brake LAND ROVER DISCOVERY 2002 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 4 of 1672
CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
How To Use This Manual................................................................................................................ 01-1
Repairs and Replacements ............................................................................................................. 01-1
Specifications .................................................................................................................................. 01-2
Abbreviations and Symbols ............................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
General Precautions ....................................................................................................................... 03-1
Safety Instructions .......................................................................................................................... 03-2
Environmental Precautions ............................................................................................................. 03-3
General Fitting Instructions ............................................................................................................. 03-6
Ball and Roller Bearings ................................................................................................................. 03-7
Oil Seals.......................................................................................................................................... 03-8
Joints and Joint Faces .................................................................................................................... 03-9
Locking Devices .............................................................................................................................. 03-9
Screw Threads ................................................................................................................................ 03-10
Bolt and Nut Identification ............................................................................................................... 03-11
Flexible Pipes and Hoses ............................................................................................................... 03-13
Rolling Road Testing....................................................................................................................... 03-15
Fuel Handling Precautions .............................................................................................................. 03-16
Electrical Precautions ..................................................................................................................... 03-17
Supplementary Restraint System Precautions ............................................................................... 03-18
SRS Component Replacement Policy ............................................................................................ 03-23
Air Conditioning System Precautions .............................................................................................. 03-24
Air Conditioning Compressor Replacement .................................................................................... 03-26
Body Repairs .................................................................................................................................. 03-26
GENERAL DATA ..................................................................................... 04-1
Engine - Td5 ................................................................................................................................... 04-1
Engine - V8 ..................................................................................................................................... 04-4
Fuel system - Td5 ........................................................................................................................... 04-8
Fuel system - V8 ............................................................................................................................. 04-9
Cooling system - Td5 ...................................................................................................................... 04-9
Cooling system - V8 ........................................................................................................................ 04-10
Clutch - Td5 .................................................................................................................................... 04-10
Clutch - V8 ...................................................................................................................................... 04-11
Manual gearbox - R380 .................................................................................................................. 04-12
Transfer box - LT230SE .................................................................................................................. 04-13
Automatic gearbox - ZF4HP22/24 .................................................................................................. 04-13
Rear axle......................................................................................................................................... 04-13
Front axle ........................................................................................................................................ 04-13
Steering........................................................................................................................................... 04-14
Suspension ..................................................................................................................................... 04-15
Brakes ............................................................................................................................................. 04-16
Wheels and tyres ............................................................................................................................ 04-16
Air conditioning ............................................................................................................................... 04-17
Electrical - Td5 ................................................................................................................................ 04-17
Electrical - V8 .................................................................................................................................. 04-17
Dimensions ..................................................................................................................................... 04-18
Weights ........................................................................................................................................... 04-18
Page 5 of 1672
CONTENTS
2CONTENTS
IDENTIFICATION NUMBERS .................................................................. 05-1
Vehicle Identification Number ......................................................................................................... 05-1
Identification Number Locations ..................................................................................................... 05-3
TORQUE WRENCH SETTINGS .............................................................. 06-1
Maintenance ................................................................................................................................... 06-1
Engine Td5 ..................................................................................................................................... 06-2
