steering LAND ROVER FREELANDER 2001 Workshop Manual

CONTENTS
2CONTENTS
GENERAL DATA ..................................................................................... 04-1
Engine - Td4 Diesel ........................................................................................................................ 04-1
Engine - K1.8 Petrol........................................................................................................................ 04-6
Engine - KV6 Petrol ........................................................................................................................ 04-11
Fuel system - Td4 Diesel ................................................................................................................ 04-16
Fuel system - K1.8 Petrol ............................................................................................................... 04-18
Fuel system - KV6 Petrol ................................................................................................................ 04-18
Cooling system - Td4 Diesel ........................................................................................................... 04-19
Cooling system - K1.8 Petrol .......................................................................................................... 04-19
Cooling system - KV6 Petrol ........................................................................................................... 04-19
Clutch.............................................................................................................................................. 04-20
Manual Gearbox - Getrag ............................................................................................................... 04-21
Manual Gearbox - PG1 ................................................................................................................... 04-22
Intermediate Reduction Drive (IRD)................................................................................................ 04-24
Automatic Gearbox - Jatco ............................................................................................................. 04-25
Rear Axle and Final Drive ............................................................................................................... 04-26
Steering .......................................................................................................................................... 04-27
Front Suspension............................................................................................................................ 04-28
Rear Suspension ............................................................................................................................ 04-30
Brakes............................................................................................................................................. 04-31
Wheels and tyres ............................................................................................................................ 04-32
Tyre pressures ................................................................................................................................ 04-32
Heating and Ventilation................................................................................................................... 04-33
Air Conditioning .............................................................................................................................. 04-33
Electrical - Td4 engine .................................................................................................................... 04-34
Electrical - K1.8 engine ................................................................................................................... 04-34
Electrical - KV6 engine ................................................................................................................... 04-34
Dimensions ..................................................................................................................................... 04-35
Weights ........................................................................................................................................... 04-36
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-2

CONTENTS
CONTENTS 3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine – Td4................................................................................................................................... 06-2
Engine – K1.8 ................................................................................................................................. 06-4
Engine – KV6 .................................................................................................................................. 06-6
Emission Control ............................................................................................................................. 06-8
Engine Management System – EDC .............................................................................................. 06-9
Engine Management System – MEMS ........................................................................................... 06-10
Engine Management System – Siemens ........................................................................................ 06-11
Fuel Delivery System – Diesel ........................................................................................................ 06-12
Fuel delivery system – Petrol .......................................................................................................... 06-13
Cooling System – Td4..................................................................................................................... 06-14
Cooling System – K1.8 ................................................................................................................... 06-14
Cooling System – KV6 .................................................................................................................... 06-14
Manifolds and Exhaust System – Td4 ............................................................................................ 06-15
Manifolds and Exhaust Systems – K1.8 ......................................................................................... 06-16
Manifolds and Exhaust Systems – KV6 .......................................................................................... 06-17
Clutch .............................................................................................................................................. 06-18
Manual Gearbox – PG1 .................................................................................................................. 06-19
Manual Gearbox – Getrag .............................................................................................................. 06-20
Intermediate Reduction Drive ......................................................................................................... 06-21
Automatic Gearbox – Jatco ............................................................................................................. 06-22
Driveshafts ...................................................................................................................................... 06-23
Rear Axles and Final Drive ............................................................................................................. 06-24
Steering........................................................................................................................................... 06-25
Front Suspension and Subframe .................................................................................................... 06-26
Rear Suspension and Subframe ..................................................................................................... 06-27
Brakes ............................................................................................................................................. 06-28
Supplementary Restraint Systems .................................................................................................. 06-29
Body ................................................................................................................................................ 06-30
Heating and Ventilation ................................................................................................................... 06-32
Air Conditioning............................................................................................................................... 06-33
Wipers and Washers ....................................................................................................................... 06-34
Electrical ......................................................................................................................................... 06-35
LIFTING AND TOWING ........................................................................... 08-1
Jacking ............................................................................................................................................ 08-1
Towing ............................................................................................................................................ 08-2
Emergency starting ......................................................................................................................... 08-4
CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS ...................... 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Lubrication ...................................................................................................................................... 09-3
Sealants .......................................................................................................................................... 09-4

