapors and spray
droplets from the breathing zone.

Wear appropriate gloves, eye and respiratory protection.

Antifreeze

May be flammable when undiluted.

Vapors may be given off from coolant antifreeze when heated. Avoid breathing these vapors.

Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal; SEEK
IMMEDIATE MEDICAL ATTENTION.

Battery Acids

See also Alkalis and Acids.

Gases released during battery charging are explosive. Always remove the battery from the vehicle prior to charging. Never
use naked flames or allow sparks near charging or recently charged batteries. NEVER add acid to a battery, the chemical
reaction produced will be violent and explosive. In cases of eye contact, wash affected area with copious amounts of water
and SEEK IMMEDIATE MEDICAL ATTENTION.

Make sure there is adequate ventilation during battery charging, observe NO SMOKING POLICY.

Brake Pads and Linings

Always fit the correct grade and specification of brake pads and linings. When renewing pads and linings, always replace as
complete axle sets.

Brake and Clutch Fluid

Splashes to the skin and eyes are irritating and in the long term can be damaging, avoid prolonged skin contact. In cases of
eye contact, wash affected area with copious amounts of water and SEEK IMMEDIATE MEDICAL ATTENTION.

Chemical Materials

All chemical materials should always be used with caution and stored and handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.

The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative;
superficial; life threatening; or may reduce life expectancy.

Chemical Materials - Do's

- Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any
accompanying leaflets, posters or other instructions. Material health and safety data sheets can be obtained from
manufacturers.
- Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled
clothing and have it cleaned.
- Do organise work practices and protective clothing to avoid soiling of the skin and eyes.
- Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and explosion hazards.
- Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials.
- Do keep work areas clean, uncluttered and free of spills.
- Do store chemical materials according to national and local regulations.
- Do keep chemical materials out of the reach of children.

Chemical Materials - Do Not

- Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or
harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.
- Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example when people
are inside a vehicle.
 - Do Not apply heat or flame to chemical materials except under the manufacturers instructions. Some are highly
flammable and some may release toxic or harmful fumes.
- Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes
are heavier than air and will accumulate in confined areas such as pits.
- Do Not transfer chemical materials to unlabelled containers.
- Do Not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and may cause
irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
- Do Not use emptied containers for other materials except when they have been cleaned under supervised conditions.
- Do Not sniff or smell chemical materials, even brief exposure to high concentrations of fumes can be toxic or harmful.

Corrosion Protection Materials

Some corrosion protection materials are highly flammable – observe NO SMOKING POLICY.

These materials are varied and the manufacturers instructions must always be followed. The materials may contain solvents,
resins or petroleum products. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate
ventilation and not in confined spaces.

Dust

Dust or powder produced during repair operations may be irritant, harmful or toxic. Avoid breathing dusts from powdery
chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.

Electrical Equipment

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be
labelled and preferably removed from the work station.

Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. If using cable
reel extension equipment, ALWAYS ensure that the cable is fully unwound from the reel.

Make sure that electrical equipment and flexes do not come into contact with water.

Make sure that electrical equipment is protected by the correct rated fuse.

Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.

Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.

Make sure that the designated electrical workers are trained in basic First Aid.

In cases of electrocution:

- Switch off the power supply before approaching the victim.

- If this is not possible, DO NOT TOUCH THE VICTIM but push or drag the person from the source of electricity using
dry, non-conductive material.
- Commence resuscitation if trained to do so.
- SEEK IMMEDIATE MEDICAL ATTENTION.

Exhaust Fumes

These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead
and aromatic hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation
and not in confined spaces.

Gasoline (Petrol) engine

There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be immediate or
delayed.

Gas Oil (Diesel engine)

Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

Fibre Insulation

The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.

Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the use of
gloves.

Fire
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful
fumes if burnt; others such as fluoroelastomers when burnt or damaged by excessive heat can break down and produce
highly corrosive hydrofluoric acid - See Fluoroelastomers.

Should any material be in a burnt or overheated condition, handle with extreme caution and wear protective clothing when
handling such items. Dispose of such material in accordance with local regulations.

Decontaminate and dispose of protective clothing immediately after use.

Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or
welding processes.

Make sure, before using electrical or welding equipment, that there is no fire hazard present.

Have a suitable fire extinguisher available when using welding or heating equipment.

First Aid

Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.

Splashes in the eye should be flushed carefully with clean water for at least ten minutes.

Soiled skin should be washed with soap and water.

In case of cold burns, from alternative fuels, place affected area in cool to cold water.

Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist, consult a
doctor.

If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not induce
vomiting unless this action is indicated on the label.

Fluoroelastomers (Synthetic Rubber)

Many 'O' rings, seals, hoses, flexible pipes and other similar which appear to be manufactured from natural rubber are, in fact,
made of synthetic materials called Fluoroelastomers.

Under normal operating conditions, these materials are safe and do not constitute a health hazard. However, if the materials
are damaged by burning or exposure to excessive heat, they can break down and produce highly corrosive hydrofluoric acid.

WARNING: Contact with hydrofluoric acid can cause serious burns on contact with the skin. If skin contact does occur,
carry out the following steps immediately:

Remove any contaminated clothing.

SEEK IMMEDIATE MEDICAL ATTENTION

Irrigate affected area of skin with copious amounts of cold water or limewater for 15 to 60 minutes.

Foams - Polyurethane

Used in sound and noise insulation. Cured foams used in seat and trim cushioning.

Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.

Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not
work in or near uncured materials.

The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.

Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory
protection. Do not remove the respirator immediately after spraying, wait until the vapour/mists have cleared.

Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or
the use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any
heat cutting of cured foams or partially cured foams should be carried out in areas having suitable fume extraction equipment.

Fuels

Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.

Gasoline (Petrol)

Highly flammable - OBSERVE NO SMOKING POLICY.

Swallowing gasoline (petrol) can result in mouth and throat irritation and absorption from the stomach can result in
drowsiness and unconsciousness. Small amounts can be fatal to children. Inhalation into the lungs, through vomiting, is a
very serious hazard.

Gasoline (petrol) dries the skin and can cause irritation and prolonged or repeated contact may cause dermatitis; if it is
allowed to enter the eyes, it will cause severe smarting. Wash affected area with copious amounts of water and SEEK
IMMEDIATE MEDICAL ATTENTION.

Gasoline (petrol) may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentration of
vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression
and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.

Make sure there is adequate ventilation when handling and using gasoline (petrol). Great care must be taken to avoid the
serious consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.

Special precautions apply to cleaning and maintenance operations on gasoline (petrol) storage tanks.

Gasoline (petrol) should not be used as a cleaning agent. It must not be siphoned by mouth.

Gas-oil (Diesel Fuel)

Combustible.

Prolonged skin contact with high boiling point gas oils (diesel fuel) may cause serious skin disorders including skin cancer.

Inhalation into the lungs will cause internal bleeding - SEEK IMMEDIATE MEDICAL ATTENTION.

If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.

Kerosene (Paraffin)

Used also as heating fuel, solvent and cleaning agent.

Flammable - OBSERVE NO SMOKING POLICY.

Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into
the lungs occurs.

Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.

In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene
at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is
adequate ventilation.

If swallowed, DO NOT induce vomiting - SEEK IMMEDIATE MEDICAL ATTENTION.

Gas Cylinders

Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138 bar (13800
kPa) (2000 lbf/in²) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the
valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.

Cylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel gases, for
example acetylene and propane should not be stored in close proximity to oxygen cylinders.

