engine LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
General Information - How To Use This Manual
Des cript ion and Operat ion
Copyright Statement
Copyright.© Land Rover Ltd., 2006
All rights res erved. No part of thi s publ icati on may be reproduced, s tored in a ret ri eval s yst em or t rans mit t ed in any form,electroni c, mechanical, photocopyi ng, recordi ng or other means, wi thout pri or wri tt en permi s si on of Land Rover Ltd.,Banbury Road, Li ght horne, W arwi ck, CV35 0RG
How To Use This Manual
This manual covers al l aspects necess ary in order to s ervi ce the vehicle effect ively.
The manual i s s truct ured into fi ve main secti ons , General Informat ion, Chass is , Powert rai n, El ect ri cal and Body and Paintwit h each s ect ion deali ng wit h a specific part of a vehi cl e s ys t em.
Each of t he five mai n s ect ions contain sub-sect ions deal ing wi th it ems which form a part of t hat s pecific s ys tem.
Pages at t he s t art of the manual li s t all s ect ions avai lable. Each s ect ion has a content s li s t det ail ing, where appli cable,Speci ficat ions, Des cri pt ion and Operati on, Di agnos is and Tes ti ng, General Procedures and Repair Procedures.
W here components need t o be removed or dis ass embled in s equence, each operat ion i n the s equence wil l be identi fi ednumeri cal ly and als o graphi cal ly i n an accompanying i ll us t rat ion.
All l eft -hand and ri ght-hand references t o t he vehi cl e are taken from a posi ti on s itti ng in the driver seat l ooking forward.
All l eft -hand and ri ght-hand references t o t he engi ne are taken from a pos i ti on at the flywheel looki ng t owards t he frontcamshaft pul ley.
Ins pect ion and Verificati on
Vis ual Ins pect ion Chart s , Sympt om Charts and ot her informati on charts (s uch as diagnos t ic rout ines ) or s upplement t estprocedures wit h t echnical s pecificati ons wil l navigat e t he user t o a s peci fi c t es t procedure.
Symptom Chart
The s ymptom chart indicates s ymptoms, s ources and act ions t o addres s a condit ion.
Pinpoint Test s
For el ect ri cal s yst ems , pinpoint t es t s t eps are us ed to identi fy t he s ource of a concern in a logi cal, s t ep-by-s t ep manner.Pinpoint t es t s have two col umns: CONDITIO NS and DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is us ed excl usi vel y for graphi cs and icons (wi th or wi thout capt ions ) and the DETAILS/RESULTS/ACTIONS column provi des direct ion t o another tes t s tep or s pecifi c correct ive acti ons .
The boxed numbers indicate the order in whi ch the des cribed acti on is to be carri ed out.
Component Tes ts
A component t es t is us ed when a component i s t est ed in mult ipl e pinpoint t es t s, or if a procedure i s too compl icated t o beformatt ed wi thi n a s ingle page of t he pinpoint t est .
Graphics
Test graphi cs show the meas urement or t es t t o be carried out i n a t est st ep.
A repres ent ati ve tes t er graphi c is us ed for vol tmet ers and ohmmet ers .
If mult iple measurement s are made i n a s ingle graphic, the t es t leads are drawn wi th a s ol id line unt il t he t es t l ead spl it st o indicate the mult iple measurement s , at which point dashed l ines are used.
Breakout box t ype t es t ers are repres ented by a doubl e circl e t est pi n. Tes t pins are labell ed wit h t he pin number.
• NOTE: Dimens i ons quot ed are t o des ign engineeri ng s pecificati ons wit h s ervice l imits quot ed, where appl icable.
Workshop Manual Organization
The fi ve main s ect ions, t ogether wit h t he areas whi ch they cover are given below:
Section 1 - General Informat ion.Section 2 - Chas si s.Section 3 - Powert rai n.Section 4 - Elect rical.Section 5 - Body and Paint .
Sub-s ect ion numbers appear aft er the i nit ial s ect ion number, for exampl e, Section 412-01 covers Cli mate Cont rol, whi ch ispart of t he electrical s ecti on.
In the number given above, t he first di git of the number ' 4' indicates t he s ect ion i.e. Electrical.
The s econd and t hird digit s ' 12' of t he number indicate the vehicle sys tem i.e. Climate Control.

