Land Rover Range Rover Sport L320 Workshop Service Owner's Manual

Workshop Service Manual for Range Rover Sport L320 2013 Sec.1

1: General Information

100: Service Information

100- 00: General Information

Description and Operation

About This Manual
About This Manual
Important Safety Instructions
How To Use This Manual
General Service Information
Standard Workshop Practices
Health and Safety Precautions
Solvents, Sealants and Adhesives
Road/Roller Testing
Special Tool Glossary
Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
DTC: Adaptive Damping Control Module (ADCM)
DTC: Adaptive Speed Control Module (ASCM)
DTC: Air Suspension Control Module
DTC: Anti-Lock Braking System Control Module (ABS)
DTC: Audio Amplifier Control Module (AAM)
DTC: Auto High Beam Control Module (AHBCM)
DTC: Automatic Temperature Control Module (ATC)
DTC: Central Junction Box (CJB)
DTC: Digital Radio Control Module (DRCM)
DTC: Driver/Passenger Door Module (DDM/PDM)
DTC: Driver/Passenger Seat Module (DSM/PSM)
DTC: Dynamic Response Control Module (DRM)
DTC: Electric Park Brake Control Module (EPBCM)
DTC: Electric Steering Column Lock Control Module (ESCL)
DTC: Fuel Fired Booster Heater Control Module (FFBH)
DTC: Headlamp Leveling Control Module (HCM)
DTC: Instrument Cluster (IC)
DTC: Integrated Audio Module (IAM) - High Line
DTC: Integrated Control Panel (ICP)
DTC: Integrated Control Panel B (ICPB)
DTC: Keyless Vehicle Module (KVM)
DTC: Occupant Classification Sensor Control Module (OCSCM)
DTC: Parking Aid Control Module (PACM)
DTC: Rear Differential Control Module (RDCM)
DTC: Rear Seat Entertainment Control Module (RSECM)
DTC: Rear View Camera (RVC)
DTC: Restraints Control Module (RCM)
DTC: Satellite Radio Control Module (SRCM)
DTC: Steering Angle Sensor Module (SASM)
DTC: Tailgate Control Module (TGCM)
DTC: Terrain Response Switch Pack (TR)
DTC: (TS)
DTC: Module Name: Transfer Case Control Module
DTC: Transmission Control Switch (TCS)
DTC: Transmission Control Module (TCM)
DTC: TV Control Module (TVCM)
TDV6 3.0L Diesel , DTC: Engine Control Module (ECM)
V8 5.0L Petrol/V8 S/C 5.0L Petrol, DTC: Engine Control Module (ECM)

100- 01: Identification Codes

Description and Operation

Identification Codes

100- 02: Jacking and Lifting

Description and Operation

Jacking
Lifting
Vehicle Recovery

100- 03: Maintenance Schedules

Description and Operation

Maintenance Schedules - Gasoline Engines
Maintenance Schedules - Diesel Engines

100- 11: Vehicle Transportation Aids and Vehicle Storage

Description and Operation

New Vehicle Storage

New Vehicle Storage Form

101: Pre- Delivery Information

101- 01: Pre -Delivery Inspection Manual

Description and Operation

Preliminary
Vehicle Interior
Vehicle Exterior
Road Test
Quality Assurance Checks

101- 02: Showroom Preparation

Description and Operation

Showroom Preparation

Published: 11-May-2011

General Information - About This Manual

Description and Operation

Introduction

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

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

Important Safety Instructions

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

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

Warnings, Cautions and Notes in This Manual

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

injury.

CAUTION: Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the

vehicle or equipment being used.

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

satisfactory repair.

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

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

Trustmark Authoring Standards (TAS) Removal and Installation Procedures

NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta

color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

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

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

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

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

Specification procedures will contain all technical data that are not part of a repair procedure.
TAS Graphics
Colors used in the graphic are as follows:

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

Pale Blue - is for the special tool(s) and general equipment.
There may be multiple steps assigned to one illustration.
Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts,

clamps or clips.
Items in the illustration can be transparent or use cutouts to show hidden detail(s).

TAS Symbols
Symbols are used inside the graphics and in the text area to enhance the information display. The following

paragraphs describe the various types and categories of symbols.
Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks.

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

Warning symbols are used to indicate potential risks resulting from a certain component or area.

Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a component.

Location symbols are used to show the location of a component or system within the vehicle.

Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector lever position is
to be set.

Pointer symbols are used to draw the attention to components and give special instructions such as a required
sequence or number of components. The number of components is reflected by the value inside the luty arrow. A
sequence number is located inside the circle. Numbers inside circles are also used to allocate special information
such as tightening torques or chemicals to a particular component.

Movement arrows are used to show three dimensional or rotational movements. These movements can include
specific values inside the symbol if required.

Standard tool symbols recommend the use of certain standard tools. These tools can include dimension values if
required.

The following graphic illustrates a set of symbols that are used to provide detailed information on where to apply a
material.

Measurement symbols provide detailed information on where to carry out a specific measurement. These symbols
can include specific values if required.

Special Tools and Torque Figure(s)
Special tools will be shown with the tool number in the illustration. The special tool number(s), general equipment,

material(s) and torque figure(s) used for the procedure step will be shown in the text column.

Published: 11-May-2011

General Information - About This Manual

Description and Operation

Notes, Cautions and Warnings

Throughout this manual, important information is highlighted by the use of NOTES, CAUTIONS and WARNINGS.
NOTES give additional information on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle,
and WARNINGS are given to prevent personal injury.

Published: 11-May-2011

General Information - Important Safety Instructions

Description and Operation
Safety Notice

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

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

Published: 08-Dec-2012

General Information - How To Use This Manual

Description and Operation

How to use This Manual

This manual covers all aspects necessary in order to service the vehicle effectively.
The manual is structured into five main sections, General Information, Chassis, Powertrain, Electrical and Body and

Paint with each section dealing with a specific part of a vehicle system.
Each of the five main sections contain sub -sections dealing with items which form a part of that specific system.
Pages at the start of the manual list all sections available. Each section has a contents list detailing, where

applicable, Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair
Procedures.

Where components need to be removed or disassembled in sequence, each operation in the sequence will be
identified numerically and also graphically in an accompanying illustration.

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

Workshop Manual Organization

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

Section 1 - General Information.

Section 2 - Chassis.

Section 3 - Powertrain.

Section 4 - Electrical.

Section 5 - Body and Paint.

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

In the number given above, the first digit of the number '4' indicates the section i.e. Electrical .
The second and third digits '12' of the number indicate the vehicle system i.e. Air Conditioning.
The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e. Air

Conditioning Compressor .

Published: 11-May-2011

General Information - General Service Information

Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of Land Rover technicians worldwide
and to assist them in the efficient repair and maintenance of Land Rover vehicles.

This manual provides descriptions and methods for accomplishing adjustment, service and repair work using tested
and effective procedures. Following these procedures will help ensure product reliability.

Special Tools

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

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

Important Safety Instructions

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

This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Any person
who departs from the instructions provided in this manual must first establish that they compromise neither their
personal safety nor the vehicle integrity by their choice of methods, tools or parts.

Individuals who undertake their own repairs should have some skill or training and limit repairs to components
which could not affect the safety of the vehicle or its passengers. Any repairs required to safety critical items such
as steering, brakes, suspension or supplemental restraint system should be carried out by a Land Rover Dealer.
Repairs to such items should NEVER be attempted by untrained individuals.

Warnings, Cautions and Notes which appear in this manual

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

Warnings, Cautions and Notes have the following meanings:
Warning: Procedures which must be followed to avoid the possibility of personal injury.
Caution: Calls attention to procedures which must be followed to avoid damage to components.

Note: Gives helpful information.

References

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

Fault Diagnostic Equipment

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

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

This manual is produced as a reference source to supplement T4.
Features of the equipment include:

a. Fully upgradeable support for the technician
b. Structured diagnostics to accommodate all skill levels
c. Direct print- out of screen information and test results

Testing the vehicle

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

Repairs and Replacement Parts

Land Rover parts are manufactured to the same exacting standards as the original factory fitted components. For

this reason, it is essential that only genuine Land Rover parts are used during maintenance or repair.

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

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

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

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

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

All Land Rover recommended parts have the full backing of the vehicle warranty.
Land Rover Dealers are obliged to supply only Land Rover recommended parts.

Specifications

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

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

General Information - Standard Workshop Practices

Description and Operation

Vehicle in Workshop

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

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

Published: 05-Jul-2013

Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery
disconnection/connection.For additional information, refer to: Specifications

System - General Information, Specifications).

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

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

(414-00 Battery and Charging

Towing the Vehicle

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

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

Battery - General

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

Specifications

CAUTIONS:

(414-00 Battery and Charging System - General Information, Specifications).

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

While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the
only practical way to mobilize a vehicle. Prior to attempting a jump start, refence must be made to the Electrical
Section of this manual - Jump Starting.

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

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

Always make sure that the jumper cables are adequate for the task.
Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be
connected in parallel.
Always make sure that switchable electric circuits are switched off before connecting jumper cables. This
reduces the risk of arcing occurring when the final connection is made.

General Installation Instructions

Component removal

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

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

Clean bench and provide marking materials, labels and containers before disassembling components.

Disassembling

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

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

WARNING: Suitable eye protection must be worn.

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

Cleaning components

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

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

General inspection of components

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

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

Joints and Joint Faces

All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and
install O-rings using the fingers only.

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

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

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

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

Do not allow sealant to enter tapped holes or oilways.

Locking Devices

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

Tab washers

Always release locking tabs before loosening fixings, do not reuse tab washers.

Locknuts

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

Roll pins

Always install new roll pins of the correct size.

Circlips

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

In addition to marks identifying the manufacturer, the top of the bolt head is also marked with symbols indicating

Woodruff keys

Woodruff keys may be reused provided there is no indication of wear or distortion.
Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and reuse a split pin, always make sure that replacement pins are of the correct size for
the hole in which they are to be installed.

Screw Threads

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

NOTES:

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

New Taptite bolts when used cut their own threads on the first application.

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

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

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

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

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

Bolt and Nut Identification

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

the strength grade e.g. 8.8, 10.9, 12.9, 14.9. Alternatively, some bolts and screws have the M and strength grade

symbol stamped on the flats of the hexagon.

Encapsulated ('Patched') bolts and screws

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

Self-locking bolts and screws

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

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

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

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

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

Nut identification

A nut with an ISO metric thread is marked on one face or one of the hexagonal flats with the strength grade symbol

8, 12, 14. Some nuts with the strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the
hexagonal flat opposite the strength grade marking.

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

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

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

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

Self-locking nuts

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

Air Suspension

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

Ball and Roller Bearings

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

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

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

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

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

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

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

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

Brake Pads and Linings

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

Brake Hydraulics

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

WARNING: Do not intermix brake fluid of different specifications.

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

Pipes and Hoses

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

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

WARNING: Suitable eye protection must be worn.

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

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

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

Fuel system hoses

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

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

Fuel system hose clips

Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the
clip is tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with
new clips on reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten
clips by any other method, do not install any other type of clip.

Cooling system hoses

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

Hose orientation and connection
Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or

damaged through contact with adjacent components.

Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when

Equipment

the hose is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe
provides a positive indicator.

Hose clips

Markings are usually provided on the hose to indicate the correct clip position. If no markings are provided, position
the clip directly behind the retaining lip at the end of the stub pipe. Worm drive clips should be orientated with the
crimped side of the drive housing facing towards the end of the hose or the hose may become pinched between the
clip and the stub pipe retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lbf.ft).
Make sure that hose clips do not foul adjacent components.

Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be
reused. When installing new clips, make sure clip is positioned on hose before tightening and make sure that when
clip is tightened, the tag is located in the longitudinal slot in the free end of the clip (arrowed in illustration).

Heat protection
Always make sure that heatshields and protective sheathing are in good condition; replace if damage is evident.

Particular care must be taken when routing hoses close to hot engine components such as the exhaust manifolds
and exhaust gas recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure this movement
is taken into account when routing and securing hoses.

Electrical Precautions

General

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

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

Polarity

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

High voltage circuits

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

Vehicles installed with Bi-Xenon headlamp bulbs

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

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

Connectors and harnesses

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

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

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

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

Battery Disconnection/Connection

Always refer to the Electrical Section of this manual - Battery Connection/Disconnection prior to attempting to
connect or disconnect the battery.
For additional information, refer to: Specifications
Specifications).

(414-00 Battery and Charging System - General Information,

Fuel Handling Precautions

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

General precautions
Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or

draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.
Make sure that suitable warning signs are exhibited.
Keep all sources of ignition well away from areas where fuel is being handled.
Make sure that any leadlamps are flameproof and kept clear of spillage.

WARNINGS:

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

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

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

Fuel tank and system draining

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

WARNINGS:

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

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

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

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

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

Fuel tank repairs

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

Oil seals

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

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

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

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

Supplementary Restraint System (SRS) Precautions

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

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

WARNING: The following precautions MUST be adhered to when working on the SRS system:

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

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

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

Steering wheel airbag, rotary coupler.
Passenger front airbag.
Head airbag modules - front and rear.
Seat belt pre-tensioners.
SRS harnesses, link leads and connectors.

Side (thorax) air bags.
Making the system safe
Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the

following operations:

Remove the ignition key.

Disconnect battery, earth lead first.

Wait 2 minutes for the SRS power circuit to discharge before commencing work.

NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply
failure under crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in
order to avoid the risk of accidental deployment.

Installation
In order to make sure system integrity, it is essential that the SRS system is regularly checked and maintained so

that it is ready for effective operation in the event of a collision. Carefully inspect SRS components before
installation. Do not install a part that shows signs of being dropped or improperly handled, such as dents, cracks or
deformation.

WARNING: The integrity of the SRS systems is critical for safety reasons. Make sure the following precautions

are always adhered to:

Do not install accessories or other objects to trim panels which cover ITS airbags.

CAUTIONS:

NOTES:

will need to be replaced as soon as possible to make sure full SRS protection.

SRS component testing precautions
The SRS components are triggered using relatively low operating currents, always adhere to the following :

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

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

Make sure SRS components are not contaminated by oil or grease.

Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but

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

WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only T4 to
diagnose system faults.

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

Handling and storage
Always observe the following precautions when handling SRS components:

Never drop an SRS component. The airbag diagnostic control unit is a particularly shock sensitive device and
must be handled with extreme care. Airbag modules and seat belt pre-tensioners could deploy if subjected to
a strong shock.
Never wrap your arms around an airbag module. If a module has to be carried, hold it by the cover with the

cover uppermost and the base away from your body.

Never transport airbag modules or seat belt pre-tensioners in the passenger compartment of a vehicle.

WARNINGS:

Always use the luggage compartment of the vehicle for carrying airbag modules and seat belt pre-tensioner
units.
Never attach anything to an airbag cover or any trim component covering an airbag module. Do not allow
anything to rest on top of an airbag module.
Always keep components cool, dry and free from contamination.
Never apply grease or cleaning solvents to seat belt pre-tensioner units, component failure could result.
Always store an airbag module with the deployment side uppermost. If it is stored deployment side down,
accidental deployment will propel the airbag module with sufficient force to cause serious injury.
Keep new airbag modules in their original packaging until just prior to installing. Place the old module in the
empty packaging for carriage.

When handling an inflatable tubular structure (ITS) airbag module, hold by the gas generator housing, DO NOT
hold by the airbag. Do not wrap the thumb around the gas generator while holding. Do not drape airbag over
shoulder or around neck. For seat buckle type pre-tensioners, hold by the piston tube, with the open end of the
piston tube pointing towards the ground and the buckle facing away from your body. Do not cover the end of the
piston tube. DO NOT hold buckle type pre-tensioners by the bracket assembly or cable. Never point the piston tube
towards your body or other people.

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 with the local authority.

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

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

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

Never attempt to modify, splice or repair SRS wiring.
Never install electrical equipment such as a mobile telephone, two-way radio or in-car entertainment system
in such a way that it could generate electrical interference in the airbag harness. Seek specialist advice when
installing such equipment.

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

WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS
wiring.

WARNING: Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses.
Look for possible chafing points.

Side impact crash sensor inspection
After any degree of side body damage, inspect the side impact crash sensors. Replace a crash sensor if there is any

sign of damage.

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

Rotary coupler

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

Do not unlock and rotate the rotary coupler when it is removed from the vehicle.
Do not turn the road wheels when the rotary coupler is removed from the vehicle.
Always make sure the rotary coupler is removed and installed in its central position and with the front road
wheels in the straight ahead position - refer to SRS repair section for the correct removal and installation
procedure.
If a new rotary coupler is being installed, make sure the locking tab holding the coupler's rotational position is

not broken; units with a broken locking tab must not be used.
Airbag location labels
WAITING AIRBAG LOCATION AND DESIGN LABELS - DUE MARCH - NEIL HARRISON 46404

Airbag and pre-tensioner deployment

WARNING: During deployment parts of the airbag module become hot enough to burn you. Wait 30 minutes

after deployment before touching the airbag module.

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel

who have undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules.
The following precautions must be complied with:

Only use deployment equipment approved for the intended purpose.

Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been

designated for the purpose.

Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.

Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner

units.

When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet)

away from the deployment zone.

Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS

section of this manual. In particular, make sure deployment tool is NOT connected to battery supply before

connecting to airbag module connector.

When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the 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 reuse or salvage any parts of the SRS system.

Do not lean over an airbag module when connecting deployment equipment.
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, make sure the airbag module is secure within
its correct mounting position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the
vehicle is not being scrapped, deploy the module outside of the vehicle.

SRS Component Replacement Policy

CAUTIONS:

The Restraints Control Module (RCM) will log a crash fault after every impact which is severe enough to cause

airbag deployment. It is possible to have three crashes/impacts logged after one event where, for

example, a front, side and rollover has occurred. After the third fault is logged, the SRS warning lamp
will be illuminated and the RCM must be installed. After any airbag deployment a new RCM must be
installed.

The SRS side impact sensor must be replaced if there are any signs of physical damage or if the restraints

control module (RCM) is registering a fault.

