LAND ROVER SIII Introduction and Index

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INTRODUCTION

The purpose of this manual is to assist skilled mechanicsin the efficient repair and maintenance of the range ofvehicles given on the title-page. The procedures detailed,carried out in the sequence given and using the appropriateservice tools, will enable the operations to be completed inthe time stated in the Repair Operation Times.

IndexingThe content pages list the titles and reference numbersof the divisions in alphabetical order.

Operation NumberingEach operation is followed by the number allocated to it

in a master index. The number consists of six digitsarranged in three pairs.The master index of operations has been compiled for

universal application to vehicles manufactured by BritishLeyland Motor Corporation and therefore continuity of thenumbering sequence is not maintained throughout the

manual.Each instruction within an operation has a sequence

number, and to complete the operation in the minimumtime it is essential that these instructions are performed innumerical sequence commencing at 1 unless otherwisestated. Where applicable, the sequence numbers identify thecomponents in the appropriate illustration.Where performance of an operation requires the use of a

service tool, the tool number is quoted under the operationheading and is repeated in, or following, the .instructioninvolving its use.An illustrated list of all service tools necessary to

complete the operations described in the manual is alsoincluded.

ReferencesReferences to the left- or right-hand side in the manual

are made when viewing the vehicle from the rear. With theengine and gearbox assembly removed, the water pump endof the engine is referred to as the front.To reduce repetition, 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

All genuine Land Rover replacements have the full backing ofthe Owners Service Statement.Land Rover Distributors and Dealers are obliged to supply

only genuine Land Rover service parts.

POISONOUS SUBSTANCES

WARNINGMany liquids and other substances used in motor vehiclesare poisonous and should under no circumstances beconsumed and should as far as possible be kept away fromopen wounds. These substances among others includeantifreeze, brake fluid, fuel, windscreen washer additives,lubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions whichmust be observed if petrol (gasoline) is to be handled safely.It also outlines the other areas of risk which must not beignored.This information is issued for basic guidance only, and inany case of doubt appropriate enquiries should be made ofyour local Fire Officer.

GeneralPetrol/gasoline vapour is highly flammable and in con-

fined spaces is also very explosive and toxic.When petrol/gasoline evaporates it produces 150 times its ownvolume invapour, which when diluted with air becomes a readilyignitable mixture. The vapour is heavier than air and willalwaysfall to the lowest level. Itcan readily be distributed throughout aworkshop by air current, consequently, even a small spillage ofpetrol/ gasoline is potentially very dangerous.Always have a fire extinguisher containing FOAM COl

GAS, or POWDER close at hand when handling or drainingfuel, or when dismantling fuel systems and in areas wherefuel containers are stored.



Fuel Tank RepairUnder no circumstances should a repair to any tank

involving heat treatment be carried out without firstrendering the tank SAFE, by using one of the followingmethods:a STEAMING: With the filler cap and tank unit re-

moved, empty the tank. Steam the tank for at least 2hours with low pressure steam. Position the tank sothat condensation can drain away freely, ensuring that

any sediment and sludge not volatised by the steam, iswashed out during the steaming process.b BOILING: With the filler cap and tank unit removed,

empty the tank. Immerse the tank completely inboiling water containing an effective alkaline degreas-ing agent or a detergent, with the water filling and alsosurrounding the tank for at least 2 hours. ,After steaming or boiling a signed and dated label tothis effect should be attached to the tank.



Preliminary Pages . . . .

General Specification Data

Engine Tuning Data . .

Torque Wrench Settings

General Fitting Instructions .

Recommended Service Lubricants etc.

MAINTENANCE . . . . . . . . .

CONTENTS

ENGIN E O PERATIO NS - 2 1 4 litre 4 cylin der P etrol an d D ieselSu pp lem ent for five m ain b earing eng ine at rear of m anu al

Camshaft-remove and refit . . . .-bearings-remove and refit

Connecting rods and pistons-remove and refit+overhaul .....

Crankshaft-rear oil seal-remove and refit-remove and refit-overhaul .

Cylinder-head-remove and refit .--overhaul . . . . . .-pressure check-Petrol engine .-pressure check-Diesel engine .-side cover, front-remove and refit--side cover, rear-remove and refit .

Operation PageNo. No.

· li.13.01 12-312.13.13 12-3

12.17.01 12-412.17.10 12-5

· 12.21.20 12-10

· 12.21.33 12-11

· 12.21.46 12-11

.12.29.10 12-14

.12.29.18 12-17

.12.25.01 12-13

.12.25.01 12-23

.12.25.14 12-13

.12.25.16 12-13

PageNo.

01

04

05

06

07

09

10



Crankshaft rear oil seal-remove and refit


· 12.21.20

Cylinder head-remove and refit-top overhaul

Cylinder pressures-check

· 12.29.10· 12.29.21

· 12.25.01

Distributor and oil pump drive shaft-remove and refit . . . . . . · 12.10.22

Engine assembly-remove and refit · 12.41.01

Exhaust valve rockers and shafts-remove and refit · 12.29.36

Flywheel-remove and refit-overhaul

· 12.53.07· 12.53.10

Inlet valve rockers and shafts-remove and refit . . .-overhaul (replacing bushes)

Oil filter, external-remove and refit

· 12.29.35· 12.29.55

· 12.60.01

Oil pump+remove and refit-overhaul

· 12.60.26· 12.60.32

Oil strainer-remove and refit · 12.60.20

Oil sump-remove and refit · 12.60.44

Spigot bearing-remove and refit · 12.53.20

12-41

12-4412-46

12-44

12-36

12-50

12-48

12-5112-51

12-4712-50

12-52

12-5212-52

12-52

12-53

12-52



Exhaust emission control system

-Accelerator pump linkage setting . . . .-Carburetter adjustments . . . .-Carburetter throttle prop-remove and refit-Description of system .-Fuel filter-remove and refit . . . . . . .

-Ignition system description and ignition timing .- Throttle controlled vacuum switch-check and adjust

-remove and refit

Exhaust Gas Recirculation (E.G.R.) system-Description of system-E.G.R. valve-overhaul

-remove and refit-system check

Fault diagnosis

FUEL SYSTEM


17.20.00 17-8

17.20.00 17-8

17.20.35 17-10

17.20.00 17-817.20.38 17-11

17.20.00 17-9

17.20.24 17-1017.20.25 17-10

17.45.00 17-12

17.45.02 17-12

17.45.01 17-12

17.45.20 17-13

.17-2

NOTE: Where fuel system equipment has emission control features, refer toDivision 17 of this Manual.

Accelerator throttle controls arrangements

Aircleaner-remove and refit-clean and refill

Tamperproof carburetters

Carburetter-remove and refit-overhaul and adjust

Cold start control cable-remove and refit

Diesel fuel system-general notes and arrangement

19.00.00 19-4

19.10.04 19-719.10.16 19-7

19.15.00 19-7

19.15.09 19-8

19.15.17 19-9

19.20.26 19-16

19.00.00 19-2



Expansion tank

-remove and refit


26.25.01 26-1

. 26.40.01 26-2

. 26.40.04 26-2

.26.45.01 26-3

.26.45.09 26-3

.25.50.01 26-3

.26.50.06 26--4

33.10.01 33-1

33.10.08 33-1

26.15.01

Fan blades and pulley-remove and refit

Radiator and front panel assembly-remove and refit

Radiator-remove and refit

Thermostat-remove and refit-test.

Water pump-remove and refit---overhaul

MANIFO LD AND EXHAUST SY STEM

Exhaust manifold, 2.6 litre models-remove and refit . . . . . 30.15.10

Exhaust system-front pipe-remove and refit ....-intermediate pipe-remove and refit-silencer-remove and refit .....-silencer and tail pipe-remove and refit

-tail pipe-remove and refit . . . . .

30.10.0930.10.11

30.10.1430.10.22

30.10.19

Induction and exhaust manifold, 214litre models-remove and refit . . . . . . . . . . . 30.15.01

CLUTCH

Clutch assembly-remove and refit-overhaul

26-1

30-3

30-230-230-130-2

30-1

30-3




Layshaft-remove and refit 37.20.19

Mainshaft-remove and refit-overhaul

37.20.2537.20.31

Primary pinion-remove and refit . refer to 37.12.08

Reverse idler gear-remove and refit-overhaul

37.20.1337.20.14

Reverse selector stop-remove, refit and adjust

Transfer gearbox

37.16.28

Intermediate gear assembly

-remove and refit . refer to 37.29.28

Speedometer drive housing-remove and refit-overhaul .....

37.25.0937.25.13

Transfer gearbox complete-remove and refit-overhaul .....

37.29.2537.29.28

Transmission brake-refer to Division 70 (Brakes)

Front output housing

Front output shaft housing-remove and refit-overhaul .....

37.10.0537.10.06

PROPELLER SHAFT

37-9

37-1037-10

37-4

37-937-9

37-6

37-14

37-1237-12

37-13

37-14

37-137-1



Operat ionNo.

PageNo.

Half shaft-overhaul 54.20.09-remove and refit 54.20.07

Half shaft and swivelaxle-remove and refit. 54.20.01

54-954-8

54-8

Pinion oil seal-remove and refit 54.10.20 54-7

STEERING

Drag link-remove and refit . . . . . . . .-ball joints-remove and refit

Front wheel alignment-check and adjust

Lock stops-check and adjust

Steering geometry-check

57.55.17 57-957.55.16 57-9

57.65.01 57-10

57.65.03 57-II

57.55.13 57-857.55.12 57-8

57.35.01 57-1

57.45.01 57-257.45.07 57-4

57.40.31 57-2

57.40.19 57-1

57.35.10 57-1

57.65.02 57-11

Longitudinal steering tube-remove and refit-ball joints-remove and refit

Steering box-adjust . . . . .

Steering column and box assembly-remove and refit . . . . .-overhaul .

Steering column lock and ignition/starter switch-remove and refit . . . . . . . . . .

Steering column top bearing-remove and refit

Steering damper-remove and refit



REAR SUSPENS ION

Rear hub-remove and refit . . . . . . . . .-hub bearing end-float-check and adjust-hub bearings-remove and refit-oil seal-remove and refit-stub axle-overhaul . . .-stub axle-remove and refit-supplementary information .


64.30.10 64-5

64.30.17 64-5

.64.15.04/05 64-1

64.15.01 64-164.15.13 64-264.15.14 64-264.15.15 64-264.15.21 64-364.15.20 64-3

60---7

64.20.21 64-4

64.20.04 64-4

64.20.01 64-3

Bump stop-remove and refit

Check strap-remove and refit

Rear drive flange-remove and refit

Rear road spring-hanger bracket bush-remove and refit-overhaul

-remove and refit . . . . . . . . .

Shock absorber-remove and refit 64.30.05 64-4

BRAKES

Brakes-adjust 70.25.03 70-6-bleed 70.25.02 70-5

Brake failure switch-remove and refit 70.15.36 70-4-overhaul 70.15.41 70-4

Brake warning light-general 70.10.00 70-1

Drums-front-remove and refit-rear-remove and refit

70.10.0270.10.03

70-270-2



Operation Page

No. No.

Shoes and linings-remove and refit-brake linings 70.40.10 70-14- brake shoes, front, 88 models 70.40.02 70-13- brake shoes, front, 109 models 70.40.02 70-13-brake shoes, rear, 88 models 70.40.03 70-13-brake shoes, rear, 109 models 70.40.03 70-14

.Transmission brake-adjust 70.45.09 70-17-hand lever and linkage-remove and refit 70.45.01 70-14-remove and refit 70.45.16 70-17-shoes, remove and refit 70.45.18 70-17

Vacuum system

-servo assembly-remove and refit 70.50.01 70-18-servo assembly-overhaul 70.50.06 70-19-vacuum reservoir tank-remove and refit 70.50.04 70-18

Wheel cylinders-front, 88 models-remove and refit 70.60.03 70-19-overhaul 70.60.11 70-19

-front, 109models-remove and refit 70.60.03 70-20-overhaul 70.60.11 70-20

-rear, 88 models-remove and refit 70.60.18 70-19-overhaul 70.60.26 70-19

-rear, 109 models

-remove and refit 70.60.18 70-20-overhaul 70.60.26 70-20

WHEELS AND TYRES

General ................. 74.10.00 74-1

BODY

Body repairs-general 76.00.00 76-1



Heater/blower fan motor-remove and refit-box complete-remove and refit-controls-remove and refit-fan switch-remove and refit .

/ventilator air flow . . . . . .-control cable-remove and refit

-water valve-remove and refit . . . . .-water valve control cable-remove and refit

Operation Page

No. No.

80.lS.03 80-3

80.15.29 80-4

80.20.15 80--S

80.20.01 80-480.10.02 80-180.10.22 80-2

80.10.06 80-180.10.16 80-280.10.07 80-2

80.25.15 80-S80.2S.16 80-S

80.15.16 80-4

Demister nozzles-remove and refit

Fresh air intake-remove and refit

Pipes

-feed to heater-remove and refit . .-return from heater-remove and refit

Ventilator grille panel-remove and refit

W IPER S AND WASHER S

Headlamp wipers and washers-general . . . . . . .

Windscreen washer-jets-remove and refit-pump-remove and refit-reservoir-remove and refit

-tubes-remove and refit

Windscreen wiper-arms-remove and refit .-motor and drive-remove and refit . . . . .-motor, drive and wheel boxes-remove and refit

-motor-overhaul . . . . . . . . . . . .

84.20.00 84-5

84.10.09 84-184.10.21 84-2

84.10.01 84-1

84.10.1584-1

84.15.01 84-284.15.09 84-284.15.10 84-384.15.18 84-4

ELECTRICAL OPERATIONS

Alternator




-panel illumination-rear flasher-tail and stop-warning lights

Starter motor

-remove and refit-overhaul-solenoid-remove and refit

86.45.3186.40.4586.40.7986.45.31

86.60.0186.60.1386.60.08

Switches

-remove and refit-choke warning light . . . . . . . . . .-combined, direction indicator/headlight/hom-ignition/starter-·heater/starter-lighting . . . . . . .-panel light . . . . . .-stop light . . . . . .

