Land Rover Range Rover Classic User Manual
RANGE ROVER
CLASSIC
Workshop Manual
Workshop manual
RANGE ROVER
This manual covers vehicles from
1995 model year
01
04
05
06
07
09
10
12
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
12 ENGINE 3.9 V8
17 EMISSION CONTROL
19 FUEL SYSTEM Tdi
19 FUEL SYSTEM MFI
19 CRUISE CONTROL
26 COOLING SYSTEM Tdi
26 COOLING SYSTEM V8
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
44 AUTOMATIC GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
68 AIR SUSPENSION
70 BRAKES NON ABS
70 BRAKES ABS
70 BRAKES ELECTRONIC TRACTION
CONTROL
74 WHEELS AND TYRES
76 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
17
19
26
30
33
37
41
44
47
51
54
57
60
64
68
74
70
Published by Rover Technical Communication
Rover Group Limited 1995
Publication Part No. LRL0030ENG
76
80
82
84
86
INTRODUCTION
INTRODUCTION
This workshop manual covers vehicles from 1995
model year onwards. Amendments and additional
pages will be issued to ensure that the manual
covers latest models. Amendments and additions
will be identified by the addition of a dated footer
at the bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which could not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Land
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONS and NOTES are given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer’s specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.
INFORMATION
1
01
INTRODUCTION
FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowest level.
It can readily be distributed throughout a workshop by
air current, consequently, even a small spillage of fuel
is very dangerous.
Always have a fire extinguisher containing FOAM CO
GAS, or POWDER close at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1. Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2. Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
2
tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.
A FUEL VAPOUR warning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
INFORMATION
2
INTRODUCTION
SYNTHETIC RUBBER
Many ’0’ ring seals, flexible pipes and other similar
items which appear to be natural rubber are made of
synthetic materials called Fluoroelastomers. Under
normal operating conditions this material is safe, and
does not present a health hazard. However, if the
material is damaged by fire or excessive heat, it can
break down and produce highly corrosive Hydrofluoric
acid which can cause serious burns on contact with
skin. Should the material be in a burnt or overheated
condition handle only with seamless industrial gloves.
Decontaminate and dispose of the gloves immediately
after use.
If skin contact does occur, remove any contaminated
clothing immediately and obtain medical assistance
without delay. In the meantime, wash the affected
area with copious amounts of cold water or limewater
for fifteen to sixty minutes.
RECOMMENDED SEALANTS
A number of branded products are recommended in
this manual for use during maintenance and repair
work.
These items include:
HYLOMAR GASKET AND JOINTING COMPOUND
and
HYLOSIL RTV SILICON COMPOUND.
They should be available locally from garage
equipment suppliers. If there is any problem obtaining
supplies, contact the following company for advice
and the address of the nearest supplier.
MARSTON LUBRICANTS LTD.
Hylo House,
Cale Lane,
New Springs,
Wigan WN2 1JR
USED ENGINE OIL
WARNING: Prolonged and repeated
contact with engine or motor oil will result
in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
Used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities should be provided.
Handling precautions
1. Avoid prolonged and repeated contact with oils,
particularly used engine oils.
2. Wear protective clothing, including impervious
gloves where applicable.
3. Do not put oily rags in pockets.
4. Avoid contaminatingclothes,particularly
underwear, with oil.
5. Overalls must be cleaned regularly. Discard
unwashable clothing and oil impregnated
footwear.
6. First aid treatment must be obtained immediately
for open cuts and wounds.
7. Use barrier creams, before each work period, to
help the removal of oil from the skin.
8. Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
9. Do not use gasoline, kerosene, diesel fuel,
petrol, thinners or solvents for washing the skin.
10. If skin disorders develop, obtain medical advice.
11. Where practicable, degrease components prior
to handling.
12. Where there is a risk of eye contact, eye
protection should be worn, for example, goggles
or face shields; in addition an eye wash facility
should be provided.
Disposing of used oils
Tel 01942 824242
Environmental protection precaution
It is illegal to pour used oil onto the ground, down
sewers or drains, or into waterways.
Dispose of used oil through authorised waste disposal
contractors. If in doubt contact your Local Authority for
advice on disposal facilities.
INFORMATION
3
01
INTRODUCTION
ACCESSORIES AND CONVERSIONS
DO NOT FIT unapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bay MUST be followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine water pipes, hose clips and ignition
coil clamp.
SPECIFICATION
The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any one. For the specification of a particularvehicle
purchasers should consult their Dealer
The Manufacturer reserve the right to vary their
specifications with or without notice, and at such times
and in such manner as they think fit. Major as well as
minor changes may be involved in accordance with
the Manufacturer’s policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer or Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.
SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified, only these tools should be used
to avoid the possibility of personal injury or
damage to the components. Also the amount of time
which they save can be considerable.
