ABS LAND ROVER FRELANDER 2 2006 Repair Manual

Clean bench and provide marking mat eri al s , labels and containers before di s as s embli ng components .
Disassembling
Obs erve s crupul ous cl eanl ines s when dis as sembl ing component s, parti cul arly when brake, fuel, air s us pens ion or hydrauli cs ys t em parts are dis as sembl ed. A part icle of dirt or cloth fragment could caus e a s eri ous malfunct ion i f trapped i n t hes es ys t ems .
Blow out al l tapped holes , crevi ces , oil ways and flui d pass ages wit h dry, compres s ed air.
W ARNING: Sui table eye protecti on mus t be worn.
Us e s uit abl e marker i nk to identi fy mat ing parts , do not us e a s cri ber or cent re punch as t hey coul d ini ti at e cracksor dis torti on.W i re or t ape mat ing part s t oget her where neces s ary t o prevent acci dent al i nterchange.Suit abl y identi fy parts which are to be renewed and t o thos e part s requi ri ng further ins pect ion. Keep thes e part ss eparate.To make s ure that t he correct replacement part has been obt ained, do not dis card a part due for renewal unt il aftercomparing i t wit h t he new part.
Cleaning Components
Always us e cleaning agents whi ch are s uit able for the work being undert aken and the component s being cleaned. NEVERus e gasol ine (pet rol ) as a cleaning agent (degreas er). Always make s ure that the component bei ng cleaned is compati blewit h t he cleaning agent.
Always follow the manufact urer's i ns t ructi ons regarding the us e of cleaning agents and make sure t hat t he envi ronment inwhich t he work is being undert aken is s uit able. See Healt h and Safet y Precaut ions for furt her informati on regardi ngcleaning.
General Inspection of Components
All component s s houl d be i ns pect ed for wear or damage before reas s embl ing.
Always make s ure that component t o be i ns pected i s clean and free from oil or greas e.W hen a component is t o be checked di mensi onal ly agains t desi gn s pecified values , use the appropriat e meas uringequi pment i.e. micromet ers , verniers, s urface plates , dial t es t i ndi cat ors (DTI).Always make s ure that all meas uri ng equi pment is correct ly cali brat ed before us e.Reject a component which i s not wit hin specified values /l imi ts or i f it appears t o be damaged.A component may be rei ns t alled if dimens ions obt ai ned during checki ng are at t he maximum t olerance l imi t and itis in an undamaged condi ti on.Bearing journal clearances should be checked where neces s ary us ing Pl ast igauge.
Joints and Joint Faces
All gas ket s s houl d be i ns t alled dry unles s s tat ed otherwis e. Always appl y t he s pecified l ubricant to O-rings and i nst allO-ri ngs us ing the fingers onl y.
Us e gasket removal s pray and/or plas t ic s crapers t o remove traces of old gas ket.
CAUTION: DO NOT us e met al s crapers or emery clot h as t hes e may damage the s eali ng s urfaces.
Many joi nts us e s ealants ins tead of gasket s as t he seal ing medium. W here t his is t he cas e, t he s eal ant t oget her wit h i tspart number wil l be found l is ted i n t he rel evant repair operat ion and al so in the s ealants table.
CAUTION: Always remove all t races of the ol d s eal ant prior t o reas s embly. Use plas tic s crapers, s pecifi ed s olvent swhere avail abl e or dry, l int free clot h. DO NOT us e met al scrapers or emery clot h as t hese may damage the seali ngs urfaces . Make sure t hat s eali ng s urfaces are free from oi l or greas e as sealant s wil l not adhere properly to contaminateds urfaces .
Do not all ow s ealant to ent er tapped holes or oil ways .
Locking Devices
Always repl ace locki ng devi ces wit h one of the s ame des ign and of t he correct s ize.
Tab washers
Always release locki ng t abs before l oos ening fixings , do not reus e t ab washers.
Locknuts
Always us e a backing s panner when l oos ening and t ighteni ng locknut s, brake and fuel pipe unions .
Roll pins
Always i ns t all new roll pins of t he correct s ize.
Circlips
Always i ns t all new circl ips ens uri ng that t hey are of t he correct s ize for t he groove.

A clock face sys tem is somet imes us ed as an al ternat ive method of indi cat ing t he s trengt h grade. The external chamfers ora face of t he nut is marked i n a pos it ion relati ve to the appropriat e hour mark on a cl ock face to indicate the s t rengthgrade.
A dot i s used to l ocat e t he 12 o'clock posi ti on and a das h t o indi cat e t he st rengt h grade. If t he grade i s above 12, t wodots i dent ify t he 12 o'clock posi ti on.
W hen t ight eni ng a s lot ted or cas tell ated nut , never loos en it t o i nsert a s pli t pi n except where s pecified as part of anadjus tment procedure. If di fficult y is experi enced i n correct ly pos it ioning t he s lot, alt ernati ve washers or nut s s houl d bes elect ed.
W here a nut is ti ght ened to adjust or mai ntain bearing pre-l oad, t he ti ght ening procedure must be adhered to.
Self-locking nuts
Unles s s tat ed otherwis e, sel f-locki ng nuts once removed must be di s carded and new nut s of t he s ame t ype and st rengthgrade i nst all ed.
Ball and Roller Bearings
W hen removing and i ns t alli ng bearings , make s ure t hat the foll owing pract ices are obs erved t o make s ure components erviceabi li ty:
CAUTION: Service t ools have been devel oped for removing the majori ty of beari ngs ; t hes e must al ways be usedwhere specified.