Publi s hed: 11-May-2011
General Information - Standard Workshop Practices
Des cript ion and Operat ion
Vehicle in Workshop
W hen working on a vehicl e in the workshop al ways make sure t hat :
W here practi cable, t he parking brake is appli ed and t he wheel s are securely chocked to prevent t he vehi cl e movingforwards or backwards .W henever pos si ble, t he ignit ion key i s removed before any work is carried out on t he vehi cle.If the engine i s t o be run, t here i s adequat e vent il ati on, or an extract ion hos e i s us ed to remove exhaus t fumes.There i s adequat e room to rais e the vehicle and remove t he wheel s , if neces s ary.Fender covers are al ways ins tal led i f any work i s to be carri ed out in t he engine compart ment.W here practi cable, t he batt ery i s dis connected if worki ng on the engi ne, underneath t he vehicle, or if t he vehi cl e i srai sed.
• CAUTIO NS:
Prior to dis connect ing the bat tery, refer to the El ect ri cal Secti on of this manual - Bat tery dis connect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
W hen el ect ri c arc wel ding on a vehi cl e, al ways dis connect t he generator wi ri ng to prevent t he pos si bili ty of a s urgeof current caus i ng damage to the i nternal component s of the generat or.
If us i ng welding equipment on t he vehicle, a s uit abl e fire exti nguis her is readily avail able.
Battery - General
• CAUTIO NS:
Prior to carrying out any procedures which i nvol ve dis connect ing/ or connecti ng the bat tery, refer t o t he ElectricalSect ion of t his manual - Batt ery di sconnect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
A di s charged bat tery condit ion may have been caus ed by an electrical short ci rcuit . If t his condit ion exis t s there wil lbe an apparentl y li ve circuit on the vehicle even when al l normal circuit s are s wit ched off. This can cause arcing when t hejumper cables are connect ed.
W hi le it i s not recommended that the vehicl e is jump s t art ed, i t is recognized t hat thi s may occas ionall y be t he onl ypracti cal way t o mobi lize a vehi cl e. Prior t o at tempt ing a jump s t art , reference must be made to the El ect ri cal Secti on oft hi s manual - Jump St art ing.
Followi ng jump s tart ing of a dis abl ed vehi cle, the di s charged bat tery mus t be checked for s erviceabili ty and recharged offt he vehi cl e as s oon as poss ibl e t o avoi d permanent damage.
Do not rel y on t he generator t o res t ore a di s charged bat tery. For a generat or t o recharge a batt ery, it woul d take i n exces sof eight hours cont inuous dri vi ng wi th no addi ti onal loads placed on t he batt ery.
Always make s ure that t he jumper cabl es are adequate for the tas k.Always make s ure that t he s lave batt ery i s of the same vol tage as t he vehicle bat tery. The bat teries mus t beconnected i n paral lel.Always make s ure that s wit chabl e electric circui ts are s wi tched off before connecti ng jumper cabl es. This reducest he ri sk of arci ng occurring when the final connecti on is made.
Towing the Vehicle
W ARNING: W hen t owing i s neces sary, reference mus t be made to the Jacki ng, Lift ing and Towing Secti on of thi sManual .
W hen t he vehicle i s being t owed dock the remote cont rol and s wit ch on the ignit ion. (s t eering l ock releas ed and warni ngli ght s i ll uminated). Onl y t hen wil l the s t eering, turn s ignal lamps , horn and s t op lamps be operat ional. Fail ure t o followt hes e i nst ructi ons may res ult in pers onal injury. It mus t be noted that wit h t he engine not running, t he power s t eering andbrake boost er wil l be inoperat ive t herefore, great er effort wil l be needed t o s t eer t he vehicle and apply the brakes .
General Installation Instructions
Component removal
W henever pos si ble, clean component s and the surroundi ng area before removal .
Blank off openings expos ed by component removal .Followi ng dis connecti on, s eal fuel, oil or hydrauli c li nes i mmediat ely us ing sui table bl anki ng plugs or caps .Seal open ends of expos ed oil ways us i ng sui table tapered hardwood pl ugs or cons pi cuous pl as t ic pl ugs .Immediat el y a component i s removed, place it i n a sui table contai ner; us e a s eparate cont ai ner for each componentand it s as s ociat ed part s .