Every special tool is designed with the close
co-operation of Land Rover, and no tool is put into
production which has not been tested and approved
by us. New tools are only introduced where an
operation cannot be satisfactorily carried out using
existing tools or standard equipment. The user is
therefore assured that the tool is necessary and that it
will perform accurately, efficiently and safely.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to V. L. Churchill. Overseas
orders should be placed with the local V. L. Churchill
distributor, where one exists. Countries where there is
no distributor may order direct from:
V. L. Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN11 4NF.
The tools recommended in this Workshop Manual are
listed in a multi-language illustrated catalogue,
obtainable from:
Messers. V. L. Churchill at the above address,
or from:
Land Rover Merchandising Service,
PO Box 534,
Erdington,
Birmingham, B24 0Q5,
COPYRIGHT
Land Rover 1995
All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Land Rover.
INFORMATION
4
INTRODUCTION
JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1. Use a solid level ground surface.
2. Apply parking brake.
3. Select ’P’ or 1st gear in main gearbox.
4. Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure
Bumpers
Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bell housing
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to
Owner’s Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
axle.
Raise the front of the vehicle
1. Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.
Jack or support vehicle by axles only.
INFORMATION
5
01
INTRODUCTION
2. Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3. Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1. Position cup of hydraulic arm under differential
casing.
2. Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3. Lower jack until axle sits securely on axle
stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES
Viscous coupling
The front and rear axles cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively locking the centre differential
automatically if slip occurs at any wheel.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer 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.
Two wheel dynamometers
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a ’drive on’ type ramp which supports vehicle
by its own road wheels. If a ’wheel-free’ condition is
required, use a ’drive on’ ramp incorporating a
’wheel-free’ system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using ’Two Post’ ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.
INFORMATION
6
DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
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.
INTRODUCTION
3. Secure tow rope, chain or cable to towing eye.
4. Release the parking brake.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1. Turn ignition key turn to position ’1’ to release
steering lock.
2. Select neutral in main gearbox and transfer
gearbox.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, ’snatch’ recovery
should be avoided.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST BE
removed, dependent upon which axle is
being trailed.
1. Mark propellershaft drive flanges at transfer
gearbox and axles with identification lines to
enable the propeller shaft to be refitted in its
original position.
2. Remove the propeller shaft fixings, remove the
shaft from the vehicle.
3. If the front axle is to be trailed turn ignition key to
position ’1’ to release steering lock.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.
INFORMATION
7
01
INTRODUCTION
TRANSPORTING THE VEHICLE BY TRAILER
Lashing eyes are provided on front and rear of the
chassis side members, to facilitate the securing of the
vehicle to a trailer or other means of transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
neutral in main gearbox. Selecting ’N’ will prevent
damage to parking pawl of the automatic gearbox.
FRONT OF CHASSIS
JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
REAR OF CHASSIS
1. Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2. Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected on a manual
gearbox, with an automatic gearbox select
neutral (N) or park (P) and then connect the
jump leads as follows;
A. Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B. Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C. Connect one end of second jumper cable to
negative terminal of booster battery.
INFORMATION
8
INTRODUCTION
D. Connect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY. Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade
assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3. If booster battery is installed in another vehicle,
start engine and allow to idle.
4. Start engine of vehicle with discharged battery,
following starting procedure in Owners’ Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalysts.
5. Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6. Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
INFORMATION
9
01
INTRODUCTION
ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL
Across flats (bolt size) AF............................................
After bottom dead centre ABDC...................................
After top dead centre ATDC.........................................
Alternating current a.c..................................................
Ampere amp................................................................
Ampere hour amp hr....................................................
Before bottom dead centre BBDC................................
Before top dead centre BTDC......................................
Bottom dead centre BDC.............................................
Brake horse power bhp................................................
British Standards BS....................................................
Carbon monoxide CO..................................................
Centimetre cm.............................................................
Centigrade (Celsius) C................................................
Cubic centimetre cm
Cubic inch in
...................................................
...............................................................
Degree (angle) deg or °...............................................
Degree (temperature) deg or °.....................................
Diameter dia................................................................
Direct current d.c..........................................................
Electronic Control Unit ECU........................................
Electronic Fuel Injection EFI........................................
Fahrenheit F.................................................................
Feet ft...........................................................................
Feet per minute ft/min..................................................
Fifth 5th........................................................................
First 1st........................................................................
Fluid ounce fl oz..........................................................
Foot pounds (torque) lbf ft............................................
Fourth 4th.....................................................................
Gramme (force) gf........................................................
Gramme (mass) g........................................................
Gallons gal...................................................................
Gallons (US) US gal.....................................................
High tension (electrical) H.T.........................................
Internal diameter I.D....................................................
Inches of mercury in. Hg..............................................
Inches in......................................................................
Kilogramme (force) kgf.................................................
Kilogramme (mass.) kg................................................
Kilogramme centimetre (torque) kgf.cm.......................
Kilogramme per square millimetre kgf/mm
Kilogramme per square centimetre kgf/cm
.................
.................
Kilogramme metres (torque) kgf.m..............................
Kilometres km..............................................................
Kilometres per hour km/h.............................................
Kilovolts kV...................................................................
Left-hand LH................................................................
Left-hand steering LHStg.............................................
