Land Rover Freelander 1 MY98 Body Repair Manual (LRL 0154ENG)

FREELANDE

Body Repair Manual

reparatiehandboek

Manuel de réparation

Karosseriereparaturanleitung

Manuale delle operazioni di

riparazione della carrozzeria

de carrosserie

R

Carrosserie

Manual de reparaciones

de carrocería

Manual de reparações

da carroçaria

FREELANDER

BODY REPAIR

MANUAL

INTRODUCTION
GENERAL INFORMATION
INFORMATION

RESTRAINT SYSTEMS
BODY

PANEL REPAIRS

Publication Part No. LRL 0154ENG
Published by Rover Technical Communication
 1998 ROVER GROUP LIMITED

INTRODUCTION

CONTENTS

INTRODUCTION

INTRODUCTION 1......................................................................................................

REPAIRS AND REPLACEMENTS 2...........................................................................

SPECIFICATION 2......................................................................................................

Page

INTRODUCTION

INTRODUCTION

How to use this Manual

This Body Repair Manual is designed to provide the
experienced Body Shop technician with the
information required to carry out efficient and
cost-effective repairs.

For ease of use, this Manual is structured to display
the section title at the top of each page and the
relevant sub-section at the bottom of each page. In
addition, a section icon is displayed at the top outer
corner of right-hand pages.

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

Technical data is subject to change; to facilitate the
periodic revision of technical information, each
sub-section is numbered from page 1 so that revised
sub-sections can be replaced if required.

The individual steps of procedures are to be
performed in the sequence in which they appear.
Where item numbers appear in the Figure of a
procedure, those items are referred to in the text.

References

References to the LH or RH side given in this
Manual are made when viewing the vehicle from the
rear.

Cross references may be made to sections not
included in this manual. In these cases, refer to the
relevant Workshop Manual for the referenced
information.

Operations covered in this Manual do not include
instructions for testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle should be conducted.

WARNING: It is particularly important to
test a vehicle after repairs to safety related
items have been performed.

Dimensions

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

WARNINGS, CAUTIONS and NOTES have the
following meanings:

WARNING: Procedures which must be

followed precisely to avoid the possibility
of injury.

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

NOTE: Gives helpful information.

INTRODUCTION 1

INTRODUCTION

REPAIRS AND REPLACEMENTS

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

The following points concerning repairs and the
fitting of replacement parts and accessories is
emphasised:

• Safety features and corrosion prevention
treatments embodied in the vehicle may be
impaired if other than Land Rover recommended
parts are fitted.

• In certain territories, legislation prohibits the
fitting of parts which are not compliant with the
manufacturer’s specification.

• Torque figures shown in this Manual should be
used where specified.

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

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

• Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
installation or application conform to the legal
requirements of the territory.

• The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Land Rover
recommended parts.

• All Land Rover recommended parts are covered
under the terms of the vehicle Warranty.

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

SPECIFICATION

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

This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover Dealers are not
agents of Land Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.

2

INTRODUCTION

GENERAL INFORMATION

CONTENTS

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL PRECAUTIONS 1......................................................................................

Dangerous substances 1.............................................................................................

Engine oils 2................................................................................................................

Health Protection Precautions 2..................................................................................

Environmental Protection Precautions 2......................................................................

SAFETY INSTRUCTIONS 3........................................................................................

GENERAL FITTING INSTRUCTIONS 4......................................................................

BALL AND ROLLER BEARINGS 6..............................................................................

OIL SEALS 7...............................................................................................................

JOINTS AND JOINT FACES 8....................................................................................

LOCKING DEVICES 8.................................................................................................

SCREW THREADS 9..................................................................................................

BOLT IDENTIFICATION 9...........................................................................................

NUT IDENTIFICATION 10...........................................................................................

FLEXIBLE HYDRAULIC PIPES AND HOSES 11........................................................

SERVICE TOOLS AND GARAGE EQUIPMENT 12....................................................

DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES 12....................

DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) 13......

FUEL HANDLING PRECAUTIONS

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

Page

ELECTRICAL PRECAUTIONS

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

SRS PRECAUTIONS

SUPPLEMENTARY RESTRAINT SYSTEM PRECAUTIONS 1..................................

COMPONENT REPLACEMENT POLICY 9................................................................

AIR CONDITIONING PRECAUTIONS

AIR CONDITIONING SYSTEM PRECAUTIONS 1......................................................

REMEDIAL ACTIONS 2...............................................................................................

SERVICE PRECAUTIONS 3.......................................................................................

PRECAUTIONS FOR REFRIGERANT RECOVERY, RECYCLING AND

RECHARGING 5..........................................................................................................

VEHICLE IDENTIFICATION NUMBER

VEHICLE IDENTIFICATION NUMBER 1....................................................................

IDENTIFICATION NUMBER LOCATIONS 2...............................................................

GENERAL INFORMATION

GENERAL PRECAUTIONS

Dangerous substances

WARNING: Many liquids and other
substances used in motor vehicles are
poisonous and should not be consumed

under any circumstances.

As far as possible, try to prevent skin contact
with any potentially harmful materials.
Substances to be treated with particular caution
include (but is not limited to): acid, anti-freeze,
asbestos, brake fluid, fuel, windscreen washer
additives, lubricants, refrigerant and various
adhesives.

Always read the instructions printed on labels or
stamped on components carefully.
Such instructions should be strictly complied
with; they are included to ensure your health and
personal safety is not compromised through the
incorrect use of the materials to which they
relate.

Synthetic rubber

WARNING: Many ’O’ rings, seals, hoses,
flexible pipes and other similar items

which appear to be natural rubber, are in
fact, made of synthetic materials called
Fluoroelastomers.
Under normal operating conditions this material
is safe and does not present a health hazard.
However, if the material is damaged by fire or
excessive heating, it can break down and
produce highly corrosive Hydrofluoric acid
which can cause serious burns on contact with
skin.

If skin contact does occur:

• Remove any contaminated clothing immediately.

• Irrigate effected area of skin with a copious

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

• Obtain medical assistance immediately
Should any material be in a burnt or over-heated

condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.).
Decontaminate and dispose of gloves immediately
after use.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1

GENERAL INFORMATION

Engine oils

WARNING: Prolonged and repeated
contact with mineral oil can result in the
removal of natural fats from the skin; this

may cause dryness, irritation and dermatitis.

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

Avoid excessive skin contact with used engine
oils and always adhere to the following health
protection recommendations:

Health Protection Precautions

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

• Wear protective clothing, including
impervious gloves where practicable.

• Do not put oily rags in pockets.

• Avoid contaminating clothes (particularly

underpants) with oil.

• Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.

• First aid treatment should be obtained
immediately for open cuts and wounds.

• Use barrier creams: apply before each work
period to help removal of engine oil from the

skin.

• Wash with soap and water to ensure all oil is
removed (propriety skin cleansers and nail
brushes will help).

• Use moisturisers after cleaning; preparations
containing lanolin help replace the skin’s
natural oils which have been removed.

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

• If skin disorders develop, obtain medical
advice without delay.

• Where practicable, degrease components
prior to handling.

• Wear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in the
close vicinity of the work area.

Environmental Protection Precautions

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

Burning of used engine oil in small space heaters or
boilers should only be considered for units of
approved design and in compliance with the
equipment manufacturer’s recommendations. The
heating system must meet the regulatory standards
of HMIP for small burners of less than 0.4 MW. If in
doubt check with the appropriate local authority
and/or manufacturer of the approved appliance.

Dispose of used oil and filters through authorised
waste disposal contractors and licensed waste
disposal sites, or through the waste oil reclamation
trade. If in doubt, contact the Local Authority for
advice on disposal facilities.

2

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL INFORMATION

Precautions against damage

CAUTION: Always fit wing and seat covers
before commencing work. Avoid spilling
brake fluid or battery acid on paintwork;

immediately wash off with water if this occurs.

CAUTION: Disconnect the battery earth
lead before starting work, see
ELECTRICAL PRECAUTIONS.

CAUTION: Always use the recommended
service tool or a satisfactory equivalent
where specified.

CAUTION: Protect exposed bearing
surfaces, sealing surfaces and screw
threads from damage.

SAFETY INSTRUCTIONS

Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.

Jacking

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

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

Apply the handbrake and chock the wheels.

WARNING: Never rely on a jack as the sole
means of support when working beneath
the vehicle. Use additional safety supports

beneath the vehicle.

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

Brake shoes and pads

WARNING: Always fit the correct grade
and specification of brake linings.

When renewing brake pads and brake
shoes always replace as complete axle sets
only.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 3

GENERAL INFORMATION

Brake hydraulics

WARNING: It is imperative that the correct
brake fittings are used and that threads of
components are compatible.

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

• Ensure that hoses run in a natural curve and are
not kinked or twisted.

• Fit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.

• Containers used for hydraulic fluid must be kept
absolutely clean.

• Do not store hydraulic fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.

• Do not allow hydraulic fluid to be contaminated
with mineral oil, or use a container which has
previously contained mineral oil.

• Do not re-use fluid from the system.

• Always use clean brake fluid or a recommended

alternative to clean hydraulic components.

• Fit a blanking cap to an hydraulic union and a
plug to its socket after removal to prevent the
ingress of dirt.

GENERAL FITTING INSTRUCTIONS

Component removal

Whenever possible, clean components and
surrounding area before removal.

• Blank off openings exposed by component
removal.

• Immediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or plugs
to prevent loss of fluid and ingress of dirt.

• Close open ends of oilways exposed by
component removal with tapered hardwood plugs
or conspicuous plastic plugs.

• Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.

• Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.

CAUTION: Absolute cleanliness must be

observed with hydraulic components.

Engine coolant caps and plugs

WARNING: Extreme care is necessary
when removing engine coolant caps and

plugs when the engine is hot and
especially if it is overheated. To avoid the
possibility of scalding allow the engine to cool
before attempting coolant cap or plug removal.

4

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL INFORMATION

Dismantling

Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on.

CAUTION: A particle of dirt or a cloth

fragment could cause a serious

malfunction if trapped in these systems.

• Blow out all tapped holes, crevices, oilways and

fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed during the process.

• Use marking ink to identify mating parts and

ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could initiate
cracks or distortion in marked components.

• Wire together mating parts where necessary to

prevent accidental interchange (e.g. roller
bearing components).

• Wire labels on to all parts which are to be

renewed, and to parts requiring further inspection
before being passed for reassembly; place these
parts in separate containers from those
containing parts for rebuild.

• Do not discard a part due for renewal until after

comparing it with a new part, to ensure that its
correct replacement has been obtained.

Cleaning components

Always use the recommended cleaning agent or
equivalent.

WARNING: Ensure that adequate
ventilation is provided when volatile
degreasing agents are being used.

CAUTION: Do not use degreasing
equipment for components containing
items which could be damaged by the use

of this process.

General Inspection

• Never inspect a component for wear or
dimensional check unless it is absolutely clean; a
slight smear of grease can conceal an incipient
failure.

• When a component is to be checked
dimensionally against recommended values, use
the appropriate measuring equipment (surface
plates, micrometers, dial guages etc.). Ensure
the measuring equipment is calibrated and in
good serviceable condition.

• Reject a component if its dimensions are outside
the specified tolerances, or if it appears to be
damaged. A part may be refitted if its critcal
dimension is exactly to its tolerance limit and it
appers to be in satisfactory condition.

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

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 5

GENERAL INFORMATION

BALL AND ROLLER BEARINGS

CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.

CAUTION: When hub bearings are
removed or displaced, NEW bearings must
be fitted; do not attempt to refit the old

hub bearings.

• Remove all traces of lubricant from bearing
under inspection by cleaning with a suitable
degreaser; maintain absolute cleanliness
throughout operations.

• Conduct a visual inspection for markings on
rolling elements, raceways, outer surface of outer
rings or inner surface of inner rings. Reject any
bearings found to be marked, since marking in
these areas indicates onset of wear.

