Land Rover part 6 brakes, bodywork, electrical Workshop Manual

[1—0L
Assembling
20 During assembly, smear the seals with
Castrol-Girling rubber grease and the
remaining internal items with Castrol-
Girling Brake and Clutch Fluid.
21 Fit the valve seal, flat side first, to the
end of the valve stem.
22 Fit the wave washer, domed side
toward the valve head.
23 Fit the valve spacer, legs first.
24 Fit the valve retainer.
25 Locate the spring over the retainer and
squarely seat on the valve spacer.
26 Insert the inner piston into the spring
and compress until the locking prong
on the valve retainer engages in the
groove in the piston. If necessary,
depress the locking prong to ensure
that the free end is fully engaged with
the groove shoulder.
27 Fit the piston seal.
28 Insert the inner piston and valve
assembly, valve end first, into the
cylinder.
29 Reverse 5 to 9. Torque loading for
tipping valve retainer is 4,9 to 6,2 kgf.
т. (35 to 45 Ibf. ft.).
30 Reverse 2 to 4. Do not overtighten the
reservoir fixings. Torque load 0,3 to
0,4 kgf. m. (2 to 3 1bf. ft.).
31 Refit the master cylinder. 70.30.08.
IRC 726
IRC 727 26 27
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4RC 1065
DATA
Master cylinder bore size:
88 models .......................
109 models ......................
22,2 mm (0.875 in.) diameter
25,4 mm (1.0 in.) diameter
FLUID RESERVOIR Non-Servo
Systems
Remove and refit 70.30.15
Removing
1 Lift the bonnet and prop open.
2 Make provision to catch the fluid
which will be released.
3 Disconnect the fluid outlet pipe.
4 Remove the clamp fixings.
5S Withdraw the reservoir.
R
6
7
8
efitting
Reverse instructions 2 to 5.
Bleed the hydraulic system. 70.25.02.
Close the bonnet.
¡RC 728
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BRAKE PEDAL, Non-servo systems —
Remove and refit 70.35.01 + A
Removing
1 Lift and prop the bonnet.
2 Disconnect the inlet pipe at the master
cylinder.
3 Disconnect the outlet pipe.
4 Disconnect the return spring from the
brake pedal.
5 Remove the fixings securing the brake
pedal bracket to the toe box.
6 Carefully withdraw the brake pedal
and bracket assembly from the engine
compartment, manoeuvring the pedal
through the aperture in the toe box.
7 Remove the top cover and gasket from
the brake pedal bracket.
8 Remove the nut and plain washer
retaining the master cylinder push rod
to the brake pedal trunnion, and push
the rod into the master cylinder to
clear the trunnion.
9 Using a suitable punch, drift out pin,
from the pedal shaft.
10 Remove pedal shaft.
11 Withdraw the brake pedal complete
with bushes and trunnion.
12 If required, remove the bushes, trun-
nion and distance piece from the brake
pedal.
continued IRC730
cI-—0L
Refitting
13 If removed, fit the distance piece,
trunnion and bushes to the brake
pedal. Lubricate the trunnion and
distance piece with general purpose
grease on assembly. New pedal bushes
must be reamed to 15,9 mm (0.75 in).
14 Smear the pedal bushes and shaft with
general purpose grease; locate the
pedal in position in the bracket and
secure with the shaft and pin.
15 Locate the master cylinder push rod
through the pedal trunnion and fit the
locknut and washer.
16 Remove the oil plug from the pedal
shaft; fill the shaft bore with SAE 20
oil, then replace the plug and joint
washer.
(Non-Servo systems)
17 Place the gasket in position on the
securing flange of the brake pedal
bracket. If necessary, use a little
Bostik adhesive to retain the gasket.
18 Carefully locate the brake pedal and
bracket assembly in position on the
toe box, manoeuvring the pedal
through the aperture in the toe box.
19 Secure the brake pedal and bracket
assembly to the toe box, ensuring that
the gasket remains in position.
Master cylinder and pedal setting, items 20
to 25
20 Slacken both nuts on the master
cylinder push rod.
21 Check the pedal setting which should
be 158 mm (6.250 in.) with the stop
light switch depressed to the “off”
position.
22 Adjust the pedal stop, as required, to
obtain the correct distance.
23 Adjust the master cylinder push rod
until there is 1,55 mm (0.062 in.)
approximately free play between the
push rod and the master cylinder
piston.
24
25
26
27
Tighten both locknuts.
Ensure there is 3,17 mm (0.125 in.)
minimum free movement at the pedal
before pressure is felt. If necessary,
re-adjust the master cylinder push rod
to obtain the movement.
Fit the pedal bracket cover and gasket.
Reverse instructions 1 to 4.
BRAKE PEDAL, Servo Systems
Remove and refit 70.35.01
Removing
1 Disconnect the electrical lead from the
stop light switch.
2 Disconnect the outlet pipe/s from the
master cylinder. Fit a blanking plug to
the outlet aperture/s or drain the fluid
reservoir, to prevent fluid spillage.
NOTE: The illustration inset shows a
tandem master cylinder, where fitted.
3 Disconnect the vacuum pipe from the
servo unit. |
Remove the toe-board finisher panel.
Remove the fixings securing the brake
pedal bracket to the toe box.
Withdraw the brake pedal and bracket
assembly from the engine compart-
ment, manoeuvring the pedal through
the aperture in the toe box.
7 Disconnect the brake pedal return
spring. |
8 Remove the split pin and pivot pin
from the brake pedal to servo
coupling.
9 Using a suitable punch, drift out pin
from the pedal shaft.
10 Remove the pedal shaft.
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continued
IRC 733
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IRC 734
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(Servo Systems)
11 Withdraw the brake pedal complete
with bushes.
12 If required, remove the bushes from
the pedal.
Refitting
13 If removed, fit the bushes to the brake
pedal. New bushes must be reamed to
15,9 mm (0.75 in).
14 Reverse instructions 7 to 10, using
general purpose grease to lubricate
moving parts.
15 Apply a waterproof sealant between
the joint flanges of the pedal bracket
and the toe box.
16 Reverse instructions 1 to 6.
17 Check, and if necessary, adjust the
brake pedal switch located on the
pedal box top cover to operate at
19mm to 25mm (0.750 in. to 1 in.) of
pedal movement.
18 Bleed the complete braking system.
70.25.02.
BRAKE SHOES - 88 models
Remove and refit
Front shoes
Rear shoes
70.40.02
70.40.03
Removing
Remove the road wheel.
Remove the brake drum. 70.10.02 or
70.10.03 as applicable.
DD a
3 Remove the leading shoe pull-off
spring.
4 Remove the trailing shoe anchor plate.
5 Withdraw the brake shoes together
from the pivot end first; part them by
disconnecting the return spring.
6 Retain the pistons in the wheel
cylinder, using a rubber band.
7 If required, re-line the brakes.
70.40.10. |
DATA
Brakeshoewidth ....................
IRC735
Refitting
Reverse 2 to 6, refitting the leading
shoe pull-off spring with its longest
extremity hooked over the post on the
shoe web.
9 Adjust the brakes fully on, then back
off two serrations on the adjuster.
10 Fit the road wheel.
38 mm (1.5 in.)
FRONT BRAKE SHOES —
109 models
Remove and refit 70.40.02
Removing
1 Remove the road wheel.
2 Remove the brake drum. 70.10.02. —
3 Release the brake shoes and pull-off
springs by levering the trailing edges
away from the wheel cylinders.
4 Retain the pistons in the wheel
cylinders, using a rubber band.
S If required, re-line the brake shoes.
70.40.10. |
Refitting
NOTE: Ensure that the correct width of
brake shoe is fitted as follows:
109 models with 4-cylinder engines
—57 mm (2.250 in.) wide; 109 models
with 6-cylinder engines — 76 mm (3.0
in.) wide.
6 Reverse instructions 2 to 4.
7 Adjust the brakes fully on, then back-
off two serrations on the adjusters.
8 If the brake shoe steady posts have
been disturbed, reset as follows, items
9 to 11.
9 Screw back the steady posts clear of
the brake shoes and apply the brakes.
10 Screw in the steady posts to contact
the brake shoes then secure.
11 Do not tilt the brake shoes by screw-
ing in the steady posts too far.
12 Fit the road wheel.
DATA
Brake shoe width
4 cylinder engine models ............
6 cylinder engine models ............
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IRC 683 | 7 3 д
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IRC 686
57 mm (2.250 in.)
76 mm (30 in.).
rIOL
REAR BRAKE SHOES —
109 models
Remove and refit 70.40.03
Removing
Remove the road wheel.
Remove the brake drum. 70.10.03.
Release the brake shoes by levering the
shoes away from the pivot.
Disconnect the springs.
Retain the pistons in the wheel
cylinder, using a rubber band.
If required, re-line the brake shoes.
70.40.10.
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Refitting
7 Reverse instructions 2 to 4.
8 Adjust the brakes fully on, then back-
off two serrations on the adjuster.
9 Fit the road wheel.
BRAKE LININGS
Remove and refit 70.40.10
Removing
1 Remove the brake shoes.
2 Remove the old linings from the shoes
by shearing the riveted end of the
rivets.