-windscreen wiper/washer

86.65.53

86.65.5586.65.0286.65.1086.65.1286.65.51

86.65.38

INSTRUMENTS

Coolant temperature gauge-remove and refit 88.25.14

Coolant temperature transmitter-remove and refit . . . . 88.25.20

Fuel gauge-remove and refit 88.25.26

Fuel tank gauge unit-remove and refit 88.25.32

Instrument panel-remove and refit 88.20.01

Oil pressure warning switch-remove and refit 88.25.08

86-24

86-23

86-23

86-24

86-2586-25

86-25

86-32

86-33

86-30

86-31

86-31

86-32

86-31

88-3

88-3

88-4

88-4

88-1

88-2



ABBREVIA TIO NS AND SYMBOL S

Across flats (bolt size) A.F. Negative (electrical)After bottom dead centre A.B.D.C. Newton metre NmAfter top dead centre AT.D.C. Number No.Alternating current a.c.Amperes A Ounces (force) ozfAmpere-hour Ah Ounces (mass) 'ozAtmospheres Atm Ounce inch (torque) ozfin

Outside diameter o.diaBefore bottom dead centre B.B.D.C. Overdrive 010

Before top dead centre B.T.D.C.Bottom dead centre B.D.C. Paragraphs para.Brake horse power b.h.p. Part Number Part No.Brake mean effective pressure b.m.e.p. Percentage %British Standards B.S. Pints (Imperial) pt

Pints (U.s.) U.S. ptCarbon monoxide CO Plus or minus ±

Centigrade (Celsius) C Plus (tolerance) +

Centimetres cm3 Positive (electrical) +Cubic centimetres ~~ Pounds (force) lbfCubic inches in Pounds (mass) lbCycles per minute c/min Pounds feet (torque) lbf ft

Pounds inches (torque) lbfin0

Ibf/in2Degree (angle) deg.or 0 Pounds per square inchDegree (temperature) deg. orDiameter dia. Radius rDirect current d.c. Ratio :

Reference ref.Fahrenheit F Revolutions per minute rev/minFeet ft Right-hand R.H.Feet per minute ft/min Right-hand steering R.H.Stg.Fifth 5th

"igure (illustration) Fig. Second (angle)First lst Second (numerical order) 2ndFourth 4th Single carburetter SC

Gallons (Imperial)Society of Automobile

gal Engineers S.A.E.Gallons (U.S.) U.S. gal Specific gravity sp.p.Grammes (force) gf Square centimetres ~~Grammes (mass) g Square inches m

Standard std.



GENERAL SPECIFICATION DATA

ENGINE - 2%UTRE PETROLType .Bore .Stroke .Capacity .Valve operation .

Crankshaft

Main journal diameter .

Minimum regrind diameter .Crankpin journal diameter .

Minimum regrind diameter - .Crankshaft end thrust .

Crankshaft end float

Main bearingsNumber and type .Material .Diametrical clearance .

Undersizes .

Connecting rodsType .Length between centres .

Bigend bearingsType and material .Diametrical clearance .

End float on crank pin .Undersizes .

Gudgeon pinsType .Fit in piston .Clearance in connecting rod .

iI

PistonsType .Clearance in bore, measured at bottomof skirt at r ight angles to gudgeon pinStandard size pistons. , .

Oversize pistons. . . . . . . . . . . . .

4 cylinder90,47 mm (3.562 in. )88,9 mm (3.500 in. )2286 cm3 (139.500 in.

3)

Overhead by pushrod

63,487 mm to 63,500 mm (2.4995 in. to2.500 in.)62,48 mm (2.460 in. )58,72 mm to 58,733 mm (2.312 in. to2.31275 in.)

57,70 mm (2.272 in. )Taken on thrus t washers at centre mainbearing

0,05 mm to 0,15 mm (0.002 in. to 0.006 in.)

3 halved shellsSteel shell, tin-aluminium lined0,020 mmto 0,072 mm (0.0008 in.to 0.00285in.)

0,25mm, O,50mm, 0,76 mm, 1,01mm (0.010in.,0.020 in., 0.030 in.,0.040 in.)

Horizontally split big end, plain small end175,36 mm to 175,46 mm (6.904 in. to6.908 in.)

Steel shell,copper-lead lined0,019 mmto 0,068 mm (0.00075 in. to 0.0027in.)

0,02 mm to 0,03 mm (0.007 in. to 0.012 in.)0,25 mm, 0,50 mm, 0,76 mm, 0,01 mm(0.Q10 in. , 0 .020 in. , 0 .030 in. , 0 .040 in. )

FloatingPush fit by hand0,007 mm to 0,015 mm (0.0003 in. to0.0006 in.)

Aluminium alloy, flat top

0,0479 mm to 0,0612 mm (0.0019 in. to0.0024 in.)

0,043 mm to 0,055 mm (0.0017 in. to0.0022 in.)

Piston ringsCompression .Gap in bore .Clearance in groove . . . . . . . . . . . . . .

Oil control . . . . . . . . . .Gap in bore .Clearance in groove . . . . . . . . . . . . . .

CamshaftLocation .End float .

Number of bearings .Material .

ValvesLengthInlet

Exhaust

Seat angleInlet .

Exhaust .Head diameterInlet .

Exhaust .

Stem diameterInlet .

Exhaust .

Stem to guide clearanceInlet .

Exhaust

Valve liftInlet .Exhaust .

20,38 mm to 0,50 mm (0.015 in. to 0.020 in.)0,046 mm to 0,097 mm (0.0018 in. to0.0038 in.)

10,38 mm to 0,50 mm (0.015 in. to 0.020 in.)0,038 mm to 0,089 mm (0.0015 in. to

0.0035 in.)

Right-hand side (thrust side) of engine0,06 mm ot 0,13 mm (0.0025 in. to0.0055 in.)

4Steel Shell, white metal lined

111,25 mm to 111,60 mm (4.380 in. to4.394 in.)

111,22 mm to 111,58 mm (4.379 in. to4.393 in.)

30°

45°

44,45 mm to 44,57 mm (1.750 in. to1.755 in.)

35,02 mm to 35,05 mm (1.375 in. to1.380 in.)

7 ,891 mm to 7,904 mm (0.3107 in. to0.3112 in.)

8,661 mm to 8,674 mm (0.3410 in. toO.3415in.)

0,033 mm to 0,048 mm (0.0013 in. to0.0019 in.)

0,058 mm to 0,073 mm (0.0023 in. to0.0029 in.)

10,236 mm (0.403 in. )9 ,85 mm (0.388 in. )

continued



Valve springsType .InnerLength, free .Length, under 8,0 kg (17.7 Ib) load .

OuterLength, free .Length, under 21 kg ( 46 lb.) load .

Valve t im ingInlet opens .Inlet closes .Inlet peak .Exhaust opens .Exhaust closes .Exhaust peak .

LubricationSystem .. , .System pressure, enginewarm at 2000rev/min .Oil pumpType .Drive .

End float of gearsSteel gear .

Aluminium gear .

Radial clearance of gears .

Backlash of gears

Oil pressure relief valveType .Relief valve springFulliength .Compressed length at 2,58 kg (5.7lb.) load .

Duplex interference coilEN GIN E - 2 Y-aL IT RE D IE SE LType .Bore .Stroke .Capacity .Valve operation .

4-cylinder90,47 mm (3.562 in. )88,9 mm (3.500 in. )2286 cm

3(139 in.3)

Overhead by push rod

63,487 mm to 63,500 mm (2.4995 in. to2.5000 in.). Regrinding NOTpermitted.

58,72 mm to 58,733 mm (2.312 in. to

2.31275 in.). Regrinding NOTpermitted.

Taken on thrust washers at centre mainbearing

0,05 mm to 0,15 mm (0.002 in. to0.006 in.)

3 halved shellsSteel shell, copper-lead lined, tin plated0,020 mmto 0,063 mm (0.0008 in. to 0.0025in.)

Horizontally split big end, plain small end175,38 mm to 175,43 mm (6.905 in. to

6.907 in.)

Steel shell,copper-lead lined0,019 mmto 0,068 mm (0.00075 into 0.0027in.)

0,20 mm to 0,30 mm (0.007 in. to0.012 in.)

FloatingPush fit by hand0,0076 mm to 0,0178 mm (0.0003 in. to0.0007 in.)

Aluminium alloy, with V shape recess in

crown

0,111 mm to 0,134 mm (0.0044 in. to0.0053 in.)

0,111 mm to 0,157 mm (0.0044 in.to0.0062 in.)

42,67 mm (1.680 in. )37,13 mm (1.462 in. )

46,28 mm (1.822 in. )40,30 mm (1.587 in.) Crankshaft

Main bearing journal diameter .

6° B.T.D.C.52° A.B.D.C.113° A.T.D.C.34° B.B.D.C.24° A.T.D.C.95° B.T.D.C.

Crank pin journal diameter .

Crankshaft end thrust .


Wet sump, pressure fed

2,45to 4,5 kgf/cm2 (35 to 651bf/in.2)Main bearingsNumber and type .Material .Diametrical clearance .ouble gear

Splined shaft from camshaft skew gear

0,05 mm to 0,12 mm (0.002 in. to0.005 in.)

0,07 mm to 0,15 mm (0.003 in. to

0.006 in.)0,02 mm to 0,10 mm (0.001 in. to0.004 in.)

0,15 mm to 0,28 mm (0.006 in. to0.012 in.)


B ig e n d b e ar in g sType and material .Diametrical clearance .

End float on crank pin .Non-adjustable

67,82 mm (2.670 in. )

61,23 mm (2.450 in. )

Gudgeon pinsTyp.e .: .Fit inpiston .

Clearance in connecting rod .

PistonsType

Clearance in bore, measured at bottom ofskirt at right angles to gudgeon pinStandard size pistons .

Oversize pistons .



Piston ringsCompression No.1 (top)Type .Gap in bore , .

Clearance ingroove .

Compress ion Nos. 2 and 3Type .

Gap in bore .

Clearance in groove .

Oil control No.4Type .Gap in bore .

Clearance ingroove . . . . .

CamshaftLocation .End float .. " .

Number of bearings , .Material .

ValvesLengthInlet

Exhaust

Seat angleInlet .Exhaust .

Head diameterInlet .

Exhaust .


Exhaust .


Exhaust

Valve liftInlet .Exhaust .

Square friction edge, chrome plated0,35 mm to 0,50 mm (0.014 in. to0.019 in.)

0,06 mm to 0,11 mm (0.0025 in. to0.0045 in.)

Valve springsType .InnerLength, free .Length, under 8,0 kg (l7.7Ib. ) load.

OuterLength, free .Length, under 21 kg (46 lb.) load .

Valve timingInlet opens .Inlet closes .Inlet peak .Exhaust opens . . . . . . . . .Exhaust closes . . . . . . . . . . . . . . . . .Exhaust peak .

LubricatioaSystem .System pressure, engine warm at 2000rev/min .Oil pumpType .Drive .

End float of gearsSteel gear .

. Duplex Interference coil

42,67 mm (1.680 in. )40,30 mm (1.587 in. )

46,28 mm (1.822 in. )40,30 mm (1.587 in. )

16° BTDC42° ABDC103° ATDC51° BBDC13° ATDC109° BTDC

Wet sump, pressure fed

2,5 to 4,57 kgf/cm2 (35 to 651bf/in.Z)

Double gearSplined shaft from camshaft skew gear

0,05 mm to 0,12 mm (0.002 in. to0.005 in.)

0,07 mm to 0,15 mm (0.003 in.to0.006 in.)0,02 mm to 0,10 mm (0.001 in. to0.004 in.)

0,15 mm to 0,28 mm (0.006 in.to0.012 in.)

Non-adjustable

67,82 mm (2,670 in.)

61,23 mm (2.450 in. )

Bevelled friction edge. Marked 'T' or'TOP' on upper s ide

0,25 mm to 0,38 mm (0.010 in. to0.015 in.)0,06 mm to 0,11 mm (0.0025 in. to0.0045 in.)

Expander and rails0,38 mm to 1,14 mm (0.015 in. to0.045 in.)

0 ,038 mm to 0,064 mm (0.0015 in.to 0.0025 in. )

Right-hand side (thrust side) of engine0,06 mm to 0,13 mm (0.0025 in. to0.0055 in.)

4Steel shell, white metal lined

Aluminium gear .


Blacklash of gears .116,38 mm to 116,58 mm (4.582 in.to 4.590 in.)

116,89 mm to 117,09 mm (4.602 in.to 4.610 in. )

45°45°

39,16 mm to 39,26 mm (1.542 in.to1.546 in.)

33,32 mm to 33,42 mm (1.312 in. to1.316 in.)

7,891 mm to 7,904 mm (0.3107 in. to

0.3112 in.)8,661 mm to 8,674 mm (0.3410 in. to0.3415 in.)

0,033 mm to 0,048 mm (0.0013 in. to0.0019 in.)

0,058 mm to 0,073 mm (0.0023 in. to0.0029 in.)

9,85 mm (0.388 in. )10,26 mm (0.404 in.)

Oil pressure relief valveType .Relief valve springFree length .Compressed length at 2.58 kg (5.7lb.) lead .



ENGINE - 2.6 LITRE PETROLType ,Bore , .Stroke .Capacity . .Valve operation , .

CrankshaftMain journal diameter .

Minimum regrind diameter .

Crankpin journal diameter .

Minimum regrind diameter , .Crankshaft end thrust .


Main bearingsNumber and type .Material .Diametrical clearance .

Undersizes .


Big end bearingsType and material , ..Diametrical clearance .

End float on crankpin .

Undersizes .

Gudgeon pinsType .

Fit in piston .Clearance in connecting rod .

PistonsType : .Clearance in bore, measured at bottomof skirt at right angles to gudgeon pin.Standard size and oversize pistons .....

6-cylinder77,8 mm (3.063 in.)

92,075 mm (3.625 in.)

2625 cm3 060.3 in.3)

Inlet - overhead by push rodExhaust -- side by cam follower

66,64 mm to 66,66 mm (2.624 in. to2.6245 in.)

65,63 mm (2.584 in. )

47,62 mm to 47,64 mm (1.875 in. to1.87575 in.)

46,60 (] .835 in.)Taken on thrust washers at rear mainbearing

0,05 mm to 0,15 mm (0.002 in. to0.006 in.)

7 halved shellsSteel shell, copper-lead lined, tin plated0,015 mm to 0,050 mm (0.0006 in. to0.002 in.)

0,25 mm, 0,50 mm, 0,76 mrn, 1,01 mm(0.010 in., 0.020 in. , 0 .030 in. ,0.040 in.)

Horizontally split big end, plain small end206,463 mm (8.1285 in.)

Steel shell, copper-lead, tin plated0,019 mm to 0,063 mm (0.00075 in. to0,0025 in.)