Left-hand thread LHThd...............................................
Litres litre.....................................................................
Low tension l.t..............................................................
Maximum max.............................................................
Metre m........................................................................
Millilitre ml....................................................................
Millimetre mm...............................................................
Miles per gallon mpg....................................................
Miles per hour mph......................................................
Minute (angle) ’............................................................
Minus (of tolerance) -...................................................
Negative (electrical) -...................................................
Newton metres (torque) Nm........................................
Number No..................................................................
Ohms ohm...................................................................
Ounces (force) ozf.......................................................
3
Ounces (mass) oz........................................................
3
Ounce inch (torque) ozf.in...........................................
Outside diameter O.D..................................................
Part number Part No....................................................
Percentage %...............................................................
Pints pt.........................................................................
Pints (US) US pt...........................................................
Plus (tolerance) +.........................................................
Positive (electrical) +....................................................
Pound (force) lbf..........................................................
Pounds inch (torque) in.lbf...........................................
Pound (mass) lb...........................................................
Pounds per square inch P.S.I......................................
Ratio :...........................................................................
Reference ref...............................................................
Revolution per minute rev/min.....................................
Right-hand RH.............................................................
Second (angle) "...........................................................
Second (numerical order) 2nd......................................
Specific gravity sp.gr....................................................
Square centimetres cm
Square inches in
...............................................
.........................................................
Standard wire gauge s.w.g..........................................
Synchroniser/Synchromesh synchro...........................
Third 3rd.......................................................................
Top dead centre TDC..................................................
United Kingdom UK......................................................
2
Vehicle Identification Number VIN...............................
2
Volts V.........................................................................
Watts W.......................................................................
SCREW THREADS
American Standard Taper Pipe NPTF.........................
British Standard Pipe BSP...........................................
Unified Coarse UNC....................................................
Unified Fine UNF.........................................................
2
2
10
INFORMATION
CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY
INTRODUCTION
NEW TERM (ACRONYM)
Accelerator pedal (AP).................................................
Air cleaner (ACL)..........................................................
Air conditioning (AC)....................................................
Battery positive voltage (B+)........................................
Closed loop (CL)..........................................................
Closed throttle position (CTP)......................................
Canister purge valve (CANPV)....................................
Data link connector (DLC)...........................................
Diagnostic trouble code (DTC).....................................
Distributor ignition (DI).................................................
Engine control module (ECM)......................................
Engine coolant level (ECL)...........................................
Engine coolant temperature (ECT)..............................
Engine coolant temperature sensor (ECTS)................
Engine speed (RPM)....................................................
Evaporative emission system (EVAP)..........................
Engine fuel temperature sensor (EFTS)......................
4th gear, 3rd gear etc. (4GR, 3GR)..............................
Fuel pump (FP)............................................................
Fan control module (FCM)...........................................
Generator (GEN)..........................................................
Ground (GND)..............................................................
Heated oxygen sensor (H02S)....................................
Idle air control (IAC)......................................................
Idle air control valve (IACV).........................................
Ignition control module (ICM).......................................
Inertia fuel shutoff (IFS)................................................
Inertia fuel shutoff switch (IFSS)..................................
Intake air temperature (IAT).........................................
Malfunction indicator lamp (MIL)..................................
Manifold vacuum zone (MVZ)......................................
Mass air flow sensor (MAFS).......................................
Multiport fuel injection (MFI)........................................
On board diagnostic (OBD)..........................................
Open loop (OL)............................................................
Park/neutral position (PNP).........................................
Park/neutral position switch (PNPS)............................
Programmable read only memory (PROM)..................
Relay module (RM)......................................................
Service reminder indicator (SRI)..................................
Solid state relay module (SSRM).................................
Three way catalytic converter (TWC)..........................
Throttle body (TB)........................................................
Throttle position sensor (TPS)......................................
Torque converter clutch (TCC)....................................
Transmission range (TR)..............................................
Transmission range selector (TRS).............................
Vehicle speed sensor (VSS)........................................
Wide open throttle (WOT)............................................
OLD TERM (ACRONYM)
Throttle pedal (-)..........................................................
Air cleaner (-)...............................................................
Air conditioning (AC)....................................................
Battery plus, bat +, bat feed (B+).................................
Closed loop (-).............................................................
Closed throttle, idle position (-)....................................
Charcoal canister purge valve (-).................................
Serial link (-)................................................................
Fault code (-)...............................................................
Electronic ignition (-)....................................................
Electronic control unit (ECU)........................................
Coolant level (-)...........................................................
Coolant temperature (temp).........................................
Coolant temperature thermistor (-)..............................
Engine speed (rev/min)................................................
Evaporative loss system (ELC)...................................
Fuel temperature thermistor (-)....................................
Fourth gear, 3rd gear (-)..............................................
Fuel pump (-)...............................................................
Condenser fan timer (-)................................................
Alternator (-)................................................................
Ground, earth (B-)........................................................
Lambda (02) sensor (-)................................................
Idle speed control (ISC)................................................
