freelander 1 my98 - body repair manual

8/17/2019 Freelander 1 MY98 - Body Repair Manual

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FREELANDER

Body Repair Manual

Carrosseriereparatiehandboek

Manuel de réparationde carrosserie

Karosseriereparaturanleitung

Manuale delle operazioni diriparazione della carrozzeria

Manual de reparacionesde carrocería

Manual de reparaçõesda carroçaria


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FREELANDER

BODY REPAIRMANUAL

Publication Part No. LRL 0154ENGPublished by Rover Technical Communication

© 1998 ROVER GROUP LIMITED

INTRODUCTIONGENERAL INFORMATIONINFORMATION

RESTRAINT SYSTEMSBODY

PANEL REPAIRS


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INTRODUCTION

CONTENTS Page

INTRODUCTION

INTRODUCTION 1......................................................................................................REPAIRS AND REPLACEMENTS 2...........................................................................SPECIFICATION 2......................................................................................................


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INTRODUCTION

INTRODUCTION 1

INTRODUCTION

How to use this Manual

This Body Repair Manual is designed to provide theexperienced Body Shop technician with theinformation required to carry out efficient andcost-effective repairs.

For ease of use, this Manual is structured to displaythe section title at the top of each page and therelevant sub-section at the bottom of each page. Inaddition, a section icon is displayed at the top outercorner of right-hand pages.

Each major section is preceded by a contents page,which lists titles of the topics and procedurescontained in the relevant sub-sections.

Technical data is subject to change; to facilitate theperiodic revision of technical information, eachsub-section is numbered from page 1 so that revisedsub-sections can be replaced if required.

The individual steps of procedures are to beperformed in the sequence in which they appear.Where item numbers appear in the Figure of aprocedure, those items are referred to in the text.

WARNINGS, CAUTIONS and NOTES have the

following meanings:

WARNING: Procedures which must befollowed precisely to avoid the possibilityof injury.

CAUTION: Calls attention to procedureswhich must be followed to avoid damageto components.

NOTE: Gives helpful information.

References

References to the LH or RH side given in thisManual are made when viewing the vehicle from therear.

Cross references may be made to sections notincluded in this manual. In these cases, refer to therelevant Workshop Manual for the referencedinformation.

Operations covered in this Manual do not includeinstructions for testing the vehicle after repair. It isessential that work is inspected and tested aftercompletion and if necessary a road test of thevehicle should be conducted.

WARNING: It is particularly important to

test a vehicle after repairs to safety relateditems have been performed.

Dimensions

The dimensions quoted are to design engineeringspecification with service limits where applicable.


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INTRODUCTION

2 INTRODUCTION

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essentialthat only Land Rover recommended parts are used.

The following points concerning repairs and thefitting of replacement parts and accessories isemphasised:

• Safety features and corrosion preventiontreatments embodied in the vehicle may beimpaired if other than Land Rover recommendedparts are fitted.

• In certain territories, legislation prohibits thefitting of parts which are not compliant with themanufacturer’s specification.

• Torque figures shown in this Manual should beused where specified.

• Locking devices (circlips, split pins etc.) must befitted where specified.

• If a locking device is damaged during removal, orits efficiency is impaired, it must be renewed.

• Owners purchasing accessories while travellingabroad should ensure that the accessory and itsinstallation or application conform to the legalrequirements of the territory.

• The Terms of the vehicle Warranty may beinvalidated by the fitting of other than Land Roverrecommended parts.

• All Land Rover recommended parts are covered

under the terms of the vehicle Warranty.• Land Rover Dealers are obliged to supply only

Land Rover recommended parts.

SPECIFICATION

Land Rover are constantly seeking to improve thespecification, design and production of their vehiclesand alterations take place accordingly. While everyeffort has been made to ensure the accuracy of this

Manual, it should not be regarded as an infallibleguide to current specifications of any particularvehicle.

This Manual does not constitute an offer for sale ofany particular vehicle. Land Rover Dealers are notagents of Land Rover and have no authority to bindthe manufacturer by any expressed or impliedundertaking or representation.


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GENERAL INFORMATION

CONTENTS Page

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL PRECAUTIONS 1......................................................................................Dangerous substances 1.............................................................................................Engine oils 2................................................................................................................Health Protection Precautions 2..................................................................................Environmental Protection Precautions 2......................................................................SAFETY INSTRUCTIONS 3........................................................................................GENERAL FITTING INSTRUCTIONS 4......................................................................BALL AND ROLLER BEARINGS 6..............................................................................OIL SEALS 7...............................................................................................................JOINTS AND JOINT FACES 8....................................................................................LOCKING DEVICES 8.................................................................................................SCREW THREADS 9..................................................................................................BOLT IDENTIFICATION 9...........................................................................................NUT IDENTIFICATION 10...........................................................................................FLEXIBLE HYDRAULIC PIPES AND HOSES 11........................................................SERVICE TOOLS AND GARAGE EQUIPMENT 12....................................................DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES 12....................DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) 13......

FUEL HANDLING PRECAUTIONSFUEL HANDLING PRECAUTIONS 1..........................................................................

ELECTRICAL PRECAUTIONSELECTRICAL PRECAUTIONS 1.................................................................................

SRS PRECAUTIONSSUPPLEMENTARY RESTRAINT SYSTEM PRECAUTIONS 1..................................COMPONENT REPLACEMENT POLICY 9................................................................

AIR CONDITIONING PRECAUTIONSAIR CONDITIONING SYSTEM PRECAUTIONS 1......................................................REMEDIAL ACTIONS 2...............................................................................................SERVICE PRECAUTIONS 3.......................................................................................PRECAUTIONS FOR REFRIGERANT RECOVERY, RECYCLING ANDRECHARGING 5..........................................................................................................

VEHICLE IDENTIFICATION NUMBERVEHICLE IDENTIFICATION NUMBER 1....................................................................IDENTIFICATION NUMBER LOCATIONS 2...............................................................


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GENERAL INFORMATION

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1

GENERAL PRECAUTIONS

Dangerous substances

WARNING: Many liquids and othersubstances used in motor vehicles arepoisonous and should not be consumed

under any circumstances.

As far as possible, try to prevent skin contactwith any potentially harmful materials.Substances to be treated with particular cautioninclude (but is not limited to): acid, anti-freeze,asbestos, brake fluid, fuel, windscreen washeradditives, lubricants, refrigerant and variousadhesives.

Always read the instructions printed on labels or

stamped on components carefully.Such instructions should be strictly compliedwith; they are included to ensure your health andpersonal safety is not compromised through theincorrect use of the materials to which theyrelate.

Synthetic rubber

WARNING: Many ’O’ rings, seals, hoses,flexible pipes and other similar itemswhich appear to be natural rubber, are in

fact, made of synthetic materials calledFluoroelastomers.Under normal operating conditions this materialis safe and does not present a health hazard.However, if the material is damaged by fire orexcessive heating, it can break down andproduce highly corrosive Hydrofluoric acidwhich can cause serious burns on contact withskin.

If skin contact does occur:

• Remove any contaminated clothing immediately.

• Irrigate effected area of skin with a copious

amount of cold water or limewater for 15 to 60minutes.

• Obtain medical assistance immediately

Should any material be in a burnt or over-heatedcondition, handle with extreme caution and wearprotective clothing (seamless industrial gloves,protective apron etc.).Decontaminate and dispose of gloves immediatelyafter use.


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GENERAL INFORMATION

2 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

Engine oils

WARNING: Prolonged and repeatedcontact with mineral oil can result in theremoval of natural fats from the skin; this

may cause dryness, irritation and dermatitis.

In particular, used engine oil contains potentiallyharmful carcinogenic contaminants. Adequatemeans of skin protection (barrier creams etc.)and washing facilities must be provided.

Avoid excessive skin contact with used engineoils and always adhere to the following healthprotection recommendations:

Health Protection Precautions

• Avoid prolonged and repeated contact withoils, particularly used engine oils.

• Wear protective clothing, includingimpervious gloves where practicable.

• Do not put oily rags in pockets.

• Avoid contaminating clothes (particularlyunderpants) with oil.

• Overalls must be cleaned regularly. Discardheavily soiled clothing and oil impregnatedfootwear.

• First aid treatment should be obtained

immediately for open cuts and wounds.

• Use barrier creams: apply before each workperiod to help removal of engine oil from theskin.

• Wash with soap and water to ensure all oil isremoved (propriety skin cleansers and nailbrushes will help).

• Use moisturisers after cleaning; preparationscontaining lanolin help replace the skin’snatural oils which have been removed.

• Do not use petrol, kerosene, diesel fuel, gas,oil, thinners or solvents for cleaning skin.