Encaps ulated ('pat ched') bolt s and s crews have a t hread l ocking agent appl ied t o t he t hreads during manufact ure. Mos tt hread locking agent s are col ored, the band of color extending for 360 degrees around the t hread. Some l ocking agentshowever, are neutral in color and may not be s o eas il y identi fi ed apart from a s li ght ly darker area of thread where t helocking agent has been appli ed. The l ocking agent is releas ed and acti vat ed by t he ti ght ening proces s and is thenchemical ly cured to provide t he locking acti on.
Self-locking bolts and screws
Unles s s tat ed in a s peci fic repair procedure, sel f-locki ng bolt s and s crews i.e. nylon patched or tril obul ar t hread can bereus ed provided t hat res is t ance i s fel t when the locki ng port ion enters t he femal e thread.
Nylon pat ched bolt s and s crews have a l ocking agent eit her appli ed t o, or i ns erted in t he threaded porti on. They areidenti fi ed by t he pres ence of a colored s ect ion of t hread extending approximat ely 180 degrees around the t hread or by acol ored pl ug ins ert ed int o t he bol t.
Tri lobular bolt s have a s pecial t hread form which creates a s light i nt erference wit h t he t hread of the hol e or nut i nto whichit i s s crewed.
CAUTION: Do Not reuse sel f-locki ng fas t eners in crit ical locat ions e.g. drive pl at es/flywheel or engine beari ngs . Donot ins tal l non s elf-locki ng fas teners where a sel f-locki ng fas t ener i s s pecified.
Tri lobular bolt s s hould not be used as a s ubs t it ut e for pat ched bol ts .
Nut identification
A nut wi th an ISO metric t hread i s marked on one face or one of the hexagonal fl ats wit h t he st rengt h grade s ymbol 8, 12,14. Some nuts wi th the st rength grade 4, 5 or 6 are als o marked and s ome have the metric s ymbol M on t he hexagonal fl atoppos it e t he s trengt h grade marking.

Marki ngs are us ual ly provi ded on t he hos e t o i ndi cat e t he correct cli p posi ti on. If no markings are provi ded, pos it ion t heclip direct ly behind t he ret aini ng li p at the end of t he s tub pi pe. W orm dri ve clips s hould be orient at ed wi th the crimpeds ide of t he dri ve hous ing facing t owards t he end of the hos e or t he hos e may become pi nched bet ween the cli p and t hes tub pi pe ret aining l ip. Unles s ot herwis e s t ated, worm dri ve cl ips s hould be ti ght ened to 3 Nm (2 lb-ft). Make s ure t hathose cl ips do not foul adjacent components .
Oeti ker cl ips may be removed by bendi ng the tag (arrowed) and releas ing t he free end of t he cl ip. Cli ps mus t not bereus ed. W hen ins t al li ng new cli ps , make s ure cl ip is pos it ioned on hose before ti ghtening and make s ure that when cli p ist ightened, the t ag is locat ed i n t he longit udi nal s lot i n t he free end of the cl ip (arrowed in il lus trat ion).
Heat protect ion
Always make s ure that heats hields and protecti ve s heat hing are in good condit ion; replace i f damage i s evident. Part icularcare mus t be t aken when rout ing hos es cl ose to hot engine component s s uch as the exhaust mani fol ds and exhaust gasrecircul ati on (EGR) pipes . Hoses will relax and defl ect s l ightl y when hot, make s ure thi s movement is t aken into accountwhen rout ing and s ecuring hos es .
Electrical Precautions
General
The fol lowing gui del ines are int ended t o make s ure the safet y of t he operator whil s t prevent ing damage t o t he electricaland electroni c component s of this vehi cl e.
Equipment
Pri or to commencing any t est procedure on the vehicl e, make sure t hat t he rel evant test equipment i s working correctl yand t hat any harnes s or connectors are i n good condi ti on. It is parti cul arly import ant to check t he condit ion of al l pl ugs andleads of mains operat ed equipment.
Polarity
Never revers e connect the vehicle bat tery and always make s ure the correct pol arit y when connect ing t est equipment .
High voltage circuits
W henever di sconnect ing l ive ht circuit s , always us e ins ulat ed pliers and never all ow t he open end of the ht l ead to cont actother component s, part icularly ECU's .