Stepper motor (-).........................................................
Ignition module (-)........................................................
Inertia switch (-)...........................................................
Inertia switch (-)...........................................................
Intake temperature/ambient temperature (-)................
EFI warning lamp (-)....................................................
Manifold depression, vacuum (-).................................
Air flow meter (-)..........................................................
Electronic fuel injection (EFI).......................................
Fault code display unit (-)............................................
Open loop (-)...............................................................
Park or neutral (-).........................................................
Start inhibit switch (-)...................................................
Chip, PROM (PROM)...................................................
Relay (-).......................................................................
Check engine light (-)...................................................
Control unit (-)..............................................................
Catalyst, catalytic converter (CAT)..............................
Throttle housing (-)......................................................
Throttle potentiometer (-).............................................
Direct drive clutch (DDC)..............................................
Transmission gear (-)...................................................
Shift lever, shifter (-)....................................................
Road speed transducer (-)...........................................
Full throttle, wide open throttle (WOT).........................
INFORMATION
11
01
INTRODUCTION
VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number and the
recommended maximum vehicle weights are stamped
on a plate located under the bonnet [hood] riveted to
the front of the engine compartment.
Vehicle Identification Number Plate (UK, Australia,
R.O.W., Europe)
Vehicle Identification Number Plate (Saudi Arabia)
A. Year of manufacture
B. Month of manufacture
C. Maximum vehicle weight
D. Maximum road weight-front axle
E. Maximum road weight-rear axle
F. VIN (17 digits)
A. Build date (Australia). Type approval
B. VIN (17 digits)
C. Maximum permitted laden weight for vehicle
D. Maximum vehicle and trailer weight
E. Maximum road weight-front axle
F. Maximum road weight-rear axle
The number is also stamped on the right side of the
chassis forward of the spring mounting turret.
The vehicle identification number identifies the
manufacturer, model range, wheel base, body type,
engine, steering, transmission, model year and place
of manufacture. The following example shows the
coding process.
SAL World manufacturer identifier
LH Range Rover or
LJ Discovery
G Class 100 inch
B 2 door
F 300 Tdi or
V V8i Petrol
8 5 speed LHD or
7 5 speed RHD
M 1995 MY
A Solihull site
12
INFORMATION
INTRODUCTION
European vehicle identification number (VIN)
Vehicle identification number (VIN)
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is fixed to the lock face of the front left hand
door. The information includes wheel and tyre sizes
and tyre pressures at gross axle weight ratings.
Stamped on the right hand side chassis forward of
rear wheel.
Federal (USA) vehicle identification number
Stamped on a plate rivetted to the upper left hand ’A’ post, visible through the front screen of the vehicle.
Key to vehicle identification label
A. Month and year of manufacture
B. Gross vehicle weight rating
C. Gross axle weight rating for front axle
D. Gross axle weight rating for rear axle
E. Vehicle identification number (17 digits)
F. Vehicle identification number - bar code
INFORMATION
13
01
INTRODUCTION
LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
Main gearbox R380
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Automatic gearbox
Engines are identified by the prefix:
3.9 Litre:
35D. - 9.35:1 compression, manual transmission
36D. - 9.35:1 compression, automatic transmission
37D. - 8.13:1 compression, manual transmission
38D. - 8.13:1 compression, automatic transmission
4.2 Litre:
40D. - 8.94:1 compression, automatic transmission
Engine serial number - Diesel engine
Stamped on the RH side of cylinder block above the
camshaft front cover plate.
Stamped on a plate riveted to the bottom left hand
side of the gearbox casing.
14
INFORMATION
INTRODUCTION
Transfer gearbox-Borg Warner
Stamped on a plate attached to the gearbox casing,
between filler/level and drain plug.
Front and rear axle
Stamped on the top of the left hand axle tubes.
INFORMATION
15
01
INTRODUCTION
FAULT DIAGNOSTIC EQUIPMENT
TESTBOOK
Todays Land Rover Vehicles are equipped with a
large amount of electronics to provide the best
performance of the vehicles systems.
Diagnostic equipment named TESTBOOK is available
to expand the diagnostic abilities of the dealer
workshop. This repair manual is produced with
Testbook in mind.
Features of Testbook include: - Fully upgradable
support for the technician. Structured diagnostics to
accommodate all skill levels. Touch screen operation.
Direct print out of screen information and test results.
READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a rang of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page:
Description and operation.
Fault diagnosis.
Adjustment.
Repair.
Overhaul.
Specifications, Torque.
Service tools.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
V8i drive belt. A cross reference sites this information
in: Section: V8i Engine
- Sub-section: Repairs
- Heading: Drive belt renew
ELECTRICAL TROUBLESHOOTING MANUAL
The Electrical Troubleshooting Manual is a separate
publication that is intended for use by trained Land
Rover technicians as an aid to diagnosing electrical
concerns.
It provides circuit diagrams, system diagnosis flow
charts, electrical component location tables, electrical
component location views, and circuit operation
details.