• If skin disorders develop, obtain medicaladvice without delay.

• Where practicable, degrease components

prior to handling.• Wear eye protection (e.g. goggles or face

shield) if there is a risk of eye contamination.Eye wash facilities should be provided in theclose vicinity of the work area.

Environmental Protection Precautions

It is illegal to pour used oil on to the ground, downsewers or drains, or into water courses.

Burning of used engine oil in small space heaters or

boilers should only be considered for units ofapproved design and in compliance with theequipment manufacturer’s recommendations. Theheating system must meet the regulatory standardsof HMIP for small burners of less than 0.4 MW. If indoubt check with the appropriate local authorityand/or manufacturer of the approved appliance.

Dispose of used oil and filters through authorisedwaste disposal contractors and licensed wastedisposal sites, or through the waste oil reclamationtrade. If in doubt, contact the Local Authority foradvice on disposal facilities.


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GENERAL INFORMATION


Precautions against damage

CAUTION: Always fit wing and seat coversbefore commencing work. Avoid spillingbrake fluid or battery acid on paintwork;

immediately wash off with water if this occurs.

CAUTION: Disconnect the battery earthlead before starting work, seeELECTRICAL PRECAUTIONS.

CAUTION: Always use the recommendedservice tool or a satisfactory equivalentwhere specified.

CAUTION: Protect exposed bearingsurfaces, sealing surfaces and screwthreads from damage.

SAFETY INSTRUCTIONS

Whenever possible, use a lift or pit when workingbeneath vehicle, in preference to jacking. Chockwheels as well as applying parking brake.

Jacking

The recommended jacking points are shown in theLIFTING AND TOWING sub-section of theINFORMATION section.Always ensure that any lifting apparatus hassufficient load capacity for the weight to be lifted.

Ensure the vehicle is standing on level ground priorto lifting or jacking.

Apply the handbrake and chock the wheels.

WARNING: Never rely on a jack as the solemeans of support when working beneaththe vehicle. Use additional safety supports

beneath the vehicle.

Do not leave tools, lifting equipment, spilt oil,etc., around or on the work bench area. Alwayskeep a clean and tidy work area.

Brake shoes and pads

WARNING: Always fit the correct gradeand specification of brake linings.When renewing brake pads and brake

shoes always replace as complete axle setsonly.


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GENERAL INFORMATION


Brake hydraulics

WARNING: It is imperative that the correctbrake fittings are used and that threads ofcomponents are compatible.

• Always use two spanners when loosening ortightening brake pipe or hose connections.

• Ensure that hoses run in a natural curve and arenot kinked or twisted.

• Fit brake pipes securely in their retaining clipsand ensure that the pipe run cannot contact apotential chafing point.

• Containers used for hydraulic fluid must be keptabsolutely clean.

• Do not store hydraulic fluid in an unsealed

container, it will absorb water and in thiscondition would be dangerous to use due to alowering of its boiling point.

• Do not allow hydraulic fluid to be contaminatedwith mineral oil, or use a container which haspreviously contained mineral oil.

• Do not re-use fluid from the system.

• Always use clean brake fluid or a recommendedalternative to clean hydraulic components.

• Fit a blanking cap to an hydraulic union and aplug to its socket after removal to prevent the

ingress of dirt.

CAUTION: Absolute cleanliness must beobserved with hydraulic components.

Engine coolant caps and plugs

WARNING: Extreme care is necessarywhen removing engine coolant caps andplugs when the engine is hot and

especially if it is overheated. To avoid the

possibility of scalding allow the engine to coolbefore attempting coolant cap or plug removal.

GENERAL FITTING INSTRUCTIONS

Component removal

Whenever possible, clean components andsurrounding area before removal.

• Blank off openings exposed by componentremoval.

• Immediately seal fuel, oil or hydraulic lines whenapertures are exposed; use plastic caps or plugsto prevent loss of fluid and ingress of dirt.

• Close open ends of oilways exposed bycomponent removal with tapered hardwood plugsor conspicuous plastic plugs.

• Immediately a component is removed, place it ina suitable container; use a separate container for

each component and its associated parts.• Clean bench and provide marking materials,

labels, containers and locking wire beforedismantling a component.


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GENERAL INFORMATION


Dismantling

Observe scrupulous cleanliness when dismantlingcomponents, particularly when brake, fuel orhydraulic system parts are being worked on.

CAUTION: A particle of dirt or a clothfragment could cause a seriousmalfunction if trapped in these systems.

• Blow out all tapped holes, crevices, oilways andfluid passages with an air line. Ensure that anyO-rings used for sealing are correctly replaced orrenewed, if disturbed during the process.

• Use marking ink to identify mating parts andensure correct reassembly. Do not use a centrepunch or scriber to mark parts, they could initiatecracks or distortion in marked components.

• Wire together mating parts where necessary toprevent accidental interchange (e.g. rollerbearing components).

• Wire labels on to all parts which are to berenewed, and to parts requiring further inspectionbefore being passed for reassembly; place theseparts in separate containers from thosecontaining parts for rebuild.

• Do not discard a part due for renewal until aftercomparing it with a new part, to ensure that itscorrect replacement has been obtained.

Cleaning components

Always use the recommended cleaning agent orequivalent.

WARNING: Ensure that adequateventilation is provided when volatiledegreasing agents are being used.

CAUTION: Do not use degreasingequipment for components containingitems which could be damaged by the use

of this process.

General Inspection

• Never inspect a component for wear ordimensional check unless it is absolutely clean; a

slight smear of grease can conceal an incipientfailure.

• When a component is to be checkeddimensionally against recommended values, usethe appropriate measuring equipment (surfaceplates, micrometers, dial guages etc.). Ensurethe measuring equipment is calibrated and ingood serviceable condition.

• Reject a component if its dimensions are outsidethe specified tolerances, or if it appears to bedamaged. A part may be refitted if its critcal

dimension is exactly to its tolerance limit and itappers to be in satisfactory condition.

• Use ’Plastigauge’ 12 Type PG-1 for checkingbearing surface clearances.


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GENERAL INFORMATION


BALL AND ROLLER BEARINGS

CAUTION: Never refit a ball or rollerbearing without first ensuring that it is in afully serviceable condition.

CAUTION: When hub bearings areremoved or displaced, NEW bearings mustbe fitted; do not attempt to refit the old

hub bearings.

• Remove all traces of lubricant from bearingunder inspection by cleaning with a suitabledegreaser; maintain absolute cleanlinessthroughout operations.

• Conduct a visual inspection for markings onrolling elements, raceways, outer surface of outerrings or inner surface of inner rings. Reject anybearings found to be marked, since marking inthese areas indicates onset of wear.

• Hold inner race of bearing between finger andthumb of one hand and spin outer race to checkthat it revolves absolutely smoothly. Repeat,holding outer race and spinning inner race.

• Rotate outer ring gently with a reciprocatingmotion, while holding inner ring; feel for anycheck or obstruction to rotation. Reject bearing ifaction is not perfectly smooth.

• Lubricate bearing with generous amounts oflubricant appropriate to installation.

• Inspect shaft and bearing housing fordiscoloration or other markings which indicatemovement between bearing and seatings.

• Ensure that shaft and housing are clean and freefrom burrs before fitting bearing.

• If one bearing of a pair shows an imperfection, itis advisable to replace both with new bearings;an exception could be if the faulty bearing hadcovered a low mileage, and it can be establishedthat damage is confined to only one bearing.

• When fitting a bearing to a shaft, only apply forceto the inner ring of the bearing. When fitting abearing into a housing, only apply force to the

outer ring of the bearing.

• In the case of grease lubricated bearings (e.g.hub bearings) fill the space between bearing andouter seal with the recommended grade ofgrease before fitting seal.

• Always mark components of separable bearings(e.g. taper roller bearings) when dismantling, toensure correct reassembly. Never fit new rollersin a used outer ring; always fit a complete newbearing assembly.


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GENERAL INFORMATION


OIL SEALS

Always renew oil seals which have been removedfrom their working location (whether as an individualcomponent or as part of an assembly).

• Carefully examine seal before fitting to ensurethat it is clean and undamaged.

• Ensure the surface on which the new seal is torun is free of burrs or scratches. Renew thecomponent if the original sealing surface cannotbe completely restored.

• Protect the seal from any surface which it has topass when being fitted. Use a protective sleeveor tape to cover the relevant surface.

• Lubricate the sealing lips with a recommendedlubricant before use to prevent damage during

initial use. On dual lipped seals, smear the areabetween the lips with grease.

• If a seal spring is provided, ensure that it is fittedcorrectly.