Engine V8 ....................................................................................................................................... 06-4
Emission control - Td5 .................................................................................................................... 06-5
Emission control - V8 ...................................................................................................................... 06-5
Engine management system - Td5 ................................................................................................. 06-5
Engine management system - V8................................................................................................... 06-6
Cooling system ............................................................................................................................... 06-6
Manifolds and exhaust systems - Td5 ............................................................................................ 06-6
Manifolds and exhaust systems - V8 .............................................................................................. 06-7
Clutch.............................................................................................................................................. 06-7
Manual gearbox - R380 .................................................................................................................. 06-8
Transfer box - LT230SE ................................................................................................................. 06-8
Automatic gearbox - ZF4HP22/24 .................................................................................................. 06-9
Propeller shafts ............................................................................................................................... 06-9
Axles ............................................................................................................................................... 06-9
Steering .......................................................................................................................................... 06-10
Front suspension ............................................................................................................................ 06-11
Rear suspension ............................................................................................................................. 06-12
Brakes............................................................................................................................................. 06-12
Restraint systems ........................................................................................................................... 06-13
Body................................................................................................................................................ 06-14
Heating and air conditioning ........................................................................................................... 06-15
Wipers and washers ....................................................................................................................... 06-15
Electrical ......................................................................................................................................... 06-15
LIFTING AND TOWING ........................................................................... 08-1
LIFTING .......................................................................................................................................... 08-1
TOWING ......................................................................................................................................... 08-2
TRANSPORTING ........................................................................................................................... 08-3
CAPACITIES, FLUIDS AND LUBRICANTS ............................................ 09-1
Capacities ....................................................................................................................................... 09-1
Fluids .............................................................................................................................................. 09-2
Anti-Freeze Concentration .............................................................................................................. 09-3
Lubrication ...................................................................................................................................... 09-3
MAINTENANCE ........................................................................................ 10-1
PROCEDURES
V8 engine underbonnet view .......................................................................................................... 10-1
Diesel underbonnet view ................................................................................................................ 10-2
Seats and seat belts ...................................................................................................................... 10-3
Lamps, horns and warning indicators ........................................................................................... 10-5
Wipers and washers ...................................................................................................................... 10-5
Handbrake .................................................................................................................................. 10-6
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CONTENTS
CONTENTS 3
Alarm handset battery ..................................................................................................................... 10-6
Road wheels ................................................................................................................................... 10-7
Tyres .............................................................................................................................................. 10-7
Brake pads, discs and calipers ....................................................................................................... 10-7
Road wheel speed sensors ............................................................................................................. 10-7
Brake fluid ....................................................................................................................................... 10-8
Fuel filter - diesel engine ................................................................................................................. 10-8
Fuel filter sedimenter ...................................................................................................................... 10-8
Road wheels ................................................................................................................................... 10-8
Radiator/Intercooler ........................................................................................................................ 10-8
Ambient air Temperature and pressure sensor .............................................................................. 10-8
Doors, bonnet and fuel filler flap ..................................................................................................... 10-9
Air suspension intake filter .............................................................................................................. 10-9
Anti-freeze....................................................................................................................................... 10-9
