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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

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    							07 - GENERAL FITTING REMINDERS
    CONTENTS
    Page
    INFORMATION
    GENERAL FITTING REMINDERS 1.......................................................................
    PRECAUTIONS AGAINST DAMAGE 1..................................................................
    SAFETY PRECAUTIONS 1....................................................................................
    PREPARATION 2....................................................................................................
    DISMANTLING 2.....................................................................................................
    INSPECTION-GENERAL 2.....................................................................................
    BALL AND ROLLER BEARINGS 3.........................................................................
    OIL SEALS 4...........................................................................................................
    JOINTS AND JOINT FACES 5................................................................................
    FLEXIBLE HYDRAULIC PIPES, HOSES 5.............................................................
    FUEL SYSTEM HOSES 6.......................................................................................
    METRIC BOLT IDENTIFICATION 6........................................................................
    METRIC NUT IDENTIFICATION 6..........................................................................
    KEYS AND KEYWAYS 6........................................................................................
    TAB WASHERS 6...................................................................................................
    COTTER PINS 7.....................................................................................................
    NUTS7 ...................................................................................................................
    LOCKING WIRE 7...................................................................................................
    SCREW THREADS 7..............................................................................................
    UNIFIED THREAD IDENTIFICATION 7.................................................................. 
    						
    							GENERAL FITTING REMINDERS
    1
    INFORMATION GENERAL FITTING REMINDERS
    WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
    The suggestions, cautions and warnings in the
    section are intended to serve as reminders for
    trained and experienced mechanics. This manual
    is not a definitive guide to automotive mechanics
    or workshop safety.
    Shop equipment, shop environment, and the use
    and disposal of solvents, fluids, and chemicals
    are subject to government regulations which are
    intended to provide a level of safety. It is your
    responsibility to know and comply with such
    regulations.
    PRECAUTIONS AGAINST DAMAGE
    1.Always fit covers to protect fenders before
    commencing work in engine compartment.
    2.Cover seats and carpets, wear clean overalls
    and wash hands or wear gloves before working
    inside vehicle.
    3.Avoid spilling hydraulic fluid or battery acid on
    paint work. Wash off with water immediately if
    this occurs. Use Polythene sheets to protect
    carpets and seats.
    4.Always use a recommended Service Tool where
    specified.
    5.Protect temporarily exposed screw threads by
    replacing nuts or fitting plastic caps.SAFETY PRECAUTIONS
    1.Whenever possible, use a lift when working
    beneath vehicle, in preference to jacking. Chock
    wheels as well as applying parking brake.
    WARNING: Do not use a pit when
    removing fuel system components.
    2.Never rely on a jack alone to support vehicle.
    Use axle stands carefully placed at jacking
    points to provide rigid support.
    3.Ensure that a suitable form of fire extinguisher is
    conveniently located.
    4.Check that any lifting equipment used has
    adequate capacity and is fully serviceable.
    5.Disconnect battery.
    WARNING: Do not disconnect any pipes in
    air conditioning system, unless trained
    and instructed to do so. A refrigerant is
    used which can cause blindness if allowed to
    contact eyes.
    6.Ensure that adequate ventilation is provided
    when volatile degreasing agents are being used.
    7.Do not apply heat in an attempt to free stiff
    fixings; as well as causing damage to protective
    coatings, there is a risk of damage to electronic
    equipment and brake linings from stray heat. 
    						