• Place lip of seal towards fluid to be sealed andslide into position on shaft. Use fitting sleevewhere possible to protect sealing lip fromdamage by sharp corners, threads or splines. If afitting sleeve is not available, use plastic tube ortape to prevent damage to the sealing lip.

• Grease outside diameter of seal, place square tohousing recess and press into position usinggreat care, and if possible a ’bell piece’ to ensurethat seal is not tilted. Never let weight ofunsupported shaft rest in seal.

NOTE: In some cases it may be preferableto fit seal to housing before fitting to shaft.

• Use the recommended service tool to fit an oilseal. If the correct service tool is not available,use a suitable tube approximately 0.4 mm (0.015in.) smaller than the outside diameter of the seal.Use an hammer VERY GENTLY on drift if asuitable press is not available.

• Press or drift the seal in to the depth of itshousing with the sealing lip facing the lubricant tobe retained if the housing is shouldered, or flushwith the face of the housing where no shoulder isprovided. Ensure that the seal does not enter thehousing in a tilted position.

NOTE: Most cases of failure or leakage ofoil seals are due to poor fitting, which canresult in damage to both seals and sealing

surfaces. NEVER use a seal which has beenimproperly stored or handled, such as hung on a

hook or nail.


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GENERAL INFORMATION


JOINTS AND JOINT FACES

Fit joints dry unless specified otherwise.

• Always use the correct gaskets as specified.

• When jointing compound is used, apply in a thinuniform film to metal surfaces; take care toprevent jointing compound from entering oilways,pipes or blind tapped holes.

• If gaskets and/or jointing compound isrecommended for use; remove all traces of old

jointing material prior to reassembly. Do not usea tool which will damage the joint faces andsmooth out any scratches or burrs using an oilstone. Do not allow dirt or jointing material toenter any tapped holes or enclosed parts.

• Prior to reassembly, blow through any pipes,

channels or crevices with compressed air.

LOCKING DEVICES

Tab Washers

CAUTION: Always release locking tabsand fit new locking washers, do not re-uselocking tabs. Ensure the new tab washer

is the same design as that replaced.

Locking Nuts

Always use a backing spanner when slackening ortightening brake and fuel pipe unions.

Roll Pins

Always fit new roll pins of an interference fit in thehole.

Circlips

Always fit new circlips of the correct size for thegroove.

Locking wire

Always fit locking wire of the correct type. Arrangewire so that its tension tends to tighten the boltheads or nuts to which it is fitted.

Keys and Keyways

• Remove burrs from edges of keyways with a fine

file and clean thoroughly before attempting torefit key.

• Clean and inspect key closely; keys are suitablefor refitting only if indistinguishable from new, asany indentation may indicate the onset of wear.

Fitting a split pin

CAUTION: Always fit new split-pins of thecorrect size for the hole in the bolt or stud.Do not slacken nut to enter split-pin.


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GENERAL INFORMATION


SCREW THREADS

Metric threads to ISO standards are used.

Damaged nuts, bolts and screws must always bediscarded.

NOTE: Cleaning damaged threads with adie or tap impairs the strength andcloseness of fit of the threads and is not

recommended.

CAUTION: Always ensure thatreplacement bolts are at least equal instrength to those replaced.

Castellated nuts must not be slackened to accept asplit-pin, except in recommended cases when thisforms part of an adjustment.

Do not allow oil or grease to enter blind threadedholes. The hydraulic action on screwing in the bolt orstud could split the housing.

Always tighten a nut or bolt to the recommendedtorque figure. Damaged or corroded threads canaffect the torque reading.

To check or re-tighten a bolt or screw to a specifiedtorque figure, first slacken a quarter of a turn, thenretighten to the correct torque figure.

Oil thread lightly before tightening to ensure a free

running thread, except in the case of threads treatedwith sealant / lubricant, and self-locking nuts.

BOLT IDENTIFICATION

An ISO metric bolt or screw made of steel and largerthan 6 mm in diameter can be identified by either ofthe symbols ISO M or M embossed or indented ontop of the bolt head.

In addition to marks identifying the manufacturer, the

top of the bolt head is also marked with symbolsindicating the strength grade, e.g. 8.8; 10.9; 12.9;14.9. As an alternative, some bolts and screws havethe M and strength grade symbol stamped on theflats of the hexagon.

Encapsulated bolts and screws

Encapsulated bolts and screws have amicro-encapsulated locking agent pre-applied to thethread. They are identified by a coloured sectionwhich extends 360° around the thread. The lockingagent is released and activated by the assemblyprocess and is then chemically cured to provide the

locking action.


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GENERAL INFORMATION


Unless a specific repair procedure states otherwise,encapsulated bolts may be re-used providing thethreads are undamaged and the following procedureis adopted:

• Remove loose adhesive from the bolt and

housing threads.• Ensure threads are clean and free of oil and

grease.

• Apply an approved locking agent.

NOTE: Always fit a new encapsulated boltwhen replacing; or if not available, a boltof equivalent specification treated with an

approved locking agent.

Self-locking bolts and screws

Self-locking bolts and screws, i.e. nylon patched ortrilobular thread can be re-used providing resistancecan be felt when the locking portion enters thefemale thread.

Nylon patched bolts and screws have a lockingagent pre-applied to the threads. They are identifiedby the presence of a coloured section of threadwhich extends for up to 180° around the thread.

Trilobular bolts (i.e. Powerlok) have a special threadform which creates a slight interference in the

tapped hole or threads of the nut into which it isscrewed.

CAUTION: DO NOT re-use self-lockingfasteners in critical locations (e.g. enginebearings, flywheel). Always use the

correct replacement self-locking nut, bolt orscrew.

CAUTION: DO NOT fit non self-locking

fasteners in applications where aself-locking nut, bolt or screw is specified.

NUT IDENTIFICATION

A nut with an ISO metric thread is marked on oneface or on one of the flats of the hexagon with thestrength grade symbol 8, 12, or 14. Some nuts witha strength grade 4, 5 or 6 are also marked and somehave the metric symbol M on the flat opposite thestrength grade marking.

A clock face system is sometimes used as analternative method of indicating the strength grade.The external chamfers or a face of the nut is markedin a position relative to the appropriate hour mark ona clock face to indicate the strength grade.

A dot is used to locate the 12 o’clock position and adash to indicate the strength grade. If the grade isabove 12, two dots identify the 12 o’clock position.


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GENERAL INFORMATION


Self-locking nuts

Self-locking nuts, i.e. nylon insert or deferred threadnuts can be re-used providing resistance can be feltwhen the locking portion of the nut passes over thethread of the bolt or stud.

CAUTION: Do not apply heat in an attemptto free deferred thread nuts or fittings; aswell as causing damage to protective

coatings, there is a risk of damage to electronicequipment and brake linings from stray heat.

When tightening a slotted or castellated nut, neverloosen it to insert a split pin or locking wire exceptwhere recommended as part of an adjustment. Ifdifficulty is experienced, alternative washers or nutsshould be selected, or the washer thickness

reduced.

Where self-locking nuts have been removed, it isadvisable to replace them with new ones of thesame type.

NOTE: Where bearing pre-load is involvednuts should be tightened in accordancewith special instructions.

FLEXIBLE HYDRAULIC PIPES AND HOSES

WARNING: Do not disconnect any pipes inan air conditioning refrigeration systemunless trained and instructed to do so. A

refrigerant is used which can cause blindness ifallowed to contact eyes.

• Before removing any brake or power steeringhose, clean end fittings and area surroundingthem as thoroughly as possible.

• Obtain appropriate plugs or caps beforedetaching hose end fittings, so that the ports canbe immediately covered to prevent the ingress ofdirt.

• Clean hose externally and blow through withairline. Examine carefully for cracks, separation

of plies, security of end fittings and externaldamage. Reject any faulty hoses.

• When refitting a hose, ensure that nounnecessary bends are introduced, and thathose is not twisted before or during tightening ofunion nuts.

• Fit a cap to seal a hydraulic union and a plug toits socket after removal to prevent ingress of dirt.

• Absolute cleanliness must be observed withhydraulic components at all times.

• After any work on hydraulic systems, carefully

inspect for leaks underneath the vehicle while asecond operator applies maximum brakepressure to the brakes (engine running) andoperates the steering.


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GENERAL INFORMATION


Fuel System Hoses

CAUTION: All fuel hoses are made up oftwo laminations, an armoured rubberouter sleeve and an inner viton core. If any

of the fuel system hoses have beendisconnected, it is imperative that the internalbore is inspected to ensure that the viton lininghas not become separated from the armouredouter sleeve. A new hose must be fitted ifseparation is evident.