Cooling system ............................................................................................................................... 10-9
Spark plugs - V8 engine.................................................................................................................. 10-10
Air cleaner - V8 engine ................................................................................................................... 10-11
Air cleaner and dump valve - diesel engine .................................................................................... 10-11
Auxiliary drive belt ........................................................................................................................... 10-11
Auxiliary drive belt - V8 engine ....................................................................................................... 10-12
Auxiliary drive belt - diesel engine .................................................................................................. 10-12
Fluid reservoirs ............................................................................................................................... 10-12
Steering box .................................................................................................................................... 10-13
Battery ............................................................................................................................................. 10-13
Intercooler - diesel engine............................................................................................................... 10-14
Engine oil - V8 engine ..................................................................................................................... 10-14
Engine oil - diesel engine ................................................................................................................ 10-14
Centrifuge rotor – diesel engine ...................................................................................................... 10-15
Engine oil filter - diesel engine ........................................................................................................ 10-15
Engine oil filter – V8 engine ............................................................................................................ 10-15
Manual gearbox .............................................................................................................................. 10-16
Automatic gearbox ......................................................................................................................... 10-17
Transfer box .................................................................................................................................... 10-18
Front and rear axle .......................................................................................................................... 10-19
Propeller shafts ............................................................................................................................... 10-19
Anti-roll bar links ............................................................................................................................. 10-20
ACE actuators ................................................................................................................................. 10-21
ACE filter ......................................................................................................................................... 10-21
Brake hose, brake, fuel, ACE, clutch pipes and unions/electrical harnesses ................................ 10-22
Engine, gearbox, transfer box and axles ........................................................................................ 10-23
Exhaust system............................................................................................................................... 10-23
Steering box and front suspension ................................................................................................. 10-23
Steering rod ball joints ................................................................................................................... 10-25
Dampers and SLS height sensors .................................................................................................. 10-25
Front and rear axle suspension links .............................................................................................. 10-26
Towing bracket................................................................................................................................ 10-27
Engine mountings - V8 engine ........................................................................................................ 10-27
Road/roller test................................................................................................................................ 10-28
ENGINE - Td5 ........................................................................................... 12-1-1
DESCRIPTION AND OPERATION
Td5 Engine...................................................................................................................................... 12-1-1
Cylinder block components ............................................................................................................. 12-1-2
Page 13 of 1672
CONTENTS
10 CONTENTS
MANIFOLDS AND EXHAUST SYSTEMS - V8......................................... 30-2-1
DESCRIPTION AND OPERATION
Exhaust manifold component layout ............................................................................................... 30-2-1
Inlet manifold component layout ..................................................................................................... 30-2-2
Exhaust system component layout ................................................................................................. 30-2-4
Description ...................................................................................................................................... 30-2-5
REPAIRS
Front pipe........................................................................................................................................ 30-2-9
Intermediate pipe/silencer .............................................................................................................. 30-2-10
Tail pipe .......................................................................................................................................... 30-2-11
Heat shield - brake servo - Without Secondary Air Injection .......................................................... 30-2-11
Heat shield - brake servo - With Secondary Air Injection .............................................................. 30-2-12
Gasket - inlet manifold - lower ........................................................................................................ 30-2-12
Gasket - exhaust manifold ........................................................................................................... 30-2-16
Gasket - inlet manifold - upper - Without Secondary Air Injection .................................................. 30-2-17
Gasket - inlet manifold - upper - With Secondary Air Injection ..................................................... 30-2-19
CLUTCH - Td5 .......................................................................................... 33-1-1
DESCRIPTION AND OPERATION
Clutch components ......................................................................................................................... 33-1-2
Hydraulic operation ......................................................................................................................... 33-1-4
