Land Rover Range Rover Classic User Manual

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RANGE ROVER

CLASSIC

Workshop Manual

Page 2

Workshop manual

RANGE ROVER

This manual covers vehicles from

1995 model year

01 04 05 06 07 09

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

37 41 44

47 51 54

60 64 68 74

Published by Rover Technical Communication

 Rover Group Limited 1995

Publication Part No. LRL0030ENG

80 82

84 86

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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.

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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

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

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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.

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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

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

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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.

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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.

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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.

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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.

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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.

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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.......................................................

Ounces (mass) oz........................................................

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......................................................

Vehicle Identification Number VIN...............................

Volts V.........................................................................

Watts W.......................................................................

SCREW THREADS

American Standard Taper Pipe NPTF.........................

British Standard Pipe BSP...........................................

Unified Coarse UNC....................................................

Unified Fine UNF.........................................................

2 2

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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 (-)...........................................................

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).........................

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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

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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

Page 16

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.

INFORMATION

Page 17

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

Page 18

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].

INFORMATION

Page 19

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............................

...........................................................................

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

Page 20

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

Page 21

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

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

Page 22

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

Page 23

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

Page 24

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

Page 25

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

Page 26

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

Page 27

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

Page 28

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

INFORMATION

Page 29

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

Page 30

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

INFORMATION

Page 31

GENERAL SPECIFICATION DATA

BRAKES

Front service brake

Type Outboard discs with four piston calipers.................................................................................

Operation Hydraulic, servo assisted self-adjusting.........................................................................

Pad material Ferodo 3440 non asbestos.....................................................................

Rear service brake

Type Outboard discs with two piston calipers.................................................................................

Operation Hydraulic, servo assisted, self-adjusting.........................................................................

Pad material Ferodo 3440 non asbestos.....................................................................

Parking brake

Type Mechanical-cable operated drum brake on the rear.................................................................................

Lining material Non asbestos..................................................................

Servo/master cylinder

Manufacturer Lucas Girling....................................................................

Servo type LSC 115........................................................................

Master cylinder type AS/AS.........................................................

of the transfer gearbox output shaft

Anti-lock brake system

Manufacturer/type Wabco LRC M15 - 4 channel, 4 wheel sensed............................................................

integrated anti-lock brake system.

INFORMATION

Page 32

WHEELS AND TYRES

Type and size Alloy 7.00J X 16...................................................................

Tyre size 205R16 (tubeless)..........................................................................

Type and size Steel 6.00JK X 16...................................................................

Tyre size 205R16 (tubed)..........................................................................

AIR CONDITIONING

System CFC free expansion valve system (Nippon Denso).............................................................................

Compressor Nippon Denso 10PA17.....................................................................

GENERAL SPECIFICATION DATA

NOTE: Petrol vehicles must be fitted with ’S’ or ’T’ rated tyres.

Fixed displacement swash plate

WIPER MOTORS

Tailgate wiper motor

Make/type IMOS(non-serviceable)........................................................................

Running current, wet screen at 20°C ambient 1.0 to 2.8 amps.................

Wiper speed, wet screen at 20°C ambient 37 to 43 cycles per minute.......................

Windscreen wiper motor

Make/type Lucas 28W 2-speed........................................................................

Running current (Link disconnected) 1.5 amps at 39 to 45 rev/min (normal speed)...............................

Rotary link speed 60 to 73 rev/min (high speed).............................................................

INFORMATION

Page 33

GENERAL SPECIFICATION DATA

ELECTRICAL

System 12 volt, negative ground.............................................................................

Battery

Make/type - basic Land Rover Parts and Equipment/Chloride.............................................................

Make/type - heavy duty Land Rover Parts and Equipment/Chloride....................................................

Generator

Manufacturer Magnetti Marelli....................................................................

Type A133 - 100A.................................................................................

Polarity Negative ground.............................................................................

Brush length

New 20 mm.........................................................................

Worn, minimum free protrusion

from brush box 10 mm........................................................

Brush spring pressure flush with brush box face 136 to 279 g..............

Rectifier pack output rectification 6 diodes (3 positive side and 3 ground side).....................................

Field winding supply rectification 3 diodes......................................

Stator windings 3 phase-delta connected.................................................................

Field winding rotor poles 12..................................................

Maximum speed 16,000 rev/min......................................................

Winding resistance at 20°C 2.6 ohms.....................................

Control Field voltage sensed regulation.............................................................................

Regulator-type 15 TR..................................................................

voltage 13.6 to 14.4 volts....................................................................

Nominal output

Condition Hot.................................................................

Generator speed 6000 rev/min.....................................................

Control voltage 14 volt........................................................

Amp 100 amp.........................................................................

maintenance free 9-plate-210/85/90 maintenance free 14-plate-380/120/90

Fuses

Type Autofuse (blade type).................................................................................

Horns

Make/type Klamix(Mixo)TR99........................................................................

Starter motor

V8 Engine

Make/type Lucas M78R pre-engaged........................................................................

Minimum brush length 3.5 mm.............................................

Minimum commutator diameter 28.8 mm...............................

Diesel Engine

Make and type Bosch 0.001.362.092.................................................................

blow ratings to suit individual circuits

INFORMATION

Page 34

REPLACEMENT BULBS

Exterior lights

Headlamps 12V 60/55W (Halogen) Auxiliary driving lamps 12V 55W H3 (Halogen) Sidelamps 12V 5W bayonet Tail lamps 12V 5/21W bayonet Reverse lamps 12V 21W bayonet Stop lamps 12V 21W bayonet Direction indicator lamps 12V 21W bayonet Rear side marker lamps 12V 4W bayonet Number plate lamps 12V 5W capless

Interior lights

Interior roof lamps 12V 10W ’Festoon’ Door shut face/puddle lamps 12V 5W capless Instrument panel lamps and warning lamps 14V 1.2W bulb/holder unit Ignition warning lamp (Instrument panel) 14V 2W capless SRS warning lamp (Instrument panel) 14V 1.4W capless Clock illumination 12V 2W bayonet Cigar lighter illumination 12V 1.2W capless Auxiliary switch illumination 12V 0.2W capless Auxiliary switch warning lamp 12V 0.2W capless Hazard warning switch illumination 14V 0.2W capless Automatic selector graphics illumination 12V 5W capless Heater/air conditioning graphics illumination 12V 1.2W capless

GENERAL SPECIFICATION DATA

REPLACEMENT BULBS TYPE

CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage to vehicle wiring and switches.

INFORMATION

Page 35

GENERAL SPECIFICATION DATA

VEHICLE WEIGHTS AND PAYLOAD

When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the vehicle kerb weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum values. It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither maximum axle loads nor Gross Vehicle Weight are exceeded.

Front Rear Total

Basic models Axle kg Axle kg kg

Manual

V8 engine EEC Kerb weight 990 1080 2070

Gross Vehicle Weight* 1100 1510 2510

V8 engine SE EEC Kerb weight 1055 1095 2150

Gross Vehicle Weight* 1100 1510 2510

V8 engine LSE EEC Kerb weight 1090 1095 2185 (long wheelbase models) Gross Vehicle Weight* 1200 1620 2620

Diesel engine Tdi EEC Kerb weight 1040 1070 2110

Gross Vehicle Weight* 1200 1620 2620

Tdi SE EEC Kerb weight 1105 1085 2110

Gross Vehicle Weight* 1200 1620 2620

NOTE: EEC KERB WEIGHT is the minimum vehicle specification, plus full fuel tank and 75 kg driver. GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver, passengers, and equipment. This figure is liable to vary according to legal requirements in certain

countries.

Maximum roof rack load (including weight of rack) 75 kg must be included in total vehicle weight.

INFORMATION

Page 36

VEHICLE DIMENSIONS

Overall length 4.48m...................................................................

- Long wheelbase vehicles 4.68m......................................

Overall width 1.82m....................................................................

Overall height 1.80m...................................................................

Wheelbase 2.54m.......................................................................

- Long wheelbase vehicles 2.74m......................................

Track: front and rear 1.49m.........................................................

Ground clearance: under differential 190mm................................

Turning circle 11.89m....................................................................

- Long wheelbase vehicles 13.64m......................................

Loading height 749mm.................................................................

Maximum cargo height 1.028m.....................................................

Rear opening height 0.87m.........................................................

Usable luggage capacity, rear seat folded 2.00m Usable luggage capacity, rear seat in use 1.03m

GENERAL SPECIFICATION DATA

.......................

3 3

TYRE PRESSURES

Pressures: Check Normal on and off-road use. Off-road ’emergency’ soft use

with tyres cold All speeds and loads maximum speed of 40 kph (25 mph)

Front Rear (*) Front Rear

bar 1.9 2.4 (2.6) 1.2 1.8

lbf/in

kgf/cm

(*) Long wheelbase vehicles (2.74m, 108") The pressure of tyres must be increased be 0.3 bar (3 lbf in20.2 kgf/cm2). For use with sustained driving speeds

above 160 km/hr (100 miles/hour) or with heavy axle loads. Normal operating pressures should be restored as soon as reasonable road conditions or hard ground is reached. After any usage off the road, tyres and wheels should be inspected for damage particularly if high cruising speeds are subsequently to be used.

Towing: When the vehicle is used for towing, the reduced rear tyre pressures for extra ride comfort are not applicable.

28 35 (38) 17 25

2.0 2.5 (2.7) 1.2 1.8

WARNING: Vehicles fitted with tubeless alloy road wheels as original equipment, note that these wheels DO NOT accept inner tubes and tubed tyres MUST NOT be fitted.

INFORMATION

Page 37

ENGINE - 3.9 V8

Type 3.9 Litre V8.................................................................................

Firing order 1-8-4-3-6-5-7-2.....................................................................

Cylinder Numbers

Left bank 1-3-5-7..........................................................................

Right bank 2-4-6-8........................................................................

No 1 Cylinder location Pulley end of left bank...................................................

Timing marks On crankshaft vibration damper..................................................................

Spark plugs

Make/type(8.13:1 Compression) Champion RN11YCC......................................

Gap 0.84-0.96mm(0.033-0.038in)..................................................................................

Make/type(9.35:1 Compression) Champion RN11YCC......................................

Gap 0.84-0.96mm(0.033-0.038 in)..................................................................................

ENGINE TUNING DATA

Coil

Make/type Bosch 0-221-122-392, (ETC 6574)........................................................................

Compression ratio 8.13:1 or 9.35:1.........................................................

Fuel injection system Lucas 14 CUX Hot-wire air flow sensor.....................................................

system electronically controlled

Valve Timing Inlet Exhaust

Opens 32°BTDC.............................................................................. 70°BBDC

Closes 73°ABDC.............................................................................. 35°ATDC

Duration 285°........................................................................... 285°

Valve peak 104°ATDC....................................................................... 114°BTDC

Idle speed - controlled by EFi system

- all loads off in neutral 665 to 735 rev/min............................................

- auto gearbox in gear, air con operating 650 ±28 rev/min................

- auto gearbox in gear, air con off 600 ± 28 rev/min...........................

- manual gearbox 700 ± 28 rev/min....................................................

- manual gearbox, air con operating 750 ±28 rev/min.......................

Base idle speed 525 ± 25 rev/min -...............................................................

See FUEL SYSTEM, Fault diagnosis, Base Idle

Speed Setting

Ignition Timing - dynamic at 800 rev/min max, vacuum disconnected

8.13:1 compression, non catalyst 2°BTDC ± 1°.....................................

9.35:1 compression, non catalyst 4°BTDC ± 1°.....................................

9.35:1 compression, catalyst 5°BTDC ± 1°............................................

Exhaust gas

CO content at idle 0.5 to 1.0% max.............................................................

INFORMATION

Page 38

Distributor

Make/type Lucas 35DLM8 electronic........................................................................

Rotation Clockwise............................................................................

Air gap 0.20-0.35mm..............................................................................

Part number Lucas Rover

8.13:1, non catalyst 42584A................................................. ERR 4753

9.35:1, non catalyst 42552A................................................. ERR 4754

9.35:1, catalyst 42583A........................................................ ERR 4755

Centrifugal Advance

Decelerating check-vacuum hose disconnected Distributor rpm deceleratingspeeds

8.13:1 non catalyst

2000 Distributor advance........................................................................ 5°30’ to 8°30’

1400 ........................................................................ 6°18’ to 8°30’

800 .......................................................................... 2°to 4°

9.35:1 non catalyst

2200 Distributor advance........................................................................ 7°to 10°

1400 ........................................................................ 7°48’ to 10°

650 .......................................................................... 1°to 3°

ENGINE TUNING DATA

9.35:1 catalyst

2200 Distributor advance........................................................................ 5°30’ to 8°30’

1400 ........................................................................ 6°18’ to 8°30’

800 .......................................................................... 2°to 4°

Fuel

8.13:1, non catalyst 91 RON minimum unleaded.................................................

9.35:1, non catalyst 95 RON minimum unleaded.................................................

9.35:1, catalyst 95 RON minimum unleaded........................................................

