warning LAND ROVER FRELANDER 2 2006 Repair Manual

Important Safety Instructions
Appropri at e s ervi ce methods and correct repai r procedures are es sent ial for t he s afe, rel iable operat ion of al l motor
vehi cl es as well as t he pers onal s afet y of t he individual carryi ng out t he work.
Anyone who departs from t he ins truct ions provi ded in t his manual mus t fi rs t es tabli sh that pers onal s afet y or vehi cle
int egrit y i s not compromis ed by t he choi ce of method, tools or component s .
Warnings, Cautions and Notes in This ManualW ARNING: W arni ngs are us ed t o indicate that fai lure t o fol low a procedure correct ly may res ul t in pers onal injury.CAUTION: Cauti ons are us ed t o indicat e that failure t o fol low a procedure correct ly may res ult in damage to the
vehi cl e or equipment bei ng us ed.
• NOTE: Notes are us ed t o provide addit ional ess enti al i nformati on required to carry out a compl et e and s at is factory
repair.
Generic warnings or caut ions are in their relevant des cript ion and operat ion procedure wit hi n s ect ion 100-00. If t he generic
warni ngs or cauti ons are requi red for a procedure, there wil l be a referral to t he appropri ate des cri pt ion and operat ion
procedure.
If a warni ng, cauti on or not e only appli es to one s tep, it i s placed at the beginni ng of the s peci fi c s tep.
Trustmark Authoring Standards (TAS) Removal and Installation Procedures
• NOTE: TAS s tyl e procedures can be identi fi ed by s teps t hat have no accompanying step t ext and t he magenta color of
t he elect rical connect ors and fast eners s uch as nut s , bol ts , clamps or cli ps.
A TAS removal and i nst all at ion procedure uses a s equence of color i ll us t rat ions t o indicate the order to be foll owed when
removi ng/dis ass embli ng or ins tal li ng/ass embli ng a component .
Many of the TAS procedures will have t he ins tal lat ion i nformat ion wit hi n t he removal s teps . Thes e procedures wi ll have the
fol lowing not e at t he begi nni ng of the procedure:
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Items s uch as O-ri ng s eal s, gas ket s , s eal s, s elf-l ocki ng nut s and bolt s are to be dis carded and new component s ins tal led
unles s otherwis e s tat ed wit hin the procedure. Coated nut s or bol ts are t o be reused, unles s damaged or ot herwi se st ated
wit hin the procedure.
Speci ficat ion procedures wi ll cont ain al l techni cal data that are not part of a repair procedure.
TAS Graphics
Colors used i n t he graphic are as fol lows :
Blue - Indicates t he t arget it em, it em t o be removed/ins t al led or dis as s embl ed/as sembl edGreen and Brown - Indi cat es a s econdary it em t hat needs t o be det ached, removed/ins tal led or
dis as sembl ed/ass embl ed prior t o t he t arget it emMagent a - Indicates elect rical connectors and fas teners such as nut s, bolt s , cl amps or cl ipsPale Bl ue - is for t he special t ool (s ) and general equi pment .There may be mult ipl e s teps as si gned to one ill ust rat ion.
Numbered point ers are us ed to indicate the number of electrical connect ors and fast eners s uch as nuts , bolt s, clamps or
clips .
Items i n t he il lus trati on can be transparent or us e cutouts to show hi dden det ail (s ).