Sections that contain derivatives such as engines are
further separated into within that section.
American terminology
A few words used in this manual differ to words used
in America. Where this occurs the American word is
placed inside brackets. For example: bonnet [hood],
wing [fender], ramp [hoist].
16
INFORMATION
GENERAL SPECIFICATION DATA
ENGINE - V8
Type 3.9 litre V8.................................................................................
Number of cylinders Eight, two banks of four.........................................................
Bore 94.00 mm.................................................................................
Stroke 71.12 mm...............................................................................
Capacity 3950 cm
Valve operation Overhead by push-rod................................................................
Compression ratio 8.13:1 or 9.35:1............................................................
Valve operation Overhead by push-rod................................................................
Maximum power: - 8.13:1 127kW at 4550 rev/min............................
Type 4.2 litre V8.................................................................................
Number of cylinders Eight, two banks of four.........................................................
Bore 94.00 mm.................................................................................
Stroke 77.00 mm...............................................................................
Capacity 4275 cm
Valve operation Overhead by push-rod................................................................
Compression ratio 8.94:1............................................................
Valve operation Overhead by push-rod................................................................
Maximum power 149kWat 4850 rev/min...............................................................
...........................................................................
- 9.35:1 134kW at 4750 rev/min............................
...........................................................................
3
3
Crankshaft
Main journal diameter 58.409-58.422 mm.......................................................
Minimum regrind diameter 57.393-57.406mm...............................................
Crankpin journal diameter 50.800-50.812 mm................................................
Minimum regrind diameter 49.784-49.797mm...............................................
Crankshaft end thrust Taken on thrust washers of centre main bearing.......................................................
Crankshaft end float 0.10-0.20 mm.........................................................
Main bearings
Number and type 5, Vandervell shells..............................................................
Material Lead-indium............................................................................
Diametrical clearance 0.010-0.048 mm.......................................................
Undersize bearing shells 0.254 mm, 0.508 mm..................................................
Connecting rods
Type Horizontally split big-end, plain small-end.................................................................................
Length between centres 143.81-143.71 mm...................................................
Big-end bearings
Type and material Vandervell VP lead-indium............................................................
Diametrical clearance 0.015-0.055 mm.......................................................
End-float crankpin 0.15-0.36mm............................................................
Undersize bearing shells 0.254 mm, 0.508 mm..................................................
Piston pins
Length 72.67-72.79 mm..............................................................................
Diameter 22.215-22.220 mm..........................................................................
Fit-in connecting rod Press fit.........................................................
Clearance in piston 0.002-0.007 mm..........................................................
INFORMATION
1
04
Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0.018-0.041 mm...................................
Piston rings
Number of compression rings 2..........................................
Number of control rings 1....................................................
No 1 compression ring Molybdenum barrel faced.....................................................
No 2 compression ring Tapered and marked ’T’ or ’TOP’.....................................................
Width of compression rings 1.478-1.49 mm..............................................
Compression ring gap 0.40-0.65 mm......................................................
Oil control ring type Hepworth and Grandage..........................................................
Oil control ring width 3.0 mm.........................................................
Oil control ring rail gap 0.38-1.40 mm.....................................................
Camshaft
Location Central...........................................................................
Bearings Tin-aluminium...........................................................................
Number of bearings 5..........................................................
Drive Chain 9.52 mm pitch x 54 pitches..................................................................................
GENERAL SPECIFICATION DATA
Tappets Hydraulic self-adjusting...........................................................................
Valves
Length: Inlet 116.59-117.35 mm..................................
Exhaust 116.59-117.35 mm...........................
Seat angle: Inlet 45°- 45 1/2°..................................
Exhaust 45°- 45 1/2°...........................
Head diameter: Inlet 39.75-40.00 mm..................................
Exhaust 34.226-34.480 mm...........................
Stem diameter: Inlet 8.664-8.679 mm..................................
Exhaust 8.651-8.666 mm...........................
Stem to guide clearance: Inlet 0.025-0.066 mm..................................
Exhaust 0.038-0.078 mm...........................
Valve lift (Inlet and Exhaust) 9.49 mm............................................
Valve spring length fitted 40.4 mm at pressure of 29.5 kg..................................................
Lubrication
System type Wet sump, pressure fed.....................................................................
Oil pump type Eccentric rotor...................................................................
Oil pressure 2.75 bar (40 lbf/in2) at 2500 rev/min with engine at......................................................................
Oil filter-internal Wire screen, pump intake filter in sump................................................................
Oil filter-external Full flow, self-contained cartridge...............................................................
running temperature
INFORMATION
2
GENERAL SPECIFICATION DATA
ENGINE - 300Tdi
Type Direct injection, turbocharged, intercooled.................................................................................
Number of cylinders 4.........................................................
Bore 90,47 mm.................................................................................
Stroke 97,00 mm...............................................................................
Capacity 2495 cm
Compression ratio 19.5:1 ± 0.5:1............................................................
Valve operation O.H.V. pushrod operated................................................................
Turbo charger Garrett T25..................................................................
