General Information Land Rover Range Rover L322

INTRODUCTION

This information 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 information.

This information 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 information 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 INFORMATION

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 . 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.

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

1. Blue - Indicates the target item, item to be removed/installed or disassembled/assembled
2. Green and Brown - Indicates a secondary item that needs to be detached, removed/installed or disassembled/assembled prior to the target item
3. Magenta - Indicates electrical connectors and fasteners such as nuts, bolts, clamps or clips
4. 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).

Scheme 1

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.

Scheme 2

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.

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 INFORMATION

This information 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 information Part number: LRL0477.

The information 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.

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 INFORMATION ORGANIZATION

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

1. Section 1 - General Information.
2. Section 2 - Chassis.
3. Section 3 - Powertrain.
4. Section 4 - Electrical.
5. Section 5 - Body and Paint.

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 information 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 information cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in the information must first establish that neither personal safety or vehicle integrity is compromised from choices of methods, tools or parts.

VEHICLE IN WORKSHOP

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

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

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

BATTERY - GENERAL

Jump Starting a Vehicle

1. Always make sure that the jumper cables are adequate for the task.
2. 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.
3. Make sure that the battery terminals of both batteries are fully tightened.
4. Where another vehicle is used to jump start a disabled vehicle, make sure that the two vehicles are not touching.
5. It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to make sure that the battery of the donor vehicle does not also become discharged.
6. 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. Make sure that the battery terminals are fully tightened prior to trickle charging.

TOWING THE VEHICLE

COMPONENT REMOVAL

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

1. Blank off openings exposed by component removal.
2. Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
3. Seal open ends of exposed oil ways using suitable tapered hardwood plugs or conspicuous plastic plugs.
4. Immediately a component is removed, place it in a suitable container; use a separate container for each component and its associated parts.
5. 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.

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

1. Discard all seals and O-rings and replace with new when reassembling.
2. Use suitable marker ink to identify mating parts, do not use a scriber or center punch as they could initiate cracks or distortion.
3. Wire or tape mating parts together where necessary to prevent accidental interchange.
4. Suitably identify parts which are to be renewed and parts requiring further inspection. Keep these parts separate.
5. To make sure 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 make sure that the component being cleaned is compatible with the cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure 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.

1. Always make sure that component to be inspected is clean and free from oil or grease.
2. 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).
3. Always make sure that all measuring equipment is correctly calibrated before use.
4. Reject a component which is not within specified values/limits or if it appears to be damaged.
5. A component may be reinstalled if dimensions obtained during checking are at the maximum tolerance limit and it is in an undamaged condition.
6. Bearing journal clearances should be checked where necessary using Plastigage.
7. Gaskets, seals and O-ring seals are to be re-used unless damaged.

JOINTS AND JOINT FACES

All gaskets should be installed dry unless stated otherwise. 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.

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.

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 make sure that replacement pins are of the correct size for the hole in which they are to be installed.

SCREW THREADS

1. 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.

1. 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.
2. Always make sure 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.
3. 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.
4. Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque reading.
5. 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.
6. 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.
7. 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

1. Check that threads are undamaged.
2. Remove all traces of locking agent from the threads.

1. make sure that threads are clean and free from oil or grease.
2. Apply the specified locking agent to the bolt threads.

Scheme 3

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.

Scheme 4

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.

Scheme 5

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.

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

AIR SUSPENSION

Always make sure that suitable eye protection is worn when working on the air suspension system.

BALL AND ROLLER BEARINGS

When removing and installing bearings, make sure that the following practices are observed to make sure component serviceability

1. Remove all traces from bearing under inspection by cleaning with a suitable degreasant; maintain absolute cleanliness throughout operations.
2. 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.
3. 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.
4. 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.
5. Check bearing for blueing or signs of overheating.
6. Lubricate bearing with the specified lubricant.
7. Inspect bearing surface of shaft and bearing housing for discoloration or other markings which indicate overheating of bearing or movement between bearing and seating.
8. Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
9. 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.
10. Never reinstall a bearing unless it is in a fully serviceable condition.

Scheme 6

1. 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.

1. 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.

1. Always make suitable reference marks between the components of separable bearings e.g. taper roller bearings when disassembling to make sure 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

1. Always use two spanners when loosening or tightening brake pipes or hose connections.
2. Make sure that hoses run in a natural curve and are not kinked or twisted.
3. Install brake pipes and hoses securely in their retaining clips and make sure that they cannot contact a potential chafing point.
4. Containers used for brake fluid must be kept absolutely clean.
5. Do not store brake fluid in unsealed containers, the fluid will absorb water which will lower the boiling point of the fluid.
6. 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.
7. Do not re-use brake fluid which has been bled from the system.
8. Always use brake fluid or a suitable brake cleaning fluid to clean hydraulic components.
9. Unless stated otherwise, use only clean brake fluid to lubricate hydraulic seals and components.
10. Always install blanking plugs to hoses, pipes or components immediately after disconnection.
11. Check thread compatibility of original equipment with replacement components.
12. Observe absolute cleanliness when working with hydraulic components.