Vehicles installed with Bi-Xenon headlamp bulbs
W ARNING: The foll owing precauti ons mus t be obs erved as fail ure t o comply may res ult i n expos ure to ul tra-vi ol etrays , s evere electric s hock, burns or ris k of an expl osi on.
Safet y goggl es and gl oves must be worn.Make s ure t hat headlamps are s wi tched off before removi ng bul bs.

Rear seat belt s
Side Curtain Airbag Modul es
CAUTION: If the head ai rbag modules are depl oyed, t he fol lowing component s mus t be replaced on the si de of thevehi cl e on whi ch the deployment occurred:
Side curt ain ai rbag modulesHeadl iner and all pil lar t ri msLink l ead bet ween airbag gas generat or and RCM harnes sAirbag ret aining cli psFront s eat bel t buckle pre-t ens i onersAny s ide i mpact s ens ors t hat have been phys i cal ly damaged or if a fault i s being regi st eredRCM
Additionally, the following items must be inspected for damage and replaced as necessary:
Component mount ing bracketsFront s eat bel ts , ret ractors and webbing, tongue lat chi ng functi on, 'D' l oop and body anchorage point sRear seat belt buckl es, webbing, buckle covers , t ongue l atching funct ion, and body anchorage point sAdjacent t rim componentsSeat bel t hei ght adjust ers
Rear impacts
CAUTION: If the s eat belt pre-tens ioners are deployed during a rear i mpact , the following component s mus t berepl aced:
Seat bel t pre-t ensi onersFront and rear s eat bel t ret ractors used during t he i mpactRCM
Additionally, the following items must be inspected for damage and replaced as necessary:
Seat bel t hei ght adjust ersFront s eat bel ts , ret ractors and webbing, tongue lat chi ng functi on, 'D' l oop and body anchorage point sRear seat belt buckl es, webbing, buckle covers , t ongue l atching funct ion, and body anchorage point s
Air Conditioning System Precautions
The air condi ti oni ng s yst em contai ns fl ui ds and components which coul d be pot ent ially hazardous to the s ervi ce engineeror the environment if not serviced and handl ed correctl y. The foll owing guideli nes are i ntended to alert t he s erviceengi neer t o pot ent ial s ources of danger and emphas is e t he i mport ance of ens uring t he i nt egri ty of t he Air Condit ioningoperati ng condi ti ons and component s i ns t alled to the vehicle.
W here neces s ary, addi ti onal s pecific precaut ions are det ail ed in t he relevant s ecti ons of t his Manual and als o in the Heal thand Safet y Sect ion. Thes e precauti ons mus t be referred to prior t o commenci ng repair operat ions .
The refri gerant us ed i n t he air condi ti oni ng s ys t em i s HFC-134a (Hydrofl uorocarbon) R134a.
• W ARNINGS:
Servi ci ng mus t onl y be carried out by pers onnel famil iar wit h bot h t he vehi cl e s ys tem and t he charging and t es ti ngequi pment. Al l operat ions mus t be carried out i n a wel l venti lat ed area away from open fl ame and heat sources .
R134a is a hazardous l iquid and when handl ed incorrect ly can caus e s erious injury. Sui table prot ect ive clot hi ng,cons is t ing of face protecti on, heat proof gloves, rubber boots and rubber apron or waterproof overal ls , mus t be worn whencarryi ng out operat ions on t he air condit ioning s ys tem.
Remedial act ions
W ARNING: Due to it s low evaporat ing t emperat ure, R134a must be handled wit h care. R134a spl as hed on any part oft he body will cause immedi ate freezing of t hat area. Als o, refrigerant cylinders and replenis hment t roll eys whendis charging wi ll freeze s ki n t o t hem if contact is made.
If an accident involving R134a s houl d occur, conduct t he followi ng remedi al acti ons :
If liquid R134a ent ers t he eye, do not rub i t. Gentl y run large quant it ies of eye wash over affected eye t o rai s e t het emperature. If an eye was h is not avail abl e, cool, clean wat er may be us ed t o fl ush the eye. Aft er ri nsi ng, covert he eye wit h a clean pad and s eek i mmediat e medical at t ent ion.If liquid R134a is s plas hed ont o t he s kin, run large quanti ti es of water over t he affected area to rais e thet emperature. Implement t he s ame acti on if t he s kin comes i n cont act wi th dis chargi ng cyl inders . W rap t hecont aminat ed body parts in bl ankets (or s imi lar mat eri al s ) and seek i mmediat e medical att ent ion.If the debil it at ing effect s of inhalati on of R134a vapour are s us pect ed, s eek fresh air. If t he affect ed pers on isuncons ci ous , move t hem away from t he cont aminated area t o fres h air and apply arti fici al respi rat ion and/or oxygenand s eek immedi at e medi cal at tenti on.