NOTE: Brake shoes fitted with bonded
linings: If the shoes incorporate rivet holes,
the bonded linings can be removed and
riveted linings can be fitted in their place.
If the shoes are not pre-drilled, replace-
ment shoe and lining assemblies must be
TRANSMISSION BRAKE, HAND
LEVER AND LINKAGE
Remove and refit 70.45.01
Removing
CAUTION: Before commencing work on
the hand brake mechanism, chock the road
wheels to prevent the vehicle moving.
1 From under the vehicle, disconnect
the hand brake expander rod from the
relay lever.
2 Remove the relay lever fixings.
3 LHStg models—-Remove the fixings
between the hand brake cross-shaft
and the R.H. chassis member.
4 Remove the fixings securing the hand
brake lever to the chassis.
5 Remove the hand brake assembly com-
plete from the vehicle, withdrawing
the lever grip carefully through the
rubber draught excluder in the front
of the seat box.
LHStg models—To facilitate removal,
release the hand brake lever to ratchet
fixings and withdraw the cross-shaft
and lever separately.
6 LHStg models—If required, remove the
split housings from the cross-shaft
support brackets.
7 Remove the felt dust seals and self-
lubricating bushes supporting the hand
brake cross-shaft.
continued
1RC903
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Attach the new linings to the shoes, IRC736"
commencing at the centre and working
outwards, but peen the rivets only |
sufficient to locate the linings. 6
4 With all the rivets loosely fitted, fully
secure, commencing from the centre.
Chamfer both ends of each lining.
Fit the brake shoes. IRC 906
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‚8 Remove the brake catch pin, catch and
distance pieces.
9 RHStg models—Remove the fulcrum
pin, ratchet fixings and ratchet from
the hand brake lever.
10 Unscrew the plunger and withdraw the
spring, washer and the plunger rods.
11 If required, remove the relay lever and
spindle. If necessary, press the bush
from the lever.
Refitting
12 If removed, fit the bush to the relay
lever and fit the relay lever and spindle
to the chassis.
NOTE: The bore size of a new relay lever
bush is 19,088 mm—0,0254 mm (0.7515
in. —0.001 in.).
13 Reverse instructions 1 to 11; lubricate
the cross shaft bearings with general
purpose grease.
14 Set the hand brake linkage at the
vertical adjuster rod, so that the hand
brake has one or two clicks free
movement in the “off” position.
Key to hand brake lever arrangement, RH Steering
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‘Bolt (# in UNF x 1% in long) ) Fixing
Hand brake lever
Plunger rod, upper
Plunger rod, lower
Washer for plunger spring
Spring for plunger rod
Plunger
Ratchet for hand brake
lever to
ratchet
Plain washer
Self-locking nut ( # in UNF)
Brake catch
Pin
Distance piece
Plain washer
Split pin
Pin for hand brake adjuster rod
Plain washer 1 Fixing pin to
} Fixing catch
Split pin J hand brake lever
Fulcrum pin for hand brake lever
Plain washer | Fixing pin
Spring washer / to ratchet
Split pin and lever
Spring washer brake lever to
Bolt (# in UNF x 3 in Le Fixing hand
Nut (#in UNF) chassis frame
91—0L
VO 00 Y ON Cn LV 0 =
Key to hand brake lever arrangement LH Steering
Housing-—cross shaft bearing
Bolts
Spring washer
Felt ring
Bearing—cross shaft
Distance piece
Support plate
Split pin
Pin--adjuster rod
Plain washer
Spring washer
Bolt
Cross shaft
Nut —self-locking
Plate washer
Washer
Shaft
Relay lever
Bush
Washer
Circlip
Spring anchor
Spring
Clevis pin
Fork—clevis
Split pin
Spring anchor
Nut
Rod
Nut-self-locking
Clevis pin
Split pin
Plain washer
Washer
Ratchet
Bolt
Plain washer
Distance piece
Pawl
Plunger rod—lower
Plunger rod—upper
Hand brake lever
Washer
Spring
Plunger
LI—0L
TRANSMISSION BRAKE
ASSEMBLY
Adjust. Instructions 36 to 39 70.45.09
Remove and refit
Instructions 1 to 39 70.45.16
TRANSMISSION BRAKE SHOES
Remove and refit
Instructions 1 to 7, and
32 to 39 70.45.18
Removing
NOTE: Brake shoe components are acces-
sible after removing the brake drum, which
can be detached from the gearbox output
flange and pushed back over the propeller
shaft.
Chock the road wheels.
Disconnect the brake return spring.
Remove the expander rod fork fixings.
Disconnect the expander rod from the
relay lever, and remove the propeller shaft
on the 109 in Land-Rover.
5 Remove the fixings and withdraw the
brake drum.
6 Remove the brake shoes together with
the pull-off springs. |
7 Separate the shoes by detaching the
8
9
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springs.
Withdraw the dust excluder.
Remove the expander unit fixing
plates.
10 Withdraw the expander unit.
11 Remove the spring clip from the
expander unit. |
12 Withdraw the plungers and rollers.
13 Withdraw the operating rod.
14 Remove the adjuster unit assembly.
15 Pull out the adjuster plungers.
16 Unscrew the adjuster cone.
IRC738
Inspecting
17 Clean all components in Girling clean-
ing fluid and allow to dry.
18 Examine all items for obvious wear
and replace as necessary.
19 Examine the brake drum for scoring
and ovality and skim if required.
Standard diameter is 228,6 mm (9.0
in.); reclamation limit is 0,75 mm
(0.030 in.) oversize.
20 If the brake linings are oily, check and
if necessary replace the output shaft
oil seal, Division 37.
21 If required, reline the brake shoes.
70.40.10.
Assembling
22 Fit the adjuster unit housing, do not
tighten the fixings at this stage.
23 Screw in the adjuster cone.
24 Grease and refit the adjuster plungers.
NOTE: The two plungers are identical and
may be fitted to either bore. Align the
chamfered ends of the plungers with the
cone on the adjuster.
continued
IRC 740
81--0/
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Grease and fit the expander rod.
Grease and fit the plungers and rollers.
Position the adjuster housing on the
back plate.
Fit the packing piece.
Fit the locking plate.
Fit the retainer spring.
Fit the spring clip to the expander
unit.
Fit the brake shoes and pull-off springs
together.
The fully lined end of the lower shoe
must be toward the expander housing.
The fully lined end of the upper shoe
must be toward the adjuster housing.
Reverse instructions 2 to 5.
Turn the adjuster cone fully in and
tighten the fixings.
Slacken off the adjuster cone two
‘clicks’; give the brake a firm applica-
tion to ensure that the shoes have
centralised at the expander end. The
brake drum should now be free to
rotate.
Set the hand brake linkage at the
vertical adjuster rod, so that the hand
brake has one or two clicks free
movement in the ‘off’ position.
Remove the road wheel chocks.
SERVO ASSEMBLY
Remove and refit 70.50.01
Removing
1 Remove the brake master cylinder.
70.30.01 or 70.30.08 as applicable.
Disconnect the vacuum hose from the
servo assembly.
Remove the switch plate.
Remove the rubber plugs from the
pedal box.
Remove the split pin and withdraw the
clevis pin securing the servo rod to the
pedal.
6 Remove the fixings.
7 Withdraw the servo assembly.
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Refitting
8 Reverse instructions 1 to 7. Torque
load for servo fixings is 1,2 kgf. m. (9
1bf. ft.).
VACUUM RESERVOIR TANK —
Diesel models with Servo
Remove and refit 70.50.04
34, 4 Removing
| @ 1 Remove the union bolt and washers
securing the vacuum pipes to the
vacuum tank.
2 Remove the bolts, washers and nuts
securing the vacuum tank brackets to
the vehicle.
3 Withdraw the vacuum tank and
brackets from the vehicle.
4 Remove the brackets from the vacuum
tank.
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Refitting
5 Reverse instructions 1 to 4.
61—0L
SERVO ASSEMBLY
Overhaul 70.50.06
NOTE: The Supervac servo unit can be
serviced, with a kit that is available, with-
out completely dismantling the servo. In
the event of the servo developing a major
fault, the unit must be renewed.
Dismantling
Remove the servo. 70.50.01.
Pull back the dust cover.
Remove the end cap.
Withdraw the filter.
Remove the seal and plate assembly
from the front shell recess.
Remove the non-return valve and
grommet.
CAUTION: Do not attempt to remove
or adjust the operating rod which is
pre-set and locked at the manufac-
turers.
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Reassembling (using the service kit)
8 Lubricate the non-return valve grom-
met with Girling Grease (64949009),
and fit to the front shell.
9 Fit the new non-return valve into the
grommet.
10 Smear the new seal and plate assembly
with Girling Grease (64949008), and
press into the front shell, ensuring the
plate faces inwards.
11 Fit the new filter into the neck of the
diaphragm plate.
12 Fit the new end cap.
13 Locate the new dust cover over the
lugs of the rear shell.