Care should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.

Only trained personnel should undertake work involving gas cylinders.

General Workshop Tools and Equipment

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where
required.

Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such
as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent
and may result in a fatal failure the next time that the equipment is used.

Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged
grinding wheel can disintegrate without warning and cause serious injury.

Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipment

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.

Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the underlying tissue
and cause serious injury.

Jacking

Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.

When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is applied and
wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has sufficient load capacity for
the weight of the vehicle.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Ensure that hoists have sufficient load capacity for the weight of the vehicle.

Legal Aspects

There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment in a
workshop.

For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the many
health and safety laws and regulations within their country, published by both national and local authorities.

Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin.

Used Engine Oil

Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading to dryness,
irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing facilities must be provided.

Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.

Health Protection Precautions

- Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Do not put oily rags into pockets.
- Avoid contaminating clothes, particularly underpants, with oil.
- Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
- Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations
containing lanoline replace the natural skin oils which have been removed.
- Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay.
- Where practicable, degrease components prior to handling.
- Where there is a risk of eye contact, eye protection should be worn, for example chemical goggles or face shields; in
addition an eye wash facility should be provided.

Environmental Precautions

This section provides general information which can help to reduce the environmental impacts from the activities carried out
in workshops.

Emissions to air

Many of the activities that are carried out in workshops emit gases and fumes which can contribute to global warming,
depletion of the ozone layer and/or the formation of photochemical smog at ground level. By considering how the workshop
activities are carried out, these gases and fumes can be minimised, thus reducing the impact on the environment.

Exhaust fumes

Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to atmosphere.
However, the amount of time engines are running and the position of the vehicle should be carefully considered at all times,
to reduce the release of poisonous gases and minimise the inconvenience to people living nearby.

Solvents

Some of the cleaning agents used are solvent based and will evaporate rapidly to atmosphere if used carelessly, or if
containers are left unsealed. All containers must be firmly closed when not required and solvent should be used sparingly.
Wherever possible, solvents having a low toxicity and flammability should be selected. Always follow the instructions supplied
by the solvent manufacturer. Similarly, many paints are solvent based and the spray should be used in such a way as to
reduce emissions to a minimum.

Refrigerant

It is illegal to release any refrigerant into the atmosphere. Discharge and replacement of these materials from air conditioning
units should only be carried out using the appropriate equipment.

Discharges to water

Most workshops will have two systems for discharging waste water - storm drains and foul drains. Storm drains should only
receive clean water i.e. rainwater. Foul drains will accept many of the normal waste water i.e. washing water, detergents and
domestic type waste BUT NOT oil, petrol, solvent, acids, hydraulic fluid, antifreeze and similar fluids. If in doubt, always
consult the local authority or water company.

Spillages

Every precaution must be taken to prevent spillage of oil, fuel, solvents etc., reaching the drains. All handling of such
materials must take place well away from drains and preferably in an area with a suitable containing wall to prevent discharge
into drains or watercourses. If a spillage occurs, it must be soaked up immediately using a spill kit where provided.

Checklist

Spillage prevention:

Store liquids in a secure area.

Make sure that taps on liquid containers are secure and cannot be accidentally turned on.

Protect bulk storage tanks from vandalism by locking the valves.

Transfer liquids from one container to another in an area away from open drains.

Ensure lids are replaced securely on containers.

Have spill kits available near to points of storage and liquid handling areas.

Spill Kits

Special materials are available to absorb a number of different substances. They can be in granular form, ready to use and are
supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste management.

Land contamination

Oils, fuels and solvents etc. can contaminate any soil with which they come into contact. Such materials MUST never be
disposed of by pouring on to soil and every precaution must be taken to avoid spillage reaching soil. Waste materials stored
on open ground could either leak or have contaminating substances washed off them that would contaminate the land. Always
store these materials in suitable skips or similarly robust containers.

Legal compliance

Some sites may have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is essential to know the
types of effluent which are allowed to be discharged into the drain and to check the results of any monitoring carried out by
the Water Company.

Where paint spraying operations are carried out it may be necessary to apply to the Local Authority for an air emissions
licence to operate the plant. If such a licence is necessary, additional precautions will be necessary to comply with the
requirements and the results of any air quality monitoring must be checked regularly.

Checklist

Always adhere to the following:

Know what legal consents and licences apply to the operations.

Check that the emissions and discharges comply with legal requirements.

Waste Management

Pollution can be reduced by careful handling, storage and disposal of all waste materials that occur on sites. Legislation makes
it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites.

This means that it is necessary to not only know what the waste materials are but also to have the necessary documentation
and licences.

Handling and storage of waste

Ensure that waste materials are not poured down the drain or on to soil and are stored in such a way that they do not escape
on to land or soil.

All waste must be segregated into individual types e.g. oils, metals, batteries, scrap components etc. This will prevent any
reaction between different materials and assist in disposal.

Disposal of waste

Dispose of waste in accordance with the following guidelines:

Fuel, hydraulic fluid, anti-freeze and oil: Keep separate and dispose of to specialist contractors.

Refrigerant: Collect in specialist equipment and reuse.

Detergents: Safe to pour down the foul drain if diluted.

Paint, thinners: Keep separate and dispose of to specialist contractor.

Components: Return to supplier for refurbishment or disassemble and reuse any suitable parts. Dispose of remainder
in ordinary waste.

Small parts: Reuse any suitable parts, dispose of the remainder in ordinary waste.

Metals: Can be sold if separate from general waste.

Tyres: Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of tyres by burning.

Components/materials containing asbestos: Keep separate and dispose of to specialist contractor.

Oil and fuel wastes (e.g. rags, used spill kit material): Keep separate and dispose of to specialist contractors.

Air filters: Keep separate and dispose of to specialist contractors.

Rubber/plastics: Dispose of in ordinary waste.

Hoses: Dispose of in ordinary waste.

Batteries: Keep separate and dispose of to specialist contractors.

Air bags - DANGER EXPLOSIVES: Keep separate and dispose of to specialist contractors.

Electrical components: Return to supplier for refurbishment or disassemble and reuse any suitable components.
Dispose of remainder in ordinary waste.

Catalytic converters: May be sold if kept separate from general waste.

Packaging: Compact/recycle as much as possible and dispose of in ordinary waste.

Office/paper waste: Recycle paper and toner and ink cartridges, dispose of remainder in ordinary waste.

Noise

Car alarm testing, panel beating, running engines, using air tools etc. are operations which invariably produce a large amount
of noise. The location of such activities and also the time of day must be carefully considered having regard to the proximity
of houses schools etc.

Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection
must be worn.

Solder

Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally
lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be produced.

Some fumes may be produced by the application of any flame to surfaces coated with grease, and inhalation of these should
be avoided.

Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give
toxic effects if inhaled. Respiratory protection may be necessary.

Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.

High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.

Solvents

For example acetone, white spirit, toluene, xylene, trichloroethane.

Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.

Some may be highly flammable or flammable.

Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some
can be absorbed through the skin in toxic or harmful quantities.

Splashes in the eye may cause severe irritation and could lead to loss of vision.

Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches
and, in the worst circumstances, unconsciousness.

Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be
adequate warning indications, can cause more serious toxic or harmful effects.

Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.

Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.

Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly
sealed. Do not use in confined spaces.

When spraying materials containing solvents, for example paints, adhesives, and metal coatings, use extraction ventilation or
personal respiratory protection in the absence of adequate general ventilation.