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

Impacts which do not deploy the airbags or pre-tensioners

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

Impacts which deploy the airbags or pre- tensioners

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

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

Front Airbag Deployment - Driver and Passenger

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

Driver airbag module

Passenger airbag module

Fly leads (where applicable) connecting front airbag modules to SRS harness

Front seat belt buckle pre -tensioner

Rear seat belt pre-tensioners - if installed

Driver's seat belt retractor - if installed

Rotary coupler

Any front impact sensors that have been physically damaged or if a fault is being registered

Restraints control module (RCM) if the three crashes/impacts have been stored

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

Front passenger's seat belt retractor and webbing, tongue latching function, 'D' loop and body anchorage

point

Rear seat belt buckles, webbing, buckle covers, body anchorage points and tongue latching function

Fascia moulding adjacent to passenger airbag module

Steering wheel

Front seat frames and head restraints

Steering column - if adjustment is lost or if there are signs of collapse

Seat belt height adjusters

Rear seat belts

Side Air Bags

CAUTION: If the side (thorax) air bags are deployed, the following components must be replaced on the side of

the vehicle on which the deployment occurred:

Side (thorax) airbag

Any side impact sensors that have been physically damaged or if a fault is being registered

Restraints Control Module (RCM) if the three crashes/impacts have been stored

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

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points

Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Front seat frame and head restraints

Door trim casing

Seat belt height adjusters

Rear seat belts
Head airbag modules

CAUTION: If the head airbag modules are deployed, the following components must be replaced on the side of

the vehicle on which the deployment occurred:

Head airbag modules

Link lead between airbag gas generator and restraints control module (RCM) harness

Airbag retaining clips

Internal trim finisher

Front seat belt buckle pre -tensioners

Any side impact sensors that have been physically damaged or if a fault is being registered

Restraints Control Module (RCM) if the three crashes/impacts have been stored

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

Headlining

Component mounting brackets

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points

Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Adjacent trim components

Seat belt height adjusters
Rear impacts

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

replaced:

Seat belt pre-tensioners

Front and rear seat belt retractors used during the impact

Restraints Control Module (RCM) if the three crashes/impacts have been stored

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

Seat belt height adjusters

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points

Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Air Conditioning System Precautions

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 installed to the vehicle.

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

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

WARNINGS:

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

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

Remedial actions

part of the body will cause immediate freezing of that area. Also, refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if contact is made.

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

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

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed on any

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

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. Make sure that hoses are correctly positioned before tightening couplings, and make sure
that all clips and supports are utilised.
Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected
by heat shielding.
Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of
components and panels may transmit noise and so must be eliminated.
The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value.
An additional spanner must be used to hold the union to prevent twisting of the pipe when tightening
connections.
Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings,
BUT NOT to the threads of the connection.
All protective plugs or caps must remain in place in the component until immediately prior to connection.
Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of
moisture from the air that enters it.
When disconnecting, immediately plug or cap all air conditioning pipes to prevent ingress of dirt and moisture
into the system.
Components must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 20
minutes or longer, a new receiver/drier must be installed.
The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A
receiver/drier that has been left uncapped for longer than 20 minutes must not be used; install a new unit.
The receiver/drier should be the last component connected to the system to make sure optimum dehydration
and maximum moisture protection of the system.
Use alcohol and a clean lint-free cloth to clean dirty connections.
Make sure that all new parts installed are marked for use with R134a.
When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of
this manual for the correct procedure.

Refrigerant oil

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

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

Compressor
A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release

the sealing cap; gas pressure should be heard to vent as the seal is broken.

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

Rapid refrigerant discharge
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.

Precautions for refrigerant recovery, recycling and recharging
When the air conditioning system is recharged, any existing refrigerant is first recovered from the system and

recycled. The system is then charged with the required weight of refrigerant and volume of refrigerant oil.

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

CAUTIONS:

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

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

Air Conditioning Compressor Replacement
A new compressor is supplied filled with a full charge (X cm³) of refrigerant oil.
A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of

oil to be drained:

Remove the drain plug from the old compressor.
Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor
clutch to make sure the compressor is completely drained.
Note the quantity of oil drained (Y cm³).
Calculate the quantity of oil to be drained from the new compressor using the following formula:X cm³ — (Y

cm³ + 20 cm³) = Q cm³

Remove the drain plug from the new compressor and drain Q cm3 of oil. install and tighten the compressor
drain plug.

Vehicle Weights

Item kg lb

Maximum Gross Vehicle Weight (GVW)

Petrol engine vehicles naturally aspirated 3070 6768
Petrol engine vehicles supercharged 3125 6889
Diesel engine vehicles 3070 6768
Maximum weight of unbraked trailer:
On-road 750 1650
Off-road 750 1650
Maximum towable weight (mass) - Trailers with overrun brakes
On-road 3500 7700
Off-road 1000 2205
Maximum roof rack load (Including the mass of the roof rack):
On-road 75 110
Off-road 75 110

Vehicle Dimensions

Item mm in

Length - including number plate plinth - All models 4798 188.9
Width - All models:
Mirrors extended 2170 85.4
Mirrors folded 1983 78.1
Maximum height - At standard ride height - All models:
With roof rack and rails 1784 70.2
With roof antenna module 1812 71.3
With sunroof open 1817 71.5
Wheelbase - All models 2745 108
Front overhang - All models 880 45.8
Rear overhang - All models 1163 44.5
Track - All models:
Front 1605 63.2
Rear 1612 63.5
Underbody Clearences:
Standard ride height - Running clearance to exhaust - Minimum - Kerb weight 172 6.8
Standard ride height - Ground to front undertray clearance 188 7.4
Standard ride height - Ground to rear differential casing clearance 200 7.9
Off-road height - Running clearance to exhaust - Minimum - Kerb weight 227 8.9
Off-road height - Ground to front undertray clearance 243 9.6
Off-road height - Ground to rear differential casing clearance 255 10
Suspension articulation - All models:
Front 255 10.03

Rear 310 12.2

Departure angle - Towbar NOT installed:
Standard ride height with full size spare wheel 24.1° 24.1°
Standard ride height with space saver wheel 26° 26°
Off-road height with full size spare wheel 27.4° 27.4°
Off-road height with full space saver wheel 29° 29°
Departure angle - Towbar installed - NOT NAS vehicles:
Standard ride height 15.1° 15.1°
Off-road ride height 17.8° 17.8°
Departure angle - Towbar installed - NAS vehicles:
Standard ride height 13.9° 13.9°
Off-road ride height 16.9° 16.9°
Departure angle - Adjustable height towbar installed:
Standard ride height 13.3° 13.3°
Off-road ride height 16° 16°
Wading depth:
Off-road height 700 27.5
Approach angle:
Standard ride height 30.2° 30.2°
Off-road ride height 34° 34°
Ramp angle:
Standard ride height 20° 20°
Off-road ride height 25° 25°

Published: 11-May-2011

General Information - Health and Safety Precautions

Description and Operation

Introduction

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

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

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

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

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

Acids and Alkalis

For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in batteries.
Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can

destroy ordinary protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do

not breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.
Display Eye Hazard sign.

Air Bags

Highly flammable, explosive – observe No Smoking policy.
Used within the vehicle as safety restraints.
The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C).
The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air bag

module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as
this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should
be worn when dealing with the spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved

chemical waste site.

Following any direct contact with Sodium Azide:

Wash affected areas thoroughly with water.

SEEK IMMEDIATE MEDICAL ASSISTANCE.

Air Bags - Do's

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

Air Bags - Do Not

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

Do Not use any electrical probes on the wiring circuit.

Air Suspension

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

Air Conditioning Refrigerant

Highly flammable, combustible – observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and

goggles.
If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should

also be rinsed with an appropriate irrigation solution such as a solution of 9% Sodium Chloride and Purified Water.

DO NOT RUB THE EYES AND SEEK IMMEDIATE MEDICAL ATTENTION.

Air Conditioning Refrigerant

Do Not

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

Adhesives and Sealants

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

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

Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturer's instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover

with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull skin tissue apart.
Use in well ventilated areas as vapors can cause irritation to the nose and eyes.

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

Solvent-based Adhesives/Sealers - See Solvents

Follow manufacturers instructions.

Water-based Adhesives/Sealers

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

Hot Melt Adhesives

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

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

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

Mixing should be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful

chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.

Isocyanate (Polyurethane) Adhesives/Sealers

See also Resin-based Adhesives
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity

reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the

nervous system including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to
vapour concentrations may result in adverse health effects.

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

Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in ventilated booths which incorporate facilities for removing vapors

and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.

Antifreeze

May be flammable when undiluted.
Vapors may be given off from coolant antifreeze when heated. Avoid breathing these vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed, can be fatal;

SEEK IMMEDIATE MEDICAL ATTENTION.

Battery Acids

See also Alkalis and Acids.
Gases released during battery charging are explosive. Always remove the battery from the vehicle prior to charging.

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

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

Brake Pads and Linings

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

Brake and Clutch Fluid

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

Chemical Materials

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

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

Chemical Materials - Do's

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

Chemical Materials - Do Not

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

Corrosion Protection Materials

Some corrosion protection materials are highly flammable – observe NO SMOKING POLICY.
These materials are varied and the manufacturers instructions must always be followed. The materials may contain

solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces.

Dust

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

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

Electrical Equipment

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

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

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

Make sure that electrical equipment and flexes do not come into contact with water.
Make sure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.
Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle

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

In cases of electrocution:

Switch off the power supply before approaching the victim.
If this is not possible, DO NOT TOUCH THE VICTIM but push or drag the person from the source of
electricity using dry, non -conductive material.
Commence resuscitation if trained to do so.

SEEK IMMEDIATE MEDICAL ATTENTION.

Exhaust Fumes

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

Gasoline (Petrol) engine

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

Gas Oil (Diesel engine)

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

Fibre Insulation

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

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

Fire

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

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

Decontaminate and dispose of protective clothing immediately after use.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical

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

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

First Aid

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

Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place affected area in cool to cold water.
Individuals affected by inhalation of gases and fumes should be removed to fresh air immediately. If effects persist,

consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not

induce vomiting unless this action is indicated on the label.

Fluoroelastomers (Synthetic Rubber)

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

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

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

Remove any contaminated clothing.

SEEK IMMEDIATE MEDICAL ATTENTION

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

Foams - Polyurethane

Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases

should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and

respiratory protection. Do not remove the respirator immediately after spraying, wait until the vapour/mists have
cleared.

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

Fuels

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

Gasoline (Petrol)

Highly flammable - OBSERVE NO SMOKING POLICY.
Swallowing gasoline (petrol) can result in mouth and throat irritation and absorption from the stomach can result in

drowsiness and unconsciousness. Small amounts can be fatal to children. Inhalation into the lungs, through
vomiting, is a very serious hazard.

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

SEEK IMMEDIATE MEDICAL ATTENTION.

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

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

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

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

Gas-oil (Diesel Fuel)

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

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

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

Kerosene (Paraffin)

Used also as heating fuel, solvent and cleaning agent.
Flammable - OBSERVE NO SMOKING POLICY.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid

aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from

kerosene at elevated temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and
make sure there is adequate ventilation.

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

Gas Cylinders

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

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

Care should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.

General Workshop Tools and Equipment

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

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

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

Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.
Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipment

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the

underlying tissue and cause serious injury.

Jacking

Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.
When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is

applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has
sufficient load capacity for the weight of the vehicle.

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

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

Legal Aspects

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

equipment in a workshop.
For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with

the many health and safety laws and regulations within their country, published by both national and local
authorities.

Lubricants and Greases

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

Used Engine Oil

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

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

Health Protection Precautions

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

Environmental Precautions

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

Emissions to air
Many of the activities that are carried out in workshops emit gases and fumes which can contribute to global

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

Exhaust fumes
Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to

atmosphere. However, the amount of time engines are running and the position of the vehicle should be carefully
considered at all times, to reduce the release of poisonous gases and minimise the inconvenience to people living
nearby.

Solvents
Some of the cleaning agents used are solvent based and will evaporate rapidly to atmosphere if used carelessly, or

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

Refrigerant
It is illegal to release any refrigerant into the atmosphere. Discharge and replacement of these materials from air

conditioning units should only be carried out using the appropriate equipment.
Discharges to water
Most workshops will have two systems for discharging waste water - storm drains and foul drains. Storm drains

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

Spillages
Every precaution must be taken to prevent spillage of oil, fuel, solvents etc., reaching the drains. All handling of

such materials must take place well away from drains and preferably in an area with a suitable containing wall to
prevent discharge into drains or watercourses. If a spillage occurs, it must be soaked up immediately using a spill kit
where provided.

Checklist

Spillage prevention:

Store liquids in a secure area.
Make sure that taps on liquid containers are secure and cannot be accidentally turned on.
Protect bulk storage tanks from vandalism by locking the valves.
Transfer liquids from one container to another in an area away from open drains.
Ensure lids are replaced securely on containers.

Have spill kits available near to points of storage and liquid handling areas.
Spill Kits
Special materials are available to absorb a number of different substances. They can be in granular form, ready to

use and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste
management.

Land contamination

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

Legal compliance

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

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

Checklist

Always adhere to the following:

Know what legal consents and licences apply to the operations.

Check that the emissions and discharges comply with legal requirements.

Waste Management

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

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

Handling and storage of waste
Ensure that waste materials are not poured down the drain or on to soil and are stored in such a way that they do

not escape on to land or soil.
All waste must be segregated into individual types e.g. oils, metals, batteries, scrap components etc. This will

prevent any reaction between different materials and assist in disposal.
Disposal of waste
Dispose of waste in accordance with the following guidelines:

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

Refrigerant: Collect in specialist equipment and reuse.

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

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

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

remainder in ordinary waste.

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

Metals: Can be sold if separate from general waste.

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

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

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

contractors.

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

Rubber/plastics: Dispose of in ordinary waste.

Hoses: Dispose of in ordinary waste.

Batteries: Keep separate and dispose of to specialist contractors.

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

Electrical components: Return to supplier for refurbishment or disassemble and reuse any suitable

components. Dispose of remainder in ordinary waste.

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

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

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

Noise

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

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

Solder

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

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

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

Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust

from clothing.

Solvents

For example acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged

contact. Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness,

headaches and, in the worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not

be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs, for example through vomiting, is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers

tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, for example paints, adhesives, and metal coatings, use extraction

ventilation or personal respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.

Suspended Loads

CAUTION: Never improvise lifting tackle.

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

Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for

the job, in good condition and regularly maintained.

WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING OUT OF

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

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

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

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.

WHERE CASES OF SKIN CONTACT OCCUR, SEEK IMMEDIATE MEDICAL HELP.

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

DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-

ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the
material may be Viton or any fluoroelastomer.

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

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

Welding

Viton

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

Resistance Welding

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

Arc Welding

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

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

Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any

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

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

Gas Welding (and Cutting)

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

The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra-violet emission is much less than that from arc

welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,

particularly during cutting away of damaged body parts, and inhalation of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if

brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes
and expert advice may be required.

SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS

FUEL TANKS.

Warning Symbols on Vehicles

Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out

service or repair operations on the vehicle.

Published: 11-May-2011

General Information - Solvents, Sealants and Adhesives

Description and Operation

Solvents

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

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

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

Sealers

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

It is essential that the sealant(s) specified for a particular procedure are used, DO NOT use any other sealant.
Always remove traces of old sealant using a plastic scraper or suitable solvent, never use emery cloth or metal

scrapers.

Adhesives

Whenever a procedure involves the use of an adhesive, the adhesive specified must be used and the manufacturer's
instructions regarding application together with any health and safety precautions must be followed.

Published: 11-May-2011

General Information - Road/Roller Testing

Description and Operation
Road or rolling road testing may be carried out for various reasons and a procedure detailing pre -test checks,

through engine starting and stopping, pre -driving checks, on-test checks to final checks on completion of the test
are given.

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

Pre-Test Checks

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

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

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

Starting the Engine

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

With the ignition switched off, check:

The parking brake is applied.

Automatic gearbox: The selector lever is in 'P' - Park
Transfer case: 'H' - High is selected

All instrument gauges read zero.

With the ignition switched on, check:

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

On Road Test Check:

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

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

Brake Testing

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

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

Installation is carried out.

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

Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding.
After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake temperature.

A disc which feels appreciably hotter than the others, could indicate that the pads on that disc are binding.
After completion of the test, check for:

Oil, coolant, hydraulic, air and fuel leaks.
Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission etc., which
might indicate over tightness or lack of lubrication.

Rolling Road Testing

Four -Wheel Rolling Road

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

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

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

Two- Wheel Rolling Road

CAUTION: On no account should an attempt be made to carry out any form of testing on a two-wheel rolling
road.

Published: 10-Feb-2014

General Information - Special Tool Glossary

Description and Operation

Service Tools

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

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

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

Europe and European countries not in the following list.
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Non- European Export
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]

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

United Kingdom
Tel: [phone]
Fax: [phone]
e-mail: CSS.UK@bosch -automotive.com
Scandinavia and the Baltics
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Spain and Portugal
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
North America
Tel: [phone]
Fax: [phone] or 001 586 578 7375
Australia
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Japan and East Asia
Tel: [phone]
Fax: [phone]
e-mail: jp.customerservices@service -solutions.com
Italy
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Belgium, Netherlands and Luxembourg

Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
China
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
India
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Mexico - LAM Region
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Brazil
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
France
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]
Korea
Tel: [phone]
Fax: [phone]
e-mail: [e-mail] / [e-mail]

Published: 11-May-2011

General Information - Petrol and Petrol-Ethanol Fuel Systems Health and
Safety Precautions

Description and Operation

WARNINGS:

Fuel may not give adequate warning before toxic or harmful effects arise.

Exposure to fuel can be harmful and can cause severe health damage or death.

Extreme care must be exercised when handling hot fluids. Always wash off spilled fluids from affected areas of
skin immediately.

Highly flammable mixtures are always present and may ignite when working on fuel systems. Do not allow
naked flames, sparks or lighted substances to come near fuel related components.

Fuel must not be used as a cleaning agent.

Keep fuel containers tightly closed, out of direct sunlight and in a cool area. Keep away from heat sources,
ignition sources and oxidizing agents.

SKIN CONTACT: Excessive or prolonged skin contact with diesel fuel may cause serious skin disorders including
skin cancer.

SKIN CONTACT: Fuel is mildly irritating to the skin and may cause dermatitis due to defatting effect. Remove
contaminated clothing. Wash affected areas of skin with soap and water. Seek medical attention for any persistent
skin irritation or abnormality. Wash contaminated clothing before reuse.

EYE CONTACT: Fuel is mildly irritating to the eyes. Flush with plenty of running water, blinking as often as
possible. Do not force the eyelid open. Seek medical attention for any persistent eye irritation or abnormality.

SWALLOWED: Fuel is moderately toxic and tends to foam on vomiting. If drawn into the lungs, inflammation
may develop. Do not induce vomiting. If spontaneous vomiting occurs place the victim in a forward position to
reduce the risk of fuel being drawn into the lungs. Give nothing by mouth. If breathing but unconscious, place in the
recovery position. If breathing has stopped, apply artificial respiration. Seek immediate medical attention.

INHALED: Fuel is toxic to the respiratory and other body systems. Exposure may result in various symptoms
including drowsiness, unconsciousness or severe health damage. Move a victim to fresh air. Keep a victim warm and
at rest. If unconscious, place in the recovery position. If not breathing, apply artificial respiration. Give cardiac
massage if necessary. Seek immediate medical attention.

