engine LAND ROVER FRELANDER 2 2006 Repair Manual

Gear Shi ft Indicat or Cont rol Di agram
• NOTE: A = Hardwi red; D = Hi gh Speed CAN bus ; N = Medium Speed CAN bus.
ItemPart NumberDescription1-Linear cl utch s ensor
2-Steering wheel modul e i ncludi ng st eeri ng angl e s ens or
3-Engi ne cont rol module4-Mas s air flow s ens or / Int ake ai r temperat ure sens or
5-Accelerator pedal pos it ion s ensor
6-Coolant temperat ure sens or7-Cranks haft pos i ti on s ens or
8-Ins t rument clus ter
9-Eco s wit ch10-Central junct ion box
PRINCIPLES OF OPERATION
The Gear Shi ft Indicat or takes advant age of the full y mapped engi ne to cont inually cal culat e t he engi nes performance andwhether a hi gher gear woul d provide improved fuel effi ci ency. The ECM (engi ne cont rol module) int erpret s whi ch gear iscurrent ly s elected from analys is of t he fol lowing EEC (elect ronic engine control) component i nput s:
Engi ne load; input from the MAF (mas s ai r flow) s ens or.Dri ver’s accelerat or pos it ion and demand; input from the APP (accelerator pedal pos it ion) s ens or.Engi ne t emperature; input from t he cool ant t emperat ure s ensor.Engi ne s peed; i nput from the CKP (cranks haft posi ti on) s ens or.Vehicle s peed; input from t he ECM via si gnal s from the ABS (anti -l ock brake s ys t em) module on t he high-speed CAN(controll er area network).

Publi s hed: 11-May-2011
Instrument Cluster - Instrument Cluster
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the Ins trument Clus ter, refer t o t he rel evant Descripti on and Operat ion s ecti on in t heworks hop manual .REFER to: Inst rument Cl us t er (413-01 Ins trument Cl ust er, Des cri pt ion and Operati on).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage and sys tem integrit y.2.
Visual InspectionMechanicalElectrical
Flui d levelsAcces s ory i nst all at ionsFus eW iring harnes sEl ect ri cal connectorsIns trument cl us t erCent ral Juncti on Box (CJB)Engine Cont rol Module (ECM)
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , check for Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve ext rainformat ion read by the manufact urer-approved diagnost ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces and wit h a current cal ibrat ion cert ificate. W hen tes ti ng res i st ance, always take the res is tance of the DMM l eads i ntoaccount.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
REFER to: Di agnos ti c Trouble Code (DTC) Index - DTC: Ins t rument Clus t er (IPC) (100-00 General Informat ion, Des cript ionand Operat ion).

This group of mess ages have a direct effect on the driving abi li ty and s afet y of t he vehi cl e, 'ENGINE SY STEM FAULT' forexampl e. Thi s mes s age woul d requi re an immedi at e react ion from the driver in res ponse t o t he mes s age. Pri ori ty 1mes s ages wi ll als o be accompani ed by t he appropriat e warni ng indicat or flas hing and a cont inuous chime from theins t rument clus ter. If more t han one priorit y 1 mes s age is present , each mes s age is di s pl ayed in t urn at 3 s econdint ervals .
Priority Group 2
This group of mess ages do not direct ly affect the driving abi lit y or s afet y of the vehicle, 'CHECK BRAKE PADS' for example.This mes s age mus t be noted by t he driver and the cause recti fi ed as s oon as pos s ibl e. Each of thes e mes s ages isdis played once when power mode 6 is ent ered or when t he faul t occurs for a predetermined t ime peri od. Thes e mes sagescan be recall ed by the driver by pres s ing t he t ri p res et butt on for more t han 3 s econds .
Priority Group 3
This group of mess ages rel at e t o l ow pri ori ty mes s ages , 'LOW W ASHER FLUID' for exampl e. Depending on the mes s age,s ome mes s ages are only s hown at t he end of a journey to avoid annoyance to t he driver. The mes s ages wi ll beaccompanied by a chi me when t he igni ti on is s wi tched off t o alert the driver to their presence.
MESSAGE LIST
Mes sages are dis played in a language appropriat e for t he market s peci fi cat ion of t he vehi cl e. The language can be changedif requi red us ing the Land Rover approved diagnos ti c sys t em.
• NOTE: The li s t bel ow i s s hown in al phabeti cal order.
MessageO ther WarningsReasonAction
BONNET OPENNoneHood open or not fully cl osedCl ose hoodCHECK ALL TY REPRESSURESAmber Ti re Pres sureMonit oring Sys tem(TPMS) indi cat oril lumi nat ed
Advi sory mes s age. Low pres s ure warningli mit reached i n more than 1 wheel i n lows peed mode or warning l imi t reached in anyrunning wheel and no locati on s pecified byTPMS.For addit ional informati on, refer t o: W heelsand Tires (204-04 W heel s and Tires,Descripti on and Operat ion).