Do not apply heat or flame except under specific and detailed manufacturers instructions.

Suspended Loads

CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load, for
example a suspended engine.

Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the job, in
good condition and regularly maintained.

Viton

In common with many other manufacturers vehicles, some components installed to Land Rover vehicles have seals, 'O' rings
or gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. Although Viton is the most well known
fluoroelastomer, there are others, including Fluorel and Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400°C, the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system. WHERE CASES
OF SKIN CONTACT OCCUR, SEEK IMMEDIATE MEDICAL HELP.

O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky
substance.

DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal
or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material may be Viton or
any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the
commencement of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a
limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue and final
cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Resistance Welding

This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.

Arc Welding
This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and to other
persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn,
and screens used to shield other people.

CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is
believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens
is removed from the eye.

Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied
coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary particularly
in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases or
confined spaces where adequate ventilation cannot be provided, air-fed respirators may be necessary.

CAUTION: Some of the components installed to the vehicle e.g. the interior cross beam and underbonnet cross member
are manufactured from magnesium alloy. On no account should any welding operations be attempted on these components.

Gas Welding (and Cutting)

Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these
gases, with consequent risk of fire and explosion.

The process will produce metal spatter and eye and skin protection is necessary.

The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc welding,
and lighter filters may be used.

The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.

In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may
be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING OUT OF FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.

These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service
or repair operations on the vehicle.
Published: 11-May-2011
General Information - Solvents, Sealants and Adhesives
Description and Operation

Solvents

WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals or give off
fumes which can be dangerous to health. Always follow the manufacturers instructions. If in doubt about any substance,
particularly a solvent, DO NOT use it.

CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the
manufacturer of the product for information.

The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated
with their use, and safety measures to be taken. Some of these chemicals may be included as an ingredient in a sealer or
adhesive.

Sealers

Certain procedures in this manual involve the use of sealants during installation of components. Where a sealant is required,
the application, together with the Land Rover part number is given in the General Specification at the start of each section and
an instruction that a sealant must be used appears in the relevant repair procedure.

It is essential that the sealant(s) specified for a particular procedure are used, DO NOT use any other sealant.

Always remove traces of old sealant using a plastic scraper or suitable solvent, never use emery cloth or metal scrapers.

Adhesives

Whenever a procedure involves the use of an adhesive, the adhesive specified must be used and the manufacturer's
instructions regarding application together with any health and safety precautions must be followed.
Published: 10-Feb-2014
General Information - Special Tool Glossary
Description and Operation

Service Tools

Special service tools have been developed to facilitate removal, dismantling and assembly of mechanical components in a cost
effective and time efficient manner. The use of such special tools also helps prevent the potential for damage to components.

Some operations described in this manual cannot be carried out properly without the aid of the relevant service tools.

See the following list for regional special tool points of contact:

Europe and European countries not in the following list.

Tel: 0049 (0) 6182 959 497

Fax: 0049 (0) 6182 959 226

e-mail: CSS2@bosch-automotive.com

Non-European Export

Tel: 0049 (0) 6182 959 491

Fax: 0049 (0) 6182 959 246

e-mail: CSS4@bosch-automotive.com

Overseas orders for the following countries should be placed with the local distributor.

United Kingdom

Tel: 0044 (0)1327 303400

Fax: 0044 (0)1327 303499

e-mail: CSS.UK@bosch-automotive.com

Scandinavia and the Baltics

Tel: 0049 (0) 6182 959 495

Fax: 0049 (0) 6182 959 228

e-mail: CSS5@bosch-automotive.com

Spain and Portugal

Tel: 0034 949 208329

Fax: 0034 949 208327

e-mail: CSS.iberica@bosch-automotive.com

North America

Tel: 001 866 628 5508

Fax: 001 800 578 7375 or 001 586 578 7375

Australia

Tel: 0061 3 9544 6222

Fax: 0061 3 9544 5222

e-mail: customerservice.au@service-solutions.com

Japan and East Asia

Tel: 0081 3 5436 3615

Fax: 0081 3 5436 3622

e-mail: jp.customerservices@service-solutions.com

Italy
Tel: 0039 0521 338170

Fax: 0039 0521 837370

e-mail: CSS.Italy@bosch-automotive.com

Belgium, Netherlands and Luxembourg

Tel: 0031 4645 72716

Fax: 0031 4645 72711

e-mail: CSS.Benelux@bosch-automotive.com

China

Tel: 0086 21 2218 2668

Fax: 0086 21 2218 2677

e-mail: karen.zhai@cn-bosch.com

India

Tel: 0091 20 6725 4823

Fax: 0091 96 2393 1332

e-mail: semi.singh@in.bosch.com

Mexico - LAM Region

Tel: 0052 55 2595 1630

Fax: 0052 55 2595 1639

e-mail: herramientas@service-solutions.com

Brazil

Tel: 0055 (11) 5853 7487

Fax: 0055 (11) 5853 7489

e-mail: ferramentas@service-solutions.com

France

Tel: 0033 2 52 84 00 40

Fax: 0033 2 43 60 43 62

e-mail: css-france@bosch-automotive.com

Korea

Tel: 0082 31 457 9520

Fax: 0082 31 427 9522

e-mail: sungmin.kim@kr.bosch.com / hongyoung.choi@kr.bosch.com

Published: 11-May-2011
General Information - Road/Roller Testing
Description and Operation

Road or rolling road testing may be carried out for various reasons and a procedure detailing pre-test checks, through engine
starting and stopping, pre-driving checks, on-test checks to final checks on completion of the test are given.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those
items particularly relevant to the system(s) being checked can be extracted.

Pre-Test Checks

WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not
attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and
rectified.

It is suggested that pre-test and functional tests of those systems/circuits which affect the safe and legal operations of the
vehicle, such as brakes, lights and steering, should always be carried out before the road or rolling road test.

- Engine oil level

- Engine coolant level
- Tires, for correct pressure, compatible types and tread patterns, and wear within limits.
- There is sufficient fuel in the tank to complete the test.
- Check all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note
of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on
completion of the test.

Starting the Engine

NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond half
travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or with
the accelerator pedal at full travel whilst the engine is cold.

With the ignition switched off, check:

- The parking brake is applied.

- Automatic gearbox: The selector lever is in 'P' - Park
- Transfer case: 'H' - High is selected
- All instrument gauges read zero.

With the ignition switched on, check:

- Ignition controlled warning lights come on.

- Engine temperature gauge registers a reading compatible with the engine temperature.
- Fuel gauge registers a reading appropriate to the fuel level in the tank.
- The operation of the parking brake warning light and fluid level warning indicator light.

On Road Test Check:

CAUTION: At commencement of road testing, check the brake operation while still travelling at low speed before
continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test
until the fault has been found and rectified.

- The parking brake releases completely.

- Gear changing is smooth, and there are no abnormal noises or vibrations from the gearbox.
- The engine power output is satisfactory, acceleration is smooth and accelerator pedal operation is not stiff or heavy,
and engine speed returns to idle correctly.
- There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun
conditions.
- Steering operation is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does not pull to
one side and self centres smoothly after cornering.
- All instruments register the correct readings and operate correctly.
- Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the direction
indicator control self cancels when the steering is returned to the straight ahead position.
- Heating and ventilation systems work correctly and effectively.
- Brakes operate efficiently.

