Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual

							GENERAL INFORMATION
03-20
After re-connecting the battery, the steering wheel 
must be turned to full LH and RH lock (with engine 
running). This allows the DSC system to relearn the 
steering wheel position. Failure to do so will result in 
a variety of instrument warning lights being 
illuminated. 
Battery charging
Only recharge the battery with it removed from the 
vehicle. Always ensure any battery charging area is 
well ventilated and that every precaution is taken to 
avoid naked flames and sparks.
Ignition system safety precautions
The vehicles ignition system produces high voltage 
and the following precautions should be observed 
before carrying out any work on the system.
WARNING: Before commencing work on an 
ignition system, ensure all high tension 
terminals, adapters and diagnostic equipment 
are adequately insulated and shielded to prevent 
accidental personal contacts and minimise the 
risk of shock. Wearers of surgically implanted 
pacemaker devices should not be in close 
proximity of ignition circuits or diagnostic 
equipment.
Disciplines
Switch off the ignition prior to making any connection 
or disconnection in the system to prevent electrical 
surges caused by disconnecting live connections 
damaging electronic components.
Ensure hands and work surfaces are clean and free 
of grease, swarf, etc. Grease collects dirt which can 
cause electrical tracking (short-circuits) or high-
resistance contacts.
When handling printed circuit boards, treat with care 
and hold by the edges only; note that some electronic 
components are susceptible to body static.
Connectors should never be subjected to forced 
removal or refit, especially inter-board connectors. 
Damaged contacts can cause short-circuit and open-
circuit fault conditions.
Prior to commencing test, and periodically during a 
test, touch a good vehicle body earth to discharge 
static charge. Some electronic components are 
vulnerable to the static electricity that may be 
generated by the operator.Grease for electrical connectors
Some under bonnet and under body connectors may 
be protected against corrosion by the application of a 
special grease during vehicle production. Should 
connectors be disturbed in service, repaired or 
replaced, additional grease should be applied: Part 
No. BAU 5811, available in 150 gm tubs. 
NOTE: The use of greases other than BAU 5811 
must be avoided as they can migrate into relays, 
switches etc. contaminating the contacts and leading 
to intermittent operation or failure. 
						

							GENERAL INFORMATION
03-21
Supplementary Restraint System (SRS) 
Precautions
The following precautions must be adhered to when 
working on the SRS system.
WARNING: All components of the SRS must be 
replaced every 15 years.
WARNING: Do not use rear facing child seats in 
the front passenger seat if the vehicle is fitted 
with a passenger airbag.
General Precautions
The SRS contains components which could be 
potentially hazardous to service personnel if not 
serviced and handled correctly. The following 
guidelines are intended to alert personnel to potential 
sources of danger and emphasise the importance of 
ensuring the integrity of SRS components fitted to 
the vehicle.
WARNING: Always follow the SRS Precautions 
and the correct procedures for working on SRS 
components. Persons working on SRS systems 
must be fully trained and have been issued with 
copies of the safety guidelines.
WARNING: It is imperative that before any work 
is carried out on the SRS system, the appropriate 
information is read thoroughly.
WARNING: The airbag modules contain 
extremely flammable and hazardous 
compounds. Contact with water, acids or heavy 
metals may produce harmful or explosive 
results. Do not dismantle, incinerate or bring into 
contact with electricity before the unit has been 
deployed.
WARNING: Always replace a seat belt assembly 
that has withstood the strain of a severe vehicle 
impact or if the webbing shows signs of fraying.
WARNING: Always disconnect the vehicle 
battery before carrying out any electric welding 
on a vehicle fitted with an SRS system.
CAUTION: Do not expose 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: 
lSteering system - Steering wheel airbag, 
rotary coupler
lFront fascia - Passenger front airbag
lInterior trim - Head airbag modules - front and 
rear
lSeats - Front seat belt pre-tensioners
lElectrical system - SRS harnesses, link leads 
and connectors
lFront doors - Side (thorax) air bags
Making the system safe
Before working on or in the vicinity of SRS 
components, ensure the system is rendered safe by 
performing the following operations.
lRemove the ignition key
lDisconnect battery, earth lead first
lWait 10 minutes for the SRS power circuit to 
discharge before commencing work
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 (10 minutes) 
in order to avoid the risk of accidental deployment. 
						

