Workshop manual - Range Rover Sport (L320) 2007-09

Published: 11-Ma. -2011

Gene. al Info ma ion - Abo T hi Man al
Description and Operation

No e , Ca ion and Wa ning

Throughout this manual, important information is highlighted b the use of NOTES, C AUTIONS and WARNINGS.
NOTES give additional information on a topic or procedure, C AUTIONS are given to prevent damage to the vehicle,
and WARNINGS are given to prevent personal injur .

cardiagn.com

1/1
 Published: 11-May-2011
General Infor mation - Abou t T his Manual
Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective
is to use common formats and include similar content in each manual.

This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with
tested and effective techniques. Following them will help to ensure reliability.

Im portant Safet. Instructions

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles as well as the personal safety of the individual carrying out the work.

Anyone who departs from the instructions provided in this manual must first establish that personal safety or vehicle
integrity is not compromised by the choice of method, tools or components.

Warnings, Cautions and Notes in This Manual

WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal
injury.

cardiagn.com
C AUTION: C autions are used to indicate that failure to follow a procedure correctly may result in damage to the
vehicle or equipment being used.

̀ NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory
repair.

Generic warnings or cautions are in their relevant description and operation procedure within section 100-00. If the
generic warnings or cautions are required for a procedure, there will be a referral to the appropriate description and
operation procedure.

If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.

Trustm ark Authoring Standards (TAS) Rem ov al and Installation Procedures

̀ NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta color
of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed
when removing/disassembling or installing/assembling a component.

Many of the TAS procedures will have the installation information within the removal steps. These procedures will
have the following note at the beginning of the procedure:

̀ NOTE: Removal steps in this procedure may contain installation details.

Items such as O-ring seals, gaskets, seals, self-locking nuts and bolts are to be discarded and new components
installed unless otherwise stated within the procedure. C oated nuts or bolts are to be reused, unless damaged or
otherwise stated within the procedure.

Specification procedures will contain all technical data that are not part of a repair procedure.

TAS Graphics

C olors used in the graphic are as follows:

Blue - Indicates the target item, item to be removed/installed or disassembled/assembled

Green and Brown - Indicates a secondary item that needs to be detached, removed/installed or
disassembled/assembled prior to the target item
Magenta - Indicates electrical connectors and fasteners such as nuts, bolts, clamps or clips
Pale Blue - is for the special tool(s) and general equipment.

There may be multiple steps assigned to one illustration.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps
or clips.
I. ( ).

cardiagn.com
TAS S

S .T
.

P .

H S
.
 cardiagn.com
Warning s. mbols are used to indicate potential risks resulting from a certain component or area.

Instruction s mbols are used to appl sealer, lubricant, weight, tape or cleaning detergent to a component.
 cardiagn.com
Location s. mbols are used to show the location of a component or s stem within the vehicle.

Gearshift lever or selector lever position s mbols are used to show which gearshift lever or selector lever position is
to be set.
 cardiagn.com
Pointer s. mbols are used to draw the attention to components and give special instructions such as a required
sequence or number of components. The number of components is reflected b the value inside the lut arrow. A
sequence number is located inside the circle. Numbers inside circles are also used to allocate special information such
as tightening torques or chemicals to a particular component.

Movement arrows are used to show three dimensional or rotational movements. These movements can include
specific values inside the s mbol if required.
 cardiagn.com
Standard tool s. mbols recommend the use of certain standard tools. These tools can include dimension values if
required.

The following graphic illustrates a set of s mbols that are used to provide detailed information on where to appl a
material.
 cardiagn.com
Mea. e e b ide de ai ed i f ai he e ca a ecific ea e e . The e b
ca i c de ecific a e if e i ed.

S ecia T a dT e Fig e( )

S ecia i be h i h he be i he i a i . The ecia be ( ), ge e a e i e ,

a e ia ( ) a d e fig e( ) ed f he ced e e i be h i he e c .
 Published: 11-Ma. -2011
General Infor mation - Impor tant Safet. Instruction s
Description and Operation

Safet Notice

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles, as well as the safet of the person doing the work. This manual provides general directions for
accomplishing service and repair work with tested effective techniques. Following them will help assure reliabilit .

There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill
of the person doing the work. This manual cannot possibl anticipate all such variations and provide advice or
cautions as to each. Accordingl , an one who departs from the instructions provided in the manual must first
establish that neither personal safet or vehicle integrit is compromised from choices of methods, tools or parts.

cardiagn.com
 Published: 11-May-2011
General Infor mation - How T o Us e T his Manual
Description and Operation

Cop. right Statem ent

C opyright. ̀ Land Rover Ltd., 2005

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any
form, electronic, mechanical, photocopying, recording or other means, without prior written permission of Land Rover
Ltd., Banbury Road, Lighthorne, Warwick, C V35 0RG

How to use This Manual

This manual covers all aspects necessary in order to service the vehicle effectively.

The manual is structured into five main sections, General Information, C hassis, Powertrain, Electrical and Body and
Paint with each section dealing with a specific part of a vehicle system.

Each of the five main sections contain sub-sections dealing with items which form a part of that specific system.

Pages at the start of the manual list all sections available. Each section has a contents list detailing, where applicable,
Specifications, Description and Operation, Diagnosis and Testing, General Procedures and Repair Procedures.

Where components need to be removed or disassembled in sequence, each operation in the sequence will be
identified numerically and also graphically in an accompanying illustration.

cardiagn.com
• NOTE: Dimensions quoted are to design engineering specifications with service limits quoted, where applicable.

Workshop Manual Organi ation

The five main sections, together with the areas which they cover are given below:

Se c tio n 1 - General Information.

Se c tio n 2 - C hassis.
Se c tio n 3 - Powertrain.
Se c tio n 4 - Electrical.
Se c tio n 5 - Body and Paint.

Sub-section numbers appear after the initial section number, for example, Se c tio n 412-03 covers air conditioning,
which is part of the electrical section.

In the number given above, the first digit of the number '4' indicates the section i.e . Ele c tr ic a l.

The second and third digits '12' of the number indicate the vehicle system i.e . A ir Co nd itio ning .

The last two digits of the number '03' indicate the part of the system covered by the sub-section i.e . A ir
Co nd itio ning Co m p r e s s o r .
 Published: 11-Ma. -2011
General Infor mation - General Service Infor mation
Description and Operation

Introduction

This manual has been written in a format that is designed to meet the needs of Land Rover technicians worldwide and
to assist them in the efficient repair and maintenance of Land Rover vehicles.

This manual provides descriptions and methods for accomplishing adjustment, service and repair work using tested
and effective procedures. Following these procedures will help ensure product reliabilit .

Special Tools

The Special Tool(s) Table provided at the beginning of each procedure lists the special tool(s) required to carr out
repair operations within that specific procedure. Wherever possible, illustrations are provided which will assist
technicians in identif ing the special tool(s) required and also showing such tool(s) in use.

Special tools ma be obtained from the manufacturer, SPX Tools, the addresses of their branches will be found in the
Special Tools Glossar contained within this Section.

Im portant Safet. Instructions

Appropriate service methods and correct repair procedures are essential for the safe and reliable operation of all
motor vehicles as well as ensuring the personal safet of the individual carr ing out the work.

cardiagn.com
This manual cannot possibl anticipate all such variations and provide advice or cautions as to each. An person who
departs from the instructions provided in this manual must first establish that the compromise neither their personal
safet nor the vehicle integrit b their choice of methods, tools or parts.

Individuals who undertake their own repairs should have some skill or training and limit repairs to components which
could not affect the safet of the vehicle or its passengers. An repairs required to safet critical items such as
steering, brakes, suspension or supplemental restraint s stem should be carried out b a Land Rover Dealer. Repairs
to such items should NEVER be attempted b untrained individuals.

Warnings, Cautions and Notes w hich appear in this m anual

As ou read through this manual, ou will come across Warnings, C autions and Notes. A Warning, C aution or Note is
placed at the beginning of a series of steps. If the warning, caution or note onl applies to one step, it is placed at the
beginning of the specific step after the step number.

W a r ning s , Ca utio ns and Notes have the following meanings:

W a r ning : Procedures which must be followed to avoid the possibilit of personal injur .

Ca utio n: C alls attention to procedures which must be followed to avoid damage to components.

Note: Gives helpful information.

References

References to the Left Hand (LH) or Right Hand (RH) side given in this manual are made when viewing the vehicle or
unit from the rear.

F ault Diagnostic Equipm ent

The vehicle is equipped with a number of electronic control s stems to provide optimum performance of the vehicle's
s stems.

Diagnostic Equipment (T4) is available and must be used where specified. The use of this equipment will assist with
the fault diagnostic abilities of the Dealer workshop. In particular, the equipment can be used to interrogate the
electronic s stems for diagnosis of faults which ma become evident during the life of the vehicle.

This manual is produced as a reference source to supplement T4.

Features of the equipment include:

a . Full upgradeable support for the technician

b . Structured diagnostics to accommodate all skill levels

c . Direct print-out of screen information and test results

Testing the . ehicle

Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work
is inspected and tested after completion and if necessary, a road test of the vehicle is carried out, particularly where
safety related items are concerned.

Repairs and Replacem ent Parts

Land Rover parts are manufactured to the same exacting standards as the original factory fitted components. For this
reason, it is essential that only genuine Land Rover parts are used during maintenance or repair.

Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and
accessories.

Safety features and corrosion prevention treatments embodied in the vehicle may be impaired if other than Land
Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to
manufacturer's specification. Torque wrench setting figures, where given, must be adhered to and locking devices,
where specified must be used. If the efficiency of a locking device is impaired during removal it must be replaced.

Owners purchasing accessories whilst travelling abroad must ensure that the accessory and its fitted location on the
vehicle conform to legal requirements.

The terms of the vehicle warranty may be invalidated by the fitting of parts other than those recommended by Land
Rover.

̀ NOTE: The fitting of non-approved Land Rover parts and accessories or the carrying out of non-approved alterations
or conversions may be dangerous. Any of the foregoing could affect the safety of the vehicle and occupants; also, the

cardiagn.com
terms and conditions of the vehicle warranty may also be invalidated .

All Land Rover recommended parts have the full backing of the vehicle warranty.

Land Rover Dealers are obliged to supply only Land Rover recommended parts.

Specifications

Land Rover are constantly seeking to improve the specification, design and production of their vehicles and
alterations take place accordingly. Whilst every effort is made to ensure the accuracy of this Manual, it should not be
regarded as an infallible guide to current specifications of any particular vehicle.

This Manual does not constitute an offer for sale of any particular vehicle. Land Rover dealers are not agents of Land
Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
 Published: 11-May-2011
General Infor mation - Standard W or kshop P ractices
Description and Operation

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle
moving forwards or backwards.
Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust
fumes.
There is adequate room to raise the vehicle and remove the wheels, if necessary.
Fender covers are always installed if any work is to be carried out in the engine compartment.
Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the
vehicle is raised.