Check all t ire pres s ures andadjust accordingly
CHECK ALL TY REPRESSURES FRONT LEFTLOW
Amber TPMS indicatoril lumi nat edLow pres s ure warning l imi t reached in frontleft ti re i n l ow s peed modeCheck t ire pres s ure andadjust accordingly
CHECK ALL TY REPRESSURES FRONTRIGHT LOW
Amber TPMS indicatoril lumi nat edLow pres s ure warning l imi t reached in frontri ght t ire i n low s peed modeCheck t ire pres s ure andadjust accordingly
CHECK ALL TY REPRESSURES REAR LEFTLOW
Amber TPMS indicatoril lumi nat edLow pres s ure warning l imi t reached in rearleft ti re i n l ow s peed modeCheck t ire pres s ure andadjust accordingly
CHECK ALL TY REPRESSURES REAR RIGHTLOW
Amber TPMS indicatoril lumi nat edLow pres s ure warning l imi t reached in rearri ght t ire i n low s peed modeCheck t ire pres s ure andadjust accordingly
CHECK SPARE TY REPRESSUREAmber TPMS indicatoril lumi nat ed for 20s econds and agai n ats ubs equent i gni ti oncycles
Low pres s ure warning l imi t reached in s pareti reCheck t ire pres s ure andadjust accordingly
CRANKING W ILLCOMMENCE AFTER GLOWPERIOD
Glow pl ug indi cat oril lumi nat edAmbient air t emperature below 0ºC (32ºF)None
CRUISE CONTRO L NOTPERMITTEDNoneVehi cl e operat ing paramet ers out si dethreshold for s peed cont rol operati onNone
DPF FULLHandbook s ymbolil lumi nat ed inmes sage center
Dies el parti cul at e fil ter requi res regenerat ingFor addit ional i nformati on,refer t o: Exhaus t Sys t em(309-00B Exhaus t Sys tem -TD4 2.2L Di es el,Des cri pti on and Operati on).DPF FULL VISIT DEALERNoneRegenerat ion of t he dies el parti cul at e fil terwas unsucces s fulUse the Land Roverapproved di agnos ti csys tem t o forceregenerati on of the di es elparti cul at e fil ter.
DRIVER DOOR OPENNoneDri vers door open or not ful ly clos edNone
DSC SW ITCHED OFFAmber Dynami cStabil it y Control (DSC)indicator i lluminated
Sys t em not avai lable due to DSC s wit ched offby dri verPress DSC s wit ch toreact ivat e s ys t em
ECO STOP/START FAULTTel l-tal e li ght in t heEco swi tchext inguis hed
Stop/St art not avai lable due to sys tem ors ub-s ys t em failureConnect Land Roverapproved di agnos ti csys tem t o diagnos e fault
ECO STOP/START O FFTel l-tal e li ght in t heEco swi tchext inguis hed
The Eco swi tch has been pres s edIf requi red, pres s the Ecoswi tch t o react ivate theSt op/St art s yst em
ECO STOP/START O NTel l-tal e li ght in t heEco swi tch i ll uminatedThe s ys t em has been s wit ched off and thenlat er s wi tched on wi thin the same ignit ioncycle
If requi red, pres s the Ecoswi tch t o deact ivat e t heSt op/St art s yst em

MessageO ther WarningsReasonAction
ECO STOP/STARTUNAVAILABLETel l-tal e li ght in t heEco swi tchext inguis hed
Eit her Hi ll Decent Control (HDC) or TerrainRespons e (TR) i s act iveDes elect HDC or TR i fterrain condit ions permi t
ENGINE SY STEM FAULTMalfunct ion Indi cat orLamp (MIL) il lumi nat edEngi ne Cont rol Module (ECM) has detected afault i n t he engi ne management s ys temConnect Land Roverapproved di agnos ti csys tem t o diagnos e faultFRONT LEFT TY REPRESSURE NOTMONITORED
Amber TPMS indicatorfl ashes for 75 secondsthen remainsil lumi nat ed
No t rans mis s ion from front left TPMSpres sure s ensorConnect Land Roverapproved di agnos ti csys tem t o diagnos e fault
FRONT PASSENGER DOOROPENNoneFront pas s enger door open or not fully cl osedNone
FRONT RIGHT TY REPRESSURE NOTMONITORED
Amber TPMS indicatorfl ashes for 75 secondsthen remainsil lumi nat ed
No t rans mis s ion from front ri ght TPMSpres sure s ensorConnect Land Roverapproved di agnos ti csys tem t o diagnos e fault
FUEL TANK CAP LOOSEOR MISSINGNoneNort h American vehi cl es onl y. Diagnos t icMonit oring of Tank Leakage (DMTL) pumpunabl e to pres surize t he fuel s yst em.For addit ional informati on, refer t o: Elect roni cEngi ne Cont rol s (303-14A Electroni c Engi neCont rol s - I6 3.2L Pet rol, Des cri pt ion andOperati on).