Crankshaft
Main bearing journal diameter 63,475 - 63,487 mm..........................................
Regrind dimensions 63,2333 - 63,246 mm.........................................................
Crankpin journal diameter 58,725 - 58,744 mm................................................
Regrind dimensions 58,4708 - 58,48985 mm.........................................................
Crankshaft end thrust Taken on thrust washers at centre main bearing.......................................................
Crankshaft end float 0,05 - 0,15 mm.........................................................
...........................................................................
Use 0.010 in U/S bearings
Use 0.010 in U/S bearings
3
Main bearings
Number and type 5 halved shells with oil grooves..............................................................
Diametrical clearance 0,0792 - 0,0307 mm.......................................................
Connecting rods
Length between centres 175,38 - 175,43 mm...................................................
Diametrical clearance (big-end bearings) 0,025 - 0,075 mm........................
End float on crankpin 0,15 - 0,356 mm.......................................................
Pistons
Type Aluminium alloy, combustion chamber in crown.................................................................................
Skirt diametrical clearance
(at right angle to gudgeon pin) 0,025 - 0,05 mm.........................................
Maximum height above combustion face 0,8 mm.........................
Gudgeon pins
Type Floating.................................................................................
Fit in piston Hand push fit.......................................................................
Diameter 30,1564 - 30,1625 mm..........................................................................
Clearance in connecting rod 0,0025 - 0,0163 mm............................................
INFORMATION
3
04
Piston rings
Type:
- Top Barrel edge, chrome plated........................................................................
- Second Taper faced..................................................................
- Oil control Expander and rails..............................................................
Gap in bore:
- Top 0,40 - 0,60 mm........................................................................
- Second 0,30 - 0,50 mm..................................................................
- Oil control 0,3 - 0,6 mm..............................................................
Clearance in piston grooves:
- Top 0,167 - 0,232 mm........................................................................
- Second 0,05 - 0,08 mm..................................................................
- Oil control 0,05 - 0,08 mm..............................................................
Camshaft
Drive 30 mm (1.2 in) wide dry toothed belt.................................................................................
Location Right hand side (thrust side)...........................................................................
End float 0,1 - 0,2 mm...........................................................................
Number of bearings 4..........................................................
Material Steel shell, white metal lined............................................................................
GENERAL SPECIFICATION DATA
Valves
Tappet clearance:
- Inlet and exhaust 0,20 mm...................................................
Seat angle:
- Inlet 30°.......................................................................
- Exhaust 45°.................................................................
Head diameter:
- Inlet 39,75 - 39,05 mm.......................................................................
- Exhaust 36,35 - 36,65 mm.................................................................
Stem diameter:
- Inlet 7,960 - 7,975 mm.......................................................................
- Exhaust 7,940 - 7,960 mm.................................................................
Valve lift:
- Inlet 9,67 mm.......................................................................
- Exhaust 9.97 mm.................................................................
Cam lift:
- Inlet 6,81 mm.......................................................................
- Exhaust 7,06 mm.................................................................
Valve head stand down:
- Inlet 0,81 - 1,09 mm.......................................................................
- Exhaust 0,86 - 1,14 mm.................................................................
Valve springs
Type Single coil.................................................................................
Length, free 46,28 mm......................................................................
Length, under 21 kg (46 lb) load 40,30mm......................................
INFORMATION
4
GENERAL SPECIFICATION DATA
Lubrication
System Wet sump, pressure fed.............................................................................
Pressure, engine warm at normal operating speeds 1.7-3.8 bar (25 - 55 lbf/in2)........
Oil pump:
- Type Double gear 10 teeth, sintered iron gears......................................................................
- Drive Splinedshaft from camshaft skew gear.....................................................................
- End float of both gears 0,026 - 0,135 mm..........................................
- Radial clearance of gears 0,025 - 0,075 mm.....................................
- Backlash of gears 0,1 - 0,2 mm.................................................
Oil pressure relief valve Non-adjustable....................................................
Relief valve spring:
- Full length 51.6 mm.............................................................
- Compressed length at 7.71 kg load 31.0 mm......................
Oil filter Screw-on disposable canister.............................................................................
Engine oil cooler Combined with coolant radiator and intercooler...............................................................
INFORMATION
5
04
FUEL SYSTEM - V8 Engine
Fuel system type Lucas 14CUX hot wire system electronicallycontrolled..............................................................
Fuel pump-make/type High pressure electrical, immersed in the fuel tank......................................................
Fuel pump delivery pressure 2.4-2.6bar(34-37 lbf/in2)............................................
Fuel filter Bosch in-line filter ’canister’ type..........................................................................
Airflow Sensor
Make and type Lucas ’Hot Wire’ 5AM.................................................................
Injectors
Make and type Lucas 8NJ.................................................................
Electronic Control Unit
Make and type Lucas 14CUX.................................................................
Fuel pressure regulator
Make and type Lucas 8RV.................................................................
GENERAL SPECIFICATION DATA
Fuel temperature sensor
Make and type Lucas 6TT.................................................................