Remove all t races from beari ng under i ns pecti on by cl eani ng wit h a sui table degreas ant; maintai n absol ut ecleanlines s t hroughout operati ons.Conduct a vis ual ins pect ion for markings on roll ing element s , raceways , out er s urfaces of outer or inner surfaces ofinner ri ngs . Reject any bearings found to be marked s ince marking i n thes e areas i ndicat es ons et of wear.Hold inner race of bearing between finger and t humb of one hand and rotat e outer race to check that it revol vesabsol ut ely smoot hly. Repeat holding out er race and rot ati ng inner race. DO NOT spi n t he bearing.Rotat e outer ring gentl y us ing a reci procati ng movement whi ls t holding i nner ring; feel for any check or obs truct iont o rot ati on. Reject beari ng if movement is not abs ol utel y s moot h.Check beari ng for bl uei ng or si gns of overheat ing.Lubricate bearing wi th the s pecifi ed lubricant .Ins pect bearing s urface of s haft and beari ng hous i ng for dis colorat ion or ot her markings which i ndi cat e overheati ngof bearing or movement between beari ng and s eat ing.Before ins tal li ng bearing, make s ure t hat shaft and bearing hous ing are cl ean and free from burrs .If one bearing of a pair s hows s igns of wear, overheati ng etc., i t is advis able to replace bearings as a pai r unl ess itis sus pect ed t hat one beari ng may have been fault y when i nst all ed, was i nst all ed incorrect ly or t he faul t aros e duet o oil s eal fail ure.Never reins tal l a bearing unles s i t is i n a full y s erviceabl e condi ti on.
W hen i nst all ing a bearing t o a s haft , only apply force t o t he inner ri ng of the beari ng. W hen ins t al li ng a beari ngint o a hous ing, onl y apply force t o t he out er ri ng of the bearing.

CAUTION: Service t ools have been devel oped for ins tal ling the majori ty of beari ngs ; t hese must al ways be usedwhere specified.
In the cas e of greas e l ubricated beari ngs , fil l t he s pace bet ween t he bearing and out er s eal wit h t he recommendedgrade of greas e before ins t al li ng the seal.
CAUTION: W hen a waxed oil s eal (ins tal led dry) t ype of oil s eal i s to be ins t al led, take great care that greas e doesnot cont aminate the runni ng s urface of t he s eal .
Always make s uit able reference marks bet ween t he components of s eparable bearings e.g. t aper roller beari ngswhen dis as sembl ing t o make s ure correct locati on of components when as s embli ng. Never ins tall new roll ers i n anouter ring, al ways ins tal l a new beari ng ass embly.
Brake Pads and Linings
Always i ns t all t he correct grade and s peci fi cat ion of brake pads and li nings . W hen repl acing thes e it ems , always repl ace ascomplete axl e s ets .
Brake Hydraulics
Always obs erve t he fol lowing recommendat ions when worki ng on t he braking s ys tem:
W ARNING: Do not int ermi x brake fluid of di fferent specificati ons .
Always us e t wo s panners when loos eni ng or ti ght ening brake pi pes or hos e connect ions.Make s ure t hat hos es run in a natural curve and are not kinked or twi st ed.Ins t all brake pipes and hos es s ecurel y in their retaini ng clips and make sure t hat they cannot cont act a pot enti alchafing point .Containers used for brake fluid must be kept abs ol utel y cl ean.Do not s tore brake fluid in uns ealed containers, t he fluid will abs orb wat er which wi ll lower t he boili ng point of thefl uid.Do not all ow brake flui d to be cont aminat ed wit h ot her fluids such as mi neral oil and do not put brake fl uid i n acont ainer which has previous ly been us ed for s t oring ot her fl ui ds.Do not reus e brake flui d which has been bled from t he s ys t em.Always us e brake flui d or a s uit abl e brake cleaning flui d t o clean hydraulic component s .Unles s s tat ed otherwis e, us e onl y clean brake fluid to lubri cat e hydraulic seals and components .Always i ns t all blanking plugs t o hos es, pi pes or component s immediatel y aft er dis connect ion.Check t hread compati bili ty of origi nal equipment wit h repl acement component s.Obs erve absol ute cl eanli ness when working wi th hydraul ic component s .
Pipes and Hoses
W hen removing or ins t al li ng fl exi ble hydrauli c pipes and hoses , make s ure that t he foll owing procedures are observed tomake s ure component servi ceabil it y:
Pri or to removal , clean area around hos e or pipe end which is to be dis connect ed.Obtai n appropri at e bl anking pl ugs or caps before dis connecti ng hose or pi pe end fi ttings i n order t hat connect ionscan be plugged immedi atel y fol lowing di sconnect ion.Always i ns t all blanking plugs or caps to pipes and unions immedi atel y fol lowing di sconnect ion.Clean hos e or pipe and bl ow t hrough wit h an ai r line.
W ARNING: Sui table eye protecti on mus t be worn.
Check hos es external ly for cracks , separat ion of pl ies , securi ty of end fit ti ngs and ext ernal damage; repl ace fault yhoses .Check pi pes for s igns of corros ion and chafi ng, replace as neces s ary.
CAUTION: If pipes are found to be chafed, rect ify cli ps, mount ing point s etc., to prevent furt her probl ems in service.
W hen i nst all ing hos es , make s ure that no unneces s ary bends are i ntroduced and t hat hos es are not ki nked, twi s tedor pos i ti oned cl os e t o pot ent ial chafing poi nt s .W hen i nst all ing pipes , make s ure t hat pipes are pos it ioned and cli pped cl ear of potent ial chafing point s .Always repl ace seali ng was hers i ns t alled to banjo bol ts , s ealing pl ugs etc.Always us e a backing s panner when t ightening uni ons and do not overt ight en union nuts or banjo bol ts .Aft er any work on hydraul ic s yst ems , always check for flui d leaks whil s t a s econd operat or appli es worki ng pres suret o the brake pedal or operates t he s yst em that has been worked on.