CONTENTS
4CONTENTS
MAINTENANCE ........................................................................................ 10-1
MAINTENANCE
Td4 - Diesel Engine - Under Bonnet View ...................................................................................... 10-1
K1.8 – Petrol Engine – Under Bonnet View .................................................................................... 10-2
KV6 – Petrol Engine – Under Bonnet View .................................................................................... 10-3
Seats and Seat Belts ...................................................................................................................... 10-4
Lamps, Horns and Warning Indicators ........................................................................................... 10-4
Wipers and Washers ...................................................................................................................... 10-5
Handbrake ...................................................................................................................................... 10-5
Alarm Handset Battery.................................................................................................................... 10-6
Road Wheels .................................................................................................................................. 10-6
Tyres ............................................................................................................................................... 10-7
Brake Pads and Calipers ................................................................................................................ 10-7
Brake Fluid...................................................................................................................................... 10-9
Road Wheel Speed Sensors .......................................................................................................... 10-9
Fuel Filter - Petrol ........................................................................................................................... 10-10
Fuel Filter - Diesel........................................................................................................................... 10-10
Fuel Pump and Filter assembly - Diesel - 03 Model Year onwards ................................................ 10-10
Fuel Sedimenter - Diesel - 03 Model Year onwards ....................................................................... 10-10
Door Locks, Hinges, Check Straps and Bonnet Catch ................................................................... 10-11
Anti-freeze ...................................................................................................................................... 10-12
Cooling System and Intercooler...................................................................................................... 10-12
Vent filter - turbocharger boost control solenoid valve - Td4 .......................................................... 10-13
Spark Plugs – K1.8 ......................................................................................................................... 10-13
Spark Plugs – KV6.......................................................................................................................... 10-13
Air Cleaner – Petrol Models ............................................................................................................ 10-13
Ancillary Drive Belt – Td4 ............................................................................................................... 10-14
Ancillary Drive Belt – K1.8 .............................................................................................................. 10-14
Ancillary Drive Belt – KV6 ............................................................................................................... 10-15
Camshaft Timing Belt – K1.8 .......................................................................................................... 10-15
Camshaft Timing Belt – KV6........................................................................................................... 10-16
Brake/Clutch Reservoir ................................................................................................................... 10-16
PAS Fluid Level .............................................................................................................................. 10-17
Intermediate Reduction Drive - Non NAS models .......................................................................... 10-17
Intermediate Reduction Drive - NAS models .................................................................................. 10-18
Manual Gearbox – PG1 .................................................................................................................. 10-18
Manual Gearbox – GETRAG .......................................................................................................... 10-19
Automatic Gearbox – JATCO ......................................................................................................... 10-19
Rear Axle ........................................................................................................................................ 10-20
Clutch Pipes and Unions ................................................................................................................ 10-21
Windscreen and Rear Washer Reservoir ....................................................................................... 10-21
Battery ............................................................................................................................................ 10-21
Engine Oil and Filter – Td4 ............................................................................................................. 10-22
Engine Oil and Filter – K1.8 ............................................................................................................ 10-23
Engine Oil and Filter – KV6 ............................................................................................................ 10-24
Fuel Hoses and Pipes..................................................................................................................... 10-25
Brake Hoses and Pipes ................................................................................................................. 10-26
Check Exhaust System................................................................................................................... 10-26
Suspension ..................................................................................................................................... 10-27
Steering ......................................................................................................................................... 10-28
Road Test ....................................................................................................................................... 10-28
Endorse Service Record ................................................................................................................. 10-30
Report any Unusual Features ......................................................................................................... 10-30

CONTENTS
10 CONTENTS
REAR AXLE & FINAL DRIVE ................................................................... 51-1
REPAIRS
Differential assembly ..................................................................................................................... 51-1
Cover - rear - differential ................................................................................................................. 51-2
Bush - differential mounting - front ................................................................................................. 51-3
Bush - differential mounting - rear ................................................................................................. 51-4
Oil seal - pinion .............................................................................................................................. 51-5
Oil seal - differential housing ......................................................................................................... 51-6
STEERING ................................................................................................ 57-1
ADJUSTMENTS
Power assisted steering (PAS) system - bleed............................................................................... 57-1
Cable - key interlock - adjust .......................................................................................................... 57-1
Front wheel alignment - check & adjust .......................................................................................... 57-2
Alignment - rear wheel - check & adjust ......................................................................................... 57-3
Power steering - pressure test ........................................................................................................ 57-4
REPAIRS
Power steering rack ........................................................................................................................ 57-5
Gaiter - PAS rack ............................................................................................................................ 57-8
Oil cooler - Td4 & K1.8 models ....................................................................................................... 57-9
Oil cooler - KV6 models .................................................................................................................. 57-10
Drive belt - K1.8 .............................................................................................................................. 57-11
Pump - steering - KV6 .................................................................................................................... 57-12
Pump - steering - K1.8 .................................................................................................................... 57-14
Pump - steering - Td4 ..................................................................................................................... 57-15
Nacelle - column ............................................................................................................................. 57-16
Column lock & ignition/starter switch assembly .............................................................................. 57-17
Cable - key interlock ....................................................................................................................... 57-18
Column assembly - inner & outer ................................................................................................... 57-19
Ball joint - track rod ......................................................................................................................... 57-23
Track rod......................................................................................................................................... 57-24
Steering wheel ................................................................................................................................ 57-25
FRONT SUSPENSION .............................................................................. 60-1
REPAIRS
Anti roll bar...................................................................................................................................... 60-1
Ball joint link - anti roll bar .............................................................................................................. 60-2
Mounting rubbers - anti roll bar - set .............................................................................................. 60-2
Bearing - hub ................................................................................................................................. 60-3
Damper .......................................................................................................................................... 60-7
Lower arm assembly ...................................................................................................................... 60-10
Rear beam ..................................................................................................................................... 60-13
Bush - lower arm - front .................................................................................................................. 60-15
Bush - lower arm - rear ................................................................................................................... 60-16