CAUTIONS:

Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that
absolute cleanliness is observed when working with these components.

Make sure that the workshop area in which the vehicle is being worked on is as clean and as dust free as
possible.

Published: 16-May-2012

General Information - Diagnostic Trouble Code (DTC) Index DTC:
Adaptive Damping Control Module (ADCM)

Description and Operation

Adaptive Damping Control Module (SUMB)

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or
the donor vehicle.

NOTES:

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

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

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

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

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

The table below lists all Diagnostic Trouble Codes (DTCs) that could be logged in the Suspension Control Module, for
additional Diagnosis and Testing information refer to the relevant Diagnosis and Testing Section.
For additional information, refer to: Ride and Handling Optimization
Diagnosis and Testing).

DTC Description Possible Cause Action

C101D-12Left Front

Vertical
Acceleration
Sensor - Circuit
short to battery

C101D-14Left Front

Vertical
Acceleration
Sensor - Circuit
short to ground
or open

C101D-22Left Front

Vertical
Acceleration
Sensor - Signal
amplitude >
maximum

Left front
vertical
accelerometer
circuit short to
power

Left front
vertical
accelerometer
circuit short to
ground or open
circuit
Left front
vertical
accelerometer
fault

Left front
vertical
accelerometer
signal amplitude
above
maximum
Left front
vertical
accelerometer
insecurely
mounted
Left front
vertical
accelerometer
signal circuit
short to another
circuit
Left front
vertical
accelerometer
internal fault

Refer to the electrical circuit diagrams and check left front
vertical accelerometer circuit for short to power or another
circuit. Repair circuit, clear the DTC and retest the system

Refer to the electrical circuit diagrams and check front
vertical accelerometer circuit for short to ground, open
circuit. If no fault found on wiring suspect accelerometer.
Replace accelerometer, clear DTC and retest the system

With vehicle parked on a level surface, read left front
vertical accelerometer voltage and check it lies in range 1.9
to 2.1 volts. If not OK then check electrical wiring for
shorts, loose connections and repair as required. If wiring
OK then suspect faulty accelerometer/incorrectly installed
accelerometer. Check the accelerometer is correctly
mounted, secure or renew accelerometer as required. Clear
DTC and retest system

(204-06 Ride and Handling Optimization,

C101D-26Left Front

Vertical
Acceleration
Sensor - Signal
rate of change
below threshold

Left front
vertical
accelerometer
signal rate of
change below
threshold
Left front
vertical
accelerometer
signal circuit
short to another
circuit
Left front
vertical
accelerometer
internal fault

Refer to the electrical circuit diagrams and check left front
vertical accelerometer signal circuit for faults, if circuit is
correct suspect faulty accelerometer. Replace the
accelerometer, clear the DTC and retest the system

C101D-78Left Front

Vertical
Acceleration
Sensor ­Alignment or
adjustment
incorrect

C101E-12Right Front

Vertical
Acceleration
Sensor - Circuit
short to battery

C101E-14Right Front

Vertical
Acceleration
Sensor - Circuit
short to ground
or open

Left front
vertical
accelerometer
alignment or
adjustment
incorrect
Left front
vertical
accelerometer
bracket bent
Left front
vertical
accelerometer
damaged

Right front
vertical
accelerometer
circuit short to
power

Right front
vertical
accelerometer
circuit short to
ground or open
circuit
Right front
vertical
accelerometer
fault

Check left front vertical accelerometer for location and
security, if correct suspect faulty accelerometer. Replace the
accelerometer/bracket as required, clear the DTC and retest
the system

Refer to the electrical circuit diagrams and check right front
vertical accelerometer circuit for short to power or another
circuit. Repair circuit, clear the DTC and retest the system

Refer to the electrical circuit diagrams and check right front
vertical accelerometer circuit for short to ground, open
circuit. If no fault found on wiring suspect accelerometer.
Replace accelerometer, clear DTC and retest the system

C101E-22Right Front

Vertical
Acceleration
Sensor - Signal
amplitude >
maximum

C101E-26Right Front

Vertical
Acceleration
Sensor - Signal
rate of change
below threshold

Right front
vertical
accelerometer
signal amplitude
above
maximum
Right front
vertical
accelerometer
insecurely
mounted
Right front
vertical
accelerometer
signal circuit
short to another
circuit
Right front
vertical
accelerometer
internal fault

Right front
vertical
accelerometer
signal circuit
short to another
circuit
Right front
vertical
accelerometer

With vehicle parked on a level surface, read right front
vertical accelerometer voltage and check it lies in range 1.9
to 2.1 volts. If not OK then check electrical wiring for
shorts, loose connections and repair as required. If wiring
OK then suspect faulty accelerometer/incorrectly installed
accelerometer. Check the accelerometer is correctly
mounted, secure or renew accelerometer as required. Clear
DTC and retest system

Refer to the electrical circuit diagrams and check right front
vertical accelerometer signal circuit for faults, if circuit is
correct suspect faulty accelerometer. Replace the
accelerometer, clear the DTC and retest the system

internal fault

C101E-78Right Front

Vertical
Acceleration
Sensor ­Alignment or
adjustment
incorrect

Right front
vertical
accelerometer
alignment or
adjustment
incorrect
Right front
vertical
accelerometer
bracket bent
Right front
vertical
accelerometer
damaged

Check the right front vertical accelerometer for location and
security. If correct, suspect a faulty accelerometer. Replace
the accelerometer/bracket as required, clear the DTC and
retest the system

C1024-00System

Temporarily
Disabled Due To
Power
Interruption
During Driving ­No sub type
information

C102C-12Right Rear

Vertical
Acceleration
Sensor - Circuit
short to battery

C102C-14Right Rear

Vertical
Acceleration
Sensor - Circuit
short to ground
or open

C102C-22Right Rear

Vertical
Acceleration
Sensor - Signal
amplitude >
maximum

Loss of power
to adaptive
damping system
control module
whilst driving

Right rear
vertical
accelerometer
circuit short to
power

Right rear
vertical
accelerometer
circuit short to
ground, open
circuit
Right rear
vertical
accelerometer
fault

Right rear
vertical
accelerometer ­Signal
amplitude >
maximum
Right rear
vertical
accelerometer
insecurely
mounted
Right rear
vertical
accelerometer
signal circuit
short to another
circuit
Right rear
vertical
accelerometer
internal fault

Refer to the electrical circuit diagrams and check power and
ground circuits to adaptive damping system control module
for intermittent or poor connection. Repair wiring circuits as
required, clear DTC and retest the system

Refer to the electrical circuit diagrams and check right rear
vertical accelerometer circuit for short to power or another
circuit. Repair circuit, clear the DTC and retest the system

Refer to the electrical circuit diagrams and check right rear
vertical accelerometer circuit for short to ground, open
circuit. If no fault found on wiring suspect accelerometer.
Renew accelerometer, clear DTC and retest the system

With vehicle parked on a level surface, read right rear
vertical accelerometer voltage and check it lies in range 1.9
to 2.1 volts. If not OK then check electrical wiring for
shorts, loose connections and repair as required. If wiring
OK then suspect faulty accelerometer/incorrectly installed
accelerometer. Check the accelerometer is correctly
mounted, secure or renew accelerometer as required. Clear
DTC and retest system

C102C-26Right Rear

Vertical
Acceleration
Sensor - Signal
rate of change
below threshold

Right rear
vertical
accelerometer
signal rate of
change below
threshold
Right rear
vertical
accelerometer
signal circuit
short to another
circuit
Right rear
vertical
accelerometer
internal fault

Refer to the electrical circuit diagrams and check right rear
vertical accelerometer signal circuit for faults, if circuit is
correct suspect faulty accelerometer. Replace the
accelerometer, clear the DTC and retest the system

C102C-78Right Rear

Right rear

Check right rear vertical accelerometer for location and

Vertical
Acceleration
Sensor ­Alignment or
adjustment
incorrect

vertical
accelerometer
alignment or
adjustment
incorrect
Right rear
vertical
accelerometer
bracket bent
Right rear
vertical
accelerometer
damaged

security, if correct suspect faulty accelerometer. Replace the
accelerometer/bracket as required, clear the DTC and retest
the system

C1030-12Left Rear

Vertical
Acceleration
Sensor - Circuit
short to battery

C1030-14Left Rear

Vertical
Acceleration
Sensor - Circuit
short to ground
or open circuit

C1030-22Left Rear

Vertical
Acceleration
Sensor - Signal
amplitude >
maximum

Left rear
vertical
accelerometer
circuit short to
power

Left rear
vertical
accelerometer
circuit short to
ground, open
circuit
Left rear
vertical
accelerometer
fault

Left rear
vertical
accelerometer
signal amplitude
greater than
maximum
Left rear
vertical
accelerometer
insecurely
mounted
Left rear
vertical
accelerometer
signal circuit
short circuit
Left rear
vertical
accelerometer
internal fault

Refer to the electrical circuit diagrams and check left rear
vertical accelerometer circuit. Repair circuit, clear the DTC
and retest the system

Refer to the electrical circuit diagrams and check left rear
vertical accelerometer circuit. If no fault found, suspect
accelerometer. Renew accelerometer, clear DTC and retest
the system

With vehicle parked on a level surface, check the left rear
vertical accelerometer voltage is between 1.9 to 2.1 volts. If
not, check the electrical circuit for short circuit or loose
connections and repair as required. If no circuit fault is
found, suspect faulty accelerometer/incorrectly installed
accelerometer. Check the accelerometer is correctly
mounted, secure or renew accelerometer as required, clear
DTC and retest system

C1030-26Left Rear

Vertical
Acceleration
Sensor - Signal
rate of change
below threshold

C1030-78Left Rear

Vertical
Acceleration
Sensor ­Alignment or
adjustment
incorrect

Left rear
vertical
accelerometer
signal rate of
change below
threshold
Left rear
vertical
accelerometer
signal circuit
short circuit
Left rear
vertical
accelerometer
internal fault

Left rear
vertical
accelerometer
alignment or
adjustment
incorrect
Left rear
vertical
accelerometer
bracket bent
Left rear

Refer to the electrical circuit diagrams and check left rear
vertical accelerometer signal circuit for faults. If circuit is
correct suspect the accelerometer. Renew the
accelerometer, clear the DTC and retest the system

Check the left rear vertical accelerometer for location and
security. If correct, suspect faulty accelerometer. Renew the
accelerometer/bracket as required, clear the DTC and retest
the system

vertical

C110C-01Left Front

Damper
Solenoid ­General
electrical failure

accelerometer
damaged

General
electrical failure
Left front
damper
solenoid circuit
fault

Refer to the electrical circuit diagrams and check front left
damper solenoid circuit. If no faults are evident suspect a
faulty adaptive damping system control module

C110C-14Left Front

Damper
Solenoid ­Circuit short to
ground or open

C110C-18Left Front

Damper
Solenoid ­Circuit current
below threshold

C110C-19Left Front

Damper
Solenoid ­Circuit current
above threshold

C110C-1DLeft Front

Damper
Solenoid ­Circuit current
out of range

Front left
damper
solenoid circuit
short to
ground, open
circuit or high
circuit
resistance
Front left
damper
solenoid failure

Left front
damper
solenoid circuit
current below
threshold
Front left
damper
actuator open
circuit at
startup

Front left
damper
solenoid circuit
current above
threshold

Left front
damper
solenoid circuit
current out of
range
Front left
damper
solenoid circuit
short to
ground/power,
open circuit
Front left
damper
solenoid failure

Refer to the electrical circuit diagrams and check front left
damper solenoid circuit for short to ground or open circuit.
Check for corrosion, backed out terminals and poor crimping
of terminals

Refer to the electrical circuit diagrams and check front left
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check front left
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check front left
damper solenoid circuit. Check and install a new front left
damper as required

C110C-64Left Front

Damper
Solenoid ­Signal
plausibility
failure

C110D-01Right Front

Damper
Solenoid ­General
electrical failure

C110D-14Right Front

Damper
Solenoid -

Left front
damper
solenoid signal
plausibility
failure
Front left
damper
solenoid
measured
current control
loop failed
Front left
damper
solenoid open
circuit

General
electrical failure
Right front
damper
solenoid circuit
fault

Right front
damper
solenoid circuit

Refer to the electrical circuit diagrams and check front left
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check front right
damper solenoid circuit. If no faults are evident suspect a
faulty control module

Where available, carry out any pinpoint tests associated with
this DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams and check

Circuit short to

ground or open

short to

right front damper solenoid circuit for short to ground, open

ground, open
circuit
Right front
damper failure

circuit. Check and install a new damper as required

C110D-18Right Front

Damper
Solenoid ­Circuit current
below threshold

C110D-19Right Front

Damper
Solenoid ­Circuit current
above threshold

C110D-1DRight Front

Damper
Solenoid ­Circuit current
out of range

Right front
damper
solenoid circuit
current below
threshold
Front right
damper
actuator open
circuit at
startup

Front right
damper
solenoid circuit
current above
threshold

Right front
damper
solenoid circuit
current out of
range
Front right
damper
solenoid circuit
short to
ground/power,
open circuit
Front right
damper
solenoid failure

Refer to the electrical circuit diagrams and check front right
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check front right
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check front right
damper solenoid circuit for short to ground, power or open
circuit. Check and install a new front right shock actuator as
required

C110D-64Right Front

Damper
Solenoid ­Signal
plausibility
failure

C110E-01Left Rear

Damper
Solenoid ­General
electrical failure

C110E-14Left Rear

Damper
Solenoid ­Circuit short to
ground or open

Front right
damper
solenoid
measured
current control
loop failed
Front right
damper
solenoid open
circuit

General
electrical failure
Left rear
damper
solenoid circuit
fault

Rear left
damper
solenoid circuit
short to
ground, open
circuit or high
circuit
resistance
Rear left
damper
solenoid failure

Refer to the electrical circuit diagrams and check front right
damper solenoid circuit resistance. Damper solenoid circuit
should lie in range of 2 to 3.5 ohms

Refer to the electrical circuit diagrams and check rear left
damper solenoid circuit. If no faults are evident suspect a
faulty adaptive damping system control module

Refer to the electrical circuit diagrams and check rear left
damper solenoid circuit for short to ground or open circuit.
Check for corrosion, backed out terminals and poor crimping
of terminals

C110E-18Left Rear

Damper
Solenoid ­Circuit current
below threshold

C110E-19Left Rear

Damper

Left rear
damper
solenoid circuit
current below
threshold
Rear left
damper
actuator open
circuit at
startup

Rear left
damper

Refer to the electrical circuit diagrams and check rear left
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check rear left
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Solenoid -

Circuit current

solenoid circuit

ground/power,

above threshold

C110E-1DLeft Rear

Damper
Solenoid ­Circuit current
out of range

current above
threshold

Left rear
damper
solenoid circuit
current out of
range
Rear left
damper
solenoid circuit
short to
ground/power,
open circuit
Rear left
damper
solenoid failure

Refer to the electrical circuit diagrams and check rear left
damper solenoid circuit for short to ground, power or open
circuit. Check and install a new damper as required

C110E-64Left Rear

Damper
Solenoid ­Signal
plausibility
failure

C110F-01Right Rear

Damper
Solenoid ­General
electrical failure

C110F-14Right Rear

Damper
Solenoid ­Circuit short to
ground or open

Left rear
damper
solenoid signal
plausibility
failure
Rear left
damper
solenoid
measured
current control
loop failed
Rear left
damper
solenoid open
circuit

General
electrical failure
Right rear
damper
solenoid circuit
fault

Rear right
damper
solenoid circuit
short to
ground, open
circuit or high
circuit
Resistance
Rear right
damper
solenoid failure

Refer to the electrical circuit diagrams and check rear left
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check rear right
damper solenoid circuit. If no faults are evident suspect a
faulty adaptive damping system control module

Refer to the electrical circuit diagrams and check rear right
damper solenoid circuit. Check for corrosion, backed out
terminals and poor crimping of terminals

C110F-18Right Rear

Damper
Solenoid ­Circuit current
below threshold

C110F-19Right Rear

Damper
Solenoid ­Circuit current
above threshold

C110F-1DRight Rear

Damper
Solenoid ­Circuit current
out of range

Right rear
damper
solenoid circuit
current below
threshold
Rear right
damper
actuator open
circuit at
startup

Rear right
damper
solenoid circuit
current above
threshold

Right rear
damper
solenoid circuit
current out of
range
Rear right
damper
solenoid circuit
short to

Refer to the electrical circuit diagrams and check rear right
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check rear right
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check rear right
damper solenoid circuit. Check and install a new right left
damper as required

open circuit

Rear right
damper
solenoid failure

C110F-64Right Rear

Damper
Solenoid ­Signal
plausibility
failure

C1A03-12Left Front Height

Sensor - Circuit
short to battery

C1A03-14Left Front Height

Sensor - Circuit
short to ground
or open

Right rear
damper
solenoid signal
plausibility
failure
Rear right
damper
solenoid
measured
current control
loop failed
Rear right
damper
solenoid open
circuit

Left front height
sensor circuit
short to power
Left front height
sensor circuit
shorted to
another cable
Left front height
sensor internal
fault

Wiring to left
front height
sensor (signal)
open circuit
Wiring to left
front height
sensor partial
short to ground
Wiring to left
front height
sensor short to
other cable
Left front height
sensor internal
electrical fault

Refer to the electrical circuit diagrams and check rear right
damper solenoid circuit resistance (nominal = 2 - 3.5 Ohms)

Refer to the electrical circuit diagrams and check front left
height sensor circuit. If circuit correct suspect sensor
internal fault, renew as required

Disconnect electrical connector to height sensor and inspect
connector pins & terminals for evidence of corrosion or
water ingress. If no corrosion found, disconnect harness at
adaptive damping system control module:

- A. Check for short circuits between any of the three
terminals and vehicle ground

- B. Check for electrical continuity between the two
connectors for each of the three terminals.
Reconnect electrical connector at control module only

- C. Check voltages at terminals within height sensor
connector (sensor not connected): voltage to sensor
ground connection should be ~0V, voltage to sensor
signal connection should be ~0V, voltage to sensor
supply connection should be ~5V. All voltages should
be within ± 0.15V

C1A03-21Left Front Height

Sensor - Signal
amplitude <
minimum

Left front height
sensor signal
amplitude below
minimum
Left front height
sensor linkage
not connected
Left front height
sensor or
bracket loose
Left front height
sensor bracket
bent
Incorrect height
calibration
Left front height
sensor linkage
toggled
Left front height
sensor water
ingress
Wiring to left
front height
sensor partial
short to ground
Wiring to left
front height
sensor short to
other cable
Left front height
sensor electrical
fault