Publi s hed: 11-May-2011
General Information - General Service Information
Des cript ion and Operat ion
Introduction
This manual has been wri tt en in a format t hat i s desi gned to meet the needs of Land Rover technicians worl dwide and t oas si st them in t he efficient repai r and maintenance of Land Rover vehi cl es .
This manual provides descripti ons and methods for accomplis hing adjust ment, s ervi ce and repair work usi ng t es t ed andeffect ive procedures . Fol lowi ng thes e procedures wil l hel p ens ure product rel iabil ity.
Special Tools
The Speci al Tool(s ) Tabl e provided at t he begi nni ng of each procedure li st s t he s pecial t ool (s ) requi red t o carry out repairoperati ons wit hin t hat specific procedure. W herever poss i bl e, ill ust rat ions are provided whi ch wil l as s is t t echnicians i nidenti fyi ng the s pecial tool(s ) required and als o s howing s uch tool (s ) in use.
Speci al t ools may be obt ained from the manufact urer, SPX Tool s, t he addres ses of t heir branches will be found in theSpeci al Tools Gl oss ary.For addit ional informat ion, refer t o: Special Tool Glos sary (100-00 General Informati on, Des cri pti on and Operati on).
Important Safety Instructions
Appropri at e s ervi ce methods and correct repai r procedures are es sent ial for t he s afe and reli abl e operati on of all mot orvehi cl es as well as ens uri ng the personal s afety of t he i ndi vi dual carryi ng out the work.
This manual cannot poss ibl y anti ci pat e al l s uch vari at ions and provi de advi ce or cauti ons as to each. Any pers on whodeparts from t he ins t ructi ons provi ded in this manual mus t firs t es tabl is h t hat t hey compromis e nei ther thei r personals afety nor t he vehicle i ntegri ty by their choice of met hods , tool s or parts .
Indi vi dual s who undert ake their own repai rs should have s ome skil l or training and limi t repairs t o component s which coul dnot affect t he s afety of t he vehicle or i ts pas s engers. Any repai rs requi red to s afet y cri ti cal i tems such as s t eering, brakes,s uspens ion or s uppl ement al res traint s yst em s hould be carri ed out by a Land Rover Dealer. Repairs t o s uch i tems s houldNEVER be at tempt ed by untrai ned indivi duals .
Warnings, Cautions and Notes which appear in this manual
As you read through t his manual, you wi ll come acros s W arnings, Caut ions and Notes . A W arning, Cauti on or Not e i splaced at the beginni ng of a s eries of s t eps . If the warning, caut ion or note onl y appl ies t o one s t ep, i t is pl aced at t hebegi nning of t he specific s t ep aft er the s t ep number.
Warnings, Cautions and Not es have the foll owing meanings :
Warning: Procedures which mus t be foll owed to avoid the pos s ibil it y of pers onal i njury.
Caution: Cal ls at tent ion t o procedures which mus t be foll owed to avoid damage to components .
Note: Gi ves hel pful informati on.
References
References t o the Left Hand (LH) or Right Hand (RH) si de given i n t hi s manual are made when vi ewing t he vehi cl e or unitfrom the rear.
Fault Diagnostic Equipment
The vehi cl e i s equi pped wit h a number of electroni c cont rol s yst ems t o provide opt imum performance of the vehicl e'ss ys t ems .
Land Rover approved diagnos t ic equipment is avai lable and mus t be us ed where s pecified. The use of this equi pment willas si st wit h t he fault di agnos ti c abili ti es of the Deal er workshop. In parti cul ar, t he equi pment can be us ed t o i nterrogat et he elect roni c s ys t ems for di agnos is of faul ts whi ch may become evident during t he li fe of the vehicle.
This manual is produced as a reference s ource t o s uppl ement Land Rover approved di agnos ti c equipment.
Feat ures of t he equi pment include:
a. Ful ly upgradeable s upport for t he t echnician
b. Struct ured di agnos ti cs to accommodate al l ski ll levels
c. Direct print-out of screen i nformati on and tes t res ult s
Testing the vehicle
Operat ions covered in t his manual do not include reference t o t es t ing t he vehicle after repai r. It is es s ent ial t hat work i sins pect ed and t es t ed aft er compl eti on and if neces s ary, a road tes t of the vehicle is carried out , part icul arl y where s afet yrel ated i tems are concerned.
Repairs and Replacement Parts

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

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 .