Ti ght en or repl ace t he fueltank cap. Check fuelsys tem for l eaks .
GRASS GRAVEL SNOWGras s Gravel SnowTerrai n Res pons e i condis played in mess agecent er
Advi sory mes s age. Terrain Res pons e rotarycont rol has been moved to the Grass GravelSnow posi ti on. Program will become acti veaft er 2 s econds
None
GRASS GRAVEL SNOWPROGRAM SELECTEDGras s Gravel SnowTerrai n Res pons e i condis played in mess agecent er
Advi sory mes s age. Terrain Res pons e Gras sGravel Snow special program has beens el ect ed for more t han 2 s econds and i scurrent ly acti ve
None
HDC FAULT SY STEM NOTAVAILABLESingle chime fromins trument cl ust ers ounder
Hil l Des cent Cont rol (HDC) sys tem faul t.Dri ve wit h care and do not at tempt t odes cend s teep s lopes .For addit ional informati on, refer t o: Ant i-LockCont rol - St abi li ty As s is t (206-09C Anti -LockCont rol - St abi li ty As s is t , Des cri pti on andOperati on).
Connect Land Roverapproved di agnos ti csys tem t o diagnos e fault
HDC NOT AVAILABLE INTHIS GEARGreen HDC act iveindicator flas hesIncorrect gear s el ect ed for HDC to operate.For addit ional informati on, refer t o: Ant i-LockCont rol - St abi li ty As s is t (206-09C Anti -LockCont rol - St abi li ty As s is t , Des cri pti on andOperati on).
Sel ect correct gear beforeat t empt ing des cent
HDC NOT AVAILABLESPEED TOO HIGHGreen HDC act iveindicator flas hesHDC not avai lable as current vehi cl e s peed isabove operat ing t hres hold.For addit ional informati on, refer t o: Ant i-LockCont rol - St abi li ty As s is t (206-09C Anti -LockCont rol - St abi li ty As s is t , Des cri pti on andOperati on).
Reduce s peed beforeat t empt ing des cent
HDC TEMPORARILY NOTAVAILABLE SY STEMCOOLING
Green HDC act iveindicator flas hesHDC s yst em swi tched off whi le brake s ys t emis cooli ngW ait unt il mes sage i sext inguis hed beforeat t empt ing des cent
HDC SW ITCHED O FFSingle chime fromins trument cl ust ers ounder
HDC s yst em swi tched off by driver, TerrainRespons e s ys t em or s peed thres hold hasbeen exceeded
None
HIGH ENGINE SPEED FORCOOLINGNoneIdl e s peed increased to as s is t engine cool ingNone
KEY IN IGNITIONCont inuous chi me fromins trument cl ust ers ounder
Advi sory mes s age informing the driver thatthe remot e hands et has been left i n t he s tartcont rol module, t he ignit ion has beens wit ched off, and t he dri vers door i s open
Remove t he remotehands et from t he s tartcontrol modul e
LEFT REAR DOOR O PENNoneLeft rear door open or not ful ly cl os edNone
LIGHTS ONCont inuous chi me fromins trument cl ust ers ounder
Advi sory mes s age that t he ext eri or l amps ares wit ched on, t he remot e hands et has beenremoved from the s t art control modul e andthe drivers door has been opened
Swi tch off ext eri or lamps
LOW COOLANT LEVELNoneEngi ne cool ant l evel below recommendedlevelCheck engine cool ingsys tem for l eaks and t opup as neces sary
LOW W ASHER FLUIDSingle chime fromins trument cl ust ers ounder at ignit ion on(power mode 6)
W as her flui d level bel ow t hres hol dAdd water and addi ti vemixt ure t o wi nds hiel dwas her bott le
MEMORY 1 SELECTEDNoneConfirmati on t hat memory funct ion has beens uccess ful ly carried outNone
MEMORY 2 SELECTEDNoneConfirmati on t hat memory funct ion has beens uccess ful ly carried outNone
MEMORY 3 SELECTEDNoneConfirmati on t hat memory funct ion has beens uccess ful ly carried outNone

MessageO ther WarningsReasonAction
MEMORY 1 STOREDSingle chime fromins trument cl ust ers ounder
Confirmati on t hat s et ti ngs have been s toredin the memoryNone
MEMORY 2 STOREDSingle chime fromins trument cl ust ers ounder
Confirmati on t hat s et ti ngs have been s toredin the memoryNone
MEMORY 3 STOREDSingle chime fromins trument cl ust ers ounder
Confirmati on t hat s et ti ngs have been s toredin the memoryNone
MUD RUTSMud Ruts Terrai nRespons e icondis played in mess agecent er
Advi sory mes s age. Terrain Res pons e rotarycont rol has been moved to the Mud Rut spos i ti on. Program wi ll become act ive after 2s econds
None
MUD RUTS PROGRAMSELECTEDMud Ruts Terrai nRespons e icondis played in mess agecent er
Advi sory mes s age. Terrain Res pons e MudRuts s peci al program has been s elect ed formore than 2 seconds and is current ly act ive
None
OIL SERVICE REQUIREDVISIT DEALER'SERVICE' dis played inodomet erAdvi sory mes s age informing driver that adies el parti culat e fil ter regenerat ion cycl e hascaus ed t he engi ne oil t o become dilut ed.For addit ional informati on, refer t o: Exhaus tSys t em (309-00B Exhaus t Syst em - TD4 2.2LDies el, Des cript ion and Operat ion).
