Freelander 1. Manual - part 4

GENERAL INFORMATION

03-7

General fitting instructions

Precautions against damage
To avoid damage to the vehicle when carrying out
repairs, always adhere to the following:

Always fit wing and seat covers before
commencing work. Avoid spilling brake fluid or
battery acid on paintwork; immediately wash off
with water if this occurs.

Disconnect the battery earth lead before starting
work, see ELECTRICAL PRECAUTIONS.

Always use the recommended service tool or a
satisfactory equivalent where specified.

Protect exposed bearing surfaces, sealing
surfaces and screw threads from damage.

Component removal
Whenever possible, clean components and
surrounding area before removal.

Blank off openings exposed by component
removal.

Immediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.

Close open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.

Immediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.

Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.

Dismantling
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
serious malfunction if trapped in these systems.

Use the following procedures:

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 during the process.

Use marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.

Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).

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.

Do not discard a part due for renewal until after
comparing it with a new part to ensure that its
correct replacement has been obtained.

Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.

When washing under bonnet, never direct water onto
ECM, as water ingress may occur resulting in
damage to electrical components inside.

General Inspection
All components should be inspected for wear or
damage before being reassembled.

Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.

When a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.

Reject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.

A part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition.

Use 'Plastigauge' 12 Type PG-1 for checking
bearing surface clearances.

GENERAL INFORMATION

03-8

Ball and roller bearings

General
When removing and installing bearings, ensure that
the following practices are observed to ensure
component serviceability:

Remove all traces of lubricant from the bearing
under inspection by cleaning with a suitable
degreasant; maintain absolute cleanliness
throughout operations.

Conduct a visual inspection for markings on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any 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 spin outer race to check
that it revolves absolutely smoothly. Repeat,
holding outer race and spinning inner race.

Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation. Reject bearing
if action is not perfectly smooth.

Lubricate bearing with generous amounts of
lubricant appropriate to installation.

Inspect shaft and bearing housing for
discoloration or other markings which indicate
movement between bearing and seatings.

Ensure that shaft and housing are clean and
free from burrs before fitting bearing.

If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings;
an exception could be if the faulty bearing had
covered a low mileage, and it can be
established that damage is confined to only one
bearing.

Never refit a ball or roller bearing without first
ensuring that it is in a fully serviceable condition.

When hub bearings are removed or displaced,
NEW bearings must be fitted; do not attempt to
refit the old hub bearings.

When fitting a bearing to a shaft, only apply
force to the inner ring of the bearing. When
fitting a bearing into a housing, only apply force
to the outer ring of the bearing.

In the case of grease lubricated bearings (e.g.
hub bearings) fill the space between bearing
and outer seal with the recommended grade of
grease before fitting seal.

Always mark components of separable bearings
(e.g. taper roller bearings) when dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring; always fit a complete new
bearing assembly.

GENERAL INFORMATION

03-9

Oil seals

General
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.

Carefully examine seal before fitting to ensure
that it is clean and undamaged.

Ensure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.

Protect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.

Certain oil seals are coated with a protective
wax and must be fitted dry unless stated
otherwise. Where an oil seal needs to be
lubricated prior to fitment, lubricate the sealing
lips with a recommended lubricant before use to
prevent damage during initial use. On dual
lipped seals, smear the area between the lips
with grease.

If a seal spring is provided, ensure that it is fitted
correctly.

Place lip of seal towards fluid to be sealed and
slide into position on shaft. Use fitting sleeve
where possible to protect sealing lip from
damage by sharp corners, threads or splines. If
a fitting sleeve is not available, use plastic tube
or tape to prevent damage to the sealing lip.

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. Never let weight of
unsupported shaft rest in seal.

Use the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm
(0.015 in.) smaller than the outside diameter of
the seal. Use a hammer VERY GENTLY on
drift if a suitable press is not available.

Press or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.

GENERAL INFORMATION

03-10

Joints and joint faces

General
Fit joints dry unless specified otherwise.

Always use the correct gaskets as specified.

When joining compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent joining compound from entering
oilways, pipes or blind tapped holes.

If gaskets and/or joining compound is
recommended for use; remove all traces of old
joining material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or joining material to
enter any tapped holes or enclosed parts.

Prior to reassembly, blow through any pipes,
channels or crevices with compressed air.

Locking devices

General
Always replace locking devices with one of the same
design.

Tab Washers
Always release locking tabs and fit new locking
washers, do not re-use locking tabs. Ensure the new
tab washer is the same design as that replaced.

Locking Nuts
Always use a backing spanner when loosening or
tightening locking nuts, brake and fuel pipe unions.

Roll Pins
Always fit new roll pins of an interference fit in the
hole.

Circlips
Always fit new circlips of the correct size for the
groove.

Locking wire
Always fit locking wire of the correct type. Arrange
wire so that its tension tends to tighten the bolt heads
or nuts to which it is fitted.

Keys and Keyways
Remove burrs from edges of keyways with a fine file
and clean thoroughly before attempting to refit key.

Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.

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