Land Rover Defender: 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.

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