Description ...................................................................................................................................... 33-1-6
Operation ........................................................................................................................................ 33-1-10
ADJUSTMENTS
Clutch hydraulic system - bleed ...................................................................................................... 33-1-11
REPAIRS
Clutch assembly ........................................................................................................................... 33-1-13
Master cylinder .............................................................................................................................. 33-1-14
Bearing and lever - clutch release ................................................................................................ 33-1-15
Slave cylinder ................................................................................................................................. 33-1-15
CLUTCH - V8 ............................................................................................ 33-2-1
DESCRIPTION AND OPERATION
Clutch components ......................................................................................................................... 33-2-2
Hydraulic operation ......................................................................................................................... 33-2-4
Description ...................................................................................................................................... 33-2-6
Operation ........................................................................................................................................ 33-2-10
ADJUSTMENTS
Clutch hydraulic system - bleed ...................................................................................................... 33-2-11
REPAIRS
Clutch assembly ............................................................................................................................ 33-2-13
Master cylinder ............................................................................................................................... 33-2-14
Bearing and lever - clutch release ................................................................................................ 33-2-15
Slave cylinder ................................................................................................................................. 33-2-15
Page 18 of 1672
CONTENTS
CONTENTS 15
Bushes - radius arm ...................................................................................................................... 60-39
ECU - ACE ..................................................................................................................................... 60-40
Accelerometer - ACE - upper ........................................................................................................ 60-41
Accelerometer - ACE - lower ........................................................................................................ 60-42
Pump - ACE - V8 ............................................................................................................................ 60-42
Pump - ACE - diesel ....................................................................................................................... 60-44
Valve block - ACE ......................................................................................................................... 60-46
Filter - high pressure - ACE .......................................................................................................... 60-48
Pressure transducer - ACE ........................................................................................................... 60-49
Solenoid - pressure control valve - ACE ....................................................................................... 60-50
Solenoid - directional control valve - ACE ..................................................................................... 60-51
Pipe assembly - valve block to front actuator - ACE ...................................................................... 60-51
Pipe assembly - pump or reservoir to valve block - ACE - V8 ....................................................... 60-54
Pipe assembly - pump or reservoir to valve block - ACE - diesel .................................................. 60-57
Pipe assembly - valve block to rear actuator - ACE ........................................................................ 60-61
Actuator - front - ACE .................................................................................................................... 60-63
Bushes - front long arm - ACE ........................................................................................................ 60-65
REAR SUSPENSION ................................................................................ 64-1
DESCRIPTION AND OPERATION
Rear suspension component layout (vehicles with SLS) ............................................................... 64-2
Rear suspension component layout (vehicles without SLS) .......................................................... 64-3
Rear suspension components ........................................................................................................ 64-4
Description ...................................................................................................................................... 64-6
DESCRIPTION AND OPERATION
SLS component layout .................................................................................................................... 64-9
SLS system control diagram ........................................................................................................... 64-10
Description - SLS ............................................................................................................................ 64-12
Operation ........................................................................................................................................ 64-20
ADJUSTMENTS
SLS calibration blocks..................................................................................................................... 64-23
REPAIRS
Wheel hub ....................................................................................................................................... 64-25
Road spring - rear ........................................................................................................................... 64-27
Air spring - SLS ............................................................................................................................... 64-28
Damper - rear ................................................................................................................................ 64-29
Bushes - radius arm ...................................................................................................................... 64-29
Bushes - Watts linkage ................................................................................................................. 64-31
Sensor - height - SLS...................................................................................................................... 64-32
Compressor unit - air - SLS ............................................................................................................ 64-32