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the

Left front height

sensor linkage

sensor arm over the range ±40° around the mid position

bent
Incorrect height
sensor installed

and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the height sensor.
NOTE: For angles of movement beyond ±40°, the sensor
signal will remain at a voltage of ~0.15V or ~4.85V,
depending on position of sensor lever. This is normal. When
investigation is complete, install the height sensor link to
the upper arm. If any fixings to the height sensor body or
mounting bracket were slackened, found to be loose or if a
height sensor was changed, the vehicle ride height MUST be
re-calibrated. Refer to the relevant section of the workshop
manual for the calibration procedure

C1A03-22Left Front Height

Sensor - Signal
amplitude >
maximum

Left front height
sensor signal
amplitude
above
maximum
Left front height
sensor linkage
not connected
Left front height
sensor or
bracket loose
Left front height
sensor bracket
bent
Incorrect height
calibration
Left front height
sensor linkage
toggled
Left front height
sensor water
ingress
Wiring to left
front height
sensor partial
short to ground
Wiring to left
front height
sensor short to
other cable
Left front height
sensor electrical
fault
Left front height
sensor linkage
bent
Incorrect height
sensor installed

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the
sensor arm over the range ±40° around the mid position
and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A03-76Left Front Height

Sensor - Wrong
mounting
position

C1A03-78Left Front Height

Sensor ­Alignment or
adjustment
incorrect

C1A04-12Right Front

Height Sensor ­Circuit short to

Incorrect left
front height
sensor
mounting
position

Left front height
sensor
alignment or
adjustment
incorrect

Right front
height sensor
circuit short to

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Check for correct height sensor installation and orientation.
Rectify as necessary

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Refer to the workshop manual and perform the height
sensor calibration procedure. Clear the DTC and retest the
system

Refer to the electrical circuit diagrams and check front right
height sensor circuit. If circuit correct suspect a height
sensor internal fault, renew as required

battery power

Right front
height sensor
circuit shorted
to another cable
Right front
height sensor
internal fault

C1A04-14Right Front

Height Sensor ­Circuit short to
ground or open

C1A04-21Right Front

Height Sensor ­Signal amplitude
< minimum

Wiring to right
front height
sensor (signal)
open circuit
Wiring to right
front height
sensor partial
short to ground
Wiring to right
front height
sensor short to
other cable
Right front
height sensor
internal
electrical fault

Right front
height sensor
signal amplitude
below minimum
Right front
height sensor
linkage not
connected
Right front
height sensor or
bracket loose
Right front
height sensor
bracket bent
Incorrect height
calibration
Right front
height sensor
linkage toggled
Right front
height sensor
water ingress
Wiring to right
front height
sensor partial
short to ground
Wiring to right
front height
sensor short to
other cable
Right front
height sensor
electrical fault
Right front
height sensor
linkage bent
Incorrect height
sensor installed

Disconnect electrical connector to height sensor and inspect
connector pins & terminals for evidence of corrosion or
water ingress. If no corrosion found, disconnect harness at
adaptive damping system control module:

- A. Check for short circuits between any of the three
terminals and vehicle ground

- B. Check for electrical continuity between the two
connectors for each of the three terminals.
Reconnect electrical connector at control module only

- C. Check voltages at terminals within height sensor
connector (sensor not connected): voltage to sensor
ground connection should be ~0V, voltage to sensor
signal connection should be ~0V, voltage to sensor
supply connection should be ~5V. All voltages should
be within ± 0.15V

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the
sensor arm over the range ±40° around the mid position
and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A04-22Right Front

Height Sensor ­Signal amplitude
> maximum

Right front
height sensor
signal amplitude
above
maximum
Right front
height sensor
linkage not

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect

connected

electrical connector to height sensor and inspect connecter

Right front
height sensor or
bracket loose
Right front
height sensor
bracket bent
Incorrect height
calibration
Right front
height sensor
linkage toggled
Right front
height sensor
water ingress
Wiring to right
front height
sensor partial
short to ground
Wiring to right
front height
sensor short to
other cable
Right front
height sensor
electrical fault
Right front
height sensor
linkage bent
Incorrect height
sensor installed

pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the
sensor arm over the range ±40° around the mid position
and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A04-76Right Front

Height Sensor ­Wrong mounting
position

C1A04-78Right Front

Height Sensor ­Alignment or
adjustment
incorrect

C1A05-12Left Rear Height

Sensor - Circuit
short to battery

C1A05-14Left Rear Height

Sensor - Circuit
short to ground
or open

Incorrect right
front height
sensor
mounting
position

Right front
height sensor
alignment or
adjustment
incorrect

Left rear height
sensor circuit
short to power
Left rear height
sensor circuit
shorted to
another cable
Left rear height
sensor internal
fault

Wiring to left
rear height
sensor (signal)
open circuit
Wiring to left
rear height
sensor partial
short to ground
Wiring to left
rear height
sensor short to
other cable
Left rear height
sensor internal

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Check for correct sensor installation and orientation. Rectify
as necessary

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Refer to the workshop manual and perform the height
sensor calibration procedure. Clear the DTC and retest the
system

Refer to the electrical circuit diagrams and check rear left
height sensor circuit. If circuit correct suspect a sensor
internal fault, renew as required

Disconnect electrical connector to height sensor and inspect
connector pins & terminals for evidence of corrosion or
water ingress. If no corrosion found, disconnect harness at
adaptive damping system control module:

- A. Check for short circuits between any of the three
terminals and vehicle ground

- B. Check for electrical continuity between the two
connectors for each of the three terminals.
Reconnect electrical connector at control module only

- C. Check voltages at terminals within height sensor
connector (sensor not connected): voltage to sensor
ground connection should be ~0V, voltage to sensor
signal connection should be ~0V, voltage to sensor
supply connection should be ~5V. All voltages should

electrical fault be within ± 0.15V

C1A05-21Left Rear Height

Sensor - Signal
amplitude <
minimum

Left rear height
sensor signal
amplitude below
minimum
Left rear height
sensor linkage
not connected
Left rear height
sensor or
bracket loose
Left rear height
sensor bracket
bent
Incorrect height
calibration
Left rear height
sensor linkage
toggled
Left rear height
sensor water
ingress
Wiring to left
rear height
sensor partial
short to ground
Wiring to left
rear height
sensor short to
other cable
Left rear height
sensor electrical
fault
Left rear height
sensor linkage
bent
Incorrect left
rear height
sensor installed

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the
sensor arm over the range ±40° around the mid position
and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A05-22Left Rear Height

Sensor - Signal
amplitude >
maximum

Left rear height
sensor signal
amplitude
above
maximum
Left rear height
sensor linkage
not connected
Left rear height
sensor or
bracket loose
Left rear height
sensor bracket
bent
Incorrect height
calibration
Left rear height
sensor linkage
toggled
Left rear height
sensor water
ingress
Wiring to left
rear height
sensor partial
short to ground
Wiring to left
rear height
sensor short to
other cable
Left rear height
sensor electrical

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the

fault

sensor arm over the range ±40° around the mid position

Left rear height
sensor linkage
bent
Incorrect height
sensor installed

and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A05-76Left Rear Height

Sensor - Wrong
mounting
position

C1A05-78Left Rear Height

Sensor ­Alignment or
adjustment
incorrect

C1A06-12Right Rear

Height Sensor ­Circuit short to
battery

C1A06-14Right Rear

Height Sensor ­Circuit short to
ground or open

Incorrect left
rear height
sensor
mounting
position

Left rear height
sensor
alignment or
adjustment
incorrect

Right rear
height sensor
circuit short to
power
Right rear
height sensor
circuit shorted
to another cable
Right rear
height sensor
internal fault

Wiring to right
rear height
sensor (signal)
open circuit
Wiring to right
rear height
sensor partial
short to ground
Wiring to right
rear height
sensor short to
other cable
Right rear
height sensor
internal
electrical fault

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Check for correct height sensor installation and orientation.
Rectify as necessary

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Refer to the workshop manual and perform the height
sensor calibration procedure. Clear the DTC and retest the
system

Refer to the electrical circuit diagrams and check the rear
right height sensor circuit. If circuit correct suspect a height
sensor internal fault, renew as required

Disconnect electrical connector to height sensor and inspect
connector pins & terminals for evidence of corrosion or
water ingress. If no corrosion found, disconnect harness at
adaptive damping system control module:

- A. Check for short circuits between any of the three
terminals and vehicle ground

- B. Check for electrical continuity between the two
connectors for each of the three terminals.
Reconnect electrical connector at control module only

- C. Check voltages at terminals within height sensor
connector (sensor not connected): voltage to sensor
ground connection should be ~0V, voltage to sensor
signal connection should be ~0V, voltage to sensor
supply connection should be ~5V. All voltages should
be within ± 0.15V

C1A06-21Right Rear

Height Sensor ­Signal amplitude
< minimum

Right rear
height sensor
signal amplitude
below minimum
Right rear
height sensor
linkage not
connected
Right rear
height sensor or
bracket loose
Right rear
height sensor
bracket bent
Incorrect height
calibration
Right rear
height sensor
linkage toggled
Right rear

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V

height sensor

water ingress

All voltages should be within ± 0.15V. To check sensor

Wiring to right
rear height
sensor partial
short to ground
Wiring to right
rear height
sensor short to
other cable
Right rear
height sensor
electrical fault
Right rear
height sensor
linkage bent
Incorrect height
sensor installed

operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the
sensor arm over the range ±40° around the mid position
and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A06-22Right Rear

Height Sensor ­Signal amplitude
> maximum

Right rear
height sensor ­Signal
amplitude
above
maximum
Right rear
height sensor
linkage not
connected
Right rear
height sensor or
bracket loose
Right rear
height sensor
bracket bent
Incorrect height
calibration
Right rear
height sensor
linkage toggled
Right rear
height sensor
water ingress
Wiring to right
rear height
sensor partial
short to ground
Wiring to right
rear height
sensor short to
other cable
Right rear
height sensor
electrical fault
Right rear
height sensor
linkage bent
Incorrect height
sensor installed

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Inspect for damage or loose fixings. Confirm that the correct
height sensor part number is installed, as specified in the
service parts database. To check height sensor: Disconnect
electrical connector to height sensor and inspect connecter
pins & terminals for evidence of corrosion or water ingress.
If no corrosion is found, disconnect harness at adaptive
damping system control module then: A. Check for short
circuits between any of the three terminals and vehicle
ground. B. Check for electrical continuity between the two
connectors for each of the three terminals. Reconnect
electrical connector at control module only. C. Check
voltages at terminals within height sensor connector (sensor
not connected). • Voltage to sensor ground connection
should be ~0V, voltage to sensor signal connection should
be ~0V, voltage to sensor supply connection should be ~5V
All voltages should be within ± 0.15V. To check sensor
operation on the vehicle: Check for water ingress around
the height sensors, electrical connectors or shaft end. Check
for excessive movement in the shaft in all directions. Raise
vehicle (ideally on wheels-free ramp) until suspension on
corner under investigation is at full extension to gain access
to height sensor. Access may be improved by removing
road-wheel. Carefully disconnect the height sensor link from
the upper suspension arm. Monitor the height sensor signal
voltage output for the height sensor under investigation.
Position the sensor arm so it is in the mid position and
confirm that the voltage is around 2.5 volts. Move the
sensor arm over the range ±40° around the mid position
and confirm that the voltage changes smoothly between
around 0.2 volts and 4.8 volts. If voltages are incorrect or
do not change smoothly then renew the sensor. NOTE: For
angles of movement beyond ±40°, the sensor signal will
remain at a voltage of ~0.15V or ~4.85V, depending on
position of sensor lever. This is normal. When investigation
is complete, install the height sensor link to the upper arm.
If any fixings to the height sensor body or mounting bracket
were slackened, found to be loose or if a height sensor was
changed, the vehicle ride height MUST be re-calibrated.
Refer to the relevant section of the workshop manual for
the calibration procedure

C1A06-76Right Rear

Height Sensor ­Wrong mounting
position

Incorrect right
rear height
sensor
mounting
position

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Check for correct height sensor installation and orientation.
Rectify as necessary

C1A06-78Right Rear

Right rear

(ABS) Control

electrical circuit diagrams and check the CAN network

Height Sensor ­Alignment or
adjustment
incorrect

height sensor
alignment or
adjustment
incorrect

NOTE: If any height sensor fixings were slackened or found to
be loose or if a height sensor was changed, the vehicle ride height
MUST be re-calibrated.

Refer to the workshop manual and perform the height
sensor calibration procedure. Clear the DTC and retest the
system

C1B14-1CSensor Supply

Voltage A ­Circuit voltage
out of range

C1B15-1CSensor Supply

Voltage B ­Circuit voltage
out of range

U0001-88High speed CAN

Communication
Bus - Bus off

Sensor supply
voltage A out of
range
Any height
sensor supply
partial short to
other circuit or
ground
Any height
sensor internal
failure
Internal control
module failure

Sensor supply
voltage B out of
range
Any vertical
accelerometer
supply partial
short to other
circuit or
ground.
Any vertical
accelerometer
internal failure
Internal control
module failure

Bus off Refer to the electrical circuit diagrams and check the power

Refer to the electrical circuit diagrams and check the height
sensor supply circuit. Check all height sensors. Check the
adaptive damping system control module sensor supply
output voltage. Measured voltage should be between 4.995
volts and 4.85 volts

Refer to the electrical circuit diagrams and check
accelerometer supply for circuit fault. Check all vertical
accelerometers. Check adaptive damping system control
module sensor supply output voltage. Measured voltage
should be between 4.995 volts and 4.85 volts

and ground connections to the adaptive damping system
control module. Using the manufacturer approved diagnostic
system, complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network

U0100-00Lost

Communication
With ECM/PCM
A - No sub type
information

U0101-00Lost

Communication
with TCM - No
sub type
information

U0102-00Lost

Communication
With Transfer
Case Control
Module - No sub
type information

U0103-00Lost

Communication
With Gear Shift
Control Module
A - No sub type
information

No sub type
information

No sub type
information

No sub type
information

No sub type
information

Refer to the electrical circuit diagrams and check the power
and ground connections to the engine control module. Using
the manufacturer approved diagnostic system, complete a
CAN network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the engine
control module and the adaptive damping system control
module

Refer to the electrical circuit diagrams and check the power
and ground connections to the transmission control module.
Using the manufacturer approved diagnostic system,
complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network
between the transmission control module and the adaptive
damping system control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the transfer case control module.
Using the manufacturer approved diagnostic system,
complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network
between the transfer case control module and the adaptive
damping system control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the transmission control switch.
Using the manufacturer approved diagnostic system,
complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network
between the transmission control switch and the adaptive
damping system control module

U0121-00Lost

Communication
With Anti -Lock
Brake System

No sub type
information

Refer to the electrical circuit diagrams and check the power
and ground connections to the anti-lock brake system
control module. Using the manufacturer approved diagnostic
system, complete a CAN network integrity test. Refer to the

Module - No sub

type information

between the anti-lock brake system control module and the

Control Module

adaptive damping system control module

U0126-00Lost

U0132-00Lost

U0140-00Lost

U0142-00Lost

Communication
With Steering
Angle Sensor
Module - No sub
type information

Communication
With Suspension
Control Module
A - No sub type
information

Communication
With Body
Control Module ­No sub type
information

Communication
With Body
Control Module
B - No sub type
information

No sub type
information

No sub type
information

No sub type
information

No sub type
information

Refer to the electrical circuit diagrams and check the power
and ground connections to the steering angle sensor
module. Using the manufacturer approved diagnostic
system, complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network
between the steering angle sensor module and the adaptive
damping system control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the air suspension control
module. Using the manufacturer approved diagnostic
system, complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network
between the air suspension control module and the adaptive
damping system control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the central junction box. Using
the manufacturer approved diagnostic system, complete a
CAN network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the central
junction box and the adaptive damping system control
module

Refer to the electrical circuit diagrams and check the power
and ground connections to the central junction box. Using
the manufacturer approved diagnostic system, complete a
CAN network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the central
junction box and the adaptive damping system control
module

U0155-00Lost

Communication
With Instrument
Panel Cluster
(IPC) Control
Module - No sub
type information

U0300-00Internal Control

Module Software
Incompatibility ­No sub type
information

U0401-68Invalid Data

Received from
ECM/PCM A ­Event
information

U0402-68Invalid Data

Received from
TCM - Event
information

U0403-68Invalid Data

Received From
Transfer Case
Control Module ­Event
information

U0404-68Invalid Data

Received from
Gear Shift
Control Module
A - Event
information

U0415-68Invalid Data

Received From
Anti-Lock Brake
System (ABS)
Control Module ­Event
information

U0421-68Invalid Data

Received from
Suspension

No sub type
information

No sub type
information

Event
information

Event
information

Event
information

Event
information

Event
information

Event
information

Refer to the electrical circuit diagrams and check the power
and ground connections to the instrument cluster. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
instrument cluster and the adaptive damping system control
module

Check the central junction box vehicle configuration file.
Ensure the part number of adaptive damping system control
module is correct

Check the engine control module for related DTCs and refer
to the relevant DTC index

Check the transmission control module for related DTCs and
refer to the relevant DTC index

Check the transfer case control module for related DTCs and
refer to the relevant DTC index

Check the transmission control switch for related DTCs and
refer to the relevant DTC index

Check the anti-lock brake system control module for related
DTCs and refer to the relevant DTC index

Check the air suspension control module for related DTCs
and refer to the relevant DTC index

A - Event

information

U0422-68Invalid Data

U0428-68Invalid Data

U0443-68Invalid Data

U1A14-00CAN

Received From
Body Control
Module - Event
information

Received From
Steering Angle
Sensor Module
(SASM) - Event
information

Received From
Body Control
Module B ­Event
information

Initialization
Failure - No sub
type information

Event
information

Event
information

Event
information

CAN network
harness short
circuit or
disconnected

Check the central junction box for related DTCs and refer to
the relevant DTC index

Check the steering angle sensor module for related DTCs
and refer to the relevant DTC index

Check the central junction box for related DTCs and refer to
the relevant DTC index

Refer to the electrical circuit diagrams and check the power
and ground connections to the adaptive damping system
control module. Using the manufacturer approved diagnostic
system, complete a CAN network integrity test. Refer to the
electrical circuit diagrams and check the CAN network
between the central junction box and the adaptive damping
system control module

U2100-00Initial

Configuration
Not Complete ­No sub type
information

U2101-00Control Module

Configuration
Incompatible ­No sub type
information

U3000-01Control module

- General
electrical failure

U3000-04Control Module -

System internal
failures

Car
configuration
data not loaded
(new central
junction box
installed to
vehicle and not
initialized)

Car
configuration
data
transmitted
over CAN does
not match
adaptive
damping system
control module
internal
configuration

General
electrical failure

Module internal
failure

Configure the adaptive damping system control module
using the manufacturers approved diagnostic system. Clear
DTC and retest

Carry out the new module software installation procedure
using the manufacturers approved diagnostic system. Clear
DTC and retest

Check integrity of electrical connectors and pins to the
adaptive damping system control module. Refer to the
electrical circuit diagrams and check the power and ground
circuits to the adaptive damping system control module.
Check the damper negative circuits for short to ground.
Clear the DTC and retest. If the problem persists, renew the
adaptive damping system control module

Refer to the electrical circuit diagrams and check the power
and ground circuits to the adaptive damping system control
module. Clear the DTC and retest. If the problem persists,
renew the adaptive damping system control module

U3000-43Control Module -

Special memory
failure

U3000-45Control Module -

Program
memory failure

U3000-47Control Module -

Watchdog/safety
microcontroller
failure

U3000-52Control Module -

Not activated

Module internal
failure

Module internal
failure

Module internal
watchdog/safety
micro controller
failure

Adaptive
damping system
control module
has been

Refer to the electrical circuit diagrams and check the power
and ground circuits to the adaptive damping system control
module. Clear the DTC and retest. If the problem persists,
renew the adaptive damping system control module

Refer to the electrical circuit diagrams and check the power
and ground circuits to the adaptive damping system control
module. Clear the DTC and retest. If the problem persists,
renew the adaptive damping system control module

If this DTC is logged contact your local in market support

Install the latest software via the new module installation
procedure using the manufacturers approved diagnostic
system

replaced and

U3000-54Control Module -

Missing
calibration

not
programmed

Adaptive
damping system
control module
has been
replaced and no
software is
installed

Install the latest software via the new module installation
procedure using the manufacturers approved diagnostic
system

U3003-1CBattery Voltage

- Circuit voltage
out of range

U3003-62Battery Voltage

- Signal
compare failure

Circuit voltage
out of range
(supply voltage
at adaptive
damping control
module below

10.5V or above
18V for 30
seconds)

Signal compare
failure
High resistance
connections
Adaptive
damping system
control module
internal failure

Check the battery is in good condition and fully charged,
refer to the battery care manual. Refer to the starting and
charging section of the workshop manual and check the
performance of the charging system. Refer to the electrical
circuit diagrams and check power and ground circuit to
adaptive damping system control module

Check the battery is in good condition and fully charged,
refer to the battery care manual. Refer to the starting and
charging section of the workshop manual and check the
performance of the charging system. Refer to the electrical
circuit diagrams and check power and ground circuit to
adaptive damping system control module

Published: 28-Nov-2013

General Information - Diagnostic Trouble Code (DTC) Index DTC:
Adaptive Speed Control Module (ASCM)

Description and Operation

Adaptive Speed Control Module (ASCM)

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or
the donor vehicle.