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

• Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation. Reject bearing if
action is not perfectly smooth.

• Lubricate bearing with generous amounts of
lubricant appropriate to installation.

• Inspect shaft and bearing housing for
discoloration or other markings which indicate

movement between bearing and seatings.

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

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

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

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

• Always mark components of separable bearings
(e.g. taper roller bearings) when dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring; always fit a complete new
bearing assembly.

6

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL INFORMATION

OIL SEALS

Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly).

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

• Ensure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.

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

• Lubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease.

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

• Place lip of seal towards fluid to be sealed and
slide into position on shaft. Use fitting sleeve
where possible to protect sealing lip from
damage by sharp corners, threads or splines. If a
fitting sleeve is not available, use plastic tube or
tape to prevent damage to the sealing lip.

• Grease outside diameter of seal, place square to
housing recess and press into position using
great care, and if possible a ’bell piece’ to ensure
that seal is not tilted. Never let weight of
unsupported shaft rest in seal.

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

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

• Press or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant to
be retained if the housing is shouldered, or flush
with the face of the housing where no shoulder is
provided. Ensure that the seal does not enter the
housing in a tilted position.

NOTE: Most cases of failure or leakage of
oil seals are due to poor fitting, which can

result in damage to both seals and sealing
surfaces. NEVER use a seal which has been
improperly stored or handled, such as hung on a
hook or nail.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 7

GENERAL INFORMATION

JOINTS AND JOINT FACES

Fit joints dry unless specified otherwise.

• Always use the correct gaskets as specified.

• When jointing compound is used, apply in a thin

uniform film to metal surfaces; take care to
prevent jointing compound from entering oilways,
pipes or blind tapped holes.

• If gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or jointing material to
enter any tapped holes or enclosed parts.

• Prior to reassembly, blow through any pipes,
channels or crevices with compressed air.

LOCKING DEVICES

Tab Washers

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

is the same design as that replaced.

Locking Nuts

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

Roll Pins

Always fit new roll pins of an interference fit in the
hole.

Circlips

Always fit new circlips of the correct size for the
groove.

Locking wire

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

Keys and Keyways

• Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.

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

Fitting a split pin

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

8

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL INFORMATION

SCREW THREADS

Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be

discarded.

NOTE: Cleaning damaged threads with a
die or tap impairs the strength and
closeness of fit of the threads and is not

recommended.

CAUTION: Always ensure that
replacement bolts are at least equal in
strength to those replaced.

Castellated nuts must not be slackened to accept a
split-pin, except in recommended cases when this
forms part of an adjustment.

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

Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.

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

Oil thread lightly before tightening to ensure a free
running thread, except in the case of threads treated
with sealant / lubricant, and self-locking nuts.

BOLT IDENTIFICATION

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

In addition to marks identifying the manufacturer, the
top of the bolt head is also marked with symbols
indicating the strength grade, e.g. 8.8; 10.9; 12.9;

14.9. As an alternative, some bolts and screws have

the M and strength grade symbol stamped on the
flats of the hexagon.

Encapsulated bolts and screws

Encapsulated bolts and screws have a
micro-encapsulated locking agent pre-applied to the
thread. They are identified by a coloured section
which extends 360° around the thread. The locking
agent is released and activated by the assembly
process and is then chemically cured to provide the
locking action.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 9

GENERAL INFORMATION

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

• Remove loose adhesive from the bolt and
housing threads.

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

• Apply an approved locking agent.

NOTE: Always fit a new encapsulated bolt
when replacing; or if not available, a bolt
of equivalent specification treated with an

approved locking agent.

Self-locking bolts and screws

NUT IDENTIFICATION

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

Self-locking bolts and screws, i.e. nylon patched or
trilobular thread can be re-used providing resistance
can be felt when the locking portion enters the
female thread.

Nylon patched bolts and screws have a locking
agent pre-applied to the threads. They are identified
by the presence of a coloured section of thread
which extends for up to 180° around the thread.

Trilobular bolts (i.e. Powerlok) have a special thread
form which creates a slight interference in the
tapped hole or threads of the nut into which it is
screwed.

CAUTION: DO NOT re-use self-locking
fasteners in critical locations (e.g. engine

bearings, flywheel). Always use the
correct replacement self-locking nut, bolt or
screw.

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.

10

CAUTION: DO NOT fit non self-locking

fasteners in applications where a

self-locking nut, bolt or screw is specified.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL INFORMATION

Self-locking nuts

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

CAUTION: Do not apply heat in an attempt

to free deferred thread nuts or fittings; as

well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.

When tightening a slotted or castellated nut, never
loosen it to insert a split pin or locking wire except
where recommended as part of an adjustment. If
difficulty is experienced, alternative washers or nuts
should be selected, or the washer thickness
reduced.

Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the

same type.

FLEXIBLE HYDRAULIC PIPES AND HOSES

WARNING: Do not disconnect any pipes in
an air conditioning refrigeration system

unless trained and instructed to do so. A
refrigerant is used which can cause blindness if
allowed to contact eyes.

• Before removing any brake or power steering

hose, clean end fittings and area surrounding
them as thoroughly as possible.

• Obtain appropriate plugs or caps before

detaching hose end fittings, so that the ports can
be immediately covered to prevent the ingress of
dirt.

• Clean hose externally and blow through with

airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.

• When refitting a hose, ensure that no

unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.

• Fit a cap to seal a hydraulic union and a plug to

its socket after removal to prevent ingress of dirt.

• Absolute cleanliness must be observed with

hydraulic components at all times.

• After any work on hydraulic systems, carefully

inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.

NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 11

GENERAL INFORMATION

Fuel System Hoses

CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber

outer sleeve and an inner viton core. If any
of the fuel system hoses have been
disconnected, it is imperative that the internal
bore is inspected to ensure that the viton lining
has not become separated from the armoured
outer sleeve. A new hose must be fitted if
separation is evident.

DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES

The front and rear wheels cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively applying more torque to the rear
wheels if the front wheels start to slip.

WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.

Four wheel dynamometers

Provided that front and rear dynamometer 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 tyres.

Two wheel dynamometers

IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.

SERVICE TOOLS AND GARAGE EQUIPMENT

Special service tools have been developed to
facilitate removal, dismantling and assembly of

mechanical components in a cost effective and time
efficient manner. The use of such special tools also
helps prevent the potential for damage to
components.
Some operations described in this Manual cannot be
carried out properly without the aid of the relevant
service tools.

Where specific garage equipment is required for
diagnosis and repair, reference should be made to
the Service Tools and Equipment Programme where
details of the equipment recommended by Land
Rover Service may be found.

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

• propeller shaft to the rear axle is removed

• neutral selected in gearbox

• hill descent control not selected.

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

12

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS)

WARNING: Do not attempt to test ABS

function on a dynamometer

Four wheel dynamometers

NOTE: Before testing a vehicle on a four

wheel dynamometer disconnect the ABS

valve relay. The ABS function will not
work, the ABS warning light will illuminate.
Normal braking will be available.

Provided that front and rear rollers are rotating 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
tyres.

Two wheel dynamometers

GENERAL INFORMATION

IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.

NOTE: ABS will not function on a two

wheel dynamometer. The ABS light will

illuminate during testing. Normal braking
will be available.

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

• propeller shaft to the rear axle is removed

• neutral selected in gearbox

• hill descent control not selected

If checking engine performance, ensure hill descent
control is not selected and drive shaft to rear
differential is disconnected.

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 13

GENERAL INFORMATION

FUEL HANDLING PRECAUTIONS

General

The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is
issued for basic guidance only, if in doubt consult
your local Fire Officer.

Petrol - Gasoline

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

When petrol/gasoline evaporates it produces 150
times its own volume in vapour, which when diluted
with air becomes a readily ignitable mixture. The
vapour is heavier than air and will always fall to the
lowest level. The vapour can be easily distributed
throughout a workshop by air currents;
consequently, even a small spillage of
petrol/gasoline is potentially very dangerous.

WARNING: Do not use a pit when

removing fuel system components.

Always have a fire extinguisher containing FOAM,
CO2, GAS or POWDER close at hand when
handling or draining fuel or when dismantling fuel
systems. Fire extinguishers should also be located
in areas where fuel containers are stored.

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

Fuel tank drainage

WARNING: Petrol/gasoline must not be
extracted or drained from any vehicle

whilst it is standing over a pit.
Draining or extraction of petrol/gasoline from a
vehicle fuel tank must be carried out in a well
ventilated area.
The receptacle used to contain the
petrol/gasoline must be more than adequate for
the full amount of fuel to be extracted or drained.
The receptacle should be clearly marked with its
contents, and placed in a safe storage area
which meets the requirements of local authority
regulations.

WARNING: When petrol/gasoline has been

extracted or drained from a fuel tank the

precautions governing naked lights and
ignition sources should be maintained.

Fuel tank removal

When the fuel line is secured to the fuel tank outlet
by a spring steel clip, the clip must be released
before the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.

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

Whenever petrol/gasoline is being handled, drained
or stored, or when fuel systems are being
dismantled, all forms of ignition must be
extinguished or removed; any leadlamps must be
flameproof and kept clear of spillage.

WARNING: No one should be permitted to
repair components associated with
petrol/gasoline without first having

specialist training.

FUEL HANDLING PRECAUTIONS 1

GENERAL INFORMATION

Fuel tank repairs

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

a. STEAMING: With the filler cap and tank unit
removed, empty the tank. Steam the tank for at least
two hours with low pressure steam. Position the tank
so that condensation can drain away freely, ensuring
that any sediment and sludge not volatized by the
steam is washed out during the steaming process.

b. BOILING: With the filler cap and tank unit
removed, empty the tank. Immerse the tank
completely in boiling water containing an effective
alkaline degreasing agent or a detergent, with the
water filling and also surrounding, the tank for at
least two hours.

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

Body repairs

WARNING: When body repairs involve the
use of heat, all fuel pipes which run in the

vicinity of the repair area must be
removed, and the tank outlet plugged, BEFORE
HEAT IS APPLIED. If the repair is in the vicinity
of the fuel tank, the tank must be removed.

Plastic fuel pipes are particularly susceptible to heat,

even at relatively low temperature, and can be
melted by heat conducted from some distance away.

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

2

FUEL HANDLING PRECAUTIONS

GENERAL INFORMATION

ELECTRICAL PRECAUTIONS

General

The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to
the electrical and electronic components fitted to the
vehicle. Where necessary, specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.

Equipment

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

Polarity

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

High Voltage Circuits

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

CAUTION: Exercise caution when

measuring the voltage on the coil

terminals while the engine is running, high
voltage spikes can occur on these terminals.

Connectors and Harnesses

The engine compartment of a vehicle is a
particularly hostile environment for electrical
components and connectors. Always ensure
electrically related items are dry and oil free before
disconnecting and connecting test equipment.

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

Having confirmed a component to be faulty:

• switch off the ignition and disconnect the battery.

• remove the component and support the

disconnected harness.

• when replacing the component keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.

Battery disconnection

Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.

CAUTION: To prevent damage to electrical
components ALWAYS disconnect the

battery when working on the vehicle
electrical system. The earth lead must be
disconnected first and reconnected last.
Always ensure that battery leads are routed
correctly and are not close to any potential
chafing points.

Battery charging

Only recharge the battery with it removed from the
vehicle.

Always ensure any battery charging area is well
ventilated and that every precaution is taken to avoid
naked flames and sparks.

CAUTION: Ensure disconnected
multiplugs and sensors are protected from

being contaminated with oil, coolant or
other solutions. Contamination could impair
performance or result in catastrophic failure.

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

Always ensure locking tabs are disengaged before
disconnection, and match orientation to enable
correct reconnection.

ELECTRICAL PRECAUTIONS 1

GENERAL INFORMATION

Ignition system safety precautions

WARNING: Before commencing work on

an ignition system, all high tension

terminals, adapters and diagnostic
equipment should be inspected.