Fuel s ys tem hos es

Do not t ouch t he glas s port ion of t he bulb.On no account s hould headlamps be s wi tched on wi th t he bulb removed from the headlamp.Bulb t es ti ng may only be carri ed out wit h the bul b ins t al led i n t he headl amp.Bulbs mus t be di spos ed of in accordance wit h the local aut horit y bye-laws .
Connectors and harnesses
The engi ne compart ment of a vehi cl e is a part icularl y host il e environment for el ect ri cal component s and connectors. Al waysobserve the foll owing:
Make s ure el ect ri cal ly related it ems are dry and oil free before di sconnect ing/connecti ng t es t equipment .Make s ure t hat dis connect ed mul ti pl ugs and s ens ors are prot ect ed from any pos s ibl e oil , coolant or other li qui dcont aminat ion. Any such contami nat ion could impair performance or l ead to component fail ure.Never force connectors apart or pull on t he wiring harnes s .Always make s ure locki ng t abs are dis engaged before di sconnect ing mul ti plugs etc. and make s ure that correctori ent ati on is achieved before connecti on.Make s ure t hat any protecti on covers, i nsul at ion et c. are replaced if dis t urbed.
Having confirmed t hat a component is fault y, carry out t he fol lowing:
Swit ch off t he ignit ion and di s connect t he batt ery.Remove the component and support t he dis connected harnes s .W hen replaci ng electrical components , keep oily hands away from electrical connect ions and make s ure that lockingt abs on connect ors are ful ly engaged.
Battery Disconnection/Connection
Always refer to the El ect ri cal Secti on of this manual - Bat tery Connecti on/Dis connecti on pri or t o at tempt ing t o connect ordis connect the bat tery.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
Fuel Handling Precautions
The fol lowing informati on li s ts bas ic precauti ons which mus t be obs erved if fuel i s t o be handl ed s afely. It als o outl inesother areas of ris k which mus t not be i gnored. As t his informati on is is sued for basi c gui dance only, consul t your local Fi reDepart ment where any doubt as to personal and envi ronmental s afet y exi s ts - See al so Heal th and Safety Precaut ions .
General precaut ions
Always have t he correct type of fire ext inguis her cont aining Foam, CO2, Gas or powder acces s ible when handl ing ordrai ni ng fuel or dis mantl ing fuel s ys tems . Fire exti ngui shers mus t als o be l ocat ed in areas where fuel i s s tored.
Make s ure t hat sui table warning si gns are exhibit ed.
Keep all s ources of ignit ion wel l away from areas where fuel is bei ng handl ed.
Make s ure t hat any leadlamps are fl ameproof and kept clear of spi ll age.
• W ARNINGS:
Do not di sas s emble or reas s emble fuel sys tem components whils t vehicle is over a pit .
No one should be permi tt ed to repair component s as sociat ed wit h fuel wi thout fi rs t having s peci alis t t rai ni ng.
Always dis connect t he vehi cl e batt ery before carryi ng out dis ass embly, reas s embly or drai ning work on a fuel sys tem.
Fuel t ank and s ys t em drai ning
Drai ning mus t be carried out in accordance wit h t he procedures given in the relevant Fuel Syst em s ecti on of thi s manual .
• W ARNINGS:
Never drain fuel or work on a fuel sys t em whil e t he vehi cl e i s over a pi t. Ext raction or draining of fuel must becarri ed out in a well venti lated area.
Al ways at tach fuel vapor warning l abel s t o fuel t anks i mmediat ely after drai ni ng.
Contai ners us ed for s toring fuel must be cl early marked wit h t he cont ents and pl aced i n a safe s torage area whichmeets the requi rement s of the local authorit y.
CAUTION: Some fuel l ines are now i ns t alled wit h 'quick release' connectors. If a connect or i s damaged, no at t emptmus t be made t o repai r the connect or, a new fuel line and connect or(s ) as s embly must be ins tall ed.
Always release pipe cli ps full y before att empti ng t o dis connect fuel pipes.
Fuel tank repairs
CAUTION: No at tempt s hould be made to repair a pl ast ic fuel tank. If t he s truct ure of t he t ank is damaged, a new

Air condi ti oning unit s mus t not be li ft ed by t hei r hos es , pipes or capil lary li nes .Hos es and lines mus t not be s ubjected t o any t wis t or s tress ; t he efficiency of the s ys tem wil l be impai red by ki nksor res trict ions. Make s ure that hos es are correct ly pos it ioned before t ightening coupli ngs , and make s ure that allclips and support s are ut il is ed.Flexible hos es s houl d not be pos it ioned cl oser t han 100 mm (4.0 i n) t o t he exhaus t manifold unl es s protected byheat shi el ding.Complet ed ass embli es mus t be checked for refrigerat ion l ines t ouching met al panels . Any direct contact ofcomponents and panels may t rans mit nois e and s o must be el iminated.The appropri at e t orque wrench must be us ed when t ight eni ng refri gerant connect ions to t he s ti pul at ed value. Anaddi ti onal s panner mus t be us ed t o hold t he union t o prevent t wis ti ng of the pi pe when t ightening connect ions .Before connecti ng any hos e or pipe, make s ure that refri gerant oil is appli ed t o t he seat of t he new O-ri ngs , BUTNOT to the t hreads of the connect ion.All prot ect ive pl ugs or caps mus t remai n i n place in the component unt il i mmediat el y pri or to connect ion.Make s ure component s are at room temperat ure before uncappi ng/unpl uggi ng, t o prevent condens at ion of moi s turefrom the ai r that enters it .W hen di sconnect ing, immedi ately pl ug or cap all air condi ti oni ng pipes t o prevent ingres s of dirt and mois t ure i ntot he sys t em.Component s mus t not remain uncapped/unpl ugged, if a sys t em has been left uncapped/unpl ugged for 20 mi nut esor longer, a new recei ver/drier mus t be i ns t alled.The receiver/dri er contai ns des i ccant which absorbs mois t ure. It must be pos it ively sealed at al l ti mes . Areceiver/dri er t hat has been left uncapped for longer t han 20 mi nutes mus t not be used; i nst all a new uni t.The receiver/dri er s hould be the l ast component connect ed to the sys tem t o make s ure opt imum dehydrat ion andmaximum moi st ure protecti on of the sys tem.W henever a component of t he refrigerat ion s yst em is repl aced, it will al so be neces sary t o ins t al l a newreceiver/dri er uni t.Us e alcohol and a cl ean li nt -free cl oth to cl ean di rt y connecti ons.Make s ure t hat all new part s i ns t alled are marked for us e wit h R134a.W hen a major repai r has been complet ed, a leak t es t s hould be conduct ed; refer t o t he Repai rs Secti on of thi smanual for the correct procedure.