USA-Premium unleaded (PUG) CLC or AKI 90 octane minimum..............................

95 RON minimum

Australian market variations

Fuel 91 RON minimum unleaded..................................................................................

Compression ratio 8.13:1............................................................

Spark plug Champion RN11YCC........................................................................

Spark plug gap 0.84-0.96mm (0.033-0.038 in).................................................................

Ignition Timing at 800 rev/min max

(vacuum pipe disconnected) 2°BTDC ± 1°............................................

Exhaust gas idle CO 1% max (hot)........................................................

INFORMATION

Page 39

ENGINE - 4.2 V8

Type 4.2 Litre V8.................................................................................

Firing order 1-8-4-3-6-5-7-2.....................................................................

Cylinder Numbers

Left bank 1-3-5-7..........................................................................

Right bank 2-4-6-8........................................................................

No 1 Cylinder location Pulley end of left bank...................................................

Timing marks On crankshaft vibration damper..................................................................

Spark plugs

Make/type Champion RN11YCC........................................................................

Gap 0.84-0.96mm (0.033-0.038 in)..................................................................................

Coil

Make/type Bosch 0-221-122-392, (ETC 6574)........................................................................

ENGINE TUNING DATA

Compression ratio 8.94:1.........................................................

Fuel injection system Lucas 14 CUX Hot-wire air flow sensor system.....................................................

electronically controlled

Valve Timing Inlet Exhaust

Opens 28°BTDC..................................................................... 72°BBDC

Closes 64°ABDC..................................................................... 20°ATDC

Duration 272°.................................................................. 272°

Valve peak 108°ATDC.............................................................. 116°BTDC

Idle speed - controlled by EFi system

- all loads off in neutral 665 to 735 rev/min............................................

-auto gearbox in gear, air con operating 650 ± 28 rev/min.................

-auto gearbox in gear, air con off 600 ± 28 rev/min............................

-manual gearbox 700 ± 28 rev/min.....................................................

-manual gearbox, air con operating 750 ± 28 rev/min........................

Base idle speed 525 ± 25 rev/min -...............................................................

See FUEL SYSTEM, Fault diagnosis, Base Idle

Speed Setting

Ignition Timing

Dynamic, vacuum disconnected 8°BTDC ± 1°at 800 rev/min max.............................

Exhaust gas

CO content at idle 0.5 to 1.0% max.............................................................

INFORMATION

Page 40

Distributor

Make/type Lucas 35DLM8 electronic........................................................................

Rotation Clockwise............................................................................

Air gap 0.20-0.35mm..............................................................................

Lucas 42510A...............................................................................

Rover Part number ERR 0744...........................................................

Centrifugal Advance

Decelerating check-vacuum hose disconnected Distributor rpm deceleratingspeeds

2200 7°to 10°........................................................................

1400 7°48’ to 10°........................................................................

800 1°to 3°..........................................................................

Fuel

UK, Europe and Rest of World 95 RON minimum unleaded.........................................

USA - Premium unleaded (PUG) CLC or AKI 90 octane minimum.....................................

ENGINE TUNING DATA

95 RON minimum

INFORMATION

Page 41

ENGINE TUNING DATA

ENGINE - 300Tdi

ENGINE

Type 2.5 Litre Turbo diesel with intercooler.................................................................................

Firing order 1-3-4-2.......................................................................

Injection timing 1,54 mm lift at T.D.C..................................................................

- with electronic EGR 1,40 mm lift at T.D.C...............................................

Timing marks:

Valve timing - manual Slot for pin in flywheel and TDC mark on front pulley..............................................

Valve timing - automatic Slot for pin in ring gear, access through rear engine..........................................

plate. TDC mark on front pulley

Injection timing Dial gauge inserted into pump...............................................................

Tappet clearances - inlet and exhaust 0,20 mm cold.............................

Valve timing: Inlet Exhaust

- Opens 16°B.T.D.C.................................................................... 51°BBDC

- Closes 42°ABDC................................................................... 13°ATDC

- Peak 103°ATDC...................................................................... 109°BTDC

- Lift 9,67 mm......................................................................... 9.97 mm

Maximum governed speeds:

- Full load (speed cut-off starts) 4000 rev/min..............................

- No load (flight speed) 4600 + 40 - 120 rev/min............................................

- Idle speed 720 ± 20 rev/min.............................................................

- Die-down time 4 seconds.......................................................

INJECTION PUMP

Make/type:

- Standard Bosch rotary R509 type with boost control and two...............................................................

- with Electronic EGR Bosch rotary R509/1 type with boost control and two..............................................

Direction of rotation Clockwise, viewed from drive end..........................................................

Advance box (two stage) 7°advance with 3°start retard..................................................

Back leakage rate 150-100 Atmospheres:

- New nozzle 7 seconds...........................................................

- Original nozzle 5 seconds......................................................

speed mechanical governor with auto advance and solenoid electrical shut-off. Tamper proof sealing on flight speed and fuel adjustment screws. Constant volume delivery valves.

speed mechanical governor with auto advance and solenoid electrical shut-off. Tamper proof sealing on flight speed and fuel adjustment screws. Constant volume delivery valves. GST start up excess fuel control. Throttle position sensor for EGR.

INFORMATION

Page 42

INJECTORS

Make/type

- Standard and Electronic EGR Bosch KBAL 90 P37...............................

Nozzle type DSLA 145P366......................................................................

Opening pressure (working pressure) Initial pressure 200 atmospheres..............................

Secondary 280 atmospheres

- EDC feedback injector 1 in each engine Bosch KBAL 90 P38...............

Nozzle type DSLA 145P365......................................................................

Opening pressure (working pressure) Initial pressure 200 atmospheres..............................

Secondary 300 atmospheres

- EDC standard injector 3 in each engine Bosch KBAL 90 P36...............

Nozzle type DSLA 145P365......................................................................

Opening pressure (working pressure) Initial pressure 200 atmospheres..............................

Secondary 300 atmospheres

GLOW PLUGS

Make/type Probe type, No.0100226129A Beru 12 volts........................................................................

Time to reach operating temperature of 850°C 8 seconds................

ENGINE TUNING DATA

TURBOCHARGER

Make/type Allied signal........................................................................

Maximum boost pressure 0.8-1.0 bar (12-15lbf/in2) measured at wastegate.................................................

actuator ’T’ piece

INFORMATION

Page 43

GENERAL FITTING REMINDERS

WORKSHOP SAFETY IS YOUR RESPONSIBILITY!

The suggestions, cautions and warnings in the section are intended to serve as reminders for trained and experienced mechanics. This manual is not a course in automotive mechanics or workshop safety.

Shop equipment, shop environment, and the use and disposal of solvents, fluids, and chemicals are subject to government regulations which are intended to provide a level of safety. It is your responsibility to know and comply with such regulations.

PRECAUTIONS AGAINST DAMAGE

1. Always fit covers to protect wings before

commencing work in engine compartment.

2. Cover seats and carpets, wear clean overalls and wash hands or wear gloves before working inside vehicle.

3. Avoid spilling hydraulic fluid or battery acid on paint work. Wash off with water immediately if this occurs. Use Polythene sheets to protect carpets and seats.

4. Always use a recommended Service Tool, or a satisfactory equivalent, where specified.

5. Protect temporarily exposed screw threads by replacing nuts or fitting plastic caps.

SAFETY PRECAUTIONS

1. Whenever possible use a ramp or pit when

working beneath vehicle, in preference to jacking. Chock wheels as well as applying parking brake.

WARNING: Do not use a pit when removing fuel system components.

2. Never rely on a jack alone to support vehicle.

Use axle stands carefully placed at jacking points to provide rigid support.

3. Ensure that a suitable form of fire extinguisher is conveniently located.

4. Check that any lifting equipment used has adequate capacity and is fully serviceable.

5. Disconnect negative (grounded)terminal of vehicle battery.

WARNING: Do not disconnect any pipes in air conditioning refrigeration system,

unless trained and instructed to do so. A refrigerant is used which can cause blindness if allowed to contact eyes.

6. Ensure that adequate ventilation is provided

when volatile degreasing agents are being used.

7. Do not apply heat in an attempt to free stiff nuts or fittings; as well as causing damage to protective coatings, there is a risk of damage to electronic equipment and brake linings from stray heat.

INFORMATION

Page 44

GENERAL FITTING REMINDERS

PREPARATION

1. Before removing a component, clean it and its

surrounding areas as thoroughly as possible.

2. Blank off any openings exposed by component removal, using greaseproof paper and masking tape.

3. Immediately seal fuel, oil or hydraulic lines when separated, using plastic caps or plugs, to prevent loss of fluid and entry of dirt.

4. Close open ends of oilways, exposed by component removal, with tapered hardwood plugs or readily visible plastic plugs.

5. Immediately a component is removed, place it in a suitable container; use a separate container for each component and its associated parts.

6. Before dismantling a component, clean it thoroughly with a recommended cleaning agent; check that agent is suitable for all materials of component.

7. Clean bench and provide marking materials, labels, containers and locking wire before dismantling a component.

INSPECTION-GENERAL

1. Never inspect a component for wear or

dimensional check unless it is absolutely clean; a slight smear of grease can conceal an incipient failure.

2. When a component is to be checked dimensionally against figures quoted for it, use correct equipment (surface plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift checking equipment can be dangerous.

3. Reject a component if its dimensions are outside limits quoted, or if damage is apparent. A part may, however, be refitted if its critical dimension is exactly limit size, and is otherwise satisfactory.

4. Use ’Plastigauge’12 Type PG-1 for checking bearing surface clearances. Directions for its use, and a scale giving bearing clearances in 0,0025 mm steps are provided with it.

DISMANTLING

1. Observe scrupulous cleanliness when

dismantling components, particularly when brake, fuel or hydraulic system parts are being worked on. A particle of dirt or a cloth fragment could cause a dangerous malfunction if trapped in these systems.

2. Blow out all tapped holes, crevices, oilways and fluid passages with an air line. Ensure that any O-rings used for sealing are correctly replaced or renewed, if disturbed.

3. Use marking ink to identify mating parts, to ensure correct reassembly. If a centre punch or scriber is used they may initiate cracks or distortion of components.

4. Wire together mating parts where necessary to prevent accidental interchange (e.g. roller bearing components).

5. Wire labels on to all parts which are to be renewed, and to parts requiring further inspection before being passed for reassembly; place these parts in separate containers from those containing parts for rebuild.

6. Do not discard a part due for renewal until after comparing it with a new part, to ensure that its correct replacement has been obtained.

INFORMATION

Page 45

GENERAL FITTING REMINDERS

BALL AND ROLLER BEARINGS

CAUTION: Never refit a ball or roller bearing without first ensuring that it is in a fully serviceable condition.

1. Remove all traces of lubricant from bearing

under inspection by washing in a suitable degreaser; maintain absolute cleanliness throughout operations.

2. Inspect visually for markings of any form on rolling elements, raceways, outer surface of outer rings or inner surface of inner rings. Reject any bearings found to be marked, since any marking in these areas indicates onset of wear.

3. Holding inner race between finger and thumb of one hand, spin outer race and check that it revolves absolutely smoothly. Repeat, holding outer race and spinning inner race.

4. Rotate outer ring gently with a reciprocating motion, while holding inner ring; feel for any check or obstruction to rotation, and reject bearing if action is not perfectly smooth.

5. Lubricate bearing generously with lubricant appropriate to installation.

6. Inspect shaft and bearing housing for discoloration or other marking suggesting that movement has taken place between bearing and seatings. (This is particularly to be expected if related markings were found in operation 2).

7. Ensure that shaft and housing are clean and free from burrs before fitting bearing.

8. If one bearing assembly of a pair shows an imperfection it is generally advisable to replace both with new bearings; an exception could be made if the faulty bearing had covered a low mileage, and it could be established that damage was confined to it only.

9. When fittingbearing to shaft, apply force only to inner ring of bearing, and only to outer ring when fitting into housing. (Refer to ST1042M).

10. In the case of grease lubricated bearings (e.g. hub bearings) fill space between bearing and outer seal with recommended grade of grease before fitting seal.

11. Always mark components of separable bearings (e.g. taper roller bearings) in dismantling, to ensure correct reassembly. Never fit new rollers in a used outer ring, always fit a complete new bearing assembly.

INFORMATION

Page 46

OIL SEALS

replacement seal.

1. Always fit new oil seals when rebuilding an

assembly.

2. Carefully examine seal before fitting to ensure that it is clean and undamaged.

3. Coat the sealing lips with clean grease; pack dust excluder seals with grease, and heavily grease duplex seals in cavity between sealing lips.

4. Ensure that seal spring, if provided, is correctly fitted.

5. Place lip of seal towards fluid to be sealed and slide into position on shaft, using fitting sleeve when possible to protect sealing lip from damage by sharp corners, threads or splines. If fitting sleeve is not available, use plastic tube or tape to prevent damage to sealing lip.