SERVICE TOOLS AND GARAGE EQUIPMENT

Special service tools have been developed tofacilitate removal, dismantling and assembly ofmechanical components in a cost effective and timeefficient manner. The use of such special tools alsohelps prevent the potential for damage tocomponents.Some operations described in this Manual cannot becarried out properly without the aid of the relevantservice tools.

Where specific garage equipment is required for

diagnosis and repair, reference should be made tothe Service Tools and Equipment Programme wheredetails of the equipment recommended by LandRover Service may be found.

DYNAMOMETER TESTING - NON ANTI-LOCKBRAKE VEHICLES

The front and rear wheels cannot be drivenindependently due to the viscous coupling. Thiseliminates the need for differential lock byprogressively applying more torque to the rearwheels if the front wheels start to slip.

WARNING: DO NOT attempt to driveindividual wheels with vehicle supportedon floor jacks or stands.

Four wheel dynamometers

Provided that front and rear dynamometer rollers arerotating at identical speeds and that normalworkshop safety standards are applied, there is no

speed restriction during testing, except any that mayapply to the tyres.

Two wheel dynamometers

IMPORTANT: Use a four wheel dynamometer forbrake testing if possible.

If brake testing on a single rig is necessary, thefollowing procedures should be ensured:

• propeller shaft to the rear axle is removed

• neutral selected in gearbox

• hill descent control not selected.

When checking brakes, run engine at idle speed tomaintain servo vacuum.


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GENERAL INFORMATION


DYNAMOMETER TESTING - VEHICLES WITHANTI-LOCK BRAKES (ABS)

WARNING: Do not attempt to test ABSfunction on a dynamometer

Four wheel dynamometers

NOTE: Before testing a vehicle on a fourwheel dynamometer disconnect the ABSvalve relay. The ABS function will not

work, the ABS warning light will illuminate.Normal braking will be available.

Provided that front and rear rollers are rotating atidentical speeds and that normal workshop safetystandards are applied, there is no speed restrictionduring testing except any that may apply to the

tyres.

Two wheel dynamometers

IMPORTANT: Use a four wheel dynamometer forbrake testing if possible.

NOTE: ABS will not function on a twowheel dynamometer. The ABS light willilluminate during testing. Normal braking

will be available.

If brake testing on a single rig is necessary, thefollowing procedures should be ensured:

• propeller shaft to the rear axle is removed

• neutral selected in gearbox

• hill descent control not selected

If checking engine performance, ensure hill descentcontrol is not selected and drive shaft to reardifferential is disconnected.


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GENERAL INFORMATION

FUEL HANDLING PRECAUTIONS 1

FUEL HANDLING PRECAUTIONS

General

The following information provides basic precautionswhich must be observed if petrol (gasoline) is to behandled safely. It also outlines other areas of riskwhich must not be ignored. This information isissued for basic guidance only, if in doubt consultyour local Fire Officer.

Petrol - Gasoline

Petrol/gasoline vapour is highly flammable and inconfined spaces is also explosive and toxic.

When petrol/gasoline evaporates it produces 150times its own volume in vapour, which when diluted

with air becomes a readily ignitable mixture. Thevapour is heavier than air and will always fall to thelowest level. The vapour can be easily distributedthroughout a workshop by air currents;consequently, even a small spillage ofpetrol/gasoline is potentially very dangerous.

WARNING: Do not use a pit whenremoving fuel system components.

Always have a fire extinguisher containing FOAM,CO2, GAS or POWDER close at hand when

handling or draining fuel or when dismantling fuelsystems. Fire extinguishers should also be locatedin areas where fuel containers are stored.

Always disconnect the vehicle battery beforecarrying out dismantling or draining work on a fuelsystem.

Whenever petrol/gasoline is being handled, drainedor stored, or when fuel systems are beingdismantled, all forms of ignition must beextinguished or removed; any leadlamps must beflameproof and kept clear of spillage.

WARNING: No one should be permitted torepair components associated withpetrol/gasoline without first having

specialist training.

Fuel tank drainage

WARNING: Petrol/gasoline must not beextracted or drained from any vehiclewhilst it is standing over a pit.

Draining or extraction of petrol/gasoline from avehicle fuel tank must be carried out in a wellventilated area.The receptacle used to contain thepetrol/gasoline must be more than adequate forthe full amount of fuel to be extracted or drained.The receptacle should be clearly marked with itscontents, and placed in a safe storage areawhich meets the requirements of local authorityregulations.

WARNING: When petrol/gasoline has beenextracted or drained from a fuel tank the

precautions governing naked lights andignition sources should be maintained.

Fuel tank removal

When the fuel line is secured to the fuel tank outletby a spring steel clip, the clip must be releasedbefore the fuel line is disconnected or the fuel tank isremoved. This procedure will avoid the possibility ofresidual petrol fumes in the fuel tank being ignitedwhen the clip is released.

As an added precaution fuel tanks should have a’PETROL (GASOLINE) VAPOUR’ warning labelattached to them as soon as they are removed fromthe vehicle.


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GENERAL INFORMATION

2 FUEL HANDLING PRECAUTIONS

Fuel tank repairs

Under no circumstances should a repair to any fueltank be carried out without first rendering the tankSAFE, by using one of the following methods:

a. STEAMING: With the filler cap and tank unitremoved, empty the tank. Steam the tank for at leasttwo hours with low pressure steam. Position the tankso that condensation can drain away freely, ensuringthat any sediment and sludge not volatized by thesteam is washed out during the steaming process.

b. BOILING: With the filler cap and tank unitremoved, empty the tank. Immerse the tankcompletely in boiling water containing an effectivealkaline degreasing agent or a detergent, with thewater filling and also surrounding, the tank for at

least two hours.

After steaming or boiling, a signed and dated label tothis effect should be attached to the tank.

Body repairs

WARNING: When body repairs involve theuse of heat, all fuel pipes which run in thevicinity of the repair area must be

removed, and the tank outlet plugged, BEFORE

HEAT IS APPLIED. If the repair is in the vicinityof the fuel tank, the tank must be removed.

Plastic fuel pipes are particularly susceptible to heat,even at relatively low temperature, and can bemelted by heat conducted from some distance away.

Fuel lines or tanks must not be removed whilst thevehicle is over an inspection pit.


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GENERAL INFORMATION

ELECTRICAL PRECAUTIONS 1

ELECTRICAL PRECAUTIONS

General

The following guidelines are intended to ensure thesafety of the operator whilst preventing damage to

the electrical and electronic components fitted to thevehicle. Where necessary, specific precautions aredetailed in the relevant sections of this Manual whichshould be referred to prior to commencing repairoperations.

Equipment

Prior to commencing any test procedure on thevehicle ensure that the relevant test equipment isworking correctly and any harness or connectors arein good condition. It is particularly important toensure the propriety of the lead and plugs of mains

operated equipment.

Polarity

Never reverse connect the vehicle battery andalways ensure the correct polarity when connectingtest equipment.

High Voltage Circuits

Whenever disconnecting live ht-circuits always useinsulated pliers and never allow the open end of theht-lead to contact other components - particularlyECU’s.

CAUTION: Exercise caution whenmeasuring the voltage on the coilterminals while the engine is running, high

voltage spikes can occur on these terminals.

Connectors and Harnesses

The engine compartment of a vehicle is aparticularly hostile environment for electricalcomponents and connectors. Always ensureelectrically related items are dry and oil free beforedisconnecting and connecting test equipment.

CAUTION: Ensure disconnectedmultiplugs and sensors are protected frombeing contaminated with oil, coolant or

other solutions. Contamination could impairperformance or result in catastrophic failure.

Never force connectors apart using tools to priseapart or by pulling on the wiring harness.

Always ensure locking tabs are disengaged beforedisconnection, and match orientation to enable

correct reconnection.

Ensure that any protection (covers, insulation etc.) isreplaced if disturbed.

Having confirmed a component to be faulty:

• switch off the ignition and disconnect the battery.

• remove the component and support thedisconnected harness.

• when replacing the component keep oily handsaway from electrical connection areas and pushconnectors home until any locking tabs fullyengage.

Battery disconnection

Before disconnecting the battery, disable the alarmsystem and switch off all electrical equipment. If the

radio is to be serviced, ensure the security code hasbeen deactivated.

CAUTION: To prevent damage to electricalcomponents ALWAYS disconnect thebattery when working on the vehicle

electrical system. The earth lead must bedisconnected first and reconnected last.Always ensure that battery leads are routedcorrectly and are not close to any potentialchafing points.

Battery charging

Only recharge the battery with it removed from thevehicle.

