
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 . 

Woodruff keys
W oodruff keys  may be reus ed provided t here i s no i ndi cat ion of wear or dis torti on.
Remove any burrs  from edges of keyways us ing a fine fil e.
Split pins
Never at tempt  t o s t raight en and reus e a s pli t pin, always  make s ure that  repl acement pins  are of the correct si ze for t hehole i n which t hey are to be ins tal led.
Screw Threads
Damaged nuts , bolt s and s crews mus t always be dis carded. Att empti ng to recut or repai r damaged threads  wi th at ap or di e i mpai rs  the s t rength and fi t of t he t hreads and is  not  recommended.
• NOTE: Duri ng cert ai n repai r operat ions , it  may be neces sary t o remove t races  of t hread locking agent s  us ing a tap.W here thi s is  neces sary, t he i ns t ructi on to do s o wi ll appear in the relevant operation and it  i s ess enti al that a t ap of thecorrect  s ize and t hread i s used.
Some bolt s  are coat ed wit h a thread locki ng agent  and unles s  s tat ed otherwis e, they mus t  not be reus ed. Newbolt s havi ng the same part  number as  the original  mus t always  be i nst all ed. W hen nuts  or bolt s are to bedis carded, t he repai r operat ion and relevant torque chart  will  i ncl ude an ins truct ion to that effect . Do not usepropri etary thread locki ng agent s  as  t hey may not meet the specificati on required. See al so Encapsul at ed('Patched') Bol ts  and Screws.Always  make s ure that  repl acement  nuts  and bol ts  are at  leas t equal  i n s trengt h t o thos e t hat they are repl acing.Cast ell ated nut s mus t not  be loosened t o accept  a s pli t pin except  in recommended cas es  when thi s forms  part  ofan adjus tment .Do not  all ow oil  or greas e t o enter bli nd holes , the hydrauli c acti on res ult ing from ti ght ening t he bolt  or s tud cans plit  t he housi ng and als o gi ve a fal s e torque reading.Always  t ighten a nut, bolt  or s crew to t he s peci fi ed torque fi gure, damaged or corroded threads  can give a fals et orque reading.Nut and bolt  loos ening and t ightening sequences , where gi ven, mus t ALW AY S be foll owed. Di st ort ion ofcomponents  or fault y s eal ing of joints  wil l res ul t if t he s equences  are not  fol lowed. W here an ins t ructi on is  gi ven tot ighten i n s tages , thes e s tages  mus t  be adhered t o; do not at t empt to combi ne st ages part icul arl y where cert ains tages  involve t ight eni ng by degrees.To check or re-t ighten a fi xing t o a s peci fi ed t orque, firs t loosen a quart er of a turn, t hen ret ighten to the s peci fi edt orque fi gure.Unles s  ins t ructed ot herwis e, do not lubricat e bolt  or nut  t hreads pri or t o i nst all ing.
W here it  i s  s tat ed t hat  bolt s  and s crews  may be reus ed, t he fol lowi ng procedures  must be carri ed out:
Check t hat threads  are undamaged.Remove all  t races  of locki ng agent  from the threads .
CAUTION: DO NOT us e a wi re brus h; take care t hat threads  are not damaged.
Make s ure t hat threads  are clean and free from oil  or greas e.Apply t he s pecified locki ng agent  t o t he bolt  t hreads .
Bolt and Nut Identification
An ISO met ri c bolt  or s crew made of s t eel  and l arger than 6 mm in di ameter can be identi fi ed by eit her of t he s ymbols  ISOM or M emboss ed or i ndent ed on top of t he bolt  head.
In addi ti on t o marks  i dent ifying t he manufacturer, t he top of t he bolt  head is  als o marked wit h s ymbol s  indi cat ing t hes trengt h grade e.g. 8.8, 10.9, 12.9, 14.9. Alt ernati vel y, some bol ts  and screws  have t he M and s trengt h grade s ymbols tamped on the flat s of the hexagon.
Encapsulated ('Patched') bolts and screws 