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.

commencement of work.
Dis pos abl e heavy dut y plas ti c gloves s houl d be worn at all ti mes , and the affected area was hed down usi ng wire wool anda l imewat er (calcium hydroxi de) s olut ion t o neutrali se the acid before di spos ing of t he decompos ed Vit on res i due and fi nalcleaning of t he area. Aft er us e, t he plas ti c gloves should be dis carded carefull y and s afely.
Welding
W el di ng process es i ncl ude Res i st ance W elding (Spot W eldi ng), Arc W elding and Gas W eldi ng.
Resistance Welding
This proces s may cause parti cles of molt en met al to be emit ted at a high velocit y, and t he eyes and s ki n mus t beprot ect ed.
Arc Weld ing
This proces s emit s a hi gh level of ul tra-vi ol et radiat ion whi ch may caus e arc-eye and s ki n burns t o t he operator and t oother pers ons nearby. Gas -shi el ded welding proces s es are parti cul arly hazardous i n thi s res pect . Pers onal prot ecti on mus tbe worn, and s creens us ed to shi eld ot her people.
CONTACT LENS W EARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES W HEN ARC W ELDING as t he arc spectrumis bel ieved to emit microwaves which dry out t he fluid bet ween t he lens and t he eye. This may res ult i n bli ndnes s whent he lens is removed from the eye.
Metal s patt er wil l al so occur, and appropri ate eye and skin prot ect ion i s neces s ary.
The heat of t he weldi ng arc wi ll produce fumes and gas es from the metals bei ng welded, the rods and from any appli edcoat ings or cont aminat ion on t he s urfaces being worked on. Thes e gas es and fumes may be toxic and inhalati on of thes es houl d be avoided. The us e of extract ion vent ilat ion t o remove the fumes from the working area may be neces s arypart icularl y in cas es where the general vent il ati on is poor, or where cons iderabl e weldi ng work i s anti ci pated. In ext remecas es or confined s paces where adequat e vent il ati on cannot be provided, air-fed res pirators may be neces s ary.
CAUTION: Some of t he components ins tal led t o t he vehi cl e e.g. t he int eri or cros s beam and underbonnet crossmember are manufact ured from magnesi um al loy. On no account s houl d any welding operat ions be at t empt ed on t hesecomponents .
Gas Welding (and Cutting)
Oxy-acet ylene t orches may be us ed for wel di ng and cutt ing, and s pecial care mus t be t aken to prevent l eakage of t hes egases , wit h consequent ri sk of fire and explos ion.
The process wil l produce met al spat ter and eye and s kin prot ecti on is necess ary.
The fl ame i s bri ght , and eye prot ect ion s hould be us ed, but t he ult ra-violet emi s si on is much les s than t hat from arcweldi ng, and l ighter filt ers may be us ed.
The process it sel f produces few t oxi c fumes , but s uch fumes and gases may be produced from coati ngs on the work,part icularl y duri ng cut ti ng away of damaged body parts , and inhalat ion of t he fumes s hould be avoided.
In brazing, toxic fumes may be produced from t he metal s in the brazi ng rod, and a s evere hazard may ari se if brazing rodscont aining cadmi um are used. In t hi s event parti cular care must be taken t o avoi d i nhalat ion of fumes and expert advi cemay be requi red.
SPECIAL PRECAUT IO NS MUST BE T AKEN BEFORE ANY WELDING OR CUT T ING T AKES PLACE ON VESSELS WHICHHAVE CO NT AINED COMBUST IBLE MAT ERIALS, FO R EXAMPLE BO ILING O R ST EAMING O UT OF FUEL T ANKS.
Warning Symbols on Vehicles
Decal s s howi ng warni ng s ymbol s wil l be found on various vehi cl e component s.
Thes e decals mus t not be removed. The warni ngs are for the at tent ion of owners /operat ors and persons carrying outs ervice or repair operat ions on t he vehicle.

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.