14 Fit the servo. 70.50.01.
1RCSOBA
WHEEL CYLINDER, 88 models
Front wheel cylinder
Remove and refit. Instructions 1 to §
and 14 to 18 — 70.60.03
Overhaul. Instructions 6 to 13 70.60.11
Rear wheel cylinder
Remove and refit. Instructions 1 to 5
and 14 to 18 70.60.18
Overhaul. Instructions 6 to 13 70.60.26
Removing
1 Remove the road wheel.
2 Remove the brake drum. 70.10.02.
3 Remove the brake shoes. 70.40.02.
4 Disconnect and seal the brake fluid
pipe.
5 Remove the wheel cylinder.
Dismantling
6 Withdraw the dust covers.
7 Withdraw the pistons and seals.
8 Withdraw the seal supports.
9 Withdraw the spring.
10 Remove the bleed screw.
Inspecting
11 Clean all components, using Girling
cleaning fluid, and allow to dry.
12 Inspect the cylinder bore and pistons
for corrosion, scores and wear. If any
component is not satisfactory, replace
the complete wheel cylinder assembly.
13 Provide new seals and dust covers from
the wheel cylinder overhaul kit.
Assembly
14 Lubricate the components, using the
recommended Girling brake fluid.
15 Reverse 6 to 9. Fit the piston seal with
the flat face toward the piston.
16 Fit the bleed screw, do not over-
tighten. Torque 0,5 to 0,8 kgf. m. (4
to 6 1bf. ft.).
Refitting
17 Reverse instructions 1 to 5.
18 Bleed the brakes. 70.25.02.
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02-0;
FRONT WHEEL CYLINDERS —
109 models
Remove and refit. Instructions 1 to §
and 16 and 17 70.60.03
Overhaul. Instructions 6 to 15 70.60.11
Removing
Remove the road wheel.
Remove the brake drum. 70.10.02.
Remove the brake shoes. 70.40.02.
Disconnect and seal off the brake fluid
pipe.
Remove the bleed screw (lower
cylinder only).
6 Remove the wheel cylinder.
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Dismantling
7 Withdraw the dust cover.
8 Withdraw the piston and seal.
9 Withdraw the spring.
Inspecting
10 Clean all components, using Girling
cleaning fluid, and allow to dry.
11 Inspect the cylinder bore and piston
for corrosion, scores and wear. If any
component is unsatisfactory, replace
the wheel cylinder assembly complete.
12 Provide new seals and dust covers from
the wheel cylinder overhaul kit.
Assembling
13 Lubricate the components, using the
recommended Girling brake fluid.
14 Reverse instructions 6 to 8. Fit the
piston seal with the lipped side away
from the slotted end.
15 Fit the bleed screw, do not over-
tighten. Torque 0,5 to 0,8 kgf. m. (4
to 6 1bf. ft.).
Refitting
16 Reverse instructions 1 to 5.
17 Bleed the brakes. 70.25.02.
IRC 684A
IRC 685
REAR WHEEL CYLINDER - 109
models
Remove and refit. Instructions 1 to §
and 16 and 17 70.60.18
Overhaul. Instructions 6 to 15 70.60.26
Removing
1 Remove the road wheel.
2 Remove the brake drum. 70.10.03.
3 Remove the brake shoes. 70.40.03.
4 Disconnect and seal off the brake fluid
pipe.
5 Remove the wheel cylinder.
Dismantling
6 Withdraw the dust covers.
7 Withdraw the pistons and seals.
8 Withdraw the spring and seal supports.
9 Remove the bleed screw.
Inspecting
10 Clean all components, using Girling
cleaning fluid, and allow to dry.
11 Inspect the cylinder bore and piston
for corrosion, scores and wear. If any
component is unsatisfactory, replace
the wheel cylinder assembly complete.
(109 models)
12 Provide new seals and dust covers from
the wheel cylinder overhaul kit.
Assembling
13 Lubricate the components, using the
recommended Girling brake fluid.
14 Reverse 6 to 8. Fit the piston seal with
the lipped side away from the slotted
end.
15 Fit the bleed screw, do not over-
tighten. Torque 0,5 to 0,8 kgf. m. (4
to 6 Ibf. ft.).
Refitting
16 Reverse instructions i to 5.
17 Bleed the brakes. 70.25.02.
I-#L
WHEELS AND TYRES
General 74.10.00
Tyres of correct type and dimension form
an essential part of vehicle design. Regular
tyre inspection and maintenance con-
tributes not only to safety but also to the
proper functioning of the vehicle. Road
holding, steering and braking can be
impaired by incorrect tyre pressure, badly
fitted tyres and by worn treads.
Tyres of the same size but of different
makes and tread patterns may possess
widely varying characteristics. For this
reason it is advised that tyres of the same
make, type and tread pattern are fitted to
all wheels. Tyres of different dimensions,
even if paired, must never be fitted or
transmission ‘wind-up’ on four wheel drive
will occur. This will stress transmission
components,
Where chevron tread type tyres are fitted
the apex of the vee must lead in the
direction of forward wheel rotation. Atten-
tion to this factor is necessary when
interchanging wheels.
Refer to Section 04 for wheel and tyre
data.
Wheel nuts
Wheel nuts should be evenly tightened to
10,3 to 11,7 kgf m (75 to 85 1bf ft).
Wheel tolerance
Lift
On a truly mounted and revolving wheel
the difference between the high and low
points measured at any location on either
tyre seat should not exceed 2,30 mm
(0.090 in.) maximum; 1,50 mm (0.060 in.)
desired.
Wobble
The lateral variation measured on the
vertical inside face of a flange should not
exceed 2,30 mm (0.090 in.) maximum;
1,50 mm (0.060 in.) desired.
[—9L
BODY REPAIRS
General information 76.00.00
Body panels
1 Land Rover body panels are manufac-
tured from a special aluminium-alloy
known as ‘Birmabright’.
‘Birmabright’ melts at a slightly lower
temperature than pure aluminium and
will not rust nor corrode under normal
circumstances. It is work-hardening,
but is easily annealed. Exposed to the
atmosphere, a hard oxide skin forms
on the surface.
Panel beating ‘Birmabright’
3
‘Birmabright’ panels and wings can be
beaten out after accidental damage
then must be annealed, by the applica-
tion of heat, followed by slow air-
cooling; as the melting point is low,
heat must be applied slowly and care-
fully. A practical temperature control
is to apply oil to the cleaned surface to
be annealed. Play the welding torch on
the underside of the cleaned surface
and watch for the oil to clear, leaving
the surface clean and unmarked; then
allow to cool naturally in the air, when
the area so treated will again be soft
and workable. Do not quench with oil
or water. Another method is to clean
the surface to be annealed and then
rub it with a piece of soap. Apply heat
beneath the area, as described above,
and watch for the soap stain to clear.
Then allow to cool, as for the oil
method. When applying the heat for
annealing, always hold the torch some
little distance from the metal, and
move it about, so as to avoid any risk
of melting it locally.
Gas welding ‘Birmabright’
4
A small jet must be used, one or two
sizes smaller than would be used for
welding sheet steel of comparable
thickness. For instance, use a No. 2
nozzle for welding 18 swg (0.048 in.)
sheet, and a No. 3 for 16 swg (0.064
in.) sheet.
Ts
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77
The flame should be smooth, quiet
and neutral and have a brilliant inner
core with a well defined, rounded end.
The hottest point of the flame is close
to the jet, and the flame should have a
blue to orange envelope becoming
nearly colourless at the end.
A slightly reducing flame may also be
used, that is, there may be a slight
excess of acetylene. Such a flame will
have a brilliant inner core with a
feathery white flame and a blue to
orange envelope.
Do not use an oxydising flame, which
has a short pointed inner core bluish
white with a bluish envelope.
10
11
Use only 5 per cent magnesium/
aluminium welding rod (5 Mg/A). Sifa-
lumin No. 27 (MG.5 Alloy) (Use Sif-
bronze Special flux with this rod) or a
‘Birmabright’ offcut sheet. Do not use
too wide or thick an offcut or trouble
may be experienced in making it melt
before the material which is being
welded. |
Clean off all grease and paint, dry
thoroughly then clean the edges to be
welded, and an area at least half an
inch on either side of the weld, with a
stiff wire scratch-brush or wire wool.
Cleanliness is essential. Also clean the
welding rod or strip with wire wool.
A special acid flux must be used, and
we recommend “Hari-Kari’ which is
obtainable from:
The Midland Welding Supply Co. Ltd.,
105 Lakey Lane,
Birmingham 28, England.
or
Sifbronze Special Flux,
obtainable from:
Suffolk Iron Foundry (1920) Ltd.,
Sifbronze Works,
Stowmarket, England.
A small quantity of “Hari-Kari” may be
made into a paste with water, follow-
ing the directions on the tin, and the
paste must be applied to both surfaces
to be welded and also to the rod. In
the case of Sifbronze Special Flux, use
in powder form as directed. Remem-
ber that aluminium and its alloys do
not show “red-hot” before melting, and
so there is nothing about the ap-
pearance of the metal to indicate that
it has reached welding temperature. A
little experience will enable the opera-
tor to gauge this point, but a useful
guide is to sprinkle a little sawdust
over the work; this will sparkle and
char when the right temperature is
approached; a piece of dry wood
rubbed over the hot metal will sparkle
at the point of contact.
which is
12
13
14
As the flux used is highly acid, it is
essential to wash it off thoroughly
immediately after a weld is completed.
