Range Rover Sport. Instruction - page 1

Standard Workshop Practices

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

Where practicable, the parking brake is applied and the wheels are securely chocked to prevent the vehicle moving
forwards or backwards.
Whenever possible, the ignition key is removed before any work is carried out on the vehicle.
If the engine is to be run, there is adequate ventilation, or an extraction hose is used to remove exhaust fumes.
There is adequate room to raise the vehicle and remove the wheels, if necessary.
Fender covers are always fitted if any work is to be carried out in the engine compartment.
Where practicable, the battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is
raised.

CAUTION: Prior to disconnecting the battery, refer to the Electrical Section of this manual - Battery

disconnection/connection.

CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the

possibility of a surge of current causing damage to the internal components of the generator.

If using welding equipment on the vehicle, a suitable fire extinguisher is readily available.

Towing the Vehicle

WARNING: When towing is necessary, reference must be made to the Jacking, Lifting and Towing Section

of this Manual. When the vehicle is being towed the ignition switch must be in position II (steering lock released
and warning lights illuminated). Only then will the steering, turn signal lamps, horn and stop lamps be operational.
Failure to follow these instructions may result in personal injury. It must be noted that with the engine not running,
the power steering and brake booster will be inoperative therefore, greater effort will be needed to steer the
vehicle and apply the brakes.

Battery - General

CAUTION: Prior to carrying out any procedures which involve disconnecting/ or connecting the battery,

refer to the Electrical Section of this manual - Battery disconnection/connection.

CAUTION: A discharged battery condition may have been caused by an electrical short circuit. If this

condition exists there will be an apparently live circuit on the vehicle even when all normal circuits are switched
off. This can cause arcing when the jumper cables are connected.

occasionally be the only practical way to mobilize a vehicle. Prior to attempting a jump start, refence must be
made to the Electrical Section of this manual - Jump Starting.

Following jump starting of a disabled vehicle, the discharged battery must be checked for serviceability and recharged off
the vehicle as soon as possible to avoid permanent damage.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess
of eight hours continuous driving with no additional loads placed on the battery.

Always make sure that the jumper cables are adequate for the task.
Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be
connected in parallel.
Always make sure that switchable electric circuits are switched off before connecting jumper cables. This reduces
the risk of arcing occurring when the final connection is made.

General Fitting 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 oilways 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, oilways 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 to those parts requiring further inspection. Keep these parts
separate.
To ensure 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 ensure that the component being cleaned is compatible with
the cleaning agent.

Always follow the manufacturer's instructions regarding the use of cleaning agents and ensure that the environment in which
the work is being undertaken is suitable. See Health and Safety Precautions for further information regarding cleaning.

All components should be inspected for wear or damage before reassembling.

Always ensure 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 ensure 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 refitted 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.

Joints and Joint Faces

All gaskets should be fitted dry unless stated otherwise. Always fit new 'O' rings when reassembling components, always
apply the specified lubricant to 'O' rings and fit '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. Ensure 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 oilways.

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 reuse tab washers.

Locknuts

Always use a backing spanner when loosening and tightening locknuts, brake and fuel pipe unions.

Roll pins

Always fit new roll pins of the correct size.

Circlips

Always fit new circlips ensuring that they are of the correct size for the groove.

Woodruff keys

Remove any burrs from edges of keyways using a fine file.

Split pins

Never attempt to straighten and reuse a split pin, always ensure that replacement pins are of the correct size for the hole in
which they are to be fitted.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a
tap or die impairs the strength and fit of the threads and is not recommended.

NOTE:

During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where
this is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the
correct size and thread is used.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New bolts
having the same part number as the original must always be fitted. When nuts or bolts are to be discarded, the repair
operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread locking
agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
Always ensure that replacement nuts and bolts are at least equal in strength to those that they are replacing.
Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split
the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false
torque reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of
components or faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to
tighten in stages, these stages must be adhered to; do not attempt to combine stages particularly where certain
stages involve tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified
torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to fitting.

Where it is stated that bolts and screws may be reused, the following procedures must be carried out:

Check that threads are undamaged.
Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.

Ensure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

Bolt and Nut Identification

Рассказать друзьям