5. Check front s afet y belt height adjus ters for correct operat ion.
Lamps, Horns and Warning Indicators
Check s i de, head, fog, revers ing and tail l amps for correct operat ion.Check operat ion of headlamp aut omati c levelli ng s yst em - if ins t al led.Check t urn si gnal s and hazard warni ng lamps for correct operati on.Check brake (s t op) l amps for correct operat ion.Check al l ext eri or l amp l ens es for cl arit y and condi ti on; pay parti cular at tent ion to headl amp and fog lamp lens esfor s t one chi ps or damage.Check horn for l oud, clear s ound.Swit ch on headl amps and check t hat si de/headl amp reminder warning s ounds when door is opened.Check operat ion of i nteri or courtes y lamps .Check operat ion of al l i nst rument pack warni ng and indicator l amps.
Washers and Wipers
Check al l wiper blades for condi ti on and s igns of s pl it s or damage.Check s ecurit y of wi per arms .Operat e front and rear s creen washers, check that jet s are cl ear and correctl y aimed.Operat e front and rear wipers at all s peeds and check for s moot h, s mear free operation.
Pollen Filter
Replace pol len fil ter.For addit ional informat ion, refer t o: Pollen Fi lt er (412-01 Cl imat e Control, Removal and Ins tall ati on).
Corrosion/Cosmetic Inspection
Carry out the annual corros ion/cos meti c ins pect ion us ing t he Annual Corros ion Inspecti on Sheet .
Wheels and Tires
Check t hat ti res comply wit h manufacturer's specificati on.For addit ional informat ion, refer t o: Specificati ons (204-04 W heels and Tires , Specificati ons ).Check/adjust t ire pres s ures i ncl udi ng s pare.For addit ional informat ion, refer t o: Specificati ons (204-04 W heels and Tires , Specificati ons ).Vehicle fitted with Uni-directional tires: Mark t he wheel to st ud rel ati ons hip of each road wheel and note locat ion

5.
Check front s afet y belt height adjus ters for correct operat ion.
Lamps, Horns and Warning Indicators Check s i de, head, fog, revers ing and tail l amps for correct operat ion. Check operat ion of headlamp aut omati c levelli ng s yst em - if ins t al led.
Check t urn si gnal s and hazard warni ng lamps for correct operati on.
Check brake (s t op) l amps for correct operat ion.
Check al l ext eri or l amp l ens es for cl arit y and condi ti on; pay parti cular at tent ion t
o headl amp and fog lamp lens es
for s t one chi ps or damage. Check horn for l oud, clear s ound.
Swit ch on headl amps and check t hat si de/headl amp reminder warning s ounds when door i
s opened.Check operat ion of i nteri or courtes y lamps .
Check operat ion of al l i nst rument pack warni ng and indicator l amps.
Washers and Wipers
Check al l wiper blades for condi ti on and s igns of s pl it s or damage.
Check s ecurit y of wi per arms .
Operat e front and rear s creen washers, check that jet s are cl ear and correctl y aimed
.Operat e front and rear wipers at all s peeds and check for s moot h, s mear free operati
on.Pollen Filter
Replace pol len fil ter.
For addit ional informat ion, refer t o: Pollen Fi lt er (412-01 Cl imat e Control, Removal and Ins tall ati on).
Corrosion/Cosmetic Inspection
Carry out the annual corros ion/cos meti c ins pect ion us ing t he Annual Corros ion Inspec ti on Sheet .Wheels and Tires
Check t hat ti res comply wit h manufacturer's specificati on.
For addit ional informat ion, refer t o: Specificati ons (204-04 W heels and Tires , Specificati ons ).
Check/adjust t ire pres s ures i ncl udi ng s pare.
For addit ional informat ion, refer t o: Specificati ons (204-04 W heels and Tires , Specificati ons ).
Vehicle fitted with Uni-directional tires:
Mark t he wheel to st ud rel ati ons hip of each road wheel and note locat ion