̀ C AUTIONS:

Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery
disconnection/connection.
For additional information, refer to: Specifications (414-00 Battery and C harging System - General Information,
Specifications).

cardiagn.com
When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a
surge of current causing damage to the internal components of the generator.

If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Tow ing the Vehicle

WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section of this
Manual.

When the vehicle is being towed the ignition switch must be in position II (steering lock released and warning lights
illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure to follow these
instructions may result in personal injury. It must be noted that with the engine not running, the power steering and
brake booster will be inoperative therefore, greater effort will be needed to steer the vehicle and apply the brakes.

Batter. - General

̀ C AUTIONS:

Prior to carrying out any procedures which involve disconnecting/ or connecting the battery, refer to the
Electrical Section of this manual - Battery disconnection/connection.
For additional information, refer to: Specifications (414-00 Battery and C harging System - General Information,
Specifications).

A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there
will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing
when the jumper cables are connected.

While it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the
only practical way to mobilize a vehicle. Prior to attempting a jump start, refence must be made to the Electrical
Section of this manual - Jump Starting.

Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged
off the vehicle as soon as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in
excess of eight hours continuous driving with no additional loads placed on the battery.

Always make sure that the jumper cables are adequate for the task.
Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be
connected in parallel.
 A. .T
.

Gene.al In alla ion In c ion

Componen emo al

W , .

B .
F , , .
S .
I , ;
.
C , .

Di a embling

O , , ,
.A
.

B , , , .

WARNING: S .

U ,

cardiagn.com
.
W .
S .K
.
T ,
.

Cleaning com ponen

A .
NEVER ( ) ( ). A
.

A '
.S H S P
.

Gene al in pec ion of com ponen

A .

A .
W ,
. . , , , (DTI).
A .
R / .
A
.
B P .
G , O- - .

Join and Join F ace

A .A O-
O- .

U / .

C AUTION: DO NOT .

M .W ,
.
 C AUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified
solvents where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may damage the
sealing surfaces. Make sure that sealing surfaces are free from oil or grease as sealants will not adhere properly to
contaminated surfaces.

Do not allow sealant to enter tapped holes or oilways.

Locking Dev ices

Always replace locking devices with one of the same design and of the correct size.

Tab w ashers

Always release locking tabs before loosening fixings, do not reuse tab washers.

L ocknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always install new roll pins of the correct size.

Circlips

Always install new circlips ensuring that they are of the correct size for the groove.

cardiagn.com
W oodruff ke. s

Woodruff keys may be reused provided there is no indication of wear or distortion.

Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and reuse a split pin, always make sure that replacement pins are of the correct size for
the hole in which they are to be installed.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads
with a tap or die impairs the strength and fit of the threads and is not recommended.

̀ NOTE: During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap.
Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of
the correct size and thread is used.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New
bolts having the same part number as the original must always be installed. When nuts or bolts are to be
discarded, the repair operation and relevant torque chart will include an instruction to that effect. Do not use
proprietary thread locking agents as they may not meet the specification required. See also Encapsulated
('Patched') Bolts and Screws.
Always make sure that replacement nuts and bolts are at least equal in strength to those that they are
replacing. C astellated nuts must not be loosened to accept a split pin except in recommended cases when this
forms part of an adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud
can split the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a
false torque reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of
components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is
given to tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly
where certain stages involve tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the
specified torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.

Where it is stated that bolts and screws may be reused, the following procedures must be carried out:

C heck that threads are undamaged.

Remove all traces of locking agent from the threads.
 C AUTION: DO NOT . e a i e b h; ake ca e ha h ead a e no damaged.

Make e ha h ead a e clean and f ee f om oil o g ea e.

Appl he pecified locking agen o he bol h ead .

Bolt and Nut Identification

An ISO me ic bol o c e made of eel and la ge han 6 mm in diame e can be iden ified b ei he of he
mbol ISO M o M embo ed o inden ed on op of he bol head.

cardiagn.com
In addi ion o ma k iden if ing he man fac e , he op of he bol head i al o ma ked i h mbol indica ing he
eng h g ade e.g. 8.8, 10.9, 12.9, 14.9. Al e na i el , ome bol and c e ha e he M and eng h g ade mbol
amped on he fla of he he agon.

Encapsulated ( 'P atched') bolts and scre. s

Encap la ed ('pa ched') bol and c e ha e a h ead locking agen applied o he h ead d ing man fac e.
Mo h ead locking agen a e colo ed, he band of colo e ending fo 360 deg ee a o nd he h ead. Some locking
agen ho e e , a e ne al in colo and ma no be o ea il iden ified apa f om a ligh l da ke a ea of h ead
he e he locking agen ha been applied. The locking agen i elea ed and ac i a ed b he igh ening p oce and
i hen chemicall c ed o p o ide he locking ac ion.

Self-locking bolts and scre s

Unle. a ed in a pecific epai p oced e, elf-locking bol and c e i.e. n lon pa ched o ilob la h ead can
be e ed p o ided ha e i ance i fel hen he locking po ion en e he female h ead.

N lon pa ched bol and c e ha e a locking agen ei he applied o, o in e ed in he h eaded po ion. The a e
iden ified b he p e ence of a colo ed ec ion of h ead e ending app o ima el 180 deg ee a o nd he h ead o
b a colo ed pl g in e ed in o he bol .

T ilob la bol ha e a pecial h ead fo m hich c ea e a ligh in e fe ence i h he h ead of he hole o n in o

hich i i c e ed.

cardiagn.com
C AUTION: Do No e e elf-locking fa ene in c i ical loca ion e.g. d i e pla e /fl heel o engine bea ing .
Do no in all non elf-locking fa ene he e a elf-locking fa ene i pecified.

T ilob la bol ho ld no be ed a a b i e fo pa ched bol .

N. iden ifica ion

A n i h an ISO me ic h ead i ma ked on one face o one of he he agonal fla i h he eng h g ade mbol
8, 12, 14. Some n i h he eng h g ade 4, 5 o 6 a e al o ma ked and ome ha e he me ic mbol M on he
he agonal fla oppo i e he eng h g ade ma king.

A clock face em i ome ime ed a an al e na i e me hod of indica ing he eng h g ade. The e e nal
chamfe o a face of he n i ma ked in a po i ion ela i e o he app op ia e ho ma k on a clock face o indica e
he eng h g ade.

A do i ed o loca e he 12 o'clock po i ion and a da h o indica e he eng h g ade. If he g ade i abo e 12, o
do iden if he 12 o'clock po i ion.

When igh ening a lo ed o ca ella ed n , ne e loo en i o in e a pli pin e cep he e pecified a pa of an

adj men p oced e. If diffic l i e pe ienced in co ec l po i ioning he lo , al e na i e a he o n ho ld
be elec ed.

Whe e a n i igh ened o adj o main ain bea ing p e-load, he igh ening p oced e m be adhe ed o.

Self-locking n
Unless stated otherwise, self-locking nuts once removed must be discarded and new nuts of the same t. pe and
strength grade installed.

Air S. spension

Alwa s make sure that suitable e e protection is worn when working on the air suspension s stem.

Ball and Roller Bearings

cardiagn.com
When removing and installing bearings, make sure that the following practices are observed to make sure component
serviceabilit :

C AUTION: Service tools have been developed for removing the majorit of bearings; these must alwa s be
used where specified.

Remove all traces from bearing under inspection b cleaning with a suitable degreasant; maintain absolute
cleanliness throughout operations.
C onduct a visual inspection for markings on rolling elements, racewa s, outer surfaces of outer or inner
surfaces of inner rings. Reject an bearings found to be marked since marking in these areas indicates onset
of wear.
Hold inner race of bearing between finger and thumb of one hand and rotate outer race to check that it
revolves absolutel smoothl . Repeat holding outer race and rotating inner race. DO NOT spin the bearing.
Rotate outer ring gentl using a reciprocating movement whilst holding inner ring; feel for an check or
obstruction to rotation. Reject bearing if movement is not absolutel smooth.
C heck bearing for blueing or signs of overheating.
Lubricate bearing with the specified lubricant.
Inspect bearing surface of shaft and bearing housing for discoloration or other markings which indicate
overheating of bearing or movement between bearing and seating.
Before installing bearing, make sure that shaft and bearing housing are clean and free from burrs.
If one bearing of a pair shows signs of wear, overheating etc., it is advisable to replace bearings as a pair
unless it is suspected that one bearing ma have been fault when installed, was installed incorrectl or the
fault arose due to oil seal failure.
Never reinstall a bearing unless it is in a full serviceable condition.

When installing a bearing to a shaft, onl appl force to the inner ring of the bearing. When installing a bearing
into a housing, onl appl force to the outer ring of the bearing.
 C AUTION: S. ;
.

I ,
.

C AUTION: W ( ) ,
.

A . .
.N
, .

Brake Pads and Linings

A .W ,
.

Brake H. draulics

A :

WARNING: D .

A .

cardiagn.com
M .
I
.
C .
D ,
.
D
.
D .
A .
U , .
A , .
C .
O .

Pipes and Hoses

W ,
:

P , .
O
.
A .
C .

WARNING: S .

C , , ;
.
C , .

C AUTION: I , , .,
.

W , ,
.
W , .
A , .
A .
A ,
.
Fuel s. stem hoses

All fuel hoses are made up of two laminations, an armored rubber outer sleeve and an inner viton core. Whenever a
hose is removed, make sure that the inner bore is inspected to check that the viton lining has not become separated
from the outer sleeve.

WARNING: Never attempt to repair fuel foses or rectif leaking 'quick-fit' connectors the fuel hose and
connectors must be replaced as an assembl .

cardiagn.com
Fuel s stem hose clips

C ertain fuel s stem hose clips are of the 'break-off head' t pe where a slot in the screw head shears off when the clip
is tightened to a specific torque. These clips ma be removed using a screwdriver and must be replaced with new
clips on reassembl . C lips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips b
an other method, do not install an other t pe of clip.

C ooling s stem hoses

C AUTION: The following precautions must be observed to make sure that the integrit of the cooling s stem
hoses and their connection to the s stem is maintained.

Hose orientation and connection

C orrect orientation of cooling s stem hoses is important to make sure that hoses do not become fatigued or damaged
through contact with adjacent components.
Whe.e o ien a ion ma k a e p o ided on he ho e and co e ponding componen , he ma k m be aligned hen
he ho e i in alled. Ho e m be in alled f ll on o hei connec ion poin , all a mo lded fo m on a pipe
p o ide a po i i e indica o .

Ho e clip

cardiagn.com
Ma king a e all p o ided on he ho e o indica e he co ec clip po i ion. If no ma king a e p o ided, po i ion
he clip di ec l behind he e aining lip a he end of he b pipe. Wo m d i e clip ho ld be o ien a ed i h he
c imped ide of he d i e ho ing facing o a d he end of he ho e o he ho e ma become pinched be een he
clip and he b pipe e aining lip. Unle o he i e a ed, o m d i e clip ho ld be igh ened o 3 Nm (2 lbf.f ).
Make e ha ho e clip do no fo l adjacen componen .