Ensure all cables, connectors and components
are adequately insulated and shielded.
Accidental contact with a poorly insulated
ignition system component could result in a
severe electrical shock.

Wearers of surgically implanted pacemaker
devices should not be in close proximity to
ignition circuits or diagnostic equipment.

Disciplines

Switch off the ignition prior to making any connection
or disconnection in the system to prevent electrical
surges caused by disconnecting ’live’ connections
damaging electronic components.

Grease for electrical connectors

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

NOTE: The use of greases other than BAU
5811 must be avoided as they can migrate

into relays, switches etc. contaminating
the contacts and leading to intermittent
operation or failure.

Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or
high-resistance contacts.

When handling printed circuit boards, treat with care
and hold by the edges only; note that some
electronic components are susceptible to body
static.

Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short-circuit and
open-circuit fault conditions.

Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static charge. Some electronic components are
vulnerable to the static electricity that may be
generated by the operator.

2

ELECTRICAL PRECAUTIONS

GENERAL INFORMATION

SUPPLEMENTARY RESTRAINT SYSTEM PRECAUTIONS

General

The Supplementary Restraint System (SRS)
provides active protection for vehicle occupants in
the event of a serious collision. The system
components include airbags and pre-tensioner
seatbelts which are automatically deployed when a
severe frontal crash condition is detected.

WARNING: Do not use rear facing child
seats in the front passenger seat if the
vehicle is fitted with a passenger airbag.

In order to assure system integrity, it is essential that
the SRS system is regularly checked and
maintained so that it is ready for operation in the
event of an accident.

The SRS system contains components which could
be potentially hazardous to the service engineer if
not serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring integrity of the SRS
components fitted to the vehicle.

It should be noted that these precautions are not
restricted to operations performed when servicing
the SRS system, the same care should be exercised
when working on ancilliary systems and components
located in the vicinity of SRS components; these
include but are not limited to steering system
(steering wheel airbag), body and trim components
(passenger airbag and seat belt pre-tensioners) and
electrical system components (SRS harnesses etc.).

WARNING: Always follow the Safety

Guidelines and correct procedures for

working on SRS components.

NOTE: Airbag modules should be replaced

every ten years.

Where necessary, additional specific precautions
are detailed in the relevant sections of this Manual
which should be referred to prior to commencing
repair operations.

SRS PRECAUTIONS 1

GENERAL INFORMATION

Preliminary Procedures

WARNING: Always remove the ignition
key from the starter switch, disconnect the
vehicle battery and wait 10 minutes before

and commencing work on the SRS system.

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

CAUTION: Always disconnect both battery
leads before beginning work on the SRS

system. Disconnect the negative battery
cable first. Never reverse connect the vehicle
battery and always ensure the correct polarity
when connecting test equipment.

CAUTION: Always disconnect the vehicle

battery before carrying out any electric

welding on a vehicle fitted with an SRS
system.

CAUTION: Do not expose an airbag

module or seat belt pre-tensioner to heat

exceeding 85°C (185°F).

WARNING: Never use multimeters or other
general purpose test equipment on SRS

system components or connectors.
System faults should be diagnosed through the
use of recommended test equipment only.

WARNING: Carefully inspect any SRS
component before installation. Do not
install any SRS component that shows

signs of damage such as dents, cracks or

deformity.

CAUTION: Ensure SRS components are
not contaminated with oil, grease,
detergent or water.

CAUTION: Prior to commencing any test
procedure on the vehicle, ensure that only

test equipment approved for the purpose
is being utilised and that it is in good working
order. Ensure any harness or connectors are in
good condition and any warning lamps are
functional.

2

SRS PRECAUTIONS

GENERAL INFORMATION

Component handling

WARNING: The SRS components are

sensitive and potentially hazardous if not

handled correctly; always comply with the
following handling precautions:

Storage

WARNING: Always store airbag modules
with the cover face up. If the airbag

module is stored face down, accidental
deployment could propel the unit with enough
force to cause serious injury.

WARNING: Airbag modules and seat belt

pre-tensioners are classed as explosive

devices. For overnight and longer term
storage, they must be stored in a secure steel
cabinet which has been approved as suitable for
the purpose and has been registered by the local
authority.

• Never drop an SRS component. The airbag
diagnostic control unit is a particularly shock
sensitive device and must be handled with

extreme care. Airbag modules and seat belt
pre-tensioner units could deploy if subjected
to a strong shock.

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

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

CAUTION: For the temporary storage of an
airbag module or seat belt pre-tensioner

during service, place in a designated
storage area. If there is no designated storage
area available, store in the luggage compartment
of the vehicle and inform the workshop
supervisor.

CAUTION: Always observe the following

precautions when temporarily storing an

airbag module:

• Ensure the cover is facing upwards and the

luggage compartment is secured.

• Always keep components cool, dry and free

from contamination.

• Do not allow anything to rest on the airbag

module.

• Store any removed airbag assembly on a

secure flat surface away from electrical
equipment and heat sources (exceeding 85°C
(185°F).

SRS PRECAUTIONS 3

GENERAL INFORMATION

Installation and Testing Precautions

WARNING: The integrity of SRS system
components are critical for safety
reasons. Ensure the following precautions

are always adhered to:

• Never install used SRS components from
another vehicle or attempt to repair an SRS
component.

• When repairing an SRS system only use
genuine new parts.

• Never apply electrical power to an SRS
component unless instructed to do so as part
of an approved test procedure.

• Special Torx bolts are necessary for installing
the airbag assembly - do not use other bolts.
Ensure bolts are tightened to the specified
torque (refer to SRS section).

• Ensure that SRS component fixings are
correctly positioned and torqued during
service and repair.

• The SRS Electronic Control Unit is a
non-serviceable component and no attempt
should be made to repair or modify the unit.

• Do not try to disassemble the airbag
assembly. It has no serviceable parts. Once
an airbag has been deployed, it cannot be
repaired or reused.

• If you suspect an airbag assembly could be
defective, install a new unit and dispose of
the old unit. Manually deploy the old unit
before disposal.

Precautions.

WARNING: When removing, testing or
installing an airbag module do not lean
directly over it.

See RESTRAINT SYSTEMS,

• Always use new fixings when replacing an
SRS component.

• Ensure the SRS Electronic Control Unit (ECU)
is always installed correctly. There must not
be any gap between the ECU and the bracket
to which it is mounted. An incorrectly
mounted unit could cause the system to
malfunction.

4

SRS PRECAUTIONS

SRS Harnesses and Connectors

CAUTION: Always observe the following
precautions with regards to SRS systems:

•Never attempt to modify, splice or repair

SRS wiring.

• Never install electronic 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
airbag harness. Seek specialist advice when
installing such equipment.

GENERAL INFORMATION

CAUTION: Ensure all airbag harness
connectors are mated correctly and
securely fastened. Do not leave the

connectors hanging loose.

• Do not allow SRS components to hang from
their harnesses.

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

coverings are sometimes used).

CAUTION: Always ensure SRS harnesses
are routed correctly. Be careful to avoid

trapping or pinching the SRS harness.
Route the harness to avoid possible points of
chafing.

• Always use specified earth fixings tightened

to the correct torque. Poor earthing can
cause intermittent problems that are difficult
to diagnose.

SRS PRECAUTIONS 5

GENERAL INFORMATION

Rotary Coupler

CAUTION: Always follow the procedure for

fitting and checking the rotary coupler as

instructed in the SRS section of this
manual. Comply with all safety and installation
procedures to ensure the system functions
correctly. Observe the following precautions:

• Do not install a rotary coupler if it is

suspected to be defective.

• Do not attempt to service, modify or repair a

rotary coupler.

• Do not cut, splice or modify the wires

attached to yellow SRS connector and lead.

• Always ensure the rotary coupler connectors

are mated correctly and securely fastened.

• Always ensure the battery is disconnected

before working on the rotary coupler.

• Always ensure the rotary coupler is removed

and installed in its centered position and with
the front road wheels in the straight ahead
position - refer to the SRS section of this
manual for the full correct removal and
installation procedure.

• If a new rotary coupler is being installed,

ensure the locking tab holding the coupler’s
rotational position is not broken; units with a
broken locking tab should not be used.

Warning Labels

Warning symbols are displayed at various positions
in the vehicle (either in a suitable prominent position
such as driver and passenger side glass, or
attached to the component itself) to indicateSRS
items which must be treated with particular care.
These include:

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

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

C - Do not use rear facing child seats in the front
passenger seat if the vehicle is fitted with a
passenger airbag.

Driver and Passenger side windows

6

SRS PRECAUTIONS

GENERAL INFORMATION

NOTE: It is imperative that the appropriate

publication is read thoroughly prior to any

work being undertaken on the SRS
system.

NOTE: Exact positions of SRS warning

labels may vary dependent on legislation

and market trends.
Refer to the Owner’s Handbook for additional
information regarding the SRS system.

Rotary coupler

End of Fascia

Label warning the owner not to use rear facing child
seats in the front passenger seat in vehicles fitted
with a passenger side airbag.

A - Refer to the Workshop Manual for detailed
instructions.
B - Ensure wheels are in the straight ahead position
before removal and refitting.
C - LAND ROVER Part Number/Bar code - The
code must be recorded and quoted for ordering

purposes.

SRS PRECAUTIONS 7

GENERAL INFORMATION

Airbag and Pre-tensioner Deployment

WARNING: Only personnel who have

undergone the appropriate training should

undertake deployment of airbag and
pre-tensioner modules.

WARNING: A deployed airbag is very hot,

DO NOT return to a deployed airbag

module until at least 30 minutes have
elapsed since deployment.

WARNING: Deployment procedures and

precautions as detailed in this service

manual should be strictly adhered to. The
following precautions must be complied with:

• Only use deployment equipment approved for

the intended purpose.

• Before beginning deployment procedure,

ensure deployment tool functions properly by
performing the self test procedure detailed in
SRS section of this manual.

• Deployment of airbag / pre-tensioner modules

should be performed in a well ventilated area
which has been designated for the purpose.

• Ensure airbag / pre-tensioner modules are

not damaged or ruptured before attempting to
deploy.

• Notify the relevant authorities of intention to

deploy airbag and pre-tensioner units.

• When deploying airbag pre-tensioner units,

ensure that all personnel are at least 15

metres away from the deployment zone.

• Ensure deployment tool is connected

correctly, in compliance with the instructions
detailed in the SRS section of this manual. In
particular, ensure deployment tool is NOT
connected to battery supply before
connecting to airbag module connector.

• When deploying seat belt pre-tensioners,

ensure pre-tensioner unit is secured correctly
to seat.

• When removing deployed airbag modules

and pre-tensioner units, wear protective
clothing. Use gloves and seal deployed units
in a plastic bag.

• Following deployment of any component of

the SRS system within the vehicle, all SRS
components must be replaced. DO NOT
re-use or salvage any parts of the SRS
system.

• Do not lean over airbag module when

connecting deployment equipment.

WARNING: If a vehicle is to be scrapped,
undeployed airbag modules and

pre-tensioner units must be manually
deployed. In this case airbags can be deployed
in the vehicle; before deployment, ensure the
airbag module is secure within its correct
mounting position.

CAUTION: Deployment of the driver side

airbag in the vehicle may damage the

steering wheel; if the vehicle is not being
scrapped, deploy the module outside of the
vehicle.

8

SRS PRECAUTIONS

COMPONENT REPLACEMENT POLICY

IMPACTS WHICH DO NOT DEPLOY AIRBAGS

CAUTION: Check for structural damage in
the area of the impact, paying particular
attention to bumper armatures,

longitudinals, crash cans and bracketry.

IMPACTS WHICH DEPLOY AIRBAGS

CAUTION: Renew the following
components:

• Airbag ECU.

• Airbag module(s).

• Facia harness.

• Pretensioners.

• Rotary coupler and link harness.

GENERAL INFORMATION

SRS PRECAUTIONS 9

GENERAL INFORMATION

AIR CONDITIONING SYSTEM PRECAUTIONS

General

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

Where necessary, additional specific precautions
are detailed in the relevant sections of this Manual
which should be referred to prior to commencing
repair operations.