0,15 mm to 0,38 mm (0.006 in. to0.Q15 in.)

0,25 mm, 0,50 mm, 0,76 mm, 1,01 mm(0.010 in. , 0 .020 in. , 0 .030 in. ,0.040 in.)

Fully floating

Push fit by handZero to 0,0241 mm (0.00095 in. )

Aluminium alloy, ridged top

0,048 mm to 0,060 mm (0.0019 in. to0.0024 in.)

--- --.-------.-_ ..----__--

Piston ringsCompression .Gap in bore .


Oil control .Gap in bore .


CamshaftLocation .End float .

Number of bearings .Material .

ValvesLengthInlet

Exhaust

Seat angleInlet .Exhaust .

Head diameterInlet .

Exhaust .


Exhaust .


Exhaust

Valve liftInlet .

Exhaust .

2

0,38 mm to 0,50 mm (0.015 in. to(0.020 in.)

0,046 mm to 0,097 mm (0.0018 in. to0.0038 in.)I0,38 mm to O,RO mrn (0.015 in. to0.033 in.)

0,05 mm to 0,10 mm (0.002 in. to0.004 in.)

Left-hand side of engine0,11 mm to 0,16 mm (0.0045 in. to0.0065 in.)

I

Split 'Mazak' castings

96,57 mm to 96,77 mm (3.802 in. to3.810 in.)

116,07 mm to 116,28 mm (4.570 in. to4.578 in.)

30°45°

45,54 mm to 45,64 mm (1,793 in. to1.797 in.)

32,02 mm to 32,13 mm (1.261 in. to1,265 in.)

8,68 mm to 8,69 mm (0.342 in. to0.3425 in.)

8,66 mm to 8,67 mm (0.341 in. to0.3415 in.)

0,033 mm to 0,048 mm (0.0013 in. to0.0019 in.)

0,058 mm to 0,073 mm (0.0023 in. to0.0029 in.)

9,49 mm (0.374 in.)

10,23 mm (0.403 in. )

continued



Valve springsType .InletInnerLength, free .Length under 9,7 kg (21.5 lb.) load.

OuterLength, free .Length under 31,5 kg (69.5 lb.) load.

ExhaustInnerLength, free .Length under 9,1 kg(I 6.4 lb. ) load.

OuterLength, free .Length under 18,9 kg (41.8 lb.) load.

Valve timingInlet opens .Inlet closes .Inlet peak .Exhaust opens .Exhaust closes .Exhaust peak .

LubricationSystem .

System pressure, engine warm at 2000rev/min .

Oil pumpType .Drive " .End float ofgearsSteel gear .

Aluminium gear .


Backlash of gears

Oil pressure relief valve

Type .Relief valve springFree length .Compressed length at 7,9 kg (I7.5lb.) load .

Duplex. Interference coilCLUTCHMake .Type .Drive plate diameter .Damper spring colour .

Facing material

Borg and BeckDiaphragm spring241 mm (9.500 in.)Dark green (Petrol)Dark grey/Light green (Diesel)FERODO RYZ

Single helical constant mesh withsynchro-mesh on all forward speeds

Direct1.50: 12.22: 13.68: I3.887:14.021:1

Two speed reduction on main gearboxoutput.

Two/four wheel drive control on transfer,box output

High transfer1.15: I1.53: 1

Low transfer2.35: 13.27: 1

43,26 mm (1.703 in. )36,49 mm (1.437 in. )

49,80 mm 0.960 in.)41,27 mm (1.625 in. )

TRANSMISSIONMain gearbox

Type .

5.4: 18.05: 112.0: 119.88: 120.47:121.6:1

11.1:116.5: I24.6:140.7: 142.87:144.31:1

43,26 mm (1.703 in. )38,10 mm (1.500 in. )

47,26 mm (1,861 in. )41,27 mm (1.625 in. )

Ratios:Top .Third .Second .First .Reverse: Suffix 'A' gearbox .

Suffix'B'gearbox .

7.19: 110.81: 1

15.96: 126.46:127.87:128.91:1

15.4: 123.1: 1

34.1: 156.56: 159.76:161.78:1

12° BTDC46° ABDC107° ATDC47° BBDC17° ATDC75° ABDC

Transfer gearboxType .

Spiral bevel4.7: 1109 in W/B 4.7: 1 Hypoid

fully floating

Front wheel driveWet sump, pressure fed

2,81 to 3,51 kgf/cm2 (40 to 50 1bf/in.2) Ratios:Helical and spur gear transfer gearbox . .All helical transfer gearbox .Overall rat ios (final drive) with helicaland spur gear transfer gearbox.Top .Third .Second .First .Reverse: Suffix 'A' gearbox .

Suffix 'B' gearbox .

Overall ratios (final drive) with allhelical transfer gearbox.Top .Third .

Second .First .Reverse: Suffix 'A' gearbox .

Suffix 'B' gearbox .

continued

Spur gearSplined shaft from camshaft skew gear

0,05 mm to 0,12 mm (0.002 in. to0.005 in.)

0,07 mm to 0,15 mm (0.003 in. to0.006 in.)

0,02 mm to 0,102 mm (0.001 in. to0.004 in.)

0,20 mm to 0,28 mm (0.008 in. to0.012 in.)

non-adjustable

87,0 mm (3.425 in. )

50,55 (1.990 in.)REAR AXLEType .Ratio .



FRONT AXLEDifferential .Front wheel drive .Ratio .

PROPELLER SHAFTSType .Diameter of tubular shaft .Overall length (face to face in midwayposition)

Front shaft - 4-cylinder models

Front shaft - 6-cylinder modelsRear shaft - 88 models .Rear shaft - 109 4-cylinder modelsRear shaft - 109 6-cylinder models

COOLING SYSTEMType .

Thermostat .Pressure cap . . . . . . . . . . . . . . . . . . . . . .Type of pump .

FUEL SYSTEMSpiral bevelEnclosed universal joints4.7: 1

Carburetter . . . . . . . . . . . . . . . . . . . . . . . . . see 'ENGINE TUNING DATA'

Oilbath with built in centr ifugal pre-cleaner

Mechanical0,10 to 0,17 kgf cml (1.5 to 2.5 lbf in.l )

Mechanical0,35 to 0,56 kgf cm2 (5 to 8 Ibf in.2)

Electrical - Dual inlet0,15 to 0,26 kgf cm2 (2.25 to 3.75 Ibf in.2)

CAV mechanically-governed distributor typeCAY PintauxBDNO/SPC 6209135 atm

7 seconds5 s~conds13 BTDC

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Hardy-Spicer, needle bearing50,8 mm (2.000 in.) Fuel pump

2~ litre 4-cylinder PetrolType .Pressure range . . . . . . . . . . . . . . . . . .

2~ litre 4-cylinder DieselType .Pressure range .. : . . . . . . . . . . . . . . .

2.6 litre 6-cylinder PetrolType .Pressure range . . . . . . . . . . . . . . . . . .

Injection system 2~ litre DieselInjection pump .Injectors .Nozzle size .Operating pressure of nozzle valve . .Back leakage rate 150 to 100 atm ..New nozzle .Original nozzle . . . .Start of injection .

604,8 mrn (23.812 in.)

693,7 mm (27.312 in.)554,00 mm (21.812 in.)1042,9 mm (41.062 in.)955,7 mm (37.625 in.)

Pressurized spill return system withthermostat control , pump and fanassisted

nOc (l62°F)0,6 kgf cm2 (9lbf in.l)Centrifugal



SUSPENSIONType ............... Rigid axles, semi-eliptic springsSprl.... 88-Petrol 88-Diesel I09-Petrol I09-Diesel Heavy Duty Extra Heavy DutyFront (Driver)Lekt. . .. .. .. .. .. 36.25 in. 36.25 in. 36.25 in. 36.25 in. 36.25 in. 36.25 in.Wi ............ 2.5 in. 2.5 in. 2.5 in. 2.5 in. 2.5 in. 2.5 in.No. of leaves...... 9 II II II II IIThickness1 at .............. 0.203 in. 0.203 in. 0.203 in. 0.203 in. 0.203 in. 0.203 in.8 at .............. 0.165 in.10 at............. 0.172 in. 0.172 in. 0.172 in. 0.172 in. 0.172 in.

Rate .. . .. . .. . . .. . 203 lb. in. 273 lb. in. 273 lb. in. 273 lb. in. 273 lb. in. 273 lb. in.Free camber ...... 6.080 in. 5.625 in. 5.625 in. 6.125 in. 6.125 in. 6.25 in.

Front (Passenger)Length ........... 36.25 in. 36.25 in. 36.25 in. 36.25 in., 36.25 in. 36.25 in.Width ............ 2.5 in. 2.5 in. 2.5 in. 2.5 in. 2.2 in. 2.5 in.No. of leaves...... 9 II II II II IIThickness1 at.............. 0.203 in. 0.203 in. 0.203 in. 0.203 in. 0.203 in. 0.203 in.8 at .............. 0.165 in.10 at ............. 0.172 in. 0.172 in. 0.172 in. 0.172 in. 0.172 in.Rate .. . .. . . .. . . .. 203 lb. in. 273 lb. in. 273 lb. in. 273 lb. in. 273 lb. in. 273 lb. in.Free camber ...... 5.330 in. 5.125 in. 5.125 in. 5.625 in. 5.625 in. 5.625 in.

Rear (Driver)Length ........... 48 in. 48 in. 48 in. 48 in. 48 in. 48 in.Width ............ 2.5 in. 2.5 in. 2.5 in. 2.5 in. 2.5 in. 2.5 in.No. of leaves...... II II 10 10 8 9

Thickness1 at. ............. 0.250 in. 0.250 in. 0.250 in. 0.250 in.2 at .............. 0.375 in. 0.375 in.7 at. ............. 0.156 in. 0.156 in.8 at .............. 0.281 in.9 at. ............. 0.281 in.10 at ............. 0.187 in 0.187 in.Rate .. . .. . . .. . . .. 166 lb. in. 166 lb. in. 270 lb. in. 270 lb. in. 368 lb. in. 415 lb.in.Free camber . ..... 7.420 in. 7.420 in. 9.250 in. 9.250 in. 5.187 in. 6.187 in.

Rear (Passenger)Length ........... 48 in. 48 in. 48 in. 48 in. 48 in. 48 in.Width ............ 2.5 in 2.5 in. 2.5 in. 2.5 in. 2.5 in. 2.5 in.No. of leaves...... II II 10 10 8 9Thickness1 at .............. 0.250 in. 0.250 in. 0.250 in. 0.250 in.2 at .............. 0.375 in. 0.375 in.7 at. ............. 0.156 in. 0.156 in.

8 at. ............. 0.281 in.9 at.............. 0.281 in.10 at ............. 0.187 in. 0.187 in.Rate .. . .. . . .. . . .. 166 lb. in. 166 lb. in. 270 lb. in. 270 lb. in. 368 lb. in. 415 lb. in.Free camber ...... 6.750 in. 6.750 in. 8.200 in. 8.200 in. 4.750 in. 6.187 in.

iI...,J



~I00

Hydraulic dampers .Piston diameter88 models , .109 models .

STEERINGType .Ratio: Straight ahead .

Full lock .Lowratio (109 one-ton model):Straight ahead .

Full lock .Front wheel toe-in .Camber angle . . . . . . . . . . . . . . . . . . . . .Castor angle . . . . . . . . . .Swivel pin inclination .

BRAKESSystem

FrontDrum diameter88 models .109 models .Reclamation limit .

Wheel cylinder bore diameter88 models .109 models .

Lining dimensions88 models .

109 models2710 Gross Vehicle weight .

3020 Gross Vehicle weight .

Lining material

RearDrum diameter88 models .

109 models , .Reclamation limit .Wheel cylinder bore diameter .Lining dimensions88 models .

109 models .

Lining material .

Telescopic: non-adjustable

25,4 mm (1.000 in. )34,6 mm (1.375 in. )

Recirculating ball15.6: 123.8: 1

19.6: 1

29.9: 11,2 mm to 2,4 mm (0.046 in. to 0.093 in.)l~o

370

Single l ine, non servo }Single line with servoDual line

According torequirements

Hand brakeDrum diameter .Lining dimensions .

Master cylinder bore diameter88 models, non servo .88 models, with servo .109 models, all .

WHEELSSize

88 models .109 models .109 One ton models .

228,6 mm (9.000 ins.)209,55 mm X 44,45 mm X 4,74 mm(8.250 in. X 1.750 in. X 0.187 in.)

19,00 mm (0.750 in.)22,2 mm (0.875 in. )25,4 mm (1.000 in. )

5.00F X 165.50F X 166.50L X 16

254 mm (10 in.)279,4 mm (II in.)0,75 mm (0.030 in.) oversize

31,75 mm (1.250 in.) Single leading shoe27,57 mm (1.125 in. ) Twin leading shoe

220,98 mm X 38,1 mm X 4,75 mm(8.700 in. X 1.500 in. X 0.187 in.)

264,66 mm X 57,15 mm X 4,74 mm(10.42 in. X.2.25 in. X 0.187 in. )


Don 269All Models from June 77

254 mm (10 in.)

279,4 mm (II in.)See page 7(}-231,75 mm (1.250 in. ) s ingle shoe



Don 269All Models from June 77



TYRES

Type/Size88 models: Standard .

Optional .

109 models .109 One ton model .

Cross Ply 6.00-16Cross Ply 6.50-16Cross Ply 7.00-16Cross Ply 7.50-16 with 5.50F X 16 wheelCross Ply 7.50-16Cross Ply 9.00-16

Tyre pressures

Model Normal Conditions Emergency Soft

Front Rear Front Rear

88 inch Wheelbase kg/em' 1.76 2.11 1.05 1.46.00,6.50 and 7.00 X 16 Ib/in2 25 30 15 20

bars 1.72 2.07 1.03 1.38

88 inch Wheelbase kg/cm2 1.76 2.11 0.84 1.47.50 X 16 Ib/in

225 30 12 20

bars 1.72 2.07 0.83 1.38

88 inch Wheelbase kg/cm2

1.76 2.46 1.05 1.76205 X 16 Ib/in2 25 35 15 25

bars 1.72 2.41 1.03 1.72

109 inch Wheelbase kg/em" 1.76 2.53 1.05 1.837.50 X 16 Ib/in

2 25 36 15 26For speeds up to 70mph bars 1.72 2.48 1.03 1.79

109 One Ton kg/cm2 1.4 1.4 0.7 0.79.00 X 16 Ib/in2 20 20 10 10

bars 1.38 1.38 0.7 0.7

General Notes

Emergency soft pressures should only be used in extreme conditions where loss of traction is likely to occur.Return pressures to normal immediatley the difficulties have been overcome.

