Freelander 1. Manual - part 9

GENERAL INFORMATION

03-27

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.

Impacts which do not deploy the airbags or seat
belt pre-tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.

Impacts which deploy the airbags and/or seat
belt pre-tensioners
The inspection and replacement 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.

Front airbag/ seat belt pre-tensioner deployment
(driver and passenger)
If the front airbags and/or seat belt pre-tensioners are
deployed as a result of a front, front angled or side
impact, the following parts must be replaced:

Driver airbag module

Passenger airbag module (where fitted)

SRS flyleads

SRS DCU

Rotary coupler

Front seat belt pre-tensioners

In addition, the following should be inspected for
damage and replaced as necessary:

Front seat belt and buckle tongue (anchorage
points, webbing etc.)

Fascia moulding adjacent to passenger airbag
module (where fitted)

Steering wheel (if damage is evident)

Front seat frames and head restraints (if there is
evidence of damage to the seat frame or
cushion pan)

Steering column (if adjustment is lost or there
are signs of collapse)

Front seat belt height adjusters on 'BC' posts (5
door models only)

Rear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)

Rear impacts
Rear impacts may cause the front seat belt pre-
tensioners to deploy. If this occurs, the seat belt pre-
tensioners must be replaced. In addition, the
following components should be inspected for
damage and replaced as necessary:

Front seat frames

Front seat belts and buckle (retractors,
webbing, tongue latching, buckle covers, body
anchorages and 'D' loops)

Seat belt height adjusters (5 door models only)

Rear seat belts and seat belt buckles (webbing,
buckle covers, body anchorage and tongue
latching function)

Periodic replacement of SRS components
The performance of the propellants within airbags
and seat belt pre-tensioners will deteriorate over a
period of time. As a result, it is essential that the
airbags and seat belt pre-tensioners are periodically
replaced to maintain occupant safety. Airbags, seat
belt pre-tensioners and the rotary coupler should be
replaced at the recommended intervals.

GENERAL INFORMATION

03-28

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. Always
adhere to the following precautions:

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: Do not allow a refrigerant container to
be heated by direct flame or to be placed near
any heating appliance. A refrigerant container
must not be heated above 50

Do not leave a container of refrigerant without its
cap fitted. Do not transport a container of
refrigerant that is unrestrained, especially in the
boot of a car.

WARNING: Do not smoke or weld in areas where
R134a is in use. Inhalation of concentrations of
vapour can cause dizziness, disorientation,
incoordination, narcosis, nausea or vomiting.

R134a is odourless and colourless. Do not
handle or discharge in an enclosed area, or any
area where the vapour and liquid can come in
contact with a naked flame or hot metal. R134a is
not flammable but can cause a highly toxic gas.

WARNING: Do not allow fluids other than R134a
or compressor lubricant to enter the air
conditioning system. Spontaneous combustion
may occur.

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.

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.

WARNING: Under no circumstances should
refrigerant hoses be disconnected without first
discharging the system.

Do not disconnect any pipes in an air
conditioning refrigeration system unless trained
and instructed to do so. A refrigerant is used
which can cause blindness if allowed to contact
eyes.

WARNING: Refrigerant must always be recycled
before re-use to ensure 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.

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.

GENERAL INFORMATION

03-29

Remedial actions

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 is 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. Ensure that
hoses are correctly positioned before tightening
couplings, and ensure that all clips and supports
are utilised.

Flexible hoses should not be positioned close to
the exhaust manifold (less than 100mm) 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, ensure that
refrigerant oil is applied to the seat of the new
'O' ring seals, BUT NOT to the threads of the
connection.

All protective plugs must remain in place to seal
the component until immediately prior to
connection.

Ensure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.

Components must not remain uncapped for
longer than 15 minutes. In the event of a delay,
the caps must be fitted.

When disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt and
moisture into the system.

The modulator (receiver/drier) contains
desiccant which absorbs moisture. It must be
positively sealed at all times. A modulator that
has been left uncapped must not be used, fit a
new unit.

The modulator should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection
of the system.

Whenever the refrigerant system is opened, the
modulator must be renewed immediately before
evacuating and recharging the system.

Use alcohol and a clean lint-free cloth to clean
dirty connections.

Ensure that all new parts fitted are marked for
use with R134a.

GENERAL INFORMATION

03-30

When a major repair has been completed, a leak test
should be conducted; refer to the air conditioning
section of this manual for the correct procedure.

Refrigerant oil
Use an approved refrigerant lubricating oil:

ND Oil 8

CAUTION: Do not use any other type of
refrigerant oil.

CAUTION: Refrigerant oil easily absorbs water
and must not be stored for long periods. Do not
pour unused oil back into the container.

When renewing system components, add the
quantities of refrigerant oil recommended in the Air
Conditioning section of this manual.

Compressor
A new compressor is sealed and pressurised with
Nitrogen gas. When fitting 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 in accordance with the 'Air
Conditioning Compressor Replacement Procedure'.

Air conditioning compressor
replacement

A new compressor is supplied filled with a full charge
of (X cm

) of refrigerant oil.

A new compressor is supplied with an oil fill (X cm) of
120 cm

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

1 Remove the drain plug from the old

compressor.

2 Invert the compressor and gravity drain the oil

into a calibrated measuring cylinder. Rotate the
compressor clutch to ensure the compressor is
completely drained.

3 Note the quantity of oil drained (Y cm

4 Calculate the quantity of oil to be drained from

the new compressor using the following
formula:

X cm

– (Y cm

+ 20 cm

) = Q cm

5 Remove the drain plug from the new

compressor and drain Q cm

of oil.

6 Fit and tighten the compressor drain plug.

System components
When renewing system components, add the
following quantities of refrigerant oil:

Condenser = 40 cm

Evaporator = 30 cm

Receiver drier = 15 cm

Pipe or hose = 5 cm

Content .. 7 8 9 10 ..