CONTENTS
12 CONTENTS
RESTRAINT SYSTEMS ............................................................................ 75-1
REPAIRS
Automatic belt assembly - front - 3 door ......................................................................................... 75-1
Automatic belt assembly - front - 5 door ......................................................................................... 75-2
Seat belt - centre - rear ................................................................................................................... 75-3
Seat belt - rear - LH ........................................................................................................................ 75-4
Adjustable mounting - seat belt - 'B' pillar ....................................................................................... 75-5
Stalk - rear seat belt - LH - 3 door .................................................................................................. 75-6
Stalk - rear seat belt - LH - 5 door .................................................................................................. 75-7
Pre-tensioner - seat belt - front ....................................................................................................... 75-8
Pre-tensioner - seat belt - front - deployment - off vehicle ............................................................. 75-9
Stalk - rear seat belt - centre .......................................................................................................... 75-11
Air bag - steering wheel .................................................................................................................. 75-13
Air bag - fascia - passenger - up to 04MY ...................................................................................... 75-14
Air bag - fascia - passenger - from 04MY ....................................................................................... 75-15
Diagnostic control unit (DCU) ........................................................................................................ 75-16
Airbag - passenger - deployment - off vehicle ............................................................................... 75-17
Rotary coupler - (SRS) air bag system ........................................................................................... 75-19
Airbag module - steering wheel - deployment - off vehicle ............................................................ 75-20
Airbag module - steering wheel - deployment - in-vehicle .............................................................. 75-21
Pre-tensioner - front seatbelt - deployment - in-vehicle .................................................................. 75-23
DOORS...................................................................................................... 76-1-1
ADJUSTMENTS
Door - front or rear - adjust on striker ............................................................................................ 76-1-1
Door - front - align on hinges .......................................................................................................... 76-1-2
REPAIRS
Door assembly - front - remove for access & refit .......................................................................... 76-1-3
Door assembly - rear - remove for access & refit ........................................................................... 76-1-4
Door - tail assembly - remove for access & refit ............................................................................. 76-1-5
Glass - front door .......................................................................................................................... 76-1-6
Glass - rear door ............................................................................................................................ 76-1-7
Rubber/felt - glass channel - front door ........................................................................................ 76-1-8
Rubber/felt - glass channel - rear door .......................................................................................... 76-1-9
Glass - tail door .............................................................................................................................. 76-1-10
Quarter light - rear door .................................................................................................................. 76-1-11
Glass regulator - tail door .............................................................................................................. 76-1-12
Seal - waist inner - tail door ............................................................................................................ 76-1-13
Trim casing - front door - 3 door .................................................................................................... 76-1-14
Trim casing - front door - 5 door - up to 04MY................................................................................ 76-1-15
Trim casing - front door - 5 door - from 04MY ................................................................................ 76-1-16
Trim casing - rear door - up to 04MY .............................................................................................. 76-1-18
Trim casing - rear door - from 04MY............................................................................................... 76-1-20
Trim casing - tail door ..................................................................................................................... 76-1-22
Plastic sheet - front door - lower - 3 door........................................................................................ 76-1-23
Pocket - front door - 3 door ............................................................................................................. 76-1-23
Plastic sheet - front door - upper - 3 door ....................................................................................... 76-1-24
Plastic sheet - tail door ................................................................................................................... 76-1-24
Plastic sheet - front door - 5 door .................................................................................................. 76-1-25
Plastic sheet - rear door.................................................................................................................. 76-1-25
Latch - front door - 3 door ............................................................................................................... 76-1-26
Latch - front door - 5 door .............................................................................................................. 76-1-27
Latch - rear door ............................................................................................................................. 76-1-28
Latch - tail door ............................................................................................................................... 76-1-29