Carry out s ervi ce and res etServi ce Int erval Indicator(SII) us ing t he Land Roverapproved di agnos ti csys tem
PRESS BRAKE W HENSTARTINGNoneAdvi sory mes s age to al low engi ne st art ing.Vehi cl es wit h aut omati c trans mi s si on onlyNone
PRESS CLUTCH W HENSTARTINGNoneAdvi sory mes s age to al low engi ne st art ing.Vehi cl es wit h manual transmis s ion onlyNone
PROGRAM CHANGE INPROGRESSSel ect ed TerrainRespons e icondis played in mess agecent er
Vehi cl e operat ing condi ti ons prevents el ect ion of s peci al program.For addit ional informati on, refer t o: Ride andHandl ing Opt imi zat ion (204-06 Ri de andHandl ing Opt imi zat ion, Des cript ion andOperati on).
If operat ing condi ti onschange wit hin 60 secondssel ect ed program wil l beact ivated.For addit ional i nformati on,refer t o: Ride and Handli ngOpt imizati on (204-06 Rideand Handli ng Opt imi zat ion,Des cri pti on and Operati on).
REAR LEFT TY REPRESSURE NOTMONITORED
Amber TPMS indicatorfl ashes for 75 secondsthen remainsil lumi nat ed
No t rans mis s ion from rear l eft TPMS pres s ures ens orConnect Land Roverapproved di agnos ti csys tem t o diagnos e fault
REAR RIGHT TY REPRESSURE NOTMONITORED
Amber TPMS indicatorfl ashes for 75 secondsthen remainsil lumi nat ed
No t rans mis s ion from rear right TPMSpres sure s ensorConnect Land Roverapproved di agnos ti csys tem t o diagnos e fault
RECOMMEND COMMANDSHIFT FOR DEEP SOFTSAND
Sand Terrai n Respons eicon dis played cent erAdvi sory mes s age for Terrai n Res pons es pecial program. Only dis played on vehicleswit h automat ic trans mi ss i on
Sel ect Command Shi ft i frequired
RECOMMEND STARTINGIN 2ND GEAR FO RSLIPPERY CONDITIONS
Gras s Gravel SnowTerrai n Res pons e i condis played in mess agecent er
Advi sory mes s age for Terrai n Res pons es pecial program. Only dis played on vehicleswit h manual trans mi s si on once every ignit ioncycle
Sel ect 2nd gear if requi red
REDUCED ENGINEPERFO RMANCENoneA faul t has occurred t hat has reduced enginepower out putConnect Land Roverapproved di agnos ti csys tem t o diagnos e faultRESTART REQ UIREDPRESS CLUTCHNoneW hen an engine res tart is requi red i n aStop/St art cycl e but the driver’s locati on isunknown. Eit her t he dri ver’s door or s afetybel t is unl atched
Depress cl ut ch
RIGHT REAR DOOR OPENNoneRight rear door open or not ful ly clos edNoneSANDSand Terrai n Respons eicon dis played inmes sage center
Advi sory mes s age. Terrain Res pons e rotarycont rol has been moved to the Sand pos it ion.Program wil l become act ive aft er 2 s econds
None
SAND PROGRAMSELECTEDSand Terrai n Respons eicon dis played inmes sage center
Advi sory mes s age to inform driver thatTerrai n Res pons e Sand s pecial program hasbeen sel ect ed for more t han 2 s econds and iscurrent ly acti ve
None
SELECT NEUTRAL TORESTARTNoneThe engi ne has been shut down in aStop/St art cycl e and t he dri ver has engaged agear wi thout depres si ng the cl utch.