The hottest possible water should be
used, with wire wool or a scratch-
brush. Very hot soapy water is good,
because of the alkaline nature of the
soap, which will tend to ‘kill’ the acid.
It is strongly recommended that a few
welds are made on scrap metal before
the actual repair is undertaken if the
operator is not already experienced in
welding aluminium and its alloys.
The heat of welding will have softened
the metal in the area of the repair, and
it may be hardened again by peening
with a light hammer. Many light blows
are preferable to fewer heavy ones.
Use a ‘dolly’ or anvil behind the work
to avoid denting and deformation, and
to make the hammering more effec-
tive. Filing of surplus metal from the
weld will also help to harden the work
again.
Welding tears and patching
15
16
17
18
If a tear extends to the edge of a
panel, start the weld from the end
away from the edge and also at this
point drill a small hole to prevent the
crack spreading, then work towards
the edge.
When welding a long tear, or making a
long welded joint, tack the edges to be
welded at intervals of from 50 to 100
mm (2 in. to 4 in.) with spots. This is
done by melting the metal at the
starting end and fusing into a small
amount of the filler rod, repeating the
process at the suggested intervals.
After this, weld continuously along
the joint from right to left, increasing
the speed of the weld as the material
heats up.
After the work has cooled, wash off all
traces of flux as described previously,
and file off any excess of build-up
metal.
When patching, cut the patch to the
correct shape for the hole to be filled,
but of such size as to leave a gap of 0,8
mm (0.030 in.) between it and the
panel, and then weld as described
above. Never apply an ‘overlay’ patch.
continued
TIL
Electric welding
19
20
CAUTION: The battery earth lead
must be disconnected before com-
mencing electric welding, otherwise
the alternator will be damaged.
At the Rover Factory the ‘Argon-Arc’
process is used, all atmospheric oxygen
being excluded from the weld by the
Argon gas shield. For all body repair
work normally undertaken by a Distri-
butor’s or Dealer’s service department,
the gas welding method is sufficient
and quite satisfactory.
Spot-welding
21
Spot-welding is largely used in the
manufacture of Land-Rover bodies,
but this is a process which can only be
carried out satisfactorily by the use of
the proper apparatus. Aluminium and
its alloys are very good conductors of
heat and electricity, and thus it is most
important to maintain the right condi-
tions for successful spot-welding. The
correct current density must be main-
tained, and so must the ‘dwell’ of the
electrodes. Special spot-welding
machines have been developed, but
they are expensive, and though the
actual work can be carried out by
comparatively unskilled labour, super-
vision and machine maintenance must
be in the hands of properly qualified
persons.
Riveting
22
Where both sides of the metal are
accessible and it is possible to use an
anvil or ‘dolly’, solid aluminium rivets
may be used, with a suitable punch or
‘pop’ to ensure clean, rounded heads
on the work. For riveting blind holes,
‘pop-rivets’ must be used. These are
inserted and closed by special ‘Lazy-
Tong’ ‘pop-rivet’ pliers.
Painting ‘Birmabright’
23 Refer to the procedure detailed in
Paintwork Section 78.
0917
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Radiator grille, front apron and grille panel
Key
1 Radiator grille.
2 Front apron panel
3 Horn protector plate
4 Radiator grille panel
5 Bonnet rest strip
£—9L
Bonnet
Key
1 Bonnet control
2 Washer plate
3 Striker pin
4 Bonnet
5 Hinge
6 Bush — bonnet hinge
7 Pivot pin
8 Bonnet prop
Dash
Key
1 Pedal hole cover plate
2 Nutserts
3 Drive fasteners
4 Backing plate for seal
5 Seal
6 Pedal hole cover plate
7 Heater hole cover plate
8 Nutserts
9 Dash panel
10 Tie bolts, dash to chassis
P—9L
Ventilator and flyscreen
Key
1 Dash ventilator lid
2 Air flow divider panel
3 Fascia — support panel
4 Ventilator mechanism assembly
5 Blanking plate
6 Flyscreen
7 Sealing rubber
8 Hinge pin
$—9L
Rear body — 88
Key
1
2
3
4
5
6
7
8
9
1
1
Front end panel
Nut plate
Rivet
Shim
Body side — right hand
Rear mounting angle
Floor panel
Body side — left hand
Stay
O Cross member
1 Shim
Rear body — 109 (Except station wagon)
Key
pt = О 09 -3 ON 1 PWD DD ee
—. CO
Shim
Front end panel
Body side, right hand
Rear mounting angle
Shim
Nut plate
Cover plates
Floor panel
Stay
Body side, left hand
Cross member
9—9;
Body — 109 Station Wagon
Key
1
2
3
4
5
6
7
8
9
1
1
Floor — intermediate
Sealing rubber
Floor — rear
Shim
Body side, right hand
Mounting angle
Nut plate
Body side, left hand
Stay
Front extension, left hand
Sealing rubber
mi CC
Front Door
Key
Door seal
Door seal — side frame
Fixed glass
Packing strip
Glass channel — bottom
Retainer
Channel
Sealing rubber
Buffer
Channel
Filler
Sliding glass
Filler
Channel
Side screen frame
Sealing strip
Plug — window catch
Capping
Door seal
Door — front
Door seal
Seal — window catch
Mask — window catch
Window catch
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L—IL
Sealing rubber
Door glass — sliding
Door — rear — 109 station wagon
10
11
12
13
14
15
16
17
Retainer
Channel
Filler
Packing strip
Channel
Channel
Packing strip
Rear door
Seal retainer
Protection strip
A Un A 3 59 —
Glass retainer strip — bottom
Tail door — station wagon
Glass retainer strip — side
Arch-hard top
Sealing rubber
Glass retainer — corner piece
Glass retainer strip — top
Seal
8—9L
Cab and tropical roof
Key
Cab roof
Sealing rubber, door top
Retainer for seal
Cab rear panel assembly
Rubber seal, roof to back panel, top
Rubber seal back panel to rear body
Sliding back light
Sealing rubber for back light
Channel for rubber
10 Channel, top and bottom For
11 Channel, sides back light
12 Back light catch
13-16 Fixing for catches
17 Runner for sliding back light catch
18 Cab quarter light, RH
19 Cab quarter light, LH
20 Weather strip For quarter
21 Sealing strip light
22 Sealing rubber, windscreen to roof
23 Sealing rubber, door side
24 Mounting stud
25 Mounting rail for cab
26 Mounting rail support bracket
27 Cab mounting distance piece
28 Cab tropical roof panel
29 Distance piece Fixing tropical roof
30 Rubber panel to cab roof
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Body, roof — 88 station wagon
Key
Sealing strip
Stiffener strip
Roof
Corner capping
Spacer
Rubber washer
Tropical roof
Weather strip
Roof glass
Filler strip
Seal retainer
Rubber seal
Ventilator
Retainer plate
Seal
Í
O
©
o
=
Roof trim — 88 station wagon
Key
RR SUN =
Bracket
Trim panel
Roof trim
Centre strip
Head cloth
Side rail
Bracket
01—9L
co] NU SUN =
Body roof — 109 station wagon
Key
Sealing strip
Roof
Corner capping
Spacer
Rubber washer
Tropical roof
Stiffener
Weather strip
Roof glass
Filler strip
Sealing rubber
Rubber seal
Ventilator
Retainer plate
Seal retainer
Rubber seal
Roof trim — 109 station wagon
Key
Bracket
Trim panel
Roof trim
Centre strip
Headcloth
Headcloth
Strip
Cant rail — rear
Casing
Side rail
Casing
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11-9L
Side panel and fixings — station wagon
Key
Drain channel
Sealing rubber
Sealing rubber
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Rear windows — station wagon
Key
Channel
Channel
Channel
Glass
Channel
Catch
Channel
Runner
Packing strip
Channel
Glazing strip
Retainer strip
Retainer strip
Glass
cI-—9L
CHASSIS FRAME
Alignment check 76.10.02
Procedure
With the vehicle assembled a check for
chassis ‘squareness’ can be made as follows.
Instructions 1 to 7.
1 Place the vehicle on a level floor.
2 Hold a plumb line against one of the
measuring points as illustrated. (The
measuring points are the fixed spring
shackle locations.)
3 Mark the floor directly beneath the
plumb-bob.
4 Repeat items 2 and 3 at the remaining
measuring points.
NOTE: When measuring diagonals, ensure
that exactly corresponding points are used
on each side of the chassis frame.
5 Move the vehicle and measure between
the chalk marks.
6 The diagonals between the related
measuring points should agree within
9,5 mm (0.375 in.).
7 Using a suitable trammel, make com-
parative side-to-side checks between
the front suspension front shackle pin
and the rear wheel hub centre.
8 With the vehicle upper structure
removed, comparative side-to-side
checks for chassis frame misalignment
can be made, using as datums the 9.5
mm (0.375 in.) diameter holes pro-
vided in the No. 2 and also in the
rearmost cross-member.
NOTE: The vehicle front bumper is re-
garded as the No. 1 cross-member.
9 Chassis frame dimensional checks can
be made referring to the applicable
illustration and associated key.
2RCHI
Chassis frame dimensions, 88 models
AA — Datum line
WW — Centre line of front axle
CC — Centre line of rear axle
D — 3420 mm (134.6 in.)