Brake Testing

Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users.
 CAUTION: Brake testing which includes heavy brake applications should not be carried out with new brake pads/discs
until the components have bedded-in. New brake friction components will not reach full efficiency until the bedding-in process
is complete. Note that when new parking brake shoes or rear brake discs have been installed, it is essential that the
'bedding-in' procedure given in Section 206-05 - Parking Brake Removal and Installation is carried out.

Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any
tendency to snatch, pull or drag, and any undue delay in application or release.

Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding.

After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake temperature. A disc
which feels appreciably hotter than the others, could indicate that the pads on that disc are binding.

After completion of the test, check for:

- Oil, coolant, hydraulic, air and fuel leaks.

- Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission etc., which might
indicate over tightness or lack of lubrication.

Rolling Road Testing

Four-Wheel Rolling Road

CAUTION: When utilising a four-wheel rolling road for testing, ensure all relevant health and safety requirements are
adhered to.

Provided that front and rear rollers are rotating at identical speeds and that normal workshop safety standards are applied,
there is no speed restriction during testing except any that may apply to the tires.

Ensure that the parking brake is released prior to engaging roller driving mechanism.

Two-Wheel Rolling Road

CAUTION: On no account should an attempt be made to carry out any form of testing on a two-wheel rolling road.
Published: 11-May-2011
Identification Codes - Identification Codes
Description and Operation

VIN Number

The VIN number will be found in three locations:

1. Stamped on the front of the RH front suspension turret.

2. At the bottom of the windshield glass on the LH side of the vehicle and visible from the outside.
3. UK, Europe and ROW - Not NAS/Canada - On the VIN plate attached to the LH inner wing, forward of the
suspension turret.
4. NAS/Canada - On the Tire Data/Specification label attached to the front of the LH B-pillar.

RH Front Suspension Turret VIN

Windscreen VIN

LH Inner Wing VIN

VIN number - UK, EU and ROW

 VIN Position Character Identifies
1 - 3 - World identifier SAL Land Rover (UK)
4,5 - Vehicle type LM Range Rover
6 - Class A Standard
7 - Body style M 4 Door
8 - Engine 3 428PS - AJV8 4.2 SC Petrol
8 - Engine 5 448PN - AJV8 4.4 Petrol
8 - Engine C 306D1 - 6 Cyl 3.0 diesel
9 - Transmission and steering 3 RHD Automatic
9 - Transmission and steering 4 LHD Automatic
10 - Model year 6 2006
10 - Model year 7 2007
10 - Model year 8 2008
11 - Plant A Solihull
12 - 17 - Serial number 123456 Unique six digit serial number
VIN number - NAS and Canada

VIN Position Character Identifies

1 - 3 - World identifier SAL Land Rover (UK)
4 - Model range M Range Rover
5 - Class E HSE (without luxury pack, with logic 7 and Bi-Xenon)
5 - Class F HSE (with luxury pack, logic 7 and Bi-Xenon)
5 - Class H Westminster/Autobiography
5 - Class N Standard
6 - Body style 1 4 Door Station Wagon
7 - Engine 3 428PS - AJV8 4.2 SC Petrol
7 - Engine 5 448PN - AJV8 4.4 Petrol
8 - Transmission and steering 4 LHD Automatic
9 - Check digit * Derived by calculation
10 - Model year 6 2006
10 - Model year 7 2007
10 - Model year 8 2008
11 - Plant A Solihull
12 -17 - Serial number 123456 Unique six digit serial number
LH Inner Wing, Forward of Suspension Turret, VIN Plate - Not NAS/Canada
The VIN plate contains the following information:

A - Reserved
B - Engine Description
C - Country
D - Diesel Indicator
E - Reserved
F - Headlamp Code/initial aim value - If shown
G - Colour code/group
H - Type/Approval Number - If shown
I - VIN Number
J - Gross Vehicle Weight
K - Gross Trailer Weight
L - Front Axle Weight
M - Rear Axle Weight

VIN/Certification/Tire Data Label - NAS only

The Certification Label contains the following VIN information:

 A - VIN Number
B - Bar code identification

VIN/Tire Pressure Specification Label - Canada only

The Tire Pressure Certification Label contains the following VIN information:

A - VIN Number
B - Vehicle Type

Unit/Assembly Serial Number Locations

3.0 Litre TD6 Diesel Engine Serial Number

The 3.0 Litre TD6 Diesel Engine Serial Number is stamped on the LH side of the cylinder block.

The 4.0 Litre V6 Petrol Engine Serial Number is stamped on the LH side of the cylinder block.

4.2 Litre SC and 4.4 Litre V8 Petrol Engine Serial Number

The 4.2 Litre SC and 4.4 Litre V8 Petrol Engine Serial Number is etched into the LH side of the engine block.

TD6 Automatic Transmission Serial Number

The transmission serial number is on a plate attached to the LH side of the transmission casing.

4.2 SC and 4.4 Litre Automatic Transmission Serial Number

The automatic transmission serial number is stamped on the rear LH side of the transmission casing.
Front Differential Serial Number

The Front Differential Serial Number is stamped on the underside of the differential casing and is located above the removable
cross member.

Rear Differential Serial Number

The Rear Differential Serial Number is stamped on the underside of the differential casing adjacent to the front mounting.

Transfer Case Serial Number

The Transfer Case serial number is stamped on the RH side of the transfer case and may also be on a bar coded self-adhesive
label attached to the case.
Published: 11-May-2011
Jacking and Lifting - Jacking
Description and Operation

General

WARNING: The following instructions must be adhered to before raising the vehicle off the ground:

Position vehicle on a solid, level surface.

Apply the parking brake.
Select 'P' - PARK on automatic transmission selector and 'H' High on transfer case.

WARNING: If the drive shaft(s) are to be disconnected, it will be necessary to raise all four wheels off the ground in
order that the shaft(s) can be rotated. DO NOT use the customer jack and ensure that the vehicle is adequately supported on
axle stands. With the vehicle raised, it will be necessary to release the park brake and select Neutral - 'N' in the main
transmission to enable the drive shaft(s) to be rotated

CAUTIONS:

To avoid damage to the underbody components of the vehicle, the following instructions must be adhered to:

Do not position jacks or axle stands under the following components:

Body structure other than any approved jacking or lifting points

Bumpers

Fuel lines

Fuel tank

Brake lines

Front or rear suspension arms

Steering linkage

Transfer case

Front or rear differential units

Transmission

Engine oil pan - See note below

NOTE: For certain repair operations, it may be necessary to support the engine under the oil pan. In this case, a block
of hardwood or a rubber pad must be positioned on the jack lifting pad to protect the oil pan.

Vehicle jack

The jack provided with the vehicle is only intended for use in an emergency such as changing a tire. DO NOT use the jack for
any other purpose. Refer to the Owner's Handbook for the vehicle jack location points and jacking procedures.

WARNING: Never work under a vehicle supported solely by the vehicle jack.

Hydraulic jack

A hydraulic jack with a minimum lifting capacity of 1500 kg, (3,300 lbs) must be used.

WARNINGS:

Do not commence work on the underside of the vehicle until suitable axle stands have been placed in the correct
position.

Always chock the wheels when jacking. The parking brake may be ineffective when the wheel(s) are off the ground.

Raising and Supporting the Vehicle

To assist in raising the vehicle, jacking points are provided as shown in the following illustrations.
Raising the Front of the Vehicle

Apply the parking brake.

Select 'P' - PARK on automatic transmission selector.

WARNING: Always chock the rear wheels when jacking the front of the vehicle.