							GENERAL INFORMATION
03-22
Installation
In order to ensure system integrity, it is essential that 
the SRS system is regularly checked and maintained 
so that it is ready for effective operation in the event 
of a collision. Carefully inspect SRS components 
before installation. Do not install a part that shows 
signs of being dropped or improperly handled, such 
as dents, cracks or deformation.
WARNING: The integrity of the SRS systems is 
critical for safety reasons. Ensure the following 
precautions are always adhered to.
WARNING: Do not fit accessories or other 
objects to trim panels (e.g. A Post) which cover 
ITS airbags.
lNever install used SRS components from 
another vehicle or attempt to repair an SRS 
component.
lWhen repairing an SRS system, only use 
genuine new parts.
lNever apply electrical power to an SRS 
component unless instructed to do so as part of 
an approved test procedure.
lSpecial fixings are necessary for installing an 
airbag module – do not use other fixings and 
ensure that all fixings are tightened to the 
correct torque.
lAlways use new fixings when replacing an SRS 
component.
lEnsure the SRS diagnostic control unit (DCU) is 
correctly installed. There must not be any gap 
between the DCU and the bracket to which it is 
mounted. An incorrectly mounted DCU could 
cause the system to malfunction.
CAUTION: When fitting an head airbag module, 
ensure the securing clips are locked and do not 
trap the airbag. Take care not to trap the head 
airbag when fitting interior trim components e.g. 
A post trim, headlining.
CAUTION: Ensure SRS components are not 
contaminated with oil, grease, detergent or 
water.
CAUTION: Torque wrenches should be checked 
regularly to ensure that all fixings are tightened 
to the correct torque.
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 establish 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 precautions:
WARNING: Do not use a multimeter or other 
general purpose test equipment on SRS system 
components or accidental deployment may 
occur. Use only Testbook/T4 to diagnose system 
faults.
WARNING: Do not use electrical test equipment 
on the SRS harness while it is connected to any 
of the SRS system components, it may cause 
accidental deployment and personal injury.
Handling and storage
Observe the following precautions when handling 
SRS components.
WARNING: There are regulations for the storage 
of SRS components which must be observed, 
consult your local authority for details. The SRS 
components are sensitive and potentially 
hazardous if not handled correctly; always 
comply with the following handling precautions: 
						

							GENERAL INFORMATION
03-23
lNever drop an SRS component. The airbag 
diagnostic control unit is a particularly shock 
sensitive device and must be handled with 
extreme care. Airbag modules and seat belt pre-
tensioner units could deploy if subjected to a 
strong shock.
lNever wrap your arms around an airbag 
module. If a module has to be carried, hold it by 
the cover with the cover uppermost and the 
base away from your body.
lNever transport airbag modules or seat belt pre-
tensioners in the cabin of a vehicle. Always use 
the luggage compartment of the vehicle for 
carrying airbag modules and seat belt pre-
tensioner units.
WARNING: Never attach anything to an airbag 
cover or any trim component covering an airbag 
module. Do not allow anything to rest on top of 
an airbag module.
WARNING: Always keep components cool, dry 
and free from contamination.
CAUTION: Do not apply grease or cleaning 
solvents to seat belt pre-tensioner units, 
component failure could result.
WARNING: Store the airbag module with the 
deployment side uppermost. If it is stored 
deployment side down, accidental deployment 
will propel the airbag module with sufficient force 
to cause serious injury.
WARNING: Airbag modules and seat belt pre-
tensioners are classed as explosive devices. For 
overnight and longer term storage, they must be 
stored in a secure steel cabinet which has been 
approved as suitable for the purpose and has 
been registered with the local authority.
WARNING: Store the airbag module or seat belt 
pre-tensioner in a designated storage area. If 
there is no designated storage area available, 
store in the locked loadspace of the vehicle and 
inform the workshop supervisor.
CAUTION: Improper handling or storage can 
internally damage the airbag module making it 
inoperative. If you suspect the airbag module has 
been damaged, install a new module and refer to 
the deployment/disposal procedures for 
disposal of the damaged module.
WARNING: Keep new inflatable tubular structure 
(ITS) airbag module in the original packaging 
until just prior to fitting. Place the old ITS module 
in the empty packaging for carriage.
WARNING: 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. 
						

							GENERAL INFORMATION
03-24
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.
SRS harness and connectors
Always observe the following precautions with 
regards to SRS system electrical wiring:
CAUTION: Observe the following precautions:
lNever attempt to modify, splice or repair 
SRS wiring.
lNever 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: Always ensure SRS wiring is routed 
correctly. Be careful to avoid trapping or 
pinching the SRS wiring. Do not leave the 
connectors hanging loose or allow SRS 
components to hang from their harnesses. Look 
for possible chafing points.
Side impact crash sensor inspection
After any degree of side body damage, inspect both 
side impact crash sensors. Replace a crash sensor if 
there is any sign of damage or deformation to the 
sensor fixings.
M01 0270 
						