E — 539,7 mm (21.25 in.)
F — 610 mm (24.0 in.)
G — 713,2 mm (28.08 in.)
H — 2235 mm (88.0 in.)
J — 793,7 mm (31.25 in.)
K -- 422,3 mm (16.625 in.)
L — 457 mm (18.0 in.)
M — 472,2 mm (18.58 in.)
N — 229 mm (9.0 in.)
P — 212,7 mm (8.37 in.)
Q — 290,5 mm (11.44 in.)
R — 198,4 mm (7.81 in.)
S — 120,6 mm (4.75 in.)
T — 29,3 mm (1.15 in.)
U — 82,5 mm (3.25 in.)
V — 432 mm (17.0 in.)
Ww — 387,3 mm (15.25 in.)
X — 787 mm (31.0 in.)
DD — 1536 mm (60.5 in.)
EE — 539,7 mm (21.25 in.)
FF — 610 mm (24.0 in.)
GG — 257 + 0,8 mm (10.12 0.030 in.)
HH — 254 + 0,8 тт (10.00 + 0.030 in.)
JJ — 835 + 0,8 mm (32.87 + 0.030 in.)
KK — 289,7 mm(11.40 in.)
LL — 166,7 mm (6.56 in.)
MM — 250,8 + 1,5 mm (9.875 + 0.060 in.)
NN — 768,3 mm (30.25 in.) ;
PP — 331,78 + 0,5 mm (13.062 + 0.020 in.
QQ — 9,52 mm (0.375 in.) diameter holes
£1—9L
Chassis frame dimensions, 109 models
AA — Datum line U
WW — Centre line of front axle У
CC — Centre line of rear axle W
D — 4240 mm (166.9 in.) X
E — 539,7 mm (21.25 in.) DD
F — 610 mm (24.0 in.) EE
G — 1000 mm (39.375 in.) FF
H — 2770 mm (109 in.) GG
J — 793,7 mm (31.25 in.) HH
K — 422,3 mm (16.625 in.)
L — 457 mm (18.0 in.) JJ
M — 472,2 mm (18.58 in.)
N — 229 mm (9.0 in.) KK
P — 212,7 mm (8.37 in.) LL
Q — 296,8 mm (11.68 in.)
R — 204,7 mm (8.06 in.) MM
S — 120,6 mm (4.75 in.) NN
T — 29,3 mm(1.15 in.) PP
ho EE EE RR RE
82,5 mm (3.25 in.)
432 тт (17.0 т.)
387,3 mm (15.25 in.)
787 mm (31.0 in.)
1536 mm (60.5 in.)
1070 mm (42.12 in.)
641 mm (25.2 in.)
257 + 0,8 mm (10.125 + 0.030 in.) 2.6 & 2% litre.
835 + 0,8 mm (32,87 + 0.030 in.) 2% litre
984 + 0,8 mm (38.74 + 0.030 in.) 2.6 litre
289,71 mm (11.406 in.) 2% litre
290,51 mm (11.437 in.) 2.6 litre
166,7 mm (6.56 in.)
250,7 mm (9.87 in.) 2% litre
193,7 mm (7.62 in.) 2.6 litre
763 mm (30 in.) 2% & 2.6 litre
331,8 + 0,5 mm (13.06 £ 0.062 in.)
9,52 mm (0.375 in.) diameter holes
+
0
0
FRONT FLOOR
Remove and refit 76.10.12
2% litre models, instructions 1 to 7 and
11to 13
2.6 litre models, instructions 1 to 4 and
8 to 13 |
Removing
1 Unscrew the knob and locknut from
the transfer gear lever.
2 Remove the fixings and withdraw the
dust cover from the transfer gear lever.
3 Unscrew the knob and locknut from
the four-wheel drive lever.
4 Withdraw the spring and ferrule.
2% litre models
5 Remove both halves of the front floor.
6 Remove the gearbox tunnel cover.
7 Remove a gearbox tunnel front panel.
2.6 litre models
8 Remove the gearbox tunnel cover.
9 Remove the gearbox tunnel front
panel.
10 Remove both halves of the front floor.
Refitting, both models
11 Reverse instructions 8 to 10 or 5 to 7
as applicable.
Use waterproof sealant between the
joint flanges.
12 Adjust the four-wheel drive lever
during assembly, as follows: Fit the
ferrule, spring and locknut to the
lever, depress the lever and adjust the
locknut until the compressed spring
length is 58 mm (2.312 in.), then fit
the knob and tighten the locknut.
13 Reverse instructions 1 and 2.
IRCt77
IRC175
IRC 17%6
P1-9L
FRONT WING
Remove and refit 76.10.26
Removing
o 00 . a Un + DI —
bank ped em
> OO
ja jm
Ww
po
wn
Disconnect the battery.
Jack up the vehicle and support
securely.
Remove the front wheel.
Remove the radiator grille.
Disconnect the headlamp leads at the
snap connectors.
Disconnect the side lamp and flasher
lamp at the snap connectors.
Remove the bolts securing the wing to
the radiator grille panel.
Remove the bolts securing the wing
stay.
Remove the bolts securing the wing to
the sill.
Remove the bolts securing the wing to
the cover plate.
Remove the bolts securing the mud-
shield. Remove the mudshield.
Remove the bolts securing the wing to
the scuttle and scuttle pillar.
Withdraw the front wing.
Remove the headlamp, side lamp and
flasher lamp if required.
The foregoing instructions outline the
basic wing attachment details. Depend-
ing upon whether the wing to be
removed is left or right hand, the
vehicle is fitted with left or right hand
steering, is fitted with a heater, oris a
servo brake diesel model, the following
additional operations may be neces
sary.
Bonnet removal.
Windscreen washer reservoir.
Vacuum tank — servo brake, diesel
only.
Heater fan motor and connections.
Heater air intake connections.
Steering drop arm cover box.
Wiring harness attachment to wing
valance.
Windscreen washer hose attachment to
wing valance.
Windscreen washer pump.
Refitting
16
Reverse instructions 1 to 15.
4RC 1086
Front wing
Key
1 Fixing plates
2 Wing — rear valance assembly
3 Wing — outer panel
4 Headlamp mounting panel
5 Front panel
6 Headlamp surround
Cover panels — front wing
Key
1 Bottom panel — front wing valance
2 Cover plate (2% Petrol only)
3 Cover box — steering drop arm
4 Bracket
5 Nut plate
6 Mudshield
7 Wing stay
ST—9L
SIDE DOOR GLASS
Front door 76.31.01
Rear door 76.31.02
Remove and refit
Removing
Sliding glass
1 Remove the screw and rubber stop
from the front end of the sliding glass
top channel. Remove the remaining
channel securing screws.
2 Incline the sliding glass inwards com-
plete with top channel and the filler
strip.
Remove the channel and filler strip.
Lift out the sliding glass.
3
4
Fixed glass
5 Remove the sliding glass (instructions
1 to 4 above).
6 Remove the front angle strip.
7 Carefully release the fixed glass from
the sealing compound.
8 Withdraw the fixed glass.
9 Remove the old sealing compound
from glass and door.
Refitting
Fixed glass
10 Apply fresh sealing compound to the
door frame.
11 Carefully insert the fixed glass and
press firmly into position. Remove
surplus sealing compound.
12 Fit the front angle sealing strip.
Sliding glass |
13 Fit the sliding glass, top channel and
filler strip in reverse order to instruc-
tions 1 to 4.
DOOR LOCK
Remove and refit
Side door, front 76.37.12
Side door, rear 76.37.13
Tail door 76.37.16
Removing
1 Remove the door trim where fitted.
2 Remove the screws securing the lock
to the door edge (not anti-burst type).
3 Remove the two screws securing the
top of the lock to the door.
4 Remove the tapped plate.
5 Remove the nuts securing the bottom
of the lock to the door.
6 Remove the studplate.
7 Remove the door lock and sealing
plate. (Sealing plates are not fitted to
anti-burst type locks.)
Refitting
8 Reverse instructions 1 to 7.
a |
T
ai
ÓN
FASCIA TOP RAIL
Remove and refit 76.46.04
Removing
1 Remove the screws securing the fascia
top rail end cover and heater control.
Ease the end cover aside.
Remove the screws securing the fascia
top rail end cover (passenger's side).
Withdraw the end cover.
3 Remove the two nuts and bolts secur-
ing the rear of the fascia top rail to the
fascia mounting plate.
4 Remove the screws securing the demist
outlets. Withdraw the demist outlets.
5 Remove the screws securing the front
of the fascia top rail.
6 Remove the top rail.
Refitting
7 Reverse instructions 1 to 6.
LOWER FASCIA
Remove and refit 76.46.05
Removing
1 Release the shroud from the steering
column and the lower fascia.
2 Remove the heater control panel from
the drivers end of the fascia and
disconnect the distribution control
cable.
3 Withdraw the instrument panel clear
of the dash.
4 Withdraw the demister hoses.
5 Withdraw the finisher strip from the
top edge of the lower fascia.
6 If the vehicle is fitted with auxiliary
instruments at the centre of the lower
fascia, remove as applicable.
7 Remove the end cover from the lower
fascia.