GENERAL FITTING REMINDERS

NOTE: Ensure that the seal running track is free from pits, scores, corrosion and general damage prior to fitting

7. If correct service tool is not available, use a

suitable drift approximately 0.4mm (0.015 in) smaller than outside diameter of seal. Use a hammer VERY GENTLY on drift if a press is not suitable.

8. Press or drift seal in to depth of housing if housing is shouldered, or flush with face of housing where no shoulder is provided. Ensure that the seal does not enter the housing in a tilted position.

6. Grease outside diameter of seal, place square to housing recess and press into position, using great care and if possible a ’bell piece’ to ensure that seal is not tilted. (In some cases it may be preferable to fit seal to housing before fitting to shaft). Never let weight of unsupported shaft rest in seal.

NOTE: Most cases of failure or leakage of oil seals are due to careless fitting, and

resulting damage to both seals and sealing surfaces. Care in fitting is essential if good results are to be obtained. NEVER use a seal which has been improperly stored or handled, such as hung on a hook or nail.

INFORMATION

Page 47

GENERAL FITTING REMINDERS

JOINTS AND JOINT FACES

1. Always use correct gaskets where they are

specified.

2. Use jointing compound only when recommended. Otherwise fit joints dry.

3. When jointing compound is used, apply in a thin uniform film to metal surfaces; take great care to prevent it from entering oilways, pipes or blind tapped holes.

4. Remove all traces of old jointing materials prior to reassembly. Do not use a tool which could damage joint faces.

5. Inspect joint faces for scratches or burrs and remove with a fine file or oil stone; do not allow removed material or dirt to enter tapped holes or enclosed parts.

6. Blow out any pipes, channels or crevices with compressed air, fit new ’O’ rings or seals displaced by air blast.

FLEXIBLE HYDRAULIC PIPES, HOSES

1. Before removing any brake or power steering

hose, clean end fittings and area surrounding them as thoroughly as possible.

2. Obtain appropriate plugs or caps before detaching hose end fittings, so that ports can be immediately covered to exclude dirt.

3. Clean hose externally and blow through with airline. Examine carefully for cracks, separation of plies, security of end fittings and external damage. Reject any hose found faulty.

4. When refittinghose, ensure that no unnecessary bends are introduced, and that hose is not twisted before or during tightening of union nuts.

5. Containers for hydraulic fluid must be kept absolutely clean.

6. Do not store brake fluid in an unsealed container. It will absorb water, and fluid in this condition would be dangerous to use due to a lowering of its boiling point.

7. Do not allow brake fluid to be contaminated with mineral oil, or use a container which has previously contained mineral oil.

8. Do not re-use brake fluid bled from system.

9. Always use clean brake fluid to clean hydraulic

components.

10. Fit a cap to seal a hydraulic union and a plug to its socket after removal to prevent ingress of dirt.

11. Absolute cleanliness must be observed with hydraulic components at all times.

12. After any work on hydraulic systems, inspect carefully for leaks underneath the vehicle while a second operator applies maximum pressure to the brakes (engine running) and operates the steering.

INFORMATION

Page 48

GENERAL FITTING REMINDERS

FUEL SYSTEM HOSES

CAUTION: All fuel hoses are made up of two laminations, an armoured rubber outer

sleeve and an inner viton core. If any of the fuel system hoses have been disconnected, it is imperative that the internal bore is inspected to ensure that the viton lining has not become separated from the amoured outer sleeve. A new hose must be fitted if separation is evident.

METRIC NUT IDENTIFICATION

1. A nut with an ISO metric thread is marked on

one face or on one of the flats of the hexagon with the strength grade symbol 8, 12 or 14. Some nuts with a strength 4, 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking.

2. A clock face system is used as an alternative method of indicating the strength grade. The external chamfers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade.

3. A dot is used to locate the 12 o’clock position and a dash to indicate the strength grade. If the grade is above 12, two dots identify the 12 o’clock position.

METRIC BOLT IDENTIFICATION

1. 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 head.

2. In addition to marks to identify the manufacture, the head is also marked with symbols to indicate the strength grade, e.g. 8.8, 12.9 or 14.9, where the first figure gives the minimum tensile strength of the bolt material in tens of kgf/mm2.

3. Zinc plated ISO metric bolts and nuts are chromate passivated, a gold-bronze colour.

KEYS AND KEYWAYS

1. Remove burrs from edges of keyways with a fine

file and clean thoroughly before attempting to refit key.

2. Clean and inspect key closely; keys are suitable for refitting only if indistinguishable from new, as any indentation may indicate the onset of wear.

TAB WASHERS

1. Fit new washers in all places where they are

used. Always fit a new tab washer.

2. Ensure that the new tab washer is of the same design as that replaced.

INFORMATION

Page 49

GENERAL FITTING REMINDERS

SPLIT PINS

1. Fit new split pins throughout when replacing any

unit.

2. Always fit split pins where cotter pins were originally used. Do not substitute spring washers: there is always a good reason for the use of a split pin.

3. All split pins should be fitted as shown unless otherwise stated.

SCREW THREADS

1. Both UNF and Metric threads to ISO standards

are used. See below for thread identification.

2. Damaged threads must always be discarded. Cleaning up threads with a die or tap impairs the strength and closeness of fit of the threads and is not recommended.

3. Always ensure that replacement bolts are at least equal in strength to those replaced.

4. Do not allow oil, grease or jointing compound to enter blind threaded holes. The hydraulic action on screwing in the bolt or stud could split the housing.

5. Always tighten a nut or bolt to the recommended torque value. Damaged or corroded threads can affect the torque reading.

6. To check or re-tighten a bolt or screw to a specified torque value first loosen a quarter of a turn, then re-tighten to the correct value.

7. Oil thread lightly before tightening to ensure a free running thread, except in the case of threads treated with sealant/lubricant, and self-locking nuts.

NUTS

1. When tighteninga slotted or castellated nut

never loosen it back to insert split pin or locking wire except in those recommended cases where this forms part of an adjustment. If difficulty is experienced, alternative washers or nuts should be selected, or washer thickness reduced.

2. Where self-locking nuts have been removed it is advisable to replace them with new ones of the same type.

NOTE: Where bearing pre-load is involved nuts should be tightened in accordance with special instructions.

LOCKING WIRE

1. Fit new locking wire of the correct type for all

assemblies incorporating it.

2. Arrange wire so that its tension tends to tighten the bolt heads, or nuts, to which it is fitted.

UNIFIED THREAD IDENTIFICATION

1. Bolts

A circular recess is stamped in the upper surface of the bolt head.

2. Nuts

A continuous line of circles is indented on one of the flats of the hexagon, parallel to the axis of the nut.

3. Studs, Brake Rods, etc.

The component is reduced to the core diameter for a short length at its extremity.

INFORMATION

Page 50

LUBRICANTS, FLUIDS AND CAPACITIES

RECOMMENDED LUBRICANTS AND FLUIDS USA VEHICLES

AMBIENT TEMPERATURE ˚C

COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50

Engine V8i Use oils to API 5W/20 )

service level SG or SH 5W/30 ) or 5W/40 ) RES.22.OL.G4 or CCMC-G4 10W/30

10W/40 ) 10W/50 )

15W/40 ) 15W/50 )

20W/40 ) 20W/50 )

Automatic gearbox ATF Dexron IID Final drive units API or GL5 90 EP

Swivel pin housings MIL - L - 2105 or

MIL - L - 2105B, C

or D 80W EP Power steering ATF Dexron IID Borg Warner ATF Dexron IID

transfer gearbox

Brake reservoir Brake fluid must have a minimum

boiling point of 260˚C (500˚F) and

comply with FMVSS/116/DOT 4 Lubrication nipples

(hubs, ball joints, etc.)

NLGI-2 multipurpose lithium based

grease

See table on page 3 for remaining vehicle components

INFORMATION

Page 51

RECOMMENDED LUBRICANTS AND FLUIDS

All climates and conditions

COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50

Engine V8i Oils must meet: 5W/30

LUBRICANTS, FLUIDS AND CAPACITIES

AMBIENT TEMPERATURE ˚C

RES.22.OL.G-4 5W/40

or 5W/50

CCMC G-4 or 10W/30

API SG or SH 10W/40

10W/50 15W/40

15W/50 20W/40

20W/50 25W/40

25W/50

Engine TDi RES.22.OL.PD-2 15W/40

or CCMC PD-2

or API CD Main Gearbox

Automatic Main Gearbox

manual

Final drive units API or GL5 90 EP Swivel pin housings MIL - L - 2105 or

Power steering ATF Dexron IID Borg Warner ATF Dexron IID

Transfer box

ATF Dexron IID

MIL - L - 2105B 80 EP

CorD

INFORMATION

Page 52

LUBRICANTS, FLUIDS AND CAPACITIES

Propeller shaft Front and Rear Lubrication nipples (hubs, ball joints etc.) Seat slides Door lock striker

Brake and clutch reservoirs

Engine cooling Use an ethylene glycol based anti-freeze (containing no methanol) system with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure

Battery lugs, Petroleum jelly. Earthing surfaces NOTE: Do not use Silicone Grease where paint has been removed

Air Conditioning Refrigerant R134a System Refrigerant CAUTION: DO NOT use any other type of refrigerant.

Compressor Oil Nippon denso ND-OIL8

NLGI - 2 Multi-purpose Lithium based GREASE

Brake fluids having a minimum boiling point of 260°C (500 °F) and complying with FMVSS 116 DOT4

the protection of the cooling system against frost and corrosion in all seasons.

UNIPART R134a ND-OIL8

ABS Sensor Silicone grease: Staborags NBU - Wabco 830 502,0634 bush-rear Wacker chemie 704 - Wabco 830 502,0164

Kluber GL301

LUBRICATION PRACTICE

Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and ultimately to damaged components.

Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always adhere to the recommended servicing intervals.

WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must not be consumed and must be kept away from open wounds. These substances, among others, include anti-freeze windscreen washer additives, lubricants and various adhesives.

INFORMATION

Page 53

CAPACITIES

The following capacity figures are approximate and provided as a guide only. Refer to Section 10 for correct checking procedure for oil levels.

Capacities (approx.)* Litres Imp Unit US unit

Engine sump and filter from dry

- petrol 6.6..................................................................... 11.60 pints 14.0 pints

- diesel - Tdi 7.0............................................................ 12.30 pints 14.8 pints

Manual gearbox - R380 2.7.................................................... 4.70 pints 5.7 pints

Automatic gearbox 9.1........................................................... 16.00 pints 20 pints

Transfer gearbox from dry 1.7................................................ 3.00 pints 3.6 pints

Front axle from dry 1.7........................................................... 3.00 pints 3.6 pints

Front axle swivel pin housing (each) 0.35................................ 0.60 pints 0.7 pints

Rear axle from dry 1.7............................................................ 3.00 pints 3.6 pints

Power steering box and reservoir 2.9.................................... 5.00 pints 6.0 pints

Cooling system 11.4................................................................ 20.00 pints 24 pints

Fuel tank 89.......................................................................... 19.5 gallons 23 gallons

LUBRICANTS, FLUIDS AND CAPACITIES

NOTE: * All levels must be checked by dipstick or level plugs as applicable.

When draining oil from the ZF automatic gearbox, oil will remain in the torque converter, refill to

high level on dipstick only.

ANTI-FREEZE

ENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTION

CONCENTRATION LOWER

TEMPERATURE

LIMIT

V8 Engine One part anti-freeze

Diesel Engine One part water 50%

Complete protection -33°F Vehicle may be driven away immediately from cold - 36°C

Safe limit protection -41°C Coolant in mushy state. Engine may be started and driven away after warm-up period

-42°F

Lower protection -47°C Prevents frost damage to cylinder head, block and radiator. Thaw out before starting engine

CAUTION: Anti-freeze content must never be allowed to fall below 25% otherwise damage to the engine is liable to occur. Also, anti-freeze content should not exceed 60% as this will greatly reduce the cooling effect of the coolant.

INFORMATION

-53°F

Page 54

LUBRICANTS, FLUIDS AND CAPACITIES

FUEL REQUIREMENTS

Catalyst vehicles

Vehicles equipped with catalytic converter are designed to use ONLY unleaded fuel. Unleaded fuel must be used for the emission control system to operate properly. Its use will also reduce spark plug fouling, exhaust system corrosion and engine oil deterioration.

Using fuel that contains lead will result in damage to the emission control system and could result in loss of warranty coverage. The effectiveness of the catalysts in the catalytic converters will be seriously impaired if leaded fuel is used. The vehicle is equipped with an electronic fuel injection system, which includes two oxygen sensors. Leaded fuel will damage the sensors, and will deteriorate the emission control system.

Regulations require that pumps delivering unleaded fuel be labelled UNLEADED. Only these pumps have nozzles which fit the filler neck of the vehicle fuel tank.

RECOMMENDED FUEL

Petrol engines

- with catalytic converter unleaded only, 95 RON (USA 90 CLC or AKI)..........................................

- non catalytic, 9.35:1 compression ratio leaded 97 RON/unleaded 95 RON.................

- non catalytic, 8.13:1 compression ratio leaded 90 RON/unleaded 95 RON.................