Oe ike clip ma be emo ed b bending he ag (a o ed) and elea ing he f ee end of he clip. C lip m no be
e ed. When in alling ne clip , make e clip i po i ioned on ho e befo e igh ening and make e ha hen
clip i igh ened, he ag i loca ed in he longi dinal lo in he f ee end of he clip (a o ed in ill a ion).

Hea p o ec ion

Al a make e ha hea hield and p o ec i e hea hing a e in good condi ion; eplace if damage i e iden .
Pa ic la ca e m be aken hen o ing ho e clo e o ho engine componen ch a he e ha manifold and
e. ha ga eci c a i (EGR) i e . H e i ea a d def ec igh he h , a e e hi e e i
a e i acc he i g a d ec i gh e .

Electrical Precautions

General

The f i g g ide i e a e i e ded a e e he afe f he e a hi e e i g da age he

e ec ica a d e ec ic c e f hi ehic e.

Equipment

P i c e ci g a e ced e he ehic e, a e e ha he e e a e e i e i i g
c ec a d ha a ha e c ec a e i g d c di i . I i a ic a i a chec he c di i
fa g a d ead f ai e a ed e i e .

P olarit.

Ne e e e e c ec he ehic e ba e a da a a e e he c ec a i he c ec i g e
e i e .

High voltage circuits

Whe e e di c ec i g i e h ci c i , a a e i a ed ie a d e e a he e e d f he h ead
c ac he c e , a ic a EC U' .

Vehicles installed w ith Bi-Xenon headlamp bulbs

cardiagn.com
WARNING: The f i g eca i be b e ed a fai e c a e i e e a-
i e a , e e e e ec ic h c , b i fa e i .

Safe g gg e a d g e be .
Ma e e ha head a a e i ched ff bef e e i gb b .
D ch he g a i f he b b.
O acc h d head a be i ched i h he b b e ed f he head a .
B b e i g a be ca ied i h he b b i a ed i he head a .
B b be di ed f i acc da ce i h he ca a h i b e- a .

Connectors and harnesses

The e gi e c a e f a ehic e i a a ic a h ie e i e f e ec ica c e a dc ec .

A a b e e he f i g:

Ma e e e ec ica e a ed i e a e d a d i f ee bef e di c ec i g/c ec i g e e i e .

Ma e e ha di c ec ed i g a d e a e ec ed f a ib e i , c a he i id
c a i ai .A ch c a i ai c di ai e f a ce ead c e fai e.
Ne e f ce c ec a a he i i g ha e .
A a a e e c i g ab a e di e gaged bef e di c ec i g i g e c. a d a e e ha
c ec ie a i i achie ed bef e c ec i .
Ma e e ha a ec i c e ,i ai e c. a e e aced if di bed.

Ha i g c fi ed ha a c e i fa , ca he f i g:

S i ch ff he ig i i a d di c ec he ba e .
Re e he c e a d he di c ec ed ha e .
Whe e aci g e ec ica c e , ee i ha d a a f e ec ica c ec i a d a e e ha
c i g ab c ec a e f e gaged.

Batter Disconnection/ Connection

A a efe he E ec ica Sec i f hi a a - Ba e C ec i /Di c ec i i a e i g c ec

di c ec he ba e .
F addi i a i f a i , efe : S ecifica i (414-00 Ba e a d C ha gi g S e - Ge e a I f ai ,
S ecifica i ).

F uel Handling Precautions

The f i gi f ai i ba ic eca i hich be b e ed if f e i be ha d ed afe . I a i e

he a ea f i hich be ig ed. A hi i f ai i i ed f ba ic g ida ce ,c ca
Fi e De a e he e a d b a e a a de i e a afe e i - See a Hea h a d Safe
P eca i .
General precautions

Always have the correct type of fire extinguisher containing Foam, C O2, Gas or powder accessible when handling or
draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.

Make sure that suitable warning signs are exhibited.

Keep all sources of ignition well away from areas where fuel is being handled.

Make sure that any leadlamps are flameproof and kept clear of spillage.

̀ WARNINGS:

Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.

No one should be permitted to repair components associated with fuel without first having specialist training.

Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel
system.

Fuel tank and system draining

Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this
manual.

̀ WARNINGS:

cardiagn.com
Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel must be
carried out in a well ventilated area.

Always attach fuel vapor warning labels to fuel tanks immediately after draining.

C ontainers used for storing fuel must be clearly marked with the contents and placed in a safe storage area
which meets the requirements of the local authority.

C AUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged, no
attempt must be made to repair the connector, a new fuel line and connector(s) assembly must be installed.

Always release pipe clips fully before attempting to disconnect fuel pipes.

F. el ank epai

C AUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a
new tank must be installed.

Oil eal

Never use a seal which has been improperly stored or handled.

Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
C arefully examine seal before installing to make sure that it is clean and undamaged.
Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs or
scratches. Renew the component if the sealing surface cannot be restored.
Special tools and protection sleeves are provided for installing the majority of seals and must be used when
specified.
Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing. Always
check the relevant repair procedure which will state if a seal must be installed dry. Never touch these seals
with oily hands as the oil will contaminate the protective coating and affect the sealing properties of the seal;
also, make sure that installing tools and protection sleeves are free from oil and grease. Seals which must be
lubricated prior to installing should have the recommended lubricant applied to the areas specified in the repair
procedure.
Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards the
lubricant which it is sealing.
When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to be
installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported shaft
to rest on the seal.
 Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified, use
a suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use
adhesive tape on the shaft to protect the sealing lip of the seal.

cardiagn.com
Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the
housing where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.

S. pplem en a Re ain S em (SRS) P eca ion

WARNING: Do not install rear facing child seats in the front passenger seat.

The SRS contains components which are potentially hazardous to service personnel if not handled correctly. The
following guidelines and precautions are intended to alert personnel to potential sources of danger and emphasise the
importance of ensuring the integrity of the SRS components installed to the vehicle.

WARNING: The following precautions MUST be adhered to when working on the SRS system:

T he c o e c p o c e d e m al a be e d he n o k ing o n SRS c o m p o ne n .
Pe on o k ing o n he SRS em m b e f ll a ine d a nd ha e b e e n i e d i h he a f e
g id e line .
T he a i b a g m o d le c o n a in e e m e l f la m m a b le a nd ha a d o c o m p o nd . Co n a c i h a e ,
a c id o he a m e a l m a p o d c e ha m f l o e p lo i e e l . Do no d i m a n le , inc ine a e o
b ing in o c o n a c i h e le c ic i b e f o e he ni ha b e e n d e p lo e d .
Al a e p la c e a e a b e l a e m b l ha ha i h o o d he a in o f a e e e e hic le im p a c o if
he e b b ing ho ig n o f f a ing .
Al a d i c o nne c he e hic le b a e befo e ca ing o a n e le c ic e ld ing o n a e hic le
in a lle d i h a n SRS em.

C AUTION: Do not expose airbag modules or seat belt pre-tensioners to temperatures exceeding 85 C (185 F).

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:

Steering wheel airbag, rotary coupler.

 Passenger front airbag.
Head airbag modules - front and rear.
Seat belt pre-tensioners.
SRS harnesses, link leads and connectors.
Side (thorax) air bags.

Making the system safe

Before working on or in the vicinity of SRS components, make sure the system is rendered safe by performing the
following operations:

Remove the ignition key.

Disconnect battery, earth lead first.
Wait 2 minutes for the SRS power circuit to discharge before commencing work.

̀ NOTE: The SRS uses energy reserve capacitors to keep the system active in the event of electrical supply failure
under crash conditions. It is necessary to allow the capacitors sufficient time to discharge (2 minutes) in order to
avoid the risk of accidental deployment.

Installation

In order to make sure 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. C arefully 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 the SRS systems is critical for safety reasons. Make sure the following precautions
are always adhered to:

cardiagn.com
Do no t ins ta ll a c c e s s o r ie s o r o the r o b j e c ts to tr im p a ne ls whic h c o v e r I T S a ir b a g s .
Ne v e r ins ta ll us e d SRS c o m p o ne nts f r o m a no the r v e hic le o r a tte m p t to r e p a ir a n SRS c o m p o ne nt.
W he n r e p a ir ing a n SRS s y s te m , o nly us e g e nuine ne w p a r ts .
Ne v e r a p p ly e le c tr ic a l p o we r to a n SRS c o m p o ne nt unle s s ins tr uc te d to d o s o a s p a r t o f a n
a p p r o v e d te s t p r o c e d ur e .
Sp e c ia l f ix ing s a r e ne c e s s a r y f o r ins ta lling a n a ir b a g m o d ule . d o no t us e o the r f ix ing s a nd m a k e
s ur e tha t a ll f ix ing s a r e tig hte ne d to the c o r r e c t to r q ue .
A lwa y s us e ne w f ix ing s whe n r e p la c ing a n SRS c o m p o ne nt.

̀ C AUTIONS:

Take care not to trap airbag modules when installing interior trim components.

Make sure SRS components are not contaminated by oil or grease.

̀ NOTE: Following seat belt pre-tensioner deployment, the seat belts can still be used as conventional seat belts but
will need to be replaced as soon as possible to make sure full SRS protection.

̀ NOTE: If the SRS components are to be replaced, the part number/bar code of the new unit must be recorded.

SRS component testing precautions

The SRS components are triggered using relatively low operating currents, always adhere to the following :

WARNING: Never use a multimeter or other general purpose equipment on SRS components. Use only T4 to
diagnose system faults.
 WARNING: D. SRS SRS
, .

A SRS :

cardiagn.com
N SRS .T
.A -
.
N .I ,
.
N - .A
- .
N .D
.
A , .
N - , .
A .I ,
.
K .P
.
̀ WARNINGS:

When handling an inflatable tubular structure (ITS) airbag module, hold by the gas generator housing, DO NOT
hold by the airbag. Do not wrap the thumb around the gas generator while holding. Do not drape airbag over
shoulder or around neck. For 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 type pre-tensioners by the bracket assembly or cable. Never point the piston tube towards
your body or other people.

cardiagn.com
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 with the local authority.

Store airbag modules or seat belt pre-tensioners in a designated storage area. If there is no designated storage
area available, store in the locked luggage compartment of the vehicle and inform the workshop supervisor.

C AUTION: 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.

SRS harness and connectors

Always observe the following precautions with regards to SRS system electrical wiring:

Never attempt to modify, splice or repair SRS wiring.

Never install electrical 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 wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe
protective coverings are sometimes used).
 WARNING: A. a a e e SRS i i gi ed c ec . Be ca ef a id a i g i chi g he SRS
i i g.

cardiagn.com
WARNING: D ea e he c ec ha gi g e a SRS c e ha g f hei ha e e .
L f ib e chafi g i .

Side i ac c a h e i ec i

Af e a deg ee f ide b d da age, i ec he ide i ac c a h e . Re ace a c a h e if he e i a

ig f da age.

C AUTION: Ta e e a ca e he ai i g ca i g b d e ai i he ici i f he c a h e .
A id di ec e e f he c a h e iha e e hea g , e di g a i ge i e . Ta e ca e
da age e ha e he ei a i gc e .

