Freelander 1. Manual - part 6

GENERAL INFORMATION

03-15

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.

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.

GENERAL INFORMATION

03-16

Service tools

General
Special service tools have been developed to
facilitate removal, dismantling and assembly of
mechanical components in a cost effective and time
efficient manner. The use of such special tools also
helps prevent the potential for damage to
components.

Some operations described in this Manual cannot be
carried out properly without the aid of the relevant
service tools.

Special service tools can be obtained from the
following suppliers:

Cartool (UK) Limited
Unit 3, Sterling Business Park
Salthouse Road
Brackmills
Northampton
NN4 7EX
England

(

+44 (0) 1604 760099

)

+44 (0) 1604 760017

e-mail: sales@cartooluk.co.uk

Cartool GmbH
Straussenlettenstrasse 15
85053 Ingolstadt

Germany

(

+49 (0)841 9650080

)

+49 (0)841 9650090

e-mail: i.amann@cartool.de

Rolling road testing

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

The front and rear wheels cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively applying more torque to the rear
wheels if the front wheels start to slip.

DO NOT attempt to drive individual wheels with
vehicle supported on floor jacks or stands.

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
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:

propeller shaft to the rear axle is removed/
disconnected;

neutral selected in gearbox;

hill descent control not selected.

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

GENERAL INFORMATION

03-17

Fuel handling precautions

Fuel vapour is highly inflammable 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 easily be 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 petrol (gasoline) 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

, 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.

WARNING: When fuel has been drained from a
fuel tank the precautions governing naked lights
and ignition sources should be maintained.

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
residual petrol 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
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.

GENERAL INFORMATION

03-18

Electrical precautions

General
The following guidelines are intended to ensure the
safety of the operator and ensure the prevention of
damage to the electrical and electronic components
fitted to the vehicle. Where necessary, specific
precautions are detailed in the individual procedures
of this manual.

Equipment
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to check
the condition of the lead and plugs of mains operated
equipment.

Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.

High Voltage Circuits
Whenever disconnecting live ht circuits, always use
insulated pliers and never allow the open end of the
ht lead to contact other components, particularly
ECU's.

Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.

Connectors and harnesses
The engine compartment of a vehicle is a particularly
hostile environment for electrical components and
connectors:

Always ensure electrically related items are dry
and oil free before disconnecting and
connecting test equipment.

Ensure disconnected multiplugs and sensors
are protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.

Never force connectors apart using tools to
prise apart or by pulling on the wiring harness.

Always ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.

Ensure that any protection (covers, insulation
etc.) is replaced if disturbed.

Having confirmed a component to be faulty:

Switch off the ignition and disconnect the
battery.

Remove the component and support the
disconnected harness.

When replacing the component, keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.

Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.

CAUTION: To prevent damage to electrical
components, always disconnect the battery
when working on the vehicle's electrical system.
The ground lead must be disconnected first and
reconnected last.

CAUTION: Always ensure that battery leads are
routed correctly and are not close to any
potential chafing points.

Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.

Ignition system safety precautions
The vehicle's ignition system produces high voltages
and the following precautions should be observed
before carrying out any work on the system:

WARNING: Before commencing work on an
ignition system, ensure all high tension
terminals, adapters and diagnostic equipment
are adequately insulated and shielded to prevent
accidental personal contacts and minimise the
risk of shock. Wearers of surgically implanted
pacemaker devices should not be in close
proximity of ignition circuits or diagnostic
equipment.

Disciplines
Switch off the ignition prior to making any connection
or disconnection in the system, to prevent electrical
surges caused by disconnecting 'live' connections
damaging electronic components.

Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or high-
resistance contacts.

When handling printed circuit boards, treat with care
and hold by the edges only; note that some electronic
components are susceptible to body static.

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