Land Rover Discovery: 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 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.
- 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 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
Plastigauge.
READ NEXT:
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 scrape
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.
NOTES:
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 bolt head.
In addition to marks i
SEE MORE:
REMOVAL
NOTE:
The side panel is installed in conjunction with:
Front bumper cover
Fender
Fender splash shield
Front fender mounting panel
Windshield
Front door
Rear door
Rocker panel moulding
Roof moulding
Headliner
Side air curtain module
Roof panel
Roof front panel
Roof rear panel
SPECIAL TOOL(S)
Removal
CAUTIONS:
Nuts and bolts must be tightened with the weight of the vehicle on
the suspension.
Do not allow halfshafts to hang unsupported at one end or joint
damage will occur.
Make sure the halfshaft constant velocity (CV) joints do not over
articulate. Failure to