Service precauti ons
Obs erve t he fol lowing precaut ions when handl ing component s us ed in the ai r condit ioning s ys tem:

Dust
Dus t or powder produced during repai r operati ons may be irri tant , harmful or t oxi c. Avoid breathing dus t s from powderychemical mat eri als or t hos e aris ing from dry abrasi on operati ons. W ear respi rat ory prot ect ion if vent il ati on is inadequate.
Fine dus ts of combus ti bl e mat eri al can pres ent an expl osi on hazard. Avoid expl os i ve li mit s and s ources of ignit ion.
Electrical Equipment
Electric s hock can res ul t from the us e of faul ty el ect ri cal equipment or from t he misus e of equipment in good condit ion.
Make s ure t hat elect rical equipment i s maint ained in good condit ion and frequent ly tes ted. Fault y equi pment should belabell ed and preferably removed from t he work st ati on.
Make s ure t hat fl exes , cabl es , plugs and s ocket s are not frayed, ki nked, cut, cracked or ot herwi se damaged. If us i ng cablereel extens ion equipment, ALW AY S ens ure that t he cabl e is full y unwound from t he reel .
Make s ure t hat elect rical equipment and flexes do not come int o cont act wi th water.
Make s ure t hat elect rical equipment i s prot ect ed by the correct rat ed fus e.
Never mis use elect rical equipment and never us e equipment which i s in any way fault y. The res ult s coul d be fatal.
Make s ure t hat the cables of mobil e elect rical equi pment cannot get t rapped and damaged, s uch as i n a vehicle hoi st .
Make s ure t hat the des ignated el ect ri cal workers are trained in bas i c Fi rs t Ai d.
In cases of electrocution:
Swit ch off t he power supply before approachi ng t he victi m.If this is not poss i bl e, DO NO T T OUCH T HE VICT IM but push or drag t he pers on from the s ource of electricit yus ing dry, non-conduct ive mat erial .Commence res us ci tat ion i f trained t o do s o.SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Exhaust Fumes
Thes e contai n as phyxiat ing, harmful and t oxic chemicals and part icl es such as carbon oxides , nit rogen oxi des, al dehydes ,lead and aromati c hydrocarbons . Engi nes should be run onl y under condi ti ons of adequat e exhaus t extract ion or generalvent il ati on and not in confi ned spaces .
Gasoline (Petrol) engine
There may not be adequate warning of odour or of i rrit at ion before t oxic or harmful effect s ari se. These may be i mmediat eor del ayed.
Gas Oil (Diesel engine)
Soot , dis comfort and irri tat ion us ual ly gi ve adequate warning of hazardous fume concent rat ions .
Fibre Insulation
The fi brous nature of s urfaces and cut edges can caus e s kin irri tat ion. Thi s is us uall y a physi cal and not a chemical effect .
Precaut ions s hould be taken to avoi d exces s ive s kin contact through careful organi zat ion of work pract ices and the us e ofgloves.
Fire
Many of the materials found on or ass ociated wit h t he repair of vehi cles are highly flammabl e. Some give off t oxic orharmful fumes i f burnt; ot hers s uch as fl uoroelas tomers when burnt or damaged by exces si ve heat can break down andproduce highly corrosi ve hydrofl uoric acid - See Fl uoroelas tomers.
Shoul d any mat erial be i n a burnt or overheated condit ion, handle wit h extreme caution and wear protecti ve clothi ng whenhandl ing s uch it ems . Dis pose of s uch mat erial i n accordance wit h l ocal regulat ions .
Decont aminate and dis pos e of protecti ve cl othing immedi at ely after us e.
Obs erve s trict fire s afety when st ori ng and handl ing flammabl e mat erial s or sol vent s, parti cularly near electrical equi pmentor welding proces s es.
