Part 2
Standard Workshop Practices
Pipes and Hoses
When removing or installing flexible hydraulic pipes and hoses, make sure that the following procedures are observed to make sure component serviceability:
- Prior to removal, clean area around hose or pipe end which is to be disconnected.
- Obtain appropriate blanking plugs or caps before disconnecting hose or pipe end fittings in order that connections can be plugged immediately following disconnection.
- Always install blanking plugs or caps to pipes and unions immediately following disconnection.
- Clean hose or pipe and blow through with an air line.
WARNING: Suitable eye protection must be worn.
- Check hoses externally for cracks, separation of plies, security of end fittings and external damage; replace faulty hoses.
- Check pipes for signs of corrosion and chafing, replace as necessary.
CAUTION: If pipes are found to be chafed, rectify clips, mounting points etc., to prevent further problems in service.
- When installing hoses, make sure that no unnecessary bends are introduced and that hoses are not kinked, twisted or positioned close to potential chafing points.
- When installing pipes, make sure that pipes are positioned and clipped clear of potential chafing points.
- Always replace sealing washers installed to banjo bolts, sealing plugs etc.
- Always use a backing spanner when tightening unions and do not overtighten union nuts or banjo bolts.
- After engagement of 'quick-fit' connection hoses, perform a 'tug' test to make sure connection is securely installed.
- After any work on hydraulic systems, always check for fluid leaks whilst a second operator applies working pressure to the brake pedal or operates the system that has been worked on.
Fuel system hoses
Some fuel hoses are made up of two laminations, an armored rubber outer sleeve and an inner viton core. Whenever a hose is removed, make sure that the inner bore is inspected to check that the viton lining has not become separated from the outer sleeve.
WARNING: Never attempt to repair fuel hoses or rectify leaking 'quick-fit' connectors. The fuel hose and connectors must be replaced as an assembly.
Fuel system hose clips
Certain fuel system hose clips are of the 'break-off head' type where a slot in the screw head shears off when the clip is tightened to a specific torque. These clips may be removed using a screwdriver and must be replaced with new clips on reassembly. Clips must be tightened until the portion of the slot shears off. Do not attempt to tighten clips by any other method, do not install any other type of clip.
'Quick-fit' connections are also installed to certain fuel hoses. After engagement of 'quick-fit' connections, perform a 'tug' test to make sure connection is securely installed.
Other fuel system hose clips are of the 'Jubilee' type and there may be a tamper proof cover installed over the screw head. These cover must be carefully removed before slackening the clip and should be replaced after final tightening, ensuring that the internal hexagon on the cover is correctly located on the clip screw.
Cooling system hoses
CAUTION: The following precautions must be observed to make sure that the integrity of the cooling system hoses and their connection to the system is maintained.
Hose orientation and connection
Correct orientation of cooling system hoses is important to make sure that hoses do not become fatigued or damaged through contact with adjacent components.
Where orientation marks are provided on the hose and corresponding component, the marks must be aligned when the hose is installed. Hoses must be installed fully on to their connection points, usually a moulded form on a pipe provides a positive indicator.
Hose clips
Markings 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 pipe. Worm drive clips should be orientated with the crimped side of the drive housing facing towards the end of the hose or the hose may become pinched between the clip and the stub pipe retaining lip. Unless otherwise stated, worm drive clips should be tightened to 3 Nm (2 lb-ft). Make sure that hose clips do not foul adjacent components.
Oetiker clips may be removed by bending the tag (arrowed) and releasing the free end of the clip. Clips must not be re-used. When installing new clips, make sure clip is positioned on hose before tightening and make sure that when clip is tightened, the tag is located in the longitudinal slot in the free end of the clip (arrowed in illustration).
'Quick-fit' connections are also installed to certain hoses/pipes. Inspect 'quick-fit' connections for damage, prior to connection. Replace if damaged. After engagement of 'quick-fit' connections, perform a 'tug' test to make sure connection is securely installed.
Heat protection
Always make sure that heat shields 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 manifolds and exhaust gas recirculation (EGR) pipes. Hoses will relax and deflect slightly when hot, make sure this movement is taken into account when routing and securing hoses.
Electrical Precautions
General
The following guidelines are intended to make sure the safety of the operator whilst preventing damage to the electrical and electronic components of this vehicle.
Equipment
Prior to commencing any test procedure on the vehicle, make sure that the relevant test equipment is working correctly and that any harness or connectors are in good condition. It is particularly important to check the condition of all plugs and leads of mains operated equipment.
Polarity
Never reverse connect the vehicle battery and always make sure 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.
Vehicles installed with Bi-Xenon headlamp bulbs
WARNING: The following precautions must be observed as failure to comply may result in exposure to ultra-violet rays, severe electric shock, burns or risk of an explosion.