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

t ank must  be ins tall ed.
Oil seals
Never us e a seal which has  been improperly st ored or handled.
Take great care when removi ng old seals  that t he seal ing s urfaces  and s eal hous ing are not damaged.Careful ly exami ne seal  before ins tal li ng to make s ure t hat  it  is  cl ean and undamaged.Make s ure t hat the s urface on which t he s eal i s  t o run and als o t he s eal  housi ng is  cl ean and free from burrs  ors cratches. Renew t he component  i f the s eali ng surface cannot  be rest ored.Speci al  t ools  and prot ect ion sl eeves  are provided for ins tall ing t he majori ty of s eals  and mus t  be us ed whens pecified.Many s eal s  are now coat ed wi th a prot ect ive wax and DO NOT need t o be l ubricated prior t o ins t al li ng. Al wayscheck t he rel evant  repair procedure which wil l s tat e if a seal mus t be ins t al led dry. Never t ouch t hes e seals  wit hoil y hands  as  the oi l will  contami nat e t he prot ect ive coati ng and affect  t he s eal ing properti es of the s eal; al so,make s ure that ins tal li ng tools  and protecti on s leeves  are free from oil  and greas e. Seal s  which mus t  be l ubricat edpri or to i nst all ing s hould have t he recommended lubri cant  appli ed to the areas  specified i n t he repair procedure.Make s ure t hat a s eal  i s  ins t al led t he correct  way round. For exampl e, the l ip of t he s eal must  face towards  thelubricant  whi ch it  i s s eal ing.W hen i nst all ing an oi l seal, make sure t hat  i t is  pos it ioned s quare t o s haft  and housi ng. W here t he s eal i s  t o beins t al led t o a hous ing prior t o ins t al li ng over a shaft , t ake care not to al low the wei ght  of an uns upported s haft  t ores t  on t he s eal .
Always  us e t he recommended s pecial  t ool  and prot ecti on sl eeve to ins tall  an oi l seal. If no t ool  i s  s peci fied, us e as uit abl e mandrel approximat el y 0.4 mm (0.015 in) s mall er than t he outs ide di ameter of the seal. Us e adhes ivet ape on the s haft  t o protect the s eali ng li p of the seal.
Pres s  or dri ft  t he s eal  i n t o t he dept h of it s  hous ing i f the hous ing i s s houldered or fl us h wit h the face of thehous i ng where no shoulder is  provi ded. Make s ure that  t he s eal  i s not ti lt ed in the hous ing when i t is  i nst all ed.
Supplementary Restraint System (SRS) Precautions
W ARNING: Do not ins tal l rear facing chil d s eat s  i n the front  pas s enger s eat .
The SRS cont ains  component s  which are potent iall y hazardous  t o s ervi ce personnel if not handl ed correctl y. The foll owingguideli nes  and precaut ions are intended t o alert pers onnel to pot enti al  s ources  of danger and emphasi s e the import ance ofensuring t he int egrit y of t he SRS components  ins tal led t o t he vehi cl e.
W ARNING: The foll owing precauti ons  MUST be adhered t o when worki ng on t he SRS s ys t em:
T he correct procedures must always be used w hen working on SRS components.Persons w orking on the SRS system must be fully trained and have been issued w ith the safety guidelines.T he airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids orheavy metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contactwith electricity before the unit has been deployed.Alw ays replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing 

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. 

Check t hat the flui d level is  t o t he mi d-way mark between the MAX and MIN marks  on t he fluid res ervoir, t op-up i fneces s ary.Clean t he area around the res ervoi r fi ll er cap, remove cap.
CAUTION: Do not fill reservoir above the MAX mark.
If necess ary, t op-up us ing t he recommended fluid to the mid-way mark on the reservoir.For addit ional informat ion, refer t o: Specificati ons (211-02 Power St eering, Specificati ons).Ins t all the res ervoir fill er cap.
Windshield Washer Reservoir
Remove the winds hi eld was her res ervoir fill er cap.Top-up t he res ervoir us ing a mi xt ure of an approved wi nds hiel d was her flui d and water unti l the level  i s t o thebott om of t he gauze fil ter i n t he res ervoir fil ler neck.Ins t all the res ervoir fill er cap.
Engine Oil and Filter
CAUTION: For vehi cl es  operati ng under arduous condi ti ons  s ee relevant  s ecti on.
Every 6 months or 7,500 miles (12,000 km): NAS and Gulf markets Renew engi ne oil  and filt er.For addit ional informat ion, refer t o: Specificati ons (303-01A Engine - I6 3.2L Petrol, Speci fi cat ions).
Air Filtering
CAUTION: For vehi cl es  operati ng under arduous condi ti ons  s ee relevant  s ecti on.
1. Every 2 years or 30,000 miles (48,000 km): Replace the ai r cl eaner element .For addit ional informat ion, refer t o: Air Cl eaner (303-12A Int ake Ai r Dis t ri but ion and Fi lt ering - I6 3.2L Petrol , Removal  andIns t allat ion).
Automatic Transmission
Every 10 years or 150,000 miles (240,000 km): Renew automat ic t rans mis s ion flui d.For addit ional informat ion, refer t o: Specificati ons (307-01 Aut omati c Trans mis s ion/Transaxle, Speci fi cat ions ).
Manual Transmission
Every 10 years or 150,000 miles (240,000 km): Renew manual  t rans mi ss ion fl ui d.For addit ional informat ion, refer t o: Specificati ons (308-00 Manual Trans mis s ion/Transaxle and Clutch - GeneralInformat ion, Speci ficat ions).
Power Transfer Unit
Every 10 years or 150,000 miles (240,000 km): Renew power t rans fer unit  oi l.For addit ional informat ion, refer t o: Specificati ons (205-03, Speci fi cat ions ).
Differential Assembly - Rear
Every 10 years or 150,000 miles (240,000 km): Renew rear different ial  oil .For addit ional informat ion, refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial, Specifi cat ions ).
Suspension and Body Mountings 