Coolant temperature sensor
Make and type Lucas 3TT.................................................................
Bypass Air valve (Stepper motor)
Make and type Lucas 2ACM.................................................................
Throttle potentiometer
Make and type Lucas 215SA.................................................................
Lambda sensor - catalyst vehicles
Make and type Lucas 3LS.................................................................
FUEL SYSTEM - 300Tdi Engine
Injection pump type Bosch rotary VE4/11F.
Injectors
Heater plugs
Fuel lift pump type Mechanical with hand primer............................................................
Fuel lift pump pressure 0.4 - 0.55 bar (6 - lbf/in2) at 1800 rpm.....................................................
Fuel filter Paper element in disposable canister..........................................................................
Air cleaner Paper element type........................................................................
Turbocharger Garrett T25.
...........................................................................
.....................................................................
..........................................................
...................................................................
Information, Engine - 300Tdi
See ENGINE TUNING DATA, Information, Engine
- 300Tdi
See ENGINE TUNING DATA, Information, Engine
- 300Tdi
See ENGINE TUNING DATA,
Information, Engine - 300Tdi
See ENGINE TUNING DATA,
INFORMATION
6
GENERAL SPECIFICATION DATA
COOLING SYSTEM - V8 ENGINE
Type Pressurized system with cross- flow radiator and.................................................................................
Type of pump Centrifugal...................................................................
Thermostat 88°C.......................................................................
Expansion tank cap pressure (system pressure) 1.0 bar (15 lbf/in2).............
COOLING SYSTEM - 300Tdi ENGINE
System type Pressurised, spill return, thermostatically controlled.....................................................................
Cooling fan 11 blade axial flow 433 mm diameter. 1.29:1 drive.......................................................................
Pump type Centrifugal, impeller, belt driven.........................................................................
Thermostat opening 88°C.........................................................
Expansion tank cap pressure (system pressure) 1.0 bar (15 lbf/in2).............
remote header tank, thermostat control, pump and fan
assisted
water and anti freeze mixture. Pump assisted thermo
syphon. Coolant radiator combined with oil cooler and
turbo intercooler.
ratio. Viscous coupling.
TRANSMISSION
Clutch
Make and type - V8 engine Borg and Beck, diaphragm spring..............................................
Clutch plate diameter 266.5mm.......................................................
Make and type - Diesel engine Valeo, diaphragm spring.........................................
Clutch plate diameter 235mm.......................................................
Transfer gearbox
Borg Warner Two speed reduction on main gearbox output, front.....................................................................
Transfer gearbox ratios
High 1.206:1..................................................................................
Low 3.244:1..................................................................................
Manual gearbox
Type R380 5 speed, single helical constant mesh with.......................................................................
and rear drive permanently engaged via a centre
differential controlled by a Viscous unit giving a 50/50
nominal front and rear torque split.
synchromesh on all forward gears
INFORMATION
7
04
Manual gearbox ratios:
5th 0.731:1...........................................................................
4th 1.000:1...........................................................................
3rd 1.397:1...........................................................................
2nd 2.132:1..........................................................................
1st 3.321:1...........................................................................
Reverse 3.429:1...................................................................
Diesel models low first gear 3.692:1....................................
Overall ratio (final drive): High transfer Low transfer
5th 3.119:1........................................................................... 8.39:1
4th 4.267:1........................................................................... 11.476:1
3rd 5.959:1........................................................................... 16.027:1
2nd 9.095:1.......................................................................... 24.462:1
1st 14.172:1........................................................................... 38.115
Reverse 14.629:1................................................................... 39.346:1
Diesel models low 1st gear 15.750:1..................................... 42.362
Automatic gearbox
Model ZF4HP22...............................................................................
Type Four speed and reverse epicyclic gears with fluid.................................................................................
GENERAL SPECIFICATION DATA
torque converter and lock up.
Automatic gearbox ratios
4th 0.728:1...........................................................................
3rd 1.000:1...........................................................................
2nd 1.480:1..........................................................................
1st 2.480:1...........................................................................
Reverse 2.086:1...................................................................
