Flexible pipes and hoses (Freelander 2)

When removing and installing flexible lines and hoses of the hydraulic system, follow the instructions listed below. This will ensure reliable and long-lasting operation.

• Before removing hoses or pipes, thoroughly clean the connection points and surrounding area.
• Before disconnecting hoses or lines, prepare suitable plugs or caps to plug the holes in the line or hose fitting immediately after disconnection.
• Always install plugs and caps on pipes and connections immediately after disconnecting them.
• Clean the removed hoses or pipes from the outside and blow them out from the inside with compressed air.

WARNING: Wear adequate eye protection.

• Carefully inspect the pipeline. Pay attention to the presence of cracks, cord delamination, and the reliability of the sealing of the tips. All hoses with damage are not subject to reinstallation.
• Check the pipes for corrosion and wear from friction; replace if necessary.

CAUTION: If there is evidence of wear from friction on the pipes, align the clamps, attachment points, etc. to prevent further failure.

• When installing hoses, ensure that the hoses are free of kinks, knots, bends, and do not pass through areas where they would be subject to friction.
• When securing pipes, ensure that they are routed and clamped so as to prevent them from coming into contact with potential sources of friction.
• Always replace sealing washers installed on banjo bolts, plugs, etc.
• Always use two wrenches when tightening connections. Do not overtighten connection nuts or banjo bolts.
• After any work on hydraulic systems, check for leaks. To do this, one person should be under the car and carefully inspect the connection points, and the other, while driving the car, should press hard on the brake pedal.

Engine fuel system hoses

All fuel hoses are structurally two-layered: an outer layer of reinforced rubber and an inner layer of special rubber (Viton). When removing any fuel hose, carefully inspect its inner layer. The Viton material should not have any delaminations from the outer shell.

WARNING: Never attempt to repair leaking fuel hoses and quick-connect fittings individually; they must be replaced as an assembly.

Connecting clamps of hoses of the engine fuel system

The screw head of these clamps has a special slot, the edges of which are crushed when the set tightening torque is reached, preventing the tightening force from increasing more than the set limit. Such clamps can be unscrewed using an ordinary screwdriver. When reassembling, these clamps must be replaced with new clamps with automatic tightening force regulation. The clamps must be tightened until part of the slot breaks off. Such clamps should not be tightened in any other way, nor should clamps of a different type be installed.

Engine cooling system hoses

CAUTION: Follow the instructions below to avoid damaging the cooling system hoses and their connections to the pipes.

Relative position of the hose and the branch pipe

To avoid damage from contact with adjacent parts or fatigue failure of the hose, the hose must be connected to the connecting pipe correctly.

If the hose and the branch pipe have pairing marks, they should be connected only in this position. During installation, the hose should be completely put on the connecting branch pipe. Usually, there is a special shaped boss on the branch pipe, allowing the connection to be assembled correctly.

Clamps

There are usually marks on the hose that indicate the correct position of the clamp. If there are no marks, the clamp should be positioned directly behind the flange at the end of the connecting pipe. The flange of the worm clamp should be directed towards the near end of the hose, otherwise the hose may be pinched between the clamp and the flange of the pipe. Unless otherwise specified, worm clamps should be tightened to 3 Nm. After tightening the clamp, make sure that the clamp does not touch adjacent parts.



The "Oetiker" type clamps are removed by bending the tongue (shown by the arrow in the figure) and releasing the free end of the clamp. Clamps of this type are not subject to further use. When installing a new clamp, ensure the correct position of the clamp on the hose, when tightening the clamp, align the tongue with the longitudinal slot on the outer branch of the clamp (shown by the arrow in the figure).

Protection against overheating of parts

All required heat shields and protective screens must be installed and in working order. If damage to these components is visible, they must be replaced. Pay attention to the installation of hoses adjacent to very hot engine parts, such as the exhaust manifold and exhaust gas recirculation (EGR) lines. When heated, the hoses will deform. This must be taken into account when laying and securing the hoses.