R a c e

C AUTION: A a f he ced e f i a i g a d chec i g he a c e a i c ed i he SRS

e ai ec i . C iha afe a d i a ai ced e a e e he e f ci c ec .
Ob e e he f i g eca i :

D a dc a e he a c e he i i e ed f he ehic e.
D he ad hee he he a c e i e ed f he ehic e.
A a a e e he a c e i e ed a d i a ed i i ce a ii a d i h he f ad
hee i he aigh ahead ii - efe SRS e ai ec i f he c ec e a a di a ai
ced e.
If a e a c e i bei g i a ed, a e e he c i g ab h di g he c e ' ai a ii i
b e ; i ihab e c i g ab be ed.

Ai bag ca i abe

WAITING AIRBAG LOC ATION AND DESIGN LABELS - DUE MARC H - NEIL HARRISON 46404

Airbag and pre-tensioner deplo. m ent

 WARNING: During deployment parts of the airbag module become hot enough to burn you. Wait 30 minutes
after deployment before touching the airbag module.

Deployment procedures and precautions as detailed in this manual should be strictly adhered to. Only personnel who
have undergone the appropriate training should undertake deployment of airbag and pre-tensioner modules. The
following precautions must be complied with:

Only use deployment equipment approved for the intended purpose.

Deployment of airbag / pre-tensioner modules must be performed in a well ventilated area which has been
designated for the purpose.
Make sure airbag / pre-tensioner modules are not damaged or ruptured before attempting to deploy.
Where local legislation exists, notify the relevant authorities of intention to deploy airbag and pretensioner
units.
When deploying airbag pre-tensioner units, make sure that all personnel are at least 15 metres (45 feet) away
from the deployment zone.
Make sure deployment tool is connected correctly, in compliance with the instructions detailed in the SRS
section of this manual. In particular, make sure deployment tool is NOT connected to battery supply before
connecting to airbag module connector.
When deploying seat belt pre-tensioners, make sure pre-tensioner unit is secured correctly to the seat.
When removing deployed airbag modules and pre-tensioner units, wear protective clothing. Use gloves and
seal deployed units in a plastic bag.
Following deployment of any component of the SRS system within the vehicle, all SRS components must be
replaced. DO NOT reuse or salvage any parts of the SRS system.
Do not lean over an airbag module when connecting deployment equipment.

If a vehicle is to be scrapped, undeployed airbag modules and pre-tensioner units must be manually deployed. In this

cardiagn.com
case airbags can be deployed in the vehicle. Before deployment, make sure the airbag module is secure within its
correct mounting position. Deployment of the driver's airbag in the vehicle may damage the steering wheel; if the
vehicle is not being scrapped, deploy the module outside of the vehicle.

SRS Com ponen. Replacem en Polic

̀ C AUTIONS:

The Restraints C ontrol Module (RC M) will log a crash fault after every impact which is severe enough to cause
airbag deployment. I i p o ib le o ha e h e e c a he / im p a c lo g g e d a f e o ne e e n he e , f o
e a m p le , a f o n , id e a nd o llo e ha o c c e d . A f e he hi d f a l i lo g g e d , he SRS a ning la m p
ill b e ill m ina e d a nd he e a in con ol m o d le (RCM) m b e e p la c e d .

The SRS side impact sensor must be replaced if there are any signs of physical damage or if the restraints
control module (RC M) is registering a fault.

The following information details the policy for replacement of SRS components as a result of a vehicle accident.

Impac hic h d o no d e p lo he a i b a g o p e - e n io ne

C heck for structural damage in the area of the impact paying particular attention to bumper armatures, longitudinals
and bracketry.

Impac hic h d e p lo he a i b a g o p e - e n io ne

The replacement and inspection policy is dependent on the type and severity of the crash condition. The following
guidelines are the minimum that should be exercised as a result of the deployment of specific SRS components.

Che c k f o c a l d a m a g e in he a e a o f im p a c p a ing p a ic la a e n io n o b m p e a ma e ,
lo ng i d ina l a nd b a c k e .

F on Ai bag Deplo m en - D i e and Pa enge

C AUTION: If the front airbags are deployed, the following components must be replaced:

Driver airbag module

Passenger airbag module
Fly leads (where applicable) connecting front airbag modules to SRS harness
Front seat belt buckle pre-tensioner
Rear seat belt pre-tensioners - if installed
Driver's seat belt retractor - if installed
Rotary coupler
Any front impact sensors that have been physically damaged or if a fault is being registered
 Re. ain con ol mod le (RC M) if he h ee c a he /impac ha e been o ed

A d d itio na ll. , the f o llo wing ite m s m us t b e ins p e c te d f o r d a m a g e a nd r e p la c e d a s ne c e s s a r :

F on pa enge ' ea bel e ac o and ebbing, ong e la ching f nc ion, 'D' loop and bod ancho age poin
Rea ea bel b ckle , ebbing, b ckle co e , bod ancho age poin and ong e la ching f nc ion
Fa cia mo lding adjacen o pa enge ai bag mod le
S ee ing heel
F on ea f ame and head e ain
S ee ing col mn - if adj men i lo o if he e a e ign of collap e
Sea bel heigh adj e
Rea ea bel

Side Ai Bag

C AUTION: If he ide ( ho a ) ai bag a e deplo ed, he follo ing componen m be eplaced on he ide of
he ehicle on hich he deplo men occ ed:

Side ( ho a ) ai bag
An ide impac en o ha ha e been ph icall damaged o if a fa l i being egi e ed
Re ain C on ol Mod le (RC M) if he h ee c a he /impac ha e been o ed

A d d itio na ll , the f o llo wing ite m s m us t b e ins p e c te d f o r d a m a g e a nd r e p la c e d a s ne c e s s a r :

F on ea bel , e ac o and ebbing, ong e la ching f nc ion, 'D' loop and bod ancho age poin
Rea ea bel b ckle , ebbing, b ckle co e , ong e la ching f nc ion, and bod ancho age poin
F on ea f ame and head e ain

cardiagn.com
Doo im ca ing
Sea bel heigh adj e
Rea ea bel

Head ai bag mod le

C AUTION: If he head ai bag mod le a e deplo ed, he follo ing componen m be eplaced on he ide of
he ehicle on hich he deplo men occ ed:

Head ai bag mod le

Link lead be een ai bag ga gene a o and e ain con ol mod le (RC M) ha ne
Ai bag e aining clip
In e nal im fini he
F on ea bel b ckle p e- en ione
An ide impac en o ha ha e been ph icall damaged o if a fa l i being egi e ed
Re ain C on ol Mod le (RC M) if he h ee c a he /impac ha e been o ed

A d d itio na ll , the f o llo wing ite m s m us t b e ins p e c te d f o r d a m a g e a nd r e p la c e d a s ne c e s s a r :

Headlining
C omponen mo n ing b acke
F on ea bel , e ac o and ebbing, ong e la ching f nc ion, 'D' loop and bod ancho age poin
Rea ea bel b ckle , ebbing, b ckle co e , ong e la ching f nc ion, and bod ancho age poin
Adjacen im componen
Sea bel heigh adj e

Rea impac

C AUTION: If he ea bel p e- en ione a e deplo ed d ing a ea impac , he follo ing componen m be

eplaced:

Sea bel p e- en ione

F on and ea ea bel e ac o ed d ing he impac
Re ain C on ol Mod le (RC M) if he h ee c a he /impac ha e been o ed

A d d itio na ll , the f o llo wing ite m s m us t b e ins p e c te d f o r d a m a g e a nd r e p la c e d a s ne c e s s a r :

Sea bel heigh adj e

F on ea bel , e ac o and ebbing, ong e la ching f nc ion, 'D' loop and bod ancho age poin
Rea ea bel b ckle , ebbing, b ckle co e , ong e la ching f nc ion, and bod ancho age poin

Air Conditioning S stem Precautions

The ai condi ioning em con ain fl id and componen hich co ld be po en iall ha a do o he e ice
engineer or the environment if not serviced and 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 the Air
C onditioning operating conditions and components installed to the vehicle.

Where necessary, additional specific precautions are detailed in the relevant sections of this Manual and also in the
Health and Safety Section. These precautions must be referred to prior to commencing repair operations.

The refrigerant used in the air conditioning system is HFC -134a (Hydrofluorocarbon) R134a.

̀ WARNINGS:

Servicing must only be carried out by personnel familiar with both the vehicle system and the charging and
testing equipment. All operations must be carried out in a well ventilated area away from open flame and heat
sources.

R134a is a hazardous liquid and when handled incorrectly can cause serious injury. Suitable protective clothing,
consisting of face protection, heat proof gloves, rubber boots and rubber apron or waterproof overalls, must be worn
when carrying out operations on the air conditioning system.

Remedial actions

WARNING: Due to its low evaporating temperature, R134a must be handled with care. R134a splashed on any
part of the body will cause immediate freezing of that area. Also, refrigerant cylinders and replenishment trolleys
when discharging will freeze skin to them if contact is made.

cardiagn.com
If an accident involving R134a should occur, conduct the following remedial actions:

If liquid R134a enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise
the temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing,
cover the eye with a clean pad and seek immediate medical attention.
If liquid R134a is splashed onto the skin, run large quantities of water over the affected area to raise the
temperature. Implement the same action if the skin comes in contact with discharging cylinders. Wrap the
contaminated body parts in blankets (or similar materials) and seek immediate medical attention.
If the debilitating effects of inhalation of R134a vapour are suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated area to fresh air and apply artificial respiration and/or
oxygen and seek immediate medical attention.

Service precautions

Observe the following precautions when handling components used in the air conditioning system:

Air conditioning units must not be lifted by their hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by
kinks or restrictions. Make sure that hoses are correctly positioned before tightening couplings, and make sure
that all clips and supports are utilised.
Flexible hoses should not be positioned closer than 100 mm (4.0 in) to the exhaust manifold unless protected
by heat shielding.
C ompleted assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of
components and panels may transmit noise and so must be eliminated.
The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value.
An additional spanner must be used to hold the union to prevent twisting of the pipe when tightening
connections.
Before connecting any hose or pipe, make sure that refrigerant oil is applied to the seat of the new O-rings,
B. NO to the threads of the connection.
All protective plugs or caps must remain in place in the component until immediately prior to connection.
Make sure components are at room temperature before uncapping/unplugging, to prevent condensation of
moisture from the air that enters it.
When disconnecting, immediately plug or cap all air conditioning pipes to prevent ingress of dirt and moisture
into the system.
C omponents must not remain uncapped/unplugged, if a system has been left uncapped/unplugged for 20
minutes or longer, a new receiver/drier must be installed.
The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A
receiver/drier that has been left uncapped for longer than 20 minutes must not be used; install a new unit.
The receiver/drier should be the last component connected to the system to make sure optimum dehydration
and maximum moisture protection of the system.
Whenever a component of the refrigeration system is replaced, it will also be necessary to install a new
receiver/drier unit.
Use alcohol and a clean lint-free cloth to clean dirty connections.
Make sure that all new parts installed are marked for use with R134a.
When a major repair has been completed, a leak test should be conducted; refer to the Repairs Section of this
 manual for the correct procedure.

