2001 LAND ROVER FREELANDER Workshop Manual

GENERAL INFORMATION
03-18
Fuel handling precautions
Fuel vapour is highly inflammable and in confined
spaces is also explosive and toxic. The vapour is
heavier than air and will always fall to the lowest
level. The vapour can easily be distributed
throughout a workshop by air currents;
consequently, even a small spillage of fuel is
potentially very dangerous.
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
for basic guidance only, if in doubt consult your local
Fire Officer.
General
Always have a fire extinguisher containing FOAM,
CO
2, GAS or POWDER close at hand when handling
or draining fuel or when dismantling fuel systems.
Fire extinguishers should also be located in areas
where fuel containers are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
Whenever fuel is being handled, drained or stored, or
when fuel systems are being dismantled, all forms of
ignition must be extinguished or removed; any
leadlamps must be flameproof and kept clear of
spillage.
WARNING: No one should be permitted to repair
components associated with fuel without first
having specialist training.
WARNING: Do not remove fuel system
components while the vehicle is over a pit.Fuel tank draining
Fuel tank draining should be carried out in
accordance with the procedure outlined in the FUEL
DELIVERY section of this manual and observing the
following precautions:
WARNING: Fuel must not be extracted or drained
from any vehicle while it is over a pit. Extraction
or draining of fuel must be carried out in a well
ventilated area.
The capacity of containers must be more than
adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked
with its contents and placed in a safe storage
area which meets the requirements of local
authority regulations.
WARNING: When fuel has been drained from a
fuel tank the precautions governing naked lights
and ignition sources should be maintained.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet by
a spring steel clip, the clip must be released before
the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.
As an added precaution, fuel tanks should have a
'FUEL VAPOUR' warning label attached to them as
soon as they are removed from the vehicle.
Fuel tank repairs
No attempt should be made to repair a plastic fuel
tank. If the structure of the tank is damaged, a new
tank must be fitted.
Body repairs
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
When body repairs involve the use of heat, all fuel
pipes which run in the vicinity of the repair area must
be removed, and the tank outlet plugged.

GENERAL INFORMATION
03-19
Electrical precautions
General
The following guidelines are intended to ensure the
safety of the operator and ensure the prevention of
damage to the electrical and electronic components
fitted to the vehicle. Where necessary, specific
precautions are detailed in the individual procedures
of this manual.
Equipment
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to check
the condition of the lead and plugs of mains operated
equipment.
Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High Voltage Circuits
Whenever disconnecting live ht circuits, always use
insulated pliers and never allow the open end of the
ht lead to contact other components, particularly
ECU's.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and harnesses
The engine compartment of a vehicle is a particularly
hostile environment for electrical components and
connectors:
lAlways ensure electrically related items are dry
and oil free before disconnecting and
connecting test equipment.
lEnsure disconnected multiplugs and sensors
are protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.
lNever force connectors apart using tools to
prise apart or by pulling on the wiring harness.
lAlways ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.
lEnsure that any protection (covers, insulation
etc.) is replaced if disturbed.Having confirmed a component to be faulty:
lSwitch off the ignition and disconnect the
battery.
lRemove the component and support the
disconnected harness.
lWhen replacing the component, keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.
CAUTION: To prevent damage to electrical
components, always disconnect the battery
when working on the vehicle's electrical system.
The ground lead must be disconnected first and
reconnected last.
CAUTION: Always ensure that battery leads are
routed correctly and are not close to any
potential chafing points.
Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.
Ignition system safety precautions
The vehicle's ignition system produces high voltages
and the following precautions should be observed
before carrying out any work on the system:
WARNING: Before commencing work on an
ignition system, ensure all high tension
terminals, adapters and diagnostic equipment
are adequately insulated and shielded to prevent
accidental personal contacts and minimise the
risk of shock. Wearers of surgically implanted
pacemaker devices should not be in close
proximity of ignition circuits or diagnostic
equipment.