The pressures quoted above are for laden and unladen conditions.

For extra ride comfort, the following can apply (road condition only)

88 models - l ess than 900kg on rear axle, lower tyre pressure to 1.76 kg/ern" - 251b/ in2 - 1.72 bars109 models - less than 1050kg on rear axle, lower tyre pressure to 1.76 kg/ern" - 25 lb/in" - 1.72 bars

Where special tyres ortyres otherthanthe above arefittedto thevehicle, consult your Land Rover Distributor or Dealer orthe tyre Manufacturerfor correct tyre pressures.



~ ELECTRICAL EQUIPMENTI System .-o

BatteryPetrol models: Basic .

Heavy duty .

Dieselmodels-heavy duty .

AlternatorType .Nominal output .Field resistance .Brush spring pressure .Brush minimum length .

Stator ; .Rotor .

Starter MotorPetrol modelsMake/type .Brush spring tension .Brush minimum length .

Diesel modelsMake/type .

Brush spring tension . . . . . . . . . . . . .Brush minimum length .

Wiper motorMake/type " .Armature end float .Brush minimum length .Brush spring tension .Res~tance of armature winding at 16°C(60 F) measured between adjacent com-mutator segments .Light running, rack disconnectedCurrent at 13.5 V .Speed 30 to 60 seconds from cold .

12 volt, negative earth

Chloride (6TWL921) 291Lucas (OCP/9/ II) 371Chloride (6tW Z13R) 369Lucas (OCP/13/Il) 389Chloride (6tWI5L) 243

I UnipartGBY2209UnipartGBY2240UnipartGBY2233

16 ACR34 amps at 6000 Alternator rev/min4,33 ohms ± 5%5 to 10 OlS

5,0 mm (0.2 in. ) protruding beyond thebrush box

0,138 ohms ± 5%at 2~oC3,27 ohms ± 5% at 20 C

Lucas 2MIOO1020 gms 36 OlS

9,5 mm (0.375 in. )

Lucas M45G Pre-engaged, oil andwaterproof

1,2 kg. (42 oz)8,0 mm (0.312 in. )

Lucas 14Wsingle speed0,51 to 0,25 mm (0.002 in. to 0.010 in.)4,8 mm (0.190 in. )150g to 250g (5.3 OlS to 8 OlS)

0.23 to 0.35 ohms

1.4 amps max46 to 52.rev/min



GENERAL DIMENSIONS 109 HipCapa~ Pick-up88 88 109 Station Wagon 2710 and 30 Ka Gross

Station Wagon Vehicle Weipt

Metric British Metric British Metric British Metric British Metric Bridsh

Overall length ....................... 3,62 m 142.567 in. 3,62 m 142.56in. 4,44m 175 in. 4,44m 175 in. 4,64 m 182.7 in.Overall width (all models), ............. 1,69 m 66.6 in. 1,72 m 67.7 in.Overal unladen height, hood up ... .. .. .. 1 ,97 m 77.5 in. 2,03 m 80.0 in.Overall unladen height, hood down, screenup .............................. 1,73 m 68 in.

Overall unladen height, hood down, screendown ........................... 1,46 m 57.5 in.

Overal l Unladen height , wi th cab or hardtop ............................. 1,95 m 76.875 in. 1,98 m 77.875 in. 2,06m 81 in. 2,07 m 81.375 in. 2,77 m 109 in.

Wheelbase ............................ . 2,23 m 88 in. 2,23 m 88 in . 2,77m 109 in. 2,77 m 109 in.Track ............................. 1,31 m 51.5 in 1,31 m 51.5 in. 1,33 m 52.5 in. 1,53 m 52.5 in.Turning circle ....................... 11,6 m 38 ft. 11,6 m 38 ft. 14,3 m 47 ft. 14,3 m 47 ft. 14,3 m 47 ft.Unladen ground clearance under differen-tials, 6.00 X 16 tyres ............... 178m 7 in. 178m 7 in.

Unladen ground clearance under differen-tials, 7.00 X 16 tyres ............... 197 mm 7.75 in. 197 mm 7.75 in.

Unladen ground clearance under differen-tials, 7.50 X 16 tyres ............... 209mm 8.25 in. 209mm 8.25 in. 209mm 8.25 in.

Internal body dimensions:Length (between cappings) .......... 1,206 m 47.5 in. 1,85 m 72.75 in.

Width (between cappings) ............. 1.45m 57 in. 1.45m 57in.

Height of body sides .................. 508mm 20 in 495 mm 19.5 in.Height of wheel arch ................. . 216 mm 8.5 in . 229 mm 9 in.Width of wheel arch ( to body side) 292mm 11.5 in. 349mm 13.75 in.Width of floor (between wheel arches) ... . 921 mm 36.25 in. 921 mm 36.25 in.Height, floor to roof (maximum) ... .. .. . 1,23 mm 48.5 in. 1,22 m 48 in.

~I



~ WEIGHTSI .N Short-wheelbase weights

FullLengthCanvasHood Truck Cab HardTop Station Wagon

Petrol Diesel Petrol Diesel Petrol Diesel Petrol Diesel

kg Ib kg lb kg lb kg Ib kg Ib kg lb kg lb kg lb

UNLADENWEIGHT

Front axle ....... 718 1583 747 1647 725 1599 754 1663 713 1572 742 1636 705 1555 734 1619Rear axle ... .. .. 580 1279 589 1299 582 1283 591 1303 625 1378 634 1398 713 1572 722 1592

Total ........... 1298 2862 1336 2946 1307 2882 1345 2966.1338 2950 1376 3034 1418 3127 1456 3211

EEC KERBIEIGHT

Front axle ....... 756 1667 786 1733 763 1682 793 1749 751 1656 781 1722 743 1638 773 1705

Rearaxle ... .. .. 650 1433 661 1457 652 1438 663 1462 695 1532 706 1557 783 1727 794 1751

Total ........... 1406 3100 1447 3190 1415 3120 1456 3211 1446 3188 1487 3279 1526 3365 1567 3456

GROSS kg Ib kg Ib kg Ib kg IbVEHICLEWEIGHTFront axle ....... 930 2051 930 2051 930 2050 930 2050

Rearaxle ... .. .. 1190 2624 1190 2624 1190 2624 1190 2624

Total ........... 2120 4675 2120 4675 2120 4674 2120 4674

Long-wheelbase weights

NOTE: Unladen weight is the rrummum vehicle specification-excluding fuel and driver.EEC kerb weight is the minimum vehicle specification-plusfull fueltank and 75kg (165 Ib) driver.Gross vehicle weight is the maximum all-up weight includingdriver, passengers, payload and equipment.

NOTE: For sustained cross-country use the gross vehicle weight mustbe reduced by90 kg(offthe rear axle).

Maximum Permissible TowedWeights On-road Off-road

kg lb kg Ib

Trailers without brakes ................ 500 1100 500 1100Trailers with over-run brakes ........... 2000 4400 1000 22004-wheeltrailers with continuous or semi- 3500 7700continuous brakes, i.e.coupled brakes .... (Petrol)

3500 7700 1000 2200(Diesel)

NOTE: The weights above do not authorise use outside the legislationenforced by the terri tory in which the vehicle and t raile rcombination is being operated.

High Capacity Pick-Up WeightsFull Length 12-seater 2710 kg Gross 3020 kg GrossCanvas Hood Truck Cab HardTop Station Wagon vehicle weight vehicle weight

4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinder 4-cylinderPetrol Diesel Petrol Diesel Petrol Diesel Petrol Diesel Petrol Diesel Petrol Diesel

kg Ib kg Ib kg Ib kg lb kg lb kg lb kg Ib kg Ib kg kg kg kg

UNLADEN

1815! 786WEIGHTFront axle ....... 785 1733 814 1795 794 1751 823 1733 815 1797 788 1797 819 1806 799 812 818 831Rear axle ....... 700 1544 712 1570 694 1530 706 1557 744 1641 756 1667 891 1965 890 1962 720 732 744 756Total ........... 1485 3277 1526 3365 1488 3281 1529 3372 1530 3374 1571 3464 1679 3702 17093768 1519 1544 1562 1587

EECKERBWEIGHTFront axle ........ 811 1788 839 1850 820 1808 848 1870 812 1790 840 1852 814 1795 844 1861 825 837 844 856Rear axle ... .. .. 798 1760 819 1806 792 1746 813 1793 842 1857 863 1903 989 2181 997 2198 818 839 842 863Total ........... 1609 3548 1658 3656 1612 3554 1661 3663 1654 3647 1703 3755 1803 3976 18414059 1643 1676 1686 1719

GROSS kg lb kg Ib kg lb kg lb kg kgVEHICLEWEIGHTFront axle ....... 1000 2205 1000 2205 1000 2205 1000 2205 1000 1120Rear axle ... .. .. 1710 3771 1710 3771 1710 3771 1710 3771 1710 1900Total ........... 2710 5976 2710 5976 2710 5976 2710 5976 2710 3020



ENGINE TUNING DATA

ENGINE27'4li tre 4-cylinder Petrol models (Referto Division 17 for emission controlledengines)

Type .

Capacity .Compression ratioStandard .

Optional .

Firing Order .Compression pressure8.0: 1 compression ratio .7.0: 1 compression ratio .

Idling speed .Fast idle setting .

Ignition timing, static8.0: 1 compression ratio

7.0: 1 compression ratio

Timing marks .

Valve clearance, inlet and exhaust .

DISTRIBUTORMake/type .Rotation of rotor .Contact breaker gap .

Condenser capacity .Serial number .

Centrifugal advance with TDC ignition tim-ingDecelerat ing check with vacuum unit dis -connected

Crankshaft angle380 to 42°30

0

to 340

220 to 260

120

to 160

40

to 120

00

to 40

No advance below

Engine rev/min45003500

25001200900600450

oV

i

Vacuum advanceStarts .Finishes .

In line four cylinder four stroke, overheadvalves

2286 cm3 (139.5 in.3).

8.0: I(Engine number commencing901....)

7.0: I (Engine number commencing904....)

1-3-4-2

11,2 kgf. cm2 (160 Ibf. in.2)10,2 kgf. cm2 (145 n.r. in.2)500 rev/min1,40mm (0.055 in.) throttle butterflyclearance, 1200 ± 50rev/min

TDCwhen using 90 octane fuel30

ATDC when using 85 octane fuel30

BTDCwhen using 83 octane fuelTDC when using 75 octane fuelOn crankshaft pulley

0,25 mm (0.0 lOin.)

Lucas 45DAnti-clockwise0,36 mm to 0,40 mm (0.014 in. to0.016 in.)

0.2 microfarad5069

89 mm (3.5 in.) Hg.635 mm (25.0 in.) Hg.

SPARKING PLUGSMake/type8.0: 1compression ratio .7.0: I compression ratio .

Gap .

IGNITION COILMake/type .Primary resistance at 200C (68°F) .Consumption- ignition on at engine idlespeed .

CARBURETTERMake/type .Choke diameter .Main jet .Compensating (enrichment) jet .Pump jet .Needle valve .

High altitude carburetterMain (120) .

(I17.5) .(liS) .(112.5) .

Slow running (55) .

ENGINE

27'4litre 4-cylinder Diesel modelsType .

Capacity .Compression ratio .Firing order .Idling speed .Injection timing setting .Timing marks

Valve timing - inlet and exhaust. .Injection timing .Valve clearance - inlet and exhaust .

INJECTORSMake/type .Nozzle size .Opening pressure .

HEATER PLUGSMake/type .

DISTRIBUTOR PUMPMake/type .Direction of rotation .Maximum speed setting (sealed)

Champion NI2Y or Unipart GSP 131Champion N8 or Unipart GSP 1300,75 to 0,80 mm (0.029 to 0.032 in.)

HAI23.0 to 3.5 ohms

2.0 amps approx.

Zenith 361V27 mm12515065 (short s troke, outer hole)1.75

Altitude: 1524to 2133 m (5000 to7000 ft)2133 to 2743 m (7000 to9000 ft)2743 to 3657 m (9000 to 12000 ft)3657to 4267 m (12000 to 14000 ft)2743to 4267 m (9000 to 14000 ft)

In line four cylinder four stroke, overheadvalves

2286 cm3(139.5 in.")

23.0: 1

1-3-4-2590 ± 20 rev/min13°B.T.D.C.

On engine flywheel and pump flange0,25 mm (0,010 in)

CAY PintauxBDNO/SPC 6209135 Atm

KLG GF 21OfTor Champion AG45

CAV type DPAClockwise, viewed from drive end4,200 engine rev/min



oVI

IN

ENGINE2.6 litre 6-cylinder Petrol models

Type .

Capacity .Compression ratioStandard .

Optional .

Firing order .

Compression pressure7.8:Icompression ratio .

7.0:Iompression ratio .Idling speed .Fast idle setting .Ignition timing, static and dynamic7.8: 1 compression ratio .

7.0: 1 compression ratio .

Timing marks .Valve clearanceInlet .Exhaust .

DISTRIBUTORMake/type " .Rotation of rotor .

Centrifugal advanceDecelerating check with vacuum unit dis-connected

Crankshaft angle30° to 34°26° to 28°18° to 24°10° to 16°4° to 8°0° to 4°

No advance below

Engine rev/min40003000ISOO1400800600400

Vacuum advanceStarts .Finishes .

SPARKING PLUGSMake/type .

Gap .

In line six cylinder four stroke, inlet-ov~rh~ad valves exhaust-side valves

2625 em (160.3 in.3)

7.S: 1 (Engine number commencing941....)

7.0: 1 (Engine number commencing944....)

1-5-3-6-2-4

9,48 to 10,5legf/cm2 (135 to 150Ibf/in.2) at3000 rev/min crank speed

9,84 legf/cm' (140 lbf/in.')500 rev/min1000 to 1200 rev/min

2° ATDC when using 90 octane fuel6° ATDC when using 85 octane fuel2° BTDC when using 83 octane fuelTDC when using SOoctane fuelOn crankshaft pulley

0,15 mm (0.006 in. ) engine hot0,25 mm .(0.010 in. ) engine hot or cold

Lucas 25D6Anti-clockwise

165 mm (6.5 in. ) Hg.635 mm (25.0 in.) Hg.