Filter - intake - SLS ......................................................................................................................... 64-34
Switch - ride height ......................................................................................................................... 64-34
Air valve - SLS ................................................................................................................................ 64-35
Actuator - rear - ACE ...................................................................................................................... 64-36
Bushes - rear long arm - ACE ......................................................................................................... 64-38
BRAKES ................................................................................................... 70-1
DESCRIPTION AND OPERATION
Page 19 of 1672
CONTENTS
16 CONTENTS
Brake system control component layout ......................................................................................... 70-1
Brake system control diagram ........................................................................................................ 70-2
Brake system hydraulic component layout ..................................................................................... 70-4
Description ...................................................................................................................................... 70-5
Operation ........................................................................................................................................ 70-20
DESCRIPTION AND OPERATION
Handbrake component layout ......................................................................................................... 70-25
Description ...................................................................................................................................... 70-26
ADJUSTMENTS
Handbrake .................................................................................................................................... 70-29
Brake system bleeding .................................................................................................................. 70-30
REPAIRS
Brake disc - front .......................................................................................................................... 70-33
Brake disc - rear ........................................................................................................................... 70-34
Master cylinder - brake ................................................................................................................. 70-35
Cable - handbrake ........................................................................................................................ 70-36
Switch - brake light ....................................................................................................................... 70-37
Brake pads - front ......................................................................................................................... 70-37
Brake pads - rear .......................................................................................................................... 70-38
Brake shoes - handbrake................................................................................................................ 70-39
Servo - brake .................................................................................................................................. 70-41
Vacuum pump - servo..................................................................................................................... 70-42
Housing - caliper - front ................................................................................................................ 70-43
Housing - caliper - rear ................................................................................................................. 70-44
ECU - Self levelling and anti locking brakes (SLABS) ................................................................. 70-45
Sensor – ABS – front ..................................................................................................................... 70-46
Sensor – ABS – rear ....................................................................................................................... 70-47
Modulator unit - ABS ...................................................................................................................... 70-47
Switch - Hill descent control............................................................................................................ 70-48
Switch - handbrake ....................................................................................................................... 70-49
RESTRAINT SYSTEMS ............................................................................ 75-1
DESCRIPTION AND OPERATION
SRS component layout ................................................................................................................... 75-1
SRS block diagram ......................................................................................................................... 75-2
Description - SRS ........................................................................................................................... 75-3
Operation - SRS ............................................................................................................................. 75-9
DESCRIPTION AND OPERATION
Description - seat belts ................................................................................................................... 75-11
REPAIRS
Seat belt - front .............................................................................................................................. 75-13
Seat belt - rear - centre ................................................................................................................. 75-13
Seat belt - rear - side .................................................................................................................... 75-15
Mounting - seat belt - 'B' post ...................................................................................................... 75-16
Seat belts - third row ....................................................................................................................... 75-17
Pre-tensioner - front seat belt ....................................................................................................... 75-18
Airbag module - drivers .................................................................................................................. 75-18
Airbag module - passenger ........................................................................................................... 75-19
DCU ................................................................................................................................................ 75-20
Rotary coupler ................................................................................................................................ 75-21
Airbag deployment tool - self test ................................................................................................... 75-22
Airbag module - drivers - deployment ............................................................................................. 75-23
Page 32 of 1672
INTRODUCTION
01-3
Abbreviations and Symbols
A Amperes
AAP Ambient Air Pressure
AAT Ambient Air Temperature
ABDC After Bottom Dead Centre
ABS Anti-Lock Brake System
ABS / TC Anti-lock Brake System / Traction