GENERAL INFORMATION
03-20
Disciplines
Switch off the ignition prior to making any connection
or disconnection in the system, to prevent electrical
surges caused by disconnecting 'live' connections
damaging electronic components.
Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or high-
resistance contacts.
When handling printed circuit boards, treat with care
and hold by the edges only; note that some electronic
components are susceptible to body static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short-circuit and
open-circuit fault conditions.
Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static charge. Some electronic components are
vulnerable to the static electricity that may be
generated by the operator.
Grease for electrical connectors
Some under bonnet and under body connectors may
be protected against corrosion by the application of a
special grease during vehicle production. Should
connectors be disturbed in service, or repaired or
replaced, additional grease should be re-applied:
Part No. BAU 5811, available in 150 gm tubs.
NOTE: The use of greases other than BAU 5811
must be avoided as they can migrate into relays,
switches etc. contaminating the contacts and leading
to intermittent operation or failure.
Supplementary restraint system
precautions
General
The Supplementary Restraint System (SRS)
provides active protection for vehicle occupants in
the event of a serious collision. The system
components include airbags and pre-tensioner seat
belts which are automatically deployed when a
severe frontal crash condition is detected.
The SRS pyrotechnic components could be
potentially hazardous to the service engineer if not
handled correctly. The following guidelines are
intended to alert the service engineer to potential
sources of danger and emphasise the importance of
ensuring the integrity of SRS components fitted to
the vehicle.
In order to assure system integrity, it is essential that
the SRS system is regularly checked and maintained
so that it is ready for operation in the event of an
accident.
Where necessary, additional specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
WARNING: Always follow the 'SRS Precautions'
and the correct procedures for working on SRS
components. Persons working on SRS systems
must be fully trained and have been issued with
copies of the Safety guidelines.
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: The airbag module contains sodium
azide which is poisonous and extremely
flammable. Contact with water, acid or heavy
metals may produce harmful or explosive
compounds. Do not dismantle, incinerate or
bring into contact with electricity, before the unit
has been deployed.
WARNING: Always replace a seat belt assembly
that has withstood the strain of a severe vehicle
impact, or if the webbing shows signs of fraying.
WARNING: Always disconnect the vehicle
battery before carrying out any electric welding
on a vehicle fitted with an SRS system.
CAUTION: Do not expose an airbag module or
seat belt pre-tensioner to heat exceeding 85º C
(185º F).

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

GENERAL INFORMATION
03-22
SRS component testing
The SRS components are triggered using relatively
low operating currents, always adhere to the
following precautions:
WARNING: Do not use a multimeter or other
general purpose test equipment on SRS system
components or accidental deployment may
occur. Use only Testbook to diagnose system
faults.
WARNING: Do not use electrical test equipment
on the SRS harness while it is connected to any
of the SRS system components. It may cause
accidental deployment and personal injury.
Never apply electrical power to an SRS component
unless instructed to do so as part of an approved test
procedure.
The SRS Diagnostic Control Unit is a non-
serviceable component and no attempt should be
made to repair or modify the unit.Component handling
The SRS components are sensitive and potentially
hazardous if not handled correctly; always comply
with the following handling precautions:
WARNING: The SRS components are sensitive
and potentially hazardous if not handled
correctly; always comply with the following
handling precautions:
lNever drop an SRS component. The airbag
diagnostic control unit is a particularly
shock sensitive device and must be handled
with extreme care. Airbag modules and seat
belt pre-tensioner units could deploy if
subjected to a strong shock.
lNever wrap your arms around an airbag
module. If an airbag module has to be
carried, hold it by the cover, with the cover
uppermost and the base away from your
body.
lNever transport airbag modules or seat belt
pre-tensioners in the cabin of a vehicle.
Always use the luggage compartment of the
vehicle for carrying airbag modules and seat
belt pre-tensioner units.
WARNING: Never attach anything to an airbag
cover or any trim component covering an airbag
module. Do not allow anything to rest on top of
an airbag module.
WARNING: Always keep components cool, dry
and free from contamination.