Position the lifting pad of the hydraulic jack under the centre of the front sub-frame, front cross member.

With the vehicle raised to the desired height, position axle stands under, either, the front sub-frame or the recommended
customer jacking points.

CAUTION: Position suitable material between axle stands and component/body to prevent damage.

Carefully lower jack until vehicle rests on axle stands.

WARNING: Before commencing work on the underside of the vehicle, ensure that axle stands are correctly positioned
and vehicle is securely supported.

Reverse procedure when removing vehicle from stands.

Raising the Rear of the Vehicle

Select 'P' - PARK on automatic transmission selector.

WARNING: Always chock the front wheels when jacking the rear of the vehicle.
Position the lifting pad of the hydraulic jack under the centre of the rear sub-frame, rear cross member as shown.

With vehicle raised to desired height, position axle stands under the rear sub-frame. Alternatively, the axle stands may be
positioned under, either, the recommended customer jacking points or the front mounting points of the rear sub-frame.

CAUTION: Position suitable material between axle stands and component/body to prevent damage.

Carefully lower jack until vehicle rests on axle stands.

WARNING: Before commencing work on underside of vehicle, ensure that axle stands are correctly positioned and
vehicle is securely supported.

Reverse procedure when removing vehicle from stands.

Published: 11-May-2011
Jacking and Lifting - Lifting
Description and Operation

Vehicle on Wheels - Four-Post Ramp

WARNING: If the drive shaft(s) are to be disconnected, it will be necessary to raise all four wheels off the ramp in order
that the shaft(s) can be rotated. Refer to the 'Wheel Free Lift - Four-Post Ramp' section below for lifting instructions then
release the parking brake and select NEUTRAL 'N' in the transmission.

WARNING: Do not push the vehicle backwards and forwards along the ramp in order to gain access to the drive shaft
fixings.

Position the vehicle on the ramp with the front and rear of the vehicle equidistant from the ends of the ramp. Chock the
wheels, select NEUTRAL in the transmission and where practicable, apply the parking brake.

Wheel Free Lift - Four-Post Ramp

WARNING: The vehicle cannot be supported safely in a wheel free condition using the wheel free facility of a four-post
ramp, and under no circumstances must this method be used.

Raising and Supporting the Vehicle

1. Position vehicle on ramp.

2. Position suspension in 'off-road' height.

3. Apply parking brake.

4. Raise ramp to desired height.

5. Using suitable equipment, raise the vehicle to the desired height and position axle stands to recommended customer
jacking points.

CAUTION: Place suitable material between axle stands and body to avoid damage to vehicle.

6. Lower vehicle slowly until weight of vehicle rests on axle stands and road wheels are just clear of ramp.

7. Ensure that the vehicle is correctly supported on all four axle stands.

8. Lower the ramp to suitable working height.

WARNING: Make sure that the vehicle is stable before commencing work.

NOTE: Return the suspension to 'normal ride height' when the vehicle is removed from the ramp.

Two-Post Lift

CAUTION: If the drive shaft(s) are to be removed, release the parking brake and select NEUTRAL 'N' in the transmission
in order that the shaft(s) can be rotated when the vehicle is raised to the desired height.

1. Position the vehicle with the centre of the lift pillars aligned approximately with the front of the driver/passenger seat
cushions.
2. Extend the lifting arms and position the pad of each lifting arm beneath the recommended customer jacking points.

3. Raise the vehicle until the wheels are just clear of the ground and check that the pads of each lifting arm are still correctly
positioned.

4. Raise the vehicle to the desired height.

5. Ensure that the vehicle is correctly supported on all four lifting pads, that pads are still correctly positioned and are in full
contact with the body.

WARNING: Ensure that the vehicle is stable before commencing work.

Published: 11-May-2011
Jacking and Lifting - Vehicle Recovery
Description and Operation

Towing/Lashing eyes

CAUTION: The single towing/lashing eyes at the front and rear of the vehicle are designed for vehicle recovery purposes
only and MUST not be used to tow a trailer or caravan.

The front towing/lashing eye is accessible after releasing the towing eye access panel and removing the panel.

CAUTIONS:

Ensure that during towing, the towing attachment does not contact the bumper.

The rear towing/lashing eye should only be used for towing another vehicle or for recovery purposes to enable this
vehicle to be positioned in order that the front towing eye may be used for recovery/towing.

4 Wheel Towing

CAUTIONS:

Suspended towing of this vehicle MUST NOT be attempted, if four wheel towing is not possible, vehicle must be
recovered on a suitable trailer.

The vehicle may be towed for a maximum of 1 hour or 31 miles (50 km) at a maximum speed of 31 mph (50 km/h),
these limits MUST NOT be exceeded.

The following procedures must be followed to ensure that the vehicle is towed in a safe condition and damage to the
vehicle transmission system is prevented.

1. Remove the front towing/lashing eye access panel.

2. Secure the towing attachment from the recovery vehicle to the towing/lashing eye.
 CAUTION: Ensure that the towing attachment will not contact the front bumper during towing.

3. Apply the parking brake.

4. Insert ignition key and turn the ignition switch to position 'II'.

CAUTION: If 'N' - Neutral cannot be selected, front and rear driveshafts must be removed before vehicle is towed.

6. Apply the footbrake and move the automatic transmission selector lever to the 'N' Neutral position.

NOTE: If electrical power is not available, use the manual interlock release tab on the selector lever to move the
selector lever to the Neutral position.

7. Select 'H' - HIGH on the transfer box.

CAUTION: If electrical power is not available, and 'H' - HIGH cannot be selected, the vehicle may not be towed but must
be recovered on a suitable trailer. If, however, the transfer box was in 'H' - HIGH when electrical power was lost, the vehicle
may still be towed.

8. Release the parking brake.

WARNING: Do not release the parking brake until towing is about to commence. Whilst towing, do not attempt to
remove the ignition key and do not turn the key to any position other than 'II'. With the engine switched off, the power
assisted steering system and brake booster will be inoperative thereby resulting in an increase in the effort required to turn
the steering wheel and apply the brakes.

CAUTION: The vehicle tow connections should only be used in normal road conditions, 'snatch' recovery must be
avoided.

On completion of 4 wheel towing

1. Apply the parking brake.

2. Detach towing equipment from towing/lashing eyes.

3. Install the towing eye access panel.

Transporting by trailer

CAUTION: Use the towing/lashing eyes at the front and rear of the vehicle, DO NOT secure lashing hooks or restraints
to any other part of the vehicle.

Position the vehicle, apply the parking brake and select 'N' - Neutral on the automatic transmission selector lever.
Published: 11-May-2011
Maintenance Schedules - Maintenance Schedules - Gasoline Engines
Description and Operation

Torque Specifications
Description Nm lb-ft
Seat frame fixing Torx screws 40 30
Seat belt fixing Torx screws 40 30
Road wheel nuts 140 103

CAUTION: Unless stated otherwise, the following operations must be carried out at every indicated service interval.

Underbonnet View - 4.2 Litre

A. Coolant expansion tank

B. Power Steering fluid reservoir
C. Brake fluid reservoir - LHD illustrated, RHD on opposite side
D. Engine oil filler cap
E. Engine oil level indicator
F. Windshield washer fluid reservoir

Underbonnet View - 4.4 Litre

A. Coolant expansion tank

B. Power steering fluid reservoir
C. Brake fluid reservoir
 D. Engine oil filler cap
E. Engine oil level indicator
F. Windshield washer fluid reservoir

Maintenance Operations

Seats and Safety Belts

Note: The following procedures should only be completed when carrying out Service Inspection 1 and Service Inspection 2.