Champion N5 orUnipart GSP 160 (7.8:1 and7.0:1 compressionratio)

0,75 to 0,80 mm (0.029 to 0.032 in.)

IGNITION CQIi..Make/type 6 .••. 6 .

Primary resistance at 20 C (6'8 F) .Consumption- ignition on at engine idlespeed .

CARBURETTERChoke diameter .Metering needle .Air valve return spring . . . . . . . . . . . . . .Needle valve .Fast idle interconnection setting .Float height .

Lucas HAI23.0 to 3.5 ohms

1.5 amps

Zenith-Stromberg 175CD-SE41,275 mm (1.625 in. )BIS362.Z/4JBlS277.ZBlS353.Z 1,75 mm1,1 mm or No. 57 dri ll at edge of throttle16 mm to 17 mm (0.629 in. to 0.669 in.)



TORQUE WRENCH SETTINGS

ENGINE-2~ litre 4-cylinderConnecting rod cap nuts .Main bearing cap bolts:Petrol engines-3 bearing .Diesel engines .

Cylinder head bolts:Petrol engines5/16 in. UNF .1/2 in. UNF .

Diesel engines5/16 in. UNF .1/2 in. UNF .

Rocker shaft boltsPetrol engines5/16 in. UNF .1/2 in. UNF .

Diesel engines5/16 in. UNF .1/2 in. UNF .

Starter dog:Petrol engines .Diesel engines .

Flywheel bolts .Oil filter bolts:Canister to housing .Housing to cylinder block .

Engine sump bolts .

ENGlNE-2.6 litre 6-cylinder PetrolConnecting rod cap nuts .Main bearing cap bolts . . . . . . . . . . . . . .Cylinder head bolts3/8 in. (9,5 mm approximately) dia-meter .7/16 in. (11 mm approximately) dia-meter .

Starter dog: .Flywheel bolts . . . . . . . . . . . . . . . . . . . .Sump bolts .

Fuel system

2~ litre 4-cylinder DieselInjector nuts .

Manifold and exhaust system2~ litre 4-cylinder PetrolInduction manifold to exhaust manifoldnuts .

~I

ClutchClutch cover bolts .

kgf. m.

3,5

ll,513,8

2,48,9

2,412,5

2,48,9

2,412,5

27,627,68,5 to 9,0

1,663,451,65

2,810,4

4,0

7,027,65¢;~8,5o 9,0

"~ 1,65

0,8 to 1,0

2,3

2,48 to 3,04

Ibf. ft.

25

85100

GearboxOutput drive flange nut .Layshaft bolt .

Rear axle and final driveHub driving flange bolts .Salisbury type axles:Differential case bolts .Crownwheel bolts .Differential bearing cap bolts .Differential cover bolts .

1865

1890

Rover type axlesBevel pinion driving flange nut .Crown wheel bolts .Differential bearing cap bolts .Hub driving flange nut .

Front axle and finaldriveHub driving flange bolts .Hub driving flange nut .Bevel pinion driving flange nut .Crown wheel bolts .Differential bearing cap bolts .Upper swivelpin bolts .Lower swivel pin nuts .

Steering

Steering wheel nut .Ball joint nuts .Relay lever pinch bolts .Steering box to support bracket bolt s ..S teer ing box support bracket to chassisbolts .Steering box drop arm nut .Road wheel nuts .

1865

1890

20020060to 65

122512

2075

30

5020060 to 65

12

BrakesWheel cylinder bleed nipple .Master cylinder to servo nuts .Tipping valve retainer (Dual systemmaster cylinder) .Brake failure switch end pipe unionBrake fai lure switch unit to housing ' . ..

Fluid rese rvoir to master cylinder bolt(single line servo) .Fluid reservoir to master cylinder screws(dual line servo models) .

Servo assembly securing nuts .

6 to 8

17

18 to 25~ff

kgf.m.11,757,00

4,2 to 5,2

9,1 to 10,415,3 to 17,312,9 to 14,52,8 to 3,5

11,755,5 to 6,27,0 to 8,91,4to 2,0

4,2 to 5,22,0to 2,711,755,5 to 6,27,0 to 8,97,0 to 8,97,0 to 8,9

5,44,07,67,0 to 8,5

2,08,5 to 11,010,3 to 11,7

0,5 to 0,82,2 to 2,6

4,9 to 6,22,22,2

2,8 to 3,5

0,3 to 0,41,2

continued

Ibf. ft.8550 (apply Loctite 601)

30 to 38

66 to 75111 to 125,93 to lOS

20 to 25

8540to 4550to6510 to 15

30to 3815to208540to 4550to 6550t06550t065

40305550 to 60

1560 to 8075 to 85

4 to 616 t o 19

35 to 451616

20 to 25

2 to 3

9



0 Suspension-all models kgf.m. Ibf. ft.a-I Leaf spring'U' bolts front and rear ...... 8,0 58N Shackle nuts and bolts ................ 8,3t09,7 60to70

Windscreen wipers and washersWiper blade drive adaptor bolts ... .. .. 0,34 (34 kgf', em) 2.5 (30 lbf . in. )

Electrical equipmentAlternator shaft nut ............... 3,5 to 4,2 25 to 30Heater plugs (diesel) ............... 3,4 25Starter motorPetrol models

Starter through bolts .......... 1,0 8Diesel modelsSolenoid to starter nuts ., ...... 0,62 4.5Solenoid outer terminal nuts ... . 0,41 3Starter yoke terminal outer nut .. 0,2 1.5Starter through bolts ... .. .. .. . 1,1 8Starter earth stud nut .......... 0,82 6Eccentric pivot pin locknut ... .. 2,2 16



GENERAL FITTING INSTRUCTIONS

Precautions against damageI Always fi t 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 car.3 Avoid spill ing hydraulic fluid or bat tery acid on paint

work. Wash off with water immediately if this occurs.Use Polythene sheets in boot to protect carpets.

4 Always use a recommended Service Tool, or a sa tisfac -

tory equivalent, where specified.5 Protect temporar ily exposed screw threads by replacing

nuts or fitting plastic caps.

Safety Precautions1 Whenever possible use a ramp or pit when working

beneath car , in preference to jacking. Chock wheels aswell as applying hand brake.

2 Never rely on a jack alone to support car. Use axlestands or blocks careful ly placed at j acking point s toprovide rigid location.

3 Ensure that a suitable form of fire extinguisher isconveniently located.

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

5 Inspec t power leads of any mains electri cal equipmentfor damage and check that i t isproperly ear thed.

6 Disconnect ear th (grounded) terminal of car battery.7 Do not disconnect any pipes in air conditioning

refrigeration system, if fitted, unless trained andinstructed to do so. A refrigerant is used which cancause blindness if allowed to contact eyes.

8 Ensure that adequate ventilation is provided whenvolatile de-greasing agents are being used.

CAUTION: Fume extraction equipment must be in opera-tion when trachloride, methylene chloride, chloroform, orperchlorethylene are used for cleaning purposes.

9 Do not apply heat in an attempt to free stiff nuts orfittings; as well as causing damage to protectivecoatings, there is a risk of damage to electronicequipment and brake lines from stray heat.

10 Do not leave tools, equipment, spil t oi l e tc., a round oron work area.11 Wear protec tive overall s and use barrier creams when

necessary.

o-.J

I

Preparation1 Before removing a component, clean it and its sur-

rounding areas as thoroughly as possible.2 Blank off any openings exposed by component re-

moval, using greaseproof paper and masking tape.

3 Immediately seal fuel, oil or hydraulic lines whenseparated, using plast ic caps or plugs , to prevent loss off luid and entry of dir t.

4 Close open ends of oilways, exposed by componentremoval, with tapered hardwood plugs or readily visibleplastic plugs.

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

6 Before dismantling a component, clean it thoroughlywith 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 acomponent.

Dismantling1 Observe scrupulous cleanliness when dismantling com-

ponents, pa rticularly when brake, fuel or hydraulicsystem parts are being worked on. A parti cle of dirt ora cloth fragment could cause a dangerous malfunctionif trapped in these systems.

2 Blowout all tapped holes, crevices, oilways and fluidpassages with an air l ine. Ensure that any O-rings usedfor sealing are correctly replaced or renewed, ifdisturbed.

3 Mark mating parts to ensure that they are replaced asdismantled. Whenever possible use marking ink, whichavoids possibilities of distortion or initiation of cracks,l iable if centre punch or scriber are used.

4 Wire together mating parts where necessa ry to preventaccidental interchange (e.g. roller bearing components).

5 Wire labels on to all parts which are to be renewed, andto parts requiring further inspection before beingpassed for reassembly; place these parts in separatecontainers from those containing parts for rebuild.

6 Do not discard a part due for renewal until aftercomparing it with a new part , to ensure that it s correc treplacement has been obtained.

Inspection-General1 Never inspect a component for wear or dimensional

check unless it is absolutely clean; a slight smear ofgrease can conceal an incipient failure.2 When a component is to be checked dimensionally

against figures quoted for i t, use correct equipment(surface plates, micrometers, dial gauges, etc.) inserviceable condition. Makeshift checking equipmentcan be dangerous.

3 Rejec t a component i f i ts dimensions are outside limitsquoted, or if damage isapparent. A part may, however,be ref it ted if i ts cri tical dimension is exactly l imit size,and is otherwise satisfactory.

4 Use 'Plastigauge' 12 Type PG-l for checking bearingsurface clearances; di rect ions for it s use, and a sca legiving bearing clearances in 0.0001 in. (0,0025 mm.)steps are provided with it.

Ball and RoUer BearingsNEVER REPLACE A BALL OR ROLLER BEARINGWITHOUT FIRST ENSURING THAT IT IS IN AS-NEWCONDITION.Remove all traces of lubricant from bearing underinspection by washing in petrol or a suitable de-greaser;

maintain absolute cleanliness throughout operations.2 Inspect visually for markings of any form on rolling

elements, raceways, outer surface of outer rings orinner surface of inner r ings . Reject any bearings foundto be marked, since any marking in these areasindicates onset of wear.

3 Holding inner race between finger and thumb of onehand, spin outer race and check that it revolvesabsolutely smoothly. Repeat, holding outer race andspinning inner race.

4 Rotate outer ring gently with a reciprocating motion,while holding inner ring; feel for any check orobstruction to rotat ion, and reject bearing if action is

not perfectly smooth.5 Lubricate bearing generously with lubricant appro-

priate to installation.6 Inspect shaft and bearing housing for discoloration or

other marking suggesting tha t movement has takenplace between bearing and seatings. (This is particularlyto be expected if related markings were found inoperation 2.) If markings are found, use 'Loc tite ' ininstallation of replacement bearing.

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

8 If one bearing of a pair shows an imperfection it isgeneral ly advisable to renew both bearings: an excep-tion could be made if the faulty bearing had covereda low mileage, and it could be established that damagewas confined to it only.

9 When fitt ing bearing to shaft , apply force only to innerr ing of bearing, and only to outer r ing when fit ting intohousing.



8 10 In the case of grease-lubricated bearings (e.g. hubI bearings) fill space between bearing and outer sealwithIV recommended grade of grease before fitting seal.

11 Always mark components of separable bearings (e.g.taper roller bearings) in dismantling, to ensure correctreassembly. Never fit new rollers in a used cup.

OilSeals1 Always fit new oil seals when rebuilding an assembly.

It is not physically possible to replace a seal exactlywhen it has bedded down.

2 Carefully examine sealbefore fitting to ensurethat it isclean and undamaged.

3 Smear sealinglips with clean grease;pack dust excluderseals with grease, and heavily grease duplex seals incavity between sealinglips.

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 whenpossible to protect sealing lip from damage by sharpcorners, threads or splines. If fitting sleeve is notavailable, use plastic tube or adhesive tape to prevent

damage to sealinglip.

6 Grease outside diameter of seal, place square tohousing recess and press into position, using great careand if possible a 'bell piece' to ensure that seal is nottilted. (In some cases it may be preferable to fit sealtohousing before fitting to shaft.) Never let weight ofunsupported shaft rest in seal.

6I

Flexible Hydraulic Pipes, Hoses1 Before removing any brake or power steering hose,

clean end fittings and area surrounding them asthoroughly as possible.

2 Obtain appropriate blanking caps before detachinghose end fit tings, so that ports can be immediatelycovered to exclude dirt.

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

4 When refitting hose, ensure that no unnecessary bendsare introduced, and that hose is not twisted before or

during tightening of union nuts.5 Containers for hydraulic fluid must bekept absolutely

clean.6 Do not store hydraulic fluid in an unsealed container.

Itwill absorb water, and fluid in this condition wouldbe dangerous to use due to a lowering of its boilingpoint.

7 Do not allow hydraul ic fluid to be contaminated withmineral oil, or use a container which has previouslycontained mineral oil.

8 Do not re-use fluid bled from system.9 Always use clean brake fluid to clean hydraulic

components.10 Fit a blanking cap to a hydraulic union and a plug to

its socket after removal to prevent ingressof dirt.11 Absolute cleanliness must be observed with hydraulic

components at all times.12 After any work on hydraulic systems, inspect carefullyfor leaks underneath the car while a second operatorapplies maximum pressure to the brakes (enginerunning) and operates the steering.

continued

7 If correct service tool is not available, use a suitabledrift approximately 0.015 in. (0,4 mm) smaller thanoutside diameter of seal. Use a hammer VERYGENTLYon drift if a press isnot suitable.

8 Press or drift seal in to depth of housing if housing isshouldered, or flush with face of housing where noshoulder is provided.NOTE: Most cases of failure or leakage of oil seals aredue to careless fitting, and resulting damage to bothseals and sealing surfaces. Care in fitting is essential ifgood results are to be obtained.

Joints and Joint Faces1 Alwaysuse 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 toprevent it from entering oilways, pipes or blind tappedholes.

4 Remove all traces of old jointing materials prior toreassembly. Do not use a tool which could damagejoint faces.

5 Inspect joint faces for scratches or burrs and removewith a fine file or oil stone; do not allowswarf or dirtto enter tapped holes or enclosed parts.

6 Blowout any pipes, channels or crevices with com-pressed air, renewing any O-rings or seals displaced byair blast.



Metric Bolt Identification1 An ISO metric bol t or screw, made of steel and larger

than 6 mm in diameter can be identified by either ofthe symbols ISO M or M embossed or indented on topof the head.

2 In addition to marks to ident ify the manufac ture, thehead is also marked with symbols to indicate thestrength grade e.g. 8.8, 10.9,12.9 or 14.9, where thefirst f igure gives the minimum tensile s trength of thebolt material in tens of kg/sq. mm.