Ensure that the steering wheel is in the straight ahead position, do not turn the st eering w heel prior to checking the
fluid level.
Check t hat the flui d level is  t o t he mi d-way mark between the  MAX and  MIN marks  on t he fluid res ervoir, t op-up i f
neces s ary. Clean t he area around the res ervoi r fi ll er cap, remove cap.
CAUTION: 
Do not fill reservoir above the MAX mark.
If necess ary, t op-up us ing t he recommended fluid to the mid-way mark on the reservoi r.
For addit ional informat ion, refer t o:  Specificati ons  (211-02 Power St eering, Specificati ons).
Ins t all the res ervoir fill er cap.
Windshield Washer Reservoir
Remove the winds hi eld was her res ervoir fill er cap.
Top-up t he res ervoir us ing a mi xt ure of an approved wi nds hiel d was her flui d and wate
r unti l the level  i s t o the
bott om of t he gauze fil ter i n t he res ervoir fil ler neck. Ins t all the res ervoir fill er cap.
Engine Oil and Filter
• CAUTIO NS:  For vehi cl es operati ng under arduous  condi ti ons  see relevant  secti on.
 
Vehicles operating on high sulphur content fuel - above 0.7%, the oil and filter cha nge period MUST  NOT
exceed 3 months or 3,750 miles (6,000 km).  
Vehicles operating on moderate sulphur content fuel - 0.3 to 0.7%, the oil and filte r change period MUST  NOT
exceed 6 months or 7,500 miles (12,000 km).
Renew engi ne oil  and fil ter.
For addit ional informat ion, refer t o:  Oil  Fil ter El ement  (303-01A Engine - I6 3.2L Pet rol , Removal and Ins t allat ion).
Air Filtering
CAUTION: For vehi cl es  operati ng under arduous condi ti ons  s ee relevant  s ecti on.
1. Every 2 years or 30,000 miles (48,000 km):  Replace the ai r cl eaner element .
For addit ional informat ion, refer t o:  Air Cl eaner  (303-12B Int ake Ai r Dis t ri but ion and Fi lt ering - TD4 2.2L Di es el, Removal
and Ins t allat ion).
Fuel Filter
1. Every year or 15,000 miles (24,000 km):  Drai n water from the fuel fi lt er.
1. Every 2 years or 30,000 miles (48,000 km):  Replace fuel fi lt er el ement.
For addit ional informat ion, refer t o:  Fuel  Fil ter  (310-01B Fuel  Tank and Lines  - TD4 2.2L Dies el, Removal  and Ins tall ati on).
Automatic Transmission
Every 10 years or 150,000 miles (240,000 km):  Renew automat ic t rans mis s ion flui d. 

For addit ional informat ion, refer t o:  Specificati ons  (307-01 Aut omati c Trans mis s ion/Transaxle, Speci fi cat ions ).
Manual Transmission
Every 10 years or 150,000 miles (240,000 km):  Renew manual  t rans mi ss ion fl ui d.
For addit ional informat ion, refer t o:  Specificati ons  (308-00 Manual Trans mis s ion/Transaxle and Clutch - General
Informat ion, Speci ficat ions).
Power Transfer Unit
Every 10 years or 150,000 miles (240,000 km):  Renew power t rans fer unit  oi l. For addi ti onal  informat ion, refer to:
(308-07B Transfer Case)
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D  (Removal  and
Ins tal lat ion),
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D  (Removal  and
Ins tal lat ion).
Differential Assembly - Rear
Every 10 years or 150,000 miles (240,000 km):  Renew rear different ial  oil .
For addit ional informat ion, refer t o:  Specificati ons  (205-02 Rear Drive Axle/Different ial, Specifi cat ions ).
Suspension and Body Mountings Check for free play i n all  s us pens ion and body mounti ng rubbers . Check condit ion of s uspens ion rubber boots  and gait ers .
Fuel System
Check fuel sys tem pipes , hos es  and unions  for chafi ng, l eaks  and corros ion. Electrical Harnesses
Check al l el ect ri cal  harnes s es  for chafing. Oil/Fluid Leaks
Check for oil/fluid leaks . Power Steering
Check power s teering rod bal l joi nt  fixi ngs , gait ers  and condi ti on of bal l joi nt s  an d dus t covers .Check power s teering pipes , hos es  and unions  for chafi ng, leaks  and corros ion.
Exhaust System
Check exhaust  s ys tem for l eaks , securi ty and damage. Clutch
1.  Check clut ch pipes  and unions  for chafi ng, l eaks  and corrosi on.
Fault Lamp(s) If fault  l amp(s ) are ill uminat ed, t est  the as s oci at ed s yst em us i ng Land Rover approv ed di agnos ti c equipment and
report  findi ngs . Road Test
Carry out road t est  of vehicle.
For addit ional informat ion, refer t o:  Road/Roller Tes ti ng  (100-00 General Informati on, Des cri pt ion and Operati on).
General
Endors e Service Record. Report any unus ual features of vehi cl e condi ti on and any addi ti onal work required.
Vehicles Operating Under Arduous Conditions
Recommended s ervi ce interval s  for vehicles  operat ing under arduous  condit ions  are de t ail ed below.
Braking System CAUTION: 
When vehicles are operating under arduous conditions, the following service items mu st be carried
out every 3 months or 3,750 miles (6,000 km).
Ins pect  front  brake pads  for wear.