Make s ure, before usi ng electrical or wel ding equipment, t hat there is no fi re hazard present .
Have a s uit abl e fire exti nguis her avai lable when us i ng welding or heati ng equipment.
First Aid
Apart from meeti ng any legal requirement s it is des irabl e for s omeone in the workshop t o be t rai ned in Fi rs t Aidprocedures.
Splas hes in t he eye s houl d be flus hed carefull y wit h clean wat er for at leas t ten minut es .
Soiled ski n s houl d be was hed wit h s oap and water.

Flammabl e - OBSERVE NO SMOKING POLICY .
Irrit at ion of t he mout h and t hroat may res ult from s wallowi ng. The main hazard from s wallowi ng ari ses if li qui d as pirat ionint o t he lungs occurs.
Liquid contact dri es the ski n and can caus e i rrit at ion or dermati ti s. Splas hes in the eye may be s light ly i rrit ati ng.
In normal circums t ances t he low vol ati lit y does not give ris e t o harmful vapors . Expos ure to mis t s and vapors fromkeros ene at el evat ed t emperature s houl d be avoi ded (mis ts may ari s e in dewaxing). Avoi d s ki n and eye cont act and makes ure t here i s adequat e vent il ati on.
If sw allow ed, DO NOT induce vomiting - SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Gas Cylinders
Gas es such as oxygen, acet ylene, argon and propane are normall y s tored in cyli nders at pres s ures of up t o 138 bar (13800kPa) (2000 lbf/i n²) and great care should be taken i n handl ing t hese cyli nders t o avoi d mechani cal damage t o t hem or t ot he val ve gear at tached. The contents of each cylinder s houl d be clearl y ident ifi ed by appropri ate markings .
Cylinders should be s tored in wel l vent il at ed encl osures, and protected from ice and s now or direct sunli ght . Fuel gas es,for example acetyl ene and propane should not be st ored i n clos e proximit y t o oxygen cylinders .
Care should be exerci sed to prevent l eaks from gas cyl inders and l ines and als o t o avoid s ources of ignit ion.
Only trai ned pers onnel s houl d undertake work involving gas cyli nders .
General Workshop Tools and Equipment
It is es s ent ial t hat al l tools and equipment are maint ained in good condit ion and t he correct s afet y equi pment is us edwhere required.
Never us e t ools or equipment for any purpos e other t han that for whi ch they were desi gned. Never overl oad equi pments uch as hoi st s , jacks, axle and chas si s s tands or li ft ing sl ings . Damage caus ed by overloading i s not always immediatel yapparent and may res ult i n a fatal fai lure the next t ime that t he equi pment is us ed.
Do not us e damaged or defect ive t ools or equipment, part icularly hi gh s peed equipment s uch as gri ndi ng wheel s . Adamaged grindi ng wheel can dis int egrate wit hout warning and cause serious i njury.
W ear s uit abl e eye prot ect ion when us ing grinding, chis elli ng or s and bl ast ing equi pment .
W ear a s uit able breat hing mas k when us i ng abrasi ve blas ti ng equi pment or us i ng sprayi ng equi pment.
Make s ure t here i s adequat e vent il ati on to cont rol dust s , mis t s and fumes .
High Pressure Air, Lubrication and Oil Test Equipment
Always keep high press ure equi pment i n good condi ti on, and regul arly maint ai ned, parti cularly at joint s and uni ons.
Never di rect a high press ure nozzle, for example dies el i njector, at t he s kin as the fluid may penet rat e t o t he underlyingt is sue and caus e s eri ous i njury.
Jacking
Always refer to the Jacki ng and Lifti ng s ect ion of t hi s manual prior t o rai s ing t he vehi cl e off the ground.
W hen vehicle is t o be rais ed by means of a jack, ensure t hat i t is st andi ng on l evel ground, that parking brake is appli edand wheels are chocked. ALW AY S us e t he recommended jacking poi nt s and ens ure t hat vehi cl e jack has s ufficient loadcapacit y for t he weight of t he vehi cl e.
W ARNING: Do not work on or under a vehi cle s upported onl y by a jack. Always s upport t he vehi cl e on s afet y s tands .
Ensure t hat hois t s have s uffi ci ent load capacit y for t he wei ght of t he vehi cl e.
Legal Aspects
There are many l aws and regulat ions rel at ing to healt h and s afet y i n the us e and di spos al of materials and equipment i n aworks hop.