- Australia minimum 91 RON unleaded................................................................

Diesel engines

- 300Tdi Diesel fuel oil, distillate, diesel fuel, automotive gas or...................................................................

Derv to British standard 2869, (1983) class A1 or A2.

Using fuel with an octane rating lower than stated above could seriously impair vehicle performance.

CAUTION: Do not use oxygenated fuels such as blends of methanol/gasoline or ethanol/gasoline (e.g. ’Gasohol’). Take care not to spill fuel during refuelling.

INFORMATION

Page 55

MAINTENANCE

SERVICE SCHEDULE

This section gives information on the range of service procedures.

Where required, instructions are given for carrying out each service procedure, or a cross reference is given, where the procedure can be found in this manual.

Service Schedule sheets are published separately to reflect the maintenance needs and intervals for each vehicle variant and model year. Procedures given in this manual must be used in conjunction with the service schedule sheets.

The Service Schedule sheets are available in pads from: Land Rover Merchandising PO Box 534 Erdington Birmingham B24 0QS. England.

VEHICLE INTERIOR

CHECK SEATS & BELTS

Check condition and security of seats, seat belt mountings, seat belts, buckles and opertion of inertia seat belts. Lubricate seat tilt pivots.

CHECK OPERATION OF FOOT BRAKE AND CLUTCH

If pedal feels ’spongy’ bleed system.

See BRAKES, Repair, Brake System Bleed (ABS)orSee BRAKES, Repair, Brake System Bleed (non ABS)

See CLUTCH, Repair, Bleed Hydraulic System

Check all hoses and pipes for security, fractures and leaks. Fit new hoses and pipes as necessary.

CHECK OPERATION OF LAMPS

Check operation of all lamps, horns and warning indicators.

CHECK OPERATION OF WIPERS

Check operation of front/rear screen wipers and washers and condition of wiper blades.

CHECK AIR BAG MODULE COVERS

Check visually for signs of damage.

RENEW AIR BAG MODULE

Every ten years

MAINTENANCE

Page 56

CHECK SECURITY AND OPERATION OF PARK BRAKE

Parking brake adjust

1. Select a gear or ’P’ in main gearbox.

2. Chock road wheels.

3. Release parkbrake lever.

4. Remove switch panel from centre console.

MAINTENANCE

5. Underneath vehicle, rotate brake adjuster

clockwise until brake shoes are fully expanded against drum.

6. Back off adjuster until drum is free to rotate.

7. Rotate adjustment thumbwheel below parkbrake

lever until parking brake is fully operational on third notch of ratchet.

NOTE: Cable adjustment must ONLY be used for initial setting and to compensate

for cable stretch. It MUST NOT be used to take up brake shoe wear, which MUST be adjusted at brake drum.

8. Operate parking brake to settle shoes. Recheck

parkbrake is fully operational on third notch of ratchet. Readjust if necessary.

9. Refit switch panel.

MAINTENANCE

Page 57

MAINTENANCE

VEHICLE EXTERIOR

CHECK/ADJUST HEADLAMP ALIGNMENT

Check/adjust headlamp and auxiliary alignment.

CHECK HEADLAMP LEVELLING SYSTEM

Check system for correct operation.

CHECK FRONT WHEEL ALIGNMENT

Use recognised wheel alignment equipment to perform this check and adjustment.

See STEERING,

Adjustment, Front Wheel Alignment

INSPECT BRAKE PADS FOR WEAR, CALIPERS FOR LEAKS AND CONDITION

Check thickness of brake pads, fit new pads if minimum thickness is less than 3,0mm. Check brake pads for oil contamination. If new brake pads required.

See BRAKES, Repair, Front Brake Pads

See BRAKES, Repair, Rear Brake Pads

WARNING: When renewing brake pads, it is essential that only genuine components

with correct grade of lining are used. Always fit new pads as complete axle sets, NEVER individually or as a single wheel set. Serious consequences could result from out of balance braking due to mixing of linings.

Refit road wheels Fit road wheels in original hub position. Secure in

position with wheel nuts, do not fully tighten wheel nuts at this stage, lower vehicle and finally tighten wheel nuts to correct torque.

Alloy wheels:

130 Nm.

REMOVE WHEELS, CHECK TYRES

Check tyres (including spare) for compliance with manufacturers’ specification.

Check visually for cuts, lumps, bulges, uneven tread wear and tread depth. Check road wheels for damage.

Check/adjust tyre pressures.

Steel wheels:

130 Nm.

CHECK SECURITY OF SPARE WHEEL

CHECK OPERATION OF DOORS, BONNET [HOOD] AND TAILGATE LOCKS

LUBRICATE ALL HINGES, DOOR CHECK MECHANISMS, BONNET [HOOD] CATCHES AND FUEL FILLER FLAP

MAINTENANCE

Page 58

MAINTENANCE

UNDER BONNET [HOOD] MAINTENANCE

CHECK COOLING/HEATER SYSTEMS

Check cooling/heater systems for leaks and hoses for security and condition.

Cooling system hoses should be changed at first signs of deterioration.

CHECK BRAKE SERVO HOSE FOR SECURITY AND CONDITION

CHECK FUEL EVAPORATIVE LOSS CONTROL SYSTEM FOR LEAKS - V8

CLEAN DISTRIBUTOR CAP - V8

The electronic ignition employs a Lucas 35DLM8 distributor. Internal operating parts of distributor are pre-set at factory and do not normally require resetting. Adjustments should only be made if unit is known to be faulty or damaged. Distributor maintenance consists of following items.

1. Clean outer surfaces of distributor cap to remove dirt, grease etc.

2. Unclip cap, check cap for cracks.

3. Wipe inside cap with lint free cloth.

4. Check rotor arm, cap and flash shield tracking.

DO NOT DISTURB clear plastic insulating cover (flash shield) which protects magnetic pick-up module.

LUBRICATE DISTRIBUTOR ROTOR SPINDLE - V8

CHECK FUEL FILLER CAP SEAL FOR LEAKS

CHECK CONDITION OF HEATER PLUG WIRING FOR FRAYING, CHAFING AND DETERIORATION Tdi

CHECK IGNITION WIRING

Check ignition wiring and high tension leads for fraying, chafing and deterioration.

Apply a spot of clean engine oil into rotor spindle after rotor arm has been removed.

CLEAN/ADJUST SPARK PLUGS - V8

RENEW SPARK PLUGS - V8

MAINTENANCE

Page 59

Clean, adjust and renew

1. Take great care when fitting spark plugs not to

cross-thread plug, otherwise costly damage to cylinder head will result.

2. Clean or replace spark plugs as applicable.

3. It is essential that correct type of spark plugs are

fitted.

4. Incorrect grade of plugs may lead to piston overheating and engine failure.

Remove

MAINTENANCE

5. Disconnect battery negative lead. Remove H.T.

leads from spark plugs.

6. Remove plugs and washers.

Clean spark plugs

7. Fit plug into 14 mm adaptor of approved spark

plug cleaning equipment. Wobble plug in adaptor with circular motion for three or four seconds only with abrasive blast in operation. Important: Excessive abrasive blasting will lead to severe erosion of insulator nose. Continue to wobble plug in adaptor with air only, blasting plug for a minimum of 30 seconds: this will remove abrasive grit from plug cavity.

8. Wire-brush plug threads; open gap slightly, and vigorously file electrode sparking surfaces using a point file. This operation is important to ensure correct plug operation by squaring electrode sparking surfaces.

9. Set electrode gap to recommended clearance.

10. Shows dirty plug.

11. Filing plug electrodes.

12. Clean plug, set to correct gap.

13. Test plugs in accordance with plug cleaning

machine manufacturers’ recommendations.

14. Satisfactory plugs can be refitted.

15. When pushing leads onto plugs, ensure that

shrouds are firmly seated.

Fitting H.T. leads

16. Ensure replacement H.T. leads are correctly

refitted as illustrated. Failure to observe this instruction may result in cross-firing between two closely fitted leads which are consecutive in firing order.

MAINTENANCE

Page 60

CHECK/ADJUST VALVE CLEARANCES. - Tdi

MAINTENANCE

Valve adjustment.

DATA, Information, Engine - 300Tdi

RENEW FUEL FILTER ELEMENT - Tdi

Drain off water and sediment

CAUTION: It is essential that any water and sediment in fuel filter is drained off, as water in fuel can result in damage to

injection pump.

1. Hold a small receptacle beneath drain cock.

Unscrew the drain cock half a turn.

2. Drain off water and sediment.

3. Tighten the drain cock immediately fuel starts to

flow from drain cock.

NOTE: Any delay in tightening drain cock when fuel starts to flow could possibly mean bleeding fuel system.

See GENERAL SPECIFICATION

Renew fuel filter element

1. Clean area around filter, place a container

beneath.

2. Unscrew filter, a quantity of fuel will be released, and discard filter.

3. Wet seal of new filter with fuel.

4. Screw new filter into position.

5. Ensure that drain cock is secure.

CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM FOR LEAKS AND HOSES FOR SECURITY AND CONDITION - V8

RENEW AIR CLEANER ELEMENT

- V8 CATALYST - Tdi

- V8 NON CATALYST

To renew air cleaner element

See FUEL SYSTEM, Repair, Air Cleaner

MAINTENANCE

Page 61

MAINTENANCE

CLEAN ENGINE BREATHER FILTER - V8

1. Release hose clamp and pull hose off canister.

2. Unscrew canister and remove it from rocker

cover.

3. Remove large ’O’ ring from threaded end of canister.

4. Visually inspect condition of wire screen within canister, if in poor condition fit new assembly, if in acceptable condition clean screen as follows:

5. Immerse canister in small amount of solvent and allow solvent to dissolve and loosen any debris.

6. Remove canister from solvent and dry in still air.

CLEAN PLENUM CHAMBER VENTILATION PASSAGEWAY - V8

Cleaning plenum chamber ventilation passageway can be carried out without removing plenum chamber from ram housing.

CAUTION: Care must be taken to prevent debris from passageway passing beyond throttle butterfly disc.

WARNING: Safety glasses must be worn when performing this operation. Ensure that debris is not blown into atmosphere

which could be harmful to other persons closeby.

1. Disconnect battery negative lead.

2. Release hose clamp and remove hose from

plenum chamber inlet.

3. Remove crankcase ventilation hose from side of plenum chamber.

4. Insert a piece of lint free cloth down throttle butterfly bore to prevent debris passing throttle butterfly.

5. Place a cloth over tube protruding from side of plenum from which ventilation hose was removed to prevent debris from passageway being blown into atmosphere.

WARNING: Do not use compressed air line to remove remaining solvent or debris in canister, this could cause fire or personal

injury.

Refitting breather/filter

1. Fit new rubber ’O’ ring.

2. Screw canister into rocker cover, hand tight only.

3. Refit hose, tighten clamp securely.

MAINTENANCE

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MAINTENANCE

6. Use a compressed air line with a slim bent

nozzle to enable passageway to be cleaned out from within throttle butterfly bore.

7. Any remaining matter can be dislodged using soft bent wire or pipe cleaner. Finally blow out passageway again to remove remaining debris.

8. Remove small ’T’ piece between crankcase ventilation hoses and check it is free from blockages, clean as necessary.

9. Refit ’T’ piece and hoses, tighten hose clamps securely.

RENEW CHARCOAL CANISTER - V8

Charcoal canister

Remove

1. Disconnect battery negative lead.

2. Pry out purge valve.

3. Disconnect pipe.

4. Loosen bolt.

5. Remove charcoal canister.

CHECK CONDITION OF DRIVE BELT - V8 - Tdi

RENEW - V8 - Tdi

Renew V8 drive belt.

Belt - Renew

Renew Tdi drive belt.

Belt - Renew

See ENGINE, Repair, Drive

Refit

6. Reverse removal procedure.

MAINTENANCE

Page 63

MAINTENANCE

CHECK THROTTLE AND AUTOMATIC TRANSMISSION CABLE OPERATION

CHECK/TOP UP AUTOMATIC TRANSMISSION FLUID LEVEL

NOTE: Transmission fluid level is checked when fluid is cold with engine idling in neutral.

1. Ensure vehicle is on level ground.

2. Check fluid level registers between MAX and

MIN marking on dipstick.

CHECK SECURITY OF JACK, BRACE AND CHOCKS

CHECK/TOP UP COOLING SYSTEM

1. To prevent corrosion of aluminium alloy engine

parts it is imperative that cooling system is filled with a solution of water and phosphate free anti-freeze, winter or summer. Never fill or top up with plain water.

WARNING: Do not remove filler cap when engine is hot because cooling system is pressurised and personal scalding could

result.

2. When removing filler cap, turn cap slowly

anti-clockwise, pause and allow all pressure to escape.

3. Continue to turn until cap is removed.

4. When engine is cold expansion tank coolant

should be level with top of indicator post, visible inside tank through filler hole.

5. If necessary, top up cooling system with premixed coolant. Use soft water whenever possible, if local water supply is hard, rainwater should be used.