    							07GENERAL FITTING REMINDERS
    2
    INFORMATION PREPARATION
    1.Clean components and surrounding area prior to
    removal.
    2.Blank off any openings exposed by component
    removal using greaseproof paper and masking
    tape.
    3.Immediately seal fuel, oil or hydraulic lines when
    separated, using plastic caps or plugs, to
    prevent loss of fluid and entry of dirt.
    4.Close open ends of oilways, exposed by
    component removal, with tapered hardwood
    plugs or readily visible plastic plugs.
    5.Immediately a component is removed, place it in
    a suitable container; use a separate container for
    each component and its associated parts.
    6.Before dismantling a component, clean it
    thoroughly with a recommended cleaning agent;
    check that agent is suitable for all materials of
    component.
    7.Clean bench and provide marking materials,
    labels, containers and locking wire before
    dismantling a component.
    DISMANTLING
    1.Observe scrupulous cleanliness when
    dismantling components, particularly when
    brake, fuel or hydraulic system parts are being
    worked on. A particle of dirt or a cloth fragment
    could cause a dangerous malfunction if trapped
    in these systems.
    2.Blow out all tapped holes, crevices, oilways and
    fluid passages with an air line. Ensure that any
    O-rings used for sealing are correctly replaced or
    renewed, if disturbed.
    3.Use marking ink to identify mating parts, to
    ensure correct reassembly. If a centre punch or
    scriber is used they may initiate cracks or
    distortion of components.
    4.Wire together mating parts where necessary to
    prevent accidental interchange (e.g. roller
    bearing components).
    5.Wire labels on to all parts which are to be
    renewed, and to parts requiring further
    inspection before being passed for reassembly;
    place these parts in separate containers from
    those containing parts for rebuild.
    6.Do not discard a part due for renewal until it has
    been compared with the new part, to ensure that
    its correct replacement has been obtained.INSPECTION-GENERAL
    1.Never inspect a component for wear or
    dimensional check unless it is absolutely clean;
    a slight smear of grease can conceal an incipient
    failure.
    2.When a component is to be checked
    dimensionally against figures quoted for it, use
    correct equipment (surface plates, micrometers,
    dial gauges, etc.) in serviceable condition.
    Makeshift checking equipment can be
    dangerous.
    3.Reject a component if its dimensions are outside
    limits quoted, or if damage is apparent. A part
    may, however, be refitted if its critical dimension
    is exactly limit size, and is otherwise satisfactory.
    4.Use’Plastigauge’12 Type PG-1 for checking
    bearing surface clearances. Directions for its
    use, and a scale giving bearing clearances in
    0,0025 mm steps are provided with it. 
    						
    							GENERAL FITTING REMINDERS
    3
    INFORMATION BALL AND ROLLER BEARINGS
    CAUTION: Never refit a ball or roller
    bearing without first ensuring that it is in a
    fully serviceable condition.
    1.Remove all traces of lubricant from bearing
    under inspection by washing in a suitable
    degreaser; maintain absolute cleanliness
    throughout operations.
    2.Inspect visually for markings of any form on
    rolling elements, raceways, outer surface of
    outer rings or inner surface of inner rings. Reject
    any bearings found to be marked, since any
    marking in these areas indicates onset of wear.
    3.Holding inner race between finger and thumb of
    one hand, spin outer race and check that it
    revolves absolutely smoothly. Repeat, holding
    outer race and spinning inner race.
    4.Rotate outer ring gently with a reciprocating
    motion, while holding inner ring; feel for any
    check or obstruction to rotation, and reject
    bearing if action is not perfectly smooth.
    5.Lubricate bearing generously with lubricant
    appropriate to installation.
    6.Inspect shaft and bearing housing for
    discolouration or other marking suggesting that
    movement has taken place between bearing and
    seatings. (This is particularly to be expected if
    related markings were found in operation 2).
    7.Ensure that shaft and housing are clean and free
    from burrs before fitting bearing.8.If one bearing assembly of a pair shows an
    imperfection it is generally advisable to replace
    both with new bearings; an exception could be
    made if the faulty bearing had covered a low
    mileage, and it could be established that
    damage was confined to it only.
    9.When fitting bearing to shaft, apply force only to
    inner ring of bearing, and only to outer ring when
    fitting into housing, as shown above.
    10.In the case of grease lubricated bearings (e.g.
    hub bearings) fill space between bearing and
    outer seal with recommended grade of grease
    before fitting seal.
    11.Always mark components of separable bearings
    (e.g. taper roller bearings) in dismantling, to
    ensure correct reassembly. Never fit new rollers
    in a used outer ring, always fit a complete new
    bearing assembly. 
    						