Depress cl ut ch and s electneut ral
SELECT PARK ORNEUTRAL TO STARTENGINE
NoneAdvi sory mes s age to al low engi ne st art ingNone
SPECIAL PROGRAMS OFFSpecial programs officon dis played inmes sage center
Advi sory mes s age to inform driver thats ys t em i s in special programs off modeNone
SPECIAL PROGRAMTEMPORARILY NOTAVAILABLE
Current TerrainRespons e program icondis played in mess agecent er
Temporary condit ion making special programsunavail abl e. Terrai n Respons e default s t os pecial programs off mode
Drive off-road wit h careunt il t emporary condit ionres ol ved
SY STEM CHECK INPROGRESSNoneIns t rument clus ter int ernal diagnos t ic rout ineNone

Publi s hed: 11-May-2011
Battery and Charging System - General Information -
Vehicle Jump (Emergency) Starting - Using another vehicle
• W ARNINGS:
During normal us e, bat t eries emi t expl osi ve hydrogen gas suffi ci ent t o cause severe expl os i ons and capabl e ofcaus ing serious injury - keep s parks and naked li ght s away from the engine compart ment.
DO NOT at tempt t o s tart the di s abl ed vehi cl e i f it is sus pect ed t hat t he elect rolyte in the bat tery is frozen.
Suit able eye prot ect ion must be worn when working i n t he vicinit y of t he bat t ery.
Take care when working near rot at ing parts of t he engine.
Prior to att empti ng to st art t he dis abled vehicle, ens ure t hat the parki ng brake i s appl ied or s uit abl y chock t hewheels . Ens ure that 'P' - PARK - Aut omati c Trans mis s ion or NEUTRAL - Manual Trans mi ss i on is s elect ed.
• CAUTIO NS:
Ens ure t hat al l electrical l oads are s wi tched OFF pri or to connect ing boos ter cabl es and dis connect boos t er cablespri or to us ing el ect ri cal equipment .
Ens ure t hat the bat tery of the DO NOR vehicle is of 12 volt capaci ty and that all electrical loads on t he dis abl edvehi cl e are s wit ched O FF prior t o connecti ng boost er cables .
Ens ure t hat there is no phys ical contact between t he donor and di sabl ed vehi cl es other than t he boost er cabl es .
• NOTE: Disconnect battery: If t he remote control hands et is not functi oning, it wi ll be neces s ary t o manuall y unlock thevehi cl e us ing t he key.
Carry out the following operation in the sequence given:
1. Connect one end of the Red (+) boos t er cable to t he pos it ive (+) batt ery terminal of the DISABLED vehicle.2. Connect t he other end of the Red (+) boos ter cable t o t he posi ti ve (+) batt ery t erminal of t he DONOR vehicle.
3. Connect one end of the Black (-) boos ter cabl e t o t he Ground (-) bat t ery t ermi nal of t he DONOR vehi cle.
4. Connect t he other end of the Bl ack (-) boost er cabl e t o a good eart h point e.g. unpainted metal s urface or enginemounti ng at leas t 0.5 m (20.0 i n) from t he batt ery or fuel l ines on t he DISABLED vehi cle.
5. Start the engi ne of the DO NOR vehicle and al low it t o i dl e for a few minut es .6. Start the engi ne of the DISABLED vehicle.
7. All ow engines of both vehicles t o i dle for a few mi nut es t hen swi tch off the engine of t he DONO R vehicle.
8. Dis connect t he Black (-)boos t er cable from t he eart h point of t he PREVIO USLY DISABLED vehi cl e.9. Dis connect t he Black (-)boos t er cable from t he batt ery of t he DONO R vehicle.
10. Dis connect the Red (+) boos t er cable from t he batt ery of t he DONOR vehi cl e.
11. Dis connect the Red (+) boos t er cable from t he batt ery of t he PREVIOUSLY DISABLED vehi cl e.
Vehicle Jump (Emergency) Starting - Using a Slave Battery/Starting Aid
• W ARNINGS:
During normal us e, bat t eries emi t expl osi ve hydrogen gas suffi ci ent t o cause severe expl os i ons and capabl e ofcaus ing serious injury - keep s parks and naked li ght s away from the engine compart ment.
DO NOT at tempt t o s tart the di s abl ed vehi cl e i f it is sus pect ed t hat t he elect rolyte in the bat tery is frozen.