Refrigerant oil
CAUTION: Refrigerant oil eas il y absorbs water and mus t not be s tored for long periods. Do not pour unusedrefri gerant oi l back i nto the container. Always use an approved refrigerant oi l.
W hen replaci ng component s in the ai r condit ioning s ys tem, drai n t he refri gerant oi l from t he component being replacedint o a graduat ed cont ainer. On as s embly, add t he quant it y of refri gerant oi l drained t o t he new component - See Ai rCondi ti oni ng Compres s or Repl acement in this Sect ion.
Compres s or
A new compress or is sealed and press uris ed wit h Ni trogen gas . W hen i nst all ing a new compres sor, sl owly releas e thes eal ing cap; gas pres sure s houl d be heard to vent as t he s eal i s broken.
CAUTION: A new compress or s houl d always be s ealed and could be pres suris ed wit h ni trogen gas . To avoid pos si bleoil l os s , rel eas e t he s ealing cap(s ) s lowl y. Do not remove t he cap(s ) unt il i mmediatel y pri or to connect ing t he aircondi ti oni ng pipes t o the compress or.
Rapid refrigerant dis charge
If the ai r condit ioning s ys tem is i nvol ved in accident damage and t he s yst em is punct ured, t he refri gerant will di schargerapi dl y. The rapid di scharge of refrigerant wil l als o res ult in t he los s of mos t of the oi l from t he s yst em. The compres sormus t be removed and al l the remaining oi l in t he compres s or drained and refil led as i nst ruct ed in t he air condit ionings ect ion of t his manual.
Precaut ions for refrigerant recovery, recycl ing and rechargi ng
W hen t he air condit ioning s yst em is recharged, any exi s ti ng refri gerant i s first recovered from t he s ys t em and recycled.The s ys t em i s t hen charged wit h the required weight of refrigerant and volume of refrigerant oil .
W ARNING: Refri gerant mus t al ways be recycl ed before reus e t o make s ure that the purit y of the refrigerant i s highenough for s afe us e i n the ai r condit ioni ng sys t em. Recycl ing s hould al ways be carried out wit h equipment which i s des i gncert ifi ed by Underwrit er Laborat ory Inc. for compl iance wit h SAE J1991. Ot her equipment may not recycle refrigerant t o t herequired level of purit y.
• CAUTIO NS:
A R134a Refri gerant Recovery Recycli ng Rechargi ng Stat ion mus t not be us ed wit h any ot her t ype of refrigerant .Refrigerant R134a from domes ti c and commercial s ources mus t not be used i n mot or vehi cl e air condi ti oni ng s yst ems .
The s yst em must be evacuat ed i mmediat el y before recharging commences. Del ay bet ween evacuati on and rechargingis not permit ted.
Air Condit ioning Compress or Repl acement
A new compress or is suppli ed fi ll ed wit h a full charge (X cm³) of refrigerant oi l.
A calculat ed quant it y of oil mus t be drai ned from t he new compres s or before i nst all ing. To cal cul at e t he quant it y of oil t obe drai ned:
Remove the drain pl ug from the ol d compres sor.

Air Suspension
W henever work is bei ng undertaken on t he air s us pens ion s ys tem, s uit able eye prot ection must be worn.
Air Conditioning Refrigerant
Highly fl ammable, combus t ible – observe No Smoking poli cy.
Skin contact may res ult in fros tbi te.
Ins t ructi ons gi ven by the manufact urer mus t be followed. Avoi d naked li ght s , wear s uit able protecti ve gloves and goggles .
If refrigerant comes int o contact wit h t he s ki n or eyes , rins e t he affect ed areas with wat er immedi ately. Eyes s houl d als obe rins ed wit h an appropriate irri gat ion s olut ion s uch as a s olut ion of 9% Sodi um Chl oride and Purified W at er. DO NOTRUB T HE EYES AND SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Air Conditioning Refrigerant
Do Not
Do Not expos e refrigerant bott les to s unli ght or heat.Do Not expos e refrigerant bott les to fros t .Do Not drop refrigerant bot tl es .Do Not vent refrigerant t o at mos phere under any circums t ance.Do Not mi x refri gerants .
Adhesives and Sealants
Many adhes ives and s ealants are hi ghl y fl ammable – OBSERVE NO SMOKING POLICY . Thes e it ems , s hould be s tored infl ameproof cabi net s in No Smoking areas . Cleanli nes s and t idi nes s i n us e s houl d be obs erved, for exampl e dis posablepaper covering benches . All adhesi ves and sealant s s houl d be dis pensed from applicators where pos s ibl e; contai ners ,including secondary cont ainers , s houl d be l abell ed appropri at ely.