    							07GENERAL FITTING REMINDERS
    4
    INFORMATION OIL SEALS
    NOTE: Ensure that the seal running track
    is free from pits, scores, corrosion and
    general damage prior to fitting
    replacement seal.
    1.Always fit new oil seals when rebuilding an
    assembly.
    2.Carefully examine seal before fitting to ensure
    that it is clean and undamaged.
    3.Coat the sealing lips with clean grease; pack
    dust excluder seals with grease, and heavily
    grease duplex seals in cavity between sealing
    lips.
    4.Ensure that seal spring, if provided, is correctly
    fitted.
    5.Place lip of seal towards fluid to be sealed and
    slide into position on shaft, using fitting sleeve
    when possible to protect sealing lip from damage
    by sharp corners, threads or splines. If fitting
    sleeve is not available, use plastic tube or tape
    to prevent damage to sealing lip.
    6.Grease outside diameter of seal, place square to
    housing recess and press into position, using
    great care and if possible a’bell piece’to ensure
    that seal is not tilted. In some cases it may be
    preferable to fit seal to housing before fitting to
    shaft. Never let weight of unsupported shaft rest
    in seal.
    7.If correct service tool is not available, use a
    suitable drift approximately 0,4 mm (0.015 in)
    smaller than outside diameter of seal. Use a
    hammerVERY GENTLYon drift if a press is not
    suitable.
    8.Press or drift seal in to depth of housing if
    housing is shouldered, or flush with face of
    housing where no shoulder is provided. Ensure
    that the seal does not enter the housing in a
    tilted position.
    NOTE: Most cases of failure or leakage of
    oil seals are due to careless fitting, and
    resulting damage to both seals and
    sealing surfaces. Care in fitting is essential if
    good results are to be obtained. NEVER use a seal
    which has been improperly stored or handled,
    such as hung on a hook or nail. 
    						
    							GENERAL FITTING REMINDERS
    5
    INFORMATION JOINTS AND JOINT FACES
    1.Always use correct gaskets where they are
    specified.
    2.Use jointing compound only when
    recommended. Otherwise fit joints dry.
    3.When jointing compound is used, apply in a thin
    uniform film to metal surfaces; take great care to
    prevent it from entering oilways, pipes or blind
    tapped holes.
    4.Remove all traces of old jointing materials prior
    to reassembly. Do not use a tool which could
    damage joint faces.
    5.Inspect joint faces for scratches or burrs and
    remove with a fine file or oil stone; do not allow
    removed material or dirt to enter tapped holes or
    enclosed parts.
    6.Blow out any pipes, channels or crevices with
    compressed air, fit new’O’rings or seals
    displaced by air blast.FLEXIBLE HYDRAULIC PIPES, HOSES
    1.Before removing any brake or power steering
    hose, clean end fittings and area surrounding
    them as thoroughly as possible.
    2.Obtain appropriate plugs or caps before
    detaching hose end fittings, so that ports can be
    immediately covered to exclude dirt.
    3.Clean hose externally and blow through with
    airline. Examine carefully for cracks, separation
    of plies, security of end fittings and external
    damage. Reject any hose found faulty.
    4.When refitting hose, ensure that no unnecessary
    bends are introduced, and that hose is not
    twisted before or during tightening of union nuts.
    5.Containers for hydraulic fluid must be kept
    absolutely clean.
    6.Do not store brake fluid in an unsealed
    container. It will absorb water, and fluid in this
    condition would be dangerous to use due to a
    lowering of its boiling point.
    7.Do not allow brake fluid to be contaminated with
    mineral oil, or use a container which has
    previously contained mineral oil.
    8.Do not re-use brake fluid bled from system.
    9.Always use clean brake fluid to clean hydraulic
    components.
    10.Fit a cap to seal a hydraulic union and a plug to
    its socket after removal to prevent ingress of dirt.
    11.Absolute cleanliness must be observed with
    hydraulic components at all times.
    12.After any work on hydraulic systems, inspect
    carefully for leaks underneath the vehicle while a
    second operator applies maximum pressure to
    the brakes (engine running) and operates the
    steering. 
    						