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

WARNING: The air conditioning system is
charged with a high pressure, potentially

toxic refrigerant. Repairs or servicing
must only be carried out by a trained operator
familiar with both the vehicle system and the
charging and testing equipment.

WARNING: All operations pertaining to the

air conditioning system must be carried

out in a well ventilated area. Always
observe the following precautions:

• R134a is odourless and colourless. Do not

handle or discharge in an enclosed area, or
any area where the vapour and liquid can
come into contact with a naked flame or hot
metal. R134a is not flammable, but it can
cause a highly toxic gas.

• Do not smoke or weld in areas where R134a

is in use.

• Inhalation of concentrations of vapour can

cause dizziness, disorientation,
incoordination, narcosis, nausea or vomiting.

• Refrigerant R134a from domestic and

commercial sources must not be used in
motor vehicle air conditioning systems.

WARNING: HFC-134a (R134a) is a
hazardous liquid which if handled

incorrectly can cause serious injury. The
following precautions should be adhered to at all
times when working on an air conditioning
system:

• Suitable protective clothing must be worn

when carrying out service operations on the
air conditioning system.

• Air conditioning connections should be

opened carefully to allow any liquid or
pressure to bleed off slowly.

• Do not allow a refrigerant container to be

heated by direct flame or to be placed near
any heating appliance. A refrigerant container
must not be heated above 50°C.

• Do not leave a refrigerant container without

its cap fitted.

• Do not transport a refrigerant container that

is unrestrained (especially in the luggage
compartment of a car).

• Do not allow fluids, other than R134a or

compressor lubricant, to enter the air
conditioning system; spontaneous
combustion could occur.

• R134a splashed onto exposed skin will cause

immediate freezing of that area.

• Refrigerant cylinders and replenishment

trolleys can become cooled when
discharging, this could cause skin to become
frozen to them if contact is made.

• The refrigerant used in an air conditioning

system must be reclaimed in accordance with
the recommendations stipulated by a
Refrigerant Recovery, Recycling &
Recharging Station.

AIR CONDITIONING PRECAUTIONS 1

GENERAL INFORMATION

Protective Clothing

NOTE: Suitable protective clothing
comprises:

• Wrap round safety glasses or helmet

• Heat proof gloves

• Rubber apron, or waterproof overalls

• Rubber boots.

REMEDIAL ACTIONS

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

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

Gently run large quantities of eye wash over
affected eye to raise the temperature. If an eye
wash is not available, cool, clean water may be
used to flush the eye. After rinsing, cover the eye
with a clean pad and seek immediate medical
attention.

• If liquid R134a is splashed onto the skin, run

large quantities of water over the affected area to
raise the temperature. Implement the same
action if the skin comes in contact with
discharging cylinders. Wrap the contaminated
body parts in blankets (or similar materials) and
seek immediate medical attention.

• If the debilitating effects of inhalation of R134a

vapour is 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.

WARNING: Due to its low evaporating

temperature of -30°C, R134a should be

handled with extreme care.

2

AIR CONDITIONING PRECAUTIONS

GENERAL INFORMATION

SERVICE PRECAUTIONS

CAUTION: Observe the following
precautions when handling components
used in the air conditioning system:

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

• Hoses and lines must not be subjected to any
twist or stress - the efficiency of the system
will be impaired by kinks or restrictions.
Ensure that hoses are correctly positioned
before tightening couplings, and ensure that
all clips and supports are utilised.

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

• Completed assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of components and panels may
transmit noise and so must be eliminated.

• The appropriate torque wrench must be used
when tightening refrigerant connections to
the stipulated value. An additional spanner
must be used to hold the union to prevent
twisting of the pipe when tightening
connections.

• Before connecting any hose or pipe, ensure
that refrigerant oil is applied to the seat of the
new ’O’ ring seals, BUT NOT to the threads of
the connection.

• All protective plugs must remain in place to

seal the component until immediately prior to
connection.

• Ensure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.

• Components must not remain uncapped for
longer than 15 minutes. In the event of a
delay, the caps must be fitted.

• When disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt
and moisture into the system.

• The receiver/dryer contains desiccant which
absorbs moisture. It must be positively
sealed at all times. A receiver/drier that has
been left uncapped must not be used, fit a
new unit.

• The receiver/drier should be the last
component connected to the system to
ensure optimum dehydration and maximum
moisture protection of the system.

• Whenever the refrigerant system is opened,
the receiver/dryer must be renewed
immediately before evacuating and
recharging the system.

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

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

• When a major repair has been completed, a
leak test should be conducted; refer to the air
conditioning section of this manual for the
correct procedure.

AIR CONDITIONING PRECAUTIONS 3

GENERAL INFORMATION

Refrigerant oil

Use an approved refrigerant lubricating oil:
ND Oil 8

CAUTION: Do not use any other type of
refrigerant oil.

CAUTION: Refrigerant oil easily absorbs
water and must not be stored for long
periods. Do not pour unused oil back into

the container.

When renewing system components, add the
quantities of refrigerant oil recommended in the Air
Conditioning section of this manual.

Compressor

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

Rapid refrigerant discharge

CAUTION: If the air conditioning system is
involved in accident damage and the

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

CAUTION: A new compressor should
always have its sealing cap in place and

must not be removed until immediately
prior to fitting the compressor air conditioning
pipes.

4

AIR CONDITIONING PRECAUTIONS

PRECAUTIONS FOR REFRIGERANT RECOVERY, RECYCLING AND RECHARGING

WARNING: Refrigerant must always be

recycled before reuse to ensure that the

purity of the refrigerant is high enough for
safe use in the air conditioning system.

WARNING: Recycling should always be

carried out with equipment which is

design certified by Underwriter Laboratory
Inc. for compliance with SAE-J1991. Other
equipment may not recycle refrigerant to the
required level of purity.

A R134a Refrigerant, Recovery, Recycling and
Recharging Station must not be used with any
other type of refrigerant.

CAUTION: When using an air conditioning

portable Refrigerant, Recovery, Recycling

and Recharging Station the operator must
adhere to the equipment manufacturer’s
instructions.

GENERAL INFORMATION

CAUTION: The system must be evacuated

immediately before recharging

commences. Delay between evacuation
and recharging must not be permitted.

CAUTION: Overcharging the air

conditioning system will cause excessive

head pressure.

AIR CONDITIONING PRECAUTIONS 5

GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER

Location

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

• At the centre top of the engine bulkhead.

• On a plate behind the LH lower corner of the

windscreen.

Vehicle identification number
Example: SALLNABB7VA600172
S = Geographic area (S = Europe)

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

A = 3 door models
B = 5 door models

B = Engine

A = K16 Petrol engine models
B = TCIE Diesel engine models

7 = Transmission and Steering

7 = RHD manual steering
8 = LHD manual steering

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

A - Vehicle Identification Number (VIN)
B - Gross vehicle weight
C - Gross train weight
D - Maximum front axle load
E - Maximum rear axle load

F - Paint Code
G - Trim Code

Paint and Trim colour codes:
Paint Code (F) - 3-digit code identifying the original

Paint colour is stamped on the VIN plate:
Example: 601

601 = Rioja Red
507 = Caledonian Blue
603 = Chawton White
624 = Cobar Blue
618 = White Gold
622 = Venetian Mauve
587 = Altai Silver
610 = Charleston Green
961 = Epson Green
416 = Beluga Black

Refer to Parts Catalogue for full list of colour
codes.

Trim (G) - a code identifying the original trim type

and colour is stamped on the VIN plate, refer to the
relevant Parts Catalogue for coding details:

VEHICLE IDENTIFICATION NUMBER 1

GENERAL INFORMATION

IDENTIFICATION NUMBER LOCATIONS

1. Vehicle identification number

2. Engine number

3. Gearbox number

Vehicle Identification Number

The VIN is displayed at the centre top of the engine
bulkhead and on a plate behind the LH lower corner
of the windscreen.

Engine number

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

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

Gearbox number (3)

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

2

VEHICLE IDENTIFICATION NUMBER

INFORMATION

CONTENTS

LIFTING AND TOWING

JACKING 1..................................................................................................................

TOWING 4...................................................................................................................

TRANSPORTING THE VEHICLE BY TRAILER 5.......................................................

EMERGENCY STARTING 5........................................................................................

GENERAL DATA

STEERING 1...............................................................................................................

DIMENSIONS 1...........................................................................................................

WEIGHTS 2.................................................................................................................

COMPONENT LOCATIONS

ELECTRONIC CONTROL UNITS 1............................................................................

BODY REPAIRS

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

BODY DIMENSIONS

DIMENSIONAL INFORMATION 1...............................................................................

GAPS AND PROFILES 12...........................................................................................

Page

SEALING AND CORROSION PROTECTION

APPROVED MATERIALS 1.........................................................................................

MATERIALS APPLICATIONS 4..................................................................................

APPLICATION EQUIPMENT 5....................................................................................

WATER LEAKS 8........................................................................................................

JACKING

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

• Use a solid level surface.

• Apply parking brake.

• Select 1st. gear in main gearbox and ensure

HDC is not selected.

CAUTION: To avoid damage to under body

components of the vehicle, adhere to the

following jacking procedures:

DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:

• Bumpers

• Brake or Fuel lines

• Exhaust pipe

• Suspension components

• Steering rack and linkages

• Fuel tank

• Engine sump

• Gearbox

INFORMATION

Jack or support vehicle only on approved
jacking points as detailed in the illustration
below:

LIFTING AND TOWING 1

INFORMATION

2

LIFTING AND TOWING

INFORMATION

Vehicle jack

The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to the
Owner’s Handbook for vehicle jack location points
and procedure. Never work under a vehicle only
supported by the vehicle jack.

Hydraulic jack

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

WARNING: Do not work on the underside

of a vehicle until suitable stands have

been positioned.

Raising the front of a vehicle

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

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

Raising the rear of a vehicle

Position cup of hydraulic arm under the centre of the
rear subframe crossmember at the position identified
by the embossed arrows.

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

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

Use the reverse procedure when removing a vehicle
from stands.

Wheel-free lift

Locate the lifting pads under the ends of the body
longitudinal members shown. Raise the ramp to
support the weight of the vehicle, ensure the vehicle
is secure on the lifting pads, then raise the ramp to
the required height.

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

Use the reverse procedure when removing a vehicle

from stands.

NOTE: For some repair operations it may

be necessary to use a jack to support the

engine under the sump. In this case, a
block of wood should be used on the jack to
protect the sump.

LIFTING AND TOWING 3

INFORMATION

TOWING

CAUTION: The vehicle has permanent

four-wheel drive. The following towing

instructions must be adhered to:

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

• Turn ignition key turn to position ’1’ to release

steering lock and then to position ’II’ to enable
the brake lights, wipers and direction indicators
to be operated, if necessary.

• Select neutral in gearbox and ensure HDC (hill

descent control) is deselected.

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

• Release the parking brake.

CAUTION: The brake servo and power

assisted steering system will not be

functional without the engine running.
Greater pedal pressure will be required to apply
the brakes and the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should only be used
under normal road conditions, ’snatch’ recovery
should be avoided.

Suspended tow by breakdown vehicle

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

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

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

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

CAUTION: If it is considered unsafe to turn
the starter switch to position ’I’ due to

accident damage or an electrical fault;
disconnect the battery before turning the ignition
switch.

WARNING: Do not turn the starter switch

to position ’0’ or remove the ignition key

while the vehicle is being towed.

CAUTION: The steering wheel and/or

linkage must be secured in a straight

ahead position. DO NOT use the steering
lock mechanism for this purpose.

CAUTION: Under no circumstances

should the vehicle be towed or recovered

by means of lashing to the rear subframe.
Serious damage to the subframe and body could
result.

CAUTION: Only use the rear towing eye

for towing another vehicle.