Anaerobic, Cyanoacrylate (super-g lues) and other Acrylic Ad hesives
Many are irrit ant, s ensi ti zing or harmful to the s kin and res pirat ory t ract . Some are eye i rrit ants .
Skin and eye contact should be avoi ded and the manufact urer's ins t ructi ons foll owed.
Cyanoacrylat e adhes i ves (s uper-gl ues ) MUST NOT cont act t he s ki n or eyes . If s ki n or eye ti s sue i s bonded, cover wi th aclean moi st pad and SEEK IMMEDIAT E MEDICAL AT T ENT ION. Do not att empt to pul l ski n t is sue apart. Us e i n wellvent il ated areas as vapors can caus e irri tat ion t o t he nose and eyes .
For two-pack s yst ems s ee Res in-bas ed and Is ocyanat e Adhesi ves /Seal ers .
Solvent-based Adhesives/Sealers - See Solvents
Follow manufacturers ins t ructi ons .
Water-based Adhesives/Sealers
Thos e bas ed on polymer emul si ons and rubber/latex may cont ain s mal l amount s of vol ati le, toxic and harmful chemicals .Skin and eye contact should be avoi ded and adequate vent ilat ion provi ded during us e.
Hot Melt Adhesives
In the sol id s t ate, t hey are s afe. In t he molt en s tat e t hey may caus e burns and healt h hazards may aris e from t heinhalat ion of t oxi c fumes .
Us e appropri at e protecti ve cl othing and a t hermos tat ical ly controll ed heat er wit h a t hermal cut-out and adequateextract ion.
Resin-based Adhesives/Sealers, for examp le Epoxide and Formaldehyde Resin-based
Mixi ng s hould be carri ed out in wel l vent il at ed areas as harmful or t oxi c vol ati le chemicals may be rel eas ed.
Skin contact wit h uncured res i ns and hardeners can res ult i n irri tat ion, dermat it is , and abs orpt ion of t oxic or harmfulchemical s t hrough the ski n. Splas hes can damage the eyes .
Provide adequat e venti lat ion and avoid s kin and eye contact .
Isocyanate (Polyurethane) Ad hesives/Sealers
See als o Res in-bas ed Adhesi ves
Indi vi dual s s uffering from as thma or res pi rat ory al lergi es should not work wi th or near thes e mat eri al s as s ensi ti vi tyreacti ons can occur.
Over expos ure i s irri tat ing t o t he eyes and res pirat ory sys tem. Excess ive concent rations may produce effects on thenervous s ys t em i ncl udi ng drows ines s. In extreme cas es , l os s of conscious ness may result . Long term expos ure to vapourconcentrati ons may res ult i n adverse heal th effect s.
Prol onged contact wit h t he s ki n may l ead to s ki n irri tat ion and i n s ome cas es , dermat it is .
Splas hes ent eri ng the eye wi ll cause di s comfort and pos si ble damage.

Any s praying s houl d preferably be carri ed out in venti lat ed boot hs which i ncorporat e faci li ti es for removi ng vapors ands pray dropl et s from the breathing zone.
W ear appropri at e gl oves , eye and res pirat ory protecti on.
Antifreeze
May be flammabl e when undilut ed.
Vapors may be gi ven off from coolant anti freeze when heat ed. Avoid breathi ng thes e vapors .
Anti freeze may be absorbed through t he s kin i n t oxi c or harmful quanti ti es. Ant ifreeze, i f s wal lowed, can be fat al; SEEKIMMEDIAT E MEDICAL AT T ENT ION.
Battery Acids
See als o Al kal is and Acids .
Gas es releas ed duri ng bat t ery charging are expl osi ve. Al ways remove t he batt ery from t he vehi cl e pri or to chargi ng. Neverus e naked flames or al low s parks near charging or recentl y charged bat t eries . NEVER add aci d t o a bat tery, t he chemicalreacti on produced wil l be vi olent and expl os i ve. In cases of eye contact, was h affected area wit h copious amount s of wat erand SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Make s ure t here i s adequat e vent il ati on during bat tery charging, obs erve NO SMOKING POLICY .
Brake Pads and Linings
Always fit t he correct grade and s peci fi cat ion of brake pads and l inings . W hen renewi ng pads and lini ngs , always repl aceas complete axl e s ets .
Brake and Clutch Fluid
Splas hes to t he s kin and eyes are irri tat ing and i n t he long t erm can be damagi ng, avoid prolonged s ki n cont act. In casesof eye cont act , wash affect ed area wi th copious amount s of water and SEEK IMMEDIATE MEDICAL ATTENTION.
Chemical Materials
All chemical materials should al ways be used wit h caut ion and st ored and handled wi th care. They may be toxic, harmful,corros ive, irri tant or highly fl ammable and gi ve ri se to hazardous fumes and dus t s.
The effect s of exces s ive expos ure to chemi cal s may be i mmediat e or delayed; briefl y experienced or permanent ;cumulati ve; s uperficial; life t hreatening; or may reduce l ife expect ancy.
Chemical Materials - Do's
Do careful ly read and observe hazard and precaut ion warnings given on material cont ai ners (labels ) and in anyaccompanyi ng leaflets , pos ters or ot her ins truct ions . Material heal th and safet y data s heet s can be obtained frommanufacturers .Do remove chemi cal mat eri al s from the s kin and cl othing as soon as pract icable after s oil ing. Change heavily soi ledclothi ng and have it cleaned.Do organi se work pract ices and prot ect ive clot hing t o avoi d s oil ing of t he s ki n and eyes .Do avoid breat hing vapors , aeros ols , dus t s or fumes ; inadequat e container labell ing; fi re and expl os i on hazards .Do was h before job breaks, before eati ng, s moking, dri nki ng or usi ng t oi let faci lit ies when handli ng chemicalmat erial s.Do keep work areas clean, unclut tered and free of s pi ll s.Do s t ore chemical materials according to nat ional and local regul at ions .Do keep chemical materi als out of t he reach of chi ldren.