PIPES AND HOSES

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

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

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

1. When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not kinked, twisted or positioned close to potential chafing points.
2. When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing points.
3. Always replace sealing washers installed to banjo bolts, sealing plugs etc.
4. Always use a backing spanner when tightening unions and do not over tighten union nuts or banjo bolts.
5. After engagement of 'quick-fit' connection hoses, perform a 'tug' test to make sure connection is secure.
6. 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 armored rubber outer sleeve and an inner viton core. Whenever a hose is removed, make sure that the inner bore is inspected to check that the viton lining has not become separated from the outer sleeve.

Fuel system hose clips

Scheme 7

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

Hose orientation and connection

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

Scheme 8

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 molded form on a pipe provides a positive indicator.

Hose clips

Scheme 9

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). Make sure that hose clips do not foul adjacent components.

Scheme 10

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, make sure clip is positioned on hose before tightening and make sure 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 make sure 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, make sure this movement is taken into account when routing and securing hoses.

The following guidelines are intended to make sure 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, make sure 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 make sure 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

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

1. Safety goggles and gloves must be worn.
2. Make sure that headlamps are switched off before removing bulbs.
3. Do not touch the glass portion of the bulb.
4. On no account should headlamps be switched on with the bulb removed from the headlamp.
5. Bulb testing may only be carried out with the bulb installed in the headlamp.
6. 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

1. Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
2. Make sure 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.
3. Never force connectors apart or pull on the wiring harness.
4. Always make sure locking tabs are disengaged before disconnecting electrical connectors etc. and make sure that correct orientation is achieved before connection.
5. Make sure that any protection covers, insulation etc. are replaced if disturbed.

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

1. Switch off the ignition and disconnect the battery.
2. Remove the component and support the disconnected harness.
3. When replacing electrical components, keep oily hands away from electrical connections and make sure that locking tabs on connectors are fully engaged.

BATTERY DISCONNECTION/CONNECTION

Always refer to the Electrical Section of this information - Battery Disconnect/Connect prior to attempting to connect or disconnect the battery. Refer to 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.

Make sure that suitable warning signs are exhibited.

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

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

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 information.

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

FUEL TANK REPAIRS

OIL SEALS

Never use a seal which has been improperly stored or handled.

1. Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
2. Carefully examine seal before installation to make sure that it is clean and undamaged.
3. Make sure 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.
4. Special tools and protection sleeves are provided for installing the majority of seals and must be used when specified.
5. 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, make sure 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.
6. Make sure 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.
7. When installing an oil seal, make sure 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.

1. 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.

Scheme 11

1. 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. Make sure that the seal is not tilted in the housing when it is installed.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) PRECAUTIONS

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 emphasize the importance of ensuring the integrity of the SRS components installed to the vehicle.

1. The correct procedures must always be used when working on SRS components.
2. Persons working on the SRS must be fully trained and have been issued with the safety guidelines.
3. 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.
4. Always replace a safety belt assembly that has withstood the strain of a severe vehicle impact or if the webbing shows signs of fraying.
5. Allow a period of 10 minutes to elapse after disconnecting the battery before undertaking any work on the SRS.
6. Always disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with SRS.

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

1. Driver air bag, clockspring.
2. Passenger air bag.
3. Side Air Curtains - front and rear.
4. Safety belt pre-tensioners.
5. SRS harnesses, link leads and connectors.

Making the system safe

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

1. Remove the ignition key.
2. Disconnect the battery, earth lead first.
3. 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 make sure 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.

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

Note. 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 make sure full SRS protection.

Note. 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

Handling and storage

Always observe the following precautions when handling SRS components

1. 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.
2. 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.
3. 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.
4. 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.
5. Always keep components cool, dry and free from contamination.
6. Never apply grease or cleaning solvents to safety belt pre-tensioner units, component failure could result.
7. 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.
8. Keep new air bag modules in their original packaging until just prior to installation. Place the old module in the empty packaging for carriage.

SRS harness and connectors

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

1. Never attempt to modify, splice or repair SRS wiring.
2. 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).

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.