Refrigerant oil

C AUTION: Refrigerant oil easily absorbs water and must not be stored for long periods. Do not pour unused
refrigerant oil back into the container. Always use an approved refrigerant oil.

When replacing components in the air conditioning system, drain the refrigerant oil from the component being
replaced into a graduated container. On assembly, add the quantity of refrigerant oil drained to the new component -
See Air C onditioning C ompressor Replacement in this Section.

C ompressor

A new compressor is sealed and pressurised with Nitrogen gas. When installing a new compressor, slowly release the
sealing cap; gas pressure should be heard to vent as the seal is broken.

C AUTION: A new compressor should always be sealed and could be pressurised with nitrogen gas. To avoid
possible oil loss, release the sealing cap(s) slowly. Do not remove the cap(s) until immediately prior to connecting the
air conditioning pipes to the compressor.

Rapid refrigerant discharge

If the air conditioning system is involved in accident damage and the system is punctured, the refrigerant will
discharge rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The
compressor must be removed and all the remaining oil in the compressor drained and refilled as instructed in the air
conditioning section of this manual.

cardiagn.com
Precautions for refrigerant recovery, recycling and recharging

When the air conditioning system is recharged, any existing refrigerant is first recovered from the system and
recycled. The system is then charged with the required weight of refrigerant and volume of refrigerant oil.

WARNING: Refrigerant must always be recycled before reuse to make sure that the purity of the refrigerant is
high enough for safe use in the air conditioning system. Recycling should always be carried out with equipment which
is design certified by Underwriter Laboratory Inc. for compliance with SAE J1991. Other equipment may not recycle
refrigerant to the required level of purity.

• C AUTIONS:

A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type of
refrigerant. Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle air
conditioning systems.

The system must be evacuated immediately before recharging commences. Delay between evacuation and
recharging is not permitted.

Air C onditioning C ompressor Replacement

A new compressor is supplied filled with a full charge (X cm. ) of refrigerant oil.

A calculated quantity of oil must be drained from the new compressor before installing. To calculate the quantity of oil
to be drained:

Remove the drain plug from the old compressor.

Invert the compressor and gravity drain the oil into a calibrated measuring cylinder. Rotate the compressor
clutch to make sure the compressor is completely drained.
Note the quantity of oil drained (Y cm ).
C alculate the quantity of oil to be drained from the new compressor using the following formula:X c m . — (Y
c m + 20 c m ) = Q c m
Remove the drain plug from the new compressor and drain Q cm3 of oil. install and tighten the compressor
drain plug.

Vehicle Weights

I te m kg lb
Ma x im um Gr o s s Ve hic le W e ig ht (GVW )
Petrol engine vehicles naturally aspirated 3070 6768
Petrol engine vehicles supercharged 3125 6889
Diesel engine vehicles 3070 6768
Ma . im m e ig h o f nb a k e d a ile :
On-road 750 1650
Off-road 750 1650
Ma im m o a b le e ig h (m a ) - T a ile i h o e n b ake
On-road 3500 7700
Off-road 1000 2205
Ma im m o o f a c k lo a d (I nc l d ing he m a o f he oof a c k ):
On-road 75 110
Off-road 75 110
Vehicle Dimen ion
I em mm in
Length - including number plate plinth - All models 4798 188.9
W id h - A ll m o d e l :
Mirrors extended 2170 85.4
Mirrors folded 1983 78.1
Ma im m he ig h - A a nd a d id e he ig h - A ll m o d e l :
With roof rack and rails 1784 70.2
With roof antenna module 1812 71.3
With sunroof open 1817 71.5
Wheelbase - All models 2745 108
Front overhang - All models 880 45.8
Rear overhang - All models 1163 44.5

cardiagn.com
T a c k - A ll m o d e l :
Front 1605 63.2
Rear 1612 63.5
Und e b o d Cle a e nc e :
Standard ride height - Running clearance to exhaust - Minimum - Kerb weight 172 6.8
Standard ride height - Ground to front undertray clearance 188 7.4
Standard ride height - Ground to rear differential casing clearance 200 7.9
Off-road height - Running clearance to exhaust - Minimum - Kerb weight 227 8.9
Off-road height - Ground to front undertray clearance 243 9.6
Off-road height - Ground to rear differential casing clearance 255 10
S p e n io n a ic la io n - A ll m o d e l :
Front 255 10.03
Rear 310 12.2
De p a e a ng le - T o b a NOT in a lle d :
Standard ride height with full size spare wheel 24.1 24.1
Standard ride height with space saver wheel 26 26
Off-road height with full size spare wheel 27.4 27.4
Off-road height with full space saver wheel 29 29
De p a e a ng le - T o b a in a lle d - NOT NA S e hic le :
Standard ride height 15.1 15.1
Off-road ride height 17.8 17.8
De p a e a ng le - T o b a in a lle d - NA S e hic le :
Standard ride height 13.9 13.9
Off-road ride height 16.9 16.9
De p a e a ng le - A d j a b le he ig h o b a in a lle d :
Standard ride height 13.3 13.3
Off-road ride height 16 16
W a d ing d e p h:
Off-road height 700 27.5
A p p o a c h a ng le :
Standard ride height 30.2 30.2
Off-road ride height 34 34
Ra m p a ng le :
Standard ride height 20 20
Off-road ride height 25 25
 Published: 11-May-2011
General Infor mation - Health and Safet. P recaution s
Description and Operation

Introduction

Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal
health and the environment. Also, many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health.

This subsection lists some of these hazardous operations and the materials and equipment associated with them.
Precautions necessary to avoid these hazards are identified.

The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with
health and safety in mind.

Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier should be
consulted.

WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no
circumstances be consumed and should, as far as possible, be kept from contact with the skin. These liquids and
substances include acid, anti-freeze, brake fluid, fuel, windscreen washer additives, lubricants, refrigerants and
various adhesives.

Acids and Alkalis

cardiagn.com
For example - alkalis such as caustic soda used in cleaning materials; acids such as sulphuric acid used in batteries.

Both alkalis and acids are irritant and corrosive to the skin, eyes, nose and throat. They cause burns and can destroy
ordinary protective clothing.

Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not
breath mists.

Make sure access to eye wash bottles, shower and soap are readily available for splashing accidents.

Display Eye Hazard sign.

Air Bags

Highly flammable, explosive ̀ observe No Smoking policy.

Used within the vehicle as safety restraints.

The inflator contains a high-energy propellant which, when ignited, produces a VERY HOT GAS (2500°C ).

The gas inflator (generator) used in air bags is Sodium Azide. This material is hermetically sealed in each air bag
module and is completely consumed during deployment. No attempt should be made to open an air bag inflator as
this will lead to the risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage.

After normal deployment, gloves and safety goggles should be worn during the handling process.

Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical
waste site.

F o llo wing a n d ir e c t c o nta c t with So d ium A id e :

Wash affected areas thoroughly with water.

SEEK I MMEDI A T E MEDI CA L A SSI ST A NCE.

A ir Ba g s - Do 's

Do store modules in an upright position.

Do keep modules dry.
Do carry modules with the cover side pointing away from the body.
Do place modules with their cover side upwards.
Do carefully inspect modules for damage.
Do stand to one side when connecting modules.
Do make sure all test equipment is properly calibrated and maintained.
Do wash hands after handling deployed air bags.
A ir Ba g s - Do No t

Do Not store highly flammable material together with modules or gas generators.
Do Not store gas generators at temperatures exceeding 80°C .
Do Not store modules upside down.
Do Not attempt to open a gas generator housing.
Do Not expose gas generators to open flame or sources of heat.
Do Not place anything on top of a module cover.
Do Not use damaged modules.
Do Not touch a fired module or gas generator for at least 10 minutes after firing.
Do Not use any electrical probes on the wiring circuit.

Air Suspension

Whenever work is being undertaken on the air suspension system, suitable eye protection must be worn.

Air Conditioning Refrigerant

Highly flammable, combustible ̀ observe No Smoking policy.

Skin contact may result in frostbite.

Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and
goggles.

If refrigerant comes into contact with the skin or eyes, rinse the affected areas with water immediately. Eyes should
also be rinsed with an appropriate irrigation solution such as a solution of 9% Sodium C hloride and Purified Water. DO

cardiagn.com
NOT RUB T HE EY ES A ND SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

Air Conditioning Refrigerant

Do No t

Do Not expose refrigerant bottles to sunlight or heat.

Do Not expose refrigerant bottles to frost.
Do Not drop refrigerant bottles.
Do Not vent refrigerant to atmosphere under any circumstance.
Do Not mix refrigerants.

Adhesiv es and Sealants

Many adhesives and sealants are highly flammable ̀ OBSERVE NO SMOKING POLIC Y. These items, should be stored
in flameproof cabinets in No Smoking areas. C leanliness and tidiness in use should be observed, for example
disposable paper covering benches. All adhesives and sealants should be dispensed from applicators where possible;
containers, including secondary containers, should be labelled appropriately.

Anaerobic, C. anoacr late ( super-glues) and other Acr lic Adhesives

Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye irritants.

Skin and eye contact should be avoided and the manufacturer's instructions followed.

C yanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover
with a clean moist pad and SEEK I MMEDI A T E MEDI CA L A T T ENT I ON. Do not attempt to pull skin tissue apart. Use
in well ventilated areas as vapors can cause irritation to the nose and eyes.

For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.

Solvent-based Adhesives/ Sealers - See Solvents

Follow manufacturers instructions.

W ater-based Adhesives/ Sealers

Those based on polymer emulsions and rubber/latex may contain small amounts of volatile, toxic and harmful
chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Hot Melt Adhesives

In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the
inhalation of toxic fumes.

Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut-out and adequate
e. ac i .

Resin-based Adhesives/ Sealers, for e. ample Epo ide and Formaldeh de Resin-based

Mi i g h d be ca ied i e e i a ed a ea a ha f ic a i e che ica a be e ea ed.

S i c ac ih c ed e i a d ha de e ca e i i iai , de a i i , a d ab i f ic ha f
che ica h gh he i . S a he ca da age he e e .

P ide ade ae e ia i a da id i a de e c ac .

Isoc anate ( P ol urethane) Adhesives/ Sealers

See a Re i -ba ed Adhe i e

I di id a ffe i g f a h a e i a a e gie h d ih ea he e a e ia a e ii i
eac i ca cc .

O e e e i i iai g he e e a d e i a e . E ce i e c ce a i a d ce effec he
e e i c di g d i e . I e e e ca e , fc ci e a e .L g e e e
a c ce a i a e i ad e e hea h effec .

P ged c ac i h he i a ead i i iai a di e ca e , de aii .

S a he e e i g he e e i ca e di c f a d ib e da age.

A a i g h d efe ab be ca ied i e i a ed b h hich i c a e faci i ie f e i g a

a d a d e f he b ea hi g e.

cardiagn.com
Wea a ia e g e ,e e a d e i a ec i .