4

LIFTING AND TOWING

INFORMATION

TRANSPORTING THE VEHICLE BY TRAILER

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

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

Install the vehicle on trailer and apply the parking
brake. Select neutral.

EMERGENCY STARTING

WARNING: Hydrogen and oxygen gases

are produced during normal battery

operation. This gas mixture can explode if
sources of combustion (e.g. flames, sparks or
lighted tobacco etc.) are brought near the
battery. When charging or using a battery in an
enclosed space, always ensure ventilation and
wear eye protection (goggles etc.).

WARNING: Keep dangerous substances

out of the reach of children.

Batteries contain sulphuric acid; avoid
contact with skin, eyes, or clothing.
If handling batteries, wear a protective industrial
apron and gloves and wear safety goggles to
protect against possible splashing of acid
solution.
In case of acid contacting with skin, eyes, or
clothing; flush immediately with water for a
minimum of fifteen minutes.
If acid is swallowed, drink large quantities of
milk or water, followed by milk of magnesia, a
beaten egg, or vegetable oil.

SEEK MEDICAL AID IMMEDIATELY.

To Jump Start - Negative Ground Battery

WARNING: To avoid any possibility of

injury use particular care when connecting

a booster battery to a discharged battery.

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

Ensure that:

• the ignition and all electrical accessories are

switched off

• the parking brake is applied and neutral is

selected on gearbox

LIFTING AND TOWING 5

INFORMATION

Connect the jump leads as follows:

WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an

explosion.

A. Connect one end of first jumper cable to

positive (+) terminal of booster battery.

B. Connect other end of first jumper cable to

positive (+) terminal of discharged battery.

C. Connect one end of second jumper cable to

negative terminal of booster battery.

D. Connect other end of second jumper cable to a

good earth point on the engine, NOT TO

NEGATIVE TERMINAL OF DISCHARGED
BATTERY.

CAUTION: Keep jumper leads away from
moving parts, pulleys, drive belts and fan
blade assembly.

CAUTION: If vehicle fails to start within a

maximum time of 12 seconds, switch

ignition off and investigate cause. Failure
to follow this instruction could result in
irreparable damage to catalyst.

To disconnect:

• Remove negative (-) jumper cable from the

engine and then terminal of booster battery.

• Remove positive (+) jumper cable from positive

terminals of booster battery and discharged
battery.

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

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

6

LIFTING AND TOWING

STEERING

Type Power assisted rack and pinion......................................

Steering column Height adjustable by 3.5° or 30 mm vertical movement of.............................

Turns - lock to lock: 3.16..........................

Turning circle 11.6 m (38.1 ft) kerb to kerb...............................

Wheel alignment (unladen)

Front:

Camber angle - 0° 15’ ± 45’..............................

Castor angle 3° 30’ ± 1°...............................

King pin inclination 12° 18’...........................

Toe -0° 10’ ± 5’......................................

Rear:

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

Thrust angle 0° 0’ ± 5’................................

Toe +0° 20’ ± 15’......................................

INFORMATION

steering wheel

Power Assistance System

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

Maximum flow 5.5 -0.5 litres/min. (1.45 -0.13 US gal/min), limited by flow..............................

Displacement

1.8 ’K’ Series 8.2 cm3/rev (0.50 in3/rev)..............................

2.0 ’L’ Series 9.5 cm3/rev (0.58 in3/rev)..............................

DIMENSIONS

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

Overall width:

Including mirrors 2.074 m...........................

Excluding mirrors 1.805 m...........................

Overall height (including roof rails)* 1.757 m..............

Ground clearance *:

Front 186 mm....................................

Running 220 mm..................................

Rear 214 mm.....................................

Wheelbase 2.555 m.................................

Overhang:

Front 836 mm....................................

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

Track:

Front 1534 mm....................................

Rear 1545 mm.....................................

relief valve in pump
control valve in pump

* At unladen weight

GENERAL DATA 1

INFORMATION

WEIGHTS

Unladen weight (no options):

Petrol models 1380 - 1425 kg.............................. 3045 - 3140 lb

Diesel models 1480 -1525 kg............................. 3265 - 3365 lb

Unladen weight (all options):

Petrol models 1449 - 1484 kg.............................. 3195 - 3270 lb

Diesel models 1545 -1580 kg............................. 3405 - 3485 lb

Maximum gross vehicle weight:

Petrol models 1960 kg.............................. 4322 lb

Diesel models 2050 kg............................. 4520 lb

Maximum front axle weight 1050 kg.................... 2315lb

Maximum rear axle load (must NOT be

exceeded) 1120 kg................................. 2470 lb

Maximum braked trailer weight 1800 kg................. 3970 lb

Maximum Gross Towing Weight

Petrol models 3760 kg.............................. 8291 lb

Diesel models 3850 kg............................. 8489 lb

Towing hitch downward load (nose weight) 140 kg........ 309lb

Maximum roof rack load (includes weight of rack) 75 kg. . . 165 lb

2

GENERAL DATA

INFORMATION

ELECTRONIC CONTROL UNITS

The electronic control units (ECU) fitted to vehicles
make it advisable to follow suitable precautions prior
to carrying out welding repair operations. Harsh
conditions of heat and vibration may be generated
during these operations which could cause damage
to the units.

Electrical precautions.

In particular, it is essential to follow the appropriate
precautions when disconnecting or removing the
airbag ECU.

Precautions.

ECU locations (3 door model shown, 5 door model similar)

See GENERAL INFORMATION,

See GENERAL INFORMATION, SRS

Equipment

Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. This particularly applies to
electronic control units.

1. Central control unit (on forward side of
passenger compartment fuse box, behind
driver’s glove box)

2. Airbag ECU (on transmission tunnel below
heater)

3. ABS ECU (below RH front seat)

4. Engine control module (rear of battery on LH

side of engine compartment)

COMPONENT LOCATIONS 1

INFORMATION

BODY REPAIRS

General

Body shells are of monocoque construction. Front
and rear sections of the shell are designed as
’energy absorbing’ zones. This means they are
designed to deform progressively when subjected to
impact in order to minimise the likelihood of injury to
vehicle occupants.

It is essential that design dimensions and strength
are restored in accident rectification. It is important
that neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body
repair.

Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
individual panels or panel assemblies. The repairer
will determine the repair method and this decision
will take into account a balance of economics
between labour and material costs and the
availability of repair facilities in both equipment and
skills. It may also involve considerations of the
vehicles’ downtime, replacement vehicle availability
and repair turn-around time.

Body repairs often involve the removal of
mechanical and electrical units and associated
wiring. Where necessary, refer to the relevant
section of the Workshop Manual for removal and
refitting instructions. Component removal and
refitting instructions for the BODY and SRS sections
are also included in this Manual.

Body components

Taking into consideration the differences in body
styles, suspension systems and engine and
transmission layouts, the location of the following
components as applicable to a particular vehicle is
critical:

• Front suspension upper damper mountings.

• Front suspension or sub frame mountings.

• Rear suspension upper damper mountings.

• Rear suspension mountings or lower pivots.

Additional points which can be used to check
alignment and assembly are:

• Inner holes in crossmember - side - main floor.

• Holes in front longitudinals.

• Holes in side member.

• Holes in rear longitudinals.

• Holes in rear lower panels or extension rear floor.

It is expected that a repairer will select the best and
most economic repair method possible, making use
of the facilities available. The instructions given are
intended to assist a skilled body repairer by
expanding approved procedures for panel
replacement. The objective is to restore the vehicle

to a safe running condition by carrying out a repair
which is as close as is feasible to original standard.
The results should not advertise to the experienced
eye that the vehicle has been damaged, although
the repair might not be identical in all respects to the
original factory build. Commercial bodyshop repair
facilities cannot always duplicate methods of
construction used during production.

Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion. Where
necessary a road test of the vehicle should be
carried out, particularly where safety-related items
are concerned.

Where major units have been disconnected or
removed it is necessary to ensure that fluid levels
are checked and topped up where necessary. It is
also necessary to ensure that the repaired vehicle is
in a roadworthy condition in respect of tyre
pressures, lights, washer fluid etc.

Apertures for windscreen, backlight, bonnet and
doors can be measured and checked using the
dimensional information provided and also by
offering up an undamaged component as a gauge.

BODY REPAIRS 1

INFORMATION

Straightening

Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull but rework the damaged
area using a series of pulls, releasing tension
between each stage and using the opportunity to
check alignment.

Body jig

Unless damage is limited to cosmetic panels, all
repair work to body members must be carried out on
a body jig, to ensure that impact damage has not
spread into more remote parts of the structure.
Mounting on a jig will also ensure that the
straightening and panel replacement procedures do
not cause further distortion.

If original dimensions cannot be satisfactorily
restored by these methods, damaged structural
members should be replaced. Damaged areas
should be cut away using a high speed saw, NOT an
oxy-acetylene torch.

As a rule, body dimensions are symmetrical about
the centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.

Inspection

Every accident produces individual variations in
damage. Each repair is influenced by the extent of

the damage and the facilities and equipment
available for its rectification.

Most accident damage can be visually inspected
and the approximate extent of damage assessed.
Sometimes deformation will extend beyond the
directly damaged area, and the severity of this must
be accurately established so that steps can be taken
to restore critical body components to their original
dimensions. An initial check can be carried out by
means of drop checks or, preferably, trammels.
Gauges are available which will accurately check for
body twist.

2

BODY REPAIRS

DIMENSIONAL INFORMATION

The following dimensional information is shown so
as to assist the technician in the diagnosis and
repair of body panels. The information is shown in
two different ways. There are X,Y,Z dimensions and
actual point to point dimensions.

The X,Y,Z dimensions are the measuring planes
used within Rover Group for the measurement of
body panels. The whole bodyshell is within a parallel
grid system.

The X plane is an imaginary vertical line starting at
the front of the vehicle. It is parallel to the body and
measures the length of the vehicle.

The Y plane is an imaginary line through the center
of the vehicle. All Y dimensions start from this line.
As a rule, body dimensions are symmetrical about
the centre line.

INFORMATION

The Z plane is set at a fixed distance parallel and
perpendicular to the underside of the vehicle. All Z
dimensions start from this plane.

The point to point measurements are actual
distances between two points. These points can be
holes or intersection points. Where holes are taken,
the point of measurement is always from the hole
centre.

All measurements shown are in millimetres.

BODY DIMENSIONS 1

INFORMATION

Underbody dimensional information (see following Figure)

No. Description X Y Z

1 Front sidemember, jig location hole 420 481 314
2 Front crossmember, jig location hole 340.5 350 170

3 Front damper, inboard fixing hole 975.5 515 693.5
4 Front subframe, front fixing 1036 386 98
5 Front subframe, rear outboard fixing 1326 429.5 127
6 Reinforcement outrigger, datum hole 1326 330 127
7 Front production location hole 1395 535 125
8 Trailing link fixing, centre hole 2765 463 160
9 Rear longitudinal, front jig location hole 2900 432 131.5
10 Rear subframe, front fixing 3302 465 274.5
11 Rear damper, rear fixing 3636 610 728.5
12 Rear subframe, rear fixing 3671.5 515 305
13 Rear longitudinal, rear jig location hole 4000 527 305
14 Rear production location hole 4122.5 410 301

2

BODY DIMENSIONS

INFORMATION

BODY DIMENSIONS 3

INFORMATION

4

BODY DIMENSIONS

INFORMATION

BODY DIMENSIONS 5

INFORMATION

6

BODY DIMENSIONS

INFORMATION

Front end dimensional information (see above Figure)

No. Description X Y Z

1 Front damper large hole 997 578.5 718.5
2 Front damper, inboard fixing hole 975.4 514.9 693.7
3 Front wing fixing 605 669 806
4 Rear wing fixing, dash side 1220 690 848.2
5 Outboard headlamp fixing hole 465 615 788.3
6 Inboard headlamp fixing hole 377 485 772
7 Bonnet locking platform, jig location

hole
8 Sidemember jig location hole 500 446 388
9 Headlamp mounting panel, jig location

hole
10 Front valance jig location hole 540 671.7 525

390 445 765

304 536 335

BODY DIMENSIONS 7

INFORMATION

8

BODY DIMENSIONS

INFORMATION

The measurements shown on the front windscreen aperture are the same for 5 door models.