NOTES:

CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor
kit, part number 3548-1358-00

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

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

When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places
and with a current calibration certificate. When testing resistance, always take the resistance of the digital
multimeter leads into account

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

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

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

The table below lists all Diagnostic Trouble Codes (DTCs) that could be logged in the Adaptive Speed Control Module
(ASCM), for additional Diagnosis and Testing information refer to the relevant Diagnosis and Testing Section.
For additional information, refer to: Speed Control
Testing).

DTC Description Possible Causes Action

B1A84-81Car Configuration

Data - Invalid serial
data received

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Incorrect car
configuration file
parameters in the
central junction box

(310-03A Speed Control - TDV6 3.0L Diesel, Diagnosis and

Using the manufacturer approved diagnostic
system, check and up-date the car configuration
file as necessary. Clear the DTCs and retest

C1A67-54Forward Looking

Sensor - Missing
calibration

C1A67-87Forward Looking

Sensor - Missing

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

The radar may be
horizontally
misaligned. This DTC
will clear when the
speed control sensor
is correctly aligned

NOTE: Adaptive cruise

Refer to the relevant section of the workshop
manual and carry out adaptive speed control
sensor alignment procedure
Investigate for signs of mild impact damage
around radar and mounting bracket

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault

message

persists, install a new adaptive speed control

control is disabled and
instrument pack displays
warning message "cruise not
available"

Adaptive speed
control module
internal
communication error
between DSP and
Host

module

C1A67-96Forward Looking

Sensor ­Component internal
failure

C1A67-97Forward Looking

Sensor ­Component or
system operation
obstructed or
blocked

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Adaptive speed
control module
internal
communication error
between DSP and
Host

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "radar
sensor blocked"

Adaptive speed
control module
obstructed by snow,
heavy rain or paint
protection covering
The adaptive speed
control module
misaligned

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, install a new adaptive speed control
module

Check and clear any obstructions from the sensor.
This DTC will be cleared automatically when
environmental conditions allow
Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, refer to the relevant section of the
workshop manual and adjust the adaptive speed
control module alignment

C1A67-98Forward Looking

Sensor ­Component or
system over
temperature

P174E-29Output Shaft Speed

/ ABS Wheel Speed
Correlation - Signal
invalid

U0001-88High Speed CAN

Communication Bus

- Bus off

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Adaptive speed
control module sensor
is over temperature

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Speed signals mis­match

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

Using the manufacturer approved diagnostic
system, clear the DTCs and retest
Consider the atmospheric conditions before
suspecting the component
This fault will be cleared automatically when
environmental conditions allow

Using the manufacturer approved diagnostic
system, check the anti -lock brake system control
module for related DTCs and refer to the relevant
DTC index
Clear the DTCs and retest

Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

U0100-00Lost

Communication
With ECM/PCM "A"

- No sub type

NOTE: Adaptive cruise
control is disabled and
instrument pack displays

Refer to the electrical circuit diagrams and test the
engine control module power and ground circuits
for open circuit, high resistance
Using the manufacturer approved diagnostic

information

system, perform a CAN network integrity test.

warning message "cruise not
available"

Engine control module
power or ground
circuit open circuit,
high resistance
High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

U0101-00Lost

Communication
with TCM - No sub
type information

U0103-00Lost

Communication
With Gear Shift
Control Module A ­No sub type
information

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Transmission control
module power or
ground circuit open
circuit, high resistance
High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

NOTE: Adaptive cruise
control will function as
normal

Transmission control
switch power or
ground circuit open
circuit, high resistance
High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

Refer to the electrical circuit diagrams and test the
transmission control module power and ground
circuits for open circuit, high resistance
Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

Refer to the electrical circuit diagrams and test the
transmission control switch power and ground
circuits for open circuit, high resistance
Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

U0121-00Lost

Communication
With Anti -Lock
Brake System
(ABS) Control
Module - No sub
type information

U0128-00Lost

Communication
With Park Brake
Control Module - No
sub type
information

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Anti-lock brake
system control module
power or ground
circuit open circuit,
high resistance
High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Electric park brake
control module power
or ground circuit open
circuit, high resistance
High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

Refer to the electrical circuit diagrams and test the
anti-lock brake system control module power and
ground circuits for open circuit, high resistance
Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

Refer to the electrical circuit diagrams and test the
electric park brake control module power and
ground circuits for open circuit, high resistance
Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

U0155-00Lost

Refer to the electrical circuit diagrams and test the

Communication
With Instrument
Panel Cluster (IPC)
Control Module - No
sub type
information

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Instrument cluster
power or ground
circuit open circuit,
high resistance
High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,
high resistance

instrument cluster power and ground circuits for
open circuit, high resistance
Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance

U0300-00Internal Control

Module Software
Incompatibility - No
sub type
information

U0300-55Internal Control

Module Software
Incompatibility ­Not configured

U0401-00Invalid Data

Received From
ECM/PCM - No sub
type information

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Car configuration
signal not received
Car configuration file
incorrect

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Car configuration
signal not received
Car configuration file
incorrect

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Using the manufacturer approved diagnostic
system, check and up-date the car configuration
file as necessary

Using the manufacturer approved diagnostic
system, check and up-date the car configuration
file as necessary

Using the manufacturer approved diagnostic
system, check the engine control module for
related DTCs and refer to the relevant DTC index

U0401-67Invalid Data

Received From
ECM/PCM - Signal
incorrect after
event

Missing/invalid data
from the engine
control module

- The engine
control module
did not respond
correctly to the
adaptive cruise
control cancel
request

- The engine
control module
did not respond
correctly to the
adaptive cruise
control auto
brake cancel
request

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Missing/invalid data
from the engine
control module

- The engine
control module
did not respond

Using the manufacturer approved diagnostic
system, check the engine control module for
related DTCs and refer to the relevant DTC index

correctly to the

adaptive cruise
control resume
active request

U0401-81Invalid Data

Received From
ECM/PCM - Invalid
serial data received

U0415-53Invalid Data

Received From
Anti-Lock Brake
System (ABS)
Control Module ­Deactivated

U0415-81Invalid Data

Received From
Anti-Lock Brake
System Control
Module - Invalid
serial data received

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Missing/invalid data
from the engine
control module

- The engine
control module
has inhibited
the adaptive
cruise control

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Missing/invalid data
from the anti-lock
brake system control
module

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Using the manufacturer approved diagnostic
system, check the engine control module for
related DTCs and refer to the relevant DTC index

Using the manufacturer approved diagnostic
system, check the anti -lock brake system control
module for related DTCs and refer to the relevant
DTC index

Using the manufacturer approved diagnostic
system, check the anti -lock brake system control
module for related DTCs and refer to the relevant
DTC index

U0417-67Invalid Data

Received From Park
Brake Control
Module - Signal
incorrect after
event

U0417-81Invalid Data

Received From Park
Brake Control
Module - Invalid
serial data received

Missing/invalid data
from the anti-lock
brake system control
module

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Missing/invalid data
from the electric park
brake control module

- The parking
brake module
did not respond
correctly to the
adaptive cruise
control EPB
apply request

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Using the manufacturer approved diagnostic
system, check the electric park brake control
module for related DTCs and refer to the relevant
DTC index

Using the manufacturer approved diagnostic
system, check the electric park brake control
module for related DTCs and refer to the relevant
DTC index

U0418-Invalid Data

Missing/invalid data
from the electric park
brake control module

- The parking
brake module
has inhibited
the adaptive
cruise control

Using the manufacturer approved diagnostic

68 Received From

Brake System
Control Module ­Event information

NOTE: Instrument pack
displays warning message
"forward alert not available"

Missing/invalid data
from the anti-lock
brake system control
module

- The anti -lock
brake system
control module
has inhibited
intelligent
emergency
braking /
advanced
emergency
brake assist
functions

system, check the anti -lock brake system control
module for related DTCs and refer to the relevant
DTC index

U0421-81Invalid Data

Received from
Suspension Control
Module A - Invalid
serial data received

U0423-81Invalid Data

Received From
Instrument Panel
Control Module ­Invalid serial data
received

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Missing/invalid data
from the air
suspension control
module

- The air
suspension
control module
has inhibited
the adaptive
cruise control

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Missing/invalid data
from the instrument
cluster

- The instrument
cluster has
inhibited the
adaptive cruise
control

Central junction box
missing or not
updated CAN message

Using the manufacturer approved diagnostic
system, check the air suspension control module
for related DTCs and refer to the relevant DTC
index

Using the manufacturer approved diagnostic
system, check the instrument cluster for related
DTCs and refer to the relevant DTC index

U1A00-88Private

Communication
Network - Bus off

U1A14-49CAN Initialization

Failure - Internal
electronic failure

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Speed control module
indicates bus off, on
private CAN bus

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

High speed CAN bus
circuit short circuit to
ground, short circuit
to power, open circuit,

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, contact dealer technical support. Under
no circumstance should any parts be replaced to
overcome this issue

Using the manufacturer approved diagnostic
system, perform a CAN network integrity test.
Refer to the electrical circuit diagrams and test the
high speed CAN bus circuit for short circuit to
ground, short circuit to power, open circuit, high
resistance. Clear the DTCs and retest

high resistance

U2101-00Control Module

Configuration
Incompatible - No
sub type
information

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Car configuration file
mis-match

Using the manufacturer approved diagnostic
system, check and up-date the car configuration
file as necessary

U3000-41Control Module -

General checksum
failure

U3000-42Control Module -

General memory
failure

U3000-44Control Module

data - Memory
failure

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Speed control module
internal micro
controller error

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Adaptive speed
control module
internal failure

- RAM test error

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, install a new adaptive speed control
module

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, install a new adaptive speed control
module

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, install a new adaptive speed control
module

U3000-49Control Module -

Internal electronic
failure

U3000-63Control Module -

Circuit/component
protection time-out

U3000-96Control Module -

Component internal
failure

Adaptive speed
control module
internal failure

- DSP RAM test
error

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Adaptive speed
control module
internal failure

- Clock error

NOTE: Instrument pack
displays warning message
"forward alert not available"

Adaptive speed
control module
internal protection has
been activated

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, install a new adaptive speed control
module

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, contact dealer technical support

Using the manufacturer approved diagnostic
system, clear the DTCs and retest. If the fault
persists, contact dealer technical support

Speed control module
hardware ID mismatch

U3003-16Battery Voltage -

Circuit voltage

Using the manufacturer approved diagnostic

below threshold

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Adaptive speed
control module power
or ground circuit open
circuit, high resistance
Battery/charging
system fault

system, check datalogger signal - ECU Power
Supply Voltage (0xD112). Refer to the electrical
circuit diagrams and test the adaptive speed
control module power and ground circuits for open
circuit, high resistance
Refer to the relevant section of the workshop
manual and test the battery and charging system

U3003-17Battery Voltage -

Circuit voltage
above threshold

U3003-62Battery Voltage -

Signal compare
failure

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Battery/charging
system fault

NOTE: Adaptive cruise
control is disabled and
instrument pack displays
warning message "cruise not
available"

Mis -match between
the voltage at the
adaptive speed control
module and the
voltage value
broadcast on the CAN
bus

Using the manufacturer approved diagnostic
system, check datalogger signal - ECU Power
Supply Voltage (0xD112). Refer to the relevant
section of the workshop manual and test the
battery and charging system

Using the manufacturer approved diagnostic
system, check datalogger signal - ECU Power
Supply Voltage (0xD112) - and compare it to
battery voltage

Published: 06-Aug-2012

General Information - Diagnostic Trouble Code (DTC) Index DTC: Air
Suspension Control Module

Description and Operation

Air Suspension Control Module

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or
the donor vehicle.

NOTES:

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

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

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

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

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

The table below lists all Diagnostic Trouble Codes (DTCs) that could be logged in the Ride Levelling Module, for
additional Diagnosis and Testing information refer to the relevant Diagnosis and Testing Section.
For additional information, refer to: Vehicle Dynamic Suspension
and Testing).

DTC Description Possible Causes Action

B1A84-55Car

Configuration
Data - Not
configured

C112F-72Air Spring

Valve ­Actuator stuck
open

C1130-66Air Spring Air

Supply - Signal
has too many
transitions /
events

System not configured

- Data does not
match that
expected for
specification

Incorrect software
version loaded

Corner valve stuck open
(fully or partially)
Vehicle driven while
system in "Tight
Tolerance" mode

Air spring leak
Leak in air harness to air
spring
Corner valve leak to
gallery
Air supply unit assembly
fault
Vehicle driven while
system in "Tight
Tolerance" mode

(204-05 Vehicle Dynamic Suspension, Diagnosis

Configure the car configuration file using the
approved diagnostic system. Ensure the air
suspension control module software is the correct
version (available from the TOPIx web-site). Clear
the DTC and test for normal operation

Where possible, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Complete corner valve checks. If
necessary, clear tight tolerance mode. Clear the
DTC and retest

Visually inspect the system for air leakage. Where
possible, refer to the guided diagnostic routine for
this DTC on the approved diagnostic system

C1130-7AAir Spring Air

Supply - Fluid
leak or seal
failure

C1131-92Air Supply -

Performance or
incorrect
operation

Detached or burst air
pipe
Leaking air spring or pipe
to air spring (large leak)
Loose pipe connection
Insufficient pressure from
air supply unit
Height sensor fault

Loose or burst air pipe
Detached air pipe
Leaking pipe from
reservoir valve block to

Visually inspect the system for an excessive air
leak. Check the height sensor linkage(s) for
damage/restrictions. Visually inspect the air harness
for evidence of melting, crushing, kinking or
collapsing. Where possible, refer to the guided
diagnostic routine for this DTC on the approved
diagnostic system

Visually inspect the system for air leakage. Check
the reservoir valve block pipes for correct routing
and installation

air supply unit or either

axle valve block

crushed gallery pipe

on the approved diagnostic system. Check for an air

Insufficient pressure from
air supply unit
Reservoir valve block
piped incorrectly

C1A01-19LED - Circuit

current above
threshold

C1A03-1CLeft Front

Height Sensor

- Circuit
voltage out of
range

C1A03-26Left Front

Height Sensor

- Signal rate of
change below
threshold

Switch pack LED circuit
current above threshold
LED cathode (negative)
connection shorted to
positive
One or more LEDs short
circuit

Height sensor
disconnected
Height sensor harness
wiring short circuit to
ground, power or high
resistance
Height sensor fault

Sensor signal rate of
change below threshold,
signal voltage stuck
Height sensor linkage
disconnected
Height sensor fault
Height sensor harness
wiring short circuit to
ground, power or high
resistance

NOTE: Circuit - LED_NEG -

Refer to the electrical circuit diagrams and check
the circuit between the air suspension control
module and switch pack for short circuit to battery.
Repair as necessary. Clear the DTC and test for
normal operation. If the DTC is still logged suspect
the switch pack

Check the sensor connector for damage. Refer to
the electrical circuit diagrams and check the sensor
circuit for continuity or short circuit. Check sensor
signal changes when sensor is rotated. If any
height sensor fixings are slackened or found to be
loose, or a height sensor has been changed, the
vehicle ride height must be re -calibrated. Calibrate
the system using the approved diagnostic system

Check height sensor linkage is connected and not
damaged. Visually inspect the height sensor for
security, damage and correct
orientation/installation. Check the sensor connector
for damage. Refer to the electrical circuit diagrams
and check the sensor circuit for continuity or short
circuit. Repair/renew as necessary. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system

C1A03-27Left Front

Height Sensor

- Signal rate of
change above
threshold

C1A03-29Left Front

Height Sensor

- Signal invalid

C1A03-78Left Front

Height Sensor

- Alignment or
adjustment
incorrect

Left-hand front height
sensor signal rate of
change above threshold
Height sensor harness
wiring short circuit to
ground, power or
intermittent connection
Height sensor fault

Left-hand front height
sensor signal invalid
Incorrect height
calibration process

Sensor alignment or
adjustment incorrect;
signal out of range
Height sensor linkage not
connected
Height sensor linkage
toggled
Height sensor loose
Height sensor bracket
bent
Incorrect height
calibration
Wiring to height sensor
short to ground
Wiring to height sensor
short to other cable
Height sensor electrical
fault

Check the sensor connector for damage. Refer to
the electrical circuit diagrams and check the sensor
circuit for continuity or short circuit. Visually inspect
the height sensor for security, damage and correct
orientation/installation. Repair/renew as necessary.
Where possible, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system

Calibrate the system using the approved diagnostic
system

Check height sensor linkage is connected and not
damaged. Visually inspect the height sensor for
security, damage and correct
orientation/installation. Check the sensor connector
for damage. Refer to the electrical circuit diagrams
and check the sensor circuit for continuity or short
circuit. Repair/renew as necessary. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. If any height
sensor fixings are slackened or found to be loose,
or a height sensor has been changed, the vehicle
ride height must be re-calibrated. Calibrate the
system using the approved diagnostic system

C1A03-92Left Front

Height Sensor

- Performance
or incorrect
operation

Left-hand front height
sensor height
performance not as
expected/signal changing
slower than expected
Axle valve block pipes
connected incorrectly
Height sensor incorrectly
installed
Blocked/damaged or

NOTE: If any height sensor fixings are slackened or
found to be loose, or a height sensor has been changed,
the vehicle ride height must be re-calibrated.