Antifree e

Ma be f a ab e he di ed.

Va a be gi e ff f c a a if ee e he hea ed. A id b ea hi g he e a .

A if ee e a be ab bed h gh he i i ic ha f a i ie . A if ee e, if a ed, ca be fa a ;
SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

Batter Acids

See a A a i a d Acid .

Ga e e ea ed d i g ba e cha gi g a e e i e. A a e e he ba e f he ehic e i cha gi g.

Ne e e a ed f a e a a ea cha gi g ece cha ged ba e ie . NEVER add acid a ba e ,
he che ica eac i d ced i be i e a d e i e. I ca e fe e c ac , a h affec ed a ea i h c i
a f a e a d SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

Ma e e he e i ade ae e ia i d i g ba e cha gi g, b e e NO SMOKING POLIC Y.

Brake Pads and Linings

A a fi he c ec g ade a d ecifica i fb a e ad a d i i g . Whe e e i g ad a d i i g , a a

e ace a c e e a e e .

Brake and Clutch F luid

S a he he i a d e e a e i i a i g a d i he g e ca be da agi g, a id ged i c ac . I
ca e fe e c ac , a h affec ed a ea i h c i a f a e a d SEEK IMMEDIATE MEDIC AL ATTENTION.

Chem ical Materials

A che ica a e ia h da a be ed i h ca i a d ed a d ha d ed i h ca e. The a be ic,

ha f , c i e, i i a high fa ab e a d gi e i e ha a d f e a dd .

The effec f e ce i e e e che ica a be i edia e de a ed; b ief e e ie ced e a e ;

c a i e; e ficia ; ife h ea e i g; a ed ce ife e ec a c .

Chemical Materials - Do's

D ca ef ead a d b e e ha a d a d eca i a i g gi e a e ia c ai e ( abe ) a d i

a acc a i g eaf e , e he i ci . Ma e ia hea h a d afe da a hee ca be
b ai ed f a fac e .
 Do remove chemical materials from the skin and clothing as soon as practicable after soiling. C hange heavily
soiled clothing and have it cleaned.
Do organise work practices and protective clothing to avoid soiling of the skin and eyes.
Do avoid breathing vapors, aerosols, dusts or fumes; inadequate container labelling; fire and explosion
hazards.
Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical
materials.
Do keep work areas clean, uncluttered and free of spills.
Do store chemical materials according to national and local regulations.
Do keep chemical materials out of the reach of children.

Che. ica Ma e ia -D N

Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other
toxic or harmful chemicals, give off toxic or harmful fumes or become explosive when mixed together.
Do Not spray chemical materials, particularly those based on solvents, in confined spaces, for example when
people are inside a vehicle.
Do Not apply heat or flame to chemical materials except under the manufacturers instructions. Some are
highly flammable and some may release toxic or harmful fumes.
Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations.
Some fumes are heavier than air and will accumulate in confined areas such as pits.
Do Not transfer chemical materials to unlabelled containers.
Do Not clean hands or clothing with chemicals. C hemicals, particularly solvents and fuels, will dry skin and
may cause irritation leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
Do Not use emptied containers for other materials except when they have been cleaned under supervised
conditions.
Do Not sniff or smell chemical materials, even brief exposure to high concentrations of fumes can be toxic or

cardiagn.com
harmful.

C i P ec i Ma e ia

Some corrosion protection materials are highly flammable ̀ observe NO SMOKING POLIC Y.

These materials are varied and the manufacturers instructions must always be followed. The materials may contain
solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces.

Dust or powder produced during repair operations may be irritant, harmful or toxic. Avoid breathing dusts from
powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is
inadequate.

Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and sources of ignition.

E ec ica E i e

Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good
condition.

Make sure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be
labelled and preferably removed from the work station.

Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. If using
cable reel extension equipment, ALWAYS ensure that the cable is fully unwound from the reel.

Make sure that electrical equipment and flexes do not come into contact with water.

Make sure that electrical equipment is protected by the correct rated fuse.

Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.

Make sure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.

Make sure that the designated electrical workers are trained in basic First Aid.

I ca e f e ec c i :

Switch off the power supply before approaching the victim.

If this is not possible, DO NOT T OUCH T HE VI CT I M but push or drag the person from the source of electricity
using dry, non-conductive material.
C ommence resuscitation if trained to do so.
SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.
E. haust F um es

The. e c ai a h ia i g, ha f a d ic che ica a d a ic e ch a ca b ide , i ge ide ,

a deh de , ead a d a a ic h d ca b . E gi e h d be de c di i f ade a e e ha
e ac i ge e a e i a i a d i c fi ed ace .

Gasoline ( P etrol) engine

The e a be ade ae a i g f d fi iai bef e ic ha f effec a i e. The e a be

i edia e de a ed.

Gas O il ( Diesel engine)

S , di c f a di iai a gi e ade ae a i g f ha a d f e c ce ai .

F ibre Insulation

The fib a e f face a d c edge ca ca e i i iai . Thi i a a h ica a d a che ica

effec .

P eca i h d be a e a id e ce i e i c ac h gh ca ef ga i a i f ac ice a d he
e fg e .

F ire

Ma f he a e ia f d a cia ed i h he e ai f ehic e a e high f a ab e. S e gi e ff ic

ha f f e if b ; he ch a f ea e he b da aged b e ce i e hea ca b ea d

cardiagn.com
a d d ce high c i e h d f ic acid - See F ea e .

Sh da a e ia be i a b e hea ed c di i , ha d e i h e e e ca i a d ea ec i e c hi g
he ha d i g ch i e . Di e f ch a e ia i acc da ce i h ca eg a i .

Dec a i a e a d di e f ec i e c hi g i edia e af e e.

Ob e e ic fi e afe he i g a d ha d i g f a ab e a e ia e , a ic a ea e ec ica
e i e e di g ce e .

Ma e e, bef e i g e ec ica e di g e i e , ha he e i fi e ha a d e e .

Ha e a i ab e fi e e i g i he a ai ab e he i g e di g hea i g e i e .

F irst Aid

A a f ee i g a ega e i e e i i de i ab e f e e i he h be ai ed i Fi Aid
ced e .

S a he i he e e h d be f hed ca ef i h c ea ae f a ea e i e .

S i ed i h d be a hed ih a a d ae .

I ca e fc db ,f a e ai e f e , ace affec ed a ea i c c d ae .

I di id a affec ed b i ha a i f ga e a d f e h d be e ed f e h ai i edia e . If effec e i ,

c ad c .

If i id a e a ed i ad e e ,c ad c gi i g hi he i f ai he c ai e abe . D
i d ce ii g e hi ac i i i dica ed he abe .

F luoroelastom ers (S nthetic Rubber)

Ma 'O' i g , ea , h e , f e ib e i e a d he i i a hich a ea be a fac ed f a a bbe

a e, i fac , ade f he ic a e ia ca ed F ea e .

U de a e a i g c di i , he e a e ia a e afe a d d c i e a hea h ha a d. H e e , if he
a e ia a e da aged b b i g e e e ce i e hea , he ca b ea d a d d ce high c i e
h d f ic acid.

WARNING: C ac ihh d f ic acid ca ca e e i b c ac i h he i . If i c ac d e

cc , ca he f i g e i edia e :

Re e a c a i a ed c hi g.

SEEK I MMEDI A T E MEDI CA L A T T ENT I ON

I. iga e affec ed a ea f i ihc i a fc d ae i e ae f 15 60 i e .

F oam s - Pol. urethane

U ed i da d i e i ai .C ed f a ed i ea a d i c hi i g.

U eac ed c e a e i iai ga d a be ha f he i a d e e . Wea g e a d g gg e .

I di id a i h ch ic e i a di ea e , a h a, b chia edica be , hi ie f a e gic di ea e

h d i ea c ed a e ia .

The c e , a a i ca ca e di ec i i a i , e ii i eac i a d a be ic ha f .

Va a d a i be i ha ed. The e a e ia be a ied i h ade a e e ia i a d

e i a ec i . D e e he e i a i edia e af e a i g, ai i he a / i ha e
c ea ed.

B i g f he c ed c e a d he c ed f a ca ge e a e ic a d ha f f e .S i g, a ed
fa e he e f e ec ica e i e d i gf a i g e ai a d i a / i ha e c ea ed h d
be a ed. A hea c i g f c ed f a a ia c ed f a h d be ca ied i a ea ha i g i ab e
f e e ac i e i e .

F uels

A id i c ac ihf e he e ib e. Sh dc ac cc , a h he affec ed i ih a a d ae .

Gasoline ( P etrol)

cardiagn.com
High fa ab e - OBSERVE NO SMOKING POLIC Y.

S a i g ga i e ( e ) ca e i ha d h a i iai a d ab i f he ach ca e i
d i e a d c ci e .S a a ca be fa a chi d e . I ha a i i he g , h gh i i g,
i a e e i ha a d.

Ga i e ( e ) d ie he i a d ca ca e i i a i a d ged e ea ed c ac a ca e de a i i ; if i
i a ed e e he e e , i i ca e e e e a i g. Wa h affec ed a ea i h c i a f ae a d
SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

Ga i e ( e ) a c ai a eciab e a i ie f be e e, hich i ic i ha a i a d he c ce a i
f a be e e . High c ce a i i ca e e e, e a d h a i i a i , a ea, headache,
de e i a d fd e e . Ve high c ce a i i e i a id fc ci e .

Ma e e he e i ade a e e i a i he ha d i g a d i g ga i e ( e ). G ea ca e be a e a id
he e i c e e ce f i ha a i i he e e f a b id a i i gf i age i c fi ed ace .

S ecia eca i a c ea i g a d ai e a ce e ai ga i e ( e ) age a .

Ga i e ( e ) h d be ed a a c ea i g age .I be i h ed b h.

Gas-oil ( Diesel Fuel)

C b ib e.

P ged i c ac i h high b i i g i ga i (die e f e ) a ca e e i i di de i c di g i

ca ce .

I ha a i i he g i ca e i e a b eedi g - SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

I f s wa llo we d , DO NOT ind uc e v o m iting - SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

Kerosene ( P araffin)

U ed a a hea i g f e , e a d c ea i g age .

Fa ab e - OBSERVE NO SMOKING POLIC Y.

I iai f he ha d h a a e f a i g. The ai ha a d f a i g a i e if i id
a i ai i he g cc .

Li id c ac d ie he i a d ca ca e i iai de a i i . S a he i he e e a be igh i i a i g.

I a ci c a ce he a ii d e gi e i e ha f a .E e i a d a f
e e e a e e a ed e e a e h d be a ided ( i a a i e i de a i g). A id i a de e c ac a d
a e e he e i ade a e e ia i .
I f s wa llo we d , DO NOT ind uc e v o m iting - SEEK I MMEDI A T E MEDI CA L A T T ENT I ON.

Gas C. linders

Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 138 bar
(13800 kPa) (2000 lbf/in. ) and great care should be taken in handling these cylinders to avoid mechanical damage to
them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings.