Always ensure any battery charging area is wellventilated and that every precaution is taken to avoidnaked flames and sparks.


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GENERAL INFORMATION

2 ELECTRICAL PRECAUTIONS

Ignition system safety precautions

WARNING: Before commencing work onan ignition system, all high tensionterminals, adapters and diagnostic

equipment should be inspected.

Ensure all cables, connectors and componentsare adequately insulated and shielded.Accidental contact with a poorly insulatedignition system component could result in asevere electrical shock.

Wearers of surgically implanted pacemakerdevices should not be in close proximity toignition circuits or diagnostic equipment.

Disciplines

Switch off the ignition prior to making any connectionor disconnection in the system to prevent electricalsurges caused by disconnecting ’live’ connectionsdamaging electronic components.

Ensure hands and work surfaces are clean and freeof grease, swarf, etc. Grease collects dirt which cancause electrical tracking (short-circuits) orhigh-resistance contacts.

When handling printed circuit boards, treat with careand hold by the edges only; note that someelectronic components are susceptible to bodystatic.

Connectors should never be subjected to forcedremoval or refit, especially inter-board connectors.Damaged contacts can cause short-circuit andopen-circuit fault conditions.

Prior to commencing test, and periodically during atest, touch a good vehicle body earth to dischargestatic charge. Some electronic components arevulnerable to the static electricity that may begenerated by the operator.

Grease for electrical connectors

Some under bonnet and under body connectors maybe protected against corrosion by the application ofa special grease during vehicle production. Shouldconnectors be disturbed in service, or repaired orreplaced, additional grease should be re-applied:Part No. BAU 5811, available in 150 gm tubs.

NOTE: The use of greases other than BAU5811 must be avoided as they can migrateinto relays, switches etc. contaminating

the contacts and leading to intermittentoperation or failure.


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GENERAL INFORMATION

SRS PRECAUTIONS 1

SUPPLEMENTARY RESTRAINT SYSTEMPRECAUTIONS

General

The Supplementary Restraint System (SRS)provides active protection for vehicle occupants inthe event of a serious collision. The systemcomponents include airbags and pre-tensionerseatbelts which are automatically deployed when asevere frontal crash condition is detected.

WARNING: Do not use rear facing childseats in the front passenger seat if thevehicle is fitted with a passenger airbag.

In order to assure system integrity, it is essential thatthe SRS system is regularly checked and

maintained so that it is ready for operation in theevent of an accident.

The SRS system contains components which couldbe potentially hazardous to the service engineer ifnot serviced and handled correctly. The followingguidelines are intended to alert the service engineerto potential sources of danger and emphasise theimportance of ensuring integrity of the SRScomponents fitted to the vehicle.

Where necessary, additional specific precautions

are detailed in the relevant sections of this Manualwhich should be referred to prior to commencingrepair operations.

It should be noted that these precautions are notrestricted to operations performed when servicingthe SRS system, the same care should be exercisedwhen working on ancilliary systems and componentslocated in the vicinity of SRS components; theseinclude but are not limited to steering system(steering wheel airbag), body and trim components(passenger airbag and seat belt pre-tensioners) andelectrical system components (SRS harnesses etc.).

WARNING: Always follow the SafetyGuidelines and correct procedures forworking on SRS components.

NOTE: Airbag modules should be replacedevery ten years.


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GENERAL INFORMATION

2 SRS PRECAUTIONS

Preliminary Procedures

WARNING: Always remove the ignitionkey from the starter switch, disconnect thevehicle battery and wait 10 minutes before

and commencing work on the SRS system.

The SRS system uses energy reserve capacitorsthat keep the system active in the event of electricalsupply failure under crash conditions. It is necessaryto allow the capacitor sufficient time to discharge (10minutes) in order to avoid the risk of accidentaldeployment.

CAUTION: Always disconnect both batteryleads before beginning work on the SRSsystem. Disconnect the negative battery

cable first. Never reverse connect the vehicle

battery and always ensure the correct polaritywhen connecting test equipment.

CAUTION: Always disconnect the vehiclebattery before carrying out any electricwelding on a vehicle fitted with an SRS

system.

CAUTION: Do not expose an airbagmodule or seat belt pre-tensioner to heatexceeding 85°C (185°F).

WARNING: Carefully inspect any SRScomponent before installation. Do notinstall any SRS component that shows

signs of damage such as dents, cracks ordeformity.

CAUTION: Ensure SRS components arenot contaminated with oil, grease,detergent or water.

CAUTION: Prior to commencing any testprocedure on the vehicle, ensure that onlytest equipment approved for the purpose

is being utilised and that it is in good workingorder. Ensure any harness or connectors are ingood condition and any warning lamps arefunctional.

WARNING: Never use multimeters or othergeneral purpose test equipment on SRSsystem components or connectors.

System faults should be diagnosed through theuse of recommended test equipment only.


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GENERAL INFORMATION

SRS PRECAUTIONS 3

Component handling

WARNING: The SRS components aresensitive and potentially hazardous if nothandled correctly; always comply with the

following handling precautions:

• Never drop an SRS component. The airbagdiagnostic control unit is a particularly shocksensitive device and must be handled withextreme care. Airbag modules and seat beltpre-tensioner units could deploy if subjectedto a strong shock.

• Never wrap your arms around an airbagmodule. If an airbag module has to be carried,hold it by the cover, with the cover uppermostand the base away from your body.

• Never transport airbag modules or seat beltpre-tensioners in the cabin of a vehicle.Always use the luggage compartment of thevehicle for carrying airbag modules and seatbelt pre-tensioner units.

Storage

WARNING: Always store airbag modules

with the cover face up. If the airbagmodule is stored face down, accidental

deployment could propel the unit with enoughforce to cause serious injury.

WARNING: Airbag modules and seat beltpre-tensioners are classed as explosivedevices. For overnight and longer term

storage, they must be stored in a secure steelcabinet which has been approved as suitable forthe purpose and has been registered by the localauthority.

CAUTION: For the temporary storage of anairbag module or seat belt pre-tensionerduring service, place in a designated

storage area. If there is no designated storagearea available, store in the luggage compartmentof the vehicle and inform the workshopsupervisor.

CAUTION: Always observe the followingprecautions when temporarily storing anairbag module:

• Ensure the cover is facing upwards and theluggage compartment is secured.

• Always keep components cool, dry and freefrom contamination.

• Do not allow anything to rest on the airbagmodule.

• Store any removed airbag assembly on asecure flat surface away from electricalequipment and heat sources (exceeding 85°C(185°F).


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GENERAL INFORMATION

4 SRS PRECAUTIONS

Installation and Testing Precautions

WARNING: The integrity of SRS systemcomponents are critical for safetyreasons. Ensure the following precautions

are always adhered to:

• Never install used SRS components fromanother vehicle or attempt to repair an SRScomponent.

• When repairing an SRS system only usegenuine new parts.

• Never apply electrical power to an SRScomponent unless instructed to do so as partof an approved test procedure.

• Special Torx bolts are necessary for installingthe airbag assembly - do not use other bolts.

Ensure bolts are tightened to the specifiedtorque (refer to SRS section).

• Ensure that SRS component fixings arecorrectly positioned and torqued duringservice and repair.

• Always use new fixings when replacing anSRS component.

• Ensure the SRS Electronic Control Unit (ECU)is always installed correctly. There must notbe any gap between the ECU and the bracketto which it is mounted. An incorrectly

mounted unit could cause the system tomalfunction.

• The SRS Electronic Control Unit is anon-serviceable component and no attemptshould be made to repair or modify the unit.

• Do not try to disassemble the airbagassembly. It has no serviceable parts. Oncean airbag has been deployed, it cannot berepaired or reused.

• If you suspect an airbag assembly could bedefective, install a new unit and dispose ofthe old unit. Manually deploy the old unitbefore disposal. See RESTRAINT SYSTEMS,Precautions.

WARNING: When removing, testing orinstalling an airbag module do not leandirectly over it.


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GENERAL INFORMATION

SRS PRECAUTIONS 5

SRS Harnesses and Connectors

CAUTION: Always observe the followingprecautions with regards to SRS systems:

•Never attempt to modify, splice or repair

SRS wiring.

• Never install electronic equipment (such as amobile telephone, two way radio or in-carentertainment system) in such a way that itcould generate electrical interference in theairbag harness. Seek specialist advice wheninstalling such equipment.

NOTE: SRS wiring can be identified by aspecial yellow outer protective covering(black with yellow stripe protective

coverings are sometimes used).

CAUTION: Always ensure SRS harnessesare routed correctly. Be careful to avoidtrapping or pinching the SRS harness.