Chemical Materials - Do Not
Do Not mi x chemical materials except under the manufact urers ins truct ions ; s ome chemicals can form ot her toxic orharmful chemi cal s, gi ve off t oxi c or harmful fumes or become explos ive when mixed t oget her.Do Not s pray chemical materials , part icularly t hose bas ed on s olvents , i n confined spaces , for example when peopleare ins ide a vehicle.Do Not apply heat or fl ame t o chemical materi als except under the manufact urers ins truct ions . Some are hi ghlyfl ammable and some may rel ease toxic or harmful fumes .Do Not l eave contai ners open. Fumes given off can bui ld up to t oxic, harmful or explos ive concentrati ons . Somefumes are heavier than ai r and wil l accumulate in confi ned areas s uch as pi ts .Do Not t rans fer chemical materi als t o unlabell ed cont ainers .Do Not clean hands or cl othing wit h chemicals . Chemical s , parti cul arly sol vent s and fuel s, wi ll dry ski n and maycaus e i rrit ati on leading t o dermat it is or be abs orbed t hrough t he s ki n i n t oxi c or harmful quanti ti es .Do Not us e empt ied containers for ot her mat eri al s except when t hey have been cleaned under s upervis edcondi ti ons .Do Not s niff or smel l chemi cal mat eri al s , even brief expos ure to hi gh concentrat ions of fumes can be toxic orharmful.
Corrosion Protection Materials
Some corrosi on prot ect ion mat eri als are highly flammabl e – obs erve NO SMOKING POLICY.
Thes e materials are vari ed and the manufact urers ins truct ions mus t always be foll owed. The mat eri als may contai ns olvent s , res ins or petroleum product s. Skin and eye cont act s houl d be avoided. They s hould only be s prayed in condit ionsof adequate vent il at ion and not i n confined s paces .

In cas e of cold burns, from alt ernati ve fuels , place affected area in cool to col d water.
Indi vi dual s affect ed by i nhalat ion of gas es and fumes s hould be removed t o fresh air immediatel y. If effect s pers i st ,cons ult a doct or.
If liquids are s wall owed inadvertent ly, cons ult a doctor gi vi ng him the informati on on t he cont ainer or label . Do not inducevomit ing unles s t his acti on is indicated on the l abel .
Fluoroelastomers (Synthetic Rubber)
Many 'O' rings , seals , hos es , flexible pi pes and other s imi lar which appear t o be manufact ured from natural rubber are, i nfact , made of synt het ic mat eri als call ed Fluoroelas tomers .
Under normal operat ing condit ions , thes e mat erial s are safe and do not cons t it ut e a heal th hazard. However, if t hemat erial s are damaged by burni ng or expos ure t o exces s ive heat , they can break down and produce highly corros ivehydrofl uoric acid.
W ARNING: Cont act wi th hydrofluoric acid can cause serious burns on contact wi th t he s kin. If skin cont act does occur,carry out t he followi ng s teps i mmediat el y:
Remove any cont aminated cl othing.
SEEK IMMEDIAT E MEDICAL AT T ENT ION
Irrigate affected area of s ki n wi th copious amounts of cold water or li mewater for 15 to 60 minut es.
Foams - Polyurethane
Us ed in sound and nois e i nsul at ion. Cured foams us ed in seat and t ri m cus hioning.
Unreacted component s are irri tat ing and may be harmful t o t he s kin and eyes. W ear gloves and goggles .
Indi vi dual s wit h chronic res pirat ory di seas es, as t hma, bronchial medi cal problems , or his t ories of al lergi c dis eas es s houl dnot work i n or near uncured mat eri als .
The components , vapors or s pray mi s ts can cause direct irri tat ion, s ens i ti vi ty reactions and may be toxic or harmful .
Vapors and s pray mis ts must not be i nhal ed. Thes e mat erial s mus t be appl ied wit h adequate vent il at ion and res pirat oryprot ect ion. Do not remove t he respi rator i mmediat ely after s praying, wait unti l the vapour/mis t s have cl eared.
Burning of t he uncured component s and the cured foams can generate toxic and harmful fumes. Smoking, naked fl ames ort he use of el ect ri cal equipment during foaming operat ions and unt il vapors/mi st s have cleared s hould not be al lowed. Anyheat cut ti ng of cured foams or part ial ly cured foams s houl d be carried out i n areas having s uit abl e fume extract ionequi pment.
Fuels
Avoi d s kin contact wit h fuel where poss i bl e. Should cont act occur, wash the affected ski n wit h s oap and wat er.
Gasoline (Petrol)
Highly fl ammable - O BSERVE NO SMOKING POLICY .
Swall owi ng gasol ine (petrol ) can res ult i n mouth and throat i rrit ati on and absorpt ion from t he s tomach can res ult i ndrows ines s and uncons ci ousnes s. Smal l amount s can be fat al to chi ldren. Inhal at ion into the l ungs , t hrough vomit ing, is avery s eri ous hazard.
Gas ol ine (petrol) dri es the ski n and can caus e i rrit at ion and prolonged or repeat ed contact may caus e dermati ti s; if it i sall owed to ent er the eyes , it wi ll caus e s evere s marti ng. W ash affect ed area wi th copious amount s of water and SEEKIMMEDIAT E MEDICAL AT T ENT ION.