Suit able eye prot ect ion must be worn when working i n t he vicinit y of t he bat t ery.
Take care when working near rot at ing parts of t he engine.
Prior to att empti ng to st art t he dis abled vehicle, ens ure t hat the parki ng brake i s appl ied or s uit abl y chock t hewheels . Ens ure that 'P' - PARK - Aut omati c Trans mis s ion or NEUTRAL - Manual Trans mi ss i on is s elect ed.
• CAUTIO NS:
Ens ure t hat al l electrical l oads are s wi tched OFF pri or to connect ing boos ter cabl es and dis connect boos t er cablespri or to us ing el ect ri cal equipment .
Ens ure t hat the s l ave bat tery/s tarti ng aid are of 12 volt capacit y and t hat al l elect rical l oads on the di sabl ed vehi cl eare swi tched OFF prior t o connecti ng boos t er cables .

Carry out the following operation in the sequence given:
1. Connect t he end of the Red (+) boos ter cable t o t he posi ti ve (+) batt ery t erminal vehicle of the vehicle.
2. Connect t he end of the Bl ack (-) boost er cabl e to a good eart h point e.g. unpainted metal s urface or engine mount ingat leas t 0.5 m (20.0 i n) from t he batt ery or fuel l ines on t he vehicle.
3. Start the engi ne of the vehicle and al low it t o idl e.
4. Dis connect t he Black (-) boos ter cabl e from the earth poi nt of t he vehicle.Di sconnect t he Red (+) boos t er cable from t he batt ery t erminal of t he vehicle.

Due t o t he high depth of di scharge a deal er demons trati on vehi cl e batt ery may experience, bat teri es t hat are fi tt ed t ovehi cl es us ed as deal er demons trati on vehi cl es mus t be connected t o a power s upply / charger capable of deli vering 50Amps or more whil st the vehicle is being demons trated and t he engine i s not running. Thi s wi ll prevent the bat tery frombeing damaged from "energy t hroughput " wear out during a demons t rat ion.
Software Reflash, SDD work or Ig nition On related Workshop Activities.
Due t o t he high elect rical current demand and high dept h of Dis charge that can occur duri ng vehi cl e s oft ware re-flas hact ivi ti es , SDD work or igni ti on on rel at ed work in the workshop, vehi cl es that are undergoi ng s uch act ivit ies MUST havet he elect rical s ys tem on t he vehi cl e s upported wi th a power supply / charger / vehicle maintai ner capabl e of deliveri ng 50Amps or more.
Jump Starting New vehicles Before They Have Been Delivered to the Customer.
It is t he dealer / ret ailers res ponsi bili ty to ens ure the bat tery is not al lowed t o go flat by fol lowi ng the i nst ruct ionsand process es defi ned in this manual .However i f ci rcums tances dictat e t hat a new vehi cl e mus t be jump s t arted due to a flat bat t ery whil s t the vehicle isin the dealer / retail ers care, t he batt ery on this vehi cl e mus t be repl aced wi th a new one prior to del ivery to thecus t omer at the dealer / retail ers l iabil it y.The vehi cl e s houl d als o undergo inves t igati on as t o why t he batt ery went flat.Do not connect the jump s t art ing cable t o t he negat ive (-) terminal of the bat tery. Al ways connect t o t herecommended eart hing point . As defined i n t he owners handbook or s ervice document ation for t hat vehi cl e.
Jump Starting or Boost Charging Vehicles in Service
Do not connect the jump s t art ing cable t o t he negat ive (-) terminal of the bat tery. Al ways connect t o t he recommendedeart hing point . As defined i n t he owners handbook or s ervice document ati on for t hat vehi cl e.
Charging AG M Batteries
AGM bat teries mus t not be charged wit h volt ages above 14.8 Vol ts . Doing so wil l damage t hem.
Testing AGM Batteries
Midt ronics 393, 394, 493 and 494 t es ters are not capabl e of tes ti ng AGM bat teries . Doing s o can give an incorrect res ult .
W hen i t is necess ary to tes t an AGM bat tery us e t he Midt ronics EXP1080 tes ter or t he GR1 Diagnost ics Charger.
3. EQUIPMENT (MINIMUM STANDARD) (pictures are for illustration only)
Tracti on Batt ery Charger (or si mil ar st and-alone charger)
Midt ronics EXP1080 Hand-Held Tes ter

If the el ect rolyt e level is l ow, top-up usi ng dis t ill ed water.
Maint enance free and Valve Regulat ed (AGM) bat teries are s eal ed and therefore cannot be topped up.
CHARGING SYSTEM TEST AND DIAGNOSIS
For al l vehi cl es , refer to the Chargi ng Syst em - Diagnos i s and Tes t ing i n s ect ion 414-00 of the W orks hop Manual.