C ylinders should be stored in well ventilated enclosures, and protected from ice and snow or direct sunlight. Fuel
gases, for example acetylene and propane should not be stored in close proximity to oxygen cylinders.

C are should be exercised to prevent leaks from gas cylinders and lines and also to avoid sources of ignition.

Only trained personnel should undertake work involving gas cylinders.

General Workshop Tools and Equipm ent

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used
where required.

Never use tools or equipment for any purpose other than that for which they were designed. Never overload
equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not
always immediately apparent and may result in a fatal failure the next time that the equipment is used.

Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.

cardiagn.com
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.

Wear a suitable breathing mask when using abrasive blasting equipment or using spraying equipment.

Make sure there is adequate ventilation to control dusts, mists and fumes.

High Pressure Air, Lubrication and Oil Test Equipm ent

Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.

Never direct a high pressure nozzle, for example diesel injector, at the skin as the fluid may penetrate to the
underlying tissue and cause serious injury.

Jacking

Always refer to the Jacking and Lifting section of this manual prior to raising the vehicle off the ground.

When vehicle is to be raised by means of a jack, ensure that it is standing on level ground, that parking brake is
applied and wheels are chocked. ALWAYS use the recommended jacking points and ensure that vehicle jack has
sufficient load capacity for the weight of the vehicle.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety
stands.

Ensure that hoists have sufficient load capacity for the weight of the vehicle.

Legal Aspects

There are many laws and regulations relating to health and safety in the use and disposal of materials and equipment
in a workshop.

For a safe working environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and local authorities.

Lubricants and Greases

Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes
and skin.

U sed Engine O il

Prolonged and repeated contact with engine oil will result in the removal of natural fats from the skin, leading to
dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
D. e ed e gi e i a b ica f a a ica i he e a eciab e i c ac i i e cc .

Heal.h P o ec ion P eca ion

A id ged a d e ea ed c ac i h i , a ic a ed e gi e i .
Wea ec i e c hi g, i c di g i e i g e he e ac icab e.
D i ag i c e .
A id c a i a i g c he , a ic a de a , i h i.
Hea i i ed c hi g a d i -i eg a ed f ea h d be .O e a be c ea ed eg a .
Fi Aid ea e h d be b ai ed i edia e f e c a d d .
U e ba ie c ea ,a i g he bef e each e i d, he he e a f i f he i .
Wa h i h a a d ae a e e a i i e ed ( i c ea e a d ai b he i he ).
P e a ai c ai i g a i e e ace he a a i i hich ha e bee e ed.
D e ga i e ( e ), e e e ( a affi ), die e f e (ga i ), hi e e f c ea i g i .
If i di de de e , b ai edica ad ice i h de a .
Whe e ac icab e, deg ea e c e i ha d i g.
Whe e he e i a i fe e c ac , e e ec i h d be ,f e a e che ica g gg e face
hie d ; i addi i a e e a h faci i h d be ided.

En i onm en al P eca ion

Thi ec i ide ge e a i f ai hich ca he ed ce he e i e a i ac f he ac i i ie

ca ied i h .

E i i ai

Ma f he ac i i ie ha a e ca ied i h e i ga e a d f e hich ca c ib e g ba a i g,

cardiagn.com
de e i f he e a e a d/ he f ai f h che ica ga g d e e.B c ide i g h he
h ac i i ie a e ca ied , he e ga e a d f e ca be i i i ed, h ed ci g he i ac he
e i e .

E ha f e

R i g ca e gi e i a e e ia a f h ac i i ie a d e ha f e eed be e i a ed
a he e. H e e , he a f i e e gi e a e i g a d he ii f he ehic e h d be ca ef
c ide ed a a i e , ed ce he e ea e f i ga e a d i i i e he i c e ie ce e e i i g
ea b .

S e

S e f he c ea i g age ed a e e ba ed a d i e a a e a id a he e if ed ca e e , if
c ai e a e ef ea ed. A c ai e be fi c ed he e i ed a d e h d be ed
a i g . Whe e e ib e, e ha i g a ici a d f a abi i h d be e ec ed. A a f he
i ci ied b he e a fac e . Si i a , a ai a e e ba ed a d he a h d be
ed i ch a a a ed ce e i i a i i .

Ref ige a

I i i ega e ea e a ef ige a i he a he e. Di cha ge a d e ace e f he e a e ia f ai

c di i i g i h d be ca ied i g he a ia e e i e .

Di cha ge ae

M h i ha e e f di cha gi g a e a e - d ai a df d ai . S d ai
h d ecei e c ea a e i.e. ai a e . F d ai i acce a f he a a e a e i.e. a hi g
a e , de e ge a dd e ic e a e BUT NOT i , e , e , acid , h d a ic f id, a if ee e a d i i a
f id . If i d b , a a c he ca a h i ae c a .

S i age

E e eca i be a e e e i age f i , f e , e e c., eachi g he d ai . A ha d i g f ch

a e ia a e ace e a a f d ai a d efe ab i a a ea i h a i ab e c ai i g a e e
di cha ge i d ai ae c e . If a i age cc ,i be a ed i edia e i ga i i he e
ided.

C hec i

Sp illa g e p e e n io n:

S e i id i a ec e a ea.

Ma e e ha a i id c ai e a e ec e a d ca be accide a ed .

P ec b age a f a da i b c i g he a e .
 Transfer liquids from one container to another in an area awa. from open drains.

Ensure lids are replaced securel on containers.

Have spill kits available near to points of storage and liquid handling areas.

Spill Kits

Special materials are available to absorb a number of different substances. The can be in granular form, read to
use and are supplied in suitable containers. Disposal of used spill absorbing material is dealt with in Waste
management.

Land contam ination

Oils, fuels and solvents etc. can contaminate an soil with which the come into contact. Such materials MUST never
be disposed of b pouring on to soil and ever precaution must be taken to avoid spillage reaching soil. Waste
materials stored on open ground could either leak or have contaminating substances washed off them that would
contaminate the land. Alwa s store these materials in suitable skips or similarl robust containers.

Legal com pliance

Some sites ma have a discharge consent for effluent discharge to the foul drain for a car wash etc. It is essential to
know the t pes of effluent which are allowed to be discharged into the drain and to check the results of an
monitoring carried out b the Water C ompan .

Where paint spra ing operations are carried out it ma be necessar to appl to the Local Authorit for an air
emissions licence to operate the plant. If such a licence is necessar , additional precautions will be necessar to
compl with the requirements and the results of an air qualit monitoring must be checked regularl .

cardiagn.com
C hecklist

A lwa . s a d he r e to the f o llo wing :

Know what legal consents and licences appl to the operations.

C heck that the emissions and discharges compl with legal requirements.

Waste Managem ent

Pollution can be reduced b careful handling, storage and disposal of all waste materials that occur on sites.
Legislation makes it illegal to dispose of waste materials other than to licensed waste carriers and disposal sites.

This means that it is necessar to not onl know what the waste materials are but also to have the necessar
documentation and licences.

Handling and storage of waste

Ensure that waste materials are not poured down the drain or on to soil and are stored in such a wa that the do not
escape on to land or soil.

All waste must be segregated into individual t pes e.g. oils, metals, batteries, scrap components etc. This will prevent
an reaction between different materials and assist in disposal.

Disposal of waste

Dispose of waste in accordance with the following guidelines:

F ue l, h d r a ulic f luid , a nti-f r e e e a nd o il: Keep separate and dispose of to specialist contractors.

Re f r ig e r a nt: C ollect in specialist equipment and reuse.

De te r g e nts : Safe to pour down the foul drain if diluted.

P a int, thinne r s : Keep separate and dispose of to specialist contractor.

Co m p o ne nts : Return to supplier for refurbishment or disassemble and reuse an suitable parts. Dispose of
remainder in ordinar waste.

Sm a ll p a r ts : Reuse an suitable parts, dispose of the remainder in ordinar waste.

Me ta ls : C an be sold if separate from general waste.

T r e s : Keep separate and dispose of to specialist contractor. DO NOT attempt to dispose of t res b burning.

Co m p o ne nts / m a te r ia ls c o nta ining a s b e s to s : Keep separate and dispose of to specialist contractor.

 Oil a nd f ue l wa s te s (e .g . r a g s , us e d s p ill k it m a te r ia l): Kee. e a a e a d di e f ecia i
c ac .

A ir f ilte r s : Kee e a a e a d di e f ecia i c ac .

Rub b e r / p la s tic s : Di e fi di a a e.

Ho s e s : Di e fi di a a e.

Ba tte r ie s : Kee e a a e a d di e f ecia i c ac .

A ir b a g s - DA NGER EXP LOSI VES: Kee e a a e a d di e f ecia i c ac .

Ele c tr ic a l c o m p o ne nts : Re ie f ef bi h e di a e be a d e e a i ab e
c e . Di e f e ai de i di a a e.

Ca ta l. tic c o nv e r te r s : Ma be d if e e a ae f ge e a a e.

P a c k a g ing : C ac / ec c e a ch a ib e a d di e fi di a a e.

Of f ic e / p a p e r wa s te : Rec c e a e a d e a di ca idge , di e f e ai de i di a a e.

Noise

Ca a a e i g, a e bea i g, i g e gi e , i g ai e c. a e e ai hich i a iab d ce a a ge

a f i e. The ca i f ch ac i i ie a d a he i e f da be ca ef c ide ed ha i g ega d
he i i fh e ch e c.

S e e ai a d ce high i e e e hich c d, i i e, da age hea i g. I he e ca e , i ab e ea

cardiagn.com
ec i be .

Solder

S de a e i e f e a ch ha he e i g i f he i e i be ha f he c i e e a
( a ead a d i ). S de a ica i d e a gi e i e ic ead f e , ided a ga /ai f a e i
ed. O -ace e e f a e h d be ed, a he a e ch h e a d i ca e ead f e be d ced.

S e f e a be d ced b he a ica i fa fa e face c a ed i h g ea e, a d i ha a i f he e

h d be a ided.

Re a f e ce de h d be de a e i h ca e, a e e ha fi e ead d i d ced, hich

ca gi e ic effec if i ha ed. Re i a ec i a be ece a .

S de i age a d fi i g h d be c ec ed a d e ed e e ge e a ai c a i ai b ead.

High a da d f e a h gie e a e ece a i de a id i ge i f ead i ha a i f de d f

c hi g.

Solv ents

F e a e ace e, hi e i i, e e, e e, ich e ha e.

U ed i c ea i g a d de a i g a e ia , ai , a ic , e i a d hi e .

S e a be high fa ab e fa ab e.

S i c ac i deg ea e he i a d a e i i iai a d de aii f i g e ea ed ged c ac .

S e ca be ab bed h gh he i i ic ha f a i ie .

S a he i he e e a ca e e e e i iai a dc d ead f i i .

B ief e e f high c ce ai f a i i ca e e e a d h a i iai ,d i e , di i e ,

headache a d, i he ci c a ce , c ci e .