CHECK ENGINE EMISSION CONTROL SYSTEM V8

CHECK OPERATION OF ELECTRONIC CONTROL UNIT/SYSTEMS - V8

6. When replacing filler cap it is important that it is

tightened down fully. Failure to tighten filler cap properly may result in water loss, with possible damage to engine.

The cooling system should be drained and flushed at 2 year intervals or at onset of second winter. Refer to Coolant Requirements.

See COOLING SYSTEM,

Adjustment, Coolant Requirements

MAINTENANCE

Page 64

CHECK/TOP UP POWER STEERING FLUID RESERVOIR

1. Remove fluid reservoir cap. Check that fluid is

up to high mark on dipstick.

CHECK/ TOP UP CLUTCH AND BRAKE FLUID RESERVOIRS

quantity of water.

MAINTENANCE

CAUTION: Brake fluid can damage paintwork. If spillage occurs, wash affected area IMMEDIATELY with a large

CHECK/TOP UP WASHER RESERVOIR

Top up washer reservoir to within 25 mm of filler neck. Use a screen washer solvent/anti-freeze solution to assist removing mud, flies and road film and protect against freezing.

LUBRICATE ACCELERATOR CONTROL LINKAGES AND PEDAL PIVOT

CHECK/ADJUST IGNITION TIMING - V8

Check ignition timing.

If 3.9.

Information, Engine - 3.9 V8

If 4.2.

Information, Engine - 4.2 V8

See ENGINE TUNING DATA, See ENGINE TUNING DATA,

MAINTENANCE

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MAINTENANCE

CHECK/ADJUST ENGINE IDLE SPEED - Tdi

For idle speed.

See ENGINE TUNING DATA,

Information, Engine - 300Tdi

CHECK/ADJUST STEERING BOX

Check steering box for fluid leaks.

Check that there is no backlash in steering box in straight ahead position. Adjust steering box if necessary.

See STEERING, Adjustment, Power

Steering Box

CLEAN BATTERY CONNECTIONS

Remove battery terminals, clean and coat with petroleum jelly.

RENEW CAMSHAFT DRIVE BELT - Tdi

Renew camshaft drive belt.

See ENGINE, Repair,

Camshaft Drive Belt and Gears

The engine timing gears are driven by a flexible rubber belt which must be renewed at intervals determined by the severity of operating conditions. In reasonable, temperate climate operation, renew the belt every 120,000 km (72,000 miles) or every six years whichever occurs earlier.

In adverse operating conditions such as work in dusty atmospheres, high ambient temperatures and desert and tropical zones, renew the belt every 60,000 km (36,000 miles) or every three years whichever occurs earlier.

CAUTION: If the drive belt is not renewed at the correct interval, it could fail, resulting in serious damage.

A low maintenance battery is installed in vehicle. Dependent upon climate conditions electrolyte levels should be checked as follows:

Temperate climates, every three years. Hot climates, every year.

MAINTENANCE

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MAINTENANCE

EXTERNALLY CHECK INTERCOOLER FOR OBSTRUCTION - Tdi

Clear any trapped dirt or flies from veins of intercooler

CLEAN INTERCOOLER ELEMENT - Tdi

Remove

1. Remove intercooler element.

2. Flush intercoolerwith ICI ’GENKLENE’ or

’D-SOLVE’ propriety cleaner, following the manufacturer’s instructions.

3. Dry the intercooler completely ensuring that no liquid remains in the element.

Refit

4. Refit intercooler element.

CHECK TURBO CHARGER BOOST PRESSURE Tdi

For boost pressure.

Information, Turbocharger

1. Disconnect, from turbocharger, hose to actuator.

Insert into a suitable "T" piece.

2. Connect a short length of suitable hose to turbocharger and connect other end to "T" piece.

3. Connect a further length of hose to third leg of the "T" piece and other end to a pressure gauge capable of reading in excess of 61 cm Hg. The pressure gauge hose must be capable of reaching passenger compartment so that gauge may be observed.

4. To check maximum boost pressure, drive vehicle normally but in such a manner that full throttle can be maintained whilst climbing a hill with engine speed held steady between 2,500 and 3,000 rev/min.

See ENGINE TUNING DATA,

MAINTENANCE

Page 67

MAINTENANCE

UNDER VEHICLE MAINTENANCE

Vehicles operating under severe conditions of dust, sand, mud and water should have oils changed and lubrication carried out at more frequent intervals than is recommended in maintenance schedules.

RENEW ENGINE OIL AND FILTER - Tdi

CAUTION: Serious damage to the turbocharger will result is engine is run above idling speed before oil pressure is

restored.

RENEW ENGINE OIL AND FILTER - V8

CAUTION: To prevent an airlock occuring after removing filter, fill new filter with oil

and fit immediately after removing old filter. If airlock does occur fill oil pump with petroleum jelly.

RENEW AUTOMATIC GEARBOX FLUID AND OIL SCREEN

1. Place vehicle on either ramp or level ground.

Place suitable container to drain gearbox fluid. Disconnect battery negative lead.

2. Remove gearbox dipstick, located at rear of right hand rocker cover, to aid oil drainage. Release plug from bottom of sump and allow fluid to drain completely.

3. Refit plug using a new sealing washer. Tighten to

10 Nm.

CHECK/TOP UP MANUAL GEARBOX OIL - V8

1. Place vehicle on ramp or level ground.

2. Remove oil filler level plug. If necessary, inject

new oil into the gearbox until it runs out of filler hole. Fit plug. Tighten to

30 Nm.

RENEW MANUAL GEARBOX OIL

Refill ZF Automatic Gearbox and Check Fluid Level.

NOTE: The fluid level must checked when fluid is cold and engine idling in park gear.

4. Ensure vehicle is on level ground.

5. Refill or top-up with correct quantity and grade of

fluid.

See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids

MAINTENANCE

Page 68

MAINTENANCE

6. Reconnect battery negative lead. Start and run

engine, apply footbrake, select Position 1, revert to park position, release footbrake. Check fluid level, this must be between two markings on dipstick.

RENEW TRANSFER GEARBOX OIL

1. Before renewing oil ensure that vehicle is level,

either on a ramp or on ground.

2. Disconnect battery negative lead.

3. Clean immediatearea around filler/level and

drain plugs.

WARNING: When draining gearbox care should be taken to ensure that oil is not hot as personal scalding could result.

4. Place a container under gearbox to drain oil into.

5. Remove filler/level plug to vent gearbox and

assist draining.

6. Remove drain plug and allow oil to drain.

Oil screen replacement ZF automatic gearbox.

See AUTOMATIC GEARBOX, Repair, Oil screen

7. Thoroughly clean drain plug threads prior to

applying fresh ’Hylomar’ sealant. Fit plug Tighten to

8. Fill gearbox with correct quantity and grade of oil until oil seeps from filler level hole. Wipe away any surplus oil.

9. Thoroughly clean filler/levelplug threads prior to applying fresh ’Hylomar’ sealant. Fit plug Tighten to

10. Reconnect battery negative lead.

25 Nm.

MAINTENANCE

Page 69

MAINTENANCE

CHECK/TOP UP TRANSFER GEARBOX OIL

1. Before topping up oil ensure that vehicle is level,

either on a ramp or on ground.

2. Disconnect battery negative lead.

3. Clean immediatearea around filler/level plug.

4. Remove plug and fill gearbox with recommended

grade of oil, until oil starts to seep from filler/level hole.

5. Clean any previously applied sealant from filler/level plug.

6. Apply Hylomar sealant to threads of plug and refit plug. Tighten to

25 Nm.

RENEW FRONT AND REAR AXLE OIL

1. Vehicle must be level. Place container under

axle to be drained.

2. Using a 13mm square drive wrench, remove drain and filler/level plugs from axle. Allow oil to drain completely. Clean and refit drain plug.

3. Inject new oil of recommended make and grade until it reaches level hole. Clean and refit filler/level plug and wipe away surplus oil.

7. Wipe away any surplus oil.

8. Reconnect battery negative lead.

CHECK/TOP UP FRONT AND REAR AXLE OIL

1. Vehicle must be level.

2. Using a 13mm square drive wrench, remove

filler/level plug from axle.

3. If necessary inject new oil of recommended make and grade until it reaches level hole. Clean and refit filler/level plug and wipe away surplus oil.

MAINTENANCE

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MAINTENANCE

RENEW SWIVEL PIN HOUSING OIL

1. Vehicle must be level. Place container under

swivel to be drained.

2. Remove drain and level plugs, allow oil to drain completely, clean and refit drain plug.

3. Remove filler plug and inject recommended make and grade of oil it reaches level hole.

4. Clean and refit level and filler plugs, wipe away any surplus oil.

LUBRICATE PROPELLER SHAFT SLIDING, AND UNIVERSAL JOINTS

1. Clean all grease nipples on front and rear

propeller shafts.

2. Using a low pressure hand grease gun, apply recommended grease, to grease nipples at front and rear propeller shaft universal and sliding joints.

NOTE: The rear propeller shaft flexible coupling is not fitted with a grease nipple.

MAINTENANCE

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MAINTENANCE

LUBRICATE PARKBRAKE MECHANICAL LINKAGE

CHECK VISUALLY BRAKE, FUEL, CLUTCH PIPES/UNIONS FOR CHAFING LEAKS AND CORROSION

CHECK EXHAUST SYSTEM FOR LEAKS, SECURITY AND DAMAGE

CHECK FOR FLUID LEAKS FROM POWER STEERING AND SUSPENSION SYSTEMS, HYDRAULIC PIPES AND UNIONS FOR CHAFING AND CORROSION

CHECK/TIGHTEN STEERING UNIT AND STEERING ROD BALL JOINT FIXINGS, CHECK CONDITION OF OF BALL JOINTS AND DUST COVERS

CHECK TIGHTNESS OF PROPELLER SHAFT COUPLING BOLTS

Tighten propellor shaft nuts to

47Nm.

ENSURE FRONT AND REAR AXLE BREATHERS ARE FREE FROM OBSTRUCTION

CHECK/TIGHTEN FRONT AND REAR AXLE SUSPENSION LINK FIXINGS, CHECK CONDITION OF MOUNTING RUBBERS

CLEAN FUEL SEDIMENTER - Tdi

Fuel sedimenter

The sedimenter is attached to left-hand side of chassis frame near fuel tank. It increases the working life of the fuel filter by removing larger droplets of water and larger particles of foreign matter from fuel.

Drain off water

Ball joints are lubricated for their normal life during manufacture and require no further lubrication. This applies ONLY if rubber boot has not been dislodged or damaged. Joints should be checked at specified mileage intervals but more frequently if vehicle is used under arduous conditions.

1. Check for wear in joints by moving ball joint up and down vigorously. If free movement is apparent fit a new joint assembly.

1. Loosen drain plug, allow water to run out. Tighten plug immediately pure diesel fuel starts to flow.

MAINTENANCE

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MAINTENANCE

Clean element

1. Disconnect fuel inlet pipe from sedimenter and

raise pipe above level of fuel tank. Support in this position to prevent fuel draining from tank.

2. Support sedimenter bowl, loosen bolt on top of unit and remove bowl.

3. Remove sedimenter element, clean all parts in kerosene.

CHECK FOR OIL LEAKS FROM ENGINE AND TRANSMISSION

DRAIN FLYWHEEL HOUSING IF DRAIN PLUG IS FITTED FOR WADING

CHECK/TIGHTEN FUEL TANK FIXINGS

4. Fit new seals, reassemble sedimenter.

5. Loosen drain plug, when pure diesel fuel runs

out, tighten plug.

6. Start engine and check sedimenter for leaks.

MAINTENANCE

Page 73

RENEW FUEL FILTER - V8

WARNING: Ensure that fuel handling precautions given in Section 01 -

Introduction regarding fuel handling are strictly adhered to when carrying out following instructions.

See INTRODUCTION, Information,

Fuel Handling Precautions

MAINTENANCE

ABS VEHICLES - CHECK ROAD WHEEL SPEED SENSOR ELECTRICAL HARNESS FOR DAMAGE

WARNING: The spilling of fuel is

unavoidable during this operation. Ensure

that all necessary precautions are taken to prevent fire and explosion.

1. Depressurise fuel system.

See FUEL SYSTEM,

Repair, Depressurising Fuel system

2. The fuel line filter is located on right hand

chassis side member forward of fuel tank filler neck. Access to filter is gained through right hand rear wheel arch.

3. Thoroughly clean area around hose connections to prevent ingress of foreign matter into fuel system.

RENEW OXYGEN SENSORS

See EMISSION CONTROL, Repair, Lambda

(Oxygen) Sensor

RENEW CATALYTIC CONVERTERS

See MANIFOLD AND EXHAUST SYSTEM, Repair,

Exhaust System Complete

4. Loosen two fuel unions and remove hoses from

filter canister.

5. Release securing bolt and bracket, remove filter from chassis side member.

6. Fit a new filter observing direction of flow arrow on canister.

7. Fit inlet and outlet hoses. Tighten to

8. Refit fuel pump relay.

9. Reconnect battery negative lead.

10. Recode radio.

11. Start engine and inspect hose connections for

fuel leaks.

