WARNING: Always make sure SRS wiring is routed correctly. Be careful to avoid trapping or pinching the SRS wiring.

WARNING: 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 the side impact crash sensors. Replace a crash sensor if there is any sign of
damage.

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 reinstalling components.

Clock spring

CAUTION: Always follow the procedure for installing and checking the clock spring as instructed in the SRS repairs
section. Comply with all safety and installation procedures to make sure the system functions correctly. Observe the
following precautions:

Do not unlock and rotate the clock spring when it is removed from the vehicle.
Do not turn the road wheels when the clock spring is removed from the vehicle.
Always make sure the clock spring 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.
If a new clock spring is being installed, make sure the locking tab holding the coupler's rotational position is not
broken; units with a broken locking tab must not be used.

Airbag and pre-tensioner deployment

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 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 Component Replacement Policy

• CAUTIONS:

The restraints control module (RCM) must be replaced after every time any SRS component has been
deployed.

The SRS side impact sensor must be replaced if there are any signs of physical damage or if the RCM is registering a
fault.

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

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 impact paying particular attention to bumper armatures, longitudinals
and bracketry.

Front Airbag Deployment - Driver and Passenger

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

Driver airbag module

Steering wheel
Passenger airbag module
Instrument panel
Fly leads (where applicable) connecting front airbag modules to SRS harness
All seat belt buckle pre-tensioner
All occupied seats at the time of the crash should have their seat belts replaced
Any seat belt with a deployed retractor pretensioner should be replaced.
Rotary coupler
Any front impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Front passenger's seat belt retractor and webbing, tongue latching function, 'D' loop and body anchorage point
Rear seat belt buckles, webbing, buckle covers, body anchorage points and tongue latching function
Front seat frames and head restraints
Steering column - if adjustment is lost or if there are signs of collapse
Seat belt height adjusters
Rear seat belts

Side Air Bags

CAUTION: If the side (thorax) air bags are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:

Side (thorax) airbag

Any side impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Front seat frame and head restraints
Door trim casing
Seat belt height adjusters
 Rear seat belts

Side Curtain Airbag Modules

CAUTION: If the head airbag modules are deployed, the following components must be replaced on the side of the
vehicle on which the deployment occurred:

Side curtain airbag modules

Headliner and all pillar trims
Link lead between airbag gas generator and RCM harness
Airbag retaining clips
Front seat belt buckle pre-tensioners
Any side impact sensors that have been physically damaged or if a fault is being registered
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Component mounting brackets

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points
Adjacent trim components
Seat belt height adjusters

Rear impacts

CAUTION: If the seat belt pre-tensioners are deployed during a rear impact, the following components must be
replaced:

Seat belt pre-tensioners

Front and rear seat belt retractors used during the impact
RCM

Additionally, the following items must be inspected for damage and replaced as necessary:

Seat belt height adjusters

Front seat belts, retractors and webbing, tongue latching function, 'D' loop and body anchorage points
Rear seat belt buckles, webbing, buckle covers, tongue latching function, and body anchorage points

Air Conditioning System Precautions

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 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.

• W ARNINGS:

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.

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.
Completed 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, BUT
NOT 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.
Components 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

CAUTION: 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
Conditioning Compressor Replacement in this Section.

Compressor

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.

CAUTION: 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.

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.

• CAUTIONS:

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 Conditioning Compressor Replacement

A new compressor is supplied filled with a full charge (X cm³) 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 cm³).
Calculate the quantity of oil to be drained from the new compressor using the following formula:X cm³ — (Y cm³ +
20 cm³) = Q cm³
Remove the drain plug from the new compressor and drain Q cm3 of oil. install and tighten the compressor drain
plug.

Vehicle Weights

Item kg lb
Maximum Gross Vehicle Weight (GVW) - All models (1) 2505 5511
Approximate unladen weight (2):
3.2 Petrol 1825 4015
2.2 Diesel 1820 4004
Maximum weight of unbraked trailer:
On-road 750 1650
Off-road 750 1650
Maximum towable weight (mass) - Trailers with overrun brakes:
On-road 2000 4400
Off-road 2000 4400
Gross train weight - Trailers with overrun brakes (3):
On-road 4505 9911
Off-road 4505 9911
Nose weight:
On-road 150 330
Off-road 150 330
Maximum front axle load - All models (4) 1310 2882
Maximum rear axle load - All models (4) 1360 2992
Maximum roof rack load - All models (5) 75 165
(1) The maximum permissible weight of the vehicle including passengers and load.

(2) This figure includes the toolkit, all fluids to the correct levels and spare wheel but excludes the driver and
passengers.

(3) The maximum permissible weight of the vehicle and braked trailer and their respective loads.

(4) The front and rear maximum loads cannot be reached simultaneously as this will exceed the GVW limit. When
calculating rear axle loading, remember that the trailer nose weight, the load in the vehicle's luggage area, weight
on the roof rack, and the weight of rear seat passengers must all be added together.

(5) This figure includes the weight of the roofrack.

Vehicle Dimensions
Item mm in
Length - excluding license plate plinth - All models 4500 177.2
Width - All models:
Mirrors extended 2180 85.83
Mirrors folded 2005 78.95
Maximum height - including roof rails - All models 1820 71.65
W heelbase - All models 2660 104.7
Track:
Front with 16" wheels 1611 63.43
Front with 17"/18"/19" wheels 1601 63.03
Rear with 16" wheels 1624 63.94
Rear with 17"/18"19" wheels 1614 63.54
Vehicle ride height (1):
Front 490.7±12 19.32±0.47
Rear 504.6±12 19.87±0.47
Underbody running clearance to exhaust - Minimum - Kerb weight 229 9.0
Front axle to underbody clearance 216 8.5
Rear axle to differential casing clearance 267 10.5
Suspension travel from kerb - ROW (unladen): 227 8.9
Front (bump/rebound) 105/80 4.13/3.15
Rear (bump/rebound) 130/90 5.12/3.54
Total articulation 335 13.2
Suspension travel from kerb - NAS (unladen):
Front (bump/rebound) 102/76 4/3
Rear (bump/rebound) 127/89 5/3.5
Total articulation 330 13.2
W ading depth 500 19.7
Departure angle - Towbar NOT installed 34°
Departure angle - Fixed height towbar - NOT NAS vehicles 19°
Departure angle - Detachable towbar installed - NOT NAS vehicle 18°
Departure angle - Towbar installed - NAS vehicles 19°
Approach angle 31°
Breakover angle 157°
Maximum gradient for continuous operation 30°
Maximum gradient for drive through operation (2) 45°