3 Zinc plated ISO met ric bol ts and nuts are chromatepassivated, a greenish-khaki to gold-bronze colour.

o

Metric Nut Identification

A nut with an ISO metric thread is marked on one faceor on one of the flat s of the hexagon with the strengthgrade symbol 8, 12 or 14. Some nuts with a st rength 4,5 or 6 are also marked and some have the metricsymbol M on the flat opposite the strength grademarking.

2 A clock face system isused asan al ternat ive method ofindicating the strength grade. The external chamfers ora face of the nut is marked in a posi tion rela tive to theappropriate hour mark on a clock face to indicate thestrength grade.

3 A dot is used to locate the 12 o'clock position and adash to indica te the strength grade. If the grade is

above 12, two dots identify the 12 o'clock position.

o-.I

III.>

@ ~

@@@@[56.51]

Hydraulic Fittings - MetricationWARNING: Metr ic and Unified threaded hydraulic par ts.Al though pipe connec tions to brake system unit s incor-porate threads of metric form, those for power assisteds teer ing are of UNF type. It is vital ly important that thesetwo thread forms are not confused, and careful studyshould be made of the following notes .Metric threads and met ric sizes are being introduced intomotor vehicle manufacture and some duplication of partsmust be expected. Although standardisat ion must in thelong run be good, i t would be wrong not to give warning ofthe dangers that exist while UNF and metric threadedhydraulic par ts continue together in service. Fitt ing UNFpipe nuts into metric ports and vice-versa should nothappen, but experience of the change from BSF to UNFindicated that there is no certainty in relying upon thedifference in thread size when safety is involved.To provide permanent identification of metric parts is not easybut recognition has been assisted by the followingmeans. (Illus-tration A Metric, B Unified.)1 All metric pipe nuts, hose ends, unions and bleed

screws are coloured black.2 The hexagon area of pipe nuts is indented wi th the

letter'M'.3 Metric and UNF pipe nuts are slightly different in

shape.

~G fig(~. I~ ~

F @ I ® l F = @ I~1B

The metric female nut is always used wi th a trumpet fl aredpipe and the met ric male nut i s a lways used wi th a convexflared pipe.4 All metric ports in cylinders and calipers have no

counterbores, but unfor tunately a few cylinders withUNF threads also have no counterbore. The s ituation

ports wi th counterbores are UNF, but ports not.•~I:flnterbolredare most likely to be metric. continued

5 The colour of the protective plugs in hydraulic portsindicates the size and the type of the threads, but thefunction of the plugs is protective and not designed aspos it ive identif icat ion. In production it is diff icult touse the wrong plug but human error must be taken intoaccount.

The Plug colours and thread sizes are:

RED

GREENYELLOWPINK

UNFd" x 24.UNF

j~" x 20 UNFYz " x 20 UNFrx 18 UNFMETRIC10 x 1 mm12 x 1 mm14 x 1.5 mm

BLACKGREYBROWN

6 Hose ends differ slight ly between met ric and UNF.

Gaskets are not used with metric hoses. The UNF hose issea led on the cylinder or caliper face by a copper gasket bythe metric hose seals against the bottom of the port andthere is a gap between faces of the hose and cylinder.Pipe sizes for UNF are ~ in., ~ in., and f s in outsidediameter.Metric pipe sizes a re 4.75 mm, 6 mm and 8 mm.4.75 mm pipe is exactly the same as ~ in. pipe. 6 mm pipeis .014 in. smaller than ~ in. pipe. 8 mm pipe is .002 in.larger than fs in. pipe.Convex pipe flares a re shaped different ly for metri c sizesand when making pipes for metr ic equipment, metric pipeflaring tools must be used.

~-B-~~ ~IS.65601

A

o The greatest danger lies with the confusion of 10mm andi Nuts Unified Thread Identification



-.I

I~

in. UNF pipe nuts used for ~ in. (or 4.75 mm) pipe. The 8

in. UNFpipe nut orhose can be screwed into a 10mm portbut isvery slack and easily stripped. The thread engagementisveryweak and cannot provide an adequate seal.The opposite condition, a 10 mm nut in a in. port, isdifficult and unlikely to cause trouble. The 10mm nut willscrewin 1V z or two turns and seize. It has a crossed thread'feel ' and it is impossible to force the nut far enough to sealthe pipe. With female pipe nuts the posit ion is of coursereversed.The other combinations are so different that there is nodanger of confusion.

Keys and Keyways1 Remove burrs from edges of keyways with a fine f ile

and clean thoroughly before attempting to refit key.2 Clean and inspect key closely; keys are suitable for

refitting only if ihdistinguishable from new, as anyindentation may indicate the onset of wear.

TabWashers1 Fit new washers in all places where they are used.

Always renew a used tab washer.2 Ensure that the newtab washerisof the same designas

that replaced.

Split PinsI Fit new split pins throughout when replacingany unit.2 Always fit split pins where split pins were originally

used. Do not substitute spring washers: there isalwaysa good reasonfor the use of a split pin.

3 All split pins should be fitted as shown unlessotherwise stated.

_ t l l - _

1 When tightening a slotted or castellated nut neverslacken it back to insert split pin or locking wire exceptin those recommended cases where this forms part ofan adjustment. If difficulty is experienced, alternativewashers or nuts should be selected, or washer thicknessreduced.

2 Where' self-locking nuts have been removed it isadvisable to replace them with new ones of the sametype.

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

Locking Wire1 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.

Screw Threads1 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 andcloseness of fit of the threads and isnot recommended.

3 Alwaysensure that replacement bolts are at least equalin strength to those replaced.

4 Do not al low oil , grease or jointing compound to enterblind threaded holes. The hydraulic action on screwing

in the bolt orstud could split the housing.S Always tighten a nut or bolt to the recommended

torque figure. Damaged or corroded threads can affectthe torque reading. .

6 To check or re-tighten a bolt or screw to a specifiedtorque figure, f irst slacken a quarter of a turn, thenre-tighten to the correct figure.

7 Always oil thread l ightly before tightening to ensure afree running thread, except in the case of self-lockingnuts.

1 BoltsA circular recess is stamped in the upper surface of thebolt head.

2 NutsA continuous line of circles is indented on one of theflats of the hexagon, parallel to the axisof the nut.

3 Studs, Brake Rods, etc.The component is reduced to the core diameter for ashort length at its extremity.

~2



SERVICE LUBRICANTS, FUEL, FLUIDS AND CAPACITIES

CAPACITIES

The following capacity figures are approximate and are provided as a guide only. All oil levels must be checkedusing the dipstick or level plug, as applicable with the vehicle on level ground.

Engine sump oil, 4-cylinder .Engine sump oil, 6-cylinder .

Extra when refilling after fitting new filter, 4-cylinderExtra when refilling after fitting new filter, 6-cylinderAir cleaner oil, 4-cylinderAir cleaner oil, 6-cylinderMain gearbox oilTransfe r box oil .....Rear differentialFront differential ) RoverRear differential: Salisbury 8HASwivel pin housing oil (each) . . . .Fuel tank, 4-cylinder models except Station Wagon ..Fuel tank, 6-cylinder models except Station Wagon ... ..Fuel tank, 4-cylinder and 6-cylinder Station Wagon models ..Cooling system.id-cylinder Petrol modelsCooling system, 6-cylinder Petrol modelsCooling system, Diesel models ...Hydraulic front winch, supply tank

Hydraulic front winch, gearbox

o\0.

I

COMPONENT SERVICE CLASSIFICATION

2%litre Petrol models7.0: 1 compression ratio:90 oc tane wi th 6° BTDC ignition t iming83 octane with 3° BTDCignition timing75 octane with TDC ignition timing

8.0: 1 compression ratio:90 octane with TDC ignition timing85 octane with 3° ATDC ignit ion timing

Fuel Tank 2.6 litre Petrol models7.0: 1 compression ratio:83 octane with 2° BTDC ignit ion timing80 octane with TDC ignition timing78 oc tane wi th 2° ATDC igni tion timing

7.8: 1 compression ratio:90 oc tane with 2° ATDC ignit ion timing85 octane with 6° ATDC ignit ion timing

2%litre Diesel models Diesel fuel (D.E.R.V.)

Litres

6,06,8

0,850,50,850,51,52,51,751,752,50,54550688,,1

11,27,820,0

1,0

Imperial unit

11 pints12 pints

1.5 pints1 pint1.5 pints1 pint2.5 pints4.5 pints3 pints3 pints4.5 pints1 pint10 gallons11 gallons15gallons14.25 pints20 pints13.75 pints4.5 gallons

2 pints

US unit

13 pints14 pints

1.8 pints1.2 pints1.8 pints1.2 pints3 pints5.5 pints3.5 pints3.5 pints5.5 pints1.2 pints12 gallons13 gallons18gallons17.1 pints24 pints16.5 pints7.5 gallons

2.4 pints



o\Q

IN

1

r:tIC DC DC D



RECOMMENDED LUBRICANTS AND FLUIDS FOR BRITISH ISLES ALL YEAR ROUND USE

DIAGRAMNUMBER COMPONENT BP DUCKHAMS CASTROL ESSO MOBIL PETROFINA SHELL TEXACO

20 Engine. Petrol BP Super Duckhams Castrol Esso Mobil Fina Shell Havoline18 Air cleaner Viscostat ic Hypergrade GTX Superlube Super Supergrade Super Motor Oil6 Governor 20-50 Motor Oil (l5W /50) (lOW /40) 15W/40 Motor Oil Motor Oil 15W/40

Hydraulic winch supply tank BPVF7 (15W/50) Mobil 1 15WJ40 (l5W /40)(lOW/30) or 20 /50

20 Engine. Diesel BP Super Duckharns Castrol Esso Mobil Fina Shell HavolineHydraulic winch supplytank Viscostatic Hypergrade GTX Superlube Su}:r Supergrade Super Motor Oil

18 Air cleaner 20-50 Motor Oil (15W /50) (lOW/40) 15W 400r Motor Oil Motor Oil 15W/40or (15W/50) or or Mobil 1 15W/40or (15W/40) or or

BP Vanellus Deusol Essolube (lOW/30) or Fina Delta Shell Ursa Oil LAC3 Multigrade RXSuper HDX Delvac Super Multigrade Rotella SX 15W/4020W/50 15W/40 20W/50 15W/40or 20W/50 20W/40 orBPVF7 Delvac or Eurotex

Special Rimulax Motor Oil20W/50 15W/40 HD20W/50

7 Main Fcearbox8 Trans erbox19 Front differential26 Rear differential Fina Texaco16 Swivel housing, R.H.

BPGearOil DuckhamsCastrol Esso Mobil

PontonicShell

Multigear4 Swivel housing, L.H.

S.A.E.90 EP Hypoid90Hypoy Gear Oil Mobilube

MPSpirax

Lubricant23 Steering box S.A.E.90EP GX85W/90 HD90 S.A.E.90 90EP S.A.E.90 EP13 Steering relayII Rear power take-off28 Pulley unit

Hydraulic winchgearbox

12 Drag-link balljoint, R.H.I Drag-link ball joint, L.H.15 Track-rod ball joint, R.H.2 Track-rod balljoint, L.H.14 Longitudinal arm ball joint, front

Esso Mobil Fina Marfak21 Longitudinal arm ball joint, rear BP Energrease Duckhams Castrol

Multipurpose Mobilgrease MarsonShell

All Purpose17 Front hub, R.H. L2 LBIO LMGrease RetinaxA3 Front hub, L.H.

GreaseH MP HTL2 Grease

27 Rear hub, R.H.10 Rear hub, L.H.25 Front propeller shaft

9 Rear propeller shaftWindscreen washers UNIPART SCREEN WASHER FLUID-ALL SEASONS

24 Clutch fluid reservoir UNIPART UNIVERSAL BRAKE FLUID or other brake fluidshaving a minimum boiling point of 260°C (500°F) and complying with22 Brake fluid reservoir FMVSS 116 DOT 3.

5 Engine c ooling system UNIPART UNIVERSAL ANTI-FREEZE. If this is not available use an ethylene glycol based anti-freeze (containing no methanol) withnon-phosphate corrosion inhibitors suitable foruse incast iron engines to ensure the protection ofthe coolingsystem against frostand corrosion.

o\()

IIN



11 9 7 6 5 2

r-:0C DC DC D



RECOMMENDED LUBRICANTS AND FLUIDS FOROVERSEAS AND EXTREME TEMPERATURE CONDITIONS

SERVICE CLASSIFICATION AMBIENT TEMPERATURE °CDIAGRAMNUMBER COMPONENT PERFORMANCE LEVEL S.A.E. VISCOSITY -30 -20 -10 0 +10 +20 +30

20 Engine Oils mus t mee t BL Cars Spec if ica 5VV/20,5VV/30,5VV/40

6 Governor tion BLS.22.0L.0210VV3018 Air cleaner or

Oil can The CCMC Requirements IOVV/40,IOVV/50Hydraulic winch supply tank or

A.P.I. Service Rating 15VV/40,15VV/50Petrol Diesel20VV/40,20VV/50SEorSF CCorCD

orSE/CC orSE/CCorSF/CC orSE/CDorSE/CD orSF/CCor SF/CD or SF/CD

7 Main gearbox

8 Transfer box19 Front differential26 Rear differential 90EP16 Swivel housing, R.H. A.P.I. GL4

4 Swivel housing, L.H. or

23 Steering box MIL-L-2105

13 Steering relay 80VVEPII Rear power take-off

28 Pulley unitHydraulic winch gearbox

12 Drag-link ball joint , R.H.

I Drag-link ball joint , L.H.

15 Track-rod ball joint , R.H.

2 Track-rod ball joint , L.H.14 Longitudinal arm ball joint , front

21 Longitudinal arm ball joint , rearNLGI-2 Multi-purpose lithium based grease

17 Front hub, R.H.

3 Front hub, L.H.27 Rearhub,R.H.10 Rear hub, L.H.

25 Front propeller shaft9 Rear propeller shaft

VVindscreen washers UNIPART SCREEN VVASHER FLUID-ALL SEASONS, or other proprietary screen washer fluids.