							GENERAL INFORMATION
03-25
Ensure the side impact crash sensors are installed 
correctly. There must be no gap between the sensor 
and the mounting. Use either the fixings supplied 
with the replacement or new fixings and tighten to the 
correct torque.
CAUTION: Take extra care when painting or 
carrying out bodywork repairs in the vicinity of 
the crash sensors. Avoid direct exposure of the 
crash sensors or link harnesses to heat guns, 
welding or spraying equipment. Take care not to 
damage sensor or harness when refitting 
components.
Rotary coupler precautions
CAUTION: Always follow the procedure for fitting 
and checking the rotary coupler as instructed in 
the SRS repairs section. Comply with all safety 
and installation procedures to ensure the system 
functions correctly. Observe the following 
precautions:
lDo not unlock and rotate the rotary coupler 
when it is removed from the vehicle. 
lDo not turn the road wheels when the rotary 
coupler is removed from the vehicle.
lAlways ensure the rotary coupler is removed 
and installed in its central position and with 
the front road wheels in the straight ahead 
position - refer to SRS repair section for the 
correct removal and installation procedure.
lIf a new rotary coupler is being installed, 
ensure the locking tab holding the couplers 
rotational position is not broken; units with a 
broken locking tab must not be used.
Airbag location labels
Airbag location labels are displayed at various 
positions in the vehicle. SRS components have 
additional warning labels displayed on them to 
indicate that particular care is needed when handling 
them. These include airbag modules, crash sensors, 
and seat belt pre-tensioners.
WARNING: It is imperative that before any work 
is undertaken on the SRS system, the 
appropriate information is read thoroughly.
NOTE: The following list indicates possible locations 
and content for warning labels. The exact positions 
and content may vary dependent on model year, 
legislation and market trends.
Passenger side fascia label
Driver/passenger door label 
						

							GENERAL INFORMATION
03-26
Steering wheel label
A Post label
Rotary coupler label - part no. location
The Land Rover part number must be recorded if an 
airbag module is to be replaced.Always exercise caution when working with 
components, refer to the appropriate repair operation 
when replacing components; do not attempt to prise 
open or repair module case.
Modules contain high pressure gas and flammable 
material. To prevent personal injury, observe the 
following: 
lDo not repair, dismantle, incinerate or bring into 
contact with electricity (such as voltmeters).
lDo not store in a place where temperature 
reaches 93° C (200° F) or higher.
lDo not install components in another vehicle.
lDo not install any foreign objects between 
airbag and its cover or within modules.
lService or dispose of components as directed in 
the appropriate repair operation.
Drivers airbag module label
Passengers airbag module label
Bar codes or part numbers are attached to certain 
components which are critically related to correct 
operation. The number(s) must be recorded if the 
component is to be replaced.
M01 0276
M01 0275 
						

							GENERAL INFORMATION
03-27
Front head airbag module label
A label is attached to the airbag module identifying 
the need for caution and the importance of referring 
to the relevant section of the repair manual before 
commencing work on the SRS components.
WARNING: The use of correct trim components 
is critical to the correct functioning of the airbag 
modules during deployment. Do not re-use SRS 
related interior trim components if they show 
signs of damage; always use new components.
VEHICLE RECOVERY
Towing - SRS components not deployed
Normal towing procedures are unlikely to cause an 
airbag to deploy. However, as a precaution, switch 
the ignition off and then disconnect both battery 
leads – negative (-) lead first.
Towing - SRS components deployed
Once the drivers airbag has been deployed, the 
vehicle must have a front suspended tow. However, 
as a precaution, switch the ignition off and then 
disconnect both battery leads – negative (-) lead first.Airbag and pre-tensioner deployment
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:
lOnly use deployment equipment approved for 
the intended purpose.
lDeployment of airbag / pre-tensioner modules 
should be performed in a well ventilated area 
which has been designated for the purpose.
lEnsure airbag / pre-tensioner modules are not 
damaged or ruptured before attempting to 
deploy.
lNotify the relevant authorities of intention to 
deploy airbag and pretensioner units.
lWhen deploying airbag pre-tensioner units, 
ensure that all personnel are at least 15 metres 
(45 feet) away from the deployment zone.
lEnsure deployment tool is connected correctly, 
in compliance with the instructions detailed in 
the SRS section of this manual. In particular, 
ensure deployment tool is NOT connected to 
battery supply before connecting to airbag 
module connector.
lWhen deploying seat belt pre-tensioners, 
ensure pre-tensioner unit is secured correctly to 
the seat.
lWhen removing deployed airbag modules and 
pre-tensioner units, wear protective clothing. 
Use gloves and seal deployed units in a plastic 
bag.
lFollowing deployment of any component of the 
SRS system within the vehicle, all SRS 
components must be replaced. DO NOT re-use 
or salvage any parts of the SRS system.
lDo not lean over 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 case airbags can be deployed in the 
vehicle; before deployment, ensure the airbag 
module is secure within its correct mounting position. 
Deployment of the drivers airbag in the vehicle may 
damage the steering wheel; if the vehicle is not being 
scrapped, deploy the module outside of the vehicle.
WARNING: During deployment parts of the 
airbag module become hot enough to burn you. 
Wait 30 minutes after deployment before 
touching the airbag module. 
						