Front seat fixings

1. Check front seat fixings are secured to the floor and that the seat frames show no signs of movement.

Rear seat frame front fixings

2. Check that the rear seat frame front fixings are secure and that the seat frames show no signs of movement.

Rear seat frame rear fixings

3. Release the catch and fold the rear seats forwards, check that the rear seat frame rear fixings are secured to the floor and
that the seat frames show no signs of movement.

4. Check rear seat catch locking bars are secured to the floor and show no signs of movement.

5. Fold the rear seats back on completion.

Front seat controls

6. Check operation of all seat controls.

7. Fully extend each safety belt and check that it returns unassisted; repeat for all belts.

8. Check entire length of safety belt webbing for signs of fraying or damage; repeat for all belts.

9. Connect each safety belt to the correct buckle, check safety belt buckle and tongue are secure; check that buckle releases
tongue correctly.

10. Check all safety belt and buckle mountings and fixings for security.
11. Check front safety belt height adjusters for correct operation.

Lamps, Horns and Warning Indicators

1. Check side, head, fog, reversing and tail lamps for correct operation.

2. Check operation of headlamp automatic levelling system - if installed.

3. Check turn signals and hazard warning lamps for correct operation.

4. Check brake (stop) lamps for correct operation.

5. Check all exterior lamp lenses for clarity and condition; pay particular attention to headlamp and fog lamp lenses for stone
chips or damage.

6. Check horn for loud, clear sound.

7. Switch on side/headlamps and check that side/headlamp reminder warning sounds when door is opened.

8. Check operation of interior courtesy lamps.

9. Check operation of all instrument pack warning and indicator lamps.

Washers and Wipers

1. Check all wiper blades for condition and signs of splits or damage.

2. Check security of wiper arms.

3. Operate front and rear windshield washers, check that jets are clear and correctly aimed.

4. Operate front and rear wipers at all speeds and check for smooth, smear free operation.

Check High/Low Gear Engagement

1. Select LOW range gear, drive vehicle forwards 3 to 4 vehicle lengths, stop vehicle and select HIGH range gear - gears must
engage smoothly.

Battery
1. Check battery condition by checking color of condition indicator.

Green = O.K.
Black = Battery requires charging
Yellow = New battery required

Pollen Filter

1. Replace pollen filter.

For additional information, refer to: Plenum Chamber (412-01 Air Distribution and Filtering, Removal and Installation).

Corrosion/Cosmetic Inspection

1. Carry out the annual corrosion/cosmetic inspection using the Annual Corrosion Inspection Sheet.

Wheels and Tires

1. Check that tires comply with manufacturer's specification.

For additional information, refer to: Specifications (204-04 Wheels and Tires, Specifications).

2. Check/adjust tire pressures including spare.

For additional information, refer to: Specifications (204-04 Wheels and Tires, Specifications).

3. Vehicles with Uni-directional tires installed: Mark the wheel to stud relationship of each road wheel and note location of
each road wheel to its respective hub.

4. Loosen road wheel nuts. Raise vehicle to a wheel free condition.

For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

5. Remove the road wheels.

6. Visually check tires for condition, lumps or bulges. Check tread depth across the width of the tire and around the
circumference; ensure that remaining tread depth does not contravene local legislative requirements.

NOTE: Do not install wheels at this stage.

Braking System

1. Inspect front brake pads for wear.

For additional information, refer to: Specifications (206-03 Front Disc Brake, Specifications).

2. Inspect rear brake pads for wear.

For additional information, refer to: Specifications (206-04 Rear Disc Brake, Specifications).

3. Check brake calipers for signs of fluid leaks.

4. Check brake discs for condition.

5. Check all brake booster and brake system pipes and hoses for condition, chafing and leaks.

6. Clean road wheel hub spigots and apply grease, Land Rover Part Number RYL 105020 to the wheel mating surface of each
spigot.

7. Vehicles with Uni-directional tires installed: Install road wheels on their respective hubs ensuring that stud to wheel
relationship is maintained.

8. Vehicles with NON uni-directional tires installed: Install wheels on the opposite side of the vehicle but ensure that they are
on the same axle as they were originally installed.

9. Install road wheel nuts and tighten to 140 Nm (103 lb-ft).

10. Every 3 years or 45,000 miles (72,000 km): Replace brake fluid.
For additional information, refer to: Specifications (206-06 Hydraulic Brake Actuation, Specifications) /
Brake System Bleeding (206-00 Brake System - General Information, General Procedures).

Parking Brake

1. Check the adjustment of the parking brake.

For additional information, refer to: Parking Brake Shoe and Lining Adjustment (206-05 Parking Brake and Actuation, General
Procedures).

Cooling System

1. Check specific gravity of coolant using a hydrometer.

NOTE: A suitable hydrometer is available from the Equipment Programme under Part Number 511 3302 001 00.

2. Top-up cooling system if necessary.

For additional information, refer to: Specifications (303-03A Engine Cooling - V8 S/C 4.2L Petrol, Specifications) /
Specifications (303-03B Engine Cooling - V8 4.4L Petrol, Specifications).

CAUTION: Anti-freeze concentration must be maintained at 50%.

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank whilst the system is hot.
 CAUTION: Engine coolant will damage the paint finished surfaces. If coolant is spilled, immediately remove the coolant
and wash the area with water.

3. Check the level of coolant in the expansion tank. With the engine cold, the coolant level must be to the 'UPPER LEVEL'
indicator mark above the 'COLD FILL RANGE' text on the side of the expansion tank. Ignore any coolant which may be visible
in the top section of the tank.

4. If topping-up is required, remove expansion tank filler cap and top-up coolant level to the 'UPPER LEVEL' indicator mark.
For additional information, refer to: Specifications (206-09B Anti-Lock Control - Stability Assist, Specifications) /
Specifications (303-03B Engine Cooling - V8 4.4L Petrol, Specifications).

CAUTION: Always top-up with a 50% mixture of anti-freeze and water.

5. Install expansion tank filler cap, tighten cap until ratchet is heard to 'click'.

6. Every 10 years or 150,000 miles (240,000 km): Replace the coolant.

For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - V8 S/C 4.2L
Petrol, General Procedures) /
Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - V8 4.4L Petrol, General Procedures).

Ignition System

1. Every 7 years or 105,000 miles (168,000 km) - 4.2 and 4.4 litre V8 engines: Replace spark plugs.
For additional information, refer to: Specifications (303-07A Engine Ignition - V8 S/C 4.2L Petrol, Specifications) /
Spark Plugs (303-07A Engine Ignition - V8 S/C 4.2L Petrol, Removal and Installation) /
Specifications (303-07B Engine Ignition - V8 4.4L Petrol, Specifications) /
Spark Plugs (303-07B Engine Ignition - V8 4.4L Petrol, Removal and Installation).

Air Filtering

1. Every 4 years or 60,000 miles (96,000 km): Replace the air cleaner element.
For additional information, refer to: Air Cleaner Element (303-12A Intake Air Distribution and Filtering - V8 S/C 4.2L Petrol,
Removal and Installation) /
Air Cleaner Element (303-12B Intake Air Distribution and Filtering - V8 4.4L Petrol, Removal and Installation).