8 Remove the parcel tray.
9 Remove the fixings securing the lower
fascia to the dash.
10 Withdraw the lower fascia.
11 If required, remove the heater duct
cover and the distribution flap valves,
as applicable.
Refitting
12 Reverse instructions 1 to 11. Where
applicable, ensure that the gasket is
fitted between the heater duct and the
dash.
0923
L1-—9L
FASCIA SUPPORT PANEL
Remove and refit 76.46.06
Removing
00 2 ON Un Fa Y 2 =
9
Disconnect the battery.
Remove the fascia top rail. 76.46.04.
Remove the instrument panel.
Disconnect the heater hoses from the
demister nozzles.
Remove the instrument housing.
Remove the fixings securing the venti-
lator control levers to the lids.
Remove the ventilator controls com-
plete.
If the vehicle is fitted with an auxiliary
instrument panel, remove the fixings
securing it to the fascia support panel.
Remove the fixings securing the fascia
support panel to the dash.
10 Withdraw the fascia support panel.
11 Remove the heater demister nozzles.
Refitting
12 Reverse instructions 1 to 11.
IRC922
E
CI
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FRONT SEAT BASE
Remove and refit 76.70.06
Removing
CN Un pa VR) ——
Remove the driver's floor panel.
Remove the passenger's floor panel.
Remove the gearbox cover panel.
Remove all seat cushions.
Release the safety bolts from their
anchor brackets at the seat base.
Remove the safety belt anchor brac-
kets.
7 Remove the bolts securing the seat
base.
8 Release the passenger's door check
stay.
9 Remove the handbrake draught
excluder.
10 Manoeuvre the seat base clear of the
handbrake lever.
11 Withdraw the seat base.
Refitting
12 Reverse instructions 1 to 11. Use a
suitable waterproof sealant when fit-
ting the seat base gearbox cover, and
floor panels.
81—9L
WINDSCREEN
Remove and refit 76.81.02
Removing
Soft top
1 Remove the windscreen wiper arms
and blades.
2 Release the straps securing the hood to
the windscreen frame.
3 Detach the hood tape from windscreen
hooks.
4 Roll back the hood clear of the wind-
screen.
5 Remove the bolts securing the door
top channels to the windscreen.
6 Slacken the nuts on the windscreen
clamp bolts. Swing the clamp bolts
clear of the windscreen.
7 Disconnect the wiper motor earth lead
from the windscreen frame.
8 Remove the bolts securing the wind-
screen to the hinges.
9 Remove the windscreen
Hard top
10 Remove the bolts securing the roof to
the windscreen.
11 Slacken or remove the remaining roof
fixings.
12 Carry out instructions 1 and 6 to 9.
Refitting
Soft top
13 Reverse instructions 1 to 9. Ensure
that the windscreen lower sealing strip
is properly located and in good condi-
tion.
Hard top |
14 Reverse instructions 1 and 6 to 11.
Ensure that the windscreen top and
bottom sealing strips are properly
located and in good condition before
tightening the roof fixings.
00 —) Wh A VW ND =
Windscreen assembly
Key
Seal
Windscreen frame
Windscreen glass
Glazing strip
Glass retaining strips
Centre cover strip
Windscreen clamp assembly
Windscreen hinge arm
61—9L
WINDSCREEN GLASS
Remove and refit 76.81.03
Removing
1 Remove the windscreen wiper arms
and blades.
Soft top
2 Remove the windscreen frame assem-
bly. 76.81.02.
Hard top
3 Remove the sun visors and rear view
mirror from the interior of the cab.
4 Remove the headlining strip from
above the windscreen.
5 - Remove the fascia top rail. 76.46.04.
All models
6 Remove the screws securing the glass
retaining angle strips.
7 Carefully ease the glass clear of the
screen.
8 Remove all traces of sealant from the
windscreen frame and glass retaining
strips.
Refitting
9 Line the interior of the windscreen
frame with ‘Sealastrip’.
10 Locate the glass in the windscreen
frame and press firmly into the ‘Seala-
strip’.
11 Place “Sealastrip” around the edges of
the glass to seal the angle strips when
fitted.
12 Fit the angle strips to retain the glass
and secure with the retaining screws.
13 Remove surplus “Sealant”.
Soft top
14 Fit the windscreen to the vehicle.
76.81.02.
Hard top
15 Fit the fascia top rail. 76.81.04.
16 Fit the headlining strip.
17 Fit the sun visors and rear view mirror.
[—8L
PAINTWORK
General information 78.00.00
Body panels
1
Land Rover body panels are manu-
factured from a special aluminium-
alloy known as ‘Birmabright’ and the
following paintwork procedure should
be followed on these panels.
Painting ‘Birmabright’
2
The area to be painted must be flatted
to remove the hard oxide skin which
forms on the surface of the alloy when
exposed to the atmosphere. Degrease
and dry the area, then apply a suitable
etch-primer. Unless an etch-primer is
used, paint is liable to come away as it
cannot ‘key’ into the hard oxide of an
untreated alloy surface and the use of
ICI Etching Primer P565-5002 15
recommended. It is quick and easy to
apply, and it prolongs the life of the
paint film by ensuring excellent adhe-
sion.
Application
3
The activated Etching Primer has a
limited pot-life of about 8 hours at
normal temperatures and should not
be used after this time, as it may have
inferior adhesion and corrosion resi-
stance. Any Etching Primer which has
been mixed for more than 8 hours
must be thrown away, and not
returned to the can.
Apply Etching Primer as soon as
possible after cleaning, and paint as
soon as the pre-treatment is com-
pleted. Undue delay may cause the
surface to be contaminated again and
thus nullify the treatment. Do not
leave pre-treated work overnight
before it is painted.
Etching Primer, when followed by a
suitable paint system, gives a film
which is very resistant to moisture, but
the Etching Primer itself is water
sensitive. It should therefore be coated
with paint as soon as possible when it
is dry.
10
11
Activate the Etching Primer by mixing
it with an equal volume of Activator
P273-5021 and allow to stand for 10
minutes.
Adjust the spraying viscosity of the
mixture if necessary to 22-25 sec.
BSB4 Cup by adding small quantities
of Thinner 851-565; never add more
Activator.
Apply by spray to a clean, dry surface
in a thin uniform coat, rather than a
thick heavy one which may impair
adhesion.
Air dry for at least 15 minutes before
applying undercoat by spray or for 2
hours before brush application. If
required, these times can be shortened
by force drying, this also gives in-
creased hardness to the film.
Subsequent painting follows normal
paintshop practice.
When wet flatting the subsequent
paint layers take care not to rub
through to the Etching Primer. If this
does occur allow to dry out tho-
roughly, dry flat the area and spot in
with Etching Primer.
1-08
HEATER CONTROLS
Remove and refit 80.10.02
Removing |
1 Remove the screws securing the heater
8
control knobs and withdraw the con-
trol knobs. Note that the knob
coloured red and blue is fitted to the
inner position.
Remove the screws securing the end
panel to the fascia.
Ease the end panel complete with
heater control levers away from the
fascia.
Remove the two screws securing the
heater control assembly to the end
cover. Note the two distance pieces
interposed between the control lever
assembly and the end panel.
Remove the end panel from the con-
trol lever assembly.
Slacken the pinch screws securing the
inner cables to their respective levers.
Slacken the pinch bolt and clamp
securing the outer cables to the con-
trol level assembly.
Remove the control lever assembly.
Refitting
9
Reverse instructions 1 to 9. Note that
the water valve control cable is con-
nected to the inboard lever. Check the
operation of both levers and controls
before refitting the end panel.
AH
TRC 996A
HEATER/VENTILATOR AIR
FLOW CONTROL CABLE
Remove and refit 80.10.06
Removing
1 Remove the heater controls 80.10.02
(instructions 1 to 3) and disconnect
the air flow control cable.
2 Remove the lower fascia 76.46.05.
3 Remove the heater ducting cover fix-
ings.
4 Withdraw the ducting cover to gain
access to the air distribution flaps.
5 Withdraw the distribution flaps from
the fascia.
6 Disconnect the inner cable at the flaps.
7 Withdraw the outer cable, retained at
the ducting cover by a tubular clip.
Refitting
8 Reverse instructions 2 to 7.
9 Refit the heater controls and air flow
control cable ensuring full air distri-
butor flap operation. The flaps are
easily checked after removing the air
outlet ducts in the lower fascia.
¢—08
HEATER WATER VALVE
CONTROL CABLE
Remove and refit 80.10.07
Removing
Remove the heater control assembly
and end cover from the fascia.
2 Disconnect the water valve inner and
outer cable from the control lever.
3 Disconnect the inner and outer cable
from the water valve.
4 Attach a length of cord or thin wire to
the end of the cable. This facilitates
refitting.
5 Withdraw the control cable leaving the
cord or wire in position on the vehicle.
Refitting
6 Attach the control cable to the end of
the cord or wire and draw the cable
into position. Remove the cord or
wire. о
7 Connect. outer and inner cable to
the water valve and control lever.
(Water valve closed, control lever
raised.)
8 Check lever and water valve operation
and adjust as necessary.
9 Fit the heater control assembly and
end cover to the fascia.
