Discovery 2. Manual — part 378

GENERAL INFORMATION

03-13

Self-locking nuts

Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.

Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the same
type.

Flexible Pipes and Hoses

General
When removing and installing flexible hydraulic pipes
and hoses, ensure that the following practices are
observed to ensure component serviceability.

l

Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.

l

Obtain appropriate plugs or caps before
detaching hose end fittings, so that the ports can
be immediately covered to prevent the ingress
of dirt.

l

Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.

l

When refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.

l

Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of
dirt.

l

Absolute cleanliness must be observed with
hydraulic components at all times.

l

After any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.

GENERAL INFORMATION

03-14

Fuel system hoses

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 armoured outer sleeve.
A new hose must be fitted if separation is evident.

Cooling system hoses
The following precautions MUST be followed to
ensure that integrity of cooling hoses and their
connections to system components are
maintained.

Hose orientation and connection

Correct orientation of cooling hoses is important in
ensuring that the hose does not become fatigued or
damaged through contact with adjacent
components. Where 'timing' marks (2) are provided
on the hose and corresponding connection, these
must be used to ensure correct orientation. Hoses
must be pushed fully onto their connection points.
Usually, a moulded form (3) on the stub pipe
provides a positive indicator.

GENERAL INFORMATION

03-15

Hose clips

Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2 lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.

Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold and the Exhaust Gas
Recirculation (EGR) pipe. Hoses will relax and
deflect slightly when hot; ensure this movement is
taken into account when routing and securing hoses.

Rolling Road Testing

General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.

WARNING: Do not attempt to test ABS function
on a rolling road.

Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.

Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.

Two wheel rolling road
Up to 03MY

ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.

If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:

l

Propeller shaft to the rear axle is removed.

l

Neutral selected in gearbox.

When checking brakes, run engine at idle speed to
maintain servo vacuum.

From 03MY

The differential lock must be engaged for two wheel
rolling road testing. It will also be necessary to
disconnect the propeller shaft from the transfer box
output shaft driving the axle whose wheels are NOT
on the rolling road. Additionally, the ETC system
must be deactivated by either removing the 10 amp
fuse (Number 28, labelled ABS in the main fuse box)
or disconnecting the ABS modulator pump. This
must be done with the ignition OFF ; a fault in the
ABS system may still be recorded.

WARNING; VEHICLES NOT FITTED WITH A
DIFFERENTIAL LOCK MUST NOT BE TESTED
ON A ROLLING ROAD WHERE THE ROLLERS
ARE DRIVEN BY THE VEHICLE.

GENERAL INFORMATION

03-16

Fuel Handling Precautions

Fuel vapour is highly flammable and in confined
spaces is also explosive and toxic. The vapour is
heavier than air and will always fall to the lowest
level. The vapour can be easily distributed
throughout a workshop by air currents;
consequently, even a small spillage of fuel is
potentially very dangerous.

The following information provides basic precautions
which must be observed if fuel is to be handled
safely. It also outlines other areas of risk which must
not be ignored. This information is issued for basic
guidance only, if in doubt consult your local Fire
Officer.

General
Always have a fire extinguisher containing FOAM,
CO

2

, GAS or POWDER close at hand when handling

or draining fuel or when dismantling fuel systems.
Fire extinguishers should also be located in areas
where fuel containers are stored.

Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.

Whenever fuel is being handled, drained or stored, or
when fuel systems are being dismantled, all forms of
ignition must be extinguished or removed; any
leadlamps must be flameproof and kept clear of
spillage.

WARNING: No one should be permitted to repair
components associated with fuel without first
having specialist training.

WARNING: Do not remove fuel system
components while the vehicle is over a pit.

Fuel tank draining
Fuel tank draining should be carried out in
accordance with the procedure outlined in the FUEL
DELIVERY section of this manual and observing the
following precautions.

WARNING: Fuel must not be extracted or drained
from any vehicle while it is over a pit. Extraction
or draining of fuel must be carried out in a well
ventilated area.

The capacity of containers must be more than
adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked
with its contents and placed in a safe storage
area which meets the requirements of local
authority regulations.

Fuel tank removal
When the fuel line is secured to the fuel tank outlet by
a spring steel clip, the clip must be released before
the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
fumes in the fuel tank being ignited when the clip is
released.

As an added precaution, fuel tanks should have a
'FUEL VAPOUR' warning label attached to them as
soon as they are removed from the vehicle.

Fuel tank repairs - plastic tank
No attempt should be made to repair a plastic fuel
tank. If the structure of the tank is damaged, a new
tank must be fitted.

Body repairs
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.

When body repairs involve the use of heat, all fuel
pipes which run in the vicinity of the repair area must
be removed, and the tank outlet plugged.

WARNING: If welding is to be carried out in the
vicinity of the fuel tank, the fuel system must be
drained and the tank removed before welding
commences.