VEHICLE QUIESCENT CURRENT TESTING
• NOTE: On vehicles fit t ed wit h a Bat tery Monit oring Sys t em (BMS), t he diagnos t ic routi ne for quies cent drai n t es t ing i nt he approved di agnos ti c s ys t em s hould be ut il ized.
• NOTE: If a cus t omer compl ains of a vehicle bat tery that dis charges cont inuousl y or when left for a prolonged period oft ime, it is recommended t hat a quies cent drai n tes t i s performed as des cribed below.
• NOTE: The batt ery drain s hould be meas ured usi ng an approved diagnos t ic s ys tem or a Digi tal Mult i-Meter (DVOM).
The vehi cl e s houl d be i n t he locked/armed st ate (for example vehi cl e alarm full y armed), al l doors , engine and luggagecompartment l ids are open and lat ched (s o as t o appear clos ed from an electrical point of view). The t es t s houl d t akeplace aft er the vehicle has ent ered s hutdown mode. The t ime taken for this to occur after t he igni ti on is s wi tched offvaries according t o model - Refer t o Quies cent Drain in s ecti on 414-00 of the W orks hop Manual .
• NOTE: W hen t he vehicle i s armed, t he effect of t he s ecurit y s ys t em Li ght Emi tt ing Diode (LED) flas hing i s to caus e apuls ati on in the meas ured current drain. In t hi s case, eit her the average current should be taken (usi ng a Di gi tal Mul ti -Meter (DVOM) wi th an averagi ng s ys t em) or the current reading t aken, ignori ng t he bri ef hi gh current peaks .
EQUIPMENT
Approved diagnos t ic s ys tem wit h current probe or Digit al Mul ti -Met er (DVOM) wit h current probe.
METHOD OF MEASUREMENT
Using an Approved Diagnostic System
1. Swit ch off all elect rical loads and ensure t hat t he i gni ti on is off.
2. Connect the current probe t o t he approved di agnos ti c s yst em.
3. Calibrate t he probe.
4. Ins t al l a clamp around the bat tery lead/junct ion box l ead.
5. Go t o t he Quies cent Current Tes t ing s ect ion.
Using a Digital Multi-Meter (DVOM)
• NOTE: Do not us e an i n-li ne DVOM to meas ure the qui escent drain on vehi cl es fi tt ed wi th an el ect roni c throt t le. Thecurrent exceeds t he maximum amount the fus e in the DVOM is capable of handling.
1. Swit ch off all elect rical loads and ensure t hat t he i gni ti on is off.
2. Connect the current probe t o t he DVOM.
3. Calibrate t he probe.
4. Ins t al l a clamp around the bat tery lead/junct ion box l ead.
5. Go t o t he fol lowing Qui escent Current Tes ti ng s ect ion.
QUIESCENT CU RRENT TESTING
1. Swit ch ignit ion t o ‘on’ or s elect ignit ion mode i n keyles s vehi cl es and s wit ch to ‘off’ (do not crank).
2. Remove key from i gni ti on s wit ch (where appl icabl e).
3. Open and lat ch all doors , hood and l uggage compart ment li d.
4. Lock t he vehi cle us ing t he remote funct ion on the remote hands et. (Single lock onl y t o avoi d volumet ri c alarm arming).
5. Remove any ot her pot enti al el ect ri cal drai ns such as acces s ori es plugged into acces sory s ockets .
6. Record the amperage readings after t he shut down period. The model specific Amperage readings for quies cent drain arereferenced in Qui escent Drain in secti on 414-00 of t he W orks hop Manual
7. Record the fi nal readi ng on the bat tery report form Appendi x B.
• NOTE: The preferred method of t est ing foll owing an exces s ive current cons umpti on fi gure i s t o use a current probearound i ndi vi dual junct ion box l eads t o t he various s us pect ed ci rcuit s t o ident ify a potent ial caus e. Thi s is in preference t ot he old met hod of removing fus es for t he fol lowing reasons :
Many modules t ake a cons i derabl e t ime to power down. Each t ime a fuse is removed and re-fi tt ed, t he quies centdrai n current may t ake an extended peri od of ti me t o ret urn to normal (t ypi cal ly up to 45 minut es ).The drai n may be caused by a module remaini ng act ive and prevent ing t he quies cent drai n from reduci ng to normallevels .The drai n may be caused by a rel ay winding that is act ivated. Pulli ng t he fus e can all ow t his t o ‘res et ’ and the drainwil l be los t and go un-di agnos ed.