Overall ratio (final drive): High transfer Low transfer
4th 3.11:1........................................................................... 8.36:1
3rd 4.27:1........................................................................... 11.48:1
2nd 6.32:1.......................................................................... 17.00:1
1st 10.59:1........................................................................... 28.50:1
Reverse 8.91:1................................................................... 23.96:1
INFORMATION
8
GENERAL SPECIFICATION DATA
SHIFT SPEED SPECIFICATION - AUTOMATIC ZF4HP22 GEARBOX
OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED
POSITION APPROX APPROX (RPM)
KICKDOWN
MPH KPH
KD4 - 3 D 84 - 92 136 - 150
KD3 - 2 3(D) 57 - 62 91 - 99
KD2 - 1 2(D,3) 27 - 34 44 - 56
KD3 - 4 D N/A N/A
KD2 - 3 D(3) 60 - 63 96 - 104 4750 - 5200
KD1 - 2 D(3,2) 34 - 40 56 - 64 4600 - 5250
FULL THROTTLE
FT4 - 3 D 61 - 67 98 - 108
FT3 - 2 3(D) 40 - 46 64 - 73
FT3 - 4 D 74 - 80 119 - 129 3980 - 4330
FT2 - 3 D(3) 55 - 60 88 - 96 4350 - 4800
T1 - 2 D(3,2) 29 - 34 48 - 56 3950- 465
PART THROTTLE
PT4 - 3 D 47 - 54 75 - 86
PT3 - 2 D(3) 29 - 37 48 - 59
PT2 - 1 D(3,2) 10 - 12 16 - 19
LIGHT THROTTLE
LT3 - 4 D 26 - 30 43 - 49 1430 - 1650
LT2 - 3 D(3) 18 - 22 29 - 35 1420 - 1820
LT1 - 2 D(3,2) 9 - 10 14 - 16 1180 - 1220
ZERO THROTTLE
ZT4 - 3 D 19 - 25 31 - 41
ZT3 - 2 D(3) 12 - 15 19 - 24
ZT2 - 1 D(3,2) 6 - 7 10 - 11
TORQUE CONVERTER
Lock up (IN) D 51 - 54 81 - 86 1875 - 2000
Unlock (OUT) D 49 - 52 78 - 83 1825 - 1930
Note: The speeds given in the above chart are approximate and only intended as a guide. Maximum shift
changes should take place within these tolerance parameters.
INFORMATION
9
04
Propeller shafts
Type
Front Tubular 51mm diameter.................................................................................
Front - Catalyst vehicles Solid bar 28.6mm diameter...................................................
Rear Tubular 51mm diameter.................................................................................
Universal joints Open type Hooks O3EHD.................................................................
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints,.................................................................................
Ratio 3.54:1.................................................................................
STEERING
GENERAL SPECIFICATION DATA
fully floating shafts
Power steering box
Make/type AdwestVaramatic- worm and roller box........................................................................
Ratio Variable: straight ahead 19.3:1 on lock 17.2:1.................................................................................
Steering wheel turns, lock-to-lock 3.375....................................
Steering pump
Make/type:
V8 engine ZF ’UNICORN’.........................................................................
Diesel engine Hobourn-Eaton series 500...................................................................
Operating pressure - straight ahead position - at idle 7 bar (100 p.s.i.) maximum......
Full lock (left or right) at idle 28 bar (400 p.s.i.) minimum.............................................
Full lock (left or right) 1000 rev/min 70-77 bar (1000-1100 p.s.i.)..................................
Steering geometry
Steering wheel diameter 406.4mm..................................................
Toe-out measurement 0 to 2mm toe out......................................................
Toe-out included angle 0°to 0°16’.....................................................
Camber angle 0°C.................................................................. Check with vehicle in static
unladen condition, that is,
vehicle with water,
Castor angle 3°..................................................................... oil and five gallons of fuel.
Rock the vehicle up and
down at the front to allow
Swivel pin inclination static 7°............................................... it to take up a position
10
INFORMATION
GENERAL SPECIFICATION DATA
SUSPENSION
Type:
- Coil spring suspension Coil springs controlled by telescopic dampers front..........................................
- Air suspension Air springs controlled by an ECU providing variable......................................................
Front Lateral location of axle by Panhard rod, and.................................................................................
Rear Lateral location of axle by a centrally positioned ’A’.................................................................................
SHOCK ABSORBERS
and rear.
rate springs and 5 height settings.
longitudinal location by two radius arms.
frame bolted at the apex to a ball joint mounting.
Coil spring suspension: A levelling unit is positioned
between the ball joint and upper cross member.
Longitudinal location of axle by two tubular trailing
links.
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
INFORMATION
11
04
ROAD SPRING DATA
V8i
LEFT HAND DRIVE Part No. Colour Code
Left hand front NRC4306 Blue/White
Right hand front 572315 Blue
Left hand rear ANR 3519 Brown/Red
Right hand rear ANR 3520 Brown/Yellow
Heavy duty rear NRC 4304 Red/White
RIGHT HAND DRIVE
Left hand front 572315 Blue
Right hand front 572315 Blue
Left hand rear ANR 3520 Brown/Yellow
Right hand rear ANR 3520 Brown/Yellow
Heavy duty rear NRC 4304 Red/White
GENERAL SPECIFICATION DATA
Tdi Diesel
LEFT HAND DRIVE Part No. Colour Code
Left hand front NTC 8476 White/Blue/Pink
Right hand front NRC 8477 Green/Blue/Yellow
Left hand rear ANR 3519 Brown/Red
Right hand rear ANR 3520 Brown/Yellow
Heavy duty rear NRC 4304 Red/White
RIGHT HAND DRIVE
Left hand front NRC 8477 Green/Blue/Yellow
Right hand front NRC 8477
Left hand rear ANR 3520 Brown/Yellow
Right hand rear ANR 3520
Heavy duty rear NRC 4304 Red/White
12
INFORMATION
Loading...