24 Clutch fluid reservoir UNIPART UNIVERSAL BRAKE FLUID or other brake fluids having a min imum bo iling point of 260°C (500° F) and comply-

22 Brake fluid reservoir ing with FMVSS 116 DOT 3.

5 Engine cooling system UNIPART UNIVERSAL ANTI-FREEZE. Ifthis isnot available use an ethylene glycol based anti-freeze (containing no meth-anol) wi th non-phosphate cor rosion inhib itors suit able for use in cas t i ron engines to ensure the protect ion of the cooling sys temagainst frost and corrosion. VVhenfrost protect ion isnot required use a non-phosphate corrosion inhibitor.



MAINTENANCE SUMMARY CHART -EXCLUDING AUSTRALIA

KEY: MILEAGE X 1,000 MILES

Operation No.

10.10.0310.10.0610.10.1210.10.24

Mileage

I3,9,15,21,27,33,39,456,18,30,4212,24,36,48

Operation NumberInte rval s in Miles X 1000Intervals in Kilometres X 1000

10.10.12 10.10.246 1210 20

ENGINEI Check for 0 11 leaks , .2 Renew engine oil fi1ter .3 Renew engine oil ' .4 Chec.k. crankcase breathing system for leaks, hoses for security andcondition .

5 Top-up carburetter piston damper(s) (2.6 only) .6 Check/adiust carburetter idle settings .7 Clean fuer pump sediment bowl (21, , , petrol only) .

8 Check/adjust valve clearances .: .9 Check cooling and heater systems for leaks, and hoses for security and

condition.... .. . .. .. . .

10 Check/top- up cooling system : .II Check/adjust operation of a ll washers and top-up reservoirs .12 Check driving belts; adjust or r.enew ' : .13 Lubrica te accelerator control hnkage and pedal p ivot-e-check opera tion .14 Check security of engine mountings .15 Clean engine breather filter .16 Renew engine flame trap . .17 Renew fuel filter element (2.6 only) .18 Clean fuel sedimenter (diesel) .. : '.' : : .19 Check air injection system hoses/p ip es f or secur ity and condition (2.6only) .

20 Empty, c lean and refill air cleaner oil bath : .21 Drain flywheel housing if drain plug is fitted for wading .22 Check fuel injectors for burst pressure and test for spray .

-oI

IGNITION23 Clean/adjust spark plugs .24 Renew spark plugs .25 Check distributor points, adjust or renew .26 Lubricate distributor .27 Check/adjust ignition timing, using electronic equipment .

xX

X

X

X

X

X

X

X

X

X

X

X

xX

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

XX

X

X

X

XX

Operation NumberInterva ls in Miles X 1000Interva ls in Kilomet res X 1000

TRANSMISSION28 Check for oil leaks .

29 Check/top-up clutch fluid reservoir .30 Check tightness of prop. shaft coupling bolts .31 Lubricate propshaft(s) .32 Check/top-up gearbox oil .

33 Check/top-up transfer box oil .34 Check/top-up front axle oil .35 Check/top-up rear axle/final drive oil. .36 Check hydraulic clutch pipes and hoses visually for cracks, leaks andchafing .

37 Clean axle breathers .

STEERING AND SUSPENSION38 Check condition and security of steering unit joints, relays and gaiters .39 Check security of suspension fixings .40 Check/adjust front and r ear wheel alignment .41 Check steering rack/gear for ~il/fluid leaks .42 Check shock absorbers for fluid leaks .43 Check/top-up steering relay unit .44 Check/top- up steering box .45 Check/adjust steering box , .

46 Check/top-up swivel pin housing oil .

10.10.12 10.10.24

6 1210 20

X X

X X

X

X X

X X

X XX X

X X

X X

X

X X

X

X X

X X

X X

IX

X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X

XX

XX

X

X

X

X

X

BRAKES .47 Check visually hydraulic pipes and unions for chafing, leaks and corrosion.

48 Check/top-up brake fluid reser~oir(s) . . . . .. . : .49 Check handbrake operation; adjust to manufacturer s i nstructions .50 Check footbrake operation; adjust to manufacturer's instructions (manual)

51 Inspect brake linings for wear! dru!TIs for condition .. '.' '.' .52 Lubricate handbrake mechanical linkage and cable guides (lever Pivot) .53 Check brake servo hose(s) for security and condition .

XX

XX

ELECTRICAL54 Check function of original equipment, i .e . interior and exterior lamps, horns ,wipers and warning indicators .

55 Check/top-up battery electrolyte .56 Clean and grease battery connections .57 Check/adjust headlamp alignment .58 Check, if necessary renew wiper blades .

EXHAUST AND FUEL PIPES59 Check fuel system for leaks, pipes and unions for chafing and corrosion .60 Check exhaust system for leaks and security .

oI

MAINTENANCE SUMMARY CHART-EXCLUDING AUSTRALIA At 24,000 mile (40,000 km) intervals, thefollowing operations should be carried out



tV

Operation NumberIntervals inMiles X 1000Intervals in Kilometres X 1000

10.10.12 10.10.246 1210 20

WHEELS ANDTYRES61 Check that tyres complyw ithm anufacturer's specification .62 Check/adjust tyre pressures including spare _ .63 Checktyres for tread depth and visually for external cuts infabric, exposureof ply or cord structure, lumps or bulges .

64 Check tightness of road wheel fastenings .

65 Check tyres for external cuts in tyre fabric, exposure of ply cord structure,lumps or bulges .IMPORTANT: Iftyres do not conform with legal requirements, report toowner.

66 Interchange roadwheels (including spare) .

BODY67 Lubricate all locks and hinges (NOT steering lock) .68 Check condition and security of seats and seat belts .69 Check rear viewmirror(s) for cracks and crazing .70 Check operation of all door and bonnet locks .71 Check operation of window controls : .72 Check operation of seat belt inertia reel mechanism .73 Ensurec leanl iness of controls, door handles and stee ring wheel .

GENERAL74 Road/Roller test and check f unction of a ll instrumentation .75 Report additional work required .

x X

X X

X X

X X

(0 Lubricate propeller shaft sealed slidingjoints.

(ii) Renew gearbox oil.(iii) Renew transfer box oil.( iv) Renew final drive unit(s) oil .(v) Renew swivel pin housing oil .At 36,000 mile intervals - Renew ai r filt erin brake servo unit.At 48,000 mile intervals - Clean fuelpump filter (2.6 only)

X X BRAKES - PREVENTIVE MAIN-

TENANCE

X XIn addit ion to the recommended per iodicalinspection of brake components it is advisable,

X X asthe car ages, and asa precaution against theX X effects of wear and deteriorat ion, to make a

X more searching inspection and renew parts asX necessary. See page 10-18 for details.

X X

X X

X X

X X



MAINTENANCE SUMM ARY CHART - AUSTRALIA O NL Y - ADR27A - 2% PETROL

Detailed maintenance operations for specific emiss ion control i tems are contained withinsection 17 of this manual.

MAINTENANCE INTERVALS

Service

AB

CoE

Km x 1000 OPERATION NO.

10.10.0310.10.06

10.10.1210.10.2410.10.50

1.65.15,25,35,45,55,65,75

10,30,50,7020,6040, 70

NOTE: The service schedules are based on an annua l tota l of approximately 20,000 km.Should the vehicle complete substantially less kilometres than this per annum, it isrecommended that a 'C' service is completed at six month interval s and a '0' service at

twelve month intervals.

oIIN

A B C D E

Key to operation numbers 10. 10. 10. 10. 10.and mileage intervals 10. 10. 10. 10. 10.

03 06 12 24 50

Operation DescriptionClean and test crankcase breather valve ... .. .. . X

ENGINERenew engine flame trap ................. X X

Check/top up engine oil level .............. X

Check/top up cooling system .............. X X X X XCheck/adjust operation of all washers and topup reservoirs ......................... X X X X XRenew engine oil ................ . ..... X X X XRenew engine oil filter .................. X X XLubricate accelerator control linkage (and pedalpivot) - check operation ................. X X X XCheck cooling/heater system for leaks andhoses for security anZion ............ X X X X XCheck for oil leaks . - ; ................ X X X X XCheck/adjust torque .• cylinder head nuts/bolts . .

XCheck driving belts, adjust or renew ... .. .. .. . X X XCheck security of engine mountings .......... X

Check/adjust carburetter idle settings ......... X X X

Drain flywheel housing, if drain plug is fitted(for wading) ......................... X X X X

Check security of EGR valve operating lines ... - X

Check EGR system ..................... X X

Check/adjust choke settings (Manual chokes) ... X X X

Check crankcase breathing system for leakshoses/pipes for security and condition ........ X

Key to operation numbersand mileage intervals

A

10.10.03

B

10.10.06

C

10.10.12

D

10.10.24

X

XX

X

X

X

X

X

X

XX

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

xX

E

10.10.50

Check crankcase breathing and evaporative losssystems; check hoses/pipes and restrictors forblockages, security and condition .

Check/adjust valve clearances .Clean fuel pump sediment bowl .Check/adjust carburetter throttle prop .Empty, clean element, and refill air cleaner oilbath .Clean engine breather filter .Renew engine breather filter .

IGNITION IRenew spark plugs .Lubricate distributor .Check/adjust ignition timing using electronicequipment .Check security of distributor vacuum unit lineand operation of vacuum unit . . . . . . . . . . ....Check ignition wiring for fraying, chafing anddeterioration .

Clean distributor cap, check for cracks andtracking .Check coil performance on oscilloscope .Renew distributor points .

TRANSMISSIONCheck for oil leaks .Check/top up gearbox oil .Check/top up rear axle/final drive oil .Check tightness of propeller shaft couplingbolts .Lubricate propshaftts) .Lubricate propshaft sealed sliding joint .Renew final drive unit(s) oil .Check/top up transfer box oil .Check/top up front axle oil .Renew transfer box oil .Check clutch pipes for leaks and chafing .Check/top up clutch fluid reservoir .Renew gearbox oil .Clean axle breathers - .

X

XX

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

continued

-oI~

MAINTENANCE SUMMARY CHART - AUSTRALIA ONLY

A B C D E

A B C D E



Key to opera tion numbers10. 10. 10. 10. 10.

and mileage intervals10. 10. 10. 10. 10,

03 06 12 24 50

STEERING AND SUSPENSIONX XCheck/top up swivel pin housing o il ..........

X X X X XCheck/adjust s teering box . .. .. .. .. .. .. .. .Check condition and security of steering un it

X X X X Xjoints relays and gaiters .. . . . . . . . . . . . . . . . .

Check secur ity of suspension f ix ings . .. ... ...X X X

Check/adjust front and rear wheel alignment . . . . X X X X

Renew swivel pin housing oil ........... ... X X

Check/top up s teer ing relay uni t . ... ... ... .. X X

Check shock absorbers for f lu id leaks . .. ... ... X X X X X

Check/top up steering box . .. .. .. .. .. .. .. . X X X

Check steering rack/gear f or oil/fluid leaks ..... X X X X X

BRAKESInspect b rake lining s fo r wear and d rums for

X X Xondition ...........................Check/top up brake f lu id reservoirs . .. ... ... . X X X X X

Check footbr ake operations/ad ju st toX X Xanufacturer's instructions (Manual) . . . . . . . . . X

Check hand br ake operation, adjust toX X Xanufacturer's instructions ............... X

Check brake servo hose(s) f or secur ity and

condition ........................... X X X X XLubricate hand br ake mechanical linkage andcable guides .......................... X X XCheck v isually hydraulic pipes and unions for

X Xhafing, leaks and corrosion ............... X X X

ELECTRICALCheck function of o riginal equipment, i.e.in ter io r and ex terior lamps, horn s, wipers, and

Xashers and warning indicators . . . . . . . . . . . . . X X X XCheck/top up battery electrolyte . .. .. .. .. .. .. X X X X XClean and grease battery connections . . . . . . . .. X X XCheck/adjust headlamp a lignment .. ... ... .. . X X X X XCheck, if necessary ren .ew, wiper blades . .. .. .. X X X XCheck output of charging system . .. ... .. ... . X X X X

Key to opera tion numbersand mileage intervals

10 .10.03

10.10.06

X

X

X

X

X

X

X

X

X

X

10.10.12

X

X

X

X

X

X

X

X

X

X

X

X

X

10.

10.24

X

X

X

X

XX

XX

X

X

X

X

X

X

X

X

X

X

X

FUEL AND EXHAUST PIPESCheck exhaust system for leaks and security .... X

Check fuel system fo r leaks, p ipes and unionsfor chafing and corrosion . . . . . . . . . . . . . . . . . X

Check condition of fuel filler cap seal .Renew fuel line filter .

WHEELS AND TYRESInterchange road wheels (including spare) .Check/adjust tyre pressure including spare . . . . . . X

Che~~ th~t ty res comply wi th manufac ture rsspecification .Check tightness of road whee1 fastenings . . . . . . . X

Check tyres for external cuts in the fabric,exposure of ply or cord structure, lumps or

bulges X

Check tyres for tread depth, visually forexternal cuts in fabric, exposure of ply orcord structure, lumps or bulges . . . . . . . . . . . . .*IMPORTANT - if tyres do not conform withlegal requirements report to the owner .

BODYLubricate all locks and hinges (not steeringlock) X

Check condition and security of seats and seatbelts X

Check rear view mirror for cracks and crazing .Check operation of all door , bonnet and boot lo cks. X

Check oper ation o f window contro ls X

Check operation of seat belt inertia reelmechanism X

Ensur e cleanliness o f con tr ols, doo r hand les andsteering wheel X

ROAD TESTRoad/roller test and check function of allinstrumentation . . . . . . . . . . . . . . . . . . . . . . . X

Report additional work required .

Addit iona l work

At 60,000 km/3 year intervals which everis the sooner.-

Renew the air filter in the brake servo unit.

10 .10 .50

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X



Engine oil level-All modelsInadditionto changingthe oiland filterat themileage intervals stated in the MaintenanceSummary Chart , the oil level in the sumpshould be checkeddaily or weeklydependingupon theconditionsunder whichthe vehicleisoperating.

Proceed as follows:I Stand the vehicle on level ground and

allow the oil to drain back into the

sump.2 Withdraw the dipstick, wipe it clean,

re-insert to its full depth and removeasecond time to take the reading. Addoil as necessary; never fill above the'H'mark.

3 The oil level. dipstick on 4-cylinder

models carries three marks: 'H' , 'L'and 'MIN L'. Under normal circum-stances the oil level should not beallowed to fall below the minimumlevelmark 'MIN L'.

4 However, when the Land-Rover isbeing used at steep angles, the oilshould not be allowed to fall belowthe intermediate mark 'L' . This will

obviate any danger of oil pump starva-tion when the vehicle is facing down-hill at a steep angle.