Gas ol ine (petrol) may contai n appreci abl e quanti ti es of benzene, whi ch is t oxi c upon inhalat ion and t he concentrat ion ofvapors mus t be kept very low. Hi gh concent rat ions wi ll caus e eye, nose and throat i rrit ati on, naus ea, headache, depress ionand s ymptoms of drunkennes s . Very hi gh concent rat ions wi ll res ult in rapi d l os s of conscious ness .
Make s ure t here i s adequat e vent il ati on when handl ing and us ing gas oli ne (pet rol). Great care must be taken to avoi d t hes erious consequences of i nhal at ion in t he event of vapour buil d up aris ing from s pill ages in confi ned spaces .
Speci al precauti ons appl y to cl eani ng and maint enance operat ions on gas ol ine (petrol) s torage tanks.
Gas ol ine (petrol) s houl d not be us ed as a cleaning agent. It mus t not be si phoned by mout h.
Gas-oil (Diesel Fuel)
Combust ibl e.
Prol onged s kin contact wit h hi gh boi li ng point gas oils (di es el fuel) may caus e s erious ski n dis orders including s kin cancer.
Inhalat ion i nto the l ungs will cause int ernal bl eedi ng - SEEK IMMEDIAT E MEDICAL AT T ENT ION.
If sw allow ed, DO NOT induce vomiting - SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Kerosene (Paraffin)
Us ed als o as heati ng fuel , sol vent and cleaning agent.

Health Protection Precautions
Avoi d prol onged and repeat ed cont act wit h oil s, parti cularly us ed engine oi ls .W ear prot ect ive clot hing, including i mpervious gl oves where practi cable.Do not put oily rags i nt o pocket s .Avoi d contami nat ing cl ot hes, parti cularly underpants , wi th oi l.Heavi ly s oil ed clot hi ng and oil -i mpregnated foot wear s hould not be worn. Overall s mus t be cleaned regularly.First Ai d t reatment s hould be obt ained i mmediat el y for open cuts and wounds .Us e barrier creams , appl yi ng t hem before each work peri od, t o help the removal of oil from t he s ki n.W as h wi th soap and wat er to make s ure al l oi l is removed (s kin cl eans ers and nail brushes wi ll help). Preparati onscont aining lanol ine replace the nat ural s ki n oil s which have been removed.Do not us e gasol ine (pet rol ), keros ene (paraffin), di esel fuel (gas oi l), thi nners or s ol vent s for cleaning skin.If skin dis orders develop, obtain medical advice wi thout delay.W here practi cable, degreas e component s pri or t o handling.W here there is a ri s k of eye cont act , eye protecti on s houl d be worn, for exampl e chemical goggles or face s hiel ds ;in addi ti on an eye was h facil it y s houl d be provided.
Environmental Precautions
This s ecti on provides general informati on which can help t o reduce t he environment al i mpact s from the act ivit ies carriedout in workshops .
Emis s ions t o air
Many of the act ivit ies t hat are carried out i n works hops emit gas es and fumes whi ch can contribut e to global warmi ng,depl eti on of the ozone layer and/or the format ion of phot ochemical s mog at ground level. By cons ideri ng how t he works hopact ivi ti es are carried out , thes e gases and fumes can be mi nimi s ed, t hus reduci ng t he impact on t he envi ronment.
Exhaus t fumes
Runni ng car engines i s an es sent ial part of works hop act ivi ti es and exhaust fumes need t o be venti lated to at mos phere.However, the amount of t ime engi nes are runni ng and the pos it ion of t he vehi cle s hould be carefully cons idered at al lt imes , to reduce the releas e of poi s onous gas es and mini mis e t he i nconveni ence t o peopl e l iving nearby.
Solvent s
Some of t he cl eani ng agent s us ed are sol vent based and wil l evaporate rapidl y to atmos phere i f used carel ess l y, or i fcont ainers are l eft unseal ed. Al l contai ners mus t be firmly cl os ed when not requi red and s olvent should be used sparingly.W herever poss i bl e, sol vent s havi ng a l ow t oxi ci ty and flammabi li ty should be sel ect ed. Al ways foll ow t he ins t ructi onss uppl ied by t he s olvent manufact urer. Si mil arl y, many pai nt s are s olvent bas ed and the s pray s houl d be us ed in such away as t o reduce emi ss i ons t o a mini mum.
Refrigerant
It is i ll egal t o rel eas e any refrigerant int o t he atmos phere. Dis charge and repl acement of thes e mat eri al s from aircondi ti oni ng uni ts should onl y be carried out us ing t he appropri at e equipment .
Dis charges to water
Mos t works hops wi ll have t wo s ys t ems for di schargi ng wast e wat er - st orm drai ns and foul drains . Storm drains s houl d onlyreceive clean wat er i.e. rainwat er. Foul drai ns wil l accept many of the normal was t e wat er i .e. was hing wat er, detergent sand domest ic type was te BUT NOT oi l, petrol, s olvent , acids , hydraul ic fluid, anti freeze and si mil ar fl ui ds. If in doubt ,always cons ult the l ocal authori ty or wat er company.
Spill ages
Every precauti on mus t be taken t o prevent s pi ll age of oi l, fuel , sol vent s etc., reachi ng the drains . All handl ing of s uchmat erial s mus t take pl ace wel l away from drai ns and preferably i n an area wit h a s uit able contai ni ng wall t o preventdis charge int o drai ns or watercours es . If a spi llage occurs , it mus t be s oaked up immedi ately us i ng a s pil l ki t whereprovided.
Checkli s t
Spillage prevention:
Store li quids in a s ecure area.
Make s ure t hat taps on l iquid cont ai ners are s ecure and cannot be acci dent ally turned on.
Prot ect bulk st orage t anks from vandal is m by locki ng the val ves .