30 Nm.

MAINTENANCE

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MAINTENANCE

CARRY OUT ROAD OR ROLLER TEST

WARNING: The front and rear axles cannot be driven independently due to the

viscous coupling. Before brake testing a single axle, reomve the propeller shaft to the rear axle, AND select neutral in BOTH main gearbox and transfer gearbox. Run the engine at idle speed to maintain servo vacuum.

For details of dynamometer testing

INTRODUCTION, Information, Dynamometer Testing - Non Anti-Lock Brake Vehicles See INTRODUCTION, Information, Dynamometer Testing - Vehicles with Anti-Lock Brakes (ABS)

Check following items:

1. Inhibitor switch only operates in P and N.

2. Engine for excessive noise.

3. Clutch for slip, judder or spin.

4. Automatic gear selection/shift speeds.

5. Gear selection/noise - high/low range.

6. Steering for abnormal noise/effort.

7. Steering for free play.

8. All instruments,gauges and warning indicators.

9. Heater and air conditioning systems.

10. Heated rear screen.

11. Shock absorbers - ride irregularities.

12. Foot brake, on emergency stop, pulling to one

side, binding, pedal effort.

13. Parkbrake efficiency.

14. Seat reclining and latching.

15. Fully extend seat belt, check operation of

retraction and latching. Inertia belts lock when snatched or vehicle on slope.

16. Road wheel balance.

17. Transmission for vibrations.

18. Body noises, squeaks and rattles.

19. Excessive exhaust smoke.

20. Engine idle speed.

21. Endorse service record.

22. Report any unusual features of vehicle condition

and additional work required.

See

RESET EMISSION MAINTENANCE REMINDER USA

The emission maintenance reminder is designed to activate at 52,500 and 105,000 miles respectively and will illuminate a ’Service Engine’ red warning light in instrument binnacle.

The emission maintenance reminder must be reset after required maintenance has been carried out and a new tamperproof label fitted by a Land Rover of North America dealer.

Reset

1. The control unit is located rear of RH front seat.

2. Identify control unit and remove from plug.

3. Remove tamperproof label to reveal access hole

for resetting.

4. Place a thin metallic probe into access hole and momentarily electrically short between reset pins inside unit.

MAINTENANCE

Page 75

RECOMMENDED SERVICE ITEMS

Refer to Service Schedule sheets for intervals. Clean sunroof drain tubes, clean and lubricate guide

rails and slides.

MAINTENANCE

Renew the hydraulic brake fluid.

See BRAKES,

Repair, Brake System Bleed

Renew all hydraulic brake fluid, seals, brake servo filter and flexible hoses.

All working services of the master cylinder and caliper cylinders should be examined and renewed where necessary.

ABS vehicles only - renew hydraulic brake fluid and flexible hoses examine the working surfaces of the caliper cylinders and renew the seals or cylinders where necessary.

Air cleaner - When the vehicle is used in dusty or field conditions or deep wading, frequent attention to the air cleaner may be required.

ABS vehicles used extensively in arduous off-road conditions - check the rear wheel road speed sensor for abrasive wear.

MAINTENANCE

Page 76

Tdi

DRIVE BELT INFORMATION

A single ’serpentine drive belt’ drives all the ancilliaries bar the air conditioning compressor, which has a separate drive belt. It is essential that the belts are fitted exactly as shown. It should also be noted that the water pump/viscous fan is driven in a clockwise direction.

Off road driving

Regular examination of the drive belt is essential if the vehicle is used off road. The vehicle driver should be requested to identify the type of mileage the vehicle has covered.

After every off road session the owner should inspect the belt for cuts and possible damage caused by stones. If belt has jumped, reposition belt correctly. A new belt must be fitted at the next service or before, dependant on the type of damage sustained.

Fan cowl

To ensure easy access to the drive belt the top portion of the fan cowl is detachable.

Check condition

Check condition of drive belt. Renew a belt that shows signs of wear, splitting or oil contamination.

A drive belt tensioner automatically tensions the drive belt, eliminating the need for tensioning individual drive belts. Turning the tensioner pulley in a clockwise direction will release drive belt tension.

Under normal highway use the belt must be changed at 160,000 kilometres, 96,000 miles or eight years whichever occurs first.

The drive belt must be examined at every service and replaced if necessary.

REPAIR

Page 77

ENGINE

DRIVE BELT RENEW

Service repair no - 86.10.03

NOTE: If cast lines on tensioner arm and tensioner spring case are aligned, a new drive belt must be fitted.

Remove

1. Remove fan cowl upper.

2. Apply ring spanner to tensioner pulley retaining

bolt.

3. Turn spanner to release pulley tension from belt.

4. Detach belt from pulley.

5. Release tensioner.

6. Complete removal of belt. Mark direction on belt

if refitting.

COMPRESSOR DRIVE BELT

Service repair no - 86.10.02

Remove

1. Remove auxiliary drive belt.

Renew

2. Remove compressor shield.

3. Loosen tensioner retaining bolts.

4. Remove compressor drive belt. Mark direction

on belt if refitting.

See Drive Belt

Refit

7. Reverse removal procedure.

Refit

5. Fit compressor drive belt.

6. Fit torque meter to centre of tensioner and apply

and hold a torque of retaining bolts.

7. Rotate crankshaft 2 full turns.

8. Reapply and hold a torque of

tensioner, then fully loosen and retighten 3 tensioner retaining screws to

35 Nm.

Tighten 3 tensioner

35 Nm

25 Nm.

REPAIR

Page 78

Tdi

ENGINE

Service repair no - 12.41.01

Remove

CAUTION: Seal all exposed pipe ends against ingress of dirt after disconnection.

1. Park vehicle on level ground and apply park

brake.

2. Disconnect battery negative lead.

3. Remove bonnet [hood].

See CHASSIS AND

BODY, Repair, Bonnet [Hood]

4. If air conditioning is fitted, remove RH footwell

side trim panel and disconnect harness multiplug from relay.

6. Remove engine harness grommet from bulkhead and move harness into engine bay.

7. Release battery positive lead from retaining clip at base of suspension turret.

8. Remove Radiator Assembly

See COOLING

SYSTEM, Repair, Radiator

9. Discharge air conditioning system.

See AIR CONDITIONING, Adjustment, Refrigerant Recovery Recycling Recharging

Remove retaining bolts and disconnect both pipe adaptors from rear of compressor.

10. Remove rocker cover insulation.

11. Disconnect cyclone hose from air cleaner hose.

12. Remove air cleaner hose from turbocharger.

13. Remove feed pipe/hose from turbocharger and

intercooler.

14. Disconnect heater hoses from cylinder head and heater rails.

15. Remove bolt securing transmission breather pipe clip to cylinder head; move breather pipes aside.

16. Disconnect inlet and outlet hoses from power steering pump.

17. Disconnect bypass hose from thermostat housing.

18. Release bypass hose from retaining clips on front timing cover.

19. Remove split pin securing inner throttle cable to injector pump.

20. Depress tags on outer cable adjusting nut, remove cable from mounting bracket, and move aside.

21. If automatictransmission is fitted, release kickdown cable from injector pump and mounting bracket.

5. Disconnect the two engine harness multiplugs on LH side of footwell.

REPAIR

Page 79

ENGINE

22. Disconnect feed pipe and spill return pipe from

injector pump.

23. Disconnect both pipes from fuel lift pump.

24. Disconnect servo hose from vacuum pump.

25. Remove three retaining nuts and disconnect

exhaust down pipe.

26. Remove oil cooler pipes from oil filter adaptor.

27. If automatictransmission is fitted, disconnect

feed and return pipes at gearbox oil cooler. Remove retaining bracket from LH side of cylinder block and release both oil cooler pipes.

28. Support gearbox.

29. Disconnect ground strap from starter motor.

30. On vehicles with automatic transmission, remove

fixings and detach drive plate housing access panel and gasket.

31. Working through drive plate housing aperture mark the torque convertor and drive plate to facilitate reassembly.

32. Remove the four convertor to flexible drive securing bolts, rotating crankshaft to gain access to each individual bolt.

33. Fit engine lifting bracket to the two RH rear cylinder head fixing bolts.

34. Using suitable hoist, fit lifting chains to engine.

35. Remove four bolts, from both sides, securing

front engine mounting brackets to cylinder block.

36. Remove two bolts, from both sides, securing front engine mounting bracket to bell housing.

REPAIR

Page 80

37. Remove nuts and plain washers securing front

engine mountings to chassis,and lift both engine mounting bracket assemblies from vehicle.

38. Remove engine to bell housing fixings. Leave starter motor attached.

39. Raise engine to separate from transmission.

40. Check all connections to engine have been

disconnected.

41. Remove engine.

Tdi

Refit

42. Apply Hylomar to mating faces of bell housing.

Lubricate splines of gearbox primary pinion with Rocol MV 3. If automatic transmission, coat the four drive plate to torque convertor bolts with Loctite 290. Tighten to

43. Lower engine and locate with transmission. If manual transmission locate primary pinion into clutch and engage bell housing dowels. Fit engine to bell housing fixings. Tighten to If automatic transmission fixings. Tighten to

Nm.

44. Raise engine, refit front engine mounting

brackets to cylinder block and bell housing.

45. Remove gearbox support and lower engine.

46. Tighten front engine mountings to chassis

fixings. Tighten to

47. Reverse removal procedure. 1 to 37.

39 Nm.

40 Nm.

45 Nm.

REPAIR

Page 81

CRANKSHAFT PULLEY

Service repair no - 12.21.01

ENGINE

Remove

1. Disconnect battery negative lead.

2. Drain coolant.

3. Remove top hose from radiator.

4. Remove intercooler to induction manifold hose.

5. Remove viscous fan and coupling.

COOLING SYSTEM, Repair, Viscous Coupling, Fan Blades, Pulley and Fan Cowl

6. Remove fan cowl.

7. Remove drive belt.

8. Fit crankshaft pulley retainer LRT-12-080 and

secure with four bolts.

9. Remove crankshaft pulley retaining bolt using socket and suitable long bar.

See Drive Belt Renew

See

Refit

12. Refit in reverse order, lightly greasing pulley

spigot. Tighten to

80 Nm + 90°.

10. Remove pulley retainer.

11. Remove pulley, if necessary using extractor

LRT-12-049 with thrust pad from LRT-12-031.

REPAIR

Page 82

FRONT COVER PLATE

Service repair no - 12.65.01

Tdi

Remove

1. Disconnect battery negative lead.

2. Drain coolant.

3. Remove top hose from radiator.

4. Remove inter-cooler to induction manifold hose.

5. Remove viscous coupling and fan.

See COOLING SYSTEM, Repair, Viscous Coupling, Fan Blades, Pulley and Fan Cowl

6. Remove fan cowl.

7. Remove drive belt.

8. Remove crankshaft pulley.

See Drive Belt Renew

See Crankshaft

Pulley

9. Remove 14 bolts securing front cover plate,

noting top two bolts also retain thermostat hose clips.

10. Remove cover plate complete with gasket.

11. Remove small gasket from centre bolt boss.

Seal replacement

12. Remove worn seal from cover and clean recess.

13. Support cover and fit new seal, open side fitted

into recess, using special tool LRT-12-077.

Refit

14. Refit in reverse order to removal using new

gaskets, fitting the securing bolts as shown in illustration ST3475. Tighten to

25 Nm.

REPAIR

Page 83

ENGINE

CAMSHAFT DRIVE BELT AND GEARS

Service repair no - 12.65.18

TIMING BELT

Remove

1. Remove front cover plate.

Plate

2. Position engine at TDC on No. 1 cylinder.

3. If manual gearbox: Remove blanking plug from

flywheel housing and insert timing tool LRT-12-044. If EDC - timing tool LRT-12-085 must be used. If automatic gearbox:Sited to the rear of the engine sump on engine backplate is a blanking plate. Remove 2 blanking plate bolts and insert timing tool LRT-12-044 into the larger bolt hole.

See Front Cover

6. Insert pin from special tool LRT-12-045 in

injection pump gear and through into pump flange.

NOTE: If the camshaft gear is to be removed during these operations its retaining bolt should be slackened before

the timing belt is removed.

4. Engage timing tool pin with slot in flywheel.

5. Check correct alignment of timing mark on

camshaft gear and that crankshaft key aligns with cast arrow on housing.

7. Slacken belt tensioner bolt.

8. Remove idler pulley.

9. Remove timing belt.

NOTE: During use, a belt develops a wear pattern relative to its running direction, if the original belt is to be re-used it must be

refitted so that it rotates in the original direction.

CAUTION: Belts must be stored on edge on a clean surface and in such a manner

that bends are not less than 50 mm radius. Do not bend belts at an acute angle or radius of less than 50 mm, otherwise premature failure could result.

10. Mark belt direction of rotation, using soft chalk,

to ensure correct refitment.

REPAIR

Page 84

Belt tensioner

NOTE: The belt tensioner need only be removed if it is being replaced or for access purposes to remove front cover.