Control
ac Alternating current
A/C Air Conditioning
ACE Active Cornering Enhancement
ACEA Association of Constructors of
European Automobiles
AFR Air Fuel Ratio
AP Ambient Pressure
ASC Anti-shunt Control
ATC Air Temperature Control
ATDC After Top Dead Centre
AUX Auxiliary
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BBUS Battery Backed Up Sounder
BCU Body Control Unit
BDC Bottom Dead Centre
bhp Brake Horse Power
BP Boost Pressure
BPP Brake Pedal Position
BS British Standard
BTDC Before Top Dead Centre
BWD Backward
C Celsius
CAN Controller Area Network
CD Compact Disc
CDC Centre Differential Control
CDL Central Door Locking
CD - ROM Compact Disc - Read Only
Memory
CFC Chlorofluorocarbon
CHMSL Centre High Mounted Stop Lamp
CKP Crankshaft Position
CLV Calculated Load Value
cm Centimetre
cm
2Square centimetre
cm3Cubic centimetre
CMP Camshaft Position
CPP Clutch Pedal Position
CO Carbon Monoxide
CO
2Carbon Dioxide
COB Clear Over Base
CR Common Rail
CVS Canister Vent Solenoid
dB Decibels
DDM Driver's Door Module
deg. Degree, angle or temperature
DI Direct Injection
dia. DiameterDIN Deutsche Industrie Normen
(German Industrial Standards)
dc Direct current
DCV Directional Control Valve
DOHC Double Overhead Camshaft
DSP Digital Signal Processing
DTI Dial Test Indicator
DMF Dual Mass Flywheel
DVD Digital Versatile Disc
EACV Electronic Air Control Valve
EAT Electronic Automatic
Transmission
EBD Electronic Brake pressure
Distribution
ECD European Community Directive
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable
Programmable Read Only
Memory
EGR Exhaust Gas Recirculation
EKA Emergency Key Access
ELR Emergency Locking Retractor
EN European Norm
EOBD European On Board Diagnostics
EON Enhanced Other Network
ERL Electrical Reference Library
ETC Electronic Traction Control
EUI Electronic Unit Injector
EVAP Evaporative Emission
EVR Electronic Vacuum Regulator
F Fahrenheit
ft. Feet
FBH Fuel Burning Heater
FET Field Effect Transistor
FIP Fuel Injection Pump
FTC Fast Throttle Control
FWD Forward
> Greater than
g Gramme or Gravity
gal. Gallons
GMT Greenwich Mean Time
GPS Global Positioning System
hHour
hc High compression
HC Hydro Carbons
HDC Hill Descent Control
HDOP Height Dilation Of Precision
HDPE High Density Polyethylene
HFS Heated Front Screen
Hg Mercury
HO
2S Heated Oxygen Sensor
HMW High Molecular Weight
Page 33 of 1672
INTRODUCTION
01-4
HRW Heated Rear Window
HSLA High Strength Low Alloy
ht/HT High tension
IACV Idle Air Control Valve
IAT Intake Air Temperature
ICE In-Car Entertainment
i.dia. Internal diameter
IDM Intelligent Driver Module
IF Intermediate Frequency
in
3Cubic inch
ILT Inlet Throttle
IPW Injector Pulse Width
ISO International Organisation for
Standardisation
ITS Inflatable Tubular Structure
k Thousand
kg Kilogramme
kg/h Kilogrammes per hour
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock Sensor
lb(s) Pounds
lbf Pounds force
lbf.in Pounds force inches
lbf/in
2Pounds per square inch
lbf.ft Pounds force feet
λLambda
lc Low compression
LCD Liquid Crystal Display
LED Light Emitting Diode
LEV Low Emission Vehicle
LH Left-Hand
LHD Left-Hand Drive
LSM Light Switch Module
LVS Liquid Vapour Separator
mMetre
µMicro
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MET Mechanical, Electrical and Trim
MFU Multi-Function Unit
MFL Multi-Function Logic
max. Maximum
MEMS Modular Engine Management
System
MIG Metal/Inert Gas
MIL Malfunction Indicator Lamp
MPa MegaPascal
MOSFET Metal Oxide Semiconductor Field
Effect Transistor
min. Minimum
- Minus (tolerance)
' Minute (angle)
mm Millimetre
mph Miles per hour MPi Multi-Point injection
MV Motorised Valve
MY Model Year
NAS North American Specification
(-) Negative (electrical)
Nm Newton metre
No. Number
NO
2Nitrogen Dioxide
NO
xOxides of Nitrogen
NTC Negative Temperature
Coefficient
NRV Non Return Valve
OBD On Board Diagnostics
OBM On Board Monitoring
o.dia. Outside diameter
OAT Organic Acid Technology
ORM Off-road Mode
ΩOhm
PAS Power Assisted Steering
PCB Printed Circuit Board
PCV Positive Crankcase Ventilation
PDC Parking Distance Control
PDOP Position Dilation Of Precision
PI Programme Information
PPS Pulse Per Second
PS Programme Service
psi Pounds per square inch
pts. Pints
% Percentage
+ Plus (tolerance) or Positive
(electrical)
±Plus or minus (tolerance)
PTC Positive Temperature Coefficient
PTFE Polytetrafluorethylene
PVC Polyvinyl chloride
PWM Pulse Width Modulation
RDS Radio Data Service
rRadius
:Ratio
ref Reference
REG Regionalisation
RES Rover Engineering Standards
rev/min Revolutions per minute
RF Radio Frequency
RGB Red / Green / Blue
RH Right-Hand
RHD Right-Hand Drive
ROM Read Only Memory
RON Research Octane Number
ROV Roll Over Valve
ROW Rest Of World
SAE Society of Automotive Engineers
SAI Secondary Air Injection
" Second (angle)
SLABS Self Levelling and Anti-Lock
Brake System
SLS Self Levelling Suspension
SOHC Single Overhead Camshaft
Page 36 of 1672
GENERAL INFORMATION
03-1
GENERAL INFORMATION
General Precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and
should, as far as possible, be kept from contact
with the skin. These liquids and substances
include acid, anti-freeze, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers. Under normal operating
conditions this material is safe and does not present
a health hazard. However, if the material is damaged
by fire or excessive heating, it can break down and
produce highly corrosive Hydrofluoric acid.
Contact with Hydrofluoric acid can cause serious
burns on contact with skin. If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or overheated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.).
Decontaminate and dispose of gloves immediately
after use.Lubricating oils
Avoid excessive skin contact with used lubricating
oils and always adhere to the health protection
precautions.
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Health protection precautions
The following precautions should be observed at all
times.
lWear protective clothing, including impervious
gloves where practicable.
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lApply barrier creams before each work period to
help prevent lubricating oil from contaminating
the skin.
lWash with soap and water to ensure all oil is
removed (proprietary skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol/gasoline, kerosene, diesel
fuel, oil, thinners or solvents for cleaning skin.
lWhere practicable, degrease components prior
to handling.
lIf skin disorders develop, obtain medical advice
without delay.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in close
vicinity of the work area.
Page 37 of 1672
GENERAL INFORMATION
03-2
Safety Instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes, always replace as complete axle sets.Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe cannot contact a
potential chafing point.
lContainers used for brake fluid must be kept
absolutely clean.
lDo not store brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow brake fluid to be contaminated with
mineral oil, or put new brake fluid in a container
which has previously contained mineral oil.
lDo not re-use brake fluid removed from the
system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to
prevent the ingress of dirt.
lOnly use the correct brake fittings with
compatible threads.
lObserve absolute cleanliness when working
with hydraulic components.
Cooling system caps and plugs
Extreme care is necessary when removing
expansion tank caps and coolant drain or bleed
screws when the engine is hot, especially if it is
overheated. To avoid the possibility of scalding,
allow the engine to cool before attempting removal.