GENERAL INFORMATION
03-23
WARNING: For front seat buckle type pre-
tensioners, hold by the piston tube, with the open
end of the piston tube pointing towards the
ground and the buckle facing away from your
body. Do not cover the end of the piston tube.
DO NOT hold buckle pre-tensioners by the
bracket assembly or steel cable. NEVER point
the piston tube towards your body or other
people.
CAUTION: Do not apply grease or cleaning
solvents to seatbelt pre-tensioner units,
component failure could result.Storage
There are regulations for the safe storage of SRS
components which must be observed, consult your
local authority for details.
WARNING: Airbag modules and seat belt pre-
tensioners are classed as explosive devices. For
overnight and longer term storage, they must be
stored in a secure steel cabinet which has been
approved as suitable for the purpose and has
been registered by the local authority.
WARNING: Store the airbag module with the
deployment side uppermost. If it is stored
deployment side down, accidental deployment
will propel the airbag module with enough force
to cause serious injury.
CAUTION: Improper handling or storage can
internally damage the airbag module, making it
inoperative. If you suspect the airbag module has
been damaged, install a new module and refer to
the Deployment/Disposal Procedures for
disposal of the damaged module.
Always observe the following precautions when
temporarily storing an airbag module:
lEnsure the cover is facing upwards and the
luggage compartment is secured.
lAlways keep components cool, dry and free
from contamination.
lDo not allow anything to rest on the airbag
module.
lStore any removed airbag assembly on a
secure flat surface away from electrical
equipment and heat sources (exceeding 85° C
(185° F).

GENERAL INFORMATION
03-24
SRS Harnesses and Connectors

CAUTION: Always observe the following
precautions with regards to SRS system
electrical wiring:
lNever attempt to modify, splice or repair
SRS wiring.
lNever install electronic equipment (such as
a mobile telephone, two-way radio or in-car
entertainment system) in such a way that it
could generate electrical interference in the
airbag harness. Seek specialist advice when
installing such equipment.
NOTE: SRS system wiring can be identified by a
special yellow outer sleeve protecting the wires
(black with yellow stripe protective coverings are
sometimes used).
WARNING: Always ensure SRS wiring is routed
correctly. Be careful to avoid trapping or
pinching the SRS wiring. Do not leave the
connectors hanging loose or allow SRS
components to hang from their harnesses. Look
for possible points of chafing.CAUTION: Ensure all SRS harness connectors
are mated correctly and securely fastened. Do
not leave the connectors hanging loose.
Rotary Coupler

CAUTION: Always follow the procedure for fitting
and checking the rotary coupler as instructed in
the SRS repairs section. Comply with all safety
and installation procedures to ensure the system
functions correctly. Observe the following
precautions:
lDo not install a rotary coupler if it is
suspected to be defective.
lDo not attempt to service, modify or repair a
rotary coupler.
lDo not cut, splice or modify the wires
attached to the rotary coupler.
lAlways ensure the rotary coupler
connectors are mated correctly and securely
fastened.
lAlways ensure the battery is disconnected
before working on the rotary coupler.
lDo not unlock and rotate the rotary coupler
when it is removed from the vehicle.
lDo not turn the road wheels when the rotary
coupler is removed from the vehicle.
lAlways ensure the rotary coupler is removed
and installed in its centred position and with
the front road wheels in the straight ahead
position - refer to the SRS repair section for
the correct removal and installation
procedure.
lIf a new rotary coupler is being installed,
ensure the locking tab holding the coupler's
rotational position is not broken; units with a
broken locking tab should not be used.

GENERAL INFORMATION
03-25
Warning Labels
Warning symbols are displayed at various positions
in the vehicle (either in a suitable prominent position
such as driver and passenger side glass, or attached
to the component itself) to indicate SRS items which
must be treated with particular care. These include:
A - The need for caution when working in close
proximity to SRS components.
B - Refer to the publication where the procedures,
instructions and advice can be found (usually
Workshop Manual or Owner's Handbook) for
working on the SRS system.
C - Do not use rear facing child seats in the front
passenger seat if the vehicle is fitted with a
passenger airbag.Driver and Passenger Side Windows
WARNING: It is imperative that before any work
is undertaken on the SRS system the appropriate
information is read thoroughly.
Caution labels are attached to SRS system
components and may also be applied to vehicle trim
close to SRS components and harnesses. The driver
and front passenger airbag modules have an 'SRS
AIRBAG' symbol moulded into the module's plastic
trim to identify the presence of airbags. Other SRS
warning labels include:
End of Fascia
Label located on end of fascia; warning not to use
rear facing child seats in the front passenger seat in
vehicles fitted with a front passenger airbag.