11. Remove securing bolt and withdraw tensioner

complete with spacer.

Crankshaft gear/front cover oil seal

12. If the crankshaft gear cannot be removed by

hand, use special tool LRT-12-078 with main body and thrust button from special tool LRT-12-031 as illustrated ST3478M. Withdraw gear complete with ’O’ ring seal.

Tdi

13. If necessary prise out oil seal from front cover.

14. Lubricate a new crankshaft oil seal with clean

engine oil.

15. With lip side leading, drive-in seal squarely using special tool LRT-12-079.

16. Lubricate new ’O’ ring seal with petroleum jelly and slide onto shaft, taking care not to damage seal on the woodruff keys.

17. Fit crankshaft gear, tap fully home ensuring ’O’ ring seal is properly seated.

CAMSHAFT GEAR/FRONT COVER OIL SEAL Service repair no - 12.13.05

18. Remove centre bolt from camshaft gear and

withdraw gear.

19. Remove existing oil seal from front cover using special tool LRT-12-038.

20. Lubricate a new camshaft oil seal with clean engine oil.

REPAIR

Page 85

ENGINE

24. Remove special tool pin from gear.

25. Remove three bolts and withdraw plate and

gear.

21. With lip side leading, drive-in seal squarely using special tool LRT-12-082.

22. Refit gear.

FUEL INJECTION PUMP GEAR Service repair no - 19.30.06

Remove

23. Slacken the three bolts on front of gear.

CAUTION: It is important to ensure that when the injection pump is locked no attempt must be made to rotate it. Take

care not to allow the crankshaft to be turned.

Refit

26. Fit gear and plate and secure with three bolts.

27. Insert pin from special tool LRT-12-045 in

injection pump gear and through into pump flange.

REPAIR

Page 86

Tdi

Timing belt fitting and tensioning

NOTE: It is important that belt tensioning is carried out carefully and accurately. The

following procedure involves tensioning the belt twice to ensure that it is equally tensioned between each gear. New and original belts are tensioned to different figures.

28. Ensure timing marks are correctly aligned, pin

from special tool LRT-12-045 is correctly inserted in injection pump gear and timing tool LRT-12-044 (LRT-12-085 if EDC) is fitted to flywheel housing with pin located in flywheel slot. Or if automatic: Timing tool LRT-12-044 is fitted to engine backplate and pin located in ring gear.

29. Fit belt observing rotational marks made during removal. Feed belt over gears keeping it tight on drive side.

30. Fit idler pulley.

31. Slacken injection pump gear retaining bolts.

32. Adjust belt to correctly sit in gears.

33. Slacken belt tensioner securing bolt to finger

tight.

34. Insert 13 mm square drive extension bar in tensioner plate.

NOTE: Belt tensioning should be carried out using a dial type torque meter having a

range not exceeding meter should be used in the almost vertical position.

35. Apply a tension of

11 to 13 Nm

is correct tighten clamp bolt.

36. Tighten injection pump gear bolts.

37. Remove pin from injection pump gear.

38. Disengage timing pin from timing slot in flywheel

or ring gear.

39. Rotate crankshaft one and three quarter turns in a clockwise direction; then continue rotation until timing pin in timing tool can be engaged with slot in flywheel or ring gear.

40. Disengage timing pin.

41. Insert pin from special tool LRT-12-045 in

injection pump gear and through into pump flange.

42. Slacken injection pump gear retaining bolts.

43. Slacken tensioner and retension belt.

44. Tighten injection pump gear retaining bolts.

45. Remove pin from injection pump gear.

46. Remove timing tool and refit plug.

47. Fit front cover plate using new gaskets.

for an original belt. When tension

60 Nm.

14 to 16 Nm

The torque

for a new belt or

See

Front Cover Plate

REPAIR

Page 87

ENGINE

FRONT COVER/TIMING GEAR HOUSING GASKET

Service repair no - 12.65.10

Remove

1. Remove timing belt and gears.

Drive Belt and Gears

2. Remove fuel injection pump.

SYSTEM, Repair, Fuel Injection Pump and Timing

3. Remove engine oil sump.

4. Remove oil pick up strainer.

Strainer

5. Remove bolts securing timing gear housing to

block.

6. Withdraw timing gear housing complete with gasket.

7. Clean all gasket material from mating faces.

See Camshaft

See FUEL

See Oil Sump

See Oil Pick-Up

10. Align flats on oil pump with flats on crankshaft.

11. Fit front cover to block taking care not to damage

oil seal.

12. Secure with bolts of correct length in locations where slave studs are not fitted (ST3482).

13. Remove slave studs and fit correct length bolts.

14. Tighten to

25 Nm.

Refit

8. Fit slave guide studs to locate gasket.

9. Fit new gasket, over slave studs, to cylinder

block.

15. Fit oil pick-up strainer.

Strainer

16. Fit oil sump.

17. Refit fuel injection pump.

Repair, Fuel Injection Pump and Timing

See Oil Sump

See Oil Pick-Up

See FUEL SYSTEM,

REPAIR

Page 88

Tdi

OIL SUMP

Service repair no - 12.60.44

Remove

1. Disconnect battery negative lead.

2. Drain engine oil.

3. Slacken sump securing bolts and, using a sharp

knife, break sealant around sump flange.

4. Remove bolts and withdraw sump.

OIL PICK-UP STRAINER

Service repair no - 12.60.20

Remove

1. Disconnect battery negative lead.

2. Drain engine oil.

3. Remove engine oil sump.

4. Remove bolts securing pipe support bracket.

5. Remove bolts from pipe flanges.

6. Withdraw pick-up strainer assembly.

See Oil Sump

Refit

5. Clean mating faces of sump, timing gear housing

and cylinder block.

6. Apply a 2,0 mm bead of ’Hylosil RTV102’ to the sump flange, ensuring bead is applied inboard of the bolt holes.

7. Secure sump to block with bolts. Tighten to

Nm.

8. Refill engine oil.

See LUBRICANTS, FLUIDS AND CAPACITIES, Information, Recommended Lubricants and Fluids

9. Reconnect battery negative lead.

Refit

7. Refit pick-up strainer assembly, fitting a new ’O’

ring seal at oil pump connection.

8. Apply Loctite 242E to the two screws at the bearing cap. Tighten to

9. Fit bolts to pipe flanges. Tighten to

10. Refit engine oil sump.

11. Reconnect battery negative lead.

9 Nm.

25 Nm.

See Oil Sump

REPAIR

Page 89

FLYWHEEL

Service repair no - 12.53.07

ENGINE

Remove

1. Disconnect battery negative lead.

2. Remove gearbox.

Repair, R380 Manual Gearbox

3. Remove clutch.

Assembly

4. Fit two long 8mm bolts into the clutch bolt holes,

diametrically opposite, to use as handles when lifting the flywheel off the crankshaft.

5. Remove fan cowl

6. Fit crankshaft pulley retainer LRT-12-080 and

secure with four bolts, to restrain crankshaft while removing flywheel retaining bolts.

7. Remove the bolts and lift off flywheel.

See MANUAL GEARBOX,

See CLUTCH, Repair, Clutch

Refit

8. Locate the flywheel on the crankshaft and

secure with new patched retaining bolts, progressively tighten to

147 Nm.

NOTE: To prevent excessive flywheel run-out, ensure that the mating faces of the flywheel and crankshaft are clean.

9. Check the flywheel for possible run-out by

mounting a dial test indicator with the stylus in a loaded condition resting on the flywheel face at a radius of 114mm from the centre.

10. Turn the flywheel and check that run-out does not exceed 0,05 to 0,07mm. Should run-out be excessive, remove the flywheel and check again for irregularities on the crankshaft and flywheel mating faces and the dowel.

11. Reverse removal procedure. 1 to 6.

REPAIR

Page 90

Tdi

CRANKSHAFT REAR OIL SEAL

Service repair no - 12.21.20

Remove

NOTE: The crankshaft rear oil seal is retained in its own housing, if the seal

requires replacing the housing and seal assembly (1) must be renewed complete with the housing seal (3). Housing and seal assemblies are supplied with their own former/seal guide (2) already fitted. This former must not be removed before fitting the assembly to the engine. If a seal and housing assembly is received without a former/guide fitted it must be returned to the supplier. Used formers/guides must be discarded immediately after use, under no circumstances should they be reused on other assemblies.

3. Remove clutch.

See CLUTCH, Repair, Clutch

Assembly

4. Remove flywheel.

5. Remove five bolts and withdraw seal housing

and seal assembly complete with gasket.

See Flywheel

1. Disconnect battery negative lead.

2. Remove gearbox.

See MANUAL GEARBOX,

Repair, R380 Manual Gearbox

Refit

6. Insert slave studs to seal housing mounting face.

7. Position new seal housing gasket over slave

studs and crankshaft flange onto cylinder block.

REPAIR

Page 91

ENGINE

8. Ensure housing seal is correctly seated in its

groove in new housing and seal assembly.

9. Fit new assembly, with former/guide in-situ, over crankshaft flange, this action will eject former/guide.

10. Secure assembly to cylinder block with five bolts tightened to correct torque, removing slave studs individually and inserting bolts.

11. Refit flywheel.

12. Refit clutch.

Assembly

13. Refit gearbox.

Repair, R380 Manual Gearbox

14. Reconnect battery negative lead.

See Flywheel

See CLUTCH, Repair, Clutch

See MANUAL GEARBOX,

CRANKSHAFT BEARING BUSH

Service repair no - 12.21.45

1. Disconnect battery negative lead.

2. Remove gearbox.

Repair, R380 Manual Gearbox

3. Remove clutch.

Assembly

See MANUAL GEARBOX,

See CLUTCH, Repair, Clutch

4. Remove flywheel.

5. Remove bearing bush.

NOTE: The bearing bush can be removed by using one of the following methods.

Method 1.

Obtain a short length of steel rod of a diameter having a good slide fit in the bore of the bush. Pack the bore with grease and insert the steel rod into the end of the bore, give a sharp blow with a hammer and the grease should drive out the bush. It is recommended that the bush and rod be covered by a suitable cloth or rag to prevent grease from splashing.

See Flywheel

REPAIR

Page 92

Tdi

Method 2.

Thread the bore of the existing bush and using a suitable bolt extract the bush. Thoroughly clean bush location ensuring all swarf is removed.

Fitting

6. Fit new bush using a suitable shouldered drift,

inserting bush flush with end of crankshaft.

7. Refit flywheel.

8. Refit clutch.

See Flywheel

See CLUTCH, Repair, Clutch

Assembly

9. Refit gearbox.

See MANUAL GEARBOX,

Repair, R380 Manual Gearbox

10. Reconnect battery negative lead.

FLYWHEEL HOUSING

Service repair no - 12.53.01

Remove

1. Disconnect battery negative lead.

2. Remove gearbox.

See MANUAL GEARBOX,

Repair, R380 Manual Gearbox

3. Remove clutch.

See CLUTCH, Repair, Clutch

Assembly

4. Remove flywheel.

5. Remove starter motor.

6. Remove two bolts from top of flywheel housing.

7. Remove four bolts from bottom of flywheel

housing.

8. Remove six inner bolts and lift off flywheel housing.

See Flywheel

Refit

9. Clean rear face of housing and mating face on

block, ensuring all old sealant is removed.

REPAIR

Page 93

ENGINE

10. Apply sealant to flywheel housing mating face on

cylinder block (Fig. J5944).

OIL FILTER

Service repair no - 12.60.01

Remove

1. Place drain tray under filter.

2. Unscrew filter anti-clockwise, using a strap or

spanner.

11. Fit housing to cylinder block and secure with bolts as removed. Tighten to

12. Remove surplus sealant from block.

13. Refit starter motor.

14. Refit flywheel.

15. Refit clutch.

Assembly

16. Refit gearbox.

Repair, R380 Manual Gearbox

17. Reconnect battery negative lead.

See Flywheel

See CLUTCH, Repair, Clutch

See MANUAL GEARBOX,

45 Nm.

Refit

3. Smear clean engine oil on seal of new filter.

4. Screw on filter until sealing ring touches

machined face, then tighten a further half turn by hand only. Do not over tighten.

REPAIR

Page 94

Tdi

OIL TEMPERATURE CONTROL VALVE

Service repair no - 12.60.69

Remove

1. Disconnect oil cooler pipes.

2. Remove two bolts and carefully withdraw

thermostat extension housing (1) complete with O ring seal (2), thermostat (3), two washers (4) and spring (5).

OIL FILTER HEAD GASKET

Service repair no - 12.60.03

Renew

1. Disconnect oil cooler pipes.

2. Disconnect pressure switch lead.

3. Remove securing bolts and withdraw head

complete with gasket.

4. Clean mating faces.

3. Clean adaptor housing.

4. Inspect all parts and renew as necessary.

Refit

5. Fit thermostatto extension housing ensuring pin

locates in hole.