Re ea ed ged e e e ce i e b e c ce ai f a i ,f hich he e igh

be ade a e a i g i dica i , ca ca e e e i ic ha f effec .

A i ai i he g ,f e a e h gh i i g, i he e i c e e ce f a i g.

A id a he he i ,e e a dc hi g. Wea ec i e g e , g gg e a d c hi g if ece a .

Ma e e he e i g d e ia i he i e, a id b ea hi g f e , a a d a i a d ee c ai e
igh ea ed. D e i c fi ed ace .

Whe a i g a e ia c ai i g e ,f e a e ai , adhe i e , a d e a c a i g , e e ac i
e ia i e a e i a ec i i he ab e ce f ade a e ge e a e i a i .
Do not apply heat or flame except under specific and detailed manufacturers instructions.

S. pended Load

C AUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised
load, for example a suspended engine.

Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for
the job, in good condition and regularly maintained.

Vi on

In common with many other manufacturers vehicles, some components installed to Land Rover vehicles have seals,
'O' rings or gaskets which contain a material known as 'Viton'.

Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. Although Viton is the most well
known fluoroelastomer, there are others, including Fluorel and Tecmoflon.

When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to
temperatures in excess of 400 C , the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid.

This acid is extremely corrosive and may be absorbed directly, through contact, into the general body system.
W HERE CA SES OF SKI N CONT A CT OCCUR, SEEK I MMEDI A T E MEDI CA L HELP .

cardiagn.com
O-rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black
sticky substance.

DO NOT, under any circumstances touch them or the attached components.

Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected O-
ring, seal or gasket. If they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious as the material
may be Viton or any fluoroelastomer.

If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the
commencement of work.

Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralise the acid before disposing of the decomposed Viton residue
and final cleaning of the area. After use, the plastic gloves should be discarded carefully and safely.

Welding

Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.

Re i ance W elding

This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be
protected.

A c W elding

This process emits a high level of ultra-violet radiation which may cause arc-eye and skin burns to the operator and
to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal
protection must be worn, and screens used to shield other people.

C ONTAC T LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPEC TAC LES WHEN ARC WELDING as the arc
spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This may result in
blindness when the lens is removed from the eye.

Metal spatter will also occur, and appropriate eye and skin protection is necessary.

The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any
applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and
inhalation of these should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable welding work is
anticipated. In extreme cases or confined spaces where adequate ventilation cannot be provided, air-fed respirators
may be necessary.

C AUTION: Some of the components installed to the vehicle e.g. the interior cross beam and underbonnet cross
. e be a e a fac ed f ag e i a .O acc h da e di g e ai be a e ed
he e c e .

Gas W elding ( and Cutting)

O -ace e e che a be ed f e di g a d c i g, a d ecia ca e be a e e e ea age f

he e ga e , i h c e e i f fi e a d e i .

The ce i d ce e a a e a de e a d i ec i i ece a .

The f a e i b igh , a d e e ec i h d be ed, b he a- i e e i i i ch e ha ha f a c

e di g, a d igh e fi e a be ed.

The ce i ef d ce fe ic f e ,b ch f e a d ga e a be d ced f c ai g he ,
a ic a d i gc i ga a f da aged b d a , a d i ha a i f he f e h d be a ided.

I b a i g, ic f e a be d ced f he e a i he b a i g d, a d a e e e ha a d a a i e if
b a i g d c ai i g cad i a e ed. I hi e e a ic a ca e be a e a id i ha a i ff e
a d e e ad ice a be e i ed.

SP ECI A L P RECA UT I ONS MUST BE T A KEN BEF ORE A NY W ELDI NG OR CUT T I NG T A KES P LA CE ON VESSELS
W HI CH HA VE CONT A I NED COMBUST I BLE MA T ERI A LS, F OR EXA MP LE BOI LI NG OR ST EA MI NG OUT OF F UEL
T A NKS.

Warning S. m bols on Vehicles

Deca h i g a i g b i be f d a i ehic e c e .

cardiagn.com
The e deca be e ed. The a i g a e f he a e i f e / e a a d e ca i g
e ice e ai e ai he ehic e.
 P. b i hed: 11-Ma -2011
General Infor mation - Sol. ents, Sealants and Adhesi es
De c i i a dO e ai

Sol ents

WARNING: A a ha d e a e , ea e a d adhe i e ihe e e ca e. S e c ai che ica

gi e ff f e hich ca be da ge hea h. A a f he a fac e i ci . If i d b ab a
b a ce, a ic a a e , DO NOT e i.

C AUTION: If i d b ab he i abi i fa ie a e ea e f a a ic a a ica i ,

c ac he a fac e f he d c f i f ai .

The Hea h a d Safe P eca i b ec i efe e c ed che ica a d a e ia , ha a d

a cia ed i h hei e, a d afe ea e be a e . S e f he e che ica a be i c ded a a
i g edie i a ea e adhe i e.

Sealers

C e ai ced e i hi a a i e he e f ea a d i gi a ai fc e . Whe e a ea a i
e i ed, he a ica i , ge he i h he La d R e a be i gi e i he Ge e a S ecifica i a he a
f each ec i a da i ci ha a ea a be ed a ea i he e e a e ai ced e.

I i e e ia ha he ea a ( ) ecified f a a ic a ced e a e ed, DO NOT e a he ea a .

cardiagn.com
A a e e ace f d ea a i ga a ic c a e i ab e e , e e e e e c h e a
c a e .

Adhesi es

Whe e e a ced e i e he e f a adhe i e, he adhe i e ecified be ed a d he a fac e '

i ci ega di g a ica i ge he iha hea h a d afe eca i be f ed.
 Published: 11-May-2011
General Infor mation - R oa d/ R oller T esting
Description and Operation

Road or rolling road testing may be carried out for various reasons and a procedure detailing pre-test checks,
through engine starting and stopping, pre-driving checks, on-test checks to final checks on completion of the test are
given.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead,
those items particularly relevant to the system(s) being checked can be extracted.

Pre-Test Checks

WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found,
do not attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak
is found and rectified.

It is suggested that pre-test and functional tests of those systems/circuits which affect the safe and legal operations of
the vehicle, such as brakes, lights and steering, should always be carried out before the road or rolling road test.

Engine oil level

Engine coolant level
Tires, for correct pressure, compatible types and tread patterns, and wear within limits.
There is sufficient fuel in the tank to complete the test.
C heck all around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make

cardiagn.com
a note of any apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the
leak on completion of the test.

Starting the Engine

̀ NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond
half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine
speed or with the accelerator pedal at full travel whilst the engine is cold.

W ith the ig nitio n s . itc he d o f f , c he c k :

The parking brake is applied.

A uto m a tic g e a r b o : The selector lever is in 'P' - Park
T r a ns f e r c a s e : 'H' - High is selected
All instrument gauges read zero.

W ith the ig nitio n s itc he d o n, c he c k :

Ignition controlled warning lights come on.

Engine temperature gauge registers a reading compatible with the engine temperature.
Fuel gauge registers a reading appropriate to the fuel level in the tank.
The operation of the parking brake warning light and fluid level warning indicator light.

On Road Test Check:

C AUTION: At commencement of road testing, check the brake operation while still travelling at low speed before
continuing with the test. If the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road
test until the fault has been found and rectified.

The parking brake releases completely.

Gear changing is smooth, and there are no abnormal noises or vibrations from the gearbox.
The engine power output is satisfactory, acceleration is smooth and accelerator pedal operation is not stiff or
heavy, and engine speed returns to idle correctly.
There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or
overrun conditions.
Steering operation is smooth, accurate, not excessively heavy or with excessive free play or vibration. Does
not pull to one side and self centres smoothly after cornering.
All instruments register the correct readings and operate correctly.
Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the
direction indicator control self cancels when the steering is returned to the straight ahead position.
Heating and ventilation systems work correctly and effectively.
Brakes operate efficiently.

Brake Testing
A. id b a e e i g b ad he e i ca ca e i c e ie ce da ge he ad e .

C AUTION: B a e e i g hich i c de hea b a e a ica i h d be ca ied ih e b a e

ad /di c i he c e ha e bedded-i . Ne b a e f ic i c e i each f efficie c i he
beddi g-i ce i c e e. N e ha he e a i gb a e h e ea b a e di c ha e bee i a ed, i i
e e ia ha he 'beddi g-i ' ced e gi e i Sec i 206-05 - Pa i g B a e Re a a dI a ai i ca ied
.

Te he b a e a e e a eed i hi he a e a i g a ge i g b h igh a d hea eda e e. N e

a e de c a ch, d ag, a d a d e de a i a ica i e ea e.

A he ehic e c a a d e a e de c e ide, e ide ce ha he b a e a e bi di g.

Af e i g he ehic e ( i edia e af e a e i d f hea b a i g), ca ef chec he b a e e e a e.

A di c hich fee a eciab h e ha he he ,c d i dica e ha he ad ha di c a e bi di g.

Af e c e i f he e , chec f :

Oi , c a , h d a ic, ai a d f e ea .
Ab a e e a e fa i gc e a e b ie , e.g. hee h b , a i i e c., hich
igh i dica e e igh e ac f b ica i .

Rolling Road Testing

F o ur -W he e l Ro lling Ro a d

cardiagn.com
C AUTION: Whe ii i g a f - hee i g ad f e i g, e e a ee a hea h a d afe e i e e
a e adhe ed .

P ided ha f a d ea e a e a i g a ide ica eed a d ha a h afe a da d a e

a ied, he e i eed e ic i d i g e i g e ce a ha a a he i e .

E e ha he a i gb a e i e ea ed i e gagi g e d i i g echa i .

T . o -W he e l Ro lling Ro a d

C AUTION: O acc h da a e be ade ca a f f e i g a - hee i g

ad.
 P. : 11-M -2011
General Infor mation - Special T ool Glos sar.
D O

Serv ice Tools

S ,
.T
.

S .

A U K E G ,A ,S
S :

SP X UK Ltd .,

G H ,

E P ,

D ,

N ,

NN11 5YJ

cardiagn.com
E

T e l: 0044 (0) 1327 303467/303455

F a : 0044 (0) 1327 706632

e -m a il: @ . .

O .

G ,A S

SP X Eur o p e GMBH,

P 4,

63512 H ,

T e l: 0049 61829590

F a : 0049 6182959299

SP X I b e r ic a SA ,

C /F A ,

158 72 (N O ),

19004 G ,

T e l: 0034 949208381

F a : 0034 949208327

N A

SP X Co r p o r a tio n

665, E D ,

O ,

MN 55060,
USA

T e l: 0018 772979110

F a . : 0018 005787375

Australia

SP X A us tr a lia ,

28, C la. ton Road,

Notting Hill,

Victoria 3168,

Australia

T e l: 0061 00395446222

F a : 0061 00395445222

e -m a il: sales@sp .com.au

Japan and East Asia

Ja te k Ltd .,

5 - 53, Mina acho 2-chome,

cardiagn.com
Kohoku-ku,

Yokohama,

Kanaga a 223-0051,

Japan

T e l: 0081 455627700

F a : 0081 455627800