BODY DIMENSIONS 9

INFORMATION

10

BODY DIMENSIONS

INFORMATION

BODY DIMENSIONS 11

INFORMATION

GAPS AND PROFILES

The following information is to be used as a guide to
assist the technician in refitting exterior body panels
and trim items so as to achieve a correctly aligned
vehicle.

Gap A - Bonnet to Bumper overrider. Even gaps
side to side, tolerance +/- 1.0mm.

Gap B - Bonnet to headlamp. Even gaps side to
side, tolerance +/- 1.0mm.

Gap C - Headlamp to Bumper overrider. Visually
even gaps within 2.0mm.

12

BODY DIMENSIONS

INFORMATION

Section D-D, headlamp to wing, gap (3.0mm
minimum). If the wing has been exposed to oven
curing set gap to 4.4 mm to enable subsequent
expansion.

Section E-E and F-F, wing to bonnet, gaps.
Section G-G, wing to front door, gap. Profile of wing

to front door is 0.0mm nominal, tolerance
+1.0/-0.0mm.

Section H-H and J-J, front door frame to body, gap.
Profile of front door frame to body is -2.5mm
nominal, tolerance +0.0/-1.0mm.

Section K-K and L-L, front door to rear door, gaps.
Profile of front door to rear door is 0.0mm nominal,
tolerance +0.0/-1.0mm.

Section M-M, bottom of door to sill, gap.
Section N-N and P-P, rear door to body, gaps.

Profile of rear door to body is 0.0mm nominal,
tolerance +1.0/-0.0mm.

BODY DIMENSIONS 13

INFORMATION

Section P-P, taildoor to rear lamp, gap. Section Q-Q, taildoor to rear bumper, gap.

14

BODY DIMENSIONS

INFORMATION

APPROVED MATERIALS

Description - Usage Supplier Part Number
Cavity waxes

Inner Cavity Wax (Amber) 3M 08901/11/21
Inner Cavity Wax (Transparent) 3M 08909/19/29

Cavity Wax Croda PW57

Engine bay waxes/lacquers

Astrolan Engine Bay Wax and Cosmetic Wax Astors DA3243/1
Engine Bay and Cosmetic Wax/Lacquer Croda PW197

Engine Bay Cosmetic Wax/Lacquer Dinol 4010

Miscellaneous materials

Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts 3M 08080
Flexible Parts Repair Material - rubber modified polypropylene parts 3M 05900
Waterproof Cloth Tape - sealing panel apertures 3M Y387/Y3998

Sound Dampening Foam Gurit-Essex Betacore 7999

Water Shedder Repair (Aerosol) Teroson -

Seam sealers

Body Caulking - type (b) gaps between panels 3M 08568
Bolted Panel Sealer - between bolted panels 3M 08572
Drip Chek Clear - bolted, spot welded and bonded panel edges; type

(a) and (b) gaps between panels; type (c) clinch joints

3M 08401

Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints 3M 08531

Continued.....

SEALING AND CORROSION PROTECTION 1

INFORMATION

Description - Usage Supplier Part Number
Seam sealers (continued)

Polyurethane Seam Sealer - bolted, spot welded and bonded panel
edges; type (a) and (b) gaps between panels; type (b) clinch joints

Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch
joints

Sprayable Sealer - lap joints 3M 08800/23
Super Seam Sealer - lap joints; type (b) clinch joints 3M 08537
Weld Thru’ Sealer - between spot welded panels 3M 08626

Betafill Clinch and Brushable Sealer - type (b) clinch joints Gurit-Essex 10211/15/20
Clinch, Joint and Underbody Coating - lap joints Gurit-Essex 10101/10707

Leak Chek Clear - between bolted panels; spot welded and bonded
panel edges; type (c) clinch joints; type (a) gaps between panels

Putty - type (b) gaps between panels Kent Industries -

Polyurethane Seam Sealer - bolted, spot welded and bonded panel
edges; between bonded panels; type (a) and (b) gaps between panels

3M 08684/89/94

3M 08703/83/88

Kent Industries 10075

PPG 6500

Polyurethane Seam Sealer - bolted, spot welded and bonded panel
edges; between bonded panels; type (b) gaps between panels

Teroson 92

Terolan Light Seam Sealer - bolted, spot welded and bonded panel
edges; type (a) and (b) gaps between panels; between bonded panels;
type (c) clinch joints

Terolan Special Brushable Seam Sealer - lap joints Teroson ­Terostat Sprayable Seam Sealer - bolted, spot welded and bonded

panel edges; between bonded panels; type (b) gaps between panels
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps between

panels; spot welded and bonded panel edges

Sealing Compound - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panels

Teroson -

Teroson 9320

Teroson -

Wurths 8901001/-/6

Continued.....

2

SEALING AND CORROSION PROTECTION

INFORMATION

Description - Usage Supplier Part Number
Structural adhesives

Automotive Structural Adhesive - between bonded panels; type (a)
clinch joints

Two Part Structural Epoxy - between bonded and spot welded panels;
type (a) clinch joints

Underbody sealers

Body Schutz 3M 08861
Spray Schutz 3M 08877

Crodapol Brushable Underbody Sealer Croda PV75

Terotex Underseal (CP 02) Teroson 9320

Underbody waxes

Bodyguard (Aerosol) 3M 08158/9

3M 08122

Ciba-Geigy XB5106/7

Underbody Wax Croda PW61

Underbody Wax Dinol Tectacote 205

Weld-through primers

Weld Thru’ Coating 3M 05913
Zinc Spray 3M 09113

Zinc Rich Primer ICI P-565 634

SEALING AND CORROSION PROTECTION 3

MATERIALS APPLICATIONS

INFORMATION

1. Between panels - bolted

2. Panel edges - bolted

3. Between panels - spot welded

4. Panel edges - spot welded

5. Between panels - bonded

6. Panel edges - bonded

7. Clinch joints - type (a)

8. Clinch joints - type (b)

9. Clinch joints - type (c)

10. Gaps between panels - type (a)

11. Gaps between panels - type (b)

12. Lap joint

4

SEALING AND CORROSION PROTECTION

APPLICATION EQUIPMENT

Suitable application equipment is available from the
following manufacturers and suppliers:

3M Automotive Trades Group.......................................

Cooper Pegler Burgess Hill.............................

SATA Spray Equipment Minden Industrial Ltd......................

INFORMATION

3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. [phone]

Sussex RH15 9LA
Tel. [phone]

16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk IP32 7DX
Tel. [phone]

3M Body Schutz Pistol Spraygun 08004

A pistol type spraygun constructed from case and
machined light alloy and designed for use with 3M
screw fit Body Schutz containers.

NOTE: Always clean gun after use with
appropriate solvent to maintain efficiency.

3M Caulking Gun 8002

A lightweight, robust metal skeleton gun designed to
accept 325mm (13") cartridge for dispensing
sealants etc. This gun provides rapid cartridge
insertion and loading, with a quick-release lever for
accurate control of material ejection and shut-off.

3M Pneumatic Cartridge Gun 08012

Air line-fed gun for applying 3M cartridge products.
Excellent for ease of application to obtain a smooth
bead. Regulator valve for additional control.

3M Pneumatic Applicator Guns

3M Applicator Gun 08190.

For the application of 3M Structural Adhesive 08120.

3M Inner Cavity Wax Applicator Gun

This equipment accepts 1-litre canisters and has a
750mm flexible tube.

The approved system is available from all 3M
refinishing factors.

Air line-fed gun for application of 3M sachet sealers
(Part Number 08006 for 200ml and 310ml sachet
applications, and Part Number 08007 for all size
sachets including 600ml).

Also available: Heavy Duty Manual Gun 08013.

SEALING AND CORROSION PROTECTION 5

INFORMATION

Cooper Pegler Falcon Junior Pneumatic Gun
(Airless)

Intended primarily for applying transit wax, this
pneumatic sprayer has a 5-litre container with
integral hand pump and provides an effective means
of wax spraying without the need for compressed air
or additional services.

A selection of nozzles, lances, hose lengths and a
trigger valve assembly with integral filter allows
flexibility in use. Additional applications include
general maintenance, wax injection and paint
application. Heavy-bodied materials may also be
applied. All parts are fully replaceable and a wide
range of nozzle configurations is available.

SATA Schutz Gun Model UBE

The SATA Schutz Gun is approved for the
retreatment of vehicle underbody areas with
protective coatings as supplied in 1 litre,
purpose-designed ’one-way’ containers. The screw
thread fitting (female on the gun) is standard to most
Schutz-type packs.

Full operating details are supplied with the
equipment.

NOTE: Always clean gun after use with
appropriate solvent to maintain efficiency.

SATA HKD1 Wax Injection Injection Equipment

This equipment is approved for carrying out cavity
wax re-treatment. The SATA HKD1 set comprises a
high quality forged gun with 1-litre pressure feed
container, a flexible nylon lance, a straight 1100mm
steel lance and hooked- wand lance. A
quick-change coupling is provided as a standard
fitting to allow lances to be easily interchanged.
Each lance has an integral, machined nozzle with
specialised spray characteristics to suit the type of
box section to be treated.

Cavity wax application equipment and
techniques

1. Air inlet

2. Flow control (spray pattern adjustment)

3. Pressure cup (1 litre capacity). Maximum

pressure 140PSI (9.7 bar, 9.84kg/cm3)

4. Gun connector

5. Lance nipple connection

6. Flexible lance

7. Rigid directional hook wand (forward cone

spray pattern)

8. Flexible nylon lance (1100mm) with 360° spray
pattern

9. Rigid lance (1100mm) with 360° spray pattern

Specifications of Model UBE:
Air consumption: 7 ft3/min (200 litres/min) @ 45

2

lbf.in
Weight: 23.3oz (220 grams)

6

SEALING AND CORROSION PROTECTION

INFORMATION

When re-treating wax-injected areas which have
been disturbed during repairs, it is necessary to use
a compressed air spray gun with integral pressure
cup and a selection of interchangeable lances.

The following points must be observed during use,
according to the attachments fitted:

• Use the rigid or flexible lance attachments with
360° spray dispersal when treating enclosed
areas, to ensure maximum coverage.

• Where openings are restricted, use the hook
nozzle to provide a more directional spray (e.g.
inside narrow or short box sections).

• Spray exposed underbody surfaces directly from
the gun less lance attachment and without
disconnecting the fluid coupling.

1100mm rigid lance

The nozzle on the rigid lance produces a 360°
circular spray pattern combined with a
forward-directed spray. Although wax is distributed
to all box section surfaces in a single stroke,
effective and complete coverage is obtained in long
straight structures and box section cavities by
spraying on both inward and outward strokes of the
lance.

Hook nozzle on flexible lance

The rigid hook produces a highly atomised,
forward-directed, fully conical spray pattern having
long range and good dispersion characteristics. This
combination has good directional capabilities for
treating short, narrow sections, and may also be
used for direct spraying of inner wheel arches etc.

In use, position the flat area at the end of the lance
at 180° to the nozzle spray direction. This will help to
guide the spray more accurately when it is
concealed in a box section or access hole.

For general spraying, move the nozzle in an arc
from side to side as required, to ensure full
coverage.

NOTE: Ensure that all wax
injection/application equipment is kept
clean. Use white spirit for this purpose

immediately after wax injection operations.

The rigid lance also provides the positional accuracy
required in shaped sections, by allowing visual
assessment.

CAUTION: Do not force the lance into
access holes when using this attachment.

1100mm flexible nylon lance

This lance is similar in pattern to the rigid version,
but provides the additional penetration required for
curved sections or in places where access is
difficult. Its main limitation is a lack of positional
accuracy inside box sections.