Clockspring

1. Do not unlock and rotate the clockspring when it is removed from the vehicle.
2. Do not turn the road wheels when the clockspring is removed from the vehicle.
3. Always make sure 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.
4. If a new clockspring is being installed, make sure 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

Deployment procedures and precautions as detailed in this information 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

1. Only use deployment equipment approved for the intended purpose.
2. Deployment of air bag/pre-tensioner modules must be performed in a well ventilated area which has been designated for the purpose.
3. Make sure air bag/pre-tensioner modules are not damaged or ruptured before attempting to deploy.
4. Where local legislation exists, notify the relevant authorities of intention to deploy air bag and pretensioner units.
5. When deploying air bag pre-tensioner units, make sure that all personnel are at least 15 meters (45 feet) away from the deployment zone.
6. Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS section of this information. In particular, make sure deployment tool is NOT connected to battery supply before connecting to air bag module connector.
7. When deploying safety belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
8. When removing deployed air bag modules and pre-tensioner units, wear protective clothing. Use gloves and seal deployed units in a plastic bag.
9. 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.
10. 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, make sure 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

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

1. Driver air bag module
2. Passenger air bag module
3. Fly leads (where applicable) connecting front air bag modules to SRS harness
4. Front safety belt buckle pre-tensioner
5. Rear safety belt pre-tensioners - if installed
6. Driver safety belt retractor - if installed
7. Clockspring
8. Any front impact sensors that have been physically damaged or if a fault is being registered
9. 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

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

Side Air Bags

1. Side air curtains
2. Any side impact sensors that have been physically damaged or if a fault is being registered
3. 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

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

Side Air Curtain modules

1. Side air curtain modules
2. Link lead between side air curtain gas generator and restraints control module (RCM) harness
3. Side air curtain module retaining clips
4. Internal trim finisher
5. Front safety belt buckle pre-tensioners
6. Any side impact sensors that have been physically damaged or if a fault is being registered
7. 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

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

Rear impacts

1. Safety belt pre-tensioners
2. Front and rear safety belt retractors deployed during the impact
3. 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

1. Safety belt height adjusters
2. Front safety belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
3. 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 emphasize 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 information 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.

Remedial actions

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

1. 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.
2. 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.
3. If the debilitating effects of inhalation of R134a vapor 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

1. A/C units must not be lifted by their hoses, pipes or capillary lines.
2. Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by kinks or restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make sure that all clips and supports are utilized.
3. Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected by heat shielding.
4. 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.
5. 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.
6. Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings, BUT NOT to the threads of the connection.
7. All protective plugs or caps must remain in place in the component until immediately prior to connection.
8. Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of moisture from the air that enters it.
9. When disconnecting, immediately plug or cap all pipes to prevent ingress of dirt and moisture into the system.
10. 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.
11. 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; install a new unit.
12. The receiver/drier should be the last component connected to the system to make sure optimum dehydration and maximum moisture protection of the system.
13. Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new receiver/drier unit.
14. Use alcohol and a clean lint-free cloth to clean dirty connections.
15. Make sure that all new parts installed are marked for use with R134a.
16. When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this information for the correct procedure.

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 pressurized 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.

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 information.

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.

A/C Compressor Replacement

A new compressor is supplied filled with a full charge (X cm 3 ) 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

1. Remove the drain plug from the old compressor.
2. Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor clutch to make sure the compressor is completely drained.
3. Note the quantity of oil drained (Y cm 3 ).
4. Calculate the quantity of oil to be drained from the new compressor using the following formula: X cm 3 - (Y cm 3 + 20 cm 3 ) = Q cm 3
5. Remove the drain plug from the new compressor and drain Q cm 3 of oil. Install and tighten the compressor drain plug.

IDENTIFYING VEHICLE WEIGHTS AND DIMENSIONS

VEHICLE WEIGHTS

* 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

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

This information 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 information Part number: LRL0477.

The information 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.

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.

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

1. Section 1 - General Information.
2. Section 2 - Chassis.
3. Section 3 - Powertrain.
4. Section 4 - Electrical.
5. Section 5 - Body and Paint.

Glossary of Terms

This glossary of terms is intended to cover mainly emissions-related (to SAE J 1930) terminology, and other abbreviations that may be used in this information.

The required term may be looked-up in the left-hand column, and subsequent columns give the standard acronym, unit or abbreviation, and definition.

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.