1RC 993
HEATER WATER VALVE
Remove and refit 80.10.16
Removing
1 Partially drain the coolant from the
radiator.
2 Slacken the inner cable fixing.
3 Slacken the outer cable clamp fixing.
4 Free the inner cable and withdraw
from the valve.
5 Release the heater hose clips and slide
the hose away from the water valve.
6 Unscrew and withdraw the heater
water valve complete with adaptor.
7 Withdraw the adaptor sealing washer.
Refitting
8 Reverse instructions 3 to 7; do not
tighten the inner cable fixing at this
stage.
9 Set the water valve in the closed
position.
10 Set the cable control lever in the fully
up ‘cold’ position. |
11 Take up all slack in the inner cable
then secure the outer cable to the
water valve.
12 Top up the radiator.
HEATER FAN SWITCH
Remove and refit 80.10.22
Removing
1 Disconnect the battery.
2 Remove the lock ring and wave washer
securing the heater switch to the
instrument panel.
3 Remove the two screws securing the
instrument panel and ease the panel
towards the steering wheel.
4 Release the electrical connections
from the heater switch. Note the
electrical connection cable colours and
their relative position on the switch.
5 Withdraw the switch.
Refitting
6 Reverse instructions 1 to 5.
£-08
DEMISTER HOSES
Remove and refit 80.15.01
Passenger’s side hose instructions 1 to 3.
Driver’s side hose instructions 4 to 7.
В Removing—passenger's side hose.
.- 1 Disengage the hose upper end from the
nozzle adaptor.
2 Withdraw the hose from the rubber
connector.
Refitting
3 Reverse instructions 1 and 2.
Removing—driver’s side hose
Withdraw the instrument panel suf-
ficient to gain access to the hose
88.20.01, instructions 1 to 5.
5 Disengage the hose upper end from the
nozzle adaptor.
6 Withdraw the hose from the rubber
connector.
Refitting
7 Reverse instructions 4 to 6.
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DEMISTER NOZZLES
Remove and refit 80.15.03
Passenger’s side—instructions 1 to 4.
Driver’s side—instructions 6 to 13
Removing—passenger’s side nozzle
1 Remove the demister hose. 80.15.01.
2 Remove the fresh air grille.
3 Remove the nozzle adaptor.
4 Manoeuvre the nozzle out through th
fresh air grille aperture.
Refitting
5 Reverse instructions 1 to 4.
Removing—driver’s side nozzle
6 Disconnect the battery earth lead.
7 Remove the switch shrouds from the
steering column. Co
8 Withdraw the instrument panel clear
of ¿he dash, 88.20.01, instructions 1
to 5.
9 Remove the fresh air grille.
10 Withdraw the demister hose.
11 Remove the nozzle adaptor.
12 Manoeuvre the nozzle out through the
fresh air grille aperture.
Refitting
13 Reverse instructions 6 to 12.
IRC 988A
00
T
+
AIR DISTRIBUTION FLAPS
Remove and refit 80.15.09
This operation is described in operation
80.10.06.
VENTILATOR GRILLE PANEL
Remove and refit 80.15.16
Removing
1 Remove the hinge pins.
2 Remove the control lever fixings.
3 Remove the ventilator control to dash
fixings.
4 Withdraw the ventilator control and
quadrant assembly.
Refitting
5 Check the lever operation in the
quadrant. If required, adjust the
special locknut to alter the spring
loading on the lever.
6 Reverse instructions 1 to 4.
FRESH AIR INTAKE
Remove and refit 80.15.29
Removing
1 Remove the fixings.
2 Withdraw the intake grille assembly.
3 If required, withdraw the air inlet seal.
Refitting
4 Reverse instructions 1 to 3.
1RC995
IRC 992
HEATER BOX COMPLETE
Remove and refit 1 to 7,
12& 13 80.20.01
HEATER RADIATOR
Remove and refit 1 to 13 80.20.29
Removing
1 Frominside the cab remove the trim board
rail, if fitted.
Withdraw the trim board from the clip, if
fitted.
Remove the heater box lower fixings.
Disconnect the heater water hoses.
Disconnect the air inlet hose.
Remove the heater box upper fixings.
Withdraw the heater box.
If removal of the heater radiator is
required, proceed as follows, instruc-
tions 9 and 10.
Remove the fixings and withdraw the
detachable side panel.
10 Withdraw the radiator and pipes
assembly.
09 —> ©\ MA N
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Refitting
11 If the heater radiator was removed
reverse instructions 9 and 10..
12 Ensure that the joint seal is present
and sound. |
13 Reverse instructions 1 to 7.
IRC 987
2
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$—08
HEATER/BLOWER FAN MOTOR
Remove and refit 80.20.15
Removing
1 Disconnect the battery.
2 Disconnect the blower motor leads.
3 From inside the cab remove the trim
board rail.
4 Withdraw the trim board from the
clip.
5 Remove the blower motor fixings.
6 Disconnect the air hose at the matrix
inlet.
7 Remove the wing panel rear top fixing
ой.
8 Manoeuvre the blower motor assembly
clear, lifting .the wing panel sufficient
to allow passage.
9 Withdraw the air inlet seal.
Refitting
10 Fit the blower motor but omit the air
inlet seal at this stage.
11 Remove the air intake grille.
12 Fit the air inlet seal and replace the
— intake grille.
13 Reverse 2 to 7. Connect the electrical
leads from the blower motor at the
snap connectors as follows: Brown
lead with green marker band — to
green/slate lead; green/yellow lead —
to green/yellow lead.
HEATER PIPES
Remove and refit
Feed to heater
Return from heater
80.25.15
80.25.16
Removing
1 Partially drain the coolant.
2 Disconnect the hoses.
3 Remove the fixings and withdraw the
pipe.
Refitting
4 Reverse instructions 1 to 3.
1RC984
1-78
WASHER RESERVOIR
Remove and refit 84.10.01
1 Remove the washer reservoir filler cap
complete with suction tube and filter
from the reservoir.
2 Remove the three screws, washers and
nuts securing the reservoir to the wing
valance.
3 Remove the reservoir.
4 Diesel models with vacuum tank and
servo only.
Removal of the washer reservoir neces-
sitates the prior removal of the
vacuum tank complete with mounting
brackets and washer reservoir. For
details refer 70.50.04.
Refitting
5 Reverse instructions 1 to 3
WASHER TUBES
Remove and refit 84.10.15
Removing
1 Disconnect the battery.
2 Disconnect the washer tubes from the
washer pump.
3 Remove the washer reservoir cap and
withdraw the pump inlet tube com-
plete with filter.
4 Release the delivery tube (pump to
car) from its retaining clips.
5 Unscrew the windscreen washer jets
and remove the jets from the washer
tubes.
6 Ease back the panel tray trim edging
from the top of the wiper motor
cover.
7 Remove the screws securing the wiper
motor cover and withdraw the cover.
8 Remove the two screws securing the
instrument panel and ease the panel
towards the steering wheel.
9 Release the demist tubes from the
upper fascia vents.
10 Remove the upper fascia.
11 Remove the retaining clips from the
washer tubes.
12 Withdraw the washer tubes (3) and
their connecting tee piece.
WASHER JETS
Remove and refit 84.10.09
Removing
1 Unscrew the washer jet.
2 Withdraw the jet and washer tube
from the jet holder.
3 Detach the jet from the washer tube.
Refitting
4
Engage the jet in the washer tube.
5 Wind the jet and tube anti-clockwise
approximately the number of turns
required to secure the jet in the jet
holder.
6 Push the jet and tube into the jet
holder and screw the jet into position.
The washer tube will unwind to its
normal free position.
SF
|
Refitting
13 Reverse instructions 1 to 12.
When threading the tube from the tee
piece to the washer pump through the
bulkhead it will be found advan-
tageous to unscrew the plate holding
the washer tube grommet to the front
of the bulkhead.
0995
v8
WASHER PUMP
Remove and refit 84.10.21
Removing
1 Disconnect the battery.
2 Disconnect the washer tubes from the
washer pump. Note the suction tube
(washer reservoir tube) is fitted to the
pump union adjacent to the radiator.
3 Detach the electrical feed wire and
earth wire from the pump.»
4 Remove the two bolts and washers
securing the pump, pump bracket and
earth wire to the wing valance.
5 Remove the pump, pump bracket and
earth wire.
Refitting
6 Reverse instructions 1 to 5.
WIPER ARMS
Remove and refit 84.15.01
Removing
Using a small screwdriver, hold back
the spring clip which retains the wiper
arm on the spindle.
2 Withdraw the wiper arm from the
spindle boss.
Refitting
3 Allow the motor to move to the “park”
position.
4 Push the arm on to the boss, locating
it on the splines so that the wiper
blade is just clear of the screen rail.
5 Ensure that the spring retaining clip is
located in the retaining groove on the
OSS.
0444
WIPER MOTOR AND DRIVE
Remove and refit 84.15.09
Removing
1 Disconnect the battery.
2 Remove the wiper arms.
3 Remove the screws securing the wiper
motor cover and withdraw the cover.
4 Disconnect the power supply plug
from the wiper motor.
5 Disconnect the union nut securing the
wheelbox drive cable tubing to the
wiper motor.