Check that the vehicle is free of obstructions. Check
the height sensor for correct installation and torque
of fixings. If necessary, calibrate the system using
the approved diagnostic system. Where available,
refer to the guided diagnostic routine for this DTC

Blocked/damaged or

crushed air spring pipe

spring leak. Check the air harness for evidence of

pipes for correct routing and installation. Refer to

Corner valve stuck closed
(mechanically)
Reservoir valve stuck
open (mechanically)

melting, crushing, kinking or collapsing. Check the
front and rear valve block pipes for correct routing
and installation. Refer to the approved diagnostic
system for corner, reservoir and exhaust valve
checks. Check the corner valve for leaks

C1A04-1CRight Front

Height Sensor

- Circuit
voltage out of
range

C1A04-26Right Front

Height Sensor

- Signal rate of
change below
threshold

C1A04-27Right Front

Height Sensor

- Signal rate of
change above
threshold

Right-hand front height
sensor signal voltage out
of range
Height sensor
disconnected
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor fault

Right-hand front height
sensor signal rate of
change below
threshold/signal voltage
stuck
Height sensor linkage
disconnected
Height sensor fault
Height sensor harness
wiring short circuit to
ground, short circuit to
power or short to each
other

Right-hand front height
sensor signal rate of
change above threshold
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor fault

Check the sensor connector for damage. Refer to
the electrical circuit diagrams and check the sensor
circuit for continuity or short circuit. Check sensor
signal changes when sensor is rotated. If any
height sensor fixings are slackened or found to be
loose, or a height sensor has been changed, the
vehicle ride height must be re -calibrated. Calibrate
the system using the approved diagnostic system

Check height sensor linkage is connected and not
damaged. Visually inspect the wiring harness and
connectors for water ingress. Where possible, refer
to the guided diagnostic routine for this DTC on the
approved diagnostic system

Visually inspect the wiring harness and connectors
for damage or water ingress. Visually inspect the
height sensor for security, damage and correct
orientation/installation. Repair/renew as necessary.
Where possible, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system

C1A04-29Right Front

Height Sensor

- Signal invalid

C1A04-78Right Front

Height Sensor

- Alignment or
adjustment
incorrect

C1A04-92Right Front

Height Sensor

- Performance
or incorrect
operation

Right-hand front height
sensor signal invalid
Incorrect height
calibration process

Sensor alignment or
adjustment incorrect;
signal out of range
Height sensor linkage not
connected
Height sensor linkage
toggled
Height sensor loose
Height sensor bracket
bent
Incorrect height
calibration
Wiring to height sensor
short to ground
Wiring to height sensor
short to other cable
Height sensor electrical
fault

Right-hand front height
sensor height changing
slower than expected
Axle valve block pipes
incorrectly installed
(unions reversed)
Height sensor incorrectly
installed
A gallery pipe is
blocked/damaged/crushed
An air spring pipe is
blocked/damaged/crushed
Corner valve stuck closed
Reservoir valve stuck
open (mechanically)

Calibrate the system using the approved diagnostic
system

Check height sensor linkage is connected and not
damaged. Visually inspect the height sensor for
security, damage and correct
orientation/installation. Check the sensor connector
for damage. Refer to the electrical circuit diagrams
and check the sensor circuit for continuity or short
circuit. Repair/renew as necessary. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. If any height
sensor fixings are slackened or found to be loose,
or a height sensor has been changed, the vehicle
ride height must be re-calibrated. Calibrate the
system using the approved diagnostic system

NOTE: If any height sensor fixings are slackened or
found to be loose, or a height sensor has been changed,
the vehicle ride height must be re-calibrated.

Check that the vehicle is free of obstructions. Check
the height sensor for correct installation and torque
of fixings. If necessary, calibrate the system using
the approved diagnostic system. Where available,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Check for an air
spring leak. Check the air harness for evidence of
melting, crushing, kinking or collapsing. Check the
front and rear valve block pipes for correct routing
and installation. Check the reservoir valve block

the approved diagnostic system for corner,

C1A05-1CLeft Rear

corner valve for leaks

Height Sensor

- Circuit
voltage out of
range

Right-hand front height
sensor signal voltage out
of range
Height sensor
disconnected
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor fault

reservoir and exhaust valve checks. Check the
corner valve for leaks

Check the sensor connector for damage. Refer to
the electrical circuit diagrams and check the sensor
circuit for continuity or short circuit. Check sensor
signal changes when sensor is rotated. If any
height sensor fixings are slackened or found to be
loose, or a height sensor has been changed, the
vehicle ride height must be re -calibrated. Calibrate
the system using the approved diagnostic system

C1A05-26Left Rear

Height Sensor

- Signal rate of
change below
threshold

C1A05-27Left Rear

Height Sensor

- Signal rate of
change above
threshold

C1A05-29Left Rear

Height Sensor

- Signal invalid

C1A05-78Left Rear

Height Sensor

- Alignment or
adjustment
incorrect

Left-hand rear height
sensor signal voltage
stuck whilst vehicle is
driven
Height sensor linkage
disconnected
Height sensor fault
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance

Left-hand rear height
sensor signal rate of
change above threshold
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor linkage
disconnected
Height sensor failure

Left-hand rear height
sensor signal invalid
Incorrect height
calibration process

Sensor alignment or
adjustment incorrect;
signal out of range
Height sensor linkage not
connected
Height sensor linkage
toggled
Height sensor loose
Height sensor bracket
bent
Incorrect height
calibration
Wiring to height sensor
short to ground
Wiring to height sensor
short to other cable
Height sensor electrical
fault

Check height sensor linkage is connected and not
damaged. Visually inspect the wiring harness and
connectors for water ingress. Where available, refer
to the guided diagnostic routine for this DTC on the
approved diagnostic system

Check height sensor linkage is connected and not
damaged. Visually inspect the wiring harness and
connectors for water ingress. Where available, refer
to the guided diagnostic routine for this DTC on the
approved diagnostic system

Calibrate the system using the approved diagnostic
system

Check height sensor linkage is connected and not
damaged. Visually inspect the height sensor for
security, damage and correct
orientation/installation. Check the sensor connector
for damage. Refer to the electrical circuit diagrams
and check the sensor circuit for continuity or short
circuit. Repair/renew as necessary. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. If any height
sensor fixings are slackened or found to be loose,
or a height sensor has been changed, the vehicle
ride height must be re-calibrated. Calibrate the
system using the approved diagnostic system

C1A05-92Left Rear

Height Sensor

- Performance
or incorrect
operation

Left-hand rear height
sensor height changing
slower than expected
Axle valve block pipes
connected incorrectly
Height sensor incorrectly
installed
A gallery pipe is
blocked/damaged/crushed
An air spring pipe is
blocked/damaged/crushed
Corner valve stuck closed
(mechanically)
Reservoir valve stuck
open (mechanically)

NOTE: If any height sensor fixings are slackened or
found to be loose, or a height sensor has been changed,
the vehicle ride height must be re-calibrated.

Check that the vehicle is free of obstructions. Check
the height sensor for correct installation and torque
of fixings. If necessary, calibrate the system using
the approved diagnostic system. Where available,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Check for an air
spring leak. Check the air harness for evidence of
melting, crushing, kinking or collapsing. Check the
front and rear valve block pipes for correct routing
and installation. Check the reservoir valve block
pipes for correct routing and installation. Refer to
the approved diagnostic system for corner,
reservoir and exhaust valve checks. Check the

C1A06-1CRight Rear

62

Articulation -

service message. Check the condition and security

Height Sensor

- Circuit
voltage out of
range

Right-hand front height
sensor signal voltage out
of range
Height sensor
disconnected
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor fault

Check the sensor connector for damage. Refer to
the electrical circuit diagrams and check the sensor
circuit for continuity or short circuit. Check sensor
signal changes when sensor is rotated. If any
height sensor fixings are slackened or found to be
loose, or a height sensor has been changed, the
vehicle ride height must be re -calibrated. Calibrate
the system using the approved diagnostic system

C1A06-26Right Rear

Height Sensor

- Signal rate of
change below
threshold

C1A06-27Right Rear

Height Sensor

- Signal rate of
change above
threshold

C1A06-29Right Rear

Height Sensor

- Signal invalid

C1A06-78Right Rear

Height Sensor

- Alignment or
adjustment
incorrect

Right-hand rear height
sensor signal voltage
stuck whilst vehicle is
driven
Height sensor linkage
disconnected
Height sensor fault
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance

Right- hand rear height
sensor signal rate of
change above threshold
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor linkage
disconnected
Height sensor fault

Right-hand rear height
sensor signal invalid
Incorrect height
calibration process

Sensor alignment or
adjustment incorrect;
signal out of range
Height sensor linkage not
connected
Height sensor linkage
toggled
Height sensor loose
Height sensor bracket
bent
Incorrect height
calibration
Wiring to height sensor
short to ground
Wiring to height sensor
short to other cable
Height sensor electrical
fault

Check height sensor linkage is connected and not
damaged. Visually inspect the wiring harness and
connectors for water ingress. Where possible, refer
to the guided diagnostic routine for this DTC on the
approved diagnostic system

Check height sensor linkage is connected and not
damaged. Visually inspect the wiring harness and
connectors for water ingress. Where possible, refer
to the guided diagnostic routine for this DTC on the
approved diagnostic system

Calibrate the system using the approved diagnostic
system

Check height sensor linkage is connected and not
damaged. Visually inspect the height sensor for
security, damage and correct
orientation/installation. Check the sensor connector
for damage. Refer to the electrical circuit diagrams
and check the sensor circuit for continuity or short
circuit. Repair/renew as necessary. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. If any height
sensor fixings are slackened or found to be loose,
or a height sensor has been changed, the vehicle
ride height must be re-calibrated. Calibrate the
system using the approved diagnostic system

C1A06-92Right Rear

C1A07-

Height Sensor

- Performance
or incorrect
operation

Cross

Right-hand rear height
sensor height changing
slower than expected
Axle valve block pipes
incorrectly installed
(unions reversed)
Height sensor incorrectly
installed
A gallery pipe is
blocked/damaged/crushed
An air spring pipe is
blocked/damaged/crushed
Corner valve stuck shut
(mechanically)
Reservoir valve stuck
open (mechanically)

NOTE: If any height sensor fixings are slackened or
found to be loose, or a height sensor has been changed,
the vehicle ride height must be re-calibrated.

Check that the vehicle is free of obstructions. Check
the height sensor for correct installation and torque
of fixings. If necessary, calibrate the system using
the approved diagnostic system. Where available,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Check for an air
spring leak. Check the air harness for evidence of
melting, crushing, kinking or collapsing. Check the
front and rear valve block pipes for correct routing
and installation. Check the reservoir valve block
pipes for correct routing and installation. Refer to
the approved diagnostic system for corner,
reservoir and exhaust valve checks. Check the
corner valve for leaks

Follow the process detailed in the relevant special

Signal compare
failure

NOTE: This DTC may be set
by a fault relating to any of the
height sensors. It will only set if
fault is present and vehicle
speed is greater than 55kph
(35mph) for more than 25
seconds.

Incorrect height
calibration, e.g. height
sensor removed and re­installed or renewed
without re-calibrating
Height sensor linkage
damaged/bent (after
calibration)
Height sensor linkage
loose/disconnected
Height sensor bracket
damaged/bent
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor fault

of the height sensor bracket(s). Check the height
sensor for correct installation and fixings torque. If
any height sensor fixings are slackened or found to
be loose, or a height sensor has been changed, the
vehicle ride height must be re -calibrated. Calibrate
the system using the approved diagnostic system

C1A08-1CPressure

Sensor Supply

- Circuit
voltage out of
range

C1A10-64Pressure

Fluctuates
When System
Inactive ­Signal
plausibility
failure

C1A13-64Pressure Does

Not Decrease
When Venting
Gallery - Signal
plausibility
failure

Pressure sensor supply
voltage out of range
Pressure sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Pressure sensor failure
Wiring to pressure sensor
short to other cable

Signal plausibility failure
Axle valve block pipes
connected incorrectly
Pneumatic parts
disconnected while
system active
Corner valve stuck open
(mechanically)
Pressure sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Pressure sensor fault
(calibration drift)
Pressure gallery leak
Exhaust valve fault

Signal plausibility failure
Reservoir valve block
pipes incorrectly installed
(unions reversed)
Exhaust valve stuck
closed
Exhaust valve does not
hold minimum retention
pressure
Gallery pipe
blocked/damaged
Air suspension exhaust
silencer blocked/restricted
Axle valve block pipes
connected incorrectly
Pressure sensor fault

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check the pressure sensor circuit. Renew the sensor
if faulty

Check the air spring pipes from the front and rear
valve blocks are connected to the correct ports.
Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check for leaks. Refer to the electrical
circuit diagrams and check the pressure sensor
circuit. Renew the sensor if faulty

Check the pipes from the reservoir valve block are
connected to the correct ports. Where available,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Refer to the
electrical circuit diagrams and check the pressure
sensor circuit. Renew the sensor if faulty

C1A18-64Pressure

Increase Too
Rapid When
Filling
Reservoir ­Signal
plausibility
failure

Signal plausibility failure
Reservoir valve stuck
closed (mechanically)
Reservoir pipe
blocked/damaged
Reservoir port
blocked/restricted
Pressure sensor fault

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Renew the sensor if faulty

C1A20-64Pressure

Signal plausibility failure

Where available, refer to the guided diagnostic

C1A29- Switch Ride height change switch

Increase Too
Slow When
Filling
Reservoir ­Signal
plausibility
failure

Gallery pipe air leak
Air supply unit fault
Reservoir pipe air leak
Reservoir air leak
Intake filter
blocked/restricted
Intake pipe
blocked/restricted
Air suspension intake
silencer blocked/restricted
Corner valve stuck open

routine for this DTC on the approved diagnostic
system. Check the Air suspension intake pipe and
silencer for blockage/restriction

C1A24-64No

Temperature
Increase When
Compressor
Requested ­Signal
plausibility
failure

C1A24-67No

Temperature
Increase When
Compressor
Requested ­Signal incorrect
after event

C1A27-12Compressor -

Circuit short to
battery

Signal plausibility failure
Air supply unit cylinder
head temperature sensor
disconnected
Air supply unit cylinder
head temperature sensor
detached from cylinder
head
Air supply unit cylinder
head temperature sensor
fault

Signal plausibility failure
Air supply unit cylinder
head temperature sensor
disconnected
Air supply unit cylinder
head temperature sensor
fault
Air supply unit
disconnected
Air supply unit ground
circuit high resistance
Air supply unit fault

Air supply unit voltage
present when air supply
unit not requested
Air supply unit relay fault
Air supply unit harness
wiring short circuit to
power
Air supply unit motor
connector disconnected
Air supply unit ground
terminal loose

NOTE: Circuit - COMP_TEMP_SIG - COMP_TEMP_GND

-

Check the security of the air supply unit cylinder
head temperature sensor and electrical connection.
Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system

NOTE: Circuit - COMP_TEMP_SIG - COMP_TEMP_GND

-

Check the security of the air supply unit cylinder
head temperature sensor and electrical connection.
Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system

NOTE: Circuit - COMP_V -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check the air supply unit power supply circuit.
Check the security and integrity of the air supply
unit ground connection. Check the operation of the
air supply unit relay. Repair/renew as necessary

C1A27-14Compressor -

Circuit short to
ground or open

C1A27-29Compressor -

Signal invalid

C1A28-64Wrong Number

of LEDs
Illuminated ­Signal
plausibility
failure

Air supply unit circuit
short to ground or open
circuit
Air supply relay/air supply
unit fusible link (Fuse
10E) in battery junction
box failed/not installed
Air supply unit relay
failure

Air supply unit relay
control voltage signal
invalid

Switch pack disconnected
Air suspension control
module supply (BATTERY)
fuse (26E) in battery
junction box failed
LED circuit short circuit to
power
One or more LEDs short
circuit to each other
Switch pack failure
Switch pack harness
wiring short circuit to
ground, short circuit to
power or high resistance

NOTE: Circuit - COMP_V -

Check/renew fuses as necessary. Where available,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Check the
operation of the air supply unit relay. Repair/renew
as necessary

Refer to DTC C1A27-12 which will be set first

NOTE: Circuit - LED_NEG - HIGH_LED - STD_HT_LED

- CRAWL_LED - ACCESS_HT_LED - RAISING_LED -

LOWERING LED -

Check/renew fuse as necessary. Refer to the
electrical circuit diagrams and check LED circuits for
short to ground, power or open circuit. Repair as
necessary. Check for high resistance between air
suspension control module and center console
switch pack. Check for one or more LEDs short
circuit to each other. Clear the DTC and test for
normal operation. If no fault was found with the
above circuit tests and the DTC is persists, suspect
center console switch pack

92 Activation Too

Long ­Performance or
incorrect
operation

performance or incorrect
operation
Switch pressed for more
than 255 seconds
Switch pack harness
wiring short circuit to
ground, short circuit to
power
Switch pack failure

NOTE: Circuit - LOWER_SW - RAISE_SW -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check circuits for short to ground, power, or
between harness. Check for high resistance
between air suspension control module and center
console switch pack. Check switch pack for
mechanical damage, stuck contacts. Clear the DTC
and test for normal operation. If no fault was found
with the above circuit tests and the DTC is persists,
suspect center console switch pack

C1A30-64Both Switches

Pressed At
Same Time ­Signal
plausibility
failure

C1A31-01Left Front

Corner Valve ­General
electrical
failure

C1A32-01Right Front

Corner Valve ­General
electrical
failure

Signal plausibility failure
Air suspension control
module supply (BATTERY)
fuse (26E) in battery
junction box failed
Switch pack harness
wiring short circuit to
ground
Switch pack failure