ACIDS AND ALKALIS

For example - alkalis such as caustic soda used in cleaning materials; acids such as sulfuric 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

1. Wash affected areas thoroughly with water.
2. SEEK IMMEDIATE MEDICAL ASSISTANCE.

Air Bags - Do's

1. Do store modules in an upright position.
2. Do keep modules dry.
3. Do carry modules with the cover side pointing away from the body.
4. Do place modules with their cover side upwards.
5. Do carefully inspect modules for damage.
6. Do stand to one side when connecting modules.
7. Do make sure all test equipment is properly calibrated and maintained.
8. Do wash hands after handling deployed air bags.

Air Bags - Do Not

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

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.

Do Not

1. Do Not expose refrigerant bottles to sunlight or heat.
2. Do Not expose refrigerant bottles to frost.
3. Do Not drop refrigerant bottles.
4. Do Not vent refrigerant to atmosphere under any circumstance.
5. 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 vapor 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.

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

1. 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.
2. Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned.
3. Do organize work practices and protective clothing to avoid soiling of the skin and eyes.
4. Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and explosion hazards.
5. Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials.
6. Do keep work areas clean, uncluttered and free of spills.
7. Do store chemical materials according to national and local regulations.
8. Do keep chemical materials out of the reach of children.

CHEMICAL MATERIALS - DO NOT

1. 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.
2. Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example when people are inside a vehicle.
3. 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.
4. 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.
5. Do Not transfer chemical materials to unlabeled containers.
6. 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.
7. Do Not use emptied containers for other materials except when they have been cleaned under supervised conditions.
8. 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

1. Switch off the power supply before approaching the victim.
2. 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.
3. Commence resuscitation if trained to do so.
4. 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 odor 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.

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 vapor/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 vapor 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/in 2 ) 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 information 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.

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

1. Avoid prolonged and repeated contact with oils, particularly used engine oils.
2. Wear protective clothing, including impervious gloves where practicable.
3. Do not put oily rags into pockets.
4. Avoid contaminating clothes, particularly underpants, with oil.
5. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly.
6. First Aid treatment should be obtained immediately for open cuts and wounds.
7. Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
8. 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.
9. Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
10. If skin disorders develop, obtain medical advice without delay.
11. Where practicable, degrease components prior to handling.
12. 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 minimized, 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 minimize 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

1. Store liquids in a secure area.

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

1. Protect bulk storage tanks from vandalism by locking the valves.

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

1. Ensure lids are replaced securely on containers.

1. 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

1. Know what legal consents and licences apply to the operations.

1. 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

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

1. Refrigerant: Collect in specialist equipment and reuse.

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

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

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

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

1. Metals: Can be sold if separate from general waste.

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

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

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

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

1. Rubber/plastics: Dispose of in ordinary waste.

1. Hoses: Dispose of in ordinary waste.

1. Batteries: Keep separate and dispose of to specialist contractors.

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

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

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

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

1. 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

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 neutralize 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.

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.

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 information 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.

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 information cannot be carried out properly without the aid of the relevant service tools.

ROAD/ROLLER TESTING

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

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.

1. Engine oil level
2. Engine coolant level
3. Tires, for correct pressure, compatible types and tread patterns, and wear within limits.
4. There is sufficient fuel in the tank to complete the test.
5. 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

1. The parking brake is applied.
2. Automatic gearbox: The selector lever is in 'P' - Park
3. Transfer case: 'H' - High is selected
4. All instrument gauges read zero.

With the ignition switched on, check

1. Ignition controlled warning lights come on.
2. Engine temperature gauge registers a reading compatible with the engine temperature.
3. Fuel gauge registers a reading appropriate to the fuel level in the tank.
4. The operation of the parking brake warning light and fluid level warning indicator light.

ON ROAD TEST CHECK

1. The parking brake releases completely.
2. Gear changing is smooth, and there are no abnormal noises or vibrations from the gearbox.
3. 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.
4. There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun conditions.
5. Steering operation is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does not pull to one side and self centers smoothly after cornering.
6. All instruments register the correct readings and operate correctly.
7. 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.
8. Heating and ventilation systems work correctly and effectively.
9. Brakes operate efficiently.

BRAKE TESTING

Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users.

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

1. Oil, coolant, hydraulic, air and fuel leaks.
2. 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

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

BLUETOOTH MODULE (TEL)

Note. If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval program is in operation, prior to the installation of a new module/component.

Note. Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read by the manufacturer-approved diagnostic system).

Note. Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

Note. Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.

Note. If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be the cause. Always check for loose connections and corroded terminals.

The table below lists all Diagnostic Trouble Codes (DTCs) that could be logged in the Bluetooth Module, for additional Diagnosis and Testing information refer to the relevant Diagnosis and Testing. For additional information, refer to: Cellular Phone (415-00 Information and Entertainment System - General Information, Diagnosis and Testing).

See also:
• Specifications
• Specifications