6 Remove the screws securing the wiper
motor clamp bracket. Note that the
screws engage a tapped plate on the
engine side of the bulkhead.
7 Withdraw the wiper motor complete
with clamp and wheelbox drive cable.
Note the rubber pad fitted between
the wiper motor and the bulkhead.
Refitting
8 Enter the drive cable in the wheelbox
tubing. This may necessitate turning
the wheelbox wiper spindles by hand
to allow the drive cable to engage the
wheelbox gears.
9 Reverse instructions 1 to 7.
IRC933
£-#8
WIPER MOTOR DRIVE AND
WHEELBOXES
Remove and refit 84.15.10
Removing
1 Disconnect the battery.
2 Remove the windscreen wiper arms.
3 Remove the drive adaptor from the
wheelbox spindles.
4 Remove the grommet from the wheel-
box spindles.
5 Remove the nut and washer securing
the wheelboxes to the vehicle.
6 Remove the wiper motor and drive
cable. 84.15.09.
7 Remove the two screws securing the
00
9
10
11
12
instrument panel and ease the panel
towards the steering wheel.
Release the demist tubes from the
upper fascia vents.
Remove the upper fascia. 76.46.04.
Slacken the nuts securing the wheel-
box back plates.
Release the drive cable tubes from the
wheelboxes.
Remove the drive cable tubes and the
wheelboxes.
Refitting
13
Reverse instructions 1 to 12.
|/
0989
v—78
WIPER MOTOR
Overhaul 84.15.18
Dismantling
1 Remove the wiper motor and drive.
84.15.09.
Remove the gearbox cover.
Remove the circlip and plain washer
securing the connecting rod.
Withdraw the connecting rod.
Withdraw the flat washer.
Remove the circlip and washer secur-
ing the shaft and gear.
Clean any burrs from the gear shaft
and withdraw the gear.
Withdraw the dished washer.
Add alignment marks to the yoke and
- gearbox for reassembly.
10 Remove the yoke securing bolts.
11 Withdraw the yoke and armature.
12 Remove the brush gear assembly.
13 Remove the limit switch.
KO 00 =) An U ND
IRC 934
Inspecting
14 Check the brushes for excessive wear,
if they are worn to 4,8 mm (0.190 in.)
in length, fit a new brush gear assem-
bly.
15 Using a push type gauge, check that
the brush spring pressure is 140 to 200
g (5 to 7 0z.) when the bottom of the
brush is level with the bottom of the
slot in the brush box. Fit a new brush
gear assembly if the springs are not
satisfactory.
16 Test the armature for insulation and
open- or short-circuits. Use a test lamp
(110V, 15W). Fit a new armature if
faulty.
17 Examine the gear wheel for damage or
excessive wear.
Assembling.
18 Reverse instructions 1 to 13 noting
instructions 19 to 26.
19
20
21
22
23
24
25
26
Use Ragosine Listate Grease to lubri-
cate the gear wheel teeth, armature
shaft worm gear, connecting rod and
pin, cable rack and wheelbox gear
wheels.
Use Shell Turbo 41 oil sparingly to
lubricate the bearing bushes, armature
shaft bearing journals, gear wheel shaft
and wheelbox spindles. Thoroughly
soak the felt washer in the yoke
bearing with oil.
Tighten the yoke fixing bolts. Torque
23 kgf. cm. (20 Ibf. in.).
If a replacement armature is being
fitted, slacken the thrust screw to
provide end-float for fitting the yoke.
Fit the dished washer beneath the gear
wheel with its concave side towards
the gear wheel.
Ensure that the larger of the two
washers is fitted to the crankpin
beneath the connecting rod.
Armature end-float: Hold the yoke
vertical with the adjuster screw upper-
most. Carefully screw in the adjuster
until resistance is felt then, screw back
a quarter turn. This will give the
required end-float.
Connect the leads between the wiper
motor and the limit switch.
DATA
Windscreen wiper motor
Armatureend float ................
Brush length, minimum. ............
Brush spring tension . ..............
Resistance of armature winding at 16°C
(69 F) measured between adjacent com-
mutatorsegments . ................
Light running, rack disconnected: Cur-
rentat 13.5V..... iia.
Speed, 60 seconds from cold. ........
IRC 935
0,1 mm to 0,2 mm (0.004 in.
to 0.008 in.)
4,8 mm (0.190 in.)
140 to 200 g(5 to 7 oz.)
0.23 to 0.35 ohms
2.0 amps
60 to 70 rev/min
$—78
HEADLAMP WIPERS AND
WASHERS
General 84.20.00
For certain markets and as an optional
extra, headlamp wipers and washer equip-
ment can be fitted. This installation does
not involve extra controls: the headlamp
wipers and washers are engineered to func-
tion only when the headlamps are illumi-
nated and windscreen washer is operated.
CU Pa WI =
KEY TO CIRCUIT DIAGRAM
Windscreen washer pump
Vehicle washer switch
Headlamp wiper relay
Headlamp wiper delay unit
Vehicle lighting switch
Headlamp washer pump
Headlamp wiper motor
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1-98
ELECTRICAL EQUIPMENT
General 86.00.00
The electrical system is Negative earth, and
it is most important to ensure correct
polarity of the electrical connections at ail
times. Any incorrect connections made
when reconnecting cables may cause irre-
parable damage to the semiconductor
devices used in the alternator and regula-
tor. Incorrect polarity would also seriously
damage any transistorised equipment such
as radio and tachometer etc.
Before carrying out any repairs or main-
tenance to an electrical component, always
disconnect the battery.
The V-drive fan belt used with alternators
is not the same as that used with d.c.
machines. Use only the correct Rover
replacement fan belt. Occasionally check
that the engine and alternator pulleys are
accurately aligned.
It is essential that good electrical connec-
tions are maintained at all times. Of parti-
cular importance are those in the charging
circuit (including those at the battery)
which should be occasionally inspected to
see that they are clean and tight. In this
way any significant increase in circuit
resistance can be prevented.
Do not disconnect battery cables while the
engine is running or damage to the semi-
conductor devices may occur. It is also
inadvisable to break or make any connec-
tions in the alternator charging and control
circuits while the engine is running.
The electronic voltage regulator employs
micro-circuit techniques resulting in im-
proved performance under difficult service
conditions. The whole assembly is encapsu-
lated in silicone rubber and housed in an
aluminium heat sink, ensuring complete
protection against the adverse affects of
temperature, dust, and moisture etc.
The regulating voltage is set during manu-
facture to give the required regulating
voltage range of 14.1 to 14.5 volts, and no
adjustment is necessary. The only main-
tenance needed is the occasional check on
terminal connections and wiping with a
clean dry cloth.
The alternator system provides for direct
connection of a charge (ignition) indicator
warning light, and eliminates the need for a
field switching relay or warning light con-
trol unit. As the warning lamp is connected
in the charging circuit, lamp failure will
cause loss of charge. Lamp should be
checked regularly and a spare carried.
When using rapid charge equipment to
re-charge the battery, the battery must be
disconnected from the vehicle.
C— 98
BASIC CIRCUIT DIAGRAM 2% AND 2.6 LITRE PETROL MODELS, R.H.
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KEY TO BASIC CIRCUIT DIAGRAM 2% AND 2.6 LITRE PETROL MODELS, R.H. AND L.H. STEERING, NEGA TIVE EARTH
O 00 —) С сл + Ч) В) =
Starter motor
Solenoid, starter motor
Switch for horns
Horn
Inspection sockets
Instrument panel illumination
Instrument panel illumination
Switch, panel lights
Tail lamp, LH
Tail lamp, RH
Side lamp, LH
Side lamp, RH
Headlamp, LH dipped beam
Headlamp, RH dipped beam
Warning light, headlamp main beam
Headlamp, LH main beam
Headlamp, RH main beam
Direction indicator lamp, rear RH
Direction indicator lamp, front RH
Direction indicator lamp, front LH
Direction indicator lamp, rear LH
Battery
Switch, ignition and starter
Switch, lights
Switch, headlamp flash and dip
26
Warning light, indicator RH
Warning light, indicator LH
Fuses, 1 to 8, 35 amp
Indicator unit, flasher
Switch, direction indicators
Alternator, Lucas 16 ACR
Warning light, ignition
Ignition coil
Warning light, oil pressure
Warning light, choke
Voltage stabiliser, fuel gauge and water
temperature gauge
Switch, stop lamp
Switch, windscreen wiper
Fuel pump, 6-cylinder models only
Switch, cold start warning light
Fuel gauge
Water temperature gauge
Screenwiper motor
Distributor
Switch, oil pressure
Fuel tank unit
Water temperature transmitter unit
Stop lamp, LH
Stop lamp, RH
Screenwasher motor (when fitted)
Key to cable colours
Black
Green
Light
Brown
Purple
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Red
Blue
White
Yellow
The last letter of a colour code denotes the tracer colour
Snap connection and/or plugs and sockets
a+ Earth connections via cables
af Earth connections via terminals or fixing
bolts
—R— Clinch connection
7 —98
BASIC CIRCUIT DIAGRAM 2% LITRE 4-CYLINDER DIESEL MODELS, R.H. AND L.H. STEERING, NEGATIVE EARTH
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