Route the harness to avoid possible points ofchafing.

• Always use specified earth fixings tightenedto the correct torque. Poor earthing cancause intermittent problems that are difficultto diagnose.

CAUTION: Ensure all airbag harnessconnectors are mated correctly andsecurely fastened. Do not leave the

connectors hanging loose.

• Do not allow SRS components to hang from

their harnesses.


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GENERAL INFORMATION

6 SRS PRECAUTIONS

Rotary Coupler

CAUTION: Always follow the procedure forfitting and checking the rotary coupler asinstructed in the SRS section of this

manual. Comply with all safety and installationprocedures to ensure the system functionscorrectly. Observe the following precautions:

• Do not install a rotary coupler if it issuspected to be defective.

• Do not attempt to service, modify or repair arotary coupler.

• Do not cut, splice or modify the wiresattached to yellow SRS connector and lead.

• Always ensure the rotary coupler connectorsare mated correctly and securely fastened.

• Always ensure the battery is disconnectedbefore working on the rotary coupler.

• Always ensure the rotary coupler is removedand installed in its centered position and withthe front road wheels in the straight aheadposition - refer to the SRS section of thismanual for the full correct removal andinstallation procedure.

• If a new rotary coupler is being installed,ensure the locking tab holding the coupler’srotational position is not broken; units with a

broken locking tab should not be used.

Warning Labels

Warning symbols are displayed at various positionsin the vehicle (either in a suitable prominent positionsuch as driver and passenger side glass, orattached to the component itself) to indicateSRSitems which must be treated with particular care.These include:

A - The need for caution when working in closeproximity to SRS components.

B - Refer to the publication where the procedures,instructions and advice can be found (usuallyWorkshop Manual or Owner’s Handbook) forworking on the SRS system.

C - Do not use rear facing child seats in the frontpassenger seat if the vehicle is fitted with apassenger airbag.

Driver and Passenger side windows


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GENERAL INFORMATION

SRS PRECAUTIONS 7

NOTE: It is imperative that the appropriatepublication is read thoroughly prior to anywork being undertaken on the SRS

system.

NOTE: Exact positions of SRS warninglabels may vary dependent on legislationand market trends.

Refer to the Owner’s Handbook for additionalinformation regarding the SRS system.

Rotary coupler

A - Refer to the Workshop Manual for detailedinstructions.

B - Ensure wheels are in the straight ahead positionbefore removal and refitting.C - LAND ROVER Part Number/Bar code - Thecode must be recorded and quoted for orderingpurposes.

End of Fascia

Label warning the owner not to use rear facing childseats in the front passenger seat in vehicles fittedwith a passenger side airbag.


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GENERAL INFORMATION

8 SRS PRECAUTIONS

Airbag and Pre-tensioner Deployment

WARNING: Only personnel who haveundergone the appropriate training shouldundertake deployment of airbag and

pre-tensioner modules.

WARNING: A deployed airbag is very hot,DO NOT return to a deployed airbagmodule until at least 30 minutes have

elapsed since deployment.

WARNING: Deployment procedures andprecautions as detailed in this servicemanual should be strictly adhered to. The

following precautions must be complied with:

• Only use deployment equipment approved forthe intended purpose.

• Before beginning deployment procedure,ensure deployment tool functions properly byperforming the self test procedure detailed inSRS section of this manual.

• Deployment of airbag / pre-tensioner modulesshould be performed in a well ventilated areawhich has been designated for the purpose.

• Ensure airbag / pre-tensioner modules arenot damaged or ruptured before attempting todeploy.

• Notify the relevant authorities of intention todeploy airbag and pre-tensioner units.

• When deploying airbag pre-tensioner units,ensure that all personnel are at least 15metres away from the deployment zone.

• Ensure deployment tool is connectedcorrectly, in compliance with the instructionsdetailed in the SRS section of this manual. Inparticular, ensure deployment tool is NOTconnected to battery supply beforeconnecting to airbag module connector.

• When deploying seat belt pre-tensioners,ensure pre-tensioner unit is secured correctlyto seat.

• When removing deployed airbag modulesand pre-tensioner units, wear protectiveclothing. Use gloves and seal deployed unitsin a plastic bag.

• Following deployment of any component ofthe SRS system within the vehicle, all SRScomponents must be replaced. DO NOTre-use or salvage any parts of the SRSsystem.

• Do not lean over airbag module whenconnecting deployment equipment.

WARNING: If a vehicle is to be scrapped,undeployed airbag modules andpre-tensioner units must be manually

deployed. In this case airbags can be deployedin the vehicle; before deployment, ensure theairbag module is secure within its correctmounting position.

CAUTION: Deployment of the driver sideairbag in the vehicle may damage thesteering wheel; if the vehicle is not being

scrapped, deploy the module outside of thevehicle.


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GENERAL INFORMATION

SRS PRECAUTIONS 9

COMPONENT REPLACEMENT POLICY

IMPACTS WHICH DO NOT DEPLOY AIRBAGS

CAUTION: Check for structural damage inthe area of the impact, paying particularattention to bumper armatures,

longitudinals, crash cans and bracketry.

IMPACTS WHICH DEPLOY AIRBAGS

CAUTION: Renew the followingcomponents:

• Airbag ECU.

• Airbag module(s).

• Facia harness.

• Pretensioners.

• Rotary coupler and link harness.


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GENERAL INFORMATION

AIR CONDITIONING PRECAUTIONS 1

AIR CONDITIONING SYSTEM PRECAUTIONS

General

The air conditioning system contains fluids andcomponents which could be potentially hazardous tothe service engineer or the environment if notserviced and handled correctly. The followingguidelines are intended to alert the service engineerto potential sources of danger and emphasise theimportance of ensuring the integrity of the AirConditioning operating conditions and componentsfitted to the vehicle.

Where necessary, additional specific precautionsare detailed in the relevant sections of this Manualwhich should be referred to prior to commencingrepair operations.

The refrigerant used in the air conditioning system isHFC-134a (Hydrofluorocarbon) R134a.

WARNING: The air conditioning system ischarged with a high pressure, potentiallytoxic refrigerant. Repairs or servicing

must only be carried out by a trained operatorfamiliar with both the vehicle system and thecharging and testing equipment.

WARNING: All operations pertaining to the

air conditioning system must be carriedout in a well ventilated area. Always

observe the following precautions:

• R134a is odourless and colourless. Do nothandle or discharge in an enclosed area, orany area where the vapour and liquid cancome into contact with a naked flame or hotmetal. R134a is not flammable, but it cancause a highly toxic gas.

• Do not smoke or weld in areas where R134ais in use.

• Inhalation of concentrations of vapour cancause dizziness, disorientation,incoordination, narcosis, nausea or vomiting.

• Refrigerant R134a from domestic andcommercial sources must not be used inmotor vehicle air conditioning systems.

WARNING: HFC-134a (R134a) is ahazardous liquid which if handledincorrectly can cause serious injury. The

following precautions should be adhered to at alltimes when working on an air conditioningsystem:

• Suitable protective clothing must be wornwhen carrying out service operations on theair conditioning system.

• Air conditioning connections should beopened carefully to allow any liquid orpressure to bleed off slowly.

• Do not allow a refrigerant container to beheated by direct flame or to be placed nearany heating appliance. A refrigerant containermust not be heated above 50°C.

• Do not leave a refrigerant container withoutits cap fitted.

• Do not transport a refrigerant container thatis unrestrained (especially in the luggagecompartment of a car).

• Do not allow fluids, other than R134a orcompressor lubricant, to enter the airconditioning system; spontaneouscombustion could occur.

• R134a splashed onto exposed skin will causeimmediate freezing of that area.

• Refrigerant cylinders and replenishmenttrolleys can become cooled whendischarging, this could cause skin to becomefrozen to them if contact is made.

• The refrigerant used in an air conditioningsystem must be reclaimed in accordance withthe recommendations stipulated by aRefrigerant Recovery, Recycling &Recharging Station.


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GENERAL INFORMATION

2 AIR CONDITIONING PRECAUTIONS

Protective Clothing

NOTE: Suitable protective clothingcomprises:

• Wrap round safety glasses or helmet• Heat proof gloves

• Rubber apron, or waterproof overalls

• Rubber boots.

REMEDIAL ACTIONS

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

• If liquid R134a enters the eye, do not rub it.

Gently run large quantities of eye wash overaffected eye to raise the temperature. If an eyewash is not available, cool, clean water may beused to flush the eye. After rinsing, cover the eyewith a clean pad and seek immediate medicalattention.