    							07GENERAL FITTING REMINDERS
    6
    INFORMATION FUEL SYSTEM HOSES
    CAUTION: All fuel hoses are made up of
    two laminations, an armoured rubber outer
    sleeve and an inner viton core. If any of
    the fuel system hoses have been disconnected, it
    is imperative that the internal bore is inspected to
    ensure that the viton lining has not become
    separated from the amoured outer sleeve. A new
    hose must be fitted if separation is evident.
    METRIC BOLT IDENTIFICATION
    1.An ISO metric bolt or screw, made of steel and
    larger than 6 mm in diameter can be identified by
    either of the symbols ISO M or M embossed or
    indented on top of the head.
    2.In addition to marks to identify the manufacture,
    the head is also marked with symbols to indicate
    the strength grade, e.g. 8.8, 12.9 or 14.9, where
    the first figure gives the minimum tensile
    strength of the bolt material in tens of kgf/mm
    2.
    3.Zinc plated ISO metric bolts and nuts are
    chromate passivated, a gold-bronze colour.METRIC NUT IDENTIFICATION
    1.A nut with an ISO metric thread is marked on
    one face or on one of the flats of the hexagon
    with the strength grade symbol 8, 12 or 14.
    Some nuts with a strength 4, 5 or 6 are also
    marked and some have the metric symbol M on
    the flat opposite the strength grade marking.
    2.A clock face system is used as an alternative
    method of indicating the strength grade. The
    external chamfers or a face of the nut is marked
    in a position relative to the appropriate hour
    mark on a clock face to indicate the strength
    grade.
    3.A dot is used to locate the 12 O’clock position
    and a dash to indicate the strength grade. If the
    grade is above 12, two dots identify the 12
    O’clock position.
    KEYS AND KEYWAYS
    1.Remove burrs from edges of keyways with a fine
    file and clean thoroughly before attempting to
    refit key.
    2.Clean and inspect key closely; keys are suitable
    for refitting only if indistinguishable from new, as
    any indentation may indicate the onset of wear.
    TAB WASHERS
    1.Fit new washers in all places where they are
    used. Always fit a new tab washer.
    2.Ensure that the new tab washer is of the same
    design as that replaced. 
    						
    							GENERAL FITTING REMINDERS
    7
    INFORMATION COTTER PINS
    1.Fit new cotter pins throughout when replacing
    any unit.
    2.Always fit cotter pins where cotter pins were
    originally used. Do not substitute spring
    washers: there is always a good reason for the
    use of a cotter pin.
    3.All cotter pins should be fitted as shown unless
    otherwise stated.
    NUTS
    1.When tightening a slotted or castellated nut
    never loosen it to insert cotter pin or locking wire
    except in those recommended cases where this
    forms part of an adjustment. If difficulty is
    experienced, alternative washers or nuts should
    be selected, or washer thickness reduced.
    2.Where self-locking nuts have been removed it is
    advisable to replace them with new ones of the
    same type.
    NOTE: Where bearing pre-load is involved
    nuts should be tightened in accordance
    with special instructions.
    LOCKING WIRE
    1.Fit new locking wire of the correct type for all
    assemblies incorporating it.
    2.Arrange wire so that its tension tends to tighten
    the bolt heads, or nuts, to which it is fitted.SCREW THREADS
    1.Both UNF and Metric threads to ISO standards
    are used. See below for thread identification.
    2.Damaged threads must always be discarded.
    Cleaning up threads with a die or tap impairs the
    strength and closeness of fit of the threads and
    is not recommended.
    3.Always ensure that replacement bolts are at
    least equal in strength to those replaced.
    4.Do not allow oil, grease or jointing compound to
    enter blind threaded holes. The hydraulic action
    on screwing in the bolt or stud could split the
    housing.
    5.Always tighten a nut or bolt to the recommended
    torque value. Damaged or corroded threads can
    affect the torque reading.
    6.To check or re-tighten a bolt or screw to a
    specified torque value first loosen a quarter of a
    turn, then re-tighten to the correct value.
    7.Oil thread lightly before tightening to ensure a
    free running thread, except in the case of
    threads treated with sealant/lubricant, and
    self-locking nuts.
    UNIFIED THREAD IDENTIFICATION
    1. Bolts
    A circular recess is stamped in the upper surface
    of the bolt head.
    2. Nuts
    A continuous line of circles is indented on one of
    the flats of the hexagon, parallel to the axis of
    the nut.
    3. Studs, Brake Rods, etc.
    The component is reduced to the core diameter
    for a short length at its extremity. 
    						
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