Trans fer li quids from one cont ai ner t o another i n an area away from open drai ns .
Ensure li ds are replaced s ecurel y on cont ainers .
Have s pi ll kit s availabl e near t o point s of s torage and liquid handl ing areas .
Spill Ki ts
Speci al mat eri als are avai lable to abs orb a number of di fferent subs tances. They can be in granular form, ready t o us e andare suppli ed in sui table cont ai ners . Dis posal of used spi ll absorbing mat eri al i s deal t wit h i n W as t e management .
Land contamination
Oil s , fuels and s olvents etc. can cont aminate any soi l wit h which t hey come int o cont act . Such materials MUST never bedis posed of by pouri ng on t o s oil and every precauti on mus t be t aken t o avoid s pil lage reaching s oil . W as te materials

Some operat ions may produce high noi se levels whi ch could, i n ti me, damage hearing. In thes e cases , s uit abl e earprot ect ion mus t be worn.
Solder
Solders are mi xtures of met als such t hat t he mel ti ng point of the mixture i s bel ow that of t he const it uent metals (normal lylead and t in). Sol der appli cat ion does not normal ly gi ve ri se to toxic l ead fumes , provided a gas /ai r fl ame i s used.Oxy-acet ylene flames s hould not be us ed, as they are much hot t er and will cause lead fumes to be produced.
Some fumes may be produced by t he appl icati on of any fl ame t o s urfaces coat ed wi th grease, and i nhalat ion of t heses houl d be avoided.
Removal of exces s s older s houl d be undertaken wi th care, t o make sure t hat fine l ead dus t i s not produced, which can givet oxi c effect s if i nhal ed. Res pirat ory protecti on may be necess ary.
Solder spi ll age and fil ings s houl d be coll ect ed and removed promptl y to prevent general air contami nat ion by lead.
High st andards of pers onal hygi ene are necess ary in order t o avoid inges t ion of l ead or i nhal ati on of sol der dus t fromclothi ng.
Solvents
For example acet one, whi te s pirit , t ol uene, xylene, trichloroet hane.
Us ed in cl eani ng and dewaxi ng materials , paint s, pl as t ics , res ins and t hinners .
Some may be highly flammabl e or fl ammable.
Skin contact wil l degreas e t he s kin and may res ult i n irri tat ion and dermati ti s fol lowing repeat ed or prolonged cont act.Some can be abs orbed t hrough the s kin in t oxic or harmful quant it ies .
Splas hes in t he eye may cause severe irri tat ion and coul d l ead to los s of vi s ion.
Bri ef expos ure of high concent rat ions of vapors or mis t s wil l caus e eye and t hroat irri tat ion, drows ines s, di zzines s ,headaches and, i n t he wors t circums t ances , unconscious nes s .
Repeat ed or prolonged expos ure to excess i ve but l ower concent rat ions of vapors or mis t s , for which t here might not beadequat e warni ng indicati ons , can caus e more s eri ous toxic or harmful effect s .
As pi rat ion i nto the l ungs , for example through vomi ti ng, i s the most serious cons equence of s wall owi ng.
Avoi d s plas hes to the s kin, eyes and cl othi ng. W ear prot ecti ve gl oves , goggl es and clothi ng if neces s ary.
Make s ure t here i s good vent il ati on when in us e, avoi d breat hing fumes, vapors and spray mis t s and keep contai nerst ightl y s eal ed. Do not us e i n confined s paces .
W hen s praying materials contai ning s olvents , for example pai nt s , adhes ives , and metal coat ings , use ext racti onvent il ati on or pers onal res piratory prot ect ion i n t he abs ence of adequate general venti lati on.
Do not apply heat or fl ame except under s peci fi c and detail ed manufacturers i ns t ructi ons .
Suspended Loads
CAUTION: Never improvi se lift ing t ackle.
There i s always a danger when loads are lifted or s us pended. Never work under an unsupported, s us pended or rais ed l oad,for example a s us pended engi ne.
Always make s ure that l ift ing equi pment s uch as jacks , hoi st s , axl e s tands and s li ngs are adequat e and s uit abl e for thejob, i n good condit ion and regul arl y maint ained.
Viton
In common wi th many ot her manufact urers vehi cl es, s ome components i nst all ed to Land Rover vehi cl es have seals , 'O 'ri ngs or gas kets whi ch cont ain a material known as 'Vit on'.
Vit on is a fluoroelas tomer, that i s a s ynt heti c rubber type whi ch contai ns Fluori ne. Al though Vit on is the mos t wel l knownfl uoroelas tomer, there are ot hers , including Fl uorel and Tecmofl on.
W hen us ed under des ign condit ions fl uoroelas tomers are perfectl y s afe. If, however, they are expos ed t o t emperatures inexces s of 400°C, t he material wil l not burn, but wi ll decompos e, and one of the products formed is hydrofluori c acid.
This acid is extremely corros ive and may be abs orbed di rectl y, t hrough cont act , int o t he general body s ys tem. WHERECASES OF SKIN CONT ACT OCCUR, SEEK IMMEDIAT E MEDICAL HELP.
O-ri ngs , s eal s or gaskets which have been expos ed to very high t emperat ures wi ll appear charred or as a black s ti ckys ubs t ance.
DO NOT, under any ci rcums tances touch t hem or the at t ached component s.
Enqui ri es should be made t o determine whet her Vi ton or any ot her fluoroel as t omer has been us ed i n the affect ed O-ring,s eal or gas ket . If t hey are of nat ural rubber or ni trile there is no hazard. If in doubt , be caut ious as t he material may beVit on or any fl uoroelas tomer.
If Vi ton or any ot her fluoroel as t omers have been us ed, t he affect ed area should be decontami nated before t he