• If liquid R134a is splashed onto the skin, runlarge quantities of water over the affected area toraise the temperature. Implement the sameaction if the skin comes in contact withdischarging cylinders. Wrap the contaminatedbody parts in blankets (or similar materials) and

seek immediate medical attention.

• If the debilitating effects of inhalation of R134avapour is suspected, seek fresh air. If theaffected person is unconscious, move them awayfrom the contaminated area to fresh air and applyartificial respiration and/or oxygen and seekimmediate medical attention.

WARNING: Due to its low evaporatingtemperature of -30°C, R134a should behandled with extreme care.


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GENERAL INFORMATION


SERVICE PRECAUTIONS

CAUTION: Observe the followingprecautions when handling componentsused in the air conditioning system:

• Air conditioning units must not be lifted bytheir hoses, pipes or capillary lines.

• Hoses and lines must not be subjected to anytwist or stress - the efficiency of the systemwill be impaired by kinks or restrictions.Ensure that hoses are correctly positionedbefore tightening couplings, and ensure thatall clips and supports are utilised.

• Flexible hoses should not be postioned closeto the exhaust manifold (less than 100mm)unless protected by heat shielding.

• Completed assemblies must be checked forrefrigeration lines touching metal panels. Anydirect contact of components and panels maytransmit noise and so must be eliminated.

• The appropriate torque wrench must be usedwhen tightening refrigerant connections tothe stipulated value. An additional spannermust be used to hold the union to preventtwisting of the pipe when tighteningconnections.

• Before connecting any hose or pipe, ensurethat refrigerant oil is applied to the seat of the

new ’O’ ring seals, BUT NOT to the threads ofthe connection.

• All protective plugs must remain in place toseal the component until immediately prior toconnection.

• Ensure components are at room temperaturebefore uncapping, to prevent condensation ofmoisture from the air that enters it.

• Components must not remain uncapped forlonger than 15 minutes. In the event of adelay, the caps must be fitted.

• When disconnecting, immediately cap all airconditioning pipes to prevent ingress of dirtand moisture into the system.

• The receiver/dryer contains desiccant whichabsorbs moisture. It must be positivelysealed at all times. A receiver/drier that hasbeen left uncapped must not be used, fit anew unit.

• The receiver/drier should be the lastcomponent connected to the system toensure optimum dehydration and maximummoisture protection of the system.

• Whenever the refrigerant system is opened,the receiver/dryer must be renewedimmediately before evacuating andrecharging the system.

• Use alcohol and a clean lint-free cloth toclean dirty connections.

• Ensure that all new parts fitted are marked foruse with R134a.

• When a major repair has been completed, aleak test should be conducted; refer to the airconditioning section of this manual for thecorrect procedure.


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GENERAL INFORMATION

4 AIR CONDITIONING PRECAUTIONS

Refrigerant oil

Use an approved refrigerant lubricating oil:

ND Oil 8

CAUTION: Do not use any other type ofrefrigerant oil.

CAUTION: Refrigerant oil easily absorbswater and must not be stored for longperiods. Do not pour unused oil back into

the container.

When renewing system components, add thequantities of refrigerant oil recommended in the AirConditioning section of this manual.

Compressor

A new compressor is sealed and pressurised withNitrogen gas. When fitting a new compressor, slowlyrelease the sealing cap; gas pressure should beheard to vent as the seal is broken.

CAUTION: A new compressor shouldalways have its sealing cap in place andmust not be removed until immediately

prior to fitting the compressor air conditioningpipes.

Rapid refrigerant discharge

CAUTION: If the air conditioning system isinvolved in accident damage and thesystem is punctured, the refrigerant will

discharge rapidly. The rapid discharge ofrefrigerant will also result in the loss of most ofthe oil from the system. The compressor must beremoved and all the remaining oil in thecompressor drained and refilled as instructed inthe air conditioning section of this manual.


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GENERAL INFORMATION


PRECAUTIONS FOR REFRIGERANT RECOVERY,RECYCLING AND RECHARGING

WARNING: Refrigerant must always berecycled before reuse to ensure that thepurity of the refrigerant is high enough for

safe use in the air conditioning system.

WARNING: Recycling should always becarried out with equipment which isdesign certified by Underwriter Laboratory

Inc. for compliance with SAE-J1991. Otherequipment may not recycle refrigerant to therequired level of purity.

A R134a Refrigerant, Recovery, Recycling andRecharging Station must not be used with anyother type of refrigerant.

CAUTION: When using an air conditioningportable Refrigerant, Recovery, Recyclingand Recharging Station the operator must

adhere to the equipment manufacturer’sinstructions.

CAUTION: The system must be evacuatedimmediately before rechargingcommences. Delay between evacuation

and recharging must not be permitted.

CAUTION: Overcharging the airconditioning system will cause excessivehead pressure.


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GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER 1

VEHICLE IDENTIFICATION NUMBER

Location

The Vehicle Identification Number (VIN) plate isattached to the LH ’B’ post.The VIN is also stamped in the following locations:

• At the centre top of the engine bulkhead.

• On a plate behind the LH lower corner of thewindscreen.

A - Vehicle Identification Number (VIN)

B - Gross vehicle weightC - Gross train weightD - Maximum front axle loadE - Maximum rear axle loadF - Paint CodeG - Trim Code

Vehicle identification number

Example: SALLNABB7VA600172

S = Geographic area (S = Europe)A = Country (A = UK)L = Manufacturer (L = Land Rover)LN = Marque/Model (LN = Freelander)A = Trim Level (A = Trim Level 1)B = Body

A = 3 door modelsB = 5 door models

B = Engine

A = K16 Petrol engine modelsB = TCIE Diesel engine models

7 = Transmission and Steering7 = RHD manual steering8 = LHD manual steering

V = Model change (V = 1997 Model year)A = Assembly plant (A = Solihull)6 figures = Serial number

Paint and Trim colour codes:

Paint Code (F) - 3-digit code identifying the original

Paint colour is stamped on the VIN plate:

Example: 601

601 = Rioja Red507 = Caledonian Blue603 = Chawton White624 = Cobar Blue618 = White Gold622 = Venetian Mauve587 = Altai Silver610 = Charleston Green961 = Epson Green416 = Beluga Black

Refer to Parts Catalogue for full list of colourcodes.

Trim (G) - a code identifying the original trim typeand colour is stamped on the VIN plate, refer to therelevant Parts Catalogue for coding details:


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GENERAL INFORMATION

2 VEHICLE IDENTIFICATION NUMBER

IDENTIFICATION NUMBER LOCATIONS

1. Vehicle identification number2. Engine number3. Gearbox number

Vehicle Identification Number

The VIN is displayed at the centre top of the enginebulkhead and on a plate behind the LH lower cornerof the windscreen.

Engine number

1.8 ’K’ Series Engine: Stamped on the front face ofthe cylinder block adjacent to the gearbox.

2.0 ’L’ Series Engine: Stamped on the front face ofthe cylinder block at top centre.

Gearbox number (3)

Manual Gearbox - PG1: Stamped on a labelattached to the front face of the clutch housing.


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INFORMATION

CONTENTS Page

LIFTING AND TOWING

JACKING 1..................................................................................................................TOWING 4...................................................................................................................TRANSPORTING THE VEHICLE BY TRAILER 5.......................................................EMERGENCY STARTING 5........................................................................................

GENERAL DATASTEERING 1...............................................................................................................DIMENSIONS 1...........................................................................................................WEIGHTS 2.................................................................................................................

COMPONENT LOCATIONSELECTRONIC CONTROL UNITS 1............................................................................

BODY REPAIRSBODY REPAIRS 1.......................................................................................................

BODY DIMENSIONSDIMENSIONAL INFORMATION 1...............................................................................GAPS AND PROFILES 12...........................................................................................

SEALING AND CORROSION PROTECTIONAPPROVED MATERIALS 1.........................................................................................MATERIALS APPLICATIONS 4..................................................................................

APPLICATION EQUIPMENT 5....................................................................................WATER LEAKS 8........................................................................................................


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INFORMATION

LIFTING AND TOWING 1

JACKING

The following instructions must be carried out beforeraising the vehicle off the ground:

• Use a solid level surface.

• Apply parking brake.• Select 1st. gear in main gearbox and ensure

HDC is not selected.

CAUTION: To avoid damage to under bodycomponents of the vehicle, adhere to thefollowing jacking procedures:

DO NOT POSITION JACKS OR AXLE STANDSUNDER THE FOLLOWING COMPONENTS:

• Bumpers

• Brake or Fuel lines

• Exhaust pipe• Suspension components

• Steering rack and linkages

• Fuel tank

• Engine sump

• Gearbox

Jack or support vehicle only on approvedjacking points as detailed in the illustrationbelow:


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INFORMATION

2 LIFTING AND TOWING


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INFORMATION


Vehicle jack

The jack provided with the vehicle is only intended tobe used in an emergency, for changing a tyre. DoNOT use the jack for any other purpose. Refer to theOwner’s Handbook for vehicle jack location pointsand procedure. Never work under a vehicle onlysupported by the vehicle jack.