Left-hand front corner
valve general electrical
failure
Front valve block
disconnected
Front valve block circuit
short circuit to ground,
open circuit or high
resistance
Left-hand front corner
valve failure

Right-hand front corner
valve general electrical
failure
Front valve block
disconnected
Front valve block circuit
short circuit to ground,
open circuit or high
resistance
Right-hand front corner
valve failure

NOTE: Circuit - LOWER_SW - RAISE_SW -

Check/renew fuse as necessary. Where available,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Refer to the
electrical circuit diagrams and check circuits for
short to ground, power, or between harness. Check
for high resistance between air suspension control
module and center console switch pack. Check
switch pack for mechanical damage, stuck contacts.
Clear the DTC and test for normal operation. If no
fault was found with the above circuit tests and the
DTC is persists, suspect center console switch pack

NOTE: Circuit - FL_CV_POS - FL_CV_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block assembly
if faulty. Clear the DTC and retest

NOTE: Circuit - FR_CV_POS - FR_CV_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block
assembly. Clear the DTC and retest

C1A33-01Left Rear

Corner Valve ­General
electrical
failure

C1A34-01Right Rear

Corner Valve ­General
electrical
failure

C1A35-01Reservoir

Valve - General

Left-hand rear corner
valve, general electrical
failure
Rear valve block
disconnected
Rear valve block circuit
short circuit to ground,
open circuit or high
resistance
Left-hand rear corner
valve failure

Right-hand rear corner
valve general electrical
failure
Rear valve block circuit
short circuit to ground,
open circuit or high
resistance
Rear valve block
disconnected
Right-hand rear corner
valve failure

Reservoir valve general
electrical failure

NOTE: Circuit - RL_CV_POS - RL_CV_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block assembly
if faulty. Clear the DTC and retest

NOTE: Circuit - RR_CV_POS - RR_CV_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block assembly
if faulty. Clear the DTC and retest

NOTE: Circuit - RES_V_POS - RES_V_NEG -

electrical

Reservoir valve block

failure

harness wiring short
circuit to ground or open
circuit
Reservoir valve block
disconnected
Reservoir valve block
failure

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block assembly
if faulty. Clear the DTC and retest

C1A36-01Exhaust Valve

- General
electrical
failure

C1A37-01Front Cross-

Link Valve ­General
electrical
failure

C1A38-01Rear Cross -

Link Valve ­General
electrical
failure

C1A68-1CLeft Front

Height Sensor
Supply - Circuit
voltage out of
range

Exhaust valve general
electrical failure
Exhaust valve harness
wiring short circuit to
ground or open circuit
Exhaust valve
disconnected
Exhaust valve failure

Front cross-link valve
general electrical failure
Front valve block harness
wiring short circuit to
ground or open circuit
Front valve block
disconnected
Front cross-link valve
failure

Rear cross -link valve
general electrical failure
Rear valve block harness
wiring short circuit to
ground or open circuit
Rear valve block
disconnected
Rear cross -link valve
failure

Left-hand front height
sensor supply circuit
voltage out of range
Height sensor harness
wiring short circuit to
ground or power
Height sensor failure

NOTE: Circuit - EXH_V_POS - EXH_V_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. If exhaust valve is faulty, renew
the air supply unit. Clear the DTC and retest

NOTE: Circuit - F_XV_POS - F_XV_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block assembly
if faulty. Clear the DTC and retest

NOTE: Circuit - R_XV_POS - R_XV_NEG -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check valve circuit. Renew the valve block assembly
if faulty. Clear the DTC and retest

NOTE: If a height sensor is changed, the vehicle ride

height must be re-calibrated.

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check the height sensor connector for
damage and security. Refer to the electrical circuit
diagrams and check height sensor circuit. Renew
the sensor if faulty. Clear the DTC and retest

C1A69-1CRight Front

Height Sensor
Supply - Circuit
voltage out of
range

C1A70-1CLeft Rear

Height Sensor
Supply - Circuit
voltage out of
range

C1A71-1CRight Rear

Height Sensor
Supply - Circuit
voltage out of
range

Right-hand front height
sensor supply circuit
voltage out of range
Height sensor harness
wiring short circuit to
ground or power
Height sensor failure

Left-hand rear height
sensor supply circuit
voltage out of range
Height sensor harness
wiring short circuit to
ground, short circuit to
power or high resistance
Height sensor failure

Right-hand rear height
sensor supply circuit
voltage out of range
Height sensor harness
wiring short circuit to
ground or power
Height sensor failure

NOTE: If a height sensor is changed, the vehicle ride

height must be re-calibrated.

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check the height sensor connector for
damage and security. Refer to the electrical circuit
diagrams and check height sensor circuit. Renew
the sensor if faulty. Clear the DTC and retest

NOTE: If a height sensor is changed, the vehicle ride

height must be re-calibrated.

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check the height sensor connector for
damage and security. Refer to the electrical circuit
diagrams and check height sensor circuit. Renew
the sensor if faulty. Clear the DTC and retest

NOTE: If a height sensor is changed, the vehicle ride

height must be re-calibrated.

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check the height sensor connector for
damage and security. Refer to the electrical circuit
diagrams and check height sensor circuit. Renew

the sensor if faulty. Clear the DTC and retest

C1A99-1CPressure

suspension control module

Sensor ­Circuit voltage
out of range

Pressure sensor circuit
voltage out of range
Sensor disconnected
Pressure sensor circuit
short circuit to ground or
to each other
Pressure sensor fault

NOTE: Circuit - PRESSURE_5V - PRESSURE_SIG -

PRESSURE_GND -

Where available, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check the sensor connector for damage
and security. Refer to the electrical circuit diagrams
and check height sensor circuit. Renew the sensor if
faulty. Clear the DTC and retest

C1B18-62Module Power

Supplies ­Signal compare
failure

C1B21-1CCompressor

Brush Card
Temperature
Sensor ­Circuit voltage
out of range

U0073-88Control Module

Communication
Bus 'A' Off ­Bus off

Signal compare failure
Inconsistent battery and
ignition voltages received
by air suspension control
module
Air suspension control
module supply circuit(s)
short circuit to ground
Air suspension control
module supply circuit(s)
high resistance

Air supply unit brush card
temperature sensor
circuit voltage out of
range
Air supply unit brush card
temperature sensor
harness wiring short
circuit to ground, short
circuit to power or high
resistance
Air supply unit brush card
temperature sensor
failure

CAN bus connections
short circuit to each other

Where available, refer to the guided diagnostic
routine for this code on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check the power supply circuits to the module.
Check the module connector for security and
integrity

NOTE: Circuit - MOT_TEMP_SIG - MOT_TEMP_GND -

Where available, refer to the guided diagnostic
routine for this code on the approved diagnostic
system. Refer to the electrical circuit diagrams and
check the air supply unit temperature circuit
between the air supply unit and the module. Renew
the air supply unit if temperature sensor faulty

Refer to the electrical circuit diagrams and check
the power and ground connections to the ride
levelling module. Using the manufacturer approved
diagnostic system, complete a CAN network
integrity test. Refer to the electrical circuit
diagrams and check the CAN network

U0100-00Lost

Communication
With ECM/PCM
"A" - No sub
type
information

U0101-00Lost

Communication
With TCM - No
sub type
information

U0102-00Lost

Communication
With Transfer
Case Control
Module - No
sub type
information

U0122-00Lost

Communication
With Vehicle
Dynamics
Control Module

- No sub type
information

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the engine
control module. Using the manufacturer approved
diagnostic system, complete a CAN network
integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
engine control module and the air suspension
control module

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the
transmission control module. Using the
manufacturer approved diagnostic system, complete
a CAN network integrity test. Refer to the electrical
circuit diagrams and check the CAN network
between the transmission control module and the
air suspension control module

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the transfer
case control module. Using the manufacturer
approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
transfer case control module and the air suspension
control module

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the vehicle
dynamics control module. Using the manufacturer
approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
anti-lock brake system control module and the air

U0126-00Lost

information

Communication
With Steering
Angle Sensor
Module - No
sub type
information

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the steering
angle sensor module. Using the manufacturer
approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
steering angle sensor module and the air
suspension control module

U0128-00Lost

Communication
With Park
Brake Control
Module - No
sub type
information

U0133-00Lost

Communication
With Active
Roll Control
Module - No
sub type
information

U0136-00Lost

Communication
With
Differential
Control Module

- Rear - No sub
type
information

U0138-00Lost

Communication
with All Terrain
Control Module

- No sub type
information

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the park
brake module. Using the manufacturer approved
diagnostic system, complete a CAN network
integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
electric park brake control module and the air
suspension control module

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the active roll
control module. Using the manufacturer approved
diagnostic system, complete a CAN network
integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
dynamic response control module and the air
suspension control module

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the
differential control module. Using the manufacturer
approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
rear differential control module and the air
suspension control module

CAN bus fault Refer to the electrical circuit diagrams and check

the power and ground connections to the all terrain
control module. Using the manufacturer approved
diagnostic system, complete a CAN network
integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
terrain response switchpack and the air suspension
control module

U0140-00Lost

Communication
With Body
Control Module

- No sub type
information

U0300-55Internal

Control Module
Software
Incompatibility

- Not
configured

U0416-68Invalid Data

Received From
Vehicle
Dynamics
Control Module

- Event
information

U0417-68Invalid Data

Received From
Park Brake
Control Module

- Event
information

U0428-68Invalid Data

Received From
Steering Angle
Sensor Module

- Event

CAN bus fault Refer to the electrical circuit diagrams and check

Incorrect software loaded
CAN wiring to central
junction box high
resistance
Incorrect instrument
cluster CAN configuration

Invalid data received
from anti-lock brake
system control module

Invalid data received
from electric park brake
control module

Invalid data received
from steering angle
sensor module

the power and ground connections to the body
control module. Using the manufacturer approved
diagnostic system, complete a CAN network
integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
central junction box and the air suspension control
module

Configure the air suspension control module and
instrument cluster as necessary using the approved
diagnostic system

Check the anti-lock brake system control module
for related DTCs and refer to the relevant DTC
index

Check the electric park brake control module for
related DTCs and refer to the relevant DTC index

Check the steering angle sensor module for related
DTCs and refer to the relevant DTC index

U1A14-49CAN

Internal electronic failure Refer to the electrical circuit diagrams and check

Electrical leakage

Initialization
failure­Internal
electronic
failure

the power and ground connections to the module.
Using the manufacturer approved diagnostic
system, complete a CAN network integrity test.
Refer to the electrical circuit diagrams and check
the CAN network

U2000-67Motor

Temperature ­Signal incorrect
after event

U2007-11Valve(s) -

Circuit short to
ground

U2007-67Valve(s) -

Signal incorrect
after event

Motor signal incorrect
after event
Air supply unit brush card
temperature sensor not
connected electrically
Air supply unit brush card
temperature sensor
failure
Air supply unit
disconnected
Air supply unit ground
connection disconnected

Valve circuit short circuit
to ground when system is
inactive
Water ingress to wiring
harness or connectors
Valve harness wiring
short circuit to ground or
high resistance

Valve signal incorrect
after event
Valve positive
connections shorted to
power or ground
Electrical leakage
between permanent
battery volts and any
valve positive connection

NOTE: Circuit - MOT_TEMP_SIG - MOT_TEMP_GND -

Where possible, refer to the guided diagnostic
routine for this DTC on the approved diagnostic
system. Check the air supply unit connector for
security and integrity. Check the air supply unit
ground connection. Renew the air supply unit if
temperature sensor faulty

Visually inspect the wiring harness and connectors
between the air suspension control module and the
control valves for water ingress. Refer to the
electrical circuit diagrams and check the valve
circuits

Visually inspect the wiring harness and connectors
between the air suspension control module and the
control valves for water ingress. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system

U210A-16Temperature

Sensor ­Circuit voltage
below
threshold

U3000-05Control Module

- System
programming
failures

U3000-1CControl Module

- Circuit
voltage out of
range

U3000-1DControl Module

- Circuit
current out of
range

Air supply unit cylinder
head temperature sensor
circuit voltage below
threshold
Temperature sensor
circuit short to ground or
short to other cable

System programming
failures, air suspension
control module has been
set in tight tolerance
mode using diagnostic
tester

Circuit voltage out of
range
Vehicle battery voltage
has been too low to
operate the air
suspension system
Valve positive circuit
intermittent short to
ground

Circuit current out of
range
Rear valve block
disconnected
Any valve positive short
circuit to ground (more
than 20A flowing)

NOTE: Circuit - COMP_TEMP_SIG - COMP_TEMP_GND

-

Refer to the electrical circuit diagrams and check
the air supply unit temperature circuit between the
air supply unit and the control module. Renew the
air supply unit assembly

This DTC is not a fault but is logged when the air
suspension has been set in tight tolerance mode.
Use the manufacturers approved diagnostic
equipment to set system into normal (customer)
mode

This may not be a fault. Check the battery state of
charge and check for other DTCs that would
determine a flat battery condition. Clear the DTC
and retest. If the DTC persists, visually inspect the
wiring harness and connectors between the air
suspension control module and the control valves
for water ingress. Refer to the electrical circuit
diagrams and check the valve circuits

Check the rear valve block connector for security
and integrity (rear axle valve block is used as part
of power-up diagnostic check). Refer to the
electrical circuit diagrams and check the valve
circuits

U3000-49Control Module

- Internal
electronic
failure

Valve signal incorrect
after event
Valve circuit isolation
switch test failed
Valve positive
connections shorted to
power or ground

Visually inspect the wiring harness and connectors
between the air suspension control module and the
control valves for water ingress. Where possible,
refer to the guided diagnostic routine for this DTC
on the approved diagnostic system. Clear the DTC
and retest. If the problem persists, renew the air
suspension control module

between permanent

battery volts and any
valve positive connection
Internal electronic failure

U3000-52Control Module

- Not activated

U3000-53Control Module

- Deactivated

U3000-54Control Module

- Missing
calibration

U3000-55Control Module

- Not
configured

U3002-62Vehicle

Identification
Number ­Signal compare
failure

U300D-01Ignition Input

On/Start ­General
electrical
failure

Not activated, vehicle has
been set in manufacturing
mode using diagnostic
tester

Deactivated; the system
has been deflated using
the diagnostic deflation
routine

Missing calibration;
module has not been
calibrated (height
sensors)

Not configured; system
set in calibration mode
using diagnostic tester

Signal compare failure
Air suspension control
module has been
swapped from another
vehicle (NOTE Air
suspension requires re­calibration)
Instrument pack has been
changed and not re­coded

General electrical failure
Ignition fuse
failed/missing
No wake-up signal to
module

This DTC is not a fault, use the manufacturers
approved diagnostic equipment to set system into
normal (customer) mode

This DTC is not a fault. Clear deflation routine using
manufacturers approved diagnostic equipment

This DTC is not a fault, use the manufacturers
approved diagnostic equipment to calibrate the ride
height

This DTC is not a fault, use the manufacturers
approved diagnostic equipment to calibrate the ride
height

Program the relevant module using the approved
diagnostic system and calibrate the ride height

Refer to the electrical circuit diagrams and check
the power supply fuse and circuit to the air
suspension control module

Published: 08-May-2012

General Information - Diagnostic Trouble Code (DTC) Index DTC: Anti­Lock Braking System Control Module (ABS)

Description and Operation

Anti-Lock Braking System (ABS)

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules
does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or
the donor vehicle.

NOTES:

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

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

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

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

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

The table below lists all Diagnostic Trouble Codes (DTCs) that could be logged in the ABS module, for additional
Diagnosis and Testing information refer to the relevant Diagnosis and Testing Section.
For additional information, refer to: Anti-Lock Control - Traction Control
Control, Diagnosis and Testing).

DTC Description Possible Causes Action

C0030-38Left Front Tone

Wheel - Signal
frequency
incorrect

C0031-14Left Front

Wheel Speed
Sensor ­Circuit short to
ground or open

C0031-25Left Front

Wheel Speed
Sensor - Signal
shape /
waveform
failure

Signal frequency
incorrect
Damaged ABS
sensor ring

Sensor short
circuit to ground
or open circuit
Sensor fault

Sensor short
circuit to ground
Sensor fault

Check front left wheel speed sensor ring for missing teeth
or damage. After rectification, either clear the DTCs and
cycle the ignition or cycle the ignition and drive the vehicle
above 15kph to ensure the lamps extinguish. When cycling
the ignition, allow sufficient time for the 'P' symbol
illumination to extinguish on the gear shifter (if installed)
before returning the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

(206-09A Anti-Lock Control - Traction

C0031-2FLeft Front

Wheel Speed
Sensor - Signal
erratic

Sensor circuit
fault
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to

extinguish on the gear shifter (if installed) before returning

the ignition state to on

C0031-31Left Front

Wheel Speed
Sensor - No
signal

C0031-62Left Front

Wheel Speed
Sensor - Signal
compare failure

C0031-64Left Front

Wheel Speed
Sensor - Signal
plausibility
failure

No sensor signal
Sensor fault

Sensor signal
compare failure
Sensor fault

Sensor signal
plausibility failure
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C0033-38Right Front

Tone Wheel ­Signal
frequency
incorrect

C0034-14Right Front

Wheel Speed
Sensor ­Circuit short to
ground or open

C0034-25Right Front

Wheel Speed
Sensor - Signal
shape /
waveform
failure

Signal frequency
incorrect
Damaged wheel
speed sensor ring

Sensor short
circuit to ground
or open
Sensor fault

Sensor signal
shape / waveform
failure
Sensor short
circuit to ground
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C0034-2FRight Front

Wheel Speed
Sensor - Signal
erratic

C0034- Right Front

Sensor signal
erratic
Sensor fault

No sensor signal Check the sensor lead and connector for damage. If

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

31 Wheel Speed

Sensor - No

Sensor fault damaged, renew the sensor. Refer to the electrical circuit

rectification, either clear the DTCs and cycle the ignition or

signal

diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C0034-62Right Front

Wheel Speed
Sensor - Signal
compare failure

C0034-64Right Front

Wheel Speed
Sensor - Signal
plausibility
failure

C0036-38Left Rear Tone

Wheel - Signal
frequency
incorrect

Sensor signal
compare failure
Sensor fault

Sensor signal
plausibility failure
Sensor fault

Signal frequency
incorrect
Damaged wheel
speed sensor ring

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C0037-14Left Rear

Wheel Speed
Sensor ­Circuit short to
ground or open

C0037-25Left Rear

Wheel Speed
Sensor - Signal
shape /
waveform
failure

C0037-2FLeft Rear

Wheel Speed
Sensor - Signal
erratic

Sensor short
circuit to ground
or open circuit
Sensor fault

Sensor signal
shape / waveform
failure
Sensor short
circuit to ground
Sensor fault