ENGINE

(1) Check for oil leaks in engine compart-

ment; rectify as necessary

-oIV

(2) & (3) Engine oil changes and fil ter replace-ment. Oil changes

To change the engine oil:1 Run the engine to warm up the oil,

then stop.2 Remove the drain plug in the right-

hand side of the sump. Allow oil todrain away completely and replace theplug.

To change filter located at right-handside of engine on 4-cylinder models,

left-hand side on 6-cylinder models.3 Place oil tray under engine.4 Unscrew the bolt from the filter

adaptor.5 Remove the container .

6 Remove the element.7 Discard the used filter element and

large rubber washer.8 Washthe container in petrol .9 Place the new filter element in the

container and reassemble the unit,using the new large rubber washersupplied with the element.

10 Ensure that all the sealing washers arein position and intact, and that thecontainer is correctly located in theadaptor.

Tighten the filter retaining bolt to 1,66kgfm (121bf ft).

11 Refill with oil of the correct gradethrough the filler at the front of theengine; the total capacity including

filter is: 4-cylinder models: 6,0 litres(11 Imperial pints) 12 US pints; 6-

cylinder models: 5,5 litres (10 Im-perial pints) 11USpints.

12 Run engine and check for oil leaks atfilter and drain plug.

oI0\

(4)Crankcase breathing systemExamine for leaks and changepipes or clipswhere necessary.

Carburetter slow-running adjustment-6-cylinder models. (Basic Carburetter only)I Run the engine until normal operating



(5)Carburetter hydraulic damper-6-

cylinder Petrol modelsI Unscrew the cap on top of the suctionchamber, withdraw cap and hydraulicdamper, replenish the damper reservoiras necessary with SAE 20 oil to withinabout 12 mm (0.5 in.) from the top ofthe tube. Then replace cap andhydraulic damper.

(6)Carburetter slow-running adjustment-4-cylinder Petrol models. (Basic Carburettersonly)

The only adjustments provided at thecarburetter are a throttle stop screw and avolume control screw.Should the carburetter require adjustmentfor any reason, proceed asfollows:1 Run the engine until normal operating

temperature is obtained. If necessaryadjust the throt tle stop screw to givethe correct idling speed.

2 Adjust the volume control screw sothat the enginewill idle evenlywith no

tendency to stall on snap closure ofthe throttle.

3 Check that, as the throttle is openedslowly, there is a clear positive accele-ration of the engine speed.

4 Finally, it may be necessary to re-adjust the throttle stop screw to giveasatisfactory idle speed.

temperature is obtained. If necessaryadjust slow-run screw to give thecorrect idling speed.

2 Lift the carburetter piston approxi-mately 1mm (0.031 in.)

3 If the engine speeds up immediatelythe mixture is too rich and the jetadjustment screw must be turned anti-clockwise, thus weakening the mix-ture; if the engine stops immediately,

the mixture is too weak and the jetadjustment screw should be turnedclockwise to enrich the mixture.If the engine just falters and thencontinues to run evenly the adjust-ment is correct.

4 Finally adjust the slow-run screw toget a smooth idling speed.

5 The fast idle screw should not requireadjustment.

6 For startin~ at temperatures down to-ISoC (0 F) push and turn thespring-loaded choke adjustment screwso that the peg is at right-anglesto theslot as illustrated. Leave in this posi-tion.When starting at temperatures below

-ISoC (OoF) turn the screw until pegisrecessed in slot.

(7)Fuel sediment bowl-4-cylinder petrolmodelsThe fuel sediment bowl, located on theright-hand side of the engine providesadditional filtration between the pump andcarburetter.Clean as follows:I Remove the bowl by slackening the

thumb screw and swingingthe retainer

to one side.2 Remove and clean the filter gauze in

cleanpetrol.3 Ensure that the sealing washer is in

good condition.4 Replace gauze and refit the bowl.5 Prime the pump by operating the hand

lever.

Fuel pump 6-cylinder petrol models-Clean



fdterA single type elect ric fuel pump is fit tedand is located above the r ight hand chassismember midway along the vehicle,To remove the pump for fil ter cleaning,proceed as follows:1 Disconnect the fuel pump feed lead at

the snap connector.2 Disconnect the fuel inlet pipe from the

pump and block the end of the pipeby suitable means to prevent fuel

draining from the tank.3 Disconnect the outlet pipe.4 Remove the two nuts securing the

pump, ear th braid and rubber mount-ings to the support bracket andremove the pump.

-oI

-oJ

Filter cleaning5 Remove the inlet and outlet unions.6 Release the end cover from the

bayonet fixing.7 Withdraw the filter and clean using a

compressed air j et from the inside ofthe filter.

8 Remove the magnet from the endcover and clean. Replace the magnet inthe centre of the end cover .

9 Reassemble the fuel pump and refit tothe vehic le by reversing the removalprocedure. Use a new gasket for theend cover if necessary. Ensure that thefeed lead is reconnected and the ear thbraid fitted securely to the fixingpoints.The inlet and outlet unions are atunequal distances from the feed lead.To ensure correct fuel pipe connec-tions when refitt ing the pump, posi -tion the union nearest the feed leadconnection towards the front of thevehicle.

2RA277

(8)Tappet adjustment

The correct clearance is: 4-cylinder models,inlet and exhaust, 0,25 mm (0.010 in.)

engine hot. 6-cyclinder models , inlet 0,15mm (0.006 in.) engine hot and exhaust0,25 mm (0.010 in.) wi th the engine hot orcold.To carry out tappet adjustment, proceed asfollows:I Rotate the engine in the running direc-

tion until the valve receiving attentionis fully open and then rotate theengine one complete turn, to bring thetappet on to the back of the cam.

2 Check the tappet clearance with afeeler gauge.

3 If adjustment is required, slacken thelocknut.

4 Rotate the tappet adj usting screw unti l

the clearance is correct; re- tighten thelocknut, taking care to ensure that thisoperation does not upset the clear-ance.

5 Repeat for the other valves in turn.

-oI00

(9)Cooling systemExamine the cooling system for leaks and

AU models3 The cooling system is pressurised and



rectify as necessa ry. Renew hoses every80,000 km (48,000 miles).

Frost precautionsIn cold weather, when the temperaturemay drop to or below freezing point,precautions must be taken to preventfreezing of the water in the cooling system.As a thermosta t is fit ted in the system, it i s

possible for the radiator block to freeze incold weather even though the enginerunning temperature is quite high; for thisreason, the use of an anti-freezing mixtureis essential.Only anti-freeze solutions recommended inSection 09 shouldbe used.Land-Rovers leavingthe factory have the cool-ing system filled with 50% mixture of anti-freezeand water. This givesprotection down to-20°C to-36°C.When the temperature is between DoC andminus 18°C (32°F and OaF), use one par t ofanti-freeze to twoparts ofwater.Proceed as follows:1 Ensure that the cool ing system is leak-

proof; anti-freeze solutions are far more'searching' at joints than water.

2 Drain and flush the system. Drain plugunder radiator at right-hand side.

3 Drain tap or plug for cylinder block4-cylinder at left -hand side of engineadjacent to dipstick. 6-cylinder at right-hand side of engine adjacent to enginebreather.

4 Pour in approximately 4,5 litres (onegallon) of water, add solution, thentop up with water to within 12 to 19mm (0.5 to 0.75 in.) below bottom offiller neck.

5 Run the engine to ensure a goodcirculation of the mixture.

NOTE: When anti-freeze is not required thecooling system must be flushed out with cleanwaterand refilledwith a mixture one part Mar-stons SQ36 inhibitor to nine parts ofwater.

(10)Radiator water level1 The radiator filler cap is under the

bonnet panel.

Diesel models2 Never run the engine without water,

not even for a very brief period,otherwise the injectors may beseriously damaged. This is due to thevery high rate of heat transfer in theregion of the injector nozzles.

care must be taken when removing theradiator f il ler cap, especially when theengine is hot.

4 When removing the filler cap first turnit anti-clockwise to the s top and allowall pressure to escape, before press ingit down and turning further in thesame direction to lift i t off .

5 When replacing the filler cap, it isimportant that it is tightened downfully, not just to the first stop. Fa ilureto t ighten the fil ler cap properly mayresult in water loss, with possibledamage to the engine through over-heating.

6 All models have a semi-sealed coolingsystem, that is, an overflow bottleattached to the left-hand side of theradiator.

7 The water level in the cooling systemis checked at the radiator only andtopping-up is also carried out in thenormal manner through the radiatorfill er. The pipe in the overflow bottl eshould always be submerged in water .

8 With a cold engine the correct waterlevel is 12 to 19 mm (0.5 to 0.75 in.)

below the bottom of the filler neck.For capacities see Division 09.Use soft water wherever possible; ifthe local water supply is hard, rain-water should be used.

(11)Water level, windscreen washer asapplicableThe windscreen washer reservoir (optionalequipment in some counties) , is located onthe right-hand bulkhead.1 Remove reservoir cap by turning anti-

clockwise.2 Top up reservoir to within approxi-

'mately 25 mm (lin. ) below bottom of

filler neck.3 Use Clearalex windscreen washerpowder in the bot tle; this will removemud, f lies and road film.

4 In cold weather, to prevent freezing ofthe water , add 'Isopropyl Alcohol' . DoNOT use methylated spiri ts , which hasa detrimental effect on the screen-washer impeller.

(11) Fan belt adjustment (14) Engine mountings

Check security of engine mountings;



4 cylinder models:

1 Check by thumb pressure between thefan and crankshaft pulleys, Movementshould be 6,3 to 9,5 mm (0.25 to0.375 in.)

If necessary adjust as follows:2 Slacken the pivot bolt securing the

alternator to the mounting bracket.3 Slacken the adjusting bolt.4 Pivot the alternator inwards or out-

wards as necessary and adjust until thecorrect belt tension is obtained.5 Tighten adjust ing and pivot bolts.

6-cy/inder models:6 Check by thumb pressure between the

fan and crankshaft pulleys. Movementshould be 8 to 11 mm (0.312 to 0.437in.) Adjust as above.

Air pump drive belt adjustment, 6-cylindermodels1 Check by thumb pressure midway

between the air pump and water pumppulleys. Movement should be 6,3 mm

(0.25 in.). If necessary, adj ust asfollows:

2 Slacken the pivot bolts securing the airpump to the top mounting bracket .

3 Slacken the nut and bolt securing theair pump to the adjustment bracket.

4 Pivot the air pump as necessary andadjus t unti l the correct belt tens ion isobtained.

5 Tighten the adjusting and pivot boltsand nuts.

(13)Accelerator liDkage-aU Models

1 Lubricate the accelerator l inkage us ing

clean engine oil paying particularattention to accelerator cross craftbrackets, bell crank bushes and balljoint sockets on the control rods.

2 Check the linkage for correct opera-tion and ensure that there is no

- tendency to s tick.f > Badly worn parts should be replaced as\0 soon as possible.

rectify as necessary.Engine sump bolts, seeoperation 12.60.44.

(IS) Engine breather filters-all ModelsClean as follows:I Remove the filters.2 Wash the gauze thoroughly by swi lling

the units in petrol.3 Re-wet the gauzes by dipping in clean

engine oi l and shake off the surplus;4-cylinder models , replace the enginebreather filter with the slot facingforward and the oil filler filter withthe slot facing the rear of the vehicle.

4 Models with sealed engine breathersystem. Connect hose to top breather.

(16)Crankcase emission control, name-traptype (as applicable)Replace as follows:

I Detach the rubber hoses from eachs ide of the f lame trap by compress ingthe clips.

2 Withdraw flame trap.3 Fit new flame trap by reversing

removal procedure.4 Warm up engine and re-adjust carbu-

retter if necessary.

oI

(17) Fuel' fil ter, paper element type=-Dieselmodels

(18) Fuel sedimenter-Diesel models

The sedimenter increases the working life



Drain off wa te r as fol lows :1 Slacken off dra in plug to allow water

to run out.2 When pure diesel fuel is emitted,

t ighten dra in plug.

Change filter element as follows: In someinstances it may be advantageous tor emove the comp lete unit befor e attemp t-ing to change the f il te r e lement .3 Support element holder.4 Unscrew the special bolt on the top of

the filter, the element holder cart nowbe removed.

5 Remove and discard the used element.

6 Wash the element holder in petrol orfuel oil .

7 If necessary renew both the largerubber washer and the small rubber

washer in the filter top, also renew thelarge rubber washer in the elementholder.

8 Push the new element on to the filtertop spigot with the perforated holes in

the element to the top.9 Fit the element holder to the bottom

of the element, and secure with thespecial bolt.

10 Prime the system and check for fuelleaks.

o

Fuel f il te r e lement , 6-cy linder model s

The fuel filter element, located on the dashat the right-hand side of the engine com-partment, provides additional filtrationbetween pump and carburetter.Replace element as fol lows:I Support element holder.

2 Unscrew the special bolt at bottom offilter. The element holder can now beremoved.

3 Remove and d iscard the u sed element.4 Thoroughly clean the element holder

in petrol.5 If necessary renew the upper and

lower centre seals and also the seal forthe centre bolt .

6 Fit the new element, large hole upper-most into the holder using the sealsuppli ed with the e lement .

7 Place the element holder in positionand secu re with the special bolt.

8 Start the engine and check for fuelleaks.

of the fuel filter by removing the largerdroplets of water and larger particles off oreign matter fr om the fuel.

Dra in off wa te r as fol lows :Slacken off drain plug to allow water

to run out.2 When pure diesel fuel is emitted,

tighten drain plug. Dismantle and

c lean as detai led below.3 Disconnect fuel inlet pipe at sedi-

menter and raise pipe above level offuel tank to prevent draining fromtank. Suppor t in this po sition.

4 Suppor t sed imenter bowl and unscrewbolt on top of unit.

5 The lower bowl and element can nowbe removed.

6 Clean a ll par ts in pet ro l.7 Fit new oil seals and reverse removal

procedure.8 Slacken off the drain plug, when pure

diesel fuel runs out tighten plug. Starteng ine and check for air leak s.

(19) Air injection system-6-cylinder modelsmodels

The air pump driven by the engine, deliversair to the exhaust valves via the air rail. A

check valve prevents damage to the pumpshould backfire or belt breakage occur. A

relief valve, located in the air pump, isrequired to dump part of the air at highspeeds to p revent pump damage.

LAND ROVER SIII Introduction and Index

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Transcript of LAND ROVER SIII Introduction and Index