For a s afe worki ng envi ronment and t o avoi d environment al poll uti on, workshops s hould be famil iar, i n detai l, wi th t hemany healt h and s afety laws and regul ati ons wit hi n t hei r count ry, publ is hed by both nat ional and local aut horit ies .
Lubricants and Greases
Avoi d all prolonged and repeat ed contact wit h mi neral oils . All l ubricants and greases may be irri tat ing t o t he eyes ands ki n.
Used Engine Oil
Prol onged and repeat ed cont act wi th engi ne oil wil l res ult i n t he removal of nat ural fat s from the s kin, leading to drynes s ,irri tat ion and dermati ti s. In addit ion, used engi ne oil cont ains potent iall y harmful cont aminants whi ch may caus e s kincancer. Adequat e means of s kin protecti on and washi ng facil it ies mus t be provi ded.
Do not employ us ed engine oi ls as l ubricants or for any appli cat ion where appreciable s kin cont act i s li kel y t o occur.

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

Publi s hed: 11-May-2011
General Information - Road/Roller Testing
Des cript ion and Operat ion
Road or roll ing road t es t ing may be carri ed out for various reasons and a procedure det ail ing pre-t es t checks , throughengi ne s tarti ng and s topping, pre-driving checks , on-t es t checks to final checks on complet ion of t he tes t are given.
Unles s complete vehi cl e performance is bei ng checked, t he ful l road t est procedure need not be carried out . Ins tead, t hos eit ems part icularly relevant t o t he s yst em(s) bei ng checked can be ext racted.
Pre-Test Checks
W ARNING: If t he brake s yst em hydraul ic fluid level i s l ow, pedal travel i s exces si ve or a hydraulic leak is found, donot att empt to road t est t he vehicle unt il t he reas on for t he low fl ui d l evel, excess ive pedal travel or hydraulic leak isfound and rect ified.
It is s ugges t ed that pre-t es t and funct ional t es ts of t hose sys tems/circuit s whi ch affect t he safe and l egal operati ons oft he vehi cl e, s uch as brakes , light s and s teeri ng, should al ways be carri ed out before the road or roll ing road tes t .
Engi ne oil l evelEngi ne cool ant levelTires, for correct pres sure, compat ible types and tread patt erns , and wear wi thi n limi ts .There i s s ufficient fuel in the t ank to compl ete the t est .Check al l around the engine, t rans mis s ion and under the vehicle for oil , coolant , hydraul ic and fuel l eaks . Make anote of any apparent leaks and wipe off t he surrounding areas t o make it easi er to identi fy t he extent of the leakon complet ion of t he tes t.
Starting the Engine
• NOTE: On i nit ial dri ve away from cold and wit hi n t he fi rs t 1.5 km (1 mile), do not depress accelerat or pedal beyond halft ravel unt il t he vehi cl e has att ained a minimum s peed of 25 km/h (15 mil es /h). Never operat e at high engi ne speed or wi tht he accelerat or pedal at ful l travel whil st the engine i s cold.
With the ignition off, check:
The parking brake is appli ed.Automatic transmission: The s el ect or lever is i n 'P' - PARK.Manual transmission: The gear l ever i s in NEUTRAL.All i ns t rument gauges read zero.
With the ignition on, check:
Igni ti on cont roll ed warni ng li ght s come on.Engi ne t emperature gauge regis t ers a readi ng compat ibl e wi th t he engine t emperat ure.Fuel gauge regi st ers a reading appropriate to the fuel l evel i n t he tank.The operati on of the parki ng brake warning l ight and fl ui d l evel warni ng indicator light.
On Road Test Check:
CAUTION: At commencement of road tes ti ng, check the brake operati on while s ti ll travel li ng at low speed beforecont inuing wit h t he tes t. If t he brakes pul l to one si de, or appear to be ot herwi se fault y, do not cont inue wit h t he roadt es t unti l the fault has been found and rect ified.