Carry out all spraying on the outward stroke of the
lance. Withdraw the lance slowly to ensure sufficient
coverage. Do not withdraw the lance too quickly.

Ensure that the nylon tube of the lance is kept away
from the edges of the access hole to eliminate
abrasion and extend the life of the tube. Take care
to ensure that spraying ceases just before the
nozzle emerges from the access hole. To assist in
this process paint the final 30mm of the nozzle with
RED paint.

SEALING AND CORROSION PROTECTION 7

INFORMATION

WATER LEAKS

Where water leakage is involved, always adopt a
logical approach to the problem using a combination
of skill, experience and intuition. Do not reach a
conclusion based only on visual evidence, such as
assuming that a wet footwell is caused by a leak
emanating from the windscreen. It will often be found
that the source of the leak is elsewhere. Use of the
correct procedure will increase the chance of
locating a leak, however obscure it may seem.

Tools and equipment

The following tools and equipment are
recommended for the purpose of detection and
rectification of water leaks:

1. Garden sprayer (hand-operated).

2. Wet/dry vacuum cleaner.

3. Dry, absorbent cloths.

4. Battery torch.

5. Small mirror.

6. Weatherstrip locating tool.

7. Trim panel remover.

8. Small wooden or plastic wedges.

9. Dry compressed air supply.

10. Hot air blower.

11. Sealer applicators.

12. Ultrasonic leak detector.

During leak detection, the vehicle should be
considered in three basic sections:

• The front interior space.

• The rear passenger space.

• The loadspace or boot.

Testing

From the information supplied by the customer it
should be possible for the bodyshop operator to
locate the starting point from which the leak may be
detected. After the area of the leak has been
identified, find the actual point of entry into the
vehicle.

The sequence of testing is particularly important.
Start at the lowest point and work slowly upwards, to
avoid testing in one area while masking the leak in
another. For example, if testing started at the level of
the windscreen, any water cascading into the
plenum chamber could leak through a bulkhead
grommet and into the footwells. Even at this point it
could still be wrongly assumed that the windscreen
seal was at fault.

Another important part of identifying a water leak is
by visual examination of door aperture seals,
grommets and weatherstrips for damage,
deterioration or misalignment, together with the fit of
the door itself against the seals.

Sealing

When the point of the leak has been detected, it will
then be necessary to rectify it using the following
procedure:

1. Renew all door aperture seals and
weatherstrips which have suffered damage,
misalignment or deterioration.

2. Check all body seals to ensure that they are
correctly located on their mounting
flanges/faces using a lipping tool if necessary.

3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.

4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.

5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork),
avoid removing the glass if possible. Apply the
approved material at the appropriate location
(i.e. glass to weatherstrip or glass to body).

A simple and effective means in the first instance is
an ordinary garden spray with provision for pressure
and jet adjustment, which will allow water to be
directed in a jet or turned into a fine spray. Use a
mirror and a battery-powered torch (NOT a mains
voltage inspection lamp) to see into dark corners.

8

SEALING AND CORROSION PROTECTION

RESTRAINT SYSTEMS

CONTENTS

DESCRIPTION AND OPERATION

SEAT BELTS & SUPPLEMENTARY RESTRAINT SYSTEM 1.................

SEAT BELTS 1......................................................

SUPPLEMENTARY RESTRAINT SYSTEM (SRS) 4.........................

REPAIRS

SEAT BELT - FRONT - 3 DOOR 1.......................................

SEAT BELT - FRONT - 5 DOOR 2.......................................

SEAT BELT - CENTRE - REAR - 5 DOOR 3...............................

SEAT BELT - SIDE - REAR - 5 DOOR 4..................................

ADJUSTABLE MOUNTING - SEAT BELT - ’B/C’ POST 5.....................

SEAT BELT BUCKLE - REAR - 3 DOOR 6.................................

SEAT BELT BUCKLE - REAR - 5 DOOR 7.................................

PRETENSIONER - SEAT BELT - FRONT 7................................

SEAT BELT BUCKLE - CENTRE - REAR - 5 DOOR 8........................

AIRBAG - STEERING WHEEL 10........................................

AIRBAG - PASSENGER 11............................................

ROTARY COUPLER 12...............................................

DIAGNOSTIC CONTROL UNIT (DCU) 13.................................

Page

SEAT BELTS & SUPPLEMENTARY RESTRAINT SYSTEM

Seat belts are provided as the primary restraint for
all occupants. The supplementary restraint system
provides additional protection for front seat
occupants.

SEAT BELTS

RESTRAINT SYSTEMS

webbing is subjected to a sharp pull. The car sensor
activates the locking system if the vehicle is
subjected to sudden deceleration or a severe tilt
angle.

Front seat belts

The inertia reel of each front seat belt is attached to
the related B/C post, behind the finishers. The
webbing runs from the inertia reel, through a height
adjuster, to an anchor point either at the base of the
B/C post (five door models), or on a bar attached to
the inner sill (three door models).

An inertia reel, three point seat belt is installed at
each seat position. The inertia reels are of the
Emergency Locking Retractor (ELR) type which
incorporate a liftshaft locking system with webbing
sensor and car sensor activating mechanisms. The
webbing sensor activates the locking system if the

Front seat belt components

Three door models Five door models

The buckle assembly for each belt, consisting of a
buckle attached to a flexible stalk and an integrated
pretensioner, is secured to the inboard side of the
related front seat frame.

DESCRIPTION AND OPERATION 1

RESTRAINT SYSTEMS

Rear seat belts

Three door models

The inertia reel of each rear seat belt is attached to a
bracket on top of the related rear suspension turret,
behind the loadspace rear quarter trim. The webbing
runs from the inertia reel, through a loop on the D
post, to an anchor point in the rear wheel arch.

The buckle for each belt is directly attached to the
inboard side of the related rear seat frame.

Rear seat belt components - three door models

2

DESCRIPTION AND OPERATION

RESTRAINT SYSTEMS

Five door models

The inertia reel of each outboard rear seat belt is
attached to the related D post, behind the D/E post
finisher. The webbing runs from the inertia reel,
through a loop on the D post, to an anchor point in
the rear wheel arch.

The inertia reel for the centre rear seat belt is
installed in a recess in the back of the rear seat. The
webbing runs from the inertia reel, over the top of
the seat, to an anchor point in the lower frame of the
right rear seat.

Rear seat belt components - five door models

The buckle assembly for each belt, consisting of a
buckle attached to a length of webbing, is fixed to
the lower frames of the rear seats. The buckle
assembly for the right seat belt shares an anchor
point with the webbing of the centre seat belt.

DESCRIPTION AND OPERATION 3

RESTRAINT SYSTEMS

SUPPLEMENTARY RESTRAINT SYSTEM (SRS)

Precautions

Making the system safe

Before working on, or in the area of, the SRS, make
the system safe as follows:

1. Remove the key from ignition switch.

2. Disconnect both battery leads, earth lead first.

3. Wait 10 minutes to allow the SRS back-up power
to fully discharge.

General

Carefully inspect SRS parts before installation. Do
not install a part that shows signs of being dropped
or improperly handled, such as dents, cracks or
deformation.

The airbag ECU is a shock sensitive device and
must be handled with extreme care. Because the
crash sensor is incorporated inside the airbag ECU,
it is imperative that the bolts securing the airbag
ECU and its bracket are tightened to their correct
torque.

When carrying an airbag module, hold it by the
cover, with the cover uppermost and the base away
from your body. Do not wrap your arms around the
module.

Do not try to disassemble an airbag module or seat
belt pretensioner. They have no serviceable parts
and, once deployed, cannot be repaired or reused.

Do not expose an airbag module or seat belt
pretensioner to heat exceeding 85°C/185°F) or allow
it to be contaminated with oil, grease, detergent or
water.

For temporary storage of an airbag module or seat
belt pretensioner during service, place in a
designated storage area or, if no designated storage
area is available, in the loadspace of the vehicle;
always lock the vehicle and inform the workshop
supervisor.

Airbag modules and seat belt pretensioners are
classed as explosive articles. For overnight and
longer term storage, they must be stored in an
approved, secure steel cabinet which has been
registered by the local authority.

Do not install used SRS parts from another vehicle.
When repairing a SRS, use only new parts.

Always use new fixings when replacing SRS parts.
Do not use a multimeter or other general test

equipment to check SRS parts or connectors.

After completing work, check that the electrical
connectors are installed correctly.

Handling and storage

WARNING: If the airbag is improperly
stored face down, accidental deployment
could propel the unit with enough force to

cause serious injury.

CAUTION: Improper handling or storage
can internally damage the airbag module,

making it inoperative. If you suspect the
airbag module has been damaged, install a new
unit and refer to the Workshop Manual for
Deployment/Disposal Procedures.

Do not allow anything to rest on an airbag module.

4

DESCRIPTION AND OPERATION

SRS wiring

Never attempt to modify, splice or repair SRS wiring.
Never install electronic equipment such as a mobile

telephone, two way radio or in car entertainment
system in such a way that it interferes electrically
with the SRS wiring.

Always ensure SRS wiring is routed correctly. Be
careful to avoid trapping or pinching the SRS wiring.
Ensure the are no possible chafing points.

Always use specified earth fixings tightened to the
correct torque. Poor earthing can cause intermittent
problems that are difficult to diagnose.

Ensure all SRS wiring connectors are mated
correctly and securely fastened. Do not leave the
connectors hanging loose.

Warning labels

RESTRAINT SYSTEMS

Warning labels are displayed on SRS parts and
prominent places on the vehicle to indicate:

• The need for caution when working in close

proximity to SRS parts.

• That, if a passenger airbag module is installed,

rearward facing child seats are prohibited on
front passenger seats.

• The publication where suitable reference and

advice can be found (usually the Workshop
Manual or Owner’s Handbook).

DESCRIPTION AND OPERATION 5

RESTRAINT SYSTEMS

System description

The supplementary restraint system (SRS) provides
additional protection for front seat occupants during
a frontal collision above a preset severity.

SRS component location

Impact zone for SRS activation (approximate)

1. SRS warning lamp

2. Passenger’s airbag module (optional)

3. Rotary coupler

4. Driver’s airbag module

5. Airbag ECU

6. Seat belt pretensioners

6

DESCRIPTION AND OPERATION

RESTRAINT SYSTEMS

The SRS is an electronically controlled, single point
sensing system. The system comprises an airbag
Electronic Control Unit (ECU), a driver’s airbag
module, a passenger’s airbag module (optional), two
seat belt pretensioners and a warning lamp.
Interconnecting wiring for the system is contained in
yellow sleeving and integrated into the vehicle
harnesses. A rotary coupler connects the vehicle
harness to the driver’ airbag module. On vehicles
with a passenger’s airbag module, a link lead
connects the module to the vehicle harness. An ISO
9141 K line (bi-directional) serial communication link
connects the airbag ECU to the vehicle’s diagnostic
socket.

SRS schematic

The system is operational only while the ignition is
on. With the ignition on, any frontal collision is
detected by the airbag ECU. If the impact is above
the preset severity, the ECU sends out simultaneous
fire signals to the airbag modules and the seat belt
pretensioners. The airbag modules then deploy
protective airbags in front of the driver and front seat
passenger, and the seat belt pretensioners retract to
tighten the front seat belts. Collision detection to full
deployment of the airbags and pretensioners takes
approximately 45 milliseconds.

WARNING: All the SRS parts, including the
wiring harness, link lead (where fitted) and
rotary coupler, must be renewed after the

airbags and pretensioners have deployed.

1. Ignition power supply

2. Instrument pack

3. Warning lamp

4. Airbag ECU

5. Rotary coupler

6. Driver’s airbag module

7. Passenger’s airbag module

8. Seat belt pretensioners

9. Diagnostic socket

DESCRIPTION AND OPERATION 7

RESTRAINT SYSTEMS

Airbag ECU

The airbag ECU controls the operation of the system
and also contains the collision detection sensors.
The airbag ECU is attached to a bracket on the
transmission tunnel, directly below the heater. A
vehicle earth output connects to one of the fixings. A
30 pin connector provides the airbag ECU
connection with the vehicle harness.