Hydraulic jack

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

WARNING: Do not work on the undersideof a vehicle until suitable stands havebeen positioned.

Raising the front of a vehicle

Position the cup of the hydraulic arm under thecentre of the front body crossmember assembly.

Use jack to raise front road wheels to enable safetystands to be installed under the front end of eachlongitudinal member as shown.Carefully lower jack until vehicle sits securely onboth safety stands. Remove trolley jack.

Before working on the underside of a vehiclere-check the stability of the vehicle on the stands.

Use the reverse procedure when removing a vehiclefrom stands.

NOTE: For some repair operations it maybe necessary to use a jack to support theengine under the sump. In this case, a

block of wood should be used on the jack toprotect the sump.

Raising the rear of a vehicle

Position cup of hydraulic arm under the centre of therear subframe crossmember at the position identifiedby the embossed arrows.

Use jack to raise rear road wheels to enable safetystands to be installed under the rear ends of thebody longitidinal members as shown.Carefully lower jack until vehicle sits securely onboth safety stands. Remove trolley jack.

Before working on the underside of a vehicle,re-check the stability of the vehicle on the stands.

Use the reverse procedure when removing a vehiclefrom stands.

Wheel-free lift

Locate the lifting pads under the ends of the bodylongitudinal members shown. Raise the ramp tosupport the weight of the vehicle, ensure the vehicleis secure on the lifting pads, then raise the ramp tothe required height.


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INFORMATION


TOWING

CAUTION: The vehicle has permanentfour-wheel drive. The following towinginstructions must be adhered to:

Towing the vehicle on all four wheels with driveroperating steering and brakes.

• Turn ignition key turn to position ’1’ to releasesteering lock and then to position ’II’ to enablethe brake lights, wipers and direction indicatorsto be operated, if necessary.

• Select neutral in gearbox and ensure HDC (hilldescent control) is deselected.

• Secure tow rope, chain or cable to towing eye.

• Release the parking brake.

CAUTION: The brake servo and powerassisted steering system will not befunctional without the engine running.

Greater pedal pressure will be required to applythe brakes and the steering system will requiregreater effort to turn the front road wheels.The vehicle tow connection should only be usedunder normal road conditions, ’snatch’ recovery

should be avoided.

Suspended tow by breakdown vehicle

CAUTION: To prevent vehicle damage,rear propeller shaft MUST BE removed.

Mark propeller shaft drive flanges and matingflanges with identification lines to enable thepropeller shaft to be refitted in its original position.

Remove the propeller shaft fixings then remove theshaft from the vehicle.

If the front of the vehicle is to be trailed, turn ignitionkey to position ’I’ to release steering lock.

CAUTION: If it is considered unsafe to turnthe starter switch to position ’I’ due toaccident damage or an electrical fault;

disconnect the battery before turning the ignitionswitch.

WARNING: Do not turn the starter switchto position ’0’ or remove the ignition keywhile the vehicle is being towed.

CAUTION: The steering wheel and/orlinkage must be secured in a straightahead position. DO NOT use the steering

lock mechanism for this purpose.

CAUTION: Under no circumstancesshould the vehicle be towed or recoveredby means of lashing to the rear subframe.

Serious damage to the subframe and body couldresult.

CAUTION: Only use the rear towing eyefor towing another vehicle.


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INFORMATION


TRANSPORTING THE VEHICLE BY TRAILER

Lashing rings are provided at the front and rear ofthe body to facilitate the securing of the vehicle to atrailer or other means of transportation.

CAUTION: Underbody components mustnot be used as lashing points. The lashingrings must not be used for towing.

Install the vehicle on trailer and apply the parkingbrake. Select neutral.

EMERGENCY STARTING

WARNING: Hydrogen and oxygen gasesare produced during normal batteryoperation. This gas mixture can explode if

sources of combustion (e.g. flames, sparks orlighted tobacco etc.) are brought near thebattery. When charging or using a battery in anenclosed space, always ensure ventilation andwear eye protection (goggles etc.).

WARNING: Keep dangerous substancesout of the reach of children.Batteries contain sulphuric acid; avoid

contact with skin, eyes, or clothing.If handling batteries, wear a protective industrialapron and gloves and wear safety goggles toprotect against possible splashing of acid

solution.In case of acid contacting with skin, eyes, orclothing; flush immediately with water for aminimum of fifteen minutes.If acid is swallowed, drink large quantities ofmilk or water, followed by milk of magnesia, abeaten egg, or vegetable oil.

SEEK MEDICAL AID IMMEDIATELY.

To Jump Start - Negative Ground Battery

WARNING: To avoid any possibility ofinjury use particular care when connectinga booster battery to a discharged battery.

Position vehicles so that jump leads will reach,ensuring that vehicles DO NOT TOUCH,alternatively a fully charged slave battery may bepositioned on the floor adjacent to the vehicle.

Ensure that:

• the ignition and all electrical accessories areswitched off

• the parking brake is applied and neutral isselected on gearbox


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INFORMATION


Connect the jump leads as follows:

WARNING: Making final cable connectioncould cause an electrical arc which ifmade near battery could cause an

explosion.

A. Connect one end of first jumper cable topositive (+) terminal of booster battery.

B. Connect other end of first jumper cable topositive (+) terminal of discharged battery.

C. Connect one end of second jumper cable tonegative terminal of booster battery.

D. Connect other end of second jumper cable to agood earth point on the engine, NOT TONEGATIVE TERMINAL OF DISCHARGEDBATTERY.

CAUTION: Keep jumper leads away frommoving parts, pulleys, drive belts and fanblade assembly.

If the booster battery is installed in another vehicle,start engine and allow to idle.

Start engine of vehicle with discharged battery,following starting procedure in Owners’ Handbook.

CAUTION: If vehicle fails to start within amaximum time of 12 seconds, switchignition off and investigate cause. Failure

to follow this instruction could result inirreparable damage to catalyst.

To disconnect:

• Remove negative (-) jumper cable from theengine and then terminal of booster battery.

• Remove positive (+) jumper cable from positiveterminals of booster battery and dischargedbattery.


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INFORMATION

GENERAL DATA 1

STEERING

Type Power assisted rack and pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering column Height adjustable by 3.5° or 30 mm vertical movement of. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

steering wheel

Turns - lock to lock: 3.16. . . . . . . . . . . . . . . . . . . . . . . . . .Turning circle 11.6 m (38.1 ft) kerb to kerb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel alignment (unladen)Front:Camber angle - 0° 15’ ± 45’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Castor angle 3° 30’ ± 1°. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .King pin inclination 12° 18’. . . . . . . . . . . . . . . . . . . . . . . . . . .Toe - 0° 10’ ± 5’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear:Camber angle - 0° 30’ ± 45’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thrust angle 0° 0’ ± 5’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Toe + 0° 20’ ± 15’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Assistance SystemMaximum Operating Pressure 9203 -300 kPa (1334 -43.5 lbf.in2), limited by pressure. . . . . . . . . . . . . . . . . .

relief valve in pumpMaximum flow 5.5 -0.5 litres/min. (1.45 -0.13 US gal/min), limited by flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

control valve in pumpDisplacement

1.8 ’K’ Series 8.2 cm3 /rev (0.50 in3 /rev). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0 ’L’ Series 9.5 cm3 /rev (0.58 in3 /rev). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIMENSIONS

Overall length (inc. spare) 4.382 m. . . . . . . . . . . . . . . . . . . . .Overall width:

Including mirrors 2.074 m. . . . . . . . . . . . . . . . . . . . . . . . . . .Excluding mirrors 1.805 m. . . . . . . . . . . . . . . . . . . . . . . . . . .

Overall height (including roof rails)* 1.757 m. . . . . . . . . . . . . .Ground clearance *:

Front 186 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running 220 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear 214 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheelbase 2.555 m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhang:

Front 836 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear (inc. spare wheel) 989 mm. . . . . . . . . . . . . . . . . . . . . .

Track:Front 1534 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear 1545 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* At unladen weight


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INFORMATION

2 GENERAL DATA

WEIGHTS

Unladen weight (no options):Petrol models 1380 - 1425 kg. . . . . . . . . . . . . . . . . . . .

freelander 1 my98 - body repair manual

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