Range Rover Classic. Manual — part 12
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.
07
GENERAL 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
SPLIT PINS
1. Fit new split pins throughout when replacing any
unit.
2. Always fit split pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a split pin.
3. All split pins should be fitted as shown unless
otherwise stated.
NUTS
1. When tightening a slotted or castellated nut
never loosen it back to insert split 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.
LUBRICANTS, FLUIDS AND CAPACITIES
1
INFORMATION
RECOMMENDED LUBRICANTS AND FLUIDS -
USA VEHICLES
AMBIENT TEMPERATURE ˚C
COMPONENT
SPECIFICATION
VISCOSITY
-30
-20
-10
0
10
20
30
40
50
Engine V8i
Use oils to API
5W/20 )
service level
SG or SH
5W/30 )
or
5W/40 )
RES.22.OL.G4
or
CCMC-G4
10W/30
10W/40 )
10W/50 )
15W/40 )
15W/50 )
20W/40 )
20W/50 )
Automatic gearbox
ATF Dexron IID
Final drive units
API or GL5
90 EP
Swivel pin housings
MIL - L - 2105 or
MIL - L - 2105B, C
or D
80W EP
Power steering
ATF Dexron IID
Borg Warner
ATF Dexron IID
transfer gearbox
Brake reservoir
Brake fluid must have a minimum
boiling point of 260˚C (500˚F) and
comply with FMVSS/116/DOT 4
Lubrication nipples
(hubs, ball joints,
etc.)
NLGI-2 multipurpose lithium based
grease
See table on page 3 for remaining vehicle components
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