- Safety goggles and gloves must be worn.
- Make sure that headlamps are switched off before removing bulbs.
- Do not touch the glass portion of the bulb.
- On no account should headlamps be switched on with the bulb removed from the headlamp.
- Bulb testing may only be carried out with the bulb installed in the headlamp.
- Bulbs must be disposed of in accordance with the local authority bye-laws.
Connectors and harnesses
The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors. Always observe the following:
- Make sure electrically related items are dry and oil free before disconnecting/connecting test equipment.
- Make sure that disconnected multiplugs and sensors are protected from any possible oil, coolant or other liquid contamination. Any such contamination could impair performance or lead to component failure.
- Never force connectors apart or pull on the wiring harness.
- Always make sure locking tabs are disengaged before disconnecting multiplugs etc. and make sure that correct orientation is achieved before connection.
- Make sure that any protection covers, insulation etc. are replaced if disturbed.
Having confirmed that a component is faulty, carry out the following:
- Switch off the ignition and disconnect the battery.
- Remove the component and support the disconnected harness.
- When replacing electrical components, keep oily hands away from electrical connections and make sure that locking tabs on connectors are fully engaged.
Battery Disconnection/Connection
Always refer to the Electrical Section of this product - Battery Connection/Disconnection prior to attempting to connect or disconnect the battery. For additional information, refer to Specifications Service and Repair
Fuel Handling Precautions
The following information lists 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. As this information is issued for basic guidance only, consult your local Fire Department where any doubt as to personal and environmental safety exists - See also Health and Safety Precautions.
General precautions
Always have the correct type of fire extinguisher containing Foam, CO2, Gas or powder accessible when handling or draining fuel or dismantling fuel systems. Fire extinguishers must also be located in areas where fuel is stored.
Make sure that suitable warning signs are exhibited.
Keep all sources of ignition well away from areas where fuel is being handled.
Make sure that any leadlamps are flameproof and kept clear of spillage.
WARNING: Do not disassemble or reassemble fuel system components whilst vehicle is over a pit.
WARNING: No one should be permitted to repair components associated with fuel without first having specialist training.
Always disconnect the vehicle battery before carrying out disassembly, reassembly or draining work on a fuel system.
Fuel tank and system draining
Draining must be carried out in accordance with the procedures given in the relevant Fuel System section of this product.
WARNING: Never drain fuel or work on a fuel system while the vehicle is over a pit. Extraction or draining of fuel must be carried out in a well ventilated area.
WARNING: Never switch on or operate mobile (cellular) phones in the vicinity of vehicles when operations are being carried out on the fuel system.
WARNING: Always attach fuel vapor warning labels to fuel tanks immediately after draining.
WARNING: Containers used for storing fuel must be clearly marked with the contents and placed in a safe storage area which meets the requirements of the local authority.
CAUTION: Some fuel lines are now installed with 'quick release' connectors. If a connector is damaged, no attempt must be made to repair the connector, a new fuel line and connector(s) assembly must be installed.
Always release pipe clips fully before attempting to disconnect fuel pipes.
Fuel tank repairs
CAUTION: No attempt should be made to repair a plastic fuel tank. If the structure of the tank is damaged, a new tank must be installed.
Oil seals
Never use a seal which has been improperly stored or handled.
- Take great care when removing old seals that the sealing surfaces and seal housing are not damaged.
- Carefully examine seal before installing to make sure that it is clean and undamaged.
- Make sure that the surface on which the seal is to run and also the seal housing is clean and free from burrs or scratches. Renew the component if the sealing surface cannot be restored.
- Special tools and protection sleeves are provided for installing the majority of seals and must be used when specified.
- Many seals are now coated with a protective wax and DO NOT need to be lubricated prior to installing. Always check the relevant repair procedure which will state if a seal must be installed dry. Never touch these seals with oily hands as the oil will contaminate the protective coating and affect the sealing properties of the seal; also, make sure that installing tools and protection sleeves are free from oil and grease. Seals which must be lubricated prior to installing should have the recommended lubricant applied to the areas specified in the repair procedure.
- Make sure that a seal is installed the correct way round. For example, the lip of the seal must face towards the lubricant which it is sealing.
- When installing an oil seal, make sure that it is positioned square to shaft and housing. Where the seal is to be installed to a housing prior to installing over a shaft, take care not to allow the weight of an unsupported shaft to rest on the seal.
- Always use the recommended special tool and protection sleeve to install an oil seal. If no tool is specified, use a suitable mandrel approximately 0.4 mm (0.015 in) smaller than the outside diameter of the seal. Use adhesive tape on the shaft to protect the sealing lip of the seal.
- Press or drift the seal in to the depth of its housing if the housing is shouldered or flush with the face of the housing where no shoulder is provided. Make sure that the seal is not tilted in the housing when it is installed.