INTRODUCTION
01-4
HRW Heated Rear Window
ht/HT High tension
HSLA High Strength Low Alloy
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
IF Intermediate Frequency
in Inch
in
2Square inch
in3Cubic inch
ILT Inlet Throttle
ISO International Organisation for
Standardisation
ITS Inflatable Tubular Structure
k Thousand
kg Kilogramme
kg/h Kilogrammes per hour
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lLitre
lb(s) Pounds
lbf Pounds force
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet
λLambda
lc Low compression
LCD Liquid Crystal Display
LED Light Emitting Diode
LEV Low Emission Vehicle
LH Left-Hand
LHD Left-Hand Drive
LSM Light Switch Module
LVS Liquid Vapour Separator
mMetre
µMicro
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MFU Multi-Function Unit
MFL Multi-Function Logic
max. Maximum
MEMS Modular Engine Management
System
MIG Metal/Inert Gas
MIL Malfunction Indicator Lamp
MPa MegaPascal
MOSFET Metal Oxide Semiconductor Field
Effect Transistor
min. Minimum
- Minus (tolerance)
' Minute (angle)
mm Millimetre
mph Miles per hour MPi Multi-Point injection
MV Motorised Valve
MY Model Year
NAS North American Specification
(-) Negative (electrical)
Nm Newton metre
No. Number
NO
2Nitrogen Dioxide
NO
xOxides of Nitrogen
NTC Negative Temperature
Coefficient
NRV Non Return Valve
OBD On Board Diagnostics
OBM On Board Monitoring
o.dia. Outside diameter
OAT Organic Acid Technology
ORM Off-road Mode
ΩOhm
PAS Power Assisted Steering
PCB Printed Circuit Board
PCV Positive Crankcase Ventilation
PDC Parking Distance Control
PDOP Position Dilation Of Precision
PI Programme Information
PPS Pulse Per Second
PS Programme Service
psi Pounds per square inch
pts. Pints
% Percentage
+ Plus (tolerance) or Positive
(electrical)
±Plus or minus (tolerance)
PTC Positive Temperature Coefficient
PTFE Polytetrafluorethylene
PWM Pulse Width Modulation
RDS Radio Data Service
rRadius
:Ratio
ref Reference
REG Regionalisation
RES Rover Engineering Standards
rev/min Revolutions per minute
RF Radio Frequency
RGB Red / Green / Blue
RH Right-Hand
RHD Right-Hand Drive
ROM Read Only Memory
RON Research Octane Number
ROV Roll Over Valve
ROW Rest Of World
SAE Society of Automotive Engineers
SAI Secondary Air Injection
" Second (angle)
SLABS Self Levelling and Anti-Lock
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft
SPE Single Point Entry

GENERAL INFORMATION
03-1
GENERAL INFORMATION
General precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
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, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
WARNING: Many of the fluids used in motor
vehicles, such as coolant, brake fluid and power
steering fluid, are inflammable. Take care not to
spill fluids when topping-up, a fire may result. If
spillage does occur, ensure the area is
thoroughly cleaned before starting the engine.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers.
Under normal operating conditions this material is
safe and does not present a health hazard. However,
if the material is damaged by fire or excessive
heating, it can break down and produce highly
corrosive Hydrofluoric acid which can cause serious
burns on contact with skin.
If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or over-heated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.). Decontaminate and dispose of
gloves immediately after use.Lubricating oils
WARNING: Avoid excessive skin contact with used
engine oil. Used engine oil contains potentially
harmful contaminants which may cause skin cancer
or other serious skin disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats from
the skin, leading to dryness, irritation and dermatitis.
Health protection precautions
The following precautions should be observed at all
times:
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lWear protective clothing, including impervious
gloves where practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lUse barrier creams: apply before each work
period to help prevent lubricating oil from
contaminating the skin.
lWash with soap and water to ensure all oil is
removed (propriety skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol, kerosene, diesel fuel, gas, oil,
thinners or solvents for cleaning skin.
lIf skin disorders develop, obtain medical advice
without delay.
lWhere practicable, degrease components prior
to handling.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in the
close vicinity of the work area.

