Part 1
Standard Workshop Practices
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
- Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle moving forwards or backwards.
- Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
- If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust fumes.
- There is adequate room to raise the vehicle and remove the wheels, if necessary.
- Fender covers are always installed if any work is to be carried out in the engine compartment.
- Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is raised.
CAUTION: Prior to disconnecting the battery, refer to the Electrical Section of this product - Battery disconnection/connection and the following paragraphs.
CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a surge of current causing damage to the internal components of the generator.
- If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.
Battery - General
WARNING: It is essential that a period of 10 minutes elapses after the battery is disconnected before any work is undertaken on any part of the SRS.
CAUTION: After re-connecting the battery, the steering wheel must be turned to full left-hand and right-hand 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.
CAUTION: Prior to carrying out any procedures which involve disconnecting/connecting the battery, refer to the Electrical Section of this product - Battery disconnection/connection.
CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jumper cables are connected.
Jump Starting a Vehicle
CAUTION: While it is not recommended that a vehicle is jump started, it is recognized that this may occasionally be the only practical way to mobilize a vehicle. Reference should be made to the following and also to the Electrical Section of this product - Jump Starting.
CAUTION: It is advisable not to use starter/charger sets for jump starting but if this is unavoidable, make sure that the sets are not used in the 'START' mode.
- Always make sure that the jumper cables are adequate for the task.
- Always make sure that the slave battery is of the same voltage (12 volts) as the vehicle battery. The batteries must be connected in parallel.
- Make sure that the battery terminals of both batteries are fully tightened.
- Where another vehicle is used to jump start a disabled vehicle, make sure that the two vehicles are not touching.
- It is advisable that the engine of the donor vehicle is switched off during jump starting; take care to make sure that the battery of the donor vehicle does not also become discharged.
- Always make sure that switchable electric circuits are OFF before connecting jump cables. This reduces the risk of arcing occurring when the final connection is made.
Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged as soon as possible to avoid permanent damage.
Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight hours continuous driving with no additional loads placed on the battery.
Trickle charging (defined as voltages <16 volts) may be carried out with the battery connected. Make sure that the battery terminals are fully tightened prior to trickle charging.
CAUTION: Boost charging may only be carried out with the battery disconnected from the vehicle.
Towing the Vehicle
WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section of this Manual.
When the vehicle is being towed the ignition switch must be in position II (steering lock released and warning lights illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational. Failure to follow these instructions may result in personal injury. It must be noted that with the engine not running, the power steering and brake booster will be inoperative therefore, greater effort will be needed to steer the vehicle and apply the brakes.
General Installation Instructions
Component removal
Whenever possible, clean components and the surrounding area before removal.
- Blank off openings exposed by component removal.
- Following disconnection, seal fuel, oil or hydraulic lines immediately using suitable blanking plugs or caps.
- Seal open ends of exposed oil ways using suitable 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 and containers before disassembling components.
Disassembling
Observe scrupulous cleanliness when disassembling components, particularly when brake, fuel, air suspension or hydraulic system parts are disassembled. A particle of dirt or cloth fragment could cause a serious malfunction if trapped in these systems.
- Blow out all tapped holes, crevices, oil ways and fluid passages with dry, compressed air.
WARNING: Suitable eye protection must be worn.
- Discard all seals and O-rings and replace with new when reassembling.
- Use suitable marker ink to identify mating parts, do not use a scriber or centre punch as they could initiate cracks or distortion.
- Wire or tape mating parts together where necessary to prevent accidental interchange.
- Suitably identify parts which are to be renewed and parts requiring further inspection. Keep these parts separate.
- To make sure that the correct replacement part has been obtained, do not discard a part due for renewal until after comparing it with the new part.
Cleaning components
Always use cleaning agents which are suitable for the work being undertaken and the components being cleaned. NEVER use gasoline (petrol) as a cleaning agent (degreaser). Always make sure that the component being cleaned is compatible with the cleaning agent.
Always follow the manufacturer's instructions regarding the use of cleaning agents and make sure that the environment in which the work is being undertaken is suitable. See Health and Safety Precautions for further information regarding cleaning.
General inspection of components
All components should be inspected for wear or damage before reassembling.
- Always make sure that component to be inspected is clean and free from oil or grease.
- When a component is to be checked dimensionally against design specified values, use the appropriate measuring equipment i.e. micrometers, verniers, surface plates, dial test indicators (DTI).
- Always make sure that all measuring equipment is correctly calibrated before use.
- Reject a component which is not within specified values/limits or if it appears to be damaged.
- A component may be reinstalled if dimensions obtained during checking are at the maximum tolerance limit and it is in an undamaged condition.
- Bearing journal clearances should be checked where necessary using Plastigage.
- Gaskets, seals and O-ring seals are to be re-used unless damaged.
Joints and Joint Faces
All gaskets should be installed dry unless stated otherwise. Always apply the specified lubricant to O-rings and install O-rings using the fingers only.
Use gasket removal spray and/or plastic scrapers to remove traces of old gasket.
CAUTION: DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces.
Many joints use sealants instead of gaskets as the sealing medium. Where this is the case, the sealant together with its part number will be found listed in the relevant repair operation and also in the sealants table.
CAUTION: Always remove all traces of the old sealant prior to reassembly. Use plastic scrapers, specified solvents where available or dry, lint free cloth. DO NOT use metal scrapers or emery cloth as these may damage the sealing surfaces. Make sure that sealing surfaces are free from oil or grease as sealants will not adhere properly to contaminated surfaces.
Do not allow sealant to enter tapped holes or oil ways.
Locking Devices
Always replace locking devices with one of the same design and of the correct size.
Tab washers
Always release locking tabs before loosening fixings, do not re-use tab washers.
Locknuts
Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.
Roll pins
Always install new roll pins of the correct size.
Circlips
Always install new circlips ensuring that they are of the correct size for the groove.
Woodruff keys
Woodruff keys may be re-used provided there is no indication of wear or distortion.
Remove any burrs from edges of keyways using a fine file.
Split pins
Never attempt to straighten and re-use a split pin, always make sure that replacement pins are of the correct size for the hole in which they are to be installed.
Screw Threads
- Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap or die impairs the strength and fit of the threads and is not recommended.
NOTE:
During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the correct size and thread is used.
- Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be re-used. New bolts having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
- Always make sure that replacement nuts and bolts are at least equal in strength to those that they are replacing. Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an adjustment.
- Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split the housing and also give a false torque reading.
- Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque reading.
- Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve tightening by degrees.
- To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified torque figure.
- Unless instructed otherwise, do not lubricate bolt or nut threads prior to installation.
Where it is stated that bolts and screws may be re-used, the following procedures must be carried out:
- Check that threads are undamaged.
- Remove all traces of locking agent from the threads.
CAUTION: DO NOT use a wire brush; take care that threads are not damaged.
- make sure that threads are clean and free from oil or grease.
- Apply the specified locking agent to the bolt threads.