Sensor signal
erratic
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C0037-31Left Rear

Wheel Speed
Sensor - No
signal

No sensor signal
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After

cycle the ignition and drive the vehicle above 15kph to

ensure the lamps extinguish. When cycling the ignition,

extinguish on the gear shifter (if installed) before returning

allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C0037-62Left Rear

Wheel Speed
Sensor - Signal
compare failure

C0037-64Left Rear

Wheel Speed
Sensor - Signal
plausibility
failure

C0039-38Right Rear

Tone Wheel ­Signal
frequency
incorrect

Sensor signal
compare failure
Sensor fault

Sensor signal
plausibility failure
Sensor fault

Signal frequency
incorrect
Damaged wheel
speed sensor ring

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C003A-14Right Rear

Wheel Speed
Sensor ­Circuit short to
ground or open

C003A-25Right Rear

Wheel Speed
Sensor - Signal
shape /
waveform
failure

C003A-2FRight Rear

Wheel Speed
Sensor - Signal
erratic

Sensor short
circuit to ground
or open circuit
Sensor fault

Sensor signal
shape / waveform
failure
Sensor short
circuit to ground
Sensor fault

Sensor signal
erratic
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

heck the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C003A-31Right Rear

Wheel Speed
Sensor - No
signal

No sensor signal
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to

the ignition state to on

C003A-62Right Rear

Wheel Speed
Sensor - Signal
compare failure

Sensor signal
compare failure
Sensor fault

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

C003A-64Right Rear

Wheel Speed
Sensor - Signal
plausibility
failure

C0051-28Steering Wheel

Position Sensor

- Signal bias
level out of
range / zero
adjustment
failure

C0051-67Steering Wheel

Position Sensor

- Signal
incorrect after
event

Sensor signal
plausibility failure
Sensor fault

Signal bias level
out of range/zero
adjustment failure
Incorrect angle
sensor installed
Wheel speed
sensor wiring
incorrectly wired
across one axle
Steering angle
sensor fault

Sensor signal
incorrect after
event
Steering angle
sensor fault
Control module
software error

Check the sensor lead and connector for damage. If
damaged, renew the sensor. Refer to the electrical circuit
diagrams and check the circuit between the wheel speed
sensor and the anti-lock brake system control module. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Check for a correctly installed steering angle sensor. Refer
to the electrical circuit diagrams and check the circuit
between the wheel speed sensors and the anti-lock brake
system control module to ensure the sensors on one axle
are correctly wired to the correct control module left or
right pin outs. Renew the steering angle sensor. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle (not always in a
straight line) for at least 9 seconds to ensure the lamps
extinguish. When cycling the ignition, allow sufficient time
for the 'P' symbol illumination to extinguish on the gear
shifter (if installed) before returning the ignition state to on

Check for other DTCs that may aid diagnosis, especially in
the steering angle sensor module. Renew the steering angle
sensor. Clear the DTC and retest. If the problem persists,
renew the anti-lock brake system control module

C0062-28Longitudinal

Acceleration
Sensor - Signal
bias level out
of range / zero
adjustment
failure

C0062-54Longitudinal

Acceleration
Sensor ­Missing
calibration

C0062-64Longitudinal

Acceleration
Sensor - Signal
plausibility
failure

C0063-14Yaw Rate

Sensor ­Circuit short to
ground or open

C0063-1CYaw Rate

Sensor ­Circuit voltage
out of range

C0063-27Yaw Rate

Sensor - Signal
rate of change
above

Sensor signal bias
level out of
range/zero
adjustment failure
Incorrectly
installed sensor

Sensor missing
calibration
Incorrect sensor
installed
Incorrectly
configured sensor

Sensor signal
plausibility failure
Incorrectly
installed sensor

Sensor circuit
short to ground or
open
Sensor fault

Sensor circuit
voltage out of
range

Sensor circuit
power supply fuse
failure
Sensor insecurely

Check installation and mounting of sensor cluster. Clear the
DTC and retest, if problem persists renew the sensor. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Ensure the correct sensor has been installed. Check
mounting, connector and fuse of the sensor. Configure the
sensor cluster using the manufacturers approved diagnostic
system

Clear the DTC and retest. Check mounting, connector and
fuse of the sensor. Configure the sensor cluster using the
manufacturers approved diagnostic system

The most likely cause of the fault is an open circuit on the
harness. Refer to the electrical circuit diagrams and check
the circuit between the sensor and the anti-lock brake
system control module. Repair as necessary. Clear the DTC
and retest. If the problem persists, renew the sensor

Refer to the electrical circuit diagrams and check the
sensor power supply circuit

Refer to the electrical circuit diagrams and check the
sensor power supply fuse. Check the yaw rate sensor
connector condition. Ensure the sensor is correctly secured.
If problem persists, renew the sensor. If the problem still

threshold mounted

persists, renew the anti-lock brake system control module

Sensor fault
Control module
software error

C0063-28Yaw Rate

Sensor - Signal
bias level out
of range / zero
adjustment
failure

C0063-41Yaw Rate

Sensor ­General
checksum
failure

C0063-49Yaw Rate

Sensor ­Internal
electronic
failure

C0063-4AYaw Rate

Sensor ­Incorrect
component
installed

C0063-64Yaw Rate

Sensor - Signal
plausibility
failure

Sensor signal bias
level out of
range/zero
adjustment failure
Sensor insecurely
mounted
Sensor fault

Sensor general
checksum failure
Sensor fault
Control module
fault

Sensor internal
electronic failure

Incorrect sensor
installed

NOTE: This DTC is
set when the sensor
value is not within the
expected range
compared to the steering
angle senor.

Sensor signal
plausibility failure
Sensor insecurely
mounted

Ensure the sensor is correctly secured. If problem persists,
renew the sensor

Renew the sensor. If the problem persists, renew the anti­lock brake system control module

Clear the DTC and retest. If the problem persists, renew
the sensor

Clear the DTC and retest. If the fault still exists renew the
yaw rate sensor with the suitable sensor cluster and repeat
test cycle

NOTE: This DTC can be set if the vehicle is being tested on

chassis dyno rollers.

Ensure the sensor is correctly secured. Check that the
steering angle sensor is correctly calibrated using the
manufacturers recommended diagnostic system. If problem
persists, renew the sensor. After rectification, either clear
the DTCs and cycle the ignition or cycle the ignition and
drive the vehicle above 80kph (not always in a straight
line) to ensure the lamps extinguish. When cycling the
ignition, allow sufficient time for the 'P' symbol illumination
to extinguish on the gear shifter (if installed) before
returning the ignition state to on

C0063-86Yaw Rate

Sensor - Signal
invalid

C0063-95Yaw Rate

Sensor ­Incorrect
assembly

C0063-96Yaw Rate

Sensor ­Component
internal failure

C0064-64Roll Rate

Sensor - Signal
plausibility
failure

C006A-54Multi-axis

Acceleration
Sensor ­Missing
calibration

Sensor signal
invalid
Incorrectly
configured sensor

Sensor incorrect
assembly/internal
sensor fault

Sensor power
supply
intermittent
connection
Sensor ground
intermittent
connection
Sensor internal
failure

Sensor signal
plausibility failure
Sensor insecurely
mounted

Sensor missing
calibration
Serial number of
yaw rate sensor
saved in stored in
control module
memory does not
match serial
number of sensor
Incorrect sensor
installed

Clear the DTC and retest. If the problem persists, renew
the sensor

Ensure the correct sensor has been installed. Clear the DTC
and retest. If the problem persists, renew the sensor. If the
problem persists, renew the anti-lock brake system control
module

Refer to the electrical circuit diagrams and check the
sensor power supply and ground connections to the sensor.
Check the sensor connecter and anti-lock brake system
control module for security and integrity (water ingress of
damaged pins). If the problem persists, renew the yaw rate
sensor. Calibrate the new sensor using the manufacturers
approved diagnostic system. If the fault returns after an
ignition cycle, renew the control module

Ensure the sensor is correctly installed/secured. Clear DTC
and retest. If problem persists, renew the sensor

Check that the correct sensor has been installed. Configure
the sensor cluster using the manufacturers approved
diagnostic system. If calibration fails several times, renew
the control module

Installed sensor

C0072-4BBrake

Temperature
Too High ­Over
temperature

not correctly
calibrated

Excessive use of
brakes
Excessive use of
traction control
system

This DTC is for information only. Clear the DTC

C101F-49Generic Valve

Failure ­Internal
electronic
failure

C1109-24Vehicle

Dynamics
Control Switch

- Signal stuck
high

C1A77-16Valve Relay

Supply Circuit ­Circuit voltage
below
threshold

C1A90-12Wheel Speed

Sensor Supply

- Circuit short
to battery

C1A95-4AWheel Speed

Sensor ­Incorrect
component
installed

C1A95-64Wheel Speed

Sensor - Signal
plausibility
failure

Anti-lock brake
system modulator
internal fault

NOTE: If the
dynamic stability control
switch is pressed for
longer than 1 minute, the
switch is deemed to be
malfunctioning.

Signal stuck high

- dynamic stability
control switch
operation fault

Circuit voltage
below threshold
Fuse
Harness/connector
damaged

Wheel speed
sensor supply
circuit short
circuit to power

The incorrect
wheel speed
sensor has been
installed

Signal plausibility
failure
Wheel speed
sensor fault (any)
Sensor ring
damaged,
incorrect or
defective
Harness fault
Incorrect
wheel/tire
assembly size

Renew the anti-lock brake system control module

Check the switch operation. Refer to the electrical circuit
diagrams and check the dynamic stability control switch
and circuits. Check and install a new dynamic stability
control switch as required

Refer to the electrical circuit diagrams and check the
harness connection and fuse to the valve relay circuits

Refer to the electrical circuit diagrams and check the wheel
speed sensor power supply line circuits between the
sensors and the anti-lock brake system control module

Check the correct wheel speed sensors are installed. Clear
the DTC and retest

Check for correct wheel/tire sizes. Check the wheel speed
sensors and circuits for damage. Remove the sensor and
visually inspect the sensor ring on the constant velocity
joint for missing or damaged teeth. If the sensor ring is
damaged, renew the constant velocity joint. Use an
oscilloscope to examine the signals from all wheel speed
sensors for abnormal high frequencies (modulation and
peak signals). Renew sensors as necessary. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph for at
least 30 seconds to ensure the lamps extinguish. When
cycling the ignition, allow sufficient time for the 'P' symbol
illumination to extinguish on the gear shifter (if installed)
before returning the ignition state to on

C1A96-64Brake Light

Switch - Signal
plausibility
failure

C1A97-24Lateral

Accelerometer

- Signal stuck
high

C1A98-2FYaw Rate

Sensor - Signal
erratic

Signal plausibility
failure
Stop lamp switch
fault
Harness/connector
issue

Signal stuck high
Yaw rate/lateral
acceleration
sensor internal
error

Yaw rate sensor
signal fault for 2
minutes

Check the Stop lamp function. Ensure the brake pedal
switch is correctly installed and configured. Refer to the
electrical circuit diagrams and check the brake pedal switch
circuit, rectify as necessary. Check the engine control
module for DTCs. After rectification, either clear the DTCs
and cycle the ignition or cycle the ignition and drive the
vehicle above 15kph with at least one brake pedal press to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Renew the combined lateral acceleration/yaw rate sensor

Information only, regard as normal operation. Clear the
DTC, cycle the ignition and retest. If the fault reoccurs,
renew the combined lateral acceleration/yaw rate sensor.

When cycling the ignition, allow sufficient time for the 'P'

C1A98-96Yaw Rate

Sensor ­Component
internal failure

Incorrect
assembly
Sensor installation
incorrect
Yaw rate/lateral
acceleration
sensor internal
error

symbol illumination to extinguish on the gear shifter (if
installed) before returning the ignition state to on

Check the combined lateral acceleration/yaw rate sensor
installation and orientation. Check mounting, connector and
fuse of the sensor. Clear the DTC and retest. If the problem
persists, renew the combined lateral acceleration/yaw rate
sensor

C1B00-29Steering Angle

Sensor - Signal
invalid

C1B00-49Steering Angle

Sensor ­Internal
electronic
failure

C1B00-64Steering Angle

Sensor - Signal
plausibility
failure

C1B00-92Steering Angle

Sensor ­Performance or
incorrect
operation

Sensor signal
invalid
Sensor installation
incorrect
steering angle
sensor fault

Sensor internal
electronic failure

Sensor signal
plausibility failure
Sensor installation
incorrect
steering angle
sensor fault
Yaw rate sensor
installation
incorrect

Sensor
performance or
incorrect
operation
Sensor installation
incorrect
steering angle
sensor fault

Check steering angle sensor module for DTCs. Check the
steering angle sensor installation and orientation. Clear the
DTC and retest. If the problem persists, renew the sensor

Check steering angle sensor module for DTCs. Renew the
sensor

Check steering angle sensor module for DTCs. Check the
steering angle sensor installation and orientation. Check the
yaw rate sensor installation and orientation. Clear the DTC
and retest. If the problem persists, renew the steering
angle sensor module

Check steering angle sensor module for DTCs. Check the
steering angle sensor installation and orientation. Check the
yaw rate sensor installation and orientation. Clear the DTC
and retest. If the problem persists, renew the steering
angle sensor

C1B02-16Return Pump -

Circuit voltage
below
threshold

C1B02-49Return Pump -

Internal
electronic
failure

C1B22-24Hill Descent

Switch - Signal
stuck high

C2009-64Front Axle

Wheel Speed
Sensors
Swapped ­Signal
plausibility
failure

C200A-64Rear Axle

Wheel Speed

Return pump
circuit voltage
below threshold
Harness damaged
Defective fuse

Anti-lock brake
system control
module internal
electronic failure

NOTE: If the hill
decent control switch is
pressed for longer than 1
minute, the switch is
deemed to be
malfunctioning.

Signal stuck high
Harness/connector
issue

Sensor location
swapped

Sensor location
swapped

Refer to the electrical circuit diagrams and check the
circuit, fuses and the connection to the anti-lock brake
system control module. Rectify as necessary. After
rectification, either clear the DTCs and cycle the ignition or
cycle the ignition and drive the vehicle above 15kph to
ensure the lamps extinguish. When cycling the ignition,
allow sufficient time for the 'P' symbol illumination to
extinguish on the gear shifter (if installed) before returning
the ignition state to on

Renew the anti-lock brake system modulator

Check the switch operation. Refer to the electrical circuit
diagrams and check the switch and circuit for short to
power

Swap the front wheel speed sensor locations. Clear the DTC
and retest. In order to clear the DTC/warning lamp after
fault is rectified, the vehicle must be driven above 15km/h

Swap the rear wheel speed sensor locations. Clear the DTC
and retest. In order to clear the DTC/warning lamp after

Sensors

Swapped -

fault is rectified, the vehicle must be driven above 15km/h

U0001-88High Speed

Signal
plausibility
failure

CAN
Communication
Bus - Bus off

CAN bus off Refer to the electrical circuit diagrams and check the power

and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network

U0074-88Control Module

Communication
Bus "B" Off ­Bus off

U0100-00Lost

Communication
With ECM/PCM
"A" - No sub
type
information

U0101-00Lost

Communication
With TCM - No
sub type
information

U0102-00Lost

Communication
With Transfer
Case Control
Module - No
sub type
information

U0103-00Lost

Communication
With Gear Shift
Control Module
A - No sub
type
information

CAN Bus off Refer to the electrical circuit diagrams and check the power

No sub type
information

No sub type
information

No sub type
information

No sub type
information

and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the engine
control module and the anti-lock brake system control
module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
transmission control module and the anti-lock brake system
control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the transfer
case control module and the anti-lock brake system control
module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the gear
shift control module and the anti-lock brake system control
module

U0104-00Lost

Communication
With Cruise
Control Module

- No sub type
information

U0123-00Lost

Communication
With Yaw Rate
Sensor Module

- No sub type
information

U0126-00Lost

Communication
With Steering
Angle Sensor
Module - No
sub type
information

U0128-00Lost

Communication
With Park
Brake Control
Module - No
sub type
information

No sub type
information

No sub type
information

No sub type
information

No sub type
information

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the cruise
control module and the anti-lock brake system control
module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the yaw rate
sensor control module and the anti-lock brake system
control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the steering
angle sensor module and the anti-lock brake system control
module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the park
brake control module and the anti-lock brake system
control module

U0132-00Lost

No sub type

Refer to the electrical circuit diagrams and check the power

Communication
With
Suspension
Control Module
"A" - No sub
type
information

U0133-00Lost

Communication
With Active
Roll Control
Module - No
sub type
information

information

No sub type
information

and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the
suspension control module and the anti-lock brake system
control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the dynamic
response control module and the anti-lock brake system
control module

U0136-00Lost

Communication
With
Differential
Control Module

- Rear - No sub
type
information

U0138-00Lost

Communication
With All
Terrain Control
Module - No
sub type
information

U0140-00Lost

Communication
With Body
Control Module

- No sub type
information

U0300-00Internal

Control Module
Software
Incompatibility

- No sub type
information

U0401-68Invalid Data

Received from
ECM/PCM A ­Event
information

U0402-68Invalid Data

Received from
TCM - Event
information

U0403-68Invalid Data

Received From
Transfer Case
Control Module

- Event
information

U0404-68Invalid Data

Received From
Gear Shift
Control Module
A - event
information

U0405-68Invalid Data

Received From
Cruise Control
Module - Event
information

U0417-68Invalid Data

Received From
Park Brake
Control Module

- Event
information

U0421-68Invalid Data

Received from

No sub type
information

No sub type
information

No sub type
information

Control module
has been installed
to the incorrect
vehicle

Invalid data
received

Invalid data
received

Invalid data
received

Event information

- transmission
control switch
related concern

Invalid data
received

Invalid data
received

Invalid data
received

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the rear
differential control module and the anti-lock brake system
control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the all
terrain control module and the anti-lock brake system
control module

Refer to the electrical circuit diagrams and check the power
and ground connections to the module. Using the
manufacturer approved diagnostic system, complete a CAN
network integrity test. Refer to the electrical circuit
diagrams and check the CAN network between the central
junction box and the anti-lock brake system control module

Ensure the correct module is installed

Check the engine control module for related DTCs and refer
to the relevant DTC index

Check the transmission control module for related DTCs
and refer to the relevant DTC index

Check the transfer case control module for related DTCs
and refer to the relevant DTC index

Check the transmission control switch for related DTCs and
refer to the relevant DTC index

Check the speed control module for related DTCs and refer
to the relevant DTC index

Check the park brake control module for related DTCs and
refer to the relevant DTC index

Check the air suspension control module for related DTCs
and refer to the relevant DTC index