6. Fit two washers and spring to thermostat.

7. Fit a new ’O’ ring to extension housing.

8. Insert spring into adaptor and secure extension

housing to adaptor with bolts. Tighten to

9 Nm.

5. Refit head with new gasket.

6. Secure with bolts Tighten to

7. Refit pipes and reconnect pressure switch.

45 Nm.

REPAIR

Page 95

ENGINE

CYLINDER HEAD GASKET

Service repair no - 12.29.02

Remove

1. Disconnect battery negative lead.

2. Remove bonnet [Hood].

BODY, Repair, Bonnet [Hood]

3. Drain coolant.

4. Remove air cleaner assembly.

SYSTEM, Repair, Air Cleaner

5. Detach crankcase ventilation valve and side

breather hose from rocker cover and move to one side.

6. Remove injection pipes.

7. Disconnect spill rail from fuel injectors.

8. Remove fuel injectors and sealing washers.

Identify each injector to the location from which it is removed.

Injectors

9. Remove inter-connecting harness from glow

plugs.

10. Remove glow plugs.

Repair, Glow Plugs

See FUEL SYSTEM, Repair,

See CHASSIS AND

See FUEL

See FUEL SYSTEM,

11. Remove top hose, radiator to thermostat.

12. Disconnect by-pass hose from thermostat.

13. Disconnect hose, thermostatto water pump.

14. Disconnect water temperature sensor lead.

15. Remove hose inter-cooler to induction manifold.

16. Remove induction manifold.

AND EXHAUST SYSTEM, Repair, Exhaust Manifold - Tdi

17. Remove exhaust manifold and turbocharger

assembly.

SYSTEM, Repair, Exhaust Manifold - Tdi

18. Disconnect heater hose from water pump and

move heater rail aside.

19. Disconnect heater hose from rear of cylinder head.

20. Remove bolt securing air cleaner mounting bracket to support strut.

21. Remove bolt securing harness bracket to cylinder head.

22. Remove rear lifting bracket, this will also release clips securing transmission and engine breather pipes and multiplug. Note loose spacer under clip securing engine breather pipe and multiplug.

See MANIFOLD AND EXHAUST

See MANIFOLD

REPAIR

Page 96

Tdi

23. Remove rocker cover.

24. Remove nuts and bolts and withdraw rocker

shaft assembly.

26. Remove valve stem caps.

27. Evenly slacken, then remove, bolts retaining

cylinder head to block. Two of the bolts also secure the air cleaner mounting bracket.

28. Lift off cylinder head and remove gasket.

Refit

29. Ensure face of cylinder block is thoroughly clean.

30. Select new gasket of correct thickness.

CAUTION: Three thicknesses of gasket are available, different thicknesses are

identified by the number of small holes punched in the right hand side of the gasket. One hole identifies the thinnest gasket and three holes the thickest. When renewing gaskets the gasket being fitted must be of the same thickness as the one removed. Therefore if the removed gasket had two holes punched in the side the replacement gasket must also have two holes punched in the side.

31. Place gasket on cylinder block with identification

holes positioned towards rear on right hand side and side marked TOP uppermost.

25. Remove push rods, store as an identified set to allow refitment to same location.

32. Clean mating face of cylinder head.

33. Lower cylinder head onto block ensuring correct

location with dowels.

REPAIR

Page 97

ENGINE

NOTE: Cylinder head retaining bolts can be used up to a maximum of five times.

34. Lubricate threads of bolts with light oil and fit to

positions illustrated.

Bolt sizes:

M10 x 117mm locations 3, 5, 12, and 13. M12 x 140mm locations 1, 2, 7, 8, 9, 10, 15, 16, 17,

and 18. M12 x 100mm locations 4, 6, 11, 14.

39. Tighten all bolts through 60°strictly in sequence illustrated.

40. Repeat 60°tightening procedure, again strictly in sequence illustrated.

41. Tighten the ten longer bolts (M12 x 140mm) a further 20°, again following the sequence illustrated.

NOTE: Repositioning of the pointer will be necessary to reach all bolts, the pointer can be fitted to the rocker shaft securing

studs using two nuts.

CAUTION: The double tightening procedure must be carried out, on no

account should the total angles of tightening be performed in one operation, otherwise damage to the cylinder head may occur.

42. Fit valve stem caps.

43. Fit push rods to locations from which they were

removed.

44. Fit rocker shaft assembly evenly tightening securing nuts and bolts to correct torque.

45. Fit rocker cover ensuring oil seal is satisfactory for continued use.

35. Tighten bolts so that underside of heads just make contact with cylinder head.

36. Following the sequence illustrated tighten all bolts to

37. Attach degree disc special tool LRT-12-007 to a power bar.

38. Make a suitable pointer from welding rod and attach to a bolt screwed into a rocker shaft securing bolt hole.

40 Nm.

NOTE: Rocker cover seals can be re-used up to a maximum of five times.

46. Secure rocker cover with special seal washers

and nuts tightened to correct torque.

47. Refit remainder of items by reversing operations 1 to 22 tightening securing bolts to correct torque where applicable.

REPAIR

Page 98

Tdi

VACUUM PUMP

Service repair no - 70.50.19

Remove

NOTE: To ease pump removal set engine to T.D.C. on No.1 cylinder.

1. Disconnect battery negative lead.

2. Detach servo hose from vacuum pump.

GENERATOR

Service repair no - 86.10.02

Remove

1. Disconnect battery negative lead.

2. Remove drive belt.

3. Disconnect electrical leads from rear of

generator.

4. Remove securing bolt from bottom of generator.

5. Remove long through bolt from top fixing and

withdraw generator.

See Drive Belt Renew

3. Remove six bolts securing vacuum pump.

4. Detach pump complete with harness bracket.

Note location of bracket for refitting.

Refit

5. Clean mating faces of pump and block.

6. Loosely assemble pump to block with a new

gasket and with harness bracket located under head of bolt noted during removal.

7. Evenly tighten bolts, to depress pump plunger, finally tightening to

8. Connect vacuum hose and secure with clip.

9. Reconnect battery negative lead.

25 Nm.

Refit

6. Reverse removal procedure.

REPAIR

Page 99

TORQUE VALUES

NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque.

Engine block

Bearing cap 133...............................................................................................

Blanking plug, oil gallery, rear 37....................................................................

Oil squirt jet assembly 17................................................................................

Drain plug, cylinder block 25...........................................................................

Oil squirt jet, vacuum pump cam 7.................................................................

Connecting rod to cap 59................................................................................

Oil pick up assembly to bearing cap 9...........................................................

Oil pick up assembly to front cover 25............................................................

Camshaft thrust plate 9..................................................................................

Oil drain pipe to block (internal) 25.................................................................

Oil drain pipe to block (external) 25................................................................

Sump to cylinder block and front cover 25......................................................

Drain plug, oil sump 35...................................................................................

Tappet guide 14..............................................................................................

Breather side cover assembly 25....................................................................

Baffle plate to breather side cover 4..............................................................

Vacuum pump 25............................................................................................

Fuel lift pump 25.............................................................................................

Flywheel housing 45.......................................................................................

Flywheel housing clutch cover stud 10...........................................................

Plug, flywheel housing 12...............................................................................

Rear oil seal assembly 25...............................................................................

Oil filter adaptor 45..........................................................................................

Waxstat adaptor to oil filter adaptor 9............................................................

Oil pressure switch 17.....................................................................................

Oil filter, spin on 13.........................................................................................

Oil cooler unions to filter adaptor 45...............................................................

Oil level tube 25..............................................................................................

Engine mounting foot to cylinder block 85......................................................

Engine mounting foot to flywheel housing 45.................................................

Engine mounting foot rubber to mounting foot (bolt and nut) 85.....................

Tdi

Flywheel to crankshaft 146..............................................................................

Clutch cover plate to flywheel 34....................................................................

Flex drive plate to crankshaft (auto) 146..........................................................

Flex drive plate to ring gear (auto) 25.............................................................

Flex drive plate to torque converter (auto) 45.................................................

SPECIFICATIONS, TORQUE

Page 100

ENGINE

Cylinder head

Cylinder head to cylinder block See repair section......................................................

Stub pipe heater feed 22.................................................................................

Water temperature sensor 14.........................................................................

Blanking plug cylinder head 14.......................................................................

Engine lifting brackets 25................................................................................

Electrical harness clip bracket 25...................................................................

Exhaust manifold stud 10................................................................................

Exhaust manifold nut 45.................................................................................

Inlet manifold stud 8.......................................................................................

Inlet manifold nut and bolt 25..........................................................................

Air temperature sensor, inlet manifold 14.......................................................

Blanking plug, inlet manifold 14......................................................................

Heatshield to inlet manifold 6.........................................................................

Glow plug 20...................................................................................................

Glow plug terminal nut 2................................................................................

Injector clamp (stud) 8...................................................................................

Injector clamp (nut) 25....................................................................................

Thermostat housing 25...................................................................................

Water outlet elbow to thermostat housing 25..................................................

Water temperature switch, thermostathousing 11..........................................

Plug thermostat housing 6.............................................................................

Rocker shaft pedestal bolt 5 + 50°.....................................................................

Rocker cover (stud) 8.....................................................................................

Rocker cover (fixing nut) 10............................................................................

Breather cyclone to rocker cover 9................................................................

Tappet adjusting nut 16..................................................................................

Front cover to cylinder block 25......................................................................

Front cover plate to front cover 25..................................................................

Static idler - timing belt (stud) 10.....................................................................

Static idler - timing belt (nut) 45......................................................................

Tensioner (timing belt) 45...............................................................................

Camshaft hub bolt 80......................................................................................

Timing pulley to camshaft hub 25...................................................................

Fuel injection pump (stud) 8...........................................................................

Fuel injection pump (nut) 25...........................................................................

Abutment bracket to injection pump 25...........................................................

Support bracket injection pump to cylinder block 25.......................................

Fuel injection pump access plte to front cover plate 25..................................

Timing pulley to injection pump hub 25...........................................................

TV Damper pulley bolt to crankshaft 80 + 90°.....................................................

Fan pulley to hub 25.......................................................................................

Fan and viscous coupling to hub 45...............................................................

Auto tensioner, auxiliary drive (stud) 14..........................................................

Auto tensioner, auxiliary drive (nut) 45...........................................................

Auxiliary mounting bracket to cylinder block (stud) 8.....................................

Auxiliary mounting bracket to cylinder block (bolt and nut) 25........................

Water pump to block and mounting plate 25..................................................

Water pump pulley to hub 25..........................................................................

SPECIFICATIONS, TORQUE

Land Rover Range Rover Classic User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

REFERENCES

REPAIRS AND REPLACEMENTS

DIMENSIONS

POISONOUS SUBSTANCES

INFORMATION

FUEL HANDLING PRECAUTIONS

SYNTHETIC RUBBER

RECOMMENDED SEALANTS

USED ENGINE OIL

WHEELS AND TYRES

STEAM CLEANING

SPECIFICATION

SPECIAL SERVICE TOOLS

COPYRIGHT

JACKING

DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES

HYDRAULIC VEHICLE RAMP (FOUR POST)

TWO POST VEHICLE RAMPS

DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS)

TOWING

TRANSPORTING THE VEHICLE BY TRAILER

JUMP STARTING

ABBREVIATIONS AND SYMBOLS USED IN THIS MANUAL

CROSS REFERENCE OF EMISSION SYSTEM TERMINOLOGY

VEHICLE IDENTIFICATION NUMBER (VIN)

LOCATION OF IDENTIFICATION NUMBERS

FAULT DIAGNOSTIC EQUIPMENT

READING THIS MANUAL

ENGINE - V8

INFORMATION

ENGINE - 300Tdi

FUEL SYSTEM - V8 Engine

FUEL SYSTEM - 300Tdi Engine

COOLING SYSTEM - V8 ENGINE

COOLING SYSTEM - 300Tdi ENGINE

TRANSMISSION

SHIFT SPEED SPECIFICATION - AUTOMATIC ZF4HP22 GEARBOX

STEERING

SUSPENSION

SHOCK ABSORBERS

ROAD SPRING DATA

BRAKES

WHEELS AND TYRES

AIR CONDITIONING

WIPER MOTORS

ELECTRICAL

REPLACEMENT BULBS

VEHICLE WEIGHTS AND PAYLOAD

VEHICLE DIMENSIONS

TYRE PRESSURES

ENGINE - 3.9 V8

INFORMATION

ENGINE - 4.2 V8

ENGINE - 300Tdi

GENERAL FITTING REMINDERS

PRECAUTIONS AGAINST DAMAGE

SAFETY PRECAUTIONS

INFORMATION

PREPARATION

INSPECTION-GENERAL

DISMANTLING

BALL AND ROLLER BEARINGS

OIL SEALS

JOINTS AND JOINT FACES

FLEXIBLE HYDRAULIC PIPES, HOSES

FUEL SYSTEM HOSES

METRIC NUT IDENTIFICATION

METRIC BOLT IDENTIFICATION

KEYS AND KEYWAYS

TAB WASHERS

SPLIT PINS

SCREW THREADS

NUTS

LOCKING WIRE

UNIFIED THREAD IDENTIFICATION