Incorporated into the airbag ECU is a mechanical
safing sensor, an electronic single point sensor and
integrated circuits for control and diagnostics. The
mechanical safing sensor is a normally open switch
that closes at the preset deceleration limit. The
single point sensor is an accelerometer that
produces an output proportional to the vehicle’s
deceleration .

Airbag ECU

Power back-up

The airbag ECU incorporates capacitors to ensure
the system will function if the external power supply
is disconnected during a collision:

• A hardware capacitor provides power for 200
milliseconds to enable system operation and
collision recording.

• Individual capacitors for each fire signal output
provide power for 150 milliseconds.

The capacitors are kept charged while the ignition is
on by a dc-dc voltage converter incorporated into the
airbag ECU. It can take up to 10 minutes from the
ignition being switched off for the energy stored in
the capacitors to fully dissipate and make the
system inert.

Airbag ECU pin connections
Pin Description Pin Description

1. RH pretensioner (+ve)

2. RH pretensioner (-ve)

3. LH pretensioner (+ve)

4. LH pretensioner (-ve)

5. Vehicle supply

6. Vehicle earth

7. SRS warning lamp

8. Not used

9. ISO 9141 K line

10. Driver airbag module (+ve)

11. Driver’s airbag module (-ve)

12. Not used

13. Passenger’s airbag (+ve) - where fitted

14. Passenger’s airbag (-ve) - where fitted

15. to 30. Not used

8

DESCRIPTION AND OPERATION

RESTRAINT SYSTEMS

Operation

When the ignition is switched on, the airbag ECU
performs a bulb check of the SRS warning lamp as
part of the power up procedure. The lamp should be
extinguished after approximately 5 seconds,
indicating that the system is fully operational. If the
lamp remains illuminated, a fault has been detected
and repair action is required.

While the ignition is on, data from the single point
sensor is continuously monitored by the airbag ECU.
If the data from the single point sensor indicates
vehicle deceleration is at or above the preset limit,
and the mechanical safing sensor is closed, the
ECU interprets this as a collision that requires
deployment of the airbags and retraction of the seat
belt pretensioners. It then activates transistors to
send fire signals to the airbag modules and the seat
belt pretensioners. Simultaneously, the airbag ECU
records in memory the following information:

• The error code of the last permanent fault (if any)
detected before the collision.

• Internal program information about the collision
as seen by the airbag ECU.

• The diagnostic status of the airbag and seat belt
pretensioner circuits before deployment.

• The voltage of each power backup capacitor
before deployment.

• Information on the airbag ECU internal program
status.

If external power is lost during the collision,
recording of the last three above items only occurs if

there is sufficient power in the backup capacitors
after outputting the fire signals.

Diagnostics

While the ignition is on the diagnostic function of the
airbag ECU monitors the SRS for faults. If a fault is
detected, the airbag ECU stores a related fault code
in memory and switches the earth output to
illuminate the SRS warning lamp. With a supply
voltage range fault, the warning lamp is illuminated
only for the duration of the fault. With all other faults,
including intermittent faults, the warning lamp is
illuminated for the remainder of the drive cycle. At
the next ignition on, if the fault is still present the
warning lamp remains illuminated after the lamp
check; if the fault does not recur, the warning lamp
extinguishes but the fault code remains stored in
memory. An intermittent fault will be cleared from
memory if 40 drive cycles are completed without its
recurrence.

After detecting a fault, the system may retain some
operational capability:

• If a fault is detected in an airbag or pretensioner
circuit, only that circuit is disabled; the other
airbag and pretensioner circuits remain
operational and their related components will still
be deployed in a collision.

• If an internal or power supply fault is detected,
the complete system will be disabled.

• If a fault exists in the SRS warning lamp circuit,
the lamp will not illuminate during the lamp check
at ignition on, but, provided there are no other
faults, the system will otherwise be fully
operational.

When deployment and collision event recording has
been completed, the airbag ECU enters crash
locked mode and illuminates the SRS warning lamp.
In crash locked mode the airbag ECU is
permanently disabled and must be replaced during
subsequent repair action. Crash locked mode
cannot be cleared using Testbook.

DESCRIPTION AND OPERATION 9

RESTRAINT SYSTEMS

Fault code retrieval and fault diagnosis of the SRS
can only be done using Testbook. Additional SRS
information that can be read using Testbook is the:

• Airbag ECU bar code.

• Evolution number of the hardware, software and

diagnostic protocol.

• Status of the crash locked mode.

• Vehicle identification number (VIN) data.

Diagnostic checks performed by the airbag ECU
include:

• Monitoring of the airbag and pretensioner circuits
for open/short circuits.

• Internal errors.

• Supply voltage (limits are 8.6 to 19.0 V at power

up, 6.0 to 19.0 V during drive cycle).

Airbag modules

During a frontal collision each airbag module
deploys a gas filled bag to form a protective cushion
between the front seat occupant and the steering
wheel or fascia/windshield. The driver’s airbag
module is attached to the centre of the steering
wheel. Where fitted, the passenger’s airbag module
is installed in the fascia, above the glovebox.

Each airbag module has a gas generator attached to
a folded airbag installed in a housing. The driver’s
airbag has an inflated volume of 45 litres; the
passenger’s airbag has an inflated volume of 120
litres. The gas generator of the driver’s airbag
module is filled with a nitrocellulose based material;
the gas generator of the passenger’s airbag module
is filled with a sodium azide based material.
The outlet of the gas generators incorporates a filter
screen to prevent solid combustion by-products
entering the airbag during deployment. An igniter
(squib) in each generator provides an ignition source
when triggered by a fire signal from the airbag ECU.
A 2 pin connector provides the interface between the
igniter and the vehicle wiring.

On the driver’s airbag module, the housing is closed
by a cover that forms the steering wheel centre pad;
split lines are formed in the inner surface of the
cover to direct the airbag through the required exit
point during deployment. On the passenger’s airbag
module, the housing is closed by a trim panel
profiled to match the fascia; a tethered deployment
door forms an integral part of the trim panel.

10

DESCRIPTION AND OPERATION

Both airbag modules operate in the same way. On
receipt of a fire signal from the airbag ECU, the
igniter ignites the material in the gas generator. The
burning material rapidly produces a large amount of
nitrogen gas which passes through the filter screen
into the airbag, forcing the airbag to unfold. On the
driver airbag module, the unfolding airbag ruptures
the cover along the split lines; on the passenger
airbag module, the unfolding airbag breaks the
deployment door fixings to the module housing and
trim panel, and the deployment door lifts off the
fascia (but remains tethered to the module housing).
Once free of the housing the airbag inflates to its full
extent. Vents in the airbag prevent excess pressure
bursting the bag and, as soon as the material in the
gas generator is exhausted, allows the airbag to
instantly deflate.

RESTRAINT SYSTEMS

DESCRIPTION AND OPERATION 11

RESTRAINT SYSTEMS

Driver’s airbag module components

Passenger’s airbag module components

1. Cover

2. Split lines

3. Electrical connector

4. Housing

5. Fixing

1. Trim panel

2. Deployment door section

3. Housing

4. Fixing bracket

5. Tethers

6. Electrical connector

12

DESCRIPTION AND OPERATION

RESTRAINT SYSTEMS

Seat belt pretensioners

During a frontal collision the seat belt pretensioners
tighten the front seat belts to ensure the occupants
are securely held in their seats. A pretensioner is
integrated into the buckle assembly of each front
seat belt.

The two pretensioners are handed, but otherwise
identical. Each pretensioner has a tube containing
propellant and a piston. The piston is attached to a
steel cable, the opposite end of which is attached to
the seat belt buckle. An igniter (squib) in the base of
tube provides an ignition source when triggered by a
fire signal from the airbag ECU. A fly lead with a 2
pin connector links the igniter to the vehicle wiring.

On receipt of a fire signal from the airbag ECU, the
igniter ignites the propellant. The burning propellant
rapidly produces nitrogen gas that drives the piston
along the tube, pulling on the cable and drawing the
buckle towards the buckle assembly fixing point on
the seat.

SRS warning lamp

The SRS warning lamp provides system status
information for the driver. The lamp consists of a
bulb behind a red SRS graphic at the base of the
tachometer in the instrument pack. The bulb is a
serviceable item that can be renewed from the rear
of the instrument pack.

Seat belt pretensioner components

1. Seat belt buckle

2. Gaiter

3. Steel cable

4. Fixing

5. Igniter

6. Fly lead

7. Vent

8. Tube

DESCRIPTION AND OPERATION 13

RESTRAINT SYSTEMS

Rotary coupler

The rotary coupler is installed on the steering
column to provide the interface between the fixed
wiring harness and the moveable driver airbag
module and horn buttons on the steering wheel.

A rotating link harness is encapsulated into a plastic
cassette comprising outer and inner housings with
integral connectors. Screws attach the outer housing
to the steering column switch assembly and the
inner housing is keyed to the steering wheel by its
connector. The inner housing can turn a maximum
of six revolutions in relation to the outer housing. For
maintenance purposes the outer housing
incorporates a position indicator wheel; a white tab
is visible on the wheel when the rotary coupler is
centralised. To prevent breaking the rotating link
harness, both the steering and the rotary coupler
must be centralised when removing and installing
the steering wheel.

Rotary coupler components

1. Fly lead (to airbag module)

2. Outer housing

3. Position indicator wheel

4. Inner housing

14

DESCRIPTION AND OPERATION

RESTRAINT SYSTEMS

SEAT BELT - FRONT - 3 DOOR

Service repair no - 76.73.13

Remove

1. Remove seat base finisher.

and seat belts.

2. Remove body side rear trim casing.

BODY, Interior trim components.

See BODY, Seats

See

Refit

1. Position reel and tighten bolt to 31 Nm.

2. Extend belt, position top mounting and tighten

Torx bolt to 31 Nm.

3. Fit top mounting cover.

4. Secure belt retaining strap.

5. Fit lower mounting to seat belt, position

mounting, fit and tighten Torx bolts to 40 Nm.

6. Fit trim casing.

components.

7. Fit seat base finisher.

seat belts.

See BODY, Interior trim

See BODY, Seats and

3. Remove 2 Torx bolts securing seat belt lower
mounting and remove mounting from seat belt.

4. Release seat belt retaining strap.

5. Remove cover from upper mounting.

6. Remove Torx bolt from upper mounting.

7. Remove bolt from seat belt reel and remove

reel.

REPAIRS 1

RESTRAINT SYSTEMS

SEAT BELT - FRONT - 5 DOOR

Service repair no - 76.73.13

Remove

1. Remove seat base finisher.

and seat belts.

2. Remove ’B/C’ post upper finisher.

Interior trim components.

See BODY, Seats

See BODY,

Refit

1. Position reel and tighten bolt to 31 Nm.

2. Extend belt, position top mounting and tighten

nut to 31 Nm.

3. Secure belt retaining strap.

4. Fit ’B/C’ post upper finisher.

Interior trim components.

5. Fit seat base finisher.

seat belts.

See BODY,

See BODY, Seats and

3. Release seat belt retaining strap.

4. Remove nut from seat belt upper mounting.

5. Remove bolt from seat belt reel and remove

reel.

2

REPAIRS

SEAT BELT - CENTRE - REAR - 5 DOOR

Service repair no - 76.73.20

Remove

RESTRAINT SYSTEMS

1. Remove RH rear seat.

seat belts.

See BODY, Seats and

4. Remove 5 screws and remove both end covers

from seat hinges.

5. Remove 3 Torx bolts and remove squab from
cushion.

2. Remove 2 screws and remove seat belt reel
cover.

6. Release rear of cushion cover from seat frame.

7. Release sides and front of cushion cover from

seat frame.

3. Remove nut and release seat belt reel.

REPAIRS 3