Front End Accessory Drive (FEAD) Belt

1. Check the condition of the FEAD belt.

2. Remove all traces of mud and dirt from the belt and pulleys.

3. Check the belt for signs of oil contamination, splitting and wear.

4. Every 10 years or 150,000 miles (240,000 km): Replace the FEAD belt.
For additional information, refer to: Accessory Drive Belt (303-05A Accessory Drive - V8 S/C 4.2L Petrol, Removal and
Installation) /
Accessory Drive Belt (303-05B Accessory Drive - V8 4.4L Petrol, Removal and Installation).

Supercharger/Cooling Fan Drive Belt

1. Check the condition of the supercharger/cooling fan drive belt.

2. Remove all traces of mud and dirt from the drive belt and pulleys.

3. Check the drive belt for signs of oil contamination, splitting and wear.

4. Every 7 years or 105,000 miles (168,000 km): Replace the supercharger drive belt.
For additional information, refer to: Cooling Fan Belt (303-05A Accessory Drive - V8 S/C 4.2L Petrol, Removal and
Installation).

Fluid Levels

Brake fluid reservoir

1. Check the fluid level in the brake fluid reservoir, the level must be to the 'MAX' mark on the reservoir; top-up if necessary.

2. Clean the area around the reservoir filler cap, remove cap.

3. If necessary, top-up using the recommended fluid to the 'MAX' mark on the reservoir.
For additional information, refer to: Specifications (206-00 Brake System - General Information, Specifications).

4. Install the reservoir filler cap.

Power steering fluid reservoir

CAUTION: To prevent over filling, check/top-up the system with the engine switched off and the system cold. Ensure
that the steering wheel is in the straight ahead position, do not turn the steering wheel prior to checking the fluid level.

1. Check that the fluid level is to the mid-way mark between the 'MAX' and 'MIN' marks on the fluid reservoir, top-up if
necessary.

2. Clean the area around the reservoir filler cap, remove cap.

3. If necessary, top-up using the recommended fluid to the mid-way mark on the reservoir.
For additional information, refer to: Specifications (211-02 Power Steering, Specifications).
.

CAUTION: Do not fill reservoir above the 'MAX' mark.

4. Install the reservoir filler cap.

Windshield washer reservoir

1. Remove the windshield washer reservoir filler cap.

2. Top-up the reservoir using a mixture of an approved windshield washer fluid and water until the level is to the bottom of
the gauze filter in the reservoir filler neck.

3. Install the reservoir filler cap.

Engine Oil and Filter

1. Renew engine oil and filter.

For additional information, refer to: Specifications (303-01A Engine - V8 S/C 4.2L Petrol, Specifications) /
Engine Oil Draining and Filling (303-01A Engine - V8 S/C 4.2L Petrol, General Procedures) /
Specifications (303-01B Engine - V8 4.4L Petrol, Specifications) /
Engine Oil Draining and Filling (303-01B Engine - V8 4.4L Petrol, General Procedures).

Automatic Transmission

1. Every 10 years or 150,000 miles (240,000 km): Renew automatic transmission fluid.
For additional information, refer to: Specifications (307-01A Automatic Transmission/Transaxle - V8 S/C 4.2L Petrol,
Specifications) /
Transmission Fluid Drain and Refill (307-01A Automatic Transmission/Transaxle - V8 S/C 4.2L Petrol, General Procedures) /
Specifications (307-01B Automatic Transmission/Transaxle - V8 4.4L Petrol, Specifications) /
Transmission Fluid Drain and Refill (307-01B Automatic Transmission/Transaxle - V8 4.4L Petrol, General Procedures).

Transfer Case

1. Every 5 years or 75,000 miles (120,000 km): Renew transfer case oil.
For additional information, refer to: Specifications (308-07B Transfer Case, Specifications) /
Transfer Case Draining and Filling (308-07B Transfer Case, General Procedures).

Drive Axle/Differential

1. Every 10 years or 150,000 miles (240,000 km): Renew front drive axle/differential oil.
For additional information, refer to: Differential Draining and Filling (205-03 Front Drive Axle/Differential, General
Procedures).

2. Every 10 years or 150,000 miles (240,000 km): Renew rear drive axle/differential oil.
For additional information, refer to: Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General Procedures).

Suspension and Body Mountings

Note: The procedures in this section should only be completed when carrying out Service Inspection 1 and Service Inspection
2.

1. Check for free play in all suspension and body mounting rubbers.

2. Check condition of suspension rubber boots and gaiters.

Fuel System

1. Check fuel system pipes, hoses and unions for chafing, leaks and corrosion.

2. Every 10 years or 150,000 miles (240,000 km): Renew the fuel filter.
For additional information, refer to: Fuel Filter (310-01A Fuel Tank and Lines - V8 S/C 4.2L Petrol, Removal and Installation) /
Fuel Filter (310-01B Fuel Tank and Lines - V8 4.4L Petrol, Removal and Installation).

Oil/Fluid Leaks
1. Check for oil/fluid leaks.

Power Steering

Note: The procedures in this section should only be completed when carrying out Service Inspection 1 and Service Inspection
2.

1. Check power steering rod ball joint fixings, gaiters and condition of ball joints and dust covers.

2. Check power steering pipes, hoses and unions for chafing, leaks and corrosion.

Fault Lamp(s)

1. If fault lamp(s) are illuminated, test the associated system using T4 and report findings.

Road Test

1. Carry out road test of vehicle.

For additional information, refer to: Road/Roller Testing (100-00 General Information, Description and Operation).

General

1. Endorse Service Record.

2. Report any unusual features of vehicle condition and any additional work required.
Published: 11-May-2011
Maintenance Schedules - Maintenance Schedules - Diesel Engines
Description and Operation

Torque Specifications
Description Nm lb-ft
Seat frame fixing Torx screws 40 30
Seat belt fixing Torx screws 40 30
Road wheel nuts 140 103

CAUTION: Unless stated otherwise, the following operations must be carried out at every indicated service interval.

Underbonnet View - TD6 Diesel Engine

A. Engine oil filler cap

B. Brake fluid reservoir - LHD illustrated, RHD on opposite side
C. Windshield washer fluid reservoir
D. Engine oil level indicator
E. Power steering fluid reservoir
F. Coolant expansion tank

Maintenance Operations

Seats and Safety Belts

Note: The procedures in this section should only be completed when carrying out Service Inspection 1 and Service Inspection
2.

Front seat fixings

1. Check that the front seat frame fixing Torx screws are secure and that the seat frames show no signs of movement.

Rear seat frame front fixings

2. Check that the rear seat frame front fixings are secure and that the seat frames show no signs of movement.

Rear seat frame rear fixings

3. Release the catch and fold the rear seats forwards, check that the rear seat frame rear fixings are secure and that the seat
frames show no signs of movement.

4. Check that the rear seat catch locking bars are secured to the floor and show no signs of movement.

5. Fold the rear seats back on completion.

Front seat controls

6. Check operation of all seat controls.

7. Fully extend each safety belt and check that it returns unassisted; repeat for all belts.

8. Check entire length of safety belt webbing for signs of fraying or damage; repeat for all belts.

9. Connect each safety belt to the correct buckle, check safety belt buckle and tongue are secure; check that buckle releases
tongue correctly.

10. Check all safety belt and buckle mountings and fixings for security.

11. Check front safety belt height adjusters for correct operation.

Lamps, Horns and Warning Indicators

1. Check side, head, fog, reversing and tail lamps for correct operation.
2. Check operation of headlamp automatic levelling system - if installed.