							GENERAL INFORMATION
03-28
SRS Component Replacement Policy 
The following information details the policy for 
replacement of SRS components; either as a result 
of a vehicle accident or as a result of vehicle age.
WARNING: All components of the SRS must be 
replaced every 15 years.
Impacts which do not deploy the airbags or pre-
tensioners
Check for structural damage in the area of the impact 
paying particular attention to bumper armatures, 
longitudinals and bracketry.
Impacts which deploy the airbags or pre-
tensioners
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.
Check for structural damage in the area of the 
impact paying particular attention to bumper 
armatures, longitudinals and bracketry.
CAUTION: The SRS DCU must be replaced after 
every deployment has occurred.
CAUTION: The SRS side impact sensor must be 
replaced after every side deployment has 
occurred. Only replace the side impact sensor on 
the deployed side.
Front airbag deployment (driver and passenger)
If the front airbags are deployed, the following 
components must be replaced:
lDriver airbag module
lPassenger airbag module
lFly leads (where applicable) connecting front 
airbag modules to SRS harness
lFront seat belt buckle pre-tensioners
lRear seat belt pre-tensioners - if fitted
lDrivers seat belt retractor - if fitted
lRotary coupler
lSRS DCUIn addition, the following should be inspected for 
damage and replaced as necessary:
lFront passengers seat belt retractor - webbing, 
tongue latching, D loop, body anchorage point
lRear seat belt buckles - webbing, buckle covers, 
body anchorage, and tongue latching function
lFascia moulding adjacent to passenger airbag 
module
lSteering wheel
lFront seat frames and head restraints
lSteering column - if adjustment is lost or if there 
are signs of collapse
lSeat belt height adjusters
lRear seat belts
Side (Thorax airbags)
If the side (thorax) airbags are deployed, the 
following components must be replaced on the side 
of the vehicle on which the deployment occurred:
lSide (thorax) airbag.
lBoth side impact sensors.
lSRS DCU.
In addition, the following should be inspected for 
damage and replaced as necessary:
lFront seat belts - retractors, webbing, tongue 
latching, D loop, body anchorage points
lRear seat buckles - webbing, buckle covers, 
tongue latching, body anchorage points
lFront seat frame and head restraints
lDoor trim casing
lSeat belt height adjusters
lRear seat belts
Head airbag modules
If the head airbag modules are deployed, the 
following components must be replaced on the side 
of the vehicle on which deployment occurred:
lHead airbag modules
lLink lead between airbag gas generator and 
SRS harness
lAirbag retaining clips
lInternal trim finisher
lFront seat belt buckle pre-tensioners
lSRS DCU
lBoth side impact crash sensors
In addition, the following should be inspected for 
damage and replaced as necessary:
lHeadlining
lMounting brackets
lFront seat belts – retractors, webbing, tongue 
latching, D loop and body anchorage points.
lRear seat belt buckles – webbing, buckle 
covers, tongue latching and body anchorage 
points
lAdjacent trim components
lSeat belt height adjusters 
						

							GENERAL INFORMATION
03-29
Rear impacts
If the seat belt pre-tensioners are deployed during a 
rear impact, the following components must be 
replaced:
lSeat belt pre-tensioners.
lSRS DCU.
lFront and rear seat belt retractors used during 
impact.
In addition, the following components should be 
inspected for damage and replaced as necessary:
lFront seat frames and head restraints
lSeat belt height adjusters
lFront seat belts, retractors, webbing, tongue 
latching, D loop and body anchorage points
lRear seat belt buckles, webbing, buckle covers, 
tongue latching, and body anchorage points
lSRS side impact sensor.
Periodic replacement of SRS components
The performance of the propellants within airbags 
and pre-tensioners will deteriorate over a period of 
time. 
As a result, it is essential that airbags, seat belt 
pre-tensioners and the rotary coupler are 
replaced every 15 years.
Air Conditioning System Precautions
General
The air conditioning system contains fluids and 
components which could be potentially hazardous to 
the service 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 
Conditioning operating conditions and components 
fitted to the vehicle.
Where necessary, additional specific precautions are 
detailed in the relevant sections of this Manual which 
should be referred to prior to commencing repair 
operations.
The refrigerant used in the air conditioning system is 
HFC-134a (Hydrofluorocarbon) R134a.
WARNING: 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.
WARNING: 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.