GENERAL INFORMATION
03-14
Self-locking nuts
Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
DO NOT apply heat in an attempt to free deferred
thread nuts or fittings; as well as causing damage to
protective coatings, there is a risk of damage to
electronic equipment and brake linings from stray
heat.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the same
type.
Where bearing pre-load is involved, nuts should be
tightened in accordance with special instructions.
Flexible pipes and hoses
General
When removing and installing flexible hydraulic pipes
and hoses, ensure that the following practices are
observed to ensure component serviceability:
lBefore removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
lObtain appropriate plugs or caps before
detaching hose end fittings, so that the ports
can be immediately covered to prevent the
ingress of dirt.
lClean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
lWhen refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.
lFit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of
dirt.
lAbsolute cleanliness must be observed with
hydraulic components at all times.
lAfter any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.
Do not disconnect any pipes in an air
conditioning refrigeration system unless trained
and instructed to do so. A refrigerant is used
which can cause blindness if allowed to contact
eyes.

GENERAL INFORMATION
03-21
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:
lSteering system – steering wheel airbag,
rotary coupler.
lFront fascia – passenger front airbag (where
fitted); SRS DCU behind centre console, on
transmission tunnel under the HeVAC system.
lFront seats – seat belt pre-tensioners, integral
with seat belt buckle assembly.
lElectrical system – SRS harnesses, link leads
and connectors.
Making the SRS system safe
Before working on or in the vicinity of SRS
components, ensure the system is rendered safe by
performing the following procedures:
lRemove the ignition key from the ignition switch.
lDisconnect both battery leads, earth lead first.
lWait 10 minutes for the SRS DCU back-up
power circuit to discharge.
The SRS system uses energy reserve capacitors
that keep the system active in the event of electrical
supply failure under crash conditions. It is necessary
to allow the capacitor sufficient time to discharge (10
minutes) in order to avoid the risk of accidental
deployment.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.Installation
In order to assure 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 SRS system
components is critical for safety reasons. Ensure
the following precautions are always adhered to:
lNever install used SRS components from
another vehicle or attempt to repair an SRS
component.
lWhen repairing an SRS system only use
genuine new parts.
lNever apply electrical power to an SRS
component unless instructed to do so as
part of an approved test procedure.
lSpecial Torx bolts are necessary for
installing the airbag module — do not use
other bolts. Ensure bolts are tightened to the
correct torque.
lAlways use new fixings when replacing an
SRS component.
lEnsure the SRS Diagnostic Control Unit
(DCU) is always installed correctly. There
must not be any gap between the DCU and
the bracket to which it is mounted. An
incorrectly mounted DCU could cause the
system to malfunction.
CAUTION: Ensure SRS components are not
contaminated with oil, grease, detergent or
water.
Ensure that SRS component fixings are correctly
positioned and torqued during service and repair.
CAUTION: Torque wrenches should be regularly
checked for accuracy to ensure that all fixings
are tightened to the correct torque.
If you suspect an airbag assembly could be
defective, install a new unit and dispose of the old
unit. Manually deploy the old unit before disposal.

GENERAL INFORMATION
03-28
SRS component replacement policy
The following information details the policy for
replacement of SRS components; either as a result
of a vehicle accident or as a result of vehicle age.
Impacts which do not deploy the airbags or seat
belt pre-tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.
Impacts which deploy the airbags and/or seat
belt pre-tensioners
The inspection and replacement 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.
Front airbag/ seat belt pre-tensioner deployment
(driver and passenger)
If the front airbags and/or seat belt pre-tensioners are
deployed as a result of a front, front angled or side
impact, the following parts must be replaced:
lDriver airbag module
lPassenger airbag module (where fitted)
lSRS flyleads
lSRS DCU
lRotary coupler
lFront seat belt pre-tensioners
In addition, the following should be inspected for
damage and replaced as necessary:
lFront seat belt and buckle tongue (anchorage
points, webbing etc.)
lFascia moulding adjacent to passenger airbag
module (where fitted)
lSteering wheel (if damage is evident)
lFront seat frames and head restraints (if there is
evidence of damage to the seat frame or
cushion pan)
lSteering column (if adjustment is lost or there
are signs of collapse)
lFront seat belt height adjusters on 'BC' posts (5
door models only)
lRear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)Rear Impact
If the seat belt pre-tensioners are deployed during a
rear impact, the following components must be
replaced:
lSeat belt pre-tensioners
lFront and rear automatic seat belt assemblies
used during an impact.
lSRS DCU
In addition, the following components should be
inspected for damage and replaced as necessary:
lFront seat frames
lFront seat belts and buckle (retractors,
webbing, tongue latching, buckle covers, body
anchorages and 'D' loops)
lSeat belt height adjusters (5 door models only)
lRear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)
Periodic replacement of SRS components
The performance of the propellants within airbags
and seat belt pre-tensioners will deteriorate over a
period of time. As a result, it is essential that the
airbags and seat belt pre-tensioners are periodically
replaced to maintain occupant safety. Airbags, seat
belt pre-tensioners and the rotary coupler should be
replaced at the recommended intervals.