The parking brake releas es completel y.Gear changing i s s mooth, and t here are no abnormal noi s es or vi brati ons from t he t rans mis s ion.The engi ne power out put is s ati s factory, accel erati on is smoot h and accel erator pedal operat ion is not s ti ff orheavy, and engi ne s peed ret urns t o idl e correctl y.There i s no exces s ive or abnormall y colored s moke from t he engi ne under normal driving, heavy l oad or overruncondi ti ons .Steering operat ion i s s moot h, accurat e, not exces s ively heavy or wit h exces s ive free pl ay or vibrat ion. Does not pul lt o one s ide and s elf centres smoot hly after corneri ng.All i ns t rument s regis t er the correct readi ngs and operate correctl y.Swit ches and controls operat e s moothl y and posi ti vel y, warning or i ndi cat or light s operate correctl y and thedirect ion i ndi cat or cont rol s elf cancels when the s t eering i s ret urned t o t he s traight ahead pos it ion.Heati ng and vent il at ion sys tems work correct ly and effect ively.Brakes operate efficientl y.
Brake Testing
Avoi d brake t es ti ng on busy roads where i t can caus e i nconveni ence or danger t o ot her road users.
CAUTION: Brake t es ti ng which i ncludes heavy brake appl icati ons should not be carri ed out wit h new brake pads /dis csunti l the component s have bedded-i n. New brake fri ct ion component s wi ll not reach ful l efficiency unt il t he beddi ng-inprocess is complet e. Not e t hat when new parking brake shoes or rear brake di scs have been ins t al led, it i s es sent ial thatt he 'beddi ng-in' procedure i s carri ed out.For addit ional informat ion, refer t o: Parking Brake Shoes Bedding-In (206-05 Parking Brake and Actuati on, GeneralProcedures).
Test t he brakes at s everal speeds wit hin the normal operat ing range usi ng both light and heavy pedal pres s ure. Note anyt endency to snat ch, pull or drag, and any undue del ay in appli cat ion or release.

Publ is hed: 27-Apr-2011
General Information - Diagnostic Trouble Code (DTC) IndexDTC: Terrain
Response Control Module (ATCM)
Des cript ion and Operat ion
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.2.
Visual InspectionMechanicalElectrical
* Ti re condit ion, pres sures, et cDriveline, Engine, Transmis s ion, Sus pensi on,component s (correct ins tall ati on, damage, etc)
Fus esHarness es /Connect orsTerrai n res pons e modul eEngi ne Cont rol Module (ECM)Transmis s ion Control Modul e (TCM)Ant i-Lock Brake Sys t em control modul eAct ive On-demand cont rol moduleDynami c s us pensi on cont rol module * Controllerarea network (CAN) ci rcuit s
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 ep.3.
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/t rans mis s ion i s s uspect and the vehicle remai ns under manufacturer warrant y, refer t o t heW 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/transmis s ion.
• 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 addi ti onalinformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to threedeci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t ance, always take t he res i st ance of t heDMM leads int o account.
• 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: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• 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 .
Des cript ion And Operat ion
For a detail ed descripti on of the Terrain Respons e s ys t em, refer t o t he rel evant Descript ion and Operat ion secti on in theworks hop manual .For addit ional informat ion, refer t o: Ride and Handli ng Opti mizat ion (204-06 Ride and Handli ng Opt imi zat ion, Descripti onand Operat ion).
Terrain Response C ontrol ModuleDT CDescriptionPossible CauseAction
C1A00-46Control Module -cal ibrat ion /paramet ermemory fai lure
The Terrain Res ponseCont rol Modul e hasi ndi cat ed a cali brat ion /paramet er memoryfail ure for embeddeds ys tems us i ng FLASHmemory. Thi s i sequivalent t o EEPROM inRAM/ROM/EEPROMembedded s ys t emsCorrupti on in thenon-volat il e memorys t orage s yst em(EEPROM) in t he TerrainRes pons e Cont rolModule
Rect ify thi s DTC before att empti ng t o rect ify others . Recordal l DTCs logged and clear them. W it h ignit ion on sel ect aterrain res pons e s peci al program, t urn off the i gnit ion, thenturn back on the i gni ti on and veri fy t he s elected s peci alprogram is s t il l act ive. If t he s el ect ed t errai n res ponsespecial program is not s t il l act ive and has ret urned t o t hegeneral program, confirm i f DTC has ret urned. Repeatprocedure agai n once more. If DTC is st il l pres ent i nst all anew terrai n res pons e rotary cont rol and control modul e. Referto the warranty pol icy and procedures manual if a module issus pect