APPENDIX A BATTERY TEST PROCESS
It is recommended t hat this tes t is conduct ed at leas t 24 hours after t he vehi cl e engine has been run or t he batt erycharged to avoi d the need of s urface charge removal or i f thi s t ime cons traint is unaccept abl e due t o circums t ances , thenconduct the charge s t ri p removal process .
Part 1 - Surface Charge Removal
• NOTE: Before carryi ng out a batt ery t est you must ens ure t hat there is no bat t ery s urface charge present .
• NOTE: The batt ery may be t es t ed eit her on a bench or on t he vehicle.
In the cas e of on-vehicle tes ti ng, t he batt ery must be is olated from t he vehi cl e by removal of t he bat t ery negati ve(-) cable from the bat tery t ermi nal before t he measurement is t aken unl ess the vehicle has a transi t rel ay fi tt ed oris in t rans it mode.
A vehicle which has had it s batt ery charged or been dri ven in a 24 hour period before t he tes t , must have i ts s urfacecharge removed us ing one of t he fol lowi ng methods :
1. If 24 hours have pas s ed s ince the las t ti me t he engine was run or the bat tery charged, proceed t o `Part 2 - Bat teryTest '.
2. Turn on t he i gni ti on. Swi tch on t he headlamps on hi gh beam for a mini mum 3 minut es .
3. Swit ch off t he headl amps . For vehi cl es tes t ed aft er t he t rans it relay has been removed, di s connect t he batt ery byremoval of the negati ve (-) cabl e. Vehi cl es wit h a trans i t relay fit t ed or wit h a l ow current t rans port mode enabled do notneed to have t he batt ery di s connect ed.
4. W ait a maximum of 5 mi nut es before recordi ng tes t res ult s for any bat tery measurements .
Part 2 - Battery Test
• NOTE: The batt ery s urface charge mus t be removed before t his t est i n accordance with the procedure in Part 1 above.Ensure t hat t he batt ery terminal connect ors are clean. W hen connecti ng t he Midt ronics t est ing equipment , connect the REDclip to the pos it ive (+) batt ery terminal fi rs t, and t hen connect the BLACK cl ip t o t he negat ive (-) bat tery t ermi nal . Rockt he cl ips backward and forward to ens ure a good connecti on to the bat tery.
• NOTE: Mi dt roni cs 393, 394. 493 and 494 t es ters mus t not be us ed t o t est AGM batt eri es as thes e t est ers are not capableof correctl y t es t ing AGM batt eries and can gi ve an incorrect resul t. For AGM batt ery tes ti ng us e the EXP1080 t es t er or t heGR1 Di agnos ti cs charger.
CAUTION: DO NOT connect t he t es t er to any ot her ci rcuit or chas s is poi nt ot her than t he batt ery negati ve terminal.
1. Att ach the Midtronics tes t er t o t he batt ery.
2. Fol low the i nst ruct ions on t he tes t er t o t est the bat tery. Ens ure t he correct batt ery type and s ize i s s elect ed.
3. Perform the acti on based on the t es ter res ult s (s ee table bel ow).
4. Ent er the readings and t es t code obtained on the Bat tery Report Form (Appendi x B) or equi val ent whi ch records as ami ni mum the t echni ci an's name, Vehi cl e Ident ificati on Number (VIN), Dat e of check, Midtronics code and Bat t ery Volt agefrom the Mi dtroni cs tes ter.
At t he end of the t est , t he bat t ery negati ve (-) cabl e s houl d be re-att ached to t he batt ery terminal.
T EST ER RESULT SACT ION
GOOD BATTERYReturn t o s ervice.
GOOD RE-CHARGEFully charge bat tery and ret urn to servi ce.CHARGE AND RE-TESTFully charge bat tery. Remove s urface charge. Re-tes t batt ery. If s ame res ult repl ace bat tery.
REPLACE BATTERY OR BADCELL BATTERYVeri fy s urface charge removed. Dis connect bat tery from vehicle and re-tes t. If res ult repeat saft er surface charge removal , replace batt ery. DO NOT RECHARGE.
UNABLE TO DO TESTDis connect batt ery from vehi cl e and re-t es t .
APPENDIX B : BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY
• NOTE: Fields marked wi th * are mandat ory and mus t be complet ed.
General InformationYES /NO YES /NO
Cus tomer Name: Dealer/Retai ler Code:*
Repair Order Number:*Batt ery Dat e Code:* Repair Order Dat e:*Number of Ti mes Bat teryCharged:*
Repair Order Dat e: Technici ans Name:*
Vehicle Identi fi cat ion Number (VIN):*Technici ans Si gnat ure:*
Gi ve a detail ed descripti on of the sympt oms experienced by the cus tomer (att ach a s eparate sheet if necess ary)-
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