3. Check turn signals and hazard warning lamps for correct operation.

4. Check brake (stop) lamps for correct operation.

5. Check all exterior lamp lenses for clarity and condition; pay particular attention to headlamp and fog lamp lenses for stone
chips or damage.

6. Check horn for loud, clear sound.

7. Switch on headlamps and check that side/headlamp reminder warning sounds when door is opened.

8. Check operation of interior courtesy lamps.

9. Check operation of all instrument pack warning and indicator lamps.

Washers and Wipers

1. Check all wiper blades for condition and signs of splits or damage.

2. Check security of wiper arms.

3. Operate front and rear windshield washers, check that jets are clear and correctly aimed.

4. Operate front and rear wipers at all speeds and check for smooth, smear free operation.

Check High/Low Gear Engagement

1. Select LOW range gear, drive vehicle forwards 3 to 4 vehicle lengths, stop vehicle and select HIGH range gear - gears must
engage smoothly.

Battery

1. Check battery condition by checking color of condition indicator.

Green = O.K.
Black = Battery requires charging
Yellow = New battery required

Pollen Filter
1. Replace pollen filter.
For additional information, refer to: Plenum Chamber (412-01 Air Distribution and Filtering, Removal and Installation).

Corrosion/Cosmetic Inspection

1. Carry out the annual corrosion/cosmetic inspection using the Annual Corrosion Inspection Sheet.

Wheels and Tires

1. Check that tires comply with manufacturer's specification.

For additional information, refer to: Specifications (204-04 Wheels and Tires, Specifications).

2. Check/adjust tire pressures including spare.

For additional information, refer to: Specifications (204-04 Wheels and Tires, Specifications).

3. Vehicles with Uni-directional tires installed: Mark the wheel to stud relationship of each road wheel and note location of
each road wheel to its respective hub.

4. Loosen road wheel nuts. Raise vehicle to a wheel free condition.

For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

5. Remove the road wheels.

6. Visually check tires for condition, lumps or bulges. Check tread depth across the width of the tire and around the
circumference; ensure that remaining tread depth does not contravene local legislative requirements.

NOTE: Do not install wheels at this stage.

Braking System

1. Inspect front brake pads for wear.

For additional information, refer to: Specifications (206-03 Front Disc Brake, Specifications).

2. Inspect rear brake pads for wear.

For additional information, refer to: Specifications (206-04 Rear Disc Brake, Specifications).

3. Check brake calipers for signs of fluid leaks.

4. Check brake discs for condition.

5. Check all brake booster and brake system pipes and hoses for condition, chafing and leaks.

6. Clean road wheel hub spigots and apply grease, Land Rover Part Number RYL 105020 to the wheel mating surface of each
spigot.

7. Vehicles with Uni-directional tires installed: Install road wheels to their respective hubs ensuring that stud to wheel
relationship is maintained.

8. Vehicles with NON uni-directional tires installed: Install wheels on the opposite side of the vehicle but ensure that they on
the same axle as they were originally installed.

9. Install road wheel nuts and tighten to 140 Nm (103 lb-ft).

10. Every 3 years or 45,000 miles (72,000 km): Replace brake fluid.
For additional information, refer to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures)
/
Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).

Parking Brake
1. Check the adjustment of the parking brake.
For additional information, refer to: Parking Brake Shoe and Lining Adjustment (206-05 Parking Brake and Actuation, General
Procedures).

Cooling System

1. Check specific gravity of coolant using a hydrometer.

NOTE: A suitable hydrometer is available from the Equipment Programme under Part Number 511 3302 001 00.

2. Top-up cooling system if necessary.

CAUTION: Anti-freeze concentration must be maintained at 50%.

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank whilst the system is hot.

CAUTION: Engine coolant will damage the paint finished surfaces. If coolant is spilled, immediately remove the coolant
and wash the area with water.

3. Check the level of coolant in the expansion tank. With the engine cold, the coolant level must be to the 'UPPER LEVEL'
indicator mark above the 'COLD FILL RANGE' text on the side of the expansion tank. Ignore any coolant which may be visible
in the top section of the tank.

4. If topping-up is required, remove expansion tank filler cap and top-up coolant level to the 'UPPER LEVEL' indicator mark.

CAUTION: Always top-up with a 50% mixture of anti-freeze and water.

5. Install expansion tank filler cap, tighten cap until ratchet is heard to 'click'.

6. Every 4 years or 60,000 miles (96,000 km): Replace the coolant.

Air Filtering

1. This procedure should only be completed when carrying out Service Inspection 2: Replace the air cleaner element.
For additional information, refer to: Air Cleaner Element (303-12C Intake Air Distribution and Filtering - 3.0L - Td6, Removal
and Installation).

Front End Accessory Drive (FEAD) Belt

1. Check the condition of the ancillary FEAD belt.

2. Remove all traces of mud and dirt from the belt and pulleys.

3. Check the belt for signs of splitting and wear.

Fluid Levels

Brake fluid reservoir

1. Check the fluid level in the brake fluid reservoir, the level must be to the 'MAX' mark on the reservoir; top-up if necessary.

2. Clean the area around the reservoir filler cap, remove the cap.

3. If necessary, top-up using the recommended fluid to the 'MAX' mark on the reservoir.
For additional information, refer to: Specifications (206-00 Brake System - General Information, Specifications).

4. Install the reservoir filler cap.

Power steering fluid reservoir

CAUTION: To prevent over filling, check/top-up the system with the engine switched off and the system cold. Ensure
that the steering wheel is in the straight ahead position, do not turn the steering wheel prior to checking the fluid level.

1. Check that the fluid level is to the mid-way mark between the 'MAX' and 'MIN' marks on the fluid reservoir, top-up if
necessary.

2. Clean the area around the reservoir filler cap, remove the cap.

3. If necessary, top-up using the recommended fluid to the mid-way mark on the reservoir.
For additional information, refer to: Specifications (211-02 Power Steering, Specifications).

CAUTION: Do not fill reservoir above the 'MAX' mark.

4. Install the reservoir filler cap.

Windshield washer reservoir

1. Remove the windshield washer reservoir filler cap.

2. Top-up the reservoir using a mixture of an approved windshield washer fluid and water until the level is to the bottom of
the gauze filter in the reservoir filler neck.

3. Install the reservoir filler cap.

Engine Oil and Filter

1. Renew engine oil and filter.

Suspension and Body Mountings

Note: The procedures in this section should only be completed when carrying out Service Inspection 1 and Service Inspection
2.

1. Check for free play in all suspension and body mounting rubbers.

2. Check condition of suspension rubber boots and gaiters.

Fuel System

1. Check fuel system pipes, hoses and unions for chafing, leaks and corrosion.

2. Complete this procedure when carrying out Service Inspection 2 only. Renew the fuel filter element.

Oil/Fluid Leaks

1. Check for oil/fluid leaks.

Power Steering

Note: The procedures in this section should only be completed when carrying out Service Inspection 1 and Service Inspection
2.

1. Check power steering rod ball joint fixings, gaiters and condition of ball joints and dust covers.

2. Check power steering pipes, hoses and unions for chafing, leaks and corrosion.

Fault Lamp(s)

1. If fault lamp(s) are illuminated, test the associated system using T4 and report findings.

Road Test

1. Carry out road test of vehicle.

For additional information, refer to: Road/Roller Testing (100-00 General Information, Description and Operation).

General

1. Endorse Service Record.

2. Report any unusual features of vehicle condition and any additional work required.